Carrier PG8JEA, PG8MEA Installation, Start-up, Operating And Service And Maintenance Instructions

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Page 1

PG8MEA PG8JEA

4 --- W AY M ULT I P OI S E IN D U C E D --- C O M B U S T I O N

GAS FURNACE

Installation, Start---Up Operating and

Service and Maintenance Instructions

Series C

SAFETY CONSIDERATIONS 2........................

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

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

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

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

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

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

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

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

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

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

ELECTROSTATIC DISCHARGE PRECAUTIONS

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

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

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

Upflow Installation 10..............................

Downflow Installation 11...........................

Horizontal Installation 13...........................

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

Air Ducts 14.....................................

Gas Piping 16....................................

Electrical Connection 20............................

115--V Wiring 20..................................

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

24 Volt Wiring 21.................................

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

VENTING 25.......................................

General 25......................................

Masonry Chimney Requirements 25...................

Appliance Application Requirements 26................

Additional Venting Requirements 28...................

Sidewall Venting 28................................

START--UP, ADJUSTMENT, AND SAFETY CHECK 32.....

General 32.......................................

Start--up Procedures 32.............................

Adjustments 32...................................

Check Safety Controls 34...........................

Checklist 36......................................

SERVICE AND MAINTENANCE PROCEDURES 41.......

Introduction 41...................................

Electrical Controls and Wiring 41.....................

Care and Maintenance 42...........................

Cleaning and/or Replacing Filter 43...................

Blower Motor and Wheel 43.........................

Cleaning Heat Exchanger 44.........................

Sequenceof Operation 45...........................

Wiring Diagrams 47...............................

Troubleshooting 47................................

REPLACEMENT INFORMATION GUIDE 51.............

Always Ask For

Use of the AHRI Certified TM Mark indicates a manufacturer’s participation in the program. For verification of certification for individual products, go to www.ahridirectory.org.

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

Portions of the text and tables are reprinted from NFPA 54/ANSI Z223.1--2012E, 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.

Page 2

SAFETY CONSIDERATIONS

WARNING

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

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

Improper installation, adjustment, alteration, service, maintenance, or use could cause carbon monoxide poisoning, explosion, fire, electrical shock, or other conditions which may cause personal injury or property damage. Consult a qualified service agency, local gas supplier, or your distributor or branch for information or assistance. The qualified service agency must use only factory--authorized and listed kits or accessories when modifying this product.

PG8MEA

FURNACE RELIABILITY HAZARD

Improper installation or misapplication of furnace may require excessive servicing or cause premature component failure.

Application of this furnace should be indoors with special attention given to vent sizing and material, gas input rate, air temperature rise, unit leveling, and unit sizing.

Improper installation, adjustment, alteration, service, maintenance, or use can cause explosion, fire, electrical shock, or other conditions which may cause death, personal injury, or property damage. Consult a qualified installer, service agency, or your distributor or branch for information or assistance. The qualified installer or agency must use factory--authorized kits or accessories when modifying this product. Refer to the individual instructions packaged with the kits or accessories when installing.

Follow all safety codes. Wear safety glasses, protective clothing, and work gloves. Have a fire extinguisher available. Read these instructions thoroughly and follow all warnings or cautions include in literature and attached to the unit. Consult local building codes, the current editions of the National Fuel Gas Code (NFGC) NFPA 54/ANSI Z223.1 and the National Electrical Code (NEC) NFPA 70.

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

Understand the signal words DANGER, WARNING,and

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

severe personal injury or death. WARNING signifies hazards which could result in personal injury or death. CAUTION is used to identify unsafe practices which may result in minor personal injury or product and property damage. NOTE is used to highlight suggestions which will result in enhanced installation, reliability, or operation.

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.

CAUTION

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

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

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

4. Combustion products must be discharged outdoors. Connect this furnace to an approved vent system only, as specified in the “Venting” section of these instructions.

5. Never test for gas leaks with an open flame. Use a commercially available soap solution made specifically for the detection of leaks to check all connections, as specified in the “Gas Piping” section.

6. Always install furnace to operate within the furnace’s intended temperature--rise range with a duct system which has an external static pressure within the allowable range, as specified in the “Start--Up, Adjustments, and Safety Check” section. See furnace rating plate.

7. When a furnace is installed so that supply ducts carry air circulated by the furnace to areas outside the space containing the furnace, the return air shall also be handled by duct(s) sealed to the furnace casing and terminating outside the space containing the furnace. See “Air Ducts” section.

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

9. The furnace may be used for construction heat provided that the furnace installation and operation complies with the first CAUTION in the LOCATION section of these instructions.

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

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

12. Maintain a 1--in. (25 mm) clearance from combustible materials to supply air ductwork for a distance of 36 inches (914 mm) horizontally from the furnace. See NFPA 90B

or local code for further requirements.

13. These furnaces SHALL NOT be installed directly on carpeting, tile, or any other combustible material other than wood flooring. In downflow installations, factory accessory floor base MUST be used when installed on combustible materials and wood flooring. Special base is not required when this furnace is installed on manufacturer’s Coil Assembly Part No. CAR, CAP, CNRV, and CNPV, or when Coil Box Part No. KCAKC is used. See Fig. 2 for clearance to combustible construction information.

INTRODUCTION

Series 120/C 4--way multipoise Category I fan--assisted furnace is CSA design--certified. A Category I fan--assisted furnace is an appliance equipped with an integral mechanical means to either draw or force products of combustion through the combustion chamber and/or heat exchanger. The furnace is factory--shipped for use with natural gas.

This furnace is not approved for installation in mobile homes, recreational vehicles, or outdoors. This furnace is designed for minimum continuous return--air temperature of 60_F(16_C)db or intermittent operation down to 55_F(13_C) db such as when

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used with a night setback thermostat. Return--air temperature

[736.9]

Ø7/8

[22.2]

ACCESSORY

5 15/16 [150.7]

28.39

[721.2]

Ø7/8 [22.2]

ACCESSORY

14 7/8 [337.3]

(BOTH SIDES)

Ø7/8 [22.2] ACCESSORY

Ø7/8

[22.2]

ACCESSORY

Ø1 3/4 [44.5] GAS ENTRY

Ø1/2 [12.7] THERMOSTAT WIRE ENTRY

22 1/16

[560]

SIDE INLET

(BOTH SIDES)

11 7/16 [290.7]

9 11/16 [245.4]

[197.8]

7 13/16

Ø7/8

[22.2]

J.BOX PROVISION

Ø7/8 [22.2] JUNCTION BOX LOCATION

Ø1 3/4 [44.5] GAS ENTRY

1 15/16 [49.2]

[25.4]

1 1/4 [31.8]

29 9/16 [750.7]

1 15/16

[49.2]

5 5/8

[143.3]

5 7/16

[138.5]

6 13/16

[172.3]

Ø1/2

[12.7]

THERMOSTAT WIRE ENTRY

[481.7]

OUTLET

21.6

[549.5]

BOTTOM INLET

33 1/4

[843.9]

9 9/16 [243.3]

3/4

[19.1]

5 7/8 [148.5]

3 7/16 [86.8]

9 7/8

[250.7]

27 3/4 [704.7]

2 5/16 [59]

FRONT OF CASING

TOP OF CASING

4 13/16 [122.2]

27 3/4 [704.7]

5 7/8

[148.5]

8 5/8 [219]

5 1/2 [140.3]

8 7/16 [213.5]

FRONT OF CASING

TOP OF CASING

6.1

[155.7]

2 1/16 [51.6]

5.1

[130.5]

1.7 [43.5]

Ø7/8 [22.2] ACCESSORY (2)

AIR FLOW

BOTTOM RETURN

WIDTH

AIR FLOW

KNOCK OUTS FOR VENTING(5 PLACES)

must not exceed 85_F(29_C) db. Failure to follow these return--air temperature limits may affect reliability of heat exchangers, motors, and controls. (See Fig. 3).

5.1

[130.5]

2 1/16 [51.6]

1.7 [43.5]

Ø7/8 [22.2] ACCESSORY (2)

FRONT OF CASING

1 15/16 [49.2]

5 15/16 [150.7]

5 1/2 [140.3]

8 7/16 [213.5]

9 7/8

[250.7]

27 3/4 [704.7]

33 1/4

[843.9]

NOTES:

1. Two additional 7/8 ---in. (22 mm) diameter holes are located in the top plate.

2. Minimum return ---air openings at furnace, based on metal duct. If flex duct is used, see flex duct manufacturer’s recommendations for equivalent diameters.

AIR FLOW

ACCESSORY

THERMOSTAT WIRE ENTRY

ACCESSORY

21.6

[549.5]

BOTTOM INLET

28.39

[721.2]

[736.9]

Ø7/8

[22.2]

Ø7/8

[22.2]

Ø1/2

[12.7]

6.1

[155.7]

3 7/16 [86.8]

5 7/8 [148.5]

2 5/16 [59]

TOP OF CASING

Ø7/8 [22.2] JUNCTION BOX LOCATION

Ø1 3/4 [44.5] GAS ENTRY

AIR FLOW

BOTTOM RETURN

WIDTH

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

NOTE: Remove all shipping brackets and materials before operating the furnace.

FRONT OF CASING

8 5/8 [219]

6 13/16

[172.3]

5 7/8

[148.5]

TOP OF CASING

3/4

[19.1]

29 9/16 [750.7]

9 9/16 [243.3]

27 3/4 [704.7]

KNOCK OUTS FOR VENTING(5 PLACES)

5 7/16

[138.5]

1 15/16

[49.2]

4 13/16 [122.2]

J.BOX PROVISION

ACCESSORY

[143.3]

Ø7/8

[22.2]

Ø7/8

[22.2]

5 5/8

AIR FLOW

[481.7]

OUTLET

Ø1/2 [12.7] THERMOSTAT WIRE ENTRY

Ø1 3/4 [44.5] GAS ENTRY

Ø7/8 [22.2] ACCESSORY

22 1/16

[560]

SIDE INLET

(BOTH SIDES)

7 13/16

[197.8]

14 7/8 [337.3]

(BOTH SIDES)

[25.4]

9 11/16 [245.4]

1 1/4 [31.8]

a. For 800 CFM ---16 ---in. (406 mm) round or 14 1/2 x 12 ---in. (368 x 305 mm) rectangle.

b. For 1200 CFM ---20 ---in. (508 mm) round or 14 1/2 x 19 1/2 ---in. (368 x 495 mm) r e ctangle.

c. For 1600 CFM ---22 ---in. (559 mm) round or 14 1/2 x 22 1/16 ---in. (368 x 560mm) rectangle.

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

a combination of 1 side an d the bottom, or the bottom only will ensur e adequate return a ir openings for airfl ow requirements above 1800 CFM.

11 7/16 [290.7]

A10290

PG8MEA

WIDTH

FURNACE SIZE

CABINET

045--- 08/024045 14--- 3/16 (360) 12--- 9/16 (319) 9--- 5/16 (237) 12--- 11/16 (322) 4 (102) 104 (47) 16 (406) 070--- 16/048070 17--- 1/2 (445) 15 ---7/8 (403) 11 --- 9/16 (294) 16 (406) 4 (102) 126 (57) 16 (406) 090--- 16/048090 21 (533) 19 --- 3/8 (492) 13 --- 5/16 (338) 19--- 1/2 (495) 4 (102) 140 (64) 20 (508) 110--- 20/060110 21 (533) 19 --- 3/8 (492) 13 --- 5/16 (338) 19--- 1/2 (495) 4 (102) 152 (69) 20 (508) 135--- 20/060135 24--- 1/2 (622) 22 ---7/8 (581) 15 --- 1/16 (383) 23 (584) 4 (102)* 163 (74) 24 (610)

*135 and 155 size furnaces require a 5 or 6 ---in. (127 or 152 mm) vent. Use a vent adapter between furnace and vent stack. See Installation Instructions for complete installation requirements.

OUTLET

WIDTH

Fig. 1 -- Dimensional Drawing

Table1–Dimensions

TOP AND

BOTTOM FLUE

COLLAR

BOTTOM

INLET WIDTH

VENT

CONNECTION

SIZE

SHIP WT.

LB. (KG)

ACCESSORY

CABINET SIZE

FILTER MEDIA

IN. (MM)

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PG8MEA

A10269

Fig. 2 -- Clearances to Combustibles

Page 5

A02055

Fig. 3 -- Return Air Temperature

CODES AND STANDARDS

Follow all national and local codes and standards in addition to these instructions. The installation must comply with regulations of the serving gas supplier, local building, heating, plumbing, and other codes. In absence of local codes, the installation must comply with the national codes listed below and all authorities having jurisdiction. In the United States, follow all codes and standards for the following:

Safety

S USA: National Fuel Gas Code (NFGC) NFPA

54--2012/ANSI Z223.1--2012 and the Installation Standards, Warm Air Heating and Air Conditioning Systems ANSI/NFPA 90B

General Installation

S Current edition of the NFGC and the NFPA 90B. For

copies, contact the National Fire Protection Association Inc., Batterymarch Park, Quincy, MA 02269; (www.NFPA.org) or for only the NFGC, contact the American Gas Association, 400 N. Capitol Street, N.W., Washington, DC 20001 (www.AGA.org).

Combustion and Ventilation

S NFGC NFPA54/ANSI Z223.1--2012 Section 9.3, Air

for Combustion and Ventilation.

Duct

Systems

S 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 or 2004 HVAC Systems and Equipment Handbook Chapters 9 and 16.

Acoustical Lining and Fibrous Glass

S Current edition of SMACNA and NFPA 90B as tested

by UL Standard 181 for ClassI Rigid Air Ducts

Gas Piping and Gas Pipe Pressure T

S NFGC NFPA54/ANSI Z223.1--2012; chapters 5, 6, 7,

and 8 and National Plumbing Codes.

Air

Duct

esting

Electrical

Connections

S National Electrical Code (NEC) ANSI/NFPA 70--2011.

enting

S NFGC NFPA 54 / ANSI Z223.1--2012; Chapters 12

and 13.

ELECTROSTATIC DISCHARGE (ESD)

PRECAUTIONS PROCEDURE

CAUTION

FURNACE RELIABILITY HAZARD

Improper installation or service of furnace may cause premature furnace component failure.

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

1. Disconnect all power to the furnace. Multiple disconnects maybe required. DO NOT TOUCH THE CONTROL OR ANY WIRE CONNECTED TO THE CONTROL PRIOR TO DISCHARGING YOUR BODY’S ELECTROSTATIC CHARGE TO GROUND.

2. Firmly touch the clean, unpainted, metal surface of the furnace chassis which is close to the control. Firmly touch the clean, unpainted, metal surface of the furnace chassis which is close to the control. Tools held in a person’s hand during grounding will be satisfactorily discharged.

3. After touching the chassis, you may proceed to service the control or connecting wires as long as you do nothing to recharge your body with static electricity (for example; DO NOT move or shuffle your feet, do not touch ungrounded objects, etc.).

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

5. Use this procedure for installed and uninstalled (ungrounded) furnaces.

6. Before removing a new control from its container, discharge your body’s electrostatic charge to ground to protect the control from damage. If the control is to be installed in a furnace, follow items 1 through 4 before bringing the control or yourself in contact with the furnace. Put all used and new controls into containers before touching ungrounded objects.

7. An ESD service kit (available from commercial sources) mayalsobeusedtopreventESDdamage.

PG8MEA

Page 6

THE BLOWER IS LOCATED

TO THE RIGHT OF THE

BURNER SECTION, AND

AIR CONDITIONED AIR IS

DISCHARGED TO THE LEFT.

THE BLOWER IS

LOCATED BELOW THE

BURNER SECTION, AND

CONDITIONED AIR IS

DISCHARGED UPWARD.

THE BLOWER IS

LOCATED ABOVE THE

BURNER SECTION, AND

PG8MEA

CONDITIONED AIR IS

DISCHARGED DOWNWARD

Fig. 4 -- Multipoise Orientations

LOCATION

GENERAL

This multipoise furnace is shipped in packaged configuration. Some assembly and modifications are required when used in any of the four applications shown in Fig. 4.

