NFPA | The National Fire Protection Association
Oxbox | Affordable quality heating and cooling systems
Instruction Manual for OXBOX models including: J962V D Two Stage Condensing Gas Furnaces With Variable Speed Blower, J962V D, Two Stage Condensing Gas Furnaces With Variable Speed Blower, Furnaces With Variable Speed Blower, Variable Speed Blower, Speed Blower
Oxbox | Resources
File Info : application/pdf, 36 Pages, 4.31MB
DocumentDocumentTwo-Stage Condensing Gas Furnaces With Variable Speed Blower INSTALLATION INSTRUCTIONS 96.0% AFUE J962V*D Downflow Furnace WARNING FIRE OR EXPLOSION HAZARD · Failure to follow safety warnings exactly could result in serious injury, death or property damage. · Installation and service must be performed by a qualified installer, service agency or the gas supplier. · Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance. WHAT TO DO IF YOU SMELL GAS · Do not try to light any appliance. · Do not touch any electrical switch; do not use any phone in your building. · Leave the building immediately. · Immediately call your gas supplier from a neighbors phone. Follow the gas suppliers instructions. · If you cannot reach your gas supplier, call the fire department. DO NOT DESTROY. PLEASE READ CAREFULLY & KEEP IN A SAFE PLACE FOR FUTURE REFERENCE. TABLE OF CONTENTS IMPORTANT SAFETY INFORMATION..............................3 REQUIREMENTS & CODES ..............................................4 Combustion Air Quality ....................................................5 Heating Load....................................................................5 Installation in a Garage ....................................................5 Clearances to Combustible Materials ..............................6 Operation of Furnace During Construction ......................6 COMBUSTION AIR & VENTING REQUIREMENTS ..........7 Direct Vent Systems ........................................................8 Conventional Vent Systems - Confined Spaces ..............8 Air From Inside..............................................................8 Outdoor Air from a Crawl Space or Vented Attic...........8 Outdoor Air Using Vertical Ducts ..................................8 Outdoor Air Using Horizontal Ducts ..............................9 Air Directly Through an Exterior Wall ............................9 Alternate Method of Providing Air from Outside:...........10 Conventional Vent Systems - Unconfined Spaces ..........10 Category IV Venting.........................................................10 Vent Pipe Material.........................................................10 Vent Pipe Length & Diameter........................................10 Vent Pipe Installation ....................................................11 Outdoor Terminations - Horizontal Venting...................11 Outdoor Terminations - Vertical Venting .......................12 Vent Freezing Protection...............................................13 Existing Installations......................................................13 Condensate Disposal.......................................................13 CIRCULATING AIR REQUIREMENTS...............................13 Plenums & Air Ducts ........................................................13 Return Air Connections....................................................14 Supply Air Connections....................................................14 Acoustical Treatments .....................................................14 FURNACE INSTALLATION................................................14 General Requirements.....................................................14 Installation on a concrete slab.......................................15 Inducer & Venting Options ...............................................15 Inducer Assembly Rotation ...........................................15 Pressure Switch Tubing ................................................16 Accessories......................................................................16 Finish Flange.................................................................16 Rubber Grommets.........................................................16 PVC Components .........................................................16 Typical Orientation .................................................17 Alternate Orientation ..............................................17 Condensate Drain Lines................................................17 GAS SUPPLY & PIPING.....................................................17 Leak Check ......................................................................18 High Altitude Application (Natural Gas Only) ...................19 Converting from Natural Gas to LP / Propane .................19 ELECTRICAL WIRING .......................................................20 Line Voltage Wiring..........................................................20 Grounding ........................................................................21 Thermostat / Low Voltage Connections ...........................21 Single Stage AC & Single Stage Thermostat................21 Single Stage AC & Two Stage Thermostat ...................21 Two-Stage AC & Two-Stage Thermostat......................21 Autostaging for Single Stage Thermostats ......................21 Autostaging for Two-Stage Thermostats .........................22 Blower Speed Configuration ............................................22 Fixed Speed Blower Applications..................................22 Dehumidification Options .................................................22 Heat Anticipator ...............................................................22 START-UP & ADJUSTMENTS...........................................22 Pre-Start Check List.........................................................22 Start-up Procedures.........................................................23 Verifying & Adjusting Input Rate ......................................23 Verifying & Adjusting Temperature Rise ..........................24 Verifying Burner Operation ..............................................24 OPERATING SEQUENCE ..................................................24 Heating Cycle...................................................................24 Cooling Cycle...................................................................24 Fan Mode.........................................................................25 MAINTENANCE ..................................................................25 FIGURES & TABLES..........................................................26 Figure 23. J962V*D Cabinet Dimensions......................26 Gas Information ...............................................................27 Table 6. Gas Flow Rates...............................................27 Table 7. Gas Pipe Capacities........................................27 Table 8. High Altitude Deration - Propane Gas.............28 Table 9. Natural Gas Heating Values............................28 Table 10. High Altitude Deration - Natural Gas with HIGH Heating Value......................................29 Table 11. High Altitude Deration - Natural Gas with LOW Heating Value ......................................29 Electrical Information .......................................................30 Figure 24. Two-Stage Fixed Speed Motor Control Board ...........................................................30 Figure 25. Two-Stage Furnace Control Board ..............30 Figure 26. Wiring Diagram for Two-Stage, Fixed Speed Downflow Furnaces ..........................31 Venting Information..........................................................32 Table 12. Vent Termination Clearances........................32 Figure 27. J962V*D Inducer & Venting Options............33 Figure 28. Horizontal & Vertical Venting .......................34 Figure 29. J962V*D Component Locations...................34 TROUBLESHOOTING ........................................................35 Table 13. Furnace Control Board Fault Conditions.......35 Table 14. Motor Control Board Fault Conditions...........35 FURNACE COMPONENTS ................................................35 INSTALLATION CHECKLIST.............................................36 2 IMPORTANT SAFETY INFORMATION INSTALLER: Please read all instructions before servicing this equipment. Pay attention to all safety warnings and any other special notes highlighted in the manual. Safety markings are used frequently throughout this manual to designate a degree or level of seriousness and should not be ignored. WARNING - indicates a potentially hazardous situation that if not avoided, could result in personal injury or death. CAUTION - indicates a potentially hazardous situation that if not avoided, may result in minor or moderate injury or property damage. WARNING: The safety information listed in this manual must be followed during the installation, service, and operation of this unit. Unqualified individuals should not attempt to interpret these instructions or install this equipment. Failure to follow safety recommendations could result in possible damage to the equipment, serious personal injury or death. WARNING: Unless otherwise noted in these instructions, only factory authorized kits or accessories may be used with or when modifying this product. WARNING: Improper installation, service, adjustment, or maintenance may cause explosion, fire, electrical shock or other hazardous conditions which may result in personal injury or property damage. Unless otherwise noted in these instructions, only factory authorized kits or accessories may be used with this product. WARNING: Do not install this furnace if any part has been submerged under water. A flood damaged furnace is extremely dangerous. Attempts to use the furnace may result in fire or explosion. A qualified service agency should be contacted to inspect the furnace and to replace any electrical or control system parts that have been wet or under water. · To minimize equipment failure or personal injury, it is essential that only qualified individuals install, service, or maintain this equipment. If you do not posses mechanical skills or tools, call your local dealer for assistance. · Follow all precautions in the literature, on tags, and on labels provided with the equipment. Read and thoroughly understand the instructions provided with the equipment prior to performing the installation and operational checkout of the equipment. · Use caution when handling this appliance or removing components. Personal injury can occur from sharp metal edges present in all sheet metal constructed equipment. · Do not store any of the following on, or in contact with, the unit: Rags, brooms, vacuum cleaners, or other cleaning tools, spray or aerosol cans, soap powders, bleaches, waxes, cleaning compounds, plastics or plastic containers, paper bags or other paper products, gasoline, kerosene, cigarette lighter fluid, dry cleaning fluids, paint thinners, or other volatile fluids. · The installer should become familiar with the units wiring diagram before making any electrical connections to the unit. See Figure 26 (page 31) or the unit wiring label. · Always reinstall the doors on the furnace after servicing. Do not operate the furnace without all doors and covers in place. 3 REQUIREMENTS & CODES WARNING: The safety information listed below must be followed during the installation, service, and operation of this furnace. Failure to follow safety recommendations could result in possible damage to the equipment, serious personal injury or death. · This furnace must be installed in accordance with these instructions, all applicable local building codes and the current revision of the National Fuel Gas Code (NFPA54/ANSI Z223.1) or the Natural Gas and Propane Installation Code, CAN/CGA B149.1. · Use only with type of gas approved for this furnace. Refer to the furnace rating plate. · Install this furnace only in a location and position as specified on page 6. · Provide adequate combustion and ventilation air to the furnace space as specified on page 7, page 8, page 9, & page 10. · Provide adequate clearances around the vent air intake terminal as specified in Figure 7 (page 12), Figure 8 (page 12), Figure 9 (page 12), & Figure 10 (page 12). · Combustion products must be discharged outdoors. Connect this furnace to an approved vent system only, as specified on page 10, page 11, page 11, & page 12. · Never test for gas leaks with an open flame. Use a commercially available soap solution to check all connections. See page 18. · This furnace is designed to operate with a maximum external pressure rise of 0.5 inches of water column. Consult the rating plate for the proper circulating air flow and temperature rise. It is important that the duct system be designed to provide the correct flow rates and external pressure rise. An improperly designed duct system can result in nuisance shutdowns, and comfort or noise issues. · When supply ducts carry air circulated by the furnace to areas outside the space containing the furnace, the return air shall also be handled by duct(s) sealed to the furnace casing and terminating in the conditioned space. See page 13. · A gas-fired furnace for installation in a residential garage must be installed as specified on page 5. · This furnace may not be used for temporary heating of buildings or structures under construction. See the disclaimer listed on page 6. · This furnace is not approved for installation in mobile homes. Installing this furnace in a mobile home could cause fire, property damage, and/or personal injury. · The Commonwealth of Massachusetts requires compliance with regulation 248 CMR 4.00 and 5.00 for installation of through the wall vented gas appliances as follows: 1. For direct-vent appliances, mechanical-vent heating appliances or domestic hot water equipment, where the bottom of the vent terminal and the air intake is installed below four feet above grade the following requirements must be satisfied: a.) A carbon monoxide (CO) detector and alarm shall be placed on each floor level where there are bedrooms. The detector shall comply with NFPA 720 (2005 Edition) and be mounted in the living area outside the bedroom(s). b.) A (CO) detector shall be located in the room that houses the appliance or equipment and shall: · Be powered by the same electrical circuit as the appliance or equipment. Only one service switch shall power the appliance and the (CO) detector; · Have battery back-up power; · Meet ANSI/UL 2034 Standards and comply with NFPA 720 (2005 Edition); and Approved and listed by a Nationally Recognized Testing Laboratory as recognized under 527 CMR. c.) A Product-approved vent terminal must be used, and if applicable, a product-approved air intake must be used. Installation shall be in strict compliance with the manufacturer's instructions. A copy of the installation instructions shall remain with the appliance or equipment at the completion of the installation. d.) A metal or plastic identification plate shall be mounted at the exterior of the building, four feet directly above the location of vent terminal. The plate shall be of sufficient size, easily read from a distance of eight feet away, and read "Gas Vent Directly Below". 2. For direct-vent appliances, mechanical-vent heating appliances or domestic hot water equipment where the bottom of the vent terminal and the air intake is installed above four feet above grade the following requirements must be satisfied: a.) A (CO) detector and alarm shall be placed on each floor level where there are bedrooms. The detector shall comply with NFPA 720 (2005 Edition) and be mounted in the living area outside the bedroom(s). b.) The (CO) detector shall: · Be located in the room that houses the appliance or equipment; · Be hard-wired or battery powered or both. · Shall comply with NFPA 720 (2005 Edition). c.) A product-approved vent terminal must be used, and if applicable, a product-approved air intake must be used. Installation shall be in strict compliance with the manufacturer's instructions. A copy of the installation instructions shall remain with the appliance or equipment at the completion of the installation. 