Heat Controller 80+ AFUE, Installation Instructions Manual

Page 1: ...pplier s instructions If you cannot reach your gas supplier call the fire department RISQUE D INCENDIE OU D EXPLOSION Le non respect des avertissements de sécurité pourrait entraîner des blessures graves la mort ou des dommages matériels L installation et l entretien doivent être effectués par un installateur qualifié un organisme de service ou le fournisseur de gazstaller service agency or the ga...

Page 2: ...emoval 15 Alternate Bottom Panel Removal 15 GAS SUPPLY PIPING 16 Leak Check 16 High Altitude Application 17 Conversion to LP Propane 19 ELECTRICAL WIRING 19 Line Voltage Wiring 19 Grounding 20 Thermostat Low Voltage Connections 21 Heat Anticipator 21 Twinning 21 START UP ADJUSTMENTS 22 Pre Start Checklist 22 Start Up Procedures 22 Verifying Adjusting Input Rate 22 Verifying Adjusting Temperature R...

Page 3: ...on when handling this appliance or removing components Personalinjurycanoccurfromsharpmetal edgespresentinallsheetmetalconstructedequipment 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...

Page 4: ...nces Duct Systems USandCANADA AirConditioningContractorsAssociation ACCA Manual D Sheet Metal and Air Conditioning ContractorsNationalAssociation SMACNA orAmerican 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 Test...

Page 5: ...s 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 with the furnace including electrical supply gas supply duct work and venting The furnace must be controlled by a thermostat properly installed accor...

Page 6: ...cordés à la systéme d évacuation évacuent correctementtelqueprescritci dessus rouvrirles portes et les fenêtres et remettre les ventilateurs d évacuation les registres de foyers et tout autre appareil fonctionnant au gaz à leur état de fonctionnement initial Carbon monoxide poisoning hazard Failure to follow the steps outlined below for each appliance connected to the venting system being placed i...

Page 7: ...o the furnace The required sizing of these openings is determined by whetherinsideoroutsideairisusedtosupportcombustion 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 Air From Inside If combustion air is taken from the heated space the two openings must each ...

Page 8: ...Vertical Ducts Inlet Air Duct must be at least 1 sq in per 4 000 Btuh of total input rating Inlet and Outlet Ducts must extend above attic insulation Outlet Air Duct must be at least 1 sq in per 4 000 Btuh of total input rating Ventilation Louvers at each end of attic Attic Insulation 12 Max Furnace Water Heater Vent or Chimney Total Input Rating Btuh Minimum Free Area Each Opening Round Duct Diam...

Page 9: ...ent sizing tables in the NFGC the MAX capacity of the vent must be greater than the furnaces high fire rate The MIN capacity must be lower than the low fire rate If the venting system is inappropriate for the furnace the venting system will need to be modified to comply with NFGC or local Installation In An Unconfined Space An unconfined space is an area including all rooms not separated by doors ...

Page 10: ...ensate leakage or spillage The existing vent system should also be checked to make sure it remains in compliance with NFGC If it isn t the vent system must be brought into compliance before installing the furnace Horizontal Venting Horizontal vent systems must be sealed with a high temperaturesealantthatcanwithstandtemperaturesof 450 F Recommended sealants Dow Corning Sealant 736 RTV GE 106 RTV Hi...

Page 11: ...gned so that the return air supply to the furnace is equal to the return air supply under normal indoor return air applications 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...

Page 12: ...to install all the needed gaskets and grommets around penetrations into the furnace such as for electrical wiring Furnace INstallATION These Installation procedures are suggested for typical furnace installations Since each installation is different the sequence of instructions may differ from the actual installation Only qualified HVAC technicians should install this furnace The installer must be...

Page 13: ...gas furnaces are shipped with the bottom panel installed as shown in Figure 18 page 26 If the furnace is installed with side return air the bottom panel mustnotberemoved Ifthefurnaceisinstalledwithbottom return air the bottom panel must be removed See Bottom Panel Removal on page 15 Horizontal Furnaces WARNING The furnace must not be installed directly on carpeting tile oranycombustiblematerialoth...

Page 14: ...amageorpersonalinjury WARNING Thedownflowsub basekitmustnotbeinstalled directly on carpeting tile or any combustible material other than wood flooring Failure to comply may result in fire property damage or personal injury Downflow sub base kits are factory supplied accessories andarelistedaccordingtothecabinetletterofthefurnace For A size cabinets use Sub Base kit 902974 only For B C and D size c...

Page 15: ...e furnace in reverse order Bottom Panel Removal The steps listed below explain the proper method for removingthebottompanelfromthefurnace SeeFigure11 1 Remove the door 1 from the blower compartment 2 Disconnect the blower motor wiring harness 2 from the control board 3 Remove two screws 3 securing the blower assembly 4 to the furnace 4 Carefully pull the blower assembly 4 out thru the front of the...

