92-24161-22 Rev. 21 High Efficiency Modulating Gas Furnace

INSTALLATION INSTRUCTIONS
FOR (-)GFD UPFLOW, (-)GGD DOWNFLOW, & (-)GJD
DEDICATED HORIZONTAL HIGH EFFICIENCY
MODULATING CONDENSING GAS FURNACES
(-)GFD
(-)GJD
MODULATING
THERMOSTAT
INSTALLATION
SEE PAGE 46
(-)GGD
ISO 9001:2000
92-24161-22-21
SUPERSEDES 92-24161-22-20
IMPORTANT: All Rheem products
meet current Federal OSHA Guidelines
for safety. California Proposition 65
warnings are required for certain products, which are not covered by the
OSHA standards.
CONTENTS
California's Proposition 65 requires
warnings for products sold in California
that contain, or produce, any of over
600 listed chemicals known to the
State of California to cause cancer or
birth defects such as fiberglass insulation, lead in brass, and combustion
products from natural gas.
General Information ...............................................................................................6
All “new equipment” shipped for sale in
California will have labels stating that
the product contains and/or produces
Proposition 65 chemicals. Although we
have not changed our processes, having the same label on all our products
facilitates manufacturing and shipping.
We cannot always know “when, or if”
products will be sold in the California
market.
Condensate Drain/Optional Neutralizer ...............................................................34
You may receive inquiries from customers about chemicals found in, or
produced by, some of our heating and
air-conditioning equipment, or found in
natural gas used with some of our
products. Listed below are those chemicals and substances commonly associated with similar equipment in our
industry and other manufacturers.
•
•
•
•
Glass Wool (Fiberglass) Insulation
Carbon Monoxide (CO)
Formaldehyde
Benzene
More details are available at the
Websites for OSHA (Occupational
Safety and Health Administration), at
www.osha.gov and the State of
California's OEHHA (Office of
Environmental Health Hazard
Assessment), at www.oehha.org.
Consumer education is important since
the chemicals and substances on the
list are found in our daily lives. Most
consumers are aware that products
present safety and health risks, when
improperly used, handled and maintained.
2
Safety Information..................................................................................................3
Installation Check List ............................................................................................5
Location Requirements and Considerations..........................................................9
Venting and Combustion Air Piping .....................................................................18
Non-Direct Vent Pipe Installation .........................................................................20
Direct Vent Pipe Installation.................................................................................24
Gas Supply and Piping ........................................................................................38
Electrical Wiring ...................................................................................................43
Thermostats .........................................................................................................45
Applications..........................................................................................................48
Accessories..........................................................................................................59
High Altitude Installations.....................................................................................63
Integrated Furnace Control ..................................................................................67
Start-Up Procedures ............................................................................................70
Maintenance ........................................................................................................73
Troubleshooting ...................................................................................................76
Wiring Diagram ....................................................................................................84
Installation Instructions are updated on a regular basis. This is done as product
changes occur or if new information becomes available. In this publication, an
arrow ➤ denotes changes from the previous edition or additional new material.
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.
SAFETY INFORMATION
!
WARNING
INSTALL THIS FURNACE ONLY
IN A LOCATION AND POSITION
AS SPECIFIED IN THE LOCATION REQUIREMENTS AND
CONSIDERATIONS SECTION OF
THESE INSTRUCTIONS.
PROVIDE ADEQUATE COMBUSTION AND VENTILATION AIR TO
THE FURNACE SPACE AS
SPECIFIED IN THE VENTING
SECTION OF THESE INSTRUCTIONS.
!
WARNING
PROVIDE ADEQUATE COMBUSTION AND VENTILATION AIR TO
THE FURNACE SPACE AS
SPECIFIED IN 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 VENT PIPE INSTALLATION
SECTION OF THESE INSTRUCTIONS.
!
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 TION INSTRUCTIONS.
!
WARNING
USE ONLY WITH TYPE OF GAS
APPROVED FOR THIS FURNACE. REFER TO THE FURNACE
RATING PLATE.
!
WARNING
ALWAYS INSTALL 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
DUCTING SECTION OF THESE
INSTRUCTIONS. SEE ALSO
FURNACE RATING PLATE.
!
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
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
THIS FURNACE IS NOT
APPROVED OR RECOMMENDED
FOR INSTALLATION ON ITS
BACK, WITH ACCESS DOORS
FACING UPWARDS, OR WITH
SUPPLY AIR DISCHARGING TO
THE RIGHT-HAND SIDE WHEN
FACING THE FRONT OF THE
FURNACE. SEE FIGURES 5 AND
6 FOR PROPER INSTALLATION
OF HORIZONTAL MODELS.
!
WARNING
DO NOT JUMPER OR OTHERWISE BYPASS OVERTEMPERATURE OR ANY OTHER LIMITS
OR SWITCHES ON THE FURNACE. IF ONE OF THESE LIMITS
OR SWITCHES SHOULD TRIP OR
OPEN, THE USER IS TO BE
INSTRUCTED TO CALL A QUALIFIED INSTALLER, SERVICE
AGENCY OR THE GAS SUPPLIER. FOR MANUALLY
RESETABLE SWITCHES, THE
USER IS FURTHER INSTRUCTED
TO NEVER RESET THE SWITCH,
BUT TO CALL A QUALIFIED
TECHNICIAN. MANUAL RESET
SWITCHES MAY REQUIRE FURTHER CORRECTIVE ACTIONS.
FAILURE TO FOLLOW THIS
WARNING COULD RESULT IN
CARBON MONOXIDE POISONING, SERIOUS INJURY OR
DEATH. IF THE UNIT IS
INSTALLED IN A CLOSET, THE
DOOR MUST BE CLOSED WHEN
MAKING THIS CHECK.
INSTALLERS AND TECHNICIANS
ARE INSTRUCTED TO REPLACE
ANY LIMIT OR SAFETY
SWITCH/DEVICE ONLY WITH
IDENTICAL REPLACEMENT
PARTS.
!
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 ABOVE THE FLOOR.
THIS IS TO REDUCE 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.
!
WARNING
USE OF THIS FURNACE IS
ALLOWED DURING CONSTRUCTION IF THE FOLLOWING
TEMPORARY INSTALLATION
REQUIREMENTS ARE MET.
INSTALLATION MUST COMPLY
WITH ALL INSTALLATION
INSTRUCTIONS INCLUDING:
• PROPER VENT INSTALLATION;
• FURNACE OPERATING
UNDER THERMOSTATIC CONTROL;
• RETURN AIR DUCT SEALED
TO THE FURNACE;
• AIR FILTERS IN PLACE;
• SET FURNACE INPUT RATE
AND TEMPERATURE RISE
PER RATING PLATE MARKING;
• MEANS FOR PROVIDING
OUTDOOR AIR REQUIRED
FOR COMBUSTION;
• RETURN AIR TEMPERATURE
MAINTAINED BETWEEN 55°F
(13°C) AND 80°F (27°C); AND;
• CLEAN FURNACE, DUCT
WORK AND COMPONENTS
UPON SUBSTANTIAL COMPLETION OF THE CONSTRUCTION PROCESS, AND VERIFY
FURNACE OPERATING CONDITIONS INCLUDING IGNITION, INPUT RATE, TEMPERATURE RISE AND VENTING,
ACCORDING TO THE
INSTRUCTIONS.
3
!
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
4).
• 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.
4
NOTICE
IMPROPER INSTALLATION, OR
INSTALLATION NOT MADE IN
ACCORDANCE WITH THE CSA
INTERNATIONAL (CSA) CERTIFICATION OR THESE INSTRUCTIONS, CAN RESULT IN UNSATISFACTORY OPERATION AND/OR
DANGEROUS CONDI-TIONS AND
ARE NOT COVERED BY THE UNIT
WARRANTY.
NOTICE
IN COMPLIANCE WITH RECOGNIZED CODES, IT IS RECOMMENDED THAT AN AUXILIARY
DRAIN PAN BE INSTALLED
UNDER ALL EVAPORATOR COILS
OR UNITS CONTAINING EVAPORATOR COILS THAT ARE 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 COIL
DRAIN PAN OR A STOPPAGE IN
THE PRIMARY CONDENSATE
DRAIN PIPING. SEE ACCESSORIES SECTION OF THESE
INSTRUCTIONS FOR AUXILIARY
HORIZONTAL OVERFLOW PAN
INFORMATION (MODEL RXBM).
INSTALLATION CHECK LIST
REFER TO INSTALLATION INSTRUCTIONS
GAS SUPPLY
Adequate pipe size
TERMINATIONS – DIRECT VENT
VERTICAL
Correct supply pressure (during furnace operation)
Intake – 12" min. above roof/snow level
Manifold pressure
Correct relationship – exhaust to intake
No gas leaks
ELECTRICAL
115 V.A.C. supply (Single Circuit)
VERTICAL – CONCENTRIC (RXGY-E03A)
Intake – 12" min. above roof/snow level
HORIZONTAL – STANDARD (RXGY-D02, -D02A, -D03,
-D03A)
Polarity observed
Correct relationship – exhaust to intake
Furnace properly grounded (Earth ground)
12" min. above grade/snow level
Adequate wire size
FURNACE INSTALLATION
Adequate clearance to combustibles
Adequate clearance for service (at front)
DUCT STATIC PRESSURE
in. w.c. on heating speed
in. w.c. on cooling speed
HORIZONTAL – ALTERNATE (RXGY-D02, -D02A, -D03,
-D03A, -D04 OR -D04A)
Correct relationship – exhaust to intake
Above anticipated snow level
HORIZONTAL – CONCENTRIC (RXGY-E03A)
12" min. above grade/snow level
Intake “Y” rotated above center
Exhaust sloped toward furnace
Air temperature rise
VENTING – NON-DIRECT VENT (VERTICAL ONLY)
CONDENSATE LINE
Trap filled with water
Vented
in. diameter – exhaust pipe
ft. of pipe – exhaust
no. of elbows
Sloped toward drain
Condensate drain line hoses connected
and clamped
TERMINATION – NON-DIRECT VENT (VERTICAL ONLY)
12" min. above roof/snow level
Model #
Freeze protection (if necessary)
Serial #
______ Neutralizer (if needed)
Date of installation
VENTING – DIRECT VENT
in. diameter – intake pipe
in. diameter – exhaust pipe
ft. of pipe – intake air
no. of elbows – intake air
HORIZONTAL – STANDARD
12" min. above grade/snow level
HORIZONTAL – ALTERNATE
Above anticipated snow level
ft. of pipe – exhaust pipe
no. of elbows – exhaust pipe
5
GENERAL INFORMATION
The (-)GFD,(-)GGD and (-)GJD
series furnaces are design-certified
by CSA for use with natural and L.P.
gases as follows:
• As direct vent, central forced air
furnaces with all combustion air
supplied directly to the furnace
burners through a special air intake
system outlined in these instructions.
• As non-direct, central forced air furnace taking combustion air from
the installation area or using air
ducted from the outside.
• IMPORTANT: Proper application,
installation and maintenance of this
furnace are required if consumers
are to receive the full benefits for
which they have paid.
CSA International - U.S.
8501 East Pleasant Valley Road
Cleveland, Ohio, 44131
Install this furnace in accordance with
the American National Standard
Z223.1 – latest edition entitled
“National Fuel Gas Code” (NFPA54,
90A and 90B) and requirements or
codes of the local utilities or other
authorities having jurisdiction. This is
available from the following:
Canadian installations must be
installed in accordance with CSA,
local installation codes and
authorities having jurisdiction.
CSA is available from:
National Fire Protection
Association, Inc.
Batterymarch Park
Quincy, MA 02269
CSA International - Canada
178 Rexdale Blvd.
Etobicoke (Toronto), Ontario,
Canada M9W-1R3
➤ FIGURE 2
FIGURE 1
UPFLOW FURNACE (-)GFD
DOWNFLOW FURNACE (-)GGD
I678
ITEM
NO. PART NAME
6
ITEM
NO. PART NAME
ITEM
NO. PART NAME
1
CONDENSATE TRAP
14
TOP PLATE
1
GAS VALVE
2
DOOR SWITCH
15
BURNER
2
CAPACITOR
3
JUNCTION BOX
16
IGNITER
3
LOW PRESSURE SWITCH
4
TRANSFORMER
17
COMBUSTION AIR INLET
4
HIGH PRESSURE SWITCH
5
LOW PRESSURE SWITCH
18
GAS VALVE
5
BLOWER HOUSING
6
HIGH PRESSURE SWITCH
19
CAPACITOR
6
POWER FACTOR CHOKE
7
EXHAUST TRANSITION
20
INDUCED DRAFT BLOWER
7
BLOWER MOTOR
8
CONNECTOR
21
POWER FACTOR CHOKE
8
DOOR SWITCH
9
MAIN LIMIT
22
IGNITION CONTROL
9
JUNCTION BOX
10
EXHAUST AIR PIPE
23
INTEGRATED FURNACE CONTROL
10
COMBUSTION AIR INLET
11
VENT CAP PLUG
24
BLOWER MOTOR
11
HALC
12
FLAME SENSOR
25
R/A SENSOR
12
TOP PLATE
13
OVERTEMPERATURE SWITCH
26
BLOWER HOUSING
13
RETURN AIR SENSOR
ITEM
NO. PART NAME
14
15
16
17
18
19
20
21
22
23
24
25
26
27
VENT CAP PLUG
EXHAUST AIR PIPE
INTEGRATED FURNACE CONTROL
TRANSFORMER
IGNITION CONTROL
INDUCED DRAFT BLOWER
CONNECTOR
EXHAUST TRANSITION
MAIN LIMIT
CONDENSATE TRAP
IGNITER
OVERTEMPERATURE SWITCH
BURNER
FLAME SENSOR
➤ FIGURE 3
HORIZONTAL FURNACE (-)GJD
27
FACTORY-INSTALLED STREET ELBOW
7
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.
!
IMPROPER INSTALLATION, OR
INSTALLATION NOT MADE IN
ACCORDANCE WITH THE CSA
INTERNATIONAL (CSA) CERTIFICATION OR THESE INSTRUCTIONS,
CAN RESULT IN UNSATISFACTORY
OPERATION AND/OR DANGEROUS
CONDI-TIONS AND ARE NOT COVERED BY THE UNIT WARRANTY.
•
•
•
NOTICE
IN COMPLIANCE WITH RECOGNIZED CODES, IT IS RECOMMENDED THAT AN AUXILIARY DRAIN PAN
BE INSTALLED UNDER ALL EVAPORATOR COILS OR UNITS CONTAINING EVAPORATOR COILS THAT ARE
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 COIL
DRAIN PAN OR A STOPPAGE IN THE
PRIMARY CONDENSATE DRAIN PIPING. SEE ACCESSORIES SECTION
OF THESE INSTRUCTIONS FOR
AUXILIARY HORIZONTAL OVERFLOW PAN INFORMATION (MODEL
RXBM).
•
•
•
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
4).
• 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.
8
NOTICE
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 a level position to
ensure proper condensate
drainage. Make sure unit is level in
both directions within 1/8”.
Install the unit in accordance with
any local code which may apply
and the national codes. Latest edi-
FIGURE 4
MIGRATION OF DANGEROUS SUBSTANCES, FUMES, AND ODORS INTO LIVING SPACES
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
•
•
•
•
tions 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.
LOCATION REQUIREMENTS AND CONSIDERATIONS
GENERAL INFORMATION
! CAUTION
DO NOT USE THIS FURNACE
DURING CONSTRUCTION IF
AIR LADEN CORROSIVE COMPOUNDS ARE PRESENT SUCH
AS CHLORINE AND FLUORINE.
OTHERWISE, PROVISIONS
MUST BE TAKEN TO PROVIDE
CLEAN, UNCONTAMINATED
COMBUSTION AND VENTILATION AIR TO THE FURNACE.
FURNACE COMBUSTION AND
VENTILATION AIR CONTAMINATED WITH THESE COMPOUNDS FORMS ACIDS DURING COMBUSTION WHICH CORRODES THE HEAT EXCHANGER
AND COMPONENT PARTS.
SOME OF THESE CONTAMINANTS ARE FOUND IN, BUT
NOT LIMITED TO, PANELING,
DRY WALL, ADHESIVES,
PAINTS, STAINS, VARNISHES,
SEALERS, AND MASONRY
CLEANING MATERIALS.
!
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
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 ABOVE THE FLOOR.
THIS IS TO REDUCE THE RISK
OF IGNITING FLAMMABLE
VAPORS WHICH MAY
BE PRESENT IN A GARAGE.
ALSO, THE FURNACE MUST BE
LOCATED OR PROTECTED TO
AVOID PHYSICAL DAMAGE BY
VEHICLES. FAILURE TO FOLLOW THESE WARNINGS CAN
CAUSE A FIRE OR EXPLOSION,
RESULTING IN PROPERTY DAMAGE, PERSONAL INJURY OR
DEATH.
1. IMPORTANT: If installing the unit
over a finished ceiling or living
area, be certain to install an auxiliary condensate drain pan under
the entire unit. Extend this auxiliary drain pan under any evaporator coil installed with the furnace
and the open portion of the con-
densate drain assembly. See
“Condensate Drain/Neutralizer”
section for more details.
2. IMPORTANT: If using a cooling
evaporator coil with this furnace.
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.
3. IMPORTANT: Install the furnace
level. If it is not level, condensate
cannot drain properly, possibly
causing furnace shut down.
NOTE: These furnaces are approved
for installation in attics, as well as
alcoves, utility rooms, closets and
crawlspaces. Make provisions to prevent freezing of condensate.
5. 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.
6. Install the furnace level and
plumb. If it is not level, condensate cannot drain properly, possibly causing furnace to shut
down.
IMPORTANT: Do not attempt to twin
the modulating furnace. The characteristics of the ECM blower motor
preclude twinning applications.
4. IMPORTANT: If this furnace is
installed in a garage, attic or any
other unconditioned space, a selfregulating heat tape must be
installed around the condensate
trap and along the entire length of
the condensate drain in the unconditioned space.
The heat tape should meet the following requirements:
a. The heat tape must be UL listed.
b. Install the heat tape per the
manufacturer’s instructions for
the entire length of drain pipe in
the unconditioned space.
c. The heat tape should be rated
at 3 or 5 watts per foot at 120V.
FIGURE 4
HORIZONTAL FURNACE WITH HEAT TAPE ON CONDENSATE TRAP
SUPPLY
AIR
DRAIN
PIPE
HEAT
TAPE
TRAP
RETURN
AIR
9
!
FIGURE 6
HORIZONTAL FURNACE INSTALLED W/SUPPORT BRACKETS
GAS
PIPE
INTAKE
VENT
ELECTRICAL
CONDUIT
SUPPLY
AIR
TRAP
RETURN
AIR
FIGURE 7.
CAUTION
THIS FURNACE IS NOT
APPROVED OR RECOMMENDED
FOR INSTALLATION ON ITS BACK,
WITH ACCESS DOORS FACING
UPWARDS, OR WITH SUPPLY AIR
DISCHARGING TO THE RIGHT
HAND SIDE WHEN FACING THE
FRONT OF THE FURNACE.
THE FOLLOWING MODELS
INCLUDE THE ADDITIONAL BRACKET (WHICH MUST BE REMOVED)
ON THE BLOWER ASSEMBLY:
SEE FIGURES 5 AND 6 FOR PROPER INSTALLATION OF HORIZONTAL MODELS.
CLEARANCE ACCESSIBILITY
FIGURE 7
REMOVING SHIPPING BRACKET
(-)GFD/GGD/or GJD-09EZCMS
(-)GFD/GGD/or GJD-10EZCMS
(-)GFD/GGD/or GJD-12ERCMS
(-)GGD Furnace Special Base For
BTU’s
Combustible Floors
60, 75
RXGC-B17
90, 105
RXGC-B21
120
RXGC-B24
See name/rating plate and clearance
label for specific model number and
clearance information.
Upflow furnaces are shipped with
a bottom closure panel installed.
When bottom return air is used,
remove the panel by removing the
two screws attaching the panel to
the front base angle. See filter section for details.
FOR PURPOSES OF SERVICING
THIS APPLIANCE, ACCESSIBILITY
CLEARANCES, WHERE GREATER,
SHOULD TAKE PRECEDENCE OVER
FIRE PROTECTION CLEARANCES.
92-24379-01
CAUTION
SOME MODELS HAVE A SHIPPING
BRACKET INSTALLED TO PROTECT THE BLOWER ASSEMBLY
DURING SHIPPING.
LOCATE AND REMOVE THE SHIPPING BRACKET FROM THE SIDE
OF THE BLOWER HOUSING
BEFORE OPERATING UNIT. SEE
10
(-)GFD upflow furnaces and (-)GGD
downflow furnaces are designed
and certified for installation on
combustible (wood only) floors.
(-)GGD downflow furnaces may be
installed on a cased evaporator coil
mounted on a combustible (wood
only) floor or (for installations without an evaporator coil) installed on
a special base for combustible
floors mounted to a combustible
(wood only) floor. The necessary
floor base for installing a (-)GGD
furnace in the downflow configuration to a combustible (wood only)
floor is an accessory sold through
finished goods. Following is a list
of floor base models by furnace
input size.
The design of forced air furnaces with
models as listed in the tables under
Figures 9, 10 and 11 are certified by
CSA Laboratories for the clearances to
combustible materials shown in inches.
Service clearance of at least 24 inches
is recommended in front of
all furnaces.
!
FURNACES MUST NOT BE
INSTALLED DIRECTLY ON CARPET,
TILE OR OTHER COMBUSTIBLE
MATERIAL. INSTALLATION ON A
COMBUSTIBLE MATERIAL OTHER
THAN WOOD FLOORING MAY
RESULT IN FIRE CAUSING DAMAGE, PERSONAL INJURY OR
DEATH.
(-)GGD FURNACES MAY NOT BE
INSTALLED DIRECTLY TO A COMBUSTIBLE FLOOR. A SPECIAL
FLOOR BASE IS REQUIRED.
EXHAUST
VENT
!
WARNING
FIGURE 8
BASE FOR COMBUSTIBLE FLOORS
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. Vent from the furnace to the termination with minimal length and elbows.
3. Locate the furnace near the existing gas piping. If running a new gas
line, locate the furnace to minimize
the length and elbows in the gas
piping.
4. Locate the furnace to maintain
proper clearance to combustibles
as shown in Figures 9, 10 & 11.
!
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.
11
12
NOTE: For 1800 or more CFM, both side
returns must be used when not using a
bottom return configuration.
(-)GFD
UPFLOW MODELS
FIGURE 9
PHYSICAL DIMENSIONS AND CLEARANCE TO COMBUSTIBLES, UPFLOW MODELS
AIRFLOW
AO39201
(SUPPLY)
(-)GJD
AIRFLOW
(RETURN)
NOTE: For 1800 or more CFM, both side
returns must be used when not using a
bottom return configuration.
IMPORTANT: THIS FURNACE MAY
ONLY BE INSTALLED SO AS WHEN
FACING THE FRONT OF THE FURNACE, SUPPLY AIR IS DISCHARGED ON THE LEFT HAND
SIDE.
!FIGURE 10
DIMENSIONS AND CLEARANCES TO COMBUSTIBLES, HORIZONTAL MODELS
13
!FIGURE 11
(-)GGD
DOWNFLOW MODELS
(Downflow Configuration)
DIMENSIONS AND CLEARANCES TO COMBUSTIBLES, DOWNFLOW MODELS
AIRFLOW
A084901.S01
JWR 7-21-99
14
DUCTING
Proper airflow is required for the correct
operation of this furnace.
Too little airflow can cause erratic operation and can damage the heat
exchanger. The supply and return duct
must carry the correct amount of air for
heating and cooling if summer air conditioning is used.
Size the ducts according to acceptable
industry standards and methods. The
total static pressure drop of the supply
and return duct should not exceed 0.2"
w.c.
!
WARNING
NEVER ALLOW THE PRODUCTS
OF COMBUSTION FROM THE
FLUE TO ENTER THE RETURN
AIR DUCTWORK OR THE CIRCULATED AIR SUPPLY. ALL RETURN
DUCTWORK MUST BE ADEQUATELY SEALED AND
SECURED TO THE FURNACE
WITH SHEET METAL SCREWS;
AND JOINTS, TAPED. SECURE
ALL OTHER DUCT JOINTS WITH
APPROVED CONNECTIONS AND
SEAL AIRTIGHT. WHEN A FURNACE IS MOUNTED ON A PLATFORM WITH RETURN THROUGH
THE BOTTOM, IT MUST BE
SEALED AIRTIGHT BETWEEN
THE FURNACE AND THE RETURN
AIR PLENUM. THE FLOOR OR
PLATFORM MUST PROVIDE
PHYSICAL SUPPORT OF THE
FURNACE WITHOUT SAGGING,
CRACKS, OR GAPS AROUND THE
BASE, PROVIDING A SEAL
BETWEEN THE SUPPORT AND
THE BASE.
FAILURE TO PREVENT PRODUCTS OF COMBUSTION FROM
BEING CIRCULATED INTO THE
LIVING SPACE CAN CREATE
POTENTIALLY HAZARDOUS CONDITIONS, INCLUDING CARBON
MONOXIDE POISONING THAT
COULD RESULT IN PERSONAL
INJURY OR DEATH.
DO NOT, UNDER ANY CIRCUMSTANCES, CONNECT RETURN OR
SUPPLY DUCTWORK TO OR
FROM ANY OTHER HEAT PRODUCING DEVICE SUCH AS A
FIREPLACE INSERT, STOVE, ETC.
DOING SO MAY RESULT IN FIRE,
CARBON MONOXIDE POISONING,
EXPLOSION, PERSONAL INJURY
OR PROPERTY DAMAGE.
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 the factory-provided filter.
UPFLOW UNITS
1. Position the unit to minimize long
runs of duct or runs of duct with
many turns and elbows.
!
WARNING
UPFLOW FURNACE: A 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 POTENTIALLY
HAZARDOUS CONDITIONS, INCLUDING CARBON MONOXIDE POISONING
OR DEATH.
2. Open the return air compartment.
a. If using side return air, do not
remove the bottom base.
b. Cut an opening in the side .
The opening should be cut the
full width of the knockouts on
the unit.
NOTE: When using side
return, return air plenums,
RXGR-C17B, C21B and C24B
are available from the factory.
c. Remove the bottom base, if
using bottom return air.
Remove the panel by removing the two screws attaching
the base to the front base
angle. See Figure 12.
NOTE: Where the maximum
airflow is 1800 CFM or more,
both sides or the bottom must
be used for return air.
3. Connect the return duct or return
air cabinet to the unit. Make the
connection air tight to prevent
entraining combustion gases from
an adjacent fuel-burning appliance.
4. Be sure to have adequate
space for the unit filter.
NOTE: DO NOT take return air
from bathrooms, kitchens, furnace
rooms, garages, utility or laundry
rooms, or cold areas. DO NOT
use a rear air return.
5. 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.
6. Connect the supply air plenum to
the furnace plenum opening.
IMPORTANT: If a flexible duct
connector must be used, it MUST
be rated for a minimum temperature of 250°F. continuous.
FIGURE 12
BOTTOM PANEL REMOVAL
NOTE: FILTER AND FILTER-ROD ARE SHIPPED
ON TOP OF SOLID BOTTOM. REMOVE FILTER
AND FILTER ROD TO ACCES SOLID BOTTOM
542201-B1
15
DOWNFLOW UNITS
1. Position the unit to minimize long
runs of duct or runs of duct with
many turns and elbows.
2. 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.
3. If installing on a combustible floor
and not using an air conditioning
plenum, install the special base for
combustible floors. See Figure 8.
! WARNING
THE DOWNFLOW FURNACE DESIGN
IS CERTIFIED FOR INSTALLATION
ON A NON-COMBUSTIBLE FLOOR.
USE THE SPECIAL BASE SPECIFIED
ON THE FURNACE CLEARANCE
LABEL. FAILURE TO INSTALL THE
SPECIAL BASE MAY RESULT IN
FIRE, PROPERTY DAMAGE, PERSONAL INJURY OR DEATH. THIS
SPECIAL BASE IS SHIPPED FROM
THE FACTORY AS AN ACCESSORY.
4. Connect the furnace to the supply
air plenum.
5. 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 fuelburning appliance.
6. Be sure to have adequate space
for the unit filter.
NOTE: DO NOT take return air
from bathrooms, kitchens, furnace
rooms, garages, utility or laundry
rooms, or cold areas.
