Bryant 310AAV, 310JAV User Manual

Download

Page 1

310AAV/JAV

Induced-Combustion

4-Way Multipoise Furnace

Installation, Start-up, Operating, and

Service and Maintenance Instructions

-Series A

The 310AAV/JAV 4-Way Multipoise Gas Furnace was designed by Bryant dealers for Bryant dealers. Applications are easy with 4-way multipoise

design, through-the-furnace downflow venting, 13 different venting options, and a door designed for easy service access. An inner blower door is provided for tighter sealing in sensitive applications. The 310AAV/JAV furnace is approved for use with natural or propane gas, and the 310JAV is also approved for use in Low NOx Air Quality Management Districts.

STANDARD FEATURES

• Noise elimination combustion system

• Microprocessor based control center Adjustable heating air temperature rise LED diagnostics and self test feature

• Patented blocked vent safeguard to ensure proper furnace venting

• All models are Chimney Friendly when used with accessory vent kit

• Four-position furnace: upflow, horizontal right, horizontal left,

downflow

Thirteen different vent options

• Heat pump compatible

• Hot surface ignition (HSI)

• Residential installations eligible for consumer financing through the Comfort

Credit Program

• Twinning in Upflow, Downflow and Horizontal

LIMITED WARRANTY

• 20-year warranty on “Super S™” heat exchanger

• 5-year parts warranty on all other components

Catalog No: 5331-007 Form No. II 310A-45-3 12-02

Page 2

Single-Stage

Induced-Combustion

4-Way Multipoise Furnace

Cancels: II 310A-45-2/IM-PG8J-02 II 310A45-3 / IM-PG8J-03

Installation, Start-up, Operating, and

Service and Maintenance Instructions

Series 100/A

NOTE: Read the entire instruction manual before starting the

installation. This symbol → indicates a change since the last issue.

TABLE OF CONTENTS

SAFETY CONSIDERATIONS .....................................................2

INTRODUCTION..........................................................................4

CODES AND STANDARDS........................................................4

Safety.........................................................................................4

General Installation...................................................................4

Combustion and Ventilation Air ..............................................4

Duct Systems ............................................................................5

Acoustical Lining and Fibrous Glass Duct..............................5

Gas Piping and Gas Pipe Pressure Testing..............................5

Electrical Connections ..............................................................5

ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS

PROCEDURE ................................................................................5

LOCATION....................................................................................5

General......................................................................................5

Location Relative to Cooling Equipment ................................6

AIR FOR COMBUSTION AND VENTILATION......................6

Unconfined Space .....................................................................7

Confined Space .........................................................................7

INSTALLATION...........................................................................8

Upflow Installation ...................................................................8

Bottom Return Air Inlet......................................................8

Side Return Air Inlet...........................................................8

Leveling Legs (If Desired)..................................................8

Downflow Installation ..............................................................8

Bottom Return Air Inlet......................................................9

Horizontal Installation ..............................................................9

Suspended Unit Support......................................................9

Platform Unit Support.........................................................9

Roll-Out Protection..............................................................9

Bottom Return Air Inlet......................................................9

Side Return Air Inlet...........................................................9

Filter Arrangement....................................................................9

Air Ducts...................................................................................9

General Requirements .........................................................9

Ductwork Acoustical Treatment .......................................11

Supply Air Connections ....................................................12

Return Air Connections.....................................................13

Gas Piping...............................................................................13

Electrical Connections ............................................................15

115-V Wiring.....................................................................16

J-Box Relocation ...............................................................16

Electrical Connection to J-Box.........................................16

For Power Cord Installation..............................................16

For BX Cable Installation.................................................17

For Power Cord Installation..............................................17

EFFICIENCY RATING CERTIFIED

REGISTERED QUALITY SYSTEM

24-V Wiring.......................................................................17

Accessories ........................................................................17

Venting....................................................................................18

General Venting Requirements .........................................19

Masonry Chimney Requirements......................................19

Appliance Application Requirements ...............................21

Additional Venting Requirements.....................................21

Sidewall Venting ...............................................................21

START-UP, ADJUSTMENT, AND SAFETY CHECK............21

General....................................................................................21

Start-Up Procedures................................................................23

Adjustments.............................................................................23

Check Safety Controls............................................................29

Checklist..................................................................................30

SERVICE AND MAINTENANCE PROCEDURES..................30

Introduction.............................................................................30

General...............................................................................30

Electrical Controls and Wiring .........................................30

Care and Maintenance ............................................................31

Cleaning and/or Replacing Air Filter ...............................32

Blower Motor and Wheel..................................................32

Cleaning Heat Exchanger..................................................33

Sequence of Operation............................................................34

Wiring Diagrams.....................................................................35

Troubleshooting ......................................................................35

CERTIFIED

Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.

Book 1 4 Tab 6a 8a

PC 101 Catalog No. See Cover Printed in U.S.A. Form 58ST-11SI Pg 1 12-02 Replaces: 58ST-2SI

Page 3

33-5/16"

28-7/8"

25-1/4"

22-9/16"

JUNCTION BOX LOCATION

7/8" DIA

ACCESSORY

1/2" DIA THERMOSTAT

WIRE ENTRY

3-15/16"

LEFT HAND GAS

ENTRY

7/8" DIA. ACCESSORY

24-7/8"

4-13/16"

8-7/16"

1-7/16"

ALTERNATE

VENT OUTLET

3-3/4"

1-9/16"

2-9/16"

13/16"

JUNCTION BOX

LOCATION (TYP)

5 PLACES (TYP)

AIRFLOW

19"

OUTLET

1-1/2" DIA. RIGHT HAND GAS ENTRY

1/2" DIA. THERMOSTAT WIRE ENTRY

7/8" DIA. ACCESSORY

13/16"

11/16"

14-7/8"

11/16"

NOTES:

1. Two additional 7/8-in. diameter holes are located in the top plate.

2. Minimum return-air openings ar furnace, based on metal duct. If flex duct is used, see flex duct manufacturer’s recommendations for equivalent diameters. a. For 800 CFM-16-in. round or 14 1/2 x 12-in. rectangle. b. For 1200 CFM-20-in. round or 14 1/2 x 19 1/2-in. rectangle. c. For 1600 CFM-22-in. round or 14 1/2 x 22-in. rectangle. d. For airflow requirements above 1800 CFM, see Air Delivery table in Product Data literature for specific use of single side inlets. The use of both side inlets, a combination of 1 side and the bottom, or the bottom only will ensure adequate return air openings for airflow requirements above 1800 CFM.

21-5/8"

BOTTOM INLET

1-11/16"

5-1/2"

11/16"

22-1/16"

SIDE INLET

1-1/4"

→ Fig. 1—Dimensional Drawing

SAFETY CONSIDERATIONS

Sheet metalparts may have sharp edgesor burrs. Use care and

Improper installation, adjustment, alteration, service, maintenance, or use can cause carbon monoxide poisoning, explosion, fire, electrical shock, or other conditions which may cause personal injury or property damage. Consult a qualified installer, service agency, local gas supplier, or your distributor or branch for information or assistance. The qualified installer or agency must use only factory-authorized and listed kitsor accessories whenmodifying this product. Failure to follow this warning could result in electrical shock, fire, personal injury, or death.

Application of this furnace should be indoors with special

→

attention given to vent sizing and material, gas input rate, air temperature rise, unit leveling, and unit sizing. Improper installation or misapplication of furnace can require excessive servicing or cause premature component failure.

Installing andservicing heating equipment can be hazardous due to

→

gas and electrical components. Only trained and qualified personnel should install, repair, or service heating equipment.

Untrained personnel can perform basic maintenance functions such as cleaning and replacing air filters. All other operations must be performed by trained service personnel. When working on heating equipment, observe precautions in literature, on tags, and on labels attached to or shipped with unit and other safety precautions that may apply.

These instructions cover minimum requirements and conform to existing national standards and safety codes. In some instances, these instructions exceed certain local codes and ordinances, especially those that may not have kept up with changing residential construction practices. We require these instructions as a minimum for a safe installation.

wear appropriate protective clothing and gloves when handling parts. Failure to follow this caution could result in personal injury.

Wear safety glasses and work gloves. Have fire extinguisher available during start-up and adjustment procedures and service calls.

This is the safety-alert symbol

. When you see this symbol on the furnace and in instructions or manuals, be alert to the potential for personal injury.

Understand the signal words DANGER, WARNING, CAUTION, and NOTE. These words are used with the safety-alert symbol. DANGER identifies the most serious hazards which will result in severe personal injury or death. WARNING signifies a hazard which could result in personal injury or death. CAUTION is used to identify unsafe practices which would result in minor personal injury or product and property damage. NOTE is used to highlight suggestions which will result in enhanced installation, reliability, or operation.

1. Use only with type of gas approved for this furnace. Refer to the furnace rating plate.

2. Install this furnace only in a location and position as specified in the “Location” section of these instructions.

3. Provide adequate combustionand ventilation airto the furnace space as specified in “Air for Combustion and Ventilation” section.

4. Combustion products must be discharged outdoors. Connect this furnace to an approved vent system only, as specified in the “Venting” section of these instructions.

5. Never test for gas leaks with an open flame. Use a commercially available soap solution made specifically for the detection of leaks to check all connections, as specified in the “Gas Piping” section.

A02304

Page 4

INSTALLATION

MINIMUM INC HES CLEARANCE TO COMBUSTIBLE CONSTRUCTION

DISTANCE MINIMALE EN POUCES AUX CONSTRUCTIONS COMBUSTIBLES

This forced air furnace is equipped for use with

natural gas at altitudes 0-10,000 ft (0-3,050m).

An accessory kit, supplied by the manufacturer,shall be used to convert to propane gas use or may be required for some natural gas applications.

This furnace is for indoor installation in a building constructed on site.

This furnace is appro ved for UPFLOW, DOWNFLOW, and HORIZONTAL installations.

Cette fournaise est approuvée pour l´inst alla tio n H O R IZ O N TA L E et la circulation d´air VER S LE HAUT et VER S LE BAS .

Clearance arrows do not change with furnace orientation.

Les fléches de dégagement

ne changent pas avec

l´orientation de la fournaise.

This furnace may be installed on com bustible floori ng i n alcove or closet at mini mum clearance as indicated by the diagram from combustible mate rial .

This furnace may be used w ith a Type B-1 Ven t and may be vented i n commo n wit h other gasfired appliances .

Cette fournaise à air pulsé est équipée pour utilisation avec gaz naturel et altitudes comprises entre 0-3,050m (0-10,000 pi).

Utili ser une trousse de conversion, fournie par le fabri cant, pour passer au gaz propane ou pour certaines installations au gaz naturel.

TOP / PLENUM

DESSUS / CHAMBRED’AIR

MIN

Cette fournaise est prévue pour être installée dans un bâtiment construit sur place.

Cette fournaise peut être installée sur un plancher combustible dans une alcôve ou dans un garde-robe en respectant le minimum d'espace libre des matériaux combustibles, tel qu'indiqué sur le dia gramm e ..

Cette fournaise peut être utilisée avec un conduit d´évacuation de Type B-1 ou conn ectée au conduit commu n d´autres appareils à gaz..

BOTTOM

DESSOUS

†

Vent C learance to combustibles:

For Single Wall vents 6 inches (6 po). For Type B-1 vent type 1 inch (1 po).

Dégagement de l´évent avec combu stibles:

Pour conduit d´évacuation à paroi simple 6 po (6 in c h e s ). Pour conduit d´évacuation de Type B-1 1 po (1 inch).

Clearance in inches Dégagem ent (po).

MINIMUM INCHES CLEARA NCE TO COM BUSTIBLE CONSTRUCTION

DOWNFLOW POSITIONS:

Installation on non-com bus tible floors only.

†

For Installation on combustible flooring only when installed on special base, Part No. KGASB 0201ALL,

Co il Assem b ly , Part No . CD5 o r CK5, or Coil Cas in g, Part N o . KCA KC.

18 inches front clearance required for alcove.

Indicates supply or return sides when furnace is in the horizontal position. Line contact only permissible

between lines formed by intersections of the T op and two Sides of the furnace jacket, and building joists, studs or framing.

DÉGAGE MENT MINIMUM EN POUCES AVEC ÉLÉMENTS

DE CONSTRUCTION COM BUSTIB LES

POUR LA POSITION COURANT DESCENDANT:

Pour l´installation sur plancher non com b ustible seulement.

†

Pour l´installation sur un plancher combustible seulement quand on utilise la base sp éciale, pièce

n KGASB 02 0 1 AL L , l ´ensemble serpentin, pièce n CD5 ou CK5, ou le carter de serpentin, pièce

n KCAKC .

Dans une alcôve, on doit maintenir un dégagem ent à l´avant de 18 po (450 mm).

La position indiquée concerne le côté d´entrée ou de retour quand la fournaise est dans la

position horizo ntale.

Le contact n´est permis qu´entre les lignes formées par les intersections du dessus et des

deux côtés de la chem ise de la fournaise et les solives, montant sous cadre de charpente.

→ Fig. 2—Clearances to Combustibles

327590-101 REV. B

30"

MIN

A02330

6. Always install furnace to operate within the furnace’s intended temperature-rise range with a duct system which has an external static pressure within the allowable range, as specified in the “Start-Up, Adjustments, and Safety Check” section. See furnace rating plate.

7. When a furnace is installed so that supply ducts carry air circulated by the furnace to areas outside the space containing the furnace, the return air shall also be handled by duct(s) sealed to the furnace casing and terminating outside the space containing the furnace. See “Air Ducts” section.

8. A gas-fired furnacefor installation ina residential garage must be installed as specified in the warning box in the “Location” section.

9. The furnace is not to be used for temporary heating of buildings or structures under construction.

10. These Multipoise Gas-Fired Furnaces are CSA (A.G.A. and

→

C.G.A.) design-certified for natural and propane gases (see furnace rating plate) and for installation in alcoves, attics, basements, closets, utility rooms, crawlspaces, and garages. The furnace is factory-shipped for use with natural gas. A

Page 5

Table 1—Dimensions (IN.)

UNIT SIZE A B C

045-08/024045 14-3/16 12-9/16 12-11/16 4 104 045-12/036045 14-3/16 12-9/16 12-11/16 4 107 070-08/024070 14-3/16 12-9/16 12-11/16 4 111 070-12/036070 14-3/16 12-9/16 12-11/16 4 115 070-16/048070 17-1/2 15-7/8 16 4 123 090-14/042090 17-1/2 15-7/8 16 4 126 090-16/048090 21 19-3/8 19-1/2 4 139 090-20/060090 21 19-3/8 19-1/2 4 145 110-12/036110 17-1/2 15-7/8 16 4 134 110-16/048110 21 19-3/8 19-1/2 4 145 110-22/066110 21 19-3/8 19-1/2 4 151 135-16/048135 21 19-3/8 19-1/2 4 148 135-22/066135 24-1/2 22-7/8 23 4 163 155-20/060155 24-1/2 22-7/8 23 4 170

*5” or 6” vent connector may be required in some cases.

CSA (A.G.A. and C.G.A.) listed gas conversion kit is required to convert furnace for use with propane gas.

→

11. See Fig. 2 for required clearances to combustibles.

→

12. Maintain a 1-in. clearance from combustible materials to supply air ductwork for a distance of 36 inches horizontally from the furnace. See NFPA 90B or local code for further requirements.

→

13. These furnaces SHALL NOT be installed directly on carpeting, tile, or any other combustible material other than wood flooring. In downflow installations, factory accessory floor base MUST be used when installed on combustible materials and wood flooring. Special base is not required when this furnace is installed on manufacturer’s Coil Assembly Part No. CD5 or CK5, or when Coil Box Part No. KCAKC is used.

INTRODUCTION

→

This 4–way multipoise Category I fan-assisted furnace is CSA (A.G.A. and C.G.A.) design-certified for natural and propane gas and for installation in alcoves, attics, basements, closets, utility rooms, crawlspaces, and garages. A fan-assisted furnace is an appliance equipped with an integral mechanical means to either draw or force products of combustion through the combustion chamber and/or heat exchanger. The furnace is factory-shipped for use with natural gas. A CSA (A.G.A. and C.G.A.) listed gas conversion kit is required to convert furnace for use with propane gas. This furnace is not approved for installation in mobile homes, recreational vehicles, or outdoors.

This furnace is designed for minimum continuous return-air temperature of 60°F db or intermittent operation down to 55°Fdb such as when used with a night setback thermostat. Return-air temperature must not exceed 85°F db. Failure to follow these return-air limits may affect reliability of heat exchangers, motors, and controls. (See Fig. 3.)

For accessoryinstallation details, referto the applicableinstruction literature.

NOTE: Remove all shipping brackets and materials before operating the furnace.

other codes. In absence of local codes, the installation must comply with the national codes listed below and all authorities having jurisdiction.

In the United States and Canada, follow all codes and standards for the following:

Step 1—Safety

• US: National Fuel Gas Code (NFGC) NFPA 54–2002/ANSI Z223.1–2002 and the Installation Standards, Warm Air Heating and Air Conditioning Systems ANSI/NFPA 90B

• CANADA: CAN/CGA-B149.1–and .2–M00 National Standard of Canada. Natural Gas and Propane Installation Codes (NSCNGPIC)

Step 2—General Installation

• US: Current edition of the NFGC and the NFPA 90B. For copies, contact the National Fire Protection Association Inc., Batterymarch Park, Quincy, MA 02269; or for only the NFGC, contact the American Gas Association, 400 N. Capitol, N.W., Washington DC 20001 or www.NFPA.org.

• CANADA: NSCNGPIC. For a copy, contact Standard Sales,

Fig. 3—Return Air Temperature

CSA International, 178 Rexdale Boulevard, Etobicoke (Tor-

CODES AND STANDARDS

Follow allnational and local codes andstandards in addition to these instructions. The installation must comply with regulations

of the serving gas supplier, local building, heating, plumbing, and

onto), Ontario, M9W 1R3 Canada

Step 3—Combustion and Ventilation Air

• US: Section 5.3 of the NFGC, Air for Combustion and Ventilation

VENT

CONN*

SHIP WT. (LB)

A02055

Page 6

THE BLOWER IS LOCATED

TO THE RIGHT OF THE

BURNER SECTION, AND

AIR CONDITIONED AIR IS

DISCHARGED TO THE LEFT .

THE BLOWER IS

LOCATED BELOW THE

BURNER SECTION, AND

CONDITIONED AIR IS

DISCHARGED UPWARD.

THE BLOWER IS

LOCATED ABOVE THE

BURNER SECTION, AND

CONDITIONED AIR IS

DISCHARGED DOWNWARD

Fig. 4—Multipoise Orientations

• CANADA: Part 7 of NSCNGPIC, Venting Systems and Air Supply for Appliances

Step 4—Duct Systems

• US and CANADA: Air Conditioning Contractors Association (ACCA) Manual D, Sheet Metal and Air Conditioning Contractors National Association (SMACNA), or American Society of Heating, Refrigeration, and Air Conditioning Engineers (ASHRAE) 2001 Fundamentals Handbook Chapter 34.

Step 5—Acoustical Lining and Fibrous Glass Duct

• US and CANADA: current edition of SMACNA and NFPA 90B as tested by UL Standard 181 for Class I Rigid Air Ducts

Step 6—Gas Piping and Gas Pipe Pressure Testing

• US: NFGC; chapters 5, 6, 7, and 12 and National Plumbing Codes

→

• CANADA: NSCNGPIC Parts 3, 4, 5, A, B, E and H.

