installation instructions - ac direct instructions ... complete the following installation...
TRANSCRIPT
92-24161-24-09SUPERSEDES 92-24161-24-08
INSTALLATION INSTRUCTIONSFOR UPFLOW/HORIZONTAL (-)GPL AND DOWNFLOW (-)GLL TWO STAGE INDUCED DRAFT GAS FURNACES
2
Before beginning any troubleshooting procedure, complete the following installation checklist. A furnace malfunction issometimes caused by an improper installation. By completing this checklist, the problem may be found and corrected. Makecopies of the checklist and complete one for every Low Profile Furnace service call for your records.
INSTALLATION CHECKLIST(Refer to this manual for specifics.)
GAS SUPPLY
Adequate pipe size
No gas leaks
Proper supply and manifold gas pressure (check with an accurate U-tube manometer with the furnace and all other gasappliances operating.)
ELECTRICAL
Correct thermostat and subbase Thermostat model Subbase model
Correct thermostat mode and setting
Correct line supply voltage
Correct power supply polarity is required with electronic ignition
Correct furnace ground to electrical panel
DC microamp (μA) flame signal (hot surface ignition units)
Correct control voltage
Measure and set heat anticipator amperage
Air conditioning low voltage wires connected to terminals “Y” “C” - not with wire nuts
VENTING
Correct vent pipe diameter and length (according to CSA tables) Vent connection size
Correct venting material (according to CSA tables)
Correct lining for masonry chimneys
Adequate clearance from combustibles
Proper negative pressure reading in the vent
Vent pipe secured to induced draft blower housing
COMBUSTION AIR
Proper source of combustion air
Correct combustion air opening size
FURNACE INSTALLATION
Adequate clearance from combustibles
Adequate clearance for service
Proper air temperature rise (See furnace rating plate)
External static pressure inches w.c.
Correct filter(s)
Correct cooling coil or accessories (if equipped)
Adequate supply and return air ducting Return Air Duct Size Supply Air Duct Size
Air ducts sealed to prevent leakage
33
IMPORTANT: To insure proper installation and operation 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 fordamage prior to installation and start-up.
CONTENTS
Safety Precautions ...................................................................................................1
Installation Check List ..............................................................................................2
General Information..................................................................................................5
Location Requirements and Considerations ............................................................5
Combustion and Ventilation Air..............................................................................10
Vent Pipe Installation..............................................................................................13
Gas Supply and Piping...........................................................................................16
Electrical Wiring......................................................................................................20
Accessories ............................................................................................................21
High Altitude Installations .......................................................................................22
Installation with High Efficiency Premium Cooling Systems ..................................23
Start-Up Procedures...............................................................................................26
Air Flow...................................................................................................................33
Safety Features ......................................................................................................34
Maintenance...........................................................................................................36
Troubleshooting......................................................................................................39
Wiring Diagram.......................................................................................................41
IMPORTANT: All Rheem productsmeet current Federal OSHA Guidelinesfor safety. California Proposition 65warnings are required for certainproducts, which are not covered by theOSHA standards.
California's Proposition 65 requireswarnings for products sold in Californiathat contain, or produce, any of over600 listed chemicals known to the Stateof California to cause cancer or birthdefects such as fiberglass insulation,lead in brass, and combustion productsfrom natural gas.
All “new equipment” shipped for sale inCalifornia will have labels stating thatthe product contains and/or producesProposition 65 chemicals. Although wehave not changed our processes,having the same label on all ourproducts facilitates manufacturing andshipping. We cannot always know“when, or if” products will be sold in theCalifornia market.
You may receive inquiries fromcustomers about chemicals found in, orproduced by, some of our heating andair-conditioning equipment, or found innatural gas used with some of ourproducts. Listed below are thosechemicals and substances commonlyassociated with similar equipment inour industry and other manufacturers.
• Glass Wool (Fiberglass) Insulation• Carbon Monoxide (CO)• Formaldehyde• Benzene
More details are available at theWebsites for OSHA (OccupationalSafety and Health Administration), atwww.osha.gov and the State ofCalifornia's OEHHA (Office ofEnvironmental Health HazardAssessment), at www.oehha.org.Consumer education is important sincethe chemicals and substances on thelist are found in our daily lives. Mostconsumers are aware that productspresent safety and health risks, whenimproperly used, handled andmaintained.
4
NEVER TEST FOR GAS LEAKSWITH AN OPEN FLAME. USE ACOMMERCIALLY AVAILABLESOAP SOLUTION MADESPECIFICALLY FOR THEDETECTION OF LEAKS TO CHECKALL CONNECTIONS, ASSPECIFIED IN GAS SUPPLY ANDPIPING SECTION OF THESEINSTRUCTIONS.
ALWAYS INSTALL FURNACE TOOPERATE WITHIN THEFURNACE'S INTENDEDTEMPERATURE-RISE RANGEWITH A DUCT SYSTEM WHICHHAS AN EXTERNAL STATICPRESSURE WITHIN THEALLOWABLE RANGE, ASSPECIFIED IN DUCTING SECTIONOF THESE INSTRUCTIONS. SEEALSO FURNACE RATING PLATE.
WHEN A FURNACE IS INSTALLEDSO THAT SUPPLY DUCTS CARRYAIR CIRCULATED BY THEFURNACE TO AREAS OUTSIDETHE SPACE CONTAINING THEFURNACE, THE RETURN AIRSHALL ALSO BE HANDLED BYDUCT(S) SEALED TO THEFURNACE CASING ANDTERMINATING OUTSIDE THESPACE CONTAINING THEFURNACE.
WHEN THIS FURNACE ISINSTALLED IN A RESIDENTIALGARAGE, IT MUST BE INSTALLEDSO THE BURNERS AND IGNITIONSOURCE ARE LOCATED NO LESSTHAN 18 INCHES ABOVE THEFLOOR. THIS IS TO REDUCE THERISK OF IGNITING FLAMMABLEVAPORS WHICH MAYBE PRESENT IN A GARAGE.ALSO, THE FURNACE MUST BELOCATED OR PROTECTED TOAVOID PHYSICAL DAMAGE BYVEHICLES. FAILURE TO FOLLOWTHESE WARNINGS CAN CAUSE AFIRE OR EXPLOSION, RESULTINGIN PROPERTY DAMAGE,PERSONAL INJURY OR DEATH.
INSTALLATION MUST COMPLYWITH ALL INSTALLATIONINSTRUCTIONS INCLUDING:
• PROPER VENT INSTALLATION'
• FURNACE OPERATING UNDERTHERMOSTATIC CONTROL;
• RETURN AIR DUCT SEALED TOTHE FURNACE;
• AIR FILTERS IN PLACE;
• SET FURNACE INPUT RATEAND TEMPERATURE RISE PERRATING PLATE MARKING;
• MEANS FOR PROVIDINGOUTDOOR AIR REQUIRED FORCOMBUSTION;
• RETURN AIR TEMPERATUREMAINTAINED BETWEEN 55°F(13°C) AND 80°F (27°C) AND
• CLEAN FURNACE, DUCT WORKAND COMPONENTS UPONSUBSTANTIAL COMPLETIONOF THE CONSTRUCTIONPROCESS, AND VERIFYFURNACE OPERATINGCONDITIONS INCLUDINGIGNITION, INPUT RATE,TEMPERATURE RISE ANDVENTING, ACCORDING TO THEINSTRUCTIONS.
! WARNING
! WARNING
! WARNING
! WARNING
! WARNING
! WARNING
! WARNING
! WARNING
! WARNING
SAFETY INFORMATION
USE ONLY WITH TYPE OF GASAPPROVED FOR THIS FURNACE.REFER TO THE FURNACE RATINGPLATE.
INSTALL THIS FURNACE ONLY INA LOCATION AND POSITION ASSPECIFIED IN THE LOCATIONREQUIREMENTS ANDCONSIDERATIONS SECTION OFTHESE INSTRUCTIONS. PROVIDEADEQUATE COMBUSTION ANDVENTILATION AIR TO THEFURNACE SPACE AS SPECIFIEDIN THE VENTING SECTION OFTHESE INSTRUCTIONS.
PROVIDE ADEQUATECOMBUSTION AND VENTILATIONAIR TO THE FURNACE SPACE ASSPECIFIED IN THE COMBUSTIONAND VENTILATION AIR SECTIONOF THESE INSTRUCTIONS.
COMBUSTION PRODUCTS MUSTBE DISCHARGED OUTDOORS.CONNECT THIS FURNACE TO ANAPPROVED VENT SYSTEM ONLY,AS SPECIFIED IN VENT PIPEINSTALLATION SECTION OFTHESE INSTRUCTIONS.
! WARNINGDO NOT OPERATE THE SYSTEMFOR EXTENDED PERIODSWITHOUT FILTERS. A PORTIONOF THE DUST ENTRAINED IN THEAIR MAY TEMPORARILY LODGEIN THE AIR DUCT RUNS AND ATTHE SUPPLY REGISTERS. ANYCIRCULATED DUST PARTICLESWILL BE HEATED AND CHARREDBY CONTACT WITH THEFURNACE HEAT EXCHANGER.THIS SOOTY RESIDUE WILL SOILCEILINGS, WALLS, DRAPES,CARPETS AND OTHERHOUSEHOLD ARTICLES. SOOTDAMAGE MAY ALSO RESULTWITH, OR WITHOUT, FILTERS INPLACE, WHEN CERTAIN TYPESOF CANDLES ARE BURNED, ORCANDLEWICKS ARE LEFTUNTRIMMED.
5
GENERAL INFORMATION
DO NOT USE THIS FURNACEDURING CONSTRUCTION IF AIRLADEN CORROSIVE COMPOUNDSARE PRESENT SUCH AS CHLORINEAND FLUORINE. OTHERWISE,PROVISIONS MUST BE TAKEN TOPROVIDE CLEAN,UNCONTAMINATED COMBUSTIONAND VENTILATION AIR TO THEFURNACE. FURNACECOMBUSTION AND VENTILATIONAIR CONTAMINATED WITH THESECOMPOUNDS FORMS ACIDSDURING COMBUSTION WHICHCORRODES THE HEATEXCHANGER AND COMPONENTPARTS. SOME OF THESECONTAMINANTS ARE FOUND IN,BUT NOT LIMITED TO, PANELING,DRY WALL, ADHESIVES, PAINTS,STAINES, VARNISHES, SEALERS,AND MASONRY CLEANINGMATERIALS.
1. NOTE: This furnace is shipped withheat exchanger support bracketsinstalled under the back of the heatexchanger. These may be removedbefore installation, but it is notrequired.
LOCATION
THIS FURNACE IS NOT APPROVEDFOR INSTALLATION IN A MOBILEHOME. DO NOT INSTALL THISFURNACE IN A MOBILE HOME.INSTALLATION IN A MOBILE HOMECOULD CAUSE FIRE, PROPERTYDAMAGE, PERSONAL INJURY ORDEATH.
2. IMPORTANT: This furnace is notapproved or recommended forinstallation on its back, with accessdoors facing upwards.
3. This furnace is suitable forinstallation in buildings constructedon-site. This heating unit should becentralized with respect to the heatdistribution system as much aspracticable.
4. IMPORTANT: If installing the unitover a finished ceiling or living area,be certain to install an auxiliarycondensate drain pan under anyevaporator coil installed with thefurnace.
NOTE: These furnaces areapproved for installation in attics, aswell as alcoves, utility rooms,closets and crawlspaces.
5. IMPORTANT: Support this unitwhen installed. For attic or crawlspace installation, horizontalfurnaces may be installed oncombustible wood flooring or byusing support brackets. See Figure1.
6. IMPORTANT: If installing in a utilityroom, be sure the door is wideenough to:
a. allow the largest part of thefurnace to pass; or
b. allow any other appliance (suchas a water heater) to pass.
The (-)GPL and (-)GLL series furnacesare design certified by CSA for use withnatural and propane gases as follows:
As a Category I furnace, it may bevented vertically with type B-1 ventpipe and also may be commonvented as described in theseinstructions.
These furnaces are design certified byCSA for use with natural or propanegases as Category 1 furnaces andmust be vented vertically only. Theyare not designed for horizontalventing.
This furnace should be installed inaccordance with the American NationalStandard Z223.1 - latest edition bookletentitled “National Fuel Gas Code”(NFPA 54) (in Canada, CSA B149.1and .2 Installation Codes for gasburning appliances), and therequirements or codes of the local utilityor other authority having jurisdictionincluding local plumbing or waste watercodes.
Additional helpful publications availablefrom the “National Fire ProtectionAssociation” are: NFPA-90A –
Installation of Air Conditioning andVentilating Systems 1985 or latestedition. NFPA-90B – Warm Air Heatingand Air Conditioning Systems 1984.
These publications are available from:
National Fire Protection Association,Inc.
Batterymarch ParkQuincy, MA 02269
CSA-INTERNATIONAL178 Rexdale Blvd.Etobicoke (Toronto), OntarioCanada M9W, 1R3
GENERAL INFORMATION
LOCATION REQUIREMENTS AND CONSIDERATIONS
WARNING!
FIGURE 1HORIZONTAL FURNACE INSTALLED W/SUPPORT BRACKETS
EXHAUSTVENT
GASPIPE
ELECTRICALCONDUIT
ST-A0799-01
CAUTION!
6
REDU
CED
CLEA
RANC
E (IN
.)
Mod
elA
BC
DE
Left
Righ
tBa
ckTo
pFr
ont
Vent
Ship
.Si
deSi
deW
gts.
0517
1 /216
11/32
121 /8
➀15
03➁
01
36➂
105
lbs.
0721
1927/32
137 /8
➀18
1 /20
00
13
6➂11
5 lb
s.
1021
1927/32
137 /8
➀18
1 /20
00
13
6➂12
0 lb
s.
1224
1 /223
11/32
155 /8
➀22
00
01
36➂
140
lbs.
CLE
AR
AN
CE
TO
CO
MB
US
TIB
LE M
AT
ER
IAL
(INC
HE
S)
UP
FLO
W A
ND
UP
FLO
W/H
OR
IZO
NTA
L M
OD
ELS
TO
P
LEFT
SID
E
FRO
NT
RIG
HT
SID
E
BO
TT
OM
241 /2
2613
/16
265 /8
2411
/32
2411
/32
19/3
2
9 /16
247 /1
6
281 /1
6
265 /8
143 /8
111 /2
34
15 /8D
IA.