HORIZONTAL UNITS
((-)GJD MODELS)
IMPORTANT: This furnace may only be
installed so as when facing the front of
the furnace, supply air is discharged on
the left hand side.
1. Position the unit to minimize long
runs or runs with many turns and
elbows.
2. 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.
3. Connect the furnace to the supply
air plenum.
16
4. Connect the return air ducting to the
return air opening at the right end of
the unit. Make the connection air
tight to prevent entraining combustion gases from an adjacent fuelburning appliance.
5. Be sure to have adequate space
for the unit filter.
NOTE: DO NOT take return air from
bathrooms, kitchens, furnace rooms,
garages, utility or laundry rooms, or
cold areas.
! Return air can come from : (1) outside the building, (2) from return air
ducting from several inside rooms, or
(3) a combination of the two. When
using outside air, design and adjust
the system to maintain a return air
temperature above 55°F during the
heating season. If return air comes
from both inside and outside the
building, design the ducting system
with a diverting damper so that the
volume of return air entering the furnace equals that which would normally enter through the return air
intake of the furnace. Any duct opening pulling return air from the outside
must not be any higher nor closer
than 10 feet to the furnace exhaust
vent.
SUPPLY AIR SENSOR
Each furnace comes shipped from the
factory with a supply air sensor. Install
the sensor, in the supply air plenum
trunk, with two, field supplied, #8 sheet
metal screws, using the following guidelines:
1. 12” downstream of the evaporator
coil, if installed.
2. If no evaporator coil is used, locate
the sensor out of direct line-of-site
of the heat exchanger and not closer than 18” downstream of the furnace outlet.
NOTE: In downflow circumstances
where building construction does not
allow for the placement of the sensor to
fall within these parameters, the supply
air sensor should not be connected.
This means that the furnace will run
under default parameters. When running under default parameters, the “82”
code will appear for 90 seconds. After
that, the fault code will be stored in the
control board’s memory and will show
only upon power cycling. Default airflow
parameters can be manually adjusted.
See section discussing Integrated
Furnace Control (IFC) board in this
manual.
3. Attach the supply air sensor wires
onto the terminals marked “SA
Sensor” on the integrated furnace
control board (See Figure 13).
4. Do not extend the supply-air sensor
wire.
NOTE: Improper placement of the
supply air sensor can adversely
affect furnace temperature rise.
FIGURE 13
SUPPLY AIR SENSOR TERMINALS
17
VENTING AND COMBUSTION AIR PIPING
GENERAL INFORMATION
!
WARNING
READ AND FOLLOW ALL
INSTRUCTIONS IN THIS SECTION. FAILURE TO PROPERLY
VENT THIS FURNACE OR PROTECT IT FROM INADEQUATE
COMBUSTION AIR CAN CAUSE
CARBON MONOXIDE POISONING, AN EXPLOSION OR FIRE,
RESULTING IN PROPERTY DAMAGE, PERSONAL INJURY OR
DEATH.
OVER TEMPERATURE
SAFETY SWITCHES
Furnaces are equipped with safety
switches in the burner compartment to
protect against over temperature conditions. If a switch is tripped, it must be
manually reset.
!
WARNING
DO NOT JUMPER OVERTEMPERATURE OR ANY OTHER
SAFETY SWITCHES! IF ONE OF
THESE OVER TEMPERATURE
SWITCHES SHOULD TRIP, CALL
A QUALIFIED INSTALLER, SERVICE AGENCY OR THE GAS
SUPPLIER. DO NOT RESET THE
SWITCHES WITHOUT TAKING
CORRECTIVE ACTION. FAILURE
TO DO SO CAN RESULT IN CARBON MONOXIDE POISONING OR
DEATH. IF THIS UNIT IS
INSTALLED IN A CLOSET, THE
DOOR MUST BE CLOSED WHEN
MAKING THIS CHECK.
REPLACE THE OVER TEMPERATURE SAFETY SWITCHES ONLY
WITH THE IDENTICAL REPLACEMENT PART.
!
WARNING
IN CANADA, PRODUCTS CERTIFIED FOR INSTALLATION AND
INTENDED TO BE VENTED WITH
PLASTIC VENT SYSTEMS (PVC,
CPVC) MUST USE VENT SYSTEMS THAT ARE CERTIFIED TO
THE STANDARD FOR TYPE BH
GAS VENTING SYSTEMS, ULC
S636.
18
THE COMPONENTS OF THE
CERTIFIED MATERIAL MUST
NOT BE INTERCHANGED WITH
OTHER VENT SYSTEMS OR
UNLISTED PIPE/FITTINGS.
PLASTIC COMPONENTS AND
SPECIFIED PRIMERS AND
GLUES OF THE CERTIFIED SYSTEM MUST BE FROM A SINGLE
SYSTEM MANUFACTURER AND
NOT INTERMIXED WITH OTHER
SYSTEM MANUFACTURER’S
PARTS.
NOTE: INLET AIR PIPING IS NOT
CONSIDERED TO BE A PART OF
THE “VENTING SYSTEM”. THE
REQUIREMENT THAT VENT MATERIAL BE CERTIFIED TO ULC S636
DOES NOT APPLY TO INLET AIR
PIPING.
4.
5.
6.
INSTALLATION WITH
PRE-EXISTING VENT
SYSTEMS
When the installation of this furnace
replaces an existing furnace that is
removed from a vent system serving
other appliances (such as a water
heater), the existing vent system is likely
to be too large to properly vent the
remaining attached appliances.
Follow the steps below with each appliance remaining connected to the original common vent system. Place the
appliance to be tested in operation,
while the other appliances remaining
connected to the common vent system
are not in operation. Test the operation
of each appliance individually by the following method.
1. Permanently seal any unused
openings in the common venting
system.
2. 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.
3. If 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
7.
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.
Follow the lighting instructions.
Place the appliance being
inspected into operation. Adjust
the thermostat so the appliance
will operate continuously.
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.
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.
If improper venting is observed
during any of the above tests,
resize the common venting system. Refer to latest edition of the
National Fuel Gas Code ANSI
Z223.1, or the CSA-GAMA venting tables for Category I furnaces.
NOTE: Schedule 40 ABS-DWV
pipe and fittings may be used as
an alternate to PVC pipe for the
combustion air inlet and vent
pipes.
NOTE: Cellular core PVC is also
approved for use. It must be
schedule 40 PVC-DWV cellular
pipe manufactured under ASTM
F-891.
JOINING PIPE AND
FITTINGS
!
WARNING
PVC SOLVENT CEMENTS AND
PRIMERS ARE HIGHLY FLAMMABLE. PROVIDE ADEQUATE
VENTILATION AND DO NOT
ASSEMBLE COMPONENTS
NEAR HEAT SOURCE OR AN
OPEN FLAME. DO NOT
SMOKE. AVOID SKIN OR EYE
CONTACT. OBSERVE ALL CAUTIONS AND WARNINGS PRINTED ON MATERIAL CONTAINERS. FAILURE TO FOLLOW
THESE GUIDELINES MAY
RESULT IN FIRE, EXPLOSION
OR ASPHYXIATION CAUSING
PERSONAL INJURY OR DEATH.
All pipe, fittings, solvent cement,
primers and procedures must conform
to American National Standard
Institute and American Society for
Testing and Materials (ANSI/ASTM)
standards as shown below:
IMPORTANT: The plastic combustion
air and venting components are MADE
of PVC. If using ABS piping, ensure that
the solvent cement is compatible for
joining PVC to ABS components or use
a mechanical connection that can withstand the vent temperatures and is corrosion resistant.
CEMENTING JOINTS
Properly seal all joints in the PVC vent
using the following materials and procedures:
PVC CLEANER-PRIMER AND
PVC MEDIUM-BODY SOLVENT
CEMENT
IMPORTANT: After cutting pipe, remove
all ragged edges and burrs. This is
important to prevent increase in pressure drop throughout the system.
1. Cut pipe end square. Chamfer edge
of pipe. Clean fitting socket and
pipe joint area of all dirt, grease and
moisture.
2. After checking pipe and socket for
proper fit, wipe socket and pipe with
cleaner-primer. Apply
a liberal coat of primer to inside surface of socket and outside of pipe.
READ INSTRUCTIONS INCLUDED
WITH THE PRIMER FOR PROPER
INSTALLATION.
PIPE & FITTING MATERIAL
Schedule 40 PVC (Pipe)
Schedule 40 PVC (Cellular Core Pipe)
ASTM
SPECIFICATION
D1785
F891
Schedule 40 PVC (Fittings)
D2466
SDR-21PVC (Pipe)
D2241
SDR-26 PVC (Pipe)
D2241
Schedule 40 ABS Cellular Core DWV (Pipe)
3. Apply a thin coat of cement
evenly in the socket. Quickly
apply a heavy coat of cement to
the pipe end and insert pipe into
fitting with a slight twisting movement until it bottoms out.
NOTE: Cement must be fluid; if
not, recoat.
4. Hold the pipe in the fitting for 30
seconds to prevent the tapered
socket from pushing the pipe out
of the fitting.
5. Wipe all excess cement from the
joint with a rag. Allow 15 minutes
before handling. Cure time varies
according to fit, temperature and
humidity.
NOTE: Stir the solvent cement
frequently while using. Use a
natural bristle, one inch wide
brush or the applicator supplied
with the can.
IMPORTANT: For Proper Installation
DO NOT use solvent cement that has
become curdled, lumpy or thickened.
DO NOT thin. Observe shelf precautions printed on containers. For application below 32°F, use only low-temperature-type solvent cement.
For correct installation of the vent
pipe, follow the instructions provided
by the manufacturers of the pipe,
primer and solvent.
F628
Schedule 40 ABS (Pipe)
D1527
Schedule 40 ABS (Fittings)
D2468
ABS-DWV (Drain Waste & Vent)
(Pipe & Fittings)
D2661
PVC-DWV (Drain Waste & Vent)
(Pipe & Fittings)
D2665
19
NON-DIRECT VENT PIPE INSTALLATION
(FOR VERTICAL TERMINATIONS ONLY)
COMBUSTION AIR
!
WARNING
ALWAYS PROVIDE THIS FURNACE AND ANY OTHER FUEL
BURNING APPLIANCE WITH
ENOUGH FRESH AIR FOR
PROPER COMBUSTION AND
VENTILATION OF THE FLUE
GASES. MOST BUILDING
CODES REQUIRE THAT OUTSIDE AIR BE SUPPLIED INTO
THE FURNACE AREA. FAILURE TO DO SO CAN CAUSE
DEATH FROM CARBON
MONOXIDE POISONING.
Provide adequate facilities for combustion and ventilation air in accordance with section 5.3, Air for
Combustion and Ventilation of the
National Fuel Gas Code, ANSI
Z223.1 - latest edition; CAN/CGA
B149.1 and .2, or applicable provisions of the local building codes.
These combustion and ventilation
facilities must not be obstructed.
IMPORTANT: Air for combustion and
ventilation must not come from a
corrosive atmosphere. Any furnace
failure due to corrosive elements in
the atmosphere is excluded from
warranty coverage.
The following types of installation (but
not limited to the following) 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.
Exposure to the following substances
in the combustion air supply (but not
limited to the following) also
REQUIRE OUTDOOR AIR for combustion:
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 RESULT
IN EXPLOSION, FIRE, PROPERTY
DAMAGE, CARBON MONOXIDE
POISONING, PERSONAL INJURY
OR DEATH.
Combustion air requirements are
determined by whether the furnace
is in an open (unconfined) area or in
a confined space such as a closet or
small room.
• 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
• Anti-static fabric softeners for
clothes dryers
• Masonry acid washing materials
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 produce
highly corrosive condensate.
20
!
FURNACE LOCATED IN AN
UNCONFINED SPACE
Using indoor air for combustion.
An unconfined space must have at
least 50 cubic feet for each 1,000
BTUH of the total input for all
appliances in the space. Here are a
few examples of the room sizes
required for different inputs. The
sizes are based on 8 foot ceilings.
See Table 1.
TABLE 1
UNCONFINED SPACE DIMENSIONS
BTUH Minimum Sq. Feet
Input With 8 foot Ceiling
60,000
375
75,000
469
90,000
563
105,000
657
120,000
750
Typical Room Size
15' x 25' OR 19' x 20'
15' x 32' OR 20' x 24'
20' x 28' OR 24' x 24'
20' x 33' OR 26' x 25'
25' x 30' OR 24' x 32'
If the open space containing the furnace is in a building constructed to
severely limit outside air infiltration
(contemporary energy efficient construction methods), outside air may
still be required for the furnace to
operate and vent properly. Outside
air openings should be sized the
same as for a confined space.
FURNACE LOCATED IN A
CONFINED SPACE.
A confined space (any space smaller than shown before as “unconfined”) must have openings into
the space, which are located in
accordance with the requirements set forth in the following
subsections A and B. The openings must be sized by how they
connect to the heated area or to the
outside, and by the input of all
appliances in the space.
If the confined space is within a
building with tight construction,
combustion air must be taken from
outdoors or areas freely communicating with the outdoors.
A. USING INDOOR AIR FOR
COMBUSTION
IMPORTANT: DO NOT take air from
a heated space with a fireplace,
exhaust fan or other device that may
produce a negative pressure.
If combustion air is taken from the
heated area (see Figure 14), the
openings must each have at least
100 square inches of free area.
Each opening must have at least
one square inch of free area for
each 1,000 BTUH of total input in
the space. See Table 2.
INDOOR AIR OPENING DIMENSIONS
Free Area
Each Opening
60,000
100 square inches
75,000
100 square inches
90,000
100 square inches
105,000
105 square inches
120,000
120 square inches
IMPORTANT: Do not take air from
an attic space that is equipped with
power ventilation.
The confined space must communicate with the outdoors in accordance
with Methods 1 or 2. The minimum
dimension of air openings shall not
be less than 3 inches. Where ducts
are used, they shall be of the same
cross-sectional area as the free area
of the openings to which they connect.
Method 1
Two permanent openings, one located within 12 inches of the top and
one located within 12 inches of the
bottom of the enclosure, shall be provided. The openings shall communicate directly, or by ducts, with the outdoors or spaces (crawl or attic) that
freely communicate with the outdoors.
TABLE 2
BTUH
Input
B. USING OUTDOOR AIR FOR
COMBUSTION
a. Where directly communicating
with the outdoors or where communicating to the outdoors
through vertical ducts as shown in
Figure 15, each opening shall
have a minimum free area of 1
square inch for each 4000 BTUH
of total appliance input rating in
the enclosure. See Table 3.
FIGURE 14
AIR FROM HEATED SPACE
TABLE 3
VERTICAL OUTDOOR AIR OPENING
DIMENSIONS
BTUH
Input
Free Area
Each Opening
Round Pipe
Size
60,000
15.00 square inches
5"
75,000
18.75 square inches
5"
90,000
22.50 square inches
6"
105,000
26.25 square inches
6"
120,000
30.00 square inches
7"
AO77501
21
b. Where communicating with outdoors through horizontal ducts,
each opening shall have a minimum
free area of 1 square inch for each
2000 BTUH of total input rating of
all equipment in the enclosure. See
Table 4 and Figure 16.
Combustion air openings must not be
restricted in any manner.
CONSULT LOCAL CODES FOR SPECIAL REQUIREMENTS.
FIGURE 15
AIR FROM ATTIC/CRAWL SPACE
TABLE 4
HORIZONTAL OUTDOOR AIR
OPENING DIMENSIONS
BTUH
Input
Free Area
Each Opening
Round Pipe
Size
60,000
30.00 square inches
7"
75,000
37.50 square inches
7"
90,000
45.00 square inches
8"
105,000
52.50 square inches
9"
120,000
60.00 square inches
9"
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 free area of:
a. One square inch for each 3000
BTUH of the total input rating of
all equipment located in the
enclosure (see Table 5), and
A077601
FIGURE 16
OUTSIDE AIR USING A HORIZONTAL INLET & OUTLET
b. Not less than the sum of the
areas of all vent connectors in the
confined space.
If the unit is installed where there is
an exhaust fan, sufficient ventilation
must be provided to prevent the
exhaust fan from creating a negative
pressure.
TABLE 5
VERTICAL OR HORIZONTAL
OUTDOOR AIR OPENING DIMENSIONS
22
BTUH
Input
Free Area
Each Opening
Round Pipe
Size
60,000
20.00 square inches
6"
75,000
25.00 square inches
6"
90,000
30.00 square inches
7"
105,000
35.00 square inches
7"
120,000
40.00 square inches
8"
A077701
INSTALLATION GUIDELINES
IMPORTANT: When installed as a nondirect furnace, only vertical terminations
are allowed. Do not use horizontal terminations when the furnace is installed with
a non-direct vent.
All exhaust vent piping must be installed
in compliance with Part 7, Venting of
Equipment, of the latest edition of the
National Fuel Gas Code NFPA 54/ANSI
A223.1, or CAN/CGA-B149.1 and .2,
local codes or ordinances and these
instructions.
VENTING GUIDELINES - Non-Direct
Vent
1. IMPORTANT: Do not common vent
with any other appliance. Do not
install in the same chase or chimney with a metal or high temperature plastic pipe from another gas or
fuel-burning appliance unless the
required minimum clearances to
combustibles are maintained
between the PVC pipe and other
pipes.
2. Use only medium or long radius
sweep elbows, such as PVC-DWV
elbows.
NOTE: For upflow and downflow
installations, extend the exhaust
pipe a minimum of 18" vertically
above the furnace cabinet before
turning the vent.
3. Vertical vent piping is preferred.
4. Install all horizontal piping as follows:
• Slope horizontal vent piping
upward a minimum of 1/4" per
foot of run so that condensate
drains toward the furnace.
• Support horizontal vent piping at
least every four feet. No sags or
dips are permitted.
5. Insulate all vent runs through
unconditioned spaces where belowfreezing temperatures are expected,
with 1" thick medium density, foil
faced fiber glass or equivalent
Rubatex/Armaflex insulation. For
horizontal runs where water may
collect and freeze, wrap the vent
pipe with self-regulating, 3 or 5 Watt
heat tape. The heat tape must be
U.L. listed and installed per the
manufacturer’s instructions.
6. All piping between the furnace and
the roof penetration is 2" or 3" as
specified in Table 6. Table 6 lists the
maximum allowable exhaust vent
pipe length for the number of
elbows used, based on the furnace
size.
IMPORTANT: Use Only standard
vertical terminations when installing
the modulating furnace as a nondirect vent appliance.
7. The minimum vent length is 5 feet.
8. All piping through the roof is 2".
When using 3" pipe, reduce to
2" within 18" of the inside of the
roof.
9. Vertical through-the-roof installations do not require any special
vent termination. Use 2" PVC
pipe extending a minimum of 12
inches above the anticipated
level of snow accumulation.
10. Elbows must be a minimum of
15” apart.
11. No screens may be used to
cover combustion air or
exhaust.
➤ TABLE 6
NON-DIRECT VENT APPLICATIONS
MAXIMUM ALLOWABLE LENGTH IN FEET OF EXHAUST PIPE
UPFLOW FURNACES (-)GFD
FURNACE PIPE
INPUT
SIZE
TERMINATION
(VERTICAL VENT
TERMINATIONS
ONLY)
NUMBER OF ELBOWS
22°, 45° OR 90°
MEDIUM / LONG RADIUS ONLY
1-2
3-4
5-6
2"
STANDARD
40'
35'
30'
3"
STANDARD
120'
120'
120'
2"
STANDARD
20'
15'
10'
3"
STANDARD
120'
120'
120'
90,000
3"
STANDARD
110'
105'
95'
105,000
3"
STANDARD
110'
105'
95'
120,000
3"
STANDARD
45'
35'
30'
60,000
75,000
DOWNFLOW AND HORIZONTAL FURNACES (-)GGD & (-)GJD
FURNACE PIPE
INPUT
SIZE
TERMINATION
(VERTICAL VENT
TERMINATIONS
ONLY)
NUMBER OF ELBOWS
22°, 45° OR 90°
MEDIUM / LONG RADIUS ONLY
1-2
3-4
5-6
2"
STANDARD
30'
25'
20'
3"
STANDARD
120'
120'
120'
2"
STANDARD
20'
15'
10'
3"
STANDARD
120'
120'
120'
90,000
3"
STANDARD
90'
80'
75'
105,000
3"
STANDARD
45'
40'
35'
120,000
3"
STANDARD
40'
35'
30'
60,000
75,000
NOTES:
1. N.R. - NOT RECOMMENDED.
2. MAXIMUM OF 6 ELBOWS MAY BE USED. DO NOT COUNT ELBOWS IN ALTERNATE TERMINATION KIT.
MEDIUM OR LONG SWEEP ELBOWS MAY BE USED.
3. A 45 OR 22.5 DEGREE ELBOW IS CONSIDERED ONE ELBOW.
4. CONCENTRIC TERMINATION NO. RXGY-E03A IS FOR THRU-THE-ROOF OR THRU-THE-WALL VENTING.
5. USE KITS RXGY-D02 OR D02A (2") OR RXGY-D03 OR D03A (3") FOR STANDARD OR ALTERNATE
THRU-THE-WALL VENTING.
6. USE KITS RXGY-D04 OR D04A FOR ALTERNATE VENTING OF 120,000 BTUH UNITS WITH LONG RUNS.
7. NO SCREENS MAY BE USED TO COVER COMBUSTION AIR AND EXHAUST.
* A = 17 1⁄2” CABINET WIDTH
B = 21” CABINET WIDTH
23
DIRECT VENT PIPE INSTALLATION
!
WARNING
READ AND FOLLOW ALL
INSTRUCTIONS IN THIS SECTION. FAILURE TO PROPERLY
VENT THIS FURNACE CAN
CAUSE CARBON MONOXIDE
POISONING OR AN EXPLOSION
OR FIRE, RESULTING IN PROPERTY DAMAGE, PERSONAL
INJURY OR DEATH.
Direct vent installations require a dedicated combustion air and venting system. All air for combustion is taken
from outside and all combustion products are discharged to the outdoors.
Therefore, no ventilation or combustion air openings are required.
INSTALLATION
GUIDELINES
All exhaust piping must be installed in
compliance with Part 7, “Venting of
Equipment,” of the latest edition of the
National Fuel Gas Code NPFA 54, 90A
and 90B ANSI Z223.1-, local codes or
ordinances and these instructions.
1. IMPORTANT: Do not common
vent with any other appliance. Do
not install in the same chase or
chimney with a metal or high temperature plastic pipe from another
gas or fuel-burning appliance
unless the required minimum
clearances to combustibles are
maintained between the approved
PVC pipe and other pipes.
2. Use only medium or long radius
sweep elbows.
NOTE: For all installations. Extend
the combustion air exhaust pipe a
minimum of 18" vertically above
the furnace cabinet before turning
the vent.
TABLE 7
DIRECT VENT APPLICATIONS
MAXIMUM ALLOWABLE LENGTH IN FEET OF EACH EXHAUST PIPE AND INTAKE AIR PIPE
FURNACE
INPUT
PIPE
SIZE
2”
90,000
105,000
120,000
Standard
RXGY-D02/RXGY-D02A/RXGY-G02
Concentric
RXGY-E03A, RXGY-G02
NUMBER OF ELBOWS
22.5, 45 or 90 Degrees
Medium / Long Radius ONLY
1-2
3-4
5-6
40
35
30
30
25
20
120
120
120
Alternate
RXGY-D02, RXGY-D02A
RXGY-D03/RXGY-D03A,RXGY-G02
3”
Concentric
RXGY-E03A, RXGY-G02
Alternate
RXGY-D03, RXGY-D03A
110
105
100
2”
Standard
RXGY-D02, RXGY-D02A, RXGY-G02
20
15
10
Standard
RXGY-D03/RXGY-D03A
Concentric
RXGY-E03A/RXGY-G02
120
120
120
100
95
85
110
105
95
50
40
35
110
105
95
50
40
35
45
35
30
3”
3”
3”
3”
Alternate
RXGY-D03, RXGY-D03A
Standard
RXGY-D03, RXGY-D03A, RXGY-G02
Concentric
RXGY-E03A/RXGY-G02
Alternate
RXGY-D03, RXGY-D03A
Standard
RXGY-D03, RXGY-D03A, RXGY-G02
Concentric
RXGY-E03A, RXGY-G02
Alternate
RXGY-D03, RXGY-D03A
Standard
RXGY-D03, RXGY-D03A, RXGY-G02
Concentric
RXGY-E03A, RXGY-G02
Alternate
RXGY-D03, RXGY-D03A
20
N/A
N/A
Alternate
RXGY-D04, RXGY-D04A
45
35
30
DOWNFLOW (-)GGD AND HORIZONTAL (-)GJD FURNACES
FURNACE
INPUT
PIPE
SIZE
TERMINATION
VENT TERMINATION
KIT RECOMMENDED
NUMBER OF ELBOWS
22.5, 45 or 90 Degrees
Medium / Long Radius ONLY
1-2
2”
60,000
3”
2”
75,000
3”
3. Vertical piping is preferred.
3-4
5-6
Standard
RXGY-D02, RXGY-D02A, RXGY-G02
30
25
20
Concentric
RXGY-E03A, RXGY-G02
30
25
20
Standard
RXGY-D03, RXGY-D03A, RXGY-G02
120
120
120
Concentric
RXGY-E03A, RXGY-G02
120
120
120
Standard
RXGY-D02, RXGY-D02A, RXGY-G02
20
15
10
Concentric
RXGY-E03A, RXGY-G02
20
15
10
Standard
RXGY-D03, RXGY-D03A, RXGY-G02
120
120
120
Concentric
RXGY-E03A, RXGY-G02
120
120
120
Standard
RXGY-D03, RXGY-D03A, RXGY-G02
70
60
55
Concentric
RXGY-E03A, RXGY-G02
70
60
55
90,000
3”
• Slope horizontal vent piping
upward a minimum of 1/4" per foot
of run so that condensate drains
toward the furnace.
105,000
3”
120,000
3”
• Support horizontal vent piping at
least every four feet. No sags or
dips are permitted.
NOTES:
1. N.R. - NOT RECOMMENDED
2. MAXIMUM OF 6 ELBOWS MAY BE USED. DO NOT COUNT ELBOWS IN ALTERNATE TERMINATION KIT.
MEDIUM OR LONG SWEEP ELBOWS MAY BE USED.
3. A 45 DEGREE ELBOW IS CONSIDERED ONE ELBOW.
4. CONCENTRIC TERMINATION NO. RXGY-E03/RXGY-E03A IS FOR THRU-THE-ROOF OR THRU-THE-WALL
VENTING.
5. USE KITS RXGY-DO2/D02A (2"), RXGY-G02 (2"), OR RXGY-D03/D03A (3") FOR STANDARD OR ALTERNATE
THRU-THE-WALL VENTING.
6. USE KITS RXGY-D04/D04A FOR ALTERNATE VENTING OF 120,000 BTUH UNITS WITH LONG RUNS.
7. KIT NUMBERS CONTAINING SUFFIX “A” ARE APPROVED FOR INSTALLATION IN CANADA.
8. NO SCREENS MAY BE USED TO COVER COMBUSTION AIR AND EXHAUST.
(A*) = 171⁄2” CABINET
(B*) = 21” CABINET
**ALTERNATE VENT NOT PERMITTED ON DOWNFLOW/HORIZONTAL MODELS.
4. Install all horizontal piping as follows:
24
VENT TERMINATION
KIT RECOMMENDED
Standard
60,000
75,000
TERMINATION
Standard
RXGY-D03, RXGY-D03A, RXGY-G02
45
40
35
Concentric
RXGY-E03A, RXGY-G02
45
40
35
Standard
RXGY-D03, RXGY-D03A, RXGY-G02
40
35
30
Concentric
RXGY-E03A/RXGY-G02
40
35
30
FIGURE 17
STANDARD VERTICAL DIRECT VENTING
UPFLOW MODEL SHOWN (TYPICAL FOR DOWNFLOW/HORIZONTAL MODELS)
5
DETAIL A
EXHAUST
TERMINATION
1
12”
5
2
3
NOTES:
THE COMBUSTION AIR PIPE
MUST TERMINATE IN THE
SAME PRESSURE ZONE AS
THE EXHAUST PIPE.
INCREASE THE 12-IN. MINIMUM
TO KEEP TERMINAL OPENING ABOVE
ANTICIPATED LEVEL OF SNOW ACCUMULATION WHERE APPLICABLE.
WHEN 3-IN. DIAM. PIPE IS USED,
REDUCE TO 2-IN. DIAMETER BEFORE
PENETRATING ROOF. A MAXIMUM OF
18 IN. OF 2-IN. PIPE MAY BE USED
BEFORE PASSING THROUGH ROOF.
SUPPORT VERTICAL PIPE EVERY 6
FEET.
EXHAUST TERMINATION - TERMINATE
THE LAST 12 INCHES WITH 2” PVC
PIPE ON 90,000 AND 120,000 BTUH
MODELS. REDUCE AND TERMINATE
THE LAST 12 INCHES WITH 11/2” PVC
PIPE ON 60,000 THROUGH 75,000 BTUH
MODELS.
SEE DETAIL A.
1
5
4
2
3
5
4
5
5. Insulate all vent runs through
unconditioned spaces where
below-freezing temperatures are
expected with 1" thick medium
density, foil faced fiber glass or
equivalent Rubatex/Armaflex insulation. For horizontal runs where
water may collect, wrap the vent
pipe with self-regulating, 3 or 5
Watt heat tape. The heat tape
must be U.L. listed and installed
per the manufacturer’s instructions.
6. All piping between the furnace
and the roof or outside wall penetration is 2" or 3" as specified in
Table 7. Table 7 lists the maximum allowable length for the
exhaust vent pipe and intake air
pipe for the number of elbows
used, based on the type of termination and furnace size.
7. The minimum vent length is 5
feet.
8. All piping through the roof or outside wall is 2". When using 3"
pipe, reduce to 2" within 18" of
the inside of the roof or outside
wall (except 120,000 BTUH
model using the RXGY-D04 or
D04A Horizontal Vent Kit).
ST-A0407-00
10. Elbows must be a minimum of 15”
apart.
11. No screens may be used to cover
combustion air or exhaust.
VERTICAL TERMINATIONS
STANDARD VERTICAL TERMINATIONS (See Figure 16)
Combustion Air Piping: Use two medium-radius sweep elbows to keep the
inlet downward and prevent the entry of
rain. The inlet opening of the combustion air termination must be a
minimum of 12" above the anticipated level of snow accumulation.
Exhaust Vent Piping: The exhaust vent
must terminate at least 12 inches
above the combustion air termination
inlet. The 2" vent pipe used to penetrate the roof must be reduced to 1 1/2"
PVC for the last 12" for the 60,000 and
75,000 BTUH furnace models. No
reduction of the 2" pipe is necessary for
the 90,000 through 120,000 BTUH
models. The maximum length of the
exposed vent pipe above the roof is
30".
9. Terminate the vent using one of
the following termination options.
25
CONCENTRIC TERMINATIONS
CONCENTRIC VENT KIT
NO. RXGY-E03A (SEE FIGURE 18)
This kit is for vertical and horizontal
intake air/vent runs. One
5-in. diameter hole is required for
installation. See Figure 18 for the general layout. Complete installation
instructions are included with the kit.
NOTE: The following IPEX brand concentric terminations (System 636) may
be purchased in the field and used in
place of factory supplied kits:
3” Concentric Kit – Item # 196006
FIGURE 18
CONCENTRIC VENT KIT NO. RXGY-E03A
(DIRECT VENT INSTALLATIONS)
ITEM No.
VERTICAL INSTALLATION
MAINTAIN 12 IN.
MINIMUM CLEARANCE
ABOVE HIGHEST
ANTICIPATED SNOW
LEVEL. MAXIMUM OF
24 IN. ABOVE ROOF.
DESCRIPTION
1
2.5" PVC PIPE SCHEDULE 40 -- 37.125" LONG
2
4" PVC PIPE SCHEDULE 40 -- 24" LONG
3
3" x 3" x 4" SPECIAL CONCENTRIC FITTING
4
3" x 45° STREET ELBOW (FIELD SUPPLIED)
5
PVC RAINCAP
A
HORIZONTAL INSTALLATION
FIELD-SUPPLIED
STRAP
A
NOTE: AIR INTAKE NOT
ORIENTATION SENSITIVE.
26
1" MAXIMUM
A NOTE: Drain tee is not needed for the inlet pipe.
INSTALLATION – RXGY-G02 Side Wall Vent
This termination for horizontal venting only.
This termination for direct vent application only.
Important: Do no install on the prevailing winter wind side of the structure
Note: Multi-venting-No common venting.
FIGURE
? ?19
VENT KIT
OPTIONS
? INSTALLATION
?
?
?
EXHAUST
AIR
INTAKE
NOTE: Install the vent and air intake piping into the vent plate openings. Seal all gaps between the
pipes and wall. Be Sure To Use Silicone Sealant to seal the vent pipe to the vent cap to permit field
disassembly for annual inspection and cleaning. Also seal all pipe penetrations in wall. To prevent
possibility of condensate freeze-up or recirculation, do not install vent kits one above the other.
FIGURE 20
TYPICAL INSTALLATION
For 90000 thru 120000 BTUH modelsreduce to a length between 12 inches
and 30 inches of 2 inch pipe.
For 60000 thru 75000 BTUH modelswhen 3 inch pipe is used: reduce last 30
inches to 18 inches of 2 inch pipe and
12 inches of 1-1/2 inch pipe to maintain
velocity.
Note: Vent should protrude a
maximum of 2-1/4” beyond vent plate.
Air intake should protrude a maximum
of 1inch beyond vent plate.
Seal all wall cavities
ST-A1075
27
HORIZONTAL TERMINATIONS
STANDARD HORIZONTAL TERMINATIONS (SEE FIGURE 21)
NOTE: All furnaces with horizontal air
intakes (except those using horizontal
concentric vent kit RXGY-E03A) must
have a drain tee assembly and trap
installed in the combustion air pipe as
close to the furnace as possible. This is
to drain any water that may enter the
combustion air pipe to prevent it from
entering the furnace vestibule area.
These parts are included in horizontal
vent kits RXGY-D02, RXGY-D03 and
RXGY-D04.
NOTE: The combustion air and exhaust
terminations must be at least 12 inches
above grade or anticipated snow levels.
Use alternate horizontal terminations
when termination locations are limited
and higher snow levels are anticipated.
NOTE: Ensure the location of the combustion air inlet with respect to the
exhaust vent terminal complies with
Figure 21, detail C.
Combustion Air Piping: Use a 2" PVC
coupling with a wind deflector vane (provided) installed as follows:
1. Install a 2" coupling to the combustion air pipe at the outside wall to
prevent the termination from being
pushed inward.
2. Cut a 2 1/4" length of 2" PVC pipe
and connect this to the coupling.
3. Connect another 2" coupling to the
end of the 2 1/4" length of pipe.
Terminate this outer coupling 4
inches from the wall.
4. Attach the vane in the final 2" coupling in the vertical position with
PVC cement.
IMPORTANT: To insure proper furnace operation, install the vane in the
vertical position as shown in Figure
21, Detail B. Failure to install the vane
properly can result in nuisance tripping of the pressure switch.
FIGURE 21
1
STANDARD HORIZONTAL DIRECT VENTING
UPFLOW MODEL SHOWN
(TYPICAL FOR DOWNFLOW/HORIZONTAL MODELS)
2
Exhaust Vent Piping:
60,000 and 75,000 BTUH models:
Install a 2" to 1 1/2" reducer coupling at the outside wall to prevent
the termination from being pushed
inward. Reduce the 2" vent pipe
used to penetrate the wall to 1 1/2"
PVC for the last 12" of the run.
Terminate the 1 1/2" PVC exhaust
vent at least 12 inches from the outside wall.
90,000 through 120,000 BTUH
models: Install a 2" coupling at the
outside wall to prevent the termination from being pushed inward. No
reduction of the 2" pipe used to
penetrate the wall is necessary.
Terminate the 2" PVC exhaust vent
at least 12 inches from the outside
wall.
3
NO SCREENS OR ELBOWS
AT THE END OF THE PIPES
DETAIL C
5
NOTES:
SUPPORT HORIZONTAL
PIPE EVERY FOUR FEET.
WHEN 3 IN. PIPE IS USED REDUCE TO
2 IN. BEFORE PENETRATING OUTSIDE WALL.
18 IN. MAXIMUM. 2 IN. DIAMETER
PIPE MAY BE USED INSIDE THE
WALL.
DETAIL “A” - EXHAUST TERMINATION
TERMINATE THE LAST 12 INCHES
WITH 2” PVC PIPE ON 90,000 AND
120,000 BTUH MODELS. REDUCE
AND TERMINATE THE LAST 12 INCHES WITH 11/2” PVC PIPE ON 60,000
THROUGH 75,000 BTUH MODELS.
INCREASE THE 12 IN. MINIMUM
ABOVE GRADE TO KEEP TERMINAL
OPENINGS ABOVE ANTICIPATED
LEVEL OF SNOW ACCUMULATION
WHERE APPLICABLE.
DETAIL “B”, INSTALL WIND DEFLECTOR VANE IN 2 IN. PVC COUPLING IN
VERTICAL POSITION USING PVC
SOLVENT.
THE COMBUSTION AIR TERMINATION
MUST BE IN THE SAME PRESSURE
ZONE AS THE EXHAUST TERMINATION.
4
➀
➁
DETAIL A
12”
EXHAUST
TERMINATION
➂
➃
DETAIL C
EXHAUST/INTAKE RELATIONSHIP
6
DETAIL B
COMBUSTION AIR TERMINATION
➄
➅
28
ST-A0407-00
ALTERNATE HORIZONTAL TERMINATIONS (See Figure 22)
FIGURE 22
ALTERNATE HORIZONTAL DIRECT VENT TERMINATION
EXHAUST VENT
21/2" PVC FOR MODELS WITH 120,000 BTUH INPUT
(KIT NO. RXGY-D04)
2" PVC FOR MODELS WITH INPUTS OF 90,000 THRU 120,000
BTUH. REDUCE TO 11/2" FOR MODELS WITH INPUTS OF 60,000
AND 75,000 BTUH. ELBOWS AND RISERS ARE 2" PVC.
NOTE: This method is not permitted
on modulation downflow ((-)GGD) or
horizontal ((-)GJD) furnace models.
NOTE: The combustion air and
exhaust terminations must be at least
12 inches above grade or anticipated
snow levels. Alternate horizontal terminations allow the combustion air
and exhaust terminations to be raised
a maximum of 60 inches above the
wall penetrations to maintain the
required clearance.
SEE DETAIL A
3" MAX.
NOTE: 3-1/2"
MAX. WHEN
D04 KIT IS
USED.
DETAIL A
M
O
FR
60" MAX.
"
12
PIPE
SUPPORT
STRAP
DETAIL C
EXHAUST VENT FOR
MODELS WITH INPUT OF
60,000 AND 75,000 BTU
EXHAUST/INTAKE RELATIONSHIP
NOTE: Ensure the location of the
combustion air inlet with respect to
the exhaust vent terminal complies
with Figure 22.
NOTE: If combustion air vent pipe is extended more
than 24 inches, insulate the vent pipes between the
two outside 90° elbows with closed cell insulation
such as rubatex, armaflex, or equivalent.
Combustion Air Piping: Use a 2" PVC
elbow with a wind deflector vane (provided) installed as follows:
1. Install a 2" elbow to the combustion
air pipe at the outside wall to prevent
the termination from being pushed
inward.
2. Cut an adequate length of 2" PVC
pipe as needed to clear the anticipated snow level and connect this to
the elbow.
3. Connect another 2" elbow to the
end of the pipe such that the inlet is
facing away from the wall. This outer
coupling must terminate 4 inches
from the wall.
4. Attach the vane in the final 2" elbow
in the vertical position with PVC
solvent.
IMPORTANT: To insure proper furnace operation, the supplied vane
must be installed in the vertical position as shown in Figure 21, Detail B.
L
AL
W
NOTE: If combustion air vent pipe is
extended more than 24 inches, insulate the vent pipe between the two
outside 90° elbows with closed cell
insulation such as rubatex, armaflex
or equivalent.
INTAKE VENT
21/2" PVC FOR MODELS WITH
120,000 BTUH INPUT.
2" PVC ELBOWS AND RISER
MODELS WITH INPUTS OF 75,000
THRU 120,000 BTUH.
USE KIT NO. RXGY-D02 OR D02A WHEN 2"
PIPE IS USED BETWEEN FURNACE AND
OUTSIDE WALL. USE KIT NO. RXGY-D03
OR D03A WHEN 3" PIPE IS USED.
I339
Exhaust Vent Piping:
Exhaust Vent Termination:
1. Install a 2" elbow to the exhaust vent
pipe at the outside wall to prevent the
termination from being pushed
inward.
60,000 and 75,000 BTUH models:
Reduce the 2" vent pipe used to
penetrate the wall and extend the
terminations to 1 1/2" PVC for the
last 12" of the run. Install a 2" to 1
1/2" reducer bushing in the last 2"
elbow. Connect a length of 1 1/2"
PVC pipe such that the exhaust vent
terminates at least 12 inches from
the outside wall. See Figure 22,
Detail A.
90,000 through 120,000 BTUH models: No reduction of the 2" pipe used
to penetrate the wall is necessary.
Terminate the 2" PVC exhaust vent
at least 12 inches from the outside
wall.
120,000 BTUH model with the
RXGY-D04 or D04A Horizontal Vent
Kit: Venting and terminations install
the same as above except the 2"
pipe and connectors are replaced
with 2 1/2" pipe and connectors.
2. Cut an adequate length of 2" PVC
pipe as needed to insure proper location of the exhaust vent termination
with respect to the combustion air
inlet and connect this to the elbow.
3. Connect another 2" elbow to the end
of the pipe such that the inlet is facing away from the wall.
29
LOCATION REQUIREMENTS
HORIZONTAL DIRECT VENTS
!
CAUTION
THE COMBUSTION PRODUCTS
AND MOISTURE IN THE FLUE
GASES WILL CONDENSE AS
THEY LEAVE THE TERMINATION.
THE CONDENSATE CAN FREEZE
ON THE EXTERIOR WALL,
UNDER THE EAVES AND ON
SURROUNDING OBJECTS.
SOME DISCOLORATION TO THE
EXTERIOR OF THE BUILDING IS
TO BE EXPECTED. HOWEVER,
IMPROPER LOCATION OR
INSTALLATION CAN RESULT IN
STRUCTURAL OR EXTERIOR
FINISH DAMAGE TO THE BUILDING AND MAY RECIRCULATE
PRODUCTS OF COMBUSTION
INTO THE COMBUSTION AIR
TERMINAL AND FREEZE.
In addition to the minimum clearances
listed above, the vent location should
be governed by the following guidelines.
1. Do not terminate under any kind of
patio or deck. If running the vent
under a deck, insulate it to insure
no condensate freezes and blocks
the pipe. The insulation must be
waterproof.
For vent considerations, the edge
of the deck must be considered
the outside wall.
2. Do not terminate behind any area
that may allow the flue products to
become stagnant and recirculate.
3. Do not locate on the side of a
building with prevailing winter
winds. This will help prevent moisture from freezing on walls and
overhangs (under eaves).
4. Do not extend vent directly
through brick or masonry surfaces. Use a rust-resistant sheet
metal or plastic backing plate
behind vent. See Figure 17.
5. Do not locate too close to shrubs
as condensate may stunt or
kill them.
6. Minimum vertical clearances of 1
foot are recommended for overhangs up to 1 foot horizontal.
The vertical clearance should be
increased equally for each additional increase in horizontal overhang to a maximum vertical
clearance of 6 feet.
7. Caulk all cracks, seams and
joints within 6 feet horizontally
as well as 6 feet above and
below vent. See Figure 23.
NOTE: In Canada vent terminations
must be in accordance with the current
CSA-B149 Gas Installation Code and/or
local codes.
The vent must be installed with the following minimum clearances. See
Figures 23 and 24.
FIGURE 23
MOISTURE ZONES
1. Locate the bottom of the vent terminal and the air inlet at least 12
inches above grade. Increase the
12-in. minimum to keep the terminal openings above the level of
snow accumulation, where applicable.
2. Do not terminate the vent over public walkways or over an area where
condensate or vapor could create a
nuisance or hazard.
3. Locate the vent terminal at least
one foot from any opening through
which flue gases could enter a
building.
4. Locate the vent terminal at least 3
feet above any forced air inlet
located within 10 feet, except the
combustion air inlet of a direct vent
appliance.
5. Allow the vent terminal minimum
horizontal clearance of 4 feet from
electric meters, gas meters, regulators and relief equipment.
6. Locate the furnace combustion air
inlet a sufficient distance from the
vent of any other gas or fuel burning appliance or electric clothes
dryer to prevent recirculation of the
flue gases into the furnace combustion air inlet. The only exception
to this requirement is the case of
multiventing two or more furnaces,
which is covered in the section on
multiventing in these instructions.
30
2 FT. SQ. SHEET METAL PLATE ON BRICK OR
MASONRY SURFACE RECOMMENDED, BUT
NOT REQUIRED BY CODE.
Canadian Installations
US Installations
US Installations
Natural Gas and Propane Installation Code
National Fuel Gas Code
Canadian Installations
FIGURE 24
DIRECT VENT TERMINAL CLEARANCES
31
FIGURE 25
FIGURE 26
TWO FURNACE VENTING THROUGH ROOF
TWO FURNACE VENTING THROUGH WALL
TWO-PIPE VENTING
TWO-PIPE VENTING
EXHAUST VENT
MODELS 06-07
TO BE REDUCED TO
1-1/2” PVC LAST 12”.
3” MININUM
24” MAXIMUM
3” MININUM
24” MAXIMUM
CONCENTRIC VENTING
CONCENTRIC VENTING
8” MININUM
24” MAXIMUM
8"
MINIMUM 12" ABOVE AVERAGE
SNOW ACCUMULATION. MAXIMUM
OF 24 IN. ABOVE ROOF.
SEE CONCENTRIC
VENT SECTION
ON PAGE 23
FOR MORE
INFORMATION.
6' MINIMUM
10' RECOMMENDED
MINIMUM 12"
ABOVE GRADE
MAXIMUM 1"
DISTANCE
FROM WALL
8"
8” MININUM
24” MAXIMUM
8.
Painted surfaces must be sound
and in good condition with no
cracking, peeling, etc. Painted
surfaces will require maintenance.
9. Do not expose 3" x 2" reducer/
bushing to outdoor ambient temperatures.
32
MULTIVENTING
IF VENTING TWO OR MORE FURNACES NEAR EACH OTHER IS
REQUIRED, EACH FURNACE
MUST BE INDIVIDUALLY VENTED –
NO COMMON VENTING IS PERMITTED. See Figures 25 and 26 for positioning of the terminations. When
more than two furnaces are to be
vented, there must be at least 4 feet
between the first two furnaces and
the third, etc.
SEE CONCENTRIC VENT SECTION
ON PAGE 23 FOR MORE INFORMATION.
CONNECTING TO
FURNACE
IMPORTANT: Clean and deburr all
pipe cuts. The shavings must not be
allowed to block the exhaust, inlet or
condensate drain pipes.
IMPORTANT: When indoor combustion air is used, the inlet air opening
at the furnace must be protected
from accidental blockage. On downflow models, install a double elbow in
the top inlet air opening. See Figure
29.
UPFLOW MODELS
The exhaust air pipe connection is a 2in. female PVC pipe fitting extending
through the left side of the furnace top
plate. See Figure 27. This opening has a
protective cap which should be removed
just prior to installing the exhaust pipe.
When 2-in. pipe is used, connect it
directly to this fitting. When 3-in. pipe is
used, connect a 2 to 3-in. coupling to
this fitting with a short piece of 2-in. PVC
pipe.
The inlet combustion air connection
is at the right side of the top plate.
An alternate combustion inlet air connection may be made on the right side of
the jacket. The alternate connection
opening has a plastic cap. A combustion
inlet air connection fitting is supplied with
the furnace and it must be installed in
the furnace by screwing it into the opening. Make sure the rubber “O-ring” supplied with the furnace is used with this
fitting. See Figure 27.
IMPORTANT: When using indoor combustion air, the furnace air opening must
be protected from accidental blockage.
Install a 2-inch 90° elbow pointing downward on the side or a double elbow
pointing downward in the top opening.
See Figure 28.
FIGURE 27
UPFLOW MODELS -- COMBUSTION AIR AND VENT PIPE CONNECTION
“O” RING
TOP PLATE
VENT CAP/PLUG
EXHAUST AIR PIPE
COMBUSTION
AIR ADAPTER
NOTE:
WHEN COMBUSTION AIR INLET IS IN
OPTIONAL POSITION SWAP LOCATION
OF INLET AIR ADAPTER AND “O” RING
WITH PLUG.
PLUG OPT. COMBUSTION
AIR INLET POSITION
EXHAUST TRANSITION
INDUCED DRAFT
BLOWER
CONNECTOR
CONDENSATE TRAP
I515
FIGURE 28
UPFLOW MODELS -- COMBUSTION AIR FITTING
➤DOWNFLOW & HORIZONTAL
MODELS
NOTE: Combustion air inlet and exhaust
outlet air pipes are reversed for downflow and horizontal models from that of
upflow.
The exhaust pipe connection is a 2-in.
PVC pipe fitting extending through the
right side of the furnace top cover. This
opening has a protective cap which
should be removed just prior to installing
the exhaust pipe. When 2-in. pipe is
used, connect it directly to this fitting.
When 3-in. pipe is used, connect with a
2- to 3-in. coupling directly to the 2-in.
pipe.
The combustion inlet air connection is a
2-in. extruded hole on the left side of the
top plate. When a 2-in. pipe is used,
attach a 2-in. PVC coupling over this
hole with RTV sealant and also add two
sheet metal screws through the coupling
into the extrusion to secure it in place,
and add the required piping. When 3-in.
pipe is required, use a 2- to 3-in. coupling and add the required piping. See
Figure 29.
➤ FIGURE 29
DOWNFLOW AND HORIZONTAL MODELS -- COMBUSTION AIR AND VENT PIPE
CONNECTION
IMPORTANT: Always pre-drill holes
before securing with screws. Using selftapping screws without first pre-drilling
causes the PVC fitting to crack.
33
CONDENSATE DRAIN/OPTIONAL NEUTRALIZER
GENERAL INFORMATION
!
CAUTION
FIGURE 30
UPFLOW CONDENSATE DRAIN
DO NOT RUN DRAIN OUTDOORS.
FREEZING OF CONDENSATE CAN
CAUSE PROPERTY DAMAGE.
IMPORTANT: Do not connect into a common drain line with an air conditioner
evaporator coil drain located below the
furnace. A blocked or restricted drain line
can result in overflow of the coil pan and
negate the furnace blocked-drain shutoff
control.
➤ IMPORTANT: If installing the unit over
a finished ceiling or living area, be certain
to install an auxiliary condensate drain
pan under the entire unit extending out
under the condensate tee. With the minimum 51⁄2" riser for upflow models
or 13⁄4" for downflow models installed
above the tee, a blocked drain will result
in overflow from the riser. if the furnace is
installed in an attic, crawlspace or other
area where freezing temperatures may
occur, the furnace drain can freeze while
shut off for long periods of time.
If required by local codes, install a condensate neutralizer cartridge in the drain
line. Install cartridge in horizontal position
only. Also install an overflow line if routing
to a floor drain (see Figures 30 & 31). If
available, install a condensate pump that
is resistant to acidic water. Pumps are
available from your local distributor. If
pump used is not resistant to acidic water,
a condensate neutralizer must be used
ahead of the pump. The condensate
pump must have an auxiliary safety
switch to prevent operation of the furnace
and resulting overflow of condensate in
the event of pump failure. The safety
switch must be wired through the “R” circuit only (low voltage) to provide operation
in either heating or cooling modes.
When selecting neutralizer cartridges and
condensate pumps, use the following
data:
CONDENSATE PRODUCTION:
MAX (ALL MODELS) = 1-2 gallons per hr.
NOTE:
SEE UPFLOW MODEL
NOTES FOR PIPE
HEIGHT
NEUTRALIZER CARTRIDGE
(OPTIONAL)
OVERFLOW LINE
(REQUIRED ONLY WHEN
OPTIONAL NEUTRALIZER
CARTRIDGE IS USED.)
TO FLOOR DRAIN OR CONDENSATE PUMP
34
AO51601
➤ FIGURE 31
DOWNFLOW CONNECTION
NOTE: SEE DOWNFLOW
MODEL NOTES
pH LEVEL:
3.2 - 4.5 using OUTDOOR air
2.2 - 4.5 using INDOOR air
(neutral pH = 7.0)
UPFLOW MODELS
The condensate drain trap is located in
the blower compartment on the left- hand
side of the jacket. A short piece of 1⁄2-in.
PVC pipe and a 1⁄2-in. tee are provided.
Connect the 1⁄2-in. pipe to the elbow on
the trap and the tee to this pipe so that
the open end is upward. Run a drain tube
from the bottom of the tee to a floor drain
or condensate pump.
IMPORTANT: If installing the unit over a
finished ceiling or living area, be certain
to install an auxiliary condensate drain
pan under the entire unit extending out
under the condensate tee.
CONDENSATE TRAP
DRAIN LINE
OVERFLOW LINE
(REQUIRED ONLY WHEN
OPTIONAL NEUTRALIZER
CARTRIDGE IS USED.)
CONDENSATE TRAP
DRAIN LINE
NEUTRALIZER CARTRIDGE
(OPTIONAL)
TO FLOOR DRAIN OR CONDENSATE PUMP
A085001
IMPORTANT: There are two options
when choosing a height for the condensate riser:
CONDENSATE OVERFLOW: With a
51⁄2 inch riser installed above the tee,
a blocked drain will result in overflow
from the riser.
FURNACE SHUTDOWN: To cause
the furnace to shut down when a
blocked drain is present, install a riser
which is a minimum of 1013⁄16”. If the
furnace is installed in an attic, crawlspace or other area where freezing
temperatures may occur, the furnace
drain can freeze while shut off for long
periods of time.
Use a solvent cement that is compatible with PVC material. Cut the drain
hoses to the appropriate length and
connect to the trap with hose clamps.
Tighten the clamps with pliers and
check for leaks after attaching.
DOWNFLOW MODELS
IMPORTANT: There are two options
when choosing a height for the condensate riser:
CONDENSATE OVERFLOW: With a
13⁄4 inch riser installed above the tee,
a blocked drain will result in overflow
from the riser.
FURNACE SHUTDOWN: To cause
the furnace to shut down when a
blocked drain is present, install a riser
which is a minimum of 51⁄2”. If the furnace is installed in an attic, crawlspace or other area where freezing
temperatures may occur, the furnace
drain can freeze while shut off for long
periods of time.
Use a solvent cement that is compatible with PVC material.
RXGY-H01
CONVERTING TO LEFT
DRAIN FOR DOWNFLOW
MODELS
To convert downflow models to lefthand drain, a kit (RXGY-H01) must be
ordered from the distributor. The kit
includes a 24” piece of 1⁄2” black PVC
pipe, a 2-9/16” length of black hose, a
2” rubber grommet, a 1-5/8” plug and
instructions. Note the location of the
alternate drain hole as shown in Figure
33.
To convert to left side drainage, remove
the long molded hose from the trap.
Remove the double-elbow black molded hose from the trap and exhaust transition and discard. Remove the trap
from its mounting bracket, rotate it 180
degrees and mount in place with the
drainage elbow pointing to the left.
Reattach the long black molded hose.
Use the 2-9/16” length of black hose
included in the RXGY-H01 kit between
the trap and exhaust transition. Clamp
hoses tight with white nylon clamps.
Remove the plug from the 2” alternate
drain hole (see Figure 33) and replace
it with the 2” rubber grommet supplied in the RXGY- H01 downflow
alternate drain kit. Also, remove the
1-5/8” grommet supplied in the primary drain hole and replace it with the
1-5/8” diameter plug that is also supplied in the RXGY-H01 downflow
alternate drain kit. Both the hole-plug
and grommet must be in place to
insure a good seal in the burner compartment.
A length of 1/2” black PVC pipe is also
provided in the RXGY-H01 downflow
alternate drain kit. Glue one end of
the pipe to the elbow in the trap. Cut
the pipe so that it extends through
the alternate drain hole in the left side
of the cabinet one inch (see Figure
33). Connect the1/2” PVC tee (supplied with the furnace) to the pipe
with a 1-3/4” riser. Use the 1-5/8”
plug supplied in the RXGY-H01
downflow alternate drain kit to seal
the right side drainage hole.
IMPORTANT: Do not connect into a
common drain line with an air conditioner evaporator coil drain located
above the furnace. A blocked or
restricted drain line can result in overflow of the coil pan and negate the
furnace blocked-drain shutoff control.