Page 16: ... OR EXPLOSION HAZARD Failure to follow safety warnings exactly could result in serious injury 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 t...

Page 17: ...altitude For example at 2 000 feet the input needs to be reduced 8 at 3 000 feet 12 etc This deration is in reference to the input rate and gas heating value at sea level Toderatethefurnacerequiresknowingtheheatingvalueof the gas at the installation site Heating values at particular job sites vary for two reasons 1 The chemical mixture of the gas varies across regions and is expressed as the sea l...

Page 18: ...STATUS FLAME 180 COOL HEAT 120 90 60 BLOWER OFF DELAY LOW ML MH HIGH EAC L1 XFMR HUM 24V L1A 5 NEUTRALS 2 6 3 4 1 7 8 9 5 2 6 3 4 1 FAN 8 3 5 See Note R C Y G W STATUS FLAME 180 COOL HEAT 120 90 60 BLOWER OFF DELAY LOW ML MH HIGH EAC L1 XFMR HUM 24V L1A 5 NEUTRALS 2 6 3 4 1 7 8 9 5 2 6 3 4 1 FAN R C Y G W STATUS FLAME 180 COOL HEAT 120 90 60 BLOWER OFF DELAY LOW ML MH HIGH EAC L1 XFMR HUM 24V L1A ...

Page 19: ...ice size is 57 Whenconversioniscomplete verifythemanifoldpressure andinputratearecorrectaslistedintheTables Approved conversion kits are listed below The United States LP Propane Gas Sea Level and High Altitude Conversion Kit P N 904914 is for LP Propane conversion in the United States at altitudes between zero and 10 000 ft above sea level Please follow the instructions provided with the kit The ...

Page 20: ...H80A GDD80A Furnace Input Btuh Cabinet Width in Nominal Electrical Supply Maximum Operating Voltage Minimum Operating Voltage Maximum Furnace Amperes Minimum Wire Gauge Maximum Fuse or Circuit Breaker Amps 045A3XE 45 000 14 1 4 115 60 1 127 103 6 3 14 15 054A3XE 54 000 14 1 4 115 60 1 127 103 6 3 14 15 072B4XE 72 000 17 1 2 115 60 1 127 103 9 7 14 20 072C5XE 72 000 21 115 60 1 127 103 9 0 14 15 09...

Page 21: ...ally installed Please contact your distributor for the proper upgrade motor kit 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 Twinning Si...

Page 22: ...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 label attached to the furnace 4 Set the thermostat above room temperature and verify the Operating Sequence Page 23 5 After 5 minutes of operation set the thermostat below roomtemperatureandverif...

Page 23: ...in place of or upstream of the filter s 3 Setthethermostataboveroomtemperatureandobserve the Operating Sequence 4 Remove the close off immediately after the limit switch opens If the furnace continues to operate with no return air set the thermostat below room temperature shut off power to the furnace and replace the limit switch OPERATING SEQUENCE The operating sequences for the heating cooling a...

Page 24: ...l 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 the thermostat is properly installed and is not being 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...

Page 25: ...ly remove the inducer assembly from the furnace GDD80A models Carefully remove the inducer assembly and combustion tube assembly from the furnace DO NOT BREAK THE SEALS AT EACH END OF THE COMBUSTION AIR TUBE 14 Remove all screws securing the collector pan to the furnace 15 Removethecollectorpanandgasketfromthefurnace 16 Attach a round wire brush to a length of high grade stainlesssteelcable Attach...

Page 26: ... 054A3XE 072B4XE 17 1 2 11 3 4 15 7 8 16 1 8 072C5XE 090B4XE 21 14 19 3 8 19 7 8 090C5XE 108C5XE 126D5XE 24 1 2 15 1 4 22 7 8 23 1 8 NOTE Dimensions shown in Inches 18 5 8 C 7 34 1 2 22 1 2 28 25 3 8 22 1 2 25 22 1 4 29 1 2 23 B 7 Gas 1 5 8 X 3 1 2 X 45 T stat Ø 7 8 Gas 1 5 8 X 3 1 2 Electric Ø 7 8 Front Brace D BOTTOM VIEW RIGHT SIDE LEFT SIDE TOP VIEW 19 A FRONT VIEW FLANGES Accepts 4 Type B Ven...

Page 27: ...1 685 32 1 645 32 1 590 34 1 550 34 1 485 36 1 415 38 Med High 1 400 38 1 360 39 1 340 40 1 310 41 1 275 42 1 245 43 1 190 45 1 125 47 Med Low 1 235 43 1 215 44 1 180 45 1 155 46 1 130 47 1 100 48 1 060 50 1 005 53 Low 975 55 940 57 930 57 890 60 865 62 840 63 810 66 775 69 090B4XE Bottom Return 90 000 High 1 610 41 1 575 42 1 530 44 1 485 45 1 440 46 1 385 48 1 340 50 1 275 52 Med High 1 295 51 1...

Page 28: ...270 63 1 225 65 1 175 68 108C5XE Side Return 108 000 High 2 295 35 2 235 36 2 180 37 2 110 38 2 050 39 1 975 41 1 900 42 1 810 44 Med High 2 130 38 2 075 39 2 035 39 1 970 41 1 915 42 1 845 43 1 765 45 1 675 48 Med Low 1 770 45 1 750 46 1 710 47 1 675 48 1 630 49 1 585 50 1 520 53 1 430 56 Low 1 445 55 1 425 56 1 410 57 1 375 58 1 350 59 1 320 61 1 275 63 1 225 65 108C5XE Side Bottom or 2 Sides 10...

Page 29: ...260 53 1250 53 1220 55 1195 57 1170 57 1120 60 Med Low 1 155 58 1235 54 1115 60 1095 61 1065 63 1040 66 1015 66 980 68 Low 910 73 885 75 860 78 835 80 810 82 785 85 765 87 735 91 108C5XE 108 000 High 2 395 33 2 335 34 2 285 35 2 230 36 2 200 36 2 140 37 2 080 38 2 000 40 Med High 2 190 37 2 135 37 2 115 38 2 080 38 2 030 39 1 975 41 1 915 42 1 810 44 Med Low 1 785 45 1 770 45 1 740 46 1 725 46 1 6...

Page 30: ...ff Diagnostic Description Low Flame Sensor Signal Flame Present FAULT CONDITIONS Yellow LED Continuous Flash On Alternating Flash Replaces 710915B IGNITOR INDUCER FLAME SENSOR C BLOWER LIMIT DOOR SWITCH R 4 SPEED MOTOR WHITE RED BLUE ORANGE BLACK GAS VALVE H MH ML L C FLAME ROLLOUT SUPPLY AIR LIMIT VENT LIMIT SWITCH ON SELECT MODELS R C Y G W LOW ML MH HIGH EAC L1 XFMR HUM 1 2 3 4 5 6 7 8 9 1 2 3 ...

Page 31: ...PER REVOLUTION OF GAS METER 1 5 10 10 360 1 800 3 600 12 300 1 500 3 000 14 257 1 286 2 571 16 225 1 125 2 250 18 200 1 000 2 000 20 180 900 1 800 22 164 818 1 636 24 150 750 1 500 26 138 692 1 385 28 129 643 1 286 30 120 600 1 200 32 113 563 1 125 34 106 529 1 059 36 100 500 1 000 38 95 474 947 40 90 450 900 42 86 429 857 44 82 409 818 46 78 391 783 48 75 375 750 50 72 360 720 52 69 346 692 54 67...

Page 32: ...7 57 57 ORIFICE SIZE 9 0 9 0 9 0 9 0 9 0 9 0 MANIFOLD PRESSURE 8 000 to 10 000 FT 59 57 57 57 57 57 ORIFICE SIZE 8 5 8 5 8 5 8 5 8 5 8 5 MANIFOLD PRESSURE LOCAL HEATING VALUES FOR NATURAL GAS ALTITUDE ABOVE SEA LEVEL BTU PER CUBIC FOOT 650 700 750 800 850 900 950 1 000 1 050 2 000 FT LOW LOW LOW LOW LOW LOW HIGH HIGH HIGH 3 000 FT LOW LOW LOW LOW LOW LOW HIGH HIGH HIGH 4 000 FT LOW LOW LOW LOW LOW...

Page 33: ...LD PRESSURE 9 000 to 9 999 FT 51 49 49 49 49 49 ORIFICE SIZE 2 6 2 8 2 8 2 8 2 8 2 8 MANIFOLD PRESSURE Table 10 High Altitude Deration Chart for Natural Gas Low Heating Value NATURAL GAS w LOW HEATING VALUE ALTITUDE ABOVE SEA LEVEL INPUT BTU 45 000 54 000 72 000 90 000 108 000 126 000 0 to 1 999 FT 49 47 47 47 47 47 ORIFICE SIZE 3 5 3 5 3 5 3 5 3 5 3 5 MANIFOLD PRESSURE 2 000 to 2 999 FT 49 47 47 ...

Page 34: ...t operate check the flame roll out switch and reset if necessary See Figure 20 for component location 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 ...

Page 35: ...Transformer Blower Assembly Control Board Main Air Limit Switch Figure 20 Component Locations Combustion Tube Gas Manifold Gas Valve Inducer Assembly Control Board Pressure Switch Transformer Blower Assembly behind blower panel Burner Assembly Flame Sensor Roll Out Switch Igniter Main Air Limit Switch Blower Door Switch behind blower panel Downflow Furnace ...

Page 36: ...fully before starting the installation Return these instructions to the customer s package for future reference PROPOSITION 65 WARNING This product contains chemicals known to the state of California to cause cancer birth defects or other reproductive harm WARNING ELECTRICAL SYSTEM Electrical connections tight YES NO Line voltage polarity correct YES NO Supply Voltage _____________________________...