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INSTALLATION INSTRUCTIONS
FOR UPFLOW/HORIZONTAL 80PJ, AND
DOWNFLOW 80LJ INDUCED DRAFT
GAS FURNACES
!
Recognize this symbol as an indication of Important Safety Information!
WARNING
!
IF THE INFORMATION IN THESE INSTRUCTIONS IS NOT
FOLLOWED EXACTLY, A FIRE OR EXPLOSION MAY RESULT,
CAUSING PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.
WARNING
!
PROPOSITION 65: THIS FURNACE CONTAINS FIBERGLASS
INSULATION. RESPIRABLE PARTICLES OF FIBERGLASS ARE
KNOWN TO THE STATE OF CALIFORNIA TO CAUSE CANCER.
EXHAUST GAS FROM THIS FURNACE CONTAINS CHEMICALS,
INCLUDING CARBON MONOXIDE, KNOWN TO THE STATE OF
CALIFORNIA TO CAUSE BIRTH DEFECTS OR OTHER REPRO-
DUCTIVE HARM.
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.
Do Not Destroy this Manual.
Please read carefully and keep
in a safe place for future
reference by a serviceman.
FOR YOUR SAFETY
!
— Do not store or use gasoline or other
flammable vapors and liquids, or other
combustible materials 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.
• 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 fire department.
• Do not return to your home until
authorized by the gas supplier or fire
department.
— DO NOT RELY ON SMELL ALONE TO
DETECT LEAKS. DUE TO VARIOUS
FACTORS, YOU MAY NOT BE ABLE TO
SMELL FUEL GASES.
• U.L. recognized fuel gas and CO
detectors are recommended in all
applications, and their installation should
be in accordance with the manufacturer's
recommendations and/or local 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
performed by a qualified installer, service
agency or the gas supplier.
92-24161-31-01
SUPERSEDES 92-24161-31-00
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Summary of Contents for WEATHERKING 80PJ
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Page 1: Safety Precautions
INSTALLATION INSTRUCTIONS FOR UPFLOW/HORIZONTAL 80PJ, AND DOWNFLOW 80LJ INDUCED DRAFT GAS FURNACES Recognize this symbol as an indication of Important Safety Information! WARNING IF THE INFORMATION IN THESE INSTRUCTIONS IS NOT FOLLOWED EXACTLY, A FIRE OR EXPLOSION MAY RESULT, CAUSING PROPERTY DAMAGE, PERSONAL INJURY OR DEATH. -
Page 2: Installation Check List
Before beginning any troubleshooting procedure, complete the following installation checklist. A furnace malfunction is sometimes caused by an improper installation. By completing this checklist, the problem may be found and corrected. Make copies of the checklist and complete one for every Low Profile Furnace service call for your records. INSTALLATION CHECKLIST (Refer to this manual for specifics.) GAS SUPPLY... -
Page 3: Table Of Contents
CONTENTS Safety Precautions ....................1 Installation Check List ....................2 Location Requirements and Considerations ............4 Combustion and Ventilation Air................9 Vent Pipe Installation....................13 Gas Supply and Piping...................15 Electrical Wiring......................19 Accessories ......................20 Start-Up Procedures....................20 Air Flow........................23 Maintenance......................26 Troubleshooting......................28 Wiring Diagrams.....................30 IMPORTANT: TO INSURE PROPER INSTALLATION AND OPERATION OF THIS PRODUCT, COMPLETELY READ ALL INSTRUCTIONS PRIOR TO ATTEMPTING TO ASSEMBLE, INSTALL, OPERATE, MAINTAIN OR REPAIR THIS PRODUCT. -
Page 4: General Information
GENERAL INFORMATION The 80PJ and 80LJ series furnaces are (NFPA 54) and the requirements or These publications are available from: design certified by CSA for use with codes of the local utility or other National Fire Protection Association, natural and propane gases as follows: authority having jurisdiction including Inc. - Page 5 CLEARANCE TO COMBUSTIBLE MATERIAL (INCHES) BOTTOM UPFLOW AND UPFLOW/HORIZONTAL MODELS REDUCED CLEARANCE (IN.) Left Right Ship. Model Back Front Vent Side Side Wgts. 4† 6‡ 85 lbs. 3† 6‡ 105 lbs. 6‡ 120 lbs. 6‡ 140 lbs. 6‡ 150 lbs. May require 3 to 4 or 3 or 5 adapter.
- Page 6 CLEARANCE TO COMBUSTIBLE MATERIAL (INCHES) DOWNFLOW MODELS REDUCED CLEARANCE (IN.) BOTTOM Left Right Ship. Model Back Front Vent Side Side Wgts. 4† 6‡ 85 lbs. 3† 6‡ 105 lbs. 6‡ 120 lbs. 6‡ 140 lbs. 6‡ 150 lbs. May require 3 to 4 or 3 or 5 adapter. †...
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Page 7: Clearance - Accessibility
CLEARANCE – UPFLOW UNIT DESIGN REQUIRES KEPT CLEAR AND FREE OF ALL A SOLID METAL BASE PLATE (SEE COMBUSTIBLE MATERIALS ACCESSIBILITY TABLE ON THIS PAGE OR INCLUDING GASOLINE AND OTHER The design of forced air furnaces with FURNACE CLEARANCE LABEL FOR FLAMMABLE VAPORS AND input ratings as listed in the tables on PART NUMBER) MUST BE IN PLACE... - Page 8 GAPS, ETC., AROUND THE BASE 3. Connect the return duct or return air BASE IS SHIPPED FROM THE cabinet to the unit. Make the FACTORY AS AN ACCESSORY. AS TO PROVIDE A SEAL BETWEEN connection air tight to prevent THE SUPPORT AND THE BASE. 4.
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Page 9: Combustion And Ventilation Air
IMPORTANT: Air for combustion and FIGURE 5 ventilation must not come from a HORIZONTAL RETURN AIR DUCT corrosive atmosphere. Any failure due to corrosive elements in the atmosphere is excluded from warranty coverage. The following types of installation may require OUTDOOR AIR for combustion, due to chemical exposures: •... - Page 10 Combustion air must be free of acid FIGURE 7 forming chemicals; such as sulphur, AIR FROM ATTIC/CRAWL SPACE fluorine and chlorine. These elements are found in aerosol sprays, detergents, bleaches, cleaning solvents, air fresheners, paint and varnish removers, refrigerants and many other commercial and household products.
- Page 11 FIGURE 8 OUTSIDE AIR USING A HORIZONTAL INLET & OUTLET a. One square inch for each 3000 VERTICAL OUTDOOR AIR HORIZONTAL OUTDOOR AIR BTUH of the total input rating of all OPENING DIMENSIONS OPENING DIMENSIONS equipment located in the enclosure, BTUH Free Area Round...
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Page 12: Draft Inducer
VENTING FIGURE 9 ATTACHING TO DRAFT INDUCER COLLAR GENERAL INFORMATION The furnace must be vented in accordance with these instructions, National Fuel Gas Code, ANSI Z223.1 and/or the Natural Gas Installation Code and requirements or codes of the local utility or other authority having jurisdiction. -
Page 13: Power Vent Systems
“B-1” VERTICAL VENTING FIGURE 10 TYPICAL VENTING WITH “B-1” VENT Type “B-1” vents must be installed in accordance with the terms of their listings and the vent manufacturer’s instructions. “B-1” vents must be supported and spaced in accordance with their listings and the manufacturer’s instructions. -
Page 14: Existing Vent Systems
FIGURE 11 DEDICATED VENTING THROUGH CHIMNEY WITH “B-1” VENT EXISTING VENT SYSTEMS 3. Insofar as is practical, close all 6. After it has been determined that each appliance that remains building doors, windows and all IMPORTANT RETROFIT connected to the common venting doors between the space where the VENTING INSTRUCTIONS system properly vents (when tested... -
Page 15: Gas Supply And Piping
GAS SUPPLY AND PIPING GAS SUPPLY FIGURE 12 GAS PIPING INSTALLATION WARNING UPFLOW & DOWNFLOW THIS FURNACE IS EQUIPPED AT THE FACTORY FOR USE ON NATURAL GAS ONLY. CONVER- SION TO LP GAS REQUIRES A SPECIAL KIT SUPPLIED BY THE DISTRIBUTOR OR MANU- FACTURER. -
Page 16: Gas Pressure
GAS PRESSURE FIGURE 14 TYPICAL LP KIT CONTENTS Natural gas supply pressure should be 5" to 7" w.c. LP gas supply pressure should be 11" to 14" w.c. This pressure must be maintained with all other gas-fired appliances in operation. Never exceed a maximum gas supply pressure of 14"... -
Page 17: Nox Models
LP CONVERSION ORIFICE SIZING CHART RATING PLATE ELEVATION The valve can be converted to use INPUT liquefied petroleum (LP) gas by BTU/HR 0 TO 7,999 FT. 8,000 FT. AND ABOVE replacing the pressure regulator spring HEATING VALUE @ 1,000 BTU/FT , SPECIFIC GRAVITY 0.62 with the conversion kit spring. -
Page 18: Setting Gas Pressure
SETTING GAS PRESSURE The maximum gas supply pressure to 3. Turn on the gas supply and regulator to the furnace for natural gas the furnace should be 7 w.c. natural operate the furnace and all other units. With LP gas, have the LP gas, or 14 w.c. -
Page 19: Electrical Wiring
ELECTRICAL WIRING FIGURE 17 ISOLATION RELAY WARNING TURN OFF ELECTRIC POWER AT THE FUSE BOX OR SERVICE PANEL BEFORE MAKING ANY ELECTRICAL CONNECTIONS. ALSO, THE GROUND CONNECTION MUST BE COMPLETED BEFORE MAKING LINE VOLTAGE CONNECTIONS. FAILURE TO DO SO CAN RESULT IN ELECTRICAL SHOCK, SEVERE PERSONAL INJURY OR DEATH. -
Page 20: Accessories
INSTALLATIONS using the process of flame rectification. If the burners don’t light, ELECTRONIC AIR CLEANER IMPORTANT: TWINNING OF 80PJ the system goes through another 1. Electronic air cleaner line voltage AND 80LJ UNITS REQUIRES AN ignition sequence. It does this up to power can be supplied from the screw ACCESSORY TWINNING KIT. -
Page 21: Setting Blower Timings
SETTING BLOWER TIMINGS CHANGING BLOWER SPEED Heating speeds should not be reduced where it could cause the furnace air The UTEC control boards have four WARNING temperature to rise to exceed the quick connect terminals for connecting maximum outlet air temperature DISCONNECT THE ELECTRICAL the motor speed leads. - Page 22 Furnaces for use on LP gas, the LP ORIFICE SIZING CHART gas supply pressure must be set RATING PLATE ELEVATION between 11.0 and 14.0 W.C. by INPUT means of the tank or branch supply BTU/HR 0 TO 7,999 FT. 8,000 FT. AND ABOVE regulators.
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Page 23: Air Flow
AIR FLOW FIGURE 20 TEMPERATURE RISE MEASUREMENT The importance of proper air flow over the heat exchanger cannot be over emphasized. One of the most common causes of heat exchanger failure is overheating due to low air flow. An air flow table is located inside the blower door and on the following pages. - Page 24 BLOWER PERFORMANCE DATA – 80PJ UPFLOW/HORIZONTAL MODELS CFM AIR DELIVERY BLOWER MOTOR BLOWER EXTERNAL STATIC PRESSURE INCHES WATER COLUMN MODEL (BTU) SIZE H.P. SPEED MED-LO 50,000 11X6 MED-HI 1115 1090 1070 1040 1015 1270 1250 1225 1200 1165 1130 1085...
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Page 25: Safety Features
LUBRICATION FIGURE 22 The blower motor and induced draft DOWNFLOW BLOWER REMOVAL motor are prelubricated by the manufacturer and do not require further attention. The motor must be cleaned periodically by a qualified installer, service agency, or the gas supplier to prevent the possibility of overheating due to an accumulation of dust and dirt on the windings or on the motor... -
Page 26: Maintenance
ELECTRICAL SHOCK RESULTING IN SEVERE PERSONAL INJURY OR DEATH. FILTERS NOTE: 80PJ and 80LJ models are not factory equipped with filters. Filters must be field installed. Keep the air filters clean at all times. Vacuum dirt from filter, wash with detergent and water, air dry thoroughly and reinstall. -
Page 27: System Operation Information
SYSTEM OPERATION If during inspection the flue • IMPORTANT: It is recommended passageways and vent system are that at the beginning of the heating INFORMATION determined to require cleaning, the season and approximately midway Advise The Customer following procedures should be in the heating season a visual followed (by a qualified installer, inspection be made of the main... - Page 28 FIGURE 23 TROUBLESHOOTING FLOWCHART...
- Page 29 FIGURE 64 RGTA & RGTJ MODELS W/INTEGRATED FURNACE CONTROL (IFC) UTEC 1029-927, JOHNSON CONTROLS 6961 DAJ-2401 OR UTEC 1012-925...
- Page 30 FIGURE 24 WIRING DIAGRAM...
- Page 32 CM 0301...
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