Bryant 310AAV Installation, start-up, operating, and service and, 310JAV Installation & Operating Instructions Manual
310AAV/JAV
Induced-Combustion
4-Way Multipoise Furnace
Installation, Start-up, Operating, and
Service and Maintenance Instructions
-Series C
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: 5331-012 Form No. II 310A-45-5 5-05
Installation, Start-up, Operating, and
Service and Maintenance Instructions
Series 120/C
NOTE: Read the entire instruction manual before starting the
installation.
This symbol → indicates a change since the last issue.
→
Portions of the text and tables are reprinted from NFPA 54/ANSI Z223.1-2002©,
with permission of National Fire Protection Association, Quincy, MA 02269 and
American Gas Association, Washington DC 20001. This reprinted material is not the
complete and official position of the NFPA or ANSI on the referenced subject, which
is represented only by the standard in its entirety.
TABLE OF CONTENTS
SAFETY CONSIDERATIONS.....................................................2
INTRODUCTION..........................................................................4
CODES AND STANDARDS........................................................4
Safety.........................................................................................5
General Installation...................................................................5
Combustion and Ventilation Air..............................................5
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 ................................7
AIR FOR COMBUSTION AND VENTILATION ......................7
INSTALLATION.........................................................................10
Upflow Installation .................................................................10
Bottom Return Air Inlet....................................................10
Side Return Air Inlet.........................................................10
Leveling Legs (If Desired)................................................10
Downflow Installation ............................................................10
Bottom Return Air Inlet....................................................11
Horizontal Installation ............................................................11
Suspended Furnace Support..............................................11
Platform Furnace Support .................................................11
Roll-Out Protection............................................................11
Bottom Return Air Inlet....................................................11
Side Return Air Inlet.........................................................11
Filter Arrangement..................................................................11
Air Ducts.................................................................................11
General Requirements .......................................................11
Ductwork Acoustical Treatment .......................................12
Supply Air Connections ....................................................12
Return Air Connections.....................................................14
Gas Piping...............................................................................15
Electrical Connections ............................................................19
115-V Wiring.....................................................................19
J-Box Relocation ...............................................................20
Electrical Connection to J-Box.........................................21
Power Cord Installation in Furnace J-Box .......................21
BX Cable Installation in Furnace J-Box ..........................22
Single-Stage
Induced-Combustion
4-Way Multipoise Furnace
Cancels: II 310A-45-4/IM-PG8J-04
II310A-45-5/IM-PG8J-05
24-V Wiring.......................................................................22
Accessories ........................................................................22
Venting....................................................................................22
General Venting Requirements .........................................23
Masonry Chimney Requirements......................................23
Appliance Application Requirements ...............................24
Additional Venting Requirements.....................................26
Sidewall Venting ...............................................................26
START-UP, ADJUSTMENT, AND SAFETY CHECK ............27
General....................................................................................27
Start-Up Procedures................................................................27
Adjustments.............................................................................31
Check Safety Controls............................................................34
Checklist..................................................................................35
SERVICE AND MAINTENANCE PROCEDURES..................35
Introduction.............................................................................35
General...............................................................................35
Electrical Controls and Wiring.........................................36
Care and Maintenance ............................................................37
Cleaning and/or Replacing Air Filter ...............................37
Blower Motor and Wheel..................................................37
Cleaning Heat Exchanger..................................................40
Sequence of Operation............................................................44
Wiring Diagrams.....................................................................45
Troubleshooting ......................................................................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-13SI Pg 1 5-05 Replaces: 58ST-12SI
26-1/8"
(FLUE COLLAR)
7/8" DIA
ACCESSORY
5-15/16"
33-5/16"
28-7/8"
25-1/4"
22-9/16"
JUNCTION BOX
LOCATION
1/2" DIA THERMOSTAT
WIRE ENTRY
3-15/16"
LEFT HAND GAS
ENTRY
7/8" DIA. ACCESSORY
24-7/8"
4-13/16"
8-9/16"
ALTERNATE
2-7/16"
1-5/16"
1-1/8"
A
D
13/16"
F
JUNCTION BOX
LOCATIONS (TYP)
VENT OUTLET
5 PLACES (TYP)
5-1/2"
AIRFLOW
19"
OUTLET
1/2" DIA. K.O.THERMOSTAT
WIRE ENTRY
1-3/4" DIA.RIGHT HAND
GAS ENTRY
7/8" DIA. K.O. WIRE ENTRY
7/8" DIA. ACCESSORY
13/16"
11/16"
14-7/8"
7-3/4"
9-5/8"
11-1/2"
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
24"
CASING
1-11/16"
5-1/2"
11/16"
E
3-3/4"
1-1/2"
22-1/16"
SIDE INLET
1-1/4"
1"
→ Fig. 1—Dimensional Drawing
SAFETY CONSIDERATIONS
FIRE, EXPLOSION, ELECTRICAL SHOCK, AND
CARBON MONOXIDE POISONING HAZARD
Failure to follow this warning could result in dangerous
operation, serious injury, death, or property damage.
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
service agency, local gas supplier, or your distributor or
branch for information or assistance. The qualified service
agency must use only factory-authorized and listed kits or
accessories when modifying this product.
FURNACE RELIABILITY HAZARD
Improper installation or misapplication of furnace may require excessive servicing or cause premature component
failure.
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.
Installing and servicing 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 furnace 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.
CUT HAZARD
Failure to follow this caution may result in personal injury.
Sheet metal parts may have sharp edges or burrs. Use care and
wear appropriate protective clothing, safety glasses and
gloves when handling parts and servicing furnaces.
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, and CAUTION. 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 hazards which may 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.
2
A04037
INSTALLATION
MINIMUM INCHES 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 approved for UPFLOW, DOWNFLOW, and
HORIZONTAL installations.
Cette fournaise est approuvée pour l 'installation HORIZONTALE
et la circulation d 'air VERS LE HAUT et VERS LE BAS.
Clearance arrows
do not change with
furnace orientation.
1"
Les fléches de dégagement
l 'orientation de la fournaise.
This furnace may be installed on combustible
flooring in alcove or closet at minimum clearance
as indicated by the diagram from combusitble
material.
This furnace may be used with a Type B-1 Vent
and may be vented in common with other gas
fired appliances.
Cette fournaise à air pulsé est équipée
pour utilisation avec gaz naturel et altitudes
comprises entre 0-3,050m (0-10,000 pi).
Utiliser une trousse de conversion, fournie par
le fabricant, pour passer au gaz propane ou pour
certaines installations au gaz naturel.
0"
A
0"
*
B
A
C
R
K
R
I
È
R
E
E
D
I
S
É
T
Ô
C
TOP / PLENUM
F
FO
DESSUS / CHAMBRED'AIR
E
C
E
A
S
N
I
A
R
U
N
R
U
T
N
O
T
R
N
F
A
V
A
F
R
O
A
N
V
T
A
N
T
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
´
indiqué sur le diagramme.
qu
Cette fournaise peut être utilisée avec un
´
évacuation de Type B-1 ou connectée
conduit d
au conduit ommun d 'autres appareils à gaz.
Vent Clearance 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 combustibles:
Pour conduit d´évacuation à paroi simple 6 po (6 inches).
Pour conduit d
BOTTOM
DESSOUS
"
0
†
´
évacuation de Type B-1 1 po (1 inch).
MINIMUM INCHES CLEARANCE TO COMBUSTIBLE CONSTRUCTION
DOWNFLOW POSITIONS:
Installation on non-combusibible floors only.
†
For Installation on combustible flooring only when installed on special base, Part No. KGASB0201ALL,
Coil Assembly, Part No. CD5 or CK5, or Coil Casing, Part No. KCAKC.
18 inches front clearance required for alcove.
Ø
Indicates supply or return sides when furnace is in the horizontal position. 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.
DÉGAGEMENT MINIMUM EN POUCES AVEC ÉLÉMENTS
DE CONSTRUCTION COMBUSTIBLES
POUR LA POSITION COURANT DESCENDANT:
Pour l´installation sur plancher non combustible seulement.
†
Pour l´installation sur un plancher combustible seulement quand on utilise la base spéciale, pièce
nº KGASB0201ALL, l
´
ensemble serpentin, pièce nº CD5 ou CK5, ou le carter de serpentin, pièce
nº KCAKC.
Dans une alcôve, on doit maintenir un dégagement à l´avant de 18 po (450mm).
Ø
La poistion indiquée concerne le côté d
*
position horizontale.
Le contact n
´
est permis qu´entre les lignes formées par les intersections du dessus et des
´
entrée ou de retour quand la fournaise est dans la
deux côtés de la cherrise de la fournaise et les solives, montant sous cadre de charpente.
327590-101 REV. C
→ Fig. 2—Clearances to Combustibles
ne change pas avec
0"
E
D
*
I
È
S
T
Ô
C
S
E
R
E
N
V
I
T
R
C
E
E
T
I
E
N
3"
MIN
Ø
Clearance in inches
Dégagement (po).
24"
MIN
A04123
3
→ Table 1—Dimensions (IN.)
FURNACE
SIZE
045-08/024045 14-3/16 12-9/16 12-11/16 9-5/16 4 104
045-12/036045 14-3/16 12-9/16 12-11/16 9-5/16 4 107
070-08/024070 14-3/16 12-9/16 12-11/16 9-5/16 4 111
070-12/036070 14-3/16 12-9/16 12-11/16 9-5/16 4 115
070-16/048070 17-1/2 15-7/8 16 11-9/16 4 126
090-14/042090 17-1/2 15-7/8 16 11-9/16 4 127
090-16/048090 21 19-3/8 19-1/2 13-5/16 4 140
090-20/060090 21 19-3/8 19-1/2 13-5/16 4 146
110-12/036110 17-1/2 15-7/8 16 11-9/16 4 135
110-16/048110 21 19-3/8 19-1/2 13-5/16 4 146
110-22/066110 21 19-3/8 19-1/2 13-5/16 4 152
135-16/048135 21 19-3/8 19-1/2 13-5/16 4 149
135-22/066135 24-1/2 22-7/8 23 15-1/16 4 163
155-20/060155 24-1/2 22-7/8 23 15-1/16 4 170
* 5” or 6” vent connector may be required in some cases.
A
CABINET WIDTH
D
SUPPLY-AIR
WIDTH
(IN.)
E
RETURN-AIR
WIDTH
(IN.)
F
C.L. TOP AND
BOTTOM
FLUE COLLAR
(IN.)
FLUE
COLLAR*
(IN.)
SHIP WT. (LB)
3. Provide adequate combustion and ventilation air to 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.
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 furnace for installation in a 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. See page 7 caution
box regarding the heating of buildings under construction.
