INSTALLATION INSTRUCTIONS FOR DOWNFLOW SINGLE STAGE GAS FURNACES (-)801S DOWNFLOW SERIES (-)801P DOWNFLOW SERIES (-)(-)80DSS DOWNFLOW SERIES (-)(-)80DSP DOWNFLOW SERIES U.L. and/or C.S.A. recognized fuel gas and CO (carbon monoxide) detectors are recommended in all applications, and their installation should be in accordance with the manufacturer’s recommendations and/or local laws, rules, regulations, or customs.
Contents TABLE OF CONTENTS 1 TABLE OF CONTENTS. . . . . . . . . . . . . . . . . . . . . . . 2 2 GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . 3 Receiving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 California Proposition 65 Note . . . . . . . . . . . . . . . . . . 4 Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 3 SAFETY INFORMATION. . . . . . . . . . . . . . . . . . . . . . 6 Warnings . . . . . . . . . . . . . . . . . . . . . . .
GENERAL INFORMATION The (-)801S/(-)801P series furnaces are design certified by CSA for use with natural and propane gases as follows: As a Category I furnace, it may be vented vertically with type B1 vent pipe and also may be common vented as described in these instructions. This furnace should be installed in accordance with the American National Standard Z223.
General Information GENERAL INFORMATION (cont.) Install this furnace in accordance with the American National Standard Z223.1 – latest edition entitled “National Fuel Gas Code” (NFPA54) and requirements or codes of the local utilities or other authorities having jurisdiction. This is available from the following: National Fire Protection Association, Inc. Batterymarch Park Quincy, MA 02269 RECEIVING Immediately upon receipt, all cartons and contents should be inspected for transit damage.
Installation Instructions remain with the furnace as a reference guide to the servicing contractor. We recommend that performance and installation data be recorded for future reference on this sheet to meet service and warranty obligations so that job site information is available when required.
SAFETY INFORMATION ! WARNING DO NOT INSTALL THIS FURNACE IN A MOBILE HOME!! THIS FURNACE IS NOT APPROVED FOR INSTALLATION IN A MOBILE HOME. DOING SO COULD CAUSE FIRE, PROPERTY DAMAGE, PERSONAL INJURY OR DEATH. ! WARNING INSTALL THIS FURNACE ONLY IN A LOCATION AND POSITION AS SPECIFIED IN THE LOCATION REQUIREMENTS AND CONSIDERATIONS SECTION OF THESE INSTRUCTIONS.
SAFETY ! WARNING BLOWER AND BURNERS MUST NEVER BE OPERATED WITHOUT THE BLOWER DOOR IN PLACE. THIS IS TO PREVENT DRAWING GAS FUMES (WHICH COULD CONTAIN HAZARDOUS CARBON MONOXIDE) INTO THE HOME THAT COULD RESULT IN PERSONAL INJURY OR DEATH. ! WARNING ALWAYS INSTALL THE FURNACE TO OPERATE WITHIN THE FURNACE’S INTENDED TEMPERATURE-RISE RANGE WITH A DUCT SYSTEM WHICH HAS AN EXTERNAL STATIC PRESSURE WITHIN THE ALLOWABLE RANGE, AS SPECIFIED IN THE DUCTING SECTION OF THESE INSTRUCTIONS.
LOCATION REQUIREMENTS GENERAL INFORMATION ! WARNING WHEN THIS FURNACE IS INSTALLED IN A RESIDENTIAL GARAGE, IT MUST BE INSTALLED SO THE BURNERS AND IGNITION SOURCE ARE LOCATED NO LESS THAN 18 INCHES [450MM] ABOVE THE FLOOR. THIS IS TO PREVENT THE RISK OF IGNITING FLAMMABLE VAPORS WHICH MAY BE PRESENT IN A GARAGE. ALSO, THE FURNACE MUST BE LOCATED OR PROTECTED TO AVOID PHYSICAL DAMAGE BY VEHICLES.
265/8 GAS CONNECTION 26 /16 13 ELECTRIC CONNECTION LOW VOLTAGE C 63/16 203/8 S.A. 233/8 E BOTTOM Location AIRFLOW SIGHT GLASS /8 5 193/4 3 5 2311/32 241/2 15 R.A. 2311/32 241/2 12 B 13 /8 19 /32 21 10(B) A 121/8 1611/32 171/2 10(A) 27 16 /32 17 /2 07 /4 /8 155/8 155/8 7 12 /8 11 1 103/8 1227/32 1 14 05 C B A Model NOTE: IN DOWNFLOW CONFIGURATION, OPTIONAL AIR CUTOUT IS NOT PERMITTED.
DUCTING Proper air flow is required for the correct operation of this furnace. Restricted air flow can cause erratic operation and can damage the heat exchanger. The duct system must carry the correct amount of air for heating and cooling if summer air conditioning is used. ! WARNING SOME HEATING AIRFLOW VALUES MAY BE HIGHER THAN THOSE REQUIRED FOR COOLING. BE SURE TO SIZE DUCT FOR THE MAXIMUM POSSIBLE AIRFLOW VALUE. SIZE AIRFLOW DISTRIBUTION SYSTEM TO ACCEPTABLE INDUSTRY STANDARDS AND METHODS.
DUCTING TABLE 1 NON-COMBUSTIBLE FLOOR BASES Floor Base No. Size Cabinet RXGC-B14 14 RXGC-B17 17 RXGC-B21 21 RXGC-B24 24 FIGURE 5 NON-COMBUSTIBLE FLOOR BASE INSTALLATION INSTRUCTIONS COMBUSTIBLE COMBUSTIBLE FLOOR FLOOR MATERIAL MATERIAL NON-COMBUSTIBLE NON-COM FLOOR BASE FLOOR BASE A 21 5/8" FLOOR FLOOR CUTOUT CUTOUT DIMENSIONS DIMENSIONS 21 5/8" FLOOR BASE NO. CABINET WIDTH FLOOR CUTOUT DIMENSION “A” RXGC-B14 14.0” 13.4” RXGC-B17 17.5” 17.0” RXGC-B21 21.0” 20.0” RXGC-B24 24.
Combustion Air COMBUSTION AND VENTILATION AIR COMBUSTION AIR REQUIREMENTS IMPORTANT: This is not a direct vent furnace. Review venting instructions before installing. ! WARNING THIS FURNACE AND ANY OTHER FUEL-BURNING APPLIANCE MUST BE PROVIDED WITH ENOUGH FRESH AIR FOR PROPER COMBUSTION AND VENTILATION OF THE FLUE GASES. MOST HOMES WILL REQUIRE THAT OUTSIDE AIR BE SUPPLIED INTO THE FURNACE AREA. FAILURE TO DO SO CAN CAUSE DEATH FROM CARBON MONOXIDE POISONING.
COMBUSTION AND VENTILATION AIR (cont.) FURNACE LOCATED IN A CONFINED SPACE ! WARNING ALL FURNACE INSTALLATIONS MUST COMPLY WITH THE NATIONAL FUEL GAS CODE, NFPA 54 AND LOCAL CODES TO PROVIDE ADEQUATE COMBUSTION AND VENTILATION AIR FOR THE FURNACE. FAILURE TO DO SO CAN RESULT IN EXPLOSION, FIRE, PROPERTY DAMAGE, CARBON MONOXIDE POISONING, PERSONAL INJURY OR DEATH. For improved indoor air quality, added safety and product performance we recommend direct vent type installations.
Combustion Air COMBUSTION AND VENTILATION AIR (cont.) COMBUSTION AIR REQUIREMENTS: CONFINED AND UNCONFINED SPACES TABLE 4: 9: MINIMUM FREE AREA AREA REQUIRED REQUIRED TABLE MINIMUM FREE FOR EACH EACH OPENING OPENING (WHEN (WHEN TWO TWOOPENINGS OPENINGS FOR ARE USED) USED) WITH ARE WITH A A FURNACE: FURNACE: 1. LOCATED IN A CONFINED SPACE 2. USING OUTDOOR OUTDOOR AIR 2. USING AIR FOR FOR COMBUSTION COMBUSTION 3. COMMUNICATING DIRECTLY 3. COMMUNICATING DIRECTLY TO TO THE THE 3.
COMBUSTION AND VENTILATION AIR (cont.) FIGURE 7 VENT PENETRATIONS FOR NON DIRECT VENT FURNACES AIR FROM ATTIC/CRAWL SPACE NON-DIRECT VENT AIR FROM ATTIC OR CRAWL SPACE 1 SQ. INCH PER 4000 BTUH OUTLET AIR GAS WATER HEATER FURNACE GABLE VENT VENT PENETRATIONS FOR NON DIRECT VENT FURNACES AIR FROM ATTIC/CRAWL SPACE NON-DIRECT VENT OUTSIDE AIR USING A HORIZONTAL DUCT VENTILATED ATTIC GABLE OR SOFFIT VENTS OPTIONAL 1 SQ.
Combustion Air COMBUSTION AND VENTILATION AIR (cont.) VENTING GENERAL INFORMATION IMPORTANT APPLICATION NOTES The furnace must be vented in accordance with these instructions, National Fuel Gas Code, ANSI Z223.1 and requirements or codes of the local utility or other authority having jurisdiction.
COMBUSTION AND VENTILATION AIR (cont.) Single appliance venting of a fan assisted furnace into a tile-lined masonry chimney is prohibited. The chimney must be lined with either Type B vent or with a listed, single wall system. Reference National Fuel Gas Code, ANSI Z223.1. See Figure 11 for typical B-1 vent chase. ! WARNING DO NOT CONNECT THIS FURNACE TO A CHIMNEY USED TO VENT A SOLID FUEL APPLIANCE (WOOD OR COAL).
Combustion Air COMBUSTION AND VENTILATION AIR (cont.) POWER VENT SYSTEMS When vertical venting is not possible, the only acceptable method for horizontal venting is with the use of Tjernlund model GPAK1TR or Field Controls models SWG-4R power venter. Type B vent pipe and fittings must be used. Common venting is not permitted All application and installation instructions supplied with the power venter must be followed.
GAS SUPPLY GAS SUPPLY AND PIPING NATURAL GAS AND PROPANE (LIQUEFIED PETROLEUM GAS / LPG) SAFETY IMPORTANT SAFETY INFORMATION GAS SUPPLY • FURNACES USING PROPANE GAS ARE DIFFERENT FROM NATURAL GAS MODELS. A NATURAL GAS HEATER WILL NOT FUNCTION SAFELY ON PROPANE AND VICE VERSA. CONVERSIONS OF HEATER GAS TYPE SHOULD ONLY BE MADE BY QUALIFIED INSTALLERS USING FACTORY SUPPLIED COMPONENTS. THE FURNACE SHOULD ONLY USE THE FUEL TYPE IN ACCORDANCE WITH LISTING ON RATING PLATE.
GAS SUPPLY GAS PIPING Gas Supply ! WARNING THIS FURNACE IS EQUIPPED AT THE FACTORY FOR USE ON NATURAL GAS ONLY. CONVERSION TO LP GAS REQUIRES A SPECIAL KIT IS AVAILABLE AT THE DISTRIBUTOR. FAILURE TO USE THE PROPER CONVERSION KIT CAN CAUSE FIRE, CARBON MONOXIDE POISONING, EXPLOSION, PROPERTY DAMAGE, PERSONAL INJURY OR DEATH. SEE THE CONVERSION KIT INDEX SUPPLIED WITH THE FURNACE. THIS INDEX IDENTIFIES THE PROPER LP GAS CONVERSION KIT REQUIRED FOR EACH PARTICULAR FURNACE.
GAS SUPPLY (cont.) GAS PRESSURE FIGURE 13 TYPICAL GAS VALVE (HONEYWELL) REGULATOR CAP Gas Supply IMPORTANT: ENSURE that the furnace gas valve is not to be subjected to high gas line supply pressures. DISCONNECT the furnace and its individual manual gas stop from the gas supply piping during any pressure testing that exceeds 1/2 PSIG. (3.48 kPa). Natural gas supply pressure must be 5" to 10.5" w.c. LP gas supply pressure must be 11" to 13" w.c.
