Carrier 59TN6A User Manual

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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 ........................................ 5

AIR FOR COMBUSTION AND VENTILATION .......... 9

CONDENSATE TRAP ............................... 12

Upflow ........................................ 12

Downflow ..................................... 12

Horizontal ...................................... 12

CONDENSATE DRAIN ............................. 16

INSTALLATION ................................... 19

Upflow ........................................ 19

Downflow ..................................... 19

Horizontal ...................................... 20

Filter Arrangement ............................... 20

AIR DUCTS ....................................... 27

Ductwork Acoustical Treatment ..................... 27

GAS PIPING ...................................... 31

ELECTRICAL CONNECTIONS ....................... 32

115-V Wiring ................................... 32

J-Box Installation ................................ 33

24-V Wiring .................................... 33

Accessories ..................................... 33

Alternate Power Supplies .......................... 34

VENTING ........................................ 40

Special Venting Requirements for Installations in Canada . 40

Materials ....................................... 41

Venting Systems ................................. 41

Locating Vent Termination ......................... 41

Size the Vent and Combustion Air Pipes ............... 42

Combustion Air and Vent Piping Insulation Guidelines ... 42

Configure the Furnace ............................ 43

Installing the Vent Termination ...................... 44

Venting System Length Calculations ................. 48

START-UP, ADJUSTMENT, AND SAFETY CHECK ...... 61

Select Setup Switch Positions ........................ 61

Prime Condensate Trap ............................. 61

Purge Gas Lines ................................... 61

Adjustments ...................................... 62

Check Safety Controls .............................. 64

Checklist ........................................ 64

SERVICE AND MAINTENANCE PROCEDURES ........ 72

Cleaning Heat Exchangers ........................... 77

SEQUENCE OF OPERATION ........................ 81

PARTS REPLACEMENT GUIDE ...................... 88

TABLE

Loose Parts Bag Contents .............................. 6

Minimum Clearances to Combustible Materials ............. 6

Minimum Free Area Required ......................... 11

Minimum Space Volumes ............................. 11

Filter Size Information ............................... 21

Opening Dimensions ................................ 23

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

Maximum Capacity of Pipe ........................... 32

Electrical Data ...................................... 35

Vent Termination Kit for Direct Vent (2-Pipe) Systems ...... 41

Combustion-Air Vent Pipe, Fitting 8: Cement Material ....... 45

Maximum Allowable Exposed Vent Lengths Insulation ...... 46

Maximum Equivalent Vent Length ...................... 47

Deductions from Maximum Equivalent Vent Length ........ 47

Altitude Derate Multiplier for U.S.A ..................... 69

Blower Off Delay Setup Switch ........................ 69

Gas Rate .......................................... 69

Orifice Size and Manifold Pressure ..................... 70

Always Ask For

Use of the AHRI Cellified rMMark indicates a manufacturer's participation in the program. For

verification of certification for individual products, go to www.ahridirectory.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 a crawl 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) in. 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.

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 not approved for installation in mobile homes,

recreational vehicles, or outdoors. 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). 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:

Safety

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

• 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 copies, contact the National Fire Protection Association Inc., Batterymarch Park, Quincy,

MA 02269; or for only the NFGC contact the American Gas Association, 400 N. Capitol, N.W., Washington DC 20001

• 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-B149.1-2010, 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 @proved 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

control from damage. If the control is to be installed in a furnace, follow items 1 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.AnESDservicekit(availablefromcommercialsources) mayalsobeusedtopreventESDdamage.

ACCESSORIES

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

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 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 iniury or death and unit component damage.

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

shorten furnace life. Air contaminants are found in aerosol sprays, detergents, bleaches, cleaning solvents, salts, air fresheners, and other household products. Do not install

furnace in a corrosive or contaminated atmosphere. Make sure all combustion and circulating air requirements are met, in addition to all local codes and ordinances.

The following types of furnace installations may require

OUTDOOR AIR for combustion due to chemical exposures:

• Commercial buildings

• Buildings with indoor pools

• Laundry rooms

• Hobby or craft rooms

• 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

injury, death and/or property damage. When the furnace is installed in a residential garage, the

burners and ignition sources nmst be located at least 18 in. (457 ram) above the floor. The furnace must be located or protected to avoid damage by vehicles. When the furnace is

FIRE HAZARD

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

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

return-air ducts to the back of the furnace. (See Fig. 4.) installed in a public garage, airplane hangar, or other building having a hazardous atmosphere, the furnace nmst

be installed in accordance with the NFPA 54/ANSI Z223.1-2009 or CAN/CSA B149.2-2010. (See Fig. 5.)

Location Relative to Cooling Equipment

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.

Table 1 - Factory-Supplied Installation Parts

DESCRIPTION

Outlet Choke Plate (provided with 40K BTUH furnaces only; see Note)

Air Intake Pipe Flange

Vent Pipe Flange

Pipe Flange Gaskets

Sharp Tip Screws (Vent and Inlet Flanges)

Vent Pipe Coupling

Vent Pipe Coupling Clamps

Pressure Switch Tube

Rubber Drain Elbow

Drain Tube Clamps

1/2-in. CPVC to 3/4-in. PVC Pipe Adapter

Gas Line Grommet

Junction Box Cover

Junction Box Base

Green Ground Screw

Blunt Tip Screws (Junction Box)

Thermostat Wire Grommet

Drain Extension Tube (Z-pipe) (Provided separately in furnace)

QUANTITY

1 1 1

1 1

1 1 1

1 1

NOTE: Only used for 40K BTUH furnaces from 0-2000 ft. (0 to 610 M) above sea level for total equivalent vent lengths under 10 ft. (3 M)

Table 2 - Minimum Clearances to Combustible Materials for All Units

POSITION CLEARANCE

Rear 0 (0 mm)

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 (0 mm)

Vent 0 (0 mm)

Top of Furnace 1 in. (25 mm)

Recommended

6 15/1_

[176.1]

611116 [17o.1]

26 11/16

_ 26 3/8

_ 23 5/16

- 20 5/8 _

k.i

.=.

-.J

CONDENSATE DRAIN TRAP _\

_r_

LOCAT,ON[1o1.__

THERMOSTAT ENTRY

[670.0]

[592,91

[522.7]

19 1/8

14s5.61_

AIR FLOW

[678.1 ]

25 1/8

[63s.7]

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

[22.a 2 1/2 _-_

_ 3/lO

[76.21

VENT

AIR INTAKE

F_3

/ [76.2]

AIR INTAKE

[44.61

[88,4]

[76.21 1

13/4

FURNACE SIZE

(MODELS)

(59TN6)

060-14

080=14

08_20

100-22 120-22

A S C SHIPPING

(CABINET WIDTH) (OUTLET WIDTH) (BOTTOM INLET WIDTH) D WEIGHT

Inches mm Inches mm inches mm mm LBS KG

171/2 445

21 533

241/2 622

15 7/8 403 16 406

193/8 492 191/2 495

22 7/8 581 23 584

_A_

_B_

OUTLET WIDTH

AIR FLOW

inches

8 3/4

101/2

12 114

140.0 63.0

222

150.0 67.5

154.5 70.2

267

164.5 74.0

311 188.5 84.8

[76.2[

AIR INTAKE

Ill1 =,

NOTE: ALL DIMENSIONS IN INCH [MM]

29 1/2

[749.3]

283/4

173o,51

26 11/16

1678.1 ]

26 3/8

[669.01

227116

[569.8]

1/16

[838.8]

AIR FLOW

_ _ 13/4

[_-61 GAS CONN

.... _/_7/8

[22.2]

.... _7/8

, [22.2]

_ THERMOSTAT ENTRY

[101.61

........ _7/8

[ [22.2] POWER CONN

_ 7/8SIDE INLET

_ 7/8122"21 I

[25.4]

[588,31

1834.o1

26 5/16

[SSS.8]

I I 1518.8 181/.166 2_';'!

[17.5] BOTTOM RETURN [17.5[ 1 5/16

WIDTH [33.3]

[22.2]

23 3/8

[6_.oI

26 3/16

1668.81

SD_02,1 ,':

[26.41

AIRFLOW

THE BLOWER IS LOCATED

TOTHE RIGHT OFTHE

BURNER SECTION, AND

AIR CONDiTiONED AiR iS

DISCHARGED TO THE LEFT.

THE BLOWER iS

LOCATED ABOVE TH E

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

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.

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).

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)

A04003

Table 3 - 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 Round Duct Free Area of Round Duct Free Area of Open- Round Duct

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

60,000 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.

FURNACE WATER HEATER TOTAL INPUT

100,000 + 30,000 = (130,000 divided by 4,000) = 32.5 Sq. In. for each two Vertical Ducts or Openings

60,000 + 40,000 = (100,000 divided by 3,000) = 33.3 Sq. In. for each Single Duct or Opening 80,000 + 30,000 = (110,000 divided by 2,000) = 55.0 Sq, In. for each two Horizontal Ducts

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 60 80 100 120 140

ACH Space Volume Ft3 (M3)

0,60 (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)

0.10 (178.0) (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 2,100 1,680 1,800 2,400 3,000 3,600 4,200

1,575 2,100 2,625 2,100 2,250 3,000 3,750 4,500 5,250

2,100 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

OUTDOORSI "._,_._

_ I I ! JJ }i

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

1sa,a &/ I _o IVENT k-l_

PER2000 "/ ;IBI _ _ ITHROUGH FI:_

BTUFF !i I <;5 I ROOF F_ql S._

,' //I II I1£'"

DUOTS// II 8

, _:

.uT;°ORS// II

..........NN N ',

// II,so

// I II 40(

1SQN /J I _ _ = _M ,

PER 2000 ,_/'IAI _ _ 7- _:_-- BTUFF T :0

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

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

! J I i i BTL

i .......... _ L L_P=-I

A l i i 12"MAX/

OROULAT,.GA,RDUCTS J\

A&BC&DD&EF&G

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

Opening and Duct Opening and Duct ing and Duct

Sq, In (Sq, mm) In. (mm) Dia Sq, In (Sq, mm) In. (mm) Dia Sq, In (mm) In. (mm) Dia.

EXAMPLES: Determining Free Area

-- 1 SQIN.

Duss-h / °TU.

PER 4000

(305mm)

CIRCULATING AiR

I I

1 1

I I

INTERIOR

HEATED

SPACE

DUCTS

VENT THROUGH ROOF

I I

_: 12" AX(S05mm)

-_- 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)

r(305mm)"

:_8TX_ 1so,..

I TO PER 4000

OUTDOORS BTUH*

Outdoors

A03174

CIRCULATING AIR DUCTS

* 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

A03175

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 fllmace in the downflow position.

• Fig. 9 shows the condensate trap and tubing before and after relocation, Refer to Fig. 9 to begin the trap conversion,

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

Condensate Trap - Horizontal Orientation.

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

When the fl_mace 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 (trap grommet) is required for

all direct-vent horizontal installations (only). The kit contains a rubber

casing grommet designed to seal between the furnace casing and the condensate trap. (See Fig. 16.)

NOTE: The Horizontal Installation Kit (trap grommet) is NOT required for single-pipe, ventilated combustion air, or other non-direct vent applications.

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. Allow at least 1/4-in. (6 mm) per foot of slope away from

the furnace in horizontal sections of drain line. To Relocate the Condensate Trap:

• Remove the knockout in the casing for the condensate trap.

• Install the grommet in the casing when required.

• Orient the fl_mace in the desired position.

• Allow for 2 in. (51 mm) of clearance underneath the fllmace 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,

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

Collector Box

Plugs

Condensate Trap

Relief Port

Fig. 8 - Upllow Trap Configuration

Vent Pipe Clamp

Pressure Switch

UPFLOW TRAP CONFIGURATION

1 & 2 Stage Units

(Appearance may vary)

Clamp

Vent Elbow

Collector Box

Plug

Condensate Trap

Relief Port

Trap

Outlet

Port

Al1307

Remove relief tube from relief port on condensate trap.

._ Remove pressure switch tube from

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

,'}_) Remove tube from relief port.

(_ emove the screw

(_) nstall the two plugs

previously removed on the open ports

of the collector box.

that secures the trap to the collector box and

remove trap.

to vent elbow.

(_ Loosen clamp on inlet

(1 and 2 Stage Units)

Remove middle and bottom plugs. DO NOT DISCARD.

Unconverted Factory Configuration as

Viewed in the Downflow Orientation

Connect the new pressure switch tube from Loose Parts bag to /f_ Route tube through inducer port on front pressure switch. _ stand-offs to adjust position

/ _ of the tube.

/ / .| N J Trim excess tube.

/ / Sk"J Connect Pressure switch

/ / / tube to port on collector

_,_ _=_ _ ' / 1 box.

(_ Connect relief tube

to port on collector box.

desired position and

(_ otate elbow to

tighten clamp to

15 lb.-in.

(_ Slide tube in stand-offs

to adjust length.

_ _/(_)_ _/_ f_ Attach condensate trap

_.\__ -_ IP===t II \ 'J J with screw to collector box.

__ _ Connect relief tube to

____------- relief port on condensate

" J,,O I "-I trap.

(1 and 2 Stage Units) /_

Downflow Trap Configuration

Fig. 9 - Downflow Trap Configuration

(Appearance may vary)

Align condensate trap

ports of collector box.

Al1587

collector box.

(_ emove plug from

DO NOT DISCARD.

If alternate vent position is required, loosen clamp

on inlet of vent elbow.

As Viewed in the Horizontal Right Orientation

NOTE: Remove knockout in casing before re-installing the condensate trap.

trap with screw to

(_ ttach condensate

collector box.

1_ Remove the screw that secures

(1 AND 2 STAGE UNITS)

Unconverted Factory Configuration

the trap to the collector box and

remove trap.

Slide relief tube in stand-offs

to adjust length.

Vent elbow shown in alternate

orientation. Tighten clamp on inlet to vent elbow 15 lb.-in.

open port of

(_) nstall plug on

collector box

(1 AND 2 STAGE UNITS)

Horizontal Right Trap Configuration

Fig. 10 - Horizontal Right Trap Configuration

(Appearance may vary)

Align trap over middle and right-hand port on collector box.

Al1573

If alternate vent position is required, loosen clamp

on vent elbow inlet.

from port on collector --

(_ emove relief tube

box.

(1 AND 2 STAGE UNITS)

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

and remove trap.

Remove relief tube from relief port on condensate

trap.

Remove front pressure switch tube and discard.

A new tube is shipped in the Loose Parts bag.

Remove middle and right plug from collector box.

DO NOT DISCARD.

NOTE: Remove knockout in casing before re-installing the

condensate trap.

(_ Rotate 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.

Unconverted Factory Trap Configuration

As Viewed in the Horizontal Left Orientation

Install two plugs previously removed in open ports on

collector box. Connect relief tube to port

on collector box.

Connect the new pressure switch tube from Loose Parts bag to port

on front pressure switch.

(1 AND 2 STAGE UNITS)

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

(Appearance may vary)

Al1574

CONDENSATE DRAIN CONNECTION

FROZEN AND BURST WATER PIPE HAZARD Failure to protect against the risk of freezing may result in

property damage. Special precautions MUST be made if installing furnace in an

area which may drop below freezing. This can cause improper operation or damage to equipment. If furnace environment

has the potential of freezing, the drain trap and drain line must be protected. The use of electric heat tape or RV antifreeze is

recommended for these installations.

PROPERTY DAMAGE HAZARD Failure to follow this caution may result in burst water pipes

and/or property damage.

If a condensate pump is installed, a plugged condensate drain or a failed pump may cause the furnace to shut down. Do not leave the home unattended during freezing weather without turning off water supply and draining water pipes or otherwise protecting against the risk of frozen pipes.

DO NOT trap the drain line in any other location than at the condensate drain trap supplied with the furnace. If possible, DO

NOT route the drain line where it may freeze. The drain line must terminate at an inside drain to prevent freezing of the condensate

and possible property damage. Special precautions MUST be made if installing furnace in an area

which may drop below freezing. This can cause improper operation or damage to the equipment. If the furnace environment

has the potential of freezing, the drain trap and drain line must be protected. A self-regulating, shielded and waterproof heat tape

rated at 3 to 6 watt per foot at 115 volt, 40°F (4°C) may be used to help provide freeze protection. Wrap the drain trap and drain line with the heat tape and secure with the ties. Follow the heat

tape manufacturer's recommendations. Prime the trap before furnace operation.

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/facing the furnace from the front.)

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 rubber drain elbow and two spring clamps from the loose parts bag.

3. Slide a spring clamp 1 inch (25 mm) down the plain end (the end without the formed grommet) of the drain elbow.

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

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

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

spring clamp.

The remaining drain line can be constructed from field supplied

l/2-in. CPVC or 3/4-in. PVC pipe, in compliance with local

building codes. A factory-supplied l/2-in. CPVC to 3/4-in. PVC

adapter is supplied in the loose parts bag for use as required.

7. Install the adapter or connect the l/2-in. CPVC pipe by sliding a spring clamp over the open end of the grommet on

the outside the furnace casing.

8. Open the spring clamp and insert the long end of the adapter or the l/2-in. CPVC pipe into the outlet stub on the

drain tube.

9. Connect additional condensate piping to a code-approved drain, or to a condensate pump approved for use with acidic

furnace condensate and compatible with mineral and

vegetable oils, such as canola oil.

Allow at least l/4-in. (6 mm) per foot of slope away from the furnace in horizontal sections of drain line.

For Left Side Condensate Drain Connection:

1. For left side condensate drainage, the drain line is routed from the condensate trap, behind the inducer (upflow) or

gas valve (downflow) and out through the left side of the furnace casing. A pre-formed l/2-in. CPVC "Z-pipe" is

provided with the furnace. The Z-pipe is long enough to extend across the casing for drain connections.

2. The Z-pipe is connected to the condensate trap and the outside of the furnace by modifying the formed rubber

drain elbow as shown in Fig. 17.

3. Locate the Z-pipe. Remove the pre-formed drain elbow and four spring clamps from the loose parts bag.

4. Remove the formed grommet from the rubber drain elbow

by cutting the elbow along the vertical line located about

1-3/8 in. (35 mm) away from the formed grommet. See Fig.

15. DO NOT DISCARD THE FORMED GROMMET OR THE RUBBER ELBOW. Both of these pieces will be used.

Assemble and route the drain line to the opposite side of the furnace as detailed below:

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

6. From the outside of the casing, insert the angled end of the Z-pipe through drain hole in the side left of the casing and

behind the inducer or gas valve. Allow the Z-pipe to

temporarily rest on the blower shelf (upflow) or burner box (downflow).

7. After inserting the Z pipe through the casing, slide a spring clamp over each end of the Z pipe.

8. From inside the casing, insert the short end of the formed grommet cut from the rubber drain elbow through the

7/8-in. drain knockout in the casing.

9. Pull the grommet through the casing from the outside until it is seated in the knockout.

10. Align the Z-pipe with the long end of the grommet inside the furnace and insert slightly. The angled end of the tube at

the other side of the casing should be facing the front of the furnace.

11. Slide a spring clamp over the end of the remaining rubber drain elbow.

12. Attach the drain elbow to the angled end of Z-pipe and the drain trap outlet stub. Adjust the length of Z-pipe inserted

into the grommet at the opposite side of the furnace as necessary for proper fit and positioning. In both upflow and

downflow orientations, the Z-pipe should NOT be resting on any sheet metal parts.

13.SecuretherubberelbowtothedraintrapandtheZ-pipe withspringclamps.

14.SecurethegrommettotheZ-pipewiththespringclamp.

Theremainingdrainlinecanbeconstructedfromfieldsupplied l/2-in.CPVCor3/4-in.PVCpipe,incompliancewithlocal

buildingcodes.Afactory-suppliedl/2-in.CPVCto3/4-in.PVC adapterissuppliedintheloosepartsbagforuseasrequired.

15.Installtheadapterorconnectthel/2-in.CPVCpipeby slidingaspringclampovertheopenendofthegrommeton

theoutsidethefurnacecasing.

16.Openthespringclampandinsertthelongendof the adapterorthel/2-in.CPVCpipeintotheoutletstubonthe

draintube.

17.Connectadditionalcondensatepipingtoacode-approved drain,ortoacondensatepumpapprovedforusewithacidic

furnacecondensateandcompatiblewithmineraland vegetableoils,suchascanolaoil.

Allow at least l/4-in. (6 mm) per foot of slope away from the fur- nace in horizontal sections of drain line.

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 for direct vent applications, only. The grommet is NOT required for single-pipe, or oth-

er non-direct-vent applications.

2. The condensate trap outlet extends 2 in. (51 ram) 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.

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

4. Install the drain trap grommet in the casing if required for direct vent applications. If necessary, remove the trap, install

the grommet and re-install the trap.

5. Remove the pre-formed rubber drain elbow, and two spring clamps from the loose parts bag.

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

7. Connect the cut elbow or grommet to the outlet of the condensate trap with 1 spring clamp.

The remaining drain line can be constructed from field-supplied l/2-in. CPVC or 3/4-in. PVC pipe, in compliance with local build-

ing codes. A factory-supplied l/2-in. CPVC to 3/4-in. PVC adapter is supplied in the loose parts bag for use as required.

8. Install the adapter or connect the l/2-in. CPVC pipe by sliding a spring clamp over the open end of the elbow or

grommet on the outside the furnace casing.

9. Open the spring clamp and insert the long end of the adapter or the 1/2-in. CPVC pipe into the outlet stub on the

drain tube.

10. Connect additional condensate piping to a code-approved drain, or to a condensate pump approved for use with acidic

furnace condensate and compatible with mineral and vegetable oils, such as canola oil.

Allow at least 1/4-in. (6 ram) per foot of slope away from the furnace in horizontal sections of drain line.

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

_T----TE E

TOOPEN

DRAIN

Fig. 13 - Example of Field Drain Attachment

Al1276

INSTALL CLAMPS ON DRAIN TUBE ATTACH DRAIN TUBE TO CONDENSATE?

DRAIN TRAP

PULL DRAIN STUB /

THROUGH CASING / /

/' / "_\

' : / \

OPEN SPRING CLAMP

INSERT FACTORY-SUPPLIED 1/2-1N. CPVC TO 3/4-1N. PVC ADAPTER OR 1/2-iN CPVC PtPE

*CLAMP MAY BE LOCATED ON OUTSIDE OF DRAIN TUBE

RIGHT SiDE DRAIN iNSTALLATiON

/ \

/ _,

Fig. 14 - Formed Tube Grommet

NOTE: Trap grommet is required only for direct-vent applications.

Remove knockout, Install grommet before

relocating condensate

trap.

Al1342A

Fig. 16 - Horizontal Drain Trap Grommet

Al1582

Cut line for left side condensate drain.

Do not disc

l !

Attach tube to condensate

Cut formed end off

Formed end of grommet

of "Z" pipe to modified

condensate drain tube

Connect short end

ube

Factory supplied 1/2-in. CPVC to

3/4-in. PVC adapter

TRAP, DRAIN ELBOW WITH DISCHARGE PIPE

Formed end of grommet Open spring clamp. Insert 1/2-in. to 3/4-in. CPVC to

PVC adapter or 1/2-in.

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

CPVC pipe

1-3/8 in (35 ram)

Fig. 15 - Modify Drain 1hbe

Al1581

LEFT SIDE DRAIN ROUTED BEHIND INDUCER

Al1583

Fig. 17 - Drain Trap Connection and Routing

(Appearance May Vary)

INSTALLATION

NOTE: This furnace is certified to leak 2% or less of nominal air conditioning CFM delivered when pressurized to 1-inch water

column with all present air inlets, air outlets, and plumbing and electrical ports sealed, including bottom closure in upflow and

horizontal applications.

Upflow Installation

NOTE: The furnace must be pitched 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, humidifier, 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 injury,

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

Follow instructions below.

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 must be pitched 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. Determine application being installed from Table 6.

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

3. Construct plenum to dimensions specified in Table 6 and Fig. 19.

4. Install special base coil assembly or coil box as shown in in Fig. 19.

NOTE: It is recommended that the perforated supply-air duct flanges be completely removed from furnace when installing the furnace on a factory-supplied cased coil or coil box. To remove the supply-air duct flange, use wide duct pliers or hand seamers to bend flange back and forth until it breaks off. Be careful of sharp edges. (See Fig. 20.)

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

mm) (max) corrosion-resistant machine bolts, washers and nuts. NOTE: Bottom closure must be used when leveling legs are used.

It may be necessary to remove and reinstall bottom closure panel to install leveling legs. To remove bottom closure panel, see Item 1 in Bottom Return Air Inlet section in Step 1 above.

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.

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 must 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-@proved accessory subbase, or a factory-@proved air conditioning coil casing. DO NOT cut main

furnace casing to attach supply side air duct, humidifier, or other

accessories. All accessories MUST be connected to duct external to furnace 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 must be connected to return-air opening (bottom inlet). DO NOT cut into casing sides (left or right).

Bypass humidifier 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:

Horizontal Installation

NOTE: The furnace must 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. 270 For furnaces with 1-in. (25 mm) 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. 280 Secure angle iron to bottom of furnace as shown.

Roll-Out Protection

Provide a minimum 12-in. x 22-in. (305 x 559 mm) piece of sheet metal for flame roll-out protection in front of burner area for furnaces closer than 12-in. (305 mm) above the combustible deck

or suspended furnaces closer than 12-in. (305 mm) to joists. The sheet metal MUST extend underneath the furnace casing by 1-in.

(25 mm) with the door removed. The bottom closure panel on furnaces of widths 17-1/2-in. (445

mm) 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.

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.

FIRE, EXPLOSION, AND CARBON MONOXIDE POISONING HAZARD

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

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

return-air ducts to the back of the furnace.

MINOR PROPERTY HAZARD

Failure to follow this caution may result in minor property damage,

Local codes may require a drain pan under entire furnace and condensate trap when a condensing furnace is used in an attic application or over a finished ceiling.

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:

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 fre, personal iniury 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.

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

mm) filter or 4-in. (102 mm) 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

mm) Media Cabinet is shipped with the 14-3/16-in. (360 mm) 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.)

Fordownflowapplications,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

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.

horizontal position, refer to Fig. 26. If both side and bottom openings are used in Fig. 26, each opening used will require a

filter.

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 635 x 19) (406 x 635 x 19)

21 (533) (406 x 635 x 19) (508 x 635 x 19)

24-1/2 (622) (406 x 635 x 19) (610 x 635 x 19)

Recommended to maintain air filter face velocity. See Product Data for part number.

1- 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 3/4 16 x 25 x 3/4 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 3/4"

(406 x 635 x 19) or Washable or Media*

(406 x 665 x 11 O)

(1) 20 x 25 x 6/4"

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

(508 x 665 x 11 O)

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

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

(610 x 635 x 11 O)

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

Furnace

21-in. Furnace

4:Ibn or less, AC

capaci b, airflow

4-in. Block Off Plate

16-in. Media Cabinet

Media Cabinet lnstallatig-n

Side Return

it ,4

21- or 24-1/2-in.

Furnace

Up to 5-rlbn AC

capacity airflow

20- or 24-in. Media

Cabinet

Bottom Return Plenum

20- or -24-in. Media Cabinet Installation

for Combination Side and Bottom Return

20-in. Media Cabinet

Media Cabinet Installation Option for

4-Ton or Less A/C Capacity

it ,4

21-in, Furnace up to 5-Ton AC

Capacity

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

Capacity

<_45 °

Transition j

20- or 24-in. Media Cabinet

20- or -24-in. Media Cabinet Installation

with Angled Transition

14 3/16 in. Furnace

Screw } ._1 I_. =:Screw

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

14 3/16 in. Furnace

Ncrews]l 5

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

A11437

Fig. 18 - Media Filter

(OR COIL CASING

WHEN USED)

FURNACE

APPROVED

COIL ASSEMBLY

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

14-3/16*

(360) Downflow applications on combustible flooring (KGASB sub- 11 - 13/16 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 16-3/4 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

(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 23- 3/4 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 we 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

A10491

DISCHARGE DUCT FLANGE

UPFLOW DOWNFLOW HORIZONTAL

[......

(8mm)

(44mm)

120 °_

MIN

YES

120°_

YES

MIN

A10493

Fig. 20 - Duct Flanges

(8mm)

(44mm) 13/4"

(44mm) 1

Fig. 21 - Leveling Legs

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

__ J

FRONT

UPFLOW OR DOWNFLOW

Fig. 23 - Furnace Pitch Requirements

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

HORIZONTAL

Al1237

NOT PERMITTED

l 0

n_lunN

AI_

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

F/ET JRN

AIR

A11036

Fig. 24 - Upflow Return Air Configurations and Restrictions

HORIZONTAL

(

RETURN NOT PERMITTED FOR

NOTE: RESTRIO11ON SAME FOR

14ORIZONAI I_T AIR

Fig. 25 - Downflow Return Air Configurations

and Restrictions

HORIZONAL RETURN AIR

RESTRICTIONS

Al1037 /

Fig. 26 - Horizontal Return Air Configurations

and Restrictions

Al1038

COMBUSTION-AIRPIPE (SEEVENTINGSECTION)-X

A 12-1N. (305 mm) MIN HORIZONTAL PIPE \

SECTION IS RECOMMENDED WITH A SHORT (5 TO 8 FT / 1.5 TO 2.4 M) VENT

SYSTEM TO REDUCE EXCESSIVE CONDENSATE DROPLETS FROM EXITING THE VENT PIPE.

MANUAL SHUTOFF _INDOOR

GAS VALVE / COIL

SEDIMENT_ CONDENSATE

TRAP TRAP

30 IN. (762 mm)

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

a rea.

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

VENTING SECTION FOR ALLOWABLE VENT CONFIGURATIONS

Fig. 27 - Working Platform for Attic Installation

NOTE: Local codes may require a drain pan and condensate trap when a condensing furnace is installed over a finished ceiling.

COMBUSTION-AIRPIPE

_(SEEVENTINGSECTION)

_1/4-IN ROD

NOTE: EXTEND ANf

IRON OUT FOR COIL SUPPORT/ HEX NUT

& WASHER (4)

REQD. PER ROD

ROD LOCATION / USING DIMPLE /

LOCATORS

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

top of furnace and combustible material

Al1154

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

3. Furnace shown is a direct vent application. Refer to the Venting section for allowable vent

configurations.

Fig. 28 - Suspended Furnace Installation

NOTE: Local codes may require a drain pan and condensate trap when a condensing furnace is installed over a finished ceiling.

Al1155

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.

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.

Unit Size

080-14

CIg Default:

Table 7 - Cooling 4 and Heating Air Delivery - CFM (Bottom Retnrn 5 with Filter)

Clg/CF Switch Settings I External Static Pressure (ESP)

swx-3i swx-2I swx-1I 0.110.210.3 10.410.510.610.7 10.6 10.911.0

OFFI OFFI OFF 11060110701106011060110751106511050110351102511010

OFDe_ult:I OFFI OFFI OFF15451530152015251510I

OFF OFF ON 545 530 520 525 510 See note 4

OFF ON OFF 710 710 710 695 690 See note 4

OFF ON ON 875 880 890 895 895 890 885 880 870 855

Coohng (SW2)

Cont Fan

(sw3)

CIg SW2:

Heating

(swl)

ON OFF OFF 1060 1070 1080 1080 1075 1065 1050 1035 1025 1010

ON OFF ON 1235 1240 1250 1255 1255 1250 1230 1190 1155 1115

ON ON OFF 1235 1240 1250 1255 1255 1250 1230 1190 1155 1115

ON ON ON 1235 1240 1250 1255 1255 1250 1230 1190 1155 1115

I M_x,momo,_A,rf,ow211425114251140511370113351130011260112251119011155

LowHeotA,rf,ow31655165516601670167016651660165516451765

Unit Size

080-14

CIg Default:

Clg/CF Switch Settings I External Static Pressure (ESP)

swx-3i swx-2I swx-1I 0.110.210.3 10.410.510.610.7 10.6 10.911.0

OFFI OFFI OFF 11055110651106011075110651105011045110351102511005

See note 4

I I I

CFSefault: I OFF I OFF

OFF OFF

I OFF15201505150514951490I

ON 520 505 505 495 490 See note 4

See note 4

I I I

Coohng (SW2)

Cont Fan

(SW3)

OFF ON

ON OFF

ON ON OFF 1245 1245 1255 1255 1260 1255 1250 1235 1220 1185

ON ON ON 1245 1245 1255 1255 1260 1255 1250 1235 1220 1185

OFF 665 685 680 660 665 See note 4

ON 885 895 905 900 900 895 885 875 860 845

OFF 1055 1065 1080 1075 1065 1050 1045 1035 1025 1005

ON 1245 1245 1255 1255 1260 1255 1250 1235 1220 1185

o/gsw2:I M_x,momo,_A,rf,ow2115201465114501415113751335113001265112251190

Heating

(SW1) H ig h Heat Airflow 3 1520 1485 1450 1415 1375 1335 1300 1265 1225 1190

Low Heat Airflow 3 1055 1065 1080 1075 1065 1050 1045 1035 1025 1005

Unit Size

080-20

CIg Default:

Table 7 - Cooling 4 and Heating Air Delivery - CFM (Bottom Return 5 with Filter) (Continued)

Clg/CF Switch Settings I External Static Pressure (ESP)

swx-3i swx-2I swx-1I 0.110.210.3 10.410.510.610.7 10.6 10.911.0

OFFI OFFI OFF 11745117551175511760117551175011745117251170511665

OFDe_ult:I OFFI OFFI OFF17001710175017251750I

OFF OFF ON 700 710 750 725 750 See note 4

OFF ON OFF 830 860 870 890 960 See note 4

OFF ON ON 1045 1045 1060 1070 1070 1070 1095 1090 1080 1070

Coohng (SW2)

Cont Fan

(SW3)

CIg SW2:

Heating

(SWl)

Unit Size

ON OFF OFF 1215 1220 1245 1240 1235 1235 1225 1220 1235 1235

ON OFF ON 1370 1370 1390 1390 1400 1395 1400 1390 1390 1385

ON ON OFF 1745 1755 1755 1760 1755 1750 1745 1725 1705 1685

ON ON ON 1745 1755 1755 1760 1755 1750 1745 1725 1705 1685

M_x,momO,_A,rf,ow2119201920119451945119451960119501940119151900

Htgh Heat Atrflow 3 1340 1355 1370 1385 1380 1385 1400 1400 1385 1380

Low Heat Atrflow 3 1080 1115 1115 1120 1125 1135 1125 1120 1125 1110

Clg/CF Switch Settings I External Static Pressure (ESP)

swx-3i swx-2I swx-1i 0.1 0.210,3 0.410,5 0.610,7 0.610,9

100-22

CIg Default:

OFFI OFFI OFF I 16201625I 16401645I 16401635I 16251605I 1760

See note 4

I I I

1.0

1770

OFDe_ult:I OFFI OFFI OFF1750 7401745 7301715 Seenote4

OFF OFF ON 750 740 745 730 715 See note 4

I I

OFF ON OFF 900 900 915 910 905 See note 4

OFF ON ON 1070 1075 1095 1095 1090 1085 1095 1080 1065 1070

Coohng (SW2)

ContFan

(sw3)

ON OFF OFF 1280 1285 1305 1305 1310 1305 1295 1300 1290 1285

ON OFF ON 1440 1445 1465 1465 1470 1485 1480 1485 1475 1460

ON ON OFF 1820 1825 1840 1845 1840 1835 1825 1805 1780 1770

ON ON ON 2135 2140 2140 2135 2140 2130 2115 2100 2070 2015

o/gsw2:I M_x,momo,_A,rf,ow2121602165121752170121602150121352120120652020

Heatmg

(swl)

Htgh Heat Atrflow 3 1570 1575 1595 1595 1600 1605 1600 1600 1590 1575

Low Heat At rflow 3 1365 1385 1395 1395 1395 1400 1400 1405 1395 1380

2t)

Table 7 - Cooling 4 and Heating Air Delivery - CFM (Bottom Return 5 with Filter) (Continued)

Unit Size

CF Default: OFF See note 4

OFF ON 745 705 680 See note 4

OFF OFF 925 900 885 See note 4

OFF ON 1100 1105 1085 See note 4

Cooling (SW2) ....

Cont Fan

(SW3) ....

CIg SW2: Maximum CIg Airflow 2

ON OFF 1255 1280 1275 1285 I 1270 1260 1250 1230

ON ON 1455 1465 1465 1470 I 1455 1450 1435 1415

ON OFF 1855 1855 1850 1830 I 1805 1775 1750 1730

ON ON 2200 2190 2185 2170 I 2145 2085 1990 1890

Switch Settings External Static Pressure (ESP)

SWx-1

Heating

(SWl)

_. Set SW1-5 to ON for nominal 400 CFM/ton (+15% airflow).

Set SW4-3 to ON for nominal 325 CFM/ton (-7% airflow). Set both SW1-5 and SW4-3 to ON for nominal 370 CFM/ton (+7% airflow).

The above adjustments in airflow are subject to motor horsepower range/capacity.

2. Maximum cooling airflow is achieved when switches SW2-1, SW2-2, SW2-3 and SW1-5 are set to ON, and SW4-3 is set to OFF.

3. All heating CFM's are when low heat rise adjustment switch (SW1-3) and comfort/efficiency adjustment switch (SW1-4) are both set to OFF.

4. Ductwork must be sized for high-heating CFM within the operational range of ESP. Operation within the blank areas of the chart is not re- commended because high-heat operation will be above 1.0 ESP.

5. All airflows on 21" (533 mm)casing size furnaces are 5% less on side return only installations.

6. Side returns for 24.5" (622 mm)casing sizes require two sides, or side and bottom, to allow sufficient airflow at the return of the furnace.

7. Airflows over 1800 CFM require bottom return, two-side return, or bottom and side return; otherwise excessive watt draws may result. A minimum filter size of 20" x 25" (508 x 635 mm) is required.

Low Heat Airflow 3

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

line.

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

separate line running directly from meter to furnace. 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.

NOMINAL LENGTH OF PIPE - FT (M)

IRON PIPE

1-1/4 (32) 1400 950 770 550 580 1-1/2 (39) 21 O0 1450 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/ANSl Z223.1-2009.

Table 8 - Maximum Capacity of 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) 350 250 200 170 151

1 (25) 580 455 375 320 285

Left Side Gas Entry. Gas Pipe Grommet Required For Direct

Vent Applications.

Gas Pipe Grommet Required For Direct Vent Applications

Fig. 29 - Gas Entry

Al1338

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.

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.

FRONT

MANUAL ,._

SHUTOFF [

VALVE

(REQUIRED)

SEDIMENT TRAP

Fig. 30 - Typical Gas Pipe Arrangement

UNION _

NOTE: Union may be inside the vestibule where permitted by

local codes.

Al1035

ELECTRICAL CONNECTIONS

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.

l15-V Wiring

Furnace must have a l15-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.

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.

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.

Thermostats

A single stage heating and cooling thermostat can be used with the furnace. The furnace control board CPU will control the furnace

and outdoor unit staging. A two stage heating and cooling thermostat can also be used to control the staging. For two stage thermostat control of the furnace staging, turn SWI-2 ON at the

furnace control board, For two stage thermostat control of a 2-stage outdoor unit, remove the ACRDJ jumper from the furnace control

board. Refer to typical thermostat wiring diagrams and the

Sequence of Operation section for additional details, Consult the thermostat installation instructions for specific information about

configuring the thermostat, See Fig. 35 and 36,

Accessories .(See Fig. 33 and 350

1, Electronic Air Cleaner (EAC)

Connect an accessory Electronic Air Cleaner (if used) using l/4-in, female quick connect terminals to the two male l/4-in, quick-connect terminals on the control board

marked EAC-I 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 blower 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.)

3. Communication Connector (communication connection) This connection is used when the furnace is controlled by

an optional communicating User Interface instead of a standard thermostat. The communication plug is supplied

with the User Interface. Refer to the instructions supplied with the User Interface for complete details. See Fig. 35.

4. Outside Air Thermistor (OAT) The OAT connection is used in coniunction with commu-

nicating User Interface. It is not required when the furnace is controlled by a standard type thermostat. Refer to the in-

structions supplied with the User Interface for complete de- tails.

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 alternate power supply must generate the same voltage, phase, and

frequency (Hz) as shown in Table 9 or the furnace rating plate. Power from an alternate power supply that is non-sinusoidal may

damage the furnace electronics or cause erratic operation. Contact the alternate power supply manufacturer for specifications

and details.

Table9- Electrical Data

TWO-STAGE ECM FURNACES

UNIT SIZE VOLTS-

HERTZ-

PHASE

080-14 115-60-1 127 104 8.5 080-14 115-60-1 127 104 8.5

080-20 115-60-1 127 104 13.6

100-22 115-60-1 127 104 13.7 120-22 115-60-1 127 104 13.7

*Permissiblelimitsofthevoltagerangeatwhichtheunitoperatessatisfactorily.

# 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.

OPERATING VOLTAGE

RANGE*

Maximum* Minimum*

MAXIMUM

UNIT

AMPS

UNIT

AMPACITY#

11.5

17.9

18.0

MINIMUM

WIRE

SIZE

AWG

14 14

12 12 12

MAXIMUM

WIRE

LENGTH

FT (M):I:

32 (9.8) 32 (9.8)

32 (9.8) 31 (9.4) 31 (9.4)

MAXIMUM

FUSE OR CKT

BKR

AMPSI"

15 15

2O 2O 2O

Jq3OX _ MOUNTING

SCREWS _"--.

J-BOX

MOUNTING BRACKET

GROUND

LINEVOLTAGE

GROUND_

NEUTRAL'

ELECTRIC

DISCONNECT

SWITCH

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

A11299

Al1146

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

I TO Hum_dilier Leads

I To Hum_dff_e r Leads

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

NOTE 2

-_ To HUMTerminal On I

Furnace Conirol Board

.... FIELD 24-VOLT WIRING

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

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

208/230- OR 460-VOLT

Al1157

TERMINAL

BLOCK

FURNACE

Fig. 34 - Typical Two-Stage Field Wiring Diagram

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

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

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

CONDENSING

UNIT

A11401

MODEL PLUG

CONNECTOR _

SWI SETUP

SWITCHES AND

BLOWER OFF- _DELAY

AIR CONDITIONING

(A/C) AIRFLOW

SETUP SWITCHES

COMMUNICATION

CONNECTOR

CONTINUOUS FAN

(CF) AIRFLOW

SETUP SWITCHES

OUTDOOR SW4 SETUP

AIR TEMP SWITCHES

HUMIDIFIER

_-_ TERMINAL (24WAC

0.5 AMP MAX.

24-V THERMOSTAT

TERMINALS <

STATUS AND COMM

LED LIGHTS

FUSE3-AMP

3-AMP FUSE _ SEC-2 SEC-1 _D I I I I

ACRDJ

[] []

[] [] []

" z "T E_Cq

TRANSFORMER_4_VAC'_"E_I=_--' = __L_ I I

CONNECTIONS

/ I I

====F_I_ 1 ,--. Iq_oo_ I I

115-VAC (L2) NEUTRAL _,---4 _Z m . . 'k

_V Iv17HK42FZ0433411 == -_'X&I VS.S,HI LO_%

c /,oil T \ \\

PLH_ARNLOWsVcOoLTNAGcETMoAR_N/ "---1/ PA_TNUMB_ANyD VOL_I_VACo(L_L;NT_oNS\

SOFTWARE EAC-I TERMINAL

VERSION (115-VAC 1.0 AMP MAX.)

Fig. 35 - Example of Variable Speed Furnace Control

ACRDJ - AIR

CONDITIONING

RELAY DISABLE

JUMPER

O_ FLASH

UPGRADE

CONNECTOR

(FACTORY

ONLY)

PL3-ECM BLOWER

HARNESS

CONNECTOR

PL2-HOTSURFACE

IGNITER&INDUCER

MOTOR CONNECTOR

Al1617

THERMOSTAT TWO-STAGE SINGLE-SPEED THERMOSTAT

FURNACE AIR CONDITIONER FURNACE HEAT PUMP

TWO-STAGE SINGLE-SPEED

HEAT STAGE 2 __

N/Ar_

HEAT STAGE 1 __

COOL STAGE 1 __

FAN __

24 VAC HOT _ _

DEHUMIDIFY __

24 VAC COMM __

HUMIDIFY __

N/A I_

OUTDOOR [[_!_- ........ _/ OUTDOOR L_,

SENSOR _ / SENSOR _' ',

CONNECT,ONLl_q ............................ :

Modulating and 2-Stage Furnace with Single-Speed Air Conditioner

THERMOSTAT

HEAT STAGE 2 __

COOL STAGE 1 I__

HEAT STAGE 1 __

COOL STAGE 2 __

FAN __

24 VAC HOT __

DEHUMIDIFY [___

24 VAC COMM __

HUMIDIFY I_1_ _

N/A I_

%_E_&%OR_-I_ -

--N-°--T!JI--

C!3

.........._ ........._-D

.........._:: ......._[3

I HUM "''"

....... _t HUMIDIFIER(24VAC) ___i

See notes 2, 5, 7, 10, 11, and 16

TWO-STAGE TWO-SPEED

FURNACE AIR CONDITIONER

NOTE 11

NOTE 12

........ HUMIDIFIER ____

........ _ OUTDOORsENSOR

-F_q

-I_q

I HUM

(24 VAC)

CONNECT,ONLIZS-

See notes 2, 5, 8, 10, 11, 12 and 16

Modulating and 2-Stage Furnace with Two-Speed Air Conditioner

Fig. 36 - Thermostat Wiring Diagrams

RVS COOLING

HEAT STAGE 3 r_

(FURNACE HI)

NOTE 11

-E_

F_q

HEAT STAGE 2

(FURNACE LO)

HEAT/COOL STAGE 1

(COMPRESSOR)

FAN __

24 VAC HOT

DEHUMIDIFY

24 VAC COMM

HUMIDIFY

N/A I_

- 1_]- .......

- [_c_- .....

...... .VAC,

......_]

HUM "'" .....

HUMIDIFIER _'

......

CON"EOT'ONLIZ5

See notes 1, 2, 4, 6, 7, 9, 10,11, 15, and 16

Modulating and 2-Stage Furnace with Single-Speed Heat Pump

THERMOSTAT TWO-STAGE TWO-SPEED

RVS COOLING

HEAT/COOL STAGE 1

(COMPRESSOR LO) r_

HEAT STAGE 3 I_

(FURNACE)

HEAT/COOL STAGE 2

(COMPRESSOR HI)

FAN

24 VAC HOT

DEHUMIDIFY

24 VAC COMM

HUMIDIFY [_

N/A [_

OUTDOOR [ -_1- ....... 6_J OUTDOOR l_

SENSOR--q-- [ SENSOR I..... ;

............_ ...... RLD

.... (24 VAC)

CONNECT,ONLI_ -- I

See notes 1,2,3,4,6,8,9, 10, 12, 13, 15, and16

Modulating and 2-Stage Furnace with Two-Speed Heat Pump

FURNACE HEAT PUMP

__ -_-D

F_q

....... IZ!D::-....

I HUM """ ......... s

-- i

_q HUMIDIFIER t_L

Al1274

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. Configuration 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. Optional connection - If wire is connected to W2 on furnace control board, either dip switch SWI-2 or SWI-LHT on furnace control should be set in ON position to allow thermostat to control furnace staging.

12. Optional connection - If wire is connected, ACRDJ jumper on furnace control should be removed to allow thermostat to control outdoor unit staging.

13. Furnace must control its own staging operation via furnace control algorithm. This is factory default.

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

15. 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

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

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 IPEXInc.

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 arrat 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 personnel qualifid et ce, une fois par annde.

Les autoritd es 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.

A furnaceshallnotbeconnectedto 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 DIAM. OF COMBUS-

(2-PIPE) SYSTEM TION AIR AND VENT

TERMINATION KIT PIPES - IN. (mm)

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

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

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

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

2-in. (51 mm) 2-Pipe Termination 1, 1-1/2 or 2

Termination Bracket

Kit System (25, 36, 51 mm)

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

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 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-BI49.1-10. 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. See Table 10 for available options.

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.

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 air terminations 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 ram) 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 ram) pipe. Any pipe diameter change should be made

outside furnace casing in vertical pipe. Any change in 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 Maxinmm Equivalent Vent

Length in Table 13 or 15, minus the number of fittings nmltiplied 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 Maxinmm 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 (Alberta and Saskat- chewan, when required) record the equivalent length of the

Tee used.

6. Calculate each individual Maximum Vent Length by sub- tracting the equivalent lengths of the fittings of the individu-

al vent and combustion air pipes from the Maximum Equi-

valent Vent Length shown in Table 13 and 15.

7. 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.

8. 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: If the calculated Maximum Vent Lengths results in different diameter pipes for the vent and combustion air, select the larger diameter for both pipes.

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 fittings 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 pipe lengths of 10 ft. (3.0 M) or less, 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.

For vent systems longer than 10 ft. (3.0 M), any larger diameter show in Table 13 or 15 may be used.

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.

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 in 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 l/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 Fig. 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.

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 mm) flashing for a 2 in. (51 mm) concentric vent or a 5-in. diameter

(127 mm) flashing for a 3-in. (76 mm) 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 must 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 mm) diameter hole for 2-in. (51 mm) kit, or

one 5-in. (127 mm) diameter hole for 3-in. (76 mm) 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 mm) 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 mm) 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 mm) 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.

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

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

Two Stage

Furnace High

Heat Input

40000*

60000

80000

Table 12 - Maximum Allowable Exposed Vent Lengths Insulation Table - Ft. / M

No Insulation 3/8-in. (9.5 mm)

Winter Design

Tempo F (oC)

20 (-10)

0 (-20)

-20 (-30)

-40 (-40)

20 (-10) M 9.1 15.5 15.5 13.7 N/A 9.1 41.1 42.1 36.6 N/A 9.1 41.1 49.4 43.0 N/A

0 (-20) M 9.1 7.3 7.0 4.9 N/A 9.1 28.3 25.0 21.0 N/A 9.1 33.8 29.9 25.3 N/A

-20 (-30) M 5.5 3.4 2.7 0.3 N/A 9.1 19.8 17.1 13.4 N/A 9.1 24.1 20.7 16.8 N/A

-40 (-40) M 3.0 0.9 0.0 0.0 N/A 9.1 14.6 12.2 8.8 N/A 9.1 18.0 15.2 11.6 N/A

20 (-10) M 6.1 19.5 19.5 17.1 14.3 6.1 21.3 52.7 45.7 38.1 6.1 21.3 53.3 53.9 44.8

0 (-20) M 6.1 9.8 9.1 6.7 3.4 6.1 21.3 31.7 26.5 20.4 6.1 21.3 37.8 31.7 25.0

-20 (-30) M 6.1 5.2 4.3 1.8 0.0 6.1 21.3 21.6 17.4 12.2 6.1 21.3 26.2 21.6 15.8

-40 (-40) M 4.6 2.1 1.5 0.0 0.0 6.1 18.6 15.8 12.2 7.3 6.1 21.3 19.5 15.2 10.1

Pipe

Length in

Ft. &M

Ft.

Ft. 30.0 51.0 51.0 45.0 N/A 30.0 135.0 138.0 120.0 N/A 30.0 135.0 162.0 141.0 N/A

Ft. 30.0 24.0 23.0 16.0 N/A 30.0 93.0 82.0 69.0 N/A 30.0 111.0 98.0 83.0 N/A

Ft. 18.0 11.0 9.0 1.0 N/A 30.0 65.0 56.0 44.0 N/A 30.0 79.0 68.0 55.0 N/A

Ft. 10.0 3.0 0.0 0.0 N/A 30.0 48.0 40.0 29.0 N/A 30.0 59.0 50.0 38.0 N/A

Ft. 20.0 64.0 64.0 56.0 47.0 20.0 70.0 173.0 150.0 125.0 20.0 70.0 175.0 177.0 147.0

Ft. 20.0 32.0 30.0 22.0 11.0 20.0 70.0 104.0 87.0 67.0 20.0 70.0 124.0 104.0 82.0

Ft. 20.0 17.0 14.0 6.0 0.0 20.0 70.0 71.0 57.0 40.0 20.0 70.0 86.0 71.0 52.0

Ft. 15.0 7.0 5.0 0.0 0.0 20.0 61.0 52.0 40.0 24.0 20.0 70.0 64.0 50.0 33.0

PipeDiametePinches(mm)

1.5 2.0 2.5 3.0 4.0

(38) (51) (64) (76) (102)

40.0 35.0 35.0 N_ N_

12.2 10.7 10.7 N_ N_

19.0 14.0 12.0 N_ N_

5.8 4.3 3.7 N_ N_

9.0 3.0 1.0 N_ N_

2.7 0.9 0.3 N_ N_

3.0 0.0 0.0 N_ N_

0.9 0.0 0.0 N_ N_

PipeDiametePinches(mm)

1.5 2.0 2.5 3.0 4.0

(38) (51) (64) (76) (102)

50.0 104.0 94.0 N_ N_

15.2 31.7 28.7 N_ N_

50.0 61.0 54.0 N_ N_

15.2 18.6 16.5 N_ N_

50.0 41.0 35.0 N_ N_

15.2 12.5 10.7 N_ N_

39.0 29.0 23.0 N_ N_

11.9 8.8 7.0 N_ N_

1/2-in.(12.7mm)

PipeDiamete_inches(mm)

1.5 2.0 2.5 3.0 4.0

(38) (51) (64) (76) (102)

50.0 122.0 110.0 N_ N_

15.2 37.2 33.5 N_ N_

50.0 74.0 65.0 N_ N_

15.2 22.6 19.8 N_ N_

50.0 51.0 43.0 N_ N_

15.2 15.5 13.1 N_ N_

48.0 37.0 30.0 N_ N_

14.6 11.3 9.1 N_ N_

Ft. N/A 25.0 79.0 70.0 59.0 N/A 25.0 110.0 186.0 155.0 25.0 110.0 219.0 182.0

20 (-10) M N/A 7.6 24.1 21.3 18.0 N/A 7.6 33.5 56.7 47.2 7.6 33.5 66.8 55.5

Ft. N/A 25.0 40.0 31.0 19.0 N/A 25.0 110.0 109.0 86.0 25.0 110.0 131.0 104.0

100000

120000

* Not all families have these models. * Pipe length (ft) specified for maximum pipe lengths located in unconditioned spaces. Pipes located in unconditioned space cannot exceed total allowable pipe

length calculated from Table 13 or 15. 1-Insulation thickness based on R value of 3.5 per in.

0 (-20) M N/A 7.6 12.2 9.4 5.8 N/A 7.6 33.5 33.2 26.2 7.6 33.5 39.9 31.7

Ft. N/A 23.0 21.0 13.0 0.0 N/A 25.0 91.0 74.0 54.0 25.0 110.0 90.0 68.0

-20 (-30) M N/A 7.0 6.4 4.0 0.0 N/A 7.6 27.7 22.6 16.5 7.6 33.5 27.4 20.7 Ft. N/A 13.0 10.0 1.0 0.0 N/A 25.0 68.0 53.0 35.0 25.0 83.0 66.0 46.0

-40 (-40) M N/A 4.0 3.0 0.3 0.0 N/A 7.6 20.7 16.2 10.7 7.6 25.3 20.1 14.0

Ft. N/A N/A 15.0 85.0 73.0 N/A N/A 15.0 100.0 190.0 N/A N/A 15.0 100.0 224.0

20 (-10) M N/A N/A 4.6 25.9 22.3 N/A N/A 4.6 30.5 57.9 N/A N/A 4.6 30.5 68.3

Ft. N/A N/A 15.0 41.0 29.0 N/A N/A 15.0 100.0 109.0 N/A N/A 15.0 100.0 131.0

0 (-20) M N/A N/A 4.6 12.5 8.8 N/A N/A 4.6 30.5 33.2 N/A N/A 4.6 30.5 39.9

Ft. N/A N/A 15.0 20.0 7.0 N/A N/A 15.0 94.0 71.0 N/A N/A 15.0 114.0 88.0

-20 (-30) M N/A N/A 4.6 6.1 2.1 N/A N/A 4.6 28.7 21.6 N/A N/A 4.6 34.7 26.8 Ft. N/A N/A 15.0 7.0 0.0 N/A N/A 15.0 69.0 48.0 N/A N/A 15.0 85.0 62.0

-40 (-40) M N/A N/A 4.6 2.1 0.0 N/A N/A 4.6 21.0 14.6 N/A N/A 4.6 25.9 18.9

NOTE: Maximum Equivalent Vent Length (MEVL) includes standard and concentric vent termination and does NOT include elbows.

Use Table 14 - Deductions from Maximum Equivalent Vent Length to determine allowable vent length for each application.

Table 13 - Maximum Equivalent Vent Length - Ft. (M)

0 to 4500 Ft. (0 to 1370 M) Altitude

Unit Size

Altitude

BTU/Hr

FT (M)

40,000 _ (64.0) 250 (76.2)

60, OOO (41.1) 235 (71.6) 265 (80.8) 0 to 2000 80,000 (21.3) 175 (53.3) 235 (71.6) 265 (80.8) (0 to 610) 100,OOO (7.6) 110 (33.5) 235 (71.6) 265 (80.8)

2001 to 3000 80,000 (19.5) 165 (50.3) 222 (67.7) 249 (75.9)

(610 to 914) 100,OOO (6.7) 104 (31.7) 223 (68.0) 250 (76.2)

3001 to 4000 80,000 (18.0) 155 (47.2) 210 (64.0) 232 (70.7)

(914 to 1219) 100,OOO (5.8) 96 (29.9) 211 (64.3) 236 (71.9)

4001 to 4500 80,000 (17.1) 150 (45.7) 202 (61.6) 224 (68.3)

(1219 to 100,OOO (5.2) 94 (28.7) 205 (62.5) 229 (69.8)

1370)

NOTES: See notes at end of venting tables.

See Table 15 for altitudes over 4500 ft. (1370 M)

120,000 15 (4.6) 100 (30.5) 250 (76.2)

140,000 4 10 (6.0) 90 (27.4) 210 (64.0)

40,000 (60.4) 232 (70.7)

60,000 (38.7) 222 (67.7) 250 (76.2)

120,000 11 (6.4) 96 (28.6) 237 (72.2)

140,000 4 80 (24.4) 185 (56.4)

40,000 (56.1) 214 (65.2)

60,000 (36.3) 210 (64.0) 235 (71.6)

120,000 6 (2.4) 66 (26.2) 224 (68.3)

140,000 4 79 (24.1) 158 (48.2)

40,000 (53.9) 205 (62.5)

60, OOO (35.1) 204 (62.2) 228 (69.5)

120,000 86 (25.6) 217 (66.1)

140,000 4 69 (21 .O) 146 (44.5)

50 I (15.2) I 210

I 60 i (9.1) i 165

I 45 I (13.7) I 198

I 27 1(8.2) 1127

I 69 I (11.9)I 184 I 26 I (7.0) I 119

I 36 I (11.0)I 177

I 21 I (6.4) I 115

DIRECT VENT (2-PIPE) AND NON-DIRECT VENT (1 -PIPE)

Vent Pipe Diameter (in.) ]

1-1/2 I 2

70 25

64 22

59 19

56 17

2-1/2

ELBOW CONFIGURATIONS

VENTTERMINAL CONFIGU RATIONS

Concentric

Long

Medium Mitered

"-LL--J ton or

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) 8 (2.4) 8 (2.4)

Medium Radius 90 ° Elbow 5 (1.5) 5 (1.5) 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 46 ° Elbow 4 (1.2) 4 (1.2) 4 (1.2) 4 (1.2) 4 (1.2) Medium Radius 46 ° Elbow 2.5 (0.8) 2.5 (0.8) 2.5 (0.8) 2.5 (0.8) 2.5 (0.8)

Long Radius 46° 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) Concentric Vent Termination O (O.O) O (O.O) Standard Vent Termination O (O.O) O (O.O) O (O.O) O (O.O) O (O.O)

Al1580

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 multiplied by the deduction for each elbow in Table 14.

