Carrier 58CTX15510020, 58CTX13510022, 58CTX13510016, 58CTX11010022, 58CTX11010016 Installation Guide

...

Download

Installation, Start-up, Operating and

Service and Maintenance Instructions

SAFETY CONSIDERATIONS ........................ 2 SERVICE AND MAINTENANCE PROCEDURES ..... 44

INTRODUCTION .................................. 3 Introduction ................................... 44

CODES AND STANDARDS .......................... 5 Care and Maintenance ........................... 45

Safety ........................................... 5

General Installation ................................ 5

Combustion and Ventilation Air ...................... 5

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

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

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

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

Venting ......................................... 5

ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS

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

LOCATION ....................................... 6

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

INSTALLATION .................................. 10

UPFLOW INSTALLATION ...................... 10

DOWNFLOW INSTALLATION ................... 11

HORIZONTAL INSTALLATION .................. 11

FILTER ARRANGEMENT ....................... 15

AIR DUCTS ................................... 15

GAS PIPING .................................. 17

ELECTRICAL CONNECTIONS .................. 21

VENTING .................................... 26

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

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

Start-Up Procedures .............................. 34

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

Check Safety Controls ............................. 39

Checklist ....................................... 39

Sequence of Operation ........................... 49

Wiring Diagrams ............................... 52

Troubleshooting ................................ 52

PARTS REPLACEMENT INFORMATION GUIDE ..... 55

Always Ask For

Use of the AltRI Certified IM Mark indicates a manul'acturer's participation in the program. For verification of certification l'or individual products,

go to www.ahridirectory.org.

ISO9001

QMt-SAI Global

NOTE: Read the entire instruction manual before starting the installation.

Portions of the text and tables are reprinted from NFPA 54/ANSI Z223.1-2012©, with permission of National Fire Protection

Association, Quincy, MA 02269 and American Gas Association, Washington DC 20001. This reprinted material is not the

complete and official position of the NFPA or ANSI on the referenced subject, which is represented only by the standard in

its entirety.

_z1[_6

f_7/8

[,4e,_t

51_ _JR_

_,N _15sN

_39

[_L_2

JU_ Ig2N t_2A_

27 _V4

57/S--

O_S_ 55/S--

_1U4

NOTES:

1. Two additional 7/8-in. (22 mm) 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. (406 mm) round or 14 1/2 x 12-in. (368 x 305 mm) rectangle.

b. For 1200 CFM-20-in. (508 mm) round or 14 1/2 x 19 1/2-in. (368 x 495 mm) rectangle. c. For 1600 CFM-22-in. (559 mm) round or 14 1/2 x 22 1/16-in. (368 x 560mm) rectangle.

d. For airflow requirements above 1800 CFM, see Air Delivery table in Product Data literature for specific use of single side inlets. The use of both side inlets,

a combination of 1 side and the bottom, or the bottom only will ensure adequate return air openings for airflow requirements above 1800 CFM.

Fig. 1 - Dimensional Drawing

A10290

Table 1 - Dimensions - In. (mm)

FURNACE SIZE CABINET BOTTOM CONNECTION FILTER MEDIA

045 - 08/024045 045 - 12/036045

070 - 08/024070 070 - 12/036070 070 - 16/048070 090 - 14/042090 090 - 16/048090

090 - 20/060090 110-12/036110 110-16/048110 110-22/066110 135-16/048135

135 -22/066135 155 -20/060155 22- 7/8 (581)

WIDTH OUTLET WIDTH BOTTOM FLUE iNLET WIDTH SIZE LB (KG) CABINET

14-3/16 (360) 12-9/16 (319) 9-5/16 (237) 12-11/16 (322) 4 (102) 104 (47) 16 (406) 14-3/16 (360) 12-9/16 (319) 9-5/16 (237) 12-11/16 (322) 4 (102) 107 (49) 16 (406) 14-3/16 (360) 12-9/16 (319) 9-5/16 (237) 12-11/16 (322) 4 (102) 111 (50) 16 (406) 14-3/16 (360) 12-9/16 (319) 9-5/16 (237) 12-11/16 (322) 4 (102) 115 (52) 16(406)

17-1/2 (445) 15-7/8 (403) 11-9/16 (294) 16 (406) 4 (102) 126 (57) 16 (406) 17-1/2 (445) 15-7/8 (403) 11-9/16 (294) 16 (406) 4 (102) 127 (58) 16 (406)

21 (533) 19-3/8 (492) 13-5/16 (338) 19-1/2 (495) 4 (102) 140 (64) 20 (508) 21 (533) 19-3/8 (492) 13-5/16 (338) 19-1/2 (495) 4 (102) 146 (66) 20 (508)

17-1/2 (445) 15-7/8 (403) 11-9/16 (294) 16 (406) 4 (102) 135 (61) 16 (406)

21 (533) 19-3/8 (492) 13-5/16 (338) 19-1/2 (495) 4 (102) 146 (66) 20 (508) 21 (533) 19-3/8 (492) 13-5/16 (338) 19-1/2 (495) 4 (102) 152 (69) 20 (508)

21 (533) 19-3/8 (492) 13-5/16 (338) 19-1/2 (495) 4 (102)1- 149 (68) 20 (508) 24-1/2 (622) 22-7/8 (581) 15-1/16 (383) 23 (584) 4 (102)1- 163 (74) 24 (610) 24-1/2 (622) 15-1/16 (383) 23 (584) 4 (102)1- 170 (77) 24 (610)

"135 and 155 size furnaces require a 5 or 6-in. (127 or 152 complete installation requirements.

A C D VENT ACCESSORY

B TOP & SHIP WT

COLLAR

mm) vent. Use a vent adapter between furnace and vent stack. See Installation Instructions for

SAFETY CONSIDERATIONS

FIRE, EXPLOSION, ELECTRICAL SHOCK, AND

CARBON MONOXIDE POISONING HAZARD

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

Improper installation, adjustment, alteration, service, maintenance, or use could cause carbon monoxide

poisoning, explosion, fire, electrical shock, or other conditions which may cause personal iniury or property damage. Consult a qualified service agency, local gas supplier, or your distributor or branch for information or

assistance. The qualified service agency must use only factory-authorized and listed kits or accessories when modifying this product.

FURNACE RELIABILITY HAZARD

Improper installation or misapplication of furnace may

require excessive servicing or cause premature component

failure.

Application of this furnace should be indoors with special

attention given to vent sizing and material, gas input rate,

air temperature rise, unit leveling, and unit sizing.

CUT HAZARD

Failure to t\_llow this caution may result in personal injury.

Sheet metal parts may have sharp edges or burrs. Use care

and wear appropriate protective clothing, safety glasses and

gloves when handling parts, and servicing furnaces.

Improper installation, adjustment, alteration, service, maintenance, or use can cause explosion, fire, electrical shock, or

other conditions which may cause death, personal injury, or property damage. Consult a qualified installer, service agency, or

your distributor or branch for information or assistance. The qualified installer or agency must use factory-authorized kits or

accessories when modifying this product. Refer to the individual instructions packaged with the kits or accessories when installing.

Follow all safety codes. Wear safety glasses, protective clothing, and work gloves. Have a fire extinguisher available. Read these

instructions thoroughly and follow all warnings or cautions include in literature and attached to the unit. Consult local

building codes, the current editions of the National Fuel Gas Code (NFGC) NFPA 54/ANSI Z223.1 and the National

Electrical Code (NEC) NFPA 70.

Recognize safety information. This is the safety-alert symbol/_. When you see this symbol on the unit and in instructions or manuals, be alert to the potential for personal iniury.

Understand the signal words DANGER, WARNING, and CAUTION. These words are used with the safety-alert symbol. DANGER identifies the most serious hazards which will result in

severe personal iniury or death. WARNING signifies hazards which could result in personal iniury or death. CAUTION is

used to identify unsafe practices which may result in minor personal iniury or product and property damage. NOTE is used

to highlight suggestions which will result in enhanced installation, reliability, or operation.

product and property damage. NOTE is used to highlight suggestions which will result in enhanced installation, reliability,

or operation.

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

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

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

4. Combustion products nmst be discharged outdoors. Con- nect this furnace to an approved vent system only, as spe-

cified in the "Venting" section of these instructions.

5. Never test for gas leaks with an open flame. Use a com- mercially available soap solution made specifically for the

detection of leaks to check all connections, as specified in the "Gas Piping" section.

6. Always install furnace to operate within the furnace's in- tended temperature-rise range with a duct system which

has an external static pressure within the allowable range, as specified in the "Start-Up, Adjustments, and Safety

Check" section. See furnace rating plate.

7. When a furnace is installed so that supply ducts carry air circulated by the furnace to areas outside the space con-

taining the furnace, the return air shall also be handled by duct(s) sealed to the furnace casing and terminating out- side the space containing the furnace. See "Air Ducts" sec- tion.

8. A gas-fired furnace for installation in a residential garage must be installed as specified in the warning box in the

"Location" section.

9. The furnace may be used for construction heat provided that the furnace installation and operation complies with

the first CAUTION in the LOCATION section of these in- structions.

10. These Multipoise Gas-Fired Furnaces are CSA (formerly A.G.A. and C.G.A.) design-certified for use with natural

and propane gases (see furnace rating plate) and for install- ation in alcoves, attics, basements, closets, utility rooms,

crawlspaces, and garages. The furnace is factory-shipped for use with natural gas. A CSA (A.G.A. and C.G.A.) lis-

ted accessory gas conversion kit is required to convert fur- nace for use with propane gas.

11. See Fig. 2 for required clearances to combustible construc- tion.

12. Maintain a 1-in. (25 mm) clearance from combustible ma- terials to supply air ductwork for a distance of 36 inches

(914 mm) horizontally from the furnace. See NFPA 90B or local code for further requirements.

13. These furnaces SHALL NOT be installed directly on car- peting, tile, or any other combustible material other than

wood flooring. In downflow installations, factory access- ory floor base MUST be used when installed on combust-

ible materials and wood flooring. Special base is not re- quired when this furnace is installed on manufacturer's

Coil Assembly Part No. CAR, CAP, CNRV, CNPV or when Coil Box Part No. KCAKC is used. See Fig. 2 for

clearance to combustible construction information.

INTRODUCTION

The Series 140/E 4-way multipoise Category I fan-assisted furnace is CSA (formerly A.G.A. and C.G.A.) design-certified. A

Category I fan-assisted furnace is an appliance equipped with an integral mechanical means to either draw or force products of

combustion through the combustion chamber and/or heat exchanger. The furnace is factory-shipped for use with natural

gas.Thisfurnaceisnotapprovedforinstallationin mobile homes,recreationalvehicles,oroutdoors.

Thesefurnacesshallnotbeinstalleddirectlyoncarpeting,tile,or anyothercombustiblematerialotherthanwoodflooring.For

downflowinstallations,afactoryaccessoryfloorbasemustbe usedwheninstalledoncombustiblematerialsandwoodflooring.

Thisspecialbaseisnotrequiredwhenthisfurnaceisinstalledon themanufacturer'scoilassembly,orwhenthemanufacturer'scoil

boxisused.SeeFig.2forclearancetocombustiblematerial information.

Thisfurnaceisdesignedforminimumcontinuousreturn-air temperatureof60°F(16°C)dborintermittentoperationdownto

MINIMUMINCHESCLEARANCETO COMBUSTIBLECONSTRUCTION

This forced air furnace is

improper adjustment, alteration, service, maintenance, or installation can cause

serious injury or death. Read and follow instructions and

precautions in User's information Manual provided with this furnace, installation

and service must be performed by a

qualified service agency or the gas

supplier.

Check entire gas assembly for leaks after lighting this appliance.

iNSTALLATION

1. This furnace must be installed in accordance with the manufacturer's

instructions and local codes. In the absence of local codes, follow the National

Fuel Gas Code ANSI Z223.1 / NFPA54 or CSA B-149. 1 Gas Installation Code.

2. This furnace must be installed so there are provisions for combustion and ventilation

air. See manufacturer's installation information provided with this appliance.

OPERATION |

This furnace is equipped with manual reset limit switch(es) in burner compartment to

protect against overheat conditions that can result from inadequate combustion air

supply or blocked vent conditions.

1. Do not bypass limit switches.

2. If a limit opens, call a quallified serviceman to correct the condition

and reset limit switch.

equipped for use with natural gas at altitudes 0 - 10,000 ft

(0 - 3,050m).

An accessory kit, supplied by

the manufacturer, shall be used to convert to propane gas use or may be required for some

natural gas applications.

This furnace is for indoor

installation in a building constructed on site.

This furnace may be installed

on combustible flooring in alcove or closet at minimum clearance

as indicated by the diagram from combustible material.

This furnace may be used with

a Type B-1 Vent and may be vented in common with other

gas fired appliances.

DOWNFLOWPOSITIONS:

Installation on non-combustible floors only. For Installation on combustible flooring only when installed on special

base, Part No. KGASB0201ALL or NAHA01101SB, Coil Assembly, Part No. CAR, CAP, CNPV, CNRV, END4X, ENW4X, WENC, WTNC,

WENW OR WTNW.

18 inches front clearance required for alcove.

indicates supply or return sides when furnace is in the horizontal position. Line contact only permissible between lines formed by

intersections of the Top and two Sides of the furnace jacket, and building joists, studs or framing.

Fig. 2 - Clearances to Combustibles

55°F(13°C)dbsuchaswhenusedwithanightsetback thermostat.Return-airtemperaturemustnotexceed80°F(27°C) db.Failureto followthesereturn-airtemperaturelimitsmay

affectreliabilityofheatexchangers,motors,andcontrols.(See Fig.3.)

Foraccessoryinstallationdetails,referto theapplicable instructionliterature.

NOTE:Removeallshippingbracketsandmaterialsbefore operatingthefurnace.

iNSTALLATiON

This furnace is approved for UPFLOW, DOWNFLOW, and

HORIZONTAL installations.

Clearancearrows donotchangewith

furnaceorientation.

Clearancein inches

Vent Clearance to combustiNes:

For SingleWall vents 6 inches(6 po). ForType B=I venttype 1 inch(1 po).

MINIMUM INCHES CLEARANCE TO

COMBUSTIBLE CONSTRUCTION

IIIIIIIIIIIIIIIIIIIIIIIIIII

336996-101 REV. C

A10269

FRONT

Step 7 -- Electrical Connections National Electrical Code (NEC) ANSI/NFPA 70-2008

Step 8 -- Venting NFGC; NFPA 54 / ANSI Z223.1-2012 chapters 12 and 13

_'_\ MAX80°F/27 C

ELECTROSTATIC DISCHARGE (ESD)

PRECAUTIONS PROCEDURE

MIN60°F / 16 C

A06745

Fig. 3 - Return Air Temperature

CODES AND STANDARDS

Follow all national and local codes and standards in addition to these instructions. The installation must comply with

regulations of the serving gas supplier, local building, heating, plumbing, and other codes. In absence of local codes, the

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

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

Step 1 -- Safety

National Fuel Gas Code (NFGC) NFPA 54-2012/ANSI Z223.1-2012 and the Installation Standards, Warm Air Heating and Air Conditioning Systems ANSI/NFPA 90B

Step 2 -- General Installation

Current edition of the NFGC and the NFPA 90B. For copies, contact the National Fire Protection Association Inc.,

Batterymarch Park, Quincy, MA 02269; (www.NFPA.org) or for

only the NFGC, contact the American Gas Association, 400 N. Capitol Street, N.W., Washington DC 20001 (www.AGA.org.)

Step 3 -- Combustion and Ventilation Air

Section 9.3 of the NFGC, NFPA 54/ANSI Z223.1-2012 Air for Combustion and Ventilation

Step 4 -- Duct Systems

Air Conditioning Contractors Association (ACCA) Manual D, Sheet Metal and Air Conditioning Contractors National

Association (SMACNA), or American Society of Heating, Refrigeration, and Air Conditioning Engineers (ASHRAE) 2001 Fundamentals Handbook Chapter 34 or 2000 HVAC Systems and Equipment Handbook Chapters 9 and 16.

Step 5 -- Acoustical Lining and Fibrous Glass Duct

Current edition of SMACNA and NFPA 90B as tested by UL Standard 181 for Class I Rigid Air Ducts

Step 6 -- Gas Piping and Gas Pipe Pressure Testing NFPA 54 / ANSI Z223.1-2012; chapters 5, 6, 7, and 8 and

National Plumbing Codes

FURNACE RELIABILITY HAZARD Improper installation or service of furnace may cause

premature furnace component failure. Electrostatic discharge can affect electronic components.

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

1. Disconnect all power to the furnace. Multiple disconnects

may be required. DO NOT TOUCH THE CONTROL OR ANY WIRE CONNECTED TO THE CONTROL PRIOR

TO DISCHARGING YOUR BODY'S ELECTROSTATIC CHARGE TO GROUND.

2. Firmly touch the clean, unpainted, metal surface of the fur- nace chassis which is close to the control. Tools held in a

person's hand during grounding will be satisfactorily dis- charged.

3. After touching the chassis, you may proceed to service the control or connecting wires as long as you do nothing to

recharge your body with static electricity (for example; DO NOT move or shuftle your feet, do not touch un-

grounded objects, etc.).

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

or wires.

5. Use this procedure for installed and uninstalled (ungroun- ded) furnaces.

6. Before removing a new control from its container, dis- charge your body's electrostatic charge to ground to pro-

tect the control from damage. If the control is to be in- stalled in a furnace, follow items 1 through 4 before

bringing the control or yourself in contact with the fur- nace. Put all used and new controls into containers before

touching ungrounded objects.

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

DISCHARGED TO THE LEFT.

DISCHARGED DOWNWARD AIRFLOW

THE BLOWER iS LOCATED

TOTHE RIGHT OFTHE

BURNER SECTION, AND

AIR CONDiTiONED AiR iS

THE BLOWER iS

LOCATED ABOVE THE

BURNER SECTION, AND

CONDiTiONED AIR iS

AIRFLOW

Fig. 4 - Multipoise Orientations

THE BLOWER iS

LOCATED BELOW THE

BURNER SECTION, AND

CONDiTiONED AiR iS

DISCHARGED UPWARD.

! ¢>

AIRFLOW

THE BLOWER iS

LOCATED TO THE LEFT

OF THE BURNER SECTION,

AND CONDiTiONED AiR iS

DISCHARGED TO THE RIGHT.

A02097

LOCATION

GENERAL

This multipoise furnace is shipped in packaged configuration. Some assembly and modifications are required when used in any

of the four applications shown in Fig. 4. NOTE: For high-altitude installations, the high-altitude conversion kit MUST be installed at or above 5500 ft. (1676 M)

above sea level. Obtain high-altitude conversion kit from your area authorized distributor.

This furnace must:

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

• not be installed directly on any combustible material other than wood flooring for upflow applications. Downflow installations require use of a factory-approved floor base or coil assembly when installed on combustible materials or wood flooring (refer to SAFETY CONSIDERATIONS).

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

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

furnace clearance to combustible construction label.

The following types of furnace installations may require OUTDOOR AIR for combustion due to chemical exposures:

• Commercial buildings

• Buildings with indoor pools

• Laundry rooms

• Hobby or craft rooms, and

• Chemical storage areas

If air is exposed to the following substances, it should not be used for combustion air, and outdoor air may be required for

combustion:

• Permanent wave solutions

• Chlorinated waxes and cleaners

• Chlorine based swimming pool chemicals

• Water softening chemicals

• De-icing salts or chemicals

• Carbon tetrachloride

• Halogen type refrigerants

• Cleaning solvents (such as perchloroethylene)

• Printing inks, paint removers, varnishes, etc.

• Hydrochloric acid

• Cements and glues

• Antistatic fabric softeners for clothes dryers

• Masonry acid washing materials

CARBON MONOXIDE POISONING AND []NIT

DAMAGE HAZARD

Failure to follow this warning could result in personal iniury or death, and furnace damage.

Corrosive or contaminated air may cause failure of parts containing flue gas, which could leak into the living space. Air for combustion must not be contaminated by halogen compounds, which include fluoride, chloride, bromide, and iodide. These elements can corrode heat exchangers and

shorten furnace life. Air contaminants are found in aerosol sprays, detergents, bleaches, cleaning solvents, salts, air

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

in addition to all local codes and ordinances.

All fuel-burning equipment must be supplied with air for fuel combustion. Sufficient air must be provided to avoid negative

pressure in the equipment room or space. A positive seal must be made between the furnace cabinet and the return-air duct to

prevent pulling air from the burner area and from draft safeguard opening.

FIRE,INJURYORDEATHHAZARD Failureto follow this 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 (457 mm) above the floor. The furnace must be located or protected to avoid damage by vehicles. When the furnace is installed in a public garage, airplane hangar, or other building having a hazardous atmosphere, the furnace must be installed in accordance with the NFGC. (See Fig.

5.)

18-IN. (457.2 mm)

MINIMUM TO BURNERS

Fig. 5 - Installation in a Garage

FIRE HAZARD

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

Do not install the furnace on its back or hang furnace with control compartment facing downward. Safety control operation will be adversely affected. Never connect

return-air ducts to the back of the furnace. (See Fig. 60

A93044

PROPERTY DAMAGE HAZARD

Improper use or installation of this furnace may cause

premature component failure. This gas furnace may be used

for construction heat provided that:

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

-The furnace is controlled by a thermostat. It may not be "hot wired" to provide heat continuously to the structure

without thermostatic control.

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

-The temperature of the return air to the furnace is maintained between 55°F (13°C) and 80°F (27°C), with

no evening setback or shutdown. The use of the furnace while the structure is under construction is deemed to be

intermittent operation per our installation instructions.

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

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

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

-Verify proper furnace operating conditions including ignition, gas input rate, air temperature rise, and venting

accordin_ to these installation instructions.

LOCATION RELATIVE TO COOLING EQUIPMENT The cooling coil must be installed parallel with, or on the

downstream side of the unit to avoid condensation in the heat exchangers. When installed parallel with the furnace, dampers or

other flow control must prevent chilled air from entering the furnace. If the dampers are manually operated, they must be equipped with means to prevent operation of either unit unless

the damper is in the full-heat or full-cool position.

Fig. 6 - Prohibit Installation on Back

AIR FOR COMBUSTION AND

VENTILATION

Provisions for adequate combustion, ventilation, and dilution air must be provided in accordance with: U.S. installations: Section 9.3 of the NFPA 54 /A ANSI Z223.1-2012, Air for Combustion and Ventilation, and applicable provisions of the local building codes.

A02054

FURNACE CORROSION HAZARD Failure to follow this caution may result in furnace damage.

Air for combustion nmst not be contaminated by halogen compounds, which include fluoride, chloride, bromide, and

iodide. These elements can corrode heat exchangers and shorten furnace life. Air contaminants are found in aerosol

sprays, detergents, bleaches, cleaning solvents, salts, air fresheners, and other household products.

CARBON MONOXIDE POISONING HAZARD

Failure to follow this warning could result in personal injury or death.

The operation of exhaust fans, kitchen ventilation fans, clothes dryers, attic exhaust fans or fireplaces could create a

NEGATIVE PRESSURE CONDITION at the furnace. Make-up air MUST be provided for the ventilation devices,

in addition to that required by the furnace. Refer to Carbon Monoxide Poisoning Hazard warning in venting section of these instructions to determine if an adequate amount of make-up air is available.

The requirements for combustion and ventilation air depend upon whether or not the furnace is located in a space having a volume

of at least 50 cubic feet per 1,000 Btuh input rating for all gas appliances installed in the space.

• Spaces having less than 50 cubic feet per 1,000 Btuh require the

Outdoor Combustion Air Method.

• Spaces having at least 50 cubic feet per 1,000 Btuh may use the

Indoor Combustion Air, Standard or Known Air Infiltration

Method.

Outdoor Combustion Air Method

1. Provide the space with sufficient air for proper combus- tion, ventilation, and dilution of flue gases using perman-

ent horizontal or vertical duct(s) or opening(s) directly communicating with the outdoors or spaces that freely

communicate with the outdoors.

2. Fig. 7 illustrates how to provide TWO OUTDOOR OPENINGS, one inlet and one outlet combustion and

ventilation air opening, to the outdoors.

e. One opening MUST commence within 12 in. (300 ram)

of the ceiling and the second opening MUST commence within 12 in. (300 ram) of the floor.

f. Size openings and ducts per Fig. 7 and Table 2.

g. TWO HORIZONTALDUCTS require I -in 2 of free area

per 2,000 Btuh (1,100 mm2/kW) of combined input for all gas appliances in the space per Fig.7 and Table 2.

h. TWO OPENINGS OR VERTICAL DUCTS require 1

-in 2 of free area per 4,000 Btuh (550 mm2/kW) for com- bined input of all gas appliances in the space per Fig. 7

and Table 2.

3. ONE OUTDOOR OPENING requires:

a. One square inch of free area per 3,000 Btuh (734

mm2/kW) for combined input of all gas appliances in the space per Table 2 and

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

in the space.

Table 2 - Minimum Free Area Required for Each Combustion Air opening of 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. MM/KW) (1 SQ. IN./3,000 BTUH) (734 SQ. MM/KW) (1 SQ. IN./4,000 BTUH) (550 SQ. MM/KW)

iNPUT Free Area of Opening Round Duet Free Area of Opening Round Duet Free Area of Opening Round Duet

(BTUH) and Duet Dia. and Duet Dia. and Duet Dia.

Sq. In. (Sq. ram) In. (ram) Sq. In. (Sq. ram) In. (ram) Sq. In. (Sq. ram) In. (ram)

44,000 22 (14194 / 6 (152 / 14.7 (9484/ 5 (127 / 11 (7096 / 4 (102 / 66,000 33 (21290) 7 (178) 22 (14193) 6 (152) 16.5 (10645) 5 (127)

88,000 44 (28387) 8 (203) 29.3 (18903) 7 (178) 22 (14193) 6 (152) 110,000 55 (35484) 9 (229) 36.7 (23677) 7 (178) 27.5 (17742) 6 (152) 132,000 66 (42580) 10 (254) 44 (28387) 8 (203) 33 (21290) 7 (178) 154,000 77 (49677) 10 (254) 51.3 (33096) 9 (229) 38.5 (24839) 8 (203)

EXAMPLES: Determining Free Area

FURNACE WATER HEATER

110,000 + 30,000 = (140,000 divided by 4,000)

66,000 + 40,000 = (106,000 divided by 3,000) 88,000 4- 30,000 = (118,000 divided by 2,000)

TOTAL INPUT

= 35.0 Sq. In. for each two Vertical Ducts or Openings = 35.3 Sq. In. for a Single Duct or Opening

= 59.0 Sq. In. for each of two Horizontal Ducts

CIRCULATING AIR

DUCTS

I I I I I I

I I I

INTERIOR

HEATED

SPACE

CIRCULATING AIR DUCTS

[_ VENTTHROUGH ROOF

I I

I I I I

I I

12" MAX (305mm)

z ,

------1 SO IN. PER 1000 BTUH* IN DOOR O R WALL

UNCONFINED SPACE

6" MtN (152mm)

(FRONT)0

1 SQ IN. PER 1000 BTUH* IN DOOR

-- OR WALL

L 12" MAX (305ram)

OUTDOORS BTUH*

*Minimum dimensions of 3-in. (76 mm). Note: Use any of the following combinations of openings:

A&BC&DD&EF&G

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

Outdoors

PER 4000

A03174

The opening shall commence within 12 in. (300 ram) of the ceiling. Appliances in the space shall have clearances of at least 1

in. (25 ram) from the sides and back and 6 in. (150 ram) from the front. The opening shall directly communicate with the outdoors or shall conmmnicate through a vertical or horizontal duct to the

outdoors or spaces (crawl or attic) that freely communicate with the outdoors.

Indoor Combustion Air@ NFPA & AGA Standard and Known-Air-Infiltration Rate Methods

Indoor air is permitted for combustion, ventilation, and dilution, if the Standard or Known-Air-Infiltration Method is used.

CARBON MONOXIDE POISONING HAZARD

Failure to follow this warning could result in death and/or personal iniury.

Many homes require air to be supplied from outdoors for furnace combustion, ventilation, and dilution of flue gases.

The furnace combustion air supply must be provided in

accordance with this instruction manual.

* Minimum opening size is 100 sq in. (64516 sq, mm) with minimum

dimensions of 3 in. (76 mm)

1-Minimum of 3 in. (76 mm) when type-B1 vent is used.

A03175

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

Indoors

The Standard Method:

1. The space has no less volume than 50 cubic feet per 1,000 Btuh of the maximum input ratings for all gas appliances

installed in the space and

2. The air infiltration rate is not known to be less than 0.40 air changes per hour (ACH).

The Known Air Infiltration Rate Method shall be used, if the infiltration rate is known to be:

1. Less than 0.40 ACH and

2. Equal to or greater than 0.10 ACH

Infiltration rates greater than 0.60 ACH shall not be used. The minimum required volume of the space varies with the number of

ACH and shall be determined per Table 3 or Equations 1 and 2. Determine the minimum required volume for each appliance in

the space and add the volumes together to get the total n_ininmm required volume for the space.

Table3 - Minimum Space Volumes for 100 % Combustion, Ventilation, and Dilution from Indoors

OTHER THAN FAN-ASSISTED TOTAL FAN-ASSISTED TOTAL

ACH

0.60 1,050 1,400 1,750 1,100 1,650 2,200 2,750 3,300 3,850

0.50 1,260 1,680 2,100 1,320 1,980 2,640 3,300 3,960 4,620

0.40 1,575 2,100 2,625 1,650 2,475 3,300 4,125 4,950 5,775

0.30 2,100 2,800 3,500 2,200 3,300 4,400 5,500 6,600 7,700

0.20 3,150 4,200 5,250 3,300 4,950 6,600 8,250 9,900 11,550

0.10 6,300 8,400 10,500 6,600 9,900 13,200 16,500 19,800 23,100

0.00 NP NP NP NP NP NP NP NP NP

NP = Not Permitted

Table 3-Minimum Space Volumes were determined by using the following equations from the National Fuel Gas Code ANSI

Z223.1-2012/NFPA 54-2012, 9.3.2.2:

1. For other than fan-assisted appliances, such as a draft

hood-equipped water heater:

Volume - 21ft3 _ I °ther

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

Volume _ 15ft 3 _ I fan

If: Iother = combined input of all other than fan-assisted

Ifan = combined input of all fan-assisted appliances in

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

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

1. Adjoining rooms can be considered part of a space if: a. There are no closeable doors between rooms.

b. Combining spaces on same floor level. Each opening

shall have free area of at least 1 in.2/1,000 Btuh (2,000 mm2/kW) of the total input rating of all gas appliances

in the space, but not less than 100 in. 2 (0.06 m2). One opening shall commence within 12 in. (300 ram) of the

ceiling and the second opening shall commence within 12 in. (300 ram) of the floor. The nfininmm dimension

of air openings shall be at least 3 in. (80 ram). (See Fig.

8.)

c. Combining space on different floor levels. The volumes

of spaces on different floor levels shall be considered as conmmnicating spaces if connected by one or more per- manent openings in doors or floors having free area of

at least 2 in.2/1,000 Btuh (4,400 mm2/kW) of total input rating of all gas appliances.

2. An attic or crawlspace may be considered a space that

freely conmmnicates with the outdoors provided there are adequate permanent ventilation openings directly to out- doors having free area of at least 1-in.2/4,000 Btuh of

total input rating for all gas appliances in the space.

3. In spaces that use the Indoor Combustion Air Method, in-

filtration should be adequate to provide air for combus- tion, permanent ventilation and dilution of flue gases.

(1,000s BTUH GAS INPUT RATE) (1,000s BTUH GAS INPUT RATE)

30 40 50 44 66 88 110 132 154

S _ace Volume (ft.3)

However, in buildings with unusually tight construction, additional air MUST be provided using the methods de-

scribed 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 con-

tinuous, sealed vapor barrier. Openings are gasketed or sealed and

Other ACH 000 Btu/hr

A04002

b. Doors and openable windows are weatherstripped and

c. Other openings are caulked or sealed. These include

joints around window and door frames, between sole

plates and floors, between wall-ceiling joints, between wall panels, at penetrations for plumbing, electrical and

gas lines, etc.

Fan ACH 000 Btu/hr

Combination of Indoor and Outdoor Air

1. Indoor openings shall comply with the Indoor Combus-

A04003

tion Air Method below and,

2. Outdoor openings shall be located as required in the Out- door Combustion Air Method mentioned previously and,

appliances in Btuh/hr

Btuh/hr

3. Outdoor openings shall be sized as follows:

a. Calculate the Ratio of all Indoor Space volume divided

by required volume for Indoor Combustion Air Meth- od below.

Outdoor opening size reduction Factor is 1 nfinus the Ratio in a. above.

Mininmm size of Outdoor openings shall be the size re- quired in Outdoor Combustion Air Method above nml-

tiplied by reduction Factor in b. above. The minimum dimension of air openings shall be not less than 3 in. (80

mm).

INSTALLATION

UPFLOW INSTALLATION Bottom Return Air Inlet

These furnaces are shipped with bottom closure panel installed in bottom return-air opening. Remove and discard this panel when

bottom return air is used. To remove bottom closure panel, perform the following:

1. Tilt or raise furnace and remove 2 screws holding bottom filler panel. (See Fig. 90

2. Rotate bottom filler panel downward to release holding

tabs.

3. Remove bottom closure panel.

4. Reinstall bottom filler panel and screws.

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

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

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

Bottom

Bottom Filler Panel

A10273

Fig. 9 - Removing Bottom Closure Panel

Levelin_ Le_s (If Desired) In upflow position with side return inlet(s), leveling legs may be

used. (See Fig. 10.) Install field-supplied, 5/16 x 1-1/2 in. (8 x 38 ram) (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 in Step 1 above.

To install leveling legs:

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

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

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

4. Adjust outside nut to provide desired height, and tighten inside nut to secure arrangement.

5. Reinstall bottom closure panel if removed.

(8ram)

DOWNFLOW INSTALLATION NOTE: For downflow applications, this furnace is approved for

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

• Special Base, KGASB

• Cased Coil Assembly Part No. CNPV, CNRV, CAP, and CAR

• Coil Box Part No. KCAKC

1. Deternfine application being installed from Table 4.

2. Construct hole in floor per Table 4 and Fig. 11.

3. Construct plenum to dimensions specified in Table 4 and Fig. 11.

4. If downflow subbase, KGASB is used, install as shown in Fig. 12. If Coil Assembly Part No. CNPV, CNRV, CAP,

CAR or Coil Box Part No. KCAKC is used, install as shown in Fig. 13.

NOTE: It is recommended that the perforated supply-air duct flanges be completely folded over or removed from furnace when installing the furnace on a factory-supplied cased coil or coil box. To remove the supply-air duct flange, use wide duct pliers or hand seamers to bend flange back and forth until it breaks off. Be

careful of sharp edges. (See Fig. 14.) Bottom Return Air Inlet

These furnaces are shipped with bottom closure panel installed in bottom return-air opening. Remove and discard this panel when

bottom return air is used. To remove bottom closure panel, perform the following:

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

2. Rotate bottom filler panel downward to release holding

tabs.

3. Remove bottom closure panel.

4. Reinstall bottom filler panel and screws.

HORIZONTAL INSTALLATION The furnace can be installed horizontally in an attic or crawl space

on either the left-hand (LH) or right-hand (RH) side. The furnace can be hung from floor joists, rafters or trusses or installed on a

non-combustible platform, blocks, bricks or pad.

1 3/4

(44ram)

(8ram)

5/16"

(44mm) 1 3/4"

(44mm) 1

Fig. 10 - Leveling Legs

1 3/4"

(44ram)

(8ram)

A89014

FIRE, EXPLOSION, AND CARBON MONOXIDE POISONING HAZARD

Failure to follow this warning could result in personal iniury, death, or property damage.

Do not install the furnace on its back or hang furnace with control compartment facing downward. Safety control operation will be adversely affected. Never connect

return-air ducts to the back of the furnace.

Suspended Furnace Support The furnace may be supported under each end with threaded rod,

angle iron or metal plumber's strap as shown. (See Fig. 15 and

16.) Secure angle iron to bottom of furnace as shown. Heavy-gauge sheet metal straps (plumber's straps) may be used to suspend the furnace from each bottom corner. To prevent

screws from pulling out, use 2 #8 x 3/4-in. (19 ram) screw into the side and 2 #8 x 3/4-in. (19 ram) screw in the bottom of the

furnace casing for each strap. (See Fig. 15 and 16 0 If the screws are attached to ONLY the furnace sides and not the

bottom, the straps nmst be vertical against the furnace sides and not pull away from the furnace sides, so that the strap attachment

screws are not in tension (are loaded in shear) for reliable support.

Platform Furnace Support

Construct working platform at location where all required furnace clearances are met. (See Fig. 2 and 17.) For furnaces with 1-in.

(25 ram) clearance requirement on side, set furnace on non-combustible blocks, bricks or angle iron. For crawlspace installations, if the furnace is not suspended from the floor joists,

the ground underneath furnace must be level and the furnace set on blocks or bricks.

Roll- Out Protection

Provide a n_ininmm 17-3/4-in. x 22-in. (451 x 559 ram) piece of sheet metal for flame roll-out protection in front of burner area

for furnaces closer than 12 inches (305 ram) above the combustible deck or suspended furnaces closer than 12 inches

(305 ram) to joists. The sheet metal MUST extend underneath the furnace casing by 1 in. (25 ram) with the door removed.

The bottom closure panel on furnaces of widths 17-1/2 in. (445 ram) and larger may be used for flame roll-out protection when bottom of furnace is used for return air connection. See Fig. 17.

for proper orientation of roll-out shield. Bottom Return Air Inlet

These furnaces are shipped with bottom closure panel installed in bottom return-air opening. Remove and discard this panel when

bottom return air is used. To remove bottom closure panel, perform the following:

1. Tilt or raise furnace and remove 2 screws holding bottom

filler panel. (See Fig. 9.)

2. Rotate bottom filler panel downward to release holding

tabs.

3. Remove bottom closure panel.

4. Reinstall bottom filler panel and screws.

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

bottom return-air opening. This panel MUST be in place when side return air inlet(s) are used without a bottom return air inlet,

FURNACE

(OR COIL CASING

WHEN USED)

COMBUSTIBLE

FLOORING

SUBBASE

SHEET METAL

PLENUM

FLOOR

OPENING

Fig. 12 - Furnace, Plenum, and Subbase installed on a

Combustible Floor

FURNACE

APPROVED

COIL ASSEMBLY

COIL BOX

A96285

Fig. 11 - Floor and Plenum Opening Dimensions

A96283

_ COMBUSTIBLE

FLOORING "_

SHEET METAL _

PLENUM

FLOOR

OPENING

A08556

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

Installed on a Combustible Floor

Table 4 - Opening dimensions - In. (mm)

FURNACE

CASING

APPLICATION

WIDTH

Upflow Applications on Combustible or Noncombustible Floor- 12-11/16 21-5/8 13-5/16 22-1/4

Downflow Applications on Noncombustible Flooring (KGASB 12-9/16 19 13-3/16 19-5/8

14-3/16 Downflow applications on combustible flooring (KGASB sub- 11 - 18/16 19 18- 7/16 20- 5/8

(376) base required) (284) (483) (341) (600)

Downflow Applications on Combustible Flooring with CNPV,

CNRV, CAR, or CAP Coil Assembly or KCAKC coil box

Upflow Applications on Combustible or Noncombustible Floor- 16 21 -5/8 16-5/8 22-1/4

Downflow Applications on Noncombustible Flooring (KGASB 15-7/8 19 16-1/2 19-5/8

17-1/2 Downflow applications on combustible flooring (KGAS B su b- 15-1/8 19 16-3/4 20-5/8

(445) base required) (384) (483) (425) (600)

Downflow Applications on Combustible Flooring with CNPV,

CNRV, CAR, or CAP Coil Assembly or KCAKC coil box

Upflow Applications on Combustible or Noncombustible Floor- 19-1/2 21-5/8 20-1/8 22-1/4

Downflow Applications on Noncombustible Flooring (KGASB 19-3/8 19 20 19-5/8

21 Downflow applications on combustible flooring (KGASB sub- 18-5/8 19 20-1/4 20-5/8

(533) base required) (473) (483) (514) (600)

Downflow Applications on Combustible Flooring with CNPV,

CNRV, CAR, or CAP Coil Assembly or KCAKC coil box

Upflow Applications on Combustible or Noncombustible Floor- 23 21 - 1/8 28- 5/8 22-1/4

Downflow Applications on Noncombustible Flooring (KGASB 22-7/8 19 28-1/2 19-5/8

24-1/2 Downflow applications on Combustible flooring (KGAS B sub- 22-1/8 19 28- 3/4 20-5/8

(622) base required) (562) (483) (603) (600)

Downflow Applications on Combustible Flooring with CNPV,

CNRV, CAR, or CAP Coil Assembly or KCAKC coil box

ing (KGASB subbase not required) (322) (549) (338) (565)

subbase not required) (819) (483) (335) (498)

(KGASB subbase not required) (819) (483) (338) (508)

ing (KGASB subbase not required) (406) (549) (422) (565)

subbase not required) (403) (483) (419) (498)

(KGASB subbase not required) (394) (483) (419) (508)

ing (KGASB subbase not required) (495) (549) (511) (565)

subbase not required) (492) (483) (508) (498)

(KGASB subbase not required) (483) (483) (508) (508)

ing (KGASB subbase not required) (584) (537) (600) (565)

subbase not required) (581) (483) (597) (498)

(KGASB subbase not required) (572) (483) (597) (508)

PLENUM OPENING FLOOR OPENING

A B C D

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

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

19 19 20 20

22-1/2 19 28-1/2 20

U PFLOW DOWN FLOW HO REZO NTAL

[......

YES

NO NO

120°_ MIN

YES

YES 120°_ YES 120°_ YES

/\ /\

MIN MIN

Fig. 14 - Duct Flanges

YES

A02020

UTER DOOF

ASSEMBLY

8" (203mm) MIN FOR DOOR REMOVAL

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

1/4'1 (6mm) THREADED ROD

4 REQ.

SECURE ANGLE IRON TO BOTTOM OF FURNACE WITH

3 #8 xS/4'' (19ram) SCREWS TYPICAL FOR 2 SUPPORTS

1" (25mm) SQUARE, 1-1/4"xt-1/4"xl/8" (32x32x3mm)

ANGLE IRON OR UNI-STRUT MAY BE USED

OUTER DOOR ASSEMB_

A10130

Fig. 15 - Horizontal Unit Suspension

22 GAUGE GALVANIZED STRAPS TYPICAL

FOR 4 STRAPS

AIR

METHOD 2

BACK OF FURNACE

METHOD 1 FOLD ALL STRAPS UNDER FURNACE AND SECURE WTH

(4) #8 x 3/4 (t9 ram) SHEET METAL SCREWS (2 SCREWS IN SIDE AND 2SCREWS

IN BOTTOM).

USE (4) #8 x 3/4 (19 ram) 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

A10131

LINECONTACTONLYPERMISSIBLEBETWEEN

LINESFORMEDBYINTERSECTIONSOF THETOPANDTWOSIDESOFTHEFURNACE JACKETANDBUILDINGJOISTS,

STUDS,ORFRAMING.

EQUIPMENT MANUAL

SHUT-OFF GAS VALVE

SEDIMENT

TRAP

UNION

ENTRY

Fig. 17 - Typical Attic Installation

VENT

_0-1N.(762mm)

MIN WORK AREA

173/4" (451 mm)OVERALL

4 3/4" (121mm) UNDER DOOR 1" (25mm) UNDER FURNACE

EXTEND OUT 12" (305mm) FROM FACE OF DOOR

*WHEN USED WITH

SINGLE WALL VENT CONNECTIONS

A10164

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

CARBON MONOXIDE POISONING HAZARD

Failure to follow this warning could result in personal iniury, or death.

Never operate a furnace without a filter or with filter access door removed.

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

required. Refer to the instructions supplied with the external filter rack for

assembly and installation options. AIR DUCTS

General Requirements The duct system should be designed and sized according to

accepted national standards such as those published by: Air Conditioning Contractors Association (ACCA), Sheet Metal and Air Conditioning Contractors National Association (SMACNA)

or American Society of Heating, Refrigerating and Air Conditioning Engineers (ASHRAE) or consult The Air Systems

Design Guidelines reference tables available from your local distributor. The duct system should be sized to handle the

required system design CFM at the design external static pressure. The furnace airflow rates are provided in Table 5-Air Delivery CFM (With Filter).

When a furnace is installed so that the supply ducts carry air circulated by the furnace to areas outside the space containing the

furnace, the return air shall also be handled by duct(s) sealed to the furnace casing and ternfinating outside the space containing

the furnace. Secure ductwork with proper fasteners for type of ductwork used.

Seal supply- and return-duct connections to furnace with code approved tape or duct sealer. NOTE: Flexible connections should be used between ductwork

and furnace to prevent transnfission of vibration.

Ductwork passing through unconditioned space should be insulated to enhance system performance. When air conditioning

is used, a vapor barrier is recommended. Maintain a 1-in. (25 ram) clearance from combustible materials

to supply air ductwork for a distance of 36 in. (914 ram) horizontally from the furnace. See NFPA 90B or local code for further requirements.

Ductwork Acoustical Treatment NOTE: Metal duct systems that do not have a 90 ° elbow and 10

ft. (3 M) of main duct to the first branch take-off may require internal acoustical lining. As an alternative, fibrous ductwork may

be used if constructed and installed in accordance with the latest edition of SMACNA construction standard on fibrous glass

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

air ducts. Supply Air Connections

For a furnace not equipped with a cooling coil, the outlet duct shall be provided with a removable access panel. This opening

shall be accessible when the furnace is installed and shall be of such a size that the heat exchanger can be viewed for possible

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

Upflow and Horizontal Furnaces

Connect supply-air duct to 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 casing (when used). DO NOT cut main furnace casing side to attach

supply air duct, hunfidifier, or other accessories. All accessories MUST be connected to duct external to furnace main casing.

NOTE: For horizontal applications, the top-most flange may be bent past 90 ° to allow the evaporator coil to hang on the flange temporarily while the remaining attachment and sealing of the coil are performed.

Table5 - Air Delivery - CFM (With Filter)*

FURNACE

SIZE

045- 08 /

024045

045-12/

036045

070-081 /

024070

070-12/

036070

070-16/

048070

090-14/

042090

090-16/

048090

090- 20/

060090

110-12/

036110

110-16/

048110

110-22/ Bottom Sides or

066110 1 Side & Bottom

*A filter is required for each return-air inlet. Airflow performance included 3/4-in. (19 mm) washable filter media such as contained in factory-authorized ac- cessory filter rack. To determine airflow performance without this filter, assume an additional 0.1 In. W.C. available external static pressure.

-- Indicates unstable operating conditions.

RETURN-AIR

INLET

Bottom or

Side(s)

Bottom or

Side(s)

Bottom or

Side(s)

Bottom or

Side(s)

Bottom or

Side(s)

Bottom or

Side(s)

Bottom or

Side(s)

Bottom Only

Both Side or 1 Side & Bottom

1Side Only

Bottom or

Side(s)

Bottom or

Side(s)

Bottom Only

1Side Only

SPEED

High 1120 1075 1020 960 895 815 720 605 455 340

Med - High 930 890 850 805 750 680 600 500 345 195

Med - Low 820 785 750 700 650 585 505 400 235 - -

Low 725 690 655 605 555 495 405 305 ....

High 1465 1400 1325 1250 1175 1085 980 860 725 560

Med - High 1295 1260 1210 1155 1090 1015 930 830 700 545

Medium 1150 1120 1085 1040 985 920 835 740 620 510

Med - Low 1030 1010 980 945 895 835 765 685 570 345

Low 860 835 810 780 745 700 635 555 445 260

High 1140 1105 1055 1010 955 885 815 715 545 390

Med - High 915 885 855 825 785 725 655 530 420 280

Med - Low 795 770 740 700 655 600 510 420 325 - -

Low 690 665 630 590 550 475 415 340 245 - -

High 1440 1400 1355 1300 1240 1170 1090 1000 890 745

Med - High 1180 1165 1150 1125 1085 1030 970 890 785 645

Medium 1015 1020 1010 990 965 925 875 800 700 560

Med - Low 885 885 880 865 845 815 770 700 605 475

Low 695 700 700 690 670 640 600 540 460 345

High 1840 1790 1730 1670 1605 1530 1450 1370 1275 1170

Med - High 1610 1575 1535 1485 1435 1370 1305 1230 1145 1055

Medium 1460 1430 1400 1360 1315 1260 1205 1130 1055 965

Med - Low 1260 1240 1215 1180 1145 110 1040 985 915 835

Low 1065 1040 1015 985 955 915 875 825 765 695

High 1650 1600 1535 1465 1385 1285 1175 1055 895 645

Med - High 1515 1485 1440 1380 1300 1220 1115 990 830 600

Med - Low 1385 1360 1320 1260 1195 1120 1025 915 710 565

Low 1205 1180 1160 1120 1065 1005 925 810 630 510

High 1710 1695 1665 1585 1480 1390 1245 1110 955 775

Med - High 1470 1475 1450 1390 1335 1230 1120 1005 855 690

Med - Low

Low

High 2380 2295 2205 2105 2005 1900 1775 1650 1510 1335

Med - High 2185 2115 2045 1960 1875 1770 1655 1535 1400 1240

Medium 1905 1865 1815 1740 1670 1590 1490 1390 1245 1110

Med - Low 1595 1565 1530 1485 1430 1355 1275 1160 1055 920

Low 1340 1310 1280 1225 1170 1120 1040 955 850 750

High 2485 2415 2330 2230 2135 2030 1920 1790 1645 1485

Med- High 2175 2130 2070 2000 1930 1840 1740 1620 1495 1345

Medium 1845 1815 1770 1720 1655 1580 1500 1395 1270 1090

Med - Low 1540 1515 1475 1435 1385 1335 1270 1175 1045 915

Low 1280 1250 1220 1190 115 1105 1035 945 845 745

High 2420 2345 2265 2165 2070 1960 1850 1720 1570 1420

Med - High 2160 2110 2045 1960 1885 1790 1695 1570 1445 1305

Medium 1850 1815 1765 1710 1635 1560 1480 1380 1250 1110

Med - Low 1530 1490 1455 1420 1375 1320 1250 1160 1055 905

Low 1290 1250 1220 1190 115 1110 1040 950 835 740

High 1625 1575 1515 1445 1355 1260 1165 990 785 595

Med - High 1510 1470 1415 1355 1285 1185 1070 890 725 530

Med - Low 1360 1335 1295 1250 1180 11 O0 985 810 670 475

Low 1195 1180 1155 1115 1065 980 860 740 605 410

High 2055 1990 1910 1815 1695 1575 1425 1230 1090 910

Med - High 1750 1725 1670 1605 1515 1400 1255 1120 975 785

Medium 1545 1525 1490 1445 1355 1260 1135 1020 880 750

Med - Low 1300 1290 1275 1235 1165 1085 1005 895 750 620

Low 1050 1045 1015 975 935 880 815 715 610 515

High 2530 2460 2380 2285 2200 2085 1970 1835 1695 1545

Med-High 2225 2190 2135 2075 1995 1910 1805 1695 1565 1430

Medium 1895 1885 1865 1820 1770 1700 1610 1520 1410 1290

Med - Low 1565 1555 1535 1505 1465 1410 1350 1265 1175 1050

Low 1320 1295 1265 1235 1205 1160 1105 1035 950 870

High .... 2415 2330 2235 2125 1995 1860 1735 1605

Med- High 2205 2175 2120 2065 1975 1900 1790 1685 1580 1460

High 2485 2430 2360 2270 2175 2070 1950 1825 1685 1535

Med-High 2155 2135 2100 2040 1970 1885 1790 1680 1560 1420

Medium 1830 1830 1810 1780 1730 1665 1595 1505 1395 1275

Med - Low 1520 1505 1490 1470 1430 1385 1330 1250 1165 1055

Low 1275 1260 1240 1210 1180 1135 1090 1025 930 840

0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0

2060 2000 1930 1835 1755 1620 1490 1315 1115 910

1260 1365 1245 1225 1165 1090 995 880 750 600 1030 1025 1020 990 940 890 810 720 615 500

EXTERNAL STATIC PRESSURE (IN. W.C.)

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

FURNACE RETURN-AIR EXTERNAL STATIC PRESSURE (IN. W.C.)

SIZE INLET 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0

Bottom High 2090 2010 1930 1835 1710 1590 1470 1335 1025 835

135-16/ or Med-High 1790 1755 1705 1640 1550 1465 1360 1210 945 785

048135 Med - Low 1545 1525 1500 1450 1380 1315 1215 1005 855 670

135-22/ or Med-High 2180 2145 2060 2010 1945 1865 1765 1660 1515 1325

066135 Med - Low 1880 1850 1820 1780 1715 1635 1540 1415 1290 1160

155- 20/

060155 .... 2375 2285 2200 2105 1995 1870 1730 1570

-- Indicates unstable operating conditions.

Downflow Furnaces

Connect supply-air duct to supply-air outlet on furnace. Bend flange inward past 90 ° with wide duct pliers. (See Fig. 14.) The

supply-air duct must be connected to ONLY the furnace supplyoutlet or air conditioning coil casing (when used). When

installed on combustible material, supply-air duct must be connected to ONLY the factory-approved accessory subbase, or

a factory approved air conditioning coil casing. DO NOT cut main furnace casing to attach supply side air duct, humidifier, or

other accessories. All accessories MUST be connected to duct external to furnace casing.

Return Air Connections

Side(s) Low 1325 1320 1295 1265 1210 1150 995 865 745 540

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

Only Med - Low 1880 1850 1820 1780 1715 1635 1540 1415 1290 1160

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

1 Side & Bottom

1 Side Only Med-High 2125 2065 1995 1910 1815 1710 1610 1490 1340 1175

Bottom Only

BothSides Or I

Side& Bottom

1 Side Only 2140 2095 2040 1975 1890 1810 1705 1595 1480 1325

SPEED

High 2485 2400 2310 2215 2110 2000 1880 1725 1535 1355

Low 1640 1635 1615 1585 1530 1465 1370 1255 1150 1040

High 2320 2250 2155 2055 1970 1855 1725 1600 1450 1280

Med - Low

Low

High

Med-High

Med - Low

Low

High

Med-High

High

Med-High

1845 1825 1765 1710 1650 1570 1475 1370 1240 11 O0 1640 1620 1580 1540 1485 1410 1330 1220 1080 960

2465 2430 2375 2305 2230 2110 2000 1865 1725 2115 2105 2075 2030 1980 1910 1830 1725 1590 1425 1800 1790 1770 1735 1695 1640 1570 1465 1345 1225 1570 1565 1550 1525 1495 1445 1370 1270 1175 1070

2155 2135 2095 2040 1975 1895 1790 1685 1550 1400

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

GAS PIPING

FIRE OR EXPLOSION HAZARD

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

Never purge a gas line into a combustion chamber. Never test for gas leaks with an open flame. Use a commercially

available soap solution made specifically for the detection

of leaks to check all connections.

1545

FIRE HAZARD

Failure to follow this warning could cause personal injury, death and/or property damage.

Never connect return-air ducts to the back of the furnace. Follow instructions below.

Downflow Furnaces

The return-air duct must be connected to return-air opening (bottom inlet) as shown in Fig. 1. DO NOT cut into casing sides (left or right). Side opening is permitted for only upflow and most

horizontal furnaces. Bypass humidifier connections should be made at ductwork or coil casing sides exterior to furnace. (See

Fig. 19.)

Upflow and Horizontal Furnaces

The return-air duct must be connected to bottom, sides (left or right), or a combination of bottom and side(s) of main furnace casing as shown in Fig. 1. Bypass humidifier may be attached

into unused return air side of the furnace casing. (See Fig. 18 and

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

FIRE OR EXPLOSION HAZARD Failure to follow this warning could result in personal

iniury, death, and/or property damage. Use proper length of pipe to avoid stress on gas control

manifold and a gas leak.

FIRE OR EXPLOSION HAZARD Failure to protect gas valve inlet from water and debris

could result in death, personal iniury and/or property damage.

Gas valve inlet and/or inlet pipe must remain capped until gas supply line is permanently installed to protect the valve from moisture and debris. Also, install a sediment trap in the gas supply piping at the inlet to the gas valve.

UPFLOW RETURN AIR CONFIGURATIONS AND RESTRICTIONS

AIR FLOW MODELS RETURN AIR RETURN AIR RETURN AIR RETURN AIR |

066.060,-22AND YES YES YES YES |

-20 MODELS ALLOTHERMODELS YES YES YES YES

CONNECTION 1 CONNECTION 2 CONNECTION 3 COMBINATIONS

1ONLY ONLY ON_ OF1,2, AND 3

]

Fig. 18 - Upflow Return Air Configurations and Restrictions

DOWNFLOWRETLJRNAIRCONFIGURATIONSANDRESTRICTIONS

AIR FLOW MODELS RETURN AIR RETURN AmR RETURN AIR RETURN AIR

066.066, -22 AND YES NO NO NO

-20 MODELS ALL OTHER MODELS YES NO NO NO

Fig. 19 - Downflow Return Air Configurations and Restrictions

RE]URN

AIR

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

A02075

A02163

A RFLOWMODELS

AIR

RETURN /

.............INOTPERMITTEDFOR

AIR FLOWMODELS

.........................////_L_ ......................... HORIZONAL

HORIZONALNO]E;RESIRICHONLEFTSAMEFOR _ AIR RESTRICTIONS

Fig. 20 - Horizontal Return Air Configurations and Restrictions

RETURN RETURNAIR

',% / HORIZONTAL RETURN AIR CONFIGURATIONS AND RESTRICTIONS

AIR FLOW MODELS RETURN AIR RETURN AiR RETURN AIR RETURN AIR

066.060, -22 AND YES NO NO NO

-20 MODELS ALL OTHER MODELS YES YES YES YES

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

A02162

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

Table 6 - Maximum Capacity of Pipe

NOMINAL

IRON PIPE

SIZE

IN. (MM)

1/2 (12.7)

3/4 (19.0)

1 (25.4)

1-1/4

(31.8)

1-1/2

(38.1)

Cubic ft. of natural gas per hr for gas pressures of 0.5 psig (14-In. W.C.)

or less and a pressure drop of 0.5-In. W.C. (based on a 0.60 specific gravity gas). Ref: Table 6 and NFPA54/ANSI Z223.1-2012.

INTERNAL LENGTH OF PIPE - FT.(M)

DIA.

IN. (MM) (3.0) (6.0) (9.1) (12.1) (15.2)

0.622 (158) 175 120 97 82 73

0.824

(20.9) 360 250 200 170 151

1.049

(26.6) 680 465 375 320 285

1.380

(35.0) 1400 950 770 660 580

1.610

(40.9) 2100 1460 1180 990 900

10 20 30 40 50

Installations nmst be made in accordance with all authorities having jurisdiction. If possible, the gas supply line should be a

separate line running directly from meter to furnace. NOTE: In the state of Massachusetts:

1. Gas supply connections MUST be performed by a li- censed plumber or gas fitter.

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

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

4. The use of copper tubing for gas piping is NOT approved by the state of Massachusetts.

Refer to Table 6 for recommended gas pipe sizing. Risers nmst be used to connect to furnace and to meter. Support all gas piping with appropriate straps, hangers, etc. Use a minimum of 1 hanger

every 6 ft. (1.8 M). Joint compound (pipe dope) should be applied sparingly and only to male threads of joints. Pipe dope

must be resistant to the action of propane gas.

FIRE OR EXPLOSION HAZARD

Failure to follow this warning could result in personal iniury, 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 furnace

gas control valve and extend a n_ininmm of 2 in. (51 ram) outside the furnace.

An accessible manual equipment shutoff valve MUST be installed external to furnace casing and within 6 ft. of furnace. A l/8-in. (3 ram) NPT plugged tapping, accessible for test gauge

connection, MUST be installed immediately upstream of gas supply connection to furnace and downstream of manual equipment shutoff valve.

NOTE: The furnace gas control valve inlet pressure tap connection is suitable to use as test gauge connection providing

test pressure DOES NOT exceed maximum 0.5 psig (14-In. W.C.) stated on gas control valve. (See Fig. 48.) Some

installations require gas entry on right side of furnace (as viewed in upflow). (See Fig. 21.)

TOP VIEW OF BURNER AND MANIFOLD ASSEMBLY

90 ° Elbow

Supply g

2"(51mm) Nipple

Street Elbow

L Gas Valve

A08551

Fig. 21 - Burner and Manifold

Install a sediment trap in riser leading to furnace as shown in Fig.

22. 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 manifold and

exterior manual equipment gas shutoff valve.

GAS SUPPLY /_

MANUAL _/ II SHUTOFF _ _

VALVE

(REQUI RED)j_'_,

SEDIMENT-- [

TRAP /

UNION .--,r

A02035

Fig. 22 - Typical Gas Pipe Arrangement

FURNACE DAMAGE HAZARD Failure to follow this caution may result in furnace damage.

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

NOTE2

115-VOLT FIELD-

SUPPLIED

FUSED

DISCONNECT

A 1/8-in. (3 ram) NPT plugged tapping, accessible for test gauge connection, MUST be installed immediately upstream of gas

supply connection to furnace and downstream of manual equipment shutoff valve.

Piping should be pressure and leak tested in accordance with NFGC in the United States, local, and national plumbing and gas

codes before the furnace has been connected. After all connections have been made, purge lines and check for leakage at

furnace prior to operating furnace. If pressure exceeds 0.5 psig (14-In. W.C.), gas supply pipe nmst

be disconnected from furnace and capped before and during supply pipe pressure test. If test pressure is equal to or less than

0.5 psig (14-In. W.C.), turn off electric shutoff switch located on furnace gas control valve and accessible manual equipment shutoff valve before and during supply pipe pressure test. After

all connections have been made, purge lines and check for leakage at furnace prior to operating furnace.

The gas supply pressure shall be within the maximum and minimum inlet supply pressures marked on the rating plate with

the furnace burners ON and OFF. ELECTRICAL CONNECTIONS

ELECTRICAL SHOCK HAZARD

Failure to follow this warning could result in personal iniury 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. 23 for field wiring diagram showing typical field 115-v wiring. Check all factory and field electrical connections for

tightness. Field-supplied wiring shall conform with the linfitations of 63 °F

(33 ° C) rise.

JUNCTION BOX @

CONTROL

BOX @

24-VOLT

TERMINAL

BLOCK

FURNACE

NOTES: 1. Connect Y/Y2-terminal as shown for proper operation.

Fig. 23 - Field Wiring Diagram

.... FIELD 24-VOLT WIRING

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

-- FACTORY 24-VOLT WIRING FACTORY 115-VOLT WIRING

FIELD-SUPPLIED

FUSED DISCONNECT

208/230- OR

460-VOLT

PHASE

=-__---1208/230-

= _.L_rT-r-L__ __LVO LT

r _ - -I (SINGLE

--_---_.--.._--- JPHASE

I -GNDI

CONDENSING

UNIT

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

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

ELECTRICAL SHOCK AND FIRE HAZARD Failure to follow this warning could result in personal

iniury, death, or property damage. The cabinet MUST have an uninterrupted or unbroken

ground according to NEC ANSI/NFPA 70-2008 or local codes to nfininfize personal iniury if an electrical fault should occur. This may consist of electrical wire, conduit

approved for electrical ground or a listed, grounded power

cord (where pernfitted by local code) when installed in

accordance with existing electrical codes. Refer to the power cord manufacturer's ratings for proper wire gauge. Do not use gas piping as an electrical ground.

FURNACE MAY NOT OPERATE HAZARD

Failure to follow this caution may result in internfittent

furnace operation,

Furnace control must be grounded for proper operation or

else control will lock out. Control nmst remain grounded

through green/yellow wire routed to gas valve and manifold

bracket screw,

l15-V WIRING Verify that the voltage, frequency, and phase correspond to that

specified on unit rating plate. Also, check to be sure that service provided by utility is sufficient to handle load imposed by this

equipment. Refer to rating plate or Table 7 for equipment electrical specifications.

A95236

Table7 - Electrical Data

FURNACE

SIZE

045- 08/024045 115- 60-1 5.3 7.42 14 045-12/036045 115-60-1 7.1 9.67 14

070- 08/024070 115- 60-1 5.2 7.22 14 070-12/036070 115- 60-1 7.3 9.90 14 070-16/048070 115-60-1 10.1 13.42 14 090-14/042090 115- 60-1 8.2 10.84 14 090-16/048090 115- 60-1 9.9 13.0 14 090-20/060090 115-60-1 12.9 16.70 12 110-12/036110 115-60-1 8.2 10.76 14 110-16/048110 115-60-1 10.1 13.19 14 110-22/066110 115-60-1 13.7 17.60 12 135-16/048135 115-60-1 10.2 13.28 14 135-22/066135 115-60-1 14.5 18.61 12 155-20/060155 115-60-1 15.0 19.34 12

Permissible limits of the voltage range at which the unit operates satisfactorily. # Unit ampacity = 125% of largest operating component's full load amps plus 100% of all other potential operating components (EAC, humidifier, etc.) full load amps. t Time-delay type isrecommended. $ Length shown is as measured 1 way along wire path between unit and service panel for maximum 2% voltage drop.

VOLTS-

HERTZ-

PHASE

U.S. Installations: Make all electrical connections in accordance with National Electrical Code (NEC) ANSI/NFPA 70-2008 and

OPERATING VOLTAGE

RANGE

MAX* MIN.*

127 104 127 104 127 104 127 104 127 104 127 104 127 104 127 104

127 104 127 104 127 104 127 104 127 104 127 104

MAX

UNIT

AMPS

UNIT

AMPACITY#

5. Route J-Box wires within furnace away from sharp edges, rotating parts, and hot surfaces.

MAXIMUM

WIRE

LENGTH

FT. (M):I:

49 (14.9)

38(11.5) 51(15.5)

37 (11.2)

27 (8.2)

34 (10.3)

28 (8.5) 34 (10.3) 34 (10.3)

28 (8.5)

32 (9.7)

27 (8.2)

30(9.1)

29 (8.8)

MAXIMUM

FUSE OR

CKT BKR

AMPSI

15 15 15 15 15 15 15 2O

15 15 2O 15 2O 2O

any local codes or ordinances that might apply.

Factol Ins

MINIMUM

WIRE

GAUGE

FIRE HAZARD

Failure to follow this warning could result in personal injury, death, or property damage.

Do not connect aluminum wire between disconnect switch

and furnace. Use only copper wire.

Use a separate branch electrical circuit with a properly sized fuse or circuit breaker for this furnace. See Table 7 for wire size and

fuse specifications. A readily accessible means of electrical disconnect must be located within sight of the furnace.

NOTE: Proper polarity must be maintained for 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. 24 .)

NOTE: The J-Box cover need not be removed from the J-Box in order to move the J-Box. Do NOT remove green ground

screw inside J-Box.

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 the two screws removed in Step 1.

A10291

Fig. 24 - Relocating J-Box

ELECTRICAL CONNECTION TO J-BOX

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

cover and bracket.

Electrical Box on Furnace Casing Side. See Fig. 25.

FIRE OR ELECTRICAL SHOCK HAZARD

Failure to follow this warning could result in personal injury, death, or property damage.

If field-supplied manual disconnect switch is to be mounted on furnace casing side, select a location where a drill or fastener cannot damage electrical or gas components.

Fig. 25 - Field-Supplied Electrical Box on Furnace Casing

A10141

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 posi- tion the hole in the electrical box over the hole in the fur-

nace 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.

24.)

5. Pull furnace power wires out of 1/2-inch (12 mm) diamet- er hole in J-Box. Do not loosen wires from strain-relief

wire-tie on outside of J-Box.

6. Route furnace power wires through holes in casing and electrical box and into electrical box.

7. Pull field power wires into electrical box.

8. Remove cover from furnace J-Box.

9. Route field ground wire through holes in electrical box and casing, and into furnace J-Box.

10. Reattach furnace J-Box to furnace casing with screws 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. 23. Use best practices

(NEC in U.S. for wire bushings, strain relief, etc.

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

POWER CORD INSTALLATION IN FURNACE J-BOX NOTE: Power cords must be able to handle the electrical

requirements listed in Table 7. Refer to power cord manufacturer's listings.

1. Remove cover from J-Box.

2. Route listed power cord through 7/8-inch (22 mm) dia- meter hole in J-Box.

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

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

5. Connect line voltage leads as shown in Fig. 23.

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 7/8-inch (22 mm) diameter hole in J-Box.

3. Secure BX cable to J-Box bracket with connectors ap- proved for the type of cable used.

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

5. Connect line voltage leads as shown in Fig. 23.

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.

33.) Connect terminal Y/Y2 as shown in Fig. 26-32 for proper cooling operation. Use only AWG No. 18, color-coded, copper

thermostat wire. The 24-v circuit contains an automotive-type, 3-amp. fuse

located on the control. Any direct shorts during installation, service, or maintenance could cause this fuse to blow. If fuse

replacement is required, use ONLY a 3-amp. fuse of identical size.

THERMIDISTAT TWO-STAGE TWO-SPEED THERMIDISTAT TWO-STAGE TWO-SPEED

FURNACE AIR CONDITIONER FURNACE HEAT PUMP

HEAT STAGE 2

COOL STAGE I

HEAT STAGE 1

COOL STAGE 2

FAN [_

24 VAC HOT [_

DEHUMIDIFY [_

24 VAC COMM [_

HUMIDIFY

N/A [_

CONNECT,ON

NOTE 11

NOTE 12

I HUM "'"-

_ HUMIDIFIER

(24 VAC)

OUTDOOR

SENSOR

See notes 2, 5, 8, 10, 11 and 12 on the page following these figures

Fig. 26 - Two-Stage Furnace with Two-Speed Air

Conditioner

THERMIDISTAT TWO-STAGE SINGLE-SPEED

FURNACE HEAT PUMP

A03179

RVSCOOLING_

F_7

HEAT/COOL STAGE 1

(COMPRESSOR LO)

"EA_pSuTAGcEE_ IW_ _"

HEA:_%O%E%Z%IFm]

FAN r_7

24 rAG HOT _7

DEHUMiDiFY r_

24 rAG COMM _7

HUMIDIFY

N/A I_

............. r_{7 ........

___EosE_L2.... _ ........

I HUM "'"-. ......

