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HVAC Partners 801S series Installation Instructions Manual

Downflow single stage gas furnaces
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INSTALLATION INSTRUCTIONS

FOR DOWNFLOW SINGLE STAGE GAS FURNACES
(-)801S
DOWNFLOW SERIES
(-)801P
DOWNFLOW SERIES
(-)(-)80DSS DOWNFLOW SERIES
(-)(-)80DSP DOWNFLOW SERIES
ISO 9001:2008
Factory Use Only
U.L. and/or C.S.A. recognized fuel gas and CO (carbon monoxide) detectors are rec-
ommended in all applications, and their installation should be in accordance with the
manufacturer's recommendations and/or local laws, rules, regulations, or customs.
92-24161-143-01
SUPERSEDES 92-24161-143-00

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  • Page 1: Installation Instructions

    INSTALLATION INSTRUCTIONS FOR DOWNFLOW SINGLE STAGE GAS FURNACES (-)801S DOWNFLOW SERIES (-)801P DOWNFLOW SERIES (-)(-)80DSS DOWNFLOW SERIES (-)(-)80DSP DOWNFLOW SERIES U.L. and/or C.S.A. recognized fuel gas and CO (carbon monoxide) detectors are rec- ommended in all applications, and their installation should be in accordance with the manufacturer’s recommendations and/or local laws, rules, regulations, or customs.

  • Page 2: Table Of Contents

    TABLE OF CONTENTS 1 TABLE OF CONTENTS..... . . 2 11 TWINNING ....... . 27 Furnace Twinning Installations .

  • Page 3: General Information

    GENERAL INFORMATION NOTE: A heat loss calculation should be performed to properly The (-)801S/(-)801P series furnaces are design certified by CSA determine the required furnace BTU size for the structure. Also, for use with natural and propane gases as follows: the duct must be properly designed and installed for proper air- As a Category I furnace, it may be vented vertically with type B- flow.

  • Page 4: Receiving

    GENERAL INFORMATION (cont.) Install this furnace in accordance with the American National Stan- CALIFORNIA RESIDENTS ONLY dard Z223.1 – latest edition entitled “National Fuel Gas Code” IMPORTANT: All manufacturer products meet current Federal (NFPA54) and requirements or codes of the local utilities or other OSHA Guidelines for safety.

  • Page 5: Checklist

    Installation Instructions remain with the furnace as a reference guide to the servicing contractor. We recommend that performance and installation data be recorded for future reference on this sheet to meet service and warranty obligations so that job site information is available when required. Installation Checklist REFER TO INSTALLATION INSTRUCTIONS G S SUPPLY...

  • Page 6: Safety Information

    SAFETY INFORMATION W RNING W RNING DO NOT INSTALL THIS FURNACE IN A MOBILE HOME!! COMBUSTION AND VENTILATION AIR MUST BE PRO- THIS FURNACE IS NOT APPROVED FOR INSTALLATION VIDED TO THE FURNACE AS REQUIRED BY THE NA- IN A MOBILE HOME. DOING SO COULD CAUSE FIRE, TIONAL FUEL-GAS CODE (U.S.) AND THE COMBUSTION PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.

  • Page 7: Important Information About Efficiency And Quality

    SAFETY W RNING W RNING BLOWER AND BURNERS MUST NEVER BE OPERATED DUCT LEAKS CAN CREATE AN UNBALANCED SYSTEM WITHOUT THE BLOWER DOOR IN PLACE. THIS IS TO PRE- AND DRAW POLLUTANTS SUCH AS DIRT, DUST, FUMES VENT DRAWING GAS FUMES (WHICH COULD CONTAIN AND ODORS INTO THE HOME CAUSING PROPERTY HAZARDOUS CARBON MONOXIDE) INTO THE HOME THAT DAMAGE.

  • Page 8: Location Requirements

    LOCATION REQUIREMENTS GENERAL INFORMATION SITE SELECTION W RNING 1. Select a site in the building near the center of the pro- WHEN THIS FURNACE IS INSTALLED IN A RESIDENTIAL posed, or existing, duct system. GARAGE, IT MUST BE INSTALLED SO THE BURNERS 2.

  • Page 9: Upflow Dimensions & Clearance Table

    FIGURE 3 DOWNFLOW DIMENSIONS...

  • Page 10: Ducting

    DUCTING Proper air flow is required for the correct operation of this 5. Connect the return air ducting to the return air opening furnace. Restricted air flow can cause erratic operation and at the top of the unit. Make the connection air tight to can damage the heat exchanger.
  • Page 11 DUCTING TABLE 1 NON-COMBUSTIBLE FLOOR BASES Floor Base Size Cabinet RXGC-B14 RXGC-B17 RXGC-B21 RXGC-B24 FIGURE 5 NON-COMBUSTIBLE FLOOR BASE INSTALLATION INSTRUCTIONS COMBUSTIBLE COMBUSTIBLE FLOOR FLOOR MATERIAL MATERIAL NON-COM- NON-COM BUSTIBLE FLOOR BASE FLOOR BASE 21 5/8" FLOOR CUTOUT FLOOR CUTOUT DIMENSIONS DIMENSIONS FLOOR...

  • Page 12: Combustion And Ventilation Air

    COMBUSTION AND VENTILATION AIR COMBUSTION AIR REQUIREMENTS W RNING IMPORTANT: This is not a direct vent furnace. eview venting instructions before installing. ALL FURNACE INSTALLATIONS MUST COMPLY WITH THE NATIONAL FUEL GAS CODE AND LOCAL CODES TO W RNING PROVIDE ADEQUATE COMBUSTION AND VENTILATION AIR FOR THE FURNACE.
  • Page 13 COMBUSTION AND VENTILATION AIR (cont.) COMBUSTION AIR REQUIREMENTS: CONFINED AND UNCONFINED SPACES FURNACE LOCATED IN A CONFINED SPACE ALL FURNACE INSTALLATIONS MUST COMPLY WITH THE NATIONAL FUEL GAS CODE, NFPA 54 AND LOCAL rating which is smaller than that which is specified in Table 1 as CODES TO PROVIDE ADEQUATE COMBUSTION AND A confined space is defined as any space for a given furnace input VENTILATION AIR FOR THE FURNACE.
  • Page 14 COMBUSTION AND VENTILATION AIR (cont.) COMBUSTION AIR REQUIREMENTS: CONFINED AND UNCONFINED SPACES TABLE 9 : MINIMUM FREE AREA REQUIRED T BLE 3: MINIMUM FREE RE REQUIRED T BLE 5: MINIMUM FREE RE REQUIRED TABLE 1 1: MINIMUM FREE AREA REQUIRED FOR EACH OPENING (WHEN TWO OPENINGS FOR E CH OPENING (WHEN TWO OPENINGS FOR E CH OPENING (WHEN TWO OPENINGS...
  • Page 15 COMBUSTION AND VENTILATION AIR (cont.) COMBUSTION AIR REQUIREMENTS: CONFINED AND UNCONFINED SPACES FIGURE 7 FIGURE 8 AIR FROM ATTIC/CRAWL SPACE OUTSIDE AIR USING A HORIZONTAL INLET & OUTLET OUTLET AIR GABLE IN ATTIC VENT MUST BE VENTILATED ABOVE ATTIC GABLE OR INSULATION SOFFIT VENTS OUTLET AIR...

  • Page 16: Venting

    COMBUSTION AND VENTILATION AIR (cont.) VENTING GENERAL INFORMATION IMPORTANT APPLICATION NOTES When the furnace is used as a replacement, the existing vent The furnace must be vented in accordance with these instructions, system should be inspected to assure that there are no obstruc- National Fuel Gas Code, ANSI Z223.1 and requirements or codes tions, blockage, or any signs of corrosion and is properly sized for of the local utility or other authority having jurisdiction.

  • Page 17: Special Vent Systems (Svs)

    COMBUSTION AND VENTILATION AIR (cont.) VERTICAL VENT SYSTEMS: Single appliance venting of a fan assisted furnace into a tile-lined 1. A gas vent shall terminate above the roof surface with a listed masonry chimney is prohibited. The chimney must be lined with cap or listed roof assembly.

  • Page 18: Power Vent Systems

    COMBUSTION AND VENTILATION AIR (cont.) POWER VENT SYSTEMS 1. Visually inspect the venting system for proper size and hori- zontal pitch and determine that there is no blockage, restric- When vertical venting is not possible, the only acceptable method tion, leakage, corrosion or other deficiencies which could for horizontal venting is with the use of Tjernlund model GPAK- cause an unsafe condition.

  • Page 19: Gas Supply

    GAS SUPPLY GAS SUPPLY AND PIPING NATURAL GAS AND PROPANE IMPORTANT SAFETY INFORMATION AND WILL RISE, POSSIBLY ACCUMULATING IN (LIQUEFIED PETROLEUM GAS / LPG) HIGHER PORTIONS OF THE STRUCTURE. SAFETY • IF A GAS LEAK IS PRESENT OR SUSPECTED: - DO NOT ATTEMPT TO FIND THE CAUSE YOUR- SELF.

  • Page 20: Gas Piping

    GAS SUPPLY GAS PIPING IMPORTANT: It is permissible to run flexible gas connector inside the unit to a piece of black pipe. If local codes allow the use of a flexible gas appliance connector, always use a new listed connec- THIS FURNACE IS EQUIPPED AT THE FACTORY tor.

  • Page 21: Gas Pressure

    GAS SUPPLY (cont.) GAS PRESSURE IMPORTANT: ENSURE that the furnace gas valve is not to be subjected to high gas line supply pressures. FIGURE 13 TYPICAL GAS VALVE (HONEYWELL) DISCONNECT the furnace and its individual manual gas stop from the gas supply piping during any pressure testing that ex- ceeds 1/2 PSIG.

  • Page 22: Setting Gas Pressure

    GAS SUPPLY (cont.) GAS PRESSURE SETTING GAS PRESSURE The maximum gas supply pressure to the furnace must not ELEVATIONS ABOVE 2000 FT. REQUIRE THAT THE exceed 10.5" w.c. natural gas, or 13" w.c. LP gas. The mini- FURNACE INPUT RATING BE ADJUSTED AND THAT mum supply gas pressure to the gas valve should be 5 w.c.

  • Page 23: Electrical Wiring

    ELECTRICAL WIRING ELECTRICAL WIRING FIGURE 14 TURN OFF ELECTRIC POWER AT FUSE BOX OR SERVICE PANEL BEFORE MAKING ANY ELECTRI- CAL CONNECTIONS. FAILURE TO DO SO CAN CAUSE ELECTRICAL SHOCK RESULTING IN PER- SONAL INJURY OR DEATH. THE CABINET MUST HAVE AN UNINTERRUPTED GROUND ACCORDING TO THE LATEST EDITION OF THE NATIONAL ELECTRICAL CODE, ANSI/NFPA70 OR LOCAL CODES THAT APPLY.

  • Page 24: Thermostat

    ELECTRICAL WIRING REVERSING ELECTRICAL CONNECTION & THERMOSTAT THERMOSTAT Install the room thermostat in accordance with the instruction sheet packed in the box with the thermostat. Run the thermostat The room thermostat must be compatible with the furnace. See lead wires inside the blower compartment and connect to low manufacturer’s thermostat spec sheet for compatability concerns.

  • Page 25: Lp Conversion

    LP CONVERSION NOTE: The valve can be converted to use liquified petroleum (LP) 4. Turn the gas supply back on and check for proper operation gas by replacing the pressure regulator spring with the conversion and manifold pressure. kit spring. This LP kit spring allows the regulator to maintain the 5.

  • Page 26: Accessories

    ACCESSORIES ELECTRONIC AIR CLEANER FILTERS (See Figure 20) Line voltage power can be supplied from the terminal labeled Keep filters clean at all times. A filter is not provided with the “EAC” and a line voltage neutral terminal on the control board. furnace, but one must be field-supplied and installed.

  • Page 27: Twinning

    Twinning operation of two furnaces, installed side-by-side, con- UT ELECTRONIC CONTROLS 1194- nected by a common duct system with main power supplied by 200 CONTROL BOARD the same source, and controlled by a common thermostat can be done with the UT Electronic Controls 1194-200 integrated control (62-104058-02) boards.
  • Page 28 ST-A1194-25 THERMOSTAT 1-STAGE NOTE: A FAULT CODE 20 WILL FLASH TO INDICATE A TWINNING PROBLEM. CONFIRM PROPER WIRING IF THIS FAULT IS PRESENT.
  • Page 29 ST-A1194-25 THERMOSTAT 2-STAGE...

  • Page 30: High Altitude

    HIGH ALTITUDE NATURAL GAS AT HIGH ALTITUDES From Table F.1 of National Fuel Gas Code Handbook, 2002 (3.5 W RNING w.c. column). Orifice required at Sea Level: #40 INSTALLATION OF THIS FURNACE AT ALTITUDES ABOVE 2000 FT (610 m) SHALL BE IN ACCORDANCE WITH From Table F.4 of National Fuel Gas Code Handbook, Orifice re- quired at 5000 ft.
  • Page 31 TABLE 4 SUPPLEMENTAL ORIFICE SIZE CHART NATURAL GAS ORIFICE SELECTION BASED ON HEATING VALUE & ELEVATION* Notes: 1. All (-)80+ units are factory equiped with orifices sized for 1050 sea level heating value gas. 2. Local utilities adjust the sea level heating value of gasses used at higher elevations to compensate for appliance operation at altitude. Installer must be aware of the local heating value (sea level standard) to use the chart below.

  • Page 32: Lp Gas At High Altitudes

    LP GAS (TABLE 5) based on an 11" of water column pressure at the orifice, which dif- fers from products that use 10" of water column at the orifice. This NOTE: Keep any parts removed during LP conversion procedure difference requires a deviation from the NFGC orifice size recom- stored with the product literature for future use.

  • Page 33: Startup Procedures

    START-UP PROCEDURES This furnace is equipped with a direct ignition control. Each time SEQUENCE OF OPERATION the room thermostat calls for heat, the ignitor lights the main UT ELECTRONIC CONTROLS burners directly. See the lighting instructions on the furnace. Integrated Controls with Direct Spark Ignition. TO START THE FURNACE 1.

  • Page 34: Diagnostics & Fault Codes

    DIAGNOSTICS AND FAULT CODES Sequence of display: A. The first two-digit fault will be displayed once as described All furnace controls come standard with a 7-segment diagnostic above. display. During standby mode with no fault codes present, the B. The upper-most horizontal segment of the seven-segment display will read “0”...

  • Page 35: Lockout

    LOCKOUT HARD LOCKOUT All lockout conditions can be cleared immediately provided that the original fault causing the lockout is cleared and power to the Three conditions shall cause a hard lockout: unit is cycled off and then back on again or (soft lockout only) if a 1.

  • Page 36: Field Selections & Adjustments

    FIELD SELECTIONS –– DIPSWITCHES A dipswitch bank; SW1 is provided for some field adjustments. Heating blower off delay, cooling (and heat-pump) blower off 90 seconds delay, display (7-Segment) orientation and fault clear are the ad- (Factory Setting) justments and functions that can be handled using the dip- 120 seconds switches.

  • Page 37: Fault Clear

    FAULT CLEAR switch becomes on/off/on/off/on/off or off/on/off/on/off/on MANUAL FAULT CLEAR; SW4 within 30 seconds. When this action is detected within 30 sec- Faults will automatically be cleared from the fault buffer after one onds, the fault code memory buffer shall be cleared. Be sure to week.
  • Page 38 TABLE 6 TIMING DIAGRAM CLOSED OPEN OPEN ST-A1194-27-X0 The maximum gas supply pressure to the furnace should be To change orifice spuds, shut off the manual gas valve and re- 10.5" w.c. for natural gas and 13.0" w.c. for L.P. The minimum move the gas manifold.

  • Page 39: Adjusting Or Checking Furnace Input . 38 22 Setting Input Rate

    TABLE 7 METER TIME (%!%)&!*(%&*+&(*+/!%,&"+0&,%-.+0,&1.)&+.)("$&*+2/!&)"!*+3&.1&1/)+"-%,&%4/*22%0&1.)&+"!/)"$& 3",&.)&$525 <%"!*+3&="$/%&.1&3",&>#!/?1! (%!%)&,*B%& *+2/!& :777 :7D7 ::77 ;677 >#!/?<)A >1! ?)%=A " !" & 678777 !& & %& & & & & "& & "% & 968777 & #& & & & & & '& %&...

  • Page 40: Airflow

    AIRFLOW The importance of proper air flow over the heat exchanger cannot FIGURE 24 be over emphasized. TEMPERATURE RISE MEASUREMENT C UTION IT IS IMPORTANT THAT EACH DUCT SYSTEM BE SIZED AND INSTALLED FOR THE SPECIFIC APPLICATION BY PROPERLY APPLYING THE APPROPRIATE INDUSTRY AC- CEPTED STANDARD.

  • Page 41: Blower Speed Selection

    TABLE 8 IR FLOW PERFORM NCE – (-)801S & (-)801P & (-)(-)80DSS/(-)(-)80DSP SERIES MODELS CFM ir Delivery Motor HP [W] External Static Pressure, ” W.C. [kPa] Model Blower Size IN [MM] Speed Tap 0.1 [0.02] 0.2 [0.05] 0.3 [0.07] 0.4 [0.10] 0.5 [0.12] 0.6 [0.15] 0.7 [0.17]...

  • Page 42: Safety Features

    SAFETY FEATURES LIMIT CONTROL/HALC PRESSURE SWITCH The high limit cut-off temperature is set at the factory and cannot This furnace is equipped with a normally-open pressure switch be adjusted. The temperature setting prevents the air tempera- that monitors pressure conditions within the furnace vent system ture leaving the furnace from exceeding the maximum outlet air during the heating cycle.

  • Page 43: Maintenance

    MAINTENANCE GAS FURNACE (DIRECT DRIVE) INSTRUCTIONS MAINTENANCE THESE INSTRUCTIONS ARE INTENDED AS AN AID TO FIRE, ELECTRICAL SHOCK, CARBON MONOXIDE POI- QUALIFIED SERVICE PERSONNEL FOR PROPER IN- SONING, EXPLOSION, PROPERTY DAMAGE, PERSONAL STALLATION, ADJUSTMENT AND OPERATION OF THIS INJURY OR DEATH. UNIT.

  • Page 44: System Operation Information

    MAINTENANCE LUBRICATION FIGURE 26 DOWNFLOW BLOWER REMOVAL ADVISE THE CUSTOMER or radios to influence the thermostat operation. 6. Except for the mounting platform, keep all combustible 1. Keep the air filters clean. The heating system will oper- articles 3 feet from the furnace and vent system. ate better, more efficiently and more economically.

  • Page 45: Annual Inspection

    MAINTENANCE ANNUAL INSPECTION • The furnace should operate for many years without ex- • IMPORTANT: It is recommended that at the beginning of cessive scale build-up in the flue passageways. However, the heating season, the flame sensor be cleaned with it is recommended that a qualified installer, service fine steel wool or Scotch Bright Pad by a qualified in- agency, or the gas supplier annually inspect the flue pas-...

  • Page 46: Diagnostics

    FIGURE 27 DIAGNOSTIC FLOWCHART CODE DESCRIPTION KEY TO ABBREVIATIONS NOTE: Always verify gas valve inlet and outlet gas Standby IBM = Indoor Blower Motor FLAME (AMBER) LED CODES pressure . IDM = Induced Draft Motor Compressor on (cooling or heat pump heat) OFF = No Flame Presen t IFC = Integrated Furnace Control Gas heat on...

  • Page 47: Wiring Diagram

    FIGURE 28 FOR MODELS WITH UT ELECTRONIC CONTROLS 1028-928 INTEGRATED FURNACE CONTROL AND DIRECT SPARK IGNITION...
  • Page 48 CM 0614...

This manual is also suitable for:

80dss series801p series80dsp series

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