23
15
20D
7 /8D
IA.
7 /8D
IA.
19/3
219
/32
3 /4
143 /8
111 /2
11 /4
2317
/32
C
GA
S C
ON
NE
CT
ION
ELE
CT
RIC
AL
CO
NN
EC
TIO
N
OP
TIO
NA
L R
ET
UR
N A
IR C
UT
OU
T(E
ITH
ER
SID
E)
FO
R U
SE
WIT
HE
XT
ER
NA
L S
IDE
FIL
TE
R F
RA
ME
LOW
VO
LTA
GE
E
A B
➀M
ay re
quire
3”
to 4
” or
3”
or 5
” ad
apte
r.➁
May
be
0” w
ith ty
pe B
ven
t.➂
May
be
1” w
ith ty
pe B
ven
t.
FIGURE 2(-)GPL UPFLOW/HORIZONTAL DIMENSIONS
IMP
OR
TA
NT
:Thi
s fu
rnac
e is
not
app
rove
d or
rec
omm
ende
d fo
rin
stal
latio
n on
its
back
, with
acc
ess
door
s fa
cing
upw
ards
.
RE
TU
RN
AIR
AIR
FLO
W
SU
PP
LYA
IR
7
FIGURE 3(-)GLL DOWNFLOW DIMENSIONS
REDU
CED
CLEA
RANC
E (IN
.)
Mod
elA
BC
DE
Left
Righ
tBa
ckTo
pFr
ont
Vent
Ship
.Si
deSi
deW
gts.
517
1 /216
11/32
121 /8
➀16
5 /80
3➁0
13
6➂10
5 lb
s.
0721
1927/32
137 /8
➀16
5 /80
00
16
6➂11
5 lb
s.
1021
1927/32
137 /8
➀20
1 /80
00
16
6➂12
0 lb
s.
1224
1 /223
11/32
155 /8
➀23
5 /80
00
13
6➂14
0 lb
s.
TO
PB
OT
TO
M
241 /2
193 /4
CA B
D
LOW
VO
LTA
GE
GA
S C
ON
NE
CT
ION
ELE
CT
RIC
CO
NN
EC
TIO
N
E
265 /8
2613
/16
63 /1620
3 /8
233 /8
5 /85 /8
3 /4
5 /8
34
233 /8
203 /8
63 /16
247 /1
6
265 /820
1 /8
281 /1
6
7 /8D
IA.
1 /2D
IA.
15 /8D
IA.
➀M
ay re
quire
3”
to 4
” or
3”
or 5
” ad
apte
r.➁
May
be
0” w
ith ty
pe B
ven
t.➱
May
be
1” w
ith ty
pe B
ven
t.
CLE
AR
AN
CE
TO
CO
MB
US
TIB
LE M
AT
ER
IAL
(INC
HE
S)
DO
WN
FLO
W M
OD
ELS
NO
TE
:IN
DO
WN
FLO
W C
ON
FIG
UR
AT
ION
, OP
TIO
NA
L A
IR C
UT
OU
T IS
NO
T P
ER
MIT
TE
D.
RE
TU
RN
AIR
AIR
FLO
W
SU
PP
LYA
IR
8
CLEARANCE –ACCESSIBILITYThe design of forced air furnaces withinput ratings as listed in the tables onthe following pages are certified byCSA for the clearances to combustiblematerials shown in inches.
See name/rating plate and clearancelabel for specific model number andclearance information.
Service clearance of at least 24 inchesis recommended in front of all furnaces.
ACCESSIBILITY CLEARANCES,WHERE GREATER, MUST TAKEPRECEDENCE OVER FIREPROTECTION CLEARANCES.
UPFLOW AND HORIZONTALFURNACES MUST NOT BEINSTALLED DIRECTLY ONCARPETING, TILE OR OTHERCOMBUSTIBLE MATERIAL OTHERTHAN WOOD FLOORING.INSTALLATION ON ACOMBUSTIBLE MATERIAL CANRESULT IN FIRE CAUSINGPROPERTY DAMAGE, SEVEREPERSONAL INJURY OR DEATH.
DOWNFLOW UNIT DESIGN ISCERTIFIED FOR INSTALLATION ONNON-COMBUSTIBLE FLOOR. ASPECIAL COMBUSTIBLE FLOORSUB-BASE IS REQUIRED WHENINSTALLING ON A COMBUSTIBLEFLOOR. FAILURE TO INSTALL THESUB-BASE MAY RESULT IN FIRE,PROPERTY DAMAGE, PERSONALINJURY OR DEATH. THIS SPECIALBASE IS OFFERED AS ANACCESSORY FROM THE FACTORY.SEE THE CLEARANCE LABELLOCATED INSIDE THE FURNACEFOR THE APPROPRIATE MODELNUMBER.
THE SPECIAL BASE IS NOTREQUIRED WHEN THE FURNACE ISINSTALLED ON TOP OF AN AIRCONDITIONING PLENUM.
A gas-fired furnace for installation in aresidential garage must be installed sothat the burner(s) and the ignitionsource are located not less than 18”above the floor and the furnace islocated or protected to avoid physicaldamage by vehicles.
UPFLOW UNIT DESIGN REQUIRESA SOLID METAL BASE PLATE (SEETABLE 1 OR FURNACECLEARANCE LABEL FOR PART
PLACEMENT OF COMBUSTIBLEMATERIALS ON, AGAINST ORAROUND THE FURNACE JACKETCAN CAUSE AN EXPLOSION ORFIRE RESULTING IN PROPERTYDAMAGE, PERSONAL INJURY ORDEATH. THE FURNACE OWNERSHOULD BE CAUTIONED THAT THEFURNACE AREA MUST NOT BEUSED AS A BROOM CLOSET ORFOR ANY OTHER STORAGEPURPOSES.
DUCTINGProper air flow is required for thecorrect operation of this furnace. Toolittle air flow can cause erraticoperation and can damage the heatexchanger. The duct system mustcarry the correct amount of air forheating and cooling. Position the unitminimize long runs or runs with manyturns and elbows.
Size the ducts according to acceptableindustry standards and methods. Thetotal static pressure drop (includingevaporator coil, if used) of the entiresystem should not exceed 0.5” w.c. Besure to have adequate space for unitfilter.
IMPORTANT: Some high efficiencyfilters have a greater than normalresistance to air flow. This canadversely affect furnace operation. BESURE TO CHECK AIR FLOW if usingany filter other than the factory-provided filter.
NOTE: DO NOT take return air frombathrooms, kitchens, furnace rooms,garages, utility or laundry rooms, orcold areas.
IMPORTANT: When using outside air,design and adjust the system tomaintain a return air temperatureabove 50°F during the heating season.
NEVER ALLOW PRODUCTS OFCOMBUSTION OR THE FLUEPRODUCTS TO ENTER THERETURN AIR DUCTWORK, OR THECIRCULATING AIR SUPPLY. ALLRETURN DUCTWORK MUST BEADEQUATELY SEALED ANDSECURED TO THE FURNACE WITHSHEET METAL SCREWS, ANDJOINTS TAPED. WHEN A FURNACEIS MOUNTED ON A PLATFORM,WITH RETURN THROUGH THEBOTTOM, IT MUST BE SEALEDAIRTIGHT BETWEEN THE FURNACEAND THE RETURN AIR PLENUM.
NUMBER) BE IN PLACE WHEN THEFURNACE IS INSTALLED WITH SIDEOR REAR AIR RETURN DUCTS.FAILURE TO INSTALL A BASE PLATECOULD CAUSE PRODUCTS OFCOMBUSTION TO BE CIRCULATEDINTO THE LIVING SPACE ANDCREATE POTENTIALLY HAZARDOUSCONDITIONS, INCLUDING CARBONMONOXIDE POISONING.
SITE SELECTION1. Select a site in the building near the
center of the proposed, or existing,duct system.
2. Give consideration to the vent systempiping when selecting the furnacelocation. Be sure the venting systemcan travel from the furnace to thetermination with minimal length andelbows.
3. Locate the furnace near the existinggas piping. Or, if running a new gasline, locate the furnace to minimizethe length and elbows in the gaspiping.
4. Locate the furnace to maintain properclearance to combustibles as shownin Figures 2 & 3.
WHEN COILS ARE USED WITH AIRHANDLERS OR FURNACES ANDINSTALLED ABOVE A FINISHEDCEILING OR LIVING AREA, IT ISRECOMMENDED THAT ANAUXILIARY SHEET METALCONDENSATE DRAIN PAN BEFABRICATED AND INSTALLEDUNDER ENTIRE UNIT. FAILURE TODO SO CAN RESULT IN PROPERTYDAMAGE.
COMBUSTIBLE MATERIAL MUSTNOT BE PLACED ON OR AGAINSTTHE FURNACE JACKET OR WITHINTHE SPECIFIED CLEARANCES OFTHE VENT PIPE. THE AREA AROUNDTHE FURNACE MUST BE KEPTCLEAR AND FREE OF ALLCOMBUSTIBLE MATERIALSINCLUDING GASOLINE AND OTHERFLAMMABLE VAPORS AND LIQUIDS.
CAUTION!
WARNING!
WARNING!
WARNING!
TABLE 1
FURNACE BASE BASEWIDTH PLATE NO. PLATE SIZE
14” RXGB-D14 115/8” x 239/16”171/2” RXGB-D17 151/8” x 239/16”21” RXGB-D21 185/8” x 239/16”
241/2” RXGB-D24 255/8” x 239/16”
9
THE RETURN AIR PLENUM MUSTBE PERMANENTLY ENCLOSED.NEVER USE A DOOR AS A PART OFTHE RETURN AIR PLENUM. THEFLOOR OR PLATFORM MUSTPROVIDE SOUND PHYSICALSUPPORT OF THE FURNACE,WITHOUT SAGGING, CRACKS,GAPS, ETC., AROUND THE BASE ASTO PROVIDE A SEAL BETWEENTHE SUPPORT AND THE BASE.
FAILURE TO PREVENT PRODUCTSOF COMBUSTION FROM BEINGCIRCULATED INTO THE LIVINGSPACE CAN CREATE POTENTIALLYHAZARDOUS CONDITIONS,INCLUDING CARBON MONOXIDEPOISONING THAT COULD RESULTIN PERSONAL INJURY OR DEATH.
DO NOT, UNDER ANYCIRCUMSTANCES, CONNECTRETURN OR SUPPLY DUCTWORKTO OR FROM ANY OTHER HEATPRODUCING DEVICE SUCH AS AFIREPLACE INSERT, STOVE, ETC.DOING SO MAY RESULT IN FIRE,CARBON MONOXIDE POISONING,EXPLOSION, PERSONAL INJURYOR PROPERTY DAMAGE.
BLOWER AND BURNERS MUSTNEVER BE OPERATED WITHOUTTHE BLOWER DOOR IN PLACE.THIS IS TO PREVENT DRAWINGGAS FUMES (WHICH COULDCONTAIN HAZARDOUS CARBONMONOXIDE) INTO THE HOME THATCOULD RESULT IN PERSONALINJURY OR DEATH.
UPFLOW UNITS1. Set furnace in place and connect the
return duct or return air cabinet tounit. Make the connection air-tight toprevent entraining combustiongases from any adjacent fuel-burning appliances. Unit return airmay be connected on the sides orbottom of the return aircompartment.
a. Openings in the side must be cutout the full width of the knockoutson the unit. If using side return air,THE BOTTOM base must beinstalled.
NOTE: Where the maximumairflow is 1800 CFM or more, bothsides or the bottom must be usedfor return air.
b. If using bottom return air, placefurnace over return air plenum andseal furnace bottom to return airplenum.
A SOLID METAL BASE PLATE, (SEETABLE 1) MUST BE IN PLACEWHEN THE FURNACE ISINSTALLED WITH SIDE OR REARAIR RETURN DUCTS. FAILURE TOINSTALL A BASE PLATE COULDCAUSE PRODUCTS OFCOMBUSTION TO BE CIRCULATEDINTO THE LIVING SPACE ANDCREATE POTENTIALLYHAZARDOUS CONDITIONS,INCLUDING CARBON MONOXIDEPOISONING OR DEATH.
2. If summer air conditioning is desired,position the indoor coil on the top ofthe unit. Insure that no air canbypass this coil.
3. Connect the supply air plenum to thefurnace plenum opening.
DOWNFLOW UNITS
THE DOWNFLOW FURNACEDESIGN IS CERTIFIED FORINSTALLATION ON A NON-COMBUSTIBLE FLOOR. IFINSTALLED ON A COMBUSTIBLEFLOOR, USE THE SPECIAL BASESPECIFIED ON THE FURNACECLEARANCE LABEL. FAILURE TOINSTALL THE SPECIAL BASE MAYRESULT IN FIRE, PROPERTYDAMAGE, PERSONAL INJURY ORDEATH. THIS SPECIAL BASE ISSHIPPED FROM THE FACTORY ASAN ACCESSORY.
1. Position the unit over the supply airplenum and connect.
a. If installing on a combustible floorand not using an evaporatorcoil box, install the specialcombustible floor base. See Figure 4.
b. If summer air conditioning isdesired, position the indoor coil onthe bottom of the unit. Insure thatno air can bypass this coil.
2. Connect the return air ducting to thereturn air opening at the top of theunit. Make the connection air tight toprevent entraining combustiongases from an adjacent fuel-burningappliance.
HORIZONTAL UNITS1. Unit can be mounted for left or right
side airflow configuration.
2. Position the unit on adequatesupports or by using supportbrackets (see Figure 1) and connectsupply plenum.
3. If summer air conditioning is desired,position the indoor coil on the supplyair side of the unit. Insure that no aircan bypass this coil.
4. Secure the four angle bracketsshipped with the unit to the return airopening. See Figure 5. Connect thereturn air ducting to the return airopening at the top of the unit. Makethe connection air tight to prevententraining combustion gases froman adjacent fuel-burning appliance.
NOTE: Do not block furnace accesswith support rods. Maintain clearancesrecommended in Figure 2. Allowenough space for proper service,maintenance or replacement of theheat exchanger and blower assembly.