GAS SUPPLY (cont.) GAS PRESSURE SETTING GAS PRESSURE The maximum gas supply pressure to the furnace must not exceed 10.5" w.c. natural gas, or 13" w.c. LP gas. The minimum supply gas pressure to the gas valve should be 5⬙ w.c. natural gas or 11⬙ w.c. LP gas. A properly calibrated manometer is required for accurate gas pressure measurements. SUPPLY GAS PRESSURE MEASUREMENT Gas Supply An inlet pressure tap is on the input side of the gas valve. 1.
ELECTRICAL WIRING ELECTRICAL WIRING ! WARNING FIGURE 14 TURN OFF ELECTRIC POWER AT FUSE BOX OR SERVICE PANEL BEFORE MAKING ANY ELECTRICAL CONNECTIONS. FAILURE TO DO SO CAN CAUSE ELECTRICAL SHOCK RESULTING IN PERSONAL INJURY OR DEATH. ! WARNING THE CABINET MUST HAVE AN UNINTERRUPTED GROUND ACCORDING TO THE LATEST EDITION OF THE NATIONAL ELECTRICAL CODE, ANSI/NFPA70 OR LOCAL CODES THAT APPLY. DO NOT USE GAS PIPING AS AN ELECTRICAL GROUND. A GROUND SCREW IS PROVIDED IN THE JUNCTION BOX.
ELECTRICAL WIRING REVERSING ELECTRICAL CONNECTION & THERMOSTAT THERMOSTAT The room thermostat must be compatible with the furnace. See manufacturer’s thermostat spec sheet for compatability concerns. Generally, all thermostats that are not of the “current robbing” type are compatible with the integrated furnace control. The low voltage wiring should be sized as shown. NOTE: Do not use 24 volt control wiring smaller than No. 18 AWG.
LP CONVERSION NOTE: The valve can be converted to use liquified petroleum (LP) gas by replacing the pressure regulator spring with the conversion kit spring. This LP kit spring allows the regulator to maintain the proper manifold pressure for LP gas. See Figure 18. 4. Turn the gas supply back on and check for proper operation and manifold pressure. 5. Attach the notice label alerting the next service technician that the furnace has been converted to LP gas.
ACCESSORIES FIELD INSTALLED OPTION ACCESSORIES ELECTRONIC AIR CLEANER FILTERS (See Figure 20) Line voltage power can be supplied from the terminal labeled “EAC” and a line voltage neutral terminal on the control board. This will power the electronic air cleaner whenever the circulating air blower is in operation. Keep filters clean at all times. A filter is not provided with the furnace, but one must be field-supplied and installed.
TWINNING FURNACE TWINNING INSTALLATIONS IMPORTANT: Only twin furnaces with identical control boards. IMPORTANT: Only bottom returns can be used. No more than two furnaces can share the same supply and return. Furnaces must have same heating and blower capacity. Twinning furnaces must operate off the same phase of power. It should be noted that both blowers will run simultaneously when there is a call for heating, cooling or fan.
TWINNING Twinning CONTROL BOARDS THERMOSTAT R 28 UT ELECTRONIC CONTROLS 1194-200 CONTROL BOARD, TWINNING CONNECTION – SINGLE STAGE OPERATION G W COOLING CONTACTOR FIGURE 21 Y NOTE: A FAULT CODE 20 WILL FLASH TO INDICATE A TWINNING PROBLEM. CONFIRM PROPER WIRING IF THIS FAULT IS PRESENT.
COOLING CONTACTOR UT ELECTRONIC CONTROLS 1194-200 CONTROL BOARD, TWINNING CONNECTION – TWO STAGE OPERATION THERMOSTAT R Y G ST-A1194-25 2-STAGE W1 Twinning FIGURE 22 TWINNING CONTROL BOARDS (cont.
