Carrier 59SP5A User Manual

Installation, Start-up, Operating and

Service and Maintenance Instructions

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

SAFETY CONSIDERATIONS ......................... 3

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

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

ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS ... 4

ACCESSORIES ..................................... 5

LOCATION ........................................ 7

General ......................................... 7

AIR FOR COMBUSTION AND VENTILATION ......... 10

Introduction .................................... 10

CONDENSATE TRAP ............................... 13

Upflow ........................................ 13

Downflow ..................................... 13

Horizontal Right ................................. 14

Horizontal Left .................................. 14

CONDENSATE DRAIN ............................. 18

INSTALLATION ................................... 20

Upflow ........................................ 20

Downflow ..................................... 20

Horizontal ...................................... 21

Filter Arrangement ............................... 22

AIR DUCTS ....................................... 28

General Requirements ............................. 28

Ductwork Acoustical Treatment ..................... 28

GAS PIPING ...................................... 29

ELECTRICAL CONNECTIONS ....................... 30

115-V Wiring ................................... 30

J-Box Installation ................................ 31

24-V Wiring .................................... 31

Accessories ..................................... 31

Alternate Power Supplies .......................... 31

VENTING ........................................ 37

Special Venting Requirements for Installations in Canada . 37

General ........................................ 37

Materials ....................................... 38

Venting Systems ................................. 38

Locating the Vent Termination ...................... 38

Combustion Air and Vent Piping Insulation Guidelines ... 39

START-UP, ADJUSTMENT, AND SAFETY CHECK ...... 57

General ......................................... 57

Prime Condensate Trap ............................. 57

Purge Gas Lines ................................... 57

Adjustments ...................................... 57

SERVICE AND MAINTENANCE PROCEDURES ........ 65

Cleaning Heat Exchangers ........................... 70

SEQUENCE OF OPERATION ........................ 75

PARTS REPLACEMENT GUIDE ...................... 80

TABLES

Loose Parts Bag ..................................... 5

Minimum Clearances to Combustible Materials ............. 8

Minimum Free Area Required ......................... 12

Minimum Space Volumes ............................. 12

Filter Size Information ............................... 22

Opening Dimensions ................................ 24

Air Delivery CFM ................................... 28

Maximum Capacity of Pipe ........................... 30

Electrical Data ...................................... 32

Vent Ternfination Kit for Direct Vent (2-Pipe) System ....... 38

Combustion-Air Vent Pipe, Fitting & Cement Material ....... 42

Maxinmm Allowable Exposed Vent Lengths Insulation ...... 43

Maximum Equivalent Vent Length ...................... 44

Deductions from Maximum Equivalent Vent Length ........ 44

Blower Speed Taps .................................. 59

Blower Off Delay Setup Switch ........................ 59

Altitude DerateMultiplierfor U.S.A..................... 60

Gas Rate .......................................... 62

Orifice Size and Manifold Pressure ..................... 63

_ Always Ask For

Use of the AHRI Certified
TM Mark indicales a
manufacturer's

participalion in the
program For verification

of certification [or individual
products, go to
www ahddirectory org

Portions of the text and tables are reprinted from NFPA 54/ANSI
Z223.1-2009©, 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.

ISO9001

Required Notice for Massachusetts Installations

IMPORTANT

The Commonwealth of Massachusetts requires compliance with regulation 248 CMR as follows:

5.08: Modifications to NFPA-54, Chapter 10

2) Revise 10.8.3 by adding the following additional requirements:
a. For all side wall horizontally vented gas fueled equipment installed in every dwelling, building or structure used in

whole or in part for residential purposes, including those owned or operated by the Commonwealth and where the
side wall exhaust vent termination is less than seven (7) feet above finished grade in the area of the venting,

including but not limited to decks and porches, the following requirements shall be satisfied:

1. INSTALLATION OF CARBON MONOXIDE DETECTORS. At the time of installation of the side wall horizontal vented

gas fueled equipment, the installing plumber or gasfitter shall observe that a hard wired carbon monoxide detector with an
alarm and battery back-up is installed on the floor level where the gas equipment is to be installed. In addition, the installing

plumber or gasfitter shall observe that a battery operated or hard wired carbon monoxide detector with an alarm is installed on
each additional level of the dwelling, building or structure served by the side wall horizontal vented gas fueled equipment. It

shall be the responsibility of the property owner to secure the services of qualified licensed professionals for the installation of
hard wired carbon monoxide detectors

a. In the event that the side wall horizontally vented gas fueled equipment is installed in acrawl space or an attic, the hard wired

carbon monoxide detector with alarm and battery back-up may be installed on the next adjacent floor level.

b. In the event that the requirements of this subdivision can not be met at the time of completion of installation, the owner shall

have a period of thirty (30) days to comply with the above requirements; provided, however, that during said thirty (30) day
period, a battery operated carbon monoxide detector with an alarm shall be installed.

2. APPROVED CARBON MONOXIDE DETECTORS. Each carbon monoxide detector as required in accordance with the
above provisions shall comply with NFPA 720 and be ANSI/UL 2034 listed and IAS certified.

3. SIGNAGE. A metal or plastic identification plate shall be permanently mounted to the exterior of the building at a minimum
height of eight (8) feet above grade directly in line with the exhaust vent terminal for the horizontally vented gas fueled
heating appliance or equipment. The sign shall read, in print size no less than one-half (1/2) inch in size, "GAS VENT

DIRECTLY BELOW. KEEP CLEAR OF ALL OBSTRUCTIONS".

4. INSPECTION. The state or local gas inspector of the side wall horizontally vented gas fueled equipment shall not approve the
installation unless, upon inspection, the inspector observes carbon monoxide detectors and signage installed in accordance

with the provisions of 248 CMR 5.08(2)(a)1 through 4.

5. EXEMPTIONS: The following equipment is exempt from 248 CMR 5.08(2)(a)1 through 4:

(1.) The equipment listed in Chapter 10 entitled "Equipment Not Required To Be Vented" in the most current edition of

NFPA 54 as adopted by the Board; and

(2.) Product Approved side wall horizontally vented gas fueled equipment installed in a room or structure separate from

the dwelling, building or structure used in whole or in part for residential purposes.

c. MANUFACTURER REQUIREMENTS - GAS EQUIPMENT VENTING SYSTEM PROVIDED. When the

manufacturer of Product Approved side wall horizontally vented gas equipment provides a venting system design
or venting system components with the equipment, the instructions provided by the manufacturer for installation of

the equipment and the venting system shall include:

1. Detailed instructions for the installation of the venting system design or the venting system components; and

2. A complete parts list for the venting system design or venting system.

d. MANUFACTURER REQUIREMENTS - GAS EQUIPMENT VENTING SYSTEM NOT PROVIDED. When

the manufacturer of a Product Approved side wall horizontally vented gas fueled equipment does not provide the
parts for venting the flue gases, but identifies "special venting systems", the following requirements shall be

satisfied by the manufacturer:

1. The referenced "special venting system" instructions shall be included with the appliance or equipment installation
instructions; and

2. The "special venting systems" shall be Product Approved by the Board, and the instructions for that system shall include a
parts list and detailed installation instructions.

e. A copy of all installation instructions for all Product Approved side wall horizontally vented gas fueled equipment,

all venting instructions, all parts lists for venting instructions, and/or all venting design instructions shall remain
with the appliance or equipment at the completion of the installation.

For questions regarding these requirements, please contact the Commonwealth of Massachusetts Board of State Examiners of Plumbers and

Gas Fitters, 239 Causeway Street, Boston, MA 02114. 617-727-9952.

SAFETY CONSIDERATIONS

FIRE, EXPLOSION, ELECTRICAL SHOCK, AND

CARBON MONOXIDE POISONING HAZARD

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

Improper installation, adjustment, alteration, service,
maintenance, or use can cause carbon monoxide poisoning,
explosion, fire, electrical shock, or other conditions which
may cause personal 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 nmst use only factory-authorized

and listed kits or accessories when modifying this product.

FURNACE RELIABILITY HAZARD
Failure to follow this caution may result in unit component

damage.
Application of this furnace should be indoors with special

attention given to vent sizing and material, gas input rate,
air temperature rise, unit leveling, and unit sizing.

Improper installation, 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 nmst use factory-authorized kits or accessories

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

Installing and servicing heating equipment can be hazardous due to
gas and electrical components. Only trained and qualified

personnel should install, repair, or service heating equipment.
Untrained personnel can perform basic maintenance functions such

as cleaning and replacing air filters. All other operations must be
performed by trained service personnel. When working on heating
equipment, observe precautions in literature, on tags, and on labels

attached to or shipped with furnace and other safety precautions
that may apply.

These instructions cover minimum requirements and conform to
existing national standards and safety codes. In some instances,
these instructions exceed certain local codes and ordinances,

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

minimum for a safe installation.
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

included in literature and attached to the unit.

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.

This is the safety-alert symbol A'x When you see this symbol on
the furnace 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 a hazard

which could result in personal iniury or death. CAUTION is used
to identify hazards which may result in nfinor personal iniury or

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

operation.

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

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

3. Provide adequate combustion and ventilation air to the fur-
nace space as specified in "Air for Combustion and Ventila-

tion" section.

4. Combustion products must 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 commer-
cially available soap solution made specifically for the de-

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

6. Always install furnace to operate within the furnace's inten-
ded temperature-rise range with a duct system which has an

external static pressure within the allowable range, as spe-
cified 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 contain-

ing 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. See "Air Ducts" section.

8. A gas-fired furnace for installation in a residential garage
nmst 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 instruc-
tions.

10. These Multipoise Gas-Fired Furnaces are CSA design-cer-
tified for use with natural and propane gases (see furnace
rating plate) and for installation in alcoves, attics, base-

ments, 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.) listed accessory gas conversion kit is
required to convert furnace for use with propane gas.

11. See Table 2 for required clearances to combustible con-
struction.

12. Maintain a 1-in. (25 ram) clearance from combustible ma-
terials 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.

13. These furnaces SHALL NOT be installed directly on carpet-
ing, tile, or any other combustible material other than wood

flooring. In downflow installations, factory accessory floor

base MUST be used when installed on combustible materi-

als and wood flooring. Special base is not required when
this furnace is installed on manufacturer's Coil Assembly
Part No. CNRV, CNPV, CAP, or CAR or when Coil Box
Part No. KCAKC is used. See Table 2 for clearance to com-

bustible construction information.

il

INTRODUCTION

This 4-way multipoise Category IV condensing furnace is CSA
design-certified as a direct (2-pipe) or non-direct vent (1-pipe)

furnace. (See Fig. 2.)The furnace is factory-shipped for use with
natural gas. The furnace can be converted in the field for use with
propane gas when a factory-supplied conversion kit is used. Refer

to the furnace rating plate for conversion kit information.
This furnace is approved for installation in a mobile home when a

factory-supplied accessory mobile home conversion kit is used.
The conversion kit is required for use with both natural and
propane gas. The furnace must also be installed on a

factory-supplied accessory combustible floor base or evaporator
coil casing.

This furnace is designed for minimum continuous return-air
temperature of 60°F (15°C) db or intermittent operation down to

55°F (13°C) db such as when used with a night setback
thermostat. Return-air temperature must not exceed 80°F (27°C)

db. Failure to follow these return-air temperature limits may affect
reliability of heat exchangers, motors, and controls. (See Fig. 3).

g

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

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

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

cause the furnace and/or vent to fail prematurely.
For accessory installation details, refer to the applicable instruction

literature.
NOTE: Remove all shipping materials, loose parts bag, and

literature before operating the furnace. (See Table 1).

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 and Canada, follow all codes and standards for
the following:

Safet2_

• US: National Fuel Gas Code (NFGC) NFPA 54-2009/ANSI
Z223.1-2009 and the Installation Standards, Warm Air Heating
and Air Conditioning Systems ANSI/NFPA 90B

• A manufactured (Mobile) home installation must conform with
the Manufactured Home Construction and Safety Standard, Title
24 CFR, Part 3280, or when this standard is not @plicable, the
Standard for Manufactured Home Installation (Manufactured
Home Sites, Communities, and Set-Ups),ANSI/NCS A225.1,

and/or CAN/CSA-Z240, MH Series Mobile Homes

• CANADA: National Standard of Canada, Natural Gas and
Propane Installation Code (NSCNGPIC CAN/CSA

B149.1-2010

General Installation

• US: NFGC and the NFPA 90B. For copaes, contact the National
Fire Protection Association Inc., Batterymarch Park, Quincy,
MA 02269; or for only the NFGC contact the American Gas

Association, 400 N. Capitol, N.W., Washington DC 20001

• CANADA: NSCNGPIC. For a copy, contact Standard Sales,
CSA International, 178 Rexdale Boulevard, Etobicoke

(Toronto), Ontario, Mgw IR3, Canada

Combustion and Ventilation Air

• US: Section 9.3 of the NFPA54/ANSI Z223.1-2009 Air for

Combustion and Ventilation

• CANADA: Part 8 of the CAN/CSA B149.1-2010, Venting
Systems and Air Supply for Appliances

Duct Systems

• US and CANADA: Air Conditioning Contractors Association
(ACCA) Manual D, Sheet Metal and Air Conditioning Contractors
National Association (SMACNA), or American Society of Heating,
Refrigeration, and Air Conditioning Engineers (ASHRAE) 2005

Fundamentals Handbook Chapter 35

Acoustical Lining and Fibrous Glass Duct

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

Gas Piping and Gas Pipe Pressure Testing

• US: NFPA 54/ANSI Z223.1-2009 NFGC; Chapters 5, 6, 7, and 8
and national plumbing codes.
CANADA: CAN/CSA-BI49A-2010, Parts 4, 5, 6, and 9.

In the state of Massachusetts:

• This product must be installed by a licensed plumber or gas fitter.

• When flexible connectors are used, the maximum length shall
not exceed 36 in. (914 mm).

• When lever type gas shutoffs are used they shall be T-handle type.

• The use of copper tubing for gas piping is not approved by the
state of Massachusetts.

Electrical Connections

• US: National Electrical Code (NEC) ANSI/NFPA 70-2011

• CANADA: Canadian Electrical Code CSA C22.1

ELECTROSTATIC DISCHARGE (ESD)

PRECAUTIONS PROCEDURE

FURNACE RELIABILITY HAZARD

Failure to follow this caution may result in unit component
damage.

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

1. Disconnect all power to the furnace. Multiple disconnects
may be required. DO NOT TOUCH THE CONTROL

OR ANY WIRE CONNECTED TO THE CONTROL

PRIOR TO DISCHARGING YOUR BODY'S
ELECTROSTATIC CHARGE TO GROUND.

2. Firmly touch the clean, unpainted, metal surface of the 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 shuffle your feet, do not touch ungrounded
objects, etc.).

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

surface of the furnace again before touching control or
wires.

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

6. Before removing a new control from its container, discharge
your body's electrostatic charge to ground to protect the

Table 1 - Loose Parts Bag Contents (Provided in blower compartment)

Qty

1
1

2

10

1

2

1
1

1
1

2

1
1

1
1
1

1

3

1

Air Intake Pipe Flange
Vent Pipe Flange
Coupling Flange Gaskets

Sharp Tip Screws (Vent and Inlet Flanges)
Vent Pipe Coupling
Vent Pipe Coupling Clamps

Pressure Switch Tube

Outlet Choke Plate (used with 40k BTUH furnaces, only)

Drain Tube Elbow
Drain Extension Tube

Drain Tube Clamps
Drain Line Grommet

Gas Line Grommet
Gas Line Knockout Plug

Junction Box Cover
Junction Box Base

Green Ground Screw

Blunt Tip Screws (Junction Box)

Thermostat Wire Grommet

control from damage. If the control is to be installed in a
furnace, follow items I through 4 before bringing the con-

trol or yourself in contact with the furnace. Put all used and
new controls into containers before touching ungrounded

objects.

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

ACCESSORIES

See Product Data Sheet for a list of accessories for this product.

Description

26 11116

[678.1]

263/8

[670.0]

25 1/8

[62O.7]

23 5/16

1592.9]

A_RFLOW 12_.31

CONDENSATE DRAIN TRAP

LOCATION \\\\

SIDE INLET

22

[55&3]

[634.0]

265/16

166S.6!

7/8 .......... _-_

_7/8 ....

122.21 _q_

THERMOSTAT ENTRY

126.4]

¢,7/8 _

615/II

[176.1]

11/16

[170.11

2 3/10

[58.41

176,21
VENT

-_3

[76.2|

/ AIR INTAKE

,;hI 3/4

/ 'CONN

[76.2]
VENT

[22.2] POWER CONN

1413/16

[376.3]

169/16
[42O.9]

175/16

[439.2]

FURNACE SIZE

(MODELS)

(59SP5)

040,10
060-14

580,16
100-16

120-22

2O

_4 25

[61

9] [6:
22" /15

[58 .9|

(CABINET WIDTH)

inches mm

14 3/16 361

17112 445

21 533

24 1/2 622

28

[71

,91 1_

28 /8

[_ ,4]

/16

,.1]

A

B

(OUTLET WIDTH)

_nches mm
12 1/2 319

15 7/8 403

19 3/8 492

22 718 581

_A_

_B_

OUTLET WIDTH

AIR FLOW

C

(BO]q-OM INLET WIDTH)

inches mm

12 9/16 322

16 406

19 1/2 495

23 584

® ® 'l

' ® ® ,_i °]_

11/16_4_c__11/16

[17,5] BOTTOM RETURN [17.5]

WIDTH

D SHIPPING

inches mm LBS KG

7 1/8 181 120.9 54.0

83!4 222

10 1/2 267 165.5 74.5

12 1/4 311 169.5 653

[76,2]

AIR INTAKE

116

21

L7]

IZ

2_

_8

;.9]

WEIGHT

141,6 63.4
151,0 67,9

_3

[76.2] I

1 5/16

[_._l

NOTE: ALL DIMENSIONS IN INCH [MM]

291/2
[749,3]

283/4

Fa0,51

26 11116

[678.1 ]

_3/8

[37o.01

;_ 7/16

[670.0]

21 1/16

AIR FLOW

f

\ F_I 3/4
,' F [44.5]

_" GAS CONN

.,,_ _ _ [22.2]

................._ 7/8

[22.21

THERMOSTAT ENTRY

_' _ 7/8

_i_--i [22.2] POWER CONN

SIDE INLET _q_

233/8

[S_2.0]

265/16

[658,6]

$D_,024 4

I

[2&4]

8

rD

LOCATION

PERSONAL INJURY AND/OR PROPERTY
DAMAGE HAZARD

Improper use or installation of this furnace may result in
premature furnace component failure. This gas furnace may
be used for heating buildings under construction provided

that:

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

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

without thermostatic control.

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

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

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

intermittent operation per our installation instructions.

-The air temperature rise is within the rated rise range on
the furnace rating plate, and the 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

according to these installation instructions.

General
These furnaces are shipped with the following materials to assist in

proper furnace installation. These materials are shipped in the
main blower compartment.

See Table 1 for loose parts bag contents.
This furnace must:

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

• not be installed directly on any combustible material other than
wood flooring (refer to SAFETY CONSIDERATIONS).

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

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

2 or on the furnace clearance to combustible construction label.

CARBON MONOXIDE POISONING / COMPONENT
DAMAGE HAZARD

Failure to follow this warning could result in personal injury
or death and unit component damage.

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

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

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

in addition to all local codes and ordinances.

The following types of furnace installations may require

OUTDOOR AIR for combustion due to chemical exposures:

• Commercial buildings

• Buildings with indoor pools

• Laundry rooms

• Hobby or craft rooms

• 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

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.

FIRE, INJURY OR DEATH HAZARD
Failure to follow this warning could result in personal

iniury, 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 in.
(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 NFPA 54/ANSI
Z223.1-2009 or CAN/CSA B149.2-2010. (See Fig. 5.)

ii

ii

Location Relative to Cooling Equipment

FIRE HAZARD
Failure to follow this warning could result in personal

iniury, 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. 4.)

Table 2 - Minimum Clearances to Combustible Materials for All Units

POSITION CLEARANCE

REAR 0

FRONT (Combustion air openings in furnace and in structure) 1 in. (25 mm)

Required for service *24 in. (610 mm)

All Sides of Supply Plenum 1 in. (25 mm)

Sides 0

Vent 0

Top of Furnace 1 in. (25 mm)

Recommended

The cooling coil nmst 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 nmst be

equipped with means to prevent operation of either unit unless the
damper is in the full-heat or full-cool position.

AIRFLOW

THE BLOWER IS LOCATED

TOTHE RIGHT OFTHE

BURNER SECTION, AND

AIR CONDiTiONED AiR iS

DISCHARGED TO THE LEFT.

THE BLOWER iS

LOCATED ABOVE THE

BURNER SECTION, AND

CONDiTiONED AIR IS

DISCHARGED DOWNWARD AIRFLOW

Fig. 2 - 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

SUPPLYAIR

32° F/0 ° C MINIMUM INSTALLED
AMBIENT OR FREEZE
PROTECTION REQUIRED

Fig. 3 - Freeze Protection and Return Air Temperature

FRONT

RETURN

AIR

MAX80 °F / 27°C

MIN60°F / 16°O

A10490

BACK FRONT

Fig. 4 - Prohibited Installations

A10494

18-iN. (457.2 mm)
MiNiMUM TO BURNERS

A93044

Fig. 5 - Installation in a Garage

il

AIR FOR COMBUSTION AND

VENTILATION

Introduction

Direct Vent (2-pipe) Applications
When the furnace is installed as a direct vent (2-pipe) furnace, no

special provisions for air for combustion are required. However,
other gas appliances installed in the space with the furnace may

require outside airfor combustion. Follow the guidelines below to
insure thatother gas appliances have sufficient air for combustion.

Non-Direct Vent (1-pipe) Applications

When the furnace is installed as a non-direct vent (l-pipe) furnace,
it will be necessary to insure there is adequate air for combustion.
Other gas appliances installed with the furnace may also require air

for combustion and ventilation in addition to the amount of
combustion air and ventilation air required for the furnace. Follow

the guidelines below to insure that the furnace and other gas
appliances have sufficient air for combustion.

Ventilated Combustion Air Applications
When the furnace is installed using the ventilated combustion air

option, the attic or crawlspace nmst freely communicate with the
outdoor to provide sufficient air for combustion. The combustion

air pipe cannot be terminated in attics or crawlspaces that use
ventilation fans designed to operate during the heating season. If
ventilation fans are present in these areas, the combustion air pipe

nmst terminate outdoors as a Direct Vent/2-Pipe system.
All air for combustion is piped directly to the furnace from a space

that is well ventilated with outdoor air (such as an attic or crawl
space) and the space is well isolated from the living space or

garage. In addition, other gas appliances installed in the space with
the furnace may require outside air for combustion. Follow the

guidelines below to insure that the roof or crawlspace walls have
sufficient free area to provide sufficient air for combustion and
ventilation for the furnaces. The guidelines below can be used to

insure that other gas appliances have sufficient air for combustion.
Provisions for adequate combustion, ventilation, and dilution air

must be provided in accordance with:

• U.S.A. Installations: Section 9.3 of the NFPA 54/ANSI
Z223.1-2009, Air for Combustion and Ventilation and

applicable provisions of the local building codes.

• Canada: Part 8 of the CAN/CSA-B149.1-2010, Venting
Systems and Air Supply for Appliances.

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
iniury 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 the
Carbon Monoxide Poisoning Hazard warning in the venting
section of these instructions to determine if an adequate
amount of make-up air is availaMe.

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 (4.8 cubic
meters per kW) require the Outdoor Combustion Air Method.

• Spaces having at least 50 cubic feet per 1,000 Btuh (4.8 cubic
meters per kW) 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 combustion,
ventilation, and dilution of flue gases using permanent hori-

zontal or vertical duct(s) or opening(s) directly communicat-
ing with the outdoors or spaces that freely communicate

with the outdoors.

2. Fig. 6 illustrates how to provide TWO OUTDOOR
OPENINGS, one inlet and one outlet combustion and vent-

ilation air opening, to the outdoors.

a. 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.

b. Size openings and ducts per Fig. 6 and TaMe 3.

c. TWO HORIZONTAL DUCTS require I sq. in. (645 sq.

ram) of free area per 2,000 Btuh (1,100 mm2/kW) of com-
bined input for all gas appliances in the space per Fig. 6and

Table 3.

d. TWO OPENINGS OR VERTICAL DUCTS require 1

sq. in. (645 sq. ram) of free area per 4,000 Btuh (550
mm2/kW) for combined input of all gas appliances in the
space per Fig. 6 and Table 3.

3. ONE OUTDOOR OPENING requires:

a. 1 sq. in. (645 sq. ram) of free area per 3,000 Btuh (734

mm2/kW) for combined input of all gas appliances in the
space per Fig. 6 and Table 3.

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

the space.

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.

10

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

Indoor air is pernfitted 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 personal
iniury or death.

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.

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 deternfined per Table 4 or Equations 1 and 2.
Deternfine the minimum required volume for each appliance in the

space and add the volumes together to get the total minimum
required volume I\_r the space.

Table 4 - Minimum Space Volumes were deternfined by using the
following equations from the current edition of the National Fuel

Gas Code ANSI Z223.1/NFPA 54, 9.3.2.2:

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

Volume _ 21ft3 ("- !other __

Other ACH _000 Btu/hrJ

A04002

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

of the floor. The minimum dimension of air openings shall
be at least 3 in. (80 ram). (See Fig. 7.)

c. Combining space on different floor levels. The volumes of

spaces on different floor levels shall be considered as com-
municating spaces if connected by one or more permanent

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
communicates with the outdoors provided there are ad-

equate permanent ventilation openings directly to outdoors
having free area of at least 1-in.2/4,000 Btuh of total input

rating for all gas appliances in the space.

3. In spaces that use the Indoor Combustion Air Method, in-
filtration should be adequate to provide air for combustion,

permanent ventilation and dilution of flue gases. However,
in buildings with unusually tight construction, additional air

MUST be provided using the methods described in the
Outdoor Combustion Air Method section.

4. Unusually tight construction is defined as Construction

with:

a. Walls and ceilings exposed to the outdoors have a continu-

ous, sealed vapor barrier. Openings are gasketed or sealed

and

b. Doors and openable windows are weatherstripped and

c. Other openings are caulked or sealed. These include joints

around window and door frames, between sole plates and

floors, between wall-ceiling joints, between wall panels,

at penetrations for plumbing, electrical and gas lines, etc.

Combination of Indoor and Outdoor Air

1. Indoor openings shall comply with the Indoor Combus-

tion Air Method below and,

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

3. Outdoor openings shall be sized as follows:

a. Calculate the Ratio of all Indoor Space volume divided by

required volume for Indoor Combustion Air Method be-
low.

b. Outdoor opening size reduction Factor is I nfinus the Ra-

tio in a. above.

c. Minimum size of Outdoor openings shall be the size re-

quired in Outdoor Combustion Air Method above multi-
plied by reduction Factor in b. above. The minimum di-
mension of air openings shall be not less than 3 in. (80 ram).

ii

Volume _ 15ft 3 ("_ I _ _'_

Fan ACH _000" Btu/hr/

If: Iother = combined input of all other than fan-assisted appliances
in Btuh/hr

Ifan = combined input of all fan-assisted appliances in Btuh/hr
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 I 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)

J

A04003

11

Table3 - Minimum Free Area Required for Each Combustion Air Opening or Duct to Outdoors

TWO HORIZONTAL DUCTS SINGLE DUCT OR OPENING TWO OPENINGS OR

FURNACE (1,100 SQ, MM/KW) (734 SQ, MM/KW) (1 SQ, IN,/4,000 BTUH)

INPUT (550 SQ, MM/KW)
(BTUH) Free Area of Free Area of Free Area of

40,000* 20 (12904) 5 (127) 14 (8696) 5 (127) 10 (6452) 4 (102)

80,000 30 (19355) 6 (152) 20 (13043) 5 (127) 15 (9678) 5 (127)
80,000 40 (25807) 7 (178) 27 (17391) 6 (152) 20 (12904) 5 (127)

100,000 50 (32258) 8 (203) 34 (21739) 7 (178) 25 (16130) 6 (152)
120,000 60 (38709) 9 (229) 40 (26087) 7 (178) 30 (19355) 6 (152)

140,000" 70 (45161) 10 (254) 47 (30435) 8 (203) 35 (22581) 7 (178)

*Not all families have these models.