Standard vent terminations and concentric vent terminations count for zero deductions. See Vent Manufacturers' data for equivalent lengths of flexible vent piping.

DO NOT ASSUME that one foot of flexible vent pipe is equivalent to one foot of standard PVC vent pipe.

Example

A direct-vent 60,000 Btuh furnace installed at 2100 ft. (640 M) with 2-in.(51 mm) 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

No deduction for Concentric Vent Kit

Maximum Vent Length

3ft. = -9ft.

1.5 ft. = -3ft. Oft. = -Oft.

= 127 ft.

= 115 ft.

(From Table 13) (From Table 14) (From Table 14) (From Table 14)

For EACH vent or inlet pipe

NOTE: Maximum Equivalent Vent Length (MEVL) includes standard and concentric vent termination and does NOT include elbows.

Use Table 14 - Deductions from Maximum Equivalent Vent Length to determine allowable vent length for each application.

Table 15 - Maximum Equivalent Vent Length - Ft. (M)

4501 to 10,000 Ft. (1371 to 3048 M) Altitude

Altitude FT (M) 5

4501 to 5000

(1370 to 80,000

1524) 100,000

5001 to 8000 80,000

(1524 to 100,000

1829)

8001 to 7000 80,000

(1829 to 100,000

2134)

7001 to 8000 80,000

(2134 to 100,000

2438)

Unit Size

40,000 50,000

120,000

40,000 50,000

120,000

40,000 50,000

120,000

40,000 50,000

120,000

1-1/2 2 2-1/2 3

DIRECT VENT (2-PIPE) AND SINGLE-PIPE

Vent Pipe Diameter (in.) 1

40,000 50,000

8001 to 9000 80,000

(2438 to 100,000

2743)

9001 to 50,000

10,000 80,000

(2743 to 100,000

3048) 120,000

NOTES:

1. Use only the vent pipe sizes shown for each furnace. It is NOT necessary to choose the smallest diameter pipe possible for venting.

2. NA - Not allowed. Pressure switch will not close, or flame disturbance may result.

3. Total equivalent vent lengths under 10' for 40,000 BTUH furnaces from 0 to 2000 ft. (0 to 610 M) above sea level require use of an outlet choke plate. Failure to use an outlet choke when required may result in flame disturbance or flame sense lockout.

4. Not all furnace families include 140,000 BTUH input models.

5. Vent sizing for Canadian installations over 4500 It (1370 M) above sea level are subject to acceptance by local authorities having jurisdiction.

6. Size both the combustion air and vent pipe independently, then use the larger size 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. Elbow 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) linear feet (meters) for all applications.

10. Use 3-in. (76 mm) diameter vent termination kit for installations requiring 4-in. (102 mm) diameter pipe.

120,000

40,000

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

INDUCER OUTLET CHOKE 40,000 BTUH MODELS ONLY

Al1285

s_ r

UPFLOW LEFT CONFIGURATION

Any otherunused

knockout may be used

_rcombustion air

connedion.

Any other unused

knockout be used

may

for combustion air

connection.

Rotate vent elbow to

required position.

A11309

UPFLOW VERTICAL VENT

00 '>: : .... l k'j

Any other unused __0 &_._5)

knockout may be used _ _. - ,_

connection. _ _ _:!_"o

Rotate vent elbow to (D

required position.

UPFLOW RIGHT CONFIGURATION

A11310

A11308

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.

Fig. 39 - Upflow Configurations (Appearance may vary)

A11399

Rotate vent elbow to

,(3_J, required position.

Rotate vent elbow to

required position.

Any other unused

knockout may be used

for combustion air

connection.

Al1311

Al1312

DOWNFLOW LEFT CONFIGURATION

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.

C) 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.

C) 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)

Al1400

HORIZONTAL LEFT -

VERTICAL VENT CONFIGURATION

AI 1327

A11328

HORIZONTAL LEFT - LEFT VENT CONFIGURATION

HORIZONTALLEFT-

Al1329

RIGHT VENT CONFIGURATION*

*RequiresAccessoryInternalVent Kit

SeeProductDatafor CurrentKitNumber

(_ Attach vent pipe adapter with gasket to furnace casing. (_) Align notches in rubber coupling over standoffs on adapter. Slide clamps over the coupling.

Q Slide vent pipe through adapter and coupling into vent elbow. (_ Insert vent pipe into vent elbow.

C) 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. 41 - Horizontal Left (Appearance may vary)

A11340

-- ALTERNATE COMBUSTION

AIR

CONNECTIONS

HORIZONTAL RIGHT - VERTICAL VENT CONFIGURATION

Al1337

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. C) 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. 42 - Horizontal Right (Appearance may vary)

A11341

VENT PIPE ADAPTER WITH GASKET

INSTALLED ON FURNACE VENT PIPE IS CUT FLUSH WITH TOP OF

ADAPTER.

ALIGN NOTCHES IN VENT PIPE COUPLING OVER STAND-OFF

ON ADAPTER. TORQUE LOWER

CLAMP 15 LB-IN, WHEN REMAINING VENT PIPE IS INSTALLED, TORQUE

UPPER CLAMP TO 15 LB-IN.

VENT PIPE FLUSH WITH ADAPTER

Point elbow down towards back of furnace

VENT PIPE FLUSH SHOWING COUPLING

Al1339

Fig. 43 - Vent Pipe Flush with Adaptor

12"

256.0 mm

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

................................ /

I _ V!

Item

Clearance Description Canadian Installation (1) U.S. Installation (2)

Clearance above grade, veranda, porch, deck, bah 12 in. (305 ram). 18 in. (457 ram) above roof surface. 12 in. (305 ram) cony or anticipated snow level

Clearance to a window or door that may be opened and </- 100,000 Btuh (30 kW), 36 in. (914 ram) for and </- 50,000 Btuh (15 kW), 12 in. (305 ram) for

Clearance to a permanently closed window Vertical clearance to a ventilated soffit located above

the terminal within a horizontal distance of 2 feet (61 cm) from the centerline of the terminal

Clearance to an unventilated soffit

Clearance to an outside corner

Clearance to an inside corner Clearance to each side of the centerline extended

above electrical meter or gas service regulator as- sembly

Clearance to service regulator vent outlet

Clearance to non-mechanical air supply inlet to

building or the combustion air inlet to any other applb ance

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 above or below vent terminal of the furnace to a dryer

M or water heater vent, or other appliance's direct vent 12 in. (305 ram) 12 in. (305 ram)

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

O 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 CSA B149.1, Natural Gas and Propane Installation Code. (2) In accordance with the current ANSI Z223.1 .NFI'A 54, National Fuel (;as Code

Notes:

1. The vent Iklr this appliance stiall not terminate: a. Overpub[icwa[kways: lit

b. Near so,it vents of crawl space vents or ottier areas wtiere condensa_ or vapor could create a nuisance or hazard or property damage; or

c. Where condensate vapor could cause damage or could be de_imental to the operation of regula_lrs, relief valves, or other equipment.

2. When locating vent terminations, consideration must be given to prevailing winds, location, and other conditions which may cause recirculadon of the combustion products of adjacent vents. Recirculadon can cause poor combustion, inlet condensate problems, and accelerated co_oshm of the heat exchangers.

3. Avoid venting under a deck or large overhang. Recirculation could occur and cause per_lrmance or system problems.

12 in. (305 ram) for appliances > t0,000 Btuh (3kW) 9 in. (229 ram) for appliances > 10,000 Btuh (3kW)

appliances > 100,000 Btuh (30 kW) appliances > 500,000 Btuh (15 kW)

For clearances not specified in ANSI Z223.1/NFPA 54 or CSA B149.1, 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 ff. (4.6 M) above the meter/ 3 ft. (.9 M) within 15 ff. (4.6 M) above the meter/ regulator assembly regulator assembly

3 ff. (.9 M)

12 in. (305 ram) for appliances > t0,000 Btuh(3kW) and </- 100,000 Btuh (30 kW), 36 in. (914 ram) for appliances > 100,000 Btuh (30 kW)

5 ft. (1.8 M)

12 in. (305 ram). Permitted onty if veranda, porch,

sides beneath the floor.

7 ft. (2.1 M). A vent shall not terminate above a side- or CSA B149.1, clearances shall be in accordance

For clearances not specified in ANSI Z223.1/NFPA 54 or CSA B149.1, clearances shall be in accordance

with local installation codes and the requirements of the gas supplier and the manufacturer's installation

instructions.

*3 ft. (.9M) *For clearances not specified in ANSI Z223.1 /NFPA 54or CSA B149.1, 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 ram) for appliances > 10,000 Btuh (3kW)

and </- 50,000 Btuh (15 kW), 12 in. (305 ram) for appliances > 500,000 Btuh (15 kW)

3 ff. (.9 M) For clearances not specified in ANSI Z223.1/NFPA 54

or CSA B149.1, 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 Z223.1/NFPA 54

instructions.

Fig. 45 - Direct Vent Termination Clearance

Al1046

JJJJ ...... // i

I_ VENT TERMINAL

Item Clearance Description Canadian Installation (1) U.S. Installation (2)

A cony or anticipatedClearance above grade, veranda, porch, deck, bal-snowlevel 12 in. (305 mm). 18 in. (457 mm) above roof surface. 12 in. (305 mm)

Clearance to a window or door that may be opened and12 in. (305t00,000mm)forBtuhapptiances(30kW),></_36t0'000(914BtUhin,mm) for(3kw)' (.3 M) above the opening.4 ft. (t .2 M) below or to the side of the opening. 1 ft.

Clearance to a permanently closed window Vertical clearance to a ventilated soffit located above

the terminal within a horizontal distance of 2 feet (61 cm) from the centerline of the terminal

Clearance to an unventilated soffit

Clearance to an outside corner

Clearance to an inside corner Clearance to each side of the centedine extended

above electrical meter or gas service regulator as- sembly

I Clearance to service regulator vent outlet 3 ft. (.9 M) accordance with local installation codes and the

Clearance to non- mechanical air suppty inlet to

J building or the combustion air inlet to any other appli- and </- t00,000 Btuh (30kW), 36 in. (914 mm) for (.3 M) above the opening.

ance appliances > 100,000 Btuh (30 kW)

K Clearance to a mechanical air supply inlet 6 ft. (1.8 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 or water heater vent, or other appliance's direct ventab°ve or below vent terminal of the furnace to a dryer 12 in. (305 mm) 12 in.

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

O 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 witb tbe currem CSA B14_JA. Nalural (}as and Propane Insl_lllalion (_)tt_'. (2) In accordance wilb Ibe currem ANSI Z223.] .NFPA 51. National Fuel (}as (:ode

Noles:

]. The xenl for Ibis appliance sbal] nol lerminale:

a. Over public walkways: or

b. Ne_tr so|l'il venls o| crzlwl spzlcc \ {'Ills or olber areas where ct)ndensale or vzq?tlr could create a nuisance or hazard or properly damage: or

c. Where condensale vapor could cause damage or could bc dcli-ilTlenlztl Io Ibc opcralion ill regul_llors, relivf \ zincs, iIr olhcr equipmenL

2. When localing vent lerminations, consideralion must be given Io prevailing winds, h)caliom and olber conditions which ma} cause recb'ctHation of Ibe combustion producls of adjacent venls.

Recirculalion can czttlse poor combustion, inlel cond{,nsztle problems, and act'der_ti_'d corrosion of Ibe heal excbangers.

3. Axoid xenting und{'r a deck or hirge ox erbang. Recb'cuhttion could occur and c_itlSt' pc'r|i)rmance or s_slem probh'ms.

(_' AIR SUPPLY INLET

6 in. (t52 mm) for appliances </- t0,000 Btuh (3kW)

appliances > 100,000 Btuh (30 kW)

For clearances not specified in ANSI Z223.t/NFPA 54 or CSA B149.t, 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 15 ft. (4.6 M) above the meter/regu-

regulator assembly lator assemMy.

12 in. (305 mm) for appliances>6in" (t52 mm) f°r appliances </-t0,000Btuht0'000Btuh(3k\_)(3kW), 4 ft. (t.2 M) below or to the side of the opening, lff.

12 in. (305 mm). Permitted only if veranda, porch, orCSA B149.t, clearances shall be in accordance

sides beneath the floor, the gas supplier and the manufacturer's installation

E_ AREAWHERE TERMINAL IS NOT PERMITED

For clearances not specified in ANSI Z223.t/NFPA 54

or CSA B149.t, 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 CSA B149.t, clearances shall be in

requirements of the gas supplier and the manufacturer's

installation instructions.

For clearances not specified in ANSI Z223.t/NFPA 54

instructions.

(305am)

7 ft. (2.1 M). A vent shall not terminate above a side-

Fig. 46 - Ventilated Combustion Air and Non-Direct Vent Termination Clearance

A11047

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_ 305mm)

mnmum earance

above highest a_licipated

snow bevel maximum of

24 in (610ram) above roof

Side walHermination with 2 ehbows (preferred)

[i::::°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

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

_ _._ ea ance to overhang per code

12 IN, SEPARATION BETWEEN BOTTOM OF "_

COMBUSTION AIR AND

BOTTOM OF VENT

MAINTAIN 12 IN. CLEARANCE

ABOVE HIGHEST ANTICIPATED SNOW

LEVEL OR GRADE,

WHICHEVER IS

GREATER.

Fig. 49 - Alberta and Saskatchewan Vent Termination

Al1346

Ventilated Combustion

// Air intake pipe _U

-"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

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/WI, 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.

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.

1. Remove blower door.

2. Locate A/C setup switches on furnace control.

3. Determine air conditioning tonnage used.

4. Configure the switches for the required cooling airflow.

NOTE: Excessive airflow caused by improper A/C switch setup may cause condensate blow-off in cooling mode.

5. Replace blower door.

Continuous Fan (CF) Setup Switches (SW3)

The CF setup switches are used to select desired airflow when thermostat is in continuous fan mode or to select low-cooling

airflow for two-speed cooling units. This setup feature allows continuous fan airflow or low-cooling airflow to be adjusted. To set desired continuous fan airflow or low-cooling airflow:

1. Remove blower door.

2. Locate CF setup switches on furnace control.

3. Determine desired continuous fan airflow or low-cooling airflow.

4. Configure the switches for the required continuous fan or low-cooling airflow.

5. Replace blower door.

Setup Switch (SW4)

Setup switches SW4 are used for applications using a

communicating User Interface and to adjust airflow. Refer to Fig. 55 for configuration of SW4 airflow options.

Prime Condensate Trap with Water

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.

Select Setup Switch Positions

There are four sets of setup switches on the furnace control board. These switches configure the furnace for correct application

requirement. They also select the airflow settings for Air Conditioning and Continuous Fan CFMs.

The Setup Switch locations are shown and described on Fig. 55. The set up switches are also shown on the unit wiring label.

Setup Switches (SW1)

The furnace control has 8 setup switches that may be set to meet the application requirements. To set these setup switches for the

appropriate requirement:

• Remove blower door.

• Locate setup switches on furnace control.

• Configure the set-up switches as necessary for the application.

• Replace blower door.

NOTE: If a bypass humidifier is used, setup switch SWl-3 (Low Heat Rise Adjust) should be in ON position. This compensates for

the increased temperature in return air resulting from bypass. NOTE: If modulating dampers are used, blower motor

automatically compensates for modulating dampers.

Air Conditioning (A/C) Setup Switches (SW2)

The air conditioning setup switches are used to match furnace airflow to cooling unit used.

To set the desired cooling airflow:

[]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. 59.)

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.

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

injury, death, and/or property damage. Never purge a gas line into a combustion chamber. Never

test for gas leaks with an open flame. Use a commercially

available soap solution made specifically for the detection of leaks to check all connections. A fire or explosion may result causing property damage, personal injury or loss of

line.

Adjustments

FIRE HAZARD Failure to follow this warning could result in personal

injury, 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 16.

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 19.

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

Table 19.

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

tersection to find orifice size and low-and high-heat mani- fold pressure settings 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 19.

Use only factory-supplied orifices. See EXAMPLE 1.

EXAMPLE 1

EXAMPLE: 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. for high heat, 1.4-in. w.c. for low

heat

* 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 low fire 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. Move setup SWI--2 on furnace control to ON position to

lock furnace in low-heat operation. (See Fig. 55 and Fig.

35.)

f. Manually close blower door switch.

g. Jumper R and W/WI thermostat connections on control to

start furnace. (See Fig. 35.)

h. Remove regulator adjustment cap from low heat gas valve

pressure regulator (See Fig. 51) and turn low-heat adjust- ing screw (3/16 or smaller fiat-tipped screwdriver) coun-

terclockwise (out) to decrease input rate or clockwise (in) to increase input rate.

NOTE: DO NOT set low-heat manifold pressure less than 1.3-in. W.C. or more than 1.7-in. W.C. for natural gas. If manifold pressure is outside this range, change main burner orifices.

i. Install low-heat regulator adjustment cap. j. Move setup switch SW1-2 to offposition after completing

low-heat adjustment.

k. Leave manometer or similar device connected and proceed

to Step 4.

2. Adjust manifold pressure to obtain high fire input rate. (See Fig. 51.)

a. Jumper R to W/WI and W2 thermostat connections on fur-

nace control. This keeps furnace locked in high-heat oper-

ation.

b. Remove regulator adjustment cap from high-heat gas

valve pressure regulator (See Fig. 51) and turn high heat

adjusting screw (3/16-in. or smaller fiat-tipped screw- driver) counterclockwise (out) to decrease input rate or clockwise (in) to increase input rate.

NOTE: DO NOT set high-heat manifold pressure less than

3.2-in. W.C. or more than 3.8 in. W.C. for natural gas. If manifold pressure is outside this range, change main burner orifices to obtain

manifold pressure in this range.

c.Whencorrectinputisobtained,replacecapsthatconceal

gasvalveregulatoradjustmentscrews.Mainburnerflame shouldbeclearblue,almosttransparent(SeeFig.57.)

d.RemovejumpersRtoW/WIandRtoW2.

3.Verifynaturalgasinputratebyclockingmeter. a.Turnoffallothergasappliancesandpilotsservedbythe

meter.

b.MovesetupswitchSWI-2toONposition.Thiskeepsfur-

nacelockedinlow-heatoperation.

c.JumperRtoW/WI.

d.Runfurnacefor3minutesinlow-heatoperation.

e.Measuretime(insec)forgasmetertocomplete1revolu-

tionandnotereading.The2or5cubicfeetdialprovides amoreaccuratemeasurementofgasflow.

f. RefertoTable18forcubicft.ofgasperhr.

g. Multiplygasratecuft./hrbyheatingvalue(Btuh/cuft.)

toobtaininput.Ifclockedratedoesnotmatchrequiredin- putfromStep1,increasemanifoldpressuretoincreasein-

putordecreasemanifoldpressuretodecreaseinput.Repeat stepsbthrougheuntilcorrectlow-heatinputisachieved.

Re-installlowheatregulatorsealcapongasvalve.

h.MovesetupswitchSWI-2toOFFpositionandjumperR

toW/WI,andW2.Repeatitemsdthroughgforhigh-heat operation.

Adjust Temperature Rise

NOTE: Blower door must be installed when taking temperature rise reading. Leaving blower door off will result in incorrect

temperature measurements.

specified on furnace rating plate. If temperature rise is out- side this range, proceed as follows:

(1.) Check gas input for low- and high-heat operation. (2.) Check derate for altitude if applicable.

(3.) Check all return and supply ducts for excessive

restrictions causing static pressure greater than

0.5-In. W.C.

(40 Ensure Low Heat Rise Adjust switch SWl-3 on

furnace control is in ON position when a bypass humidifier is used. (See Fig. 35 for switch loca-

tion.)

(5.) Make sure proper model plug is installed.

Remove thermostat jumpers and release blower door switch.

Repeat Steps a through c as required to adjust for high heat temperature rise.

When correct high heat input rate and temperature rise is

achieved, turn gas valve ON/OFF switch to OFF.

Release blower door switch.

g. h.

Remove manometer or similar device from gas valve.

Re-install manifold pressure tap plug in gas valve. (See Fig. 510

FIRE HAZARD

Failure to 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 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,

• Shortened furnace life

• Component damage. Temperature rise must be within limits specified on furnace

rating plate. Recommended operation is at midpoint of rise range or slightly above.

When setup switch SW1-4 is ON, operation will be near the high end of the rise range for improved comfort.

Furnace must operate within ranges of temperature rise specified on the furnace rating plate. Determine air temperature rise as

follows:

a. Place thermometers in return and supply ducts as near fur-

nace as possible. Be sure thermometers do not see heat ex- changer so that radiant heat does not affect readings. This

practice is particularly important with straight-run ducts.

b. When thermometer readings stabilize, subtract return-air

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

NOTE: Temperature rise can be determined for low-heat operation by placing setup switch SWI-2 on furnace control in ON position. For high-heat operation, place setup switch SWI-2 in OFF position and jumper R-W2 on furnace control. DO NOT forget to return setup switch to OFF position and remove R-W2

jumper upon completion of testing.

c. This furnace is capable of automatically providing proper

airflow to maintain the temperature rise within the range

j. Remove thermostat jumper wire from furnace control

board.

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

1. Proceed to "Set Blower Off Delay" before installing blower door.

Adjust Blower Off Delay (Heat Mode)

a. Remove blower door if installed.

b. Turn Dip switch SW-7 or SW-8 ON or OFF for desired

blower off delay. (See Table 17 and Fig. 35, Fig. 55 and Fig. 64.)

Adjust Cooling Airflow - High-Speed and

Low-Speed Cooling

The ECM blower can be adjusted for a range of airflows for low-speed or high-speed cooling. See Table 7 - Air Delivery -

CFM (With Filter ) and Fig. 55 - Furnace Setup Switches and Descriptions. Depending on the model size, the cooling airflow can be adjusted from 1.5 to 6 tons based on 350 CFM ton.

NOTE: 6 ton airflow will truncate at 2200 CFM on applicable models.

The high-speed or single-speed cooling airflow is adjusted by turning Setup switches SW2-1, SW2-2 and SW2-3 either ON or

OFF. Select the required airflow from Table 7. Table 7 is based upon 350 CFM per ton. For other CFM per ton Setup switch selections, see Fig. 35, Fig. 55 and Fig. 64.

The Continuous Fan airflow selection via Setup switches SW3 is

also the airflow for low-speed cooling when the furnace is used with a 2-speed cooling or heat pump unit. Adjust the Continuous

Fan CFM Setup switches SW3 to match the airflow required for low-speed cooling. Select the required airflow from Table 7 and

Fig. 55.

NOTE: The airflow selected via SW3 (Low-Speed Cooling Airflow) cannot exceed the airflow selected via SW2 (High-Speed Cooling Airflow). For other CFM per ton Setup switch selections,

see Fig. 35 and Fig. 55. NOTE: The airflow settings for SW2 and SW3 selections are the

same, EXCEPT for the default values. See Table 7. For a complete explanation of cooling airflow, refer to the section

titled "Sequence of Operation." Adjust Continuous Fan Airflow (and Low-Speed

Cooling Airflow) NOTE: When the furnace is used with a 2-speed cooling or heat

pump unit, the airflow selected for continuous fan via Setup switch SW3 will also be the airflow used for low-speed cooling, and vice

versa. The continuous fan speed can be further adjusted at a conventional thermostat using the continuous fan speed select

function. Changing the continuous fan speed at a conventional thermostat DOES NOT change the low-speed cooling airflow

selected via SW3 at the control board. NOTE: When the furnace is used with a 2-speed cooling or heat

pump unit, adjust the Continuous Fan CFM Setup switches SW3 to match the airflow required for low-speed cooling.

Select the required continuous fan airflow using Setup switches SW3 as shown in Fig. 55 and Table 7.

Adjust Thermostat Heat Anticipator.

a. Mechanical thermostat. Set thermostat heat anticipator to

match the amp. draw of the electrical components in the R-W/W1 circuit. Accurate amp. draw readings can be ob-

tained at the wires normally connected to thermostat sub- base terminals, R and W.The thermostat anticipator should

NOT be in the circuit while measuring current.

(1.) Set SWl-2 switch on furnace control board to ON. (2.) Remove thermostat from subbase or from wall.

(3.) Connect an amp. meter as shown in Fig. 53 across

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

(4.) Record amp. draw across terminals when furnace is

in low heat and after blower starts.

(5.) Set heat anticipator on thermostat per thermostat

instructions and install on subbase or wall.

(6.) Turn SWl-2 switch OFF. (7.) Install blower door.

b. 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 Limit Switch This control shuts off combustion system and energizes air-

circulating blower motor, if furnace overheats. By using this method to check limit 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 limit control

does not function during this test, cause must be determined and corrected.

a. Run furnace for at least 5 minutes.

b. Gradually block off return air with a piece of cardboard or

sheet metal until the limit trips.

c. Unblock return air to permit normal circulation.

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

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

motor is disconnected, shut down furnace immediately.

e. Determine reason pressure switch did not function prop-

erly and correct condition.

f. Turn off 115-v power to furnace.

g. Reconnect inducer motor wires, replace door, and turn on

115-v power.

h. Blower will run for 90 sec before beginning the call for heat

again.

i. Furnace should ignite normally.

Checklist

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

2. Verify that switches SWl-1 and SWl-6 are OFF and other setup switches are set as desired. Verify that switches

SWl-7 and SWl-8 for the blower OFF DELAY are set as desired 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.

Regulator Adjustment Regulator Seal Cap under Cap

l/8"NPTInlet Pressu[eTap

Fig. 51 - Gas Valve

Al1152

THERMOSTAT SUBBASE TERMINALS WITH THERMOSTAT REMOVED

(ANITICIPATOR, CLOCK, ETC.,

MUST BE OUT OF CIRCUIT.)

BURNER

ORIFICE

A93059

Fig. 52 - Orifice Hole

FROM UNiT 24-V

CONTROL TERMINALS

EXAMPLE: 5.0 AMPS ON AMMETER = 0,5 AMPS FOR THERMOSTAT

10 TURNS AROUND JAWS ANTICIPATOR SETTING

Fig. 53 - Amp. Draw Check with Ammeter

A96316

SERVICE

.......... Ifsta_scodereceiisnaededd_ned _ 'R"_ lead,reseti:x:,,_,_,andputsebpswitch"SWI-1"

in_eONposi_::_.Todearfnastatuscodehisto._/putse_ sv,_ch"SWl-l"in_naON_ andju_

LED CODE STATUS

CONTINUOUS OFF - Checkfor115VACatL1andL2,and24VACatSEC-landSEC-2. CONTINUOUS ON- C,X_ntrolhas24VAC_.

_P|D FLASHING Unevoltage(115VAC)polarityisreversed.

EACHOFTHEFOLLOWINGSTATUSCODESISASINGLEORTWODIGITNUMBERWITHTHEFIRSTNUMBERDETERMINEDBYTHE NUMBEROFSHORTFLASHESANDTHESECONDNUMBERAFTERTHEPLUS(+)SIGNISTHENUMBEROFLONGFLASHES,

11NOPREVIOUSCODE.Storedstatuscodesareerasedautomaticallyafter72hoursorasspecifiedabove, 12BLOWERONAFTERPOWERUP.(115VACor24VAC)-Blowerrunsfor90seconds,ifunitispoweredupduringa

callforheat(R.W/W1closed)or(R.W/W1opens)duringtheblowerondelayperiod,

13LIMITCIRCUITLOCKOUT.Lockoutoccursifthelimit,orflamerolloutswitchisopenlongerthan3minutesor

10successivelimittripsoccurredduringhigh-heat,Controlwillautoresetafter3hours,Refertostatuscode#33, 14IGNITIONLOCKOUT.Controlwillauto-resetafter3hours,Refertostatuscode#34, 15BLOWERMOTORLOCKOUT.Indicatestheblowerfailedtoreach250RPMortheblowerfailedtocommunicatewithin30

secondsafterbeingturnedONintwosuccessiveheatingcycles,Controlwillautoresetafter3hours,Refertostatuscode#41,

21 GASHEATINGLOCKOUT.ControlwillNOTautoreset,Checkfor:-Mis-wiredgasvalve,-Defectivecontrol(valverelay) 22ABNORMALFLAME.PROVINGSIGNAL.Flameisprovedwhilegasvalveisde.energized,Inducerwillrununtilfault

iscleared,Checkfor: -Leakygasvalve, - Stuck.opengasvalve,

23 PRESSURESWITCHDIDNOTOPEN-Checkfor:-Obstructedpressuretubing,-Pressureswitchstuckclosed, 24 SECONDARYMOLTAGEFUBEISOPEN-Checkfor:-Shortcircuifinsecondaryvoltage(24VAC)widng,

25 MODELSELECTIONORSETUPERROR-Eitherindicatesthemodelplug(PL4)ismissingorincorrectorsetupswitch

"SW1.1"or"SWl-6"ispositionedimproperly,Ifcodeflashesonly4timesonpower-upcontrolisdefaultingtomodelselection

31 HIGH.HEATPRESSURESWITCHORRELAYDIDNOTCLOSEORREOPENED• Indicatesthehigh-heatpressureswitch

inputfailedtocloseoropenedduringhigh-heat,Controlrelaymaybedefectiveorgasvalveismis-wired,Refertostatus code#32,

32LOW.HEATPRESSURESWffOHDIDNOTCLOSEORREOPENED.Indicatesthelow-heatpressureswitchinputfailedto

closeonacallforlow-heat,oropenedduringlow-heat,Ifopensduring5minutesafterignitionthenextheatingcyclewillbe restrictedtohigh-heat,Checkfor: - Properventsizing, -Excessivewind, -Pluggedcondensatedrain,

-Lowinletgaspressure(ifLGPSused), -Restrictedcombustionairsupply, -Improperpressureswitchwiring,

-Waterinventpiping,possiblesaggingpipe. -Disconnectedorobstructedpressuretubing.

-Failedor"Out.d-Calibration"pressureswitches.

33LIMITCIRCUITFAULT.Indicatesthelimit,orflamerolloutisopenorthefurnaceisoperatinginhigh-heatonlymodedueto

2successivelowheatlimittrips.Blowerwillrunfor4minutesoruntilopenswitchremakeswhicheverislonger.Ifopen longerthan3minutes,codechangestolockout#13.Ifopenlessthan3minutesstatuscode#33continuestoflashuntil

blowershutsoff.Flamerolloutswitchrequiresmanualreset.Checkfor:.Improperlimitswflchornolimitgasket

-Defectiveswitchorconnections. -Looseblowerwheel.

-Improperlow-heatorhigh-heatgasinputadjustment. -Stuckhigh-heatsolenoidingasvalve.

34 IGNfflONPROVINGFAULT. Oontrolwilltrythreemoretimesbeforealockout#14occurs.Ifflamesignalislostduringblower

on-delaypedod,blowerwillcomeonfortheselectedbloweroff-delay.Checkfor: -Gasvalvedefectiveorturned"OFF".

-DefectiveHotBur[aceIgniter.-Manualvalveshut.off. -Lowinletgaspressure.-Flamesensormustnotbegrounded.

-Controlgroundcontinuity.-Inadequateflamecarryoverorroughignition.

-Green/YellowwireMUSTbeconnectedtofurnacesheetmetal.-Oxidebuilduponflamesensor(cleanwithfinesteelwool).

-Properflamesensemicroamps(.5microampsDOTin,4.0-6.0nominal).

41 BLOWERMOTORFAULT.Indicatestheblowerfailedtoreach250RPMortheblowerfailedtocommunicatewithin

theprescribedtimelimits.ThirtysecondsafterbeingturnedONortensecondsduringsteady-stateoperation.

43 LOW,HEATPRESSURESWITCHOPENWHILEHIGH.HEATPRESSURESWITCHISCLOSED,Checkfor:

-Pluggedcondensatedrain,-Lowinletgaspressure(ifLGPSused),-Waterinventpiping,possiblysaggingpipe,

-Improperpressureswitchwiring, -Stuckopenlow-heatpressureswitch,-Disconnectedorobstructedpressuretubing,

45CONTROLCIRCUITRYLOCKOUT-Auto-resetafterlhourlockoutdueto:-Flamesensecircuitfailure,

-Gasvalverelaystuckopen, -Softwarecheckerror,

Resetpowertoclearlockout,Replacecontrolifstatuscoderepeats,

_1 CONPONENT TEST

Toinitiatethecomponenttestsequence,shut"OFF"theroomthermostatordisconnectthe"R"thermostat lead.Resetpowerandthenputsetupswitch"SW1-6"intheONpositiontostartthecomponenttest sequence.OnceinitiatedthefurnacecontrolwillturntheinducerON.Theinducermotorwillrunforthe entiretest.ThehotsurfaceigniterandblowermotorwillbeturnedONfor15secondseach.Whenthe bloweristurnedOFFtheinducerwillbeturnedOFF.Whenthecomponenttestiscompletedoneormore ofthefollowingcodeswillflash.

.... 25SETUPERROR-Sameascode25above,

.... completedputsetupswitch"SW1-6"intheOFFpositionendreconnectthe"R"thermostatlead.

_t terminals"R",'WNV1",and'Y/Y2'sJ_l_aneouslyun_]sta_scode#11is_shed.

storedinmemory,Checkthefollowing:-Thermostatcallwith"SWl-I"ON, -Thermostatcallwith°SW1-6"OH,

-°SWI-I"and"SWl-6"bothONtogether, -Twodifferentfurnacemodelstwinned,

-SeeRatingPlateformodelplugnumberandresistancevaluesifcodeflashescontinuously,

CODE DESCRIPTION

11IndicatesblowermotortestedOK,Visualcheckofhotsurfaceigniterandinducerrequired,

418LOWERMOTORFAULT-Indicatesblowermotorfailedtest,Checkblower,wiring,andfurnacecontrol,

.... Torepeatcomponenttestturnsetupswitch"SW1-6"OFFandthenbackON,Aftercomponenttestis

Fig. 54 - Service Label Information

338308-201Re_ E

A11596

Model Size

060-14 080-14 060-20 080-20 100-22 120-22

Model Size

060-14 080-14 060-20 080-20 100-22 120-22

Model Size

NOMINAL AIRFLOW BASED ON 350 CFM/TON (Factory Default - SW1-5 = OFF, SW4-3 = OFF)

SW2 Clg Default SW3 CF Default COOLING (SW2) AND CONTINUOUS FAN (SW3) AIRFLOW: SET-UP SWITCH POSITIONS

1050 1050 1750 1750 1750 1750

33 2 1N

2 1 N

525 525 700 700 700 875

3 2 1 N

525 525 700 700 700 700

3 2 I N

700 700 875 875 875 875

3 2 1N

875

875 1050 1050 1050 1050

3 2 1N

1050 1050 1225

1225 1225 1225

3 2 1 N

1225 1225 1400 1400 1400 1400

3 2 1N 3 2 1N

1225 1225 1225 1225 1750 1750 1750 1750 1750 2100 1750 2100

NOMINAL AIRFLOW BASED ON 400 CFM/TON (SW1=5 = ON, SW4=3 = OFF)

SW2 Dig DeDult

3 2 1 N

1200

1200 2000 2000 2000 2000

SW3 CF Default COOLING (SW2) AND CONTINUOUS FAN (SW3) AIRFLOW: SET-UP SWITCH POSITIONS

3 2 1N

600 600 800 800 800

1000

3 2 1N

60O 600 800 80O 80O 80O

3 2 I N

800

800 1000 1000 1000 1000

3 2 1N

1000 1000 1200 1200 1200 1200

3 2 1N

1200 1200 1400 1400 1400 1400

3 2 1N

1400 1400 1600 1600 1600 1600

3 2 1N

1400

1400 2000 2000 2000 2000

NOMINAL AIRFLOW BASED ON 325 CFM/TON (SW1=5 = OFF, SW4=3 = ON)

SW2 CIg Default

SW3 CF Default COOLING (SW2) AND CONTINUOUS FAN (SW3) AIRFLOW: SET-UP SWITCH POSITIONS

3 2 t N

1400

1400 2000 2000 2100 2100

060-14 080-14 060-20 080-20 100-22 120-22

Model Size

060-14 080-14

06O-2O 080-20

100-22 120-22

3 2 1N

976 976

1627

1627 1627

1627

3 2 1N

488 488

651 651 651

814

3 2 1N

488 488 651 651 651

651

3 2 1 N

651 651 814 814 814

814

3 2 1 N

814 814 976 976 976

976

3 2 1 N

976

976 1139 1139 1139

1139

3 2 1 N

1139 1139 1302 1302 1302

1302

NOMINAL AIRFLOW BASED ON 370 CFM/TON (SWI-5 = ON, SW4-3 = ON)

SW2 Dig DeDult SW3

CF Default COOLING (SW2) AND CONTINUOUS FAN (SW3) AIRFLOW: SET-UP SWITCH POSITIONS

3 2 1N 3 2 1N 3 2 1N 3 2 I N 3 2 1N 3 2 1N 3 2 1N

1116 558 558 744 930 1116 1302 1116 558 558 744 930 1116 1302 1860 744 744 930 1116 1302 1488 1860 744 744 930 1116 1302 1488 1860 744 744 930 II16 1302 1488 1860 930 744 930 1116 1302 1488

Fig. 55 - Furnace Setup Switches and Description

3 2 1 N

1139 1139 1627 1627 1627

1627

3 2 1N

1302 1302 1860 1860 1860 1860

3 2 1 N

1139 1139 1627 1627 1953

1953

3 2 1 N

1302 1302 1860

1860 2100 2100

Al1623

IZ®i

SETUP SWITCH

SWI-1

SW1-2

SW1-3

SW1-4

SW1-5

SW1-6

SW1-7 & SW1-8

SW4-3

Furnace Setup Switch Description

SWITCH NAME

Status Code Recovery

Low Heat Only

(Adaptive Heat Mode when

SW1-2 is OFF)

Low Heat Rise Adjustment

Comfort/Efficiency Adjustment

CFM per ton adjust

Component Self Test

Blower OFF delay

Intermediate

CFM per ton Adjust

NORMAL POSITION

OFF

ON or OFF

OFF

DESCRIPTION OF USE

I'urn ON to retrieve up to 7 stored status codes for iroubleshooting assistance when R thermostat

ead is disconnected.

_Vhen SWl-2 is OFF allows low heat operation witf

single stage thermostat. Turn ON when using Ewo-stage thermostat to allow Low Heat operation Nhen R to W/Wf closes and High Heat operation

Nhen R to W/W1 and W2 close. I'urn ON to increase Low Heat airflow by 18

3ercent. This compensates for increased return ail Eemperature caused with bypass humidifier. This €lso increases the low heat inducer speed 15

3ercent. I'urn ON to decrease low heat airflow by 7 percent.

end high heat airflow 10 percent for maximum comfort.

I'urn ON for 400 CFM per ton, Turn OFF for 350 _FM per ton. See also SW4.

I'urn ON to initiate Component Self Test for :roubleshooting assistance when R thermostat

ead is disconnected. Turn OFF when Self Test is

,'ompleted.

3lower Off Delay time - adjustable 90 seconds to 180 seconds. See table in Adjustments section or "efer to unit wiring diagram.

&llows additional CFM per ton selections when Jaed with SW 1-5

325 CFM per ton (nominal) when SW 4-3 ON and

-3W 1-5 OFF

350 CFM per ton (nominal) when SW 4-3 OFF and

-3W 1-5 OFF

370 CFM per ton (nominal) when SW4-3 ON and

-3W 1-5 ON

_,00 CFM per ton (nominal) when SW 1-5 ON and

-3W4-3 OFF

See Air Delivery Tables for model specific CFM _a. static pressure

.......,,,,,,,,,,,,,,

1 --

_zO

ir-q_

1 _zO

m mF"l co

AIR CONDITIONING (A/C) SETUP SWITCHES

3W 2, AC (Cooling Airflow) SETUP SWITCHES

I-he AC setup switch selects desired cooling or high stage cooling (two stage units) airflow.

3ee Air Delivery Tables for specific switch settings

CONTINUOUS FAN (CF) SETUP SWITCHES

iSW 3, CF (Continuous Fan) SETUP SWITCHES

!The CF setup switch selects desired Continuous Fan Airflow

l-he CF switch position is the low cooling airflow selection for two stage cooling units.

Fhe CFM values in the Air Delivery Tables for SW 3 settings are the same as SW 2 settings.

!SW 3 cannot be set for airflow higher than SW 2

3ee Air Delivery Tables for specific switch settings

Fig. 55 - Furnace Setup Switches and Description (Continued)

A11364 A2V96

Table16- Altitude Derate Multiplier for U.S.A.

ALTITUDE PERCENT DERATE

0-2000 2001-3000 3001-4000 4001-5000 5001-8000

8001-7000 7001-8000 8001-9000

9001-10,000

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

SECONDS

FOR 1 REVOLUTION

10 11 12 13 14

15 18 17 18 19

20 21 22 23 24

25 28 27 28 29

30 31 32 33 34

35 38 37 38 39

40 41 42 43 44

45 48 47 48 49

0-810

810-914

914-1219 1219-1524 1524-1829

1829-2134

2134-2438 2438-2743 2743-3048

DERATE

0 4-6 6-8

8-10

10-12 12-14

14-16 16-18 18-20

MULTIPLIER

FACTOR*

1.00

0.95

0.96

0.91

0.89

0.87

0.85

0.83

0.81

Table 18 - Gas Rate (CU ft./hr)

SIZE OF TEST DIAL SECONDS

Cu Ft. 2 Cu Ft. 5 Cu Ft. FOR 1 REVOLUTION

660 720 1800 50 627 655 1636 51 300 600 1500 52

277 555 1385 56 257 514 1286 54

240 480 1200 55 225 450 1125 56 212 424 1059 57 200 400 1000 58 189 679 947 59

180 660 900 60 171 343 857 62 164 627 818 64 157 313 783 66 150 300 750 68

144 288 720 70 168 277 692 72 136 267 667 74 129 257 646 76 124 248 621 78

120 240 600 80 116 262 581 82 116 225 566 84 109 218 545 86 106 212 529 88

103 206 514 90 100 200 500 92

97 195 486 94 95 189 474 96 92 185 462 98

90 180 450 100 88 176 469 102 86 172 429 104 84 167 419 106 82 164 409 108

80 160 400 110 78 157 391 112 76 153 383 116 75 150 675 120 73 147 367

Table 17 - Blower Off Delay Setup Switch

DESIRED HEATING MODE

BLOWER OFF DELAY (SEC.)

9O 120 150

180

SETUP SWITCH

(SW1-7 AND -8)

POSITION

SW1-7 SW1-8

OFF OFF

ON OFF

OFF ON

ON ON

SIZE OF TEST DIAL

1Cu Ft. 2 Cu Ft.

72 144 71 141 69 138 68 136 67 133

65 131 64 129 63 126 62 124 61 122

60 120 58 116 56 112 54 109 53 106

51 103 50 100 48 97 47 95 46 92

45 90 44 88 43 86 42 84 41 82

40 80 39 78 38 76 38 75 37 74

36 72 35 71 35 69 34 68 33 67

33 65 32 64 31 62 30 60

5 Cu Ft.

36O 355 346 34O 333

327 321 316 310 3O5

3OO 29O 281 273 265

257 25O 243 237 231

225 22O 214 2O9 2O5

2OO

196 192 188 184

18O 178 173 17O 167

164 161 155 15O

Table 19 - Orifice Size and Manifold Pressure (In. W.C.) for Gas Input Rate

TWO-STAGE FURNACE

(TABULATED DATA BASED ON 20,000 BTUH HIGH-HEAT/13,000 BTUH LOW-HEAT PER BURNER,

DERATED 2%/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 Mnfld Press Orifice Mnfld Press Orifice Mnfld Press Orifice Mnfld Press

ft (m) _ No......___h/Low Noi Hi,.h/Low Noi Hi,.h/Low Noi High/Low

900 43 3.8 / 116 42 3.2 / 114 42 3.3 / 114 42 3.4 / 114

0 925 43 3.6 / 1.5 43 3.7 / 1.6 43 3.8 / 1.6 42 3.2 / 1.4

t..

_. 1025 44 3.3 / 1.4 44 3.5 / 1.5 44 3.6 / 1.5 44 3.7 / 1.6

t..

__ 1000 46 3.8 / 1.6 45 3.8 / 1.6 44 3.2 / 1.4 44 3.3 / 1.4

.-_ (915) 825 43 3.6 / 1.5 43 3.7 / 1.6 43 3.8 / 1.6 42 3.2 / 1.4

t..

O 850 44 3.8 / 1.6 43 3.5 / 1.5 43 3.6 / 1.5 43 3.7 / 1.6 _' to 875 44 3.6 / 1.5 44 3.7 / 1.6 43 3.4 / 1.4 43 3.5 / 1.5

t..

O 825 44 3.8 / 1.6 43 3.4 / 1.4 43 3.5 / 1.5 43 3.6 / 1.5

t..

O 800 44 3.7 / 1.6 44 3.8 / 1.6 43 3.4 / 1.5 43 3.5 / 1.5

.-_ (1830) 725 43 3.6 / 1.5 43 3.7 / 1.6 43 3.8 / 1.6 42 3.3 / 1.4

t..

O 750 43 3.4 / 1.4 43 3.5 / 1.5 43 3.6 / 1.5 43 3.7 / 1.6 ,_ to

• 775 44 3.6 / 1.5 44 3.7 / 1.6 43 3.4 / 1.4 43 3.5 / 1.5

(0) 950 43 3.4 / 1.4 43 3.5 / 1.5 43 3.6 / 1.5 43 3.7 / 1.6

975 44 3.7 / 1.6 44 3.8 / 1.6 43 3.4 / 1.5 43 3.6 / 1.5

to 1000 44 3.5 / 1.5 44 3.6 / 1.5 44 3.8 / 1.6 43 3.4 / 1.4

2000 1050 44 3.2 / 1.3 44 3.3 / 1.4 44 3.4 / 1.4 44 3.5 / 1.5 (610) 1075 45 3.7 / 1.6 45 3.8 / 1.6 44 3.3 / 1.4 44 3.4 / 1.4

U.S.A. 800 42 3.4 / 1.4 42 3.5 / 1.5 42 3.6 / 1.5 42 3.7 / 1.6

2001 (611) 825 43 3.8 / 1.6 42 3.3 / 1.4 42 3.4 / 1.4 42 3.5 / 1.5

to 850 43 3.6 / 1.5 43 3.7 / 1.6 42 3.2 / 1.3 42 3.3 / 1.4

3000 (914) 875 43 3.4 / 1.4 43 3.5 / 1.5 43 3.7 / 1.5 43 3.8 / 1.6

Canada 925 44 3.5 / 1.5 44 3.6 / 1.5 44 3.8 / 1.6 43 3.4 / 1.4

2001 (611) 950 44 3.3 / 1.4 44 3.4 / 1.5 44 3.6 / 1.5 44 3.7 / 1.6

to 975 44 3.2 / 1.3 44 3.3 / 1.4 44 3.4 / 1.4 44 3.5 / 1.5

3001 800 43 3.8 / 1.6 42 3.2 / 1.4 42 3.3 / 1.4 42 3.4 / 1.4

4000 900 44 3.4 / 1.4 44 3.5 / 1.5 44 3.7 / 1.5 44 3.8 / 1.6

(1219)

4001 775 43 3.7 / 1.6 43 3.8 / 1.6 42 3.3 / 1.4 42 3.4 / 1.4

(1220) 800 43 3.5 / 1.5 43 3.6 / 1.5 43 3.7 / 1.6 43 3.8 / 1.6

5000 875 44 3.3 / 1.4 44 3.5 / 1.5 44 3.6 / 1.5 44 3.7 / 1.6

(1524) 900 44 3.2 / 1.3 44 3.3 / 1.4 44 3.4 / 1.4 44 3.5 / 1.5

5001 750 43 3.7 / 1.5 43 3.8 / 1.6 42 3.2 / 1.4 42 3.3 / 1.4

(1525) 775 43 3.4 / 1.4 43 3.5 / 1.5 43 3.7 / 1.5 43 3.8 / 1.6

6000 850 44 3.3 / 1.4 44 3.4 / 1.4 44 3.5 / 1.5 44 3.6 / 1.5

(1829)

6001 700 42 3.2 / 1.3 42 3.3 / 1.4 42 3.4 / 1.4 42 3.5 / 1.5

7000 800 44 3.4 / 1.4 44 3.5 / 1.5 44 3.6 / 1.5 44 3.7 / 1.6

(2133) 825 44 3.2 / 1.3 44 3.3 / 1.4 44 3.4 / 1.4 44 3.5 / 1.5

1100 46 3.7 / 1.6 46 3.8 / 1.6 45 3.8 / 1.6 44 3.2 / 1.4

900 44 3.7 / 1.6 44 3.8 / 1.6 43 3.5 / 1.5 43 3.6 / 1.5

775 42 3.3 / 1.4 42 3.4 / 1.4 42 3.5 / 1.5 42 3.6 / 1.5

925 44 3.2 / 1.4 44 3.4 / 1.4 44 3.5 / 1.5 44 3.6 / 1.5 950 45 3.7 / 1.6 44 3.2 / 1.3 44 3.3 / 1.4 44 3.4 / 1.4

750 42 3.3 / 1.4 42 3.4 / 1.4 42 3.5 / 1.5 42 3.6 / 1.5

850 44 3.5 / 1.5 44 3.7 / 1.5 44 3.8 / 1.6 43 3.4 / 1.4

925 46 3.8 / 1.6 45 3.7 / 1.6 44 3.2 / 1.4 44 3.3 / 1.4 725 42 3.2 / 1.4 42 3.3 / 1.4 42 3.4 / 1.5 42 3.5 / 1.5

825 44 3.5 / 1.5 44 3.6 / 1.5 44 3.7 / 1.6 44 3.8 / 1.6

875 45 3.7 / 1.6 44 3.2 / 1.3 44 3.3 / 1.4 44 3.4 / 1.4 900 46 3.7 / 1.6 46 3.8 / 1.6 45 3.8 / 1.6 44 3.2 / 1.4

675 42 3.4 / 1.4 42 3.5 / 1.5 42 3.6 / 1.5 42 3.8 / 1.6

850 46 3.8 / 1.6 45 3.8 / 1.6 44 3.2 / 1.4 44 3.3 / 1.4

Al1252A

Table 19 - Orifice Size and Manifold Pressure (In. W.C.) for Gas Input Rate (Continued)

(TABULATED DATA BASED ON 20,000 BTUH HIGH-HEAT/13,000 BTUH LOW-HEAT PER BURNER,

DERATED 2°/o/1000 FT (305M) ABOVE SEA LEVEL)

ALTITUDE AVG. GAS

RANGE HEAT VALUE 0.58

AT ALTITUDE Orifice Mnfld Press

ft (m) _ No__ ,,,,,,_h/Low

650

7001 675

--_ (2134) 700 O 725

<' to

8000 775

(2438) 800

8001 650

c (2439) 675

O <.' to 700

9000 750

__ 775

9001 600

--_ (2744) 625 O 650

<' to 675

10000 700

* Orifice numbers shown in BOLD are factory-installed.

750

825 625

725

42 3.4 / 1.4 42 3.5 / 1.5 42 3.6 / 1.5 43 3.8 / 1.6 42 3.2 / 1.4 42 3.3 / 1.4 43 3.5 / 1.5 43 3.7 / 1.5 43 3.8 / 1.6

44 3.8 / 1.6 43 3.4 / 1.4 43 3.5 / 1.5 44 3.5 / 1.5 44 3.7 / 1.5 44 3.8 / 1.6

44 3.3 / 1.4 44 3.4 / 1.4 44 3.5 / 1.5 45 3.8 / 1.6 44 3.2 / 1.4 44 3.3 / 1.4 46 3.7 / 1.6 46 3.8 / 1.6 45 3.8 / 1.6 42 3.4 / 1.4 42 3.5 / 1.5 42 3.6 / 1.5 43 3.8 / 1.6 42 3.2 / 1.4 42 3.3 / 1.4 43 3.5 / 1.5 43 3.6 / 1.5 43 3.7 / 1.6 44 3.7 / 1.6 43 3.4 / 1.4 43 3.5 / 1.5 44 3.5 / 1.5 44 3.6 / 1.5 44 3.7 / 1.6 44 3.3 / 1.4 44 3.4 / 1.4 44 3.5 / 1.5 45 3.7 / 1.6 44 3.2 / 1.3 44 3.3 / 1.4 42 3.3 / 1.4 42 3.4 / 1.5 42 3.6 / 1.5 43 3.7 / 1.6 42 3.2 / 1.3 42 3.3 / 1.4 43 3.5 / 1.5 43 3.6 / 1.5 43 3.7 / 1.6 44 3.7 / 1.6 44 3.8 / 1.6 43 3.4 / 1.4 44 3.4 / 1.4 44 3.5 / 1.5 44 3.7 / 1.5

TWO-STAGE FURNACE

SPECIFIC GRAVITY OF NATURAL GAS

0.60 0.62

Orifice Mnfld Press Orifice Mnfld Press

No. Hi,h/Low No. Hi,h/Low

3.4 / 1.4

0,64

Orifice Mnfld Press

No. Hi2h/Low

42 3.7 / 1.6 42 3.4 / 1.5 42 3.2 / 1.4 43 3.6 / 1.5 43 3.4 / 1.4

44 3,7 / 1.5 44 3,4 / 1.4 44 3.2 / 1,4 42 3.7 / 1.6 42 3.4 / 1.4 42 3.2 / 1.3 43 3.6 / 1.5 44 3,8 / 1.6 44 3,6 / 1.5 44 3,4 / 1.4 42 3.7 / 1.6 42 3.4 / 1.4 43 3.8 / 1.6 43 3.5 / 1.5 44 3,8 / 1.6 44 3,5 / 1.5

Al1252B

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 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 suitaMe 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. 64 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. 63) 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

The stored status codes will NOT be erased from the control memory, when 115- or 24-v power is interrupted. The control will

store up to the last 7 Status Codes in order of occurrence.

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

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

a. Leave l15-v power to furnace turned on.

b. Look into blower door indicator for current LED status.

c. Remove blower door.

NOTE: The Status Codes cannot be retrieved by disconnecting the limit switch. To retrieve Status Codes, follow the procedure

below.

2.TurnSetupSwitch,SWI-1"ON."

3.Manuallycloseblowerdoorswitch.

4.Controlwillflashupto7StatusCodes.

5. The last Status Code, or 8th Code, will be Code 11.

6. Turn SWI-1 "OFF."

7. A continuously-lit Amber LED will appear and indicates proper operation.

8. Release blower door switch, install blower door and refer to the SERVICE label on the control door for more inform-

ation.

Component Self-Test Component Test can ONLY be initiated by performing the

following:

1. Remove blower door.

2. Remove the wire from the "R" terminal of the control board.

3. Turn Setup Switch, SW-1-6 "ON."

4. Manually close blower door switch.

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.

ELECTRICALSHOCK HAZARD Failure to follow this warning could result in personal iniury,

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.

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.

5. Component Test sequence will function as follows: a. The furnace control CPU turns the inducer motor ON at

high-heat speed and keeps it ON through step c.

b. After waiting 10 sec the furnace control CPU turns the hot

surface igniter ON for 15 sec, then OFF.

c. The furnace control CPU then turns the blower motor

BLWM on at mid-range airflow for 15 sec, then OFF.

d. After shutting the blower motor OFF the furnace control

CPU switches the inducer to low-heat speed for 10 sec, then OFF.

NOTE: The EAC terminals are energized when the blower is operating. After the component test is completed, 1 or more status codes (11 or 25) will flash. See component test section or Service Label (Fig.

54) for explanation of status codes. NOTE: To repeat component test, turn setup switch SWI-6 OFF

then back ON.

6. RELEASE BLOWER DOOR SWITCH, reattach wire to

"R" terminal on furnace control board and replace blower door.

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 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.

The minimum maintenance on this furnace is as follows:

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

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

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

4. Inspect burner compartment before each heating season for rust, corrosion, soot or excessive dust. If necessary, have

furnace and burner serviced by a qualified service agency.

5. Inspect the vent pipe/vent system before each heating sea- son for water leakage, sagging pipes or broken firings.

Have vent pipes/vent system serviced by a qualified service agency.

6. Inspect any accessories attached to the furnace such as a hu- midifier or electronic air cleaner. Perform any service or

maintenance to the accessories as recommended in the ac- cessory instructions.

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 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.

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. 61 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 reas- sembling.

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.

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.

ELECTRICALOPERATIONHAZARD Failuretofollowthiswarningcouldresultinpersonalinjury

ordeath. Blowerdoorswitchopens115-vpowerto control.No

componentoperationcanoccurunlessswitchis closed.

Cautionmustbetakenwhenmanuallyclosingthisswitchfor

servicepurposes.

16.Downfloworhorizontalfurnaceswithventpipethrough furnaceonly:

a.Installandconnectshortpieceofventpipeinsidefurnace

toexistingvent.

b.Connectventconnectortoventelbow.

17.Turnonelectricalsupply.Manuallycloseblowerdoor switch.Useapieceoftapetoholdswitchclosed.Checkfor

properrotationandspeedchangesbetweenheatingand coolingbyjumperingRtoGandRtoY/Y2onfurnace

controlthermostatterminals.If outdoortemperatureisbe- low70°F,turnoffcircuitbreakertooutdoorunitbefore runningfurnaceinthecoolingcycle.Turnoutdoorcircuit

breakeronaftercompletingcoolingcycle.(SeeFig.35.)

NOTE:If R-W/Wlthermostatterminalsarejumperedatthetime blowerdoorswitchisclosed,blowerwillrunfor90secbefore

beginningaheatingcycle.

a.Performcomponentself-testasshownatthebottomofthe

SERVICElabel,locatedonthecontroldoor.

b.Verifyblowerisrotatinginthecorrectdirection

18.If furnaceis operatingproperly,RELEASEBLOWER DOORSWITCH.Removeanyjumpersorreconnectany

disconnectedthermostatleads.Replaceblowerdoor.

19.Turnongassupplyandcyclefurnacethroughonecomplete heatingcycle.Verifythefurnacetemperatureriseasshown

inAdjustmentsSection.Adjusttemperatureriseasshownin AdjustmentsSection.

CleaningBurnersandFlameSensor Thefollowingitemsmustbeperformedbyaqualifiedservice

technician.If theburnersdevelopanaccumulationoflightdirtor dust,theymaybecleanedbyusingthefollowingprocedure:

NOTE:Useaback-upwrenchonthegasvalvetopreventthe valvefromrotatingonthemanifoldordamagingthemountingto theburnerassembly.

ELECTRICALSHOCKANDFIREHAZARD Failuretofollowthiswarningcouldresultinpersonaliniury,

death,and/orpropertydamage. Turnoffthegasandelectricalsuppliestothefurnaceand

installlockouttagbeforeperforminganymaintenanceor service.Followtheoperatinginstructionsonthelabel

attachedtothefurnace.

RefertoFig.62.

1.Disconnectpoweratexternaldisconnect,fuseorcircuit breaker.

2.Turnoffgasatexternalshut-offorgasmeter.

3.Removecontroldoorandsetaside.

4.TurnelectricswitchongasvalvetoOFF.

5.Disconnectthegaspipefromgasvalveandremovepipe fromthefurnacecasing.

6.Removeindividualwiresfromterminalsongasvalve.

7.DisconnectHotSurfaceIgniter(HSI)wiresfromHSI.

8.DisconnectFlameSensorwirefromFlameSensor.

9.Supportthemanifoldandremovethe4screwsthatsecure themanifoldassemblytotheburnerassemblyandsetaside.

Notethelocationofthegreen/yellowwireandgroundter- minal.

10.Inspecttheorificesinthemanifoldassemblyforblockages orobstructions.Removeorificeandcleanorreplaceorifice.

11.Removethefourscrewsthatattachthetopplateofthecas- ingtothefurnace.

12.Raisetopplateupslightlyandpropitupwithasmallpiece ofwoodorfoldedcardboard.

13.Supporttheburnerassemblyandremovethescrewsthatat- tachtheburnerassemblytotheheatexchangercellpanel.

14.Removewiresfrombothrolloutswitches.

15.Slideone-pieceburneroutofslotsonsidesofburneras- sembly.

16.Removetheflamesensorfromtheburnerassembly.

17.(Optional)RemovetheHotSurfaceIgniter(HSI)and

bracketfromtheburnerassembly.

18.Checkigniterresistance.Nominalresistanceis40to70 ohmsatroomtemperatureandisstableoverthelifeofthe

igniter.

19.Cleanburnerwithabrushandavacuum.

20.Cleantheflamesensorwithfinesteelwool(0000grade). Donotusesandpaperoremerycloth.

Toreinstallburnerassembly:

1.InstalltheHotSurfaceIgniter(HSI)andbracketinburner assembly.

2.Installflamesensoronburner.

3.Aligntheedgesoftheone-pieceburnerwiththeslotsinthe burnerassemblyandslidetheburnersforwarduntiltheyare

fullyseatedintheburnerassembly.

4.Aligntheorificesinthemanifoldassemblywiththesupport

ringsontheendoftheburner.

5.Inserttheorificesinthesupportringsoftheburners.

NOTE:Ifmanifolddoesnotfitflushagainsttheburner,donot forcethemanifoldontheburnerassembly.Theburnersarenot fullyseatedforwardintheburnerassembly.Removethemanifold

andcheckburnerpositioningintheburnerassemblyassembly

beforere-installingthemanifold.

6.Attachthegreen/yellowwireandgroundterminaltooneof themanifoldmountingscrews.

7.Installtheremainingmanifoldmountingscrews.

8.Checktheigniteralignment.SeeFig.56,58and62.

9.Attachthewirestotheroll-outswitches.

10.Aligntheburnerassemblywiththeopeningsintheprimary cellinletpanelandattachtheburnerassemblytothecell panel.

11.Connectthewirefortheflamesensor.

12.ConnectthewirefortheHotSurfaceIgniter.

NOTE:Usepropane-resistantpipedopetopreventleaks.Donot useTeflontape.

13.Installthegaspipetothegasvalve.

FIREOR'EXPLOSIONHAZARD Failuretofollowthiswarningcouldresultinpersonal

iniury,death,and/orpropertydamage. Neverpurgeagaslineintoacombustionchamber.Never

testforgasleakswithanopenflame.Useacommercially availablesoapsolutionmadespecificallyforthedetection

ofleakstocheckallconnections.Afireorexplosionmay resultcausingpropertydamage,personaliniuryorlossof

line.

14.Checkforgasleakswithacommerciallyavailablesoap solutionmadespecificallyforthedetectionofleaks.

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. 56, 58 and 62.

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. 62 .)

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. 62.)

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 injury, 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. 59)

5. Attach a flmnel 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.

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:TheHeatPad,whenused,shouldbewrappedaroundthe condensatedraintrap.Thereisnoneedtouseheattapewithinthe furnacecasing.Mostheattapesaretemperatureactivated,anditis notpracticaltoverifytheactualheatingofthetape.Checkthe following:

1.Checkforsignsofphysicaldamagetoheattapesuchas nicks,cuts,abrasions,gnawingbyanimals,etc.

2.Checkfordiscoloredheattapeinsulation.If anydamageor discoloredinsulationisevident,replaceheattape.

3.Checkthatheattapepowersupplycircuitison.

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

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.

7. Clean heat exchanger openings with a vacuum and a soft brush. (See Fig. 60.)

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. 570

12. Check for gas leaks.

FIRE OR'EXPLOSION HAZARD

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

Never purge a gas line into a combustion chamber. Never test for gas leaks with an open flame. Use a commercially available soap solution made specifically for the detection of leaks to check all connections. A fire or explosion may result causing property damage, personal injury or loss of

line.

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.

Since the furnace uses a condensing heat exchanger, some water

will accumulate in the unit as a result of the heat transfer process. Therefore, once it has been operated, it cannot be turned off and

left off for an extended period of time when temperatures will reach 32°F (0°C) or lower unless winterized. Follow these

)rocedures to winterize your furnace:

2. Remove control door.

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. 62.)

NOTE: Burner cover, manifold, gas valve, and burner assembly should be removed as one assembly.

[]NIT 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/swimming pool antifreeze or equivalent).

2. Turn off gas and electrical supplies to your furnace.

3. Remove furnace control door.

4. Remove the top unused rubber plug from the port on the collector box opposite the condensate trap. See Fig. 59.

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 funnel into the tube.

7. Pour 1 quart of anti-freeze solution into the funnel/tube. Antifreeze should run through the inducer housing, overfill

condensate trap and flow to an open drain.

8. Replace the rubber plug in the port on the collector box.

9. Remove the nfiddle unused rubber plug from the port on the collector box opposite the condensate trap. See Fig. 59.

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 furnace is re-started, flush condensate pump with clear water to check for proper operation before re-starting

furnace.

14. Propylene glycol need not be removed before re-starting furnace.

3/8-in.

9.6 mm

3/16-in.

4.6 mm

+0.8

2.5 mm_1.5

Al1620

Fig. 58 - Igniter Position - Side View

t Iv " to

(64.4)

Fig. 56 - Igniter Position - Top View

Burner Flame

/- Burner

Al1405

Al1392

Fig. 59 - Priming Condensate Trap

Fig. 57 - Burner Flame

Al1461

Al1273

Fig. 60 - Cleaning Heat Exchanger Cell

MOTORSHAFT

SET - /

"- MOTOR WHEEL HUB

SCREW LOCATION

BLO HSG ASSY

BRACKET

BRACKET ENGAGEMENT

DETAIL A

SEE DETAILA _X .

CUTOFF, BLOWER

BRACKET_

CAPACITOR OR POWER CHOKE

(WHEN USED)

WHEEL, BLOWER

-- BLOWER HSG ASSY

MOTOR, BLOWER

A11584

Fig. 61 - Blower Assembly

BURNER SUPT ASSY

BURNER ASSY

IGNITER

BRACKET, IGNITER

FLAME ROLLOUT

SWITCH

'__.,,,, FLAME SENSOR

(BELOW BURNER)

Fig. 62 - Burner Assembly

A11403

SEQUENCE OF OPERATION

NOTE: Furnace control must be grounded for proper operation or else control will lock out. Control is grounded through

green/yellow wire routed to gas valve and burner box screw. Using the schematic diagram in Fig. 64, 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/Wl or W/Wl-and-W2), 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. Two-Stage Heating (Adaptive Mode) with Single-Stage

Thermostat See Fig. 35 and 36 for thermostat connections

NOTE: The low-heat only switch SWI-2 selects either the low-heat only operation mode when ON, (see item 2. below) or the adaptive heating mode when OFF in response to a call for heat. (See Fig. 55.) When the W2 thermostat terminal is energized it will always cause high-heat operation when the R-to-W circuit is closed, regardless of the setting of the low-heat only switch. This

furnace can operate as a two-stage furnace with a single-stage thermostat because the furnace control CPU includes a

programmed adaptive sequence of controlled operation, which selects low-heat or high-heat operation. This selection is based upon the stored history of the length of previous gas-heating periods of the single-stage thermostat.

The furnace will start up in either low- or high-heat. If the furnace starts up in low-heat, the control CPU determines the low-heat on-time (from 0 to 16 minutes) which is permitted before

switching to high-heat. If the power is interrupted, the stored history is erased and the

control CPU will select low-heat for up to 16 minutes and then switch to high-heat, as long as the thermostat continues to call for heat. Subsequent selection is based on stored history of the

thermostat cycle times. The wall thermostat "calls for heat", closing the R-to-W circuit.

The furnace control performs a self-check, verifies the low-heat and high-heat pressure switch contacts LPS and HPS are open, and

starts the inducer motor IDM in high-speed.

a. Inducer Prepurge Period

(1.) If the furnace control CPU selects low-heat opera-

tion the inducer motor IDM comes up to speed, the low-heat pressure switch LPS closes, and the fur-

nace control CPU begins a 15-sec prepurge period. If the low-heat pressure switch LPS fails to remain

closed the inducer motor IDM will remain running at high-speed. After the low-heat pressure switch

re-closes the furnace control CPU will begin a 15-sec prepurge period, and continue to run the

inducer motor IDM at high-speed.

(20 If the furnace control CPU selects high-heat opera-

tion, the inducer motor IDM remains running at high-speed, and the high-heat pressure switch re-

lay HPSR is de-energized to close the NC contact. When sufficient pressure is available the high-heat

pressure switch HPS closes, and the high-heat gas valve solenoid GV-HI is energized. The furnace

control CPU begins a 15-sec prepurge period after the low-heat pressure switch LPS closes. If the

high-heat pressure switch HPS fails to close and the low-heat pressure switch LPS closes, the fur-

nace will operate at low-heat gas flow rate until the high-heat pressure switch closes for a maximum of

2 minutes after ignition.

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

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

c. Trial-For-Ignition Sequence -When the igniter warm-

up period is completed the main gas valve relay contact

GVR closes to energize the gas valve solenoid GV-M. The

gas valve solenoid GV-M permits gas flow to the burners where it is ignited by the HSI. Five sec after the GVR

closes, a 2-sec flame proving period begins. The HSI ig- niter will remain energized until the flame is sensed or until

the 2-sec flame proving period begins. If the furnace con- trol CPU selects high-heat operation, the high-heat gas

valve solenoid GV-HI is also energized.

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

flame-proving sensor electrode FSE, the inducer motor IDM switches to low-speed unless the furnace is operating

in high-heat, and the furnace control CPU begins the blower-ON delay period and continues to hold the gas

valve GV-M open. If the burner flame is not proved within two sec, the control CPU will close the gas valve GV-M,

and the control CPU will repeat the ignition sequence for

up to three more Trials-For-Ignition before going to Igni- tion-Lockout. Lockout will be reset automatically after

three hours, or by momentarily interrupting 115 v ac power to the furnace, or by interrupting 24 vac power at SECI or

SEC2 to the furnace control CPU (not at W/WI, G, R, etc.).

If flame is proved when flame should not be present, the furnace control CPU will lock out of Gas-Heating mode

and operate the inducer motor IDM on high speed until

flame is no longer proved.

e. Blower-On delay - If the burner flame is proven the

blower-ON delays for low-heat and high-heat are as fol- lows:

Low-heat - 45 sec after the gas valve GV-M is opened the blower motor BLWM is turned ON at low-heat airflow.

High-heat - 25 sec after the gas valve GV-M is opened the BLWM is turned ON at high-heat airflow. Simultan-

eously, the humidifier terminal HUM and electronic air cleaner terminal EAC-1 are energized and remain ener-

gized throughout the heating cycle.

f. Switching from Low- to High-Heat - If the furnace con-

trol CPU switches from low-heat to high-heat, the furnace control CPU will switch the inducer motor IDM speed

from low to high. The high-heat pressure switch relay HPSR is de-energized to close the NC contact. When suffi-

cient pressure is available the high-heat pressure switch HPS closes, and the high-heat gas valve solenoid GV-HI

is energized. The blower motor BLWM will transition to high-heat airflow five sec after the furnace control CPU

switches from low-heat to high-heat.

g. Switching from High- to Low-Heat -The furnace con-

trol CPU will not switch from high-heat to low-heat while the thermostat R-to-W circuit is closed when using a

single-stage thermostat.

h. Blower-OffDelay -When the thermostat is satisfied, the

R to W circuit is opened, de-energizing the gas valve GV- M, stopping gas flow to the burners, and de-energizing the

humidifier 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 at low-heat airflow or transition to low-

heat airflow for 90, 120, 150, or 180 sec (depending on se-

lection at blower-OFF delay switches). The furnace con- trol CPU is factory-set for a 120-sec blower-OFF delay.

2. Two-Stage Thermostat and Two-Stage Heating See Fig. 35 and 36 for thermostat connections.

NOTE: In this mode the low-heat only switch SWI-2 must be ON to select the low-heat only operation mode in response to closing the thermostat R-to-Wl circuit. Closing the thermostat R-to- Wl-and-W2 circuits always causes high-heat operation,

regardless of the setting of the low-heat only switch. The wall thermostat "calls for heat", closing the R-to-Wl circuit

for low-heat or closing the R-to-Wl-and-W2 circuits for high-heat. The furnace control performs a self-check, verifies the

low-heat and high-heat pressure switch contacts LPS and HPS are open, and starts the inducer motor IDM in high-speed.

The start up and shut down functions and delays described in item

1. above apply to the 2-stage heating mode as well, except for switching from low- to high-Heat and vice versa.

a. Switching from Low- to High-Heat - If the thermostat

R-to-W1 circuit is closed and the R-to-W2 circuit closes, the furnace control CPU will switch the inducer motor

IDM speed from low to high. The high-heat pressure switch relay HPSR is de-energized to close the NC contact.

When sufficient pressure is available the high-heat pres- sure switch HPS closes, and the high-heat gas valve solen- oid GV-HI is energized. The blower motor BLWM will

transition to high-heat airflow five sec after the R-to-W2 circuit closes.

b. Switching from High- to Low-Heat -If the thermostat

R-to- W2 circuit opens, and the R-to-W1 circuit remains closed, the furnace control CPU will switch the inducer motor IDM speed from high to low. The high-heat pres-

sure switch relay HPSR is energized to open the NC contact and de-energize the high-heat gas valve solenoid GV-HI.

When the inducer motor IDM reduces pressure suffi- ciently, the high-heat pressure switch HPS will open. The

gas valve solenoid GV-M will remain energized as long as the low-heat pressure switch LPS remains closed. The

blower motor BLWM will transition to low-heat airflow five sec after the R-to-W2 circuit opens.

3. 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 cooling airflow. Cooling airflow is based on the A/C selection shown in Fig. 55. The electronic air cleaner

terminal EAC-I is energized with 115 vac when the blower motor BLWM is operating.

When the thermostat is satisfied, the R-to-G-and-Y cir- cuits are opened. The outdoor unit will stop, and the fur-

nace blower motor BLWM will continue operating at cool- ing airflow for an additional 90 sec. Jumper Y/Y2 to

DHUM to reduce the cooling off-delay to 5 sec. (See Fig.

35.)

b. Single-Stage Thermostat and Two-Speed Cooling

(Adaptive Mode) - See Fig. 35 and 36 for thermostat connections.

This furnace can operate a two-speed cooling unit with a single-stage thermostat because the furnace control CPU

includes a programmed adaptive sequence of controlled operation, which selects low-cooling or high-cooling op-

eration. This selection is based upon the stored history of the length of previous cooling period of the single-stage

thermostat.

NOTE: The air conditioning relay disable jumper ACRDJ must be connected to enable the adaptive cooling mode in response to a

call for cooling. (See Fig. 35.) When ACRDJ is in place the furnace control CPU can turn on the air conditioning relay ACR to

energize the Y/Y2 terminal and switch the outdoor unit to high-cooling. The furnace control CPU can start up the cooling unit in either low- or high-cooling. If starting up in low-cooling, the furnace

control CPU determines the low-cooling on-time (from 0 to 20 minutes) which is permitted before switching to high-cooling. If

the power is interrupted, the stored history is erased and the furnace control CPU will select low-cooling for up to 20 minutes and then energize the air conditioning relay ACR to energize the Y/Y2 terminal and switch the outdoor unit to high-cooling, as long as the thermostat continues to call for cooling. Subsequent selection is based on stored history of the thermostat cycle times. The wall thermostat "calls for cooling", closing the

R-to-G-and-Y circuits. The R-to-Yl circuit starts the outdoor unit on low-cooling speed, and the R-to-G-and-Yl circuits starts

the furnace blower motor BLWM at low-cooling airflow which is the true on-board CF selection as shown in Fig. 35. If the furnace control CPU switches from low-cooling to high-cooling, the furnace control CPU will energize the air conditioning relay ACR. When the air conditioning relay ACR is

energized the R-to-Yl-and-Y2 circuits switch the outdoor unit to high-cooling speed, and the R-to-G-and-Yl-and-Y/Y2 circuits transition the furnace blower motor BLWM to high-cooling

airflow. High-cooling airflow is based on the A/C selection shown

in Fig. 35. NOTE: When transitioning from low-cooling to high-cooling the

outdoor unit compressor will shut down for 1 minute while the furnace blower motor BLWM transitions to run at high-cooling

airflow.

The electronic air cleaner terminal EAC-1 is energized with 115 vac whenever the blower motor BLWM is operating. When the thermostat is satisfied, the R-to-G-and-Y circuit are opened. The outdoor unit stops, and the furnace blower BLWM

and electronic air cleaner terminal EAC-1 will remain energized for an additional 90 sec. Jumper Y1 to DHUM to reduce the cooling off-delay to 5 sec. (See Fig. 35.)

c. Two-Stage Thermostat and Two-Speed Cooling

See Fig. 35 and 36 for thermostat connections

NOTE: The air conditioning relay disable jumper ACRDJ must be disconnected to allow thermostat control of the outdoor unit

staging. (See Fig. 350 The thermostat closes the R-to-G-and-Y1 circuits for

low-cooling or doses the R-to-G-and-Yl-and-Y2 circuits for high-cooling. The R-to-Y1 circuit starts the outdoor unit on low-cooling speed, and the R-to-G-and-Y1 circuit starts the

furnace blower motor BLWM at low-cooling airflow which is the true on-board CF (continuous fan) selection as shown in Fig. 56.

The R-to-Yl-and-Y2 circuits start the outdoor unit on high-cooling speed, and the R-to- G-and-Y/Y2 circuits start the

furnace blower motor BLWM at high-cooling airflow. High-cooling airflow is based on the A/C (air conditioning)

selection shown in Fig. 55. The electronic air cleaner terminal EAC-1 is energized with 115

vac whenever the blower motor BLWM is operating. When the thermostat is satisfied, the R-to-G-and-Y1 or R-to-

G-and-Yl-and-Y2 circuits are opened. The outdoor unit stops,

and the furnace blower BLWM and electronic air cleaner terminal EAC-1 will remain energized for an additional 90 sec. Jumper Y1

to DHUM to reduce the cooling off-delay to 5 sec. (See Fig. 35.)

4. Dehumidification Mode See Fig. 35 and 36 for thermostat connections.

The dehumidification output, D or DHUM on the Thermo-

statshouldbeconnectedtothe 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, the fur-

nace control dehumidification capability is activated. If the DHUM input is removed for more than 48 hours, the fur-

nace control reverts back to non-dehumidification mode. The cooling operation described in item 3. above also ap-

plies to operation with a dehumidification thermostat. The exceptions are listed below:

a. Low cooling-When the R-to-G-and-Y1 circuit is closed

and there is a demand for dehumidification, the furnace blower motor BLWM will drop the blower airflow to 86

percent of low-cooling airflow which is the true on-board CF (continuous fan) selection as shown in Fig. 55.

b. High cooling-When the R-to-G-and Y/Y2 circuit is

closed and there is a demand for dehumidification, the fur- nace blower motor BLWM will drop the blower airflow to 86 percent of high-cooling airflow. High-cooling airflow

is based on the A/C (air conditioning) selection shown in Fig. 55.

c. Cooling off-delay-When the "call for cooling" is satisfied

and there is a demand for dehumidification, the cooling blower-off delay is decreased from 90 sec to 5 sec.

