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ISO 9001:2008

INSTALLATION INSTRUCTIONS

FOR DOWNFLOW SINGLE STAGE GAS FURNACES

(-)801S

DOWNFLOW SERIES

(-)801P

DOWNFLOW SERIES

(-)(-)80DSS DOWNFLOW SERIES
(-)(-)80DSP DOWNFLOW SERIES

U.L. and/or C.S.A. recognized fuel gas and CO (carbon monoxide) detectors are rec-
ommended in all applications, and their installation should be in accordance with the
manufacturer’s recommendations and/or local laws, rules, regulations, or customs.

92-24161-143-01

SUPERSEDES 92-24161-143-00



Factory Use Only

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Содержание 801P series

Страница 1: ...LOW SERIES 80DSP DOWNFLOW SERIES U L and or C S A recognized fuel gas and CO carbon monoxide detectors are rec ommended in all applications and their installation should be in accordance with the manufacturer s recommendations and or local laws rules regulations or customs 92 24161 143 01 SUPERSEDES 92 24161 143 00 Factory Use Only ...

Страница 2: ...RXGW B01 Chimney Adapter 26 11 TWINNING 27 Furnace Twinning Installations 27 Control Boards 28 29 12 HIGH ALTITUDE 30 Natural Gas at High Altitudes 30 LP Gas at High Altitudes 32 13 STARTUP PROCEDURES 33 Sequence of Operation 33 14 DIAGNOSTICS FAULT CODES 34 15 LOCKOUT 35 16 FIELD SELECTIONS ADJUSTMENTS 36 Field Selections Dipswitches 36 17 FAULT CLEAR 37 18 FAULT RECALL 37 19 FLAME STATUS L E D 3...

Страница 3: ...h natural and propane gases as follows As a Category I furnace it may be vented vertically with type B 1 vent pipe and also may be common vented as described in these instructions This furnace should be installed in accordance with the American National Standard Z223 1 latest edition booklet entitled National Fuel Gas Code NFPA 54 and the requirements or codes of the local utility or other authori...

Страница 4: ...A90A Installation of Air Conditioning and Ventilating Sys tems NFPA90B Installation of warm air heating and air conditioning systems The equipment has been evaluated in accordance with the Code of Federal Regulations Chapter XX Part 3280 CALIFORNIA RESIDENTS ONLY IMPORTANT All manufacturer products meet current Federal OSHA Guidelines for safety California Proposition 65 warnings are required for ...

Страница 5: ...perature rise in heat record air temperature rise ______ Air temperature rise in cool record air temperature rise VENTING ______ Correct vent pipe diameter and length according to NFGC tables _________________ Vent connection size ______ Correct venting material according to NFGC tables ______ Correct lining for masonry chimneys ______ Adequate clearance from combustibles ______ Proper negative pr...

Страница 6: ...ND BURNER DOOR INSTALLED IF THE FURNACE IS INSTALLED IN A CLOSET THE CLOSET DOOR MUST ALSO BE CLOSED FOR THIS TEST REPEAT THE TEST AT THE MINIMUM INPUT RATE IF THE FURNACE IS A MULTI STAGE FURNACE WARNING USE ONLY WITH THE TYPE OF GAS APPROVED FOR THIS FURNACE REFER TO THE FURNACE RATING PLATE WARNING NEVER TEST FOR GAS LEAKS WITH AN OPEN FLAME USE A COMMERCIALLY AVAILABLE SOAP SOLUTION MADE SPECI...

Страница 7: ...EAS ALL JOINTS SEAMS AND OPENINGS IN THE EQUIPMENT AND DUCT MUST BE SEALED TO LIMIT THE MIGRATION OF TOXIC FUMES AND ODORS IN CLUDING CARBON MONOXIDE FROM MIGRATING INTO THE LIVING SPACE IF AIR MOVING EQUIPMENT OR DUCTWORK IS LO CATED IN SPACES CONTAINING FUEL BURNING AP PLIANCES SUCH AS WATER HEATERS OR BOILERS ALL JOINTS SEAMS AND OPENINGS IN THE EQUIP MENT AND DUCT MUST ALSO BE SEALED TO PRE VE...

Страница 8: ...nace to the termination with minimal length and elbows 3 Locate the furnace near the existing gas piping Or if running a new gas line locate the furnace to minimize the length and elbows in the gas piping 4 Locate the furnace to maintain proper clearance to combustibles as shown in following Figure 3 CLEARANCE ACCESSIBILITY The design of forced air furnaces with input ratings as listed in the tabl...

Страница 9: ...11 32 15 5 8 23 5 8 0 0 0 1 3 6 140 lbs 15 24 1 2 23 11 32 15 5 8 23 5 8 0 0 0 1 3 6 150 lbs TOP BOTTOM 24 1 2 19 3 4 C A B D LOW VOLTAGE GAS CONNECTION ELECTRIC CONNECTION E S A R A 26 5 8 26 13 16 6 3 16 20 3 8 23 3 8 5 8 5 8 3 4 5 8 34 23 3 8 20 3 8 6 3 16 24 7 16 26 5 8 20 1 8 28 1 16 7 8 DIA 7 8 DIA 1 5 8 DIA CLEARANCE TO COMBUSTIBLE MATERIAL INCHES DOWNFLOW MODELS NOTE IN DOWNFLOW CONFIGURAT...

Страница 10: ... side return air cut out is not permitted Do not take return air from the back of the unit 6 If a filter is installed near the furnace be sure to have adequate space for installation and removal of the unit filter NOTE DO NOT take return air from furnace rooms garages or cold areas Avoid return air from utility rooms kitchens laundry rooms and bathrooms DUCTING Ducting WARNING BLOWER AND BURNERS M...

Страница 11: ...FLOOR CUTOUT DIMENSIONS FLOOR BASE NO CABINET WIDTH FLOOR CUTOUT DIMENSION A RXGC B14 RXGC B17 RXGC B21 14 0 17 5 21 0 13 4 17 0 20 0 RXGC B24 24 5 23 5 A 21 5 8 FLOOR CUTOUT DIMENSIONS COMBUSTIBLE FLOOR MATERIAL NON COM BUSTIBLE FLOOR BASE TABLE 1 NON COMBUSTIBLE FLOOR BASES Floor Base Size No Cabinet RXGC B14 14 RXGC B17 17 RXGC B21 21 RXGC B24 24 ...

Страница 12: ...total input of all appliances in the space If the open space containing the appliances is in a building with tight construction contempo rary construction outside air may still be required for the appliances to burn and vent properly Outside air openings should be sized the same as for a confined space IMPORTANT ONLY THE CURRENT VENT INSTRUC TIONS APPLY All gas furnaces cannot be common vented OVE...

Страница 13: ...east one square inch of free area for each 1 000 BTUH of total input in the space Table 2 shows some typical examples of openings required for com bustion air openings required for a confined space B USING OUTDOOR AIR FOR COMBUSTION IMPORTANT Do not take air from an attic space that is equipped with power ventilation The confined space must communicate with the outdoors in accordance with Methods ...

Страница 14: ...0 19 5 100 000 25 6 125 000 32 8 150 000 38 8 TABLE 3 MINIMUM FREE AREA REQUIRED FOR EACH OPENING WHEN TWO OPENINGS ARE USED WITH A FURNACE 1 LOCATED IN A CONFINED SPACE 2 USING OUTDOOR AIR FOR COMBUSTION 3 COMMUNICATING DIRECTLY TO THE 3 OUTSIDE THROUGH AN OPENING OR 3 THROUGH A VERTICAL DUCT TABLE 10 MINIMUMFREE AREA REQUIRED FOR EACH OPENING WHEN TWO OPENINGS ARE USED WITH A FURNACE 1 LOCATED I...

Страница 15: ...e must be sufficient ventilation to prevent the exhaust fan from creating a negative pressure in the room Combustion air openings must NOT BE RESTRICTED in any manner CONSULT LOCAL CODES FOR SPECIAL REQUIREMENTS B Method 3 For the optimum in quiet operation attic air may be brought di rectly to the furnace IMPORTANT In applications using Method 3 for combustion air the attic must be ventilated by ...

Страница 16: ...with vertical B 1 vent systems and lined masonry chimneys Follow the National Fuel Gas Code ANSI Z223 1 for proper installation practices NOTE Follow combustion air instructions as outlined in this man ual Single wall vent connectors to B 1 vent or masonry chimneys may be used under the guidelines of the National Fuel Gas Code ANSI Z223 1 The entire length of the vent connector shall be readily ac...

Страница 17: ...or serving draft hood equipped appli ances shall not be greater than 75 percent of the vertical height of the vent Single appliance venting of a fan assisted furnace into a tile lined masonry chimney is prohibited The chimney must be lined with either Type B vent or with a listed single wall system Reference National Fuel Gas Code ANSI Z223 1 See Figure 11 for typical B 1 vent chase SPECIAL VENT S...

Страница 18: ...venting system NOTE Ensure existing venting system complies with latest addi tion of National Fuel Gas Code ANSI Z223 1 and all local codes regulations 1 Visually inspect the venting system for proper size and hori zontal pitch and determine that there is no blockage restric tion leakage corrosion or other deficiencies which could cause an unsafe condition 2 Insofar as is practical close all build...

Страница 19: ...OOR PROPANE GAS IS HEAVIER THAN AIR AND TENDS TO COLLECT AT LOWER LEVELS MAKING IT MORE DIFFICULT TO SMELL AT NOSE LEVEL NATURAL GAS IS LIGHTER THAN AIR AND WILL RISE POSSIBLY ACCUMULATING IN HIGHER PORTIONS OF THE STRUCTURE IF A GAS LEAK IS PRESENT OR SUSPECTED DO NOT ATTEMPT TO FIND THE CAUSEYOUR SELF NEVER USE AN OPEN FLAME TO TEST FOR GAS LEAKS THE GAS CAN IGNITE RESULTING IN DEATH PERSONAL IN...

Страница 20: ...e gas connectors to a maximum of 36 Install a ground joint union outside the cabinet and within 3 feet to easily remove the control valve assembly Install a manual shut off valve in the gas line outside the furnace cas ing The valve should be readily accessible to turn the gas supply on or off Install a drip leg in the gas supply line as close to the fur nace as possible Always use a pipe compound...

Страница 21: ...ORIFICES MAY OR MAY NOT NEED TO BE CHANGED SEE THE SECTION TITLED HIGH ALTITUDE INSTALLATIONS OF THIS BOOK FOR INSTRUCTIONS FIGURE 13 TYPICAL GAS VALVE HONEYWELL REGULATOR CAP WARNING NEVER PURGE A GAS LINE INTO THE COMBUS TION CHAMBER NEVER USE MATCHES FLAME OR ANY IGNITION SOURCE FOR CHECKING LEAK AGE FAILURE TO ADHERE TO THIS WARNING CAN CAUSE A FIRE OR EXPLOSION RESULTING IN PROPERTY DAMAGE PE...

Страница 22: ...move any restrictions in the gas supply piping or enlarge the gas pipe See Tables 2 and 3 With LP gas have the LP supplier adjust the line pressure at the regulator MANIFOLD GAS PRESSURE MEASUREMENT Natural gas manifold pressure should be 3 5 w c LP gas manifold pressure should be 10 0 w c Only small variations in gas pressure should be made by adjusting the pressure regula tor 1 With the gas to t...

Страница 23: ...s should be taken 1 The furnace must NOT be electrically connected to line volt age prior to reversing the electrical connection 2 Remove the junction box from the furnace cabinet wall by re moving the two screws that hold it to the cabinet Leave the wires connected to the junction box 3 Remove 7 8 plug from hole opposite j box location Drill 2 3 16 Ø holes in the jacket NOTE Dimples marks are pro...

Страница 24: ...rmostat Run the thermostat lead wires inside the blower compartment and connect to low voltage terminals as shown on the wiring diagram Never install the thermostat on an outside wall or where it will be influenced by drafts concealed hot or cold water pipes or ducts lighting fix tures radiation from fireplace sun rays lamps televisions radios or air streams from registers REVERSING ELECTRICAL CON...

Страница 25: ...wer and the gas supply to the furnace 2 Remove the burner door from the furnace 3 Remove the burner assembly handle with care 4 Remove the two screws attaching the NOx insert retainer bracket to the center panel and remove NOx inserts 5 Put the two screws back into the holes in the center panel 6 Re install the burner assembly 7 Replace burner door 8 Turn on electrical power and gas supply to the ...

Страница 26: ...g section of this manual for more information See National Fuel Gas Code for sizing options FILTERS See Figure 20 Keep filters clean at all times A filter is not provided with the furnace but one must be field supplied and installed It is recommended to replace the furnace filter periodically to maintain optimum furnace performance RXGW B01 CHIMNEY ADAPTER IMPORTANT CHIMNEY ADAPTER IS CERTIFIED FO...

Страница 27: ...heating cooling or fan NOTE Duct system must be adequate to provide correct airflow to each furnace for supply and return UT ELECTRONIC CONTROLS 1194 200 CONTROL BOARD 62 104058 02 1 Single Stage Operation a Control board ONE is on furnace connected to the ther mostat b The 24 VAC supply to both control boards must be in phase with each other c Connect the C W and TWIN terminals to counterparts on...

Страница 28: ... CODE 20 WILL FLASH TO INDICATE A TWINNING PROBLEM CONFIRM PROPER WIRING IF THIS FAULT IS PRESENT TWINNING CONTROL BOARDS FIGURE 21 UT ELECTRONIC CONTROLS 1194 200 CONTROL BOARD TWINNING CONNECTION SINGLE STAGE OPERATION THERMOSTAT ST A1194 25 1 STAGE ...

Страница 29: ...29 R Y G W2 W1 COOLING CONTACTOR FIGURE 22 UT ELECTRONIC CONTROLS 1194 200 CONTROL BOARD TWINNING CONNECTION TWO STAGE OPERATION TWINNING CONTROL BOARDS cont THERMOSTAT ST A1194 25 2 STAGE Twinning ...

Страница 30: ...eating Value I H Q 25000 1050 23 81ft3 I Sea Level input per burner 25000 H Sea Level Heating Value 1050 Q 23 81 ft3 Natural Gas per hour From Table F 1 of Natural Fuel Gas Code Handbook 2002 3 5 w c column Orifice required at Sea Level 43 From Table F 4 of National Fuel Gas Code Handbook 2002 Orifice required at 5000 ft elevation 4 de rate per thousand ft 45 Orifice required at 8000 ft elevation ...

Страница 31: ...ODEL NATURAL GAS ORIFICE SELECTION BASED ON HEATING VALUE ELEVATION Table is derived from Appendix of the National Fuel Gas Code To determine the correct orifice for your installation consult the National Fuel Gas Code tables F 1 and F 4 2 Local utilities adjust the sea level heating value of gasses used at higher elevations to compensate for appliance operation at altitude Installer must be aware...

Страница 32: ...de LP orifices are based on an 11 of water column pressure at the orifice which dif fers from products that use 10 of water column at the orifice This difference requires a deviation from the NFGC orifice size recom mendations The Sea Level input should still be reduced by 4 per thousand ft and the orifice size must be selected based on the reduced input in Table 5 Input per Orifice Altitude burne...

Страница 33: ...ignition 4 The spark igniter is energized to light the gas burners and stays energized for the up to 7 seconds after the gas valve opens 5 8 seconds after the gas valve opens the remote flame sen sor must prove flame ignition for one second using the process of flame rectification If the burners don t light the system goes through another ignition sequence It does this up to four times before ente...

Страница 34: ...as occurred four times in a row the control enters one hour lockout and fault codes 10 and 11 will be displayed alternately as described above 2 When flame is lost five times in a row the control enters one hour lockout and fault codes 10 and 13 will be displayed alternately as described above A D 3 While the control is in one hour lockout due to an unexpected flame the fault codes 14 unexpected f...

Страница 35: ...hour period will commence after flame is no longer detected Dead Blower has been detected main limit circuit open for more than 150 seconds When voltage has unexpectedly been detected on the gas valve circuit and voltage goes away when inducer is shut off The seven segment display will alternately display 10 and the code number for the fault causing the lockout Lockout will auto matically be reset...

Страница 36: ...etting of the SW1 dipswitch is OFF The factory setting display orientation is with the control placed in a vertical orientation and the low volt age terminal block T2 is in the bottom position Heat Blower Off Delay SW2 SW3 A means of controlling the HEAT speed blower off delay time is provided The dipswitches are labeled SW2 and SW3 The fol lowing table defines the settings SW2 SW3 OFF OFF 90 seco...

Страница 37: ...be cleared from the fault buffer after one week The fault buffer can also be manually cleared if this is de sired For the first 30 seconds after a change in state of dip switch SW4 the furnace control will wait to determine if the switch becomes on off on off on off or off on off on off on within 30 seconds When this action is detected within 30 sec onds the fault code memory buffer shall be clear...

