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92-24161-61-00
INSTALLATION INSTRUCTIONSFOR INDUCED DRAFT GAS FURNACES80PS UPFLOW/HORIZONTAL SERIES80LS DOWNFLOW SERIES
U.L. recognized fuel gas and CO (carbon monoxide) detectors are recommended inall applications, and their installation should be in accordance with themanufacturer’s recommendations and/or local laws, rules, regulations, or customs.
Upflow Models Downflow ModelsModel Number Input (Btu) Tons Model Number Input (Btu) Tons80PS05EAR** 50,000 3 80LS05EAR** 50,000 380PS05NAR** 50,000 3 80LS07EBR** 75,000 480PS07EBR** 75,000 3 80LS07EAR** 75,000 380PS07NBR** 75,000 3 80LS10EBR** 100,000 380PS07EER** 75,000 4 80LS10ECR** 100,000 580PS07NER** 75,000 4 80LS10EDR** 100,000 5.580PS10EBR** 100,000 3 80LS12EDR** 125,000 580PS10ECR** 100,000 4.5 80LS15EDR** 150,000 580PS10EDR** 100,000 580PS10NDR** 100,000 580PS12EDR** 125,000 580PS15EDR** 150,000 5
2
Before beginning any troubleshooting procedure, complete the following installation checklist. A furnace malfunction issometimes caused by an improper installation. By completing this checklist, the problem may be found and corrected. Makecopies of the checklist and complete one for every Low Profile Furnace service call for your records.
INSTALLATION CHECKLIST(Refer to this manual for specifics.)
GAS SUPPLY
Adequate pipe size
No gas leaks
Proper supply and manifold gas pressure (check with an accurate U-tube manometer with the furnace and all other gasappliances operating.)
ELECTRICAL
Correct thermostat and subbase Thermostat model Subbase model
Correct thermostat mode and setting
Correct line supply voltage
Correct power supply polarity is required with electronic ignition
Correct furnace ground to electrical panel
DC microamp (μA) flame signal (hot surface ignition units)
Correct control voltage
Measure and set heat anticipator amperage
Air conditioning low voltage wires connected to terminals “Y” “C” - not with wire nuts
VENTING
Correct vent pipe diameter and length (according to CSA tables) Vent connection size
Correct venting material (according to CSA tables)
Correct lining for masonry chimneys
Adequate clearance from combustibles
Proper negative pressure reading in the vent
Vent pipe secured to induced draft blower housing
COMBUSTION AIR
Proper source of combustion air
Correct combustion air opening size
Optional attic combustion air pull
Non-attic combustion air pull
FURNACE INSTALLATION
Adequate clearance from combustibles
Adequate clearance for service
Proper air temperature rise (See furnace rating plate)
External static pressure inches w.c.
Correct filter(s)
Correct cooling coil or accessories (if equipped)
Adequate supply and return air ducting Return Air Duct Size Supply Air Duct Size
Air ducts sealed to prevent leakage
33
IMPORTANT: TO INSURE PROPER INSTALLATION AND OPERATION OFTHIS PRODUCT, COMPLETELY READ ALL INSTRUCTIONS PRIOR TOATTEMPTING TO ASSEMBLE, INSTALL, OPERATE, MAINTAIN OR REPAIRTHIS PRODUCT. UPON UNPACKING OF THE FURNACE, INSPECT ALLPARTS FOR DAMAGE PRIOR TO INSTALLATION AND START-UP.
CONTENTS
Installation Check List ............................................................................................2
Safety Information..................................................................................................4
General Information ...............................................................................................5
Location Requirements and Considerations ..........................................................6
Combustion and Ventilation Air............................................................................11
Vent Pipe Installation ...........................................................................................15
Gas Supply and Piping ........................................................................................18
Electrical Wiring ...................................................................................................22
Thermostat ...........................................................................................................22
Accessories..........................................................................................................23
Furnace Twinning ................................................................................................23
High Altitude Installations.....................................................................................24
Start-Up Procedure ..............................................................................................27
Air Flow ................................................................................................................29
Blower Performance Data....................................................................................30
Safety Features....................................................................................................31
Maintenance ........................................................................................................32
Troubleshooting ...................................................................................................35
Wiring Diagram ....................................................................................................36
Important: All manufacturer productsmeet current Federal OSHA Guidelinesfor safety. California Proposition 65warnings are required for certainproducts, which are not covered by theOSHA standards.
California's Proposition 65 requireswarnings for products sold in Californiathat contain, or produce, any of over600 listed chemicals known to the Stateof California to cause cancer or birthdefects such as fiberglass insulation,lead in brass, and combustion productsfrom natural gas.
All “new equipment” shipped for sale inCalifornia will have labels stating thatthe product contains and/or producesProposition 65 chemicals. Although wehave not changed our processes,having the same label on all ourproducts facilitates manufacturing andshipping. We cannot always know“when, or if” products will be sold in theCalifornia market.
You may receive inquiries fromcustomers about chemicals found in, orproduced by, some of our heating andair-conditioning equipment, or found innatural gas used with some of ourproducts. Listed below are thosechemicals and substances commonlyassociated with similar equipment inour industry and other manufacturers.
• Glass Wool (Fiberglass) Insulation• Carbon Monoxide (CO)• Formaldehyde• Benzene
More details are available at theWebsites for OSHA (OccupationalSafety and Health Administration), atwww.osha.gov and the State ofCalifornia's OEHHA (Office ofEnvironmental Health HazardAssessment), at www.oehha.org.Consumer education is important sincethe chemicals and substances on thelist are found in our daily lives. Mostconsumers are aware that productspresent safety and health risks, whenimproperly used, handled andmaintained.
4
USE ONLY WITH TYPE OF GASAPPROVED FOR THIS FURNACE.REFER TO THE FURNACE RATINGPLATE.
INSTALL THIS FURNACE ONLY INA LOCATION AND POSITION ASSPECIFIED IN THE LOCATIONREQUIREMENTS ANDCONSIDERATIONS SECTION OFTHESE INSTRUCTIONS.
PROVIDE ADEQUATECOMBUSTION AND VENTILATIONAIR TO THE FURNACE SPACE ASSPECIFIED IN THE VENTINGSECTION OF THESEINSTRUCTIONS.
COMBUSTION PRODUCTS MUSTBE DISCHARGED OUTDOORS.CONNECT THIS FURNACE TO ANAPPROVED VENT SYSTEM ONLY,AS SPECIFIED IN VENT PIPEINSTALLATION SECTION OFTHESE INSTRUCTIONS.
THE MANUFACTURER IS NOTRESPONSIBLE FOR EQUIPMENTTHAT IS MISMATCHED ORIMPROPERLY INSTALLED.
NEVER TEST FOR GAS LEAKSWITH AN OPEN FLAME. USE ACOMMERCIALLY AVAILABLESOAP SOLUTION MADESPECIFICALLY FOR THEDETECTION OF LEAKS TO CHECKALL CONNECTIONS, ASSPECIFIED IN GAS SUPPLY ANDPIPING SECTION OF THESEINSTRUCTIONS.
ALWAYS INSTALL FURNACE TOOPERATE WITHIN THEFURNACE'S INTENDEDTEMPERATURE-RISE RANGEWITH A DUCT SYSTEM WHICHHAS AN EXTERNAL STATICPRESSURE WITHIN THEALLOWABLE RANGE, ASSPECIFIED IN DUCTING SECTIONOF THESE INSTRUCTIONS. SEEALSO FURNACE RATING PLATE.
WHEN A FURNACE IS INSTALLEDSO THAT SUPPLY DUCTS CARRYAIR CIRCULATED BY THEFURNACE TO AREAS OUTSIDETHE SPACE CONTAINING THEFURNACE, THE RETURN AIRSHALL ALSO BE HANDLED BYDUCT(S) SEALED TO THEFURNACE CASING ANDTERMINATING OUTSIDE THESPACE CONTAINING THEFURNACE.
WHEN THIS FURNACE ISINSTALLED IN A RESIDENTIALGARAGE, IT MUST BE INSTALLEDSO THE BURNERS AND IGNITIONSOURCE ARE LOCATED NO LESSTHAN 18 INCHES ABOVE THEFLOOR. THIS IS TO REDUCE THERISK OF IGNITING FLAMMABLEVAPORS WHICH MAYBE PRESENT IN A GARAGE.ALSO, THE FURNACE MUST BELOCATED OR PROTECTED TOAVOID PHYSICAL DAMAGE BYVEHICLES. FAILURE TO FOLLOWTHESE WARNINGS CAN CAUSE AFIRE OR EXPLOSION, RESULTINGIN PROPERTY DAMAGE,PERSONAL INJURY OR DEATH.
USE OF THIS FURNACE ISALLOWED DURINGCONSTRUCTION IF THEFOLLOWING TEMPORARYINSTALLATION REQUIREMENTSARE MET. INSTALLATION MUSTCOMPLY WITH ALLINSTALLATION INSTRUCTIONSINCLUDING:
• PROPER VENT INSTALLATION;
• FURNACE OPERATING UNDERTHERMOSTATIC CONTROL;
• RETURN AIR DUCT SEALED TOTHE FURNACE;
• AIR FILTERS IN PLACE;
• SET FURNACE INPUT RATEAND TEMPERATURE RISE PERRATING PLATE MARKING;
• MEANS FOR PROVIDINGOUTDOOR AIR REQUIRED FORCOMBUSTION;
• RETURN AIR TEMPERATUREMAINTAINED BETWEEN 55°F(13°C) AND 80°F (27°C); AND
• CLEAN FURNACE, DUCT WORKAND COMPONENTS UPONSUBSTANTIAL COMPLETION OFTHE CONSTRUCTIONPROCESS, AND VERIFYFURNACE OPERATINGCONDITIONS INCLUDINGIGNITION, INPUT RATE,TEMPERATURE RISE ANDVENTING, ACCORDING TO THEINSTRUCTIONS.
! WARNING
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SAFETY INFORMATION
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The 80% gas furnaces are designcertified by CSA for use with natural andpropane gases as follows:
As a Category I furnace, it may bevented vertically with type B-1 ventpipe and also may be commonvented as described in theseinstructions.
This furnace should be installed inaccordance with the American NationalStandard Z223.1 - latest edition bookletentitled “National Fuel Gas Code”(NFPA 54) (in Canada, CSA B149.1 and.2 Installation Codes for gas burningappliances), and the requirements orcodes of the local utility or otherauthority having jurisdiction includinglocal plumbing or waste water codes.The National Appliance EnergyConservation Act (NAECA) of 1987states that any gas furnacemanufactured after January 1, 1992,must have a minimum Annual FuelUtilization Efficiency (AFUE) of 78%.The higher the AFUE percentage themore usable heat energy the consumergets for every dollar of fuel purchased.This is similar to the EPA's minimum gasmileage requirement for automobiles. Itgives the consumer a relatively easyway to make direct efficiencycomparisons between different furnacebrands and styles.A high AFUE value, which translates intoa low operating cost, is not the onlyconcern that consumers have. They alsowant a furnace with a reasonableinstalled cost. They want a furnace thatprovides them with comfort – their mainconcern. And they expect a furnace withexceptional reliability and longevity.Gas furnace manufacturers are alwaysstriving to provide consumers with thebest furnace value. The Low ProfileFurnace addresses all those consumerneeds. It gives exceptional efficiencywith a low installation cost. It delivers thecomfort the customer wants along withthe reliability they expect.The key to all these customer benefits isthe furnace's heat exchanger. Thematerials used to construct the furnacein general and the heat exchanger inparticular make it a rugged, long lastingunit. The unique heat exchanger designprovides the customer with a furnaceonly 34 inches high. This gives theconsumer a unit easily installed inalmost every location that accepts allcustomary accessories.With the introduction of higher efficiencyfurnaces, special attention must be paidto the venting system. Only listedventing systems may be used as statedin the installation instructions and theNational Fuel Gas Code, ANSI Z223.1(NFPA 54), or the Canadian CAN/CGAB149.1 and B149.2 Installation Codesfor Gas Burning Appliances. Sincefurnace technology and ventingrequirements are changing, awarenessof local, state, and federal codes andindustry changes is imperative.
GENERAL INFORMATION
IMPORTANT INFORMATIONABOUT EFFICIENCY ANDINDOOR AIR QUALITYCentral cooling and heating equipmentis only as efficient as the duct systemthat carries the cooled or heated air. Tomaintain efficiency, comfort and goodindoor air quality, it is important to havethe proper balance between the airbeing supplied to each room and the airreturning to the cooling and heatingequipment.
Proper balance and sealing of the ductsystem improves the efficiency of theheating and air conditioning systemand improves the indoor air quality ofthe home by reducing the amount ofairborne pollutants that enter homesfrom spaces where the ductwork and /or equipment is located. Themanufacturer and the U.S.Environmental Protection Agency’sEnergy Star Program recommend thatcentral duct systems be checked by aqualified contractor for proper balanceand sealing.
DUCT LEAKS CAN CREATE ANUNBALANCED SYSTEM AND DRAWPOLLUTANTS SUCH AS DIRT,DUST, FUMES AND ODORS INTOTHE HOME CAUSING PROPERTYDAMAGE. FUMES AND ODORSFROM TOXIC, VOLATILE ORFLAMMABLE CHEMICALS, AS WELLAS AUTOMOBILE EXHAUST ANDCARBON MONOXIDE (CO), CAN BEDRAWN INTO THE LIVING SPACETHROUGH LEAKING DUCTS ANDUNBALANCED DUCT SYSTEMSCAUSING PERSONAL INJURY ORDEATH (SEE FIGURE 1).
• IF AIR-MOVING EQUIPMENT ORDUCTWORK IS LOCATED INGARAGES OR OFF-GARAGESTORAGE AREAS - ALL JOINTS,SEAMS, AND OPENINGS IN THEEQUIPMENT AND DUCT MUST BESEALED TO LIMIT THEMIGRATION OF TOXIC FUMESAND ODORS INCLUDING CARBONMONOXIDE FROM MIGRATINGINTO THE LIVING SPACE.
FIGURE 1MIGRATION OF DANGEROUS SUBSTANCES, FUMES, AND ODORS INTO LIVING SPACES
NOTE: Always perform a proper heatloss calculation before specifying thefurnace size. This ensures that thefurnace is sized to adequately,economically, heat the building andprovide the correct airflow for yourapplication.IMPORTANT: PROPER APPLICATION,INSTALLATION AND MAINTENANCEOF THIS FURNACE IS A MUST IFCONSUMERS ARE TO RECEIVE THEFULL BENEFITS FOR WHICH THEYHAVE PAID.Additional helpful publications availablefrom the “National Fire ProtectionAssociation” are: NFPA-90A –
Installation of Air Conditioning andVentilating Systems 1985 or latestedition. NFPA-90B – Warm Air Heatingand Air Conditioning Systems 1984.These publications are available from:
National Fire Protection Association,Inc.
Batterymarch ParkQuincy, MA 02269CSA-INTERNATIONAL178 Rexdale Blvd.Etobicoke (Toronto), OntarioCanada M9W, 1R3
WARNING!