5. Super-Dehumidify Mode

Super-Dehumidify mode can only be entered if the furnace control is in the Thermidistat mode and there is a demand

for dehumidification. The cooling operation described in item 3 above also applies to operation with a dehumidifica-

tion thermostat. The exceptions are listed below:

a. When the R-to-Yl circuit is closed, R-to-G circuit is

open, and there is a demand for dehumidification, the fur- nace blower motor BLWM will drop the blower airflow to

65 percent of low-cooling airflow for a maximum of 10 minutes each cooling cycle or until the R-to-G circuit

closes or the demand for dehumidification is satisfied. Low-cooling airflow is the true on-board CF (continuous

fan) selection as shown in Fig. 55.

b. When the R-to-Y/Y2 circuit is closed, R-to-G circuit is

open, and there is a demand for dehumidification, the fur- nace blower motor BLWM will drop the blower airflow to

65 percent of high-cooling airflow for a maximum of 10 minutes each cooling cycle or until the R-to-G circuit

closes or the demand for dehumidification is satisfied. High-cooling airflow is based on the A/C (air condition-

ing) selection shown in Fig. 55.

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.

6. Continuous Blower Mode When the R-to-G circuit is closed by the thermostat, the

blower motor BLWM will operate at continuous blower air- flow. Continuous blower airflow selection is initially based

on the CF (continuous fan) selection shown in Fig. 55. Factory default is shown in Fig. 55. Terminal EAC-I is en- ergized as long as the blower motor BLWM is energized.

During a call for heat, the furnace control CPU will trans- ition the blower motor BLWM to continuous blower air-

flow, low-heat airflow, or the mid-range airflow, whichever is lowest. The blower motor BLWM will remain ON until

the main burners ignite then shut OFF and remain OFF for the blower-ON delay (45 sec in low-heat, and 25 sec in

high-heat), allowing the furnace heat exchangers to heat up

more quickly, then restarts at the end of the blower-ON delay period at low-heat or high-heat airflow, respectively.

The blower motor BLWM will revert to continuous-blower airflow after the heating cycle is completed. In high-heat,

the furnace control CPU will drop the blower motor BLWM to low-heat airflow during the selected blower-OFF delay

period before transitioning to continuous-blower airflow. When the thermostat "calls for low-cooling", the blower

motor BLWM will switch to operate at low-cooling airflow. When the thermostat is satisfied, the blower motor BLWM

will operate an additional 90 sec at low-cooling airflow be-

fore transitioning back to continuous-blower airflow. When the thermostat "calls for high-cooling", the blower

motor BLWM will operate at high cooling airflow. When the thermostat is satisfied, the blower motor BLWM will op-

erate an additional 90 sec at high-cooling airflow before transitioning back to continuous-blower airflow. When the

R-to-G circuit is opened, the blower motor BLWM will continue operating for an additional 5 sec, if no other func-

tion requires blower motor BLWM operation. Continuous Blower Speed Selection from Thermostat To

select different continuous-blower airflow 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 airflow from the factory setting

to the next highest CF selection airflow as shown in Fig. 55. Momentarily turning off the FAN switch again at the ther-

mostat will shift the continuous-blower airflow up one more increment. If you repeat this procedure enough you

will eventually shift the continuous-blower airflow to the

lowest CF selection as shown in Fig. 55. The selection can

be changed as many times as desired and is stored in the

memory to be automatically used following a power inter- ruption.

NOTE: If the blower-off delay is set to the maximunL the

adjustable continuous-fan feature is locked (i.e., fan speed cannot

be changed from its current setting).

7, Heat pump

See Fig. 35 and 36 for thermostat connections. When installed with a heat pump, the furnace control auto-

matically changes the timing sequence to avoid long blower off times during demand defrost cycles. Whenever W/WI is energized along with YI or Y/Y2, the furnace control CPU

will transition to or bring on the blower motor BLWM at

cooling airflow, low-heat airflow, or the mid-range airflow,

whichever is lowest. The blower motor BLWM will remain

on until the main burners ignite then shut OFF and remain OFF for 25 sec before coming back on at heating airflow.

When the W/Wl input signal disappears, the furnace con- trol begins a normal inducer post-purge period while chan-

ging the blower airflow. If Y/Y2 input is still energized the furnace control CPU will transition the blower motor

BLWM airflow to cooling airflow. If Y/Y2 input signal dis- appears and the YI input is still energized the furnace con-

trol CPU will transition the blower motor BLWM to low- cooling airflow. If both the YI and Y/Y2 signals disappear

at the same time, the blower motor BLWM will remain on at low-heat airflow for the selected blower-OFF delay period.

At the end of the blower- OFF delay, the blower motor

BLWM will shut OFF unless G is still energized, in which case the blower motor BLWM will operate at continuous

blower airflow.

Component Self-Test

Refer to page 73 for instructions.

START

IsAMBERLEDstatus light on?

YES

Troub leshooting Guide

-_ s there115V at L1 andL2?

I Is there 24V at SEC-1 and SEC-2?

YES

Is door switch closed?

YES

I"_ I Is there 115V going to switch?

Is door switch closed?

Is circuit breaker closed?

]

_! YES

Replacefurnace control.

I s AMBER LED status light blinkingrapidly without a pause?

1! NO

ON/OFF slowly with a combination of

I Is AMBER LED status light blinking

short and long flashes?

Determine status code. The status code is a 2 digit number with the first digit

determined bythe number of short

flashes and the second digit by the

number off ong flashes?

_°

!! YES

I__ Check for correct line voltage polarity. If

that was flashed.

Go to section below for the status code

units are twinned, check for proper low- voltage (24V) transformer phasing.

To recall previous status codes disconnect the R thermostat connection, reset power, and put setup

switch BWI-I in the ON position. The AMBER LED will flash the status codes in the order of occurrence.

Record status codes until status code #I I flashes (I short and 1 long flash). After status code #11 flashes the status codes will repeat. Status codes are erased after 72 hours or can be manually erased

by putting setup switch BW1-1 in the ON position and jumpering R, W/W1, and Y/Y2 simultaneously until status code #11 is flashed. When done put setup switch BW1-1 in the OFF position.

Was there a previous status code otherthan #I I?

l [ Replace d..... itch.

--_ Replace transformer.

t_ Does the control respond to WA_VI, W2,

Y1, Y/Y2, and G (24V) thermostat signals?

Run system through a low-heat, high- heat, or cooling cycle to check operation.

Status codes are erased after 72 hours or can be manually erased by putting

setup switch SWl-1 in the ON position and jumpering R, W/W1, and Y/Y2

simultaneously until status code #I I is

flashed.

I Replace furnace control.

YES

7! YES

1 I

Check for continuity in wire from circuit breaker to furnace.

Close circuit breaker and go back to START.

Check room thermostat or interconnecting cable.

Is 24V present at WA,VI, W2, Y1, Y/Y2 or G thermostat terminals on the furnace

control?

Disconnect all the thermostat wires from the furnace control.

Does the problem repeat when using a jumper wire?

YES

l.o

I YES

1.°

The thermostat is not compatible with the furnace control. Either install a ballast

resistor, connect the Com24V thermostat terminal to the thermostat, or replace the thermostat.

NO PREVIOUS CODE Status codes are erased after 72 hours or can be manually erased by putting setup switch SWl-] in

the ON position and jumpering R, W/W1, and Y/Y2 simultaneously until status code

#1 ] is flashed. Run system through a low- heat, high-heat, 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/W1 closed) or when (R-W/W1 opens)

during the blower on-delay period.

13 LIMIT CIRCUIT LOCKOUT Lockout

occurs if the limit or flame rollout switch is open longer than 3 minutes or 10

successive limit trips occurred during high- heat. 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.

15 BLOWER MOTOR LOCKOUT Indicates

the blower failed to reach 250 RPM or the blower failed to communicate within 30

seconds after being turned ON in two successive heating cycles, Control will

auto-reset after 3 hours, See code 41.

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 PRESSURESWITCH 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,

LOW-HEAT PRESSURESWITCH DID NOT CLOSE OR REOPENED If open

longer than 5 minutes, inducer shuts off for 15 minutes before retry, If opens

during blower on-delay period, blower will come on for the selected blower off-delay.

Check for:

- Proper vent sizing.

- Air leak between vestibule and blower compartment.

- Low inlet gas pressure (if LGPS used).

- Restricted vent,

- Disconnected or obstructed pressure

tubing,

- Defective or miswired pressure switches

- Excessive wind.

- Plugged condensate drain.

- Water in vent piping, possible sagging pipe,

- Defective inducer motor.

- Low inducer voltage (115V)

LIMIT CIRCUIT FAULT Indicates the limit or a flame rollout switch is open or the furnace is operating in high-heat only

mode due to 2 successive low-heat limit trips. Blower will run for4 rain. or until

open switch remakes whichever is longer, If open longer than 3 rain., code changes

to lockout #13. If open less than 3 rain. status code #33 continues to flash until

blower shuts off. Flame rollout switch requires manual reset, Check for:

- Loose blower wheel.

- Defective switch or connections,

- Improper low- or high-heat gas input

adjustment.

- Improper limit switch or no limit gasket,

- Dirtyfllter or restricted duct system.

IGNITION PROVING FAILURE Iffl ame is not sensed during the trial for ignition

period, the control will repeat the ignition sequence 3 more times before lockout #14

occurs. Iffl ame 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-offvalve.

- 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 component test mode. To check the igniter remove the R

thermostat connection from the control, reset power, and put setup switch SW1-6 in

the ON position to start the component test. Does the igniter glow orange/white by the

end of the 15 second warm-up period?

43 LOW-HEAT PRESSURESWITCH OPEN

WHILE HIGH-HEAT PRESSURE SWITCH IS CLOSED - Check for:

- Low-heat pressure switch stuck open.

- Disconnected or obstructed pressure tube.

- Miswired pressure switches,

- Low inlet gas pressure (if LGPS used).

- Plugged condensate drain.

- Water in vent piping, possible sagging pipe.

Unplug igniter harness from control and repeat component test by turning setup

switch SW1-6 OFF and then back ON. Check for 115V between pin 3 and

NEUTRAUL2 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

I Do the main b ....... ignite? I_

I Do the main b ........ tay on?

i /

Repeat call for heat and check flame INO sensor current during trial for ignition

period. Is the DC microamps below 0.57

Clean flame sensor with fine steel wool and recheck current. Nominal current is

4.0 to 6.0 microamps.

I Is current near typical value?

I Will main burners ignite and stay on?

l Fixed.

YES

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

]_l Check connections. If OK,

.YES

¢q

I_ Replace furnace control.

if code repeats.

Check for continuity in the harness and igniter. Replace

Replace furnace control. defective component.

replace control.

turned on. Replace valve.

Check that all gas valves are

Check for:

- Inadequate flame carryover or rough ignition.

- Lowinlet 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, repeat check

in high-heat. If burners will still not stay on replace

control. If burners operate in high-heat then switch to low- heat, check manifold

pressure. If OK, check burner carryover and flame sensor location.

Replace electrode,

25 INVALID MODEL SELECTION OR

SETUP ERROR- If status code 25 only

flashes 4 times on power-up the control is

missing its model plug PL4 and is

defaulting to the model selection stored in

memory. If status code 25 flashes continuously it could indicate any of the

following:

- Model plug PL4 is missing and there is no valid model stored in permanent memory. This will happen if you forget

to install the model plug PL4 on a

service replacement control.

- Thermostat call with SWl-1 ON.

- Thermostat call with SWl-6 ON.

- SWl-1 and SW]-6 both ON.

- Two different furnace models twinned.

- Service replacement control is incorrect. Need non-modulating board with software version Vl 7 or later.

HIGH-HEAT PRESSURE SWITCH OR

RELAY DID NOT CLOSE OR

_°

REOPENED - Check for:

- Control relay may be defective.

- Gas valve is miswired.

- See status code 32.

41 BLOWER MOTOR FAULT- Indicates the

blower failed to reach 250 RPM or the blower failed to communicate within the

prescribed time limits. Thirty seconds

after being turned ON or ten seconds

during steady-state operation. Turn power offand check the following items first before proceeding to the next step.

- Rubbing blower wheel.

- Loose blower wheel.

- Wiring from furnace control to blower motor.

Remove the R thermostat connection from

the furnace control, disconnect both

connectors from the blower motor PL13 and PL]4. Does the blower wheel turn

freely?

Replace the blower control module attached to the blower motor. Follow the instructions with

the blower control module to make sure the entire blower motor does not need to be

replaced.

You have an open wire or bad terminal on the BLUE wire between the furnace control and the

blower motor.

Replace the furnace control.

._ Turn power back on. Is there115VAC atPL14-S and PL14-47

q s there 12-VDC at PL13-7 RED (+) andPL13-1 GREEN (-)7

PL3-2 GREEN (-)?

I Is there 12-VDC at Pk3-1 RED (+) and

Replace the furnace control.

Is there 5-VDC at PL13-16 YELLOW (+) and PL13-1 GREEN (-)?

The voltage just measured should be very stable and should not fluctuate more

than .02-VDC. If the voltage fluctuates more than this get a different voltmeter before proceeding.

Turn power off, reconnect PL13 and PL]4 to the blower motor, then turn

power back on. Connect a DC voltmeter across PL3-3 YELLOW (÷) and PL3-2

GREEN (-). Does the voltage fluctuate more than it did in the previous step?

YES

terminal on either the BLACK or

WHITE power leads between

the furnace control and the blower motor. If you have a

You have an open wire or bad power choke disconnect it and

check continuity.

You have an open wire or bad terminal on either the RED or GREEN wire between the

furnace control and the blower motor.

I NO

Is there S-VDC at PL3-3 I YELLOW (+) and PL3-2

GREEN (-)?

YES

You have an open wire or bad I terminal on the YELLOW wire

between the furnace control and

the blower motor.

Connect a DC voltmeter across Pk3-4 BLUE (+) and Pk3-2 GREEN (-). Does the voltage

fluctuate as described two steps back?

Does the voltage fluctuate as described in the

previous step?

_ YES

Replace the blower control module attached to the blower motor. Follow the instructions with

the blower control module to make sure the entire blower motor does not need to be

replaced.

Turn power off, disconnect Pkl3 and PL14 from the blower motor, then turn

power back on. Connect a DC voltmeter across Pk]3-16 BLUE (+) and Pk]3-] GREEN (-). The voltage should be near 0-VDC but it will fluctuate briefly several

times a second. If you have an analog

voltmeter the needle will briefly go high several times a second. If you have a digital voltmeter with a bar graph it will

show a large change in magnitude on the bar graph several times a second. If you have a standard digital voltmeter it will show a brieffl uctuation in voltage and the

magnitude may vary depending on the voltmeter used.

CONNECTION DIAGRAM

SEE RATING PLATE FOF

MODEL PLUG USE

HSI LO

BRN BRN

TO115VACFIELD-DISCONNECTSWITCH

K _L2 EQUIPMENT

PL31_ _ _ _1 PL13

_ PLY2 _ _PL12 r _ nlwM 1

GROUND _"

< --4qA ....... )

I rr-e \ j

SCHEMATIC DIAGRAM

EAC [ _

HUM

__EAO-_ EAC-__

FRS2 LS FRS1

PL1-6

o H_LHL_ CAP-

i i

NOTES:

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

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

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

4. Symbols are electrical representation only.

5. Solid lines inside PCB are printed circuit board conductors and are Rot included in legend.

6. Replace only with a 3 amp fuse.

7. Inductor is used with 3/4 hp and 1 hp ECM Blower motors.

8. Factory connected when (LGPS) not used.

9. Blower off-delay, gas heating selections are (90, 120, 150, 180) seconds, cooling or heat pump 90 seconds or 5 seconds when

dehumidify call is active.

10. Ignition lockout will occur after four consecutive usuccessful trials for ignition. Control will auto-reset after three hours.

11. Inducer motor (IDM) contains internal auto-reset thermal overload switch.

12. Any of the 5 wires shown within the NEUTRAL L2 boxcan be connected to any terminal within the box.

13. Blower motor (BLWM) is locked rotor overload protected by redundant electronic control circuits.

Fig. 64 - Wiring Diagram

--me

Qm_

JUNCTIONTERMINAL

0 CONTROLTERMINAL FACTORYCONTROLWIRING(24VAC)

I I1_ CONTROLTERMINAL

"J'- FIELDEARTHGROUND -- CONDUCTORONCONTROL

I _-- _ FIELDWIRINGSCREWTERMINAL

/-)7 EQUIPMENTGROUND --4 e,-, PLUGRECEPTACLE

NC AirConditioning(AdjustableAirflow-CFM) ILK BlowerDoorInterlockSwitch,SPST(N,O,)

ACR Air ConditioningRelay,SPST(N.O.) IND Inductor(Note#7) ACRDJ AirConditioningRelayDefeatJumper LED LightEmittingDiodeforStatusCodes

BLWM BlowerMotor(ECM) LOPS LowGasPressureSwitch,SPST(N,O,) CF ContinuousFan AdjustableAirflow-CFM LPS Low-HeatPressureSwitch,SPST N.O. CAP-f Capacitor LS Lm t Sw tch,Auto-Reset,SPSTN,C, COMMR CommunicationRelay,SPDT PCB PrintedCircuitBoard CPU Microproceasor/Cirouitty PL1 12-CircuitConnector

DHUM DHUMConnection24VAC) PL2 4-CircuitHSI& IDMConnector EAC-1 EectronoA rC eanerConnecton PL3 4-ClmuitECMBLWMConnector

(115VAC1,0AmpMax,) PL4 4-CircuitModelPlugConnector EAC-2 ElectronicAirCleanerConnectionCommon) PL7 4-CimuitCommunicationConnector FRS-I,2 Fame-RooutSwitch,Man,Reset,SPST N,C, PL9 2-CircuitOATConnector FSE Flamee-ProvingSensorElectrode PLfO 2-CgcuitHSlConnector

FU1 Fuse,3Amp,AutomotiveBladeType PLff 12-CirculIDMConnector

FactoryInstalled PL12 1-CircuitInductorSpliceConnector

FU2 FuseorDisconnect PLf3 5-CircuitBlowerGirl,Connector GV GasValve PU4 4-CircuitBlowerPowerConnector

GVR GasValveRelay,DPST(N,O,) SWI-1 ManualSwitch,StatusCodeRecall HPS High-HeatPressureSwitch,SPST(N.O.) SWl-2 ManualSwitch,MinimumHeatOnly HPSR High-HeatPressureSwitchRelay,SPSTN,C, SWl-3 ManualSwitch,MWIntHeatRiseAdj. HSI HotSurfaceIgniter(115VAC) SW1-4 ManualSwitch,Comfort/Effy,Ad,

HSlR HotSurfaceIgniterRelay,SPST(N.O.) SW1-5 ManualSwitch,CoolingCFM/Ton HUM 24VACHumidifierConnection(0,5AmpMax,) SWf-6 ManualSwitch,ComponentTest HUMR HumidifierRelay,SPSTN,O, SWl-7,8 ManualSwitches,BlowerOff-Delay IDM InducedDraftMotor,2-Speed,PSC SW4-1 ManualSwitch,TwinningMain(OFF)/ Sec, IDR InducerMotorRelay,SPST(N,O,) SW4-2&3 ForFutureUse IHI/LOR InducerMotorSpeedChangeRelay,SPDT TRAN Transformer,115VAC/ 24VAC

_ FACTORYPOWERWIRING(115VAC)

FIELDCONTROLWIRING(24VAC)

338308:20] Rev. E

Al1597

PARTS REPLACEMENT INFORMATION GUIDE

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

59TN6A 120 V 24 .... 22

HEATING COOLING

SIZE (CFM)

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.

Manufacturer reserves the right to change, at any time, specification8 and design8 without notice and without obligations,

Catalog No: 59TN6A-05SI

Replaces: 59TN6A- O4Sl

Carrier 59TN6A User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual