Single Stage Condensing Gas Furnaces 95.0% AFUE INSTALLATION INSTRUCTIONS J951X*U (95.0% AFUE) Upflow / Horizontal Furnace J951X*D (95.0% AFUE) Downflow Furnace 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 Heating Load..................................................................... 5 Installation in a Garage..................................................... 5 Clearances to Combustible Materials................................ 5 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.
1. For direct-vent appliances, mechanical-vent heating appliances or domestic hot water equipment, where the bottom of the vent terminal and the air intake is installed below four feet above grade the following requirements must be satisfied: a.) A carbon monoxide (CO) detector and alarm shall be placed on each floor level where there are bedrooms. The detector shall comply with NFPA 720 (2005 Edition) and be mounted in the living area outside the bedroom(s). b.
Heating Load This furnace should be sized to provide the design heating load requirement. Heating load estimates can be made using approved methods available from Air Conditioning Contractors of America (Manual J); American Society of Heating, Refrigerating, and Air Conditioning Engineers; or other approved engineering methods. Excessive oversizing of the furnace could cause the furnace and/or vent to fail prematurely.
shall be available for the final inspection of the furnace prior to occupancy. • This furnace is designed to operate with return air temperatures in ranges normally found in occupied residences, including setbacks. Minimum continuous return temperature must not be below 60° F (15° C). Occasionally a temporary return temperature of 55° F (12° C) is acceptable. However, operation with a return temperature below 55° F (12° C) is not allowed.
IMPORTANT INFORMATION: • This furnace must be vented in compliance with the current revision of the National Fuel Gas Code (ANSI-Z223.1/NFPA54). Instructions for determining the adequacy of an installation can be found in the current revision of the NFGC (ANSI Z223.1 / NFPA54). Refer to the NFGC for approved vent tables. Consult local codes for special requirements. These requirements are for US installations as found in the NFGC.
Outdoor Air Using Vertical Ducts EXAMPLE If the combined input rate of all appliances is less than or equal to 100,000 Btuh, each opening must have a free area of at least 100 in2. If the combined input rate of all appliances is 120,000 Btuh, each opening must have a free area of at least 120 in2. Vent or Chimney NOTES: Each opening must be at least 100 sq. in. or 1 sq. in. per 1,000 Btuh of total input rating, whichever is greater. 12” Max.
Air Directly Through An Exterior Wall If combustion air is provided directly through an exterior wall, the two openings must each have free area of at least one square inch per 4,000 Btuh of total appliance input. See Figure 6. Vent or Chimney See Note --- 12" Max NOTE: Each opening to outside must be at least 1 sq. in. per 4,000 Btuh of total input rating.
Vent Pipe Material Vent and combustion air pipe and fittings must be one of the following materials in the list and must conform to the indicated ANSI/ASTM standards. MATERIALS STANDARDS Schedule 40PVC.......................................................D1785 CPVC.........................................................................D1784 PVC-DWV..................................................................D2665 SDR-21 & SDR-26.....................................................D2241 ABS-DWV....
• Route piping as direct as possible between the furnace and the outdoors. Horizontal piping from inducer to the flue pipe must be sloped 1/4” per foot to ensure condensate flows towards the drain tee or PVC trap. Longer vent runs require larger pipe diameters. Refer to the Inducer & Venting Options section on page 15 for additional information. • If a Direct Vent (2-pipe) system is used, the combustion air intake and the vent exhaust must be located in the same atmospheric pressure zone.
1/2" Armaflex Insulation or Equivalent (if required) Outside Wall NOTE: Vent Configuration to Provide 12" Minimum height above Snow Level. Figure 9. Alternate Horizontal Vent Installation 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.
For Installations where there is limited clearance for the J-Trap (such as an attic where it may be installed between ceiling joists), either side of the J-Trap can be shortened to a minimum of 3 Inches. See Figure 11 (page 15). CIRCULATING AIR REQUIREMENTS WARNING: Do not allow combustion products to enter the circulating air supply.
Downflow Furnaces • To attach the return air duct to the furnace, bend the flanges on the furnace upward 90° with wide duct pliers. See Figure 29 for furnace flange locations. NOTE: If system installation includes AC coil casing, bend the flanges on the coil casing upward 90° before attaching the return air duct. • Secure the return air ductwork to the furnace or coil casing (if installed) with sheet metal screws. Make sure the screws penetrate the sheet metal casing and flanges.