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GENERAL INFORMATION1. NOTE: This furnace is shipped with
heat exchanger support bracketsinstalled under the back of the heatexchanger. These may be removedbefore installation, but it is notrequired.
LOCATION
THIS FURNACE IS NOT APPROVEDFOR INSTALLATION IN A MOBILEHOME. DO NOT INSTALL THISFURNACE IN A MOBILE HOME.INSTALLATION IN A MOBILE HOMECOULD CAUSE FIRE, PROPERTYDAMAGE, PERSONAL INJURY ORDEATH.2. IMPORTANT: This furnace is not
approved or recommended forinstallation on its back, with accessdoors facing upwards.
3. This furnace is suitable forinstallation in buildings constructedon-site. This heating unit should becentralized with respect to the heatdistribution system as much aspracticable.
4. NOTE: These furnaces areapproved for installation in attics, as
well as alcoves, utility rooms,closets and crawlspaces.
5. IMPORTANT: Support this unit wheninstalled. For attic or crawl spaceinstallation, horizontal furnaces maybe installed on combustible woodflooring or by using support brackets.See Figure 2.
6. IMPORTANT: If installing in a utilityroom, be sure the door is wideenough to:a. allow the largest part of the
furnace to pass; orb. allow any other appliance (such
as a water heater) to pass.
LOCATION REQUIREMENTS AND CONSIDERATIONS
WARNING!FIGURE 2HORIZONTAL FURNACE INSTALLED W/SUPPORT BRACKETS
ST-A0799-01
NOTE: Do not block furnaceaccess with support rods. Maintainclearances recommended in Figure 2.Allow enough space for proper servicemaintenance or replacement of the heatexchanger and blower assembly.
EXHAUSTVENT
• IF AIR-MOVING EQUIPMENT ORDUCTWORK IS LOCATED INSPACES CONTAINING FUELBURNING APPLIANCES SUCH ASWATER HEATERS OR BOILERS -ALL JOINTS, SEAMS, ANDOPENINGS IN THE EQUIPMENTAND DUCT MUST ALSO BESEALED TO PREVENTDEPRESSURIZATION OF THESPACE AND POSSIBLEMIGRATION OF COMBUSTIONBYPRODUCTS INCLUDINGCARBON MONOXIDE INTO THELIVING SPACE.
IMPROPER INSTALLATION, ORINSTALLATION NOT MADE INACCORDANCE WITH THEUNDERWRITERS LABORATORY(UL) CERTIFICATION OR THESEINSTRUCTIONS, CAN RESULT INUNSATISFACTORY OPERATIONAND/OR DANGEROUS CONDI-TIONS AND ARE NOT COVERED BYTHE UNIT WARRANTY.
IN COMPLIANCE WITHRECOGNIZED CODES, IT ISRECOMMENDED THAT ANAUXILIARY DRAIN PAN BEINSTALLED UNDER ALLEVAPORATOR COILS OR UNITSCONTAINING EVAPORATOR COILSTHAT ARE LOCATED IN ANY AREAOF A STRUCTURE WHERE
DAMAGE TO THE BUILDING ORBUILDING CONTENTS MAY OCCURAS A RESULT OF AN OVERFLOW OFTHE COIL DRAIN PAN OR ASTOPPAGE IN THE PRIMARYCONDENSATE DRAIN PIPING. SEEACCESSORIES SECTION OF THESEINSTRUCTIONS FOR AUXILIARYHORIZONTAL OVERFLOW PANINFORMATION (MODEL RXBM).
RECEIVINGImmediately upon receipt, all cartonsand contents should be inspected fortransit damage. Units with damagedcartons should be opened immediately.If damage is found, it should be notedon the delivery papers, and a damageclaim filed with the last carrier. • After unit has been delivered to job
site, remove carton taking care not todamage unit.
• Check the unit rating plate for unitsize, electric heat, coil, voltage,phase, etc. to be sure equipmentmatches what is required for the jobspecification.
• Read the entire instructions beforestarting the installation.
• Some building codes require extracabinet insulation and gasketingwhen unit is installed in atticapplications.
• If installed in an unconditioned space,apply caulking around the powerwires, control wires, refrigerant tubingand condensate line where they enter
the cabinet. Seal the power wires onthe inside where they exit conduitopening. Caulking is required toprevent air leakage into andcondensate from forming inside theunit, control box, and on electricalcontrols.
• Install the unit in such a way as toallow necessary access to thecoil/filter rack and blower/controlcompartment.
• Install the unit in a level position toensure proper condensate drainage.Make sure unit is level in bothdirections within 1/8”.
• Install the unit in accordance withany local code which may apply andthe national codes. Latest editionsare available from: “National FireProtection Association, Inc.,Batterysmarch Park, Quincy, MA02269.” These publications are:
• ANSI/NFPA No. 70-(Latest Edition)National Electrical Code.
• NFPA90A Installation of AirConditioning and VentilatingSystems.
• NFPA90B Installation of warm airheating and air conditioning systems.
• The equipment has been evaluatedin accordance with the Code ofFederal Regulations, Chapter XX,Part 3280.
NOTICE
NOTICE
REDU
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CLEA
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E (IN
.)
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ont
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Ship
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105 /8
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36➂
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s.
7517
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11/32
123 /8
➀15
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13
6➂10
5 lb
s.
100
171 /2
1611/32
123 /8
➀15
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5 lb
s.
100
2119
27/32
141 /8
➀18
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120
lbs.
125
241 /2
2311/32
157 /8
➀22
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150
241 /2
2311/32
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FIGURE 3UPFLOW/HORIZONTAL DIMENSIONS
IMP
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2119
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➀23
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150
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155 /8
➀23
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8
FIGURE 4DOWNFLOW DIMENSIONS
TO
PB
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241 /2
193 /4
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247 /1
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9
CLEARANCE –ACCESSIBILITYThe design of forced air furnaces withinput ratings as listed in the tables onthe following pages are certified byCSA for the clearances to combustiblematerials shown in inches.
See name/rating plate and clearancelabel for specific model number andclearance information.
Service clearance of at least 24 inchesis recommended in front of all furnaces.
ACCESSIBILITY CLEARANCES,WHERE GREATER, MUST TAKEPRECEDENCE OVER FIREPROTECTION CLEARANCES.
UPFLOW AND HORIZONTALFURNACES MUST NOT BEINSTALLED DIRECTLY ONCARPETING, TILE OR OTHERCOMBUSTIBLE MATERIAL OTHERTHAN WOOD FLOORING.INSTALLATION ON ACOMBUSTIBLE MATERIAL CANRESULT IN FIRE CAUSINGPROPERTY DAMAGE, SEVEREPERSONAL INJURY OR DEATH.
A gas-fired furnace for installation in aresidential garage must be installed sothat the burner(s) and the ignitionsource are located not less than 18”above the floor and the furnace islocated or protected to avoid physicaldamage by vehicles.
DOWNFLOW UNIT DESIGN ISCERTIFIED FOR INSTALLATION ONNON-COMBUSTIBLE FLOOR. ASPECIAL COMBUSTIBLE FLOORSUB-BASE IS REQUIRED WHENINSTALLING ON A COMBUSTIBLEFLOOR. FAILURE TO INSTALL THESUB-BASE MAY RESULT IN FIRE,PROPERTY DAMAGE, PERSONALINJURY OR DEATH. THIS SPECIALBASE IS OFFERED AS ANACCESSORY FROM THE FACTORY.SEE THE CLEARANCE LABELLOCATED INSIDE THE FURNACEFOR THE APPROPRIATE MODELNUMBER.
THE SPECIAL BASE IS NOTREQUIRED WHEN THE FURNACE ISINSTALLED ON TOP OF AN AIRCONDITIONING PLENUM.
DUCTINGProper air flow is required for thecorrect operation of this furnace. Toolittle air flow can cause erraticoperation and can damage the heatexchanger. The duct system mustcarry the correct amount of air forheating and cooling. Position the unitminimize long runs or runs with manyturns and elbows.
Size the ducts according to acceptableindustry standards and methods. Thetotal static pressure drop (includingevaporator coil, if used) of the entiresystem should not exceed 0.5” w.c. Besure to have adequate space for unitfilter. NOTE: Airflow external staticpressure measurements do not includefilter or coil.
IMPORTANT: Some high efficiencyfilters have a greater than normalresistance to air flow. This canadversely affect furnace operation. BESURE TO CHECK AIR FLOW if usingany filter other than the factory-provided filter.
NOTE: DO NOT take return air frombathrooms, kitchens, furnace rooms,garages, utility or laundry rooms, orcold areas.
IMPORTANT: When using outside air,design and adjust the system tomaintain a return air temperatureabove 50°F during the heating season.
NEVER ALLOW PRODUCTS OFCOMBUSTION OR THE FLUEPRODUCTS TO ENTER THERETURN AIR DUCTWORK, OR THECIRCULATING AIR SUPPLY. ALLRETURN DUCTWORK MUST BEADEQUATELY SEALED ANDSECURED TO THE FURNACE WITHSHEET METAL SCREWS, ANDJOINTS TAPED. WHEN A FURNACEIS MOUNTED ON A PLATFORM,WITH RETURN THROUGH THEBOTTOM, IT MUST BE SEALEDAIRTIGHT BETWEEN THE FURNACEAND THE RETURN AIR PLENUM.THE RETURN AIR PLENUM MUSTBE PERMANENTLY ENCLOSED.NEVER USE A DOOR AS A PART OFTHE RETURN AIR PLENUM. THEFLOOR OR PLATFORM MUSTPROVIDE SOUND PHYSICALSUPPORT OF THE FURNACE,WITHOUT SAGGING, CRACKS,GAPS, ETC., AROUND THE BASEAS TO PROVIDE A SEAL BETWEENTHE SUPPORT AND THE BASE.
SITE SELECTION1. Select a site in the building near the
center of the proposed, or existing,duct system.
2. Give consideration to the vent systempiping when selecting the furnacelocation. Be sure the venting systemcan travel from the furnace to thetermination with minimal length andelbows.
3. Locate the furnace near the existinggas piping. Or, if running a new gasline, locate the furnace to minimizethe length and elbows in the gaspiping.
4. Locate the furnace to maintain properclearance to combustibles as shownin Figures 3 and 4.
WHEN COILS ARE USED WITH AIRHANDLERS OR FURNACES ANDINSTALLED ABOVE A FINISHEDCEILING OR LIVING AREA, IT ISRECOMMENDED THAT ANAUXILIARY SHEET METALCONDENSATE DRAIN PAN BEFABRICATED AND INSTALLEDUNDER ENTIRE UNIT. FAILURE TODO SO CAN RESULT IN PROPERTYDAMAGE. RUN CONDENSATE TO ALOCATION WHERE IT ISNOTICEABLE.
COMBUSTIBLE MATERIAL MUSTNOT BE PLACED ON OR AGAINSTTHE FURNACE JACKET OR WITHINTHE SPECIFIED CLEARANCES OFTHE VENT PIPE. THE AREA AROUNDTHE FURNACE MUST BE KEPTCLEAR AND FREE OF ALLCOMBUSTIBLE MATERIALSINCLUDING GASOLINE AND OTHERFLAMMABLE VAPORS AND LIQUIDS.PLACEMENT OF COMBUSTIBLEMATERIALS ON, AGAINST ORAROUND THE FURNACE JACKETCAN CAUSE AN EXPLOSION ORFIRE RESULTING IN PROPERTYDAMAGE, PERSONAL INJURY ORDEATH. THE FURNACE OWNERSHOULD BE CAUTIONED THAT THEFURNACE AREA MUST NOT BEUSED AS A BROOM CLOSET ORFOR ANY OTHER STORAGEPURPOSES.
CAUTION!
WARNING!
WARNING!
WARNING!
WARNING!
TABLE 1
FURNACE BASE BASEWIDTH PLATE NO. PLATE SIZE
14” RXGB-D14 115/8” x 239/16”171/2” RXGB-D17 151/8” x 239/16”21” RXGB-D21 185/8” x 239/16”
241/2” RXGB-D24 255/8” x 239/16”
10
FAILURE TO PREVENT PRODUCTSOF COMBUSTION FROM BEINGCIRCULATED INTO THE LIVINGSPACE CAN CREATE POTENTIALLYHAZARDOUS CONDITIONS,INCLUDING CARBON MONOXIDEPOISONING THAT COULD RESULTIN PERSONAL INJURY OR DEATH.
DO NOT, UNDER ANYCIRCUMSTANCES, CONNECTRETURN OR SUPPLY DUCTWORKTO OR FROM ANY OTHER HEATPRODUCING DEVICE SUCH AS AFIREPLACE INSERT, STOVE, ETC.DOING SO MAY RESULT IN FIRE,CARBON MONOXIDE POISONING,EXPLOSION, PERSONAL INJURYOR PROPERTY DAMAGE.
BLOWER AND BURNERS MUSTNEVER BE OPERATED WITHOUTTHE BLOWER DOOR IN PLACE.THIS IS TO PREVENT DRAWINGGAS FUMES (WHICH COULDCONTAIN HAZARDOUS CARBONMONOXIDE) INTO THE HOME THATCOULD RESULT IN PERSONALINJURY OR DEATH.
UPFLOW UNITS1. Set furnace in place and connect the
return duct or return air cabinet tounit. Make the connection air-tight toprevent entraining combustiongases from any adjacent fuel-burning appliances. Unit return airmay be connected on the sides orbottom of the return aircompartment.
a. Openings in the side must be cutout the full width of the knockoutson the unit. If using side return air,THE BOTTOM base plate mustbe installed.
NOTE: Where the maximumairflow is 1800 CFM or more, bothsides or the bottom must be usedfor return air.
b. If using bottom return air, placefurnace over return air plenum andseal furnace bottom to return airplenum.
A SOLID METAL BASE PLATE, (SEETABLE 1) MUST BE IN PLACEWHEN THE FURNACE ISINSTALLED WITH SIDE AIRRETURN DUCTS. FAILURE TOINSTALL A BASE PLATE COULDCAUSE PRODUCTS OFCOMBUSTION TO BE CIRCULATEDINTO THE LIVING SPACE ANDCREATE POTENTIALLYHAZARDOUS CONDITIONS,INCLUDING CARBON MONOXIDEPOISONING OR DEATH.
2. If summer air conditioning is desired,position the indoor coil on the supplyair side of the furnace. Insure that noair can bypass this coil.
3. Connect the supply air plenum to thefurnace plenum opening.
DOWNFLOW UNITS
THE DOWNFLOW FURNACEDESIGN IS CERTIFIED FORINSTALLATION ON A NON-COMBUSTIBLE FLOOR. IFINSTALLED ON A COMBUSTIBLEFLOOR, USE THE SPECIAL BASESPECIFIED ON THE FURNACECLEARANCE LABEL. FAILURE TOINSTALL THE SPECIAL BASE MAYRESULT IN FIRE, PROPERTYDAMAGE, PERSONAL INJURY ORDEATH. THIS SPECIAL BASE ISSHIPPED FROM THE FACTORY ASAN ACCESSORY.
