Carrier 090-14/042090, 070-12/036070, 090-16/048090, 090-20/060090, 110-12/036110 Installation, Start-up, Operating And Service And Maintenance Instructions

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Single-Stage Delu×e

Induced-Combustion

4-W M lti i F rn

Cancels: II 311A-45-5 II 311A-45-6

4-06

Installation,

Service and

Series 120/C

NOTE: Read the entire instruction manual belk)re starling the installation.

This symbol --> indicates a change since tile last issue.

Start-up, Operating, and

Maintenance Instructions

--> Portions Ill tile lext and t tbles are reprinted fiom NFPA 541ANSI Z223.1-2002©. __

wilh pernfission ol Naliontl Fire Protection Association, Quincy, MA 02269 uld

Amefic u] GIs AssocJ ttJon, W tshhlglon DC 20001. This reprhlled nlalerial is not Ihe

complete and official position ol tile NFPA or ANSI on tile rel_renced subiecl, which ! is represented only by the sland trd in ils entirety.

TABLE OF CONTENTS

SAFETY CONS1OERATIONS .....................................................2

INTRODUCTION .......................................................................... 3

CODES AND STANDARDS ........................................................ 3

Salcty ......................................................................................... 3

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

EFFiCiENCY

CERTIFIED

ISO 9001:2000

ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS

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

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

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

Location Relative to Cooling Eqnipment ................................ 7

AIR FOR COMBUSTION AND VENTILATION ...................... 7

INSTALLATION ......................................................................... 1tt

Upflow Installation ................................................................. lit

Bottom Return Air Inlet .................................................... lit

Side Return Air Inlet ......................................................... lit

Leveling Legs (If Desired) ................................................ lit

Downflow Installation ............................................................ 1It

Bottom Return Air Inlet .................................................... 11

Horizontal Installation ............................................................ 12

Suspended Unit Support .................................................... 12

Platlorm Unit Support ....................................................... 12

Roll-Out Protection ............................................................ 12

Bottom Return Air Inlet .................................................... 13

Side Return Air Inlet ......................................................... 13

Filter Arrangement .................................................................. 13

Air Ducts ................................................................................. 13

General Requirements ....................................................... 13

Ductwork Acoustical Treatment ....................................... 13

Supply Air Connections .................................................... 13

Return Air Connections ..................................................... 14

Gas Piping ............................................................................... 17

Electrical Connections ............................................................ 19

115-V Wiring ..................................................................... 19

J-Box Relocation ............................................................... 20

Electrical Connection to J-Box ......................................... 20

BX Cable Installation ........................................................ 21

24-V Wiring ....................................................................... 21

Accessories ........................................................................ 21

Venting .................................................................................... 21

General Venting Requirements ......................................... 23

Masonry Chimney Requirements ...................................... 23

Appliance Application Requirements ............................... 27

Additional Venting Requirements ..................................... 29

Sidewall Venting ............................................................... 29

START-UP, ADJUSTMENT, AND SAFETY CHECK ............ 33

General .................................................................................... 33

Start-Up Procedures ................................................................ 33

Adjustments ............................................................................. 34

Check Salbty Controls ............................................................ 36

Checklist .................................................................................. 37

SERVICE AND MAINTENANCE PROCEDURES .................. 40

Introduction ............................................................................. 40

General ............................................................................... 40

Electrical Controls and Wiring ......................................... 40

Cam and Maintenance ............................................................ 44

Cleaning and/or Replacing Air Filter ............................... 44

Blower Motor and Wheel .................................................. 44

Cleaning Heat Exchanger .................................................. 45

Sequence of Operation ............................................................ 48

Wiring Diagrams ..................................................................... 50

Troubleshooting ...................................................................... 50

Power Cord Installation ..................................................... 21

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

PC 101 Printed in U.S.A. Pg 1 4-06

26-1/8"

(FLUE COLLAR)

5-15/16" ......

7/8" DIA I

ACCESSORY

33-5/16"

11/16"--

-- 25-1/4" --

-- 22-9/16" --

JUNCTION BOXm

LOCATION i;

112" DEATHERMOSTAT ....

WIRE ENTRY _*

3-15116" i_ ........

LEFT HAND GASS

ENTRY

7/8" D[A ACCESSORY_

21-5/8"

BOTTOM FNLET

__ 24 _ __

CASENG

24-7/8"

i i

5-1/2"

_1-11/16"

A D

LOCATFONS (TYP)

5 PLACES (TYP)

5-1/21'

11/16"

AIRFLOW

OUTLET j

7-3/4"

14W/8"

1-1/4"

22-1/16"

SIDEINLET

A04037

NOTES:

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

2. Minimum return-air openings at 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 1600CFM-22-in. roundor 14 1/2x 22-in. rectangle. d. For airflow requirements above 1800CFM, 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 orthe bottom only will ensure adequate return air openings for airflow requirements above 1800CFM.

Fig. 1--Dimensional Drawing

SAFETY CONSIDERATIONS

FIRE, EXPLOSION, ELECTRICAL SHOCK, AND CARBON MONOXIDE POISONING HAZARD

Failure to lk_llow this warning could result in dangerous operation, serious injury, death, or properly damage.

hnproper installation, adjustment, alteration, service, mainte- nance, or use could cause carbon monoxide poisnning, explo

sion, fire, electrical shock, or other conditions which may cause personal injury or property damage. Consult a qualilied

service agency, local gas supplier, or your distributor or branch lor inlormation or assistance. The qualified service agency nmst use only factory-authorized and listed kits or accessnries when modif_¢ing this product.

FURNACE RELIABILITY HAZARD hnproper 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 perlkmn basic maintenance limctions such as cleaning and replacing air filters. All other operations nmst be perlbrmed by trained service personneh When working on heating equipment, observe precautions in literature, on tags, and

on labels attached to or shipped with furnace and other salety

precautions that may apply.

These instructions cover mininmm requirements and conlorm to existing national standards and salety codes. In some instances,

these instructions exceed certain local codes and ordinances,

especially those that may not have kept up with changing residen- tial construction practices. We require these instructions as a

nfininnnu for a safe installation.

CUT HAZARD Failure to lollow this caution may result in personal injury. Sheet metal parts may have sharp edges or burrs. Use cam and

wear appropriate protective clothing, sali_ty glasses and gloves when handling parts and servicing lilrnaces.

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

calls.

This is the sali:ty-alert symbol Z_ • When you see this symbol on the flmmce and in instructions or manuals, be alert to the potential

lk>r personal injury. Understand the signal words DANGER, WARNING, and CAU-

TION. These words are used with the sali:ty-alert symboh DAN- GER 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 sugges- tions which will result in enhanced installation, reliability, or operation.

1. Use only with type of gas approved lk)r this furnace. Reli:r to the furnace rating plate.

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

3. Provide adequate combustion and ventilation air to the furnace space as specified in "Air liar Combustion and Ventilation"

section.

4. Combustion products nmst be discharged outdoors. Connect this furnace to an approved vent system only, as specilied in

Table 1--Dimensions 0N.)

F FILTER

D E

C.L. TOP AND FLUE MEDIA

A SUPPLY-AIR RETURN-AIR

FURNACE SiZE CABINET WIDTH WIDTH WIDTH BOTTOM COLLAR* SHIP WT (LB) CABINET

(iN,) (iN,) FLUE COLLAR (iN,) SiZE

(iN.) (iN.)

045-08/024045 14-3/18 12-9/18 12-11/18 9-8/18 4 114 18 045-12/036045 14-3/18 12-9/18 12-11/16 9-8/16 4 117 16

070-08/024070 14-3/18 12-9/18 12-11/18 9-8/18 4 121 18 070-12/036070 14-3/18 12-9/18 12-11/16 9-8/16 4 125 16 070-16/048070 17-1/2 15-7/8 18 11-9/18 4 138 18

090-14/042090 17-1/2 15-7/8 18 11-9/18 4 135 16 090-16/048090 21 19-3/8 19-1/2 13-5/18 4 180 20 090-20/080090 21 19-3/8 19-1/2 13-5/18 4 158 20

110-12/036110 17-1/2 15-7/8 18 11-9/18 4 143 16 110-16/048110 21 19-3/8 19-1/2 13-5/18 4 158 20

110-22/086110 21 19-3/8 19-1/2 13-5/18 4 182 20 135-16/048135 21 19-3/8 19-1/2 13-5/18 4 159 20 135-22/086135 24-1/2 22-7/8 23 18-1/18 4 173 24 155-201060155 24-1/2 22-7/8 23 18-1/18 4 180 24

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

the "Venting" section of these instructions.

5. Never test liar gas leaks with an open flame. Use a commer- cially available soap solution made specifically liar the detec- tion of leaks to check all connections, as specified in the "Gas

Piping" section.

6. Always install lilrnace to operate within the limlace's intended temperature-rise range with a duct system which has an external static pressure within the allowable range, as speci-

lied in the "Start-Up, Adjustments, and Salety Check" section. See furnace rating plate.

7. When a lklrnace is installed so that supply ducts carry air circulated by the luruace to areas outside the space containing

the luruace, the return air shall also be handled by duct(s)

sealed to the Rirnace casing and terminating outside the space

containing the furnace. See "Air Ducts" section.

8. A gas-fired furnace lor installation in a residential garage nmst

be installed as specified in the warning box in the "Location"

section.

9. The fl]ruace may beused lot construction heat provided that

the fllrnace installation and operation complies with the Ill'st

CAUTION in the LOCATION section of these instructions.

10. These Multipoise Gas-Fired Furnaces are CSA (lbrmerly A.G.A. and C.G.A.) design-certified ff_r use with natural and propane gases (see Rirnace rating plate) and liar installation in alcoves, attics, basements, closets, utility rooms, crawlspaces, and garages. The Rirnace is factory-shipped liar use with natural gas. A CSA listed gas conversion kit is required to

convert limmce liar use with propane gas.

11. See Fig. 2 lot required clearances to combustible construction.

12. Maintain a 1-in. clearance from combustible materials to supply air ductwork lot a distance of 36 inches horizontally

li"om the furnace. See NFPA 90B or local code liar lurther requirements.

13. These l_.lrnaces SHALL NOT be installed directly on carpet- ing, tile, or any other combustible material other than wood flooring. In downflow installations, factory accesso U floor

base MUST be used when installed on combustible materials and wood flooring. Special base is not required when this

lurnace is installed on manulhcturer's Coil Assembly Part No. CD5 or CK5, or when Coil Box Part No. KCAKC is used. See

Fig. 2 l_}l*clearance to combustible construction inlkmnation.

iNTRODUCTiON

Series 120/C 4 way nmltipoise Category I lau-assisted ll.ll'nace is CSA design-certified. A Category I lau-assisted furnace is an appliance equipped with an integral mechanical means to either draw or lorce products of combustion through the combustion chamber and/or heat exchanger. The furnace is factou-shipped lot use with natural gas. This furnace is not approved lor installation

in mobile homes, recreational vehicles, or outdoors. This l_lrnace is designed l_)r minimum continuous return-air

temperature of 60°F db or intermittent operadou down to 55°F db such as when used with a night setback daermostat. Return-air

temperature must not exceed 85°F db. Failure to l_fllow these return-air temperature limits may aflcct reliability of heat exchang- ers, motors, and controls. (See Fig. 3.)

For accessory installation details, reler to the applicable instruction literature.

NOTE: Remove all shipping brackets and materials belom oper- ating the l_rnace.

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 iustalladou must

comply with the national codes listed below and all authorities having jurisdiction.

In the United States and Canada, fl}llow all codes and standards lot the l_)llowing:

Step l ISafety

[IS: National Fuel Gas Code (NFGC) NFPA 54 2002/ANSI Z223.1 2002 and the Installation Standards, Warm Air Heating

and Air Conditioning Systems ANS1/NFPA 90B CANADA: CSA B149.1-00 National Standard of Canada Natural Gas and Propane Installation Codes (NSCNGPIC)

INSTALLATION

MINIMUM INCHES CLEARANCE TO COMBUSTIBLE CONSTRUCTION

DISTANCE MINIMALE EN POUCES AUX CONSTRUCTIONS COMBUSTIBLES

This forced air furnace is equipped for use with This furnaceisapprovedforUPFLOW,DOWNFLOW,and

natural gas at altitudes 0-10,000 fi (0-3,050m). HORIZONTALinsta]laiJons.

An accessory kit, supplied by the Cettefoumaiseestapprouveepour I 'installationHORIZONTALE manufacturer, shall be used to convert to propane etla circulationd 'airVERS LEHAUTet VERSLEBAS. gas use or may be required for some natural gas 1-...'_"b> applications. Qearancearrows i'_r Lesfl6chesde degagement

This furnace is for indoor installation in a do notchangewith _ _ ! ne changepasavec

tumaceorientation. _ _ I I 'orientationdela foumaise.

building con@'ucted on site.

This furnace may be instatfad on cornbustibfa _ !!

flooring in alcove or closet at minimum clearance

aSmateriaLindicatedby the diagram from combusitbfa X_AR_ _ _._ .U/

Tbls furnace may be used with a Type BH Vent .._-..L,._ERE_.." _ _ and may be vented in common with other gas ._ _. _ _._b

fired appliances. "'_£ _ r"_

Cette fournaise a air pulse est equip6e ? _

pour utilbation avec gaz naturel et altitudes

comprises enb'e 0-3,050m (0H0,000 P0-

Utiliser une trousse de COnversion, fourble par

fa fabdcant, pour passer au gaz propane ou pour certaines installations au gaz natureL ""

Cette fuurnaise est pr6vue pour eb-e N,_ 8_ V" fastallee darts un b_timent construit sur place. _ _ _ Clearancein inches

Cette fournaise peut 6b'e instatlee sur _ / Degagement(po).

un plancher combustible dans une alc6ve ou darts un garde_robe en respectant faminimum

d'espace libre des mat@iaux combustibfas, tel VentClearance to combustibles: qulndique sur fa diagramme. ForSingleWail venis6 inches(6 po).

Cette foumaise peut _tre uti[isee ave(; un ForType B-1venttype 1inch (1po).

Degagement de l'@ent avec combustibles:

conduit d'evacuation deType Bq ou connectee Pourcondui_d'evacuationa paroisimple6 po (6 inches). au conduit ommun d 'autres appareils a gaz. Pourconduitd'evacuationdeType B:I 1_o(1

MINIMUM INCHES CLEARANCE TO COMBUSTIBLE CONSTRUCTION

DOWNFLOWPOSITIONS:

1- thstallationon non-combusfaible floors only.

For Installation on combestible 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 cfaarance required for alcove.

-k 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 buildingjoists,

studs or framing.

DF:GAGEMENT MINIMUM EN POUCES AVEC €:LEMENTS

DE CONSTRUCTION COMBUSTIBLES

POURLA POSITIONCOURANTDESCENDANT:

1- Pourl'instatlation sur plancher non combustible seulement.

Pour I1nstallationsur un piancher combustible seulement quand on utilise ta base speciafa, piece

no KGASB0201ALL I'ensembfa serpentin, piece no CD5 ou CK5 ou le carter de serpentin, piece no KCAKC.

O Dans une alc6ve, on doit maintenir undegagement a Favant de 18 po (450ram).

-k La poistion fadiquee concerne le c6t6 d'entree ou de retour quand lafournaise est dans la

position horizontafa.

Le contact n'est permis qu'enb'e fas tignes formees par fas intersections dudessus et des

deux c6t6s de la cherdse de la fournaise et fas solives, montant sous cadre de charpente.

327590-101 REV. C

Fig. 2--Clearances to Combustibles

A04123

MAX 85°F

FRONT

/J MIN60OF

A02055

Fig. 3iReturn Air Temperature

Step 2iGeneral installation

• US: Current edition of tile NFGC and tile NFPA 9(lB. For

copies, contact the National Fire Protection Association Inc., Batterymarch Park, Quincy, MA 02269: (www.NFPA.org) or

%r only the NFGC, contact the American Gas Association, 400 N. Capitol Street, N.W., Washington, DC 2(t(t(tl

(www.AGA.org).

= CANADA: NSCNGP1C. For a copy, contact Standard Sales,

CSA International, 178 Rexdale Boulevard, Etobicoke (Tor- onto), Ontario, M9W IR3 Canada

Step 3--Combustion and Ventilation Air

• US: Section 8.3 of the NFG(', Air %r Combustion and

Ventilation

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

Supply lot Appliances

Step 4--Duct Systems

• [IS and CANADA: Air Conditioning Contractors Association

(ACCA) Manual D, Sheet Metal and Air Conditioning Con- tractors National Association (SMACNA), or American Soci-

ety of Heating, Reli"igeration, and Air Conditioning Engineers (ASHRAE) 2001 Fundamentals Handbook Chapter 34 or 2(t(t(t

HVAC Systems and Equipment Handbook Chapters 9 and 16.

Step 5iAcoustical Lining and Fibrous Glass Duct

• {IS and CANADA: current edition of SMACNA and NFPA

9(tB as tested by UL Standard 181 lor Class 1 Rigid Air Ducts

Step 6iGas Piping and Gas Pipe Pressure Testing

• US: NFG('; chapters 5, 6, 7, and ]2 and National Plumbing

('odes

• 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

Step 8--Venting , {IS: NFGC; chapters l(t and 13

= CANADA: NSCNGPIC Part 7 and Appendix C

ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS

PROCEDURE

FURNACE RELIABILITY HAZARD hnproper installation or service of furnace may cause prema-

ture furnace component failure. Electrostatic discharge can affect electronic components. Follow the Electrostatic Discharge Precautions Procedure listed below during fln'nace installation and servicing to protect the furnace electronic controh Precautions will pre- vent electrostatic discharges fl'om 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 DIS- CHARGING YOUR BODY'S ELECTROSTATIC CHARGE

TO GROUND.

2. Firmly touch the clean, unpainted, metal surface of the limmce chassis which is close to the controh Tools held in a person's band 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 (lbr example; DO NOT move or shuffle your IL'et, do not touch ungrounded

objects, etc.).

4. If you touch ungrounded objects (and recharge your body with static electricity), firndy touch a clean, unpainted metal

surlilce of the furnace again betk_retouching control or wires.

5. Use this procedure li)r installed and uninstalled (ungrounded) lul'naces.

6. Belbm ren-ioving a new control li"om 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 lurnace, lbllow items 1 through 4 belore bringing the control

or yourself in contact with the limmce. Put all used and new controls into containers belbm touching ungrounded objects.

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

LOCATION

GENERAL This nmltipoise furnace is shipped in packaged configuration.

Some assembly and modifications are required when used in any of the %ur applications shown in Fig. 4.

This furnace nmst:

be installed so the electrical components are protected from water.

not be installed directly on any combustible material other than wood flooring (reli:r to SAFETY CONSIDERATIONS).

be located as close to the chinmey or vent and attached to an air distribution system. Reler to Air Ducts section.

be provided ample space lor servicing and cleaning. Always comply with minimum fire protection clearances shown on the

furnace clearance to combustible label.

THE BLOWER IS LOCATED

TOTHE RIGHT OF THE

BURNER SECTION, AND

AIR CONDITIONED AIR IS

DISCHARGED TO THE LEFT.

THE BLOWER IS

LOCATED ABOVE THE

BURNER SECTION, AND

CONDITIONED AIR IS

DISCHARGED DOWNWARD

AIRFLOW

THE BLOWER IS

LOCATED BELOW THE

BURNER SECTION, AND

CONDITIONED AIR IS

DISCHARGED UPWARD.