100,000 + 30,000 =

60,000 + 40,000 =

I FURNACE WATER HEATER

80,000 + 30,000 =

Table 4 - Minimum Space Volumes for 100 % Combustion, Ventilation and Dilution Air from Outdoors

OTHER THAN FAN-ASSISTED TOTAL FAN-ASSISTED TOTAL

(1,000'S BTUH GAS INPUT RATE) (1,000'S BTUH GAS INPUT RATE)

30 40 50 40 80 80 100 120 140

ACH Space Volume Ft3 (M 3)

0.80 (29.7) (39.6) (49.5) (39.6) (42.5) (56.6) (70.8) (84.9) (99.1)

0.50 (35.6) (47.5) (59.4) (47.5) (51.0) (67.9) (84.9) (101.9) (118.9)

0.40 (44.5) (59.4) (74.3) (59.4) (63.7) (84.9) (106.1 ) (127.3) (148.6)

0.30 (59.4) (79.2) (99.1) (79.2) (84.9) (113.2) (141.5) (169.8) (198.1)

0.20 (89.1) (118.9) (148.6) (118.9) (127.3) (169.8) (212.2) (254.6) (297.1)

O.10 (178. O) (237.8) (297.3) (237.8) (254.6) (339.5) (424.4) (509.2) (594.1)

0.00 NP NP NP NP NP NP NP NP NP

NP = Not Permitted

1,050 1,400 1,750 1,400 1,500 2,000 2,500 3,000 3,500

1,260 1,680 2,1 O0 1,680 1,800 2,400 3,000 3,600 4,200

1,575 2,1 O0 2,625 2,1 O0 2,250 3,000 3,750 4,500 5,250

2,1 O0 2,800 3,500 2,800 3,000 4,000 5,000 6,000 7,000

3,150 4,200 5,250 4,200 4,500 6,000 7,500 9,000 10,500

6,300 8,400 10,500 8,400 9,000 12,000 15,000 18,000 21,000

(1 SQ, IN,/2,000 BTUH) (1 SQ, IN,/3,000 BTUH) VERTICAL DUCTS

Opening and Round Duct Opening and Round Duct Opening and Round Duct

Duct In, (mm) Dia Duct In, (mm) Dia Duct In, (mm) Dia,

Sq, In (Sq, mm) Sq, In (Sq, mm) Sq, In (mm)

EXAMPLES: Determining Free Area

TOTAL INPUT

(130,000 divided by 4,000) = 32.5 Sq. In. for each two Vertical Ducts or Openings
(100,000 divided by 3,000) = 33.3 Sq. In. for each Single Duct or Opening

(110,000 divided by 2,000) = 55.0 Sq. In. for each two Horizontal Ducts

12

DUCTS PER 4000

-- 1 SQIN.

OUTDOORSI "%,>G_

I I [i i

1 1

(305mm) 12"MAX] J I I D II 1-_

1sa,a &/ I _ IMEaT lJ_

PER2000 "/ :IB I _ _ I THROUGH FI:_
B1VH* ! I <;_ I ROOF F:_. _.._,.,.

" //I I& IIPE

_a i bu

// rQ II

DUCTS II o

u;°oRs// II

1SQN /J I _ _ = _M ,

PER20004,/IAI _ _ 7- i:::_--

BTUH* _/ :O 7-

......, @ O

// II so

PE "

// II 40 0.

! -J Ii I I BTL

[ 12

A i i i i 12"MAX/

" I ( 05mm)"

?

(305mm)

(305mm)

CIRCULATING AIR

!

I

I

I

DUCTS

I ['1

I I I I

I I II

I

INTERIOR

HEATED

SPACE

I I I

VENT THROUGH ROOF

_: 12" AX(305mm)

0

-_- 1 SQ IN.
PER 1000

BTUH* IN DOOR

OR WALL

UNCONFINED
SPACE

6" MIN (152mm)
(FRONT)0

1 SQ IN.
PER 1000

BTUH* IN DOOR

-- OR WALL

12" MAX (305mm)

il

J TO PER 4000

OUTDOORS BTUFF

*Minimum dimensions of 3-in. (76 mm).

NOTE: Use any of the following combinations of openings:

A&BC&DD&EF&G

Fig. 6 - Air for Combustion, Ventilation, and Dilution for

Outdoors

A03174

CONDENSATE TRAP

Condensate Trap - Upflow Orientation
When the furnace is installed in the upflow position, it is not

necessary to relocate the condensate trap or associated tubing.
Refer to Fig. 8 for upflow condensate trap information. Refer to

Condensate Drain section for information how to install the
condensate drain.

Condensate Trap - Downflow Orientation.

When the furnace is installed in the downflow position, the
factory-installed trap will be located at the upper left corner of the

collector box. When the furnace is installed in the downflow
orientation, the factory-installed trap must be relocated for proper

condensate drainage.
To Relocate the Condensate Trap:

• Orient the furnace in the downflow position.

• Fig. 9 shows the condensate trap and tubing before and after
relocation.

• Remove the relief tube from the condensate trap.

• Remove the screw that secures the condensate trap to the
collector box.

• Remove the trap.

• Remove the relief tube from the port on the collector box. It is
not necessary to remove the tube from the inducer assembly.

• Remove the pressure switch tube from the front pressure switch
and discard the tube. A new pressure switch tube is shipped in
the loose parts bag.

• Loosen the clamp around the inlet of the vent elbow on the
inducer.

• Remove the nfiddle and bottom plugs from the lower right side
of the collector box and set aside. Do Not Discard Plugs.

CIRCULATING AIR DUCTS

l'

* 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.

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

Indoors

• Refer to the appropriate figure to begin the trap conversion.

• Install the 2 plugs previously removed from the collector box in
the ports where the condensate trap was removed.

• Install the trap over the ports on the lower right side of the
collector box.

• Secure the trap to the collector box with the screw.

• Connect the relief tube to the condensate trap to the relief port of
the condensate trap.

• If necessary, slide the relief tube in the inducer stand-offs to
adjust the position of the tube.

• Connect the relief tube to the relief port of the condensate trap.

• Connect the new pressure switch tube to the port on the front
pressure switch. Route the tube through the stand-offs on the
inducer assembly and connect to the port on the collector box.
Trim off any excess tube to avoid sags or kinks in the tube.

• Rotate the vent elbow to the desired position and tighten the
clamp 15 in.-lbs.

• Refer to Condensate Drain section for information how to install
the condensate drain.

A03175

Condensate Trap - Horizontal Orientation.

When the furnace is installed in the horizontal right position, the
factory-installed trap will be located at the bottom of the collector

box. When the furnace is installed in the horizontal left position,
the factory-installed trap will be located at the top of the collector

box. The trap must be repositioned on the collector box for proper
condensate drainage.

When the furnace is installed as a direct-vent furnace, a field
supplied, accessory Horizontal Installation Kit is required for all

horizontal installations. The kit contains a rubber Casing Grommet
designed to seal between the furnace casing and the condensate

trap. (See Fig. 17).

13

NOTE: The condensate trap extends below the side of the casing
in the horizontal position. A minimum of 2 in. (51 mm) of

clearance is required between the casing side and the furnace
platform for the trap to extend out of the casing in the horizontal
position.

To Relocate the Condensate Trap:

• Remove the knockout in the casing for the Casing Grommet.

• Install the grommet in the casing.

• Orient the furnace in the desired position.

• Allow for 2 in. (51 mm) of clearance underneath the furnace for
the condensate trap and drain line.

• Fig. 10 shows the condensate trap and tubing before and after
relocation in the horizontal right position.

• Fig. 11 shows the condensate trap and tubing before and after
relocation in the horizontal left position.

• Refer to the appropriate figure to begin the trap conversion.

• Remove the relief tube from the condensate trap.

ii

• Remove the screw that secures the condensate trap to the
collector box.

• Remove the trap.

• Remove the relief tube from the port on the collector box. It is
not necessary to remove the tube from the inducer assembly.

For Horizontal Left only:

• Remove the pressure switch robe from the front pressure switch
and discard the tube. A new pressure switch tube is shipped in
the loose parts bag.

For Horizontal Right only:

• The pressure switch tube location is not modified.

• Loosen the clamp around the inlet of the vent elbow on the

inducer.

• Remove the plugs from the collector box and set aside. Do Not
Discard Plugs.

For Horizontal Left only:

• Remove the middle and right plug from the ports at the bottom
of the collector box.

For Horizontal Right only:

• Remove the plug to the right of the condensate trap.

• Refer to the appropriate figure to begin the trap conversion,

• Install the plugs previously removed from the collector box in
the ports where the condensate trap was removed.

• Install the trap over the ports on the lower side of the collector

box.

• Secure the trap to the collector box with the screw.

• Connect the relief tube to the condensate trap to the relief port of
the condensate trap.

• If necessary, slide the relief tube in the inducer stand-offs to
adjust the position of the tube.

• Connect the relief tube to the relief port of the condensate trap,

For Horizontal Left only:

• Connect the new pressure switch tube to the port on the front
pressure switch. Route the tube through the stand-offs on the
inducer assembly and connect to the port on the collector box.
Trim off any excess tube to avoid sags or kinks in the tube.

• Rotate the vent elbow to the desired position and tighten the
clamp 15 in.-lbs.

• Refer to Condensate Drain section for information how to install
the condensate drain,

Collector Box

Plugs

Condensate Trap

Relief Port

Vent Pipe Clamp

Pressure Switch

Port

UPFLOW TRAP CONFIGURATION

1 & 2 Stage Units

Fig. 8 - Upflow Trap Configuration

Elbow Clamp

Elbow

Collector Box

Plug

Condensate Trap

Relief Port

Outlet

Al1307

14

Remove pressure switch tube from

front pressure switch and discard.

Remove relief tube from relief
port on collector trap.

Remove trap from
collector box.

Loosen clamp on inlet
to vent elbow.

Unconverted Factory Configuration

As Viewed in the Downflow Orientation

(1 and 2 Stage Units)

,'_ Remove tube from relief port.

ii

Remove middle and bottom
plugs. DO NOT DISCARD.

(_) Install plugs in

(_ Connect relief tube

open ports on

collector box.

to port on collector

box.

desired position and

Rotate elbow to

tighten clamp to

15 lb.-in.

(_ Slide tube in stand-offs

to adjust length.

Connect tube from Loose Parts bag
to port on front pressure switch.

(1 and 2 Stage Units)

Route tube through inducer
stand-offs.

Trim excess tube.
Connect pressure switch
tube to port on collector

box.

Attach condensate trap
with screw to collector box.

Connect relief tube to
relief port on condensate

trap.

Align condensate trap
over middle and bottom

ports of collector box.

Downflow Trap Configuration

Fig. 9 - Downflow Trap Configuration

15

Al1280

Remove plug from

collector box.

DO NOT DISCARD.

If alternate vent position
is required, loosen clamp

on inlet of vent elbow.

ii

©

(1 AND 2 STAGE UNITS)

Unconverted Factory Trap Configuration

As Viewed in the Horizontal Right Orientation

Slide relief tube in stand-offs
to adjust length.

Remove trap from

collector box.

trap with screw to

Attach condensate

collector box.

open port on

(_ nstall plug in

collector box. (1 AND 2 STAGE UNITS)

Vent elbow shown in alternate
orientation. Tighten clamp on

inlet to vent elbow 15 lb.-in.

Align trap over middle and

right-hand post on collector box.

Horizontal Right Trap Configuration

Al1402

Fig. 10 - Horizontal Right Trap Configuration

ld

If alternate vent position
is required, loosen clamp

on vent elbow inlet.

from port on collector

(_) emove relief tube

box.

Remove trap from collector
box.

Remove relief tube from
relief port on condensate

trap.

Remove front pressure

switch tube and discard.

ii

Remove middle and right
plug from collector box.

(1 AND 2 STAGE UNITS)

Unconverted Factory Trap Configuration

As Viewed in the Horizontal Left Orientation

(_ otate elbow to

desired position
and torque clamp

on inlet 15 lb.-in.

(_ Slide relief tube instand-offs to adjust

length.

(_ ttach condensatetrap with screw to

collector box.

(_ Align trap over middleand right-hand port on

collector box.

(1 AND 2 STAGE UNITS)

Install plug in open

ports on collector box.

Connect relief tube to port
on collector box.

Connect tube from Loose
Parts bag to port on front

pressure switch.

Route pressure switch tube
underneath relief tube and

connect to port on
collector box.

Connect relief tube to relief
port on condensate trap.

Horizontal Left Trap Configuration

Fig. ll - Horizontal Left Configuration

17

Al1282

ii

CONDENSATE DRAIN CONNECTION

Upflow/Downflow Orientation
In the Upflow or Downflow orientation, the condensate trap is

inside the furnace casing. The condensate drain must be routed
from the trap through the furnace casing. The condensate drain can

be routed through the left or right side of the casing. (The left or
right side is as you are viewing the furnace.) The furnace

condensate drain can be connected to the Air Conditioning
condensate drain as shown in Fig. 13.

NOTE: On narrower casings, it may be easier to remove the
condensate trap, connect the drain line components and re-install
the condensate trap. Read the steps thoroughly to familiarize
yourself with the required steps.

For Right Side Condensate Drain:

1. Remove the 7/8-in. knock-out from the right side of the
casing. (See Fig. 12 .)

2. Remove the pre-formed drain tube and two spring clamps
from the loose parts bag.

3. Slide a spring clamp 1 in. (25 mm) down the plain end of
the drain tube.

4. From inside the casing, insert the formed grommet end of
the tube through the 7/8-in. knockout in the casing.

5. Pull the tube through the casing from the outside until it is
seated in the knockout

6. Attach the plain end of the drain tube to the outlet stub on
the drain trap. Secure the drain tube to the trap with the

spring clamp.

7. Slide a spring clamp over the open end of the drain tube
outside the casing.

8. Open the spring clamp and connect a field-supplied 1/2-in.
CPVC street elbow to the open end of the drain tube. (See

Fig. 14.)

9. Connect additional 1/2-in. CPVC piping to a condensate
pump approved for use with acidic furnace condensate or to

a code-approved drain.

For Left Side Condensate Drain Connection:

1. For left side condensate drainage, the drain line is routed
from the condensate trap, behind the inducer and out

through the left side of the casing. A pre-formed "Z" pipe is
provided in the loose parts bag shipped with the furnace.

The "Z" pipe is long enough to extend out of the casing on
the 14 3/16-in. (360 mm) wide furnace. Larger casings will

require a field supplied CPVC pipe and to extend the drain
line out of the furnace.

2. The "Z" pipe is connected to the condensate trap by
modifying the formed rubber drain tube. Connect the drain
line as shown below:

3. Remove the knock-out from the left side of the casing. (See
Fig. 12.)

4. Install the grommet for the l/2-in. CPVC drain line in the
7/8-in. knockout in the casing.

5. Remove the pre-formed drain tube, the offset l/2-in. CPVC
pipe and two spring clamps from the loose parts bag.

6. Remove the formed grommet on the tube by cutting the
tube along the vertical line located about 1 in. (25 mm)

away from the formed grommet.(See Fig. 15.)

7. Slide a spring clamp 1 in. (25 mm) down the plain end of
the drain tube.

8. With the bend in the tube oriented horizontally and plain
end of the tube pointing away from you, insert the l/2-in.

CPVC pipe into the other end of the drain tube. Rotate the
tube so the offset in the tube points away from you. Slide a

spring clamp over the open end of the l/2-in. CPVC tube

and secure the cut end of drain tube to the pipe. (See Fig.

16)

9. Prime the bare end of the pipe with CPVC primer.

10. Route the offset pipe behind the inducer assembly and

through the grommet in the casing, if the "Z" pipe is long
enough. If the "Z" pipe is not long enough, continue with

installation.

11. Attach the plain end of the drain tube to the outlet stub on
the drain trap. Secure the drain tube to the trap with the

spring clamp.

12. If the "Z" pipe does not extend through the casing, slide a

piece of field supplied CPVC through the grommet in the
casing, otherwise, go to Step 17.

13. Cement a 1/2-in. CPVC coupling to the end of the CPVC
pipe.

14. Apply cement to the end of the "Z" pipe connected to the
condensate trap.

15. Connect the field-supplied CPVC pipe to the CPVC pipe
connected to the condensate trap.

16. Cut off excess CPVC pipe outside the casing.

17. Connect additional 1/2-in. CPVC piping to a condensate
pump approved for use with acidic furnace condensate or to

a code-approved drain.

18. When a condensate pump is not used, slope the pipe away
from the furnace to allow for proper drainage.

Horizontal Orientation

1. In the Horizontal orientation, a field supplied accessory
drain trap grommet is required to seal the gap between the

casing and the condensate trap. The condensate trap outlet
extends 2 in. (51 mm) below the furnace casing. To allow

for servicing the trap, the condensate drain tube in the loose
parts bag can be modified to make a coupler to allow for

future service of the condensate trap and drain line.

2. Remove the knock-out for the condensate trap in the side of
the casing.

3. Install the drain trap grommet in the casing. If necessary,
remove the trap, install the grommet and re-install the trap.

4. Remove the pre-formed drain tube, the offset l/2-in. CPVC
pipe and two spring clamps from the loose parts bag.

5. Remove the formed grommet on the tube to create an elbow
or straight connector. (See Fig. 15.)

6. Connect the cut tube to the outlet of the condensate trap
with 1 spring clamp.

7. Slide the other spring clamp down the plain end of the drain
tube.

8. Connect additional l/2-in. CPVC piping to the open end of
the tube.

9. Slide the spring clamp down over the l/2-in. CPVC pipe

10. Connect additional l/2-in. CPVC piping to a condensate
pump approved for use with acidic furnace condensate or to
a code-approved drain.

11. When a condensate pump is not used, slope the pipe away
from the furnace to allow for proper drainage.

18

INSTALL CLAMPS ON DRAIN TUBE
ATTACH DRAIN TUBE TO CONDENSATF---- 7

DRAIN TRAP

PULL DRAIN STUB

THROUGH CASING

/

/

/

/

,/

/

0

¢

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.

Fig. 12 - Knockout Removal

OPENSTAND
PIPEFOR

A/COR

HUMIDIFIER
DRAIN

Al1305

OPEN SPRING CLAMP

INSERT FIELD - SUPPLIED

1/2'" CPVC DRAIN PIPE
* CLAMP MAY BE LOCATED
ON OUTSIDE OF DRAIN TUBE

RIGHT SIDE DRAIN INSTALLATION

Fig. 14 - Formed 1hhe Grommet

Cut and remove formed end of
drain tube for left side and horizontal

drain connection

\

\

\

il

Al1342

U

_'='_TE E

TO OPEN

DRAIN

"-I

Fig. 13 - Example of Field Drain Attachment

RIGHT SIDE DRAIN ELBOW

Al1388

Fig. 15 - Modify Drain 1hbe

Al1276

19

ii

Attach tube to condensate trap

Cut formed end off \

condensate drain tube \

Field supplied 1/2"CPVC Connect short end _ _]_

_7UlPl_l,_g2t,drnainexten,sion of"Z"pipetomodified\_ \" i_

TRAP, DRA_N ELBOW WiTH D_SCHARGE P_PE

Modified drain tube connect to
condensate trap and"Z" pipe

Field supplied 1/2"

CPVC to drain

ommet from

loose parts bag

LEFT SIDE DRAIN ROUTED BEHIND INDUCER

Field-supplied 1/2"CPVC coupling & drain
pipe 17 1/2'; 21"and 24 1/2"casings

\

\

A11344

Fig. 16 - Drain Trap Connection and Routing

trap

Horizontal Drain Trap Grommet

Al1348

Fig. 17 - Horizontal Drain Trap Grommet

INSTALLATION

Upflow Installation
NOTE: The furnace nmst be pitched forward as shown in Fig. 23

for proper condensate drainage.
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.

Connect supply-air duct to flanges on furnace supply-air outlet.
Bend flange upward to 90 ° with wide duct pliers. (See Fig. 20.)

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.

Return Air Connections

FIRE HAZARD
A failure to follow this warning could cause personal iniury,

death and/or property damage.
Never connect return-air ducts to the back of the furnace.

Follow instructions below.

The return-air duct nmst be connected to bottom, sides (left or
right), or a combination of bottom and side(s) of main furnace
casing. Bypass hunfidifier may be attached into unused return air

side of the furnace casing. (See Fig. 24, 25, 26.)
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 4 screws holding bottom
plate. (See Fig. 22.)

2. Remove bottom plate.

3. Remove bottom closure panel.

4. Reinstall bottom plate 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
some HORIZONTAL configurations. Do not use side return-air

openings in DOWNFLOW configuration. (See Fig. 24, 25, 26.)
Leveling Legs (If Desired)
In upflow position with side return inlet(s), leveling legs may be

used. (See Fig. 21.) 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 nmst 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.

2. For each leg, install nut on bolt and then install bolt with
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 in-
side nut to secure arrangement.

5. Reinstall bottom closure panel if removed.

Downflow Installation

NOTE: The furnace nmst be pitched forward as shown in Fig. 23
for proper condensate drainage.

Supply Air Connections

NOTE: For downflow @plications, this furnace is @proved for
use on combustible flooring when any one of the following 3

accessories are used:

• Special Base, KGASB

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

• Coil Box Part No. KCAKC

1. Deternfine application being installed from Table 6.

2. Construct hole in floor per Table 6 and Fig. 19.

2O

3.ConstructplenumtodimensionsspecifiedinTable6 and
Fig.19.

4.Installspecialbasecoilassemblyorcoilboxasshowninin
Fig.19.

NOTE:It isrecommendedthattheperforatedsupply-airduct
fangesbecompletelyremovedfromfurnacewheninstallingthe
furnaceonafactory-suppliedcasedcoilorcoilbox.Toremovethe
supply-airductflange,usewideductpliersorhandseamersto

bendflangebackandforthuntilitbreaksoff.Becarefulofsharp
edges.(SeeFig.20.)

FIRE,EXPLOSION,ANDCARBONMONOXIDE
POISONINGHAZARD

Failuretofollowthiswarningcouldresultinpersonal
injury,death,orpropertydamage.

Donotinstallthefurnaceonitsbackorhangfurnacewith
controlcompartmentfacingdownward.Safetycontrol
operationwill be adverselyaffected.Neverconnect

return-airductstothebackofthefurnace.

CUTHAZARD
Failureto 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.

Connect supply-air duct to supply-air outlet on furnace. Bend
flange inward past 90 ° with wide duct pliers (See Fig. 20.) The

supply-air duct nmst be connected to ONLY the furnace supply
outlet 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, hunfidifier, or other

accessories. All accessories MUST be connected to duct external to
furnace casing.
Return Air Connections

FIRE HAZARD
A 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.

The return-air duct nmst be connected to return-air opening
(bottom inlet). DO NOT cut into casing sides (left or right).

Bypass hunfidifier connections should be made at ductwork or coil
casing sides exterior to furnace. (See Fig. 25.)

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 4 screws holding bottom
plate. (See Fig. 22.)

2. Remove bottom plate.

3. Remove bottom closure panel.

4. Reinstall bottom plate and screws.

Horizontal Installation

NOTE: The furnace nmst be pitched forward as shown in Fig. 23

for proper condensate drainage.

The furnace can be installed horizontally in an attic or crawlspace
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.

Platform Furnace Support

Construct working platform at location where all required furnace

clearances are met. (See Table 2 and Fig. 27.) 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.

Suspended Furnace Support

The furnace must be supported under the entire length of the
furnace with threaded rod and angle iron. (See Fig. 28.) Secure

angle iron to bottom of furnace as shown.

Roll-Out Protection
Provide a minimum 12-in. x 22-in. (305 x 559 ram) piece of sheet

metal for flame roll-out protection in front of burner area for
furnaces closer than 12-in. (305 ram) above the combustible deck
or suspended furnaces closer than 12-in. (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. 27 for

proper orientation of roll-out shield.

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.

Connect supply-air duct to flanges on furnace supply-air outlet.

Bend flange upward to 90 ° with wide duct pliers. (See Fig. 20.)
The supply-air duct must be connected to ONLY the furnace
supply-outlet-air duct flanges or air conditioning coil casing

(when used). DO NOT cut main furnace casing side to attach
supply air duct, humidifier, or other accessories. All accessories

MUST be connected to duct external to furnace main casing.
Return Air Connections

The return-air duct must be connected to bottom of the furnace.
The side of casing that faces downward may also be used for return

air connection. A combination of the bottom and downward

facing side may also be used. The side of the casing cannot be
used as a return air connection. Bypass humidifier may be attached

into unused return air side of the furnace casing. (See Fig. 26.)
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:

21

ii

il

1. Tilt or raise furnace and remove 4 screws holding bottom
plate. (See Fig. 22.)

2. Remove bottom plate.

3. Remove bottom closure panel.

4. Reinstall bottom plate 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.

Not all horizontal furnaces are approved for side return air
connections (See Fig. 26.)

Filter Arrangement

FIRE, CARBON MONOXIDE AND POISONING
HAZARD

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

Never operate a furnace without a filter or filtration device
installed. Never operate a furnace with filter or filtration

device access doors removed.

FOR FURNACES SHIPPED WITH A

MEDIA CABINET

There are no provisions for an internal filter rack in these furnaces.
An external filter is required.

The furnace is shipped with a factory-supplied Media Filter

Cabinet. The Media Filter Cabinet uses either a standard I-in. (25

ram) filter or 4-in. (102 ram) wide Media Filter which can be
purchased separately. A field supplied accessory air cleaner may

also be used in place of the media cabinet.

The Media Cabinet is sized for bottom return applications for use
in upflow, downflow and horizontal applications. A 16-in. (406

ram) Media Cabinet is shipped with the 14-3/16-in. (360 ram)
furnace and includes block-off plates

For upflow side return applications, the Media Cabinet (or field
supplied accessory air cleaner) can be installed on the side of the

furnace or side and bottom when a bottom plenum is used. (See
Fig. 18 and 24.)

For downflow applications, the Media Cabinet (or field supplied

accessory air cleaner) nmst only be connected to the bottom

opening on the furnace. See Fig. 18 and 25.
For horizontal applications, the Media Cabinet (or field supplied

accessory air cleaner) for all models can be connected to the
bottom opening on the furnace. For side return use in the
horizontal position, refer to Fig. 26. If both side and bottom

openings are used in Fig. 26, each opening used will require a
filter.

The media cabinet (or field supplied accessory air cleaner) can also
be installed in the common return duct prior to entering the return

air opening in any orientation.
Refer to the instructions supplied with Media Cabinet or accessory

air filter for assembly and other details.

See Table 5 for filter size details.

Table 5 - Filter Size Information - In. (mm)

FURNACE CASING WIDTH FILTER TYPE

14-3/161- (360) (406 x 635 x 19) (356 x 635 x 19)

17-1/2 (445) (406 x 665 x 19) (406 x 665 x 19)

21 (566) (406 x 635 x 19) (508 x 635 x 19)

24-1/2 (622) (406 x 665 x 19) (610 x 665 x 19)

Recommended to maintain air filter face velocity. See Product Data for part number.
Not all families have these models.

