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8

THIS FURNACE IS EQUIPPED
WITH A BLOWER DOOR SAFETY
SWITCH. DO NOT DISABLE THIS
SWITCH. FAILURE TO FOLLOW
THIS WARNING CAN RESULT IN
ELECTRICAL SHOCK, PERSONAL
INJURY OR DEATH.

!

WARNING

SHOULD OVERHEATING OCCUR
OR THE GAS SUPPLY FAIL TO
SHUT OFF, CLOSE THE MANUAL
GAS VALVE FOR THE APPLIANCE
BEFORE SHUTTING OFF THE
ELECTRICAL SUPPLY. FAILURE
TO DO SO CAN CAUSE AN
EXPLOSION OR FIRE RESULTING
IN PROPERTY DAMAGE,
PERSONAL INJURY OR DEATH.

!

WARNING

INSTALLATION OF THIS FURNACE
AT ALTITUDES ABOVE 2000 FT
(610 m) SHALL BE IN
ACCORDANCE WITH LOCAL
CODES, OR IN THE ABSENCE OF
LOCAL CODES, THE NATIONAL
FUEL GAS CODE, ANSI
Z223.1/NFPA 54 OR NATIONAL
STANDARD OF CANADA,
NATURAL GAS AND PROPANE
INSTALLATION CODE, CAN
B149.1.

INSTALLATION OF THIS
APPLIANCE AT OR ABOVE 5000
FT (1525 M) SHALL BE MADE IN
ACCORDANCE WITH THE LISTED
HIGH ALTITUDE CONVERSION KIT
AVAILABLE WITH THIS FURNACE.

!

CAUTION

!

WARNING

TURN OFF ELECTRIC POWER AT
FUSE BOX OR SERVICE PANEL
BEFORE MAKING ANY
ELECTRICAL CONNECTIONS.
FAILURE TO DO SO CAN CAUSE
ELECTRICAL SHOCK RESULTING
IN PERSONAL INJURY OR DEATH.

!

CAUTION

ELEVATIONS ABOVE 2000 FT
REQUIRE THAT THE FURNACE
INPUT RATING BE ADJUSTED
AND THAT THE SIZE OF THE
BURNER ORIFICES BE RE-
CALCULATED BASED ON
ELEVATION AND GAS HEATING
VALUE. THE BURNER ORIFICES
MAY (OR MAY NOT) NEED TO BE
CHANGED. SEE THE SECTION
TITLED “HIGH ALTITUDE
INSTALLATIONS” OF THIS BOOK
FOR INSTRUCTIONS.

!

WARNING

THE CABINET MUST HAVE AN
UNINTERRUPTED GROUND
ACCORDING TO THE LATEST
EDITION OF THE NATIONAL
ELECTRICAL CODE, ANSI/
NFPA70- OR IN CANADA, THE
CANADIAN ELECTRICAL CODE,
CSA-C221 OR LOCAL CODES
THAT APPLY. DO NOT USE GAS
PIPING AS AN ELECTRICAL
GROUND. A GROUND SCREW IS
PROVIDED IN THE JUNCTION
BOX. FAILURE TO DO SO CAN
CAUSE ELECTRICAL SHOCK
RESULTING IN PERSONAL
INJURY OR DEATH.

DISCONNECT THE ELECTRICAL
SUPPLY TO THE FURNACE
BEFORE ATTEMPTING TO
CHANGE THE BLOWER SPEED.
FAILURE TO DO SO CAN CAUSE
ELECTRICAL SHOCK RESULTING
IN PERSONAL INJURY OR DEATH.

DO NOT OPERATE THE SYSTEM
FOR EXTENDED PERIODS
WITHOUT FILTERS. A PORTION OF
THE DUST ENTRAINED IN THE AIR
MAY TEMPORARILY LODGE IN
THE AIR DUCT RUNS AND AT THE
SUPPLY REGISTERS. ANY
RECIRCULATED DUST PARTICLES
WILL BE HEATED AND CHARRED
BY CONTACT WITH THE FURNACE
HEAT EXCHANGER. THIS RESIDUE
WILL SOIL CEILINGS, WALLS,
DRAPES, CARPETS AND OTHER
HOUSEHOLD ARTICLES.