,_T_:__[_

,_h--E__[_

I:L]OUTDOOR_S_,

........ / SENSOR [_ [[

CONNECT,ON

See notes 1, 2, 3, 4, 6, 8, 9, 10, 12, 13 and 15 on the page folow[ng these figures

Fig. 28 - Two-Stage Furnace with Two-Speed Heat Pump

(Dual Fuel)

DUAL FUEL TWO-STAGE SINGLE-SPEED

THERMOSTAT FURNACE HEAT PUMP

A03178

RVS COOLING E_J r

HEATSTAGE3r_ _

(FURNACEHI)

___EO_T_E_2)....

F_q

HEAT STAGE 2

(FURNACE LO)

HEAT/CcOoCLpSTAsGoERI ) [_

FAN

24 VAC HOT

DEHUMIDIFY [_

24 VAC COMM _-

HUMIDIFY [_

N/A [_

I HUM "'-. ......

........ #-:

-<--IB

........%

CONNECT,ON

Fig. 27 - Two-Stage Furnace with Single-Speed Heat Pump

See notes 1,2, 4, 6, 7, 9, 10, 11, and 15 on the page folowing these figures

(Dual Fuel)

A03180

RVS COOLING[__

HEATSTAGE3r_ _ -

(PURNACEHI)

HEAT STAGE 2rw _ _

(FURNACELO)

HEAT/COOL STAGE 1 [_1 r _

(COMPRESSOR)_

FAN[__

24VACHOT[__

24 VAC COMM [__

N/A [_

RVS SENSING [_

-<_-D

OsUT_sOO_-I:Z_-

CONNECT,ONLI2_"

See notes 1, 2, 4, 11,14,15, and 16 on the page following these figures

Fig. 29 - Dual Fuel Thermostat with Two-Stage Furnace

and Single-Speed Heat Pump

A03181

DUAL FUEL TWO-STAGE TWO-SPEED TWO-STAGE TWO-STAGE TWO-SPEED

THERMOSTAT FURNACE HEAT PUMP THERMOSTAT FURNACE AIR CONDITIONER

RVS COOLING

H EA(Tc/CMOpORLSsTo#RGLEo1)

HEA_FSTAGEE3 I_

HEAT/COOL STAGE 2

(COMPRESSOR HI)

FAN

24 VAC HOT [_

24 VAC COMM [_

N/A I_

RVS SENSING I_

___._O_T_E_j _2___

-[_ ............

HUM

OUTOOOR

°S E s%R ........

CONNECT,ONLl q

See notes 1, 2, 3, 4, 12, 13, 14, 15, and 17 on the page following these figures

Fig. 30 - Dual Fuel Thermostat with Two-Stage Furnace

and Two-Speed Heat Pump

SENSOR _ II

SINGLE-STAGE TWO-STAGE

THERMOSTAT FURNACE

A03182

-I_r ---

-I Jq

NOTE 11

E23- [!3-

NOTE 12

-F¥7_ --

-I-q

EB-

B HUM

See notes 2, 11, and 12 on the page following these figures

Fig. 31 - Two-Stage Thermostat with Two-Stage Furnace

and Two-Speed Air Conditioner

TWO-SPEED

AIR CONDITIONER

A03183

-I q

-I_r ---

HUM

See notes 1 and 2 on the page following these figures

Fig. 32 - Single-Stage Thermostat with Two-Stage Furnace and Two-Speed Air Conditioner

FOR FIGURES 26-32

1. Heat pump MUST have a high pressure switch for dual fuel applications.

2. Refer to outdoor equipment Installation Instructions for additional information 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 for air conditioner installations. This is factory default.

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

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

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

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

9. NO connection should be made to the furnace HUM terminal when using a Thermidistat.

10. Optional connection: If wire is connected, dip switch SW1-2 on furnace control should be set in ON position to allow Thermidistat/Thermostat to control furnace staging,

11. Optional connection: If wire is connected, ACRDJ jumper on furnace control should be removed to allow Thermidistat/Thermostat to control outdoor unit

staging,

12. When using both a two-stage furnace and a two-stage heat pump, the furnace must control its own high-stage heating operation via furnace control

algorithm.

13. The RVS Sensing terminal "E' should not be connected. This is internally used to sense defrost operation.

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

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

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

A03184

ACCESSORIES

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

ing 1/4-in female quick connect terminals to the two male 1/4-in quick-connect terminals on the control board

marked EAC-1 and EAC-2. The terminals are rated for 115VAC, 1.0 amps maximum and are energized during

blower motor operation. (See Fig. 33.)

2. Humidifier (HUM) Connect an accessory 24 VAC, 0.5 amp. maximum hu-

midifier (if used) to the 1/4-in male quick-connect HUM terminal and COM-24V screw terminal on the control

board thermostat strip. The HUM terminal is energized when gas valve relay (GVR) is energized. (See Fig. 33.)

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

SETUP SWITCHES

LOW-HEAT ONLY AND

BLOWER OFF-DELAY

TWINNING AND/OR COMPONENT TEST

TERMINAL

r =_ _oo

NOTE: DO NOT connect furnace control HUM terminal to HUM (humidifier) terminal on Thermidistat, Zone Controller or

similar device. See Thermidistat'_, Zone Controller, thermostat, or controller manufacturer's instructions for proper connection.

VENTING The furnace shall be connected to a listed factory built chimney

or vent or a clay-tile lined masonry or concrete chimney. Venting into an unlined masonry chimney or concrete chimney is

prohibited. When an existing Category I furnace is removed or replaced, the original venting system may no longer be sized to

properly vent the attached appliances. An improperly sized Category I venting system could cause the formation of condensate in the furnace and vent, leakage of condensate and

combustion products, and spillage of combustion products into the living space.

ACRDJ - AIR CONDITIONING

_ RELAY DISABLE JUMPER

24-V-THERMOSTAT

TERMINALS

':O I V_) I TEST/TWIN >

HUMIDIFIER TERMINAL

(24-VAC 0.5 AMP MAX.)

3-AMP FUSE

LED OPERATION &

DIAGNOSTIC LIGHT

115-VAC (L2) NEUTRAL _

CONNECTIONS Bi"i°R B,WR

I HEAT -- _ _ _ = -_

:,b Dr1I1

TRANSFORMER 24-VAC

CONNECTIONS

PL1 - LOW VOLTAGE MAIN

HARNESS CONNECTOR

PL3

(X LO HEAT, _j_ coo=_L_jt1.AMpg_lSVAO==IX - g=s

11_-VAC/utUNE PLY-HOTSURFACE

BLOWERSPEED_',SPARE-_COOL\VOLTAGECONNECTIONIGNITERSINDUCER

SELECTION_-_<ALS_ _ \ MOTORCONNECTOR

/EAC-_ TERMINAL

_ (115-VAC 1.0 AMP MAX.)

Fig. 33 - Furnace Control-PSC Blower Motor

A02017

CARBONMONOXIDEPOISONINGHAZARD

Failureto follow the steps outlined below for each

appliance connected to the venting system being placed into

operation could result in carbon monoxide poisoning or death. The following steps shall be followed for each

appliance connected to the venting system being placed into

operation, while all other appliances connected to the venting system are not in operation:

1. Seal any unused openings in venting system.

2. Inspect the venting system for proper size and horizontal pitch, as required in the National Fuel Gas

Code, ANSI Z223.1/NFPA 54 and these instructions. Determine that there is no blockage or

restriction, leakage, corrosion and other deficiencies,

which could cause an unsafe condition.

3. As far as practical, close all building doors and

windows and all doors between the space in which

the appliance(s) connected to the venting system are located and other spaces of the building.

4. Close fireplace dampers.

5. Turn on clothes dryers and any appliance not connected to the venting system. Turn on any

exhaust fans, such as range hoods and bathroom exhausts, so they are operating at maximum speed.

Do not operate a summer exhaust fan.

6. Follow the lighting instructions. Place the appliance being inspected into operation. Adjust the thermostat

so appliance is operating continuously.

7. Test for spillage from draft hood equipped appliances at the draft hood relief opening after 5

minutes of main burner operation. Use the flame of a match or candle.

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

accordance with the National Fuel Gas Code, ANSI Z223.1/NFPA 54.

9. After it has been determined that each appliance connected to the venting system properly vents when

tested as outlined above, return doors, windows, exhaust fans, fireplace dampers and any other

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

Vent system or vent connectors may need to be resized. Vent systems or vent connectors must be sized to approach minimum

size as determined using appropriate table found in the NFGC. GENERAL VENTING REQUIREMENTS Follow all safety codes for proper vent sizing and installation

requirements, including local building codes, the National Fuel Gas Code ANSI Z223.1-2012/NFPA 54-2012 (NFGC), Parts 12

and 13 in the United States, the local building codes, and furnace and vent manufacturers' instructions.

These furnaces are design-certified as Category I furnaces in accordance with ANSI Z21.47-2012/CSA 2.3-2012 and operate

with a non-positive vent static pressure to minimize the potential for vent gas leakage. Category I furnaces operate with a flue loss

not less than 17% to minimize the potential for condensation in the venting system. These furnaces are approved for common

venting and multi-story venting with other fan assisted or draft

hood equipped appliances in accordance with the NFCG, local building codes, and furnace and vent manufacturers' instructions.

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

CARBON MONOXIDE POISONING HAZARD

Failure to follow this warning could result in personal iniury or death.

Do not bypass the draft safeguard switch, as an unsafe condition could exist which must be corrected.

1. If a vent (common or dedicated) becomes blocked, the fur- nace will be shut off by the draft safeguard switch located

on the vent elbow.

2. Two-stage furnaces require Type B vent connectors out- side the casing in all configurations. Single wall vent con-

nector may be used inside the furnace casing with the transition to Type B vent outside the furnace casing. Size the connector so that the FAN-Min vent connector capa-

city is equal to or lower than the low fire rate of the fur- nace and the FAN-Max vent connector capacity is equal

to or higher than the furnace high fire rate.

3. Do not vent this Category I furnace into a single wall ded- icated or common vent. The dedicated or common vent is

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

4. Vent connectors serving Category I furnaces shall not be connected into any portion of a mechanical draft system

operating under positive pressure.

5. Do not vent this appliance with any solid fuel burning ap- pliance.

6. Category I furnaces must be vented vertically or nearly vertically unless equipped with a listed mechanical venter. See the SIDEWALL VENTING section.

7. Do not vent this appliance into an unlined masonry china- ney. Refer to Chimney Inspection Chart, Fig. 34.

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

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

If a clay tile-lined masonry chimney is being used and it is exposed to the outdoors below the roof line, relining might be

required. Chimneys shall conform to the Standard for Chimneys, Fireplaces, Vents, and Solid Fuel Burning Appliances ANSI/NFPA 211-2012 in the United States and must be in good

condition. U.S.A.-Refer to Sections 13.1.8 and 13.2.20 of the NFPA 54 /

ANSI Z223.1-2012 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 NFPA 54 / ANSI Z223.1-2012, 13.1.8 and

13.2.20 regarding alternative venting design and the exception, which cover installations such as the Chimney Adapter Kits

which are listed for use with these furnaces. See Product Data Sheet for accessory listing.

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

Rebuild

crown.

Is chimney No

property lined with

clay tile liner?

Yes

IS liner and top seal in good

condition?

N_ Reline

Clay

tile misalignment,

missing sections,

gaps?

Condensate

drainage at bottom

of chimney?

Chimney

exposed to

outdoors below

roof line?

Remove mortar

and tile debris

_'es

_Suitable h

/[_No "'_ instructions for / _ _ "

/ _ _ application /

/_,_ ,,,_÷h_,_,, _ V_ .... Line chimney with property

__'_. _'_ I bUlIaD,e sized, listed flexible metal

-._,L_u, ._ ..... ._' _'/Yes t liner orTyp_ B vent per

"_ype-_ venv/ _lr NFGC Vent

/ Iq r.himn_/ _ r,l_ / Part C of

__himney adapter ventin_e

" _ asinale / I I " _ instructions for / I

._s _ furnace? / I t _ application / [

/ _ Sizing Table. _ and liner or

_i[ a_rP_c_rioPner........ Installahon,

1Yes = ".............. . Nor _uJraDle

bultable

a ey i

'n_'o_n_ mn eY vent manL

a pe pe i

Install chimney

adapter per instructions.

Chimney is

acceptable for use.

A10133

Fig. 34 - Chimney Inspection Chart

The Chinmey Adapter Kit is a listed alternative venting system for these furnaces. See the kit instructions for complete details.

This furnace is pernfitted to be vented into a clay tile-lined masonry chinmey that is exposed to the outdoors below the roof

line, provided:

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

2. This furnace is common vented with at least 1 draft hood- equipped appliance, and

3. The combined appliance input rating is less than the max- imum capacity given in Table 8, and

4. The input rating of each space heating appliance is greater than the minimum input rating given in Table 9 for the local 99% Winter Design Temperature. Chinmeys having

internal areas greater than 38 in2 (24516 mm2)require fur- nace input ratings greater than the input ratings of these

furnaces. See footnote at bottom of Table 9, 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 chinmey adapter kit with a

furnace listed for use with the kit, alisted chinmey-lining system, or a Type-B common vent.

Inspections before the sale and at the time of installation will deternfine the acceptability of the chinmey or the need for repair

and/or (re)lining. Refer to Fig. 34 to perform a chinmey inspection. If the inspection of a previously used tile-lined

chinmey:

a. Shows signs of vent gas condensation, the chinmey

should be relined in accordance with local codes and the authority having jurisdiction. The chinmey should be re-

lined with a listed metal liner, Type-B vent, or a listed chinmey adapter kit shall be used to reduce condensation.

If a condensate drain is required by local code, refer to the NFPA 54 /ANSI Z223.1-2012, Section 12.10 for ad-

ditional information on condensate drains.

b. Indicates the chinmey exceeds the maximum pernfissible

size in the tables, the chinmey should be rebuilt or relined to conform to the requirements of the equipment being

installed and the authority having jurisdiction.

A chinmey without a clay tile liner, which is otherwise in good condition, shall be rebuilt to conform to ANSI/NFPA 211 or be

lined with a UL listed 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 chinmey, no other

appliance shall be vented into the annular space between the chinmey and the metal liner.

Exterior Masonry Chimney FAN + NAT

Installations with Type-B Double-Wall Vent

Connectors ©NFPA & AGA

Table 8 - Combined Appliance Maximum Input Rating in

Thousands of BTUH per Hour

INTERNAL AREA OF CHIMNEY

VENT HEIGHT

FT. (M)

5 (1.8)

8 (2.4)

10 (6.)

15 (4.5)

20 (6.0)

30 (9.1)

12 19 28 38

(7741) (12258) (18084) (24518)

74 119 178 257 80 130 193 279

84 168 207 299 N R 152 233 334 N R N R 250 668

NR NR NR 404

SO. IN. (SO. MM)

Table 9 - Minimum Allowable Input Rating of Space-Heat-

ing Appliance in Thousands of BTUH per Hour

INTERNAL AREA OF CHIMNEY

VENT HEIGHT

(FT)

Temperature: 17 to 28°F (-8 to -3°C)

6 (1.8) 0 55 99 141 8 (2.4) 52 74 111 154

10 (6.0) NR 90 125 169 15 (4.6) NR NR 167 212

20 (6.1) NR NR 212 258 30 (9.1) NR NR NR 362

Temperature: 5 to 18°F * (-15 to -9°C)

6 (1.8) NR 78 121 166 8 (2.4) NR 94 165 182

10 (6.0) NR 111 149 198 15 (4.6) NR NR 196 247

20 (6.1) NR NR NR 293 30 (9.1) NR NR NR 377

Temperature: -10 to 4°F * (-23 to -18°C)

6 (1.8) NR NR 145 196 8 (2.4) NR NR 159 216

10 (6.0) NR NR 175 261 15 (4.6) NR NR NR 286

20 (6.1) NR NR NR 333 30 (9.1) NR NR NR NR

Temperature: -11 °F (-24°C) or lower

Not recommended for any vent configuration.

*The 99.6% heating db temperatures found in the 1997 or 2001 ASHRAE Fundamentals Handbook, Climatic Design Information chapter, Table 1A (United States) or the 2005 ASHRAE Fundamentals handbook, Climatic Design Information chapter, and the CD-ROM included with the 2005

ASHRAE Fundamentals Handbook.

12 19 28 38

(7741) (12258) (18084) (24518)

Local 99% Winter Design

SQ. IN. (SQ. aM)

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

of the venting system. If the appliances are sized, installed, adjusted, and operated properly, the venting system and/or the appliances should not suffer from condensation and corrosion.

The venting system and all appliances shall be installed in accordance with applicable listings, standards, and codes.

The furnace should be sized to provide 100% of the design heating load requirement plus any margin that occurs because of

furnace model size capacity increments. Heating load estimates can be made using approved methods available from Air

Conditioning Contractors of America (Manual J); American Society of Heating, Refrigerating, and Air-Conditioning Engineers; or other approved engineering methods. Excessive

over-sizing of the furnace could cause the furnace and/or vent to fail prematurely. When a metal vent or metal liner is used, the

vent must be in good condition and be installed in accordance with the vent manufacturer's instructions.

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

1. The return-air temperature must be at least 60°F (15°C) db except for brief periods of time during warm-up from

setback at no lower than 55°F (13°C) db or during initial start-up from a standby condition.

2.Adjustthe gas input rate per the installation instructions.

Low gas input rate causes low vent gas temperatures, caus- ing condensation and corrosion in the furnace and/or vent-

ing system. Derating is permitted only for altitudes above 2000 fl

3. Adjust the air temperature rise to the midpoint of the rise range or slightly above. Low air temperature rise can cause

low vent gas temperature and potential for condensation problems.

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

Air for combustion must not be contaminated by halogen compounds which include chlorides, fluorides, bromides, and

iodides. These compounds are found in many common home products such as detergent, paint, glue, aerosol spray, bleach,

cleaning solvent, salt, and air freshener, and can cause corrosion of furnaces and vents. Avoid using such products in the

See Venting Notes after Fig. 47.

combustion-air supply. Furnace use during construction of the building could cause the furnace to be exposed to halogen

compounds, causing premature failure of the furnace or venting system due to corrosion.

Vent dampers on any appliance connected to the common vent can cause condensation and corrosion in the venting system. Do

not use vent dampers on appliances common vented with this furnace.

ADDITIONAL VENTING REQUIREMENTS A 4 in. (102 ram) round vent elbow is supplied with the furnace.

A 5 in. or 6 in. (127 or 152 ram) vent connector may be required for some model furnaces. A field-supplied 4 in. to 5 in. (102 to

127 ram) or 4 in. to 6 in. (102 mm to 152 ram) sheet metal increaser fitting is required when 5 in. or 6 in. (127 or 152 ram) vent connector is used. See Fig. 35-47 Venting Orientation for

approved vent configurations.

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

these figures

Fig. 35 - Upflow Application-Vent Elbow Up

A03208

T o o _

S "\

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

A03209

Fig. 36 - Upflow Application-Vent Elbow Right

SEENOTES:1,2,3,4,5,7,8,9 onthepagefollowing thesefigures

SEENOTES:1,2,4,5,6,7,8,9,10 onthepagefollowingthesefigures

A03210

Fig. 37 - Downflow Application-Vent Elbow Up then Left

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

on the page following these figures

A03207

Fig. 39 - Downflow Application-Vent Elbow Left then Up

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

these figures.

Fig. 38 - Downflow Application-Vent Elbow Up

A03211

A03212

Fig. 40 - Downflow Application-Vent Elbow Up then Right

.o .

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

following these figures

Fig. 41 - Horizontal Left Application - Vent Elbow Left

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

A03213

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

,\ j

Fig. 44 - Horizontal Left Application - Vent Elbow Up

o o0_

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

A03215

Fig. 42 - Horizontal Left Application - Vent Elbow Right

then Up

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

Fig. 43 - Horizontal Right Application - Vent Elbow Right

A03214

A03218

A03216

Fig. 45 - Horizontal Left Application - Vent Elbow Right

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

following these figures

A03219

Fig. 46 - Horizontal Right Application - Vent Elbow Left

then Up

/-X

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

A02068

Fig. 47 - Horizontal Right Application-Vent Elbow Left

VENTING NOTES FOR FIG. 35 - 47

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

2. Immediately increase to 5-in. or 6-in. (127 or 152 ram) vent connector outside furnace casing when 5-in. (127 ram) vent connector is required, refer to Note 1 above.

3. Side outlet vent for upflow and downflow installations nmst use Type B vent immediately after exiting the furnace, except when factory-approved Downflow Vent Guard Kit, is used in the downflow position. See Product Data Sheet for accessory listing.

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

5. Four-in. (102 ram) single-wall (26 ga. rain.) vent must be used inside furnace casing and when the factory-approved Downflow Vent Guard Kit is used external to the furnace. See Product Data Sheet for accessory listing.

6. Accessory Downflow Vent Guard Kit required in downflow installations with lower vent configuration. See Product Data Sheet for accessory listing.

7. Chinmey Adapter Kit may be required for exterior masonry chinmey applications. Refer to Chinmey Adapter Kit for sizing and complete application details. See Product Data Sheet for accessory listing.

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

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

10. The total height of the vent and connector shall be at least seven feet (2 M) for the 154,000 Btuh gas input rate model when installed in a downflow application with furnace elbow turned to left side with the connector elbow outside furnace casing pointing upward.

(See Fig. 40.)

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

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

FURNACE VENT FURNACE

ORIENTATION ORIENTATION INPUT(BTUH/HR) IN. (mm)* FT. (M)**

Vent elbow left, then 154,000

Downflow up Fig. 39 110,000 (036/- 12 only)

Horizontal Left 132,000 5 (127) 7 (.65)

Vent elbow right,

then up Fig. 42

Vent Elbow up Fig.

Horizontal Left 162,000 5 (127) 7 (.65)

Horizontal Left 154,000 5 (127) 7 (.65)

Downflow 110,000 (036/- 12 only) 5 (127) 10 (3.0)

Vent elbow right Fig.

Vent elbow up, then

Vent elbow up then

left Fig. 37

right Fig. 40

132,000 5 (127) 12 (3.6)

154,000

MINIMUM VENT MINIMUM VERTICAL

DIAMETER VENT HEIGHT

*4 in.(102 mm) inside casin¢ or vent guard **Including 4 in. (102 mm) vent section(s)

NOTE: All vent configurations must also meet National Fuel Gas Code venting requirements NFGC.

CUT HAZARD Failure to follow this caution may result in personal iniury.

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

gloves when handling parts and servicing furnaces.

NOTE: Vent connector length for connector sizing starts at furnace vent elbow. The 4-in. (102 mm) vent elbow is shipped

for upflow configuration and may be rotated for other positions. Remove the 3 screws that secure vent elbow to furnace, rotate furnace vent elbow to position desired, re-install screws. The factory-supplied vent elbow does NOT count as part of the

number of vent connector elbows. The vent connector can exit the furnace through one of 5

locations on the casing.

1. Attach the single wall vent connector to the furnace vent elbow, and fasten the vent connector to the vent elbow

with at least two field-supplied, corrosion-resistant, sheet metal screws located 180 ° apart.

NOTE: An accessory flue extension is available to extend from the furnace elbow to outside the furnace casing. See Product Data Sheet for accessory listing. If flue extension is used, fasten the flue extension to the vent elbow with at least two field-supplied, corrosion-resistant, sheet metal screws located 180 ° apart. Fasten

the vent connector to the flue extension with at least two field-supplied, corrosion resistant sheet metal screws located

180 ° apart.

