Rheem 801T Series, 801C Series, 80MSC Series, 80MSX Series, FF TS80 Series Installation Instructions Manual

...

INSTALLATION INSTRUCTIONS

ACCREDITED

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FOR UPFLOW/HORIZONTAL SINGLE STAGE GAS FURNACES WITH CONSTANT-TORQUE AIR CIRCULATION BLOWER

(-)801T UPFLOW/ HORIZONTAL SERIES (-)801C UPFLOW/ HORIZONTAL SERIES (-)(-)80MSX UPFLOW/ HORIZONTAL SERIES (-)(-)80MSC UPFLOW/ HORIZONTAL SERIES

SUPERSEDES 92-24161-144-10

92-24161-144-11

TABLE OF CONTENTS

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

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

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

Contents

Material Information ..........................4

Efficiency Testing Notice ......................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

Supply Gas Pressure Measurement ............26

Manifold Gas Pressure Measurement ...........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 .......................... 33-34

12 HIGH ALTITUDE ...........................35

Natural Gas at High Altitudes..................35

LP Gas at High Altitudes .....................37

13 STARTUP PROCEDURES ...................38

Sequence of Operation ......................38

14 DIAGNOSTICS AND FAULT CODES ..........39

15 LOCKOUT ................................40

16 FIELD SELECTIONS & ADJUSTMENTS .......41

Field Selections – Dipswitches.................41

17 FAULT CLEAR ............................42

18 FAULT RECALL ...........................42

19 FLAME STATUS L.E.D. .....................42

20 TIMING DIAGRAM..........................42

21 ADJUSTING OR CHECKING FURNACE INPUT . 43

22 SETTING INPUT RATE......................44

23 AIRFLOW .................................45

Blower Speed Selection ......................46

24 SAFETY FEATURES........................47

25 MAINTENANCE ............................48

26 SYSTEM OPERATION INFORMATION.........49

27 ANNUAL INSPECTION......................49

28 REPLACEMENT PARTS ....................49

24 TROUBLESHOOTING.......................50

30 WIRING DIAGRAM .........................51

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.

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 80% single stage constant torque 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 B-1 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 National 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.

ITEM

NO.

DESCRIPTION

DOOR SWITCH

TRANSFORMER

JUNCTION BOX

LOW VOLTAGE TERMINAL

SOLID METAL BASE PAN

FURNACE CONTROL

CONTROL MOUNTING PLATE

BLOWER

IGNITER

GAS VALVE

INDUCED DRAFT BLOWER

4” FLUE ADAPTER (OPTIONAL)

COMBUSTION AIR INLET

MAIN LIMIT

COMBUSTION AIR DIFFUSER

MAIN PRESSURE SWITCH

BURNER

FLAME SENSOR

HEAT ASSISTED LIMIT CONTROL (HALC)

OVER TEMPERATURE SWITCH

General Information

ST-A1220-20-00

GENERAL INFORMATION (cont.)

Install this furnace in accordance with the American National Standard Z223.1 – latest edition entitled “National Fuel Gas Code” (NFPA54) and requirements or codes of the local utilities or other authorities having jurisdiction. This is available from the following:

National Fire Protection Association, Inc. Batterymarch Park

General Information

Quincy, MA 02269

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.

MATERIAL INFORMATION

All manufacturer products meet current Federal OSHA Guidelines for safety. Most consumers are aware that products present safety and health risks, when improperly used, handled and maintained. More details are available at the Websites for OSHA (Occupational Safety and Health Administration), at www.osha. gov.

EFFICIENCY TESTING NOTICE

For purposes of verifying or testing efficiency ratings, the test procedure in Title 10 Appendix N to Subpart B of Part 430 (Uniform Test Method for Measuring the Energy Consumption of Furnaces and Boilers) and the clarifying provisions provided in the AHRI Operations Manual for Residential Furnaces that were applicable at the date of manufacture should be used for test set up and performance.

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 obligations so that job site information is available when required.

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

______ Correct wire size (record type and gauge)

FURNACE INSTALLATION

______ Correct clearance to combustibles (record clearance)

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

______ Remove shipping bracket from blower

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

Checklist

______ Non-attic combustion air pull

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 CAN RESULT IN UNSATISFACTORY OPERATION AND/OR DANGEROUS CONDITIONS AND ARE NOT COVERED BY THE MANU-

FACTURER’S WARRANTY.

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

Safety Information

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

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.

WARNING

COMBUSTION PRODUCTS MUST BE DISCHARGED OUTDOORS. CONNECT THIS FURNACE TO AN APPROVED VENT SYSTEM ONLY, AS SPECIFIED IN THE VENT PIPE INSTALLATION SECTION OF THESE INSTRUCTIONS.

WARNING

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.

WARNING

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.

WARNING

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.

WARNING

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.

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;

-FURNACE OPERATING UNDER THERMOSTAT CON-

TROL;

-RETURN AIR DUCT SEALED TO THE FURNACE;

-AIR FILTERS IN PLACE;

-SET FURNACE INPUT RATE AND TEMPERATURE

RISE PER RATING PLATE MARKINGS;

-MEANS FOR PROVIDING OUTDOOR AIR REQUIRED

FOR COMBUSTION;

-RETURN AIR TEMPERATURE MAINTAINED BE-

TWEEN 55°F (13°C) AND 80°F (27°C); AND

-CLEAN FURNACE, DUCT WORK AND COMPO-

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).

LOCATION REQUIREMENTS

GENERAL INFORMATION

WARNING

WHEN THIS FURNACE IS INSTALLED IN A RESIDENTIAL GARAGE, IT MUST BE INSTALLED SO THE BURNERS AND IGNITION SOURCE ARE LOCATED NO LESS THAN 18 INCHES [450MM] ABOVE THE FLOOR. THIS IS TO PREVENT 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 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. An auxiliary drain pan should extend under any evaporator coil installed with the furnace.

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.

2. 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.

3. IMPORTANT: This furnace is not approved or recommended

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

4. 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.

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

6. 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.

Location

7. 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.

8. IMPORTANT: This furnace is shipped with a blower motor support bracket. This bracket must be removed before operating furnace. Remove (2) screws from front of blower and slide bracket off motor shaft.

WARNING

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

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 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 (61 cm) is recommended in front of all furnaces.

NOTE: Use recommended 24” (61 cm) clearance if ac-

cessibility clearances are greater than fire protection clearances.

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

LOCATION REQUIREMENTS

NOTE:

GENERAL INFORMATION (cont.)

