Carrier 986TC Installation, Start-Up, Operating And Service And Maintenance Instructions Download

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986TC

TWO--STAGE, VARIABLE--SPEED MULTIPOISE

35 in. (889 mm) Tall CONDENSING GAS FURNACE

Installation, Start--up, Operating and

Service and Maintenance Instructions

NOTE

: Read the entire instruction manual before starting the installation.

SECTION

SAFETY CONSIDERATIONS

. . . . . . . . . . . . . . . . . . . . . . . . .

INTRODUCTION

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CODES AND STANDARDS

. . . . . . . . . . . . . . . . . . . . . . . . . . .

ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS

. . .

ACCESSORIES

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

LOCATION

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

AIR FOR COMBUSTION AND VENTILATION

. . . . . . . . . .

CONDENSATE TRAP

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CONDENSATE DRAIN

. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

INSTALLATION

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

AIR DUCTS

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

GAS PIPING

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ELECTRICAL CONNECTIONS

. . . . . . . . . . . . . . . . . . . . . . .

VENTING

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

START--UP, ADJUSTMENT, AND SAFETY CHECK

. . . . . .

SERVICE AND MAINTENANCE PROCEDURES

. . . . . . . .

SEQUENCE OF OPERATION

. . . . . . . . . . . . . . . . . . . . . . . .

PARTS REPLACEMENT GUIDE

. . . . . . . . . . . . . . . . . . . . . .

TABLE

Loose Parts Bag Contents

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Minimum Clearances to Combustible Materials

. . . . . . . . . . . . .

Minimum Free Area Required

. . . . . . . . . . . . . . . . . . . . . . . . .

Minimum Space Volumes

. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Filter Size Information

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Opening Dimensions

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Air Delivery CFM

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Maximum Capacity of Pipe

. . . . . . . . . . . . . . . . . . . . . . . . . . .

Electrical Data

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Vent Termination Kit for Direct Vent (2--Pipe) Systems

. . . . . .

Combustion--Air Vent Pipe, Fitting & Cement Material..

. . . . .

Maximum Allowable Exposed Vent Lengths Insulation

. . . . . .

Maximum Equivalent Vent Length

. . . . . . . . . . . . . . . . . . . . . .

Deductions from Maximum Equivalent Vent Length

. . . . . . . .

Altitude Derate Multiplier for U.S.A.

. . . . . . . . . . . . . . . . . . . .

Blower Off Delay Setup Switch

. . . . . . . . . . . . . . . . . . . . . . . .

Gas Rate

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Orifice Size and Manifold Pressure

. . . . . . . . . . . . . . . . . . . . .

Use of the AHRI Certified TM Mark indicates a

manufacturer’s participation in the program.

For verification of certification for individual

products, go to www.ahridirectory.org .

Portions of the text and tables are reprinted from NFPA 54/ANSI Z223.1

, with permission of National Fire Protection Association,

Quincy, MA 02269 and American Gas Association, Washington DC 20001. This reprinted material is not the complete and official position

of the NFPA or ANSI on the referenced subject, which is represented only by the standard in its entirety.

Summary of Contents for 986TC

Page 1: ...mation 28 Opening Dimensions 29 Air Delivery CFM 31 Maximum Capacity of Pipe 34 Electrical Data 38 Vent Termination Kit for Direct Vent 2 Pipe Systems 43 Combustion Air Vent Pipe Fitting Cement Material 52 Maximum Allowable Exposed Vent Lengths Insulation 53 Maximum Equivalent Vent Length 53 Deductions from Maximum Equivalent Vent Length 55 Altitude Derate Multiplier for U S A 75 Blower Off Delay ...

Page 2: ...e exhaust vent terminal for the horizontally vented gas fueled heating appliance or equipment The sign shall read in print size no less than one half 1 2 in in size GAS VENT DIRECTLY BELOW KEEP CLEAR OF ALL OBSTRUCTIONS 4 INSPECTION The state or local gas inspector of the side wall horizontally vented gas fueled equipment shall not approve the installation unless upon inspection the inspector obse...

Page 3: ...nctions such as cleaning and replacing air filters All other operations must be performed by trained service personnel When working on heating equipment observe precautions in literature on tags and on labels attached to or shipped with furnace and other safety precautions that may apply These instructions cover minimum requirements and conform to existing national standards and safety codes In so...

Page 4: ...ght setback thermostat Return air temperature must not exceed 80_F 27_C db Failure to follow these return air temperature limits may affect reliability of heat exchangers motors and controls See Fig 3 The furnace should be sized to provide 100 percent of the design heating load requirement plus any margin that occurs because of furnace model size capacity increments None of the furnace model sizes...

Page 5: ...o prevent ESD damage ACCESSORIES See Product Data Sheet for a list of accessories for this product LOCATION PERSONAL INJURY AND OR PROPERTY DAMAGE HAZARD Improper use or installation of this furnace may result in premature furnace component failure Unless otherwise prohibited this gas furnace may be used for heating buildings under construction provided that The furnace is permanently installed wi...

Page 6: ...furnace cabinet and the return air duct to prevent pulling air from the burner area FIRE INJURY OR DEATH HAZARD Failure to follow this warning could result in personal injury death and or property damage When the furnace is installed in a residential garage the burners and burner ignition devices must be located at least 18 in 457 mm above the floor The furnace must be located or protected to avoi...

Page 7: ... 17 1 2 445 15 7 8 403 16 406 8 3 4 222 151 0 68 5 42080C17 17 1 2 445 15 7 8 403 16 406 8 3 4 222 152 5 69 2 60080C21 21 533 19 3 8 492 19 1 2 495 10 1 2 267 171 5 77 8 66100C21 21 533 19 3 8 492 19 1 2 495 10 1 2 267 179 81 2 66120C24 24 1 2 622 22 7 8 581 23 584 12 1 4 311 195 88 4 Fig 1 Dimensional Drawing ...

Page 8: ...OWER IS LOCATED TO THE LEFT OF THE BURNER SECTION AND CONDITIONED AIR IS DISCHARGED TO THE RIGHT A12181 Fig 2 Multipoise Orientations 60 80 27 C 16 C SUPPLY AIR SEE PRODUCT DATA FOR ACCESSORY CONDENSATE TRAP HEATER AND CONDENSATE DRAIN LINE PROTECTION A150573 Fig 3 Freeze Protection and Return Air Temperature BACK POSITIONED DOWNWARD AIR RETURN CUT IN BACK BACK POSITIONED UPWARD A12182 Fig 4 Prohi...

Page 9: ... exchangers and shorten furnace life Air contaminants are found in aerosol sprays detergents bleaches cleaning solvents salts air fresheners and other household products CAUTION CARBON MONOXIDE POISONING HAZARD Failure to follow this warning could result in personal injury or death The operation of exhaust fans kitchen ventilation fans clothes dryers attic exhaust fans or fireplaces could create a...

Page 10: ...m2 kW of the total input rating of all gas appliances in the space but not less than 100 in 2 0 06 m2 One opening shall commence within 12 in 300 mm of the ceiling and the second opening shall commence within 12 in 300 mm of the floor The minimum dimension of air openings shall be at least 3 in 80 mm See Fig 7 c Combining space on different floor levels The volumes of spaces on different floor lev...

Page 11: ...s Table 4 Minimum Space Volumes for 100 Combustion Ventilation and Dilution Air from Outdoors OTHER THAN FAN ASSISTED TOTAL 1 000 S BTUH GAS INPUT RATE FAN ASSISTED TOTAL 1 000 S BTUH GAS INPUT RATE ACH 30 40 50 40 60 80 100 120 140 Space Volume Ft3 M3 0 60 1 050 29 7 1 400 39 6 1 750 49 5 1 400 39 6 1 500 42 5 2 000 56 6 2 500 70 8 3 000 84 9 3 500 99 1 0 50 1 260 35 6 1 680 47 5 2 100 59 4 1 680...

Page 12: ...ox for proper condensate drainage See the bottom images in Fig 11 and 12 A field supplied accessory Horizontal Installation Kit trap grommet is required for all direct vent horizontal installations only The kit contains a rubber casing grommet designed to seal between the furnace casing and the condensate trap See Fig 8 Remove knockout Install grommet before relocating condensate trap NOTE Trap gr...

Page 13: ...ox Plugs Pressure Switch Port Condensate Trap Outlet Condensate Trap Relief Port Collector Box Plug Vent Elbow Vent Elbow Clamp Vent Pipe Clamp UPFLOW TRAP CONFIGURATION 1 2 Stage Units A11307 Fig 9 Upflow Trap Configuration Appearance may vary ...

Page 14: ...pen ports of the collector box Connect relief tube to port on collector box Rotate elbow to desired position and tighten clamp to 15 lb ïin Slide tube in standïoffs to adjust length Connect the new pressure switch tube from Loose Parts bag to port on front pressure switch Route tube through inducer standïoffs to adjust position of the tube Trim excess tube Connect pressure switch tube to port on c...

Page 15: ...ation Attach condensate trap with screw to collector box Slide relief tube in standïoffs to adjust length Vent elbow shown in alternate orientation Tighten clamp on inlet to vent elbow 15 lb ïin Align trap over middle and rightïhand port on collector box NOTE Remove knockout in casing before reïinstalling the condensate trap Install plug on open port of collector box Horizontal Right Trap Configur...

Page 16: ...ed position and torque clamp on inlet 15 lb in Slide relief tube in stand offs to adjust length Attach condensate trap with screw to collector box Align trap over middle and right hand port on collector box Install two plugs previously removed in open ports on collector box Connect relief tube to port on collector box Connect the new pressure switch tube from Loose Parts bag to port on front press...

Page 17: ...t hard piped together and b There is an air gap at the point where the two drain lines meet or c All condensate piping is at least 3 4 in PVC and there is a relief tee at the top of condensate drain piping as shown below NOTE On narrower casings it may be easier to remove the condensate trap connect the drain line components and re install the condensate trap Read the steps thoroughly to familiari...

Page 18: ...from field supplied 1 2 in CPVC or 3 4 in PVC pipe in compliance with local building codes A factory supplied 1 2 in CPVC to 3 4 in PVC adapter is supplied in the loose parts bag for use as required 15 Install the adapter or connect the 1 2 in CPVC pipe by sliding a spring clamp over the open end of the grommet on the outside the furnace casing 16 Open the spring clamp and insert the long end of t...