4 The information listed below is for reference purposes only and does not necessarily have jurisdiction over local or state codes. Always consult with local authorities before installing any gas appliance. Combustion & Ventilation Air · US: National Fuel Gas Code (NFGC), Air for Combustion and Ventilation · CANADA: Natural Gas and Propane Installation Codes (NSCNGPIC), Venting Systems and Air Supply for Appliances Duct Systems · US and CANADA: Air Conditioning Contractors Association (ACCA) Manual D, Sheet Metal and Air Conditioning Contractors National Association (SMACNA), or American Society of Heating, Refrigeration, and Air Conditioning Engineers (ASHRAE) Fundamentals Handbook Electrical Connections · US: National Electrical Code (NEC) ANSI/NFPA 70 · CANADA: Canadian Electrical Code CSA C22.1 Gas Piping & Gas Pipe Pressure Testing · US: NFGC and National Plumbing Codes · CANADA: NSCNGPIC General Installation · US: Current edition of the NFGC and the NFPA 90B. For copies, contact the National Fire Protection Association Inc., Batterymarch Park, Quincy, MA 02269; or American Gas Association, 400 N. Capitol, N.W., Washington DC 20001 or www.NFPA.org · CANADA: NSCNGPIC. For a copy, contact Standard Sales, CSA International, 178 Rexdale Boulevard, Etobicoke (Toronto), Ontario, M9W 1R3 Canada Safety · US: (NFGC) NFPA 541999/ANSI Z223.1 and the Installation Standards, Warm Air Heating and Air Conditioning Systems ANSI/NFPA 90B. · CANADA: CAN/CGA-B149.1 and .2M00 National Standard of Canada. (NSCNGPIC) Combustion Air Quality CAUTION: Combustion air must not be drawn from a corrosive atmosphere. To maximize heat exchanger life, the combustion air must be free of chemicals that can form corrosive acidic compounds in the combustion gases. The recommended source of combustion air is to use outdoor air. However, the use of indoor air in most applications is acceptable except as listed: · If the furnace is installed in a confined space, it is required that the necessary combustion air come from the outdoors by way of attic, crawl space, air duct, or direct opening. For Installations in confined spaces, see page 8 for combustion air requirements. · Installations in these locations may require outdoor air for combustion, due to chemical exposures: Commercial buildings Buildings with indoor pools Furnaces installed in laundry rooms Furnaces installed in hobby or craft rooms Furnaces installed near chemical storage areas · Exposure to the following substances in the combustion air supply may require outdoor air for combustion: Permanent wave solutions Chlorinated waxes and cleaners Chlorine based swimming pool chemicals Water softening chemicals De-icing salts or chemicals Carbon Tetrachloride Halogen type refrigerants Cleaning solvents (perchloroethylene) Printing inks, paint removers, varnishes, etc. Hydrochloric Acid Cements and glues Antistatic fabric softeners Masonry acid washing materials Heating Load This furnace should be sized to provide the design heating load requirement. Heating load estimates can be made using approved methods available from Air Conditioning Contractors of America (Manual J); American Society of Heating, Refrigerating, and Air Conditioning Engineers; or other approved engineering methods. Excessive oversizing of the furnace could cause the furnace and/or vent to fail prematurely. The ductwork should be appropriately sized to the capacity of the furnace to ensure its proper airflow rating. For installations above 2,000 ft., the furnace should have a sea level input rating large enough that it will meet the heating load after deration for altitude. Two-stage furnaces operate at two input rates to better meet heating loads. The lower heating rate (low fire) is 65% of the high fire rate. The greatest degree of control over the furnace can be gained by controlling it with a two stage thermostat. This allows the thermostat to directly request either high or low fire. However, it is possible to operate the furnace using a single stage thermostat. In this application the furnace control can be set to increase from low to high fire, based on a timer. See Autostaging for Single Stage Thermostats (page 21). Furnaces are properly sized to meet the expected maximum heating load. But this load occurs infrequently. So, during more moderate weather, the furnace is likely to use low fire a considerable part of the time. This is normal and has the benefit of quieter and more efficient operation. Installation in a Garage This Gas-fired furnace may be installed in a residential garage with the provision that the burners and igniter are located no less than 18 inches (457mm) above the floor. The furnace must be located or protected to prevent physical damage by vehicles. 5 WARNING: Do not place combustible material on or against the furnace cabinet or within 6 inches of the vent pipe. Do not place combustible materials, including gasoline or any other flammable vapors and liquids, in the vicinity of the furnace. Clearances to Combustible Materials This furnace is Design Certified in the U.S. and Canada by CSA International for the minimum clearances to combustible materials. NOTE: The furnace is listed for installation on combustible or non-combustible flooring. However, wood is the only combustible flooring allowed for installation. Downflow models must use the appropriate subase kit when installing over a wood floor. To obtain model number and specific clearance information, refer to the furnace rating plate, located inside of the furnace cabinet. Access for positioning and servicing the unit must be considered when locating unit. The need to provide clearance for access to panels or doors may require clearance distances over and above the requirements. Allow 24 inches minimum clearance from the front of the unit. However 36 inches is strongly recommended. See Figure 1 for minimum clearance requirements. CLEARANCES TO COMBUSTIBLE MATERIALS BACK TOP LEFT SIDE VENT RIGHT SIDE FRONT Left Side ................. 0 Inches Right Side............... 0 Inches Vent ........................ 0 Inches Top .......................... 0 Inches Front ........................4 Inches Back........................ 0 Inches Allow 24 in. minimum clearance for servicing. Recommended clearance is 36 in. Figure 1. Minimum Clearances to Combustible Materials Operation of Furnace During Construction CAUTION: Failure to follow these instructions will void the factory warranty and may significantly reduce the life or the performance of the furnace, and/ or result in other unsafe conditions. It is the responsibility of the installing contractor to insure these provisions are met. Operating gas furnaces in construction environments can cause a variety of problems with the furnace. Proper use of commercial portable space heating equipment during construction is recommended. This gas furnace may be used during construction if it is not in violation of any applicable codes and the following criteria are met: · The installation must meet all applicable codes. The furnace must be permanently installed according to the instructions supplied with the furnace. This includes the electrical supply, gas piping, duct work, and venting. The furnace must be controlled by a room thermostat properly installed according to the instructions supplied with the furnace and thermostat. The installation must include a properly installed air filter in the return air duct, sealed to the furnace with no by-pass air. The filter must be inspected frequently and replaced when necessary. · The furnace input rate and air temperature rise must be checked and verified to be within the acceptable ranges as marked on the furnace nameplate. · Before occupying the structure: The air filter must be replaced or cleaned, the duct work must be inspected and cleaned of any construction debris, and the furnace must be cleaned and/or repaired if found to be dirty, damaged, or malfunctioning in any way by a qualified HVAC technician. The furnace shall be inspected and approved by applicable local authority even if this requires redundant inspections. · Serial numbers for furnaces used during construction must be submitted in writing (fax and email also acceptable). This information will be used to track the long-term affects of the use during construction on furnaces. Proof of this submittal shall be available for the final inspection of the furnace prior to occupancy. · This furnace is designed to operate with return air temperatures in ranges normally found in occupied residences, including setbacks. Minimum continuous return temperature must not be below 60° F (15° C). Occasionally a temporary return temperature of 55° F (12° C) is acceptable. However, operation with a return temperature below 55° F (12° C) is not allowed. · The installing contractor and / or builder must: -- Comply with the requirements of this section. -- Complete the attached Use of Furnace During Construction checklist. -- Email copy of completed Use of Furnace During Construction checklist to warranty@nortek.com -- Leave original completed Use of Furnace During Construction checklist with furnace. -- Disclose use of the furnace during construction to the homeowner in advance of the sale. 6 COMBUSTION AIR & VENTING REQUIREMENTS WARNING: CARBON MONOXIDE POISONING HAZARD Failure to follow the steps outlined below for each appliance connected to the venting system being placed into operation could result in carbon monoxide poisoning or death. The following steps shall be followed with each individual appliance connected to the venting system being placed in operation, while all other appliances connected to the venting system are not in operation: 1.Seal any unused openings in the venting system. 2.Inspect the venting system for proper size and horizontal pitch, as required in the National Fuel Gas Code, ANSI Z223.1/NFPA 54 or the CSA B149.1, Natural Gas and Propane Installation Codes and these instructions. Determine that there is no blockage or restriction, leakage, corrosion and other deficiencies which could cause an unsafe condition. 3.As far as practical, close all building doors and windows and all doors between the space in which the appliance(s) connected to the venting system are located and other spaces of the building. 4.Close fireplace dampers. 5.Turn on clothes dryers and any appliance not connected to the venting system. Turn on any exhaust fans, such as range hoods and bathroom exhausts, so they are operating at maximum speed. Do not operate a summer exhaust fan. 6.Follow the lighting instructions. Place the appliance being inspected into operation. Adjust the thermostat so appliance is operating continuously. 7.Test for spillage from draft hood equipped appliances at the draft hood relief opening after 5 minutes of main burner operation. Use the flame of a match or candle. 8.If improper venting is observed during any of the above tests, the venting system must be corrected in accordance with the National Fuel Gas Code, ANSI Z223.1/NFPA 54 and/or CSA B149.1, Natural Gas and Propane Installation Codes. 9.After it has been determined that each appliance connected to the venting system properly vents when tested as outlined above, return doors, windows, exhaust fans, fireplace dampers and any other gas-fired burning appliance to their previous conditions of use. IMPORTANT INFORMATION: · This furnace must be vented in compliance with the current revision of the National Fuel Gas Code (ANSI-Z223.1/NFPA54). Instructions for determining the adequacy of an installation can be found in the current revision of the NFGC (ANSI Z223.1 / NFPA54). Consult local codes for special requirements. These requirements are for US installations as found in the NFGC. · Furnace installation using methods other than those described in the following sections must comply with the National Fuel Gas Code (NFGC) and all applicable local codes. · Requirements in Canada (B149.1) are structured differently. In Canada, venting shall conform to the requirements of the current (CAN/CGA B149.1) installation codes. Consult local codes for special requirements. · Provisions must be made during the installation of this furnace that provide an adequate supply of air for combustion. The combustion air from the outside needs to be clear of chemicals that can cause corrosion. The inlet pipe should not be placed near corrosive chemicals such as those listed on page 5. WARNING: Upon completion of the furnace installation, carefully inspect the entire flue system both inside and outside the furnace to assure it is properly sealed. Leaks in the flue system can result in serious personal injury or death due to exposure of flue products, including carbon monoxide. WARNING: This furnace must not be vented with other appliances, even if that appliance is of the condensing type. Common venting can result in severe corrosion of other appliances or their venting and can allow combustion gases to escape through such appliances or vents. Do not vent the furnace to a fireplace chimney or building chase. This condensing furnace is certified for installation either as a Direct Vent (2-pipe) or Conventional (1-pipe) appliance. Direct Vent appliances draw combustion air from the outdoors and vent combustion products back outside. Installation with air taken from around the furnace is often referred to as Conventional installation - i.e. only the vent (exhaust) pipe is provided. Another important consideration when selecting one or two pipe installation is the quality of the Indoor air which can sometimes be contaminated with various household chemicals . These chemicals can cause severe corrosion in the furnace combustion system. A 2-pipe installation 7 has the additional advantage that it isolates the system from the effects of negative pressure in the house. CAUTION: Exhaust fans, clothes dryers, fireplaces and other appliances that force air from the house to the outdoors can create a negative pressure inside the house, resulting in improper furnace operation or unsafe conditions such as flame roll out. It is imperative that sufficient air exchange with the outdoors is provided to prevent depressurization. Additional information about testing negative pressure problems can be found in the National Fuel Gas Code. Air From Inside If combustion air is taken from the heated space, the two openings must each have a free area of at least one square inch per 1,000 Btuh of total input of all appliances in the confined space, but not less than 100 square inches of free area. See Example and Figure 2. EXAMPLE If the combined input rate of all appliances is less than or equal to 100,000 Btuh, each opening must have a free area of at least 100 in2. If the combined input rate of all appliances is 120,000 Btuh, each opening must have a free area of at least 120 in2. Air openings on top of the furnace and openings in closet doors or walls must never be restricted. If the furnace is operated without adequate air for combustion, the flame roll-out switch will open, turning off the gas supply to the burners. IMPORTANT NOTE This safety device is a manually reset switch. DO NOT install jumper wires across these switches to defeat their function or reset a switch without identifying and correcting the fault condition. If a switch must be replaced, use only the correct sized part specified in the Replacement Parts List provided online. Direct Vent Systems Direct vent appliances draw combustion air from the outdoors and vent combustion products back outside, isolating the entire system from the indoor space. It is important to make sure that the whole system is sealed and clearances to combustibles are maintained regardless of the installation being in a confined or unconfined space. Conventional Vent Systems - Confined Spaces A confined space is an area with volume less than 50 cubic feet per 1,000 Btuh of the combined input rates of all appliances drawing combustion air from that space. Furnace closets, small equipment rooms and garages are confined spaces. Furnaces installed in a confined space which supply heated air to areas outside the space must draw return air from outside the space and must have the return air ducts tightly sealed to the furnace. Ducts must have cross - sectional area at least as large as the free area of their respective openings to the furnace space. Attics or crawl spaces must connect freely with the outdoors if they are the source of air for combustion and ventilation. The required sizing of these openings is determined by whether inside or outside air is used to support combustion, the method by which the air is brought to the space, and by the total input rate of all appliances in the space. In all cases, the minimum dimension of any combustion air opening is 3 inches. Vent or Chimney NOTES: Each opening must be at least 100 sq. in. or 1 sq. in. per 1,000 Btuh of total input rating, whichever is greater. Openings must start at no more than 12 inches from the top and bottom of the enclosure. Water Heater 12" Max. See Notes Furnace See Notes 12" Max. TOTAL INPUT RATING (BTUH) 38,000 60,000 80,000 100,000 120,000 140,000 160,000 MINIMUM FREE AREA (EACH OPENING) 100 sq. In 100 sq. In 100 sq. In 100 sq. In 120 sq. In 140 sq. In 160 sq. In ROUND DUCT DIAMETER 12 inches 12 inches 12 inches 12 inches 13 inches 14 inches 15 inches Figure 2. Combustion Air Drawn from Inside Outdoor Air from a Crawl Space or Vented Attic When the openings can freely exchange air with the outdoors, each opening shall have a minimum free area of 1 square inch per 4,000 Btuh of total appliance input. The openings shall exchange directly, or by ducts, with the outdoor spaces (crawl or attic) that freely exchange with the outdoors. See Figure 3 (page 9). Outdoor Air Using Vertical Ducts If combustion air is taken from outdoors through vertical ducts, the openings and ducts must have a minimum free area of one square inch per 4,000 Btuh of total appliance input. See Figure 4 (page 9). 