Oxbox J951X D Series, Installation Instructions Manual

Page 1: ...aller 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 touch any electrical switch do not use any phone in your building Leave the building immediately Immediatelycallyourgassupplierfromaneighborsphone Followthegassuppliersinstruct...

Page 2: ... 19 Alternate Bottom Panel Removal 19 GAS SUPPLY PIPING 20 Leak Check 20 High Altitude Application Natural Gas Only 20 Converting from Natural Gas to LP Propane 22 ELECTRICAL WIRING 23 Line Voltage Wiring 23 Grounding 23 Thermostat Low Voltage Connections 24 Twinning 24 One stage heating 24 Two stage heating 25 Heat Anticipator 25 START UP ADJUSTMENTS 25 Pre Start Check List 25 Start up Procedures...

Page 3: ...ene cigarette lighter fluid dry cleaning fluids paint thinners or other volatile fluids The installer should become familiar with the units wiring diagram before making any electrical connections to the unit See Figure 32 page 31 Figure 33 page 36 or the unit wiring label Always reinstall the doors on the furnace after servicing Do not operate the furnace without all doors and covers in place REQU...

Page 4: ...lationinstructionsshallremainwiththeappliance or equipment at the completion of the installation The information listed below is for reference purposes only and does not necessarily have jurisdiction over local or state codes Always consult with local authorities before installing any gas appliance Combustion Ventilation Air US National Fuel Gas Code NFGC Air for Combustion and Ventilation CANADA ...

Page 5: ...abovetherequirements Allow24inchesminimum clearance from the front of the unit However 36 inches is strongly recommended See Figure 1 for minimum clearance requirements Operation of Furnace During Construction CAUTION Failure to follow these instructions will void the factory warranty and may significantly reduce the life or the performance of the furnace and or result in other unsafe conditions I...

Page 6: ...entingsystemforpropersizeand horizontalpitch asrequiredintheNationalFuel Gas Code ANSI Z223 1 NFPA 54 or the CSA B149 1 Natural Gas and Propane Installation Codes and these instructions Determine that there is no blockage or restriction leakage corrosion and other deficiencies which could cause an unsafe condition 3 As far as practical close all building doors and windows and all doors between the...

Page 7: ...N Exhaust fans clothes dryers fireplaces and other appliances that 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 sufficient air exchange with the outdoors is provided to prevent depressurization Additional information about how to test for negative pressure ...

Page 8: ...ouvers For Unheated Crawl Space Inlet Air Ventilation Louvers each end of attic NOTE Air openings shall each have a free area of not less than one square inch per 4 000 Btuh of the total input rating of all equipment in the enclosure Alternate Air Inlet Outlet Air Figure 4 Combustion Air Drawn from a Crawl Space or Vented Attic Figure 5 Combustion Air Drawn from Outside Through Horizontal Ducts TO...

Page 9: ... greater than 50 cubic feet per 1 000 Btuh of the combined input rates of all appliances 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 it may be necessary to provide outside air to ensure adequate combustion and venting even though the furnace is ...

Page 10: ...system to ULC S636 However this requirement does not apply to the finish flanges or piping internal to the furnace Vent Pipe Length Diameter In order for the furnace to operate properly the combustion air and vent piping must not be excessively restrictive The venting system should be designed to have the minimum number of elbows or turns Transition to the final vent diameter should be done as clo...

Page 11: ...tion and conformance to applicable codes A vent terminal must be located at least 3 feet above any forced air inlet located within 10 feet This does not apply to the combustion air inlet of a direct vent two pipe appliance In Canada CSA B149 1 takes precedence over these instructions See Table 12 All minimum clearances must be maintained to protect building materials from degradation by flue gases...

Page 12: ...the combustion air inlet must be positioned pointing away from the exhaust vent 8 Min 36 Max Plumbing Vent Roof Boot Both Pipes WINTER DESIGN TEMPERATURE MAXIMUM FLUE PIPE LENGTH FEET IN UNCONDITIONED EXTERIOR SPACES WITHOUT INSULATION WITH INSULATION 20 45 70 0 20 70 20 10 60 NOTE Insulation thickness greater than 3 8 inch based on an R value of 3 5 ft x F x hr BTU x in Table 2 Vent Protection If...

Page 13: ...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 damper must be installed to prevent chilled air from entering the furnace and condensing on the heat exchanger If a manually operated damper is installed it must be des...