10. These Multipoise Gas-Fired Furnaces are CSA (formerly
A.G.A. and C.G.A.) design-certified for use with 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 CSA listed gas conversion kit is required to
convert furnace for use with propane gas.
11. See Fig. 2 for required clearances to combustible construction.
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. See
Fig. 2 for clearance to combustible construction information.
INTRODUCTION
This Series 120/C 4–way multipoise Category I fan-assisted
→
furnace is CSA design-certified. A Category I 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 factoryshipped 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°F db
such as when used with a night setback thermostat. Return-air
temperature must not exceed 85°F db. Failure to follow these
return-air temperature limits may affect reliability of heat exchangers, motors, and controls. (See Fig. 3.)
For accessory installation details, refer to the applicable instruction
literature.
NOTE: Remove all shipping brackets and materials before operating the furnace.
CODES AND STANDARDS
Follow all national and local codes and standards in addition to
these instructions. The installation must comply with regulations
of the serving gas supplier, local building, heating, plumbing, and
other codes. In absence of local codes, the installation must
comply with the national codes listed below and all authorities
having jurisdiction.
4
→
Step 8—Venting
• US: NFGC; chapters 10 and 13
• CANADA: NSCNGPIC Part 7 and Appendix C
60
Fig. 3—Return Air Temperature
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: CSA B149.1-00 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 (www.NFPA.org); or
for only the NFGC, contact the American Gas Association, 400
N. Capitol Street, N.W., Washington, DC 20001
(www.AGA.org).
• CANADA: NSCNGPIC. For a copy, contact Standard Sales,
CSA International, 178 Rexdale Boulevard, Etobicoke (Toronto), Ontario, M9W 1R3 Canada
Step 3—Combustion and Ventilation Air
→
• US: Section 8.3 of the NFGC, Air for Combustion and
Ventilation
• 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 or 2000
HVAC Systems and Equipment Handbook Chapters 9 and 16.
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, and 5, and Appendices 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
A02055
ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS
FURNACE RELIABILITY HAZARD
→
Improper installation or service of furnace may cause premature furnace component failure.
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.
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 the clean, unpainted, metal surface 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
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.
GENERAL
Some assembly and modifications are required when used in any
of the four applications shown in Fig. 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 SAFETY CONSIDERATIONS).
• be located close to the chimney or 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 construction label.
PROCEDURE
LOCATION
5
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
CARBON MONOXIDE POISONING HAZARD
→
Failure to follow this warning could result in personal injury
or death, and unit component damage.
Corrosive or contaminated air may cause failure of parts
containing flue gas, which could leak into the living space.
Air for combustion must not be contaminated by halogen
compounds, which include fluoride, chloride, bromide, and
iodide. These elements can corrode heat exchangers and
shorten furnace life. Air contaminants are found in aerosol
sprays, detergents, bleaches, cleaning solvents, salts, air
fresheners, and other household products. 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.
→
The following types of furnace installations may require OUTDOOR AIR for combustion due to chemical exposures:
• Commercial buildings
• Buildings with indoor pools
• Laundry rooms
• Hobby or craft rooms, and
• Chemical storage areas
→
If air is exposed to the following substances, it should not be used
for combustion air, and outdoor air may be required for combustion:
• Permanent wave solutions
• Chlorinated waxes and cleaners
• Chlorine based swimming pool chemicals
• Water softening chemicals
• De-icing salts or chemicals
• Carbon tetrachloride
• Halogen type refrigerants
• Cleaning solvents (such as perchloroethylene)
• Printing inks, paint removers, varnishes, etc.
• Hydrochloric acid
• Cements and glues
• Antistatic fabric softeners for clothes dryers
• Masonry acid washing materials
THE BLOWER IS
LOCA TED T O THE LEFT
OF THE BURNER SECTION,
AND CONDITIONED AIR IS
DISCHARGED TO THE RIGHT .
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 draft safeguard
opening.
18-IN. MINIMUM
TO BURNERS
Fig. 5—Installation in a Garage
FIRE, INJURY OR DEATH HAZARD
Improper location or inadequate protection could result in fire
or explosion.
When the furnace is installed in a residential garage, the
burners and ignition sources must be located at least 18 inches
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. 5.)
6
A02097
A93044
PERSONAL INJURY AND/OR PROPERTY DAMAGE
→
HAZARD
Improper use or installation of this furnace may cause
premature furnace component failure.
This gas furnace may be used for heating buildings under
construction 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 dust into combustion air, which can cause fouling
and plugging of furnace components.
-The temperature of the return air to the furnace is maintained between 55°F (13°C) and 80°F (27°C), 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.
-Verify proper furnace operating conditions including igni-
tion, gas input rate, air temperature rise, and venting
according to these installation instructions.
→
FIRE, INJURY OR DEATH HAZARD
Failure to follow this warning could result in unsafe furnace
operation.
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 back of furnace. (See Fig. 6.)
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
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.
Fig. 6—Prohibit Installation on Back
AIR FOR COMBUSTION AND VENTILATION
Provisions for adequate combustion, ventilation, and dilution air
must be provided in accordance with:
• U.S. installations: Section 8.3 of the NFGC, Air for Combus-
tion and Ventilation, and applicable provisions of the local
building codes.
• Canadian installations: Part 7 of the NSCNGPIC, Venting
Systems and Air Supply for Appliances, and all authorities
having jurisdiction.
→
FURNACE CORROSION HAZARD
Failure to follow this caution may result in furnace damage.
Air for combustion must not be contaminated by halogen
compounds, which include fluoride, chloride, bromide, and
iodide. These elements can corrode heat exchangers and
shorten furnace life. Air contaminants are found in aerosol
sprays, detergents, bleaches, cleaning solvents, salts, air
fresheners, and other household products.
→
CARBON MONOXIDE POISONING HAZARD
Failure to follow this warning could result in personal injury
or death.
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 air MUST be provided for 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 if an adequate amount of make-up air is
available.
→
The requirements for combustion and ventilation air depend upon
whether or not the furnace is located in a space having a volume
of at least 50 cubic feet per 1,000 Btuh input rating for all gas
appliances installed in the space.
• Spaces having less than 50 cubic feet per 1,000 Btuh require
the OUTDOOR COMBUSTION AIR METHOD.
• Spaces having at least 50 cubic feet per 1,000 Btuh may use the
INDOOR COMBUSTION AIR, STANDARD or KNOWNAIR INFILTRATION METHOD.
A02054
7
→
FURNACE
(BTUH)
110,000 55 9 36.7 7 27.5 6
132,000 66 10 44 8 33 7
154,000 77 10 51.3 9 38.5 8
Table 2–Minimum Free Area Required for Each Combustion Air Opening or Duct to Outdoors
TWO HORIZONTAL DUCTS
(1 SQ. IN./2,000 BTUH) (1,100 SQ. MM/KW)
INPUT
44,000 22 6 14.7 5 11 4
66,000 33 7 22 6 16.5 5
88,000 44 8 29.3 7 22 6
Free Area of
Opening and Duct
(Sq. In.)
Round Duct
(in. Dia)
SINGLE DUCT OR OPENING
(1 SQ. IN./3,000 BTUH) (734 SQ. MM/KW)
Free Area of
Opening and Duct
(sq In.)
Round Duct
(in. Dia)
TWO OPENINGS OR VERTICAL DUCTS
(1 SQ. IN./4,000 BTUH) (550 SQ. MM/KW)
Free Area of
Opening and Duct
(Sq In.)
EXAMPLES: Determining Free Area
FURNACE WATER HEATER TOTAL INPUT
110,000 + 30,000 = (140,000 divided by 4,000) = 35.0 Sq. In. for each two Vertical Ducts or Openings
66,000 + 40,000 = (106,000 divided by 3,000) = 35.3 Sq. In. for a Single Duct or Opening
88,000 + 30,000 = (118,000 divided by 2,000) = 59.0 Sq. In. for each of two Horizontal Ducts
→ Table 3–Minimum Space Volumes for 100% Combustion, Ventilation, and
Dilution from Indoors
OTHER THAN FAN-ASSISTED TOTAL
ACH
0.60 1,050 1,400 1,750 1,100 1,650 2,200 2,750 3,300 3,850
0.50 1,260 1,680 2,100 1,320 1,980 2,640 3,300 3,960 4,620
0.40 1,575 2,100 2,625 1,650 2,475 3,300 4,125 4,950 5,775
0.30 2,100 2,800 3,500 2,200 3,300 4,400 5,500 6,600 7,700
0.20 3,150 4,200 5,250 3,300 4,950 6,600 8,250 9,900 11,550
0.10 6,300 8,400 10,500 6,600 9,900 13,200 16,500 19,800 23,100
0.00 NP NP NP NP NP NP NP NP NP
NP = Not Permitted
(1,000’S BTUH GAS INPUT RATE)
30 40 50 44 66 88 110 132 154
Space Volume (ft
FAN-ASSISTED TOTAL
(1,000’S BTUH GAS INPUT RATE)
3
)
Round Duct
(In. Dia)
Outdoor Combustion Air Method
→
1. Provide the space with sufficient air for proper combustion,
ventilation, and dilution of flue gases using permanent horizontal or vertical duct(s) or opening(s) directly communicating with the outdoors or spaces that freely communicate with
the outdoors.
2. Fig. 7 illustrates how to provide TWO OUTDOOR OPENINGS, one inlet and one outlet combustion and ventilation air
opening, to the outdoors.
a. One opening MUST commence within 12″ (300 mm) of
the ceiling and the second opening MUST commence
within 12″ (300 mm) of the floor.
b. Size openings and ducts per Fig. 7 and Table 2.
c. TWO HORIZONTAL DUCTS require 1 square inch of
free area per 2,000 Btuh (1,100 mm
2
/kW) of combined
input for all gas appliances in the space per Fig. 7 and Table
2.
d. TWO OPENINGS OR VERTICAL DUCTS require 1
square inch of free area per 4,000 Btuh (550 mm
combined input of all gas appliances in the space per Fig.
7 and Table 2.
3. ONE OUTDOOR OPENING requires:
a. 1 square inch of free area per 3,000 Btuh (734 mm
for combined input of all gas appliances in the space per
Table 2 and
2
/kW) for
2
/kW)
b. Not less than the sum of the areas of all vent connectors in
the space.
The opening shall commence within 12″ (300 mm) of the ceiling.
Appliances in the space shall have clearances of at least 1″ (25
mm) from the sides and back and 6″ (150 mm) from the front. The
opening shall directly communicate with the outdoors or shall
communicate through a vertical or horizontal duct to the outdoors
or spaces (crawl or attic) that freely communicate with the
outdoors.
Indoor Combustion Air© NFPA & AGA
Standard and Known-Air-Infiltration Rate Methods
→
Indoor air is permitted for combustion, ventilation, and dilution,
if the Standard or Known-Air-Infiltration Method is used.
CARBON MONOXIDE POISONING HAZARD
Failure to supply outdoor air via grilles or ducts could result
in death and/or personal injury.
Many homes require air to be supplied from outdoors for
furnace combustion, ventilation, and dilution of flue gases.
The furnace combustion air supply must be provided in
accordance with this instruction manual.
8
DUCTS
OUTDOORS
TO
1 SQ IN.
PER 4000
BTUH*
CIRCULATING AIR
DUCTS
VENT THROUGH ROOF
12″ MAX
1 SQ IN.
PER 2000
BTUH*
DUCTS
TO
OUTDOORS
1 SQ IN.
PER 2000
BTUH*
12″ MAX
CIRCULA TING AIR DUCTS
*Minimum dimensions of 3 in.
NOTE:
B
CIRCULA TING
A
CLEARANCE IN FRONT
Use any of the following
combinations of openings:
A & B C & D D & E F & G
AIR DUCTS
OPENINGS SHALL BE
OF COMBUSTION AIR
D
VENT
THROUGH
ROOF
AT LEAST 3 IN.
OUTDOORS
C
DUCT
TO
E
12″ MAX
F
1 SQ IN.
BTUH*
1 SQ IN.
BTUH*
G
1 SQ IN.
PER 4000
BTUH*
12″
MAX
PER
4000
OUTDOORS
PER
4000
12″
MAX
A03174
→ Fig. 7—Air for Combustion, Ventilation and
Dilution for Outdoors
12" MAX
1 SQ IN.
PER 1000
BTUH* IN DOOR
OR WALL
INTERIOR
HEATED
SPACE
CIRCULATING 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.
UNCONFINED
SPACE
6" MIN
(FRONT)
1 SQ IN.
PER 1000
BTUH* IN DOOR
OPENINGS SHALL B E A T LEAST 3 IN.
OR WALL
CLEARANCE IN FRONT OF COMBUSTION AIR
†
12" MAX
A03175
→ Fig. 8—Air for Combustion, Ventilation and
Dilution from Indoors
The Standard Method:
1. The space has no less volume than 50 cubic feet per 1,000
Btuh of the maximum input ratings for all gas appliances
installed in the space and
2. The air infiltration rate is not known to be less than 0.40 air
changes per hour (ACH).
The Known Air Infiltration Rate Method shall be used, if the
infiltration rate is known to be:
1. Less than 0.40 ACH and
2. Equal to or greater than 0.10 ACH
Infiltration rates greater than 0.60 ACH shall not be used. The
minimum required volume of the space varies with the number of
ACH and shall be determined per Table 3 or Equations 1 and 2.
Determine the minimum required volume for each appliance in the
space and add the volumes together to get the total minimum
required volume for the space.
Table 3-Minimum Space Volumes were determined by using the
following equations from the National Fuel Gas Code ANSI
Z223.1-2002/NFPA 54-2002,8.3.2.2:
1. For other than fan-assisted appliances, such as a draft
hood-equipped water heater:
3
Volume
Other
21ft
=
ACH
I
other
1000 Btu/hr
A04002
2. For fan-assisted appliances such as this furnace:
Volume
15ft
=
Fan
ACH
fan
1000 Btu/hr
3
I
If:
= combined input of all other than fan-assisted appli-
I
other
ances in Btu/hr
I
= combined input of all fan-assisted appliances in Btu/hr
fan
ACH = air changes per hour (ACH shall not exceed 0.60.)
→
The following requirements apply to the Standard Method and to
the Known Air Infiltration Rate Method.
1. Adjoining rooms can be considered part of a space if:
a. There are no closable doors between rooms.
b. Combining spaces on same floor level. Each opening shall
have free area of at least 1 in.
of the total input rating of all gas appliances in the space,
but not less than 100 in.
2
/1,000 Btuh (2,000 mm2/kW)
2
(0.06 m2). One opening shall
commence within 12″ (300 mm) of the ceiling and the
second opening shall commence within 12″ (300 mm) of
the floor. The minimum dimension of air openings shall be
at least 3 in. (80 mm). (See Fig. 8.)
A04003
9
c. Combining space on different floor levels. The volumes of
spaces on different floor levels shall be considered as
communicating spaces if connected by one or more permanent openings in doors or floors having free area of at least
2
2 in.
/1,000 Btuh (4,400 mm2/kW) of total input rating of
all gas appliances.
2. An attic or crawlspace may be considered a space that freely
communicates with the outdoors provided there are adequate
permanent ventilation openings directly to outdoors having
free area of at least 1-in.
2
/4,000 Btuh of total input rating for
all gas appliances in the space.
3. In spaces that use the Indoor Combustion Air Method,
infiltration should be adequate to provide air for combustion,
permanent ventilation and dilution of flue gases. However, in
buildings with unusually tight construction, additional air
MUST be provided using the methods described in the
Outdoor Combustion Air Method section.
Unusually tight construction is defined as
Construction with:
a. Walls and ceilings exposed to the outdoors have a continu-
ous, sealed vapor barrier. Openings are gasketed or sealed
and
b. Doors and openable windows are weatherstripped and
c. Other openings are caulked or sealed. These include joints
around window and door frames, between sole plates and
floors, between wall-ceiling joints, between wall panels, at
penetrations for plumbing, electrical and gas lines, etc.
→
Combination of Indoor and Outdoor Air
1. Indoor openings shall comply with the Indoor Combustion
Air Method below and,
2. Outdoor openings shall be located as required in the Outdoor
Combustion Air Method mentioned previously and,
3. Outdoor openings shall be sized as follows:
a. Calculate the Ratio of all Indoor Space volume divided by
required volume for Indoor Combustion Air Method
below.
b. Outdoor opening size reduction Factor is 1 minus the
Ratio in a. above.
c. Minimum size of Outdoor openings shall be the size
required in Outdoor Combustion Air Method above
multiplied by reduction Factor in b. above. The minimum
dimension of air openings shall be not less than 3 in. (80
mm).
INSTALLATION
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 raise furnace and remove 2 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 side return air is used.
A02098
Fig. 9—Removing Bottom Closure Panel
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 must be 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 Item
1. in Bottom Return Air Inlet section.
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 nut to provide desired height, and tighten inside
nut to secure arrangement.
5. Reinstall bottom closure panel if removed.
DOWNFLOW INSTALLATION
NOTE: For downflow applications, this furnace is approved for
use on combustible flooring when any one of the following 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.
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 to bend flange back and forth until it breaks off. Be careful
of sharp edges. (See Fig. 14.)
10
5
⁄16″
5
⁄16″
1 3⁄4″
3
⁄4″
1
5
⁄16″
5
⁄16″
3
1
⁄4″
3
⁄4″
1
A02071
Fig. 10—Leveling Legs
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 raise furnace and remove 2 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.
HORIZONTAL INSTALLATION
Platform Furnace 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 furnace on non-combustible
blocks, bricks or angle iron. For crawlspace installations, if the
furnace is not suspended from the floor joists, the ground underneath furnace must be level and the furnace set on blocks or bricks.
Roll-Out Protection
Provide a minimum 17-3/4″ X22″ piece of sheet metal for flame
roll-out protection in front of burner area for furnaces closer than
12 inches above the combustible deck or suspended furnaces
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 panel on furnaces of widths 17-1/2 in. and
larger may be used for flame 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
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 raise furnace and remove 2 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 side
return air inlet(s) is used without a bottom return air linlet.
Not all horizontal furnaces are approved for side return air
connections (See Fig. 20.)
FILTER ARRANGEMENT
FIRE, EXPLOSION, AND CARBON MONOXIDE
→
POISONING HAZARD
Failure to follow this warning could result in dangerous
operation, serious injury, death or property damage.
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.
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
non-combustible platform, blocks, bricks or pad.
Suspended Furnace 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
furnace from each bottom corner. To prevent screws from pulling
out, use 2 #8 x ¾-in. screws into the side and 2 #8 x ¾-in. screws
in the bottom of the furnace casing for each strap. (See Fig. 15 and
16.)
→
If the screws are attached to ONLY the furnace sides and not the
bottom, the straps must be vertical against the furnace sides and
not pull away from the furnace sides, so that the strap attachment
screws are not in tension (are loaded in shear) for reliable support.
FIRE, CARBON MONOXIDE AND POISONING
HAZARD
Failure to follow this warning could result in fire, personal
injury, or death.
Never operate a furnace without a filter or with filter access
door removed.
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.
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
11
FURNACE
CASING
WIDTH
14–3/16
17–1/2
21
24-1/2
Table 4—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
CFM at the design external static pressure. The furnace airflow
rates are provided in Table 5-AIR DELIVERY-CFM (With Filter).
When a furnace is installed so that the supply ducts carry air
circulated by the furnace to areas outside the space containing the
furnace, the return air shall 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.
NOTE: 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 a 1-in. clearance from combustible materials to supply air
ductwork for a distance of 36 in. horizontally from the furnace. See
NFPA 90B or local code for further requirements.
Ductwork Acoustical Treatment
NOTE: 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 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.
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.
Upflow and Horizontal Furnaces
Connect supply-air duct to flange on furnace supply-air outlet.
Bend flange upward to 90° with wide duct pliers. (See Fig. 14.)
The supply-air duct must be connected to ONLY the furnace
supply-outlet-air duct flanges or air conditioning coil casing (when
used). DO NOT cut main furnace casing side to attach supply air
duct, humidifier, or other accessories. All accessories MUST be
connected external to furnace main casing.
NOTE: For horizontal applications, the top-most flange may be
→
bent past 90 degrees to allow the evaporator coil to hang on the
flange temporarily while the remaining attachment and sealing of
the coil are performed.
12
A
PLENUM
OPENING
B
FURNACE
(OR COIL CASING
WHEN USED)
COMBUSTIBLE
D
FLOORING
FLOOR
OPENING
C
A96283
Fig. 11—Floor and Plenum Opening Dimensions
CD5 OR CK5
COIL ASSEMBLY
COMBUSTIBLE
DOWNFLOW
SUBBASE
SHEET METAL
PLENUM
FLOOR
OPENING
A96285
Fig. 12—Furnace, Plenum, and Subbase Installed on
a Combustible Floor
FURNACE
OR KCAKC
COIL BOX
FLOORING
→
Fig. 13—Furnace, Plenum, and Coil Assembly or Coil Box Installed on a Combustible Floor
Downflow Furnaces
Connect supply-air duct to supply-air outlet on furnace. Bend
flange inward past 90° with wide duct pliers. (See Fig. 14.) The
supply-air duct must be connected to ONLY the furnace supplyoutlet or air conditioning coil casing (when used). When installed
on combustible material, supply-air duct must be connected to
ONLY the accessory subbase, KGASB0201ALL, or factory ap-
SHEET METAL
PLENUM
FLOOR
OPENING
A04140
proved 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.
13
UPFLO
W OWNFLOW
D
HORIZONTAL
120˚
MIN
90˚
PREFERRED
PREFERRED
PERMITTED
PREFERRED
120˚
MIN
PREFERRED
PERMITTED PERMITTED
Fig. 14—Duct Flanges
1
/4" THREADED ROD
4 REQ.
120˚
MIN
90˚
PREFERRED
PREFERRED
A02329
OUTER DOOR
ASSEMBLY
8" MIN FOR DOOR
REMOVAL
(2) HEX NUTS, (2) WASHERS & (2) LOCK WASHERS
REQ. PER ROD
→ Fig. 15—Horizontal Unit Suspension
Return Air Connections
FIRE HAZARD
Failure to follow this warning could cause a fire, personal
injury, or death.
Never connect return-air ducts to the back of the furnace.
Follow instructions below.
Downflow Furnaces
The return-air duct must be connected to return-air opening
(bottom inlet) as shown in Fig. 19. DO NOT cut into casing sides
(left or right). Side opening is permitted for only upflow and most
SECURE ANGLE
IRON TO BOTTOM
OF FURNACE WITH
3
/4" SCREWS
3 #8 x
TYPICAL FOR 2 SUPPORTS
1
1" SQUARE, 1
OR UNI-STRUT MAY BE USED
/4" x 11/4" x 1/8" ANGLE IRON
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. 18 and 20. Bypass humidifier may be
attached to unused side return air side of the furnace casing. (See
Fig. 18 and 20.)
Not all horizontal furnaces are approved for side return air
connections. (See Fig. 20.)
14
A05027
Fig. 16—Horizontal Suspension with Straps
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
22
17 3/4
″
A02014
17 3/4
″ OVER ALL
4 3/4
″ UNDER DOOR
1″ UNDER FURNACE
TYPE-B
VENT
MIN*
″
6
″
30-IN. MIN
WORK AREA
EXTEND OUT 12″ OUT
FROM FACE OF DOOR
* WHEN USED WITH
SINGLE WALL VENT
CONNECTIONS
A02164
GAS PIPING
FIRE OR EXPLOSION HAZARD
Failure to follow this warning could result in personal injury,
death and/or property damage.
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.
FIRE OR EXPLOSION HAZARD
→
Failure to follow this warning coud result in personal injury,
death, and/or property damage.
Use proper length of pipe to avoid stress on gas control
manifold and a gas leak.
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.
15
→
FURNACE
SIZE
024045
036045
024070
036070
048070
042090
048090
060090
036110
048110
066110
*A filter is required for each return-air inlet. Airflow performance included 1-in. washable filter media such as contained in factory-authorized accessory filter rack. To
determine airflow performance without this filter, assume an additional 0.1 in. wc available external static pressure.
-- Indicates unstable operating conditions.
RETURN-AIR
INLET
Bottom
or
Side(s)
Bottom
or
Side(s)
Bottom
or
Side(s)
Bottom
or
Side(s)
Bottom
or
Side(s)
Bottom
or
Side(s)
Bottom
or
Side(s)
Bottom
Only
Both Sides or
1 Side & Bottom
1 Side Only
Bottom
or
Side(s)
Bottom
or
Side(s)
Bottom
Only
Bottom Sides or
1 Side & Bottom
1 Side Only
Table 5—Air Delivery - CFM (With Filter)*
SPEED
High
Med-High
Med-Low
High
Med-High
Med-Low
High
Med-High
Med-Low
High
Med-High
Med-Low
High
Med-High
Med-Low
High
Med-High
Med-Low
High
Med-High
Med-Low
High
Med-High
Med-Low
High
Med-High
Med-Low
High
Med-High
Med-Low
High
Med-High
Med-Low
High
Med-High
Med-Low
High
Med-High
Med-Low
High
Med-High
Med-Low
High
Med-High
Med-Low
0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0
1085
920
820
1440
1360
1250
1030
835
725
1425
1320
1200
1805
1630
1460
1650
1515
1385
2060
1790
1505
2405
2225
2020
2530
2285
1995
2475
2260
1950
1625
1510
1360
2035
1745
1530
2530
2230
1920
2235
1920
2540
2125
1035
875
775
1375
1300
1210
1010
815
700
1375
1280
1175
1740
1585
1420
1600
1485
1360
1985
1765
1505
2310
2155
1955
2450
2215
1945
2395
2190
1910
1575
1470
1335
1965
1710
1515
2470
2205
1900
--
-2200
1900
2495
2120
1795
EXTERNAL STATIC PRESSURE (IN. WC)
975
830
730
1305
1240
1160
980
790
675
1320
1240
1145
1670
1530
1385
1535
1440
1320
1915
1715
1480
2220
2080
1880
2365
2150
1900
2300
2110
1855
1515
1415
1295
1880
1650
1470
2400
2165
1880
2415
2155
1880
2430
2105
1790
915
770
680
1240
1175
1100
945
760
645
1265
1205
1105
1600
1470
1325
1465
1380
1260
1820
1645
1440
2130
1995
1805
2270
2075
1840
2200
2035
1795
1445
1355
1250
1790
1560
1400
2320
2110
1845
2350
2100
1845
2355
2060
1765
845
710
620
1160
1115
1040
900
720
600
1200
1140
1050
1530
1405
1280
1385
1300
1195
1720
1560
1375
2025
1895
1730
2165
1985
1770
2090
1940
1730
1355
1285
1180
1680
1450
1310
2220
2035
1795
2250
2040
1795
2265
2010
1720
770
640
555
1070
1040
965
845
675
555
1125
1075
990
1445
1330
1220
1285
1220
1120
1610
1470
1300
1920
1785
1630
2065
1890
1685
1985
1845
1650
1260
1185
1100
1495
1340
1215
2115
1950
1730
2145
1955
1730
2175
1940
1650
675
555
470
975
950
885
775
610
475
1035
995
920
1360
1255
1155
1175
1115
1025
1490
1345
1190
1790
1675
1535
1940
1780
1600
1865
1735
1555
1165
1070
985
1365
1205
1095
2000
1855
1650
2015
1850
1650
2065
1840
1585
565
440
360
870
850
790
680
490
390
940
905
840
1280
1170
1080
1055
990
915
1340
1195
1045
1660
1565
1420
1805
1660
1480
1730
1620
1445
990
890
810
1215
1090
990
1865
1740
1555
1875
1740
1555
1935
1730
1500
390
250
190
730
725
670
490
375
300
830
790
725
1180
1080
995
895
830
710
1135
1010
890
1530
1420
1275
1670
1525
1350
1585
1475
1310
785
725
--
1075
955
830
1730
1615
1460
1715
1595
1460
1785
1615
1390
195
--
--
560
575
520
335
265
--
655
620
555
1075
990
910
645
600
565
925
820
740
1350
1260
1135
1505
1360
1180
1425
1325
1150
--
--
--
875
750
670
1590
1485
1340
1560
1470
1340
1650
1485
1280
16
→
FURNACE
SIZE
048135
066135
060155
*A filter is required for each return-air inlet. Airflow performance included 1-in. washable filter media such as contained in factory-authorized accessory filter rack. To
determine airflow performance without this filter, assume an additional 0.1 in. wc available external static pressure.
-- Indicates unstable operating conditions.
RETURN-AIR
INLET
Bottom
or
Side(s)
Bottom
Only
Bottom, Sides or
1 Side & Bottom
1 Side Only
Bottom
Only
Both Sides Or
1 Side & Bottom
1 Side Only
Table 5—Air Delivery - CFM (With Filter)* (Continued)
SPEED
High
Med-High
Med-Low
High
Med-High
Med-Low
High
Med-High
Med-Low
High
Med-High
Med-Low
High
Med-High
Med-Low
High
Med-High
Med-Low
High
Med-High
Med-Low
0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0
2090
1790
1545
2485
2195
1880
2180
1880
2135
1880
2465
2115
1800
2155
1800
2140
1800
2010
1755
1525
2400
2150
1850
--
--
--
--
-2145
1850
-2085
1850
2430
2105
1790
-2135
1790
-2095
1790
EXTERNAL STATIC PRESSURE (IN. WC)
1930
1705
1500
2310
2090
1820
2385
2060
1820
2245
2035
1820
2375
2075
1770
2375
2095
1770
2260
2040
1770
1835
1640
1450
2215
2000
1780
2305
2010
1780
2155
1975
1780
2305
2030
1735
2285
2040
1735
2180
1975
1735
1710
1550
1380
2110
1920
1715
2195
1945
1715
2055
1895
1715
2230
1980
1695
2200
1975
1695
2085
1890
1695
1590
1465
1315
2000
1825
1635
2085
1865
1635
1940
1795
1635
2110
1910
1640
2105
1895
1640
1975
1810
1640
1470
1360
1215
1880
1720
1540
1960
1765
1540
1825
1685
1540
2000
1830
1570
1995
1790
1570
1865
1705
1570
1335
1210
1005
1725
1565
1415
1825
1660
1415
1695
1565
1415
1865
1725
1465
1870
1685
1465
1740
1595
1465
1025
945
855
1535
1405
1290
1670
1515
1290
1555
1445
1290
1725
1590
1345
1730
1550
1345
1605
1480
1345
835
785
670
1355
1255
1160
1465
1325
1160
1385
1265
1160
1545
1425
1225
1570
1400
1225
1455
1325
1225
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.
NOTE: In the state of Massachusetts:
→
1. Gas supply connections MUST be performed by a licensed
plumber or gas fitter.
2. When flexible connectors are used, the maximum length
shall not exceed 36 inches (915 mm).
3. When lever handle type manual equipment shutoff valves are
used, they shall be T-handle valves.
4. The use of copper tubing for gas piping is NOT approved by
the state of Massachusetts.
Refer to Table 6 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.
→
FIRE OR EXPLOSION HAZARD
Failure to follow this warning could result in death, personal
injury and/or property damage.
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 served another gas appliance.
Black iron pipe shall be installed at the furnace gas control
valve and extend a minimum of 2-in. outside the furnace.
→
FURNACE OVERHEAT HAZARD
Failure to follow this caution may result in property damage.
Connect gas pipe to gas valve using a backup wrench to avoid
damaging gas controls.
installed immediately upstream of gas supply connection to
furnace and downstream of manual equipment shutoff valve.
NOTE: The gas valve inlet pressure tap connection is suitable to
use as test gauge connection providing test pressure DOES NOT
exceed maximum 0.5 psig (14-in. wc) stated on gas control valve.