!

CAUTION

!

WARNING

HOLES IN THE VENT PIPE OR
HEAT EXCHANGER CAN CAUSE
TOXIC FUMES TO ENTER THE
HOME, RESULTING IN CARBON
MONOXIDE POISONING OR
DEATH. THE VENT PIPE OR HEAT
EXCHANGER MUST BE
REPLACED IF THEY LEAK.

!

WARNING

!

WARNING

THE MEASURED TEMPERATURE
RISE SHOULD BE AS CLOSE TO
THE MIDDLE OF THE STATED
RANGE AS POSSIBLE. FOR
EXAMPLE, IF THE RISE RANGE IS
40 TO 70 DEGREES, THE MOST
IDEAL RISE WOULD BE 55
DEGREES (THE MIDDLE OF THE
RISE RANGE). IN ALL
APPLICATIONS, THE INSTALLER
MUST ADJUST THE
TEMPERATURE RISE TO THIS
"MIDDLE" POINT AS CLOSELY AS
POSSIBLE. ALSO, THE
TEMPERATURE RISE SHOULD
NEVER BE ABOVE OR FALL
BELOW THE STATED RANGE.
DOING SO COULD CAUSE
DAMAGE TO THE HEAT
EXCHANGER OR INTERMITTENT
OPERATION WHICH COULD CAUSE
INJURY OR DEATH AND WILL VOID
THE MANUFACTURER'S
WARRANTY FOR THIS PRODUCT.

!

WARNING

THESE INSTRUCTIONS ARE

INTENDED AS AN AID TO

QUALIFIED SERVICE

PERSONNEL FOR PROPER

INSTALLATION, ADJUSTMENT

AND OPERATION OF THIS UNIT.

READ THESE INSTRUCTIONS

THOROUGHLY BEFORE

ATTEMPTING INSTALLATION OR

OPERATION. FAILURE TO

FOLLOW THESE INSTRUCTIONS

MAY RESULT IN IMPROPER

INSTALLATION, ADJUSTMENT,

SERVICE OR MAINTENANCE,

POSSIBLY RESULTING IN FIRE,

ELECTRICAL SHOCK, CARBON

MONOXIDE POISONING,

EXPLOSION, PROPERTY

DAMAGE, PERSONAL INJURY

OR DEATH.

DISCONNECT MAIN ELECTRICAL
POWER TO THE UNIT BEFORE
ATTEMPTING ANY MAINTE-
NANCE. FAILURE TO DO SO CAN
CAUSE ELECTRICAL SHOCK
RESULTING IN PERSONAL INJURY
OR DEATH.

!

CAUTION

ELEVATIONS ABOVE 2000 FT
REQUIRE THAT THE FURNACE
INPUT RATING BE ADJUSTED
AND THAT THE SIZE OF THE
BURNER ORIFICES BE RE-
CALCULATED BASED ON
ELEVATION AND GAS HEATING
VALUE. THE BURNER ORIFICES
MAY (OR MAY NOT) NEED TO BE
CHANGED. THE FOLLOWING
EXAMPLES SHOW HOW TO
DETERMINE IF AN ORIFICE
CHANGE WILL BE NECESSARY
AND HOW TO DETERMINE THE
NEW ORIFICE SIZE.

IN CANADA, AS AN ALTERNATE
TO ADJUSTING THE BURNER
ORIFICE SIZE, THE MANIFOLD
GAS PRESSURE MAY BE
ADJUSTED. THIS METHOD IS
COVERED LATER IN THIS
SECTION. THIS METHOD OF
ADJUSTING MANIFOLD
PRESSURE MAY ONLY BE USED
IN CANADIAN INSTALLATIONS.

!