..........................................._ HORIZO

q ..................................... IAIRFLOW

TBEB OWER,S

LOCATED TO THE LEFT

OF THE BURNER SECTION,

AND CONDITIONED AIR IS

A02097

Fig. 4--Multipoise Orientations

CARBON MONOXIDE POISONING HAZARD Failure to R)llow this warning cotlld 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 Ikw combustion must not be contaminated by halogen compounds, which include fluoride, chloride, bromide, and iodide. These elements can corrode heat exchangers and

shorten lurnace lilk_. Air contaminants are Iimnd in aerosol sprays, detergents, bleaches, cleaning solvents, salts, air

fresheners, and other household products. Do not install furnace in a corlTosive or contaminated atmosphere. Make sure all combustion and circulating air requirements are met,

in addition to all local codes and ordinances.

The Ikfllowing types of furnace installations may require OUT-

DOOR AIR lor combustion due to chemical exposures:

Connnercial buildings Buildings with indoor pools Laundry rooms Hobby or el'all rooms, and

Chemical storage areas

If air is exposed to the lollowing substances, it should not be used lkwcombustion air, and outdoor air may be required lot conlbus-

tion:

Permanent wave solutions Chlorinated waxes and cleaners

Chlorine based swinnning pool chemicals Water soflening chenficals De-icing salts or chemicals

Carbon tetrachloride Halogen type refiigerants

Cleaning solvents (such as perchloroethylene) Printing inks, paint removers, varnishes, etc. Hydrochloric acid Cements and glues Antistatic fabric softeners lot clothes dryers Masonry acid washing materials

All fuel-burning equipment must be supplied with air lot 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 fi'om the burner area and from dral_ salk:guard opening.

18-1N. MINIMUM

TO BURNERS

Fig. 5--installation in a Garage

A93044

FIRE, INJURY OR DEATH HAZARD Failure to 12)llowthis warning could result in personal injury, death, and/or property damage. 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 Rn'nace 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.)

PERSONAL INJURY AND/OR PROPERTY DAMAGE HAZARD

hnproper use or installation of this furnace may cause premature fl]rnace component failure.

This gas lurnace may be used %r heating buildings under

construction provided that:

-The furnace is permanently installed with all electrical wiring, piping, venting and dncting installed according to

these installation instructions. A return air duct is pa)vided,

sealed to the lm'nace casing, and terminated outside the space

containing the lurnace. 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 lilrnace is controlled by a thermostat. It may not be "hot wired" to provide heat continuously to the structure without

thermostatic controh

-Clean outside air is provided %r combustion. This is to minimize the corrosive el'li_ctsof adhesives, sealers and other

construction materials. It also prevents the entrainment of

drywall dust into combustion air, which can cause flmling and plugging of furnace components.

-The temperature of the return air to the li]rnace 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 interndttent

operation per our installation instructions.

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

-The filters used to clean the circulating air during the

construction process nmst be either changed or thoroughly cleaned prior to occupancy.

-The furnace, ductwork and filters are cleaned as necessary to remove duwall dust and construction debris li"om all HVAC

system components after construction is completed.

-Verily proper limmce operating conditions including igni-

tion, gas input rate, air temperature rise, and venting accord-

ins to these installation instructions.

FIRE HAZARD Failure to follow this warning could result in personal injury,

death andk)r property damage. Do not install the furnace on its back or hang furnace with control compartment facing downward. Sali_ty control opera- tion will be adversely afli:cted. Never connect return-air ducts to the back of the furnace. (See Fig. 6.)

LOCATION RELATIVE TO COOLING EQUIPMENT

The cooling coil n]ust 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 n]ust prevent chilled air li"om entering the furnace. If the dampers are manually operate& they must be equipped with means to prevent operation of either unit unless the damper is in the full-heat or lull-cool position.

BACK

A02054

Fig. 6--Prohibit Installation on Back

AIR FOR COMBUSTION AND VENTILATION

Provisions lot adequate combustion, ventilation, and dilution air nmst be provided in accordance with:

U.S. installations: Section 8.3 of the NFGC, Air %r Combus- tion and Ventilation, and applicable provisions of the local

building codes. Canadian installations: Part 7 of the NSCNGPIC, Venting

Systems and Air Supply lbr Appliances, and all authorities having jurisdiction.

FURNACE CORROSION HAZARD Faihn'e to lbllow this caution may result in furnace damage.

Air [or combustion nn]st not be contaminated by halogen compounds_ which inch]de fluoride, chloride, bromide_ and iodide. These elements can corl:ode heat exchangers and

shorten furnace lili:. Air contaminants are flmnd in aerosol sprays, detergents, bleaches, cleaning solvents, salts, air

li"esheners, and other household products.

CARBON MONOXIDE POISONING HAZARD Faih]re 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 li;rnace.

Make-up air MUST be provided li)r the ventilation devices, in addition to that required by the fln'nace. Reli:r to Carbon Monoxide Poisoning Hazard warning in venting section of these instructions to determine if an adequate amount of

make-up air is available.

The requirements %r combustion and ventilation air depend upon whether or not the lurnace is located in a space having a volume of at least 50 cubic licet per 1,000 Btuh input rating lbr all gas

appliances installed in the space.

Spaces having less than 50 cubic li_et per 1,000 Btnh require the OUTDOOR COMBUSTION AIR METHOD.

Spaces having at least 50 cubic li_etper 1,000 Btuh may use the INDOOR COMBUSTION AIR, STANDARD or KNOWN-

AIR INFILTRATION METHOD.

Outdoor Combustion Air Method

1. Provide the space with sufficient air %r proper combustion, ventilation, and dilution of flue gases using permanent hori- zontal or vertical duct(s) or opening(s) directly comnmnicat- ins with the outdoors or spaces that freely commmficate with

the outdoors.

Table 2-Minimum Free Area Required for Each Combustion Air Opening or Duct to Outdoors

TWO HORIZONTAL DUCTS SINGLE DUCT OR OPENING TWO OPENINGS OR VERTICAL DUCTS

FURNACE (1 SQ. IN./2,000 BTUH) (1,100 SQ. IvIM/KW) (1 SQ. IN./3,000 BTUH) (734 SQ. MM/KW) (1 SQ. IN./4,000 BTUH) (550 SQ. IvIM/KW)

iNPUT Free Area 01 Free Area 01 Free Area of

(BTUH) Opening and Duct Round Duct Opening and Duct Round Duct Opening and Duct Round Duct

(Sq. In.) (in. Dia) (sq In.) (in. Dia) (Sq In.) (In. Dia)

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 6 110,000 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

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 FAN-ASSISTED TOTAL

{1,000'S BTUR GAS iNPUT RATE) (1,000'S BTUR GAS iNPUT RATE)

ACH

30 I 40 ! 50 44 ! 66 I 88 I 110 ! 132 I 154

Space Volume (ft3)

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

2. Fig. 7 illustrates how to provide TWO OUTDOOR OPEN-

INGS, one inlet and one outlet combustion and ventilation air

opening, to the outdoors.

a. One opening MUST commence within 12" (300 ram) of

the ceiling and the second opening MUST colnmence within 12" (300 rain) 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 (l,lO0 nnn2/kW) of cembined

input R)r all gas appliances in the space per Fig. 7 and Table

d. TWO OPENINGS OR VERTICAL DUCTS require 1

square inch ol free area per 4,000 Btuh (. 50 mm-/l<W) l_r 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 Bmh (734 elnl2/kW)

liar combined input of all gas appliances in the space per Table 2 and

b. Not less than the sum of the areas ef all vent connectors in

the space.

The opening shall commence within 12" (300 nnn) of the ceiling.

Appliances in the space shall have clearances of at least l" (25 ram) l_'om the sides and back and 6" (150 nnn) from the l_'ont. The

opening shall directly comnmnicate with the outdoors or shall communicate thamgh a vertical or horizontal duct to the outdoors er spaces (crawl or attic) that l]'eely conmmnicate with the

eutdoors. Indoor Combustion Air{) NFPA & AGA

Standard and Known-Air-Infiltration Rate Methods Indoor air is permitted R)r combustion, ventilatiom and dilution,

if the Standard or Known-Air-Infiltratlon Method is used.

CARBON MONOXIDE POISONING HAZARD Failure to lollow this warning could result

in death and/or personal injury. Many homes require air to be supplied l]'om outdoors lk_r

furnace combustion, ventilation, and dilution of flue gases. The furnace combustion air supply must be provided in

accordance with this instruction manual.

The Standard Method:

1. The space has no less vohnne than 50 cubic IL'et per l,I)I)I) Btuh of the maxinmm input ratings lk)r 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).

12"MAX

1SQIN. A PER 2000

BTUH*

[

DUCTS

OUTDOORS

i SQIN.

PER 2000 BTUH* f

CIRCULATING AIR DUCTS

I, ii 12"MAX

DL_C_T_"-- 1SQIN.

TO PER 4000

OUTDOORS BTUH* *Minimum dimensions of 3 in. NOTE: Use any of the following

combinations of openings: A&B C&D D&E F&G

A03174

Fig. 7--Air for Combustion, Ventilation, and

Dilution for Outdoors

The Known Air Infiltration Rate Method shall be used, if the

irffiltration rate is known to be:

1. Less than 0.40 ACH and

2. Equal to or greater than 0.10 ACH

Infiltration rates greater dnm 0.60 ACH shall not be used. The nfinimum required volume of tile space varies with the number of

ACH and shall be detemfined per Table 3 or Equations 1 and 2. Determine tile minimum required volume %r each appliance in the space and add the vohnnes together to get the total udnimum

required vohnne %r the space. Tahle 3-Mininmm Space Volumes were determined by using the

fl}llowing equations fi'nm the National Fuel Gas Code ANSI

Z223.1-2002/NFPA .54-2002,8.3.2.2:

1. For other than fan-asslsted appliances, such as a drali hood-equipped water heater:

-21ft3_ Iother ._

Volume Oth,_--A---"C-Hp0-0 B'iu/hFJ

A04002

2. For fan-assisted appliances such as this furnace:

-- 1S_t 3 I fan

A04003

CIRCULATING AIR ]_l

DUCTS

I I I I I I I I I I I I I I I I I I

INTERIOR

HEATED

SPACE

IRCULATING AIR DUCTS

VENT THROUGH ROOF

_< 12" AX

U-z -=--1SQ IN.

PER1000

TUH*,NDOOR

OR WALL

UNCONFINED

! SPACE

6" MIN

(FRONT)t

z_ 1SQIN. <Lu PER 1000

rr a_ BTUH* IN DOOR <O __--ORWALL

iii

L12" MAX

* Minimum opening size is 100 sq in. with

minimum dimensions of 3 in.

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

A03175

Fig. 8--Air for Combustion, Ventilation, and

Dilution from Indoors

l[:

lo,,.. , = combined input ol' all other than fan-assisted appli-

ances in Btu/hr

lh, , = combined input of all fan-assisted appliances in Btu/hr

ACH = air changes per hour (ACH shall not exceed 0.60.)

The %llowing requirements apply to the Standard Method and to the Known Air Infiltration Rate Method.

I. Adjoining rooms can be considered part of a space if:

a. There are no closable doors between l'ooms. b. Combining spaces on same floor level. Each opening shall

have fi'ee area of at least 1 in.2/l,000 Btuh (2,000 mme/kW) of the total input rating of all gas appliances ilk the space, but net less than 100 in. 2 (0.06 m2). One opening shall connnence within 12" (300 ram) of the ceiling and the second opening shall commence within 12" (300 ram) of the floor. The mininmm dimension of air openings shall be at least 3 in. (80 ram). (See Fig. 8.)

c. Combining space on dilli:rent floor levels. The volumes of

spaces on difii:rent floor levels shall be considered as communicating spaces if connected by one or more perma- nent openings ilk deers or floors having l)'ee area of at least 2 in.2/l,000 Btah (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

BO]qOM FILLER PANEL

BOTTOM CLOSURE PANEL

A02098

Fig. 9--Removing Bottom Closure Panel

fi'ee area of at least l-in.2/4,000 Btuh of total input rating lot all gas appliances in the space.

3. In spaces that use the Indoor Combustion Air Method, infiltration should be adequate to provide air lor combustion,

permanent ventilation and dilntion of title gases. However, in buildings with unusually tight constrnctiom 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 fi'ames, between sole plates and floors, between wall-ceiling joints, between wall panels, at penetrations lor 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 Comlmstlon Air Method mentioned previously and,

3. Outdoor openings shall be sized as lollows: a. Calculate the Ratio of all Indoor Space volume divided by

required volume lot 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 ndnimum dimension of air openings shall be not less than 3 in. (80

mm).

INSTALLATION

UPFLOW INSTALLATION Bottom Return Air Inlet

These lurnaces 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, perlorm the lollowing:

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.

Fig. 10--Leveling Legs

A89014

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.

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. 111.) Install field-supplied, 5/16 X l-l/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 bole. (Install flat washer if desired.)

3. Install another nut on other side of fiwnace 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 fllrnace is approved lor use on combustible flooring when any one of the fl}llowing 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 speci/Sed in Table 3 and Fig.

11.

FURNACE

(OR COIL CASING

WHEN USED)

COMBUSTIBLE

FLOORING

SUBBASE

PLENUM

__ FLOOR __

OPENING

• . A96283

Fig. 11iFloor and Plenum Opening Dimensions

Fig. 12iFurnace, Plenum, and Subbase Installed on

a Combustible Floor A96285

FURNACE

CD5 OR CK5

COIL ASSEMBLY

OR KCAKC

COIL BOX

COMBUSTIBLE

FLOORING

SHEET METAL____=._

PLENUM

__ FLOOR

OPENING

A04140

Fig. 13--Furnace, Plenum, and Coil Assembly or Coil

Box Installed on a Combustible Floor

A04140

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 perlbrated supply-air duct flanges be completely fblded over or removed li"om furnace when installing the fimlace 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 lbrth until it breaks off. Be careful of sharp edges. (See Fig. 14.)

Bottom Return Air Inlet These furnaces are shipped with bottom closure panel installed in

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

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.

FURNACE

CASING

WIDTH

TaNe 4--Opening Dimensions 0n.)

APPLICATION

Upflow Applications on Combustible or Noncombustible

Flooring (KGASB subbase not required) 13-5/16

Downflow Applications on Noncombustible Flooring 13-3/16

(KGASB subbase not required)

14-3/16 Downflow applications on combustible flooring (KGASB 13-7/16

subbase required)

Downflow Applications on Combustible Flooring with CD5 or

CK5 Coil Assembly or KCAKC coil box (KGASB subbase 13-5/16

not required)

Upflow Applications on Combustible or Noncombustible 16-5/8

Flooring (KGASB subbase not required)

Downflow Applications on Noncombustible Flooring 16-1/2

(KGASB subbase not required)

17-1/2 Downflow applications on combustible flooring (KGASB 16-3/4

subbase required)

Downflow Applications on Combustible Flooring with CD5 or

CK5 Coil Assembly or KCAKC coil box (KGASB subbase 16-1/2

not required)

Upflow Applications on Combustible or Noncombustible 20-1/8

Flooring (KGASB subbase not required)

Downflow Applications on Noncombustible Flooring 20

(KGASB subbase not required)

21 Downflow applications on combustible flooring (KGASB 20-1/4

subbase required)

Downflow Applications on Combustible Flooring with CD5 or

CK5 Coil Assembly or KCAKC coil box (KGASB subbase 20

not required)

Upflow Applications on Combustible or Noncombustible 23-5/8

Flooring (KGASB subbase not required)

Downflow Applications on Noncombustible Flooring 23-1/2

(KGASB subbase not required)

24-1/2 Downflow applications on Combustible flooring (KGASB 23-3/4

subbase required)

Downflow Applications on Combustible Flooring with CD5 or

CK5 Coil Assembly or KCAKC coil box (KGASB subbase 23-1/2

not required)

PLENUM OPENING

A B

12-11/16 21-5/8

12-9/16 19

11-13/16 19

12-5/16 19

16 21-5/8

15-7/8 19

15-1/8 19

15-1/2 19

19-1/2 21-5/8

19-3/8 19

18-5/8 19

19 19

23 21-1/8

22-7/8 19

22-1/8 19

22-1/2 19

FLOOR OPENING

22-1/4

19-5/8

20-5/8

22-1/4

19-5/8

20-5/8

22-1/4

19-5/8

20-5/8

22-1/4

19-5/8

20-5/8

4. Reinstall bottom filler panel and screws.

HORIZONTAL INSTALLATION

FIRE, EXPLOSION, AND CARBON MONOXIDE POISONING HAZARD

Failure to lk)llow this walTning could result in personal injury, death, and/or property damage. Do not install the furnace on its back or hang lklrnace with control compamnent facing downward. Sali:ty control opera- tion will be adversely al_i:cted. Never connect return-air ducts

to the back of the furnace.

The lurnace can be installed horizontally in an attic or crawl space on either the leli-hand (LH) or right-hand (RH) side. The furnace can be hung l)'om floor joists, rafters or trusses or installed on a

non-combustible platlkwm, 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 lhrnace li"om each bottom corner. To prevent screws li"om pulling

out, use 2 #8 x 3A-in. screws into the side and 2 #8 x 3A-in. screws in the bottom of the lurnace casing lkw each strap. (See Fig. 15 and

16.) If the screws arc attached to ONLY the lklrnace sides and not the bottom, the straps nmst be vertical against the furnace sides and

not pull away fi'om the furnace sides, so thai the strap attachment screws arc not in tension (are loaded in shear) liar reliable support.

Platliwm Furnace Support Construct working platform at location where all rcqnired furnace

clearances are met. (See Fig. 2 and 17.) For furnaces with l-in. clearance requirement on side, set furnace on noncombustible

blocks, bricks or angle iron. For crawl space installations_ if the furnace is not suspended li"om the floor joists, the ground under-

neath lilrnace mnst be level and the furnace set on blocks or bricks. Roll-Out Protection Provide a ndnimum 17-3/4" X 22" piece of sheet metal 1()1"flame

roll-out protection in li"ont of burner area lot lilrllaces closer than

12 inches above the combustible deck or suspended furnaces closer than 12 inches to joists. The sheet metal MUST extend underneath the limnace 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 liw flame roll-out protection when bottom of furnace is used li_r return air connection. See Fig. 17 liw proper

orientation of roll-out shield.

PREFERRED

DOW NFLOW

PREFERRED

HORIZONTAL

PREFERRED

120_

MIN

PREFERRED

120_

MIN

PREFERRED

PERMITTED PERMITTED PERMITTED

Fig. 14--Duct Flanges

A02329

Bottom Return Air Inlet

These lurnaces are shipped with bottom closure panel installed in

bottom return-air opening. Remove and discard this panel when bott()m return air is used. To remove bottom closurc panel, perli_rm the fl}llowing:

1. Tilt or raise lurnace and remove 2 screws holding bottom filler panel. (See Fig. 9.)

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

3. Remove bottom c]osnrc 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 inlet.

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

FILTER ARRANGEMENT

CARBON MONOXIDE AND POISONING HAZARD

Failure to fi)llow this warning could result in personal in.jury, or death.

Never operaIe a lurnace without a filter or with filter access door removed.

There are no provisions lot an internal filter rack in these furnaces.

Deluxe furnaces are shipped with a factory supplied Media Filter Cabinet. The Media Filter Cabinet uses either the factory-supplied

standard l-in. l]lter or a 4 in. wide Media Filter which can be purchased separately.

Relier to the instructions supplied with Media Cabinet fl_r 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 Hearing, RefYigerating and Air Conditioning Engineers (ASHRAE) or consult The Air ,5).'stenz.sDe.sign G,id_,- lines rclierence tables available li"om your local distributor. The duct system should be sized to handle the required system design CFM at the design external static pressure. The furnace airflow rates are provided in Table 5-AIR DELIVERY-CFM (With Filter).

When a lk_rnace is installed so that the supply ducts carry air circulated by the lin'nace 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. Secure ductwork with proper lasteners lot 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 lkn'nace to prevent transmission of vibration. Ductwork pass-

ing through unconditioned space should be insulated and sealed to enhance system perlbrmance. When air conditioning is used, a vapor barrier is recommended.

Maintain a 1-in. clearance fi'om combustible materials to supply air ductwork lot adistance of 36 in. horizontally from the lurnace. See NFPA 9(tB or local code fl}r further requirements.

Ductwork Acoustical Treatment NOTE: Metal duct systems that do not have a 90 degree elbow

and lit fl 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 construclion standard on fibrous glass ducts.

Both acoustical lining and fibrous ductwork shall comply with NFPA 9(tB as tested by UL Standard 181 lor 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 limlace is installed and shall be of such a size that the heat exchanger can be viewed lot possible openings using

light assistance or a probe can be inserted lor sampling the air stream. The cover attachment shall prevent leaks.

I I I I

V4" THREADED ROD 4 REQ.

UTER DOOR

&SSEMBLY

8" MIN FOR DOOR REMOVAL

SECURE ANGLE

IRON TO BOTTOM OF FURNACE WITH 3 #8 x 3/4"SCREWS TYPICAL FOR 2 SUPPORTS

1" SQUARE, 1V4" x 1V4"x %" ANGLE IRON

OR UNI-STRUT MAY BE USED

(2) HEX NUTS, (2) WASHERS & (2) LOCK WASHERS

REQ. PER ROD

A05027

Fig. 15--Horizontal Unit Suspension

[Jpflow and Horizontal Furnaces Connect supply-air duct to flanges 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 easing (when used). DO NOT cut main furnace casing side to attach supply air

duct, humidifier, or other accessories. All accessories MUST be

connected to duct external to l_lrnaee 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 perlormed.

Downflow Furnaces Connect supply-air duct to supply-air outlet on limmce. Bend

flange inward past 90 ° with wide duct pliers. (See Fig. 14.) The

supply-air duet nmst be connected to ONLY the limmce supply- outlet 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 a factory

approved air conditioning coil casing. DO NOT cut main furnace casing to attach supply side air duct, humidifier, or other accesso-

ries. All accessories MUST be connected to duct external to

lhrnace casing.

Return Air Connections

FIRE HAZARD Failure to lk_llow this warning could cause personal injury

death andk_r property damage. Never connect return-air duets to the back of the furnace. Follow instructions below.

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

(bottom inlet) as shown in Fig. 19. DO NOT cut into easing sides (left or right). Side opening is permitted lbr only upflow and most horizontal furnaces. (See Fig. 19.) Bypass humidifier connections should be made at ductwork or coil casing sides exterior to

furnace. Upflow and Horizontal Furnaces

The return-air duct nmst 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 into tmused return air side of the furnace casing. (See Fig.

18 and 20.)

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

OUTER DOOR

ASSEMB_ X

II II

I! !1

22 GAUGE GALVANIZED

FOR 4 STRAPS

AIR

BACK QP FURNACE

METHOD 1 FOLD ALL STRAPS UNDER FURNACE AND SECURE WTH

(4) #8 x 3/4 SHEET METAL SCREWS (2 SCREWS IN SIDE AND 2 SCREWS

IN BOTTOM).

METHOD 2 USE (4) #8 x 3/4 SHEET

METAL SCREWS FOR EACH STRAR THE STRAPS SHOULD BE VERTICAL AGAINST THE FURNACE SIDES AND NOT PULL AWAY FROM THE FURNACE SIDES.

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.

17 3/4" OVER ALL 4 3/4" UNDER DOOR 1" UNDER FURNACE

EXTEND OUT 12" OUT FROM FACE OF DOOR

A03176

30-IN. MIN

* WHEN USED WITH SINGLE WALL VENT CONNECTIONS

EQUIPMENT

SHUT-OFF GAS VALVE

SEDIMEN] UNION

TRAP

Fig. 17--Typical Attic Installation

A03177

Table 5--Air Delivery - CFM (With Filter)*

FURNACE

SIZE

024045

036045

024070

036070

048070

042090

048090

060090

036110

048110

066110

RETURN-AIR

INLET

Bottom

Side(s) Bottom

Side(s)

Bottom

Side(s)

Bottom

Side(s)

Bottom

Side(s)

Bottom

Only

Both Sides or

1 Side & Bottom

1 Side Only

Bottom

Side(s)

Bottom

Side(s)

Bottom

Only

Bottom Sides or

1 Side & Bottom

1 Side Only

EXTERNAL STATIC PRESSURE (IN,

SPEED

0.1 0.2 0.3 0.4 0.5 0.6

High 1085 1035 975 915 845 770

Med-High 920 875 830 770 710 840

Med-Low 820 775 730 680 620 555

High 1440 1375 1305 1240 1160 1070

Med-High 1360 1300 1240 1175 1115 1040

Med-Low 1250 1210 1160 1100 1040 985

Low 1085 1055 1035 990 945 885

High 1030 1010 980 945 900 845

Med-High 835 815 790 780 720 675

Med-Low 725 700 875 645 800 555

High 1425 1375 1320 1265 1200 1125

Med-High 1320 1280 1240 1205 1140 1075

Med-Low 120 1175 1145 1105 1050 990

Low 1040 1030 1010 985 945 895

High 1808 1740 1670 1600 1530 1445

Med-High 1630 1585 1530 1470 1405 1330

Med-Low 1460 1420 1385 1325 1280 1220

Low 1275 1250 1225 1195 1155 1105

High 1650 1600 1535 1465 1385 1285

Med-High 1515 1485 1440 1380 1300 1220

Med-Low 1385 1360 1320 1260 1195 1120

Low 1205 1180 1160 1120 1085 1005

High 2060 1985 1915 1820 1720 1610

Med-High 1790 1765 1715 1645 1560 1470

Med-Low 1505 1505 1480 1440 1375 1300

Low 1225 1225 1220 1195 1155 1085

High 2405 2310 2220 2130 2025 1920

Med-High 2225 2155 2080 1995 1895 1785

Med-Low 2020 1955 1880 1805 1730 1630

Low 1810 1765 1715 1645 1565 1480

High 2530 2450 2385 2270 2185 2065

Med-High 2285 2215 2150 2075 1985 1890

Med-Low 1995 1945 1900 1840 1770 1685

Low 1770 1740 1700 1645 1575 1505

High 2475 2395 2300 2200 2090 1985

Med-High 2260 2190 2110 2035 1940 1845

Med-Low 1950 1910 1855 1795 1730 1650

Low 1730 1695 1650 1600 1535 1470

High 1625 1575 1515 1445 1355 1260

Med-High 1510 1470 1415 1355 1285 1185

Med-Low 1360 1335 1295 1250 1180 1100

Low 1195 1180 1155 1115 1085 980

High 2035 1965 1880 1790 1680 1495

Med-High 1745 1710 1650 1560 1450 1340

Med-Low 1530 1515 1470 1400 1310 1215

Low 1270 1265 1235 1195 1130 1055

High 2530 2470 2400 2320 2220 2115

Med-High 2230 2205 2165 2110 2035 1950

Med-Low 1920 1900 1880 1845 1795 1730

Low 1640 1650 1635 1610 1575 1520

High .... 2415 2350 2250 2145

Med-High 2235 2200 2155 2100 2040 1955

High 2540 2495 2430 2355 2285 2175

Med-High 2125 2120 2105 2060 2010 1940

*A filter is required for each return-air inlet. Airflow performance included 1-in. washable filter media such as contained determine airflow performance without this filter, assume an additional 0.1 in. wc available external static pressure.

-- Indicates unstable operating conditions.

wc)

0.7 0.8 0.9 1.0

675 565 390 195 555 440 250 -- 470 380 190 --

975 870 730 580 950 850 725 575 885 790 870 520 810 715 595 435

775 680 490 335 610 490 375 265 475 390 300 --

1035 940 830 655

995 905 790 620 920 840 725 555 845 765 655 505

1360 1280 1180 1075 1255 1170 1080 990 1155 1080 995 910 1050 980 910 835

1175 1055 895 645 1115 990 830 600

1025 915 710 565

925 810 830 510

1490 1340 1135 925 1345 1195 1010 820

1190 1045 890 740

985 870 735 620

1790 1860 1530 1350 1675 1565 1420 1260 1535 1420 1275 1135 1390 1280 1145 1005

1940 1805 1670 1505 1780 1860 1525 1360 1600 1480 1350 1180 1415 1325 1190 1040

1865 1730 1585 1425 1735 1820 1475 1325 1555 1445 1310 1150 1385 1285 1165 1000

1165 990 785 595 1070 890 725 530

985 810 670 475 860 740 805 410

1365 1215 1075 875 1205 1090 955 750

1095 990 830 670

970 875 720 600

2000 1865 1730 1590

1855 1740 1615 1485 1650 1555 1460 1340 1455 1375 1285 1170

2015 1875 1715 1560

1850 1740 1595 1470

2065 1935 1785 1650

1840 1730 1615 1485

in factory-authorized accessory filter rack. To

Table 5--Air Delivery - CFM (With Filter)* (Continued)

FURNACE

SIZE

048135

066135

060155

RETURN-AIR

iNLET

Bottom

Side(s)

Bottom

Only

Bottom, Sides or

1 Side & Bottom

1 Side Only

Bottom

Only

Both Sides Or

1 Side & Bottom

1 Side Only

SPEED

EXTERNAL STATIC PRESSURE (IN, we)

0.1 0.2 0.3 0.4 0.8 0.8 0.7 0.8 0.9 1.0

High 2090 2010 1930 1835 1710 1590 1470 1335 1025 835

Med-High 1790 1755 1705 1640 1550 1465 1360 1210 945 785

Med-Low 1545 1525 1500 1450 1380 1315 1215 1005 855 670

Low 1325 1320 1295 1285 1210 1150 995 865 745 540

High 2485 2400 2310 2215 2110 2000 1880 1725 1535 1355

Med-High 2195 2150 2090 2000 1920 1825 1720 1565 1405 1255

Med-Low 1880 1850 1820 1780 1715 1835 1540 1415 1290 1160

Low 1640 1635 1615 1585 1530 1465 1370 1255 1150 1040

High .... 2385 2305 2195 2085 1960 1825 1670 1465

Med-High 2180 2145 2060 2010 1945 1865 1765 1660 1515 1325

High .... 2245 2155 2055 1940 1825 1695 1555 1385

Med-High 2135 2085 2035 1975 1895 1795 1685 1565 1445 1265

High 2465 2430 2375 2305 2230 2110 2000 1865 1725 1545

Med-High 2115 2105 2075 2030 1980 1910 1830 1725 1590 1425

Med-Low 1800 1790 1770 1735 1695 1640 1570 1465 1345 1225

Low 1570 1565 1550 1525 1495 1445 1370 1270 1175 1070

High .... 2375 2285 2200 2105 1995 1870 1730 1570

Med-High 2155 2135 2095 2040 1975 1895 1790 1685 1550 1400

High .... 2260 2180 2085 1975 1865 1740 1605 1455

Med-High 2140 2095 2040 1975 1890 1810 1705 1595 1480 1325

*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.

GAS PIPING

t , =

FIRE OR EXPLOSION HAZARD Failure to Iollow this warning could result in personal injury,

death, and/or property damage. Never purge a gas line into a combustion chamber. Never test lbr gas leaks with an open flame. Use a commercially available soap solution made specil]cally liar the detection of

leaks to check all connections.

FIRE OR EXPLOSION HAZARD Failure to Iollow this warning coud result in personal injury,

death, andk_r property damage. Use proper length of pipe to avoid stress on gas control manili_dd and a gas leak.

Gas piping must be installed in accordance with national and local codes. Rel;,:'rto current edition of NFGC in the U.S., the NSCNG-

P1C in Canada. Installations must be made in accordance with all authorities

having jurisdiction. If possible, the gas supply line should be a separate line running directly l)'om meter to lurnace.

NOTE: In the state of Massachusetts:

1. Gas supply connections MUST be perlormed by a licensed

plumber or gas fitter.

2. When flexible connectors are used, the maxiumm length shall not exceed 36 inches (915 ram).

3. When lever handle type manual equipment shutoff valves am used, they shall be T-handle valves.

4. The use of copper robing liar gas piping is NOT approved by the state of Massachusetts.

Reli:r to Table 6 for recommended gas pipe sizing. Risers lnnst 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 6fl. 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 12_llowdais warning could result in personal injury,

death, 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 limlace gas control valve and extend a minimnm of 2 in. outside the l_lrnace.

FURNACE OVERHEAT HAZARD Failure to lollow this caution may result in property damage.

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

An accessible manual equipment shutoff' valve MUST be installed external to lilrnace casing and within 6 fl of furnace. A l/8-in. NPT plugged tapping, accessible lkn"test gauge connection, MUST be installed immediately upstream of gas supply connection to furnace and downstream of manual equipment shutoff valve.

NOTI=: The furnace gas control valve inlet pressure tap connec- tion is suitable to use as test gauge connection providing test pressure DOES NOT exceed maximum 0.5 psig (14-in. we) stated on gas control valve. (See Fig. 52.)

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 li_rnace 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 l/8-in. NPT plugged tapping, accessible liar test gauge connection, MUST be installed immedi- ately upstream of gas supply connection to lurnace and down- stream of manual equipment shutoff valve.

['_ UPFLOW RETURN AIR CONFIGURATIONS AND RESTRICTIONS

AIR FLOW MODELS RETURN AIR RETURN AmR RETURN AIR

CONNECTION t CONNECTION 2 CONNECTmON 3 ONLY ONLY ONLY

066.060, -22 AND YES YES YES

-20 MODELS ALL OTHER MODELS YES YES YES YES

UP,LOW

HESTHIcrloNS

Fig. 18--Upflow Return Air Configurations and Restrictions

RETURN AIR COMBINATmQNS OF 1,2, AND3

YES

A02075

DOWNFLOWRETURNAIRCONF1GURATIONSANDRESTRICTIONS

_J _ t AIR FLOW MODELS RETURN AIR RETURN AIR

CONNECTION 1 CONNECTION 2 ONLY ONLY

066.060, -22 AND YES NO

-20 MODELS ALL OTHER MODELS YES NO NO

suPPLY

AIR

RETURN AIR RETURN AIR CONNECTION 3 COMBINATIONS

ONLY OF 1, 2, AND 3 NO NO

Fig. 19--Downflow Return Air Configurations and Restrictions

A02163

RETURN

AIRFtOWMODELSi

...........................................J

IIII

li .....

o 2 IIII " _

.... _ IIII

"z_#'"{ IIII

j\. orP RMIrr_r?FORi

066,C'_0,-22-0

i AIRF_OWMODELS

.............../' ii

RE_'URN AIR

_[ORIZOAL*NOTE RESTRICTIONLEFTSAM£ [Q£ _ AIR Rf S[[_IC[IO S

@ | HORIZONTAL RETURN AIR CONFIGURATIONS AND RESTRICTIONS

AIR FLOW MODELS RETURN AIR RETURN AIR RETURN AIR RETURN AIR

CONNECTION 1 CONNECTION 2 CONNECTION 3 COMBINATIONS ONLY ONLY ONLY OF 1, 2, AND 3

066.060, -22 AND YES NO NO NO

-20 MODELS ALL OTHER MODELS YES YES YES YES

Fig. 20--Horizontal Return Air Configurations and Restrictions

A02162

Table 6iMa×imum Capacity of Pipe*

NOMINAL

IRON

PiPE

SiZE

(iN.)

1/2

3/4

1 1-1/4 1-1/2

iNTERNAL

DIAMETER

(iN.)

0.822

0.824

1.049

1.380

1.810

LENGTH OF PIPE (FT)

10 20 30 40 80

175 120 97 82 73 380 250 200 170 181

680 465 378 320 285

1400 950 770 860 580

2100 1460 1180 990 900

* 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.

TOP VIEW OF BURNER AND MANIFOLD ASSEMBLY

90° Elbow_

2" Nipple

90 ° Elbow

Close Nipple L Gas Valve

Fig. 21aiBurner and Manifold

Supply

A05028

The gas supply pressure shall be within tile maxiumu_ and minimun_ inlet snpply pressures marked on the rating plate with

the lurnace burners ON and OFF. ELECTRICAL CONNECTIONS

ELECTRICAL SHOCK HAZARD Failure to lollow this warning could result in personal injury

or death. Blower access panel door switch opens l15-v power to

control. No component operation can occur. Do not bypass or close switch with panel removed.

See Fig. 25 lor field wiring diagl'am showing typical field 115-v wiring. Check all factory and field electrical connections liar tightness.

Field-supplied wiring shall conlbrm with the limitations of 63°F (33°C) rise.

ELECTRICAL SHOCK AND FIRE HAZARD Failure to lk>llow this warning could result in personal injury,

death, or properly damage. The cabinet MUST have an uninterrupted or unbroken ground according to NEC ANSI/NFPA 70-2002 and Canadian Elec- trical Code CSA C22.1 or local codes to ndnimize personal injury if an electrical fault should occur. This may consist of electrical wire, conduit approved lbr electrical ground or a listed, grounded power cord (where permitted by local code)

when installed in accordance with existing electrical codes. Relier to the power cord manufucmrer's ratings for proper wire gauge. Do not use gas piping as an electrical ground.

SUPPLY j_

MANUAL_/ SHUTOFF J_

VALVE

(REQUIRED/f& J_

SEDIMENT-- t

TRAP /

UNION"J

A02035

Fig. 21 b--Typical Gas Pipe Arrangement

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 beik_re the furnace has been connected. After all connections have been made, purge lines and check liar leakage at furnace prior to operating furnace.

If pressure exceeds 0.5 psig (14-in. wc), gas supply pipe must be disconnected from lisrnace and capped belbre and during supply pipe pressure test. If test pressure is equal to or less than 0.5 psig (14-in. we), turn off electric shutolT switch located on furnace gas control valve and accessible manual equipment shutolT valve belbrc and during supply pipe pressure test. Alter all connections have been made, purge lines and check liar leakage at furnace prior to operating lurnace.

FIURNACE MAY NOT OPERATE Failure to lk_llow this caution may result in intermitent

flmmce operation. Furnace control nmst be grounded lbr proper operation or else control will lock out. Control ulust remain grounded through green/yellow wire routed to gas valve and mani{k_ld bracket

screw.

15-V WIRING

Verily that the voltage, fi'equency, and phase correspond to that specified on unit rating plate. Also, check to be sure that service provided by utility is sulTicient to handle load imposed by this equipment. Refer to rating plate or Table 7 lk_r equipment electrical specifications.

U.S. installations: Make all electrical connections in accordance with National Electrical Code (NEC) ANS1/NFPA 70-2002 and any local codes or ordinances that might apply. Canadian installations: Make all electrical connections in accor-

dance with Canadian Electrical Code CSA C22.1 or authorities having ,jurisdiction.

FIRE HAZARD Failure to lk>llow this warning could result in personal injury,

death, or property damage. Do not connect aluminum wire between disconnect switch

and lurnace. Use only copper wire.

Use a separate, fused branch electrical circuit with a properly sized fuse or circuit breaker liar this lurnace. See Table 7 lk_r wire size

OPERATING

FURNACE SIZE VOLTAGE RANGE

Maximum* Minimum*

045-08/024045 127 104 045-12/036045 127 104 070-08/024070 127 104 070-12/036070 127 104

070-16/048070 127 104 090-14/042090 127 104 090-16/048090 127 104 090-20/060090 127 104

110-12/036110 127 104 110-16/048110 127 104

110-22/066110 127 104 135-16/048135 127 104 135-22/066135 127 104

155-20/060155 127 104

* Permissible limits of the voltage range at which the unit

VOLTS-

HERTZ-

PHASE

118-60-1 115-60-1 118-60-1 115-60-1

118-60-1 115-60-1 118-60-1 115-60-1 118-60-1

115-60-1 118-60-1 115-60-1 118-60-1

115-60-1

Table 7--Electrical Data

5.4

7.0

5.0

6.8

9.5

8.2

10.0

13.6

8.2

10.1

14.8

10.2

14.4

15.0

operates satisfactorily•

UNIT

AMPACffY#

MINIMUM

WiRE GAUGE

MAXIMUM

WiRE LENGTH (FT)$

52 40

28 34 28

34 28

30 27 30

MAXIMUM

FUSE OR CKT BKR

AMPSt

15 15 15 15

15 15 15

15 15

2O 2O

7.54 14

9.50 14

7.06 14

9.22 14

12.60 14

10.83 14

13.13 14

17.61 12

10.75 14

13.12 14

18.89 12

13.27 14

18.55 12

18.33 12

# 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.

1 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.

and fl_se specifications. A readily accessible means of electrical disconnect must be located within sight of the liJrnace.

NOTE: Proper polarity must be maintained %r l15-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 fl'om 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.

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

3. Move J-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 fl'om 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 flmmce J-Box bracket with at least

two field-supplied screws through holes in electrical box into

holes in bracket. Use bhmt-nose screws that will not pierce wire insulation.

3. Route fln'nace power wires through holes in electrical box and

J-Box brackeL and make field-wire connections in electrical

box. Use best practices (NEC in U.S. and CSA C22.1 in Canada) lor wire bushings, strain relief, etc.

4. Route and secure field ground wire to green ground screw on

J-Box bracket.

FACTORY

INSTALLED

LOCATION

Fig. 22--Relocating J-Box

TWO

;7 ALTERNATE

FIELD

LOCATION

A02099

5. Connect line voltage leads as shown in Fig. 25.

6. Reinstall cover to J-Box. Do not pinch wires between cover and bracket.

Electrical Box on Furnace Casing Side See Fig. 23.

FIRE OR ELECTRICAL SHOCK HAZARD Failure to %llow this warning could resuh in personal injury,

death, or property damage. If lield-supplied manual disconnect switch is to be mounted on liarnace 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.

A03221

Fig. 23--Field-Supplied Electrical Box on

Furnace Casing

3. Fasten the electrical box to casing by driving two field- supplied screws from inside electrical box into casing steel.

4. Remove and save two screws holding J-Box. (See Fig. 22.)

5. Pull limlace power wires out of l/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 intn electrical box.

8. Remove cover li"om limmce J-Box.

9. Route field ground wire through holes in electrical box and

casing, and into lurnace J-Box.

10. Reattach lilrnace J-Box to lurnace casing with screws re- moved 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) lot 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 nmst be able to handle the electrical require-

ments listed in Table 5. Reli:r to power cord manufacturer's listings.

1. Remove cover li"om 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 lbr 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.

BX CABLE INSTALLATION IN FURNACE J-BOX

1. Remove cover from J-Box.

2. Route BX cable into 718-inch diameter hole in J-Box.

3. Secure BX cable to J-Box bracket with connectors approved lor 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.

23.) Connect terminal Y/Y2 as shown in Fig. 24 lot 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 li_se of identical size.

ACCESSORIES

1. Electronic Air Cleaner (EAC) Connect an accessory Electronic Air Cleaner (if used) using

l/4-in li:male quick connect terminals to the two male l/4-in quick-connect terminals on the control board marked EAC-1 and EAC-2. The terminals are rated lor 115 VAC, 1.0 amps maxinmm and arc energized during blower motor operation. (See Fig. 24.)

2. Hnmidifier (HUM) Connect an accessory 24 VAC, 0.5 amp maximum humidifier

(if used) to the l/4-in male quick-connect HUM terminal and COM-24VSCreWterminal on the control board thern_ostat strip. The HUM terminal is energized when gas valve relay (GVR)

is energized. (See Fig. 24.)

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

NOTF: DO NOT connect lilrnace control HUM terminal to HUM (humidifier) terminal on Thermidistat _M,Zone Controller or simi-

lar device. See Thermidistat _M, Zone Controller, thermostat, or controller manufacturer's instructions lk)r proper connection.

VENTING The furnace shall be connected to a listed factory built chinmey or

vent, or a clay-tile lined masonry or concrete chinmey. Venting into an unlined masonry chinmey or concrete chinmey is prohib-

ited. 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 lbrmation of condensate in the furnace and vent, leakage of condensate and combustion products, and spillage of cnmbnstion products into the living space.

BLOWER OFF-DELAY

TWINNING AND/OR COMPONENT TEST

TERMINAL

24-V THERMOSTAT

TERMINALS

3-AMP FUSE

HUMIDIFIER TERMINAL

(24-VAC 0.5 AMP MAX.)

TRANSFORMER 24-VAC

CONNECTIONS

SEC=2 SEC=1

LED OPERATION & _ 4_-

DIAGNOSTIC LIGHT _ _ 4

115-VAC(L2)NEUTRAL I-'_-

CONNECTIONS

[_ I AMP@

/ " !

\ 115 VAC (L1) LINE PL2-HOT SURFACE

........... )i-... SPARE-2 FAN \ VOLTAGE CONNECTION IGNITER & INDUCER

SEL_L_IV_qHT_M_ALS _ _ \ MOTOR CONNECTOR

/ EAC-1 TERMINAL

(115-VAC 1.0 AMP MAX.)

PL1 -LOW VOLTAGE MAIN HARNESS CONNECTOR

Fig. 24--Furnace Control

.... FIELD 24-V WIRING

.... FIELD 115-, 208/230-, 460-V WIRING

-- FACTORY 24-V WIRING

-- FACTORY 115-VWIRING

NOTE 2

F,VEWIRE--

THREE-WIRE --_ _-_ I I L

HEATING-ONLY _"_-_G_i i

BLOWER DOOR SWITCH--_. _

c ....i

..... N I

115-V FIELD- AUXILIARY O ---

SUPPLIED J-BOX L

DISCONNECT

24-_--

TERMINAL

BLOCK

FURNACE

NOTE 1

THERMOSTAT

(_(_ TERMNALS

I L I I

I I

FIELD-SUPPLIED DISCONNECT

ii!iiiiiii/iiiiiiii_i_

..........

'i CONDENS,NG

L TWO UNIT

WIRE

208/230-OR 460-V

THREE

PHASE

208/230-V SINGLE

PHASE

NOTES: 1. ConnectY-terminal in furnace as shown for proper blower operation.

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

3. If any of the original wire, as supplied, must be replaced, use same type or equivalent wire.

Fig. 25--Heating and Cooling Application Wiring Diagram with 1-Stage Thermostat

A02142

A99440

CARBON MONOXIDE POISONING HAZARD Failure to Ibllow the steps outlined below Ibr each appliance

connected to the venting system being placed into operation could result in carbon monoxide poisoning or death.

The %llowing steps shall be lollowed lbr 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 lor proper size and horizontal

pitch, as required in the National Fuel Gas Code, ANSI

Z223. I/NFPA 54 or CSA B149.1, Natural Gas and Prol)atle hlstallatio_l Code and these instructions.

Determine that there is no blockage or restriction, leakage, corrosion and other deficiencies, which could cause an

unsale 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 sunm_er exhaust fan.

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

7. Test %r spillage fi'om draft hood equipped appliances at the

drali hood relief opening alter 5 ndnutes 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 nmst be corrected in accordance with the National Fuel Gas Code, ANSI Z223.1/NFPA .54

and/or (7\S_B149.1, Natutvd 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 cormectors, must be sized to approach nlil'dlnum size as determined using appropriate table lbund in the NFGC or

NSCNGP1C. GENERAL VENTING REQUIREMENTS

Follow all salety codes %r proper vent sizing and installation requirements, including local building codes, the National Fuel

Gas Code ANSI Z223.1-2002/NFPA .54-2002 (NFGC), Parts It) and 13 in the United States or the Natiomd Stcm&_rd qf' Canada,

Narulvd Gas and Propane hlstalh_rion Code CSA-B149.1-011

(NSCNGPIC), Section 7 and Appendix C in Canada, the local building codes, and lhrnace and vent manufacturers' instructions.

These lhrnaces are design-certified as Category I furnaces in

accordance with ANSI Z21.47-2IIII3/CSA 2.3-211113 and operate with a non-positive vent static pmssurc to minimize the potential lbr vent gas leakage. Category 1 lhrnaces operate with a flue loss not less than 17 percent to minimize the potential lbr condensation in the venting system. These furnaces are approved lot common venting and multistory venting with other fan assisted or drali hood equipped appliances in accordance with the NFGC or the NSCNGPIC, the local building codes, and lurnace and vent

manufacturers' instructions.

The lbllowing inlormation and warning nlust be considered in addition to the requirements defined in the NFGC and the

NSCNGP1C.

CARBON MONOXIDE POISONING HAZARD Faihn'e to %llow this warning could result in personal iniury

or death. Do not bypass the draft salegnard switch, as an unsali:

condition could exist which nmst be corrected.

1. If a vent (common or dedicated) becomes blocked, the fln'nace will be shut off by the draft salbguard switch located on the

vent elbow.

2. Do not vent this Catego U I furnace into a single-wall dedicated or connnon vent. The dedicated or connnon vent is

considered to be the vertical portion of the vent system that terminates outdoors.

3. Vent connectors serving Category 1 furnaces shall not be connected into any portion of a mechanical drali system operating under positive pressure.

4. In the U.S.: Do not vent this appliance with any solid fi_el burning appliance. In Canada: Check with the authority having jurisdiction lbr approval on use with solid lhel burning appliance.

5. Category 1 lhrnaces nmst be vented vertically or nearly vertically unless equipped with a listed power ventor.

6. Do not vent this appliance into an unlined masonry chimney. Reli:r to Chinmey Inspection Chart, Fig. 32.

MASONRY CHIMNEY REQUIREMENTS NOTE: These furnaces are CSA design-certified lbr use in

exterior tile-lined masonry chinmeys with a factory accessory Chinmey Adapter Kit. Reli:r to the furnace rating plate lk_rcorrect

kit usage. The Chimney Adapter Kits are lbr use with ONLY furnaces having a Chimney Adapter Kit numbers marked on the

furnace rating plate. If a clay tile-lined masonry chinmey is being used and it is exposed

to the outdoors below the roof line, relining ndght be required. Chinmeys shall conlorm to the Standard %r Chinmeys, Fireplaces, Vents, and Solid 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 nmst be in good condition. U.S.A.-Relbr 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 lbr use with these furnaces. The Chinmey Adapter Kit is listed alternative venting system lbr

these lurnaces. See the kit instructions lbr complete details.

THERMIDISTAT SINGLE-STAGE SINGLE-SPEED THERMIDISTAT SINGLE-STAGE SINGLE-SPEED

FURNACE AIR CONDITIONER FURNACE HEAT PUMP

N/A

HEAT STAGE 1 [_

COOL STAGE 1 [_

FAN [_

24 VAC HOT [_

DEHUMIDIFY [_

24 VAC COMM [_

HUMIDIFY

N/A [_

OUTDOOR _[_

Do%s°,%_

[_ HUM

/1 '

HUMIDIFIER i

(24 VAC)

OUTDOOR

SENSOR

See notes 2,5,7, and 10 on the page following these figures.

A04215

Fig. 26-Single-Stage Furnace with Single-Speed

Air Conditioner

THERMIDISTAT SINGLE-STAGE TWO-SPEED

FURNACE AIR CONDITIONER

N/AI_

COOL STAGE 1

HEAT STAGE 1

COOL STAGE 2

FAN [_

24 VAC HOT [_

DEHUMIDIFY [_

24 VAC DOMM [_

HUMIDIFY [_

N/A [_

°s_t_°°2_?_

CONNECt'ONL_

[_ HUM

z_--- {_

l ["UM'D'F'ERt...........i

(24 MAC)

OUTDOOR

SENSOR

See notes 2,5,8, and 10 on the page following these figures.

RVS COOLING

N/A [_

HEAT STAGE 2

(FURNACE)

HEAT/COOL STAGE 1

(COMPRESSOR)

FAN [_

24 VAC HOT [_

DEHUMIDIFY [_

24 VAC COMM [_

HUMIDIFY [_

N/A [_

OUTDOOR_[2_

coS_°,%/[2_

_ HUM "'"-.

HOM,D,F,ER

..... (24 VAC) ...........

page following these figures.

A04217

Fig. 28-Single-Stage Furnace with Single-Speed

Heat Pump (Dual Fuel)

THERM;D;STAT SINGLE-STAGE TWO-SPEED

FURNACE HEAT PUMP

.vsCOOL.NG_ ............................................................

HEAT,OOOLSTAGE,_/CO=P_ESSO_LO/ ..................C_ .............._

HEAT STAGE 3 _ .........

HEA_,go%{70%,_........OTE,__ ......

FAN[_ ......................C_ ....\ []

_4VADHOT_ ........._ ....

DEHUM'D'FY[3_ ..........................

4MAOCOMM ...................................

_ HUM ""'-.

HUMIDIFY [_ ....... _ HUMIDIFIER(24VAC)

N/A [_

°s_T2°°2 [[2_ ....

DONNEO_'ON/12_

page following these figures.

A04216

Fig. 27-Single Stage Furnace with Two-Speed

Air Conditioner

A04218

Fig. 29-Single-Stage Furnace with Two-Speed

Heat Pump (Dual Fuel)

DUAL FUEL SINGLE-STAGE SINGLE-SPEED DUAL FUEL SINGLE.STAGE TWO-SPEED

THERMOSTAT FURNACE HEAT PUMP THERMOSTAT FURNACE HEAT PUMP

RVS COOLING

NfA [_

HEAT STAGE 2

(FURNACE)[_/_VI_

HEAT/COOLSTAGE1

(COMPRESSOR)_

FAN[_

24 VAC HOT[_

24 VAC COMM [_

NfA [_

RVSSENS,NG[_J" '_'iJ " J' i

OUTDOOR ......

See notes 1,2, 4, 11, 12, and 13 on the page following these figures.

A04219

Fig. 30-Dual Fuel Thermostat with Single-Stage

Furnace and Single-Speed Heat Pump

RVS COOLING

HEAT/COOL STAGE 1

(COMPRESSOR LO)

HEAT/COOL STAGE 2

(COMPRESSOR HI)

FAN [_

24 VAC HOT [_

24 VAC COMM [_

RVS SENSING [_

OUTDOOR _[_

coS_°,%_[_

7 f []

/' • []

i::i []

• ........ i

See notes 1,2, 3, 4,11,12, and 14 on the page following these figures.

A04220

Fig. 31-Dual Fuel Thermostat with Single-Stage

Furnace and Two-Speed Heat Pump

TWO-STAGE SINGLE-STAGE TWO-SPEED

THERMOSTAT FURNACE AIR CONDITIONER

-r-q

-F_ -o

.F'_.°

HUM

See note 2 on the page following these figures.

", HUMIDFIER ...

(24VAC)

A04221

Fig. 32-Two-Stage Thermostat with Single-Stage

Furnace and Two-Speed Air Conditioner

Notes For Figures 26=32

1. Heat pun_p MUST have a high pressure switch lk_rdual fuel applications.

2. Rel_:r to outdoor equipment Installation Instructions lk_l"additional inlk_l'mation and setup procedure.

3. Outdoor Air Temperature Sensor must be attached in all dual fuel applications.

4. Dip switch No. 1 on Thermidistat should be set in OFF position lk_rair conditioner installations. This is factory default.

5. Dip switch No. 1 on Thermidistat should be set in ON position lk_rheat pump installations.

6. Dip switch No. 2 on Thermidistat should be set in OFF position lk)r single-speed compressor operation. This is factory default.

7. Dip switch No. 2 on Thermidistat should be set in ON position lk_rtwo-speed compressor operation.

8. Configuration Option No. 10 "Dual Fuel Selection" nmst be turned ON in all dual fuel applications.

9. NO connection should be made to the lin'nace HUM terminal when using a Thermidistat.

10. The RVS Sensing terminal '%" should not be connected. This is internally used to sense del_'ost operation.

11. DO NOT SE1bECT the "FURNACE INTERFACE" or "BALANCE POINT" option on the two-speed heat pnmp control board. This is controlled internally by the Thermidistat/Dual Fuel Thermostat.

12. Dip switch D on Dual Fuel Thermostat should be set in OFF position lk_rsingle-speed compressor operation. This is factory default.

13. Dip switch D on Dual Fuel Thermostat should be set in ON position lor two-speed compressor operation.

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 dralX hood- equipped appliance, and

3. The combined appliance input rating is less than the maximnm capacity given in Table A, and

4. The input rating of each space beating appliance is greater than the mininmm input rating given in Table B Xk)rthe local 99(A Winter Design Temperature. Chinmeys having internal

areas greater than 38 square inches require furnace input ratings greater than the input ratings of these furnaces. See

R)otnote 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 chiumey adapter kit with

these X'urnaces, which are listed lor use with the kit, a listed chiumey-lining system, or a Type-B counnon vent.

Inspections belore the sale and at the time of installation will determine the acceptability of the chiumey or the need Xi_rrepair and/or (re)lining. Rel_:r to the Fig. 33 to perXkmn a chiumey inspection. If the inspection of a previously used tile-lined chim- ney:

a. Shows signs of vent gas condensation, the chiumey 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 chiumey adapter

kit shall be used to reduce condensation. Xf a condensate drain is required by local code, reli:r to the NFGC, Section

10.9 R)r additional inR)rmation 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 conXimn to ANS1/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 cbinmey and the metal liner.

Exterior Masonry Chimney FAN + NAT

installations with Type-B Double-WaJJ Vent

Connectors ©NFPA & AGA

Table A--Combined Appliance Maximum input

Rating in Thousands of BTU per Hour

iNTERNAL AREA OF CHIMNEY

VENT HEIGHT (FT) (SQ, IN.)

8 10 15 20

74 119 178 257 80 130 193 279

84 138 207 299 NR 152 233 334 NR NR 250 368 NR NR NR 404

,2°

,€

Table B--Minimum Alowable input Rating of

Space-Heating Appliance in

Thousands of BTU per Hour

i INTERNAL AREA OF CHIMNEY

VENT (SQ. IN.)

NaGHT(FT) 12 I 19 I 28 I a8

Lecal 99% Winter Design

Temperature: 17 to 26 degrees F*

6 0 55 99 141 8 52 74 111 154

10 NR 90 125 169

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

Lecal 99% Winter Design

Temperature: -10 te 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*

Not recommended for any vent

configuration

*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 chap- ter, Table 1A (United States) and 2A (Canada).

APPLIANCE APPLXCAT1ON REQUIREMENTS Appliance operation has a significant impact on the perXormance

of the venting system. If the appliances are size& installe& adjusted, and operated properly, the venting system and/or the appliances should not sufli:r l?'omcondensation and corrosion. The venting system and all appliances shall be installed in accordance with applicable listings, standards, and codes.

The lurnace 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 l_'om Air Condi- tioning Contractors of America (Manual J); American Society of Heating, Refl'igerating, and Air-Conditioning Engineers; or other approved engineering methods. Excessive oversizing of the fur- nace could cause the li_rllace and/or vent to fail prematurely.

When a metal vent or metal liner is used, the yen{ must be in good condition and be installed in accordance with the vent manulk_c-

turer's instructions.

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.

-'_ orb r ick ?

\,,

Rebuild

crown.

Is chimney No

property lined with

clay tile liner?

s "

liner and top No Reline

seal in good

co dto \.t.cess >.

y Repair

Debris __

in cleanout? Remove mortar

Mortar, tile, metal venl and tile debris

fuel oil residue?

)r liner. _ '-

Clay

tile misalignment, missing sections,

gaps?