2. Vent the furnace with the appropriate connector as shown in Fig. 35-47.

3. Determine the correct location of the knockout to be re- moved.

4. Use a hammer and screwdriver to strike a sharp blow between the tie points and work the slug back and forth

until the slug breaks free.

less with metal hangers or straps to ensure there is no movement after installation.

SIDEWALL VENTING This furnace is not approved for direct sidewall horizontal

venting. In the U.S.: Per section 12.4.3 of the NFPA 54 / ANSI Z223.1-2012, any listed mechanical venter may be used, when

approved by the authority having jurisdiction. Select the listed mechanical venter to match the Btuh input of the

furnace being vented. Follow all manufacturer's installation requirements for venting and termination included with the listed

mechanical venter.

START-UP, ADJUSTMENT, AND SAFETY

CHECK

Step 1 -- General

FIRE HAZARD

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

This furnace is equipped with manual reset limit switches in the gas control area. The switches open and shut off power to the gas valve if a flame roll-out or overheating condition occurs in the gas control area. DO NOT bypass the switches. Correct problem before resetting the switches.

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

2. Make thermostat wire connections at the 24-v terminal block on the furnace control. Failure to make proper con- nections will result in improper operation. (See Fig. 33.)

3. Gas supply pressure to the furnace must be greater than

4.5-In. W.C. (0,16 psig ) but not exceed 14-In. W.C. (0.5 psig).

BURN HAZARD

Failure to follow this caution may cause personal injury. Hot vent pipe is within reach of small children when

installed in downflow position. See the following instruction.

An accessory Vent Guard Kit, is REQUIRED for downflow applications where the vent exits through the lower portion of the

furnace casing. (See Fig. 39.) Refer to the Vent Guard Kit Instructions for complete details and see Product Data Sheet for

accessory listing. The horizontal portion of the venting system shall slope upwards

not less than 1/4-in. per linear ft. (6 mm/.3 M) from the furnace to the vent and shall be rigidly supported every 5 ft. (1.5 M) or

CUT HAZARD

Failure to follow this caution may result in personal iniury. Sheet metal parts may have sharp edges or burrs. Use care

and wear appropriate protective clothing, safety glasses and gloves when handling parts and servicing furnaces,

4. Check all manual-reset switches for continuity.

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

6. Setup switch descriptions The 2 stage furnace has DIP switches used to select thermostat staging and blower off

delay timings. For switch locations on Furnace control board, See Fig. 33 and 52.

7. Setup switch descriptions - See Table 10.

Table 10 - 2-Stage Furnace Setup Switch Description

SETUP SWITCH NORMAL DESCRIPTION

SWITCH NO. NAME POSITION OF USE

When OFF, allows 2-stage operation with a single stage thermostat.

SW- 1 Adaptive Heat Mode OFF

SW-2 Blower OFF delay ON or OFF See Table 14.

SW-3 Blower OFF delay ON or OFF See Table 14.

Turn ON when using 2 stage thermostat to allow Low Heat operation

when R to W/W1 closes and High Heat operation when R to W/W1

and W2 close.

Control blower OFF delay time. Used in conjunction with SW-3.

Control blower OFF delay time. Used in conjunction with SW-2.

Step 2 -- Start-Up Procedures

FIRE AND EXPLOSION HAZARD

Failure to follow this warning could cause personal iniury, death and/or property damage.

Never test for gas leaks with an open flame. Use a commercially available soap solution made specifically for

the detection of leaks to check all connections.

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

2. Check gas lines for leaks.

ELECTRICALSHOCK HAZARD

Failure to follow this warning could result in personal injury, or death.

Blower access door switch opens 115-v power to control. No component operation can occur unless switch is closed.

Caution must be taken when manually closing this switch

for service purposes.

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

lead from furnace control board. Manually close blower door switch. Short (jumper) the COM-24v terminal on control to the TEST/TWIN 3/16-in. (8 mm) quick-con-

nect terminal on control until the LED goes out (approx- imately 2 sec). Gas valve and humidifier will not be turned

on. Remove jumper from terminals. (See Fig. 33 and Table 10.)

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

Refer to service label attached to furnace or See Fig. 51. Component test sequence is as follows:

a. LED will display previous status code 4 times.

b. Inducer motor starts on high-speed and continues to run

until Step g of component test sequence.

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

d. Blower motor operates on LO-HEAT speed for 10 sec.

e. Blower motor operates on HI-HEAT speed for 10 sec.

f. Blower motor operates on COOL speed for 10 sec.

g. Inducer motor goes to low-speed for 10 sec., then stops. h. Reconnect R lead to furnace control board, remove tape

from blower door switch and re-install blower door.

4. Operate furnace per instruction on inner door.

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

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

Step 3 -- Adjustments

FIRE HAZARD

Failure to follow this warning could result in iniury, death

and/or property damage.

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

[]NIT DAMAGE HAZARD Failure to follow this caution may result in reduced furnace

life. DO NOT re-drill orifices. Improper drilling (burrs, out-of

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

impingement of heat exchangers, causing failures.

Furnace gas input rate on rating plate is for installations at altitudes up to 2000 ft. (610 M). Furnace input rate must be

within +/-2% of furnace rating plate input. For altitudes above 5500 ft. (1676 M), a field-supplied high altitude pressure switch

is required.

1. Determine the correct gas input rate. The input rating for altitudes above 2,000 ft. (610 M) must be reduced by 4% for each 1,000 ft. (305 M) above sea

level. For installations below 2000 ft. (610 M), refer to the unit

rating plate. For installations above 2000 ft. (610 M), multiply the in-

put on the rating plate by the derate multiplier in Table 11 for the correct input rate.

2. Determine the correct orifice and manifold pressure adjust- ment. All models in all positions except Low NOx models

in downflow and horizontal positions use Table 15 (22,000 BTUH per burner).

Table11- Altitude Derate Multiplier for U.S.A.

ALTITUDE PERCENT DERATE MULTiPLiER

FT.(M) OF DERATE FACTOR*

0-2000

(0- 61O)

2001-3000

(61O-914)

3001-4000

(914-1219)

4001-5000

(1219-1524)

5001-6000

1524-1829)

6001-7000

(1829-2134)

7001-8000

(2134- 2438)

8001-9000

(2438-2743) 9001-10,000

(2743-3048)

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

Low NOx models in downflow or horizontal positions MUST use Table 16 (21,000 BTUH per burner). See input listed on

rating plate.

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

from local gas supplier.

b. Obtain average yearly gas specific gravity from local gas

supplier.

c. Find installation altitude in Table 15 or 16.

d. Find closest natural gas heat value and specific gravity

in Table 15 or 16.

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

intersection to find orifice size and low-and high-heat manifold pressure settings for proper operation.

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

ASSUME ORIFICE SIZE. ALWAYS CHECK AND VERIFY.

g. Replace orifice with correct size, if required by Table 15

or 16. Use only factory-supplied orifices. See EXAMPLE 1.

EXAMPLE 1:(0-2000 ft. / 0-610 M altitude) For 22,000 Btuh per burner application, use Table 15. Heating value = 1000 Btuh/cu ft. Specific gravity = 0.62

Therefore: Orifice No. 43"

Manifold pressure: 3.7-In. W.C. for high-heat

1.6-In. W.C. for low-heat

* 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. Ac[iust manifold pressure to obtain low fire input rate. (See Fig. 48.)

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

b. Remove manifold pressure tap plug from gas valve.

c. Connect a water colunm manometer or sinfilar device to

manifold pressure tap.

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

0 1.00

8-I2 0.90

12-16 0.86

16-20 0.82

20-24 0.78

24-28 0.74

28-32 0.70

32-36 0.66

36-40 0.62

A06667

Fig. 48 - Redundant Automatic Gas Control Valve

e. Move setup switch LHT (SW-1) on furnace control to

ON position to lock furnace in low-heat operation. (See Fig. 33 and Table 10.)

f. Manually close blower door switch.

g. Jumper R and W/WI thermostat connections on control

to start furnace. (See Fig. 33.)

h. Remove regulator adjustment cap from low-heat gas

valve pressure regulators. (See Fig. 48.) Turn low-heat adjusting screw (3/16 in. (5 ram) or smaller flat tipped

screwdriver) counterclockwise (out) to decrease input rate or clockwise (in) to increase input rate.

NOTE: DO NOT set low-heat manifold pressure less than

1.4-In. W.C. or more than 1.7-In. W.C. for natural gas. If manifold pressure is outside this range, change main burner

orifices.

i. Install low-heat regulator adjustment cap.

j. Leave manometer or sinfilar device connected and pro-

ceed to Step 4.

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

4. Verify natural gas low-heat input rate by clocking meter.

NOTE: Gas valve regulator adjustment caps nmst be in place for proper input to be clocked.

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

meter.

b. Run for 3 nfinutes in low-heat operation.

c. Measure time (in sec) for gas meter to complete I revolu-

tion and note reading. The 2 or 5 cubic feet dial provides a more accurate measurement of gas flow.

BURNER --_

ORIFICE

A93059

Fig. 49 - Orifice Hole

d. Refer to Table 12 for cubic fl. of gas per hr.

e. Multiply gas rate cu ft./hr by heating value (Btuh/cu ft.

) to obtain input. If clocked rate does not match required input from Step 1, increase manifold pressure to increase input or decrease manifold pressure to decrease input. Repeat steps b through e until correct low heat input is

achieved. Re-install low-heat regulator seal cap on gas valve.

5. Set low-heat temperature rise. The furnace must operate within the temperature rise ranges specified on the furnace

rating plate. Do not exceed temperature rise ranges spe-

cified on unit rating plate for high-and low-heat. Determine the temperature rise as follows:

NOTE: Blower access door must be installed when taking temperature rise reading. Leaving blower access door off will

result in incorrect temperature measurements.

ELECTRICALSHOCK HAZARD Failure to follow this warning could result in personal

injury or death. Disconnect l15-v electrical power and install lockout tag

before changing speed tap.

a. Verify unit is running in low heat per Step 3. Place ther-

mometers in return and supply ducts as close to furnace as possible. Be sure thermometers do not see radiant heat

from heat exchangers. Radiant heat affects temperature rise readings. This practice is particularly important with

straight-run ducts.

b. When thermometer readings stabilize, subtract return-air

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

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

(1.) Gas input for low heat operation. (2.) Derate for altitude if applicable. (3.) Return and supply ducts for excessive restrictions

causing static pressures greater than 0.50-In. W.C.

Table12- Gas Rate (cu ft./hr)

SECONDS

FOR 1

REVOLUTION

10 11

12 13

14 15 16

17 18 19

2O 21 22

23 24

25 26 27

28 29 3O

31 32 33

34 35

36 37 38

39 40 41

42 43 44

45 46 47

48 49

SIZE OF TEST DIAL

CU FT. 2 CU FT. 5

360 720 327 655

300 600 277 555

257 514 240 480 225 450

212 424 200 400 189 379

180 360 171 343 164 327

157 313 150 300

144 288 138 277 133 267

129 257 124 248 120 240

116 232 113 225 109 218

106 212 103 206

100 200

97 195 95 189

92 185 90 180 88 176

86 172 84 167 82 164

80 160 78 157 76 153

75 150 73 147

CU FT.

1800 1636

1500 1385

1286 1200 1125

1059 1000

947 9OO

857 818

783 75O

72O 692 667

643 621 6OO

581 563 545

529 514

5OO 486 474

462 45O 439

429 419 409

4OO 391 383

375 367

SECONDS

FOR 1

REVOLUTION

5O 51

52 53

54 55 56

57 58 59

6O 62 64

66 68

70 72 74

76 78 80

82 84 86

88 90

92 94 96

98 100 102

104 106 108

110 112 116

120

SIZE OF TEST DIAL

1 CU FT.

72 71

69 68

67 65 64

63 62 61

60 58 56

54 53

51 50 48

47 46 45

44 43 42

41 40

39 38 38

37 36 35

35 34 33

33 32 31

2 Cu FT.

144 141

138 136

133 131 129

126 124 122

12O 116 112

109 106

103 100

97 95

92 90

88 86 84

82 80

78 76 75

74 72 71

69 68 67

65 64 62

5 Cu FT.

36O 355

346 34O

333 327 321

316 310 3O5

3OO 29O 281

273 265

257 25O 243

237 231 225

22O 214 2O9

2O5 2OO

196 192 188

184 18O 178

173 17O 167

164 161 155

15O

c. Adjust air temperature rise by adjusting blower speed. In-

crease blower speed to reduce temperature rise. Decrease blower speed to increase temperature rise. For low heat,

speed selection can be low (factory setting), med-low, or med (5-speed blowers only).

d. Remove thermostat jumpers and remove Blower Access

Door.

e. To change motor speed selection for low heat, remove

blower motor lead from control LO-HEAT terminal. (See Fig. 33.) Select desired blower motor speed lead

from 1 of the other terminals and relocate it to the LO- HEAT terminal. (See Table 13 for lead color identifica-

tion). Reconnect original lead to SPARE terminal.

f. Repeat steps a through e.

FURNACE OVERHEATING HAZARD Failure to follow this caution may result in reduced furnace

life. Recheck temperature rise. It must be within limits specified

on the rating plate. Recommended operation is at the midpoint of rise range or slightly above.

g. When correct low heat input rate and temperature rise is

achieved, proceed to Step 6.

6. Adjust Manifold Pressure to Obtain High Heat Rate

a. Remove high fire regulator adjustment cap from gas

valve pressure regulator.

b. Jumper R, W/WI and W2 thermostat connections on

control to run furnace in high heat. (See Fig. 33.)

c. d. Turn high-heat adjusting screw (3/16-in. (5 mm) or

smaller flat tipped screwdriver) counterclockwise (out) to decrease input rate or clockwise (in) to increase rate.

d. Re-install high-fire adjustment caps.

e. Leave manifold or similar device connected and proceed

to Step 7.

NOTE: DO NOT set high-heat manifold pressure less than

3.2-In. W.C. or more than 3.8-In. W.C. for natural gas. If manifold pressure is outside this range, change main burner orifices.

7. Verify natural gas high heat input rate by clocking meter.

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

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

meter.

b. Run for 3 minutes in high-heat operation.

c. Measure time (in sec) for gas meter to complete I revolu-

tion and note reading.

d. Refer to Table 12 for cubic ft. of gas per hr.

e. Multiply gas rate cu ft./hr by heating value (Btuh/cu ft.)

to obtain input.

NOTE: Using the 2 cu. ft. or 5 cu. ft. gas meter dial provides greater accuracy in verifying gas input rate.

If clocked rate does not match required input from Step 1, increase manifold pressure to increase input or decrease manifold

pressure to decrease input. Repeat steps b through e until correct high heat input is achieved. Re-install high-heat regulator seal

cap on gas valve.

8. Set high heat temperature rise. Jumper R to W/WI and W2 to check high-gas-heat tem-

perature rise. Do not exceed temperature rise ranges spe- cified on furnace rating plate for high heat. The furnace

must operate within the temperature rise ranges specified on the furnace rating plate.

Determine the air temperature rise as follows:

NOTE: Blower access door must be installed when taking temperature rise reading. Leaving blower access door off will result in incorrect temperature measurements.

a. Verify the furnace is operating in high heat per Step 6.

Place thermometers in return and supply ducts as close to furnace as possible. Be sure thermometers do not see radiant heat from heat exchangers. Radiant heat affects

temperature rise readings. This practice is particularly im- portant with straight-run ducts.

b. When thermometer readings stabilize, subtract return-air

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

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

(1.) Gas input for low-and high-heat operation. (2.) Derate for altitude if applicable. (3.) Return and supply ducts for excessive restrictions

causing static pressures greater than 0.50-In. W.C.

(4.) Dirty filter.

c. Adjust air temperature rise by adjusting blower speed. In-

crease blower speed to reduce temperature rise. Decrease blower speed to increase temperature rise. For high heat, speed selection can be med-high, med (5-speed blowers

only), or med-low (factory setting).

ELECTRICALSHOCK HAZARD

Failure to follow this warning could result in personal iniury or death.

Disconnect l15-v electrical power and install lockout tag before changing speed tap.

d. To change motor speed selection for high heat, remove

blower motor lead from control HI-HEAT terminal. (See Fig. 33.) Select desired blower motor speed lead from

1 of the other terminals and relocate it to the HI-HEAT terminal. DO NOT use the low-heat tap that was already

set. (See Table 13 for lead color identification). Recon- nect original lead to SPARE terminal.

e. Repeat steps a thru d.

f. When correct high heat input rate and temperature rise is

achieved, turn gas valve ON/OFF switch to OFF. g. Remove Blower Access Door. h. Remove manometer or similar device from gas valve.

i. Re-install manifold pressure tap plug in gas valve. (See

Fig 54.)

FIRE HAZARD Failure to reinstall manifold pressure tap plug in gas valve

could result in personal iniury, property damage or death. Reinstall manifold pressure tap plug in gas valve to prevent

gas leak.

j. Remove thermostat jumper wire from furnace control

board.

k. Turn LHT switch OFF.

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

m. Proceed to Step 9, "Set Blower Off Delay" before in-

stalling blower access door.

FURNACE OVERHEATING HAZARD Failure to follow this caution may result in reduced furnace

life.

Recheck temperature rise. It must be within limits specified on the rating plate. Recommended operation is at the

midpoint of rise range or slightly above.

9. Set Blower Off Delay a. Remove Blower Access Door if installed.

b. Turn Dip switch 2 and 3 ON or OFF for desired blower

off delay. (See Table 14 and Fig 34.)

10. Set thermostat heat anticipator. a. Mechanical thermostat - Set thermostat heat anticipator

to match the amp. draw of the electrical components in the R-W/Wl circuit. Accurate amp. draw readings can

be obtained at the wires normally connected to thermostat subbase terminals, R and W. The thermostat anticipator

should NOT be in the circuit while measuring current.

(1.) Set LHT switch on furnace control board to ON. (2.) Remove thermostat from sub-base or from wall. (3.) Connect an amp. meter as shown in Fig. 50 across

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

(4.) Record amp. draw across terminals when furnace is

in low heat and after blower starts.

(5.) Set heat anticipator on thermostat per thermostat in-

structions and install on subbase or wall.

(6.) Turn LHT switch OFF. (7.) Install blower access door.

b. Electronic thermostat: Set cycle rate for 3 cycles per hr.

11. Set airflow CFM for cooling

Select the desired blower motor speed lead for cooling air- flow. See Table 5-Air Delivery-CFM (With Filter). See

Table 13 for lead color identification.

Table 13 - Speed Selection

COLOR SPEED AS SHIPPED

White Common BLW Black High COOL

Yellow Med - High SPARE

Orange1- Med SPARE

Blue Med- Low HI- HEAT

Red Low* LO HEAT

* Continuous-blower speed-as shippeddefault 1-Not all models equipped with 5 speed motors

Table 14 - 2-Stage Furnace Blower OFF delay Setup Switch

DESIRED HEATING MODE SETUP SWITCH SETUP SWITCH

BLOWER OFF DELAY (SEC.) SW-2 SW-3

90 OFF OFF

120 OFF ON 150 ON OFF

180 ON ON

TERMINALS WITH THERMOSTAT REMOVED

(ANITICIPATOR, CLOCK, ETC.,

MUST BE OUT OF CIRCUIT.)

I0 TURNS

FROM UNIT 24-V

CONTROL TERMINALS

EXAMPLE; 5.0 AMPS ON AMMETER = 0.5 AMPS FOR THERMOSTAT

10 TURNS AROUND JAWS ANTICIPATOR SETTING

SUBBASE

AMMETER

A96316

Fig. 50 - Amp. Draw Check with Ammeter

Step 4 -- Check Safety Controls

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

1. Check Main Limit Switch(es) This control shuts off combustion system and energizes

air-circulating blower motor, if furnace overheats. By us- ing this method to check limit control, it can be established

that limit is flmctioning properly and will operate if there is a restricted return-air supply or motor failure. If limit

control does not flmction during this test, cause must be determined and corrected.

a. Run furnace for at least 5 minutes.

b. Gradually block off return air with a piece of cardboard

or sheet metal until the limit trips.

c. Unblock return air to permit normal circulation.

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

2. Check draft safeguard switch. The purpose of this control is to cause the safe shutdown

of the furnace during certain blocked vent conditions.

a. Verify vent pipe is cool to the touch.

b. Disconnect power to furnace and remove vent connector

from furnace vent elbow.

c. Restore power to furnace and set room thermostat above

room temperature.

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

minutes, then block vent elbow in furnace 80% of vent area with a piece of flat sheet metal.

e. Furnace should cycle offwithin 2 minutes. If gas does not

shut off within 2 minutes, determine reason draft safe-

guard switch did not flmction properly and correct condi- tion.

f. Remove blockage from furnace vent elbow.

g. Switch will auto-reset when it cools. h. Re-install vent connector.

NOTE: Should switch remain open longer than 3 minutes, furnace control board will lockout the furnace for 3 hours. To

reset furnace control board, turn thermostat below room temperature or from HEAT to OFF and turn 115-v power OFF,

then back ON.

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

a. Turn off 115-v power to furnace.

b. Disconnect inducer motor lead wires from wire harness.

c. Turn on 115-v power to furnace.

d. Set thermostat to "call for heat" and wait I minute. When

pressure switch is functioning properly, hot surface ig- niter should NOT glow and control diagnostic light

flashes astatus code 32. If hot surface igniter glows when inducer motor is disconnected, shut down furnace imme-

diately.

e. Determine reason pressure switch did not function prop-

erly and correct condition.

f, Turn off 115-v power to furnace,

g. Reconnect inducer motor wires, replace outer door, and

turn on 115-v power.

h. Blower will run for 90 seconds before beginning the call

for heat again.

i. Furnace should ignite normally.