CAUTION

IT IS IMPORTANT THAT EACH
DUCT SYSTEM BE SIZED AND
INSTALLED FOR THE SPECIFIC
APPLICATION BY PROPERLY
APPLYING THE APPROPRIATE
INDUSTRY ACCEPTED
STANDARD. IF LESS THAN
MINIMUM STANDARDS ARE
APPLIED, THE EQUIPMENT USER
COULD EXPECT TO EXPERIENCE
HIGHER UTILITY BILLS, MAJOR
COMPONENT FAILURE, VARYING
DEGREES OF AIR NOISE OR
OTHER UNSATISFACTORY
ISSUES, OVER WHICH THE
MANUFACTURER HAS NO
CONTROL.

Summary of Contents for GF0-1D105AS60

Page 1: ...ons and their installation should be in accordance with the manufacturer s recommendations and or local laws rules regulations or customs Upflow Models Downflow Horizontal Models Model Number Input Bt...

Page 2: ...diameter exhaust pipe ft of pipe intake air no of elbows intake air ft of pipe exhaust pipe no of elbows exhaust pipe Exhaust vent temp TERMINATIONS DIRECT VENT VERTICAL Intake 12 min above roof snow...

Page 3: ...ate of California to cause cancer or birth defects such as fiberglass insulation lead in brass and combustion products from natural gas All new equipment shipped for sale in California will have label...

Page 4: ...IN PLACE SET FURNACE INPUT RATE AND TEMPERATURE RISE PER RATING PLATE MARKING MEANS FOR PROVIDING OUTDOOR AIR REQUIRED FOR COMBUSTION RETURN AIR TEMPERATURE MAINTAINED BETWEEN 55 F 13 C AND 80 F 27 C...

Page 5: ...AL LAWS RULES REGULATIONS OR CUSTOMS IMPROPER INSTALLATION ADJUSTMENT ALTERATION SERVICE OR MAINTENANCE CAN CAUSE INJURY PROPERTY DAMAGE OR DEATH REFER TO THIS MANUAL INSTALLATION AND SERVICE MUST BE...

Page 6: ...use FIRE PROPERTY DAMAGE PERSONAL INJURY OR DEATH WARNING DO NOT LIFT THE UNIT BY THE HEAT EXCHANGER TUBES DOING SO CAN CRACK THE HEAT EXCHANGER ASSEMBLY AND CAUSE CO2 TO BE RELEASED INTO THE ENVIRONM...

Page 7: ...DE ADEQUATE VENTILATION AND DO NOT ASSEMBLE NEAR HEAT SOURCE OR AN OPEN FLAME DO NOT SMOKE AVOID SKIN OR EYE CONTACT OBSERVE ALL CAUTIONS AND WARNINGS PRINTED ON MATERIAL CONTAINERS FAILURE TO FOLLOW...

Page 8: ...RAPES CARPETS AND OTHER HOUSEHOLD ARTICLES CAUTION WARNING HOLES IN THE VENT PIPE OR HEAT EXCHANGER CAN CAUSE TOXIC FUMES TO ENTER THE HOME RESULTING IN CARBON MONOXIDE POISONING OR DEATH THE VENT PIP...

Page 9: ...ht of eight 8 feet above grade directly in line with the exhaust vent terminal for the horizontally vented gas fueled heating appliance or equipment The sign shall read in print size no less than one...

Page 10: ...B149 is available from CSA INTERNATIONAL 178 Rexdale Blvd Toronto Ontario Canada M9W 1R3 GENERAL INFORMATION FIGURE 1 UPFLOW FURNACE FIGURE 2 DOWNFLOW HORIZONTAL FURNACE ITEM ITEM NO PART NAME NO PART...

Page 11: ...FUMES AND ODORS INTO THE HOME CAUSING PROPERTY DAMAGE FUMES AND ODORS FROM TOXIC VOLATILE OR FLAMMABLE CHEMICALS AS WELL AS AUTOMOBILE EXHAUST AND CARBON MONOXIDE CO CAN BE DRAWN INTO THE LIVING SPACE...

Page 12: ...with this furnace a be sure the air passes over the heat exchanger before passing over the cooling coil The cooled air passing over the warm ambient air inside the heat exchanger tubes can cause conde...

Page 13: ...attic or crawl space installation it may be installed on combustible wood flooring or by using support brackets See Figure 5 5 IMPORTANT If installing in a utility room be sure the door is wide enoug...

Page 14: ...0 1 2 0 111 2 5 60 17 1 2 16 11 32 15 5 8 2 15 13 25 32 0 0 0 1 2 0 117 3 75 17 1 2 16 11 32 15 5 8 2 15 13 25 32 0 0 0 1 2 0 123 4 75 21 19 27 32 19 1 8 2 18 1 2 17 9 32 0 0 0 1 2 0 123 4 5 90 21 19...

Page 15: ...16 2 20 1 8 17 3 8 0 0 0 1 2 0 123 90 21 19 11 32 19 3 16 2 20 1 8 17 3 8 0 0 0 1 2 0 148 105 21 19 11 32 19 3 16 2 20 1 8 17 3 8 0 0 0 1 2 0 152 120 24 1 2 23 11 32 22 5 8 2 23 5 8 20 7 8 0 0 0 1 2...

Page 16: ...0 123 75 21 19 27 32 19 3 16 2 20 1 8 17 3 8 0 0 0 1 2 0 123 90 21 19 27 32 19 3 16 2 20 1 8 17 3 8 0 0 0 1 2 0 148 105 21 19 27 32 19 3 16 2 20 1 8 17 3 8 0 0 0 1 2 0 152 120 24 1 2 23 11 32 22 5 8...

Page 17: ...ition the unit to minimize long runs of duct or runs of duct with many turns and elbows 2 Open the return air compartment UPFLOW FURNACE A SOLID METAL BASE PLATE MUST BE INSTALLED IN THE FURNACE BOTTO...

Page 18: ...S Furnaces are equipped with safety switches in the control compartment to protect against overtemperature VENTING AND COMBUSTION AIR PIPING WARNING WARNING 4 Connect the furnace to the supply air ple...

Page 19: ...ces The following steps should be followed with each appliance remaining connected to the original common vent system Place the appliance to be tested in operation while the other appliances remaining...

Page 20: ...the flue products and are highly corrosive after they condense ALL FURNACE INSTALLATIONS MUST COMPLY WITH THE NATIONAL FUEL GAS CODE AND LOCAL CODES TO PROVIDE ADEQUATE COMBUSTION AND VENTILATION AIR...

Page 21: ...Area Round Pipe Input Each Opening Size 45 000 11 25 square inches 4 60 000 15 00 square inches 5 75 000 18 75 square inches 5 90 000 22 50 square inches 6 105 000 26 25 square inches 6 120 000 30 00...

Page 22: ...spaces crawl or attic that freely communicate with the outdoors and shall have a minimum free area of a 1 square inch for each 3 000 BTUH of the total input rating of all equipment located in the enc...

Page 23: ...um clearances to combustibles are maintained between the PVC pipe and other pipes 5 All vent runs through unconditioned spaces where below freezing temperatures are expected should be insulated with 1...

Page 24: ...IMPROPER LOCATION OR INSTALLATION CAN CAUSE STRUCTURAL OR EXTERIOR FINISH DAMAGE TO THE BUILDING Non direct venting location requirements are slightly different in some cases than direct venting Insta...

Page 25: ...25 FIGURE 17 OTHER THAN DIRECT VENT TERMINAL CLEARANCES Natural Gas and Propane Installation Code National Fuel Gas Code Canadian Installations US Installations Canadian Installations US Installations...

Page 26: ...nt pipe length is 5 feet Size the exhaust and combustion air intake pipes as specified in Table 2 This table lists the maximum allow able length in feet of the exhaust and combustion air intake pipes...

Page 27: ...d horizontal intake air termination for all models is a 2 in PVC coupling with a wind deflector vane provided attached Cut a 21 4 in length of 2 in PVC pipe Connect this pipe and another 2 in PVC coup...

Page 28: ...ternate horizontal direct vent termination kits RXGY D02 1 2 in tee with reducer assembly 2 1 2 in PVC 6 in dia trap 3 PVC vane 4 2 in PVC elbow 5 11 2 in PVC nipple with coupling 6 PVC strap 7 vent t...