8 Vent or Chimney Furnace Alternate Air Inlet Ventilation Louvers (each end of attic) ----- Outlet Air Water Heater Inlet Air NOTE: Air openings shall each have a free area of not less than one square inch per 4,000 Btuh of the total input rating of all equipment in the enclosure. --------- ----- Ventilation Louvers For Unheated Crawl Space Figure 3. Combustion Air Drawn from a Crawl Space or Vented Attic Ventilation Louvers at each end of attic Vent or Chimney Attic Insulation Air Duct must be at least 1 sq. in. per 4,000 Btuh of total input rating. Water Furnace Heater Ducts must extend above attic insulation. Air Duct must be at least 1 sq. in. per 4,000 Btuh of total input rating. TOTAL INPUT RATING (BTUH) 38,000 60,000 80,000 100,000 120,000 140,000 160,000 12" Max MINIMUM FREE AREA (EACH OPENING) 10 sq. In 15 sq. In 20 sq. In 25 sq. In 30 sq. In 35 sq. In 40 sq. In ROUND DUCT DIAMETER 4 inches 5 inches 5 inches 6 inches 6 inches 7 inches 8 inches Figure 4. Combustion Air Drawn from Outside Through Vertical Ducts Outdoor Air Using Horizontal Ducts If combustion air is taken from outdoors through horizontal ducts, the openings and ducts must have a minimum free area of one square inch per 2,000 Btuh of total appliance input. Ducts must have cross - sectional area at least as large as the free area of their respective openings to the furnace space. See Figure 5. Air Directly Through an Exterior Wall If combustion air is provided directly through an exterior wall, the two openings must each have free area of at least one square inch per 4,000 Btuh of total appliance input. See Figure 6. Vent or Chimney Water Heater Air Duct Furnace Air Duct Air Ducts must be at least 1 sq. in. per 2,000 Btuh of total input rating. TOTAL INPUT RATING (BTUH) 38,000 60,000 80,000 100,000 120,000 140,000 160,000 MINIMUM FREE AREA (EACH OPENING) 20 sq. In 30 sq. In 40 sq. In 50 sq. In 60 sq. In 70 sq. In 80 sq. In ROUND DUCT DIAMETER 5 inches 6 inches 7 inches 8 inches 9 inches 10 inches 10 inches Figure 5. Combustion Air Drawn from Outside Through Horizontal Ducts Vent or Chimney See Note ----- 12" Max See Note 12" Max. ----- NOTE: Each opening to outside must be at least 1 sq. in. per 4,000 Btuh of total input rating. Water Heater Furnace TOTAL INPUT RATING (BTUH) 38,000 60,000 80,000 100,000 120,000 140,000 160,000 MINIMUM FREE AREA (EACH OPENING) 10 sq. In 15 sq. In 20 sq. In 25 sq. In 30 sq. In 35 sq. In 40 sq. In ROUND DUCT DIAMETER 4 inches 5 inches 5 inches 6 inches 6 inches 7 inches 8 inches Figure 6. Combustion Air Drawn from Outside Through an Exterior Wall 9 Alternate Method of Providing Air from Outside: If acceptable under local Codes, it is permitted to provide outside air using one opening (See NFGC). Generally, confined spaces must have 2 openings in the space for combustion air. One opening must be within 12 inches of the ceiling, and the other must be within 12 inches of the floor. However, an alternative method recently adopted by the NFGC uses one opening within 12 inches of the top of the space. This method may be used if it is acceptable to the local codes. THE FOLLOWING CONDITIONS MUST BE MET: 1. The opening must start within 12" of the top of the structure and connect with the out of doors through vertical or horizontal ducts or be ducted to a crawl or attic space that connects with the out of doors. 2. The opening must have a minimum free area of 1 in2. per 3,000 Btu per hour of the total input rating of all equipment located in the enclosure. 3. The free area must not be less than the sum of all the areas of the vent connectors in the enclosure. Conventional Vent Systems - Unconfined Spaces An unconfined space is an area including all rooms not separated by doors with a volume greater than 50 cubic feet per 1,000 Btuh of the combined input rates of all appliances which draw combustion air from that space. In general, a furnace installed in an unconfined space will not require outside air for combustion. However, in homes built for energy efficiency (low air change rates), it may be necessary to provide outside air to ensure adequate combustion and venting, even though the furnace is located in an unconfined space. See Example below. EXAMPLE A space with a water heater rated at 45,000 Btuh input and a furnace rated at 75,000 Btuh requires a volume of 6,000 cubic feet [50 x (45 + 75) = 6,000] to be considered unconfined. If the space has an 8 foot ceiling, the floor area of the space must be 750 sq. ft. (6,000 / 8 = 750). Category IV Venting WARNING: Upon completion of the furnace installation, carefully inspect the entire flue system both inside and outside the furnace to assure it is properly sealed. Leaks in the flue system can result in serious personal injury or death due to exposure of flue products, including carbon monoxide. This furnace is classified as a "Category IV" appliance, which requires special venting materials and installation procedures. This section specifies installation requirements for Conventional (1-pipe) and Direct Vent (2-pipe) piping. For 1- pipe installations, install vent piping as described in this section and provide air for combustion and ventilation according to page 7, page 8, page 9, & page 10. The length of vent and combustion air piping for either type of installation are shown in Table 1 (page 11). Category IV appliances operate with positive vent pressure and therefore require vent systems which are thoroughly sealed. They also produce liquid condensate, which is slightly acidic and can cause severe corrosion of ordinary venting materials. Furnace operation can be adversely affected by restrictive vent and combustion air piping. The inducer assembly on this furnace can be rotated to vent the flue products out of the left or right side of the furnace. This increases the flexibility of which direction the vent pipe can exit the furnace. Vent Pipe Material Vent and combustion air pipe and fittings must be one of the following materials in the list and must conform to the indicated ANSI/ASTM standards. MATERIALS STANDARDS Schedule 40PVC ...................................................... D1785 CPVC........................................................................ D1784 PVC-DWV................................................................. D2665 SDR-21 & SDR-26....................................................D2241 ABS-DWV ................................................................. D2661 Schedule 40 ABS .....................................................F628 Foam / Cellular Core PVC ........................................F891 *PolyPro® by DuraVent .............................................ULC-S636 *InnoFlue® by Centrotherm.................UL1738 and ULC-S636 *When using PolyPro® or InnoFlue®, all venting and fittings must be from the same manufacturer with no interchanging of other materials. Refer to specific instructions supplied with the PolyPro and InnoFlue vent kits. When joining PVC to PVC, use cement that conforms to ASTM standard D2564. PVC primer must meet standard ASTM F656. When joining ABS to ABS, use cement that conforms to ASTM standard D2235. When joining PVC to ABS, use cement as specified in procedure from ASTM standard D3138. In Canada, all plastic vent pipes and fittings including any cement, cleaners, or primers must be certified as a system to ULC S636. However this requirement does not apply to the finish flanges or piping internal to the furnace. Vent Pipe Length & Diameter In order for the furnace to operate properly, the combustion air and vent piping must not be excessively restrictive. · The venting system should be designed to have the minimum number of elbows or turns. · Transition to the final vent diameter should be done as close to the furnace outlet as practical. · Always use the same size or a larger pipe for combustion air that is used for the exhaust vent. Table 1 indicates the maximum allowable pipe length for a furnace of known input rate, when installed with piping of selected diameter and number of elbows. To use the table, the furnace input rate, the centerline length and the number of elbows on each pipe must be known. When estimating the length of vent runs, consideration must be made to the effect of elbows and other fittings. This is conveniently handled using the idea of "equivalent length". This means the fittings are assigned a linear length that accounts for the pressure drop they will cause. For example: a 2" diameter, long radius elbow is worth 10 FURNACE MODELS (BTU) 60,000 80,000 100,000 115,000 SINGLE VENT PIPE LENGTH (FT.) WITH 1 LONG RADIUS ELBOW* OUTLET 2" DIAMETER 60 30 30 N/A OUTLET 3" DIAMETER 90 90 90 90 DUAL VENT PIPE LENGTH (FT.) WITH 1 LONG RADIUS ELBOW ON EACH PIPE* INLET / OUTLET 2" DIAMETER 60 30 25 N/A INLET / OUTLET 3" DIAMETER 90 90 90 90 *NOTES: 1. Subtract 2.5 ft. for each additional 2 inch long radius elbow, 5 ft. for each additional 2 inch short radius elbow, 3.5 ft. for each additional 3 inch long radius elbow, and 7 ft. for each additional 3 inch short radius elbow. Subtract 5 ft for each 2" tee and 8 ft for each 3" tee. Two 45 degree elbows are equivalent to one 90 degree elbow. 2. This table applies for elevations from sea level to 2,000 ft. For higher elevations, decrease pipe lengths by 8% per 1,000 ft of altitude. Table 1. Vent Pipe Lengths the equivalent of 2.5 feet of linear run. A 90 degree tee is worth 7 ft. The equivalent lengths of tees and various elbows are listed in Table 1 . Measure the linear length of the vent run and then add in the equivalent length of each fitting. The total length, including the equivalent fitting lengths, must be less than the maximum length specified in Table 1. Vent Pipe Installation CAUTION: Combustion air must not be drawn from a corrosive atmosphere. This furnace has been certified for installation with zero clearance between vent piping and combustible surfaces. However, it is good practice to allow space for convenience in installation and service. · In the absence of local codes, the location of any combustion air inlet relative to any vent terminal must be at least 8 inches. This includes installations involving more than one furnace. · The quality of outdoor air must also be considered. Be sure that the combustion air intake is not located near a source of solvent fumes or other chemicals which can cause corrosion of the furnace combustion system. (See list of substances on page 5). · Route piping as direct as possible between the furnace and the outdoors. Horizontal piping from inducer to the flue pipe must be sloped 1/4" per foot to ensure condensate flows towards the drain tee or PVC trap. Longer vent runs require larger pipe diameters. Refer to the Inducer & Venting Options section on page 15 for additional information. · If a Direct Vent (2-pipe) system is used, the combustion air intake and the vent exhaust must be located in the same atmospheric pressure zone. This means both pipes must exit the building through the same portion of exterior wall or roof as shown in Figure 7, Figure 8, Figure 9, & Figure 10 (page 12). · Piping must be mechanically supported so that its weight does not bear on the furnace. Pipe supports must be installed a minimum of every 5 feet along the vent run to ensure no displacement after installation. Supports may be at shorter intervals if necessary to ensure that there are no sagging sections that can trap condensate. See Figure 28 (page 34). It is recommended to install couplings along the vent pipe, on either side of the exterior wall. These couplings may be required by local code. · If breakable connections are required in the combustion air inlet pipe (if present) and exhaust vent piping, then straight neoprene couplings for 2" or 3" piping with hose clamps can be used. These couplings can be ordered through your local furnace distributor. To install a coupling: 1. Slide the rubber coupling over the end of the pipe that is attached to the furnace and secure it with one of the hose clamps. 2. Slide the other end of the rubber coupling onto the other pipe from the vent. 3. Secure the coupling with the second hose clamp, ensuring that the connection is tight and leak free. Outdoor Terminations - Horizontal Venting · Vent and combustion air intake terminations shall be installed as depicted in Figure 7 & Figure 8 and in accordance with these instructions: · Vent termination clearances must be consistent with the NFGC, ANSI 2223.1/NFPA 54 and/or the CSA B149.1, Natural Gas and Propane Installation Code. Table 12 (page 32) lists the necessary distances from the vent termination to windows and building air intakes. · Vent and combustion air intake terminations must be located to ensure proper furnace operation and conformance to applicable codes. A vent terminal must be located at least 3 feet above any forced air inlet located within 10 feet. This does not apply to the combustion air inlet of a direct vent (two pipe) appliance. In Canada, CSA B149.1, takes precedence over these instructions. See Table 12. · All minimum clearances must be maintained to protect building materials from degradation by flue gases. See Figure 7. · For optimal performance, vent the furnace through a wall that experiences the least exposure to winter winds. · The vent termination shall be located at least 3 ft. horizontally from any electric meter, gas meter, regulator and any relief equipment. These distances apply ONLY 11 3168""MMainx.. secMuoreudn(bttioontgwhkapiltlipfwaeicsthe) pslcarteews Exohpatuiosnt vent C Exohpatuiosnt vent A Exohpatuiosnt vent B 90° Elbow Coamir binulsettion (al3l 8p6"o" MsMitiainox.n. s) 1e2x"pme(bcintoe.tdhtospmnipoaewxsi)mleuveml Figure 7. Inlet & Exhaust Pipe Clearances 50o,r0tDle0eir0srmesBcinttuavhlent 9 in. Note 2 4 ft 4 ft Mechanical draft vent terminal Note 2 NOTES: 1. All dimensions shown are minimum requirements. 2. Exterior vent terminations must be located at least 12" above the maximum expected snow level. tdeMrramefctinhvaaelnnitcal 12 in. Mdetreacrhfmtavinneiacnalt l 3 ft. 12 in. Note 2 L1the0asfnst. Forced air inlet Direct vent terminal - more than 50,000 Btuh Figure 8. Vent Locations 19" Max. (See Note) 12" Above Maximum Expected Support Snow Level Outside Wall 1/2" Armaflex Insulation or Equivalent (if required) NOTE: Vent Configuration to Provide 12" Minimum height above Snow Level. Figure 9. Alternate Horizontal Vent Installation to U.S. installations. In Canada, CSA B149.1, takes precedence over these instructions. · Do not install the vent terminal such that exhaust is directed into window wells, stairwells, under decks or into alcoves or similar recessed areas, and do not terminate above any public walkways. · If venting horizontally, a side wall vent kit is available according to the pipe diameter size of the installation. For 2 inch pipe use side wall vent kit #904617, and for 3 inch pipe use kit #904347. Please follow the instructions provided with the kit. · Concentric vent kits are available for both 2" and 3" applications. Each size has one that meets UL 1738 and one that meets ULC S636. Refer to the technical sales literature for kit numbers. · When the vent pipe must exit an exterior wall close to the grade or expected snow level where it is not possible to obtain clearances shown in Figure 7, a riser may be provided as shown in Figure 9. Insulation is required to prevent freezing of this section of pipe. See Table 2 for vent freezing protection. Outdoor Terminations - Vertical Venting Termination spacing requirements from the roof and from each other are shown in Figure 10. The roof penetration must be properly flashed and waterproofed with a plumbing roof boot or equivalent flashing. Vent and combustion air piping may be installed in an existing chimney which is not in use provided that: · Both the exhaust vent and air intake run the length of the chimney. · The top of the chimney is sealed and weatherproofed. · The termination clearances shown in Figure 10 are maintained. · No other gas fired or fuel-burning equipment is vented through the chimney. WINTER DESIGN TEMPERATURE 20 0 -20 MAXIMUM FLUE PIPE LENGTH (FEET) IN UNCONDITIONED & EXTERIOR SPACES WITHOUT INSULATION 45 20 10 WITH INSULATION* 70 70 60 *NOTE: Insulation thickness greater than 3/8 inch, based on an R value of 3.5 (ft x F x hr) / (BTU x in.) Table 2. Vent Protection Elbows on the combustion air inlet must be positioned pointing away from the exhaust vent. Plumbing Vent Roof Boot (Both Pipes) Combustion Air Exhaust Vent 12" Above Maximum Expected Snow Level (Both pipes) 386" "MMina.x. Figure 10. Vertical Vent Termination 12 Vent Freezing Protection CAUTION: When the vent pipe is exposed to temperatures below freezing (i.e., when it passes through unheated spaces, chimneys, etc.) the pipe must be insulated with 1/2 inch thick sponge rubber insulation, Armaflex-type insulation or equivalent. Insulating pipe is important to avoid condensate icing. Neutralizer kit P/N 902377 is available for use with this furnace. Please follow the instructions provided with the kit. For Installations where there is limited clearance for the J-Trap (such as an attic where it may be installed between ceiling joists), either side of the J-Trap can be shortened to a minimum of 3 Inches. CIRCULATING AIR REQUIREMENTS WARNING: · Table 2 (page 12) lists the maximum length of flue pipe that can travel through an unconditioned space or an exterior space. The total vent length must not exceed the lengths noted in Table 1 (page 11). For Canadian installations, please refer to the Canadian Installation Code (CAN/CGA-B149.1) and/or local codes. · For extremely cold climates or for conditions of short furnace cycles (i.e. set back thermostat conditions) the last 18 inches of vent pipe can be reduced. It is acceptable to reduce from 3" to 2-1/2", 3" to 2", or 2" to 1-1/2" if the total vent length is at least 15 feet in length and the vent length is within the parameters specified in Table 1. The restriction should be counted as 3 equivalent feet. Smaller vent pipes are less susceptible to freezing, but must not be excessively restrictive. The length of the 2 inch pipe must not be longer than 18 inches. · To prevent debris or creatures from entering the combustion system, a protective screen may be installed over the combustion air intake opening. The screens hole size must be large enough to prevent air restriction. Existing Installations When an existing furnace is removed from a vent system serving other appliances, the existing vent system may not be sized properly to vent the remaining appliances (For example: water heater). An improperly sized venting system can result in the formation of condensate, leakage, or spillage. The existing vent system should be checked to make sure it is in compliance with NFGC and must be brought into compliance before installing the furnace. NOTE: If replacing an existing furnace, it is possible you will encounter an existing plastic venting system that is subject to a Consumer Product Safety Commission recall. The pipes involved in the recall are High Temperature Plastic Vent (HTPV). If your venting system contains these pipes DO NOT reuse this venting system! This recall does not apply to other plastic vent pipes, such as white PVC or CPVC. Check for details on the CPSC website or call their toll-free number (800) 758-3688. Condensate Disposal The method for disposing of condensate varies according to local codes. Consult your local code or authority having jurisdiction. Each of the condensate drain lines must be J-trapped using field supplied parts. After the condensate lines are J-trapped, they may be combined together into a single run to the drain. The drain lines must be routed downward to ensure proper drainage from furnace. Do not allow combustion products to enter the circulating air supply. Failure to prevent the circulation of combustion products into the living space can create potentially hazardous conditions including carbon monoxide poisoning that could result in personal injury or death. All return ductwork must be secured to the furnace with sheet metal screws. For installations in confined spaces, all return ductwork must be adequately sealed. When return air is provided through the bottom of the furnace, the joint between the furnace and the return air plenum must be air tight. The surface that the furnace is mounted on must provide sound physical support of the furnace with no gaps, cracks or sagging between the furnace and the floor or platform. Return air and circulating air ductwork must not be connected to any other heat producing device such as a fireplace insert, stove, etc. This may result in fire, explosion, carbon monoxide poisoning, personal injury, or property damage. Plenums & Air Ducts · Plenums and air ducts must be installed in accordance with the Standard for the Installation of Air Conditioning and Ventilating Systems (NFPA No. 90A) or the Standard for the Installation of Warm Air Heating and Air Conditioning Systems (NFPA No. 90B). · It is recommended that the outlet duct contain a removable access panel. The opening should be accessible when the furnace is installed in service and shall be of a size that smoke or reflected light may be observed inside the casing to indicate the presence of leaks in the heat exchanger. The cover for the opening shall be attached in such a way as to prevent leaks. · If outside air is used as return air to the furnace for ventilation or to improve indoor air quality, the system must be designed so that the return air is not less than 60° F (15° C) during operation. If a combination of indoor and outdoor air is used, the ducts and damper system must be designed so that the return air supply to the furnace is equal to the return air supply under normal, indoor return air applications. 13 · When a cooling system is installed which uses the furnace blower to provide airflow over the indoor coil, the coil must be installed downstream (on the outlet side) of the furnace or in parallel with the furnace. · If a cooling system is installed in parallel with the furnace, a damper must be installed to prevent chilled air from entering the furnace and condensing on the heat exchanger. If a manually operated damper is installed, it must be designed so that operation of the furnace is prevented when the damper is in the cooling position and operation of the cooling system is prevented when the damper is in the heating position. · It is good practice to seal all connections and joints with industrial grade sealing tape or liquid sealant. Requirements for sealing ductwork vary from region to region. Consult with local codes for requirements specific to your area. Return Air Connections · In applications where the supply ducts carry heated air to areas outside the space where the furnace is installed, the return air must be delivered to the furnace by duct(s) secured to the furnace casing, running full size and without interruption. Do not use the back of the furnace for return air. · Position the furnace with the return air ductwork ensuring even alignment of furnace (or coil casing) air opening and return air duct. NOTE: The ductwork must have an opening equal to that of the return air opening of the furnace (or coil casing). See Figure 23 (page 26) for return air opening size. · To attach the return air duct to the downflow furnace, bend the flanges on the furnace upward 90° with wide duct pliers. See Figure 23 for furnace flange locations. NOTE: If system installation includes AC coil casing, bend the flanges on the coil casing upward 90° before attaching the return air duct. · Secure the return air ductwork to the furnace or coil casing (if installed) with sheet metal screws. Make sure the screws penetrate the sheet metal casing and flanges. Supply Air Connections · The supply air must be delivered to the heated space by duct(s) secured to the furnace or coil box casing, running full size and without interruption. · To attach the supply air duct, bend the flanges on the furnace upward 90° with wide duct pliers. See Figure 23 (page 26) for furnace flange locations. NOTE: If system installation includes AC coil casing, bend the flanges on the coil casing upward 90° before attaching the supply air duct. · Position the supply air ductwork onto the furnace ensuring even alignment of furnace air opening and supply air duct. NOTE: The ductwork must have an opening equal to that of the supply air opening of the furnace. See Figure 23 for supply air opening size. Acoustical Treatments Damping ducts, flexible vibration isolators, or pleated media-style filters on the return air inlet of the furnace may be used to reduce the transmission of equipment noise eminating from the furnace. These treatments can produce a quieter installation, particularly in the heated space. However, they can increase the pressure drop in the duct system. Care must be taken to maintain the proper maximum pressure rise across the furnace, temperature rise and flow rate. This may mean increasing the duct size and/or reducing the blower speed. These treatments must be constructed and installed in accordance with NFPA and SMACNA construction standards. Consult with local codes for special requirements. For best sound performance, be sure to install all the needed gaskets and grommets around penetrations into the furnace, such as for electrical wiring. FURNACE INSTALLATION General Requirements · The J962V*D series gas furnace may only be installed as a downflow application. · The furnace must be leveled at installation and attached to a properly installed duct system. See Figure 1 (page 6) for the required clearances needed to move the furnace to its installation point (hallways, doorways, stairs, etc). · The furnace must be installed so that all electrical components are protected from water. · The furnace must be installed upstream from a refrigeration system. (If applicable) · The cabinet plug must always be used to close the hole in the side of the furnace when rotating the inducer. · The furnace requires special venting materials and installation procedures. See page 7, page 8, page 9, & page 10 for venting guidelines and specifications. WARNING: The furnace must not be installed directly on carpeting, tile, or any combustible material other than wood flooring. WARNING: Failure to install the downflow sub-base kit may result in fire, property damage or personal injury. To install the furnace on combustible flooring, a special sub-base is required. Downflow sub-base kits are factory supplied accessories and are listed according to the cabinet letter of the furnace. For `B', `C', and `D' size cabinets use Kit #904911. Please follow the instructions provided with the kit. A downflow sub-base kit is not necessary if the furnace is installed on a factory or site-built cased air conditioning coil. However, the plenum attached to the coil casing must be installed so that its surfaces are at least 1" from combustible construction. 14 Opening in concrete floor "A" "B" CABINET SIZE DIM. "A" DIM. "B" B 16 5/8 19 1/4 C 20 1/8 19 1/4 D 23 5/8 19 1/4 NOTE: Dimensions shown in Inches. Table 3. Cutout Dimensions 1-Pipe Options 2-pipe Options B, C, & D, WIDTH CABINETS VENT OPTIONS Right Option 1 Up Option 2 Left Option 3 Right Option 4 Up Option 5 Left Option 6 Table 4. Vent & Inducer Blower Options Inducer Assembly Rotation WARNING: Concrete Floor Furnace Sheet Metal Plenum Inducer rotation must be completed before the furnace is connected to gas and electric. If both utilities have been connected, follow the shutdown procedures printed on the furnace label and disconnect the electrical supply. CAUTION: Figure 11. Furnace on a Concrete Slab Installation on a concrete slab 1. Create an opening in the floor according to the dimensions in Table 3. 2. Position the plenum and the furnace as shown in Figure 11. Inducer & Venting Options To increase installation flexibility, the inducer assembly can be rotated to 2 different positions (`B', `C', & `D' width cabinets only). Each variation has slightly different requirements with regard to condensate disposal and, in some cases, the need to seal the furnace cabinet. Before using Table 4, the number of pipes (1-pipe or 2-pipe) connected to the furnace must be known. First find the side that the pipes will exit from the furnace and then select the option that properly matches your installation type from Figure 27 (page 33). NOTE: It is important that Direct Vent (2-pipe) systems maintain an airtight flow path from the air inlet to the flue gas outlet. The furnace ships from the factory with two holes in the cabinet for the air inlet and flue gas outlet. In certain configurations, it is necessary to remove and relocate a plastic cap in the furnace cabinet. If changing the position of the air inlet and flue gas outlet, it is required that the previous hole be closed off with the plastic cap to maintain air tightness in the furnace. The hole locations for J962V*D furnaces are shown in Figure 23 (page 26). It is good practice to label all wires prior to disconnection. Wiring errors can cause improper and dangerous operation. 1. Disconnect the electrical harness from the inducer assembly. 2. Remove the inducer assembly ground wire from the blower deck or door. 3. Remove 3 screws securing the inducer assembly to the header box. 4. Remove drain tube from inline drain assembly. 5. Rotate the inducer assembly to its new position. 6. Secure the inducer assembly to the header box by reinstalling the four screws. NOTE: An extra screw is provided in the parts package with downflow furnaces. 7. Remove the cabinet plug from side of furnace and reinstall in hole on opposite side of cabinet. 8. Connect all condensate drains as required for your installation. See Table 4 (page 15), Figure 27 (page 33). 9. Reconnect the electrical harness to the inducer assembly. 10.Reconnect the inducer assembly ground wire to the blower deck or door. 11.Verify proper operation as detailed on the furnace label. 15 AIR FLOW Figure 12. Pressure Switch Tubing for J962V*D Downflow Furnaces Pressure Switch Tubing Figure 12 displays the proper routing of pressure switch tubing for J962V*D furnaces. The J962V*D furnace requires only one pair of switches to be connected to the inducer's static tap. Accessories The components in Figure 13 (page 16) & Figure 14 (page 16) are included in the extra parts bag supplied with the purchase of the J962V*D furnace. Depending on your particular installation, some of these components are optional and may not be used. Please refer to the descriptions and accompanying figures when installing these items. Finish Flange The finish flange must be installed to vent the combustion air pipe through the top of the furnace. NOTE: For proper installation it is important that the pipe and screw holes in the finish flange, gasket, and cabinet are aligned. 1. Position flange gasket over hole in the furnace cabinet. 2. Position finish flange on top of the flange gasket. NOTE: Make sure the flange is properly oriented so that the FRONT lettering is located near the front of the furnace as shown in Figure 13. 3. Secure flange and gasket to cabinet with three field supplied sheet metal screws. 12 34 5678 Rubber Grommets The 2 1/4" rubber grommet is used to seal the opening between the furnace cabinet and the 2" PVC vent pipe. The rubber grommet should be installed in the 3" hole prior to running the vent pipe out of cabinet. No sealants are required. See Figure 13. The 7/8" rubber grommet is used to seal the opening between the furnace cabinet and the gas pipe. The rubber grommet should be installed in the 1 5/8" hole prior to running the gas pipe into the cabinet. No sealants are required. The 3/4" rubber grommet is used if venting out the left side of the cabinet and the drain tube is routed through the blower deck. Remove the plastic plug from the hole and install the grommet before routing the drain tube. PVC Components IMPORTANT NOTES: · Before permanently installing these components, it is recommended you dry-fit them first to ensure proper fit and alignment with other vent pipes. · The 2" PVC pipe shown in Figure 14 is not provided in the extra parts bag. · The PVC Tee & Trap are not included with the J962V*D furnaces. However the PVC Trap (P/N 664659) can be purchased thru your local distributor. The 2" PVC Tee and Trap are used when the inducer is rotated to vent out thru the left or right side of the furnace cabinet. See Figure 14. INSTALLATION OF PVC COMPONENTS (TYPICAL ORIENTATION) 2" PVC Pipe from Inline Drain Assembly (Not Included) 2" PVC Tee 1/2" x 3/4" Hose Barb PVC Trap 1/2" Tubing (Field Supplied) FRONT lettering must be located near front of furnace FRONT Flange Gaskets Inlet Air Finish Flange ø 2 1/4" Rubber Grommet ø 7/8" Rubber Grommet Figure 13. Finish Flange & Rubber Grommets INSTALLATION OF PVC COMPONENTS (ALTERNATE ORIENTATION) 2" PVC Pipe from Inline Drain Assembly (Not Included) 2" PVC Tee 2" PVC Elbow (Field Supplied) 1/2" x 3/4" Hose Barb PVC Trap 1/2" Tubing (Field Supplied) Figure 14. PVC Components 16 The 1/2" x 3/4" hose barb can be used to route the condensate drain to the outside of the cabinet. It must be installed from inside the cabinet with the threaded end inserted thru the 1 1/16" hole. See Figure 23 (page 26) for hole location The condensate drain should be connected to the barbed end. Attach 1" PVC drain line to the threaded end. Typical Orientation 1. Install the PVC Tee vertically on the 2" vent pipe that is extending out the side of the cabinet. Permanently bond them together using appropriate primer and cement. Refer to the typical orientation shown in Figure 14. 2. Install the reducer or PVC trap (if supplied) on the bottom end of the PVC Tee. Permanently bond them together using appropriate primer and cement. 3. Install the 1/2" x 1/2" hose barb on the 2" PVC reducer. NOTE: Do not over tighten! Use an adequate amount of Teflon tape on the threads. Do not use liquid sealants. 4. Verify all connections and joints for tight fit and proper alignment with other vent pipes. Alternate Orientation 1. Install the 2" PVC Tee horizontally on the 2" vent pipe that is extending out the side of the cabinet. Permanently bond them together using appropriate primer and cement. Refer to the alternate orientation shown in Figure 14. 2. Install the 2" PVC Elbow on the end of the 2" PVC Tee. Permanently bond them together using appropriate primer and cement. 3. Install the reducer or PVC trap (if supplied) on the bottom end of the PVC Tee. Permanently bond them together using appropriate primer and cement. 4. Install the 1/2" x 1/2" hose barb on the 2" PVC reducer. NOTE: Do not over tighten! Use an adequate amount of Teflon tape on the threads. Do not use liquid sealants. 5. Verify all connections and joints for tight fit and proper alignment with other vent pipes Condensate Drain Lines IMPORTANT NOTE If the furnace is installed in an area where temperatures fall below freezing, special precautions must be made for insulating condensate drain lines that drain to the outdoors. If condensate freezes in the lines, this will cause improper operation or damage to the furnace. It is recommended that all drain lines on the outside of the residence be wrapped with an industry approved insulation or material allowed by local code. The placement of the condensate drain lines will depend on the configuration selected in Table 4, (page 15). The drain lines can be routed out the left or right side of the furnace, but must maintain a downward slope to ensure proper condensate drainage. The J-trap may need to be rotated to the side that matches your setup in Figure 27 (page 33). To rotate the J-trap, loosen the clamp on the drain tube, rotate the J-trap to either side, and retighten the clamp. THREE GENERAL RULES APPLY: · Each condensate drain line within the furnace must be separately trapped using a J-Trap or field supplied loop. After individually trapping the condensate lines, it is acceptable to combine the drains. · There must always be a drain attached to the collector at the outlet of the secondary heat exchanger. · There must always be a drain at the lowest point of the venting system. NOTE: If using a condensate pump, the furnace drain line must be installed above the pumps water line. EXCEPTIONS AND CLARIFICATIONS TO THE GENERAL RULES: · In some cases, the lowest point in the vent system is where it connects to the inducer. In this case one drain at this location is sufficient. · If the vent exits the furnace horizontally, the vent may be turned vertically with a tee. The drip leg formed by the tee must include a drain (Option 1, Option 2, Option 3, Option 6). · In certain cases, it is permitted to drain the inducer back into the top drain of the collector (Option 1, Option 2, Option 4, & Option 5). To ensure proper drainage of condensate, make sure the drain line does not sag or becomes twisted. The drain tube supplied with the furnace may need to be trimmed. GAS SUPPLY & PIPING WARNING: FIRE OR EXPLOSION HAZARD · Failure to follow safety warnings exactly could result in serious injury, death or property damage. · Installation and service must be performed by a qualified installer, service agency or the gas supplier. · Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance. WHAT TO DO IF YOU SMELL GAS · Do not try to light any appliance. · Do not touch any electrical switch; do not use any phone in your building. · Leave the building immediately. · Immediately call your gas supplier from a neighbor's phone. Follow the gas supplier's instructions. · If you cannot reach your gas supplier, call the fire department. · All gas piping must be installed in compliance with local codes and utility regulations. In the absence of local codes the gas line installation must comply with the latest edition of the National Fuel Gas Code (ANSI Z223.1) or (CAN/CGA B149.1) Installation Codes. 17 · Some local regulations require the installation of a manual main shut-off valve and ground joint union external to the furnace. The shut-off valve should be readily accessible for service and/or emergency use. Consult the local utility or gas supplier for additional requirements regarding placement of the manual main gas shut-off. See Figure 15 (page 18). · Per ANSI 21.47, A 1/8-inch NPT plugged tapping, accessible for test gauge connection, must be installed immediately upstream of the gas supply connection to the furnace external to the cabinet. If local codes allow the use of a flexible gas appliance connector, always use a new listed connector. Do not use a connector that has previously serviced another gas appliance. · Gas piping must never run in or through air ducts, chimneys, gas vents, or elevator shafts. · Compounds used on threaded joints of gas piping must be resistant to the actions of liquefied petroleum gases. · The main gas valve and main power disconnect to the furnace must be properly labeled by the installer in case emergency shutdown is required. · Flexible gas connectors are not recommended for this type of furnace but may be used if allowed by local jurisdiction. Only new flexible connectors may be used. Do not reuse old flexible gas connectors. · A drip leg should be installed in the vertical pipe run to the unit. See Figure 15. Table 7 (page 27) lists gas flow capacities for standard pipe sizes as a function of length in typical applications based on nominal pressure drop in the line. NOTE: The `A' width furnace can only be installed with right side gas entry. `B', `C', & `D' width furnaces may be installed for either left or right side gas entry. When connecting the gas supply, provide clearance between the gas supply line and the entry hole in the furnace casing to avoid unwanted noise and/or damage to the furnace. Typical gas hookups are shown in Figure 15. Leak Check WARNING: FIRE OR EXPLOSION HAZARD Failure to follow safety warnings exactly could result in serious injury, death or property damage. Never test for gas leaks with an open flame. Use a commercially available soap solution made specifically for the detection of leaks to check all connections. A fire or explosion may result causing property damage, personal injury or loss of life. After the gas piping to the furnace is complete, all connections must be tested for gas leaks. This includes pipe connections at the main gas valve, emergency shutoff valve and flexible gas connectors (if applicable). The soap and water solution can be applied on each joint or union using a small paintbrush. If any bubbling is observed, the connection is not sealed adequately and must be retightened. Repeat the tightening and soap check process until bubbling ceases. IMPORTANT NOTE When pressure testing gas supply lines at pressures greater than 1/2 psig (14 inch W.C.), the gas supply piping system must be disconnected from the furnace to prevent damage to the gas control valve. If the test pressure is less than or equal to 1/2 psig (14 inch W.C.), close the manual shut-off valve. Left Side Entry Right Side Entry See Note "A" Shut - Off Valve Dripleg Ground Joint Union Elbow See Note "B" Pipe Nipple Plug Gas Valve Elbow See Note "A" Shut - Off Valve See Note "B" Pipe Nipple Dripleg Ground Gas Joint Valve Union Manifold Burner Assembly Manifold NOTE A: Consult local codes for Shut-Off Valve location requirements NOTE B: Inducer assembly omitted for clarity of pipe installation. Figure 15. Typical Gas Connections 18 High Altitude Application (Natural Gas Only) The installation of this furnace at altitudes above 2,000 feet must meet the requirements of the National Fuel Gas Code or local jurisdiction. In Canada, the requirements for high altitude are different and governed by CGA B149.1. Please consult your local code authority. This may be accomplished in the usual way, by clocking the gas meter and using the local gas heating value. See Verifying & Adjusting the Input Rate section (page 23). IMPORTANT NOTE Observe the action of the burners to make sure there is no yellowing, lifting or flashback of the flame. WARNING: The reduction of input rating necessary for high altitude installation may only be accomplished with factory supplied orifices. Do not attempt to drill out orifices in the field. Improperly drilled orifices may cause fire, explosion, carbon monoxide poisoning, personal injury or death. For US installations only: To avoid nuisance tripping at altitudes from 7500 to 10,000 feet, a pressure switch conversion may be required. Consult the tables in the LP and High altitude and LP gas conversion kit for installations in the US. Converting from Natural Gas to LP / Propane WARNING: The furnaces are shipped from the factory with orifices and gas regulator settings for natural gas operation at sea level altitudes. At 2,000 feet, the NFGC requires that this appliance be derated 4% for each 1,000 feet of altitude. For example, the input needs to be reduced 8% at 2,000 feet, 12% at 3,000 feet, etc. This deration is in reference to the input rate and gas heating value at sea level. To derate the furnace requires knowing the heating value of the gas at the installation site. Heating values at particular job sites vary for two reasons: 1. The chemical mixture of the gas varies from region to region and is expressed as the "sea level heating value". 2. The heating value varies by altitude. For this reason, particularly in high altitude areas, the local gas utility usually specifies the heating value at the residence's gas meter as the "local value". For added flexibility, two tables have been provided for natural gas installations with high or low heating values at sea level. Table 10 (page 29) & Table 11 (page 29) contain the orifice sizes and manifold pressure to use at various altitudes. Table 10 (HIGH) is for natural gas installations with a heating value of more than 1,000 Btu per cubic foot and Table 11 (LOW) is for less than 1,000 Btu per cubic foot. To determine which table to use: 1. Consult your local utility for the local heating value at your installation. 2. From Table 9 (page 28), find your local heating value as supplied by the utility company. Follow down the column and stop at your altitude level. 3. If your sea level heating value is HIGH, use Table 10 or if it's LOW, use Table 11. See example. EXAMPLE Elevation: .................................................. 5,000 feet Type of Gas:........................................... Natural Gas Local Heating Value of Gas: .............................. 750 From Table 9, find 750 and follow down the column, stop at the 5,000 feet row. The heating value listed is LOW. Table 11 will be used to determine orifice size and manifold pressure. The furnace was shipped from the factory equipped to operate on natural gas. Conversion to LP / Propane gas must be performed by qualified service personnel using a factory supplied conversion kit. Failure to use the proper conversion kit can cause fire, explosion, property damage, carbon monoxide poisoning, personal injury, or death. Conversion to LP / Propane is detailed in the installation instructions provided with the conversion kit. Generally, this will require the replacement of the burner orifices and the spring assembly in the pressure regulator. Approved conversion kits are listed below: · Installations in the United States: For Propane (LP) conversion or for LP gas installations in altitudes between 2,000 ft. and 10,000 ft. above sea level, use the LP & High Altitude LP Gas Conversion Kit (P/N 905028) for Installations in the United States. Please follow the instructions provided with the kit. · Installations in Canada: For Propane (LP) conversion or for LP Gas installations in altitudes between zero and 4,500 ft. above sea level, use the LP & High Altitude LP Gas Conversion Kit (P/N 905029) for Installations in Canada. Please follow the instructions provided with the kit. If the installation is in the U.S. above 2,000 ft., refer to Table 8 (page 28) to determine the correct orifice size and regulator pressure. See Example below. EXAMPLE Elevation: .................................................. 5,000 feet Type of Gas:.........................................Propane Gas Input BTUH of Furnace: ................................ 80,000 From Table 8, find 5,000 and follow across the row; stop at the 80,000 btuh column. At first stage, the manifold pressure listed is 4.2, but at 2nd stage the pressure is 9.0. The listed orifice size is 56. When conversion is complete, verify the manifold pressure and input rate are correct as listed in the Tables. After changing the regulator pressure or changing the orifices, it is required that you measure the gas input rate. 19 ELECTRICAL WIRING WARNING: ELECTRICAL SHOCK, FIRE OR EXPLOSION HAZARD Failure to follow safety warnings exactly could result in serious injury, death or property damage. Improper servicing could result in dangerous operation, serious injury, death or property damage. · Before servicing, disconnect all electrical power to furnace. · When servicing controls, label all wires prior to disconnecting. Reconnect wires correctly. · Verify proper operation after servicing. · Electrical connections must be in compliance with all applicable local codes, and the current revision of the National Electric Code (ANSI/NFPA 70). · For Canadian installations the electrical connections and grounding shall comply with the current Canadian Electrical Code (CSA C22.1 and/or local codes). IMPORTANT NOTE: · If replacing any of the original wires supplied with the furnace, the replacement wire must be copper wiring and have a temperature rating of at least 105°F (40°C). For electrical specifications, refer to the furnace nameplate or Table 5 (page 20). Line Voltage Wiring It is recommended that the line voltage (115 VAC) to the furnace be supplied from a dedicated branch circuit containing the correct fuse or circuit breaker for the furnace. See Table 5 below. IMPORTANT NOTES: · An electrical disconnect must be installed readily accessible from and located within sight of the furnace. See Figure 16 or the wiring diagram label inside of the control door. Any other wiring methods must be acceptable to authority having jurisdiction. · Proper line voltage polarity must be maintained in order for the control system to operate correctly. Verify the incoming neutral line is connected to the white wire and the incoming HOT line is connected to the black wire. The furnace will not operate unless the polarity and ground are properly connected as shown in Figure 16. Field Line Voltage Wiring Factory Line Voltage Wiring Field Supplied Fused Service Panel Field Supplied Disconnect within Sight of Furnace Field Supplied Panel Connector Black (Hot) White (Neutral) Green or Bare (Ground) Ground Black White Ground Black White Black White Ground Junction Box (may be int. or ext. to the furnace). These connections can be made in the field supplied disconnect at the furnace. NOTE: Connections made within the furnace burner compartment do not require a junction box. FURNACE INPUT (BTUH) 60,000 80,000 100,000 115,000 CABINET WIDTH (IN.) 17 1/2 21 21 24 1/2 Figure 16. Line Voltage Field Wiring NOMINAL ELECTRICAL SUPPLY 115-60-1 115-60-1 115-60-1 115-60-1 MAXIMUM OPERATING VOLTAGE 127 127 127 127 MINIMUM OPERATING VOLTAGE 103 103 103 103 MAXIMUM FURNACE AMPERES 6.2 8.7 11.7 11.7 MAXIMUM FUSE OR CIRCUIT BREAKER AMPS* 15 15 15 15 THERMOSTAT WIRE GAUGE 24 22 20 18 RECOMMENDED THERMOSTAT WIRE LENGTH 2 - WIRE - HEATING 55 ft. 90 ft. 140 ft. 225 ft. 4 OR 5 WIRE - COOLING 25 ft. 45 ft. 70 ft. 110 ft. * Time-delay fuses or circuit breakers are required. Table 5. Wire Length & Voltage Specifications 20 Grounding WARNING: To minimize personal injury, the furnace cabinet must have an uninterrupted or unbroken electrical ground. The controls used in this furnace require an earth ground to operate properly. Acceptable methods include electrical wire or conduit approved for ground service. Do not use gas piping as an electrical ground! Thermostat / Low Voltage Connections · The furnace is designed to be controlled by a 24 VAC thermostat. The thermostat's wiring must comply with the current provisions of the NEC (ANSI/NFPA 70) and with applicable local codes having jurisdiction. · Twinning of two stage furnaces is no longer supported. Please contact your furnace distributor for details. · The thermostat must be installed according to the instructions supplied by the thermostat manufacturer. Low voltage connections (24 VAC) from the thermostat are wired to the terminal strip on the integrated control in the furnace. Recommended minimum wire gauge for thermostat wiring is shown in Table 5 (page 20). · The thermostat should be mounted about 5 feet above the floor on an inside wall. DO NOT install the thermostat on an outside wall or any other location where its operation may be adversely affected by radiant heat from fireplaces, sunlight, or lighting fixtures, and convective heat from warm air registers or electrical appliances. Refer to the thermostat manufacturer's instruction sheet for detailed mounting information. · Depending on the type of air conditioning unit and thermostat used, both blower applications utilize three basic wiring configurations. Single Stage AC & Single Stage Thermostat This option does not use the full two-stage control capability of the furnace, but the possibility of timed autostaging is available. See also Autostaging for Single Stage Thermostats. · Connect the thermostat's W output to the furnace control boards W1 terminal. This allows the furnace to always run in low output mode. See Figure 17. · Always connect the thermostat C & R to the furnace control board C & R. · For cooling, connect the thermostats Y signal to the furnace control board Y / Y2 terminal. · Field supplied wires should also connect Y / Y2 & C to the outdoor unit's Y & C terminals. Single Stage AC & Two Stage Thermostat This option uses the full two stage heating capability of the furnace with a single stage outdoor unit. See Figure 18. · Connect the thermostat's W1 & W2 outputs to the furnace control board's W1 & W2 terminals. · Always connect the thermostat C & R to the furnace control board C & R · For cooling, connect the thermostats Y signal to the furnace control board Y / Y2 terminal. · Field supplied wires should also connect Y / Y2 & C to the outdoor unit's Y & C terminals. ROOM THERMOSTAT (SINGLE STAGE) W Y G 1 C R DHUM DHUM Y C A/C CONDENSING UNIT (SINGLE STAGE) HIGH EFFICIENCY BLOWER MOTOR CONTROL BOARD Y/Y2 G W1 R Y1 W2 C TWO STAGE FURNACE BOARD Figure 17. Wiring Configuration 1 ROOM THERMOSTAT (TWO - STAGE) WW Y G 2 1 C R DHUM DHUM Y HIGH EFFICIENCY C BLOWER MOTOR CONTROL BOARD A/C CONDENSING UNIT (SINGLE STAGE) Y/Y2 G W1 R Y1 W2 C TWO STAGE FURNACE BOARD Figure 18. Wiring Configuration 2 ROOM THERMOSTAT (TWO STAGE) YY WW 2 1 G 2 1 C R DHUM DHUM Y2 Y1 C A/C CONDENSING UNIT (TWO STAGE) HIGH EFFICIENCY BLOWER MOTOR CONTROL BOARD Y/Y2 G W1 R Y1 W2 C TWO STAGE FURNACE BOARD Figure 19. Wiring Configuration 3 Two-Stage AC & Two-Stage Thermostat This option uses the full two stage heating capability of the furnace with a two stage outdoor unit. See Figure 19. · Connect the thermostat's W1 & W2 outputs to the furnace control board's W1 & W2 terminals. · Always connect the thermostat C & R to the furnace control board C & R. · For cooling, connect the thermostat Y & Y1 to the furnace control board's Y / Y2 & Y1 terminal's. · Field supplied wires should also connect the Y / Y2 & Y1 signals to the outdoor unit's Y & Y1 terminals. · Connect terminal C to the outdoor unit's C. Autostaging for Single Stage Thermostats The Autostaging feature makes it possible to use a single stage thermostat and still receive some of the benefits of 2-stage furnace operation. If Autostage is enabled, the furnace will drop to LOW fire after initially starting in HIGH fire. After a period of 10 minutes, the furnace will 21 then stage up to HIGH fire, until the heating load is met. See Figure 17 and the Low Voltage Connection section on page 21. The autostaging option on the furnace control board is selected using the autostage jumper located near the thermostat terminal block. See Figure 25 (page 30). When the autostage jumper is moved from OFF to ON, the following occurs during a call for heat: Setting the Autostage jumper in the ON position signals the control to utilize a 10 minute delay between LOW fire and HIGH fire when a call for heat is supplied via 24V signal to W1. This setting is the same as jumping R to W2. NOTE: If the autostage jumper is in the ON position and a W1 demand is present when power is applied to the furnace, the first heat cycle will run in second stage heat with no autostaging. After the first cycle, the furnace will resume normal autostaging operation. DO NOT jump W1 & W2 together while the autostage jumper is in the ON position. Autostaging for Two-Stage Thermostats The Autostage setting on the furnace control board Figure 25 (page 30) is disabled when shipped from the factory. This feature will be not used when paired with a two-stage thermostat. The autostage jumper setting (P7) must be kept on OFF to allow the thermostat to adjust stages. Blower Speed Configuration Two-stage furnaces use high efficiency circulating air motors that come in two variations and both are controlled differently. The fixed speed furnace uses a motor control board that maintains constant motor torque, while the variable speed furnace uses a motor control board that maintains constant CFM airflow. Both boards use the same furnace control board. Fixed Speed Blower Applications The fixed speed motor control board (Figure 24 (page 30)) contains a set of dip switches for setting the blower speed. Use pins 1 to 4 to set the blower speed for heating and pins 5 to 8 to set the speed for cooling. To determine the appropriate switch settings for your installation, see the separate blower table attachment. For thermostats with a dehumidifier output, use a field supplied wire to connect the thermostat's dehumidifier output to the terminal marked DEHUM. The thermostat should be set so that the DEHUM output should be high (positive) when dehumidification is needed. See also Dehumidification Options section. CAUTION: The terminal marked "Y1_IN" on the variable speed motor control board is not an output to drive the outdoor unit. DO NOT connect Y1_IN on the motor control board to the outdoor unit. Dehumidification Options The motor control board (Figure 24 (page 30)) has a DEHUM connection that allows the system to increase the amount of humidity that is removed from the circulating air. This is accomplished by reducing the CFM and allowing the cooling coil to become colder. This will only occur when there is a call for cooling. There are many ways that this can be electrically wired: · If the room thermostat incorporates a humidity sensor and DEHUM output, connect the DEHUM on the thermostat to the DEHUM terminal on the motor control board. See Figure 20 (page 23). · If using a separate humidistat, connect the DEHUM & R terminals on the humidistat to the DEHUM & R terminals on the motor control board. See Figure 24. In this option, the DEHUM output of the humidistat must be set to be normally open and closed when there is a call for humidification. · If a humidistat is not available, it is an acceptable option to connect the R & DEHUM via a field supplied normally open relay. See Figure 21 (page 23). The R & DEHUM terminals should be connected across the normally open relay terminals. The O (B) & C terminals should then be connected across the relay coil. This option causes the blower to run at a reduced CFM for 10 minutes after a call for cooling. Heat Anticipator Set the heat anticipator according to the instructions supplied by the thermostat manufacturer. To determine the heat anticipator setting: 1. Add the current draw of the system components; or 2. Measure the current flow on the thermostat R & W circuit after the circulating blower motor has started. START-UP & ADJUSTMENTS Pre-Start Check List Verify the polarity of the connections are correct, the line voltage power leads are securely connected and the furnace is properly grounded. Verify that all needed thermostat wires are securely connected to the correct leads on the terminal strip of the circuit board. See Figure 17 (page 21), Figure 18 (page 21), & Figure 19 (page 21). Verify the gas line service pressure does not exceed 10.0 inches of water column, and is not less than 4.5 inches W.C. for natural gas. For LP gas the line service pressure must not exceed 14 in. W.C., and must not be less than 11.0 in. W.C. Verify the roll-out and manual reset switch is closed. If necessary, press the button to reset the switch. DO NOT install a jumper wire across a switch to defeat its function. If a switch reopens on start-up, DO NOT reset the switch without identifying and correcting the fault condition. Verify the blower door is in place, closing the door switch in the line voltage circuit. Verify the gas line has been purged and all connections are leak free. 22 HUMIDISTAT DHUM R MOTOR CONTROL BOARD DHUM R Figure 20. DEHUM Wiring Configuration with Humidistat ADDED RELAY (Normally Open) O (B) C BLOWER CONTROL R DEHUM Figure 21. DEHUM Wiring Configuration without Humidistat 2-STAGE GAS VALVES HI Input Adjusting Screw Lo Input Adjusting Screw Manifold Pressure Tap IN Inlet Pressure Tap ON OFF ON / OFF Knob Model VR8205Q2381 ON / OFF Switch HI Input Adjusting Screw Lo Input Adjusting Screw Manifold Pressure Tap Model VR9205Q1028 Inlet Pressure Tap Figure 22. HI & LO Input Adjusting Screws Start-up Procedures Do not perform these steps until all of the checks in the previous steps have been completed: 1. Set the thermostat to the lowest setting. 2. Turn off all electrical power to the furnace. 3. Follow the Operating Instructions on the furnace label. 4. Set the thermostat above room temperature and verify the Operating Sequence. See page 24. 5. After 5 minutes of operation, set the thermostat below room temperature and verify steps 11 & 12 of the Operating Sequence. Verifying & Adjusting Input Rate The input rate must be verified for each installation to prevent over-firing of the furnace. NOTE: The input rate must not exceed the rate shown on the furnace rating plate. At altitudes above 2,000 feet, it must not exceed that on the rating plate less 4% for each 1,000 feet. To determine the exact input rate, perform the following procedures: 1. Shut off all other gas fired appliances. 2. Start and run the furnace in high fire for at least 3 minutes. 3. Measure the time (in seconds) required for the gas meter to complete one revolution. 4. Convert the time per revolution to cubic feet of gas per hour using Table 6 (page 27). 5. Multiply the gas flow rate in cubic feet per hr by the heating value of the gas in Btu per cubic ft to obtain the input rate in Btuh. See example below. EXAMPLE: · Time for 1 revolution of a gas meter with a 1 cubic ft dial = 40 seconds. · From Table 6 read 90 cubic ft gas per hr. · Local heating value of the gas (obtained from gas supplier) = 1,040 Btu per cubic ft. · Input rate = 1,040 x 90 = 93,600 Btuh. 6. The manifold pressure must be set to the appropriate value for each installation by a qualified installer, service agency or the gas supplier. WARNING: Do not attempt to drill the gas orifices. Use only factory supplied orifices. Improperly drilled orifices may cause fire, explosion, carbon monoxide poisoning, personal injury or death. a. Remove plastic cap from pressure regulator. b. Obtain the manifold pressure setting required for this installation by referring to Table 8 (page 28) for Propane or Table 10 & Table 11 (page 29) for Natural Gas. c. Using an Allen wrench, turn the the LO Input Adjusting Screw on the LO side of the regulator to adjust the reduced input setting or turn the HI Input Adjusting Screw on the side of the regulator to adjust the full input setting. See Figure 22 (page 23). 23 NOTE: Turning the adjusting screw clockwise increases the pressure and counterclockwise reduces the pressure. d. Reinstall plastic cap after adjustment is complete. Verifying & Adjusting Temperature Rise Confirm the temperature rise through the furnace is within the limits specified on the furnace rating plate. Any temperature rise outside the specified limits could result in premature failure of the heat exchanger. 1. Place thermometers in the return and supply air stream as close to the furnace as possible. To avoid false readings, the thermometer on the supply air side must be shielded from direct radiation from the heat exchanger. 2. Adjust all registers and duct dampers to the desired position and run the furnace for 10 to 15 minutes in high fire before taking any temperature readings. The temperature rise is the difference between the supply and return air temperatures. For typical duct systems, the temperature rise will fall within the limits specified on the rating plate with the blower speed at the factory recommended setting. If the measured temperature rise is outside the specified limits, it may be necessary to change the speed of the blower. NOTE: Lowering the blower speed increases the temperature rise and a higher blower speed will decrease the temperature rise. The furnace is equipped with a multi-speed motor. Heating and cooling speed selection is made by moving the switches on the integrated control located in the furnace. Verifying Burner Operation CAUTION: The door over the burners may only be open for inspection purposes only. The door must be installed during unattended operation. 1. Remove the burner compartment door. 2. Set the thermostat above room temperature and observe the ignition sequence. The burner flame should carry over immediately between all burners without lifting off, curling, or floating. The flames should be blue, without yellow tips. 3. After validating flame characteristics, change thermostat setting to below room temperature. 4. Verify burner flame is completely extinguished. 5. Replace the burner compartment door. OPERATING SEQUENCE The operating sequences for the heating, cooling, and fan modes are described below. Refer to the field and furnace wiring diagrams: Figure 16 (page 20), Figure 17 (page 21), Figure 18 (page 21), Figure 19 (page 21) & Figure 26 (page 31). Heating Cycle 1. The thermostat calls for heat by energizing the W1 terminal with 24VAC. 2. The control checks to see the pressure switch is open. If the switch is closed, the furnace will shut down for 5 minutes before retrying 3. If the pressure switch is open, the control energizes the inducer motor and waits for the pressure switch to close. The pressure switch must close within 12 seconds. 4. The control runs the inducer for a 30 second pre-purge time. 5. The control energizes the igniter output for the appropriate adaptive warm-up time limit. 6. The furnace always ignites the burners in high fire. If the call for heat is for low rate, the furnace will move down to low fire after the flames stabilize. 7. If the flame is proved and ignites the gas, the control de-energizes the igniter. The gas valve and inducer remains energized. The control goes to blower on delay. 8. The control energizes the blower on the selected HEAT speed 22 seconds after the gas valve opened. The gas valve and inducer remain energized. 9. If there is a call for high fire, the gas valve moves to the high fire position and the blower speeds are increased. The furnace will remain in high fire until the demand for heat is satisfied. 10.If autostaging is enabled (single stage thermostat) the demand for heat has lasted more than the selected time, the furnace automatically moves up to high fire. Autostage time is ON (10 minutes) or OFF, depending on the Jumper (P7) setting on the furnace control board. 11.When the thermostat demand for heat is satisfied, the control de-energizes the gas valve. The inducer output remains on for a 30 second post-purge period. 12.The circulating air blower will continue to run for the selected Blower Off Delay(P5). This may be 60, 90, or 120 seconds depending on the jumper setting on the furnace control board. Cooling Cycle 1. The thermostat calls for cooling by energizing the Y / Y2 or Y1 terminal with 24VAC. 2. The control energizes the blower in the cooling speed and sends 24VAC to the contactor in the condensing unit. 3. When the thermostat removes the call for cooling, the contactor in the outdoor condensing unit is de-energized and the control continues to run the fan for a period of 60 seconds. 24 Fan Mode · When the thermostat energizes the G terminal for continuous fan (without calling for heat or cooling), the indoor fan is energized on the selected FAN speed. · If a call for cooling occurs during continuous fan, the blower will switch over to the selected COOL speed. · If the W terminal receives a call for heat during continuous fan, the blower will de energize. · A call for fan is ignored while in lockout. · For continuous fan operation, the blower motor will operate at 35% of the selected high-speed torque when equipped with a fixed speed motor control board. The blower motor will operate at 50% of the high-speed CMF when equipped with a variable speed motor control board. MAINTENANCE WARNING: ELECTRICAL SHOCK, FIRE OR EXPLOSION HAZARD Failure to follow safety warnings exactly could result in serious injury, death or property damage. Improper servicing could result in dangerous operation, serious injury, death or property damage. · Before servicing, disconnect all electrical power to furnace. · When servicing controls, label all wires prior to disconnecting. Reconnect wires correctly. · Verify proper operation after servicing. PropeProper maintenance is most important to achieve the best performance from a furnace. Follow these instructions for years of safe, trouble free operation. · These maintenance instructions are primarily intended to assist qualified technicians experienced in the proper maintenance and operation of this appliance. · Always reinstall the doors on the furnace after servicing or cleaning/changing the filters. Do not operate the furnace without all doors and covers in place. · Verify that the thermostat is properly installed and is not affected by drafts or heat from lamps or other appliances. · To achieve the best performance and minimize equipment failure it is recommended that a yearly maintenance checkup be performed. At a minimum, this check should include the following items: Air Filter(s) - Air filter(s) are not supplied with the furnace as shipped from the factory. The installer must provide a high velocity filter and rack for a filter in the return air duct adjacent to the furnace, or in a return air grill to the furnace. WARNING: Never operate the furnace without a filter in place. Dust and lint in the return air can build up on internal components, resulting in loss of efficiency, equipment damage, and possible fire. It is recommended that filters be 1" or 2" thick and be cleaned or replaced monthly. Filters designed to remove smaller particles such as pollen, may require additional maintenance. Filters for side return and bottom return applications are available from most local distributors. Blower Compartment - Dirt and lint can create excessive loads on the motor resulting in higher than normal operating temperatures and shortened service life. It is recommended that the blower compartment be cleaned of dirt or lint that may have accumulated in the compartment or on the blower and motor as part of the annual inspection. Cleaning of Burners - If the burners must be cleaned, follow the steps below and see Figure 29 (page 34) and for component location. 1. Shut off gas supply to the furnace either at the meter or at a manual valve in the supply piping. 2. Turn off all power to the furnace and set the thermostat to it's lowest setting. 3. Remove the burner door from the furnace. 4. Turn the gas control switch to the OFF position. 5. Disconnect the wires from the gas valve, igniter, flame sensor, and flame rollout switch. CAUTION: To prevent damage to the unit or internal components, it is recommended that two wrenches be used when loosening or tightening nuts. Do not over tighten! 6. Using two wrenches, separate the ground-joint union in the gas supply piping at the furnace. 7. Remove the piping between the Gas Valve and the ground-joint union. (If applicable). 8. Remove all screws securing the Manifold Assembly to the Burner Box. 25 9. Carefully remove the burner assembly from the furnace. DO NOT DAMAGE THE IGNITER WHILE REMOVING THE BURNER ASSEMBLY. 10.Inspect the burners for accumulated dust or debris. If necessary carefully clean them with a soft wire brush and a vacuum cleaner. DO NOT DAMAGE THE IGNITER WHILE CLEANING THE BURNER. 11.Replace all the parts in reverse order from which they were removed. 12.Follow the lighting instructions found on the furnace door to return the furnace to operation. Verify proper operation after servicing. Heat Exchanger & Burner Maintenance - The furnace should operate for many years without soot buildup in the flue passageways, however, the flue, vent system, and burners should be inspected and cleaned (if required) by a qualified service technician annually to ensure continued safe operation. Pay attention to any deterioration from corrosion or other sources. WARNING: Holes in the vent pipe or heat exchanger can cause combustion products to enter the home. Replace the vent pipe or heat exchanger if leaks are found. Failure to prevent the circulation of combustion products into the living space can create potentially hazardous conditions including carbon monoxide poisoning that could result in personal injury or death. Lubrication - The bearings in the blower motor and inducer blower used in these furnaces are pre-lubricated and sealed by the manufacturer. No further oiling of the bearings is required for the life of the motor. Vent System - Check the inlet pipe (if applicable) and outlet pipe to ensure they are not blocked by debris. Any damaged section of vent pipe must be replaced, and any obstruction or blockage must be removed prior to operating the furnace. FIGURES & TABLES J962V*D 96% DOWNFLOW FURNACE CABINET SIZE `B' Cabinet `C' Cabinet `D' Cabinet DIM. "A" 17 1/2 21 24 1/2 DIM. "B" 15 7/8 19 3/8 22 7/8 DIM. "C" 16 1/8 19 5/8 23 1/8 TOP VIEW B FLANGES 19 NOTE: Dimensions shown in inches. Flue 3 Combustion Air 7 1/2 28 25 1/4 22 1/4 25 1/2 Electric (Ø 7/8) Gas (Ø 1 5/8) T-stat (Ø 7/8) A Electric (Ø 7/8) Gas (Ø 1 5/8) 34 1/2 10 1/4 17 1/4 22 1/2 Vent pipe (Ø 3") Cond. (Ø 1 1/16) LEFT SIDE FRONT VIEW Figure 23. J962V*D Cabinet Dimensions 18 1/2 BOTTOM VIEW C Front Brace 22 1/4 25 Vent pipe (Ø 3") 22 1/2 25 3/8 Cond. (Ø 1 1/16) RIGHT SIDE 26 22 1/2 17 1/4 17 7/16 29 1/2 Gas Information GAS FLOW RATES (CUBIC FEET PER HOUR) GAS FLOW RATES (CUBIC FEET PER HOUR) TIME FOR ONE REVOLUTION (SECONDS) 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40 42 44 46 48 50 52 54 56 58 60 62 64 CUBIC FEET PER REVOLUTION OF GAS METER 1 5 10 360 1,800 3,600 300 1,500 3,000 257 1,286 2,571 225 1,125 2,250 200 1,000 2,000 180 900 1,800 164 818 1,636 150 750 1,500 138 692 1,385 129 643 1,286 120 600 1,200 113 563 1,125 106 529 1,059 100 500 1,000 95 474 947 90 450 900 86 429 857 82 409 818 78 391 783 75 375 750 72 360 720 69 346 692 67 333 667 64 321 643 62 310 621 60 300 600 58 290 581 56 281 563 TIME FOR ONE REVOLUTION (SECONDS) 66 68 70 72 74 76 78 80 82 84 86 88 90 92 94 96 98 100 102 104 106 108 110 112 114 116 118 120 CUBIC FEET PER REVOLUTION OF GAS METER 1 5 10 55 273 545 53 265 529 51 257 514 50 250 500 49 243 486 47 237 474 46 231 462 45 225 450 44 220 439 43 214 429 42 209 419 41 205 409 40 200 400 39 196 391 38 191 383 38 188 375 37 184 367 36 180 360 35 176 353 35 173 346 34 170 340 33 167 333 33 164 327 32 161 321 32 158 316 31 155 310 31 153 305 30 150 300 Table 6. Gas Flow Rates CAPACITY OF BLACK IRON GAS PIPE (CU. FT. PER HOUR) FOR NATURAL GAS W/ SPECIFIC GRAVITY = 0.60 NOMINAL PIPE LENGTH OF PIPE RUN (FEET) DIAMETER (IN.) 10 20 30 40 50 60 70 80 1/2 130 90 75 65 55 50 45 40 3/4 280 190 150 130 115 105 95 90 1 520 350 285 245 215 195 180 170 1 1/4 1,050 730 590 500 440 400 370 350 1 1/2 1,600 1,100 890 760 670 610 Input To Furnace (Btu/hr) Cubic Feet Per Hour Required = Heating Value of Gas (Btu/Cu. Ft.) NOTE: The cubic feet per hour listed in the table above must be greater than the cubic feet per hour of gas flow required by the furnace. To determine the cubic feet per hour of gas flow required by the furnace, divide the input rate of the furnace by the heating value (from gas supplier) of the gas. Table 7. Gas Pipe Capacities 27 HIGH ALTITUDE DERATION PROPANE GAS ALTITUDE ABOVE SEA LEVEL 0 to 1,999 FT 2,000 to 2,999 FT 3,000 to 4,999 FT 5,000 to 5,999 FT 6,000 to 7,999 FT 8,000 to 10,000 FT 60,000 1ST 2ND 55 4.2 10.0 55 4.2 9.0 55 4.2 8.5 56 4.2 10.0 56 4.2 9.0 56 4.2 8.5 INPUT (BTU) & STAGE 80,000 100,000 1ST 2ND 1ST 2ND 55 55 4.2 10.0 4.2 10.0 55 55 4.2 9.0 4.2 9.0 55 55 4.2 8.5 4.2 8.5 56 56 4.2 10.0 4.2 10.0 56 56 4.2 9.0 4.2 9.0 56 56 4.2 8.5 4.2 8.5 115,000 1ST 2ND 55 4.2 10.0 55 4.2 9.0 55 4.2 8.5 56 4.2 10.0 56 4.2 9.0 56 4.2 8.5 ORIFICE SIZE MANIFOLD PRESSURE ORIFICE SIZE MANIFOLD PRESSURE ORIFICE SIZE MANIFOLD PRESSURE ORIFICE SIZE MANIFOLD PRESSURE ORIFICE SIZE MANIFOLD PRESSURE ORIFICE SIZE MANIFOLD PRESSURE Table 8. High Altitude Deration - Propane Gas LOCAL HEATING VALUES FOR NATURAL GAS ALTITUDE ABOVE SEA LEVEL 2,000 FT 3,000 FT 4,000 FT 5,000 FT 6,000 FT 7,000 FT 8,000 FT 9,000 FT 10,000 FT 650 LOW LOW LOW LOW LOW LOW LOW LOW LOW 700 LOW LOW LOW LOW LOW LOW LOW LOW LOW BTU PER CUBIC FOOT 750 LOW LOW LOW LOW LOW LOW LOW LOW HIGH 800 LOW LOW LOW LOW LOW LOW HIGH HIGH HIGH 850 LOW LOW LOW LOW HIGH HIGH HIGH HIGH HIGH 900 LOW LOW HIGH HIGH HIGH HIGH HIGH HIGH HIGH 950 HIGH HIGH HIGH HIGH HIGH HIGH HIGH HIGH HIGH 1,000 HIGH HIGH HIGH HIGH HIGH HIGH HIGH HIGH HIGH 1,050 HIGH HIGH HIGH HIGH HIGH HIGH HIGH HIGH HIGH Table 9. Natural Gas Heating Values 28 HIGH ALTITUDE DERATION NATURAL GAS WITH HIGH HEATING VALUE ALTITUDE ABOVE SEA LEVEL 0 to 1,999 FT 2,000 to 2,999 FT 3,000 to 3,999 FT 4,000 to 4,999 FT 5,000 to 5,999 FT 6,000 to 6,999 FT 7,000 to 7,999 FT 8,000 to 8,999 FT 9,000 to 9,999 FT 60,000 1ST 2ND 45 1.7 3.5 45 1.7 3.3 45 1.7 3.1 45 1.7 2.9 45 1.7 2.8 48 1.7 3.5 48 1.7 3.3 48 1.7 3.0 48 1.7 2.8 INPUT (BTU) & STAGE 80,000 100,000 1ST 2ND 1ST 2ND 45 1.7 3.5 45 1.7 3.5 45 45 1.7 3.3 1.7 3.3 45 45 1.7 3.1 1.7 3.1 45 45 1.7 2.9 1.7 2.9 45 45 1.7 2.8 1.7 2.8 48 48 1.7 3.5 1.7 3.5 48 48 1.7 3.3 1.7 3.3 48 48 1.7 3.0 1.7 3.0 48 1.7 2.8 48 1.7 2.8 115,000 1ST 2ND 46 1.7 3.5 46 1.7 3.3 46 1.7 3.1 46 1.7 2.9 46 1.7 2.8 48 1.7 3.5 48 1.7 3.3 48 1.7 3.0 48 1.7 2.8 ORIFICE SIZE MANIFOLD PRESSURE ORIFICE SIZE MANIFOLD PRESSURE ORIFICE SIZE MANIFOLD PRESSURE ORIFICE SIZE MANIFOLD PRESSURE ORIFICE SIZE MANIFOLD PRESSURE ORIFICE SIZE MANIFOLD PRESSURE ORIFICE SIZE MANIFOLD PRESSURE ORIFICE SIZE MANIFOLD PRESSURE ORIFICE SIZE MANIFOLD PRESSURE Table 10. High Altitude Deration - Natural Gas with HIGH Heating Value HIGH ALTITUDE DERATION NATURAL GAS WITH LOW HEATING VALUE) ALTITUDE ABOVE SEA LEVEL 0 to 1,999 FT 2,000 to 2,999 FT 3,000 to 3,999 FT 4,000 to 4,999 FT 5,000 to 5,999 FT 6,000 to 6,999 FT 7,000 to 7,999 FT 8,000 to 8,999 FT 9,000 to 9,999 FT 60,000 1ST 2ND 45 1.7 3.5 45 1.7 3.5 45 1.7 3.4 45 1.7 3.2 45 1.7 3.1 45 1.7 2.9 48 1.7 3.5 