This furnace must:

S be installed so the electrical components are protected

from water.

S not be installed directly on any combustible material

other than wood flooring for upflow applications. Downflow installations require use of a factory--approved floor base or coil assembly when installed on combustible materials or wood flooring (refer to SAFETY CONSIDERATIONS).

S be located as close to the chimney or vent and attached

to an air distribution system. Refer to Air Ducts section.

S be provided ample space for servicing and cleaning.

Always comply with minimum fire protection clearances shown on the furnace clearance to combustible label.

WARNING

CARBON MONOXIDE POISONING HAZARD

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

Corrosive or contaminated air may cause failure of parts containing flue gas, which could leak into the living space. Air for combustion must not be contaminated by halogen compounds, which include fluoride, chloride, bromide, and iodide. These elements can corrode heat exchangers and shorten furnace life. Air contaminants are found in aerosol sprays, detergents, bleaches, cleaning solvents, salts, air fresheners, and other household products. Do not install furnace in a corrosive or contaminated atmosphere. Make sure all combustion and circulating air requirements are met, in addition to all local codes and ordinances.

THE BLOWER IS

LOCATED TO THE LEFT

OF THE BURNER SECTION,

AND CONDITIONED AIR IS

DISCHARGED TO THE RIGHT.

A02097

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

S Commercial buildings

S Buildings with indoor pools

S Laundry rooms

S Hobby or craft rooms, and

S 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:

S Permanent wave solutions

S Chlorinated waxes and cleaners

S Chlorine based swimming pool chemicals S Water softening chemicals

S De--icing salts or chemicals

S Carbon tetrachloride

S Halogen type refrigerants

S Cleaning solvents (such as perchloroethylene)

S Printing inks, paint removers, varnishes, etc.

S Hydrochloric acid

S Cements and glues

S Antistatic fabric softeners for clothes dryers S Masonry acid washing materials

Page 7

All fuel--burning equipment must be supplied with air for fuel combustion. Sufficient air must be provided to avoid negative pressure in the equipment room or space. A positive seal must be made between the furnace cabinet and the return--air duct to prevent pulling air from the burner area and from draft safeguard opening.

18-IN. (457.2 mm)

MINIMUM TO BURNERS

A93044

Fig. 5 -- Installation in a Garage

WARNING

FIRE HAZARD

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

When the furnace is installed in a residential garage, the burners and ignition sources must be located at least 18 inches above the floor. The furnace must be located or protected to avoid damage by vehicles. When the furnace is installed in a public garage, airplane hangar, or other building having a hazardous atmosphere, the furnace must be installed in accordance with the NFGC.

CAUTION

PERSONAL INJURY AND/OR PROPERTY DAMAGE HAZARD

Improper use or installation of this furnace may cause premature furnace component failure.

This gas furnace may be used for heating buildings under construction provided that:

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

--The furnace is controlled by a thermostat. It may not be “hot wired” to provide heat continuously to the structure without thermostatic control.

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

--The temperature of the return air to the furnace is maintained between 55_F(13_C) and 80_F(27_C), with no evening setback or shutdown. The use of the furnace while the structure is under construction is deemed to be intermittent operation per our installation instructions.

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

PG8MEA

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

TWO HORIZONTAL DUCTS

FURNACE

INPUT

(BTUH)

44,000 22 (14193) 6 (152) 14.7 (9484) 5 (127) 11 (7097) 4 (102) 66,000 33 (21290) 7 (178) 22 (14193) 6 (152) 16.5 (10645) 5 (127)

88,000 44 (28387) 8 (203) 29.3 (18903) 7 (178) 22 (14193) 6 (152) 110,000 55 (35484) 9 (229) 36.7 (23677) 7 (178) 27.5 (17742) 6 (152) 132,000 66 (42581) 10 (254) 44 (28387) 8 (203) 33 (21290) 7 (178)

(1 SQ. IN./2,000 BTUH)

(1,100 SQ. MM/KW)

Free Area of Open-

ing and Duct

(sq.in./sq.mm)

Round Duct

Diameter

(in./mm)

SINGLE DUCT OR OPENING

(1 SQ. IN./3,000 BTUH)

(734 SQ. MM/KW)

Free Area of Open-

ing and Duct

(sq.In./sq.mm)

Round Duct

Diameter

(in. / mm)

TWO OPENINGS OR VERTICAL

Free Area of

Opening and Duct

(sq.In./sq.mm)

DUCTS

(1 SQ. IN./4,000 BTUH)

(550 SQ. MM/KW)

Round Duct

Diameter

(In./mm)

EXAMPLES: Determining Free Area

FURNACE WATER HEATER TOTAL INPUT

110,000 + 30,000 = (140,000 divided by 4,000) = 35.0 Sq. In. for each two Vertical Ducts or Openings

66,000 + 40,000 = (106,000 divided by 3,000) = 35.3 Sq. In. for a Single Duct or Opening 88,000 + 30,000 = (118,000 divided by 2,000) = 59.0 Sq. In. for each of two Horizontal Ducts

Page 8

Table 3 – Minimum Space volumes for 100% combustion, Ventilation, and Dilution from Indoors

OTHER THAN FAN---ASSISTED TOTAL

ACH*

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

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

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

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

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

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

0.00 NP NP NP NP NP NP NP NP

*Air Changes/Hour

(1,000’S BTUH GAS INPUT RATE

30 40 50 44 66 88 110 132

SpaceVolume(ft.3)

FAN---ASSISTED TOTAL

(1,000’S BTUH GAS INPUT RATE)

WARNING

FIRE HAZARD

PG8MEA

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. 6.)

Fig. 6 -- Prohibit Installation on Back

CAUTION

FURNACE CORROSION HAZARD

Failure to follow this caution may result in furnace damage. Air for combustion must not be contaminated by halogen

compounds, which include fluoride, chloride, bromide, and iodide. These elements can corrode heat exchangers and shorten furnace life. Air contaminants are found in aerosol sprays, detergents, bleaches, cleaning solvents, salts, air fresheners, and other household products.

LOCATION RELATIVE TO COOLING EQUIPMENT

The cooling coil must be installed parallel with, or on the downstream side of the unit to avoid condensation in the heat exchangers. When installed parallel with the furnace, dampers or other flow control must prevent chilled air from entering the furnace. If the dampers are manually operated, they must be equipped with means to prevent operation of either unit unless the damper is in the full--heat or full--cool position.

A02054

AIR FOR COMBUSTION AND

VENTILATION

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

S U.S. installations: Section 9.3 of the NFGC

NFPA54/ANSI Z223.1--2012, Air for Combustion and Ventilation, and applicable provisions of the local building codes.

WARNING

CARBON MONOXIDE POISONING HAZARD

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

The operation of exhaust fans, kitchen ventilation fans, clothes dryers, attic exhaust fans or fireplaces could create a NEGATIVE PRESSURE CONDITION at the furnace. Make--up air MUST be provided for the ventilation devices, in addition to that required by the furnace. Refer to Carbon Monoxide Poisoning Hazard warning in venting section of these instructions to determine if an adequate amount of make--up air is available.

The requirements for combustion and ventilation air depend upon whether or not the furnace is located in a space having a volume of at least 50 cubic feet per 1,000 Btuh input rating for all gas appliances installed in the space.

S Spaces having less than 50 cubic feet per 1,000 Btuh

require the OUTDOOR COMBUSTION AIR METHOD.

S Spaces having at least 50 cubic feet per 1,000 Btuh

may use the INDOOR COMBUSTION AIR, STANDARD or KNOWN AIR INFILTRATION

METHOD.

Outdoor Combustion Air

1. Provide the space with sufficient air for proper combustion, ventilation, and dilution of flue gases using permanent horizontal or vertical duct(s) or opening(s) directly communicating with the outdoors or spaces that freely communicate with the outdoors.

2. Fig. 7 illustrates how to provide TWO OUTDOOR OPENINGS, one inlet and one outlet combustion and ventilation air opening, to the outdoors.

e. OneopeningMUST commencewithin 12--in. (300 mm)

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

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

Method

Page 9

1 SQ IN.

12 ″ MAX

(305mm)

PER 4000 BTUH*

1 SQ IN .

BTUH*

1 SQ IN .

BTUH*

1 SQ IN. PER 4000 BTUH*

12 ″

(305mm)

MAX

PER

4000

OUTDOORS

PER 4000

12 ″

(305mm)

MAX

A03174

DUCTS

O UTDOORS

(305mm)

12 ″ MAX

1 SQ IN. PER 2000 BTUH*

DUCT S

OUTDOORS

1 SQ IN. PER 2000 BTUH*

(305mm)

12 ″ MAX

CIRCULA TING AIR DUCT S

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

A&B, C&D, D&E, F&G

AIR DUCTS

C IRCULA TING

OF COMB USTION AIR

CLEARANCE IN FRONT

VENT THR OUGH R OOF

(76mm)

AT LEAST 3 IN .

OPENINGS SHALL BE

DUCT

OUTDOORS

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

Outdoors

CIRCULATING AIR

DUCTS

INTERIOR

HEATED

SPACE

CIRCULATING AIR DUCTS

*Minimum opening size is 100 in.2with minimum dimensions of 3 in. (76 mm).

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

VENT THROUGH ROOF

12" MAX

1 SQ IN. PER 1000 BTUH* IN DOOR OR WALL

UNCONFINED SPACE

(152mm)

6" MIN (FRONT)

1 SQ IN. PER 1000 BTUH* IN DOOR

OPENINGS SHALL BE AT LEAST 3 IN.

OR WALL

CLEARANCE IN FRONT OF COMBUSTION AIR

12" MA X

(305mm)

A03175

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

Indoors

PG8MEA

g. TWO HORIZONTAL DUCTS require 1 square inch of

free area per 2,000 Btuh (1,100 mm

/kW) of combined input for all gas appliances in the space per Fig. 7 and Tab le 2.

h. TWO OPENINGS OR VERTICAL DUCTS require 1

square inch of free area per 4,000 Btuh (550 mm

/kW) for combined input of all gasappliances in the spaceper Fig. 7 and Table 2.

3. ONE OUTDOOR OPENING requires:

a. 1 square inch offree area per 3,000Btuh (734 mm

/kW) for combined input of all gasappliances in the spaceper Tab le 2 an d

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

in the space.

The opening shall commence within 12” (300 mm) of the ceiling. Appliances in the space shall have clearances of at least 1” (25 mm) from the sides and back and 6” (150 mm) from the front. The opening shall directly communicate with the outdoors or shall communicate through a vertical or horizontal duct to the outdoors or spaces (crawl or attic) that freely communicate with the outdoors.

Indoor Combustion Air -- NFPA & AGA Standard and Known--Air--Infiltration Rate Methods Indoor air is permitted for combustion, ventilation, and dilution,

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

WARNING

The Standard Method:

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

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

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

1. Less than 0.40 ACH and

2. Equal to or greater than 0.10 ACH

Infiltration rates greater than 0.60 ACH shall not be used. The minimum required volume of the space varies with the number of ACH and shall be determined per Table 3 or Equations 1 and 2. Determine the minimum required volume for each appliance in the space and add the volumes together to get the total minimum required volume for the space. Table 3 -- Minimum Space Volumes were determined by using the following equations from the National Fuel Gas Code ANSI Z223.1--2012/NFPA 54--2012, 9.3.2.2:

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

Volume

Other

21ft ACH

other

1000 Btu/hr

A04002

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

CARBON MONOXIDE POISONING HAZARD

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

Many homes require air to be supplied from outdoors for furnace combustion, ventilation, and dilution of flue gases. The furnace combustion air supply must be provided in accordance with this instruction manual.

Volume

Fan

15ft ACH

fan

1000 Btu/hr

A004003

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

Page 10

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 1 in.

/kW) of the total input rating of all gas appliances

mm in the space, but not less than 100 in.

/1,000 Btuh (2,000

(0.06 m2). One openingshallcommencewithin 12”(300mm)ofthe ceiling and the second opening shall commence within 12” (300 mm) of the floor. The minimum dimension of air openings shall be at least 3 in. (80 mm). (See Fig. 8.)

c. Combining space on different floor levels. Thevolumes

of spaces on different floor levels shall be considered as communicating spaces if connected by one or more permanent openings in doors or floors having free area of at least 2 in.

PG8MEA

rating of all gas appliances.

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

/1,000 Btuh (4,400 mm2/kW) of total input

freely communicates with the outdoors provided there are adequate permanent ventilation openings directly to outdoors having free area of at least 1--in.

/4,000 Btuh of total

input rating for all gas appliances in the space.

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

infiltration should be adequate to provide air for combustion, permanent ventilation and dilution of flue gases. However, in buildings with unusually tight construction, additional air MUST be provided using the methods describedintheOutdoor Combustion Air Method section.

Unusually tight construction is defined as construction with:

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

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

b. Doors and openable windows are weatherstripped and

c. Other openings are caulked or sealed. These include

joints around window and door frames, between sole plates and floors, between wall--ceiling joints, between wall panels, at penetrations for plumbing, electrical and gas lines, etc.

Combination of Indoor and Outdoor

Air

1. Indoor openings shall comply with the Indoor Combustion Air Method below and,

2. Outdoor openings shall be located as required in the 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 IndoorCombustion Air Meth- od below.

b. Outdooropeningsize reduction Factoris1 minus theRa-

tio in a. above.

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

quiredin Outdoor CombustionAirMethodabovemultiplied by reduction Factor in b. above. The minimum dimension of air openings shall be not less than 3 in. (80 mm).

INSTALLATION

UPFLOW INSTALLATION

Bottom Return Air Inlet

These furnaces are shipped with bottom closure panel installed in bottom return--air opening. Remove and discard this panel when bottom return air is used. To remove bottom closure panel, perform the following:

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

Bottom Closure Panel

Bottom Filler Panel

A10273

Fig. 9 -- Removing Bottom Closure Panel

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

3. Remove bottom closure panel.

4. Reinstall bottom filler panel and screws.

Side Return Air

These furnaces are shipped with bottom closure panel installed in bottom return--air opening. This panel MUST be in place when only side return air is used.

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

Leveling Legs (If Desir

In upflow position with side return inlet(s), leveling legs may be used. (See Fig. 10.) Install field--supplied, 5/16 x 1--1/2 in. (8 x 38 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.

To install leveling legs:

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

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

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

Inlet

ed)

Page 11

(8mm)

(44mm)

16

1 3/ 4

(8mm)

16

/ 4

(44mm)

PLENUM

OPENING

(8mm)

/ 16

(8mm)

16

(44mm)

4

A89014

(44mm)

Fig. 10 -- Leveling Legs

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

5. Reinstall bottom closure panel if removed.

DOWNFLOW INSTALLA

TION

NOTE: For downflow applications, this furnace is approved for

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

S Special Base, KGASB S Cased Coil Assembly Part No. CNPV, CNRV, CAP, or

CAR

S Coil Box Part No. KCAKC

1. Determine application being installed from Table 4.

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

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

4. If downflow subbase KGASB is used, install as shown in Fig. 12. If Coil Assembly Part No. CNPV, CNRV, CAP and CNR or Coil Box Part No. KCAKC is used, install as shown in Fig. 13.

NOTE: It is recommended that the perforated supply--air duct flanges be completely folded over or removed from furnace when installing the furnace on a factory--supplied cased coil or coil box. To remove the supply--air duct flange, use wide duct pliers or hand seamers to bend flange back and forth until it breaks off. Be careful of sharp edges. (See Fig. 14.)

Bottom Return Air

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

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

3. Remove bottom closure panel.

4. Reinstall bottom filler panel and screws

Inlet

FLOOR

OPENING

Fig. 11 -- Floor and Plenum Opening Dimensions

FURNACE

(OR COIL CASING

WHEN USED)

COMBUSTIBLE

FLOORING

DOWNFLOW

SUBBASE

SHEET METAL

PLENUM

FLOOR

OPENING

Fig. 12 -- Furnace, Plenum, and Subbase Installed

on a Combustible Floor

PG8MEA

A96283

A96285

Page 12

FURNACE

APPROVED

COIL ASSEMBLY

COIL BOX

COMBUSTIBLE

FLOORING

SHEET METAL

PLENUM

FLOOR

OPENING

PG8MEA

A08556

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

Coil Box Installed on a Combustible Floor

FURNACE

CASING

WIDTH

14–3/16

(360)

17–1/2

(445)

(533)

24--- 1/2

(622)

Table 4 – Opening Dimensions -- In. (mm)

APPLICATION

Upflow Applications on Combustible or Noncombustible Floor-

ing (KGASB subbase not required)

Downflow Applications on Noncombustible Flooring (KGASB

subbase not required)

Downflow applications on combustible flooring (KGASB sub-

base required)

Downflow Applications on Combustible Flooring with CNPV,

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

(KGASB subbase not required)

Upflow Applications on Combustible or Noncombustible Floor-

ing (KGASB subbase not required)

Downflow Applications on Noncombustible Flooring (KGASB

subbase not required)

Downflow applications on combustible flooring (KGASB sub-

base required)

Downflow Applications on Combustible Flooring with CNPV,

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

(KGASB subbase not required)

Upflow Applications on Combustible or Noncombustible Floor-

ing (KGASB subbase not required)

Downflow Applications on Noncombustible Flooring (KGASB

subbase not required)

Downflow applications on combustible flooring (KGASB sub-

base required)

Downflow Applications on Combustible Flooring with CNPV,

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

(KGASB subbase not required)

Upflow Applications on Combustible or Noncombustible Floor-

ing (KGASB subbase not required)

Downflow Applications on Noncombustible Flooring (KGASB

subbase not required)

Downflow applications on Combustible flooring (KGASB sub-

base required)

Downflow Applications on Combustible Flooring with CNPV,

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

(KGASB subbase not required)

PLENUM OPENING FLOOR OPENING

A B C D

12--- 11/16

(322)

12--- 9/16

(319)

11--- 13/16

(284)

12--- 5/16

(313)

(406)

15--- 7/8

(403)

15--- 1/8

(384)

15--- 1/2

(394)

19--- 1/2

(495)

19--- 3/8

(492)

18--- 5/8

(473)

(483)

(584)

22--- 7/8

(581)

22--- 1/8

(562)

22--- 1/2

(572)

21--- 5/8

(549)

(483)

21--- 5/8

(549)

(483)

21--- 5/8

(549)

(483)

21--- 1/8

(537)

(483)

13--- 5/16

(338)

13--- 3/16

(335)

13--- 7/16

(341)

13--- 5/16

(338)

16--- 5/8

(422)

16--- 1/2

(419)

16--- 3/4

(425)

16--- 1/2

(419)

20--- 1/8

(511)

(508)

20--- 1/4

(514)

(508)

23--- 5/8

(600)

23--- 1/2

(597)

23--- 3/4

(603)

23--- 1/2

(597)

22--- 1/4

(565)

19--- 5/8

(498)

20--- 5/8

(600)

(508)

22--- 1/4

(565)

19--- 5/8

(498)

20--- 5/8

(600)

(508)

22--- 1/4

(565)

19--- 5/8

(498)

20--- 5/8

(600)

(508)

22--- 1/4

(565)

19--- 5/8

(498)

20--- 5/8

(600)

(508)

Page 13

HORIZONTAL INSTALLA

WARNING

TION

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

FILTER

ARRANGEMENT

FIRE, EXPLOSION, AND CARBON MONOXIDE POISONING HAZARD

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

The furnace can be installed horizontally in an attic or crawl space on either the left--hand (LH) or right--hand (RH) side. The furnace can be hung from floor joists, rafters or trusses or installed on a non--combustible platform, blocks, bricks or pad.

Suspended Furnace

The furnace may be supported under each end with threaded rod, angle iron or metal plumber’s strap as shown. (See Fig. 15 and

16.) Secure angle iron to bottom of furnace as shown. Heavy--gauge sheet metal straps (plumber’s straps) may be used to suspend the furnace from each bottom corner. To prevent screws from pulling out, use 2 #8 x 3/4--in. (19 mm) screws into the side and 2 #8 x 3/4--in. (19 mm) screws in the bottom of the furnace casing for each strap. (See Fig. 15 and 16.) If the screws are attached to ONLY the furnace sides and not the bottom, the straps must be vertical against the furnace sides and not pull away from the furnace sides, so that the strap attachment screws are not in tension (are loaded in shear) for reliable support.

Platform Furnace

Construct working platform at location where all required furnace clearances are met. (See Fig. 2 and 17.) For furnaces with 1--in. (25 mm) clearance requirement on side, set furnace on noncombustible blocks, bricks or angle iron. For crawl space installations, if the furnace is not suspended from the floor joists, the ground underneath furnace must be level and the furnace set on blocks or bricks.

Roll--Out Pr

Provide a minimum 17--3/4 in. x 22 in. (451 mm x 559 mm) piece of sheet metal for flame roll--out protection in front of burner area for furnaces closer than 12 inches (305 mm) above the combustible deck or suspended furnaces closer than 12 inches (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. 17 for proper orientation of roll--out shield.

Bottom Return Air

1. Tilt or raise furnace and remove two screws holding bot-

2. Rotate bottom filler panel downward to release holding

3. Remove bottom closure panel.

4. Reinstall bottom filler panel and screws. Side Return Air

Side Return Air

These furnaces are shipped with bottom closure panel installed in bottom return--air opening. This panel MUST be in place when side return air inlet(s) is used without a bottom return air inlet.

otection

tom filler panel. (See Fig. 9.)

tabs.

Inlet

Support

Inlet

WARNING

CARBON MONOXIDE AND POISONING HAZARD

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

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

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

A field--supplied accessory external filter is required. Refer to the instructions supplied with the external filter rack for

assembly and installation options.

DUCTS

AIR General Requir

The duct system should be designed and sized according to accepted national standards such as those published by: Air Conditioning Contractors Association (ACCA), Sheet Metal and Air Conditioning Contractors National Association (SMACNA) or American Society of Heating, Refrigerating and Air Conditioning Engineers (ASHRAE) or consult The Air Systems Design Guidelines reference tables available from your local distributor. The duct system should be sized to handle the required system design CFM at the design external static pressure. The furnace airflow rates are provided in Table 5 -- AIR DELIVERY--CFM (With Filter). When a furnace is installed so that the supply ducts carry air circulated by the furnace to areas outside the space containing the furnace, the return air shall also be handled by duct(s) sealed to the furnace casing and terminating outside the space containing the furnace. Secure ductwork with proper fasteners for type of ductwork used. Seal supply-- and return--duct connections to furnace with code approved tape or duct sealer.

NOTE: Flexible connections should be used between ductwork and furnace to prevent transmission of vibration. Ductwork passing through unconditioned space should be insulated and sealed to enhance system performance. When air conditioning is used, a vapor barrier is recommended. Maintain a 1--in. (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 Tr 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.

Supply Air

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 airstream. The cover attachment shall prevent leaks.

ements

eatment

Connections

PG8MEA

Page 14

Upflow and Horizontal Furnaces Connect supply--air duct to flanges on furnace supply--air outlet. Bend flange upward to 90_ with wide duct pliers. (See Fig. 14.) The supply--air duct must be connected to ONLY the furnace supply--outlet--air duct flanges or air conditioning coil casing (when used). DO NOT cut main furnace casing side to attach supply air duct, humidifier, or other accessories. All accessories MUST be connected to duct external to furnace main casing.

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

UPFLOW DOWNFLOW HORIZONTAL

Downflow

Furnaces

Connect supply--air duct to supply--air outlet on furnace. Bend flange inward past 90_ with wide duct pliers. (See Fig. 14.) The supply--air duct must be connected to ONLY the furnace supply outlet or air conditioning coil casing (when used). When installed on combustible material, supply--air duct must be connected to ONLY the factory--approved accessory subbase or a factory-approved air conditioning coil casing. DO NOT cut main furnace casing to attach supply side air duct, humidifier, or other accessories. All accessories MUST be connected to duct external to furnace casing.

90

YES

90

YES

PG8MEA

120 MIN

YES

120

MIN

Fig. 14 -- Duct Flanges

YES

4 " (6mm) THREADED ROD

4 REQ.

120

MIN

YES

A02020

OUTER DOOR A S SEMBLY

8" (203mm) FOR DOOR REMOVAL

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

MIN

1” (25mm) SQUARE, 1-1/4”x1-1/4”x1/8” (32x32x3mm) ANGLE IRON OR UNI-STRUT MAY BE USED

Fig. 15 -- Horizontal Unit Suspension

SECURE ANGLE IRON TO BOTTOM OF FURNACE WITH

/4" (19mm) SCREWS

3 #8 x TYPICAL FOR 2 SUPPORTS

A10130

Page 15

METHOD 1 FOLD ALL STRAPS UNDER FURNACE AND SECURE WTH (4) #8 x 3/4 (19 mm) SHEET METAL SCREWS (2 SCREWS IN SIDE AND 2 SCREWS IN BOTTOM).

Fig. 16 -- Horizontal Suspension with Straps

METHOD 2 USE (4) #8 x 3/4 (19 mm) SHEET METAL SCREWS FOR EACH STRAP. THE STRAPS SHOULD BE VERTICAL AGAINST THE FURNACE SIDES AND NOT PULL AWAY FROM THE FURNACE SIDES.

PG8MEA

A10131

LINE CONT A CT ONL Y PERMISSIBLE BETWEEN LINES FORMED BY INTERSECTIONS OF THE T OP AND TW O SIDES OF THE FURNA CE JA CKET AND BUILDING JOISTS , STUDS , OR FRAMING.

EQUIPMENT MANU AL

SHUT -OFF GAS VA LV E

SEDIMENT

TRAP

UNION

SHEET MET AL

GAS ENTR Y

17 3 / 4 ″

(559mm)

″

(451mm)

6 ″

M IN

TYPE-B VENT

(152mm)

Fig. 17 -- Typical Attic Installation

17 3 / 4 ″ 4 3 / 4 ″ 1 ″

(25mm)

EXTEND OUT 12 ″ FR OM FA CE OF DOOR

30-IN . (762mm) MIN WORK AREA

(451mm)

(121mm)

OVERALL

UNDER DOOR

UNDER FURNACE

(305mm)

* WHEN USED W ITH SINGLE W ALL VEN T CONNECTIONS

A10164

Page 16

PIPING

Connections

WARNING

CAUTION

Return Air

FIRE HAZARD

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

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

Downflow Furnaces The return--air duct must be connected to return--air opening (bottom inlet) as shown in Fig. 20. DO NOT cut into casing sides (left or right). Side opening is permitted for only upflow and most horizontal furnaces. (See Fig. 20.) Bypass humidifier connections should be made at ductwork or coil casing sides exterior to furnace.

Upflow and Horizontal Furnaces The return--air duct must be connected to bottom, sides (left or

PG8MEA

right), or a combination of bottom and side(s) of main furnace casing as shown in Fig. 19 and 21. Bypass humidifier may be attached into unused return air side of the furnace casing. (See Fig. 19 and 21.) Not all horizontal furnaces are approved for side return air connections. (See Fig. 21.)

GAS

FIRE OR EXPLOSION HAZARD

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

Never purge a gas line into a combustion chamber. Never test for gas leaks with an open flame. Use a commercially available soap solution made specifically for the detection of leaks to check all connections.

FIRE OR EXPLOSION HAZARD

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

Use proper length of pipe to avoid stress on gas control manifold and a gas leak.

FURNACE OVERHEAT HAZARD

Failure to follow this caution may result in property damage.

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

WARNING

FIRE OR EXPLOSION HAZARD

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

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

Installations must be made in accordance with all authorities having jurisdiction. If possible, the gas supply line should be a separate line running directly from meter to furnace.

NOTE: In the state of Massachusetts:

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

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

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

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

Refer to Table 6 for recommended gas pipe sizing. Risers must be used to connect to furnace and to meter. Support all gas piping with appropriate straps, hangers, etc. Use a minimum of 1 hanger every 6 ft. (2 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.

An accessible manual equipment shutoff valve MUST be installed external to furnace casing and within 6 ft. (2 M) of furnace. A 1/8--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.

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. 47.)

Some installations require gas entry on right side of furnace (as viewed in upflow.) (See Fig. 22.)

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

18. Connect acapped nipple into lower end of tee. Capped nipple should extend below level of furnace gas controls. Place a ground joint union between furnace gas control valve and exterior manual equipment gas shutoff valve. A 1/8--in. (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.

Page 17

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

UNIT SIZE COLOR SPEED

Gray 5 1185 1145 1115 1075 1035 980 905 820 720 580

045 ---08/

024045

070 ---16/

048070

090 ---16/

048090

110 ---20/

060110

135 ---20/

060135

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

--- --- Indicates unstable operating conditions.

Yellow 4 920 880 835 800 755 720 680 645 605 540

Blue 3 735 685 625 585 530 490 435 395 345 295

Orange 2 820 765 725 670 630 580 545 490 455 405

Red 1 650 595 535 490 430 390 330 280 235 --- ---

Gray 5 1625 1585 1535 1495 1460 1415 1365 1295 1220 1125

Yellow 4 1405 1360 1320 1280 1240 1195 1155 1115 1070 1030

Blue 3 1240 1200 1155 1110 1065 1020 975 935 895 850

Orange 2 1190 1140 1095 1050 1000 955 915 870 830 790

Red 1 1035 985 930 885 835 785 745 695 650 600

Gray 5 1845 1800 1755 1710 1665 1595 1500 1400 1275 1105

Yellow 4 1590 1545 1500 1455 1410 1365 1315 1270 1180 1000

Blue 3 1365 1320 1270 1215 1170 1125 1070 1025 955 900

Orange 2 1225 1160 1110 1060 1010 950 895 830 770 710

Red 1 1100 1030 960 875 805 730 645 570 505 425

Gray 5 2255 2205 2150 2100 2040 1985 1920 1835 1735 1615

Yellow 4 1600 1525 1465 1400 1335 1275 1210 1150 1080 1015

Blue 3 1945 1890 1830 1770 1715 1655 1600 1545 1480 1430

Orange 2 1420 1340 1280 1200 1140 1065 1005 925 865 790

Red 1 1280 1205 1140 1055 990 910 840 760 695 630

Gray 5 2295 2240 2185 2125 2070 2005 1925 1805 1670 1545

Yellow 4 1725 1660 1605 1545 1460 1395 1340 1285 1230 1170

Blue 3 1910 1865 1800 1745 1685 1610 1545 1485 1435 1380

Orange 2 1630 1575 1510 1435 1365 1300 1245 1185 1130 1065

Red 1 1430 1355 1285 1200 1125 1075 1015 945 855 800

0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1

EXTERNAL STATIC PRESSURE (In. W.C.)

PG8MEA

Table 6 – Maximum Capacity of Pipe*

NOMINAL IRON

PIPE

SIZE IN. (mm) In. (mm) 10 20 30 40 50

1/2 (13) 0.622 (16) 175 (53) 120 (37) 97 (30) 82 (25) 73 (22) 3/4 (19) 0.824 (21) 360 (110) 250 (76) 200 (61) 170 ( 52) 151 (46)

1 (25) 1.049 (27) 680 (207) 465 (142) 375 (114) 320 (98) 285 (87) 1---1/4 (32) 1.380 (35) 1400 (427) 950 (290) 770 (235) 660 (201) 580 (177) 1---1/2 (38) 1.610 (41) 2100 (640) 1460 (445) 1180 (360) 990 (301) 900 (274)

* Cubic ft. of n atural 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: Chapter 6 ANSI Z223 ---2012/NFPA 54 ---2012.

INTERNAL

DIAMETER

LENGTH OF PIPE --- FT. (M)

Piping should be pressure and leak tested in accordance with NFGC in the United States, local, and national plumbing and gas codes before the furnace has been connected. After all connections have been made, purge lines and check for leakage at furnace prior to operating furnace.

If pressure exceeds 0.5 psig (14--In. W.C.), gas supply pipe 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

GAS SUPPLY

MANUAL SHUTOFF VALV E (REQUIRED)

SEDIMENT TRAP

UNION

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.

A02035

Fig. 18 -- Typical Gas Pipe Arrangement

Page 18

PG8MEA

A02075

Fig. 19 -- Upflow Return Air Configurations and Restrictions

Fig. 20 -- Downflow Return Air Configurations and Restrictions

A02163

Page 19

Fig. 21 -- Horizontal Return Air Configurations and Restrictions

2” (51mm)

Street Elbow

PG8MEA

A02162

A08551

Fig. 22 -- Burner and Manifold

Page 20

Table 7 – Electrical Data

VOLTS-

FURNACE MODEL

045-08 / 024045 115 - 60 - 1 127 104 8.1 10.9 34 (10) 15 14 070-16 / 048070 115 - 60 - 1 127 104 10.8 14.2 26 (8) 15 14 090-16 / 048090 115 - 60 - 1 127 104 11.4 14.8 25 (7) 15 14 110-20 / 060110 115 - 60 - 1 127 104 14.2 18.2 31 (9) 20 12 135-20 / 060135 115 - 60 - 1 127 104 14.2 18.2 31 (9) 20 12

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

etc.) ful l load amps.

{ Time--- delay type is recommended. } Length shown is as measured one way along wire path between unit and service panel for maximum 2 percent voltage drop.

ELECTRICAL CONNECTIONS

HERTZ-

PHASE

WARNING

PG8MEA

ELECTRICAL SHOCK HAZARD

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

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

See Fig. 25 for field wiring diagram showing typical field 115--v wiring. Check all factory and field electrical connections for tightness.

Field--supplied wiring shall conform with the limitations of 63_F (35_C) rise.

WARNING

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. 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.

CAUTION

FURNACE MAY NOT OPERATE

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 must remain grounded through green/yellow wire routed to gas valve and manifold bracket screw.

OPERATING

VOLTAGE*

(VOLTS)

MAX MIN

MAX UNIT

(AMPS)

UNIT

AMPACITY#

(AMPS)

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

Make all electrical connections in accordance with National Electrical Code (NEC) ANSI/NFPA 70--2011 and any local codes or ordinances that might apply.

FIRE HAZARD

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

Do not connect aluminum wire between disconnect switch and furnace. Use only copper wire.

Use a separate, fused branch electrical circuit with a properly sized fuse or circuit breaker for this furnace. See Table 7 for wire size and fuse specifications. A readily accessible means of electrical disconnect must be located within sight of the furnace.

NOTE: Proper polarity must be maintained for 115--v wiring. If polarity is incorrect, control LED status indicator light will flash rapidly and furnace will NOT operate.

J--BOX RELOCA NOTE: If factory location of J--Box is acceptable, go to next

section (ELECTRICAL CONNECTION TO J--BOX). NOTE: On 14--in. (356 mm) wide casing models, the J--Box

shall not be relocated to other side of furnace casing when the vent pipe is routed within the casing.

1. Remove and save two screws holding J--Box.

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

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

3. Move J--Box to desired location.

4. Fasten J--Box to casing with two screws removed in Step

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

MAX WIRE

LENGTH‡

FT. (M)

MAX FUSE/

CKT BKR†

(AMPS)

WARNING

TION

MIN

WIRE

GAGE

115 --V WIRING

Verify that the voltage, frequency, and phase correspond to that specified on unit rating plate. Also, check to be sure that service provided by utility is sufficient to handle load imposed by this

Page 21

ELECTRICAL CONNECTION TO Electrical Box on Furnace Casing Side

WARNING

FIRE OR ELECTRICAL SHOCK HAZARD

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

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

1. Select and remove a hole knockout in the casing where the electrical box is to be installed.

NOTE: Check that duct on side of furnace will not interfere with installed electrical box.

2. Remove the desired electrical box hole knockout and position the hole in the electrical box over the hole in the furnace casing.

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

4. Remove and save two screws holding J--Box.

5. Pull furnace power wires out of 1/2--in. (12 mm) diameter hole in J--Box. Do not loosen wires from strain--relief wire--tie on outside of J--Box.

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

7. Pull field power wires into electrical box.

8. Remove cover from furnace J--Box.

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

10. Reattach furnace J--Box to furnace casing with screws removedinStep4.

11. Secure field ground wire to J--Box green ground screw.

12. Complete electrical box wiring and installation. Connect line voltage leads as shown in Fig. 25. Use best practices (NEC in U.S. for wire bushings, strain relief, etc.

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

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

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

1. Remove cover from J--Box.

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

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

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

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

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

BX CABLE INSTALLATION IN FURNACE

1. Remove cover from J--Box.

2. Route BX cable into 7/8--inch diameter hole in J--Box.

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

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

J--BOX

A10141

Fig. 23 -- Field--Supplied Electrical Box on Furnace Casing

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

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

WIRING

24--V

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

23.) Connect terminal Y/Y2 as shown in Fig. 24 for proper cooling operation. Use only AWG No. 18, color--coded, copper thermostat wire.

The 24--v circuit contains an automotive--type, 3--amp. fuse located on the control. Any direct shorts during installation, service, or maintenance could cause this fuse to blow. If fuse replacement is required, use ONLY a 3--amp. fuse of identical size.

ACCESSORIES

1. Electronic Air Cleaner (EAC) Connect an accessory Electronic Air Cleaner (if used) using 1/4--in female quick connect terminals to the two male 1/4--in quick--connect terminals on the control board marked EAC--1 and EAC--2. The terminals are rated for 115 VAC, 1.0 amps maximum and are energized during blower motor operation. (See Fig. 24.)

2. Humidifier (HUM) Connect an accessory 24 VAC, 0.5 amp. maximum humidifier (if used) to the 1/4--in male quick--connect HUM terminal and COM--24V screw terminal on the control board thermostat strip. The HUM terminal is energized when gas valve relay (GVR) is energized. (See Fig. 24.)

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

NOTE: DO NOT connect furnace control HUM terminal to HUM (humidifier) terminal on humidity sensing thermostat, zone controller or similar device. See humidity sensing thermostat, zone controller, thermostat, or controller manufacturer’s instructions for proper connection.

PG8MEA

Page 22

BLOWER OFF-DELAY

24-V THERMOSTAT TERMINALS

3-AMP FUSE

LED OPERATION & DIAGNOSTIC LIGHT

TWINNING AND/OR COMPONENT TEST TERMINAL

HUMIDIFIER TERMINAL (24-VAC 0.5 AMP. MAX)

PG8MEA

BLOWER SPEED SELECTION TERMINALS

115-VAC (L2) NEUTRAL CONNECTIONS

HEAT

COOL

FAN

SPARE 2 SPARE 1

115-VAC (L1) NEUTRAL CONNECTIONS

EAC-1 TERMINAL (115-VAC 1.0 AMP. MAX.)

TRANSFORMER 24-VAC CONNECTIONS

PL1-LOW VOLTAGE DRAIN HARNESS CONNECTOR

PL2-HOT SURFACE IGNITER & INDUCER MOTOR CONNECTOR

A08063

Fig. 24 -- Furnace Control

FIELD 24-V WIRING FIELD 115-, 208/230-, 460-V WIRING FACTORY 24-V WIRING FACTORY 115-V WIRING

FIVE WIRE

THREE-WIRE

NOTE 2

WCR GY

THERMOSTAT TERMINALS

FIELD-SUPPLIED DISCONNECT

HEATING-ONLY

BLOWER DOOR SWITCH

208/230- OR 460-V THREE

BLK

WHT

GND

115-V FIELD-

SUPPLIED

DISCONNECT

BLK

WHT

GND

AUXILIARY J-BOX

O N

R O

COM

Y/Y2

24-V

TERMINAL

NOTE 1

GND

CONDENSING UNIT

TWO WIRE

PHASE

208/230-V SINGLE PHASE

BLOCK

FURNACE

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

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

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

A99440

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

Page 23

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

See notes 1, 2, 4, 6, 7, 9, 10 and 12 on the page following these figures.

PG8MEA

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

Conditioner

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

A04215

A04217

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

Pump (Dual Fuel)

See notes 1, 2, 3, 4, 6, 8, 9, 10 and 12 on the page following these figures.

Fig. 27 -- Single Stage Furnace with Two--Speed Air Condi-

tioner

A04216

A04218

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

(Dual Fuel)

Page 24

HUMIDFIER

(24VAC)

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

HUMIDFIER

(24VAC)

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

PG8MEA

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

and Single--Speed Heat Pump

See note 2 on the page following these figures.

A04219

Fig. 31 -- Dual Fuel Thermostat with Single--Stage Furnace

and Two--Speed Heat Pump

HUMIDFIER

(24VAC)

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

NOTES FOR FIGURES 26 -- 32

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

2. Refer to outdoor equipment Installation Instructions for additional information and setup procedure.

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

4. Dip switch No. 1 on humidity sensing thermostat should be set in OFF position for air conditioner installations. This is factory default.

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

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

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

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

9. NO connection should be made to the furnace HUM terminal when using a humidity sensing thermostat.

10. The RVS Sensing terminal “L” should not be connected. This is internally used to sense defrost operation.

11. DO NOT SELECT the “FURNACE INTERFACE” or “BALANCE POINT” option on the two--speed heat pump control board. This is controlled internally by the humidity sensing thermostat/Dual Fuel Thermostat.

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

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

A04220

A04221

Page 25

VENTING

The furnace shall be connected to a listed factory built chimney or vent, or a clay--tile lined masonry or concrete chimney. Venting into an unlined masonry chimney or concrete chimney is prohibited.

When an existing Category I furnace is removed or replaced, the original venting system may no longer be sized to properly vent the attached appliances. An improperly sized Category I venting system could cause the formation of condensate in the furnace and vent, leakage of condensate and combustion products, and spillage of combustion products into the living space.

WARNING

CARBON MONOXIDE POISONING HAZARD

Failure to follow the steps outlined below for each appliance connected to the venting system being placed into operation could result in carbon monoxide poisoning or death. The following steps shall be followed for each appliance connected to the venting system being placed into operation, while all other appliances connected to the venting system are not in operation:

1. Seal any unused openings in venting system.

2. Inspect the venting system for proper size and horizontal pitch, as required in the National Fuel Gas Code, ANSI Z223.1/NFPA 54 and these instructions. Determine that there is no blockage or restriction, leakage, corrosion and other deficiencies, which could cause an unsafe condition.

3. As far as practical, close all building doors and windows and all doors between the space in which the appliance(s) connected to the venting system are located and other spaces of the building.

4. Close fireplace dampers.

5. Turn on clothes dryers and any appliance not connected to the venting system. Turn on any exhaust fans, such as range hoods and bathroom exhausts, so they are operating at maximum speed. Do not operate a summer exhaust fan.

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

7. Test for spillage from draft hood equipped appliances at the draft hood relief opening after 5 minutes of main burner operation. Use the flame of a match or candle.

8. If improper venting is observed during any of the above tests, the venting system must be corrected in accordance with the National Fuel Gas Code, ANSI Z223.1/NFPA 54.

9. After it has been determined that each appliance connected to the venting system properly vents when tested as outlined above, return doors, windows, exhaust fans, fireplace dampers and any other gas--fired burning appliance to their previous conditions of use.

GENERAL VENTING

Follow all safety codes for proper vent sizing and installation requirements, including local building codes, the National Fuel Gas Code ANSI Z223.1--2012/NFPA 54--2012 (NFGC), Parts 12 and 13, the local building codes, and furnace and vent manufacturers’ instructions.

These furnaces are design--certified as Category I furnaces in accordance with ANSI Z21.47--2012/CSA 2.3--2012 and operate with a non--positive vent static pressure to minimize the potential for vent gas leakage. Category I furnaces operate with a flue loss not less than 17 percent to minimize the potential for condensation in the venting system. These furnaces are approved for common venting and multistory venting with other fan assisted or draft hood equipped appliances in accordance with the NFGC, the local building codes, and furnace and vent manufacturers’ instructions. The following information and warning must be considered in addition to the requirements defined in the NFGC.

1. If a vent (common or dedicated) becomes blocked, the furnace will be shut off by the draft safeguard switch located on the vent elbow.

2. Do not vent this Category I furnace into a single--wall dedicated or common vent. The dedicated or common vent is considered to be the vertical portion of the vent system that terminates outdoors.

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

4. Do not vent this appliance with any solid fuel burning appliance.

5. Category I furnaces must be vented vertically or nearly vertically unless equipped with a listed power venter.

6. Do not vent this appliance into an unlined masonry chimney. Refer to Chimney Inspection Chart, Fig. 33.

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

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

If a clay tile--lined masonry chimney is being used and it is exposed to the outdoors below the roof line, relining might be required. Chimneys shall conform to the Standard for Chimneys, Fireplaces, Vents, and Solid Fuel Burning Appliances ANSI/NFPA 211--2012 and must be in good condition.

U.S.A.--Refer to Sections 13.1.8 and 13.2.20 of the NFGC NFPA54/ANSI Z223.1--2012 or the authority having jurisdiction to determine whether relining is required. If relining is required, use a properly sized listed metal liner, Type--B vent, or a listed alternative venting design.

NOTE: See the NFPA54/ANSI Z223.1--2012, 13.1.8 and

13.2.20 regarding alternative venting design and the Exception, which cover installations such as the Chimney Adapter Kits, which are listed for use with these furnaces. See Product Data Sheet for accessory listing.

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

REQUIREMENTS

PG8MEA

Vent system or vent connectors may need to be resized. Vent systems or vent connectors, must be sized to approach minimum size as determined using appropriate table found in the NFGC.

Page 26

This furnace is permitted to be vented into a clay tile--lined masonry chimney that is exposed to the outdoors below the roof line, provided:

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

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

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

4. The input rating of each space heating appliance is greater than the minimum input rating given in Table 9 for the local 99% Winter Design Temperature. Chimneys having internal areas greater than 38 square inches require furnace input ratings greater than the input ratings of these furnaces. See footnote at bottom of Table 9, and

5. The authority having jurisdiction approves.

If all of these conditions cannot be met, an alternative venting design shall be used, such as the listed chimney adapter kit with these furnaces, which are listed for use with the kit, a listed chimney--lining system, or a Type--B common vent.

Inspections before the sale and at the time of installation will

PG8MEA

determine the acceptability of the chimney or the need for repair and/or (re)lining. Refer to the Fig. 33 to perform a chimney inspection. If the inspection of a previously used tile--lined chimney:

a. Shows signs of vent gas condensation, the chimney

should be relined in accordance with local codes and the authority having jurisdiction. The chimney should berelined with a listed metal liner, Type--B vent, or a listed chimney adapterkitshallbeusedto reducecondensation. If a condensate drain is required by local code, refer to the NFGC NFPA54/ANSI Z223.1--2012, Section 12.10 for additional information on condensate drains.

b. Indicates the chimney exceeds the maximum permissible

sizein the tables,thechimney should be rebuiltorrelined to conform to the requirements of the equipment being installed and the authority having jurisdiction.

A chimney without a clay tile liner, which is otherwise in good condition, shall be rebuilt to conform to ANSI/NFPA 211 or be lined with a UL listed metal liner or UL listed Type--B vent. Relining with a listed metal liner or Type--B vent is considered to be a vent--in--a--chase.

If a metal liner or Type--B vent is used to line a chimney, no other appliance shall be vented into the annular space between the chimney and the metal liner.

Exterior Masonry Chimney FAN + NAT

Installations with Type--B Double Wall Vent

Connectors NFPA & AGA

Table 8 – Combined ApplianceMaximum Input Rating in

Thousands of BTUH per Hour

VENT HEIGHT

FT. (M)

6 (1.8) 74 119 178 257

8 (2.4) 80 130 193 279 10 (3.0) 84 138 207 299 15 (4.5) NR 152 233 334 20 (6.0) NR NR 250 368 30 (9.1) NR NR NR 404

INTERNAL AREA OF CHIMNEY

(7741)19(12258)28(18064)38(24516)

(MM2)

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

ing Appliance in Thousands of BTUH per Hour

INTERNAL AREA OF CHIMNEY

VENT HEIGHT

FT (M)

Temperature: 17 to 26_F ( --- 8 t o --- 3 _C)

6 (1.8) 0 55 99 141

8 (2.4) 52 74 111 154 10 (3.0) NR 90 125 169 15 (4.6) NR NR 167 212 20 (6.1) NR NR 212 258 30 (9.1) NR NR NR 362

Temperature: 5 to 16_F * ( --- 1 5 t o --- 9 _C)

6 (1.8) NR 78 121 166

8 (2.4) NR 94 135 182 10 (3.0) NR 111 149 198 15 (4.6) NR NR 193 247 20 (6.1) NR NR NR 293 30 (9.1) NR NR NR 377

Temperature: ---10 to 4_F * ( --- 2 3 t o --- 1 6 _C)

6 (1.8) NR NR 145 196

8 (2.4) NR NR 159 213 10 (3.0) NR NR 175 231 15 (4.6) NR NR NR 283 20 (6.1) NR NR NR 333 30 (9.1) NR NR NR NR

Temperature: ---11_F ( --- 2 4 _C) or lower

Not recommended for any vent configuration.

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

(7741)19(12258)28(18064)38(24516)

Local 99% Winter Design

.(MM2)

APPLIANCE APPLICATION REQUIREMENTS

Appliance operation has a significant impact on the performance of the venting system. If the appliances are sized, installed, adjusted, and operated properly, the venting system and/or the appliances should not suffer from condensation and corrosion. The venting system and all appliances shall be installed in accordance with applicable listings, standards, and codes.

The furnace should be sized to provide 100 percent of the design heating load requirement plus any margin that occurs because of furnace model size capacity increments. Heating load estimates can be made using approved methods available from Air 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. When a metal vent or metal liner is used, the vent must be in good condition and be installed in accordance with the vent manufacturer’s instructions.

Page 27

CHIMNEY INSPECTION CHART

For additional requirements refer to the National Fuel Gas Code NFPA 54/ANSI Z223.1 and ANSI/NFPA 211

Chimneys, Fireplaces, Vents, and Solid Fuel Burning Appliances

Crown

condition:

Missing mortar

or brick?

Is chimney

property lined with

clay tile liner?

Ye s

liner and top

seal in good

condition?

Ye s

Debris

in cleanout?

Mortar, tile, metal vent,

fuel oil residue?

Ye s

Rebuild

crown.

Repair

liner or top seal

or reline chimney as

necessary.

Repair

Mortar

or tile

debris?

Reline

Ye s

Remove mortar

and tile debris

PG8MEA

Clay tile misalignment, missing sections,

gaps?

Condensate

drainage at bottom

of chimney?

Chimney

exposed to

outdoors below

roof line?

Chimney is

acceptable for use.

Remove metal vent

or liner.

Ye s

lined with properly

sized, listed liner or

Ye s

Is chimney

Type-B vent?

Ye s

Is chimney

to be dedicated to

a single

furnace?

Consult

Par t B of

chimney adapter venting

instructions for

application

suitability.

Suitable

Ye s

Install chimney

adapter per

instructions.

chimney adapter venting

Not Suitable

Consult

Par t C of

instructions for

application

suitability

Line chimney with property

sized, listed flexible metal

liner or Type-B vent per

Sizing Tables and liner or

vent manufacturer’s

Installation instructions.

Suitable

Install chimney

adapter per instructions.

NFGC

Ven t

A10133

Fig. 33 -- Chimney Inspection Chart

Page 28

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

1. The return--air temperature must be at least 60_F (16_C)db except for brief periods of time during warm--up from setback at no lower than 55_F(13_C) db or during initial start--up from a standby condition.

2. Adjust the gas input rate per the installation instructions. Low gas input rate causes low vent gas temperatures, causing condensation and corrosion in the furnace and/or venting system. Derating is permitted only for altitudes above 2000 ft. (610 M).

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

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

Air for combustion must not be contaminated by halogen compounds which include chlorides, fluorides, bromides, and iodides. These compounds are found in many common home

PG8MEA

products such as detergent, paint, glue, aerosol spray, bleach, cleaning solvent, salt, and air freshener, and can cause corrosion of furnaces and vents. Avoid using such products in the combustion--air supply. Furnace use during construction of the building could cause the furnace to be exposed to halogen compounds, causing premature failure of the furnace or venting system due to corrosion.

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

ADDITIONAL VENTING

A 4” (101 mm) round vent elbow is supplied with the furnace. A 5--inch (127 mm) or 6-- inch (152 mm) vent connector may be required for some model furnaces. A field--supplied 4--inch--to--5--inch (101 -- 127 mm) or 4--inch--to--6--inch (101 -152 mm) sheet metal increaser fitting is required when 5--inch (127 mm) or 6--inch (152 mm) vent connector is used. See Fig. 34 -- 46 Venting Orientation for approved vent configurations.

NOTE: Vent connector length for connector sizing starts at furnace vent elbow. The 4--inch vent elbow is shipped for upflow configuration and may be rotated for other positions. Remove the 3 screws that secure vent elbow to furnace, rotate furnace vent elbow to position desired, reinstall screws. The factory--supplied vent elbow does NOT count as part of the number of vent connector elbows.

The vent connector can exit the furnace through one of 5 locations on the casing.

1. Attach the single wall vent connector to the furnace vent elbow, and fasten the vent connector to the vent elbow with at least two field--supplied, corrosion--resistant, sheet metal screws located 180_ apart.

REQUIREMENTS

NOTE: An accessory flue extension is available to extend from

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

2. Vent the furnace with the appropriate connector as shown in Fig. 34 -- 46.

3. Determine the correct location of the knockout to be removed.

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

CAUTION

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.

CAUTION

BURN HAZARD

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

installed in downflow position. See the following instruction.

An accessory Vent Guard Kit is REQUIRED for downflow applications where the vent exits through the lower portion of the furnace casing. See Fig. 38 and Product Data Sheet for accessory listing. Refer to the Vent Guard Kit Instructions for complete details.

The horizontal portion of the venting system shall slope upwards not less than 1/4--in. per linear ft. (21 mm/M) from the furnace to the vent and shall be rigidly supported every 5 ft. (2 M) or less with metal hangers or straps to ensure there is no movement after installation.

SIDEWALL

This furnace is not approved for direct sidewall horizontal venting.

Per section 12.4.3 of the NFPA54/ANSI Z223.1--2012, any listed mechanical venter may be used, when approved by the authority having jurisdiction.

Select the listed mechanical venter to match the Btuh input of the furnace being vented. Follow all manufacturer’s installation requirements for venting and termination included with the listed mechanical venter.

VENTING

Page 29

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

follow exclusively the National Fuel Gas Code.

FURNACE

ORIENTATION

VENT ORIENTATION

FURNACE INPUT

(BTUH/HR)

MIN. VENT DIAMETER

IN (MM)*

MIN. VERTICAL VENT

Downflow Vent elbow left, then up Fig. 38 132,000 5 (127 ) 12 (4) Horizontal Left Vent elbow right, then up Fig. 41 132,000 5 (127 ) 7(2) Horizontal Left Vent elbow right Fig. 42 132,000 5 (127 ) 7(2)

NOTE: All vent configurations must also meet National Fuel Gas Code venting requirements NFGC *4 in. (102 mm) inside casing or ven t guard **Including 4 in. (102 mm) vent section(s)

HEIGHT

FT. (M)**

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

Fig. 34 -- Upflow Application--Vent Elbow Up

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

A03208

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

A03210

Fig. 36 -- Downflow Application--Vent Elbow Up then Left

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

Fig. 35 -- Upflow Application--Vent Elbow Right

A03209

A03211

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

Page 30

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

Fig. 38 -- Downflow Application--Vent Elbow Left then Up

A03207

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

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

A03213

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

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

A03212

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

A03214

Fig. 41 -- Horizontal Left Application--Vent Elbow Right

then Up

Page 31

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

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

A03214

Fig. 42 -- Horizontal Right Application--Vent Elbow Right

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

following these figures

A03215

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

Fig. 44 -- Horizontal Right Application--Vent Elbow Left

then Up

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

Fig. 45 -- Horizontal Left Application--Vent Elbow Right

A03219

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A03216

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

VENTING NOTES FOR FIGURES 34 -- 46

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

2. Immediately increase to 5--inch (127 mm) or 6--inch (152 mm) vent connector outside furnace casing when 5--inch (127 mm) vent connector isrequired, refer to Note 1 above.

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

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

5. Four--inch single--wall (26 ga. min.) vent must be used inside furnace casing and when the Downflow Vent Guard Kit is used external to the furnace. SeeTableNOTAG for accessory listing.

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

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

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

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

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

A02068

Page 32

START--UP, ADJUSTMENT, AND SAFETY

CHECK

General

WARNING

FIRE HAZARD

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

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

PG8MEA

CUT HAZARD

Failure to follow this caution may result in personal injury.

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

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

2. Make thermostat wire connections at the 24--v terminal block on the furnace control. Failure to make proper connections will result in improper operation. (See Fig. 25.)

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

4.5--In. W.C. (0.16 psig ) but not exceed 14--In. W.C. (0.5 psig).

4. Check all manual--reset switches for continuity.

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

6. Replace outer door.

Start--Up Procedur

CAUTION

WARNING

ELECTRICAL SHOCK HAZARD

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

Blower access door switch opens 115--v power to control. No component operation can occur unless switch is closed. Caution must be taken when manually closing this switch for service purposes.

NOTE: The furnace control allows all components, except the gas valve, to be run for short period of time. This feature helps diagnose a system problem in case of a component failure. Component test feature will not operate if any thermostat signal is present at the control. Component test sequence is as follows: Refer to service label attached to furnace or see Fig. 50.

a. LED will display previous status code 4 times.

b. Inducer motor starts and continues to run until Step f of

component test sequence.

c. Hot surface igniter is energized for 15 sec., then off.

d. Blower motor operates on HEAT speed for 10 sec.

e. Blower motor operates on COOL speed for 10 sec.

f. Inducer motor stops.

g. Reconnect R lead tofurnace controlboard, releaseblower

door switch and re--install blower door.

4. Operate furnace per instruction on door.

5. Verify furnace shut down by lowering thermostat setting below room temperature.

6. Verify furnace restarts by raising thermostat setting above room temperature.

Adjustments

WARNING

FIRE HAZARD

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

DO NOT bottom out gas valve regulator adjusting screw. This can result in unregulated manifold pressure and result in excess overfire and heat exchanger failures.

FIRE AND EXPLOSION HAZARD

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

Never test for gas leaks with an open flame. Use a commercially available soap solution made specifically for the detection of leaks to check all connections.

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

2. Check gas lines for leaks.

3. To Begin Component Self--Test: Remove blower access door. Disconnect the thermostat R lead from the furnace control board. Manually close the blower door switch closed. Short (jumper) the COM--24v terminal on control to the TEST/TWIN 3/16--inch quick connect terminal on control until LED goes out (approximately 2 sec). Gas valve and humidifier will not be turned on. (See Fig. 24.)

CAUTION

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.

48.)

Furnace gas input rate on rating plate is for installations at altitudes up to 2000 ft. (610 M). Furnace input rate must be within +/--2 percent of furnace rating plate input. For altitudes above 5500 ft. (1676 M), a field--supplied high altitude pressure switch is required.

1. Determine the correct gas input rate. The input rating for altitudes above 2,000 ft. (610 M) must

Page 33

be reduced by 4 percent for each 1,000 ft. (305 M) above sea level. For installations below 2000 ft. (610 M), refer to the unit rating plate. For installations above 2000 ft. (610 M), multiply the input on the rating plate by the de--rate multiplier in Table 8 for the correct input rate.

2. Determine the correct orifice and manifold pressure adjustment. There are two different orifice and manifold adjustment tables. All models in all positions, except Low NOx models in downflow or horizontal positions, use Table 12 (22,000 Btuh/Burner). Low NOx models in the downflow or horizontal positions must use Table 13 (21,000 Btuh/Burner). See input listed on rating plate.

a. Obtainaverage yearly gasheat value(at installed altitude)

from local gas supplier.

b. Obtain average yearly gas specific gravity from local gas

supplier.

c. Find installation altitude in Table 12 or 13.

d. Find closest natural gas heat value and specific gravity

in Table 12 or 13.

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

intersection to find orificesize and manifold pressure settings for proper operation.

f. Check and verify burner orifice size in furnace. NEVER

ASSUME ORIFICE SIZE. ALWAYS CHECK AND VERIFY.

g. Replace orifice with correct size if required by Table 10,

11, 12 and 13. Use only factory--supplied orifices. See EXAMPLE 1.

Table 10 – Altitude Derate Multiplier for U.S.A.

ALTITUDE

(FT . / M)

0–2000 (0--- 610) 0 1.00

2001–3000 (610--- 914) 8–12 0.90

3001–4000 (914--- 1219) 12–16 0.86 4001–5000 (1219--- 1524) 16–20 0.82 5001–6000 (1524--- 1829) 20–24 0.78 6001–7000 (1829--- 2134) 24–28 0.74 7001–8000 (2134--- 2438) 28–32 0.70 8001–9000 (2438--- 2743) 32–36 0.66

9001–10,000 (2743--- 3048) 36–40 0.62

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

PERCENT

DERATE

MULTIPLIER

FACTOR*

EXAMPLE 1: (0 to 2000 ft. (0 to 610 M) altitude)

For 22,000 Btuh per burner application use Table 12. Heating value = 1000 Btuh/cu ft. Specific gravity = 0.62 Therefore: Orifice No. 43* Manifold pressure: 3.7--In. W.C. *Furnace is shipped with No. 43 orifices. In this example all main burner orifices are the correct size and do not need to be changed to obtain proper input rate.

3. Adjust manifold pressure to obtain correct input rate. a. Turn gas valve ON/OFF switch to OFF.

b. Remove manifold pressuretapplug from gas valve. (See

Fig. 47.)

c. Connect a water column manometer or similar device to

manifold pressure tap.

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

e. Manually close blower door switch.

f. Set thermostat to call for heat.

g. Remove regulator seal cap and turn regulator adjusting

screw counterclockwise (out) to decrease input rate of clockwise (in) to increase input rate.

h. Install regulator seal cap.

i. Leave manometer or similar device connected and pro-

ceed to Step 4.

NOTE: DO NOT set manifold pressure less than 3.2--In. W.C. or more than 3.8--In. W.C. for natural gas at sea level. If manifold pressure is outside this range, change main burner orifices. Refer to Table 10, 11, 12 and 13.

NOTE: If orifice hole appears damaged or it is suspected to have been redrilled, check orifice hole with a numbered drill bit of correct size. Never redrill an orifice. A burr--free and squarely aligned orifice hole is essential for proper flame characteristics.

4. Verify natural gas input rate by clocking meter.

NOTE: Gas valve regulator adjustment cap must be in place for proper input to be clocked.

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

meter.

b. Run furnace for 3 minutes in heating operation.

c. Measure time (in sec) for gas meterto complete 1revolu-

tion and notereading. The2 or5 cubic feet dialprovides a more accurate measurement of gas flow.

d. Refer to Table 12 for cubic ft. of gas per hr.

e. Multiply gasrate (cu ft./hr) by heating value (Btuh/cu ft.)

to obtain input.

If clocked rate does not match required input from Step 1, increase manifold pressure to increase input or decrease manifold pressure to decrease input. Repeat steps b through e until correct input is achieved. Reinstall regulator seal cap on gas valve.

5. Set temperature rise. The furnace must operate within the temperature rise ranges specified on the furnace rating plate. Do not exceed temperature rise range specified on unit rating plate. Determine the temperature rise as follows:

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

WARNING

ELECTRICAL SHOCK HAZARD

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

Disconnect 115--v electrical power and install lockout tag before changing speed tap.

a. Place thermometers in return and supply ducts as close

to furnace as possible. Be sure thermometers do not see radiant heat from heat exchangers. Radiant heat affects temperature risereadings. This practiceisparticularly important with straight--run ducts.

b. Whenthermometerreadings stabilize, subtract return--air

temperaturefromsupply--airtemperature to determineair temperature rise.

NOTE: If the temperature rise is outside this range, first check:

(1.) Gas input for heating operation. (2.) Derate for altitude if applicable. (3.) Return and supply ducts for excessive restrictions

causing static pressures greater than 0.50--In. W.C.

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Page 34

c. Adjustair temperature rise by adjusting blower speed. In-

crease blower speed to reduce temperature rise. Decrease blower speed to increase temperature rise

d. Turn thermostat down below room temperature and re-

move blower access door.

e. To change motor speed selection for heating, remove

blowermotorlead from control HEAT terminal (See Fig.

24.) Select desired blower motor speed lead from one of the other terminals and relocate it to the HEAT terminal (See Table 5 for lead color identification).Reconnectoriginal lead to SPARE terminal.

f. Repeat steps a through e.

g. When correct input rate and temperature rise is achieved,

turn gas valve ON/OFF switch to OFF.

h. Remove manometer or similar device from gas valve.

i. Reinstall manifold pressure tap plug in gas valve.

FIRE HAZARD

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

Reinstall manifold pressure tap plug in gas valve to prevent gas leak.

FURNACE OVERHEATING HAZARD

Failure to follow this caution may result in reduced furnace life.

Recheck temperature rise. It must be within limits specified on the rating plate. Recommended operation is at the mid--point of rise range or slightly above.

WARNING

CAUTION

PG8MEA

6. Set thermostat heat anticipator.

a. Mechanical thermostat -- Set thermostat heat anticipator

to match the amp. draw of the electrical components in the R--W circuit. Accurate amp. draw readingscan beobtained at the wires normally connected to thermostat subbase terminals, R and W. The thermostat anticipator should NOT be in the circuit while measuring current.

(1.) Remove thermostat from subbase or from wall. (2.) Connect an amp. meter as shown in Fig. 49 across

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

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

in heating and after blower starts.

(4.) Setheatanticipator onthermostatperthermostatin-

structions and install on subbase or wall.

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

7. Adjust blower off delay The blower off delay has 4 adjustable settings from 90 sec to 180 sec. The blower off delay jumpers are located on the furnace control board. (See Fig. 24.) To change the blower off delay setting, move the jumper from one set of pins on the control to the pins used for the selected blower off delay. Factory off delay setting is 120 sec.

8. Set airflow CFM for cooling Select the desired blower motor speed lead for cooling airflow. See Table 5--Air Delivery--CFM (With Filter) for lead color identification.

Check Safety Contr

The flame sensor, gas valve, and pressure switch were all checked in the Start--up procedure section as part of normal operation.

1. Check Main Limit Switch(es) This control shuts off combustion control system and energizes air--circulating blower motor, if furnace overheats. By using this method to check limit control, it can be established that limit is functioning properly and will operate if there is a restricted duct system or motor failure. If limit control does not function during this test, cause must be determined and corrected.

a. Run furnace for at least 5 minutes.

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

or sheet metal until the limit trips.

c. Unblock return air to permit normal circulation.

ols

Fig. 47 -- Gas Control Valve

Fig. 48 -- Orifice Hole

BURNER

ORIFICE

A06666

A93059

Page 35

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

2. Check draft safeguard switch. The purpose of this control is to cause the safe shutdown of the furnace during certain blocked vent conditions.

a. Verify vent pipe is cool to the touch.

b. Disconnect power to furnace and remove vent connector

from furnace vent elbow.

c. Restore power to furnaceand set room thermostat above

room temperature.

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

minutes, then block vent elbow in furnace 80 percent of vent area with a piece of flat sheet metal.

e. Furnace should cycleoff within2minutes. Ifgasdoes not

shut off within 2 minutes, determine reason draft safeguardswitch did not functionproperlyandcorrectcondition.

f. Remove blockage from furnace vent elbow. g. Switch will auto--reset when it cools. h. Re--install vent connector.

NOTE: Should switch remain open longer than 3 minutes, furnace control board will lockout the furnace for 3 hours. To reset furnace control board, turn thermostat below room temperature or from HEAT to OFF and turn 115v power OFF, then back ON.

3. Check Pressure Switch This control proves operation of the draft inducer blower.

a. Turn off 115--v power to furnace.

b. Disconnect inducer motor lead wires from wire harness.

c. Turn on 115--v power to furnace.

d. Setthermostat to “call forheat” and wait 1 minute. When

pressure switch is functioning properly, hot surface igniter should NOT glow and control diagnostic light flashes a statuscode32. Ifhotsurfaceigniter glowswhen inducermotorisdisconnected, shut down furnaceimmediately.

e. Determine reason pressure switch did not functionprop-

erly and correct condition.

f. Turn off 115--v power to furnace.

g. Reconnect inducer motor wires, replace outer door, and

turn on 115--v power.

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

heat again.

i. Furnace should ignite normally.

THERMOSTAT SUBBASE TERMINALS WITH THERMOSTAT REMOVED (ANITICIPATOR, CLOCK, ETC., MUST BE OUT OF CIRCUIT.)

HOOK-AROUND AMMETER

R Y W G

10 TURNS

FROM UNIT 24-V CONTROL TERMINALS

EXAMPLE:

5.0 AMPS ON AMMETER 10 TURNS AROUND JAWS

0.5 AMPS FOR THERMOSTAT

ANTICIPATOR SETTING

Fig. 49 -- Amp. Draw Check with Ammeter

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A96316

Page 36

SECONDS

FOR 1 REVOLUTION

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Table 11 – Gas Rate (Cu Ft./Hr.)

SIZE OF TEST DIAL

Cu Ft.

10 360 720 1800 50 72 144 360 11 327 655 1636 51 71 141 355 12 300 600 1500 52 69 138 346 13 277 555 1385 53 68 136 340 14 257 514 1286 54 67 133 333 15 240 480 1200 55 65 131 327 16 225 450 1125 56 64 129 321 17 212 424 1059 57 63 126 316 18 200 400 1000 58 62 124 310 19 189 379 947 59 61 122 305 20 180 360 900 60 60 120 300 21 171 343 857 62 58 116 290 22 164 327 818 64 56 112 281 23 157 313 783 66 54 109 273 24 150 300 750 68 53 106 265 25 144 288 720 70 51 103 257 26 138 277 692 72 50 100 250 27 133 267 667 74 48 97 243 28 129 257 643 76 47 95 237 29 124 248 621 78 46 92 231 30 120 240 600 80 45 90 225 31 116 232 581 82 44 88 220 32 113 225 563 84 43 86 214 33 109 218 545 86 42 84 209 34 106 212 529 88 41 82 205 35 103 206 514 90 40 80 200 36 100 200 500 92 39 78 196 37 97 195 486 94 38 76 192 38 95 189 474 96 38 75 188 39 92 185 462 98 37 74 184 40 90 180 450 100 36 72 180 41 88 176 439 102 35 71 178 42 86 172 429 104 35 69 173 43 84 167 419 106 34 68 170 44 82 164 409 108 33 67 167 45 80 160 400 110 33 65 164 46 78 157 391 112 32 64 161 47 76 153 383 116 31 62 155 48 75 150 375 120 30 60 150 49 73 147 367

2CuFt. 5CuFt. 1CuFt. 2CuFt. 5CuFt.

SECONDS

FOR 1 REVOLUTION

SIZE OF TEST DIAL

Checklist

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

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

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

4. Cycle test furnace with room thermostat.

5. Check operation of accessories per manufacturer’s instructions.

6. Review User’s Guide with owner.

7. Attach literature packet to furnace

Page 37

Table 12 – Orifice Size* and Manifold Pressure (In. W.C.) for Gas Input Rate

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A10180

Page 38

Table 12 -- Orifice Size* and Manifold Pressure (In. W.C.) for Gas Input Rate (CONT)

PG8MEA

A10180A

Page 39

Table 13 – Orifice Size* And Manifold Pressure (In. W.C.) For Gas Input Rate

PG8MEA

A10181

Page 40

Table 13-- Orifice Size* And Manifold Pressure (In. W.C.) For Gas Input Rate (CONT)

PG8MEA

A10181A

Page 41

SERVICE AND MAINTENANCE

PROCEDURES

WARNING

FIRE, INJURY, OR DEATH HAZARD

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

The ability to properly perform maintenance on this equipment requires certain knowledge, mechanical skills, tools, and equipment. If you do not possess these, do not attempt to perform any maintenance on this equipment other than those procedures recommended in the User’s Manual.

WARNING

ELECTRICAL SHOCK, FIRE OR EXPLOSION HAZARD

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

Before installing, modifying, or servicing system, main electrical disconnect switch must be in the OFF position and install a lockout tag. There may be more than one disconnect switch. Lock out and tag switch with a suitable warning label. Verify proper operation after servicing.

CAUTION

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.

INTRODUCTION

GENERAL

These instructions are written as if the furnace is installed in an upflow application. An upflow furnace application is where the blower is located below the combustion and controls section of the furnace, and conditioned air is discharged upward. Since this furnace can be installed in any of the 4 positions shown in Fig. 4, you must revise your orientation to component location accordingly.

ELECTRICAL CONTROLS AND

WIRING

The electrical ground and polarity for 115--v wiring must be properly maintained. Refer to Fig. 25 for field wiring information and to Fig. 54 for furnace wiring information.

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

The 24--v circuit contains an automotive--type, 3--amp. fuse located on the control. (See Fig. 24.) Any shorts of the 24--v wiring during installation, service, or maintenance will cause this fuse to blow. If fuse replacement is required, use ONLY a 3--amp. fuse. The control LED will display status code 24 when fuse needs to be replaced.

Proper instrumentation is required to service electrical controls. The control in this furnace is equipped with a Status Code LED (Light--Emitting Diode) to aid in installation, servicing, and troubleshooting. Status codes can be viewed at the sight glass in blower access door. The furnace control LED is either ON continuously, rapid flashing, or a code composed of 2 digits. The first digit is the number of short flashes, the second digit is the number of long flashes.

For an explanation of status codes, refer to service label located on blower access door or Fig. 50 and the troubleshooting guide which can be obtained from your distributor.

See Fig. 55 for a brief Troubleshooting Guide.

For Controls With an Amber

The stored status code will not be erased from the control memory, if 115-- or 24--v power is interrupted.

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

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

a. Leave 115--v power to furnace turned on.

b. Remove outer access door.

c. Look into bloweraccessdoorsightglass for currentLED

status.

d. BRIEFLY remove insulated terminal wire fromthe draft

safeguard (DSS) switch until LED goes out, then reconnect it.

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

2. When above items have been completed, the LED flashes status code 4 times. Record this status code for further troubleshooting.

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

LED

PG8MEA

WARNING

ELECTRICAL OPERATION HAZARD

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

There may be more than one electrical supply to the furnace. Check accessories and cooling unit for additional electrical supplies that must be shut off during furnace servicing. Lock out and tag switch with a suitable warning label.

Page 42

SERVICE

If st atus code recall is needed, brie fly remove then rec onnect one main limi t wire to dis play stored sta tus code. On RED LED boards do not remove power or blower door before in itiating st atus code recall. Aft er status code r ecall is complete d component test will occur.

EACH OF THE FOLLOWING STATUS CODES IS A TWO DIGIT NUMBER WI TH THE FIRST DIGIT DETERMINED BY THE NUMBER OF SHORT FLASHES AND THE SECOND DIGIT BY THE NUMBER OF LONG FLASHES.

11 NO PR EVIOUS CODE - Stored status code is erased automatically after 72 hours. On

RED LED boards stored status codes can also be e rased when power (115 VAC or 24 VAC) to control is interrupted.

12 BLOWER ON AFTER POWER UP (115 VAC or 24 VAC) -Blower runs for 90 seconds,

if unit is powered up during a call for heat (R-W closed) or R-W opens during blower on-delay.

13 LIMIT CIRCUIT LOCKOUT - Lockout occurs if the limit, draft saf eguard, flame rollout, or

blocked vent switch (if used) is open longer than 3 minutes.

- Control will auto reset after three hours. - Refer to #33.

14 IGNITION LOCKOUT - Control will auto-reset after three hours. Refer to #34. 21 GAS HEATI NG LOCKOUT - Control will NOT auto reset.

Check for: - Mis-wired gas valve -Defective control (valve relay)

22 ABNORMAL FLAME-PROVING SIGNAL - Flame is prove d while gas valve is de-

energized. Inducer will run until fault is cleared. Check for: - Leaky gas valve

- Stuck-open gas valve

23 PRESS URE SWITCH DID NOT OPEN Check for:

- Obstructed pressure tubing. - Pressure switch stuck closed.

24 SECONDARY VOLTAGE FUSE IS OPEN Check for:

- Short circuit in sec ondary voltage (24VAC) wiring.

COMPONENT TEST

To initiate the component test sequence, shut OFF the room thermostat or disconnect the "R" thermostat lead. Briefly short the TEST/TWIN terminal to the "Com 24 V" terminal. Status LED will flash code and then turn ON t he inducer motor. The inducer motor will run for the entire component test. The hot surface ignitor, blower motor fan speed (on AMBER LED boards

PG8MEA

only) blower motor-heat speed, and blower motor-cool speed will be turned ON for 10-15 seconds each. Gas Valve and Humidifier will not be turned on.

LED CODE

CONTINUOUS OFF - Check for 115VAC at L1 and L2, and 24VAC at SEC-1 and SEC-2. CONTINUOUS ON - Control has 24VAC power. RAPID FLASHING - Line voltage (115VAC) polarity reversed. If twinned, refer to twinning kit instructions.

327596-101 REV. B

STATUS

31 PRESSURE SWITCH DID NOT CLOSE OR REOPENED - If open longer t han five minutes,

inducer shuts off for 15 minutes before retry. Check for: - Excessive wind

- Proper vent sizing - Defective inducer motor

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

- Inadequate combustion air supply - Disconnected or obstr ucted pressure tubing

- Low inlet gas pressure (if LGPS used) - Restricted vent If it opens during blower on-delay period, blower will come on for the selected blower off-delay.

33 LIMIT CIRCUIT FAULT - Indicates a limit, draft safeguard, flame rollout, or blocked vent

switch (if used) is open. Blower will run for 4 minut es or until open switch remakes whichever is longer. If open longer than 3 minutes, code c hanges to lockout #13. If open less than 3 minutes st atus code #33 continues to flash until blower shuts off. Flame rollout switch and BVS S require manual reset. Check for: - Restricted vent

- Proper vent sizing - Loose blower wheel. - Excessive wind

- Dirty filter or restricted duct system.

- Defective blower motor or capacitor. - Defective switch or connections.

- Inadequate combustion air supply (Flame Roll-out Switch open).

34 IGNITION PRO VING FAILURE - Control will try three more times before lockout #14

occurs. If flame signal lost during blower on-delay period, blower will come on for the selected blower off-delay. Check for: - Flame sensor must not be grounded

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

- Proper flame sense microamps (.5 microamps D.C. min., 4.0 - 6.0 nominal).

- Gas valve defective or gas valve turned off - Manual v alve shut-off

- Defective Hot Surface Ignitor - Control ground continuity

- Low inlet gas pressure - Inadequate flame carryover or rough ignition

- Green/Yellow wire MUST be connected to furnace sheet metal

45 CONTROL CIRCUITRY LOCKOUT Auto-reset after one hour lockout due to;

- Gas valve relay stuck open - Flame sense circuit fa ilure - Software check error Reset power to clear lockout. Replace control if status code repeats.

Fig. 50 -- Service Label

A04223

CARE AND

MAINTENANCE

WARNING

FIRE OR EXPLOSION HAZARD

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

Never store anything on, near, or in contact with the furnace, such as:

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

2. Soap powders, bleaches, waxes or other cleaning compounds, plastic or plastic containers, gasoline, kerosene, cigarette lighter fluid, dry cleaning fluids, or other volatile fluids.

3. Paint thinners and other painting compounds, paper bags, or other paper products.

For continuing high performance and to minimize possible equipment failure, periodic maintenance must be performed on this equipment. Consult your local dealer about proper frequency of maintenance and the availability of a maintenance contract.

WARNING

ELECTRICAL SHOCK AND FIRE HAZARD

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

Turn off the gas and electrical supplies to the unit and install lockout tag before performing any maintenance or service. Follow the operating instructions on the label attached to the furnace.

WARNING

CARBON MONOXIDE POISONING AND

FIRE HAZARD

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

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

CAUTION

CUT HAZARD

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

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

The minimum maintenance on this furnace is as follows:

1. Check and clean/replace 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 season for rust, corrosion, water leakage, sagging pipes or broken fittings. Have vent pipes/vent system serviced by a qualified service agency.

Page 43

6. Inspect any accessories attached to the furnace such as a humidifier or electronic air cleaner. Perform any service or maintenance to the accessories as recommended in the accessory instructions.

CLEANING AND/OR REPLACING AIR FIL

TER

The air filter arrangement will vary depending on the application. The filter is exterior to the furnace casing.

NOTE: If the filter has an airflow direction arrow, the arrow must point towards the blower.

Table 14 – Filter Size Information (In. / mm)

FURNACE

CASING

WIDTH

In. (mm)

14---1/2

(368)

17---1/2

(445)

21 (533)

24 (610)

* Recommended

FILTER SIZE (In. / mm)

Side Return Bottom Return

16 x 25 x 3/4

(406 x 635 x 19)

16 X 25 X 3/4

(406 x 635 x 19)

16 x 25 x 3/4

(406 x 635 x 19)

16 x 25 x 3/4

(406 x 635 x 19)

14 x 25 x 3/4

(356 x 635 x 19)

16 X 25 X 3/4

(406 x 635 x 19)

20 X 25 X 3/4

(508 x 635 x 19)

24 X 25 X 3/4

(610 x 635 x 19)

FILTER TYPE

Wash able*

Media cabinet filter procedures :

1. Turn off electrical supply to furnace before removing filter access door.

2. Remove filter cabinet door.

3. Slide filter out of cabinet.

4. If equipped with permanent, washable 3/4--in. (19 mm) filter, clean filter by spraying cold tap water through filter in opposite direction of airflow. Rinse filter and let dry. Oiling or coating of the filter is not recommended. See Table 14 for size information.

5. If equipped with factory--specified disposable media filter, replace only with media filter having the same part number and size. For expandable replacement media, refer to the instructions included with the replacement media.

6. Slide filter into cabinet.

7. Replace filter cabinet door.

8. Turn on electrical supply to furnace.

BLOWER MOTOR AND

WHEEL

WARNING

ELECTRICAL SHOCK HAZARD

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

Blower access door switch opens 115--v power to control. No component operation can occur unless switch is closed. Caution must be taken when manually closing this switch for service purposes.

NOTE: The blower wheel should not be dropped or bent as balance will be affected. The following steps should be performed by a qualified service agency.

To ensure long life and high efficiency, clean accumulated dirt and grease from blower wheel and motor annually.

The inducer and blower motors are pre--lubricated and require no additional lubrication. These motors can be identified by the absence of oil ports on each end of the motor.

Clean blower motor and wheel as follows:

1. Turn off electrical supply to furnace.

2. Remove outer door.

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

a. Disconnect vent connector from furnace vent elbow.

b. Disconnect and remove short piece of vent pipe from

within furnace.

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

5. All factory wires can be left connected, but field thermostat connections may need to be disconnected depending on their length and routing.

6. Remove two screws holding blower assembly to blower deck and slide blower assembly out of furnace.

7. Clean blower wheel and motor using a vacuum with soft brush attachment. Blower wheel blades may be cleaned with a small paint or flux brush. Do not remove or disturb balance weights (clips) on blower wheel blades.

8. Vacuum any loose dust from blower housing, wheel and motor.

9. If a greasy residue is present on blower wheel, remove wheel from the blower housing and wash it with an appropriate degreaser. To remove wheel:

NOTE: Before disassembly, mark blower motor, and blower housing so motor and each arm is positioned at the same location during reassembly.

a. Disconnectpowerchokewires (ifused) and ground wire

attached to blower housing.

b. Remove screws securing cutoff plate and remove cutoff

plate from housing.

c. Loosen set screw holding blower wheel on motor shaft

(160+/--20 in.--lb. when reassembling).

d. Removeboltsholding motor to blower housing and slide

motoroutofwheel (40+/--10 in.--lb. whenreassembling).

e. Remove blower wheel from housing.

f. Clean wheel and housing.

10. Reassemble motor and blower by reversing steps 11f through 11a, finishing with 11a. Be sure to reattach ground wire to the blower housing.

11. Verify that blower wheel is centered in blower housing and set screw contacts the flat portion of the motor shaft. Loosen set screw on blower wheel and reposition if 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 two screws securing blower assembly to blower deck.

CAUTION

UNIT DAMAGE HAZARD

Failure to follow this caution may result in shortened heat exchanger life.

Heating fan speed(s) MUST be adjusted to provide proper air temperature rise as specified on the rating plate. Recommended operation is at the midpoint of the rise range or slightly above. Refer to “SET TEMPERATURE RISE” under START--UP, ADJUSTMENT, and SAFETY CHECK.

NOTE: Refer to Table 5 for motor speed lead relocation if leads were not identified before disconnection.

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Page 44

15. Refer to furnace wiring diagram, and connect thermostat leads if previously disconnected.

16. To check blower for proper rotation:

a. Turn on electrical supply.

WARNING

ELECTRICAL SHOCK HAZARD

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

Blower access door switch opens 115--v power to furnace control. No component operation can occur unless switch is closed. Exercise caution to avoid electrical shock from exposed electrical components when manually closing this switch for service purposes.

b. Manually close blower access door switch.

NOTE: If thermostat terminals are jumpered at the time blower access door switch is closed, blower will run for 90 sec before

PG8MEA

beginning a heating or cooling cycle.

c. Perform component self--test as shown at the bottom of

the SERVICE label, located on the front ofblower access door.

d. Verify blower is rotating in the correct direction.

17. If furnace is operating properly, RELEASE BLOWER ACCESS DOOR SWITCH. Remove any jumpers or reconnect any disconnected thermostat leads. Replace blower access door.

18. Downflow or horizontal furnaces with vent pipe through furnace only:

a. Installandconnect short pieceofventpipeinsidefurnace

to existing vent.

b. Connect vent connector to vent elbow.

19. Reinstall outer door.

20. Cycle furnace through one complete heating and cooling cycle. Verify the furnace temperature rise as shown in “Adjustments” Section. Adjust temperature rise as shown in “Adjustments” Section. If outdoor temperature is below 70_F, ( 21 _C) turn off circuit breaker to outdoor unit before running furnace in the cooling cycle. Turn outdoor circuit breaker on after completing cooling cycle.

CLEANING HEAT The following steps should be performed by a qualified

service agency: NOTE: If the heat exchangers get a heavy accumulation of soot

and carbon, they should be replaced rather than trying to clean them thoroughly. A heavy build--up of soot and carbon indicates that a problem exists which needs to be corrected, such as improper adjustment of manifold pressure, insufficient or poor quality combustion air, incorrect size or damaged manifold orifice( s), improper gas, or a restricted heat exchanger. Action must be taken to correct the problem.

If it becomes necessary to clean the heat exchangers because of dust or corrosion, proceed as follows:

1. Turn OFF gas and electrical power to furnace.

2. Remove outer access door.

3. Disconnect vent connector from furnace vent elbow.

4. For downflow or horizontal furnace having an internal vent pipe, remove internal vent pipe within the casing.

5. Disconnect wires to the following components. Mark wires to aid in reconnection of (be careful when disconnecting wires from switches because damage may occur):

EXCHANGER

a. Draft safeguard switch.

b. Inducer motor.

c. Pressure switch(es).

d. Limit over--temperature switch.

e. Gas valve.

f. Hot surface igniter. g. Flame--sensing electrode. h. Flame rollout switches.

6. Remove screws that fasten the collector box assembly to the cell panel. Be careful not to damage the collector box. Inducer assembly and elbow need not be removed from collector box.

7. Disconnect gas line from gas manifold.

8. Remove the 5 screws that attach the burner assembly to the cell panel. The gas valve and individual burners need not be removed from support assembly. Remove NOx baffles if installed.

NOTE: Be very careful when removing burner assembly to avoid breaking igniter. See Fig. 51 and 52 for correct igniter location.

9. Using field--provided 25--caliber rifle cleaning brush, 36--in. (914 mm) long, 1/4” (6 mm) diameter steel spring cable, a variable speed, reversible electric drill, and vacuum cleaner, clean cells as follows:

a. Remove metal screw fitting from wire brush to allow in-

sertion into cable.

b. Insert the twisted wire end of brush into end of spring

cable, and crimp tight with crimping tool or crimp by striking with ball--peenhammer.TIGHTNESSISVERY IMPORTANT.

9/32”

7.1mm

5/16”

7.9mm

A05025

Fig. 51 -- Igniter Position--Side View

1-7/8

47.6 mm

A05026

Fig. 52 -- Igniter Position--Top View

Page 45

NOTE: The materials needed in item 9 can usually be purchased at local hardware stores.

(1.) Attach variable--speed, reversible drill to the end of

spring cable (end opposite brush).

(2.) Insert brush end of cable into the outlet opening of

cell and slowly rotate with drill. DO NOT force cable. Gradually insert cable into upperpass ofcell. (See Fig. 53 .)

(3.) Work cable in and out of cell 3 or 4 times to obtain

sufficient cleaning. DO NOT pull cable with great force. Reverse drill and gradually work cable out.

(4.) Insert brush end of cable in burner inlet opening of

cell, and proceed to clean 2 lower passes of cell in same manner as upper pass.

(5.) Repeat foregoing procedures until each cell in fur-

nace has been cleaned.

(6.) Using vacuum cleaner, remove residue from each

cell.

(7.) Using vacuum cleaner with soft brush attachment,

clean burner assembly. (8.) Clean flame sensor with fine steel wool. (9.) Install NOx baffles (if removed).

(10.) Reinstall burner assembly. Center burners in cell

openings.

10. Remove old sealant from cell panel and collector box flange.

11. Spray releasing agent on the heat exchanger cell panel where collector box assembly contacts cell panel.

NOTE: A releasing agent such as cooking spray or equivalent (must not contain corn or canola oil, aromatic or halogenated hydrocarbons or inadequate seal may occur) and RTV sealant (G.E. 162, 6702, or Dow--Corning 738) are needed before starting installation. DO NOT substitute any other type of RTV sealant. G.E. 162 (P771--9003) is available through RCD in 3--oz. tubes.

12. Apply new sealant to flange of collector box and attach to cell panel using existing screws, making sure all screws are secure.

13. Reconnect wires to the following components. (Use connection diagram on wiring label, if wires were not marked for reconnection locations.):

a. Draft safeguard switch.

b. Inducer motor.

c. Pressure switch(es).

d. Limit over--temperature switch.

e. Gas valve.

f. Hot surface igniter. g. Flame--sensing electrode. h. Flame rollout switches.

i. Install NOx baffles (if removed).

14. Reinstall internal vent pipe, if applicable.

15. Reinstall vent connector on furnace vent elbow. Securely fasten vent connector to vent elbow with 2 field--supplied, corrosion--resistant, sheet metal screws located 180_ apart.

16. Replace blower access door only, if it was removed.

17. Set thermostat above room temperature and check furnace for proper operation.

18. Verify blower airflow and speed changes between heating and cooling.

19. Check for gas leaks.

20. Replace outer access door.

A91252

Fig. 53 -- Cleaning Heat Exchanger Cell

WARNING

FIRE OR EXPLOSION HAZARD

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

Sequence of Operation NOTE: Furnace control must be grounded for proper operation

or control will lock out. Control is grounded through green/yellow wire routed to gas valve and manifold bracket screw. Using the schematic diagram in Fig. 54, follow the sequence of operation through the different modes. Read and follow the wiring diagram very carefully.

NOTE: If a power interruption occurs during a call for heat (W), the control will start a 90--second blower--only ON period two seconds after power is restored, if the thermostat is still calling for gas heating. The Amber LED light will flash code 12 during the 90--second period, after which the LED will be ON continuous, as long as no faults are detected. After the 90--second period, the furnace will respond to the thermostat normally.

The blower door must be installed for power to be conducted through the blower door interlock switch ILK to the furnace control CPU, transformer TRAN, inducer motor IDM, blower motor BLWM, hot--surface igniter HSI, and gas valve GV.

1. Heating (See Fig. 25 for thermostat connections.) The wall thermostat “calls for heat,” closing the R--to--W circuit. The furnace control performs a self--check, verifies the pressure switch contacts PRS are open, and starts the inducer motor IDM.

a. Inducer Prepurge Period-- As the inducer motor IDM

comes uptospeed, thepressureswitch contacts PRS close to begin a 15--second prepurge period.

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

the Hot--Surface igniter HSIis energized for a 17--second igniter warm--up period.

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

up period is completed, the main gas valve relay contacts GVR close to energize the gas valve GV, the gas valve opens,and 24 vac power is supplied for a field--installed humidifier at the HUM terminal. The gas valveGV permitsgas flow to theburners whereitisignited by theHSI. Five seconds after the GVR closes, a 2--second flame provingperiodbegins. TheHSI igniterwill remain ener-

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PG8MEA

2. Cooling Mode

gized until theflame is sensedor until the 2--second flame proving period begins.

d. Flame--Proving-- When theburnerflameisproved atthe

flame--proving sensor electrode FSE, thefurnace control CPU begins the blower--ON delay period and continues to hold the gas valve GV open. If the burnerflame is not proved within two seconds, the control CPU will close the gas valve GV, andthe controlCPU will repeattheignition sequence for up to three more Trials--For--Ignition before going to Ignition--Lockout. Lockout will be reset automatically after three hours or by momentarily interrupting 115 vac power to the furnace, or by interrupting 24 vac power at SEC1 or SEC2 to the furnace control CPU (not at W, G, R, etc.). If flameis proved when flameshould not be present,the furnace control CPUwilllock out of Gas--Heating mode and operate the inducer motor IDM until flame is no longer proved.

e. Blower--On Delay-- If the burner flame is proven, the

blower motor is energized on HEAT speed 25 seconds after the gas valve GV is energized. Simultaneously, the electronic air cleaner terminal EAC--1 is energized and remains energized aslong as the blower motor BLWM is energized.

f. Blower--OffDelay-- When the thermostat issatisfied, the

R--to--W circuit is opened, de--energizing the gas valve GV, stopping gas flow to the burners, and de--energizing the humidifier terminal HUM. The inducer motor IDM will remain energizedfor a 5--second post--purge period. The blower motor BLWM and air cleaner terminal EAC--1 will remain energized for 90, 120, 150, or 180 seconds(dependingon theblower--OFFdelayselection). The furnacecontrol CPU isfactory--setfora120--second blower--OFF delay.