Page 29: ...NT KIT NO RXGY E03 This kit is for vertical horizontal intake air vent runs and may be installed through roofs and sidewalls One 5 diameter hole is required for the installation See Figure 19 for the...

Page 30: ...rations in wall To prevent possibility of condensate freeze up or recirculation do not install vent kits one above the other NOTE The vent illustration in Figure 21 can be used for Non direct vent ter...

Page 31: ...THE LAST 12 INCHES WITH 11 2 PVC PIPE ON 45 000 THROUGH 75 000 BTUH MODELS SEE DETAIL A 6 30 MAXIMUM EXPOSED VENT LENGTH PITCHED ROOF INSTALLATIONS NOTES 1 SUPPORT HORIZONTAL PIPE EVERY FOUR FEET 2 W...

Page 32: ...32 FIGURE 24 DIRECT VENT TERMINAL CLEARANCES Natural Gas and Propane Installation Code National Fuel Gas Code Canadian Installations US Installations Canadian Installations US Installations...

Page 33: ...ustion air inlet minimum of 3 feet from the vent of any other gas or fuel burning appliance or clothes dryer to prevent recirculation of the flue gases into the furnace combustion air inlet The only e...

Page 34: ...IS PERMITTED See Figures 26 and 27 for positioning of the terminations When more than two furnaces are to be vented there must be at least 4 feet between the first two furnaces and the third etc FIGUR...

Page 35: ...pe fitting extending through the right side of the furnace top cover This opening has a pro tective cap which should be removed just prior to installing the exhaust pipe When 2 in pipe is used con nec...

Page 36: ...drain or condensate pump IMPORTANT If installing the unit over a finished ceiling or living area be certain to install an auxiliary condensate drain pan under the entire unit extending out under the...

Page 37: ...D NO KINKS ALLOWED CONDENSATE TRAP IFC MOUNTING PLATE TO FLOOR DRAIN DOWNFLOW UNITS To convert downflow models to left hand drain a kit RXGY H01 must be ordered from the distributor The kit includes a...

Page 38: ...he elbow in the trap Cut the pipe so that it extends through the alternate drain hole in the left side of the cabinet one inch see Figure 34 Connect the1 2 PVC tee supplied with the furnace to the pip...

Page 39: ...ke place with the furnace in the horizontal position Refer to Figure 36 for Steps 6 11 5 Locate the parts bag in the burner compartment Install two plastic plugs in the side of the jacket from bottom...

Page 40: ...area where freezing temperatures may occur the furnace drain can freeze while shut off for long periods of time Provisions must be made to prevent freezing of condensate see Figure 2 Use a solvent cem...

Page 41: ...line directly from the meter to the furnace Consult the local gas company for the location of the manual main shut off valve The gas line and manual gas valve must be adequate in size to prevent undue...

Page 42: ...ion IMPORTANT ENSURE that the furnace gas control valve not be subjected to high gas line supply pressures DISCONNECT the furnace and its individual shut off valve from the gas supply piping during an...

Page 43: ...ts that use 10 of water column at the orifice This difference requires a deviation from the NFGC orifice size recommendations The Sea Level input should still be reduced by 4 per thousand ft and the o...

Page 44: ...the same gas line as the furnace 4 Note or adjust the line gas pressure to give A 5 10 5 w c for natural gas B 11 13 w c for LP gas 5 Shut off the gas at the manual gas valve and remove the U Tube ma...

Page 45: ...42 MANIFOLD PRESSURE READING FIGURE 43 UPFLOW GROUNDING CONNECTIONS JUNCTION BOX CONDENSATE TRAP CONTROL IS GROUNDED WHEN ATTACHED TO BLOWER LOW VOLTAGE TERMINALS IFC MOUNTING PLATE BLOWER COMPARTMEN...

Page 46: ...electrical connections be certain that the voltage frequency and phase corresponds to that specified on the furnace rating plate For single furnace application maximum over current protection is 15 a...