FIGURE 4COMBUSTIBLE FLOOR BASE
WARNING!
WARNING!
WARNING!
10
THIS FURNACE AND ANY OTHERFUEL-BURNING APPLIANCE MUSTBE PROVIDED WITH ENOUGHFRESH AIR FOR PROPERCOMBUSTION AND VENTILATIONOF THE FLUE GASES. MOSTHOMES WILL REQUIRE THATOUTSIDE AIR BE SUPPLIED INTOTHE FURNACE AREA. FAILURE TODO SO CAN CAUSE DEATH FROMCARBON MONOXIDE POISONING.
Adequate facilities for providing air forcombustion and ventilation must beprovided in accordance with section5.3, Air for Combustion andVentilation, of the National Fuel GasCode, ANSI, Z223.1 latest edition orCSA B149.1 and .2 or, applicableprovisions for the local building codes,and not obstructed so as to prevent theflow of air to the furnace.
OVERTEMPERATURESAFETY SWITCHESThis furnace is equipped with safetyswitches in the burner compartment toprotect against overtemperatureconditions caused by inadequatecombustion air supply. The switchesare located just above the burners onthe furnace center panel on upflow anddownflow models and also on eachside of the burners onupflow/horizontal and horizontal “only”models, and must be manually reset iftripped. DO NOT jumper this switch. Ifthis switch should trip, a qualifiedfurnace installer, service agency or the
FIGURE 5HORIZONTAL RETURN AIR DUCT
FIGURE 6AIR FROM HEATED SPACE
gas supplier should be called to checkand/or correct for adequate combustionair supply. If this unit is mounted in acloset, the door must be closed whenmaking this check of the installation.
DO NOT reset the overtemperatureswitch without taking corrective actionto assure that an adequate supply ofcombustion air is maintained under allconditions of operation.
Replace this switch only with theidentical replacement part.
COMBUSTION AIRREQUIREMENTSIMPORTANT: Air for combustion andventilation must not come from acorrosive atmosphere. Any failure dueto corrosive elements in theatmosphere is excluded from warrantycoverage.
The following types of installation mayrequire OUTDOOR AIR forcombustion, due to chemicalexposures:
• Commercial buildings• Buildings with indoor pools• Furnaces installed in laundry rooms• Furnaces in hobby or craft rooms• Furnaces installed near chemical
storage areas.
Exposure to the following substancesin the combustion air supply may alsorequire OUTDOOR AIR forcombustion:
• Permanent wave solutions• Chlorinated waxes and cleaners• Chlorine-based swimming pool
chemicals• Water softening chemicals• De-icing salts or chemicals• Carbon tetrachloride• Halogen type refrigerants• Cleaning solvents (such as
perchloroethylene)• Printing inks, paint removers,
varnishes, etc.• Hydrochloric acid• Cements and glues• Antistatic fabric softeners for clothes
dryers• Masonry acid washing materials
COMBUSTION AND VENTILATION AIRWARNING!
FOUR ANGLE BRACKETS ARE SHIPPED WITH EACHUNIT THAT CAN BE INSTALLED HORIZONTALLY. THESEBRACKETS MAY BE USED TO SECURE THE RETURNAIR DUCT TO A HORIZONTAL UNIT.
(LEFT-HAND AIRFLOW POSITION SHOWN)
REAR VIEW
RETURN
AIRFLOW
11
Combustion air must be free of acidforming chemicals; such as sulphur,fluorine and chlorine. These elementsare found in aerosol sprays,detergents, bleaches, cleaningsolvents, air fresheners, paint andvarnish removers, refrigerants andmany other commercial and householdproducts. Vapors from these productswhen burned in a gas flame form acidcompounds. The acid compoundsincrease the dew point temperature ofthe flue products and are highlycorrosive after they condense.
ALL FURNACE INSTALLATIONSMUST COMPLY WITH THENATIONAL FUEL GAS CODE ANDLOCAL CODES TO PROVIDEADEQUATE COMBUSTION ANDVENTILATION AIR FOR THEFURNACE. FAILURE TO DO SO CANCREATE HAZARDOUS CONDITIONSRESULTING IN PROPERTYDAMAGE, BODILY INJURY ORDEATH FROM SMOKE, FIRE ORCARBON MONOXIDE.
Combustion air requirements aredetermined by whether the furnace isin an open (unconfined) area or in aconfined space such as a closet orsmall room.
EXAMPLE 1.FURNACE LOCATED IN ANUNCONFINED SPACE
Using indoor air for combustion.
An unconfined space must have atleast 50 cubic feet for each 1,000BTUH of the total input for allappliances in the space. Here are afew examples of the room sizesrequired for different inputs. The sizesare based on 8 foot ceilings.
BTUH Minimum Sq. Feet Typical Room SizeInput With 8' Ceiling With 8' Ceiling
50,000 312 14�x24� or 18�x18�
75,000 469 15�x31� or 20�x24�
100,000 625 20�x31� or 25�x25�
125,000 833 23�x34� or 26�x30�
If the open space containing thefurnace is in a building with tightconstruction (contemporaryconstruction), outside air may still berequired for the furnace to operate andvent properly. Outside air openingsshould be sized the same as for aconfined space.
FIGURE 7AIR FROM ATTIC/CRAWL SPACE
EXAMPLE 2.FURNACE LOCATED IN ACONFINED SPACE
A confined space (any space smallerthan shown above as “unconfined”)must have openings into the spacewhich are located in accordance withthe requirements set forth in thefollowing subsections A and B. Size theopenings by how they are connected tothe heated area or to the outside, andby the input of all appliances in thespace.
If confined space is within a buildingwith tight construction, combustion airmust be taken from outdoors or areafreely communicating with theoutdoors.
A. USING INDOOR AIR FORCOMBUSTION (See Figure 6)
IMPORTANT: Air should not be takenfrom a heated space with a fireplace,exhaust fan or other device that mayproduce a negative pressure.
If combustion air is taken from theheated area, the openings musteach have at least 100 squareinches of free area. Each openingmust have at least one square inchof free area for each 1,000 Btuh oftotal input in the space. Here aresome examples of typical openingsrequired.
Btuh Free AreaInput Each Opening
100,000 100 Square Inches150,000 150 Square Inches
B. USING OUTDOOR AIR FORCOMBUSTION (See Figure 7)
IMPORTANT: Never takecombustion air from an attic spacethat is equipped with powerventilation.
The confined space mustcommunicate with the outdoorsaccording to Methods 1 and 2. Theminimum air opening dimensionshall not be less than 3 inches.When using ducts, they shall be ofthe same cross-sectional area asthe free area of the openings towhich they connect.
WARNING!
12
IMPORTANT: If the furnace is in alocation with an exhaust fan, theremust be sufficient ventilation to preventthe exhaust fan from creating anegative pressure in the room.
Combustion air openings must NOTBE RESTRICTED in any manner.
CONSULT LOCAL CODES FORSPECIAL REQUIREMENTS.
Air opening in the furnace casing front,return air grilles, and warm air registersmust not be obstructed.
B: Method 1
Provide two permanent openings,one located within 12 inches of thetop and one located within 12inches of the bottom of theenclosure. Each opening shallcommunicate directly, or by ducts,with the outdoors or spaces (crawlor attic) that freely communicatewith the outdoors.
a. Where directly communicatingwith the outdoors or wherecommunicating to the outdoorsthrough VERTICAL DUCTS,each opening shall have aminimum free area of 1 squareinch for each 4000 BTUH oftotal appliance input rating in theenclosure (see Figure 7). Hereare typical duct sizes:
b. Where communicating withoutdoors through HORIZONTALDUCTS, each opening shall havea minimum free area of 1 squareinch for each 2000 BTUH oftotal input rating for all equipmentin the enclosure (see Figure 8).Here are typical duct sizes:
FIGURE 8OUTSIDE AIR USING A HORIZONTAL INLET & OUTLET
B: Method 2
One permanent opening, located within12 inches of the top of the enclosure,shall be permitted where theequipment has clearances of at least 1inch from the sides and back and 6inches from the front of the appliance.The opening shall directlycommunicate with the outdoors orcommunicate through a vertical orhorizontal duct to the outdoors orspaces (crawl or attic) that freelycommunicate with the outdoors andhave a minimum free area of:
a. One square inch for each 3000BTUH of the total input rating of allequipment located in the enclosure,AND
b. Not less than the sum of the areas ofall vent connectors in the confinedspace.
VERTICAL OUTDOOR AIROPENING DIMENSIONS
BTUH Free Area RoundInput Each Opening Pipe Size
50,000 12.50 sq. inches 4”
75,000 18.75 sq. inches 5”
100,000 25.00 sq. inches 6”
125,000 31.25 sq. inches 7”
HORIZONTAL OUTDOOR AIROPENING DIMENSIONS
BTUH Free Area RoundInput Each Opening Pipe Size50,000 25.00 sq. inches 6”
75,000 37.50 sq. inches 7”
100,000 50.00 sq. inches 8”
125,000 62.50 sq. inches 9”
FIGURE 9ATTACHING TO DRAFT INDUCER COLLAR
13
GENERAL INFORMATIONThe furnace must be vented inaccordance with these instructions,National Fuel Gas Code, ANSI Z223.1and/or the Natural Gas InstallationCode, CSA-B149.1 & .2 andrequirements or codes of the local utilityor other authority having jurisdiction.
IMPORTANT: This furnace is notcertified for use with a power venter orany other type of horizontal venting.
DEVICES ATTACHED TO THE FLUEOR VENT FOR THE PURPOSE OFREDUCING HEAT LOSS UP THECHIMNEY HAVE NOT BEEN TESTEDAND HAVE NOT BEEN INCLUDEDIN THE DESIGN CERTIFICATION OFTHIS FURNACE. WE, THEMANUFACTURER, CANNOT ANDWILL NOT BE RESPONSIBLE FORINJURY OR DAMAGE CAUSED BYTHE USE OF SUCH UNTESTEDAND/OR UNCERTIFIED DEVICES,ACCESSORIES OR COMPONENTS.
DRAFT INDUCER
VENT PIPE ATTACHING HOLESMUST BE PREDRILLED IN THEDRAFT INDUCER COLLAR TOPREVENT PLASTIC MATERIALFROM CRACKING. DRILL 1/8�DIAMETER HOLES THROUGH THEVENT PIPE AND COLLAR AND USE#8 SCREWS TO ATTACH. SEEFIGURE 9. FAILURE TO FOLLOWTHIS WARNING CAN CAUSERECIRCULATION OF FLUEPRODUCTS CAUSING CARBONMONOXIDE POISONINGRESULTING IN PERSONAL INJURYOR DEATH.
NOTE: On downflow units, be certainthat the vent pipe is positioned overthe induced draft motor outlet. Attachthe vent pipe to the induced draftmotor collar as noted above.
IMPORTANT APPLICATIONNOTESWhen the furnace is used as areplacement, the existing vent systemshould be inspected to assure thatthere are no obstructions, blockage, orany signs of corrosion.
NOTE: When the vent table permitsmore than one diameter of pipe for aconnector or vent, the smallestpermitted diameter must be used, ventpipe may be type “B-1,” either rigid orsuitable flexible construction thatcarries a U.L. listing.
Common venting is allowed withvertical B-1 vent systems, and linedmasonry chimneys. Follow the NationalFuel Gas Code, ANSI Z223.1 and/orthe Natural Gas Installation Code,CSA-B149.1 & .2 for proper installationpractices.
Single wall vent connectors to “B-1vent or masonry chimneys” may beused under the guidelines of theNational Fuel Gas Code, ANSI Z223.1and/or the Natural Gas InstallationCode, CSA-B149.1 & .2.
The entire length of the ventconnector shall be readilyaccessible for inspection, cleaningand replacement.
WARNING!
WARNING!
FURNACE CATEGORYINFORMATIONThis furnace is shipped as a Category Itype induced draft furnace. A CategoryI furnace operates with a nonpositivevent pressure and has a vent gastemperature at least 140°F above thedew point of the vent gases. ACategory I type may be a draft hoodequipped furnace or have a fanassisted combustion system (induceddraft). The inducer is used to pull flueproducts through the combustionchamber and as they leave thefurnace, most of the energy has beendissipated. The buoyant effect of theflue gases provides venting to theoutdoors.
During the off cycle, the inducer is offand there is very little flow through thevent, cooling the vent. During the oncycle there is no dilution airflow, aswith a draft hood type furnace.Although the vent heats up rapidlywithout dilution air, the flue productscontain more water vapor, whichresults in a higher dew pointtemperature. It is most important thatyou follow the guidelines in theseinstructions to prevent the possibleformation of condensation in theventing system.
As a Category I furnace it may bevented vertically with type B-1 ventpipe and also may be common vented,as described in these instructions.
VENTING
A0991-01
VENT PIPEADAPTERCONNECTOR*
*SEE PAGE 14VERTICAL VENTING
PRE-DRILLATTACHINGHOLES
DRAFT INDUCEROUTLET
14
“B-1” VERTICAL VENTINGType “B-1” vents must be installed inaccordance with the terms of theirlistings and the vent manufacturer’sinstructions.
“B-1” vents must be supported andspaced in accordance with their listingsand the manufacturer’s instructions. Allvents must be supported to maintaintheir minimum clearances fromcombustible material.
VERTICAL VENTING
CategorizedFurnace Vent
Input Size Required50K 3”75K *4”
100K *4”125K *4”
*NOTE: All furnaces have a 3” ventconnection as shipped from the factory. A 3”to 4” or 3” to 5” vent transition is required onall but the 50,000 BTUH models whenvertically vented or common vented withmetal vent pipes. THE VENT TRANSITIONCONNECTION MUST BE MADE AT THEFURNACE VENT EXIT. It must originatewith an adapter if required, at the furnaceflue collar and terminate either in a listedcap or roof assembly. When commonventing, the vent connector size may differfrom the above diameters depending onapplication. See ANSI Z21.47-1993/CSA-2.3-M93 or latest edition tables.
VERTICAL VENT SYSTEMS:1. A gas vent shall terminate above the
roof surface with a listed cap orlisted roof assembly. Gas vents 12inches in size or smaller with listedcaps shall be permitted to beterminated in accordance withFigure 10, provided they are at least8 feet from a vertical wall or similarobstruction. All other gas vents shallterminate not less than 2 feet abovethe highest point where they passthrough the roof and at least 2 feethigher than any portion of a buildingwithin 10 feet.