HIGH ALTITUDE NATURAL GAS AT HIGH ALTITUDES ! WARNING INSTALLATION OF THIS FURNACE AT ALTITUDES ABOVE 2000 FT (610 m) SHALL BE IN ACCORDANCE WITH LOCAL CODES, OR IN THE ABSENCE OF LOCAL CODES, THE NATIONAL FUEL GAS CODE, ANSI Z223.1/NFPA 54. High Altitude ! CAUTION ELEVATIONS ABOVE 2000 FT. REQUIRE THAT THE FURNACE INPUT RATING BE ADJUSTED AND THAT THE SIZE OF THE BURNER ORIFICES BE RE-CALCULATED BASED ON ELEVATION AND GAS HEATING VALUE. THE BURNER ORIFICES MAY (OR MAY NOT) NEED TO BE CHANGED.
HIGH ALTITUDE NATURAL GAS AT HIGH ALTITUDES (cont.) TABLE 9 SUPPLEMENTAL ORIFICE SIZE CHART NATURAL GAS ORIFICE SELECTION BASED ON HEATING VALUE & ELEVATION* Notes: 1. All (-)80+ units are factory equiped with orifices sized for 1050 sea level heating value gas. 2. Local utilities adjust the sea level heating value of gasses used at higher elevations to compensate for appliance operation at altitude. Installer must be aware of the local heating value (sea level standard) to use the chart below.
HIGH ALTITUDE LP GAS AT HIGH ALTITUDES LP GAS (TABLE 10) NOTE: Keep any parts removed during LP conversion procedure stored with the product literature for future use. LP Gas is a manufactured gas that has consistent heating value across most regions. based on an 11" of water column pressure at the orifice, which differs from products that use 10" of water column at the orifice. This difference requires a deviation from the NFGC orifice size recommendations.
START-UP PROCEDURES SEQUENCE OF OPERATIONS This furnace is equipped with a direct ignition control. Each time the room thermostat calls for heat, the ignitor lights the main burners directly. See the lighting instructions on the furnace. TO START THE FURNACE TO SHUT DOWN THE FURNACE 1. Set the room thermostat to its lowest setting and wait for furnace to shut down. 2. Remove the burner compartment control access door. 3.
FAULT CODES FAULT CODES DIAGNOSTICS AND FAULT CODES All furnace controls come standard with a 7-segment diagnostic display. During standby mode with no fault codes present, the display will read “0” (zero).
1-STAGE LOCKOUT LOCKOUT All lockout conditions can be cleared immediately provided that the original fault causing the lockout is cleared and power to the unit is cycled off and then back on again or (soft lockout only) if a heat call is cycled off for greater than 2 seconds but less than 20 seconds. The furnace control will not initiate a heat cycle during any lockout condition.
Field Selections FIELD SELECTIONS & ADJUSTMENTS FIELD SELECTIONS –– DIPSWITCHES A dipswitch bank; SW1 is provided for some field adjustments. Heating blower off delay, cooling (and heat-pump) blower off delay, display (7-Segment) orientation and fault clear are the adjustments and functions that can be handled using the dipswitches. Seven-Segment Display Orientation; SW1 As the control will be applied in a multi-position furnace a means of changing the orientation of the seven segment display is required.
TIMING DIAGRAM, FIELD SELECTIONS & ADJUSTMENTS MANUAL FAULT CLEAR; SW4 Faults will automatically be cleared from the fault buffer after one week. The fault buffer can also be manually cleared if this is desired. For the first 30 seconds after a change in state of dipswitch SW4, the furnace control will wait to determine if the switch becomes on/off/on/off/on/off or off/on/off/on/off/on within 30 seconds. When this action is detected within 30 seconds, the fault code memory buffer shall be cleared.
Field Selections TIMING DIAGRAM, FIELD SELECTIONS & ADJUSTMENTS TABLE 11 TIMING DIAGRAM OFF OFF ON OFF OFF CLOSED OPEN OPEN ON OFF OFF OFF ON OFF OFF ON OFF OFF ON OFF OFF ON OFF OFF ON OFF ST-A1194-27-X0 ADJUSTING OR CHECKING FURNACE INPUT The maximum gas supply pressure to the furnace should be 10.5" w.c. for natural gas and 13.0" w.c. for L.P. The minimum gas supply pressure for purposes of input adjustment to the furnace should be 5" w.c. for natural gas and 11.0" w.c. for L.P.