FIGURE 32
UPFLOW OPPOSITE SIDE CONDENSATE TRAP CONNECTION
(NO KIT REQUIRED)
51/2” MINIMUM
HEIGHT OPEN
END
REVERSING THE TRAP
UPFLOW MODELS
The trap may be moved to the right
side for right-side drainage. Open the
knockout for the drain on the right side
of the cabinet. Remove the bracket
holding the trap from the left side.
Seal the left side drain hole with a
plug provided in the cloth bag with the
furnace. Position the mounting bracket
and trap so that the drain elbow is
centered in the hole on the right. See
Figure 32.
Drill two holes in the cabinet to mount
the bracket. Mount the trap and bracket to the right side with the drain
elbow pointing through the knockout.
Connect the 1⁄2" pipe and tee as noted
above. Route the drain hoses behind
the top of the electric box, cut to the
appropriate length, and connect to the
trap with hose clamps.
IMPORTANT: Do not connect into a
common drain line with an air conditioner evaporator coil drain located
above the furnace. A blocked or
restricted drain line can result in overflow of the coil pan and negate the
furnace blocked drain shutoff control.
A051701
FIGURE 33
DOWNFLOW OPPOSITE SIDE CONDENSATE TRAP CONNECTION
(REQUIRES RXGY-H01 KIT)
DRAIN VENT
DRAIN
EXTENSION
TEE
EXISTING DRAIN HOLE.
PLUG WITH 15⁄8” PLUG
SUPPLIED IN KIT
ALTERNATE DRAIN HOLE
LOCATED HERE ON JACKET.
(REMOVE PLASTIC PLUG AND
REPLACE WITH GROMMET).
TO FLOOR
DRAIN OR
CONDENSATE PUMP
ROTATE TRAP 180° AND
INSTALL RIGID PIPE FROM
ELBOW TO OPPSOITE SIDE
OF JACKET AS SHOWN
CONDENSATE TRAP
I394
35
CONDENSATE DRAIN
FOR HORIZONTAL
((-)GJD) INSTALLATION
!
WARNING
HORIZONTAL ((-)GJD) MODELS
ARE SHIPPED WITHOUT A DRAIN
TRAP ATTACHED. IT MUST BE
ATTACHED (AS DESCRIBED
BELOW) IN THE FIELD. FAILURE TO
INSTALL THE DRAIN TRAP AS
DESCRIBED CAN CAUSE THE FURNACE TO SHUT DOWN UNEXPECTEDLY.
NOTE: The following steps should
take place with the furnace in the
horizontal position.
Refer to Figure 36 for Steps 1-8.
1. Locate the parts bag in the burner
compartment.
2. Remove the red vinyl covers that
cover the vent drain and heat
exchanger drain (see Figure 34).
3. Fill the trap assembly G with a
cup of water.
4. Attach the gasket H onto the trap
assembly so that the gasket holes
on the gasket line up with the
holes on the trap assembly.
5. Insert the trap assembly with gasket up through the existing hole in
the jacket and secure from inside
the jacket. Use two screws provided. Screw down into the two
“ears” molded into either side of
the trap. Snug the trap assembly
against the furnace jacket compressing the gasket slightly to
eliminate any air leaks. Do not
overtighten!
6. Attach the black molded rubber
90° elbow I to the straight spout
on the trap top using a white
nylon clamp J . Attach the other
end of the rubber elbow to the
spout K located on the exhaust
transition E using a white nylon
clamp.
7. Cut 1.0 inch from the long end of
the black molded hose L . Attach
the 90° end of the hose L to the
collector box. Then attach the
other end of the black molded
hose to the 45° elbow molded into
the top of the trap assembly.
Clamp the hose tight with white
nylon clamps.
IMPORTANT: Tighten all clamp
connections with a pair of pliers
and check for leaks after conversion is complete.
8. IMPORTANT: There are two
options when choosing a height
for the condensate riser:
CONDENSATE OVERFLOW:
With a 13⁄4 inch riser installed
above the tee, a blocked drain will
result in overflow from the riser.
FURNACE SHUTDOWN: To
cause the furnace to shut down
36
when a blocked drain is present,
install a riser which is a minimum
of 51⁄2”. If the furnace is installed
in an attic, crawlspace or other
area where freezing temperatures
may occur, the furnace drain can
freeze while shut off for long periods of time. Provisions must be
made to prevent freezing of condensate.
Use a solvent cement that is compatible with PVC material.
NOTE: See location requirements
and combustion section for additional
recommendations.
FILLING THE TRAP
FILL THE TRAP ASSEMBLY WITH
WATER BEFORE OPERATING THE
FURNACE. Do this by removing the
drain hose from the trap or from the
connection to the secondary coil.
Pour about a cup of water into the
vent trap. Any excess water flows into
the house drain when the trap is full.
FIGURE 34
REMOVE VINYL CAPS BEFORE INSTALLING THE DRAIN SYSTEM.
REMOVE THESE
RED VINYL
COVERS TO
INSTALL THE
DRAIN SYSTEM
FIGURE 35
HORIZONTAL CONDENSATE DRAIN
CONDENSATE TRAP CONVERSION FROM DOWNFLOW TO
HORIZONTAL INSTALLATION
FIGURE 36
HORIZONTAL POSITION: CONDENSATE TRAP INSTALLATION
FOR HORIZONTAL OPERATION
I534
37
GAS SUPPLY AND PIPING
GAS SUPPLY
!
FIGURE 37
GAS PIPING -- UPFLOW INSTALLATION
WARNING
THIS FURNACE IS EQUIPPED
AT THE FACTORY FOR USE ON
NATURAL GAS ONLY. CONVERSION TO LP GAS REQUIRES A
SPECIAL KIT AVAILABLE FROM
THE DISTRIBUTOR. FAILURE TO
USE THE PROPER CONVERSION KIT CAN CAUSE FIRE,
CARBON MONOXIDE POISONING, EXPLOSION, PROPERTY
DAMAGE, PERSONAL INJURY
OR DEATH.
See the conversion kit index supplied with the furnace. This index
identifies the proper LP Gas
Conversion Kit required for each
particular furnace.
IMPORTANT: Any additions, changes
or conversions required for the furnace
to satisfactorily meet the application
should be made by a qualified installer,
service agency or the gas supplier,
using factory-specified or approved
parts.
GROMMET
MAIN GAS VALVE
TOP VIEW OF GAS LINE AND VALVE
IN OPTIONAL POSITION
BURNERS
NOTE: WHEN GAS LINE IS IN
OPT. POSITION, SWAP LOCATION OF GROMMET AND
PLUG.
OPTIONAL GAS LINE
POSITION
4 TO 5 FEET
ABOVE FLOOR
REQ’D BY SOME
UTILITIES.
PLUG
(IN NORMAL
POSITION)
MANIFOLD
PRESSURE TAP
GROMMET
(IN NORMAL
POSITION)
MANIFOLD
DRIP LEG
STA0518-01
GAS VALVE
UNION
(TYPICAL INSTALLATION)
IMPORTANT: Do not run a flexible gas connector inside the unit.
➤ FIGURE 38
GAS PIPING -- HORIZONTAL INSTALLATION
IMPORTANT: Connect this furnace
only to gas supplied by a commercial
utility.
IMPORTANT: A U.L. recognized
fuel gas and CO detector(s) are recommended in all applications, and their
installation should be in accordance
with the manufacturer’s recommendations and/or local laws, rules, regulations or customs.
GAS PIPING
Install the gas piping according to all
local codes and regulations of the utility company.
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
➤ FIGURE 39
GAS PIPING -- DOWNFLOW INSTALLATION
GROMMET
MAIN GAS VALVE
TOP VIEW OF GAS LINE AND VALVE
IN OPTIONAL POSITION
4 TO 5 FT.
ABOVE
FLOOR
REQ’D BY
SOME
UTILITIES.
NOTE:
WHEN GAS LINE IS IN OPT.
POSITION, SWAP LOCATION
OF GROMMET AND PLUG.
GAS VALVE
PLUG
(IN NORMAL
POSITION)
GROMMET
(IN NORMAL
POSITION)
MANIFOLD
PRESSURE TAP
DRIP LEG
MANIFOLD
UNION
BURNERS
A087301-01-00
38
to the combination gas valve on the
furnace. Refer to Table 8 for the recommended gas pipe size for natural gas
and Table 9 for L.P. See Figures 37, 38
& 39 for typical gas pipe connections.
Install a ground joint union between
the manual gas stop and the main
gas valve to easily remove the control valve assembly. Install a manual
gas stop in the gas line outside the
furnace cabinet. The gas stop 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.
Any strains on the gas valve can
change the position of the gas orifices in
the burners. This can cause erratic furnace operation.
GAS PRESSURE
GAS VALVE
Natural gas supply pressure should
be 5" to 10.5" w.c. LP gas supply
pressure should be 11" to 13" w.c.
This pressure must be maintained
with all other gas-fired appliances in
operation.
This furnace has a 24-volt operated
valve. It has ports for measuring
supply pressure and manifold pressure. A manual control is on the
valve body. It can be set to only the
“ON” or “OFF” positions. See
Figure 40.
!
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.
FIGURE 40
GAS VALVE
MANUAL CONTROL
To check for gas leakage, use an
approved chloride-free soap and water
solution, an electronic combustible gas
detector, or other approved method.
IMPORTANT: Do not run a flexible gas
connector inside the unit. 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 requires
that all flexible gas connectors be less
than 36”.
The gas pipe grommet in the cabinet
does not seal around a flexible gas connector. It is important to have all
openings in the cabinet burner compartment sealed for proper furnace
operation.
IMPORTANT: To insure a good seal, the
gas pipe that runs through the grommet
must be 1/2” schedule 40 black pipe.
IMPORTANT: Ensure that the furnace
gas control valve is not subjected to
high gas line supply pressures (13.5”
w.c. or above).
DISCONNECT the furnace and its individual shut-off valve from the gas supply
piping during any pressure testing that
exceeds 1/2 PSIG (3.23 kPa or 13"
w.c.).
39
TABLE 8
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:
Gas Input of Furnace (BTU/HR)
Heating Value of Gas (BTU/FT3)
The gas input of the furnace is marked on the furnace rating plate. The heating value of the gas
(BTU/FT3) may be determined by consulting the local natural gas utility or the LP gas supplier.
Cu. Ft. Per Hr. Required =
TABLE 9
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, 150,000
Equivalent length of pipe, 60 ft. = 3/4" IPS required.
LP COPPER TUBE SIZING TABLE
Sizing between single or second stage (low pressure) regulator and appliance. Maximum capacity of pipe in thousands of BTU
per hour of undiluted propane gases (at 11" w.c. setting).
Outside Diameter
Copper Tubing,
Type L
40
Length of Pipe, Feet
10
20
30
40
50
60
80
100
125
150
3/8"
49
34
27
23
20
19
16
14
11
10
1/2"
110
76
61
52
46
42
36
32
28
26
5/8"
206
141
114
97
86
78
67
59
52
48
3/4"
348
239
192
164
146
132
113
100
89
80
7/8"
536
368
296
253
224
203
174
154
137
124
LP CONVERSION
IMPORTANT: LP gas from trucks used
to transport liquid-based fertilizers can
contain chemicals that will damage the
furnace. Verify that your gas supplier
does not use the same truck to transport materials other than LP.
This furnace is shipped from the factory for use on natural gas only. For use
on LP gas, a proper conversion is
required.
Conversion of this furnace for use on
LP gas requires conversion kit RXGJFP07 for U.S. and RXGJ-FP08 for
Canada. This kit includes an LP gas
valve.
!
2. Remove the gas valve and manifold assembly.
3. Replace the orifice spuds.
4. Remove the natural gas valve from
the manifold assembly and replace
with the LP valve included in the
kit.
5. Re-attach the manifold assembly to
the unit and connect the gas line to
the gas valve.
7. Check unit for leaks.
8. Follow lighting instructions to
put the furnace into operation.
9. Check manifold pressure.
Consult Table 11, if there is any
question concerning orifice sizing.
NOTE: No LP orifices are included
in the kit. LP orifices must be selected based on the altitude of the
installation. See orifice chart.
6. Place the conversion label, included in the kit, adjacent to the CSA
rating plate.
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. SEE THE SECTION
TITLED “HIGH ALTITUDE INSTALLATIONS” OF THIS BOOK FOR
INSTRUCTIONS.
FIGURE 41
SUPPLY-LINE PRESSURE TAP
NOTE: Order the correct LP conversion kit available from the local distributor. Furnace conversion to LP gas
must be performed by a qualified
installer, service agency, or the gas
supplier.
To change orifice spuds for either conversion to LP or for elevation:
1. Shut off the manual gas valve and
disconnect the gas line at the
union ahead of the unit gas valve.
SUPPLY-LINE
PRESSURE TAP
41
SETTING GAS PRESSURE
A properly calibrated pressure gauge
or U-Tube manometer is required for
accurate gas pressure measurements.
!
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. SEE
THE SECTION TITLED “HIGH ALTITUDE INSTALLATIONS” OF THIS
BOOK FOR INSTRUCTIONS.
Supply Gas Pressure Measurement.
1. With gas shut off to the furnace
at the manual gas valve outside
the unit, remove the line
pressure tap plug on the gas
valve. See Figure 41.
2. Connect a U-Tube manometer to
the pressure tap.
3. Turn on the gas supply and
operate the furnace at 100% and
all other gas-fired units on the
same gas line as the furnace.
4. Note or adjust the supply-line
pressure to give:
A. 5" - 10.5" w.c. for natural gas.
B. 11" - 13" w.c. for LP gas.
5. Shut off the gas at the manual
gas valve and remove the
U-Tube manometer.
6. Replace the supply-line pressure
tap plug before turning on the
gas.
7. Check unit for leaks.
If the supply-line pressure is above
these ranges, install an in-line gas
regulator to the furnace for natural
gas units. With LP gas, have the LP
supplier reduce the supply-line pressure at the regulator.
If supply-line pressure is below these
ranges, either remove any restrictions
in the gas supply piping or enlarge
the gas pipe. See Tables 8 and 9.
With LP gas, have the LP supplier
adjust the supply-line pressure at the
regulator.
!
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. SEE
THE SECTION TITLED “HIGH ALTITUDE INSTALLATIONS” OF THIS
BOOK FOR INSTRUCTIONS.
➤ MANIFOLD GAS PRESSURE
MEASUREMENT.
1. With the gas to the unit shut off
at the manual gas valve, remove
the outlet pressure tap plug in
the gas valve. See Figure 42.
2. Connect the positive pressure
hose to the pressure tap.
3. Note the manifold gas pressure
to be:
FIGURE 42
REGULATOR CAP
MANIFOLD PRESSURE TAP LOCATION
A. 3.5" w.c. (±.3) for natural
gas .
B. 10.0" w.c. ( ±.5) for LP gas.
4. To adjust the pressure regulator,
remove the regulator cap.
NOTE: Only small variations in
gas pressure should be made by
adjusting the pressure regulator.
5. Turn the adjustment screw, using
a 3⁄32" allen wrench, clockwise to
increase pressure, or counterclockwise to decrease pressure.
See Figure 43.
6. Check manifold gas pressure.
7. Repeat step 5 & 6 if needed.
OUTLET MANIFOLD PRESSURE TAP
FIGURE 43
GAS VALVE PRESSURE ADJUSTMENT (3/32" ALLEN WRENCH)
8. Securely replace the regulator
cap.
NOTE: Shut off gas at the manual gas valve and remove the UTube manometer.
9. Replace the manifold pressure
tap plug before turning on
the gas.
10. Check unit for leaks.
NOTE: Do not use gas valve pressure adjustment as a means to
adjust temperature rise. The blower
motor will change speed to maintain
a reasonably constant temperature
rise.
42
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 IN CANADA, THE
CANADIAN ELECTRICAL CODE,
CSA-C22.1 OR LOCAL CODES
THAT APPLY. A GROUND SCREW
IS PROVIDED IN THE JUNCTION
BOX. FAILURE TO PROPERLY
CONNECT THE GROUND WIRE
CAN CAUSE ELECTRICAL
SHOCK RESULTING IN PERSONAL INJURY OR DEATH.
!
the electrical disconnect to the junction
box on the left side of the furnace, inside
the blower compartment. See Figure 44.
For the proper connection, refer to the
appropriate wiring diagram located on the
inside cover of the furnace control box
and in these instructions.
Make all electrical connections in
accordance with the latest edition of
the National Electrical Code
ANSI/NFPA70 – or in Canada, the
Canadian Electrical Code Part 1CSA Standard C22.1 and local codes
having jurisdiction.
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.
These may be obtained from:
IMPORTANT: L1 terminal and neutral terminal polarity must be observed when
making field connections to the furnace.
The ignition control will NOT sense flame
if 120 vac and neutral terminals
reversed.
National Fire Protection
Association, Inc.
Batterymarch Park
Quincy, MA 02269
Canadian Standards Association
178 Rexdale Boulevard
Rexdale, Ontario, Canada M9W 1R3
FIGURE 44
JUNCTION BOX LOCATION
UPFLOW
MODELS
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.
IMPORTANT: The furnace must be
installed so that the electrical components are protected from water.
A grounding wire is provided to connect
to the incoming grounding wire from
line power. The furnace must be permanently grounded in accordance with all
national and local codes.
Before proceeding with the electrical
connections, be certain that the service
panel voltage, frequency and phase corresponds to that specified on the furnace rating plate. Maximum over-current
protection is 15 amperes.
➤
DOWNFLOW/
HORIZONTAL
MODELS
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. Connect from
43
ELECTRICAL CHECKS
Line Power Check
The furnace must have a nominal 115
volt power supply for proper operation. If there is not a consistent power
supply, contact a licensed electrician
to correct the problem.
1. With the blower compartment door
off, manually hold the push button
door switch in.
2. Call for heat at the thermostat.
3. With the unit operating, use a voltmeter to measure the voltage from
any 120 VAC terminal to any neutral connection.
4. The voltage should be a nominal
115 volts (acceptable 105120VAC).
This test should be made with the unit
in full operation.
Polarity Check
Proper line voltage polarity, or phasing, is a must for this furnace to operate. Use a volt meter to make this
check.
1. With the blower compartment door
off, manually hold the push button
door switch in.
2. Use a voltmeter to measure the
voltage from any 120 VAC terminal
to any bare metal ground on the
furnace.
3. The voltage should be a nominal
115 volts (acceptable 105120VAC).
4. Use a voltmeter to measure the
voltage from any neutral terminal
to the bare metal ground on the
furnace.
5. The voltage should be less than
1.0 VAC.
6. If the voltage from any 120 VAC
terminal to ground is less than 1.0
VAC volts and the voltage from a
neutral to ground is a nominal 115
volts, the polarity is reversed.
7. To correct the problem, either
reverse the hot and neutral wires
to the furnace or have a licensed
electrician check the building
wiring.
Control Voltage Check
1. With the blower compartment
door off, manually hold the push
button door switch in.
2. Call for heat at the thermostat.
3. With the unit operating, use a
voltmeter to measure the voltage
from control voltage terminal “W”
to terminal “C” on the furnace
control board.
4. The voltage should be a nominal
24 volts (Acceptable 18-30 VAC).
This test should be made with the
unit in full operation.
44
THERMOSTATS
THERMOSTAT WIRING
NOTE: For fully modulating function,
the furnace must be installed with the
(-)HC-TST401MDMS Modulating
Touch-Screen Thermostat.
FIGURE 45
24-VOLT TERMINALS
NOTE: Do not use 24 volt control wire
smaller than No. 18 AWG.
Wire all thermostats to the 24V connections on the integrated furnace control.
See Figures 46, 47, 48, 49, and 50.
NOTE: A larger wire gage may be be
required for longer lengths of thermostat wire.
For proper installation of the Variable
Output Thermostat, follow the
“Thermostat Installation, Programming
and Troubleshooting Manual” included
as section II of this manual. For proper
installation of a Single-Stage or TwoStage Thermostat, see the Installation
Instructions included with the thermostat.
➤ FURNACE OPERATION USING
MODULATING, SINGLE-STAGE, AND
TWO-STAGE THERMOSTATS
The modulating furnace with the UT
Electronic Controls IFC is also capable
of operating with a single-stage or a
two-stage thermostat as well as the
modulating thermostat. Furnaces
equipped with part # 62-24174-01 (rev
-02 or newer) or 62-24174-02 (all revisions) will operate with either singlestage or two-stage thermostats as a
modulating system using an algorithm
that utilizes three distinct firing rates;
40%, 65% and 100% of the furnace
heating capacity (See below for operation of each).
Figures 46, 47, 48, 49 and 50 detail
how to wire the modulating furnace for
operation with a modulating thermostat, a single-stage thermostat or a
two-stage thermostat.
➤ FURNACE OPERATION WITH A
MODULATING THERMOSTAT
As described previously in this manual,
operation with a modulating thermostat
when installed as shown in Figure 46
is fully modulating between 40% and
100% of furnace capacity. The firing
rate is first determined by the thermostat and then sent to the furnace. This
is the optimum mode of operation and
will give the best temperature control
with minimal temperature variation
from the desired set point.
should be in the “OFF” position from the
factory. The lack of the modulating “V”
signal will automatically be sensed as a
single-stage thermostat and the furnace
will operate accordingly.
With a single-stage thermostat (installed
as shown in Figure 49), during a call for
heat, the furnace will operate as follows:
Phase 1: 0 to 5 minutes = 40% of furnace capacity
Phase 2: 5 to 12 minutes = 65% of furnace capacity
Phase 3: After 12 minutes = 100 % of
furnace capacity
NOTE: If the call for heat ends during
any phase, the furnace will terminate
immediately at the firing rate of that
phase.
If switches 1 & 2 of SW2 are in the
“ON” position (See Figure 56), the furnace will always operate at 40% with a
single-stage thermostat installed as
shown in Figure 40. THIS CONFIGURATION IS NEITHER RECOMMENDED NOR APPROVED.
➤ FURNACE OPERATION WITH A
SINGLE STAGE THERMOSTAT
To operate the furnace with a singlestage thermostat, set switches 1 & 2 of
SW2 (See Figure 56) to the “OFF”
position. Note that these switches
45
➤
FIGURE 46
OUTDOOR SENSOR
MODULATING THERMOSTAT
S
–
12 FT
(1)
WIRING DIAGRAM FOR MODULATING HEAT (NO DUAL FUEL)
+
Y Y2
Y (Y2)
YH (Y2)
V / W2
*
YL (Y1)
YL* (Y1)
*
THERMOSTAT MODEL: (-)HC-TST401MDMS
REMOTE SENSOR: F1451378
*2 STAGE COOLING ONLY
(1) FOR REMOTE SENSOR INSTALLATION
(1) SEE THERMOSTAT INSTALLATION INSTRUCTIONS
FIGURE 47
FULLY MODULATING – TYPICAL DUAL FUEL APPLICATION – SINGLE STAGE HEAT PUMP
46
FIGURE 48
FULLY MODULATING – TYPICAL DUAL FUEL APPLICATION - TWO STAGE HEAT PUMP
➤
FIGURE 49
WIRING DIAGRAM FOR SINGLE-STAGE HEAT
1-STAGE ELECTRONIC THERMOSTAT*
Y Y2
***
YH (Y2)
Y (Y2)
YL (Y1)
YL (Y1)
***
*
**
NO MECHANICAL THERMOSTATS.
40%, 65%, and 100% FIRING RATE IN SINGLE-STAGE OPERATION. 40% FIRING RATE IN TWO-STAGE OPERATION
(DIP SWITCH SET SW2 — SWITCHES 1 & 2 OFF).
*** 2 STG. COOLING ONLY.
47
FIGURE 50
WIRING DIAGRAM FROM TWO-STAGE HEAT
2-STAGE ELECTRONIC THERMOSTAT*
Y Y2
YH (Y2)
****
Y (Y2)
YL (Y1)
YL (Y1)
****
*
**
NO MECHANICAL THERMOSTATS.
40% FIRING RATE IN TWO-STAGE OPERATION
(DIP SWITCH SET SW2 — SWITCHES 1 & 2 ON).
*** 65% and 100% FIRING RATE IN TWO-STAGE OPERATION (W & W2 ENERGIZED).
**** 2 STAGE COOLING ONLY.
FURNACE OPERATION WITH A TWOSTAGE THERMOSTAT
To set the furnace for operation with
two-stage thermostats, set switches 1 &
2 of SW2 to the “ON” position (See
Figure 56). Note that these switches
should be in the “OFF” position from
the factory. With both switches in the
“ON” position, the furnace can still recognize a “V” signal present and will still
operate with a modulating thermostat.
However, with both switches of SW2 in
the “ON” position, the furnace is set to
operate with a two-stage thermostat as
well.
M a two-stage thermostat (installed
With
as shown in Figure 50) and switch settings configured as described above,
during a call for heat, the furnace will
operate as follows:
First Stage
(“W”=ON and “W2”=OFF)
40% of furnace capacity always
Second Stage
(“W”=ON and “W2”=ON)
Phase 1: 0 to 5 minutes = 65% of furnace capacity
Phase 2: After 5 minutes = 100% of
furnace capacity
NOTE: If the call for heat ends during
any phase and/or stage, the furnace
will terminate immediately at the firing
rate of that phase and/or stage.
APPLICATIONS
INSTALLATION
!
MODULATING TOUCHSCREEN THERMOSTAT
Model
Programming Choices
(-)HC-TST401MDMS Non-Programmable 5/1/1 Day
WARNING
M
7 Day
THERMOSTAT INSTALLATION
AND ALL COMPONENTS OF THE
CONTROL SYSTEM SHALL CONFORM TO CLASS II CIRCUITS PER
THE NEC CODE.
REMOVE OLD THERMOSTAT
THERMOSTAT APPLICATION GUIDE
Description
Modulating PWM output, gas furnace
Yes
Heat Pump (with Aux. or Emergency Heat), 2 Stage
Yes
Systems with up to 3 Stages Heat, 2 Stages Cool
Yes
Heat Only Systems
Yes
Wired Remote Temperature Sensor (Indoor/Outdoor)
Yes
Dual Fuel Feature (Heat Pump Mode)
Yes
For complete product specifications, see
the Installation Instructions supplied with
thermostat.
FIGURE 51
(-)HC-TST401MDMS
MODULATING TOUCHSCREEN THERMOSTAT
A standard heat/cool thermostat consists of three basic parts:
1. The cover, which may be either a
snap-on or hinge type.
2. The base, which is removed by
loosening all captive screws.
3. The switching subbase, which is
removed by unscrewing the
mounting screws that hold it on
the wall or adapter plate. Before
removing wires from old thermostat, label each wire with the
terminal designation from which
it was attached. Disconnect the
wires from the old thermostat one
at a time. Do not let wires fall
back into the wall.
INSTALLING NEW THERMOSTAT
1. Pull the thermostat body off the
thermostat base. Forcing or prying
on the thermostat will cause damage to the unit. Rear view of thermostat
2. Place base over hole in wall and
mark mounting hole locations on
wall using base as a template.
48
3. Move base out of the way. Drill
mounting holes. If you are using existing mounting holes and the holes
drilled are too large and do not allow
you to tighten base snugly, use plastic
screw anchors to secure the base.
4. Fasten base snugly to wall using
mounting holes shown in Figure 52
and two mounting screws. Leveling is
for appearance only and will not affect
thermostat operation.
5. Connect wires to terminal block on
base using appropriate wiring
schematic (see Figures 46, 47 & 48).
6. Push excess wire into wall and plug
hole with a fire resistant material
(such as fiberglass insulation) to prevent drafts from affecting thermostat
operation.
7. Carefully line the thermostat up with
the base and snap into place.
BATTERY LOCATION
2 “AA” alkaline batteries are included in
the thermostat at the factory with a battery tag to prevent power drainage.
Remove the battery tag to engage the
batteries. To replace batteries, set system to OFF, remove thermostat
from wall and install the batteries in the
rear along the top of the thermostat
(see Figure 52).
WIRING CONNECTIONS
Refer to equipment manufacturers’
instructions for specific system wiring
information. After wiring, see CONFIGURATION section for proper thermostat
configuration. For wiring diagrams, see
Figures 46, 47 & 48.
Wiring diagrams shown are for typical
systes and describe the thermostat terminal functions.
TERMINAL DESIGNATION DESCRIPTIONS
Terminal Designation
B ..................
O ..................
Y2 . . . . . . . . . . . . . . . . . .