2. A type B-1 gas vent shall terminateat least 5 feet in vertical heightabove the highest connectedequipment draft hood or flue collar.
3. Must rise 1/4” per foot away from thefurnace on horizontal runs and besupported with straps or hangers soit has no sags or dips. Supports at 4foot intervals and at all elbows arerecommended.
4. The vent connector must bemechanically fastened to the outletcollar of the furnace with at least (2)sheet metal screws except ventconnectors that are B-1 material.
DO NOT CONNECT THIS FURNACETO A CHIMNEY USED TO VENT ASOLID FUEL APPLIANCE (WOODOR COAL). VENTING WITH A SOLIDFUEL APPLIANCE CAN LEAD TOIMPROPER FUNCTIONING OF THEUNIT, AND DUE TO SOOTING, THEPOSSIBILITY OF FIRE RESULTINGIN PROPERTY DAMAGE,PERSONAL INJURY OR DEATH.
SPECIAL VENT SYSTEMS (SVS)IMPORTANT: It is THE FURNACEMANUFACTURER’s position now thatnew installations of any HTPV pipeused in a category III vent application,including Selkirk’s Selvent™ II HTPVproduct, should cease immediately.
These shall be assembled inaccordance with the manufacturer’sinstructions. See Figure 9.
5. Any angle greater than 45 degreesfrom the vertical is consideredhorizontal. The total horizontaldistance of a vent plus the horizontalvent connector serving draft-hoodequipped appliances shall not begreater than 75 percent of thevertical height of the vent.
NOTE: Refer to the National Fuel GasCode, ANSI Z223.1 and/or the NaturalGas Installation Code, CSA-B149.1 & .2.
Single appliance venting of a fanassisted furnace into a tile-linedmasonry chimney is prohibited. Thechimney must be lined with either TypeB vent or with a listed, single wall,metal lining system. ReferenceNational Fuel Gas Code, ANSI Z223.1and/or the Natural Gas InstallationCode, CSA-B149.1 & .2. See Figure 11for typical B-1 vent chase.
FIGURE 10TYPICAL VENTING WITH “B-1” VENT
WARNING!
15
2. Visually inspect the venting systemfor proper size and horizontal pitchand determine that there is noblockage, restriction, leakage,corrosion or other deficiencies whichcould cause an unsafe condition.
3. Insofar as is practical, close allbuilding doors, windows and alldoors between the space where theappliances remaining connected tothe common venting system arelocated. Turn on clothes dryers andany appliance not connected to thecommon venting system. Turn onany exhaust fans, such as rangehoods and bathroom exhausts, sothey will operate at maximum speed.Do not operate a summer exhaustfan. Close fireplace dampers.
4. Follow the lighting instructions.Place the appliance being inspectedinto operation. Adjust the thermostatso the appliance will operatecontinuously.
FIGURE 11DEDICATED VENTING THROUGHCHIMNEY WITH “B-1” VENT
5. Test for spillage at the draft hoodrelief opening after 5 minutes ofmain burner operation. Use theflame of a match or candle, orsmoke from a cigarette, cigar, orpipe.
6. After it has been determined thateach appliance that remainsconnected to the common ventingsystem properly vents (when testedas outlined above) return doors,windows, exhaust fans, fireplacedampers and any other gas-burningappliance to their previousconditions of use.
7. If improper venting is observedduring any of the above tests, thecommon venting system must beresized. Refer to National Fuel GasCode, ANSI Z223.1 and/or theNatural Gas Installation Code, CSA-B149.1 & .2.
EXISTING VENT SYSTEMSIMPORTANT RETROFITVENTING INSTRUCTIONSIf this furnace is a replacementinstallation, ALWAYS INSPECT theexisting vent system to be sure thereare no obstructions, blockages, or signsof corrosion.
When the existing furnace is removedfrom a venting system serving otherappliances, the venting is likely to betoo large to properly vent the remainingattached appliances.
The following steps shall be followedwith each appliance that remainsconnected to the common ventingsystem, while the other appliances thatremain connected to the commonventing systems are not in operation.
NOTE: When the vent table permitsmore than one diameter of pipe for aconnector or vent, the smallestpermitted diameter must be used.1.Seal any unused openings in thecommon venting system.
1. Seal any unused openings in thecommon venting system.
16
FIGURE 12GAS PIPING INSTALLATION
UPFLOW & DOWNFLOW
GAS SUPPLY AND PIPINGGAS SUPPLY
THIS FURNACE IS EQUIPPED ATTHE FACTORY FOR USE ONNATURAL GAS ONLY. CONVERSIONTO LP GAS REQUIRES A SPECIALKIT SUPPLIED BY THEDISTRIBUTOR OR MANUFACTURER.MAILING ADDRESSES ARE LISTEDON THE FURNACE RATING PLATE,PARTS LIST AND WARRANTY.FAILURE TO USE THE PROPERCONVERSION KIT CAN CAUSE FIRE,CARBON MONOXIDE POISONING,EXPLOSION, PROPERTY DAMAGE,PERSONAL INJURY OR DEATH.
See the conversion kit index suppliedwith the furnace. This index identifiesthe proper LP Gas Conversion Kitrequired for each particular furnace.
IMPORTANT: Any additions, changesor conversions required for the furnaceto satisfactorily meet the applicationshould be made by a qualified installer,service agency or the gas supplier,using factory-specified or approvedparts. In the commonwealth ofMassachusetts, installation must beperformed by a licensed plumber or gasfitter for appropriate fuel.
IMPORTANT: Connect this furnace onlyto gas supplied by a commercial utility.
IMPORTANT: A U.L. recognizedfuel gas and CO detector(s) arerecommended in all applications,and their installation should be inaccordance with the detectormanufacturer’s recommendationsand/or local laws, rules, regulations orcustoms.
GAS PIPINGInstall the gas piping according to alllocal codes, state codes and regulationsof the utility company, whichever holdsjurisdiction.
If possible, run a separate gas supplyline directly from the meter to thefurnace. Consult the local gas companyfor the location of the manual main shut-off valve. The gas line and manual gasvalve must be adequate in size toprevent undue pressure drop andnever smaller than the pipe size tothe combination gas valve on thefurnace. Refer to Table 2 for the recom-mended pipe size for natural gas andTable 3 for LP gas pipe sizes.
! WARNING
HORIZONTAL
IMPORTANT: It is permissible to runflexible gas connector inside the unit toa piece of black pipe. If local codesallow the use of a flexible gas applianceconnector, always use a new listedconnector. Do not use a connectorwhich has previously serviced anothergas appliance. Under Massachusettslaw, the use of flexible gas connectorsis not permitted.
Install a ground joint union outsidethe cabinet to easily remove thecontrol valve assembly. Install amanual shut-off valve in the gas lineoutside the furnace casing. The valveshould be readily accessible to turn thegas supply on or off. Install a drip leg inthe gas supply line as close to thefurnace as possible. Always use a pipecompound resistant to the action ofliquefied petroleum gases on allthreaded connections.
IMPORTANT: When making gas pipeconnections, use a back-up wrench toprevent any twisting of the controlassembly and gas valve.
Any strains on the gas valve canchange the position of the gas orificesin the burners. This can cause erraticfurnace operation.
IMPORTANT: ENSURE that thefurnace gas control valve not besubjected to high gas line supplypressures.
DISCONNECT the furnace and itsindividual shut-off valve from the gassupply piping during any pressuretesting that exceeds 1/2 PSIG (3.48 kPa).
MANUALGAS VALVE(IN CLOSEDPOSITION)
UNION
4 TO 5 FEETABOVE FLOOR
REQ’D BY SOMEUTILITIES
DRIP LEG
FLAME SENSOR
GAS VALVE
MANIFOLD
DIRECTSPARK
BURNERS
MANUAL GAS VALVE(IN CLOSED POSITION)
4 TO 5 FEETABOVE FLOOR
REQ’D BY SOMEUTILITIES.
DRIP LEG UNIONDUCT
FLAME SENSOR
BURNERS
DIRECT SPARK
MANIFOLDGAS VALVE
STA-0764-01
ST-A0763-01
17
GAS PRESSUREIMPORTANT: The maximum gassupply pressure to the furnace shouldbe 10.5( w.c. for natural gas and 13(w.c. for LP gas.
Natural gas supply pressure shouldoperate between 5� to 10.5� w.c. LPgas supply pressure should be 11� to13� w.c. This pressure must bemaintained with all other gas-firedappliances in operation.
NOTE: Do not exceed a gas pressure of13 (w.c.).
ELEVATIONS ABOVE 2000 FTREQUIRE THAT THE FURNACEINPUT RATING BE ADJUSTED ANDTHAT THE SIZE OF THE BURNERORIFICES BE RE-CALCULATEDBASED ON ELEVATION AND GASHEATING VALUE. THE BURNERORIFICES MAY (OR MAY NOT) NEEDTO BE CHANGED. SEE THESECTION TITLED “HIGH ALTITUDEINSTALLATIONS” OF THIS BOOKFOR INSTRUCTIONS.
NEVER PURGE A GAS LINE INTOTHE COMBUSTION CHAMBER.NEVER USE MATCHES, FLAME ORANY IGNITION SOURCE FORCHECKING LEAKAGE. FAILURE TOFOLLOW THIS WARNING CANCAUSE AN EXPLOSION OR FIRERESULTING IN PROPERTYDAMAGE, PERSONAL INJURY ORDEATH.
To check for gas leakage, use anapproved chloride-free soap and watersolution, an electronic combustible gasdetector, or other approved method.
! WARNING
LP CONVERSIONNOTE: For installation, see specific LPkit installation instructions.
The valve can be converted to useliquefied petroleum (LP) gas byreplacing the pressure regulator springwith the conversion kit spring. This LPkit spring allows the regulator tomaintain the proper adjusted manifoldpressure for LP gas. The correct burnerLP orifices are included in the kit.
NOTE: Order the correct LP conversionkit from the local distributor. Furnaceconversion to LP gas must beperformed by a qualified technician.
ELEVATIONS ABOVE 2000 FTREQUIRE THAT THE FURNACEINPUT RATING BE ADJUSTED ANDTHAT THE SIZE OF THE BURNERORIFICES BE RE-CALCULATEDBASED ON ELEVATION AND GASHEATING VALUE. THE BURNERORIFICES MAY (OR MAY NOT) NEEDTO BE CHANGED. SEE THESECTION TITLED “HIGH ALTITUDEINSTALLATIONS” OF THIS BOOKFOR INSTRUCTIONS.
NOx MODELSWhen converting furnaces equippedwith NOx inserts to LP gas, remove theNOx insert assemblies. Steps forremoval are listed below:
1. Turn off all electrical power and thegas supply to the furnace.
2. Remove the burner door from thefurnace.
3. Remove the igniter assembly –handle with care.
4. Remove the two screws attachingthe NOx insert retainer brackets tothe center panel. Pull the retainerrod.
5. Put the two screws back into theholes in the center panel.
6. Re-install the igniter and burnerassemblies.
7. Replace burner door.
8. Turn on electrical power and gassupply to the unit.
NOTE: Some NOx models may haveone less NOx insert
! CAUTION! CAUTION
18
SETTING GAS PRESSUREThe maximum gas supply pressure tothe furnace should be 10.5” w.c.natural gas, or 13” w.c. LP gas. Theminimum supply gas pressure to thegas valve should be 5" w.c. natural gasor 11" w.c. LP gas. A properlycalibrated manometer is required foraccurate gas pressure measurements.
ELEVATIONS ABOVE 2000 FTREQUIRE THAT THE FURNACEINPUT RATING BE ADJUSTED ANDTHAT THE SIZE OF THE BURNERORIFICES BE RE-CALCULATEDBASED ON ELEVATION AND GASHEATING VALUE. THE BURNERORIFICES MAY (OR MAY NOT)NEED TO BE CHANGED. SEE THESECTION TITLED “HIGH ALTITUDEINSTALLATIONS” OF THIS BOOKFOR INSTRUCTIONS.Manifold Gas PressureMeasurement. Natural gas manifoldpressure should be 3.5" w.c.; LP gasmanifold pressure should be 10"w.c. Only small variations on gaspressure should be made by adjustingthe pressure regulator.1. With the gas shut off at the manual
gas valve, remove the pressuretap plug in the gas manifold or thegas valve outlet. See Figure 26.
2. Connect a U-Tube manometer tothis pressure tap. See Figure 27.
3. Turn on the gas supply andoperate the furnace in high speed.
4. Note or adjust the manifold gaspressure to give:A. 3.5" w.c. for natural gas high fire.B. 10" w.c. for LP gas high fire.
5. To adjust the pressure regulatorfor high fire, remove the regulatorcap located on the side of theregulator. See Figure 14.
6. Turn the adjustment screwclockwise to increasre pressure orcounterclockwise to decreasepressure.
7. Securely replace the regulator capfor high fire.
8. Operate the furnace in low speed.9. Note or adjust the manifold
pressure to give:A. 1.7" w.c. for natural gas low fire.B. 4.9" w.c. for LP gas low fire.
10. To adjust the pressure regulatorfor low fire, remove the regulatorcap on the top of the regulator.See Figure 14.
11. Turn the adjustment screwclockwise to increase pressure orcounterclockwise to decreasepressure.
12. Securely replace the regulator capfor low fire.
TABLE 2NATURAL GAS PIPE CAPACITY TABLE (CU. FT./HR.)
Capacity of gas pipe of different diameters and lengths in cu. ft. per hr. with pressure drop of 0.3 in. and specificgravity of 0.60 (natural gas).
Nominal Length of Pipe, FeetIron PipeSize, Inches 10 20 30 40 50 60 70 80
1/2 132 92 73 63 56 50 46 433/4 278 190 152 130 115 105 96 901 520 350 285 245 215 195 180 170
1-1/4 1,050 730 590 500 440 400 370 3501-1/2 1,600 1,100 890 760 670 610 560 530
After the length of pipe has been determined, select the pipe size which will provide the minimum cubic feet per hourrequired for the gas input rating of the furnace. By formula:
Gas Input of Furnace (BTU/HR)Cu. Ft. Per Hr. Required = Heating Value of Gas (BTU/FT3)
The gas input of the furnace is marked on the furnace rating plate. The heating value of the gas (BTU/FT3) may bedetermined by consulting the local natural gas utility or the LP gas supplier.