48 1.7 3.3 48 1.7 3.1 INPUT (BTU) & STAGE 80,000 100,000 1ST 2ND 1ST 2ND 45 1.7 3.5 45 1.7 3.5 45 45 1.7 3.5 1.7 3.5 45 45 1.7 3.4 1.7 3.4 45 45 1.7 3.2 1.7 3.2 45 45 1.7 3.1 1.7 3.1 45 45 1.7 2.9 1.7 2.9 48 48 1.7 3.5 1.7 3.5 48 48 1.7 3.3 1.7 3.3 48 1.7 3.1 48 1.7 3.1 115,000 1ST 2ND 46 1.7 3.5 46 1.7 3.5 46 1.7 3.4 46 1.7 3.2 46 1.7 3.1 46 1.7 2.9 48 1.7 3.5 48 1.7 3.3 48 1.7 3.1 ORIFICE SIZE MANIFOLD PRESSURE ORIFICE SIZE MANIFOLD PRESSURE ORIFICE SIZE MANIFOLD PRESSURE ORIFICE SIZE MANIFOLD PRESSURE ORIFICE SIZE MANIFOLD PRESSURE ORIFICE SIZE MANIFOLD PRESSURE ORIFICE SIZE MANIFOLD PRESSURE ORIFICE SIZE MANIFOLD PRESSURE ORIFICE SIZE MANIFOLD PRESSURE Table 11. High Altitude Deration - Natural Gas with LOW Heating Value 29 OUTPUT TERMINALS HUMIDIFIER OUTPUT W_OUT Y/Y2_OUT Y1_OUT H_OUT RED Electrical Information STATUS LIGHTS L2-OUT L2-IN RED GREEN L1-IN L1-OUT DEHUMIDIFIER OUTPUT NOT FOR FIELD USE R C OFF ON FAN SPEED DHUM_IN 1 2 3 4 5 6 7 8 Y1_IN HEAT COOL SENSOR EXPANSION PORT CONNECTION TO FURNACE CONTROL BOARD GROUND MOTOR WIRING HARNESS FOR USE WITH IQ OUTDOOR UNITS Figure 24. Two-Stage Variable Speed Motor Control Board INPUT TERMINALS FOR WIRING TO THE MOTOR CONTROL BOARD Y/Y2 Y1 G W2 W1 C R FUSE STATUS AUTO STAGE OFF ON EXPANSION THERMOSTAT CONNECTIONS PORT GREEN RED 10 11 12 789 456 123 YELLOW (FLAME) BLOWER OFF 60 90 120 DELAY 180 INPUTS 12345 NEUTRALS EAC XMFR LINE LINE HUM XMFR-N LINE- N LINE- N Figure 25. Two-Stage Furnace Control Board 30 WHITE BLACK Figure 26. Wiring Diagram for Two-Stage, Variable Speed Downflow Furnaces 31 WIRING DIAGRAM For 80+ and 90+ 2-Stage Variable Speed Downflow Furnaces Refer to the Installation Instructions provided with the kit for the proper heating and cooling speeds for your application. This wiring diagram shows connections and termination required for the blower kit only. Use in addition to the wiring diagram for the furnace. If any of the origInal wire as supplied with the furnace must be replaced, it must be replaced with wiring material having a temperature rating of at least 105° C. Use copper conductors only. HIGH PRESSURE SWITCH LOW PRESSURE SWITCH WHITE W/ BLK STRIPES 24 V BLK W/ WHITE STRIPES 1234 1234 WHITE 120 V BLACK FAULT CONDITIONS Diagnostic Description Green LED Red LED Control Fault (No Power) Off Off L1 / Neutral Polarity Fault Flash Flash 1 Hour Lockout Alternating Flash Normal Operation On On Pressure Switch Closed Fault On Flash Pressure Switch Open Fault Flash On Open Limit Switch Fault Flash Off Motor Fault On Off Diagnostic Description Yellow LED Low Flame Sensor Signal Continuous Flash Flame Present On PART OF MOTOR BROWN GRAY 12 BLACK WHITE L1-IN L1OUT VIOLET VIOLET ORANGE ORANGE GREEN GAS VALVE C 33 HI 2 2 LO 1 1 BROWN BROWN YELLOW FLAME SENSOR RED BLUE Y/Y2 Y1 G W2 W1 C R 10 11 12 789 456 123 BLWR OFF DELAY RWX TCXOM RC MOTOR CHOKE (ON 3/4 AND 1HP MODELS ONLY) BLACK BLACK L2-IN L2-OUT GREEN RED W/O Y/Y2 Y1 H COOL HEAT FAN SPEED DHUM Y1 SEN GND PWM MODE SPEED FAULT COMMON HP OPEN OPEN R C RX GND TX W RC R DX+ DXC 11 33 44 88 CFM MOTOR ORANGE 7 7 WHITE 6 6 BLACK 5 5 YELLOW 2 2 RED WHITE BLACK BLACK BLACK WHITE BLUE SUPPLY AIR LIMIT FLAME ROLL-OUT BLUE VENT LIMIT (ON SELECT MODELS) WHITE (NEUTRAL) BLACK 120V GROUND GREEN WHITE BLACK BLACK DOOR SWITCH RESISTOR (SELECT MODELS) INDUCER 12345 BLACK BLACK RED WHITE BLACK LEGEND: FIELD WIRING LOW VOLTAGE HIGH VOLTAGE C 11 H 22 L 1 23 1 23 LINE- N LINE- N XMFR-N HUM LINE LINE XMFR EAC IGNITOR BLUE BLACK WHITE YELLOW 1 1 YELLOW RED 2 2 RED BLACK 3 3 BLACK WHITE 4 4 WHITE ORANGE 5 5 ORANGE BLUE 66 77 88 BLACK 99 WHITE BLUE BLUE BLOWER LIMIT BLOWER DECK LIMIT BLOWER LIMIT 1016089A 12/16 Venting Information VENT TERMINAL AIR SUPPLY INLET AREA WHERE TERMINAL IS NOT PERMITTED CANADIAN INSTALLATIONS A US INSTALLATIONS B CLEARANCE LOCATION DIRECT VENT (2-PIPE) & CONVENTIONAL VENT (1-PIPE) FURNACES DIRECT VENT (2-PIPE) FURNACES CONVENTIONAL VENT (1-PIPE) FURNACES A = Clearance above grade, veranda, porch, deck, balcony, or maximum expected snow level. 12 inches (30cm) 6 inches (15cm) for appliances < 10,000 Btuh (3kW) B = Clearance to window or door that may be opened. 12 inches (30cm) for appliances 10,000 Btuh - 100,000 Btuh (30kW) C = Clearance to permanently closed window Vertical clearance to ventilated soffit located D = above the terminal within a horizontal distance of 2 feet (61cm) from the center line of the terminal. E = Clearance to unventilated soffit. F = Clearance to outside corner. G = Clearance to inside corner. 36 inches (91cm) for appliances > 100,000 Btuh (30Kw) * * * * * H = Clearance to each side of center line extended above meter/regulator assembly. 3 feet (91cm) within a height 15 feet above the meter/regulator assembly I = Clearance to service regulator vent outlet. 3 feet (1.83m) Clearance to non-mechanical air supply inlet to J = building or the combustion air inlet to any other appliance. 6 inches (15cm) for appliances < 10,000 Btuh (3kW) 12 inches (30cm) for appliances 10,000 Btuh - 100,000 Btuh (30kW) 36 inches (91cm) for appliances > 100,000 Btuh (30Kw) 12 inches (30cm) 6 inches (15cm) for appliances < 10,000 Btuh (3kW) 9 inches (23cm) for appliances 10,000 Btuh - 50,000 Btuh (30kW) 12 inches (30cm) for appliances > 50,000 Btuh (30Kw) * * * * * * * 6 inches (15cm) for appliances < 10,000 Btuh (3kW) 9 inches (23cm) for appliances 10,000 Btuh - 50,000 Btuh (30kW) 12 inches (30cm) for appliances > 50,000 Btuh (30Kw) 12 inches (30cm) 4 ft. (1.2m) below or to side of opening; 1 ft. (300mm) above opening * * * * * * * 4 ft. (1.2m) below or to side of opening; 1 ft. (300mm) above opening K = Clearance to mechanical air supply inlet. 6 feet (1.83m) 3 feet (91cm) above if within 10 feet (3m) horizontally 3 ft. (91cm) above if within 10 feet (3m) horizontally L = Clearance above paved sidewalk or driveway located on public property. 7 feet (2.13m) c * 7 ft. (2.13m) M = Clearance under veranda, porch, deck, or balcony. 12 inches (30cm) d * * a: In accordance with the current CSA B149.1 Natural Gas and Propane Installation Guide Code b: In accordance with the current ANSI Z223.1 / NFPA 54 Natural Fuel Gas Code c: A vent shall not terminate directly above a sidewalk or paved driveway that is located between two single family dwellings and serves both dwellings. d: Permitted only if veranda, porch, deck, or balcony is fully open on a minimum of two sides beneath the floor. * For clearances not specified in ANSI Z223.1 / NFPA 54 or CSA B149.1, the following statement shall be included: "Clearance in accordance with local installation codes, and the requirements of the gas supplier and the manufacturers installation instructions" Table 12. Vent Termination Clearances 32 FLUE PIPE DOWNFLOW - 1 PIPE OPTIONS (B, C, & D WIDTH CABINETS ONLY) COMBUSTION AIR Rubber Grommet COMBUSTION AIR COMBUSTION AIR OPTION 1 X See NOTE 5 Rubber Grommet FLUE PIPE PVC Tee PVC Trap OPTION 2 Plug Plug PVC Tee PVC Trap Plug See VIEW A for drain line positions See VIEW B for drain line positions Plug FLUE PIPE X See NOTE 5 OPTION 3 Rubber Grommet See VIEW C for drain line positions VIEW -A- Inline Drain (Factory Supplied) VIEW -B- Field Supplied Drain Line Attached to PVC Trap (Do Not Trap) VIEW -C- Inline Drain (Factory Supplied) See NOTE 4 Field Supplied Drain Line Attached to PVC Trap (Do Not Trap) Collector Box Drain (Factory Equipped) See NOTE 3 Collector Box Drain (Factory Equipped) See NOTE 3 NOTES: 1. See Accessories section (page 16) for optional PVC Tee configurations and drainage options. 2. Drain line traps may be positioned inside or outside the cabinet. 3. All drain lines must be trapped with J-Trap or field supplied loop and drained externally from the cabinet. 4. Inline drain is required only if "X" is greater than 6 feet. 5. Horizontal piping from inducer to flue pipe must be sloped 1/4" per foot to ensure drainage to PVC trap. Inline Drain Collector Box Drain (Field Supplied) (Factory Equipped) See NOTES 3 & 4 See NOTE 3 DOWNFLOW - 2 PIPE OPTIONS (B, C, & D WIDTH CABINETS ONLY) COMBUSTION AIR FLUE PIPE COMBUSTION AIR Plug COMBUSTION AIR FLUE PIPE Plug Flange Rubber Grommet Flange Plug Flange OPTION 4 X See NOTE 5 Rubber Grommet See VIEW A for drain line positions PVC Tee PVC Trap OPTION 5 Plug Plug PVC Tee PVC Trap See VIEW B for drain line positions Plug FLUE PIPE X See NOTE 5 OPTION 6 Rubber Grommet See VIEW C for drain line positions Figure 27. J962V*D Inducer & Venting Options 33 Support System on Vertical Rise Couplings with 2 Hose Clamps (Optional) COMBUSTION AIR FLUE PIPE 1 2 34 5678 90° Elbow Couplings with 2 Hose Clamps (Optional) COMBUSTION AIR FLUE PIPE See Note Seal/Caulk Around Pipes at Building 90° Elbow Upward Pitch - 1/4" per foot (Flue Pipe) Wall 7" 12" Min. Normal Snow Level 1 2 34 5678 NOTE: Straps or other suitable supports at minimum of 5 ft. Intervals. First support placed as close to furnace connection as possible. AIR FLOW AIR FLOW VERTICAL VENTING W/ 2-PIPES (B, C, & D WIDTH CABINETS) HORIZONTAL VENTING W/ 2-PIPES (B, C, & D WIDTH CABINETS) Figure 28. Horizontal & Vertical Venting (B, C, & D Width Cabinets) Blower Assembly (behind blower panel) Motor Choke (C & D cabinets only) Finish Flange Furnace Control Board Motor Control Board 1 2 34 5678 Blower Door Switch (behind blower panel) Transformer Pressure Switches Vent Limit Switch AIR FLOW Inducer Assembly Gas Valve Igniter Main Air Limit Switch Flame Sensor Burner Assembly Roll-Out Switch Gas Manifold Figure 29. J962V*D Component Locations 34 TROUBLESHOOTING If the furnace fails to operate check the following: · Is the thermostat operating properly? · Are the blower compartment door(s) in place? · Is the furnace disconnect closed? · Has the circuit breaker tripped or the control board fuse burned open? · Is the gas turned on? · Are any manual reset switches open? · Is the filter dirty or plugged? · Is the flame sensor coated? (Remove and clean with steel wool. Do not use emery cloth or sandpaper! · Are all the LED's on the furnace and motor control boards constantly ON? If not, refer to Table 13 & Table 14 or the wiring diagram (Figure 26 (page 31) to determine fault condition. IMPORTANT NOTE The furnace will lock out after 5 failed attempts for ignition and will try again every hour if the call for heat remains. · If the Inducer Blower is operating, and items above have been verified, check the Blower Limit Switch and reset if necessary. See Figure 29 (page 34). · If the furnace operates when the Blower Limit Switch is reset, contact a qualified service technician to identify and repair the problem. DIAGNOSTIC DESCRIPTION Control Fault (No Power) L1/Neutral Polarity Fault 1 Hour Lockout Normal Operation Pressure Switch Closed Fault Pressure Switch Open Fault Open Limit Switch Fault Motor Fault DIAGNOSTIC DESCRIPTION Low Flame Sensor Signal Flame Present GREEN LED RED LED Off Off Flash Flash Alternating Flash On On On Flash Flash On Flash Off On Off YELLOW LED Continuous Flash On · If the furnace still doesn't operate, check the Flame Roll-out Switches (Figure 29) and reset if necessary. · If the furnace operates when the Flame Rollout Switch is reset, contact a qualified service technician to identify and repair the problem. FURNACE COMPONENTS The descriptions below are various functional components that affect the operation and shutting down of this furnace. Some of these components and their locations are shown in Figure 29 (page 34). If any component of the furnace must be replaced, use only factory authorized replacement parts specified in the Replacement Parts List provided online. Blower Limit Switch - Prevents operation when blower is not operational. Condensate Drain Switch - The Condensate Drain Switch will shut down the furnace if the condensate drain from the Collector Pan becomes clogged. Flame Sensor - Verifies when a flame has carried over from the igniter to the opposite end burner. If no flame is detected, the furnace will shut down within 4 seconds. Flame Roll-Out Switch - Verifies that the burner flames are drawn into the heat exchanger tubes. If the burner flames are not properly drawn into the heat exchanger, the flame roll-out switch will close the gas valve and initiate the shutdown cycle. Gas Valve - Controls the flow of gas to the burners. When the gas valve is energized it automatically opens and regulates the gas pressure in the manifold. Inducer Assembly - Vents products of combustion to the outside. Pressure Switches - Verifies that the inducer is drawing the combustion gases through the heat exchanger. The pressure switch prevents furnace operation with excessive flue / condensate blockage or improper inducer operation. Supply Air Limit Switch - Prevents the air temperature leaving the furnace from exceeding the maximum allowable outlet air temperature. Table 13. Furnace Control Board Fault Conditions DIAGNOSTIC DESCRIPTION Variable Speed Furnaces Control Fault (No Power) Normal Operation Motor Fault Communications Fault GREEN LED Off On On Flash RED LED Off On Flash Flash Table 14. Motor Control Board Fault Conditions 35 INSTALLATION CHECKLIST INSTALLER NAME: CITY: STATE: INSTALLATION ADDRESS: CITY: STATE: UNIT MODEL # UNIT SERIAL # Minimum clearances as shown in Figure 1 (page 6)? YES NO Has the owner's information been reviewed with the home-owner? YES NO Has the literature package been left near the furnace? YES NO ATTENTION INSTALLERS: It is your responsibility to know this product better than your customer. This includes being able to install the product according to strict safety guidelines and instructing the customer on how to operate and maintain the equipment for the life of the product. Safety should always be the deciding factor when installing this product and using common sense plays an important role as well. Pay attention to all safety warnings and any other special notes highlighted in the manual. Improper installation of the furnace or failure to follow safety warnings could result in serious injury, death, or property damage. These instructions are primarily intended to assist qualified individuals experienced in the proper installation of this appliance. Some local codes require licensed installation/service personnel for this type of equipment. Please read all instructions carefully before starting the installation. Return these instructions to the customer's package for future reference. ELECTRICAL SYSTEM Electrical connections tight? Line voltage polarity correct? YES NO YES NO Supply Voltage: ............................................................... VOLTS Has the thermostat been calibrated? YES NO Is the thermostat level? YES NO Is the heat anticipator setting correct? YES NO GAS SYSTEM Gas Type: (circle one) Gas pipe connections leak tested? Natural Gas YES Propane NO Gas Line Pressure:.......................................................... (in - W.C.) Installation Altitude:............................................................(FT.) Deration Percentage:.........................................................(%) Furnace Input:....................................................................(Btuh) Supply Air Temperature: ...................................................(° F) Return Air Temperature: ...................................................(° F) Temperature Rise: ............................................................(° F) COMBUSTION AIR & VENTING SYSTEM Is there adequate fresh air supply for combustion and ventilation? YES NO Vent free from restrictions? Filter(s) secured in place? Filter(s) clean? Flue connections tight? Is there proper draft? YES NO YES NO YES NO YES NO YES NO TwentyThreeC, LLC 800 Beaty Street, Davidson NC 28036 https://www.oxboxhvac.com For more information contact your local dealer (distributor) Since the manufacturer has a policy of continuous product and product data improvement, it reserves the right to change the design and specification without notice. 01/23 TwentyThreeC, LLC. 1027212C (Replaces 1027212B)