Bard 403293A User Manual

IMPORTANT

Installers' Information Manual, Users' Information Manual, Wiring Diagram, Parts List and Warranty are inside or attached and should be read before the Installation is started or before service is attempted.

After factory final assembly, this furnace has been dielectrically tested. Operation tests have

been performed on the burners, fan control and blower motor.

- TO THE INSTALLER -

AFFIX THIS PACKET ADJACENT TO

THE FURNACE.

- TO THE OWNER -

RETAIN THIS PACKET AND ITS CONTENTS FOR

FURTHER REFERENCE.

TABLE OF CONTENTS:

INSTALLERS' MANUAL

INSTALLERS' INFORMATION MANUAL GAMA VENTING TABLES ADDENDUM SIDEWALL VENTING ADDENDUM

USER'S MANUAL

(PRINTED IN RED AND BLACK AND INSERTED IN THE CENTER OF THIS PACKET.)

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408320 A

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MANUAL PACKET 403293 A

INSTRUCTION ASSEMBLY 408310 B

COVER ASSEMBLY 406303 A

PARTS

FUNCTIONAL PARTS LIST

The format of this parts list allows you to get the part number quickly. It allows you to easily identify the part and the part number. Propane Conversion Kit and Filter Frames are also listed in the parts list.

If you do not know the part number, find the part illustra

tion to the left and note the illustration number. Locate the

illustration number in the Parts List on the back foldout of this packet Read across the list to locate the part number for the appropriate size furnace.

EXAMPLE: You need an inducer motor relay for a

60,000 BTUH input 1/3 H.P. furnace:

1. Find the inducer motor relay in the illustration and get the illustration number (In this case 13).

2. Go to the table and read down to illustration number 13.

3. Read across the row to find the part number for the 60,000 BTUH input

1/3 H.P.furnace.

Read part number 9043-316.

408360 A

INSTALLERS' MANUAL

To assure both sate and proper operation, please caretully toliow the instructions in this manual to correctly install this new turnace.

ATTENTION, INSTALLER! After installing turnace, give the user:

—Users’ Information Manual —Parts List —Installers’ Information Manual —Warranty Information

ATTENTION, USER! Your furnace installer should give you the above four important documents relating

to your furnace. Keep these as long as you keep your furnace. Pass these documents on to later furnace purchasers or Users'. If any of the four documents is missing or damaged, contact your installer or furnace manufacturer for replacement. For efficient service, please give your furnace model and serial number, listed in Section 1 of your Users’ Information Manual or from your furnace rating plate. Throughout this Installers' Information Manual, we frequently use the word "you" when referring to the person responsible for application, installation and service of your furnace. Please remember to have only qualified service technicians perform these services.

WARNING', Individuals who install this furnace, must have the training and experience necessary to Install gas furnaces. They must also have training and experience necessary to Install related comfort air conditioning appliances. Improper installation could create a hazard, resulting In damage, injury or death.

While we have written these instructions as accurately and thoroughly as possible, they may not cover every system variation or contingency. Also, questions of interpretation may arise. For more information, solutions to particular problems or clarification, contact your focal distributor or the manufacturer. See the furnace rating plate for who to contact.

Furnace installation must follow all applicable NATIONAL, STATE and LOCAL CODES.

UPFLOW

ELECTRONIC IGNITION INDUCED DRAFT FURNACE

WARNING: FOR YOUR SAFETY, 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 THE BUILDING; — IMMEDIATELY CALL YOUR GAS SUPPLIER FROM A NEIGHBOR'S PHONE; FOLLOW GAS

SUPPLIER'S INSTRUCTIONS;

— IF YOU CANNOT REACH GAS SUPPLIER, CALL FIRE DEPARTMENT.

HORIZONTAL

DOWNFLOW

IMPORTANT SAFETY NOTE: After installing the furnace, show the user how to turn off gas and

electricity to furnace. Point out control and switch locations for turning off gas and electricity. Go over Sections 4 and 6 of Users' Information Manual and Section 29 in this manual with user. Make sure user understands the importance of following all safety precautions.

920101

404200 A

SECTION

_________________________

TABiE Of CONTENTS

____________________________________

PAPE

SECTION 1 SECTION SECTION 3 SECTION 4 SECTION 5 SECTION 6 SECTION

SECTION 8 SECTION 9 SECTION

10 SECTION 11 SECTION 12 SECTION SECTION

14 SECTION 15 SECTION SECTION

SECTION

18 SECTION 19

SECTION 20

SECTION 21

SECTION 22 SECTION

SECTION 24 SECTION 25 SECTION 26 SECTION 27 SECTION

SECTION 29 SECTION 30

PREPARING TO INSTALL FURNACE..............................................................................................................................2

IMPORTANT SAFETY RULES..........................................................................................................................................3

MEETING CODES.............................................................................................................................................................3

DETERMINING BEST FURNACE LOCATION..................................................................................................................3

IDENTIFYING FURNACE DIMENSIONS. SPECIFICATIONS, AND POSITION..............................................................4

ALLOWING FOR CLEARANCES.......................................................................................................................................7

SUSPENDING FURNACE.................................................................................................................................................8

PROVIDING FOR COMBUSTION AND VENTILATION AIR........................................................................................... 9

PROVIDING FOR PROPER VENTING

......

...........................................................................

-........................................13

TOOLS NEEDED FOR INSTALLATION..........................................................................................................................17

INSTALLING GAS PIPING.............................................................................................................................................. 18

INSTALLING ELECTRICAL WIRING.............................................................................................................................. 19

FOLLOWING FIELD WIRING DIAGRAMS......................................................................................................................19

ADJUSTING ROOM THERMOSTAT HEAT ANTICIPATOR...........................................................................................19

SEQUENCE OF OPERATION.........................................................................................................................................20

INSTALLING DUCTWORK..............................................................................................................................................20

SELECTING AND INSTALLING FILTER FRAMES.........................................................................................................23

CHECKING BEFORE STARTING FURNACE.................................................................................................................25

ADJUSTING PILOT..........................................................................................................................................................25

ADJUSTING MANIFOLD PRESSURE.............................................................................................................................26

CHECKING GAS INPUT..................................................................................................................................................27

ORIFICE SIZE..................................................................................................................................................................29

DERATING FOR HIGH ALTITUDES...............................................................................................................................29

ADJUSTING BLOWER SPEED.......................................................................................................................................30

MEASURING DUCT WORK STATIC PRESSURE.........................................................................................................31

MEASURING AIR TEMPERATURE RISE.......................................................................................................................32

CHECKING CONTROLS.................................................................................................................................................33

BLOWER TIMINGS..........................................................................................................................................................33

MAINTAINING FURNACE IN GOOD WORKING ORDER............................................................................................. 34

GETTING OTHER INFORMATION AND PUBLICATIONS.............................................................................................34

SICTION 1 -

PREPARING TO INSTALL TURNACB.

A. Literature.

Review this manual. Users’ Information Manual and Parts List. In particular, see User's Information Manual and Parts List for location and identification of furnace com ponents.