Step 7—Electrical Connections

• US: National Electrical Code (NEC) ANSI/NFPA 70–2002

• CANADA: Canadian Electrical Code CSA C22.1

→

ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS

Electrostatic discharge can affect electronic components. Take precautions during furnace installation and servicing to protect the furnace electronic control. Precautions will prevent electrostatic discharges from personnel and hand tools which are held during the procedure. These precautions will help to avoid exposing the control to electrostatic discharge by putting the furnace, the control, and the person at the same electrostatic potential.

PROCEDURE

THE BLOWER IS

LOCA TED T O THE LEFT

OF THE BURNER SECTION,

AND CONDITIONED AIR IS

DISCHARGED TO THE RIGHT .

A02097

NOT move or shuffle your feet, do not touch ungrounded objects, etc.).

4. If you touch ungrounded objects (and recharge your body with static electricity), firmly touch a clean, unpainted metal surface of the furnace again before touching control or wires.

5. Use this procedure for installed and uninstalled (ungrounded) furnaces.

6. Before removing a new control from its container, discharge your body’s electrostatic charge to ground to protect the control from damage. If the control is to be installed in a furnace, follow items 1 through 4 before bringing the control or yourself in contact with the furnace. Put all used and new controls into containers before touching ungrounded objects.

7. An ESD service kit (available from commercial sources) may also be used to prevent ESD damage.

LOCATION

Step 1—General

Some assembly and modifications are required when used in any of the four applications shown in Figure 4.

This furnace must:

• be installed so the electrical components are protected from water.

• not be installed directly on any combustible material other than wood flooring. Refer to Introduction section.

• be located close to the chimney/vent and attached to an air distribution system. Refer to Air Ducts section.

• be provided ample space for servicing and cleaning. Always comply with minimum fire protection clearances shown on the furnace clearance to combustible label.

1. Disconnect all power to the furnace. Multiple disconnects may

be required. DO NOT TOUCH THE CONTROL OR ANY WIRE CONNECTED TO THE CONTROL PRIOR TO DISCHARGING YOUR BODY’S ELECTROSTATIC CHARGE TO GROUND.

2. Firmly touch theclean, unpainted, metalsurface of the furnace chassis which is close to the control. Tools held in a person’s hand during grounding will be satisfactorily discharged.

3. After touching the chassis, you may proceed to service the control or connecting wires as long as you do nothing to recharge your body with static electricity (for example; DO

Do not install furnace in a corrosive or contaminated atmosphere. Make sure all combustion and circulating air requirements are met, in addition to all local codes and ordinances.

Page 7

This gas furnace may be used for construction heat provided that:

-The furnace is permanently installed with all electrical wiring, piping, venting and ducting installed according to these installation instructions. A return air duct is provided, sealed to the furnace casing, and terminated outside the space containing the furnace. This prevents a negative pressure condition as created by the circulating air blower, causing a flame rollout and/or drawing combustion products into the structure.

-The furnace is controlled by a thermostat. It may not be ″hot wired″ to provide heat continuously to the structure without thermostatic control.

-Clean outside air is provided for combustion. This is to minimize the corrosive effects of adhesives, sealers and other construction materials. It also prevents the entrainment of drywall dustinto combustion air,which can cause fouling and plugging of furnace components.

-The temperature of the return air to the furnace is no less than 55 degrees F, with no evening setback or shutdown. The use of the furnace while the structure is under construction is deemed to be intermittent operation per our installation instructions.

-The air temperature rise is within the rated rise range on the furnace rating plate, and the firing rate has been set to the nameplate value.

-The filters used to clean the circulating air during the construction process must be either changed or thoroughly cleaned prior to occupancy.

-The furnace, ductwork and filters are cleaned as necessary to remove drywall dust and construction debris from all HVAC system components after construction is completed.

DO NOT install the furnace on its back or facing down.

→

Safety control operation will be adversely affected. Never connect return-air ducts to back of furnace. Failure to follow this warning could result in fire, personal injury, or death. (See Fig. 5.)

furnace. If the dampers are manually operated, they must be equipped with means to prevent operation of either unit unless the damper is in the full-heat or full-cool position.

AIR FOR COMBUSTION AND VENTILATION

Provisions for adequate combustion and ventilation air must be provided in accordance with Section 5.3 of the NFGC, Air for Combustion and Ventilation, or applicable provisions of the local building codes.

Canadian installations must be installed in accordance with NSCNGPIC Part 7 and all authorities having jurisdiction.

18-IN. MINIMUM

TO BURNERS

A93044

Fig. 6—Installation in a Garage

When the furnace is installed in a residential garage, the burners andignition sources must be located at least 18inches above the floor. The furnace must be located or protected to avoid damage by vehicles. When the furnace is installed in a public garage, airplane hangar, or other building having a hazardous atmosphere, the furnace must be installed in accordance with the NFGC or NSCNGPIC. (See Fig. 6.)

Air for combustion must not be contaminated by halogen compounds, which include fluoride, chloride, bromide, and iodide. These elements are found in aerosol sprays, detergents, bleaches, cleaning solvents, salts, air fresheners, and other household products.

A02054

Fig. 5—Prohibit Installation on Back

Step 2—Location Relative to Cooling Equipment

The cooling coil must be installed parallel with, or on the downstream side of the unit to avoid condensation in the heat exchangers. When installed parallel with the furnace, dampers or other flow control must prevent chilled air from entering the

All fuel-burning equipment must be supplied with air for fuel combustion. Sufficient air must be provided to avoid negative pressure in the equipment room or space. A positive seal must be made between the furnace cabinet and the return-air duct to prevent pulling air from the burner area and from blocked vent safeguard opening.

→

The operation of exhaust fans, kitchen ventilation fans, clothes dryers, attic exhaust fans or fireplaces could create a NEGATIVE PRESSURE CONDITION at the furnace. Make-up airMUST be providedfor the ventilation devices, in addition to that required by the furnace. Refer to Carbon Monoxide Hazard warning in venting section of these instructions to determine amount of make-up air required.

The requirements for combustion and ventilation air depend upon whether the furnace is located in an unconfined or confined space.

Page 8

Table 2–Minimum Free Area of Combustion Air Opening*

AIR FROM INDOOR

FURNACE

INPUT

(BTUH)

44,000 100 11 4 22 6 14.7 5 66,000 100 16.5 5 33 7 22.0 6

88,000 100 22.0 6 44.0 8 29.3 7 110,000 110 27.5 6 55 9 36.7 7 132,000 132 33 7 66 10 44.0 8 154,000 154 38.5 7 77 10 51.3 8

* Free area shall be equal toor greater than the sumof the areas of all vent connectors in the confined space. Opening area must be increased if other gas appliances in the space require combustion air.

UNCONFINED SPACE

Free Area

of Opening

(Sq In.)

OUTDOOR AIR THROUGH

VERTICAL DUCTS

Free Area of

Opening and Duct

(Sq. In.)

Round Pipe

(in. Dia)

OUTDOOR AIR THROUGH

HORIZONTAL DUCTS

Free Area of

Opening and Duct

(sq In.)

Round Pipe

(in. Dia)

OUTDOOR AIR THROUGH

SINGLE DUCT

Free Area of

Opening and Duct

(Sq In.)

Round Pipe

(In. Dia)

Step 1—Unconfined Space

An unconfined space has a volume of at least 50 cu ft for each 1000 Btuh total input for all appliances (furnaces, clothes dryers, water heaters, etc.) in the space.

For example:

FURNACE

INPUT (BTUH)

44,000 294 66,000 441

88,000 587 110,000 734 132,000 881 154,000 1028

MINIMUM WITH

7–1/2 FT CEILING (SQ. FT.)

If the unconfined space is constructed unusually tight, air for combustion and ventilation must come from either the outdoors or spaces freely communicating with the outdoors. Combustion and ventilation openings must be equivalent to those used for a confined space (defined below). Return air must not be taken from the room unless an equal or greater amount of air is supplied to the room.

Step 2—Confined Space

A confined space has a volume less than 50 cu ft per 1000 Btuh of total input ratings of all appliances installed in that space. A confined space must have provisions for supplying air for combustion, ventilation, and dilution of flue gases using one of the following methods in Table 2 and Fig. 7 and 8.

NOTE: When determining the free area of an opening, the blocking effect of louvers, grilles, and screens must be considered. If the free area of the louver or grille design is unknown, assume wood louvers have a 20 percent free area and metal louvers or grilles have a 60 percent free area. Screens must not be smaller than 1/4-in. mesh. Louvers and grilles must be constructed so they cannot be closed.

The opening size depends upon whether air comes from outside of the structure or an unconfined space inside the structure.

1. Air from inside the structure requires 2 openings (for structures not of unusually tight construction):

a. Each opening must have a minimum free area of not less

than 1 sq in per 1000 Btuh of total input rating for all gas utilization equipment in the confined space, but not less than 100 sq in. The minimum dimension of air openings should be no smaller than 3 in. (See Table 2 and Fig. 7 ).

b. If building construction is unusually tight, a permanent

opening directly communicating with the outdoors shall be provided. (See next section).

AIR

DUCTS

INTERIOR

HEATED

SPACE

AIR DUCTS

* Minimum opening size is 100 sq in. with minimum dimensions of 3 in.

†

Minimum of 3 in. when type-B1 vent is used.

VENT THROUGH ROOF

12″ MAX

1 SQ IN. PER 1000 BTUH* IN DOOR OR WALL

UNCONFINED SPACE

CONFINED

SPACE

6″ MIN (FRONT)

1 SQ IN. PER 1000 BTUH* IN DOOR OR WALL

†

12″ MAX

A02038

Fig. 7—Confined Space: Air for Combustion and

Ventilation from an Unconfined Indoor Space

c. If the furnace is installed on a raised platform to provide a

return-air plenum, and return air is taken directly from the hallway or space adjacent to furnace, all air for combustion must come from outdoors.

2. Air from outside the structure requires 1 of the following: a. If combustion air is taken from outdoors through 2 vertical

ducts, the openings and ducts must have at least 1 sq in. of free area per 4000 Btuh of total input for all equipment within the confined space. (See Fig. 8 and Table 2.)

b. If combustion air is taken from outdoors through 2 hori-

zontal ducts, the openings and ducts must have at least 1 sq in. of free area per 2000 Btuh of total input for all equipment within the confined space. (SeeFig. 8 and Table

2.)

Page 9

DUCTS

OUTDOORS

1 SQ IN. PER 4000

BTUH

12″ MAX

1 SQ IN. PER 2000

BTUH

DUCTS

OUTDOORS

1 SQ IN. PER 2000

BTUH

*Minimum dimensions of 3 in.

NOTE:

AIR

DUCTS

″ MAX

AIR DUCTS

Use any of the following combinations of openings: A & B C & D D & E F & G

VENT THROUGH ROOF

DUCT

OUTDOORS

CONFINED

SP A CE

12″ MAX

1 SQ IN.

BTUH*

1 SQ IN.

BTUH*

1 SQ IN. PER 4000

BTUH

12″ MAX

PER

4000

OUTDOORS

PER 4000

12″ MAX

A02165

Fig. 8—Confined Space: Air for Combustion and

Ventilation from Outdoors

c. If combustion air is taken from the outdoors through a

single opening or duct (horizontal or vertical) commencing within 12 in. of the top of the confined space, the opening and duct must have at least 1 sq in. of free area per 3000 Btuh ofthe total input for all equipment within theconfined space and not less than the sum of the areas of all vent connectors in the confined space. Equipment clearances to the structure shall be at least 1 in. from the sides and back and 6 in. from the front of the appliances. See Table 2 and Fig. 8.

When ducts are used, they must be of the same cross sectional area as the free area of the openings to which they connect. The minimum dimension of ducts must not be less than 3 in.

INSTALLATION

Step 1—Upflow Installation

BOTTOM RETURN AIR INLET These furnaces are shipped with bottom closure panel installed in

bottom return-air opening. Remove and discard this panel when bottom return air is used. To remove bottom closure panel, perform the following:

1. Tilt or raisefurnace and remove2 screws holding bottom filler panel. (See Fig. 9.)

2. Rotate bottom filler panel downward to release holding tabs.

3. Remove bottom closure panel.

4. Reinstall bottom filler panel and screws.

Fig. 9—Removing Bottom Closure Panel

SIDE RETURN AIR INLET These furnaces are shipped with bottom closure panel installed in

bottom return-air opening. This panel MUST be in place when only side return air is used.

→

NOTE: Side return-air openings can be used in UPFLOW and most HORIZONTAL configurations. Do not use side return-air openings in DOWNFLOW configuration.

LEVELING LEGS (IF DESIRED) In upflow position with side return inlet(s), leveling legs may be

used. (See Fig. 10.) Install field-supplied, 5/16 X 1 1/2 in. (max) corrosion-resistant machine bolts, washers and nuts.

NOTE: Bottom closure mustbe used when leveling legs are used. It may be necessary to remove and reinstall bottom closure panel to install leveling legs. To remove bottom closure panel, see Fig.

9. To install leveling legs:

1. Position furnace on its back. Locate and drill a hole in each bottom corner of furnace. (See Fig. 10.)

2. For each leg, install nut on bolt and then install bolt and nut in hole. (Install flat washer if desired.)

3. Install another nut on other side of furnace base. (Install flat washer if desired.)

4. Adjust outside nutto provide desired height, andtighten inside nut to secure arrangement.

5. Reinstall bottom closure panel if removed.

Step 2—Downflow Installation NOTE: For downflow applications, this furnace is approved for

use on combustible flooring when any one of the 3 accessories are used:

• Special Base, KGASB

• Cased Coil Assembly Part No. CD5 or CK5

• Coil Box Part No. KCAKC

1. Determine application being installed from Table 3.

2. Construct hole in floor per Table 3 and Fig. 11.

3. Construct plenum to dimensions specified in Table 3 and Fig.

11.

4. If downflow subbase, KGASB is used, install as shown in Fig.

12. If Coil Assembly Part No. CD5 or CK5 or Coil Box Part No. KCAKC is used, install as shown in Fig. 13.

A02098

Page 10

⁄16″

1 3⁄4″

⁄16″

PLATFORM UNIT SUPPORT Construct working platform at location where all required furnace

clearances are met. (See Fig. 2 and 17.) For furnaces with 1-in. clearance requirement on side, set unit on non-combustible blocks, bricks or angle iron. For crawlspace installations, if the unit is not suspended from the floor joists, the ground underneath unit must be level and the unit set on blocks or bricks.

⁄4″

⁄16″

⁄4″

Fig. 10—Leveling Legs

NOTE: It is recommended that the perforated supply-air duct

flanges be completely folded over or removed from furnace when installing the furnace on a factory-supplied cased coil or coil box. To remove the supply-air duct flange, use wide duct pliers or hand seamers tobend flange back and forthuntil it breaks off. Becareful of sharp edges. (See Fig. 14.)

BOTTOM RETURN AIR INLET

→

These furnaces are shipped with bottom closure panel installed in bottom return-air opening. Remove and discard this panel when bottom return air is used. To remove bottom closure panel, perform the following:

1. Tilt or raisefurnace and remove2 screws holding bottom filler panel. (See Fig. 9.)

2. Rotate bottom filler panel downward to release holding tabs.

3. Remove bottom closure panel.

4. Reinstall bottom filler panel and screws.

Step 3—Horizontal Installation

A02071

ROLL-OUT PROTECTION Provide a minimum 17 3/4″ X22″ piece of sheet metal for roll-out

protection in front of burner area for units closer than 12 inches above the combustible deck or suspended units closer than 12-in. to joists. The sheet metal MUST extend underneath the furnace casing by 1 in. with the door removed.

The bottom closure pan on furnaces of widths 17 1/2 in. and larger may be used for roll-out protection when bottom of furnace is used for return air connection. See Fig. 17 for proper orientation of roll-out shield.

BOTTOM RETURN AIR INLET

→

1. Tilt or raisefurnace and remove2 screws holding bottom filler panel. (See Fig. 9.)

2. Rotate bottom filler panel downward to release holding tabs.

3. Remove bottom closure panel.

4. Reinstall bottom filler panel and screws.

SIDE RETURN AIR INLET

→

These furnaces are shipped with bottom closure panel installed in bottom return-air opening. This panel MUST be in place when only one side return air is used.

Not all horizontal furnaces are approved for side return air

→

connections (See Fig. 20.)

Step 4—Filter Arrangement

Never operate a furnace without a filter or with filter access door removed. Failure to follow this warning could result in fire, personal injury, or death.

Do not install the furnace on its back or hang furnace with control compartment facing downward. Safety control operation will be adversely affected. Never connect return-air ducts to the back of the furnace. Failure to follow this warning could result in fire, personal injury, or death.

The furnace can be installed horizontally in an attic or crawl space on either the left-hand (LH) or right-hand (RH) side. The furnace can be hung from floor joists, rafters or trusses or installed on a platform, non-combustible blocks, bricks or pad.

SUSPENDED UNIT SUPPORT The furnace may be supported under each end with threaded rod,

angle iron or metal plumber’s strap as shown. (See Fig. 15 and 16.) Secure angle iron to bottom of furnace as shown. Heavy-gauge sheet metal straps (plumber’s straps) may be used to suspend the unit from each bottom corner. To prevent screws from pulling out, use2#8x¾-in. screw into the side and2#8x¾-in. screw in the bottom of the furnace casing for each strap. (See Fig. 15 and 16.)

There are no provisions for an internal filter rack in these furnaces. A field-supplied accessory external filter rack is required.

This furnace requires KGAFR0301ALL 1″ external filter rack or a suitable field-supplied substitute, such as the Media Cabinet.

Refer to the instructions supplied with external filter rack for assembly and installation options.

Step 5—Air Ducts

GENERAL REQUIREMENTS The duct system should be designed and sized according to

accepted national standards such as those published by: Air Conditioning Contractors Association (ACCA), Sheet Metal and Air Conditioning Contractors National Association (SMACNA) or American Society of Heating, Refrigerating and Air Conditioning Engineers (ASHRAE) or consult The Air Systems Design Guide- lines reference tables available from your local distributor. The duct system should be sized to handle the required system design CFM at the design external static pressure.

Page 11

PLENUM

OPENING

FURNACE

(OR COIL CASING

WHEN USED)

COMBUSTIBLE

FLOORING

FLOOR

OPENING

A96283

Fig. 11—Floor and Plenum Opening Dimensions

COIL ASSEMBLY

DOWNFLOW

SUBBASE

SHEET METAL

PLENUM

FLOOR

OPENING

A96285

Fig. 12—Furnace, Plenum, and Subbase Installed on

a Combustible Floor

FURNACE

CD5 OR CK5

OR KCAKC

COIL BOX

COMBUSTIBLE

FLOORING

SHEET METAL

OPENING

Fig. 13—Furnace, Plenum, and Coil Assembly or Coil Box Installed on a Combustible Floor

When a furnace is installed so that the supply ducts carry air to areas outside the space containing the furnace, the return air must also be handled by a duct(s) sealed to the furnace casing and terminating outside the space containing the furnace.

Secure ductwork with proper fasteners for type of ductwork used. Seal supply- and return-duct connections to furnace with code approved tape or duct sealer.

PLENUM

FLOOR

A96284

Flexible connections should be used between ductwork and furnace to prevent transmission of vibration. Ductwork passing through unconditioned space should be insulated and sealed to enhance system performance. When air conditioning is used, a vapor barrier is recommended.

Maintain a1-in. clearance from combustible materialsto supply air ductwork fora distance of 36 in. horizontally from thefurnace. See NFPA 90B or local code for further requirements.