Y ..................
G ..................
RC . . . . . . . . . . . . . . . . . .
RH . . . . . . . . . . . . . . . . . .
C ..................
V ..................
W/E . . . . . . . . . . . . . . . . .
W2 . . . . . . . . . . . . . . . . . .
- ...................
S ..................
+ ..................
Description
Changeover valve for heat pump energized constantly in heating
Changeover valve for heat pump energized constantly in cooling
2nd Stage Compressor
Compressor Relay
Fan Relay
Power for Cooling
Power for Heating
Common wire from secondary side of cooling
PWM Output
Heat Relay/Emergency Heat Relay (Stage 1)
2nd Stage Heat (3rd Stage Heat in HP2)
Common (DC) for wired remote temperature sensor
Frequency signal from remote temperature sensor
Power (DC) to remote temperature sensor
FIGURE 52
(-)HC-TST401MDMS BASE
+
Mounting
Hole
Mounting
Hole
S
Y2
W2
W/E
Place Level
across
Mounting Tabs
(for appearance only)
V
Place Level
across
Mounting Tabs
(for appearance only)
Rear view of thermostat
2 "AA" Batteries
49
THERMOSTAT QUICK REFERENCE
Home Screen Description
Figure 53
52 – Home Screen
Screen Display
Display
Figure
Room
Temperature
Day of Week
Set Temperature
Time of Day
Temperature
UP/Down used for
modifying set point
as well as to
navigating the menus
System
Switch
Fan
Switch
Enters comfort
temperature settings
into the schedule
Indicates when
thermostat is calling
for Heat or Cool
Battery Level Indicator
Indicating the current power level
Full power remaining.
Half power remaining.
Change
The batteries should be replaced at this time.
Programming and Configuration Items
1
2
Indicates period of day being programmed.
3
RUN SCHEDULE (run program) button.
4
SET TIME button or HOLD temperature button.
5
Displays "Change Filter" when the system has run
for the programmed filter time period as a reminder
to change or clean your filter.
6
COPY button or INSTALLER CONFIG button.
7
CLEAN DISPLAY button allows 30 seconds to wipe off
the display or ADVANCE DAY button for programming.
8
Used in programming to set time and in configuration
menu to change selections.
9
"Hold Until" indicates the time when a temporary hold
period will end.
10
"Hours" and "Days" displays during steps in installer
configuration.
11
The words "Hold At" are displayed when the thermostat is in the HOLD mode. "Temporary Hold At" is
displayed when the thermostat is in a temporary HOLD
mode.
12
50
Displays and "Keypad Lockout" when in keypad
lockout mode.
Displays and "Temperature Limit" and "Keypad
Lockout" when limited range is activated and locked.
Displays only "Temperature Limit" when limited range
is activated.
"System On" indicates when heating or cooling stage
is energized. "+2" also indicates when a second stage
is energized.
Menu key for entering
different modes such as
Cleaning, Configuration, Set
Time and Set Schedule
Figure
Figure 54
53 – Programming
Programming &
& Configuration
Configuration Items
Items
15
11
10
9
1
8
13
12
2
14
3
7
6
5
4
13
"Copy" indicates the copy program feature is being
used during programming.
14
A steady "Cool Savings" display indicates the feature
is enabled in the installer menu. A flashing "Cool
Savings" display indicates the feature is active.
15
"Remote" indicates that the indoor remote temperature
sensor, is being accessed. "Outdoor Remote" indicates the outdoor remote temperature sensor is being
accessed.
INSTALLER/CONFIGURATION MENU
To enter the menu: Press the Menu touch key. Press and hold for 5 seconds the Installer Config touch key. This displays
to advance to the next menu item or
to return to a previous menu item. Press
menu item #1 in the table below. Press
or
to change a menu item.
NonMenu
Reference Program- Program- Press
mable
mable Button
Number
1
1
1
Displayed
(Factory
Default)
MS 2
CONFIGURATION MENU
or
Press
to select from
listed options
Comments
HP 1, HP 2, SS 1
Selects Multi-Stage (MS 2, No Heat Pump), Heat Pump 1
(HP 1, 1 compressor), Heat Pump 2 (HP 2, 2 compressor
or 2 speed compressor), or Single Stage.
2
2
2
(GAS)
ELE
GAS setting: furnace controls blower.
ELE setting: thermostat controls blower.
3
3
3
Days, (7) P
5-1-1 or 0
4
4
NA
PS (4)
2
Morning, Day,
Day, Night
Evening, Night
5
5
4
Programs per week. (0 = non-programmable)
Program periods per day.
4 = Morning, Day, Evening, Night
2 = Day, Night
Cool-Off-
Cool-Off-Heat,
Heat-Auto
Off-Heat, Cool-Off
Cool-Off-Heat-
Cool-Off-Heat-Emer,
Emer-Auto
Off-Heat-Emer, Cool-Off
System switch configuration in non heat pump mode.
System switch configuration, heat pump mode.
6
6
NA
E (On)
OFF
7
7
5
Cr, Heat (FA)
SL
8
8
6
Cr, Cool (FA)
SL
Selects Adjustable Anticipation, cycle rate, Cool
9
9
7
Cr/AU, Emer (FA)
SL
Selects Adjustable Anticipation, cycle rate auxiliary, (This item is
10
10
8
CL (OFF)
On
Selects Compressor Lockout.
11
11
9
dL (On)
OFF
12
12
10
dL (LO)
HI
13
13
11
0
4, LO to 4, HI
Selects Energy Management Recovery, E (with programming option on)
Selects Adjustable Anticipation, cycle rate, Heat
only to appear if HP 1 or HP 2 is selected above).
Selects Continuous Display backlight & intensity.
Selects Backlight Intensity.
Selects Adjustable Ambient Temperature Display [range -4 (LO) to
+4 (HI)].
14
14
12
F
C
15
15
13
b (On)
OFF
16
16
14
dS (On)
OFF
17
17
15
AS, Heat (OFF)
On
Selects Automatic Schedule for comfort temperature Programming,
18
18
16
AS, Cool (OFF)
On
Selects Automatic Schedule for comfort temperature Programming,
19
19
17
CS, (OFF)
1-2-3-4-5-6
Selects F/ C Displa y (temperature units in Fahrenheit or Celsius).
Selects audible Beeper On/Off.
Selects Daylight Saving Time calculation.
heat mode.
cool mode.
Selects Cool Saving Feature & amount.
Cool Savings
20
20
18
HL, Heat (99)
62-98
TEMPERATURE LIMIT, HEAT (max. heat set point).
21
21
19
LL, Cool (45)
46-82
TEMPERATURE LIMIT, COOL (min. cool set point).
22
22
20
OFF,
Keypad Lockout
L (total), P (partial),
Selects Keypad Lockout.
Temperature Limit
(limited temperature range)
000
001-999
Selects Keypad Lockout Combination (active only if keypad Lockout
is selected).
23
23
21
FS, Heat (On)
OFF
24
24
22
FS, Cool (On)
OFF
Fast second stage of heat (not available if SS1 is selected above).
Fast second stage of cool (not available if SS1 or HP1 is selected
above).
25
25
23
Remote (OFF)
On
In, Remote
Outdoor Remote
LS (On)
OFF
Remote temperature sensor, enable/disable.
Remote temperature sensor (Indoor/Outdoor).
Local temp. Sensor enable/disable (only when Indoor Remote is
selected On).
26
26
24
dF (5)
5-50
Selects Dual Fuel Feature & setpoint (in Fahrenheit) (applicable only
Cd (15)
0-99
Selects Compressor delay in seconds (only when dF is selected >5).
when HP1 or HP2 is selected).
27
27
25
AO (80)
35 to 80
28
28
26
Change Filter
On
Selects Change filter feature
25-1975 (in increments
Change filter, duration hours.
Selects Auxiliary Off setpoint (applicable only when HP1 or HP2
is selected).
(OFF)
200 Hours
of 25 hours)
51
INSTALLER/CONFIGURATION MENU
1) This control can be configured for:
MS2 Multi-Sta ge System (2 heat/2 cool)
HP1 Hea t Pump with one stage of compressor
(2 heat/1 cool)
HP2 Hea t Pump with two stage compressor or two
compressor system, Gas or Electric backup; (Dual Fuel
see menu item 35) (3 heat/2 cool)
SS1 Sing le Stage System (3 wire zone see wiring
diagram 37-6808A)
2) GAS or Electric (ELE) fan operation. If the heating
system requires the thermostat to energize the fan,
select ELE. Select GAS if the heating system energizes
the fan on a call for heat. Note: Resetting the thermostat switches the option to ELE.
3) Programs per week This control can be configured for
7 independent day or 5/1/1 day programming or nonprogrammable modes. Default is 7-day mode. The
display indicates "7 Days" as default. Other options "5
Days" or "0 Days" can be selected by pressing touch
or
. If "0 Days" is selected for non-programkeys,
mable mode, the step for EMR will be skipped, as this
feature will not be available in this mode.
4) Program Steps per day This control can be configured for 4 or 2 program steps per day. Default is "4 PS"
and can be toggled between 4 PS and 2 PS by pressing
or
touch keys.
the
5) System Switch Configuration (MS2/SS1) This
thermostat is configured for Heat and Cool with Auto
changeover default (Cool-Off-Heat-Auto). Can be
configured as Heat & Cool (Cool-Off-Heat), or Heat Only
(Off-Heat), or Cool Only (Cool-Off).
When the control is in heat pump configuration (HP1/
HP2), the system switch configuration will have an
additional mode available namely, Emer for Emergency
Mode.
6) Energy Management Recovery (EMR) (this step is
skipped if configured as non-programmable).
When set to "On" causes the thermostat to start heating
or cooling early to make the building temperature reach
the program setpoint at the time you specify.
Example: Let us say, the heating program is 65 F a t
night and 70 a t 7 AM. If the building temperature is 65 F,
the difference is 5 F. Allowing 5 minutes per F rise, the
thermostat setpoint will change to 70 a t 6:35 AM.
Cooling allows more time per F, because it takes
longer to reach temperature.
7, 8 & 9) Cycle Rate Selection The factor y default setting
is fast cycle (FA Cr) in all modes (Heat, Cool, Emer). To
or
toggle
slow cycling (SL, Cr), press touch keys
between FA & SL. The cycle rates are as below different
selections:
Mode
Fast rate
Slow rate
Heat
0.6 F
1.2 F
Cool
1.2 F
1.7 F
Emer
1.2 F
1.7 F
10) Select Compressor Lockout (CL) Selecting CL On
will cause the thermostat to wait 5 minutes between
cooling cycles. This is intended to help protect the
compressor from short cycling. Some of the newer
compressors have already got a time delay built in and
do not require this feature to be activated in the thermostat. Your compressor manufacturer can tell you if
this lockout feature is already present in their system.
When the thermostat compressor time delay is activated,
it will flash the set point for up to five minutes.
52
11) Select Continuous Backlight In low lighting conditions, display backlight improves the display contrast.
When C terminal is connected, selecting dL On will turn
the backlight on continuously. Selecting dL Off will turn
the backlight on momentarily after any key is pressed.
When C terminal is not powered (battery only), dL On
enables the momentary backlight whenever a key is
pressed.
12) Select Backlight Intensity This ther mostat has the
ability to provide two selectable intensities of the backor
touch keys you can
light: HI and LO. Using
toggle the selection between HI and LO.
13) Select Temperature Display Adjustment 4 LO to 4 HI
This allows you to adjust the room temperature display
by an amount in the range of -4 F to +4 F in 1 steps b y
or
touch keys. Your thermostat was
using the
accurately calibrated at the factory, however you have the
option to change the display temperature value to match
your previous thermostat, if you so prefer.
14) Select °F or °C Readout Select the desired temper or . Factory default is F.
ature unit by pressing
15) Select Audio Prompting (Beeper) On or Off F actory
default setting is on (b, On). If you wish to turn off the
beeper select OFF.
16) Select Daylight Saving Time Calculation T his feature
will allow the thermostat to calculate the DST automatically and apply it to the Real Time Clock display. Default
or
touch keys to select the feature, OFF.
On. Use
17 & 18) Select Automatic Schedule With just one touc h
of the Auto Schedule key this feature allows you to
program a desired comfort temperature into all the
program periods along with a 6 set bac k for night
periods of both Heat and Cool programs. Factory default
is "On" for both. When Heat AS On and Cool AS On are
activated while in Heat or Cool mode, select desired
setpoint temperature and press Auto Schedule. Auto
Schedule will flash, press it again to copy. This value will
be copied into all the morning, day and evening program
periods. The night program periods will be with a 6 F set
back.
19) Select Cool Savings™: With Cool Savings ena bled,
the thermostat will make small adjustments to the sensed
temperature during periods of high demand to reduce AC
system running time and save energy. When the cooling
system has been running for more than 20 minutes,
humidity in the home will be lower and a higher
temperature will feel comfortable. After 20 minutes of run
time, the thermostat will start decreasing the sensed
temperature in steps of less than one degree as the
system continues to run. These adjustments will eventually cause the system to satisfy the thermostat to turn the
system off and reduce the energy consumption. When
the Cool Savings f eature is active and making adjustments, the display will flash CoolSavings”. The amount
of the adjustments to the sensed temperature is dependent on the Cool Savings v alue that is set, 1 being the
least adjustment and 6 being the most adjustment. With
this feature set to OFF, no change will occur when the AC
system is continuously running during the periods of high
demand. Periods of high demand will normally occur
during the late afternoon and early evening on the hottest
days of the summer. As demand lessens the adjustments
to sensed temperature are reversed until sensed
temperature returns to normal and “CoolSavings” no
longer flashes.
INSTALLER/CONFIGURATION MENU
20) Heat Temperature Limit Range This f eature adjusts
the highest setpoint temperature for heat. The default
setting is 99 F. It can be changed between 62 F and
or
key. The "temperature
98 F b y pressing the
limit" icon will be displayed to the left of your setpoint
temperature when using this feature. The "temperature
limit" icon will flash if an attempt is made to adjust the
temperature beyond the range selected.
21) Cool Temperature Limit Range T his feature adjusts
the lowest setpoint temperature for cool. The default
setting is 45 F. It can be changed between 46 F and
or
key. The "temperature
82 F b y pressing the
limit" icon will be displayed to the left of your setpoint
temperature when using this feature. The "temperature
limit" icon will flash if an attempt is made to adjust the
temperature beyond the range selected.
22) Keypad Lockout This step allows y ou to select the
type of lockout or limited range security required. If no
to
lockout or limited range security is required, press
advance the menu.
Three security settings are available in this menu item.
or
keys to select the lockout desired.
Use the
Lockout selections are:
"Keypad Lockout and L" = Total Lockout. Total Lockout
locks all keys.
"Keypad Lockout and P" = Partial Lockout. Partial Lockor
keys to operate within your
out allows only the
set temperature limits.
"Temperature Limit/Keypad Lockout" prevents
changing the temperature limits in the Configuration
Menu.
Keypad Lockout Combination Number Selection
Display will read "OFF" "Keypad Lockout".
Skip this step and continue through the configuration
menu items 19 thru 22 if you require an Air Filter Change
out indicator or Humidifier Pad Change out indicator by
button to advance.
pressing the
Return to this point when you are ready to start your
selected lock-out and continue by:
or
keys to select ON.
Pressing
Press . Display will read "000".
Pressing
or
keys to select your keypad lockout
combination number. Note: "000" is not a valid
combination choice.
Record the number you select for future use.
to exit the menu. The security feature you
Press
select will start in 10 seconds. The system button will
remain active for 10 seconds to allow setting Heat, Off,
Cool or Auto.
23 & 24) Select Fast Second Stage ON or OFF In the r un
mode, with the fast Heat feature enabled (FA Heat On), if
the Heat setpoint temperature is manually raised by 3 F
the
(2 C) or more a bove the actual temperature using
second stage will energize immediately. With FA OFF,
second stage will not energize until the setpoint temperature is 1 F or more a bove actual temperature for more
than ten minutes. The Fast Cool feature (FA Cool)
provides the same controls when the setpoint temperature is lowered.
25) Select Remote Temperature Sensor This control
allows one wired remote temperature sensor (indoor or
outdoor) be connected to it and indicates the measured
temperature in clock digits. This menu enables you to
select the remote sensor and also configure it as indoor
or outdoor temperature sensor. Factory default is off.
Select Remote On and Remote in (for indoor) or
Outdoor Remote.
Local Temperature Sensor disable This is applica ble
only when indoor remote temperature sensor is enabled.
Factory default is On LS. You can make it Off LS if you
or
touch keys.Then, only the
desire by using
indoor remote temperature reading will be used for
control.
26) Select Dual Fuel Feature and Setpoint This f eature
is applicable only in heat pump modes. When the feature
is selected, the thermostat will switch to gas heat and
inhibit the compressor when the outside temperature
(monitored by the outside remote sensor), falls below the
or
touch keys, select x, DF
DF setpoint. By using
where x=5 to 50; factory default is 5 which disables the
feature. This feature requires an outdoor remote temperature sensor (WR# F145-1378), however does not
need a fossil fuel kit.
Select Compressor Delay When the DF feature is
enabled, the shut down of the compressor stage(s) are
delayed by a programmable time after the auxiliary stage
is energized to minimize the duration during which the
system may blow cooler air. Default delay is 60 seconds
or
touch keys any value be(60, Cd). By using
tween 0 and 99 can be selected.
27) Select Auxiliary Offset Point T his feature is applicable only in heat pump modes. When the outdoor temperature is above the Auxiliary Off (AO) setpoint, the
auxiliary stages will be inhibited so the temperature will
be maintained by only the heat pump. Factory default is
80, which disables the feature. AO setpoint cannot be set
or
at or below Dual Fuel (DF) setpoint. By using
touch keys, select x, AO where x=35 to 80.
28) Select Change Filter Run Time The ther mostat
will display "Change Filter" after a set time of blower
operation. This is a reminder to change or clean your air
filter. This time can be set from 25 to 1975 hours in 25
hour increments. A selection of OFF will cancel this
feature. When "Change Filter" is displayed, you can
clear it by pressing Clean Display. In a typical application,
200 hours of run time is approximately 30 days.
53
OPERATING YOUR THERMOSTAT
Choose the Fan Setting (Auto or On or Prog)
Fan Auto is the most commonly selected setting and runs
the fan only when the heating or cooling system is on.
Fan On selection runs the fan continuously for increased air
circulation or to allow additional air cleaning.
Fan Prog will cycle the fan for -10 minutes on and 20
minutes off if the thermostat has not called for heat or cool
during the past 60 minutes.
Choose the System Setting
(Cool, Off, Heat, Emer, Auto)
Press the SYSTEM button to select:
Heat: Thermostat controls only the heating system.
Off: Heating and Cooling systems are off.
Cool: Thermostat controls only the cooling system.
Auto: Auto Changeover is used in areas where both heating
and cooling may be required on the same day. AUTO allows
the thermostat to automatically select heating or cooling
depending on the indoor temperature and the selected heat
and cool temperatures. When using AUTO, be sure to set the
Cooling temperatures more than 1 Fahrenheit higher than
the heating temperature.
Emer: Setting is available only when the thermostat is
configured in HP1 or HP2 mode.
Manual Operation for
Non-Programmable Mode Thermostats
Press the SYSTEM button to select Heat or Cool and use
or
buttons to adjust the temperature to your
the
desired setting. After selecting your desired settings you can
also press the SYSTEM button to select AUTO to allow
the thermostat to automatically change between Heat and
Cool.
Manual Operation (Bypassing the Program)
Programmable Thermostats
Press
or
and the HOLD button and adjust the temperature wherever you like. This will override the program. The
HOLD feature bypasses the program and allows you to
adjust the temperature manually, as needed. Whatever
temperature you set in HOLD will be maintained 24 hours a
day, until you manually change the temperature or press Run
Schedule to cancel HOLD and resume the programmed
schedule.
IMPORTANT!
Program Override (Temporary Override)
Press
or
buttons to adjust the temperature. This will
override the temperature setting for a (default) four hour
override period. The override period can be shortened by
or lengthened by pressing . Program Override
pressing
period can range from 15 minutes to 7 days.
Example: If you turn up the heat during the morning program, it will be automatically lowered later, when the temporary hold period ends. To cancel the temporary setting at any
time and return to the program, press Run Schedule.
If the SYSTEM button is pressed to select AUTO the
thermostat will change to Heat or Cool, whichever ran last. If
it switches to heat but you want cool, or it changes to cool
or
buttons simultabut you want heat, press both
neously to change to the other mode.
Special Test Mode for PWM (V) output
(Installer function only)
The PWM (V) output controls the modulating gas valve.
Amplitude of this signal is about 10 VDC, frequency is 1 HZ
and the pulse width is variable 350 to 950 in steps of 50
msec.
To activate the modulating test mode, press and hold the
Installer Config touch key until the display changes to show
dC (in actual temperature digits) and 05 (default) in clock
digits (at least 10 seconds). If the touch key is released
before the display changes the test mode will not be activated and the installer menu mode will be active. On entering
the modulating test mode, the display (05) will indicate the
duty cycle of 5% (pulse width of 50 msec) corresponding to
no call for heat.
key to change the display to 35 (duty cycle 35%).
Press
The W output will energize and within one second the pulse
width modulated V output will also be activated with a pulse
width of 350 msec.
or
touch keys to increase or decrease the pulse
Use
width in steps of 50 milliseconds (5% change in duty cycle).
The maximum duty cycle is 95% (maximum pulse width of
950 milliseconds).
This special test mode will be exited by pressing Run
Schedule touch key or when there is no keypad activity for
over 60 minutes.
PROGRAMMING
Set Current Time and Day
1) Press Menu key to enter installer menu. Then press
Set Time once to indicate hour & A or P designation in
clock display.
or
touch key until you
2) Press and hold either the
reach the correct hour and A or P designation.
3) Press Set Time again to display minutes only in clock
display.
or
touch keys until you
4) Press and hold either the
reach the correct minutes.
5) Press Set Time once again to display year.
or
touch key until you
6) Press and hold either the
reach the correct year.
54
7) Press Set Time once again to display month.
or
touch key until you
8) Press and hold either the
reach the correct month.
9) Press Set Time once again to display date of the month
along with day of the week at top row (which is automatic).
or
touch key until you
10) Press and hold either the
reach the correct day of the month. The correct day of
the week is displayed at the top row.
11) Press Run Schedule once; now the display will show the
correct time and room temperature.
PROGRAMMING
Automatic Daylight Saving Calculation
Automatic Schedule
The Real Time Clock will adjust automatically for daylight
savings time, in the following manner until 2007:
Increment one hour at 2 AM on the first Sunday of April and
decrement one hour at 2 AM of the last Sunday of October
every year.
From March 2007, the adjustment will occur every year as
follows: Increment one hour at 2 AM on the second Sunday
of March and decrement one hour at 2 AM on the first
Sunday of November.
The daylight saving feature can be enabled or disabled in
installer configuration mode.
After entering installer configuration mode, momentarily
or
touch key until the display indicates dS (in
press
actual temperature digits) and on (default in c lock digits).
and
keys will toggle display and operation from On to
OFF.
This feature provides a method to program every day with
the most popular time and temperature profile using one key
press. For this feature to be available, the Auto schedule
options (AS Cool or AS Heat) should be set on in the
installer configuration.
Programming Tip: Copy Button
You may copy any daily program to another day or group of
days by pressing the Copy button. In 7 day programming
mode when the Copy button is pressed, the other 6 days of
the week will flash. To copy the current program into the
remaining six days, simply press the Copy button again. To
copy the current program to another day of the week, press
Advance Day to select the day and press Copy to paste the
program. In 5/1/1 day programming mode the copy function
is similar. The weekday (Mon-Fri) program can be copied to
Sat and Sun (both flashing) or use Advance Day to choose
Sat or Sun and press the Copy button to paste the program.
Fill in the blank schedule on the next page then:
Enter the Heating Program
1) Press the Menu button and then press Set Schedule.
Press SYSTEM button to select either "Heat" or "Cool" in
the system switch area indicating the active mode being
programmed. You can switch to the other mode by
pressing the system switch at any time.
2) The top of the display will show the day(s) being programmed. The time and set at temperature are also
displayed. "Morning" will also be displayed to indicate
the period.
or
key to change the temperature to your
3) Press
selected temperature for the 1st heating period (Morning).
or
key to adjust the start time for period.
4) Press
The time will change in 15 minute increments.
5) Press FAN to select Auto or Prog.
6) After you have set the time and the temperature for the
period to begin, press Set Schedule to advance to the
next program period.
7) Repeat steps 2 through 6 until all of the program times
and temperatures are set for all program periods on
that day.
8) Press "Advance Day" to change to the next day and
repeat steps 2 through 8.
9) When programming is complete and all of the times and
temperatures match your desired heating schedule, press
Run Schedule. The thermostat will now run your program.
Select the desired Comfort Temperature in the setpoint.
When the Auto Schedule touch key is pressed, it will start
flashing indicating that it is now ready to insert the displayed
temperature setpoint as the Comfort Temperature for the
selected system mode currently in (Heat/Cool). A second
press of the Auto Schedule touch key will complete the
process. A 6 o F setback temperature will also be inserted for
the night step. Once it is done, the touch key display Auto
Schedule will disappear disabling any further operation of
Auto Schedule touch key. If desired it can be enabled again
in the installer configuration menu.
Entering Fan Program
The FAN touch key is used to select FAN Auto operation
(fan energized with a call for cool but not on with a call for
heat) to FAN On (fan on continuous) or FAN PROG (fan
programmed to cycle fixed time automatically). Each press of
the FAN touch key will change the mode from Auto to On to
Prog. FAN Auto or FAN On or FAN On Prog will display in
the run mode for as long as the fan is in that position. When
FAN Prog position is selected and the system is in the Cool,
Heat or Auto mode, the circulator blower (fan) will cycle ON
for 10 minutes, OFF for 20 minutes when the thermostat has
not called for cooling or heating for the past 60 minutes.
To improve indoor air quality, the system circulator can be
programmed to run during any program time period by
touching the FAN touch key in the appropriate program time
period when in the Menu mode for that particular day.
The display shall indicate Prog (under the FAN icon) when in
Menu mode and the fan is programmed to come on during
that time.
In the menu mode, each time the fan key is pressed, the fan
operation and display will change from FAN Auto to FAN
Prog. The display shall indicate FAN On Prog when in run
mode and the fan is programmed to run for that particular
time period.
When in Run Schedule mode and the FAN touch key is
pressed, it will override the schedule, and the display and fan
operation shall change to FAN Auto and the fan is stopped.
Further key depression will change it to FAN On (continuous
blower on) and to FAN Prog (cycling 10 minutes on and 20
minutes off if there is no call for heat or cool for 60 minutes).
The Run Schedule touch key will also be indicated, meaning
that it is an override on the scheduled program. The override
will last until next schedule comes up or the Run Schedule
touch key is depressed.
Enter the Cooling Program
1) Press the SYSTEM button until the Cool icon appears.
2) Follow Enter Heating Program instructions for entering
cooling times and temperatures.
55
PROGRAMMING
Energy Saving Factory Pre-Program
The (-)HC-TST401MDMS thermostats are programmed with the energy saving settings shown in the table below for all days
of the week. If this program suits your needs, simply set the thermostat clock and press the RUN button.
The table below shows the factory set heating and cooling schedule for all days of the week.
* Wake Up
(Morning)
Heating
Program
Cooling
Program
Leave For Work
(Day)
* Return Home
(Evening)
Go To Bed
(Night)
6:00 AM
70 F
8:00 AM
62 F
5:00 PM
70 F
10:00 PM
62 F
6:00 AM
78 F
8:00 AM
85 F
5:00 PM
78 F
10:00 PM
82 F
* You can eliminate these two program periods in the configuration menu (reference #3) if the building is occupied all day.
Day will change to 6:00 am and can be programmed as required.
Planning Your Program – Important
The Heating and Cooling Program schedules below allow you to pencil in your own program times and temperatures.
The (-)HC-TST401MDMS comes configured for 7 day programming and can also be configured for 5+1+1 programming (see
configuration section).
Factory settings are listed on Monday, Saturday and Sunday. If you are re-programming a 5+1+1 day schedule, pencil in your
own times and temperatures directly below the factory times and temperatures.
If you are re-programming a 7 day fill in all lines with the times and temperatures you want.
Keep the following guidelines in mind when planning your program.
In Heating, lower temperatures will save energy.
In Cooling, higher temperatures will save energy.