(See Fig. 46.)
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 furnace gas controls. Place a ground
joint union between furnace gas control valve and exterior manual
equipment gas shutoff valve. A 1/8-in. NPT plugged tapping,
accessible for test gauge connection, MUST be installed immediately upstream of gas supply connection to furnace and downstream of manual equipment 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.
If pressure exceeds 0.5 psig (14-in. wc), gas supply pipe must be
→
disconnected from furnace and capped before and during supply
pipe 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 equipment shutoff valve
before and during supply pipe pressure test. After all connections
have been made, purge lines and check for leakage at furnace prior
to operating furnace.
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.
An accessible manual equipment 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 gauge connection, MUST be
17
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
18
A02163
A02162
→
* Cubic ft of natural 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 ANSI Z223-2002/NFPA 54-2002.
Table 6—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
→ Fig. 21a—Right Side Gas Entry Example
GAS
SUPPLY
MANUAL
SHUTOFF
VALVE
(REQUIRED
SEDIMENT
TRAP
UNION
A02327
ELECTRICAL SHOCK AND FIRE HAZARD
Failure to follow this warning could result in serious injury,
death, or property damage.
The cabinet MUST 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 gauge. Do not use gas piping as an electrical ground.
FURNACE MAY NOT OPERATE
→
Failure to follow this caution may result in furnace operation
stopping and water pipes freezing during cold weather.
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. Refer to rating plate or Table 7 for equipment electrical
specifications.
U.S. installations: Make all electrical connections in accordance
with National Electrical Code (NEC) ANSI/NFPA 70-2002 and
any local codes or ordinances that might apply.
Canadian installations: Make all electrical connections in accordance with Canadian Electrical Code CSA C22.1 or authorities
having jurisdiction.
→
FIRE HAZARD
Failure to follow this warning could result in serious injury,
death, or property damage.
Do not connect aluminum wire between disconnect switch
and furnace. Use only copper wire.
Fig. 21b—Typical Gas Pipe Arrangement
ELECTRICAL CONNECTIONS
ELECTRICAL SHOCK HAZARD
Failure to follow this warning could result in serious personal
injury or death.
Blower access panel door switch opens 115-v power to
control. No component operation can occur. Do not bypass or
close switch with panel removed.
See Fig. 25 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
Use a separate, fused branch electrical circuit with a properly sized
fuse or circuit breaker for this furnace. See Table 7 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 (Electrical Connection to J-Box).
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 and save two screws holding J-box. (See Fig. 22.)
→
NOTE: The J-Box cover need not be removed from the J-Box in
order to move the J-Box. Do NOT remove green ground screw
inside J-Box. The ground screw is not threaded into the casing
flange and can be lifted out of the clearance hole in casing while
swinging the front edge of the J-Box outboard of the casing.
19
→ Table 7—Electrical Data
FURNACE SIZE
045-08/024045 115-60-1 127 104 5.4 7.54 49 15 14
045-12/036045 115-60-1 127 104 7.0 9.50 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 6.8 9.22 40 15 14
070-16/048070 115-60-1 127 104 9.5 12.60 29 15 14
090-14/042090 115-60-1 127 104 8.2 10.83 34 15 14
090-16/048090 115-60-1 127 104 10.0 13.13 28 15 14
090-20/060090 115-60-1 127 104 13.6 17.61 32 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 14.8 18.99 30 20 12
135-16/048135 115-60-1 127 104 10.2 13.27 27 15 14
135-22/066135 115-60-1 127 104 14.4 18.55 30 20 12
155-20/060155 115-60-1 127 104 15.0 19.33 29 20 12
* Permissible limits of the voltage range at which the unit operates satisfactorily.
# Unit ampacity = 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.
VOLTSHERTZ-
PHASE
OPERATING
VOLTAGE RANGE
Maximum* Minimum*
MAXIMUM
UNIT AMPS
UNIT
AMPACITY#
MAXIMUM
WIRE LENGTH (FT)‡
MAXIMUM
FUSE OR CKT BKR
AMPS†
MINIMUM
WIRE GAUGE
TWO
Fig. 22—Relocating J-Box
2. Cut wire tie on loop in furnace wires attached to J-Box.
3. Move box to desired location.
4. Fasten J-Box to casing with two screws removed in Step 1.
5. Route J-Box wires within furnace away from sharp edges,
rotating parts, and hot surfaces.
ELECTRICAL CONNECTION TO J-BOX
Field-Supplied Electrical Box on Furnace J-Box Bracket
→
See Fig. 23.
1. Remove cover from furnace J-Box.
2. Attach electrical box to furnace J-Box bracket with at least
two field-supplied screws through holes in electrical box into
holes in bracket. Use blunt-nose screws that will not pierce
wire insulation.
3. Route furnace power wires through holes in electrical box and
J-Box bracket, and make field-wire connections in electrical
box. Use best practices (NEC in U.S. and CSA C22.1 in
Canada) for wire bushings, strain relief, etc.
A02099
A03221
→ Fig. 23—Field-Supplied Electrical Box on
Furnace Casing
4. Route and secure field ground wire to green ground screw on
J-Box bracket.
5. Connect line voltage leads as shown in Fig. 25.
6. Reinstall cover to J-Box. Do not pinch wires between cover
and bracket.
20
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
J2
TEST/TWIN
0.5 AMP@24VAC
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
PLT 1
1-AMP@
EAC-1
(115-VAC 1.0 AMP MAX.)
PR-1
115VAC
115 VAC (L1) LINE
VOLTAGE CONNECTION
EAC-1 TERMINAL
Fig. 24—Furnace Control
HUMIDIFIER TERMINAL
(24-VAC 0.5 AMP MAX.)
TRANSFORMER 24-VAC
CONNECTIONS
PL1-LOW VOLTA GE MAIN
HARNESS CONNECTOR
L1
PL2 1
PL2-HOT SURFACE
IGNITER & INDUCER
MOTOR CONNECTOR
A02100
Electrical Box on Furnace Casing Side
→
See Fig. 23.
FIRE OR ELECTRICAL SHOCK HAZARD
Failure to follow this warning could result in personal injury,
death, or property damage.
If field-supplied manual disconnect switch is to be mounted
on furnace casing side, select a location where a drill or
fastener cannot damage electrical or gas components.
1. Select and remove a hole knockout in the casing where the
electrical box is to be installed.
NOTE: Check that duct on side of furnace will not interfere with
installed electrical box.
2. Remove the desired electrical box hole knockout and position
the hole in the electrical box over the hole in the furnace
casing.
3. Fasten the electrical box to casing by driving two fieldsupplied screws from inside electrical box into casing steel.
4. Remove and save two screws holding J-Box. (See Fig. 22.)
5. Pull furnace power wires out of 1/2-inch diameter hole in
J-Box. Do not loosen wires from strain-relief wire-tie on
outside of J-Box.
6. Route furnace power wires through holes in casing and
electrical box and into electrical box.
7. Pull field power wires into electrical box.
8. Remove cover from furnace J-Box.
9. Route field ground wire through holes in electrical box and
casing, and into furnace J-Box.
10. Reattach furnace J-Box to furnace casing with screws removed in Step 4.
11. Secure field ground wire to J-Box green ground screw.
12. Complete electrical box wiring and installation. Connect line
voltage leads as shown in Fig. 25. Use best practices (NEC in
U.S. and CSA C22.1 in Canada) for wire bushings, strain
relief, etc.
13. Reinstall cover to J-Box. Do not pinch wires between cover
and bracket.
POWER CORD INSTALLATION IN FURNACE J-BOX
NOTE: Power cords must be able to handle the electrical require-
ments listed in Table 5. Refer to power cord manufacturer’s
listings.
→
1. Remove cover from J-Box.
2. Route listed power cord through 7/8-inch diameter hole in
J-Box.
3. Secure power cord to J-Box bracket with a strain relief
bushing or a connector approved for the type of cord used.
4. Secure field ground wire to green ground screw on J-Box
bracket.
5. Connect line voltage leads as shown in Fig. 25.
→
6. Reinstall cover to J-Box. Do not pinch wires between cover
and bracket.
21
FIVE WIRE
THREE-WIRE
HEATING-ONLY
BLOWER DOOR SWITCH
BLK
WHT
115-V FIELD-
SUPPLIED
DISCONNECT
BLK
WHT
GND
AUXILIARY
J-BOX
Fig. 25—Heating and Cooling Application Wiring Diagram with 1–Stage Thermostat
GND
FURNACE
NOTE 2
W
C
R
O
N
T
G
R
O
COM
L
Y/Y2
24-V
TERMINAL
BLOCK
FIELD 24-V WIRING
FIELD 115-, 208/230-, 460-V WIRING
FACTORY 24-V WIRING
FACTORY 115-V WIRING
WCR GY
NOTE 1
NOTES: Connect Y-terminal in furnace as shown for proper blower operation.
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.
THERMOSTAT
TERMINALS
CONDENSING
UNIT
TWO
WIRE
FIELD-SUPPLIED
DISCONNECT
208/230- OR
460-V
THREE
PHASE
208/230-V
SINGLE
PHASE
GND
A99440
BX CABLE INSTALLATION IN FURNACE J-BOX
1. Remove cover from J-Box.
→
2. Route BX cable into 7/8-inch diameter hole in J-Box.
3. Secure BX cable to J-Box bracket with connectors approved
for the type of cable used.
4. Secure field ground wire to green ground screw on J-Box
bracket.
5. Connect line voltage leads as shown in Fig. 25.
→
6. Reinstall cover to J-Box. Do not pinch wires between cover
and bracket.
24-V WIRING
Make field 24-v connections at the 24-v terminal strip. (See Fig.
24.) Connect terminal Y as shown in Fig. 25 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.
(See Fig. 24.)
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
C
OM-24V screw terminal on the control board thermostat strip.
The HUM terminal is energized when pressure switch (PRS)
closes. (See Fig. 24.)
NOTE: A field-supplied, 115-v controlled relay connected to
EAC terminals may be added if humidifier operation is desired
during blower operation.
NOTE: 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.
VENTING
The furnace shall be connected to a listed factory built chimney or
→
vent or a clay-tile lined masonry or concrete chimney. Venting into
an unlined masonry chimney or concrete chimney is prohibited.
When an existing Category I furnace is removed or replaced, the
→
original venting system may no longer be sized to properly 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.
22
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 to the 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 Code and these instructions. Deter-
mine 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. Test for spillage from draft 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
Code.
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. Vent
systems or vent connectors 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 ANSI Z223.1-2002/NFPA 54-2002 (NFGC), Parts 10
and 13 in the United States or the National Standard of Canada,
Natural Gas and Propane Installation Code CSA-B149.1-00
(NSCNGPIC), Section 7, Appendix C in Canada, the local
building codes, and furnace and vent manufacturers’ instructions.