Downflow Furnaces Two-pipe installation shown Flue pipe vented to outside WARNING: The furnace must not be installed directly on carpeting, tile, or any combustible material other than wood flooring. Wood or non-combustible platform Coil Plenum Combustion Air WARNING: Condensate Drain Lines Failure to install the downflow sub-base kit may result in fire, property damage or personal injury. J-Trap Height 3” Min. Figure 11.
J951X*U & J951X*D SERIES - CONVENTIONAL (1 PIPE) VENT DIRECTION UPFLOW Right Option 1 N/A N/A Option 9 Up N/A Option 5 Option 6 Option 10 Left Option 2 N/A N/A Option 11 HORIZONTAL RIGHT HORIZONTAL LEFT DOWNFLOW J951X*U & J951X*D SERIES - DIRECT VENT (2-PIPE) VENT DIRECTION UPFLOW HORIZONTAL RIGHT HORIZONTAL LEFT DOWNFLOW Right Option 3 N/A N/A Option 12 Up N/A Option 7 Option 8 Option 13 Left Option 4 N/A N/A Option 14 Table 4. Vent & Inducer Blower Options 6.
Alternate Pressure Switch Location In some inducer orientations, the inducer pressure switch may interfere with gas pipe installation. Determine the side of the cabinet the gas pipe will enter and see if the inducer pressure switch needs to be moved. If the pressure switch interferes with the gas pipe, use these instructions for relocating it to an alternate location: 1. Shut off any electrical power to the furnace. 2. Label and disconnect the tubing and wires from the pressure switch (Figure 16). 3.
PVC Components IMPORTANT NOTES: INSTALLATION OF PVC COMPONENTS (TYPICAL ORIENTATION) • Before permanently installing these components, it is recommended you dry-fit them first to ensure proper fit and alignment with other vent pipes. • The 2” PVC components shown in Figure 19 are not provided in the extra parts bag for *SC & *SL models. However the PVC Trap (P/N 664659) can be purchased thru your local distributor.
than the original tubing ID supplied by the manufacturer. The drain line should slope downward away from the furnace to ensure proper drainage. • The placement of the condensate drain lines will depend on the configuration selected in Table 4 (page 16). The 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. The J-trap may need to be rotated to the side that matches your setup.
GAS SUPPLY & PIPING 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. • 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.
J951X*U SERIES Burner Assembly Manifold See Note “A” Shut-Off Valve Burner Assembly Manifold Gas Valve See Note “A” Gas Valve Pipe Nipple See Note “B” Plug Drip Leg Pipe Nipple Shut-Off Valve See Note “B” Drip Leg Elbow Elbow Ground Joint Union Ground Joint Union Left Side Entry Right Side Entry Figure 23.
The furnaces are shipped from the factory with orifices and gas regulator settings for natural gas operation at sea level altitudes. At 2,000 feet, the NFGC requires that this appliance be derated 4% for each 1,000 feet of altitude. For example, the input needs to be reduced 8% at 2,000 feet, 12% at 3,000 feet, etc. This deration is in reference to the input rate and gas heating value at sea level. To derate the furnace requires knowing the heating value of the gas at the installation site.
ELECTRICAL WIRING Line Voltage Wiring WARNING: ELECTRICAL SHOCK, FIRE OR EXPLOSION HAZARD Failure to follow safety warnings exactly could result in serious injury, death or property damage. Improper servicing could result in dangerous operation, serious injury, death or property damage. • Before servicing, disconnect all electrical power to furnace. • When servicing controls, label all wires prior to disconnecting. Reconnect wires correctly. • Verify proper operation after servicing.
Field Supplied Fused Service Panel Field Line Voltage Wiring Factory Line Voltage Wiring Black (Hot) White (Neutral) Field Supplied Disconnect within Sight of Furnace Field Supplied Panel Connector Black Black Black White White White Green or Bare (Ground) Ground Ground Ground Junction Box (may be int. or ext. to the furnace). These connections can be made in the field supplied disconnect at the furnace.
SINGLE STAGE HEATING (WITH TWINNING) AC UNIT THERMOSTAT Y R G W1 C RELAY W2 NO COM RED WHITE R C Y G W C Expansion Port R G W Expansion Port Y FURNACE BOARD Expansion Port 6-Pin Wiring Harness Expansion Port 6-Pin Wiring Harness FURNACE BOARD BLOWER CONTROL BOARD BLOWER CONTROL BOARD TWIN TERMINAL TWIN TERMINAL SECONDARY FURNACE PRIMARY FURNACE TWO STAGE HEATING (WITH TWINNING) AC UNIT THERMOSTAT Y R G W1 C RELAY W2 NO RED COM C R C Y G W Expansion Port R G W Expa
Capscrew 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: Figure 28. Regulator Capscrew 6. The manifold pressure must be set to the appropriate value for each installation by a qualified installer, service agency or the gas supplier.
Fault Conditions There is a green and a red LED (labeled “Status”) on the motor control board to provide system faults as described below. Refer to Table 14 (page 40) to determine motor control board fault conditions. OPERATING SEQUENCE The operating sequences for the heating, cooling, and fan modes are described below. Refer to the field and furnace wiring diagrams: Figure 25 (page 24), Figure 26 (page 24), Figure 31 (page 30) and Figure 32 (page 31). Heating Cycle 1.
Cleaning of Burners - If the burners must be cleaned, follow steps 1-12. See Figure 37 (page 41) or Figure 38 (page 41) for component location. 1. Shut off gas supply to the furnace at the meter or at a manual valve in the supply piping. 2. Turn off all power to the furnace and set the thermostat to it’s lowest setting. 3. Remove the burner door from the furnace. 4. Turn the gas control switch to the OFF position. 5. Disconnect the wires from the gas valve, igniter, flame sensor, and flame rollout switch.
FIGURES & TABLES TOP VIEW J951X*U UPFLOW / HORIZONTAL FURNACES DIM -B- DIM -C- 17 1/2 15 7/8 16 1/8 21 19 3/8 19 5/8 24 1/2 22 7/8 23 1/8 FL AN 19 GE S NOTE: Dimensions shown in inches.
Figure 31.
LADDER DIAGRAM Single Stage Furnaces L1 GND DOOR SWITCH N NEUTRAL GND L1 FLAME SENSOR GND P1-7 K4 EAC K3 P2-3 NEUTRAL BLOWER MOTOR CHOKE (SOME MODELS) NEUTRAL ELECTRONIC AIR CLEANER P2-6 HOT SURFACE IGNITOR HUM K2 NEUTRAL HUMIDIFIER P2-1 P2-4 INDUCER NEUTRAL XFORMER 120 VAC See Note TRANSFORMER R 3A FUSE W 24 VAC 24V TO MOTOR RELAYS P1-8 G SUPPLY AIR ROLL-OUT LIMIT LIMIT P1-3 P1-6 MICRO Y P1-5 K1 PRESSURE SWITCH BLOWER LIMIT SWITCH BLOWER DECK LIMIT SWITCH See Note
Gas Information GAS FLOW RATES (CUBIC FEET PER HOUR) TIME FOR ONE REVOLUTION (SECONDS) 10 12 GAS FLOW RATES (CUBIC FEET PER HOUR) CUBIC FEET PER REVOLUTION OF GAS METER 1 5 10 TIME FOR ONE REVOLUTION (SECONDS) 360 300 1,800 1,500 3,600 3,000 66 68 CUBIC FEET PER REVOLUTION OF GAS METER 1 5 10 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 1,63
HIGH ALTITUDE DERATION – PROPANE GAS ALTITUDE ABOVE SEA LEVEL 0 to 1,999 FT 2,000 to 2,999 FT 3,000 to 4,999 FT 5,000 to 5,999 FT 6,000 to 7,999 FT 8,000 to 10,000 FT INPUT (BTU) 38,000 38,000 (SC MODELS) (SD MODELS) 54,000 72,000 90,000 108,000 118,000 120,000 56 60 56 56 56 56 55 55 10.0 10.0 10.0 10.0 10.0 10.0 10.0 10.0 ORIFICE SIZE MANIFOLD PRESSURE 56 60 56 56 56 56 55 55 ORIFICE SIZE 9.0 9.0 9.0 9.0 9.0 9.0 9.0 9.
HIGH ALTITUDE DERATION – NATURAL GAS WITH HIGH HEATING VALUE ALTITUDE ABOVE SEA LEVEL 0 to 1,999 FT 2,000 to 2,999 FT 3,000 to 3,999 FT 4,000 to 4,999 FT 5,000 to 5,999 FT 6,000 to 6,999 FT 7,000 to 7,999 FT 8,000 to 8,999 FT 9,000 to 9,999 FT INPUT (BTU) 38,000 38,000 (SC MODELS) (SD MODELS) 54,000 72,000 90,000 108,000 118,000 120,000 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 45 51 47 47 47 47 46 45 ORIFICE SIZE 3.0 3.2 3.
Venting Information AIR SUPPLY INLET VENT TERMINAL AREA WHERE TERMINAL IS NOT PERMITTED CANADIAN INSTALLATIONS CLEARANCE LOCATION A= B= Clearance above grade, veranda, porch, deck, balcony, or maximum expected snow level. Clearance to window or door that may be opened.
J951X*U & J951X*D Series HORIZONTAL VENTING w/ 2-Pipes Straps or Other Suitable Supports at minimum of 5 ft. Intervals (Upflow Furnace Shown) Seal/Caulk Around Pipes at Building 90° Elbow 90° Elbow COMBUSTION AIR See Table 2 for 2” PVC pipe lengths (field supplied) Upward Pitch - 1/4” per foot (Flue Pipe) FLUE PIPE Coupling with 2 Hose Clamps (Optional) 90° Elbow First support placed as close to furnace connection as possible 12” Min.
J951X*U SERIES UPFLOW - 1 PIPE OPTIONS PVC Tee Plug PVC Trap See NOTE 5 PVC Tee Rubber Grommet OPTION 1 X Plug See NOTE 5 FLUE PIPE X COMBUSTION AIR FLUE PIPE COMBUSTION AIR OPTION 2 PVC Trap Rubber Grommet See VIEW A for drain line positions See VIEW P for drain line positions VIEW -A- VIEW -B- Field Supplied Drain Line Attached to PVC Trap (Do Not Trap) Inline Drain Tube (Factory Supplied) See NOTE 4 Collector Box Drain (Factory Equipped) See NOTES 2 & 3 Inline Drain Tube (Field S
Option 5 J951X*U SERIES HORIZONTAL LEFT - 1 PIPE OPTION Rubber Grommet Option 6 FLUE PIPE FLUE PIPE J951X*U SERIES HORIZONTAL RIGHT - 1 PIPE OPTION Rubber Grommet COMBUSTION AIR COMBUSTION AIR See VIEW C for drain line positions See VIEW D for drain line positions Plug Plug Inline Drain (Factory Supplied) See NOTE 3 VIEW -C- VIEW -DInline Drain (Factory Supplied) See NOTE 2 Collector Box Drain (Factory Equipped) See NOTE 2 Collector Box Drain (Factory Equipped) See NOTE 2 NOTES: 1.
Option 10 FLUE PIPE Plug PVC Tee Plug See NOTE 5 COMBUSTION AIR COMBUSTION AIR Plug X Option 9 FLUE PIPE Rubber Grommet PVC Trap X Option 11 Plug COMBUSTION AIR FLUE PIPE J951X*D SERIES DOWNFLOW - 1 PIPE OPTIONS See NOTE 5 PVC Tee Rubber Grommet PVC Trap Rubber Grommet See VIEW E for drain line positions See VIEW F for drain line positions Field Supplied Drain Line Attached to PVC Trap (Do Not Trap) Inline Drain (Factory Supplied) See NOTE 4 Collector Box Drain (Factory Equipped)
TROUBLESHOOTING If the furnace fails to operate check the following: • Is the thermostat operating properly? • Are the blower compartment door(s) in place? • Is the furnace disconnect closed? • Has the circuit breaker tripped or the control board fuse burned open? • Is the gas turned on? • Are any manual reset switches open? • Is the filter dirty or plugged? • Is the flame sensor coated? (Remove and clean with steel wool.
UPFLOW / HORIZONTAL FURNACE (J951X*U SERIES) Flame Sensor Finish Flange Burner Assembly Roll-Out Switch Igniter Main Air Limit Switch Gas Valve Furnace Control Board Inducer Limit Switch Pressure Switch (Inducer) Inducer Assembly Pressure Switch (Condensate) Transformer Blower Door Switch 1 2 34 5678 Motor Control Board Motor Choke Blower Assembly Figure 37.
INSTALLATION CHECKLIST ELECTRICAL SYSTEM INSTALLER NAME: CITY: STATE: INSTALLATION ADDRESS: CITY: Electrical connections tight? YES NO Line voltage polarity correct? YES NO Supply Voltage:................................................................