Page 19: ... trap 5 Remove the pre formed rubber drain elbow and two spring clamps from the loose parts bag 6 Connect the full or modified elbow and or grommet to the outlet of the condensate trap with one spring clamp Avoid misalignment of the drain pipe which may cause kinks in the elbow or grommet 7 The remaining drain line can be constructed from field supplied 1 2 in CPVC or 3 4 in PVC pipe in compliance...

Page 20: ...ssure DIRECTION OF AIRFLOW Condensing Furnace Evaporator Coil Blower 3 4 PVC 1 2 3 4 1 2 CPVC or larger Positive pressure Pressure lower than areas with Negative pressure 3 4 PVC DIRECTION OF AIRFLOW 1 2 3 4 3 4 3 4 Open standpipe 3 4 Condensing Furnace Evaporator Coil Blower 3 4 PVC 3 4 1 2 CPVC or larger Positive pressure Pressure lower than areas with Negative pressure 3 4 PVC DIRECTION OF AIRF...

Page 21: ...Negative pressure 3 4 PVC Open standpipe Optional when coil drain is not connected to furnace drain TEE 1 2 CPVC to 3 4 PVC adapter from loose parts bag DIRECTION OF AIRFLOW A170135 Fig 18 Example of Field Drain Attachment INSTALLATION Cabinet air leakage is less than 2 at 1 0 in W C Cabinet air leakage is less than 1 4 at 0 5 in W C when tested in accor dance with ASHRAE Standard 193 NOTICE Upflo...

Page 22: ...guration See Fig 22 23 and 24 Leveling Legs If Desired In upflow position with side return inlet s leveling legs may be used See Fig 20 Install field supplied 5 16 x 1 1 2 in 8 x 38 mm max corrosion resistant machine bolts washers and nuts NOTE Bottom closure must be used when leveling legs are used It may be necessary to remove and reinstall bottom closure panel to install leveling legs To remove...

Page 23: ...l the furnace on its back or hang furnace with control compartment facing downward Safety control operation will be adversely affected Never connect return air ducts to the back of the furnace WARNING MINOR PROPERTY HAZARD Failure to follow this caution may result in minor property damage Local codes may require a drain pan under entire furnace and condensate trap when a condensing furnace is used...

Page 24: ... air connection See Fig 24 Bottom Return Air Inlet These furnaces are shipped with bottom closure panel installed in bottom return air opening Remove and discard this panel when bottom return air is used To remove bottom closure panel see Fig 25 or 26 Side Return Air Inlet These furnaces are shipped with bottom closure panel installed in bottom return air opening This panel MUST be in place when s...

Page 25: ... install the four 4 screws Representative drawing only some models may vary in appearance A170124 Fig 26 Removing Bottom Closure Panel 4 Screws 2 IN 51 mm ROLLOUT PROTECTION REQUIRED Install 12 x 22 305x559 mm sheet metal in front of burner compartment area The sheet metal MUST extend underneath the furnace casing by 1 in 25 mm with the door removed The bottom closure panel may be used for flame r...

Page 26: ...w side return applications the Media Cabinet or field supplied accessory air cleaner can be installed on the side of the furnace or side and bottom when a bottom plenum is used See Fig 29 and 22 For downflow applications the Media Cabinet or field supplied accessory air cleaner must only be connected to the bottom opening on the furnace See Fig 29 and 23 For horizontal applications the Media Cabin...

Page 27: ...2 5 cm 2 in 5 cm 600 283 0 04 10 0 05 13 0 06 15 0 09 22 0 20 51 0 13 34 800 378 0 05 13 0 07 18 0 08 21 0 13 32 0 29 72 0 20 49 1000 472 0 06 16 0 11 28 0 11 28 0 17 43 0 27 67 1200 566 0 07 18 0 15 37 0 14 36 0 22 56 1400 661 0 08 21 0 19 48 0 18 45 0 28 70 1600 755 0 09 23 0 24 60 0 21 54 1800 850 0 10 25 0 26 64 20 x 25 Filter 508 x 635 mm Factory Accessory Washable Factory Accessory Media Rep...

Page 28: ... Media Cabinet 21 in Furnace 4 Ton or less AC capacity airflow 20 in Media Cabinet 4 in Block Off Plate 1 2 in Screws 20 or 24 in Media Cabinet Bottom Return Plenum 21 or 24 1 2 in Furnace Up to 5 Ton AC capacity airflow 45 Transition 20 or 24 in Media Cabinet Screw 14 3 16 in Furnace Filler plates Screw 14 3 16 in Furnace with Filler Plates Centered 14 3 16 in Furnace Filler plate Screws 14 3 16 ...

Page 29: ...se not required 15 7 8 403 19 483 16 1 2 419 19 5 8 498 Downflow applications on combustible flooring Subbase required 15 1 8 384 19 483 16 3 4 425 20 5 8 600 Downflow Applications on Combustible Flooring with coil assembly coil or coil box Subbase not required 15 1 2 394 19 483 16 1 2 419 20 508 21 533 Upflow Applications on Combustible or Noncombustible Flooring Subbase not required 19 1 2 495 2...

Page 30: ...onnections to furnace with code approved tape or duct sealer NOTE Flexible connections should be used between ductwork and furnace to prevent transmission of vibration Ductwork passing through unconditioned space should be insulated to enhance system performance When air conditioning is used a vapor barrier is recommended Maintain a 1 in 25 mm clearance from combustible materials to supply air duc...