Step 5 -- ChecMist

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

2. Verify that switches for LHT and OFF-DELAY are blower OFF-DELAY are selected as desired.

3. Verify that blower and burner access doors are properly in- stalled.

4. Cycle test furnace 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 furnace.

Table 15 - Orifice Size* and Manifold Pressures (In. W.C.) for Gas Input Rate

(TABULATED DATA BASED ON 22,000 BTUH HIGH-HEAT / 14,500 BTUH LOW-HEAT PER BURNER,

DERATED 4%/1000 FT (305M) ABOVE SEA LEVEL)

ALTITUDE AVG. GAS SPECIFIC GRAVITY OF NATURAL GAS

RANGE HEAT VALUE 0.58 0.60 0.62

AT ALTITUDE Orifice MnfldPress Orifice MnfldPress Orifice MnfldPress

ft (m) IBtu/cu ftI No. Hi,h/Low No. ai_h/Low No. Hi,h/Low

0 925 42 3.3 / 1.4 42 3.4 / 1.5 42 3.5 / 1.5

(0) 950 43 3.8 / 1.7 42 3.3 / 1.4 42 3.4 / 1.5

"-i

to 1000 43 3.5 / 1.5 43 3.6 / 1.6 43 3.7 / 1.6

2000 1050 44 3.6 / 1.6 43 3.2 / 1.4 43 3.4 / 1.5 (610) 1075 44 3.4 / 1.5 44 3.5 / 1.5 43 3.2 / 1.4

2001 (611) 875 43 3.5 / 1.5 43 3.6 / 1.6 43 3.7 / 1.6

3000 (914) 925 44 3.5 / 1.5 43 3.2 / 1.4 43 3.3 / 1.4

3001 800 43 3.6 / 1.6 43 3.8 / 1.6 42 3.2 / 1.4 (915) 825 43 3.4 / 1.5 43 3.5 / 1.5 43 3.7 / 1.6

4000 900 44 3.3 / 1.4 44 3.4 / 1.5 44 3.5 / 1.5

(1219) 925 45 3.8 / 1.6 44 3.2 / 1.4 44 3.3 / 1.5

4001 775 43 3.4 / 1.5 43 3.5 / 1.5 43 3.6 / 1.6

(1220) 800 43 3.2 / 1.4 43 3.3 / 1.4 43 3.4 / 1.5

5000 875 45 3.7 / 1.6 45 3.8 / 1.7 44 3.3 / 1.4

(1524) 900 46 3.7 / 1.6 46 3.8 / 1.7 45 3.7 / 1.6

5001 750 43 3.2 / 1.4 43 3.3 / 1.4 43 3.4 / 1.5

(1525) 775 44 3.4 ! 1.5 44 3.5 ! 1.5 43 3.2 / 1.4

6000 850 46 3.6 / 1.6 46 3.7 / 1.6 46 3.8 / 1.7

(1829) 875 47 3.8 / 1.7 46 3.5 / 1.5 46 3.6 / 1.6

6001 700 44 3.6 / 1.6 43 3.3 / 1.4 43 3.4 / 1.5

(1830) 725 44 3.4 / 1.5 44 3.5 / 1.5 44 3.6 / 1.6

7000 800 46 3.5 / 1.5 46 3.6 / 1.6 46 3.8 / 1.6

(2133) 825 47 3.7 / 1.6 46 3.4 / 1.5 46 3.5 / 1.5

900 42 3.5 / 1.5 42 3.6 / 1.6 42 3.7 / 1.6

975 43 3.6 / 1.6 43 3.8 / 1.6 42 3.2 / 1.4

1025 43 3.3 / 1.4 43 3.4 / 1.5 43 3.5 / 1.5

1100 44 3.3 / 1.4 44 3.4 / 1.5 44 3.5 / 1.5

800 42 3.4 / 1.5 42 3.5 / 1.5 42 3.6 / 1.6 825 42 3.2 / 1.4 42 3.3 / 1.4 42 3.4 / 1.5 850 43 3.7 / 1.6 43 3.8 / 1.6 42 3.2 / 1.4

900 43 3.3 / 1.4 43 3.4 / 1.5 43 3.5 / 1.5

950 44 3.4 / 1.5 44 3.5 / 1.5 44 3.6 / 1.6 975 44 3.2 / 1.4 44 3.3 / 1.4 44 3.4 / 1.5

1000 45 3.7 / 1.6 45 3.8 / 1.7 44 3.2 / 1.4

775 42 3.2 ! 1.4 42 3.3 ! 1.4 42 3.4 / 1.5

850 43 3.2 / 1.4 43 3.3 / 1.4 43 3.4 / 1.5 875 44 3.5 / 1.5 44 3.6 / 1.6 43 3.3 / 1.4

950 46 3.8 / 1.6 45 3.7 / 1.6 45 3.8 / 1.7 750 43 3.6 / 1.6 43 3.8 / 1.6 42 3.2 / 1.4

825 44 3.4 / 1.5 44 3.6 / 1.5 43 3.2 / 1.4 850 44 3.2 / 1.4 44 3.4 / 1.5 44 3.5 / 1.5

925 46 3.5 ! 1.5 46 3.6 ! 1.6 46 3.7 / 1.6 725 43 3.4 / 1.5 43 3.5 / 1.5 43 3.6 / 1.6

800 44 3.2 / 1.4 44 3.3 / 1.4 44 3.4 / 1.5 825 46 3.8 / 1.7 45 3.8 / 1.6 44 3.2 / 1.4

900 47 3.6 / 1.6 47 3.8 / 1.6 46 3.4 / 1.5 675 43 3.4 / 1.5 43 3.5 / 1.5 43 3.6 / 1.6

750 45 3.8 ! 1.7 44 3.3 ! 1.4 44 3.4 / 1.5 775 46 3.7 / 1.6 45 3.7 / 1.6 45 3.8 / 1.7

850 47 3.5 / 1.5 47 3.6 / 1.6 47 3.8 / 1.6

0.64

Orifice Mnfld Press

No. Hi,h/Low

41 3.5 / 1.5 42 3.7 / 1.6 42 3.5 / 1.5 42 3.3 / 1.4

43 3.8 / 1.7 43 3.6 / 1.6 43 3.5 / 1.5 43 3.3 / 1.4 43 3.2 / 1.4

42 3.7 / 1.6 42 3.5 / 1.5 42 3.3 / 1.4 43 3.8 / 1.7 43 3.6 / 1.6

43 3.4 / 1.5 43 3.2 / 1.4 44 3.5 / 1.5 44 3.4 / 1.5 42 3.5 / 1.5

42 3.3 / 1.4 43 3.8 / 1.6 43 3.6 / 1.5 43 3.4 / 1.5

43 3.2 / 1.4 44 3.4 / 1.5 44 3.3 / 1.4 42 3.3 / 1.4 43 3.8 / 1.6

43 3.5 / 1.5 43 3.3 / 1.4 44 3.6 / 1.6 44 3.4 / 1.5 44 3.2 / 1.4

46 3.8 / 1.7 43 3.7 / 1.6 43 3.5 / 1.5 43 3.3 / 1.4 44 3.5 / 1.5

44 3.3 / 1.4 45 3.8 / 1.6 46 3.7 / 1.6 46 3.5 / 1.5 43 3.7 / 1.6

43 3.5 / 1.5 43 3.2 / 1.4 44 3.5 / 1.5 44 3.2 / 1.4 45 3.7 / 1.6

46 3.6 / 1.6 46 3.4 / 1.5

A10184

Table 15 - Orifice Size and Manifold Pressures (In. W.C.) for Gas Input Rate (cont.)

(TABULATED DATA BASED ON 22,000 BTUH HIGH-HEAT/14,500 BTUH LOW-HEAT PER BURNER,

DERATED 4%/1000 FT (305M) ABOVE SEA LEVEL)

ALTITUDE AVG. GAS

RANGE HEAT VALUE

AT ALTITUDE

ft (m) IStu/cu ft_

65O

7001 675

(2134) 700

8000 775

(2438) 800

8001 650

(2439) 675

9000 750

127431 775

9001 600

(2744) 625

10000 700

130461 725

* Orifice numbers shown inBOLD are factory-installed.

725 750

825 625

700 725

650 675

Orifice MnfldPress Orifice MnfldPress Orifice MnfldPress

No. Hi,h/Low No. Hi,h/Low No. Hi,h/Low

44 3.6 / 1.6 43 3.2 / 1.4 43 3.4 / 1.5 44 3.3 / 1.5 44 3.5 / 1,5 44 3.6 / 1.6 45 3.8 / 1.6 44 3.2 / 1,4 44 3.3 / 1.4

46 3.7 / 1.6 46 3.8 / 17 45 3.7 / 1.6 46 3.4 / 1.5 46 3.6 / 15 46 3.7 / 1.6 47 3.6 / 1.6 47 3.8 / 1,6 46 3.4 / 1.5

47 3.4 / 1.5 47 3.5 / 15 47 3.7 / 1.6 48 3.7 / 1.6 48 3.8 / 16 47 3.4 / 1.5 44 3.3 / 1.5 44 3.5 / 1,5 44 3.6 / 1.6

45 3.7 / 1.6 44 3.2 / 14 44 3.3 / 1.4 46 3.6 / 1.6 46 3.8 / 1,6 45 3.7 / 1.6

47 3.8 / 1.7 46 3.5 / 15 46 3.6 / 1.6 47 3.6 / 1.6 47 3.7 / 16 47 3.8 / 1.7 48 3.8 / 1.7 47 3.5 / 1,5 47 3.6 / 1.6

48 3.6 / 1.5 48 3.7 / 1,6 48 3.8 / 1.7 45 37/16 45 38/17 44 33 /1 4

46 3.6 / 1.6 46 3.7 / 16 46 3.8 / 1.7 47 3.8 / 1.6 46 3.4 / 1,5 46 3.6 / 1.5

47 3.5 / 1.5 47 3.6 / 16 47 3.7 / 1.6 48 3.7 / 1.6 48 3.8 / 17 47 3.5 / 1.5 48 3.5 / 1.5 48 3.6 / 1,6 48 3.7 / 1.6

SPECIFIC GRAVITY OF NATURAL GAS

0.58 0.60 0.62

0.64

Orifice Mnfld Press

No. Hi,h/Low

43 3.5 / 1.5 43 3.2 / 1.4 44 3.4 / 1.5

44 3.2 / 1.4 46 3.8 / 1.6 46 3.6 / 1.5

47 3.8 / 1.6 47 3.6 / 1.5 43 3.2 / 1.4

44 3.4 / 1.5 45 3.8 / 1.7

46 3.7 / 1.6 46 3.5 / 1.5 47 3.7 / 1.6

47 3.5 / 1.5 44 34 / 15

45 3.8 / 1.6 46 3.7 / 1.6

46 3.4 / 1.5 47 3.6 / 1.6 46 3.8 / 1.7

A10184A

Table 16 - Orifice Size* and Manifold Pressures (In. W.C.) for Gas Input Rate

(TABULATED DATA BASED ON 21,000 BTUH HIGH-HEAT / 14,500 BTUH LOW-HEAT PER BURNER,

DERATED 4%/1000 FT (305M) ABOVE SEA LEVEL)

ALTITUDE AVG. GAS SPECIFIC GRAVITY OF NATURAL GAS

RANGE HEAT VALUE 0.58 0.60 0.62

AT ALTITUDE Orifice MnfldPress Orifice MnfldPress Orifice MnfldPress

ft (m) IBtu/cu ft) No. ai_lh/Low No. ai_lh/Low No. ai_lh/Low

0 925 43 3.7 / 1.8 43 3.8 / 1.8 42 3.2 / 1.5

(0) 950 43 3.5 / 1.7 43 3.6 / 1.7 43 3.7 / 1.8

to 1000 44 3.6 / 1.7 43 3.3 / 1.6 43 3.4 / 1.6

2000 1050 44 3.3 / 1.6 44 3.4 / 1.6 44 3.5 / 1.7 (610) 1075 45 3.8 / 1.8 44 3.2 / 1.5 44 3.3 / 1.6

2001 (611) 875 43 3.2 / 1.5 43 3.3 / 1.6 43 3.4 / 1.6

3000 (914) 925 44 3.2 / 1.5 44 3.3 / 1.6 44 3.5 / 1.6

3001 800 43 3.3 / 1.6 43 3.4 / 1.6 43 3.5 / 1.7 (915) 825 44 3.6 / 1.7 43 3.2 / 1.5 43 3.3 / 1.6

4000 900 46 3.8 / 1.8 45 3.8 / 1.8 44 3.2 / 1.5

(1219) 925 46 3.6 / 1.7 46 3.7 / 1.8 45 3.7 / 1.8

4001 775 44 3.6 / 1.7 43 3.2 / 1.5 43 3.3 / 1.6

(1220) 800 44 3.3 / 1.6 44 3.4 / 1.6 44 3.6 / 1.7

5000 875 46 3.5 / 1.7 46 3.7 / 1.7 46 3.8 / 1.8

(1524) 900 47 3.8 / 1.8 46 3.5 / 1.7 46 3.6 / 1.7

5001 750 44 3.3 / 1.6 44 3.4 / 1.6 44 3.5 / 1.7

(1525) 775 45 3.7 / 1.8 44 3.2 / 1.5 44 3.3 / 1.6

6000 850 47 3.7 / 1.8 47 3.8 / 1.8 46 3.5 / 1.7

(1829) 875 47 3.5 / 1.7 47 3.6 / 1.7 47 3.7 / 1.8

6001 700 44 3.3 / 1.6 44 3.4 / 1.6 44 3.5 / 1.7

(1830) 725 45 3.7 / 1.8 45 3.8 / 1.8 44 3.3 / 1.6

7000 800 47 3.6 / 1.7 47 3.8 / 1.8 46 3.4 / 1.6

(2133) 825 47 3.4 / 1.6 47 3.5 / 1.7 47 3.6 / 1.7

900 42 3.2 / 1.5 42 3.3 / 1.6 42 3.4 / 1.6

975 43 3.3 / 1.6 43 3.4 / 1.6 43 3.5 / 1.7

1025 44 3.4 / 1.6 44 3.6 / 1.7 43 3.2 / 1.5

1100 46 3.8 / 1.8 45 3.7 / 1.8 44 3.2 / 1.5

800 43 3.8 / 1.8 42 3.2 / 1.5 42 3.3 / 1.6 825 43 3.5 / 1.7 43 3.7 / 1.7 43 3.8 / 1.8

850 43 3.3 / 1.6 43 3.5 / 1.6 43 3.6 / 1.7

900 44 3.4 / 1.6 44 3.5 / 1.7 43 3.2 / 1.5

950 45 3.7 / 1.8 45 3.8 / 1.8 44 3.3 / 1.6 975 46 3.7 / 1.8 46 3.8 / 1.8 45 3.8 / 1.8

1000 46 3.5 / 1.7 46 3.6 / 1.7 46 3.8 / 1.8

775 43 3.5 / 1.7 43 3.7 / 1.7 43 3.8 / 1.8

850 44 3.4 / 1.6 44 3.5 / 1.7 44 3.6 / 1.7 875 45 3.8 / 1.8 44 3.3 / 1.6 44 3.4 / 1.6

950 46 3.4 / 1.6 46 3.5 / 1.7 46 3.7 / 1.7 750 43 3.3 / 1.6 43 3.4 / 1.6 43 3.5 / 1.7

825 45 3.8 / 1.8 44 3.2 / 1.5 44 3.4 / 1.6 850 46 3.8 / 1.8 45 3.7 / 1.8 45 3.8 / 1.8

925 47 3.6 / 1.7 47 3.7 / 1.8 47 3.8 / 1.8 725 44 3.5 / 1.7 43 3.2 / 1.5 43 3.3 / 1.6

800 46 3.7 / 1.8 46 3.8 / 1.8 45 3.8 / 1.8 825 46 3.5 / 1.7 46 3.6 / 1.7 46 3.7 / 1.8

900 48 3.8 / 1.8 47 3.4 / 1.6 47 3.5 / 1.7

675 44 3.5 / 1.7 43 3.2 / 1.5 43 3.3 / 1.6

750 46 3.6 / 1.7 46 3.8 / 1.8 45 3.7 / 1.8 775 46 3.4 / 1.6 46 3.5 / 1.7 46 3.6 / 1.7

850 48 3.7 / 1.7 48 3.8 / 1.8 47 3.4 / 1.6

0.64

Orifice Mnfld Press

No. Hi_h/Low

42 3.5 / 1.7 42 3.3 / 1.6

43 3.8 / 1.8 43 3.7 / 1.7 43 3.5 / 1.7 43 3.3 / 1.6 43 3.2 / 1.5

44 3.4 / 1.6

44 3.3 / 1.6 42 3.4 / 1.6 42 3.2 / 1.5

43 3.7 / 1.8

43 3.5 / 1.7 43 3.3 / 1.6

44 3.6 / 1.7 44 3.4 / 1.6

44 3.2 / 1.5 45 3.7 / 1.8 42 3.2 / 1.5

43 3.7 / 1.7 43 3.4 / 1.6

43 3.2 / 1.5 44 3.5 / 1.7 44 3.3 / 1.6

45 3.8 / 1.8 46 3.8 / 1.8 43 3.6 ! 1.7 43 3.4 / 1.6

43 3.2 / 1.5 44 3.5 / 1.6 44 3.3 / 1.6

45 3.7 / 1.8 46 3.7 / 1.8 46 3.5 / 1.7

43 3.4 / 1.6 43 3.2 / 1.5 44 3.4 / 1.6 44 3.2 / 1.5

46 3.8 / 1.8 46 3.6 / 1.7

46 3.4 / 1.6 47 3.7 / 1.7

43 3.4 / 1.6 43 3.2 / 1.5

44 3.4 / 1.6

45 3.8 / 1.8 46 3.8 / 1.8 46 3.5 / 1.7

47 3.8 / 1.8 47 3.5 / 1.7

A10185

Table 16 - Orifice Size* and Manifold Pressures (In. W.C.) for Gas Input Rate (cont.)

(TABULATED DATA BASED ON 21,000 BTUH HIGH-HEAT/14,500 BTUH LOW-HEAT PER BURNER,

DERATED 4%/1000 FT (305M) ABOVE SEA LEVEL)

ALTITUDE AVG. GAS

RANGE HEAT VALUE

AT ALTITUDE

(m) tStu/cu ftI

65O

7001 675

(2134) 700

,4."

<..

* Orifice numbers shown inBOLD are factory-installed.

8000 775

(2438) 800

8001 650

(2439) 675

9000 750

127431 775

9001 600

(2744) 625

10000 700

13048) 725

725 750

825 625

700 725

650 675

Orifice MnfldPress Orifice MnfldPress Orifice MnfldPress

No. Hi,h/Low No. Hi_h/Low No. Hi,h/Low

44 3.3 / 1.6 44 3.4 / 1.6 44 3.5 / 1.7 45 3.7 / 1.8 45 3.8 / 1,8 44 3.3 / 1.6 46 3.6 / 1.7 46 3.7 / 1,8 46 3.8 / 1.8

47 3.8 / 1.8 46 3.5 / 1.7 46 3.6 / 1.7 47 3.5 / 1.7 47 3.7 / 1.8 47 3.8 / 1.8 48 3.8 / 1.8 47 3.4 / 1,6 47 3.6 / 1.7

48 3.6 / 1.7 48 3.7 / 1.8 48 3.8 / 1.8 48 3.3 / 1.6 48 3.5 / 1.6 48 3.6 11.7 45 3.7 / 1.8 45 3.8 / 1,8 44 3.3 / 1.6

46 3.6 / 1.7 46 3.7 / 1.8 46 3.8 / 1.8 47 3.8 / 1.8 46 3.4 / 1,6 46 3.5 / 1.7

47 3.5 / 1.7 47 3.6 / 1.7 47 3.7 / 1.8 48 3.7 / 1.8 48 3.8 / 1.8 47 3.5 / 1.7 48 3.5 / 1.7 48 3.6 / 1,7 48 3.7 / 1.8

46 3.6 / 1.7 46 3.7 / 1.8 46 3.8 / 1.8 47 3.7 / 1.8 47 3.8 / 1.8 46 3.5 / 1.7

47 3.4 / 1.6 47 3.6 / 1,7 47 3.7 / 1.8 48 3.6 / 1.7 48 3.8 / 1.8 47 3.4 / 1.6

48 3.4 / 1.6 48 3.5 / 1.7 48 3.6 / 1.7

SPECIFIC GRAVITY OF NATURAL GAS

0.58 0.60 0.62

3.8 / 1.8 48 3.4 / 1,6 48 3.5 / 1.7

3.7 / 1.8 3.8 / 1,8 48 3.4 11.6

0.64

Orifice Mnfld Press

No. Hi_h/Low

43 3.2 / 1.5

44 3.4 / 1.6 45 3.8 / 1.8

46 3.7 / 1.8 46 3.5 / 1.6 47 3.7 / 1.7

47 3.4 / 1.6 48 3.7 / 1.8 44 3.4 / 1.6

45 3.8 / 1.8 46 3.7 / 1.7

46 3.4 / 1.6 47 3.6 / 1.7 48 3.8 / 1.8

48 3.6 / 1.7 45 3.7 / 1.8

46 3.6 / 1.7 47 3.8 / 1.8

47 3.5 / 1.7 48 3.7 / 1.8 48 3.5 / 1.7

A10185A

SERVICE AND MAINTENANCE

PROCEDURES

FIRE, PERSONAL INJURY AND UNIT DAMAGE HAZARD

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

The ability to properly perform maintenance on this equipment requires certain knowledge, mechanical skills, tools, and equipment. If you do not possess these, do not

attempt to perform any maintenance on this equipment other

than those procedures recommended in the User's Manual.

ELECTRICAL SHOCK, FIRE OR EXPLOSION HAZARD

Failure to follow this warning could result in personal injury or death.

Before installing, modifying, or servicing system, main electrical disconnect switch must be in the OFF position and install a lockout tag. There may be more than one disconnect switch. Lock out and tag switch with a suitable warning label. Verify proper operation after servicing.

UNIT OPERATION HAZARD Failure to follow this caution may result in improper unit

operation or failure of unit components. Label all wires prior to disconnection when servicing

controls. Wiring errors can cause improper and dangerous operation.

ENVIRONMENTAL HAZARD Failure to follow this caution may result in environmental

pollution. Remove and recycle all components or materials (i.e. oil,

refrigerant, control board, etc.) before unit final disposal.

Step 1 -- Introduction

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

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

the furnace, and conditioned air is discharged upward. Since this furnace can be installed in any of the 4 positions shown in Fig. 4,

you must revise your orientation to component location accordingly.

ELECTRICAL CONTROLS AND WIRING

ELECTRICALSHOCK HAZARD

Failure to follow this warning could result in personal iniury or death.

There may be more than one electrical supply to the furnace. Check accessories and cooling unit for additional electrical supplies that must be shut off during furnace servicing. Lock out an tag switch with a suitable warning

label.

The electrical ground and polarity for 115-v wiring must be properly maintained. Refer to Fig. 23 for field wiring information

and to Fig. 52 for furnace wiring information. NOTE: If the polarity is not correct, the STATUS LED on the

control will fash rapidly and prevent the furnace from heating. The control system also requires an earth ground for proper operation of the control and flame-sensing electrode.

The 24-v circuit contains an automotive-type, 3-amp. fuse located on the control. (See Fig. 31.) Any shorts of the 24-v

wiring during installation, service, or maintenance will cause this fuse to blow. If fuse replacement is required, use ONLY a 3-amp.

fuse. The control LED will display status code 24 when fuse needs to be replaced.

Proper instrumentation is required to service electrical controls. The control in this furnace is equipped with a Status Code LED

(Light-Enfitting Diode) to aid in installation, servicing, and troubleshooting. Status codes can be viewed at the sight glass in

blower access door. The furnace control LED is either ON continuously, rapid flashing, or a code composed of 2 digits. The

first digit is the number of short flashes, the second digit is the number of long flashes.

For an explanation of status codes, refer to service label located on blower access door or Fig. 51, and the troubleshooting guide

which can be obtained from your distributor. See Fig. 56 for a brief Troubleshooting guide.

For Controls with an Amber LED The stored status codes will NOT be erased from the control

memory, if 115- or 24-v power is interrupted. The control will store up to five (5) status codes.

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

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

a. Leave l15-v power to furnace turned on.

b. Remove outer access door.

c. Look into blower access door sight glass for currentLED

status.

d. BRIEFLY remove insulated ternfinal wire from the draft

safeguard (DSS) switch until LED goes out, then recon- nect it.

NOTE: If wire to 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 for further

troubleshooting. After the LED flashes status code four times, BRIEFLY remove wire again from DSS switch un-

til LED goes out, then reconnect it to retrieve previous status code (if available). Repeat as needed for more previ-

ous status codes or until Code 11 appears.

If staius code recall is needed, briefly remove then reconnect one main limit _re to display last stored statL_s code. On RED LED boards de not remove power or blower dOOr before initiaing staius code recall.

EACH OF THE FOLLOWING STATUS CODES IS A _ DIGIT NUMBER W1TH THE FIRST DIGIT DETERMINED BY THE NUMBER OF SHORT FLASHES AND THE SECOND DIGIT BY THE NUMBER OF LONG FLASHES.

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

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

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

selected blower off-delay time, if unit is powered up during a calt for heat (R-W/W1 closed) or (R-W/W1) opens during blower omdetay.

13 LIMIT CIRCUIT LOCKOUT - Lockout occurs if a limit, draft safeguard, flame rottout,

or blocked vent switch (if used) is open longer than 3 minutes.

- Coetrot wiit auto reset after three hours. - Refer to #33.

14 IGNITION LOCKOUT - Control wilt auto-reset after three hours. Refer to #34. 21 GAS HEATING LOCKOUT - Control wilt 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 wilt run until fault is cleared. Check for:

- Leaky gas valve - Stuck-open gas valve

23 PRESSURE SWITCH DID NOT OPEN Check for: - Obstructed pressure tubieg

24 SECONDARY VOLTAGE FUSE IS OPEN Check for: - Short circuit in secondary

voltage (24VAC) wiring.

31 HIGH-HEAT PRESSURE SWITCH OR RELAY DID NOT CLOSE OR REOPENED

Control relay may be defective, refer to status code #32

COMPONENTTEST

To initiate the component test sequence, shut OFF the room thermostat or disconnect the

"R" thermostat lead. Briefly short the TEST/TWIN terminal to the "Com 24V" termieN. Status LED wilt flash last status code and then turn ON the inducer motor. The inducer

motor wilt start ie HIGH speed and remain on HIGH speed untiI the end of the test then shift to LOW speed for 7 to 15 seconds. The hot surface igniter, blower motor LO HEAT speed, blower motor HI HEAT speed, and blower motor COOL speed wilt be turned ON for

10-15 seconds each. Gas Valve and Humidifier wilt not be turned on. When the blower is

turned OFF the inducer wilt be switched to tow-speed for 10 seconds.

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 - Line voltage (115VAC) polarity reversed, If twinned, refer to twinning kit instructions,

32 LOW-HEAT PRESSURE SWITCH DID NOT CLOSE OR REOPENED - If open longer than

five minutes, ieducer shuts off for 15 mieutes before retry, If opens during blower on-delay period, blower wilt come on for the selected blower off-delay. Check for:

- Excessive wind - Restricted vent - Defective inducer motor

- Proper vent sizing - Defective pressure switch - Low inducer voltage (115 VAC)

- Inadequate combustion air supply - Low inlet gas pressure (if LGPS used)

- Disconnected or obstructed pressure tubieg

33 LIMIT CIRCUIT FAULT - Indicates a limit, draft safeguard, flame rotteut, or blocked vent

switch (if used) is open, Blower wilt rue for 4 minutes or until open switch remakes

whichever is longer, If open teeger than 3 minutes, code changes to tockeut #13. If open

tess than 3 mieutes status code #33 continues to flash until blower shuts off. Flame rettout switch and BVSS require manual reset, Check for: - Dirty filter or restricted duct system

- Defective blower meter or capacitor - Proper vent sizing - Restricted vent

- Defective switch or connections - Loose blower wheel - Excessive wied

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

34 IGNITION PROVING FAILURE - Control wilt try three mere times before lockout #14 occurs,

- Pressure switch stuck closed

If flame signal test durieg blower on-delay period, blower wilt come on for the selected blower off-delay. Check for: - Oxide buildup on flame sensor (clean with fine steel wool)

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

- Manual valve shut-off - Coetrot ground continuity

- Gas valve defective or gas valve turned Off - Low ietet gas pressure

- Inadequate flame carryover Or rough ignition - Defective Hot Surface Ignitor

- Flame sensor must not be grounded

- Green/Yellow wire MUST be connected to furnace sheet metal

43 LOW-HEAT PRESSURE SWITCH OPEN WHILE HIGH-HEAT PRESSURE SWITCH IS

CLOSED - Check for: - Disconnected or obstructed pressure tubing

- Mis-wired pressure switches - Low-heat pressure switch stuck open

- Low inlet gas pressure (if LGPS used)

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

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

Fig. 51 - Service Label

327598-101 REV. C

Step 2 -- Care and Maintenance

SERVICE

A04210

FIRE OR EXPLOSION HAZARD Failure to follow this warning could result in personal

iniury, 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, vacuum cleaners, or other cleaning tools.

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

or other volatile fluids.

3. Paint thinners and other painting compounds, paper bags, or other paper products. Exposure to these

materials could lead to corrosion of the heat exchanger.

For continuing high performance and to minimize possible furnace failure, periodic maintenance must be performed on this

furnace. Consult your local dealer about proper frequency of maintenance and the availability of a maintenance contract.

ELECTRICAL SHOCK AND FIRE HAZARD Failure to follow this warning could result in personal

iniury, death or property damage. Before installing, modifying, or servicing system, main

electrical disconnect switch must be in the OFF position and install a lockout tag. There may be more than one disconnect switch. Lockout and tag switch with a suitable warning label.

CARBON MONOXIDE POISONING AND FIRE

HAZARD

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

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

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

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

The minimum maintenance on this furnace is as follows:

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

2. Check blower motor and wheel for cleanliness each heat- ing and cooling season. Clean as necessary.

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

sary.

4. Inspect burner compartment before each heating season for rust, corrosion, soot or excessive dust. If necessary,

have furnace and burner serviced by a qualified service agency.

5. Inspect the vent pipe/vent system before each heating sea- son for rust, corrosion, water leakage, sagging pipes or

broken fittings. Have vent pipes/vent system serviced by a qualified service agency.

6. Inspect any accessories attached to the furnace such as a humidifier or electronic air cleaner. Perform any service or

maintenance to the accessories as recommended in the ac- cessory instructions.

CONNECTION DIAGRAM

SELECT CHART

SW LO-HT BLOWER

ONLY OFF-DElAY

NORM go

nl*ii

III II_T SEC.OFF

ON 1! H_T

l LO

OFF u ONLY SEC

OFF see.

O_ ii 180 PLI

* FACTORY SE MINGS

_2 _ ACRDJ

I 3 _

OFFII I III z _O

SEC.

FRS1 DSS / \ LS2_ LS1 FRS2A I BREAKER& DISCONNECT

R (WHEN USED) (WHEN USED) [-I _ }

NOTE #10 /

RED_ FUSE OR CIRCUIT

GRN/YEL II

BLK

GRN/YEL

NEUTP.AI I M i NOTE I/2

HSI L-/ ....

,#,

TO 115VAC FIELD-DISCONNECT SWITCH

EQUIPM N1

GROUND

L1 L_

IHI!LOR PL2

IDR

BHI!LOR

LO HEAT

EAC-1 EAC-2

11 m

SCHEMATIC DIAGRAM

(NATURAL GAS & PROPANE)

PL5 PL4

FT/

ACR ACRD_

BHI/ OR BH1/CLR

BIWR BIWM BVSS CAP CPU DHUM DSS EAC-1

EAC-2 ERS1,2 FSE FUI FU2

GND GV

GVR 1,2 HPS HPSR HSI HSIR

HUM IDM

IDR IHI/LOR ILK JB LD LGPS LPS LSI, 2 OL PCB

AIR CONDITIONING REW\Y, SPST (N.O.) AIR CONDITIONING RELAY DISABLE JUMPER PL1

SLOWER MOTOR SPEED CHANGE RLAY, SPDT PL2 BLOWER MOTOR SPEED CHANGE RELAY, SPDT PI3 BOWR MOTOR RELAV, SPST-(N.O.) PL4

BOWER MOTOR, PERMANENT-SPLIT-CAPACIIOR PL5 BLOCKED VEN[ SHUTOFF SWITCH, MANUAL-RESE[, SPS[ -(N,C,) PLT CAPACITOR IRAN

MICROPROCESSOR AND CIRCUFRY 1EST/:WiN DUM CONNEC ION

DRAFI SAFE GUARD SWI/CH, AU O-RESE1, SPS -(N.C )

L CTRONIC AIR CLEAN R CON NECTION (I15 VAC 1.0 AMP MAX,)

ELECTRONIC AIR CLEANER CONNECqON (COMMON) O FLAME ROLLOUT SW, -MANUAL RESET,SPST-(N,C)

FLAME-PROVING EL CTROD FUSE, 3 AMR AUTOMOTIVE BLADE TYPE, FACTORY INSTALLED

FUSE OR CIRCUIT BREAKER CURRENT INTERRUPT DEVICE

(FIELD SUPPLIED AND INSTALLED)

EQUIPMENT GROUND _ _ _ GAS VAlVE-REDUNDANT

GAS VALVE RELAY, DPST-(N.O.) ....

HIGH-I AT PRESSUR SWI CH, SPST(N.O.) HIGH-HAT PRESSURE SWICH RELAv, SPST (k,C,) HOI SURFACE IGNITER (115VAC)

HO SURFACE IGNI1ER RELAY,SPST(N.O.) 24VAC HUMIDIFIER CONNEC ION (0.5 AMP. MAX.) _"

INDUCED DRAT MOTOR, SHADED-POLE /-)-7 INDUCED DRAFT MOTOR RELAZ SPST-(N.O.)

INDUCER MOTOR SPEED CHANGE RELAv, SPDT BLOWER ACCESS PANEL INIERLOCK SWITCH, SPST(N,O,/ UKCTION BOX --_ )--

lIGHT- MI ING DIODE FOR STATUSCODES AMBER lOW GAS PRESSURE SWITCH SPST-(N,O.)

I OW-HEAT PR SSURE SWITCH, SPST (N.O.) lIMIT SWITCH AUTO-RES E SPST(N.C.)

AUTO-RESET IN ERNAL MOTOR OVERLOAD 1EMPERAIURE SWITCH (N.C.)

PRINTED ,. IRCUIT BOARD CONTROL

WHF

RED

BLU

12-CIRCUI1 PCB CONNECTOR 3-CIRCUIT PCB NSI & IDM CONNECTOR

6-CIRCUIT ICIV MOTOR CONNECTOR (NOT SHOWN)

3 CIRCUIT IDM CONNECTOR 2-CIRCUIT HSI CONNEC1OR

3-CIRCUIT FACTORY TESTCONNECTOR TRANS QRMER, 115VAC/2 VAC COMPONENT TESI & TWINNING [ERMINAL

JUNCIlON UNMARKED TERMINAL

PCB CQNTRO TERMINAL

FACTORY POWER WIRING (115VAC)

FACTORY CONTROL WIRING (24VAC)

FIELD CON/ROL WIRING (I 15VAC) FIELD CON[ROL WIRING (24VAC)

CONDUCTOR ON CONTROL PCB

FIELD WIRING SCREW TERMINAL

FIELD EARTH GROUND

EQUIPMENT GROUND

FIELD SPJCE

PLUG RECEPTACLE

Table 17 - Filter Size Information (In. / Mm)

FURNACE CASING WIDTH

14-1/2 (368)

17-1/2 (445)

21 (533)

24 (610)

Recommended

** Some furnaces may have 2 filters.

SIDE

RETURN

16 x25 x 3/4

(406 x635 x 19)

16 x25 x 3/4

(406 x635 x 19)

16 x25 x 3/4

(406 x635 x 19)

16 x25 x 3/4

(406 x635 x 19)

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

NOTE: If the filter has an airflow direction arrow, the arrow must point towards the blower.

CUT HAZARD

Failure to follow this caution may result in personal injury. Sheet metal parts may have sharp edges or burrs. Use care

and wear appropriate protective clothing, safety glasses and gloves when handling parts and servicing furnaces.

Accessory media cabinet filter procedures:

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

2. Remove filter cabinet door.

3. Slide filter out of cabinet.

4. If equipped with permanent, washable 3/4-in. (19 ram) fil- ter, clean filter by spraying cold tap water through filter in opposite direction of airflow. Rinse filter and let dry. Oil-

ing or coating of the filter is not recommended. See Table 17 for size information.

5. If equipped with factory-specified disposable media filter, replace only with media filter having the same part num-

ber and size. For expandable replacement media, refer to the instructions included with the replacement media.

6. Slide filter into cabinet.

7. Replace filter cabinet door.

8. Turn on electrical supply to furnace.

BLOWER MOTOR AND WHEEL

ELECTRICALSHOCK HAZARD

Failure to follow this warning could result in personal iniury or death.

Blower access door switch opens 115-v power to control. No component operation can occur unless switch is closed.

Caution nmst be taken when manually closing this switch

for service purposes.

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

The following steps should be performed by a qualified

service agency.

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

FILTERSIZE

The inducer and blower motors are pre-lubricated and require no additional lubrication. These motors can be identified by the

absence of oil ports on each end of the motor. Clean blower motor and wheel as follows:

BOTTOM

RETURN

14 x25 x 3/4

(356 x635 x 19)

16 x25 x 3/4

(406 x635 x 19)

20 x25 x 3/4

(508 x635 x 19)

24 x25 x 3/4

(610 x635 x 19)

1. Turn off electrical supply to furnace.

FILTER TYPE

Washable*

2. Remove outer door.

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

door:

a. Disconnect vent connector from furnace vent elbow.

b. Disconnect and remove short piece of vent pipe from

within furnace.

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

5. All factory wires can be left connected, but field thermo- stat connections may need to be disconnected depending

on their length and routing.

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

7. 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.

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

9. If a greasy residue is present on blower wheel, remove wheel from the blower housing and wash itwith an appro-

priate degreaser. To remove wheel:

NOTE: Before disassembly, mark blower mounting arms, motor, and blower housing so motor and each arm is positioned at the

same location during reassembly.

a. Disconnect capacitor wires (if equipped) and ground wire

attached to blower housing.

b. Remove screws securing cutoff plate and remove cutoff

plate from housing.

c. Loosen set screw holding blower wheel on motor shaft

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

d. Remove bolts holding motor to blower housing and slide

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

e. Remove blower wheel from housing.

f. Clean wheel and housing.

10. Reassemble motor and blower by reversing steps 9a, through 9e. Be sure to reattach ground wire to the blower

housing.

11. Verify that blower wheel is centered in blower housing and set screw contacts the flat portion of the motor shaft.

Loosen set screw on blower wheel and reposition if neces- sary.

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

13. Reinstall blower assembly in furnace.

UNITDAMAGEHAZARD Failureto follow this caution may result in shortened heat

exchanger life. Heating fan speed(s) MUST be adjusted to provide proper

air temperature rise as specified on the rating plate. Recommended operation is at the midpoint of the rise range or slightly above. Refer to "SET TEMPERATURE RISE" under START-UP, ADJUSTMENT, and SAFETY

CHECK.

14. Reinstall 2 screws securing blower assembly to blower deck.

15. Refer to furnace wiring diagram, and connect thermostat leads if previously disconnected.

16. To check blower for proper rotation:

a. Turn on electrical supply.

b. Manually close blower access door switch.

NOTE: If thermostat terminals are jumpered at the time blower access door switch is closed, blower will run for 90 sec before

beginning a heating or cooling cycle.

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

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

d. Verify blower is rotating in the correct direction.

17. If furnace is operating properly, RELEASE BLOWER ACCESS DOOR SWITCH. Remove any jumpers or re-

connect any disconnected thermostat leads. Replace blower access door.

ELECTRICALSHOCK HAZARD Failure to follow this warning could result in personal

iniury, or death. Blower access door switch opens l15-v power to furnace

control. No component operation can occur unless switch is closed. Exercise caution to avoid electrical shock from

exposed electrical components when manually closing this switch for service purposes.

problem exists which needs to be corrected, such as improper adjustment of manifold pressure, insufficient or poor quality

combustion air, incorrect size or damaged manifold orifice(s), improper gas, or a restricted heat exchanger. Action must be taken

to correct the problem. If it becomes necessary to clean the heat exchangers because of

dust or corrosion, proceed as follows:

1. Turn OFF gas and electrical power to furnace.

2. Remove outer access door.

3. Disconnect vent connector from furnace vent elbow.

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

5. Disconnect wires to the following components. Mark wires to aid in reconnection of (be careful when discon- necting wires from switches because damage may occur):

a. Draft safeguard switch.

b. Inducer motor.

c. Pressure switches.

d. Limit overtemperature switch.

e. Gas valve.

f. Hot surface igniter.

g. Flame-sensing electrode h. Flame rollout switches.

6. Remove screws that fasten the collector box assembly to the cell panel. Be careful not to damage the collector box.

Inducer assembly and elbow need not be removed from collector box.

7. Disconnect gas line from gas manifold.

8. Remove the 5 screws that attach the burner assembly to the cell panel. The gas valve and individual burners need not be removed from support assembly. Remove NOx baffles if installed.

NOTE: Be very careful when removing burner assembly to avoid breaking igniter. See Fig. 53 and 54 for correct igniter

location.

9/32"

7.1 mm

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

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

to existing vent.

b. Connect vent connector to vent elbow.

19. Reinstall outer door.

20. Turn on gas supply and cycle furnace through one com- plete heating and cooling cycle. Verify the furnace temper-

ature rise as shown in Adjustments Section. Adjust tem- perature rise as shown in Adjustments Section. If outdoor

temperature is below 70°F (21°C) turn off circuit breaker to outdoor unit before running furnace in the cooling

cycle. Turn outdoor circuit breaker on after completing cooling cycle.

CLEANING HEAT EXCHANGER The following steps should be performed by a qualified

service agency: NOTE: If the heat exchangers get a heavy accumulation of soot

and carbon, they should be replaced rather than trying to clean them thoroughly. A build-up of soot and carbon indicates that a

A05025

Fig. 53 - Igniter Position-Side View

9. Using field-provided 25-caliber rifle cleaning brush, 36-in. (914 ram) long l/4-in. (6 ram) diameter steel spring cable, a variable speed, reversible electric drill, and

vacuum cleaner, clean cells as follows:

a. Remove metal screw fitting from wire brush to allow in-

sertion into cable.

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

cable, and crimp tight with crimping tool or crimp by

strikingwithball-peenhammer.TIGHTNESSISVERY IMPORTANT.

NOTE:Thematerialsneededinitem9canusuallybepurchased atlocalhardwarestores.

(1.)Attachvariable-speed,reversibledrilltotheendof

springcable(endoppositebrush).

(2.)Insertbrushendofcableintotheoutletopeningof

cellandslowlyrotatewithdrill.DONOTforce cable.Graduallyinsertcableintoupperpassofcell. (SeeFig.55.)

(3.)Workcableinandoutofcell3or4timestoobtain

sufficientcleaning.DONOTpullcablewithgreat force.Reversedrillandgraduallyworkcableout.

(4.)Insertbrushendofcableinburnerinletopeningof

cell,andproceedtoclean2lowerpassesofcellin samemannerasupperpass.

(5.)Repeatforegoingproceduresuntileachcellinfur-

nacehasbeencleaned.

(6.)Usingvacuumcleaner,removeresiduefromeach

cell.

(7.)Usingvacuumcleanerwithsoftbrushattachment,

cleanburnerassembly. (8.)Cleanflamesensorwithfinesteelwool. (9.)InstallNOxbaffles(ifremoved.)

(10.)Reinstallburnerassembly.Centerburnersincell

openings.

10.Removeoldsealantfromcellpanelandcollectorbox flange.

11.Sprayreleasingagentontheheatexchangercellpanel wherecollectorboxassemblycontactscellpanel.

NOTE:A releasingagentsuchascookingsprayorequivalent (mustnotcontaincornorcanolaoil,aromaticorhalogenated hydrocarbonsorinadequatesealmayoccur)andRTVsealant (G.E.162,6702,orDow-Corning738)areneededbefore

startinginstallation.DONOTsubstituteanyothertypeofRTV sealant.G.E.162(P771-9003)isavailablethroughRCDin3-oz.

tubes.

12.Applynewsealanttoflangeofcollectorboxandattachto cellpanelusingexistingscrews,makingsureallscrews

aresecure.

13.Reconnectwirestothefollowingcomponents(Use con-

nection diagram on wiring label, if wires were not marked for reconnection locations.):

a. Draft safeguard switch.

b. Inducer motor.

c. Pressure switches.

d. Limit overtemperature switch.

e. Gas valve.

f. Hot surface igniter.

g. Flame-sensing electrode. h. Flame rollout switches.

14. Reinstall internal vent pipe, if applicable.

15. Reinstall vent connector on furnace vent elbow. Securely fasten vent connector to vent elbow with 2 field-supplied,

corrosion-resistant, sheet metal screws located 180 ° apart.

1-7/8

O (47'imm)

A05026

Fig. 54 - Igniter Position-Top View

A91252

Fig. 55 - Cleaning Heat Exchanger Cell

16. Replace blower access door only, if it was removed.

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

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

FIRE OR EXPLOSION HAZARD

Failure to follow this warning could result in personal iniury death and/or property damage.

Never test for gas leaks with an open flame. Use a commercially available soap solution made specifically for

the detection of leaks to check all connects.

19. Check for gas leaks.

20. Replace outer access door.

Step 3 -- Sequence of Operation

NOTE: Furnace control must be grounded for proper operation or control will lockout. Control is grounded through green wire connected to gas valve and burner bracket screw. Using the schematic diagram in Fig. 52, follow the sequence of operation through the different modes. Read and follow the wiring diagram very carefully.

NOTE: If a power interruption occurs during a call for heat (W/W1 or W/Wl-and-W2), the control run the blower for the

selected blower off-delay period two seconds after power is restored and if the thermostat is still calling for gas heating. The LED light will flash code 12 during this period, after which the LED will be ON continuous, as long as no faults are detected. After this period, the furnace will respond to the thermostat normally.

The blower door must be installed for power to be conducted through the blower door interlock switch ILK to the furnace

controlCPU,transformer TRAN, inducer motor IDM, blower

motor BLWM, hot-surface igniter HSI, and gas valve GV.

1, Two-Stage Heating (Adaptive mode) with Single-

Stage Thermostat (See Fig. 23 or 32 for thermostat connections)

NOTE: The low-heat only switch (LHT) selects either the low-heat only operation mode when ON, (see item 2. below) or

the adaptive heating mode when OFF in response to a call for heat. (See Fig. 33.) When the W2 thermostat terminal is energized it will always cause high-heat operation when the R to W circuit is closed, regardless of the setting of the low-heat only switch. This furnace can operate as a two-stage furnace with a single-stage thermostat because the furnace control CPU includes a programmed adaptive sequence of controlled operation, which selects low-heat or high-heat operation. This selection is based

upon the stored history of the length of previous gas-heating periods of the single-stage thermostat.

The furnace will start up in either low- or high-heat. If the furnace starts up in low-heat, the control CPU determines the

low-heat on-time (from 0 to 16 minutes) which is permitted before switching to high-heat.

If the power is interrupted, the stored history is erased and the control CPU will select low-heat for up to 16 minutes and then

switch to high-heat, as long as the thermostat continues to call for heat. Subsequent selection is based on stored history of the

thermostat cycle times. The wall thermostat "calls for heat", closing the R to W circuit.

The furnace control performs a self-check, verifies the low-heat and high-heat pressure switch contacts LPS and HPS are open,

and starts the inducer motor IDM in high-speed.

a. Inducer Prepurge Period

(1.) If the furnace control CPU selects low-heat opera-

tion the inducer motor IDM comes up to speed, the low-heat pressure switch LPS closes, and the fur-

nace control CPU begins a 15-second prepurge period. After the low-heat pressure switch re-closes

the furnace control CPU will begin a 15-second pre- purge period, and continue to run the inducer motor IDM at high-speed.

(20 If the furnace control CPU selects high-heat opera-

tion, the inducer motor IDM remains running at high-speed, and the high-heat pressure switch relay HPSR is de-energized to close the NC contact.

When sufficient pressure is available the high-heat pressure switch HPS closes, and the high-heat gas

valve solenoid GV-HI is energized. The furnace control CPU begins a 15-second prepurge period

after the low-heat pressure switch LPS closes. If the high-heat pressure switch HPS fails to close and the

low-heat pressure switch LPS closes, the furnace will operate at low-heat gas flow rate until the high-

heat pressure switch closes for a maximum of 2 minutes after ignition.

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

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

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

up period is completed the main gas valve relay contacts GVR-I and -2 close to energize the gas valve solenoid

GV-M, the gas valve opens, and 24 vac power is supplied for a field-installed humidifier at the HUM terminal. The

gas valve solenoid GV-M permits gas flow to the burners where it is ignited by the HSI. Five sec after the GVR closes, a 2-sec flame proving period begins. The HSI ig-

niter will remain energized until the flame is sensed or un- til the 2-sec flame proving period begins. If the furnace

control CPU selects high-heat operation, the high-heat gas valve solenoid GV-HI is also energized.

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

flame-proving sensor electrode FSE, the inducer motor IDM switches to low-speed unless running at high-

speed, and the furnace control CPU begins the blower- ON delay period and continues to hold the gas valve GV-

M open. If the burner flame is not proved within two seconds, the control CPU will close the gas valve GV-M,

and the control CPU will repeat the ignition sequence for up to three more Trials-For-Ignition before going to Ig-

nition- Lockout. Lockout will be reset automatically after three hours, by momentarily interrupting 115 vac

power to the furnace, or by interrupting 24 vac power at SEC1 or SEC2 to the furnace control CPU (not at W/WI,

G, R, etc.). If flame is proved when flame should not be present, the furnace control CPU will lock out of Gas- Heating mode and operate the inducer motor IDM on

high speed until flame is no longer proved.

e. Blower-ON Delay-If the burner flame is proven the

blower-ON delay for low-heat and high-heat are as fol- lows:

Low-Heat-45 seconds after the gas valve GV-M is en- ergized the blower motor (BLWM) is energized at LO

HEAT speed. High-Heat-25 seconds after the gas valve GV-M is en-

ergized the BLWM is energized at HI HEAT speed. Sim- ultaneously, the electronic air cleaner (EAC-1) terminal

is energized and remains energized as long as the BLWM is energized.

f. Switching from Low-to High-Heat-If the furnace con-

trol CPU switches from low-heat to high-heat, the fur- nace control CPU will switch the inducer motor IDM

speed from low to high. The high-heat pressure switch relay HPSR is de-energized to close the NC contact.

When sufficient pressure is available the high-heat pres- sure switch HPS closes, and the high-heat gas valve

solenoid GV-HI is energized. The blower motor BLWM will switch to HI HEAT speed five seconds after the fur-

nace control CPU switches from low-heat to high-heat.

g. Switching from High- to Low-Heat-The furnace con-

trol CPU will not switch from high-heat to low-heat while the thermostat R-to-W circuit is closed when using

a single stage thermostat.

h. Blower-OFF Delay-When the thermostat is satisfied, the

R to W circuit is opened, de-energizing the gas valve GV-M, stopping gas flow to the burners, and de-energiz-

ing the humidifier terminal HUM. The inducer motor IDM will remain energized for a 5-second post-purge

period. The blower motor BLWM and air cleaner termin- al EAC-I will remain energized for 90, 120, 150, or 180

seconds (depending on selection at blower-OFF delay switches). The furnace control CPU is factory-set for a

120-second blower-OFF delay.

2. Two-Stage Thermostat and Two-Stage Heating (See Fig. 31 for thermostat connections)

NOTE: In this mode the LHT nmst be ON to select the low-heat only operation mode in response to closing the thermostat

R-to-Wl circuit. Closing the thermostat R-to-Wl-and-W2 circuits always causes high-heat operation, regardless of the setting of the low-heat-only switch.

The wall thermostat "calls for heat", closing the R-to-Wl circuit for low-heat or closing the R-to-W1 and-W2 circuits for

high-heat. The furnace control performs a self-check, verifies the low-heat and high-heat pressure switch contacts LPS and HPS

are open, and starts the inducer motor IDM in high-speed.

The start up and shut down flmctions and delays described in item 1. above apply to the 2-stage heating mode as well, except

for switching from low- to high-Heat and vice versa.

a. Switching from Low- to High-Heat-If the thermostat

R-to- Wl circuit is closed and the R-to-W2 circuit closes, the furnace control CPU will switch the inducer

motor IDM speed from low to high. The high-heat pres- sure switch relay HPSR is de-energized to close the NC

contact. When sufficient pressure is available the high- heat pressure switch HPS closes, and the high-heat gas

valve solenoid GV-HI is energized. The blower motor BLWM will switch to HI HEAT speed five seconds after

the R-to-W2 circuit closes.

b, Switching from High- to Low-Heat-If the thermostat

R-to-W2 circuit opens, andtheR-to-W1 circuit remains closed, the furnace control CPU will switch the inducer

motor IDM speed from high to low. The high-heat pres- sure switch relay HPSR is energized to open the NC con-

tact and de-energize the high-heat gas valve solenoid GV-HI. When the inducer motor IDM reduces pressure

sufficiently, the high-heat pressure switch HPS will open. The gas valve solenoid GV-M will remain ener-

gized as long as the low-heat pressure switch LPS re- mains closed. The blower motor BLWM will switch to

LO HEAT speed five seconds after the R-to-W2 circuit opens.

3. Cooling Mode-The thermostat "calls for cooling." a. Single-Speed Cooling-

(See Fig. 27 for thermostat connections) The thermostat closes the R-to-G-and-Y circuits. The

R-to- Y circuit starts the outdoor unit, and the R-to- G-and-Y/Y2 circuits start the furnace blower motor

BLWM on COOL speed. The electronic air cleaner ternfinal EAC-1 is energized

with 115 vac when the blower motor BLWM is operating.

When the thermostat is satisfied, the R-to-G and-Y cir- cuits are opened. The outdoor unit will stop, and the fur-

nace blower motor BLWM will continue operating on the COOL speed for an additional 90 seconds. Jumper Y/Y2

to DHUM to reduce the cooling off-delay to 5 seconds. (See Fig. 24.)

b, Single-Stage Thermostat and Two-Speed Cooling

(Adaptive Mode) (See Fig. 32 for thermostat connections)

This furnace can operate a two-speed cooling unit with a single-stage thermostat because the furnace control

CPU includes a programmed adaptive sequence of con- trolled operation, which selects low-cooling or high-

cooling operation. This selection isbased upon the stored history of the length of previous cooling period of the

single-stage thermostat.

NOTE: The air conditioning relay disable jumper ACRDJ must be connected to enable the adaptive cooling mode in response to

a call for cooling. (See Fig. 33.) When ACRDJ is in place, the furnace control CPU can turn on the air conditioning relay ACR

to energize the Y/Y2 ternfinal and switch the outdoor unit to high-cooling.

The furnace control CPU can start up the cooling unit in either low- or high-cooling. If starting up in low-cooling, the furnace

control CPU deternfines the low-cooling on-time (from 0 to 20 nfinutes) which is pernfitted before switching to high-cooling. If

the power is interrupted, the stored history is erased and the furnace control CPU will select low-cooling for up to 20 nfinutes

and then energize the air conditioning relay ACR to energize the Y/Y2 ternfinal and switch the outdoor unit to high-cooling, as

long as the thermostat continues to call for cooling. Subsequent selection is based on stored history of the thermostat cycle times.

The wall thermostat "calls for cooling", closing the R-to-G-and-Y circuits. The R-to-Y1 circuit starts the outdoor

unit on low-cooling speed, and the R-to-G-and-Y1 circuits starts the furnace blower motor BLWM at low-cool speed (same speed as LO HEAT).

If the furnace control CPU switches from low-cooling to high-cooling, the furnace control CPU will energize the air

conditioning relay ACR. When the air conditioning relay ACR is energized the R-to-Yl-and-Y2 circuits switch the outdoor unit

to high-cooling speed, and the R-to-G-and-Yl-and-Y/Y2 circuits switch the furnace blower motor BLWM to COOL speed.

NOTE: When transitioning from low-cooling to high-cooling the outdoor unit compressor will shut down for 1 nfinute while

the BLWM continues to run at low-cool speed (same speed as LO-HEAT) until the outdoor unit compressor comes back on at

high speed. The electronic air cleaner ternfinal EAC-1 is energized with 115

vac whenever the blower motor BLWM is operating. When the thermostat is satisfied, the R-to-G-and-Y circuit are opened. The outdoor unit stops, and the furnace blower BLWM and

electronic air cleaner ternfinal EAC-1 will remain energized for an additional 90 seconds. Jumper Y1 to DHUM to reduce the

cooling off-delay to 5 seconds. (See .Fig. 34.)

c. Two-Stage Thermostat and Two-Speed Cooling (See

Fig. 31 for thermostat connections)

NOTE: The air conditioning relay disable jumper ACRDJ must be disconnected to allow thermostat control of the outdoor unit

staging. (See Fig. 33.) The thermostat closes the R-to-G-and-Y1 circuits for

low-cooling or closes the R-to-G-and-Yl-and-Y2 circuits for high-cooling. The R-to-Y1 circuit starts the outdoor unit on

low-cooling speed, and the R-to-G-and-Y1 circuit starts the furnace blower motor BLWM on low-cool speed (same speed as

LO HEAT). 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 furnace blower motor BLWM on COOL speed. The

electronic air cleaner ternfinal EAC-1 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-Yl-and-Y2 circuits are opened. The outdoor unit stops, and the furnace blower BLWM and electronic air cleaner

ternfinal EAC-1 will remain energized for an additional 90 seconds. Jumper Y1 to DHUM to reduce the cooling off-delay to

5 seconds. (See Fig. 33.)

4, Thermidistat Mode

(See Fig. 26 - 28 for Thernfidistat connections) The dehu- midification output, DHUM on the Thermidistat should be

connected to the furnace control thermostat ternfinal DHUM. When there is a dehunfidify demand, the DHUM

input is activated, which means 24 vac signal is removed from the DHUM input ternfinal. In other words, the

DHUM input logic is reversed. The DHUM input is turned ON when no dehunfidify demand exists. Once 24 vac is detected by the furnace control on the DHUM input,

the furnace control operates in Thernfidistat mode. If the DHUM input is low for more than 48 hours, the furnace

control reverts back to non-Thernfidistat mode. The cooling operation described in item 3. above also ap-

plies to operation with a Thernfidistat. The exceptions are listed below:

a. Low cooling - When the R-to-G-and-Y1 circuit is

closed and there is ademand for dehunfidification,the fur- nace blower motor BLWM will continue running at low- cool speed (same speed as LO HEAT).

b. High cooling -When the R-to-G-and-Y/Y2 circuit is

closed and there is ademand for dehunfidification,the fur- nace blower motor BLWM will drop the blower speed

fromCOOLtoHIHEATforan_axinmmof10minutes beforerevertingbacktoCOOLspeed.Ifthereisstilla

demandfordehumidificationafter20minutes,thefur- nacecontrolCPUwilldroptheblowerspeedbacktoHI

HEATspeed.Thisalternating10-minutecyclewillcon- tinueaslongasthereisacallforcooling.

c.Coolingoff-delay- Whenthe"callforcooling"issatis-

fiedandthereisademandfordehumidification,thecool- ingblower-offdelayisdecreasedfrom90secondsto5

seconds.

5. 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 set to LO HEAT, HI HEAT, or COOL speed). Factory default is LO HEAT speed. Terminal

EAC-I is energized as long as the blower motor BLWM is energized. During a call for heat, the blower BLWM will

stop during igniter warm-up (17 seconds), ignition (7 seconds), and blower-ON delay (45 seconds in low-heat,

and 25 seconds in high-heat), allowing the furnace heat exchangers to heat up more quickly, then restarts at the

end of the blower-ON delay period at LO HEAT or HI HEAT speed respectively. The blower motor BLWM will revert to continuous-blower speed after the heating cycle

is completed. In high-heat, the furnace control CPU will hold the blower motor BLWM at HI HEAT speed during

the selected blower-OFF delay period before reverting to continuous-blower speed.

When the thermostat "calls for low-cooling", the blower motor BLWM will switch to operate at low-cool speed

(same speed as LO HEAT). When the thermostat is satis- fied, the blower motor BLWM will operate an additional

90 seconds on low-cool speed before reverting back to continuous-blower speed. When the thermostat "calls for high-cooling", the blower

motor BLWM will operate at COOL speed. When the thermostat is satisfied, the blower motor BLWM will oper-

ate an additional 90 seconds on COOL speed before re- verting back to continuous-blower speed.

When the R-to-G circuit is opened, the blower motor BLWM will continue operating for an additional 5

seconds, if no other function requires blower motor BLWM operation.

Continuous Blower Speed Selection from Thermostat To select different continuous-blower speeds from the

room thermostat, momentarily turn off the FAN switch or push button on the room thermostat for 1-3 seconds after the blower motor BLWM is operating. The furnace control

CPU will shift the continuous-blower speed from the fact- ory setting of LO HEAT to HI HEAT speed. Momentarily

turning off the FAN switch again at the thermostat will shift the continuous-blower speed from HI HEAT to

COOL. Repeating the procedure will shift the continuous- blower speed from COOL to LO HEAT speed. The selec-

tion can be changed as many times as desired and is stored in the memory to be automatically used following a power

interruption.

NOTE: If the blower-off delay is set to the maximum, the adjustable continuous-fan feature is locked (i.e., fan speed cannot

be changed from its current setting).

6. Heat Pump (See Fig. 27-30 for thermostat connections)

When installed with aheat pump, the furnace control auto- matically changes the timing sequence to avoid long

blower off times during demand defrost cycles. When the R-to- W/Wl-and-Y1 or R-to-W/Wl-and-Yl-and-G

circuits are energized the furnace control CPU will switch to or turn on the blower motor BLWM at low-cool speed (same speed as LO HEAT), and begin a low-heat cycle.

The blower motor BLWM will remain on until the end of the prepurge period, then shut off for 24 seconds then

come back on at LO HEAT speed. When the W/W1 input signal disappears, the furnace control begins a normal in-

ducer post-purge period and the blower remains running at LO HEAT speed. If the R-to- W/Wl-and-Yl-and-G signals disappear at the same time, the blower motor

BLWM will remain on for the selected blower- OFF delay period. If the R-to-W/Wl-and-Y1 signals disappear,

leaving the G signal, the blower motor BLWM will remain on for the selected blower-OFF delay period then switch

to continuous-blower speed. When the R-to-W/Wl-and-Y/Y2, R-to-W/Wl-and- Y/Y2- and-G, R-to-W/Wl-and-Yl-and-Y/Y2, or R-to-W/Wl-and- Yl-and-Y/Y2-and-G circuits are en-

ergized the furnace control CPU will switch to or turn on the blower motor BLWM at COOL speed, and begin a high-heat cycle. The blower motor BLWM will remain on

until the end of the prepurge period, then shut off for 24 seconds then come back on at HI HEAT speed. When the

W/W1 input signal disappears, the furnace control begins a normal inducer post-purge period and the

blower switches to COOL speed after a 3 second delay. If the R-to-W/Wl-and-Y/Y2-and-G or R-to-W/Wl-and

-Yl-and- Y/Y2-and-G signals disappear at the same time, the blower motor BLWM will remain on for the se-

lected blower-OFF delay period. If the R-to-W/Wl- and-Y/Y2 or R-to-W/W1- and-Yl-and-Y/Y2 signals

disappear, leaving the G signal, the blower motor BLWM will remain on for the selected blower- OFF delay period then switch to continuous-blower speed.

Step 4 -- Wiring Diagrams Refer to wiring diagram, Fig. 52.

Step 5 -- Troubleshooting Refer to the service label. (See Fig. 51--Service Label.) The

Troubleshooting Guide can be a useful tool in isolating furnace operation problems. Beginning with the word "Start," answer

each question and follow the appropriate arrow to the next item. The Guide will help to identify the problem or failed component.

After replacing any component, verify correct operation sequence.

START

Is LED status light on?

YES

TROUBLESHOOTING GUIDE

J_ Is there 115V at L1 and L2?

YES

! Is there 24v at sEC-1 and SEC-2?

-_-_ Is door switch closed?

I ls there 115V going to switch?

_ switch closed?

YES

14Is circuit breaker closed?

r YES

I_ YES

YES

l | Check for continuity in wire from circuit

breaker to furnace.

Close circuit breaker and go back to START. k

Check room thermostat or 1interconnecting cable.

furnace control.

I Disconnect all the thermostat wires from the

I Replace furnace control. I

_ Replace transformer.

I s LED status light blinking rapidlywithout a pause?

l ls LED status light blinking ON/OFF slowly

with a combination of short and long flashes?

_°

Determine status code. The status code is a 2 digit number with the first digit determined

i i

t_ t_

by the number of short flashes and the second d gt by the number of long flashes?

t Go to section below for the status code that _._ _E° I Was there a previous status code other

was flashed. _ than # 11?

YES

Check for correct line voltage polarity. If un ts are tw nned check for proper low-

voltage (24V) transformer phasing.

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 out. LED will flash the status code of the previous fault or status code #11 (1 short and 1

long flash) if there was no previous fault. After the control repeats the code 4 times, the control will start the component test sequence Once indicated the control will turn QN at HI HEAT speed. The inducer will run for the entire component test. The HSI. blower motor LQ HEAT speed. HI HEAT speed, and C©OL speed will run for 10 15 seconds each. Gas valve and humidifier will

not be turned on When the blower motor is turned OFF the inducer will be switched to low-speed for 10 seconds.

_ DoesthecontrolrespondtoW/Wl,W2,Yl,_ Is24VpresentatW/W1W2,Y1,Y/Y2orG IY/Y2, and G (24V) thermostat signals? thermostat terminals on the furnace control?

Run system through a low-heat, high-heat, or cooling cycle to check operation Status

codes are erased after 72 hours. Qn RED LED boards stored status codes can also be

erased whenever (115V or 24V) is interrupted.

YES

Replace furnace control, jumper wire?

! _.._1 Does the problem repeat when using a

furnace control. Ether nsta a ba ast resistor. connect the Com24V thermostat terminal to

I The thermostat is not compatible with the I

the thermostat, or replace the thermostat.

NO PREVIOUS CODE Stored codes are erased after 72 hours. On RED LED boards stored status codes can also be

erased whenever power (t t5V or 24V) is interrupted. Run system through a

._111

low-heat, high-heat, or cooling cycle to check system,

BLOWER ON AFTER POWER UP

(115V OR 24V) Normal operation.

Blower runs for the selected blower off- delay, if unit is powered up during a call

for heat (R-W/W1 closed) or when (R- W/Wt 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

__,t

power and wait 5 minutes to retry.

Check for:

- Stuck closed gas valve relay on control.

- Miswire or short to gas valve wire.

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 tS OPEN Check for:

- Short circuit in secondary voltage (24V) wiring including thermostat

leads. Disconnect thermostat leads

to isolate short circuit.

HIGH-HEAT PRESSURE SWITCH OR RELAY DID NOT CLOSE OR

REOPENED - Check for:

- Control relay may be defective.

- Gasvalve is miswired.

- See status code 32.

LOW-HEAT PRESSURE SWITCH DID NOT CLOSE OR REOPENED If open

longer than 5 minutes, inducer shuts off for t5 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.

LIMIT CIRCUIT FAULT Indicates the limit, draft safeguard flame rollout, or

blocked vent shutoff switch* (if used) is open. Blower will run for 4 minutes or until open switch remakes whichever is longer. If open longer than 3 minutes, code changes to lockout #13 If open less

than 3 rain. status code #33 continues to flash until blower shuts off, Flame

rollout switch and BVSS requires manual reset. Check for:

- Dirty filter or restricted duct system,

- 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,

IGNITION PROVING FAILURE Ifflame 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/Yellow 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 Rthermostat 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?

* Blocked vent shutoff switch used in Chimney Adapter Kit

YES

-I

WHILE HIGH-HEAT PRESSURE

SWITCH IS CLOSED - Check for:

- Low-heat pressure switch stuck open.

- Disconnected or obstructed pressure tube.

43 LOW-HEAT PRESSURE SWITCH OPEN

- Miswired pressure switches.

- Low inlet gas pressure (if LGPS used).

Unplug igniter harness from control and initiate another component test sequence. Check for t t5V between pin I and

NEUTRAL-L2 on the control. Was 1t5V present for the t5 second period?

Reconnect the R thermostat lead and set

thermostat to call for heat. Connect voltmeter

across gas valve connections. Does gas valve receive 24V?

YES

Does gas valve open and allow gas to flow?

YES

DO the main burners ignite?

YES

Do the main burners stay on?

Repeat call for heat and check flame sensor current during trial for ignition period. Is the

DC microamps below 0.5?

V YEs

Clean flame sensor with fine steel wool and recheck current. Nominal current is 4.0 to

6.0 microamps.

Is current near typical value?

I_YES

Will main burners ignite and stay on?

YES

Fixed.

reset after t hour lockout due to:

- Flame circuit failure.

- Gas valve relay stuck open.

- Software check error. Reset power to clear lockout. Replace

45 CONTROLCIRCUITRY LOCKOUT Auto-

control if code repeats.

,N_ i Replace furnace control. I YES J Checkforcontinuityintheharnessandigniter.

Replace defective component.

Check connections. If OK, replace control.

Check that all gas valves are turned on,

Replace valve.

Check for:

- Inadequate flame carryover or rough ignition.

- Low inlet gas pressure.

- Proper firing rate.

_ llow blower to come on and repeat test tocheck for intermittent operation.

- Blocked or incorrect carry- over gap. (.045" nominal)

Check connections and retry. If current is

near typical value (4.0-6.0 nominal) and burners will not stay on repeat check in high-

heat. if burners will still not stay on replace control, if burners operate in high-heat then switch to low-heat, check manifold pressure.

If OK, check burner carryover and flame

sensor location.

Replace electrode.

Replace furnace control.

I I

PARTS REPLACEMENT INFORMATION GUIDE

CASING GROUP Outer door Blower door

Top filler plate

Bottom filler plate Bottom enclosure

ELECTRICAL GROUP Control bracket

Junction box Linfit switch(es)

Circuit board Door switch

Transformer Wiring harness l15v

Wiring harness 24v

BLOWER GROUP

Blower housing Blower cutoff

Blower motor Blower wheel

Capacitor (where used) Capacitor strap (where used)

Grommet Power choke (where used)

GAS CONTROL GROUP Manifold

Burner assembly Orifice

Flame sensor Hot surface igniter

Gas valve Manual reset linfit switches

Burner support assembly

HEAT EXCHANGER GROUP Heat exchanger cell

Cell panel Lox NOx baffle (California models only)

INDUCER GROUP Housing assembly

Pressure switch Inducer motor

Inducer wheel Vent elbow assembly

Draft safeguard switch

TO OBTAIN INFORMATION ON PARTS: Consult your installing dealer or classified section of your local telephone directory under "Heating Equipment" or "Air Conditioning Contractors and Systems" headings for dealer listing by brand name or contact:

CARRIER CORPORATION

Consumer Relations Department

P.O. Box 4808

Syracuse, New York 13221-4808

1 - 800 - CARRIER

Have available the model number, series number, and serial number located on the unit rating plate to ensure correct replacement part.

Example of Model Number

MODEL VARIATION VOLTAGE SERIES PACKAGING AIRFLOW

58CTA 155 --- 1 4 1 20

WARNING: Improper installation, adjustment, alteration, service, or maintenance can cause personal injury, property damage, or death. Consult a qualified installer, service agency, or your local gas supplier for information or assistance. The qualified installer or service agency

must use only factory-authorized replacement parts, kits, or accessories when modifying this product.

HEATING COOLING

SIZE (CFM)

Manufacturer reserves the right to change, at any time, specification8 and design8 without notice and without obligations,

Catalo_ No:58CT- 12SI

Replaoes:58(T I1SI

Carrier 58CTX15510020, 58CTX13510022, 58CTX13510016, 58CTX11010022, 58CTX11010016 Installation Guide

Specifications and Main Features

Frequently Asked Questions

User Manual