These furnaces are design-certified as Category I furnaces in
→
accordance with ANSI Z21.47-2003/CSA 2.3-2003 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 multistory venting with other fan assisted or draft
hood equipped appliances in accordance with the NFCG or the
NSCNGPIC, the local building codes and furnace and vent
manufacturers’ instructions.
The following information and warning must be considered in
addition to the requirements defined in the NFGC and the
NSCNGPIC.
CARBON MONOXIDE POISONING HAZARD
Failure to follow this warning could result in a build-up of
carbon monoxide and lead to personal injury or death.
Do not bypass the draft safeguard switch, as an unsafe
condition could exist which must be corrected.
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.
2. Do not connect this Category I furnace into 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 U.S.: 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. 26.
MASONRY CHIMNEY REQUIREMENTS
NOTE: 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 a clay tile-lined masonry chimney is being used 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 211-2003
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.
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 system for
these furnaces. See the kit instructions for complete details.
Canada (and U.S.A.)-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 appliance input rating is less than the maximum
capacity given in Table A, and
23
4. The input rating of each space heating appliance is greater
than the minimum input rating given in Table B for the local
99% 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.
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. 26 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.
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.
→ Exterior Masonry Chimney FAN + NAT
Installations with Type-B Double-Wall Vent
Connectors
©NFPA & AGA
Table A—Combined Appliance Maximum Input
Rating in Thousands of BTU per Hour
INTERNAL AREA OF CHIMNEY
VENT HEIGHT (FT)
12 19 28 38
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
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 Condi-
(SQ. IN.)
Table B—Minimum Alowable 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
5 to 16°F
-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*
tioning 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 to the midpoint of the rise range
or slightly above. Low air temperature rise can cause low vent
gas temperature and potential for condensation problems.
INTERNAL AREA OF CHIMNEY
12 19 28 38
Not recommended for any vent
(SQ. IN.)
configuration
24
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 Code CSA-B149.1 in Canada.
Crown
condition:
Missing mortar
or brick?
No
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
No
Yes
No
Rebuild
crown.
Repair
liner or top seal
or reline chimney as
necessary.
Repair
Mortar
or tile
debris?
Reline
Yes
Remove mortar
and tile debris
No
Clay
tile misalignment,
missing sections,
gaps?
No
Condensate
drainage at bottom
of chimney?
No
Chimney
exposed to
outdoors below
roof line?
No
Chimney is
acceptable for use.
Remove metal vent
or liner.
Yes
lined with properly
sized, listed liner or
Yes
Yes
No
No
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.
No
chimney adapter venting
Not Suitable
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. 26—Chimney Inspection Chart
25
A03206
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 many common 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.
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. 32–44 Venting Orientation for approved vent
configurations.
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.
NOTE: An accessory flue extension KGAFE0112UPH is avail-
→
able to extend from the furnace elbow to outside the furnace
casing. If flue extension is used, fasten the flue extension to the
vent elbow with at least two field-supplied, corrosion-resistant,
sheet metal screws located 180° apart. Fasten the vent connector to
the flue extension with at least two field-supplied, corrosionresistant sheet metal screws located 180° apart.
2. Vent the furnace with the appropriate connector as shown in
Fig. 32–44.
CUT HAZARD
→
Failure to follow this caution may result in personal injury.
Sheet metal parts may have sharp edges or burrs. Use care and
wear appropriate protective clothing, safety glasses, and
gloves when handling parts and servicing furnaces.
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 in door.
NOTE: If this furnace is equipped with knockouts in the door for
→
the vent, a number of techniques can be used to remove these
knockouts as seen in Fig. 27 through 31. The knockout in the
bottom of the door is unique due to its flanging and is not easily
removed by first cutting the two tie points at the edge of the door,
using aviation-type tin snips. (See Fig. 27.) A sharp blow to the
rounded end of the knockout (See Fig. 28.) will separate more tie
points and allow the knockout to be pulled loose. (See Fig. 29.)
Remove all burrs and sharp edges.
For the knockouts in the other locations on the door (top and
sides), tin snips can also be used along the door edges; however,
the preferred method is to use a hammer and screwdriver to strike
a sharp blow (See Fig. 30.) directly to the knockout tie points or
use a hammer in the upper left corner of the desired knockout. (See
Fig. 31.) Remove all burrs and sharp edges.
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 slope upwards
not less than 1/4-in. per linear ft (21mm/m) from the furnace to the
vent and 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.
In the U.S.: Per section 10.3.4 of the NFGC, any listed mechanical
venter may be used, when approved by the authority having
jurisdiction.
→
In Canada: Per section 7.24.2 of the NSCNGPIC, any listed
venters may be used, when approved by the authority having
jurisdiction.
Select the listed mechanical venter to match the Btuh input of the
furnace being vented. Follow all manufacturer’s installation requirements for venting and termination included with the listed
mechanical venter.
→ Fig. 27—Using Tin Snips to Cut Tie Points
A04127
26
A04131
→ Fig. 31—Remove Knockout with Hammer
START-UP, ADJUSTMENT, AND SAFETY CHECK
A04128
→ Fig. 28—Rounded End of Knockout
A04129
→ Fig. 29—Knockout Pulled Loose
A04130
→ Fig. 30—Hammer and Screwdriver Used for
Knockout
Step 1—General
FIRE HAZARD
Failure to follow this warning could result in a fire and lead
to property damage, personal injury, or death.
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.
CUT HAZARD
Failure to follow this caution may result in personal injury.
Sheet metal parts may have sharp edges or burrs. Use care and
wear appropriate protective clothing, safety glasses, and
gloves when handling parts and servicing furnaces.
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. 25.)
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
FIRE AND EXPLOSION HAZARD
Failure to follow this warning could cause property damage,
personal injury, or death.
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.
1. Purge gas lines after all connections have been made.
2. Check gas lines for leaks.
27
SEE NOTES: 1,2,4,7,8,9
on the page following
these figures
Fig. 32—Upflow Application-Vent Elbow Up
A03208
SEE NOTES: 1,2,4,5,7,8,9
on the page following
these figures
A03211
Fig. 35—Downflow Application-Vent Elbow Up
SEE NOTES: 1,2,3,4,7,8,9
on the pages following
these figures
A03209
Fig. 33—Upflow Application-Vent Elbow Right
SEE NOTES:1,2,3,4,5,7,8,9
on the page following
these figures
A03210
Fig. 34—Downflow Application-
Vent Elbow Up then Left
SEE NOTES: 1,2,4,5,6,7,8,9,10
on the page following these figures
Fig. 36—Downflow Application-
Vent Elbow Left then Up
SEE NOTES:1,2,3,4,5,7,8,9
on the page following
these figures.
Fig. 37—Downflow Application-
Vent Elbow Up then Right
A03207
A03212
28
SEE NOTES: 1,2,4,7,8,9 on the page
following these figures
A03213
Fig. 38—Horizontal Left Application-Vent Elbow Left
SEE NOTES: 1,2,4,5,7,8,9 on the page
following these figures
Fig. 40—Horizontal Left Application-Vent Elbow Up
A03215
SEE NOTES: 1,2,4,5,7,8,9 on the page
following these figures
Fig. 39—Horizontal Left Application-
Vent Elbow Right then Up
SEE NOTES: 1,2,4,7,8,9 on the page
following these figures
Fig. 42—Horizontal Right Application-
Vent Elbow Right
A03214
A03218
SEE NOTES: 1,2,4,5,7,8,9 on the page
following these figures
A03216
Fig. 41—Horizontal Left Application-Vent Elbow Right
SEE NOTES: 1,2,4,5,7,8,9 on the page
following these figures
A03219
Fig. 43—Horizontal Right Application-
Vent Elbow Left then Up
29
SEE NOTES: 1,2,4,5,7,8,9
A02068
Fig. 44—Horizontal Right Application-Vent Elbow Left
Venting Notes for Figures 32-44
1. For common vent, vent connector sizing and vent material:
United States--use the NFGC
Canada--use the NSCNGPIC
2. Immediately increase to 5-inch or 6-inch vent connector outside furnace casing when 5-inch vent connector is 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, Downflow Vent Guard Kit, is used in the downflow position.
4. Type-B vent where required, refer to Note 1 above.
5. Four-inch 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 lower vent configuration.
7. Chimney Adapter Kit may be required for exterior masonry chimney applications. Refer to Chimney Adapter Kit, KGACA02014FC or
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.
10. The total height of the vent and connector shall be at least seven feet for the 154,000 Btuh gas input rate model when installed in a downflow
application with furnace elbow turned to left side with the connector elbow outside furnace casing pointing upward. (See Fig. 36.)
Caution!! For the following applications, use the minimum vertical vent heights 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
Horizontal Left
Horizontal Left
Downflow
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. 36
Vent elbow right,
then up
Fig. 39
Vent Elbow up
Fig. 40
Vent elbow right
Fig. 41
Vent elbow up then left
Fig. 34
Vent elbow up, then right
Fig. 37
154,000
132,000
110,000(036/-12 only)
154,000
132,000
154,000
132,000
154,000 5 7
110,000
(036/-12 only)
110,000
(036/-12 only)
MINIMUM
VENT DIAMETER (IN.)*
512
57
57
510
510
MINIMUM VERTICAL VENT HEIGHT (FT)**
30
ELECTRICAL SHOCK HAZARD
Failure to follow this warning could result in electrical shock,
personal injury, or death.
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.
3. To Begin Component Self-Test:
→
Remove blower access door. Disconnect the thermostat R lead
from furnace control board. Manually close the blower door
switch. Short (jumper) the C
TEST/TWIN 3/16-inch quick connect terminal on control
until LED goes out (approximately 2 sec). Gas valve and
humidifier will not be turned on. (See Fig. 24.)
NOTE: The furnace control allows all components, 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. 49.
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 igniter 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
→
FIRE HAZARD
Failure to follow this warning could result in reduced furnace
life, property damage, injury and death.
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.
→
FURNACE DAMAGE HAZARD
Failure to follow this caution may result in reduced furnace
life.
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.
47.)
Furnace gas input rate on rating plate is for installations at altitudes
up to 2000 ft. Furnace input rate must be within ±2 percent of
furnace rating plate input.
OM-24V terminal on control to the
1. Determine the correct gas input rate.
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. 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 8 for the correct input
rate.
In Canada:
The input rating must be derated by 10 percent for altitudes of
2,000 ft. to 4,500 ft. above sea level 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 12 (22,000
BTUH/Burner)
Low NOx models in the downflow or horizontal positions
must use Table 13 (21,000 BTUH/Burner). See input listed on
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 12 or 13.
d. Find closest natural gas heat value and specific gravity in
Table 12 or 13.
e. Follow heat value and specific gravity lines to point of
intersection to find orifice size and manifold pressure
settings for proper operation.
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 12 or
13. Use only factory-supplied orifices. See EXAMPLE 2.
For 22,000 BTUH burner applications use Table 12
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. 46.)
c. Connect a water column manometer or similar device to
manifold pressure tap.
d. Turn gas valve ON/OFF switch to ON.
→
e. Manually close blower door switch.
31
L 2
327559-101 REV. E
NEUTRAL
SCHEMATIC DIAGRAM
CONNECTION DIAGRAM
(NATURAL & PROPANE GASES)
TO 115VAC FIELD DISCONN ECT SWITCH
LS2
LS1
FRS2
EQUIPMEN T GROUND
NEUTRAL
L2
L1
RED
RED
RED
GV
RED
L2
CAP
LO
SPARE-1
ILK
(WHEN USED)
EAC-2
BLWM
START
OL
COM
HI
MED LO
HEAT
COOL
BHT/CLR
EAC-1
HSIR
ORG
ORG
IDR
BLWR
(WHEN USED)
BLK
BLU
L1
BVSS
NOTE #10
DSS
RED
FRS1
RED
GRN/YEL
NOTE #5
IDM
HSI
2
1
PL3
2
1
PL2
115VAC
TRAN
PR1
WHT
TRAN
LGPS
(WHEN USED)
RED
PRS
24VAC
BVSS
(WHEN USED)
DSS
FRS1
SEC-2
SEC-1
YEL
BLK
NOTE #11
FSE
LS2
NOTE #10
(WHEN USED)
LS1
FRS2
PL1-6
PL1-8
NOTE #6
GRN/YEL
R
W
WHT
HSI
1
2
PL3
BLK
WHT
F U 1
IDM
PRS
NOTE #11
LGPS
PL1-2
HUM
PRINTED CIRCIUT BOARD
NOTE #2
FUSE OR CIRCUIT BREAKER &
DISCONNECT SWITCH (WHEN REQ D)
WHT
JB
BLK
WHT (COM)
NOTE #3
GV
FSE
(WHEN USED)
PL1-9
PL1-11
PL1-3
PL1-5
PL1-4
PL1-10
GVR
CPU
PL1-1
PL1-7
A05038
NOTE #5
PCB
TEST/TWIN
Y
L1
NEUTRAL
FU2
BLK
WHT
GND
LS 1, 2 LIMIT SWITCH, AUTO-RESET, SPST(N.C.)
ILK
BLK
WHT
OL AUTO-RESET INTERNAL MOTOR OVERLOAD
24V
OM
G
C
1. If any of the original equipment wire is replaced use wire rated for 105¡C.
2. Use only copper w ire betw ee n the discon ne ct switch and the furnac e junc tion bo x (JB ).
3. This wire must be connected to furnace sheet metal for control to prove flame.
4. Symbols are electrical representation only.
NOTES:
TEMPERATURE SWITCH (N.C.)
PCB PRINTED CIRCUIT BOARD CONTROL
PL1 11-CIRCUIT PCB CONN ECTOR
PL2 2-CIRCUIT CONNE C T O R
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 selection.
auto-reset after three hou rs.
6. Replace only with a 3 am p fuse.
7. Inducer (IDM) and blow er (BL WM) motors contain internal auto-reset thermal overload sw itches (O L ).
8. Neutral connections are interchangeab le w ithin the NE U TRAL connector block.
9. Blower motor speed sele ctions ar e for avera ge cond itions, see in s tallation instruction s fo r details on
10. Factory connected when BVSS (Chimney Adapter Accessory Kit) is not installed.
11. Factory connected when LGP S 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 se co nds when J2 is cut.
12. Ig n itio n - lo ckout wil l o c c u r a f te r four cons e cutive un success f u l tria l s -f o r -ignition. Control will
13. Blower-on delay: gas heating 25 seconds, cooling or heat pump 2 seconds.
14. Blower-off delay: gas heating selections are 90, 120, 150 or 180 seco nd s, co oling or heat p ump
EQUIPMENT GROUND
FIELD SPLICE
PLUG RECEPTACLE
→ Fig. 45—Furnace Wiring Diagram
YEL
ORN
GRN/YEL
PCB
RED
BLU
180
120
J1
90
BLOWER OFF-DELAY
JUMPER SELECT OR
150
HUM
TEST/TWIN
J 2
Y
om
G
PRINTED CIRCIUT BOARD
R
W
24V
C
FU1
NOTE #6
RED
11
L2
SEC-1
LED
EAC-2
SEC-2
NEUTRAL
NOTE #8
1
2
PL2
WHT
PL1
12345678910
BLWR
BHT/CLR
BLW
PR1
EAC-1
BLWM
L1
SPARE 2
BLK (HI)
COOL
HEAT
SPARE 1
WHT
(COM )
CAP
GRN/YEL
BRN
BRN
START
OL
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.)
EAC-1 ELECTRONIC AIR CLEANER CONNECTION (115 VAC 1.0 AMP MAX.)
BLU
(MED LO)
LEGEN
D
EAC-2 ELECTRONIC AIR CLEANER CONNECTION (COMMON)
(FIELD INSTALLED & SUPPLIED)
FRS 1, 2 FLAME ROLLOUT SW. -MANUAL RESET, SPST-(N.C.)
FSE FLAME-PROVING ELECTRODE
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 V ALVE 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 - H EATING
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.)
32
Table 8–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.
f. Set thermostat to call for heat.
g. Jumper R and W thermostat connections on furnace control
board to start furnace.
h. Remove regulator seal cap and turn regulator adjusting
screw counterclockwise (out) to decrease input rate of
clockwise (in) to increase input rate.
i. Install regulator seal cap.
j. 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
to Table 12 or 13.
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.
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 served by the
meter.
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 2 or 5 cubic feet dial provides a
more accurate measurement of gas flow.
d. Refer to Table 10 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. Reinstall 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:
→
NOTE: Blower access door must be installed when taking temperature rise reading. Leaving blower access door off will result in
incorrect temperature measurements.
a. Place thermometers in return and supply ducts as close to
furnace as possible. Be sure thermometers do not see
PERCENT
OF DERATE
DERATE MULTIPLIER
FACTOR*
REGULATOR
SEAL CAP
REGULATOR
ADJUSTMENT
SCREW
ON/OFF SWITCH
REGULATOR SPRING
1/2˝ NPT INLET
GAS PRESSURE
REGULATOR
INLET
PRESSURE TAP
1/2˝ NPT OUTLET
ADJUSTMENT
MANIFOLD
PRESSURE TAP
A04166
→ Fig. 46—Gas Control Valve
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.) Return and supply ducts for excessive restrictions causing static
pressures greater than 0.50-in. wc.
4.) Dirty filter.
ELECTRICAL SHOCK HAZARD
Failure to follow this warning could result in personal injury
or death.
Disconnect 115-v electrical power before changing speed tap.
c. Adjust air temperature rise by adjusting blower speed.
Increase blower speed to reduce temperature rise. Decrease
blower speed to increase temperature rise.
BURNER
ORIFICE
A93059
Fig. 47—Orifice Hole
33
Table 9—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.
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.
24.) Select desired blower motor speed lead from one of the
other terminals and relocate it to the HEAT terminal (See
Table 9 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. Reinstall manifold pressure tap plug in gas valve.
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. 48—Amp Draw Check With Ammeter
A96316
FIRE HAZARD
→
Leaking gas could be ignited and cause fire, explosion,
personal injury, property damage or death.
Reinstall manifold pressure tap plug in gas valve to prevent
gas leak.
j. Reinstall blower access door if removed.
k. Turn gas valve ON/OFF switch to ON.
→
FURNACE OVERHEATING HAZARD
Failure to properly set temperature rise may cause excessive
furnace temperatures and shorten furnace life.
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.
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.
(1.) Remove thermostat from subbase or from wall.
(2.) Connect an amp meter as shown in Fig. 48 across the
R and W terminals or R and W wires at wall.
(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. 24.)
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.
8. Set airflow CFM for cooling
→
Select the desired blower motor speed lead for cooling
airflow. See Table 5-Air Delivery-CFM (With Filter). See
Table 9 for lead color identification.
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 Switch(es)
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 cause normal circulation.
d. Burners will re-light when furnace cools down.
2. Check draft safeguard switch.
The purpose of this control is to cause 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.
34
Table 10–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
e. Furnace should cycle off within 2 minutes. If gas does not
→
SIZE OF TEST DIAL
1
Cu Ft2Cu Ft5Cu Ft
SECONDS
FOR 1
REVOLUTION
shut off within 2 minutes, determine reason draft safeguard
switch did not function properly and correct condition.
f. Remove blockage from furnace vent elbow.
g. Switch will auto-reset when it cools.
→
h. Re-install vent connector.
→
NOTE: Should switch remain open longer than 3 minutes,
furnace control board will lockout the furnace for 3 hours. To reset
furnace control board, turn thermostat below room temperature or
from HEAT to OFF and turn 115v power OFF, then back ON.
3. Check Pressure Switch
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
SIZE OF TEST DIAL
1
Cu Ft2Cu Ft5Cu Ft
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.
h. Blower will run for 90 sec before beginning the call for
→
heat again.
i. Furnace should ignite normally.
→
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. Attach literature packet to furnace.
SERVICE AND MAINTENANCE PROCEDURES
FIRE, INJURY, OR DEATH HAZARD
Failure to follow this warning could result in possible damage
to this equipment, serious personal injury, or death.
The ability to properly perform maintenance on this equipment requires certain 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.
ELECTRICAL SHOCK, FIRE, OR EXPLOSION
→
HAZARD
Failure to follow this warning could result in personal injury,
death, or property damage.
Before servicing, disconnect all electrical power to furnace.
Verify proper operation after servicing.
→
ELECTRICAL OPERATION HAZARD
Failure to follow this caution may result in improper furnace
operation or failure of furnace.
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.
35
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 FOLLOWING STATUS COD ES IS A TW O D IGIT NUMBER WITH THE FIRST DIGIT DETERM INED BY THE N U MB ER O F SH ORT F LASHES 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 LIMIT CIRCUIT LOCKOUT - Lockout occurs if the limit, draft safeguard, flame rollout, or
blocked vent switch (if used) is open longer than 3 minutes.
- 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 terminal 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 voltage (115VAC) polarity reversed. If twinned, refer to twinning kit instructions.
327596-101 REV. B
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) - Defective 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, blower will come on for the selected blower
off-delay.