FILTER CABINET HEIGHT - IN (MM) FILTER SIZE - IN (MM) FILTER TYPE

16 (406) (1) 16 x 25 x 4-5/16

20 (508) (1) 20 x 25 x 4-5/16

24 (610) (1) 24 x 25 x 4-5/16

Filters with a side return-air may have a different filter size. Measure the filter to obtain the correct size.
Recommended to maintain air filter face velocity. See Product Data for part number.

SIDE RETURN BOTTOM RETURN

16 x 25 x 6/4 14 x 25 x 6/4 Washable*

16 x 25 x 6/4 16 x 25 x 6/4 Washable*

16 x 25 x 6/4 20 x 25 x 6/4 Washable*

16 x 25 x 6/4 24 x 25 x 6/4 Washable*

Air Filter Located in Filter Cabinet

FILTER SIZE

(1) 16 x 25 x 6/4"

(406 x 665 x 19) or Washable or Media*

(406 x 665 x 110)

(1) 20 x 25 x 6/4"

(508 x 665 x 19) or Washable or Media*

(508 x 665 x 110)

(1) 24 x 25 x 3/4"or

(610 x 665 x 19) or Washable or Media*

(610 x 635 x 110)

22

k I V xl

14-3/16 and 17-1/2-in.

Furnace

m

16-in. Media Cabinet /

Media Cabinet Installation

Side Return

V "4

21- or 24-1/2-in.

t?urnace

Up to 5-Ton AC

capacity airflow

21-in. Furnace

4-Ton or less, AC

capacity airflow

_t

t

20-in. Media Cabinet

4-in.
Block Off

Plate

Media Cabinet Installation Option for

4-Ton or Less A/C Capacity

21-in. Furnace
up to 5-Ton AC

Capacity

20- or 24-in. Media

Cabinet

Bottom Return l lenum

_X

20- or -24-in. Media Cabinet Installation

for Combination Side and Bottom Return

14-3/16-in. Furnace

R

s.... i 4 g

24-1/2-in. Furnace
up to 4-Ton AC

Capacity

Transition j

20- or 24-in. Media Cabinet ._..J

20- or -24-in. Media Cabinet Installation

with Angled Transition

14-3/16-in. Furnace

Screwsi _7

is....

!_ _ Filler plates

14-3/16-in. Furnace with Filler Plates, Centered

14-3/16-in. Furnace with Filler Plates, Off-Set to Right

A11437

Fig. 18 - Media Filter

23

(OR COIL CASING

WHEN USED)

FURNACE

APPROVED

COIL ASSEMBLY

OR

COIL BOX

_ COMBUSTIBLE

FLOORING

SUBBASE

SHEET METAL

PLENUM

-- FLOOR --
OPENING

SHEET METAL_

PLENUM

__ FLOOR __

OPENING

Fig. 19 - Installation on Combustible Flooring

FURNACE

Table 6 - Opening Dimensions

CASING

WIDTH

APPLICATION

IN.(mm)

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

14-3/161-

(360) Downflow applications on combustible flooring (KGASB sub- 11 - 16/16 19 13- 7/16 20- 5/8

Downflow Applications on Combustible Flooring with CNPV, 12-5/16 19 13-5/16 20

CNRV, CAR or CAP Coil Assembly or KCAKC coil box (KGASB (619) (483) (338) (508)

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

(445) Downflow applications on combustible flooring (KGASB sub- 15-1/8 19 16-6/4 20-5/8

Downflow Applications on Combustible Flooring with ON PV, 15-1/2 19 16-1/2 20

CNRV, CAR or CAP Coil Assembly or KCAKC coil box (KGASB (394) (483) (419) (508)

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

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

Downflow Applications on Combustible Flooring with CNPV, 19 19 20 20

CNRV, CAR or CAP Coil Assembly or KCAKC coil box (KGASB (483) (483) (508) (508)

Upflow Applications on Combustible or Noncombustible Floor- 26 21 - 1/8 26- 5/8 22-1/4

Downflow Applications on Noncombustible Flooring (KGASB 22- 7/8 19 26-1/2 19- 5/8

24-1/2

(622) Downflow applications on Combustible flooring (KGASB su b- 22-1/8 19 26- 6/4 20- 5/8

Downflow Applications on Combustible Flooring with ON PV, 22-1/2 19 26-1/2 20

CNRV, CAR or CAP Coil Assembly or KCAKC coil box (KGASB (572) (483) (597) (508)

Not all families h_ve these models.

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

subbase not required) (319) (483) (335) (498)

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

subbase not required)

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

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

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

subbase not required)

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

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

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

subbase not required)

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

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

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

subbase not required)

In. (mm)

PLENUM OPENING FLOOR OPENING

A B C D

F

A10491

24

DISCHARGE DUCT
FLANGE

UPFLOW DOWNFLOW HORIZONTAL

[......

(8mm)

5/

1

(44mm)

120 °_

MIN

YES

\

YES 120°_

'\

YES

YES

YES

YES

MIN

NQ

NQ

Fig. 20 - Duct Flanges

(8mm)

(44mm) 1 3/4"

(44mm) 1

Fig. 21 - Leveling Legs

LEVEL 0-IN. (0 MM) TO
1/2-1N. (13 MM) MAX

__ J

FRONT

BOTTOM
CLOSURE
PANEL

BOTFOMPLATE

A89014

Al1092

Fig. 22 - Removing Bottom Closure Panel

MIN 1/4-1N. (6 MM) TO
1/2-1N. (13 MM) MAX

/

UPFLOW OR
DOWNFLOW

Fig. 23 - Furnace Pitch Requirements

HORIZONTAL

Al1237

25

NOT PERMITTED

l 0

d

n_URN

AI_

0

R_-- ANY COMBINATION OF 1,2, OR 3 PERMITTED

_T JRN

AIR

A11036

Fig. 24 - Upflow Return Air Configurations and Restrictions

Al1037

Fig. 25 - Downflow Return Air Configurations

and Restrictions

0

N

HORIZONAL

2d

RETURN AIR
RESTRICTIONS

• NOTE: RESTRICTION SAME FOR A

HOR[ZONAL LEFT (_ T AIR

Fig. 26 - Horizontal Return Air Configurations and Restrictions

Al1038

COMBUSTION - AIR PIPE
(SEEVENTING SECTION) \\

A 12-IN. (305 mm) MIN HORIZONTAL PIPE
SECTION IS RECOMMENDED WITH A

5 TO 8 FT / 1.5 TO 2.4 M) VENT

\

\

_VENT

MANUAL S
SHUTOFF
GAS VALVE

TRAP

30 IN. (762 mm)

COIL

CONDENSATE--
TRAP

NOTE: FURNACE SHOWN AS DIRECT VENT APPLICATION. REFER TO THE

VENTING SECTION FOR ALLOWABLE VENT CONFIGURATIONS

Fig. 27 - Working Platform for Attic Installation

ROLLOUT PROTECTION REQUIRED

Install 12"x 22"(305 x 559 mm) sheet
metal in front of burner compartment

COMBUSTION-AIR PIPE
(SEEVENTING SECTION)

--_ .... VENT

ii

Al1154

ROD

NOTE: EXTEND

,/

IRON OUT FOR
COIL

o%o%,o2/

LOCATORS

HEX NUT

& WASHER (4)

REQD. PER ROD

NOTES: 1. A 1 In. (25mm) clearance minimum between

top of furnace and combustible material

2. The entire length of furnace must be
supported when furnace is used in horizontal
position to ensure proper drainage.

3. Furnace shown isa direct vent application,
Refer to the Venting section for allowable vent

configurations,

Al1155

Fig. 28 - Suspended Furnace Installation

27

ii

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 7-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 terminating outside the space containing the

furnace.

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

approved tape or duct sealer.
NOTE: Flexible connections should be used between ductwork

and furnace to prevent transmission of vibration.

Table 7 - Air Delivery - CFM (With Filter)

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

BTUH SUPPLY SPEED

5(Gry) 1120 1080 1030 980 925 875 820 760 690 630

4(Yel) 880 845 810 780 740 710 680 640 615 570

40000 SIDE/BOTTOM 3(Blu) 695 665 620 575 535 495 455 420 370 280

2(Org) 640 595 540 495 460 420 370 310 260 230
1(Red) 570 525 475 425 385 330 255 220
5(Gry) 1720 1670 1620 1565 1505 1440 1375 1295 1220 1135

4(Yel) 1325 1285 1255 1220 1185 1145 1115 1075 1040 1000

60000 SIDE/BOTTOM 3(Blu) 1010 970 925 875 835 785 745 690 660 620

2(0 rg) 1160 1115 1080 1045 1000 960 920 875 840 785
1(Red) 785 715 655 595 530 490 435 385 340 285

5(Gry) 1810 1770 1720 1665 1610 1540 1475 1400 1315 1235

4(Yel) 1535 1500 1475 1435 1405 1370 1340 1310 1245 1160

80000 SIDE/BOTTOM 3(Blu) 1380 1340 1305 1270 1240 1200 1165 1130 1090 1050

2(Org) 1180 1130 1095 1060 1015 975 935 895 850 800
1(Red) 1100 1045 1010 970 920 885 845 790 745 690
5(Gry) 2040 1970 1885 1795 1720 1635 1540 1450 1360 1230

4(Yel) 1550 1505 1460 1415 1365 1325 1280 1230 1180 1135

100000 SIDE/BOTTOM 3(Blu) 1780 1730 1690 1645 1610 1555 1481 1400 1310 1210

2(0 rg) 1345 1295 1250 1195 1155 1105 1055 1000 955 915
1(Red) 1390 1350 1295 1260 1200 1160 1105 1050 1010 965
5(Gry) 2275 2230 2185 2130 2055 1950 1825 1710 1610 1500

4(Yel) 1875 1820 1770 1720 1660 1600 1550 1505 1450 1390

120000 SIDE/BOTTOM 3(Blu) 2170 2125 2075 2025 1975 1900 1790 1695 1590 1470

2(Org) 1475 1420 1350 1280 1215 1165 1105 1050 995 930
1(Red) 1625 1565 1505 1445 1385 1325 1275 1225 1170 1130

*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
accessory 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.

0,1 0,2 0,3 0,4 0,5 0,6 0,7 0,8 0,9 1

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 mm) clearance from combustible materials to

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

requirements.

Ductwork Acoustical Treatment

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

and 10 ft. (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.
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.

28

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. A fire or explosion may
result causing property damage, personal iniury or loss of

life.

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

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

manifold and gas valve.

FIRE OR EXPLOSION HAZARD

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

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

current edition of CAN/CSA B149.1 in Canada.
Installations must be made in accordance with all authorities
having jurisdiction. If possible, the gas supply line should be a

separate line running directly from meter to furnace.
NOTE: Use a back-up wrench on the inlet of the gas valve when

connecting the gas line to the gas valve.
NOTE: In the state of Massachusetts:

1. Gas supply connections MUST be performed by a licensed
plumber or gas fitter.

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

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

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

Refer to Table 8 for recommended gas pipe sizing. Risers must be
used to connect to furnace and to meter. Support all gas piping

with appropriate straps, hangers, etc. Use a minimum of 1 hanger
every 6 ft. (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
A 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 minimum of 2-in. (51 mm)

outside the furnace.

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.

An accessible manual equipment shutoff valve MUST be installed
external to furnace casing and within 6 ft. (1.8 M) of furnace.

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

30. Connect a capped nipple into lower end of tee. Capped nipple
should extend below level of furnace gas controls. Place a ground

joint union between furnace gas control valve and exterior manual
equipment gas shutoff valve.

A l/8-in. (3 mm) 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 the
current addition of the NFGC in the United States, local, and

national plumbing and gas codes before the furnace has been
connected. Refer to current edition of NSCNGPIC in Canada.

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

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. 51.)

If pressure exceeds 0.5 psig (14-in. w.c.), gas supply pipe must be
disconnected from furnace and capped before and during supply
pipe pressure test. If test pressure is equal to or less than 0.5 psig

(14-in. 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.

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

viewed in upflow). (See Fig. 29.)

Gas Pipe Grommet

For direct vent (2-pipe) applications, the knockout for the gas pipe
must be sealed to prevent air leakage. Remove the knockout, install
the grommet in the knockout, then insert the gas pipe. The

grommet is included in the loose parts bag. See Fig. 29.

29

g

Table 8 - Maximum Capacity of Pipe

NOMINAL LENGTH OF PIPE - FT (M)

IRON PIPE

SIZE 10 20 30 40 50

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

1/2 (13) 175 120 97 82 73
3/4 (19) 360 250 200 170 151

1 (25) 680 465 375 320 285

1-1/4 (32) 1400 950 770 660 580
1-1/2 (39) 2100 1460 1180 990 900

* Cubic ft of 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 8 above and 6.2 of NFPA54/ANSI Z223.1-2009.

Left Side Gas Entry. Gas Pipe
Grommet Required For Direct

Vent Applications.

Gas Pipe Grommet Required
For Direct Vent Applications

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

33 ° C) rise.

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

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

ground according to NEC ANSI/NFPA 70-2011 or local
codes to minimize personal injury if an electrical fault

should occur. In Canada, refer to Canadian Electrical Code
CSA C22.1. This may consist of electrical wire, conduit

approved for electrical ground or a listed, grounded power
cord (where permitted by local code) when installed in
accordance with existing electrical codes. Refer to the
power cord manufacturer's ratings for proper wire gauge.
Do not use gas piping as an electrical ground.

MANUAL ,._

SHUTOFF [

VALVE

(REQUIRED)

J

SEDIMENT
TRAP

Fig. 30 - Typical Gas Pipe Arrangement

ELECTRICAL CONNECTIONS

Fig. 29 - Gas Entry

/

/

UNION _

NOTE: Union may be inside the
vestibule where permitted by

local codes.

FRONT

I

Al1338

Al1035

FURNACE MAY NOT OPERATE HAZARD
Failure to follow this caution may result in intermittent

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

Furnace must have a 115-v power supply properly connected and
grounded.

NOTE: Proper polarity must be maintained for 115-v wiring. If
polarity is incorrect, control LED status indicator light will flash

rapidly and furnace will NOT operate.
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 9 for equipment electrical
specifications.

U.S.A. Installations: Make all electrical connections in accordance
with the current edition of the National Electrical Code (NEC)

ANSI/NFPA 70 and any local codes or ordinances that might

apply.
Canada Installations: Make all electrical connections in
accordance with the current edition of the Canadian Electrical
Code CSA C22.1 and any local codes or ordinances that might
apply.

ELECTRICAL SHOCK HAZARD

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

Blower door switch opens 115-v power to control. No
component operation can occur. Do not bypass or close

switch with blower door removed.

See Fig. 34 for field wiring diagram showing typical field 115-v
wiring. Check all factory and field electrical connections for

tightness.

FIRE HAZARD
Failure to follow this warning could result in personal

iniury, death, or property damage.
Do not connect aluminum wire between disconnect
switch and furnace. Use only copper wire. See Fig. 32.

Use a separate, fused branch electrical circuit with a properly sized
fuse or circuit breaker for this furnace. See Table 9 for wire size

and fuse specifications. A readily accessible means of electrical

disconnect must be located within sight of the furnace.

3O

J-Box Installation

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

iniury, 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.

The J-Box is used when field line voltage electrical connections are
made to the furnace wiring harness inside the furnace casing. The

J-Box is not required if a field-supplied electrical box is attached to
the outside of the furnace casing and the box is grounded to the
green ground wire of the main wiring harness and the earth ground

of the field electrical supply.
The J-Box cover, mounting bracket and screws are shipped in the

loose parts bag included with the furnace. The J-Box can be
mounted on the left or right side of the casing, as viewed from the

upflow position.
Remove the J-Box cover and mounting bracket from the loose

parts bag. Select a 7/8-in. (22 mm) knock-out on the desired side
of the casing. Remove the knock-out from the casing. Drill two (2)

l/8-in. (3 mm) pilot holes in the casing dimples by the desired
7/8-in. (22 mm) knock-out.

Align the J-Box mounting bracket against the inside of the casing
and secure the mounting bracket with the screws. (See Fig. 31.)

Electrical Box on Furnace Casing Side
NOTE: Check that duct on side of furnace will not interfere with

installed electrical box.

1. Fasten a field-supplied external electrical box to the outside
of the casing by driving two field-supplied screws from in-

side electrical box into casing. (See Fig. 32.)

2. Route field power wiring into external electrical box.

3. Pull furnace power wires through l/2-in. (12 mm) diameter
hole in J-Box. If necessary, loosen power wires from strain-

relief wire-tie on furnace wiring harness.

4. Connect any code required external disconnect(s) to field
power wiring.

5. Route external field power wires through holes in electrical
box and casing.

6. Connect field ground wire and factory ground wire to green
ground screw on J-Box mounting bracket as shown in Fig.

31.

7. Connect field power and neutral leads to furnace power
leads as shown in Fig. 34.

8. Attach furnace J-Box cover to mounting bracket with
screws supplied in loose parts bag. Do not pinch wires

between cover and bracket.

9. Complete external disconnect wiring and installation. Con-
nect line voltage leads as shown in Fig. 32. Use best prac-

tices (NEC in U.S.A. for wire bushings, strain relief, etc.,
CANADA: Canadian Electrical Code CSA C22.1)

Power Cord Installation in Furnace J-Box
NOTE: Power cords must be able to handle the electrical

requirements listed in Table 9. Refer to power cord manufacturer's
listings.

1. Install J-Box mounting bracket to inside of furnace casing.
(See Fig. 31 .)

2. Route listed power cord through 7/8-in. (22 mm) diameter
hole in casing and J-Box bracket.

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

4. Pull furnace power wires through l/2-in. (12 mm) diameter

hole in J-Box. If necessary, loosen power wires from
strain--relief wire-tie on furnace wiring harness.

5. Connect field ground wire and factory ground wire to green

ground screw on J-Box mounting bracket as shown in Fig.

31.

6. Connect power cord power and neutral leads to furnace
power leads as shown in Fig. 34.

7. Attach furnace J-Box cover to mounting bracket with
screws supplied in loose parts bag. Do not pinch wires

between cover and bracket. (See Fig. 31).

BX Cable Installation in Furnace J-Box

1. Install J-Box mounting bracket to inside of furnace casing.
See Fig. 31.

2. Route BX connector through 7/8-in. (22 mm) diameter
hole in casing and J-Box bracket.

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

4. Connect field ground wire and factory ground wire to green
ground screw on J-Box mounting bracket as shown in Fig.

31.

5. Connect field power and neutral leads to furnace power
leads, as shown in Fig. 34.

6. Attach furnace J-Box cover to mounting bracket with
screws supplied in loose parts bag. Do not pinch wires

between cover and bracket.

24-V Wiring

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

35.) Connect terminal Y/Y2 as shown in Fig. 34 for proper cooling
operation. Use only AWG No. 18, color-coded, copper thermostat

wire.
NOTE: Use AWG No. 18 color-coded copper thermostat wire for

lengths up to 100 ft. (30.5 M). For wire lengths over 100 ft., use
AWG No. 16 wire.

The 24-v circuit contains an atttomotive-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. See Fig. 35.

Accessories (See Fi_. 33 and 35,)

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

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

marked EAC-1 and EAC-2. The terminals are rated for
II5VAC, 1.0 amps maximum and are energized during

blower motor operation.

2. Humidifier (HUM)

The HUM terminal is a 24 VAC output, energized when the gas
valve relay is operating during a call for heat.

Connect an accessory 24 VAC, 0.5 amp. maximum humidifier (if

used) to the ¼-in. male quick-connect HUM terminal and

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

NOTE: If the humidifier has its own 24 VAC power supply, an
isolation relay may be required. Connect the 24 VAC coil of the
isolation relay to the HUM and COM/24V screw terminal on the

control board thermostat strip. (See Fig. 33.)

Alternate Power Supplies

This furnace is designed to operate on utility generated power
which has a smooth sinusoidal waveform. If the furnace is to be

operated on a generator or other alternate power supply, the

alternate power supply must produce a smooth sinusoidal

waveform for compatibility with the furnace electronics. The

31

alternatepowersupplymustgeneratethe same voltage, phase, and

frequency (Hz) as shown in Table 9 or the furnace rating plate.

Contact the alternate power supply manufacturer for specifications
and details,

Power from an alternate power supply that is non-sinusoidal may
damage the furnace electronics or cause erratic operation.

Table 9 - Electrical Data

UNIT SIZE

40,000 11.0
60,000 13.0

80,000 13.0
100,000 16.1
120,000 16.1

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

etc.) full load amps.
1"Time-delay type is recommended.
_Length shown is as measured one way along wire path between furnace and service panel for maximum 2 percent voltage drop.

VOLTS-
HERTZ-

PHASE

115-60-1
115-60-1

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

OPERATING VOLTAGE

RANGE*

Maximum* Minimum*

127 104
127 104

127 104
127 104
127 104

MAXIMUM

UNIT

AMPS

6.8

8.4

8.4

10.9

10.9

UNIT

AMPACITY#

MINIMUM MAXIMUM

WIRE WIRE

SIZE LENGTH

AWG FT (M):_

14 33 (10.0)
14 26 (8.5)

14 28 (8.5)
12 35 (10.6)
12 35 (10.6)

GROUND--

MAXIMUM

FUSE OR CKT

BKR

AMPSt

15
15

15
2O
2O

J-BOX
LOCATIONS

Fig. 31 - Installing J-Box (When Used)

Al1299

NEUTRAL

ELECTRIC

DISCONNECT

SWITCH

®

Fig. 32 - Field-Supplied Electrical Box on Furnace Casing

Al1146

32

I To Hum_dilier Leads

I To Hum_d_fie r Leads

Fig. 33 - Field-supplied Isolation Relay for Humidifiers with Internal Power Supply

NOTE 2

FIVEWIRE_ @_ @_ TERMINALSTHERMOSTAT

THREE-WIRE I I I I II

HEATING_ON Ly _"_ ___ {i I I L

BLOWERDOORSWITCH--&______" '' "--{,'

W HT_ ..... JWHI L_ [ O _ ------1----J II

f_ GND T I __

115-VFIELD- AUXILIARY n _ __1 [ II

SUPPLIED J-BOX _ _ / ] I

DISCONNECT (_ ..... _N_O_T_E_I.... J

24-V

TERMINAL WIRE

BLOCK

FURNACE

Fig. 34 - Typical Single-Stage Wiring Diagram

NOTES: 1.

/

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

2.

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

3.

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

same type or equivalent wire.

To HUMTerminal On I

Furnace Conirol Board

.... FIELD 24-V WIRING

.... FIELD 115-, 208/230-, 460-VWIRING

-- FACTORY 24-VWIRING
FACTORY 115-V WIRING

iiiiiiii_iiiiiiiii!iiiii

iiiii,;iit!!iiiY_Y#i?_ii_

I

I

FIELD-SUPPLIED
DISCONNECT

208/230- OR
460-V
THREE

PHASE

208/230-V

SINGLE
PHASE

SiN

"---

Al1157

g

A11387

33

1 J

TEST / TWIN

o o BLOWER OFF-DELAY

24-V THERMOSTAT
TERMINALS

TWINNING AND/OR

COMPONENT TEST

TERMINAL

ii

HUM

0.5-AMP

@24VAC

[FUSE 3-AM_

SEC-2 SEC-1

OPERATION &

C'eO'_P" LIGHTDIAGNOSTIC

_ r-

OOM

_ .-I!

m

0
[]

[]
[]
[]

[]
[]
[]
[]
D

[]
[]

-- (115 VAC 1.0 AMP MAX.)

HUMIDIFIER TERMINAL
(24-VAC 0.5 AMP MAX)

3-AMP FUSE

TRANSFORMER 24VAC
CONNECTIONS

PL1 - LOW VOLTAGE MAIN
HARNESS CONNECTOR

BLOWER SPEED
SELECTION TERMINALS

EAC TERMINAL

= 1

c_l ' '

r _ _ 1_'_ CONNECTIONS

F---'I | [ r-"m,,_-INPUT

115-VAC (L2) EAC-1

_ NEUTRAL

/ 115 VAC (L1)

L1 BL-1

PL-2 HOT SURFACE
IGNITOR (HSI) &

INDUCER MOTOR
(IND) CONNECTOR

I I

_ g

PR-1 IND HSl

Fig. 35 - Single Stage Furnace Control

34

Al1391

THERMOSTAT SINGLE-STAGE SINGLE-SPEED THERMOSTAT SINGLE-STAGE TWO-SPEED

FURNACE AIR CONDITIONER FURNACE AIR CONDITIONER

N_

N_

HEAT STAGE 1 [_

COOL STAGE 1 [_

FAN [_

24 MAC HOT [_

* DEHUMIDIFY [_

24 VAC COMM [_

HUM ""- •

HUMIDIFY

N/A [_

Os_gOoO2_

(24 VAC)

SENSOR

CONNECTONL[_

See notes 2, 5, 7, 10, and 14

Single-Stage Furnace with Single-Speed Air Conditioner

N/A

COOL STAGE 1

HEAT STAGE 1

COOL STAGE 2

FAN [_

24 VAC HOT

* DEHUMIDIFY

24 VAC COMM [_

HUMIDIFY

N/A [_

F_

C_

_HUMDFER_i

°S_N_S°°R_

CONNECT,ONL_

See notes 2, 5, 8, 10, and 14

Single-Stage Furnace with Two-Speed Air Conditioner

HUM

(24 MAC)

OUTDOOR ]_

SENSOR

ii

THERMOSTAT SINGLE-STAGE SINGLE-SPEED

RVS COOLING_

N/A[_

HEAT STAGE 2 [_

(FURNACE)

HEAT/COOL STAGE 1

(COMPRESSOR)

FAN [_

24 VAC HOT [_

* DEHUMIDIFY [_

24 VAC COMM [_

HUMIDIFY [_

N/A

%T_s°°R_[_

FURNACE HEAT PUMP

CK_

HUM

HOM,O,F,ER_ i

(24 VAC)

_ OUTDOOR _z_,

SENSOR

CONNECT,ON_

See notes 1, 2, 4, 6, 7, 9, 10, 12 and 14

THERMOSTAT SINGLE-STAGE TWO-SPEED

RVS COOLING_

HEAT/COOL STAGE 1 _ .................. _ ......

(COMPRESSOR LO)

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

(FURNACE)

HEAT/COOL STAGE 2 _o NOTE 12

(COMPRESSOR HI) _ ........... _ .....

FAN_ ...........

FURNACE HEAT PUMP

_4"ACHOT_.............._ ........

*OEHUM,D,FY_ I_

_4MACCOMM_............._

HUM "'-. ......

HUMIDIFY

N/A

°s_gs°°2_ .....

/_J HUMIDIFIER [/_ i

..... (24 VAC) - -

!_t OUTDOOR ]_

SENSOR

CONNECT,ON_

See notes 1, 2, 3, 4, 6, 8, 9, 10 12 and 14

Single-Stage Furnace with Single-Speed Heat Pump Single-Stage Furnace with Two-Speed Heat Pump

Fig. 36 - Thermostat Wiring Diagrams

35

A11275

NOTES FOR THERMOSTAT WIRING DIAGRAMS

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. If the heat pump date code is 1501E or earlier, select the "ZONE" position on the two speed heat pump control. Heat pumps with date
code 1601E and later do not have or require a "ZONE" selection.

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

5. Configure the thermostat for air conditioner installations. Refer to thermostat instructions.

6. Configure thermostat for heat pump installations. Refer to thermostat instructions.

7. Configure thermostat for single-stage compressor operation. Refer to thermostat instructions.

8. Configure thermostat for two-stage compressor operation. Refer to thermostat instructions.

9. Configure thermostat for Dual Fuel Operation. Refer to thermostat instructions.

10. NO connection should be made to the furnace HUM terminal when using a thermostat with a 24 volt humidifier output.

11. The RVS Sensing terminal "L" should not be connected. This is used internally to sense defrost operation.

12. If thermostat has internal control of heat pump balance point, DO NOT SELECT the "FURNACE INTERFACE" or "BALANCE

POINT" option on the two-speed heat pump control board. Refer to thermostat instructions.

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

14. Configure Dehumidify function to remove 24 VAC from Dehum terminal on a demand to dehumidify.

36

VENTING

Furnace is set in place in the required orientation.

Special Venting Requirements for Installations in
Canada

Installation in Canada must conform to the requirements of
CAN/CSA B149 code. Vent systems must be composed of pipe,

fittings, cements, and primers listed to ULC $636. The special
vent fittings and accessot T concentric vent termination kits and

accessot T external drain trap have been certified to ULC $636 for
use with those Royal Pipe and IPEX PVC vent components which

have been certified to this standard. In Canada, the primer and
cement must be of the same manufacturer as the vent system

GVS-65 Primer (Pm_le) for Royal Pipe or IPEX System 636,
PVC/CPVC Primer, Pm_le Violet for Flue Gas Venting and
GVS-65 PVC Solvent Cement for Royal Pipe or IPEX System

636(1)t, PVC Cement for Flue Gas Venting, rated Class IIA, 65 deg
C. must be used with this venting system - do not mix primers and

cements from one manufacturer with a vent system from a different
manufacturer. Follow the manufacturer's instructions in the use of

primer and cement and never use primer or cement beyond its
expiration date.

The safe operation, as defined by ULC $636, of the vent system is
based on following these installation instructions, the vent system
manufacturer's installation instructions, and proper use of primer

and cement. All fire stop and roof flashing used with this system
must be UL listed material. Acceptability under Canadian standard

CAN/CSA B149 is dependent upon full compliance with all
installation instructions. Under this standard, it is recommended

that the vent system be checked once a year by qualified service
personnel.

The authority having jurisdiction (gas inspection authority,
municipal building department, fire department, etc) should be

consulted before installation to determine the need to obtain a
permit.

*IPEX System 636T'_isa trademark of IPEX Inc.

Consignes sp6ciales pour l'installation de
ventilation au Canada

L'installation faite au Canada doit se conformer aux exigences du
code CAN/CSA B149-2010. Ce syst_me de ventillation doit se

composer de tuyaux, raccords, ciments et appr_ts conformes au
ULC $636. La tuyauterie de ventillation des gaz, ses accessoires,

le terminal concentrique mural ainsi que l'ensemble du drain de
condensat extdrieur ont _td certifids ULCS 636 pour l'application

des composantes Royal Pipe, IPEX PVC qui sont certifides 5. ce
standard. Au Canada, l'appr_t et le ciment doivent _tre du m_me

fabricant que le syst_me d'@acuation. L'appr_t GVS-65 (Purple) et
le ciment-solvant GVS-65 doivent _tre utilis6 avec les Royal Pipe.

Syst_me IPEX 636, appr_t PVC/CPVC, Purple pour @acuation
des gaz de combustion et syst_me IPEX 636(1)t, ciment PVC pour

@acuation des gaz de combustion, cord classe IIA, 65 deg C.
doivent _tre utilis6s avec le syst_me d'@acuation IPEX 636 - Ne

pas combiner 1 'appr_t et le ciment d'un manufacturier avec un
syst_me d'@acuation d'un manufacturier different.

Bien suivre les indications du manufacturier lors de l'utilisation de

l'apprat et du ciment et ne pas utiliser ceux-ci si la date d'expiration
est atteinte.

L'opdration sdcuritaire, tel que ddfinit par ULC $636, du systame
de ventilation est basd sur les instructions d'installation suivantes,

ainsi que l'usage approprid de l'apprat et ciment. Tout arret feu et
solin de toit utilisds avec ce systame doivent atre des matdriaux
listds UL. L'acceptation du standard Canadien CAN/CSA B149

est directement relid fi l'installation conforme aux instructions ci-
haut mentionndes. Le standard Canadien recommande 1' inspection

par un personel qualifid et ce, une fois par annde.

Les autoritdes ayant juridiction (inspecteurs de gas, inspecteurs en
bfitiments, d@artement des incendies, etc) devraient _tre consultdes

avant l'installation afin de d_terminer si un permis est requis.

CARBON MONOXIDE POISONING HAZARD
Failure to follow the steps outlined below for each appliance

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

The following steps shall be followed for each appliance
connected to the venting system being placed into operation,
while all other appliances connected to the venting system are
not in operation:

1. Seal any unused openings in venting system.

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

Code, NFPA 54/ANSI Z223.1-2009 and these
instructions. In Canada, refer to CAN/CSA-
B149.1-2010. Determine that there is no blockage or

restriction, leakage, corrosion and other defciencies,
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, NFPA

54/ANSI Z223.1-2009. In Canada, refer to CAN/

CSA-BI49.1-2010.

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.

General

If this furnace replaces a furnace that was connected to a vent
system or chimney, the vent or vent connectors of other remaining

appliances may need to be re-sized. Vent systems or vent

connectors of other appliances must be sized to the minimum size

as determined using appropriate table found in the current edition
of National Fuel Gas Code NFPA 54/ANSI Z-223.1. In Canada,
refer to CAN/CSA-BI49.1.

An abandoned masonry chimney may be used as a raceway for
properly insulated and supported combustion-air (when

applicable) and vent pipes. Each furnace must have its own set of
combustion-air and vent pipes and be terminated individually, as

shown in Fig. 47 for Direct Vent (2-Pipe) system or Fig. 48 for
ventilated combustion air option.

ii

37

ii

A furnace shall not be connected to a chinmey flue serving a
separate appliance designed to burn solid fuel.

Other gas appliances with their own venting system may also use
the abandoned chinmey as a raceway providing it is permitted by

local code, the current edition of the National Fuel Gas Code and
the vent or liner manufacturer's installation instructions. Care must

be taken to prevent the exhaust gases from one appliance from
contaminating the combustion air of other gas appliances.

Do not take combustion air from inside the chinmey when using
ventilated combustion air or single pipe vent option.

These furnaces can be vented as either direct vent furnace,
ventilated combustion air system or non-direct (single pipe) vent

system. Each type of venting system is described below. Common
venting between furnaces or other appliances prohibited.

Materials

U.S.A.
Combustion air and vent pipe, fittings, primers, and solvents nmst

conform to American National Standards Institute (ANSI)
standards and American Society for Testing and Materials (ASTM)

standards. See Table 11 for approved materials for use in the
U.S.A.

Canada

Special Venting Requirements for Installations in Canada
Installation in Canada nmst conform to the requirements of

CAN/CSA B149 code. Vent systems must be composed of pipe,
fittings, cements, and primers listed to ULC $636.

Venting Systems

A factory accessory KGAVT vent termination kit nmst be used for
all direct vent terminations. Termination kits are available for 2-in.

or 3-in. pipe. See Table 10 for available options.

Table 10 - Vent Termination Kit for Direct Vent (2-pipe)

Systems

DIRECT VENT TERMINATION COMBUSTION AIR

(2- PIPE) SYSTEM AND VENT PIPES

TERMINATION KIT

2-in. (51 mm) Single Penetration 2-1/2

Concentric Vent Kit of Wall or Roof (24, 36, 51,64

3-in. (76 mm) Single Penetration 2-1/2, 6 or 4

Concentric Vent Kit of wall or Roof (64, 76, 102 mm)

2-in. (51 mm) 2-Pipe

Termination Termination 1, 1-1/2 or 2

Bracket Kit System (25, 36, 51 mm)

3-in. (76 mm) 2-Pipe 2-1/2, 6 or 4

Termination Termination

Bracket Kit System (64, 76, 102 mm)

Direct Vent / 2-Pipe System

In a direct-vent (2-pipe) system, all air for combustion is taken
directly from outdoor atmosphere, and all flue products are
discharged to outdoor atmosphere. Combustion-air and vent pipes
nmst terminate together in the same atmospheric pressure zone,

either through the roof or a sidewall (roof termination preferred). A
factory accessory vent termination kit MUST be used in a direct

vent (2-pipe) system. See Fig. 45 for required clearances.

Ventilated Combustion Air Systems

In a ventilated combustion air option, the vent terminates and
discharges the flue products directly to the outdoors similar to a

direct vent system. See Fig. 46 for required clearances.
All air for combustion is piped directly to the furnace from a space

that is well ventilated with outdoor air (such as an attic or crawl
space) and the space is well isolated from the living space or
garage. Combustion air requirements for this option are the same as
the requirements for providing outside air for combustion for a

DIAM. OF

- IN. (mm)

1, 1-1/2, 2, or

mm)

single pipe vent system. Refer to the "Air For Combustion and
Ventilation Section.

Provisions for adequate combustion, ventilation, and dilution air
must be provided in accordance with:

U.S.A. Installations: Section 9.3 NFPA 54/ANSI Z223.1-2009,
Air for Combustion and Ventilation and applicable provisions of

the local building codes.

Canadian Installations: Part 8 of CAN/CSA-B149.1-10. Venting

Systems and Air Supply for Appliances and all authorities having
jurisdiction.

Non-Direct Vent (1-pipe) System

In a non direct-vent (1-pipe) system, all air for combustion is taken
from the area adjacent to furnace, and all flue products are
discharged to outdoor atmosphere. Air for combustion nmst be

supplied as described in the Air For Combustion and Ventilation

Section. Do not use an abandoned chinmey to supply outside air to
the furnace. See Fig. 46 for required clearances.

Provisions for adequate combustion, ventilation, and dilution air
must be provided in accordance with:

U.S.A. Installations: Section 9.3 NFPA 54/ANSI Z223.1-2009, Air
for Combustion and Ventilation and applicable provisions of the

local building codes.

Canadian Installations: Part 8 of CAN/CSA-B149.1-10. Venting

Systems and Air Supply for Appliances and all authorities having
jurisdiction.

A combustion air pipe to the outdoors is not required for a single
pipe vent system. A 12-in. (304 ram) long pipe with a 2-in. (51

ram) tight radius 90 degree elbow is required to be attached to the
combustion air pipe adapter on the furnace. (See Fig. 44)

Locating the Vent Termination

General
NOTE: Termination Requirements for the Provinces of

Alberta and Saskatchewan are located at the end of this
section.

Combustion-air (direct vent/2-pipe system only) and vent pipe
must terminate outside structure, either through sidewall or roof.

For vent termination clearance, refer to Fig 45 for Direct
Vent/2-Pipe system and Fig. 46 for Non-direct Vent/I-Pipe

system. For exterior termination arrangements, refer to Fig. 47 for
Direct Vent/2-Pipe system and Fig. 48 for Non- Direct/l-Pipe

system.
Roof termination is preferred since it is less susceptible to damage

or contamination, and it has less visible vent vapors. Sidewall
terminations require sealing or shielding of building surfaces with a

corrosive resistance material due to corrosive combustion products
of vent system.

NOTE: (Direct Vent/2-Pipe system ONLY) A factory accessory
termination kit MUST be used.

When determining appropriate location for termination, consider
the following guidelines:

1. Comply with all clearance requirements stated in Fig 45 or
Fig 46 per application.

2. Termination or termination kit should be positioned where
vent vapors will not damage plants/shrubs or air condi-

tioning equipment.

3. Termination or termination kit should be positioned so that

it will not be affected by wind eddy, such as inside building
corners, nor by recirculation of flue gases, airborne leaves,

or light snow.

4. Termination or termination kit should be positioned where it
will not be damaged by or subjected to foreign objects such

as stones, balls, etc.

38

5. Termination or termination kit should be positioned where
vent vapors are not objectionable.

Direct Vent / 2-Pipe System
Direct vent (2-pipe) vent and combustion air pipes must terminate

outside the structure. Follow all clearances as shown Fig 45.

Allowable vent and combustion airterminations are shown in Fig.

47.
Ventilated Combustion Air

The vent pipe for a Ventilated Combustion Air System must
terminate outdoors. Follow all vent termination clearances shown

in Fig 46. Allowable vent terminations are shown in Fig 48. The
combustion air pipe terminates in a well-ventilated attic or crawl
space. Follow the clearances as shown in Fig. 50.

The combustion air pipe cannot terminate in attics or crawl spaces
that use ventilation fans designed to operate in the heating season.

If ventilation fans are present in these areas, the combustion air
pipe must terminate outdoors as a Direct Vent System.

Non-Direct Vent / 1-Pipe System

The vent pipe for a Non Direct Vent (I-pipe) system must
terminate outdoors. Follow all vent termination clearances shown

in Fig 46. Allowable vent terminations are shown in Fig. 48
A combustion air pipe to the outdoors is not required for a

Non-Direct Vent System. A 12-in. long section of pipe with a
tight radius 2-in. (50.8 mm) 90 degree elbow is required to be

attached to the furnace.
Termination Requirements for the Provinces of Alberta and

Saskatchewan

The Provinces of Alberta and Saskatchewan require a minimum
unobstructed distance of 4 ft. (1.2 M) from the foundation to the

property line of the adjacent lot for vent termination of any
appliance with an input over 35,000 btuh. If there is less than 4 ft.

(1.2 M) of unobstructed distance to the property line of the
adjacent lot, no type of vent termination is permitted for appliances
with inputs greater than 35,000 btuh.

There are no additional restrictions on unobstructed distances
greater than 8 ft. (2.4 M). All single, two-pipe and concentric vents

nmy be used, providing all other Code and manufacturer's
requirements in these instructions are adhered to. Refer to the

appropriate Vent Termination section above for locating the vent
termination

If the unobstructed distance from the foundation to the property
line of the adjacent lot is no less than 4 ft. (1.2 M) and no greater

than 8 ft. (2.4 M), it will be necessary to re-direct the flue gas
plume. In this situation, a concentric vent kit cannot be used. A

2-pipe termination (or single pipe termination when permitted) that
re-directs the flue gas away by use of an elbow or tee, certified to
ULC $636 from the adjacent property line must be used. See Fig.

49.
The concentric vent kit currently cannot be modified to attach an

elbow to the vent portion of the rain cap. A tee attached to the rain
cap could potentially direct the flue gas plume toward the intake air

stream and contaminate the incoming combustion air for the
furnace.

Refer to Fig. 49 for terminations approved for use in Alberta and
Saskatchewan.

Size the Vent and Combustion Air Pipes
General

Furnace combustion air and vent pipe connections are sized for
2-in. (51 mm) pipe. Any pipe diameter change should be made

outside furnace casing in vertical pipe. Any change is diameter to
the pipe must be made as close to the furnace as reasonably

possible.
The Maximum Vent Length for the vent and combustion air pipe

(when used) is determined from the Maximum Equivalent Vent

Length in Table 13 or 15, minus the number of fittings multiplied
by the deduction for each type of fitting used from Table 14.

The measured length of pipe used in a single or 2-pipe termination
is included in the total vent length. Include a deduction for a Tee

when used for Alberta and Saskatchewan terminations. Concentric
vent terminations, pipe lengths or elbows do not require a

deduction from the Maximum Equivalent Vent Length.

1. Measure the individual distance from the furnace to the ter-
mination for each pipe.

2. Select a Maximum Equivalent Vent Length (MEVL) longer
than the measured distance of the individual vent and com-

bustion air connections to the vent termination.

3. Count the number of elbows for each pipe.

4. For each pipe, multiply the number of elbows by the equi-

valent length for the type of elbow used. Record the equi-
valent length of all the elbows for each pipe.

5. If a Tee is used on the termination, record the equivalent
length of the Tee used.

6. Record the equivalent length of the termination to be used.

7. Subtract the equivalent lengths of the fittings and termina-
tions from the Maximum Equivalent Vent Length.

8. If the Maximum Vent Length calculated is longer than the
individual measured length of the vent pipe and combustion

air pipe, then the diameter of pipe selected may be used.

9. If the Maximum Vent Length calculated is shorter than the
individual measured length of either the vent pipe or the

combustion air pipe, recalculate the Maximum Vent Length
using the next larger diameter pipe.

NOTE: The vent pipe and combustion air pipe must be the same
diameter.

NOTE: If the Maximum Vent Length for diameter of the pipe
selected is longer than the measured length and the equivalent
length of all the fitting and terminations, recalculate using the next
smaller diameter. If the recalculated Maximum Vent Length is
longer than the measured length of the vent pipe and combustion

air pipe, then that diameter of pipe selected may be used.

When installing vent systems of short pipe lengths, use the smallest

allowable pipe diameter. Do not use pipe size greater than required

or incomplete combustion, flame disturbance, or flame sense
lockout may occur.

Combustion Air and Vent Piping Insulation

Guidelines

NOTE: Use closed cell, neoprene insulation or equivalent.
The vent pipe may pass through unconditioned areas. The amount

of exposed pipe allowed is shown in Table 12.

1. Using winter design temperature (used in load calculations),
find appropriate temperature for your application and fur-

nace model.

2. Determine the amount of total and exposed vent pipe.

3. Determine required insulation thickness for exposed pipe
length(s).

4. When combustion air inlet piping is installed above a sus-
pended ceiling, the pipe MUST be insulated with moisture

resistant insulation such as Armaflex or other equivalent
type of insulation.

5. Insulate combustion air inlet piping when run in warm, hu-
mid spaces.

6. Install the insulation per the insulation manufacturer's in-
stallation instructions.

NOTE: Pipe length (ft. / M) specified for maximum pipe lengths
located in unconditioned spaces cannot exceed total allowable pipe

length as calculated from Table 13 or 15.

ii

39

Configure the Furnace

CARBON MONOXIDE POISONING HAZARD
Failure to follow this warning could result in personal

iniury or death.
To route the vent pipe and combustion air pipe through the

furnace, the manufacturer supplied kit must be used. Failure
to properly seal the blower compartment from the furnace
vestibule could result in the circulation of carbon monoxide

throughout the structure. The vent pipe and combustion air
pipe must be a continuous pipe while passing through the

blower compartment. Seals supplied in this kit must be
installed per the instructions provided. Follow all
procedures outlined in these instructions.

Install the Vent and Combustion Air Pipe
With the furnace installed in the required position, remove the

desired knockouts from the casing. It will be necessary to remove
one knockout for the vent pipe and the other knockout for the

combustion air connection. (See Fig. 12.)
Use a fiat blade screwdriver and tap on the knockout on opposite

sides, where the knockout meets the casing. Fold the knockout
down with duct pliers and work the knockout back and forth until

it is removed. Trim any excess metal from the knockout with tin
snips.

The vent elbow can be rotated to the required location on the
casing if necessary. See Fig 38. To rotate the vent elbow:

1. Loosen the clamp on the inlet of the vent elbow attached to
the inducer.

2. Rotate the vent elbow to the required position. There are
rounded notches on the vent elbow to align it with the

inducer housing for each orientation.

3. Tighten the clamp around the vent elbow. Torque the clamp
to 15 lb-in. See Fig. 39-42.

Installing the Vent Pipe Adapter and Combustion Air

Pipe Adapter

CARBON MONOXIDE POISONING HAZARD

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

To route the vent pipe and combustion air pipe through the
furnace, the manufacturer supplied kit must be used. Failure
to properly seal the blower compartment from the furnace

vestibule could result in the circulation of carbon monoxide
throughout the structure. The vent pipe and combustion air

pipe must be a continuous pipe while passing through the
blower compartment. Seals supplied in this kit must be
installed per the instructions provided. Follow all
procedures outlined in these instructions.

NOTE: The rubber coupling that attaches to the vent pipe adapter
must be used. The adapter seals the vent pipe to the casing and

reduces the strain on the vent elbow attached to the inducer.

1. Apply the gaskets to the vent pipe and combustion air pipe
adapters. See Fig. 3%

NOTE: The vent pipe adapter has a larger ID than the combustion
air pipe adapter.

2. Align the screw holes in the plastic vent pipe adapter with
the dimples in the casing.

3. Pilot drill the screw holes for the adapter in the casing and
attach the vent pipe adapter to the furnace with sheet metal

screws

4. Slide the end of the rubber vent coupling with notches in it
over the standoffs on the vent pipe adapter.

5. Insert a length of vent pipe through the coupling into the
outlet of the vent elbow.

6. Tighten the clamp around the outlet of the vent elbow.

Torque the clamp to 15 lb-in.

Install the remaining vent and combustion air pipes as shown
below. It is recommended that all pipes be cut, prepared, and

preassembled before pem_anently cementing any joint.

1. Working from furnace to outside, cut pipe to required
length(s).

2. Deburr inside and outside of pipe.

3. Chamfer outside edge of pipe for better distribution of
primer and cement.

4. Clean and dry all surfaces to be joined.

5. Check dry fit of pipe and mark insertion depth on pipe.

6. Insert the vent pipe into the vent elbow.

7. Torque clamp on vent elbow 15 lb-in.

8. Torque clamp on vent coupling 15 lb-in.

9. Insert the combustion air pipe into the adapter.

10. Pilot drill a screw hole through the adapter into the combus-
tion air pipe and secure the pipe to the adapter with sheet

metal screws.

11. Seal around the combustion air pipe with silicone or foil
tape.

12. After pipes have been cut and preassembled, apply generous
layer of cement primer to pipe fitting socket and end of pipe

to insertion mark. Quickly apply approved cement to end of
pipe and fitting socket (over primer). Apply cement in a

light, uniform coat on inside of socket to prevent buildup of
excess cement. Apply second coat.

13. While cement is still wet, twist pipe into socket with 1/4-in.
turn. Be sure pipe is fully inserted into fitting socket.

14. Wipe excess cement from joint. A continuous bead of ce-
ment will be visible around perimeter of a properly made

joint.

15. Handle pipe joints carefully until cement sets.

16. Horizontal portions of the venting system shall be suppor-
ted to prevent sagging. Support combustion air piping and

vent piping a minimum of every 5 ft. (1.5M) [3 ft. (.91M)

for SDR-21 or -26 PVC] using perforated metal hanging
strap or commercially available hangars designed to support
plastic pipe.

17. Prevent condensate from accumulating in the pipes by slop-
ing the combustion air piping and vent piping downward

towards furnace a minimum of 1/4-in. per linear ft. with no
sags between hangers.

18. Complete the vent and combustion air pipe installation by
connecting the concentric vent or by installing the required

termination elbows as shown in Figs. 47, 48 and 49.
For Ventilated Combustion Air Termination, See Fig. 50

19. Use appropriate methods to seal openings where combus-
tion air pipe and vent pipe pass through roof or sidewall.

Optional Installation of the vent pipe

This option provides a disconnect point for the vent pipe. The vent
pipe must be cemented to the plastic vent pipe adapter to maintain

a sealed vestibule. See Fig. 43.

1. Insert a length of vent pipe through the casing into the
outlet of the vent elbow.

4O

2. Slide the plastic vent pipe adapter over the length of the
vent pipe down to the furnace casing. Mark the pipe where

it is flush with the outlet of the adapter.

3. Remove the pipe from the furnace and the adapter and cut
off any excess pipe.

4. Clean and prime the end of the pipe that is flush with the
vent adapter with a primer that is appropriate for the type of

pipe being used.

5. Re-insert the pipe through the casing into the vent elbow.

6. Tighten the clamp around the outlet of the vent elbow.
Torque the clamp to 15 lb-in.

7. Apply cement to the end of the pipe and to the inside of the
plastic vent adapter.

8. Slide the adapter over the vent pipe and align the screw
holes in the adapter with the dimples in the furnace casing.

9. Pilot drill 1/8-in. screw holes for the adapter in the casing
and secure the adapter to the furnace with sheet metal

screws.

10. Loosen the clamps on the rubber vent coupling.

11. Slide the end of the coupling with notches in it over the
standoffs in the vent pipe adapter.

12. Tighten the clamp of the coupling over the vent pipe
adapter. Torque the lower clamp around the vent pipe

adapter to 15 lb-in.

13. Pilot drill a 1/8-in. hole in the combustion air pipe adapter.

14. Complete the vent and combustion air pipe as shown in
"Install the Vent and Combustion Air Pipe"

Installing the Vent Termination

Roof Terminations

A roof termination of any type will require a 4-in. (102 ram)
flashing for a 2 in. (51 ram) concentric vent or a 5-in. diameter

(127 ram) flashing for a 3-in. (76 ram) concentric vent kit. For
two-pipe or single pipe vent systems, a flashing for each pipe of the

required diameter will be necessary.
It is recommended that the flashing be installed by a roofer or

competent professional prior to installing the concentric vent. The
terminations can be installed on a flat or pitched roof.

Concentric Vent
Single or multiple concentric vent nmst be installed as shown in

Fig. 47. Maintain the required separation distance between vents
or pairs of vents as shown in Fig. 47 and all clearance shown in

Fig. 45.
Cut one 4-in. (102 ram) diameter hole for 2-in. (51 ram) kit, or

one 5-in. (127 ram) diameter hole for 3-in. (76 ram) kit in the
desired location.

Loosely assemble concentric vent/combustion air termination
components together using instructions in kit.

Slide assembled kit with rain shield REMOVED through hole in
wall or roof flashing.
NOTE: Do not allow insulation or other materials to accumulate

inside of pipe assembly when installing it through hole.
Disassemble loose pipe fittings. Clean and cement using same

procedures as used for system piping.
Two-Pipe and Single-Pipe Terminations

Single and two pipe vent must be installed as shown in Fig. 47 and

48. Maintain the required separation distance between vents or
pairs of vents as shown in Fig. 47 and 48. and all clearance shown

in Fig. 45 and 46 .
Cut the required number of holes in the roof or sidewall for vent

and (when used) combustion air pipes. Sidewall holes for two-pipe
vent terminations should be side-by-side, allowing space between

the pipes for the elbows to fit on the pipes.

Holes in the roof for two pipe terminations should be spaced no
more than 18 in. (457 ram) apart.

Termination elbows will be installed after the vent and (if used)
combustion air pipe is installed.

Sidewall Terminations

Concentric Vent

Determine an appropriate location for termination kit using the
guidelines provided in section "Locating The Vent Termination" in

this instruction.

1. Cut one 4-in. diameter hole for 2-in. kit, or one 5-in. dia-
meter hole for 3-in. kit.

2. Loosely assemble concentric vent/combustion air termina-
tion components together using instructions in kit.

3. Slide assembled kit with rain shield REMOVED through
hole.

NOTE: Do not allow insulation or other materials to accumulate
inside of pipe assembly when installing it through hole.

4. Locate assembly through sidewall with rain shield posi-
tioned no more than 1-in. (25 ram) from wall as shown in

Fig. 47.

5. Disassemble loose pipe fittings. Clean and cement using
same procedures as used for system piping.

2-Pipe and 1-Pipe Vent Termination

Determine an appropriate location for termination kit using the
guidelines provided in section "Locating The Vent Termination" in

this instruction.

1. Cut 2 holes, 1 for each pipe, of appropriate size for pipe size
being used.

2. Loosely install elbow in bracket and place assembly on
combustion-air pipe.

3. Install bracket as shown in Fig. 47 and 49.

NOTE: For applications using vent pipe option indicated by
dashed lines in Fig. 47 and 48, rotate vent elbow 90 ° from
position.

4. Disassemble loose pipe fittings. Clean and cement using
same procedures as used for system piping.

(Direct Vent / 2-Pipe System ONLY)

When 2 or more furnaces are vented near each other, 2 vent

terminations may be installed as shown in Fig. 47, but next vent
termination must be at least 36 in. (914 ram) away from first 2

terminations. It is important that vent terminations be made as

shown in Fig. 47 to avoid recirculation of flue gases.