After installing furnace, give this Installers' Information Manual, Users' Information Manual, Warranty and Parts List to user. You may have questions as you install the furnace. If you need help on any of the installation in structions or other matters relating to the furnace, contact the office where you bought the furnace. You may also refer to the furnace rating plate for a contact name.

B, Installation Positions.

1. You may install furnace as-shipped in an upflow or horizontal configuration in one of three positions shown in Figure 1.

VENT

OUTLET

VENT

OUTLET

HORiZONTAL

LEFT SIDE DOWN

TVPE 1

UPftOW

TVPE 2

HORIZONTAL

RIGHT SIDE OOWN

TVPE 3

FIGURE 1

2. You may convert furnace quickly and easily from its as-shipped configuration. After conversion, you can install it as a downflow or horizontal furnace In one of three positions shown in Figure 2.

VENT OUTLET

VENT

OUTLET

G. Provide adequate combustion and ventilation air to space

where furnace is being installed. See Section 8 for more information. Connect this furnace to an approved vent system, venting combustion products outdoors. See Sec

tion 9 for more information.

H. Never test for gas leaks with an open flame. Use a com

mercial soap made specifically for leak detection to check

all connections. See Section 11 for more information.

VENT OUTLET

TYPE 4

TYPE 5

TYPE 6

FIGURE 2

SECTION 2 — IMPORTANT SAFETY RULES* WARNING: Read and exactly follow these rules. Fail

ure to do so could cause Improper furnace operation, resulting In damage, injury or death.

A. Signal words.

To alert you to potential hazards, we use the signal words

"WARNING" and "CAUTION" throughout this

manual. "WARNING" alerts you to situations that could cause serious injury or death. "CAUTION” alerts you to situations that could cause minor or moderate injury or property damage. To help you, we use the words "must" and "should" in this manual. "Must" is mandatory, "Should" is advisory.

6. Use only the type of gas approved for this furnace; refer to furnace rating plate.

WARNING: Only use natural gas In furnaces de

signed for natural gas. Only use Propane (LP) gas for furnaces designed for Propane (L.P) gas. Make sure furnace will operate properly on gas type avail able to user. Do not use this furnace with butane. Using wrong gas could create a hazard, resulting In

damage, injury, or death.

C. DO NOT install this furnace outdoors or in a mobile home,

trailer or recreational vehicle. It is not A.G.A. designcertified for these installations. This furnace is suitable for a home built on site or manufactured home completed

at final site.

D. Carefully choose furnace installation site. DO NOT di

rectly expose furnace to drafts, wind or other outdoor conditions. See Section 8 for more information.

E. DO NOT install furnace in a corrosive or contaminated

atmosphere. Make sure all combustion and ventilation

air requirements are adhered to in addition to local codes

and ordinances. See Section 8 for more information.

F. DO NOT use this furnace during construction when ad

hesives, sealers, and/or new carpets are being installed.

If the furnace must be used during construction, provide

clean outdoor air for combustion and ventilation to ^rnace space. See Section 8 for more information.

I. Always install duct system with furnace. Be sure duct

system has external static pressure within allowable fur nace range. See Sections 16 and 25 for more information.

J. Completely seal supply and return air ducts to furnace

casing. Duct work must run to an area outside furnace air space. Seal duct work wherever it runs through walls, ceilings or floors. See Section 16 for more information.

SECTION 3 — MEETING CODES.

Before installing furnace, make sure you know all applicable codes, National, state and local codes may take precedence over any instructions in this manual. Be sure to consult:

— Authorities having jurisdiction over furnaces; — Local code authorities for information on electrical

wiring, gas piping and vent pipe;

— Current National Fuel Gas Code ANSI Z223.1/NFPA

54:

— Current National Electrical Code ANSI/NFPA 70.

See Section 30 for information on getting copies of these codes.

SECTION 4 — DETERMINING BEST FURNACE LOCATION.

You may install this furnace as an upflow or downflow fur nace in an alcove, attic, basement, closet, garage, or utility room. Install furnace so all electrical components are pro tected from water.

You may install it as a horizontal furnace in an alcove, garage, attic, basement or crawl space.

Select furnace location to meet all requirements in this manual, making sure to refer to;

— Section 2 for safety rules; — Section 6 for minimum clearances; — Section 7 for furnace suspension; — Section 8 for combustion and ventilation air; — Section 9 for venting: — Section 11 for gas piping;

— Section 12 for electrical wiring; — Section 16 and 25 for duct work; — Section 17 for filters.

Consult local code authorities for additional location require ments.

Locate the furnace close to the chimney/vent and as near the center of the air distribution system as possible. Install furnace as level as possible.

Provide ample space for servicing and cleaning. Location

must allow 30 inches minimum front clearance for service. Always comply with minimum clearances shown on inside of front door. Do not install furnace directly on carpeting, tile or any combustible material other than wood flooring.

NOTE: A combustible floor base, available from manu

facturer, is required for downflow furnace installation on

wood flooring. HAZARDOUS LOCATIONS. When furnace is in a residential garage, it must be installed

so that burners and ignition source are located no less than fS'inches above the floor. Also, furnace should be protected

from physical damage by vehicles. When furnace is in public garages, airplane hangers, or other

buildings having hazardous atmospheres, install unit in ac cordance with recommended good practice requirements of the National Fire Protection Association, Inc. See Section 30.

SECTION 5 — IDENTIFYING FURNACE DI

MENSIONS, SPECIFICATIONS, AND POSITION.

2, Furnace as-shipped position may be converted to a

downflow furnace by following instructions in B. be low. Once conversion is complete, furnace may be installed as a downflow furnace. Furnace may also then be installed as a horizontal on its right or left side. See Figure 2.

WARNING: Do not install furnace on its back. Doing so could cause a fire, resulting In damage, injury or death.

See Figure 3 for dimensional drawings and specification table. B. Converting furnace from as-shipped configuration.

READ ALL INSTRUCTIONS THOROUGHLY BEFORE STARTING CONVERSION.

NOTE: Start conversion with furnace on its back.

A. A unique feature of this furnace is that it may be installed

as an upflow furnace, horizontal furnace, or downflow

furnace (minor conversion required).

1. Furnace as-shipped is an upflow furnace. Furnace may be installed in this position or may be installed as a horizontal on its right or left side without any conversion. See Figure 1.

BTUH* INPUT

40,000 40,000 1/3 3" 60,000 1/4 4"

60.000 1/3 4" 60,000 80,000 80,000 60,000

80,000 3/4 4" 100,000 1/3 4" 100,000 100,000 3/4 4" 120,000 1/2 5" 120,000 140,000 3/4 5" 140,000 3/4

'See Furnace rating plate located on blower door.

MOTOR*

H.P.

1/4

1/2 4“ 1/4 1/3 1/2

1/2

3/4

VENT

DIAMETER

4" 4" 4"

5' 5'

FURNACE

WIDTH

14-1/2 14-1/2 14-1/2 14-1/2 12-7/8" 17-1/2 14-1/2 14-1/2 17-1/2 20-1/2 13-7/8" 18-15/16" (2) 10-4 17-1/2 15-7/8" 15-15/16" 17-1/2 20-1/2 20-1/2 18-7/8" 18-15/16" 20-1/2 23-1/2 21-7/8" 21-15/16" 23-1/2

RETURN AIR SIZE

13- 23 /3 2" X B

WARNING: When servicing controls, all wires must be labeled prior to disconnection. Mlswlring can cause improper operation resulting In damage, Injury, or death.

1. Remove front door. Study components described in conversion. See Figure 4.

SUPPLY AIR SIZE

78-1S/16'* X C

12-7/8" 12-15/16" 10-4 50-80 12-7/8* 12-15/16" 10-6

12-7/8" 12-15/16" 15-7/8" 15-15/16" 10-8

12-7/8" 12-15/16* 12-7/8" 12-15/16" 10-6 15-7/8" 15-15/16*

15-7/8" 15-15/16* 10-8 18-7/8"

18-7/8" 18-15/16" (2) 10-4 21-7/8"

12-15/16" 10-6 45-75

18-15/16"

21-15/16*

BLOWER

WHEEL

SIZE

10-4 45-75

10-4

10-8 50-80 10-6 55-85 1245

(2) 10-4

10-8

(2} 10-4 (2) 10-6

TEMP

RISE “F

30-60 1265

35-65 1635 50-80 915 40-70 1235

40-70 1930 50-80 1585

40-70 45-75 1660 45-75 45-75 I860 50-80 2235

CFM

at 0.50“ W.C.

805 850

1260

1645

1950 1965

FURNACE AND DIMENSIONS SPECIRCATIONS

FIGURE 3

AS-SHIPPED CONFIGURATION

FIGURE 4

CONVERTED CONFIGURATION

FIGURE 5

2. Remove two junction box mounting screws from top

plate. Remove four top plate mounting screws. Save all screws. Remove top plate and front duct flange.

3. Disconnect pressure switch wires and inducer motor connector wires.

4. Remove ten screws from the inducer pan; save screws. DO NOT drop screws into heat exchanger openings.

5. Lift inducer pan (with inducer motor and pressure switch stilt in place) about 1/4 inch and tilt left side up to clear casing flanges. Use care not to damage inducer gasket.

NOTE: If possible, decide on direction of gas entry now. Screws to inlet gas valve fitting are accessible. See Section 11.

6. Rotate inducer pan 180 degrees, line up mounting holes and place inducer pan in furnace. Use care not to damage gasket. Replace ten screws in in ducer pan. See Figure 5.

7. Pressure switch wires will no longer reach pressure switch. Remove cable tie around excess length of red/yellow piggyback, blue and purple pressure switch wires.

8. Connect pressure switch wires as follows. Wires are numbered on insulation near terminals.

a. #1 Purple wire to pressure switch, terminal 'C

(Common).

b. #2 Blue wire to pressure switch, terminal 'NC

(Normally Closed).

c. #7 and #8 Red/Yellow piggyback wire to pres

sure switch, terminal 'NO' (Normally Open).

d. Route all pressure switch wires over inducer

motor. e. Reconnect inducer motor connector. f. Replace wire tie in area that prevents wires from

touching hot surfaces.

9. Rgmove four screws that secure bottom plate to cas ing sides. Remove bottom plate; save screws,

10. Install top plate, removed in step 2, where bottom plate was. Secure with four screws. Inducer outlet is now lined up with vent outlet in top plate.

11. Stand up furnace with top plate down. Line front duct

flange up with holes. Place bottom plate on top of duct flange and secure both to casing with four screws.

12. Install junction box on bottom plate using two #6B

screws removed in Step 2. Junction box cover and screw of junction box must face front of furnace.

13. Gasket around flue collar must be in place. If gasket is loose, glue It. If gasket is damaged, replace it.

14. Install a single wall vent pipe section (minimum length 30 inches) (Field-Supplied) to inducer outlet with three

equally spaced screws. This pipe serves as an in ducer outlet extension to which an appropriate vent can be attached. Due to minor variations in vent pipe, available from different manufacturers in the field, and to assure the tightest seal possible, inducer out

let extension is not supplied with furnace. Additional vent pipe sections or Type B1 adapter may then be

added when installing the furnace.

WARNINGS If Inducer outlet extension Is shorter than 30 Inches and chimney or vent becomes blocked, com bustion products may be drawn Into furnace. This could cause nausea or asphyxiation, resulting In Injury or death.

15. Conversion from as-shipped configuration is now complete.

SECTION 6 — ALLOWING FOR CLEARANCES.

WARNING: Do not Install furnace on Its back, doing so could cause a fire, resulting In damage. Injury or death.

Establishing clearances from combustible material.

Locate clearance label on inside of front door. See Figure 6.

WARNINGS Furnace Installation must meet all minimum clearances from combustible material specified In this manual and all applicable codes. Failure to provide re quired clearance between furnace and combustible mate rials could cause a fire, resulting In damage, injury, or death.

WARNINGS This furnace Is A.G.A. design certified for direct Installation on wood flooring for upflow and hori zontal positions.

• Do not install furnace on carpeting, tile or other

combustible material.

• Do not Install furnace In a closet In horizontal

position.

• Do not Install furnace on wood flooring without

special base In downflow position.

MINIMUM INCHES CLEARANCE

CLOSET.

UPFLOW POSITION

• FOR CASING WIDTHS 17 INCHES OR LARGER 0 CLEARANCE MAY BE USED. 18 INCH FRONT CLEARANCE REQUIRED FOR ALCOVE. FOR INSTALLATION ON COMBUSTIBLE FLOORING.

MINIMUM INCHES CLEARANCE CLOSET.

DOWNFLOW POSITJON

• FOR CASING WIDTHS 17 INCHES OR LARGER 0 CLEARANCE MAY BE USED. 18 INCH FRONT CLEARANCE REOUIRED FOR ALCOVE. FOR INSTALLATION ON COMBUSTIBLE FLOORING ONLY WHEN INSTALLED ON SPECIAL BASE PART N0. 4-024400.

MINIMUM INCHES CLEARANCE

• CLEARANCE SHOWN IS FOR AIR INLET AND AIR OUTLET ENDS. VENT MUST MAINTAIN CLEARANCE LISTED ABOVE. FOR INSTALLATION ON COMBUSTIBLE FLOORING.

FOR HORIZONTAL POSITION LINE CONTACT IS ONLY PERMISSIBLE BETWEEN LINES FORMED BY INTERSECTIONS OF TOP AND TWO SIDES OF FURNACE JACKET AND BUILDING JOISTS. STUDS OR FRAMING.

ALL POSITIONS RLOUIRE 30 INCHES FRONT CLEARANCE FOR SERVICE*

TOP SIDES BACK

1 1* 0

1 0 0 2

TOP SIDES BACK

1 1* 0 6 1 0

HORiZONTAL POSmON

TOP SIDES* BACK 1 2* 1

0 COMBUSTIBLE MATERIAL IN ALCOVE OR

FRONT VENT

0 COMBUSTIBLE MATERIAL IN ALCOVE OR

FRONT VENT

0 2

rO COMBUSTIBLE MATERIAL IN ALCOVE.

