J801X*U ULTRA-LOW NOX SERIES, SINGLE STAGE, NON-CONDENSING GAS FURNACE 80% AFUE INSTALLATION INSTRUCTIONS Upflow / Horizontal Furnace This product complies with SJVAPCD 4905 and SCAQMD 1111 with NOx levels below 14 ng/J when operated on natural gas. WARNING FIRE OR EXPLOSION HAZARD • Failure to follow safety warnings exactly could result in serious injury, death or property damage. • Installation and service must be performed by a qualified installer, service agency or the gas supplier.
TABLE OF CONTENTS IMPORTANT SAFETY INFORMATION..........................3 REQUIREMENTS & CODES..........................................3 Combustion Air Quality...............................................4 Clearances to Combustible Materials.........................4 Heating Load..............................................................4 Installation in a Garage...............................................4 Operation of Furnace During Construction.................
IMPORTANT SAFETY INFORMATION INSTALLER: Please read all instructions before servicing this equipment. Pay attention to all safety warnings and any other special notes highlighted in the manual. Safety markings are used frequently throughout this manual to designate a degree or level of seriousness and should not be ignored. WARNING - indicates a potentially hazardous situation that if not avoided, could result in personal injury or death.
Society of Heating, Refrigeration, and Air Conditioning Engineers (ASHRAE) Fundamentals Handbook Electrical Connections • US: National Electrical Code (NEC) ANSI/NFPA 70 Gas Piping & Gas Pipe Pressure Testing • US: NFGC and National Plumbing Codes General Installation • US: Current edition of the NFGC and the NFPA 90B. For copies, contact the National Fire Protection Association Inc., Batterymarch Park, Quincy, MA 02269; or American Gas Association, 400 N. Capitol, N.W., Washington DC 20001 or www.NFPA.
CLEARANCES TO COMBUSTIBLE MATERIALS* UPFLOW & DOWNFLOW APPLICATIONS FRONT FRONT BOTTOM SIDE TOP RIGHT SIDE TOP WARNING: HORIZONTAL APPLICATIONS VENT VENT LEFT SIDE BACK COMBUSTION AIR & VENTING REQUIREMENTS SIDE Left Side.................. 0 Inches Top...........................1 Inch Right Side................ 0 Inches Front......................... †4 Inches Vent......................... 6 Inches Back........................ 0 Inches †Allow 24 in. minimum clearance for servicing.
current revision of the NFGC (ANSI Z223.1 / NFPA54). Consult local codes for special requirements. These requirements are for US installations as found in the NFGC. CAUTION: 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 operation or unsafe conditions such as flame roll out.
Ventilation Louvers at each end of attic Vent or Chimney Outlet Air Duct must be at least 1 sq. in. per 4,000 Btuh of total input rating. Attic Insulation Water Heater Inlet and Outlet Ducts must extend above attic insulation. Furnace Inlet Air Duct must be at least 1 sq. in. per 4,000 Btuh of total input rating. 12" Max --- Furnace See Note --- 12" Max 12" Max Vent or Chimney NOTE: Each opening to outside must be at least 1 sq. in. per 4,000 Btuh of total input rating.
Category I Venting This furnace is listed as a Category I vented appliance. Category I furnaces generally operate with a slight negative pressure (draft) and must be vented vertically or near vertical. Additionally it is important to guard against excessive condensation. WARNING: Upon completion of the furnace installation, carefully inspect the entire flue system both inside and outside the furnace to assure it is properly sealed.
CIRCULATING AIR REQUIREMENTS WARNING: Do not allow combustion products to enter the circulating air supply. Failure to prevent the circulation of combustion products into the living space can create potentially hazardous conditions including carbon monoxide poisoning that could result in personal injury or death. All return ductwork must be secured to the furnace with sheet metal screws. For installations in confined spaces, all return ductwork must be adequately sealed.
casing, bend the flanges on the coil casing upward 90° before attaching the supply air duct. • Position the supply air ductwork onto the furnace ensuring even alignment of furnace air opening and supply air duct. NOTE: The ductwork must have an opening equal to that of the supply air opening of the furnace. See Figure 16 for supply air opening size.
Horizontal Furnaces WARNING: The furnace must not be installed directly on carpeting, tile, or any combustible material other than wood flooring. • The Ultra-Low NOx series gas furnace can be installed horizontally (Figure 7) in an attic, basement, crawl space or alcove. They can also be suspended from a ceiling in a basement or utility room in either a right to left airflow or left to right airflow as shown in Figure 8. • Ultra-Low NOx series furnaces are shipped with the bottom panel installed.
GAS SUPPLY & PIPING Door WARNING: Screws Screws Blower Assembly Front Brace Bottom Panel Figure 10. Bottom Panel Removal Alternate Bottom Panel Removal If the bottom panel cannot be removed using the previous instructions, the steps below are an alternate method for removing the bottom panel. See Figure 11. 1. Remove the door from the blower compartment. 2. Remove all screws securing the bottom panel to the front brace. 3. Remove two screws securing the furnace cabinet to the blower deck. 4.
Shut - Off Valve 1/8” NPT Plug See Note See Note Gas Valve Shut - Off Valve 1/8” NPT Plug Plug Dripleg Dripleg Ground Joint Union Ground Joint Union Left Side Entry Right Side Entry NOTE: Some utilities require Shut- Off Valve to be 4 - 5 feet above floor. Figure 12. Typical Gas Connections The furnace may be installed for either left or right side gas entry by removing the 1/2” plug from the tee and replacing it to the side not used.
EXAMPLE Elevation:.......................................................5,000 feet Type of Gas:............................................... Natural Gas Local Heating Value of Gas:................................... 750 From Table 8, find 750 and follow down the column, stop at the 5,000 feet row. The heating value listed is LOW. Table 10 will be used to determine orifice size and manifold pressure After changing the regulator pressure or the orifices, it is required that you measure the gas input rate.
MINIMUM CIRCUIT AMPACITY (MCA) MAXIMUM FUSE OR CIRCUIT BREAKER AMPS* 7.2 8.73 15 9.5 12.1 11.60 14.85 20 25 FURNACE MODEL *SA- FURNACE INPUT (BTUH) CABINET WIDTH (IN.) NOMINAL ELECTRICAL SUPPLY MAXIMUM OPERATING VOLTAGE MINIMUM OPERATING VOLTAGE (†) MAXIMUM FURNACE AMPERES J801X055A 55,000 14 1/4 120-60-1 132 108 J801X070B J801X100C 70,000 100,000 17 1/2 21 120-60-1 120-60-1 132 132 108 108 * Time-delay fuses or HACR rated circuit breakers are reccomended.
2. Adjust all registers and duct dampers to the desired position and run the furnace for 10 to 15 minutes before taking any temperature readings. The temperature rise is the difference between the supply and return air temperatures. Capscrew For typical duct systems, the temperature rise will fall within the limits specified on the rating plate with the blower speed at the factory recommended setting.
5. The control energizes the igniter output for a 30 second warm-up period. 6. The control energizes the main gas valve for 3 seconds. 7. If the flame is proved after igniting the gas, the control deenergizes the igniter. The gas valve and inducer remain energized. The control goes to blower on delay. 8. If flame is present, the control energizes the blower on the selected HEAT speed 30 seconds after the gas valve opened. The gas valve remains energized while the inducer ramps to Max.
be inspected and cleaned (if required) by a qualified service technician annually to ensure continued safe operation. Pay attention to any deterioration from corrosion or other sources. Lubrication - The bearings in the blower motor and inducer blower used in these furnaces are pre-lubricated and sealed by the manufacturer. No further oiling of the bearings is required for the life of the motor. TROUBLESHOOTING Access Cover Perimeter Screws (x8) Figure 16. Ignitor Flame Sensor Bracket 4.
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 locations are shown in Figure 17. If any component of the furnace must be replaced, use only factory authorized replacement parts specified in the Replacement Parts List. Blower Limit Switch (Reverse Airflow Limit) - Prevents operation when blower is not operational. Flame Sensor - Verifies when a flame is present.