If you plan on using Auto Changeover, do not program the heating higher than the cooling.
Worksheet for Re-Programming 5+1+1 and 7 Day Program
Heating
Program
Wake Up
(Morning)
Fan
Leave For Work
(Day)
Fan
Return Home
(Evening)
Fan
Go To Bed
(Night)
Fan
6:00 AM
70 F
Auto 8:00 AM
62 F
Auto 5:00 PM
70 F
Auto 10:00 PM 62 F
Auto
SAT
6:00 AM
70 F
Auto 8:00 AM
62 F
Auto 5:00 PM
70 F
Auto 10:00 PM 62 F
Auto
SUN
6:00 AM
70 F
Auto 8:00 AM
62 F
Auto 5:00 PM
70 F
Auto 10:00 PM 62 F
Auto
MON
TUE
WED
THU
FRI
Cooling
Program
Wake Up
(Morning)
Fan
Leave For Work
(Day)
Fan
Return Home
(Evening)
Fan
Go To Bed
(Night)
Fan
6:00 AM
78 F
Auto 8:00 AM
85 F
Auto 5:00 PM
78 F
Auto 10:00 PM 82 F
Auto
SAT
6:00 AM
78 F
Auto 8:00 AM
85 F
Auto 5:00 PM
78 F
Auto 10:00 PM 82 F
Auto
SUN
6:00 AM
78 F
Auto 8:00 AM
85 F
Auto 5:00 PM
78 F
Auto 10:00 PM 82 F
Auto
MON
TUE
WED
THU
FRI
56
PROGRAMMING
Wired Remote Temperature Sensing
Dual Fuel Temperature Set Point
One remote temperature sensor can be installed indoor or
outdoor and connected to the thermostat by a maximum
cable length of 100 meters (300 ft). Three terminals, +, S & are provided on the terminal block to connect to the WhiteRodgers standard wired remote sensor. This sensor will be
read by the thermostat only when 24VAC is present.
When used as indoor sensor, the readings can be weighted
with the local sensor for specific program periods. User can
enable or disable the remote sensor in the installer configuration mode and also the outdoor temperature can be
selected to show on the display.
The Thermostat can monitor outside temperature through an
outdoor remote sensor if installed and switch to gas heat and
inhibit the compressor when in heat pump mode and outside
temperature is below a user selectable value. This temperature is called the dual fuel temperature set point. This
eliminates the need for a fossil fuel kit.
For this feature to be functional the following conditions are
to be met:
1. The thermostat must be in heat pump mode;
2. The outdoor temperature sensor must be enabled and
operational.
Once in the installer configuration mode, momentarily press
or
touch key until display indicates Remote (at the
the
top left of the LCD) and OFF (default in clock digits).
or
touch key will toggle the operation and
Pressing
display from Remote OFF to Remote On.
When Remote On is selected, press
key for the display to
indicate Remote In (for indoor remote).
or
keys will toggle the operation and display from
The
Remote In to Outdoor Remote.
When any remote is selected the temperature will display in
the clock digits for one second alternating with the current
time for three seconds when in Run Schedule mode.
Outdoor Remote will indicate at the top left of display for
outdoor remote reading.
Only Remote will show at top left for indoor remote reading.
(oF or oC will not indicate with remote temperature readings).
Once in the installer configuration mode, step through the
menu items until the display indicates dF (for dual fuel) in the
actual temperature digits and 5 (default) in clock digits.
or
touch keys will increment the dual fuel
Pressing the
temperature setpoint from 5 to 50 (default unit is Fahrenheit).
When the dual fuel temperature setpoint is any value above
5oF this feature is enabled. If the actual outdoor temperature
is lower than this temperature setpoint the heat pump will be
inhibited. If the balance point temperature setpoint is 5oF the
feature is disabled.
When the dual fuel feature is enabled, the shut down of the
compressor stage(s) are delayed a programmable time with
a default of 60 seconds after the auxiliary stage is energized
to minimize the time that the system may blow cooler air.
is
Only when the dual fuel feature is enabled and the
pressed after the dual fuel feature dF is selected, the display
will indicate Cd (for compressor delay) in actual temperature
digits and 60 (default) in clock digits.
Pressing the
or
touch keys will increment the compressor delay time to 99 seconds or decrement down to 0
second.
or
touch keys are held depressed, the setpoint
If the
will increment or decrement one degree at the rate of one
degree every one half second for the first three seconds and
thereafter at double the speed.
Sensing Range:
Outdoor temperature range is -40 to 140oF
Indoor temperature range is 32 oF to 99 oF
Weight of Remote Reading:
When in view schedule mode the weight of the indoor remote
sensor will be shown in the left actual temperature digits
designated as A2 (default for average weight), H4 (high
weight) or L1 (low weight). The period (Morning, Day,
Evening, Night) will also be shown to the right of the weight
value in the actual temperature digits.
and
keys at the
When in view schedule mode, press
the same time to sequence the indoor remote temperature
sensor weight from A2 to H4 to L1 and back to A2 for each of
the program period times for each day. (The H4 weight is
twice the weight of A2 and A2 is twice the weight of L1).
When Remote In is selected (with Remote selected to On),
key for the display to indicate the status of the local
press
sensor LS On (default for thermostat local sensor operaand
keys will toggle the function and
tional). The
display from LS (shown in actual temperature digits) and On
(shown in clock digits) to LS OFF to designate the local
sensor is disabled.
The local sensor may be disabled only if the indoor remote
sensor is enabled and functional.
If the indoor remote sensor is disabled or not functional, the
local sensor will automatically enable and display in the run
schedule mode.
The actual temperature displayed in the run mode is the
mathematical weighted sum of the two temperature sensors
local and indoor remote.
(Outdoor remote sensor is not used for this computation).
If the remote sensor is absent or not enabled then the actual
temperature will be as measured by the local sensor.
57
TROUBLESHOOTING
Reset Operation
Note: When thermostat is reset, installer configuration menu settings and programming will reset to factory settings.
If a voltage spike or static discharge blanks out the display or causes erratic thermostat operation, you can reset the thermostat by removing
the wires from terminals R and C (do not short them together) and removing batteries for 2 minutes. After resetting the thermostat, replace
the wires and batteries. If the thermostat has been reset and still does not function correctly contact your heating/cooling service person or
place of purchase.
Note: Be sure to review the installer configuration menu settings.
To reset the programming, clock and configuration settings, press
and
and the SYSTEM button simultaneously. The thermostat
should go blank and then all segments will be displayed momentarily.
Symptom
Possible Cause
Corrective Action
No Heat/No Cool/No Fan
(common problems)
1. Blown fuse or tripped circuit breaker.
2. Furnace power switch to OFF.
3. Furnace blower compartment door or
panel loose or not properly installed.
4. Loose connection to thermostat or system.
Replace fuse or reset breaker.
Turn switch to ON.
Replace door panel in proper position to engage safety
interlock or door switch.
Tighten connections.
No Heat
1. Pilot light not lit.
2. Furnace Lock-Out Condition. Heat
may also be intermittent.
Re-light pilot.
Many furnaces have safety devices that shut down when a
lock-out condition occurs. If the heat works intermittently
contact the furnace manufacturer or local HVAC service
person for assistance.
Diagnostic: Set SYSTEM Switch to HEAT and raise the
setpoint above room temperature. Within a few seconds
the thermostat should make a soft click sound. This sound
usually indicates the thermostat is operating properly. If
the thermostat does not click, try the reset operation listed
above. If the thermostat does not click after being reset
contact your heating and cooling service person or place
of purchase for a replacement. If the thermostat clicks,
contact the furnace manufacturer or a HVAC service
person to verify the heating is operating correctly.
3. Heating system requires service or
thermostat requires replacement.
No Cool
1. Cooling system requires service or
thermostat requires replacement.
Same as diagnostic for No Heat condition except set the
thermostat to COOL and lower the setpoint below the
room temperature. There may be up to a five minute delay
before the thermostat clicks in Cooling.
Heat, Cool or Fan
Runs Constantly
1. Possible short in wiring.
2. Possible short in thermostat.
3. Possible short in heat/cool/fan system.
4. FAN Switch set to Fan ON.
Check each wire connection to verify they are not shorted
or touching together. No bare wire should stick out from
under terminal block. Try resetting the thermostat as
described above. If the condition persists the manufacturer
of your system or service person can instruct you on how
to test the Heat/Cool system for correct operation. If the
system operates correctly, replace the thermostat.
Thermostat Setting &
Thermostat Thermometer
Disagree
1. Thermostat thermometer setting
requires adjustment.
The thermometer can be adjusted +/- 4 degrees. See
Temperature Display Adjustment in the Configuration
Menu section.
Furnace (Air Conditioner)
Cycles Too Fast or Too Slow
(narrow or wide
temperature swing)
1. The location of the thermostat and/or
the size of the Heating System may
be influencing the cycle rate.
Digital thermostats provide precise control and cycle faster
than older mechanical models. The system turns on and
off more frequently but runs for a shorter time so there is
no increase in energy use. If you would like an increased
cycle time, choose SL for slow cycle in the Configuration
menu, step 6 (heat) or 7 (cool). If an acceptable cycle rate
is not achieved, contact a local HVAC service person for
additional suggestions.
Forgot Keypad
Lockout Code
58
Press the menu button (button will disappear) and hold in
for 20 seconds. This unlocks the thermostat.
ACCESSORIES
FIELD-INSTALLED
OPTION ACCESSORIES
TWINNING: Twinning is NOT permitted
on any modulating ((-)GFD, (-)GGD or
(-)GJD) furnace model.
ELECTRONIC AIR CLEANER
Line voltage power can be supplied from
the screw terminal “EAC”, see Figure 55,
and a line voltage neutral screw terminal
on the control board. This will power the
electronic air cleaner whenever the
ECM2+ blower is operating and delivering the recommended minimum CFM.
The 60 and 75 KBTU models, which are
capable of a maximum delivery of 1200
CFM, will operate the electronic air
cleaner at 500 CFM and above. The 90,
105 and 120 KBTU models, which are
capable of a maximum delivery of 2000
CFM, will operate the electronic air
cleaner at 800 CFM and above. These
limits are set to prevent excessive production of ozone at the lower airflows of
the modulating furnace and are based
on average requirements of commercially available electronic air cleaners. The
continuous fan speeds are set to always
provide adequate airflow for electronic
air cleaner operation.
humidifiers controlled by a 24 VAC
control circuit, an optional 24 VAC
humidistat can be installed (see
Figure 56). With the optional humidistat, two separate conditions must
be met before humidification of the
conditioned space can begin: 1)
There must be a heat call and the
heat speed blower must be running
and 2) The humidistat must determine that there is a need for humidification.
HUMIDIFIER
The humidifier contacts (labeled
HUMIDIFIER on the IFC) are “dry” contacts on the IFC. This means that the
terminals are connected directly to the
contacts of a board-mounted relay. The
coil of the relay is controlled by the
microprocessor of the IFC. The coil is
engaged roughly any time the heat
speed blower is engaged so that
humidification is active any time the
heat blower is running. In addition to
this control, on 24 VAC humidifiers or
FIGURE 56
WIRING FOR OPTIONAL HUMIDIFIER
LOW VOLTAGE
CONTROL WIRING
LINE VOLTAGE
FIGURE 55
EAC TERMINAL
LOW VOLTAGE
CONTROL WIRING
I681
59
DEHUMIDIFICATION IN COOLING
OPERATION
Dehumidification in the cooling mode
can be accomplished by two different
methods. Both methods will reduce the
amount of airflow in cooling by 15%.
This reduced airflow will cause more
water to condense on the evaporator
coil thus reducing the humidity in the
conditioned space.
IMPORTANT: The manufacturer
requires that all cooling systems
installed with either dehumidification
feature enabled MUST have a coil of the
type with an expansion valve. In addition
to these requirements, evaporator coils
must have a freeze-stat (part #RXRXAM01) installed to prevent possible coil
freeze-up. Note that the RCBA coils
must have BOTH an expansion valve kit
and a freeze-stat installed per manufacturer’s instructions.
Method A: THERMOSTAT DEMAND
DE-HUMIDIFICATION
This method for dehumidification relies
on an algorithm in the modulating thermostat (part #41-24312-04) to calculate
a need for dehumidification based on
the number and frequency of cooling
calls over a specified period of time.
The feature is enabled on the thermostat interface panel. Please read and
follow the instructions for the modulating thermostat to enable this feature.
Please note that the thermostat can
only estimate when there is a need for
dehumidification by looking at the
recent history of cooling calls. This is
not a true measurement of humidity.
For true humidity measurement, a
humidistat must be installed per the
instructions in method B below.
Method B: ON-DEMAND DE-HUMIDIFICATION–REFERENCE FIGURES 57
THRU 59
For proper installation of OnDemand De-Humidification, ensure
the following:
On UTECH IFC Revision –03 (6224174-01 rev 03)or newer (After May
12, 2004) or all revisions of 62-2417402, an additional method for dehumidification was added to the function of the
IFC. This method is not available on
units constructed before this date.
A. Install one wire from one humidistat contact terminal to the IFC
“YL” terminal and another wire
from the remaining humidistat
contact terminal to the IFC “R”
terminal.
The following methods for dehumidification utilize the most accurate means for
sensing humidity. A humidistat should
be installed to the control board “YL” or
“DEHUM” and “R” terminals.
ON DEMAND DEHUMIDIFICATION
ON UTECH IFC #62-24174-01
REVISION 03 (62-24174-01 Rev -03)
A humidistat should be installed to the
control board “YL” and “R” terminals.
PLEASE NOTE THAT TWO-STAGE
COOLING AND ON-DEMAND DEHUMIDIFICATION CANNOT BE USED
AT THE SAME TIME (IFC REV. 03
ONLY). The dip switch position #6 of
bank SW-1 is used to select between
either two-stage cooling or on-demand
de-humidification, both features can not
be used at the same time because
there is only one input used for both.
Also, if neither feature is to be used, it
does not matter if the dip switch is in
the “ON” or “OFF” position. Any humidistat can be used provided it is of the
type that can handle 24 volts and
opens the contacts when there is a
need for de-humidification.
FIGURE 57
UT Electronic Controls IFC. 62-24174-02
Shown with Nec. Jumper location for activation of dehumidification control.
SW1
(C.)
Remove
this jumper
(J5) to
enable
dehumidification
60
SW2
SW3
B. When installing, be sure to use a
humidistat and NOT a de-humidistat.
C. Position dip switch #6 of bank
SW-1 to the “ON” position.
D. It is not possible to use twostage cooling and de-humidification feature at the same time.
NOTE: When the dip switch position
#6 of bank SW-1 is in the on position, a 24 volt signal from the
humidistat must be supplied at all
times to keep the blower running at
the correct cooling speed. When the
24 VAC signal is absent, the IFC
assumes there is a need for dehumidification and operates the
blower at the reduced rate. This is
what is known as “reverse-logic”. In
other words, when a 24 VAC signal
is present, normal operation occurs
(100% cooling CFM), however,
when there is no signal present, the
IFC goes into the dehumidification
mode and reduces the airflow by
15%. This could be confusing and
will cause the cooling speed to be
reduced by 15% if the dip-switch is
in the “on” position but no humidistat
is connected.
FIGURE 58
WIRING FOR OPTIONAL DEHUMIDIFIER
HUMIDISTAT USED TO CONTROL DEHUMIDIFICATION IN COOLING
IFC 62-24174-01 REV. 03 ONLY! POSITION #6
OF SW1 MUST BE IN “ON” POSITION
REMOVE
FOR
DEHUM
ENABLE J5
J5
IFC 62-24174-02: REMOVE THIS JUMPER
(J5) TO ENABLE DEHUMIDIFICATION
(IFC 62-24174-01 REV. 03) OR DEHUM (IFC 62-24174-02 -ALL
REVISIONS)
HUMIDISTAT
(24V)
(CONTACTS OPEN
WHEN HUMIDITY
IS ABOVE SET POINT)
ON DEMAND DEHUMIDIFICATION
IFC #62-24174-02
FIGURE 59
WIRING FOR OPTIONAL DEHUMIDIFIER WITH HUMIDIFIER
HUMIDISTAT USED TO CONTROL BOTH HUMIDIFIER IN HEATING
AND DEHUMIDIFIER IN COOLING (HUMIDIFIER WITH INTEGRAL
POWER SUPPLY)
IFC 62-24174-01 REV. 03 ONLY! POSITION #6
OF SW1 MUST BE IN “ON” POSITION
REMOVE
FOR
DEHUM
ENABLE
J5
IFC
IFC 62-24174-02: REMOVE
THIS JUMPER (J5) TO ENABLE
DEHUMIDIFICATION
(IFC 62-24174-01 REV 03) OR DEHUM (IFC 62-24174-02
-ALL REVISIONS)
HUMIDISTAT
(24V)
(CONTACTS
OPEN WHEN
HUMIDITY IS
ABOVE SET
POINT)
NEUTRAL OR COMMON
HUMIDIFIER WITH
INTERNAL
+110VAC OR 24VAC POWER SUPPLY
SPST RELAY
W/ N.O CONTACTS
RATED 24V COIL
AND 24V OR 110V
CONTACTS AS
NECESSARY FOR
HUMIDIFIER
IMPORTANT: Do not remove the
jumper at J5 unless a humidistat is
installed to the “DEHUM” terminal of
the IFC. In addition, the control
allows the use of two-stage cooling
and dehumidification at the same
time and separate cooling airflows
for high efficiency (up to16 SEER)
cooling. (see section labeled “FURNACE INSTALLATION WITH HIGH
EFFICIENCY PREMIUM COOLING
SYSTEMS”).
For IFC Revision #62-24174-02
(AVAILABLE 2ND QUARTER 2005)
or later, a new dehumidification terminal has been added to the thermostat terminal block. This terminal
will permit the user to install dehumidification without the need to
manipulate any dip-switches.
However, to activate the ODD feature, a jumper located at position J5
(between the thermostat terminal
block and dip switch bank SW-2 on
the IFC – see Figure 57) must be
removed and discarded. This jumper
applies 24 volts to the “dehum” terminal at all times in order to prevent
the control from reverting to the
lower (dehumidification) speed when
no voltage is applied.
61
FIGURE 60
WIRING FOR OPTIONAL DEHUMIDIFICATION WITH HUMIDIFIER AND SEPARATE POWER
SUPPLY.WIRING DIAGRAM FROM TWO-STAGE HEAT
HUMIDISTAT USED TO CONTROL BOTH HUMIDIFIER IN HEATING
AND DEHUMIDIFIER IN COOLING (110V HUMIDIFIER WITHOUT
INTEGRAL POWER SUPPLY)
IFC 62-24174-01 REV. 03 ONLY! POSITION #6
OF SW1 MUST BE IN “ON” POSITION
REMOVE
FOR
DEHUM
ENABLE
J5
IFC 62-24174-02: REMOVE
THIS JUMPER (J5) TO ENABLE
DEHUMIDIFICATION
(IFC 62-24174-01 REV 03) OR DEHUM (IFC 62-24174-02
-ALL REVISIONS)
For proper installation of OnDemand De-Humidification, ensure
the following:
A. Install one wire from one humidistat contact terminal to the IFC
“DEHUM” terminal and another
wire from the remaining humidistat contact terminal to the IFC
“R” terminal.
B. When installing, be sure to use a
humidistat and NOT a de-humidistat.
C. The jumper at position J5 on the
control (see Figure 57) has been
removed.
OTHER ACCESSORIES
AVAILABLE
These kits are available through the
finished goods department.
HUMIDISTAT
(24V)
(CONTACTS
OPEN WHEN
HUMIDITY IS
ABOVE SET
POINT)
CONCENTRIC VENT TERMINATION
KIT = RXGY-E03A
HORIZONTAL, TWO-PIPE TERMINATION KIT = RXGY-D02/D02A,
RXGY-D03/D03A, OR RXGYD04/D04A
NEUTRAL OR COMMON
HUMIDIFIER WITH
EXTERNAL 110V
OR 24V POWER
+110VAC OR 24VAC SUPPLY
VENT TERMINATION KIT: RXGYG02
CONDENSATE PUMP KIT: RXGYB01
SPST RELAY
W/N.O CONTACTS
RATED 24V COIL
AND 24V OR 110V
CONTACTS AS
NECESSARY FOR
HUMIDIFIER
NEUTRALIZER KIT: RXGY-A01
110V OR 24V
POWER SUPPLY
AS NECESSARY
FOR HUMIDIFIER
EXTERNAL BOTTOM FILTER RACK:
RXGF-CB
EXTERNAL SIDE FILTER RACK:
RXGF-CA
These parts are available through
ProStock parts department.
ALTERNATE (LEFT-SIDE) DRAIN
KIT (DOWNFLOW MODELS ONLY):
RXGY-H01
THERMOSTAT AND ACCESSORIES FOR THERMOSTAT
Programmable Modulating Thermostat:
(-)HC-TST401MDMS
Remote Sensor:
(For Mod Thermostat Above Only)
F1451378
Thermostat Wall Plate For Mod Thermostat Above Only:
F61-2600
62
HIGH ALTITUDE INSTALLATIONS
(-)GFD/(-)GGD/(-)GJD -HIGH
ALTITUDE OPTION #278
! WARNING
FOR (-)GGD-06 AND (-)GJD-06 MODELS, A PRESSURE SWITCH CHANGE
IS NOT NECESSARY AT ANY ELEVATION. FOR (-)GGD-07 AND (-)GJD-07
MODELS, A PRESSURE SWITCH
CHANGE IS REQUIRED AT ELEVATIONS ABOVE 8,000 FT. FOR ALL
OTHER (-)GFD/(-)GGD/(-)GJD FURNACES, A PRESSURE SWITCH
CHANGE IS REQUIRED AT ELEVATIONS ABOVE 5,000 FT. OPTION
CODE -278 OR THE APPROPRIATE
HIGH-ELEVATION KIT WILL CONVERT
THE FURNACE FOR USE ABOVE THE
APPROPRIATE ELEVATION STATED
HERE. DO NOT INSTALL THE -278
OPTION FURNACE OR THE HIGH
ALTITUDE KIT BELOW THE STATED
ELEVATION. DOING SO CAN CAUSE
SERIOUS PERSONAL INJURY OR
DEATH OR EQUIPMENT FAILURE.
Furnaces can be ordered from the factory already converted for high altitude
elevations. The factory option for high
altitude elevations would be ordered as
a 278 option (example: a 105k BTU
upflow furnace which is factory converted for high altitude elevations would
have the model number (-)GFD10EZCMS278). These factory converted
furnaces come with pressure switches
for high-altitude elevations already
attached. Also, different burner orifices
are installed at the factory which are one
drill size smaller (#51 DMS) than standard (-)GFD/(-)GGD/(-)GJD gas furnaces (#50 DMS). The smaller orifice is
installed to accommodate for average
heating values expected in most high
altitude areas and a required 4% per
thousand feet reduction in input as specified by the National Fuel Gas Code
(NFGC). Specific orifices should always
be recalculated for all high altitude
installations as outlined below. Orifices
should be changed, if necessary, based
on gas heating value and elevation.
HIGH ALTITUDE CONVERSION
KITS AND OPTIONS
! WARNING
FOR (-)GGD-06 & (-)GJD-06 MODELS,
A PRESSURE SWITCH CHANGE IS
NOT NECESSARY AT ANY ELEVATION. FOR (-)GGD-07 & (-)GJD-07
MODELS, A PRESSURE SWITCH
CHANGE IS REQUIRED AT ELEVATIONS ABOVE 8,000 FT. FOR ALL
OTHER (-)GFD/(-)GGD/(-)GJD FURNACES, A PRESSURE SWITCH
CHANGE IS REQUIRED AT ELEVATIONS ABOVE 5,000 FT. OPTION
CODE -278 OR THE APPROPRIATE
HIGH-ELEVATION KIT WILL CONVERT
THE FURNACE FOR USE ABOVE THE
APPROPRIATE ELEVATION STATED
HERE. DO NOT INSTALL THE -278
OPTION FURNACE OR THE HIGH
ALTITUDE KIT BELOW THE STATED
ELEVATION. DOING SO CAN CAUSE
SERIOUS PERSONAL INJURY OR
DEATH OR EQUIPMENT FAILURE.
HIGH ALTITUDE FIELD
CONVERSION KITS (GFD MODELS)
MODEL
(-)GFD-06XXXXX
(-)GFD-07XXXXX
(-)GFD-09XXXXX
(-)GFD-10XXXXX
(-)GFD-12XXXXX
INPUT(BTU)
60,000
75,000
90,000
105,000
120,000
sand feet. NOTE: Factory installed
orifices are calculated and sized
based on a sea level Natural Gas
heating value of 1075 BTU per cubic
ft. Regional reduced heating values
may nullify the need to change orifices except at extreme altitudes.
Table 10 shows some quick conversions based on elevation and gas
heating value. This table is combined and simplified from Tables F1
and F4 of the NFGC.
KIT NO.
RXGY-F06
RXGY-F07
RXGY-F06
RXGY-F05
RXGY-F05
EXAMPLES
HIGH ALTITUDE FIELD
CONVERSION KITS (GGD & GJD
MODELS)
MODEL
INPUT(BTU)
(-)GGD/(-)GJD-06XXXXX 60,000
(-)GGD/(-)GJD-07XXXXX 75,000
(-)GGD/(-)GJD-09XXXXX 90,000
(-)GGD/(-)GJD-10XXXXX 105,000
(-)GGD/(-)GJD-12XXXXX 120,000
KIT NO.
No Kit
Required
RXGY-F23
(8000 ft and
above only)
RXGY-F24
RXGY-F25
RXGY-F26
Orifice Selection for High Altitude
Applications
Natural Gas
!
CAUTION
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 OR NATIONAL
STANDARD OF CANADA, NATURAL
GAS AND PROPANE INSTALLATION
CODE, CAN B149.1.
INSTALLATION OF THIS APPLIANCE
AT OR ABOVE 5000 FT (1525 m)
SHALL BE MADE IN ACCORDANCE
WITH THE LISTED HIGH ALTITUDE
CONVERSION KIT AVAILABLE WITH
THIS FURNACE.
34” 90 Plus furnaces (except for opt
-278 models) installed at high elevations require the installation of a high
altitude kit for proper operation. The
high altitude kit consists of a high altitude pressure switch that replaces the
pressure switch attached to the induced
draft blower.
The pressure switch must be installed
at elevations above those listed.
Elevations above 2000 ft. require the
furnace to be de-rated 4% per thou-
The following are examples of orifice
sizing using the National Fuel Gas
Code Appendix F. For a simplified
estimation of orifice size based on
heating value and elevation use
Tables 10 and 11. However, calculations are the best method.
Example: 900 BTU/ft3 Regional
Natural Gas Heating Value
I/H=Q
15000 / 900 = 16.68 ft3/hr
I = Sea Level input (per burner):
15000
H = Sea Level Heating Value: 900
Q = 16.68 ft3 Natural Gas per hour.
From Table F.1 of National Fuel Gas
Code Handbook, 2002 (3.5! w.c. column)
Orifice required at Sea Level: # 48
From Table F.4 of National fuel Gas
Code Handbook, 2002
Orifice required at 5000 ft. elevation
(4% de-rate per thousand ft): # 50
Orifice required at 8000 ft. elevation
(4% de-rate per thousand ft): # 51
Example: 1050 BTU/ft3 Regional
Natural Gas Heating Value
I/H=Q
15000 / 1050 = 14.63 ft3/hr
I = Sea Level input (per burner):
15000
H = Sea Level Heating Value: 1050
Q= 14.28 ft3 Natural Gas.
From Table F.1 of National Fuel Gas
code Handbook, 2002 (3.5! w.c. column)
Orifice required at Sea Level: # 50
From Table F.4 of National Fuel Gas
code Handbook, 2002
Orifice required at 5000 ft. elevation
(4% de-rate per thousand ft): # 51
Orifice required at 8000 ft. elevation
(4% de-rate per thousand ft): # 52
TABLE 10
Natural Gas Orifice Drill Size (4% per 1000 ft. De-Rate)
IMPORTANT: For 90+ Furnaces only. Do not use this chart for any 80+ Furnace.