Inducer Outlet Restrictor

To improve efficiency and operation of 40,000 BTUH input
models on very short vent systems, an inducer outlet restrictor is
required to be installed on the outlet of the inducer assembly. The

outlet restrictor is shipped in the loose parts bag.
To determine if the outlet restrictor is required, see Table 13 and

Table 15. Failure to use an outlet choke when required may

result in flame disturbance or flame sense lockout.

To install the outlet restrictor:

1. Remove the vent elbow from the inducer outlet.

2. Align the lock tabs on the outlet restrictor with the slots on
inside outlet of the inducer assembly.

3. Snap the outlet restrictor in place.

4. Re-install the vent elbow.

5. Torque vent elbow clamp 15-1b. in.

ii

41

Table11 - Approved Combustion-Air and Vent Pipe, Fitting and Cement Materials (U.S.A. Installations)

ASTM SPECIFICATION SOLVENT CEMENT

(MARKED ON MATERIAL) MATERIAL PIPE FITTINGS AND PRIMERS DESCRIPTION

D1527
D1785

D2235
D2241
D2466
D2468

D2564
D2661
D2665

F438
F441

F442
F493

F628

F656
F891

ABS Pipe --
PVC Pipe --

For ABS -- --

PVC Pipe --
PVC -- Fittings

ABS -- Fittings

For PVC -- --

ABS Pipe Fittings
PVC Pipe Fittings

CPVC -- Fittings
CPVC Pipe --
CPVC Pipe --

For CPVC -- --

ABS Pipe --

For PVC -- --

PVC Pipe --

Solvent Cement

Solvent Cement

DWV at Schedule-40 IPS sizes

Solvent Cement

Cellular Core DWV at Schedule-40

Primer

Cellular Core Schedule-40 & DWV

Schedule-40
Schedule-40

For ABS

SDR-21 & SDR-26

Schedule-40
Schedule-40

For PVC

DWV
Schedule-40
Schedule-40

SDR

For CPVC

IPS sizes

For PVC

42

Single

Stage

Furnace

Input

40000*

80000

80000

Table 12 - Maximum Allowable Exposed Vent Lengths Insulation Table - Ft. / M

Maximum Length of Uninsulated and Insulated Vent Pipe-Ft (M)

Winter
Design

Temp °F

(°C)

20 (-1 O)

0 (-20)

-20 (-30)

-4o (-4o)

20 (-10) M 9.1 18.6 18.6 16.5 N/A 9.1 41.1 49.7 43.3 N/A 9.1 41.1 58.2 50.6 N/A

0 (-20) M 9.1 9.4 9.1 7.0 N/A 9.1 34.4 30.5 25.9 N/A 9.1 41.1 36.6 30.8 N/A

-20 (-30) M 7.3 5.2 4.6 2.1 N/A 9.1 24.7 21.3 17.4 N/A 9.1 29.9 25.9 21.3 N/A

-40 (-40) M 4.6 2.4 1.5 0.0 N/A 9.1 18.6 15.8 12.2 N/A 9.1 22.9 19.5 15.5 N/A

20 (-10) M 6.1 21.3 23.8 21.3 18.3 6.1 21.3 53.3 55.8 46.9 6.1 21.3 53.3 65.5 55.2

0 (-20) M 6.1 12.8 12.5 10.1 6.4 6.1 21.3 40.2 33.8 27.1 6.1 21.3 47.9 40.5 32.6

-20 (-30) M 6.1 7.6 7.0 4.3 0.3 6.1 21.3 28.7 23.5 17.4 6.1 21.3 34.4 28.7 21.6

-40 (-40) M 6.1 4.3 3.7 0.9 0.0 6.1 21.3 21.6 17.1 11.6 6.1 21.3 26.2 21.3 15.2

Pipe

Length in

Ft. &M

Ft.

M

Ft.

M

Ft.

M

Ft.

M

Ft. 30 61 61 54 N/A 30 135 163 142 N/A 30 135 191 166 N/A

Ft. 30 31 30 23 N/A 30 113 100 85 N/A 30 135 120 101 N/A

Ft. 24 17 15 7 N/A 30 81 70 57 N/A 30 98 85 70 N/A

Ft. 15 8 5 0 N/A 30 61 52 40 N/A 30 75 64 51 N/A

Ft. 20 70 78 70 60 20 70 175 183 154 20 70 175 215 181

Ft. 20 42 41 33 21 20 70 132 111 89 20 70 157 133 107

Ft. 20 25 23 14 1 20 70 94 77 57 20 70 113 94 71

Ft. 20 14 12 3 0 20 70 71 56 38 20 70 86 70 50

No Insulation 3/8-in. (9.5 mm) Insulation

Pipe Diameter-in. (mm)

1 1/2 2 2 1/2 3 4

(38) (51) (64) (76) (102)

48 42 42 N/A N/A

14.6 12.8 12.8 N/A N/A
25 19 17 N/A N/A

7.6 5.8 5.2 N/A N/A
14 7 5 N/A N/A

4.3 2.1 1.5 N/A N/A

7 0 0 N/A N/A

2.1 0.0 0.0 N/A N/A

Pipe Diameter-in. (mm)

1 1/2 2 2 1/2 3 4

(38) (51) (64) (76) (102)

50 122 111 N/A N/A

15.2 37.2 33.8 N/A N/A
50 75 66 N/A N/A

15.2 22.9 20.1 N/A N/A
50 52 45 N/A N/A

15.2 15.8 13.7 N/A N/A
50 38 31 N/A N/A

15.2 11.6 9.4 N/A N/A

1/2-in, (12.7 mm) Insulation

Pipe Diameter-in. (mm)

1 1/2 2 2 1/2 3 4

(38) (51) (64) (76) (102)

50 144 130 N/A N/A

15.2 43.9 39.6 N/A N/A
50 90 79 N/A N/A

15.2 27.4 24.1 N/A N/A
50 64 55 N/A N/A

15.2 19.5 16.8 N/A N/A
50 48 40 N/A N/A

15.2 14.6 12.2 N/A N/A

20 (-10) M N/A 7.6 30.2 27.1 23.8 N/A 7.6 33.5 71.0 80.8 N/A 7.6 33.5 71.6 69.8

100000

120000

0 (-20) M N/A 7.6 16.8 14.0 10.1 N/A 7.6 33.5 44.2 35.7 N/A 7.6 33.5 52.7 42.7

-20 (-30) M N/A 7.6 10.4 7.3 3.4 N/A 7.6 33.5 31.4 24.1 N/A 7.6 33.5 37.8 29.6

-40 (-40) M N/A 7.0 6.1 3.4 0.0 N/A 7.6 29.0 23.5 16.8 N/A 7.6 33.5 28.7 21.3

20 (-10) M N/A N/A 4.6 30.2 26.2 N/A N/A 4.6 30.5 66.8 N/A N/A 4.6 30.5 76.2

0 (-20) M N/A N/A 4.6 15.5 11.6 N/A N/A 4.6 30.5 39.6 N/A N/A 4.6 30.5 47.5

-20 (-30) M N/A N/A 4.6 8.5 4.3 N/A N/A 4.6 30.5 26.8 N/A N/A 4.6 30.5 32.9

-4o(-4o)

*Not all families have these models.

Ft. N/A 25 99 89 78 N/A 25 110 233 265 N/A 25 110 235 229

Ft. N/A 25 55 46 33 N/A 25 110 145 117 N/A 25 110 173 140

Ft. N/A 25 34 24 11 N/A 25 110 103 79 N/A 25 110 124 97

Ft. N/A 23 20 11 0 N/A 25 95 77 55 N/A 25 110 94 70

Ft. N/A N/A 15 99 86 N/A N/A 15 100 219 N/A N/A 15 100 250

Ft. N/A N/A 15 51 38 N/A N/A 15 100 130 N/A N/A 15 100 156

Ft. N/A N/A 15 28 14 N/A N/A 15 100 88 N/A N/A 15 100 108

Ft. N/A N/A 15 14 0 N/A N/A 15 85 62 N/A N/A 15 100 79

M N/A N/A 4.6 4.3 0.0 N/A N/A 4.6 25.9 18.9 N/A N/A 4.6 30.5 24.1

43

Table 13 - Maximum Equivalent Vent Length - Ft. (M)

0 to 4500 Ft. (0 to 1370 M) Altitude

NOTE: Maximum Equivalent Vent Length (MEVL) does" NOT include elbows or terminations. Use Table 14 - Deductions from

Maximum Equivalent Vent Length to determine allowable vent length for each application.

DIRECT VENT (2-PIPE) AND NON-DIRECT VENT (1-PIPE)

Altitude

FT (M)

0 to 2000
(0 to 610)

2001 to 3000

(610 to 914)

3001 to 4000

(914 to 1219)

4001 to 4500 60,000

(1219 to 80,000

1370) 100,000

NOTE: See notes at end of venting tables.

See Table 15 for altitudes over 4500 ft. (1370 M)

*Not all families have these models.

Unit Size Vent Pipe

BTU/Hr

40,000 *2

60,000
80,000

100,000
120,000

40,000"

60,000
80,000

100,000
120,000
40,000"

60,000
80,000

100,000
120,000

40,000"

120,000

1-1/2

50 (15.2)

30 (9.1)

20 (6.1)

45 (13.7)
27 (8.2)

17 (5.2)

39 (11.9)
23 (7.0)

15 (4.6)

36 (11.0)
21 (6.4)

14 (4.3)

2 2-1/2

210 (64.0) 250 (76.2)
135 (41.1) 235 (71.6) 265

70 (21.3) 175 (53.3) 235
25 (7.6) 110 (33.5) 235

15 (4.6) 1O0
198 (60.4) 232 (70.7)
127 (38.7) 222 (67.7) 250

64 (19.5) 165 (50.3) 222
22 (6.7) 104 (31.7) 223

11 (3.4) 93
184 (56.1) 214 (65.2)
119 (36.3) 210 (64.0) 235

59 (18.0) 155 (47.2) 210
19 (5.8) 98 (29.9) 211

8 (2.4) 86

177 (53.9) 205 (62.5)
115 (35.1) 204 (62.2) 226

56 (17.1) 150 (45.7) 202
17 (5.2) 94 (28.7) 205

Diameter (in.)

(60.8)

(71.6) 265 (80.8)
(71.6) 265 (80.8)

(30.5) 250 (76.2)

(76.2)
(67.7) 249 (75.9)

(68.0) 250 (76.2)
(28.3) 237 (72.2)

(71.6)
(64.0) 232 (70.7)

(64.3) 236 (71.9)
(26.2) 224 (68.3)

(69.5)

(61.6) 224 (68.3)
(62.5) 229 (69.8)

83

(25.3) 217 (66.1)

Table 14 - Deductions from Maximum Equivalent Vent Length - Ft. (M)

Pipe Diameter (in): 1-1/2 2 2-1/2 3* 4*

Mitered 90 ° Elbow 8 (2.4) 8 (2.4) 8 (2.4)

Medium Radius 90 ° Elbow 5 (1.5) 5 (1.5) 5 (1.5)

Long Radius 90 ° Elbow 3 (0.9) 3 (0.9) 3 (0.9) 3 (0.9) 3 (0.9)

Mitered 45 ° Elbow 4 (1.2) 4 (1.2) 4 (1.2)

Medium Radius 45 ° Elbow 2.5 (0.8) 2.5 (0.8) 2.5 (0.8)

Long Radius 45 ° Elbow 1.5 (0.5) 1.5 (0.5) 1.5 (0.5) 1.5 (0.5) 1.5 (0.5)

Tee 16 (4.9) 16 (4.9) 16 (4.9) 16 (4.9) 16 (4.9)

Note: 3- and 4-in. Vent

Venting System Length Calculations

The maximum length for each vent pipe (inlet or exhaust) equals the Maximum Equivalent Vent Length (MEVL) from Table 13 or Table 15
minus the number of elbows nmltiplied by the deduction for each elbow in Table 14.

Standard vent terminations and concentric vent terminations count for zero deductions.

Example

A direct-vent 60,000 Btuh furnace installed at 2100 ft. (640 M ) with 2-in. (51 ram) vent piping. Venting system includes, FOR EACH
PIPE, (3) 90° long radius elbows, (2) 45 ° long radius elbows and a concentric vent kit.

Maximum Equivalent Vent Length

Deduct (3) 90 long radius
Deduct (2) 45 long radius

Maximum Vent Length

3 x 3ft. = 9ft.
2 x 1.5 ft. = 3ft.

= 127 ft.

= 115 ft.

(From Table 13)
(From Table 14)
(From Table 14)

For EACH vent or inlet pipe

44

Table 15 - Maximum Equivalent Vent Length - Ft. (M)

4501 to 10,000 Ft. (0 to 1370 M) Altitude

NOTE: Maximum Equivalent Vent Length (MEVL) does NOT include elbows or terminations. Use Table 14 - Deductions from

Maximum Equivalent Vent Length to determine allowable vent length for each application.

DIRECT VENT (2-PIPE) AND NON-DIRECT VENT (1-PIPE)

Altitude

FT (M)

4501 to 5000 60,000 (33.8) 221 (67.4)

(1370 to 80,000 (16.5) 195 (59.4) 216 (65.8)

1524) 100,000 (4.9) 200 (61.0) 222 (67.7)

5001 to 8000 60,000 (31.4) 186 (56.7) 207 (63.1)

(1524 to 80,000 (14.9) 137 (41.8) 183 (55.8) 200 (61.0)

1829) 100,000 (3.7) 85 (25.9) 188 (57.3) 208 (63.4)

8001 to 7000 60,000 (29.3) 174 (53.0) 194 (59.1)

(1829 to 80,000 (13.4) 120 (36.6) 171 (52.1) 185 (56.4)

2134) 100,000 (6.0) 79 (24.1) 178 (54.6) 195 (59.4)

7001 to 8000 60,000 (27.1) 163 (49.7) 181 (55.2)

(2134 to 80,000 (12.2) 120 (36.6) 159 (48.5) 170 (51.8)

2438) 100,000 73 (22.3) 167 (50.9) 182 (55.5)

8001 to 9000 60,000 (25.0) 152 (46.3) 168 (51.2)

(2438 to 80,000 (10.7) 111 (36.8) 148 (45.1) 156 (47.5)

2743) 100,000 67 (20.4) 157 (47.9) 170 (51.8)

9001 to 60,000 (26.2) 142 (43.3) 156 (47.5)

10,000 80,000 (9.4) 103 (31.4) 137 (41.8) 142 (43.3)

(2743 to

3048) 100,000 62 (18.9) 147 (44.8) 157 (47.9)

Unit Size

1-1/2 J 2

40,000* (52.1)

33 I (10'1) I 171

I 20 I (61)I 111

54
16

120,000 80 (24.4) 211 (64.6)
40,000* (48.2) 179 (54.6)

120,000 74 (22.6) 199 (60.7)
40,000* (44.2) 162 (49.4)

120,000 68 (20.7) 187 (57.0)
40,000* (40.5) 146 (44.5)

I 27 I (62>I 156

I 16 I (4.9) J 103

49
12

I 21 I (6.4) I 145
I 13 I (4.0) I 96

44
10

I 15 I (4.6) I 133

Vent Pipe Diameter

2-1/2

196 (59.7)
198 (60.4)
146 (44.5)

91 (27.7)

I 10 I (6.0) I 89

40

120,000 62 (18.9) 175 (56.3)
40,000* (36.9) 130 (39.6)

120,000 56 (17.1) 164 (50.0)
40,000" (33.5) 115 (35.1)

120,000 51 (15.5) 156 (46.6)

I 10 I /60) I 121

I 7 I (2'1) I 82

35

I 5 I /15)I 110

76
31

Notes:

1. 3- and 4-in. Vent pipe systems require long radius elbows.

2. Total equivalent vent lengths under 10' for 40,000 BTUH require the use of an outlet choke plate at altitudes 0 to 2000 ft (0 to 610 M).
Failure to use an outlet choke when required may result in flame disturbance or flame sense lockout.

3. Vent sizing for Canadian installations over 4500 ft (1370m) above sea level are subject to acceptance by the local authorities having jurisdiction.

4. NA - Not allowed; pressure switch will not close, or flame disturbance may result.

5. Do not use pipe size greater than those specified in table or incomplete combustion, flame disturbance, or flame sense lockout may occur.

6. Size both the combustion-air and vent pipe independently, then use the larger diameter for both pipes.

7. Assume the two 45 ° elbows equal one 90 ° elbow. Wide radius elbows are desirable and may be required in some cases.

8. Elbows and pipe sections within the furnace casing and at the vent termination should not be included in vent length or elbow count.

9. The minimum pipe length is 5 ft. (1.5 M) for all applications.

10. Use 3-in. (76 mm) diameter vent termination kit for installations requiring 4-in. (102 mm) diameter pipe.

45

ii

Attach gaskets to vent pipe and
combustion air adapters.

Fig. 37 - Vent Coupling and Adapter with Gaskets

Vent Coupling and Adapter

Al1314

INDUCER OUTLET

VENT ELBOW CLAMP
TORQUE 15 LB-IN.

VENT PIPE CLAMP
TORQUE 15 LB-IN.

ELBOW

Fig. 38 - Inducer Vent Elbow

46

INDUCER OUTLET CHOKE
40,000 BTUH MODELS ONLY

Al1285

Any other unused

knockout be used

may

for combustion air

connection.

Rotate vent elbow to

required position.

x_ r

UPFLOW LEFT CONFIGURATION

Any otherunused

knockout may be used

_rcombustion air

connedion.

C) Attach vent pipe adapter with gasket to furnace casing.

Align notches in rubber coupling over standoffs on adapter. Slide clamps over the coupling.

(_ Slide vent pipe through adapter and coupling into vent elbow.
1_ Insert vent pipe into vent elbow.

(_ Torque all clamps 15 lb.-in.
@ Attach combustion air pipe adapter with gasket to furnace.

(_ Attach combustion air pipe to adapter with silicone. Pilot drill a 1/8-in.

hole in adapter and secure with a #7 x 1/2-in sheet metal screw.

A11309 A11308

A11310

UPFLOW VERTICAL VENT

A11399

Fig. 39 - Uptlow Configurations (Appearance may vary)

47

Rotateventelbowto

requiredposition.

\s

Al1311

OWNFLOW LEFT CONFIGURATION

Rotate vent elbow to

required position.

Any other unused <_

knockout may be used

for combustion air

connection.

Al1312

DOWNFLOW RIGHT CONFIGURATION

Al1313

Downflow Vertical

Requires Accessory Internal Vent Kit.

See Product Data for current kit number.

(_) Attach vent pipe adapter with gasket to furnace casing.
(_) Align notches in rubber coupling over standoffs on adapter. Slide clamps over the coupling.

G) Slide vent pipe through adapter and coupling into vent elbow.
(_) Insert vent pipe into vent elbow.

(_ Torque all clamps 15 lb.-in.
@ Attach combustion air pipe adapter with gasket to furnace.

(_ Attach combustion air pipe to adapter with silicone. Pilot drill a 1/8-in.

hole in adapter and secure with a #7 x 1/2-in sheet metal screw.

Fig. 40 - Downflow Configurations (Appearance may vary)

48

Al1400

HORIZONTAL LEFT -

VERTICAL VENT CONFIGURATION

Al1327

HORIZONTAL LEFT -
LEFT VENT CONFIGURATION

I

A11328

ii

HORIZONTALLEFT-
RIGHT VENT CONFIGURATION*

*RequiresAccessoryInternalVentKit
SeeProductDataforCurrentKitNumber

(_ Attach vent pipe adapter with gasket to furnace casing.
(_ Align notches in rubber coupling over standoffs on adapter. Slide clamps over the coupling.

G) Slide vent pipe through adapter and coupling into vent elbow.
(_ Insert vent pipe into vent elbow.

(_ Torque all clamps 15 lb.-in.
@ Attach combustion air pipe adapter with gasket to furnace.

(Z) Attach combustion air pipe to adapter with silicone. Pilot drill a 1/8-in.

hole in adapter and secure with a #7 x 1/2-in sheet metal screw.

Fig. 41 - Horizontal Left (Appearance may vary)

Al1329

A11340

49

g

_--_ ALTERNATE

CONNECTIONS

HORIZONTAL RIGHT -

VERTICAL VENT CONFiGURATiON

Al1337

ALTERNATE
COMBUSTION
AiR

\

HORIZONTAL RIGHT -
LEFT VENT CONFIGURATION*

*Requires internal Vent Kit
See Product Data for Current Kit Number

Al1336

HORIZONTAL RIGHT -

Al1335

RIGHT VENT CONFIGURATION

(_ Attach vent pipe adapter with gasket to furnace casing.
(_) Align notches in rubber coupling over standoffs on adapter. Slide clamps over the coupling.

(_ Slide vent pipe through adapter and coupling into vent elbow.
(_ Insert vent pipe into vent elbow.

(_ Torque all clamps 15 lb.-in.
@ Attach combustion air pipe adapter with gasket to furnace.

(Z) Attach combustion air pipe to adapter with silicone. Pilot drill a 1/8-in.

hole in adapter and secure with a #7 x 1/2-in sheet metal screw.

Fig. 42 - Horizontal Right (Appearance may vary)

50

A11341

ALIGN NOTCHES IN VENT PiPE
COUPLING OVER STAND-OFF

ON ADAPTER. TORQUE LOWER

VENT PiPE ADAPTER WiTH GASKET

INSTALLED ON FURNACE VENT
PiPE IS CUT FLUSH WiTH TOP OF

CLAMP 15 LB-IN. WHEN REMAINING
VENT PiPE iS INSTALLED, TORQUE

UPPER CLAMP TO 15 LBqN.

/

VENT PIPE FLUSH WITH ADAPTER VENT PIPE FLUSH SHOWING COUPLING

Fig. 43 - Vent Pipe Flush with Adaptor

Point elbow down towards

Al1339

uace

2 Omm

CASING SIDE ATTACHMENT
COMBUSTION AIR PIPE

(NON-DIRECT VENT)

Fig. 44 - Combustion Air Pipe Attachment

TOP PLATE ATTACHMENT
COMBUSTION AIR PIPE

(NON-DIRECT VENT)

Al1345

51

ii

0 _

M

Item

Clearance Description Canadian Installation (I) U.S. Installation (2)

A

Clearance above grade veranda porch deck, bal 12 in. (305 mm). 18 in. (457 mm) above roof surface. 12 in. (305 mm)
cony or anticipated snow level

B

Clearance to a window or door that may be opened and </- 100,000 Btuh (30 kW), 36 in. (914 mm) for and </- 50,000 Btuh (I5 kW), I2 in. (305 mm) for

C

Clearance to a permanently closed window
Vertical clearance to a ventilated soffit located above

D

the terminal within a horizontal distance of 2feet (61
cm) from the centerline of the terminal

E

Clearance to an unventilated soffit

F

Clearance to an outside corner

G

Clearance to an inside corner
Clearance to each side of the centerline extended

H

above electrical meter or gas service regulator as
sembly

I Clearance to service regulator vent outlet

Clearance to non- mechanical air supply inlet to

J

building or the combustion air inlet to any other appli
ance

K

Clearance to a mechanical air supply inlet

L Clearance under a veranda porch deck, or balcony deck, or balcony is fully open on a minimum of two

Clearance to each side of the centerline extended

M above or below vent terminal of the furnace to a dryer

or water heater vent or other appliance's direct vent 12 in. (305 mm) 12 in. (305 mm)
intake or exhaust

Clearance to the vent terminal of a dryer vent water

N heater vent or other appliances direct vent intake or 3 ft. (.9 M) 3 ft. (.9 M)

exhaust

© Clearance from a plumbing vent stack 3 ft. (.9 M) 3 ft. (.9 M)

p Clearance above paved sidewalk or paved driveway walk or paved driveway that is located between two with local installation codes and the requirements of

located on public property single family dwellings and serves both dwellings, the gas supplier and the manufacturer's installation

(1) In accordance with the current (: A N / CSA B 149.1, Natural Gas and Propane Installation (:ode.
(2) In accordance with the current ANSI Z223.1 .NFPA 54. National Fuel Gas (:ode

Notes:

1. The vent tier this appliance shall not terminate:
a. Over public walkways; or
b. Near sottit vents ot crawl space vents or other areas where condensale or Valtor could create a nuisance or hazard or property danlage; or
c. Where condensate vapor could cause damage or court be detrimental to the operation ill ¸regulators, reliel ¸vah'es, or other equipment.

2. When locating vent terminations, consideration must be given to prevailing winds, location, and other conditions which may cause recircukdkln ill¸ the combustkln products ill ¸ adjacenl venls.
Recirculation can cause poor combustion, inlet condensate problems, and accelerated corrosion (1t¸the heat exchangers.

3. Avoid venling under a deck or large overhang. Recircukdkln could occur and cause pertormance or system problems.

12 in. (305 mm) for appliances > 10,000 Btuh (3kW) 9 in. (229 mm) for appliances > I0,000 Btuh (3kW)

appliances > 100,000 Btuh (30 kW) appliances > 500,000 Btuh (15 kW)

For clearances not specified in ANSI Z223.I/NFPA 54 or
C A N / CSA BI49.1 clearances shall be in accordance
with local installation codes and the requirements of
the gas supplier and the manufacturer's installation

instructions.

3 ft. (.9 M) within 15 ft. (4.6 M) above the meter/ 3 ft. (.9 M) within I5 ft. (4.6 M) above the meter/
regulator assembly regulator assembly

3 ft. (.9 M)

12 in. (305 mm) for appliances > 10,000 Btuh(3kW)
and </- 100,000 Btuh (30 kW), 36 in. (914 mm) for
appliances > 100,000 Btuh (30 kW)

6 ft. (I .8 M)

12 in. (305 mm). Permitted only if veranda porch,

sides beneath the floor.

7 ft. (2.I M). A vent shall not terminate above a side- CAN/CSA Bt49.I, clearances shall be in accordance

For clearances not specified in ANSI Z223.I/NFPA 54 or
C A N / CSA BI49.1 clearances shall be in accordance
with local installation codes and the requirements of
the gas supplier and the manufacturer's installation

instructions.

*3 ft. (.9 M) *For clearances not specified in ANSI Z223.1
/NFPA 54or C A N / CSA BI49.I, clearances shall be in

accordance with local installation codes and the

requirements of the gas supplier and the manufacturer's

installation instructions.
9 in. (229 mm) for appliances > I0,000 Btuh (3kW)

and </- 50,000 Btuh (I5 kW), I2 in. (305 mm) for
appliances > 500,000 Btuh (15 kW)

3 ft. (.9 M)

For clearances not specified in ANSI Z223.I/NFPA 54 or
C A N / CSA BI49.1 clearances shall be in accordance

with local installation codes and the requirements of
the gas supplier and the manufacturer's installation

instructions.

For clearances not specified in ANSI Z223.t/NFPA 54 or

instructions.

Fig. 45 - Direct Vent Termination Clearance

A11046

52

................. /

/

/

/

/

/

/

/

..........._ \

\\\ j -......

....... >

D VENT TERMINAL

Item Clearance Description Canadian Installation (I) U.S. Installation (2)

A Clearance above grade veranda porch deck, bal 12 in. (305 mm). 18 in. (457 mm) above roof surface. 12 in. (305 mm)

cony or anticipated snow level

B

Clearance to a window or door that may be opened and </- 100.000 Btuh (30kW) 36 in. (914 mm) for (.3 M) above the opening.

C

Clearance to a permanently closed window
Vertical clearance to a ventilated soffit located above

D

the terminal within a horizontal distance of 2 feet (61
cm) from the centerline of the terminal

E

Clearance to an unventilated soffit

F

Clearance to an outNde corner

G

Clearance to an inside corner
Clearance to each side of the centerline extended

H

above electrical meter or gas service regulator as
sembly

I Clearance to service regulator vent outlet 3 ft. (.9 M) be in accordance with local installation codes and the

Clearance to non mechanical air supply inlet to 6 in. (152 mm) for appliances </ I0.000 Btuh (3kW)

J building or the combustion air inlet to any other appli 12 in. (305 mm) for appliances > 10.000 Btuh (3kW) 4 ft. (1.2 M) below or to the side of the opening. 1 ft.

ance appliances > 100,000 Btuh (30 kW)

K Clearance to a mechanical air supply inlet 6 ft. (I .8 M) 3 ft. (.9 M)

L Clearance under a veranda porch deck, or balcony deck. or balcony is fully open on a minimum of two with local installation codes and the requirements of

Clearance to each side of the centerline extended

M above or below vent terminal of the furnace to a dryer

or water heater vent or other appliance's direct vent 12 in. (305 mm) 12 in. (305 mm)
intake or exhaust

Clearance to the vent terminal of a dryer vent water

N heater vent or other appliances direct vent intake or 3 ft. (.9 M) 3 ft. (.9 M)

exhaust

Q Clearance from a plumbing vent stack 3 ft. (.9 M) 3 ft. (.9 M)

p Clearance above paved sidewalk or paved driveway walk or paved driveway that is located between two 7 ft. (2.1 M).

located on public property single family dwellings and serves both dwellings.

(1) In accordance wilh Ihe current ( A N / (SA B 149.], Natural Gas and Propane Inslallalion (ode.
(2) In accordance wilh Ihe currenl ANSI Z223.1 .NFPA 54. Nalional Fuel Gas (ode

Noles:

]. The venl fl)r this appliance shall nol lerminale:

a. Over publicwalkways; or

b. Near soflil vents ol crawl space vents or other areas where condensate or vapor cotlld creale a nuisance or hazard or property dan]age; or

c. Where condensate vapor could cause dan]age or could be detril_qental to the operation oI' regulators, relic[ valves, or olher equipment.

2. When localing vent terl_inalions, consideration must be given to prevailing winds, localion, and other condilions which may cause recirculalion oI' Ihe combuslion products oI' adjacenl vents.
Recirculation can cause poor COlllbuslion. inlet condensale problems, and accelerated corrosion of the heat exchangers.

3. Avoid venling under a deck or large overhang. Recircuhdion could occur and cause pert'ormance or syslem problems.

(_'_ AIR SUPPLY INLET

6 in. (152 mm) for appliances </ I0.000 Btuh (3kW)
12 in. (305 mm) for appliances > 10.000 Btuh (3kW) 4 ft. (1.2 M) below or to the side of the opening. 1 ft.

appliances > 100,000 Btuh (30 kW)

For clearances not specified in ANSI Z223.1/NFPA 54 or
CAN/CSA B149.I, clearances shall be in accordance
with local installation codes and the requirements of
the gas supplier and the manufacturer's installation

instructions.

3 ft. (.9 M) within I5 ft. (4.6 M) above the meter/ 3 ft. (.9 M) within 15 ft. (4.6 M) above the meter/regu
regulator assembly lator assembly.

and </- 100.000 Btuh (30kW) 36 in. (914 mm) for (.3 M) above the opening.

12 in. (305 mm). Permitted only if veranda, porch. C A N / CSA BI49.1. clearances shall be in accordance

sides beneath the floor, the gas supplier and the manufacturer's installation

7 ft. (2.I M). A vent shall not terminate above a side

E_ AREA WHERE TERMINAL IS NOT PERMITED

For clearances not specified in ANSI Z223.t/NFPA 54 or
CAN/CSA B149.I, clearances shall be in accordance
with local installation codes and the requirements of
the gas supplier and the manufacturer's installation

instructions.

* 3 ft. (.9 M) * For clearances not specified in ANSI
Z223.1/NFPA 54 or C A N / CSA Bt49.1. clearances shall

requirements of the gas supplier and the manufacturer's
installation instructions.

For clearances not specified in ANSI Z223.1/NFPA 54 or

instructions.

Fig. 46 - Ventilated Combustion Air and Non-Direct Vent Termination Clearance

ii

A11047

53

ii

Con_ntric Vent and Corn bustion Air

Roof Termination {ptefurted) ......

clearance above

\\\\\

Fig. 47 - Combustion Air and Vent Pipe Termination for Direct Vent (2-Pipe) System

A05090

Roof Termination (Preferred)

cr_ 305ram)mnmum earance

above highest a_licipated

snow bevel maximum of

24 in (610ram) above roof

Side walHermination
with 2 ehbows (preferred)

if:b°i

Abandoned masonry
used as raceway
(percode)

12 in (305 ram) rain from

overhang or roof

Maintain 12 in (305ram)
minimum clearance

above highest a_licipated
snow level or grade
whichever is greater

6 in (152ram) minimum clearance

between wal[ aid end of vent pipe

10 in (254mm) maximum pipe [enql]

12 in rain (305 mm)fron

overhang or roof

Sidewall Termination

with Straight Pipe (preferred)

Fig. 48 - Vent Pipe Termination for Non-Direct Vent and Ventilated Combustion Air System

ghest anticipated

snow level or grade

whichever is greater

_O5mm)

A05091

54

\

NOTE: This illustration is for
reference only, Your unit may

differ in appearance or may not
include all components shown.

OVERHANG OR ROOF

12-in

30A8 cm

Above anticipated
snow UeveU

/ COMBUSTION AIR

(ELBOW PARALLEL

TO WALL)

L10F024=1

UVL_IN£_

EXHAUST -I r

_ __ L ea ance to overhang per code

12 IN, SEPARATION
BETWEEN BOTTOM OF I"

COMBUSTION AIR AND

BOTTOM OF VENT

MAINTAIN 12 IN.
CLEARANCE

ABOVE HIGHEST
ANTICIPATED SNOW

LEVEL OR GRADE,

WHICHEVER IS

GREATER.

J

Fig. 49 - Alberta and Saskatchewan Vent Termination

55

Al1346

Ventilated Combustion

// Air intake pipe _U

ii

/

-"19-_ Pipe hangar _ _ _

_ R" [7_ mm _,

Ventilated Combustion Air 12" (305 mm)
intake termination in crawl

space

CRAWL SPACE

Ventilated Combustion
Air intake pipe

Vent through

roof flashing

ATTI C

Fig. 50 - Vent Terminations for Ventilated Combustion Air

56

ff

12" (305 ram) rain. above
highest level of insulation

A10497

START-UP, ADJUSTMENT, AND SAFETY

CHECK

General

1. Furnace must have a 115-v power supply properly connec-
ted and grounded.

NOTE: Proper polarity must be maintained for l15-v wiring.
Control status indicator light flashes rapidly and furnace does not
operate if polarity is incorrect.

2. Thermostat wire connections at terminals R, W, G, and
Y/Y2 must be made at 24-v terminal block on furnace con-

trol.

3. Natural gas service pressure must not exceed 0.5 psig (14-
in. w.c.), but must be no less than 0.16 psig (4.5-in. w.c.).

4. Blower door must be in place to complete l15-v electrical
circuit to furnace.

Purge Gas Lines
If not previously done, purge the lines after all connections have

been made and check for leaks,

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. A fire or explosion may
result causing property damage, personal iniury or loss of

life.

Adjustments

UNIT OPERATION HAZARD
Failure to follow this caution may result in intermittent unit

operation or performance satisfaction.
These furnaces are equipped with a manual reset limit

switch in burner assembly. This switch opens and shuts off
power to the gas valve is an overheat condition (flame

rollout) occurs in burner assembly. Correct inadequate
combustion-air supply or improper venting condition

before resetting switch. DO NOT jumper this switch.

Before operating furnace, check flame rollout manual reset switch
for continuity. If necessary, press button to reset switch.

EAC-I terminal is energized whenever blower operates. HUM
terminal is only energized when blower is energized in heating.

Prime Condensate Trap with Water

[]NIT OPERATION HAZARD

Failure to follow this caution may result in intermittent unit
operation or performance satisfaction.

Condensate trap must be PRIMED or proper draining may
not occur. The condensate trap has two internal chambers
which can ONLY be primed by pouring water into the
inducer drain side of condensate trap.

1. Remove upper and middle collector box drain plugs oppos-
ite of the condensate trap. (See Fig. 57.)

2. Connect field-supplied 1/2-in. (13 mm) OD tube to upper
collector box drain connection.

3. Insert field-supplied funnel into tube.

4. Pour one quart of water into funnel/tube. Water should run
through collector box, overfill condensate trap, and flow in-

to open field drain.

5. Remove funnel; replace collector box drain plug.

6. Connect field-supplied l/2-in. (13 mm) OD tube to middle
collector box drain port.

7. Pour one quart of water into funnel/tube. Water should run
through collector box, overfill condensate trap, and flow in-

to open field drain.

8. Remove funnel and tube from collector box and replace col-
lector box drain plug.

g

FIRE HAZARD
Failure to follow this warning could result in personal

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 overfire and heat exchanger failures.

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

life.

DO NOT redrill orifices. Improper drilling (burrs,
out-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. (See Fig.

52.)

For proper operation and long term reliability, the Furnace input
rate must be within +2 percent of input rate on furnace rating plate.

The gas input rate on rating plate is for installations at altitudes up
to 2000 ft. (609.6M).

In the USA., the input rating for altitudes above 2000 ft. (609.6M)
must be reduced by 2 percent for each 1000 ft. (304.8M) above sea

level. Refer to Table 18.
In Canada, the input rating must be derated by 5 percent for

altitudes of 2000 ft. (609.6M) to 4500 ft. (1371.6M) above sea

level.
To adjust manifold pressure to obtain the proper input rate, first,

determine if the furnace has the correct orifice installed. At higher

altitudes or different gas heat contents, it may be necessary to

change the factory orifice to a different orifice. Tables have been
provided in the furnace installation instructions to match the

required orifice to the manifold pressure to the heat content and
specific gravity of the gas. To do this:

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 20.

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

Table 20.

57

g

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

tersection to find orifice size and manifold pressure setting

for proper operation.

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

ASSUME ORIFICE SIZE. ALWAYS CHECK AND
VERIFY.

NOTE: For Canadian altitudes of 2000 to 4500 ft. (609.6 to

1371.6M), use USA altitudes of 2001 to 3000 ft. (609.6 to

914.4M).
NOTE: If orifice hole appears damaged or it is suspected to have

been redrilled, check orifice hole with a numbered drill bit of
correct size. Never redrill an orifice. A burr-free and squarely

aligned orifice hole is essential for proper flame characteristics.

g. Replace orifice with correct size, if required by Table 20.

Use only factory-supplied orifices. See EXAMPLE 1.

EXAMPLE 1:0 - 2000 ft. (0 - 609.6M) altitude
Heating value = 1050 Btu/cu ft.

Specific gravity = 0.62
Therefore: Orifice No. 44

Manifold pressure: 3.4-in. w.c.
* Furnace is shipped with No. 44 orifices. In this example, all main

burner orifices are the correct size and do not need to be changed to
obtain proper input rate.

1. Adjust manifold pressure to obtain input rate. (See Fig. 51.)

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

b. Remove manifold pressure tap plug from gas valve.

c. Connect a water column manometer or similar device to

manifold pressure tap.

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

e. Manually close blower door switch.

f. Jumper R and W thermostat connections on control to start

furnace. (See Fig. 35.)

g. Remove regulator adjustment cap from gas valve pressure

regulator (See Fig. 51.) and turn adjusting screw (3/16 or
smaller flat-tipped screwdriver) counterclockwise (out) to

decrease input rate or clockwise (in) to increase input rate.

NOTE: DO NOT set 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 to obtain manifold
pressure in this range.

h. When correct input is obtained, replace cap that conceals

gas valve regulator adjustment screws. Main burner flame
should be clear blue, almost transparent (See Fig. 59.)

i. Remove jumper R to W.

2. Verify natural gas input rate by clocking meter.

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

meter.

b. Jumper R to W.

c. Run furnace for 3 minutes.

d. Measure time (in sec) for gas meter to complete 1 revolu-

tion and note reading. The 2 or 5 cubic feet dial provides
a more accurate measurement of gas flow.

e. Refer to Table 19 for cubic ft. of gas per hr.

f. Multiply gas rate cu fl./hr by heating value (Btuh/cu ft.)

to obtain input. If clocked rate does not match required in-
put from Step 1, increase manifold pressure to increase in-

put or decrease manifold pressure to decrease input. Repeat
steps b through e until correct input is achieved. Re-install

regulator seal cap on gas valve.

Adjust Temperature Rise

NOTE: Blower door must be installed when taking temperature
rise reading. Leaving blower door off will result in incorrect
temperature measurements.

FURNACE OVERHEATING HAZARD
Failure to follow this caution may result in shortened

furnace life.
Set air temperature rise within limits specified on the rating

plate to prevent reduced life of furnace components.

FURNACE DAMAGE HAZARD
Failure to follow this caution may result in overheating the

heat exchangers or condensing flue gases in heat exchanger
areas not designed for condensate.

Temperature rise must be within limits specified on unit
rating plate.

[]NIT DAMAGE HAZARD

Failure to follow this caution may result in component
damage,

Temperature rise must be within limits specified on furnace
rating plate. Recommended operation is at midpoint of rise
range or slightly above,

This furnace must operate within the temperature rise ranges
specified on the furnace rating plate. Determine the air temperature

as follows:

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

to furnace as possible. Be sure thermometers do not "see"
heat exchangers so that radiant heat does not affect
thermometer readings. This is particularly important with

straight run ducts.

b. When thermometer readings stabilize, subtract return-air

temperature from supply-air temperature to determine
temperature rise.

If the temperature rise is outside this range, check the following:

a. Gas input for gas heat operation.

b. Derate for altitude if applicable.

c. Return and supply ducts for excessive restrictions causing

static pressures greater than 0.50-in. w.c.

d. Adjust temperature rise by adjusting blower speed.

• Increase blower speed to reduce temperature rise.

• Decrease blower speed to increase temperature rise.

58

ELECTRICALOPERATIONHAZARD
Failuretofollowthiswarningcouldresultinpersonalinjury

ordeath.
Disconnect115velectricalpowerbeforechangingspeedtap.

Table 16 - Blower Speed Taps

FACTORY ATTACHED

COLOR SPEED TO:

Gray 5 Cool

Yellow 4 Spare

Blue 3 Heat

Orange 2 Spare

Fled 1 LO HT/Cont. Fan

Read following caution before changing taps).

[]NIT DAMAGE HAZARD

To avoid operating outside the rise range and avoid
component damage:

1. NEVER connect Speed Tap 1 (Red) wire to "HEAT."

2. NEVER connect Speed Tap 2 (Orange) wire to "HEAT"
on all models.

To change blower motor speed selections for heating mode,
remove blower motor lead from control HEAT ternfinal. (See Fig.

35) Select desired blower motor speed lead from one of the other
motor leads and relocate it to HEAT ternfinal. (See Table 16 for
lead color identification.) Reconnect original lead on SPARE

ternfinal.

Adjust Blower Off Delay (Heat Mode)

The blower off delay has four adjustable settings from 90 sec to
180 sec. (See Table 17.) The blower off delay jumpers are located

on the furnace control (See Fig. 35 and Fig. 63.) To change the
blower off delay setting, move the jumper from one set of pins on

the control to the pins used for the desired blower off delay.
Factory blower off delay setting is 120 sec.

Table 17 - Blower Off Delay Jumper Positions

PINS 1 AND 2 2 AND 3 3 AND 4 4 AND 5

Time (in sec.) 90 120 150 180

Adjust Cooling Airflow

The cooling airflow can be set from the remaining blower speed

taps. Refer to the Air Delivery Tables in these instructions.

Adjust Continuous Fan Airflow

The Continuous Fan airflow can be set from the remaining blower
speed taps. Refer to the Air Delivery Tables in these instructions.
The Continuous Fan speed can be changed to any other speed tap

by toggling the Fan switch at the thermostat. See the Sequence of
Operation for details.

FIREHAZARD
Failureto follow this warning could result in personal

iniury, death, and/or property damage.
Reinstall manifold pressure tap plug in gas valve to prevent

gas leak.

FURNACE OVERHEATING HAZARD
Failure to follow this caution may result in reduced furnace

life.
Recheck temperature rise. It nmst be within linfits specified

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

Adjust Thermostat Heat Anticipator

When using a non-electronic thermostat, the thermostat heat

anticipator must be set to match the amp draw of the electrical

components in R-W circuit. Accurate amp draw readings can be

obtained at the thermostat subbase terminals R and W. Fig. 53
illustrates the easy method of obtaining actual amp draw. The amp

reading should be taken after blower motor has started and furnace
is heating. Connect ammeter wires as shown in Fig. 53. The

thermostat anticipator should not be in the circuit while measuring
current. If thermostat has no subbase, the thermostat must be

disconnected from R and W wires during current measurement.

See thermostat manufacturer's instructions for ac[iusting heat

anticipator and for varying heating cycle length. For an electronic

thermostat, set cycle rate for 3 cycles per hr.

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 Linfit Switch
This control shuts off combustion system and energizes air-

circulating blower motor, if furnace overheats. By using this
method to check linfit control, it can be established that lim-

it is functioning properly and will operate if there is a re-
stricted return-air supply or motor failure. If linfit control

does not function during this test, cause nmst be determined
and corrected.

a. Run furnace for at least 5 nfinutes.

b. Gradually block off return air with a piece of cardboard or

sheet metal until the limit trips.

c. Unblock return air to pernfit normal circulation.

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

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

a. Turn off 115-v power to furnace.

b. Disconnect inducer motor lead wires from wire harness.

c. Turn on 115-v power to furnace.

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

low pressure switch is functioning properly, hot surface
igniter should NOT glow and control diagnostic light

flashes a status code 31. If hot surface igniter glows when
inducer motor is disconnected, shut down furnace immedi-

ately.

e. Deternfine reason low pressure switch did not function

properly and correct condition.

f. Turn off 115-v power to furnace.

59

g

g. Reconnect inducer motor wires, replace door, and turn on

l15-v power.

h. Blower will run for 90 sec before beginning the call for

heat again.

i. Furnace should ignite normally.

ChecMist

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

2. Verify that jumper for the blower OFF DELAY is set as de-
sired per Table 17.

3. Verify that blower and control doors are properly installed.

4. Cycle test furnace with room thermostat.

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

6. Review Owner's Manual with owner.

7. Attach literature packet to furnace.

SiNGLE-STAGE

TERMINALS WITH

SUBBASE

THERMOSTAT REMOVED

(ANITICIPATOR, CLOCK, ETC.,
MUST BE OUT OF CIRCUIT.)

HOOK-AROUND

AMMETER

10 TURNS

ii

PressureTap

ON/O_tch

Fig. 51 - Gas Valve

RegulatorSealCap

Regu[atorAdjustment
RegulatorSealCap underCap

Al1153

FROM UNIT 24-V
CONTROL TERMINALS

EXAMPLE:

9001-10,000

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

5.0AMPSON AMMETER 0.5AMPSFORTHERMOSTAT

10 TURNS AROUND JAWS ANTICIPATOR SETTING

Fig. 53 - Amp. Draw Check with Ammeter

Table 18 - Altitude Derate Multiplier for U.S.A.

ALTITUDE PERCENT DERATE

FZ

0-2000
2001-3000
3001-4000
4001-5000

5001-6000
6001-7000
7001-8000
8001-9000

M

0-610

610-914

914-1219

1219-1524
1524-1829

1829- 2134
2134- 2438
2438- 2743
2743- 3048

=

DERATE

8-10

10-12
12-14
14-16
16-18
18-20

4-6
6-8

OF

A96316

MULTIPLIER

FACTOR*

0

1.00

0.95

0.93

0.91

0.89

0.87

0.85

0.83

0.81

-- BURNER --_

Fig. 52 - Orifice Hole

)

ORIFICE

A93059

60

SERVICE

................. Ifstatuscoderecallisneeded,brieflyremovethenreconnectonemainlimitwireto

..... displaylaststoredstatuscode.Afteronestatuscoderecamliscompletedcomponent

...... testwilloccur.

LED CODE STATUS

CONTINUOUS OFF- Check for 115VACat L1 & L2,& 24VAC at SEC-1& SEC-2.
CONTINUOUS ON- Control has 24VAC power.

RAPID FLASHING - Line voltage (115VAC) polarityreversed. If twinned,

EACHOFTHEFOLLOWINGSTATUSCODESiSATWODiGiTNUMBERWITHTHEFIRSTDiGiTDETERMINED
BYTHENUMBEROFSHORTFLASHESANDTHESECONDDiGiTBYTHENUMBEROFLONGFLASHES,

1t NOPREVIOUSCODE.Storedstatuscodesareerasedautomaticallyafter72hours.
12BLOWERONAFTERPOWERUP(115VACor24VAC)•Blowerrunsfor90seconds,ifunitis poweredup

duringacallforheat(R-Wclosed)orR-Wopensduringbloweron-delay.

13LIMITCIRCUITLOCKOUT.Lockoutoccursifalimitorflamerolloutswitchisopenlongerthan3minutes.

-Controlwillautoresetafterthreehours. •Referto#33
14IGNITIONLOCKOUT.Controlwillauto-resetafterthreehours.Referto#34.
21GASHEATINGLOCKOUT.ControlwillNOTautoreset.Checkfor:

-Mis-wiredgasvalve -Defectivecontrol(valverelay)

22ABNORMALFLAME.PROVINGSIGNAL.Flameisprovedwhilegasvalveisde-energized.

Nucerwillrununtilfaultiscleared.Checkfor: -Leakygasvalve-Stuck-opengasvalve

23PRESSURESWITCHDIDNOTOPEN.Checkfor: -Obstructedpressuretubing

-Pressureswitchstuckclosed

24SECONDARYVOLTAGEFUSEISOPEN.Checkfor: -Shortcircuitinsecondaryvoltage(24VAC)wiring.
31PRESSURESWITCHDIDNOTCLOSEORREOPENED-IfLPSopenlongerthanfiveminutes,inducershutsoff

forI5 minutesbeforeretry.IfHPSremainsopenforoneminuteaftergasvalvecloses(afterthreesuccesivetrials),

thenfurnacecontrolwilllockoutfor3hoursbeforeretry.Checkfor:

- Excessivewind -Restrictedvent - Defectiveinducermotor

- Lowinletgaspressure(ifLGPSused) - Defectivepressureswitch -Lowinducervoltage(115VAC)

- Inadequatecombustionairsupply- Properventsizing - Disconnectedorobstructedpressuretubing

-Condensatedrainagerestrictedorblocked

Ifitopensduringbloweron-delayperiod,blowerwillcomeonfortheselectedbloweroff-delay.

33LIMffCIRCUITFAULT.Indicatesalimitorflamerollout,switchisopen.Blowerwillrunfor4minutesoruntil

openswitchremakeswhicheverislonger.Ifopenlongerthan3minutes,codechangestolockout#I3. If
openlessthan3minutesstatuscode#33continuestoflashuntilblowershutsoff.Flamerolloutswitch
requiresmanualreset.Checkfor:-Dirtyfilterorrestrictedductsystem-Properventsizing

-Restrictedvent - Looseblowerwheel -Excessivewind - Defectiveblowermotor

-Defectiveswitchorconnections -Inadequatecombustionairsupply(FlameRoll-outSwitchopen).

34 IGNiTiONPROVINGFAILURE-Controlwilltrythreemoretimesbeforelockout#I4occurs.

Ifflamesignallostduringbloweron-delayperiod,blowerwillcomeonfortheselectedbloweroff-delay.

Checkfor: -Oxidebuilduponflamesensor(cleanwithfinesteelwool)

-Properflamesensemicroamps(.5microampsD.C.rain.,4.0-6.0nominal)

-Manualvalveshut-off-Controlgroundcontinuity-Gasvalvedefectiveorgasvalveturnedoff

-Lowinletgaspressure-Inadequateflamecarryoverorroughignition-DefectiveHotSurfaceIgnitor

-Flamesensormustnotbegrounded - Green/yellowwireMUSTbeconnectedtofurnacesheetmetal

45CONTROLCIRCUITRYLOCKOUT.Auto-resetafteronehourlockoutdueto;- Gasvalverelaystuckopen

-Flamesensecircuitfailure - Softwarecheckerror
Resetpowertoclearlockout.Replacecontrolifstatuscoderepeats.

referto twinning kit instructions.

ii

COMPONENT TEST

ToinitiatethecomponenttestsequenceshutOFFtheroomthermostatordisconnectthe"R"thermostat
lead.BrieflyshorttheTEST/TWiNterminaltothe"Corn24V"terminalStatusLEDwillflashlaststatus

codeandthenturnONtheinducermotor.Theinducermotorwillrunfortheentirecomponenttest.The
hotsurfaceignitor,blowermotorFANspeed(ifequiped)blowermotorHEATspeed,andblowermotor

COOLspeedwillbeturnedONfor10-15secondseach.GasValveandHumidifierwillnotbeturnedon.

/

Jr-

...... 3383 11-2 Rev,C

Fig. 54 - Service Label Information

61

Al1410

SECONDS

FOR 1 REVOLUTION

10
11

12
13
14
15

16
17
18
19

20
21

22
23
24
25

26
27
28
29
30

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.

36O
327

3OO
277
257
24O

225
212
2OO
189
18O

171
164
157
150
144

138
133
129
124
120

116
113
109
106
103

100

97
95
92
90

88
86
84
82
80

78
76
75
73

Table 19 - Gas Rate (CU ft./hr)

2 Cu Ft. 5

72O
655

6OO
555
514
48O

45O
424
4OO
379
36O

343
327
313
300
288

277
267
257
248
240

232
225
218
212
206

200

195
189
185
180

176
172
167
164
160

157
153
150
147

Cu Ft.
1800

1636
1500
1385
1286
1200

1125
1059
1000

947
900

857
818
783
750
720

692
667
643
621
600

581
563
545
529
514

500
486
474
462
450

439
429
419
409
400

391
383
375
367

SECONDS

FOR 1 REVOLUTION

50
51

52
53
54
55

56
57
58
59
60

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
6O

58
56
54
53
51

5O
48
47
46
45

44
43
42
41
40

39
38
38
37
36

35
35
34
33
33

32
31
30

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
60

5 Cu Ft.

360
355

346
340
333
327

321
316
310
3O5
3OO

290
281
273
265
257

250
243
237
231
225

220
214
209
205
200

196
192
188
184
180

178
173
170
167
164

161
155
150

62

Table 20 - Orifice Size and Manifold Pressure (in. w.c.) for Gas Input Rate

SINGLE-STAGE FURNACE

(TABULATED DATA BASED ON 20,000 BTUH PER BURNER, DERATED 2°/o/1000 FT (305M) ABOVE SEA LEVEL)

ALTITUDE AVG. GAS SPECIFIC GRAVITY OF NATURAL GAS

RANGE HEAT VALUE 0.58 0.60 0.62 0.64

AT ALTITUDE Orifice Manifold Orifice Manifold Orifice Manifold Orifice Manifold

ft (m) _ No. Pressure No. Pressure No. Pressure No. Pressure

900 43 3.8 42 3.2 42 3.3 42 3.4

"o

t-

O 975 44 3.7 44 3.8 43 3.4 43 3.6

r..

,_ Canada 925 44 3.5 44 3.6 44 3.8 43 3.4
_ 2001 (611) 950 44 3.3 44 3.4 44 3.6 44 3.7

.-_ (915) 825 43 3.6 43 3.7 43 3.8 42 3.2
O 850 44 3.8 43 3.5 43 3.6 43 3.7

.-_ (1220) 800 43 3.5 43 3.6 43 3.7 43 3.8

r..