Page 12

FURNACE

CASING

WIDTH

14–3/16

17–1/2

24-1/2

Table 3—Opening Dimensions (In.)

APPLICATION

Upflow Applications on Combustible or Noncombustible

Flooring (KGASB subbase not required)

Downflow Applications on Noncombustible Flooring

(KGASB subbase not required)

Downflow applications on combustible flooring (KGASB

subbase required)

Downflow Applications on Combustible Flooring with CD5 or

CK5 Coil Assembly or KCAKC coil box (KGASB subbase

not required)

Upflow Applications on Combustible or Noncombustible

Flooring (KGASB subbase not required)

Downflow Applications on Noncombustible Flooring

(KGASB subbase not required)

Downflow applications on combustible flooring (KGASB

subbase required)

Downflow Applications on Combustible Flooring with CD5 or

CK5 Coil Assembly or KCAKC coil box (KGASB subbase

not required)

Upflow Applications on Combustible or Noncombustible

Flooring (KGASB subbase not required)

Downflow Applications on Noncombustible Flooring

(KGASB subbase not required)

Downflow applications on combustible flooring (KGASB

subbase required)

Downflow Applications on Combustible Flooring with CD5 or

CK5 Coil Assembly or KCAKC coil box (KGASB subbase

not required)

Upflow Applications on Combustible or Noncombustible

Flooring (KGASB subbase not required)

Downflow Applications on Noncombustible Flooring

(KGASB subbase not required)

Downflow applications on Combustible flooring (KGASB

subbase required)

Downflow Applications on Combustible Flooring with CD5 or

CK5 Coil Assembly or KCAKC coil box (KGASB subbase

not required)

PLENUM OPENING FLOOR OPENING

ABCD

12-11/16 21-5/8 13-5/16 22-1/4

12-9/16 19 13-3/16 19-5/8

11-13/16 19 13-7/16 20-5/8

12-5/16 19 13-5/16 20

16 21-5/8 16-5/8 22-1/4

15-7/8 19 16-1/2 19-5/8

15-1/8 19 16-3/4 20-5/8

15-1/2 19 16-1/2 20

19-1/2 21-5/8 20-1/8 22-1/4

19-3/8 19 20 19-5/8

18-5/8 19 20-1/4 20-5/8

19 19 20 20

23 21-1/8 23-5/8 22-1/4

22-7/8 19 23-1/2 19-5/8

22-1/8 19 23-3/4 20-5/8

22-1/2 19 23-1/2 20

UPFLO

90˚

120˚

MIN

W OWNFLOW

PREFERRED

PERMITTED

120˚

MIN

→ Fig. 14—Duct Flanges

DUCTWORK ACOUSTICAL TREATMENT Metal duct systems that do not have a 90 degree elbow and 10 ft

of main duct to the first branch take-off may require internal acoustical lining. As an alternative, fibrous ductwork may be used if constructed and installed in accordance with the latest edition of

HORIZONTAL

90˚

PREFERRED

PERMITTED PERMITTED

120˚ MIN

SMACNA construction standard on fibrous glass ducts. Both acoustical lining and fibrous ductwork shall comply with NFPA 90B as tested by UL Standard 181 for Class 1 Rigid air ducts.

PREFERRED

A02329

Page 13

OUTER DOOR ASSEMBLY

8" MIN FOR DOOR REMOVAL

(2) HEX NUTS, (2) WASHERS & (2) LOCK WASHERS REQ. PER ROD

→ Fig. 15—Horizontal Unit Suspension

/4" THREADED ROD

4 REQ.

SECURE ANGLE IRON TO BOTTOM OF FURNACE WITH 3 #8 x TYPICAL FOR 2 SUPPORTS

1" SQUARE, 1 OR UNI-STRUT MAY BE USED

/4" x 11/4" x 1/4" ANGLE IRON

/4" SCREWS

A02345

Fig. 16—Horizontal Suspension with Straps

SUPPLY AIR CONNECTIONS

→

For a furnace not equipped with a cooling coil, the outlet duct shall be provided with a removable access panel. 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 possible openings using light assistance or a probe can be inserted for sampling the air stream. The cover attachment shall prevent leaks.

A02014

Upflow and Horizontal Furnaces Connect supply-air duct to flange on furnace supply-air outlet.

Bend flange upward to 90° with wide duct pliers. The supply-air duct attachment must ONLY be connected to furnace supplyoutlet-air duct flanges or air conditioning coil casing (when used). DO NOT cut main furnace casing to attach supply side air duct, humidifier, or other accessories. All accessories MUST be connected external to furnace main casing.

Page 14

LINE CONTACT ONLY PERMISSIBLE BETWEEN LINES FORMED BY INTERSECTIONS OF THE TOP AND TWO SIDES OF THE FURNACE JACKET AND BUILDING JOISTS, STUDS, OR FRAMING.

MANUAL SHUTOFF

GAS VALVE

SEDIMENT

TRAP

Fig. 17—Typical Attic Installation

SHEET METAL

GAS ENTRY

17 3/4

″

17 3/4

″ OVER ALL

4 3/4

″ UNDER DOOR

1″ UNDER FURNACE

TYPE-B VENT

MIN*

″

30-IN. MIN WORK AREA

EXTEND OUT 12″ OUT FROM FACE OF DOOR

* WHEN USED WITH SINGLE WALL VENT CONNECTIONS

A02164

Downflow Furnaces Connect supply-air duct to supply-air opening on furnace. The

supply-air duct attachment must ONLY be connected to furnace supply/outlet or air conditioning coil casing (when used). When installed on combustible material, supply-air duct attachment must ONLY be connected to the accessory subbase, KGASB0201ALL, or factory approved air conditioning coil casing. DO NOT cut main furnace casing to attach supply side air duct, humidifier, or other accessories. All accessories MUST be connected external to furnace casing.

RETURN AIR CONNECTIONS

Never connect return-air ducts to the back of the furnace. A failure tofollow this warning can cause a fire, personalinjury, or death.

Downflow Furnaces The return-air duct must be connected to return-air opening

(bottom inlet) as shown in Fig. 1. DO NOT cut into casing sides (left or right). Side opening is permitted for only upflow and most horizontal furnaces. Bypass humidifier connections should be made at ductwork or coil casing sides exterior to furnace.

Upflow and Horizontal Furnaces The return-air duct must be connected to bottom, sides (left or

right), or a combination of bottom and side(s) of main furnace casing as shown in Fig. 1. Bypass humidifier may be attached to unused side return air portion of the furnace casing. (See Fig. 18, 19, and 20.)

Not all horizontal furnaces are approved for side return air connections. (See Fig. 20.)

Step 6—Gas Piping

Never purge a gas line into a combustion chamber. Never test

→

for gas leaks with an open flame. Use a commercially available soap solution made specifically for the detection of leaks to check all connections. A failure to follow this warning could result in fire, explosion, personal injury, or death.

Gas piping must be installed in accordance with national and local codes. Refer to current edition of NFGC in the U.S., the NSCNGPIC in Canada.

Installations must be made in accordance with all authorities having jurisdiction. If possible, the gas supply line should be a separate line running directly from meter to furnace.

Refer to Table 4 for recommended gas pipe sizing. Risers must be used to connect to furnace and to meter. Support all gas piping with appropriate straps, hangers, etc. Use a minimum of 1 hanger every 6 ft. Joint compound (pipe dope) should be applied sparingly and only to male threads of joints. Pipe dope must be resistant to the action of propane gas.

→

If local codes allow the use of a flexible gas appliance connector, always use a new listed connector. Do not use a connector which has previously serviced another gas appliance. Black iron pipe shall be installed at the gas valve and extend a minimum of 2-in. outside the furnace.

Page 15

Fig. 18—Upflow Return Air Configurations and Restrictions

A02075

Fig. 19—Downflow Return Air Configurations and Restrictions

Fig. 20—Horizontal Return Air Configurations and Restrictions

A02163

A02162

Page 16

→

* Cubic ft of gas per hr for gas pressures of 0.5 psig (14–in. wc) or less and a pressure drop of 0.5–in wc (based on a 0.60 specific gravity gas). Ref: Table 12.2 NFPA 54-2002.

Table 4—Maximum Capacity of Pipe*

NOMINAL

IRON PIPE SIZE

(IN.)

1/2 0.622 175 120 97 82 73 3/4 0.824 360 250 200 170 151

1 1.049 680 465 375 320 285 1-1/4 1.380 1400 950 770 660 580 1-1/2 1.610 2100 1460 1180 990 900

INTERNAL

DIAMETER

(IN.)

LENGTH OF PIPE (FT)

10 20 30 40 50

Connect gas pipe to gas valve using a backup wrench to avoid damaging gas controls.

Use proper length of pipe to avoid stress on gas control manifold. Failure to follow this warning could result in a gas leak resulting in fire, explosion, personal injury, or death.

An accessible manual shutoff valve MUST be installed external to

→

furnace casing and within 6 ft of furnace. A 1/8-in. NPT plugged tapping, accessible for test gage connection, MUST be installed immediately upstream of gas supply connection to furnace and downstream of manual shutoff valve.

NOTE: The gas valve inlet pressure tap connection is suitable to

→

use as test gage connection providing test pressure DOES NOT exceed maximum 0.5 psig (14-in. wc) stated on gas control valve. (See Fig. 50.)

Some installations require gas entry on right side of furnace (as

→

viewed in upflow). (See Fig. 21a.) Install a sediment trap in riser leading to furnace as shown in Fig

21b. Connect a capped nipple into lower end of tee. Capped nipple should extend below level of gas controls. Place a ground joint union between gas control manifold and exterior manual equipment gas shutoff valve. A 1/8-in. NPT plugged tapping, accessible for testgage connection, MUSTbe installed immediately upstream of gas supply connection to furnace and downstream of manual shutoff valve.

Piping should be pressure and leak tested in accordance with

→

NFGC in the United States or NSCNGPIC in Canada, local, and national plumbing and gas codes before the furnace has been connected. After all connections have been made, purge lines and check for leakage at furnace prior to operating furnace.

GAS SUPPLY

MANUAL SHUTOFF VALVE (REQUIRED

SEDIMENT TRAP

UNION

Fig. 21b—Typical Gas Pipe Arrangement

If pressure exceeds 0.5 psig (14-in. wc), gas supply pipe must be

→

disconnected from furnace and capped before pressure test. If test pressure is equal to or less than 0.5 psig (14-in. wc), turn off electric shutoff switch located on furnace gas control valve and accessible manual shutoff valve before test. After all connections have been made, purge lines and check for leakage.

The gas supply pressure shall be within the maximum and

→

minimum inlet supply pressures marked on the rating plate with the furnace burners ON and OFF.

Step 7—Electrical Connections

Blower access panel door switch opens 115-v power to control center. No component operation can occur. Do not bypass or close switch with panel removed. Failure to follow this warning could result in personal injury or death.

See Fig. 24 for field wiring diagram showing typical field 115-v wiring. Check all factory and field electrical connections for tightness.

Field-supplied wiring shall conform with the limitations of 63°F

→

(33°C) rise.

A02035

90° Elbow

2" Nipple

Street Elbow

Gas Valv e

→ Fig. 21a—Right Side Gas Entry Example

A02327

The cabinetMUST have an uninterrupted or unbroken ground according to NEC ANSI/NFPA 70-2002 and Canadian Electrical Code CSA C22.1 or local codes to minimize personal injury if an electrical fault should occur. This may consist of electrical wire, conduit approved for electrical ground or a listed, grounded power cord (where permitted by local code) when installed in accordance with existing electrical codes. Refer to the power cord manufacturer’s ratings for proper wire gage. Do not use gas piping as an electrical ground. Failure to follow this warning could result in electrical shock, fire, or death.

Page 17

→ Table 5—Electrical Data

UNIT SIZE

045-08/024045 115-60-1 127 104 5.6 7.77 47 15 14 045-12/036045 115-60-1 127 104 7.0 9.47 39 15 14 070-08/024070 115-60-1 127 104 5.0 7.06 52 15 14 070-12/036070 115-60-1 127 104 6.7 9.19 40 15 14

070-16/048070** 115-60-1 127 104 9.8 12.59 28 15 14

090-14/042090 115-60-1 127 104 8.1 10.83 34 15 14 090-16/048090 115-60-1 127 104 9.8 12.95 28 15 14

090-20/060090** 115-60-1 127 104 12.9 17.60 34 20 12

110-12/036110 115-60-1 127 104 8.2 10.75 34 15 14 110-16/048110 115-60-1 127 104 10.1 13.12 28 15 14 110-22/066110 115-60-1 127 104 13.7 17.62 32 20 12 135-16/048135 115-60-1 127 104 10.1 13.12 28 15 14 135-22/066135 115-60-1 127 104 14.4 18.55 30 20 12 155-22/060155 115-60-1 127 104 15.0 19.33 29 20 12

* Permissible limits of the voltage range at which the unit operates satisfactorily. # Unitampacity = 125 percent of largest operating component’s full load amps plus 100 percent of all other potential operating components’ (EAC, humidifier, etc.) full load amps.

† Time-delay type is recommended. ‡ Length shown is as measured 1 way along wire path between unit and service panel for maximum 2 percent voltage drop.

** Preliminary

VOLTSHERTZ-

PHASE

Furnace control must be grounded for proper operation or control will lock out. Control is grounded through green/yellow wire routed to gas valve and manifold bracket screw.

115-V WIRING Verify that the voltage, frequency, and phase correspond to that

specified on unit rating plate. Also, check to be sure that service provided by utility is sufficient to handle load imposed by this equipment. Referto rating plateor Table 5 for equipment electrical specifications. Make all electrical connections in accordance with National Electrical Code (NEC) ANSI/NFPA 70-2002 and any local codes or ordinances that might apply. For Canadian installations, all electrical connections must be made in accordance with Canadian Electrical Code CSA C22.1 or authorities having jurisdiction.

OPERATING

VOLTAGE RANGE

Maximum* Minimum*

MAXIMUM

UNIT AMPS

UNIT

AMPACITY#

MAXIMUM

WIRE LENGTH (FT)‡

MAXIMUM

FUSE OR CKT BKR

AMPS†

MINIMUM

WIRE GAGE

TWO

A02099

Fig. 22—Relocating J-Box

Do not connect aluminum wire between disconnect switch and furnace. Use only copper wire.

Use a separate, fused branch electrical circuit with a properlysized fuse or circuit breaker for this furnace. See Table 5 for wire size and fuse specifications. A readily accessible means of electrical disconnect must be located within sight of the furnace.

NOTE: Proper polarity must be maintained for 115-v wiring. If polarity is incorrect, control LED status indicator light will flash rapidly and furnace will NOT operate.

J-BOX RELOCATION NOTE: If factory location of J-Box is acceptable, go to next

section (J-Box Cover Installation). NOTE: On 14″ wide casing models, the J-Box shall not be

relocated to other side of furnace casing when the vent pipe is routed within the casing.

1. Remove screws holding auxiliary J-box. (See Fig. 22.)

2. Cut wire tie on loop in wires to J-box.

3. Locate box to desired location.

4. Fasten J-Box to casing with screws.

5. Route J-box wires within furnace away from sharp edges and hot surfaces.

ELECTRICAL CONNECTION TO J-BOX

If manual disconnect switch is to be mounted on furnace, select a location where a drill or fastener will not contact electrical or gas components.

1. Attach electrical box to J-Box bracket.

2. Route wires through hole in electrical box and J-Box bracket.

3. Secure ground wire to green screw on J-Box bracket.

4. Connect line voltage leads as shown in Fig. 24.

FOR POWER CORD INSTALLATION Power cords must be able to handle the electrical requirements

listed in Table 5. Refer to power cord manufacturer’s listings.

Page 18

BLOWER OFF-DELAY

J2 JUMPER

24-V THERMOST AT

TERMINALS

3-AMP FUSE

LED OPERATION &

DIAGNOSTIC LIGHT

115-VAC(L2)NEUTRAL

CONNECTIONS

COOL HEAT

BLOWER SPEED

SELECTION TERMINALS

G Com W Y R

24V

STATUS CODE LED

COOL HEAT

SPARE-1

SPARE-2

TEST/TWIN

FUSE 3-AMP

SEC-2 SEC-1

EAC-2 L2

NUETRAL

BLW

SPARE-1 SPARE-2

TWINNING AND/OR

COMPONENT TEST

TERMINAL

BLOWER OFF-DELAY

90 150

120 180

PLT

HUM

0.5 AMP@24VAC

PLT 1

1-AMP@ 115VAC

PR-1

EAC-1

115 VAC (L1) LINE

VOLTAGE CONNECTION

EAC-1 TERMINAL

(115-VAC 1.0 AMP MAX.)

Fig. 23—Furnace Control

HUMIDIFIER TERMINAL

(24-VAC 0.5 AMP MAX.)

TRANSFORMER 24-VAC

CONNECTIONS

PL1-LOW VOLT AGE MAIN

HARNESS CONNECTOR

PL2 1

PL2-HOT SURFACE

IGNITER & INDUCER

MOTOR CONNECTOR

A02100

1. Route listed power cord through hole in J-Box.

2. Secure power cord to J-Box bracket with a strain relief bushing or a connector approved for the type of cord used.

3. Secure ground wire to green screw on J-Box bracket.

4. Connect line voltage leads as shown in Fig. 24.

FOR BX CABLE INSTALLATION

1. Route BX cable to hole in J-Box.

2. Secure BX cable to J-Box bracket with connectors approved for the type of cable used.

3. Secure ground wire to green screw on J-Box bracket.

4. Connect line voltage leads as shown in Fig. 24.

J-BOX COVER INSTALLATION

1. Remove J-Box cover from blower access door on furnace and reinstall blower access door screw.

2. Fold tab on J-box cover to bracket with pliers.

3. Insert tab of J-box cover into slot of J-box bracket.

4. Secure J-Box cover to bracket with screw provided.

5. Remove U-shaped cut-out from outer door to clear J-box.

24-V WIRING Make field 24-v connections at the 24-v terminal strip. (See Fig.

23.) Connect terminal Y as shown in Fig. 24 for proper cooling operation. Use only AWG No. 18, color-coded, copper thermostat wire.

The 24-v circuit contains an automotive-type, 3-amp fuse located on the control. Any direct shorts during installation, service, or

maintenance could cause this fuse to blow. If fuse replacement is required, use ONLY a 3-amp fuse of identical size.

ACCESSORIES

1. Electronic Air Cleaner (EAC) Connect an accessory Electronic Air Cleaner (if used) using 1/4-in female quick connect terminals to the two male 1/4-in quick-connect terminals on the control board marked EAC-1 and EAC-2. The terminals are rated for 115 VAC, 1.0 amps maximum and are energized during blower motor operation.

2. Humidifier (HUM) Connect an accessory 24 VAC, 0.5 amp maximum humidifier (if used) to the 1/4-in male quick-connect HUM terminal and

OM-24V screw terminal on the control board thermostat strip.

C The HUM terminal is energized when pressure switch (PRS) closes.

NOTE: A field-supplied, 115-v controlled relay connected to EAC terminals may be added if humidifier operation is desired during blower operation.

Page 19

NOTE 2

FIVE WIRE

WCR GY

THREE-WIRE

HEATING-ONLY

BLOWER DOOR SWITCH

BLK

WHT

BLK

WHT

O N

GND

115-V FIELD-

SUPPLIED

DISCONNECT

GND

AUXILIARY J-BOX

R O

COM

Y/Y2

NOTE 1

24-V

TERMINAL

BLOCK

FURNACE

NOTES: Connect Y-terminal in furnace as shown for proper blower operation.

Fig. 24—Heating and Cooling Application Wiring Diagram with 1–Stage Thermostat

DO NOT connect furnace control HUM terminal to HUM (humidifier) terminal on Thermidistat™, Zone Controller or similar device. See Thermidistat™, Zone Controller, thermostat, or controller manufacturer’s instructions for proper connection.

FIELD 24-V WIRING FIELD 115-, 208/230-, 460-V WIRING FACTORY 24-V WIRING FACTORY 115-V WIRING

THERMOSTAT TERMINALS

FIELD-SUPPLIED DISCONNECT

208/230- OR 460-V THREE PHASE

208/230-V SINGLE PHASE

GND

CONDENSING UNIT

TWO WIRE

1. Some thermostats require a "C" terminal connection as shown.

2. If any of the original wire, as supplied, must be replaced, use

3. same type or equivalent wire.

When an existing furnace is removed or replaced in a venting

→

system, the venting system may not be properly sized to vent the attached appliances. An improperly sized Category I venting system could cause the formation of condensate in the furnace and vent, leakage of condensate and combustion products, and spillage of combustion products into the living space, etc.

A99440

Step 8—Venting

→

The furnace shall be connected to a factory built chimney or vent complying with a recognized standard, or a masonry or concrete chimney lined with a lining material acceptable to the authority having jurisdiction. Venting into an unlined masonry chimney or concrete chimney is prohibited.

Page 20

CARBON MONOXIDE POISONING HAZARD Failure to follow the steps outlined below for each appliance connected to the venting system being placed into operation could result in carbon monoxide poisoning or death. The following steps shall be followed for each appliance connected to the venting system being placed into operation, while all other appliances connected tothe venting system are not in operation:

1. Seal any unused openings in venting system.

2. Inspect the venting system for proper size and horizontal pitch, as required in the National Fuel Gas Code, ANSI Z223.1/NFPA 54 or the CSA B149.1, Natural Gas and Propane Installation Codes and these instructions. Determine that there is no blockage or restriction, leakage, corrosion and other deficiencies, which could cause an unsafe condition.

3. As 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.

4. Close fireplace dampers.

5. 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 are operating at maximum speed. Do not operate a summer exhaust fan.

6. Follow the lighting instructions. Place the appliance being inspected into operation. Adjust the thermostat so appliance is operating continuously.

7. Testfor spillage fromdraft hood equipped appliances at the draft hood relief opening after 5 minutes of main burner operation. Use the flame of a match or candle.

8. If improper venting is observed during any of the above tests, the venting system must be corrected in accordance with the National Fuel Gas Code, ANSI Z223.1/NFPA 54 and/or CSA B149.1, Natural Gas and Propane Installation Codes.

9. 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-fired burning appliance to their previous conditions of use.

Vent system or vent connectors may need to be resized. For any

→

other appliances when resizing vent systems or vent connectors, system or connector must be sized to approach minimum size as determined using appropriate table found in the NFGC or NSCNGPIC.

GENERAL VENTING REQUIREMENTS Follow all safety codes for proper vent sizing and installation

requirements, including local building codes, the National Fuel Gas Code(NFGC) ANSI Z223.1-2002/NFPA 54-2002, Parts 7 and 13 inthe United States or theNational Standard of Canada, Natural Gas and Propane Installation Code (NSCNGPIC) CSA-B149.1-00, Section 7 and Appendix C in Canada.

These furnaces are design-certified as Category I furnaces in accordance with ANSI Z21.47/CSA 2.3-2001 and operate with a non-positive vent static pressure to minimize the potential for vent gas leakage. Category I furnaces operate with a flue loss not less than 17 percent to minimize the potential for condensation in the venting system. These furnaces are approved for common venting and multi-story venting with other fan assisted or draft hood equipped appliances in accordance with the NFCG or the NSCNGPIC.

The following information and warning must be considered in addition to the requirements defined in the NFGC and the NSCNGPIC.

1. If a vent (common or dedicated) becomes blocked, the furnace will be shut off by the draft safeguard switch located on the vent elbow.

Do not bypass the draft safeguard switch, as an unsafe condition could exist which must be corrected. Failure to follow this warning could result in a build-up of carbon monoxide and lead to personal injury or death.

2. Do not connect this appliance to a single-wall dedicated or common vent. The dedicated or common vent is considered to be the vertical portion of the vent system that terminates outdoors.

3. Vent connectors serving Category I furnaces shall not be connected into any portion of a mechanical draft system operating under positive pressure.

4. In the US, do not vent this appliance with any solid fuel burning appliance. In Canada, check with the authority having jurisdiction for approval on use with solid fuel burning appliance.

5. Category I furnaces must be vented vertically or nearly

→

vertically unless equipped with a listed power ventor.

6. Do not vent this appliance into an unlined masonry chimney.

→

Refer to Chimney Inspection Chart, Fig. 25.

MASONRY CHIMNEY REQUIREMENTS

These furnaces are CSA design-certified for use in exterior clay tile-lined masonry chimneys with a factory accessory Chimney Adapter Kit. Refer to the furnace rating plate for correct kit usage. The Chimney Adapter Kits are for use with ONLY furnaces having a Chimney Adapter Kit number marked on the furnace rating plate.

If aclay tile-lined masonrychimney is beingused and it is exposed to the outdoors below the roof line, relining might be required. Chimneys shall conform to the Standard for Chimneys, Fireplaces, Vents, and Soild Fuel Burning Appliances ANSI/NFPA 211-2000 in the United States and to a Provincial or Territorial Building Code in Canada (in its absence, the National Building Code of Canada) and must be in good condition.

U.S.A.-Refer to Sections 13.1.9 and 13.2.20 of the NFGC or the authority having jurisdiction to determine whether relining is required. If relining is required, use a properly sized listed metal liner, Type-B vent, or a listed alternative venting design.

Page 21

NOTE: See the NFGC, 13.1.9 and 13.2.20 regarding alternative venting design and the exception, which cover installations such as the Chimney Adapter Kits KGACA02014FC and KGACA02015FC, which are listed for use with these furnaces.

The Chimney Adapter Kit is listed alternative venting design for these furnaces. See the kit instructions for complete details.

Canada-This furnace is permitted to be vented into a clay tile-lined masonry chimney that is exposed to the outdoors below the roof line, provided:

1. Vent connector is Type-B double-wall, and

2. This furnace is common vented with at least 1 draft hoodequipped appliance, and

3. The combined applianceinput rating isless than the maximum capacity given in Table A, and

4. The input rating of each space heating appliance is greater than the minimum input rating given in the appropriate Table B for Masonry Chimneys for the local winter design temperature. Chimneys having internal areas greater than 38 square inches require furnace input ratings greater than the input ratings of these furnaces. See footnote at bottom of Table B, and

5. The authority having jurisdiction approves.

If all of these conditions cannot be met, an alternative venting design shall be used, such as the listed chimney adapter kit with these furnaces listed for use with the kit, a listed chimney-lining system, or a Type-B common vent.

Exterior Masonry Chimney,

FAN + NAT Installations with

Type-B Double-Wall Vent Connectors

Table A—Combined Appliance

Maximum Inut Rating in

Thousands of BTU per Hour

VENT

HEIGHT (FT)

6 74 119 178 257

8 80 130 193 279 10 84 138 207 299 15 NR 152 233 334 20 NR NR 250 368 30 NR NR NR 404

INTERNAL AREA OF CHIMNEY

12 19 28 38

(SQ. IN.)

Table B—Minimum Allowable Input Rating of

Space-Heating Appliance in

Thousands of BTU per Hour

VENT

HEIGHT (FT)

Local 99% Winter Design

Temperature: 17 to 26 degrees F*

6 0 55 99 141 8 52 74 111 154

10 NR 90 125 169

17 to 26 F

5to16F

-10 to 4 F

-11 F or lower

*The 99% Winter Design Dry-Bulb (db) temperatures are found in the 1993 ASHRAE Fundamentals Handbook, Chapter 24, Table 1 (United States) and 2 (Canada), or use the 99.6% heating db temperatures found in the 1997 or 2001 ASHRAE Fundamentals Handbook, Climatic Design Information chapter, Table 1A (United States) and 2A (Canada).

15 NR NR 167 212 20 NR NR 212 258 30 NR NR NR 362

Local 99% Winter Design

Temperature: 5 to 16 degrees F*

6 NR 78 121 166

8 NR 94 135 182 10 NR 111 149 198 15 NR NR 193 247 20 NR NR NR 293 30 NR NR NR 377

Local 99% Winter Design

Temperature: -10 to 4 degrees F*

6 NR NR 145 196

8 NR NR 159 213 10 NR NR 175 231 15 NR NR NR 283 20 NR NR NR 333 30 NR NR NR NR

Local 99% Winter Design

Temperature: -11 degrees F or lower*

Inspections before the sale and at the time of installation will determine the acceptability of the chimney or the need for repair and/or (re)lining.Refer to Fig.25 to perform a chimney inspection. If the inspection of a previously used tile-lined chimney:

a. Shows signs of vent gas condensation, the chimney should

be relined in accordance with local codes and the authority having jurisdiction. The chimney should be relined with a listed metal liner, Type-B vent, or a listed chimney adapter kit shall be used to reduce condensation. If a condensate drain is required by local code, refer to the NFGC, Section

10.9 for additional information on condensate drains.

b. Indicates the chimney exceeds the maximum permissible

size in the tables, the chimney should be rebuilt or relined to conform to the requirements of the equipment being installed and the authority having jurisdiction.

INTERNAL AREA OF CHIMNEY

12 19 28 38

Not recommended for any vent

(SQ. IN.)

configuration

Page 22

A chimney without a clay tile liner, which is otherwise in good condition, shall be rebuilt to conform to ANSI/NFPA 211 or be lined with a UL listed (ULC listed in Canada) metal liner or UL listed Type-B vent. Relining with a listed metal liner or Type-B vent is considered to be a vent-in-a-chase.

If a metal liner or Type-B vent is used to line a chimney, no other appliance shall be vented into the annular space between the chimney and the metal liner.

APPLIANCE APPLICATION REQUIREMENTS Appliance operation has a significant impact on the performance

of the venting system. If the appliances are sized, installed, adjusted, and operated properly, the venting system and/or the appliances should not suffer from condensation and corrosion. The venting system and all appliances shall be installed in accordance with applicable listings, standards, and codes.

The furnace should be sized to provide 100 percent of the design heating load requirement plus any margin that occurs because of furnace model size capacity increments. Heating load estimates can be made using approved methods available from Air Conditioning Contractors of America (Manual J); American Society of Heating, Refrigerating, and Air-Conditioning Engineers; or other approved engineering methods. Excessive oversizing of the furnace could cause the furnace and/or vent to fail prematurely.

When a metal vent or metal liner is used, the vent must be in good condition and be installed in accordance with the vent manufacturer’s instructions.

To prevent condensation in the furnace and vent system, the following precautions must be observed:

1. The return-air temperature must be at least 60°F db except for brief periods of time during warm-up from setback at no lower than 55°F db or during initial start-up from a standby condition.

2. Adjust the gas input rate per the installation instructions. Low gas input rate causes low vent gas temperatures, causing condensation and corrosion in the furnace and/or venting system. Derating is permitted only for altitudes above 2000 ft.

3. Adjust the air temperature rise range to the midpoint or slightly above. Low air temperature rise can cause low vent gas temperature and potential for condensation problems.

4. Set the thermostat heat anticipator or cycle rate to reduce short cycling.

Air for combustion must not be contaminated by halogen compounds which include chlorides, fluorides, bromides, and iodides. These compounds are found in manycommon home products such as detergent, paint, glue, aerosol spray, bleach, cleaning solvent, salt, and air freshener, and can cause corrosion of furnaces and vents. Avoid using such products in the combustion-air supply. Furnace use during construction of the building could cause the furnace to be exposed to halogen compounds, causing premature failure of the furnace or venting system due to corrosion.

Vent dampers on any appliance connected to the common vent can cause condensation and corrosion in the venting system. Do not use vent dampers on appliances common vented with this furnace.

NOTE: Vent connector length for connector sizing starts at furnace vent elbow. The 4 inch vent elbow is shipped for upflow configuration and may be rotated for other positions. Remove the 3 screws that secure vent elbow to furnace, rotate furnace vent elbow to position desired, re-install screws. The factory-supplied vent elbow does NOT count as part of the number of vent connector elbows.

The vent connector can exit the door through one of 5 locations on the door.

1. Attach the single wall vent connector to the furnace vent elbow, and fasten the vent connector to the vent elbow with at least two field-supplied, corrosion-resistant, sheet metal screws located 180° apart.

2. Vent the furnace with the appropriate connector as shown in Fig. 26–38.

Personal injury can result form sharp metal edges, etc. Be careful when removing parts. Gloves and safety glasses should be worn when servicing equipment.

3. Orient the door to determine the correct location of the door cutout to be removed.

4. Use aviation-type tin snips to remove the correct U-shaped cut-out on door.

An accessory Vent Guard Kit, KGAVG0101DFG is REQUIRED for downflow applications for use where the vent exits through the lower portion of the furnace casing door. Refer to the Vent Guard Kit Instructions for complete details.

The horizontal portion of the venting system shall maintain a minimum of 1/4-in. upward slope per linear ft and it shall be rigidly supported every 5 ft or less with metal hangers or straps to ensure there is no movement after installation.

SIDEWALL VENTING This furnace is not approved for direct sidewall horizontal venting

without the use of an add-on power venter. In the U.S.: Per the NFGC, any listed power venter may be used,

when approved by the authority having jurisdiction. In Canada: Only power venters approved by the appliance

manufacturer and where allowed by the authority having jurisdiction may be used for sidewall venting.

The only approved power venter is the Field Controls SWG-4D and SWG-5D sidewall power venter. Select the power venter to match the btuh input of the appliance being vented. Follow all manufacturer’s installation requirements for venting and termination included with the power venter.

START-UP, ADJUSTMENT, AND SAFETY CHECK

Step 1—General

ADDITIONAL VENTING REQUIREMENTS A4″ round vent elbow is supplied with the furnace. A 5 inch or 6

inch vent connector may be required for some model furnaces. A field-supplied 4 inch to 5 inch or 4 inch to 6 inch sheet metal increaser fitting is required when 5 inch or 6 inch vent connector is used. See Fig. 26–38 Venting Orientation for approved vent configurations.

This furnace is equipped with manual reset limit switches in the gas control area. The switches open and shut off power to the gas valve if a flame rollout or overheating condition occurs in the gas control area. DO NOT bypass the switches. Correct inadequate combustion air supply problem and reset the switches. Failure to follow this warning can cause fire, explosion, personal injury, or death.

Page 23

CHIMNEY INSPECTION CHART

For additional requirements refer to the National Fuel Gas Code NFPA 54/ANSI Z223.1 and ANSI/NFPA 211

Chimneys, Fireplaces, Vents, and Solid Fuel Burning Appliances in the U.S.A. or to the Canadian

installation Codes CSA-B149.1 in Canada.

Crown

condition:

Missing mortar

or brick?

Is chimney

property lined with

clay tile liner?

Yes

Is liner and top seal in good

condition?

Yes

Debris

in cleanout?

Mortar, tile, metal vent

fuel oil residue?

Yes

Rebuild

crown.

Repair

liner or top seal

or reline chimney as

necessary.

Repair

Mortar

or tile

debris?

Reline

Yes

Remove mortar

and tile debris

Clay

tile misalignment,

missing sections,

gaps?

Condensate

drainage at bottom

of chimney?

Chimney

exposed to

outdoors below

roof line?

Chimney is

acceptable for use.

Remove metal vent

or liner.

Yes

lined with properly

sized, listed liner or

Yes

Is chimney

Type-B vent?

Yes

Is chimney

to be dedicated to

a single

furnace?

Consult

Part B of

chimney adapter venting

instructions for

application

suitability .

Suitable

Yes

Install chimney

adapter per

instructions.

chimney adapter venting

Not Suitable

Consult

Part C of

instructions for

application

suitability

Line chimney with property

sized, listed flexible metal

liner or Type-B vent per

NFGC or NSCNGPIC Vent

Sizing Tables and liner or

vent manufacturer’s

Installation instructions.

Suitable

Install chimney

adapter per

instructions.

Fig. 25—Chimney Inspection Chart

A02101

Page 24

Personal injury can result form sharp metal edges, etc. Be careful when removing parts. Gloves and safety glasses should be worn when servicing equipment.

1. Maintain 115-v wiring and ground. Improper polarity will result in rapid flashing LED and no furnace operation.

2. Make thermostat wire connections at the 24-v terminal block on the furance control. Failure to make proper connections will result in improper operation. (See Fig. 24.)

3. Gas supply pressure to the furnace must be greater than 4.5-in. wc (0.16 psig) but not exceed 14-in. wc (0.5 psig).

4. Check all manual-reset switches for continuity.

5. Install blower compartment door. Door must be in place to operate furnace.

6. Replace outer door.

Step 2—Start-Up Procedures

Never purge a gas line into a combustion chamber. Never use matches, candles, flame, or other sources of ignition for the purpose of checking leakage. Use a soap-and-water solution to check for leakage. Failure to follow this warning can cause fire, explosion, personal injury, or death.

1. Purge gas lines after all connections have been made.

2. Check gas lines for leaks.

Blower access door switch opens 115-v power to control. No

→

component operation can occur unless switch is closed. Caution must be taken when manually closing this switch for service purposes. Failure to follow this warning could result in electrical shock, personal injury, or death.

3. To Begin Component Self-Test: Disconnect the thermostat R lead from furnace control board. Manually close the blower door switch. Briefly short the TEST/TWIN terminal to the C

OM 24V terminal until LED goes out. Remove jumper from

terminals. (See Fig. 23.)

NOTE: The furnace control allows allcomponents, except the gas valve, to be run for short period of time. This feature helps diagnose a system problem in case of a component failure. Component test feature will not operate if any thermostat signal is present at the control.

Component test sequence is as follows: Refer to service label attached to furnace or see Fig. 43.

a. LED will display previous status code 4 times. b. Inducer motor starts and continues to run until Step f of

component test sequence. c. Hot surface ignitor is energized for 15 sec., then off. d. Blower motor operates on HEAT speed for 10 sec. e. Blower motor operates on COOL speed for 10 sec. f. Inducer motor stops. g. Reconnect R lead to furnace control board, release blower

door switch and re-install blower door.

4. Operate furnace per instruction on door.

5. Verify furnace shut down by lowering thermostat setting below room temperature.

6. Verify furnace restarts by raising thermostat setting above room temperature.

Step 3—Adjustments

DO NOT bottom out gas valve regulator adjusting screw. This can result in unregulated manifold pressure and result in excess overfire and heat exchanger failures.

DO NOT redrill orifices. Improper drilling (burrs, out-ofround holes, etc.) can cause excessive burner noise and misdirection of burner flames. This can result in flame impingement of heat exchangers, causing failures. (See Fig.

41.)

Furnace gas input rate onrating plate isfor installations ataltitudes up to 2000 ft. Furnace input rate must be within ±2 percent of furnace rating plate input.

In the U.S.A., the input rating for altitudes above 2,000 ft. must be reduced by 4 percent for each 1,000 ft. above sea level. In Canada, input rating must be reduced by 10 percent for altitudes of 2,000 ft. to 4,500 ft. above sea level.

1. Determine the correct gas input rate. In the U.S.: For installations below 2000 ft., refer to the unit rating plate. For installations above 2000 ft., multiply the input on the rating plate by the de-rate multiplier in Table 6 for the correct input rate.

In Canada: At installation altitudes from 2000 to 4500 ft, this furnace must be derated 10 percent by an authorized Gas Conversion Station or Dealer. To determine correct input rate for altitude, see example 1 and use 0.90 as derate multiplier factor.

EXAMPLE 1:

88,000 BTUH INPUT FURNACE INSTALLED AT 4300 FT.

Derate Furnace Input Rate

Furnace Input Rate X Multiplier = at Installation

at Sea Level Factor Altitude

88,000 X 0.90 = 79,200

2. Determine the correct orifice and manifold pressure adjustment. There are two different orifice and manifold adjustment tables. All models in all positions, except Low NOx models in downflow or horizontal positions, use Table 10 (22,000 BTUH/Burner) Low NOx models in the downflow or horizontal positions must use Table 11 (21,000BTUH/Burner). See input listed on furnace rating plate.

a. Obtain average yearly gas heat value (at installed altitude)

from local gas supplier.

b. Obtain average yearly gas specific gravity from local gas

supplier. c. Find installation altitude in Table 10 or 11. d. Find closest natural gas heat value and specific gravity in

Table 10 or 11. e. Follow heat value and specific gravity lines to point of

intersection to find orifice size and manifold pressure

settings for proper operation.

Page 25

SEE NOTES: 1,2,4,7,8,9

A02058

Fig. 26—Upflow Application-

Vent Elbow Up

SEE NOTES: 1,2,4,5,7,8,9

A02061

Fig. 29—Downflow

Application-Vent Elbow Up

SEE NOTES: 1,2,3,4,7,8,9

A02059

Fig. 27—Upflow Application-

Vent Elbow Right

SEE NOTES: 1,2,4,5,6,7,8,9

A02062

Fig. 30—Downflow

Application-Vent Elbow Left

then Up

SEE NOTES:1,2,3,4,5,7,8,9

Fig. 28—Downflow

Application-Vent Elbow Up

then Left

SEE NOTES: 1,2,3,4,7,8,9

Fig. 31—Downflow

Application-Vent Elbow Up

then Right

A02060

A02063

See Venting Notes on page 26.

Page 26

SEE NOTES: 1,2,4,7,8,9

A02064

Fig. 32—Horizontal Left Application-Vent Elbow Left

SEE NOTES: 1,2,4,5,7,8,9

A02067

Fig. 35—Horizontal LeftApplication-VentElbow Right

SEE NOTES: 1,2,4,5,7,8,9

A02065

Fig. 33—Horizontal LeftApplication-VentElbow Right

then Up

SEE NOTES: 1,2,4,5,7,8,9

A02066

Fig. 34—Horizontal Left Application-Vent Elbow Up

f. Check and verify burner orifice size in furnace. NEVER

ASSUME ORIFICE SIZE. ALWAYS CHECK AND VERIFY.

g. Replace orifice with correct size if required by Table 13 or

14. Use only factory-supplied orifices. See EXAMPLE 2.

22,000 BTUH burner applications use Table 10 EXAMPLE 2: (0–2000 ft altitude) Heating value = 1000 Btu/cu ft Specific gravity = 0.62 Therefore: Orifice No. 43* Manifold pressure: 3.7-in. wc * Furnace is shipped with No. 43 orifices. In this example all main burner orifices are the correct size and do not need to be changed to obtain proper input rate.

3. Adjust manifold pressure to obtain correct input rate. a. Turn gas valve ON/OFF switch to OFF b. Remove manifold pressure tap plug from gas valve. (See

Fig. 40.)

SEE NOTES: 1,2,4,5,7,8,9

A02068

Fig. 36—Horizontal RightApplication-VentElbow Left

See Venting Notes on Page 26

c. Connect a water column manometer or similar device to

manifold pressure tap. d. Turn gas valve ON/OFF switch to ON. e. Set thermostat to call for heat. f. Jumper R and W thermostat connections on furnace control

board to start furnace.

g. Remove regulator seal cap and turn regulator adjusting

screw counterclockwise (out) to decrease input rate of

clockwise (in) to increase input rate. h. Install regulator seal cap. i. Leave manometer or similar device connected and proceed

to Step 4.

NOTE: DO NOT set manifold pressure less than 3.2-in wc or more than 3.8-in. wc for natural gas at sea level. If manifold pressure is outside this range, change main burner orifices or refer Table 10 or 11.

NOTE: If orifice hole appears damaged or it is suspected to have been redrilled, check orifice hole with a numbered drill bit of correct size. Never redrill an orifice. A burr-free and squarely aligned orifice hole is essential for proper flame characteristics.

Page 27

A02069

SEE NOTES: 1,2,4,7,8,9

Fig. 37—Horizontal Right Application-Vent Elbow

Right

SEE NOTES: 1,2,4,5,7,8,9

A02070

Fig. 38—Horizontal RightApplication-VentElbow Left

then Up

4. Verify natural gas input rate by clocking meter.

NOTE: Gas valve regulator adjustment cap must be in place for proper input to be clocked.

a. Turn off all other gas appliances and pilots. b. Run furnace for 3 minutes in heating operation. c. Measure time (in sec) for gas meter to complete 1 revolu-

tion and note reading. The 2cubic feet dial provides a more

accurate measurement of gas flow. d. Refer to Table 8 for cubic ft of gas per hr. e. Multiply gas rate (cu ft/hr) by heating value (Btu/cu ft) to

obtain input.

If clocked rate does not match required input from Step 1, increase manifold pressure to increase input or decrease manifold pressure to decrease input. Repeat steps b through e until correct input is achieved. Re-install regulator seal cap on gas valve.

5. Set temperature rise. The furnace must operate within the temperature rise ranges specified on the furnace rating plate. Do not exceed temperature rise range specified on unit rating plate. Determine the temperature rise as follows:

a. Place thermometers in return and supply ducts as close to

furnace as possible. Be sure thermometers do not see radiant heat from heat exchangers. Radiant heat affects temperature rise readings. This practice is particularly important with straight-run ducts.

b. When thermometer readings stabilize, subtract return-air

temperature from supply-air temperature to determine air temperature rise.

NOTE: Blower access door must be installed for proper temperature rise measurement.

NOTE: If the temperature rise is outside this range, first check:

1.) Gas input for heating operation.

2.) Derate for altitude if applicable.

3.) Returnand supply ductsfor excessive restrictions causing static pressures greater than 0.50-in. wc.

4.) Dirty filter.

Venting Notes for Fig. 26-38

1. For common vent, vent connector sizing and vent material: United States, latest edition of the National Fuel Gas Code (NFGC), ANSI Z223.1/NFPA 54. In Canada, latest edition of the National Standards of Canada, Natural Gas and Propane Installation Code (NSCNGPIC), CSA B149.1-00.

2. Immediately increase to 5–inch vent connector outside furnace casing when 5-inch vent connector required, refer to Note 1 above.

3. Side outlet vent for upflow and downflow installations must use Type B vent immediately after exiting the furnace, except when KGAVG0101DFG is used in the downflow position.

4. Type B vent where required, refer to Note 1 above.

5. 4” single wall (26 ga. min.) vent must be used inside furnace casing and when the KGAVG0101DFG Downflow Vent Guard Kit is used external to the furnace.

6. Accessory Downflow Vent Guard Kit, KGAVG0101DFG required in downflow installations with bottom vent configuration.

7. Chimney Adapter Kit required for exterior masonry chimney applications. Refer to Chimney Adapter Kit, KGACA02014FC and KGACA02015FC for sizing and complete application details.

8. Secure vent connector to furnace elbow with (2) corrosion-resistant sheet metal screws, spaced approximately 180° apart.

9. Secure all other single wall vent connector joints with (3) corrosion resistant screws spaced approximately 120° apart. Secure Type B vent connectors per vent connector manufacturer’s recommendations.

Disconnect 115-v electrical power before changing speed tap. Failure to follow this warning could result in personal injury.

c. Adjust air temperature rise by adjusting blower speed.

Increase blower speed to reduce temperature rise. Decrease blower speed to increase temperature rise.

d. Turn thermostat down below room temperature and re-

move blower access door.

e. To change motor speed selection for heating, remove

blower motor lead from control HEAT terminal (See Fig.

39.) Selectdesired blower motorspeed lead from one of the other terminals and relocate it to the HEAT terminal (See Table 7 for lead color identification). Reconnect original

lead to SPARE terminal. f. Repeat steps a through e. g. When correct input rate and temperature rise is achieved,

turn gas valve ON/OFF switch to OFF. h. Remove manometer or similar device from gas valve. i. Re-install manifold pressure tap plug in gas valve.

Failure to reinstall manifold pressure tap plug in gas valve will resultin fire, explosion,personal injury, property damage or death.

j. Re-install blower access door if removed. k. Turn gas valve ON/OFF switch to ON.

Recheck temperature rise. It must be within limits specified on the rating plate. Recommended operation is at the midpoint of rise range or slightly above

6. Set thermostat heat anticipator.

Page 28

L 2

NEUTRAL

327559-101 REV. E

CAP

SCHEMATIC DIAGRAM

(NATU RAL & PROPANE GASES)

EQUIPMENT GROUND

NEUTRAL

ILK

EAC-2

BLWM

START

COM

MED LO

HEA T

COOL

SPARE-1

BHT/CLR

EAC-1

HSIR

BLWR

TO 115VA C FIELD DISCONNECT SWITCH

NOTE #10

GRN/YEL

ORG

BVSS

(WHEN USED)

ORG

DSS

FRS1

NOTE #5

BLK

RED

BLU

RED

LS2

(WHEN USED)

RED

LS1

RED

FRS2

RED

CONNECTION DIAGRAM

IDM

HSI

PL3

BVSS

LS2

NOTE #10

(WHEN USED)

DSS

LS1

FRS1

FRS2

PL1-6

PL1-8

PRS

NOTE #11

(WHEN USED)

LGPS

(WHEN USED)

PL1-2

PL1-4

NOTE #3

FSE

PL1-9

PL1-11

PL1-3

PL1-5

PL1-10

GVR

PL1-1

PL1-7

A02141

PL2

IDR

WHT

TRAN

RED

SEC-2

24VA C

115VAC

SEC-1

TRAN

PR1

LGPS

(WHEN USED)

PRS

NOTE #6

F U 1

YEL

IDM

BLK

NOTE #11

FSE

GRN/YEL

HUM

WHT

FUSE OR CIRCUIT BREAKER &

WHT

HSI

PL3

BLK

WHT

WHT (COM)

CPU

TEST/TWIN

PRINTED CIRCIUT BOARD

NEUTRAL

NOTE #2

FU2

WHT

GND

ILK

BLK BLK

DISCONNECT SWITCH (WHEN REQ’D)

LS 1, 2 LIMIT SWITCH, AUTO-RESET, SPST(N.C.)

OL AUTO-RESET INTERNAL MOTOR OVERLOAD

TEMPERATURE SWITCH (N.C.)

PCB PRINTED CIRCUIT BOARD CONTROL

NOTE #5

PCB

24V

1. If any of the original equipment wire is replaced use wire rated for 105°C.

2. Use only copper wire between the disconnect switch and the furnace junction box (JB).

3. This wire must be connected to furnace sheet metal for control to prove flame.

4. Symbols are electrical representation only.

NOTES:

PL1 11-CIRCUIT PCB CONNECT OR

PL2 2-CIRCUIT CONNECTOR

PL3 2-CIRCUIT HSI, CONNECTOR

PRS PRESSURE SWITCH, SPST-(N.O.)

TEST/TWIN COMPONENT TEST & TWIN TERMINAL

TRAN TRANSFORMER-115VAC/24VAC

5. Solid lines inside PCB are printed circuit board conductors and are not included in legend.

JUNCTION

UNMARKED TERMINAL

PCB CONTROL TERMINAL

FACTORY WIRING (115VAC)

optimum speed se lection.

auto-reset after three hours.

6. Replace only with a 3 am p fuse.

7. Inducer (IDM) and blower (BLWM) motors contain internal auto-reset thermal overload sw itches (OL ).

8. Neutral connections are interchangeable within the NEUTRAL connector block.

9. Blower motor speed selections are for av erag e c on ditions, see installation instructions for details on

10. Factory connected when BVSS (Chimney Adapter Accessory Kit) is not installed.

11. Factory connected w hen LGPS is not used.

FACTORY WIRING (24VAC)

FIELD WIRING (115VAC)

FIELD WIRING (24VAC)

CONDUCTOR ON CONTROL PCB

FIELD WIRING SCREW TERMINAL

FIELD EARTH GROUND

90 seconds or 5 seconds when J2 is cut.

12. Ignition-lockou t w i ll occur afte r f o u r consec u ti ve unsuccessful trials-fo r- ig n itio n . Control will

13. Blower-on delay: gas heating 25 seconds, cooling or heat pump 2 seconds.

14. Blower-off delay: gas hea ting se lections are 90, 120 , 150 o r 18 0 seco nd s, co oling or hea t pump

EQUIPMENT GROUND

FIELD SPLICE

PLUG RECEPTACLE

Fig. 39—Furnace Wiring Diagram

PCB

BLOWER OFF-DELAY

JUMPER SELECT OR

J 2

180

120

150

TEST/TWIN

PRINTED CIRCIUT BOARD

24V

YEL

ORN

GRN/YEL

RED

BLU

HUM

FU1

NOTE #6

RED

SEC-1

LED

EAC-2

SEC-2

NEUTRAL

NOTE #8

PL2

WHT

PL1

12345678910

BLWR

BHT/CLR

BLW

PR1

EAC-1

BLWM

SPARE 2

BLK (HI)

COOL

HEAT

SPA RE 1

WHT

(COM )

CAP

GRN/YEL

BRN

START

RED (LO)

BHT/CLR BLOWER MOTOR SPEED CHANGE RELAY, SPDT

BLWR BLOWER MOTOR RELAY, SPST-(N.O.)

BLWM BLOWER MOTOR, PERMANENT-SPLIT-CAPACITOR

BVSS BLOCKED VENT SHUTOFF SWITCH, MANUAL-RESET, SPST -(N.C.)

CAP CAPACITOR

CPU MICROPROCESSOR AND CIRCUITRY

DSS DRAFT SAFE GUARD SWITCH, AUTO-RESET, SPST -(N.C.)

BLU

(MED LO )

LEGEN

EAC-1 ELECTRONIC AIR CLEANER CONNECTION (115 VAC 1.0 AMP MAX.)

EAC-2 ELECTRONIC AIR CLEANER CONNECTION (COMMON)

FRS 1, 2 FLAME ROLLOUT SW. -MANU AL RESET, SPST-(N.C.)

FSE FLAME-PROVING ELECTRODE

(FIELD INSTALLED & SUPPLIED)

FU 1 FUSE, 3 AMP, AUTOMOTIVE BLADE TYPE, FACTORY INSTALLED

FU 2 FUSE OR CIRCUIT BREAKER CURRENT INTERRUPT DEVICE

GND EQUIPMENT GROUND

GV GAS VALVE-REDUNDANT

GVR GAS VALVE RELAY, SPST-(N.O.)

HSI HOT SURFACE IGNITER (115 VAC)

HSIR HOT SURFACE IGNITER RELAY, SPST-(N.O.)

HUM 24VAC HUMIDIFIER CONNECTION (0.5 AMP. MAX.)

IDM INDUCED DRAFT MOTOR, SHADED-POLE

IDR INDUCED DRAFT MOTOR RELAY, SPST-(N.O.)

ILK BLOWER ACCESS PANEL INTERLOCK SWITCH, SPST-(N.O.)

J1 BLOWER - OFF DELAY JUMPER SELECTOR - HEATING

J2 BLOWER - OFF DELAY JUMPER - COOLING

JB JUNCTION BOX

LED LIGHT-EMITTING DIODE FOR STATUS CODES - RED

LGPS LOW GAS PRESSURE SWITCH, SPST-(N.O.)

Page 29

Caution!! For the following applications, use the minimum vertical vent sections as specified below.

For all other applications, follow exclusively the National Fuel Gas Code.

FURNACE ORIENTATION VENT ORIENTATION FURNACE INPUT(BTU/HR)

Downflow

Horizontal Left

Downflow

NOTE: All vent configurations must also meet National Fuel Gas Code venting requirements NFGC. *4 in. inside casing or vent guard **Including 4 in. vent section(s)

Vent elbow left, then up

Fig. 30

Vent elbow right,

then up

Fig. 33

Vent Elbow up

Fig. 34

Vent elbow right

Fig. 35

Vent elbow up then left

Fig. 28

Vent elbow up, then right

Fig. 31

154,000 132,000

110,000(036/-12 only)

154,000 132,000

154,000 5 7 110,000

(036/-12 only)

110,000

(036/-12 only)

MINIMUM

VENT DIAMETER (IN.)*

512

510

MINIMUM VERTICAL VENT HEIGHT (FT)**

Table 6–Altitude Derate Multipler for U.S.A.

ALTITUDE

(FT)

0–2000 0 1.00 2001–3000 8–12 0.90 3001–4000 12–16 0.86 4001–5000 16–20 0.82 5001–6000 20–24 0.78 6001–7000 24–28 0.74 7001–8000 28–32 0.70 8001–9000 32–36 0.66

9001–10,000 36–40 0.62

* Derate multiplier factors are based on midpoint altitude for altitude range.

PERCENT

OF DERATE

DERATE MULTIPLIER

FACTOR*

BURNER

ORIFICE

ON AND OFF SWITCH

GAS PRESSURE REGULATOR ADJUSTMENT

INLET PRESSURE TAP

MANIFOLD PRESSURE T AP

A00157

Fig. 40—Redundant Automatic Gas Control Valve

a. Mechanical thermostat—Set thermostat heat anticipator to

match the amp draw of the electrical components in the R-W circuit. Accurate amp draw readings can be obtained at the wires normally connected to thermostat subbase terminals, R and W. The thermostat anticipator should NOT be in the circuit while measuring current.

Fig. 41—Orifice Hole

Table 7—Speed Selection

COLOR SPEED AS SHIPPED

White Common BLW Black High COOL

Yellow† Med-High SPARE

Blue* Med-Low SPARE

Red* Low HEAT

* 1/5 HP motor models: BLUE to HEAT, RED to SPARE. † Not available on 1/5 HP motors. NOTE: Continuous blower is the HEAT speed.

(1.) Remove thermostat from subbase or from wall. (2.) Connect an amp meter as shown in Fig. 42 across the

R and W terminals or R and W wires.

(3.) Record amp draw across terminals when furnace is in

heating and after blower starts.

(4.) Set heat anticapator on thermostat per thermostat

instructions and install on subbase or wall.

b. Electronic thermostat: Set cycle rate for 4 cycles per hr.

7. Adjust blower off delay The blower off delay has 4 adjustable settings from 90 sec to 180 sec. The blower off delay jumpers are located on the furnace control board. (See Fig. 23.)

A93059

Page 30

Table 8–GAS RATE (CU FT/HR)

SECONDS

FOR 1

REVOLUTION

10 360 720 1800 50 72 144 360 11 327 655 1636 51 71 141 355 12 300 600 1500 52 69 138 346 13 277 555 1385 53 68 136 340 14 257 514 1286 54 67 133 333 15 240 480 1200 55 65 131 327 16 225 450 1125 56 64 129 321 17 212 424 1059 57 63 126 316 18 200 400 1000 58 62 124 310 19 189 379 947 59 61 122 305 20 180 360 900 60 60 120 300 21 171 343 857 62 58 116 290 22 164 327 818 64 56 112 281 23 157 313 783 66 54 109 273 24 150 300 750 68 53 106 265 25 144 288 720 70 51 103 257 26 138 277 692 72 50 100 250 27 133 267 667 74 48 97 243 28 129 257 643 76 47 95 237 29 124 248 621 78 46 92 231 30 120 240 600 80 45 90 225 31 116 232 581 82 44 88 220 32 113 225 563 84 43 86 214 33 109 218 545 86 42 84 209 34 106 212 529 88 41 82 205 35 103 206 514 90 40 80 200 36 100 200 500 92 39 78 196 37 97 195 486 94 38 76 192 38 95 189 474 96 38 75 188 39 92 185 462 98 37 74 184 40 90 180 450 100 36 72 180 41 88 176 439 102 35 71 178 42 86 172 429 104 35 69 173 43 84 167 419 106 34 68 170 44 82 164 409 108 33 67 167 45 80 160 400 110 33 65 164 46 78 157 391 112 32 64 161 47 76 153 383 116 31 62 155 48 75 150 375 120 30 60 150 49 73 147 367

SIZE OF TEST DIAL

Cu Ft2Cu Ft5Cu Ft

SECONDS

FOR 1

REVOLUTION

To change the blower off delay setting, move the jumper from one set of pins on the control to the pins used for the selected blower off delay. Factory off delay setting is 120 sec.

Step 4—Check Safety Controls

The flame sensor, gas valve, and pressure switch were all checked in the Start-up procedure section as part of normal operation.

1. Check Main Limit Switches This control shuts off combustion control system and energizes air-circulating blower motor, if furnace overheats. By using this method to check limit control, it can be established that limit is functioning properly and will operate if there is a restricted duct system or motor failure. If limit control does not function during this test, cause must be determined and corrected.

a. Run furnace for at least 5 minutes. b. Gradually block off return air with a piece of cardboard or

sheet metal until the limit trips.

c. Unblock return air to permit normal circulation.

SIZE OF TEST DIAL

Cu Ft2Cu Ft5Cu Ft

THERMOSTAT SUBBASE TERMINALS WITH THERMOSTAT REMOVED (ANITICIPATOR, CLOCK, ETC., MUST BE OUT OF CIRCUIT.)

HOOK-AROUND AMMETER

R Y W G

10 TURNS

FROM UNIT 24-V CONTROL TERMINALS

EXAMPLE:

5.0 AMPS ON AMMETER 10 TURNS AROUND JAWS

0.5 AMPS FOR THERMOSTAT

ANTICIPATOR SETTING

Fig. 42—Amp Draw Check With Ammeter

d. Burners will re-light when furnace cools down.

2. Check draft safeguard switch. The purpose of this control is to permit the safe shutdown of the furnace during certain blocked vent conditions.

a. Verify vent pipe is cool to the touch. b. Disconnect power to furnace and remove vent connector

from furnace vent elbow.

c. Restore power to furnace and set room thermostat above

room temperature.

d. After normal start-up, allow furnace to operate for 2

minutes, then block vent elbow in furnace 80 percent of

vent area with a piece of flat sheet metal. e. Furnace should cycle off within 2 minutes. f. Remove blockage and reconnect vent pipe to furnace vent

elbow. g. Switch will auto-reset when it cools. h. If control board locks out furnace, cycle 115 vac power to

reset control.

3. Check Pressure Switch(es) This control proves operation of the draft inducer blower.

a. Turn off 115-v power to furnace. b. Disconnect inducer motor lead wires from wire harness. c. Turn on 115-v power to furnace. d. Set thermostat to ″call for heat″ and wait 1 minute. When

pressure switch is functioning properly, hot surface igniter should NOT glow and control diagnostic light flashes a status code 32. If hot surface igniter glows when inducer motor is disconnected, shut down furnace immediately.

e. Determine reason pressure switch did not function properly

and correct condition. f. Turn off 115-v power to furnace. g. Reconnect inducer motor wires, replace outer door, and

turn on 115-v power.

A96316

Page 31

Step 5—Checklist

1. Put away tools and instruments. Clean up debris.

2. Check that blower OFF-DELAY time is selected as desired.

3. Verify that blower and burner access doors are properly installed.

4. Cycle test furnace with room thermostat.

5. Check operation of accessories per manufacturer’s instructions.

6. Review User’s Guide with owner.

7. Leave literature packet near furnace.

SERVICE AND MAINTENANCE PROCEDURES

The ability to properly perform maintenance on this equipment requirescertain knowledge, mechanical skills, tools,and equipment. If you do not possess these, do not attempt to perform any maintenance on this equipment other than those procedures recommended in the User’s Manual. FAILURE TO FOLLOW THIS WARNING COULD RESULT IN POSSIBLE DAMAGE TO THIS EQUIPMENT, SERIOUS PERSONAL INJURY, OR DEATH.

ELECTRICAL SHOCK, FIRE, OR EXPLOSION HAZARD

→

Failure to follow safety warnings exactly could result in dangerous operation, serious injury, death, or property damage. Improper servicing could result in dangerous operation, serious injury, death, or property damage.

- Before servicing, disconnect all electrical power to furnace.

- When servicing controls, label all wires prior to disconnecting. Reconnect wires correctly.

- Verify proper operation after servicing.

Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation.

Step 1—Introduction

GENERAL These instructions are written as if the furnace is installed in an

upflow application. An upflow furnace application is where the blower is located below the combustion and controls section of the furnace, and conditioned air is discharged upward. Since this furnace can be installed in any of the 4 positions shown in Fig. 4, you must revise your orientation to component location accordingly.

ELECTRICAL CONTROLS AND WIRING

There may be more than 1 electrical supply to the unit. Check accessories and cooling unit for additional electrical supplies

The electrical ground and polarity for 115-v wiring must be properly maintained. Refer to Fig. 24 for field wiring information and to Fig. 39 for furnace wiring information.

NOTE: If the polarity is not correct, the STATUS LED on the control will flash rapidly and prevent the furnace from heating.

The control system also requires an earth ground for proper operation of the control and flame-sensing electrode.

The 24-v circuit contains an automotive-type, 3-amp fuse located on the control. (See Fig. 23.) Any shorts of the 24-v wiring during installation, service, or maintenance will cause this fuse to blow. If fuse replacement is required, use ONLY a 3-amp fuse. The control LED will display status code 24 when fuse needs to be replaced.

Proper instrumentation is required to service electrical controls. The control in this furnace is equipped with a Status Code LED (Light-Emitting Diode) to aid in installation, servicing, and troubleshooting. It can be viewed through the sight glass in blower access door. The furnace control LED is either ON continuously, rapid flashing, or a code composed of 2 digits. The first digit is the number of short flashes, the second digit is the number of long flashes.

For an explanation of status codes, refer to service label located on blower access door or Fig. 43, and the troubleshooting guide at the end of this procedure. The furnace control will store 1 status code for 72 hours.

For Controls With a Red LED The stored status codes WILL be erased from the control memory,

if 115- or 24-v power is interrupted.

1. To retrieve status code, proceed with the following:

NOTE: NO thermostat signal may be present at control, and all blower-OFF delays must be completed.

a. Leave 115-v power to furnace turned on. b. Remove outer access door. c. Look into blower access door sight glass for current LED

status. DO NOT remove blower access door or terminate 115-v power to control or status code will be lost.

d. BRIEFLY remove insulated terminal wire from the draft

safeguard switch (DSS) until LED goes out (1 to 2 sec), then reconnect it.

2. When above items have been completed, the LED flashes status code 4 times. Record this status code for further troubleshooting.

3. Component self-test will begin. Refer to COMPONENT TEST section for complete test sequence.

4. Check LED status.

5. Refer to the SERVICE label on the front of the blower access door for more information.

Component Self-Test

Component Test can also be initiated by performing the following:

1. Remove outer access door.

2. Remove blower access door.

3. Remove the wire from the ″R″ terminal of the control board.

4. Manually close blower access door switch.

Blower access door switch opens 115-v power to control. No component operation can occur unless switch is closed. Caution must be taken when manually closing this switch for service purposes. Failure to follow this warning could result in electrical shock, personal injury, or death.

5. BRIEFLY short (jumper) TEST/TWIN, 3/16-in. quickconnect male terminal on control (behind Y terminal) to the C

OM-24V terminal on furnace control. (See Fig. 23.)

Page 32

SERVICE

If status code recall is needed, briefly remove then reconnect one main limit wire to display stored status code. On RED LED boards do not remove power or blower door before initiating status code recall. After status code recall is completed component test will occur.

EACH OF THE FOLLOW ING STATUS CODES IS A TWO DIGIT NUMBER WITH THE FIRST DIGIT DETERMINED BY THE NUMB ER O F SH ORT FLASH ES AN D TH E SECOND DIGIT BY THE NUMBER OF LONG FLASHES.

11 NO PREVIOUS CODE - Stored status code is erased automatically after 72 hours. On

RED LED boards stored status codes can also be erased when power (115 VAC or 24 VAC) to control is interrupted.

12 BLOWER ON AFTER POWER UP (115 VAC or 24 VAC) -Blower runs for 90 seconds,

if unit is powered up during a call for heat (R-W closed) or R-W opens during blower on-delay.

13 LIM IT CIRCUIT LOCKOUT - Loc kout occurs if the limit, draft safeguard, flame rollout, or

blocked vent switch (if used) is open longer than 3 minutes or 10 successive limit trips occurred during high-heat. - Control will auto reset after three hours. - Refer to #33.

14 IGNITION LOCKOUT - Control will auto-reset after three hours. Refer to #34. 21 GAS HEATING LOCKOUT - Control will NOT auto reset .

Check for: - Mis-wired gas valve -Defective control (valve relay)

22 ABNORMAL FLAME-PROVING SIGNAL - Flame is proved while gas valve is de-

energized. Inducer will run until fault is cleared. Check for: - Leaky gas valve

- Stuck-open gas valve

23 PRESSURE SWITCH DID NOT OPEN Check for:

- Obstructed pressure tubing. - Pressure switch stuck closed.

24 SECONDARY VOLTAGE FUSE IS OPEN Check for:

- Short circuit in secondary voltage (24VAC) wiring.

COMPONENT TEST

To initiate the component test sequence, shut OFF the room thermostat or disconnect the "R" thermostat lead. Briefly short the TEST/TWIN ter minal to the "Com 24V" terminal. Status LED will flash code and then turn ON the inducer motor. The inducer motor will run for the entire component test. The hot surface ignitor, blower motor fan speed (on AMBER LED boards only) blower motor-heat speed, and blower motor-cool speed will be turned ON for 10-15 seconds each. Gas Valve and Humidifier will not be turned on.

LED CODE

CONTINUOUS OFF - Check for 115VAC at L1 and L2, and 24VAC at SEC-1 and SEC-2. CONTINUOUS ON - Control has 24VAC power . RAPID FLASHING - Line v oltage (115VAC) polarity reversed. If twinned, refer to twinning kit instructions.

327596-101 REV. A

STATUS

31 PRESSURE SWITCH DID NOT CLOSE OR REOPENED - If open longer than five minutes,

inducer shuts off for 15 minutes before retry. Check for: - Excessive wind

- Proper vent sizing - Defective inducer motor

- Low inducer voltage (115VAC) - Def ective pressure switch

- Inadequate combustion air supply - Disconnected or obstructed pressure tubing

- Low inlet gas pressure (if LGPS used) - Restricted vent If it opens during blower on-delay period, blow er will come on for the selected blower off-delay.

33 LIMIT CIRCUIT FAULT -Indicates the limit, draft safeguard, flame rollout, or blocked vent

switch (if used) is open or the furnace is operating in high-heat only mode due to 2 successive low heat limit trips. Blower will run for 4 minutes or until open switch remakes whichever is longer. If open longer than 3 minutes, code changes to lockout #13. If open less than 3 minutes status code #33 continues to flash until blower shuts off. Flame rollout switch and BVSS require manual reset. Check for: - Restricted vent

- Proper vent sizing - Loose blower wheel. - Excessive wind

- Dirty filter or restricted duct system.

- Defective blower motor or capacitor. - Defective switch or connections.

- Inadequate combustion air supply (Flame Roll-out Switch open).

34 IGNITION PROVING FAILURE - Control will try three more times before lockout #14

occurs. If flame signal lost during blower on-delay period, blower will come on for the selected blower off-delay. Check for: - Flame sensor must not be grounded

- Oxide buildup on flame sensor (clean with fine steel wool).

- Proper flame sense microamps (.5 microamps D.C. min., 4.0 - 6.0 nominal).

- Gas valve defective or gas valve turned off - Manual valve shut-off

- Defective Hot Surface Ignitor - Control ground continuity

- Low inlet gas pressure - Inadequate flame carryover or rough ignition

- Green/Y ellow wire MUST be connected to furnace sheet metal

45 CONTROL CIRCUITRY LOCKOUT Auto-reset after one hour lockout due to;

- Gas valve relay stuck open - Flame sense circuit failure - Software check error Reset power to clear lockout. Replace control if status code repeats.

Fig. 43—Service Label

NOTE: If TEST/TWIN to COM-24V terminals are jumpered

longer than 2 sec, LED will flash rapidly, and test request will be ignored.

6. Component Test will function as follows: a. LED flashes a status code 4 times. Record this status code

for further troubleshooting.

b. Inducer motor starts and continues to run until step f of

component test sequence.

c. Hot surface igniter is energized for 15 sec, then de-

energized. d. Blower operates at HEAT speed for 10 sec, then turns off. e. Blower operates at COOL speed for 10 sec, then turns off. f. Inducer motor turns off.

Items a through f above will assist in furnace troubleshooting since all componentsare functionally operated except thegas valve. This procedure is also referred to as ″Component Test Sequence.″

7. Check LED status. If no previous fault is in history, control will flash status code 11.

8. If LED status indicates proper operation, RELEASE BLOWER ACCESS DOOR SWITCH, reattach wire to ″R″ terminal on furnace control board, replace blower access door, and replace burner access door.

Step 2—Care and Maintenance

For continuing high performance and to minimize possible equipment failure, periodic maintenance must be performed on this equipment. Consult your local dealer about proper frequency of maintenance and the availability of a maintenance contract.

Never store anything on, near, or in contact with the furnace, such as:

1. Spray or aerosol cans, rags, brooms, dust mops, vacuum cleaners, or other cleaning tools.

2. Soap powders, bleaches, waxes or other cleaning compounds, plastic or plastic containers, gasoline, kerosene, cigarette lighter fluid, dry cleaning fluids, or other volatile fluids.

3. Paint thinners and other painting compounds, paper bags, or other paper products. A failure to follow this warning could result in corrosion of the heat exchanger, fire, personal injury, or death.

Turn off the gas and electrical supplies to the unit before performing any maintenance or service. Follow the operating instructions on the label attached to the furnace. A failure to follow this warning could result in personal injury.

Never operate unit without a filter or with filter access door removed. A failure to follow this warning could result in fire, personal injury, or death.

A02027

Personal injury can result from sharp metal edges, etc. Be

→

careful when removing parts. Gloves and safety glasses should be worn when servicing equipment

The minimum maintenance on this equipment is as follows:

1. Check and clean air filter each month or more frequently if required. Replace if torn.

2. Check blower motor and wheel for cleanliness each heating and cooling season. Clean as necessary.

Page 33

3. Check electrical connections for tightness and controls for proper operation each heating season. Service as necessary.

4. Inspect burner compartment before each heating season for rust, corrosion, soot or excessive dust. If necessary, have furnace and burner serviced by a qualified professional.

5. Inspect the vent pipe/vent system before each heating season for rust, corrosion, water leakage, sagging pipes or broken fittings. Have vent pipes/vent system serviced by a qualified professional.

6. Inspect any accessories attached to the furnace such as a humidifier or electronic air cleaner. Perform any service or maintenance to the accessories as recommended in the accessory instructions.

CLEANING AND/OR REPLACING AIR FILTER The air filter arrangement may vary depending on the application.

The filter is exterior to the furnace casing. NOTE: If the filter has an airflow directionarrow, the arrow must

point towards the blower.

Personal injury can result from sharp metal edges, etc. Be careful when removing parts. Gloves and safety glasses should be worn when servicing equipment

Media cabinet filter procedures: NOTE: Media cabinet or 1″ Filter Rack are accessories and are

not included from the factory with the standard furnace model.

1. Turn off electrical supply to furnace before removing filter access door.

2. Remove filter cabinet door.

3. Slide filter out of cabinet.

4. If equipped with permanent, washable 1″ filter, clean filter by spraying cold tap water through filter in opposite direction of airflow. Rinse filter and let dry. Oiling or coating of the filter is not recommended. See Table 9 for size information.

5. If equipped with factory-specified disposable media filter, replace only with media filter having the same part number and size. For expandable replacement media, refer to the instructions included with the replacement media. If equipped with KGAFR0301ALL external filter rack, See Table 9.

6. Slide filter into cabinet.

7. Replace filter cabinet door.

8. Turn on electrical supply to furnace.

Table 9—FILTER SIZE INFORMATION (IN.)

FURNACE

CASING WIDTH

14-1/2 (1) 16 X 25 X 1 (1) 14 X 25 X 1 Cleanable* 17-1/2 (1) 16 X 25 X 1 (1) 16 X 25 X 1 Cleanable*

21 (1) 16 X 25 X 1 (1) 20 X 25 X 1 Cleanable*

24** (1) 16 X 25 X 1 (1) 24 X 25 X 1 Cleanable*

* Recommended ** Some furnaces may have 2 filters

FILTER QUANTITY AND SIZE

Side Return Bottom Return

FILTER

TYPE

BLOWER MOTOR AND WHEEL

Blower access door switch opens 115-v power to control. No

→

The blower wheel should not be dropped or bent as balance will be affected.

The following steps should be performed by a qualified service technician.

To ensure long life and high efficiency, clean accumulated dirt and grease from blower wheel and motor annually.

The inducer and blower motors are pre-lubricated and require no additional lubrication. These motors can be identified by the absence of oil ports on each end of the motor.

Clean blower motor and wheel as follows:

1. Turn off electrical supply to furnace.

2. Unscrew the thumbscrew on outer door and remove outer door.

3. For downflow or horizontal furnaces having vent pipes within the furnace that pass in from of the blower access door:

a. Disconnect vent connector from furnace vent elbow. b. Disconnect and remove short piece of vent pipe from

within furnace.

4. Remove 2 screwsfrom blower accessdoor and remove blower access door.

5. Disconnect blower leadsfrom furnace control. Note wire color and location for reassembly. All other factory wires can be left connected, but field thermostat connections may need to be disconnected depending on their length and routing.

6. Remove 2 screws from control box to blower shelf.

7. Hang control box from front of furnace casing and away from blower compartment.

8. Remove 2 screws holding blower assembly to blower deck and slide blower assembly out of furnace.

9. Clean blower wheel and motor using a vacuum with soft brush attachment. Blower wheel blades may be cleaned with a small paint or flux brush. Do not remove or disturb balance weights (clips) on blower wheel blades.

10. Vacuum any loose dust from blower housing, wheel and motor.

11. If a greasy residue is present on blower wheel, remove wheel from the blower housing and wash it with an appropriate degreaser. To remove wheel:

NOTE: Before disassembly, mark blower motor, and blower housing so motor and each arm is positioned at the same location during reassembly.

a. Disconnect capacitor wires and ground wire attached to

blower housing.

b. Remove screws securing cutoff plate and remove cutoff

plate from housing. c. Loosen set screw holding blower wheel on motor shaft. d. Remove bolts holding motor to blower housing and slide

motor out of wheel.

Page 34

e. Remove blower wheel from housing. f. Clean wheel and housing.

12. Reassemble motor and blower by reversing steps 11f, finishing with 11a. Be sure to reattach ground wire to the blower housing.

13. Verify that blower wheel is centered in blower housing and set screw contacts the flat portion of the motor shaft. Loosen set screw on blower wheel and reposition if necessary.

14. Spin the blower wheel by hand to verify that the wheel does not rub on the housing.

15. Reinstall blower assembly in furnace.

16. Reinstall control box assembly in furnace.

Heating fan speed(s) MUST be adjusted to provide proper air temperature rise as specified on the rating plate. Failure to adjust the heating speed(s) may shorten heat exchanger life. Recommended operation is at the midpoint of the rise range or slightly above. Refer to ″SET TEMPERATURE RISE″ under START-UP, ADJUSTMENT, and SAFETY CHECK.

NOTE: Refer to Table 7 for motor speed lead relocation if leads were not identified before disconnection.

17. Reconnect blower leads to furnace control. Refer to furnace wiring diagram, and connect thermostat leads if previously disconnected. (See Fig. 39.)

18. To check blower for proper rotation: a. Turn on electrical supply.

Blower access door switch opens 115-v power to furnace control. No component operation can occur. Caution must be taken when manually closing this switch for service purposes. Failure to follow this warning could result in electrical shock, personal injury, or death.

b. Manually close blower access door switch.

NOTE: If thermostat terminals are jumpered at the time blower access door switch is closed, blower will run for 90 sec before beginning a heating or cooling cycle.

c. Perform component self-test as shown at the bottom of the

SERVICE label, located on the front of blower access door.

d. Verify blower is rotating in the correct direction.

19. If furnace is operating properly, RELEASE BLOWER ACCESS DOOR SWITCH. Replace blower access door and remove any jumpers or reconnect anydisconnected thermostat leads.

20. Downflow or horizontal furnaces with vent pipe through furnace only:

a. Install and connect short piece of vent pipe inside furnace

to existing vent.

b. Connect vent connector to vent elbow.

21. Reinstall casing door.

22. Turn on gas supply and cycle furnace through one complete heating and cooling cycle. Verify the unit temperature rise as shown in Adjustments Section. Adjust temperature rise as shown in Adjustments Section. If outdoor temperature is below 70° F, turn off circuit breaker to outdoor unit before running furnace in the cooling cycle. Turn outdoor circuit breaker on after completing cooling cycle.

CLEANING HEAT EXCHANGER

The following steps should be performed by a qualified service technician:

NOTE: If the heat exchangers get a heavy accumulation of soot and carbon, they should be replaced rather than trying to clean them thoroughly. A build-up of soot and carbon indicates that a problem exists which needs to be corrected, such as improper adjustment of manifold pressure, insufficient or poor quality combustion air, incorrect size or damaged manifold orifice(s), improper gas, or a restricted heat exchanger. Action must be taken to correct the problem.

If it becomes necessary to clean the heat exchangers because of dust or corrosion, proceed as follows:

1. Turn OFF gas and electrical power to furnace.

2. Remove outer access door.

3. Disconnect vent connector from furnace vent elbow.

4. For downflow or horizontal furnace having an internal vent pipe, remove internal vent pipe within the casing.

5. Disconnect wires to the following components. Mark wires to aid in reconnection of:

a. Draft safeguard switch. b. Inducer motor. c. Pressure switch(es). d. Limit overtemperature switch. e. Gas valve. f. Hot surface igniter. g. Flame-sensing electrode h. Flame rollout switches. i. Remove NOx baffles on low NOx models.

6. Remove screws that fasten the collector box assembly to the cell panel. Be careful not to damage the collector box. Inducer assembly and elbow need not be removed from collector box.

7. Disconnect gas line from gas manifold.

8. Remove the 4 screws that attach the burner assembly to the cell panel. The gas valve and individual burners need not be removed from support assembly.

NOTE: Be very careful when removing burner assembly to avoid breaking igniter. See Fig. 44 and 45 for correct igniter location.

9/32”

11/32”

A02150

Fig. 44—Position of Igniter to Burner

Page 35

7/8”

A02151

Fig. 45—Position of Igniter to Burner

9. Using field-provided 25-caliber rifle cleaning brush, 1/4″

diameter steel spring cable, 36 in. long, a variable speed, reversible electric drill, and vacuum cleaner, clean cells as follows:

a. Remove metal screw fitting from wire brush to allow

insertion into cable.

b. Insert the twisted wire end of brush into end of spring

cable, and crimp tight with crimping tool or crimp by striking with ball-peen hammer. TIGHTNESS IS VERY IMPORTANT.

NOTE: The materials needed in item 9 can usually be purchased at local hardware stores.

(1.) Attach variable-speed, reversible drill to the end of

spring cable (end opposite brush).

(2.) Insert brush end of cable into the outlet opening of cell

and slowly rotate with drill. DO NOT force cable. Gradually insertcable into upper pass ofcell. (See Fig.

46.)

(3.) Work cable in and out of cell 3 or 4 times to obtain

sufficient cleaning. DO NOT pull cable with great force. Reverse drill and gradually work cable out.

(4.) Insert brush end of cable in burner inlet opening of

cell, and proceed to clean 2 lower passes of cell in same manner as upper pass.

(5.) Repeat foregoing procedures until each cell in furnace

has been cleaned. (6.) Using vacuum cleaner, remove residue from each cell. (7.) Using vacuum cleaner with soft brush attachment,

clean burner assembly. (8.) Clean flame sensor with fine steel wool. (9.) Reinstall burner assembly. Center burners in cell

openings.

10. Remove old sealant from cell panel and inducer backing plate flange.

11. Spray releasing agent on the heat exchanger cell panel where collector box assembly contacts cell panel.

NOTE: A releasing agent such as cooking spray or equivalent (must not contain corn or canola oil, aromatic or halogenated hydrocarbons or inadequate seal may occur) and RTV sealant (G.E. 162, 6702, or Dow-Corning 738) are needed before starting installation. DO NOT substitute any other type of RTV sealant. G.E. 162 (P771-9003) is available through RCD in 3-oz tubes.

12. Apply new sealant to flange of inducer assembly and attach to cell panel using existing screws, making sure all screws are secure.

Fig. 46—Cleaning Heat Exchanger Cell

13. Reconnect wires to the following components (Use connection diagram on wiring label, if wires were not marked for reconnection locations.):

a. Draft safeguard switch. b. Inducer motor. c. Pressure switch(es). d. Limit overtemperature switch. e. Gas valve. f. Hot surface igniter. g. Flame-sensing electrode. h. Flame rollout switches. i. Install NOx baffles (if removed).

14. Reinstall internal vent pipe, if applicable.

15. Reinstall vent connector on furnace vent elbow. Securely fasten vent connector to vent elbow with 2 field-supplied, corrosion-resistant, sheet metal screws located 180° apart.

16. Replace blower access door only.

17. Set thermostat above room temperature and check furnace for proper operation.

18. Verify blower airflow and speed changes between heating and cooling.

19. Check for gas leaks.

Never use a match or other open flame to check for gas leaks. Use a soap-and-water solution. A failure to follow this warning could result in fire, personal injury, or death.

20. Replace outer access door.

Step 3—Sequence of Operation

→

NOTE: Furnace control must be grounded for properoperation or control will lock out. Control is grounded through green/yellow wire routed to gas valve and manifold bracket screw.

Using the schematic diagram in Fig. 39, follow the sequence of operation through the different modes. Read and follow the wiring diagram very carefully.

NOTE: If a power interruption occurs during a call for heat (W), the control will start a 90-second blower-only ON period two seconds after power is restored, if the thermostat is still calling for gas heating. The red LED light will flash code 12 during the 90-second period, after which the LED will be ON continuous, as long as no faults are detected. After the 90-second period, the furnace will respond to the thermostat normally.

A91252

Page 36

The blower door must be installed for power to be conducted through the blower door interlock switch ILK to the furnace control CPU, transformer TRAN, inducer motor IDM, blower motor BLWM, hot-surface igniter HSI, and gas valve GV.

1. Heating

(See Fig. 24 for thermostat connections.) The wall thermostat ″calls for heat″, closing the R to W circuit. The furnace control performs a self-check, verifies the pressure switch contacts PRS is open, and starts the inducer motor IDM.

a. Inducer Prepurge Period- As the inducer motor IDM

comes up to speed, the pressure switch contacts PRS close, 24 vac power is supplied for a field installed humidifier at the HUM terminal and the control begins a 15-second prepurge period.

b. Igniter Warm-Up- At the end of the prepurge period, the

Hot-Surface Igniter HSI is energized for a 17-second igniter warm-up period.

c. Trial-for-Ignition Sequence- When the igniter warm-up

period is completed the main gas valve relay contacts GVR close to energize the gas valve GV, the gas valve opens. The gas valve GV permits gas flow to the burners where it is ignited. After 5 seconds, the igniter HSI is de-energized and a 2-second Flame-Proving period begins.

d. Flame-Proving- When the burner flame is proved at the

flame-proving sensor electrode FSE, the furnace control CPU begins the blower-ON delay period and continues to hold the gas valve GV open. If the burner flame is not proved within two seconds, the control CPU will close the gas valve GV, and the control CPU will repeat the ignition sequence for up to three more Trials-For-Ignition before going to Ignition-Lockout. Lockout will be reset automatically after three hours, by momentarily interrupting 115 vac power to the furnace, or by interrupting 24 vac power at SEC1 or SEC2 to the furnace control CPU (not at W, G, R, etc.)

If flame is proved when flame should not be present, the furnace control CPU will lock out of Gas-Heating mode and operate the inducer motor IDM until flame is no longer proved.

e. Blower-On Delay- If the burner flame is proven, the

blower motor is energized on HEAT speed 25 seconds after the gas valve GV is energized. Simultaneously, the electronic air cleaner terminal EAC-1 is energized and remains energized as long as the blower motor BLWM is energized.

f. Blower-Off Delay- When the thermostat is satisfied, the

R-to-W circuit is opened, de-energizing the gas valve GV, stopping gas flow to the burners, and de-energizing the humidifier terminal HUM. The inducer motor IDM will remain energized for a 5-second post-purge period. The blower motor BLWM and air cleaner terminal EAC-1 will remain energized for 90, 120, 150, or 180 seconds (depending on the blower-OFF delay selection). The furnace control CPU is factory-set for a 120-second blower-OFF delay.

2. Cooling Mode

(See Fig. 24 for thermostat connections) The thermostat closes the R-to-G-and-Y circuits. The R-to-Y

circuit starts the outdoor unit, and the R-to-G and Y circuits start the furnace blower motor BLWM on COOL speed. The electronic air cleaner terminal EAC-1 is energized with 115 vac when the blower motor BLWM is operating. When thethermostat is satisfied, the R-to-G-and-Y circuits are opened. The outdoor unit will stop, and the furnace blower motor BLWM will continue operating on the COOL speed for an additional 90 seconds. Cut jumper J2 to reduce the cooling off-delay to 5 seconds. (See Fig. 23.)

3. Continuous Blower Mode

When the R-to-G circuit is closed by the thermostat, the blower motor BLWM will operate on continuous-blower speed (sameas HEAT speed). Terminal EAC-1 is energized as long as the blower motor BLWM is energized. During a call for heat, the blower BLWM will stop during igniter warm-up (17 seconds), ignition, and blower-ON delay (25 seconds), allowing the furnace heat exchangers to heat up more quickly, then restarts at the end of the blower-ON delay period at HEAT speed. When the thermostat ″calls for cooling″, the blower motor BLWM will operate at COOL speed. When the thermostat is satisfied, the blower motor BLWM will operate an additional 90 seconds on COOL speed before reverting back to continuous-blower speed. When the R-to-G circuit is opened, the blower motor BLWM will continue operating for an additional 5 seconds, if no other function requires blower motor BLWM operation.

4. Heat Pump

When installed with a heat pump, the furnace control automatically changes the timing sequence to avoid long blower off times during demand defrost cycles. When the R-to-Wand-Y or R-to-W-and-Y-and-G circuits are energized the furnace control CPU will continue to turn on the blower motor BLWM at HEAT speed, and begin a heating cycle. The blower motor BLWM will remain on until the end of the prepurge period, then shut off for 24 seconds then come back on at HEAT speed. When the W input signal disappears, the furnace control begins a normal inducer post-purge period and the blower switches to COOL speed after a 3 second delay. If the R-to-W-and-Y-and-G signals disappear at the same time, the blower motor BLWM will remain on for the selected blower-OFF delay period. If the R-to-W-and-Y signals disappear, leaving the G signal, the blower motor BLWM will continue running the blower motor BLWM at HEAT speed after the selected blower-OFF delay period is completed.

Step 4—Wiring Diagrams

Refer to Fig. 24 and 39 for wiring diagrams.

Step 5—Troubleshooting

Refer to the service label. (See Fig. 43—Service Label.) The Troubleshooting Guide can be a useful tool in isolating

furnace operation problems. Beginning with the word “Start,” answer each question and follow the appropriate arrow to the next item.

The Guide will help to identify the problem or failed component. After replacing any component, verify correct operation sequence.

Page 37

TABLE 10—Orifice Size* and Manifold Pressure For Gas Input Rate

(Tabulated Data Based On 22,000 Btuh Per Burner, Derated 4 Percent For Each 1000 Ft Above Sea Level)

ALTITUDE

RANGE

(FT)

U.S.A. and Canada

ALTITUDE

RANGE

(FT)

U.S.A. and Canada

ALTITUDE

RANGE

(FT)

2000

U.S.A.

Altitudes

2001

3000

Canada

Altitudes

2000

4500

AVG GAS

HEAT VALUE

(BTU/CU FT)

900 42 3.5 42 3.6 42 3.7 41 3.5 925 42 3.3 42 3.4 42 3.5 42 3.7 950 43 3.8 42 3.3 42 3.4 42 3.5

975 43 3.6 43 3.8 42 3.2 42 3.3 1000 43 3.5 43 3.6 43 3.7 43 3.8 1025 43 3.3 43 3.4 43 3.5 43 3.6 1050 44 3.6 43 3.2 43 3.4 43 3.5 1075 44 3.4 44 3.5 43 3.2 43 3.3 1100 44 3.3 44 3.4 44 3.5 43 3.2

AVG GAS

HEAT VALUE

(BTU/CU FT)

800 42 3.4 42 3.5 42 3.6 42 3.7

825 42 3.2 42 3.3 42 3.4 42 3.5

850 43 3.7 43 3.8 42 3.2 42 3.3

875 43 3.5 43 3.6 43 3.7 43 3.8

900 43 3.3 43 3.4 43 3.5 43 3.6

925 43 3.1 43 3.2 43 3.3 43 3.4

950 43 2.9 43 3.0 43 3.1 43 3.2

975 43 2.8 43 2.9 43 3.0 43 3.1 1000 43 2.6 43 2.7 43 2.8 43 2.9

AVG GAS

HEAT VALUE

(BTU/CU FT)

0.58 0.60 0.62 0.64

Orifice

No.

Orifice

No.

Orifice

No.

Manifold

Pressure

0.58 0.60 0.62 0.64 Manifold

Pressure

0.58 0.60 0.62 0.64 Manifold

Pressure

SPECIFIC GRAVITY OF NATURAL GAS

Orifice

No.

SPECIFIC GRAVITY OF NATURAL GAS

Orifice

No.

SPECIFIC GRAVITY OF NATURAL GAS

Orifice

No.

Manifold

Pressure

Manifold

Pressure

Manifold

Pressure

Orifice

No.

Orifice

No.

Orifice

No.

Manifold

Pressure

Manifold

Pressure

Manifold

Pressure

Orifice

No.

Orifice

No.

Orifice

No.

Manifold Pressure

(FT)

3001

4000

HEAT VALUE

(BTU/CU FT)

4001

5000

U.S.A. Only

ALTITUDE

RANGE

U.S.A. Only

* Orifice numbers 43 are factory installed

775 42 3.2 42 3.3 42 3.4 42 3.5 800 43 3.6 43 3.8 42 3.2 42 3.3 825 43 3.4 43 3.5 43 3.7 43 3.8 850 43 3.2 43 3.3 43 3.4 43 3.6 875 43 3.0 43 3.1 43 3.3 43 3.4 900 43 2.9 43 3.0 43 3.1 43 3.2 925 43 2.7 43 2.8 43 2.9 43 3.0 950 43 2.6 43 2.7 43 2.8 43 2.8

AVG GAS

750 43 3.6 43 3.8 42 3.2 42 3.3 775 43 3.4 43 3.5 43 3.6 43 3.8 800 43 3.2 43 3.3 43 3.4 43 3.5 825 43 3.0 43 3.1 43 3.2 43 3.3 850 43 2.8 43 2.9 43 3.0 43 3.1 875 43 2.7 43 2.8 43 2.9 43 2.9 900 43 2.5 43 2.6 43 2.7 43 2.8 925 43 2.4 43 2.5 43 2.6 43 2.6

0.58 0.60 0.62 0.64

Orifice

No.

Manifold

Pressure

SPECIFIC GRAVITY OF NATURAL GAS

Orifice

No.

Manifold

Pressure

Orifice

No.

Manifold

Pressure

Orifice

No.

Manifold Pressure

Page 38

Table 10—Orifice Size* And Manifold Pressure For Gas Input Rate (Continued)

(Tabulated Data Based On 22,000 Btuh Per Burner, Derated 4 Percent For Each 1000 Ft Above Sea Level)

ALTITUDE

RANGE

(FT)

5001

6000

U.S.A. Only

ALTITUDE

RANGE

(FT)

6001

7000

U.S.A. Only

ALTITUDE

RANGE

(FT)

AVG GAS HEAT VALUE AT ALTITUDE

(BTU/CU FT)

725 43 3.4 43 3.5 43 3.6 43 3.7 750 43 3.2 43 3.3 43 3.4 43 3.5 775 43 3.0 43 3.1 43 3.2 43 3.3 800 43 2.8 43 2.9 43 3.0 43 3.1 825 43 2.6 43 2.7 43 2.8 43 2.9 850 43 2.5 43 2.5 43 2.6 43 2.7 875 43 2.3 43 2.4 43 2.5 43 2.6 900 43 2.2 43 2.3 43 2.3 43 2.4

AVG GAS

HEAT VALUE

AT ALTITUDE

(BTU/CU FT)

675 43 3.4 43 3.5 43 3.6 43 3.7 700 43 3.1 43 3.3 43 3.4 43 3.5 725 43 2.9 43 3.0 43 3.1 43 3.2 750 43 2.7 43 2.8 43 2.9 43 3.0 775 43 2.6 43 2.7 43 2.7 43 2.8 800 43 2.4 43 2.5 43 2.6 43 2.7 825 43 2.3 43 2.3 43 2.4 43 2.5 850 43 2.1 43 2.2 43 2.3 43 2.4

AVG GAS

HEAT VALUE

AT ALTITUDE

(BTU/CU FT)

0.58 0.60 0.62 0.64

Orifice

No.

Orifice

No.

Orifice

No.

Manifold

Pressure

0.58 0.60 0.62 0.64 Manifold

Pressure

0.58 0.60 0.62 0.64 Manifold

Pressure

SPECIFIC GRAVITY OF NATURAL GAS

Orifice

No.

SPECIFIC GRAVITY OF NATURAL GAS

Orifice

No.

SPECIFIC GRAVITY OF NATURAL GAS

Orifice

No.

Manifold

Pressure

Manifold

Pressure

Manifold

Pressure

Orifice

No.

Orifice

No.

Orifice

No.

Manifold

Pressure

Manifold

Pressure

Manifold

Pressure

Orifice

No.

