Amana AMV9, ACV9 User Manual

1.03 Mb

AMV9/ACV9

TWO-STAGE VARIABLE SPEED

GAS-FIRED WARM AIR FURNACE

INSTALLATION INSTRUCTIONS

Installer: Affix all manuals adjacent to the unit.

(Type FSP CATEGORY IV Direct or Non Direct Vent Air Furnace)

These furnaces comply with requirements
embodied in the American National Standard		®
/ National Standard of Canada ANSI
Z21.47·CSA-2.3 Gas Fired Central Furnaces.	C		US

RECOGNIZE THIS SYMBOL AS A SAFETY PRECAUTION.

ATTENTION INSTALLING PERSONNEL

As a professional installer you have an obligation to know the product better than the customer. This includes all safety precautions and related items.

Prior to actual installation, thoroughly familiarize yourself with this Instruction Manual. Pay special attention to all safety warnings. Often during installation or repair it is possible to place yourself in a position which is more hazardous than when the unit is in operation.

Remember, it is your responsibility to install the product safely and to know it well enough to be able to instruct a customer in its safe use.

Safety is a matter of common sense...a matter of thinking before acting. Most dealers have a list of specific good safety practices...follow them.

The precautions listed in this Installation Manual are intended as supplemental to existing practices. However, if there is a direct conflict between existing practices and the content of this manual, the precautions listed here take precedence.

*NOTE: Please contact your distributor or our website for the applicable product data book

referred to in this manual.

www.amana-hac.com

IO-253H

07/06

Table of Contents
I. Component Identification ...............................................................................................................................................	5
II. Safety ..............................................................................................................................................................................	6
ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS ...................................................................................................	6
III. Product Application ......................................................................................................................................................	6
IV. Location Requirements & Considerations..................................................................................................................	7
GENERAL .........................................................................................................................................................	7
CLEARANCES AND ACCESSIBILITY ...........................................................................................................................	8
FURNACE SUSPENSION ........................................................................................................................................	8
EXISTING FURNACE REMOVAL ..............................................................................................................................	8
THERMOSTAT LOCATION .......................................................................................................................................	9
V. Combustion & Ventilation Air Requirements ...............................................................................................................	9
VI. Installation Positions ...................................................................................................................................................	11
VII. Horizontal Applications & Considerations ................................................................................................................	11
GENERAL ........................................................................................................................................................	11
DRAIN TRAP AND LINES .....................................................................................................................................	11
LEVELING ........................................................................................................................................................	11
ALTERNATE VENT/FLUE AND COMBUSTION AIR CONNECTIONS .....................................................................................	11
ALTERNATE ELECTRICAL AND GAS LINE CONNECTIONS ............................................................................................	12
DRAIN PAN .....................................................................................................................................................	12
FREEZE PROTECTION ........................................................................................................................................	12
FURNACE SUSPENSION ......................................................................................................................................	12
VIII. Propane Gas /High Altitude Installations ...............................................................................................................	12
IX. Vent/Flue Pipe & Combustion Air Pipe .....................................................................................................................	12
GENERAL .......................................................................................................................................................	12
DUAL CERTIFICATION: NON-DIRECT/DIRECT VENT ...................................................................................................	12
MATERIALS AND JOINING METHODS .....................................................................................................................	13
PROPER VENT/FLUE AND COMBUSTION AIR PIPING PRACTICES .................................................................................	13
TERMINATION LOCATIONS ...................................................................................................................................	13
CANADIAN VENTING REQUIREMENTS .....................................................................................................................	13
STANDARD FURNACE CONNECTIONS .....................................................................................................................	14
ALTERNATE FURNACE CONNECTIONS .....................................................................................................................	14
NON-DIRECT VENT (SINGLE PIPE) PIPING ............................................................................................................	16
DIRECT VENT (DUAL PIPE) PIPING ......................................................................................................................	17
VENT/INTAKE TERMINATIONS FOR INSTALLATION OF MULTIPLE DIRECT VENT FURNACES ..................................................	18
CONCENTRIC VENT TERMINATION .........................................................................................................................	18
X. Condensate Drain Lines & Drain Trap ........................................................................................................................	18
GENERAL .......................................................................................................................................................	18
UPRIGHT INSTALLATIONS .....................................................................................................................................	19
HORIZONTAL INSTALLATIONS ................................................................................................................................	20
XI. Electrical Connections ................................................................................................................................................	21
WIRING HARNESS ............................................................................................................................................	21
115 VOLT LINE CONNECTIONS ............................................................................................................................	21
24 VOLT THERMOSTAT WIRING ............................................................................................................................	22
SINGLE-STAGE THERMOSTAT APPLICATION .............................................................................................................	22
24 VOLT DEHUMIDISTAT WIRING ..........................................................................................................................	22
FOSSIL FUEL APPLICATIONS ...............................................................................................................................	23
115 VOLT LINE CONNECTION OF ACCESSORIES (HUMIDIFIER AND ELECTRONIC AIR CLEANER) .......................................	23
24 VOLT HUMIDIFIER ........................................................................................................................................	23
XII. Gas Supply and Piping ..............................................................................................................................................	23
GENERAL .......................................................................................................................................................	23
GAS PIPING CONNECTIONS ................................................................................................................................	24
PROPANE GAS TANKS AND PIPING ......................................................................................................................	25
XIII. Circulating Air & Filters ............................................................................................................................................	26
DUCTWORK - AIR FLOW .....................................................................................................................................	26
BOTTOM RETURN AIR OPENING [UPFLOW MODELS] ...............................................................................................	26
FILTERS - READ THIS SECTION BEFORE INSTALLING THE RETURN AIR DUCTWORK .......................................................	27
UPRIGHT INSTALLATIONS .....................................................................................................................................	27
HORIZONTAL INSTALLATIONS ................................................................................................................................	28

Table of Contents
XIV. Startup Procedure & Adjustment .............................................................................................................................	28
HEAT ANTICIPATOR SETTING ................................................................................................................................	28
DRAIN TRAP PRIMING .......................................................................................................................................	28
FURNACE OPERATION .........................................................................................................................................	28
GAS SUPPLY PRESSURE MEASUREMENT ..............................................................................................................	28
GAS MANIFOLD PRESSURE MEASUREMENT AND ADJUSTMENT ..................................................................................	29
GAS INPUT RATE MEASUREMENT (NATURAL GAS ONLY) .........................................................................................	29
TEMPERATURE RISE .........................................................................................................................................	30
CIRCULATOR BLOWER SPEEDS ...........................................................................................................................	30
BLOWER HEAT OFF DELAY TIMINGS ...................................................................................................................	32
XV. Normal Sequence of Operation ................................................................................................................................	32
POWER UP .....................................................................................................................................................	32
HEATING MODE ...............................................................................................................................................	32
COOLING MODE ..............................................................................................................................................	32
FAN ONLY MODE .............................................................................................................................................	33
XVI. Operational Checks ..................................................................................................................................................	33
BURNER FLAME ...............................................................................................................................................	33
XVII. Safety Circuit Description .......................................................................................................................................	33
GENERAL .......................................................................................................................................................	33
INTEGRATED CONTROL MODULE ..........................................................................................................................	33
PRIMARY LIMIT ................................................................................................................................................	33
AUXILIARY LIMIT ...............................................................................................................................................	33
ROLLOUT LIMIT ................................................................................................................................................	33
PRESSURE SWITCHES ........................................................................................................................................	33
FLAME SENSOR ...............................................................................................................................................	33
XVIII. Troubleshooting ......................................................................................................................................................	33
ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS .................................................................................................	33
DIAGNOSTIC CHART ..........................................................................................................................................	34
RESETTING FROM LOCKOUT ...............................................................................................................................	34
XIX. Maintenance .............................................................................................................................................................	34
ANNUAL INSPECTION ..........................................................................................................................................	34
FILTERS ..........................................................................................................................................................	34
BURNERS .......................................................................................................................................................	34
INDUCED DRAFT AND CIRCULATOR BLOWERS .........................................................................................................	34
CONDENSATE TRAP AND DRAIN SYSTEM (QUALIFIED SERVICER ONLY) ......................................................................	35
FLAME SENSOR (QUALIFIED SERVICER ONLY) ......................................................................................................	35
FLUE PASSAGES (QUALIFIED SERVICER ONLY) .....................................................................................................	35
XX. Internal Filter Removal .............................................................................................................................................	35
XXI. Before Leaving an Installation ................................................................................................................................	35
XXII. Repair & Replacement Parts ..................................................................................................................................	35

	APPENDIX
Troubleshooting Chart	...................................................................................................................................................... 37
Wiring Diagram ................................................................................................................................................................	39

WARNING

IF THE INFORMATION IN THESE INSTRUCTIONS IS NOT FOLLOWED EXACTLY, A FIRE OR EXPLOSION MAY RESULT CAUSING PROPERTY DAMAGE, PERSONAL INJURY OR LOSS OF LIFE.

– 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.

•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.

– INSTALLATION AND SERVICE MUST BE PERFORMED BY A QUALIFIED INSTALLER, SERVICE AGENCY OR THE GAS SUPPLIER.

WARNING

SHOULD OVERHEATING OCCUR OR THE GAS SUPPLY FAIL TO SHUT OFF, TURN OFF THE MANUAL GAS SHUTOFF VALVE EXTERNAL TO THE FURNACE BEFORE TURNING OFF THE ELECTRICAL SUPPLY.

CARBON MONOXIDE POISONING HAZARD

Special Warning for Installation of Furnace or Air Handling Units in Enclosed Areas such as Garages, Utility Rooms or Parking Areas

Carbon monoxide producing devices (such as an automobile, space

heater, gas water heater, etc.) should not be operated in enclosed areas such as unventilated garages, utility rooms or parking areas because of

the danger of carbon monoxide (CO) poisoning resulting from the exhaust emissions. If a furnace or air handler is installed in an enclosed area such as a garage, utility room or parking area and a carbon monoxide producing device is operated therein, there must be adequate, direct outside ventilation.

This ventilation is necessary to avoid the danger of CO poisoning which can occur if a carbon monoxide producing device continues to operate in the enclosed area. Carbon monoxide emissions can be (re)circulated throughout the structure if the furnace or air handler is operating in any

mode.

CO can cause serious illness including permanent brain damage or death.

B10259--216

TO THE OWNER

It is important that you fill out the owner’s registration card and mail it today. This will assist us in contacting you should any service or warranty information change in the future. When filling in the registration card, be sure to include the model, manufacturing, and serial numbers, plus the installation date.

Your warranty certificate is also supplied with the unit. Read the warranty carefully and note what is covered. Keep the warranty certificate in a safe location for future reference.

If additional information or operating instructions are required, contact the dealer where the purchase was made.

Homeowner Notice:

If the residence is left unattended for an extended period of time (i.e., 4 hours or greater), have your heating system periodically checked to ensure proper operation. Potential circumstances beyond our control such as power outages, gas service interruptions, product installation, or component failures could result in heating system operational problems.

TO THE INSTALLER

Before installing this unit, please read this manual thoroughly to familiarize yourself with specific items which must be adhered to, including but not limited to: unit maximum external static pressure, gas pressures, BTU input rating, proper electrical connections, circulating air temperature rise, minimum or maximum CFM, and motor speed connections.

TRANSPORTATION DAMAGE

All units are securely packed in shipping containers tested according to International Safe Transit Association specifications. The carton must be checked upon arrival for external damage. If damage is found, a request for inspection by carrier’s agent must be made in writing immediately.

The furnace must be carefully inspected on arrival for damage and bolts or screws which may have come loose in transit. In the event of damage the consignee should:

1.Make a notation on delivery receipt of any visible damage to shipment or container.

2.Notify carrier promptly and request an inspection.

3.With concealed damage, carrier must be notified as soon as possible - preferably within five days.

4.File the claim with the following support documents within a nine month statute of limitations.

•Original or certified copy of the Bill of Lading, or indemnity bond.

•Original paid freight bill or indemnity in lieu thereof.

•Original or certified copy of the invoice, showing trade and other discounts or reductions.

•Copy of the inspection report issued by carrier’s representative at the time damage is reported to carrier.

The carrier is responsible for making prompt inspection of damage and for a thorough investigation of each claim. The distributor or manufacturer will not accept claims from dealers for transportation damage.

Keep this literature in a safe place for future reference.

I. COMPONENT IDENTIFICATION

BLOWER COMPARTMENT BURNER COMPARTMENT

31 32

6	7	8	7	9	10			5	27		28			10
	7	8	7	9	10			5	27		28			10
					11			33						11
					11
					3
					13	12	26	25
*	*					12	26	25
*	*	*
	*													29
*	*	*			14									29
					16	15	24							3
					17 18		24
								3
							23							16 15
					19
								32
							18
					20	21	18							30	17
						21								30	17
						22									31
						22	19							1219
							19	20						1219
			W R					20						21	20
			Intell-Ignition
					23		21
							21
					24		14
					26			13						2	22
	28		27		25			9	7	8	7	6	4	1
	28		27					9	7	8	7	6	4

BURNER COMPARTMENT BLOWER COMPARTMENT

	Upflow/Horizontal		Counterflow/Horizontal
1	Two-Stage Gas Valve	22	Drain Trap
2	Gas Line Entrance (Alternate)	23	Blower Door Interlock Switch
3	Pressure Switch(es)	24	Inductor (Not All Models)
4	Gas Manifold	25	Two-Stage Integrated Control Module
5	Combustion Air Intake Connection		(with fuse and diagnostic LED)
6	Hot Surface Igniter	26	24 Volt Thermostat Connections
7	Rollout Limit	27	Transformer (40 VA)
8	Burners	28	ECM Variable Speed Circulator Blower
9	Flame Sensor	29	Auxiliary Limit
10	Flue Pipe Connection	30	Junction Box
11	Flue Pipe	31	Electrical Connection Inlets
12	Combustion Air Intake (Alternate)	32	Coil Front Cover
13	Primary Limit	33	Combustion Air Inlet Pipe

14Gas Line Entrance

15Flue Pipe Connection (Alternate)

16Rubber Elbow

17Two-Speed Induced Draft Blower

18Electrical Connection Inlets (Alternate)

19Coil Front Cover Pressure Tap

20Coil Front Cover Drain Port

21Drain Line Penetrations

II. SAFETY

Please adhere to the following warnings and cautions when installing, adjusting, altering, servicing, or operating the furnace.

WARNING

TO PREVENT PERSONAL INJURY OR DEATH DUE TO IMPROPER INSTALLATION, ADJUSTMENT, ALTERATION, SERVICE OR MAINTENANCE, REFER TO THIS MANUAL. FOR ADDITIONAL ASSISTANCE OR INFORMATION, CONSULT A QUALIFIED INSTALLER, SERVICE AGENCY OR THE GAS SUPPLIER.

WARNING

THIS PRODUCT CONTAINS OR PRODUCES A CHEMICAL OR CHEMICALS WHICH MAY CAUSE SERIOUS ILLNESS OR DEATH AND WHICH ARE KNOWN TO THE STATE OF CALIFORNIA TO CAUSE CANCER, BIRTH DEFECTS OR OTHER REPRODUCTIVE HARM.

WARNING

TO PREVENT POSSIBLE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH DUE TO ELECTRICAL SHOCK, THE FURNACE MUST BE LOCATED TO PROTECT THE ELECTRICAL COMPONENTS FROM WATER.

WARNING

HEATING UNIT SHOULD NOT BE UTILIZED WITHOUT REASONABLE, ROUTINE, INSPECTION, MAINTENANCE AND SUPERVISION. IF THE BUILIDNG IN WHICH ANY SUCH DEVICE IS LOCATED WILL BE VACANT, CARE SHOULD BE TAKEN THAT SUCH DEVICE IS ROUTINELY INSPECTED, MAINTAINED AND MONITORED. IN THE EVENT THAT THE BUILDING MAYBE EXPOSED TO FREEZING TEMPERATURES AND WILL BE VACANT, ALL WATER-BEARING PIPES SHOULD BE DRAINED, THE BUILDING SHOULD BE PROPERLY WINTERIZED, AND THE WATER SOURCE CLOSED. IN THE EVENT THAT THE BUILDING MAY BE EXPOSED TO FREEZING TEMPERATURES AND WILL BE VACANT, ANY HYDRONIC COIL UNITS SHOULD BE DRAINED AS WELL AND, IN SUCH CASE, ALTERNATIVE HEAT SOURCES SHOULD BE UTILIZED.

ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS

NOTE: Discharge static electrictiy accumulated in the body before touching the unit. An electrostatic discharge can adversely affect electrical components.

Use the following precautions during furnace installation and servicing to protect the integrated control module from damage. By putting the furnace, the control, and the person at the same electrostatic potential, these steps will help avoid exposing the integrated control module to electrostatic discharge. This procedure is applicable to both installed and non-installed (ungrounded) furnaces.

1.Disconnect all power to the furnace. Do not touch the integrated control module or any wire connected to the control prior to discharging your body’s electrostatic charge to ground.

2.Firmly touch a clean, unpainted, metal surface of the furnace near the control. Any tools held in a person’s hand during grounding will be discharged.

3.Service integrated control module or connecting wiring following the discharge process in step 2. Use caution not to recharge your body with static electricity; (i.e., do not move or shuffle your feet, do not touch ungrounded objects, etc.).

If you come in contact with an ungrounded object, repeat step 2 before touching control or wires.

4.Discharge your body to ground before removing a new control from its container. Follow steps 1 through 3 if installing the control on a furnace. Return any old or new controls to their containers before touching any ungrounded object.

III.PRODUCT APPLICATION

This furnace is primarily designed for residential home-heating applications. It is NOT designed or certified for use in mobile homes, trailers or recreational vehicles. This unit is NOT designed or certified for outdoor applications. The furnace must be installed indoors (i.e., attic space, crawl space, or garage area provided the garage area is enclosed with an operating door).

This furnace can be used in the following non-industrial commercial applications:

Schools, Office buildings, Churches, Retail stores Nursing homes, Hotels/motels, Common or office areas

In such applications , the furnace must be installed with the following stipulations:

•It must be installed per the installation instructions provided and per local and national codes.

•It must be installed indoors in a building constructed on site.

•It must be part of a ducted system and not used in a free air delivery application.

•It must not be used as a “make-up” air unit.

•It must be installed with two-pipe systems for combustion air, especially if VOC’s or other contaminants are present in the conditioned space.

•All other warranty exclusions and restrictions apply This furnace is an ETL dual-certified appliance and is appropriate for use with natural or propane gas (NOTE: If using propane, a propane conversion kit is required).

Dual certification means that the combustion air inlet pipe is optional and the furnace can be vented as a:

Non-direct vent (single pipe) central forced air furnace in which combustion air is taken from the installation area or from air ducted from the outside or,

Direct vent (dual pipe) central forced air furnace in which all combustion air supplied directly to the furnace burners through a special air intake system outlined in these instructions.

This furnace may be used as a construction site heater ONLY if the following conditions are met:

•The vent system is permanently installed per these installation instructions.

•A room thermostat is used to control the furnace. Fixed jumpers that provide continuous heating CANNOT be used.

•Return air ducts are provided and sealed to the furnace.

•A return air temperature range between 60ºF (16ºC) and 80ºF (27ºC) is maintained.

•Air filters are installed in the system and maintained during construction, replaced as appropriate during construction, and upon completion of construction are replaced.

•The input rate and temperature rise are set per the furnace rating plate.

•100% outside air is provided for combustion air requirements during construction. Temporary ducting can be used.

NOTE: Do not connect the temporary duct directly to the furnace. The duct must be sized according to the instructions under Section V, Combustion and Ventilation Air Requirements, Section 5.3.3.

•The furnace heat exchanger, components, duct system, air filters and evaporator coils are thoroughly cleaned following final construction clean up.

•All furnace operating conditions (including ignition, input rate, temperature rise and venting) are verified according to these installation instructions.

NOTE: The Commonwealth of Massachusetts requires that the following additional requirements must also be met:

•Gas furnaces must be installed by a licensed plumber or gas fitter.

•A T-handle gas cock must be used.

•If the unit is to be installed in an attic, the passageway to and the service area around the unit must have flooring.

To ensure proper installation and operation, thoroughly read this manual for specifics pertaining to the installation and application of this product.

WARNING

POSSIBLE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH DUE TO FIRE, EXPLOSION, SMOKE, SOOT, CONDENSTAION, ELECTRICAL SHOCK OR CARBON MONOXIDE MAY RESULT FROM IMPROPER INSTALLATION, REPAIR, OPERATION, OR MAINTENANCE OF THIS PRODUCT.

WARNING

TO PREVENT PROPERTY DAMAGE, PERSONAL INJURY OR DEATH DUE TO FIRE, DO NOT INSTALL THIS FURNACE IN A MOBILE HOME, TRAILER, OR RECREATIONAL VEHICLE.