The thermostat “calls for cooling.”

a. Single--Speed Cooling

(See Fig. 25 -- 32 for thermostat connections) The thermostat closes the R--to--G--and--Y circuits. The R--to-- Y circuit starts the outdoor unit, and the R--to-G--and--Y/Y2 circuits start the furnace blower motor BLWM on COOL speed. The electronic air cleaner terminal EAC--1 is energized with 115vacwhen theblower motor BLWM isoperating. When the thermostat is satisfied, the R--to--G--and--Y circuitsareopened.The outdoor unitwillstop,and the furnaceblower motorBLWMwillcontinueoperatingonthe COOL speed for an additional90seconds. Jumper Y/Y2 to DHUM to reduce the cooling off--delay to 5 seconds. (See Fig. 24.)

b. Two--Speed Cooling

(See Fig. 25 -- 32 for thermostat connections.) The thermostat closes the R--to--G--and--Y1 circuits for low--coolingorclosestheR--to--G--and--Y1--and--Y2circuits for high--cooling. The R--to--Y1 circuit starts the outdoor unit on low--cooling speed, and the R--to-G--and--Y1 circuit starts the furnace blower motor BLWM on low--cool speed (same speed as FAN). The R--to--Y1--and--Y2 circuitsstarttheoutdoor unitonhigh-cooling speed, and the R--to--G and-- Y/Y2 circuits start the furnace blower motor BLWM on COOL speed. The electronic air cleaner terminal EAC--1 is energized with 115 vac whenever the blowermotor BLWMis operating. When the thermostat is satisfied, the R--to--G--and--Y1 or R--to--G--and--Y1 and Y2 circuits are opened. The outdoor unit stops,and the furnaceblower BLWM and electronic air cleaner terminal EAC--1 will remain energized

for an additional90 seconds. Jumper Y1toDHUM to reduce the cooling off--delay to 5 seconds. (See Fig. 24.)

3. Humidity Sensing Thermostat Mode (See Fig. 26 -- 29 for humidity sensing thermostat connections.) The dehumidification output, DHUM on the humidity sensing thermostat should be connected to the furnace control thermostat terminal DHUM. When there is a dehumidify demand, the DHUM input is activated, which means 24 vac signal is removed 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 detected by the furnace control on the DHUM input, the furnace control operates in humidity sensing thermostat mode. If the DHUM input is low for more than 48 hours, the furnace control reverts back to non--humidity sensing thermostat mode. The cooling operation described in item 2. above also applies to operation with a humidity sensing thermostat. The exceptions are listed below:

a. When the R--to--G--and--Y1 circuit is closed and there is

ademandfordehumidification,thefurnaceblowermotor BLWM will continue running at low--cool speed (same speed as FAN).

b. When the R--to--G--and--Y/Y2 circuit is closed and there

isademand fordehumidification, thefurnaceblowermotor BLWM will drop the blower speed from COOL to HEAT for a maximum of 10 minutes before reverting back to COOL speed. If there is still a demand for dehumidification after 20 minutes, the furnace control CPU will drop the blower speed back to HEAT speed. This alternating 10-- minute cycle will continue as long as there is a call for cooling.

c. When the “call for cooling” is satisfied and there is a de-

mand for dehumidification, thecooling blower--off delay is decreased from 90 seconds to 5 seconds.

4. Continuous Blower Mode When the R--to--G circuit is closed by the thermostat, the blower motor BLWM will operate on continuous--blower speed (can be adjusted to FAN, HEAT, or COOL speed) at the thermostat. Factory default is FAN speed. Terminal EAC--1 is energized as long as the blower motor BLWM is energized. During a call for heat, the blower BLWM will stop during igniter warm--up (17 seconds), ignition (7 seconds), and blower--ON delay (25 seconds), allowing the furnace heat exchangers to heat up more quickly, then restarts at the end of the blower--ON delay period at HEAT speed. In heating, the furnace control CPU will hold the blower motor BLWM at HEAT speed during the selected blower-OFF delay period before reverting to continuous--blower speed. When the thermostat “calls for low--cooling,” the blower motor BLWM will switch to operate at low--cool speed (same speed as FAN). When the thermostat is satisfied, the blower motor BLWM will operate an additional 90 seconds on low--cool speed (same speed as FAN) before reverting back to continuous--blower speed. When the thermostat “calls for high--cooling”, the blower motor BLWM will operate at COOL speed. When the thermostat is satisfied, the blower motor BLWM will operate an additional 90 seconds on COOL speed before reverting back to continuous--blower speed. When the R--to--G circuit is opened, the blower motor BLWM will continue operating for an additional 5 seconds, if no other function requires blower motor BLWM operation.

Continuous Blower Speed Selection from Thermostat

--To select different continuous--blower speeds from the

Page 47

room thermostat, momentarily turn off the FAN switch or push button on the room thermostat for 1--3 seconds after the blower motor BLWM is operating. The furnace control CPU will shift the continuous--blower speed from the factory setting of FAN to HEAT speed. Momentarily turning off the FAN switch again at the thermostat will shift the continuous--blower speed from HEAT to COOL. Repeating the procedure will shift the continuous--blower speed from COOL to FAN speed. The selection can be changed as many times as desired and is stored in the memory to be automatically used following a power interruption.

5. Heat pump

(See Fig. 25 -- 32 for thermostat connections.) When installed with a heat pump, the furnace control automatically changes the timing sequence to avoid long blower off times during demand defrost cycles. When the R--to-W--and--Y1 or R--to--W--and--Y1--and--G circuits are energized the furnace control CPU will switch to or turn on the blower motor BLWM at HEAT speed, and begin a heating cycle. The blower motor BLWM will remain on until the end of the prepurge period, then shut off for 24 seconds then come back on at HEAT speed. When the W input signal disappears, the furnace control begins a normal inducer post--purge period and the blower remains running at HEAT speed for the selected blower--OFF delay period then switches to low--cool speed (same speed as FAN). If the R--to--W--and--Y1--and--G signals disappear at the same time, the blower motor BLWM will remain on for the selected blower--OFF delay period. If the R--to-W--and--Y1 signals disappear, leaving the G signal, the blower motor BLWM will remain on for the selected

blower--OFF delay period then switch to continuous-blower speed. When the R--to--W--and--Y/Y2, R--to-W -- a n d -- Y / Y 2 -- a n d -- G , R -- t o -- W -- a n d -- Y 1 -- a n d -- Y / Y 2 , o r R--to--W-- and--Y1--and--Y/Y2--and--G circuits are energized the furnace control CPU will switch to or turn on the blower motor BLWM at HEAT speed, and begin a heating cycle. The blower motor BLWM will remain on until the end of the prepurge period, then shut off for 24 seconds then come back on at HEAT speed. When the W input signal disappears, the furnace control begins a normal inducer post--purge period and the blower switches to COOL speed after a 3 second delay. If the R--to--W--and-Y/Y2--and--G or R--to--W--and--Y1--and --Y/Y2--and--G signals disappear at the same time, the blower motor BLWM will remain on for the selected blower--OFF delay period. If the R--to--W--and--Y/Y2 or R--to--W--and-Y1--and--Y/Y2 signals disappear, leaving the G signal, the blower motor BLWM will remain on for the selected blower--OFF delay period then switch to continuous blower speed.

Diagrams

Wiring

Refer to Fig. 54 for wiring diagram.

oubleshooting

Refer to the service label. (See Fig. 50.) The Troubleshooting Guide (See Fig. 55) 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.

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Page 48

PG8MEA

A11289

Fig. 54 -- Wiring Diagram

Page 49

Is door switch closed?

YES

Is circuit breaker closed?

Is there 115V going to switch?

YES

Check for continuity in wire from circuit breaker

Replace door switch.

Is 24V present at W, Y1 (if present), Y/Y2 or

G thermostat terminals on the furnace control?

YES

Disconnect all the thermostat wires from the

furnace control.

er and go back to START.

Check room thermostat or

to furnace.

Close circuit break

interconnecting cable.

Does the problem repeat when using

a jumper wire?

YES

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.

PG8MEA

YES

On RED LED boards stored

Replace transformer.

shorting the TEST/TWIN

Does the control respond to W, Y1 (if present),

Y/Y2, and G (24V) thermostat signals?

Run system through a heating or cooling cycle

to check operation. Status codes are erased

after 72 hours.

status codes can also be erased whenever

(115V or 24V) is interrupted.

Replace furnace control.

YES

Is there 115V at L1 and L2?

YES

START

Is LED status light on?

YES

Is there 24V at SEC-1 and SEC-2?

Replace furnace control.

code by momentarily

status

k for proper low-voltage

Check for correct line voltage polarity. If units

are twinned, chec

YES

Is LED status light blinking rapidly without a

pause?

recall status code briefly remove and reconnect one RED wire from the draft

(24V) transformer phasing.

safeguard switch to display stored status code. On RED LED control do not

remove power or blower access panel before initiating status code recall. You

can also recall the previous

terminal to Com24V terminal until the LED goes out. LED will flash the status

code of the previous fault or status code #11 (1 short and 1 long flash) if there

was no previous fault. After the control repeats the code 4 times, the control

flashes?

Is LED status light blinking ON/OFF slowly

with a combination of short and long

YES

Determine status code. The status code is a

Fig. 55 -- Troubleshooting Guide

Gas valve and humidifier will not be turned on.

Was there a previous status code

YES

Go to section below for the status code that

will go through a brief component test sequence. The inducer will start and run

for the entire component test. The HSI, blower motor FAN speed (AMBER LED

boards only) HEAT speed, and COOL speed will run for 10 – 15 seconds each.

2 digit number with the first digit determined

by the number of short flashes and the second

digit by the number of long flashes?

other than #11?

was flashed.

A02106A

Page 50

Auto-reset after 1 hour lockout due to:

45 CONTROL CIRCUITRY LOCKOUT

- Flame circuit failure.

- Gas valve relay stuck open.

- Software check error.

Reset power to clear lockout. Replace

control if code repeats.

ignite

Replace furnace control.

Check for continuity in the harness and

Replace defective component.

Check connections. If OK, replace control.

Check that all gas valves are turned on.

Replace valve.

k for:

ignition.

Chec

- Inadequate flame carryover or rough

- Low inlet gas pressure.

- Proper firing rate

- Blocked or incorrect carry- over gap.

(.045” nominal)

Allow blower to come on and repeat test to

k connections and retry. If current is

check for intermittent operation.

Chec

near typical value (4.0-6.0 nominal) and

burners will not stay on, replace control.

nace control.

Replace electrode.

Replace fur

PG8MEA

ness from control and initiate

Unplug igniter har

another component test sequence. Check

for 115V between pin 1 and NEUTRAL-L2 on

the control. Was 115V present for the 15

isconnected or obstructed pressure

OR REOPENED – If open longer than 5

minutes, inducer shuts off for 15 minutes

31 PRESSURE SWITCH DID NOT CLOSE

before retry. If opens during blower on-

delay period, blower will come on for the

selected blower off-delay. Check for:

- Proper vent sizing.

tubing.

- Low inlet gas pressure (if LGPS used).

- Inadequate combustion air supply.

-D

- Defective inducer motor.

- Low inducer voltage (115V).

- Defective pressure switch.

YES

second period?

- Excessive wind.

- Restricted vent.

lve

YES

connections. Does gas va ve

Reconnect the R thermostat lead and set

thermostat to call for heat. Connect voltmeter

across gas val

receive 24V?

Does gas valve open and allow gas to flow?

eguard, flame rollout, or

limit, draft saf

blocked vent shutoff switch* (if used) is

33 LIMIT CIRCUIT FAULT – Indicates the

status code #33

open. Blower will run for 4 minutes or

until open switch remakes whichever is

longer. If open longer than 3 minutes,

code changes to lockout #13. If open

less than 3 min.

YES

rollout switch and BVSS requires

continues to flash until blower shuts off.

Flame

YES

Do the main burners ignite?

Loose blower wheel.

manual reset. Check for:

- Dirty filter or restricted duct system.

- Defective blower motor or capacitor.

- Defective switch or connections.

YES

Do the main burners stay on?

xcessive wind.

(flame rollout switch open).

- Restricted vent.

- Inadequate combustion air supply

- Proper vent sizing.

-E

YES

Repeat call for heat and check flame sensor

current during trial for ignition period. Is the

DC microamps below 0.5?

OVING FAILURE – If flame

is not sensed during the trial for ignition

34 IGNITION

Clean flame sensor with fine steel wool and

YES

period, the control will repeat the ignition

sequence 3 more times before lockout

#14 occurs. If flame signal is lost during

the blower on-delay period, blower will

come on for the selected blower off-delay.

recheck current. Nominal current is 4.0 to 6.0

microamps.

Check the following items first before

proceeding to the next step.

- Gas valve turned off.

- Green/Yellow wire MUST be connected

- Manual shut-off valve.

lame sensor must not be grounded.

to furnace sheet metal.

-F

YES

alue?

Is current near typical v

To determine whether the problem is in

the gas valve, igniter, or flame sensor the

system can be operated in the component

YES

Will main burners ignite and stay on?

of the 15 second

test mode to check the igniter. First

remove the R thermostat connection from

the control and initiate the component

test sequence. Does the igniter glow

orange/white by the end

-up period? rm wa

Fixed.

are erased after 72 hours. On RED LED

boards stored status codes can also be

erased whenever power (115V or 24V)

is interrupted. Run system through a

heating or cooling cycle to check system.

(115V OR 24V) – Normal operation.

Blower runs for 90 seconds, if unit is

powered up during a call for heat (R-W

closed) or when (R-W opens) during the

blower on-delay period.

11 NO PREVIOUS CODE – Stored codes

12 BLOWER ON AFTER POWER UP –

itch*(if used) is

occurs if the limit, draft safeguard, flame

rollout, or blocked vent sw

13 LIMIT CIRCUIT LOCKOUT – Lockout

open longer than 3 minutes. Control will

auto-reset after 3 hours. See code 33.

ignite gas and prove flame in 4 attempts.

Control will auto-reset after 3 hours.

See status code 34.

14 IGNITION LOCKOUT – System failed to

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.

or:

Flame is proved while gas valve is de-

energized. Inducer will run until fault is

cleared. Check f

22 ABNORMAL FLAME-PROVING SIGNAL

* Blocked vent shutoff switch used in Chimney Adapter Kit

isolate

GE FUSE IS OPEN

wiring including thermostat leads.

Disconnect thermostat leads to

- Stuck open or leaky gas valve.

Check for:

- Obstructed pressure tube.

23 PRESSURE SWITCH DID NOT OPEN

- Pressure switch stuck closed.

24 SECONDARY VOLTA

Check for:

-Short circuit in secondary voltage (24V)

short circuit.

A05032

Page 51

PARTS REPLACEMENT INFORMATION GUIDE

CASING GROUP

Outer door Blower door Top filler plate Bottom filler plate Bottom enclosure

ELECTRICAL

Control bracket Junction box Limit switch(es) Circuit board Door switch Transformer Wiring harness 115v Wiring harness 24v

BLOWER

Blower housing Blower cutoff Blower motor Blower wheel Capacitor (where used) Capacitor strap (where used) Grommet Power choke (where used)

GROUP

GAS CONTROL

Manifold Burner assembly Orifice Flame sensor Hot surface igniter Gas valve Manual reset limit switches Burner support assembly

HEAT EXCHANGER

Heat exchanger cell Cell panel Lox NOx baffle (California models only)

INDUCER

Housing assembly Pressure switch Inducer motor Inducer wheel Vent elbow assembly Draft safeguard switch

GROUP

PG8MEA

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:

PAYNE HEATING & COOLING

Consumer Relations Department

P.O. Box 4952

Syracuse, New York 13221--4952

1--800--417--2963

Have available the model number, series number, and serial number located on the unit rating plate to ensure correct replacement part.

Example of Model Number

MODEL

PG8M E A 060 135 A B JA

WARNING: Improper installation, adjustment, alteration, service, or maintenance can cause personal injury, property damage, or death. Consult a qualified installer, service agency, or your local gas supplier for information or assistance. The qualified installer or service agency must use only factory--authorized replacement parts, kits, or accessories when modifying this product.

ELECTRIC-

AL SUPPLY

MAJOR

SERIES

COOLING

SIZE

HEATING

SIZE

VARIATION

MINOR SERIES

VARIATION

Page 52

PG8MEA

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

Edition Date: 08/13

Catalog No: IM--PG8MEA--05

Replaces: I M -- P G 8 M E A -- 0 4

Carrier PG8JEA, PG8MEA Installation, Start-up, Operating And Service And Maintenance Instructions

Specifications and Main Features

Frequently Asked Questions

User Manual