background image

3

 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 and ladder diagram before making any electrical 

connections to the unit. See 

Figure 24 (page 36)

Figure 

25 (page 37)

, or the units wiring label.

• Always reinstall the doors on the furnace after 

servicing. Do not operate the furnace without all doors 

and covers in place.

REQUIREMENTS & CODES

 WARNING:

The 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 

FIGURES & TABLES ......................................................31

Figure 23. *SD Cabinet Dimensions ............................. 31

Airflow Data

Table 7. *SD 050U-23EA Blower Data

(Heating Airflow) ............................................ 32

Table 8. *SD 050U-23EA Blower Data

(Cooling Airflow) ............................................. 33

Table 9. *SD 100U-35EC Blower Data

(Heating Airflow) ............................................ 34

Table 10. *SD 100U-35EC Blower Data

(Cooling Airflow) ........................................... 35

Electrical Information

Figure 24. *SD Wiring Diagram .................................... 36

Figure 25. *SD Ladder Diagram ................................... 37

Gas Information

Table 11. Gas Flow Rates ............................................ 38

Table 12. Gas Pipe Capacities ..................................... 38

Table 13. Natural Gas Heating Values ......................... 38

Venting Information

Table 14. Vent Termination Clearances ....................... 39

Figure 26. Horizontal & Vertical Venting ...................... 40

Figure 27. Venting Options for Upflow Installations ..... 41

Figure 28. Venting Options for 1 Pipe

Horizontal Installations ................................ 42

Figure 29. Venting Options for 2-Pipe

Horizontal Installations ................................ 43

Figure 30. *SD 050U-23EA Pressure Switch

Tube Locations ........................................... 44

Figure 31. *SD 100U-35EC Pressure Switch

Tube Locations ........................................... 45

INSTALLATION CHECKLIST .........................................48

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.

Summary of Contents for SD Ultra Low Nox Series

Page 1: ...asoline 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...

Page 2: ...Pressure Switch Location 14 Accessories 15 Finish Flange 15 Rubber Grommets 15 PVC Components 15 Typical Orientation 15 Alternate Orientation 16 Optional PVC Pipe Installation 16 Condensate Drain Line...

Page 3: ...tallation 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 installe...

Page 4: ...ping Gas Pipe Pressure Testing US NFGC and National Plumbing Codes General Installation US Current edition of the NFGC and the NFPA 90B For copies contact the National Fire Protection Association Inc...

Page 5: ...36 in Figure 1 Minimum Clearances to Combustible Materials COMBUSTION AIR VENTING REQUIREMENTS WARNING CARBON MONOXIDE POISONING HAZARD Failure to follow the steps outlined below for each appliance c...

Page 6: ...hat force air from the house to the outdoors can create a negative pressure inside the house resulting in improper furnace operationorunsafeconditionssuchasflameroll out It is imperative that sufficie...

Page 7: ...ces crawl or attic that freely exchange with the outdoors See Figure 3 Figure 3 Combustion Air Drawn from a Crawl Space or Vented Attic TOTAL INPUT RATING BTUH MINIMUM FREE AREA EACH OPENING ROUND DUC...

Page 8: ...which draw combustion air from that space In general a furnace installed in an unconfined space will not requireoutsideairforcombustion However inhomesbuiltfor energy efficiency low air change rates...

Page 9: ...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 e...

Page 10: ...g 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...

Page 11: ...ustion 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 weat...

Page 12: ...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 operat...

Page 13: ...any combustible material other than wood flooring SD series gas furnaces are shipped with the bottom panel installed as shown in Figure 23 page 31 If the furnace is installed with only side return air...

Page 14: ...he left or right side of the furnace use the extra screw provided in the parts package 6 Remove the cabinet plug from side of furnace and reinstall in hole on opposite side of cabinet 7 Install in lin...

Page 15: ...m the top to the bottom section of the cabinet or open grommet holes in the cabinet PVC Components IMPORTANT NOTES Before permanently installing these components it is recommended you dry fit them fir...

Page 16: ...retighten the clamp It is permissible to locate the trap away from the furnace The condensate drain system J trap and drain tube should be no more than 30 equivalent feet while maintaining 1 4 per foo...

Page 17: ...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 mus...

Page 18: ...y omitted for clarity of pipe installation Gas Valve See Note B See Note A Plug Flexible Gas Line Flexible Gas Line FURNACE INPUT MAIN BURNER ORIFICE SIZE MAIN AIR ORIFICE DIAMETER MANIFOLD PRESSURE 5...

Page 19: ...page 36 Figure 25 page 37 or the unit wiring label IMPORTANT NOTES An electrical disconnect must be installed readily accessible from and located within sight of the furnace See Figure 24 page 36 or...

Page 20: ...k White Black White 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 grounde...

Page 21: ...possible The thermometer on the supply air side must be shielded from direct radiation from the heat exchanger to avoid false readings 2 Adjustallregistersandductdamperstothedesiredposition and run t...

Page 22: ...ower motor is running tP is displayed following with the Tap number For instance If the blower motor has been set for Tap 4 tP4 will be displayed Ifanalarmisdetected theerrorcodedisdisplayedstarting w...

Page 23: ...3 digit display will show 1dL which means idle Press the MENU button the control will show the options on the display Keep pressing the MENU button the options are Err L6F Cr Cod OdU HOd COF COP HtP...

Page 24: ...36 and Figure 25 page 37 Heating Cycle 1 ThethermostatcallsforheatbyenergizingtheWterminal with 24VAC 2 The control checks the HLI input for a closed limit 3 The control performs a circuitry check an...

Page 25: ...eady for the next call Cooling Cycle When Y1 and G or Y1 Y2 and G signals are detected the control will operate in compressor cooling mode The Electronic Air Cleaner EAC relay will energize 5 seconds...