Страница 38: ...he size of the burner orifices To change orifice spuds shut off the manual gas valve and re move the gas manifold On LP gas furnaces the LP gas supply pressure must be set between 11 and 13 w c by means of the tank or branch supply regulators The furnace manifold pressure should be set at 10 w c at the gas control valve For elevations up to 2 000 feet rating plate input ratings apply For high alti...

Страница 39: ... local gas utility to obtain the yearly average heating value and orifice size required to fire each individual burner at 25 000 BTU HR NOTE Refer to the High Altitude Section of this manual and the National Fuel Gas Code for high altitude rate ad justment above 2 000 ft TABLE 7 METER TIME 0123 456 27829 2 A2B2 2B2C766 C 7028 C 76 D 2 02 C70E A28762 2C5F C2 27829 0 0 1 2 3 1 1 4 22 0 1 3 525 67877...

Страница 40: ...e air flow is too much or the mani fold pressure needs to be adjusted Use lower speed tap on the multi speed blower IMPORTANT The measured temperature rise should be in the middle of the range IMPORTANT Some high efficiency filters have a greater than nor mal resistance to airflow This can adversely affect furnace opera tion BE SURE TO CHECK AIRFLOW if using any filter other than factory provided ...

Страница 41: ... 1310 1295 1265 1235 1205 Low 921 896 870 845 819 783 746 Med Lo 1094 1066 1037 1014 990 949 907 Med Hi 1239 1211 1182 1164 1146 1117 1087 High 1424 1398 1372 1339 1306 1267 1228 Low 1210 1205 1195 1180 1165 1155 1130 Med Lo 1580 1560 1550 1530 1495 1465 1430 Med Hi 1915 1880 1825 1790 1740 1675 1600 High 2050 1995 1940 1885 1835 1770 Low 935 910 885 855 825 785 760 Med Lo 1070 1055 1040 1010 980 ...

Страница 42: ... the heating cycle In the event of a flame roll out condition the switch will shut the furnace down Switches for the 801S 801P furnaces are located on either side of the burner cover plate and just above the burners on the blower di vider panel The 801S and 801P requires only one switch on the left side of burner cover plate If a switch is tripped it must be manually reset DO NOT jumper or reset t...

Страница 43: ...for proper removal of the blower as sembly on downflow models GAS FURNACE DIRECT DRIVE INSTRUCTIONS CAUTION DO NOT OPERATE THE SYSTEM FOR EXTENDED PE RIODS WITHOUT FILTERS A PORTION OF THE DUST ENTRAINED IN THE AIR MAY TEMPORARILY LODGE IN THE AIR DUCT RUNS AND AT THE SUPPLY REGIS TERS ANY RECIRCULATED DUST PARTICLES WILL BE HEATED AND CHARRED BY CONTACT WITH THE FURNACE HEAT EXCHANGER THIS RESIDU...

Страница 44: ...g load on the system 4 Avoid excessive use of kitchen exhaust fans 5 Do not permit the heat generated by television lamps or radios to influence the thermostat operation 6 Except for the mounting platform keep all combustible articles 3 feet from the furnace and vent system 7 IMPORTANT Replace all blower doors and compart ment covers after servicing the furnace Do not oper ate the unit without all...

Страница 45: ...heat exchanger tubes the heat exchanger assembly should be replaced IMPORTANT It is recommended that at the beginning of the heating season the flame sensor be cleaned with fine steel wool or Scotch Bright Pad by a qualified in staller service agency or the gas supplier IMPORTANT It is recommended that an annual inspec tion and cleaning of all furnace markings be made to as sure legibility Attach ...

Страница 46: ...s or overtemperature limits do not need to be reset Make sure no flame rollout in burner compartment due to blocked flu or heat exchanger OVERFIRE ensure furnace is not overtemperature temp rise is above stated range Check gas valve proper orifice size gas pressure etc Is Limit circuit open or opening and closing Note IFC Status LED should be blinking a Fault Code Is the IFC sensing a good flame N...

Страница 47: ...47 Wiring Diagrams FIGURE 28 FOR MODELS WITH UT ELECTRONIC CONTROLS 1028 928 INTEGRATED FURNACE CONTROL AND DIRECT SPARK IGNITION ...

Страница 48: ...48 CM 0614 ...

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