Page 31: ...0 1125 1120 1120 1115 1110 1100 1095 1085 ON ON ON 1115 1120 1125 1120 1120 1115 1110 1100 1095 1085 Heating SW1 High Heat Airflow3 1055 1060 1065 1065 1055 1050 1040 1035 1025 1010 Low Heat Airflow3 750 770 775 775 770 765 755 745 740 735 Unit Size 42080C17 Clg CF Switch settings External Static Pressure ESP Clg Switches SW2 3 SW2 2 SW2 1 Clg Default OFF OFF OFF 1085 1095 1095 1100 1100 1095 1090...

Page 32: ...235 1225 1220 1235 1235 Heating SW1 High Heat Airflow3 1340 1355 1370 1385 1380 1385 1400 1400 1385 1380 Low Heat Airflow3 1080 1115 1115 1120 1125 1135 1125 1120 1125 1110 Unit size 66100C21 Clg CF Switch settings External Static Pressure ESP Clg Switches SW2 3 SW2 2 SW2 1 Clg Default OFF OFF OFF 1820 1825 1840 1845 1840 1835 1825 1805 1780 1770 CF Switches SW3 3 SW3 2 SW3 1 Low Clg Default OFF O...

Page 33: ... above adjustments in airflow are subject ot motor horsepower range capacity 2 Maximum cooling airflow is achieved when switches SW2 1 SW2 2 SW2 3 and SW1 5 are set to ON and SW4 3 is set to OFF 3 All heating CFM s are when comfort efficiency adjustment switch SW1 4 is set to OFF 4 Ductwork must be sized for high heating CFM within the operational range of ESP Operation within the blank areas of t...

Page 34: ...ddition of the NFGC in the United States local and national plumbing and gas codes before the furnace has been connected Refer to current edition of NSCNGPIC in Canada After all connections have been made purge lines and check for leakage at furnace prior to operating furnace NOTE The furnace gas control valve inlet pressure tap connection is suitable to use as test gauge connection providing test...

Page 35: ... may consist of electrical wire conduit approved for electrical ground or a listed grounded power cord where permitted by local code when installed in accordance with existing electrical codes Refer to the power cord manufacturer s ratings for proper wire gauge Do not use gas piping as an electrical ground WARNING FURNACE MAY NOT OPERATE HAZARD Failure to follow this caution may result in intermit...

Page 36: ...ork gas piping or the indoor coil drain See Fig 32 for alternate electric entry through top panel 1 Select and remove 7 8 in 22 mm knock out on the desired side of the casing Remove the knock out from the casing NOTE If electrical entry through the furnace top panel is used a 7 8 in 22 mm hole must be drilled through the top panel 2 Drill two 2 1 8 in 3 mm pilot holes through the dimples in the fu...

Page 37: ... ground wire to green ground screw on J Box mounting bracket as shown in Fig 34 5 Connect field power and neutral leads to furnace power leads as shown in Fig 37 6 Attach furnace J Box cover to mounting bracket with screws supplied in loose parts bag Do not pinch wires be tween cover and bracket FIRE EXPLOSION ELECTRICAL SHOCK AND CARBON MONOXIDE POISONING HAZARD Failure to follow this warning cou...

Page 38: ... is to be operated on a generator or other alternate power supply the alternate power supply must produce a smooth sinusoidal waveform for compatibility with the furnace electronics The alternate power supply must generate the same voltage phase and frequency Hz as shown in Table 11 or the furnace rating plate Power from an alternate power supply that is non sinusoidal may damage the furnace elect...

Page 39: ...CTIONS 3 AMP FUSE STATUS AND COMM LED LIGHTS SW1 SETUP SWITCHES AND BLOWER OFF DELAY MODEL PLUG CONNECTOR AIR CONDITIONING A C AIRFLOW SETUP SWITCHES COMMUNICATION CONNECTOR CONTINUOUS FAN CF AIRFLOW SETUP SWITCHES OUTDOOR AIR TEMP CONNECTOR HUMIDIFIER TERMINAL 24 VAC 0 5 AMP MAX FLASH UPGRADE CONNECTOR FACTORY ONLY SW4 SETUP SWITCHES SOFTWARE VERSION PART NUMBER AND DATE CODE WWYY ACRDJ AIR CONDI...

Page 40: ... pump MUST have a high pressure switch for HYBRID HEATr dual fuel applications 2 Refer to outdoor equipment Installation Instructions for additional information and setup procedure 3 If the heat pump date code is 1501E or earlier select the ZONE position on the two speed heat pump control Heat pumps with date code 1601E and later do not have or require a ZONE selection 4 Outdoor Air Temperature Se...

Page 41: ... and GVS 65 PVC Solvent Cement for Royal Pipe or IPEX System 636 1 t PVC Cement for Flue Gas Venting rated Class IIA 65 deg C must be used with this venting system do not mix primers and cements from one manufacturer with a vent system from a different manufacturer Follow the manufacturer s instructions in the use of primer and cement and never use primer or cement beyond its expiration date The s...