WARNING

UPFLOW AND HORIZONTAL FURNACES ARE DESIGN-

CERTIFIED 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

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

AIR FLOW

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

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

RETURN

AIR

SUPPLY

AIR

HOT

ST-A1220-04

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

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

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

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

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

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

① MAY REQUIRE 3" TO 4" OR 3" TO 5" ADAPTER.

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

② MAY BE 0" WITH TYPE B VENT.

③ MAY BE 1" WITH TYPE B VENT.

LEFT SIDE

REDUCED CLEARANCE (IN.)

SHIP

WGTS.

FIGURE 4

UPFLOW/HORIZONTAL DIMENSIONS

Ship.

REDUCED CLEARANCE (IN.)

Back Top Front Vent

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

4” adapter optional.

¿ May be 0” with type B vent.

¿ May be 1” with type B vent.

*See furnace speck sheet for availability.

Left Right

/8 0 4¿ 0 1 3 6¿ 85 lbs.

/2 0 3¿ 0 1 3 6¿ 105 lbs.

/2 0 0 0 1 3 6¿ 120 lbs.

/2 0 0 0 1 3 6¿ 140 lbs.

/2 1

/2 2

/8 ¿ 11

/8 ¿ 15 2

/8 ¿ 18

/2 0 0 0 1 3 6¿ 150 lbs.

/2 2

/8 ¿ 18

/8 ¿ 22 2

ST-A1220-04

Location

/32 10

/32 12

/32 14

/32 15

/2 16

CLEARANCE TO COMBUSTIBLE MATERIAL (INCHES)

UPFLOW/HORIZONTAL MODELS

Input A B C D E F

Side Side Wgts.

050 14 12

075 17

075 21 19

/32 15

/2 23

100 21 19

125 24

150 24

DUCTING

Proper air flow is required for the correct operation of this 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.

WARNING

ZONING SYSTEMS ARE NOT DIRECTLY SUPPORTED IN THIS MANUAL. IF A THIRD PARTY SYSTEM IS USED REFER TO THE MANUFACTURER OF THAT PRODUCT FOR INSTALLATION AND OPERATION INSTRUCTIONS.

ZONING SYSTEMS USED ON THIS PRODUCT MUST HAVE SENSORS TO PREVENT FURNACES AND/OR HEATING ELEMENTS FROM CYCLING ON INTERNAL LIMIT CONTROLS. THE ZONING SYSTEM MUST NOT ALLOW THE EVAPORATOR COILS AND/OR HYDRONIC COILS TO FREEZE.

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.

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

THE SOLID METAL BASE 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.

Ducting

DUCTING

FIGURE 5

NOTE:

SOLID BASE PLATE PROVIDED WITH 80%

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

SINGLE STAGE CONSTANT TORQUE MODELS ONLY.

WHEN SOLID BASE PLATE IS USED . TAPE AROUND BOTTOM FLANGES OF CABINET

WHEN SOLID BASE PLATE IS USED, TAPE

BEFORE THE UNIT IS INSTALLED.

AROUND BOTTOM FLANGES OF CABINET BEFORE THE UNIT IS INSTALLED.

SOLID BASE FLANGE

FITS UNDER

CABINET BOTTOM

FIGURE 6

Ducting

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.

CUT OUT USING

EMBOSSED ANGLES

AS A GUIDE

FOR PROPER SIZE

23” X 14”

FIGURE 7

ST-A1220-10-X0

ST-A1220-10

I R F L O W

CUT OUT USING

EMBOSSED ANGLES

AS A GUIDE

FOR PROPER SIZE

23” X 14”

ST-A1220-08

ST-A1220-11-X0

ST-A1220-11

DUCTING

NOTE:

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

AIR FLOW

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.

FIGURE 8

HORIZONTAL FURNACE INSTALLED W/SUPPORT BRACKETS

FIGURE 9

HORIZONTAL RETURN AIR DUCT (LEFT-HAND AIRFLOW POSITION SHOWN)

AIRFLOW

RETURN

REAR VIEW

FOUR ANGLE BRACKETS, SHIPPED WITH 80% SINGLE STAGE CONSTANT TORQUE UNITS, CAN BE INSTALLED HORIZONTALLY. THESE BRACKETS MAY BE USED TO SECURE THE RETURN AIR DUCT TO A HORIZONTAL UNIT.

ST-A1220-03

Ducting

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 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 (unconned) area or in a conned 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 unconned

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 conned 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

REPLACE ANY SAFETY CONTROL COMPONENT WITH IDENTICAL OEM REPLACEMENT PARTS ONLY.

COMBUSTION AND VENTILATION AIR (cont.)

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

WARNING

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 identied in the National Fuel Gas Code.

Combustion air requirements are determined by whether the

furnace is in an open (unconned) area or in a conned space

such as a closet or small room.

WARNING

READ AND FOLLOW THE GENERAL VENTING REQUIREMENTS AND GUIDELINES OF THIS MANUAL FOR ADDI-

TIONAL VENTING REQUIREMENTS PERTAINING TO ALL FURNACE INSTALLATIONS (INCLUDING DIRECT AND NON-DIRECT VENTING). FAILURE TO FOLLOW ALL INSTRUCTIONS IN THIS MANUAL CAN RESULT IN EQUIPMENT FAILURE, EQUIPMENT DAMAGE, PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.

FURNACE LOCATED IN AN UNCONFINED SPACE

USING INDOOR AIR FOR COMBUSTION:

An unconned 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 species minimum space requirements and a few ex-

amples 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 conned space.

TABLE 1: MINIMUM SPACE REQUIREMENTS

TABLE 7: MINIMUM SPACE REQUIREMENTS

FOR UNCONFINED SPACE, NON-DIRECT VENT

FOR UNCONFINED SPACE, NON-DIRECT VENT*

Input

(BTUH)

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

Minimum

Space

(Cubic Ft)

Minimum Area

with 8

Ceilings (sq )

Typical Room

Size w/ 8'

Ceilings ( x )

FURNACE LOCATED IN A CONFINED SPACE

A conned space is dened as any space for a given furnace input rating which is smaller than that which is specied in Table

1 as minimum for an “unconned” space. If the space is less than

that specied in this table, the space is dened as “conned”. If the space is small enough to be designated as “conned”,

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 appliances in the space.

If the conned 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 replace, exhaust fan or other device that may produce negative pressure.

If combustion air is taken from the heated area, the open-

ings 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 conned space.

TABLE 8: MINIMUM FREE AREA

TABLE 2: MINIMUM FREE AREA

OPENING REQUIRED FOR A

FURNACE LOCATED IN A

FURNACE LOCATED IN A CONFINED SPACE USING

B. USING OUTDOOR AIR FOR COMBUSTION:

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

The conned space must communicate with the outdoors in

METHOD 1:

Two permanent openings, one located within 12 inches of

CONFINED SPACE USING

INDOOR AIR FOR COMBUSTION.

Free Area for Each

Input (BTUH)

50,000 100

75,000 100

100,000 100

125,000 130

150,000 150

equipped with power ventilation.

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.

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.

Opening (sq inches)

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

TABLE 1 1: MINIMUM FREE AREA REQUIRED FOR AN OPENING (WHEN O N E OPENING IS USED) WITH A FURNACE:

1. LOCATED IN A CONFINED SPACE

2. USING OUTDOOR AIR FOR COMBUSTION

3. COMMUNICATING DIRECTLY TO THE *

Total I nput 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

OUTSIDE.

COMBUSTION AND VENTILATION AIR (cont.)

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

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 ORIZONTAL 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 OPENING (WHEN O N E OPENING IS USED) WITH A FURNACE:

1. LOCATED IN A CONFINED SPACE

2. USING OUTDOOR AIR FOR COMBUSTION

3. COMMUNICATING DIRECTLY TO THE *

Total I nput 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.

TABLE 1 1: MINIMUM FREE AREA REQUIRED FOR AN OPENING (WHEN O N E OPENING IS USED) WITH A FURNACE:

1. LOCATED IN A CONFINED SPACE

2. USING OUTDOOR AIR FOR COMBUSTION

3. COMMUNICATING DIRECTLY TO THE *

Total I nput 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.

),*85( $,5)520+($7('63$&(

COMBUSTION AIR REQUIREMENTS: CONFINED AND UNCONFINED SPACES

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

1. LOCATED IN A CONFINED SPACE

Combustion Air

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 species 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 hori-

zontal 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

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 AN OPENING (WHEN ONE OPENING IS USED) WITH A FURNACE:

1. LOCATED IN A CONFINED SPACE

2. USING OUTDOOR AIR FOR COMBUSTION

3. COMMUNICATING DIRECTLY TO THE

3. OUTSIDE.

12). Table 4 species 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

+($7(5

:$7(5

*$6

´

0$;

127( ($&+23(1,1*6+$// +$9($)5(($5($2) 127/(667+$121( 648$5(,1&+3(5 %783(5+2852) 7+(727$/,1387 5$7,1*2)$// (48,30(17,17+(

´

0$;

(1&/2685(%87127 /(667+$1 648$5(,1&+(6

)851$&(

VENT PENETRATIONS

for non direct vent furnaces

air from heated space

ST-A1227-01

COMBUSTION AND VENTILATION AIR (cont.)

FIGURE 7 AIR FROM ATTIC/CRAWL SPACE

FIGURE 8 OUTSIDE AIR USING A HORIZONTAL INLET & OUTLET

COMBUSTION AIR REQUIREMENTS: CONFINED AND UNCONFINED SPACES

Combustion Air

FIGURE 11

NON-DIRECT VENT AIR FROM ATTIC

VENT PENETRATIONS

for non direct vent furnaces

air from attic/crawl space

OR CRAWL SPACE

287/(7$,5 ,1$77,& 0867%( $%29( ,168/$7,21

64,1&+3(5

%78+

287/(7$,5

*$6

:$7(5

+($7(5

*$%/(

9(17

)851$&(

237,21$/64,1&+3(5%78+,1/(7$,5

64,1&+3(5 %78+,1/(7$,5

9(17,/$7(' $77,&*$%/(25

62)),79(176

´0$;

ST-A1227-02

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

rating of all equipment located in the enclosure and B. Not less than the sum of the areas of all vent connectors

in the conned space.

If the unit is installed where there is an exhaust fan, sufcient

ventilation must be provided to prevent the exhaust fan from creating negative pressure.

FIGURE 12

NON-DIRECT VENT OUTSIDE AIR USING A HORIZONTAL DUCT

OUTLET AIR 1 SQ. INCH PER 4000 BTUH

INLET AIR 1 SQ. INCH PER 4000 BTUH

*$6 :$7(5 +($7(5

)851$&(

´

0$;

VENT PENETRATIONS

for non direct vent furnaces

air from attic/crawl space

OUTLET AIR 1 SQ. INCH

PER 2000 BTUH

INLET AIR 1 SQ. INCH

PER 2000 BTUH

ST-A1227-03

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.

FIGURE 13

COMBUSTION AIR FITTING – NON-ATTIC COMBUSTION AIR PULL

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” MINIMUM CLEARANCE

#8 SCREWS

6” MIN.

GROUND OR SHELF SURFACE

EXHAUST

METAL FLUE PIPE ONLY

#8 SCREWS

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

Combustion Air

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.

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 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.

Combustion Air

IMPORTANT APPLICATION NOTES

When the furnace is used as a replacement, the existing vent 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 or 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.

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.

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 AND VENTILATION AIR (cont.)

FIGURE 15 TYPICAL VENTING WITH “B-1” VENT

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

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.

3. Must rise 1/4” 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 tilelined 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. See Figure 18 for typical B-1 vent chase.

NOTE: A chimney adapter is available as an accessory (see accessory 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 posi-

tion now that new installations of any HTPV pipe used in a category III vent application, including Selkirk’s Selvent™ II HTPV product, should cease immediately.

FIGURE 15

TYPICAL VENTING WITH “B-1” VENT

LISTED CAP

ST-A1220-24

LISTED GAS VENT

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

ROOF PITCH = X/12

FIGURE 16

ATTACHING TO DRAFT INDUCER COLLAR

A0991-01

COMBUSTION AND VENTILATION AIR (cont.)

FIGURE 17

1. STANDARD 3” FLUE CONNECTION.

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

FRESH AIR INLET

Combustion Air

ST-A1220-09-01

FIGURE 18

DEDICATED VENTING THROUGH CHIMNEY WITH “B-1” VENT

ST-A1220-09

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 GPAK-1TR or Field Controls models SWG-4R power venter. Type B vent pipe and fittings must be used. Common venting is

Combustion Air

not permitted

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

addition 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.

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

GAS SUPPLY AND PIPING

GAS SUPPLY

IMPORTANT SAFETY INFORMATION

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

GAS SUPPLY

WARNING

• 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 MANUFAC-

TURER’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

(Continued on next column)

AIR 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 USE AN OPEN FLAME TO TEST FOR GAS LEAKS. THE GAS CAN IGNITE RESULTING IN DEATH, PERSONAL INJURY, OR PROPERTY DAMAGE.

- DO NOT TRY TO LIGHT ANY APPLIANCE.

- DO NOT TOUCH 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 IN-

STRUCTIONS.

- 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.

- 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.

Gas Supply

GAS SUPPLY

GAS PIPING

WARNING

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,

Gas Supply

using 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 in- side 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.

IMPORTANT: ENSURE that the furnace gas control valve not be 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 ex-

ceeds 1/2 PSIG (3.48 kPa).

FIGURE 19

GAS PIPING INSTALLATION

GAS PIPE INSTALLATION

MANUAL GAS VALVE

(IN CLOSED

POSITION)

4 TO 5 FEET

ABOVE FLOOR

REQ’D BY SOME

UTILITIES

DRIP LEG

4 TO 5 FEET

ABOVE FLOOR

REQ’D BY SOME

UTILITIES

DRIP LEG

UNION

DIRECT

SPARK

IGNITOR

BURNERS

FLAME SENSOR

UPFLOW

BURNERS

FLAME SENSOR

HORIZONTAL

MANUAL GAS VALVE (IN CLOSED POSITION)

DUCT

MANIFOLD

UNION

GAS VALVE

MANIFOLD

DIRECT SPARK IGNITOR

GAS VALVE

GAS PRESSURE

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

exceeds 1/2 PSIG. (3.48 kPa).

Natural gas supply pressure must be 5” to 10.5” w.c. LP gas supply pressure must be 11” to 13” w.c. This pressure

must 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 20A

TYPICAL GAS VALVE (HONEYWELL)

REGULATOR CAP

GAS SUPPLY (cont.)

FIGURE 20B

WHITE RODGERS GAS VALVE

REGULATOR CAP

WARNING

NEVER PURGE A GAS LINE INTO THE COMBUSTION CHAMBER. NEVER USE MATCHES, FLAME OR ANY IGNITION SOURCE FOR CHECKING LEAKAGE. FAILURE TO ADHERE TO THIS WARNING CAN CAUSE A FIRE OR EXPLOSION RESULTING IN PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.

TO CHECK FOR GAS LEAKAGE, USE AN APPROVED CHLORIDE-FREE SOAP AND WATER SOLUTION, OR OTHER APPROVED METHOD.

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 Figures 20A and 20B.

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/FT3) may be determined by consulting the local natural gas utility or the LP gas supplier.

Gas Input of Furnace (BTU/HR) Heating Value of Gas (BTU/FT3)

GAS SUPPLY (cont.)

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 59 w.c. natural gas or 119 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, remove the inlet pressure tap plug.

2. Connect a manometer to the pressure tap.

3. Turn on the gas supply and operate the furnace and all

Gas Supply

other gas-fired units on the same gas line as the furnace.

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

A. 59 - 10.59 w.c. for natural gas.

B. 119 - 139 w.c. for LP gas.

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

6. Replace the pressure tap plug before turning on the gas.

7. 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,a high pressure in line gas regulator may be required. Consult local gas utility. 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.

CAUTION

MANIFOLD GAS PRESSURE MEASUREMENT

Natural gas manifold pressure should be 3.5” (± .3) w.c. LP gas manifold pressure should be 10.0” (± .5) w.c. 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. Connect a manometer to this pressure tap.

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

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

A. 3.59 (± .3) w.c. for natural gas.

B. 10.09 (± .5) w.c. for LP gas.

5. To adjust the pressure regulator, remove the regulator cap. (See Figures 20A and 20B.)

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

7. Securely replace the regulator cap.

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

9. Replace the pressure tap plug before turning on the gas.

10. 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.

GAS PRESSURE

LP CONVERSION

NOTE: The valve can be converted to use liquified petro-

leum (LP) gas by replacing the pressure regulator spring with the conversion kit spring. This LP kit spring allows the regulator to maintain the proper manifold pressure for LP gas. See Figure 21.

NOTE: Order the correct LP conversion kit from the furnace manufacturer. Furnace conversion to LP gas must be performed by a qualified installer, service agency or the gas supplier.

NOx MODELS

When converting furnaces equipped with NOx inserts to LP gas, remove the NOx insert assemblies. Steps for removal are listed below:

1. Turn off all electrical power and the gas supply to the furnace.

2. Remove the burner door from the furnace.

3. Remove the burner assembly – handle with care.

4. Remove the two screws attaching the NOx insert retainer bracket to the center panel and remove NOx inserts.

5. Put the two screws back into the holes in the center panel.

6. Re-install the burner assembly.

7. Replace burner door.

8. Turn on electrical power and gas supply to the unit.

NOTE: Some NOx models may have one less NOx insert.

ORIFICE INSTALLATION

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

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 selection chart in High Alt. Instruction Section.

To change orifice spuds for either conversion to LP or for elevation:

1. Shut off the manual main gas valve and remove the gas manifold.

2. Replace the orifice spuds.

3. Reassemble in reverse order.

4. Turn the gas supply back on and check for proper operation and manifold pressure.

5. Attach the notice label alerting the next service technician that the furnace has been converted to LP gas.

WARNING

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 MANUFACTUR-

ER’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

LP Conversion

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

Example (LP): Input BTU requirement of unit, 120,000 Equivalent length of pipe, 60 ft. = 3/4” IPS required.

ELECTRICAL WIRING

WARNING

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.

WARNING

THE CABINET MUST HAVE AN UNINTERRUPTED GROUND ACCORDING TO THE LATEST EDITION OF THE NATIONAL ELECTRICAL CODE, ANSI/ NFPA70 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.

These may be obtained from:

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

FIGURE 22

LOCKING TABS

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

REVERSING THE ELECTRICAL CONNECTION (JUNCTION BOX)

NOTE: Reversing the junction box is not possible in 14.0 inch

cabinets.

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 j-box 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

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 (removed in Step 2) to the door switch.

THERMOSTAT

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 lead wires inside the blower compartment and connect to low 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

ISOLATION RELAY FOR CURRENT-ROBBING THERMOSTAT

FIGURE 25

LINE VOLTAGE CONNECTIONS

LINE

L1B XFMR HUM

EAC

ST-A1227-04

NEUTRALS

SPARK

IGNITION

TOWER

ST-A1220-18-00

ST-A0804-01

Electrical Wiring

ACCESSORIES

ST-A1220-27-00

1. STANDARD 3” FLUE CONNECTION.

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

FIELD INSTALLED OPTIONAL ACCESSORIES

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 circulat-

Accessories

ing 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.

FIGURE 26

1. STANDARD 3” FLUE CONNECTION

2. 4” ADAPTER OPTIONAL

SEE NATIONAL FUEL GAS CODE FOR SIZING OPTIONS

FILTERS (See Figure 27)

Keep filters clean at all times. A filter is not provided with the 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 80% SINGLE STAGE CONSTANT TORQUE MODELS.

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

ST-A1220-27

ACCESSORIES

FIELD INSTALLED OPTION ACCESSORIES (cont.)

FIGURE 27

FILTER LOCATIONS

FLANGE WRAPS AROUND BACK AND SCREWS TO THE REAR OF THE FURNCE, AT THE LOCATIONS PROVIDED

CUT OUT USING

EMBOSSED ANGLES

AS A GUIDE

FOR PROPER SIZE

23” X 14”

FIELD SUPPLIED FILTER

RXGF-CD ACCESSORY FILTER RACK

SIDE RETURN

ST-A1220-07-X0

Accessories

ST-A1220-07-00

FIELD SUPPLIED FILTER

BOTTOM RETURN

RXGF-CB ACCESSORY FILTER RACK

RXGF-CB

ACCESSORY FILTER RACK

FIELD SUPPLIED FILTER

ST-A1220-06-X0

HORIZONTAL RETURN

ST-A1220-06-00

TWINNING

FURNACE TWINNING INSTALLATIONS

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 1194-250 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 to each furnace for supply and return.

Twinning

UT ELECTRONIC CONTROLS 1194-250 CONTROL BOARD

(62-104058-02)

1. Single Stage Operation

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

mostat.

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

phase with each other.

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

parts 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.

See Figure 28 for twinning wire diagram for 1-stage thermostat.

See Figure 29 for twinning wire diagram for 2-stage thermostat.

CONTROL BOARDS

UT ELECTRONIC CONTROLS 1194-250 CONTROL BOARD, TWINNING CONNECTION -- SINGLE PHASE OPERATION

TWINNING

THERMOSTAT

CONTACTOR

COOLING

ST-A1220-25-00

Twinning

FIGURE 28

UT ELECTRONIC CONTROLS 1194-250 CONTROL BOARD, TWINNING CONNECTION – SINGLE STAGE OPERATION

TWINNING

UT ELECTRONIC CONTROLS 1194-250 CONTROL BOARD, TWINNING CONNECTION -- TWO PHASE OPERATION

CONTROL BOARDS (cont.)

THERMOSTAT

ST-A1220-26-00

Twinning

CONTACTOR

COOLING

FIGURE 29

UT ELECTRONIC CONTROLS 1194-250 CONTROL BOARD, TWINNING CONNECTION – TWO STAGE OPERATION

NATURAL GAS AT HIGH ALTITUDES

HIGH ALTITUDE

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

CAUTION

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 above sea level.

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 E, 2015 edition. 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/ft3 Regional Natural Gas Heating Value

I/H = Q 25000 / 900 = 27.78 ft

I = Sea Level input (per burner): 25000 H = Sea Level Heating Value: 900 Q = 27.78 ft3 Natural Gas per hour.

From Table E1.1a of National Fuel Gas Code, 2015 (3.5( w.c. column).

Orifice required at Sea Level: #40 From Table E1.1d of National Fuel Gas Code, 2015. 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 ft3 Natural Gas per hour.

From Table E1.1a of National Fuel Gas Code, 2015 (3.59 w.c. column).

Orifice required at Sea Level: #43 From Table E1.1d of National Fuel Gas Code, 2015 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: # 60 drill size orifice required Part # 62-22175-60

High Altitude

HIGH ALTITUDE

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

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*

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.

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 43 43 43 44 44 45 46 47

42 42 42 43 43 44 44 45 46

42 42 43 43 44 44 45

40 41 41 42 42 43 43 44 44

39 40 41 41 42 42 43 43 44

38 39 39 40 41 42 42 43 43

37 38 38 39 40 41 41 42 43

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

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

)

@ Sea

Level**

1,000-1,100

900-999

800-899

700-799

NATURAL GAS AT HIGH ALTITUDES (cont.)

TABLE 8

SUPPLEMENTAL ORIFICE SIZE CHART

NATURAL GAS ORIFICE SELECTION BASED ON HEATING VALUE & ELEVATION*

Notes:

1. All (-)80+ units are factory equipped with orices sized for 1050 sea level heating value gas.

2. Installer must be aware of the local heating value (sea level standard) to use the chart below.

3. This chart is based on the National Fuel Gas Code (NFGC) Annex E, 2015 Edition, based on natural gas with a specic gravity of 0.60

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

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.

ELEVATION

High Altitude

Grey Cells Indicate Factory

Orifice Size

1,000-1,100

Gas Heating

Value

(BTU's/ft

@ Sea

Level**

*Table is derived from Appendix of the National Fuel Gas Code. To determine the correct orice for your installation consult the National Fuel Gas Code tables E1.1(a) and E1.1(d), 2015 Edition

**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.

900-999

)

800-899

700-799

Sea Level to 1,999'

2,000' to

2,999'

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

42 41 40

39 38 37

37 36 35

3,000' to

3,999'

42 43 43 43 44 44 45 46 47 42 42 42 43 43 44 44 45 46 41 40 41 41 42 42 43 43 44 44 39 40 41 41 42 42 43 43 44 38 39 39 40 41 42 42 43 43 38 39 39 40 41 42 42 43 43 37 38 38 39 40 41 41 42 43 36 36 37 37 38 39 40 41 42

4,000' to

4,999'

5,000' to

5,999'

42 42 43 43 44 44 45

6,000' to

6,999'

7,000' to

7,999'

8,000' to

8,999'

9,000' to

9,999' 10,000'

LP GAS AT HIGH ALTITUDES

HIGH ALTITUDE

LP GAS (TABLE 9)

NOTE: Keep any parts removed during LP conversion procedure

stored with the product literature for future use.

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

TABLE 9

LP GAS IMPORTANT: 80+ MODELS ONLY! DO NOT USE THIS CHART WITH ANY 90+ MODELS.

Input (per Orifice Altitude burner) 25000 Size

0 to 2000 ft. 25,000 54

2000*-3000* 23,000 54

3000*-4000* 22,000 54

4000*-5000* 21,000 54

5000*-6000* 20,000 55

6000*-7000* 19,000 55

7000*-8000* 18,000 55

8000*-9000* 17,000 55

9000*-10000* 16,000 55

are 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.

High Altitude

START-UP PROCEDURES

SEQUENCE OF OPERATIONS

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. (See Section of this book titled Adjusting Input Rate.)

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.

Start-Up Procedure

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.

2. The air proving negative pressure switch(es) closes.

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

8. 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 8-second 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.

FAULT CODES

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:

CODE Description

0 STANDBY

C COMPRESSOR ON (COOLING OR HEAT-PUMP HEAT)

H GAS HEAT ON

F CONTINUOS FAN ON

10 1 HOUR LOCKOUT

11 FAILED IGNITION

12 LOW FLAME SENSE

13 FLAME LOST

14 UNEXPECTED FLAME

20 TWINNING FAULT

22 MAIN LIMIT OR HALC OPEN

26 LINE AND NEUTRAL REVERSED

33 MRLC (MANUAL RESET LIMIT CONTROL) (AKA ROLL-OUT) OPEN

55 PRESSURE SWITCH STUCK CLOSED WHEN SHOULD BE OPEN

57 PRESS SWITCH STUCK OPEN WHEN SHOULD BE CLOSED

61 BLOWER FAULT – BLOWER UNABLE TO RUN

93 INTERNAL CONTROL FAULT

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.

DUAL FAULTS DISPLAYED

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

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

one-hour 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 unex-

pected 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).

Fault Codes

1-STAGE LOCKOUT

LOCKOUT

All lockout conditions can be cleared immediately provided that the original fault causing the lockout is cleared and power to the unit is cycled off and then back on again or (soft lockout only) if

Lockout

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 ve times in one heat call.

- Undesired ame has been detected. The one-hour period will commence after ame 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

Three conditions shall cause a hard lockout:

1. The control senses an unspecied 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 be reset by cycling the heat call.

HARD LOCKOUT

FIELD SELECTIONS & ADJUSTMENTS

FIELD SELECTIONS –– DIPSWITCHES

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 in the bottom position.

Heat Blower-Off Delay; SW2 & SW3

A means of controlling the HEAT speed blower “off” delay time is provided. The dipswitches are labeled SW2 and SW3. The following table defines the settings:

FIGURE 30

DIPSWITCH MAP

1 2 3 4

SW2 SW3

OFF OFF 90 seconds (Factory Setting) ON OFF 120 seconds OFF ON 160 seconds ON ON 180 seconds

Cooling & Heat-Pump Heat Blower Off Delay; SW4

A means of controlling the COOL speed blower “off” delay time is required. The dipswitch is labeled SW4. The following table defines the settings:

SW4

OFF 30 seconds (Factory Setting) ON 45 seconds

Field Selections

Switch 1

Seven Segment

Display Orientation

Switch Setting Orientation

OFF

Downflow

Upflow

ST-A1194-110-00

Switch Pair 4 & 5

Heat Blower Off Delay

Switch Setting

OFF OFF

OFF

Airflow Adjustments

90 Seconds (Factory)

120 Seconds

160 Seconds

180 Seconds

Switch 4

Cool Off Delay

Switch Setting Airflow Adjustments

OFF

45 Seconds

30 Seconds (Factory)

Manual Fault Clear

On/Off 3 TImes for Fault Clear

Off/On 3 times for Fault Clear

TIMING DIAGRAM, FIELD SELECTIONS & ADJUSTMENTS

FAULT CLEAR

MANUAL FAULT CLEAR; SW4

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 SW4, the furnace control will wait to determine if the switch becomes on/off/on/off/on/off or off/on/off/on/off/on

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 diagnostic aid to the

FLAME STATUS L.E.D. (AMBER)

Field Selections

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. The L.E.D. is off when

TIMING DIAGRAM

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.

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

there is no flame detected.

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

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

OFF

OPEN

OFF

CLOSED

OPEN

OFF

TIMING DIAGRAM, FIELD SELECTIONS &

TABLE 10

TIMING DIAGRAM

ADJUSTMENTS

Field Selections

ST-A1194-27-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 pressure readings.

The manifold pressure should be set at 3.5” w.c. for natural gas and 10.0” w.c. 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 above- specified 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. See Table 11.

TIMING DIAGRAM, FIELD SELECTIONS & ADJUSTMENTS

TABLE 11

METER TIME

METER TIME IN MINUTES AND SECONDS FOR NORMAL INPUT RATING OF FURNACES EQUIPPED FOR NATURAL

GAS OR L.P.

INPUT

(BTU/HR)

50,000

75,000

Field Selections

100,000

125,000

150,000

METER SIZE

(FT3/REV)

ONE TEN ONE TEN ONE TEN ONE TEN ONE

TEN

Formula: Input BTU/HR =

Formula: Input BTU/HR = Time (in seconds) for 1 cubic ft of Gas

900 1000 1040 1100 2500 MIN SEC MIN SEC MIN SEC MIN SEC MIN SEC

1 5 1 12 1 15 1 19 3 0 10 48 12 0 12 29 13 12 30 0 0 43 0 48 0 50 0 53 2 0 7 12 8 0 8 19 8 48 20 0 0 32 0 36 0 37 0 40 1 30 5 24 6 0 6 14 6 36 15 0 0 26 0 29 0 30 0 32 1 12 4 19 4 48 4 60 5 17 12 0 0 22 0 24 0 25 0 26 1 0 3 36 4 0 4 10 4 24 10 0

Heating Value of Gas (BTU/ft3) × 3600 x correction factor

HEATING VALUE OF GAS (BTU/FT3)

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.

AIRFLOW

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 ot 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.

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 below the nameplate range, the gas input rate may need to be adjusted or the airflow may be too high. If the gas input is correct, select the next lowest speed tap for the heating function. If the measured temperature rise is above the nameplate range, the gas input rate may need to be adjusted or the duct system may be too restrictive due to undersized ducts. An undersized return duct is a common cause of an overly restrictive duct system.

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

TEMPERATURE RISE MEASUREMENT

FIGURE 32

TYPICAL FURNACE NAME PLATE

Airow

WARNING

THE MEASURED TEMPERATURE RISE MUST BE WITHIN THE TEMPERATURE RISE RANGE SPECIFIED ON THE RATING PLATE. OPERATING THE UNIT WITH A RISE OUTSIDE THE STATED RANGE 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.

TABLE 12

AIR FLOW PERFORMANCE – (-)801T/(-)801C, (-)80MSX/(-)80MSC, FF(-)TS80(-)/FF(-)CS80(-) - SERIES MODELS

Input (Btu)

Cabinet Width (in)

50k

14”

75k

17”

75k

21”

100k

21”

125k

24”

NOTE: Shaded data is factory heating tap.

AIRFLOW CONTROL

SETTINGS

CIRC FAN LOW 894 775 655 595 533 496 462 423 357

HEAT OR HEAT/COOL MED. LO 971 912 875 839 804 758 713 684 644

COOL MEDIUM 1117 1081 1051 1024 995 973 938 908 878

COOL MED. HIGH 1326 1291 1275 1240 1204 1171 1144 1114 1077

COOL HIGH 1440 1432 1405 1382 1353 1322 1305 1272 1251

CIRC FAN LOW 1054 1014 964 911 860 797 711 657 606

COOL MED. LO 1363 1318 1275 1230 1189 1129 1091 1053 1012

HEAT OR HEAT/COOL MEDIUM 1447 1417 1366 1329 1288 1250 1215 1176 1137

COOL MED. HIGH 1553 1521 1478 1444 1407 1372 1332 1295 1264

COOL HIGH 1616 1574 1547 1508 1478 1438 1402 1375 1341

CIRC FAN LOW 1176 1133 1095 1048 1000 951 908 861 810

COOL MED. LO 1353 1312 1267 1236 1186 1149 1106 1079 1016

HEAT OR HEAT/COOL MEDIUM 1400 1346 1307 1276 1225 1181 1145 1103 1069

COOL MED. HIGH 1568 1537 1498 1468 1433 1399 1353 1320 1287

COOL HIGH 1785 1775 1736 1704 1673 1629 1608 1573 1550

CIRC FAN LOW 1277 1211 1164 1103 1035 967 861 800 740

HEAT OR HEAT/COOL MED. LO 1556 1498 1456 1409 1353 1308 1254 1198 1125

COOL MEDIUM 1644 1597 1554 1511 1463 1400 1358 1304 1253

COOL MED. HIGH 1879 1842 1785 1729 1692 1674 1621 1579 1537

COOL HIGH 2071 2025 1992 1948 1902 1872 1840 1795 1750

CIRC FAN LOW 1398 1338 1278 1232 1177 1130 1041 975 909

COOL MED. LO 1593 1546 1495 1454 1414 1342 1304 1251 1190

HEAT OR HEAT/COOL MEDIUM 1878 1844 1807 1753 1714 1675 1634 1578 1536

COOL MED. HIGH 2025 1967 1931 1886 1856 1812 1748 1721 1668

COOL HIGH 2165 2124 2082 2047 2012 1973 1934 1894 1859

EXTERNAL STATIC PRESSURE in INCHES OF W.C.

SPEED TAP 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9

CFM AIR DELIVERY

BLOWER SPEED SELECTIONS

Airow

The UT Electronic Controls control boards have four quick connect terminals for connecting the motor speed leads. These are:

1. FAN SPEED* — motor runs on this speed when the thermostat is in the “FAN” position.

2. COOL — connect desired cooling speed.

3. HEAT — connect desired heating speed.

4. HEAT/COOL* — connect desired speed when heating and cooling speed are the same.

CAUTION

DO NOT CONNECT ANY MOTOR SPEEDS TO “HEAT” OR “COOL” IF YOU USE THE “HEAT/COOL” TERMINAL. DOING SO WILL DAMAGE THE BLOWER MOTOR. UNUSED MOTOR WIRE TAPS MUST BE CONNECTED TO PARKING TERMINALS M1 AND M2 OF THE IFC, OR PROPERLY INSULATED.

See Table 10 for instructions for setting the blower “OFF” timings.

GAS FURNACE (DIRECT DRIVE) INSTRUCTIONS FOR CHANGING BLOWER SPEED

WARNING

DISCONNECT THE ELECTRICAL SUPPLY TO THE FURNACE BEFORE ATTEMPTING TO CHANGE THE BLOWER SPEED. FAILURE TO DO SO CAN CAUSE ELECTRICAL SHOCK RESULTING IN SEVERE PERSONAL INJURY OR DEATH.

The blower motor is wired for blower speeds required for normal operation as shown.

If additional blower speed taps are available (leads connected to “M1” and “M2” on the electronic control), speeds may be changed if necessary to fit requirements of the particular installation. Reconnect the unused motor leads to “M1” or “M2.” Check motor lead color for speed designation.

Heating speeds should not be reduced where it could cause the furnace air temperature to rise to exceed the maximum outlet air temperature specified for the unit.

SAFETY FEATURES

LIMIT CONTROL/HALC

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.

6. Overfiring the furnace with too much gas pressure.

7. Ventilation problems.

8. Failed blower motor.

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. 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 switch 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

Safety Features

MAINTENANCE

WARNING

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

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

IN 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.

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

LUBRICATION

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

Maintenance

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.

SYSTEM OPERATION INFORMATION

MAINTENANCE

ADVISE THE CUSTOMER

1. Keep the air filters clean. The heating system will operate 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 INSPECTION

• 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.

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 com- partment 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 inspec-

tion 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

Homeowners please visit www.rheem.com for product information.

Replacement parts division visit http://www.rheemparts.com/Catalog/

DIAGNOSTICS

Refer to Figure 33 for determining cause of unit problems.

WIRING DIAGRAM

Figure 34 is a complete wiring diagram for the furnace. A wiring diagram is also available on the unit.

Maintenance

FIGURE 33

INTEGRATED FURNACE CONTROL

TROUBLESHOOTING GUIDE

DIAGNOSTICS FLOWCHART

Diagnostics

DISCONNECT POWER BEFORE SERVICING.

SERVICE MUST BE BY A TRAINED, QUALIFIED

WARNING

LINE VOLTAGE

HAZARDOUS VOLTAGE

Always verify gas valve inlet and outlet gas

NOTE: pressure .

START

1) Set FAN switch to “AUTO”

2) Set thermostat to call for heat (set temp. differential to greater than 10

PREPURGE

Does the IDM Energize?

SERVICE TECHNICIAN.

CONNECTIONS

IDM Runs for 30 sec. pre-purge ?

IGNITION TRIAL

Spark Ignitor Sparking?

IBM “ON” DELAY

Does Main Burner Light and stay lit?

FLAME (AMBER) LED CODES OFF = No Flame Present RAPID BLINK = Unexpected Flame SLOW BLINK = Marginal Flame Sense STEADY ON = Normal Flame Sense

YES

CHECK BLINK CODES

- Check for open limit or limit circuit.

YES

- 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) .

** NO

“FAULT DISPLAYED ?”

24V on W to IFC?

YES

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

FOR DIRECT SPARK IGNITION

- Check ignitor connected .

- Check ignitor wires.

- Check ignitor for fractures or cracking

- Check ignitor placement .

- If problem persists, check IFC*.

Is the gas valve energized?

YES

“ATTEND TO FAULT”

- Check thermostat in “heat” mode,

batter y, wire, and connections.

Check IFC*.

Does IDM run

YES

indefinately .

YES

GO TO

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

CODE DESCRIPTION

O C H

F 10 11 12 13 14 20 22 26 33 55 57 58 59 61 93

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

- 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 flo w.

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

- Check flame carry over.

” did not

If “ resolve issue.

Standby Compressor on (cooling or heat pump heat) Gas heat on Continuous fan on 1 hour lockout Failed ignition Low flame sense Flame lost Unexpected flame Twinning fault Main limit open / HALC limit open Line and neutral reversed Mrlc (man. Reset limit cont.)(aka roll-out open) Pres. Switch stuck closed, should be open Pres. Switch stuck open, should be closed Water Sensed Circuit Open Water Sensed Blower fault - blower unable to run Internal control fault

- Check PS contact s

- Check wires for short.

- Check IFC*.

- Check switches and hoses for water or moistur e

TROUBLESHOOTING GUIDE

INTEGRATED FURNACE CONTROL (IFC)

Does IBM start on heat speed 20 seconds

STEADY HEAT

Does main burner remain lit until

Always verify gas valve inlet and outlet gas pressure.

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

NOTE:

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

Does thermostat maintain reasonable room

temperature near setpoint ?

END HEAT CALL

Set thermostat to off position (W to C = ØV)

POST-PURGE

Does gas valve shut off immediately?

Does IDM shut off after ten second post-purge?

IBM “OFF” DELAY

Does IBM shut off after a max. of 3 min?

STEADY OFF

Heat-mode troubleshootin g

after burners light ?

YES

heat call ends?

YES

END

- Check line voltage between “HEAT” and “NEUTRAL” on IFC.

- Check wires, connections, and continuity between IFC and IBM.

- Check IBM capacitor .

- Check IBM.

Is Limit circuit open Note: IFC Status LED should be blinking a Fault Code.

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

- ensure no restrictions, such as dirty filte r, dampers, closed registers, etc.

LIMITS

- ensure good wire and connections between IFC and all limits. Make sur e

limits are not open when cir culating air temperature is within a specified range.

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

ROLLOUTS 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.

Ensure thermostat is properly placed and not improperly affected by

registers, fans, sunlight, heat through walls, pipes, or wires in walls .

Double check - Is W off at IFC?

(W to C = ØV?)

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

YES

GO TO

Check IFC*.

opening and closing?

YES

“FLAME” LED BLINKING OR STEADY ON

If “E” did not resolve issue

Voltage present at gas valve?

Fault Code Present

REPEAT THIS PROCEDURE UNTIL TROUBLE-FREE OPERATION IS OBTAINED.

- 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.

- 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

NOTE: If IFC goes into lockout (“ST ATUS LED will blink code “1”), shut off main power to unit, wait 30 seconds and then reset power .

NO NO

Is t he IFC sensing a good f lame: NOTE: Flame sense l ight sh ould b e steady-on when burners are lit. I f flam e LED blinki ng, or o ff, fl ame sense is low or absent.

- Check IFC*.

YES

SEE FAULT CODES

PROBLEM

PRESENT

CHECK:

- grounding on IFC and unit.

- check for proper polarity between L1 & neutral.

- flame sense rod (clean if necessar y).

- w ire continually between flame sense rod and appropriate pin of connector on IFC

- flame carries across all burners, and all burners stay lit.

- Check heat anticipator setting. Furnace may need an isolation relay.

- Check installation instructions under section titled “Isolation Relay” for

STILL

details .

- Verify correct furnace sizing.

- Check gas valve.

YES

PS dropping out ?

GO TO

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

**System will attempt to light 4 times. Vo ltage 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.

YES

Check IFC*

ST-A1194-23-03

FIGURE 34

WIRE COLOR CODE

G........GREEN

GY......GRAY

O........ORANGE

PR......PURPLE

R........RED

W.......WHITE

Y........YELLOW

WARNING

-CABINET MUST BE PERMANE NTLY GROUNDED

AND CONFORM TO I.E.C., N.E.C., C.E.C.,

NATIONAL WIRING REGULATIONS, AND LOCAL

CODES A S APPLICABLE.

REPLACEMENT WIRE

-MUST BE THE SAME SIZE AND TYPE

OF I NSULATION AS ORIGINAL (105C. MIN.)

-FIELD INSTALLED

-FACTORY OPTION

ORIGINAL RELEASE

NO.:

ELECTRICAL WIRING DIAGRAM

MODELED

BY:

CHECKED:APPROVED:

REV:PART NO.:

DATE:

PL-2

PL-1

FOR MODELS WITH UT ELECTRONIC CONTROLS 1194-200 INTEGRATED FURNACE CONTROL AND DIRECT SPARK IGNITION

P3-1

P3-4

P3-2

P1-4

P1-2

P3-3

P1-3

90+ CT

1 STAGE

P5-1

P1-6

P1-5

MGV

BK......BLACK

BR......BROWN

BL.......BLUE

COMPONENT CODES

Wiring Diagram

INPUT / SIZE

40K / 17” WIDE

60K / 17” WIDE

70K / 17” WIDE

85K / 21” WIDE

115K / 24” WIDE

100K / 21” WIDE

NOTES

WIRING INFORMATION

LOW VOLTAGE

-FIELD INSTALLED

-FACTORY OPTION

-FACTORY STANDARD

LINE VOLTAGE

-FACTORY STANDARD

52 CM 0917

Rheem 801T Series, 801C Series, 80MSC Series, 80MSX Series, FF TS80 Series Installation Instructions Manual

Specifications and Main Features

Frequently Asked Questions

User Manual