To ensure proper furnace operation, install, operate and maintain the furnace in accordance with these installation and operation instructions, all local building codes and ordinances. In their absence, follow the latest edition of the National Fuel Gas Code (NFPA 54/ANSI Z223.1), and/or CAN/CSA B149 Installation Codes, local plumbing or waste water codes, and other applicable codes. A copy of the National Fuel Gas Code (NFPA 54/ANSI Z223.1) can be obtained from any of the following:

American National Standards Institute 1430 Broadway

New York, NY 10018

National Fire Protection Association

1 Batterymarch Park

Quincy, MA 02269

CSA International

8501 East Pleasant Valley Cleveland, OH 44131

A copy of the CAN/CSA B149 Installation Codes can also be obtained from:

CSA International

178 Rexdale Boulevard

Etobicoke, Ontario, Canada M9W 1R3

The rated heating capacity of the furnace should be greater than or equal to the total heat loss of the area to be heated. The total heat loss should be calculated by an approved method or in accordance with “ASHRAE Guide” or “Manual J-Load Calculations” published by the Air Conditioning Contractors of America.

IV. LOCATION REQUIREMENTS & CONSIDERATIONS

GENERAL

WARNING

TO PREVENT POSSIBLE EQUIPMENT DAMAGE, PROPERTY DAMAGE, PERSONAL INJURY OR DEATH, THE FOLLOWING BULLET POINTS MUST BE OBSERVED WHEN INSTALLING THE UNIT.

Follow the instructions listed below when selecting a furnace location. Refer also to the guidelines provided in Section V, Combustion and Ventilation Air Requirements.

•Centrally locate the furnace with respect to the proposed or existing air distribution system.

•Ensure the temperature of the return air entering the furnace is between 55°F and 100°F when the furnace is heating.

•Provide provisions for venting combustion products outdoors through a proper venting system. Special consideration should be given to vent/flue pipe routing and combustion air intake pipe when applicable. Refer to Section IX, Vent/Flue Pipe and Combustion Air Pipe - Termination Locations for appropriate termination locations and to determine if the piping system from furnace to termination can be accomplished within the guidelines given. NOTE: The length of flue and/or combustion air piping can be a limiting factor in the location of the furnace.

•Locate the furnace so condensate flows downwards to the drain. Do not locate the furnace or its condensate drainage system in any area subject to below freezing temperatures without proper freeze protection. Refer to

Section X, Condensate Drain Lines and Trap for further details.

•Ensure adequate combustion air is available for the furnace. Improper or insufficient combustion air can expose building occupants to gas combustion products that could include carbon monoxide. Refer to Section V, Combustion and Ventilation Air Requirements.

•Set the furnace on a level floor to enable proper condensate drainage. If the floor becomes wet or damp at times, place the furnace above the floor on a concrete base sized approximately 1-1/2" larger than the base of the furnace. Refer to the Section VII, Horizontal Applications and Considerations for leveling of horizontal furnaces.

•Ensure upflow or horizontal furnaces are not installed directly on carpeting, or any other combustible material. The only combustible material allowed is wood.

•A special accessory subbase must be used for upright counterflow unit installations over any combustible material (including wood). Refer to subbase instructions for installation details. (NOTE: A subbase will not be required if an air conditioning coil is located beneath the furnace between the supply air opening and the combustible floor.

•Exposure to contaminated combustion air will result in safety and performance-related problems. Do not install the furnace where the combustion air is exposed to the following substances:

chlorinated waxes or cleaners chlorine-based swimming pool chemicals water softening chemicals

deicing salts or chemicals carbon tetrachloride

halogen type refrigerants

cleaning solutions (such as perchloroethylene) printing inks

paint removers varnishes hydrochloric acid cements and glues

antistatic fabric softeners for clothes dryers and masonry acid washing materials

•Seal off a non-direct vent furnace if it is installed near an area frequently contaminated by any of the above substances. This protects the non-direct vent furnace from airborne contaminants. To ensure that the enclosed non-direct vent furnace has an adequate supply of combustion air, vent from a nearby uncontaminated room or from outdoors. Refer to the Section V, Combustion and Ventilation Air Requirements for details.

construction, the clearance between the door and door frame is usually adequate to satisfy this ventilation requirement.

FURNACE SUSPENSION

If suspending the furnace from rafters or joists, use 3/8" threaded rod and 2”x2”x1/8” angle iron as shown below. The length of rod will depend on the application and the clearances necessary.

3/8" DIAMETER THREADED ROD (6 PLACES)

HOLD DOWN

NUTS

SUPPORT

NUTS

PROVIDE 8" MINMUM CLEARANCE BETWEEN

CENTER ROD AND FURNACE CABINET

TO ALLOW FOR CIRCULATOR BLOWER REMOVAL

ASSURE FURNACE IS LEVEL FROM

END TO END AND HAS A SLIGHT

FORWARD TILT WITH THE FRONT

OF THE FURNACE 0"-3/4"

BELOW THE BACK OF THE FURNACE

•If the furnace is used in connection with a cooling unit, install the furnace upstream or in parallel with the cooling unit. Premature heat exchanger failure will result if the cooling unit is placed ahead of the furnace.

•If the furnace is installed in a residential garage, position the furnace so that the burners and ignition source are located not less than 18 inches (457 mm) above the floor. Protect the furnace from physical damage by vehicles.

•If the furnace is installed horizontally, the furnace access doors must be vertical so that the burners fire horizontally into the heat exchanger. Do not install the unit with the access doors on the “up/top” or “down/bottom” side of the furnace.

CLEARANCES AND ACCESSIBILITY

Installations must adhere to the clearances to combustible materials which this furnace has been design certified to. The minimum clearance information for this furnace is provided on the unit’s clearance label. These clearances must be permanently maintained. Clearances must also accommodate an installation’s gas, electrical, and drain trap and drain line connections. If the alternate combustion air intake or vent/flue connections are used additional clearance must be provided to accommodate these connections. Refer to Section IX, Vent Flue Pipe and Combustion Air Pipe for details. NOTE: In addition to the required clearances to combustible materials, a minimum of 24 inches service clearance must be available in front of the unit.

T O P

					T O P
S IDE		SID E		S ID E



					B O T TO M
		B O T TO M
	Upflow		C ou nte rflow		Horizon tal

A furnace installed in a confined space (i.e., a closet or utility room) must have two ventilation openings with a total minimum free area of 0.25 square inches per 1,000 BTU/hr of furnace input rating. Refer to Product Data Book applicable to your model* for minimum clearances to combustible surfaces. One of the ventilation openings must be within 12 inches of the top; the other opening must be within 12 inches of the bottom of the confined space. In a typical

2"X2"X1/8" ANGLE IRON
(3 PLACES)	POSITION AS CLOSE AS POSSIBLE	TILT OUTWARD TO ALLOW FOR
	POSITION AS CLOSE AS POSSIBLE	DOOR AND CIRCULATOR BLOWER
	TO BLOWER DECK TO ALLOW FOR	DOOR AND CIRCULATOR BLOWER
	TO BLOWER DECK TO ALLOW FOR	REMOVAL
	CIRCULATOR BLOWER REMVOAL	REMOVAL
	CIRCULATOR BLOWER REMVOAL
	Suspended Furnace

EXISTING FURNACE REMOVAL

NOTE: When an existing furnace is removed from a venting system serving other appliances, the venting system may be too large to properly vent the remaining attached appliances.

The following vent testing procedure is reproduced from the American

National Standard/National Standard of Canada for Gas-Fired Central Furnaces ANSI Z21.47b-2002, CSA-2.3b-2002 Section 1.23.1.

The following steps shall be followed with each appliance connected to the venting system placed in operation, while any other appliances connected to the venting system are not in operation:

a.Seal any unused openings in the venting system;

b.Inspect the venting system for proper size and horizontal pitch, as required by the National Fuel Gas Code, ANSI Z223.1 or the CSA B149 Installation Codes and these instructions. Determine that there is no blockage or restriction, leakage, corrosion and other deficiencies which could cause an unsafe condition;

c.In so far as practical, close all building doors and windows and all doors between the space in which the appliance(s) connected to the venting system are located and other spaces of the building. Turn on clothes dryers and any appliance not connected to the venting system. Turn on any exhaust fans, such as range hoods and bathroom exhausts, so they shall operate at maximum speed. Do not operate a summer exhaust fan. Close fireplace dampers;

d.Follow the lighting instructions. Place the appliance being inspected in operation. Adjust thermostat so appliance shall operate continuously;

e.Test for draft hood equipped spillage at the draft hood relief opening after 5 minutes of main burner operation. Use the flame of a match or candle;

f.After it has been determined that each appliance connected to the venting system properly vents when tested as outlined above, return doors, windows, exhaust fans, fireplace dampers and any other gas burning appliance to their previous conditions of use;

g.If improper venting is observed during any of the above tests, the common venting system must be corrected.

*NOTE: Please contact your distributor or our website for the applicable product data book referred to in this manual.

Corrections must be in accordance with the latest edition of the National Fuel Gas Code NFPA 54/ANSI Z223.1 and/or CSA B149 Installation Codes.

If resizing is required on any portion of the venting system, use the appropriate table in Appendix G in the latest edition of the National Fuel Gas Code ANSI Z223.1 and/or CSA B149 Installation Codes.

THERMOSTAT LOCATION

The thermostat should be placed approximately five feet fom the floor on a vibration-free, inside wall in an area having good air circulation. Do not install the thermostat where it may be influenced by any of the following:

•Drafts, or dead spots behind doors, in corners, or under cabinets.

•Hot or cold air from registers.

•Radiant heat from the sun.

•Light fixtures or other appliances.

•Radiant heat from a fireplace.

•Concealed hot or cold water pipes, or chimneys.

•Unconditioned areas behind the thermostat, such as an outside wall.

DRAFTS OR DEAD SPOTS	HOT
-BEHIND DOORS	COLD
-IN CORNERS	COLD
-UNDER CABINETS

Thermostat Influences

Consult the instructions packaged with the thermostat for mounting instructions and further precautions.

V. COMBUSTION & VENTILATION AIR REQUIREMENTS

WARNING

POSSIBLE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH MAY OCCUR IF THE FURNACE IS NOT PROVIDED WITH ENOUGH FRESH AIR FOR PROPER COMBUSTION AND VENTILATION OF FLUE GASES. MOST HOMES REQUIRE OUTSIDE AIR BE SUPPLIED TO THE FURNACE AREA.

Improved construction and additional insulation in buildings have reduced heat loss by reducing air infiltration and escape around doors and windows. These changes have helped in reducing heating/cooling costs but have created a problem supplying combustion and ventilation air for gas fired and other fuel burning appliances. Appliances that pull air out of the house (clothes dryers, exhaust fans, fireplaces, etc.) increase the problem by starving appliances for air.

House depressurization can cause back drafting or improper combustion of gas-fired appliances, thereby exposing building occupants to gas combustion products that could include carbon monoxide.

If this furnace is to be installed in the same space with other gas appliances, such as a water heater, ensure there is an adequate supply of combustion and ventilation air for the other appliances. Refer to the latest edition of the National Fuel Gas Code NFPA 54/

ANSI Z223.1 (Section 5.3), or CSA B149 Installation Codes (Sections 7.2, 7.3, or 7.4), or applicable provisions of the local building codes for determining the combustion air requirements for the appliances.

Most homes will require outside air be supplied to the furnace area by means of ventilation grilles or ducts connecting directly to the outdoors or spaces open to the outdoors such as attics or crawl spaces.

The following information on air for combustion and ventilation is reproduced from the National Fuel Gas Code NFPA 54/ANSI Z223.1 Section

5.3.

5.3.1General:

(a)The provisions of 5.3 apply to gas utilization equipment installed in buildings and which require air for combustion, ventilation and dilution of flue gases from within the building. They do not apply to (1) direct vent equipment which is constructed and installed so that all air combustion is obtained from the outside atmosphere and all flue gases are discharged to the outside atmosphere, or (2) enclosed furnaces which incorporate an integral total enclosure and use only outside air for combustion and dilution of flue gases.

(b)Equipment shall be installed in a location in which the facilities for ventilation permit satisfactory combustion of gas, proper venting and the maintenance of ambient temperature at safe limits under normal conditions of use. Equipment shall be located so as not to interfere with proper circulation of air. When normal infiltration does not provide the necessary air, outside air shall be introduced.

(c)In addition to air needed for combustion, process air shall be provided as required for: cooling of equipment or material, controlling dew point, heating, drying, oxidation or dilution, safety exhaust, odor control, and air for compressors.

(d)In addition to air needed for combustion, air shall be supplied for ventilation, including all air required for comfort and proper working conditions for personnel.

(e)While all forms of building construction cannot be covered in detail, air for combustion, ventilation and dilution of flue gases for gas utilization equipment vented by natural draft normally may be obtained by application of one of the methods covered in 5.3.3 and 5.3.4.

(f)Air requirements for the operation of exhaust fans, kitchen ventilation systems, clothes dryers, and fireplaces shall be considered in determining the adequacy of a space to provide combustion air requirements.

5.3.2Equipment Located in Unconfined Spaces:

In unconfined spaces (see definition below) in buildings, infiltration may be adequate to provide air for combustion ventilation and dilution of flue gases. However, in buildings of tight construction (for example, weather stripping, heavily insulated, caulked, vapor barrier, etc.), additional air may need to be provided using the methods described in 5.3.3- b or 5.3.4.

Space, Unconfined.

For purposes of this Code, a space whose volume is not less than 50 cubic feet per 1,000 BTU per hour of the aggregate input rating of all appliances installed in that space. Rooms communicating directly with the space in which the appliances are installed through openings not furnished with doors, are considered a part of the unconfined space.

5.3.3Equipment Located in Confined Spaces:

(a)All Air from Inside the Building: The confined space shall be provided with two permanent openings communicating directly with an additional room(s) of sufficient volume so that the combined volume of all spaces meets the criteria for an unconfined space. The total input of all gas utilization equipment installed in the combined space shall be considered in making this determination. Each opening shall have a minimum free area of 1 square inch per 1,000 BTU

per hour of the total input rating of all gas utilization equipment in the confined space, but not less than 100 square inches. One opening shall be within 12 inches of the top and one within 12 inches of the bottom of the enclosure.

Chimney or Gas Vent

NOTE: Each opening must have a free area of not less than one square inch per 1000 BTU of

the total input rating of all equipment in the enclosure, but not less than 100 square inches.

Opening

Water

Furnace Heater

Opening

Equipment Located in Confined Spaces; All Air from Inside Building. See 5.3.3-a.

(b)All Air from Outdoors: The confined space shall be provided with two permanent openings, one commencing within 12 inches of the top and one commencing within 12 inches of the bottom of the enclosure. The openings shall communicate directly, or by ducts, with the outdoors or spaces (crawl or attic) that freely communicate with the outdoors.

1.When directly communicating with the outdoors, each opening shall have a minimum free area of 1 square inch per 4,000 BTU per hour of total input rating of all equipment in the enclosure.

Chimney or Gas Vent

Ventilation louvers (each end of attic)

NOTE: The inlet and outlet air openings must each have a free area of not less than one square inch per 4000 BTU of the

total input rating of all equipment in the enclosure.

		Outlet Air


	Water
	Heater
Furnace	Heater	Inlet Air
Furnace

Alternate air inlet

Ventilation louvers for unheated crawl space

Equipment Located in Confined Spaces; All Air from Outdoors— Inlet Air from Ventilated Crawl Space and Outlet Air to Ventilated Attic. See 5.3.3-b

2.When communicating with the outdoors through vertical ducts, each opening shall have a minimum free area of 1 square inch per 4,000 BTU per hour of total input rating of all equipment in the enclosure.

Chimney or Gas Vent

Ventilation louvers (each end of attic)

NOTE: The inlet and outlet air openings must each have a free area of not less than one square inch per 4000 BTU of the

total input rating of all equipment in the enclosure.

Outlet Air

Water

Heater

Furnace

Inlet air duct

[ends 1 ft (300 mm)

above floor]

Equipment Located in Confined Spaces; All Air from Outdoors Through Ventilated Attic. See 5.3.3-b.

3.When communicating with the outdoors through horizontal ducts, each opening shall have a minimum free area of 1 square inch per 2,000 BTU per hour of total input rating of all equipment in the enclosure.

Chimney or Gas Vent

Outlet air duct

Water

Furnace Heater

NOTE: The air duct openings must have a free area of not less than one square inch per 2000 BTU of the total input

rating of all equipment in the enclosure*.

Inlet air duct

*If the appliance room is located against an outside wall and the air openings communicate directly with the outdoors, each opening shall have a free area of not less than one square inch per 4,000 BTU per hour of the total input rating of all appliances in the enclosure.

Equipment Located in Confined Spaces; All Air from Outdoors. See 5.3.3-b.

4.When ducts are used, they shall be of the same cross-sectional area as the free area of the openings to which they connect. The minimum dimension of rectangular air ducts shall not be less than 3 inches.

NOTE: The single opening must have

a free area of not less than one Chimney or Gas Vent square inch per 3000 BTU of

the total input rating of all equip-

ment in the enclosure, but not less than the sum of the areas of all vent connectors in the confined space.

Opening

Alternate

Water

Opening

Heater

Location

Furnace

Equipment Located in Confined Spaces; All Air from Outdoors - Single Air Opening. See 5.3.3-b.

5.When directly communicating with the outdoors, the single opening shall have a minimum free area of 1 square inch per 3,000 BTU per hour of total input rating of all equipment in the enclosure.

5.3.4Specially Engineered Installations:

The requirements of 5.3.3 shall not necessarily govern when special engineering, approved by the authority having jurisdiction, provides an adequate supply of air for combustion, ventilation, and dilution of flue gases.

5.3.5 Louvers and Grilles:

In calculating free area in 5.3.3, consideration shall be given to the blocking effect of louvers, grilles or screens protecting openings. Screens used shall not be smaller than 1/4 inch mesh. If the area through a design of louver or grille is known, it should be used in calculating the size of opening required to provide the free area specified. If the design and free area is not known, it may be assumed that wood louvers will have 20-25 percent free area and metal louvers and grilles will have 60-75 percent free area. Louvers and grilles shall be fixed in the open position or interlocked with the equipment so that they are opened automatically during equipment operation.

5.3.6 Special Conditions Created by Mechanical Exhausting or Fireplaces:

Operation of exhaust fans, ventilation systems, clothes dryers, or fireplaces may create conditions requiring special attention to avoid unsatisfactory operation of installed gas utilization equipment. Air from Inside Building. See 5.3.3-a.

VI. INSTALLATION POSITIONS

This furnace may be installed in an upright position or horizontal on either the left or right side panel. Do not install this furnace on its back. For upright upflow furnaces, return air ductwork may be attached to the side panel(s) and/or basepan. For horizontal upflow furnaces, return air ductwork must be attached to the basepan. For both upright or horizontal counterflow furnaces, return ductwork must be attached to the basepan (top end of the blower compartment). NOTE: Ductwork must never be attached to the back of the furnace. Contact your distributor for proper airflow requirements and number of required ductwork connections. Refer to “Recommended Installation Positions” figure for appropriate installation positions, ductwork connections, and resulting airflow arrangements.

VII. HORIZONTAL APPLICATIONS & CONSIDERATIONS

GENERAL

Horizontal applications, in particular, may dictate many of the installation’s specifics such as airflow direction, ductwork connections, flue and combustion air pipe connections, etc. The basic application of this furnace as a horizontal furnace differs only slightly from an upright installation. When installing a furnace horizontally, additional consideration must be given to the following:

	FURNACE MUST BE LEVEL
	FROM END TO END
	ALTERNATE VENT/FLUE	FURNACE MUST BE LEVEL
	AND COMBUSTION AIR	FURNACE MUST BE LEVEL
	INTAKE LOCATIONS	OR SLIGHTLY TILTED FORWARD
		WITH THE DOORS 0" - 3/4"
		BELOW THE BACK PANEL
		4 3/4" MINIMUM
		DRAIN TRAP
	GAS LINE WITH	CLEARANCE
	DRIP LEG (3" MINIMUM)
	DRAIN PAN	DRAIN LINE WITH 1/4" PER FOOT
	DRAIN PAN	DOWNWARD SLOPE
		DOWNWARD SLOPE
	FURNACE MUST BE SUPPORTED	24" MINIMUM SERVICE
	AT BOTH ENDS AND MIDDLE	CLEARANCE REQUIRED

Horizontal Furnace

DRAIN TRAP AND LINES

In horizontal applications the condensate drain trap is secured to the furnace side panel, suspending it below the furnace. A minimum clearance of 4 3/4 inches below the furnace must be provided for the drain trap. Additionally, the appropriate downward piping slope must be maintained from the drain trap to the drain location. Refer to Section X, Condensate Drain Trap and Lines for further details. If the drain trap and drain line will be exposed to temperatures near or below freezing, adequate measures must be taken to prevent condensate from freezing.

LEVELING

Leveling ensures proper condensate drainage from the heat exchanger and induced draft blower. For proper flue pipe drainage, the furnace must be level lengthwise from end to end. The furnace should also be level from back to front or have a slight tilt with the access doors downhill (approximately 3/4 inches) from the back panel. The slight tilt allows the heat exchanger condensate, generated in the recuperator coil, to flow forward to the recuperator coil front cover.

ALTERNATE VENT/FLUE AND COMBUSTION AIR CONNECTIONS

In horizontal installations provisions for alternate flue and combustion air piping are available for upflow furnaces with left discharge and counterflow furnaces with right air discharge. This configuration allows the flue and combustion air piping to be run vertically through the furnace. Refer to the “Recommended Installation Positions” figure for further detail. The standard piping connections may also be used in these positions. Refer to Section IX, Vent/Flue Pipe and Combustion Air Pipe for details concerning the conversion to the alternate vent/flue and combustion air connections.

AIR		ALTERNATE FLUE AND
DISCHARGE		ALTERNATE FLUE AND
DISCHARGE		COMBUSTION AIR PIPE
		COMBUSTION AIR PIPE
		LOCATIONS
Side		Side
Return		Return
Duct		Duct
Connection		Connection
		Bottom
		Return
		Duct
	Connection
	UPFLOW
	UPRIGHT
		ALTERNATE FLUE AND
		COMBUSTION AIR PIPE
		LOCATIONS
		Bottom
AIR		Return
AIR		Duct
DISCHARGE		Connection

UPFLOW HORIZONTAL

LEFT AIR DISCHARGE

Bottom
Return	AIR
Duct	AIR
Connection	DISCHARGE

UPFLOW HORIZONTAL

RIGHT AIR DISCHARGE

Recommended Installation Positions

NOTE: Alternate “vertical” piping connections can not be used when an upflow furnace is installed with supply air discharging to the right, or when a counterflow furnace is installed with supply air discharging to the left. In either case, use the standard flue and combustion air piping connections.

ALTERNATE ELECTRICAL AND GAS LINE CONNECTIONS

This furnace has provisions allowing for electrical and gas line connections through either side panel. In horizontal applications the connections can be made either through the “top” or “bottom” of the furnace.

DRAIN PAN

A drain pan must be provided if the furnace is installed above a conditioned area. The drain pan must cover the entire area under the furnace (and air conditioning coil if applicable).

FREEZE PROTECTION

Refer to Section VI, Horizontal Applications and Conditions - Drain Trap and Lines.

FURNACE SUSPENSION

If the furnace is installed in a crawl space it must be suspended from the floor joist or supported by a concrete pad. Never install the furnace on the ground or allow it to be exposed to water. Refer to

Section IV, Location Requirements and Considerations - Furnace Suspension for further details.

VIII. PROPANE GAS /HIGH ALTITUDE INSTALLATIONS

WARNING

POSSIBLE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH MAY OCCUR IF THE CORRECT CONVERSION KITS ARE NOT INSTALLED. THE APPROPRIATE KITS MUST BE APPLIED TO INSURE SAFE AND PROPER FURNACE OPERATION. ALL CONVERSIONS MUST BE PERFORMED BY A QUALIFIED INSTALLER OR SERVICE AGENCY.

This furnace is shipped from the factory configured for natural gas at standard altitude. Propane gas installations require an orifice change to compensate for the energy content difference between natural and propane gas.

High altitude installations may require both a pressure switch and an orifice change. These changes are necessary to compensate for the natural reduction in the density of both the gas fuel and the combustion air at higher altitude.

For installations above 7000 feet, please refer to your distributor for required kit(s).

Gas	Altitude	Kit	Orifice	Manifold Pressure		Pressure
Gas	Altitude	Kit	Orifice	High Stage	Low Stage	Switch Change
Natural	0-7000	None	#43	3.5" w.c.	1.9" w.c.	None

Propane		LPM-03B	#55	10.0" w.c.	6.0" w.c.	None

NOTE: In Canada, gas furnaces are only certified to 4500 feet.

Contact the distributor for a tabular listing of appropriate manufacturer’s kits for propane gas and/or high altitude installations. The indicated kits must be used to insure safe and proper furnace operation. All conversions must be performed by a qualified installer, or service agency.

IX. VENT/FLUE PIPE & COMBUSTION AIR PIPE

GENERAL

WARNING

FAILURE TO FOLLOW THESE INSTRUCTIONS CAN RESULT IN BODILY INJURY OR DEATH. CAREFULLY READ AND FOLLOW ALL INSTRUCTIONS GIVEN IN THIS SECTION.

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. LEAKS IN THE FLUE SYSTEM CAN RESULT IN SERIOUS PERSONAL INJURY OR DEATH DUE TO EXPOSURE TO FLUE PRODUCTS, INCLUDING CARBON MONOXIDE.

A condensing gas furnace achieves its high level of efficiency by extracting almost all of the heat from the products of combustion and cooling them to the point where condensation takes place. Because of the relatively low flue gas temperature and water condensation requirements, PVC pipe is used as venting material.

This furnace must not be connected to Type B, BW, or L vent or vent connector, and must not be vented into any portion of a factory built or masonry chimney except when used as a pathway for PVC as described later in this section. Never common vent this appliance with another appliance or use a vent which is used by a solid fuel appliance. Do not use commercially available “no hub connectors” other than those shipped with this product.

It is the responsibility of the installer to follow the manufacturers’ recommendations and to verify that all vent/flue piping and connectors are compatible with furnace flue products. Additionally, it is the responsibility of the installer to ensure that all piping and connections possess adequate structural integrity and support to prevent flue pipe separation, shifting, or sagging during furnace operation.

DUAL CERTIFICATION:NON-DIRECT/DIRECT VENT

This furnace is dual certified and may be installed as a non-direct vent (single pipe) or direct vent (dual pipe) appliance. A non-direct vent installation requires only a vent/flue pipe, while a direct vent installation requires both a vent/flue pipe and a combustion air intake pipe. Refer to the appropriate section for details concerning piping size, length, number of elbows, furnace connections, and terminations.

Non-Direct Vent

Vent/Flue Termination

No Terminations

Above Walkway

Non-Direct Vent

Direct Vent

Vent/Flue Terminations

MATERIALS AND JOINING METHODS

WARNING

TO AVOID BODILY INJURY, FIRE OR EXPLOSION, SOLVENT CEMENTS MUST BE KEPT AWAY FROM ALL IGNITION SOURCES (I.E., SPARKS, OPEN FLAMES, AND EXCESSIVE HEAT) AS THEY ARE COMBUSTIBLE LIQUIDS. AVOID BREATHING CEMENT VAPORS OR CONTACT WITH SKIN AND/OR EYES.

Twoor three-inch nominal diameter PVC Schedule 40 pipe meeting ASTM D1785, PVC primer meeting ASTM F656, and PVC solvent cement meeting ASTM D2564 specifications must be used. Fittings must be DWV type fittings meeting ASTM D2665 and ASTM D3311. Carefully follow the manufacturer’s instructions for cutting, cleaning, and solvent cementing of PVC.

As an alternative to PVC pipe, primer, solvent cement, and fittings, ABS materials which are in compliance with the following specifications may be used. Two-or-three-inch ABS Schedule 40 pipe must meet ASTM D1527 and, if used in Canada, must be CSA listed. Solvent cement for ABS to ABS joints must meet ASTM D2235 and, if used in Canada, must be CSA listed. The solvent cement for the PVC to ABS transition joint must meet ASTM D3138. Fittings must be DWV type fittings meeting ASTM D2661 and ASTM D3311 and, if used in Canada, must be CSA listed. Carefully follow the manufacturers’ instructions for cutting, cleaning, and solvent cementing PVC and/or ABS.

All 90° elbows must be medium radius (1/4 bend DWV) or long radius (Long sweep 1/4 bend DWV) types conforming to ASTM D3311. A medium radius (1/4 bend DWV) elbow measures 3 1/ 16” minimum from the plane of one opening to the centerline of the other opening for 2” diameter pipe, and 4 9/16” minimum for 3” pipe.

PROPER VENT/FLUE AND COMBUSTION AIR PIPING PRACTICES

Adhere to these instructions to ensure safe and proper furnace performance. The length, diameter, and number of elbows of the vent/flue pipe and combustion air pipe (when applicable) affects the performance of the furnace and must be carefully sized. All piping must be installed in accordance with local codes and these instructions.

Piping must be adequately secured and supported to prohibit sagging, joint separation, and/or detachment from the furnace. Horizontal runs of vent/flue piping must be supported every three feet and must maintain a 1/4 inch per foot downward slope, back towards the furnace, to properly return condensate to the furnace’s drain system. Allowances should be made for minor expansion and contraction due to temperature variations. For this reason, particular care must be taken to secure piping when a long run is followed by a short offset of less than 40 inches.

Precautions should be taken to prevent condensate from freezing inside the vent/flue pipe and/or at the vent/flue pipe termination. All vent/flue piping exposed to freezing temperatures below 35°F for extended periods of time must be insulated with 1/2” thick closed cell foam. Also all vent/flue piping exposed outdoors in excess of the terminations shown in this manual (or in unheated areas) must be insulated with 1/2” thick closed cell foam. Inspect piping for leaks prior to installing insulation.

TERMINATION LOCATIONS

NOTES: Refer to Section IV, Location Requirements and Considerations for combustion air contaminant restrictions.

The following bullets and diagram describe the restrictions concerning the appropriate location of vent/flue pipe and combustion air intake pipe (when applicable) terminations. Refer to Non-Di- rect Vent (Single Pipe) Piping and Direct Vent (Dual Pipe) Piping

located in this section for specific details on termination construction.

•All terminations (flue and/or intake) must be located at least 12 inches above ground level or the anticipated snow level.

•Vent terminations (non-direct and direct vent) must terminate at least 3 feet above any forced air inlet located within 10 feet.

NOTE: This provision does not apply to the combustion air intake termination of a direct vent application.

•The vent termination of a non-direct vent application must terminate at least 4 feet below, 4 feet horizontally from, or 1 foot above any door, window, or gravity air inlet into any building.

•The vent termination of a direct vent application must terminate at least 12 inches from any opening through which flue gases may enter a building (door, window, or gravity air inlet).

•The vent termination of vent pipe run vertically through a roof must terminate at least 12 inches above the roof line (or the anticipated snow level) and be at least 12 inches from any vertical wall (including any anticipated snow build up).

•A vent termination shall not terminate over public walkways or over an area where condensate or vapor could create a nuisance or hazard or could be detrimental to the operation of regulators, relief valves, or other equipment.

•The combustion air intake termination of a direct vent application should not terminate in an area which is frequently dusty or dirty.

<10'	12"	4' min.
3' min.	12"	4'
3' min.

min.

12"

Grade or Highest

min.

12" min.

Anticipated

Snow Level

12" min.

Non-Direct Vent

Forced Air

Vent/Flue Termination

Inlet

Direct Vent

Vent/Flue Termination

Vent Termination Clearances

NOTE: In Canada, the Canadian Fuel Gas Code takes precedence over the preceding termination restrictions.

CANADIAN VENTING REQUIREMENTS

In Canada, venting must conform to the requirements of the current CAN/CSA-B149 Installation Code. Use only CSA listed two or three inch diameter PVC or ABS pipe, solvent cement, and fittings throughout. Carefully follow the manufacturers’ instructions for cutting, cleaning, and solvent cementing PVC and/or ABS.

The vent can be run through an existing unused chimney provided the space between the vent pipe and the chimney is insulated and closed with a weather-tight, corrosion-resistant flashing.

STANDARD FURNACE CONNECTIONS

It is the responsibility of the installer to ensure that the piping connections to the furnace are secure, airtight, and adequately supported.

As shipped, attachment “couplings” for vent/flue and combustion air intake pipe connections are provided on the furnace’s top cover (upflow) or basepan (counterflow). To use the standard connections, field supplied vent/flue pipe and combustion air intake pipe (when applicable) should be secured directly to the furnace at these locations.

VENT/FLUE PIPE

Vent/flue pipe can be secured to the vent/flue coupling using the rubber coupling and worm gear hose clamps provided with this furnace (see “Standard Connections” figure). The rubber coupling allows separation of the vent/flue pipe from the furnace during servicing. NOTE: Do not use other commercially available “no hub connectors” due to possible material conflicts. The vent/flue pipe can also be secured using a PVC or ABS elbow or coupling using the appropriate glue (see Section IX, Materials and Joining Methods.

NOTE: For non-direct vent installations, a minimum of one 90° elbow should be installed on the combustion air intake coupling to guard against inadvertent blockage.

COMBUSTION AIR PIPE DIRECT VENT INSTALLATIONS

On upflow units secure the combustion air intake pipe directly to the air intake coupling. On counterflow units secure the combustion air intake pipe to the air intake coupling using the rubber coupling and worm gear hose clamps provided with the unit. The counterflow rubber coupling allows service removal of air intake piping internal to the furnace blower compartment. NOTE: Because of probable material conflicts, do not use other commercially available “no hub connectors”. The combustion air intake pipe can also be secured directly to the counterflow unit air intake pipe coupling.

NON-DIRECT VENT INSTALLATIONS

A minimum of one 90° elbow should be installed on the combustion air intake “coupling” to guard against inadvertent blockage.

COMBUSTION				COMBUSTION	VENT/FLUE
COMBUSTION	VENT/FLUE			AIR PIPE	VENT/FLUE
AIR PIPE	VENT/FLUE			AIR PIPE	PIPE
AIR PIPE		PIPE		(DIRECT VENT ONLY)	PIPE
(DIRECT VENT ONLY)		PIPE		(DIRECT VENT ONLY)
(DIRECT VENT ONLY)
90 PVC	RUBBER		90 PVC	RUBBER
ELBOW	COUPLING		ELBOW	COUPLINGS
(NON-DIRECT VENT)	WITH WORM		(NON-DIRECT VENT)	WITH WORM
	GEAR CLAMPS			GEAR CLAMPS

NOTE: Standard and alternate locations can be combined (i.e., an installation may use the standard combustion air intake location but use the alternate vent/flue location or vice versa), if needed.

WARNING

EDGES OF SHEET METAL HOLES MAY BE SHARP. USE GLOVES AS A PRECAUTION WHEN REMOVING HOLE PLUGS.

ALTERNATE VENT/FLUE LOCATION

The alternate vent/flue location is the large hole directly in line with the induced draft blower outlet. To use the alternate vent/flue location refer to the following steps, the “Vent/Flue Pipe Cuts” figure, and the “Alternate Vent/Flue Location” figure.

NOTE: Counterflow instructions follow the upflow instructions.

1.Remove and save the four screws securing the vent/flue coupling to the furnace top panel.

Counterflow units.

Remove and save the four screws securing the vent/flue coupling to the furnace basepan. Also remove the three screws securing the furnace’s internal vent/flue piping to the blower deck.

2.Upflow and Counterflow units.

Loosen the worm gear hose clamps on the rubber elbow and detach it from both the induced draft blower and the vent/flue pipe.

3.Upflow and Counterflow units.

Remove the vent/flue pipe from the furnace.

4.Cut the vent/flue pipe 3.75 inches from the flanged end of the pipe. See Vent/Flue Pipe Cuts figure. The section of pipe attached to the coupling will reach through the side panel to the induced draft blower. Discard remaining pipe and elbows.

Counterflow units.

Cut the vent/flue pipe 3.75 inches from the blower deck coupling. See Vent/Flue Pipe Cuts figure. Save vent/flue pipe attached to blower deck coupling for use in the alternate location. Discard remaining pipe and elbows.

FLANGE

3.75"

CUT HERE

UPFLOW

COUNTERFLOW

STANDARD CONNECTIONS

Standard Connections

ALTERNATE FURNACE CONNECTIONS

If the standard locations are undesirable for a specific installation, alternate side panel locations are available for both combustion air inlet and vent/flue pipe connections. These locations may be of particular benefit to upright upflow installations requiring additional access to an A coil, or to upright counterflow installations requiring additional access to a filter or electronic air cleaner, or to horizontal installations desiring vent/flue (and combustion air intake) piping run vertically from the side of the cabinet.

Vent/Flue Pipe Cuts

5.Remove plastic plug from alternate vent/flue location. Relocate and install plug in standard vent/flue location (top cover).

Counterflow units.

Remove plastic plug from alternate vent/flue location. Relocate and install plug in standard vent/flue location (basepan). Plug remaining hole in blower deck with plastic plug included in the drain kit bag.

6.Upflow and Counterflow units.

Insert cut section of vent/flue pipe and coupling into alternate vent/flue location. Using a rubber coupling and worm gear hose clamps from the drain kit bag, attach the vent/flue pipe and coupling to the induced draft blower. Secure the

coupling to the cabinet using the screws removed in step 1 or with field-supplied 3/8” #8 self drilling screws.

WARNING

THE RUBBER ELBOW IS NOT DESIGNED TO SUPPORAT A LOAD. WHEN THE RUBBER ELBOW IS MOUNTED EXTERNALLY TO THE FURNACE CABINET, EXTREME CARE MUST BE TAKEN TO ADEQUATELY SUPPORT FIELD-SUPPLIED VENT/FLUE PIPING, AS DAMAGE CAN RESULT IN LEAKS CAUSING BODILY INJURY OR DEATH DUE TO EXPOSURE TO FLUE GASES, INCLUDING CARBON MONOXIDE.

7.Upflow and Counterflow units.

For upright installations, externally mount the rubber elbow to the vent/flue coupling using a worm gear hose clamp. Secure field supplied vent/flue piping to the rubber elbow using a worm gear hose clamp. NOTE: Use of the alternate vent/flue location for upright installations, requires the drain trap be installed on the same side of the unit as the flue pipe.

8.Upflow and Counterflow units.

For horizontal installations, externally secure the fieldsupplied vent/flue pipe directly to the vent/flue coupling using a PVC or ABS coupling or elbow.

3	1		1.			3
3		REMOVE				3
REMOVE		REMOVE				REMOVE
REMOVE	REMOVE	4 SCREWS				REMOVE
PIPE	REMOVE	4 SCREWS				PIPE
PIPE	4 SCREWS					PIPE
	4 SCREWS					1
						1
						REMOVE
						3 SCREWS
	5					5
	REMOVE					5
	REMOVE					REMOVE
	AND RELOCATE					REMOVE
	AND RELOCATE					AND RELOCATE
						AND RELOCATE
	2					2
	DETACH RUBBER					DETATCH RUBBER
	ELBOW FROM					ELBOW FROM
	ID BLOWER AND					ID BLOWER AND
	VENT/FLUE					VENT/FLUE
	PIPE					PIPE
UPFLOW			COUNTERFLOW
						5
					ADDITIONAL PLUG
						FROM DRAIN KIT
						7
						EXTERNALLY
						MOUNT
						RUBBER ELBOW
						6
				SECURE TO
				ID BLOWER WITH
			RUBBER COUPLING
					AND HOSE
						CLAMPS
	COUNTERFLOW/UPRIGHT
	(UPFLOW SIMILAR)
	6
	SECURE TO
ID BLOWER WITH						6
RUBBER COUPLING						SECURE TO
	AND HOSE					CABINET WITH
	CLAMPS					SCREWS

UPFLOW/HORIZONTAL

(COUNTERFLOW SIMILAR)

Alternate Vent/Flue Location

ALTERNATE COMBUSTION AIR INTAKE LOCATION

The alternate combustion air intake location consists of a large, unobstructed hole (alternate vent connection is aligned with the Induced Draft Blower). To use the alternate combustion air intake location, refer to the following steps, and the “Alternate Combustion Air Intake Location” figure.

NOTE: Counterflow unit instructions follow the upflow instructions.

1.Remove and save the four screws securing the combustion air intake coupling to the furnace’s top panel (upflow).

Counterflow units.

Remove and save the four screws securing the combustion air intake coupling to the basepan. Remove an additional three screws securing the furnace’s internal combustion air intake pipe to the blower deck.

2.Remove the combustion air intake coupling and gasket from the top panel.

Counterflow units.

Remove the combustion air intake pipe from the furnace and cut the pipe at the basepan coupling. Save the basepan coupling and gasket from the blower deck coupling for use in the alternate location. Discard the remaining pipe.

3.Remove plastic plug from alternate combustion air intake location. Relocate and install plug in standard air intake location (top cover).

Counterflow units.

Remove plastic plug from alternate combustion air intake location. Relocate and install plug in standard air intake location (basepan). Plug the remaining hole in the blower deck with the plastic plug included in the drain kit bag.

4.Upflow and Counterflow units.

With the gasket facing the cabinet side panel, and the flange’s flat spot facing forward, secure the combustion air intake coupling to the cabinet using the screws removed in step 1 or with field-supplied 3/8” #8 self -drilling screws.

CAUTION

BE SURE NOT TO DAMAGE INTERNAL WIRING OR OTHER COMPONENTS WHEN REINSTALLING COUPLING AND SCREWS.

5.Upflow and Counterflow units.

For non-direct vent installations installed horizontally, a minimum of one 90° elbow should be installed on the combustion air intake coupling to guard against inadvertent blockage. No elbow is required on the alternate combustion air intake of upright installations, however, a minimum clearance of 2 inches is required to assure proper air supply.

6.Upflow and Counterflow units.

For direct vent installations, secure field-supplied combustion air intake pipe directly to the air intake coupling.

NOTE: A PVC coupling or elbow is required on counterflow units.

1				1	5
REMOVE		2		1	5
4 SCREWS		2		REMOVE	2" CLEARANCE
4 SCREWS	REMOVE			REMOVE	2" CLEARANCE
	REMOVE		2	4 SCREWS	REQUIRED
				4 SCREWS	REQUIRED
					(NON-DIRECT
		REMOVE			VENT)
		AND CUT
		3	1
		3	REMOVE
		REMOVE 3 SCREWS
		AND	3
		RELOCATE	3
		ADDITIONAL
		PLUG FROM
		DRAIN KIT			3.
					REMOVE
					AND
UPFLOW					RELOCATE
UPFLOW				COUNTERFLOW
	4		5
SECURE
TO CABINET

UPFLOW/HORIZONTAL SHOWN

(COUNTERFLOW SIMILAR)

Alternate Combustion Air Intake Location

NON-DIRECT VENT (SINGLE PIPE) PIPING

Non-direct vent installations require only a vent/flue pipe. The vent pipe can be run horizontally with an exit through the side of the building or run vertically with an exit through the roof of the building. The vent can also be run through an existing unused chimney; however, it must extend a minimum of 12 inches above the top of the chimney. The space between the vent pipe and the chimney must be closed with a weather-tight, corrosion-resistant flashing. For details concerning connection of the vent/flue pipe to the furnace, refer to Section IX, Vent/Flue Pipe and Combustion Air - Standard Furnace Connections or Alternate Furnace Connections for specific details. Refer to the following Non-Direct Vent (Single Pipe) Piping - Vent/Flue Pipe Terminations for specific details on termination construction.

Although non-direct vent installations do not require a combustion air intake pipe, a minimum of one 90° elbow should be attached to the furnace’s combustion air intake if: an upright installation uses the standard intake location, or a horizontal installation uses the alternate air intake location. This elbow will guard against inadvertent blockage of the air intake.

VENT/FLUE PIPE LENGTHS AND DIAMETERS

Refer to the following table for applicable length, elbows, and pipe diameter for construction of the vent/flue pipe system of a non-direct vent installation. In addition to the vent/flue pipe, a single 90° elbow should be secured to the combustion air intake to prevent inadvertent blockage. The tee used in the vent/flue termination must be included when determining the number of elbows in the piping system.

			UPFLOW
	Non-Direct Vent (Single Pipe)
Maximum Allowable Length of Vent/Flue Pipe (ft) (1)(2)
Unit Input	Pipe (4)			Number of Elbows (3)
	(Inch)	1	2	3	4	5	6	7	8
45,000	2	71	68	65	62	59	56	53	50
70,000	2	49	46	43	40	37	34	31	28
70,000	3	71	68	65	62	59	56	53	50
	3	71	68	65	62	59	56	53	50
90,000	3	71	68	65	62	59	56	53	50
115,000	3	49	46	43	40	37	34	31	28

		COUNTERFLOW
	Non-Direct Vent (Single Pipe)
Maximum Allowable Length of Vent/Flue Pipe (ft) (1)(2)
Unit Input	Pipe (4)			Number of Elbows (3)
	(Inch)	1	2	3	4	5	6	7	8
70,000	2	61	58	55	52	49	46	43	40
70,000	3	71	68	65	62	59	56	53	50
	3	71	68	65	62	59	56	53	50
90,000	2	61	58	55	52	49	46	43	40
90,000	3	71	68	65	62	59	56	53	50
	3	71	68	65	62	59	56	53	50

(1)One 90° elbow should be secured to the combustion air intake connection.

(2)Minimum vent length is five feet and one elbow/tee.

(3)Tee used in the vent/flue termination must be included when determining the number of elbows in the piping system.

(4)3” diameter pipe can be used in place of 2” diameter pipe.

VENT/FLUE PIPE TERMINATIONS

The vent/flue pipe may terminate vertically, as through a roof, or horizontally, as through an outside wall.

Vertical vent/flue pipe terminations should be as shown in the following figure. Refer to Section IX, Vent/Flue Pipe and Combustion Air Pipe - Termination Locations for details concerning location restrictions. The penetration of the vent through the roof must be sealed tight with proper flashing such as is used with a plastic plumbing vent.

Horizontal vent/flue pipe terminations should be as shown in the following figure. Refer to Section IX, Vent/Flue Pipe and Combustion Air Pipe - Termination Locations for details concerning location restrictions. A 2 3/8” diameter wall penetration is required for 2” diameter pipe while a 3 1/2” diameter hole is required for 3” diameter pipe. To secure the pipe passing through the wall and prohibit damage to piping connections, a coupling should be installed on either side of the wall and solvent cemented to a length of pipe connecting the two couplings. The length of pipe should be the wall thickness plus the depth of the socket fittings to be installed on the inside and outside of the wall. The wall penetration should be sealed with silicone caulking material.

In a basement installation, the vent/flue pipe can be run between joist spaces. If the vent pipe must go below a joist and then up into the last joist space to penetrate the header, two 45° elbows should be used to reach the header rather than two 90° elbows.

TEE

12 " Min To

Roof Or

Highest Anticipated

Snow Level

Vertical Termination (Single Pipe)

90º MEDIUM RADIUS

ELBOWS

12" MIN.

TO ROOF OR

HIGHEST

ANTICIPATED

SNOW LEVEL

Alternate Vertical Termination (Single Pipe)

	WALL
INSIDE	OUTSIDE
		TEE
		or
		90°ELBOW
		TURNED
		DOWN
	COUPLING
	MIN.
	12"
ELBOW OR	FROM	12"
COUPLING	WALL	TO GROUND OR
COUPLING		HIGHEST ANTICIPATED
		SNOW LEVEL

Horizontal Termination (Single Pipe)

12" MIN.

VENT/FLUE TEE or

90° ELBOW TURNED

DOWN

Horizontal Termination (Single Pipe)

Above Highest Anticipated Snow Level

DIRECT VENT (DUAL PIPE) PIPING

The inlet air screens provided in the installation instruction packet are available for the installer to use in the inlet of the combustion air pipe to prevent animals from building nests in the combustion air pipe. Installation of screens, while strongly recommended, is not required and will not affect performance of the unit.

Direct vent installations require both a combustion air intake and a vent/flue pipe. The pipes may be run horizontally and exit through the side of the building or run vertically and exit through the roof of the building. The pipes may be run through an existing unused chimney; however, they must extend a minimum of 12 inches above the top of the chimney. The space between the pipes and the chimney must be closed with a weather tight, corrosion resistant flashing. Both the combustion air intake and a vent/flue pipe terminations must be in the same atmospheric pressure zone. Refer to Section IX, Vent/Flue and Combustion Air Pipe - Termination Locations or Concentric Vent Termination for specific details on termination construction. For details concerning connection of pipes to the furnace, refer to the Section IX, Vent/Flue Pipe and Combustion Pipe - Standard Furnace Connections or Alternate Furnace Connections.

VENT/FLUE AND COMBUSTION AIR PIPE LENGTHS AND DIAMETERS

Refer to the following table for applicable length, elbows, and pipe diameter for construction of the vent/flue and combustion air intake pipe systems of a direct vent (dual pipe) installation. The number of elbows tabulated represents the number of elbows and/or tees in each (Vent/Flue & Combustion Air Intake) pipe. Elbows and/or tees used in the terminations must be included when determining the number of elbows in the piping systems.

If the combustion air intake pipe is to be installed above a finished ceiling or other area where dripping of condensate will be objectionable, insulation of the combustion air pipe may be required. Use 1/2” thick closed cell foam insulation such as Armaflex™ or Insultube™ where required.

UPFLOW

Direct Vent (Dual Pipe) Maximum Allow able Length of Vent/Flue & Combustion Air Intake Pipe (ft)

Unit Input	Termination	Pipe(4)			Number of Elbow s(1)(2)(3)
(Btu)	Style	(inch)	1	2		3	4	5	6	7	8

45,000	Standard	2	71	68		65	62	59	56	53	50
	Alternate	2	58	55		52	49	46	43	40	37

	Standard	2	49	46		43	40	37	34	31	28
70,000		3	71	68		65	62	59	56	53	50

	Alternate	2	36	33		30	27	24	21	18	15

		3	57	54		51	48	45	42	39	36

90,000	Standard	3	71	68		65	62	59	56	53	50
	Alternate	3	57	54		51	48	45	42	39	36

115,000	Standard	3	49	46		43	40	37	34	31	28
	Alternate	3	35	32		29	26	23	20	17	14

COUNTERFLOW

Direct Vent (Dual Pipe) Maximum Allow able Length of Vent/Flue & Combustion Air Intake Pipe (ft)

Unit Input	Termination	Pipe(4)			Number of Elbow s(1)(2)(3)
(Btu)	Style	(inch)	1	2		3	4	5	6	7	8

	Standard	2	49	46		43	40	37	34	31	28
70,000		3	71	68		65	62	59	56	53	50

	Alternate	2	36	33		30	27	24	21	18	15

		3	57	54		51	48	45	42	39	36

	Standard	2	61	58		55	52	49	46	43	40
90,000		3	71	68		65	62	59	56	53	50

	Alternate	2	48	45		42	39	36	33	30	27

		3	57	54		51	48	45	42	39	36

(1)Elbows and/or Tees used in the terminations must be included when determining the number of elbows in the piping system.

(2)Number of elbows tabulated are for each (Vent/Flue & Combustion air intake) pipe.

(3)Minimum length of each Vent/Flue & Combustion Air Intake pipe is five feet and one elbow/tee.

(4)3” diameter pipe can be used in place of 2” diameter pipe.

VENT/FLUE AND COMBUSTION AIR PIPE TERMINATIONS

The vent/flue and combustion air pipes may terminate vertically, as through a roof, or horizontally, as through an outside wall. Vertical pipe terminations should be as shown in the following figure. Refer to Section IX, Vent/Flue Pipe and Combustion Pipe - Termination Locations for details concerning location restrictions. The penetrations through the roof must be sealed tight with proper flashing such as is used with a plastic plumbing vent.

TEE

				VENT/FLUE
				VENT/FLUE
	COMBUSTION		90º
			90º
			MEDIUM RADIUS
			MEDIUM RADIUS
		AIR INTAKE	ELBOWS
		AIR INTAKE	ELBOWS
12"	MIN.

12" MIN.

TO ROOF OR SCREEN

HIGHEST

ANTICIPATED

SNOW LEVEL

24" MAX. 3" MIN.

Vertical Terminations (Dual Pipe)

Horizontal terminations should be as shown in the following figure. Refer to Section IX, Vent/Flue Pipe and Combustion Pipe - Termination Location for location restrictions. A 2 3/8 inch diameter wall penetration is required for 2” diameter pipe while a 3 1/2 inch diameter hole is required for 3” diameter pipe. To secure the pipe passing through the wall and prohibit damage to piping connections, a coupling should be installed on either side of the wall and solvent cemented to a pipe connecting the two couplings. The pipe length should be the wall thickness plus the depth of the socket fittings to be installed on the inside and outside of the wall. The wall penetration should be sealed with silicone caulking material.

12" MIN

3" MIN 24" MAX

Standard Horizontal Terminations (Dual Pipe)

90° MEDIUM RADIUS ELBOW

24" MAX

24" MAX	3"	MIN

AIR

INTAKE

Alternate Horizontal Vent Termination (Dual Pipe)

	12" MIN
	12" MIN.
	3" MIN.
	24" MAX.
	VENT/FLUE
SUPPORT	TEE
STRAPS
COMBUSTION	12" MIN. ABOVE
COMBUSTION	HIGHEST ANTICIPATED
AIR INTAKE.	SNOW LEVEL
SCREEN	12" MIN. ABOVE
90°	HIGHEST ANTICIPATED
MEDIUM	SNOW LEVEL
RADIUS
ELBOWS

Standard Horizontal Terminations Above Anticipated Snow

Level (Dual Pipe)

Alternate Vent Termination Above Anticipated Snow Level

(Dual Pipe)

In a basement installation, the pipes may be run between the joist spaces. If the pipes must go below the joist and then up into the last joist space to penetrate the header, two 45° elbows should be used to reach the header rather than two 90° elbows.

VENT/INTAKE TERMINATIONS FOR INSTALLATION OF MULTIPLE

DIRECT VENT FURNACES

If more than one direct vent furnace is to be installed vertically through a common roof top, maintain the same minimum clearances between the exhaust vent and air intake terminations of adjacent units as with the exhaust vent and air intake terminations of a single unit.

If more than one direct vent furnace is to be installed horizontally through a common side wall, maintain the clearances as in the following figure. Always terminate all exhaust vent outlets at the same elevation and always terminate all air intakes at the same elevation.

90°	Vents
Medium
Radius
Elbows

3" Min. 24" Max.

3" Min.

	24" Max.	24" Max.
	24" Max.	3" Min.
		3" Min.

Screen

12" Min.

Horizontal Venting Of Multiple Units

CONCENTRIC VENT TERMINATION

Refer to the directions provided with the Concentric Vent Kit (DCVK) for installation specifications.

X. CONDENSATE DRAIN LINES & DRAIN TRAP

GENERAL

A condensing gas furnace achieves its high level of efficiency by extracting almost all of the heat from the products of combustion and cooling them to the point where condensation takes place. The condensate which is generated must be piped to an appropriate drain location.

In upright installations, the furnace’s drain hoses may exit either the right or left side of the furnace. NOTE: If the alternate vent/flue outlet is utilized in an upright installation, the drain trap and drain connections must be located on the same side as the alternate vent/flue outlet.

In horizontal installations, the drain hoses will exit through the bottom (down side) of the unit with the drain trap suspended beneath the furnace. The field-supplied drain system must be in

accordance with all local codes and the instructions in the following sections.

Follow the bullets listed below when installing the drain system. Refer to the following sections for specific details concerning furnace drain trap installation and drain hose hook ups.

•The drain trap supplied with the furnace must be used.

•The drain line between furnace and drain location must be constructed of 3/4” PVC or CPVC.

•The drain line between furnace and drain location must maintain a 1/4 inch per foot downward slope toward the drain.

•Do not trap the drain line in any other location than at the drain trap supplied with the furnace.

•Do not route the drain line outside where it may freeze.

•If the drain line is routed through an area which may see temperatures near or below freezing, precautions must be taken to prevent condensate from freezing within the drain line.

•If an air conditioning coil is installed with the furnace, a common drain may be used. An open tee must be installed in the drain line, near the cooling coil, to relieve positive air pressure from the coil’s plenum. This is necessary to prohibit any interference with the function of the furnace’s drain trap.

UPRIGHT INSTALLATIONS

In an upright installation drain hoses are connected to drain ports on the rubber elbow and the recuperator coil front cover. The drain lines are then routed through the right or left side panel and into the drain trap secured to the outside of the cabinet.

NOTE: Refer to Section X, Condensate Drain Lines and Drain Trap - Alternate Vent/Flue Hose Connections for upright installations using an alternate vent/flue outlet.

STANDARD RIGHT OR LEFT SIDE DRAIN HOSE CONNECTIONS

Upright installations using the standard vent/flue outlet require drain hoses to be connected as follows. The following quantity of hoses, tubes, and hose clamps are provided with the unit.

	HOSE A
	QTY: 1
		HOSE B
	TUBE 1	QTY: 1
	TUBE 1
	QTY: 1
		TUBE 2
		QTY: 2
GREEN		RED
HOSE CLAMPS		HOSE CLAMPS
QTY: 3		QTY: 2

Hose and Tube Identification

1.Remove the rubber plug from the front cover drain port (right or left side, depending on the intended drain trap mounting).

2.Secure Hose A to front cover drain port with a red hose clamp. Route hose to rear side panel grommet hole.

NOTE: For left side drainage, grommets will have to be relocated to left side panel.

RIGHT SIDE
	PANEL
	RUBBER
	ELBOW
RUBBER ELBOW
	DRAIN PORT
RED HOSE CLAMP
	TUBE 1
HOSE	SIDE PANEL
B	GROMMET
	HOLES

TUBE(S) 2

FRONT COVER	RED HOSE	HOSE	DRAIN
FRONT COVER	CLAMP	A GREEN	TRAP
DRAIN PORT		HOSE
		CLAMPS
		(3 PLACES)

Upright “Standard” Connections - Right Side

(Upflow Shown, Counterflow Similar)

LEFT

SIDE PANEL

	FRONT COVER	RUBBER
	DRAIN PORT	ELBOW
	RED HOSE	RUBBER
	CLAMP	RUBBER
	CLAMP	ELBOW
	HOSE A	DRAIN PORT
	HOSE A
	SIDE PANEL	RED HOSE
	DRAIN	CLAMP
	HOLES	TUBE 1
	TUBE(S) 2	GREEN HOSE
		GREEN HOSE
		CLAMPS
	DRAIN	(3 PLACES)
	DRAIN	HOSE B
	TRAP	HOSE B
	TRAP

Upright “Standard” Connections - Left Side

(Upflow Shown, Counterflow Similar)

3.Cut and remove 1/4 inch from the end of the drain port on the rubber elbow.

4.Insert Tube 1 into rubber elbow drain port and secure with red hose clamp. Angle tube outward toward front of furnace.

5.Right side drains

Cut 17 3/4 inches from the long end of Hose B and discard. Secure the remaining hose to Tube 1 with a green hose clamp. Route the other end of Hose B to front right side panel grommet hole.

Left side drains

Cut “X” inches from the long end of Hose B and discard. Refer to table for appropriate length to cut. Secure remaining hose to Tube 1 with a green hose clamp. Route other end of Hose B to front left side panel grommet hole.

Cabinet Width	Models	"X" Length to Cut From Long
(inches)	(kBTU_Tons)	End of Hose B

17 1/2	45__30	7 inches
21	70__40	3 1/2 inches
24 1/2	090__50	None
24 1/2	115__50	None
	115__50

6.Insert short end of each Tube 2 through side panel grommet holes. Secure tubes to Hose A and Hose B with green hose clamps. Ensure hoses and tubes maintain a downward slope for proper drainage and that they are not kinked or binding.

For details concerning mounting of the drain trap, refer to Section X, Condensate Drain Lines and Drain Trap - Upright Drain Trap Mounting.

ALTERNATE VENT/FLUE DRAIN HOSE CONNECTIONS

Upright installations using the alternate vent/flue outlet will require

“right-side only” drain hoses to be connected as follows. Refer to

Section IX, Vent/Flue Pipe and Combustion Air Pipe for details on alternate vent/flue pipe connection.

1.Remove the rubber plug from the front cover right-side drain port. Save for use in step 3.

2.Secure Hose A to front cover drain port with a red hose clamp. Route hose to rear right side panel grommet hole.

3.Remove grommet from front right-side panel drain hole. Seal hole in grommet with large end of plug. Reinstall grommet and plug into side panel drain hole.

4.Cut 1/4 inch from the end of the drain port on the externally mounted rubber elbow. Discard cut portion.

5.Insert Tube 1 into rubber elbow drain port and secure with a red hose clamp. Angle tube outward toward front of furnace.

6.Cut 17 7/8 inches from the long end of Hose B and discard.

7.Secure remaining end of Hose B to exposed end of Tube 1 with a green hose clamp. Route hose toward right side panel grommet holes.

8.Insert short end of one Tube 2 through rear right side panel grommet drain hole. Secure tube to Hose A with a green hose clamp.

9.Insert short end of remaining Tube 2 into Hose B from rubber elbow and secure with green hose clamp. Ensure hoses and tubes maintain a downward slope for proper drainage and are not kinked or binding.

	RUBBER ELBOW	RUBBER
	(EXTERNALLY	RUBBER
	(EXTERNALLY	ELBOW
	MOUNTED)	ELBOW
FRONT COVER	MOUNTED)	DRAIN PORT
DRAIN PORT
		RED HOSE CLAMP
		TUBE 1 GREEN HOSE
		CLAMPS
		(3 PLACES)
		HOSE B
		SIDE PANEL
		GROMMET
RED HOSE	HOSE A	HOLES
RED HOSE	HOSE A	DRAIN TRAP
CLAMP	TUBE(S) 2	DRAIN TRAP
CLAMP

Upright “Alternate” Connections - Right Side Only

(Upflow Shown, Counterflow Similar)

For details concerning mounting of the drain trap, refer to the following section.

UPRIGHT DRAIN TRAP MOUNTING (LEFT OR RIGHT SIDE PANEL)

1.Insert drain tubes into drain trap and position the drain trap against the side panel. NOTE: Drain tubes must reach the bottom of the drain trap.

2.Secure drain trap to side panel at the mounting holes (dimples or crosshairs on counterflow models) located below the grommet drain holes.

3.Attach PVC drain line to drain trap outlet with either a 90° elbow or coupling.

HORIZONTAL INSTALLATIONS

RIGHT SIDE DOWN

Horizontal installations with the right side down require that the drain hoses be connected to the right side front cover drain port and the rubber elbow drain port.

NOTE: On counterflow models, relocation of the front cover pressure switch hose is required.

Make connections as follows:

1.Remove the rubber plug from the coil front cover drain port.

Counterflow furnaces

Relocate the front cover pressure switch hose connection from the left side pressure tap to the right (down) side tap. The pressure switch hose must be connected to the down side to guard against blocked drain conditions. Cut hose to appropriate length to minimize sagging. Plug left (unused) pressure tap with plug removed from right side.

2.Secure Hose A to front cover drain tap with a red hose clamp. Route hose to rear right (down) side panel grommet holes.

3.Cut 1/4 inch from the end of the drain port on the rubber elbow and discard.

4.Insert Tube 1 into rubber elbow drain port and secure with a red hose clamp. Angle tube outward toward front of furnace.

5.Cut 17 3/4 inches from the long end of Hose B and discard.

6.Secure remaining end of Hose B to exposed end of Tube 1 with a green hose clamp. Route hose to front right down side panel grommet holes.

7.Cut 5 1/2 inches straight length from the long end of each Tube 2.

FRONT COVER

DRAIN PORT

RED HOSE
CLAMP
HOSE A
HOSE B			FRONT
HOSE B			COVER
			COVER
SIDE PANEL		PRESSURE			RUBBER
SIDE PANEL			TAP		RUBBER
GROMMET			TAP		ELBOW
GROMMET					ELBOW
HOLES
					RIGHT
					SIDE
TUBES 2					PANEL
	GREEN			RUBBER ELBOW
	GREEN			DRAIN PORT
DRAIN TRAP	HOSE	TUBE 1		RED HOSE
	CLAMP	TUBE 1		RED HOSE
	CLAMP			CLAMP
	(3 PLACES)			CLAMP
	(3 PLACES)

Horizontal Connections - Right Side Down

(Upflow Shown, Counterflow Similar)

8.Insert approximately one inch of each Tube 2 through the right down side panel grommet holes. Secure tubes to Hose A and Hose B using green hose clamps. Ensure hoses and tubes maintain a downward slope for proper drainage and are not kinked or bound.

For details concerning mounting of the drain trap, refer to Section X, Condensate Drain Lines and Drain Trap - Upright Drain Trap Mounting.

LEFT SIDE DOWN

Horizontal installations with the left side panel down will require drain hoses to be connected to the left side front cover drain port and the side drain port on the rubber elbow.

1.Remove the rubber plug from the coil front cover left (down) side drain port.

2.Relocate the front cover pressure switch hose connection from the right side (as shipped) pressure tap to the left (down) side tap. The pressure switch hose must be connected to the down side to guard against blocked drain conditions. Cut hose to appropriate length to minimize sagging. Plug right (unused) pressure tap with plug removed from left side.

3.Secure Hose A to front cover drain port with a red hose clamp. Route hose to rear left (down) side panel grommet holes. NOTE: For left side drainage, grommets must be relocated to left side panel.

		INDUCED
		DRAFT BLOWER
		DRAIN PORT
		HOSE B
	FRONT	HOSE A
	COVER	HOSE A
	COVER
	PRESSURE
	TAP	GREEN HOSE
		GREEN HOSE
		CLAMPS
		(3 PLACES)
LEFT SIDE	FRONT COVER	TUBE(S) 2
PANEL	FRONT COVER
	DRAIN PORT
	RED HOSE CLAMP	DRAIN TRAP

SIDE PANEL

GROMMET

HOLES

Horizontal Connections - Left Side Down (Upflow Shown, Counterflow Similar)

4.Remove the rubber cap from the side drain port on the rubber elbow.

5.Secure the short end of Hose B to rubber elbow side drain port using a green hose clamp. NOTE: For left side drainage, route hose to far left (down) side panel grommet holes. NOTE: Horizontal left side connections (when using new side port drain elbow) does not require connecting a hose to the induced draft blower housing.

6.Cut 5 1/2 inches straight length from the long end of each Tube 2.

7.Insert approximately one inch of each Tube 2 through left side panel grommet hole. Secure tubes to Hose A and Hose B with a green hose clamps. NOTE: Tube must reach bottom of trap. Ensure hoses and tubes maintain a downward slope for proper drainage and that they are not kinked or binding.

For details concerning mounting of the drain trap, refer to Section X, Condensate Drain Lines and Drain Trap - Upright Drain Trap Mounting.

HORIZONTAL DRAIN TRAP MOUNTING (LEFT OR RIGHT SIDE PANEL)

1.Position the drain trap against side panel with drain tubes inserted into trap. Note that the trap may be orientated with the outlet facing either the furnace’s top cover or base pan.

2.Secure drain trap to side panel at the dimples or crosshairs located on either side of the grommet drain holes.

3.Confirm that tubes reach bottom of drain trap and that all hoses maintain a downward slope and are not kinked or binding.

4.Attach PVC drain line to drain trap outlet with either a 90° elbow or coupling.

XI. ELECTRICAL CONNECTIONS

WARNING

TO AVOID THE RISK OF ELECTRICAL SHOCK, WIRING TO THE UNIT MUST BE POLARIZED AND GROUNDED.

CAUTION

LABEL ALL WIRES PRIOR TO DISCONNECTION WHEN SERVICING CONTROLS. WIRING ERRORS CAN CAUSE IMPROPER AND DANGEROUS OPERATION. VERIFY PROPER OPERATION AFTER SERVICING.

WIRING HARNESS

The wiring harness is an integral part of this furnace. Field alteration to comply with electrical codes should not be required. Wires are color and number coded for identification purposes. Refer to the wiring diagram for wire routings. If any of the original wire as supplied with the furnace must be replaced, it must be replaced with wiring material having a temperature rating of at least 105°C. Any replacement wiring must be copper conductor.

115 VOLT LINE CONNECTIONS

Before proceeding with electrical connections, ensure that the supply voltage, frequency, and phase correspond to that specified on the unit rating plate. Power supply to the furnace must be N.E.C. Class 1, and must comply with all applicable codes. The furnace must be electrically grounded in accordance with local codes or, in their absence, with the latest edition of The National Electric Code, ANSI NFPA 70 and/or The Canadian Electric Code CSA C22.1.

Use a separate fused branch electrical circuit containing properly sized wire, and fuse or circuit breaker. The fuse or circuit breaker must be sized in accordance with the maximum overcurrent protection specified on the unit rating plate. An electrical disconnect must be provided at the furnace location.

NOTE: Line polarity must be observed when making field connections.

Connect hot, neutral, and ground wires as shown in the wiring diagram located on the unit’s blower door. For direct vent applications, the cabinet opening to the junction box must be sealed air tight using either an UL approved bushing such as Heyco Liquid Tight or by applying non-reactive UL approved sealant to bushing. Line polarity must be observed when making field connections. Line voltage connections can be made through either the right or left side panel. The furnace is shipped configured for a left side (right side for counterflows) electrical connection with the junction box located inside the burner compartment. To make electrical connections through the opposite side of the furnace, the junction box must be relocated to the other side of the burner compartment prior to making electrical connections. To relocate the junction box, follow the steps shown below.

CAUTION

EDGES OF SHEET METAL HOLES MAY BE SHARP. USE GLOVES A PRECAUTION WHEN REMOVING HOLE PLUGS.

1.Remove the burner compartment door.

2.Remove and save the two screws securing the junction box to the side panel.

3.Relocate junction box and associated plugs and grommets to opposite side panel. Secure with screws removed in step 2.

WARNING

TO AVOID INJURY, ELECTRICAL SHOCK OR DEATH, DISCONNECT ELECTRICAL POWER BEFORE SERVICING OR CHANGING ANY ELECTRICAL WIRING.

STANDARD	*	*	*	ALTERNATE
STANDARD		*		ALTERNATE
		*
JUNCTION BOX	*			JUNCTION BOX
JUNCTION BOX	*	*	*	JUNCTION BOX
LOCATION				LOCATION

Junction Box Relocation

WARNING

TO AVOID THE RISK OF INJURY, ELECTRICAL SHOCK OR DEATH, THE FURNACE MUST BE ELECTRICALLY GROUNDED IN ACCORDANCE WITH LOCAL CODES OR, IN THEIR ABSENCE, WITH THE LATEST EDITION OF THE NATIONAL ELECTRIC CODE.

To ensure proper unit grounding, the ground wire should run from the furnace ground screw located inside the furnace junction box all the way back to the electrical panel. NOTE: Do not use gas piping as an electrical ground. To confirm proper unit grounding, turn off the electrical power and perform the following check.

1.Measure resistance between the neutral (white) connection and one of the burners.

2.Resistance should measure 10 ohms or less.

This furnace is equipped with a blower door interlock switch which interrupts unit voltage when the blower door is opened for servicing. Do not defeat this switch.

24 VOLT THERMOSTAT WIRING

NOTE: Wire routing must not interfere with circulator blower operation, filter removal, or routine maintenance.

As a two-stage furnace, the furnace integrated control module provides terminals for both “W1” and “W2”, and “YLO” and “Y” thermostat connections. This allows the furnace to support the following system applications: ‘Two-Stage Heating Only’, ‘Two-Stage Heating with Single-Stage Cooling’, and ‘Two-Stage Heating with TwoStage Cooling’. Refer to the following figures and table for proper connections to the integrated control module.

Low voltage connections can be made through either the right or left side panel. Thermostat wiring entrance holes are located in the blower compartment. Wire routing must not interfere with circulator blower operation, filter removal, or routine maintenance.

Y			W	(
	G	R
O Y L O Y B /C G		R	W 1 W 2
				N E U
				N E U

T h e rm o s ta t ) S in g le - S ta g e H e a tin g

w ith

S in g le - S ta g e C o o lin g

D E H U M F u rn a c e In te g ra te d

T W IN

C o n tro l M o d u le

Y	C	H O T	D e h u m id is ta t
			[O p tio n a l]

R e m o te

C o n d e n s in g U n it

(S in g le - S ta g e C o o lin g )

S in g le -S ta g e H e a tin g w ith S in g le -S ta g e C o o lin g

N O T E : T o a p p ly a s in g le - s ta g e h e a tin g th e rm o s ta t, th e

th e rm o s ta t s e le c to r ju m p e r o n th e in te g ra te d C o n tro l m o d u le m u s t b e s e t o n s in g le s ta g e .

			W 2		(		T herm o stat
						Tw o -S ta ge H eating
							w ith
		Y		W 1		S ingle -S tage C ooling)
			G	R
O	Y L O Y B /C		G	R W 1 W 2		D E HU M F urnac e In tegrated
O	Y L O Y B /C		G	R W 1 W 2		T W IN	C ontro l M odule
							C ontro l M odule
					N E U
	Y	C			H O T	D ehum idistat
						[O ptiona l]

R em ote

C o nd ens ing U nit

(S ingle -S ta ge C ooling)

T w o -S ta ge H e ating w ith S in gle -S tage C oo lin g

				(		Thermostat
		YLO	W 2		Two-Stage Heating
		Y	W1		Two-StagewithCooling)
		G	R
O YLO	Y	B/C G	R W1	W 2	D EHUM Furnace Integrated
O YLO	Y	B/C G	R W1	W 2	TW IN	Control Module
						Control Module
				NEU
YLO	Y	C		HOT Dehumidistat
					[Optional]

Remote

Condensing Unit

(Two-Stage Cooling)

Two-Stage Heating with Two-Stage Cooling

Thermostat Diagrams

This furnace is equipped with a 40 VA transformer to facilitate use with most cooling equipment. Consult the wiring diagram, located on the blower compartment door, for further details of 115 Volt and 24 Volt wiring.

SINGLE-STAGE THERMOSTAT APPLICATION

A single-stage thermostat with only one heating stage can be used to control this furnace. The application of a single-stage thermostat does not offer “true” thermostat-driven two-stage operation, but provides a timed transition from low to high fire. The furnace will run on low stage for a fixed period of time before stepping up to high stage to satisfy the thermostat’s call for heat. The delay period prior to stepping up can be set at either 5 or 10 minutes through the DIP switch adjacent to the Heat Off delay DIP switches on the integrated control module. To use a single-stage thermostat, turn off power to the furnace, move the thermostat selection jumper on the integrated control module from the “two-stage” position to the “single-stage” position, turn power back on. Refer to the following figures.

T		T-Stat selection jumper in	T
W	TSTAT	single-stage thermostat	W
O	TSTAT	position.	O	TSTAT
		position.		TSTAT
S			S
I	ON		I	OFF
N	ON	3	N	OFF	3
G			G
L		2	L		2
E			E
		1			1
	DIP switch position 3: ON			DIP switch position 3: OFF
	Delay Period: 10 minutes.			Delay Period: 5 minutes.

24 VOLT DEHUMIDISTAT WIRING

The optional usage of a dehumidistat allows the furnace’s circulator blower to operate at a slightly lower speed during a combined thermostat call for cooling and dehumidistat call for dehumidifica-

tion. This lower blower speed enhances dehumidification of the conditioned air as it passes through the AC coil. For proper function, a dehumidistat applied to this furnace must operate on 24 VAC and utilize a switch which opens on humidity rise.

To install/connect a dehumidistat:

1.Turn OFF power to furnace.

2.Secure the dehumidistat neutral wire (typically the white lead) to the screw terminal marked “DEHUM” on the furnace integrated control module.

3.Secure the dehumidistat hot wire (typically the black lead) to the screw terminal marked “R” on the furnace integrated control module.

4.Secure the dehumidistat ground wire (typically the green lead) to the ground screw on the furnace junction box. NOTE: Ground wire may not be present on all dehumidistats.

5.Turn ON power to furnace.

To enable the dehumidify function on the integrated control module:

1.Cut the jumper wire labeled “CUT FOR DEHUM” located adjacent to the DEHUM screw terminal.

Once the jumper wire is cut, the dehumidify function is enabled during a combination call for cooling (T-Stat) and dehumidification (Dehum-Stat). The yellow LED adjacent to the DEHUM screw terminal will be illuminated during dehumidification.

0	YL0	Y	B/C	G	R	W1		W2	DEHUM
0	YL0	Y	B/C	G	R	W1		W2	TWIN	DEHUMIDIFICATION
									TP1	DEHUMIDIFICATION
										LED (YELLOW)
0	YL0	Y	B/C	G	R	W1		W2	TP2
			R84						TP2
			R84					R191	DS7
	DS5	DS4		DS3		R85		R191	DS7
	DS5	DS4	R22	DS3


					CUT FOR		W14		W3
					CUT FOR			R128		DEHUMIDIFICATION
					DEHUM					DEHUMIDIFICATION
						R122				JUMPER WIRE
								CR35		(CUT TO ENABLE)
								CR35

FOSSIL FUEL APPLICATIONS

This furnace can be used in conjunction with a heat pump in a fossil fuel application. A fossil fuel application refers to a combined gas furnace and heat pump installation which uses an outdoor temperature sensor to determine the most cost efficient means of heating (heat pump, gas furnace, or both).

A heat pump thermostat with three stages of heat is required to properly use a two-stage furnace in conjunction with a heat pump. Refer to the fossil fuel kit installation instructions for additional thermostat requirements.

Strictly follow the wiring guidelines in the fossil fuel kit installation instructions. All furnace connections must be made to the furnace two-stage integrated control module and the “FURNACE” terminal strip on the fossil fuel control board.

115 VOLT LINE CONNECTION OF ACCESSORIES (HUMIDIFIER AND ELECTRONIC AIR CLEANER)

WARNING

TO AVOID INJURY, ELECTRICAL SHOCK OR DEATH, DISCONNECT ELECTRICAL POWER BEFORE SERVICING OR CHANGING ANY ELECTRICAL WIRING.

The furnace’s integrated control module is equipped with line voltage accessory terminals for controlling power to an optional fieldsupplied humidifier and/or electronic air cleaner.

The accessory load specifications are as follows:

Humidifier	1.0 Amp maximum at 120 VAC
Electronic Air Cleaner	1.0 Amp maximum at 120 VAC

Turn OFF power to the furnace before installing any accessories. Follow the humidifier or air cleaner manufacturers’ instructions for locating, mounting, grounding, and controlling these accessories. Accessory wiring connections are to be made through the 1/4" quick connect terminals provided on the furnace integrated control module. The humidifier and electronic air cleaner hot and neutral terminals are identified as HUM and EAC. All field wiring must conform to applicable codes. Connections should be made as shown.

12 CIRCUIT CONNECTOR

INTEGRATED

CONTROL MODULE

EAC-N

HUM-N

HUM-H

EAC-H

HUMIDIFIER

ELECTRONIC

AIR CLEANER

OPTIONAL ACCESSORIES

Accessories Wiring

If it is necessary for the installer to supply additional line voltage wiring to the inside of the furnace, the wiring must conform to all local codes, and have a minimum temperature rating of 105°C. All line voltage wire splices must be made inside the furnace junction box.

The integrated control module humidifier terminals (HUM) are energized with 115 volts whenever the induced draft blower is energized. The integrated control module electronic air cleaner terminals (EAC) are energized with 115 volts whenever the circulator blower is energized.

24 VOLT HUMIDIFIER

A 5" long brown wire in the wire harness at the low fire pressure provides 24 VAC humidifier control. This wire is powered any time the pressure switch is closed. To connect 24 VAC HUM, connect the 24 VAC line of the humidifier to the 5” brown wire. The connection can be made by either stripping the wire and using a wire nut or by using a field supplied quick connect terminal. The wiring must conform to all local and national codes. Connect the COM side of the humidifier to the B/C terminal on the furnace control board (or to the COM side of the 24 VAC transformer). Do not connect 115V humidifier to these terminals.

XII. GAS SUPPLY AND PIPING

GENERAL

The furnace rating plate includes the approved furnace gas input rating and gas types. The furnace must be equipped to operate on the type of gas applied. This includes any conversion kits required for alternate fuels and/or high altitude.

CAUTION

TO PREVENT UNRELIABLE OPERATION OR EQUIPMENT DAMAGE, THE INLET GAS SUPPLY PRESSURE MUST BE AS SPECIFIED ON THE UNIT RATING PLATE WITH ALL OTHER HOUSEHOLD GAS FIRED APPLIANCES OPERATING.

Inlet gas supply pressures must be maintained within the ranges specified below. The supply pressure must be constant and available with all other household gas fired appliances operating. The minimum gas supply pressure must be maintained to prevent unreliable ignition. The maximum must not be exceeded to prevent unit overfiring.

	Inlet Gas Supply Pressure

Natural Gas	Minimum:5.0" W.C. Maximum :10.0" W.C.
Propane Gas	Minimum:11.0" W.C. Maximum :13.0" W.C.

HIGH ALTITUDE DERATE

When this furnace is installed at high altitude, the appropriate High Altitude orifice kit must be applied. This is required due to the natural reduction in the density of both the gas fuel and combustion air as altitude increases. The kit will provide the proper design certified input rate within the specified altitude range.

High altitude kits are purchased according to the installation altitude and usage of either natural or propane gas. Contact your distributor for a tabular listing of appropriate altitude ranges and corresponding manufacturer’s high altitude (Natural, propane gas, and/or Pressure Switch) kits.

Do not derate the furnace by adjusting the manifold pressure to a lower pressure than specified on the furnace rating plate. The combination of the lower air density and a lower manifold pressure will prohibit the burner orifice from drawing the proper amount of air into the burner. This may cause incomplete combustion, flashback, and possible yellow tipping.

In some areas the gas supplier may artificially derate the gas in an effort to compensate for the effects of altitude. If the gas is artificially derated, the appropriate orifice size must be determined based upon the BTU/ft3 content of the derated gas and the altitude. Refer to the National Fuel Gas Code, NFPA 54/ANSI Z223.1, and information provided by the gas supplier to determine the proper orifice size.

A different pressure switch may be required at high altitude regardless of the BTU/ft3 content of the fuel used. Contact your distributor for a tabular listing of appropriate altitude ranges and corresponding manufacturer’s pressure switch kits.

PROPANE GAS CONVERSION

WARNING

This unit is configured for natural gas. The appropriate manufacturer’s propane gas conversion kit, must be applied for propane gas installations. Refer to the Section VIII, Propane Gas / High Altitude Installations section for details.

GAS VALVE

This unit is equipped with a 24 volt gas valve controlled during furnace operation by the integrated control module. As shipped, the valve is configured for natural gas. The valve is field convertible for use with propane gas by replacing the regulator spring with a propane gas spring from an appropriate manufacturer’s propane gas conversion kit. Taps for measuring the gas supply pressure and manifold pressure are provided on the valve.

The gas valve has a manual ON/OFF control located on the valve itself. This control may be set only to the “ON” or “OFF” position. Refer to the lighting instructions label or Section XIV, Startup Procedure & Adjustment for use of this control during start up and shut

down periods.

GAS PIPING CONNECTIONS

GENERAL

CAUTION

TO AVOID POSSIBLE UNSATISFACTORY OPERATION OR EQUIPMENT DAMAGE DUE TO UNDERFIRING OF EQUIPMENT, USE THE PROPER SIZE OF NATURAL/PROPANE GAS PIPING NEEDED WHEN RUNNING PIPE FROM THE METER/TANK TO THE FURNACE.

When sizing a trunk line, be sure to include all appliances which will operate simultaneously when sizing a trunk line.

The gas piping supplying the furnace must be properly sized based on the gas flow required, specific gravity of the gas, and length of the run. The gas line installation must comply with local codes, or in their absence, with the latest edition of the National Fuel Gas Code, NFPA 54/ANSI Z223.1.

Natural Gas Capacity of Pipe

In Cubic Feet of Gas Per Hour (CFH)

Length of			Nominal Black Pipe Size
Pipe in Feet		1/2"	3/4"	1"	1 1/4"	1 1/2"
	10	132	278	520	1050	1600
	20	92	190	350	730	1100
	30	73	152	285	590	980
	40	63	130	245	500	760
	50	56	115	215	440	670
	60	50	105	195	400	610
	70	46	96	180	370	560
	80	43	90	170	350	530
	90	40	84	160	320	490
100		38	79	150	305	460
(Pressure 0.5 psig or less and pressure drop of 0.3" W.C.; Based on
0.60 Specific Gravity Gas)
CFH =	BTUH Furnace Input

	Heating Value of Gas (BTU/Cubic Foot)
	Heating Value of Gas (BTU/Cubic Foot)

To connect the furnace to the building’s gas piping, the installer must supply a ground joint union, drip leg, manual shutoff valve, and line and fittings to connect to gas valve. In some cases, the installer may also need to supply a transition piece from 1/2" pipe to a larger pipe size.

The following stipulations apply when connecting gas piping. Refer to Gas Piping Connections figure for typical gas line connections to the furnace.

•Use black iron or steel pipe and fittings for building piping. Where possible, use new pipe that is properly chamfered, reamed, and free of burrs and chips. If old pipe is used, be sure it is clean and free of rust, scale, burrs, chips, and old pipe joint compound.

•Use pipe joint compound on male threads ONLY. Always use pipe joint compound (pipe dope) that is APPROVED FOR ALL GASSES. DO NOT apply compound to the first two threads.

•Use ground joint unions.

•Install a drip leg to trap dirt and moisture before it can enter the gas valve. The drip leg must be a minimum of three inches long.

•Install a 1/8" NPT pipe plug fitting, accessible for test gage connection, immediately upstream of the gas supply connection to the furnace.

•Always use a back-up wrench when making the connection to the gas valve to keep it from turning. The orientation of the gas valve on the manifold must be maintained as

shipped from the factory. Maximum torque for the gas valve connection is 375 in-lbs; excessive over-tightening may damage the gas valve.

•Install a manual shutoff valve between the gas meter and unit within six feet of the unit. If a union is installed, the union must be downstream of the manual shutoff valve, between the shutoff valve and the furnace.

•Tighten all joints securely.

•Connect the furnace to the building piping by one of the following methods:

–Rigid metallic pipe and fittings.

–Semi-rigid metallic tubing and metallic fittings.

Aluminum alloy tubing must not be used in exterior locations. In order to seal the grommet cabinet penetration, rigid pipe must be used to reach the outside of the cabinet. A semi-rigid connector to the gas piping may be used from there.

•Use listed gas appliance connectors in accordance with their instructions. Connectors must be fully in the same room as the furnace.

•Protect connectors and semirigid tubing against physical and thermal damage when installed. Ensure aluminumalloy tubing and connectors are coated to protect against external corrosion when in contact with masonry, plaster, or insulation, or subjected to repeated wetting by liquids such as water (except rain water), detergents, or sewage.

				MANUAL
	GAS VALVE			SHUT OFF VALVE
	GAS VALVE			(UPSTREAM FROM			ALTERNATE
		MANUAL		(UPSTREAM FROM			ALTERNATE
MANIFOLD	BURNERS	MANUAL		GROUND JOINT			GAS LINE
		SHUT OFF VALVE		PIPE UNION)			LOCATION
ALTERNATE		(UPSTREAM FROM
ALTERNATE		GROUND JOINT
GAS LINE		PIPE UNION)
LOCATION
PLUG IN			HEIGHT REQUIRED				PLUG IN
ALTERNATE			HEIGHT REQUIRED				ALTERNATE
GAS LINE		HEIGHT REQUIRED	BY LOCAL CODE				GAS LINE
HOLE		BY LOCAL CODE					HOLE
		GROMMET		*		*	*
		IN STANDARD			*	*
		GAS LINE HOLE			*
		GAS LINE HOLE
GROUND JOINT		GROMMET					GAS VALVE
PIPE UNION		GROMMET
PIPE UNION		IN STANDARD
		IN STANDARD
		GAS LINE HOLE					MANIFOLD
							MANIFOLD

		DRIP LEG
	DRIP LEG		B URNERS
			GROUND JOINT
			PIPE UNION
	UPFLOW		COUNTERFLOW
	MANUAL SHUT-OFF VALVE		MANUAL SHUT-OFF VALVE
	(UPSTREAM FROM GROUND		MANUAL SHUT-OFF VALVE
	JOINT PIPE UNION)		(UPSTREAM FROM GROUND
		GROUND JOINT	JOINT PIPE UNION)
GROUND JOINT		PIPE UNION
PIPE UNION
	DRIP LEG		DRIP LEG
GAS VALVE	GROMMET IN STANDARD	GAS VALVE	GROMMET IN STANDARD
	GAS LINE HOLE		GAS LINE HOLE
BURNERS		BURNERS

DRAIN TRAP

MANIFOLD

PLUG IN ALTERNATE

ALTERNATE

GAS LINE HOLE

MANIFOLD

PLUG IN ALTERNATE

GAS LINE LOCATION

ALTERNATE GAS

GAS LINE HOLE

LINE LOCATION

HORIZONTAL[COUNTERFLOW]

HORIZONTAL [UPFLOW MODEL]

NOTES: 1. WHEN GAS LINE IS IN THE ALTERNATE

2. DRIP LEG MAY TERMINATE WITH

LOCATION, SWAP THE POSITION OF

A 1/2" X 1/8" PIPE PLUG TO

THE PLUG AND GROMMET.

ACCOMMODATE LINE GAS

PRESSURE MEASUREMENT.

Gas Piping Connections

CAUTION

EDGES OF SHEET METAL HOLES MAY BE SHARP. USE GLOVES A PRECAUTION WHEN REMOVING HOLE PLUGS.

DIRECT/STANDARD INLET PIPING

When gas piping enters directly to the gas valve through the standard inlet hole, the installer must supply straight pipe with a ground joint union to reach the exterior of the furnace. The rigid pipe must be long enough to reach the outside of the cabinet to seal the grommet cabinet penetration. A semi-rigid connector to the gas piping can be used outside the cabinet per local codes.

INDIRECT/ALTERNATE INLET PIPING

When gas piping enters indirectly to the gas valve through the alternate gas inlet hole the following fittings (starting from the gas valve) to reach the outside of the cabinet must be supplied:

•Coupling.

•90 degree elbow.

•2 inch close nipple.

•90 degree elbow.

•Straight pipe, with a ground joint union, to reach the exterior of the furnace. The rigid pipe must be long enough to reach the outside of the cabinet so as to seal the grommet cabinet penetration. A semi-rigid connector to the gas piping can be used outside the cabinet per local codes.

GAS PIPING CHECKS

Before placing unit in operation, leak test the unit and gas connections.

WARNING

TO AVOID THE POSSIBILITY OF EXPLOSION OR FIRE, NEVER USE A MATCH OR OPEN FLAME TO TEST FOR LEAKS.

Check for leaks using an approved chloride-free soap and water solution, an electronic combustible gas detector, or other approved testing methods.

NOTE: Never exceed specified pressures for testing. Higher pressure may damage the gas valve and cause subsequent overfiring, resulting in heat exchanger failure.

Disconnect this unit and shutoff valve from the gas supply piping system before pressure testing the supply piping system with pressures in excess of 1/2 psig (3.48 kPa).

Isolate this unit from the gas supply piping system by closing its external manual gas shutoff valve before pressure testing supply piping system with test pressures equal to or less than 1/2 psig (3.48 kPa).

PROPANE GAS TANKS AND PIPING

WARNING

PROPANE GAS IS HEAVIER THAN AIR AND ANY LEAKING GAS CAN SETTLE IN ANY LOW AREAS OR CONFINED SPACES. TO PREVENT PROPERTY DAMAGE, PERSONAL INJURY, OR DEATH DUE TO FIRE OR EXPLOSION CAUSED BY A PROPANE GAS LEAK, INSTALL A GAS DETECTION WARNING DEVICE.

A gas detecting warning system is the only reliable way to detect a propane gas leak. Rust can reduce the level of odorant in propane

gas. Do not rely on your sense of smell. Contact a local propane gas supplier about installing a gas detecting warning system. If the presence of gas is suspected, follow the instructions on Page 4 of this manual.

All propane gas equipment must conform to the safety standards of the National Board of Fire Underwriters, NBFU Manual 58.

For satisfactory operation, propane gas pressure must be 11 inch w.c. at the furnace manifold with all gas appliances in operation. Maintaining proper gas pressure depends on three main factors:

1.Vaporization rate, depending on temperature of the liquid, and “wetted surface” area of the container or containers.

2.Proper pressure regulation. (Two-stage regulation is recommended for both cost and efficiency).

3.Pressure drop in lines between regulators, and between second stage regulator and the appliance. Pipe size will depend on length of pipe run and total load of all appliances.

Complete information regarding tank sizing for vaporization, recommended regulator settings, and pipe sizing is available from most regulator manufacturers and propane gas suppliers.

Since propane gas will quickly dissolve white lead and most standard commercial compounds, special pipe dope must be used. Shellac-based compounds resistant to the actions of liquefied petroleum gases such as Gasolac®, Stalactic®, Clyde’s® or John Crane® are satisfactory.

Refer to the following illustration for typical propane gas installations.

First Stage	5 to 15 PSIG
First Stage	(20 PSIG Max.)	Continuous
Regulator	(20 PSIG Max.)	Continuous
		11" W.C.
200 PSIG		Second Stage
Maximum		Regulator

Propane Gas Installation (Typ.)

Sizing Between First and Second Stage Regulator*

Maximum Propane Capacities listed are based on 2 psig pressure drop at 10 psig setting. Capacities in 1,000 BTU/hour.

Pipe or						Nominal Pipe Size
Tubing		Tubing Size, O.D. Type L				Schedule 40
Length,	3/8"	1/2"	5/8"	3/4"	7/8"	1/2"	3/4"
Feet
10	730	1,700	3,200	5,300	8,300	3,200	7,500
20	500	1,100	2,200	3,700	5,800	2,200	4,200
30	400	920	2,000	2,900	4,700	1,800	4,000
40	370	850	1,700	2,700	4,100	1,600	3,700
50	330	770	1,500	2,400	3,700	1,500	3,400
60	300	700	1,300	2,200	3,300	1,300	3,100
80	260	610	1,200	1,900	2,900	1,200	2,600
100	220	540	1,000	1,700	2,600	1,000	2,300
125	200	490	900	1,400	2,300	900	2,100
150	190	430	830	1,300	2,100	830	1,900
175	170	400	780	1,200	1,900	770	1,700
200	160	380	730	1,100	1,800	720	1,500

To convert to capacities at 15 psig settings - multiply by 1.130

To convert to capacities at 5 psig settings - multiply by 0.879

Propane Gas Piping Chart I

Sizing Between Single or Second Stage Regulator and Appliance*

Maximum Propane Capacities Listed are Based on 1/2" W.C. pressure drop at 11" W.C. setting. Capacities in 1,000 BTU/hour.

Pipe or								Nominal Pipe Size
Tubing		Tubing Size, O.D. Type L						Schedule 40
Length,	3/8"	1/2"	5/8"	3/4"	7/8"	1-1/8"	1/2"	3/4"	1"	1-1/4"	1-1/2"
Feet
10	39	92	199	329	501	935	275	567	1,071	2,205	3,307
20	26	62	131	216	346	630	189	393	732	1,496	2,299
30	21	50	107	181	277	500	152	315	590	1,212	1,858
40	19	41	90	145	233	427	129	267	504	1,039	1,559
50	18	37	79	131	198	376	114	237	448	913	1,417
60	16	35	72	121	187	340	103	217	409	834	1,275
80	13	29	62	104	155	289	89	185	346	724	1,066
100	11	26	55	90	138	255	78	162	307	630	976
125	10	24	48	81	122	224	69	146	275	567	866
150	9	21	43	72	109	202	63	132	252	511	787
200	8	19	39	66	100	187	54	112	209	439	665
250	8	17	36	60	93	172	48	100	185	390	590

*Data in accordance with NFPA pamphlet NO. 54

Propane Gas Piping Chart II

XIII. CIRCULATING AIR & FILTERS

DUCTWORK - AIR FLOW

Duct systems and register sizes must be properly designed for the CFM and external static pressure rating of the furnace. Design the ductwork in accordance with the recommended methods of “Air Conditioning Contractors of America” Manual D.

Install the duct system in accordance with Standards of the National Board of Fire Underwriters for the Installation of Air Conditioning, Warm Air Heating and Ventilating Systems. Pamphlets No. 90A and 90B.

A closed return duct system must be used, with the return duct connected to the furnace. NOTE: Ductwork must never be attached to the back of the furnace. Flexible joints may be used for supply and return connections to reduce noise transmission. To prevent the blower from interfering with combustion air or draft when a central return is used, a connecting duct must be installed between the unit and the utility room wall. Never use a room, closet, or alcove as a return air chamber.

BOTTOM RETURN AIR OPENING [UPFLOW MODELS]

The bottom return air opening on upflow models utilizes a “lance and cut” method to remove sheet metal from the duct opening in the base pan. To remove, simply press out the lanced sections by hand to expose the metal strips retaining the sheet metal over the duct opening. Using tin snips, cut the metal strips and remove the sheet metal covering the duct opening. In the corners of the opening, cut the sheet metal along the scribe lines to free the duct flanges. Using the scribe line along the duct flange as a guide, unfold the duct flanges around the perimeter of the opening using a pair of seamer pliers or seamer tongs. NOTE: Airflow area will be reduced by approximately 18% if duct flanges are not unfolded. This could cause performance issues and noise issues.

WARNING

EDGES OF SHEET METAL MAY BE SHARP. USE GLOVES AS A PRECAUTION WHEN REMOVING SHEET METAL FROM THE DUCT OPENING.

CUT USING TIN SNIPS

PRESS OUT BY HAND

CUT FOUR CORNERS

AFTER REMOVING SHEET

METAL

SCRIBE LINES OUTLINING

DUCT FLANGES

Duct Flange Cut Outs

When the furnace is used in connection with a cooling unit, the furnace should be installed in parallel with or on the upstream side of the cooling unit to avoid condensation in the heating element. With a parallel flow arrangement, the dampers or other means used to control the flow of air must be adequate to prevent chilled air from entering the furnace and, if manually operated, must be equipped with means to prevent operation of either unit unless the damper is in the full heat or cool position.

When the furnace is installed without a cooling coil, it is recommended that a removable access panel be provided in the outlet air duct. This opening shall be accessible when the furnace is installed and shall be of such a size that the heat exchanger can be viewed for visual light inspection or such that a sampling probe can be inserted into the airstream. The access panel must be made to prevent air leaks when the furnace is in operation.

When the furnace is heating, the temperature of the return air entering the furnace must be between 55°F and 100°F.

FILTERS - READ THIS SECTION BEFORE INSTALLING THE

RETURN AIR DUCTWORK

Filters must be used with this furnace. Discuss filter maintenance with the building owner. Filters do not ship with this furnace, but must be provided by the installer. Filters must comply with UL900 or CAN/ULCS111 standards. If the furnace is installed without filters, the warranty will be voided.

On upflow units, guide dimples locate the side return cutout locations. Use a straight edge to scribe lines connecting the dimples. Cut out the opening on these lines. NOTE: An undersized opening will cause reduced airflow.

Refer to Minimum Filter Area tables to determine filter area requirements.

					UPFLOW
		COOLING AIRFLOW REQUIREMENT (CFM)
		600	800	1000		1200	1400	1600	2000
		600	800	1000		1200	1400	1600	2000
AirflowInput	0453__XA	376*	384	480		576	---	---	---

	0704__XA	---	---	627*		627*	672	768	---
	0704__XA	---	---	627*		627*	672	768	---

	0905__XA	---	---	---		836*	836*	836*	960

	1155__XA	---	---	---		940*	940*	940*	960

					COUNTERFLOW
			COOLING AIRFLOW REQUIREMENT (CFM)
		600		800	1000	1200	1400	1600	2000
		600		800	1000	1200	1400	1600	2000
Input Airflow	0704__XA	---		---	320*	320*	336	384	---

	0905__XA	---		---	---	427*	427*	427*	480

*Minimum filter area dictated by heating airflow requirement.

Permanent Minimum Filter Area (sq. in)

[Based on a 600 ft/min filter face velocity]

					UPFLOW
		COOLING AIRFLOW REQUIREMENT (CFM)

		600	800	1000		1200	1400	1600	2000

AirflowInput	0453__XA	376*	384	480		576	---	---	---

	0704__XA	---	---	564*		564*	672	768
	0704__XA	---	---	564*		564*	672	768

	0905__XA	---	---	---		752*	752*	768	960

	1155__XA	---	---	---		940*	940*	940*	960


					COUNTERFLOW
			COOLING AIRFLOW REQUIREMENT (CFM)

		600		800	1000	1200	1400	1600	2000

Input Airflow	0905__XA	---		---	---	854*	854*	854*	960
	0704__XA	---		---	641*	641*	672	768	---

*Minimum filter area dictated by heating airflow requirement.

Disposable Minimum Filter area (sq. in)

[Based on 300 ft/min filter face velocity]

UPRIGHT INSTALLATIONS

Depending on the installation and/or customer preference, differing filter arrangements can be applied. Filters can be installed in the central return register or a side panel external filter rack kit (upflows). As an alternative a media air filter or electronic air cleaner can be used as the requested filter.

The following figure shows possible filter locations.

	CENTRAL
	RETURN
	GRILLE
FILTER	SIDE RETURN
	EXTERNAL FILTER
	RACK KIT
	(EITHER SIDE)

FILTER

ACCESS

DOOR

FIL

AIR FLOW	RETURN
	DUCT

FILTER

SUPPORT BRACKET (PROVIDED)

FILTER

ILTER

CENTRAL

RETURN

GRILLE

	AIR FLOW
Possible Upright Upflow	Possible Upright
Counterflow

Filter Locations

NOTE: Internal filter retention is not provided on this furnace. If an internal installation is desired, an internal filter retention kit is available as an accessory. Please see your distributor for details.

HORIZONTAL INSTALLATIONS

Filters must be installed in either the central return register or in the return air duct work.

XIV. STARTUP PROCEDURE & ADJUSTMENT

Furnace must have a 115 VAC power supply properly connected and grounded. Proper polarity must be maintained for correct operation. In addition to the following start-up and adjustment items, refer to further information in Section XVI, Operational Checks.

HEAT ANTICIPATOR SETTING

The heat anticipator in the room thermostat must be correctly adjusted to obtain the proper number of cycles per hour and to prevent “overshooting” of the setting. Set the heat anticipator setting to 0.7 amps. Follow the thermostat manufacturer’s instructions on how to adjust the heat anticipator setting.

DRAIN TRAP PRIMING

The drain trap must be primed prior to furnace startup. To prime, fill the drain trap with water. This ensures proper furnace drainage upon startup and prohibits the possibility of flue gases escaping through the drain system.

FURNACE OPERATION

Purge gas lines of air prior to startup. Be sure not purge lines into an enclosed burner compartment.

Check for leaks using an approved chloride-free soap and water solution, an electronic combustible gas detector, or other approved method. Verify that all required kits (propane gas, high altitude, etc.) have been appropriately installed.

FURNACE STARTUP

1.Close the manual gas shutoff valve external to the furnace.

2.Turn off the electrical power to the furnace.

3.Set the room thermostat to the lowest possible setting.

4.Remove the burner compartment door.

NOTE: This furnace is equipped with an ignition device which automatically lights the burner. Do not try to light the burner by hand.

5. Move the furnace gas valve manual control to the OFF

position.

6.Wait five minutes then smell for gas. Be sure check near the floor as some types of gas are heavier than air.

7.If you smell gas after five minutes, immediately follow the instructions on page 4 of this manual. If you do not smell gas after five minutes, move the furnace gas valve manual control to the ON position.

8.Replace the burner compartment door.

9.Open the manual gas shutoff valve external to the furnace.

10.Turn on the electrical power to the furnace.

11.Adjust the thermostat to a setting above room temperature.

12.After the burners are lit, set the thermostat to desired temperature.

FURNACE SHUTDOWN

1.Set the thermostat to the lowest setting.

The integrated control will close the gas valve and extinguish flame. Following a 15 second delay, the induced draft blower will be de-energized. After a 120, 150, 180 or 210-second delay period (field selectable delay OFF [90, 120, 150, 180] plus 30-second ramp down), the circulator blower deenergizes.

2.Remove the burner compartment door and move the furnace gas valve manual control to the OFF position.

3.Close the manual gas shutoff valve external to the furnace.

4.Replace the burner compartment door.

GAS SUPPLY PRESSURE MEASUREMENT

CAUTION

TO PREVENT UNRELIABLE OPERATION OR EQUIPMENT DAMAGE, THE INLET GAS SUPPLY PRESSURE MUST BE AS SPECIFIED ON THE UNIT RATING PLATE WITH ALL OTHER HOUSEHOLD GAS FIRED APPLIANCES OPERATING.

WHITE-RODGERS 36G54 GAS VALVE

The line pressure supplied to the gas valve must be within the range specified below. The supply pressure can be measured at the gas valve inlet pressure boss or at a hose fitting installed in the gas piping drip leg. The supply pressure must be measured with the burners operating. To measure the gas supply pressure, use the following procedure.

Open to	Manometer
Atmosphere	Manometer
Atmosphere	Hose
	Hose
	Outlet	High Fire Regulator
	Outlet	Adjust	Regulator
	Pressure Boss		Vent
		A
			Low Fire
			Regulator Adjust
	Inlet
Pressure Boss		High Fire
		High Fire	Coaxial Coil
Manometer	Coil Terminal (HI)		Coaxial Coil
Manometer	Coil Terminal (HI)		Terminal (M)
			Terminal (M)
	On/Off Switch	Common
		Terminal (C)

White-Rodgers Model 36G54 Connected to Manometer

1.Turn OFF gas to furnace at the manual gas shutoff valve external to the furnace.

2.Connect a calibrated water manometer (or appropriate gas pressure gauge) at either the gas valve inlet pressure boss or the gas piping drip leg.

Gas Line

Gas

Shutoff

Valve

Gas Line

To Furnace

Open To

Atmosphere

Drip Leg Cap

With Fitting

Manometer Hose

Manometer

Measuring Inlet Gas Pressure (Alt. Method) NOTE: If measuring gas pressure at the drip leg, a field supplied hose barb fitting must be installed prior to making the hose connection. If using the inlet pressure boss on the gas valve, then use the 36G Valve Pressure Check Kit, Goodman Part No. 0151K00000S.

3.Turn ON the gas supply and operate the furnace and all other gas consuming appliances on the same gas supply line.

4.Measure furnace gas supply pressure with burners firing. Supply pressure must be within the range specified in the

Inlet Gas Supply Pressure table.

Inlet Gas Supply Pressure

Natural Gas	Minimum: 5.0" w.c.	Maximum:10.0" w.c.
Propane Gas	Minimum: 11.0" w.c.	Maximum:13.0" w.c.

If supply pressure differs from table, make the necessary adjustments to pressure regulator, gas piping size, etc., and/or consult with local gas utility.

5.Turn OFF gas to furnace at the manual shutoff valve and disconnect manometer. Reinstall plug before turning on gas to furnace.

6.Turn OFF any unnecessary gas appliances stated in step 3.

GAS MANIFOLD PRESSURE MEASUREMENT AND ADJUSTMENT

CAUTION

TO PREVENT UNRELIABLE OPERATION OR EQUIPMENT DAMAGE, THE GAS MANIFOLD PRESSURE MUST BE AS SPECIFIED ON THE UNIT RATING PLATE. ONLY MINOR ADJUSTMENTS SHOULD BE MADE BY ADJUSTING THE GAS VALVE PRESSURE REGULATOR.

Only small variations in gas pressure should be made by adjusting the gas valve pressure regulator. The manifold pressure must be measured with the burners operating. To measure and adjust the manifold pressure, use the following procedure.

1.Turn OFF gas to furnace at the manual gas shutoff valve external to the furnace.

2.Turn off all electrical power to the system.

3.Back outlet pressure test screw (inlet/outlet pressure boss) out one turn (counterclockwise, not more than one turn).

4.Attach a hose and manometer to the outlet pressure boss of the valve.

5.Turn ON the gas supply.

6.Turn on power and energize main (M) solenoid. Do not energize the HI solenoid.

7.Measure gas manifold pressure with burners firing. Adjust manifold pressure using the Manifold Gas Pressure table shown below.

8.Remove regulator cover screw from the low (LO) outlet pressure regulator adjust tower and turn screw clockwise to increase pressure, or counterclockwise to decrease pressure.

9.Energize main (M) solenoid as well as the HI terminal.

10.Remove regulator cover screw from the HI outlet pressure regulator adjust tower and turn screw clockwise to increase pressure, or counterclockwise to decrease pressure.

11.Turn off all electrical power and gas supply to the system.

12.Remove manometer hose from outlet pressure boss.

13.Turn outlet pressure test screw in to seal pressure port (clockwise, 7 in-lb minimum).

14.Turn on electrical power and gas supply to the system.

15.Turn on system power and energize valve.

16.Using a leak detection solution or soap suds, check for leaks at pressure boss screw. Bubbles forming indicate a leak. SHUT OFF GAS AND FIX ALL LEAKS IMMEDIATELY.

NOTE: For gas to gas conversion, consult your dealer for appropriate conversion.

	Manifold Gas Pressure
	Gas	Range		Nom inal
Natural	Low Stage	1.6 - 2.2"	w .c.	1.9" w .c.
	High Stage	3.2 - 3.8"	w .c.	3.5" w .c.
Propane	Low Stage	5.7 - 6.3"	w .c.	6.0" w .c.
	High Stage	9.7 - 10.3" w .c.		10.0" w .c.

GAS INPUT RATE MEASUREMENT (NATURAL GAS ONLY)

The gas input rate to the furnace must never be greater than that specified on the unit rating plate. To measure natural gas input using the gas meter, use the following procedure.

1.Turn OFF the gas supply to all other gas-burning appliances except the furnace.

2.While the furnace is operating, time and record one complete revolution of the smallest gas meter dial.

3.Calculate the number of seconds per cubic foot (sec/ft3) of gas being delivered to the furnace. If the dial is a one cubic foot dial, divide the number of seconds recorded in step 2 by one. If the dial is a two cubic foot dial, divide the number of seconds recorded in step 2 by two.

4.Calculate the furnace input in BTUs per hour (BTU/hr). Input equals the sum of the installation’s gas heating value and a conversion factor (hours to seconds) divided by the number of seconds per cubic foot. The measured input must not be greater than the input indicated on the unit rating plate.

EXAMPLE:

Installation’s gas heating (HTG) value: 1,000 BTU/ft3 (Obtained from gas supplier)

Installation’s seconds per cubic foot: 34 sec/ ft3 Conversion Factor (hours to seconds): 3600 sec/hr Input = (Htg. value x 3600) ÷ seconds per cubic foot Input = (1,000 BTU/ft3 x 3600 sec/hr) ÷ 34 sec/ ft3 Input = 106,000 BTU/hr

Minor changes to the input rate may be accomplished through manifold pressure adjustments at the gas valve. Refer to Section XIV, Startup Procedure and Adjustment - Gas Manifold Pressure Measurement and Adjustment for details. NOTE: The final manifold pressure cannot vary by more than ± 0.3” w.c. from the specified setting. Consult your local gas supplier if additional input rate adjustment is required.

5.Repeat steps 2 through 4 on high stage.

6.Turn ON gas to and relight all other appliances turned off in step 1. Be certain that all appliances are functioning properly and that all pilot burners are operating.

TEMPERATURE RISE

Temperature rise must be within the range specified on the unit rating plate. An incorrect temperature rise may result in condensing in or overheating of the heat exchanger. An airflow and temperature rise table is provided in the Product Data Book applicable to your model*. Determine and adjust temperature rise as follows:

1.Operate furnace with burners firing for approximately ten minutes. Ensure all registers are open and all duct dampers are in their final (fully or partially open) position.

2.Place thermometers in the return and supply ducts as close to the furnace as possible. Thermometers must not be influenced by radiant heat by being able to “see” the heat exchanger.

HEAT EXCHANGER

RADIATION "LINE OF SIGHT"

SUPPLY

AIR

TSUPPLY

RISE = TSUPPLY - TRETURN

TRETURN

RETURN

AIR

Temperature Rise Measurement

3.Subtract the return air temperature from the supply air temperature to determine the air temperature rise. Allow adequate time for thermometer readings to stabilize.

4.Adjust temperature rise by adjusting the circulator blower speed. Increase blower speed to reduce temperature rise. Decrease blower speed to increase temperature rise. Refer to Section XIV, Startup Procedure and Adjustment -Circulator Blower Speeds for speed changing details.

CIRCULATOR BLOWER SPEEDS

WARNING

TO AVOID PERSONAL INJURY OR DEATH DUE TO ELECTRICAL SHOCK, TURN OFF POWER TO THE FURNACE BEFORE CHANGING SPEED TAPS.

This furnace is equipped with a multi-speed circulator blower. This blower provides ease in adjusting blower speeds. The Product Data Book applicable to your model* provides an airflow table, showing the relationship between airflow (CFM) and external static pressure (E.S.P.), for the proper selection of heating and cooling speeds. The heating blower speed is shipped set at “B”, and the cooling blower speed is set at “D”. These blower speeds should be adjusted by the installer to match the installation requirements so as to provide the correct heating temperature rise and correct cooling CFM.

Use the CFM LED (green), adjacent to the integrated control module fuse to verify airflow quantity. The green CFM LED blinks once for each 100 CFM of airflow.

1.Determine the tonnage of the cooling system installed with the furnace. If the cooling capacity is in BTU/hr divide it by 12,000 to convert capacity to TONs.

Example: Cooling Capacity of 30,000 BTU/hr. 30,000/12,000 = 2.5 Tons

2.Determine the proper air flow for the cooling system. Most cooling systems are designed to work with air flows between 350 and 450 CFM per ton. Most manufacturers recommend an air flow of about 400 CFM per ton.

Example: 2.5 tons X 400 CFM per ton = 1000 CFM

The cooling system manufacturer’s instructions must be checked for required air flow. Any electronic air cleaners or other devices may require specific air flows, consult installation instructions of those devices for requirements.

3.Knowing the furnace model, locate the high stage cooling air flow charts in the Product Data Book applicable to your model*. Look up the cooling air flow determined in step 2 and find the required cooling speed and adjustment setting.

Example: A *MV90704BXA furnace installed with a 2.5 ton air conditioning system. The air flow needed is 1000 CFM. Looking at the cooling speed chart for *MV90704BXA, find the air flow closest to 1000 CFM. A cooling airflow of 990 CFM can be attained by setting the cooling speed to “C” and the adjustment to “-” (minus).

NOTE: Continuous Fan Speed will be 56% of high stage cooling.

4.Locate the blower speed selection DIP switches on the integrated control module. Select the desired “cooling” speed tap by positioning switches 1 and 2 appropriately. Select the desired “adjust” tap by positioning switches 3 and 4 appropriately. Refer to the following figure for switch positions and their corresponding taps. Turn off power to furnace for a minimum of 10 seconds, allowing motor to reset and recognize new speed selection. Turn on power to furnace. Verify CFM by counting the number of times the green CFM LED blinks.

*NOTE: Please contact your distributor or our website for the applicable product data book referred to in this manual.

	8	7	6	5	4	3	2		1
Cooling
Cooling
Speed
Speed
Tap A								O O
								F		F
								F		F
Cooling	8	7	6	5	4	3	2		1
Cooling
Speed
Speed
Tap B

								O O
								O O
								F N
								F
Cooling	8	7	6	5	4	3	2		1
Cooling
Speed
Speed
Tap C

								O O
								O O
								N F
										F
Cooling *	8	7	6	5	4	3	2		1
Cooling *
Speed
Speed
Tap D

								O O
								O O
								N N


Cooling Speed Taps
(* indicates factory setting)

8 7 6 5 4 3 2 1

Normal*

O O

F F

8 7 6 5 4 3 2 1

+ (Plus) Adjust

O O

F N

8 7 6 5 4 3 2 1

- (Minus) Adjust

O O

N F

Adjust Taps

(* indicates factory setting)

	8	7		6	5	4	3	2	1
Heating
Heating
Speed
Speed
Tap A	O O
	F		F
	F		F
Heating *	8	7		6	5	4	3	2	1
Heating *
Speed
Speed
Tap B

	O O
	O O
	F N
	F
Heating	8	7		6	5	4	3	2	1
Heating
Speed
Speed
Tap C

	O O
	O O
	N F
			F
Heating	8	7		6	5	4	3	2	1
Heating
Speed
Speed
Tap D

	O O
	O O
	N N

Heating Speed Taps (* indicates factory setting)

5.The multi-speed circulator blower also offers several custom ON/OFF ramping profiles. These profiles may be used to enhance cooling performance and increase comfort level. The ramping profiles are selected using DIP switches 5 and 6. Refer to the following figure for switch positions and their corresponding taps. Refer to the bullet points below for a description of each ramping profile. Turn OFF power to the furnace for a minimum of 10 seconds, allowing motor to reset and recognize the new profile selection. Turn ON power to the furnace. Verify profile selection by counting the green CFM LED blinks and timing each step of the ramping profile.

•Profile A provides only an OFF delay of one (1) minute at 100% of the cooling demand airflow.

100% CFM	100% CFM
OFF	OFF

Cooling 1 min

Demand

•Profile B ramps up to full cooling demand airflow by first stepping up to 50% of the full demand for 30 seconds. The motor then ramps to 100% of the required airflow. A one (1) minute OFF delay at 100% of the cooling airflow.

	100% CFM	100% CFM
OFF	50% CFM	OFF
	1/2 min	1 min

Cooling Demand

•Profile C ramps up to 82% of the full cooling demand airflow and operates there for approximately 7 1/2 minutes. The motor then steps up to the full demand airflow. Profile C also has a one (1) minute 100% OFF delay.

82% CFM100% CFM100% CFM

OFF

7 1/2 min				1 min
7 1/2 min				1 min

Cooling Demand

•Profile D ramps up to 50% of the demand for 1/2 minute, then ramps to 82% of the full cooling demand airflow and operates there for approximately 7 1/2 minutes. The motor then steps up to the full demand airflow. Profile D has a 1/ 2 minute at 50% airflow OFF delay.

					82% CFM								100% CFM				50% CFM
					82% CFM								100% CFM				50% CFM
OFF	50% CFM																	OFF




		1/2 min		7 1/2 min													1/2 min
						Cooling Demand




							8	7	6		5		4	3	2	1
			Ramping*


			Profile
			Profile
			Tap A							O O
										F F
										F F
			Ramping				8	7	6		5		4	3	2	1


			Profile
			Profile
			Tap B

										O O
										O O
										F N
										F
			Ramping				8	7	6		5		4	3	2	1


			Profile
			Profile
			Tap C

										O O
										O O
										N F
												F
							8	7	6		5		4	3	2	1
			Ramping
			Ramping
			Profile
			Profile
			Tap D

										O O
										O O
										N N


					Ramping Profiles
			(* indicates factory setting)

6.Select the heating speed from the heating speed chart in the Product Data Book applicable to your model* for your model. The adjust setting (already established by the cooling speed selection) determines which set of speeds are available. The selected speed must provide a temperature rise within the rise range listed with the particular model.

Example: The *MV90704BXA is set for 990 CFM on cooling, the “ADJUST” is set to “-” (minus). The four heating speeds available are “A Minus”, “B Minus”, “C Minus”, and “D Minus”. “A Minus” has a rise of 56°F for both stages which is within the 30-60°F rise range for the *MV90704BXA. This setting will keep electrical consumption to a minimum. Set the “Heat” speed DIP switches to “A”.

7.Select the desired “heating” speed tap by positioning switches 7 and 8 appropriately. Refer to figure above. Turn off power to furnace for a minimum of 10 seconds, allowing

motor to reset and recognize new speed selection. Turn on power to furnace. Verify selected CFM by counting the green CFM LED blinks.

In general lower heating speeds will: reduce electrical consumption, lower operating sound levels of the blower, and increase the outlet air temperature delivered to the home. The speeds available allow the blower performance to be optimized for the particular homeowner’s needs.

BLOWER HEAT OFF DELAY TIMINGS

The integrated control module provides a selectable heat off delay function. The heat off delay period may be set to 90, 120, 150, 180 seconds using the DIP switches or jumper provided on the control module. The delay is factory shipped at 150 seconds but may be changed to suit the installation requirements and/or homeowner preference. Refer to the following figures for switch positions and corresponding delay times.

	3	Heat Off


ON	2	Delay


		90 Seconds
ON	1	90 Seconds
ON	1	Heat Off


	3


ON	2	Delay
ON	2	Delay
OFF	1	120 Seconds
		120 Seconds
		Heat Off *


	3
	3
OFF	2	Delay
OFF	2	Delay
ON	1	150 Seconds
		150 Seconds



		Heat Off
	3
	3
OFF	2	Delay
OFF	2	Delay
OFF	1	180 Seconds
OFF	1	180 Seconds

Heat Off Delay

(* indicates factory setting)

Heat Off Delay Switches

XV. NORMAL SEQUENCE OF OPERATION

POWER UP

The normal power up sequence is as follows:

•115 VAC power applied to furnace.

•Integrated control module performs internal checks.

•Integrated control module flashes LED one time.

•Integrated control module monitors safety circuits continuously.

•Furnace awaits call from thermostat.

HEATING MODE

The normal operational sequence in heating mode is as follows:

•R and W1 (or R and W1/W2) thermostat contacts close, initiating a call for heat.

•Integrated control module performs safety circuit checks.

•Induced draft blower is energized on high speed for a 10second prepurge. Humidifier terminals are energized with induced draft blower.

•Induced draft blower steps to low speed following prepurge. Low stage pressure switch contacts are closed.

•Igniter warm up begins upon step to low speed and presence of closed low stage pressure switch contacts.

•Gas valve opens at end of igniter warm up period, delivering gas to burners and establishing flame.

•Integrated control module monitors flame presence. Gas valve will remain open only if flame is detected.

•If the thermostat call is for low heat, gas valve and induced draft blower will continue on low stage. If the call is for high heat, the gas valve and induced draft blower will change to high stage.

•Circulator blower is energized on heat speed following a fixed thirty second blower on delay. The circulator blower requires thirty (30) seconds to ramp up to full speed. Electronic air cleaner terminals are energized with circulator blower.

•Furnace is now operating on the specified stage called for by the two-stage thermostat.

•Furnace runs, integrated control module monitors safety circuits continuously.

•If the two-stage thermostat changes the call from low heat to high heat, the integrated control module will immediately switch the induced draft blower, gas valve, and circulator blower to their high stage settings.

•If the two-stage thermostat changes the call from high heat to low heat, the control will immediately switch the induced draft blower and gas valve to their low stage settings. The circulator blower will remain on high heating speed for thirty

(30)seconds before switching to the low heat circulating

speed.

•R and W1 (or R and W1/W2) thermostat contacts open, completing the call for heat.

•Gas valve closes, extinguishing flame.

•Induced draft blower is de-energized following a fifteen second post purge. Humidifier terminals are de-energized.

•Circulator blower continues running for the selected heat off delay period (90, 120, 150 or 180 seconds). The speed run during this period depends on the last heat call provided by the thermostat.

If the last call for heat was a call for low heat, the air circulator motor will run on low heat speed for the duration of the heat off delay period (90, 120, 150 or 180 seconds).

If the last call for heat was a call for high heat, the air circulating motor will run on the high heating speed for thirty (30) seconds and then switch to the low heating speed for the balance of the heat off delay period (60, 90, 120 or 150 seconds).

•Circulator blower and electronic air cleaner terminals are de-energized.

•Circulator blower ramps down to OFF during the 30 seconds following the heat off delay period.

•Furnace awaits next call from thermostat.

COOLING MODE

The normal operational sequence in cooling mode is as follows:

•R and YLO/G or Y/G thermostat contacts close, initiating a call for cool.

•Integrated control module performs safety circuit checks.

•Outdoor fan and compressor are energized to their appropriate speed.

2. Firmly touch a clean, unpainted, metal surface of the furnaces near the control. Any tools held in a person’s hand during grounding will be discharged.

3. Service integrated control module or connecting wiring following the discharge process in step 2. Use caution not to recharge your body with static electricity; (i.e., do not move or shuffle your feet, do not touch ungrounded objects, etc.). If you come in contact with an ungrounded object, repeat

The pressure switches are normally-open (closed during operation) negative air pressure-activated switches. They monitor the airflow (combustion air and flue products) through the heat exchanger via pressure taps located on the induced draft blower and the coil front cover. These switches guard against insufficient airflow (combustion air and flue products) through the heat exchanger and/or blocked condensate drain conditions.

sis of abnormal function. These circuits are continuously monitored during furnace operation by the integrated control module.

INTEGRATED CONTROL MODULE

The integrated control module is an electronic device which, if a potential safety concern is detected, will take the necessary precautions and provide diagnostic information through an LED.

PRIMARY LIMIT

The primary limit control is located on the partition panel and monitors heat exchanger compartment temperatures. It is a normallyclosed (electrically), automatic reset, temperature-activated sensor. The limit guards against the overheating as a result of insufficient conditioned air passing over the heat exchanger.

AUXILIARY LIMIT

The auxiliary limit controls are located on or near the circulator blower and monitors blower compartment temperatures. They are a normally-closed (electrically), manual-reset sensors. These limits guard against overheating as a result of insufficient conditioned air passing over the heat exchanger.

ROLLOUT LIMIT

The rollout limit controls are mounted on the burner/manifold assembly and monitor the burner flame. They are normally-closed (electrically), manual-reset sensors. These limits guard against burner flames not being properly drawn into the heat exchanger.

PRESSURE SWITCHES

•Circulator blower is energized on the appropriate cool speed at the level and time determined by the selected ramping profile. Electronic air cleaner terminals are energized with circulator blower.

•Furnace circulator blower and outdoor cooling unit run their

•

appropriate speed, integrated control module monitors safety circuits continuously.

R and YLO/G or Y/G thermostat contacts open, completing the call for cool.

Outdoor fan and compressor are de-energized.

Circulator blower continues running during a cool off delay period. The OFF delay time and airflow level are determined by the selected ramping profile.

Electronic air cleaner terminals and circulator blower are de-energized.

Furnace awaits next call from thermostat.

FAN ONLY MODE

The normal operational sequence in fan only mode is as follows:

•

R and G thermostat contacts close, initiating a call for fan. Integrated control module performs safety circuit checks.

Circulator blower is energized on continuous fan speed (56% of high stage cooling) following a five (5) second delay. Electronic air cleaner terminals are energized.

•Circulator blower runs, integrated control module monitors safety circuits continuously.

•

R and G thermostat contacts open, completing the call for fan.

Circulator blower is de-energized. Electronic air cleaner terminals are de-energized.

• Furnace awaits next call from thermostat.	FLAME SENSOR

	XVI. OPERATIONAL CHECKS	The flame sensor is a probe mounted to the burner/manifold as-
	BURNER FLAME	sembly which uses the principle of flame rectification to determine
	BURNER FLAME	the presence or absence of flame.
	The burner flames should be inspected with the burner compart-	XVIII. TROUBLESHOOTING
	ment door installed. A sight glass is provided for inspection pur-	XVIII. TROUBLESHOOTING

	poses. Flames should stable, quiet, soft, and blue (dust may	ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS
	cause orange tips but they must not be yellow). Flames should	NOTE: Discharge body’s static electricity before touching unit. An
	extend directly outward from the burners without curling, floating, or
	lifting off. Flames must not impinge on the sides of the heat ex-	electrostatic discharge can adversely affect electrical components.
	changer firing tubes.	Use the following precautions during furnace installation and ser-
		vicing to protect the integrated control module from damage. By
		putting the furnace, the control, and the person at the same electro-
		static potential, these steps will help avoid exposing the integrated
		control module to electrostatic discharge. This procedure is appli-
		cable to both installed and uninstalled (ungrounded) furnaces.
	Check the burner flames for:	1. Disconnect all power to the furnace. Do not touch the
	Check the burner flames for:	integrated control module or any wire connected to the control
	1. Good adjustment
	2. Stable, soft and blue	prior to discharging your body’s electrostatic charge to
	3. Not curling, floating, or lifting off.	prior to discharging your body’s electrostatic charge to
	3. Not curling, floating, or lifting off.	ground.
		ground.

Burner Flame

XVII. SAFETY CIRCUIT DESCRIPTION

GENERAL

A number of safety circuits are employed to ensure safe and proper furnace operation. These circuits serve to control any potential safety hazards and serve as inputs in the monitoring and diagno-

step 2 before touching control or wires.

DIAGNOSTIC CHART

WARNING

TO AVOID ELECTRICAL SHOCK, INJURY OR DEATH, DISCONNECT ELECTRICAL POWER BEFORE PERFORMING ANY SERVICE OR MAINTENANCE.

Refer to the Troubleshooting Chart at the end of this manual for assistance in determining the source of unit operational problems. The red diagnostic LED blinks to assist in troubleshooting the unit. The number of blinks refers to a specific fault code.

RESETTING FROM LOCKOUT

Furnace lockout results when a furnace is unable to achieve ignition after three attempts. It is characterized by a non-functioning furnace and a one flash diagnostic LED code. If the furnace is in “lockout”, it will (or can be) reset in any of the following ways.

1.Automatic reset. The integrated control module will automatically reset itself and attempt to resume normal operations following a one hour lockout period.

2.Manual power interruption. Interrupt 115 volt power to the furnace for 0 - 20 seconds.

3.Manual thermostat cycle. Lower the thermostat so that there is no longer a call for heat then reset to previous setting. Interrupt thermostat signal to the furnace for 0 - 20 seconds.

NOTE: If the condition which originally caused the lockout still exists, the control will return to lockout. Refer to Section XVIII, Troubleshooting - Diagnostic Chart for aid in determining the cause.

XIX. MAINTENANCE

WARNING

TO AVOID ELECTRICAL SHOCK, INJURY OR DEATH, DISCONNECT ELECTRICAL POWER BEFORE PERFORMING ANY MAINTENANCE. IF YOU MUST HANDLE THE IGNITER, HANDLE WITH CARE. TOUCHING THE IGNITER ELEMENT WITH BARE FINGERS, ROUGH HANDLING, OR VIBRATION COULD DAMAGE THE IGNITER RESULTING IN PREMATURE FAILURE. ONLY A QUALIFIED SERVICER SHOULD EVER HANDLE THE IGNITER.

ANNUAL INSPECTION

The furnace should be inspected by a qualified installer, or service agency at least once per year. This check should be performed at the beginning of the heating season. This will ensure that all furnace components are in proper working order and that the heating system functions appropriately. Pay particular attention to the following items. Repair or service as necessary.

•Flue pipe system. Check for blockage and/or leakage. Check the outside termination and the connections at and internal to the furnace.

•Heat exchanger. Check for corrosion and/or buildup within the heat exchanger passageways.

•Burners. Check for proper ignition, burner flame, and flame sense.

•Drainage system. Check for blockage and/or leakage. Check hose connections at and internal to furnace.

•Wiring. Check electrical connections for tightness and/or corrosion. Check wires for damage.

•Filters.

FILTERS

CAUTION

TO ENSURE PROPER UNIT PERFORMANCE, ADHERE TO THE FILTER SIZES GIVEN IN THE RECOMMENDED MINIMUM FILTER SIZE TABLE OR

PRODUCT DATA BOOK APPLICABLE TO YOUR MODEL*.

MAINTENANCE

Improper filter maintenance is the most common cause of inadequate heating or cooling performance. Filters should be cleaned (permanent) or replaced (disposable) every two months or as required. When replacing a filter, it must be replaced with a filter of the same type and size.

FILTER REMOVAL

Depending on the installation, differing filter arrangements can be applied. Filters can be installed in either the central return register or a side panel external filter rack (upflow only). A media air filter or electronic air cleaner can be used as an alternate filter. Follow the filter sizes given in the Recommended Minimum Filter size table to ensure proper unit performance.

To remove filters from an external filter rack in an upright upflow installation, follow the directions provided with external filter rack kit. To remove internal filters see Internal Filter Removal section. Internal filters are an accessory item and are not included with your furnace. For further details, see your distributor.

HORIZONTAL UNIT FILTER REMOVAL

Filters in horizontal installations are located in the central return register or the ductwork near the furnace.

To remove:

1.Turn OFF electrical power to furnace.

2.Remove filter(s) from the central return register or ductwork.

3.Replace filter(s) by reversing the procedure for removal.

4.Turn ON electrical power to furnace.

MEDIA AIR FILTER OR ELECTRONIC AIR CLEANER REMOVAL

Follow the manufacturer’s directions for service.

BURNERS

Visually inspect the burner flames periodically during the heating season. Turn on the furnace at the thermostat and allow several minutes for flames to stabilize, since any dislodged dust will alter the flames normal appearance. Flames should be stable, quiet, soft, and blue (dust may cause orange tips but they must not be yellow). They should extend directly outward from the burners without curling, floating, or lifting off. Flames must not impinge on the sides of the heat exchanger firing tubes.

INDUCED DRAFT AND CIRCULATOR BLOWERS

The bearings in the induced draft blower and circulator blower motors are permanently lubricated by the manufacturer. No further lubrication is required. Check motor windings for accumulation of dust which may cause overheating. Clean as necessary.

*NOTE: Please contact your distributor or our website for the applicable product data book referred to in this manual.

CONDENSATE TRAP AND DRAIN SYSTEM (QUALIFIED SERVICER

ONLY)

Annually inspect the drain tubes, drain trap, and field-supplied drain line for proper condensate drainage. Check drain system for hose connection tightness, blockage, and leaks. Clean or repair as necessary.

FLAME SENSOR (QUALIFIED SERVICER ONLY)

Under some conditions, the fuel or air supply can create a nearly invisible coating on the flame sensor. This coating acts as an insulator causing a drop in the flame sense signal. If the flame sense signal drops too low the furnace will not sense flame and will lock out. The flame sensor should be carefully cleaned by a qualified servicer using emery cloth or steel wool. Following cleaning, the flame sense signal should be as indicated in the Specifications Sheet.

FLUE PASSAGES (QUALIFIED SERVICER ONLY)

The heat exchanger flue passageways should be inspected at the beginning of each heating season. If necessary, clean the passageways as outlined below.

1.Turn OFF the electrical power and gas supply to the furnace.

2.Disconnect the gas line and remove the burner/ manifold assembly by removing the screws securing the assembly to the partition panel.

3.Disconnect the flue pipe system from the induced draft blower.

4.Remove the induced draft blower and, drain and pressure tap hoses from the recuperator coil front cover.

5.Remove the recuperator coil front cover to expose the coil tubes and turbulators.

6.Remove the recuperator coil turbulators individually by slowly pulling each turbulator forward firmly.

7.Clean the recuperator coil tubes using a long handle wire brush, such as a gun cleaning brush.

8.Clean the primary heat exchanger tubes using a wire brush attached to a length of high grade stainless steel cable, such as drain cleanout cable. Attach a variable speed reversible drill to the other end of the cable. Slowly rotate the cable with the drill and insert it into one of the heat exchanger tubes. While reversing the drill, work the cable in and out several times to obtain sufficient cleaning. Repeat for each tube.

9.Clean residue from furnace using a vacuum cleaner.

10.Replace the parts removed in the previous steps in reverse order.

11.Turn on electrical power and gas to furnace. Check for leaks and proper unit operation.

12.Severe heat exchanger fouling is an indication of an operational problem. Perform the checks listed in Section XIV, Startup Procedure and Adjustments to reduce the chances of repeated fouling.

XX. INTERNAL FILTER REMOVAL

Internal filters are an accessory item and are not included with your furnace. For further details, see your distributor.

BOTTOM RETURN REMOVAL

1.Turn OFF electrical power to furnace.

2.Remove blower compartment door.

3.Push back and up on the wire filter retainer to release it from under the front lip of the furnace basepan.

4.Slide filter forward and out.

5. Replace filter by reversing the procedure.

BLOWER COMPARTMENT REMOVAL

1.Turn OFF electrical power to furnace.

2.Remove blower compartment door.

3.Grasp lower portion of filter and lift up.

Front of Furnace		Front of Furnace

Blower		Blower
Blower		Blower
	ertl Fi

Grab Here

And Lift

4.Angle filter toward the blower until filter clears bottom rail.

5.Lower filter down and pull outward.

Front of Furnace			Front of Furnace

Blower			Blower
Blower			Blower

6. Replace filter by reversing procedure.

XXI. BEFORE LEAVING AN INSTALLATION

•Cycle the furnace with the thermostat at least three times. Verify cooling and fan only operation.

•Review the Owner’s Manual with the homeowner and discuss proper furnace operation and maintenance.

•Leave literature packet near furnace.

XXII. REPAIR & REPLACEMENT PARTS

•When ordering any of the listed functional parts, be sure to provide the furnace model, manufacturing, and serial numbers with the order.

•Although only functional parts are shown in the parts list, all sheet metal parts, doors, etc. may be ordered by description.

•Parts are available from your distributor.

Functional Parts List-
Gas Valve	Blower Motor
Gas Manifold	Blower Wheel
Natural Gas Orifice	Blower Mounting Bracket
Propane Gas Orifice	Blower Cutoff
Igniter	Blower Housing
Flame Sensor	Capacitor

Rollout Limit Switch	Heat Exchanger
Primary Limit Switch	Recuperator Coil
Auxiliary Limit Switch	Coil Front Cover
Pressure Switch	Integrated Control Module
Induced Draft Blower	Transformer
Door Switch

TROUBLESHOOTING CHART

Symptoms of Abnormal	Associated		Fault Description(s)	Possible Causes	Corrective Action	Cautions and Notes
Operation	LED Code2		Fault Description(s)	Possible Causes	Corrective Action	Cautions and Notes
Operation	LED Code2
• Furnace fails to operate.	NONE	• No 115 volt power to		• Manual disconnect switch	• Assure 115 and 24 volt	• Turn power OFF
• Integrated control			furnace, or no 24 volt	OFF, door switch open, or	power to furnace	prior to repair.
module diagnostic LED			power to integrated	24 volt wires improperly	integrated control	• Replace integrated
provides no signal.			control module.	connected or loose.	module.	control module
		• Blown fuse or circuit		• Blown fuse or circuit	• Check integrated control	fuse with 3A
			breaker.	breaker.	module fuse (3A).	automotive fuse.
					Replace if necessary.	• Read precautions
		• Integrated control		• Integrated control module	• Check for possible shorts	in “Electrostatic
			module has an	• Integrated control module	in 115 and 24 volt circuits.	Discharge” section
			internal fault.	has an internal fault.	Repair as necessary.	of manual.
					• Replace bad integrated
					control module.
• LED is steady ON.	ON	• Normal operation.		• Normal operation.	• None.	• Normal operation.
	ON
	CONTINUOUS
	ON
• Furnace fails to operate.		• Furnace lockout due		• Failure to establish flame.	• Locate and correct gas	• Turn power
• Integrated control	1		to an excessive	Cause may be no gas to	interruption.	OFF prior to
module diagnostic LED			number of ignition	burners, front cover	• Check front cover	repair.
is flashing ONE (1) flash.	1 FLASH		“retries” (3 total)1 .	pressure switch stuck	pressure switch
				open, bad igniter or igniter	operation (hose, wiring,
				alignment, improper	contact operation).
				orifices, or coated/oxidized	Correct if necessary.
				or improperly connected	• Replace or realign	• Igniter is
				flame sensor.	• Replace or realign
				flame sensor.	igniter.
					igniter.	fragile, handle
					• Check flame sense	fragile, handle
				• Loss of flame after	• Check flame sense	with care.
				• Loss of flame after	signal. Sand sensor if	• Sand flame
				establishment. Cause may	signal. Sand sensor if
				establishment. Cause may	coated and/or oxidized.
				be interrupted gas supply,	coated and/or oxidized.	sensor with
				be interrupted gas supply,	• Check flue piping for	sensor with
				lazy burner flames	• Check flue piping for	emery cloth.
				(improper gas pressure or	blockage, proper	• See “Vent/Flue
				(improper gas pressure or	length, elbows, and	• See “Vent/Flue
				restriction in flue and/or	length, elbows, and	Pipe” section
				restriction in flue and/or	termination.	Pipe” section
				combustion air piping),	termination.	for piping
				combustion air piping),	• Verify proper induced	for piping
				front cover pressure	• Verify proper induced	details.
				switch opening, or	draft blower perfor-
				improper induced draft	mance.
				blower performance.

• Furnace fails to operate.		•	Pressure switch	• Induced draft blower	• Replace induced draft	• Turn power OFF
• Integrated control	2		circuit is closed.	pressure switch contacts	blower pressure	prior to repair.
module diagnostic LED		•	Induced draft	sticking.	switch.	• Replace pressure
is flashing TWO (2)	2 FLASHES		blower is not	• Shorts in pressure switch		switch with proper
flashes.			operating.	circuit.	• Repair short.	replacement part.

• Induced draft blower runs		•	Pressure switch	• Pressure switch hose	• Inspect pressure	• Turn power
continuously with no	3	•	circuit not closed.	blocked, pinched or	switch hose. Repair, if	OFF prior to
further furnace operation.		•	Induced draft blower	connected improperly.	necessary,	repair.
• Integrated control	3 FLASHES		is operating.	• Blocked flue and/or inlet air	• Inspect flue and/or inlet	• Replace
module diagnostic LED				pipe, blocked drain system,	air piping for blockage,	pressure
is flashing THREE (3)				or weak induced draft	proper length, elbows,	switch with
flashes.				blower.	and termination. Check	proper
					drain system. Correct	replacement
					as necessary.	part.
				• Incorrect pressure switch	• Correct pressure
				• Incorrect pressure switch	switch setpoint or
				setpoint or malfunctioning	switch setpoint or
				setpoint or malfunctioning	contact motion.
				switch contacts.	contact motion.
				switch contacts.	• Tighten or correct
				• Loose or improperly	• Tighten or correct
				• Loose or improperly	wiring connection.
				connected wiring.	wiring connection.
				connected wiring.

1Integrated control module will automatically attempt to reset from lockout after one hour.

TROUBLESHOOTING CHART

Symptoms of Abnormal	Associated	Fault Description(s)	Possible Causes	Corrective Action	Cautions and Notes
Operation	LED Code2	Fault Description(s)	Possible Causes	Corrective Action	Cautions and Notes

• Circulator blower runs		• Primary or auxiliary	• Insufficient conditioned air	• Check filters and	• Turn power OFF
continuously. No furnace	4	limit circuit is open.	over the heat exchanger.	ductwork for blockage.	prior to repair.
operation.			Blocked filters, restrictive	Clean filters or remove
• Integrated control module	4 FLASHES		ductwork, improper	obstruction.	• See Product Data
diagnostic LED is flashing	4 FLASHES		circulator blower speed, or	• Check circulator blower	Book applicable
diagnostic LED is flashing			circulator blower speed, or	• Check circulator blower	Book applicable
FOUR (4) flashes.			failed circulator blower.	speed and performance.	to your model* for
				Correct speed or replace	allowable rise
			• Flame rollout.	blower if necessary.	range and proper
			• Misaligned burners, blocked	• Check burners for proper	circulator speed.
		• Rollout limit circuit is	flue and/or air inlet pipe, or	alignment.	• See “Vent/Flue
		open.	failed induced draft blower.	• Check flue and air inlet	Pipe” section for
			• Loose or improperly	piping for blockage,	piping details.
			connected wiring.	proper length, elbows,
				and termination. Correct
				as necessary.	• Replace pressure
				• Check induced draft	• Replace pressure
				• Check induced draft	switch with proper
				blower for proper	replacement part.
				performance. Replace, if
				necessary.
				• Tighten or correct wiring
• Induced draft blower and			• Short to ground in flame	connection.
• Induced draft blower and		• Flame sensed with	• Short to ground in flame	• Correct short at flame	• Turn power OFF
circulator blower runs	5	no call for heat.	sense circuit.	sensor or in flame	prior to repair.
continuously. No furnace				sensor wiring.
operation.	5 FLASHES		• Lingering burner flame.	• Check for lingering
• Integrated control module			• Lingering burner flame.	• Check for lingering
				flame
				flame
diagnostic LED is flashing			• Slow closing gas valve	• Verify proper operation
FIVE (5) flashes.			• Slow closing gas valve	• Verify proper operation
FIVE (5) flashes.				of gas valve
				of gas valve

• Normal furnace operation.		• Flame sense	• Flame sensor is coated/	• Sand flame sensor is	• Turn power OFF
• Integrated control module		microamp signal is	oxidized.	coated/oxidized.	prior to repair.
diagnostic LED is flashing		low.	• Flame sensor incorrectly	• Inspect for proper sensor	• Sand flame
SEVEN (7) flashes.	7		positioned in burner flame.	alignment.	sensor with
			• Lazy burner flame due to	• Check inlet air piping for	emery clot.
	7 FLASHES		improper gas pressure or	blockage, proper length,	• See “Vent/Flue
			combustion air.	elbows, and termination.	Pipe” section for
				• Compare current gas	piping details.
				pressure to rating plate	• See rating plate
				info. Adjust as needed.	• See rating plate
				info. Adjust as needed.	for proper gas
					for proper gas
					pressure.

• Furnace not operating.		• Problem with	• Improperly connected	• Check and correct wiring	• Turn power OFF
• Integrated control module		igniter circuit.	igniter	from integrated control	prior to repair.
diagnostic LED is flashing	8			module to igniter	• Replace igniter
EIGHT (8) flashes.			• Bad igniter	• Replace bad igniter	with proper silicon
	8 FLASHES		• Poor unit ground	• Check and correct unit	nitride replace-
	8 FLASHES			ground wiring	ment part.
				ground wiring	ment part.
• Furnace operating on		• High stage pressure	• Pressure switch hose blocked,	• Inspect pressure switch hose.	• Turn power OFF
low stage gas with high	9	switch circuit does not	pinched or connected	Repair, if necessary.	prior to repair.
stage induced draft blower	9	close in response to	improperly.	• Inspect flue and/or inlet air	• Replace pressure
• High stage circulator		high stage induced	• Blocked flue and/or inlet air	piping for blockage, proper	switch with proper
blower (temperature, of	9 FLASHES	draft blower operation.	pipe, blocked drain system, or	length, elbows, and terminareplacement part.
conditioned air, lower than			weak induced draft blower.	tion. Check drain system.
typical).			• Incorrect pressure switch	Correct as necessary.
• Integrated control module			setpoint or malfunctioning	• Correct pressure switch
diagnostic LED is flashing			switch contacts.	setpoint or contact motion.
NINE (9) flashes.			• Loose or improperly connected	• Tighten or correct wiring
			wiring.	connection.
• Furnace fails to operate.		• Polarity of 115 volt	• Polarity of 115 volt AC	• Review wiring diagram to	• Turn power OFF
• Integrated control module	C	power is reversed.	power to furnace or	correct polarity.	prior to repair.
diagnostic LED is flashing	C		integrated control module is
SIX (6) flashes.			reversed.	• Verify proper ground.
SIX (6) flashes.	CONTINUOUS		• Poor unit ground.	• Verify proper ground.
	CONTINUOUS		• Poor unit ground.	Correct if necessary.
	FLASHING			• Check and correct wiring.
				• Check and correct wiring.

WIRING DIAGRAM

ID BLOWER

GND

115 VAC/ 1Ø /60 HZ

TWO-STAGE PRESSURE

POWER SUPPLY WITH

SWITCH ASSEMBLY

JUNCTION

HOT

PROTECTION DEVICE

HIGH FIRE

OVERCURRENT

SURFACE

PRESS. SWITCH

IGNITER

WARNING:DISCONNECT

2 CIRCUIT

BOX

-1

PROPERLY POLARIZED

CONNECTOR

SERVICING. WIRING

WH-5

TO UNIT MUST BE

AND GROUNDED.

DISCONNECT

TWO STAGE

FLAME

POWER BEFORE

GAS VALVE

SENSOR