FRONT VENT 0 18 0 18

6 WHEN USING SINGLE WALL

1 WHEN USING B1

6 WHEN USING SINGLE WALL

1 WHEN USING B1

6 WHEN USING SINGLE WALL

1 WHEN USING B1

40ZB№

MINIMUM CLEARANCES

FROM COMBUSTIBLE MATERIALS

FIGURE 6

1. Upflow Installation. Upflow position is approved for installation on

wood flooring. Typical upflow furnace installa tions are an alcove, attic, basement, closet, ga rage, or utility room. See Figure 6 or furnace clearance plate for minimum clearances to com bustible materials.

2. Horizontal Installation

a. Horizontal position is approved for installa

tion on wood flooring. Typical horizontal fur

nace installations are an alcove, garage, at

tic, or crawl space. See Figure 6 or furnace

clearance plate for minimum clearances to combustible materials.

b. Attic Installation.

Line contact is permissible for furnaces installed in horizontal positions. The in

tersection of furnace top and sides forms

a line. This line may be in contact with

combustible material. However, maintain

a 6" clearance to vent connection unless

Type B1 vent is used. See Figure 7.

Doing any of the above could cause a fire resulting in damage, injury, or death.

TYPICAL ATTIC INSTALLATION

FIGURE 7

When using single wall vent pipe in horizon tal installations, horizontal furnaces with

14.50" high casings must be raised 1" to have 6” clearance to combustible material. See Figure 7.

Furnace installation on combustible flooring is permitted with combustible floor base available from manufacturer. Read installation instructions packaged with combustible floor base to correctly install. See Figure 8.

c. Install a platform under furnace that extends

a minimum 30" in front of furnace. This pro vides a work area and keeps insulating ma terials away from combustion air openings.

Secure platform to ioists.

WARNINOs When a furnace Is installed

In an attic or other Insulated space, keep all insulating materials at least 12" away from furnace and all burner combustion air openings. Failure to do so could cause

nausea, asphyxiation or fire, resulting In damage. Injury, or death.

d. Crawl Space Installation.

Furnace can be hung from floor joists or in

stalled on suitable blocks or pad. Pad or

blocks should provide enough height to re duce potential for water damage. See Sec tion 7.

3. Downflow Installation. You must convert furnace from as-shipped con

figuration for downflow furnace installation. See

Section 5.

DOWNFLOW FLOOR OPENING

FIGURE 8

See Figure 9 for installation diagram on com bustible floor.

4. Service Clearance. Allow minimum front clearance of 30 inches for service.

See Figure 6 or inside of front door for minimum service clearance.

SECTION 7 — SUSPENDING FURNACE.

Some installations will require that furnace be suspended from rafters or floor joists.

A common way to do this using threaded rods is shown in

Figure 10. Consider this means when people may walk un derneath furnace. Figure 11 shows another common suspen sion means using pipe strap. Other means that provide ad equate support may be used.

When furnace is not suspended in a crawl space, elevate furnace off ground to avoid water damage and allow for air conditioning coil drain.

Downflow position is approved for installation on non-combustible flooring. Typical downflow fur nace installations are an alcove, attic, closet, basement, garage, or utility room. See Figure 6

or furnace clearance plate for minimum clear

ances to combustible materials.

NOTE: Level furnace from front to back and from left to right within 1M" per four feet.

FURNACE, PLENUM, AND BASE INSTALLED ON A

COMBUSTIBLE FLOOR

FIGURE 9

SICTION S PROVIDING FOR COMBUSTION AND ViNTILATION AIR.

Before you begin installing furnace, pian to provide enough combustion and ventiiation air following:

— Current National Fuel Gas Code ANSI Z223.1/NFPA

54, Section 5;

— Local Code authorities. Refer to Section 31 of this

manual for these codes.

Ventilation is the process of replacing air which is required for furnace operation. The total amount of ventilation air pro vided within structure must equal all requirements of gas ap pliances in the building, plus any air quantities removed by range hoods, exhaust fans, etc.

Another reason to supply fresh outdoor air for combustion and ventilation is that it dilutes contaminants found in indoor air. These contaminants include bleaches, adhesives, clean ing solutions, detergents, solvents, cat litter, spray can pro pellants and most refrigerants.

WARNINDi Furnace and any other fuel-burning appli ances must have enough fresh air for propsr combus tion and ventilation. Lack of adequate combustion and ventilation air could cause nausea or asphyxiation, re

sulting in injury or death.

WARNINOi During construction, do not use air from

inside structure for combustion and ventilation. Vapors

from soma construction adhesives and materials can be come corrosive in the presence of a flame. This could cause failure of heat exchanger or vent system, result

ing in damage. Injury or death.

WARNINO: Combustion and vsntllatlon air that contains

chlorine, fluorine, bromine and Iodine could cause heat exchanger or vent system failure, resulting In damage, Injury or death,

WARNINO: When installing a furnace In an attic or other

insulated space, keep furnace free and clear of all lnsu> lating materials. Make surs all Insulation Is at least 12" away from burner combustion air openings and well away from openings into furnace space that supply air for combustion and ventilation. Failure to do this could causa nausea, asphyxiation or fire, resulting In damage, injury or death.

WARNINGS When Installing furnace in an alcove, attic,

basement, closet, garage, or utility room do not store items in front of furnace or In front of closet or utility door which would block combustion air openings to fur* nace. Failure to do this could cause nausea, asphyxia tion or fire, resulting In damags, Injury or death.

DO NOT install furnace where any combustion or ventilation air openings will allow outside air to blow directly against furnace.

WARNINGS Drafts blowing directly against furnace could

cause improper combustion which could cause heat ex changer failure or fire, resulting In damage, Injury or death.

Sufficient air MUST be provided to insure there wilt not be a negative pressure in furnace room or space. In addition, there MUST be a positive seal between furnace and return air duct to avoid pulling air from burner area.

Provide adequate combustion and ventilation air by consider' ing volume of furnace installation space. Use these instruc tions and current National Fuel Gas Code ANSI Z223.1/NFPA 54 to determine whether furnace is in an unoonfined or con fined space.

If ratio is less than 50, installation space is a con

fined space. If ratio is 50 or greater, installation space

is an unconfined space.

B. Installing furnace In confined space.

WARNING: You must provide permanent air open

ings to a conflned furnace installation space from another area as described below. Failure to do ao could result In Inadéquat# combustion and vsntllatlon air. Thsae could cause nausea, asphyxiation or fire, resulting In damage, injury or death.

1. Combustion and ventilation air openings. a. All combustion and ventilation air from inside the

structure.

1. The furnace space must be provided with two permanent openings to an additional

room(s) of sufficient volume so that the combined volume of all spaces meet the cri

teria above for an unconfined space.

The total input of all gas appliances within

the combined space must be considered in

making this determination. See Figure 12.

2. a. Each opening must have minimum free area of one square Inch per 1,000 Btuh per hour of the total combined input rat

ing of all gas appliances within the con

fined furnace space, but not less than

100 square inches. One opening must be within 12 inches of the top and an other opening within 12 inches of the

bottom of the furnace space. See Fig

ure 12.