Page 42: ...0 for single pipe or ventilated combustion air option A furnace shall not be connected to a chimney flue serving a separate appliance designed to burn solid fuel Other gas appliances with their own venting system may also use the abandoned chimney as a raceway providing it is permitted by local code the current edition of the National Fuel Gas Code and the vent or liner manufacturer s installation...

Page 43: ...ombustion air pipe to the outdoors is not required for a single pipe vent system A 12 in 304 mm long pipe with a 2 in 51 mm tight radius 90 degree elbow is required to be attached to the combustion air pipe adapter on the furnace See Fig 57 This short inlet air pipe helps to ensure stable combustion as well as allow for sound attenuation To aid sound attenuation point the inlet air pipe away from ...

Page 44: ...on of flue gases airborne leaves or light snow 5 Termination or termination kit should be positioned where it will not be damaged by or subjected to foreign objects such as stones balls etc 6 Termination or termination kit should be positioned where vent vapors are not objectionable Direct Vent 2 Pipe System CARBON MONOXIDE POISONING HAZARD Failure to follow the instructions outlined below for eac...

Page 45: ...e foundation to the property line of the adjacent lot for vent termination of any appliance with an input over 35 000 btuh If there is less than 4 ft 1 2 M of unobstructed distance to the property line of the adjacent lot no type of vent termination is permitted for appliances with inputs greater than 35 000 btuh There are no additional restrictions on unobstructed distances greater than 8 ft 2 4 ...

Page 46: ...ng used from Table 17 OPTIONAL CONFIGURATION FOR COMBUSTION AIR INLET PIPE In applications where there is a risk of excessive moisture entering the combustion air inlet pipe a moisture trap may be added to the inlet pipe to help prevent moisture from entering the furnace from the combustion air inlet pipe See Fig 44 When sizing venting systems the equivalent length of the optional moisture trap 15...

Page 47: ...e exhaust duct or there are other concerns of excessive moisture being drawn into the combustion air inlet it is encouraged to connect a drain line to the trap The trap can be constructed from a running tee of the same diameter of the intake air pipe with EITHER a removable cap attached to a 6 inch long pipe connected to the tee or the External Vent Trap Kit to help prevent contaminants from enter...

Page 48: ...application for that specific furnace input size Compare the Total Equivalent Vent Length TEVL to the MEVL 8 If the Total Equivalent Vent Length is shorter than the Maximum Equivalent Vent Length for the diameter of pipe chosen then that diameter of pipe selected may be used 9 If the Total Vent Length is longer than the Maximum Equivalent Vent Length for the diameter of pipe chosen that diameter p...

Page 49: ...nce of an internal pipe stopping ring The vent pipe can pass through the vent pipe adapter it cannot pass through the inlet pipe adapter 2 Align the screw holes in the plastic vent pipe adapter with the dimples in the casing 3 Pilot drill the screw holes for the adapter in the casing and attach the vent pipe adapter to the furnace with sheet metal screws 4 Slide the end of the rubber vent coupling...

Page 50: ...m 914 mm 914 mm 1000 mm 2 in 3 ft 3 ft 3 ft 3 ft 3 25 ft 51 mm 914 mm 914 mm 914 mm 914 mm 1000 mm 2 1 2 in 3 1 2 ft 3 ft 3 1 2 ft 3 1 2 ft 3 25 ft 64 mm 1067 mm 914 mm 1067 mm 1067 mm 1000 mm 3 in 3 1 2 ft 3 ft 3 1 2 ft 3 1 2 ft 3 25 ft 76 mm 1067 mm 914 mm 1067 mm 1067 mm 1000 mm 4 in 4 ft 3 1 2 ft 4 ft 4 ft 3 25 ft Optional Installation of the Vent Pipe NOTE DO NOT USE THIS TECHNIQUE FOR POLYPR...

Page 51: ...ittings Clean and cement using same procedures as used for system piping DO NOT CEMENT POLYPROPYLENE FITTINGS Two Pipe and Single Pipe Terminations Single and two pipe vent must be installed as shown in Fig 41 and 40 Maintain the required separation distance between vents or pairs of vents as shown in Fig 41 and 40 and all clearance shown in Fig 55 and 56 RECOMMENDED SUPPORT FOR VENT TERMINATIONS ...

Page 52: ... 3 ULC S636 vent systems must be composed of pipe fittings cements and primers from the same supplier 4 Factory accessory concentric vent kits are ULC S636 listed CANADA 1 Installation in Canada must conform to the requirements of CAN CSA B149 code 2 Vent systems must be composed of pipe fittings cements and primers from the same supplier and listed to ULC S636 3 Not all materials below may be app...

Page 53: ... 75 95 10 75 105 5 55 50 5 65 105 5 65 125 0 10 20 15 10 55 45 10 65 50 5 25 15 5 65 50 5 65 60 20 10 10 10 35 25 10 45 30 5 10 5 5 45 30 5 50 40 40 10 5 10 25 15 10 30 20 5 5 5 30 20 5 35 25 Maximum Allowable Exposed Vent Length in Unconditioned Space Meters Winter Design Temp C Unit Size 40 000 BTUH 60 000 BTUH Uninsulated 3 8 in Insulation 1 2 in Insulation Uninsulated 3 8 in Insulation 1 2 in ...

