Goodman GMVM, ACVM, GCVM, AMVM Service Instructions Manual

Service Instructions

96% Modulating Gas Furnaces

ACVM, AMVM, GCVM, GMVM

& Accessories

This manual is to be used by qualified, professionally trained HVAC technicians only. Goodman does
not assume any responsibility for property damage or personal injury due to improper service
procedures or services performed by an unqualified person.

is a registered trademark of Maytag Corporation or its related companies and is used under license to Goodman Company, L.P., Houston, TX. All rights reserved.

Copyright © 2011 - 2013 Goodman Manufacturing Company, L.P.

RS6612001r9

November 2013

1

TABLE OF CONTENTS

IMPORTANT INFORMATION ........................... 2-3

PRODUCT IDENTIFICATION ........................ 4 - 7

ACCESSORIES........................................... 8 - 10

LIGHTING INSTRUCTIONS ...............................11

PRODUCT DESIGN ...................................12 - 31

OPERATION ...............................................32 - 56

COMFORTNET™ SYSTEMS............................58

ABBREVIATIONS & DEFINITIONS ....................59

ABBREVIATIONS & OPERATION .....................60

SERVICE AND OPERATION......................61 - 62

OPERATIONAL CHECKS ..........................63 - 64

MAINTENANCE ..................................................65

SERVICING TABLE OF CONTENTS ................66

SERVICING .................................................67 - 74

TROUBLESHOOTING................................75 - 79

STATUS CODES...............................................80

IMPORTANT INFORMATION

Pride and workmanship go into every product to provide our customers with quality products. It is possible, however,
that during its lifetime a product may require service. Products should be serviced only by a qualified service technician
who is familiar with the safety procedures required in the repair and who is equipped with the proper tools, parts, testing
instruments and the appropriate service manual. REVIEW ALL SERVICE INFORMATION IN THE APPROPRIATE

SERVICE MANUAL BEFORE BEGINNING REPAIRS.

IMPORTANT NOTICES FOR CONSUMERS AND SERVICERS

RECOGNIZE SAFETY SYMBOLS, WORDS AND LABELS

WARNING

T

O PREVENT THE RISK OF PROPERTY DAMAGE, PERSONAL INJURY, OR DEATH,
DO NOT STORE COMBUSTIBLE MATER IALS OR USE GASOLINE OR OTHER
FLAMMABLE LIQUIDS OR VAPORS IN THE VICINITY OF THIS APPL IANCE.

WARNING

G

OODMAN WILL NOT BE RESPONSIBLE FOR ANY INJURY OR PROPERTY DAMAGE ARISING FROM IMPROPER SERVICE OR SERVICE PROCEDURES.

I

F YOU INSTALL OR PERFORM SERVICE ON THIS UNIT, YOU ASSUME RESPONSIBILITY FOR ANY PERSONAL INJURY OR P ROPERTY DAMAGE WHICH

MAY RESULT.

M

ANY JURISDICTIONS REQUIRE A LICENSE TO INSTALL O R SERVICE HEATING AND A IR CONDITIONING EQUIPMENT.

HIGH VOLTAG E
D

ISCONNECT ALL POWER BEFOR E SERVICING OR

INSTALLING THIS UNIT.
BE PR ESENT.
DAMAGE, PERSO NAL INJURY OR DEATH.

2

WARNING

MULTIPLE POWER SOURCES MAY

FAILURE TO DO SO M AY CAU SE PROPERTY

IMPORTANT INFORMATION

Speci al Wa r ning for Inst allation of Furnace or Air Handling Units in
Enclosed A reas such as Garage s, Utility Ro oms or Parki ng A r eas

Carbon monoxide producing devices (such as an automobile, space
heater, gas water heater, etc.) should not be operated in enclosed areas
such as un ve n tilated garages, ut ility rooms or parking areas because of
the danger of car bon monox ide (CO) poisoning resulting from the exhaust
emissions. If a furnace or air handler is installed in an enclosed area such
as a garage, utility room or parking area and a carbon monoxide producing
device is operated therein, there must be adequate, direct outside
ventilation.

This ventilation is necessary to avoid the danger of CO poisoning which
can occur if a carbon monoxide producing device continues to operate in
the enclosed area. Carbon monoxide emissions can be (re)circu l a ted
throughout the structure if t he furnace or air han dler is operating in any
mode.

CO can cause serious illness in clud ing per man e nt brain dama ge or deat h.

To locate an authorized servicer, please consult your telephone book or the dealer from whom you purchased this
product. For further assistance, please contact:

CONSUMER INFORMATION LINE
GOODMAN® BRAND PRODUCTS

TOLL FREE

1-877-254-4729 (U.S. only)

email us at:

[e-mail]

fax us at: [phone]

(Not a technical assistance line for dealers.)

(Not a technical assistance line for dealers.) Your telephone company will bill you for the call.

is a registered trademark of Maytag Corporation or its related companies and is used under license to Goodman Company, L.P., Houston, TX. All rights reserved.

CONSUMER INFORMATION LINE

AMANA® BRAND PRODUCTS

TOLL FREE

1-877-254-4729 (U.S. only)

email us at:

[e-mail]

fax us at: [phone]

(Not a technical assistance line for dealers.)

Outside the U.S., call 1-713-861-2500.

3

PRODUCT IDENTIFICATION

The model and manufacturing number are used for positive identification of component parts used in manufacturing.
Please use these numbers when requesting service or parts information.

GMVM960603BXAA

PRODUCT
TYPE:

G: G oodman
A: Amana

Brand

®

SUPPLY TYPE

M: Upflow/Horizontal
C : Downflow/Hori z ontal

FURNACE TYPE

V: Variable-Speed

COMMUNICATION FEATURE

M: Modulating Furn ac e
4-Wir e Comm unic ation Re ady

NOMINAL INPUT

060: 60,000 Btuh
080: 80,000 Btuh
10 0: 100,000 B tuh
11 5: 115,000 B tuh

AFUE

96 : 96%

AIRFLO W
CAPABILITY
@ 0.5" ES P

3: 120 0
4: 160 0
5: 200 0

CABINET
WID TH

B: 17-1/2"
C: 2 1"
D: 2 4- 1/2 "

MAJOR
REVISION

A: Initial Release

MINOR
REVISION

A: Initial R elease

ADD IT IO NAL
FEAT URE S

N: Natural Gas
X: Low NOx

is a registered trademark of Maytag Corporation or its related companies and is used under license to Goodman Company, L.P., Houston, TX. All rights reserved.

4

PRODUCT IDENTIFICATION

MODEL # MFG. # DESCRIPTION

, Downflow/Horizontal Left and Right, 40" tall,

same as AA revision above, but BA revision

Upflow/Horizontal Left or Right, 40" tall, Induced

same as AA revision above, but BA revision

ACVM96******

ACVM96******

AMVM96******

AMVM96******

ACVM96******AA

ACVM96******BA

AMV M96******AA

AMV M96******BA

Amana® Brand 96% M odulating Gas Furnace

Induced Draft, ClimateTalk™ communicating furnace. Modulating gas input fr om 35% -100% of
rated input. 4 wire serial ECM motor. Independent humidification with capable thermostat.

Amana® Brand 96% M odulating Gas Furnace,

models furnace cabinet Air Leakage must be <2.0%.

Amana® Brand 96% M odulating Gas Furnace,

Draft, ClimateTalk™ communicating furnace. Modulating gas input fr om 35% -100% of rated input.
4 wire serial ECM motor. Independent humidification wit h capable thermostat.

Amana® Brand 96% M odulating Gas Furnace,

models furnace cabinet Air Leakage must be <2.0%.

MODEL # MFG. # DESCRIPTION

GCVM96******

GCVM96******

GM VM96******

GM VM96******

GCVM96******AA

GCVM96******BA

GMVM 96******AA

GMVM 96******BA

Goodman® Brand 96% Modulating Gas Furnace

Induced Dra ft, ClimateTalk™ communicating furnace. Modulating gas input from 35% -100% of
rated input. 4 wir e serial ECM motor . Independent humidification with capable thermostat.

Goodman® Brand 96% Modulating Gas Furnace

models furnace cabinet Air Leakage must be <2.0%.

Goodman® Brand 96% Modulating Gas Furnace,

Induced Dra ft, ClimateTalk™ communicating furnace. Modulating gas input from 35% -100% of
rated input. 4 wir e serial ECM motor . Independent humidification with capable thermostat.

Goodman® Brand 96% Modulating Gas Furnace

models furnace cabinet Air Leakage must be <2.0%.

, Down flow/Horizontal Left and Right, 40" tall,

, same as the AA revision above but BA

Upflow/Horizon ta l Left or Right, 40" tall,

, same as the AA revision above but BA

5

PRODUCT IDENTIFICATION

MODEL # MFG # DESCRIPTION

The AFE18-60A control is designed for use wher e the indoor c oil is loc ated above/downst ream

. F or use with current ar c hit ec tural grey Goodman® and Amana® Br and 96% variable speed,

. F or use with current ar c hit ec tural grey Goodman® and Amana® B rand 96% variable

AFE18-60A

AMU1620
AMU1625
AMU2020
AMU2025

GMU162 0
GMU162 5
GMU202 0
GMU202 5

ASAS-10
ASAS-11
ASAS-12
ASAS-18

N/A

P1251305F
P1251306F
P1251307F
P1251308F

N/A

P1251301F
P1251302F
P1251303F
P1251304F

Foss il Fuel Kit.

of a gas or fossil fuel furnace when used wit h a heat pump. I t will operate with single and t wo stage heat
pumps and single and two st age furnaces. The AFE18-60A control will turn the heat pump unit off when t he
fur n ace is turned on. A n a nti-short c ycle featur e in itiates a 3 minute timed off dela y when the compressor goes
off.

Media Air Cleaner

modulat i ng f urnac e models. The Amana (AMU*) and Goodman ( GMU*) Media A ir Cleaner is a high efficiency
air filtration device designed to remov e d irt, d ust , pollen and other microscopic parti c les from the air pa ssing
through it. Flexible perf or mance range up to 2,000 CF M capacity. The air cleaner should be installed in the
system so that all the system air is c irculated through the air cleaner. T he air c leaner will only r emov e the
airbor n e c o ntaminants delivered t o i t. Maximum performance is obt a ined wh en the syste m blower is set for
continuous operation. Carbon filter s (optional) are available.

Electronic Air Cleaner

speed, modulating f ur nace models. The High-Efficiency E lectronic Air Cleaner is designed t o r emov e air
contaminants down t o .01 microns. Carbon filters (optional) remove odors. Dual indicat or lights show unit
operation at a gla nc e . Electronic prov ing swit ch cycles the air cleaner On/Off w ith the system fan. D urable
po wder-coat pa int finish resists corrosio n.

CFB17

CTK01

CTK01BA

CTK02**

CTK03A*

P1228004F

CTK01AA

CTK01BA

CTK02**

CTK03A*

Do wn flow Subb ase Kit

are available for the following f u r na ce widths: 17 .5" wide (CFB17), 21" wid e (CFB21) and 24" wid e (CFB24).
The kits must be used to preve nt ex cessive t emper ature f rom reaching co mbustible mate rials, if the fur n ace is
installed on a co mbustible floor. T his subbase eff ec tiv ely separat ed the fur nac e base and plenum f rom
combust ible materials. To ensure safe inst allat ion, do not install the c ount er flow floor base directly on
carpeting, tile, or other combustible mat erial other than wood flooring.

Co mmu n icating T hermostat K i t

communicat ing sy stem. Designed for use wit h compatible Amana® B rand or Goodman® Brand Air Handlers
or Furnaces and outdoor split A C or H eat P ump units. This thermostat supports up to three stages of heat, t wo
stages of cooling, dual fuel applications, dehumidific at ion, filter maintenance reminders, outdoor temperat ur e
display and advanc ed menus inc luding diagnostics. The CTK01AA k it includes a communicating t ouchscreen
thermo st at and sub base, 230V-24V 40va transformer, terminal blocks( 2 ), wire j umpers,
mounting sc rews, installation manual and homeowner guide.

Co mmu n icating T hermostat K i t

communicat ing sy stem. Designed for use wit h compatible Amana® B rand or Goodman® Brand Air Handlers
or Furnaces and outdoor split A C or H eat P ump units. This thermostat supports up to three stages of heat, t wo
stages of cooling, dual fuel applications, dehumidific at ion, filter maintenance reminders, outdoor temperat ur e
display and advanc ed menus inc luding diagnostics. The CTK01BA kit includes a communicating t ouc hscreen
thermo st at and sub base, t ermi nal blo cks(2), mount i ng scre ws, i nst alla tion manual and homeowner guid e.

Co mmu n icating T hermostat K i t

system. Designed for use wit h c ompatible A mana® Brand or G oodman® Brand A ir Handlers or Furnaces and
outdoor split A C or Heat Pump units. The CTK02** thermostat features full color, high definition display ,
advanc ed programming opt ions including humidific at ion control & heat and cool maximum temperat ur e
sett ings, a U S B pl ug allo win g de alers the ability to insert pre-progra mmed operating paramete r s and deal er
information by use of an online data entry system.

Co mmu n icating T hermostat K i t

for use with compatible Amana® Brand or Goodman® Brand A ir Handlers or Furnaces and outdoor split AC or
Heat P u mp units. The CTK03A* the r mostat features full c ol or hi gh de finition di splay, c a n b e used with
RedLINK wir eless accessories.

. For use with Goodman®, & Amana® Brand modulating furnace models. These kits

- Digitally communicating touchscreen thermostat, a necessar y part of any

- Digitally communicating touchscreen thermostat, a necessar y part of any

- Digitally communicating thermost at, a necessary part of any communic ating

- Digitally communicating touchscreen thermost at from Honeywell. Designed

6

PRODUCT IDENTIFICATION

MODEL # MFG # DESCRIPTION

DCVK-20

DCVK-30

DEHUM1

EFR01

0170K00000S

0170K00001S

P1254001F

P1254002F

P1227801F

P1221001

P1221002F

N/A

N/A

Concentric Vent Kit

terminat ions of a dir ec t v ent furnace to be "concentrically" vent ed through a wall or roof. T his kit allows a single
penetration to support terminations for bot h the vent/flue and the combustion air intake pipe. The DCVK-2 0 ( 2")
and DCV K-30 (3") kits are certified for models listed above. See specification sheets on future models for use
of the vent kit.

Dehumidistat.

models. Wall mounted, 24 volt humidity control available as a Dehumidistat used t o r educ e the airflow in the air
condit ioning mode when necessary to lower the humidity in an occ upi ed home to prevent dew build-up
assoc iated with high humidity levels. This contr o l features a moisture-sensitiv e nylon element and also
provides positive ON-OFF settings for manual operat ion . The control is a normally closed switch that opens on
humidity rise causing the blower to switch to a lower speed to c ontrol the humidit y within the struct ure.

E xt ern al F ilter R ack Kit

modulating gas furnaces. This kit is intended t o pr ovide a location, exter nal to the f ur nac e c asing for installation
of a per manent filter. The rac k is mounted over the in door air blow er c ompart ment ar ea of either side panel,
and provide filter retention as well as a loc ation for attaching r e turn air ductwork.

Side Wall Only Concentric Vent Kit

2" - 3" v ent systems. The vent ki t must terminate outside the str ucture. This kit is NOT intended for use with
single pipe (indirect vent) installations.

Side Wall Only Concentric Vent Kit

2" vent systems. The ven t kit must ter minate outside the structure. T his kit is NOT int ended for use with single
pipe (indirect vent) installation

. F or use with Amana® Br and Modulati ng furnace models. This kit is designed to allow

For use wit h Goodman® & Amana® Br and two-stage variable speed modulating furnac e

. F or use with Goodman® and A mana® Brand 96% upflow, variable speed *M VM

. For use with 96% modulating f urn ac e models. This kit is to be used with

. For use with 96% modulating f urn ac e models. This kit is to be used with

MODE L # MFG # DESCRIPTION

LPLP03

LPKMOD060UF

LPKMOD080UF

LPKMOD100UF

LPKMOD115UF

LPKMOD060CF

LPKMOD080CF

LPKMOD100CF

RF000142

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

LP Gas Low Pressure Kit

single-stage, tw o-stage and m odulating furnaces c onverted to LP gas. The kit monitors gas line pres sure wit h
a pressure sw it ch and will open the circuit to t he gas v alve if the LP tank press ure gets low .