Page 14: ...cluding installation in the upflow or horizontal positions with either right left or upflow return air J951X D series gas furnaces may only be installed as a downflow application General Requirements The furnace must be leveled at installation and attached to a properly installed duct system See Figure 1 page 5 for the required clearances needed to move the furnace to its installation point hallwa...

Page 15: ...flooring WARNING Failure to install the downflow sub base kit may resultinfire propertydamageorpersonalinjury To install an J951X D series gas furnace on combustible flooring a special sub base is required Downflow sub base kitsarefactorysuppliedaccessoriesandarelistedaccording tothecabinetletterofthefurnace Refertothetechnicalsales literature for part numbers Please follow the instructions provid...

Page 16: ...er box 4 Rotate the inducer assembly to its new position 5 Secure the inducer assembly to the header box by reinstalling the three screws If the inducer assembly is rotated to the left or right side of the furnace use the extra screw provided in the parts package J951X U J951X D SERIES CONVENTIONAL 1 PIPE VENT DIRECTION UPFLOW HORIZONTAL RIGHT HORIZONTAL LEFT DOWNFLOW Right Option 1 N A N A Option...

Page 17: ...the top of the furnace NOTE For proper installation it is important that the pipe and screw holes in the finishflanges gasket andcabinetarealigned See Figure17 1 Position flange gasket over hole in the furnace cabinet 2 Position finish flange on top of the flange gasket NOTE Make sure the flange is properly oriented so that the FRONT lettering is located near the front of the furnace as shown in F...

Page 18: ...an adequate amount of Teflon tape on the threads Do not use liquid sealants 5 Verify all connections and joints for tight fit and proper alignment with other vent pipes Optional PVC Pipe Installation When running the 2 PVC pipe out through the top of the J951X U upflow furnace there may be possible clearance issues when transitioning the PVC pipe from 2 to 3 If the size of the PVC flue needs to be...

Page 19: ... leg formed by the tee must include a drain Option 1 Option 3 Option 4 Option 11 Option 12 Option 14 In certain cases it is permitted to drain the inducer back into the top drain of the collector This drain must not sag in the middle Option 1 Option 3 Option 5 Option 7 Option 9 Option 10 Option 12 Option 13 Bottom Panel Removal The steps listed below describe how to remove the bottom panel from th...

Page 20: ... appliance A drip leg should be installed in the vertical pipe run to the unit See Figure 23 or Figure 24 Table 6 page 32 lists gas flow capacities for standard pipe sizes as a function of length in typical applications based on nominal pressure drop in the line The furnace may be installed with either left or right side gas entry When connecting the gas supply provide clearance between the gas su...

Page 21: ...hut Off Valve location requirements NOTE B Inducer assembly omitted for clarity of pipe installatio Figure 24 Typical Gas Connections Downflow Models Ground Joint Union J951X D SERIES Right Side Entry Left Side Entry See Note B See Note B Manifold See Note A See Note A NOTE A Consult local codes for Shut Off Valve location requirements NOTE B Inducer assembly omitted for clarity of pipe installati...

Page 22: ...by clocking the gas meter and using the local gas heating value See Verifying and Adjusting the Input Rate section on page 25 IMPORTANT NOTE Observe the action of the burners to make sure there is no yellowing lifting or flashback of the flame For US installations only To avoid nuisance tripping at altitudes from 7500 to 10 000 feet a pressure switch conversion may be required Consult the tables i...

Page 23: ...connect must be installed readily accessible from and located within sight of the furnace See Figure 25 page 24 or the wiring diagram label inside of the control door Any other wiring methods must be acceptable to authority having jurisdiction Proper line voltage polarity must be maintained in order for the control system to operate correctly Verify the incoming neutral line is connected to the wh...

Page 24: ...hting fixtures and convective heat from warm air registers or electrical appliances Refer to the thermostat manufacturer s instruction sheet for detailed mounting information Twinning WARNING When servicing either twinned furnace power must be turned off on both furnaces Failure to complymayresultinimproperoperationleading to damage to the furnaces or personal injury Singlestagefurnacesarenotsuppl...

Page 25: ... NOT reset the switch without identifying and correcting the fault condition Verify the blower door is in place closing the door switch in the line voltage circuit Verify the gas line has been purged and all connections are leak free Start up Procedures Do not perform these steps until all of the checks in the previous steps have been completed 1 Set the thermostat to the lowest setting 2 Turn off...