Page 47: ...y and return Furnaces must have same heating and blower capacity Twinning furnaces must operate off the same phase of power It should be noted that both blowers will run simultaneously when there is a...

Page 48: ...IN CANADA AS AN ALTERNATE TO ADJUSTING THE BURNER ORIFICE SIZE THE MANIFOLD GAS PRESSURE MAY BE ADJUSTED THIS METHOD IS COVERED LATER IN THIS SECTION THIS METHOD OF ADJUSTING MANIFOLD PRESSURE MAY ON...

Page 49: ...12 600 12 000 11 400 10 800 10 200 9 600 All calculations are performed by using the first three columns of information only Before beginning any calculations determine the individual burner Btu size...

Page 50: ...W C ALTITUDE INPUT OUTPUT ORIFICE SIZE MANIFOLD PRESSURE 0 2000 45 000 60 000 75 000 90 000 105 000 120 000 40 500 54 000 67 500 81 000 94 500 108 000 1 15mm 10 W C 2001 4500 40 500 54 000 67 500 81 0...

Page 51: ...DEATH SEQUENCE OF OPERATION UT ELECTRONIC CONTROLS INVESYS CLIMATE CONTROLS UT Electronic Controls Direct Spark Ignition 1 Each time the thermostat contacts close the induced draft blower inducer beg...

Page 52: ...OR LP GAS HEATING VALUE OF GAS BTU PER CU FT METER 900 1000 1040 1100 2500 LP INPUT SIZE BTU HR CU FT MIN SEC MIN SEC MIN SEC MIN SEC MIN SEC ONE 1 12 1 20 1 23 1 28 3 20 45 000 TEN 12 0 13 20 13 50 1...

Page 53: ...The difference is the temperature rise 5 Compare the measured temperature rise to the approved temperature rise range listed on the furnace name plate See Figure 48 If the measured temperature rise is...

Page 54: ...90 750 1520 717 HIGH 2115 998 2050 967 1990 939 1945 917 1900 897 1795 847 1690 795 DOWNFLOW 11 x 7 1 2 LOW 820 387 790 373 760 359 725 342 690 326 650 306 610 288 3 HORIZONTAL MED LO 930 439 890 420...

Page 55: ...G BLOWER SPEED DISCONNECT THE ELECTRICAL SUPPLY TO THE FURNACE BEFORE ATTEMPTING TO CHANGE THE BLOWER SPEED FAILURE TO DO SO CAN CAUSE ELECTRICAL SHOCK RESULTING IN PERSONAL INJURY OR DEATH The blower...

Page 56: ...t from filter wash with detergent and water air dry thoroughly and reinstall Keep the filters clean at all times Vacuum dirt from filter wash with detergent and water air dry thoroughly and reinstall...

Page 57: ...CKET ANGLE FILTER ROD SUPPORT ANGLE FILTER SUPPORT ANGLE SEE ANGLE DETAIL ATTACH WITH SHEET METAL SCREWS 2 REQ D ANGLE DETAIL ROD FILTER SUPPORT ANGLE ASSEMBLY F FILTER ROD SUPPORT ANGLE FILTER SUPPOR...

Page 58: ...y filters can restrict airflow The motor depends upon sufficient air flowing across and through it to keep from overheating SYSTEM OPERATION INFORMATION Advise The Customer 1 Keep the air filters clea...

Page 59: ...during ignition trial If yes go to F Did a limit open during ignition trial If yes go to D Check line voltage between HEAT and NEUTRAL on IFC Check wires connections and continuity between IFC and IBM...

Page 60: ...60 FIGURE 52 FOR MODELS WITH UT ELECTRONIC CONTROLS 1027 200 INTEGRATED FURNACE CONTROL AND DIRECT SPARK IGNITION...

Page 61: ...61 FIGURE 53 FOR MODELS WITH UT ELECTRONIC CONTROLS 1027 200 INTEGRATED FURNACE CONTROL AND DIRECT SPARK IGNITION...

Page 62: ...62...

Page 63: ...63...

Page 64: ...64 CM 1009...

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