1. Position the unit over the supply airplenum and connect.a. If installing on a combustible floor
and not using an evaporatorcoil box, install the specialcombustible floor base. SeeFigure 5.
b. If summer air conditioning isdesired, position the indoor coil onthe bottom of the unit. Insure thatno air can bypass this coil.
2. Connect the return air ducting to thereturn air opening at the top of theunit. Make the connection air tight toprevent entraining combustiongases from an adjacent fuel-burningappliance.
HORIZONTAL UNITS1. Unit can be mounted left or right
side airflow configuration.
2. Position the unit on adequatesupports or by using supportbrackets (see Figure 2) and connectsupply plenum.
3. If summer air conditioning is desired,position the indoor coil on the supplyair side of the unit. Insure that no aircan bypass this coil.
4. Secure the four angle bracketsshipped with the unit to the return airopening. See Figure 6. Connect thereturn air ducting to the return airopening at the top of the unit. Makethe connection air tight to prevententraining combustion gases froman adjacent fuel-burning appliance.
NOTE: Do not block furnace accesswith support rods. Maintain clearancesrecommended in Figure 3. Allowenough space for proper servicemaintenance or replacement of theheat exchanger and blower assembly.
WARNING!
WARNING!
WARNING!
FIGURE 5COMBUSTIBLE FLOOR BASE
11
THIS FURNACE AND ANY OTHERFUEL-BURNING APPLIANCE MUSTBE PROVIDED WITH ENOUGHFRESH AIR FOR PROPERCOMBUSTION AND VENTILATIONOF THE FLUE GASES. MOSTHOMES WILL REQUIRE THATOUTSIDE AIR BE SUPPLIED INTOTHE FURNACE AREA. FAILURE TODO SO CAN CAUSE DEATH FROMCARBON MONOXIDE POISONING.
Adequate facilities for providing air forcombustion and ventilation must beprovided in accordance with section5.3, Air for Combustion andVentilation, of the National Fuel GasCode, ANSI, Z223.1 latest edition orCSA B149.1 and .2 or, applicableprovisions for the local building codes,and not obstructed so as to prevent theflow of air to the furnace.
FIGURE 6HORIZONTAL RETURN AIR DUCT(LEFT-HAND AIRFLOW POSITION SHOWN)
FIGURE 7AIR FROM HEATED SPACE
COMBUSTION AIRREQUIREMENTSIMPORTANT: Air for combustion andventilation must not come from acorrosive atmosphere. Any failure dueto corrosive elements in theatmosphere is excluded from warrantycoverage.
The following types of installation mayrequire OUTDOOR AIR forcombustion, due to chemicalexposures:
• Commercial buildings• Buildings with indoor pools• Furnaces installed in laundry rooms• Furnaces in hobby or craft rooms• Furnaces installed near chemical
storage areas.
Exposure to the following substancesin the combustion air supply may alsorequire OUTDOOR AIR forcombustion:
• Permanent wave solutions• Chlorinated waxes and cleaners• Chlorine-based swimming pool
chemicals• Water softening chemicals• De-icing salts or chemicals• Carbon tetrachloride• Halogen type refrigerants• Cleaning solvents (such as
perchloroethylene)• Printing inks, paint removers,
varnishes, etc.• Hydrochloric acid• Cements and glues• Antistatic fabric softeners for clothes
dryers• Masonry acid washing materials
COMBUSTION AND VENTILATION AIR
WARNING!
FOUR ANGLE BRACKETS ARE SHIPPED WITH EACHUNIT THAT CAN BE INSTALLED HORIZONTALLY. THESEBRACKETS MAY BE USED TO SECURE THE RETURNAIR DUCT TO A HORIZONTAL UNIT.
IMPORTANT: This is not a direct vent furnace. Review venting instructionsbefore installing.
RETURN
AIRFLOW
REAR VIEW
12
Combustion air must be free of acidforming chemicals; such as sulphur,fluorine and chlorine. These elementsare found in aerosol sprays,detergents, bleaches, cleaningsolvents, air fresheners, paint andvarnish removers, refrigerants andmany other commercial and householdproducts. Vapors from these productswhen burned in a gas flame form acidcompounds. The acid compoundsincrease the dew point temperature ofthe flue products and are highlycorrosive after they condense.
ALL FURNACE INSTALLATIONSMUST COMPLY WITH THENATIONAL FUEL GAS CODE ANDLOCAL CODES TO PROVIDEADEQUATE COMBUSTION ANDVENTILATION AIR FOR THEFURNACE. FAILURE TO DO SO CANCREATE HAZARDOUS CONDITIONSRESULTING IN PROPERTYDAMAGE, BODILY INJURY ORDEATH FROM SMOKE, FIRE ORCARBON MONOXIDE.
Combustion air requirements aredetermined by whether the furnace isin an open (unconfined) area or in aconfined space such as a closet orsmall room. See Figures 7 and 8.
EXAMPLE 1.FURNACE LOCATED IN ANUNCONFINED SPACE
Using indoor air for combustion.
An unconfined space must have atleast 50 cubic feet for each 1,000BTUH of the total input for allappliances in the space. Here are afew examples of the room sizesrequired for different inputs. The sizesare based on 8 foot ceilings.
BTUH Minimum Sq. Feet Typical Room SizeInput With 8' Ceiling With 8' Ceiling
50,000 312 14*x24* or 18*x18*75,000 469 15*x31* or 20*x24*
100,000 625 20*x31* or 25*x25*125,000 833 23*x34* or 26*x30*150,000 938 25*x38* or 30*x31*
If the open space containing thefurnace is in a building with tightconstruction (contemporaryconstruction), outside air may still berequired for the furnace to operate andvent properly. Outside air openingsshould be sized the same as for aconfined space.
FIGURE 8AIR FROM ATTIC/CRAWL SPACE
EXAMPLE 2.FURNACE LOCATED IN ACONFINED SPACE
A confined space (any space smallerthan shown above as “unconfined”)must have openings into the spacewhich are located in accordance withthe requirements set forth in thefollowing subsections A and B. Size theopenings by how they are connected tothe heated area or to the outside, andby the input of all appliances in thespace.
If confined space is within a buildingwith tight construction, combustion airmust be taken from outdoors or areafreely communicating with theoutdoors.
A. USING INDOOR AIR FORCOMBUSTION, ALL OF THEMODELS (80PS, 80LS)
IMPORTANT: Air should not be takenfrom a heated space with a fireplace,exhaust fan or other device that mayproduce a negative pressure.
If combustion air is taken from theheated area, the openings musteach have at least 100 squareinches of free area. Each openingmust have at least one square inchof free area for each 1,000 Btuh oftotal input in the space. Here aresome examples of typical openingsrequired.
Btuh Free AreaInput Each Opening
100,000 100 Square Inches150,000 150 Square Inches
AIR INTAKE PIPE CONNECTION(80PS ONLY)
A double-elbow may be installed totop inlet air opening, BUT IS NOTREQUIRED. This will help to preventaccidental blockage of the intakeopening. Reference Figure 9 forproper elbow diameter.
NOTE: Inlet is specifically designed toprevent material from being pulled intofurnace. If elbows are not used, theintake opening must be kept clean andfree of debris.
It is also acceptable to run thecondensate drain (or refrigerant)line access over the air intake holeas long as a 1" minimum clearanceis maintained.
B. USING OUTDOOR AIR FORCOMBUSTION, ALL OF THEMODELS (80PS, 80LS)
IMPORTANT: Never takecombustion air from an attic spacethat is equipped with powerventilation.
The confined space mustcommunicate with the outdoorsaccording to Methods 1 and 2. Theminimum air opening dimensionshall not be less than 3 inches.When using ducts, they shall be ofthe same cross-sectional area asthe free area of the openings towhich they connect.
WARNING!
13
a. One square inch for each 3000BTUH of the total input rating of allequipment located in the enclosure,AND
b. Not less than the sum of the areasof all vent connectors in the confinedspace.
IMPORTANT: If the furnace is in alocation with an exhaust fan, theremust be sufficient ventilation to preventthe exhaust fan from creating anegative pressure in the room.
Combustion air openings must NOTBE RESTRICTED in any manner.
CONSULT LOCAL CODES FORSPECIAL REQUIREMENTS.
B: Method 1
Provide two permanent openings,one located within 12 inches of thetop and one located within 12inches of the bottom of theenclosure. Each opening shallcommunicate directly, or by ducts,with the outdoors or spaces (crawlor attic) that freely communicatewith the outdoors.
a. Where directly communicatingwith the outdoors or wherecommunicating to the outdoorsthrough VERTICAL DUCTS,each opening shall have aminimum free area of 1 squareinch for each 4000 BTUH of totalappliance input rating in theenclosure. Here are typical ductsizes:
b. Where communicating withoutdoors through HORIZONTALDUCTS, each opening shall havea minimum free area of 1 squareinch for each 2000 BTUH of totalinput rating for all equipment inthe enclosure. Here are typicalduct sizes:
B: Method 2
One permanent opening, located within12 inches of the top of the enclosure,shall be permitted where theequipment has clearances of at least 1inch from the sides and back and 6inches from the front of the appliance.The opening shall directlycommunicate with the outdoors orcommunicate through a vertical orhorizontal duct to the outdoors orspaces (crawl or attic) that freelycommunicate with the outdoors andhave a minimum free area of:
VERTICAL OUTDOOR AIROPENING DIMENSIONS
BTUH Free Area RoundInput Each Opening Pipe Size
50,000 12.50 sq. inches 4”
75,000 18.75 sq. inches 5”
100,000 25.00 sq. inches 6”
125,000 31.25 sq. inches 7”
150,000 37.50 sq. inches 7”
HORIZONTAL OUTDOOR AIROPENING DIMENSIONS
BTUH Free Area RoundInput Each Opening Pipe Size50,000 25.00 sq. inches 6”
75,000 37.50 sq. inches 7”
100,000 50.00 sq. inches 8”
125,000 62.50 sq. inches 9”
150,000 75.00 sq. inches 10”
FIGURE 9COMBUSTION AIR FITTING – NON-ATTIC COMBUSTION AIR PULL, 80PS ONLY
ATTACH OPTIONAL DOUBLE ELBOW TO TOP INLETAIR OPENING TO PREVENT ACCIDENTAL BLOCKAGEOF INTAKE OPENING. THIS IS NOT A REQUIREMENT.(SEE PREVIOUS PAGE.) SINGLE ELBOW IS ALLOWEDBUT MAY NOT PREVENT DEBRIS FROM BEINGDROPPED INTO THE FURNACE.
GROUND ORSHELF SURFACE
6" MIN.
6" MININUMCLEARANCE
PVCDOUBLEELBOW
#8 SCREWS
METAL FLUEPIPE ONLY
EXHAUST
#8 SCREWS
14
FIGURE 10OUTSIDE AIR USING A HORIZONTAL INLET & OUTLET
FIGURE 11COMBUSTION AIR FITTING – OPTIONAL ATTIC COMBUSTION AIR PULL, UPFLOW/HORIZONTAL MODELS ONLY
B: Method 3, Upflow/Horizontal modelsB: only
For the optimum in quiet operation,attic air may be brought directly to thefurnace.
IMPORTANT: In applications usingMethod 3 for combustion air, the atticmust be ventilated by gable or soffitvents. See Figure 8.
COMBUSTION AIR INTAKESCANNOT BE TERMINATEDOUTSIDE. DOING SO CAN CAUSEIMPROPER OPERATION OF THEFURNACE.
If attic combustion air is used, the inletair opening at the furnace must beprotected from accidental blockage.Install a 90° elbow pointing horizontallyat the top of inlet air pipe. See Figure11 (maximum of 2, 45° or 90° elbows,allowed).
INCLUDINGHORIZONTAL DIRECTION
ATTACH A 90° ELBOW TO TOP INLET AIROPENING TO PREVENT ACCIDENTAL BLOCKAGEOF INTAKE OPENING.
NOTE: Maximum length of pipe thatmay be used for combustion air is 10feet with two elbows. Lengths of morethan 10 feet can result in nuisancepressure switch trips.
CAUTION!
PVCELBOW
#8 SCREWS
#8 SCREW
METAL FLUE PIPE ONLY
10 FT. MAX.
12" MIN. FROMTOP OF INSULATION
6" MINIMUMCLEARANCE
PVCCOUPLER
EXHAUST
ATTIC SPACE
INDOOR SPACE
INSULATION
CAUTION!
USE OF SHEET METALAIR INTAKE PIPEINSTEAD OF PVC MAYRESULT IN NOISE ISSUES.
15
GENERAL INFORMATIONThe furnace must be vented inaccordance with these instructions,National Fuel Gas Code, ANSI Z223.1and/or the Natural Gas InstallationCode, CSA-B149.1 & .2 andrequirements or codes of the local utilityor other authority having jurisdiction.
DEVICES ATTACHED TO THE FLUEOR VENT FOR THE PURPOSE OFREDUCING HEAT LOSS UP THECHIMNEY HAVE NOT BEEN TESTEDAND HAVE NOT BEEN INCLUDED INTHE DESIGN CERTIFICATION OFTHIS FURNACE. WE, THEMANUFACTURER, CANNOT ANDWILL NOT BE RESPONSIBLE FORINJURY OR DAMAGE CAUSED BYTHE USE OF SUCH UNTESTEDAND/OR UNCERTIFIED DEVICES,ACCESSORIES OR COMPONENTS.
DRAFT INDUCER
VENT PIPE ATTACHING HOLESMUST BE PREDRILLED IN THEDRAFT INDUCER COLLAR TOPREVENT DAMAGING THEINDUCER. DRILL 1/8” DIAMETERHOLES THROUGH THE VENT PIPEAND COLLAR AND USE #8SCREWS TO ATTACH. SEE FIGURE12. FAILURE TO FOLLOW THISWARNING CAN CAUSERECIRCULATION OF FLUEPRODUCTS CAUSING CARBONMONOXIDE POISONINGRESULTING IN PERSONAL INJURYOR DEATH.
IMPORTANT APPLICATIONNOTESWhen the furnace is used as areplacement, the existing vent systemshould be inspected to assure thatthere are no obstructions, blockage, orany signs of corrosion and is properlysized for use with this furnace.
NOTE: When the vent table permitsmore than one diameter of pipe for aconnector or vent, the smallestpermitted diameter must be used.
Vent pipe may be type “B-1,” eitherrigid or suitable flexible constructionthat carries a u.l. listing.
Common venting is allowed withvertical B-1 vent systems, and linedmasonry chimneys. Follow the NationalFuel Gas Code, ANSI Z223.1 and/orthe Natural Gas Installation Code,CSA-B149.1 & .2 for proper installationpractices.
NOTE: Follow combustion airinstructions as outlined in this manual.
Single wall vent connectors to “B-1vent or masonry chimneys” may beused under the guidelines of theNational Fuel Gas Code, ANSI Z223.1and/or the Natural Gas InstallationCode, CSA-B149.1 & .2.
The entire length of the ventconnector shall be readilyaccessible for inspection, cleaningand replacement.
WARNING!
WARNING!