Burner Input (per burner) 15,000 BTU @ Sea Level
Annual Avg. Heat
Value (btu per ft3)
850
900
1000
1075
1170
Sea level
to 1999 ft
47
48
49
50
2000 to
2999 ft
48
49
50
51
3000 to
3999 ft
48
49
50
51
4000 to
4999 ft
49
49
50
51
5000 to
5999 ft
49
50
51
51
6000 to
6999 ft
49
50
51
52
7000 to
7999 ft
50
50
51
52
8000 to
8999 ft
50
51
52
52
51
51
52
52
52
53
53
53
63
64
17.52
16.36
15.2
13.92
12.77
47
48
49
50
51
1175
1078
987
917
856
808
51
14,400
15,000
50
49
48
47
46
51
50
49
48
47
46
13,800
51
51
50
49
48
47
13,200
52
51
50
49
48
47
12,600
52
51
50
49
49
47
12,000
52
51
51
50
49
48
11,400
52
52
51
50
49
48
10,800
53
52
51
50
50
49
10,200
53
52
52
51
50
49
9,600
53
53
52
51
51
50
9000-9999
Divide the individual burner capacity (15,000 for 90 plus) by the Heat Value for the site to determine the Cubic Foot value at Sea Level, or divide
burner capacity by the Cubic Foot value for the Heat Value. Once you have either the Cubic Foot Value or the Heat Value you can estimate the Sea
Level orifice for the site. To select the corresponding high altitude orifice, locate the site elevation on the chart above and the orifice required at Sea
Level from your calculation in the first column. The correct high altitude orifice that must be installed in each individual burner is the intersection of
these two points on the chart above.
NOTE:
Heat Value at Sea Level, for the location of the installation, is available from the Natural Gas Supplier to that site. Orifices for all altitudes are based
on Sea Level values.
All calculations are performed by using the first three columns of information only. Before beginning any calculations, determine the
individual burner Btu size and heating value at Sea Level for the installation site. Each value shown in the Heat Value column is per
burner at 3.5" W.C.
Final Firing Rate per Burner
18.57
46
NATURAL GAS QUICK REFERENCE CHART FOR ORIFICE SELECTION, AT 3.5" W.C. AND APPROXIMATE FINAL FIRING RATES
Sea
Sea Level
90 Plus Heat ELEVATION CHART (NFG recommended orifice based on 4% derate for each 1000 foot of elevation, based
Level
Cubic
Value at
on the intersection of the orifice required at Sea Level and the elevation required below)
Orifice
Foot at
15,000 Btu’s
Size
3.5" W.C.
per Burner
0-999
1000-1999
2000-2999
3000-3999
4000-4999
5000-5999
6000-6999
7000-7999
8000-8999
90 Plus ONLY models with 15,000 Btu's per Burner. DO NOT USE THIS CHART FOR ANY 80 PLUS MODEL.
SUPPLEMENTAL ORIFICE SIZE CHART
TABLE 11
LP GAS AT HIGH ALTITUDE
ELEVATIONS
LP Gas is a manufactured gas that has
consistent heating value across most
regions.
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):
The NFGC guidelines are used with the
following exception:
Orifice Part Number 62-22175-(drill
size)
The recommended LP Gas high altitude
orifice selections differ slightly in that
the NFGC LP orifice chart, as they are
not accurate for the (-)GFD or (-)GGD
gas furnace. The National Fuel Gas
Code LP orifices 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 selection shown in
Table 12.
Example 1:
#60 drill size orifice required
Part #62-22175-60
Example 2:
1.15mm drill size orifice required
Part #62-22175-91
TABLE 12
LP Gas Orifice Drill Size and per burner de-rate by elevation based
on 15,000 btu 90+ burners.
IMPORTANT: For 90+ Furnaces only. Do not use this chart for any
80+ Furnace.
Altitude
0 to 2000 ft.
2001" to 3000"
3001" to 4000"
4001" to 5000"
5001" to 6000"
6001" to 7000"
7001" to 8000"
8001" to 9000"
9001" to 10000"
Input (per
burner) 15000
15000
13200
12600
12000
11400
1080
10200
9600
9000
Orifice
Size
1.15 mm (factory)
1.15 mm
1.10 mm
#58
#59
#60
#62
#63
#64
65
ZONING SYSTEMS
The manufacturer does not currently
provide or support zoning with modulating furnace. However, zoning systems
can be installed with the system as long
as the zoning equipment manufacturers
specifications and installation instructions are met and followed.
The preferred zoning method is to use
a “bypass” system which is properly
installed for maximum efficiency. In
these systems, excess air is routed
back through the system to be used
again – this is opposed to a “dump”
system in which excess air is routed to
a zone where it is expected that the
extra heat or cooling would be least
noticed.
If installed as a “bypass” system, the
installation must have an optional
freeze stat installed to prevent the coil
from icing with excess bypass cooling.
Also, if the zoning equipment manufacturer provides a limit switch (usually
provided by the zoning manufacturer),
this limit must be installed in the system
to prevent the furnace from overheating.
FURNACE INSTALLATION
WITH HIGH-EFFICIENCY
PREMIUM COOLING
SYSTEMS
Furnace installation with Rheem/Ruud
-ARA or -ARL outdoor condensing units
can provide high efficiency (up to 16
SEER) cooling operation when combined with proper evaporator coil. For
listed cooling equipment combinations,
see the -ARA or -ARL specification
sheets and Figure 62 of this document.
Using Tables 13 and 14 and literature
provided with the cooling equipment,
the installer needs to make sure that
the proper evaporator coil, condensing
coil and airflow is configured to achieve
rated efficiency.
In accordance with Rheem/Ruud cooling equipment installation instructions,
do not install an evaporator coil or coil
casing to the furnace which is smaller
in width than the furnace cabinet.
UP TO 16 SEER COOLING
OPERATION
Check the revision number of the integrated furnace control (IFC) to determine how best to configure your furnace for high SEER operation.
IFC #62-24174-02
To achieve high SEER operation,
turn dip switch #6 of bank SW1 to
the “on” position. This will enable the
furnace operation for 16 SEER.
Actual SEER values will vary and
depend on the equipment combination. Consult the specifications
sheets and installation instructions
of the cooling equipment purchased
for a listing of the SEER ratings for
a specific combination.
ALL OTHER INTEGRATED
FURNACE CONTROLS
High SEER operation with IFC’s
other than 62-24174-02 may not
achieve rated performance or
desired comfort levels. For these
older models, there are no additional
adjustments necessary to the furnace. For optimum performance,
replace with IFC #62-24174-02.
A NOTE ABOUT
DEHUMIDIFICATION:
High SEER systems may require the
use of the onboard dehumidification
feature of this system. Be sure to
consult the section titled “ON
DEMAND DEHUMIDIFICATION” on
page 45 of this document.
TABLE 13
AIRFLOW AND CONDENSER SELECTION – PREMIUM COOLING SYSTEMS (1 STAGE COOL ONLY)
WIDTH
APPROX.
AIRFLOW
(CFM)
CONDENSING
UNIT
SW-1,#1
SW-1,#2
SW-1,#3
SW-1,#4
17.5"
17.5"
21"
21"
24.5"
24.5"
800
1000
1200
1400
1200
1400
-ARA-24
-ARA-30
-ARA-36
-ARA-42
-ARA-36
-ARA-42
OFF
ON
ON
ON
ON
ON
ON
OFF
ON
ON
ON
ON
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
FURNACE
TONS
MODEL
2
(-)GFD/GGD/GJD-06 & -07
2-1/2 (-)GFD/GGD/GJD-06 & -07*
3
(-)GFD/GGD/GJD-09 & -10*
3-1/2 (-)GFD/GGD/GJD-09 & -10*
3
(-)GFD/GGD/GJD-12
3-1/2
(-)GFD/GGD/GJD-12
MOD. FURNACE IFC DIP-SWITCH SETTINGS
Evaporator coil must be the same width as the furnace OR one size larger in width than the gas furnace.
(See condenser spec. sheet, I&O and other literature for evaporator selection)
TABLE 14
AIRFLOW AND CONDENSER SELECTION – PREMIUM COOLING SYSTEMS (2 STAGE COOL ONLY)
TONS
2
3
3
3
4
4
5
MODEL
WIDTH
APPROX.
AIRFLOW
(CFM)
(-)GFD/GGD/GJD-06 & -07
(-)GFD/GGD/GJD-06 & -07
(-)GFD/GGD/GJD-09 & -10
(-)GFD/GGD/GJD-12
(-)GFD/GGD/GJD-09 & -10
(-)GFD/GGD/GJD-12
(-)GFD/GGD/GJD-12
17.5"
17.5"
21"
24.5"
21"
24.5"
24.5"
800
1200
1200
1200
1600
1600
1800
FURNACE
SW-1,#1
SW-1,#2
SW-1,#3
SW-1,#4
-ARL/ASL-24
-ARL/ASL-36
-ARL/ASL-36
-ARL/ASL-36
-ARL/ASL-48
-ARL/ASL-48
-ARL/ASL-60
OFF
OFF
ON
ON
ON
ON
OFF
ON
OFF
ON
ON
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
Evaporator coil must be the same width as the furnace OR one size larger in width than the gas furnace.
(See condenser spec. sheet, I&O and other literature for evaporator selection)
66
MOD. FURNACE IFC DIP-SWITCH SETTINGS
CONDENSING
UNIT
INTEGRATED FURNACE CONTROL
GENERAL
DIP SWITCH SET SW1
The UT Electronic Controls IFC board
(see Figure 61) is a recent addition to
the furnace and will be a direct replacement for all Johnson Controls IFC
boards. New features have been
added to the IFC board to improve airflow performance in the heating mode.
The new board also adds two-stage
capability in addition to the existing
modulating and single-stage operation.
Also, the locations of the original dip
switches (SW1 & SW2), and the location of the seven segment display are
different than the previous Johnson
Controls IFC board. The function of
these components has not changed.
For proper setting of the airflow switches
to meet requirements, see Figure 62.
➤ IMPORTANT: The dip switches on
SW2 (used for test mode and for operation with two-stage thermostats) must
be in the “OFF” position for modulating
or single-stage operation. If both
switches are in the “ON” position, a
missing “V” signal with a call on “W” will
cause the furnace to run only at 40%.
However, with both switches in the
“ON” position, the furnace will function
with a two-stage thermostat when connected as shown in Figure 55.
➤ DIP SWITCH SET SW2
The UT Electronic Controls IFC board
has added two-stage capabilities. This
feature is activated by changing the
switches 1 & 2 of SW2 to the “ON” position and installing a two-stage thermostat as shown in Figure 55. This feature
allows the furnace to be used with a
standard two-stage thermostat. With
switches 1 & 2 of SW2 set to the “ON”
position, the furnace will go to 40% of
capacity when “W” is energized alone.
In this configuration, when “W” and “W2”
are energized, the furnace runs at 65%
for five minutes and then changes to
100%. If the call for heat ends at any
time the furnace terminates immediately
at the present firing rate.
TABLE 15
SW2 MODE SELECTION SETTINGS
Mode
Switch 1 Position Switch 2 Position
Modulating/
Single-Stage
OFF
OFF
Test 40%
ON
OFF
Test 100%
OFF
ON
Two-Stage
ON
ON
FIGURE 61
UT ELECTRONIC CONTROLS IFC BOARD
SW1
SW3
DIP SWITCH SET SW3
The UT Electronic Controls IFC
board has an added set of dip
switches labeled SW3 (see Figure
61). The function of these dip switches is to fine-tune airflow in the heating mode. The dip switches will be
set to either the 40% or 100% (or
both) firing rate, and will adjust every
point in between accordingly.
SW3 will allow for airflow adjustments at high altitude, improper temperature probe locations, or no temperature probe applications. If temperature rise range is a problem, the
technician must use temperature
probes to determine the rise range
and adjust the airflow using SW3’s
dip switches until the temperature
rise is within the specified range.
ADJUSTING AIRFLOW
All airflow adjustments on SW3
should be made with the main power
OFF. Dip switches 1 through 3 will
adjust airflow at the 100% firing rate
and dip switches 4 through 6 will
adjust the airflow at the 40% firing
rate.
100% Firing Rate
To use SW3 to change the airflow at
the 100% rate:
1) Dip switch 1 must be “ON” (or
“ADJ”). This instructs the IFC that
the high firing rate airflow will be
overridden.
2) Dip switch 2 in the “OFF” position
will decrease airflow at 100% fire,
and in the “ON” position will
increase airflow at 100% fire.
3) If dip switch 3 is “OFF” the amount
airflow will be adjusted by 7.5%. If
it is “ON” amount of airflow will be
adjusted by 15%.
40% FIRING RATE
SW2
To use SW3 to change the airflow at
the 40% rate:
1) Dip switch 4 must be “ON” (or
“ADJ”). This instructs the IFC that
the high firing rate airflow will be
overridden.
2) Dip switch 5 in the “OFF” position
will decrease airflow at 40% fire,
and in the “ON” position will
increase airflow at 40% fire.
3) If dip switch 6 is “OFF” the amount
airflow will be adjusted by 7.5%. If
it is “ON” amount of airflow will be
adjusted by 15%.
67
FIGURE 62
AIRFLOW SWITCHES (SW1)
MODULATING FURNACE COOLING AIRFLOW RATES, 1/2 HP (1200 CFM) motor settings
SW1, Pos 6 SW1, Pos. SW1, Pos.
2
1
(16 SEER)
YH
OFF
OFF
OFF
Single stage
1200 CFM
OFF
OFF
OFF
ON
ON
ON
ON
OFF
ON
ON
OFF
OFF
ON
ON
ON
OFF
ON
OFF
ON
OFF
ON
1000 CFM
800 CFM
600 CFM
1200 CFM
1000 CFM
800 CFM
600 CFM
YL
YL+YH
Low 2 stage
600 CFM
High 2 stage
1200 CFM
500 CFM
400 CFM
300 CFM
900 CFM
750 CFM
600 CFM
450 CFM
1000 CFM
800 CFM
600 CFM
1200 CFM
1000 CFM
800 CFM
600 CFM
Notes
3 Ton A/C Standard Cooling (approx. 50% of HighStage Cooling on Low Stage) This
2.5 Ton
2 Ton A/C matches cooling airflow of the original
IFC.
3 Ton A/C
HIGH SEER (16+) Premium Cooling
2.5 Ton
airflow (SW1, Position 6 is ON)
2 Ton A/C
MODULATING FURNACE COOLING AIRFLOW RATES, 1 HP (2000 CFM) motor settings
SW1, Pos 6 SW1, Pos. SW1, Pos.
(16 SEER)
2
1
OFF
OFF
OFF
OFF
OFF
ON
OFF
ON
OFF
OFF
ON
ON
ON
OFF
OFF
ON
ON
ON
68
OFF
ON
ON
ON
OFF
ON
YH
Single stage
2000 CFM
1600 CFM
1400 CFM
1200 CFM
2000 CFM
YL
Low 2 stage
1000 CFM
800 CFM
700 CFM
600 CFM
1400 CFM
YL+YH
High 2 stage
2000 CFM
1600 CFM
1400 CFM
1200 CFM
1800 CFM
1600 CFM
1275 CFM
1200 CFM
1200 CFM
1050 CFM
900 CFM
1600 CFM
1400 CFM
1200 CFM
Notes
5 Ton A/C Standard Cooling (approx. 50% of High4 Ton A/C
Stage Cooling on Low Stage) This
matches cooling airflow of the original
3.5 Ton
IFC.
3 Ton
5 Ton A/C
HIGH SEER (16+) Premium Cooling
4 Ton A/C
airflow (SW1, Position 6 is ON)
3.5 Ton
3 Ton
AIRFLOW ADJUSTMENT
EXAMPLES
Three examples of airflow adjustment
are shown below.
NOTE: All dip switches on SW3 will be
shipped in the “OFF” position.
Example 1
(see Figure 63)
PROBLEM: Temperature rise is too high
at 40% firing rate although it is within
the published range at 100% firing rate.
SOLUTION: More airflow is needed to
lower the temperature rise at 40%.
1) Set dip switches 4 and 5 of SW3 to
the “ON” position. This will produce a
7.5% increase in blower output.
2) Allow furnace to run for several minutes at 40% firing rate until temperature probes reach equilibrium.
3) If the temperature rise is still above
the published range, set switch 6 of
SW3 to the “ON” position. This will
increase the airflow rate from +7.5%
to +15% above the standard value.
EXAMPLE 2
EXAMPLE 3
(see Figure 64)
PROBLEM: Temperature rise is too low
at 100% firing rate although it is within
the published range at 40% firing rate.
SOLUTION: Less airflow is needed to
increase temperature rise at 100%.
1) Set dip switch 1 of SW3 to the “ON”
position, which overrides standard
airflow.
2) Leave switches 2 and 3 in the
“OFF” position to decrease airflow
by 7.5%.
3) Allow furnace to run for several
minutes at 100% rate until temperature probes reach equilibrium.
4) If the temperature rise is still below
the published range, set switch 3 to
the “ON” position. This will
decrease the airflow rate from 7.5% to -15% below the standard
value.
FIGURE 64
EXAMPLE 2
SW3
100%
ON
OFF
ADJ
--
5
+
6
--
2
+
3
15%
15%
5
+
6
15%
40%
SW3
STD
ADJ
--
+
15%
40%
B. If -7.5% is not enough, decrease
airflow by setting switch 3 to “ON”
position to give -15%.
7.5%
40%
A. Set switch #4 to “ON” and leave #5
and #6 set to “OFF” to decrease airflow by 7.5% at the 40% fire rate. If
necessary, set switch #6 to “ON” to
decrease airflow by 15%.
SW3
100%
ON
OFF
ADJ
STD
--
2
+
3
15%
STD
4
ADJ
--
5
+
6
B. If +7.5% is not enough, increase airflow
by setting switch 6 to “ON” position to
give +15%.
+
15%
1
40%
--
6
15%
15%
ADJ
STD
5
+
100%
ON
OFF
4
ADJ
+
6
15%
6
7.5%
7.5%
5
--
+
4
STD
--
3
7.5%
ADJ
2
--
1
STD
ADJ
5
STD
15%
4
100%
OFF
ON
+
3
7.5%
ADJ
2
SW3
--
SW3
7.5%
1
STD
EXAMPLE 3
3
100%
ON
OFF
A. Set switches 4 & 5 to “ON” position to
increase airflow by 7.5% at the 40%
fire rate.
SOLUTION: Less airflow is needed to
increase temperature rise at 40% firing rate and more is needed to
decrease temperature rise at 100%.
1) Set dip switch 4 of SW3 to the
“ON” position to override standard
airflow at 40% firing rate. Leave
switches 5 and 6 in “OFF” position
to decrease airflow by 7.5%.
2) Allow furnace to run for several
minutes at 40% rate until temperature probes reach equilibrium.
3) If temperature rise is still lower
than the published range, set
switch 6 to the “ON” position to
decrease the airflow rate from
-7.5% to -15% below the standard
value.
4) Set dip switches 1 to the “ON”
position to override standard airflow at 100% firing rate. Set switch
2 to the “ON” position to increase
airflow by 7.5%.
5) Allow furnace to run for several
minutes at 100% rate until temperature probes reach equilibrium.
6) If temperature rise is still higher
than the published range, set
switch 3 to “ON” position to
increase the airflow rate from 7.5%
to 15% above the standard value.
FIGURE 65
A. Set switch #1 to “ON” position and
leave #2 and #3 in the “OFF” position
to decrease airflow by 7.5% at the
100% fire rate.
40%
at 40% firing rate and is too high at
100%.
2
ADJ
7.5%
PROBLEM: Temperature rise is too low
1
4
7.5%
STD
4
1
ADJ
STD
--
3
100%
OFF
ON
STD
+
15%
7.5%
SW3
7.5%
--
2
EXAMPLE 1
ADJ
STD
1
FIGURE 63
(see Figure 65)
15%
7.5%
7.5%
40%
B. Set switches #1 and #2 to “ON” and
leave #3 set to “OFF” to increase
airflow by 7.5% at the 100% fire
rate. If necessary, set switch #3 to
“ON” to increase airflow by 15%.
69
START-UP PROCEDURES
TO START THE FURNACE
DIRECT SPARK IGNITION LIGHTING
INSTRUCTIONS
This appliance is equipped with a directspark ignition device. This device lights
the main burners each time the room
thermostat calls for heat (connects R to
W). See the lighting instructions on the
furnace.
During initial start-up, it is not unusual for
odor or smoke to come out of any room
registers. To ensure proper ventilation, it
is recommended to open windows and
doors, before initial firing.
The furnace has a negative pressure
switch that is a safety during a call for
heat. The induced draft blower must pull
a negative pressure on the heat
exchanger to close the negative pressure
switch. The induced draft blower must
maintain at least the negative pressure
switch set point for the furnace to operate. If the induced draft blower fails to
close or maintain the closing of the negative pressure switch, a “no heat call”
would result.
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. Set the room thermostat to its lowest
setting and turn off the furnace electrical power.
4. Turn the gas control knob to the
“ON” position.
5. Replace the burner compartment
control access door.
!
WARNING
FAILURE TO REPLACE THE
BURNER DOOR CAN CAUSE
PRODUCTS OF COMBUSTION TO
BE RELEASED INTO THE CONDITIONED AREA RESULTING IN
PERSONAL INJURY OR DEATH.
6. Turn on the manual gas stop.
7. Turn on the furnace electrical power.
8. Turn thermostat to “Heat” mode and
set the room thermostat at least 4° F
above room temperature to light the
main burners.
9. After the burners are lit, set the
room thermostat to a desired temperature.
70
FURNACE TEST MODE
FURNACE TEST SWITCHES
NOTE: The integrated furnace control
does not recognize switch setting
changes while energized. To change
settings, remove power to the board,
make changes, then return power.
NOTE: The return air sensor (factory installed) and the supply air
sensor (field installed) are
required for the furnace calibration
cycle. If the air sensors are faulty,
or not properly connected, the furnace will not attempt a calibration
cycle and will operate on factory
default parameters pre-programmed into the microprocessor.
The Integrated Furnace Control is
equipped with three sets of field selectable switches. The set with five switches (SW1) (See Figure 60) is for selecting airflow operation options (Airflow
Switches). The set with two switches
(SW2) is for placing the furnace into test
mode for initial set-up and troubleshooting and for choosing between modulating, single-stage and two-stage functions. (see Figure 61).
3. After calibration, the furnace will
then adjust to the desired Test
capacity. This allows time for the
technician to check steady-state
operation and evaluate furnace
performance.
The Test Switches (SW2) will place the
IFC into a test mode, operating the furnace at continuous input rates of either
100% of full rate (maximum fire) or 40%
of full rate (minimum fire and 2-stage
operation). This is accomplished by setting the Test Switches as indicated in
Table 16.
4. The furnace will operate at the
fixed Test capacity until one of the
following conditions:
TABLE 16
SW2 MODE SELECTION SETTINGS
Mode
Switch 1 Position Switch 2 Position
Modulating/
Single-Stage
OFF
OFF
Test 40%
ON
OFF
Test 100%
OFF
ON
Two-Stage
ON
ON
To enter the Furnace Test Mode, proceed as follows:
1. Switch the 115 volt power to the furnace OFF. Do not change settings
with control energized.
2. Position Test Switches 1 and 2 for
the desired test mode.
3. Switch the 115 volt power to the furnace ON.
4. Set the thermostat mode to HEAT,
adjust the setpoint at least 4°F
above room temperature to demand
a call for heating.
When the furnace is powered with the
test switches in a position other than
modulating/single-stage or in 2-stage
mode, the first call for heat within the
first hour after power-up will instruct the
furnace to perform as follows:
1. Normal ignition sequence
2. A calibration cycle will be performed
unless the Test Switches are set for
Test 40%. The LED status indicator
will flash “H” or “h” during the calibration cycle (see Table 18).
NOTE: Refer to Figure 70
(Furnace Test Mode Sequence of
Operation/ Troubleshooting), and
Furnace Performance Data Table
17.
a. The thermostat is satisfied and
the call for heat is removed.
b. The furnace has been in test
mode continuously for sixty
minutes, at which time the
controller will go into modulating/single-stage operation.
NOTE: The IFC will only check
the test mode switches on power
up. Terminating the test mode by
either 4a or 4b will place the furnace into modulating or singlestage operation regardless of
the test mode switch positions.
To set the furnace for normal operation:
1. Set the thermostat mode to OFF.
Always allow furnace to complete
the cool down cycle.
2. Switch the 115 volt power to the
furnace OFF. Do not change settings with control energized.
3. Position Test Switches 1 and 2 for
modulating/single-stage mode or
2-stage mode.
4. Switch the 115 volt power to the
furnace ON.
5. Set the thermostat as desired.
THERMOSTAT TEST
MODE
SEE THERMOSTAT SECTION OF
THESE INSTRUCTIONS FOR TESTMODE DIRECTIONS.
TABLE 17
FURNACE PERFORMANCE DATA
Operating
Level
Inducer
Speed
Servo Valve
Current
Manifold Pressure
Temperature
Rise
100%
High
~180 milliamps
Natural - 3.5" w.c. (±0.3")
LP - 10.0" w.c. (±0.5")
40°-70° F
90%
High
~162 milliamps
Natural - 2.8" w.c. (±0.3")
LP - 8.1" w.c. (±0.5")
40°-70° F
80%
High
~144 milliamps
70%
High
~126 milliamps
60%
High
~108 milliamps
50%
High
~90 milliamps
40%
Low
~72 milliamps
Calibration
High
~135 milliamps
Natural - 2.2" w.c. (± 0.3")
LP - 6.4" w.c. (± 0.5")
Natural - 1.7" w.c. (±0.3")
LP - 4.9" w.c. (± 0.5")
Natural - 1.3" w.c. (± 0.3")
LP - 3.6" w.c. (± 0.5")
Natural - 0.9" w.c. (± 0.3")
LP - 2.5" w.c. (± 0.5")
Natural - 0.6" w.c. (± 0.3")
LP - 1.6" w.c. (± 0.5")
Natural - 2.0" w.c. (± 0.3")
LP - 5.6" w.c. (± 0.5")
40°-70°F
40°-70°F
40°-70°F
40°-70°F
40°-70°F
40°-70°F
NOTE: Gas valve milliamp readings may vary ± 05%.
TABLE 18
NORMAL OPERATION INDICATORS - DIAGNOSTIC LED
LED
SYMBOL
DESCRIPTION
COMMENTS
All symbols indicate furnace control board is properly
powered.
O
System OFF
There is no demand from the thermostat. There
are no active faults.
System FAN ONLY
The IFC is receiving 24V on the “G”
terminal ONLY. There are no active faults.
C
System COOL
The IFC is receiving 24 V on the “YL”
and/or “YH” terminals. There are no active faults.
H
System HEAT
The IFC is receiving 24 V on the “W”
terminal. The modulating signal is present on the
“V” terminal. There are no active faults.
h
System HEAT
The IFC is receiving 24 V on the “W”
terminal. The modulating signal is NOT present on
the “V” terminal. There are no active faults.
“H”
Flashing
Calibration Cycle
The IFC is receiving 24 V on the “W”
terminal. The modulating signal is present on the
“V” terminal. The furnace is in calibration mode.
There are no active faults.
“h”
Flashing
Calibration Cycle
The IFC is receiving 24 V on the “W”
terminal. The modulating signal is NOT present on
the “V” terminal. The furnace is in calibration
mode. There are no active faults.
F
71
TO SHUT DOWN
THE FURNACE
1. Set the room thermostat to its lowest setting and turn to “OFF” position.
2. Turn off the manual gas stop and
turn off the electrical power to the
furnace.
3. Remove the burner compartment
control access door.
4. Shut off the gas to the main burners
by turning the gas control knob to
the “OFF” position.
5. Replace the burner compartment
control access door.
!
WARNING
SHOULD OVERHEATING OCCUR
OR THE GAS SUPPLY FAIL TO
SHUT OFF, CLOSE THE MANUAL
GAS VALVE FOR THE APPLIANCE BEFORE SHUTTING OFF
THE ELECTRICAL SUPPLY. FAILURE TO DO SO CAN CAUSE AN
EXPLOSION OR FIRE RESULTING IN PROPERTY DAMAGE,
PERSONAL INJURY OR DEATH.
SEQUENCE OF OPERATION
Heating Cycle Initiation
The heating cycle is always initiated by
a 24 volt signal on W of the thermostat.
When the controller senses 24 volts on
W, the following sequence occurs:
• High and low pressure switches are
checked to insure contacts are open.
• Inducer is powered on high speed for
a thirty (30) second prepurge.
• Pressure switches are monitored as
the inducer creates the vacuum to
close the contacts.
• The servo valve on the gas valve is
energized with ~180 milliamps current.
(No flow yet.)
• The controller sends 120 volts to the
ignition control, which sparks across
the electrodes.