33 LIMIT CIRCUIT FAULT - Indicates a limit, draft safeguard, flame rollout, or 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 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/Yellow 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. 49—Service Label
A04223
ELECTRICAL CONTROLS AND WIRING
ELECTRICAL SHOCK HAZARD
→
Failure to follow this warning could result in personal injury
or death.
There may be more than one electrical supply to the furnace.
Check accessories and cooling unit for additional electrical
supplies that must be shut off during furnace servicing.
The electrical ground and polarity for 115-v wiring must be
properly maintained. Refer to Fig. 25 for field wiring information
and to Fig. 45 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. 24.) 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. 49, and the troubleshooting guide which
can be obtained from your distributor. The furnace control will
store 1 status code for 72 hours.
→
See Fig. 53, a brief Troubleshooting Guide.
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 the 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.
6. Check LED status. If no previous fault is in history, control
will flash status code 11.
7. 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.
36
Table 11—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
Step 2—Care and Maintenance
FIRE OR EXPLOSION HAZARD
Failure to follow this warning could result in corrosion of heat
exchanger, fire, personal injury, or death.
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.
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.
ELECTRICAL SHOCK HAZARD
Failure to follow this warning could result in personal injury,
death or product damage.
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.
CARBON MONOXIDE POISONING AND FIRE
HAZARD
Failure to follow this warning could result in fire, personal
injury, or death.
Never operate unit without a filter or with filter access door
removed.
FILTER QUANTITY AND SIZE
Side Return Bottom Return
FILTER
TYPE
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 service agency.
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
service agency.
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 will vary depending on the application.
The filter is exterior to the furnace casing.
NOTE: If the filter has an airflow direction arrow, the arrow must
point towards the blower.
CUT HAZARD
→
Failure to follow this caution may result in personal injury.
Sheet metal parts may have sharp edges or burrs. Use care and
wear appropriate protective clothing, safety glasses, and
gloves when handling parts and servicing furnaces.
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-inch 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 11 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 11.
6. Slide filter into cabinet.
7. Replace filter cabinet door.
8. Turn on electrical supply to furnace.
BLOWER MOTOR AND WHEEL
CUT HAZARD
→
Failure to follow this caution may result in personal injury.
Sheet metal parts may have sharp edges or burrs. Use care and
wear appropriate protective clothing, safety glasses, and
gloves when handling parts and servicing furnaces.
The minimum maintenance on this furnace 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.
3. Check electrical connections for tightness and controls for
proper operation each heating season. Service as necessary.
ELECTRICAL SHOCK HAZARD
Failure to follow this warning could result in personal injury
or death.
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.
NOTE: The blower wheel should not be dropped or bent as
balance will be affected.
The following steps should be performed by a qualified service
agency.
To ensure long life and high efficiency, clean accumulated dirt and
grease from blower wheel and motor annually.
37
TABLE 12—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)
0
to
2000
U.S.A.
Altitudes
2001
to
3000
or
Canada
Altitudes
2000
to
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
Manifold
Pressure
Manifold
Pressure
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
U.S.A. Only
ALTITUDE
RANGE
U.S.A. Only
* Orifice numbers 43 are factory installed
3001
to
4000
(FT)
4001
to
5000
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
HEAT VALUE
(BTU/CU FT)
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.
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. Loosen the thumbscrew on outer door and remove outer door.
Manifold
Pressure
SPECIFIC GRAVITY OF NATURAL GAS
Orifice
No.
Manifold
Pressure
Orifice
No.
Manifold
Pressure
Orifice
No.
3. For downflow or horizontal furnaces having vent pipes within
the furnace that pass in front 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.
38
Manifold
Pressure
Table 12—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
to
6000
U.S.A. Only
ALTITUDE
RANGE
(FT)
6001
to
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
Manifold
Pressure
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
to
8000
U.S.A. Only
ALTITUDE
RANGE
(FT)
8001
to
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
0.58 0.60 0.62 0.64
Orifice
No.
Manifold
Pressure
4. Remove 2 screws from blower access door and remove blower
access door.
5. Disconnect blower leads from furnace control. Record 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 holding control box to blower shelf.
7. Hang control box from front of furnace casing and away from
blower compartment.
SPECIFIC GRAVITY OF NATURAL GAS
Orifice
No.
Manifold
Pressure
Orifice
No.
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.
Manifold
Pressure
Orifice
No.
Manifold
Pressure
39
Table 12—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
to
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
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
(160+/-20 in-lb when reassembling).
→
d. Remove bolts holding motor to blower housing and slide
motor out of wheel (40+/-20 in-lb when reassembling).
e. Remove blower wheel from housing.
f. Clean wheel and housing.
12. Reassemble motor and blower by reversing steps 11f through
11a, 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.
UNIT DAMAGE HAZARD
Failure to follow this caution may shorten heat exchanger life.
Heating fan speed(s) MUST be adjusted to provide proper air
temperature rise as specified on the rating plate. 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 9 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.
18. To check blower for proper rotation:
a. Turn on electrical supply.
SPECIFIC GRAVITY OF NATURAL GAS
Orifice
No.
Manifold
Pressure
→
ELECTRICAL SHOCK HAZARD
Orifice
No.
Failure to follow this warning could result in electrical shock,
personal injury, or death.
Blower access door switch opens 115-v power to furnace
control. No component operation can occur unless switch is
closed. Exercise caution to avoid electrical shock from
exposed electrical components when manually closing this
switch for service purposes.
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. Remove any jumpers or reconnect
any disconnected thermostat leads. Replace blower access
door.
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 furnace 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
agency:
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.
Manifold
Pressure
Orifice
No.
40
Manifold
Pressure
TABLE 13—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)
0
to
2000
U.S.A.
Altitudes
2001
to
3000
or
Canada
Altitudes
2000
to
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
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
U.S.A. Only
ALTITUDE
RANGE
U.S.A. Only
* Orifice numbers 43 are factory installed
3001
to
4000
(FT)
4001
to
5000
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
HEAT VALUE
(BTU/CU FT)
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
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.
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
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 (be careful when disconnecting wires
from switches because damage may occur):
a. Draft safeguard switch.
41
Orifice
No.
Manifold
Pressure
Table 13—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
to
to
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
to
8000
U.S.A. Only
ALTITUDE
RANGE
(FT)
8001
to
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
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.
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
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 5 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. 50 and 51 for correct igniter location.
42
Orifice
No.
Manifold
Pressure
Table 13—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
to
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
9/32˝
→
Fig. 50—Igniter Position-Side View
Fig. 51—Igniter Position-Top View
9. Using field-provided 25-caliber rifle cleaning brush, 36-in.
long, 1/4″ diameter steel spring cable, 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).
5/16˝
1-7/8”
A05025
A05026
(2.) Insert brush end of cable into the outlet opening of cell
and slowly rotate with drill. DO NOT force cable.
Gradually insert cable into upper pass of cell. (See Fig.
52.)
(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.) Install NOx baffles, if removed.
(10.) Reinstall burner assembly. Center burners in cell
openings.
10. Remove old sealant from cell panel and collector box 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 collector box and attach to cell
panel using existing screws, making sure all screws are secure.
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.
43
A91252
Fig. 52—Cleaning Heat Exchanger Cell
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, if it was removed.
17. Set thermostat above room temperature and check furnace for
proper operation.
18. Verify blower airflow and speed changes between heating and
cooling.
FIRE OR EXPLOSION HAZARD
Failure to follow this warning could result in fire, personal
injury, or death.
Never use a match or other open flame to check for gas leaks.
Use a soap-and-water solution.
19. Check for gas leaks.
20. Replace outer access door.
Step 3—Sequence of Operation
NOTE: 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.
Using the schematic diagram in Fig. 45, 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.
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. 25 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 by the HSI. Five seconds after the GVR closes, a
2-second flame proving period begins. The HSI igniter will
remain energized until the flame is sensed or until the
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. 25 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 the thermostat 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. 24.)
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 (same as 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
44
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. 25 and 45 for wiring diagrams.
Step 5—Troubleshooting
Refer to the service label. (See Fig. 49—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.
45
NO
A02106a
Is door switch closed?
NO
Is door switch closed?
NO
YES
Is circuit breaker closed?
NO
Is there 115V going to switch?
NO
YES
YES
Check for continuity in wire from circuit breaker
to furnace.
Replace door switch.
NO
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?
NO
YES
Does the control respond to W , Y1 (if present),
Y/Y2, and G (24V) thermostat signals?
NO
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.
NO
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.
Fig. 53—Troubleshooting Guide
YES
Is there 115V at L1 and L2?
NO
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
NO
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
NO
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) HEA T speed, and COOL speed will run f or 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.
46
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
A05032
(.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.
NO
YES
Unplug igniter harness from control and initiate
another component test sequence. Check
for 115V between pin 1 and NEUTRAL-L2 on
the control. Was 115V present for the 15
second period?
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
tubing.
- Low inlet gas pressure (if LGPS used).
- Inadequate combustion air supply.
- Disconnected or obstructed pressure
- Defective inducer motor.
- Defective pressure switch.
- Low inducer voltage (115V).
- Excessive wind.
NO
Reconnect the R thermostat lead and set
thermostat to call for heat. Connect voltmeter
- Restricted vent.
limit, draft safeguard, flame rollout, or
33 LIMIT CIRCUIT FAULT – Indicates the
YES
across gas valve connections. Does gas v alve
receive 24V?
Does gas valve open and allow gas to flow?
blocked vent shutoff 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
NO
NO
YES
continues to flash until blower shuts off.
Flame rollout switch and BVSS requires
YES
Do the main burners ignite?
manual reset. Check for:
- Dirty filter or restricted duct system.
- Defective blower motor or capacitor.
- Loose blower wheel.
- Defective switch or connections.
YES
NO
Do the main burners stay on?
(flame rollout switch open).
- Restricted vent.
- Inadequate combustion air supply
- Proper vent sizing.
- Excessive wind.
NO
YES
Repeat call for heat and check flame sensor
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
NO
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.
NO
YES
Is current near typical value?
to furnace sheet metal.
- Gas valve turned off.
- Green/Yellow wire MUST be connected
- Flame sensor must not be grounded.
To determine whether the problem is in
the gas valve, igniter , or flame sensor the
- Manual shut-off valve.
system can be operated in the component
NO
YES
Will main burners ignite and stay on?
test mode to check the igniter. First
remove the R thermostat connection from
Fixed.
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
blower on-delay period.
11 NO PREVIOUS CODE – Stored codes
12 BLOWER ON AFTER POWER UP –
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 – Loc k out
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
47
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 OLTAGE FUSE IS OPEN
* Blocked vent shutoff switch used in Chimney Adapter Kit
Copyright 2005 Carrier Corporation 58st13si
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-13SI Pg 48 5-05 Replaces: 58ST-12SI
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