TIMING DIAGRAM, FIELD SELECTIONS & ADJUSTMENTS Field Selections TABLE 12 METER TIME (%!%)&!*(%&*+&(*+/!%,&"+0&,%-.+0,&1.)&+.)("$&*+2/!&)"!*+3&.1&1/)+"-%,&%4/*22%0&1.)&+"!/)"$& 3",&.)&$525 *+2/!& >#!/?<)A 678777 968777 :778777 :;68777 :678777 (%!%)&,*B%& C77 >1!@?)%=A (*+ .+% !%+ .+% !%+ .+% !%+ .+% !%+ .+% !%+ ! !& & ) & " & ' & % :777 ,%- (*+ <%"!*+3&="$/%&.
AIRFLOW The importance of proper air flow over the heat exchanger cannot be over emphasized. Airflow ! CAUTION FIGURE 24 TEMPERATURE RISE MEASUREMENT IT IS IMPORTANT THAT EACH DUCT SYSTEM BE SIZED AND INSTALLED FOR THE SPECIFIC APPLICATION BY PROPERLY APPLYING THE APPROPRIATE INDUSTRY ACCEPTED STANDARD.
TABLE 13 AIR FLOW PERFORMANCE – (-)801S & (-)801P & (-)(-)80DSS/(-)(-)80DSP SERIES MODELS Model Motor HP [W] Blower Size IN [MM] 1/2 [373] 11 x 6 [279 x 152] (-)801SA075317ZSA (-)801PA075317ZSA (-)(-)80DSS075B30SA (-)(-)80DSP075B30SA 1/2 [373] 11 x 7 [279 x 178] (-)801SA075417ZSA (-)801PA075417ZSA (-)(-)80DSS075B40SA (-)(-)80DSP075B40SA 3/4 [559] 11 x 7 [279 x 178] (-)801SA100317ZSA (-)801PA100317ZSA (-)(-)80DSS100B30SA (-)(-)80DSP100B30SA 1/2 [373] 11 x 7 [279 x 178] (-)801SA100521ZSA (-)801PA1005
SAFETY FEATURES LIMIT CONTROL/HALC PRESSURE SWITCH The high limit cut-off temperature is set at the factory and cannot be adjusted. The temperature setting prevents the air temperature leaving the furnace from exceeding the maximum outlet air temperature, which, if exceeded, will shut the furnace down. This furnace is equipped with a normally-open pressure switch that monitors pressure conditions within the furnace vent system during the heating cycle.
MAINTENANCE GAS FURNACE (DIRECT DRIVE) INSTRUCTIONS MAINTENANCE ! WARNING THESE INSTRUCTIONS ARE INTENDED AS AN AID TO QUALIFIED SERVICE PERSONNEL FOR PROPER INSTALLATION, ADJUSTMENT AND OPERATION OF THIS UNIT. READ THESE INSTRUCTIONS THOROUGHLY BEFORE ATTEMPTING INSTALLATION OR OPERATION.
MAINTENANCE LUBRICATION FIGURE 26 Maintenance DOWNFLOW BLOWER REMOVAL SYSTEM OPERATION INFORMATION ADVISE THE CUSTOMER 1. Keep the air filters clean. The heating system will operate better, more efficiently and more economically. 2. Arrange the furniture and drapes so that the supply air registers and the return air grilles are unobstructed. 3. Close doors and windows. This will reduce the heating load on the system. 4. Avoid excessive use of kitchen exhaust fans. 5.
MAINTENANCE ANNUAL INSPECTION • The furnace should operate for many years without excessive scale build-up in the flue passageways. However, it is recommended that a qualified installer, service agency, or the gas supplier annually inspect the flue passageways, the vent system and the main burners for continued safe operation. Pay particular attention to deterioration from corrosion or other sources.
FIGURE 27 DIAGNOSTIC FLOWCHART DISCONNECT POWER BEFORE SERVICING. SERVICE MUST BE BY A TRAINED, QUALIFIED SERVICE TECHNICIAN.
FIGURE 28 FOR MODELS WITH UT ELECTRONIC CONTROLS 1028-928 INTEGRATED FURNACE CONTROL AND DIRECT SPARK IGNITION Wiring Diagrams 47
CM 0814