Condensate

drainage at bottom

of chimney?

Chimney

exposed to

outdoors below

roof line?

Chimney is

acceptable for use.

Yes

Suitable

/I,_ ,,,_..... _,,_ "._ .... Line chimney with property

Suttable

_'__v _ I bulTaDle sized, listed flexible metal

""_.'_-_--_' "_'_ ""._' V'/Ye_ I liner orType-B vent per

--_ype-15 vent's/ _ NFGC or NSCNGPIC Ven "-_ / _ Sizing Tables and liner or

"_-_ I" '_,_'_'_'_'_" I vent manufacturer's

I i'n_r_'fi_' I Installation instructions.

_"J_'_L L_ Not Suitable

J"---...

Is chimney _ No .... /S Part C of -'...

_ _.,7'__'_,_ '_r_himney adapter venting'_S_le

" "_ a d_ale / I _ "_ instructions for / I

'es "_a'_e? / I _,. application / I

Fig. 33--Chimney inspection Chart

A03206

To prevent condensation in the limlace and vent system, the

flHlowing precautions must be observed:

1. Tile return-air temperature must be at least 60°F db except lot

brief periods of time during warn>up fi'omsetback 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 li_rnace and/or venting

system. Derating is permitted only Xoraltitudes above 2(}(}(}It.

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

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

Air lot combustion ulnst not be contaminated by halogen com- pounds which include chlorides, fluorides, bromides, and iodides.

These compounds are Xkmndin many common home products such

as detergent, paint, glue, aerosol spray, bleach, cleaning solvent, salt, and air freshener, and can cause corrosion of limmces 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 lurnace or venting system due to corrosion.

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

ADDITIONAL VENTING REQUIREMENTS A 4" round vent elbow is supplied with the lilrnace. A 5-inch or 6-

inch vent connector may be required Xk_rsome 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. 34 46 Venting Orientation lot approved vent configurations.

NOTE: Vent connector length fl_r connector sizing starts at furnace vent elbow. The 4-inch vent elbow is shipped Xi_rupflow configuration and may be rotated liar other positions. Remove the

3 screws that secure vent elbow to lurnace, rotate furnace vent elbow to position desired, reinstall 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 tlmmgh one of 5 locations on

the door.

1. Attach the single wall vent connector to the lilrnace vent elbow, and fasten the vent connector to the vent elbow with at

least two field-supplied_ corrosion-resistant, sheet metal screws located 18()° apart.

NOTE: An accessory flue extension KGAFE0112UPH is avail- able to extend l]'om 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 18()°apart. Fasten the vent connector to the flue extension with at least two lield-supplied, corrosion- resistant sheet metal screws located 18()° apart.

2. Vent the furnace with the appropriate connector as shown in Fig. 34_/-6.

CUT HAZARD Failure to ff_llow this caution may result ilk personal injury.

Sheet metal parts may have sharp edges or burrs. Use care and wear appropriate protective clothing, sali:ty glasses and gloves when handling parts and servicing furnaces.

3. Orient the door to determine the correct location of the door cn{out to be removed.

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

NOTE: Xfthis furnace is equipped with knockouts in the door lk)r the vent, a number of techniques can be used to remove these knockouts as seen in Fig. 47 through 51. The knockout in the bottom of the door is unique due to its IXanging 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. 47.) A sharp blow to the rounded end of the knockout (See Fig. 48.) will separate more tie points and allow the knockout to be pulled loose. (See Fig. 49.) Remove all burrs and sharp edges. For the knockouts ilk the other locations on the door (top and sides), tin snips can also be used along the door edges; however, the preXi_rred method is to use a hammer and screwdriver to strike a sharp blow (See Fig. 50.) directly to the knockout tie points or use a hammer in the upper lelX corner of the desired knockout. (See Fig. 51.) Remove all burrs and sharp edges.

BURN HAZARD Failure to XkHlowthis caution may cause personal injury. Hot

vent pipe is within reach of small children when installed in downflow position.

See the flHlowing instruction.

An accessory Vent Guard Kit, KGAVG01(I1DFG is REQUXRED Xk}rdownlXow applications Xk}ruse where the vent exits through the lower portion of the furnace casing door. Reli:r to the Vent Guard Kit lnstructions Xi}rcomplete details.

The horizontal portion of the venting system shall slope upwards not less than l/4-in, per linear 1i (21 mm/m) from the furnace to the vent and shall be rigidly supported every 5 IXor less with metal hangers or straps to ensure there is no movement after installation.

SIDEWALL VENTING This furnace is not approved Xi_rdirect sidewall horizontal venting.

In the U.S.: Per section 1(}.3.4of the NFGC, any listed mechanical renter may be used, when approved by the authority having

jurisdiction.

In Canada: Per section 7.24.2 of the NSCNGPXC, any listed renters may be used, when approved by the authority having

jurisdiction.

Select the listed mechanical renter to match the Btuh input of the furnace being vented. Follow all manufacturer's installation re- quirements Xi_rventing and termination included with the listed

mechanical renter.

SEE NOTES: 1,2,4,7,8,9 on the page following

these figures

A03208

Fig. 34--Upfiow Application-Vent Elbow Up

SEE NOTES: 1,2,4,5,7,8,9 on the page following these figures

A03211

Fig. 37--Downflow Application-Vent Elbow Up

._ "°= i

SEE NOTES: 1,2,3,4,7,8,9 on the pages following these figures

A03209

Fig. 35--Upflow Application-Vent Elbow Right

SEE NOTES: 1,2,4,5,6,7,8,9,10 on the page following these figures

Fig. 38--Downfiow Application-

Vent Elbow Left then

A03207

SEE NOTES:1,2,3,4,5,7,8,9 on the page following

these figures

Fig. 36--Downfiow Application=

Vent Elbow Up then Left

A03210

SEE NOTES:1,2,3,4,5,7,8,9 on the page following

these figures.

Fig. 39--Downfiow Application-

Vent Elbow Up then Right

A03212

SEE NOTES: 1,2,4,7,8,9 on the page following these figures

A03213

Fig. 40--Horizontal Left Application-Vent Elbow Left

: tl 1i

SEE NOTES: 1,2,4,5,7,8,9 on the page

following these figures

Fig. 41--Hodzontal Left Application-

Vent Elbow Right then Up

A03214

SEE NOTES: 1,2,4,7,8,9 on the page following these figures

Fig. 44--Horizontal Right Application-

Vent Elbow Right

A03218

SEE NOTES: 1,2,4,5,7,8,9 on the page

following these figures

Fig. 42--Horizontal Left Application-Vent ElboA°_ 5

SEE NOTES: 1,2,4,5,7,8,9 on the page

following these figures

A03216

Fig. 43--Horizontal Left Application-Vent Elbow Right

SEE NOTES: 1,2,4,5,7,8,9 on the page following these figures

Fig. 45--Horizontal Right Application-

Vent Elbow Left then Up

A03219

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

Fig. 46--Horizontal Right Application-Vent Elbow Left

A02068

Venting Notes for Figures 34-46

1. For conm_on vent, vent connector sizing and vent material: United States--use the NFGC

Canada--use the NSCNGPIC

2. hnmediately increase to 5-inch or 6-inch vent connector outside furnace casing when 5-inch vent connector is required, rcl_:r to Note 1 above.

3. Side outlet vent lor upflow and downflow installations must use Type B vent immediately alter exiting the furnace, except when KGAVG0101DFG, Downflow Vent Guard Kit, is used in the downflow position.

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

5. Four-inch single-wall (26 ga. rain.) vent must be used inside lurnace 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 lot exterior masonry chimney applications. Rel_:r to Chimney Adapter Kit, KGACA(12014FC or KGACA02015FC, Ibr 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 leer I_r the 154,000 Btuh gas input rate model when installed in a downflow application with lurnace elbow turned to lel] side with the connector elbow outside furnace casing pointing upward. (See Fig. 38.)

Fig. 47--Using Tin Snips to Cut Tie Points

A04127

A04131

Fig. 51--Remove Knockout with Hammer

A04128

Fig. 48--Rounded End of Knockout

A04129

Fig. 49--Knockout Pulled Loose

A04130

Fig. 50--Hammer and Screwdriver Used for Knock-

out

START-UP, ADJUSTMENT, AND SAFETY CHECK

Step 1--General

FIRE HAZARD Failure to l_fllow this warning could result in personal injury,

death and/or property damage. This lklrnace 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 pl'oNem belbrc resetting the switches.

CUT HAZARD Faihn'e to lollow this caution may result in personal injury.

Sheet metal parts may have sharp edges or burrs. Use care and wear appropriate protective clothing, sali:ty glasses and

gloves when handling parts and servicing furnaces.

1. Maintain l lS-v wiring and ground, hnproper polarity will result in rapid flashing LED and no furnace operation.

2. Make thermostat wire connections at the 24-v terminal block on the furnace control. Faihn'e to make proper connections

will result in improper operation. (See Fig. 25.)

3. Gas supply pressure to the lilrnace 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 lor continuity.

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

6. Replace outer door.

Step 2iStart-Up Procedures

FIRE AND EXPLOSION HAZARD Failure to lollow this warning could cause personal injury,

death and/or property damage. Never purge a gas line into a combustion chamber. Never use matches, candles, flame, or other sources of ignition %r the purpose of checking leakage. Use a soap-and-waer solution to check %r leakage.

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

2. Check gas lines liar leaks.

ELECTRICALSHOCKHAZARD Failuretolollowthiswarningcouldresultinpersonalinjury,

ordeath. Bloweraccessdoorswitchopens115-vpowertocontrol.No

componentoperationcanoccurunlessswitchis closed.

Caution lnnst be taken when manually closing this switch fl}r service purposes.

3. To Begin Component Self-Test: Remove blower access door. Disconnect the thermostat R lead

lix)m the lurnace control board. Manually close the blower door switch closed. Short (jumper) the CoM-24v terminal on

control to the TEST/TWIN 3/16-inch quick connect terminal on control until LED goes out (approximately 2 see). Gas

valve and hnmidifier will not be turned on. (See Fig. 24.)

NOTE: The furnace control allows all components, except the gas valve, to be run lbr short period of time. This Ii2atul'e helps diagnose a system problem in case of a component faihn'e. Component test li:ature will not operate if any thermostat signal is present at the controh

Component test sequence is as lollows: Relcr to service label attached to furnace or see Fig. 55.

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 lk)r 15 see., then off.

d. Blower motor operates on HEAT speed lbr 1(1 sec.

e. Blower motor operates on COOL speed lbr 1(1 sec.

f. Inducer motor stops.

g. Reconnect R lead to furnace control board, release blower

door switch and re-install blower door.

4. Operate lhrnace per instruction on door.

5. Vel'ity lurnace shut down by lowering thermostat setting below room temperature.

6. Verify furnace restarts by raising thermostat setting above

ro(iu? temperature.

Step 3iAdjustments

FIRE HAZARD Failure to lollow this warning could result in injury, death

and/or property damage. DO NOT bottom out gas valve regulator adjusting screw. This can result in unregulated manilold pressure and result in excess overfire and heat exchanger failures.

FURNACE DAMAGE HAZARD Failure to li_llow this caution may result in reduced furnace

lili:. DO NOT redrill ofil]ces, hnproper drilling (burrs, out-of-

round holes, etc.) can cause excessive burner noise and misdirection of burner flames. This can result in l]ame

impingement of heat exchangers, causing failures. (See Fig.

53.)

Furnace gas input rate on rating plate is li_r installations at altitudes up to 2(t(t(t It. Furnace input rate must be within _+2 percent of furnace rating plate input. For altitudes above 5500 It., a field-

supplied high altitude pressure switch is required.

I. Determine the correct gas input rate.

In the U.S.A.: The input rating lot altitudes above 2,(t(t(t ft. nlust be reduced

by 4 percent lbr each 1,000 ft. above sea level. For installa- tions below 2(t(t(t IL, rel_,:'r to the unit rating plate. For installations above 2(t(t(t _'1., multiply the input on the rating

plate by the de-rate nmltiplier in Table 8 liar the correct input rate.

In Canada: The input rating umst be derated by 1(t percent liar altitudes of

2,000 It. to 4,500 ft. above sea level by an authorized Gas Conversion Station or Dealer. To determine correct input rate lot altitude, see example 1 and use (t.9(t as derate multiplier

factor.

2. Determine the correct orifice and manilbld pressure adjust- ment. There are two dilli_rent ofifice and manilold adjustment tables. All models in all positions, except Low NOx models in downflow or horizontal positions, use Table 11 (22,(1(1(1

Btuh/Burner). Low NOx models in the downflow or horizontal positions

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.

MINIMUM

FURNACE ORIENTATION VENT ORIENTATION FURNACE INPUT(BTU/HR) VENT DIAMETER (IN.)* MINIMUM VERTICAL VENT HEIGHT (FT)**

Downflow Vent elbow left, then up 154,000

132,000 5 12

Fig. 38 110,000(030/-12 only)

Vent elbow right, 154,000 5 7

Horizontal Loft then up

Fig. 41 132,000

Horizontal Left Vent Elbow up 154,000 5 7

Fig. 42 132,000

Vent elbow right

Horizontal Left Fig. 43 154,000 5 7

Downflow Vent elbow up then left 110,000 5 10

Fig. 36 (036/-12 only)

Downflow Vent elbow up, then right 110,000 5 10

Fig. 39 (030/-12 only)

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)

Table 8=Altitude Derate Multipler for U.S.A.

ALTITUDE PERCENT

(FT) OF DERATE

0-2000 0

2001-3000 8-12 3001-4000 12-18 4001-5000 16-20 5001-6000 20-24 6001-7000 24-28

7001-8000 28-32

8001-9000 32-38

9001-10,000 36-40

* Derate multiplier factors are based on midpoint altitude

DERATE MULTiPLiER

FACTOR*

1.00

0.90

0.88

0.82

0.78

0.74

0.70

0.68

0.62 for altitude range.

1/2" NPT INLET

INLET PRESSURETAP

REGUL_OR

REGULATOR

TMENT

SCREW

REGULATOR SPRING

GAS PRESSURE

REGULATOR

ADJUSTMENT

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

1/2- NPT OUTLET l_

Fig. 52--Gas Control Valve

MANIFOLD

A04166

must use Table 12 (21,000 Btuh/Burner). See inpnt listed on rating plate.

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

li"om local gas supplier.

b. Obtain average yearly gas specific gravity li"om local gas

supplier.

c. Find installation altitude in Table 11 or 12.

d. Find closest natural gas heat value and specific gravity in

Table 11 or 12.

e. Follow heat value and specific gravity lines to point of

intersection to find orifice size and maniflfld pl'cssure settings lot proper operation.

f. Check and veril}, burner orifice size in lurnace. NEVER

ASSUME (,)R1F1CE SIZE. ALWAYS CHECK AND VERIFY.

g. Replace orifice with correct size if required by Table 11 or

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

EXAMPLE 2:(0 2000 ft altitude) For 22,000 Btuh per burner applicafion use Table 11. Heating value = 1000 Btu/cu fl Specific gravity = 0.62

ThereR_re: Orifice No. 43*

Manilold 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 manilold pressure to obtain correct input rate. a. Turn gas valve (-)N/OFF switch to OFF. b. Remove maniflfld prcssure tap plug li"om gas valve. (See

Fig. 52.)

c. Connect a water cohlnln manon_eter or similar device to

manifl}ld pressure tap.

d. Turn gas valve (-)N/OFF switch to ON.

e. Manually close blower door switch.

f. Set thermostat to call lk_r heat.

g. Remove regulator seal cap and turn regulator adjusting

screw counterclockwise (out) to decrease input rate of

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

to Step 4.

NOTE: DO N(,)T set manifi_ld pressure less than 3.2-in wc or more than 3.8-in. wc lot natural gas at sea level. If manilold pressure is outside this range, change main burner orifices or refL'r

Table 11 or 12. NOTE: If'orifice hole appears damaged or it is suspected to have

been re&filed, check orifice hole with a numbered drill bit of correct size. Never redrill an ofifice. A burr-free and squarely aligned orifice hole is essential fl_r proper lIame charactefistics.

4. Verify natural gas input rate by clocking meter.

NOTE: Gas valve regulator a_[justment cap mnst be in place lor proper input to be clocked.

a. Turn oft all other gas appliances and pilots served by the

meter. b. Run furnace fi_r 3 minutes in heating operation.

c. Measure time (in sec) fl_rgas 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. Relbr to Table 10 fi_r cubic 1i of gas per hr.

e. Multiply gas rate (cu li/hr) by heating value (Btn/cn f[) to

obtain input.

If clocked rate does not match required input f}om Step 1, increase manilold pressure to increase input or decrease manilold 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 l_trnace nlust operate within the temperature rise ranges specified on the furnace rating plate. Do not exceed tempera- ture rise range specified on unit rating plate. Deterndne the temperature rise as lollows:

NOTE: Blower access door nmst be installed when taking tem- perature rise reading. Leaving blower access door o11will result in incorrect temperature measurements.

BURNER J

ORIFICE

Table 9--Speed Selection

COLOR SPEED AS SHIPPED

White Common BLW Black High COOL

Yellowt Med-High SPARE

Blue Med-Low HEAT

Red Low* SPARE

* Continuous-blower speed-as shipped default t Not available on 1/5 HP motors.

A93059

Fig. 53--Orifice Hole

a. Place theru]ou]eters in return and supply ducts as close to

l_lrnace as possible. Be sure thermometers do not see radiant heat from heat exchangers. Radiant heat aflccts teu]perature rise readings. This practice is particularly

important with straight-run ducts.

b. When thermon]eter readings stabilize, subtract return-air

teu]perulure from supply-air temperature to determine air teu]perulure rise.

NOTI::: Blower access door umst be installed %r proper teu]pera-

ture rise u]eusureu]eBt.

NOTF:: If the teu]perature rise is outside this range, first check:

1.) Gas input Ik>rheating operation.

2.) Derate lbr altitude il applicable.

3.) Return and supply ducts lbr excessive restrictions causing static pressures greater than 0.50-in. we.

4.)Dirty filter.

ELECTRICAL SHOCK HAZARD Failure to lollow this warning could result in personal inju W

or death. Disconnect 115-v electrical power beik>re changing speed tap.

c. Adjust air ten]perature rise by adjusting blower speed.

Increase blower speed to reduce teu]perature rise. Decrease blower speed to increase temperature rise.

d. Turn thermostat down below teen] teu]perumre and re-

move blower access door.

e. To change u]otor speed selection lot heating, ren]ove

blower n]otor lead fi'on] control HEAT ten]dnal (See Fig.

24.) Select desired blower u]otor speed lead l]'on] one of the other ten]]inals and relocate it to the HEAT tem]inul (See Table 9 Ik_r lead color identification). Reconnect original

lead to SPARE teru]inal.

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. Reu]ove munon]eter or similar device l]*om gas valve. i. Reinstall muniik_ld pressure tap plug in gas valve.

FIRE HAZARD Failure to %llow this warning coiuld result in personal injury,

death, and/or property damage. Reinstall mani%ld pressure tap plug in gas valve to prevent gas leak.

k. Turn gas valve ON/OFF switch to ON.

FURNACE OVERHEATING HAZARD Failure to this caution u]ay result in 17educed l_.trnace lilk:. Recheck ten]perature rise. It nmst be within liudts specified

on the rating plate. Reconnnended operation is at the mid- point of rise range or slightly above

6. Set theru]ostal heat anticipator. a. Mechanical thern]ostat Set thermostat heat anticipator to

match the an]p draw of the electrical components in the R-W circuit. Accurate amp draw readings can be obtained at the wires normally connected to thern]ostat subbase

terlninals, R and W. The therlnostat anticipator should

NOT be in the circuit while measuring current.

(1.) Remove thermostat fl'om subbase or from wall.

(2.) Connect an amp meter as shown in Fig. 54 across the

R and W subbase terminals or R and W wires at wall.

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

heating and after blower starts.

(4.) Set heal anticipator on thermostat per thermostat

instructions and install on subbase or wall.

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

7. Adjust blower oK delay The blower off delay has 4 adjustable settings l]'om 90 sec to

180 sec. The blower off delay jumpers arc located on the

l?lrnace 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 liar the selected blower off delay. Factory off delay setting is 120 sec.

8. Set airflow CFM lbr cooling Select the desired blower n]otor speed lead %r cooling airflow. See Table 5-Air Delivery-CFM (With Filter). See

Table 9 %r 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 noru]al operation.

1. Check Main Limit Switch(es) This control shuts off combustion control system and ener- gizes air-circulating blower motor, if furnace overheas. By using this u]ethod to check liudt control, it can be established that limit is limctioning properly and will operate if there is a restricted duct systeu] or n]otor faihn'c. If lindt control does not function during this test, cause must be detemdned and

corrected. a. Run furnace liar at least 5 n]inutes. b. Gradually block off return air with a piece of cardboard or

sheet u]etal until the liu]it trips.j. Reinstall blower access door if reu]oved.

TERMINALS WITH THERMOSTAT REMOVED

(ANITICIPATOR, CLOCK, ETC.,

MUST BE OUT OF CIRCUIT.)

FROM UNIT 24-V CONTROL TERMINALS

EXAMPLE: 5.0 AMPS ON AMMETER = 0.5 AMPS FOR THERMOSTAT

10 TURNS AROUND JAWS ANTICIPATOR SETTING

A96316

Fig. 54--Amp Draw Check With Ammeter

c. Unblock return air to permit normal circulation.

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

2. Check draft salk:guard switch. The purpose of this control is to cause the sale shutdown of the

l?lrnace during certain blocked vent conditions. a. Verify vent pipe is cool to the touch.

b. Disconnect power to furnace and remove vent connector

l?'om lilrnace vent elbow.

c. Restore power to lurnace and set room thermostat above

room temperature.

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

minutes, then block vent elbow in furnace 80 percent of vent area with a piece of fiat sheet metah

e. Furnace should cycle olT within 2 minutes. If gas does not

shut off within 2 minutes, determine reason draft salcgnard switch did not function properly and correct condition.

f. Remove blockage 15"orelurnace 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 liar 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 o11 l lS-v power to lurnace. b. Disconnect inducer motor lead wires from wire harness.

c. Turn on 115-v power to li_rnace.

d. Set thermostat to "call Ik_rheal" and wait 1 minute. When

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

e. Determine reason pressure switch did not lunction 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.

Table 10-GAS RATE (CU FT/HR)

SECONDS SIZE OF TEST DiAL SECONDS SIZE OF TEST DiAL

FOR 1 1 2 5 FOR 1 1 2 5

REVOLUTION Cu Ft Cu Ft Cu Ft REVOLUTION iCu Ft Cu Ft Cu Ft

10 360 720 1800 50 72 144 360 11 327 655 1638 51 71 141 355

12 300 600 1500 52 68 138 348 18 277 555 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 82 124 310 19 189 379 947 59 81 122 305 20 180 360 900 60 80 120 300

21 171 343 857 62 58 118 290 22 184 327 818 64 56 112 281 23 157 313 783 68 54 109 273 24 150 300 750 68 53 108 265

25 144 288 720 70 51 103 257 26 138 277 892 72 50 100 250 27 133 267 867 74 48 97 243

28 129 257 843 78 47 95 237 29 124 248 821 78 46 92 231 30 120 240 8OO 80 45 90 225 31 116 232 581 82 44 88 220

32 113 225 563 84 43 88 214 33 109 218 545 88 42 84 209 34 106 212 529 88 41 82 205 35 103 208 514 90 40 80 200

38 100 200 500 92 39 78 196 37 97 195 488 94 38 78 192 38 95 189 474 98 38 75 188 39 92 185 462 98 37 74 184

40 90 180 450 100 36 72 180 41 88 178 439 102 35 71 178 42 86 172 429 104 35 89 173

48 84 167 419 106 34 88 170 44 82 164 409 108 33 87 187 45 80 160 400 110 33 85 184

46 78 157 391 112 32 84 181 47 76 153 383 116 31 82 155 48 75 150 375 120 30 80 150 49 73 147 367

h. Blower will run lot 90 sec belol'C beginning the call R_r

heat again.

i. Furnace should ignite normally.

Step 5--Checklist

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

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

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

4. Cycle test lurnace with room thermostat.

5. Check operation of accessories per manufacturer's instruc- tions.

6. Review User's Guide with owner.

7. Attach literature packet to l_lrnace.

Table 11--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)

U.S.A. Only

ALTITUDE

RANGE

(FT)

o 0 =o to

2000

AVG GAS

HEAT VALUE

(RTU/CU FT)

9OO 925 95O 975

1000 1025 1050 1075

1100

ALTITUDE AVG GAS

RANGE HEAT VALUE

(FT) (BTU/CU FT)

U.S.A.

Altitudes

"u 2001

o 3000

=_ or

Canada

_." Altitudes

2000

:_ to

4500

8OO 825

85O 875 900

925 950 975

1000

ALTITUDE AVG GAS

RANGE HEAT VALUE

(FT) (BTU/CU FT)

3001

4000

775 8OO

825 85O 875 900

925 950

ALTITUDE AVG GAS

RANGE HEAT VALUE

(FT) (BTU/CU FT)

4001

5000

750 775

8OO 825 850

875 900 925

0.58

Orifice Manifold

No. Pressure

SPECIFIC GRAVITY OF NATURAL GAS

0.60 0.62 0.64

Orifice Manifold Orifice Manifold Orifice Manifold

No. Pressure No. Pressure No. Pressure

42 I 3.5 42 3.6 42 42 I 3.3 42 3.4 42

43 I 3.8 42 3.3 42 43 I 3.6 43 3.8 42

43 I 3.5 43 3.6 43 43 I 3.3 43 3.4 43 44 I 3.6 43 3.2 43 44 I 3.4 44 3.5 43

44 I 3.3 44 3.4 44

0.58

Orifice Manifold

No. Pressure

3.5

3.4

3.2

3.5

SPECIFIC GRAVITY OF NATURAL GAS

3.7 41 3.5

3.5 42 3.7

3.4 42 3.5

3.2 42 3.3

3.7 43 3.8 43 3.6 43 3.5 43 3.3

43 3.2

0.60 0.62 0.64

Orifice Manifold Orifice Manifold Orifice Manifold

No. Pressure No. Pressure No. Pressure

42 I 3.4 42

42 I 3.2 42

43 I 3.7 43 43 I 3.5 43

43 I 3.3 43 43 I 3.1 43 43 I 2.9 43 43 I 2.8 43 43 I 2.6 43

0.58

Orifice Manifold

No. Pressure

3.5 42

3.3 42

3.8 42

3.6 43

3.4 43

3.2 43 3.3

3.0 43 3.1

2.9 43 3.0

2.7 43 2.8

3.6 42 3.7

3.4 42 3.5

3.2 42 3.3

3.7 43 3.8

3.5 43 3.6 43 3.4

43 3.2 43 3.1 43 2.9

SPECIFIC GRAVITY OF NATURAL GAS

0.60 0.62 0.64

Orifice Manifold Orifice Manifold Orifice Manifold

No. Pressure No. Pressure No. Pressure

42 I 3.2

43 I 3.6 43 I 3.4 43 I 3.2 43 I 3.0

43 I 2.9 43 I 2.7 43 I 2.6

42 3.3 42 43 3.8 42

43 3.5 43 43 3.3 43 43 3.1 43 43 3.0 43

43 2.8 43 43 2.7 43

0.58

Orifice Manifold

No. Pressure

3.3

3.1

2.9

2.8

SPECIFIC GRAVITY OF NATURAL GAS

3.4 42 3.5

3.2 42 3.3

3.7 43 3.8

3.4 43 3.6 43 3.4 43 3.2

43 3.0 43 2.8

0.60 0.62 0.64

Orifice Manifold Orifice Manifold Orifice Manifold

No. Pressure No. Pressure No. Pressure

43 3.6 43 3.4

43 3.2 43 3.0 43 2.8

43 2.7 43 2.5 43 2.4

43 3.8 42 43 3.5 43

43 3.3 43 43 3.1 43 43 2.9 43

43 2.8 43 43 2.6 43 43 2.5 43

3.2

3.6

3.4

3.2

3.0

2.9

2.7

2.6

42 3.3 43 3.8

43 3.5 43 3.3 43 3.1

43 2.9 43 2.8 43 2.6

* Orifice numbers 43 are factory installed

Table 11--Orifice Size* And IVlanifold 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)

AVG GAS HEAT VALUE AT ALTITUDE

(BTU_U FT)

Orifice

No.

SPECiFiC GRAVITY OF NATURAL GAS

725 750

775 8OO 825 85O

875 900

AVG GAS

HEAT VALUE

AT ALTITUDE

(BTU/CU FT)

Orifice

No.

Orifice

No.

43 43 43 43

43 43

O 6001

to 43 43

6000 43 43

43 43 43 43

43 43

0.88 Manifold

Pressure

3.4

3.2

3.0

2.8

2.6

2.5

2.3

2.2

ALTITUDE

RANGE

(FT)

Orifice

No.

0.60 Manifold

Pressure

3.5

3.3

3.1

2.9

2.7

2.8

2.4

2.3

0.62

Orifice Manifold

No. Pressure

43 3.6 43 3.4

43 3.2 43 3.0 43 2.8 43 2.6

43 2.8 43 2.3

0.58 Manifold

Pressure

3.4

3.1

2.9

2.7

2.6

2.4

2.3

2.1

GRAVITY OF NATURAL GAS

Manifold

Pressure

Orifice

No.

43 3.8 43 43 3.3 43 43 3.0 43

O 6001

to 43 2.8 43

7000 43 2.7 43

43 2.8 43 43 2.3 43 43 2.2 43

GRAVITY OF NATURAL GAS

0.58 Manifold

Pressure

3.1

2.9

2.7

2.5

2.4

2.2

2.1

3.7

Orifice

No.

Orifice

No.

43 43 43 43 43

43 43 43

43 43

43 43 43 43

43 43

SPECIFIC

0.60

Orifice

No.

43 43 43 43 43

43 43 43

SPECIFIC

0.60

Orifice

No.

43 43

43 43 43 43 43

SPECIFIC

0.60

Orifice

No.

43 43 43 43 43

43 48

675 700 725 750 778

800 828 850

AVG GAS

HEAT VALUE

AT ALTITUDE

(BTU/CU FT)

0.62 Manifold

Pressure

3.6

3.4

3.1

2.9

2.7

2.6

2.4

2.3

Manifold

Pressure

ALTITUDE

RANGE

(FT)

Orifice

No.

43 3.2 43 43 3.0 43

43 2.8 43

O 7001

to 43 2.6 43

_ 8000 43 2.4 43

43 2.3 43 43 2.1 43

48 2.0 43

ALTITUDE

RANGE

(FT)

0.58 Manifold

Pressure

2.9

2.7

2.5

2.3

2.2

2.0

3.6

Orifice

No.

43 43

43 43 43 43 43

0.62 Manifold

Pressure

3.4

3.1

2.9

2.7

2.8

2.4

2.2

2.1

GRAVITY OF NATURAL GAS

0.62

Manifold

Pressure

3.0

2.8

2.6

2.4

2.2

2.1

3.7

Orifice Manifold

No. Pressure

43 3.1 43 2.9 43 2.7 43 2.5 43 2.3

43 2.2 43 2.0

650 675

700 725 780 775 8OO

825

AVG GAS

HEAT VALUE

AT ALTITUDE

(BTU/CU FT)

625 650 675 700 725

750 775

Orifice

No.

43 43 43 43 43

43 48

O 8001

4 to

9000

Orifice

No.

43 43 43 43 43

43 43

0.64 Manifold

Pressure

3.7

3.5

3.3

3.1

2.9

2.7

2.6

2.4

0.64 Manifold

Pressure

3.7

3.5

3.2

3.0

2.8

2.7

2.5

2.4

0.64 Manifold

Pressure

3.5

3.2

3.0

2.8

2.6

2.4

2.3

2.2

0.64 Manifold

Pressure

3.2

3.0

2.8

2.6

2.4

2.2

2.1

* Orifice numbers 43 are factory installed

Table 11--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)

AVG GAS

HEAT VALUE

AT ALTITUDE

(BTU/CU FT)

SPECiFiC GRAVITY OF NATURAL GAS

0.60 0.62

I Orifice

No.

43 43 43

43 48 48

0.58 Manifold

Pressure

2.7

2.5

2.3

2.1

3.7

3.5

Orifice Manifold

No. Pressure

Orifice

No.

600 43 2.8 43 625 43 2.6 43

O 9001

to 650 43 2.4 43

10,000 675 43 2.2 43

700 43 2.0 43 725 48 3.6 48

Manifold

Pressure

2.9

2.6

2.4

2.3

2.1

3.7

Orifice

No.

43 43 43

0.64 Manifold

Pressure

3.0

2.7

2.5

2.3

2.2

2.0

* Orifice numbers 43 are factory installed

SERVICE AND MAINTENANCE PROCEDURES

• = _

FIRE, INJURY, OR DEATH HAZARD Failure to follow this warning could result in personal injury, death and/or property damage.

The ability to properly perlonn maintenance on this equip-

ment requires certain knowledge, mechanical skills, tools, and equipment. If you do not possess these, do not attempt to pel'lbl'n] any maintenance on this equipment other than those procedures recommended in the User's Manuah

ELECTRICAL SHOCK, FIRE OR EXPLOSION HAZARD

Failure to lollow this warning could result in personal injury or death, or propelly damage. Belore servicing, disconnect all electrical power to lkn'nace. Veril}, proper operation alter servicing.

ELECTRICAL OPERATION HAZARD Failure to Iollow this caution may result ilkin]proper furnace

operation or failure of lurnace. Label all wires prior to disconnection when servicing con- trols. Wiring errors can cause in]proper and dangerous operation.

Step I--Introduction

GENERAL

These instructions are written as if the furnace is installed ilk an

upflow application. An upflow lixrnace application is where the blower is located below the combustion and controls section of the

li]rnace, and conditioned air is discharged upward. Since this lixrnace can be installed in any of the 4 positions shown in Fig. 4, yon tin]st revise your orientation to component location accord- ingly.

ELECTRICAL CONTROLS AND WIRING

! , 0

ELECTRICAL SHOCK HAZARD Failure to RUlow 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 fl)r addifional electrical supplies that nmst be shut o11"during li]rnace servicing.

The electrical ground and polarity R)r l15-v wiring n]ust be properly maintained. Reli:r to Fig. 25 lot field wiring inlormation and to Fig. 56 lor funmce wiring infl}nnation.

NOTE: If the polarity is not correct, the STATUS LED on the control will flash rapidly and prevent the limmce li"om heating. The control system also requires an earth ground fl_r proper operation of the control and flame-sensing electrode.

The 24-v circuit contains an automotive-type, 3-amp fuse located on the controh (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 stares code 24 when fuse needs to be replaced. Proper instmmentmion is required to service electrical controls.

The control in this lk]rnace is equipped with a Stares Code LED (Light-Emitting Diode) to aid in installation, servicing, and troubleshooting. It can be viewed tln'ough the sight glass in blower access door. The furnace control LED is either ON continuously, rapid flashing, or a code con]posed 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, reli:r to service label locmed on

blower access door or Fig. 55 and the troubleshooting guide which can be obtained from your distributor.

See Fig. 60, a brief Troubleshooting Guide. For Controls With an Amber LED

The stored status code will not be erased li"om the control n]emory, if 115- or 24-v power is interrupted.

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

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

a. Leave 115-v power to limmce turned on. b. Remove outer access door.

c. Look into blower access door sight glass lor current LED

stares. Removing blower access door will open blower access door switch and terminate 115-v power to control so

that status code is not displayed.

Table 12--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)

U.S.A. Only

ALTITUDE

RANGE

(FT)

o 0 =o to

2000

AVG GAS

HEAT VALUE

(BTU/CU FT)

900 925 950

975 1000 1025 1050

1075 1100

ALTITUDE AVG GAS

RANGE HEAT VALUE

(FT) (BTU/CU FT)

U.S.A.

Altitudes

"u 2001

o 3000

Canada

_." Altitudes _. 2000

:_ to

4500

800

825

850

875

900

925

950

975 1000

ALTITUDE AVG GAS

RANGE HEAT VALUE

(FT) (BTU/CU FT)

3001

4000

775

8OO

825

85O

875

900

925

950

ALTITUDE AVG GAS

RANGE HEAT VALUE

(FT) (BTU/CU FT)

4001

5000

750

775

8OO

825

85O

875

900

925

SPECiFiC GRAVITY OF NATURAL GAS

0.58 0.60 0.62

Orifice Manifold Orifice Manifold Orifice Manifold

No. Pressure No. Pressure No. Pressure

0.64

Orifice Manifold

No. Pressure

42 I 3.2 42 3.3 42 3.4 42

431 3.7 i43 3.8 42 3.2 42

431 3.5 i 43 3.6 43 3.7 43

43 I 3.3 i 43 3.4 43 3.5 43

44 I 3.6 i 43 3.3 43 3.4 43 44 I 3.4 i 44 3.6 43 3.2 43 44 I 3.3 i 44 3.4 44 3.5 43

45 I 3.8 44 3.2 44 3.3 44 46 I 3.8 i 45 3.7 44 3.2 44

SPECIFIC GRAVITY OF NATURAL GAS

0.58 0.60 0.62

Orifice Manifold Orifice Manifold Orifice Manifold

No. Pressure No. Pressure No. Pressure

3.5

3.3

3.8

3.7

3.5

3.3

3.2

3.4

3.3

0.64

Orifice Manifold

No. Pressure

43 I 3.8 42 3.2 42 3.3 42

43 I 3.5 i 43 3.7 43 3.8 42 431 3.3 i43 3.5 43 3.6 43

431 3.2 i 43 3.3 43 3.4 43 431 3.0 i 43 3.1 43 3.2 43

431 2.8 i 43 2.9 43 3.0 43 431 2.7 i 43 2.8 43 2.9 43

43 I 2.5 43 2.6 43 2.7 43 43 I 2.4 i 43 2.5 43 2.6 43

SPECIFIC GRAVITY OF NATURAL GAS

0.58 0.60 0.62

Orifice Manifold Orifice Manifold Orifice Manifold

No. Pressure No. Pressure No. Pressure

3.4

3.2

3.7

3.5

3.3

3.1

2.9

2.8

2.7

0.64

Orifice Manifold

No. Pressure

43 I 3.5 43 3.7 43 43 I 3.3 i 43 3.4 43

43 I 3.1 i 43 3.2 43

431 2.9 i 43 3.0 43 431 2.8 i 43 2.9 43 3.0 431 2.6 i 43 2.7 43 2.8

43 I 2.5 43 2.6 43 2.7 43 I 2.4 i 43 2.4 43 2.5

SPECIFIC GRAVITY OF NATURAL GAS

0.58 0.60 0.62

Orifice Manifold Orifice Manifold Orifice Manifold

No. Pressure No. Pressure No. Pressure

3.8 42 3.2

3.5 43 3.7

3.3 43 3.4

3.1 43 3.2 43 3.1 43 2.9

43 2.7 43 2.6

0.64

Orifice Manifold

No. Pressure

43 3.3 43 3.4 43 3.5 43 43 3.1 i 43 3.2 43 3.3 43 43 2.9 i 43 3.0 43 3.1 43 43 2.7 i 43 2.8 43 2.9 43

43 2.6 i 43 2.7 43 2.8 43 43 2.4 i 43 2.8 43 2.6 43

43 2.3 43 2.4 43 2.5 43 43 2.2 i 43 2.2 43 2.3 43

3.6

3.4

3.2

3.0

2.8

2.7

2.5

2.4

* Orifice numbers 43 are factory installed

Table 12--Orifice Size* And IVlanifold 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)

=>, O 6001

_ to

6000

ALTITUDE

RANGE

(FT)

AVG GAS

HEAT VALUE

AT ALTITUDE

(BTU/CU FT)

725 750 775 80O

825 85O 875 900

AVG GAS

HEAT VALUE

AT ALTITUDE

(BTU/CU FT)

I Orifice

No.