Page 54: ...001 8000 10 65 120 135 36 120 125 N A 55 125 135 46 130 8001 9000 5 60 115 125 33 80 110 115 50 115 125 43 120 9001 10000 N A 55 105 115 30 75 100 105 45 100 115 39 115 Maximum Equivalent Vent Length Meters Unit Size 60 000 1 80 000 100 000 2 120 000 Altitude meters Pipe Dia mm 38 51 64 76 38 51 64 76 102 51 64 76 102 64 76 102 0 610 6 0 30 4 53 3 60 9 4 5 16 7 39 6 53 3 60 9 6 0 24 3 53 3 60 9 3 ...

Page 55: ... 0 NOTES 1 Use only the smallest diameter pipe possible for venting Over sizing may cause flame disturbance or excessive vent terminal icing or freeze up 2 NA Not allowed Pressure switch will not close or flame disturbance may result 3 Vent sizing for Canadian installations over 4500 ft 1370 M above sea level are subject to acceptance by the local authorities having jurisdiction 4 Size both the co...

Page 56: ...th MEVL 95 ft 29 M For 2 pipe from Table 16 Is TEVL less than MEVL YES Therefore 2 pipe MAY be used Example 2 A direct vent 60 000 BTUH furnace installed at 2100 ft 640M Venting system includes FOR EACH PIPE 100 feet 30 M of vent pipe 95 feet 29 M of combustion air inlet pipe 3 90º long radius elbows and a polypropylene concentric vent kit Also includes 20 feet 6 1 M of flexible polypropylene vent...

Page 57: ...10FT 3 1 M OF VENT OR LESS ONLY A170006 Fig 46 Inducer Vent Elbow Avoid short horizontal offsets with 90 deg Elbows Short offsets can be difficult to slope and may trap con densate Use 45 deg Elbows where possible to ensure conden sate drainage Slope vent pipe back to the furnace at least per foot A14546 Fig 47 Near Furnace Vent Connections ...

Page 58: ... soffitt located above the vent termination within a horizontal distance of 2 ft 61 cm from the centerline of the vent termination 6 ft 2 M Clearance to a ventilation exhaust including HRV ERV on either Wall A or Wall B 12 in 305 mm Clearance above paved sidewalk or paved driveway located on public property 7 ft 2 1 M Clearance under a veranda porch deck or balcony N P No operable windows doors or...

Page 59: ... for combustion air connection UPFLOW VERTICAL VENT A11310A Fig 49 Upflow Configurations Appearance may vary See Notes for Venting Options 1 2 3 4 5 6 7 5 Rotate vent elbow to required position DOWNFLOW LEFT CONFIGURATION A11311A 1 2 3 4 5 6 7 5 Rotate vent elbow to required position Any other unused knockout may be used for combustion air connection DOWNFLOW RIGHT CONFIGURATION A11312A Requires A...

Page 60: ... LEFT RIGHT VENT CONFIGURATION A11329A Fig 51 Horizontal Left Appearance may vary See Notes for Venting Options ALTERNATE COMBUSTION AIR CONNECTIONS HORIZONTAL RIGHT VERTICAL VENT CONFIGURATION A11337 Requires Internal Vent Kit See Product Data for Current Kit Number HORIZONTAL RIGHT LEFT VENT CONFIGURATION A11336 ALTERNATE COMBUSTION AIR CONNECTIONS HORIZONTAL RIGHT RIGHT VENT CONFIGURATION A1133...

Page 61: ...rew VENT PIPE FLUSH SHOWING COUPLING VENT PIPE FLUSH WITH ADAPTER VENT PIPE ADAPTER WITH GASKET INSTALLED ON FURNACE VENT PIPE IS CUT FLUSH WITH TOP OF ADAPTER PRIME AND CEMENT VENT PIPE TO ADAPTER ALLOW TO DRY BEFORE INSTALLING VENT COUPLING ALIGN NOTCHES IN VENT PIPE COUPLING OVER STAND OFF ON ADAPTER TORQUE LOWER CLAMP 15 LB IN WHEN REMAINING VENT PIPE IS INSTALLED TORQUE UPPER CLAMP TO 15 LB I...

Page 62: ...en on a minimum of two sides beneath the floor See Note 4 Manufacturer s Recommendation See Notes 3 8 M Clearance to each side of the centerline extended above or below vent terminal of the furnace to a dryer or water heater vent or other appliance s vent intake or exhaust 12 in 305 mm 12 in 305 mm N Furnace combustion air intake clearance to a water heater vent dryer vent or other types of applia...

Page 63: ...ully open on a minimum of two sides beneath the floor See Note 4 Manufacturer s Recommendation See Notes 3 8 M Clearance to each side of the centerline extended above or below vent terminal of the furnace to a dryer or water heater vent or other appliance s direct vent intake or exhaust 12 in 305 mm 12 in 305 mm N Clearance to a moisture exhaust duct dryer vent spa exhaust etc 12 in 305 mm See Not...

Page 64: ...M OF COMBUSTION AIR AND BOTTOM OF VENT MAINTAIN 12 IN 305 MM CLEARANCE ABOVE HIGHEST ANTICIPATED SNOW LEVEL OR GRADE WHICHEVER IS GREATER COMBUSTION AIR ELBOW PARALLEL TO WALL OVERHANG 12 IN 305 MM MIN GROUND LEVEL OR SNOW LEVEL EXHAUST CLEARANCE TO OVERHANG PER CODE OPTIONAL BRACKET COUPLING A12221 Fig 57 Alberta and Saskatchewan Vent Termination ...

