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Maytag *TC Installation Instructions Manual

Two-stage condensing gas furnaces with fixed & variable speed blowers - 95.1 % afue.
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TWO-STAGE CONDENSING GAS FURNACES WITH FIXED & VARIABLE SPEED BLOWERS - 95.1 % AFUE

Installation Instructions

*TC UPFLOW/HORIZONTAL MODEL
WARNING:
FIRE 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 qualifi ed installer, service agency or the
gas supplier.
• Do not store or use gasoline or other
fl ammable 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.
• 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 fi re department.
DO NOT DESTROY THIS MANUAL. KEEP IN A SAFE PLACE FOR FUTURE REFERENCE.
*TL DOWNFLOW MODEL
AVERTISSEMENT
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 gas supplier.
• Ne pas entreposer ni utiliser de l'essence ni
d'autres vapeurs ou liquides infl ammables
dans le voisinage de cet appareil, ni de tout
autre appareil.
QUE FAIRE S'IL Y A UNE ODEUR DE GAZ
• Ne pas tenter d'allumer aucun appareil.
• Ne toucher à aucun interrupteur électrique;
n'utiliser aucun téléphone dans le bâtiment.
• Évacuer l'immeuble immédiatement.
• Appeler immédiatement le fournisseur de
gaz en employant le téléphone d'un voisin.
Respecter à la lettre les instructions du
fournisseur de gaz.
• Si personne ne répond, appeler le service des
incendies.

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   Summary of Contents for Maytag *TC

  • Page 1: Installation Instructions

    TWO-STAGE CONDENSING GAS FURNACES WITH FIXED & VARIABLE SPEED BLOWERS - 95.1 % AFUE Installation Instructions *TC UPFLOW/HORIZONTAL MODEL *TL DOWNFLOW MODEL WARNING: AVERTISSEMENT RISQUE D’INCENDIE OU D’ EXPLOSION FIRE OR EXPLOSION HAZARD • Le non-respect des avertissements de • Failure to follow safety warnings exactly sécurité...

  • Page 2: Table Of Contents

    TABLE OF CONTENTS IMPORTANT SAFETY INFORMATION .......4 Upfl ow/Horizontal Furnaces ......15 REQUIREMENTS & CODES ........4 Side Return Installations ......15 Combustion Air Quality ..........5 Bottom Return Installations ......15 Operation of Furnace During Construction ....5 Downfl ow Furnaces ..........15 Heating Load ............5 Acoustical Treatments ..........15 Clearances to Combustible Materials .......6 FURNACE INSTALLATION ........16...

  • Page 3

    Autostaging for Single Stage Thermostats .....26 Table 10 - Nominal Cooling / Heat Pump CFM - Variable Speed ........36 Autostaging for Two-Stage Thermostats ....27 Gas Information .............37 Heat Anticipator ............27 Table 11 - Gas Flow Rates .........37 Dehumidifi cation Options ........27 Blower Speed Confi...

  • Page 4: Important Safety Information

    IMPORTANT SAFETY INFORMATION • This furnace may be used for temporary heating of buildings or structures under construction. See the Please read all instructions before servicing this equipment. guidelines listed on pages 5. Pay attention to all safety warnings and any other special •...

  • Page 5: Combustion Air Quality

    with the manufacturer’s instructions. A copy of the Operating gas furnaces in construction environments can installation instructions shall remain with the appliance cause a variety of problems with the furnace. Proper use or equipment at the completion of the installation. of commercial portable space heating equipment during construction is recommended.

  • Page 6: Clearances To Combustible Materials

    For installations above 2,000 ft., the furnace should have CLEARANCES TO COMBUSTIBLE MATERIALS a sea level input rating large enough that it will meet the Left Side....0 Inches Top ......0 Inches heating load after deration for altitude. † Right Side ....0 Inches Front ...... 4 Inches Two-stage furnaces operate at two input rates to better Vent ......

  • Page 7: Combustion Air & Venting Requirements

    COMBUSTION AIR & VENTING REQUIREMENTS WARNING: AVERTISSEMENT: RISQUE D’EMPOISONNEMENT AU CARBON MONOXIDE POISONING HAZARD Failure to follow the steps outlined below MONOXYDE DE CARBONED for each appliance connected to the venting Le non-respect des consignes suivantes portant system being placed into operation could sur chacun des appareils raccordés au système result in carbon monoxide poisoning or death.

  • Page 8: General Information

    General Information burners. NOTE: This safety device is a manually reset switch. DO NOT install jumper wires across these WARNING: switches to defeat their function or reset a switch without identifying and correcting the fault condition. If Furnace installation using methods other than a switch must be replaced, use only the correct sized part those described in the following sections must specifi...

  • Page 9: Outdoor Air From A Crawl Space Or Vented Attic

    Ventilation Louvers at each end of attic Air Duct must be Vent or Vent or at least 1 sq. in. Chimney per 4,000 Btuh of Chimney Attic total input rating. Insulation NOTES: 12” Max. Ducts must Each opening must be extend above at least 100 sq.

  • Page 10: Air Directly Through An Exterior Wall

    Air Directly Through an Exterior Wall Conventional Furnaces - Unconfi ned Spaces If combustion air is provided directly through an exterior An unconfi ned space is an area including all rooms not wall, the two openings must each have free area of at separated by doors with a volume greater than 50 cubic least one square inch per 4,000 Btuh of total appliance feet per 1,000 Btuh of the combined input rates of all...

  • Page 11: Vent Pipe Material

    For 1- pipe installations, install vent piping as described in In Canada, all plastic vent pipes and fi ttings including this section and provide air for combustion and ventilation any cement, cleaners, or primers must be certifi ed as a according to pages 7 - 10.

  • Page 12: Vent Pipe Installation

    and then add in the equivalent length of each fi tting. The Outdoor Terminations - Horizontal Venting total length, including the equivalent fi tting lengths, must Vent and combustion air intake terminations shall be be less than the maximum length specifi ed in Table 2. installed as depicted in Figures 6 &...

  • Page 13: Outdoor Terminations - Vertical Venting

    • Concentric vent termination kits are available for use • The top of the chimney is sealed and weatherproofed. with these furnaces. For 2 Inch pipe use kit #904177 • The termination clearances shown in Figure 9 are and for 3 inch pipe use kit # 904176. Please follow the maintained.

  • Page 14: Existing Installations

    less susceptible to freezing, but must not be excessively CIRCULATING AIR REQUIREMENTS restrictive. The length of the 2 inch pipe must not be longer than 18 inches. WARNING: • If furnace is installed horizontally, make sure the Do not allow combustion products to enter the drainage port on the in-line drain assembly is pointed circulating air supply.

  • Page 15: Supply Air Connections

    to the furnace is equal to the return air supply under the opening in the side and secure together with sheet normal, indoor return air applications. metal screws. The screws must penetrate the duct and • When a cooling system is installed which uses the furnace cabinet.

  • Page 16: Furnace Installation

    FURNACE INSTALLATION letter of the furnace. For ‘B’, ‘C’, and ‘D’ size cabinets use Kit #904911. Please follow the instructions provided *TC series gas furnaces offer a wide range of installation with the kit. options, including installation in the upfl ow or horizontal positions with either right, left, or upfl...

  • Page 17: Inducer & Venting Options

    *TC series furnaces are shipped with the bottom panel Inducer & Venting Options installed. If furnace is installed horizontally, remove the To increase installation fl exibility, the inducer assembly bottom panel from the furnace before attaching the duct can be rotated to 2 different positions. Each variation has system.

  • Page 18: Pressure Switch Tubing

    Conventional (1 Pipe) Vent Upfl ow Horiz. Right Horiz. Left Downfl ow Right Option 1 Option 9 Option 5 Option 6 Option 10 Left Option 2 Option 11 Direct Vent (2-pipe) Vent Upfl ow Horiz. Right Horiz. Left Downfl ow Right Option 3 Option 12...

  • Page 19: Accessories

    Accessories 1. Install the 1/2” x 1/2” hose barb on the 2” PVC reducer. Do not over tighten! NOTE: Use an adequate amount of The components in Figures 17 - 19 are included in the extra Tefl on tape on the threads. Do not use liquid sealants. parts bag supplied with the purchase of *TC/*TLfurnaces.

  • Page 20: Condensate Drain Lines

    Condensate Drain Lines 6. Lift up and slide bottom panel (6) out through front of furnace. The placement of the condensate drain lines will depend on the confi guration selected in Table 4 (page 18). The 7. Reinstall the blower assembly (4) in reverse order. drain lines can be routed out the left or right side of the furnace, but must maintain a downward slope to ensure proper condensate drainage.

  • Page 21: Gas Supply & Piping

    GAS SUPPLY & PIPING All gas piping must be installed in compliance with local codes and utility regulations. In the absence of local codes WARNING: the gas line installation must comply with the latest edition of the National Fuel Gas Code (ANSI Z223.1) or (CAN/ FIRE OR EXPLOSION HAZARD CGA B149.1 or .2) Installation Codes.

  • Page 22: High-altitude Application

    To derate the furnace requires knowing the heating value of AVERTISSEMENT: the gas at the installation site. Heating values at particular job sites vary for two reasons: RISQUE D’INDENDIE OU D’EXPLOSION 1. The chemical mixture of the gas varies from region to region and is expressed as the “sea level heating Le non-respect des avertissements de value”.

  • Page 23

    UPFLOW MODELS Note “A” Note “A” Note “B” Note “B” Left Side Entry Right Side Entry DOWNFLOW MODELS Note “A” Note “A” Note “B” Note “B” Right Side Entry Left Side Entry COMPONENTS: (1) Automatic Gas Valve (2) Burner Assembly (3) Dripleg (w/ manual shut-off) (4) Elbow...

  • Page 24: Conversion To Lp / Propane

    Conversion to LP / Propane ELECTRICAL WIRING WARNING: WARNING: The furnace was shipped from the factory ELECTRICAL SHOCK, FIRE OR EXPLOSION equipped to operate on natural gas. Conversion HAZARD to LP / Propane gas must be performed by qualifi ed service personnel using a factory Failure to follow safety warnings exactly could supplied conversion kit.

  • Page 25: Grounding

    IMPORTANT NOTES: Grounding • An electrical disconnect must be installed readily WARNING: accessible from and located within sight of the furnace. See Figure 23 or the wiring diagram label To minimize personal injury, the furnace cabinet inside of the control door. Any other wiring methods must have an uninterrupted or unbroken must be acceptable to authority having jurisdiction.

  • Page 26: Thermostat

    Low voltage connections (24 VAC) from the thermostat are wired to the terminal strip on the integrated control in the furnace. Recommended minimum wire gauge for thermostat wiring is shown in Table 5 (page 25). • The thermostat should be mounted about 5 feet HIGH EFFICIENCY above the fl...

  • Page 27: Autostaging For Two-stage Thermostats

    1. Setting the Autostage jumper in the SHORT position 3. If a humidistat is not available, it is an acceptable option signals the control to utilize an 8 minute delay between to connect the R & DHUM terminals on the motor LOW fi...

  • Page 28: Start-up & Adjustments

    the appropriate switch settings for your installation, see Verifying & Adjusting Input Rate Table 9 (page 35) for heating or Table 10 (page 36) for The input rate must be verifi ed for each installation to cooling. prevent over-fi ring of the furnace. NOTE: The input rate must not exceed the rate shown on the furnace rating plate.

  • Page 29: Verifying Burner Operation

    Verifying Operation of the Supply Air Limit Lo Input HI Input Adjusting Screw Switch Adjusting Screw A properly functioning limit switch should turn off the gas valve when the return is blocked (time depends on how well the return air is blocked). The circulating air and combustion blowers should continue to run when the limit switch opens.

  • Page 30: Cooling Cycle

    (12 minutes) or OFF, depending on the Jumper (P7) Pressure Switches: Verifi es that the inducer is drawing the combustion gases through the heat exchanger. The setting on the Furnace Control Board. pressure switch prevents furnace operation with excessive 11. When the thermostat demand for heat is satisfi ed, the fl...