FIGURE 14TYPICAL GAS VALVE
INLETPRESSURETAP
OUTLETPRESSURETAP
HIGH FIREMANIFOLDPRESSUREADJUSTMENT
LOW FIREPRESSUREMANIFOLDADJUSTMENT
FIGURE 13TYPICAL HOSE CONNECTION TO LINE PRESSURE TAP
! CAUTION
19
TABLE 3LP 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 watercolumn inlet pressure).(Based on a Pressure Drop of 0.5 Inch Water Column)
Nominal Length of Pipe, FeetIron PipeSize, Inches 10 20 30 40 50 60 70 80 90 100 125 150
1/2 275 189 152 129 114 103 96 89 83 78 69 63
3/4 567 393 315 267 237 217 196 182 173 162 146 132
1 1,071 732 590 504 448 409 378 346 322 307 275 252
1-1/4 2,205 1,496 1,212 1,039 913 834 771 724 677 630 567 511
1-1/2 3,307 2,299 1,858 1,559 1,417 1,275 1,181 1,086 1,023 976 866 787
2 6,221 4,331 3,465 2,992 2,646 2,394 2,205 2,047 1,921 1,811 1,606 1,496
Example (LP): Input BTU requirement of unit, 150,000Equivalent length of pipe, 60 ft. = 3/4" IPS required.
NATURAL GAS:The maximum gas supply pressure tothe furnace should be 10.5” W.C. fornatural gas. The minimum gas supplypressure for purposes of inputadjustment to the furnace should be 5”W.C.A properly calibrated manometer orgauge is required for accurate gaspressure readings.1. When adjusting the furnace input, the
high fire input should be checked.The high fire manifold pressureshould be 3.5’ W.C. Follow thesesteps to be sure the furnace is highfire mode:a. With a single stage thermostat, the
furnace runs for 12 minutes on lowfire before shifting to high fire. Tobe certain that it is on high fire,jump terminals “W” and “W2” onthe control board in the blowercompartment.
b. With a two stage thermostat, setthe thermostat to its highest settingto keep the furnace operating inthe high fire mode.
2. To adjust high fire manifoldpressure, remove the adjustmentcover screw on the outlet end of thegas valve and turn the adjustmentscrew clockwise to increase thepressure and counterclockwise toreduce the pressure. Replace thecover screw securely. See Figure26.
3. The low fire manifold pressureshould be 1.7� W.C. As mentionedabove, the furnace remains in thelow fire mode for 12 minutes upon aheat call with a single stagethermostat. With a two stagethermostat, disconnect thethermostat lead to the “W2” terminalon the control board and the furnacewill remain in the low fire mode. Toadjust the pressure, remove theregulator cover, on top of the valve,and adjust as noted under Step 2,above. After the adjustment replacethe screw cover securely.NOTE: Use a 3/32� allen wrench formaking the pressure adjustment.
TO CHANGE ORIFICE SPUDS:1. Shut off the manual main gas valve
and remove the gas manifold.2. Replace the orifice spuds.3. Reassemble in reverse order.4. Turn the gas supply back on and
check for proper operation andmanifold pressure.
Check of input is important to preventover firing of the furnace beyond itsdesign-rated input. NEVER SET INPUTABOVE THAT SHOWN ON THERATING PLATE.TO CHECK FURNACE INPUT:1. Make certain that all other gas
appliances are shut off, with theexception of pilot burners.
2. Start the furnace3. Time the meter to measure the time
required to burn one cubic foot ofgas.
4. Use Table 4 to determine input rate.
13. Verify pressures for high and lowfire operation.
14. Shut off gas at the manual gasvalve and remove the U-Tubemanometer.
15. Replace the manifold pressure tapplug before turning on gas.
NATURAL GAS:If the supply gas line pressure isabove the operating range, installan in-line gas regulator to thefurnace. If supply gas line pressureis below the operating range, eitherremove any restrictions in the gassupply piping or enlarge the gaspipe. See Table 7.
LP GAS:If the supply gas line pressure is abovethe operating range, have the LPsupplier reduce the line pressure at theregulator. If supply gas line pressure isbelow operating range, have the LPsupplier adjust the line pressure at theregulator. See Table 8.NOTE: Depending on the amount of LPvapor and the outdoor ambienttemperature, the LP storage tank mayrequire supplemental heat to maintainproper pressure levels.
ADJUSTING OR CHECKINGFURNACE INPUT
ELEVATIONS ABOVE 2000 FTREQUIRE THAT THE FURNACEINPUT RATING BE ADJUSTED ANDTHAT THE SIZE OF THE BURNERORIFICES BE RE-CALCULATEDBASED ON ELEVATION AND GASHEATING VALUE. THE BURNERORIFICES MAY (OR MAY NOT) NEEDTO BE CHANGED. SEE THE SECTIONTITLED “HIGH ALTITUDEINSTALLATIONS” OF THIS BOOKFOR INSTRUCTIONS.
! CAUTION
TABLE 4
METER TIME IN MINUTES AND SECONDS FOR NORMALINPUT RATING OF FURNACES EQUIPPED FOR NATURAL OR LP GAS
INPUTBTU/HR
METERSIZE
CU. FT.
HEATING VALUE OF GAS BTU PER CU. FT.900 1000 1040 1100 2500
MIN. SEC. MIN. SEC. MIN. SEC. MIN. SEC. MIN. SEC.ONE 1 5 1 12 1 15 1 18 3 2050,000 TEN 10 50 12 00 12 30 13 12 30 00
ONE 0 44 0 48 0 50 0 53 2 075,000 TEN 7 12 8 0 8 19 8 48 20 0
ONE 0 33 0 36 0 38 0 40 1 30100,000 TEN 5 24 6 0 6 15 6 36 15 0
ONE 0 26 0 29 0 30 0 32 1 12125,000 TEN 4 19 4 48 5 0 5 17 12 0
ONE 0 31 0 24 0 25 0 26 1 0150,000 TEN 3 36 4 0 4 10 4 20 10 0
Heating Value of Gas (BTU/Ft3) x 3600 x correction factorInput BTU/HR =
Time in Seconds (for 1 cu.ft.) of Gas
20
FIGURE 16LINE VOLTAGE CONNECTIONSUT ELECTRONIC CONTROLS 1028-928 CONTROL BOARDS
FIGURE 15ISOLATION RELAY
ST-A0804-01
ST-A0761-01
ELECTRICAL WIRING
TURN OFF ELECTRIC POWER ATTHE FUSE BOX OR SERVICE PANELBEFORE MAKING ANYELECTRICAL CONNECTIONS.ALSO, THE GROUND CONNECTIONMUST BE COMPLETED BEFOREMAKING LINE VOLTAGECONNECTIONS. FAILURE TO DOSO CAN RESULT IN ELECTRICALSHOCK, SEVERE PERSONALINJURY OR DEATH.
IMPORTANT: The furnace must beinstalled so that the electricalcomponents are protected from water(furnace condensate).
ELECTRICAL CONNECTIONS
THE CABINET MUST BEPERMANENTLY GROUNDED. AGROUND SCREW IS PROVIDED INTHE JUNCTION BOX FOR THISPURPOSE. FAILURE TO DO SO CANRESULT IN FIRE, ELECTRICALSHOCK, PERSONAL INJURY ORDEATH.
The electrical supply requirements arelisted on the furnace rating plate.
Use a separate fused branch electricalcircuit containing a properly sized fuseor circuit breaker. Run this circuitdirectly from the main switch box to anelectrical disconnect which must bereadily accessible and located withinsight of the furnace. Connect from thedisconnect to the junction box on theleft side of the furnace, inside thecontrol compartment. See appropriatewiring diagram.
NOTE: The electrical junction boxinside the furnace control compartmentmay be relocated to the right side ifnecessary. A knockout is provided.
NOTE: L1 (hot) and neutral polaritymust be observed when making fieldconnections to the furnace. Theignition control on electric ignitionmodels will not sense flame if L1 andneutral are reversed.
Installation of the electric supply lineshould be in accordance with theNational Electric Code ANSI/NFPA No.70, latest edition, or CanadianElectrical Code Part 1 - CSA StandardC22.1 and local building codes.
This can be obtained from:
National Fire Protection AssociationBatterymarch ParkQuincy, MA 02269
Canadian Standards Association178 Rexdale Blvd.Etobicoke (Toronto), OntarioCanada M9W, 1R3
WARNING!
WARNING!
THERMOSTATA single or two stage thermostat maybe used, however a two-stagethermostat is recommended foroptimum performance.
The room thermostat must becompatible with the integrated furnacecontrol on the furnace. All thermostatsavailable from the furnacemanufacturer’s Parts Department areacceptable. Generally, all thermostatsthat are not of the “current robbing”type are compatible with the integratedfurnace control we use. For thermostatwiring diagrams, see Figures 17 and18.
HEAT ANTICIPATOR SETTINGS
If a current reading taken at thethermostat is not performed, an initialsetting of .15 amps is recommended.Adjust as needed to improve comfortlevel.
ISOLATION RELAYIMPORTANT: Not all electronic nightsetback thermostats are compatiblewith the furnace control system.Some may require an isolation relay.
If an isolation relay is needed (partnumber 42-25104-01), install it asclose to the control board aspossible. Use a single-pole, single-throw relay with a 24-volt operatingcoil. The relay contacts should bedesigned for 24-volt loads.
Connect one end of the operating coilto the thermostat “W” terminal.Connect the other end of the coil tothe “C” terminal on the control board.See Figure 15.
Connect one side of the normallyopen contacts to the control board“W” terminal.
When the thermostat calls for heat, itpowers the 24-volt operating coil.This closes the relay contacts andconducts power from terminal 3 and4 to terminal “W” on the control boardand starts the furnace ignitionsequence.
21
FIELD INSTALLED OPTIONACCESSORIESELECTRONIC AIR CLEANER1. Electronic air cleaner line voltage
power can be supplied from thescrew terminal “EAC” and a linevoltage neutral screw terminal onthe control board. See Figure 16.This will power the electronic aircleaner whenever the circulating airblower is in operation.
RXGW-B01 CHIMNEYADAPTERThis appliance is CSA certified for usewith RXGW-B01 chimney adapter.Refer to Kit Installation Instructions92-101682-01.
FURNACE TWINNINGIMPORTANT: Twinning of (-)GPL and(-)GLL models is not allowed.
FIGURE 17(-)GPL/(-)GLL THERMOSTAT CONTROL WIRING DIAGRAM1 STAGE HEAT, 1 STAGE COOL
ST-A1034-01-00
FIGURE 18(-)GPL/(-)GLL THERMOSTAT CONTROL WIRING DIAGRAM2 STAGE HEAT, 2 STAGE COOL
ST-A1032-01-00
22
80+ HIGH ALTITUDEINSTRUCTIONS
THE NATIONAL FUEL GAS CODE(NFGC) GUIDELINES SHOULD BEFOLLOWED WHEN CONVERTINGTHESE FURNACES FOR HIGHALTITUDE OPERATION.
-GPL/-GLL HIGH ALTITUDEKITSAll -GPL/-GLL models can be convertedfor high altitude using the following kits:
High Altitude Kit ModelsRXGY-F13 . . . . . . . . . . . ALL -GPL modelsRXGY-F28 . . . . . . . . . . . -GLL-05, GLL-07(all),
-GLL-10RXGY-F27 . . . . . . . . . . . -GLL-12
The kits include pressure switches andinstructions for converting the furnacefor elevations above 5,000 ft. These kitsshould never be used at elevationsbelow 5,000 ft. In addition, the kitinstructions detail how to re-calculateburner orifice size based on gas heatingvalue and elevation. The instructionsare based on a required 4% perthousand feet reduction in input asspecified by the National Fuel GasCode (NFGC). Specific orifices shouldalways be recalculated for all highaltitude installations as outlined below.Orifices should be changed, ifnecessary, based on gas heating valueand elevation.
-GPL/-GLL -HIGH ALTITUDEOPTION #278Furnaces can be ordered from thefactory already converted for highaltitude elevations. The factory optionfor high altitude elevations would beordered as a 278 option (example: a100k BTU upflow furnace which isfactory converted for high altitudeelevations would have the modelnumber -GPL-10EBRMR278). Thesefactory converted furnaces come withpressure switches for high-altitudeelevations already attached. Also,different burner orifices are installed atthe factory which are one drill sizesmaller (#43 DMS) than standard -GPL/-GLL gas furnaces (#42 DMS). Thesmaller orifice is installed toaccommodate for average heatingvalues expected in most high altitudeareas and a required 4% per thousandfeet reduction in input as specified bythe National Fuel Gas Code (NFGC).Specific orifices should always berecalculated for all high altitude
installatons as outlined below. Orificesshould be changed, if necessary, basedon gas heating value and elevation.
ELEVATIONS ABOVE 2000 FTREQUIRE THAT THE FURNACEINPUT RATING BE ADJUSTED ANDTHAT THE SIZE OF THE BURNERORIFICES BE RE-CALCULATEDBASED ON ELEVATION AND GASHEATING VALUE. THE BURNERORIFICES MAY (OR MAY NOT)NEED TO BE CHANGED. THEFOLLOWING EXAMPLES SHOWHOW TO DETERMINE IF AN ORIFICECHANGE WILL BE NECESSARY ANDHOW TO DETERMINE THE NEWORIFICE SIZE.
IN CANADA, AS AN ALTERNATE TOADJUSTING THE BURNER ORIFICESIZE, THE MANIFOLD GASPRESSURE MAY BE ADJUSTED.THIS METHOD IS COVERED LATERIN THIS SECTION. THIS METHOD OFADJUSTING MANIFOLD PRESSUREMAY ONLY BE USED IN CANADIANINSTALLATIONS.
34� 80 Plus furnaces installed above2,000 ft. require the furnace to be de-rated 4% per thousand feet.
IMPORTANT: Factory installed orificesare calculated and sized based on asea level Natural Gas heating value of1075 BTU per cubic ft.
NOTE: Orifices are available throughyour local distributor.
The following are examples of orificesizing using the National fuel Gas CodeAppendix F. For a simplified estimationof orifice size based on altitude and fuelheating value, Tables 5 and 8 can beused. However, calculations are thebest method.
Example: 900 BTU/ft3 RegionalNatural Gas Heating Value
I / H = Q25000 / 900 = 27.78 ft3
I = Sea Level input (per burner): 25000H = Sea Level Heating Value: 900Q = 27.78 ft.3 Natural Gas per hour.
From Table F.1 of National Fuel GasCode Handbook, 2002 (3.5� w.c.column).Orifice required at Sea Level: #40
From Table F.4 of National Fuel GasCode Handbook, 2002Orifice required at 5000 ft. elevation(4% de-rate per thousand ft.): #42Orifice required at 8000 ft. elevation(4% de-rate per thousand ft.): #44
Example: 1050 BTU/ft3 RegionalNatural Gas Heating Value
I / H = Q25000 / 1050 = 23.81 ft3
I = Sea Level input (per burner): 25000H = Sea Level Heating Value: 1050Q = 23.81 ft.3 Natural Gas per hour.
From Table F.1 of National Fuel Gascode Handbook, 2002 (3.5� w.c.column).Orifice required at Sea Level: #43
From Table F.4 of National Fuel Gascode Handbook, 2002Orifice required at 5000 ft. elevation(4% de-rate per thousand ft.): #45Orifice required at 8000 ft. elevation(4% de-rate per thousand ft.): #47
TABLE 5NATURAL GAS ORIFICE DRILL SIZE (4% PER 1000 FT. DE-RATE)IMPORTANT: 80+ MODELS ONLY. DO NOT USE THIS CHART WITH ANY 90+ MODELS.BURNER INPUT (PER BURNER) 25,000 BTU @ SEA LEVEL
Annual Avg. HeatValue (btu per ft3)
850
900
975
1075
1170
38 39 40 41 41 42 42 43
40 41 42 42 42 43 43 44
41 42 42 42 43 43 44 44
42 42 43 43 43 44 44 45
43 44 44 44 45 45 46 47
Sea levelto 1999 ft
2000 to2999 ft
3000 to3999 ft
4000 to4999 ft
5000 to5999 ft
6000 to6999 ft
7000 to7999 ft
8000 to8999 ft
! CAUTION ! CAUTION
23
LP GAS AT HIGH ALTITUDEELEVATION (TABLE 6)NOTE: Keep any parts removed duringLP conversion procedure stored withthe product literature for future use.
LP Gas is a manufactured gas that hasconsistent heating value across mostregions.
The NFGC guidelines are used with thefollowing exception:
The recommended LP Gas high altitudeorifice selections differ slightly in thatthe NFGC LP orifice chart, as they arenot accurate for Rheem products. TheNational Fuel Gas Code LP orifices arebased on an 11� of water columnpressure at the orifice, which differsfrom Rheem products that use 10� ofwater column at the orifice. Thisdifference requires a deviation from theNFGC orifice size recommendations.The Sea Level input should still bereduced by 4% per thousand ft. and theorifice size must be selected based onthe reduced input in Table 6.
ORIFICE ORDERINGINFORMATIONOrifice sizes are selected by adding the2-digit drill size required in the orificepart number. Drill sizes available are 39through 64; metric sizes available1.10mm (-90) and 1.15mm (-91):
Orifice Part Number 62-22175-(drillsize)
Example 1:#60 drill size orifice requiredPart # 62-22175-60
Example 2:1.15mm drill size orifice requiredPart #62-22175-91
ALTERNATE METHOD FORCANADIAN HIGH-ALTITUDEDERATEIn Canada, unless an orifice change isspecifically mandated by local codes, analternate method of altitude derationthrough a reduction in manifoldpressure is acceptable as described inTable 7. This information is based on aheating value of 1000 BTU per cubicfeet of natural gas, and 2500 BTU percubic feet of LP gas.
IMPORTANT: Actual input rates mustbe measured onsite with manifoldpressure adjustment to ensure that anactual 10% reduction in input rate isachieved.
Once this field adjustment has beenmade, the label shown in Figure 19must be affixed in a conspicuouslocation on the front of the furnacecabinet.
NOTE: This label is supplied in theinformation packet shipped with eachfurnace.
FURNACE INSTALLATIONWITH HIGH-EFFICIENCYPREMIUM COOLINGSYSTEMSFurnace installation with Rheem/Ruud -ARA or -ARL outdoor condensingunits can provide high efficiency (up to16 SEER) cooling operation. UsingTables 9 and 10, and literatureprovided with the cooling equipment,the installer needs to make sure thatthe proper evaporator coil, condensingcoil and airflow is configured to achieverated efficiency.
TABLE 7ALTERNATE METHOD FOR CANADIAN HIGH-ALTITUDE DERATEIMPORTANT: 80+ MODELS ONLY. DO NOT USE THIS CHART FOR ANY 90+ MODELS.
HIGH FIRE NATURAL GAS HIGH FIRE LP GAS
ALTITUDE INPUT OUTPUTORIFICE
SIZEMANIFOLDPRESSURE
0’ - 2000’ #42 3.5” W.C.
2001’ - 4500’ #42 2.9” W.C.
ALTITUDE INPUT OUTPUTORIFICE
SIZEMANIFOLDPRESSURE
0’ - 2000’ #54 10” W.C.
2001’ - 4500’ #54 8.1” W.C.
50,000 40,00075,000 60,000
100,000 80,000125,000 100,000150,000 120,000
45,000 36,00067,500 54,00090,000 72,000
112,500 90,000135,000 108,000
50,000 40,00075,000 60,000
100,000 80,000125,000 100,000150,000 120,000
45,000 36,00067,500 54,00090,000 72,000
112,500 90,000135,000 108,000
ALTITUDE INPUT OUTPUTORIFICE
SIZEMANIFOLDPRESSURE
0’ - 2000’ #42 1.7” W.C.
2001’ - 4500’ #42 1.4” W.C.
ALTITUDE INPUT OUTPUTORIFICE
SIZEMANIFOLDPRESSURE
0’ - 2000’ #54 4.9” W.C.
2001’ - 4500’ #54 4.0” W.C.
35,000 28,00052,500 42,00070,000 56,00087,500 70,000
105,000 84,000
31,500 25,20047,250 37,80063,000 50,40078,750 63,00094,500 75,600
35,000 28,00052,500 42,00070,000 56,00087,500 70,000
105,000 84,000
31,500 25,20047,250 37,80063,000 50,40078,750 63,00094,500 75,600
LOW FIRE NATURAL GAS LOW FIRE LP GAS
FIGURE 19MANIFOLD PRESSURE-CHANGE LABEL
THE MANIFOLD PRESSURE OF THIS APPLIANCE HAS BEEN FIELD ADJUSTED TO OBTAIN THE CORRECT INPUT RATING FOR INSTALLATION AT ALTITUDES
BETWEEN 2,000 FEET AND 4,500 FEET ELEVATION.
LA PRESSION DU DISTRIBUTEUR D'ALIMENTATION DE CET APPAREIL A ÉTÉ AJUSTÉ SUR LES LIEUX AFIN D'OBTENIR LA BONNE PUISSANCE D'ENTRÉE POUR
UNE INSTALLATION ENTRE 2000 ET 4500 PIEDS D'ALTITUDE.
92 24399 01 0192-24399-01-01
TABLE 6IMPORTANT: 80+ MODELS ONLY. DO NOTUSE THIS CHART WITH ANY 90+ MODELS.LP GAS
Input (per OrificeAltitude burner) 25000 Size
0 to 2000 ft. 25000 #542001�-3000� 24000 #543001�-4000� 23000 #544001�-5000� 22000 #545001�-6000� 21000 #546001�-7000� 20000 #547001�-8000� 19000 #558001�-9000� 18000 #559001�-10000� 17000 #55
24
TA
BLE
8S
UP
PLE
ME
NT
AL
OR
IFIC
E S
IZE
CH
AR
T
80 P
lus
Mod
els
Onl
y w
ith 2
5,00
0 B
tu's
per
Bur
ner
– D
o no
tuse
this
cha
rt fo
r an
y 90
+ m
odel
s.
NA
TU
RA
L G
AS
QU
ICK
RE
FE
RE
NC
E C
HA
RT
FO
R O
RIF
ICE
SE
LEC
TIO
N, A
T 3
.5"
W.C
. AN
D A
PP
RO
XIM
AT
E F
INA
L F
IRIN
G R
AT
ES
Fin
al F
iring
Rat
e pe
r B
urne
r
Sea
Lev
elO
rific
eS
ize
Sea
Lev
elC
ubic
Foo
t at
3.5"
W.C
.
80 P
lus
Hea
tV
alue
at
25,0
000-
999
1000
-199
920
00-2
999
3000
-399
940
00-4
999
5000
-599
960
00-6
999
7000
-799
980
00-8
999
9000
-999
9
ELE
VA
TIO
N C
HA
RT
(NFG
rec
om
men
ded
ori
fice
bas
ed o
n 4%
der
ate
for
each
100
0 fo
ot
of
elev
atio
n, b
ased
on
the
inte
rsec
tio
n o
f th
eo
rific
e re
qui
red
at
Sea
Lev
el a
nd t
he e
leva
tio
n re
qui
red
bel
ow
)
3730
.63
816
3737
3839
3940
4142
4243
3829
.25
855
3838
3940
4141
4242
4343
3928
.288
739
3940
4141
4242
4343
44
4027
.03
925
4040
4142
4242
4343
4444
4125
.98
962
4141
4242
4243
4344
4445
4224
.95
1002
4242
4243
4343
4444
4546
4322
.39
1117
4343
4444
4445
4546
4747
4421
.01
1190
4444
4545
4546
4747
4848
25,0
0024
,000
23,0
0022
,000
21,0
0020
,000
19,0
0018
,000
17,0
0016
,000
All
calc
ulat
ions
are
per
form
ed b
y us
ing
the
fir
st t
hree
co
lum
ns o
f in
form
atio
n o
nly.
Bef
ore
beg
inni
ng a
ny c
alcu
lati
ons
, det
erm
ine
the
ind
ivid
ual b
urne
r B
tu s
ize
and
hea
ting
val
ue a
t S
ea L
evel
fo
r th
e in
stal
lati
on
site
. Eac
h va
lue
sho
wn
in t
he H
eat
Val
ue c
olu
mn
is p
er b
urne
r at
3.5
" W
.C.
NO
TE
: H
eat V
alue
at S
ea L
evel
, for
the
loca
tion
of th
e in
stal
latio
n, is
ava
ilabl
e fr
om th
e N
atur
al G
as S
uppl
ier
to th
at s
ite. O
rific
es fo
r al
l alti
tude
s ar
e ba
sed
on S
ea L
evel
val
ues.
Div
ide
the
indi
vidu
al b
urne
r ca
paci
ty (
25,0
00 fo
r 80
plu
s) b
y th
e H
eat V
alue
for
the
site
to d
eter
min
e th
e C
ubic
Foo
t val
ue a
t Sea
Lev
el, o
r di
vide
bur
ner
capa
city
by
the
Cub
icF
oot v
alue
for
the
Hea
t Val
ue. O
nce
you
have
eith
er th
e C
ubic
Foo
t Val
ue o
r th
e H
eat V
alue
you
can
est
imat
e th
e S
ea L
evel
orif
ice
for
the
site
. To
sele
ct th
e co
rres
pond
ing
high
alti
tude
orif
ice,
loca
te th
e si
te e
leva
tion
on th
e ch
art a
bove
and
the
orifi
ce r
equi
red
at S
ea L
evel
from
you
r ca
lcul
atio
n in
the
first
col
umn.
The
cor
rect
hig
h al
titud
e or
ifice
that
mus
t be
inst
alle
d in
eac
h in
divi
dual
bur
ner
is th
e in
ters
ectio
n of
thes
e tw
o po
ints
on
the
char
t abo
ve.
25
TABLE 9CONDENSER SELECTION – PREMIUM COOLING SYSTEMS (1 STAGE COOL ONLY)
2 -GPL-05 17.5� -ARA-242-1/2 -GPL-05 17.5� -ARA-302-1/2 -GPL-07EBRKR 21� -ARA-302-1/2 -GPL-07EBRQR 21� -ARA-30
3 -GPL-05 17.5� -ARA-303 -GPL-07EBRKR 21� -ARA-363 -GPL-07EBRQR 21� -ARA-363 -GPL-10 21� -ARA-363 -GPL-12 24.5� -ARA-36
3-1/2 -GPL-07EBRQR 21� -ARA-423-1/2 -GPL-10 21� -ARA-423-1/2 -GPL-12 24.5� -ARA-42
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).See cooling equipment specifications sheets and installation instructions for optimum cooling airflow then consult Table 14 (page 28) of this manual for the proper dip-switchselections to achieve the specified airflow.
TONSFURNACE
MODEL WIDTHCONDENSING
UNIT
TABLE 10CONDENSER SELECTION – PREMIUM COOLING SYSTEMS (2 STAGE COOL ONLY)
2 -GPL-05 17.5� -ARL-243 -GPL-05 17.5� -ARL-363 -GPL-07EBRKR 21� -ARL-363 -GPL-07EBRQR 21� -ARL-363 -GPL-10 21� -ARL-363 -GPL-12 24� -ARL-364 -GPL-07EBRQR 21� -ARL-484 -GPL-10 21� -ARL-484 -GPL-12 24� -ARL-485 -GPL-10 21� -ARL-605 -GPL-12 24� -ARL-60
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)ECM interface #62-24340-01 can not be used with two-stage cooling since there is no YL input. See cooling equipment specifications sheets and installation instructions for optimumcooling airflow then consult Table 14 (page 28) of this manual for the proper dip-switch selections to achieve the specified airflow.
TONSFURNACE
MODEL WIDTHCONDENSING
UNIT
For two-stage cooling, the input for lowcooling (YL) is on the ECM interfacecontrol (part number 62-24340-04 only)and not on the main IFC. This was donefor convenience of production. Thisshould be noted when routingthermostat connections since low speedcooling is not wired to the same controlboard as all other thermostat terminals.