Page 65: ...mm Pipe hangar Ventilated Combustion Air intake termination in crawl space Ventilated Combustion Air intake pipe CRAWL SPACE ATTIC highest level of insulation A10497 Fig 58 Vent Terminations for Ventilated Combustion Air ...

Page 66: ... to the Adjustments section for setup switch configurations To set these setup switches for the appropriate requirement 1 Remove blower door 2 Locate setup switches on furnace control 3 Configure the setup switches as necessary for the application 4 Replace blower door NOTE If a bypass humidifier is used setup switch SW1 4 Comfort Efficiency should be in OFF Efficiency position This compensates fo...

Page 67: ...ections have been made and check for leaks FIRE OR EXPLOSION HAZARD Failure to follow this warning could result in personal injury death and or property damage Never purge a gas line into a combustion chamber 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 cau...

Page 68: ...igned orifice hole is essential for proper flame characteristics NOTICE 7 Replace orifice with correct size if required as shown in Table 21 Use only factory supplied orifices See EXAMPLE 1 EXAMPLE 1 EXAMPLE 0 2000 ft 0 609 6M altitude Heating value 1050 Btu cu ft Specific gravity 0 62 Therefore Orifice No 44 Furnace is shipped with No 44 orifices In this example all main burner orifices are the c...

Page 69: ...61 DO NOT set high heat manifold pressure less than 3 2 in w c 797 Pa or more than 3 8 in w c 947 Pa for natural gas If required manifold pressure is outside this range change main burner orifices to obtain manifold pressure in this range NOTICE c When correct input is obtained replace caps that conceal gas valve regulator adjustment screws Main burner flame should be clear blue almost transparent...

Page 70: ... derate for altitude if applicable 3 Check all return and supply ducts for excessive restrictions causing static pressure greater than 0 5 In W C 4 Ensure setup switch SW1 4 See Fig 38 for switch location 5 Make sure proper model plug is installed To lock the furnace in low heat 1 Turn SW1 2 ON at the furnace control 2 Connect a jumper across R and W W1 at the thermostat terminals at the furnace c...

Page 71: ...tch OFF 7 Install blower door b Electronic thermostat Set cycle rate for 3 cycles per hr Check Safety Controls The flame sensor gas valve and pressure switch were all checked in the Start up procedure section as part of normal operation 1 Check Main Limit Switch This control shuts off combustion system and energizes air cir culating blower motor if furnace overheats By using this method to check l...

Page 72: ...72 A190157 Fig 64 Service Label Information ...

Page 73: ...73 042060 042080 060080 066100 066120 042060 042080 060080 066100 066120 042060 042080 060080 066100 066120 042060 042080 060080 066100 066120 A13216 Fig 65 Furnace Setup Switches and Description ...

Page 74: ...74 A190155 Fig 65 Furnace Setup Switches and Description Continued ...

Page 75: ...52 69 138 346 13 277 555 1385 53 68 136 340 14 257 514 1286 54 67 133 333 15 240 480 1200 55 65 131 327 16 225 450 1125 56 64 129 321 17 212 424 1059 57 63 126 316 18 200 400 1000 58 62 124 310 19 189 379 947 59 61 122 305 20 180 360 900 60 60 120 300 21 171 343 857 62 58 116 290 22 164 327 818 64 56 112 281 23 157 313 783 66 54 109 273 24 150 300 750 68 53 106 265 25 144 288 720 70 51 103 257 26 ...

Page 76: ...75 44 3 6 1 5 44 3 7 1 6 43 3 4 1 4 43 3 5 1 5 4000 900 44 3 4 1 4 44 3 5 1 5 44 3 7 1 5 44 3 8 1 6 1219 925 44 3 2 1 4 44 3 4 1 4 44 3 5 1 5 44 3 6 1 5 950 45 3 7 1 6 44 3 2 1 3 44 3 3 1 4 44 3 4 1 4 750 42 3 3 1 4 42 3 4 1 4 42 3 5 1 5 42 3 6 1 5 4001 775 43 3 7 1 6 43 3 8 1 6 42 3 3 1 4 42 3 4 1 4 1220 800 43 3 5 1 5 43 3 6 1 5 43 3 7 1 6 43 3 8 1 6 825 44 3 8 1 6 43 3 4 1 4 43 3 5 1 5 43 3 6 1...

Page 77: ... can perform basic maintenance functions such as cleaning and replacing air filters All other operations must be performed by trained service personnel A qualified service person should inspect the furnace once a year FIRE INJURY OR DEATH HAZARD Failure to follow this warning could result in personal injury death and or property damage The ability to properly perform maintenance on this equipment ...

Page 78: ... long flashes For an explanation of status codes refer to service label located on control door or Fig 64 and the troubleshooting guide which can be obtained from your distributor Retrieving Stored Fault Codes The stored status codes will NOT be erased from the control memory when 115 or 24 v power is interrupted The control will store up to the last 7 Status Codes in order of occurrence 1 To retr...

Page 79: ...a son for water leakage sagging pipes or broken fittings Have vent pipes vent system serviced by a qualified service agency 6 Inspect any accessories attached to the furnace such as a hu midifier or electronic air cleaner Perform any service or maintenance to the accessories as recommended in the ac cessory instructions Cleaning and or Replacing Air Filter The air filter type may vary depending on...

Page 80: ...s centered in blower housing and set screw contacts the flat portion of the motor shaft Loosen set screw on blower wheel and reposition if necessary 12 Spin the blower wheel by hand to verify that the wheel does not rub on the housing 13 Reinstall blower assembly in furnace 14 Reinstall 2 screws securing blower assembly to blower deck 15 Reconnect blower leads to furnace control Refer to furnace w...

Page 81: ...life of the igniter 19 Clean burner with a brush and a vacuum 20 Clean the flame sensor with fine steel wool 0000 grade Do not use sand paper or emery cloth To reinstall burner assembly 1 Install the Hot Surface Igniter HSI and bracket in burner assembly 2 Install flame sensor on burner 3 Align the edges of the one piece burner with the slots in the burner assembly and slide the burners forward un...

Page 82: ...er of collector box 8 Remove the pressure switch tube from the collector box NOTE Do NOT blow into tube with tube connected to the pressure switch 9 Clean pressure switch port on collect box with a small wire Shake any water out of pressure switch tube 10 Reconnect tube to pressure switch and pressure switch port 11 Remove the relief tube from the port on the collector box and the trap 12 Clean th...

Page 83: ...ICAL SHOCK AND FIRE HAZARD Failure to follow this warning could result in personal injury death and or property damage Turn off the gas and electrical supplies to the furnace and install lockout tag before performing any maintenance or service Follow the operating instructions on the label attached to the furnace WARNING 2 Remove control door 3 Disconnect wires or connectors to flame rollout switc...

Page 84: ...ng furnace SET SCREW MOTOR WHEEL HUB MOTOR SHAFT FLAT SCREW MOTOR ARM GROMMET SCREW LOCATION BLOWER HSG ASSY BRACKET BRACKET ENGAGEMENT SEE DETAIL A CAPACITOR OR POWER CHOKE WHEN USED BRACKET SCREW GND BLOWER HSG ASSY MOTOR BLOWER WHEEL BLOWER CUTOFF BLOWER DETAIL A A11584 Fig 70 Blower Assembly SEQUENCE OF OPERATION NOTE Furnace control must be grounded for proper operation or else control will l...

Page 85: ...nger proved e Blower Ondelay Ifthe burnerflame isproven theblow er ON delays for low heat and high heat are as follows Low heat 45 sec after the gas valve GV M is opened the blower motorBLWM isturned ONat low heatairflow High heat 25 sec after the gas valve GV M is opened the BLWM is turned ON at high heat airflow Simultane ously the humidifier terminal HUM and electronic air cleaner terminal EAC ...

Page 86: ...the thermostat is satisfied the R to G and Y circuit are opened The outdoor unit stops and the furnace blower BLWM and electronic air cleaner terminal EAC 1 will remain energized for an additional 90 sec Jumper Y1 to DHUM to reduce the cooling off delay to 5 sec See Fig 38 c Two Stage Thermostat and Two Speed Cooling See Fig 38 and 39 for thermostat connections NOTE The air conditioning relay disa...

Page 87: ...rflow before transitioning back to continuous blower airflow When the R to G circuit is opened the blower motor BLWM will continue operating for an additional 5 sec if no other func tion requires blower motor BLWM operation Continuous Blower Speed Selection from Thermostat To select different continuous blower airflow from the room thermostat momentarily turn off the FAN switch or push button on t...

Page 88: ...in the ON position and jumpering R W W1 and Y Y2 simultaneously setup switch SW1 1 in the OFF position Was there a previous status code other than 11 Go to section below for the status code Does the control respond to W W1 W2 Y1 Y Y2 and G 24V thermostat signals Run system through a low heat high heat or cooling cycle to check operation Status codes are erased after 72 hours or can be manually era...

Page 89: ...ffl ame signal is lost during the blower on delay period blower will come on for the selected blower off delay Check the following items first before proceeding to the next step Gas valve turned off Manual shut offvalve GREEN YELLOW wire MUST be connected to furnace sheet metal Flame sensor must not be grounded To determine whether the problem is in the gas valve igniter or flame sensor the system...

Page 90: ... NO NO Is there 12 VDC at PL13 7 RED and PL13 1 GREEN YES NO Is there 12 VDC at PL3 1 RED and PL3 2 GREEN Replace the furnace control NO You have an open wire or bad terminal on either the RED or GREEN wire between the furnace control and the blower motor YES Is there 5 VDC at PL13 16 YELLOW and PL13 1 GREEN Is there 5 VDC at PL3 3 YELLOW and PL3 2 GREEN NO NO You have an open wire or bad terminal...

Page 91: ...91 A190153 Fig 72 Wiring Diagram ...

Page 92: ... contact BRYANT HEATING COOLING SYSTEMS Consumer Relations Department P O Box 4952 Syracuse New York 13221 4952 1 800 428 4326 Have available the model number series number and serial number located on the unit rating plate to ensure correct replacement part Model Nomenclature MODEL COOLING CAPACITY HEATING CAPACITY MOTOR WIDTH VOLTAGE FEATURES MINOR SERIES 986TC 42 060 V 17 A A FIRE EXPLOSION ELE...

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