A. Determining If your space Is confined or unconflned.

Two factors determine whether a furnace installation space is confined or unconfined:

— Volume of installation space; — Total gas input of appliances to be installed in that

space.

To determine which your space is:

1. First calculate furnace installation space volume in cubic feet.

2. Determine combined input rating (BTUH) of all gas appliances in furnace installation space, including furnace input. This is the total combined input rating.

3. Divide total combined input rating by 1,000. Then divide this number into installation space volume.

Here's the formula:

Space Volume

Ratio

Total lnput/1,000

For example:

Total Input

Btuh (square Inches)

40,000-100,000 100

120,000 120 140,000

b. If building is of unusually tight construc

tion, provide a permanent opening di rectly communicating with the outdoors. Opening shall have a minimum free area of one square inch per 4000 Btuh of total input rating for all equipment in the enclosure.

If return air is taken directly from hall way or space next to furnace that com municates with furnace spaces, all air for combustion must come from out doors.

b. All combustion and ventilation air from outdoors.

1. The furnace space must be provided with two permanent air openings directly to the outdoors, or by ducts to the outdoors or spaces (attic or crawl spaces) that freely ac cess the outdoors. These combustion and ventilation openings will give fresh air free access to furnace space for combustion and ventilation. You must also provide air suffi cient for all other gas appliances within fur nace space.

Free Area Per Opening

140

Ducts must freely access outdoors or spaces (attic or crawl spaces) which freely access the outdoors. Well ventilated attics or crawl spaces usually satisfy this requirement.

2. Locate one combustion and ventilation air

operîing within 12" of top of furnace space. Locate another within 12" of bottom of fur nace space.

3. When directly accessing the outdoors, each opening must have a minimum free area of

one square inch per 4,000 Btuh of total combined input rating of all gas appliances within furnace space. See Figure 13A.

4. If combustion air ducts will run vertically, ducts and each opening must have a mini mum free area of one square inch per 4,000 Btuh total combined input rating. You must allow for all gas appliances within the fur nace space. See Figure 13B.

For example:

Required

Total Input

Btuh

40,000 10.0 4

60,000 15.0 5

80,000 100,000 120,000 30.0 7 140,000 35.0

Free Area per Opening

(square inches)

20.0 6

25.0 6

Suggested

Round Pipe

(inches dia.)

5. if combustion air ducts will run horizontally, ducts and each opening must have a minimum free area of one square inch per 2,000 Btuh total combined input rating. You must allow for all gas appliances within the furnace space. See Figure 14.

CHIMNEY OR CAS vent

NOTE: EACH AIR DUCT OPENINO SHALL HAVE A FREE AREA OF NOT LESS THAN ONE SQUARE INCH PER 2.000 BTU PER HOUR OF THE TOTAL INPUT RATInC OF ALL EQUIPMENT IN THE ENCLOSURE

to 25% free area. Assume metal louvers and grilles have 60 to 75% free area. Refer to current National

Fuel Gas Code ANSI Z223.1/NFPA 54.

Example: Furnace is 100,000 Btuh input and is to be installed in a confined space that contains no other gas appliances. Rectangular combustion and ventilation air ducts will run horizontally from outdoors to furnace space.

a. Calculate free area required.

Because combustion and ventilation air ducts run horizontally, allow 2,000 Btuh. See 2b. above.

Furnace Input

Btuh

Free Area Required

2,Q0Q Btuh

per square inch

IF THE EQUIPMENT ROOM IS LOCATED AGAINST AND OUTSIDE WALL ANO THE AIR OPENINGS

COMMUNICATE OIRECTLY WITH THE OUTDOORS. EACH OPENING SHALL HAVE A FREE AfffiA

OF NOT less than one SQUARE INCH PER 4,000 BTU PER HOUR OF THE TOTAL INPUT

RATING OF ALL EQUIPMENT IN THE ENCLOSURE.

EQUIPMENT LOCATED IN CONFINED SPACES; ALL AIR FROM OUTDOORS.

FIGURE 14

For example:

Total input

Btuh

Free Area per Opening

(square Inches)

Round Pipe

(Inches dia.)

40,000 20 6 60,000 30 80,000 40

100,000

50 8 120,000 60 9 140,000 70

6. Ducts which introduce combustion and ventila tion air from outside structure into furnace space,

must have the same cross sectional area as the free area of openings to which they connect. The minimum dimension of rectangular air ducts

shall not be less than 3 inches.

2. Louvers, grilles, and screens. Sometimes, louvers, grilles, or screens cover com

bustion and ventilation air openings. If so, you must provide larger openings than those calculated above. This is necessary because louvers, grilles and screens block and reduce an opening's free area.

Louver, grille and screen manufacturers supply tech nical data on their products, which usually includes

the Tree area." Sizing the openings with louvers,

grille or screen in place will provide minimum free area to furnace space as calculated above. Do not use screen smaller than 1/4" mesh. If you do not know free area, assume that wood louvers have 20

7 8

100,000

50 square inches

2,000

Each opening must have a free area of 50 square inches.

Calculate overall area of openings to give needed

free area once you cover them to keep out rain and other outside elements.

Example: If you will use wood louvers to cover combustion and ventilation air openings and you do not know free area of wood louvers, use 20%, as suggested in ANSI Z223.1/NFPA 54.

100 x Free area

from a) above)

Louver free area

openings expressed

overall area of openings with wood louvers installed

as a percentage

100 x 50

250 square inches

Each of the two combustion and ventilation air openings must have a total area of 250 square inches. This is when wood louvers cover openings

for a 100,000 Btuh input furnace and combustion

and ventilation air ducts run horizontally.

c. Calculate minimum rectangular duct size needed.

If you choose a rectangular duct with the mini mum allowed dimension of 3", the other duct dimension must be at least 16-2/3". This is cal culated by dividing the 50 square inches of free area from a) by 3", with equals 16-2/3".

WARNINGi You must fix combustion and ventila

tion air louvers and grilles In open position or Inter

lock them with furnace operation. Furnace operation

with louvvrs or grilles closed could cause Inadequate combustion or ventilation air, resulting In Injury or death.

C. Installing furnace in unconfIned space.

Refer to current National Fuel Gas Code ANSI 2223.1/ NFPA 54 for more information. This code does not re

quire that you make special provisions for combustion

and ventilation when furnace is in an unconfined space. However, it is always prudent to arrange for combustion and ventilation air as if installation space is confined space.

In the past, infiltration through loose construction pro

vided enough air for combustion and ventilation when

furnace was in an unconfined space. Current construction

methods may now prevent infiltration of air into unconfined space. These current methods include increased insula tion, vapor barriers, tight fitting doors and windows, and weather-stripping.

D. Allowing for exhauet fan operation.

1, When furnace is in a ventilated attic, crawl space,

residertce garage, or outside the heated space, ex haust fan drafts can adversely affect its operation. These drafts can come from kitchens, bathrooms, clothes dryers or anywhere within the heated space.

WARNING: Exhaust fans that blow against fur

nace could cause heat exchanger failure or fire, resulting In damage, Injury, or death.

2. When furnace is in a repair garage or inside the heated space, exhaust fans can adversely affect its

operation. Exhaust fans in kitchens, bathrooms, clothes dryers or anywhere within heated space in crease combustion and ventilation air requirements. This is because exhaust fans reduce the amount of combustion and ventilation air available to the fur nace. A fireplace also reduces amount of combus tion and ventilation air. You must allow for these reductions.

WARNING: You must allow for reduction of air

available for combustion and ventilation by ex haust fans and fireplaces. Failure to do so could result In Inadequate combustion and ventilation sir. This could cause nausea, asphyxiation, or firs, resulting In damage, Injury, or death.

3. Exhaust fan air may contain compounds of chlorine, fluorine, bromine, and iodine. If used for combus tion, this contaminated air will adversely affect fur nace operation.

WARNING: If used for combustion and ventila

tion, contaminated exhaust fan air could cause heat exchanger or vent system failure resulting In damage, Injury, or death.

SICTION 9 —

PROVIDING P

Vent furnace using these instructions and Venting Adden dum. Also, meet requirements of local utilities and other local code authorities. You must connect furnace to a vent or fac tory-built chimney or a suitably sized, constructed and lined

masonry chimney. Vent or factory-built chimney must meet a

recognized standard. Chimney lining method and material

must comply with local requirements. Use corrosion-resistant

material meeting nationally recognized standards for vent construction.

INTING.

WARNING: Inadequate vent or chimney could allow

combustion products to collect In structure, resulting In

Injury or death.

WARNING: Vent this furnace separately from any appli

ance designed to burn solid fuel, particularly wood-burn-

Ing or coal burning appliances. Improper venting could

allow combustion products to collect In structure, result

ing In injury or death. A. Venting category.

The furnaces covered by this manual are design-certified as CATEGORY 1 for venting, CATEGORY 1 furnaces

have non-positive vent static pressure and rely on the beat content of combustion products to vent. You may common vent CATEGORY 1 furnaces.

The furnaces covered in this manual are also designcertified as CATEGORY 3 for venting, only when they are installed with manufacturer specified vent system components and installation practices.

Category 3 gas appliances rely on the heat content of combustion products and mechanical or other means to vent. You may not common vent CATEGORY 3 gas ap pliances.

B. Types of vent systems.

These definitions will help you understand the terms we use.

1. "Vent" and "chimney" refer to open passageways.

These passageways convey vent gases from vent connectors to the outside. Gases begin their final ascent at the vent or chimney. Vents and chimneys usually run vertically or nearly vertical. When they serve only one gas appliance, they are called "dedi cated" vents or chimneys. Whan they serve multiple gas appliances, they are called "common" vents or chimneys.

2. A "vent connector" connects a gas appliance to a

vent or chimney. Vent connectors usually run directly from the furnace draft inducer collar to vent or chim ney. Vent connectors may have vertical and horizon tal runs.

3. A "venting system" is a continuous open passage

way from the draft inducer collar to the outside. Venting systems usually have vent connector(s) and a vent or chimney. Venting systems commonly serve

a single furnace or a single furnace and a water

heater. Other multiple-appliance venting systems are

less common.

C. Design considerations.

1. General considerations. Avoid oversizing furnace for your application. Se

lect a furnace model with a rated heating output close to the calculated heating toad. This extends

the firing period, decreasing the potential for con densate formation in the vent.

a. Too small a vent cannot carry all combustion

products outdoors. Too large a vent will not vent combustion products rapidly enough to avoid potential for condensation. Refer to Venting Ad dendum for correct size vent.

b. Vent height must be a minimum of five feet.

Minimize vent connector horizontal runs to the extent possible for best performance.

c. The designer must consider the building's ori

entation, answering these questions. Will the vent terminate outside the building where its op

eration could be adversely affected by winds? Could any adjacent buildings adversely affect vent operation? Allowing for these factors can

reduce the possibility of downdraft conditions.

b. Use Type B1 vent connectors in or through at

tics, crawl spaces, or other cold areas. Install thimbles that meet local codes when vent con

nectors pass through walls or partitions of com bustible material.

c. Keep vent connectors as short as possible by

locating furnace as dose as practical to vent or chimney. Avoid unnecessary turns or bends which create resistance to

Adding an elbow adds resistance. For example, adding a 6" 90-degree elbow would be the equivalent of adding 20 feet of horizontal 6" pipe. 45-degree elbows have lower resistance than 90degree elbows, and can work for most vent runs.

d. You may increase vent connector diameter to

overcome installation limitations and obtain con

nector capacity equal to furnace input. Make this

increase as close as possible to draft inducer collar, allowing for necessary adapters and fit tings.

e. If you join two or more vent connectors before

they enter the vertical vent or chimney, use cau tion. See Venting Addendum.

flow of vent gases.

d. If your local experience indicates possible con

densation problems, provide for draining and disposal of venting system condensate.

2. Vent sizing. a. Sometimes the horizontal distance from the fur

nace to the vent or chimney is already given;

this is known as the horizontal vent connector

run. The vent or chimney height is also usually

given as is the Btuh input of the gas appliances

served by the vent.

Check these parameters to be sure the venting system will work. Use approved engineering practices, Venting Addendum, these instructions, and Part 7 of current National Fuel Gas Code ANSI Z223.1/NFPA 54. Use vent capacity tables in Venting Addendum to check existing or new vent sizes for CATEGORY 1 furnaces.

b. See Venting Addendum for single appliance

venting and multiple appliance (common) vent

ing. For multi-story installations, refer to current

National Fuel Gas Code ANSI Z223.1/NFPA 54.

c. Minimum vent connector diameter from furnace

to vent or chimney is same as draft inducer col lar.

3. Vent connector. a. Vent connectors must be made of noncombus

tible, corrosion resistant material capable of withstanding vent gas temperatures. They must be thick enough to withstand physical damage

and be accessible for inspection, cleaning and replacement.

f. Do not connect this furnace to any portion of a

vent system which operates under positive pres sure. Positive pressure would result with CAT

EGORY 3 and 4 appliances connected to the

vent.

g. Do not connect vent connector to a chimney flue

serving a fireplace unless you permanently seal

fireplace flue opening.

4. Vertical vent or chimney. a. Vents and chimneys usually extend vertically with

offsets not exceeding 45-degrees. Consider vent pipe runs more than 45'degrees as horizontal runs. Include their length in the total horizontal run.

b. Designer and installer must provide an appropri

ately sized common vent for all appliances con nected to it. See Venting Addendum.

c. Connect this CATEGORY 1 furnace only to vent

systems with other CATEGORY 1 appliances.

WARNING: Do not connect this Category 1

furnace to a vent system used by Category 3 and 4 appliances. Do not connect It to vents with mechanical draft systems operating at positive pressure. Improper venting could al

low combustion products to collect in struc

ture during use, resulting In damage, Injury or death.

5. Chimney. Furnace is suitable for venting into a properly sized

and lined masonry chimney. Consult National Fuel

Gas Code ANSI Z223.1/NFPA 54 for construction details. If chimney is oversized, liner is inadequate

OT evidence of condensate exists, consider using chimney as a pathway for suitably sized Type B1 vent liner. See Figure 15.

FIGURE 15

WARNIN9I Support Type B1 vent liner in ma

sonry chimney. Maintain at least a 1" clearance on all sides to reduce possibility of condensate in vent. Condensate may cause vent to deterio rate allowing combustion products to collect In structure, which could result In injury or death. See Figure 16.

NOTE; For more information on proper chimney in spection and relining procedures, Gas Research In stitute (GRI) has a topical report entitled "Masonry Chimney Inspection and Reiintng". Obtain copies

through American Gas Association (A.G.A.) at

1-800-841-8400.

6. Vent termination. a. Terminate ail verticai vents with a iisted vent

cap or roof assembly unless local codes require otherwise. See vent cap or roof assembly

manufacturer's instructions. Locate vent termi nation (vent cap or roof assembly) in an area

without positive wind pressures or eddy currents.

Eddy currents occur when air swirls over roof peaks. They can cause down-drafts and ad versely affect vent operation. See Figure 17.

FIGURE 16

WAKNINOi Vent liner muet not block opening

where other epplicncee' vent connector* enter chimney. Blocked opening* could cau»* com bustion products to collact In atructur*, r*sutt-

Ing In damag*, Injury or dssth.

WARNINOt Do not uaa unllnad masonry chlm-

naya. Thasa Incraasa risk of condansats forma tion, which may causa chlmnay to datariorata, allowing combustion products to collact In structura, raaulting In damaga. Injury or death.

Some vent terminations or caps protect against eddy currents and down-drafts, Consult their

manufacturer's instructions. Vent terminations or caps should usually be at least the same size as

the vent. They may be larger if the installation

warrants.

b. Vent systems must end at least five feet above

the highest gas appliance connection. Vent pipe must extend at least three feet above the point where it passes through the roof. Vent termina

tion must be at least two feet higher than any

portion of building within ten feet horizontal and vent termination must be at least two feet higher

than roof peaks within ten feet horizontal. See

Figures 18 and 19. Some vent cap manufactur ers offer vent caps that allow reduced clearances.

Consult their Instructions.

D. Installation.

1. Vent connectors. Attach vent connector at draft inducer collar. Make

sure flue gasket is in place providing a seat. Use a minimum of three equally spaced screws around connection. Connect all other vent pipes using three equally spaced screws at each joint. Exception is only when you use Type B1 vent pipe with self locking connections or high temperature plastic pipe.

WARNINGS Unsecured vent pips connections

may loosen. This can allow combustion products

to collact In structura, resulting In Injury or death.

Install vent connectors without any dips or sags. Slope them upward from furnace at least f/4” per foot. To prevent sagging, at each joint support vent connectors and horizontal portions using hinges, straps or equivalent. Seal all connections where vent connectors enter chimney. See Figure 15.

TERMINATION MORE THAN 10 FEET FROM RIDGE

FIGURE 18

TERMINATION 10 FEET OR LESS FROM RIDGE

FIGURE 19

WAftNINGt Failure to properly terminate

vent chimney systems could allow combus tion products to collect In structure, result ing In Injury or death.

c. Terminate venting system at least three feet

above any forced-air building inlet within ten feet. Consider doors, windows and gravity air building inlets. Locate vent termination at least four feet below, four horizontal feet from or one foot above any of these openings.

To avoid blockage, attach vent connector to a ma sonry chimney above the extreme bottom. For in spection ease, use thimble or slip joint to make vent connector removal easy. Firmly attach connector.

Insert all vent connectors into, but not beyond, inside chimney wall.

2. Vertical vent or chimney systems. Install vent materials following their listing terms,

manufacturer's instructions, these instructions and local codes.

A gas vent passing through a roof must extend through roof flashing, jack or thimble. It must termi

nate above roof surface.

E. Existing vent considerations.

Masonry chimneys previously used for venting solid fuel or oil burning equipment should be lined with suitable metal liner. Also provide an accessible clean out per cur rent National Fuel Gas Code ANSI Z223.1/NFPA 54.1.

1. Inspection of vents (chimneys). a. Make sure existing vent or chimney is proper

size and construction for appliances that will use it. The best way to do this is to size as if it were

a new installation. Compare the existing vent to your calculations and make necessary correc tions.

b. Examine vent or chimney cleanouts to make sure

they remain tightly closed when not in use. Make sure vent or chimney passageway is clear and free of obstructions. Look for evidence of con densate or deterioration in vent or chimney. Ei ther of these means an inadequate vent.

c. If you find an inadequate vent or chimney, do

not leave it as is. Repair or replace it. A new vent must meet these instructions and current

National Fuel Gas Code ANSI Z223.1/NFPA 54.

Rabuild a chimney to meet national standards.

MCriON 10 —

TOOLS NIIDID rOR INSTALLATION.

WARNINOi An Inadequate vent or chimney

could allow combuatlon products to collect

In structure, resulting In Injury or death.

d. Sometimes you wiii repiace a common vented

appliance. Make sure common vent size is cor rect for aJl appliances connected to it. If you re move a furnace from a common vent without replacing it, the vent will likely be too large for

remaining appliances. See Venting Addendum.

e. The following steps shall be followed with each

appliance remaining connected to common vent ing system placed in operation, while other ap pliances remaining connected to common venting system are not in operation.

1. Seal any unused openings in common vent ing system.

2. Visually inspect venting system for proper size and horizontal pitch and determine there is no blockage or restriction, leakage, corro sion and other deficiencies which could cause an unsafe condition.

3. Insofar as is practical, close all building doors and windows and all doors between space in which appliances remaining connected to common venting systems are located and other spaces of building. Turn on clothes dryers and any appliances not connected to common venting system. Turn on any ex haust fans, such as range hoods and bath room exhausts so they will operate at maxi mum speed. Do not operate a summer ex haust fan. Close fireplace dampers.

4. Follow Operating Instructions. Place appli ance being inspected in operation. Adjust

thermostat so appliance will operate con tinuously.

5. After it has been determined that each ap pliance remaining connected to common 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.

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

NOTE: Follow current National Fuel Gas Code ANSI 2223.1/NFPA 54 to correct im proper common vent operation. Any common vent resizing must approach minimum size

determined by using Venting Addendum.

ITEM

TOOL DESCRIPTION

HAND TOOLS

1. Carton KnHe

1/4" nut driver

5/16" nut driver

4. 3/8” nut driver

1/4" X 8" straight-

5. blade screwdriver

#2 X 8" Phillips

6. screwdriver

7/16" open end or

7. tubing wrench

2-8" to 14" pipe

wrenches

4" adjustable

9. wrench

10. 8” Channel-lock ptiei^

3/16" Allen

11. wrench

12.

9/64" Allen wrench

SUPPLIES

13. Pipe thread sealant suitable for use with

propane (LP) gas

14.

Bottle of soap solutbn

15.

2-1/8” pipe, manual shutoff valves

TEST INSTRUMENTS

16.

Volt meter with 50 and 150 volt ranges

17. Clamp around ammeter with 10 amp and higher ranges

USED FOR

Furnace removal from carton

Control box cover

Casing and blower

Blower and motor mounts

Wire terminals and manifold pressure adjustment

Components in control box

Main burner orifices

Gas pipe installatbn

Blower wheel set screw tightening

Strain reliefs

Inlet and outlet pressure tap plug removal from gas control

Honeywell gas inlet fitting

Gas pipe and controls

Gas leak checking

Gas control inlet and pressure checking

Electrbal chedt of controls and power supply

Amp draw of motors and control check

18. 10-turn coil of wire to fit on ammeter

19. "U" Tube Water

Manometer with O.V resolution 0“to 15" W.C. range

20. Slope gauge with

0.01” pressure

measurement taps

and tubing, Oto 1"

W.C. range

Room thermostat heat anticipator setting

Gas pressure

measurement

Duct work static pressure

furnace. A convenient way to do this when you have

reduced bottom clearance, is to make drip leg by using a 1/2" to Г NPT Tee, Then install a 1-1/2" long.l” NPT nipple in Tee with a Г NPT pipe cap to complete drip leg.

3. When using black iron gas pipe, install an A.G.A. listed ground joint union between drip leg (sediment

trap) and furnace gas control. Locate ground joint

union to allow easy servicing of burner assembly and gas control.

4. Install gas pipe to inlet side of furnace gas control.

21. 2 thermometers with 1 -degree

Fahrenheit

resolution, 50

degrees F to 175

degrees F range

22. Stop watch

23. Torque wrench (100 inch-pounds)

Temperature rise measured

through lurnace

Gas input meter timing

Proper screw installation

SICTION 11 — INSTALLING GAS PIPING.

Equipment needed: Save time by getting these tools before you start: Item number(s) 8,12.13 and 14 listed in Section

10.

A. Preparation.

Gas piping must meet requirements of current National

Fuel Gas Code ANSI Z223.1/NFPA 54 and local codes.

Size of pipe running to furnace depends on:

• Length of pipe;

• Number of fittings;

• Specific gravity of gas;

• Input requirements fBtuh) of all gas-fired appli ances attached to same main supply line.

Refer to current National Fuel Gas Code ANSI Z223.1/

NFPA 54 for correct gas pipe sizing information.

Plan furnace gas supply piping so it will not interfere with removal of burner assembly, front door or blower door for servicing.

Always use a pipe thread sealant which is resistant to propane (LP) gas solvent action. Sparingly apply sealant to all joints on male threads only, starting two threads back from end.

B. Installation.

1. Install A.G.A. listed manual shut-off valve in gas supply line immediately upstream of furnace. Install

1/8" NPT plugged tapping accessible for test gauge connection. Omit separate, plugged tapping if local area accepts plugged tapping in gas control inlet.

2. After in-line manual shut-off valve, install a drip leg (sediment trap) at gas supply line inlet connection to

WARNINGS Do not thread gas pipe too far. Do

ing so may cause gas control to split or crack

which could cause a gas leak or distortion or

malfunction of gas control. Thasa could causa a firs or explosion resulting in damage, Injury or death.

5. Isolate gas control from gas supply line pressure during leak check. Gas supply line test pressure de

termines how you isolate gas control.

WARNINGS At gas supply line, test pressure

equal to or less than 14 Inches W.C. (1/2 PSI). Isolate gas control from gas supply line by turning furnace gas control knob clockwise > to off posi

tion. Unexpected surges could damage gas con trol causing gas to leak, resulting In firs or ex plosion.

WARNINGS When test pressure la above 14

Inches W.C. (1/2 PSI), completely disconnect gas

control from gas supply line. Failure to Isolate

gas control from test pressure could damage H,

causing gas to leak, resulting in firs or explosion.

6. Use a commercial soap solution made to detect leaks and check all gas piping connections. Bubbles indi

cate gas leakage. Seat all leaks before proceeding.

WARNINGi Never use an open flams to check

for gas leaks. If a leak doss exist, a firs or explo sion could occur, resulting In damage. Injury or

death.

Furnace Gas Entry Piping.

1. See below for gas entry holes and knockouts.

a. A 1-1/4* X 2-3/4" knockout in top plate.

b. A 1-1/2" diameter hole and a 1-1/4" x 1-15/16"

knockout in right side of casing.

c. Two 1-5/8" diameter knockouts in left side of

casing.

2. Changing Gas Control Inlet. You may want to change direction of gas inlet elbow

on gas control. Gas control is shipped for right side gas entry. If you need top entry, remove the fitting. If you need left side gas entry, rotate the fitting 180 degrees.

a. Use 9/64" Hex Allen wrench to remove tour

screws. Check that O-ring is in bottom of gas inlet elbow. Rotate elbow to desired position.

WARNINGi Provide furnace with ita own separate elec

trical circuit, means of circuit protection and electrical disconnect switch. Follow current National Electrical Code ANSI/NFPA 70 and state and local codes. Failure to pro vide these shut-off means could cause electrical shock or fire, resulting In damage, Injury or death.

install proper electrical grounding by attaching grounding source to green wire conductor in furnace junction box. Fol low current National Electrical Code ANSI/NFPA 70 and local codes.

WARNINGS Furnace must have proper electrical ground.

Failure to provide a proper electrical ground could cause electrical shock or fire, resulting In damage. Injury or death.

fICTION 13 — FOLLOWING FIELD WIRING DIAGRAM

HEATING COOUNG

THERMOSTAT MODEL

b. Alternately tighten tour screws to 45 inch pounds

to form a gas tight seal.

c. Use a commercial soap solution made to detect

leaks and check all gas piping connections. Bubbles indicate gas leakage. Seal all leaks be

fore proceeding.

WARNINOi Never use an open flame to

check for gas leaks. If a leak does exist, a

fire or explosion could occur, resulting In

damage, Injury or death.

3. Allowing tor Electronic Air Cleaners.

Some large electronic air cleaners will interfere with incoming gas line. Install air cleaner on opposite fur nace side from gas entry or route gas pipe over top of air cleaner through one of alternate knockouts.

SICTION 12 —

INSTALLING ILICTRICAL WIRING.

Equipment Needed: Save time by getting these tools before

you start: Item number(s) 2 listed in Section 10.

Select a location for room thermostat that is away from sup

ply and return air registers, on draft-free interior wall, and not

near lights, television, direct sunlight, or other heat sources. Install thermostat following field wiring diagram in Section

13. Use electrical wiring that meets current National Electrical Code ANSI/NFPA 70 and local codes. Use Type T (63 de grees C rise) wire or equivalent. See Section 30 for code information.

TO 115V 1 PH 60 H2

POWR SUPPLY PER

LOCAL CODES

FIELD WIRING DIAGRAM

FIGURE 21

NOTE: When replacing original wire, use same type, color, or equivalent wire. Remember to renumber wire ends.

SECTION 14 — ADJUSTING ROOM THERMOSTAT HEAT ANTICIPATOR

Equipment Needed: Save time by getting these tools before you start: Item number(s)5,17 and 18 listed in Section 10.

Wire system using field wiring diagram in Section 13.

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