43 43 43 43

Orifice

No.

675 700

725 750 775 8OO

825 85O

AVG GAS

HEAT VALUE

AT ALTITUDE

(BTU/CU FT)

0.58 Manifold

Pressure

3.1

2.9

2.7

2.5

2.4

2.2

2.1

2.0

SPECIFIC GRAVITY OF NATURAL GAS

0.60

Orifice Manifold Orifice

No. Pressure No.

43 3.2 43 3.0 43 2.8 43 2.6

43 2.5 43 2.3 43 2.2 43 2.1

SPECIFIC GRAVITY OF

43 3.3 43 3.1

43 2.9

O 6001

to 43 2.7

7000 43 2.5

43 2.3 43 2.2

48 2.1

65O 675 700 725

750 778 80O 825

AVG GAS

HEAT VALUE

AT ALTITUDE

(BTU/CU FT)

ALTITUDE

RANGE

(FT)

Orifice

No.

43 43

= 43

O 7001

to 43

8000 43

43 48 48

625 65O 675

7OO 725 75O 775

Orifice

No.

43 43 43

43 48 48 49

ALTITUDE

RANGE

(FT)

0.58 Manifold

Pressure

3.1

2.9

2.7

2.5

2.3

2.2

2.1

3.7

0.58 Manifold

Pressure

2.9

2.7

2.5

2.3

2.1

2.0

3.6

3.3

0.58 Manifold

Pressure

2.7

2.5

2.3

2.1

3.7

3.5

3.8

O 8001

9000

0.60

Orifice Manifold

No. Pressure

43 3.2 43 3.0

43 2.8 43 2.6 43 2.4 43 2.3

43 2.1 43 2.0

0.62 Manifold

Pressure

43 3.3 43 3.1 43 2.9 43 2.7

43 2.6 43 2.4 43 2.3 43 2.1

NATURAL GAS

0.62

Orifice Manifold

No. Pressure

43 43

43 43 43 43

43 43

SPECIFIC GRAVITY OF NATURAL GAS

0.60 0.62

Orifice Manifold Orifice Manifold

No. Pressure No. Pressure

43 3.1 43 2.8 43 2.6 43 2.6

43 2.3 43 2.2 43 2.0 48 3.6

NATURAL GAS

0.62

Orifice Manifold

No. Pressure

43 2.8 43 2.6 43 2.4

43 2.3 43 2.1 48 3.7 48 3.8

43 3.0 43 2.7 43 2.6 43 2.4

43 2.2 43 2.1 48 3.7 48 3.5

SPECIFIC GRAVITY OF

0.60

Orifice Manifold

No. Pressure

43 2.7 43 2.5 43 2.4

43 2.2 43 2.0 48 3.6 48 3.4

Orifice

No.

43 43 43 43

Orifice

No.

43 43

43 43 43 43

43 43

Orifice

No.

43 43 43 43

43 43 43 48

Orifice

No.

43 43 43

i 48

0.64 Manifold

Pressure

3.4

3.2

3.0

2.8

2.6

2.8

2.3

2.2

0.64 Manifold

Pressure

3.4

3.2

2.9

2.8

2.6

2.4

2.3

2.1

0.64 Manifold

Pressure

3.2

2.9

2.7

2.5

2.4

2.2

2.1

3.7

0.64 Manifold

Pressure

2.9

2.7

2.5

2.3

2.2

2.0

3.6

Table 12--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)

AVG GAS

HEAT VALUE

AT ALTITUDE

(BTU_U FT)

Orifice

No.

SPECiFiC GRAVITY OF NATURAL GAS

0.58 Manifold

Pressure

2.4

2.3

2.1

3.8

3.4

3.7

Orifice

No.

Orifice

No.

0.80 Manifold

Pressure

2.5

2.3

2.2

3.8

3.5

3.8

0.62

Orifice Manifold

No. Pressure

43 2.6 43 2.4 43 2.2 43 2.1

48 3.6 48 3.4

600 43 43 43

= 628 43 43 43

O 9001

to 650 43 43 43

_ 10,000 678 48 48 43

700 48 48 48 725 49 49 48

* Orifice numbers 43 arefactoryinstalled

0.64 Manifold

Pressure

2.7

2.5

2.3

2.1

3.7

3.5

SERVICE

If status code recall is needed, briefly remove therl reconnect or_er_ain limit wire to display stored status code. O[_RED LED boards do not remove power or blower door before initiatirlgstatus code recall. After status code recall is completed corAo_3eht test will occur. LED CODE STATUS

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 - Lkle voltage (115VAC) polarity reversed. If twklned, refer to twinning kit instructions.

EACHOF THE FOLLO_MNG STATUSCODES IS A TWODIGITNUMBERW1THTHE FIRSTDIGIT DETERMINEDBY THE NUMBEROF SHORT FLASHESAND THE SECOND D4GITBY 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 mklutes.

- 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 kl 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 "Corn 24V" terminal. Status LED

component test. The hot surface ignitor, blower motor fan speed (on AMBER LED boards

will flash code and then turn ON the inducer motor. The klducer motor will run for the entire

only) blower motor-heat speed, and blower motor-cool speed will be turned ON for 1o-15 I

seconds each. Gas Valve and Humidifier will riot be turned on.

327596-1 01 REV. B

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

inducer shuts off for15 minutes before retry. Checkfor: -Excessivewkld

- Proper vent sizing - Defective inducer motor

- Low inducer voltage (115VAC) - Defective pressure switch

- Inadequate combustion air supply - Disconnected or obstructed pressure tubklg

- 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 4mklutes or until open switch remakes whichever is longer. If open longer than 3 minutes, code changes to lockout #13.

If open less than 3 mklutes status code #33 contklues to flash until blower shuts off. Flame roflout switch and BVSS require manual reset. Check for: - Restricted vent

- Proper vent sizklg - Loose blower wheel. -Excessive wkld

- 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 riot be grounded

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

- Proper flame sense microamps (._ 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/Yeflow 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.

A04223

Fig. 55--Service Label

d. BRIEFLY remove insulated terminal wire from the draft

sail:guard (DSS) switch until LED goes out, then reconnect it.

NOTE: If wire to LS or DSS is disconnected longer than 4 sec, main blower starts, and retrieval request is ignored.

2. When above items have been completed, the LED flashes status code 4 times. Record this status code liar lurther

troubleshooting.

3. Check LED status. If no previous faults in history, control will flash stares code 11.

Step 2--Care and Maintenance

FIRE OR EXPLOSION HAZARD Failure to lollow this warning could result in personal injury,

death and/or property damage. Never store anything on, near, or in contact with the furnace,

such as:

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

2. Soap powders, bleaches, waxes or other cleaning com- pounds, plastic or plastic containers, gasoline, kerosene, cigarette lighter fluid, dry cleaning fhdds, or other volatile

fluids.

3. Palm thinners and other palming COlnpounds, paper bags, or other paper products.

For continuing high perlbrmance and to minimize possible equip- ment failure, periodic maintenance umst be perlbrmed on this

equipment. Consult your local dealer about proper frequency of

maintenance and the availability of a maintenance contract.

ELECTRICAL SHOCK AND FIRE HAZARD Failure to lbllow this warning could result in personal injury,

death or property damage.

Turn off the gas and electrical supplies to the unit belbre

perlorndng any maintenance or service. Follow the operating instructions on the label attached to the furnace.

CARBON MONOXIDE POISONING AND FIRE HAZARD

Failure to lollow this warning could result in personal injury, death and/or property damage.

Never operate unit without a filter or with filter access door reuloved.

CUT HAZARD Failure to 12Hlow this caution may result in personal injury.

Sheet metal parts may have sharp edges or burrs. Use care and wear appropriate protective clothing, salety glasses and gloves when handling parts and servicing furnaces.

The mininmm maintenance on this furnace is as lbllows:

1. Check and clean air filter each mouth or more l}'equently if required. Replace il' torn.

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

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

4. Inspect burner compamnent belore each heating season lk}r rusL corrosion, soot or excessive dust. If necessary, have limmce and burner serviced by a qualified service agency.

5. Inspect the vent pipe/vent system belbre each heating season lor rust, cormsiom 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 lilrnace such as a humidifier or electronic air cleaner. Perlbml any service or

Table 13--FiRer Size information (iN.)

FURNACE

CASING WIDTH

14-1/2 17-1/2

21 24

* Recommended

FILTER SIZE

Side Return Bottom Return 16X25X1 14X25X1

16X25X1 16X25X1 16X25X1 20X25X1 16X25X1 24X25X1

FILTER

TYPE

Cleanable* Cleanable* Cleanable* Cleanable*

maintenance to the accessories as recommended in the acces- sory instructions.

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

The filter is exterior to the lurnace casing. NOTE: If the filter has an airflow direction arrow, the arrow ulust

point towards the blower.

CUT HAZARD Failure to lbllow this caution may result in personal injury.

Sheet metal parts may have sharp edges or burrs. Use cam and wear appropriate protective clothing, salety glasses and gloves when handling parts and servicing lilrnaces.

Media cahlnet filter procedures : NOTE: Media cabinet is included with single-stage deluxe fur-

llace.

1. Turn off electrical supply to furnace belbre removing filler

access door.

2. Remove filter cabinet door.

3. Slide filter out o1' cabinet.

4. If equipped with permanenL washable 1-inch lilter, clean filter by spraying cold tap water thnmgh filter in opposite direction ol' airflow. Rinse filter and let dry. Oiling or coating of the

filter is not recommended. See Table 13 lot size inlkmuation.

5. I1' equipped with factory-specified disposable media filter. replace only with media filter having the same pro1 nmnber and size. For expandable replacement media, relier to the instructions included with the replacement media. If equipped with accessory KGAFRll3(IIALL external filter rack, See

Table 13.

6. Slide filter into cabinet.

7. Replace filter cabinet door.

8. Turn on electrical supply to furnace.

BLOWER MOTOR AND WHEEL

ELECTRICAL SHOCK HAZARD Failure to lollow 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 lbr service purposes.

NOTE: The blower wheel should not be dropped or bent as balance will be al'liected.

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

To ensure hmg lilk?and high efficiency, clean accumulated dirt and

grease fronl blower wheel and motor annually.

The inducer and blower motors are pre-lubricated and require no

additional lubrication. These motors can be identified by the absence of oil ports on each end of the motor.

Clean blower motor and wheel as lollows:

1. Turn off electrical supply to furnace.

2. Loosen the dmmbscrew on outer door and remove outer door.

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

a. Disconnect vent connector l?'om lilrnace vent elbow. b. Disconnect and remove short piece of vent pipe from

within lurnace.

4. Remove 2 screws from blower access door and remove blower

access door.

5. Disconnect blower leads from furnace controh Record wire color and location lot reassembly. All other factory wires can

be leli connected, but field tl_ermostat 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 fronl fi'ont of furnace casing and away from

blower compamnent.

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 l_'om blower housing, wheel and

I_IO{OF.

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

NOTE: Beli_re 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 cutol]' plate and remove cutoff

plate 15"orehousing.

c. Loosen set screw holding blower wheel on motor shali

(160+1-20 in.-lb, when reassembling).

d. Remove bolts holding motor to blower housing and slide

motor out of wheel (40+/-10 in.-lb, when reassembling).

e. Remove blower wheel fl'(ml housing.

f. Clean wheel and housing.

12. Reassemble motor and blower by reversing steps 1If through

11a, finishing with 1l a. 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 shall. 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 lurnace.

16. Reinstall control box assembly in li,rnace.

UNIT DAMAGE HAZARD

Failure to lk)llow this caution may result in shortened heat exchanger lile. Heating fan speed(s) MUST be adjusted to provide proper air temperature rise as specified on the rating plate. Rec()m- mended operation is at the midpoint of the rise range or slightly above. RelL'r to "SET TEMPERATURE RISE" under START-UP, ADJUSTMENT, and SAFETY CHECK.

NOTE: RelL'r to Table 9 %r motor speed lead relocation if leads were not identified belore disconnection.

17. Reconnect blower leads to furnace control. RelL'r to limmce wiring diagram, and connect thermostat leads if previously

disconnected.

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

ELECTRICAL SHOCK HAZARD Faihn'e to %llow this warning could result in personal injury,

or death. Blower access door switch opens 115-v power to furnace

controh No component operation can occur unless switch is closed. Exercise caution to avoid electrical shock from

exposed electrical components when manually closing this switch %r service purposes.

b. Manually close blower access door switch.

NOTE: If thermostat temdnals are jumpered at the time blower access door switch is closed, blower will run %r 90 sec belore

beginning a heating or cooling cycle.

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

SERVICE label, located on the l?'ontof blower access door.

d. Verify blower is rotating in the correct direction

19. If furnace is operating properly, RELEASE BLOWER AC- CESS DOOR SWITCH. Remove any jumpers or reconnect

any disconnected thermostat leads. Replace blower access door.

20. Downflow or horizontal lurnaces with vent pipe through lurnace only:

a. Install and connect short piece of vent pipe inside fln'nace

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 temperamrc rise as shown in "Adjustnlents" Section. Adjust temperature rise as shown in "Adjustnlents" Section. If outdoor temperature is below 70°F, turn off circuit breaker to outdoor unit belore 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 servlee agency:

NOTE: If the heat exchangers get a heavy accunmlation of soot

and carbon, they should be replaced rather than trying to clean them thoroughly. A heavy build-up of soot and carbon indicates that a problem exists which needs to be corrected, such as improper adjustment of manilold pressure, insufficient or poor

o°° ' ° ° ° ° ° ° ° ° ° ° ° ° °

JUMPER SELB_T OR GV FR_ |$I LS2

• F CB

RED I:_O RED

150 Otd4 )

NOTE #S GRN/YEL NOTE #10 i

fie #5 Gf7/7 _/EL FRS1 DSS / I

RED RED _G_G ORG /

SEC-2 SEC-1

FUSE OR CIRCUIT BREAKER &

DESCONNECT S'¢I4TCH (WFEN REC7D)

NOTE #2

[ I NEtYFRAL

• _o "-q. '

<.... > [.... J

:_ BFANR CONTINUOUS-FAN SELECT RELAY SPDT LS 1,2 LIMIT SWITCH, AUTO-RESE_ SPST(N C )

BHT/CLR BLOWER MOTOR SPEED CHANGE RELAY, SPDT OL AUTO-RESET INTERNAL MOTOR OVERLOA[ BLWR BLOWER MOTOR RE LA',4 SPST-(N O ) TEMPERATURE SWITCH (NC)

BI _M BI O WE R MOTO R PERMAN ENT.S pI Fr4_IAPACITO R pCB p RI NTED CIRCUIT BOARD CONTROL

DE I .......................................... ]_ SPST -(N C ) .........................

CAP CAPACITOR pL2 2.CIRCUIT CONNECTOR

_j CPU MICROPROCESSOR AN D CiRCUiT Ry

DSS DRAFT SAFE GUARD SWITCH, AUTO_RESEG_ SPST -(NO) PL3 2-CIRCUIT NS£ CONNECTOR EAC.1 ELECTRONIC AIR CLEANER CONNECTION (115 VAC 1 0 AM P MAX) PRS pRESSURE SWITCH, SPST-(N O )

EAC. 2 EL ECT RON]C AiR CLEAN ER CON NECTION (COMMON) T_STrI_ViN COMpON ENT T_ST & TWiN T_RM] NAL FRS 1,2 FLAM E ROLLOUT SW _4ANUAL RESET, SPST_N C ) TRAN TRAN SF ORMER. 115 VAC_24VAC

FSE FLAME.PROVING ELFCTRODE _ JUNCTION FU 1 FUSE, 3 AM R AUTOMOTIVE BLADE TYPE, FACTORY #STALLED 0 UNMARKED TERMINAL FU 2 FUSE OR CIRCUIT BREAKER CURRENT INTERRUPT DEVICE

(RELD iNSTALLED & SUPPLIED) _ PCB CONTROL TERMINAL

GND EQUIPMENT GROUND _ FACTOR y _DRING (115VAC)

GAS VALVE-REDUNDANT -- FACTORy WIRING (24VAC)

O GAS VALVE RE LA"_ DPST.(N O )

HSI HOT SURFACE IGNITER (115 VAC) _, FIELD WIR_NG (115VAC)

HS_R HOT SURFACE IGNITER R ELA',! SPST.{N O ) -- _ _ FIELD WIRING (24VAC) HUM 24VAC HUMIDIFIER CONNECTION (05 AMP MAX) CONDUCTO R ON CONTROL PCB ]DM iNDUCED DRAFT MOTOR, SHADED-POLE

IDR INDUCED DRAFT _TOR RELAy SPST.(N O ) _ FIELD WiRiNG SCREW TERMINAL ILK BLOWER ACCESS PANEL INTERLOCK SWITCH, S PST-(N O ) _ FIELD EARTH GROUND J1 BLOWE R _OFF DELAY JUMPER SELECTOR

O jB JUNCTION BOX _ EQUIPMENT GROUND

LED UGHT.EMITTING DIODE FOR STATUS CODES. AMBER _ FIELD SPUCE

••o% #wisP°i URi%SPSi°iODD i -oI°°E@A O0

• • • • • • • • • • • • • • OO_

115VAC FIELD _S(;ONNECT SW1TCH SCHEMATIC DIAGRAM

(NA]'JRAL & PAOPANE GA_ O

O O O O

O O O O O O O O O O O O O O

FSE O

_PL_m

COM 24V I::_BNOTE_5 PL1-7 °

NOTES:

1. If any of the o:iginal e_Fnent wire is replaced t_e wire rated fo_ 105:0. O

• Useonlyo3pper_drebet_,,_entl_edisconI_:tsv4tchandthefurnace)unctionbo_(JB ).

3. This _,4re must be o3nriacled to furnace sheet rr_lal for control to prove llarr_. O

4. Synl3ols are eleclrical representation on .

5. Solid lines ir_ide PCB ale _h'_ed d r_it _oald col_d_ldols and are not h-_l uded in lege_d. II

6. Re acec_/y_'Aiha3ampfuse. I,l,l_

7. In'ca (IDM)andI_o_,_e_(BL'Alvl)motorscontainintem_auto-resetthe{realowload s_td_es (OL). 8 Neutral connections are interchargeable _dthin the NEUTRAL coilnector bk)cK

91 Nov,_'_ors_ctbnsareloravorarJecOnd_ions, s_ins_lati_linslructbnsl_d_ls_l _0

oNimum speed sc_ion.

10. FadO, y cc_m_cled wher_ BVSS Climney Adapter Accessory Kit is i_ot installed. _ •

11. g_to:y coi_l_ected when LGPS is oct t_ed. _

12. Igl_ifi on-lockc¢lt NIl occ_ af t_ fot_ coi_ecufive ul_uccess_l N ats- f_-i_ lion. ColYl cl _11 _::_ ill

auto-resetafterthreehours. _v

13.Bbv,er-ondelay:g_sl_eating25seconds,cocih'go_heatpump2 seconds, u_

14. Blov_-ofi dela : gas heating seleclbns are 90, 120, 150 or 180 seoords, coolirg or heatpUmpg0secol_s o, _ seconds _@e{_ DHUM is active. _O

15. YELLOW le_d not on all motols.

•OOOOOOOOOOOOOOO.

Fig. 56--Wirirlg Diagram A04222

9/32"_

V5,16,,

Fig. 58ilgniter PosRion=Top View

A05026

A05025

Fig. 5711gniter PosRion-Side View

quality combustion air, incorrect size or damaged maniR)ld ori- rice(s), improper gas, or a restricted heat exchanger. Action nmst

be taken to correct the problem. If it becomes necessary to clean the heat exchangers because of'

dust or corrosion, proceed as Ik}llows:

1. Turn OFF gas and electrical power to furnace.

2. Remove outer access door.

3. Disconnect vent connector l_'om lhrnace vent elbow.

4. For downflow or horizontal lhrnace having an internal vent pipe, minove internal vent pipe within the casing.

5. Disconnect wires to the lollowing components. Mark wires to aid in reconnection of (be carelhl when disconnecting wires l)'om switches because damage may occur):

a. Dral) saleguard switch. b. Inducer motor.

c. Pressure switch(es).

d. Limit overtemperature switch.

e. Gas valve.

f. Hot surface igniter.

g. Flame-sensing electrode.

b. Flame rollout switches.

6. Remove screws that fasten the collector box assembly to the

cell panel. Be carelhl not to damage the collector box. Inducer

assen-ibly and elbow need not be removed l]'om collector box.

7. Disconnect gas line from gas mani{bld.

8. Remove the 5 screws that attach the burner assembly to the

cell paneh The gas valve and individual burners need not be

ren-ioved from support assembly. Remove NOx bafl'les if installed.

NOTE: Be very careful when removing burner assembly to avoid breaking igniter. See Fig. 57 and 58 lot correct igniter location.

9. Using field-provided 25-caliber rille cleaning brush, 36-in. long, 1/4" diameter steel spring cable, a variable speed,

reversible electric drill, and vacuum cleaner, clean cells as lbllows:

a. Ren-iove metal screw fitting l_'om 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 1S VERY IMPORTANT.

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

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

spring cable (end opposite brush).

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

and slowly rotate with drill. DO NOT lorce cable. Gradually insert cable into upper pass oI_celh (See Fig.

59.)

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

sul'l]cient cleaning. DO NOT pull cable with great lorce. 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 loregoing procedures until each cell in lhrnace

has been cleaned.

(6.) Using vacuum cleaner, remove residue from each cell. (7.) Using vacuuln cleaner with sol_ brush attachment,

clean burner assembly.

(8.) Clean flame sensor with fine steel wool. (9.) Install NOx baffles (if removed).

(lO.) 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 belore 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 lk)llowing components. (Use connec- tion diagram on wiring label, if wires were not marked lot reconnection locations.):

a. Drali saleguard switch. b. Inducer motor.

c. Pressure switch(es). d. Limit over-temperature switch.

e. Gas valve. f. Hot surface igniter.

g. Flame-sensing electrode. b. Flame rollont switches.

i. Install NOx baflles (if ren-ioved).

14. Reinstall internal vent pipe, if applicable.

A91252

Fig. 59--Cleaning Heat Exchanger Cell

15. Reinstall vent connector on fllrnace vent elbow. Securely lhsten 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 thernlostaI above room temperature and check furnace %r proper operation.

18. Verily blower airflow and speed changes between heating and

cooling.

FIRE OR EXPLOSION HAZARD Failure to lollow this warning could result in personal injury,

death andk_r property damage. Never use a match or other open flame to check %r gas leaks. Use a soap-and-water solution.

19. Check lor gas leaks.

20. Replace outer access door.

Step 3--Sequence of Operation

NOTE: Furnace control nlust be grounded lot proper operation or

control will lock out. Control is grounded through green/yellow

wire routed to gas valve and mani%ld bracket screw. Using the schematic diagram in Fig. 56, lbllow the sequence of

operation through the diflbrent modes. Read and lollow the wiring

diagram very carefully. NOTE: If a power interruption occurs during a call %r heat (W),

the control will start a 90-second blower-only ON period two

seconds alter power is restored, if the thermostaI is still calling fl_r

gas heating. The Amber LED light will flash code 12 during the 90-second period, after which the LED will be ON continuous, as

hmg as no faults are detected. After the 90-second period, the lurnace will respond to the thernlostat normally.

The blower door nmst be installed %r power to be conducted through the blower door interlock switch ILK to the furnace control CPU, translormer TRAN, inducer motor 1DM, blower

motor BLWM, hot-surface igniter HS1, and gas valve GV.

1. Heating (See Fig. 25 lbr thermostat connections.)

The wall thermostat "calls lot heat," closing the R-to-W

circuit. The furnace control per%rnls a sell'check, verifies the pressure switch contacts PRS are open, and starts the inducer

motor IDM. a. Inducer Prepurge Period- As the inducer motor 1DM

conies tip to speed, the pressure switch contacts PRS close to begin a 15-second prepurge period.

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

Hot-Surlhce igniter HSI is energized %r a 17-second igniter warn>up period.

c. Trlal-for-lgnltlon Sequence- When the igniter warn>up

period iscompleted, the main gas valve relay contacts GVR

close to energize the gas valve GV, the gas valve opens,

and 24 vac power is supplied %r a field-installed humidi- fier at the HUM terminal. The gas valve GV permits gas flow to the burners where it is ignited by the HS1. 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-Provlng- 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 lot tip to three mow Trials-For-Ignition belore going to Ignition-Lockout. Lockout will be reset auto- matically after three hours or by nlomentarily interrupting

115 vac power to the lurnace, 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 filrnace control CPU will lock ()tit of Gas-Heating mode and operate the inducer motor 1DM 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 (IV is energized.

Simultaneously, the electronic air cleaner terndnal 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 tern-final HUM. The inducer motor 1DM will remain energized lot a 5-second post-purge period. The

blower motor BLWM and air cleaner terminal EAC-1 will remain energized lbr 90, 120, 150, or 180 seconds (depend-

ing on the blower-OFF delay selection). The furnace

control CPU is factory-set fl)r a 120-second blower-OFF

delay.

2. Cooling Mode Tile thermostat "calls lbr cooling."

a. Single-Speed Cooling

(See Fig. 25, 26, 28, and 30 lk_r 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/Y2 circuits start the lurnace blower motor BLWM on COOL

speed. The electronic air cleaner terminal EAC-I 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 lk_r an additional 90 seconds. Jumper Y/Y2 to DHUM to reduce the cooling off-delay to 5 seconds. (See Fig. 24.)

b. Two-Speed Cooling

(See Fig. 27, 29, 31, and 32 liar thermostat connections.)

The thermostat closes the R-to-G-and-Yl circuits lk)r

low-cooling or closes the R-to-G-and-Yl-and-Y2 circuits lor high-cooling. The R-to-Yl circuit starts the outdoor unit on low-cooling speed, and the R-to-G-and-Yl circuit starts the furnace blower motor BLWM on low-cool speed (same speed as FAN). The R-to-Yl-and-Y2 circuits start

the outdoor unit on high-cooling speed, and the R-to-G-

and-Y/Y2 circuits start the lurnace blower motor BLWM

on COOL speed. The electronic air cleaner terminal EAC-I is energized

with 115 vac whenever the blower motor BLWM is

operating.

When the thermostat is satisfied, the R-to-G-and-Y1 or R-to-G-and-Y1 and Y2 circuits are opened. The outdoor

unit stops, and the hn'nace blower BLWM and electronic air cleaner terminal EAC-1 will remain energized lk_r an additional 90 seconds. Jumper Y1 to DHUM to reduce the

cooling ofl_delay to 5 seconds. (See Fig. 24.)

3. Thermldlstat Mode

(See Fig. 26-29 liar Therinidistat connections.)

The dehunfidification output, DHUM on the Thernddistat

should be connected to the furnace control thermostat terminal DHUM. When there is a dehumidify demand, the DHUM

input is activated, which means 24 vac signal is removed fi'on_

the DHUM input terminah In other words, the DHUM input

logic is reversed. The DHUM input is turned ON when no dehunddify demand exists. Once 24 vac is detected by the lui'nace control on the DHUM input, the furnace control

operates in Thermidistat mode. If the DHUM input is low liar

mole than 48 hours, the furnace control reverts back to non-Tbermidismt mode.

The cooling operation described in item 2. above also applies to operation with a Thermidistat. The exceptions are listed

below: a. When the R-to-G-and-Y1 circuit is closed and there is a

demand ior dehunfidification, the iurnace blower motor BLWM will continue running at low-cool speed (same

speed as FAN).

b. When the R-to-G-and-Y/Y2 circuit is closed and there is a

demand liar dehumidification, the furnace blower motor BLWM will drop the blower speed fi'om COOL to HEAT

[k)r a maximum of 10 minutes belk)re reverting back to COOL speed, lfthere is still a demand lor dehumidification

alter 2(1 minutes, the lurnace control CPU will drop the blower speed back to HEAT speed. This alternating Ill-

minute cycle will continue as long as there is a call lor cooling.

c. When the "call lbr cooling" is satisfied and there is a

demand liar dehumidification, the cooling blower-off delay is decreased fi'om 9(1 seconds to 5 seconds.

4. Continuous Blower Mode When the R-to-G circuit is closed by the thermostat, the

blower motor BLWM will operate on continuous-blower speed (can be adjusted to FAN, HEAT, or COOL speed) at the thermostat. Factory default is FAN speed. Terminal EAC-I is energized as long as the blower motor BLWM is energized. During a call lk)r beat, the blower BLWM will stop during igniter warn>up (17 seconds), ignition (7 seconds), and blower-ON delay (25 seconds), allowing the lurnace heat exchangers to heat up more quickly, then restarts at the end of the blower-ON delay period at HEAT speed. In beating, the furnace control CPU will hold the blower motor BLWM at HEAT speed during the selected blower-OFF delay period befi_re reverling to continuous-blower speed. When the thermostat "calls lk)r low-cooling," the blower motor BLWM will switch to operate at low-cool speed (same speed as FAN). When the thermostat is satislied, the blower motor BLWM will operate an additional 90 seconds on low-cool speed (same speed as FAN) belbre reverting back to continuous-blower speed. When the thermostat "calls lor high-cooling", the blower motor BLWM will operate at COOL speed. When the ther- mostat is satisfie& the blower motor BLWM will operate an additional 90 seconds on COOL speed beli_re reverting back to continuous-blower speed. When the R-to-G circuit is opened, the blower motor BLWM will continue operating lbr an additional 5 seconds, if no other lkmction requires blower motor BLWM operation. Continuous Blower Speed Selection from Thermostat -To

select dil]erent continuous-blower speeds from the room thermostat, momentarily turn off the FAN switch or push-

button on the room thermostat liar 1-3 seconds al]er the blower motor BLWM is operating. The l_.n'nace control CPU will shil_

the continuous-blower speed from the factory setting of FAN to HEAT speed. Momentarily turning off the FAN switch

again at the thermostat will shill the continuous-blower speed fi'om HEAT to COOL. Repeating the procedure will shill the continuous-blower speed fi'om COOL to FAN speed. The selection can be changed as many times as desired and is stored in the memory to be automatically used lollowiug a power interruption.

5. Heat pump (See Fig. 28-31 lbr thermostat connections.) When installed with a beat pump, the furnace control auto- matically changes the timing sequence to avoid long blower off times during demand defi'ost cycles. When the R-to- W-and-Yl or R-to-W-and-Yl-and-G circuits are energized the

lurnace control CPU will switch to or 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 liar 24 seconds then come back

on at HEAT speed. When the W input signal disappears, the lurnace control begins a normal inducer post-purge period and the blower remains running at HEAT speed lor the selected blower-OFF delay period then switches to low-cool speed (same speed as FAN). If the R-to-W-and-Yl-and-G signals disappear at the same time, the blower motor BLWM will remain on lbr the selected blower-OFF delay period. If the R- to-W-and-Y1 signals disappear, leaving the G signal, the

blower motor BLWM will remain on lbr tile selected blower- OFF delay period then switch to continuous-blower speed.

When the R-to-W-and-Y/Y2, R-to-W-and-Y/Y2-and-G, R-to-

W-and-Yl-and-Y/Y2, or R-to-W-and-Yl-and-Y/Y2-and-G circuits are energized tile furnace control CPU will switch to or turn on the blower motor BLWM at HEAT speed, and

begin a beating cycle. The blower motor BLWM will remain on until the end of the prepurge period, then shut o11"lot 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

afler a 3 second delay. If the R-to-W-and-Y/Y2-and-G or

R-to-W-and-Yl-and-Y/Y2-and-G signals disappear at the

same time, the blower l'flotor BLWM will remain on [_)rthe

selected blower-OFF delay period. If the R-to-W-and-Y/Y2 or

R-to-W-and-Yl-and-Y/Y2 signals disappear, leaving the G

signal, the blower motor BLWM will remain on lot the

selected blower-OFF delay period then switch to continuous- blower speed.

Step 4--Wiring Diagrams

Relier to Fig. 56 lot wiring diagram.

Step 5--Troubleshooting

Relier to the service label. (See Fig. 55 Service Label.) The Troubleshooting Guide can be a useful tool in isolating

furnace operation problems. Beginning with the word "StarL" answer each question and flHlow the appropriate arrow to the next

item.

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

START

L Is LED status light on?

YES

Fig. 60--Troubleshooting Guide

'_'-'_ Is there 115V at L1 and L2?

_ YES

I Is there 24V at SEC-1 and SEC-2?

II YES

I Replace furnace control.

Is LED status light blinking rapidly without a pause?

,I,N°

Is LED status light blinking ON/OFF slowly NO with a combination of short and long flashes?

,_YES

Determine status code. The status code is a 2 digit number with the first digit determined

digit by the number of long flashes?

by the number of short flashes and the second

boow o.h , ,.... 1

_--_ Isdoor switch closed?

_l YES

I Is there 115V going to switch?

_l YES

Replace door switch.

_--_ Is door switch closed?

'_--_ Is circuit breaker closed? I_

'_l YES

J Check Dr continuity in wire from circuit breaker

o urnace.

Check for correct line voltage polarity. If units are twinned, check for proper low-voltage t (24V) transformer phasing. 1

--_1 Replace transformer. I Close circuit breaker and go back to START t_

To 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 ouL LED will flash the status cede 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 boards only) HEAT speed, and COOL speed will run for 10 - 15 seconds each.

Gas vak, e and humidifier will not be turned on.

Was there a previous status code other than #11 ?

I Check room thermostat orinterconnecting cable.

t NO

I,_ Doesthecont o espond oW, Y1 (pesent), I NO _1 s24Vp esentatW, Y1 ( p esent),Y/Y2 o

Y/Y2, andG (24V) th........ tat signals? _ Gth ........ tatterrninalsonthe f........... trol? I

YES _!' YES

Run system through aheating or ccoling cycle Disconnect all the thermostat wires from the to check operation. Status codes are erased furnace control.

after 72 hours. On RED LED boards stored (115V or 24V) is interrupted.

status codes can also be erased whenever /

I Replace f........... tro]. _,_ D jo_rsl_heep [rOebI...... peat wh ..... ing 1

, NO

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.

A02106a

#0o

2o=

.-7

NO PREVIOUS CODE - Stored codes are erased after 72 hours. On RED LED

erased whenever power (11 5V or 24V)

boards stored status codes can also be

is interrupted, Run system through a hea ing or cooling cycle o check system.

BLOWER ON AFTER POWER UP - (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.

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 3 hours. See code 33,

IGNITION LOCKOUT- System failed to ignite gas and prove flame in 4 attempts, Control will auto-reset after 3 hours, See status code 34.

GAS HEATING LOCKOUT-Turn off power and wait 5 minutes to retry,

Check for:

- Stuckclosedgasvalverelayoncontrol.

- Miswireorshorttogasvalvewire.

ABNORMAL FLAME-PROVING SIGNAL Flame is proved while gas valve is de- energized, Inducer will run until fault is cleared, Check for:

- Stuck open or leaky gas valve,

PRESSURE SWITCH DID NOT OPEN Check for:

- Obstructed pressure tube,

- Pressure switch stuck closed,

SECONDARY VOLTAGE FUSE IS OPEN Check for:

- Short circuit in secondary voltage (24V) wiring including thermostat leads, Disconnect thermostat leads to isolate short circuit,

PRESSURE SWITCH DID NOT CLOSE 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.

- Low inducer voltage (115V).

- Low inlet gas pressure (if LGPS used),

- Inadequate combustion air supply,

- Disconnected or obstructed pressure tubing,

- Defective inducer motor,

- Defective pressure switch,

- Excessive wind,

- Restricted vent.

33 LIMIT CIRCUIT FAULT - Indicates the

limit, draft safeguard, flame rollout, or blocked vent shutoff switch* (if used) is open, Blower will run for4 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 rain. status code #33 continues to flash until blower shuts off.

Flame rollout switch and BVSS requires

manual reset, Check for:

- Dirtyfilterorrestrictedductsystem.

- Loose blower wheel,

- Defective switch or connections,

- Defective blower motor or capacitor,

- Inadequate combustion air supply (flame rollout switch open),

- Restricted vent,

- Proper vent sizing,

- Excessive wind,

34 IGNITION PROVING FAILURE- If flame

is not sensed during the trial for ignition period, the control will repeat the ignition sequence 3 more times before lockout #14 occurs. If flame signal is lost during the blower on-delay period, blower will come on for the selected blower off-delay,

Check the following items first before

proceeding to the next step,

- Gas valve turned off.

- Manual shut-off valve.

- Green_ellow wire MUST be connected to furnace sheet metal,

- Flame sensor must not be grounded,

To determine whether the problem is in the gas valve, igniter, or flame sensor the system can be operated in the component test mode to check the igniter. First remove the R thermostat connection from

the control and initiate the component test sequence. Does the igniter glow orange/white by the end of the 15 second warm-up period?

YE 3

* Blocked vent shutoff switch used in Chimney Adapter Kit

45 CONTROL CIRCUITRY LOCKOUT

Auto-reset after 1 hour lockout due to: Flame circuit failure.

- Gas valve relay stuck open. Software check error.

Reset power to clear lockout. Replace control if code repeats.

another component test sequence. Check

Replace

furnace control.

for 115V between pin 1 and NEUTRAL-L2 on the control. Was 11 5V present for the 15

YES _ I Check for continuity in the harness and igniter.

second

period?

,-----------_ Replace defective component.

Reconnect the R thermostat lead and set Check connections, If OK, replace control, thermostat to call for heat. Connect voltmeter across

gas

valve connections. Does

gas

valve

I _ Check that all gas valves are turned on,

receive 24V? _ YES _ Replace valve.

I Does gas valve open and allow gas to flow? I NO

YES

I Do the main burners ignite?

YES

I Do the main burners stay on?

Repeat call for heat and check flame sensor current during trial for ignition period. Is the

DC m croamps be ow 0.5?

YES

Clean flame sensor with fine steel wool and recheck current. Nominal current is 4.0 to 6.0

microamps.

I Is current near typical value?

YES

I Will main burners ignite and stay on?

YES

Fixed.

Inadequate flame carryover or rough ignition. Low inlet gas pressure. Proper firing rate. Blocked or incorrect carry- over gap. (.045" nominal)

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.

,._J Replace furnace control.

A05032

Carrier 090-14/042090, 070-12/036070, 090-16/048090, 090-20/060090, 110-12/036110 Installation, Start-up, Operating And Service And Maintenance Instructions

Specifications and Main Features

Frequently Asked Questions

User Manual