FURNACE CATEGORYINFORMATIONThis furnace is shipped as a Category Itype induced draft furnace. A CategoryI furnace operates with a nonpositivevent pressure and has a vent gastemperature at least 140°F above thedew point of the vent gases. ACategory I type may be a draft hoodequipped furnace or have a fanassisted combustion system (induceddraft). The inducer is used to pull flueproducts through the combustionchamber and as they leave thefurnace, most of the energy has beendissipated. The buoyant effect of theflue gases provides venting to theoutdoors.
During the off cycle, the inducer is offand there is very little flow through thevent, cooling the vent. During the oncycle there is no dilution airflow, aswith a draft hood type furnace.Although the vent heats up rapidlywithout dilution air, the flue productscontain more water vapor, whichresults in a higher dew pointtemperature. It is most important thatyou follow the guidelines in theseinstructions to prevent the possibleformation of condensation in theventing system.
As a Category I furnace it may bevented vertically with type B-1 ventpipe and also may be common vented,as described in these instructions.
FIGURE 12ATTACHING TO DRAFT INDUCER COLLAR
VENTING
A0991-01
16
“B-1” VERTICAL VENTINGType “B-1” vents must be installed inaccordance with the terms of theirlistings and the vent manufacturer’sinstructions.
“B-1” vents must be supported andspaced in accordance with their listingsand the manufacturer’s instructions. Allvents must be supported to maintaintheir minimum clearances fromcombustible material.
VERTICAL VENTING
CategorizedFurnace Vent
Input Size Required50K 3”75K *4”
100K *4”125K *5”150K *5”
*NOTE: All furnaces have a 3” ventconnection as shipped from the factory. A 3”to 4” or 3” to 5” vent transition is required onall but the 50,000 BTUH models whenvertically vented or common vented withmetal vent pipes. THE VENT TRANSITIONCONNECTION MUST BE MADE AT THEFURNACE VENT EXIT. It must originatewith an adapter if required, at the furnaceflue collar and terminate either in a listedcap or roof assembly. When commonventing, the vent connector size may differfrom the above diameters depending onapplication. See ANSI Z21.47-1993/CSA-2.3-M93 or latest edition tables.
VERTICAL VENT SYSTEMS:1. A gas vent shall terminate above the
roof surface with a listed cap orlisted roof assembly. Gas vents 12inches in size or smaller with listedcaps shall be permitted to beterminated in accordance withFigure 13, provided they are at least8 feet from a vertical wall or similarobstruction. All other gas vents shallterminate not less than 2 feet abovethe highest point where they passthrough the roof and at least 2 feethigher than any portion of a buildingwithin 10 feet.
2. A type B-1 gas vent shall terminateat least 5 feet in vertical heightabove the highest connectedequipment draft hood or flue collar.
3. Must rise 1/4” per foot away from thefurnace on horizontal runs and besupported with straps or hangers soit has no sags or dips. Supports at 4foot intervals and at all elbows arerecommended.
4. The vent connector must bemechanically fastened to the outletcollar of the furnace with at least (2)sheet metal screws except ventconnectors that are B-1 material.
DO NOT CONNECT THIS FURNACETO A CHIMNEY USED TO VENT ASOLID FUEL APPLIANCE (WOODOR COAL). VENTING WITH A SOLIDFUEL APPLIANCE CAN LEAD TOIMPROPER FUNCTIONING OF THEUNIT, AND DUE TO SOOTING, THEPOSSIBILITY OF FIRE RESULTINGIN PROPERTY DAMAGE,PERSONAL INJURY OR DEATH.
SPECIAL VENT SYSTEMS (SVS)IMPORTANT: It is THE FURNACEMANUFACTURER’s position now thatnew installations of any HTPV pipeused in a category III vent application,including Selkirk’s Selvent™ II HTPVproduct, should cease immediately.
These shall be assembled inaccordance with the manufacturer’sinstructions. See Figure 12.
5. Any angle greater than 45 degreesfrom the vertical is consideredhorizontal. The total horizontaldistance of a vent plus the horizontalvent connector serving draft-hoodequipped appliances shall not begreater than 75 percent of thevertical height of the vent.
NOTE: Refer to the National Fuel GasCode, ANSI Z223.1 and/or the NaturalGas Installation Code, CSA-B149.1 & .2.
Single appliance venting of a fanassisted furnace into a tile-linedmasonry chimney is prohibited. Thechimney must be lined with either TypeB vent or with a listed, single wall,metal lining system. ReferenceNational Fuel Gas Code, ANSI Z223.1and/or the Natural Gas InstallationCode, CSA-B149.1 & .2. See Figure 13for typical B-1 vent chase.
FIGURE 13TYPICAL VENTING WITH “B-1” VENT
WARNING!
17
EXISTING VENT SYSTEMSIMPORTANT RETROFITVENTING INSTRUCTIONSIf this furnace is a replacementinstallation, ALWAYS INSPECT theexisting vent system to be sure thereare no obstructions, blockages, orsigns of corrosion.
When the existing furnace is removedfrom a venting system serving otherappliances, the venting is likely to betoo large to properly vent the remainingattached appliances.
The following steps shall be followedwith each appliance that remainsconnected to the common ventingsystem, while the other appliances thatremain connected to the commonventing systems are not in operation.
NOTE: When the vent table permitsmore than one diameter of pipe for aconnector or vent, the smallestpermitted diameter must be used.1.Seal any unused openings in thecommon venting system.
1. Visually inspect the venting systemfor proper size and horizontal pitchand determine that there is noblockage, restriction, leakage,corrosion or other deficiencies whichcould cause an unsafe condition.
2. Insofar as is practical, close allbuilding doors, windows and alldoors between the space where theappliances remaining connected to
FIGURE 14DEDICATED VENTING THROUGHCHIMNEY WITH “B-1” VENT
the common venting system arelocated. Turn on clothes dryers andany appliance not connected to thecommon venting system. Turn onany exhaust fans, such as rangehoods and bathroom exhausts, sothey will operate at maximum speed.Do not operate a summer exhaustfan. Close fireplace dampers.
3. Follow the lighting instructions.Place the appliance being inspectedinto operation. Adjust the thermostatso the appliance will operatecontinuously.
4. Test for spillage at the draft hoodrelief opening after 5 minutes ofmain burner operation. Use theflame of a match or candle, orsmoke from a cigarette, cigar, orpipe.
5. After it has been determined thateach appliance that remainsconnected to the common ventingsystem properly vents (when testedas outlined above) return doors,windows, exhaust fans, fireplacedampers and any other gas-burningappliance to their previousconditions of use.
6. If improper venting is observedduring any of the above tests, thecommon venting system must beresized. Refer to National Fuel GasCode, ANSI Z223.1 and/or theNatural Gas Installation Code, CSA-B149.1 & .2.
POWER VENT SYSTEMSWhen vertical venting is not possible,the only acceptable method forhorizontal venting is with the use ofTjernlund model GPAK-1TR or FieldControls models SWG-4R powerventer. Type B vent pipe and fittingsmust be used. Common venting is notpermitted
All application and installationinstructions supplied with the powerventer must be followed.
Please address all questions regardingpower venter installation, agencylistings and furnace model compatibilityto:
Tjernlund Products, Inc.(800) 255-4208 or (612) 426-2993
Field Controls L.L.C.(800) 742-8368 or (919) 522-0214
CHIMNEY-FRIENDLYADAPTER SYSTEMThis furnace can be used with chimneyadapter RXGW-B01.
18
FIGURE 15GAS PIPING INSTALLATION
GAS PIPE INSTALLATION
GAS SUPPLY AND PIPINGGAS SUPPLY
THIS FURNACE IS EQUIPPED ATTHE FACTORY FOR USE ONNATURAL GAS ONLY. CONVERSIONTO LP GAS REQUIRES A SPECIALKIT AVAILABLE FROM THEDISTRIBUTOR. FAILURE TO USETHE PROPER CONVERSION KIT CANCAUSE FIRE, CARBON MONOXIDEPOISONING, EXPLOSION,PROPERTY DAMAGE, PERSONALINJURY OR DEATH.
See the conversion kit index suppliedwith the furnace. This index identifiesthe proper LP Gas Conversion Kitrequired for each particular furnace.
IMPORTANT: Any additions, changesor conversions required for the furnaceto satisfactorily meet the applicationshould be made by a qualified installer,service agency or the gas supplier,using factory-specified or approvedparts. In the commonwealth ofMassachusetts, installation must beperformed by a licensed plumber or gasfitter for appropriate fuel.
IMPORTANT: Connect this furnaceonly to gas supplied by a commercialutility.
IMPORTANT: A U.L. recognizedfuel gas and CO detector(s) arerecommended in all applications,and their installation should be inaccordance with the detectormanufacturer’s recommendationsand/or local laws, rules, regulations orcustoms.
GAS PIPING (SEE FIGURE 15)Install the gas piping according to alllocal codes, state codes and regulationsof the utility company, whichever holdsjurisdiction.
If possible, run a separate gas supplyline directly from the meter to thefurnace. Consult the local gas companyfor the location of the manual main shut-off valve. The gas line and manual gasvalve must be adequate in size toprevent undue pressure drop andnever smaller than the pipe size tothe combination gas valve on thefurnace. Refer to Table 2 for the recom-mended pipe size for natural gas andTable 3 for LP gas pipe sizes.
IMPORTANT: It is permissible to runflexible gas connector inside the unit to
! WARNING
a piece of black pipe. If local codesallow the use of a flexible gas applianceconnector, always use a new listedconnector. Do not use a connectorwhich has previously serviced anothergas appliance. Massachusetts lawlimits flexible gas connectors to amaximum of 36”.
Install a ground joint union outsidethe cabinet to easily remove thecontrol valve assembly. Install amanual shut-off valve in the gas lineoutside the furnace casing. The valveshould be readily accessible to turn thegas supply on or off. Install a drip leg inthe gas supply line as close to thefurnace as possible. Always use a pipecompound resistant to the action ofliquefied petroleum gases on allthreaded connections.
IMPORTANT: When making gas pipeconnections, use a back-up wrench toprevent any twisting of the controlassembly and gas valve. Do notovertighten the connection.
Any strains on the gas valve canchange the position of the gas orificesin the burners. This can cause erraticfurnace operation.
IMPORTANT: ENSURE that thefurnace gas control valve not besubjected to high gas line supplypressures.
DISCONNECT the furnace and itsindividual shut-off valve from the gassupply piping during any pressuretesting that exceeds 1/2 PSIG (3.48 kPa).
GROMMET(IN NORMAL POSITION)
GAS VALVE
MANIFOLD
MANIFOLD
FLAME SENSOR
FLAMESENSOR
BURNERS
BURNERS
DIRECT SPARKIGNITOR
DIRECT SPARK IGNITOR
MANUAL GAS VALVE (IN CLOSED POSITION)
UNION
DUCTUNION
DRIP LEG
DRIP LEG
4 TO 5 FEETABOVE FLOOR
REQ'D BY SOMEUTILITIES
4 TO 5 FEETABOVE FLOOR
REQ'D BY SOMEUTILITIES
GROMMET(IN NORMALPOSITION)
UPFLOW & DOWNFLOW
HORIZONTAL
MANUAL GAS VALVE(IN CLOSED POSITION)
GAS VALVE
19
LP CONVERSIONNOTE: For installation, see specific LPkit installation instructions.
The valve can be converted to useliquefied petroleum (LP) gas byreplacing the pressure regulator springwith the conversion kit spring. This LPkit spring allows the regulator tomaintain the proper adjusted manifoldpressure for LP gas. The correct burnerLP orifices are included in the kit.
NOTE: Order the correct LP conversionkit from the local distributor. Furnaceconversion to LP gas must beperformed by a qualified technician.
ELEVATIONS ABOVE 2000 FTREQUIRE THAT THE FURNACEINPUT RATING BE ADJUSTED ANDTHAT THE SIZE OF THE BURNERORIFICES BE RE-CALCULATEDBASED ON ELEVATION AND GASHEATING VALUE. THE BURNERORIFICES MAY (OR MAY NOT) NEEDTO BE CHANGED. SEE THESECTION TITLED “HIGH ALTITUDEINSTALLATIONS” OF THIS BOOKFOR INSTRUCTIONS.
GAS PRESSUREIMPORTANT: The maximum gassupply pressure to the furnace shouldbe 10.5” w.c. for natural gas and 13”w.c. for LP gas.
Natural gas supply pressure shouldoperate between 5" to 10.5” w.c. LPgas supply pressure should be 11” to13” w.c. This pressure must bemaintained with all other gas-firedappliances in operation.
NOTE: Do not exceed a gas pressureof 13” w.c.
ELEVATIONS ABOVE 2000 FTREQUIRE THAT THE FURNACEINPUT RATING BE ADJUSTED ANDTHAT THE SIZE OF THE BURNERORIFICES BE RE-CALCULATEDBASED ON ELEVATION AND GASHEATING VALUE. THE BURNERORIFICES MAY (OR MAY NOT) NEEDTO BE CHANGED. SEE THESECTION TITLED “HIGH ALTITUDEINSTALLATIONS” OF THIS BOOKFOR INSTRUCTIONS.
NEVER PURGE A GAS LINE INTOTHE COMBUSTION CHAMBER.NEVER USE MATCHES, FLAME ORANY IGNITION SOURCE FORCHECKING LEAKAGE. FAILURE TOFOLLOW THIS WARNING CANCAUSE AN EXPLOSION OR FIRERESULTING IN PROPERTYDAMAGE, PERSONAL INJURY ORDEATH.
To check for gas leakage, use anapproved chloride-free soap and watersolution, an electronic combustible gasdetector, or other approved method.
! WARNING
! CAUTION
! CAUTION
NOx MODELSWhen converting furnaces equippedwith NOx inserts to LP gas, remove theNOx insert assemblies. Steps forremoval are listed below:
1. Turn off all electrical power and thegas supply to the furnace.
2. Remove the burner door from thefurnace.
3. Remove the igniter assembly –handle with care.
4. Remove the two screws attachingthe NOx insert retainer brackets tothe center panel. Pull the retainerrod.
5. Put the two screws back into theholes in the center panel.
6. Re-install the igniter and burnerassemblies.
7. Replace burner door.
8. Turn on electrical power and gassupply to the unit.
NOTE: Some NOx models may haveone less NOx insert.
20
TABLE 3LP GAS PIPE CAPACITY TABLE (CU. FT./HR.)
SETTING GAS PRESSUREThe maximum gas supply pressure tothe furnace should be 10.5” w.c.natural gas, or 13” w.c. LP gas. Theminimum supply gas pressure to thegas valve should be 5" w.c. natural gasor 11" w.c. LP gas. A properlycalibrated manometer is required foraccurate gas pressure measurements.
ELEVATIONS ABOVE 2000 FTREQUIRE THAT THE FURNACEINPUT RATING BE ADJUSTED ANDTHAT THE SIZE OF THE BURNERORIFICES BE RE-CALCULATEDBASED ON ELEVATION AND GASHEATING VALUE. THE BURNERORIFICES MAY (OR MAY NOT)NEED TO BE CHANGED. SEE THESECTION TITLED “HIGH ALTITUDEINSTALLATIONS” OF THIS BOOKFOR INSTRUCTIONS.
Supply Gas Pressure Measurement.A line pressure tap is on the inlet sideof the gas valve.
1. With gas shut off to the furnace atthe manual gas valve outside theunit, remove the input pressure tapplug.
2. Connect a U-Tube manometer tothe pressure tap. See Figure 16.
3. Turn on the gas supply andoperate the furnace and all othergas-fired units on the same gasline as the furnace.
4. Adjust the line gas pressure tosupply:
A. 5” - 10.5” w.c. for natural gas.
B. 11” - 13” w.c. for LP gas.
5. Shut off the gas at the manual gasvalve and remove theU-Tube manometer.
6. Replace the pressure tap plugbefore turning on the gas.
NATURAL GAS:If the supply gas line pressure is abovethe operating range, install an in-linegas regulator to the furnace. If supplygas line pressure is below theoperating range, either remove anyrestrictions in the gas supply piping orenlarge the gas pipe. See Table 2.
LP GAS:If the supply gas line pressure is abovethe operating range, have the LPsupplier reduce the line pressure at theregulator. If supply gas line pressure isbelow operating range, have the LPsupplier adjust the line pressure at theregulator. See Table 3.
NOTE: Depending on the amount of LPvapor and the outdoor ambienttemperature, the LP storage tank mayrequire supplemental heat to maintainproper pressure levels. Ensure LPstorage tank does not drop below 15%capacity during heating season.
FIGURE 16TYPICAL HOSE CONNECTION TO LINE PRESSURE TAP
Maximum capacity of pipe in thousands of BTU per hour of undiluted liquefied petroleum gases (at 11 inches watercolumn inlet pressure).(Based on a Pressure Drop of 0.5 Inch Water Column)
Nominal Length of Pipe, FeetIron PipeSize, Inches 10 20 30 40 50 60 70 80 90 100 125 150
1/2 275 189 152 129 114 103 96 89 83 78 69 63
3/4 567 393 315 267 237 217 196 182 173 162 146 132
1 1,071 732 590 504 448 409 378 346 322 307 275 252
1-1/4 2,205 1,496 1,212 1,039 913 834 771 724 677 630 567 511
1-1/2 3,307 2,299 1,858 1,559 1,417 1,275 1,181 1,086 1,023 976 866 787
2 6,221 4,331 3,465 2,992 2,646 2,394 2,205 2,047 1,921 1,811 1,606 1,496
Example (LP): Input BTU requirement of unit, 150,000Equivalent length of pipe, 60 ft. = 3/4" IPS required.
TABLE 2NATURAL GAS PIPE CAPACITY TABLE (CU. FT./HR.)
Capacity of gas pipe of different diameters and lengths in cu. ft. per hr. with pressure drop of 0.3 in. and specificgravity of 0.60 (natural gas).
Nominal Length of Pipe, FeetIron PipeSize, Inches 10 20 30 40 50 60 70 80
1/2 132 92 73 63 56 50 46 433/4 278 190 152 130 115 105 96 901 520 350 285 245 215 195 180 170
1-1/4 1,050 730 590 500 440 400 370 3501-1/2 1,600 1,100 890 760 670 610 560 530
After the length of pipe has been determined, select the pipe size which will provide the minimum cubic feet per hourrequired for the gas input rating of the furnace. By formula:
Gas Input of Furnace (BTU/HR)Cu. Ft. Per Hr. Required = Heating Value of Gas (BTU/FT3)
The gas input of the furnace is marked on the furnace rating plate. The heating value of the gas (BTU/FT3) may bedetermined by consulting the local natural gas utility or the LP gas supplier.
! CAUTION
21
TABLE 4
ADJUSTING OR CHECKINGFURNACE INPUT
ELEVATIONS ABOVE 2000 FTREQUIRE THAT THE FURNACEINPUT RATE BE ADJUSTED ANDTHAT THE SIZE OF THE BURNERORIFICES BE RE-CALCULATEDBASED ON ELEVATION AND GASHEATING VALUE. THE BURNERORIFICES MAY (OR MAY NOT) NEEDTO BE CHANGED. SEE THE SECTIONTITLED “HIGH ALTITUDEINSTALLATIONS” OF THIS BOOKFOR INSTRUCTIONS.
NATURAL GAS:The maximum gas supply pressure tothe furnace should be 10.5” W.C. fornatural gas. The minimum gas supplypressure for purposes of inputadjustment to the furnace should be 5”W.C.
A properly calibrated manometer orgauge is required for accurate gaspressure readings.
The manifold pressure should be set at3.5” W.C. for natural gas. Only smallvariations in the gas flow should bemade by means of the pressureregulator adjustment.
To adjust the pressure regulator:
1. Remove the regulator cap.
2. Turn the adjustment screw clockwiseto increase pressure orcounterclockwise to decreasepressure.
3. Replace the regulator cap securely.
LP GAS:Furnaces for use on LP gas, the LP gassupply pressure must be set between11.0” and 13.0” W.C. by means of thetank or branch supply regulators. Thefurnace manifold pressure should be setat 10” W.C. at the gas control valve. Forelevations up to 8,000 feet, rating plateinput ratings apply. For high altitudes(elevations 8,000 and over) and for anynecessary major changes in the gasflow rate the orifice spud must bechanged.
TO CHANGE ORIFICE SPUDS:
1. Shut off the manual main gas valveand remove the gas manifold.
2. Replace the orifice spuds.
3. Reassemble in reverse order.
4. Turn the gas supply back on andcheck for leaks.
5. Check for proper operation andmanifold pressure.
Check of input is important to preventover firing of the furnace beyond itsdesign-rated input. NEVER SET INPUTABOVE THAT SHOWN ON THERATING PLATE.
TO CHECK FURNACE INPUT:
1. Make certain that all other gasappliances are shut off, with theexception of pilot burners.
2. Start the furnace
3. Time the meter to measure the timerequired to burn one cubic foot ofgas.
4. Use Table 4 to determine input rate.
METER TIME IN MINUTES AND SECONDS FOR NORMALINPUT RATING OF FURNACES EQUIPPED FOR NATURAL OR LP GAS
INPUTBTU/HR
METERSIZE
CU. FT.
HEATING VALUE OF GAS BTU PER CU. FT.900 1000 1040 1100 2500
MIN. SEC. MIN. SEC. MIN. SEC. MIN. SEC. MIN. SEC.ONE 1 5 1 12 1 15 1 18 3 2050,000 TEN 10 50 12 00 12 30 13 12 30 00
ONE 0 44 0 48 0 50 0 53 2 075,000 TEN 7 12 8 0 8 19 8 48 20 0
ONE 0 33 0 36 0 38 0 40 1 30100,000 TEN 5 24 6 0 6 15 6 36 15 0
ONE 0 26 0 29 0 30 0 32 1 12125,000 TEN 4 19 4 48 5 0 5 17 12 0
ONE 0 31 0 24 0 25 0 26 1 0150,000 TEN 3 36 4 0 4 10 4 20 10 0
Heating Value of Gas (BTU/Ft3) x 3600 x correction factorInput BTU/HR =
Time in Seconds (for 1 cu.ft.) of Gas
! CAUTION
22
NOTE: Electric to furnace must besupplied by a commercial utility.Proper voltage is 110-125 volts.
TURN OFF ELECTRIC POWER ATTHE FUSE BOX OR SERVICEPANEL BEFORE MAKING ANYELECTRICAL CONNECTIONS.
ALSO, THE GROUND CONNECTIONMUST BE COMPLETED BEFOREMAKING LINE VOLTAGECONNECTIONS. FAILURE TO DOSO CAN RESULT IN ELECTRICALSHOCK, SEVERE PERSONALINJURY OR DEATH.
IMPORTANT: The furnace must beinstalled so that the electricalcomponents are protected from waterdue to improper flue installation orevaporator condensate drain run-off,etc.
ELECTRICAL CONNECTIONS
THE CABINET MUST BEPERMANENTLY GROUNDED. AGROUND SCREW IS PROVIDED INTHE JUNCTION BOX FOR THISPURPOSE. FAILURE TO DO SO CANRESULT IN FIRE, ELECTRICALSHOCK, PERSONAL INJURY ORDEATH.
The electrical supply requirements arelisted on the furnace rating plate.
Use a separate fused branch electricalcircuit containing a properly sized fuseor circuit breaker. Run this circuitdirectly from the main switch box to anelectrical disconnect which must bereadily accessible and located withinsight of the furnace. Connect from thedisconnect to the junction box on theleft side of the furnace, inside thecontrol compartment. See appropriatewiring diagram.
NOTE: The electrical junction boxinside the furnace control compartmentmay be relocated to the right side ifnecessary. A knockout is provided.
NOTE: L1 (hot) and neutral polaritymust be observed when making fieldconnections to the furnace. Theignition control on electric ignitionmodels will not sense flame if L1 andneutral are reversed.
Installation of the electric supply lineshould be in accordance with theNational Electric Code ANSI/NFPA No.70, latest edition, or CanadianElectrical Code Part 1 - CSA StandardC22.1 and local building codes.
This can be obtained from:
National Fire Protection AssociationBatterymarch ParkQuincy, MA 02269
WARNING!
WARNING!
ELECTRICAL WIRING
thermostat lead wires inside the controlcompartment. Connect the thermostatas shown on the wiring diagram. Neverinstall the thermostat on an outsidewall or where it will be influenced bydrafts, concealed hot or cold waterpipes, lighting fixtures, radiation fromfireplace, rays of sun, lamps, television,radios or air streams from registers.Refer to the instructions packed withthe thermostat for best anticipatoradjustment or selection or see below.
HEAT ANTICIPATOR SETTINGS
For adjusting the thermostat heatanticipator setting; (a) add the currentdraw of the various components in thesystem or (b) using jumper wire,measure the current flow between theR and W thermostat circuits. Set thethermostat heat anticipator accordingto the current flow measured.
Canadian Standards Association178 Rexdale Blvd.Etobicoke (Toronto), OntarioCanada M9W, 1R3
THERMOSTATThe room thermostat must becompatible with the integrated furnacecontrol on the furnace. Generally, allthermostats that are not of the “currentrobbing” type are compatible with theintegrated furnace control used.
NOTE: An isolation relay (part number42-25104-01) may assist with “currentrobbing” type thermostat compatibilityproblems. Use a single-pole, single-throw relay with a 24-volt AC coil. Thecontacts should be rated for .5 ampsminimum at 24 volts. See Figure 17.
Install the room thermostat inaccordance with the instruction sheetin the box with the thermostat. Run the
FIGURE 17ISOLATION RELAY
ST-A0804-01
TABLE 5FIELD WIRE SIZE FOR 24 VOLT CONTROL CIRCUITS
SOLID COPPER WIRE - AWG
3.0 16 14 12
2.5 16 14 12
2.0 18 16 14
50 100 150
LENGTH OF RUN - FEET ➀
➀ Wire length equals twice the run distance
NOTE: Do not use 24 volt control wiring smaller than No. 18.
THER
MOS
TAT
LOAD
- AM
PS
23
FIELD INSTALLED OPTIONACCESSORIESELECTRONIC AIR CLEANER (EAC)Spade terminal for EAC is provided onthese models.
HUMIDIFIERNOTE: There is no “HUM” terminal onupflow models.
NOTE: Maximum current –1.0 ampsfor each option.
FOSSIL FUEL KITRefer to specification sheet forapproved fossil fuel kit number.
RXGW-B01 CHIMNEYADAPTERIMPORTANT: CHIMNEY ADAPTERIS CERTIFIED FOR USE ONUPFLOW MODELS.
This appliance is CSA certified for usewith RXGW-B01 Chimney Adapter.Refer to Kit Installation Instructions 92-101682-01.
FURNACE TWINNINGINSTALLATIONSIMPORTANT: ONLY TWINFURNACES WITH IDENTICALCONTROL BOARDS.
IMPORTANT: TWINNING OF THESEUNITS REQUIRES AN ACCESSORYTWINNING KIT. REFER TO THEFURNACE SPECIFICATION SHEETFOR PROPER KIT. DO NOTATTEMPT TO TWIN THESE MODELSBY USING THE INSTRUCTIONSBELOW.
IMPORTANT: ONLY BOTTOMRETURNS CAN BE USED. NO MORETHAN TWO FURNACES CAN SHARETHE SAME SUPPLY AND RETURN.FURNACES MUST HAVE SAMEHEATING AND BLOWER CAPACITY.TWINNING FURNACES MUSTOPERATE OFF THE SAME PHASEOF POWER.
NOTE: Limit of two furnaces perthermostat.
Twinning operation of two furnaces,installed side-by-side, connected by acommon duct system with main powersupplied by the same source.
The “OK” LED will blink five times iftwinning is not set up properly.
UT ELECTRONIC CONTROLS 1028-928 CONTROL BOARD1. Single Stage Operation
(See Figure 16)a. Control board "ONE" is on
furnace connected to thethermostat.
b. The 24 VAC supply to bothcontrol boards must be in phasewith each other.
c. Connect the "C," "W" and"TWIN" terminals tocounterparts on each control.
d. Both control boards must haveswitch #3 in the "ON" position.
2. Two Stage Operation(See Figure 17)
a. Follow above instructions.Connect "W2" on thermostat to"W" on control board "TWO".
FIGURE 18LINE VOLTAGE CONNECTIONS
UT ELECTRONIC CONTROLS 1097-200 CONTROL BOARD
24
80+ HIGH ALTITUDEINSTRUCTIONS(TABLES 6 & 9)
INSTALLATION OF THIS FURNACEAT ALTITUDES ABOVE 2000 FT (610m) SHALL BE IN ACCORDANCEWITH LOCAL CODES, OR IN THEABSENCE OF LOCAL CODES, THENATIONAL FUEL GAS CODE, ANSIZ223.1/NFPA 54 OR NATIONALSTANDARD OF CANADA, NATURALGAS AND PROPANE INSTALLATIONCODE, CAN B149.1.
34" 80 Plus furnaces installed above2,000 ft. require the furnace to be de-rated 4% per thousand feet.
IMPORTANT: Factory installed orificesare calculated and sized based on asea level Natural Gas heating value of1075 BTU per cubic ft.
NOTE: Orifices are available throughyour local distributor.
Reference Tables 6 and 9 forappropriate orifice sizing.
The following are examples of orificesizing using the National Fuel Gas CodeAppendix F:
For a simplified estimation of orifice sizebased on gas heating value andelevation, Tables 6 and 9 may be used.However, calculations are the bestmethod.
Example: 900 BTU/ft3 RegionalNatural Gas Heating Value
I/H = Q25000 / 900 = 27.78 ft3
I = Sea Level input (per burner): 25000H = Sea Level Heating Value: 900Q = 27.78 ft3 Natural Gas per hour.
From Table F.1 of National Fuel GasCode Handbook, 2002 (3.5� w.c.column).
Orifice required at Sea Level: #40
From Table F.4 of National Fuel GasCode Handbook, 2002Orifice required at 5000 ft. elevation (4%de-rate per thousand ft): #42
Orifice required at 8000 ft. elevation (4%de-rate per thousand ft.): #44
Example: 1050 BTU/ft3 RegionalNatural Gas Heating Value
I / H = Q25000 / 1050 = 23.81ft3
I = Sea Level input (per burner): 25000H = Sea Level Heating Value: 1050Q = 23.81 ft3 Natural Gas per hour.
From Table F.1 of Natural Fuel GasCode Handbook, 2002 (3.5� w.c.column).
Orifice required at Sea Level: #43
From Table F.4 of National Fuel GasCode Handbook, 2002
Orifice required at 5000 ft. elevation(4% de-rate per thousand ft.): #45
Orifice required at 8000 ft elevation (4%de-rate per thousand ft): #47
LP GAS (TABLE 7)NOTE: Keep any parts removed duringLP conversion procedure stored withthe product literature for future use.
LP Gas is a manufactured gas that hasconsistent heating value across mostregions.
The NFGC guidelines are used with thefollowing exception:
The recommended LP Gas highaltitude orifice selections differ slightlyin that the NFGC LP orifice chart, asthey are not accurate for Rheemproducts. The National Fuel Gas CodeLP orifices are based on an 11" ofwater column pressure at the orifice,which differs from products that use 10"of water column at the orifice. Thisdifference requires a deviation from theNFGC orifice size recommendations.The Sea Level input should still bereduced by 4% per thousand ft. and theorifice size must be selected based onthe reduced input in Table 7.
FIGURE 19MANIFOLD PRESSURE-CHANGE LABEL
THE MANIFOLD PRESSURE OF THIS APPLIANCE HAS BEEN FIELD ADJUSTED TO OBTAIN THE CORRECT INPUT RATING FOR INSTALLATION AT ALTITUDES
BETWEEN 2,000 FEET AND 4,500 FEET ELEVATION.
LA PRESSION DU DISTRIBUTEUR D'ALIMENTATION DE CET APPAREIL A ÉTÉ AJUSTÉ SUR LES LIEUX AFIN D'OBTENIR LA BONNE PUISSANCE D'ENTRÉE POUR
UNE INSTALLATION ENTRE 2000 ET 4500 PIEDS D'ALTITUDE.
92-24399-01-01
! CAUTION
Natural Gas Orifice Drill Size (4% per 1000 ft. De-Rate)IMPORTANT: 80+ Models only. Do not use this chart for any 90+ Models.
Burner Input (per burner) 25,000 BTU @ Sea Level
Sea level 2000 to 3000 to 4000 to 5000 to 6000 to 7000 to 8000 toto 1999 ft 2999 ft 3999 ft 4999 ft 5999 ft 5999 ft 7999 ft 8999 ft
38 39 40 41 41 42 42 4340 41 42 42 42 43 43 4441 42 42 42 43 43 44 4442 42 43 43 43 44 44 4543 44 44 44 45 45 46 47
Annual Avg. HeatValue (btu per ft3)
850900975
10751170
TABLE 6
TABLE 7LP GASIMPORTANT: 80+ MODELS ONLY! DO NOTUSE THIS CHART WITH ANY 90+ MODELS.
Input (per OrificeAltitude burner) 25000 Size
0 to 2000 ft. 25000 #542000�-3000� 24000 #543000�-4000� 23000 #544000�-5000� 22000 #545000�-6000� 21000 #546000�-7000� 20000 #547000�-8000� 19000 #558000�-9000� 18000 #559000�-10000� 17000 #55
25
ORIFICE ORDERINGINFORMATIONOrifice sizes are selected by adding the2-digit drill size required in the orificepart number. Drill sizes available are 39through 64; metric sizes available1.10mm (-90) and 1.15mm (-91):
Orifice Part Number 62-22175-(drill size)
Example 1:# 60 drill size orifice requiredPart # 62-22175-60
Example 2:1.15mm drill size orifice requiredPart # 62-22175-91
ALTERNATE METHOD FORCANADIAN HIGH-ALTITUDEDERATEIn Canada, unless an orifice change isspecifically mandated by local codes,an alternate method of altitude derationthrough a reduction in manifoldpressure is acceptable as described inTable 8. This information is based on aheating value of 1000 BTU per cubicfeet of natural gas, and 2500 BTU percubic feet of LP gas. IMPORTANT: Actual input rates mustbe measured onsite with manifoldpressure adjustment to ensure that anactual 10% reduction in input rate isachieved.Once this field adjustment has beenmade, the label shown in Figure 19must be affixed in a conspicuouslocation on the front of the furnacecabinet.NOTE: This label is supplied in theinformation packet shipped with eachfurnace.
TABLE 8ALTERNATE METHOD FOR CANADIAN HIGH-ALTITUDE DERATEIMPORTANT: 80+ MODELS ONLY! DO NOT USE THIS CHART WITH ANY 90+ MODELS.
NATURAL GAS LP GAS
ALTITUDE INPUT OUTPUTORIFICE
SIZEMANIFOLDPRESSURE
0’ - 2000’
50,00075,000100,000125,000150,000
40,00060,00080,000100,000120,000
#42 3.5” W.C.
2001’ - 4500’
45,00067,50090,000112,500135,000
36,00054,00072,00090,000108,000
#42 2.9” W.C.
ALTITUDE INPUT OUTPUTORIFICE
SIZEMANIFOLDPRESSURE
0’ - 2000’
50,00075,000100,000125,000150,000
40,00060,00080,000100,000120,000
#54 10” W.C.
2001’ - 4500’
45,00067,50090,000112,500135,000
36,00054,00072,00090,000108,000
#54 8.1” W.C.
26
TA
BL
E 9
SU
PP
LE
ME
NT
AL
OR
IFIC
E S
IZE
CH
AR
T
80 P
lus
Mod
els
only
with
25,
000
Btu
's p
er B
urne
r. D
o no
t use
this
cha
rt fo
r an
y 90
+ m
odel
s.
NA
TU
RA
L G
AS
QU
ICK
RE
FE
RE
NC
E C
HA
RT
FO
R O
RIF
ICE
SE
LEC
TIO
N, A
T 3
.5"
W.C
. AN
D A
PP
RO
XIM
AT
E F
INA
L F
IRIN
G R
AT
ES
Fin
al F
iring
Rat
e pe
r B
urne
r
Sea
Lev
elO
rifi
ceS
ize
Sea
Lev
elC
ub
icF
oo
t at
3.5"
W.C
.
80 P
lus
Hea
tV
alu
e at
25,0
000-
999
1000
-199
920
00-2
999
3000
-399
940
00-4
999
5000
-599
960
00-6
999
7000
-799
980
00-8
999
9000
-999
9
EL
EV
AT
ION
CH
AR
T (
NF
G r
eco
mm
end
ed o
rifi
ce b
ased
on
4%
der
ate
for
each
100
0 fo
ot
of
elev
atio
n, b
ased
on
th
e in
ters
ecti
on
of
the
ori
fice
req
uir
ed a
t S
ea L
evel
an
d t
he
elev
atio
n r
equ
ired
bel
ow
)
3730
.63
816
3737
3839
3940
4142
4243
3829
.25
855
3838
3940
4141
4242
4343
3928
.288
739
3940
4141
4242
4343
44
4027
.03
925
4040
4142
4242
4343
4444
4125
.98
962
4141
4242
4243
4344
4445
4224
.95
1002
4242
4243
4343
4444
4546
4322
.39
1117
4343
4444
4445
4546
4747
4421
.01
1190
4444
4545
4546
4747
4848
25,0
0024
,000
23,0
0022
,000
21,0
0020
,000
19,0
0018
,000
17,0
0016
,000
All
calc
ula
tio
ns
are
per
form
ed b
y u
sin
g t
he
firs
t th
ree
colu
mn
s o
f in
form
atio
n o
nly
. Bef
ore
beg
inn
ing
an
y ca
lcu
lati
on
s, d
eter
min
e th
e in
div
idu
al b
urn
er B
tu s
ize
and
hea
tin
g v
alu
e at
Sea
Lev
el f
or
the
inst
alla
tio
n s
ite.
Eac
h v
alu
e sh
ow
n in
th
e H
eat
Val
ue
colu
mn
is p
er b
urn
er a
t 3.
5" W
.C.
NO
TE
: H
eat V
alue
at S
ea L
evel
, for
the
loca
tion
of th
e in
stal
latio
n, is
ava
ilabl
e fr
om th
e N
atur
al G
as S
uppl
ier
to th
at s
ite. O
rific
es fo
r al
l alti
tude
s ar
e ba
sed
on S
ea L
evel
val
ues.
Div
ide
the
indi
vidu
al b
urne
r ca
paci
ty (
25,0
00 fo
r 80
plu
s) b
y th
e H
eat V
alue
for
the
site
to d
eter
min
e th
e C
ubic
Foo
t val
ue a
t Sea
Lev
el, o
r di
vide
bur
ner
capa
city
by
the
Cub
icF
oot v
alue
for
the
Hea
t Val
ue. O
nce
you
have
eith
er th
e C
ubic
Foo
t Val
ue o
r th
e H
eat V
alue
you
can
est
imat
e th
e S
ea L
evel
orif
ice
for
the
site
. To
sele
ct th
e co
rres
pond
ing
high
alti
tude
orif
ice,
loca
te th
e si
te e
leva
tion
on th
e ch
art a
bove
and
the
orifi
ce r
equi
red
at S
ea L
evel
from
you
r ca
lcul
atio
n in
the
first
col
umn.
The
cor
rect
hig
h al
titud
e or
ifice
that
mus
t be
inst
alle
d in
eac
h in
divi
dual
bur
ner
is th
e in
ters
ectio
n of
thes
e tw
o po
ints
on
the
char
t abo
ve.
27
LIGHTING INSTRUCTIONSThis appliance is equipped with a directspark ignition device. This device lightsthe main burners each time the roomthermostat (closes) calls for heat. Seelighting instructions on the furnace.TO START FURNACE
1. BE SURE THAT THE MANUAL GASVALVE HAS BEEN IN THE “OFF”POSITION FOR AT LEAST FIVEMINUTES. DO NOT ATTEMPT TOMANUALLY LIGHT THE MAINBURNERS. FAILURE TO FOLLOWTHIS WARNING CAN CAUSE AFIRE OR AN EXPLOSIONRESULTING IN PROPERTYDAMAGE, PERSONAL INJURY ORDEATH.
2. Set the thermostat to lowest setting.3. Turn off all electric power to the
appliance.4. This appliance does not have a pilot.
It is equipped with an ignition devicewhich automatically lights the burner.Do NOT try to light the burner by hand.
5. Remove burner compartment door.6. Move switch to the "OFF" position.
NOTE: Use only your hand to movethe gas control switch. Never usetools. If the switch will not move byhand, don't try to repair it; call aqualified service technician. Forceor attempted repair may result in afire or explosion.
7. Wait five (5) minutes to clear out anygas. Then smell for gas, includingnear the floor. If you smell gas, STOP!Follow the safety instructions on thefront page of this manual. If you don'tsmell gas, go to the next step.
8. Move switch from "OFF" position to"ON" position.
9. Replace burner compartment door.10.Turn on all electric power to the
appliance.11.Turn manual gas valve to the “ON”
position.12.Set the thermostat to desired setting.13. If the appliance will not operate, follow
the instructions below to shut downfurnace and call your servicetechnician or gas supplier.
TO TURN OFF GAS TO FURNACE1. Set the thermostat to the lowest setting.2. Turn off all electric power to the
appliance if service is to be performed.3. Turn manual gas valve to the “OFF”
position.4. Remove control door.5. Move switch to the "OFF" position.6. Replace control door.
WARNING!
SHOULD OVERHEATING OCCUR ORTHE GAS SUPPLY FAIL TO SHUTOFF, SHUT OFF THE MANUAL GASVALVE TO THE APPLIANCE BEFORESHUTTING OFF THE ELECTRICALSUPPLY. FAILURE TO DO SO CANCAUSE AN EXPLOSION OR FIRERESULTING IN PROPERTY DAMAGE,PERSONAL INJURY OR DEATH.
SEQUENCE OF OPERATIONUT Electronic Controls Direct SparkIgnition1. Each time the thermostat contacts
close, the induced draft blower(inducer) begins a prepurge cycle.
2. The air proving negative pressureswitch(es) closes.
3. 30 seconds after the pressureswitch(es) close, the sparkigniter energizes. The induceddraft blower operates for thecomplete heating cycle.
4. After the spark igniter energizes,the gas valve opens for a 8second trial for ignition.
5. The igniter lights the gas burners.6. After the gas valve opens the
flame sensor must prove flameignition for one second using theprocess of flame rectification. If theburners don’t light, the systemgoes through another ignitionsequence. It does this up to fourtimes.
7. The main blower starts 20 secondsafter the burners ignite.
8. When the thermostat cycle ends,the gas valve closes, the burnersgo out, the induced draft blowerstops after a 10-second post-purge, and the negative pressureswitch(es) open.
9. The main blower continues untiltimed off by the setting on theintegrated furnace control board.
Sequence if the system doesn’t lightor doesn’t sense flame:1. On a call for heat, the control runs
the inducer for 30 seconds to pre-purge.
2. After the 30-second pre-purge, thespark igniter energizes. Theinducer continues to run.
3. After the spark igniter energizes,the gas valve opens for an 8-second trial for ignition. Theinducer continues and the igniterstays energized.
4. If flame is not sensed within 8seconds after the gas valve opens,the gas valve closes, the igniter de-energizes and:
5. The inducer completes a 10-second post-purge, the inducerstops, and the control verifies thatthe pressure switch has opened.Once the open pressure switch isconfirmed, the control begins the
next ignition cycle by energizingthe inducer for a pre-purge of 30seconds. After the pre-purge, theigniter energizes and the gas valveopens (inducer continues to run). Ifno flame is sensed on the secondattempt, the control goes into a“self-healing” mode, in which theblower and the inducer run for 3minutes before another ignitionattempt is made.
6. The control attempts to ignite up tofour times (first attempt followed bythree retries). After the fourthfailure to ignite, the control goesinto a one-hour “soft-lockout”during which the control will notrespond to the thermostat heat call(W). The lockout can be reset byshutting off main power to thefurnace for five seconds, or byturning the heat call (W) from thethermostat off and then back on.
7. The above sequence will repeatafter a one hour delay. It willcontinue repeating until ignition issuccessful or the call for heat isterminated.
8. To reset the lock out, make andbreak power either at thethermostat or at the unit disconnectswitch for 5 to 10 seconds. It thengoes through another set of trialsfor ignition.
WARNING!
START-UP PROCEDURE
28
SETTING BLOWER TIMINGS*NOTE: These taps are not available onUT Electronic Controls 1097-200.
NOTE: This does not apply to UTElectronic Controls 1097-200 modelsbecause the heat tap functions as thecontinuous fan tap as well.
See Figure 20 for instructions for settingthe blower “OFF” timings.
GAS FURNACE (DIRECTDRIVE) INSTRUCTIONS FORCHANGING BLOWER SPEED
DISCONNECT THE ELECTRICALSUPPLY TO THE FURNACE BEFOREATTEMPTING TO CHANGE THEBLOWER SPEED. FAILURE TO DOSO CAN CAUSE ELECTRICALSHOCK RESULTING IN SEVEREPERSONAL INJURY OR DEATH.
The blower motor is wired for blowerspeeds required for normal operationas shown.
If additional blower speed taps areavailable, speeds may be changed ifnecessary to fit requirements of theparticular installation. Check motor leadcolor for speed designation.
Heating speeds should not be reducedwhere it could cause the furnace airtemperature to rise to exceed themaximum outlet air temperaturespecified for the unit.
IMPORTANT: Always check airtemperature rise after changing theheating speed for any reason or if thereare any changes to the duct system.
WARNING!
FIGURE 20UT Electronic Controls 1097-200BLOWER OFF TIMINGS
29
AIR FLOWThe importance of proper air flow overthe heat exchanger cannot be overemphasized.
IT IS IMPORTANT THAT EACH DUCTSYSTEM BE SIZED AND INSTALLEDFOR THE SPECIFIC APPLICATIONBY PROPERLY APPLYING THEAPPROPRIATE INDUSTRYACCEPTED STANDARD. IF LESSTHAN MINIMUM STANDARDS AREAPPLIED, THE EQUIPMENT USERCOULD EXPECT TO EXPERIENCEHIGHER UTILITY BILLS, MAJORCOMPONENT FAILURE, VARYINGDEGREES OF AIR NOISE OR OTHERUNSATISFACTORY ISSUES, OVERWHICH THE MANUFACTURER HASNO CONTROL.One of the most common causes ofheat exchanger failure is overheatingdue to low air flow. An air flow table islocated inside the blower door and onthe following pages.
TEMPERATURE RISE CHECKTo determine if the air flow is correct,make a temperature rise check.1. Insert a thermometer in the supply
air duct as close to the furnace aspossible yet out of a direct line fromthe heat exchanger. See Figure 21.
2. Insert a thermometer in the returnair duct as close to the furnace aspossible.
3. Operate the furnace.4. When the thermometer in the
supply air duct stops rising(approximately five minutes),subtract the return air temperaturefrom the supply air temperature.The difference is the temperaturerise.
5. Compare the measuredtemperature rise to the approvedtemperature rise range listed onthe furnace name plate. See Figure22.
If the measured temperature rise isabove the approved range, either the airflow is too low or the manifold pressureneeds to be adjusted. More air must bemoved by speeding up the blower, byremoving restrictions in the ductsystem, or by adding more supply orreturn air duct. If the measuredtemperature rise is below the approvedrange, either the air flow is too much orthe manifold pressure needs to beadjusted. Use lower speed tap on themulti-speed blower.IMPORTANT: The measuredtemperature rise should be in themiddle of the range.IMPORTANT: Some high-efficiencyfilters have a greater than normalresistance to airflow. This canadversely affect furnace operation. BESURE TO CHECK AIRFLOW if usingany filter other than factory-providedfilter.
FIGURE 21TEMPERATURE RISE MEASUREMENT
LUBRICATIONThe indoor blower motor and induceddraft motor are prelubricated by themotor manufacturer and do not requirefurther attention.The motors must be cleanedperiodically by a qualified installer,
FIGURE 22TYPICAL FURNACE NAME PLATE
service agency, or the gas supplier toprevent the possibility of overheatingdue to an accumulation of dust and dirton the windings or on the motor exterior.Air filters should be kept clean. Dirtyfilters can restrict airflow and results inmotor overheating.
CAUTION!
AIR CONDITIONING DIVISIONFORT SMITH, ARKANSAS
30
BLOWER PERFORMANCE DATA – DOWNFLOW MODELS
50K 11 x 6[279 x 152]
11 x 6[279 x 152]
11 x 7[279 x 178]
11 x 7[279 x 178]
11 x 10[279 x 254]
11 x 10[279 x 254]
1/2[373]
1/2[373]
1/2[373]
1/2[373]
1/2[373]
3/4[559]
LOW 735 [347] 715 [337] 690 [326] 660 [311] 635 [300] 605 [286] 575 [271]MED-LO 1025 [484] 1015 [479] 995 [470] 975 [460] 955 [451] 930 [439] 905 [427]MED-HI 1185 [559] 1165 [550] 1150 [543] 1130 [533] 1100 [519] 1075 [507] 1040 [491]HIGH 1345 [635] 1330 [628] 1310 [618] 1295 [611] 1265 [597] 1235 [583] 1205 [569]
LOW 1210 [571] 1205 [569] 1195 [564] 1180 [557] 1165 [550] 1155 [545] 1130 [533]MEDIUM 1580 [746] 1560 [736] 1550 [732] 1530 [722] 1495 [706] 1465 [691] 1430 [675]
HIGH 1915 [904] 1880 [887] 1825 [861] 1790 [845] 1740 [821] 1675 [791] 1600 [755]
LOW 1070 [505] 1055 [498] 1040 [491] 1010 [477] 980 [477] 945 [446] 905 [427]MEDIUM 1240 [585] 1210 [571[ 1190 [562] 1165 [550] 1135 [536] 1095 [517] 1055 [498]
HIGH 1420 [670] 1395 [658] 1370 [647] 1340 [632] 1305 [616] 1265 [597] 1220 [576]
LOW 1303 [615] 1304 [615] 1280 [604] 1250 [590] 1222 [577] 1188 [561] 1160 [547]MEDIUM 1697 [801] 1674 [790] 1655 [781] 1638 [773] 1621 [765] 1581 [746] 1542 [728]
HIGH 2078 [981] 2068 [976] 2037 [961] 2010 [949] 1988 [938] 1938 [915] 1898 [896]
LOW 1690 [798] 1670 [788] 1655 [781] 1615 [762] 1585 [748] 1565 [739] 1525 [720]MEDIUM — 2085 [984] 2055 [970] 2005 [946] 1970 [930] 1945 [918] 1880 [887]
HIGH — 2410 [1137] 2355 [1111] 2305 [1088] 2240 [1057] 2165 [1022] 2100 [991]
LOW 1104 [521] 1081 [510] 1050 [496] 1025 [484] 999 [471] 971 [458] 940 [444]MEDIUM 1284 [606] 1269 [599] 1236 [583] 1206 [569] 1179 [556] 1139 [538] 1102 [520]
HIGH 1478 [698] 1438 [679] 1397 [659] 1362 [643] 1392 [657] 1282 [605] 1242 [586]75K
75K
100K
100K
100K
11 x 10[279 x 254]
11 x 10[279 x 254]
3/4[559]
3/4[559]
LOW — 1690 [798] 1660 [783] 1635 [772] 1580 [746] 1535 [724] 1480 [698]MEDIUM — 2090 [986] 2035 [960] 1985 [937] 1930 [911] 1850 [837] 1785 [842]
HIGH — 2395 [1130] 2335 [1102] 2260 [1067] 2185 [1031] 2080 [982] 1965 [927]
LOW 1675 [791] 1650 [779] 1620 [765] 1570 [741] 1545 [729] 1485 [701] 1425 [673]MEDIUM 2105 [993] 2075 [979] 2035 [960] 1990 [939] 1955 [923] 1900 [897] 1815 [857]
HIGH — — — — — — —
120K
150K
3
3
4
3
5
5.5
5
5
INPUTTONSBLOWER
SIZE[mm]
MOTORH.P.[W]
BLOWERSPEED
.1 [.02] .2 [.05] .3 [.07] .4 [.10] .5 [.12] .6 [.15] .7 [.17]
CFM [L/s] AIR DELIVERYEXTERNAL STATIC PRESSURE INCHES [kPa] WATER COLUMN
IMPORTANT: Airflow must be checked at the return and the furnace outlet ahead of the coil.NOTES: Airflow external static pressure does not include filter or coil.
Note: Recommended blower speeds are in bold.
BLOWER PERFORMANCE DATA – UPFLOW/HORIZONTAL MODELS
IMPORTANT: Airflow must be checked at the return and the furnace outlet ahead of the coil.NOTES: Airflow external static pressure does not include filter or coil.
50K 11 x 6[279 x 152]
11 x 7[279 x 178]
11 x 7[279 x 178]
11 x 7[279 x 178]
11 x 10[279 x 254]
11 x 10[279 x 254]
11 x 10[279 x 254]
11 x 10[279 x 254]
1/2[373]
1/2[373]
1/2[373]
1/2[373]
1/2[373]
3/4[559]
3/4[559]
3/4[559]
LOW 675 [319] 655 [309] 635 [300] 610 [288] 585 [276] 555 [262] 520 [245]MED-LO 950 [448] 930 [439] 905 [427] 880 [415] 860 [406] 830 [392] 800 [380]MED-HI 1115 [526] 1090 [514] 1070 [505] 1040 [491] 1015 [479] 985 [465] 945 [446]HIGH 1270 [599] 1250 [590] 1225 [578] 1200 [566] 1165 [550] 1130 [533] 1085 [512]
LOW 1245 [588] 1220 [576] 1195 [564] 1165 [550] 1135 [536] 1105 [522] 1065 [503]MED 1555 [734] 1515 [715] 1475 [696] 1435 [677] 1395 [658] 1350 [637] 1300 [614]HIGH 1810 [854] 1755 [838] 1705 [805] 1645 [776] 1585 [748] 1530 [722] 1470 [694]
LOW 1050 [496] 1040 [491] 1030 [486] 990 [467] 960 [453] 920 [434] 890 [420]MED 1220 [576] 1195 [564] 1160 [547] 1140 [538] 1105 [522] 1065 [503] 1020 [481]HIGH 1410 [665] 1380 [651] 1345 [635] 1300 [614] 1255 [592] 1205 [569] 1150 [543]
LOW 1295 [611] 1275 [602] 1250 [590] 1225 [578] 1195 [564] 1165 [550] 1135 [536]MED 1645 [776] 1615 [762] 1580 [746] 1550 [732] 1510 [713] 1465 [691] 1425 [672]HIGH 2045 [965] 2000 [944] 1955 [923] 1905 [899] 1845 [871] 1785 [842] 1720 [812]
LOW 1645 [776] 1615 [762] 1580 [746] 1550 [732] 1510 [713] 1465 [691] 1425 [673]MED 2045 [965] 2000 [944] 1955 [923] 1905 [899] 1845 [871] 1785 [842] 1720 [812]HIGH 2320 [1095] 2260 [1067] 2200 [1038] 2130 [1005] 2060 [972] 1985 [937] 1910 [901]
LOW 1645 [776] 1635 [772] 1615 [762] 1590 [750] 1560 [736] 1520 [717] 1470 [694]MED 2050 [967] 2015 [951] 1980 [934] 1935 [913] 1885 [890] 1835 [866] 1775 [838]HIGH 2365 [1116] 2310 [1090] 2250 [1062] 2185 [1031] 2115 [998] 2035 [960] 1950 [920]
LOW 1620 [765] 1595 [753] 1570 [741] 1545 [729] 1515 [715] 1480 [698] 1440 [680]MED 2010 [949] 1985 [937] 1960 [925] 1915 [904] 1850 [873] 1800 [850] 1730 [816]HIGH 2340 [1104] 2275 [1074] 2215 [1045] 2145 [1012] 2080 [982] 2010 [949] 1940 [916]
LOW 1093 [563] 1066 [503] 1039 [490] 1008 [476] 977 [461] 941 [444] 905 [427]MED 1241 [586] 1212 [572] 1183 [558] 1150 [543] 1118 [528] 1076 [508] 1033 [487]HIGH 1393 [657] 1359 [642] 1326 [626] 1293 [610] 1259 [594] 1214 [573] 1169 [552]
75K
75K
100K
100K
100K
120K
150K
3
3
4
3
4.5
5
5
5
INPUTTONSBLOWER
SIZE[mm]
MOTORH.P.[W]
BLOWERSPEED
.1 [.02] .2 [.05] .3 [.07] .4 [.10] .5 [.12] .6 [.15] .7 [.17]
CFM [L/s] AIR DELIVERYEXTERNAL STATIC PRESSURE INCHES [kPa] WATER COLUMN
Note: Recommended blower speeds are in bold.
31
LIMIT CONTROLThe high limit cut-off temperature is setat the factory and cannot be adjusted.The temperature setting prevents theair temperature leaving the furnacefrom exceeding the maximum outlet airtemperature, which, if exceeded, willshut the furnace down.
There are several reasons for a limitswitch to open and almost alwaysinvolve low airflow through the furnace.
1. A dirty or restricted air filter.
2. A dirty or restricted cooling coil.
3. Undersized or restricted return airsystem.
4. Undersized or restricted supply airsystem.
5. A problem affecting the mainblower:
A. A wrong speed tap selection.
B. Failing motor bearings.
C. Low voltage to the motor.
D. Dirty blower wheel.
E. Wrong motor rotation.
F. Blower wheel slipping on theF. motor shaft.
6. Overfiring the furnace with too muchgas pressure.
7. Ventilation problems.
ROLL-OUT SAFETYSWITCHESFurnaces are equipped with safetyswitches to protect against roll-outconditions in the burner compartment,which, if tripped, will terminate theheating cycle. In the event of a roll-outcondition, the switch will shut thefurnace down. Switches for theupflow/horizontal models furnaces arelocated on either side of the burnercover plate and just above the burnerson the blower divider panel. Thedownflow model requires only oneswitch on the left side of burner coverplate. If a switch is tripped, it must bemanually reset. DO NOT jumper orreset this switch. If this switch shouldtrip, a qualified installer, service agencyor the gas supplier should be called todiagnose and/or correct the source oftripping. If this unit is mounted in acloset, the door must be closed whenmaking this check.
PRESSURE SWITCHThis furnace is equipped with anormally-open pressure switch thatmonitors pressure conditions within thefurnace vent system during the heatingcycle.
There are several reasons for thepressure switch not to close.
1. An inoperative induced draft blower.
2. A loose or leaky pressure switchhose.
3. A blockage in the vent.
4. Severe downdrafts canceling thedraft from the inducer fan.
5. A leaky gasket at the induced draftblower.
6. Improperly sized or installed vent.
The pressure switch contacts mustopen before the unit can go throughanother heating cycle.
See troubleshooting chart in this bookfor troubleshooting recommendations.
SAFETY FEATURES
32
FIGURE 23FILTER RETAINING ROD
DISCONNECT MAIN ELECTRICALPOWER TO THE UNIT BEFOREATTEMPTING ANY MAINTENANCE.FAILURE TO DO SO CAN CAUSEELECTRICAL SHOCK RESULTINGIN SEVERE PERSONAL INJURY ORDEATH.
FILTERS
Filter application and placement arecritical to airflow, which may affect theheating and cooling systemperformance. Reduced airflow canshorten the life of the systems majorcomponents, such as motor, limits,elements, heat exchanger, evaporatorcoil or compressor. Consequently, werecommend that the return air ductsystem have only one filter location.The most common location will beinside the furnace or air handler or afilter base. For systems with a returnair filter grill or multiple filter grills, canhave a filter installed at each of thereturn air openings. DO NOT DOUBLEFILTER THE RETURN AIR DUCTSYSTEM. DO NOT FILTER THESUPPLY AIR DUCT SYSTEM.
TABLE 10 FILTER SIZESMAINTENANCEWARNING!
*NOTE: Some filtersmust be ordered orresized to fit certainunits andapplications.
UPFLOW FILTER SIZES AS SHIPPED
PART FURNACE INPUT BOTTOM SIDE QUANTITYNO. WIDTH BTUH SIZE SIZE
54-24094-01 14 50 121/4" X 25" 153/4" X 25" 154-24094-01 171/2" 75 & 100 153/4" X 25" 153/4" X 25" 154-24094-02 21" 100 191/4" X 25" 153/4" X 25" 154-24094-03 241/2" 125 & 150 223/4" X 25" 153/4" X 25" 1
FILTERROD45-24095-01
NOTE: These models are notfactory equipped with filters or filterrods. Filters must be field installed.
IMPORTANT: Do not operate thesystem for extended periods withoutfilters. A portion of the dust entrainedin the air may temporarily lodge in theair duct runs and at the supplyregisters. Any circulated dust particleswill be heated and charred by contactwith the furnace heat exchanger. Thissooty residue will soil ceilings, walls,drapes, carpets, and other householdarticles. Soot damage may also resultwith, or without, filters in place, whencertain types of candles are burned, orcandlewicks are left untrimmed.
If high efficiency filters or electronic aircleaners are used in the system, it isimportant that the airflow is notreduced to maximize systemperformance and life. Always verify thatthe systems airflow is not impaired bythe filtering system that has beeninstalled, by performing a temperaturerise and temperature drop test.
Keep the air filters clean at all times.Vacuum dirt from filter, wash withdetergent and water, air dry thoroughlyand reinstall.
See Table 10 and Figures 24 and 25 forproper filter sizes and locations.
1. 14”- 50,000 BTUH unit requiresremoval of 31/2” segment of filter andframe to get proper width for abottom filter.
2. 21”-100,000 BTUH unit requiresremoval of 31/2” segment of filter andframe to get proper width for a sidefilter.
3. 241/2”-125,000 and 150,000 BTUHunits require removal of 7” segmentof filter and frame to get proper width for a side filter.
33
FIGURE 24UPFLOW FILTER RETAINING ROD (SIDE RETURN)
FILTERROD45-24095-01
FILTER RODSUPPORTANGLEAE-60520-01
FILTER SUPPORTANGLE(SEE ANGLE DETAIL)AE-61883-01
FILTER RODSUPPORTANGLEAE-60520-01
FILTERSUPPORTANGLEAE-61883-01
CUT-OUT AND DRILL DETAILFILTER AND ROD ASSEMBLY
ROD & FILTER SUPPORT ANGLE ASSEMBLY
SOLID BOTTOM MAY BE ORDERED FROM THE FACTORY.
FIGURE 25DOWNFLOW FILTER INSTALLATION
34
SYSTEM OPERATIONINFORMATIONAdvise The Customer To:1. Keep the air filters clean. The heating
system will operate better, moreefficiently and more economically.
2. Arrange the furniture and drapes sothat the supply air registers and thereturn air grilles are unobstructed.
3. Close doors and windows. This willreduce the heating load on thesystem.
4. Avoid excessive use of kitchen &bathroom exhaust fans.
5. Do not permit the heat generated bytelevision, lamps or radios toinfluence the thermostat operation.
6 Except for the mounting platform,keep all combustible articles threefeet from the furnace and ventsystem.
7. IMPORTANT: Replace all blowerdoors and compartment covers afterservicing the furnace. Do not operatethe unit without all panels and doorssecurely in place.
8. Proper operation of the system withconstant air circulation.
COMBUSTIBLE MATERIAL MUSTNOT BE PLACED ON OR AGAINSTTHE FURNACE JACKET OR WITHINTHE SPECIFIED CLEARANCES OFTHE VENT PIPE. THE AREA AROUNDTHE FURNACE MUST BE KEPTCLEAR AND FREE OF ALLCOMBUSTIBLE MATERIALSINCLUDING GASOLINE AND OTHERFLAMMABLE VAPORS AND LIQUIDS.PLACEMENT OF COMBUSTIBLEMATERIALS ON, AGAINST ORAROUND THE FURNACE JACKETCAN CAUSE AN EXPLOSION ORFIRE RESULTING IN PROPERTYDAMAGE, PERSONAL INJURY ORDEATH. THE FURNACE OWNERSHOULD BE CAUTIONED THAT THEFURNACE AREA MUST NOT BEUSED AS A BROOM CLOSET ORFOR ANY OTHER STORAGEPURPOSES.
ANNUAL INSPECTIONThe furnace should operate for manyyears without excessive scale build-upin the flue passageways, however, it isrecommended that a qualified installer,service agency, or the gas supplieractually inspect the flue passageways,the vent system and the main burnersfor continued safe operation payingparticular attention to deterioration fromcorrosion or other sources.
HOLES IN THE VENT PIPE OR HEATEXCHANGER CAN CAUSE TOXICFUMES TO ENTER THE HOMERESULTING IN CARBON MONOXIDEPOISONING OR DEATH. THE VENTPIPE OR HEAT EXCHANGER MUSTBE REPLACED IF THEY LEAK.
• IMPORTANT: It is recommendedthat at the beginning of the heatingseason and approximately midwayin the heating season a visualinspection be made of the mainburner flames for the desired flameappearance by a qualified installer,service agency, or the gas supplier.
• IMPORTANT: It is alsorecommended that at the beginningof the heating season, the flamesensor be cleaned with steel woolby a qualified installer, serviceagency, or the gas supplier.
• IMPORTANT: It is recommendedthat an annual inspection andcleaning of all furnace markings bemade to assure legibility. Attach areplacement marking, which can beobtained through the distributor, ifany are found to be illegible ormissing.
IMPORTANT: FOR Nox MODELS –At the beginning of the heating seasona visual inspection of the Nox deviceshould be made to ensure they havenot become obstructed by insectsnests or anything else which mayeffect performance.
LUBRICATIONThe indoor blower motor and induceddraft motor are prelubricated by themotor manufacturer and do not requirefurther attention.
The motors must be cleanedperiodically by a qualified installer,service agency, or the gas supplier toprevent the possibility of overheatingdue to an accumulation of dust and dirton the windings or on the motorexterior. Air filters should be keptclean. Dirty filters can restrict airflowand results in motor overheating.
Reference Figure 26 for properremoval of the blower assembly ondownflow models.
REPLACEMENT PARTSContact your local distributor for acomplete parts list.
NOx MODELSWhen converting furnaces equippedwith NOx inserts to LP gas, remove theNOx insert assemblies.
TROUBLESHOOTINGRefer to Figure 27 for determiningcause of unit problems.
WIRING DIAGRAMFigure 28 is the complete wiringdiagram for the furnace and powersources.
WARNING!
WARNING!
FIGURE 26DOWNFLOW BLOWER REMOVAL
35
FIGURE 27TROUBLESHOOTING FLOWCHART
GO TOE
WARNINGINTEGRATED FURNACE CONTROL (IFC)TROUBLESHOOTING GUIDE
HAZARDOUS VOLTAGELINE VOLTAGECONNECTIONS
DISCONNECT POWER BEFORE SERVICING.SERVICE MUST BE BY A TRAINED, QUALIFIEDSERVICE TECHNICIAN.
NOTE: Most failures are not due to the IFC. Double check all otherpossibilities, including the ground connection, before replacing the IFC.
NOTE: Always verify gas valve inlet and outlet gaspressure. KEY TO ABBREVIATIONS
IBM = Indoor Blower MotorIDM = Induced Draft MotorIFC = Integrated Furnace ControlPS = Pressure Switch(es)SE = Spark ElectrodeHSI = Hot-Surface IgnitionDSI = Direct-Spark Ignition
FLAME (AMBER) LED CODESOFF = No Flame PresentRAPID BLINK = Unexpected FlameSLOW BLINK = Marginal Flame SenseSTEADY ON = Normal Flame Sense
BLINK CODES (GREEN LED)1 Blink - Soft lockout
Reset System power andstart over from beginning
2 Blinks - PS Circuit opengo to point “F.”
3 Blinks - Limit circuit opengo to point “D.”
4 Blinks - PS Circuit closedGo to point “G.”
5 Blinks - Twin Fault (Optional)*Go to point “H.”
1) Set FAN switch to “AUTO”2) Set thermostat to call for heat (set temp. differ-
ential to greater than 10°F
Does the IDM Energize?
IDM Runs for 30 sec. pre-purge?
Spark Ignitor Electrode (SE) Energizesor HSI Ignitor Glowing?
Does Main Burner Light and stay lit? Is the gas valve energized?
PS dropping out? Check IFC*
Does IBM start on heat speed 20 secondsafter burners light?
Does main burner remain lit untilheat call ends?
Does thermostat maintain reasonable room temperature near setpoint?
Set thermostat to off position (W to C = ØV)
Does gas valve shut off immediately?
Does IDM shut off after ten second post-purge?
Does IBM shut off after a max. of 3 min?
ENDHeat-mode troubleshooting
“POWER” LED ON?
24V on W to IFC?
Is “STATUS” LED blinking,steady-on, or off?
Check IFC*.
Check IFC*.
Does IDM runindefinately.
Does IDM Run for 60 sec. and then off for Five minutes
- Check thermostat in “heat” mode,battery, wire, and connections.
SEE BLINK CODES
- Check 24V at IFC.- Check Fuse.- Check Door Switch and Line Power.- Check Transformer.- Check Breaker.
- Check PS contacts- Check wires for short.- Check IFC*.- Check switches and hoses for
water or moisture
- For Twinned units, check that both IFCs are set for “TWIN” and wiresare connected between “TWIN” terminals.
- Check IFC*.- For twinned units, ensure transformers are in phase.
(if out of phase, flame LED will be dim).- For non-twinned units, ensure “TWIN” is in the single (OFF) position.- For Twinned units – ensure both IFC‘s have same part number.
- Check PS, PS Hoses, and wires.- Check for blocked vent, excessive vent length or elbows, or
blocked heat exchanger.- Check IDM wired correctly.- Ensure against excessive wind, which can open pressure switch.- If downflow 90+, check aux. limit – shoud be closed- Check for intermittent P.S. operation.- Check switches and hoses for water or moisture.
- Check gas supply and manifold pressure.- Ensure L1 and Neutral not swapped on IFC and junction box.- Check SE alignment.- Check orifice or other restrictions to gas flow.- Check flame sense rod (clean with sandpaper).- Check flame carry over.
- Check wires, continuity, and connection between IFC and gas valve.- Ensure 24 V between appropriate pins on connector of IFC.- Ensure manual switch on valve is in the “ON” position.- 90+ check aux. limit open? Should be closed- 90+ upflow models – check drain pressure switch between IFC and
gas valve – should be closed – replace drain pressure switch if drainis not blocked or clear drain if blocked.
- Did a pressure switch open during ignition trial? If yes, go to F- Did a limit open during ignition trial? If yes, go to D- Check line voltage between “HEAT” and “NEUTRAL” on IFC.
- Check wires, connections, and continuity between IFC and IBM.- Check IBM capacitor.- Check IBM.
CHECK:- grounding on IFC and unit.- check for proper polarity between L1 & neutral.- flame sense rod (clean if necessary).- wire continually between flame sense rod and appropriate pin of
connector on IFC- flame carries across all burners, and all burners stay lit.
CHECK:AIRFLOW - ensure no restrictions, such as dirty filter, dampers, closed registers, etc.LIMITS - ensure good wire and connections between IFC and all limits. Make surelimits are not open when circulating air temperature is within a specified range.ROLLOUTS - ensure rollouts or overtemperature limits do not need to be reset. Makesure no flame rollout in burner compartment due to blocked flu or heat exchanger.OVERFIRE - ensure furnace is not overtemperature (temp rise is above stated range).Check gas valve, proper orifice size, gas pressure, etc.
Is Limit circuit or IDM wire through aux. limit open oropening and closing?Note: IFC Status LED should be blinking a Fault Code 3.
Is the IFC sensing a good flame: NOTE:Flame sense light should be steady-onwhen burners are lit. If flame LED blinking,or off, flame sense is low or absent.
Ensure thermostat is properly placed and not improperly affected byregisters, fans, sunlight, heat through walls, pipes, or wires in walls.
- Check heat anticipator setting. Furnace may need an isolation relay.- Check installation instructions under section titled “Isolation Relay” for
details.- Verify correct furnace sizing.
NOTE: If IFC goes into lockout (“STATUS LED will blink code “1”), shutoff main power to unit, wait 30 seconds and then reset power.
PROBLEMSTILL
PRESENT
“STATUS” LEDBLINKING
“FLAME” LED BLINKINGOR STEADY ON
If “E” did notresolve issue
Double check - Is W off at IFC?(W to C = ØV?)
Voltage present at gas valve? - Check gas valve.
SEE BLINK CODES
- Check IFC*.
Check IFC*.
*Most failures are not due to the IFC. Doublecheck all other possibilities, including theground connection or wire connections, beforereplacing the IFC.Ensure TSTAT is not in “FAN” position.
Is “STATUS” LED blinking?Is “FLAME” LED blinking or steady-on?
**System will attempt to light 4 times. Voltageis present at gas valve for only 7 seconds dur-ing each trial for ignition. The entire system willgo into a 1 hour lockout after 4 attempts. Themain blower and IDM will run 180 secondsbetween 2nd and 3rd ignition attempts.
- Check line voltage at IDM.- Check wires and connections between IDM and IFC.- Ensure line voltage on IDM pins of IFC connector.- Check IDM capacitor (90+ only).
CHECK BLINK CODES- Check for open limit or limit circuit.- Check for intermittent PS operation.- Check for vent restrictions.- Ensure vent lengths not excessive or
too small diameter.- Check for blocked heat exchanger.
FOR SPARK IGNITION- Check SE wire & connections.- Clean SE with sandpaper. Replace SE if necessary.- If problem persists, check IFC*.- Check SE gas and proper SE ground.- Check SE wire for spark arcing to metal before electrode.FOR HOT SURFACE IGNITION- Check ignitor connected.- Check ignitor wires.- Check ignitor resistance. If open circuit, low or high resistance, replace.- Check ignitor for fractures or cracking- Check ignitor placement.- If problem persists, check IFC*.
START
REPEAT THIS PROCEDURE UNTIL TROUBLE-FREE OPERATION IS OBTAINED.
NO
NO
NO
If “I” did notresolve issue.
NO NO
NO
NO
NO
NO
NONO
NO
NO
NO
NO
NO
NO
NO
BLINKING
YES
YES
YESYES
YES
YES
YES
YES
YES
YES
YES
YESYES
YES
YES
YES
YES
YES
STEADY-ON
I
D
F
H
E
G
YES
NO
YES
PREPURGE
IGNITION TRIAL
IBM “ON” DELAY
STEADY HEAT
END HEAT CALL
POST-PURGE
IBM “OFF” DELAY
STEADY OFF
NO
OFF
**
92-101654-01-00
GO TOF
GO TOI
PREPURGE
36 CM 0407
FIGURE 28FOR MODELS WITH UT ELECTRONIC CONTROLS 1027-200 INTEGRATED FURNACE CONTROL AND DIRECT SPARK IGNITION