Page 26: ...rnace is shipped from the factory pre wired for 4 blower speeds There is a fifth alternate speed available on the motor To utilize the alternate speed remove the wire at the motor plug of the desired speed to be changed H MH ML L Reconnect this wire to the alternate motor plug speed tap Verifying Burner Operation CAUTION The door over the burners may only be open for inspection purposes only The d...

Page 27: ...n the selected FAN speed See Figure 26 page 24 for fan speed settings If a call for cooling occurs during continuous fan the blower will switch over to the selected COOL speed If the W terminal receives a call for heat during continuous fan the blower will de energize A call for fan is ignored while in lockout MAINTENANCE WARNING ELECTRICAL SHOCK FIRE OR EXPLOSION HAZARD Failure to follow safety w...

Page 28: ...LEANING THE BURNER 11 Replace all the parts in reverse order from which they were removed 12 Follow the lighting instructions found on the furnace door to return the furnace to operation Verify proper operation after servicing Vent System Check the inlet pipe if applicable and outlet pipe to ensure they are not blocked by debris Any damaged section of vent pipe must be replaced and any obstruction...

Page 29: ... Vent pipe Ø 3 Cond Ø 1 1 16 FRONT VIEW 28 3 Flue Combustion Air 7 1 2 J951X U UPFLOW HORIZONTAL FURNACES MODEL S DIM A DIM B DIM C J951X038BU 17 1 2 15 7 8 16 1 8 J951X054BU J951X072CU 21 19 3 8 19 5 8 J951X090CU J951X108DU 24 1 2 22 7 8 23 1 8 J951X120DU NOTE Dimensions shown in inches Figure 30 J951X D Cabinet Dimensions A 23 1 2 C 34 1 2 22 1 2 2 3 4 Bottom Panel 25 3 8 22 1 2 17 1 4 17 7 8 28...

Page 30: ...ginal wire as supplied with the furnace must be replaced it must be replaced with wiring material having a temperature of at least 105 C Use copper conductors only Diagnostic Description Green LED Red LED Control Fault No Power Off Off L1 Neutral Polarity Fault Flash Flash 1 Hour Lockout n O n O n o i t a r e p O l a m r o N Pressure Switch Closed Fault On Flash Pressure Switch Open Fault Flash On...

Page 31: ...OR ELECTRONIC AIR CLEANER HUMIDIFIER HOT SURFACE IGNITOR INDUCER 120 VAC 24 VAC TRANSFORMER K4 K3 K2 P1 7 EAC P2 3 HUM P2 1 XFORMER NEUTRAL NEUTRAL NEUTRAL NEUTRAL P2 4 P2 6 NEUTRAL SUPPLY AIR LIMIT ROLL OUT LIMIT VENT LIMIT BLOWER LIMIT SWITCH BLOWER DECK LIMIT SWITCH 24V R W G Y C P1 8 P1 3 P1 5 P1 6 P1 2 COM P1 4 K1 PRESSURE SWITCH 24V K8 GND P1 9 GAS VLV MICRO TO MOTOR RELAYS 3A FUSE BLOWER MO...

Page 32: ... 44 220 439 84 43 214 429 86 42 209 419 88 41 205 409 90 40 200 400 92 39 196 391 94 38 191 383 96 38 188 375 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 BLACK IRON GAS PIPE CU FT PER HOUR FOR NATURAL GAS W SPECIFIC GRAVITY 0 60 NOMINAL PIPE DIAMETER IN...

Page 33: ...SSURE 6 000 to 7 999 FT 57 61 57 57 57 57 56 56 ORIFICE SIZE 9 0 8 0 9 0 9 0 9 0 9 0 9 0 9 0 MANIFOLD PRESSURE 8 000 to 10 000 FT 57 61 57 57 57 57 56 56 ORIFICE SIZE 8 5 7 5 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 L...

Page 34: ... 000 to 9 999 FT 49 53 49 49 49 49 48 48 ORIFICE SIZE 3 0 2 8 2 8 2 8 2 8 2 8 2 8 2 8 MANIFOLD PRESSURE HIGH ALTITUDE DERATION NATURAL GAS WITH LOW HEATING VALUE ALTITUDE ABOVE SEA LEVEL INPUT BTU 38 000 SC MODELS 38 000 SD MODELS 54 000 72 000 90 000 108 000 118 000 120 000 0 to 1 999 FT 45 51 47 47 47 47 46 45 ORIFICE SIZE 3 5 3 5 3 5 3 5 3 5 3 5 3 5 3 5 MANIFOLD PRESSURE 2 000 to 2 999 FT 45 51...