UP TO 16 SEER COOLING OPERATION
SINGLE-STAGE COOLING: All IFCpart numbers and revisions arecompatible.
TWO-STAGE COOLING:
Check the part number of two-stageinterface control (part #62-24340-01 or62-24340-04). For proper operation ofhigh SEER equipment with two-stagecooling, the part should be 62-24340-04. The 62-24340-01 will not operatelow speed cooling and therefore will notwork with two-stage cooling systems
and should be replaced with the 62-24340-04 for high SEER two-stagecooling systems. One way to tell if thecontrol is the 62-24340-04 is to look atthe part to see if there is a thermostatconnection for low speed cooling (YL)on the control. This will be a screw typeinput like those of the thermostat inputson the main IFC. If no YL connection isavailable on the interface control, thefurnace is not compatible with highSEER equipment or will need to bereplaced.
A. Furnaces constructed up to January,2005 are not compatible with highSEER two-stage systems and willneed to be replaced with the newerfurnace to insure proper operationwith high SEER cooling equipment.
B. For furnaces constructed afterFebruary, 2005, but before May 15,2005, the interface control can bereplaced with the newer version toconvert the furnace for high SEERtwo-stage cooling. For this scenario,
contact the Rheem servicedepartment and a replacementcontrol will be shipped. BE SURETO REPLACE THE CONTROLBEFORE OR DURINGINSTALLATION. OTHERWISE, THESYSTEM MAY BE DOWN WHILEPARTS ARE BEING SHIPPED.
C. For furnaces constructed after May15, 2005 (date code F1805 or later),all components necessary for properoperation of high SEER equipmentare present on the furnace. Thereshould be no additionalmodifications necessary.
A NOTE ABOUT DEHUMIDIFICATION:
High SEER systems may require theuse of the onboard dehumidificationfeature of this system. Be sure toconsult the section titled“DEHUMIDIFICATION” on page 28 ofthis document.
26
DIRECT SPARK IGNITIONLIGHTING INSTRUCTIONSThis appliance is equipped with adirect spark ignition device. This devicelights the main burners each time theroom thermostat (closes) calls for heat.See lighting instructions on thefurnace.
TO START FURNACE
1. BE SURE THAT THE MANUALGAS CONTROL HAS BEEN INTHE “OFF” POSITION FOR ATLEAST FIVE MINUTES. DO NOTATTEMPT TO MANUALLY LIGHTTHE MAIN BURNERS. FAILURETO FOLLOW THIS WARNING CANCAUSE A FIRE OR ANEXPLOSION RESULTING INPROPERTY DAMAGE,PERSONAL INJURY OR DEATH.
2. Set the room thermostat to thelowest setting.
3. Turn the gas control knob to the“On” position, or move the gascontrol lever to the “On” position.
4. Replace the control access door.5. Turn on the electrical power.6. Set the room thermostat to a point
above room temperature to light themain burners. After the burners arelit, set room thermostat to a desiredtemperature.
TO SHUT DOWN FURNACE1. Set the room thermostat to its
lowest setting.2. Shut off the gas to main burners by
turning the gas control knob to the“Off” position, or by depressing thegas control lever and moving it tothe “Off” position.
SHOULD OVERHEATING OCCUROR THE GAS SUPPLY FAIL TOSHUT OFF, SHUT OFF THEMANUAL GAS VALVE TO THEAPPLIANCE BEFORE SHUTTINGOFF THE ELECTRICAL SUPPLY.FAILURE TO DO SO CAN CAUSE ANEXPLOSION OR FIRE RESULTINGIN PROPERTY DAMAGE,PERSONAL INJURY OR DEATH.Sequence of operation with a singlestage thermostata. Connect the “W” terminal on the
thermostat to the W2 terminal on thecontrol board.
b. When there is a call for heat, the “R”and “W2” contacts close and theIFC runs a self check routine toverify that the pressure switchcontacts are open. The limit switchcontacts are constantly monitored.
START-UP PROCEDURES
WARNING!
WARNING!
c. The induced draft motor starts onhigh until the low pressure switchcontacts close (a maximum of 60seconds), and then changes to lowspeed. After a 30 second pre-purge,the spark ignitor energizes and thelow stage of the gas valve opens,lighting the burners.
d. After the gas valve opens, theremote flame sensor must proveignition for one second using theprocess of flame rectification. If theburners do not light, the systemgoes through another ignitionsequence. It does this up to 4 times.(2 tries on low fire and 2 tries onhigh fire.)
e. The main blower starts on lowspeed 20 seconds after the burnerslight. The furnace operates on lowfire for 12 minutes and then, if thethermostat is not satisfied, shifts tohigh fire, causing the draft inducer togo to high speed, the gas valve to100% and the main blower goes toheat speed.
f. When the thermostat cycle ends, thegas valve closes, and the burnersgo out.
g. The draft inducer will continuerunning for a 10 second (low speed)or 5 second (high speed) postpurge.
h. The main blower will run for 90seconds on high speed or 120seconds on low speed. (This timingis field adjustable, for 60, 90, 120 or150 seconds). See Figure 21 forswitch settings.
Sequence if the system doesn’t lightor doesn’t sense flame:a. If flame is not sensed within 8
seconds after the gas valve opens,the valve closes and the ignitor isde-energized. The induced draftmotor will run for 60 seconds on low,stop momentarily, and then restart.
b. The ignition process goes throughone more try on low fire. If this fails,there are two tries on high fire with a30 second interpurge between trials.During high fire ignition attempts,the inducer steps to high speed, thehigh pressure switch closes (bothpressure switches are now closed),and the gas valve steps to 100%.
c. If there is no ignition after the 2ndtrial on high fire, the furnace goesinto soft lockout for one hour.
d. The sequence repeats after a onehour delay and continues repeatinguntil ignition is successful or the callfor heat is terminated.
e. To reset the lockout, make andbreak power either at the thermostator at the unit disconnect switch for 5to 10 seconds. The furnace will thengo through another set of trials forignition.
f. If flame is established andmaintained during the trial forignition period and flame is lost, thegas valve is de-energized, the draftinducer completes a post-purge of10 seconds. The indoor blowermotor will be energized and/orremain energized on low speed forlow fire and heat speed for high firefor the selected delay off time.When the inter-purge delay is over,the control verifies the pressureswitch has opened and then initiatesanother ignition trial period. Thecontrol will recycle up to 5 flamelosses (4 re-cycles) within a singlecall for heat before going intolockout.
Sequence of operation with twostage thermostatConnect W1 and W2 terminals on thethermostat to W and W2 terminals onthe control board.Call for 1st stage heata. R and W thermostat contacts close
and the control module runs a self-check routine. After the controlmodule verifies that both sets ofpressure switch contacts are open,the induced draft motor starts onhigh until the low pressure switchcontacts close (a maximum of 60seconds), then changes to lowspeed.
b. After a 30 second pre-purge, thespark igniter energizes and the gasvalve (low stage) opens, lighting theburners.
c. After the burners light, the remoteflame sensor must prove ignition. Ifthe burners do not light, the systemgoes through another ignitionsequence. It does this up to 4 times(2 tries on low fire and 2 tries onhigh fire).
d. The main blower starts on lowspeed 20 seconds after the gasvalve opens. The furnace continuesto run on low until the call for heat issatisfied or the 2nd stage contactsclose. If the 1st stage call for heat issatisfied the gas valve closes andthe induced draft motor continuesrunning for a 10 second post purgetime. the main blower runs for 120seconds (this timing is fieldadjustable). See Figure 23 for switchsettings.
Call for 2nd stage heat after 1ststage
R and W2 thermostat contacts close,calling for 2 stage heat. The induceddraft motor then switches to highspeed and the high pressure switchcontacts will close. The gas valveswitches to high fire and the mainblower switches to heating speed.
27
2nd stage heat satisfied, 1st stageheat still required.R and W2 thermostat contacts open.The induced draft motor switches to lowspeed, the main blower motor switchesto low speed and the gas valvechanges to low fire. The furnacecontinues to run in this mode until the1st stage heat call is satisfied. Thesystem will shut down as noted in “c,”under 1st stage call for heat.
INTEGRATED FURNACECONTROL & ECM MOTORSETTINGSThese furnaces have ECM blowermotors. These motors deliver a constantlevel of air flow over a wide range ofexternal static pressures (0.1 to 0.8�W.C.). The interface board, foundbeside the furnace integrated controlboard, provides the requiredcommunications between the mainintegrated furnace control and the ECMblower motor. There is a bank of 4 dipswitches on the integrated furnacecontrol which controls the blower offtimings. See section on BLOWER OFFTIMINGS FOR ECM MOTORS andFigure 22 for proper switch settings.
There is a bank of 12 dip switches onthe interface board which define theoperation of the ECM motor. Only thefirst eleven switches are used for thisapplication. See Figure 20. Theseswitches (except for switches 9 and 12)are actually broken down into five dipswitch pairs. Switches 1 and 2 act as apair as do switches 3 and 4, 5 and 6, 7and 8, and 10 and 11. The assignmentsof the switch pairs are shown in Table 11.
*IMPORTANT: Only traditionalhumidistats will work with this feature.
Dehumidistats will not work properlywith this feature.
+See Page 27 under Dehumidification.
HEATING AIRFLOWADJUSTMENTSThe furnace is shipped with low andhigh fire heating airflows. These areset from the factory to let the furnaceoperate at the mid point of thetemperature rise range. Thetemperature may vary slightly due tofurnace input and voltage variations.The installer is given the option of threeair flow options in the heating mode asshown in Table 12. Switches 1 and 2on the interface control regulate thesteady state heating mode airflow.
In the heating mode, the ECM motor isprogrammed to ramp up to its targetCFM over a fifteen (15) second period.After any of the user selected “Off”delays, see Figures 25 and 26, theECM motor will ramp down to 50% ofsteady state CFM for approximatelythirty (30) seconds. The motor will thenramp down to an off position.
*NOTE: Airflow for models (-)GPL-07EBRKR and (-)GLL-07EBRKRcannot be adjusted to give a rise lowerthan mid-rise on high fire.
COOLING AIRFLOWADJUSTMENTSThe furnace motor is programmed toprovide cooling airflows of 11⁄2, 2, 21⁄2and 3 tons in the (-)GPL/LL-05 EBMKRand -07 EBRKR units. Airflows of 21⁄2,3, 31⁄2, and 4 tons are available in the(-)GPL/LL-07 EBRQR units. Airflows of3, 31⁄2, 4 and 5 tons are available in the-10 EBRMR and -12 EARMR units.See Tables 14 and 16 for airflowoptions. Furnaces are shipped from thefactory set for maximum coolingairflow. Adjustments to the coolingairflow may be made using switches 7and 8 as shown in Table 13.
TABLE 11
SWITCHES FUNCTION
1 & 2 Heating Airflow
3 & 4 Cooling Off/On DelayProfiles
5 & 6 Nominal Cooling/Heat Pump Air Flow
7 & 8+ Latent/Sensible Airflow Adjustment
9 Continuous Fan Airflow
10 & 11* On DemandDehumidification
Settings
12 Not Used
TABLE 12HEATING AIR FLOW SELECTIONS(SWITCHES 1 & 2)
Switch TemperatureSelection Rise °F
A Mid-Rise
B Mid-Rise
C* Mid-Rise –10°F
D Mid-Rise + 10°F
FIGURE 21
FIGURE 20
FIGURE 22BLOWER OFF TIMINGSUTEC 1095 - 101 CONTROL WITHINTERFACE BOARD AND ECM MOTOR
NOTE: SWITCH #3 MUST BE IN OFFPOSITION.
ON
NORMAL ECMLOW HIGH COOLING COOLING SWITCH SWITCHFIRE FIRE SWITCH 4 ON 1 2
#4 OFF
80 50 30 0 OFF ON
110 80 40 30 OFF OFF
150 120 60 20 ON OFF
170 140 90 50 ON ON
TABLE 13AIR FLOW ADJUSTMENT (SWITCHES 7 & 8)
Switch Air FlowSelection Adjustment
A No Adjustment
B +10%
C -10%
D No Adjustment
28
CONTINUOUS FANADJUSTMENTSThere are two options for theadjustment of continuous fan. Withswitch 9 “ON” the speed will be highfan. With switch 9 “OFF” the speed willbe soft fan. The cfm for these speedswill be a calculated percentage of theheating airflow speeds selected.
SETTING BLOWER OFFTIMINGS FOR COOLINGAND HEAT PUMPOPERATIONThere is a bank of four dip switches onthe main furnace control board forsetting blower off timings. Switches 1and 2 adjust the times. (See Figure 22.)
IMPORTANT: Switch 3 on theintegrated furnace control board is notused and must be in the “OFF” position.If put in the “On” position a 5 blink faultwill be flashed on the IFC.
When Switch 4 is in the “on” position onthe main IFC, the blower will continue itsnormal speed for 0, 30, 20 or 50seconds after a cooling or heat pumpcycle has ended. This also is dependentupon the settings of Switches 1 and 2 onthe IFC, see Figure 20. The blower will
then enter one of four “off” delay profilesas shown in Figure 23. The profile isdetermined by the settings of Switches 3and 4 on the interface board. Forexample: If the switches are in position“A” as shown in Figure 21, then profile“A”, as shown in Figure 23, is enteredafter the blower off timing.
These switch combinations between themain IFC and interface control boardallow for a wide range of “off” delaytimings. Switches 3 and 4 on the ECMinterface control can be used with anymain IFC switch 1 and 2 setting tocontrol how the blower turns “on” and“off”. Possible “off” delay timings andprofiles are shown in Table 15.
A corresponding cooling/heat pump “On”delay is also chosen by Switches 3 and4 on the interface control as shown inFigure 24. For example, if “Off” delayprofile “A” is chosen in Figure 23, then“ON” delay profile “A” in Figure 24 isautomatically chosen.
