Rheem (-)(-)80MDP100C40SA, (-)(-)80MDP050A30SA, (-)802PA125524MSA, (-)(-)80MDP125D50SA, (-)802PA150524MSA Installation Instructions Manual

ISO 9001:2008

INSTALLATION INSTRUCTIONS

S

T-A1 220 -01 -X0

FOR UPFLOW/HORIZONTAL TWO STAGE GAS FURNACES (-)802P UPFLOW/HORIZONTAL SERIES

(-)(-)80MDP UPFLOW/HORIZONTAL SERIES

U.L. and/or C.S.A. recognized fuel gas and CO (carbon monoxide) detectors are recommended in all applications, and their installation should be in accordance with the manufacturer’s recommendations and/or local laws, rules, regulations, or customs.

 Factory Use Only

92-24161-146-02

SUPERSEDES 92-24161-146-01

TABLE OF CONTENTS

1 TABLE OF CONTENTS. . . . . . . . . . . . . . . . . . . . . . . 2

2 GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . 3

Receiving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Contents

California Proposition 65 Note . . . . . . . . . . . . . . . . . . 4

Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

3 SAFETY INFORMATION. . . . . . . . . . . . . . . . . . . . . . 6

Warnings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Important Information About Efficiency and Quality. . 7

4 LOCATION REQUIREMENTS . . . . . . . . . . . . . . . . . 8

Site Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Clearance – Accessibility . . . . . . . . . . . . . . . . . . . . . . 8

Upflow Dimensions and Clearance Table . . . . . . . . . 9

5 DUCTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Upflow Installations. . . . . . . . . . . . . . . . . . . . . . . . . . 11

Horizontal Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

6 COMBUSTION AND VENTILATION AIR . . . . . . . . 14

Combustion Air Requirements . . . . . . . . . . . . . . . . . 14

Venting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

“B-1” Vertical Venting . . . . . . . . . . . . . . . . . . . . . . . . 19

Special Vent Systems (SVS) . . . . . . . . . . . . . . . . . . 20

Power Vent Systems . . . . . . . . . . . . . . . . . . . . . . . . 22

Existing Vent Systems . . . . . . . . . . . . . . . . . . . . . . . 22

7 GAS SUPPLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Gas Supply and Piping. . . . . . . . . . . . . . . . . . . . . . . 23

Gas Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Gas Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Setting Gas Pressure . . . . . . . . . . . . . . . . . . . . . . . . 26

8 LP CONVERSION . . . . . . . . . . . . . . . . . . . . . . . . . . 27

9 ELECTRICAL WIRING . . . . . . . . . . . . . . . . . . . . . . 28

Reversing The Electrical Connection. . . . . . . . . . . . 28

Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

10 ACCESSORIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Field Installed Option Accessories. . . . . . . . . . . . . . 30

Electronic Air Cleaner. . . . . . . . . . . . . . . . . . . . . . . . 30

Humidifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

RXGW-B01 Chimney Adapter . . . . . . . . . . . . . . . . . 30

Four Inch Flue Adapter. . . . . . . . . . . . . . . . . . . . . . . 30

11 TWINNING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Furnace Twinning Installations. . . . . . . . . . . . . . . . . 32

Control Boards . . . . . . . . . . . . . . . . . . . . . . . . . . 33-35

12 HIGH ALTITUDE . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Natural Gas at High Altitudes . . . . . . . . . . . . . . . . . . 36

LP Gas at High Altitudes. . . . . . . . . . . . . . . . . . . . . . 38

13 STARTUP PROCEDURES . . . . . . . . . . . . . . . . . . . 39

Sequence of Operation . . . . . . . . . . . . . . . . . . . . . . 39

14 DIAGNOSTICS AND FAULT CODES. . . . . . . . . . . 40

15 LOCKOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

16 FIELD SELECTIONS & ADJUSTMENTS . . . . . . . 42

Field Selections – Dipswitches. . . . . . . . . . . . . . . . . 42

17 FAULT CLEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

18 FAULT RECALL. . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

19 FLAME STATUS L.E.D.. . . . . . . . . . . . . . . . . . . . . . 43

20 TIMING DIAGRAM. . . . . . . . . . . . . . . . . . . . . . . . . . 43

21 ADJUSTING OR CHECKING FURNACE INPUT . 44

22 SETTING INPUT RATE . . . . . . . . . . . . . . . . . . . . . . 45

23 AIRFLOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Blower Speed Selection . . . . . . . . . . . . . . . . . . . . . . 47

24 SAFETY FEATURES. . . . . . . . . . . . . . . . . . . . . . . . 48

25 MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

26 SYSTEM OPERATION INFORMATION . . . . . . . . . 50

27 ANNUAL INSPECTION . . . . . . . . . . . . . . . . . . . . . . 50

28 REPLACEMENT PARTS. . . . . . . . . . . . . . . . . . . . . 50

24 TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . 51

30 WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . 52

IMPORTANT: TO INSURE PROPER INSTALLATION AND OPERATION OF THIS PRODUCT, COMPLETELY READ ALL INSTRUCTIONS PRIOR TO ATTEMPTING TO ASSEMBLE, INSTALL, OPERATE, MAINTAIN OR REPAIR THIS PRODUCT. UPON UNPACKING OF THE FURNACE, INSPECT ALL PARTS FOR DAMAGE PRIOR TO INSTALLATION AND START-UP.

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ST-A1220-16-00

1.) DOOR SWITCH

2.) TRANSFORMER

3.) JUNCTION BOX

4.) LOW VOLTAGE TERMINAL

5.)HEAT ASSISTED LIMIT CONTROL (HALC)

6.) SOLID METAL BASE PAN

7.) FURNACE CONTROL

8.) CONTROL MOUNTING PLATE

9.) CAPACITOR

10.) BLOWER

11.) IGNITER

12.) GAS VALVE

13.) INDUCED DRAFT BLOWER

14.) 4” FLUE ADAPTER (OPTIONAL)

15.) COMBUSTION AIR INLET

16.) MAIN LIMIT

17.) COMBUSTION AIR DIFFUSER

18.) PRESSURE SWITCHES, HIGH AND LOW STAGE

19.) OVER TEMPERATURE SWITCH

20.) BURNER

21.) FLAME SENSOR

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GENERAL INFORMATION

NOTE: A heat loss calculation should be performed to properly

determine the required furnace BTU size for the structure. Also, the duct must be properly designed and installed for proper airflow. Existing ductwork must be inspected for proper size and to make sure that it is properly sealed. Proper airflow is necessary for both user comfort and equipment performance.

Before opening the furnace carton, verify that the data tags on the carton specify the furnace model number that was ordered from the distributor and are correct for the installation. If not, return the unit without opening the carton. If the model number is correct, open the carton and verify that the furnace rating label specifies the same furnace model number that is specified on the carton label. If the model numbers do not match, return the furnace to the distributor.

IMPORTANT: Proper application, installation and maintenance of this furnace and system is a must if consumers are to receive the full benefits for which they have paid.

FIGURE 1

FURNACE COMPONENTS

The (-)802P/(-)(-)80MDP series furnaces are design certified by CSA for use with natural and propane gases as follows:

As a Category I furnace, it may be vented vertically with type B1 vent pipe and also may be common vented as described in these instructions.

This furnace should be installed in accordance with the American National Standard Z223.1 - latest edition booklet entitled “National Fuel Gas Code” (NFPA 54), and the requirements or codes of the local utility or other authority having jurisdiction including local plumbing or waste water codes.

With the introduction of higher efficiency furnaces, special attention must be paid to the venting system. Only listed venting systems may be used as stated in the installation instructions and the Na- tional Fuel Gas Code, ANSI Z223.1 (NFPA 54),. Since furnace technology and venting requirements are changing, awareness of local, state, and federal codes and industry changes is imperative.

General Information

ST-A1220-16

3

GENERAL INFORMATION (cont.)

Install this furnace in accordance with the American National Standard Z223.1 – latest edition entitled “National Fuel Gas Code”

NFPA54) or, for Canada, CSA B149.1; Canadian Natural Gas

( and Propane Installation Code and requirements or codes of the local utilities or other authorities having jurisdiction. This is available from the following:

General Information

National Fire Protection Association, Inc. Batterymarch Park Quincy, MA 02269

CSA-INTERNATIONAL 5060 Spectrum Way Mississauga, Ontario Canada L4W5N6 Online: www.csa.ca

RECEIVING

Immediately upon receipt, all cartons and contents should be inspected for transit damage. Units with damaged cartons should be opened immediately. If damage is found, it should be noted on the delivery papers, and a damage claim filed with the last carrier.

• After unit has been delivered to job site, remove carton taking care not to damage unit.

• Check the unit rating plate for unit size, electric heat, coil, voltage, phase, etc. to be sure equipment matches what is required for the job specification.

• Read the entire instructions before starting the installation.

• Some building codes require extra cabinet insulation and gasketing when unit is installed in attic applications.

• If installed in an unconditioned space, apply caulking around the power wires, control wires, refrigerant tubing and condensate line where they enter the cabinet. Seal the power wires on the inside where they exit conduit opening. Caulking is required to prevent air leakage into and condensate from forming inside the unit, control box, and on electrical controls.

• Install the unit in such a way as to allow necessary access to the coil/filter rack and blower/control compartment.

• Install the unit in accordance with any local code which may apply and the national codes. Latest editions are available from: “National Fire Protection Association, Inc., Batterymarch Park, Quincy, MA 02269.” These publications are:

• ANSI/NFPA No. 70-(Latest Edition) National Electrical Code.

• NFPA90A Installation of Air Conditioning and Ventilating Systems.

• NFPA90B Installation of warm air heating and air conditioning systems.

• The equipment has been evaluated in accordance with the Code of Federal Regulations, Chapter XX, Part 3280.

CALIFORNIA RESIDENTS ONLY

IMPORTANT: All manufacturer products meet current Federal

OSHA Guidelines for safety. California Proposition 65 warnings are required for certain products, which are not covered by the OSHA standards.

California's Proposition 65 requires warnings for products sold in California that contain, or produce, any of over 600 listed chemicals known to the State of California to cause cancer or birth defects such as fiberglass insulation, lead in brass, and combustion products from natural gas.

All “new equipment” shipped for sale in California will have labels stating that the product contains and/or produces Proposition 65 chemicals. Although we have not changed our processes, having the same label on all our products facilitates manufacturing and shipping. We cannot always know “when, or if” products will be sold in the California market.

You may receive inquiries from customers about chemicals found in, or produced by, some of our heating and air-conditioning equipment, or found in natural gas used with some of our products. Listed below are those chemicals and substances commonly associated with similar equipment in our industry and other manufacturers.

• Glass Wool (Fiberglass) Insulation

• Carbon Monoxide (CO)

• Formaldehyde

• Benzene

More details are available at the Websites for OSHA (Occupational Safety and Health Administration), at www.osha.gov State of California's OEHHA (Office of Environmental Health Hazard Assessment), at www.oehha.org. portant since the chemicals and substances on the list are found in our daily lives. Most consumers are aware that products present safety and health risks, when improperly used, handled and maintained.

Consumer education is im-

and the

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Installation Instructions remain with the furnace as a reference guide to the servicing contractor. We recommend that performance and installation data be recorded for future reference on this sheet to meet service and warranty

bligations so that job site information is available when required.

o

Installation Checklist

REFER TO INSTALLATION INSTRUCTIONS

GAS SUPPLY

______ Correct pipe size (record size)

______ Correct supply pressure (during furnace operation) (record pressure)

______ Manifold pressure (record upstream pressure)

______ No gas leaks

______ L.P. Kit Number (if applicable) (record kit number)

ELECTRICAL

______ 115 V.A.C. supply (Dedicated Circuit) (record voltage)

______ Polarity observed

______ Furnace properly grounded

Checklist

______ Correct wire size (record type and gauge)

FURNACE INSTALLATION

______ Correct clearance to combustibles (record clearance)

______ Correct clearance for service (at front) (record clearance)

DUCT STATIC PRESSURE

______ in. w.c. on heating speed (record static pressure)

______ in. w.c. on cooling speed (record static pressure)

______ Air temperature rise in heat (record air temperature rise)

______ Air temperature rise in cool (record air temperature rise)

VENTING

______ Correct vent pipe diameter and length (according to NFGC tables) _________________ Vent connection size

______ Correct venting material (according to NFGC 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

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SAFETY INFORMATION

WARNING

!

DO NOT INSTALL THIS FURNACE IN A MOBILE HOME!! THIS FURNACE IS NOT APPROVED FOR INSTALLATION IN A MOBILE HOME. DOING SO COULD CAUSE FIRE, PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.

WARNING

!

INSTALL THIS FURNACE ONLY IN A LOCATION AND POSITION AS SPECIFIED IN THE LOCATION REQUIREMENTS AND CONSIDERATIONS SECTION OF THESE INSTRUCTIONS.

WARNING

!

IMPROPER INSTALLATION, OR INSTALLATION NOT MADE IN ACCORDANCE WITH THE CSA INTERNATIONAL (CSA) CERTIFICATION OR THESE INSTRUCTIONS, CAN RESULT IN UNSATISFACTORY OPERATION AND/OR DANGEROUS CONDITIONS AND ARE NOT COVERED BY THE MANUFACTURER’S WARRANTY.

WARNING

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DO NOT BYPASS, JUMPER, OR REMOVE ANY SAFETY SWITCH FROM THE FURNACE CONTROL CIRCUIT. IF A SAFETY SWITCH CAUSES THE FURNACE TO SHUT DOWN OR OPERATE INTERMITTENTLY, IT IS AN INDICATION OF A POTENTIAL SAFETY HAZARD THAT MUST BE ADDRESSED BY A QUALIFIED TECHNICIAN, SERVICE AGENCY OR THE GAS SUPPLIER. DO NOT RESET SAFETY CONTROLS WITHOUT CORRECTIVE ACTION

Safety Information

AND/OR VERIFICATION OF PROPER SAFE OPERATION BY A QUALIFIED INSTALLER, SERVICE AGENCY OR THE GAS SUPPLIER.

REPLACE ANY SAFETY CONTROL COMPONENT ONLY WITH IDENTICAL OEM REPLACEMENT PARTS. WHEN A NEW SAFETY SWITCH IS INSTALLED, IT MUST BE TESTED FOR A MINIMUM OF 15 MINUTES WITH THE FURNACE OPERATING AT MAXIMUM INPUT RATE AND WITH BOTH BLOWER AND BURNER DOOR INSTALLED. IF THE FURNACE IS INSTALLED IN A CLOSET, THE CLOSET DOOR MUST ALSO BE CLOSED FOR THIS TEST. REPEAT THE TEST AT THE MINIMUM INPUT RATE IF THE FURNACE IS A MULTI-STAGE FURNACE.

WARNING

!

USE ONLY WITH THE TYPE OF GAS APPROVED FOR THIS FURNACE. REFER TO THE FURNACE RATING PLATE.

WARNING

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COMBUSTION AND VENTILATION AIR MUST BE PROVIDED TO THE FURNACE AS REQUIRED BY THE NATIONAL FUEL-GAS CODE (U.S.) AND CSA B149.1 (CANADA) AND THE COMBUSTION AND VENTILATION AIR SECTION OF THESE INSTRUCTIONS.

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WHEN A FURNACE IS INSTALLED SO THAT SUPPLY DUCTS CARRY AIR CIRCULATED BY THE FURNACE TO AREAS OUTSIDE THE SPACE CONTAINING THE FURNACE, THE RETURN AIR SHALL ALSO BE HANDLED BY DUCT(S) SEALED TO THE FURNACE CASING AND TERMINATING OUTSIDE THE SPACE CONTAINING THE FURNACE.

!

WHENEVER THE FACTORY RETURN-AIR CONNECTION IS NOT USED IT MUST BE SEALED. A SOLID METAL BASE PLATE MUST BE INSTALLED AND SEALED. FACTORY BASE PLATES ARE AVAILABLE AS ACCESSORY ITEMS. (PART NUMBERS ARE LISTED IN THE SPEC SHEET FOR THE FURNACE.) FAILURE TO INSTALL AND SEAL THE BASE PLATE AND RETURN AIR DUCT CONNECTIONS MAY ALLOW CARBON MONOXIDE AND OTHER CONTAMINANTS TO BE DRAWN INTO THE CONDITIONED AIR SPACE AND DISTRIBUTED THROUGHOUT THE HEATED SPACE.

!

DO NOT OPERATE THE SYSTEM WITHOUT FILTERS. A PORTION OF THE DUST ENTRAINED IN THE AIR MAY TEMPORARILY LODGE IN THE AIR DUCT RUNS AND AT THE SUPPLY REGISTERS. ANY CIRCULATED DUST PARTICLES WILL BE HEATED AND CHARRED BY CONTACT WITH THE FURNACE HEAT EXCHANGER. THIS SOOTY RESIDUE WILL SOIL CEILINGS, WALLS, DRAPES, CARPETS AND OTHER HOUSEHOLD ARTICLES. SOOT DAMAGE MAY ALSO RESULT WITH, OR WITHOUT, FILTERS IN PLACE, WHEN CERTAIN TYPES OF CANDLES ARE BURNED, OR CANDLEWICKS ARE LEFT UNTRIMMED.

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WARNING

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NEVER TEST FOR GAS LEAKS WITH AN OPEN FLAME. USE A COMMERCIALLY AVAILABLE SOAP SOLUTION MADE SPECIFICALLY FOR THE DETECTION OF LEAKS TO CHECK ALL CONNECTIONS, AS SPECIFIED IN GAS SUPPLY AND PIPING SECTION OF THESE INSTRUCTIONS.

6

WARNING

!

IN COMPLIANCE WITH RECOGNIZED CODES, IT IS RECOMMENDED THAT AN AUXILIARY DRAIN PAN BE INSTALLED UNDER THIS FURNACE AND ANY INSTALLED EVAPORATOR COIL THAT IS LOCATED IN ANY AREA OF A STRUCTURE WHERE DAMAGE TO THE BUILDING OR BUILDING CONTENTS MAY OCCUR AS A RESULT OF AN OVERFLOW OF THE A/C COIL DRAIN PAN.

SAFETY

WARNING

!

BLOWER AND BURNERS MUST NEVER BE OPERATED WITHOUT THE BLOWER DOOR IN PLACE. THIS IS TO PREVENT DRAWING GAS FUMES (WHICH COULD CONTAIN HAZARDOUS CARBON MONOXIDE) INTO THE HOME THAT COULD RESULT IN PERSONAL INJURY OR DEATH.

WARNING

!

ALWAYS INSTALL THE FURNACE TO OPERATE WITHIN THE FURNACE’S INTENDED TEMPERATURE-RISE RANGE WITH A DUCT SYSTEM WHICH HAS AN EXTERNAL STATIC PRESSURE WITHIN THE ALLOWABLE RANGE, AS SPECIFIED IN THE DUCTING SECTION OF THESE INSTRUCTIONS. SEE ALSO FURNACE RATING PLATE.

THE FURNACE MAY BE USED FOR HEATING OF BUILDINGS OR STRUCTURES UNDER CONSTRUCTION.

INSTALLATION MUST COMPLY WITH ALL INSTALLATION INSTRUCTIONS INCLUDING:

PROPER VENT INSTALLATION;

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FURNACE OPERATING UNDER THERMOSTATCONTROL; RETURN AIR DUCT SEALED TO THE FURNACE;

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AIR FILTERS IN PLACE;SET FURNACE INPUT RATE AND TEMPERATURERISE PER RATING PLATE MARKINGS; MEANS FOR PROVIDING OUTDOOR AIR RE-

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QUIRED FOR COMBUSTION; RETURN AIR TEMPERATURE MAINTAINED BE-

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TWEEN 55°F (13°C) AND 80°F (27°C); AND CLEAN FURNACE, DUCT WORK AND COMPO-

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NENTS UPON SUBSTANTIAL COMPLETION OF THE CONSTRUCTION PROCESS, AND VERIFY THAT THE FURNACE OPERATING CONDITIONS INCLUDING IGNITION, INPUT RATE, TEMPERATURE RISE AND VENTING, ACCORDING TO THE INSTRUCTIONS AND CODES.

WARNING

!

DUCT LEAKS CAN CREATE AN UNBALANCED SYSTEM AND DRAW POLLUTANTS SUCH AS DIRT, DUST, FUMES AND ODORS INTO THE HOME CAUSING PROPERTY DAMAGE. FUMES AND ODORS FROM TOXIC, VOLATILE OR FLAMMABLE CHEMICALS, AS WELL AS AUTOMOBILE EXHAUST AND CARBON MONOXIDE (CO), CAN BE DRAWN INTO THE LIVING SPACE THROUGH LEAKING DUCTS AND UNBALANCED DUCT SYSTEMS CAUSING PERSONAL INJURY OR DEATH (SEE FIGURE 2).

• IF AIR-MOVING EQUIPMENT OR DUCTWORK IS LOCATED IN GARAGES OR OFF-GARAGE STORAGE AREAS - ALL JOINTS, SEAMS, AND OPENINGS IN THE EQUIPMENT AND DUCT MUST BE SEALED TO LIMIT THE MIGRATION OF TOXIC FUMES AND ODORS INCLUDING CARBON MONOXIDE FROM MIGRATING INTO THE LIVING SPACE.

• IF AIR-MOVING EQUIPMENT OR DUCTWORK IS LOCATED IN SPACES CONTAINING FUEL BURNING APPLIANCES SUCH AS WATER HEATERS OR BOILERS ALL JOINTS, SEAMS, AND OPENINGS IN THE EQUIPMENT AND DUCT MUST ALSO BE SEALED TO PREVENT DEPRESSURIZATION OF THE SPACE AND POSSIBLE MIGRATION OF COMBUSTION BYPRODUCTS INCLUDING CARBON MONOXIDE INTO THE LIVING SPACE.

FIGURE 2

MIGRATION OF DANGEROUS SUBSTANCES, FUMES, AND ODORS INTO LIVING SPACES

Safety Information

IMPORTANT INFORMATION ABOUT EFFICIENCY AND INDOOR AIR QUALITY

Central cooling and heating equipment is only as efficient as the duct system that carries the cooled or heated air. To maintain efficiency, comfort and good indoor air quality, it is important to have the proper balance between the air being supplied to each room and the air returning to the cooling and heating equipment.

Proper balance and sealing of the duct system improves the efficiency of the heating and air conditioning system and improves the indoor air quality of the home by reducing the amount of airborne pollutants that enter homes from spaces where the ductwork and / or equipment is located. The manufacturer and the U.S. Environmental Protection Agency’s Energy Star Program recommend that central duct systems be checked by a qualified contractor for proper balance and sealing.

Adapted from Residential Duct Diagnostics and Repair, with permission of Air Conditioning Contractors of America (ACCA).

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LOCATION REQUIREMENTS

GENERAL INFORMATION

WARNING

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WHEN THIS FURNACE IS INSTALLED IN A RESIDENTIAL GARAGE, IT MUST BE INSTALLED SO THE BURNERS AND IGNITION SOURCE ARE LOCATED NO LESS THAN

8 INCHES [450MM] ABOVE THE FLOOR. THIS IS TO PRE-

1 VENT THE RISK OF IGNITING FLAMMABLE VAPORS WHICH MAY BE PRESENT IN A GARAGE. ALSO, THE FURNACE MUST BE LOCATED OR PROTECTED TO AVOID PHYSICAL DAMAGE BY VEHICLES. FAILURE TO FOLLOW THESE WARNINGS CAN CAUSE A FIRE OR EXPLOSION, RESULTING IN PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.

1. IMPORTANT: If installing the unit over a finished ceiling or liv- ing area, be certain to install an auxiliary condensate drain pan under the entire unit. This auxiliary drain pan should extend under any evaporator coil installed with the furnace.

2. IMPORTANT: If using a cooling evaporator coil with this fur- nace, be sure the air passes over the heat exchanger before passing over the cooling coil. The cooled air passing over the warm ambient air inside the heat exchanger tubes can cause condensation inside the tubes resulting in corrosion and eventual failure.

If there are manual dampers, they must be equipped to prevent heating or cooling operation unless the damper is in the full heat or cool position.

3. NOTE: This furnace is shipped with heat exchanger support brackets installed under the back of the heat exchanger. These may be removed before installation, but it is not required.

4. IMPORTANT: This furnace is not approved or recommended

for installation on its back, with access doors facing upwards.

5. This furnace is suitable for installation in buildings constructed on-site. This heating unit should be centralized with respect to the heat distribution system as much as practicable.

6. NOTE: These furnaces are approved for installation in attics, as well as alcoves, utility rooms, closets and crawlspaces.

Location

7. IMPORTANT: Support this unit when installed. For attic or crawl space installation, horizontal furnaces may be installed on combustible wood flooring or by using support brackets. See Figure

3.

8. IMPORTANT: If installing in a utility room, be sure the door is wide enough to:

a. allow the largest part of the furnace to pass; or

b. allow any other appliance (such as a water heater) to pass.

WARNING

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THIS FURNACE IS NOT APPROVED OR RECOMMENDED FOR INSTALLATION ON ITS BACK, WITH ACCESS DOORS FACING UPWARDS.

SITE SELECTION

1. Select a site in the building near the center of the proposed, or existing, duct system.

2. Give consideration to the vent system piping when selecting the furnace location. Be sure the venting system can get from the furnace to the termination with minimal length and elbows.

3. Locate the furnace near the existing gas piping. Or, if running a new gas line, locate the furnace to minimize the length and elbows in the gas piping. See Figure 3.

4. Locate the furnace to maintain proper clearance to combustibles as shown in following Figure 4.

WARNING

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DO NOT LIFT THE UNIT BY THE HEAT EXCHANGER TUBES. DOING SO CAN DAMAGE THE HEAT EXCHANGER ASSEMBLY.

CLEARANCE – ACCESSIBILITY

The design of forced air furnaces with input ratings as listed in the tables under Figure 4 are certified by CSA-International for the clearances to combustible materials shown in inches.

See name/rating plate and clearance label for specific model number and clearance information.

Service clearance of at least 24 inches (30 cm) is recommended in front of all furnaces.

NOTE: Use recommended 24” (30 cm) clearance if accessibility clearances are greater than fire protection clearances.

ACCESSIBILITY CLEARANCES, WHERE GREATER, MUST TAKE PRECEDENCE OVER FIRE PROTECTION CLEARANCES.

8

LOCATION REQUIREMENTS

NOTE:

HORIZONTAL LEFT ORIENTATION DEPICTED IN ILLUSTRATION. HORIZONTAL RIGHT ORIENTATION IS SIMILAR IN INSTALLATION.

AI

R

FLO

W

GENERAL INFORMATION (cont.)

WARNING

!

UPFLOW AND HORIZONTAL FURNACES ARE DESIGNCERTIFIED FOR INSTALLATION ON COMBUSTIBLE FLOORS. NOTE, HOWEVER, THAT FURNACES MUST NOT BE INSTALLED DIRECTLY ON CARPETING, TILE OR OTHER COMBUSTIBLE MATERIAL OTHER THAN WOOD FLOORING. INSTALLATION ON A COMBUSTIBLE MATERIAL CAN RESULT IN FIRE, CAUSING PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.

FIGURE 3

ST-A1220-03

WARNING

!

COMBUSTIBLE MATERIAL MUST NOT BE PLACED ON OR AGAINST THE FURNACE JACKET. THE AREA AROUND THE FURNACE MUST BE KEPT CLEAR AND FREE OF ALL COMBUSTIBLE MATERIALS INCLUDING GASOLINE AND OTHER FLAMMABLE VAPORS AND LIQUIDS. PLACEMENT OF COMBUSTIBLE MATERIALS ON, AGAINST OR AROUND THE FURNACE JACKET CAN CAUSE AN EXPLOSION OR FIRE RESULTING IN PROPERTY DAMAGE, PERSONAL INJURY OR DEATH. THE HOMEOWNER SHOULD BE CAUTIONED THAT THE FURNACE AREA MUST NOT BE USED AS A BROOM CLOSET OR FOR ANY OTHER STORAGE PURPOSES.

Location

9

BOTTOM

TOP

LEFT SIDE FRONT RIGHT SIDE

GAS

CONNECTION

ELECTRICAL CONNECTION

LINE VOLTAGE

ELECTRICAL CONNECTION

LOW VOLTAGE

OPTIONAL

GAS CONNECTION

OPTIONAL LOW

VOLTAGE WIRING

OPTIONAL LINE VOLTAGE

WIRING

A

I

R

F

L

O

W

RETURN

AIR

SUPPLY

AIR

HOT

MODEL A B C D E F RIGHT SIDE BACK TOP FRONT VENT

5 14 13 27/32 10 5/8 ༃ 11 1/2 1 7/8 0 4༄ 0 1 3 6༅ 85 lbs.

7 17 1/2 16 11/32 12 3/8 ༃ 15 2 1/2 0 3༄ 0 1 3 6༅ 105 lbs.

10 21 19 27/32 14 1/8 ༃ 18 1/2 2 1/2 0 0 0 1 3 6༅ 120 lbs.

12 24 1/2 23 11/32 15 7/8 ༃ 22 2 1/2 0 0 0 1 3 6༅ 140 lbs.

15 24 1/2 23 11/32 15 7/8 ༃ 22 2 1/2 0 0 0 1 3 6༅ 150 lbs.

༃MAY REQUIRE 3" TO 4" OR 3" TO 5" ADAPTER.

4" ADAPTER INCLUDED WITH (-)801P UNITS.

༄MAY BE 0" WITH TYPE B VENT.

༅MAY BE 1" WITH TYPE B VENT.

LEFT SIDE

REDUCED CLEARANCE (IN.)

SHIP

WGTS.

FIGURE 4

UPFLOW/HORIZONTAL DIMENSIONS

Ship.

Back Top Front Vent

REDUCED CLEARANCE (IN.)

4” adapter optional.

➁ May be 0” with type B vent.

➂ May be 1” with type B vent.

➀ May require 3” to 4” or 3” or 5” adapter.

Left Right

/8 0 4➁ 0 1 3 6➂ 85 lbs.

/2 0 3➁ 0 1 3 6➂ 105 lbs.

/2 0 0 0 1 3 6➂ 120 lbs.

/2 0 0 0 1 3 6➂ 140 lbs.

1

7

/2 1

1

/8 ➀ 11

/8 ➀ 15 2

5

3

/2 0 0 0 1 3 6➂ 150 lbs.

1

/2 2

1

/8 ➀ 18

/8 ➀ 22 2

1

7

ST-A1220-04

/32 10

/32 12

/32 14

/32 15

27

11

/2 16

1

Model A B C D E F

Side Side Wgts.

5 14 13

CLEARANCE TO COMBUSTIBLE MATERIAL (INCHES)

UPFLOW/HORIZONTAL MODELS

Location

7 17

/32 15

27

11

/2 23

1

10 21 19

12 24

15 24

10

roper air flow is required for the correct operation of this

P furnace. Restricted air flow can cause erratic operation and can damage the heat exchanger. The duct system must carry the correct amount of air for heating and cooling if summer air conditioning is used.

WARNING

!

SOME HEATING AIRFLOW VALUES MAY BE HIGHER THAN THOSE REQUIRED FOR COOLING. BE SURE TO SIZE DUCT FOR THE MAXIMUM POSSIBLE AIRFLOW VALUE.

SIZE AIRFLOW DISTRIBUTION SYSTEM TO ACCEPTABLE INDUSTRY STANDARDS AND METHODS. TOTAL STATIC PRESSURE DROP OF THE AIR DISTRIBUTION SYSTEM SHOULD NOT EXCEED .8 INCHES W.C. THIS WILL INCLUDE ANY AIR CONDITIONER COIL, AIR FILTRATION SYSTEM, ZONING SYSTEM, DUCTWORK, ETC. REFER TO ADDED EQUIPMENT TECHNICAL INFORMATION TO OBTAIN PRESSURE DROP INFORMATION WHEN EQUIPMENT IS OPERATING AT RECOMMENDED HEATING OR COOLING CFMS.

IMPORTANT: When using outside air, design and adjust

the system to maintain a return air temperature ABOVE 55° F during the heating season.

NOTE: Return air grilles and warm air registers must not be obstructed or closed.

DUCTING

UPFLOW INSTALLATIONS

1. Position the unit to minimize long runs of duct or runs of duct with many turns and elbows.

2. For side return: Cut an opening in the side. The opening should be cut the full width and height of the knockouts on the unit. See Figure 6.

3. If summer air conditioning is desired, position the indoor coil on the supply-air side of the unit. Ensure that no air can bypass the coil.

4. Connect the furnace to the supply air plenum. See Figure 7.

5. Connect the return air ducting to the return-air opening at the bottom and/or side of the unit. Make the connections air-tight to prevent the migration of toxic fumes and odors including carbon monoxide from migrating into the living space.

6. If a filter is installed near the furnace, be sure to have adequate space for installation and removal of the unit filter.

7. NOTE: Where the maximum airflow is 1800 CFM or more, BOTH sides or the bottom must be used for the return air. Do not take return air from the back of the unit.

NOTE: DO NOT take return air from furnace rooms, garages or cold areas. Avoid return air from utility rooms, kitchens, laundry rooms and bathrooms.

WARNING

!

UPFLOW FURNACE: THE SOLID METAL BASE (SHIPPED WITH THE FURNACE) PLATE MUST BE INSTALLED IN THE FURNACE BOTTOM WHEN USING SIDE AIR RETURN. FAILURE TO INSTALL A BASE PLATE COULD CAUSE THE PRODUCTS OF COMBUSTION TO CIRCULATE INTO THE LIVING SPACE AND CREATE POTENTIAL LY HAZARDOUS CONDITIONS, INCLUDING CARBON MONOXIDE POISONING OR DEATH. FOR BOTTOM RETURN, A SOLID METAL BASE PAN MUST NOT BE INSTALLED. SEE FIGURE 5.

WARNING

!

BLOWER AND BURNERS MUST NEVER BE OPERATED WITHOUT THE BLOWER DOOR IN PLACE. THIS IS TO PREVENT DRAWING GAS FUMES (WHICH COULD CONTAIN HAZARDOUS CARBON MONOXIDE) INTO THE HOME THAT COULD RESULT IN PERSONAL INJURY OR DEATH.

Ducting

11

DUCTING

NOTE: SOLID BASE PLATE PROVIDED WITH (-)801P MODELS ONLY.

WHEN SOLID BASE PLATE IS USED . TAPE AROUND BOTTOM FLANGES OF CABINET BEFORE THE UNIT IS INSTALLED.

LIFT UP, PULL OUT

1. REMOVE 2 SCREWS, LIFT BASE UP, SLIDE FORWARD TO REMOVE.

2. INSTALLATION IS REVERSE OF REMOVAL. ** VERIFY REAR FLANGE IS SEALED PROPERLY AS SHOWN IN DETAIL.

ST-A1220-10-X0

SOLID BASE FLANGE

F

ITS UNDER

CABINET BOTTOM

FIGURE 5

Ducting

FIGURE 6

ST-A1220-08

ST-A1220-10

FIGURE 7

ST-A1220-11

12

DUCTING

NOTE:

H

ORIZONTAL LEFT ORIENTATION DEPICTED IN ILLUSTRATION.

H

ORIZONTAL RIGHT ORIENTATION IS SIMILAR IN INSTALLATION.

A

I

R

F

LO

W

NOTE: DO NOT BLOCK FURNACE ACCESS WITH SUPPORT RODS, ALLOW SPACE FOR PROPER SERVICE MAINTIENCE OR REPLACEMENT OF THE HEAT EXCHANGER AND BLOWER ASSEMBLY .

HORIZONTAL UNITS

1. Position the unit to minimize long runs of duct or runs of duct with many turns and elbows.

2. Unit can be mounted left or right side airflow configuration.

3. Position the unit on adequate supports or by using support brackets (see Figure 8) and connect supply plenum.

4. If summer air conditioning is desired, position the indoor coil on the supply air side of the unit. Insure that no air can bypass this coil.

5. Secure the four angle brackets to the return air opening. See Figure 9. Connect the return air ducting to the return air opening at the top of the unit. Make the connection air tight to prevent entraining combustion gases from an adjacent fuel-burning appliance.

NOTE: Do not block furnace access with support rods. Maintain clearances recommended in Figure 8. Allow enough space for proper service maintenance or replacement of the heat exchanger and blower assembly.

IGURE 8

F

B

RT

PPO

W/SU

ED

L

A

ST

E IN

AC

N

R

U

F

L

A

T

N

O

IZ

R

O

H

S

ET

K

AC

R

FIGURE 9

HORIZONTAL RETURN AIR DUCT

LEFT-HAND AIRFLOW POSITION SHOWN)

(

RETURN

REAR VIEW

FOUR ANGLE BRACKETS CAN BE INSTALLED HORIZONTALLY. THESE BRACKETS MAY BE USED TO SECURE THE RETURN AIR DUCT TO A HORIZONTAL UNIT.

AIRFLOW

ST-A1220-03

Ducting

13

COMBUSTION AND VENTILATION AIR

COMBUSTION AIR REQUIREMENTS

IMPORTANT: This is not a direct vent furnace. Review venting instructions before installing.

WARNING

!

Combustion Air

THIS FURNACE AND ANY OTHER FUEL-BURNING APPLIANCE MUST BE PROVIDED WITH ENOUGH FRESH AIR FOR PROPER COMBUSTION AND VENTILATION OF THE FLUE GASES. MOST HOMES WILL REQUIRE THAT OUTSIDE AIR BE SUPPLIED INTO THE FURNACE AREA. FAILURE TO DO SO CAN CAUSE DEATH FROM CARBON MONOXIDE POISONING.

WARNING

!

ADEQUATE FACILITIES FOR PROVIDING AIR FOR COMBUSTION AND VENTILATION MUST BE PROVIDED IN ACCORDANCE WITH SECTION 5.3, AIR FOR COMBUSTION AND VENTILATION, OF THE NATIONAL FUEL GAS CODE, ANSI, Z223.1 LATEST EDITION OR CSA B149.1 AND .2 OR, APPLICABLE PROVISIONS FOR THE LOCAL BUILDING CODES, AND NOT OBSTRUCTED SO AS TO PREVENT THE FLOW OF AIR TO THE FURNACE.

1. IMPORTANT: Air for combustion and ventilation must not

come from a corrosive atmosphere. Any failure due to corrosive elements in the atmosphere is excluded from warranty coverage.

2. Combustion air must be free of acid forming chemicals; such

as sulphur, fluorine and chlorine. These elements are found in aerosol sprays, detergents, bleaches, cleaning solvents, air fresheners, paint and varnish removers, refrigerants and many other commercial and household products. Vapors from these products when burned in a gas flame form acid compounds. The acid compounds increase the dew point temperature of the flue products and are highly corrosive after they condense.

3. The following types of installation may require OUTDOOR AIR

for combustion, due to chemical exposures:

• Commercial buildings

• Buildings with indoor pools

• Furnaces installed in laundry rooms

• Furnaces in hobby or craft rooms

• Furnaces installed near chemical storage areas.

4. If combustion air is exposed to the following substances (but

not limited to the following), it should not be used and the furnace may require outdoor air for combustion.

• 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 curing and acid washing materials

WARNING

!

ALL FURNACE INSTALLATIONS MUST COMPLY WITH THE NATIONAL FUEL GAS CODE AND LOCAL CODES TO PROVIDE ADEQUATE COMBUSTION AND VENTILATION AIR FOR THE FURNACE. FAILURE TO DO SO CAN CREATE HAZARDOUS CONDITIONS RESULTING IN PROPERTY DAMAGE, BODILY INJURY OR DEATH FROM SMOKE, FIRE OR CARBON MONOXIDE.

Combustion air requirements are determined by whether the furnace is in an open (unconfined) area or in a confined space such as a closet or small room.

When the furnace is installed in the same space with other gas appliances, such as a water heater, be sure there is an adequate supply of combustion and ventilation air for the furnace and the other appliances. Do not delete or reduce the combustion air supply required by the other gas appliances in this space. See Z223.1, National Fuel Gas Code (NFPA 54). An unconfined space must have at least 50 cubic feet (volume) for each 1,000 BTUH of the total input of all appliances in the space. If the open space containing the appliances is in a building with tight construction (contemporary construction), outside air may still be required for the appliances to burn and vent properly. Outside air openings should be sized the same as for a confined space.

IMPORTANT: ONLY THE CURRENT VENT INSTRUCTIONS APPLY. All gas furnaces cannot be common-vented.

OVERTEMPERATURE SAFETY SWITCHES

Furnaces are equipped with safety switches in the burner compartment to protect against over-temperature conditions caused by inadequate combustion air supply. The switches are located in the burner compartment. If a switch is tripped it must be manually reset after clearing the fault condition which caused it to open.

WARNING

!

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14

COMBUSTION AND VENTILATION AIR (cont.)

TABLE 7: MINIMUM SPACE REQUIREMENTS FOR UNCONFINED SPACE, NON-DIRECT VENT*

Input

(BTUH)

Minimum

Space

(Cubic Ft)

Minimum Area

with 8

Ceilings (sq )

Typical Room

Size w/ 8'

Ceilings ( x )

50,000

2,500

313

16 x 20

75,000

3,750

470

24 x 20

100,000

5,000

625

32 x 20

125,000

6,300

790

36 x 30

150,000 7,500 940 32 x 30

TABLE 8: MINIMUM FREE AREA OPENING REQUIRED FOR A FURNACE LOCATED IN A CONFINED SPACE USING INDOOR AIR FOR COMBUSTION.

Input (BTUH)

Free Area for Each

Opening (sq inches)

50,000

100

75,000

100

100,000

100

125,000

130

150,000 150

COMBUSTION AIR REQUIREMENTS: CONFINED AND UNCONFINED SPACES

Combustion Air

ARNI

W

!

ALL FURNACE INSTALLATIONS MUST COMPLY WITH THE NATIONAL FUEL GAS CODE, NFPA 54 AND LOCAL CODES TO PROVIDE ADEQUATE COMBUSTION AND VENTILATION AIR FOR THE FURNACE. FAILURE TO DO SO CAN RESULT IN EXPLOSION, FIRE, PROPERTY DAMAGE, CARBON MONOXIDE POISONING, PERSONAL INJURY OR DEATH.

For improved indoor air quality, added safety and product performance we recommend direct vent type installations. If non-direct type vent system is used, the requirements for combustion air must be provided as identified in the National Fuel Gas Code.

Combustion air requirements are determined by whether the furnace is in an open (unconfined) area or in a confined space such as a closet or small room.

WARNING

!

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FURNACE LOCATED IN AN UNCONFINED SPACE

USING INDOOR AIR FOR COMBUSTION:

An unconfined space must have at least 50 cubic feet for each 1,000 BTUH of total input for all appliances in the space. Table 1 below specifies minimum space requirements and a few examples of the room sizes required for different inputs. The sizes are based on 8-foot ceilings.

If the open space containing the furnace is in a building with tight construction, outside air may still be required for the furnace to operate and vent properly. Outside air openings should be sized the same as for a confined space.

FURNACE LOCATED IN A CONFINED SPACE

A confined space is defined as any space for a given furnace input rating which is smaller than that which is specified in Table 1 as minimum for an “unconfined” space. If the space is less than that specified in this table, the space is defined as “confined”.

If the space is small enough to be designated as “confined”, it must have openings into the space which are located in accordance with the requirements set forth in the following subsections A and B. Size connected to the heated area or to the outside, and by the input of ALL

If the confined space is within a building with tight construction, combustion air must be taken from outdoors or from an area freely communicating with the outdoors.

A. USING INDOOR AIR FOR COMBUSTION:

IMPORTANT: Air should not be taken from a heated space

with a fireplace, exhaust fan or other device that may produce negative pressure.

If combustion air is taken from the heated area, the openings must each have at least 100 square inches of free area. Each opening must have at least one square inch of free area for each 1,000 BTUH of total input in the space. Table 2 shows some typical examples of openings required for combustion air openings required for a confined space.

TABLE 2: MINIMUM FREE AREA OPENING REQUIRED FOR A FURNACE LOCATED IN A CONFINED SPACE USING INDOOR AIR FOR COMBUSTION.

appliances in the space.

TABLE 1: MINIMUM SPACE REQUIREMENTS FOR UNCONFINED SPACE, NON-DIRECT VENT

B. USING OUTDOOR AIR FOR COMBUSTION:

IMPORTANT: Do not take air from an attic space that is

equipped with power ventilation. The confined space must communicate with the outdoors in

accordance with Methods 1 or 2 below. The minimum dimension of air openings shall not be less than 3 inches. Where ducts are used, they shall be of the same cross-sectional area as the free area of the openings to which they connect.

METHOD 1:

Two permanent openings, one located within 12 inches of the top and one located within 12 inches of the bottom of the enclosure, shall be provided. The openings shall communicate directly, or by ducts, with the outdoors or spaces (crawl or attic) that freely communicate with the outdoors.

15

TABLE 9 : MINIMUM FREE AREA REQUIRED FOR EACH OPENING (WHEN TWO OPENINGS ARE USED) WITH A FURNACE:

1. LOCATED IN A CONFINED SPACE

2. USING OUTDOOR AIR FOR COMBUSTION

3. COMMUNICATING DIRECTLY TO THE OUTSIDE THROUGH AN OPENING OR THROUGH A VERTICAL VENT DUCT.*

Total Input for

ALL Gas

Appliances

(BTUH)

Free Area for

Each Opening

when 2 Separate

Openings are

used (sq inches)

Round Pipe Duct

Diameter (Vercal

Duct Only) (inches)

50,000

13

5

75,000

19

5

100,000

25

6

125,000

32

8

150,000 38 8

COMBUSTION AND VENTILATION AIR (cont.)

TABLE 1 0: MINIMUM FREE AREA REQUIRED FOR EACH OPENING (WHEN TWO OPENINGS ARE USED) WITH A FURNACE:

1. LOCATED IN A CONFINED SPACE

2. USING OUTDOOR AIR FOR COMBUSTION

3. COMMUNICATING DIRECTLY TO THE

OUTSIDE THROUGH A H ORIZONTA L DUCT.

Total Input for

ALL Gas

Appliances

(BTUH)

Free Area for

Each Opening

when 2 Separate

Openings are

used (sq inches)

Round Pipe Duct

Diameter

(Horizontal Duct

Only) (inches)

50,000

25

6

75,000

38

8

100,000

50

8

125,000

63

10

150,000 75 10

TABLE 1 1: MINIMUM FREE AREA REQUIRED FOR AN O P E N I NG ( W H E N O N E OPENING I S USED) WITH A FURNACE:

1. LOCATED IN A CONFINED SPACE

2. USING OUTDOOR AIR FOR COMBUSTION

3. COMMUNICATING DIRECTLY TO THE

*

Total Input for

ALL Gas

Appliances

(BTUH)

Free Area for an

Opening when 1

Opening is used

(sq inches)

Round Pipe Duct

Diameter (inches)

50,000 25 6

75,000

38

8

100,000

50

8

125,000

63

10

150,000 75 10

OUTSIDE.

GAS

WATER

HEATER

FURNACE

12”

MAX

12”

MAX

NOTE: EACH OPENING SHALL HAVE A FREE AREA OF NOT LESS THAN ONE SQUARE INCH PER 1,000 BTU PER HOUR OF THE TOTAL INPUT RATING OF ALL EQUIPMENT IN THE ENCLOSURE, BUT NOT LESS THAN 100 SQUARE INCHES.

COMBUSTION AIR REQUIREMENTS: CONFINED AND UNCONFINED SPACES

TABLE 3: MINIMUM FREE AREA REQUIRED FOR EACH OPENING (WHEN TWO OPENINGS ARE USED) WITH A FURNACE:

Combustion Air

1. LOCATED IN A CONFINED SPACE

2. USING OUTDOOR AIR FOR COMBUSTION

3. COMMUNICATING DIRECTLY TO THE

3. OUTSIDE THROUGH AN OPENING OR

3. THROUGH A VERTICAL DUCT.

A. Where directly communicating with the outdoors through an

opening or where communicating to the outdoors through vertical ducts as shown in Figure 11, each opening shall have a minimum free area of 1 square inch for each 4,000 BTUH of total appliance input rating of all equipment in the enclosure. Table 3 specifies the minimum area for each of the 2 combustion air openings and minimum round duct diameter for direct openings and vertical ducting only.

B. Where communicating with the outdoors through horizontal ducts, each opening shall have a minimum free area of 1 square inch for each 2,000 BTUH of total appliance input rating of all equipment in the enclosure (see Figure 12). Table 4

TABLE 4: MINIMUM FREE AREA REQUIRED FOR EACH OPENING (WHEN TWO OPENINGS ARE USED) WITH A FURNACE:

1. LOCATED IN A CONFINED SPACE

2. USING OUTDOOR AIR FOR COMBUSTION

3. COMMUNICATING DIRECTLY TO THE

3. OUTSIDE THROUGH A HORIZONTAL DUCT.

TABLE 5: MINIMUM FREE AREA REQUIRED FOR EACH OPENING (WHEN TWO OPENINGS ARE USED) WITH A FURNACE:

1. LOCATED IN A CONFINED SPACE

2. USING OUTDOOR AIR FOR COMBUSTION

3. COMMUNICATING DIRECTLY TO THE

3. OUTSIDE THROUGH A HORIZONTAL DUCT.

specifies the minimum area for each of the 2 combustion air openings and minimum round duct diameter for horizontal ducting only.

METHOD 2:

One permanent opening located within 12 inches of the top of the enclosure, shall be permitted where the equipment has clearances of at least 1 inch from the sides and back and 6 inches from the front of the appliance. The opening shall directly communicate with the outdoors or communicate through a vertical or horizontal duct to the outdoors or spaces (crawl or attic) that freely communicate with the outdoors, and shall have a minimum of:

FIGURE 10

NON-DIRECT VENT AIR FROM HEATED SPACE

VENT PENETRATIONS

FOR NON DIRECT VENT FURNACES

AIR FROM HEATED SPACE

16

ST-A1227-01

COMBUSTION AND VENTILATION AIR (cont.)

GAS WATER HEATER

FURNACE

OPTIONAL 1 SQ. INCH PER 4000 BTUH INLET AIR

GABLE

VENT

VENTILATED ATTIC GABLE OR SOFFIT VENTS

OUTLET AIR IN ATTIC MUST BE ABOVE INSULATION

1

SQ. INCH PER

4000 BTUH INLET AIR

1

2” MAX

1 SQ. INCH PER

4000 BTUH

OUTLET AIR

GAS WATER HEATER

FURNACE

12”

MAX

I

NLET AIR 1 SQ. INCH

P

ER 2000 BTUH

OUTLET AIR 1 SQ. INCH

PER 2000 BTUH

O

UTLET AIR

1

SQ. INCH PER

4000 BTUH

INLET AIR 1 SQ. INCH PER 4000 BTUH

COMBUSTION AIR REQUIREMENTS: CONFINED AND UNCONFINED SPACES

ENT PENETRATIONS

FIGURE 11

NON-DIRECT VENT

IR FROM ATTIC

A OR CRAWL

PACE

S

VENT PENETRATIONS

OR NON DIRECT VENT FURNACES

F

AIR FROM ATTIC/CRAWL SPACE

T-A1227-02

S

FIGURE 12

ON-DIRECT VENT

N

UTSIDE AIR

O

SING A

U

ORIZONTAL

H

UCT

D

V

FOR NON DIRECT VENT FURNACES

AIR FROM ATTIC/CRAWL SPACE

Combustion Air

ST-A1227-03

A. 1 Square inch for each 3,000 BTUH of the total input rat-

ing of all equipment located in the enclosure and

B. Not less than the sum of the areas of all vent connectors

in the confined space.

If the unit is installed where there is an exhaust fan, sufficient ventilation must be provided to prevent the exhaust fan from creating negative pressure.

FIGURE 13

COMBUSTION AIR FITTING – NON-ATTIC COMBUSTION AIR PULL

6" MIN.

AIR INTAKE PIPE CONNECTION

A double-elbow may be installed to top inlet air opening, BUT IS NOT REQUIRED. This will help to prevent accidental blockage of the intake opening. Reference Figure 13 for proper elbow diameter.

NOTE: Inlet is specifically designed to prevent material from

being pulled into furnace. If elbows are not used, the intake opening must be kept clean and free of debris.

ATTACH OPTIONAL DOUBLE ELBOW TO TOP INLET AIR OPENING TO PREVENT ACCIDENTAL BLOCKAGE OF INTAKE OPENING. THIS IS NOT A REQUIREMENT. (SEE PREVIOUS PAGE.) SINGLE ELBOW IS ALLOWED BUT MAY NOT PREVENT DEBRIS FROM BEING DROPPED INTO THE FURNACE.

PVC DOUBLE ELBOW

6" MININUM CLEARANCE

#8 SCREWS

EXHAUST

METAL FLUE PIPE ONLY

#8 SCREWS

GROUND OR SHELF SURFACE

17

COMBUSTION AND VENTILATION AIR (cont.)

It is also acceptable to run the condensate drain (or refrigerant) line access over the air intake hole as long as a 1" minimum clearance is maintained.

Combustion air openings must not be restricted in any manner.

IMPORTANT: When indoor combustion air is used, the inlet air

Combustion Air

opening at the furnace must be protected from accidental blockage.

IMPORTANT: If the furnace is in a location with an exhaust fan, there must be sufficient ventilation to prevent the exhaust fan from creating a negative pressure in the room.

Combustion air openings must NOT BE RESTRICTED in any manner.

CONSULT LOCAL CODES FOR SPECIAL REQUIREMENTS.

B: Method 3

For the optimum in quiet operation, attic air may be brought directly to the furnace.

IMPORTANT: In applications using Method 3 for combustion air, the attic must be ventilated by gable or soffit vents.

FIGURE 14

COMBUSTION AIR FITTING – OPTIONAL ATTIC COMBUSTION AIR PULL

ATTACH A 90° ELBOW TO TOP INLET AIR OPENING TO PREVENT ACCIDENTAL BLOCKAGE OF INTAKE OPENING.

CAUTION

!

COMBUSTION AIR INTAKES CANNOT BE TERMINATED OUTSIDE. DOING SO CAN CAUSE IMPROPER OPERATION OF THE FURNACE.

COMBUSTION AIR FROM ATTIC

If attic combustion air is used, the inlet air opening at the furnace must be protected from accidental blockage. Install a 90° elbow pointing horizontally at the top of inlet air pipe. See Figure 14 (maximum of 2, 45° or 90° elbows, allowed).

NOTE: Maximum length of pipe that may be used for combustion air is 10 feet with two elbows. Lengths of more than 10 feet can result in nuisance pressure switch trips.

18

12" MIN. FROM TOP OF INSULATION

10 FT. MAX.

INCLUDING HORIZONTAL DIRECTION

#8 SCREW

!

CAUTION

USE OF SHEET METAL AIR INTAKE PIPE INSTEAD OF PVC MAY RESULT IN NOISE ISSUES.

PVC ELBOW

INSULATION

6" MINIMUM CLEARANCE

PVC COUPLER

EXHAUST

ATTIC SPACE

METAL FLUE PIPE ONLY

INDOOR SPACE

#8 SCREWS

COMBUSTION AND VENTILATION AIR (cont.)

VENTING

GENERAL INFORMATION

The furnace must be vented in accordance with these instructions, National Fuel Gas Code, ANSI Z223.1 and/or the Natural Gas Installation Code, CSA-B149.1 & .2 and requirements or codes of the local utility or other authority having jurisdiction.

WARNING

!

DEVICES ATTACHED TO THE FLUE OR VENT FOR THE PURPOSE OF REDUCING HEAT LOSS UP THE CHIMNEY HAVE NOT BEEN TESTED AND HAVE NOT BEEN INCLUDED IN THE DESIGN CERTIFICATION OF THIS FURNACE. WE, THE MANUFACTURER, CANNOT AND WILL NOT BE RESPONSIBLE FOR INJURY OR DAMAGE CAUSED BY THE USE OF SUCH UNTESTED AND/OR UNCERTIFIED DEVICES, ACCESSORIES OR COMPONENTS.

DRAFT INDUCER

WARNING

!

VENT PIPE ATTACHING HOLES MUST BE PREDRILLED IN THE DRAFT INDUCER COLLAR TO PREVENT DAMAGING THE INDUCER. DRILL 1/8” DIAMETER HOLES THROUGH THE VENT PIPE AND COLLAR AND USE #8 SCREWS TO ATTACH. SEE FIGURE 16. FAILURE TO FOLLOW THIS WARNING CAN CAUSE RECIRCULATION OF FLUE PRODUCTS CAUSING CARBON MONOXIDE POISONING RESULTING IN PERSONAL INJURY OR DEATH.

FURNACE CATEGORY INFORMATION

This furnace is shipped as a Category I type induced draft furnace. A Category I furnace operates with a nonpositive vent pressure and has a vent gas temperature at least 140°F above the dew point of the vent gases. A Category I type may be a draft hood equipped furnace or have a fan assisted combustion system (induced draft). The inducer is used to pull flue products through the combustion chamber and as they leave the furnace, most of the energy has been dissipated. The buoyant effect of the flue gases provides venting to the outdoors.

During the off cycle, the inducer is off and there is very little flow through the vent, cooling the vent. During the on cycle there is no dilution airflow, as with a draft hood type furnace. Although the vent heats up rapidly without dilution air, the flue products contain more water vapor, which results in a higher dew point temperature. It is most important that you follow the guidelines in these instructions to prevent the possible formation of condensation in the venting system.

As a Category I furnace it may be vented vertically with type B-1 vent pipe and also may be common vented, as described in these instructions.

IMPORTANT APPLICATION NOTES

hen the furnace is used as a replacement, the existing vent

W system should be inspected to assure that there are no obstructions, blockage, or any signs of corrosion and is properly sized for use with this furnace.

NOTE: When the vent table permits more than one diameter of pipe for a connector or vent, the smallest permitted diameter must be used.

Vent pipe may be type “B-1,” either rigid or suitable flexible construction that carries a U.L. listing.

Common venting is allowed with vertical B-1 vent systems, and lined masonry chimneys. Follow the National Fuel Gas Code, ANSI Z223.1 and/or the Natural Gas Installation Code, CSAB149.1 & .2 for proper installation practices.

NOTE: Follow combustion air instructions as outlined in this manual.

Single wall vent connectors to “B-1 vent or masonry chimneys” may be used under the guidelines of the National Fuel Gas Code, ANSI Z223.1 and/or the Natural Gas Installation Code, CSAB149.1 & .2.

The entire length of the vent connector shall be readily accessible for inspection, cleaning and replacement.

“B-1” VERTICAL VENTING

NOTE: Refer to the National Fuel Gas Code, ANSI Z223.1 and/or the Natural Gas Installation Code, CSA-B149.1 & .2.

Type “B-1” vents must be installed in accordance with the terms of their listings and the vent manufacturer’s instructions.

“B-1” vents must be supported and spaced in accordance with their listings and the manufacturer’s instructions. All vents must be supported to maintain their minimum clearances from combustible material.

VERTICAL VENTING

Categorized Furnace Vent

Input Size Recommended (See NFGC)

50K 3”

75K *4” 100K *4” 125K *5” 150K *5”

*NOTE: All furnaces have a 3” vent connection as shipped from the factory. A 3” to 4”, 3” to 5”, or 4” to 5” vent transition may be required when vertically vented or common vented with metal vent pipes. THE VENT

TRANSITION CONNECTION MUST BE MADE AT THE FURNACE VENT EXIT. It must originate with an adapter if required, at the furnace

flue collar and terminate either in a listed cap or roof assembly. When common venting, the vent connector size may differ from the above diameters depending on application. See National Fuel Gas Code ANSI Z223.1 or latest edition tables.

Combustion Air

19

COMBUSTION AND VENTILATION AIR (cont.)

LISTED CAP

LISTED GAS VENT

ROOF PITCH = X/12

12

X

- MINIMUM ALLOWABLE HEIGHT

F

ROOF PITCH “H” (MIN.) FT.

FLAT TO 6/12 1.0

OVER 6/12 TO 7/12 1.25

OVER 7/12 TO 8/12 1.5 OVER 8/12 TO 9/12 2.0 OVER 9/12 TO 10/12 2.5

OVER 10/12 TO 11/12 3.25

OVER 11/12 TO 12/12 4.0 OVER 12/12 TO 14/12 5.0 OVER 14/12 TO 16/12 6.0 OVER 16/12 TO 18/12 7.0 OVER 18/12 TO 20/12 7.5 OVER 20/12 TO 21/12 8.0

ST-A1220-24

VERTICAL VENT SYSTEMS:

1. A gas vent shall terminate above the roof surface with a listed cap or listed roof assembly. Gas vents 12 inches in size or smaller with listed caps shall be permitted to be terminated in accordance with Figure 15, provided they are at least 8 feet

rom a vertical wall or similar obstruction. All other gas vents

f

Combustion Air

shall terminate not less than 2 feet above the highest point where they pass through the roof and at least 2 feet higher than any portion of a building within 10 feet.

2. A type B-1 gas vent shall terminate at least 5 feet in vertical height above the highest connected equipment draft hood or flue collar.

1

3. Must rise

/4” per foot away from the furnace on horizontal runs and be supported with straps or hangers so it has no sags or dips. Supports at 4 foot intervals and at all elbows are recommended.

4. The vent connector must be mechanically fastened to the outlet collar of the furnace with at least (2) sheet metal screws except vent connectors that are B-1 material. These shall be assembled in accordance with the manufacturer’s instructions. See Figures 16 and 17.

5. Any angle greater than 45 degrees from the vertical is considered horizontal. The total horizontal distance of a vent plus the horizontal vent connector serving draft-hood equipped appliances shall not be greater than 75 percent of the vertical height of the vent.

Single appliance venting of a fan assisted furnace into a tile-lined masonry chimney is prohibited. The chimney must be lined with either Type B vent or with a listed, single wall, metal lining system. Reference National Fuel Gas Code, ANSI Z223.1 and/or the Natural Gas Installation Code, CSA-B149.1 & .2. See Figure 18

or typical B-1 vent chase.

f

OTE: A chimney adapter is available as an accessory (see ac-

N

cessory section of this manual). Follow manufacturer’s instructions.

WARNING

!

DO NOT CONNECT THIS FURNACE TO A CHIMNEY USED TO VENT A SOLID FUEL APPLIANCE (WOOD OR COAL). VENTING WITH A SOLID FUEL APPLIANCE CAN LEAD TO IMPROPER FUNCTIONING OF THE UNIT, AND DUE TO SOOTING, THE POSSIBILITY OF FIRE RESULTING IN PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.

SPECIAL VENT SYSTEMS (SVS)

IMPORTANT: It is THE FURNACE MANUFACTURER’s position

now that new III vent application, including Selkirk’s Selvent™ II HTPV product, should cease immediately.

installations of any HTPV pipe used in a category

FIGURE 15

TYPICAL VENTING WITH “B-1” VENT

ST-A1220-24

20

FIGURE 16

ATTACHING TO DRAFT INDUCER COLLAR

A0991-01

COMBUSTION AND VENTILATION AIR (cont.)

FR ESH AIR INLE T

ST-A1220-09-01

1. STANDARD 3” FLUE CONNECTION.

2. 4” ADAPTER - OPTIONAL SEE NATIONAL FUEL GAS CODE FOR SIZING OPTIONS

1.

2.

FIGURE 17

Combustion Air

FIGURE 18

DEDICATED VENTING THROUGH CHIMNEY WITH “B-1” VENT

ST-A1220-09

21

COMBUSTION AND VENTILATION AIR (cont.)

POWER VENT SYSTEMS

When vertical venting is not possible, the only acceptable method for horizontal venting is with the use of Tjernlund model GPAK1TR or Field Controls models SWG-4R power venter. Type B vent pipe and fittings must be used. Common venting is not per-

Combustion Air

mitted

All application and installation instructions supplied with the power venter must be followed.

Please address all questions regarding power venter installation, agency listings and furnace model compatibility to:

Tjernlund Products, Inc. (800) 255-4208 or (612) 426-2993

Field Controls L.L.C. (800) 742-8368 or (919) 522-0214

EXISTING VENT SYSTEMS

IMPORTANT RETROFIT VENTING INSTRUCTIONS

If this furnace is a replacement installation, ALWAYS INSPECT the existing vent system to be sure there are no obstructions, blockages, or signs of corrosion.

When the existing furnace is removed from a venting system serving other appliances, the venting is likely to be too large to properly vent the remaining attached appliances.

The following steps shall be followed with each appliance that remains connected to the common venting system, while the other appliances that remain connected to the common venting systems are not in operation.

NOTE: When the vent table permits more than one diameter of pipe for a connector or vent, the smallest permitted diameter must be used.1. Seal any unused openings in the common venting system.

NOTE: Ensure existing venting system complies with latest addi-

tion of National Fuel Gas Code ANSI Z223.1 and all local codes/regulations.

1. Visually inspect the venting system for proper size and horizontal pitch and determine that there is no blockage, restriction, leakage, corrosion or other deficiencies which could cause an unsafe condition.

. Insofar as is practical, close all building doors, windows and all

2

doors between the space where the appliances remaining connected to the common venting system are located. Turn on clothes dryers and any appliance not connected to the common venting system. Turn on any exhaust fans, such as range hoods and bathroom exhausts, so they will operate at maximum speed. Do not operate a summer exhaust fan. Close fireplace dampers.

3. Follow the lighting instructions. Place the appliance being inspected into operation. Adjust the thermostat so the appliance will operate continuously.

4. Test for spillage at the draft hood relief opening after 5 minutes of main burner operation. Use the flame of a match or candle, or smoke from a cigarette, cigar, or pipe.

5. After it has been determined that each appliance that remains connected to the common venting system properly vents (when tested as outlined above) return doors, windows, exhaust fans, fireplace dampers and any other gas-burning appliance to their previous conditions of use.

6. If improper venting is observed during any of the above tests, the common venting system must be resized. Refer to National Fuel Gas Code, ANSI Z223.1 and/or the Natural Gas Installation Code, CSA-B149.1 & .2.

22

GAS SUPPLY AND PIPING

GAS SUPPLY

IMPORTANT SAFETY INFORMATION

NATURAL GAS AND PROPANE (LIQUEFIED PETROLEUM GAS / LPG) SAFETY

GAS SUPPLY

ARNI

W

!

• FURNACES USING PROPANE GAS ARE DIFFERENT FROM NATURAL GAS MODELS. A NATURAL GAS HEATER WILL NOT FUNCTION SAFELY ON PROPANE AND VICE VERSA. CONVERSIONS OF HEATER GAS TYPE SHOULD ONLY BE MADE BY QUALIFIED INSTALLERS USING FACTORY SUPPLIED COMPONENTS. THE FURNACE SHOULD ONLY USE THE FUEL TYPE IN ACCORDANCE WITH LISTING ON RATING PLATE. ANY OTHER FUEL USAGE WILL RESULT IN DEATH OR SERIOUS PERSONAL INJURY FROM FIRE AND/OR EXPLOSION.

• BOTH NATURAL GAS AND PROPANE HAVE AN ODORANT ADDED TO AID IN DETECTING A GAS LEAK. SOME PEOPLE MAY NOT PHYSICALLY BE ABLE TO SMELL OR RECOGNIZE THIS ODORANT. IF YOU ARE UNSURE OR UNFAMILIAR WITH THE SMELL OF NATURAL GAS OR PROPANE, ASK YOUR LOCAL GAS SUPPLIER. OTHER CONDITIONS, SUCH AS “ODORANT FADE,” WHICH CAUSES THE ODORANT TO DIMINISH IN INTENSITY, CAN ALSO HIDE, CAMOUFLAGE, OR OTHERWISE MAKE DETECTING A GAS LEAK BY SMELL MORE DIFFICULT.

• UL OR CSA RECOGNIZED FUEL GAS DETECTORS ARE RECOMMENDED IN ALL ENCLOSED PROPANE AND NATURAL GAS APPLICATIONS WHEREIN THERE IS A POTENTIAL FOR AN EXPLOSIVE MIXTURE OF FUEL GAS TO ACCUMULATE. FUEL DETECTOR INSTALLATION SHOULD BE IN ACCORDANCE WITH THE DETECTOR MANUFACTURER’S RECOMMENDATIONS AND/OR LOCAL LAWS, RULES, REGULATIONS, OR CUSTOMS.

• BEFORE ATTEMPTING TO LIGHT THE FURNACE, MAKE SURE TO LOOK AND SMELL FOR GAS LEAKS. USE A SOAPY SOLUTION TO CHECK ALL GAS FITTINGS AND CONNECTIONS.

BUBBLING AT A CONNECTION INDICATES A LEAK THAT MUST BE CORRECTED. WHEN SMELLING TO DETECT A GAS LEAK, BE SURE TO ALSO SNIFF NEAR THE FLOOR. PROPANE GAS IS HEAVIER THAN AIR AND TENDS TO COLLECT AT LOWER LEVELS MAKING IT MORE DIFFICULT TO SMELL AT NOSE LEVEL. NATURAL GAS IS LIGHTER THAN AIR

NG

(Continued on next column)

AND WILL RISE, POSSIBLY ACCUMULATING IN HIGHER PORTIONS OF THE STRUCTURE.

• IF A GAS LEAK IS PRESENT OR SUSPECTED:

- DO NOT ATTEMPT TO FIND THE CAUSE YOURSELF.

- NEVER LEAKS. THE GAS CAN IGNITE RESULTING IN DEATH, PERSONAL INJURY, OR PROPERTY DAMAGE.

- DO NOTTRY TO LIGHT ANY APPLIANCE.

- DO NOTTOUCH AND ELECTRICAL SWITCH.

- DO NOT USE ANY PHONE IN YOUR BUILDING.

- LEAVE THE BUILDING IMMEDIATELY AND CALL THE GAS SUPPLIER FROM A NEIGHBOR’S PHONE. FOLLOW THE GAS SUPPLIER’S INTRUCTIONS.

- IF YOU CANNOT REACH YOUR GAS SUPPLIER, CALL THE FIRE DEPARTMENT.

- DO NOT RETURN TO THE BUILDING UNTIL AUTHORIZED BY THE GAS SUPPLIER OR FIRE DEPARTMENT.

• SHOULD OVERHEATING OCCUR OR THE GAS SUPPLY FAIL TO SHUT OFF, TURN OFF THE MANUAL GAS CONTROL VALVE TO THE FURNACE.

• CONSULT WITH THE LOCAL BUILDING DEPARTMENT AND FUEL GAS SUPPLIER BEFORE INSTALLING THE HEATER:

- THE INSTALLATION AND PURGING OF GAS PIPING MUST CONFORM TO LOCAL CODES, UTILITY COMPANY REQUIREMENTS, AND THE LATEST EDITION OF NATIONAL FUEL GAS CODE (NFGC) - ANSI Z223.1/NFPA 54, OR CSA B149.1, NATURAL GAS AND PROPANE INSTALLATION CODE.

- LP FURNACES SHOULD NOT BE INSTALLED BELOW GRADE (IN A BASEMENT FOR EXAMPLE) IF SUCH INSTALLATION IS PROHIBITED BY FEDERAL, STATE, PROVINCIAL, AND/OR LOCAL LAWS, RULES, REGULATIONS, OR CUSTOMS.

- INSTALLATION OF A GAS PRESSURE REGULATOR MAY BE REQUIRED IN THE GAS SUPPLY LINE. THE REGULATOR SHOULD NOT EXCEED THE MAXIMUM SUPPLY PRESSURE LISTED ON THE FURNACE RATING PLATE. DO NOT USE AN INDUSTRIAL-TYPE GAS REGULATOR.

- FOLLOW ALL LOCAL CODES AND SECTION 8.3 OF NFGC WITH REGARD TO PURGING OF GAS PIPING TO ENSURE THAT THE AIR AND/OR FUEL GAS IN THE GAS PIPING IS PROPERLY VENTED TO A LOCATION WHERE AN EXPLOSIVE MIXTURE CANNOT ACCUMULATE.

USE AN OPEN FLAME TO TEST FOR GAS

Gas Supply

23

GAS SUPPLY

GAS PIPING

ARNI

W

!

NG

THIS FURNACE IS EQUIPPED AT THE FACTORY FOR USE ON NATURAL GAS ONLY. CONVERSION TO LP GAS REQUIRES A SPECIAL KIT IS AVAILABLE AT THE DISTRIBUTOR. FAILURE TO USE THE PROPER CONVERSION KIT CAN CAUSE FIRE, CARBON MONOXIDE POISONING, EXPLOSION, PROPERTY DAMAGE, PERSONAL INJURY OR DEATH. SEE THE CONVERSION KIT INDEX SUPPLIED WITH THE FURNACE. THIS INDEX IDENTIFIES THE PROPER LP GAS CONVERSION KIT REQUIRED FOR EACH PARTICULAR FURNACE.

IMPORTANT: Any additions, changes or conversions required for

the furnace to satisfactorily meet the application should be made by a qualified installer, service agency or the gas supplier, using

Gas Supply

factory-specified or approved parts.

IMPORTANT: Connect this furnace only to gas supplied by a commercial utility or commercial fuel provider.

IMPORTANT: A U.L. or CSA recognized fuel gas and CO detec- tor(s) are recommended in all applications, and their installation should be in accordance with the detector manufacturer’s recommendations and/or local laws, rules, regulations or customs.

Install the gas piping according to all local codes, state codes and regulations of the utility company, whichever holds jurisdiction.

If possible, run a separate gas supply line directly from the meter to the furnace. Consult the local gas company for the location of the manual main shut-off valve. The gas line and manual gas

valve must be adequate in size to prevent undue pressure drop and never smaller than the pipe size to the combination gas valve on the furnace. Refer to Table 6 for the recom mended

pipe size for natural gas and Table 7 for LP gas pipe sizes.

IMPORTANT: It is permissible to run flexible gas connector inside the unit to a piece of black pipe. If local codes allow the use of a flexible gas appliance connector, always use a new listed connector. Do not use a connector which has previously serviced another gas appliance. Massachusetts law limits flexible gas connectors to a maximum of 36”.

Install a ground joint union outside the cabinet and within 3 feet to easily remove the control valve assembly. Install a manual shut-off valve in the gas line outside the furnace casing. The valve should be readily accessible to turn the gas supply

on or off. Install a drip leg in the gas supply line as close to the furnace as possible. Always use a pipe compound resistant to the action of liquefied petroleum gases on all threaded connections.

IMPORTANT: When making gas pipe connections, use a back-up wrench to prevent any twisting of the control assembly and gas valve. Do not overtighten the connection.

Any strains on the gas valve can change the position of the gas orifices in the burners. This can cause erratic furnace operation.

MPORTANT: ENSURE that the furnace gas control valve not be

I

subjected to high gas line supply pressures.

DISCONNECT the furnace and its individual shut-off valve from the gas supply piping during any pressure testing that exceeds

1/2 PSIG (3.48 kPa).

FIGURE 19

AS PIPING INSTALLATION

G

GAS PIPE INSTALLATION

ANUAL GAS VALVE

M

IN CLOSED

(

OSITION)

P

4 TO 5 FEET

ABOVE FLOOR

REQ'D BY SOME

UTILITIES

DRIP LEG

ABOVE FLOOR

REQ'D BY SOME

DRIP LEG

4 TO 5 FEET

UTILITIES

FLAME SENSOR

UNION

BURNERS

DIRECT

SPARK

IGNITOR

UPFLOW

BURNERS

FLAME SENSOR

HORIZONTAL

MANUAL GAS VALVE (IN CLOSED POSITION)

DUCT

UNION

MANIFOLD

GAS VALVE

MANIFOLD

DIRECT SPARK IGNITOR

GAS VALVE

24

GAS PRESSURE

GAS SUPPLY (cont.)

IMPORTANT: ENSURE that the furnace gas valve is not to be

subjected to high gas line supply pressures. DISCONNECT the furnace and its individual manual gas stop

from the gas supply piping during any pressure testing that ex-

ceeds 1/2 PSIG. (3.48 kPa).

atural gas supply pressure must be 5" to 10.5" w.c. LP gas

N

upply pressure must be 11" to 13" w.c. This pressure must

s

be maintained with all other gas-fired appliances in operation.

The minimum gas supply pressure to the gas valve for proper furnace input adjustments is 5" w.c. for natural gas, however 6" to 7" is recommended. The minimum gas supply pressure is 11" w.c. for LP gas.

CAUTION

!

ELEVATIONS ABOVE 2000 FT. REQUIRE THAT THE FURNACE INPUT RATING BE ADJUSTED AND THAT THE SIZE OF THE BURNER ORIFICES BE RECALCULATED BASED ON ELEVATION AND GAS HEATING VALUE. THE BURNER ORIFICES MAY (OR MAY NOT) NEED TO BE CHANGED. SEE THE SECTION TITLED “HIGH ALTITUDE INSTALLATIONS” OF THIS BOOK FOR INSTRUCTIONS.

FIGURE 20

YPICAL GAS VALVE (WHITE RODGERS)

T

I

NLET

PRESSURE TAP

WARNING

!

LI

GAS

A

URGE

P

R

E

V

NE

ON

TI OR

GE

A

US

CA

ROP

P

ATH.

DE TO

ROV

P LUTI

CHAMBE

ANY

FAI

.

A

E

RTY

E

CK

CHE

D

E

ON,

TI

GNI

I LURE

RE

FI

AMA

D

FOR

CHLORI

OTHE

OR

R.

ON

TO

OR

GAS

V

NE

OURCE

S

ADHE

X

E

GE

-FRE

DE

AP

R

,

LE

E

P

R

RE

LOS

E

P

NE

US

RS

AKA

S

E

ROV

O

UTLET PRESSURE TAP

O

NT

I

MATCHE

E FOR

THI

TO

RE

ON

I

ONAL

,

GE

OAP

ME

D

E

THE

CHE

W

S

ULTI

S

NJ

I

E

US

AND W

THOD.

LOW-FIRE M PRESSURE ADJUSTMENT

COMBUS

FLAME

,

S

NG

CKI

NG

ARNI

UR

AN

NG

OR

Y

AP

I

-

ATE

HIGH-FIRE MANIFOLD P

RESSURE

ADJUSTMENT

ANIFOLD

-

AK

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Gas Supply

-

GAS VALVE

This furnace has a 24-volt gas valve. It has ports for measuring supply and manifold gas pressure. The valve body contains a pressure regulator to maintain proper manifold gas pressure.

A control switch is on the valve body. It can be set to only the “ON” or “OFF” positions. The gas valve is a slow-opening valve. See Figure 20.

When energized, it takes 2 to 3 seconds to fully open.

TABLE 6

NATURAL 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 specific gravity of 0.60 (natural gas).

Nominal Length of Pipe, Feet Iron Pipe

Size, Inches 10 20 30 40 50 60 70 80

1/2 132 92 73 63 56 50 46 43 3/4 278 190 152 130 115 105 96 90 1 520 350 285 245 215 195 180 170

1-1/4 1,050 730 590 500 440 400 370 350 1-1/2 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 hour required for the gas input rating of the furnace. By formula:

Cu. Ft. Per Hr. Required =

The gas input of the furnace is marked on the furnace rating plate. The heating value of the gas (BTU/FT termined by consulting the local natural gas utility or the LP gas supplier.

Gas Input of Furnace (BTU/HR) Heating Value of Gas (BTU/FT

3

)

3

) may be de-

25

GAS SUPPLY (cont.)

GAS PRESSURE

SETTING GAS PRESSURE

The maximum gas supply pressure to the furnace must not exceed 10.5" w.c. natural gas, or 13" w.c. LP gas. The minimum supply gas pressure to the gas valve

should be 5⬙ w.c. natural gas or 11⬙ w.c. LP gas. A properly calibrated manometer is required for accurate gas pressure measurements.

SUPPLY GAS PRESSURE MEASUREMENT

An inlet pressure tap is on the input side of the gas valve.

1. With gas shut off to the furnace at the manual gas valve outside the unit.

Gas Supply

2. Loosen (do NOT remove) the inlet pressure tap using a 3/32⬙ allen-head wrench (see Figure 20).

3. Connect a manometer to the pressure tap. The pressure tap requires a 5/16⬙ I.D. hose.

A kit is available from Prostock Replacement Parts

which includes the following:

A. 3/32⬙ allen-head wrench B. 5/16⬙ to 1/4⬙ hose reducer fitting C. Short piece of 5/16⬙ I.D. hose Kit part number is: F0092-100300S1

4. Turn on the gas supply and operate the furnace and all other gas-fired units on the same gas line as the furnace.

5. Note or adjust the line gas pressure to give:

A. 5⬙ - 10.5⬙ w.c. for natural gas.

B. 11⬙ - 13⬙ w.c. for LP gas.

6. Shut off the gas at the manual gas valve and remove the manometer and hose.

7. Tighten the allen-head screw in the inlet pressure tap using a 3/32⬙ allen-head wrench (see Figure 20).

8. Turn on the gas supply and check for gas leaks using an approved leak detector. Do NOT use a flame of any kind to check for leaks. Repair any leaks and repeat.

If the supply gas line pressure is above these ranges, install an in-line gas regulator to the furnace for natural gas units. With LP gas, have the LP supplier reduce the line pressure at the regulator.

If supply gas line pressure is below these ranges, either remove any restrictions in the gas supply piping or enlarge the gas pipe. See Tables 6 and 7. With LP gas, have the LP supplier adjust the line pressure at the regulator.

ON

UTI

A

C

!

ELEVATIONS ABOVE 2000 FT. REQUIRE THAT THE FURNACE INPUT RATING BE ADJUSTED AND THAT THE SIZE OF THE BURNER ORIFICES BE RECALCULATED BASED ON ELEVATION AND GAS HEATING VALUE. THE BURNER ORIFICES MAY (OR MAY NOT) NEED TO BE CHANGED. SEE THE SECTION TITLED “HIGH ALTITUDE INSTALLATIONS” OF THIS BOOK FOR INSTRUCTIONS.

Manifold Gas Pressure Measurement. Natural gas manifold pressure should be 3.5" w.c. for high fire and

1.8" w.c. for low fire. LP gas manifold pressure should be 10.0" w.c. for high fire and 4.9" w.c. for low fire. Only

small variations in gas pressure should be made by adjusting the pressure regulator.

1. With the gas to the unit shut off at the manual gas valve, remove the outlet pressure tap plug.

2. Loosen (do NOT remove) the outlet pressure tap plug using a 3/32⬙ allen-head wrench (see Figure 20).

3. Connect a manometer to this pressure tap. The pressure tap requires a 5/16⬙ I.D. hose.

A kit is available from Prostock Replacement Parts

which includes the following:

A. 3/32⬙ allen-head wrench B. 5/16⬙ to 1/4⬙ hose reducer fitting C. Short piece of 5/16⬙ I.D. hose Kit part number is: F0092-100300S1

4. Turn on the gas supply and operate the furnace (apply a heat call).

5. Note or adjust the manifold gas pressure to give:

A. 3.5⬙ w.c. high fire/1.8⬙ w.c. low fire natural gas.

B. 10.0⬙ w.c. high fire/1.9⬙ w.c. low fire L.P. gas.

6. To adjust the pressure regulators, remove the regulator caps. (See Figure 20.)

7. Turn the adjustment screw clockwise to increase pressure, or counterclockwise to decrease pressure.

8. Securely replace the regulator caps.

9. Shut off gas at the manual gas valve and remove the manometer and hose.

10. Tighten the allen-head screw in the inlet pressure tap using a 3/32⬙ allen-head wrench (see Figure 20).

11. Turn on the gas supply and apply a heat call to the furnace then check for gas leaks using an approved leak detector. Do NOT use a flame of any kind to check for leaks. Repair any leaks and repeat.

26

N

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LP CONVERSION

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ARNI

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!

NG

LP TANKS FROM LOCAL LP SUPPLIER MUST NOT BE USED TO STORE ANYTHING (SUCH AS FERTILIZER) EXCEPT LP GAS. THIS INCLUDES ALL DELIVERY VESSELS (LP TRUCKS). IF MATERIAL OTHER THAN LP GAS IS USED IN THE SAME VESSELS/TANK AS THE LP GAS, THE LP GAS CAN BECOME CONTAMINATED AND DAMAGE THE FURNACE. THIS WILL VOID THE MANUFACTURER’S WARRANTY. CONTACT THE SUPPLIER TO MAKE SURE FERTILIZER IS NOT USED IN THE SAME TANKS USED TO STORE AND DELIVER LP GAS.

FIGURE 21

TYPICAL LP KIT CONTENTS

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LP Conversion

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TABLE 7

LP GAS PIPE CAPACITY TABLE (CU. FT./HR.)

Maximum capacity of pipe in thousands of BTU per hour of undiluted liquefied petroleum gases (at 11 inches water column inlet pressure). (Based on a Pressure Drop of 0.5 Inch Water Column)

Nominal Length of Pipe, Feet Iron Pipe

Size, 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

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Example (LP): Input BTU requirement of unit, 120,000

Equivalent length of pipe, 60 ft. = 3/4" IPS required.

27

LOCKING TABS

ELECTRICAL WIRING

ARNI

W

!

TURN OFF ELECTRIC POWER AT FUSE BOX OR SERVICE PANEL BEFORE MAKING ANY ELECTRICAL CONNECTIONS. FAILURE TO DO SO CAN CAUSE ELECTRICAL SHOCK RESULTING IN PERSONAL INJURY OR DEATH.

ARNI

W

!

THE CABINET MUST HAVE AN UNINTERRUPTED GROUND ACCORDING TO THE LATEST EDITION OF THE NATIONAL ELECTRICAL CODE, ANSI/NFPA70OR IN CANADA, THE CANADIAN ELECTRICAL CODE, CSA-C221 OR LOCAL CODES THAT APPLY. DO NOT USE GAS PIPING AS AN ELECTRICAL GROUND. A GROUND SCREW IS PROVIDED IN THE JUNCTION BOX. FAILURE TO DO SO CAN CAUSE ELECTRICAL SHOCK RESULTING IN PERSONAL INJURY OR DEATH.

WARNING

!

THIS FURNACE IS EQUIPPED WITH A BLOWER DOOR SAFETY SWITCH. DO NOT DISABLE THIS SWITCH. FAILURE TO FOLLOW THIS WARNING CAN RESULT IN ELECTRICAL SHOCK, PERSONAL INJURY OR DEATH.

NG

These may be obtained from:

National Fire Protection Association, Inc. Batterymarch Park Quincy, MA 02269

FIGURE 22

ST-A1220-05

ELECTRICAL CONNECTIONS

Before proceeding with the electrical connections, be certain that the voltage, frequency and phase corresponds to that specified on the furnace rating plate. For single furnace application, maximum over-current protection is 15 amperes.

Use a separate fused branch electrical circuit containing a properly sized fuse or circuit breaker. Run this circuit directly from the main switch box to an electrical disconnect that is readily accessible and located near the furnace (as required by code). Connect from the electrical disconnect to the junction box on the left side of the furnace, inside the blower compartment. For the proper connection, refer to the appropriate wiring diagram located on the inside cover of the furnace control box and in these instructions.

NOTE: The electrical junction box may be moved to the right side if necessary. A knockout is provided. Seal the opposite hole with plug provided.

NOTE: L1 (hot) and L2 (neutral) polarity must be observed when making field connections to the furnace. The ignition control may not sense flame if L1 and L2 are reversed. Make all electrical connections in accordance with the latest edition of the National Electrical Code ANSI/NFPA70.

Electrical Wiring

28

REVERSING THE ELECTRICAL CONNECTION (JUNCTION BOX)

If the line voltage electrical needs to be moved to the opposite side of the furnace, the following steps should be taken:

1. The furnace must NOT be electrically connected to line voltage prior to reversing the electrical connection.

2. Disconnect the wires from the door switch.

3. Remove the junction box from the furnace cabinet wall by removing the two screws that hold it to the cabinet. Leave the wires connected to the junction box.

4. Remove 7/8” plug from hole opposite j-box location. Drill 2 @ 3/16” Ø holes in the jacket. NOTE: Dimples/marks are provided in the sheet metal for correct drilling location.

5. Move the junction box to the opposite side of the cabinet. Install using the two screws removed in step 3 above. Note that all screws penetrating the junction box must be blunt – no sharp tipped screws can be used.

6. Replace the plug from the opposite of the furnace (the new jbox location) to the old j-box location and install qty=2 1/4” plugs from parts bag in empty screw holes in old location of j-box into the mounting screw holes in the old junction box location.

ELECTRICAL WIRING

2

HEAT COOL

LOW

HT/FAN

M2 M1 H/C

EAC

L1B XFMR HUM

SPARK

IGNITION

TOWER

NEUTRALS

LINE

P2

REVERSING ELECTRICAL CONNECTION & THERMOSTAT

7. Using a flat screwdriver, squeeze the retaining arms on the door switch and gently pry the door switch from it’s opening.

8. Install the door switch in the same opening on the opposite of the furnace and reconnect the electrical connectors (re-

oved in Step 2) to the door switch.

m

THERMOSTAT

See Field Selections – Dipswitchs for heating “auto staging” options. The room thermostat must be compatible with the furnace. See manufacturer’s thermostat spec sheet for compatability concerns. Generally, all thermostats that are not of the “current robbing” type are compatible with the integrated furnace control. The low voltage wiring should be sized as shown.

FIGURE 23

TYPICAL THERMOSTAT WIRING

NOTE: Do not use 24 volt control wiring smaller than No. 18

AWG.

Install the room thermostat in accordance with the instruction sheet packed in the box with the thermostat. Run the thermostat

ead wires inside the blower compartment and connect to low

l voltage terminals as shown on the wiring diagram. Never install the thermostat on an outside wall or where it will be influenced by drafts, concealed hot or cold water pipes or ducts, lighting fixtures, radiation from fireplace, sun rays, lamps, televisions, radios or air streams from registers.

FIGURE 24

SOLATION RELAY

I

FIGURE 25

LINE VOLTAGE CONNECTIONS

ST-A1227-06

ST-A1205-08A-X0

Electrical Wiring

ST-A1227-07

29

ACCESSORIES

FI

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LD

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T

A

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D

OP

TI

ON

AC

C

E

S

OR

I

E

S

ELECTRONIC AIR CLEANER

Line voltage power can be supplied from the terminal labeled “EAC” and a line voltage neutral terminal on the control board. This will power the electronic air cleaner whenever the circulating

Accessories

air blower is in operation.

HUMIDIFIER

Line voltage power is supplied from the terminal labeled “HUM” to a line voltage neutral terminal on the control board. This will power the humidifier whenever the induced draft motor is energized.

NOTE: Maximum current – 1.0 amps for each option (humidifier or electronic air cleaner).

RXGW-C01 4-INCH FLUE ADAPTER

(See Figure 26)

Refer to “Venting” section of this manual for more information. See National Fuel Gas Code for sizing options.

FILTERS (See Figure 26)

eep filters clean at all times. A filter is not provided with the

K

furnace, but one must be field-supplied and installed.

It is recommended to replace the furnace filter periodically to maintain optimum furnace performance.

RXGW-B01 CHIMNEY ADAPTER

IMPORTANT: CHIMNEY ADAPTER IS CERTIFIED FOR USE

ON (-)802P MODELS.

This appliance is CSA certified for use with RXGW-B01 Chimney Adapter. Refer to Kit Installation Instructions 92-101682-01.

30

ST-A1220-07-X0

RXGF-CD ACCESSORY FILTER RACK

FIELD SUPPLIED FILTER

FLANGE WRAPS AROUND BACK AND S

CREWS TO T HE

R

EAR OF THE FUR NCE, AT THE L

OCATIONS

PROVIDED

CUT OUT USING

E

MBO SSED ANGL ES

AS A GUID E

FOR PROPER SIZE

23” X 14”

RXGF-CB

$&&(6625<),/7(55$&.

FIELD SUPPLIED FILTER

ST-A1220-06-X0

F

I

E

L

D

FIGURE 26

ILTER LOCATIONS

F

ACCE

I

N

S

T

A

L

E

D

O

P

T

I

O

N

A

C

E

S

O

R

I

E

S

(

c

o

n

S

ORIE

t

.

)

S

Accessories

FIELD SUPPLIED FILTER

BOTTOM RETURN

SIDE RETURN

RXGF-CB ACCESSORY FILTER RACK

ST-A1220-07-00

ST-A1220-06-00

HORIZONTAL RETURN

31

TWINNING

FU

R

N

AC

E

TW

I

N

I

N

G

I

N

S

T

A

LLA

TI

ON

S

Twinning operation of two furnaces, installed side-by-side, connected by a common duct system with main power supplied by the same source, and controlled by a common thermostat can be done with the UT Electronic Controls 1095-300 integrated control boards.

IMPORTANT: Only twin furnaces with identical control boards.

IMPORTANT: Only bottom returns can be used. No more than

two furnaces can share the same supply and return. Furnaces must have same heating and blower capacity. Twinning furnaces must operate off the same phase of power.

It should be noted that both blowers will run simultaneously when there is a call for heating, cooling or fan.

NOTE: Duct system must be adequate to provide correct airflow

Twinning

to each furnace for supply and return.

UT ELECTRONIC CONTROLS 1095-300 CONTROL BOARD (62-104059-01)

1. Single Stage Operation

a. Control board “ONE” is on furnace connected to the

thermostat.

b. The 24 VAC supply to both control boards must be

in phase with each other.

c. Connect the “C,” “W”, “W2” and “TWIN” terminals to

counterparts on each control.

d. Twinning is automatically detected when wire is con-

nected to the twin terminal on both controls. If twinning is detected and then lost in the same power cycle, the furnace control will declare and display fault code 20 at the seven-segment display.

➀ See Figure 27 for twinning wire diagram for 1-stage

thermostat.

➁ See Figure 28 for twinning wire diagram for 1-stage

thermostat and times staging.

➂ See Figure 29 for twinning wire diagram for a 2-stage

thermostat.

32

C

ON

TR

OL

B

OA

R

D

TWINNING

S

ST-A1205-05-X0

Twinning

FIGURE 27

UT ELECTRONIC CONTROLS 1095-300 CONTROL BOARD, TWINNING CONNECTION – SINGLE STAGE OPERATION

33

TWINNING

C

ON

TR

OL

Twinning

B

OA

R

D

S

(

cont

.

)

ST-A1205-06-X0

FIGURE 28

UT ELECTRONIC CONTROLS 1095-300 CONTROL BOARD, TWINNING CONNECTION – ONE STAGE THERMOSTAT & TIMED STAGING GAS HEAT OPERATION

34

C

ON

TR

OL

B

OA

R

D

S

(

cont

TWINNING

.

)

ST-A1205-07-X0

FIGURE 29

UT ELECTRONIC CONTROLS 1095-300 CONTROL BOARD, TWINNING CONNECTION –TWO-STAGE OPERATION

Accessories

35

HIGH ALTITUDE

NATURAL GAS AT HIGH ALTITUDES

From Table F.1 of National Fuel Gas Code Handbook, 2002 (3.5ⴖ

WARNING

!

INSTALLATION OF THIS FURNACE AT ALTITUDES ABOVE 2000 FT (610 m) SHALL BE IN ACCORDANCE WITH LOCAL CODES, OR IN THE ABSENCE OF LOCAL CODES,

HE NATIONAL FUEL GAS CODE, ANSI Z223.1/NFPA 54

T OR NATIONAL STANDARD OF CANADA, NATURAL GAS AND PROPANE INSTALLATION CODE, CAN B149.1.

ON

UTI

A

C

!

ELEVATIONS ABOVE 2000 FT. REQUIRE THAT THE FURNACE INPUT RATING BE ADJUSTED AND THAT THE SIZE OF THE BURNER ORIFICES BE RE-CALCULATED BASED ON ELEVATION AND GAS HEATING VALUE. THE BURNER ORIFICES MAY (OR MAY NOT) NEED TO BE CHANGED. THE FOLLOWING EXAMPLES SHOW HOW TO DETERMINE IF AN ORIFICE CHANGE WILL BE NECESSARY AND HOW TO DETERMINE THE NEW ORIFICE SIZE.

34" 80 Plus furnaces installed above 2,000 ft. require the furnace to be de-rated 4% per thousand feet.

IMPORTANT: Factory installed orifices are calculated and sized based on a sea level Natural Gas heating value of 1050 BTU per cubic ft.

NOTE: Orifices are available through your local distributor. Reference Table 8 for approximate orifice sizing. The following are examples of orifice sizing using the National

Fuel Gas Code Appendix F: For a simplified estimation of orifice size based on gas heating

value and elevation, Table 8 may be used. However, calculations are the best method.

Example: 900 BTU/ft

I/H = Q 25000 / 900 = 27.78 ft

I = Sea Level input (per burner): 25000 H = Sea Level Heating Value: 900 Q = 27.78 ft3Natural Gas per hour.

3

Regional Natural Gas Heating Value

3

w.c. column). Orifice required at Sea Level: #40 From Table F.4 of National Fuel Gas Code Handbook, Orifice re-

quired 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 Regional Natural Gas Heating Value

I / H = Q 25000 / 1050 = 23.81ft

I = Sea Level input (per burner): 25000 H = Sea Level Heating Value: 1050 Q = 23.81 ft3Natural Gas per hour.

From Table F.1 of Natural Fuel Gas Code Handbook, 2002 (3.5⬙ w.c. column).

Orifice required at Sea Level: #43 From Table F.4 of National Fuel Gas Code 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

ORIFICE ORDERING INFORMATION

Orifice sizes are selected by adding the 2-digit drill size required in the orifice part number. Drill sizes available are 39 through 64; metric sizes available 1.10mm (-90) and 1.15mm (-91):

Orifice Part Number 62-22175-(drill size)

Example 1: # 60 drill size orifice required Part # 62-22175-60

Example 2:

1.15mm drill size orifice required Part # 62-22175-91

3

High Altitude

36

Notes:

3. This chart is based on the National Fuel Gas Code (NFGC) Annex F based on natural gas with a secific gravity of 0.60

Sea Level

to 1,999'

2,000' to

2,999'

3,000' to

3,999'

4,000' to

4,999'

5,000' to

5,999'

6,000' to

6,999'

7,000' to

7,999'

8,000' to

8,999'

9,000' to

9,999' 10,000'

43 44 44 44 45 45 46 47 47 48 42 42 43 43 43 44 44 45 46 47

42

42 43 43 43 44 44 45 46 47

41

42 42 42 43 43 44 44 45 46

40

41

42

42 42 43 43 44 44 45

39

40 41 41 42 42 43 43 44 44

38

39 40 41 41 42 42 43 43 44

37

38 39 39 40 41 42 42 43 43

37

38 39 39 40 41 42 42 43 43

36

37 38 38 39 40 41 41 42 43

35

36 36 37 37 38 39 40 41 42

5. Furnace operation is optimized when operating at design rate. Installer is responsible to verify rate.

6. This table applies to 80+ models only with 25,000BTU/Burner. DO NOT

USE THIS CHART FOR ANY 90+ FURNACE MODEL.

NATURAL GAS ORIFICE SELECTION BASED ON HEATING VALUE & ELEVATION*

*Table is derived from Appendix of the National Fuel Gas Code . To determine the correct orifice for your installation consult the National Fuel Gas Code tables F.1 and F.4

2. Local utilities adjust the sea level heating value of gasses used at higher elevations to compensate for appliance operation at altitude. Installer must be aware of the local heating value (sea level standard) to use the chart below.

4. The recommended orifices below allow the furnace to operate within 10% of design rate. However, NFGC calculations are the best method.

1. All (-)80+ units are factory equiped with orifices sized for 1050 sea level heating value gas.

ELEVATION

Grey Cells Indicate Factory

Orifice Size

Gas Heating

Value

(BTU's/ft

3

)

@ Sea

Level**

1,000-1,100

900-999

800-899

700-799

**Be sure to use sea level heating value. When requesting the heating value from a local utility, it must be converted to sea level equivalent in order to use this table.

N

ATU

TABLE 8

SUPPLEMENTAL ORIFICE SIZE CHART

R

A

L

GA

S

AT

H

I

GH

HIGH ALTITUDE

A

L

TI

TU

D

E

S

(

cont

.

)

High Altitude

37

HIGH ALTITUDE

LP

GA

S

AT

H

I

GH

A

L

TI

TU

D

E

S

LP GAS (TABLE 9)

NOTE: Keep any parts removed during LP conversion procedure

tored with the product literature for future use.

s

LP Gas is a manufactured gas that has consistent heating value across most regions.

The NFGC guidelines are used with the following exception:

The recommended LP Gas high altitude orifice selections differ slightly in that the NFGC LP orifice chart, as they are not accurate for these products. The National Fuel Gas Code LP orifices are

TABLE 9

P GAS

L

MPORTANT: 80+ MODELS ONLY! DO NOT

I

SE THIS CHART WITH ANY 90+ MODELS.

U

Input (per Orifice Altitude burner) 25000 Size

0 to 2000 ft. 25000 #54 2000*-3000* 24000 #54 3000*-4000* 23000 #54 4000*-5000* 22000 #54 5000*-6000* 21000 #54 6000*-7000* 20000 #54 7000*-8000* 19000 #55 8000*-9000* 18000 #55

High Altitude

9000*-10000* 17000 #55

based on an 11" of water column pressure at the orifice, which differs from products that use 10" of water column at the orifice. This difference requires a deviation from the NFGC orifice size recommendations. The Sea Level input should still be reduced by 4% per thousand ft. and the orifice size must be selected based on the reduced input in Table 9.

38

S

E

QU

E

N

C

E

OF

OP

E

R

A

TI

ON

START-UP PROCEDURES

S

This furnace is equipped with a direct ignition control. Each time the room thermostat calls for heat, the ignitor lights the main burners directly. See the lighting instructions on the furnace.

TO START THE FURNACE

1. Remove the burner compartment control access door.

2. IMPORTANT: Be sure that the manual gas control has been in the “OFF” position for at least five minutes. Do not attempt to manually light the main burners.

3. Turn off the furnace electrical power and set the room thermostat to its lowest setting.

4. Turn the gas control to the “ON” position or move the gas control lever to the “On” position.

5. Replace the burner compartment control access door.

6. Turn on the furnace electrical power.

7. Set the room thermostat to a point above room temperature to light the main burners.

8. After the burners are lit, set the room thermostat to a desired temperature.

9. Operate gas heat for a minimum period of 15 minutes and adjust input rate (page 44) and observe condensate system for leaks. Correct leaks and set rate, shutdown furnace and repeat until no leaks in condensate system can be detected.

TO SHUT DOWN THE FURNACE

1. Set the room thermostat to its lowest setting and wait for furnace to shut down.

2. Remove the burner compartment control access door.

3. Shut off the gas to the main burners by turning the gas control to the “OFF” position.

WARNING

!

SHOULD OVERHEATING OCCUR OR THE GAS SUPPLY FAIL TO SHUT OFF, CLOSE THE MANUAL GAS VALVE FOR THE APPLIANCE BEFORE SHUTTING OFF THE ELECTRICAL SUPPLY. FAILURE TO DO SO CAN CAUSE AN EXPLOSION OR FIRE RESULTING IN PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.

SEQUENCE OF OPERATION

UT ELECTRONIC CONTROLS Integrated Controls with Direct Spark Ignition.

1. Each time the thermostat “W” (Heating) contacts close, the furnace control checks to make sure the pressure switch is open. Next the induced draft blower (inducer) begins a prepurge cycle. Inducer starts on high.

2. After proving high and low pressure switches have closed, inducer slows to low speed.

3. After the 30-second pre-purge, the gas valve opens on low

fire for an 8-second trial for ignition.

4. The spark igniter is energized to light the gas burners and

stays energized for the up to 7 seconds after the gas valve opens.

5. 8 seconds after the gas valve opens the remote flame sensor must prove flame ignition for one second using the

process of flame rectification. If the burners don’t light, the system goes through another ignition sequence. It does this up to four times before entering a 1-hour lockout.

6. The main blower starts approximately 20 seconds after the burners ignite.

7. After blower starts unit will shift to either low or high heat as determined by thermostat.

8. When the thermostat “W” (Heat Call) ends, the gas valve closes, flame is extinguished, the induced draft blower stops after a 10-second post-purge, and the negative pressure switches opens.

9. The main blower continues until timed off by the setting on the integrated furnace control board.

Sequence if the system doesn’t light or doesn’t sense flame:

1. On a call for heat, the furnace control checks to make sure the pressure switch is open. Next the control runs the inducer for 30 seconds to prepurge.

2. After the 30-second pre-purge, the gas valve opens for an 8second trial for ignition. The inducer continues and the igniter stays energized.

3. If flame is not sensed during the 8th second after the gas valve opens, the gas valve closes, and the igniter de-energizes.

4. The inducer stops (may take up to 20 seconds for inducer fan to stop rotating) and the control verifies that the pressure switch has opened. Once the open pressure switch is confirmed, the control begins the next ignition cycle by energizing the inducer for a pre-purge of 30 seconds. After a 30-second pre-purge period, the gas valve is energized and the control looks for a flame signal for up to 8 seconds. If no flame is sensed, the cycle is repeated up to 4 times before entering a 1-hour lockout.

Start-Up Procedure

39

FAULT CODES

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T!

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dBV!a=6;;b= 6!;V\"NW!Ba6H 8!\HEbN6=!BH!W\c W!;a66E!

O!

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W\cW!a=6;;b= 6!;V\"NW!NdB; 6E!

K!

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<<!!!

J<! @dBV6=!C [bd"!L!@dBV6=!bH [@d6!"B!=bH! <O!

F

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S

DIAGNOSTICS AND FAULT CODES

All furnace controls come standard with a 7-segment diagnostic display. During standby mode with no fault codes present, the display will read “0” (zero). During normal thermostat heating, cooling or continuous fan operation, a letter will be displayed to describe the mode of operation as follows:

C = Cooling or Heat-Pump Heat Operation

F = Continuous Fan Operation

H = Gas Heating Operation

When the control senses a fault present, it will display a code to help in diagnoses. A list of normal operating codes and potential fault codes follows:

The method for displaying a two-digit fault is to display the first (most significant) digit for one second immediately followed by the second digit – which is also displayed for a duration of one second. A ½ second pause is then displayed. Cycle repeats until the fault is cleared. Each fault is flashed (displayed) a minimum of two times even if the fault condition has cleared before the fault can be displayed twice.

Sequence of display:

A. The first two-digit fault will be displayed once as described

above.

B. The upper-most horizontal segment of the seven-segment

display is energized for ½ second.

C. The second two-digit fault is displayed once as described

above.

D. The upper-most horizontal segment of the seven-segment

display is energized for ½ again.

This cycle repeats until one fault is gone (in which case the remaining fault will be displayed as described above) or both faults are gone or otherwise as noted below:

1. When a failed ignition has occurred four times in a row, the control enters one-hour lockout and fault codes “10” and “11” will be displayed alternately as described above.

2. When flame is lost five times in a row, the control enters onehour lockout and fault codes “10” and “13” will be displayed alternately as described above (A-D).

3. While the control is in one-hour lockout due to an unexpected flame, the fault codes “14” (unexpected flame) and “10” (soft lockout) will be displayed alternately at the seven-segment display as described above (A-D).

4. While the control has entered a one-hour lockout after declaring a dead blower after the main limit control has been open for more than 150 seconds, the fault codes “61” (Non-operational blower) and “10” (soft lockout) will be displayed alternately as described above (A-D). Note: the dead blower fault and associated one-hour lockout will occur up to four times in one heat call. Upon declaring this fault for the fourth time in one heat call, the control will enter hard lockout.

5. When the main limit has been open during a gas heat call for more than 150 seconds and has not yet re-closed, the fault codes “61” (Non-operational blower) and “22” (open limit) will be displayed alternately as described above (A-D) until the limit re-closes.

The higher priority fault code will be displayed until the condition is corrected then the lower priority fault code will display (provided the fault condition is still present).

DUAL FAULTS DISPLAYED

In some cases when two faults are present simultaneously, both faults are displayed. These exceptions for dual faults are noted below.

Fault Codes

40

L

O

C

K

O

U

T

1-S

TAGE

LOCK

OUT

All lockout conditions can be cleared immediately provided that

he original fault causing the lockout is cleared and power to the

t unit is cycled off and then back on again or (soft lockout only) if a heat call is cycled off for greater than 2 seconds but less than 20 seconds.

The furnace control will not initiate a heat cycle during any lockout condition. A call for compressor or continuous fan will generally be responded to but control will display the lockout error fault code instead of the “C” (for compressor) or “F” (for Continuous fan).

FIVE-MINUTE LOCKOUT

A five minute “soft” lockout will be initiated if the low pressure switch fails to close after 60 seconds of continuous inducer operation at the beginning of a normal heat cycle (pressure switch proving period). The seven-segment display will display the appropriate fault. Lockout will automatically be reset after five minutes.

ONE-HOUR LOCKOUT

A one hour “soft” lock out will be initiated when:

- Flame has not been detected after four ignition trials.

- Flame has been lost for five times in one heat call.

- Undesired flame has been detected. The one-hour period will commence after flame is no longer detected.

- Dead Blower has been detected (main limit circuit open for more than 150 seconds)

- When voltage has unexpectedly been detected on the gas valve circuit and voltage goes away when inducer is shut off.

The seven-segment display will alternately display “10” and the code number for the fault causing the lockout. Lockout will automatically be reset after one hour

HARD LOCKOUT

Three conditions shall cause a hard lockout:

1. The control senses an unspecified internal fault. Fault code “93” is set and displayed. This lockout condition cannot be reset by cycling the heat call.

2. Voltage is detected unexpectedly on the gas valve contacts (welded relay) and will not clear by cycling the inducer. Fault code “93” is set and displayed. This lockout condition cannot be reset by cycling the heat call.

3. The furnace control will declare that the blower motor is inoperable (dead) if the main limit control has been open for more than 150 seconds. Gas heating is terminated. However, the control continues to try to operate heating for up to four attempts in case the blower motor starts working again. If a dead blower has been declared four times in one heat call, the furnace control enters a hard-lockout. Fault code “61” is set and displayed. This lockout condition CAN cling the heat call.

be reset by cy-

Lockout

41

FI

E

LD

FIE

S

E

LE

C

LD S

TI

ON

S

E

–– D

LE

I

P

CTIONS

S

W

I

TC

H

E

& ADJUS

S

TM

E

NTS

A dipswitch bank; SW1 is provided for some field adjustments. Heating blower off delay, cooling (and heat-pump) blower off delay, display (7-Segment) orientation and fault clear are the adjustments and functions that can be handled using the dipswitches.

Seven-Segment Display Orientation; SW1

As the control will be applied in a multi-position furnace a means of changing the orientation of the seven segment display is required. This dipswitch is to be labeled SW1. Factory setting of the SW1 dipswitch is OFF. The factory setting display orientation is with the control placed in a vertical orientation and the low voltage terminal block T2 is on the left.

Cool Blower-Off Delay; SW2 & SW3

A means of selecting the cooling speed blower “off” delay time is provided. In legacy mode, dipswitches are required to select the delay time. These dipswitches are to be la-

Field Selections

beled SW2 and SW3. The following table defines the settings:

FIGURE 30

DIPSWITCH MAP

Selection* SW2 SW3 Selection A OFF OFF 30 seconds

Note: Factory setting = 30 seconds B ON OFF 45 seconds C OFF ON 60 seconds D ON ON 0 seconds

*(ref only)

Heat Blower Off Delay; SW4, SW5

Two dipswitches (SW4, SW5) can be used to select heat blower off delays (in seconds) in legacy mode.

Selection* SW4 SW5 Heat OFF Delay (high & low) A OFF OFF 90 (Factory Setting) B ON OFF 120 C OFF ON 160 D ON ON 180

*(ref only)

42

TIM

ING DIAGRAM

, FIE

LD S

E

LE

CTIONS

&

F

I

E

L

D

S

E

L

E

C

T

I

O

N

S

–

D

I

P

S

W

Auto Stage; SW6 & SW7

There are applications where a single stage thermostat is used with the two stage furnace. With this application the furnace will initially operate in the low heat stage. Based upon a user selected time, the furnace will automatically stage to high heat stage mode. auto staging will take place with a 24VAC signal on “W1” when autostaging is turned on. “W2” will be recognized as a call for stage 2 heat even when autostaging is active. The following dipswitches are available to accommodate this requirement:

Selection* SW6 SW7 AutoStage A OFF OFF Normal 2 stage operation

(Autostaging is off) (factory setting)

B ON OFF AutoStage, 10 minutes on

low, then to high with call on “W1”

F

A

U

L

T

C

L

E

A

R

MANUAL FAULT CLEAR; SW8

Faults will automatically be cleared from the fault buffer after one week. The fault buffer can also be manually cleared if this is desired. For the first 30 seconds after a change in state of dipswitch SW8, the furnace control will wait to determine if the

ADJUS

I

T

C

H

E

S

(

c

o

n

t

i

n

u

e

C

D ON ON AutoStage, 20 minutes on

Manual Fault Clear; SW8

For the first 30 seconds after a change in state of dipswitch SW8, the furnace control will wait to determine if the switch becomes on/off/on/off/on/off or off/on/off/on/off/on within 30 seconds. When this action is detected within 30 seconds, the fault code memory buffer shall be cleared.

switch becomes on/off/on/off/on/off or off/on/off/on/off/on within 30 seconds. When this action is detected within 30 seconds, the fault code memory buffer shall be cleared. Be sure to return the dipswitch to the original state (on or off) or is in the desired position after clearing the fault buffer using this method.

OFF ON AutoStage, 15 minutes on

TM

d

)

low, then to high with call on “W1”

low, then to high with call on W1” *(ref only)

E

NTS

Field Selections

FAULT RECALL

Upon power reset, the three most recent faults which are less than one week old will be flashed in succession from the most recent to the oldest. This will be done as a diag-

FLAME STATUS L.E.D. (AMBER)

A yellow or amber L.E.D. is provided to indicate flame status. When normal flame is sensed, the flame L.E.D. is continuously on. The flame L.E.D. will flash at a rate of one to four flashes per second if a weak flame is detected. If an unexpected flame is detected, the L.E.D. will flash rapidly.

TIMING DIAGRAM

On the next page is a timing diagram for normal heat sequence. This diagram assumes no faults are present during the heat call.

nostic aid to the field technician. After one week, a fault will be removed from the fault buffer.

The L.E.D. is off when there is no flame detected.

For more diagnostics information, consult the wiring diagram and troubleshooting chart at the end of this book.

43

TIM

ING DIAGRAM

, FIE

LD S

E

LE

CTIONS

&

ADJUS

TABLE 10

IMING DIAGRAM

T

Field Selections

TM

E

NTS

ST-A1205-10-X0

ADJUSTING OR CHECKING FURNACE INPUT

The maximum gas supply pressure to the furnace should be 10.5" w.c. for natural gas and 13.0" w.c. for L.P. The minimum gas supply pressure for purposes of input adjustment to the furnace should be 5" w.c for natural gas and

11.0" w.c. for L.P. A calibrated manometer is required for accurate gas pres-

sure readings. The manifold pressure should be set at 3.5" w.c. high fire,

1.8" low fire, for natural gas and 10.0" w.c. high fire and

4.9" w.c. low fire for L.P. Only small variations in the gas flow should be made by means of the pressure regulator adjustment. In no case should the final manifold pressure vary more than plus or minus 0.3" w.c. from the abovespecified pressures. To adjust the pressure regulator, remove the regulator cap and turn the adjustment screw clockwise to increase pressure or counterclockwise to decrease pressure. Then replace the regulator cap securely. Any necessary major changes in the gas flow rate should be made by changing the size of the burner orifices.

To change orifice spuds, shut off the manual gas valve and remove the gas manifold. On LP gas furnaces, the LP gas supply pressure must be set between 11" and 13" w.c. by means of the tank or branch supply regulators. The furnace manifold pressure should be set at 10" w.c. at the gas control valve. For elevations up to 2,000 feet, rating plate input ratings apply. For high altitudes (elevations over 2,000 ft.), see conversion kit index for derating and orifice spud sizes.

Checking furnace input is important to prevent over firing beyond its design-rated input. NEVER SET INPUT ABOVE THAT SHOWN ON THE RATING PLATE. Use the following table or formula to determine input rate. Start the furnace and measure the time required to burn one cubic foot of gas. Prior to checking the furnace input, make certain that all other gas appliances are shut off, with the exception of pilot burners. Time the meter with only the furnace in operation.

44

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TIM

ING DIAGRAM

, FIE

LD S

E

LE

CTIONS

&

TABLE 11

ETER TIME

M

ADJUS

TM

E

NTS

Field Selections

SETTING INPUT RATE

The furnace is shipped from the factory with #42 orifices. They are sized for natural gas having a heating value of 1050 BTU/cu. ft. and a specific gravity of .60.

Since heating values vary geo-graphically, the manifold pressure and/or gas orifice size may need to be changed to adjust the furnace to its nameplate input. Consult the local gas utility to obtain the yearly average heating value

and orifice size required to fire each individual burner at 25,000 BTU/HR.

NOTE: Refer to the High Altitude Section of this manual and the National Fuel Gas Code for high altitude rate adjustment above 2,000 ft.

45

AIRFLOW

E

NERGY

PERFORMANCE

VERIFIED

802PA075417MSA

XXXXXX

HIGH FIRE

AIR TEMPERATURE RISE

LOW FIRE FIRE

25 TO 55 °F (°C) 20 TO 50 °F (°C)

91-22176-09

ASSEMBLED IN THE USA

The importance of proper air flow over the heat exchanger cannot be over emphasized.

CAUTION

!

IT IS IMPORTANT THAT EACH DUCT SYSTEM BE SIZED AND INSTALLED FOR THE SPECIFIC APPLICATION BY PROPERLY APPLYING THE APPROPRIATE INDUSTRY ACCEPTED STANDARD. IF LESS THAN MINIMUM STANDARDS ARE APPLIED, THE EQUIPMENT USER COULD EXPECT TO EXPERIENCE HIGHER UTILITY BILLS, MAJOR COMPONENT FAILURE, VARYING DEGREES OF AIR NOISE OR OTHER UNSATISFACTORY ISSUES, OVER WHICH THE MANUFACTURER HAS NO CONTROL.

One of the most common causes of heat exchanger failure is overheating due to low air flow. An air flow table is located inside the blower door and on the following pages.

TEMPERATURE RISE CHECK

To 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 as possible yet out of a direct line from the heat exchanger. See Figure 31.

2. Insert a thermometer in the return air duct as close to the furnace as possible.

3. Operate the furnace.

4. When the thermometer in the supply air duct stops rising (approximately five minutes), subtract the return air temperature from the supply air temperature. The difference is the temperature rise.

Airflow

5. Compare the measured temperature rise to the approved temperature rise range listed on the furnace name plate. See Figure 32.

If the measured temperature rise is above the approved range, either the air flow is too low or the manifold pressure needs to be adjusted. More air must be moved by speeding up the blower, by removing restrictions in the duct system, or by adding more supply or return air duct. If the measured temperature rise is below the approved range, either the air flow is too much or the manifold pressure needs to be adjusted. Use lower speed tap on the multi-speed blower.

IMPORTANT: The measured temperature rise should be in the middle of the range.

IMPORTANT: Some high-efficiency filters have a greater than normal resistance to airflow. This can adversely affect furnace operation. BE SURE TO CHECK AIRFLOW if using any filter other than factory-provided filter.

FIGURE 31

EMPERATURE RISE MEASUREMENT

T

FIGURE 32

TYPICAL FURNACE NAME PLATE

WARNING

!

THE MEASURED TEMPERATURE RISE SHOULD BE AS CLOSE TO THE MIDDLE OF THE STATED RANGE AS POSSIBLE. FOR EXAMPLE, IF THE RISE RANGE IS 40 TO 70°F (4.5°-21°C), THE MIDDLE OF THE RISE RANGE IS 55°F (12.8°C). IN ALL APPLICATIONS, THE INSTALLER MUST ADJUST THE TEMPERATURE RISE TO THIS “MIDDLE” POINT AS CLOSELY AS POSSIBLE. ALSO, THE TEMPERATURE RISE SHOULD NEVER BE ABOVE OR FALL BELOW THE STATED RANGE. DOING SO COULD CAUSE DAMAGE TO THE HEAT EXCHANGER OR INTERMITTENT OPERATION. THIS COULD CAUSE INJURY OR DEATH AND WILL VOID THE MANUFACTURER’S WARRANTY FOR THIS PRODUCT.

46

TABLE 12

AIR FLOW PERFORMANCE – (-)802P/(-)(-)80MDP SERIES MODELS

Model

-)802PA050314MSA

(

-)(-)80MDP050A30SA

(

(-)802PA075417MSA

(-)(-)80MDP075B30SA

-)802PA100521MSA

(

-)(-)80MDP100C40SA

(

(-)802PA125524MSA

-)(-)80MDP125D50SA

(

-)802PA150524MSA

(

(-)(-)80MDP150D50SA

**Low Heating *High Heating

Motor HP

Blower Size,

IN.

1/3

11 x 6

/2

1 1 x 7

1

1/2

11 x 10

/4

3

1 x 10

1

3/4

11 x 10

CFM Air Delivery

External Static Pressure, ” W.C.

Speed Tap 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8

Low** 823 803 787 732 718 691 651 593 Med. Lo* 1030 1018 1006 976 929 897 850 808

Med. Hi 1129 1132 1112 1087 1054 1028 971 919

High 1361 1353 1331 1297 1264 1232 1164 1117

Low** 1229 1200 1181 1155 1120 1078 1013 970

Med. Lo 1308 1267 1266 1233 1204 1176 1113 1062

Med. Hi* 1553 1542 1516 1491 1451 1417 1358 1306

High 1969 1924 1893 1840 1803 1728 1657 1570

Low** 1209 1182 1131 1112 1051 976 929 867

Med. Lo* 1438 1420 1386 1350 1320 1293 1248 1186

Med. Hi 1902 1883 1844 1817 1753 1700 1636 1547

High 2071 2037 2001 1962 1905 1856 1807 1709

Low** 1358 1354 1331 13091 1250 1224 1154 1089

Med. Lo 1541 1517 1476 1453 1416 1371 1339 1277

Med. Hi* 1799 1774 1746 1712 1691 1629 1554 1495

High 2015 1989 1929 1902 1862 1815 1742 1665 Low** 1411 1395 1370 1334 1310 1252 1220 1150 Med. Lo 1606 1579 1569 1537 1499 1468 1407 1346

Med. Hi* 1889 1891 1849 1828 1764 1717 1659 1609

High 2178 2160 2105 2067 2024 1976 1916 1832

BLOWER SPEED SELECTIONS

The furnace controls have four active quick connect terminals for connecting the motor speed leads. These are:

1. LO HEAT/FAN — motor runs on this speed when the thermostat is in the “FAN ON” position or when low stage heat (W) is energized.

2. COOL — connect desired cooling speed.

3. HI HEAT — connect desired high heating speed.

4. H/C (for heat/cool) — connect desired speed when high heating and cooling speed are the same.

In addition to the active motor terminals, there are two motor parking terminals (labeled M1 and M2) available for placing any unused motor taps. All unused motor taps should be connected to either M1 or M2. These terminals (M1 and M2) will not be energized under any condition.

Airflow

IMPORTANT: Do not connect any motor speeds to “HI HEAT” and/or “COOL” if you use the “HEAT/COOL” terminal.

If cooling speed and fan speed are desired to be the same, this may be accomplished by not connecting “Y” to the integrated furnace control.

See selection titled “Field Selections – Dipswitches” for setting the heating and cooling blower off delay times.

47

SAFETY FEATURES

LIMIT CONTROL

The high limit cut-off temperature is set at the factory and cannot be adjusted. The temperature setting prevents the air temperature leaving the furnace from exceeding the maximum outlet air temperature, which, if exceeded, will shut the furnace down.

There are several reasons for a limit switch to open and almost always involve low airflow through the furnace.

1. A dirty or restricted air filter.

2. A dirty or restricted cooling coil.

3. Undersized or restricted return air system.

4. Undersized or restricted supply air system.

5. A problem affecting the main blower:

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 the

F. motor shaft.

G. Bad run capacitor.

6. Overfiring the furnace with too much gas pressure.

7. Ventilation problems.

FLAME ROLL-OUT SAFETY SWITCHES

Furnaces are equipped with safety switches to protect against flame roll-out conditions in the burner compartment, which, if tripped, will terminate the heating cycle. In the event of a flame roll-out condition, the switch will shut the furnace down. Switches for the furnaces are located on either side of the burner cover plate and just above the burners on the blower divider panel. If a switch is tripped, it must be manually reset. DO NOT jumper or reset this switch. If this switch should trip, a qualified installer, service agency or the gas supplier should be called to diagnose and/or correct the source of tripping. If this unit is mounted in a closet, the door must be closed when making this check.

PRESSURE SWITCH

This furnace is equipped with a normally-open pressure switches that monitors pressure conditions within the furnace vent system during the heating cycle.

There are several reasons for the pressure switch not to close.

1. An inoperative induced draft blower.

2. A loose or leaky pressure switch hose.

3. A blockage in the vent.

4. Severe downdrafts canceling the draft from the inducer fan.

5. A leaky gasket at the induced draft blower.

6. Improperly sized or installed vent.

The pressure switch contacts must open before the unit can go through another heating cycle.

See diagnostic chart in this book for diagnostic recommendations.

WARNING

!

DO NOT BYPASS, JUMPER, OR REMOVE ANY SAFETY SWITCH FROM THE FURNACE CONTROL CIRCUIT. IF A SAFETY SWITCH CAUSES THE FURNACE TO SHUT DOWN OR OPERATE INTERMITTENTLY, IT IS AN INDICATION OF A POTENTIAL SAFETY HAZARD THAT MUST BE ADDRESSED BY A QUALIFIED TECHNICIAN, SERVICE AGENCY OR THE GAS SUPPLIER. DO NOT RESET SAFETY CONTROLS WITHOUT CORRECTIVE ACTION AND/OR VERIFICATION OF PROPER SAFE OPERATION BY A QUALIFIED INSTALLER, SERVICE AGENCY OR THE GAS SUPPLIER.

REPLACE ANY SAFETY CONTROL COMPONENT ONLY WITH IDENTICAL OEM REPLACEMENT PARTS. WHEN A NEW SAFETY SWITCH IS INSTALLED, IT MUST BE TESTED FOR A MINIMUM OF 15 MINUTES WITH THE FURNACE OPERATING AT MAXIMUM INPUT RATE AND WITH BOTH BLOWER AND BURNER DOOR INSTALLED. IF THE FURNACE IS INSTALLED IN A CLOSET, THE CLOSET DOOR MUST ALSO BE CLOSED FOR THIS TEST. REPEAT THE TEST AT THE MINIMUM INPUT RATE IF THE FURNACE IS A MULTI-STAGE FURNACE.

Safety Features

48

MAINTENANCE

ARNI

W

!

THESE INSTRUCTIONS ARE INTENDED AS AN AID TO QUALIFIED SERVICE PERSONNEL FOR PROPER INSTALLATION, ADJUSTMENT AND OPERATION OF THIS UNIT. READ THESE INSTRUCTIONS THOROUGHLY BEFORE ATTEMPTING INSTALLATION OR OPERATION. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN IMPROPER INSTALLATION, ADJUSTMENT, SERVICE OR MAINTENANCE, POSSIBLY RESULTING IN

NG

FILTERS

CAUTION

!

DO NOT OPERATE THE SYSTEM FOR EXTENDED PERIODS WITHOUT FILTERS. A PORTION OF THE DUST ENTRAINED IN THE AIR MAY TEMPORARILY LODGE IN THE AIR DUCT RUNS AND AT THE SUPPLY REGISTERS. ANY RECIRCULATED DUST PARTICLES WILL

LUBRICATION

FIRE, ELECTRICAL SHOCK, CARBON MONOXIDE POISONING, EXPLOSION, PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.

DISCONNECT MAIN ELECTRICAL POWER TO THE UNIT BEFORE ATTEMPTING ANY MAINTENANCE. FAILURE TO DO SO CAN CAUSE ELECTRICAL SHOCK RESULTING IN PERSONAL INJURY OR DEATH.

BE HEATED AND CHARRED BY CONTACT WITH THE FURNACE HEAT EXCHANGER. THIS RESIDUE WILL SOIL CEILINGS, WALLS, DRAPES, CARPETS AND OTHER HOUSEHOLD ARTICLES.

IMPORTANT: DO NOT attempt to lubricate the bearings on

the blower motor or the induced draft blower motor. Addition of lubricants can reduce the motor life and void the warranty.

The blower motor and induced draft blower motor are permanently lubricated by the manufacturer and do not require further attention.

It is recommended that the blower motor and induced draft blower motor be cleaned periodically by a qualified installer, service agency, or the gas supplier to prevent the

possibility of overheating due to an accumulation of dust and dirt on the windings or on the motor exterior. And, as suggested elsewhere in these instructions, the air filters should be kept clean. Dirty filters can restrict airflow. The motor depends upon sufficient air flowing across and through it to keep from overheating.

Maintenance

49

M

AINTE

S

Y

S

TE

M

NANCE

OP

E

R

ATI

ON

I

N

FOR

MA

TI

ON

ADVISE THE CUSTOMER

1. Keep the air filters clean. The heating system will oper-

ate better, more efficiently and more economically.

2. Arrange the furniture and drapes so that the supply air

registers and the return air grilles are unobstructed.

3. Close doors and windows. This will reduce the heating

load on the system.

4. Avoid excessive use of kitchen exhaust fans.

5. Do not permit the heat generated by television, lamps

ANNUAL INSPECTIO

• The furnace should operate for many years without excessive scale build-up in the flue passageways. However, it is recommended that a qualified installer, service agency, or the gas supplier annually inspect the flue passageways, the vent system and the main burners for continued safe operation. Pay particular attention to deterioration from corrosion or other sources.

• IMPORTANT: It is recommended that at the beginning and at approximately half way through the heating season, a visual inspection be made of the main burner flames for the desired flame appearance by a qualified installer, service agency or the gas supplier. If the flames are distorted and/or there is evidence of back pressure, check the combustion and ventilation air system for blockage. If there is carbon and scale in the heat exchanger tubes, the heat exchanger assembly should be replaced.

N

or radios to influence the thermostat operation.

6. Except for the mounting platform, keep all combustible articles 3 feet from the furnace and vent system.

7. IMPORTANT: Replace all blower doors and compart- ment covers after servicing the furnace. Do not operate the unit without all panels and doors securely in place.

8. Explain the advantages of continuous fan operation to the customer.

• IMPORTANT: It is recommended that at the beginning of the heating season, the flame sensor be cleaned with fine steel wool or Scotch Bright Pad by a qualified installer, service agency or the gas supplier.

• IMPORTANT: It is recommended that an annual inspection and cleaning of all furnace markings be made to assure legibility. Attach a replacement marking, which can be obtained through the distributor, if any are found to be illegible or missing.

WARNING

!

HOLES IN THE VENT PIPE OR HEAT EXCHANGER CAN CAUSE TOXIC FUMES TO ENTER THE HOME, RESULTING IN CARBON MONOXIDE POISONING OR DEATH. THE VENT PIPE OR HEAT EXCHANGER MUST BE REPLACED IF THEY LEAK.

REPLACEMENT PARTS

Please visit www.myrheem.com/myruud.com for replacement parts information.

DIAGNOSTICS

Refer to Figure 33 for determining cause of unit problems.

WIRING DIAGRAM

Maintenance

Figure 34 is a complete wiring diagram for the furnace.

A wiring diagram is also available on the unit.

50

FIGURE 33

GO TO

E

NOTE: Always verify gas valve inlet and outlet gas pressure.

KEY TO ABBREVIATIONS I

BM = Indoor Blower Motor IDM = Induced Draft Motor IFC = Integrated Furnace Control PS = Pressure Switch(es) SE = Spark Electrode DSI = Direct-Spark Ignition

FLAME (AMBER) LED CODES OF F = N o F l am e P r es e n t RAPID BLINK = Unexpected Flame SLOW BLINK = Marginal Flame Sense S

TEADY ON = Normal Flame Sense

Does the IDM Energize?

IDM Runs for 30 sec. pre-purge?

Spark Ignitor Sparking?

D

oes Main Burner Light and stay lit?

I

s the gas valve energized?

PS dropping out?

Check IFC*

Does IBM start on heat speed 20 seconds

after burners light ?

Does main burner remain lit until

heat 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?

END

Heat-mode troubleshootin g

“FAULT DISPLAYED ?”

24V on W to IFC?

C

heck IFC*.

Does IDM run indefinately .

Does IDM Run for 60 sec. and then off for Five minutes

- Check thermostat in “heat” mode, battery, wire, and connections.

-

Check PS contacts

- Check wires for short.

-

Check IFC*.

- Check switches and hoses for water or moisture

- 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.

- 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 igniter alignment .

- Check orifice or other restrictions to gas flow.

- Check flame sense rod (clean with scotch brite pad).

- 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 drain is 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 sure limits are not open when circulating air temperature is within a specified range. ROLLOUTS

- ensure rollouts or overtemperature limits do not need to be reset. Make sure 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 open

or

opening and closing?

Note: IFC Status LED should be blinking a Fault Code.

Is the IFC sensing agood flame: NOTE: Flame sen se light sho uld b e steady-o n whenburnersare lit. If flameLED blinking, or off, flame sense is low or absent.

Ensure thermostat is properly placed and not improperly affected by registers, 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.

N

OTE: If IFC goes into lockout (“STATUS LED will blink code “1”), shut

off main power to unit, wait 30 seconds and then reset power.

PROBLEM

STILL

PRESENT

Fault Code Present

“FLAME” LED BLINKING OR STEADY ON

If “E” did not resolve issue

Double check - Is W off at IFC?

(W to C = ØV?)

Voltage present at gas valve?

- Check gas valve.

SEE F AULT C ODES

- Check IFC*.

Check IFC*.

*Most failures are not due to the IFC. Double check all other possibilities, including the ground connection or wire connections, before replacing the IFC.

Ensure TSTATis not in “FAN” position. Is disply flashing a fault code Is “FLAME” LED blinking or steady-on?

**System will attempt to light 4 times. Voltage is present at gas valve for only 7 seconds during each trial for ignition. The entire system will go into a 1 hour lockout after 4 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).

CHE CK BL INK C ODES

-Check for open limit or limit circuit.

FOR DIRECT SPARK IGNITION

- Check ignitor connected .

- Check ignitor wires.

- Check ignitor for fractures or cracking

- Check ignitor placement .

- If problem persists, check IFC*.

REPEAT THIS PROCEDURE UNTIL TROUBLE-FREE OPERATION IS OBTAINED.

1

) Set FAN switch to “AUTO”

2) Set thermostat to call for low HT ( “W” terminal)

START

YES

NO

If “

I

” did not

resolve issue.

NO

N

O

NO

YES

Y

ES

YES

I

D

F

E

G

YES

NO

YES

PREPURGE

IGNITION TRIAL

IBM “ON” DELAY

STEADY STATE LOW HT

END HEAT CALL

POST-PURGE

IBM “OFF” DELAY

STEADY OFF

NO

**

ST-A1227-08-00

GO TO

F

GO TO

I

WARNING

HAZARDOUS VOLTAGE

LINE VOLTAGE

CONNECTIONS

DISCONNECT POWER BEFORE SERVICING.

SERVICE MUST BE BY A TRAINED, QUALIFIED

SERVICE TECHNICIAN.

NOTE:

Always verify gas valve inlet and outlet

gas

pressure.

INTEGRATED FURNACE CONTROL (IFC)

DIAGNOSTICS GUIDE

NOTE: Most failures are not due to the IFC. Double check all othe r

possibilities, including the ground connection, before replacing the IFC.

BLOCKED DRAIN - (fault “59” should be present)

Set T-stat to High Heat - Energize W2 + W

Fault

Priority

24 22 21 19 23 13 15 14 16

2

20

4

17

3 6 9 8

7 11 18

1

CODE

DESCRIPTION

O C H h

F 10 11 12 13 14 20 22 26 33 44 4

6

4

5

5 57 61 93

Standby Compressor on (cooling or heat pump heat) High Gas heat on Low gas heat on Continuous fan on 1 Hour lockout Failed ignition Low flame sense Flame lost Unexpected flame Twinning fault Main limit open Line and Neutral reversed MRLC(Man. Reset limit cont.)(aka roll-out) open Low Pres. Switch Closed L

ow Pres. Switch Open, Indcr on low Speed

L

ow Pres. Switch Open, Indcr on High Speed

H

igh Pres. Switch Closed High Pres. Switch Open Blower Fault - blower unable to run Internal control fault

“ATTEND TO FAULT”

- For Twinned units, check that both IFCs are set for “TWIN” and wires are 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.

H

Check for high gas valve relay

on IFC stuck closed. Replace

IFC, if neccessary

Do IDM, IBM & Gas Valve Shift to High Heat?

STEADY HIGH HEAT

CHECK:

-IDM

-IDM Capacitor

-Low Pres. Sw. wiring

-Hoses to Low Pres. Sw.

CHECK:

-IBM

-IBM Capacitor

-Wiring

-Flame Sense Rod

Low Pressure

Switch Open?

High Gas Valve

Energized?

24 VAC on

W2?

Check

T- STAT

NO

YES

YES YES

YES

Restore thermostat to

normal operation.

DIAGNOSTICS FLOWCHART

Diagnostics

51

Wiring Diagram

FIGURE 34

FOR MODELS WITH UT ELECTRONIC CONTROLS 1028-928 INTEGRATED FURNACE CONTROL AND DIRECT SPARK IGNITION

52

CM 0814

Rheem (-)(-)80MDP100C40SA, (-)(-)80MDP050A30SA, (-)802PA125524MSA, (-)(-)80MDP125D50SA, (-)802PA150524MSA Installation Instructions Manual

Specifications and Main Features

Frequently Asked Questions

User Manual