Orifice

No.

Orifice

No.

Manifold Pressure

650 43 3.1 43 3.2 43 3.4 43 3.5 675 43 2.9 43 3.0 43 3.1 43 3.2

7001

8000

U.S.A. Only

ALTITUDE

RANGE

(FT)

8001

9000

U.S.A. Only

* Orifice numbers 43 are factory installed

700 43 2.7 43 2.8 43 2.9 43 3.0 725 43 2.5 43 2.6 43 2.7 43 2.8 750 43 2.4 43 2.4 43 2.5 43 2.6 775 43 2.2 43 2.3 43 2.4 43 2.4 800 43 2.1 43 2.1 43 2.2 43 2.3 825 48 3.7 43 2.0 43 2.1 43 2.2

AVG GAS

HEAT VALUE

AT ALTITUDE

(BTU/CU FT)

625 43 2.9 43 3.0 43 3.1 43 3.2 650 43 2.7 43 2.8 43 2.9 43 3.0 675 43 2.5 43 2.6 43 2.7 43 2.8 700 43 2.3 43 2.4 43 2.5 43 2.6 725 43 2.2 43 2.2 43 2.3 43 2.4 750 43 2.0 43 2.1 43 2.2 43 2.2 775 48 3.6 48 3.7 43 2.0 43 2.1

SPECIFIC GRAVITY OF NATURAL GAS

0.58 0.60 0.62 0.64

Orifice

No.

Manifold

Pressure

Orifice

No.

Manifold

Pressure

Orifice

No.

Manifold

Pressure

Orifice

No.

Manifold Pressure

Page 39

Table 10—Orifice Size* And Manifold Pressure For Gas Input Rate (Continued)

(Tabulated Data Based On 22,000 Btuh Per Burner, Derated 4 Percent For Each 1000 Ft Above Sea Level)

ALTITUDE

RANGE

(FT)

9001

10,000

U.S.A. Only

* Orifice numbers 43 are factory installed

AVG GAS

HEAT VALUE

AT ALTITUDE

(BTU/CU FT)

600 43 2.7 43 2.8 43 2.9 43 3.0 625 43 2.5 43 2.6 43 2.6 43 2.7 650 43 2.3 43 2.4 43 2.4 43 2.5 675 43 2.1 43 2.2 43 2.3 43 2.3 700 48 3.7 43 2.0 43 2.1 43 2.2 725 48 3.5 48 3.6 48 3.7 43 2.0

0.58 0.60 0.62 0.64

Orifice

No.

Manifold

Pressure

SPECIFIC GRAVITY OF NATURAL GAS

Orifice

No.

Manifold

Pressure

Orifice

No.

Manifold

Pressure

Orifice

No.

Manifold

Pressure

Page 40

TABLE 11—Orifice Size* and Manifold Pressure For Gas Input Rate

(Tabulated Data Based On 21,000 Btuh Per Burner, Derated 4 Percent For Each 1000 Ft Above Sea Level)

ALTITUDE

RANGE

(FT)

U.S.A. and Canada

ALTITUDE

RANGE

(FT)

U.S.A. and Canada

ALTITUDE

RANGE

(FT)

2000

U.S.A.

Altitudes

2001

3000

Canada

Altitudes

2000

4500

AVG GAS

HEAT VALUE

(BTU/CU FT)

900 42 3.2 42 3.3 42 3.4 42 3.5 925 43 3.7 43 3.8 42 3.2 42 3.3 950 43 3.5 43 3.6 43 3.7 43 3.8

975 43 3.3 43 3.4 43 3.5 43 3.7 1000 44 3.6 43 3.3 43 3.4 43 3.5 1025 44 3.4 44 3.6 43 3.2 43 3.3 1050 44 3.3 44 3.4 44 3.5 43 3.2 1075 45 3.8 44 3.2 44 3.3 44 3.4 1100 46 3.8 45 3.7 44 3.2 44 3.3

AVG GAS

HEAT VALUE

(BTU/CU FT)

800 43 3.8 42 3.2 42 3.3 42 3.4

825 43 3.5 43 3.7 43 3.8 42 3.2

850 43 3.3 43 3.5 43 3.6 43 3.7

875 43 3.2 43 3.3 43 3.4 43 3.5

900 43 3.0 43 3.1 43 3.2 43 3.3

925 43 2.8 43 2.9 43 3.0 43 3.1

950 43 2.7 43 2.8 43 2.9 43 2.9

975 43 2.5 43 2.6 43 2.7 43 2.8 1000 43 2.4 43 2.5 43 2.6 43 2.7

AVG GAS

HEAT VALUE

(BTU/CU FT)

0.58 0.60 0.62 0.64

Orifice

No.

Orifice

No.

Orifice

No.

Manifold

Pressure

0.58 0.60 0.62 0.64 Manifold

Pressure

0.58 0.60 0.62 0.64 Manifold

Pressure

SPECIFIC GRAVITY OF NATURAL GAS

Orifice

No.

SPECIFIC GRAVITY OF NATURAL GAS

Orifice

No.

SPECIFIC GRAVITY OF NATURAL GAS

Orifice

No.

Manifold

Pressure

Manifold

Pressure

Manifold

Pressure

Orifice

No.

Orifice

No.

Orifice

No.

Manifold

Pressure

Manifold

Pressure

Manifold

Pressure

Orifice

No.

Orifice

No.

Orifice

No.

Manifold

Pressure

Manifold

Pressure

Manifold

Pressure

(FT)

3001

4000

HEAT VALUE

(BTU/CU FT)

4001

5000

U.S.A. Only

ALTITUDE

RANGE

U.S.A. Only

* Orifice numbers 43 are factory installed

775 43 3.5 43 3.7 43 3.8 42 3.2 800 43 3.3 43 3.4 43 3.5 43 3.7 825 43 3.1 43 3.2 43 3.3 43 3.4 850 43 2.9 43 3.0 43 3.1 43 3.2 875 43 2.8 43 2.9 43 3.0 43 3.1 900 43 2.6 43 2.7 43 2.8 43 2.9 925 43 2.5 43 2.6 43 2.7 43 2.7 950 43 2.4 43 2.4 43 2.5 43 2.6

AVG GAS

750 43 3.3 43 3.4 43 3.5 43 3.6 775 43 3.1 43 3.2 43 3.3 43 3.4 800 43 2.9 43 3.0 43 3.1 43 3.2 825 43 2.7 43 2.8 43 2.9 43 3.0 850 43 2.6 43 2.7 43 2.8 43 2.8 875 43 2.4 43 2.5 43 2.6 43 2.7 900 43 2.3 43 2.4 43 2.5 43 2.5 925 43 2.2 43 2.2 43 2.3 43 2.4

0.58 0.60 0.62 0.64

Orifice

No.

Manifold

Pressure

SPECIFIC GRAVITY OF NATURAL GAS

Orifice

No.

Manifold

Pressure

Orifice

No.

Manifold

Pressure

Orifice

No.

Manifold

Pressure

Page 41

Table 11—Orifice Size* And Manifold Pressure For Gas Input Rate (Continued)

(Tabulated Data Based On 21,000 Btuh Per Burner, Derated 4 Percent For Each 1000 Ft Above Sea Level)

ALTITUDE

RANGE

(FT)

5001 6000

U.S.A. Only

ALTITUDE

RANGE

(FT)

6001 7000

U.S.A. Only

ALTITUDE

RANGE

(FT)

AVG GAS HEAT VALUE AT ALTITUDE

(BTU/CU FT)

725 43 3.1 43 3.2 43 3.3 43 3.4 750 43 2.9 43 3.0 43 3.1 43 3.2 775 43 2.7 43 2.8 43 2.9 43 3.0

800 43 2.5 43 2.6 43 2.7 43 2.8 825 43 2.4 43 2.5 43 2.5 43 2.6 850 43 2.2 43 2.3 43 2.4 43 2.5 875 43 2.1 43 2.2 43 2.3 43 2.3 900 43 2.0 43 2.1 43 2.1 43 2.2

AVG GAS

HEAT VALUE

AT ALTITUDE

(BTU/CU FT)

675 43 3.1 43 3.2 43 3.3 43 3.4 700 43 2.9 43 3.0 43 3.1 43 3.2 725 43 2.7 43 2.8 43 2.9 43 2.9 750 43 2.5 43 2.6 43 2.7 43 2.8 775 43 2.3 43 2.4 43 2.5 43 2.6 800 43 2.2 43 2.3 43 2.3 43 2.4 825 43 2.1 43 2.1 43 2.2 43 2.3 850 48 3.7 43 2.0 43 2.1 43 2.1

AVG GAS

HEAT VALUE

AT ALTITUDE

(BTU/CU FT)

0.58 0.60 0.62 0.64

Orifice

No.

Orifice

No.

Orifice

No.

Manifold

Pressure

0.58 0.60 0.62 0.64 Manifold

Pressure

0.58 0.60 0.62 0.64 Manifold

Pressure

SPECIFIC GRAVITY OF NATURAL GAS

Orifice

No.

SPECIFIC GRAVITY OF NATURAL GAS

Orifice

No.

SPECIFIC GRAVITY OF NATURAL GAS

Orifice

No.

Manifold

Pressure

Manifold

Pressure

Manifold

Pressure

Orifice

No.

Orifice

No.

Orifice

No.

Manifold

Pressure

Manifold

Pressure

Manifold

Pressure

Orifice

No.

Orifice

No.

Orifice

No.

Manifold

Pressure

Manifold

Pressure

Manifold

Pressure

650 43 2.9 43 3.0 43 3.1 43 3.2 675 43 2.7 43 2.7 43 2.8 43 2.9

7001

8000

U.S.A. Only

ALTITUDE

RANGE

(FT)

8001

9000

U.S.A. Only

* Orifice numbers 43 are factory installed

700 43 2.5 43 2.6 43 2.6 43 2.7 725 43 2.3 43 2.4 43 2.5 43 2.5 750 43 2.1 43 2.2 43 2.3 43 2.4 775 43 2.0 43 2.1 43 2.2 43 2.2 800 48 3.6 48 3.7 43 2.0 43 2.1 825 48 3.3 48 3.5 48 3.6 48 3.7

AVG GAS

HEAT VALUE

AT ALTITUDE

(BTU/CU FT)

625 43 2.7 43 2.7 43 2.8 43 2.9 650 43 2.5 43 2.5 43 2.6 43 2.7 675 43 2.3 43 2.4 43 2.4 43 2.5 700 43 2.1 43 2.2 43 2.3 43 2.3 725 48 3.7 43 2.0 43 2.1 43 2.2 750 48 3.5 48 3.6 48 3.7 43 2.0 775 49 3.8 48 3.4 48 3.5 48 3.6

SPECIFIC GRAVITY OF NATURAL GAS

0.58 0.60 0.62 0.64

Orifice

No.

Manifold

Pressure

Orifice

No.

Manifold

Pressure

Orifice

No.

Manifold

Pressure

Orifice

No.

Manifold

Pressure

Page 42

Table 11—Orifice Size* And Manifold Pressure For Gas Input Rate (Continued)

(Tabulated Data Based On 21,000 Btuh Per Burner, Derated 4 Percent For Each 1000 Ft Above Sea Level)

ALTITUDE

RANGE

(FT)

9001

10,000

U.S.A. Only

* Orifice numbers 43 are factory installed

AVG GAS HEAT VALUE AT ALTITUDE

(BTU/CU FT)

600 43 2.4 43 2.5 43 2.6 43 2.7 625 43 2.3 43 2.3 43 2.4 43 2.5 650 43 2.1 43 2.2 43 2.2 43 2.3 675 48 3.6 48 3.8 43 2.1 43 2.1 700 48 3.4 48 3.5 48 3.6 48 3.7 725 49 3.7 49 3.8 48 3.4 48 3.5

0.58 0.60 0.62 0.64

Orifice

No.

Manifold

Pressure

SPECIFIC GRAVITY OF NATURAL GAS

Orifice

No.

Manifold

Pressure

Orifice

No.

Manifold

Pressure

Orifice

No.

Manifold Pressure

Page 43

A02106a

Is door switch closed?

YES

Is circuit breaker closed?

Is there 115V going to switch?

YES

Check for continuity in wire from circuit breaker

to furnace.

Replace door switch.

Check room thermostat or

Close circuit breaker and go back to START.

Replace transformer.

interconnecting cable.

YES

Is 24V present at W, Y1 (if present), Y/Y2 or

G thermostat terminals on the furnace control?

YES

Does the control respond to W , Y1 (if present),

Y/Y2, and G (24V) thermostat signals?

Disconnect all the thermostat wires from the

furnace control.

Run system through a heating or cooling cycle

to check operation. Status codes are erased

after 72 hours. On RED LED boards stored

status codes can also be erased whenever

(115V or 24V) is interrupted.

Does the problem repeat when using

a jumper wire?

YES

Replace furnace control.

The thermostat is not compatible with the

furnace control. Either install a ballast resistor,

connect the Com24V thermostat terminal to

the thermostat, or replace the thermostat.

TROUBLESHOOTING GUIDE

YES

Is there 115V at L1 and L2?

YES

START

Is LED status light on?

YES

Is there 24V at SEC-1 and SEC-2?

Replace furnace control.

Check for correct line voltage polarity. If units

are twinned, check for proper low-voltage

(24V) transformer phasing.

YES

Is LED status light blinking rapidly without a

pause?

T o recall status code briefly remove and reconnect one RED wire from the draft

safeguard switch to display stored status code. On RED LED control do not

remove power or blower access panel before initiating status code recall. You

can also recall the previous status code by momentarily shorting the TEST/TWIN

terminal to Com24V terminal until the LED goes out. LED will flash the status

code of the previous fault or status code #11 (1 short and 1 long flash) if there

was no previous fault. After the control repeats the code 4 times, the control

will go through a brief component test sequence. The inducer will start and run

for the entire component test. The HSI, blower motor FAN speed (AMBER LED

YES

Is LED status light blinking ON/OFF slowly

with a combination of short and long flashes?

Determine status code. The status code is a

2 digit number with the first digit determined

by the number of short flashes and the second

Was there a previous status code

boards only) HEAT speed, and COOL speed will run for 10 – 15 seconds each.

Gas valve and humidifier will not be turned on.

digit by the number of long flashes?

other than #11?

YES

Go to section below for the status code that

was flashed.

Page 44

Auto-reset after 1 hour lockout due to:

45 CONTROL CIRCUITRY LOCKOUT

- Flame circuit failure.

- Gas valve relay stuck open.

- Software check error.

Reset power to clear lockout. Replace

control if code repeats.

Replace furnace control.

Check for continuity in the harness and igniter.

Replace defective component.

Check connections. If OK, replace control.

Check that all gas valves are turned on.

Replace valve.

ignition.

Check for:

- Inadequate flame carryover or rough

A02106b

(.045” nominal)

- Low inlet gas pressure.

- Proper firing rate.

- Blocked or incorrect carry- over gap.

Allow blower to come on and repeat test to

check for intermittent operation.

Check connections and retry. If current is

near typical value (4.0-6.0 nominal) and

burners will not stay on, replace control.

Replace electrode.

Replace furnace control.

OR REOPENED – If open longer than 5

minutes, inducer shuts off for 15 minutes

before retry. If opens during blower on-

delay period, blower will come on for the

selected blower off-delay. Check for:

- Proper vent sizing.

31 PRESSURE SWITCH DID NOT CLOSE

Unplug igniter harness from control and initiate

another component test sequence. Check

for 115V between pin 1 and NEUTRAL-L2 on

tubing.

- Low inlet gas pressure (if LGPS used).

- Inadequate combustion air supply.

- Disconnected or obstructed pressure

- Defective inducer motor.

- Low inducer voltage (115V).

- Defective pressure switch.

YES

the control. Was 115V present for the 15

second period?

- Excessive wind.

- Restricted vent.

Reconnect the R thermostat lead and set

limit, draft safeguard, flame rollout, or

33 LIMIT CIRCUIT FAULT – Indicates the

YES

thermostat to call for heat. Connect voltmeter

across gas valve connections. Does gas v alve

receive 24V?

Does gas valve open and allow gas to flow?

blocked vent switch* (if used) is open.

Blower will run for 4 minutes or until open

switch remakes whichever is longer. If

open longer than 3 minutes, code

changes to lockout #13. If open less

than 3 min. status code #33 continues

to flash until blower shuts off. Flame

YES

Do the main burners ignite?

rollout switch and BVSS requires manual

reset. Check for:

- Dirty filter or restricted duct system.

- Loose blower wheel.

YES

Do the main burners stay on?

(flame rollout switch open).

- Defective blower motor or capacitor.

- Defective switch or connections.

- Inadequate combustion air supply

- Restricted vent.

- Proper vent sizing.

Repeat call for heat and check flame sensor

- Excessive wind.

YES

current during trial for ignition period. Is the

DC microamps below 0.5?

is not sensed during the trial for ignition

34 IGNITION PROVING FAILURE – If flame

Clean flame sensor with fine steel wool and

recheck current. Nominal current is 4.0 to 6.0

microamps.

YES

period, the control will repeat the ignition

sequence 3 more times before lockout

#14 occurs. If flame signal is lost during

the blower on-delay period, blower will

come on for the selected blower off-delay.

Check the following items first before

proceeding to the next step.

- Gas valve turned off.

to furnace sheet metal.

- Green/Yellow wire MUST be connected

- Flame sensor must not be grounded.

- Manual shut-off valve.

YES

Is current near typical value?

Will main burners ignite and stay on?

To determine whether the problem is in

the gas valve, igniter , or flame sensor the

system can be operated in the component

test mode to check the igniter. First

YES

Fixed.

remove the R thermostat connection from

the control and initiate the component

test sequence. Does the igniter glow

orange/white by the end of the 15 second

warm-up period?

are erased after 72 hours. On RED LED

boards stored status codes can also be

erased whenever power (115V or 24V)

is interrupted. Run system through a

heating or cooling cycle to check system.

(115V OR 24V) – Normal operation.

Blower runs for 90 seconds, if unit is

powered up during a call for heat (R-W

closed) or when (R-W opens) during the

11 NO PREVIOUS CODE – Stored codes

12 BLOWER ON AFTER POWER UP –

blower on-delay period.

occurs if the limit, draft safeguard, flame

rollout, or blocked vent s witch*(if used) is

open longer than 3 minutes. Control will

13 LIMIT CIRCUIT LOCK OUT – Lockout

auto-reset after 3 hours. See code 33.

ignite gas and prove flame in 4 attempts.

14 IGNITION LOCKOUT – System failed to

Control will auto-reset after 3 hours.

See status code 34.

power and wait 5 minutes to retry.

21 GAS HEATING LOCKOUT – Turn off

Check for:

- Stuck closed gas valve relay on control.

- Miswire or short to gas valve wire.

Flame is proved while gas valve is de-

energized. Inducer will run until fault is

cleared. Check for:

- Stuck open or leaky gas valve.

22 ABNORMAL FLAME-PRO VING SIGNAL

Check for:

- Obstructed pressure tube.

23 PRESSURE SWITCH DID NOT OPEN

- Pressure switch stuck closed.

wiring including thermostat leads.

Disconnect thermostat leads to isolate

short circuit.

Check for:

- Short circuit in secondary voltage (24V)

24 SECONDAR Y V OLTA GE FUSE IS OPEN

* Blocked vent switch used in Chimney Adapter Kit

Page 45

Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.

Book 1 4 Tab 6a 8a

PC 101 Catalog No. See Cover Printed in U.S.A. Form 58ST-11SI Pg 44 12-02 Replaces: 58ST-2SI