Page 26: ...be inspected and cleaned if required by a qualified service technician annually to ensure continued safe operation Pay attentiontoanydeteriorationfromcorrosionorothersources WARNING Holes in the vent...

Page 27: ...ce the recycle count will start over Internal Control Fault E2 3 Internal relay in the control board has failed Replace the board Control senses 24V output to the gas valve If voltage is not sensed to...

Page 28: ...2 Measure the pressure If the pressure is as expected replacethepressuretransducer There should not be measurable amount of pressure when furnace is idle Atacallforheatthecontrolmonitorsthepressure se...

Page 29: ...s stuck on the board Replace the board The control senses 24V output from internal relays at all times If power is detected at the HLO output on the 12 pin plug at any time even without a call for hea...

Page 30: ...nsate Drain Switch The Condensate Drain Switch will shut down the furnace if the condensate drain from the Collector Pan becomes clogged BlowerLimitSwitch Preventsoperationoftheblowermotor when the bl...

Page 31: ...TTOM VIEW TOP VIEW 4 Knockouts both sides 1 LEFT SIDE RIGHT SIDE 3 1 4 Gas 1 5 8 T stat 7 8 Electric 7 8 Vent pipe 3 Cond 1 1 16 T stat 7 8 Electric 7 8 Gas 1 5 8 Condensate 1 1 16 Vent pipe 3 Combust...

Page 32: ...0 5 CFM RISE CFM RISE CFM RISE CFM RISE CFM RISE 050U T23A 50 000 BTU Hr Input 50 000 Btuh Input Btuh Output Bottom Tap 9 Tap 8 Tap 7 Tap 6 Tap 5 970 45 935 47 915 48 880 50 845 52 Tap 4 875 50 835 53...

Page 33: ...50 1 315 1 285 1 255 1 225 1 200 Tap 8 1 290 1 260 1 230 1 195 1 160 1 135 1 100 1 070 Tap 7 1 145 1 115 1 090 1 055 1 030 995 960 920 Tap 6 1 045 1 015 980 950 920 885 855 825 Tap 5 935 915 880 845 8...

Page 34: ...0 Btuh Input 95 000 Btuh Output Bottom Only 9 8 7 6 1 850 48 1 790 49 1 745 50 1 700 52 1 650 53 5 1 745 50 1 690 52 1 645 53 1 590 55 1 535 57 4 1 480 59 1 420 62 1 360 65 3 2 1 Side Only 9 8 7 6 1 7...

Page 35: ...95 1 015 945 870 790 715 665 615 1 980 905 835 740 665 590 525 440 Bottom Side 9 2 245 2 195 2 155 2 095 2 065 2 070 2 015 1 950 8 2 080 2 030 1 980 1 930 1 880 1 820 1 765 1 705 7 1 915 1 875 1 820 1...

Page 36: ...GROUND TO CHASSIS TO CHASSIS Refer to the Installation Instructions provided with the furnace for the proper heating and cooling speeds for your application Refer to the Installation Instructions for...

Page 37: ...R TWIN W2 W1 B C Y2 GND Y1 O R G PRESSURE TRANSDUCER GND P1 5V INDUCER PRESSURE SWITCH 1 INDUCER PRESSURE SWITCH 2 COLLECTOR SWITCH PS2 PS1 PS0 MVC HLI ILI HLO MVL GND 5A FUSE K4 TR TH K2 GAS VALVE FL...

Page 38: ...88 375 98 37 184 367 100 36 180 360 102 35 176 353 104 35 173 346 106 34 170 340 108 33 167 333 110 33 164 327 112 32 161 321 114 32 158 316 116 31 155 310 118 31 153 305 120 30 150 300 CAPACITY OF BL...

Page 39: ...tended above meter regulator assembly I Clearance to service regulator vent outlet J Clearance to non mechanical air supply inlet to building or the combustion air inlet to any other appliance 6 inche...

Page 40: ...st slope upward 1 4 per foot 5 7 90 Elbows 90 Elbow COMBUSTION AIR Straps or other suitable supports at minimum 5 ft intervals both pipes 90 Elbows Flue Pipe must slope upward 1 4 per foot First suppo...

Page 41: ...E 2 Inline Drain Field Supplied See NOTES 2 3 Collector Box Drain Factory Equipped See NOTE 2 X See NOTE 5 X See NOTE 5 FLUE PIPE X See NOTE 5 X See NOTE 5 FLUE PIPE Inline Drain Tube Factory Supplied...

Page 42: ...IGHT 1 PIPE OPTIONS Plug VIEW D VIEW E VIEW F VIEW G COMBUSTION AIR FLUE PIPE OPTION 7 OPTION 8 COMBUSTION AIR Rubber Grommet See VIEW D for drain line positions See VIEW E for drain line positions Pl...

Page 43: ...d See NOTES 2 3 Collector Box Drain Factory Equipped See NOTE 2 Inline Drain Field Supplied See NOTES 2 3 Field Supplied Drain Line Attached to PVC Trap Do Not Trap COMBUSTION AIR FLUE PIPE Flange COM...

Page 44: ...ft Installation Inducer Vertical Horizontal Left Installation Inducer Rotated Left Horizontal Right Installation Inducer Vertical Horizontal Right Installation Inducer Rotated Right Alternate Location...

Page 45: ...lation Inducer Vertical Horizontal Left Installation Inducer Rotated Left Horizontal Right Installation Inducer Vertical Horizontal Right Installation Inducer Rotated Right Alternate Locations Alterna...

Page 46: ...46...

Page 47: ...47...

Page 48: ...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...

Reviews: