Dettson C45-1-D, C105-1-D, C75-1-D, C45-2-D, C60-2-D Installation Manual And User's Manual

ATTENTION: Do not tamper with the unit or its controls. Call a qualified service technician.
INSTALLER / SERVICE TECHNICIAN: Use the information in this manual for the installation / servicing of the furnace and

These instructions must be read and understood completely before attempting installation.

HOMEOWNER: PLEASE Keep this manual nears the furnace for future reference.

Manufactured by:

Industries Dettson Inc.
Sherbrooke (Québec) Canada

www.dettson.com

2015-07-09 X40223 rev. I

keep the document near the unit for future reference.

TABLE OF CONTENT

1- Safety regulation .............................................. 5

1.1- Safety labeling and warning signs ................ 5

1.2- Important information ................................... 5

1.3- Detection systems ........................................ 5

2- Introduction ....................................................... 7

2.1- Codes and standards ................................... 8

2.1.1- Safety ............................................................ 8

2.1.2- General installation ........................................ 8

2.1.3- Combustion and air ventilation....................... 8

2.1.4- Duct systems ................................................. 8

2.1.5- Acoustical lining and fibrous glass duct ......... 8

2.1.6- Gas piping and pipe pressure testing ............. 8

2.1.7- Electrical connections .................................... 8

2.2- Electrostatic discharge ................................. 8

2.3- Location ....................................................... 8

2.3.1- Location relative to cooling equipment ........... 9

2.4- Introduction .................................................. 9

2.4.1- Direct vent (2 pipes applications) ................... 9

2.4.2- Non direct vent (1 pipe) applications ............ 10

2.4.3- Ventilated combustion air applications ......... 10

2.5- Connecting to furnace ................................ 10

2.5.1- Combustion air piping .................................. 11

2.5.2- Exhaust vent piping ..................................... 11

3- Installation ....................................................... 11

3.1- Upflow orientation ...................................... 12

3.1.1- Right side condensate drain connection ...... 13

3.1.2- Left side condensate drain connection ......... 13

3.2- Down flow orientation ................................. 13

3.2.1- Down flow condensate drain connection ...... 13

3.2.2- Downflow venting drainaged ........................ 13

3.2.3- Condensate box pressure switch ................. 13

3.3- Horizontal right orientation ......................... 13

3.3.1- Horizontal right condensate drain

connection ................................................................. 13

3.3.2- Horizontal right vent drainage ...................... 14

3.3.3- Condensate box pressure switch ................. 14

3.4- Horizontal left orientation ........................... 14

3.4.1- Horizontal left condensate drain connection 14

3.4.2- Condensate box pressure switch ................. 15

4- Duct installation .............................................. 15

4.1- Return air connections ............................... 15

4.1.1- Bottom return air inlet .................................. 15

4.1.2- Side return air inlet ...................................... 15

4.2- Filter arrangement ...................................... 15

4.3- Supply air ducts ......................................... 15

4.4- General requirements ................................ 15

4.4.1- Duct work acoustical treatment .................... 16

5- Gas piping ....................................................... 17

5.1- Gas pipe grommet ..................................... 18

6- Electrical connections ................................... 18

6.1- 120 V wiring ............................................... 18

6.2- 24 V wiring ................................................. 19

6.3- Thermostats ............................................... 19

6.4- Alternate power supply .............................. 19

6.5- blower speeds (4 speed PSC motor) ......... 19

7- Venting ............................................................. 23

7.1- Special venting requirements for installations

in canada ................................................................. 23

7.2- General ...................................................... 23

7.3- Materials .................................................... 23

7.4- Direct vent - 2 pipes system ....................... 23

7.5- Size of the vent and combustion air pipes . 23

7.6- Combustion air and vent piping insulation

guidelines ................................................................ 26

7.7- Installing the vent termination .................... 27

7.7.1- Concentric vent ........................................... 27

7.7.2- Two pipes termination ................................. 27

7.7.3- Sidewall termination .................................... 27

8- Start up, adjustment and safety check ......... 27

8.1- To start the furnace .................................... 27

8.2- Unit operation hazard ................................. 28

8.3- Setup switches ........................................... 28

8.4- Option switches – 1 stage, PSC ................. 28

8.4.1- Heat mode .................................................. 28

8.4.2- Cool mode ................................................... 28

8.4.3- Manual fan on mode .................................... 29

8.4.4- Twinning interface ....................................... 29

8.4.5- System lockout and diagnostic features ....... 29

8.4.6- System lockout features .............................. 29

8.4.7- Diagnostic features ...................................... 29

8.5- Option switches – 2 stage, PSC ................. 29

8.5.1- Heat mode .................................................. 29

8.5.2- Cool mode ................................................... 30

8.5.3- Manual fan on mode .................................... 30

8.5.4- Twinning interface ....................................... 30

8.5.5- System lockout and diagnostic features ....... 30

8.5.6- System lockout ............................................ 30

8.5.7- Last fault mode ............................................ 30

8.5.8- Fault code reset .......................................... 30

8.5.9- Diagnostic features ...................................... 30

8.6- Option switch settings – 2 stage ECM........ 32

8.6.1- Thermostat type and heat-fan-off delay ....... 32

8.6.2- Multi-stage thermostat set-up, factory
default 32

8.6.3- Single stage thermostat set-up, module

controls staging ......................................................... 32

8.6.4- Heat fan off delay timing .............................. 32

8.6.5- De-humidification connection ....................... 32

8.6.6- Normal operation – heat on ......................... 32

8.6.7- Normal operation – heat off ......................... 32

8.6.8- Cool mode ................................................... 32

8.6.9- Adjust cooling airflow – dipswitch S3-1 and
S3-2 32

8.6.10- Manual fan on mode ............................... 32

8.7- Troubleshooting ......................................... 33

8.7.1- System lockout ............................................ 33

8.7.2- System reset ............................................... 33

8.7.3- Thermostat reset ......................................... 33

8.7.4- Auto restart ................................................. 33

8.7.5- Diagnostic features ...................................... 33

8.7.6- Fault code retrieval ...................................... 33

8.7.7- CFM indicator .............................................. 33

8.8- Prime condensate trap with water .............. 35

8.8.1- Check safety controls .................................. 35

8.8.2- Checklist ..................................................... 35

9- Operating your furnace .................................. 35

9.1- Start up instructions ................................... 35

9.2- Shutting down the furnace ......................... 35

9.2.1- To turn off gas to furnace ............................ 35

10- Maintenance of your furnace .................. 36

10.1- Cleaning/replacing the filter ........................ 36

10.1.1- Filter location .......................................... 36

10.2- Lubrication ................................................. 36

10.3- Burner flame .............................................. 36

10.4- Condensate collection and disposal system

(if applicable) ........................................................... 36

10.5- Rollout switch ............................................. 36

10.6- Safety interlock switch................................ 36

10.7- repair parts ................................................. 36

2

INDEX OF FIGURES

Figure 1 Freeze protection and return air temp. ............... 8

Figure 2 Installation in a garage ....................................... 9

Figure 3 Prohibited installation ......................................... 9

Figure 4 Dimensional drawing ........................................ 10

Figure 5 Vent coupling and adapter with gaskets ........... 11

Figure 6 Vent termination ............................................... 11

Figure 7 Drain Trap ........................................................ 12

Figure 8 Left side condensate drain connection ............. 12

Figure 9 Right side condensate drain connection .......... 12

Figure 10 : Down flow orientation ................................... 13

Figure 11 Condensate pressure switch .......................... 13

Figure 12 Horizontal right drain trap position .................. 14

Figure 13 Horizontal right condensate tubing ................. 14

Figure 14 Pressure switch assembly .............................. 14

Figure 15 Horizontal left condensate drain connection .. 15

INDEX OF TABLES

Figure 16 Return air base ............................................... 15

Figure 17 Typical gas pipe arrangement ........................ 17

Figure 18 Power cord installation in the furnace ............ 19

Figure 19 Wiring diagram – One stage PSC .................. 20

Figure 20 : Two Stage PSC - Furnace Control ............... 21

Figure 21 : Two Stage ECM - Furnace Control .............. 22

Figure 22 Direct venting ................................................. 24

Figure 23 Multi venting ................................................... 25

Figure 24 Control Switch – Modulating Valve ............ 35

Figure 25 Typical Flame Appearance ........................ 36

Figure 26 Exploded view 1 stage PSC ........................... 37

Figure 27 Exploded view 2 stage PSC ........................... 40

Figure 28 Exploded view 2 stage ECM .......................... 43

Table 1 Minimum clearance to combustible material for all

units.................................................................................. 9

Table 2 Loose parts list .................................................... 9

Table 3 Air flow capacity and blower data 2 stage

variable........................................................................... 16

Table 4 : Air flow capacity and blower data 2 stage direct

drive ............................................................................... 16

Table 5 : Air flow capacity and blower date 1 stage direct

drive ............................................................................... 17

Table 6 Maximum capacity of pipe in Ft³ of gas/hr ......... 17

Table 7 Gas pressure ..................................................... 17

Table 8 Electrical data .................................................... 18

Table 9 : Suggested fan speed on 1 stage furnace ........ 19

Table 10 : Suggested fan speed on 2 stage furnace ...... 19

Table 11 : Maximum equivalent straight vent length (two

stage and modulating) .................................................... 25

Table 12 Maximum equivalent straight vent length (single

stage) ............................................................................. 25

Table 13 Deduction for fitting ......................................... 26

Table 14 Approved combustion air and vent pipe, fitting

and cement materials (U.S.A. Installation) ..................... 26

Table 15: Option switches positions........................... 28

Table 16: Option switches S1-3 & S1-4 positions ...... 29

Table 17: Option switches S1-1 & S1-2 positions ...... 29

Table 18: Duty cycles ................................................. 29

Table 19: DIP Switches .............................................. 32

Table 20: Duty cycle .................................................. 32

Table 21: DIP Switches .............................................. 32

Table 22 : Dipswitch setting for airflow selection ............ 32

Table 23 Part list - 1 stage PSC ..................................... 39

Table 24: Part list – 2 Stage, PSC ............................. 42

Table 25: Part list – 2 Stage, ECM ............................. 45

Table 26 CFM for 45,000 BTU PSC motor ..................... 46

Table 27 CFM in heating for 45,000 BTU 2 stage ECM

motor .............................................................................. 46

Table 28 CFM in cooling for 45,000 BTU 2 stage ECM

motor .............................................................................. 46

Table 29 CFM for 60,000 BTU PSC motor ..................... 47

Table 30 CFM in heating for 60,000 BTU 2 stage ECM

motor .............................................................................. 47

Table 31 CFM in cooling for 60,000 BTU 2 stage ECM

motor .............................................................................. 47

Table 32 CFM for 75,000 BTU PSC motor ..................... 48

Table 33 CFM in heating for 75,000 BTU 2 stage ECM

motor .............................................................................. 48

Table 34 CFM in cooling for 75,000 BTU 2 stage ECM

motor .............................................................................. 48

Table 35 CFM for 105,000 BTU PSC motor ................... 49

Table 36 CFM in heating for 105,000 BTU 2 stage ECM

motor .............................................................................. 49

Table 37 CFM in cooling for 105,000 BTU 2 stage ECM

motor .............................................................................. 49

Table 38 CFM for 120,000 BTU PSC motor ................... 50

Table 39 CFM in heating for 120,000 BTU 2 stage ECM

motor .............................................................................. 50

Table 40 CFM in cooling for 120,000 BTU 2 stage ECM

motor .............................................................................. 50

Table 41 2 stage variable speed gas furnace (ECM) ..... 51

Table 42 2 Stage fixed speed gas furnace (PSC) .......... 51

Table 43 1 Stage fixed speed gas furnace (PSC) .......... 51

Table 44 Maximum equivalent straight vent length for 1

stage unit (1-D) .............................................................. 51

Table 45 Maximum equivalent straight vent length for

modulating and 2 stage unit (M-V;2-D and 2-V) ............. 51

ANNEX I : CFM TABLES ......................................................................................................................................................... 46

ANNEX II : SPECIFICATION SHEET....................................................................................................................................... 51

INDEX OF ANNEXES

3

REQUIRED NOTICE FOR MASSACHUSETTS INSTALLATIONS

IMPORTANT

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

5.08: Modifications to NFPA-54, Chapter 10. Revise 10.8.3 by adding the following additional requirements:

For all side wall horizontally vented gas fuelled equipment installed in every dwelling, building or structure used in whole or in part for residential
purposes, including those owned or operated by the commonwealth and where the side wall exhaust vent termination is less than seven (7)
feet above finished grade in the area of the venting, including but not limited to decks and porches, the following requirements shall be satisfied:

Installation of Carbon Monoxide Detectors

At the time of installation of the side wall horizontal vented gas fuelled equipment, the installing plumber or gas fitter shall observe that a hard
wired carbon monoxide detector with an alarm and battery backup is installed on the floor level where the gas equipment is to be installed. In
addition, the installing plumber or gas fitter shall observe that a battery operated or hard wired carbon monoxide detector with an alarm is
installed on each additional level of the dwelling, building or structure served by the side wall horizontal vented gas fuelled equipment. It shall
be the responsibility of the property owner to secure the services of qualified license professionals for the installation of hard wired carbon
monoxide detectors.

In the event that the side wall horizontally vented gas fuelled equipment is installed in a crawl space or an attic, the hard wired carbon monoxide
detector with alarm and battery backup may be installed on the next adjacent floor level.

In the event that the requirements of this subdivision cannot be met at the time of completion of installation, the owner shall have a period of
thirty (30) days to comply with the above requirement; provided, however, that during said thirty (30) day period, a battery operated carbon
monoxide detector with an alarm shall be installed.

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

SIGNAGE: A metal or plastic identification plate shall be permanently mounted to the exterior of the building at a minimum height of eight (8)
feet above grade directly in line with the exhaust vent terminal for the horizontally vented gas fuelled heating appliance or equipment. The sign
shall read, in print size no less than in-half (1/2) inch in size, “gas vent directly below. Keep clear of all obstruction”.

INSPECTION: the state of local gas inspector of the side wall horizontally vented gas fuelled equipment shall not approve the installation
unless, upon inspection, the inspector observes carbon monoxide detectors and signage installed in accordance with the provisions of 248
CMR 5.08 (2) (a) 1 through 4:

EXEMPTION: the following equipment is exempt from 248 CMR 5.08(2) (a) 1 through 4:
The equipment listed in Chapter 10 entitled “equipment not required to be vented “in the most current edition of NFPA 54 as adopted by the

board; and
Product approved side wall horizontally vented gas fuelled equipment installed in a room or structure separate from the dwelling, building or

structure in whole or in part for residential purposes.

MANUFACTURER REQUIREMENTS – GAS EQUIPMENT VENTING SYSTEM PROVIDED

When the manufacturer of product approved side wall horizontally vented gas equipment provides a venting system design or venting system
component with the equipment, the instructions provided by the manufacturer for installation of the equipment and the venting system shall
include:

Detailed instructions for the installation of the venting system design or the venting system components; and a complete parts list for the
venting system design or venting system.

MANUFACTURER REQUIREMENTS – GAS EQUIPMENT VENTING SYSTEM PROVIDED

When the manufacturer of product approved side wall horizontally vented gas fuelled equipment does not provide the parts or venting the flue

gases, but identifies “special venting system”, the following requirements shall be satisfied by the manufacturer:
The referenced “special venting system” shall be product approved by the board, and the instruction for that system shall include a parts list

and detailed installation instructions.
A copy of all installation instructions for all product, approved side wall horizontally vented gas fuelled equipment, all venting instructions, all

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

For questions regarding these requirements, please contact the Commonwealth of Massachusetts board of State Examiners
of Plumbers and Gas Fitters, 239 Causeway Street, Boston, MA, 02114, tel.: [phone].

4

1- SAFETY REGULATION

DANGER

Immediate hazards that WILL result in death, serious bodily injury
and/or property damage

WARNING

Hazards or unsafe practices that CAN result in death, bodily injury
and/or property damage.

Non-observance of the safety regulations outlined in this manual will
potentially lead to consequences resulting in death, serious bodily injury
and/or property damage.

WARNING

Installations and repairs performed by unqualified persons can result in
hazards to them and to others. Installations must conform to local codes
or, in the absence of same, to codes of the country having jurisdiction.

The information contained in this manual is intended for use by a
qualified technician, familiar with safety procedures and who is
equipped with the proper tools and test instruments

WARNING

CARBON MONOXIDE POISONING/COMPONENT DAMAGE
HAZARD

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

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

WARNING

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

Failure to follow this warning could result in dangerous operation,
personal injury, death, or property damage. Improper installation,
adjustment, alteration, service, maintenance, or use can 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.

WARNING

FIRE, EXPLOSION, AND CARBON MONOXIDE POISONING
HAZARD

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

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

1.1- SAFETY LABELING AND WARNING SIGNS

The words DANGER, WARNING AND CAUTION are used to identify the
levels of seriousness of certain hazards. It is important that you understand
their meaning. You will notice these words in the manual as follows:

NOTE: is used to highlight suggestions which will result in enhanced

installation, reliability or operation.

1.2- IMPORTANT INFORMATION

a) It is the homeowner’s responsibility to engage a qualified

technician for the installation and subsequent servicing of this
furnace;

b) Before calling for service, be sure to have the information page

of your manual close by in order to be able to provide the
contractor with the required information, such as the model and
serial numbers of the furnace.

1.3- DETECTION SYSTEMS

It is recommended that carbon monoxide detectors be installed wherever
oil or gas fired heaters are used. Carbon monoxide can cause bodily harm
or death. For this reason, agency approved carbon monoxide detectors
should be installed in your residence and properly maintained to warn of
dangerously high carbon monoxide levels.

There are several sources of possible smoke and flames in a residence.
Smoke and flames can cause bodily harm or death. For this reason, agency
approved smoke detectors should be installed in your residence and
properly maintained, to warn early on, of a potentially dangerous fire. Also,
the house should be equipped with approved and properly maintained fire
extinguishers.

Your unit is equipped with safety devices that can prevent it from
functioning when anomalies are detected such as a blocked venting
system.

Untrained personnel can perform basic maintenance functions such as
cleaning and replacing air filters. All other operations must be performed
by trained service personnel. When working on heating equipment,
observe precautions in literature, on tags, and on labels attached to or
shipped with furnace and other safety precautions that may apply.

These instructions cover minimum requirements and conform to existing
national standards and safety codes. In some instances, these instructions
exceed certain local codes and ordinances, especially those that may not
have kept up with changing residential construction practices. We require
these instructions as a minimum for a safe installation.

Follow all safety codes. Wear safety glasses, protective clothing, and work
gloves. Have a fire extinguisher available. Read these instructions
thoroughly and follow all warnings or cautions included in literature and
attached to the unit.

5

CAUTION

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. Use only with type of gas approved for this furnace. Refer to

CAUTION

PERSONAL INJURY AND/OR PROPERTY DAMAGE HAZARD
Improper use or installation of this furnace may result in premature

furnace component failure. This gas furnace may be used for heating
buildings under construction provided that.

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

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

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

The temperature of the return air to the furnace is maintained between
60°F (16 °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.

CAUTION

Frozen and burst water pipe hazard
Failure to protect against the risk of freezing may result in property

damage. Special precautions MUST be made if installing furnace in an
area which may drop below freezing. This can cause improper operation
or damage to equipment. If furnace environment has the potential of
freezing, the drain trap and drain line must be protected

WARNING

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

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

ignitions sources must be located at leat 18” (457 mm) above the floor.
The furnace must be located or protected to avoid damage by vehicles.
When the furnace is installed in a public garage, airplane hangar, or
other building having a hazardous atmosphere, the furnace must be
installed in accordance with the NFPA 54/ANSI Z223.1-2009 or
CAN/CSA B149.2-2010 (Figure 2 Installation in a garage)

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 duct to the back of the
furnace. (Figure 3 Prohibited installation)

CAUTION

Property damage hazard
Failure to follow this caution may result in burst water pipes and/or

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

Ensure all condensate drain connections are secured and liquid tight.
Use the furnished tube clamps and verify tightness

the furnace rating plate.

2. Install this furnace only in a location and position as specified
in section 2.3- Location.

3. Provide adequate combustion and ventilation air to the
furnace space as specified in section 7-Venting.

4. Combustion products must be discharged outdoors. Connect
this furnace to an approved vent system only, as specified in in
section 7-Venting 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 section 4-Duct installation. See furnace rating label.

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 section 4-Duct installation.

8. A gas fired furnace for installation in a residential garage
must be installed as specified in section 2.3-Location.

9. The furnace may be used for construction heat provided that
the furnace installation and operation complies with section 2.3­Location.

10. The furnace is factory shipped for use with natural gas. A
CSA (A.G.A. and C.G.A.) listed accessory gas conversion kit is
required to convert furnace for use with propane gas.

11. See Table 1 Minimum clearance to combustible material
for all units for required clearances to combustible construction.

12. Maintain a 1” (25 mm) clearance from combustible materials
to supply air ductwork for a distance of 36” (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.

6

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 iodine. These elements can
corrode heat exchangers and shorten furnace life. Air contaminants are
found in aerosol spray, detergents, bleaches, cleaning solvents, salts,
air fresheners, and other household products.

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.

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

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

WARNING

CARBON MONOXIDE POISONING HAZARD
For all venting configurations for this appliance and other gas

appliances placed into operation for the structure, provisions for
adequate combustion, ventilation, and dilution air must be provided in
accordance with:

U.S.A. Installations: Section 9.3 NFPA 54/ANSI Z223.1 1−2009, Air for

Combustion and Ventilation and applicable provisions of the local
building codes.

Canadian Installations: Part 8 of CAN/CSA−B149.1−10. Venting
Systems and Air Supply for Appliances and all authorities having
jurisdiction.

WARNING

CARBON MONOXIDE POISONING HAZARD
Failure to follow this warning could result in personal injury or death. To

route the vent pipe and combustion air pipe through the furnace, the
manufacturer supplied kit must be used. See Canadian Installations:
Part 8 of CAN/CSA−B149.1−10. Venting Systems and Air Supply for
Appliances and all authorities having jurisdiction.

Failure to properly seal the blower compartment from the furnace
vestibule could result in the circulation of carbon monoxide throughout
the structure. Seals supplied in this kit must be installed per the
instructions provided. Follow all procedures outlined in these
instructions.

2- INTRODUCTION

This 4-way multi-positioning Category IV condensing furnace is CSA
design certified as a direct vent (2 pipes) or non-direct vent (1 pipe). The
furnace is factory shipped for use with natural gas. The furnace can be
converted in the field for use with propane gas when a factory supplied
conversion kit is used. Refer to the furnace rating plate for conversion kit
information.

This Category IV furnace is approved for installation in
Manufactured/Mobile housing. The furnace must be installed in
accordance with the instruction provided in this manual. 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.
This furnace is designed for minimum continuous return air temperature of

60 °F (16 °C) or intermittent operation down to 55 °F (13 °C) such as when
used with a night setback thermostat. Return air temperature must not
exceed 80 °F (27 °C). Failure to follow these return air temperature limits
may affect reliability of heat exchangers, motors, and controls (Figure 1
Freeze protection and return air temp.).

The furnace should be sized to provide 100 % of the design heating load
requirement plus any margin that occurs because of furnace model size
capacity increments. Heating load estimates can be made using approved
methods available from Air Conditioning Contractors of America (Manual
J); American Society of Heating, Refrigerating, and Air Conditioning
Engineers; or other approved engineering methods. Excessive over sizing
of the furnace could cause the furnace and/or vent to fail prematurely.

7

2.1- CODES AND STANDARDS

CAUTION

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

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

Figure 1 Freeze protection and return air temp.

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

gas supplier, local building, heating, plumbing, and other codes. In absence
of local codes, the installation must comply with the national codes listed
below and all authorities having jurisdiction. In the United States and
Canada, follow all codes and standards for the following:

2.1.1- Safety

USA: National Fuel Gas Code (NFGC) NFPA 54-2009/ANSI Z223.1-

CANADA: National Standard of Canada, Natural Gas and Propane

2.1.2- General installation

USA: NFGC and the NFPA 90B. For copies, contact the National Fire

CANADA: NSCNGPIC. For a copy, contact Standard Sales, CSA

2.1.3- Combustion and air ventilation

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

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

2.1.4- Duct systems

USA and CANADA: Air Conditioning Contractors Association

2.1.5- Acoustical lining and fibrous glass duct

USA and CANADA: current edition of SMACNA, NFPA 90B as tested by

UL Standard 181 for Class I Rigid Air Ducts.

2.1.6- Gas piping and pipe pressure testing

USA: NFPA 54/ANSI Z223.1-2009 NFGC; Chapters 5, 6, 7, and 8

CANADA: CAN/CSA-B149.1-2010, Parts 4, 5, 6, and 9.

IN THE STATE OF MASSACHUSETTS:

2009 and the Installation Standards, Warm Air Heating and Air
Conditioning Systems ANSI/NFPA 90B

Installation Code (NSCNGPIC) CAN/CSA B149.1-2010

Protection Association Inc., Battery march Park, Quincy, MA
02269; or for only the NFGC contact the American Gas
Association, 400 N. Capitol, N.W.,Washington DC 20001

International, 178 Rexdale Boulevard, Etobicoke (Toronto),
Ontario, M9W 1R3, Canada

Combustion and Ventilation

Supply for Appliances

(ACCA) (Manual D), Sheet Metal and Air Conditioning
Contractors National Association (SMACNA), or American
Society of Heating, Refrigeration, and Air Conditioning
Engineers (ASHRAE).

and national plumbing codes.

 This product must be installed by a licensed plumber or gas fitter.
 When flexible connectors are used, the maximum length shall not

exceed 36”. (914 mm).

 When lever type gas shutoffs are used they shall be "T" handle

type.

 The use of copper tubing for gas piping is not approved by the state

of Massachusetts.

2.1.7- Electrical connections

USA: National Electrical Code (NEC) ANSI/NFPA 70-2011
CANADA: CAN/CSA-B149.1-2010, Parts 4, 5, 6, and 9.

2.2- ELECTROSTATIC DISCHARGE

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

2) Firmly touch the clean, unpainted, metal surface of the 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) may
also be used to prevent ESD damage.

2.3- LOCATION
General

These furnaces are shipped with the following materials to assist in proper
furnace installation. These materials are shipped in the main blower
compartment. See Table 2 Loose parts list for loose parts bag contents.
This furnace must:

 Be installed so the electrical components are protected from water;
 Not be installed directly on any combustible material other than

wood flooring;

 Be located close to the chimney or vent and attached to an air

distribution system. Refer to section 5 Ducts section;

8

 Be provided ample space for servicing and cleaning. Always

Position

Clearance in (mm)

Rear

0

Front

0

Required for service (front)

*24'' (610)

All sides of supply plenum

*1''(25)

Sides

0

Vent

0

Top of furnace

1''

Quantity

Description

1

Plastic cap 5/8"

4

Plastic cap 1/2"

10

Screw TEKS HEX WSH #8-18 x ½

1

2" PVC pipe (Length = 1.5")

1

Drain trap

1

Drain trap gasket

2

Gasket wall pipe flange

2

Wall pipe flange

1

Clear PVC tube 5/8" ID x 24"

1

Clear PVC tube 1/2" ID x 24"

comply with minimum fire protection clearances shown in Table 1
Minimum clearance to combustible material
for all units or on the furnace rating label.

Table 1 Minimum clearance to combustible material

for all units

*See local buildings codes.

Table 2 Loose parts list

furnace should be located as close to the chimney (vertical venting) or to
the outside vent wall (horizontal venting) as possible.

When installing the furnace, provisions must be made to insure the supply
of adequate combustion and ventilation air in accordance with the air for
combustion and ventilation section of the National Fuel Gas Code, NFPA
5/ANSI Z223.1-2002, or latest edition, or applicable provisions of the local
building code.

If this furnace is to be installed down flow or in horizontal position, see
section 3-Installation of this manual.

Figure 2 Installation in a garage

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

 Commercial buildings
 Buildings with indoor pools
 Laundry rooms
 Hobby or craft rooms, and
 Chemical storage areas

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

 Permanent wave solutions
 Chlorinated waxes and cleaners
 Chlorine based swimming pool chemicals
 Water softening chemicals
 De-icing salts or chemicals
 Carbon tetrachloride Halogen type refrigerants
 Cleaning solvents (such as perchloroethylene)
 Printing inks, paint removers, varnishes, etc.
 Hydrochloric acid
 Cements and glues
 Antistatic fabric softeners for clothes dryers
 Masonry acid washing materials

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.

Place the unit so that proper venting can be achieved, with a minimum
number of elbows, in accord with the instructions in this manual. The

Figure 3 Prohibited installation

2.3.1- 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. The coling coil
should be at least 6” above heat exchanger.

2.4- INTRODUCTION

2.4.1- Direct vent (2 pipes applications)

When this furnace is installed as a direct vent (2 pipes) furnace; no special
provisions for air for combustion are required. However, other gas
appliances installed in the space with the furnace may require outside air
for combustion. Follow the guidelines below to insure that other gas
appliances have sufficient air for combustion.

Direct vent installations require a dedicated combustion air and venting
system. All air for combustion is taken from outside and all combustion
products are discharged to the outdoors.

Therefore, no ventilation or combustion air openings are required.
In Canada, refer to manufacturer's instructions for supporting ULC S636

venting.

9

2.4.2- Non direct vent (1 pipe) applications

IMPORTANT: Clean and deburr all pipe cuts. The shavings must not

allowed to block the exhaust, inlet or condensate drain
pipes.

IMPORTANT: Do not common vent with any other appliance. Do not

install in the same chase or chimney with a metal or
high temperature plastic pipe from another gas or fuel­burning appliance unless the required minimum
clearances to combustibles are maintained between
the approved PVC pipe and other pipes.

When the furnace is installed as a non-direct vent (1 pipe) furnace, it will
be necessary to insure there is adequate air for combustion. Other gas
appliances installed with the furnace may also require air for combustion
and ventilation in addition to the amount of combustion air and ventilation
required for the furnace.

2.4.3- Ventilated combustion air applications

When the furnace is installed using the ventilated combustion air option,
the attic or crawlspace must freely communicate with the outdoor to provide
sufficient air for combustion. The combustion air pipe cannot be terminated
in attics or crawlspaces that uses ventilation fans designed to operate
during the heating season. If ventilation fans are present in these areas,
the combustion pipe must terminate outdoor as a direct vent (2 pipes)
system.

Figure 4 Dimensional drawing

All air for combustion is piped directly to the furnace from a space that is
well ventilated with outdoor air (such as an attic, crawlspace or equipment
closet) and the space is well isolated from the living space or garage. In
addition, other gas appliances installed in the space with the furnace may
require outside air for combustion.

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

U.S.A. Installations: Section 5.3 of the NFPA 54/ANSI Z223.1-2009, Air for
Combustion and Ventilation and applicable provisions of the local building
codes.

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

2.5- CONNECTING TO FURNACE

The exhaust air pipe connection is a 2” female PVC pipe fitting extending
through the back right side of the furnace top plate.(See Figure 5 Vent
coupling and adapter with gaskets). When 2” pipe is used, connect it
directly to this fitting. When 3” pipe is used, connect a 2” to 3” coupling to
this fitting with a short piece of 2” PVC pipe. The inlet combustion air
connection is at the front right side of the top plate.

All exhaust piping must be installed in compliance with Part 7, “Venting of
Equipment,” of the latest edition of the National Fuel Gas Code NPFA 54,

90A and 90B ANSI Z223.1-, local codes or ordinances and these
instructions:

10

Figure 5 Vent coupling and adapter with gaskets

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. Insulate all vent runs through unconditioned spaces where below
freezing temperatures are expected with 1" thick medium
density, foil faced fiberglass or equivalent Rubatex/Armaflex
insulation.

3. For horizontal runs where water may collect, wrap the vent pipe
with self-regulating, 3 or 5 Watt heat tape. The heat tape must
be U.L./CSA. listed and installed per the manufacturer’s
instructions.

4. All piping between the furnace and the roof or outside wall
penetration is between 2” and 4”. The Table 11 and Table 13
Deduction for fitting list the maximum allowable length for the
exhaust vent pipe and intake air pipe for the number of elbows
used based on the type of termination and furnace size.

5. The minimum vent length is 5 feet.

6. All piping through the roof or outside wall is 2".

7. Terminate the vent using one of the termination options shown
in Figure 6 Vent termination

8. Elbows must be a minimum of 15” apart.

9. No fine screens may be used to cover combustion air or exhaust.

NOTE: For all installations. Extend the combustion air exhaust pipe of 18"

vertically above the furnace cabinet before turning the vent.

NOTE: Vertical piping is preferred.

Figure 6 Vent termination

2.5.1- Combustion air piping

Use a 90° elbow or two medium-radius sweep elbows to keep the inlet
downward and prevent the entry of rain. The inlet opening of the
combustion air termination must be a minimum of 12” above the
anticipated level of snow accumulation.

Install termination as follow:

1. Install a 2" coupling to the combustion air pipe at the outside wall
to prevent the termination from being pushed inward.

2. Cut a 2 1/4" length of 2" PVC pipe and connect this to the
coupling.

3. Connect another 2" coupling to the end of the 2 1/4" length of
pipe. Terminate this outer coupling 4" from the wall.

4. Attach the elbow in the final 2" coupling in the vertical position
with PVC cement.

2.5.2- Exhaust vent piping

The exhaust vent must terminate at least 12” above the combustion air
termination inlet. The maximum length of the exposed vent pipe above the
roof is 30".

All horizontal venting must be done with direct venting (2 pipes).
NOTE: The combustion air and exhaust terminations must be at least 12”

above grade or anticipated snow levels. Use alternate horizontal
terminations when termination locations are limited and higher
snow levels are anticipated.

NOTE: Ensure the location of the combustion air inlet with respect to the

exhaust vent terminal complies with

Figure 22 Direct venting.
NOTE: Slope horizontal vent piping upward a minimum of 1/4" per foot of

run so that condensate drains toward the furnace.

NOTE: Support horizontal vent piping at least every four feet. No sags or

dips are permitted.

NOTE: All furnaces with horizontal air intakes must have a drain tee

assembly and trap installed in the combustion air pipe as close to
the furnace as possible. This is to drain any water that may enter
the combustion air pipe to prevent it from entering the furnace
vestibule area.

3- INSTALLATION

The furnace is factory built for upflow position. In this position, the drain
trap can be installed on right or left side depending on air return duct.

When installing the furnace in other orientation than the upflow position,
simply re-route the tubing accordingly with the instructions provided in this
section of the manual.

11

Figure 7 Drain Trap

3.1- UPFLOW ORIENTATION

In the Upflow orientation, the condensate trap can be to the right or to the
left of the furnace. The condensate drain must be routed from the trap
through the furnace casing. Remove the knock out parts of metal and
route the hoses to the drain trap. The condensate drain can be routed
through the left (Figure 8 Left side condensate drain connection or right (

Figure 9 Right side condensate drain connection side of the casing. (The
left or right side is as you are viewing the furnace.)

Figure 8 Left side condensate drain connection

Figure 9 Right side condensate drain connection

12

3.1.1- Right side condensate drain connection

1. Remove the oblong knock-out from the right side of the casing.

2. Place the drain trap gasket on drain trap, in a way that the holes
are aligned.

3. Install the drain trap on the right side, the three outlet stub of the
drain trap toward the interior of the furnace. The three outward
stubs ends are now inside the furnace.

4. Slide the three clamps down the plain end of the drain tubes that
are already connected inside the furnace.

5. Secure the drain tubes to the trap with the clamps provided.

6. Screw in place the drain trap with two head tapping screws on
the right side of the furnace.

7. Connect the outlet drain from the drain trap to an additional
condensate piping in compliance with the local building codes;
that is a code approved drain, or to a condensate pump
approved for use with acidic furnace condensate.

3.1.2- Left side condensate drain connection

1. Remove the oblong knock-out from the side of the casing.

2. Place the drain trap gasket on drain trap.

3. Install the drain trap on the side, the two outlet stubs of the drain
trap toward the interior of the furnace. The two outward stubs
ends are now inside the furnace.

4. Slide the three clamps down the plain end of the drain tubes.

5. Secure the drain tubes to the trap with the clamps provided.

6. Screw in place the drain trap with two head tapping screws on
the side of the furnace.

7. Connect the outlet drain from the drain trap to an additional
condensate piping in compliance with the local building codes;
that is a code approved drain, or to a condensate pump approved
for use with acidic furnace condensate.

3.2- DOWN FLOW ORIENTATION

To install the furnace in down flow position, few steps are needed for
proper operation.

NOTE: It is STRONGLY RECOMMENDED to use the optional downflow base

to ensure the 2’’ clearance around the supply duct going through

the floor and the proper slope of the furnace for condensate
drainage. Also, the base allows sufficient spacing for the venting
and the drain trap.

that is a code approved drain, or to a condensate pump approved
for use with acidic furnace condensate.

Figure 10 : Down flow orientation

3.2.2- Downflow venting drainaged

All furnace with horizontal exhaust vent piping must have a drain tee
assembly and trap installed in the exhaust pipe as close to the furnace as
possible.

3.2.3- Condensate box pressure switch

The 3/16 stub just beside the drain of the condensate box must be drilled
or cut open. The PVC tubing of the pressure switch -0.2 (nearest to the ID
blower) must be connected to this stub.

Figure 11 Condensate pressure switch

3.2.1- Down flow condensate drain connection Remove all

PVC tubes from the ID blower, condensate box and vent collector and
block the stubs with furnished 5/8’’ & 1/2’’ black caps.

2. Remove the knock-out from the bottom left side of the casing.

3. Place the drain trap gasket on drain trap.

4. Install the drain trap on the bottom left side, the three outlet stubs
of the drain trap toward the interior of the furnace. The three
outward stubs ends are now inside the furnace.

5. Screw in place the drain trap with 2 head tapping screws on the
side of the furnace.

6. Install two 1/2’’ black plastic cap on the 1/2” stub of the drain trap.
See Figure 10 : Down flow orientation

7. Cut 20’’ of furnished 5/8’’ clear PVC tube and connect one end
on the port on the lower right side of the condensate box.

8. Connect the other end to 5/8’’ stub of the drain trap and secure
the tube on the gas manifold with a tie wrap.

9. Connect the outlet drain from the drain trap to an additional
condensate piping in compliance with the local building codes;

3.3- HORIZONTAL RIGHT ORIENTATION

3.3.1- Horizontal right condensate drain connection

1. Remove all PVC tubes from the ID blower, condensate box and
vent collector and block the stubs with furnished 5/8’’ & 1/2’’ black
caps.

2. Remove the knock-outs from the bottom middle side of the
casing.

3. Place the drain trap gasket on the drain trap.

13

4. Screw in place the drain trap with 2 head tapping screws on the
side of the furnace.

5. Install two 1/2” black plastic cap on the stubs of the drain trap
inside the furnace.

6. Connect a piece of 5/8’’ PVC tube to the bottom left of the
condensate box and route with an elbow to the drain trap.

7. Install the drain trap on the bottom middle side, the three outlets
stubs of the drain trap toward the interior of the furnace.

8. Connect the outlet drain from the drain trap to an additional
condensate piping in compliance with the local building codes or
to a condensate pump approved for use with acidic furnace
condensate.

NOTE : The drain trap must be vertical.

Figure 12 Horizontal right drain trap position

3.3.3- Condensate box pressure switch

The 3/16 stub just beside the drain of the condensate box must be drilled
or cut open. The PVC tubing of the pressure switch -0.2 (nearest to the ID
blower) must be connected to this stub.

The pressure switch needs now to be electrically connected in series with
the low fire pressure switch (top) with the brown jumper. See Figure 14
Pressure switch assembly and wiring diagrams.

Figure 14 Pressure switch assembly

Figure 13 Horizontal right condensate tubing

3.3.2- Horizontal right vent drainage

All furnace with horizontal exhaust vent piping must have a drain tee
assembly and trap installed in the exhaust pipe as close to the furnace as
possible (See Figure 13 Horizontal right condensate tubing).

3.4- HORIZONTAL LEFT ORIENTATION

3.4.1- Horizontal left condensate drain connection

1. Remove the knock-outs from the bottom middle side of the
casing.

2. Drill open the bottom stub of the ID blower if not already open.
Be sure to remove all debris.

3. Reroute the ID blower drain tube from the bottom of the ID blower
casing to one of the 1/2” stub. Do not screw the drain trap to

the furnace casing.

4. Block the other open ID blower drain with a 1/2’’ black cap.

5. Reroute the condensate box drain tube from the bottom of the
condensate box through the casing.

6. Reroute de vent collector drain tube to one of the 1/2” stub.

7. Apply the neoprene 7/8’’ gasket around the 5/8’’ and 1/2” tubes
at the point where they cross the furnace casing to seal the
passage.

8. Plug the 5/8’’ and 1/2” tubes to the drain trap, securing the
connections with the clamps. The drain trap must be vertical.

9. Connect the outlet drain from the drain trap to an additional
condensate piping in compliance with the local building codes; or
to a condensate pump approved for use with acidic furnace
condensate.

14

Figure 15 Horizontal left condensate drain connection

Figure 16 Return air base

4.1.1- Bottom return air inlet

In Upflow orientation, for the bottom inlet, it is possible to use a return air
base. This base allows the connection of the duct on the side with a bottom
inlet. (See

Figure 16 Return air base)

1. Cut a rectangular opening on the bottom plate of the furnace. To
know what dimension to be used, refer to the input of the furnace
as showed on Figure 4 Dimensional drawing. Install the return
air inlet as per local codes.

3.4.2- Condensate box pressure switch

The 3/16” stub just beside the drain of the condensate box must be drilled
or cut open. The PVC tubing of the pressure switch nearest to the ID
blower must be connected to this stub.

The pressure switch needs to be electrically connected in series with the
low fire pressure switch (top) with the brown jumper. See Figure 14
Pressure switch assembly and wiring diagrams.

4- DUCT INSTALLATION

4.1- RETURN AIR CONNECTIONS

The return air duct must be connected to bottom, left side or right side
NOTE: In downflow configuration, side return air is not permitted, it must

be connected to bottom.

4.1.2- Side return air inlet

1. Remove 4 knock-outs on the side of the furnace on 8 knock-outs
available. Use the knock-outs related to the furnace size as
shown on Figure 4 Dimensional drawing. This concerns the width
of the return outlet.

2. Install the return air inlet as per local codes.

4.2- FILTER ARRANGEMENT

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

4.3- SUPPLY AIR DUCTS

The supply air duct must be connected ONLY to 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: Many states, provinces and localities are considering or have

implemented standards and/or restrictions on duct sizing
practices, ductwork leakage, and/or ductwork thermal, airflow and
electrical efficiencies. CONSULT LOCAL CODE OFFICIALS for
ductwork design and performance requirement in your area.

4.4- GENERAL REQUIREMENTS

The duct system should be designed and sized according to accepted
national standards such as those published by: Air Conditioning
Contractors Association (ACCA), Sheet Metal and Air Conditioning
Contractors National Association (SMACNA) or American Society of
Heating, Refrigerating and Air Conditioning Engineers (ASHRAE) or

15

consult The Air Systems Design Guidelines reference tables available

INPUT

HIGH

45,000

60,000

75,000

105,000

120,000

LOW

31,500

42,000

52,500

73,500

84,000

OUTPUT

HIGH

42,750

57,000

71,475

99,750

115,080

LOW

29,925

39,900

50,032

69,825

80,556

EFFICIENCY

95

95

95.3

95

95.9

TEMP. RISE

40-70 °F

MAX

CFM

HIGH

Please see tables in Annex I

LOW

COOLING

DIRECT DRIVE

MOTOR TYPE

ECM

DIRECT DRIVE

MOTOR HP

1/2

3/4

3/4 1 1

BLOWER WHEEL

DIAMETER X WIDTH

11 x 6

11 x 8

11 x 9

11 x 11

11 x 11

INPUT

HIGH

45,000

60,000

75,000

105,000

120,000

LOW

31,500

42,000

52,500

73,500

84,000

OUTPUT

HIGH

42,750

56,640

71,775

99,540

115,200

LOW

29,925

39,648

50,242

69,678

80,640

EFFICIENCY

95

94.4

95.7

94.8

96

TEMP. RISE

40-70 °F

MAX
CFM

HIGH

Please see tables in Annex I

LOW

COOLING

DIRECT DRIVE

MOTOR TYPE

PSC

DIRECT DRIVE

MOTOR HP

1/2

1/2

3/4

1 1

BLOWER WHEEL

DIAMETER X WIDTH

11 x 6

11 x 8

11 x 9

11 x 11

11 x 11

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 3 Air flow capacity and blower data. When a furnace is
installed so that the supply ducts carry air circulated by the furnace to
areas outside the space containing the furnace, the return air shall also be
handled by duct(s) sealed to the furnace casing and terminating outside
the space containing the furnace.

Secure ductwork with proper fasteners for type of ductwork used. Seal
supply and return duct connections to furnace with code approved tape or
duct sealer.

NOTE: Flexible connections should be used between ductwork and

furnace to prevent transmission of vibration.
Ductwork passing through unconditioned space should be

insulated to enhance system performance. When air conditioning
is used, a vapour barrier is recommended.

Table 3 Air flow capacity and blower data 2 stage variable

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.

4.4.1- Duct work acoustical treatment

NOTE: Metal duct systems that do not have a 90 degree elbow and 10 ft.

(3 M) of main duct to the first branch take-off may require internal
acoustical lining. As an alternative, fibrous ductwork may be used
if constructed and installed in accordance with the latest edition of
SMACNA construction standard on fibrous glass ducts. Both
acoustical lining and fibrous ductwork shall comply with NFPA
90B as tested by UL Standard 181 for Class 1 Rigid air ducts.

NOTE: For horizontal applications, the top most flange may be bent past

90° to allow the evaporator coil to hang on the flange temporarily
while the remaining attachment and sealing of the coil are
performed.

Table 4 : Air flow capacity and blower data 2 stage direct drive

16

Table 5 : Air flow capacity and blower date 1 stage direct drive

INPUT

HIGH

45,000

60,000

75,000

105,000

120,000

OUTPUT

HIGH

42,750

57,000

71,475

100,065

115,440

EFFICIENCY

95

95

95.3

95.3

96.2

TEMP. RISE

40-70 °F

MAX
CFM

HIGH

Please see tables in Annex I

COOLING

DIRECT DRIVE

MOTOR TYPE

PSC

DIRECT DRIVE

MOTOR HP

1/2

1/2

3/4 1 1

BLOWER WHEEL

DIAMETER X WIDTH

11 x 6

11 x 8

11 x 9

11 x 11

11 x 11

Nominal

Iron pipe

size in.

(mm)

Internal dia.

in. (mm)

Length of pipe - FT (M)

10 (3.0)

20 (6.0)

30 (9.1)

40

(12.1)

50

(15.2)

1/2 (13)

0.622 (158)

175

120

97

82

73

3/4 (19)

0.824 (20.9)

360

250

200

170

151

1 (25)

1.049 (26.6)

680

465

375

320

285

1-1/4 (32)

1.380 (35.0)

1400

950

770

660

580

1-1/2 (39)

1.610 (40.9)

2100

1460

1180

990

900

Gas Pressure in w.c.

(psig)

Natural gas

Propane

Maximum

10.5 (0.38)

13.0 (0.47)

Minimum

4.5 (0.16)

11.0 (0.40)

5- GAS PIPING

Gas piping must be installed in accordance with national and local codes.
Refer to current edition of NFGC in the U.S.A. Refer to current edition of
CAN/CSA B149.1 in Canada. Installations must be made in accordance
with all authorities having jurisdiction. If possible, the gas supply line
should be a separate line running directly from meter to furnace.

NOTE: Use a back-up wrench on the inlet of the gas valve when

connecting the gas line to the gas valve.

NOTE: In the state of Massachusetts:

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

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

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

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

Report to Table 6 Maximum capacity of pipe for recommended gas pipe
sizing. Support all gas piping with appropriate straps, hangers, etc. Use a
minimum of 1 hanger every 6 ft (1.8 m). Joint compound (pipe dope)
should be applied sparingly and only to male threads of joints. Pipe dope
must be resistant to the action of propane gas.

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

Install a sediment trap in riser leading to furnace as shown in Figure 17
Typical gas pipe arrangement. Connect a capped nipple into lower end of
tee. Capped nipple should extend below level of furnace gas controls.
Place a ground joint union between furnace gas control valve and exterior
manual equipment gas shutoff valve.

Figure 17 Typical gas pipe arrangement

A 1/8” (3 mm) NPT plugged tapping, accessible for test gauge connection,
MUST be installed immediately upstream of gas supply connection to
furnace and downstream of manual equipment shutoff valve.

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

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

Table 7 Gas pressure

Table 6 Maximum capacity of pipe in Ft³ of gas/hr

* Cubic feet of gas per hr for gas pressures of 0.5 psig (14 in. w.c)
(Based on a 0.60 specific gravity gas)
Ref: Table 6.2 of NFPA54/ANSI Z223.1-2009

If pressure exceeds 0.38 psig (10.5 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 0.38 psig (10.5 in.
W.C.), turn off electric shutoff switch located on furnace gas control valve
and accessible manual equipment shutoff valve before and during supply
pipe pressure test. After all connections have been made, purge lines and
check for leakage at furnace prior to operating furnace.

17

The gas supply pressure shall be within the maximum and minimum inlet

WARNING

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

property damage.
Do not connect aluminium wire between disconnect switch and

furnace. Use only copper wire.

Max. Min.

45 000 120-60-1 127 104 10.7 12,6 14 29 (8.8) 15

60 000 120-60-1 127 104 13.1 15,6 12 36 (11.0) 20

75 000 120-60-1 127 104 13.1 15,6 12 36 (11.0) 20

105 000 120-60-1 127 104 15.8 19 12 36 (11.0) 20

120 000 120-60-1 127 104 15.8 19 12 36 (11.0) 20

Max. Min.

45 000 120-60-1 127 104 10.7 12.6 14 29 (8.8) 15

60 000 120-60-1 127 104 12.6 15 14 29 (8.8) 15

75 000 120-60-1 127 104 12.6 15 14 29 (8.8) 15

105 000 120-60-1 127 104 15.8 19 12 36 (11.0) 20

120 000 120-60-1 127 104 15.8 19 12 36 (11.0) 20

Max. Min.

45 000 120-60-1 127 104 12.8 15.3 14 36 (11.0) 20

60 000 120-60-1 127 104 12.5 14.9 12 29 (8.8) 15

75 000 120-60-1 127 104 12.5 14.9 14 29 (8.8) 15

105 000 120-60-1 127 104 15.8 19.1 12 36 (11.0) 20

120 000 120-60-1 127 104 15.8 19.1 12 36 (11.0) 20

Max. Min.

45 000 120-60-1 127 104 13.4 15.9 12 36 (11.0) 20

60 000 120-60-1 127 104 13.1 15.5 12 36 (11.0) 20

75 000 120-60-1 127 104 13.1 15.5 12 36 (11.0) 20

105 000 120-60-1 127 104 16.4 19.6 12 36 (11.0) 20

120 000 120-60-1 127 104 16.4 19.6 12 36 (11.0) 20

1 stage PSC motor

Unit Size

Volts-Hertz-

Phase

Operating Voltage

Range

Maximum

Unit Amps

Unit

Ampacity

Minimum

Wire Size

AWG

Maximum

Wire Length

Ft( m)

Maximum Fuse

or CKT BKR

Amp

2 stage PSC motor

Unit Size

Volts-Hertz-

Phase

Operating Voltage

Range

Maximum

Unit Amps

Unit

Ampacity

Minimum

Wire Size

AWG

Maximum

Wire Length

Ft( m)

Maximum Fuse

or CKT BKR

Amp

2 stage variable speed

Unit Size

Volts-Hertz-

Phase

Operating Voltage

Range

Maximum

Unit Amps

Unit

Ampacity

Minimum

Wire Size

AWG

Maximum

Wire Length

Ft( m)

Maximum Fuse

or CKT BKR

Amp

Modulating furnace

Unit Size

Volts-Hertz-

Phase

Operating Voltage

Range

Maximum

Unit Amps

Unit

Ampacity

Minimum

Wire Size

AWG

Maximum

Wire Length

Ft( m)

Maximum Fuse

or CKT BKR

Amp

supply pressures marked on the rating plate with the furnace burners and
in Table 7 Gas pressure.

5.1- GAS PIPE GROMMET

For direct vent (2 pipes) applications, the hole for the gas pipe on the
cabinet must be sealed to prevent air leakage. Install the grommet in the
hole, then insert the gas pipe and apply fillet paste.

6- ELECTRICAL CONNECTIONS

Check all factory and field electrical connections for tightness.
Supplied field wiring shall conform to the limitations of 63°F (33°C) rise.

6.1- 120 V WIRING

Furnace must have a 120 V power supply properly connected and
grounded.

NOTE: Proper polarity must be maintained for 120 V wiring. If polarity is

incorrect, control LED status indicator light will flash rapidly and
furnace will NOT operate.

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

Table 8 Electrical data for equipment electrical specifications.

U.S.A. Installations:

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

Canada Installations:

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

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

Table 8 Electrical data for wire size and fuse specifications. A readily
accessible means of electrical disconnect must be located within sight of
the furnace.

.

Table 8 Electrical data

18

Figure 18 Power cord installation in the furnace

INPUT

HEATING

COOLING

45,000

LOW

MED-HIGH

60,000

MED-LOW

MED-HIGH

75,000

MED-LOW

MED-HIGH

105,000

HIGH

MED-HIGH

120,000

HIGH

MED-HIGH

INPUT

HEATING 1st

STAGE

HEATING 2

nd

STAGE

COOLING

45,000

LOW

MED-LOW

MED-HIGH

60,000

LOW

MED-LOW

MED-HIGH

75,000

LOW

MED-LOW

MED-HIGH

105,000

LOW

MED-HIGH

MED-LOW

120,000

MED-LOW

HIGH

MED-HIGH

6.2- 24 V WIRING

Make field 24 V connections at the 24 V terminal strip. Connect terminal
Y/Y2 for proper cooling operation. Use only AWG No. 18, color-coded,

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

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

blower speeds. See airflow tables in annexe for the relation between CFM
and external static pressure applicable to your model. The cooling and
heating blower speed are shipped with the suggested fan speed describe
in table 9 and table 10. These blower speeds are set for a temperature
rise of 55°F. Blowers should be adjusted by the installer to match the
installation requirements so as to provide the correct heating temperature
rise and cooling load. To adjust the circulator blower speed, proceed as
follow:

1. Turn off the power to the furnace

2. Select the heating and cooling blower speeds that match the
installation requirements from the airflow tables in annexe.

3. Relocate the desired motor leads to the desire speed on the
motor.

4. If heating and cooling speeds are the same, a jumper wire must
be used between the heat and cool terminal on the control
board. The unused leads must be connected to the “PARK”
terminal on the control board.

5. Turn on power to the furnace.

6. Verify proper temperature rise. Excessive temperature rise can
cause limit switch tripping.

Table 9 : Suggested fan speed on 1 stage furnace

6.3- THERMOSTATS

Thermostats and Control Settings for Two Stage Furnaces.

A single stage or two stage heating and single stage or two stage cooling
thermostat may be used with the furnace. Consult the thermostat
installation instructions for specific information about configuring the
thermostat.

Thermostats and Control Settings for Single Stage furnaces.

A single stage heating and single stage or two stage cooling thermostat
may be used with the furnace. Consult the thermostat installation
instructions for specific information about configuring the thermostat.

6.4- ALTERNATE POWER SUPPLY

The furnace is designed to operate on utility generated power which has
a smooth sinusoidal waveform. If the furnace is to be operated on a
generator or other alternate power supply must produce a smooth
sinusoidal waveform for compatibility with the furnace electronics. The
alternate power supply must generate the same voltage, phase, and
frequency (Hz) as shown in

Table 8 Electrical data or the furnace rating plate.
Power from an alternate power supply that is non-sinusoidal may damage

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

details.

6.5- BLOWER SPEEDS (4 SPEED PSC MOTOR)

Furnace with model number CXX-1-D and CXX-2-D are equipped with a
multi-speed circulator blower. This blower provides ease in adjusting

Table 10 : Suggested fan speed on 2 stage furnace

19

Figure 19 Wiring diagram – One stage PSC

20

Figure 20 : Two Stage PSC - Furnace Control

21

Figure 21 : Two Stage ECM - Furnace Control

22

7- VENTING

systems must be composed of pipe, fittings, cements, and
primers listed to ULC S636.

7.1- SPECIAL VENTING REQUIREMENTS FOR
INSTALLATIONS IN CANADA

The special vent fittings and accessory concentric vent termination kits
and accessory external drain trap have been certified to ULC S636 for use
with those Royal Pipe and IPEX PVC vent components which have been
certified to this standard.

In Canada, the primer and cement must be of the same manufacturer as
the vent system GVS-65 Primer (Purple) for Royal Pipe or IPEX System
636, PVC/CPVC Primer, Purple Violet for Flue Gas Venting and GVS-65
PVC Solvent Cement for Royal Pipe or IPEX System 636(1)t, PVC
Cement for Flue Gas Venting, rated Class IIA, 65 C. must be used with
this venting system - do not mix primers and cements from one

manufacturer with a vent system from a different manufacturer.

Follow the manufacturer’s instructions in the use of primer and cement

and never use primer or cement beyond its expiration date.

The safe operation, as defined by ULC S636, of the vent system is based

on following these installation instructions, the vent system manufacturer’s

installation instructions, and proper use of primer and cement.
All fire stop and roof flashing used with this system must be UL listed

material.
Acceptability under Canadian standard CAN/CSA B149 is dependent

upon full compliance with all installation instructions. Under this standard,
it is recommended that the vent system be checked once a year by
qualified service personnel.

The authority having jurisdiction (gas inspection authority, municipal
building department, fire department, etc.) should be consulted before
installation to determine the need to obtain a permit.

*IPEX System 636™ is a trademark of IPEX Inc.

7.2- GENERAL

If this furnace replaces a furnace that was connected to a vent system or
chimney, the vent or vent connectors of other remaining appliances may
need to be re-sized. Vent systems or vent connectors of other appliance
must be sized to the minimum size as determined using appropriate table
found in the current edition of National Fuel Gas Code NFPA 54/ANSI Z-

223.1. In Canada, refer to CAN/CSA-B149.1.

An abandoned masonry chimney may be used as a raceway for properly
insulated and supported combustion-air (when applicable) and vent pipes.
Each furnace must have its own set of combustion air and vent pipes and
be terminated individually.

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

Other gas appliances with their own venting system may also use the
abandoned chimney as a raceway providing it is permitted by local code,
the current edition of the National Fuel Gas Code, and the vent or liner

manufacturer’s installation instructions. Care must be taken to prevent the

exhaust gases from one appliance from contaminating the combustion air
of other gas appliances.

7.3- MATERIALS

USA: Combustion air and vent pipe, fittings, primers, and solvents

must conform to American National Standards Institute (ANSI)
standards and American Society for Testing and Materials
(ASTM) standards. See Table 14 Approved combustion air and
vent pipe, fitting and cement materials (U.S.A. Installation for
approved materials for use in the U.S.A.)

CANADA: Special Venting Requirements for Installations in Canada must

conform to the requirements of CAN/CSA B149 code. Vent

7.4- DIRECT VENT - 2 PIPES SYSTEM

In a direct vent (2 pipes) system, all air for combustion is taken directly from

outdoor atmosphere, and all flue products are discharged to outdoor

atmosphere. Combustion air and vent pipes must terminate together in the

same atmospheric pressure zone, either through the roof (preferred) or a

sidewall. See

Figure 22 Direct venting for references to clearances required by National
code authorities.

TERMINATION REQUIREMENTS FOR THE PROVINCE OF ALBERTA
AND SASKATCHEWAN

The Provinces of Alberta and Saskatchewan require a minimum
unobstructed distance of 4 ft. (1.2 M) from the foundation to the property
line of the adjacent lot for vent termination of any appliance with an input
over 35,000 BTU/h. If there is less than 4 ft. (1.2 M) of unobstructed
distance to the property line of the adjacent lot, no type of vent termination
is permitted for appliances with inputs greater than 35,000 BTU/h. There
are no additional restrictions on unobstructed distances greater than 8 ft.
(2.4 M).

All single, two pipes and concentric vents may be used, providing all other

Code and manufacturer’s requirements in these instructions are adhered

to.
If the unobstructed distance from the foundation to the property line of the

adjacent lot is no less than 4 ft. (1.2 M) and no greater than 8 ft. (2.4 M),
it will be necessary to re-direct the flue gas plume. In this situation, a
concentric vent kit cannot be used.

A 2 pipes termination (or single pipe termination when permitted) that
redirects the flue gas away by use of an elbow or tee, certified to ULC
S636 from the adjacent property line must be used.

7.5- SIZE OF THE VENT AND COMBUSTION AIR
PIPES

Furnace combustion air and vent pipe connections are sized for 2” pipe.
Any pipe diameter change should be made outside furnace casing in
vertical pipe. Any change in diameter to the pipe must be made as close
to the furnace as reasonably possible.

The Maximum Vent Length for the vent and combustion air pipe (when used)
is determined from the Maximum Equivalent Vent Length in Table 11 or Table
12 Maximum equivalent straight vent length (single stage), minus the number

of fittings multiplied by the deduction for each type of fitting used from Table

13 Deduction for fitting. The measured length of pipe used in a single or two

pipes termination is included in the total vent length. Include a deduction for

a Tee when used for Alberta and Saskatchewan terminations.

1. Measure the individual distance from the furnace to the
termination for each pipe.

2. Select a Maximum Equivalent Vent Length (MEVL) longer than
the measured distance of the individual vent and combustion air
connections to the vent termination.

3. Count the number of elbows for each pipe.

4. For each pipe, multiply the number of elbows by the equivalent
length for the type of elbow used. Record the equivalent length
of all the elbows for each pipe.

5. If a Tee is used on the termination, record the equivalent length
of the Tee used. (see Table 13 Deduction for fitting)

6. Record the equivalent length of the termination to be used.

7. Subtract the equivalent lengths of the fittings and terminations
from the Maximum Equivalent Vent Length.

23

8. If the Maximum Vent Length calculated is longer than the
individual measured length of the vent pipe and combustion air
pipe, then the diameter of pipe selected may be used.

9. If the Maximum Vent Length calculated is shorter than the
individual measured length of either the vent pipe or the
combustion air pipe, recalculate the Maximum Vent Length using
the next larger diameter pipe.

NOTE: The vent pipe and combustion air pipe must be the same

diameter.

Figure 22 Direct venting

NOTE: If the Maximum Vent Length for diameter of the pipe selected is

longer than the measured length and the equivalent length of all
the fitting and terminations, recalculate using the next smaller
diameter. If the recalculated Maximum Vent Length is longer than
the measured length of the vent pipe and combustion air pipe,
then that diameter of pipe selected may be used.

When installing vent systems of short pipe lengths use the smallest
allowable pipe diameter.

Do not use pipe size greater than required or incomplete combustion,
flame disturbance, or flame sense lockout may occur.

24

Figure 23 Multi venting

Altitude (ft)

Unit size (Btu/hr)*
Vent pipe diameter (in.)

2"

3" and 4"

0 to 4500 ft

15,000

300

N/A

30,000

180

N/A

45,000

70

90

60,000

70

90

75,000

70

90

105,000

15

80

120,000

10

65

Altitude

(ft)

Unit size

(Btu/hr)*

Vent pipe diameter (in.)

2"

3" and 4"

0 to 4500 ft

45,000

70

90

60,000

45

90

75,000

30

90

105,000

N/A

70

120,000

N/A

40

Table 11 : Maximum equivalent straight vent length (two stage and modulating)

Table 12 Maximum equivalent straight vent length (single stage)

25

Table 13 Deduction for fitting

Type of elbow

Equivalent Length (ft.)

45° Standard

5

45° Long sweap

2½

90° Standard

10

90° Long sweap

5

Tee

1.5

ASTM SPECIFICATION

(MARKED ON MATERIAL)

MATERIAL PIPE FITTINGS

SOLVENT CEMENT

AND PRIMERS

DESCRIPTION

D1527 ABS PIPE - - Schedule-40

D1765 PVC PIPE - - Schedule-40

D2235 For ABS - - Solvent Cement For ABS

D2241 PVC PIPE - - SDR-21 & SDR-26

D2466 PVC - Fittings - Schedule-40

D2468 ABS - Fittings - Schedule-40

D2564 For ABS - - Solvent Cement For PVC

D2661 ABS PIPE Fittings - DWV at Schedule-40 IPS Sizes

D2665 PVC PIPE Fittings - DWV at Schedule-40 IPS Sizes

F438 CPVC - Fittings - Schedule-40

F441 CPVC PIPE - - Schedule-40

F442 CPVC PIPE - - SDR

F493 For CPVC - - Solvent Cement For CPVC

F628 ABS PIPE - - Cellulare Core DWV at Schedule-40 IPS sizes

F656 For PVC - - Primer For PVC

F891 PVC PIPE - - Cellulare Core Schedule-40 & DWV

Table 14 Approved combustion air and vent pipe, fitting and cement materials (U.S.A. Installation)

7.6- COMBUSTION AIR AND VENT PIPING
INSULATION GUIDELINES

The vent pipe may pass through unconditioned areas.

1. Using winter design temperature (used in load calculations), find
appropriate temperature for your application and furnace model.

2. Determine the amount of total and exposed vent pipe.

3. Determine required insulation thickness for exposed pipe
length(s).

4. When combustion air inlet piping is installed above a suspended
ceiling, the pipe MUST be insulated with moisture resistant

insulation such as Armaflex™ or other equivalent type of

insulation.

5. Insulate all vent runs through unconditioned spaces where below
freezing temperatures are expected with 1" thick medium
density, foil faced fiberglass or equivalent Rubatex/Armaflex
insulation.

6. In extremely cold climate areas, use heat trace cable as
regulated per local codes.

7. For horizontal runs where water may collect, wrap the vent pipe
with self-regulating, 3 or 5 Watt heat tape. The heat tape must

be U.L./CSA. listed and installed per the manufacturer’s

instructions.

8. Insulate combustion air inlet piping when run in warm, humid
spaces.

9. Install the insulation per the insulation manufacturer’s installation
instructions.

NOTE: Pipe length specified for maximum pipe lengths located in

unconditioned spaces cannot exceed total allowable pipe length as

calculated from Table 11 and Table 12 Maximum equivalent straight vent

length (single stage).

NOTE: The rubber coupling with drain that attaches to the vent pipe

adapter must be used. The adapter seals the vent pipe to the
casing and reduces the strain on the vent elbow attached to the
inducer.

Apply the wall pipe flange gaskets to the vent wall pipe and combustion
air wall pipe flanges.

NOTE: The vent wall pipe flange and the combustion air wall pipe flange

have the same ID.

1. Place the wall pipe flange over the 1.750” of 2” diameter pipe
provided.

2. Align the pipe on the rubber coupling with drain and tighten the
clamp around the rubber coupling.

3. Align the screw holes in the plastic wall pipe flange with the
dimples in the casing.

4. Pilot drill the screw holes for the flange in the casing and attach
the vent wall pipe flange to the furnace with sheet metal screws

5. Repeat for the air combustion wall pipe flange and secure to the
top casing.

Install the remaining vent and combustion air pipes. It is recommended
that all pipes be cut, prepared, and preassembled before permanently
cementing any joint.

1. Working from furnace to outside, cut pipe to required length(s).

2. Deburr inside and outside of pipe.

3. Chamfer outside edge of pipe for better distribution of primer and
cement.

26

4. Clean and dry all surfaces to be joined.

5. Check dry fit of pipe and mark insertion depth on pipe.

6. Insert the vent pipe into the vent elbow.

7. Insert the combustion air pipe into the adapter.

8. Pilot drill a screw hole through the adapter into the combustion
air pipe and secure the pipe to the adapter with sheet metal
screws.

9. Seal around the combustion air pipe with silicone or foil tape.

10. After pipes have been cut and preassembled, apply generous
layer of cement primer to pipe fitting socket and end of pipe to
insertion mark. Quickly apply approved cement to end of pipe
and fitting socket (over primer). Apply cement in a light, uniform
coat on inside of socket to prevent build-up of excess cement.
Apply second coat.

11. While cement is still wet, twist pipe into socket with ¼ in. turn. Be
sure pipe is fully inserted into fitting socket.

12. Wipe excess cement from joint. A continuous bead of cement will
be visible around perimeter of a properly made joint.

13. Handle pipe joints carefully until cement sets.

14. Horizontal portions of the venting system shall be supported to
prevent sagging. Support combustion air piping and vent piping
a minimum of every 5 ft. (1.5 M) [3 ft. (.91 M) for SDR-21 or -26
PVC] using perforated metal hanging strap or commercially
available hangars designed to support plastic pipe.

15. Prevent condensate from accumulating in the pipes by sloping
the combustion air piping and vent piping downward towards
furnace a minimum of ¼ in. per linear ft. with no sags between
hangers.

16. Complete the vent and combustion air pipe installation by
installing the required termination elbows. See Figure 6 Vent
termination.

17. Use appropriate methods to seal openings where combustion air
pipe and vent pipe pass through roof or sidewall.

7.7- INSTALLING THE VENT TERMINATION

A roof termination of any type will require a 4” (102 mm) flashing for a 2”
(51 mm) concentric vent or a 5” diameter (127 mm) flashing for a 3” (76
mm) concentric vent kit. For two-pipe or single pipe vent systems, a
flashing for each pipe of the required diameter will be necessary. It is
recommended that the flashing be installed by a roofer or competent
professional prior to installing the concentric vent. The terminations can
be installed on a flat or pitched roof.

7.7.1- Concentric vent

Single or multiple concentric vent must be installed as shown in Figure 23
Multi venting. Maintain the required separation distance between vents or
pairs of vents and all clearance.

Cut one 4 in. (102 mm) diameter hole for 2 in. (51 mm) kit, or one 5 in.
(127 mm) diameter hole for 3 in. (76 mm) kit in the desired location.
Loosely assemble concentric vent/combustion air termination
components together using instructions in kit. Slide assembled kit with rain
shield REMOVED through hole in wall or roof flashing.

NOTE: Do not allow insulation or other materials to accumulate inside
of pipe assembly when installing it through hole. Disassemble loose pipe
fittings. Clean and cement using same procedures as used for system
piping.

7.7.2- Two pipes termination

Two pipes vent must be installed as shown in Figure 23 Multi
ventingMaintain the required separation distance between vents or pairs
of vents and all clearance. Cut the required number of holes in the roof or
sidewall for vent and combustion air pipes. Sidewall holes for two pipes
vent terminations should be side-by-side, allowing space between the
pipes for the elbows to fit on the pipes. Holes in the roof for two pipe

terminations should be spaced no more than 18” (457 mm) apart.
Termination elbows will be installed after the vent and combustion air pipe
is installed.

When 2 or more furnaces are vented near each other, the next vent
termination must be at least 36 in. (914 mm) away from first 2 terminations.
It is important that vent terminations be made as shown in Figure 23 Multi
ventingto avoid recirculation of flue gases.

7.7.3- Sidewall termination

Determine an appropriate location for termination kit using Figure 22 Direct

venting and Figure 23 Multi venting.

1. Cut one 4” diameter hole for 2” kit, or one 5” diameter hole for 3”
kit.

2. Loosely assemble concentric vent/combustion air termination
components together using instructions in kit.

3. Slide assembled kit with rain shield REMOVED through hole
(NOTE: Do not allow insulation or other materials to accumulate
inside of pipe assembly when installing it through hole).

4. Locate assembly through sidewall with rain shield positioned no
more than 1” (25 mm) from wall.

5. Disassemble loose pipe fittings. Clean and cement using same
procedures as used for system piping.

6. Cut 2 holes, 1 for each pipe, of appropriate size for pipe size
being used.

7. Loosely install elbow in bracket and place assembly on
combustion-air pipe.

8. Disassemble loose pipe fittings. Clean and cement using same
procedures as used for system piping.

8- START UP, ADJUSTMENT AND SAFETY

CHECK

1. Furnace must have a 120 V power supply properly connected
and grounded (NOTE: Proper polarity must be maintained for
120 V wiring. Control status indicator light flashes rapidly and
furnace does not operate if polarity is incorrect.)

2. Thermostat wire connections at terminals R, W/W1, G, Y/Y2, etc.
must be made at 24 V terminal block on furnace control

3. Natural gas service pressure must not exceed 0.38 psig (10.5 in.
w.c.), but must be no less than 0.16 psig (4.5-in. w.c.). Propane
service pressure must dot exceed 0.47 psig (13 in. w.c.) but must
be no less than 0.40 psig (11 in. w.c.)

4. Blower door must be in place to complete 120 V electrical circuit
to furnace.

8.1- TO START THE FURNACE

This appliance is equipped with a hot surface ignition device. This device
lights the main burners each time the room thermostat calls for heat. See
the lighting instructions on the furnace.

During initial start-up, it is not unusual for odour or smoke to come out of
any room registers. To ensure proper ventilation, it is recommended to
open windows and doors before initial firing.

The furnace has a negative pressure switch that is a safety during a call
for heat. The induced draft blower must pull a negative pressure on the
heat exchanger to close the negative pressure switch. The induced draft
blower must maintain at least the negative pressure switch set point for
the furnace to operate. If the induced draft blower fails to close or maintain
the closing of the negative pressure switch, a “no heat call” would result.

27

1. Remove the burner compartment control access door.

WARNING

Failure to replace the burner door can cause products of combustion
to be released into the conditioned area resulting in personal injury or
death.

COOL

delay to fan-off:

Set switch

#1

45 sec.*

On

90 sec.

Off

HEAT

delay to fan-on:

Set switch

#2

30 sec.*

On

45 sec.

Off

HEAT

delay to fan-off:

Set switch

#3 #4

60 sec.

On

On

90 sec.

Off

On

120 sec.

On

Off

180 sec.*

Off

Off

2. IMPORTANT: Be sure that the manual gas control has been in

the “OFF” position for at least five minutes. Do not attempt to

manually light the main burners.

3. Set the room thermostat to its lowest setting and turn off the
furnace electrical power.

4. Turn the gas control knob to the “ON” position.

5. Replace the burner compartment control access door.

6. Turn on the manual gas stop.

7. Turn on the furnace electrical power.

8. Put thermostat to “Heat” mode and set the room thermostat at
least 10°F above room temperature to light the main burners.

9. After the burners are lit, set the room thermostat to a desired
temperature.UNIT OPERATION HAZARD

These furnaces are equipped with a manual reset limit switch in burner
assembly. This switch opens and shuts off power to the gas valve if an
overheat condition (flame rollout) occurs in burner assembly. Correct
inadequate combustion-air supply or improper venting condition before
resetting switch. DO NOT jumper this switch.

Before operating furnace, check flame rollout manual reset switch for
continuity. If necessary, press de button to reset switch. EAC-1 terminal is
energized whenever blower operates. HUM terminal is only energized
when blower is energized in heating.

8.3- SETUP SWITCHES

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

1. Turn off electrical power.

2. Remove upper door.

3. Locate setup switches on furnace control.

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

5. Replace upper door and turn on electrical power.

8.4- OPTION SWITCHES – 1 STAGE, PSC

The option switches on the 50A55-843 control are used to determine the
length of the cool delay-to-fan-off, heat delay-to fan-on and heat delay­to-fan-off periods. The following table shows the time periods that will
result from the various switch positions.

Table 15: Option switches positions

* Factory setting

8.4.1- Heat mode

In a typical system, a call for heat is initiated by closing the thermostat

contacts. This starts the 50A55 control’s heating sequence. The inducer

blower and optional humidifier are energized and the igniter is powered
within one second. This controller has an adaptive algorithm that adjusts
the duration of the igniter warm-up, to extend igniter life. Upon initial
application of power, the warm-up time is 17 seconds. The igniter on-time
will then be increased or decreased depending on whether or not flame is
achieved. The warm-up time is limited to a maximum of 21 seconds.
During the first 64 warm-up periods following power-up, the warm-up time
may not be less than 17 seconds.

Upon a call for heat, if the warm-up time has not been locked, it will be
decreased by one second. This reduction of the igniter on time will
continue until flame fails to be achieved (resulting in a retry).

In the event of a retry, the warm-up time will be increased by two seconds
and locked in at that duration. Once the warm-up time is locked, it remains
fixed until another call for heat results in a retry, in which case the warm­up time is again increased by two seconds and remains locked.

In the event of two successive retry attempts, the warm-up time will be
unlocked and set to 21 seconds. If flame is then achieved, the warm-up
time will begin adapting again with the next call for heat. If, however, this
third attempt fails to achieve flame, the control will go into system lockout.

At the end of the igniter warm-up time, both valves in the 36E manifold
gas valve are opened. Flame must be detected within 4 seconds.

If flame is detected, the delay-to-fan-on period begins. After the delay-to­fan-on period ends, the optional electronic air cleaner is energized and the
circulator fan is energized at heat speed. When the thermostat is satisfied,
the gas valve is de-energized. After proof of flame loss, the heat delay-to­fan-off period begins and the inducer blower remains energized to purge
the system for 15 seconds. When the purge is complete, the inducer
blower and humidifier are de-energized. After the delay-to-fan-off period
ends, the circulator fan and electronic air cleaner are de-energized.

If flame is not detected, both valves are de-energized, the igniter is turned

off, and the 50A55 control goes into the “retry” sequence. The “retry”

sequence provides a 60 seconds wait following an unsuccessful ignition
attempt (flame not detected). After this wait, the ignition sequence is
restarted with an additional 2 seconds of igniter warm-up time. If this
ignition attempt is unsuccessful, one more retry will be made before the
control goes into system lockout.

If flame is detected, then lost, the 50A55 control will repeat the initial
ignition sequence for a total of four “recycle”. After four unsuccessful
“recycle” attempts, the control will go into system lockout.

If flame is established for more than 10 seconds after ignition, the 50A55
controller will clear the ignition attempt (or retry) counter. If flame is lost
after 10 seconds, it will restart the ignition sequence. This may occur a
maximum of five times before system lockout.

During burner operation, a momentary loss of power of 50 milliseconds or
longer will de-energize the main gas valve. When power is restored, the
gas valve will remain de-energized and a restart of the ignition sequence
will begin immediately. A momentary loss of gas supply, flame blowout, or
a shorted or open condition in the flame probe circuit will be sensed within

2.0 seconds. The gas valve will de-energize and the control will restart the
ignition sequence. Recycles will begin and the burner will operate normally
if the gas supply returns, or the fault condition is corrected, before the last
ignition attempt. Otherwise, the control will go into system lockout.

If the control has gone into system lockout, it may be possible to reset
the control by a momentary power interruption of one second or longer.
Refer to SYSTEM LOCKOUT FEATURES.

8.4.2- Cool mode

In a typical system, a call for cool is initiated by closing the thermostat
contacts. This energizes the 50A55 control and the compressor. The cool
delay-to-fan-on period begins. After the delay period ends, the optional
electronic air cleaner is energized, and the circulator fan is energized at
cool speed. After the thermostat is satisfied, the compressor is de­energized and the cool mode delay-to-fan-off period begins. After the

28

delay-to-fan off period ends, the circulator fan and electronic air cleaner

1 flash, then pause

System lockout

2 flashes, then pause

Pressure switch stuck closed

3 flashes, then pause

Pressure switch stuck open

4 flashes, then pause

Open limit switch

5 flashes, then pause

Open rollout switch

6 flashes, then pause

115 Volt AC power reversed/Improper
ground

7 flashes, then pause

Low flame sense signal

Continuous flashing
no pause)

Flame has been sensed when no
flame should be present (no call for
heat)

HEAT delay to

fan-off:

On “S1,”

set switch #:

3 4

90 sec.*

Off

Off

120 sec.

Off

On

150 sec.

On

Off

180 sec.

On

On

2nd Stage delay for single stage thermostats

Delay Time:

On "S1"

set switch #

1 2

Off*

Off

Off

10 min

On

Off

Auto min

Off

On

20 min

On

On

Average
Calculated Duty
Cycle % Equals

Or less

than

Low to High
Stage Delay

Demand

0

38

12 minutes

Light

38

50

10 minutes

Light to Average

50

62

7 minutes

Average

62

75

5 minutes

Average to Heavy

75

88

3 minutes

Heavy Light

88

100

1 minute

Heavy

(optional) are de-energized.

8.4.3- Manual fan on mode

If the thermostat fan switch is moved to the ON position, the circulator fan
(cool speed) and optional electronic air cleaner are energized. When the
fan switch is returned to the AUTO position, the circulator fan and
electronic air cleaner (optional) are de-energized.

8.4.4- Twinning interface

If the control has six screw terminals, one of which is designated TWIN,
the control is equipped with a single wire twinning interface. If twinning is
used, either control will process a call for heat, cool or fan as described
above. However, after the heat, cool, or fan-on delay time expires, both
units will energize the circulator blowers at the same time. Likewise, after
the heat, cool, or fan-off delay time expires, both units will de-energize the
circulator blowers at the same time. This allows for proper air flow to be
obtained.
To assure proper control operation, both controls must share a common
transformer ground (TR).
To enable twinning, do the following.

1. Power supplied to both furnaces must be from the same phase of
the incoming 120 VAC power.

2. Connect the TWIN screw terminals on the 50A55-843 of the
furnaces to be twinned to each other using a single wire (14-22
AWG.).

8.4.5- System lockout and diagnostic features

8.4.6- System lockout features

When system lockout occurs, the gas valve is de-energized, the circulator
blower is energized at heat speed, and, if flame is sensed, the inducer
blower is energized. The diagnostic indicator light will flash or glow
continuously to indicate system status. (System lockout will never override
the precautionary features.)
To reset the control after system lockout, do one of the following:

1. Interrupt the call for heat or cool at the thermostat for at least one
second but less than 20 seconds (if flame is sensed with the gas
valve de-energized, interrupting the call for heat at the thermostat
will not reset the control).

2. Interrupt the 24 VAC power at the control for at least one second.
You may also need to reset the flame rollout sensor switch.

3. After one hour in lockout, the control will automatically reset itself.

8.4.7- Diagnostic features

The 50A55-843 control continuously monitors its own operation and the
operation of the system. If a failure occurs, the LED will indicate a failure
code as shown below. If the failure is internal to the control, the light

will stay on continuously. In this case, the entire control should be
replaced, as the control is not field-repairable.

If the sensed failure is in the system (external to the control), the LED will
flash in the following flash-pause sequences to indicate failure status
(each flash will last approximately 0.25 seconds, and each pause will last
approximately 2 seconds).

The LED will also flash once at power-up.

8.5- OPTION SWITCHES – 2 STAGE, PSC

Option switches on the 50M51-843 control are used to determine the
length of the delay-to-fan-off periods. The following tables show the time
periods that will result from the various switch positions.
When using a single stage thermostat, second stage delay is based on
the setting of switch S1-1, S1-2 shown below.

Table 16: Option switches S1-3 & S1-4 positions

*Factory default setting

Table 17: Option switches S1-1 & S1-2 positions

*Factory default-setting – two-stage thermostat

8.5.1- Heat mode

In a typical system, a call for first stage heat is initiated by closing the W1
thermostat contacts. The inducer blower is energized at high speed and
the control waits for the low pressure switch contacts to close. The
humidifier (optional) is also energized at this time. Once the low pressure
switch contacts close, a 15 second pre-purge is initiated. Then the inducer
changes to low speed and the 120V igniter is powered. At the end of the
igniter warm-up time, the first stage of the two stage manifold gas valve is
energized (low fire).

Flame must be detected within 4 seconds. If flame is detected, the 45
seconds HEAT delay-to-fan-on period begins. After the delay-to-fan-on
period ends, the 50M51 control will energize the circulator fan at low heat
speed. The electronic air cleaner (optional) will also energize at this time.

For a two-stage thermostat, a call for second stage heat (W1 and W2)
after a call for first stage heat will energize the inducer at high speed and
the circulator at high heat speed. The second stage pressure switch
contacts will close and energize the second stage gas valve (high fire).

For a single-stage thermostat, when a call for heat occurs (W1), a 10, 20
minutes or auto mode heat staging timer will be activated (timing is
selectable with option switches S1-1 and S1-2 positions). Following this
delay, the second stage heat is energized as above.

The AUTO model algorithm is a method of energizing the second stage
gas valve based on the recent average of the heating duty cycle. During
a typical heating day, the low to high stage delay is determined by using
the average calculated duty cycle from the table below.

Once the specified delay time has expired the second stage valve will be
energized.

See the table below for the different duty cycles.

Table 18: Duty cycles

When the second stage of the thermostat is satisfied, the inducer motor is
reduced to low speed and the second stage gas valve is de-energized.

29

On the 50M51 control, the circulator will remain at high heat speed for 30
seconds following the opening of the second stage gas valve and then is
reduced to low heat speed.

When the first stage of the thermostat is satisfied, the first stage gas valve
is de-energized and the HEAT delay-to-fan-off begins timing. The inducer
will post purge for an additional 15 seconds, then the inducer and
humidifier will turn off. Upon completion of the HEAT delay-to-fan-off
period, the 50M51 circulator is turned off. The electronic air cleaner on the
control is also de-energized at this time.

If flame is not detected during the trial-for-ignition period or if the flame is
detected/sensed and then lost before completion of 10 seconds of
establishment, the gas valve is de-energized, the igniter is turned off, and

the control goes into the “retry” sequence.
The “retry” sequence provides a 60 seconds wait with the inducer inter-

purge following an unsuccessful ignition attempt (flame not detected).
After this wait, the ignition attempt is restarted. Two retries will be
attempted before the control goes into system lockout.

If flame is established for more than 10 seconds after ignition, the 50M51
controller will clear the ignition attempt (or retry) counter. If flame is lost
after 10 seconds, the control will restart the ignition sequence.

A momentary loss of gas supply, flame blowout, or a shorted or open
condition in the flame probe circuit will be sensed within 2 seconds. The
gas valve will de-energize and the control will restart the ignition
sequence. Recycles will begin and the burner will operate normally if the
gas supply returns, or the fault condition is corrected, before the last
ignition attempt. Otherwise, the control will go into system lockout.

If the control has gone into system lockout, it may be possible to reset the
control by a momentary power interruption of 10 seconds or longer. Refer
to SYSTEM LOCKOUT AND DIAGNOSTIC FEATURES.

8.5.2- Cool mode

In a typical single stage cooling system (Y connection), a call for cool is
initiated by closing the thermostat contacts. This energizes the
compressor and the electronic air cleaner (optional).

The circulator will be energized at cool speed after the COOL delay-to­fan-on period. After the thermostat is satisfied, the compressor is de­energized and the COOL delay-to-fan-off period begins. After the COOL
delay-to-fan-off period ends, the circulator and the electronic air cleaner
are de-energized.

energized, interrupting the call for heat at the thermostat will not
reset the control).

2. Interrupt the 24 VAC power at the control for at least 20 seconds.
You may also need to reset the flame rollout sensor switch.

3. After one hour in lockout, the control will automatically reset itself.

8.5.7- Last fault mode

To retrieve fault codes, push and release the "LAST ERROR" button for
more than 1/5 second and less than 5 seconds. (Control will indicate this
period by solid GREEN for 1/5 to 5 seconds). The LED will flash up to five
stored fault codes, beginning with the most recent. If there are no fault
codes in memory, the LED will flash two green flashes. The control will
flash the most recent error first and the oldest error last (last in first out).
There shall be 2 seconds between codes. Solid LED error codes will not
be displayed.

8.5.8- Fault code reset

To clear the fault code memory, push and hold the "LAST ERROR" button
for more than 5 seconds and less than 10 seconds. (Control will indicate
this period by RAPID GREEN FLASH for 5 seconds to 10 seconds.) The
LED will flash three green flashes when the memory has been cleared.

8.5.9- Diagnostic features

The 50M51 control continuously monitors its own operation and the
operation of the system. If a failure occurs, the red LED on the control will
flash a failure code. If the failure is internal to the control, the light will stay
on. In this case, the entire control should be replaced, as the control is not
fielded repairable.
If the sensed failure is in the system (external to control), the LED will flash
in the following flash-pause sequences to indicate failure status (each
flash will last approximately 0.25 seconds, and each pause will last
approximately 2 seconds.)
During a second-stage error condition, the red LED when in lockout will
flash groups of double pulses. The red LED will flash on for approximately
1/15 second then off for 1/15 second then on for 1/15 second, then off for
3/10 second. The pause between groups of flashes is approximately 2
seconds. The diagnostics will indicate the specific fault through the
following codes:

8.5.3- Manual fan on mode

If the thermostat fan switch is moved to the ON position, the circulator fan
(low heat speed) and the electronic air cleaner (optional) are energized.
When the fan switch is returned to the AUTO position, the circulator and
electronic air cleaner are de-energized.

8.5.4- Twinning interface

The 50M51 is equipped with a single wire twinning interface. If twinning is
used, either control will process a call for heat, cool or fan as described
previously. However, after the heat or cool on delay time expires, both
units will energize the circulator blowers at the same time. Likewise, after
the heat or cool-off delay time expires, both units will de-energize the
circulator at the same time. This allows for the proper air flow to be
obtained.

In a twinned application, the controls are able to communicate no matter
how the transformers are phased.

To enable twinning, connect the TWIN screw terminals on the 50M51
controls of the furnaces to be twinned to each other using a single wire
(14-22 AWG).

8.5.5- System lockout and diagnostic features

8.5.6- System lockout

When system lockout occurs, the gas valve is de-energized and the low
speed inducer blower and the low heat speed circulator are energized.
The electronic air cleaner (optional) will also energize at this time. The
diagnostic indicator light will flash to indicate the system status.

To reset the control after system lockout, do one of the following:

1. Interrupt the call for heat at the thermostat for at least one second
but less than 20 seconds (if flame is sensed with the gas valve de-

30

Green
LED
Flash

Amber
LED
Flash

Red
LED
Flash

Error/Condition

Comments/Troubleshooting

1

Flame sensed when no flame
should be present

Verify the gas valve is operating and shutting down properly.
Flame in burner assemble should extinguish promptly at the
end of the cycle. Check orifices and gas pressure.

2

Pressure switch stuck closed/
inducer error

Pressure switch stuck closed. Check switch function, verify
inducer is turning off.

3

1st-stage pressure switch stuck
open/inducer error

Check pressure switch function and tubing. Verify inducer is
turning on the pulling sufficient vacuum to engage switch.

4

Open limit switch

Verify continuity through rollout switch circuit.

5

Open rollout/open fuse detect

Verify continuity through rollout switch circuit, check fuse.

6

1st-stage pressure switch cycle
lockout

If the first stage pressure switch cycles 5 times (open,
closed) during one call for heat from the thermostat the
control will lockout. Check pressure switch for fluttering,
inconsistent closure or poor vacuum pressure.

7

External lockout (retries)

Failure to sense flame is often caused by carbon deposits
on the flame sensor, a disconnected or shorted flame
sensor lead or a poorly grounded furnace. Carbon deposits
can be cleaned with emery cloth. Verify sensor is not
contacting the burner and is located in a good position to
sense flame. Check sensor lead for shorting and verify
furnace is grounded properly.

8

External lockout (ignition recycles
exceeded where flame is
established and then lost)

Check items for exceeded retries listed above and verify
valve is not dropping out allowing flame to be established
and then lost.

9

Grounding or Reversed polarity

Verify the control and furnace are properly grounded. Check
and reverse polarity (primary) if incorrect.

10

Module gas valve contacts
energized with no call for heat

Verify valve is not receiving voltage from a short. If a valve
wiring is correct and condition persists, replace module.

11

Limit switch open – possible blower
failure overheating limit

Possible blower failure, restricted air flow through appliance
or duct work. Verify continuity through limit switch circuit and
correct overheating cause.

12

Module Igniter contact failure

Fault code indicates the module igniter contacts are not
functioning properly. Replace module.

Solid

Module - internal fault condition

Module contacts for gas valve not operating or processor
fault. Reset control. If condition persists replace module.

Rapid

Twinning error Check wire
connections.

If condition persists, replace module.

3
double

2nd-stage Pressure Switch Stuck
Open/Inducer Error

Check pressure switch function and tubing. Verify inducer is
turning on and pulling sufficient vacuum to engage switch.

1

Normal Operation with call for first
stage heat

Normal operation - first stage

2

Normal Operation with call for
second stage heat

Normal operation - first stage

3

W2 present with no W1

Second stage call for heat on thermostat circuit with no call
for first stage. Verify dip switches are set for two stage
thermostat and check thermostat first stage circuit.
Configured for a multi-stage thermostat the Module will not
initiate heating unless first stage call from thermostat is
received.

4

Y present with no G call

Module will allow cooling to operate with only a "Y signal
from the thermostat but will also trigger this code. Verify
thermostat is energizing both "Y" and "G" on call for cool.
Check "G" terminal connections.

Rapid

Low
flame
sense
current

Low flame sense current is often caused by carbon deposits
on the flame sensor, a poorly grounded furnace or a
misaligned flame sense probe. Carbon deposits can be
cleaned with emery cloth. Check for improve furnace and
module ground. Verify sensor is located in or very near
flame as specified by the appliance manufacturer.

1

Standby or Call for Cool

Normal operation. Waiting for call from thermostat or
receiving thermostat call for cool.

31

8.6- OPTION SWITCH SETTINGS – 2 STAGE ECM

A B C

D

COOL

S3-1

OFF

ON

OFF

ON

S3-2

OFF

OFF

ON

ON

HEAT

S4-3

OFF

ON

OFF

ON

S4-4

OFF

OFF

ON

ON

Average

calculated

Duty Cycle

% Equals

or is less

than

Low to

High Stage

Delay

Demand

0 38 12 minutes Light

38 50 10 minutes Light to Average

50 62 7 minutes Average

62 75 5 minutes Average to Heavy

75 88 3 minutes Heavy light

88 100 1 minute Heavy

8.6.1- Thermostat type and heat-fan-off delay

8.6.5- De-humidification connection

DIP switch S5-2 (see table above) is set to “On” from the factory for
systems that do not have a dehumidification terminal connection from the
thermostat. For systems using a thermostat that provides a De­Humidification option move DIP switch S5-2 to “Off”.

Table 19: DIP Switches

8.6.2- Multi-stage thermostat set-up, factory default

DIP switches S7-1 and S7-2 (see table above) are set to the “Off” position
from the factory for use with a multi-stage thermostat. This allows the
thermostat to control staging between low and high fire.

8.6.3- Single stage thermostat set-up, module controls
staging

DIP switches, S7-1 and S7-2 (see table above) configure for a single stage
thermostat. Options include a 10 minutes delay on second stage, 20
minutes delay on second stage or an Auto setting allowing the module to
calculate the time delay for second stage based on average demand. The

“Average Calculated Duty Cycle” table shows how the module calculates

staging based on demand.

Table 20: Duty cycle

8.6.6- Normal operation – heat on

When the thermostat calls for heat the module verifies the pressure
switches are open and energizes the inducer (high speed) and optional
humidifier contacts. When the low pressure switch contacts close a 15
second pre-purge begins. After 15 seconds the inducer switches to low
speed and the 120 VAC igniter is energized. The igniter warms up for 17
seconds and the gas valve is energized on low fire. Flame must be
detected within 4 seconds. If flame is detected, a 45 seconds heat, fan on
time delay begins. This allows the heat exchanger to warm up before
energizing the circulator on low speed and (optional) Electronic Air
Cleaner contact. When the thermostat (or module) initiates second stage
the inducer is energized at high speed.
This closes the second stage inducer pressure switch then energizes the
second stage on the gas valve and then the high heat circulator speed.

8.6.7- Normal operation – heat off

When the thermostat satisfies for second stage, the control will switch high
speed inducer and high fire gas valve to low speed inducer and low fire
gas valve. After the 30 seconds high heat fan delay the circulator will drop
to low speed. When the thermostat satisfies for first stage the gas valve
de-energizes and the inducer will run low speed for a 15 seconds post­purge. The circulator runs until the heat off delay ends.

Note: If the module is configured for a single stage thermostat and

running on second stage when the call for heat ends, the
circulator will drop to low speed after 30 seconds and continue
until the heat off delay ends.

8.6.8- Cool mode

In a typical system, a call for cool is initiated by closing Y and G. This
energizes the compressor and the electronic air cleaner (optional). The
electronic air cleaner and the G and (Y or Ylo outputs to the Circulator
motor will energize after the 5 seconds cool on delay period. After the
thermostat is satisfied, the compressor is de-energized and the control
starts a 60 seconds cool circulator speed off delay. After 60 seconds the
circulator is de-energized.

8.6.4- Heat fan off delay timing

DIP switches S7-3 and S7-4 (see table above) configure the number of
seconds the blower will run after the call for heat ends. Factory default is
90 seconds.Heat pump and de-humidification

Table 21: DIP Switches

Heat pump systems

DIP switch S5-1 (see table above) is set to “On” from the factory for use
with conventional (non-Heat Pump systems). For heat pump systems
move the S5-1 DIP switch to the “Off” position. This will continuously
output an O signal to the motor whenever there is Y signal and run the
circulator blower at a constant speed when the pump is operating.

8.6.9- Adjust cooling airflow – dipswitch S3-1 and S3-2

The ECM blower can be adjusted for a range of airflow for Low Speed or
High Speed cooling.Refer to CFM tables in Annexe for the relation
between airflow, external static pressure and dipswitch setting. .

Table 22 : Dipswitch setting for airflow selection

8.6.10- Manual fan on mode

If the thermostat fan switch is moved to the “ON” position, the electronic

air cleaner (optional) and the G circulator output to the circulator motor will
be energized. When the fan switch is returned to the AUTO position, the
G circulator output and the electronic air cleaner are de-energized.

32

8.7- TROUBLESHOOTING

8.7.1- System lockout

When a system lockout occurs (1 hour), the gas valve is de-energized, the
low speed inducer blower is energized for the 60 seconds inter-purge
period and the circulator is energized for selected heat off delay if it was
previously ON. The diagnostic indicator light will flash the fault that is
present (refer to diagnostic table).

To reset the control after system lockout, do one of the following:

8.7.2- System reset

Remove 24 VAC power to the control for twenty (20) seconds
or longer to reset the control.

8.7.3- Thermostat reset

Remove the call for heat from the thermostat for a period of between (1)
second and less 20 seconds. If flame is sensed with the gas valve de­energized, interrupting the call for heat at the thermostat will not reset the
control.

8.7.4- Auto restart

After one (1) hour of internal or external lockout, the control will
automatically reset itself and go into an auto restart purge for 15 seconds.

8.7.5- Diagnostic features

The control continuously monitors its own operation and the operation of
the system. If a failure occurs the diagnostic indicator LED (DSI) will flash

a “RED” failure code. If a failure is internal to the control the “RED”

indicator will stay on continuously. In this case, the entire control should
be replaced as the control is not field-repairable. If the LED is continuously
OFF, there may be no power to the control or a failure within the control.
If the sensed failure is in the system (external to the control), the LED will
flash RED in the sequence listed in the Diagnostic Table. The LED will

also indicate “System Status” as per the Amber and Green LED signatures

listed in the Diagnostic Table. The LED will flash one RED flash at power
up.

8.7.6- Fault code retrieval

To retrieve fault codes, push and release the “LAST ERROR” button for

more than 1/5 seconds and less than 5 seconds. (Control will indicate this
period by solid GREEN for 1/5 seconds. to 5 seconds). The LED will flash
up to five stored fault codes, beginning with the most recent. If there are
no fault codes in memory, the LED will flash two green flashes. The control
will flash the most recent error first and the oldest error last (last in first
out). There shall be 2 seconds between codes. Solid LED error codes will
not be displayed.

NOTE: These error codes may be different from furnace

label or furnace manual.

8.7.7- CFM indicator

The LED (DS2) CFM flashes when the blower motor is running. The
flashing indicates the motor CFM (cubic feet per minute) air flow
designated by the furnace manufacturer. Consult the furnace
manufacturer for flash code detail.

33

Green
LED
Flash

Amber
LED
Flash

Red
LED
Flash

Error/Condition

Comments/Troubleshooting

1

Flame sensed when no flame
should be present

Verify the gas valve is operating and shutting down properly.
Flame in burner assemble should extinguish promptly at the
end of the cycle. Check orifices and gas pressure.

2

Pressure switch stuck closed/
inducer error

Pressure switch stuck closed. Check switch function, verify
inducer is turning off.

3

1st-stage pressure switch stuck
open/inducer error

Check pressure switch function and tubing. Verify inducer is
turning on the pulling sufficient vacuum to engage switch.

4

Open limit switch

Verify continuity through rollout switch circuit.

5

Open rollout/open fuse detect

Verify continuity through rollout switch circuit, check fuse.

6

1st-stage pressure switch cycle
lockout

If the first stage pressure switch cycles 5 times (open,
closed) during one call for heat from the thermostat the
control will lockout. Check pressure switch for fluttering,
inconsistent closure or poor vacuum pressure.

7

External lockout (retries)

Failure to sense flame is often caused by carbon deposits
on the flame sensor, a disconnected or shorted flame
sensor lead or a poorly grounded furnace. Carbon deposits
can be cleaned with emery cloth. Verify sensor is not
contacting the burner and is located in a good position to
sense flame. Check sensor lead for shorting and verify
furnace is grounded properly.

8

External lockout (ignition recycles
exceeded where flame is
established and then lost)

Check items for exceeded retries listed above and verify
valve is not dropping out allowing flame to be established
and then lost.

9

Grounding or Reversed polarity

Verify the control and furnace are properly grounded. Check
and reverse polarity (primary) if incorrect.

10

Module gas valve contacts
energized with no call for heat

Verify valve is not receiving voltage from a short. If a valve
wiring is correct and condition persists, replace module.

11

Limit switch open – possible blower
failure overheating limit

Possible blower failure, restricted air flow through appliance
or duct work. Verify continuity through limit switch circuit and
correct overheating cause.

12

Module Igniter contact failure

Fault code indicates the module igniter contacts are not
functioning properly. Replace module.

Solid

Module - internal fault condition

Module contacts for gas valve not operating or processor
fault. Reset control. If condition persists replace module.

Rapid

Twinning error Check wire
connections.

If condition persists, replace module.

3
double

2nd-stage Pressure Switch Stuck
Open/Inducer Error

Check pressure switch function and tubing. Verify inducer is
turning on and pulling sufficient vacuum to engage switch.

1

Normal Operation with call for first
stage heat

Normal operation - first stage

2

Normal Operation with call for
second stage heat

Normal operation - first stage

3

W2 present with no W1

Second stage call for heat on thermostat circuit with no call
for first stage. Verify dip switches are set for two stage
thermostat and check thermostat first stage circuit.
Configured for a multi-stage thermostat the Module will not
initiate heating unless first stage call from thermostat is
received.

4

Y present with no G call

Module will allow cooling to operate with only a "Y signal
from the thermostat but will also trigger this code. Verify
thermostat is energizing both "Y" and "G" on call for cool.
Check "G" terminal connections.

Rapid

Low
flame
sense
current

Low flame sense current is often caused by carbon deposits
on the flame sensor, a poorly grounded furnace or a
misaligned flame sense probe. Carbon deposits can be
cleaned with emery cloth. Check for improve furnace and
module ground. Verify sensor is located in or very near
flame as specified by the appliance manufacturer.

1

Standby or Call for Cool

Normal operation. Waiting for call from thermostat or
receiving thermostat call for cool.

34

8.8- PRIME CONDENSATE TRAP WITH WATER

Control Switch - Single Stage Valve

Control Switch - 2 Stage Valve

UNIT OPERATION HAZARD

Failure to follow this caution may result in intermittent unit operation or
performance satisfaction. Condensate trap must be PRIMED or proper
draining may not occur. The condensate trap has two internal
chambers which can ONLY be primed by pouring water into the side or
top drain inlet of condensate trap.

NOTE: Temperature rise can be determined for Minimum Heat,

Intermediate Heat and Maximum Heat operation by locking
the furnace in each mode of operation. The mode of
operation is based on the position of Set-up switch on the
furnace control board. The furnace is capable of
automatically providing proper airflow to maintain the
temperature rise within the range specified on furnace rating
plate. If temperature rise is outside this range, proceed as
follows:

a. Check gas input for minimum, intermediate and maximum heat

operation.
b. Check derate for altitude if applicable.
c. Check all return and supply ducts for excessive restrictions

causing static pressure greater than 0.5 in. w.c.
d. Check Troubleshooting Guide for Variable Speed Step

8.8.1- Check safety controls

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

1. Check Main Limit Switch

a. This control shuts off combustion system and energizes air-

circulating blower motor, if furnace overheats. By using this
method to check limit control, it can be established that limit
is functioning properly and will operate if there is a restricted
return air supply or motor failure. If limit control does not
function during this test, cause must be determined and

corrected.
b. Run furnace for at least 5 minutes.
c. Gradually block off return air with a piece of cardboard or

sheet metal until the limit trips.
d. Unblock return air to permit normal circulation.
e. Burners will re-light when furnace cools down.
f. Check Pressure Switch(es)
g. This control proves operation of the draft inducer blower.
h. Turn off 115 V power to furnace.
i. Disconnect inducer motor lead wires from wire harness.
j. Turn on 115 V power to furnace.
k. Set thermostat to “call for heat” and wait 1 minute. When

pressure switch is functioning properly, hot surface igniter

should NOT glow and control diagnostic light flashes a status

code 32. If hot surface igniter glows when inducer motor is

disconnected, shut down furnace immediately.
l. Determine reason pressure switch did not function properly

and correct condition.
m. Turn off 115 V power to furnace.
n. Reconnect inducer motor wires, replace blower door, and

turn on 115 V power.
o. Blower will run for 90 seconds before beginning the call for

heat again.
p. Furnace should ignite normally.

8.8.2- Checklist

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

2. Verify that blower and control doors are properly installed.

3. Cycle test furnace with room thermostat.

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

5. Review Owner’s Manual with owner.

6. Attach literature packet to furnace.

9- OPERATING YOUR FURNACE

These furnaces are equipped with an ignition device which automatically
lights the burners. Do not try to light the burners by hand.

Before operating, smell around furnace area for gas. Be sure to smell
near floor because some gas is heavier than air and will settle to the
lowest point. See WHAT TO DO IF YOU SMELL GAS on page 44 if the
odour of gas is present. Use only your hand to turn the gas control knob;
never use tools. If the knob will not turn by hand, don’t try to repair it.
Call a qualified service technician. Force or attempted repair may

result in a fire or explosion.

9.1- START UP INSTRUCTIONS

1. STOP! Read the previous safety information.

2. Set the thermostat to the lowest setting.

3. Turn off all electric power to the furnace.

4. Remove the burner compartment access panel.

5. This appliance is equipped with an automatic ignition device.

Do not try to light the burners by hand.

6. Move the gas control switch to “OFF” (see Figure 24).

Figure 24 Control Switch – Modulating Valve

7. Wait 5 minutes to clear out any gas, then smell for gas (including
at the bottom of the unit near the ground). If you smell gas, stop
and follow the directions in WHAT TO DO IF YOU SMELL GAS
on page 44. If you don’t smell gas, continue to next step.

8. Move the gas control knob or switch to “ON”.

9. Replace the burner compartment access panel.

10. Turn on all electric power to the furnace.

11. Set the thermostat to the desired setting.

12. If the furnace will not operate, follow the instructions found below
in to turn off Gas to Furnace and call your service technician or
gas supplier.

9.2- SHUTTING DOWN THE FURNACE

To shut down the furnace, set the thermostat to the “OFF” position.

9.2.1- To turn off gas to furnace

1. Set the thermostat to the lowest setting.

2. Turn off all electric power to the furnace if service is to be
performed.

3. Remove the burner compartment access panel.

4. Move the gas control knob or switch to “OFF” (see Figure 24). Do
not force.

5. Replace the burner compartment access panel.

35

10- MAINTENANCE OF YOUR FURNACE

There are routine maintenance steps you should take to keep your
furnace operating efficiently. This maintenance will assure longer life,
lower operating costs, and fewer service calls.

In addition to the maintenance procedures listed in this manual, there
are also other service and maintenance procedures that require the
skills of a service person that has specialized tools and training.

Personal injury can result if you are not qualified to do this work.

Please call your dealer when service is needed.
Your gas furnace is designed to give many years of efficient, satisfactory

service. However, the varied air pollutants commonly found in most
areas can affect longevity and safety. Chemicals contained in everyday
household items such as laundry detergents, cleaning sprays, hair
sprays, deodorizers, and other products which produce airborne
residuals may have an adverse effect upon the metals used to construct
your appliance. The cabinet of the furnace can be cleaned with soap and
water. Grease spots can be removed with a household cleaning agent.

It is important that you conduct periodic physical inspections of your
appliance, paying special attention to the gas burner and the flue outlet
from the furnace. These components are located at the front of the unit.
A flashlight will be useful for these inspections. Make one inspection
prior to the beginning of the heating season and another during the
middle.
Should you observe unusual amounts of any of the following conditions,
it is important that you call your authorized dealer at once to obtain a
qualified service inspection:

 Rust, flakes, or other deposits
 Coatings
 Corrosion

Even if no unusual rust or other conditions are observed, it is
recommended that the furnace be inspected and serviced at least
once per year by a qualified service technician. Regular inspections

and planned maintenance will assure many years of economic
performance from your gas furnace.

10.1- CLEANING/REPLACING THE FILTER

It is very important to clean or replace the air filter regularly.
Dirty filters are the most common cause of inadequate heating or cooling

performance and can sharply increase the operational costs of your unit.
In some cases, they can double the cost. The air filter should be

inspected at least every 6 weeks and cleaned or replaced as
required.

Your furnace may use either a disposable filter or a cleanable filter. The
type of filter may be indicated on a label attached to the filter. If a
disposable filter is used, replace with the same type and size. To remove
excess dirt from a cleanable filter, shake filter and/or use a vacuum
cleaner. Wash filter in soap or detergent water and replace after filter is
dry.

Cleanable filters do not need to be oiled after washing. Cleanable filters
may be replaced with disposable filters.

If your air distribution system has a central return air filter-grille, the
furnace does not need a filter. Filter grilles can be maintained the same
way as cleanable filters (see above).

10.1.1- Filter location

The filter on your furnace will be located in one of two different locations:

- On one side of the furnace

- On the bottom of the furnace

is present. If your observations indicate improper flame adjustment, call
your authorized service dealer for service. Do not attempt to adjust

flame!

Your service representative will perform this adjustment correctly.

Figure 25 Typical Flame Appearance

10.4- CONDENSATE COLLECTION AND DISPOSAL

SYSTEM (IF APPLICABLE)

If the furnace has a condensate drain, it is incorporated within the
furnace and is self-priming. The condensate system must not be

exposed to temperatures under 32°F.

Make sure the condensate drain line does not become blocked or
plugged. Visual inspection of condensate flow can easily be made while
the furnace is operating. Use a flashlight to illuminate discharge end of
the condensate drain that is placed in the sewer opening. The furnace
will not operate properly if condensate drain line becomes blocked or
plugged. If this event occurs, have the furnace inspected by a qualified
service technician.

10.5- ROLLOUT SWITCH

This unit is equipped with a manual reset high temperature sensor or
rollout switch. In the unlikely event of a sustained burner flame rollout,
the rollout switch will shut off the flow of gas by closing the gas valve.
The switch is located inside the gas burner area. Flame rollout can be
caused by blockage of the power vent system, a blocked heat
exchanger, or improper gas pressure or adjustment. If this event occurs,
the unit will not operate properly. The gas supply to the unit should be
shut off and no attempt should be made to place it in operation. The
system should be inspected by a qualified service technician.

10.6- SAFETY INTERLOCK SWITCH

The blower compartment door on your high efficiency gas furnace is
equipped with a safety interlock switch that will automatically shut off
your complete system (including blower) once the door is removed. This
is for your personal safety. Be sure to check your furnace for proper
operation once the door or panel has been replaced. If the system does
not operate once the panel has been replaced, try removing and
replacing it once again. If the furnace still does not operate, call your
dealer for service.

10.7- REPAIR PARTS

The repair parts are available from your local distributor. When ordering
parts: include the complete furnace model number and serial number
which are printed on the rating plate located on the furnace. For part
numbers refer to

10.2- LUBRICATION

Lubrication of the bearings in the circulating air blower motor and the
combustion blower motor is not recommended.

10.3- BURNER FLAME

While the furnace is in operation, observe the burner flames. Compare
these observations to Figure 25 to determine if proper flame adjustment

36

Figure 26 Exploded view 1 stage PSC

37

38

Table 23 Part list - 1 stage PSC

#

Description

C45-1-D

C60-1-D

C75-1-D

C105-1-D

C120-1-D

1

Heat exchanger assembly

B40508-03

B40508-04

B40508-05

B40508-07

B40508-08

2

Back panel assembly

B40511-01

B40511-02

B40511-03

B40511-03

B40511-03

3

Right panel assembly

B40510-33

B40510-33

B40510-33

B40510-33

B40510-33

4

Loose part bag

B40569-01

B40569-02

B40569-02

B40569-02

B40569-02

5

Hose 5/8

B30157-34

B30157-34

B30157-34

B30157-34

B30157-34

6

Hose 1/2

B30157-38

B30157-38

B30157-38

B30157-38

B30157-38

7

Hose 3/16

B30157-40

B30157-40

B30157-40

B30157-40

B30157-40

8

Floor

B40546-01

B40546-02

B40546-02

B40546-03

B40546-03

9

Blower assembly

B40518-01

B40518-02

B40518-03

B40518-04

B40518-04

10

Electric blower kit

B40590-01

B40590-01

B40590-01

B40590-02

B40590-02

11

Separator assembly

B40513-07

B40513-08

B40513-09

B40513-11

B40513-12

12

Inducer restrictor

B40563-07

B40563-04

B40698

N/A

N/A

13

Pressure switch assembly

B40675-03

B40675-04

B40675-05

B40675-07

B40675-08

14

Gas valve

R01H012

R01H012

R01H012

R01H012

R01H012

15

Control card assembly

B40697

B40697

B40697

B40697

B40697

16

Lower door assembly

B40570-01

B40570-02

B40570-02

B40570-03

B40570-03

17

Upper door assembly

B40571-01

B40571-02

B40571-02

B40571-03

B40571-03

18

Left panel assembly

B40509-01

B40509-01

B40509-01

B40509-01

B40509-01

19

Elect. Kit inverter/blower

B40589-01

B40589-01

B40589-01

B40589-02

B40589-02

20

Elect. Kit principal harness

B40591-01

B40591-01

B40591-01

B40591-02

B40591-02

21

Complete gas manifold assembly

B40514-03

B40514-04

B40514-05

B40514-07

B40514-08

22

ID blower assembly

B40578-04

B40578-01

B40578-01

B40578-01

B40578-01

23

Top panel assembly

B40512-01

B40512-02

B40512-02

B40512-03

B40512-03

24

Blower rail

B40552

B40552

B40552

B40552

B40552

25

Door switch

L07H001

L07H001

L07H001

L07H001

L07H001

26

Observation port w Dettson logo

B40565

B40565

B40565

B40565

B40565

27

Observation port

L04Z022

L04Z022

L04Z022

L04Z022

L04Z022

28

Grommet

G14F017

G14F017

G14F017

G14F017

G14F017

29

Pressure switch support

B40560

B40560

B40560

B40560

B40560

30

Pressure switch (condensate box)

R99F035

R99F035

R99F035

R99F035

R99F035

31

Pressure switch

R99F043

R99F042

R99F048

R99F039

R99F039

32

Drain trap gasket

B40568

B40568

B40568

B40568

B40568

33

PVC pipe

B40571-02

B40571-01

B40571-01

B40571-01

B40571-01

34

Drain trap

B40535

B40535

B40535

B40535

B40535

35

Venting flange gasket

B40567

B40567

B40567

B40567

B40567

36

Venting flange

B40533

B40533

B40533

B40533

B40533

37

Igniter

R03K005

R03K005

R03K005

R03K005

R03K005

38

Roll out switch

R02N022

R02N022

R02N022

R02N022

R02N022

39

Gas manifold assembly

B40527

B40528

B40529

B40531

B40532

40

Orifice #48 natural gas

R04I001

R04I001

R04I001

R04I001

R04I001

41

Flame detector

R03J004

R03J004

R03J004

R03J004

R03J004

42

Clamp 5/8

G99Z035

G99Z035

G99Z035

G99Z035

G99Z035

43

Elbow 5/8

G07J007

G07J007

G07J007

G07J007

G07J007

44

Condensate box

B40526-01

B40526-02

B40526-02

B40526-03

B40526-04

45

High limit

R02N026

R02N024

R02N023

R02N024

R02N024

46

Baffle

B40572

B40572

B40572

B40572

B40572

47

Smoke box

B40539-01

B40539-02

B40539-02

B40539-03

B40539-04

48

Rubber collar for venting

B40580

B40580

B40580

B40580

B40580

49

ID blower

Z01K007

Z01K007

Z01K007

Z01K007

Z01K007

50

Elbow 1/2

G07J006

G07J006

G07J006

G07J006

G07J006

51

Clamp 1/2

G99Z034

G99Z034

G99Z034

G99Z034

G99Z034

52

Capacitor

L01I002

L01I002

L01I005

L01I003

L01I003

53

Motor assembly PSC

B03684-02

B03684-02

B01891-07

B01891-08

B01891-08

54

Motor PSC

L06H004

L06H004

L06I004

L06K004

L06K004

55

Motor mounting bracket

B01889

B01889

B01889

B01889

B01889

56

Blower

Z01I033

Z01I035

Z01I036

Z01I038

Z01I038

57

Oval cap for capitor

L99Z007

L99Z007

L99Z007

L99Z007

L99Z007

58

Bracket for capacitor

B01024

B01024

B01024

B01024

B01024

59

Control board 24V

R99G013

R99G013

R99G013

R99G013

R99G013

60

Control board support

B40559

B40559

B40559

B40559

B40559

61

Transformer 120V-24V

L01F009

L01F009

L01F009

L01F009

L01F009

62

ID blower and PVC elbow ass

N/A

B40766-01

B40766-01

B40766-01

B40766-01

Options

C45-1-D

C60-1-D

C75-1-D

C105-1-D

C120-1-D

Bottom return base assembly

B40691-01

B40691-02

B40691-02

B40691-03

B40691-03

Downflow base

B40632-01

B40632-02

B40632-02

B40632-03

B40632-03

Transition A coil

B40693-01

---

---

---

---

Conversion kit propane

B40574-07

B40574-10

B40574-13

B40574-19

B40574-21

Orifice #56 (LP)

R01I002

R01I002

R01I002

R01I002

R01I002

Replacement kit for drain trap

K01021

K01021

K01021

K01021

K01021

39

Figure 27 Exploded view 2 stage PSC

40

41

#

Description

C45-2-D

C60-2-D

C75-2-D

C105-2-D

C120-2-D

1

Heat exchanger assembly

B40508-03

B40508-04

B40508-05

B40508-07

B40508-08

2

Back panel assembly

B40511-04

B40511-05

B40511-05

B40511-06

B40511-06

3

Right panel assembly

B40510-34

B40510-34

B40510-34

B40510-34

B40510-34

4

Loose part bag

B40569-01

B40569-02

B40569-02

B40569-02

B40569-02

5

Hose 5/8

B30157-34

B30157-34

B30157-34

B30157-34

B30157-34

6

Hose 1/2

B30157-38

B30157-38

B30157-38

B30157-38

B30157-38

7

Hose 3/16

B30157-40

B30157-40

B30157-40

B30157-40

B30157-40

8

Floor

B40546-01

B40546-02

B40546-02

B40546-03

B40546-03

9

Blower assembly

B40518-01

B40518-02

B40518-03

B40518-04

B40518-04

10

Electric blower kit

B40594-01

B40594-01

B40594-01

B40594-02

B40594-02

11

Separator assembly

B40513-01

B40513-02

B40513-03

B40513-05

B40513-06

12

Inducer restrictor

B40563-07

B40563-04

B40698

N/A

N/A

13

Pressure switch assembly

B40675-11

B40675-12

B40675-13

B40675-15

B40675-16

14

Gas valve

R01I003

R01I003

R01I003

R01I003

R01I003

15

Control card assembly

B40696

B40696

B40696

B40696

B40696

16

Lower door assembly

B40570-04

B40570-05

B40570-05

B40570-06

B40570-06

17

Upper door assembly

B40571-01

B40571-02

B40571-02

B40571-03

B40571-03

18

Left panel assembly

B40509-02

B40509-02

B40509-02

B40509-02

B40509-02

19

Elect. Kit inverter/blower

B40592-01

B40592-01

B40592-01

B40592-02

B40592-02

20

Elect. Kit principal harness

B40593-01

B40593-01

B40593-01

B40593-02

B40593-02

21

Complete gas manifold assembly

B40514-03

B40514-04

B40514-05

B40514-07

B40514-08

22

ID blower assembly

B40578-05

B40578-02

B40578-02

B40578-02

B40578-02

23

Top panel assembly

B40512-01

B40512-02

B40512-02

B40512-03

B40512-03

24

Blower rail

B40552

B40552

B40552

B40552

B40552

25

Door switch

L07H001

L07H001

L07H001

L07H001

L07H001

26

Observation port w Dettson logo

B40565

B40565

B40565

B40565

B40565

27

Observation port

L04Z022

L04Z022

L04Z022

L04Z022

L04Z022

28

Grommet

G14F017

G14F017

G14F017

G14F017

G14F017

29

Pressure switch support

B40560

B40560

B40560

B40560

B40560

30

Pressure switch (condensate box)

R99F035

R99F035

R99F035

R99F035

R99F035

31

Pressure switch (high fire)

R99F043

R99F042

R99F048

R99F039

R99F041

32

Pressure switch (low fire)

R99F039

R99F050

R99F050

R99F050

R99F050

33

Garniture purgeur

B40568

B40568

B40568

B40568

B40568

34

PVC pipe

B40571-02

B40571-01

B40571-01

B40571-01

B40571-01

35

Drain trap

B40535

B40535

B40535

B40535

B40535

36

Venting flange gasket

B40567

B40567

B40567

B40567

B40567

37

Venting flange

B40533

B40533

B40533

B40533

B40533

38

Igniter

R03K005

R03K005

R03K005

R03K005

R03K005

39

Roll out switch

R02N022

R02N022

R02N022

R02N022

R02N022

40

Gas manifold assembly

B40527

B40528

B40529

B40531

B40532

41

Orifice #48 natural gas

R04I001

R04I001

R04I001

R04I001

R04I001

42

Flame detector

R03J004

R03J004

R03J004

R03J004

R03J004

43

Clamp 5/8

G99Z035

G99Z035

G99Z035

G99Z035

G99Z035

44

Elbow 5/8

G07J007

G07J007

G07J007

G07J007

G07J007

45

Condensate box

B40526-01

B40526-02

B40526-02

B40526-03

B40526-04

46

High limit

R02N026

R02N024

R02N023

R02N024

R02N024

47

Baffle

B40572

B40572

B40572

B40572

B40572

48

Smoke box

B40539-01

B40539-02

B40539-02

B40539-03

B40539-04

49

Rubber collar for venting

B40580

B40580

B40580

B40580

B40580

50

ID blower

Z01K006

Z01K006

Z01K006

Z01K006

Z01K006

51

Elbow 1/2

G07J006

G07J006

G07J006

G07J006

G07J006

52

Clamp 1/2

G99Z034

G99Z034

G99Z034

G99Z034

G99Z034

53

Capacitor

L01I002

L01I002

L01I005

L01I003

L01I003

54

Motor assembly PSC

B03684-02

B03684-02

B01891-07

B01891-08

B01891-08

55

Motor PSC

L06H004

L06H004

L06I004

L06K004

L06K004

56

Motor mounting bracket

B01889

B01889

B01889

B01889

B01889

57

Blower

Z01I033

Z01I035

Z01I036

Z01I038

Z01I038

58

Oval cap for capitor

L99Z007

L99Z007

L99Z007

L99Z007

L99Z007

59

Bracket for capacitor

B01024

B01024

B01024

B01024

B01024

60

Control board 24V

R99G015

R99G015

R99G015

R99G015

R99G015

61

Control board support

B40559

B40559

B40559

B40559

B40559

62

Transformer 120V-24V

L01F009

L01F009

L01F009

L01F009

L01F009

63

ID blower and PVC elbow ass

N/A

B40766-02

B40766-02

B40766-02

B40766-02

Options

C45-2-D

C60-2-D

C75-2-D

C105-2-D

C120-2-D

Bottom return base assembly

B40691-01

B40691-02

B40691-02

B40691-03

B40691-03

Downflow base

B40632-01

B40632-02

B40632-02

B40632-03

B40632-03

Transition A coil

B40693-01

---

---

---

---

Conversion kit propane

B40574-08

B40574-11

B40574-14

B40574-20

B40574-23

Orifice #56 (LP)

R01I002

R01I002

R01I002

R01I002

R01I002

Replacement kit for drain trap

K01021

K01021

K01021

K01021

K01021

Table 24: Part list – 2 Stage, PSC

42

Figure 28 Exploded view 2 stage ECM

43

44

Table 25: Part list – 2 Stage, ECM

#

Description

C45-2-V

C60-2-V

C75-2-V

C105-2-V

C120-2-V

1

Heat exchanger assembly

B40508-03

B40508-04

B40508-05

B40508-07

B40508-08

2

Back panel assembly

B40511-04

B40511-05

B40511-05

B40511-06

B40511-06

3

Right panel assembly

B40510-34

B40510-34

B40510-34

B40510-34

B40510-34

4

Loose part bag

B40569-01

B40569-02

B40569-02

B40569-02

B40569-02

5

Hose 5/8

B30157-34

B30157-34

B30157-34

B30157-34

B30157-34

6

Hose 1/2

B30157-38

B30157-38

B30157-38

B30157-38

B30157-38

7

Hose 3/16

B30157-40

B30157-40

B30157-40

B30157-40

B30157-40

8

Floor

B40546-01

B40546-02

B40546-02

B40546-03

B40546-03

9

Blower assembly

B40604-03

B40604-04

B40604-05

B40604-07

B40604-08

10

Electric blower kit

B40581-01

B40581-01

B40581-01

B40581-02

B40581-02

11

Electric blower kit

B03242-04

B03242-04

B03242-04

B03242-05

B03242-05

12

Separator assembly

B40513-01

B40513-02

B40513-03

B40513-05

B40513-06

13

Inducer restrictor

B40563-07

B40563-04

B40698

N/A

N/A

14

Pressure switch assembly

B40675-19

B40675-20

B40675-21

B40675-23

B40675-24

15

Gas valve

R01I003

R01I003

R01I003

R01I003

R01I003

16

Control card assembly

B40695

B40695

B40695

B40695

B40695

17

Lower door assembly

B40570-07

B40570-08

B40570-08

B40570-09

B40570-09

18

Upper door assembly

B40571-01

B40571-02

B40571-02

B40571-03

B40571-03

19

Left pannel assembly

B40509-02

B40509-02

B40509-02

B40509-02

B40509-02

20

Elect. Kit inverter blower

B40592-01

B40592-01

B40592-01

B40592-02

B40592-02

21

Elect. Kit principal harness

B40593-01

B40593-01

B40593-01

B40593-02

B40593-02

22

Complete gas manifold assembly

B40514-03

B40514-04

B40514-05

B40514-07

B40514-08

23

ID blower assembly

B40578-05

B40578-02

B40578-02

B40578-02

B40578-02

24

Top panel assembly

B40512-01

B40512-02

B40512-02

B40512-03

B40512-03

25

Blower rail

B40552

B40552

B40552

B40552

B40552

26

Door switch

L07H001

L07H001

L07H001

L07H001

L07H001

27

Observation port w Dettson logo

B40565

B40565

B40565

B40565

B40565

28

Observation port

L04Z022

L04Z022

L04Z022

L04Z022

L04Z022

29

Grommet

G14F017

G14F017

G14F017

G14F017

G14F017

30

Pressure switch support

B40560

B40560

B40560

B40560

B40560

31

Pressure switch (condensate box)

R99F035

R99F035

R99F035

R99F035

R99F035

32

Pressure switch (high fire)

R99F043

R99F042

R99F048

R99F039

R99F041

33

Pressure switch (low fire)

R99F039

R99F050

R99F050

R99F050

R99F050

34

Drain trap gasket

B40568

B40568

B40568

B40568

B40568

35

PVC pipe

B40571-02

B40571-01

B40571-01

B40571-01

B40571-01

36

Drain trap

B40535

B40535

B40535

B40535

B40535

37

Venting flange gasket

B40567

B40567

B40567

B40567

B40567

38

Venting flange

B40533

B40533

B40533

B40533

B40533

39

Igniter

R03K005

R03K005

R03K005

R03K005

R03K005

40

Roll out switch

R02N022

R02N022

R02N022

R02N022

R02N022

41

Gas manifold assembly

B40527

B40528

B40529

B40531

B40532

42

Orifice #48 natural gas

R04I001

R04I001

R04I001

R04I001

R04I001

43

Flame detector

R03J004

R03J004

R03J004

R03J004

R03J004

44

Clamp 5/8

G99Z035

G99Z035

G99Z035

G99Z035

G99Z035

45

Elbow 5/8

G07J007

G07J007

G07J007

G07J007

G07J007

46

Condensate box

B40526-01

B40526-02

B40526-02

B40526-03

B40526-04

47

High limit

R02N026

R02N024

R02N023

R02N024

R02N024

48

Baffle

B40572

B40572

B40572

B40572

B40572

49

Smoke box

B40539-01

B40539-02

B40539-02

B40539-03

B40539-04

50

Rubber collar for venting

B40580

B40580

B40580

B40580

B40580

51

ID blower

Z01K006

Z01K006

Z01K006

Z01K006

Z01K006

52

Elbow 1/2

G07J006

G07J006

G07J006

G07J006

G07J006

53

Clamp 1/2

G99Z034

G99Z034

G99Z034

G99Z034

G99Z034

54

Inductance

B03141-02

B03141-01

B03141-01

B03141

B03141

55

Motor assembly ECM (EON 5.0)

B03240-12

B03716-02

B03716-03

B03241-09

B03241-10

56

Motor ECM (EON 5.0)

B03811-25

B03812-09

B03812-10

B03813-15

B03813-16

57

Motor mounting bracket

B01889

B01889

B01889

B01889

B01889

58

Blower

Z01I033

Z01I035

Z01I036

Z01I038

Z01I038

59

Control board 24V

R99G016

R99G016

R99G016

R99G016

R99G016

60

Control board support

B40559

B40559

B40559

B40559

B40559

61

Transformer 120V-24V

L01F009

L01F009

L01F009

L01F009

L01F009

62

ID blower and PVC elbow ass

N/A

B40766-02

B40766-02

B40766-02

B40766-02

Options

C45-2-V

C60-2-V

C75-2-V

C105-2-V

C120-2-V

Bottom return base assembly

B40691-01

B40691-02

B40691-02

B40691-03

B40691-03

Downflow base

B40632-01

B40632-02

B40632-02

B40632-03

B40632-03

Transition A coil

B40693-01

---

---

---

---

Conversion kit propane

B40574-09

B40574-12

B40574-15

B40574-21

B40574-24

Orifice #56 (LP)

R01I002

R01I002

R01I002

R01I002

R01I002

Replacement kit for drain trap

K01021

K01021

K01021

K01021

K01021

45

ANNEX I : CFM TABLES

Motor speed

Static pressure

0.1

0.2

0.3

0.4

0.5

0.6

0.7

0.8

0.9 1 HIGH

N/A

1095

1045

1020

970

915

845

780

710

640

MED-HI

N/A

1045

980

940

880

835

775

715

665

585

MED

N/A

950

910

865

820

780

730

670

600

565

LOW

N/A

925

875

835

800

760

710

660

605

545

1st stage -Heating

Motor speed

Static pressure

0.1

0.2

0.3

0.4

0.5

0.6

0.7

0.8

0.9

1

A

505

495

485

475

470

465

460

450

450

445 B 620

600

590

585

580

580

570

570

560

555

C

545

535

530

525

520

515

505

500

495

495

D

440

430

420

415

410

405

400

400

395

385

2nd stage - Heating

Motor speed

Static pressure

0.1

0.2

0.3

0.4

0.5

0.6

0.7

0.8

0.9

1

A

730

715

705

690

690

685

680

670

670

665

B

915

890

865

850

845

845

840

835

830

810 C 740

725

710

700

700

690

685

685

680

670

D

655

640

635

630

625

620

615

605

600

590

1st stage - Cooling

Motor speed

Static pressure

0.1

0.2

0.3

0.4

0.5

0.6

0.7

0.8

0.9 1 A

N/A

895

880

880

860

860

860

845

835

820

B

695

680

680

670

670

665

660

655

650

645 C 520

510

505

490

485

480

475

470

470

475

D

365

360

360

355

355

350

345

335

325

310

2nd stage - Cooling

Motor speed

Static pressure

0.1

0.2

0.3

0.4

0.5

0.6

0.7

0.8

0.9 1 A

N/A

1075

1060

1025

990

960

925

895

860

820 B 870

850

840

840

830

825

820

810

805

795

C

670

655

655

655

635

635

635

630

625

615

D

460

455

450

445

440

440

440

435

425

420

Table 26 CFM for 45,000 BTU PSC motor

Table 27 CFM in heating for 45,000 BTU 2 stage ECM motor

Table 28 CFM in cooling for 45,000 BTU 2 stage ECM motor

46

Table 29 CFM for 60,000 BTU PSC motor

Motor speed

Static pressure

0.1

0.2

0.3

0.4

0.5

0.6

0.7

0.8

0.9

1

HIGH

N/A

N/A

1370

1305

1230

1155

1085

1005

945

860

MED-HI

N/A

1195

1134

1085

1025

975

925

875

814

740

MED

N/A

1150

1100

1050

1000

955

905

860

795

725

LOW

N/A

1005

980

945

905

865

820

780

720

655

1st stage -Heating

Motor speed

Static pressure

0.1

0.2

0.3

0.4

0.5

0.6

0.7

0.8

0.9

1

A

N/A

745

735

725

720

705

705

695

685

675

B

N/A

910

910

900

895

890

880

870

865

855

C

N/A

835

825

820

815

805

795

790

780

775

D

N/A

770

770

770

765

755

750

750

735

730

2nd stage - Heating

Motor speed

Static pressure

0.1

0.2

0.3

0.4

0.5

0.6

0.7

0.8

0.9

1

A

N/A

1125

1120

1110

1100

1100

1090

1080

1075

1075

B

N/A

N/A

1355

1350

1340

1335

1325

1315

1305

1265

C

N/A

1250

1230

1230

1220

1220

1215

1205

1195

1190

D

N/A

1180

1180

1175

1165

1165

1160

1155

1150

1140

1st stage - Cooling

Motor speed

Static pressure

0.1

0.2

0.3

0.4

0.5

0.6

0.7

0.8

0.9

1

A

N/A

1300

1295

1295

1280

1280

1265

1250

1230

1230

B

N/A

1080

1070

1065

1050

1045

1050

1040

1035

1035

C

N/A

890

870

860

860

850

835

835

825

820

D

N/A

720

690

675

665

655

645

635

630

610

2nd stage - Cooling

Motor speed

Static pressure

0.1

0.2

0.3

0.4

0.5

0.6

0.7

0.8

0.9 1 A

N/A

N/A

1555

1515

1475

1445

1415

1370

1330

1285

B

N/A

N/A

1375

1370

1360

1350

1340

1325

1285

1255

C

N/A

1145

1145

1135

1130

1125

1115

1110

1105

1095

D

N/A

900

890

885

880

870

860

855

845

835

Table 30 CFM in heating for 60,000 BTU 2 stage ECM motor

Table 31 CFM in cooling for 60,000 BTU 2 stage ECM motor

47

Table 32 CFM for 75,000 BTU PSC motor

Motor speed

Static pressure

0.1

0.2

0.3

0.4

0.5

0.6

0.7

0.8

0.9

1

HIGH

N/A

1615

1540

1440

1355

1280

1204

1182

1060

980

MED-HI

N/A

1670

1590

1480

1382

1300

1219

1192

1065

982

MED

N/A

1496

1388

1289

1188

1133

1087

1083

1015

975

LOW

1272

1197

1148

1108

1042

967

913

824

777

749

1st stage -Heating

Motor speed

Static pressure

0.1

0.2

0.3

0.4

0.5

0.6

0.7

0.8

0.9

1

A

N/A

995

985

985

985

980

985

975

985

980

B

N/A

1320

1300

1280

1280

1260

1235

1210

1160

1150

C

N/A

1145

1105

1100

1105

1110

1105

1105

1110

1100

D

N/A

915

915

920

925

925

925

925

925

920

2nd stage - Heating

Motor speed

Static pressure

0.1

0.2

0.3

0.4

0.5

0.6

0.7

0.8

0.9

1

A

N/A

N/A

1425

1415

1385

1345

1320

1300

1255

1225

B

N/A

N/A

1570

1495

1425

1365

1325

1310

1285

1245

C

N/A

N/A

1430

1445

1435

1385

1365

1335

1300

1260

D

N/A

N/A

1465

1440

1380

1360

1330

1300

1260

1225

1st stage - Cooling

Motor speed

Static pressure

0.1

0.2

0.3

0.4

0.5

0.6

0.7

0.8

0.9

1

A

N/A

1240

1225

1215

1210

1200

1195

1180

1155

1105

B

N/A

1060

1030

1010

1020

1020

1010

1010

1005

1010

C

N/A

845

830

840

840

830

830

830

835

835

D

N/A

655

650

650

650

650

650

650

650

645

2nd stage - Cooling

Motor speed

Static pressure

0.1

0.2

0.3

0.4

0.5

0.6

0.7

0.8

0.9 1 A

N/A

N/A

1575

1515

1470

1415

1365

1325

1270

1215

B

N/A

N/A

1430

1420

1390

1350

1295

1250

1220

1165

C

N/A

1075

1070

1070

1070

1075

1080

1075

1080

1090

D

N/A

690

690

695

690

690

690

695

695

695

Table 33 CFM in heating for 75,000 BTU 2 stage ECM motor

Table 34 CFM in cooling for 75,000 BTU 2 stage ECM motor

48

Table 35 CFM for 105,000 BTU PSC motor

Motor speed

Static pressure

0.1

0.2

0.3

0.4

0.5

0.6

0.7

0.8

0.9

1

HIGH

N/A

1740

1615

1515

1430

1355

1285

1195

1110

1030

MED-HI

N/A

1655

1550

1435

1360

1285

1230

1150

1080

990

MED

N/A

1405

1325

1240

1180

1135

1070

1005

930

845

LOW

N/A

1130

1065

1025

975

935

870

830

775

705

1st stage -Heating

Motor speed

Static pressure

0.1

0.2

0.3

0.4

0.5

0.6

0.7

0.8

0.9

1

A

N/A

1255

1230

1225

1220

1220

1215

1210

1205

1205

B

N/A

1490

1475

1465

1460

1465

1460

1450

1445

1420

C

N/A

1350

1340

1345

1345

1345

1340

1340

1335

1325

D

N/A

1135

1130

1130

1125

1125

1125

1120

1115

1115

2nd stage - Heating

Motor speed

Static pressure

0.1

0.2

0.3

0.4

0.5

0.6

0.7

0.8

0.9

1

A

N/A

N/A

1750

1720

1725

1705

1665

1620

1565

1525

B

N/A

N/A

1850

1830

1775

1700

1660

1610

1555

1515

C

N/A

N/A

1860

1825

1770

1705

1655

1610

1555

1520

D

N/A

1645

1650

1650

1650

1640

1625

1605

1555

1515

1st stage - Cooling

Motor speed

Static pressure

0.1

0.2

0.3

0.4

0.5

0.6

0.7

0.8

0.9

1

A

N/A

N/A

1525

1530

1500

1520

1515

1500

1500

1495

B

N/A

1305

1300

1300

1315

1320

1310

1310

1305

1305

C

N/A

1145

1120

1120

1125

1115

1115

1115

1115

1110

D

N/A

940

935

930

930

930

935

930

925

920

2nd stage - Cooling

Motor speed

Static pressure

0.1

0.2

0.3

0.4

0.5

0.6

0.7

0.8

0.9 1 A

N/A

N/A

1880

1835

1770

1710

1665

1610

1550

1510

B

N/A

N/A

N/A

1660

1655

1645

1630

1585

1450

1505

C

N/A

1460

1455

1450

1450

1450

1445

1450

1450

1445

D

1230

1230

1210

1215

1220

1225

1230

1230

1220

1225

Table 36 CFM in heating for 105,000 BTU 2 stage ECM motor

Table 37 CFM in cooling for 105,000 BTU 2 stage ECM motor

49

Table 38 CFM for 120,000 BTU PSC motor

Motor speed

Static pressure

0.1

0.2

0.3

0.4

0.5

0.6

0.7

0.8

0.9

1

HIGH

N/A

N/A

1490

1410

1330

1255

1180

1100

1020

930

MED-HI

N/A

N/A

1465

1380

1315

1250

1180

1100

1010

930

MED

N/A

1325

1255

1185

1120

1050

970

915

855

790

LOW

N/A

1180

1135

1080

1025

970

930

890

830

790

1st stage -Heating

Motor speed

Static pressure

0.1

0.2

0.3

0.4

0.5

0.6

0.7

0.8

0.9

1

A

N/A

N/A

1590

1570

1560

1550

1525

1490

1450

1385

B

N/A

N/A

1960

1880

1820

1770

1720

1675

1625

1570

C

N/A

N/A

1795

1780

1730

1675

1630

1575

1525

1475

D

N/A

1455

1440

1425

1425

1425

1395

1385

1370

1325

2nd stage - Heating

Motor speed

Static pressure

0.1

0.2

0.3

0.4

0.5

0.6

0.7

0.8

0.9

1

A

N/A

N/A

1985

1905

1850

1790

1750

1705

1625

1580

B

N/A

N/A

1955

1920

1850

1780

1730

1700

1615

1565

C

N/A

N/A

1955

1920

1850

1780

1730

1700

1615

1565

D

N/A

N/A

1950

1920

1865

1780

1730

1710

1615

1565

1st stage - Cooling

Motor speed

Static pressure

0.1

0.2

0.3

0.4

0.5

0.6

0.7

0.8

0.9

1

A

N/A

N/A

1840

1805

1760

1695

1640

1590

1550

1500

B

N/A

1460

1445

1430

1420

1410

1395

1385

1375

1335

C

N/A

1280

1255

1240

1230

1220

1205

1190

1175

1170

D

N/A

1050

1050

1045

1040

1035

1020

1010

1000

985

2nd stage - Cooling

Motor speed

Static pressure

0.1

0.2

0.3

0.4

0.5

0.6

0.7

0.8

0.9 1 A

N/A

N/A

2030

1930

1875

1800

1760

1695

1640

1570

B

N/A

N/A

1800

1775

1735

1685

1640

1590

1545

1475

C

N/A

1655

1620

1605

1580

1560

1555

1515

1460

1405

D

N/A

1365

1355

1350

1340

1335

1315

1310

1290

1280

Table 39 CFM in heating for 120,000 BTU 2 stage ECM motor

Table 40 CFM in cooling for 120,000 BTU 2 stage ECM motor

50

ANNEX II : SPECIFICATION SHEET

INPUT
HIGH

45 000

60 000

75 000

105 000

120 000

LOW

31 500

42 000

52 500

73 500

84 000

OUTPUT

HIGH

42 750

57 000

71 475

99 750

115 080

LOW

29 925

39 900

50 033

69 825

80 556

EFFICIENCY

95.0

95.0

95.3

95.0

95.9

TEMP. RISE

40-70 °F (22-39°C)

MAX CFM

HIGH

Please see Annex I

LOW

COOLING

COOLING CAPACITY (tons)

2

3.5 4 4

5

MOTOR HP

1/2

3/4

3/4 1 1

INPUT

HIGH

45 000

60 000

75 000

105 000

120 000

LOW

31 500

42 000

52 500

73 500

84 000

OUTPUT

HIGH

42 750

57 000

71 775

99 750

115 200

LOW

29 925

39 900

50 243

69 825

80 640

EFFICIENCY

95.0

95.0

95.7

95.0

96.0

TEMP. RISE

40-70 °F (22-39°C)

MAX CFM

Please see Annex I

COOLING CAPACITY (tons)

2

3.5 4 4

5

MOTOR HP

1/2

1/2

3/4 1 1

INPUT

45 000

60 000

75 000

105 000

120 000

OUTPUT

42 750

57 000

71 475

100 065

115 440

EFFICIENCY

95.0

95.0

95.3

95.3

96.2

TEMP. RISE

40-70 °F (22-39°C)

MAX CFM

Please see Annex I

COOLING CAPACITY (tons)

2

3.5 4 4

5

MOTOR HP

1/2

1/2

3/4 1 1

Altitude (ft)

Unit size (Btu/hr)

Vent pipe diameter (in.)

2"

3"

0 to 4500 ft

45,000

70

90

60,000

45

90

75,000

30

90

105,000

N/A

70

120,000

N/A

40

Altitude (ft)

Unit size (Btu/hr)

Vent pipe diameter (in.)

2''

3''

0 to 4500 ft

15,000

300

N/A

30,000

180

N/A

45,000

70

90

60,000

70

90

75,000

70

90

105,000

N/A

80

120,000

N/A

65

Table 41 2 stage variable speed gas furnace (ECM)

Table 44 Maximum equivalent straight vent length for 1 stage unit (1-D)

Table 42 2 Stage fixed speed gas furnace (PSC)

Table 43 1 Stage fixed speed gas furnace (PSC)

Table 45 Maximum equivalent straight vent length for modulating and 2 stage unit (M-V;2-D and 2-V)

51

52