  • Page 31: Air Filters

    • Always reinstall the doors on the furnace after servicing CAUTION: or cleaning/changing the fi lters. Do not operate the furnace without all doors and covers in place. To prevent damage to the unit or internal • Verify that the thermostat is properly installed and components, it is recommended that two is not affected by drafts or heat from lamps or other appliances.

  • Page 32: Troubleshooting

    Diagnostic Description Green LED Red LED TROUBLESHOOTING If the furnace fails to operate check the following: Control Fault (No Power) L1/Neutral Polarity Fault Flash Flash • Is the thermostat operating properly? • Are the blower compartment door(s) in place? 1 Hour Lockout Alternating Flash •...

  • Page 33: Figures & Tables

    FIGURES & TABLES TOP VIEW BOTTOM VIEW *TC 95.1% Upfl ow / Horizontal Furnace Front Brace Cabinet Dim. Dim. Dim. Size “A” “B” “C” ‘B’ Cabinet 17 1/2 15 7/8 16 1/8 Bottom ‘C’ Cabinet 19 3/8 19 5/8 Panel ‘D’...

  • Page 34: Airfl Ow Data

    AIRFLOW DATA *TC / TL FURNACES WITH FIXED SPEED BLOWERS External Static Pressure (in.W.C.) Model Number Motor Switch Settings & (0 = OFF, 1 = ON) Heating Input (Btuh) CFM Rise CFM Rise CFM Rise CFM Rise CFM Rise CFM Rise CFM Rise CFM Rise *TC / TL - 060D - 24B 1,055 1,015...

  • Page 35

    *TC / TL FURNACES WITH VARIABLE SPEED BLOWERS Switch Settings for Heat *TC / TL - 060D - VB (0 = OFF, 1 = ON) Input (BTU) 60,000 Temp Rise (° F) 1,000 1,100 “B” CABINET 1,200 1,300 1,400 1,500 1,600 1,700 Switch Settings for Heat...

  • Page 36

    *TC / TL FURNACES with VARIABLE SPEED BLOWERS “B” CABINET Switch Settings (0 = OFF, 1 = ON) Nominal A/C & HP Capacity HEAT COOL LOW HIGH 1,000 1,060 1,120 1,180 1,240 1,300 1,360 1,420 1 1,020 1,480 0 1,065 1,540 1 1,105 1,600 “C”...

  • Page 37: Gas Information

    GAS INFORMATION GAS FLOW RATES GAS FLOW RATES CUBIC FEET PER CUBIC FEET PER TIME FOR TIME FOR REVOLUTION OF GAS METER REVOLUTION OF GAS METER ONE REVOLUTION ONE REVOLUTION (SECONDS) (SECONDS) 1,800 3,600 1,500 3,000 1,286 2,571 1,125 2,250 1,000 2,000 1,800...

  • Page 38: Table 13 - High Altitude Deration Chart For Propane Gas

    PROPANE DERATION CHART INPUT (BTU) & STAGE ALTITUDE ABOVE SEA 60,000 80,000 100,000 120,000 LEVEL 1st 2nd 1st 2nd 1st 2nd 1st 2nd ORIFICE SIZE 0 to 1,999 FT 10.0 10.0 10.0 10.0 MANIFOLD PRESSURE ORIFICE SIZE 2,000 to 2,999 FT MANIFOLD PRESSURE ORIFICE SIZE 3,000 to 4,999 FT...

  • Page 39

    NATURAL GAS with HIGH HEATING VALUE INPUT (BTU) & STAGE ALTITUDE ABOVE 60,000 80,000 100,000 120,000 SEA LEVEL ORIFICE SIZE 0 to 1,999 FT MANIFOLD PRESSURE ORIFICE SIZE 2,000 to 2,999 FT MANIFOLD PRESSURE ORIFICE SIZE 3,000 to 3,999 FT MANIFOLD PRESSURE ORIFICE SIZE 4,000 to 4,999 FT...

  • Page 40: Electrical Information

    ELECTRICAL INFORMATION NOT USED EXPANSION PORT CONNECTION TO FURNACE CONTROL BOARD MOTOR WIRE HARNESS FAN SPEED 1 2 3 4 5 6 7 8 COOL HEAT STATUS Figure 30. Two-Stage Fixed Speed Motor Control Board STATUS LIGHTS L2-IN L2-OUT W_OUT Y/Y2_OUT L1-IN Y1_OUT...

  • Page 41

    COOL HEAT FAN SPEED LINE- N LINE- N XMFR-N LINE LINE XMFR Figure 33. Wiring Diagram for Two-Stage, Fixed Speed Upfl ow Furnaces...

  • Page 42

    COOL HEAT FAN SPEED BLACK BLACK LINE- N LINE- N XMFR-N LINE LINE XMFR Figure 34. Wiring Diagram for Two-Stage, Fixed Speed Downfl ow Furnaces...

  • Page 43

    COOL HEAT FAN SPEED LINE- N LINE- N XMFR-N LINE LINE XMFR Figure 35. Wiring Diagram for Two-Stage, Variable Speed Upfl ow Furnaces...

  • Page 44

    COOL HEAT FAN SPEED LINE- N LINE- N XMFR-N LINE LINE XMFR Figure 36. Wiring Diagram for Two-Stage, Variable Speed Downfl ow Furnaces...

  • Page 45: Venting Information

    VENTING INFORMATION VENT TERMINAL AIR SUPPLY INLET AREA WHERE TERMINAL IS NOT PERMITTED CANADIAN INSTALLATIONS US INSTALLATIONS Direct Vent (2-pipe) & Clearance Location Direct Vent Conventional Vent Conventional Vent (1-pipe) (2-pipe) Furnaces (1-pipe) Furnaces Furnaces Clearance above grade, veranda, porch, deck, 12 inches (30cm) 12 inches (30cm) 12 inches (30cm)

  • Page 46: Horizontal Venting

    Straps or Other Suitable HORIZONTAL VENTING Seal/Caulk Supports at minimum of 5 ft. Intervals Around Pipes (2-Pipe Shown) at Building 90° 90° Elbow Elbow COMBUSTION AIR 90° Elbow Upward Pitch - 1/4” per foot 12” Min. 7” (Flue Pipe) See Table 2 for PVC Pipe Lengths (Field Supplied) First support placed as close Wall...

  • Page 47

    UPFLOW - 1 PIPE OPTIONS COMBUSTION COMBUSTION PVC TEE, Reducer, & 1/2” x 1/2” Hose Barb PVC TEE, Reducer, & 1/2” x 1/2” Hose Barb Rubber Grommet OPTION 2 OPTION 1 Rubber Grommet See VIEW A for drain line positions See VIEW B for drain line positions VIEW -A- VIEW -B-...

  • Page 48

    HORIZONTAL RIGHT - 1 PIPE OPTION HORIZONTAL LEFT - 1 PIPE OPTION Rubber Rubber Option Option Grommet Grommet COMBUSTION AIR FLOW COMBUSTION See VIEW D for See VIEW C for Plug Plug drain line positions drain line positions Inline Drain VIEW -C- VIEW -D- Header Box...

  • Page 49

    DOWNFLOW - 1 PIPE OPTIONS COMBUSTION COMBUSTION Rubber COMBUSTION Grommet PVC TEE, Reducer, & Option 1/2” x 1/2” Option Option PVC TEE, Hose Barb Reducer, & 1/2” x 1/2” Hose Barb Rubber Grommet Rubber Grommet See VIEW E for drain line positions See VIEW F for drain line positions See VIEW G for drain line positions VIEW -F-...

  • Page 50: Location Of Furnace Components

    LOCATION OF FURNACE COMPONENTS Finish Flange Roll-Out Burner Flame Switch Assembly Sensor Pressure Switches Igniter (Inducer) Gas Valve Furnace Control Board Main Air Limit Switch Inducer Limit Switch Pressure Switches Inducer Assembly (Condensate) Transformer Blower Door Switch Motor Control Box Motor Choke (C &...

  • Page 52: Installation / Performance Checklist

    INSTALLATION / PERFORMANCE CHECK LIST ELECTRICAL SYSTEM: ATTENTION INSTALLERS: It is your responsibility to know this product better than your customer. Electrical connections tight? This includes being able to install the product according to strict Line voltage polarity correct? safety guidelines and instructing the customer on how to operate and maintain the equipment for the life of the product.

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