DEHUMIDIFICATIONThe interface control has two optional 24volt AC only inputs. The “B” terminalinput is provided for heat pumpapplications. This signal comes from aheat pump thermostat and tells the heatpump to switch its reversing valve to
TABLE 14COOLING AIR FLOW (SWITCHES 5 & 6)
SwitchSelection
A
B
C
D
(-)GPL/GLL-05EBMKR
1200
1000
800
600
(-)GPL/GLL-07EBRKR
1200
1000
800
600
(-)GPL/GLL-07EBRQR
1600
1400
1200
1000
(-)GPL/GLL-10EBRMRAir Flow
2000
1600
1400
1200
(-)GPL/GLL-12EARMRAir Flow
2000
1600
1400
1200
Switch Air FlowSelection Adjustment
A 15% Less cooling Airflow
B Normal Cooling Air Flow for Table 7
C On Demand Dehumidification (Humidistat controls cooling airflow)
D Normal Cooling Air Flow
TABLE 15TWO STAGE IFC’S SWITCHES 1, 2 & 4 COOLING OFF DELAY TIMINGS & PROFILES - SEE FIGURES 22-25
SWITCH #1 SWITCH #2 SWITCH #4 + PROFILE- SWITCH #4 + PROFILEOFF (SWITCHES 3 & 4 ON (SWITCHES 3 & 4
On Interface Board) On Interface Board)Off On 30 sec. +A, B, C or D 0 sec. +A, B, C, or DOff Off 40 sec. +A, B, C or D 30 sec. +A, B, C or DOn Off 60 sec. +A, B, C or D 20 sec. +A, B, C or DOn On 90 sec. +A, B, C or D 50 sec. +A, B, C or D
heat mode. If this “B” signal is alsorouted to the interface control, all airflowadjust switches (7 & 8) and “On DemandDehumidification” are bypassed in theheat mode only. The airflow will remainat the normal airflow as selected byswitches 5 & 6 throughout the heatmode. This allows the user to have aswitched (-10%) airflow adjustment fordehumidification or the “On DemandDehumidification” in cooling mode, butnot the adverse humidity and heat riseeffects of using these adjustmentsduring a heat pump’s heat mode. The“B” terminal does not apply to gasoperation.
The “On Demand Dehumidification”input allows the user to have automaticdehumidification that is controlled by theuser’s humidistat setting. Dehumidistatsare not compatible with the interfacecontrol. When the humidity exceeds thehumidistat setting, it routes a 24 volt, AConly, signal to the “On DemandDehumidification” terminal. This will inturn decrease the airflow by 15%. Thisresults in higher latent capacity andincreases the level of comfort. Thisfeature is only available in the coolingmode.
29
FIGURE 23COOLING/HEAT PUMP “OFF” DELAY PROFILES
ST-A0827-01
30
FIGURE 24COOLING/HEAT PUMP “ON” DELAY PROFILES
ST-A0828-01
31
FIGURE 25LOW HEAT “OFF” DELAY PROFILES
ST-A0829-01
32
FIGURE 26HIGH HEAT “OFF” DELAY PROFILES
ST-A0830-01
33
FIGURE 28FURNACE NAME PLATE
AIR FLOWThe importance of proper air flow overthe heat exchanger cannot be overemphasized. One of the most commoncauses of heat exchanger failure isoverheating due to low air flow. An airflow table is located inside the blowerdoor and on the following pages.
NOTE: The installation of the ductsystem is under the control of theinstalling contractor. If the duct systemis not correctly sized and installed, thehomeowner may experience air noise,low or no airflow out of some vents,component failures, or high utility bills.Other miscellaneous problems are alsopossible.
TEMPERATURE RISE CHECK
To determine if the air flow is correct,make a temperature rise check.
1. Insert a thermometer in the supplyair duct as close to the furnace aspossible yet out of a direct linefrom the heat exchanger. SeeFigure 27.
2. Insert a thermometer in the returnair duct as close to the furnace aspossible.
3. Operate the furnace.
4. When the thermometer in thesupply air duct stops rising(approximately five minutes),subtract the return air temperaturefrom the supply air temperature.The difference is the temperaturerise.
5. Compare the measuredtemperature rise to the approvedtemperature rise range listed onthe furnace name plate. SeeFigure 28.
If the measured temperature rise isabove the approved range, the air flowis too low. More air must be moved byspeeding up the blower, by removingrestrictions in the duct system, or byadding more supply or return air duct. Ifthe measured temperature rise is belowthe approved range, the air flow is toomuch. Use dip switches on the blowerinterface board to adjust airflow.
Ideally the measured temperature riseshould be in the middle of the range.
The rise range is the same for high andlow inputs.
FIGURE 27TEMPERATURE RISE MEASUREMENT
34
SAFETY FEATURES
LIMIT CONTROLThe high limit cut-off temperature is setat the factory and cannot be adjusted.The temperature setting prevents theair temperature leaving the furnacefrom exceeding the maximum outlet airtemperature, which, if exceeded, willshut the furnace down.
There are several reasons for a limitswitch to open and almost alwaysinvolve low airflow through the furnace.
1. A dirty or restricted air filter.
2. A dirty or restricted cooling coil.
3. Undersized or restricted return airsystem.
4. Undersized or restricted supply airsystem.
5. A problem affecting the mainblower;
A. A wrong speed tap selection.
B. Failing motor bearings.
C. Low voltage to the motor.
D. Dirty blower wheel.
E. Wrong motor rotation.
F. Blower wheel slipping on themotor shaft.
6. Overfiring the furnace with too muchgas pressure.
7. Ventilation problems.
FLAME ROLL-OUTSAFETY SWITCHESFurnaces are equipped with safetyswitches to protect against flame roll-out conditions in the burnercompartment, which, if tripped, willterminate the heating cycle. In theevent of a flame roll-out condition, theswitch will shut the furnace down.Switches for the (-)GPN/(-)GPPfurnaces are located on either side ofthe burner cover plate and just abovethe burners on the blower dividerpanel. If a switch is tripped, it must bemanually rest. DO NOT jumper or reset this switch. If this switch shouldtrip, a qualified installer, service agencyor the gas supplier should be called todiagnose and/or correct the sourse oftripping. If this unit is mounted in acloset, the door must be closed whenmaking this check.
35
PRESSURE SWITCHESThis furnace has two pressureswitches for sensing a blocked ventcondition. One is for high pressure andthe other for low pressure. When thedraft inducer is running on high speed,both switches will normally close. whenrunning on low inducer speed, only thelow pressure switch will close. If thereis a blocked vent condition, failedinducer motor or leak in the pressureswitch hoses, the pressure switchcontacts will remain open. The“STATUS” light will blink twice,indicating a pressure switch problem.The high fire pressure switch is locatedin the upper position on the furnace.
LUBRICATION
The blower motor and induced draftmotor are permanently lubricated bythe manufacturer and do not requirefurther attention.
The motor must be cleanedperiodically by a qualified installer,service agency, or the gas supplier toprevent the possibility of overheatingdue to an accumulation of dust and dirton the windings or on the motorexterior. And, as suggested elsewherein these instructions, the air filtersshould be kept clean because dirtyfilters can restrict airflow and the motordepends upon sufficient air flowingacross and through it to keep fromoverheating.
Reference Figure 29 for properremoval of blower assembly ondownflow models.
FIGURE 29DOWNFLOW BLOWER REMOVAL
36
FIGURE 31BOTTOM RETURN
DISCONNECT MAIN ELECTRICALPOWER TO THE UNIT BEFOREATTEMPTING ANY MAINTENANCE.FAILURE TO DO SO CAN CAUSEELECTRICAL SHOCK RESULTINGIN SEVERE PERSONAL INJURY ORDEATH.
FILTERSFilter application and placement arecritical to airflow, which may affect theheating and cooling systemperformance. Reduced airflow canshorten the life of the system’s majorcomponents, such as motor, limits,elements, heat exchanger, evaporatorcoil or compressor. Consequently, werecommend that the return air ductsystem have only one filter location.The most common location will beinside the furnace or air handler or afilter base. For systems with a return airfilter grill or multiple filter grills, can havea filter installed at each of the return airopenings. DO NOT DOUBLE FILTERTHE RETURN AIR DUCT SYSTEM.DO NOT FILTER THE SUPPLY AIRDUCT SYSTEM.If high efficiency filters or electronic aircleaners are used in the system, it isimportant that the airflow is not reducedto maximize system performance andlife. Always verify that the system’sairflow is not impaired by the filteringsystem that has been installed, byperforming a temperature rise andtemperature drop test.NOTE: Airflow external static pressuremeasurements do not include filter orcoil.
TABLE 17 FILTER SIZES
MAINTENANCEWARNING!
FIGURE 30RESIZING FILTERS & FRAME
*NOTE: Some filters must beresized to fit certain units andapplications.
SOLID BOTTOM MAY BE ORDERED AS AN OPTION FROM THE FACTORY.
UPFLOW FILTER SIZES
FURNACE INPUT BOTTOM SIDE QUANTITYWIDTH BTUH SIZE SIZE
17-1/2" 50 & 100 153⁄4" X 25" 153⁄4" X 25" 121" 75 & 100 191⁄4" X 25" 153⁄4" X 25" 1
24-1/2" 125 223⁄4" X 25" 153⁄4" X 25" 1
DOWNFLOW FILTER SIZES
FURNACE INPUT SIZE QUANTITYWIDTH BTUH
14" 50 14" X 20" 1171/2" 75 & 100 12" X 20" 221" 100 12" X 20" 2
241/2" 125 & 150 14" X 20" 2
Unit Unit Filter Rod Filter Rod Bottom SideSize Width 203/4" 241/4"
AE-61659-02 AE-61659-03
50,000 17-1/2" 1 Cut Off 31/2" As is75,000 21" 1 Cut Off 31/2" As is
100,000 21" 1 Cut Off 31/2" As is125,000 241/2" 1 As is Cut Off 31/2"
37
FIGURE 32FILTER RETAINING RODS (SIDE RETURN)
FIGURE 33DOWNFLOW FILTER INSTALLATION
38
Keep the air filters clean at all times.Vacuum dirt from filter, wash withdetergent and water, air dry thoroughlyand reinstall.1. 171⁄2�-50,000 btuh unit requires
removal of 31⁄2� segment of filter andframe to get proper width for a bottomfilter.
2. 21�-75.000-100,000 btuh unitsrequires removal of 31⁄2� segment offilter and frame to get proper width fora side filter.
3. 241⁄2�-125,000 btuh unit requireremoval of 7� segment of filter andframe to get proper width for a sidefilter.
IMPORTANT: Do not operate thesystem without filters. A portion of thedust entrained in the air may temporarilylodge in the air duct runs and at thesupply registers. Any recirculated dustparticles will be heated and charred bycontact with the furnace heatexchanger. This residue will soilceilings, walls, drapes, carpets, andother household articles.
SYSTEM OPERATIONINFORMATIONAdvise The Customer To:1. Keep the air filters clean. The heating
system will operate better, moreefficiently and more economically.
2. Arrange the furniture and drapes sothat the supply air registers and thereturn air grilles are unobstructed.
3. Close doors and windows. This willreduce the heating load on thesystem.
4. Avoid excessive use of kitchen &bathroom exhaust fans.
5. Do not permit the heat generated bytelevision, lamps or radios toinfluence the thermostat operation.
6 Except for the mounting platform,keep all combustible articles threefeet from the furnace and ventsystem.
7. IMPORTANT: Replace all blowerdoors and compartment covers afterservicing the furnace. Do not operatethe unit without all panels and doorssecurely in place.
8. Proper operation of the system withconstant air circulation.
COMBUSTIBLE MATERIAL MUSTNOT BE PLACED ON OR AGAINSTTHE FURNACE JACKET OR WITHINTHE SPECIFIED CLEARANCES OFTHE VENT PIPE. THE AREAAROUND THE FURNACE MUST BEKEPT CLEAR AND FREE OF ALLCOMBUSTIBLE MATERIALSINCLUDING GASOLINE AND OTHERFLAMMABLE VAPORS ANDLIQUIDS. PLACEMENT OFCOMBUSTIBLE MATERIALS ON,AGAINST OR AROUND THEFURNACE JACKET CAN CAUSE ANEXPLOSION OR FIRE RESULTINGIN PROPERTY DAMAGE,PERSONAL INJURY OR DEATH.THE FURNACE OWNER SHOULD BECAUTIONED THAT THE FURNACEAREA MUST NOT BE USED AS ABROOM CLOSET OR FOR ANYOTHER STORAGE PURPOSES.
ANNUAL INSPECTIONThe furnace should operate for manyyears without excessive scale build-upin the flue passageways, however, it isrecommended that a qualified installer,service agency, or the gas supplieractually inspect the flue passageways,the vent system and the main and pilotburners for continued safe operationpaying particular attention todeterioration from corrosion or othersources.
HOLES IN THE VENT PIPE OR HEATEXCHANGER CAN CAUSE TOXICFUMES TO ENTER THE HOMERESULTING IN CARBONMONOXIDE POISONING OR DEATH.THE VENT PIPE OR HEATEXCHANGER MUST BE REPLACEDIF THEY LEAK.
• IMPORTANT: It is recommendedthat at the beginning of the heatingseason and approximately midwayin the heating season a visualinspection be made of the mainburner flames and pilot flame onstanding pilot models for the desiredflame appearance by a qualifiedinstaller, service agency, or the gassupplier.
• IMPORTANT: It is alsorecommended that at the beginningof the heating season, the flamesensor on hot surface ignitionmodels be cleaned with steel woolby a qualified installer, serviceagency, or the gas supplier.
• IMPORTANT: It is recommendedthat an annual inspection andcleaning of all furnace markings bemade to assure legibility. Attach areplacement marking, which can beobtained through the distributor, ifany are found to be illegible ormissing.
IMPORTANT: FOR Nox MODELS –At the beginning of the heating seasona visual inspection of the Nox deviceshould be made to ensure they havenot become obstructed by insectsnests or anything else which mayeffect performance.
REPLACEMENT PARTSContact your local distributor for acomplete parts list. See enclosedsheet.
TROUBLESHOOTINGRefer to Figure 34 for determiningcause of unit problems.
WIRING DIAGRAMFigure 35 is the complete wiringdiagram for the furnace and powersource.
WARNING!
WARNING!
39
FIGURE 34INTEGRATED FURNACE CONTROL (IFC) TROUBLESHOOTING GUIDE FOR UTEC 1095-101
40
41
FIGURE 35FOR MODELS WITH UT ELECTRONIC CONTROLS 1095-101 INTEGRATED FURNACE CONTROL AND ECM BLOWER MOTOR
42
43
44 CM 1105