O 825 44 3.8 43 3.4 43 3.5 43 3.6

<.' to

O 800 44 3.7 44 3.8 43 3.4 43 3.5

O 750 43 3.4 43 3.5 43 3.6 43 3.7

• 775 44 3.6 44 3.7 43 3.4 43 3.5

0 925 43 3.6 43 3.7 43 3.8 42 3.2

(0) 950 43 3.4 43 3.5 43 3.6 43 3.7

to 1000 44 3.5 44 3.6 44 3.8 43 3.4

1025 44 3.3 44 3.5 44 3.6 44 3.7

2000 1050 44 3.2 44 3.3 44 3.4 44 3.5
(610) 1075 45 3.7 45 3.8 44 3.3 44 3.4

1100 46 3.7 46 3.8 45 3.8 44 3.2

U.S.A. 800 42 3.4 42 3.5 42 3.6 42 3.7

2001 (611) 825 43 3.8 42 3.3 42 3.4 42 3.5

to 850 43 3.6 43 3.7 42 3.2 42 3.3

3000 (914) 875 43 3.4 43 3.5 43 3.7 43 3.8

900 44 3.7 44 3.8 43 3.5 43 3.6

to 975 44 3.2 44 3.3 44 3.4 44 3.5

1000 44 3.0 44 3.1 44 3.2 44 3.3

775 42 3.3 42 3.4 42 3.5 42 3.6

3001 800 43 3.8 42 3.2 42 3.3 42 3.4

to 875 44 3.6 44 3.7 43 3.4 43 3.5

4000 900 44 3.4 44 3.5 44 3.7 44 3.8

(1219) 925 44 3.2 44 3.4 44 3.5 44 3.6

950 44 3.1 44 3.2 44 3.3 44 3.4

750 42 3.3 42 3.4 42 3.5 42 3.6

4001 775 43 3.7 43 3.8 42 3.3 42 3.4

850 44 3.5 44 3.7 44 3.8 43 3.4

5000 875 44 3.3 44 3.5 44 3.6 44 3.7

(1524) 900 44 3.2 44 3.3 44 3.4 44 3.5

925 44 3.0 44 3.1 44 3.2 44 3.3

725 42 3.2 42 3.3 42 3.4 42 3.5

5001 750 43 3.7 43 3.8 42 3.2 42 3.3

(1525) 775 43 3.4 43 3.5 43 3.7 43 3.8

to

6000 850 44 3.3 44 3.4 44 3.5 44 3.6

(1829) 875 44 3.1 44 3.2 44 3.3 44 3.4

6001 700 42 3.2 42 3.3 42 3.4 42 3.5

(1830) 725 43 3.6 43 3.7 43 3.8 42 3.3

to

7000 800 44 3.4 44 3.5 44 3.6 44 3.7

(2133) 825 44 3.2 44 3.3 44 3.4 44 3.5

825 44 3.5 44 3.6 44 3.7 44 3.8

900 44 2.9 44 3.0 44 3.1 44 3.2
675 42 3.4 42 3.5 42 3.6 42 3.8

850 44 3.0 44 3.1 44 3.2 44 3.3

ii

A11253A

63

Table 20 - Orifice Size and Manifold Pressure (in. w.c.) for Gas Input Rate (Cont.)

SINGLE-STAGE FURNACE

(TABULATED DATA BASED ON 20,000 BTUH PER BURNER, DERATED 2°/all000 FT (305M) ABOVE SEA LEVEL)

ALTITUDE AVG, GAS SPECIFIC GRAVITY OF NATURAL GAS

RANGE HEAT VALUE 0.58 0.60 0.62 0.64

AT ALTITUDE Orifice Manifold Orifice Manifold Orifice Manifold Orifice Manifold

ft (m) _ No. Pressure No. Pressure No. Pressure No. Pressure

650 42 3.4 42 3.5 42 3.6 42 3.7

7001 675 43 3.8 42 3.2 42 3.3 42 3.4

--_ (2134) 700 43 3.5 43 3.7 43 3.8 42 3.2
O 725 44 3.8 43 3.4 43 3.5 43 3.6

___

= (2439) 675 43 3.5 43 3.6 43 3.7 42 3.2

0

__ 775 44 3,0 44 3,2 44 3,3 44 3,4

--_ (2744) 625 43 3.7 42 3.2 42 3.3 42 3.4
O 650 43 3.5 43 3.6 43 3.7 43 3.8

* Orifice numbers shown in BOLD are factory-installed.

to

8000 775 44 3.3 44 3.4 44 3.5 44 3.7

(2438) 800 44 3,1 44 3,2 44 3,3 44 3,4

8001 650 43 3.8 42 3.2 42 3.3 42 3.4

to

9000 750 44 3,3 44 3,4 44 3,5 44 3,6

9001 600 42 3.3 42 3.4 42 3.6 42 3.7

to 675 44 3,7 44 3,8 43 3.4 43 3.5

10000 700 44 3,4 44 3,5 44 3,7 44 3,8

_ 72_ 44 3._ 44

750 44 3.5 44 3.7 44 3.8 43 3.4

825 44 2,9 44 3,0 44 3,1 44 3,2
625 42 3.4 42 3.5 42 3.6 42 3.7

700 44 3,7 43 3.4 43 3.5 43 3.6
725 44 3,5 44 3,6 44 3,7 44 3,8

3,3 44 3.4 44 3,5

A11253 B

64

SERVICE AND MAINTENANCE

PROCEDURES

FIRE, INJURY OR DEATH HAZARD
Failure to follow this warning could result in personal

iniury, 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 service and maintenance on this

equipment other than those procedures recommended in the

Owner's Manual.

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.

ELECTRICAL SHOCK, FIRE OR EXPLOSION
HAZARD

Failure to follow this warning could result in personal
injury or 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. Lock out and tag switch with a suitable

warning label. Verify proper operation after servicing.

ELECTRICAL OPERATION HAZARD
Failure to follow this caution may result in improper

furnace operation or failure of furnace.
Label all wires prior to disconnection when servicing

controls. Wiring errors can cause improper and dangerous
operation.

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. 2,
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 and tag switch with a suitable warning label.

The electrical ground and polarity for 115-v wiring must be
properly maintained. Refer to Fig. 34 for field wiring information

and to Fig. 63 for furnace wiring information.

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

The 24-v circuit contains an automotive-type, 3-amp. fuse located
on the control. (See Fig. 35.) 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.

Troubleshooting
Refer to the service label. (See Fig. 54--Service Label.)

The Troubleshooting Guide (See Fig. 62) 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.
Proper instrumentation is required to service electrical controls.

The control in this furnace is equipped with a Status Code LED
(Light-Emitting Diode) to aid in installation, servicing, and

troubleshooting. Status codes can be viewed at the indicator in
blower door. The amber 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

control door or Fig. 54, and the troubleshooting guide which can
be obtained from your distributor.

Retrieving Stored Fault Codes
NOTE: Fault codes cannot be retrieved if a thermostat signal

(24-v on W, Y, G, etc.) is present, or if any delays such as blower
off-delays are active.

The stored status codes will NOT be erased from the control
memory when 115- or 24-v power is interrupted. See the Service

Label (Fig. 54) for more information. The most recent fault code
may be retrieved as follows:

1. Leave 115-v power connected to furnace.

2. Observe the status LED through the blower door (the lower
door on upflow applications) indicator. Refer to the Service

Label (Fig. 54) to interpret the LED.

3. Remove the Main/Control door (the upper door on upflow
installations).

4. BRIEFLY disconnect and reconnect ONE of the main limit

wires.

5. The LED will flash the last stored fault code. Refer to the
Service Label (Fig. 54) to interpret the LED.

6. A component test sequence will follow.

7. Reinstall the Main/Control door.

ii

65

g

Component Self-Test
NOTE: The furnace control component test allows all

components to run for a short time; except the gas valve and
humidifier terminal HUM are not energized. The EAC-1 terminal

is energized when the blower is energized. This feature helps
diagnose a system problem in case of a component failure. The
component test feature will not operate if any thermostat signal is
present at the control and not until all time delays are completed.

To Begin Component Self-Test:

1. Remove blower access door.

2. Disconnect the thermostat R lead from furnace control.

3. Manually close blower door switch.

Caution must be taken when manually closing this switch for
service purposes.

ELECTRICALSHOCK HAZARD

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

Blower door switch opens 115-v power to furnace control.
No component operation can occur unless switch is closed.
Exercise caution to avoid electrical shock from exposed
electrical components when manually closing this switch for
service purposes.

4. For approximately 2 sec, short (jumper) the COM-24v
terminal on control to the TEST/TWIN 3/16--in. (5 mm)
quick-connect terminal on control until the LED goes off.

Remove jumper from terminals. (See Fig. 35.)

NOTE: If TEST/TWIN and COM-24v terminals are jumpered
longer than 2 sec, LED will flash rapidly and ignore component
test request.

Component test sequence is as follows:

a. LED will display previous status code 4 times.

b. Inducer motor starts and continues to run until Step g of

component test sequence.

c. After 7 sec the hot surface igniter is energized for 15 sec.,

then off.

d. Blower motor operates on Continuous-FAN speed for 10

sec.

e. Blower motor operates on HEAT speed for 10 sec.

f. Blower motor operates on COOL speed for 10 sec.

g. Inducer motor stops.

5. Reconnect R lead to furnace control, remove tape from
blower door switch, and re-install blower door.

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

7. Verify that furnace restarts by raising thermostat setting
above room temperature.

Checklist

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

2. Verify that the jumper is removed from the TEST/TWIN
terminal. Verify that there is nothing plugged into the PLT

connector. (Note: If there is a jumper connector plugged
into PLT, remove it and discard.) (See Fig. 35.)

3. Verify that the Blower/Heat Off Delay jumpers are set as
desired. (See Fig. 35.)

4. Verify that the blower and control ("Main") doors are
properly installed.

5. Verify that the Status LED glows. If not, check that the
power supply is energized and that the blower door is

secure. (See Fig. 54.)

6. Cycle test furnace with room thermostat to be sure that it

operates properly with the room thermostat. Check all
modes including Heat, Cool and Fan.

7. Check operation of accessories per manufacturer's
instructions.

8. Review Owner's Manual with owner.

9. Attach entire literature packet to furnace.

Care and Maintenance

FIRE OR EXPLOSION HAZARD

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

Never store flammable or combustible materials 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
exchangers.

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, and/or property damage.

Turn off the gas and electrical supplies to the furnace and
install lockout tag before performing any maintenance or
service. Follow the operating instructions on the label

attached to the furnace.

CARBON MONOXIDE POISONING AND FIRE
HAZARD

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

Never operate furnace without a filter or filtration device
installed. Never operate a furnace with filter or filtration

device access doors 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.

66

2.Checkblowermotorandwheelforcleanlinesseachheating
andcoolingseason.Cleanasnecessary.

3.Checkelectricalconnectionsfortightnessandcontrolsfor
properoperationeachheatingseason.Serviceasnecessary.

4.Inspectburnercompartmentbeforeeachheatingseasonfor
rust,corrosion,sootorexcessivedust.If necessary,have

furnaceandburnerservicedbyaqualifiedserviceagency.

5.Inspecttheventpipe/ventsystembeforeeachheatingsea-
sonforwaterleakage,saggingpipesorbrokenfittings.

Haveventpipes/ventsystemservicedbyaqualifiedservice
agency.

6.Inspectanyaccessoriesattachedtothefurnacesuchasahu-
midifierorelectronicaircleaner.Performanyserviceor

maintenancetotheaccessoriesasrecommendedintheac-
cessoryinstructions.

Cleaning and/or Replacing Air Filter

The air filter type may vary depending on the application or
orientation. The filter is external to the furnace casing. There are no

provisions for an internal filter with this furnace. See "Filter
Arrangement" under the "Installation" section of this manual,

CARBON MONOXIDE POISONING AND FIRE

HAZARD

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

Never operate furnace without a filter or filtration device
installed. Never operate a furnace with filter or filtration

device access doors removed.

NOTE: If the filter has an airflow direction arrow, the arrow must
point toward the blower.
To clean or replace filters, proceed as follows:

ELECTRICAL SHOCK, FIRE OR EXPLOSION

HAZARD

Failure to follow this warning could result in personal
iniury or 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. Lock out and tag switch with a suitable
warning label. Verify proper operation after servicing.

1. Turn off electrical supply to furnace.

2. Remove filter cabinet door.

3. Slide filter out of cabinet.

4. If equipped with permanent, washable filter, clean filter by
spraying cold tap water through filter in opposite direction

of airflow. Rinse filter and let dry. Oiling or coating of the
filter is not recommended.

5. If equipped with factory specified disposable media filter,
replace only with a factory specified media filter of the same

size.

6. Slide filter into cabinet.

7. Replace filter cabinet door.

8. Turn on electrical supply to furnace.

Blower Motor and Wheel Maintenance

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

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

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

The following items should be performed by a qualified service
technician. Clean blower motor and wheel as follows:

1. Turn off electrical supply to furnace.

2. Remove blower door.

3. All factory wires can be left connected, but field thermostat
and accessory wiring may need to be disconnected depend-

ing on their length and routing.

4. If the vent and combustion air pipe passes through the

blower compartment, it will be necessary to remove the

pipes from the blower compartment.

Disconnect the vent and combustion air pipe by:

a. Loosen the clamps on the vent couplings and combustion

air pipe external to the furnace.

b. Separate the pipes from the couplings and move them

aside.

c. Loosen the clamps on the vent couplings and combustion

air pipe located on the blower shelf.

d. Separate the pipes from the blower compartment and set

aside.

e. Remove the couplings from the pipe adapters and set aside.

f. After servicing the blower, reverse steps a through e.

g. Tighten all clamps 15 lb -in.

See Fig. 60 for steps 5 through 14.

5. Remove screws securing blower assembly to blower shelf
and slide blower assembly out of furnace. Detach ground

wire and disconnect blower motor harness plugs from
blower motor.

NOTE: Blower wheel is fragile. Use care.

6. Clean blower wheel and motor by using a vacuum with soft
brush attachment. Be careful not to disturb balance weights

(clips) on blower wheel vanes. Do not bend wheel or blades
as balance will be affected.

7. If greasy residue is present on blower wheel, remove wheel
from the blower housing and wash it with an appropriate

degreaser. To remove wheel:

a. Mark blower wheel location on shaft before disassembly

to ensure proper reassembly.

b. Loosen setscrew holding blower wheel on motor shaft.

NOTE: Mark blower mounting arms and blower housing so each

arm is positioned at the same hole location during reassembly.

c. Mark blower wheel orientation and cutoff plate location to

ensure proper reassembly.

d. Remove screws securing cutoff plate and remove cutoff

plate from housing.

e. Remove bolts holding motor mounts to blower housing

and slide motor and mounts out of housing.

f. Remove blower wheel from housing.

g. Clean wheel per instructions on degreaser cleaner. Do not

get degreaser in motor.

8. Reassemble motor and blower wheel by reversing items 7b
through 7f. Ensure wheel is positioned for proper rotation.

9. Torque motor mounting bolts to 40 +/- 10 lb-in, when re-
assembling.

10. Torque blower wheel set screw to 160 +/- 20 lb-in, when
reassembling.

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 necessary.

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

ii

67

13. Reinstall blower assembly in furnace.

14. Reinstall 2 screws securing blower assembly to blower

deck.

15. Reconnect blower leads to furnace control. Refer to furnace
wiring diagram, and connect thermostat leads if previously

disconnected.

NOTE: Be sure to attach ground wire and reconnect blower
harness plugs to blower motor.

ELECTRICAL OPERATION HAZARD

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

Blower 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.

16. 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.

17. Turn on electrical supply. Manually close blower door
switch. Use a piece of tape to hold switch closed. Check for

proper rotation and speed changes between heating and
cooling by jumpering R to G and R to Y/Y2 on furnace

control thermostat terminals. If outdoor temperature is be-
low 70°F, turn off circuit breaker to outdoor unit before

running furnace in the cooling cycle. Turn outdoor circuit
breaker on after completing cooling cycle. (See Fig. 35.)

NOTE: If R-W/W1 thermostat terminals are jumpered at the time
blower door switch is closed, blower will run for 90 sec before

beginning a heating cycle.

a. Perform component self-test as shown atthe bottom of the

SERVICE label, located on the control door.

b. Verify blower is rotating in the correct direction

18. If furnace is operating properly, RELEASE BLOWER
DOOR SWITCH. Remove any jumpers or reconnect any

disconnected thermostat leads. Replace blower door.

19. Turn on gas supply and cycle furnace through one complete
heating cycle. Verify the furnace temperature rise as shown

in Adjustments Section. Adjust temperature rise as shown in
Adjustments Section.

Cleaning Burners and Flame Sensor
The following items must be performed by a qualified service

technician. If the burners develop an accumulation of light dirt or
dust, they may be cleaned by using the following procedure:

NOTE: Use a back-up wrench on the gas valve to prevent the
valve from rotating on the manifold or damaging the mounting to

the burner assembly.

ELECTRICAL SHOCK AND FIRE HAZARD

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

Turn off the gas and electrical supplies to the furnace and
install lockout tag before performing any maintenance or

service. Follow the operating instructions on the label

attached to the furnace.

Refer to Fig. 61.

1. Disconnect power at external disconnect, fuse or circuit
breaker.

2. Turn off gas at external shut-off or gas meter.

3. Remove control door and set aside.

4. Turn electric switch on gas valve to OFF.

5. Disconnect the gas pipe from gas valve and remove pipe
from the furnace casing.

6. Remove individual wires from terminals on gas valve.

7. Disconnect Hot Surface Igniter (HSI) wires from HSI.

8. Disconnect Flame Sensor wire from Flame Sensor.

9. Support the manifold and remove the 4 screws that secure
the manifold assembly to the burner assembly and set aside.

Note the location of the green/yellow wire and ground ter-
minal.

10. Inspect the orifices in the manifold assembly for blockages
or obstructions. Remove orifice and clean or replace orifice.

11. Remove the four screws that attach the top plate of the cas-
ing to the furnace.

12. Raise top plate up slightly and prop it up with a small piece
of wood or folded cardboard.

13. Support the burner assembly and remove the screws that at-
tach the burner assembly to the heat exchanger cell panel.

14. Remove wires from both rollout switches.

15. Slide one--piece burner out of slots on sides of burner-
assembly.

16. Remove the flame sensor from the burner assembly.

17. (Optional) Remove the Hot Surface Igniter (HSI) and

bracket from the burner assembly.

18. Check igniter resistance. Nominal resistance is 40 to 70
ohms at room temperature and is stable over the life of the

igniter.

19. Clean burner with a brush and a vacuum.

20. Clean the flame sensor with fine steel wool (0000 grade).
Do not use sand paper or emery cloth.

To reinstall burner assembly:

1. Install the Hot Surface Igniter (HSI) and bracket in burner
assembly.

2. Install flame sensor on burner.

3. Align the edges of the one-piece burner with the slots in the
burner assembly and slide the burners forward until they are

fully seated in the burner assembly.

4. Align the orifices in the manifold assembly with the support

rings on the end of the burner.

5. Insert the orifices in the support rings of the burners.

NOTE: If manifold does not fit fush against the burner, do not
force the manifold on the burner assembly. The burners are not
fully seated forward in the burner assembly. Remove the manifold

and check burner positioning in the burner assembly assembly

before re-installing the manifold.

6. Attach the green/yellow wire and ground terminal to one of
the manifold mounting screws.

7. Install the remaining manifold mounting screws.

8. Check the igniter alignment. See Fig. 55, 56 and 61.

9. Attach the wires to the roll-out switches.

10. Align the burner assembly with the openings in the primary
cell inlet panel and attach the burner assembly to the cell

panel.

11. Connect the wire for the flame sensor.

12. Connect the wire for the Hot Surface Igniter.

NOTE: Use propane-resistant pipe dope to prevent leaks. Do not
use Teflon tape.

13. Install the gas pipe to the gas valve.

68

FIREOREXPLOSIONHAZARD
Failureto 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. A fire or explosion may
result causing property damage, personal iniury or loss of

life.

14. Check for gas leaks with a commercially available soap
solution made specifically for the detection of leaks.

15. Turn gas on at electric switch on gas valve and at external
shut-off or meter

16. Turn power on at external disconnect, fuse or circuit break-
er.

17. Run the furnace through two complete heating cycles to
check for proper operation

18. Install control door when complete.

Servicing Hot Surface Igniter

The igniter does NOT require annual inspection. Check igniter
resistance before removal. Refer to Fig. 55, 56 and 61.

1. Turn off gas and electrical supplies to furnace.

2. Remove control door.

3. Disconnect igniter wire connection.

4. Check igniter resistance. Igniter resistance is affected by
temperature. Only check resistance when the igniter is at

room temperature.

a. Using an ohm meter, check resistance across both igniter

leads in connector.

b. Cold reading should be between 40 ohms and 70 ohms.

5. Remove igniter assembly.

a. Using a 1/4-in. driver, remove the two screws securing the

igniter mounting bracket to the burner assembly (See Fig.
61 .)

b. Carefully withdraw the igniter and bracket assembly

through the front of the burner assembly without striking
the igniter on surrounding parts.

c. Inspect igniter for signs of damage or failure.

d. If replacement is required, remove the screw that secures

the igniter on igniter bracket and remove the igniter.

6. To replace igniter and bracket assembly, reverse items 5a
through 5d.

7. Reconnect igniter harness to the igniter, dressing the igniter
wires to ensure there is no tension on the igniter itself. (See

Fig. 61.)

8. Turn on gas and electrical supplies to furnace.

9. Verify igniter operation by initiating control board self-test
feature or by cycling thermostat.

10. Replace control door.

Flushing Collector Box and Drainage System

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

death, and/or property damage.
Turn off the gas and electrical supplies to the furnace and

install lockout tag before performing any maintenance or
service. Follow the operating instructions on the label

attached to the furnace.

1. Turn off gas and electrical supplies to furnace.

2. Remove control door.

3. Disconnect pressure switch tube from pressure switch port.

NOTE: Ensure the pressure switch tube disconnected from the
pressure switch is higher than the collector box opening or water

will flow out of tube.

4. Remove the collector box plug from the top port on the up-
per corner of the collector box. (See Fig. 57)

5. Attach a funnel with a flexible tube to port on the collector

box.

6. Flush inside of collector box with water until discharge
water from condensate trap is clean and runs freely.

7. Repeat steps 4 thru 6 with middle plug on upper corner of
collector box.

8. Remove the pressure switch tube from the collector box.

NOTE: Do NOT blow into tube with tube connected to the
pressure switch.

9. Clean pressure switch port on collect box with a small wire.
Shake any water out of pressure switch tube.

10. Reconnect tube to pressure switch and pressure switch port.

11. Remove the relief tube from the port on the collector box
and the trap.

12. Clean the relief port on collect box and the trap with a small
wire. Shake any water out of the tube.

13. Reconnect relief tube to trap and collector box ports.

Cleaning Condensate Drain and Trap

NOTE: If the condensate trap is removed, a new gasket between
the trap and collector box is required. Verify a condensate trap

gasket is included in the service kit or obtain one from your local
distributor.

1. Disconnect power at external disconnect, fuse or circuit
breaker.

2. Turn off gas at external shut-off or gas meter.

3. Remove control door and set aside.

4. Turn electric switch on gas valve to OFF.

5. Disconnect external drain from condensate drain elbow or
drain extension pipe inside the furnace and set aside.

6. Disconnect the condensate trap relief hose from collector
box port and condensate trap.

NOTE: If condensate has a heat pad attached to the trap, trace the
wires for the pad back to the connection point and disconnect the
wires for the heat pad.

7. Remove the screw that secures the condensate trap to the
collector box, remove the trap and set aside.

8. Remove the trap gasket from the collector box if it did not
come off when the trap was removed.

9. Discard the old trap gasket.

10. Rinse condensate trap in warm water until trap is clean.

11. Flush condensate drain lines with warm water. Remember
to check and clean the relief port on the collector box.

12. Shake trap dry.

13. Clean port on collector box with a small wire.

To re-install Condensate Drain and Trap:

1. Remove adhesive backing from condensate trap gasket

2. Install gasket on collector box

3. Align the condensate trap with the drain opening on the col-
lector box and secure the trap with the screw

4. Attach the relief hose to the relief port on the condensate
trap and collector box.

5. Secure tubing to prevent any sags or traps in the tubing.

6. Connect condensate drain elbow or drain extension elbow
to the condensate trap

7. Connect the leads of the condensate heat pad (if used)

8. Connect external drain piping to the condensate drain elbow
or drain extension pipe.

ii

69

g

9. Turn gas on at electric switch on gas valve and at external
shut-off or meter

10. Turn power on at external disconnect, fuse or circuit break-
er.

11. Run the furnace through two complete heating cycles to
check for proper operation

12. Install control door when complete.

Checking Heat Pad Operation (If Applicable)
In applications where the ambient temperature around the furnace

is 32°F or lower, freeze protection measures are required. If this
application is where heat tape has been applied, check to ensure it

will operate when low temperatures are present.
NOTE: The Heat Pad, when used, should be wrapped around the

condensate drain trap. There is no need to use heat tape within the
furnace casing. Most heat tapes are temperature activated, and it is
not practical to verify the actual heating of the tape. Check the
following:

1. Check for signs of physical damage to heat tape such as
nicks, cuts, abrasions, gnawing by animals, etc.

2. Check for discolored heat tape insulation. If any damage or
discolored insulation is evident, replace heat tape.

3. Check that heat tape power supply circuit is on.

Cleaning Heat Exchangers

The following items must be performed by a qualified service
technician.

Primary Heat Exchangers
If the heat exchangers get an accumulation of light dirt or dust on

the inside, they may be cleaned by the following procedure:
NOTE: If the heat exchangers get a heavy accumulation of soot

and carbon, both the primary and secondary heat exchangers
should be replaced rather than trying to clean them thoroughly due
to their intricate design. A build-up of soot and carbon indicates
that a problem exists which needs to be corrected, such as improper
adjustment of manifold pressure, insufficient or poor quality
combustion air, improper vent termination, incorrect size or
damaged manifold orifice(s), improper gas, or a restricted heat
exchanger (primary or secondary). Action must be taken to correct
the problem.

1. Turn off gas and electrical supplies to furnace.

ELECTRICAL SHOCK, FIRE OR EXPLOSION

HAZARD

Failure to follow this warning could result in personal
iniury or 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. Lock out and tag switch with a suitable
warning label. Verify proper operation after servicing.

ELECTRICAL SHOCK AND FIRE HAZARD

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

Turn off the gas and electrical supplies to the furnace and
install lockout tag before performing any maintenance or
service. Follow the operating instructions on the label

attached to the furnace.

3. Disconnect wires or connectors to flame rollout switch, gas
valve, igniter, and flame sensor.

4. Using backup wrench, disconnect gas supply pipe from fur-

nace gas control valve.

5. Remove two screws attaching top filler plate and rotate up-
wards to gain access to screws attaching burner assembly to

cell panel.

6. Remove screws attaching burner assembly to cell panel.
(See Fig. 61.)

NOTE: Burner cover, manifold, gas valve, and burner assembly
should be removed as one assembly.

7. Clean heat exchanger openings with a vacuum and a soft
brush. (See Fig. 58.)

NOTE: After cleaning, inspect the heat exchangers to ensure they

are free of all foreign objects that may restrict flow of combustion

products.

8. Reverse items 6 through 1 for reassembly.

9. Refer to furnace wiring diagram and reconnect wires to
flame rollout switch, gas valve, igniter, and flame sensor.

10. Turn on gas and electrical supplies to furnace.

11. Check furnace operation through 2 complete heat operating
cycles. Look at burners. Burner flames should be clear blue,

almost transparent. (See Fig. 59.)

12. Check for gas leaks.

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. A fire or explosion may
result causing property damage, personal iniury or loss of

life.

13. Replace main furnace door.

Secondary Heat Exchangers

The condensing side (inside) of the secondary heat exchanger

CANNOT be serviced or inspected without complete removal of
the heat exchanger assembly. Detailed information on heat
exchanger removal can be obtained from your Distributor.

WINTERIZATION

[]NIT AND PROPERTY DAMAGE HAZARD

Failure to follow this caution may result in unit component or
property damage.

If the furnace is installed in an unconditioned space where the
ambient temperatures may be 32 ° F (0 ° C) or lower, freeze

protection measures must be taken to prevent minor property
or product damage.

2. Remove control door.

7O

Sincethefurnaceusesacondensingheatexchanger,somewater
willaccunmlateintheunitasaresultoftheheattransferprocess.

Therefore,onceithasbeenoperated,itcannotbeturnedoffand
leftoffforanextendedperiodoftimewhentemperatureswill
reach32°F(0°C)or lowerunlesswinterized.Followthese

)rocedurestowinterizeyourfurnace:

2-in.

(50.0)

UNIT COMPONENT DAMAGE HAZARD
Failure to follow this caution may result in damage to the

furnace and other property damage.
Do not use ethylene glycol (automotive antifreeze coolant or

equivalent). Failure of plastic components may occur.

1. Obtain propylene glycol (RV/swinmfing pool antifreeze or
equivalent).

2. Turn off gas and electrical supplies to your fllmace.

3. Remove fllmace control door.

4. Remove the top unused robber plug from the port on the
collector box opposite the condensate trap. See Fig 57.

5. Connect a field supplied 3/8-in. (9.5-ram) ID tube to the
open port on the collector box.

6. Insert a field supplied flmnel into the tube.

7. Pour 1 quart of anti-freeze solution into the flmnel/tube.
Antifreeze should mn through the inducer housing, overfill

condensate trap and flow to an open drain.

8. Replace the robber plug in the port on the collector box.

9. Remove the nfiddle unused robber plug from the port on the
collector box opposite the condensate trap. See Fig. 57.

10. Repeat Steps 5 through 8.

11. If a condensate pump is used, check with pump manufacturer
to verify pump is safe for use with antifreeze used. Allow

pump to start and pump anti-freeze to open drain.

12. Replace main door.

13. When fllmace is re-started, flush condensate pump with clear
water to check for proper operation before re-starting fllmace.

14. Propylene glycol need not be removed before re-starting
furnace.

216-in,

_ (4.6)

/

Fig. 56 - Igniter Position - Side View

Fig. 57 - Priming Condensate Trap

2.5 mm +/-.75 ram)

Al1272

g

Al1392

0 o o L _0

)0 _0

(644)

Fig. 55 - Igniter Position - Top View

Al1405

71

ii

Al1273

Fig. 58 - Cleaning Heat Exchanger Cell

Burner Flame

Burner

Manifold

Al1461

Fig. 59 - Burner Flame

72

)MMET

MOTOR SHAFT
FLAT _ / "_/-- BLOWER

SET SCREW /_ _ // /

TORQUE J _

BLO HSG ASSY

BRA(

BRACKET
ENGAGEMENT

MOTOR ARM

W gEL

I _I,SCREW

SPECIAL

(REF)

SCREW

CHOKE, POWER
(WHEN REQ'D

CUTOFF,

#

SCREW (GND)

Fig. 60 - Blower Assembly

BLOWER

HSG ASSY

MOTOR
BLOWER

A11347

73

BURNER ASSY

ii

BURNER SUPZ ASSY

IGNITER

BRACKET, IGNITER

FLAME ROLLOUT

SWITCH

'__.,,,, FLAME SENSOR

(BELOW BURNER)

Fig. 61 - Burner Assembly

A11403

74

SEQUENCE OF OPERATION

NOTE: Furnace control must be grounded for proper operation or
control will lock out. Control is grounded through green/yellow

wire routed to gas valve and manifold bracket screw. Using the
schematic diagram in Fig. 63, follow the sequence of operation

through the different modes. Read and follow the wiring diagram
very carefully.

NOTE: If a power interruption occurs during a call for heat (W),
the control will start a 90-sec blower-only ON period two sec after

power is restored, if the thermostat is still calling for gas heating.
The Amber LED light will flash code 12 during the 90-sec period,
after which the LED will be ON continuous, as long as no faults
are detected. After the 90-sec period, the furnace will respond to
the thermostat normally.

The blower door must be installed for power to be conducted
through the blower door interlock switch ILK to the furnace

control CPU, transformer TRAN, inducer motor IDM, blower
motor BLWM, hot-surface igniter HSI, and gas valve GV.

1. Heating
(See Fig. 35 and 36 for thermostat connections.)

The wall thermostat "calls for heat," closing the R-to-W
circuit. The furnace control performs a self-check, verifies

the pressure switch contacts LPS and HPS are open, and
starts the inducer motor IDM.

a. Inducer Prepurge Period- As the inducer motor IDM

comes up to speed, the low pressure switch contacts LPS
close to begin a 15-sec prepurge period. The high pressure

switch contacts HPS are ignored until one minute after the
gas valve closes.

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

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

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

up period is completed, the main gas valve relay contacts
GVR close to energize the gas valve GV, the gas valve
opens, and 24 vac power is supplied for a field-installed

humidifier at the HUM terminal. The gas valve GV 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 be-
gins. The HSI igniter will remain energized until the flame

is sensed or until the 2-sec flame proving period begins.

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

flame-proving sensor electrode FSE, the furnace control
CPU begins the blower-ON delay period and continues to

hold the gas valve GV open. If the burner flame is not
proved within two sec, the control CPU will close the gas

valve GV, and the control CPU will repeat the ignition se-
quence for up to three more Trials-For-Ignition before go-

ing to Ignition-Lockout. Lockout will be reset automatic-
ally after three hours or by momentarily interrupting 115
vac power to the furnace, or by interrupting 24 vac power

at SEC1 or SEC2 to the furnace control CPU (not at W, G,
R, etc.).
If flame is proved when flame should not be present, the
furnace control CPU will lock out of Gas-Heating mode

and operate the inducer motor IDM until flame is no longer
proved.

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

blower motor is energized on HEAT speed 25 sec after the
gas valve GV is energized.

Simultaneously, the electronic air cleaner terminal EAC-1
is energized and remains energized as long as the blower

motor BLWM is energized.

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

R-to-W circuit is opened, de-energizing the gas valve GV,

stopping gas flow to the burners, and de-energizing the hu-
midifier terminal HUM. The inducer motor IDM will re-

main energized for a 15-sec post-purge period. The
blower motor BLWM and air cleaner terminal EAC- 1 will

remain energized for 90, 120, 150, or 180 sec (depending
on the blower-OFF delay selection). The furnace control

CPU is factory-set for a 120-sec blower-OFF delay.

2. Cooling Mode
The thermostat "calls for cooling."

a. Single-Speed Cooling

(See Fig. 35 and 36 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 terminal EAC-1 is energized

with 115 vac when the blower motor BLWM is operating.
When the thermostat is satisfied, the R-to-G-and-Y 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 sec. Jumper Y/Y2 to
DHUM to reduce the cooling off-delay to 5 sec. (See Fig.

35.)

b. Two-Speed Cooling

(See Fig. 35 and 36 for thermostat connections.)
The thermostat closes the R-to-G-and-Yl circuits for

low-cooling or closes the R-to-G-and-Yl-and-Y2 cir-
cuits for high-cooling. The R-to-Yl circuit starts the out-

door unit on low-cooling speed, and the R-to-G-and-Yl
circuit starts the furnace blower motor BLWM on low-cool

speed (same speed as FAN). The R-to-Yl-and-Y2 cir-
cuits 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 terminal EAC-I is energized

with 115 vac whenever the blower motor BLWM is operat-
ing.

When the thermostat is satisfied, the R-to-G-and-Yl or
R-to-G-and-Yl and Y2 circuits are opened. The outdoor

unit stops, and the furnace blower BLWM and electronic

air cleaner terminal EAC-I will remain energized for an

additional 90 sec. Jumper YI to DHUM to reduce the cool-
ing off-delay to 5 sec. (See Fig. 35.)

3. Dehumidification Mode
(See Fig. 35 and 36 for Thermidistat connections.)

The dehumidification output, D or DHUM from a thermo-
stat should be connected to the furnace control thermostat

terminal DHUM. When there is a dehumidify demand, the
DHUM input is activated, which means 24 vac signal is re-

moved from the DHUM input terminal. In other words, the
DHUM input logic is reversed. The DHUM input is turned

ON when no dehumidify demand exists. Once 24 vac is de-
tected by the furnace control on the DHUM input, dehumid-

ification capability is activated. If the DHUM is removed
for more than 48 hr, the furnace control reverts back to
non-dehumidification mode.

The cooling operation described in item 2. above also ap-
plies to operation with a Thermidistat. The exceptions are

listed below:

a. When the R-to-G-and-Yl circuit is closed and there is a

demand for dehumidification, the furnace blower motor
BLWM will continue running at low-cool speed (same

speed as FAN).

b. When the R-to-G-and-Y/Y2 circuit is closed and there

is a demand for dehumidification, the furnace blower mo-
tor BLWM will drop the blower speed from COOL to

HEAT for a maximum of 10 minutes before reverting back
to COOL speed. If there is still a demand for dehumidifica-

ii

75

tion after 20 minutes, the furnace control CPU will drop
the blower speed back to HEAT speed. This alternating 10-

minute cycle will continue as long as there is a call for cool-
ing.

c. When the "call for cooling" is satisfied and there is a de-

mand for dehumidification, the cooling blower-off delay
is decreased from 90 sec to 5 sec.

4. Continuous Blower Mode
When the R-to-G circuit is closed by the thermostat, the

blower motor BLWM will operate on continuous-blower
speed (can be adjusted to FAN, HEAT, or COOL speed) at

the thermostat. Factory default is FAN speed. Terminal
EAC-1 is energized as long as the blower motor BLWM is

energized. During a call for heat, the blower BLWM will
stop during igniter warm-up (17 see), ignition (7 see), and

blower-ON delay (25 see), allowing the furnace heat ex-
changers to heat up more quickly, then restarts at the end of

the blower-ON delay period at HEAT speed.
In heating, the furnace control CPU will hold the blower

ii

motor BLWM at 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 FAN). When the thermostat is satis-

fied, the blower motor BLWM will operate an additional 90
sec on low-cool speed (same speed as FAN) before revert-

ing back to continuous-blower speed.
When the thermostat "calls for high-cooling', the blower

motor BLWM will operate at COOL speed. When the ther-
mostat is satisfied, the blower motor BLWM will operate an

additional 90 sec on COOL speed before reverting back to
continuous-blower speed.

When the R-to-G circuit is opened, the blower motor
BLWM will continue operating for an additional 5 sec, 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 sec after the
blower motor BLWM is operating. The furnace control

CPU will shift the continuous-blower speed from the fact-
ory setting of FAN to HEAT speed. Momentarily turning

off the FAN switch again at the thermostat will shift the
continuous-blower speed from HEAT to COOL. Repeating

the procedure will shift the continuous-blower speed from
COOL to FAN speed. The selection can be changed as

many times as desired and is stored in the memory to be
automatically used following a power interruption.

5. Heat pump
(See Fig. 35 and 36 for thermostat connections.) When in-

stalled with a heat pump, the furnace control automatically
changes the timing sequence to avoid long blower off times

during demand defrost cycles. When the R-to- W-and-Y1
or R-to-W-and-Yl-and-G circuits are energized the fur-

nace control CPU will switch to or turn on the blower motor
BLWM at HEAT speed, and begin a heating cycle. The

blower motor BLWM will remain on until the end of the

prepurge period, then shut off for 24 sec then come back on
at HEAT speed. When the W input signal disappears, the

furnace control begins a normal inducer post-purge period
and the blower remains running at HEAT speed for the se-
lected blower-OFF delay period then switches to low-cool

speed (same speed as FAN). If the R-to-W-and-Yl-and-
G signals disappear at the same time, the blower motor

BLWM will remain on for the selected blower-OFF delay
period. If the R-to- W-and-Y1 signals disappear, leaving

the G signal, the blower motor BLWM will remain on for
the selected blower-OFF delay period then switch to con-

tinuous-blower speed. When the R-to-W-and-Y/Y2,
R-to-W-and-Y/Y2-and-G, R-to-W-and-Yl-and-

Y/Y2, or R-to-W- and-Yl-and-Y/Y2-and-G circuits are

energized the furnace control CPU will switch to or turn on
the blower motor BLWM at HEAT speed, and begin a heat-

ing cycle. The blower motor BLWM will remain on until
the end of the prepurge period, then shut off for 24 sec then

come back on at HEAT speed. When the W input signal dis-
appears, the furnace control begins a normal inducer post-

purge period and the blower switches to COOL speed after
a 3 sec delay. If the R-to-W-and-Y/Y2-and-G or R-to-

W-and-Yl-and -Y/Y2-and-G signals disappear at the
same time, the blower motor BLWM will remain on for the

selected blower-OFF delay period. If the R-to-W-and-

Y/Y2 or R-to-W-and-Yl-and-Y/Y2 signals disappear,

leaving the G signal, the blower motor BLWM will remain
on for the selected blower-OFF delay period then switch to

continuous blower speed.

Component Self-Test

Refer to page 66 for instructions.

76

START

Is LED status light on? }.L_

YES

Kith

Troubleshooting Guide

Is there 115V at L1 and L2?

_l YES

i s there 24V at SECq and SECt2?

I YES

[ Replace furnace control. 1

Is door switch closed?

_! YES

i Is there 115V going to switch?

!! YES

Replace door switch.

._ Is door switch closed?

Is circuit breaker closed?

l Check for continuity in wire from circuitbreaker to furnace.

1

NO

H-

YES

Is LED status light blinking rapidly without

I a pause? I "1

r j YES [

Check for correct line voltage polarity. If
units are twinned, check for proper low-
voltage (24V) transformer phasing.

-._ Replace transformer.

Close circuit breaker and go back toSTART.

F

NO [

slowly with a combination of short and

Is LED status light blinking ON/OFF INO

long flashes?

i

Determine status code. The status code
is a 2 digit number with the first digit

determined by the number of short

"-4
"-4

flashes and the second digit by the

number of long flashes?

d_
d_

_°

I YES

b-.

To recall status code briefly remove and reconnect one RED wire from the
draft safeguard switch to display stored status code. You can also recall

the previous status code by momentarily shorting the TEST/TWiN
terminal to Com24V terminal until the LED goes out. LED will flash the
status code of the previous fault or status code #11 (1 short and 1 long
flash) if there was no previous fault. After the control repeats the code 4
times the control will go through a brief component test sequence. The

inducer will start and run for the entire component test. The HSl, blower
motor FAN speed (AMBER LED boards only) HEAT speed, and COOL
speed will run for 10 15 seconds each. Gas valve and humidifier will not

be turned on.

interconnecting cable.

I heck room thermostat or

l.o

¢b

r,"

that was flashed.

Go to section below for the status code

._ Was there a previous status code otherthan #11 ?

!_ oes the control respond to W, Y1 (if

present), Y/Y2, and G (24V) thermostat
signals?

i YES

cycle to check operation. Status codes
Run system through a heating or cooling

are erased after 72 hours.

1_ Is 24V present at W, Y1 (if present), Y/Y2

or G thermostat terminals on the furnace
control?

I YES

the furnace control.

i isconnect all the thermostat wires from

l

Replace furnace control.

_ Does the problem repeat when using a

jumper wire?

_! NO

The thermostat is not compatible with the
furnace control. Either install a ballast

resistor, connect the Com24V thermostat

co
EB

terminal to the thermostat, or replace the
thermostat.

NO PREVIOUS CODE - Stored codes are
erased after 72 hours. Run system

through a heating or cooling cycle to
check system.

12 BLOWER ON AFTER POWER UP -

(115V OR 24V) - Normal operation.
Blower runs for 90 seconds, if unit is

powered up during a call for heat (R-W
closed) or when (R-W opens) during the
blower on-delay period.

13 LIMIT CIRCUIT LOCKOUT - Lockout

occurs if the limit or flame rollout is open
longer than 3 minutes. Control will auto-

reset after 3 hours. See code 33.

14 IGNITION LOCKOUT - System failed to

ignite gas and prove flame in 4 attempts.
Control will auto-reset after 3 hours. See

status code 34.

_o

..q
oo

o

21 GAS HEATING LOCKOUT - Turn off

power and wait 5 minutes to retry. Check
for:

- Stuck closed gas valve relay on control.

- Miswire or short to gas valve wire.

22 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.

23 PRESSURE SWITCH DID NOT OPEN -

Check for:

- Obstructed pressure tube.

- Pressure switch stuck closed.

24 SECONDARY VOLTAGE FUSE IS OPEN

Check for:

- Short circuit in secondary voltage (24V)
wiring including thermostat leads.

Disconnect thermostat leads to isolate
short circuit.

31 LPS or HPS PRESSURE SWITCH DID

NOT CLOSE OR REOPENED - If opens
during blower on-delay period, blower will
come on for the selected blower off-delay.

If LPS opens longer than 5 minutes,

inducer shuts off for 15 minutes before
retry. If HPS remains open for one minute

after gas valve closes the furnace will shut
down and retry. If HPS fails to close on
three successive cycles the furnace will
lockout for 3 hrs before retry.

Check for:

- Proper vent sizing.

- Air leak between vestibule and blower
compartment.

- Low inlet gas pressure (if LGPS used).

- Disconnected or obstructed pressure
tubing.

- Defective or miswired pressure switches

- Excessive wind.

- Plugged condensate drain

- Water in vent piping, possible sagging

pipe

- Restricted vent.

- Defective Inducer motor.

- Low inducer voltage (115 VAC)

33 LIMIT CIRCUIT FAULT - Indicates the

limit, flame rollout is open. Blower will run

for 4 min. or until open switch remakes
whichever is longer. If open longer than 3

min, code changes to lockout #7. If open
less than 3 min. status code #4 continues

to flash until blower shuts off. Flame

rollout switch requires manual reset.

Check for:

- Loose blower wheel.

- Defective switch or connections.

- Dirty filter or restricted duct system.

- Improper gas input adjustment

- Improper limit switch or no limit gasket.

34 IGNITION PROVING FAILURE - If flame

is not sensed during the trial for ignition

period, the control will repeat the ignition
sequence 3 more times before lockout #14
occurs. If flame signal is lost during the

blower on-delay period, blower will come
on for the selected blower off-delay.

Check the following items first before

proceeding to the next step.

- Gas valve turned off.

- Manual shut-off valve.

- Green/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 R thermostat connection from
the control and initiate the component test

sequence. Does the igniter glow
orange/white by the end of the 15 second

warm-up period?

Y --s

Unplug igniter harness from control and
initiate another component test

sequence. Check for 115V between pin
1 and NEUTRAL-L2 on the control. Was

115V present for the 15 second period?

Reconnect the R thermostat lead and set
thermostat to call for heat. Connect
voltmeter across gas valve connections.
Does gas valve receive 24V?

flow?

I Does gas valve open and allow gas to

YES

I DO the main burners ignite?

I YES

I Uothe main burners on?

stay

No

sensor current during trial for ignition

I Repeat call for heat and check flame INOI

period. Is the DC microamps below 0.5?

_ YES

and recheck current. Nominal current is

4.0 to 6.0 microamps.

I Clean flame sensor with fine steel wool I

I s current near typical value?

YES

I ill main burners ignite and stay on?

YES

. I

m

I

,NO,

YES

[Fixed. l

45 CONTROL CIRCUITRY

LOCKOUT Auto-reset
after 1 hour lockout due

to:

- Flame circuit failure.

- Gas valve relay stuck
open.

- Software check error.
Reset power to clear

lockout. Replace

control if code repeats.

Replace furnace control.

Check for continuity in the

YES

harness and igniter. Replace
defective component.

NO

Check connections. If OK,

..-q

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.

Allow blower to come on and

repeat test to check for
intermittent operation.

Check connections and retry.
If current is near typical value

(4.0-6.0 nominal) and burners

will not stay on, replace

control.

Replace electrode. ]

Replace furnace control. ]

/

SEC.-2SEC-1

EAC-2 L2

CONNECTION DIAGRAM

PL1

NOTE #10

BLK 7 BRN BRN

BLK

WHT

LGPS

(WHENUSED)

.... 7

NOTE #101

F-YEL ..... I

CAP -2

SCHEMATIC DIAGRAM

TO115MACFIELD DISCONNECT NOTE#2 /_ EQUIPMENT GROUND

2

L1

DR

SLWR

BFANR

PL2

EAC-1

/

PL5

BLWM

PL7

EAC-2B

PL1-6 FUSE TRAN

L2

L2

L2

!=:=

H

_Z:_ I_ WHT (COM)--

p i

RED(FAN) 1 _ _ I

ORG(SPARE)2 _ / _ li

BLU(HEAT)3 _ / X _

-- BLK L

- GRNHELG

___GRY COOL 5

_PL7

PL7

BLK

/

BLK

I

ILK

GND" = -- I

•WHT--

FUSEOR CIRCUIT

BREAKER & DISCONNECT

SWITCH(WHENREQD)

NOTE #2

r........ i NEUTRAL

i

H

21

L_______J

WIll

NOTES:

1. If anyof theoriginal equipment wire is repbced use wire rated for 105°C.

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

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

4. Symbolsare electrical representation only.

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

6. Replaceonly with a 3 amp fuse.

7. Inducer(IDM) motor contains internal auto-reset thermal overload switches(OL).

8. L2 connections are interchangeable within the L2 connector block.

9. Blower motorspeed selections are for average conditions, see installation instructions
for details on optimum speed selection.

10. Factory connected when LGPS is not used.

11.Ignition lockout will occurafterfour consecutive usuccessful
trials for ignition. Controlwill auto-reset after three hours.

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

13. Blower-off delay: gas heating selections are 90, 120, 150 or 180 seconds, coolingor

heat pump 90 seconds or 5 secondswhen DHUM is active.

14. BLWM is locked - rotor overload protected by redundant electronic control circuits.

15. Inductor (When Used).

Fig. 63 - Wiring Diagram

t

FURNACETYPE ,_t:_) " • I_FS E

BACKWARDCOMPATIBLE_:::>> PL1-11 |

L -o- JUNCTIONTERMINAL _ FACTORYPOWERWlRING(115VAC)
E 0 CONTROLTERMINAL FACTORYCONTROLWIRING(24VAC)

G Imam PCBCONTROLTERMINAL .... FIELDCONTROLWIRING(24VAC)

E _ FIELDEARTHGROUND CONDUCTORONCONTROL

N -_ _ FIELDWIRINGSCREWTERMINALEQUIPMENTGROUND -4 e= PLUGRECEPTACLE

BFANR CONTINUOUS-FANSELECTRELAY,SPDT J1 BLOWER-OFFDELAYJUMPER
BHT/CLR BLOWERMOTORSPEEDCHANGERELAY,SPDT SELECTOR

BLWR BLOWERMOTORRELAY,SPST-{N.O.) JB JUNCTIONBOX
BLWM BLOWERMOTOR,PERMANENT-SPLIT-CAPACITOR LED LIGHT-EMITTINGDIODEFOR
CAP CAPACITOR STATUSCODES-AMBER

CPU MICROPROCESSORANDCIRCUITRY LGPS LOWGASPRESSURESWITCH,
EAC-1 ELECTRONICAIRCLEANERCONNECTION SPST-(N.O.)

115VAC1.0AMPMAX.) LPS COLLECTORBOXPRESSURE

EAC-2 ELECTRONCARCLEANERCONNECTON SWITCH,SPST(N.O.)

(COMMON) LS LIMITSWITCH,AUTO-RESET,

FRS1,2 FLAMEROLLOUTSW.-MANUALRESET, SPSTN.C.)

SPST-(N.C.) PCB PRNTEDC RCUTBOARD

FSE FLAME-PROVINGELECTRODE CONTROL
FU1 FUSE,3AMP,AUTOMOTIVEBLADETYPE, PL1 11-CIRCUITPCBCONNECTOR

FACTORYINSTALLED PL2 2..CIRCUITCONNECTOR

FU2 FUSEORCIRCUITBREAKERCURRENT PL3 2..CIRCUITHSI,CONNECTOR

INTERRUPTDEVICE(FIELDINSTALLED&SUPPLIED) PL4 3-CIRCUITIDM,CONNECTOR

GND EQUIPMENTGROUND PL5 5,.CIRCUITBLWMSPEEDTAP
GV GASVALVE-REDUNDANT CONNECTOR

GVR1,2 GASVALVERELAY,DPST..{N.O. PL6 #.CIRCUITBLWMPOWER
HPS INDUCERHOUSINGPRESSURESWITCH,SPST(N.O.) CONNECTOR

HSI HOTSURFACEIGNITER(I15VAC) PL7 1-CIRCUITINDUCERSPLICE
HSIR HOTSURFACEIGNITERRELAY,SPST-(N.O.) CONNECTOR

HUM 24VACHUMDIFIERCONNECTION(0.5AMP.MAX.) TEST_IN COMPONENTTEST&TWlN
IDM INDUCEDDRAFTMOTOR,PSC TERMINAL

IDR INDUCEDDRAFTMOTORRELAY,SPST-(N.O,) TRAN TRANSFORMER-115VAC/24VAC
ILK BLOWERACCESSPANELINTERLOCK

SWITCH,SPST-(N.O.)

IND INDUCTOR(SEENOTE#16) 33831 1-2 Rev. C

PL1 1 NOTE #3

,_:::>>-- PLI-9_

, >-- PL1-7_

Al1409

79

PARTS REPLACEMENT INFORMATION GUIDE

ii

Casing Group

Blower door

Bottom plate
Control door

Door knob assembly
Top filler plate

Electrical Group

3-Amp fuse
Circuit board

Control box
Door switch

Junction box
Linfit switch(es)

Transformer

Blower Group
Blower housing

Blower motor
Blower wheel

Capacitor (when used)
Capacitor strap (when used)

Cut-off plate
Power choke (where used)

Filter Group
Filter(s)

Media Cabinet (when used)

Gas Control Group

Burner

Flame sensor

Gas valve

Hot surface igniter
Manifold

Orifice

Heat Exchanger Group

Containment plate

Coupling box
Heat exchanger assembly
Primary HX cell panel

Secondary HX assembly
Tubing gaskets

Inducer Group

Collector box

Condensate trap

Condensate trap elbow

Gaskets
Inducer

Inducer assembly
Inducer motor capacitor (when used)

Inducer motor module (when used)
Pressure switch(es)

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

1 - 800 - CARRIER

Have available the model number, series number, and serial number located on the unit rating plate to ensure correct replacement part.

Model Nomenclature

MODEL MOTOR WIDTH VOLTAGE MINOR SERIES AIRFLOW

59SP5A 120 E 24 .... 22

FIRE, EXPLOSION, ELECTRICAL SHOCK AND CARBON MONOXIDE POISONING HAZARD
Failure to follow this warning could result in dangerous operation, personal injury, death or property damage.

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)

Copyright 2011 Carrier Corp. * 7310 W. Morris St. * Indianapolis, IN 46231 Printed in U.S.A. Edition Date: 08/11

Manufacturer reserves the right to change, at any time, specification8 and design8 without notice and without obligations,

80

Catalog No: 59SP5A-03SI

Replaces: 59SP5A- 02Sl