• The main solenoids on the gas valve
are energized allowing gas to flow to
the burners.
• When flame is proven, the ignition
control is de-energized - 8 second
maximum trial time.
• The gas valve maintains 100% rate
through the warm-up period - 20 seconds.
Heating Cycle Response
The heating cycle is always initiated by a
24 volt signal on W1. When the controller
senses 24 volts on W1, the following
sequence occurs:
MODULATING FUNCTION:
(“W” and “V” signal inputs, refer to dip
switch set SW2 on IFC)
After the warm-up period, the furnace
will respond to the thermostat demand
by adjusting the gas valve pressure
72
TABLE 19
METER TIME
METER TIME IN MINUTES AND SECONDS FOR NORMAL INPUT RATING OF FURNACES
EQUIPPED FOR NATURAL OR LP GAS
HEATING VALUE OF GAS BTU PER CU. FT.
INPUT
BTU/HR
60,000
75,000
90,000
105,000
120,000
METER
SIZE
CU. FT.
900
1000
1040
1100
2500 (LP)
MIN. SEC. MIN. SEC. MIN. SEC. MIN. SEC. MIN. SEC.
ONE
0
54
1
0
1
3
1
6
2
30
TEN
9
0
10
0
10
24
11
0
25
0
ONE
0
44
0
48
0
50
0
53
2
0
TEN
7
12
8
0
8
19
8
48
20
0
ONE
0
36
0
40
0
42
0
44
1
40
TEN
6
0
6
40
7
0
7
20
16
40
ONE
0
31
0
34
0
36
0
38
1
26
TEN
5
10
5
40
6
0
6
20
14
20
ONE
0
27
0
30
0
31
0
33
1
15
TEN
4
30
5
0
5
10
5
30
12
30
Formula: Input BTU/HR =
DRY Heating Value of Gas (BTU/FT3) x 3600
Where C • F =
Time in Seconds (for 1 cu. ft.) of Gas
xC•F
Gas Pressure (inch • Hg) x 520 (˚F)
Gas Temperature (˚F) x 30 (inches • Hg)
and blower speed anywhere between
40% to 100% heating capacity.
➤ TWO-STAGE FUNCTION:
(Two-stage function only applies when
both switches of SW2 are in the “ON”
position and a two-stage thermostat is
installed as shown in Figure 50.)
After the warm-up period, the furnace
will respond to the thermostat demand
by adjusting the gas valve pressure and
blower heating speeds to the “W” signal
values. “W” only = 40% gas valve pressure and blower heating speed. “W2” =
65% gas valve pressure and blower
heating speed for first five minutes and
100% thereafter. Also, if the call for heat
ends, the furnace terminates at the present rate.
➤ SINGLE-STAGE FUNCTION:
(“W” signal only)
After the warm-up period, the furnace
will respond to the thermostat demand
by altering the gas valve pressure and
blower speed as follows:
Phase 1: 0 to 5 minutes = 40% of furnace
capacity (gas valve output and blower
speed)
Phase 2: 5 to 12 minutes = 65% of furnace capacity (gas valve output and
blower speed)
Phase 3: After 12 minutes = 100% of furnace capacity (gas valve output and
blower speed)
NOTE: If the call for heat ends during any
phase, the furnace will terminate immediately at the firing rate of that phase.
Heating Cycle Termination
(“W” signal only, refer to dip switch set
SW2 on IFC)
When the 24 volt signal is removed from
W1, the heating cycle will end and the furnace will shut down and return to the
proper off cycle operation.
SETTING INPUT RATE
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. 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. Start the furnace, in
Furnace Test Mode, 100% rate, and
measure the time required to burn
one cubic foot of gas.
The furnace is shipped from the factory with #50 orifices. They are sized
for natural gas having a heating
value of 1075 BTU/cu. ft. and a specific gravity of .60. For high-altitude
models (option 278) the furnace
comes equipped with #51 orifices
installed for elevations 5,000 to
5,999 ft. These orifices may still need
to be changed based on both elevation and gas heating value. Consult
the section of this book titled “High
Altitude Installation” for details.
Since heating values vary geographically, the manifold pressure and/or
gas orifice size may need to be
changed to adjust the furnace to its
nameplate input. The rate will also
vary with altitude. Consult the local
gas utility to obtain the yearly average heating value and orifice size
required to fire each individual burner
at 15,000 BTUH. For high altitude
installations, also consult the section
of this manual titled “High Altitude
Installations” for details on how to
calculate the correct orifice size.
MAINTENANCE
TABLE 20
!
WARNING
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.
FILTERS
FILTER SIZES
UPFLOW FILTER SIZES
FURNACE
WIDTH
INPUT
KBTUH
BOTTOM
SIZE
SIDE
SIZE
QUANTITY
171/2"
60 AND 75
153/4" X 25"
153/4" X 25"
1
21"
90 AND 105
191/4" X 25"
153/4" X 25"
1
241/2"
120
223/4" X 25"
153/4" X 25"
1
FIGURE 67
RESIZING FILTERS AND FRAME
Keep the filters clean at all times.
Remove the filter. Vacuum dirt from filter,
wash with detergent and water, air dry
thoroughly and reinstall.
NOTE: Some filters must be resized to fit
certain units and applications. See Table
20 and Figures 66, 67, 68, 69 & 70.
1. 21" - 90,000 & 105,000 BTUH units
require removal of a 31/2-in. segment
of filter and frame to get the proper
width for a side filter.
REMOVE SEGMENT TO SIZE
AS REQUIRED
2. 241/2" - 120,000 BTUH unit requires
removal of a 7" segment of filter and
frame to get the proper width for a
side filter.
2409401
FILTER MAINTENANCE
FIGURE 66
UPFLOW — FILTER REPLACEMENT
542201
Instruct the user or homeowner on
how to access the filters for regular
maintenance.
Filter application and maintenance
are critical to airflow, which may
affect the heating and cooling system
performance. Reduced airflow can
shorten the life of the system’s major
components, such as motor, limits,
heat exchanger, evaporator coil or
compressor. Consequently, it is recommended that the return air duct
system have only one filter location.
The most common location will be
inside the furnace or a filter base.
Systems with a return-air filter grille
or multiple filter grilles, can have a filter installed at each of the return-air
openings. Installers are instructed to
show the homeowner or end user
where the filter has been installed.
If high efficiency filters or electronic
air cleaners are used in the system, it
is important that the airflow is not
reduced in order to maximize system
performance and life. Always verify
that the system’s airflow is not
impaired by the filtering system that
has been installed. This can be done
by performing a temperature rise and
temperature drop test.
Instruct the homeowner or end-user
to keep the filter(s) clean at all times.
Instruct them to vacuum dirt from the
filter, wash with detergent and water,
air dry thoroughly and reinstall.
The installer may install a return-air
filter in place of the furnace filter.
DO NOT DOUBLE-FILTER THE
RETURN-AIR DUCT SYSTEM. DO
NOT FILTER THE SUPPLY AIR
DUCT SYSTEM.
73
FIGURE 68
UPFLOW -- SIDE FILTER LOCATIONS
CUT-OUT AND DRILL DETAIL
ROD & FILTER SUPPORT ANGLE ASSEMBLY
FIGURE 69
FIGURE 70
DOWNFLOW -- FILTER INSTALLATION
((-)GGD MODELS)
HORIZONTAL -- FILTER INSTALLATION
((-)GJD MODELS)
AI
1332
AIRFLOW
RF
AI
LO
W
RF
LO
W
A087001.S01
A087101.S01
74
!
CAUTION
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
RECIRCULATED DUST 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 bearings are prelubricated
by the manufacturer and do not require
further attention.
The blower motor and induced draft
blower motor must be cleaned periodically by a qualified installer, service
agency, or the gas supplier to prevent
the possibility of overheating due to an
accumulation of dust and dirt on the
windings or on the motor exterior. The
air filters should be kept clean. As dirty
filters can restrict airflow. The motor
depends upon sufficient airflowing
across and through it to keep from overheating.
SYSTEM OPERATION
INFORMATION
Advise The Customer
IMPORTANT: Replace all blower doors
and compartment covers after servicing
the furnace. Do not operate the unit
without all panels and doors securely in
place.
1. Keep the air filters clean. The heating system will operate more efficiently and more economically.
2. Arrange the furniture and drapes so
that the supply air registers and the
return air grilles are unobstructed.
4. Avoid excessive use of kitchen
exhaust fans.
5. Do not permit the heat generated
by television, lamps or radios to
influence the thermostat operation.
6. Explain proper operation of the
system with constant air circulation.
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.
During the annual inspection, all electrical power to the furnace should be
turned off and then restored. This will
put the furnace into a calibration cycle
on the initial call for heat. This is a five
minute (or until the heat call is satisfied)
cycle which allows the furnace to evaluate conditions It should be noted, that
a calibration cycle will occur on the initial call for heat each time after line voltage has been interrupted to the unit.
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 vent and inlet
air system for blockage. If there is carbon and scale in the heat exchanger
tubes, the heat exchanger assembly
should be replaced.
!
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.
IMPORTANT: It is recommended that
at the beginning of the heating season, the flame sensor be cleaned with
steel wool by a qualified installer, service agency or the gas supplier.
IMPORTANT: It is recommended that
at the beginning of the heating season, the condensate trap be inspected for debris or blockage. A blocked
condensate trap can cause water to
back up into the primary heat
exchanger and lead to nuisance tripping of the over temperature switches
and/or pressure switches.
IMPORTANT: It is recommended that
at the beginning of the heating season, the condensate neutralizer (if
used) be replaced by a qualified
installer, service agency or the gas
supplier.
IMPORTANT: Drain traps will often
dry out over a summer. During annual
inspection the service person must
verify that the trap still has water. If
there is not enough water (or no
water) in the trap, the service person
must fill it to the appropriate level.
IMPORTANT: It is recommended that
an annual inspection and cleaning of
all furnace markings be made to
assure legibility. Attach a replacement
marking, which can be obtained
through the distributor, if any are
found to be illegible or missing.
REPLACEMENT PARTS
Contact your local distributor for a
complete parts list.
TROUBLESHOOTING
Figure 71 is a troubleshooting flowcharts for the sequence of operation.
Table 21 is for fault-code descriptions.
WIRING DIAGRAM
Figure 72 is a complete wiring diagram for the furnace and power
sources.
3. Close doors and windows. This will
reduce the heating load on the system.
75
FIGURE 71
SEQUENCE OF OPERATION TROUBLESHOOTING FLOWCHART
Start
1. De-energize furnace IFC
2. Set test switches (SW2) to
desired setting: 100% or 40%
3. Re-energize furnace IFC
4. Set thermostat to heat, set 4°
above room temperature
LED status display is blank
LED status display shows "H"or “h”
no
yes
1. Check transformer secondary voltage
2. Check line voltage
3. Check transformer secondary fuse
If 1, 2, and 3 check OK, replace IFC
LED status display shows "0", "C", or "F"
1. Call for heat at the thermostat, cycle furnace power, go to
"start"
LED status display shows numeric function code
1. See function code troubleshooting guide
Induced draft motor (IDM) starts
on high speed for 30 second
prepurge
Motor does not start
no
yes
1. Check status display - FUNCTION CODE 44 or 55, Check
pressure switches. FUNCTION CODE 45 or 57, Check IDM
2. Check voltage to IDM high speed tap
3. Check IDM run capacitor
If 2 & 3 check OK, replace IDM assembly
4. Check wiring
5. Check voltage on IDM pin on IFC
If 5 checks bad, replace IFC
Motor runs for 60 seconds, then cycle terminates
1. Check status display - FUNCTION CODE 45 or 57 expected,
see function code troubleshooting guide
Motor starts on low speed
1. Check wiring
Gas valve servo valve set to
100% rate (~180 milliamps D.C.)
Servo current measures less than 170 milliamps D.C.
no
yes
1. Check status display - possible codes 77 or 78, see function
code troubleshooting guide
No spark present at igniter
Direct spark igniter is activated
(8 second trial for ignition)
yes
1. Check status display - FUNCTION CODE 45 or 57 expected
no
2. Check pressure switches
3. Check 120 volts to igniter control during trial for ignition (30
seconds after IDM starts). If 3 checks OK, go to step 6. If
120 volts not present, then
4. Check wiring
5. Check 120 volts on IFC spark igniter pins, if bad replace IFC
continued on next page
6. Check spark wire connection
7. Check spark wire & electrode ceramic
8. Check spark gap (0.10 inches), if 6, 7, and 8 check OK
replace spark control
76
Burners light
no
yes
Ignition trial duration is 8 seconds. The gas valve will be energized (24 volts between M/P & C) for this period and will remain
energized only if the flame sense signal is above a minimum
threshold by this time. If the first trial is not successful, three additional trials will be made with IDM purge periods of 30 seconds at
high speed between retries.
If the burners do not light:
1. Check status display - FUNCTION CODE 11 expected
2. Check for 24 volts between "M/P" and "C" - if 24 volts not
present, go to step 5
3. Check gas line inlet pressure
4. Check manifold pressure - if steps 2 & 3 are OK, but 4 is bad
- replace gas valve
5. Check wiring
6. Check for 24 volts on the IFC valve pins - if 6 checks bad replace IFC
7. Check spark electrode position
Burners remain lit beyond 8 second trial time
Failure to sense flame:
no
yes
Indoor blower motor starts 20
seconds after gas valve opens
1. Check status display - FUNCTION CODE 11 expected - see
function code troubleshooting guide
Motor does not start:
no
1. Check status display -FUNCTION CODE 67 or 68 expected
2. Check for 120 volts to motor (5 pin plug)
yes
3. Check wiring
4. Test motor with ECM2+ motor tester (see ECM2+ motor test
procedures)
If 2, 3, and 4 test OK, replace IFC
If furnace test switches are set
to 100%, calibration cycle executes and status display blinks
"H" or ''h''. Duration is 5 minutes.
Calibration is performed with the
furnace operating at 75% capacity. The inducer will run on high
speed, the servo valve current
will be set at about 135 milliamps resulting in a manifold
pressure of around 2.0" w.c. Nat.
(5.6" w.c. L.P.)
yes
Supply air sensor faulty or not installed
no
1. Check status display - FUNCTION CODE 82 expected
2. Ensure supply air sensor is installed in the plenum and is
properly wired to the IFC
3. Check resistance of supply air sensor - if step 3 checks bad,
replace sensor
Return air sensor faulty or not installed
1. Check status display - FUNCTION CODE 81 expected
2. Check return air sensor wiring
3. Check resistance of return air sensor - if step 3 checks bad,
replace sensor
continued on next page
77
FURNACE TEST SWITCHES SET
AT 100 %
Furnace runs at 100% rate, status
display shows "H" or “h”, inducer
on high speed, servo current is
~180 milliamps, manifold pressure
is ~3.5 " w.c. and temperature rise
is 40 - 70 ºF
no
Monitor status display for abnormal indications, see function code
troubleshooting guide
no
Monitor status display for abnormal indications, see function code
troubleshooting guide
FURNACE TEST SWITCHES SET
AT 40 %
Furnace runs at 40% rate, status
display shows "H" or “h”, inducer on
low speed, servo current is ~ 72
milliamps, manifold pressure is
~0.6 " w.c. and temperature rise is
40 - 70°F
Terminate test mode
yes
1. Test mode times out in 60
minutes.
2. Remove the call for heat
from the W terminal
Status display shows "C", "F", or "H"
yes
LED status display shows "O" gas
valve off, flames off
1. Ensure thermostat is off
2. Check thermostat wiring
no
Flames remain on
1. Check 24 volts to gas valve solenoids (M/P) - if present, go to
step 2, if 24 volts is not present, shut off gas and replace the
gas valve
yes
2. Check wiring
3. Check 24 volts on IFC valve pins (MV) - if status display
shows "O" and 24 volts is present in step 3, replace IFC
Induced draft motor stops after 20
5
seconds
Induced draft motor doesn't stop
no
yes
1. Check status display - FUNCTION CODE 22 or 33 expected
2. Check over-temperature switch(es)
3. Check wiring
If steps 2 & 3 check OK, replace IFC
ECM2+ indoor blower motor stops
after 90 seconds
ECM2+ indoor blower motor does not stop running
no
yes
1. Check status display - FUNCTION CODE 22, 23 or 33 expected
2. Check main limit and over temperature switch(es)
3. Test motor with ECM2+ motor tester (see ECM2+ motor test
procedures)
Troubleshooting ends
If steps 2 & 3 check OK, replace IFC
To return system to modulating/single-stage operation (SW2):
1. De-energize IFC
2. Set furnace test switches (SW2) for desired operation
3. Re-energize IFC
4. Set thermostat for desired operation
78
REPEAT PROCEDURE UNTIL TROUBLEFREE OPERATION IS OBTAINED IN
100% AND 40% TEST MODES
Description
One-Hour Retry
Internal fault
Failed Ignition Trial
Low Flame Sense
Function Code
r
–
11
12
Flame sense level is below
predetermined threshold but
above minimum operating threshold. Remains displayed until flame
sense level rises above threshold
level or heat demand is removed.
Fault is stored in buffer after four
consecutive failed ignition trials in
a single heat call
No flame sense during ignition trial.
Remains displayed until successful
ignition, one hour retry is started or
heat demand is removed
B. Flame Sensor improperly mounted or
grounded
1. Re-install / replace flame sensor, check
wiring and connections.
1. Clean flame sensor rod
F. Burners light, but extinguish after 8
seconds or less
A. Flame sensor contaminated
1. Check for proper polarity of line voltage.
2. Check flame sensor wiring and connections.
3. Check for improperly mounted flame
sensor (positioned out of flame,
grounded).
4. Check flame sense current.
5. Clean flame sensor rod.
C. Insufficient manifold pressure, gas
valve “ON”
E. Burners don’t light
1. Check 24 VAC to gas valve.
2. Check for 170 - 190 mAmps to servo
valve.
3. Adjust valve for proper manifold pressure at 100% rate
4. If gas valve will not adjust, replace gas
valve.
1. Check for proper mounting and placement spark electrode assembly.
2. Check for proper mounting of burner
assembly.
1. Turn gas valve to the “ON” position
B. Gas valve control turned “OFF”
D. No spark at electrodes
1. Insure gas supply is connected to furnace and check for proper line pressure
A. Insufficient line gas pressure
1. Check 120 VAC at igniter control during
ignition trial.
2. Check spark wire connection at igniter
control transformer and electrode.
3. Check for short to ground of electrode
(cracked ceramic, touching burners, etc.)
4. Check igniter wire for damage.
5. If all checks OK, replace igniter control
1. Check for mis-wiring in furnace
2. Replace IFC
1. Check for function code 11 in buffer.
See solutions for function code 11.
2. Check for function code 13 in buffer.
See solutions for function code 13.
Solutions
A. Voltage sensed on the MV output
B. Software Self-test output
A. Failed ignition trial four times (code 11)
B. Lost flame sense four times (code 13)
A furnace fault has caused the
controller to execute a one-hour
retry mode.
Failed microprocessor self test or
main gas valve safety circuit fault.
Hard lockout
Probable Causes
Response Comments
FAULT CODE TROUBLESHOOTING CHART
TABLE 21
79
80
High limit circuit is open. Remains
displayed until circuit is sensed
closed.
Auxiliary limit circuit is open.
Remains displayed until circuit is
sensed closed.
Improper Flame Sense
High Limit
Auxiliary Limit
(HALC)
22
23
Flame sensed when gas valve is off.
Remains displayed until flame
sense
signal is gone.
Fault is stored in buffer after four
ignition retries in a single heat call.
14
Flame sense is below minimum
operating threshold during a heating
cycle. Remains until a successful
ignition sequence, one hour retry is
started or the heat demand is
removed.
Response Comments
Lost Flame Sense
Description
13
Function Code
1. Check Fault Buffer for ECM motor fault
history
2. Check ECM motor wiring to the control
board.
3. Test ECM motor and replace if faulty.
C. On downflow furnaces, no airflow
1. Repair jumper between pins 5 & 11
on J1.
A. On upflow furnaces jumper loose,
broken or missing
1. Replace Limit.
1. Insure properly sized orifices installed.
2. Check manifold pressure and adjust as
needed.
D. Input rate too high.
B. On downflow furnace, faulty HALC.
1. Replace limit control
C. Faulty limit control
B. Insufficient airflow
A. No airflow
B. Flame goes out in “OFF” cycle
1. Check Fault Buffer for ECM motor
fault
history
2. Check ECM motor wiring to the control board.
3. Test ECM motor and replace if faulty.
1. Check Fault Buffer for ECM motor
fault history
2. Check filters and duct work for restrictions
3. Check rate and outlet air temperature
at 100%, and 40%, compare to maximum on nameplate
4. Run furnace calibration and re–check
outlet air temperature
1. Replace IFC board
A. Flame remains lit in “OFF” cycle
1. Check that all burner assembly components are properly installed.
2. Check that all seals between the
vestibule area and the heat exchanger
area are tight
3. Insure that the combustion door gasket
is in place and the door is properly
installed.
1. Re-install / replace flame sensor, check
wiring and connections.
1. Clean flame sensor rod
Solutions
1. Repair mis-wiring to remove continuous 24V to valve.
2. Gas valve stuck open - remove and
replace.
C. Unstable flame pattern
B. Flame sensor improperly mounted or
grounded
A. Flame sensor contaminated
Probable Causes
TABLE 21
FAULT CODE TROUBLESHOOTING CHART, CONT.
Description
Over–Temperature Limit
LPS –Contacts Closed
LPS – Open – IDM=HI
Function Code
33
44
45
Low pressure switch circuit is open
during high speed IDM operation.
Remains displayed until a successful ignition sequence or the heat
demand is removed
Low pressure switch circuit is
closed when no call for heat.
Remains displayed until circuit
opens or heat demand is removed.
Over–temperature limit circuit is
open. Remains displayed until circuit is sensed closed.
Response Comments
C. Improper pressure switch setting
B. Insufficient combustion air
1. Replace Low Pressure Switch
1. Check for leaking hoses or leaking
gasket at the induced draft blower
1. Check for proper venting and termination as defined in the furnace installation instructions
C. Abnormally high negative pressure
present on vent system
A. Insufficient combustion airflow
1. Replace low pressure switch
B. Faulty switch
1. Check for shorted wires to the low
pressure switch
A. Faulty wiring
B. Insufficient combustion air
C. Unstable flame pattern
1. Check that inducer is operating at
proper speed and RPM.
2. Insure venting does not exceed the
maximum lengths specified in the
venting instructions.
3. Check that all gaskets between the
inducer and the center panel / heat
exchanger are properly installed and
no leaks exist
1. Check that all burner assembly components are properly installed.
2. Check that all seals between the burner
compartment and the heat exchanger
area are tight.
3. Insure that the door seals are in place
and the door is properly installed.
4. Check that the heat exchanger has not
been damaged; ie. crushed tubes,
breached collector boxes
1. Replace limit control.
Solutions
A. Faulty limit control
Probable Causes
FAULT CODE TROUBLESHOOTING CHART, CONT.
TABLE 21
81
82
Low pressure switch circuit is open
during low speed IDM operation.
Remains displayed until a successful ignition sequence or the heat
demand is removed
Auxiliary Limit
LPS - Open - IDM = LO
HPS – Contacts Closed
HPS - Closed - IDM = LO
HPS – Open – IDM=HI
46
55
56
57
High pressure switch circuit is open
during high speed IDM operation.
Remains displayed until a successful ignition sequence or the heat
demand is removed.
Remains displayed until heat
demand is removed
High pressure switch circuit is
closed during low speed IDM operation.
High pressure switch circuit is
closed with no call for heat.
Remains displayed until circuit
opens or heat demand is removed.
Response Comments
Description
Function Code
Solutions
1. Insure vent system has minimum recommended vent lengths.
2. Insure vent system is properly terminated.
3. Insure combustion compartment door is
properly installed.
A. Minimum vent requirements not followed
1. Replace High Pressure Switch
1. Replace High Pressure Switch
E. Faulty switch
1. Check that the maximum vent length
for the application has not been
exceeded and that the vent is properly
terminated
2. Check that the combustion air inlet
and vent pipes are not restricted
3. Check that the induced draft motor is
operating at the proper speed.
1. Check drain lines for blockage, kinks
or double traps
2. Insure drain trap has been filled with
water before operation
1. Check for leaking hoses or leaking
gasket at the induced draft blower
D. Improper pressure switch setting
C. Insufficient pressure sensed at switch
B. Condensate not draining from heat
exchanger
A. Insufficient combustion airflow
B. Improper switch setting
1. Replace high pressure switch
B.Faulty switch
1. If high altitude pressure switch is
installed and installation site elevation is
near 5,000 feet, check cold pressures on
high speed inducer to insure pressure
switch change was necessary.
2. Replace high pressure switch as needed.
1. Check that the wires to the high pressure switch have not been shorted
together
1. Replace Low Pressure Switch
E. Faulty switch
A. Faulty wiring
1. Replace Low Pressure Switch
1. Check that the maximum vent length for
the application has not been exceeded
and that the vent is properly terminated
2. Check that the combustion air inlet and
vent pipes are not restricted
3. Check that the induced draft motor is
operating at the proper speed.
1. Check drain lines for blockage, kinks
or double traps
2. Insure drain trap has been filled with
water before operation
1. Check for leaking hoses or leaking
gasket at the induced draft blower
D. Improper pressure switch setting
C. Insufficient pressure sensed at switch
B. Condensate not draining from heat
exchanger
A. Insufficient combustion airflow
Probable Causes
TABLE 21
FAULT CODE TROUBLESHOOTING CHART, CONT.
ECM feedback signal indicated the
indoor blower motor RPM is above
1200. Remains displayed until RPM
returns to normal operating range or
blower operation requirement is
removed.
ECM – RPM Range
ECM – Improper Signal
ECM – No Signal
GV Servo – Open
GV Servo – Control Fault
RAS / SAS – Out of Range
66
67
68
77
78
81/82
B. Unit installed in a “normal extreme”
installation (see solution #5)
A. ECM motor operating at RPM limit.
Probable Causes
Return / Supply air sensor out of
range. Remains displayed for 1.5
minutes after power on. After that
time codes remain in memory but
are not displayed. Recycling the
power will redisplay codes.
Gas valve current sensing circuit
tests out of range. Remains displayed until circuit tests OK or heat
demand is removed.
Gas valve servo circuit is sensed
open. Remains displayed until circuit is closed or heat demand is
removed.
ECM feedback signal missing.
Remains displayed until feedback is
corrected or blower operation
requirement is
removed.
C. Sensor Not Connected or not used
B. Faulty Thermistor Assembly
A. Faulty wiring
A. Gas valve servo coil out of specification
2. Reconnect sensor if used. If not used,
then furnace is operating normally.
1. Check resistance of thermistor.
Replace sensor if out of tolerance
1. Ensure continuity from board connector
to gas valve and to ground, check all
connections
1. Conduct the following test:
a. Turn the gas valve control knob to
the off position.
b. Disconnect servo valve connector
and place a 100-Ohm, 10-Watt
resistor across the two wires from
the furnace wiring harness (not the
wires from the gas valve).
c. Set the furnace to attempt another
ignition cycle.
d. If Function code 78 appears, replace
the IFC.
e. If Function code 11 appears, replace
the gas valve
1. Replace control board if faulty.
C. Faulty control board
1. Ensure continuity from board connector to gas valve and to ground, check
all connections.
A. Faulty wiring
1. Check resistance of servo–valve coil.
Replace valve if out of tolerance.
1. Replace control board if necessary
C. Faulty control board
B. Faulty gas valve
1. Test motor for feedback signal, replace
motor if faulty.
1. Ensure the ECM wiring harness is
complete and connected
2. Test motor feedback signal, replace if
faulty
Check for dirty filter
Check for inadequate return air supply
Check for under–sized duct work
Check for loose blower wheel
Unit installation is at environmental limits of: altitude, system static pressures,
high efficiency air filters, etc. Blower
demand requires operation at RPM limit.
1. Check motor part number, replace
motor if needed.
1.
2.
3.
4.
5.
Solutions
B. Faulty ECM motor
A. Faulty wiring
ECM Feedback signal does not follow
defined protocol – RPM / CFM blink.
Remains displayed until feedback is A. Wrong ECM motor installed
corrected or blower operation
requirement is removed.
Response Comments
Description
Function Code
TABLE 21
FAULT CODE TROUBLESHOOTING CHART, CONT.
83
FIGURE 72
WIRING DIAGRAM
84
CM 0809