Page 35: ... supply inlet to building or the combustion air inlet to any other appliance 6 inches 15cm for appliances 10 000 Btuh 3kW 6 inches 15cm for appliances 10 000 Btuh 3kW 4 ft 1 2m below or to side of opening 1 ft 300mm above opening 12 inches 30cm for appliances 10 000 Btuh 100 000 Btuh 30kW 9 inches 23cm for appliances 10 000 Btuh 50 000 Btuh 30kW 36 inches 91cm for appliances 100 000 Btuh 30Kw 12 i...

Page 36: ... close to furnace connection as possible Wall Normal Snow Level COMBUSTION AIR 90 Elbow both ends Seal Caulk Around Pipes at Building 90 Elbow 7 12 Min 90 Elbow 90 Elbow Support System on Vertical Rise COMBUSTION AIR FLUE PIPE FLUE PIPE COMBUSTION AIR HORIZONTAL VENTING w 2 Pipes Upflow Furnace Shown VERTICAL VENTING w 2 Pipes Upflow Furnace Shown PVC Tee PVC Trap PVC Tee PVC Trap PVC Tee PVC Trap...

Page 37: ... NOTE 5 Inline Drain Tube Factory Supplied See NOTE 4 Collector Box Drain Factory Equipped See NOTES 2 3 Inline Drain Tube Field Supplied See NOTE 3 Collector Box Drain Factory Equipped See NOTES 2 3 X See NOTE 5 X See NOTE 5 Field Supplied Drain Line Attached to PVC Trap Do Not Trap NOTES 1 See Accessories section page 17 for optional PVC Tee configurations and drainage options 2 Drain lines must...

Page 38: ...g Plug See VIEW D for drain line positions Flange Flange Option 5 Option 6 J951X U SERIES HORIZONTAL LEFT 1 PIPE OPTION J951X U SERIES HORIZONTAL LEFT 2 PIPE OPTION J951X U SERIES HORIZONTAL RIGHT 2 PIPE OPTION COMBUSTION AIR COMBUSTION AIR Collector Box Drain Factory Equipped See NOTE 2 Collector Box Drain Factory Equipped See NOTE 2 NOTES 1 See Accessories section page 17 for optional PVC Tee co...

Page 39: ... 4 Collector Box Drain Factory Equipped See NOTE 2 Inline Drain Factory Supplied See NOTE 4 PVC Trap PVC Tee PVC Trap PVC Tee PVC Trap PVC Tee PVC Trap Collector Box Drain Factory Equipped See NOTE 2 Collector Box Drain Factory Equipped See NOTE 2 Inline Drain Field Supplied See NOTES 2 3 X See NOTE 5 X See NOTE 5 X See NOTE 5 X See NOTE 5 Rubber Grommet Field Supplied Drain Line Attached to PVC T...

Page 40: ... Closed Fault On Flash Pressure Switch Open Fault Flash On Open Limit Switch Fault Flash Off DIAGNOSTIC DESCRIPTION YELLOW LED Low Flame Sensor Signal Continuous Flash Flame Present On Table 13 Control Board Fault Conditions FURNACE COMPONENTS The descriptions below are various functional components that affect the operation and shutting down of this furnace Some of these components and their loca...

Page 41: ...ntrol Board Pressure Switch Transformer DOWNFLOW FURNACE J951X D SERIES Figure 37 J951X U Component Locations Burner Assembly Finish Flange Flame Sensor Igniter Roll Out Switch Gas Valve Furnace Control Board Pressure Switch Condensate Transformer Blower Assembly Blower Door Switch Inducer Assembly Pressure Switch Inducer Inducer Limit Switch Main Air Limit Switch UPFLOW HORIZONTAL FURNACE J951X U...

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Page 44: ...e YES NO Filter s clean YES NO Flue connections tight YES NO Is there proper draft YES NO ATTENTION INSTALLERS It is your responsibility to know this product better than your customer This includes being able to install the product according to strict safety guidelines and instructing the customer on how to operate and maintain the equipment for the life of the product Safety should always be the ...