FIGURES & TABLES TOP VIEW ULTRA-LOW NOX UPFLOW FURNACE BOTTOM VIEW C D Front Brace DIM. -B- DIM. -C- DIM. -D- J801X055A 14 1/4 10 3/4 12 5/8 12 7/8 J801X070B 17 1/2 11 3/4 15 7/8 16 1/8 J801X100C 21 14 19 3/8 19 7/8 FL 23 AN GE S 19 Bottom Panel NOTE: Dimensions shown in Inches. 5/8 18 5/8 DIM.
Airflow Data HEATING AIRFLOW (CFM) & TEMPERATURE RISE (°F) MODEL NAME/ HEATING INPUT J801X*U RETURN AIR VIA: MOTOR SPEED TAP EXTERNAL STATIC PRESSURE (IN. W.C.) 0.1 CFM 0.2 RISE CFM 0.3 RISE 0.4 CFM RISE 50 0.
HEATING AIRFLOW (CFM) & TEMPERATURE RISE (°F) MODEL NAME/ HEATING INPUT J801X*U RETURN AIR VIA: Bottom J801X070B 70,000 BTU/Hr Side External Static Pressure (in. w.c.) MOTOR SPEED 0.1 5 - High* 4 - Alternate 3 - Medium High 2 - Med-Low** 1 - Low*** 5 - High* 4 - Alternate 3 - Medium High 2 - Med-Low** 1 - Low*** 0.2 0.3 0.4 0.
HEATING AIRFLOW (CFM) & TEMPERATURE RISE (°F) MODEL NAME/ HEATING INPUT J801X*U RETURN AIR VIA: MOTOR SPEED TAP EXTERNAL STATIC PRESSURE (IN. W.C.) 0.1 0.2 0.3 0.4 CFM RISE CFM RISE CFM RISE CFM 3 - Med-Low** 1,580 47 1,530 48 1,480 50 2 - Alternate 1,500 49 1,450 51 1,400 53 1 - Low*** 1,390 53 1,320 56 1,260 3 - Med-Low** 1,540 48 1,490 50 2 - Alternate 1,470 50 1,420 1 - Low*** 1,310 57 1,250 1,600 46 1,525 1,370 0.
Yellow LED Continuous Flash On Diagnostic Description Low Flame Sensor Signal Flame Present Figure 19. Wiring Diagram BLUE 1 2 3 4 GREEN BLACK WHITE BLACK BLACK WHITE 1 2 XFMR HUM DOOR SWITCH L1 WHITE (NEUTRAL) BLACK 120V GROUND CHASIS GND. 1 2 3 4 CHASIS GND.
LADDER DIAGRAM For 80% Ultra-Low NOx Series Single Stage Furnaces GND L1 120 Volt / 1 Ph. / 60 Hz.
Gas Information GAS FLOW RATES (CUBIC FEET PER HOUR) TIME FOR ONE REVOLUTION (SECONDS) GAS FLOW RATES (CUBIC FEET PER HOUR) CUBIC FEET PER REVOLUTION OF GAS METER CUBIC FEET PER REVOLUTION OF GAS METER 1 5 10 TIME FOR ONE REVOLUTION (SECONDS) 1 5 10 10 12 360 300 1,800 1,500 3,600 3,000 66 68 55 53 273 265 545 529 14 257 1,286 2,571 70 51 257 514 16 225 1,125 2,250 72 50 250 500 18 200 1,000 2,000 74 49 243 486 20 180 900 1,800 76 47 237 474 22 164 818 1
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 LOW LOW LOW LOW LOW HIGH HIGH HIGH 4,000 FT LOW LOW LOW LOW LOW HIGH HIGH HIGH HIGH 4,999 FT LOW LOW LOW LOW LOW HIGH HIGH HIGH HIGH Table 8.
INSTALLATION CHECKLIST ELECTRICAL SYSTEM INSTALLER NAME: CITY: STATE: YES NO Line voltage polarity correct? YES NO Supply Voltage (VOLTS): INSTALLATION ADDRESS: CITY: Electrical connections tight? STATE: UNIT MODEL # Has the thermostat been calibrated? YES NO Is the thermostat level? YES NO Is the heat anticipator setting correct? YES NO YES NO GAS SYSTEM UNIT SERIAL # Minimum clearances as shown in Figure 1, (page 5)? YES NO Has the owner’s information been reviewed with the hom