LP Conversion Kit

with LP orific es and modulat ing LP gas valve. New burners designed for use with LP gas are also included.

LP Conversion Kit

with LP orific es and modulat ing LP gas valve. New burners designed for use with LP gas are also included.

LP Conversion Kit

with LP orific es and modulat ing LP gas valve. New burners designed for use with LP gas are also included.

LP Conversion Kit

with LP orific es and modulat ing LP gas valve. New burners designed for use with LP gas are also included.

LP Conversion Kit

with LP orific es and modulat ing LP gas valve. New burners designed for use with LP gas are also included.

LP Conversion Kit

with LP orific es and modulat ing LP gas valve. New burners designed for use with LP gas are also included.

LP Conversion Kit

with LP orific es and modulat ing LP gas valve. New burners designed for use with LP gas are also included.

D ra in Coup ling Kit

kit prevents condensat e from get ting in the inducer an d routes the condens ate t o a drain.

. Des igned for application on Goodman® and Amana® Brand's 80% and 90%

For use with A/GMVM9603BX** furnace. The kit comes with a gas manifold equipped

For use with A/GMVM960805CX** furnace. The kit comes with a gas manifold equipped

For use with A/GMVM961005DX** furnace. The kit comes with a gas manifold equipped

For use with A/GMVM961155DX** furnace. The kit comes with a gas manifold equipped

For use with A/GCVM960604CX** furnac e. The kit comes with a gas manifold equipped

For use with A/GCVM960805DX** furnac e. The kit comes with a gas manifold equipped

For use with A/GCVM961005DX furnac e. The kit comes with a gas manifold equipped

For use when the drain/vent elbow has been removed in a horizontal left installation . This

7

ACCESSORIES

AMANA® BRAND Furnace Accessories

MODEL

NUM BER

Description

AMVM960603BX** X X X X X X

AMVM960805CX** X X X X X X

AMVM961005DX** X X X X X X

ACVM960604CX** X X X X X X X

ACVM960805DX** X X X X X X X

MODEL

NUM BER

Description

AMVM960603BX** X X XXXXX

AFE180-60A AMU / GMU ASAS / GSAS CFB17 CFB21 CFB24 CTK01* CTK02** CTK03AA

Fossil Fuel

Kit

0170K00000S 0170K00001S DCVK-20 DCVK-30 D EHUM1 EFR01

Concentric

Side Wall

Vent Kit (3")

Media

Air Cleaners

Not used in this application

Concentric

Side Wall

Vent Kit (2")

Electronic

Air Cleaner

Concentric

Vent Kit

(2")

Downflow

Subbase

17 .5"

Concentric

Vent Kit

(3")

Downflow

Subbase

21"

Dehumidistat

Downflow

Subbase

24.5"

External

Filter
Rack

Com.

Thermostat

Kit

LPKMOD­06/08/11UF

LPKMOD-

06/08/11CF

Propane

Gas

Conversion

Kit

Com

Thermostat

Kit

-M odulating,
High Def

Com

Thermostat

-M odulating,
High Def

Kit

AMVM960805CX** X X X X X X

AMVM961005DX** X X X X X X

ACVM960604CX** X X XXXXX

ACVM960805DX** X X XXXXX

Not used in this application

8

ACCESSORIES

g

g

GOODMAN® BRAND Furna ce Accessories

MODEL

NUM BER

Description

GM VM 960603B X** X X X X X X

GM VM 960805C X** X X X X X X

GMVM961005DX**XXX XXX

GM VM 961155DX** X X X X X X

GCVM960604CX** X X X X X X X

GCVM960805DX** X X X X X X X

GCVM961005DX**XXX XXXX

MODEL

NUM BER

Description

GMVM960603BX**XXXXXXXX

AFE180-60A AMU / GMU ASAS / GSAS CFB 17 CFB21 CFB24 CTK01* CTK02** CT K03AA

Fossil Fuel

Kit

0170K00000S 0170K00001S DC VK-20 D CVK-30 D EH UM1 EFR01

Concentric

Side Wall

Vent Kit (3")

Media

Air Cleaners

Not used in this application

Concentric

Side Wall

Vent Kit (2")

Electronic

Air Cleaner

Concentric

Vent Kit

(2")

Downflow

Subbase

17.5 "

Concentric

Vent Kit

(3")

Downflow

Subbase

21"

Dehumidistat

Downflow

Subbase

24.5"

External

Filte r

Rack

Com.

Thermostat

Kit

LPKMOD-

06/ 08/11UF

LPKMOD-

06/08 /11CF

Propane

Gas

Conversion

Kit

Com

Thermostat

Kit

-M odulating,
h Def

Hi

RF 000142

Drain Kit

Com

Thermostat

Kit

-M odulating,
h D ef

Hi

GMVM960805CX**XX XXXXX

GMVM961005DX**XX XXXXX

GMVM961155DX**XX XXXXX

GCVM960604CX**XXXXXXXX

GCVM960805DX**XXXXXXXX

GCVM961005DX**XX XXXXX

Not used in this application

9

ACCESSORIES

EXTERNAL FIL TER RACK (EFR01 )

Used on 96% Upflow Modulating Furnaces

CONCENTRIC VENT CONVERSION KIT ( DCVK-20

The DCVK-20 (2") or the DCVK-30 (3") is a concentric vent

kit approved with furnaces listed in this manual.
This concentric vent kit allows for vertical or horizontal vent

termination. The illustrations give a brief view of the kit and
its application.

Vent

Strap
(Field Supplied)

Combustion Air

Vent

See the section in this manual under "Vent Flue and Com­bustion Air Pipe Terminations" for more information or con­sult the Installation and Operating Instructions (IO-619*).

UNIT SIDE

PANEL

FRONT

OF UNIT

BASE

OF UNIT



 DCVK-30)



Roof Boot/Flashing
(Field Supplied)

RETURN AIR

CUTOUT AREA

Combustion Air

Vent

SLOTS IN FILTER
CLEAR SCREWS

ON UNIT

Maintain 12" (18" for Canada)
minimum clearance above highest
anticipated snow level. Maximum of
24" above roof.

BLOWER DECK

LOWER EDGE

SCREW

SCREWS

FILTER RACK ASSEMBLY

(FACE FILTER OPENING

TOWARDS FRONT

OF UNIT)

Flush to

1" maximum

Combustion Air

45 Elbow
(Field Supplied)

DCVK

(Horizontal Installation)

SIDE WALL VENT KIT (0170K00000S)

This side wall only vent kit #0170K00000S is to be used
with 2” - 3” vent systems. This kit is NOT intended for use
with single pipe (indirect vent) installations.

The vent kit must terminate outside the structure and may
be installed with the intake and exhaust pipes located side­by-side or with one pipe above the other.

See the section in this manual under "Vent Flue and Com­bustion Air Pipe Terminations" for more information or con­sult the Installation Instructions (IO-635).

Support (Field Supplied)

45 Elbow
(Field Supplied)

Vent

Combustion Air

DCVK

(Vertical Installation)

The vent kit must terminate outside the structure and may
be installed with the intake and exhaust pipes located side­by-side or with one pipe above the other.

See the section in this manual under "Vent Flue and Com­bustion Air Pipe Terminations" for more information or con­sult the Installation Instructions (IO-805).

Horizontal Installation

SIDE WALL VENT KIT (0170K00001S)

This side wall only vent kit #0170K00001S is to be used
with 2” vent systems. This kit is NOT intended for use with
single pipe (indirect vent) installations.

10

Ve rtic a l In s ta lla tio n

LIGHTING INSTRUCTIONS

FOR YOUR SAFETY

READ BE FO RE OPERATING

If you do not follow these instructions

WARNING:

explosion may result causing propertyExactly, a fire or
damage, personal injury or

loss of life.

A. This appliance does not have a pilot. It is equipped
with an ign itio n device which automatically lights
the burner. Do not try

to light the burner by hand.
B. smell all around the appliance

BEFORE OPERATING

area for gas. Be sure to smell next to the floor
settle on the floor.

WH AT TO DO IF YOU SMELL GAS

Do not try to light any appliance.
Do not touch any electric switch;
do not use any phone in your building.
Immediately call your gas supplier from a neighbor's
phone. Follow the gas supplier's instructions.
If you cannot reach your gas supplier,
call the fire department.

C. Use only your hand to push in or turn the gas control lever.
Never use tools. If the lever will not push in or 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.

D. Do not use this appliance if any part has been underwater.
Immediately call a qualified service technician to inspect
the appliance and to replace any part of the control
system and any gas control which has been underwater.

LIRE AVANT DE METTRE

EN MARCHELIRE

AVERTISSEMENT :

la lettre les instructions dans le presént manuel
risque de déclencher un incendie ou une explosion
entraînant des dommages matériels, des lesions
corporelles ou la perte de vies humaines.

Cet appareil ne comporte pas de veilleuse. Il est

A.

muni d'un dispositif d'allumage qui allume
automatiquement le brûleur. Ne pas tenter
d'allumer le brûleur manuellement.

B. AVANT DE LE FAIRE FONCTIONNER,

une odeur de gaz. Renifler prés du plancher, car
certains gaz sont plus lourds que l'air et
peuvent s'accumuler au niveau du sol.

QUE FAIRE S'IL Y A UNE ODEUR DE GAZ

Ne pas tenter d'allumer d'appareils.
Ne toucher à aucun interrupteur; ne pas vous servir
des téléphones dans le bâtiment.

Appelez immédiatement votre fournisseur de gaz depuis
un voisin. Suivez les instructions du fournisseur de gaz

Si vous ne pouvez rejoindre le fournisseur de gaz,

appelez le ser vice des incendies.»
C. Ne pousser ou tourner la manette d'admission du gaz
qu'à la main. Ne jamais emploer d'outil à cette fin.

Si la manette reste coincée, ne tenter pas de la
réparer; appelez un technicien qualifié. Quiconque
tente de forcer la manette ou de la réparer peut
provoquer une explosion ou un incendie.»

D. Ne pas se servir de cet appareil s'il a été plongé dans
l'eau, même partiellement. Faire inspecter l'appareil
par un technicien qualifié et remplacer toutr partie du

systéme de contrôle et toute commande qui ont été
plongées dans l'eau.»

Quiconque ne respecte pas à

er

OPERATING INSTRUCTIONS

STOP

!

STOP. "B"

"OFF"

GAS
INLET

ARRIVEE

DU GAZ

ROBINET A GAZ
MANUEL, EN POS
"ON/MARCHE"

MANUAL GAS
LEVER SHOWN
IN "ON" POS

1. Read the safety information above on
this label.

2. Set the thermostat to lowest setting.

3. Turn off all electric power to the appliance.

4. This appliance is equipped with an ignition
device which automatically lights the bur ner.
Do not try to light the burner by hand.

5. Push the gas control lever to Position.
Do not force.

6. Wait five (5) minutes to clear out any gas. Then
smell for gas, including near the floor. If you
then smell gas, Follow
in the safety. information ab ov e
on this label if you don't smell
gas, go to next step.

7. Push gas control lever
to

"ON".

8. Replace access panel.

9. Turn on all electric
power to the appliance.

10. Set thermostat to desired setting.

11. If the appliance will not operate,
follow the instructions "To Turn
Off Gas To Appliance" and call your
service technician or gas com pa ny.

TO TURN OFF GAS TO APPLIANCE

1. Set the thermostat to lowest sett ing.

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

3. Push the gas control lever to Position.
Do not force.

4. Replace control access panel.

"OFF"

MISE EN MARCHE

ARRÊTEZ

1. Lisez les instructions de sécurité dans la
section supérieure de cette étiquette.

.

2. Régler le thermostat à la température la plus basse.

3. Couper l'alimentation électrique de l'appareil.

4. Cet appareil menager etant dote d'un systeme
d'allumage automatique, ne pas essayer à
allumer le brûleur manuellement.

5. Pousse le levier du contrÔle du gaz a

position.

6. Attendre cinq (5) minutes pour laisser echapper tout le

gaz. Renifler tout autour de l'appareil, y compris prés du
plancher, pour déceler une odeur de gaz. Si c'est le cas,

Passer à l'etape B des instructions de secu rite

ARRÊTEZ.

sur la portion superieure de cette etiquette.
S'il n'y a pas d'odeur de gaz, passer à l'etàpe suivante.

7. Pousse le levier du contrôle du gaz à
position.

8. Remettre en place le panneau d'accés.

9. Mettre l' appareil sous tension.

10. Régler le thermostat à la temp érature désirée.

11. Si l'appareil ne se met pas en marche, suivre les
instructions intitulées Comment couper l'admission
de gaz de l'appareil et appeler un technicien
qualifié ou le fournisseur de gaz.

"OFF/ ARRET"

"ON/MARCHE"

POUR COUPER L'ADMISSION
DE GAZ DE L'APPAREIL

1. Régle r le thermostat à la t emp ér a t ure la plus bassé .

2. Couper l'alimentation électrique de l'appareil s'il
faut procéder à des operations d'entretien.

3. Pousse le levier du contrôle du gaz à
position.
Ne pas forcer.

4. Remettre en place le panneau d'accés.

"OFF/ ARRET"

0140F00996 REV A

11

PRODUCT DESIGN

Adhere to the following warnings and cautions when installing, adjusting, altering, servicing, or operating the furnace. To
ensure proper installation and operation, thoroughly read this manual for specifics pertaining to the installation and appli­cation of this product.

WARNING

TO

PREVENT PERSONAL INJURY OR DEATH DUE TO IMPROPER
INSTALLATION, ADJUSTMENT, ALTERATION, SERVICE OR MAINTENANCE
REFER TO THIS MANUAL
INFORMATION, CONS ULT A QUALIFIED INSTALLER, SERVICER AGENCY OR
THE GAS SUPPLIER

. FOR

ADDITIONAL ASSISTANCE OR

.

WARNING

IF

THE INFORMATION IN THESE INSTRUCTIONS IS NOT FOLLOWED

EXACTLY, A FIRE OR EXPLOSION MAY RESULT CAUSING PROPERTY

,

DAMAGE

PERSONAL INJURY OR LOSS OF LIFE

DO

NOT STORE OR USE GASOLINE OR OTHER FLAMMABLE VAPORS AND

LIQUIDS IN THE VICINITY OF THIS OR ANY OTHER APPLIANCE

.

.

WHAT TO DO IF YOU SMELL GA S:

O NOT TRY TO LIGHT ANY APPLIANCE

D



D

O NOT TOUCH ANY ELECTRICAL SWITCH; DO NOT USE ANY PHONE



IN YOUR BUILDING

I

MMEDIATELY CALL YOUR GAS SUPPLIER FROM A NEIGHBOR’S



PHONE

. F

F YOU CANNOT REACH YOUR GAS SUPPLIER, CALL THE FIRE

I



DEPARTMENT

I

NSTALLATION AND SERVICE MUST BE PERFORMED BY A QUALIFIED

INSTALLER, SERVICE AGENCY OR THE GAS SUPPLIER

.

OLLOW THE GAS SUPPLIER’S INSTRUCTIONS

.

.

.

.

W ARNING

T

HIS PRODUCT CONTAINS OR PRODUCES A CHEMICAL OR CHEMICALS
WHICH MAY CAUSE SERIOUS ILLNESS OR DEATH AND WHICH ARE
KNOWN TO THE STATE OF CALIFORNIA TO CAUSE CANCER, BIRTH
DEFECTS OR OTHER REPRODU C TIVE HARM

.

WARNING

TO

PREVENT POSSIBLE PROPERTY DAMAGE, PERSONAL INJURY OR

DEATH DUE TO ELECTRICAL SHOCK, THE FURNACE MUST BE LOCATED TO

,

PROTECT THE ELECTRICAL COMPONENTS FROM WATER

.

CARBON MONOX IDE POI SONING HAZARD

Spec ial Warnin g for Instal lat i on of Furna c e or A ir Ha n dl i n g Un it s in
Enclosed Areas such as Garages, Utility Rooms or Parking Areas

Carbon monoxide producing devices (such as an automobile, space
heater, g as water heater, etc.) should not be operated in enclosed areas
such as unventilated garages, utility rooms or parking areas because of
the danger of carbon monoxide (CO) poisoning resulting from the exhaust
emissio ns. If a furnace or air ha ndler is installed in an enclosed area such
as a garage, utility room or parking area and a carbon monoxide producing
device is operated therein, there must be adequate, direct outside
ventilation.

This ventilation is necessary to avoid the danger of CO poisoning which
can occur if a carbon monoxide producing device co ntinues to operate in
the enclosed area. Carbon monoxide emissions can be (re)circulated
through out the structure if t he furnace or air handler is operating in any
mode.

WARNING

H

EATING UNIT SHOULD NOT BE UTILIZED WITHOUT REASON ABLE
ROUTINE, INSPECTION, MAINTENANCE AND SUPERVISION
BUILDING IN WHICH ANY SUCH DEVICE IS LOCATED WILL BE VACANT
CARE SHOULD BE TAKEN THAT SUCH DEVICE IS ROUTINELY INSPECTED
MAINTAINED AND MONITORED. IN THE EVENT THAT THE BUILDING
MAYBE EXPOSED TO FREEZING TEMPERATU RES AND WILL BE VACANT
ALL WATER-BEARING PIPES SHOULD BE DRAINED, THE BUILDING SHOULD
BE PROPERLY WINTERIZED, AND THE WATER SOURCE CLOSED. IN THE
EVENT THAT THE BUILDING MAY BE EXPOS ED TO FREEZING
TEMPERATURES AND WILL BE VACANT, ANY HYDRON IC COIL UNITS
SHOULD BE DRAINED AS WELL AND, IN SUCH CASE, ALTERNATIVE HEAT
SOURCES SHOULD BE UTILIZED

.

12

. IF

THE

CO can cause serious illness including permanent brain damage or death.

-

B10259-216

,

,

,

,

S

HOULD OVERHEATING OCCUR OR THE GAS SUPPLY FAIL TO SHUT OFF
TURN OFF THE MANUAL GAS SHUTOFF VALVE EXTERNAL TO THE
FURNACE BEFORE TURNING OFF THE ELECTRICAL SUPPLY

W ARNING

,

.

P

OSSIBLE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH DUE TO
FIRE, EXPLOSION, SMOKE, SOOT, CONDENSATION, ELECTRICAL SHOCK
OR CARBON MONOXIDE MAY RESULT FROM IMPROPER INSTALLATION
REPAIR OPERATION, OR MAINTENANCE OF THIS PRODUCT

WARNING

,

.

PRODUCT DESIGN

Electrostatic Discharge (ESD) Precautions
NOTE: Discharge body’s static electricity before touching

unit. An electrostatic discharge can adversely affect electri­cal components.

Use the following precautions during furnace installation and
servicing to protect the integrated control module from dam­age. By putting the furnace, the control, and the person at
the same electrostatic potential, these steps will help avoid
exposing the integrated control module to electrostatic dis­charge. This procedure is applicable to both installed and
non-installed (ungrounded) furnaces.

1. Disconnect all power to the furnace. Do not touch the
integrated control module or any wire connected to the
control prior to discharging your body’s electrostatic
charge to ground.

2. Firmly touch a clean, unpainted, metal surface of the
furnaces near the control. Any tools held in a person’ s
hand during grounding will be discharged.

3. Service integrated control module or connecting wiring
following the discharge process in step 2. Use caution
not to recharge your body with static electricity; (i.e.,
do not move or shuffle your feet, do not touch ungrounded
objects, etc.). If you come in contact with an ungrounded
object, repeat step 2 before touching control or wires.

4. Discharge your body to ground before removing a new
control from its container. Follow steps 1 through 3 if
installing the control on a furnace. Return any old or
new controls to their containers before touching any
ungrounded object.

WARNING

TO

PREVENT PROPERTY DAMAGE, PERSONAL INJURY OR DEATH DUE TO
FIRE, DO NOT INSTALL THIS FURNACE IN A MOBILE HOME, TRAILER, OR
RECR EATIONAL VEHICLE

.

Product Description

Features

General Information

The modulating furnace is part of the Goodman® brand &
Amana® brand family of communicating ready products. The
furnace may be used with conventional single or multi-stage
thermostats as well as Goodman CTK01 communicating
thermostats & CTK02** & CTK03 communicating-modulat­ing thermostats using the ClimateTalk™ communicating pro­tocol. Burner manifold pressure is controlled by negative air
pressure created by the draft inducer. Gas valve, pressure
switch assembly, and induced draft blower are linked to­gether by pneumatic tubing. The furnace features a Honeywell
gas valve capable of variable gas input rates as low as 35%
and up to 100% of rated input. Indoor air is delivered by an
Emerson UltraTech® ECM motor which bases the CFM need
off of the burner input. The modulating furnace operation is

based off of negative pressure created by the draft inducer.
The Integrated Furnace Control (IFC) receives commands
from the room thermostat. The IFC then controls the RPM of
the (3 phase) inducer by varying the frequency and voltage
to the inducer. This is known as variable frequency drive
(VFD)..

Acceptable Equipment Combinations

With CTK0* Communicating Thermostat:

1. Modulating furnace alone

2. Modulating furnace with Goodman® brand / Amana®
brand communicating split A/C or H/P unit (no sepa­rate dual fuel control is required)

3. Modulating furnace with non-communicating 1 stage
A/C split unit (can not support a 2 stage A/C or a non­communicating heat pump)

With Conventional Non-Communicating Thermostat
(Single or Multi-Stage)

1. Modulating furnace alone

2. Modulating furnace with Goodman / Amana communi­cating split A/C or H/P unit (a dual fuel thermostat or
separate dual fuel control is required for H/P)

3. Modulating furnace with non-communicating split A/C
or H/P (a dual fuel thermostat or separate dual fuel
control is required for H/P)

Product Application
This furnace is primarily designed for residential home-heat-

ing applications. It is NOT designed or certified for use in
mobile homes, trailers or recreational vehicles. Neither is it
designed or certified for outdoor applications. The furnace
MUST be installed indoors (i.e., attic space, crawl space,
or garage area provided the garage area is enclosed with an
operating door).

This furnace can be used in the following non-industrial com­mercial applications:

Schools, Office buildings, Churches, Retail stores,

Nursing homes, Hotels/motels,

Common or office areas

In such applications, the furnace must be installed with the
following stipulations:

• It must be installed per the installation instructions pro­vided and per local and national codes.

• It must be installed indoors in a building constructed on
site.

• It must be part of a ducted system and not used in a free
air delivery application.

• It must not be used as a “make-up” air unit.

• It must be installed with two-pipe systems for combus­tion air.

13

PRODUCT DESIGN

• All other warranty exclusions and restrictions apply This
furnace is an ETL dual-certified appliance and is appropri­ate for use with natural or propane gas (NOTE: If using
propane, a propane conversion kit is required).

Dual certification means that the combustion air inlet pipe is
optional and the furnace can be vented as a:

Non-direct vent (single pipe) central forced air furnace in
which combustion air is taken from the installation area or
from air ducted from the outside or,

Direct vent (dual pipe) central forced air furnace in which
all combustion air supplied directly to the furnace burners
through a special air intake system outlined in these in­structions.

This furnace may be used as a construction site heater ONLY if
all of the following conditions are met:

• The vent system is permanently installed per these in­stallation instructions.

• A room thermostat is used to control the furnace. Fixed
jumpers that provide continuous heating CANNOT be used
and can cause long term equipment damage.

• Return air ducts are provided and sealed to the furnace.

• A return air temperature range between 60ºF (16ºC) and
80ºF (27ºC) is maintained.

• Air filters are installed in the system and maintained dur­ing construction replaced as appropriate during construc­tion, and upon completion of construction.

• The input rate and temperature rise are set per the fur­nace rating plate.

• 100% outside air is provided for combustion air require­ments during construction. Temporary ducting can be
used.

NOTE: Do not connect the temporary duct directly to the
furnace. The duct must be sized for adequate combus­tion and ventilation in accordance with the latest edition of
the National Fuel Gas Code NFPA 54/ANSI Z223.1 or
CAN/CSA B149.1 Installation Codes.

• The furnace heat exchanger, components, duct system,
air filters and evaporator coils are thoroughly cleaned fol­lowing final construction clean up.

• All furnace operating conditions (including ignition, input
rate, temperature rise and venting) are verified according
to these installation instructions.

NOTE: The Commonwealth of Massachusetts requires that
the following additional requirements must also be met:

• Gas furnaces must be installed by a licensed plumber or
gas fitter.

• A T-handle gas cock must be used.

• If the unit is to be installed in an attic, the passageway to
and the service area around the unit must have flooring.

To ensure proper furnace operation, install, operate and
maintain the furnace in accordance with these installa­tion and operation instructions, all local building codes
and ordinances. In their absence, follow the latest edition of

the National Fuel Gas Code (NFPA 54/ANSI Z223.1), and/or
CAN/CSA B149 Installation Codes, local plumbing or waste water
codes, and other applicable codes.

A copy of the National Fuel Gas Code (NFPA 54/ANSI

Z223.1) can be obtained from any of the following:

American National Standards Institute

1430 Broadway

New York, NY 10018

National Fire Protection Association

1 Batterymarch Park

Quincy, MA 02269

CSA International

8501 East Pleasant Valley

Cleveland, OH 44131

The rated heating capacity of the furnace should be greater than
or equal to the total heat loss of the area to be heated. The total
heat loss should be calculated by an approved method or in
accordance with “ASHRAE Guide” or “Manual J-Load Calcula­tions” published by the Air Conditioning Contractors of America.

A copy of the CAN/CSA B149 Installation Codes can also be

obtained from:

CSA International

178 Rexdale Boulevard

Etobicoke, Ontario, Canada M9W 1R3

Location Requirements & Considerations

Follow the instructions listed below and the guidelines provided
in the Combustion and Ventilation Air Requirements section
when selecting a furnace location.

Furnace Models

The 96% AFUE modulating furnace comes in up flow / hori­zontal and down flow / horizontal models

Upflow Models

A/GMVM960603BX**
A/GMVM960805CX**
A/GMVM961005DX**
A/GMVM961155DX**

Down Flow Models

A/GCVM960604CX**
A/GCVM960805DX**

A/GCVM961005DX

14

PRODUCT DESIGN

Furnace Components
Heat Exchanger Assembly

The primary heat exchanger is a tubular type constructed of
high quality steel (stainless steel for Amana Brand, alumi­nized for Goodman) the heat exchanger assembly consists
of primary and secondary sections crimped together on a
back transition plate. The secondary heat exchanger is a
single pass coil consisting of stainless steel tubes and alu­minum fins. These stainless steel tubes are expanded on to
the aluminum fins to enhance heat transfer. Each tube in the
secondary heat exchanger contains an internal turbulator to
effectively scrub heat from the flue gases. Flue gas conden­sation takes place in the secondary heat exchanger as la­tent heat is transferred from the flue gases to heat the condi­tioned space.

Burners

Depending on the size of the furnace, each furnace will have
from three to five inshot burners. Burners are precisely con­structed of aluminized steel and designed to provide proper
ignition and flame stability. When converting the modulating
furnace to L.P. gas, the factory installed burners must be
replaced by burners that come in the L.P. kit.

Gas Manifold Assembly

Each gas manifold is fitted with the appropriate number of
#45 natural gas orifices. At 100% of gas input, each burner
will provide approximately 20,000 BTUH. The A/
GMVM951155DX models uses #43 gas orifices at 22,500
per hour. If converting to LP gas, the factory installed mani­fold assembly must be replaced by the manifold assembly
provided in the LP kit.

ECM Motor

An Emerson® UltraTech® four wire indoor fan motor provides
supply air to the conditioned space. This is the same motor
used on Goodman & Amana previous generation communi­cating furnaces.

Induced Draft Blower (IDB)

All modulating furnace models use a three phase induced
draft blower to draw flue gases through the heat exchanger.
The inducer uses ball bearings and is permanently lubricated.
This motor is driven at varying speeds by the VFD (variable
frequency drive) section of the IFC. The IFC takes typical
single phase power supplied to the furnace and converts it to
a three phase supply to operate the draft inducer at the de­sired speed. The windings of the induced draft motor will have
equal resistance +/- 5%. Normal resistance readings at room
temperature will range from 14-17 ohms. The voltage sup­plied by the IFC to drive the induced draft blower will vary
from 15-110 volts A/C between any two windings. This would
be read between any two of the three power wires between
the IFC and the induced draft blower. This voltage to the IBD
will vary between furnace models and is dependant on what
percentage of maximum fire is being called for. The power
wires are colored red, white, and black. A green colored ground
wire is also present.

Hot Surface Igniter

Modulating furnaces use a 115 volt silicon nitride hot surface
igniter. This is the familiar and reliable 0131F00008S igniter
with 17 second warm up time. At room temperature the ig­niter has a resistance range of 37 - 68 ohms. The H.S.I. is
connected electrically to the IFC by a 3/16" push-on connec­tion.

Gas Valve

Modulating furnaces use a 24 VAC pneumatically operated
gas valve by Honeywell. The valve is energized by the inte­grated furnace control on a call for heat, wired in series through
the front-cover pressure switch. The firing rate percentage is
determined by the negative pressure created by the opera­tion of the draft inducer. The gas valve is factory set and non-
adjustable in the field. Do not remove the seal covering the
regulator screws or attempt to adjust either of the regulator
screws.

Inductor Coil

Wired in series with ¾ and 1 HP ECM motors; the inductor
coil conditions the power supply to the motor, smoothing out
spikes and electrical noise. With voltage applied to one side
of the inductor coil, the output voltage to the motor should be
the same as incoming voltage.

Integrated Furnace Control (IFC)

The IFC is the main control center for the furnace. It has
many functions including;

• Receiving commands from the thermostat for heating,
and cooling, continuous fan operation.

• Receiving commands for dehumidification and humidi­fication.

• Communicating with the ECM motor for proper air de­livery to the conditioned space.

• Assuring safe ignition by checking the state of pres­sure switches and limit switches before and after igni­tion.

• Assuring safe operation by continuously monitoring the
presence of flame, the state of the pressure switches
and limit and roll out switches.

• Displays information on the dual seven segment dis­plays regarding thermostat call, air flow delivery and
fault status

• Controlling the speed of the induced draft blower by
variable voltage & frequency.

Features of the IFC:

Aux Terminals Located next to the low voltage connector,
there are two terminals labeled aux in & aux out. A factory
jumper is installed between these two terminals. As an op­tion; the jumper may be removed and the terminals wired up
to a normally closed float switch. The switch must be closed
for normal operation. If the switch is sensed open, the IFC
will:

• Terminate a call for gas heat.

15

PRODUCT DESIGN

• When the modulating furnace is installed with a com­municating thermostat and a non-communicating a/c
unit, the IFC will open the Y1 relay to turn off the con­densing unit

• Log and display an auxiliary open error code

• Once the auxiliary switch re-closes the IFC reverts
back to normal operation

Hum Terminals A pair of ¼” HUM terminals are located on
the board to power a humidifier. These are dry contacts rated
at 1 amp. A typical application of these contacts would be to
supply one of the Hum contacts with power from the L1 ter­minal and connect the remaining Hum terminal to a humidi­fier transformer primary. When used with the CTK02** or
CTK03 thermostat, these contacts will close with a call for
humidity and the furnace indoor blower will be powered at
continuous fan speed. When used with a 24 volt control sys­tem, the Hum contacts will close on a call for heat when the
induced draft blower is powered.

EAC Terminal A ¼” EAC terminal is provided. Any time the
indoor blower motor is powered, the EAC terminal will be
powered. Contact is rated for 1 amp

Flame Proving. Flame signal is continuously monitored by
the IFC. The flame rod, flame rod wire and proper grounding
are all critical to proving the presence of flame. Because of
the design of the Honeywell flame proving system, reading
flame signal with a microamp meter will not provide reliable
and consistent results and is therefore not a recommended
practice. The IFC has a built in warning (E6) if flame signal
is approaching the low threshold.

Field Test Mode This feature can be used by the service
technician to quickly bring a furnace up to high fire. Entering
field test mode will by-pass the staging routine and allow the
furnace to run at 100% of rated input. To use field test mode;
during a call for heat, press the fault recall button twice within
5 seconds, the display will change to Ft, then press and
hold the fault recall button for a few seconds until the display
flashes Ft. The furnace will stay in field test mode for 5 min­utes or until the call for heat is removed.

Dual 7 Segment Displays The modulating furnace IFC has
dual 7 segment displays to provide service information. This
information includes; present thermostat demand, CFM, and
fault codes.

Fault Recall This feature allows the service person to check
for any fault history. The board memory is capable of record­ing and storing 10 fault codes. To use this feature, the fur­nace must not have an existing thermostat call. Pressure
fault recall button from 2-5 seconds (until the display goes
blank) then release, all faults will be displayed one at a time,
beginning with the most recent, max of 3 consecutive faults
will be stored. When all errors have been displayed the dis­play returns to ON. To erase stored faults, hold the fault
recall button until the display starts flashing, then release.

WARNING

TO

PREVENT POSSIBLE EQUIPM EN T DAMAGE, PROPERTY DAMAGE
PERSONAL INJURY OR DEATH, THE FOLLOWING BULLET POINTS MUST BE
OBSERVED WHEN INSTALLING THIS UNIT

.

,

WARNING

P

OSSIBLE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH DUE TO
FIRE, EXPLOSION, SMOKE, SOOT, COND E NSATION, ELECTRICAL SHOCK
OR CARBON MONOXIDE MAY RESU LT FROM IMPROPER INSTALLATION
REPAIR OPERATION, OR MAINTENANCE OF THIS PRODUCT

.

• Centrally locate the furnace with respect to the proposed
or existing air distribution system.

• Ensure the temperature of the return air entering the fur­nace is between 55°F and 100°F when the furnace is heat­ing.

• Provide provisions for venting combustion products out­doors through a proper venting system. Special consider­ation should be given to vent/flue pipe routing and combus­tion air intake pipe when applicable. Refer to Vent/Flue
Pipe and Combustion Air Pipe -Termination Locations for
appropriate termination locations and to determine if the
piping system from furnace to termination can be accom­plished within the guidelines given. NOTE: The length of
flue and/or combustion air piping can be a limiting factor in
the location of the furnace.

• Locate the furnace so condensate flows downwards to the
drain. Do not locate the furnace or its condensate drain­age system in any area subject to below freezing tem­peratures without proper freeze protection. Refer to Con-
densate Drain Lines and Trap for further details.

• Ensure adequate combustion air is available for the fur­nace. Improper or insufficient combustion air can expose
building occupants to gas combustion products that could
include carbon monoxide. Refer to Combustion and Ven-

tilation Air Requirements.

• Set the furnace on a level floor to enable proper conden­sate drainage. If the floor becomes wet or damp at times,
place the furnace above the floor on a concrete base sized
approximately 1-1/2" larger than the base of the furnace.
Refer to the Horizontal Applications and Considerations
for leveling of horizontal furnaces.

• Ensure upflow or horizontal furnaces are not installed di­rectly on carpeting, or any other combustible material. The
only combustible material allowed is wood.

• A special accessory subbase must be used for upright
counterflow unit installations over any combustible mate­rial (including wood). Refer to subbase instructions for
installation details. (NOTE: A subbase will not be required
if an air conditioning coil is located beneath the furnace
between the supply air opening and the combustible floor.

,

16

PRODUCT DESIGN

• Exposure to contaminated combustion air will result in
safety and performance-related problems. Do not install
the furnace where the combustion air is exposed to the
following substances:

permanent wave solutions
chlorinated waxes or cleaners
chlorine-based swimming pool chemicals
water softening chemicals
deicing salts or chemicals
carbon tetrachloride
halogen type refrigerants
cleaning solutions (such as perchloroethylene)
printing inks
paint removers
varnishes
hydrochloric acid
cements and glues
antistatic fabric softeners for clothes dryers
and masonry acid washing materials

• Isolate a non-direct furnace from an area contaminated
by any of the above substances. This protects the non-
direct vent furnace from airborne contaminants. To ensure
that the enclosed non-direct vent furnace has an adequate
supply of combustion air, vent from a nearby uncontami­nated room or from outdoors. Refer to the Combustion
and Ventilation Air Requirements for details.

• If the furnace is used in connection with a cooling unit,
install the furnace upstream or in parallel with the cool­ing coil. Premature heat exchanger failure will result if
the cooling coil is placed upstream of the furnace.

For vertical (upflow or downflow) applications, the mini­mum cooling coil width shall not be less than furnace
width minus 1”. Additionally, a coil installed above an
upflow furnace or under a counterflow furnace may be
the same width as the furnace or may be one size
larger than the furnace. Example: a “C” width coil may

be installed with a “B” width furnace.

For upflow applications, the front of the coil and fur­nace must face the same direction.

• If the furnace is installed in a residential garage, position
the furnace so that the burners and ignition source are
located not less than 18 inches (457 mm) above the floor.
Protect the furnace from physical damage by vehicles.

• If the furnace is installed horizontally, ensure the access
doors are not on the “up/top” or “down/bottom” side of the
furnace.

• Do not connect this furnace to a chimney flue that serves
a separate appliance designed to burn solid fuel.

• On Counterflow Installations, the air conditioning coil must
be downstream on the supply (positive) side of the furnace
heat exchanger.

• Counterflow Installation over a noncombustible floor. Be­fore setting the furnace over the plenum opening, ensure
the surface around the opening is smooth and level. A tight
seal should be made between the furnace base and floor
by using a silicone rubber caulking compound or cement
grout.

• Counterflow Installation over a combustible floor. If instal-
lation over a combustible floor becomes necessary, use
an accessory subbase (see Specification Sheet applicable
for your model for details.) A special accessory subbase
must be used for upright counterflow unit installations over
any combustible material including wood. Refer to sub­base instructions for installation details. Follow the instruc­tions with the subbase for proper installation.

Do not install the furnace directly on carpeting, tile, or other

combustible material other than wood flooring. (NOTE: The
subbase will not be required if an air conditioning coil is
installed between the supply air opening on the furnace
and the floor.)

CLEARANCES AND ACCESSIBILITY

*MVM96* MINIMUM CLEARNACE TO COMBUSTIBLE MATERIALS

(INCHES)

POSITION* FRONT SIDES REAR TOP FLUE FLOOR

Upflow30010C

HorizontalAlcove6040C

* = All posit ioning is determined as in st alled unit is viewed from the front.
C = I f pl aced on combust ible floor, f l oor M U ST be w ood only.
NC = For in st al l ation on non-combustible fl oor s only. A com bustible
subbase must be used f or in s t al l at ions on combustible floor in g.

*CVM96* MINIMUM CLEARNACE TO COMBUSTIBLE MATERIALS

(INCHES)

POSITION* FRONT SIDES REAR TOP FLUE FLOOR

Upflow10010NC

HorizontalAlcove6040C

* = All posit ioning is determined as in st alled unit is viewed from the front.
C = I f pl aced on combust ible floor, f l oor M U ST be w ood only.
NC = For in st al l ation on non-combustible fl oor s only. A com bustible
subbase must be used f or in s t al l at ions on combustible floor in g.

Installations must adhere to the clearances to combustible mate­rials to which this furnace has been design certified. The mini­mum clearance information for this furnace is provided on the
unit’s clearance label. These clearances must be permanently
maintained. Clearances must also accommodate an installation’s
gas, electrical, and drain trap and drain line connections. If the
alternate combustion air intake or vent/flue connections are used
additional clearance must be provided to accommodate these
connections. Refer to Vent/Flue Pipe and Combustion Air Pipe
for details. NOTE: In addition to the required clearances to com­bustible materials, a minimum of 24 inches service clearance
must be available in front of the unit.

17

PRODUCT DESIGN

TOP

TOP

SIDE SIDE SIDE

BOTTOM

BOTTOM

Upflow Counterflow Horizontal

A furnace installed in a confined space (i.e., a closet or utility
room) must have two ventilation openings with a total minimum
free area of 0.25 square inches per 1,000 BTU/hr of furnace input
rating. Refer to Specification Sheet applicable to your model for
minimum clearances to combustible surfaces. One of the venti­lation openings must be within 12 inches of the top; the other
opening must be within 12 inches of the bottom of the confined
space.

EXISTING FURNACE REMOVAL

NOTE: When an existing furnace is removed from a venting sys-

tem serving other appliances, the venting system may be too
large to properly vent the remaining attached appliances.

The following vent testing procedure is reproduced from the Ameri-

can National Standard/National Standard of Canada for
Gas-Fired Central Furnaces ANSI Z21.4,
CSA-2.3 latest edition Section 1.23.1.

The following steps shall be followed with each appliance connected
to the venting system placed in operation, while any other appliances
connected to the venting system are not in operation:

1. Seal any unused openings in the venting system;

2. Inspect the venting system for proper size and horizontal
pitch, as required by the National Fuel Gas Code, ANSI
Z223.1 or the Natural Gas and Propane Installation Code,
CSA B149.1-05 and these instructions. Determine that
there is no blockage or restriction, leakage, corrosion and
other deficiencies which could cause an unsafe condition.

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

4. Close fireplace dampers.

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

6. Follow the lighting instructions. Place the appliance being
inspected in operation. Adjust thermostat so appliance
shall operate continuously.

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

8. If improper venting is observed during any of the above
tests, the venting system must be corrected in accordance
with the National Fuel Gas Code ANSI Z223.1/NFPA 54
and/or National Gas and Propane Installation Code CSA
B149.1-05.

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 burning appliance to
their previous conditions of use.

If resizing is required on any portion of the venting system, use
the appropriate table in Appendix G in the latest edition of the
National Fuel Gas Code ANSI Z223.1 and/or CSA B149.1-05
Installation Codes.

THERMOSTAT LOCATION

The thermostat should be placed approximately five feet from
the floor on a vibration-free, inside wall in an area having good air
circulation. Do not install the thermostat where it may be influ­enced by any of the following:

• Drafts, or dead spots behind doors, in corners, or under
cabinets.

• Hot or cold air from registers.

• Radiant heat from the sun.

• Light fixtures or other appliances.

• Radiant heat from a fireplace.

• Concealed hot or cold water pipes, or chimneys.

• Unconditioned areas behind the thermostat, such as an
outside wall.

Consult the instructions packaged with the thermostat for

mounting instructions and further precautions.

Combustion & V entilation Air Requirements

WARNING

TO

AVOID PROPERTY DAMAGE, PERSONAL INJURY OR DEATH
SUFFICIEN T FRESH AIR FOR PROPER COMBUSTION AND VENTILATION OF
FLUE GASES MUST BE SUPPLIED
SUPPLIED INTO THE FURNACE AREA

. M

OST HOMES REQUIRE OUTSIDE AIR BE

.

Improved construction and additional insulation in buildings have
reduced heat loss by reducing air infiltration and escape around
doors and windows. These changes have helped in reducing
heating/cooling costs but have created a problem supplying com­bustion and ventilation air for gas fired and other fuel burning
appliances. Appliances that pull air out of the house (clothes
dryers, exhaust fans, fireplaces, etc.) increase the problem by
starving appliances for air.

House depressurization can cause back drafting or improper
combustion of gas-fired appliances, thereby exposing building
occupants to gas combustion products that could include car­bon monoxide.

,

18

PRODUCT DESIGN

If this furnace is to be installed in the same space with other gas
appliances, such as a water heater, ensure there is an adequate
supply of combustion and ventilation air for the other appliances.
Refer to the latest edition of the National Fuel Gas Code NFPA
54/ANSI Z223.1 or CAN/CSA B149 Installation Codes or appli­cable provisions of the local building codes for determining the
combustion air requirements for the appliances.

Most homes will require outside air be supplied to the furnace
area by means of ventilation grilles or ducts connecting directly
to the outdoors or spaces open to the outdoors such as attics
or crawl spaces.

Installation Positions

This furnace may be installed in an upright position or horizontal
on either the left or right side panel. Do not install this furnace
on its back. For upright upflow furnaces, return air ductwork
may be attached to the side panel(s) and/or basepan. For hori-
zontal upflow furnaces, return air ductwork must be attached to
the basepan. For both upright or horizontal counterflow furnaces,
return ductwork must be attached to the basepan (top end of
the blower compartment). NOTE: Ductwork must never be
attached to the back of the furnace. Contact your distributor for
proper airflow requirements and number of required ductwork
connections. Refer to “Recommended Installation Positions”
figure for appropriate installation positions, ductwork connec­tions, and resulting airflow arrangements.

FURNACE SUSPENSION

If suspending the furnace from rafters or joists, use 3/8" threaded
rod and 2”x2”x1/8” angle iron as shown in the following diagram.
The length of rod will depend on the application and the clear­ances necessary.

If the furnace is installed in a crawl space it must be suspended
from the floor joist or supported by a concrete pad. Never install
the furnace on the ground or allow it to be exposed to water.

2" 2" 3/8"

ANGLE IRON

XX

(3

PLACES

)

Horizontal Applications & Considerations

Horizontal applications, in particular, may dictate many of the
installation’s specifics such as airflow direction, ductwork con­nections, flue and combustion air pipe connections, etc. The
basic application of this furnace as a horizontal furnace differs
only slightly from an upright installation. When installing a fur­nace horizontally, additional consideration must be given to the
following:

DRAIN TRAP AND LINES

In horizontal applications the condensate drain trap is secured to
the furnace side panel, suspending it below the furnace. A mini­mum clearance of 4 3/4 inches below the furnace must be pro­vided for the drain trap. Additionally, the appropriate downward
piping slope must be maintained from the drain trap to the drain
location. Refer to Condensate Drain Trap and Lines for further
details. If the drain trap and drain line will be exposed to tempera­tures near or below freezing, adequate measures must be taken
to prevent condensate from freezing.

LEVELING

Leveling ensures proper condensate drainage from the heat ex­changer and induced draft blower. For proper flue pipe drainage,
the furnace must be level lengthwise from end to end. The fur­nace should also be level from back to front or have a slight tilt
with the access doors downhill (approximately 3/4 inches) from
the back panel. The slight tilt allows the heat exchanger conden­sate, generated in the recuperator coil, to flow forward to the
recuperator coil front cover.

Horizontal Furnace

19

1

PRODUCT DESIGN

ALTERNATE VENT/FLUE AND COMBUSTION AIR CONNECTIONS

In horizontal installations with the furnace laying on the left
hand side, the alternate vent connection may be used. In
this configuration, the internal elbow is removed The stan­dard piping connections may also be used in these posi­tions. Refer to Vent/Flue Pipe and Combustion Air Pipe for
details concerning the conversion to the alternate vent/flue
and combustion air connections.

When using the horizontal alternate vent configuration, you
must use the RF000142 vent drain kit. See following illustra­tion.

ALTERNATE ELECTRICAL AND GAS LINE CONNECTIONS

This furnace has provisions allowing for electrical and gas line
connections through either side panel. In horizontal applications
the connections can be made either through the “top” or “bottom”
of the furnace.

DRAIN PAN

A drain pan must be provided if the furnace is installed above a
conditioned area. The drain pan must cover the entire area under
the furnace (and air conditioning coil if applicable).

FREEZE PROTECTION

Refer to Horizontal Applications and Conditions - Drain Trap and
Lines.

Propane Gas/High Altitude Installations

WARNING

P

OSSIBLE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH MAY
OCCUR IF THE CORRECT CONVERSION KITS ARE NOT INSTALLED
APPROPRIATE KITS MUST BE APPLIED TO ENSURE SAFE AND PROPER
FURNACE OPERATION
QUALIFIED INSTALLER OR SERVICE AGENCY

. ALL

CONVERSIONS MUST BE PERFORMED BY A

.

. THE

Recommended Installation Positions

NOTE: Alternate “vertical” piping connections can not be used

when an upflow furnace is installed with supply air discharging to
the right, or when a counterflow furnace is installed with supply air
discharging to the left. In either case, use the standard flue and
combustion air piping connections.

This furnace is shipped from the factory configured for natural gas
up to 10,000 ft. altitude. Propane conversions require the
proper LP kit to compensate for the energy content differ­ence between natural and propane gas.

LP kits include a manifold assembly, including an LP gas
valve, orifices and LP burners.

Gas

Altitude Kit

Natural None

Propane LPKMOD** ***

NOTE:

Exc ept 115,000 BTU: #43

2

Exc ept 115,000 BTU: #55

0-7 000

In Canada , gas fur nace s ar e onl y c ertified to 4500 feet.

Orifice

#45

1.25MM

1

Manifold Pressure

High Stage Low Stage

3.5" w .c. 1" w.c. None

2

10.0" w. c. 2. 6" w.c. None

Pressure

Switch

Change

Fur nace Model LP Kit

A/GMVM960603BX
A/GMVM960805CX
A/GMVM961005DX

A/GMVM961155DX

LPKMOD060UF
LPKMOD080UF
LPKMOD100UF

LPKMOD115UF

A/GCVM960604CX LPKMOD060CF
A/GCVM960805DX LPKMOD080CF

A/GCVM961005DX LPKMOD100CF

The indicated kits must be used to insure safe and proper furnace
operation. All conversions must be performed by a qualified in­staller, or service agency.

20

PRODUCT DESIGN

Vent/Flue Pipe & Combustion Air Pipe

WARNING

F

AILURE TO FOLLOW THESE INSTRUCTIO N S CAN RESU LT IN BODILY
INJURY OR DEATH
GIVEN IN THIS SECTION

. C

AREFULLY READ AND FOLLOW ALL INSTRUCTIONS

.

WARNING

U

PON COMPLETION OF THE FURNACE INSTALLATION, CAREFULLY
INSPECT THE ENTIRE FLUE SYSTEM BOTH INSIDE AND OUTSIDE OF THE
FURNACE TO ASSURE IT IS PROPERLY SEALED
SYSTEM CAN RESU LT IN SERIOUS PERSONAL INJURY OR DEATH DUE TO
EXPOSURE TO FLUE PRODUCTS, INCLUDING CARBON MONOXIDE

. L

EAKS IN THE FLUE

A condensing gas furnace achieves its high level of efficiency by
extracting almost all of the heat from the products of combustion
and cooling them to the point where condensation takes place.
Because of the relatively low flue gas temperature and water con­densation requirements, PVC pipe is used as venting material.

This furnace must not be connected to Type B, BW, or L vent or
vent connector, and must not be vented into any portion of a
factory built or masonry chimney except when used as a path­way for PVC as described later in this section. Never common
vent this appliance with another appliance or use a vent which is
used by a solid fuel appliance. Do not use commercially avail­able “no hub connectors” other than those shipped with this prod­uct.

It is the responsibility of the installer to follow the manufacturers’
recommendations and to verify that all vent/flue piping and con­nectors are compatible with furnace flue products. Additionally, it
is the responsibility of the installer to ensure that all piping and
connections possess adequate structural integrity and support
to prevent flue pipe separation, shifting, or sagging during furnace
operation.

DUAL CERTIFICATION: NON-DIRECT/DIRECT VENT

This furnace is dual certified and may be installed as a non-direct
vent (single pipe) or direct vent (dual pipe) appliance. A non-direct
vent installation requires only a vent/flue pipe, while a direct vent
installation requires both a vent/flue pipe and a combustion air
intake pipe. Refer to the appropriate section for details concern­ing piping size, length, number of elbows, furnace connections,
and terminations.

.

used. Fittings must be DWV type fittings meeting ASTM D2665
and ASTM D3311. Carefully follow the pipe manufacturer’s in­structions for cutting, cleaning, and solvent cementing of PVC.

The use of Schedule 40 PVC or ABS cellular core (Foam Core)
plastic pipe is also acceptable as a flue/vent and intake pipe
material. PVC primer meeting ASTM F656 and PVC solvent ce­ment meeting ASTM D2564 specifications must be used. Fit­tings must be DWV type fittings meeting ASTM D2665 and ASTM
D3311. Carefully follow the manufactures instructions for cutting,
cleaning and solvent cementing of PVC.

MATERIALS AND JOINING METHODS

As an alternative to PVC pipe, primer, solvent cement, and fit­tings, ABS materials which are in compliance with the following
specifications may be used. Two-or-three-inch ABS Schedule
40 pipe must meet ASTM D1527 and, if used in Canada, must be
CSA listed. Solvent cement for ABS to ABS joints must meet
ASTM D2235 and, if used in Canada, must be CSA listed. The
solvent cement for the PVC to ABS transition joint must meet
ASTM D3138. Fittings must be DWV type fittings meeting ASTM
D2661 and ASTM D3311 and, if used in Canada, must be CSA
listed. Carefully follow the manufacturers’ instructions for cutting,
cleaning, and solvent cementing PVC and/or ABS.

All 90° elbows must be medium radius (1/4 bend DWV) or long
radius (Long sweep 1/4 bend DWV) types conforming to ASTM
D3311. A medium radius (1/4 bend DWV) elbow measures 3 1/
16” minimum from the plane of one opening to the centerline of
the other opening for 2” diameter pipe, and 4 9/16” minimum for 3”
pipe.

PROPER VENT/FLUE AND COMBUSTION AIR PIPING PRACTICES

Adhere to these instructions to ensure safe and proper furnace
performance. The length, diameter, and number of elbows of the
vent/flue pipe and combustion air pipe (when applicable) affects
the performance of the furnace and must be carefully sized. All
piping must be installed in accordance with local codes and these
instructions.

Piping must be adequately secured and supported to prohibit
sagging, joint separation, and/or detachment from the furnace.
Horizontal runs of vent/flue piping must be supported every three
to five feet and must maintain a 1/4 inch per foot downward slope,
back towards the furnace, to properly return condensate to the
furnace’s drain system.

PREFERRED

WARNING

TO

AVOID BODILY INJURY, FIRE OR EXPLOSION, SOLVENT CEMENTS
MUST BE KEPT AWAY FROM ALL IGNITION SOURCES (I.E
FLAMES, AND EXCESSIVE HEAT) AS THEY ARE COMBUSTIBLE LIQUIDS

VOID BREATHING CEMENT VAPO RS OR CONTA CT WITH SKIN AND/OR

A

EYES

.

Two- or three-inch nominal diameter PVC Schedule 40 pipe meet­ing ASTM D1785, PVC primer meeting ASTM F656, and PVC
solvent cement meeting ASTM D2564 specifications must be

.,

SPARKS, OPEN

.

21

PRODUCT DESIGN

ACCEPT ABLE

TRANSITION NO LESS
THAN 45 DEGREES TO
HORIZONTA L P LANE T O
AVOID CREATING A WATER
TRAP IN VENT PIPING.

NO TRANSITION ON
HORIZONTAL PLANE,
THIS CREATES A
WATER TRAP AND
RESTRICTS FLUE
GASES

Precautions should be taken to prevent condensate from freezing
inside the vent/flue pipe and/or at the vent/flue pipe termination.
All vent/flue piping exposed to temperatures below 35°F (2°C)
for extended periods of time must be insulated with 1/2” thick
closed cell foam. Also all vent/flue piping exposed outdoors in
excess of the terminations shown in this manual (or in unheated
areas) must be insulated with 1/2” thick closed cell foam. In­spect piping for leaks prior to installing insulation.

TERMINATION LOCATIONS

NOTE: Refer to Location Requirements and Considerations for

combustion air contaminant restrictions.
The following bullets and diagram describe the restrictions con-

cerning the appropriate location of vent/flue pipe and combustion
air intake pipe (when applicable) terminations. Refer to Non-Di-
rect Vent (Single Pipe) Piping and Direct Vent (Dual Pipe) Piping
located in this section for specific details on termination con­struction.

• All terminations (flue and/or intake) must be located at
least 12 inches above ground level or the anticipated snow
level.

• Vent terminations (non-direct and direct vent) must termi­nate at least 3 feet above any forced air inlet located within
10 feet.

NOTE: This provision does not apply to the combustion
air intake termination of a direct vent application.

• The vent termination of a non-direct vent application must
terminate at least 4 feet below, 4 feet horizontally from, or
1 foot above any door, window, or gravity air inlet into any
building.

• The vent termination of a direct vent application must ter­minate at least 12 inches from any opening through which
flue gases may enter a building (door, window, or gravity
air inlet).

• The vent termination of vent pipe run vertically through a
roof must terminate at least 12 inches above the roof line
(or the anticipated snow level) and be at least 12 inches
from any vertical wall (including any anticipated snow build
up).

• A vent termination shall not terminate over public walk­ways or over an area where condensate or vapor could
create a nuisance or hazard or could be detrimental to the
operation of regulators, relief valves, or other equipment.

• The combustion air intake termination of a direct vent ap­plication should not terminate in an area which is frequently
dusty or dirty.

Non-Direct Vent

&

Direct Vent

Vent/ F lue Terminations

Non-Direct Vent

Vent/Flue Termination

No Terminations
Above Walkway

4' min.

4'

min.

Grade or Highest

Anticipated
Snow Level

Forced Air

Inlet

12" min.

Vent /F lue Termi nation

Direct Vent

12" min.

Non-Direct Vent

Vent/ F lue Termin at ion

Vent Termination Clearances

NOTE: In Canada, the CAN/CSA B149 Gas Installation Code

takes precedence over the preceding termination restrictions.

22

PRODUCT DESIGN

V
X

v

DIRECT VENT TERMINAL CLEARANCES

A= Clearance above grade,

veranda, porch, deck o r
balcony. (See 1.24.6-i(9)b.)

B= Clearanc e to window or

door that may be opened.

C= Clearance to permanently

closed window.

D= Vertical clearance to ventilated soffit

located above the terminal within a
horizontal distance of 2 feet (61 cm)
from the center line of the terminal.

E= Clearance to unventilated soffit. * *
F= Clearance to outside corner. * *
G= Clearance to inside corner. * *
H= Clearance to each side of center

line extended above meter/regulator
assembly.

Canadian Installations

12 in. (30 cm) 12 in. (30 cm)

6 in. (15 cm) for appliances
10,000 Btuh (3 kW), 12 in. (30 cm) for
appliances > 10,000 Btuh (3 kW) and
100,000 Btuh (30 kW), 36 in. (91 cm)
for appliances > 100,000 Btuh (30
kW).

**

**

3 ft. (91 cm) within a height 15 ft.
(4.5 m) above the meter/regulator
assembly .

1

OTHER THAN DIRECT VENT TERMINAL CLEARANCES

A= C leara nce a bove grade,

veranda, porch, deck or
balcony. (See 1.24.6-i(9)b.)

B= C leara nce to wind ow or

door that may be opened.

C= Clearance to per man ently

closed window.

D= Vertical clearance to ventilated soffit

located above the terminal within a
horizontal distance of 2 feet (61 cm)
from the center line of the terminal.

E= C leara nce to unv ent ilated soffit. * *
F= Clearance to outside corner. * *
G= Clearance to inside corner. * *
H= Clearance to eac h side of center

line extend ed above meter/regul ator
assembly.

Canadian Installations

12 in. (30 cm) 12 in. (30 cm)

6 in. (15 cm) for appliances
10,000 Btuh (3 kW), 12 in. (30 cm) for
appliances > 10,000 Btuh (3 kW) and
100,000 Btuh (30 kW), 36 in. (91 cm)
for applia nces > 100,000 Btuh (30
kW).

**

**

3 ft. (91 cm) within a height 15 ft.
(4.5 m) above the meter/regulator
assembly.

1

U.S. Installations

6 in. (15 cm) for appliances
10,000 Btuh (3 kW), 9 in. (23 cm) for
appliances > 10,000 Btuh (3 kW) and
50,000 Btuh (15 kW), 12 i n. (30 cm) for
appliances > 500,000 Btuh (15 kW).

*

U.S. Installati ons

4 ft. (1.2 m) below or to side of
opening; 1 ft. (300 m) above opening.

*

2

2

I= Clearance to service

regulator vent outlet.

J= Clearance to nonmech ani cal air

supply inlet to building or the
combustion air inlet to any other
appliance.

K= Clearance to a mechanical

air supply inlet.

L= Clearance above paved sidew al k or

paved driveway located on public
property.

M= Clearance under veranda, porch,

deck or balcony.

1 In accordance with the current CSA B149.1, Natural Gas and Propane Installation Code.

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

† A vent shall not terminate directly above a sidewalk or paved driveway that is located between two single fanily dwellings and serves

both dwellings.

‡ Permitted only if veranda, porch, deck or balcony is fully open on a minimum of two sides beneath the floor.

* For clearances not specified in ANSI Z223.1/NFPA 54 or CSA B149.1, the following statement shall be included:

“Clearance in accordance wtih local installation codes and the requirements of the gas supplier and the manufacturer’s installation

instruction.”

I= Clearance to sevice

regulator vent outlet.

J= Cl earance to nonmechanica l ai r

supply inlet to building or the
combustion air inlet to any other
appliance.

K= Clearance to a mechanical

air supply inlet.

L= Clearance above paved sidewalk or

paved driveway located on public
property.

M= Clearance under veranda, porch,

deck or balcony.

1 In accordance with the current CSA B149.1, Natural Gas and Propane Installation Code.

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

† A vent shall not terminate directly above a sidewalk or paveable driveway that is located between two single family dwellings and

serves both dwelling.

‡ Permitted only if veranda, porch, deck or balcony is fully open on a minimum of two sides beneath the floor.

* For clearances not specified in ANSI Z223.1/NFPA 54 or CSA B149.1, the following statement shall be included:

“Clearance in accordance wtih local installation codes and the requirements of the gas supplier and the manufacturer’s installation

instruction.”

Canadian Installations

3 ft. (91 cm). *

6 in. (15 cm) for appliance s 10,000
Btuh (3 kW), 12 in. (30 cm) for
appliances > 10,0 00 Btu h (3k W) an d
100,000 Btuh (30 kW), 36 in. (91 cm)
for appliances > 100,000 Btuh (30 kW).

6 ft. (1.83 m) 3 ft. (91 cm) above if within

7 ft. (2.13m) † *

12 in. (30 cm) ‡ *

Canadian Installations

3 ft. (91 cm). *

6 in. (15 cm) for appliances 10,000
Btuh (3 kW), 12 in. (30 cm) for
appliances > 10,000 Btuh (3kW) and
100,000 Btuh (30 kW), 36 in. (91 cm)
for appliances > 100,000 Btuh (30 kW).

6 ft. (1.83 m) 3 ft. (91 cm) above if within

7 ft. (2.13m) † 7 ft. (2.13m)

12 in. (30 cm) ‡ *

1

1

U.S. Installations

6 in. (15 cm) for appliances 10,00 0
Btuh (3 kW), 9 in. (23 cm) fo r
appliances > 10,000 Btuh (3kW) and
50,000 Btuh (15 kW), 12 in. (30 cm) for
appliances > 50,000 Btuh (15 kW ).

10 ft. (3 m) horizontally.

U.S. Installations

4 ft. (1.2 m) below or to side of
opening; 1 ft. (300 m) above opening.

10 ft. (3 m) horizontally.

2

2

23

PRODUCT DESIGN

SPECIAL VENTING REQUIREMENTS FOR INSTALLATIONS IN
CANADA

All installations in Canada must conform to the requirements
of CSAB149 code. All vent system components, including
primer and cement, must be listed to ULC S636. The certi­fied pipe and fittings should be clearly marked with the ULC
standard “S636”. The primer and cement used must be of the
same manufacturer as the vent system. For Royal Pipe Sys­tem 636; use GVS-65 Primer (Purple) and GVS-65 PVC
Solvent Cement. For IPEX System 636, use PVC/CPVC
Primer, Purple or clear. Use PVC Solvent Cement (Gray).

For Canadian installations, ABS may be used as a combus­tion air pipe only. ABS is not an approved vent material in
Canada. If ABS is used as a combustion air pipe, it must be
CSA certified. Always follow the manufacturer’s instructions
in the use of primer and cement. Do not use primer and ce­ment around potential sources of ignition. Do not use primer
or cement beyond its expiration date.

The vent can be run through an existing unused chimney
provided the space between the vent pipe and the chimney is
insulated and closed with a weather-t

ight, corrosion-resistant

flashing.

STANDARD FURNACE CONNECTIONS

It is the responsibility of the installer to ensure that the piping
connections to the furnace are secure, airtight, and adequately
supported.

As shipped, attachment “couplings” for vent/flue and combustion
air intake pipe connections are provided on the furnace’s top cover
(upflow) or basepan (counterflow). To use the standard connec­tions, field supplied vent/flue pipe and combustion air intake pipe
(when applicable) should be secured directly to the furnace at
these locations.

VENT/FLUE PIPE

Vent/flue pipe can be secured to the vent/flue coupling using the
rubber coupling and worm gear hose clamps provided with this
furnace (see “Standard Connections” figure). The rubber coupling
allows separation of the vent/flue pipe from the furnace during
servicing. Combustion Air and Vent piping should be routed in a
manner to avoid contact with refrigerant lines, metering devices,
condensate drain lines, etc.

COMBUSTION AIR PIPE

DIRECT VENT INSTALLATIONS

On upflow units secure the combustion air intake pipe directly to
the air intake coupling. On counterflow units secure the com­bustion air intake pipe to the air intake coupling using the rubber
coupling and worm gear hose clamps provided with the unit. The
counterflow rubber coupling allows service removal of air intake
piping internal to the furnace blower compartment.

ON-DIRECT VENT INSTALLATIONS

N

A minimum of one 90° elbow should be installed on the combus­tion air intake “coupling” to guard against inadvertent blockage.

(DIRECT VENT ONLY)

90 PVC

ELBOW

(NON-DIRECT VENT)

COMBUSTION

AIR PIPE

OR

VENT/FLUE

PIPE

RUBBER

COUPLING

WITH WORM

GEAR CLAMPS

UPFLOW COUNTERFLOW

90 PVC
ELBOW

(NON-DIRECT VENT)

COMBUSTION

AIR PIPE

(DIR EC T VENT ONLY)

OR

RUBBER
COUPLINGS
WITH WORM

GEAR CLAMPS

VENT/FLUE

PIPE

Standard Connections

WARNING

E

DGES OF SHEET METAL HOLES MAY BE SHARP

PRECAUTION WHEN REMOVING HOLE PLUGS

.

. USE

GLOVES AS A

ALTERNATE VENT/FLUE LOCATION

The alternate vent/flue location is the large hole directly in line
with the induced draft blower outlet. To use the alternate vent/flue
location refer to the following steps and the “Alternate Vent/Flue
Location” figure.

NOTE: Counterflow instructions follow the upflow instructions.

1. Remove and save the four screws securing the vent/
flue coupling to the furnace top panel.

Counterflow units.

Remove and save the four screws securing the vent/
flue coupling to the furnace basepan. Also remove the
three screws securing the furnace’s internal vent/flue
piping to the blower deck.

24

PRODUCT DESIGN

2. Upflow and Counterflow units.
Loosen the worm gear hose clamps on the rubber el-

bow and detach it from both the induced draft blower
and the vent/flue pipe.

3. Upflow and Counterflow units.
Remove the vent/flue pipe from the furnace.

4. Cut the vent/flue pipe 3.75 inches from the flanged end
of the pipe (see “Vent/Flue Pipe Cut s” figure). The sec­tion of pipe attached to the coupling will reach through
the side panel to the induced draft blower . Discard re­maining pipe and elbows.

Counterflow units.

Cut the vent/flue pipe 3.75 inches from the blower deck cou­pling (see “Vent/Flue Pipe Cuts” figure). Save vent/flue pipe
attached to blower deck coupling for use in the alternate lo­cation. Discard remaining pipe and elbows.

FLANGE

3.75"

CUT HERE

Counterflow units.
Remove plastic plug from alternate vent/flue location.

Relocate and install plug in standard vent/flue location
(basepan). Plug remaining hole in blower deck with
plastic plug included in the drain kit bag.

6. Upflow and Counterflow units.
Insert cut section of vent/flue pipe and coupling into al-

ternate vent/flue location. Using a rubber coupling and
worm gear hose clamps from the drain kit bag, attach
the vent/flue pipe and coupling to the induced draft
blower. Secure the coupling to the cabinet using the
screws removed in step 1 or with field-supplied 3/8” #8
self tapping screws.

WARNING

THE

RUBBER ELBOW IS NOT DESIGNED TO SUPPORT A LOAD
RUBBER ELBOW IS MOUNTED EXTERNALLY TO THE FURNACE CABIN E T
EXTREME CARE MUST BE TAKEN TO ADEQUATELY SUPPORT FIELD
SUPPLIED VENT/FLUE PIPING, AS DAMAGE CAN RESU LT IN LEAKS
CAUSING BODILY INJURY OR DEATH DUE TO EXPOSURE TO FLUE GASES
INCLUDING CARBON MONOXIDE

. W

HEN THE

-

,

,

Vent/Flue Pipe Cuts

5. Remove plastic plug from alternate vent/flue location.
Relocate and install plug in standard vent/flue location
(top cover).

25

PRODUCT DESIGN

A

A

A

A

3

REMOVE

PIPE

4

REMOVE

AND RELOCATE

CABINET PLUG

2

DETACH RUBBER

ELBOW FROM

ID BLOWER AND

VENT/FLUE

PIPE

5

5

EXTERNALLY

EXTERNALLY

MOUNT

MOUNT

RUBBER ELBOW

RUBBER ELBOW

ND SECURE FLANG E

ND SECURE FLANG E

WITH 4 SC REWS

WITH 4 SC REWS

REMOVED IN STEP 1

REMOVED IN STEP 1

3

REMOVE

PIPE

INSTALL CABINET PLUGS

IN 2 LOCAT IONS

2

REMOVE

3 SCREWS

4

DETATCH RUBBER

ELBOW FROM

ID BLOWER AND

VENT/FLUE

PIPE

RUBBER ELBOW

ND SECURE FLANG E

WITH 4 SC REWS

REMOVED IN STEP 1

ID BLOWER WITH

RUBBER COUPL IN G

COUNTERFLOW-HORIZONTAL MODEL ALTERNATE VENT

TO USE ALTERNATE
COMBUSTION

IR LOCATION, REMOVE
INTERNAL PIPE AS PER
ABOVE. CAP UNUSED
CABINET OPENINGS

CABINET WITH

5

7

EXTERNALLY

MOUNT

6

SECURE TO

AND HOSE

CLAMPS

SECURE TO

SCREWS

ALTER NATE
COMBUSTION
AIR LOCATION
ON C’FLOW -HOR
MODELS

COUNTERFLOW-HORIZONTAL MODEL

AL TERNATE COMBUSTION AIR LOCATION

26

PRODUCT DESIGN

7. Upflow and Counterflow units.
For upright installations, externally mount the rubber

elbow to the vent/flue coupling using a worm gear hose
clamp. Secure field supplied vent/flue piping to the
rubber elbow using a worm gear hose clamp. NOTE:
Use of the alternate vent/flue location for upright instal­lations, requires the drain trap be installed on the
same side of the unit as the flue pipe.

8. Upflow and Counterflow units.
For horizontal installations, externally secure the

field-supplied vent/flue pipe directly to the vent/flue cou­pling using a PVC or ABS coupling or elbow .

ALTERNATE COMBUSTION AIR INTAKE LOCATION

The alternate combustion air intake location consists of a large,
unobstructed hole (alternate vent connection is aligned with the
Induced Draft Blower). To use the alternate combustion air intake
location, refer to the following steps, and the “Alternate Combus­tion Air Intake Location” figure.

1. Remove and save the four screws securing the com­bustion air intake coupling to the basepan. Remove an
additional three screws securing the furnace’s internal
combustion air intake pipe to the blower deck.

2. Remove the combustion air intake pipe from the fur­nace and cut the pipe at the basepan coupling. Save
the basepan coupling and gasket from the blower deck
coupling for use in the alternate location. Discard the
remaining pipe.

3. Remove plastic plug from alternate combustion air in­take location. Relocate and install plug in standard air
intake location (basepan). Plug the remaining hole in
the blower deck with the plastic plug included in the
drain kit bag.

4. With the gasket facing the cabinet side panel, and the
flange’s flat spot facing forward, secure the combustion
air intake coupling to the cabinet using the screws re­moved in step 1 or with field-supplied 3/8” #8 self -drill­ing screws.

CAUTION

BE

SURE NOT TO DAMAGE INTERNAL WIRING OR OTHER COMPONENTS

WHEN REIN STALLING COUPLING AND SCREWS

.

5. For non-direct vent installations installed horizon-
tally, a minimum of one 90° elbow should be installed

on the combustion air intake coupling to guard against
inadvertent blockage. No elbow is required on the al­ternate combustion air intake of upright installations,
however, a minimum clearance of 2 inches is required
to assure proper air supply .

6. For direct vent installations , secure field-supplied
combustion air intake pipe directly to the air intake
coupling.

NOTE: A PVC coupling or elbow is required on
counterflow units.

NON-DIRECT VENT (SINGLE PIPE) PIPING

Non-direct vent installations require only a vent/flue pipe. The
vent pipe can be run horizontally with an exit through the side of
the building or run vertically with an exit through the roof of the
building. The vent can also be run through an existing unused
chimney; however, it must extend a minimum of 12 inches above
the top of the chimney. The space between the vent pipe and the
chimney must be closed with a weather-tight, corrosion-resistant
flashing. For details concerning connection of the vent/flue pipe
to the furnace, refer to Vent/Flue Pipe and Combustion Air - Stan-
dard Furnace Connections or Alternate Furnace Connections for
specific details. Refer to the following Non-Direct Vent (Single
Pipe) Piping - Vent/Flue Pipe Terminations for specific details on
termination construction.

Although non-direct vent installations do not require a combus-
tion air intake pipe, a minimum of one 90° elbow should be at­tached to the furnace’s combustion air intake if: an upright instal­lation uses the standard intake location, or a horizontal installa­tion uses the alternate air intake location. This elbow will guard
against inadvertent blockage of the air intake.

VENT/FLUE PIPE LENGTHS AND DIAMETERS

Refer to the following table for applicable length, elbows, and pipe
diameter for construction of the vent/flue pipe system of a non­direct vent installation. In addition to the vent/flue pipe, a single
90° elbow should be secured to the combustion air intake to
prevent inadvertent blockage. The tee used in the vent/flue termi­nation must be included when determining the number of elbows
in the piping system.

*MVM 9/*CVM9 Di r ec t Vent (2 - Pipe) and No n-Direct Vent (1- Pipe)

Maxim um Allowable Length of Vent/Flue Pipe & Combustio n A ir Pipe (ft)

Unit Input

100,000
100,000 3 250 243 236 229 222 215 208 201 194
115,000
115,000 3 220 213 206 199 192 185 178 171 164

1) Maximum allowable limits listed on individual lengths for inlet and flue

2) Minimum requirement for each vent pipe is five (5) feet in length and

3) Tee used in the vent/flue termination must be included when deter-

4) 2 1/2” or 3” diameter pipe can be used in place of 2” diameter pipe.

5) Increased Clearance Configurations using (2) 45 deg. Elbows should

6) One 90° elbow should be secured to the combustion air intake con-

Pipe Size

(4)

(Btu)

60,000

80,000
80,000 3 250 243 236 229 222 215 208 201 194

or 2 1/2

or 2 1/2

or 2 1/2

or 2 1/2

and NOT a combination.

one elbow/tee.

mining the number of elbows in the piping system.

be considered equivalent to one 90 deg. elbow.

nection.

012345678

(in.)

2

250 245 240 235 230 225 220 215 210

2

250 245 240 235 230 225 220 215 210

2

90 85 80 75 70 65 60 55 50

2

75 70 65 60 55 50 45 40 35

Num ber of El bows

(3) (5)

(6)

(1 ) (2 )

27

PRODUCT DESIGN

VENT/FLUE PIPE TERMINATIONS

NOTE: If either a 90 degree or 45 degree elbow is used for

termination, it must be pointed downward.
The vent/flue pipe may terminate vertically, as through a roof, or

horizontally, as through an outside wall.
Vertical vent/flue pipe terminations should be as shown in the

following figure. Refer to Vent/Flue Pipe and Combustion Air
Pipe - Termination Locations for details concerning location re­strictions. The penetration of the vent through the roof must be
sealed tight with proper flashing such as is used with a plastic
plumbing vent.

Horizontal vent/flue pipe terminations should be as shown in the
following figure. Refer to Vent/Flue Pipe and Combustion Air Pipe

- Termination Locations for details concerning location restric­tions. A 2 3/8” diameter wall penetration is required for 2” diam­eter pipe. A 3” diameter hole is required for a 2 1/2” pipe and a 3
1/2” diameter hole is required for 3” diameter pipe. The wall
penetration should be sealed with silicone caulking material.

In a basement installation, the vent/flue pipe can be run between
joist spaces. If the vent pipe must go below a joist and then up
into the last joist space to penetrate the header, two 45° elbows
should be used to reach the header rather than two 90° elbows.

NOTE: Terminate both pipes in the same pressure zone
(same side of roof, no major obstacles between pipes,
etc.).

TEE (OPTIONAL)

COMBUSTION AIR INT AKE

(OPTIONAL)

*Not required for

single pipe installation

E

N

I

L

F

O

O

R

INTAKE

SCREEN

OPTIONAL

12” MIN TO ROOF OR HIGHEST
ANTICIPATED SNOW LEVEL

”

6

9

12” MIN
HEIGHT DIFFERENCE
BETWEEN
INT A KE AN D VENT

M

”

3

-

.

X

A

M

.

N

I

12" MIN.

VENT/FLUE TEE (

TURNED DOWN or

90° ELBOW TUR NED

12" MIN. ABOVE

HIGHEST ANTI CIP A T ED

SNOW LEVEL

OPTIONAL)

or

45° E L B OW

DOWN

Horizontal Termination (Single Pipe)

Above Highest Anticipated Snow Level

DIRECT VENT (DUAL PIPE) PIPING

The inlet air screens provided in the installation instruction packet
are available for the installer to use in the inlet of the combustion
air pipe to prevent animals from building nests in the combustion
air pipe. Installation of screens, while strongly recommended, is
not required and will not affect performance of the unit.

Direct vent installations require both a combustion air intake and
a vent/flue pipe. The pipes may be run horizontally and exit through
the side of the building or run vertically and exit through the roof of
the building. The pipes may be run through an existing unused
chimney; however, they must extend a minimum of 12 inches
above the top of the chimney. The space between the pipes and
the chimney must be closed with a weather tight, corrosion resis­tant flashing. Both the combustion air intake and a vent/flue pipe
terminations must be in the same atmospheric pressure zone.
Refer to Vent/Flue and Combustion Air Pipe - Termination Loca-
tions or Concentric Vent Termination for specific details on termi-
nation construction. For details concerning connection of pipes
to the furnace, refer to the Vent/Flue Pipe and Combustion Pipe

- Standard Furnace Connections or Alternate Furnace Connec­tions.

ELBOWS

STRAIGHT

28

VENT/FLUE & COMBUSTION AIR PIPE LENGTHS &DIAMETERS

Refer to the following table for applicable length, elbows, and pipe
diameter for construction of the vent/flue and combustion air in­take pipe systems of a direct vent (dual pipe) installation. The
number of elbows tabulated represents the number of elbows
and/or tees in each (Vent/Flue & Combustion Air Intake) pipe. If
there is a difference between the two pipes, count the pipe
with the most fittings. Elbows and/or tees used in the termina­tions must be included when determining the number of elbows
in the piping systems.

V

V

PRODUCT DESIGN

If the combustion air intake pipe is to be installed above a finished
ceiling or other area where dripping of condensate will be objec­tionable, insulation of the combustion air pipe may be required.
Use 1/2” thick closed cell foam insulation such as Armaflex™ or
Insultube™ where required.

VENT/FLUE AND COMBUSTION AIR PIPE TERMINATIONS

The vent/flue and combustion air pipes may terminate vertically,
as through a roof, or horizontally, as through an outside wall.

Vertical pipe terminations should be as shown in the following
figure. Refer to Vent/Flue Pipe and Combustion Pipe - Termina-
tion Locations for details concerning location restrictions. The
penetrations through the roof must be sealed tight with proper
flashing such as is used with a plastic plumbing vent.

ENT/FLUE

12" MIN.

SCREEN

(OPTIONAL)

10”- 24”

6” MAX

4” MIN

90º OR 45°

ELBOW

SCREEN

(OPTIONAL)

12" MIN. TO GRADE OR
HIGHEST ANTICIPATED

SNOW LEVEL

Standard Horizontal Terminations (Dual Pipe)

Vent & Combustion Air Intake Measurements for Stan­dard Horizontal Terminations (Dual Pipe)

Center to center = 10” min / 24” max.
Vertical separation: 0” - 24”
Vent termination from wall = 8” min / 12” max.
Combustion air intake from wall = 6” max.
Vent and intake clearance to ground

or anticipated snow level = 12” min.

_____________________________________

12" MIN. TO ROOF

OR HIGHEST ANTICIPAT ED

SNOW LEVEL

_____________________________________

TEE (OPTION AL)

ENT/FLUE

COMBUSTION

AIR INTAKE

12" MIN.

SCREEN

(OPTIONAL)

12" MIN. TO ROOF

OR HIGHEST ANTICIPATED

SNOW LEVEL

Vertical Terminations (Dual Pipe)

Horizontal terminations should be as shown in the following fig­ure. Refer to Vent/Flue Pipe and Combustion Pipe - Termination
Location for location restrictions. A 2 3/8” diameter wall penetra­tion is required for 2” diameter pipe. A 3” diameter hole is required
for a 2 1/2” pipe and a 3 1/2” diameter hole is required for 3”
diameter pipe. The wall penetration should be sealed with caulk­ing material.

90°
ELBOWS

3” - 24”

AIR
INTAKE

SCREEN

(OPTIONAL)

12" MIN. ABOVE

HIGHEST ANTICIPAT ED

SNOW LEVEL

Alternate Horizontal Vent Termination (Dual Pipe)

29

PRODUCT DESIGN

90°
ELBOWS

AIR
INTAKE

SCREEN

(OPTIONAL )

3”-24” BETWEEN PIPES

3” MIN

3”MIN
24”MAX

12” MIN SEPARATION

12" MIN. ABOVE

HIGHEST ANTICIPA TED

SNOW LEVEL

Combustion Air Intake may also be snorkeled to obtain 12” min
ground clearance.

Alternate Vent Termination Above Anticipated Snow

Level (Dual Pipe)

In a basement installation, the pipes may be run between the joist
spaces. If the pipes must go below the joist and then up into the
last joist space to penetrate the header, two 45° elbows should be
used to reach the header rather than two 90° elbows.

VENT/INTAKE TERMINATIONS FOR INSTALLATION OF M ULTIPLE
DIRECT VENT FURNACES

If more than one direct vent furnace is to be installed vertically
through a common roof top, maintain the same minimum clear­ances between the exhaust vent and air intake terminations of
adjacent units as with the exhaust vent and air intake terminations
of a single unit.

If more than one direct vent furnace is to be installed horizontally
through a common side wall, maintain the clearances as in the
following figure. Always terminate all exhaust vent outlets at the
same elevation and always terminate all air intakes at the same
elevation.

OPTIONAL
INTAKE
SCREENS

12” MIN TO GRADE OR HIGHEST
ANTICIPATED SNOW LEVEL

Termination of Multiple Direct Vent Furnaces

CONCENTRIC VENT TERMINATION

Refer to the directions provided with the Concentric Vent Kit
(DCVK) for installation specifications.

30

PRODUCT DESIGN

Condensate Drain Lines & Drain Trap

A condensing gas furnace achieves its high level of efficiency by
extracting almost all of the heat from the products of combustion
and cooling them to the point where condensation takes place.
The condensate which is generated must be piped to an appro­priate drain location.

In upright installations, the furnace’s drain hoses may exit either
the right or left side of the furnace. NOTE: If the alternate vent/flue
outlet is utilized in an upright installation, the drain trap and drain
connections must be located on the same side as the alternate
vent/flue outlet.

In horizontal installations, the drain hoses will exit through the
bottom (down side) of the unit with the drain trap suspended be­neath the furnace. The field-supplied drain system must be in
accordance with all local codes and the instructions in the follow­ing sections.

Follow the bullets listed below when installing the drain system.
Refer to the following sections for specific details concerning fur­nace drain trap installation and drain hose hook ups.

• The drain trap supplied with the furnace must be used.

• The drain line between furnace and drain location must
be constructed of 3/4” PVC.

• The drain line between furnace and drain location must
maintain a 1/4 inch per foot downward slope toward the
drain.

• Do not trap the drain line in any other location than at the
drain trap supplied with the furnace.

• Do not route the drain line outside where it may freeze.

• If the drain line is routed through an area which may see
temperatures near or below freezing, precautions must
be taken to prevent condensate from freezing within the
drain line.

• If an air conditioning coil is installed with the furnace, a
common drain may be used. An open tee must be
installed in the drain line, near the cooling coil, to relieve
positive air pressure from the coil’s plenum. This is
necessary to prohibit any interference with the function of
the furnace’s drain trap.

NOTE: In vertical installations, air conditioning coil
condensate may drain into the furnace trap as long as there
is a trap between the coil and the furnace trap and the drain
pipe is not terminating below the water level of the furnace
trap.

STANDARD RIGHT OR LEFT SIDE DRAIN HOSE CONNECTIONS

All installations positions require the use of the drain trap, hoses,
tubes, and clamps. The following quantity of hoses, tubes, and
hose clamps are provided with the unit.

HOSE A
QTY: 1

HOSE B
QTY: 1

DRAIN TRAP
QTY: 1

GREEN
HOSE CLAMPS
QTY: 3

RED
HOSE CLAMP
QTY: 1

Hose and Tube Identification

TUBE 1
QTY: 1

SILVER
HOSE CLAMP
QTY: 1

TUBE 2
QTY: 2

31

OPERATION

UPRIGHT INSTALLATIONS-TRAP ON RIGHT SIDE

In a upright installation drain hoses are connected to drain ports
on the rubber elbow and the recuperator coil front cover. The drain
lines are then routed through the right side panel and into the
drain trap secured to the outside of the cabinet.

NOTE: Refer to Alternate Vent/Flue Hose Connections for up-
right installations using an alternate vent/flue outlet.

1. Remove the rubber plug from the right side of the front
cover drain port.

2. Secure Hose A to front cover drain port with a red hose
clamp. Route hose to rear side panel grommet hole.

3. Cut and remove 1/4 inch from the end of the drain port
on the rubber elbow.

RUBBER ELBOW

(EXTERNALLY

MOUNTED)

4. Insert Tube 1 into rubber elbow drain port and secure
with silver hose clamp. Angle tube outward toward
front of furnace.

5. Cut 17 3/4 inches from the long end of Hose B and dis­card. Secure the remaining hose to Tube 1 with a
green hose clamp. Route the other end of Hose B to
front right side panel grommet hole.

For details concerning mounting of the drain trap, refer to Hori-

zontal Drain Trap Mounting.

6. Insert short end of each of tube 2 through side panel
grommet holes. Secure tubes to hoses A and B with
green hose clamps. Ensure hoses and tubes maintain
a downward slope for proper drainage and that they are
not kinked or binding.

FRONT

COVER

DRAIN

PORT

RED HOSE

CLAMP

RUBBER

ELBOW

DRAIN PORT

HOSE B

SILVER HOSE CLAMP

TUBE 1

GREEN HOSE

CLAMPS

(3 PLACE S)

HOSE A

DRAIN TRAP

TUBE(S) 2

Upright “Standard” Connections - Right Side

(Upflow Shown, Counterflow Similar)

32

OPERATION

ALTERNATE VENT/FLUE DRAIN HOSE CONNECTIONS

Upright installations using the alternate vent/flue outlet will require
“right-side only” drain hoses to be connected as follows. Refer to
Vent/Flue Pipe and Combustion Air Pipe for details on alternate
vent/flue pipe connection.

1. Remove the rubber plug/cap from the right-side drain
port on the front cover . Save for use in step 3.

2. Secure Hose A to front cover drain port with a red hose
clamp. Route hose to rear right side panel grommet
hole.

3. Remove grommet from front right-side panel drain hole.
Seal hole in grommet with large end of plug. Reinstall
grommet and plug into side panel drain hole.

4. Cut 1/4 inch from the end of the drain port on the exter­nally mounted rubber elbow. Discard cut portion.

5. Insert Tube 1 into rubber elbow drain port and secure
with a silver hose clamp. Angle tube toward trap.

6. Cut 17 3/4 inches from the long end of Hose B and dis­card.

7. Secure straight end of Hose B to exposed end of Tube
1 with a green hose clamp. Route hose toward right
side panel grommet holes.

8. Insert short end of one Tube 2 through rear right side
panel grommet drain hole. Secure tube to Hose A with
a green hose clamp.

9. Insert short end of remaining Tube 2 into Hose B from
rubber elbow and secure with green hose clamp. En­sure hoses and tubes maintain a downward slope for
proper drainage and are not kinked or binding.

FRONT

COVER

DRAIN PORT

HOSE

RED HOSE

CLAMP

HOSE

A

GREEN

HOSE

CLAMPS

(3 PLACES)

Upright “Alternate” Connections - Right Side Only

(Upflow Shown, Counterflow Similar)

RIGHT SIDE

PANEL

RUBBER

ELBOW

RUBB ER EL B O W

DRAIN PORT

SILVER HOSE CLAMP

TUBE 1

B

SIDE PANEL

GROMMET

HOLES

TUBE(S) 2

DRAIN
TRAP

33

80 5

OPERATION

UPRIGHT INSTALLATIONS-TRAP ON LEFT SIDE

NOTE: For left side trap installation, grommets must be moved

to the left side of the furnace and the plugs installed on the right
side of the furnace.

1. Remove the rubber plug/cap from the left side drain
port on the front cover.

2. Secure Hose A to front cover drain port with a red hose
clamp. Route hose to rear side panel grommet hole.

3. Cut and remove 1/4 inch from the end of the drain port
on the rubber elbow.

4. Insert Tube 1 into rubber elbow drain port and secure
with silver hose clamp. Angle tube outward toward
front of furnace.

LEFT

SIDE PANEL

FRONT COVER

DRAIN PORT

RED HOSE

CLAMP

HOSE A

5. Cut “X” inches from the long end of Hose B and dis­card. Refer to table for appropriate length to cut. Se­cure remaining hose to Tube 1 with a green hose
clamp. Route other end of Hose B to front left side
panel grommet hole.

NOTE: Long hose “B” must always be connected to Tube 1
and the elbow and not on the front cover.

6. Insert short end of each Tube 2 through side panel
grommet holes. Secure tubes to Hose A and Hose B
with green hose clamps. Ensure hoses and tubes
maintain a downward slope for proper drainage and
that they are not kinked or binding.

RUBBER

ELBOW

RUBBER

ELBOW

DRAIN PORT

SIDE PANEL

DRAIN

HOLES

TUBE(S) 2

DRAIN

TRAP

Cabinet Width

(inches)

17 1/2 60_3 7

21

Models

(kBTU_Tons)

60_4

80_5
100_ 5
115_ 5

"X" Length to Cut F r om Long

GREEN

HOSE B

HOSE CLAMP

Upright “Standard” Connections - Left Side

(Upflow Shown, Counterflow Similar)

End of Ho se B

(inches)

3 1/2

None24 1/2

2. Secure drain trap to side panel at the mounting holes
(dimples or crosshairs on counterflow models) located
below the grommet drain holes.

3. Attach PVC drain line to drain trap outlet with either a
90° elbow or coupling.

SILVER HOSE

CLAMP

TUBE 1

GREEN HOSE

CLAMP

UPRIGHT DRAIN TRAP MOUNTING (LEFT OR RIGHT SIDE PANEL)

1. Insert drain tubes into drain trap and position the drain
trap against the side panel. NOTE: Drain tubes must
reach the bottom of the drain trap.

34

OPERATION

HORIZONTAL INSTALLATIONS
RIGHT SIDE DOWN

Horizontal installations with the right side down require that the
drain hoses be connected to the right side front cover drain port
and the rubber elbow drain port.

NOTE: On counterflow models, relocation of the front cover
pressure switch hose is required.

Make connections as follows:

1. Remove the rubber plug/cap from right side of the front
cover drain port.

Counterflow furnaces

Relocate the front cover pressure switch hose connec­tion from the left side pressure tap to the right (down)
side tap. The pressure switch hose must be connected
to the down side to guard against blocked drain condi­tions. Cut hose to appropriate length to minimize sag­ging. Plug left (unused) pressure tap with plug removed
from right side.

2. Secure Hose A to front cover drain tap with a red hose
clamp. Route hose to rear right (down) side panel grom­met holes.

3. Cut 1/4 inch from the end of the drain port on the rubber
elbow and discard.

4. Insert Tube 1 into rubber elbow drain port and secure
with a silver hose clamp. Angle tube outward toward front
of furnace.

5. Cut 17 3/4 inches from the long end of Hose B and dis­card.

6. Secure remaining end of Hose B to exposed end of Tube
1 with a green hose clamp. Route hose to front right
down side panel grommet holes.

7. Cut 5 1/2 inches straight length from the long end of
each Tube 2 and discard the radius pieces.

8. Insert approximately one inch of each Tube 2 through
the right down side panel grommet holes. Secure tubes
to Hose A and Hose B using green hose clamps. En­sure hoses and tubes maintain a downward slope for
proper drainage and are not kinked or bound.

For details concerning mounting of the drain trap, refer to Con-

densate Drain Lines and Drain Trap - Horizontal Drain Trap Mount­ing.

FRO NT COVER
DRAIN PORT

RED HOSE

CLAMP

HOSE A

HOSE B

TUBES 2

DRAIN TRAP

Allow 4-3 /4”

minimum

for trap

FRONT

COVER

PRESSURE

TAP

GREEN

HOSE

CLAMP

TUBE 1

(3 PLACES)

Horizontal Connections - Right Side Down

(Upflow Shown, Counterflow Similar)

RUBBER ELBOW

DRAIN PORT

SILVER HO SE

CLAMP

RUBBER

ELBOW

RIGHT

SIDE

PANEL

VENT

FIELD SUPPLIED HOSE
AND CONNECTORS

NOTE:

MAKE SMALL
LOOP IN HOSE TO
SERVE AS “P-TRAP”

When using the horizontal alternate

vent configuration, you must use the

RF000142 vent drain kit.

RF000142 KIT

35

OPERATION

Horizontal installations with the left side panel down will require
drain hoses to be connected to the left side front cover drain port
and the side drain port on the rubber elbow.

1. Remove the rubber plug/cap from the front cover left
(down) side drain port.

2. Relocate the front cover pressure switch hose connec­tion from the right side (as shipped) pressure tap to the
left (down) side tap. The pressure switch hose must be
connected to the down side to guard against blocked
drain conditions. Cut hose to appropriate length to mini­mize sagging. Plug right (unused) pressure tap with plug
removed from left side.

3. Secure Hose A to front cover drain port with a red hose
clamp. Route hose to rear left (down) side panel grom­met holes. NOTE: For left side drainage, grommets
must be relocated to left side panel.

4. Remove the rubber cap from the side drain port on the
rubber elbow.

5. Secure the short end of Hose B to rubber elbow side
drain port using a green hose clamp. NOTE: For left
side drainage, route hose to far left (down) side panel
grommet holes. NOTE: Horizontal left side connections
(when using new side port drain elbow) does not require
connecting a hose to the induced draft blower housing.

6. Cut 5 1/2 inches straight length from the long end of
each Tube 2 and discard radius ends.

7. Insert approximately one inch of each Tube 2 through left
side panel grommet hole. Secure tubes to Hose A and
Hose B with a green hose clamps. NOTE: Tube must
reach bottom of trap. Ensure hoses and tubes maintain
a downward slope for proper drainage and that they are
not kinked or binding.

For details concerning mounting of the drain trap, refer to Con-

densate Drain Lines and Drain Trap - Horizontal Drain Trap Mount­ing.

HORIZONTAL DRAIN TRAP MOUNTING (LEFT OR RIGHT SIDE
PANEL)

1. Position the drain trap against side panel with drain tubes
inserted into trap. Note that the trap may be orientated
with the outlet facing either the furnace’s top cover or
base pan.

2. Secure drain trap to side panel at the dimples or
crosshairs located on either side of the grommet drain
holes.

3. Confirm that tubes reach bottom of drain trap and that all
hoses maintain a downward slope and are not kinked or
binding.

4. Attach PVC drain line to drain trap outlet with either a
90° elbow or coupling.

GREEN HOSE

CLAMP

PRESSURE

LEFT SI D E

PANE L

FRON T COVER

DRAIN PORT

RED HOSE CLAMP

36

FRONT
COVER

TAP

SIDE PANEL

GROMMET

HOLES

Horizontal Connections - Left Side Down

(Upflow Shown, Counterflow Similar)

HOSE B

HOSE A

GREEN HOSE

CLAMP

TUBE(S) 2

DRAIN TRAP

Allow

4-3/4” minimum

for trap

OPERATION

Electrical Connections

WARNING

HIGH VOLTAGE !

TO

AVOID THE RISK OF ELECTRICAL SHOCK, WIRING TO

THE UNIT MUST BE POLARIZED AND GROUNDED

WARNING

HIGH VOLTAGE !

TO

AVOID PERSONAL INJURY OR DEATH DUE TO
ELECTRICAL SHOCK, DISCONNECT ELECTRICAL POWER
BEFORE SERVICING OR CHANGING ANY ELECTRICAL
WIRING

.

CAUTION

L

ABEL ALL WIRES PRIOR TO DISCONNECTION WHEN SERVICING
CONTROLS
OPERATION

WIRING HARNESS

The wiring harness is an integral part of this furnace. Field
alteration to comply with electrical codes should not be required.
Wires are color coded for identification purposes. Refer to the
wiring diagram for wire routings. If any of the original wire as
supplied with the furnace must be replaced, it must be replaced
with wiring material having a temperature rating of at least 105°
C. Any replacement wiring must be a copper conductor.

115 VOLT LINE CONNECTIONS

Before proceeding with electrical connections, ensure that the
supply voltage, frequency, and phase correspond to that speci­fied on the unit rating plate. Power supply to the furnace must
be NEC Class 1, and must comply with all applicable codes.
The furnace must be electrically grounded in accordance with
local codes or, in their absence, with the latest edition of The
National Electric Code, ANSI NFPA 70 and/or The Canadian
Electric Code CSA C22.1.

Use a separate fused branch electrical circuit containing prop­erly sized wire, and fuse or circuit breaker. The fuse or circuit
breaker must be sized in accordance with the maximum
overcurrent protection specified on the unit rating plate. An elec­trical disconnect must be provided at the furnace location.

Connect hot, neutral, and ground wires as shown in the wiring
diagram located on the unit’s blower door. For direct vent appli­cations, the cabinet opening to the junction box must be sealed
air tight using either an UL approved bushing such as Heyco
Liquid Tight or by applying non-reactive UL approved sealant to
bushing.

. W

IRING ERRO RS CAN CAUSE IMPROPER AND DANGEROUS

. V

ERIFY PROPER OPERATION AFTER SERVICING

.

.

Line polarity must be observed when making field connections.
Line voltage connections can be made through either the right
or left side panel. The furnace is shipped configured for a right
side (left side for counterflows) electrical connection with the
junction box located inside the burner compartment. To make
electrical connections through the opposite side of the furnace,
the junction box must be relocated to the other side of the burner
compartment prior to making electrical connections. To relo­cate the junction box, follow the steps shown below.

NOTE: Wire routing must not to interfere with circulator blower
operation, filter removal, or routine maintenance.

JUNCTION BOX RELOCATION

WARNING

E

DGES OF SHEET METAL HOLES MAY BE SHARP

PRECAUTION WHEN REMOVING HOLE PLUGS

.

. USE

GLOVES AS A

WARNING

TO

PREVENT PERSONAL INJURY OR DEATH DUE TO ELECTRIC SHOCK
DISCONNECT ELECTRICAL POWER BEFORE INSTALLING OR SERVICING THIS
UNIT

.

,

WARNING

HIGH VOLTAGE !

TO

AVOID THE RISK OF INJURY, ELECTRICAL SHOCK OR
DEATH, THE FURNACE MUST BE ELECTRICALLY
GROUNDED IN ACCORDANCE WITH LOCAL CODES OR IN
THEIR ABSENCE, WITH THE LATEST EDITION OF THE

N

ATIONAL ELECTRIC CODE

.

Line voltage connections can be made through either the right
or left side panel. The furnace is shipped configured for a right
side electrical connection. To make electrical connections
through the opposite side of the furnace, the junction box must
be relocated to the left side prior to making electrical connec­tions. To relocate the junction box, perform the following steps.

1. Remove the burner compartment door.

2. Remove and save the two screws securing the junction
box to the side panel.

3. Relocate junction box and associated plugs and grom­mets to opposite side panel. Secure with screws re­moved in step 2.

WARNING

TO

AVOID THE RISK OF INJURY, ELECTRICAL SHOCK OR DEATH, THE

FURNACE MUST BE ELECTRICALLY GROUNDED IN ACCORDANCE WITH
LOCAL CODES OR, IN THEIR ABSENCE, WITH THE LATEST EDITION OF THE
NATIONAL ELECTRICAL CODE

.

37

OPERATION

To ensure proper unit grounding, the ground wire should run
from the furnace ground screw located inside the furnace junc­tion box all the way back to the electrical panel. NOTE: Do not
use gas piping as an electrical ground. To confirm proper unit
grounding, turn off the electrical power and perform the following
check.

1. Measure resistance between the neutral (white) con­nection and one of the burners.

2. Resistance should measure 10 ohms or less.

This furnace is equipped with a blower door interlock switch which
interrupts unit voltage when the blower door is opened for servic­ing. Do not defeat this switch.

24 VOLT THERMOSTAT WIRING

IMPORTANT NOTE

W

IRE ROUT ING MUST NOT INTERFERE WITH CIRCULATOR BLOWER

OPERATION, FILTER REMO VAL OR ROUT INE MAINTENANCE

REMO VABLE PLUG CONNECTOR IS PROVIDED WITH THE CONTROL TO

A

MAKE THERMOSTAT WIRE CONNECTIONS
WIRE CONNECTIONS MADE TO THE PLUG, AND REPLACED

STRONGLY

TERMINAL BE TWISTED TOGETH ER PRIOR TO INSERTING INTO THE PLUG
CONNECTOR
OPERATION

RECO MMENDED THAT MULTIPLE WIRES INTO A SINGLE

. F

AILURE TO DO SO MAY RESU LT IN INTERMITTENT

.

. T

HIS PLUG MAY BE REMOVED

. IT IS

.

,

IMPORTANT NOTE

DIP

SWITCH

#13 MUST BE

THE

CTK01

SET TO
COMMUNICATING
MODULATING THERMOSTAT, CHECK TO MAKE SURE DIP SWITCH
IN THE
POSITION WHEN USING A NON-COMMUNICATING SINGLE-STAGE
THERMOSTAT

COMMUN ICAT ING THERMOSTAT, DIP SWITCH

ON

POSITION

2-

OFF

POSITION (FACTORY POSITION

.

SET TO MATCH THERMOSTAT TYPE

#13

. T

HIS IS ALSO THE CORRECT SETTING FOR A NON

STAGE THERMOSTAT

. TO

USE

CTK02**

). T

HIS IS ALSO THE CORRECT

. TO

USE

MUST BE

#13 IS

-

When installed with a non-communicating thermostat, the fur­nace integrated control module provides terminals for both “W1”
and “W2”, and “Y1” and “Y2” thermostat connections. This allows
the furnace to support the following system applications: ‘Two­Stage Heating Only’, ‘Two-Stage Heating with Single Stage Cool­ing’, and ‘Two-Stage Heating with Two-Stage Cooling’. Refer to
the following figures for proper connections to the integrated con­trol module.

Low voltage connections can be made through either the right or
left side panel. Thermostat wiring entrance holes are located in
the blower compartment. The following figure shows connections
for a “heat/cool system”.

This furnace is equipped with a 40 VA transformer to facilitate use
with most cooling equipment. Consult the wiring diagram, lo­cated on the blower compartment door, for further details of 115
Volt and 24 Volt wiring.

NOTE: Use of ramping profiles requires a jumper between Y1
and O.

IMPORTANT NOTE

T

HERMOSTAT

C

OMFORT ALERT™ MODULE OR IF THE OUTDOOR UNIT IS A PART OF

THE COMFORTNET™ FAMILY OF EQUIPM EN T

“R”

REQUIRED IF OUTDOOR UNIT IS EQUIPPED WITH A

.

DEHUM

W2

W1

1Y12

24 V THERM OSTAT CONNECTIONS

Low Voltage Connections with Auxiliary Terminals

C

R

G

Y2

O

AUX

The auxiliary contacts are shipped with a factory installed
jumper. As an option, the auxiliary contacts may be wired to
a normally closed float switch. In the event of open contacts,
the furnace will be disabled until the condition is corrected.
These are 24 volt terminals fed internally , do not apply another
voltage source to these terminals.

R

R

Y C

Remote

Condensing Unit

(Single -St age Co oli n g)

NEU

Furnace Integrated

Control Module

Dehumidistat

[Optional]

Thermostat - Single-Stage Heating with Single-Stage Cooling

IMPORTANT NOTE

TO

APPLY A SINGLE-STAGE HEATING THERMOSTAT, THE THERMOSTAT
SELECTOR SWITCH ON THE INTEGRATED CONTROL MODULE
SET ON SINGLE-STAGE

.

MUST BE

_____________________________________

R

R

Y C

Remote

Condensing Unit

(Single-Stage Cooling)

Thermostat - Two-Stage Heating with Single-Stage Cooling

NEU

Furnace Integrat ed

Control Module

Dehumidistat

[Optional]

38

OPERATION

Y2

Y2

Y2

Remote

Condensing Unit

(Two-Stage Cooling)

Thermostat - Two-Stage Heating with Two-Stage Cooling

W1 W2

W1 W2

NEU

Furnace Integrated

Dehumidistat

[Optional]

Control Module

IMPORTANT NOTE

SET

DIP SWITCH

COOL I N G THERMOSTAT

#14 TO ON

POSITION WHEN USING A

.

Thermostat Wiring Diagrams

2-

STAGE

THERMOSTAT APPLICATION

The modulating furnace can be operated with a CTK01 com­municating thermostat or a CTK02** or CTK03AA communi­cating-modulating thermostat. It also facilitates operation with
a non-communicating single or two stage heat / cool thermo­stat.

NOTE: DIP switch #13 (Heating thermostat selection)must
be checked and set regardless of the thermostat chosen.
Factory setting is OFF (single stage), this is also the correct
position if using CTK02** thermostat. To use a CTK01 or a
non-communicating two stage thermostat, set the switch to
the ON position.

Operation with CTK03AA

1. Humidification Options are ON / OFF with the CTK03AA.
When “On” is selected, the humidification relay on the
furnace control board will function during a heat call if a
humidity demand exists. Selecting “Off” means the hu­midification relay will not function.

2. If the CTK03AA is set up so the compressor off delay is 0
min, it will display a cool / heat call immediately regard­less of the delay built into the outdoor unit control board.
This means the CTK03AA could show COOL ON when
the outdoor unit is still in a delay period. The recommen­dation is to set up the compressor delay to at least 3
minutes

3. Dual Fuel – When the CTK03AA calls for gas heat, the
heat pump will shut off, after a delay of approximately 3
minutes it will then turn on gas heat.

4. Dehumidification (lowering of CFM to 85%) only happens
during low stage cooling operation. The dehumidification
feature is not active during high stage cool. The CTK03AA
can be set up to overcool the home in order to reach the
RH set point.

NOTE: In non-communicating installations with a condensing
unit, DIP switch #14 must be checked and set to match a
single or two stage condensing unit. Factory setting is OFF
(single stage).

24 VOLT DEHUMIDISTAT WIRING

The optional usage of a dehumidistat allows the furnace’s circula­tor blower to operate at a slightly lower speed (85% of desired
speed) during a combined thermostat call for cooling and dehu­midistat call for dehumidification. This can be done through an
independent dehumidistat or through a thermostat’s DEHUM ter­minal (if available). This lower blower speed enhances dehumidi­fication of the conditioned air as it passes through the AC coil.
For proper function, a dehumidistat applied to this furnace must
operate on 24 VAC and utilize a switch which opens on humidity
rise. Refer to the “Thermostat Wiring Diagrams” figure for ad­ditional wiring details.

To install/connect a dehumidistat:

1. Turn OFF power to furnace.

2. Secure one dehumidistat lead to the terminal marked
“DEHUM” on the furnace integrated control module.

3. Secure the other dehumidistat lead to the terminal marked
“R” on the furnace integrated control module.

4. Secure the dehumidistat ground wire (typically the green
lead) to the ground screw on the furnace junction box.
NOTE: Ground wire may not be present on all
dehumidistats.

5. Turn ON power to furnace.

To enable the dehumidify function on the integrated control mod­ule, set the dehumidification ENABLE DIP switch from OFF to
ON.

Once the switch is set, the dehumidify function is enabled during
a combination call for cooling (T-Stat) and dehumidification
(DEHUM-Stat). Refer to the DIP switch chart in the back sec­tion of this manual.

FOSSIL FUEL APPLICATIONS

This furnace can be used in conjunction with a heat pump in a
fossil fuel application. A fossil fuel application refers to a com­bined gas furnace and heat pump installation which uses an out­door temperature sensor to determine the most cost efficient
means of heating (heat pump or gas furnace).

A heat pump thermostat with three stages of heat is required to
properly use a two-stage furnace in conjunction with a heat pump.
Refer to the fossil fuel kit installation instructions for additional
thermostat requirements.

Strictly follow the wiring guidelines in the fossil fuel kit installation
instructions. All furnace connections must be made to the fur­nace two-stage integrated control module and the “FURNACE”
terminal strip on the fossil fuel control board.

39

A

OPERATION

115 VOLT LINE CONNECTION OF ACCESSORIES (HUMIDIFIER AND
ELECTRONIC AIR CLEANER)

WARNING

HIGH VOLTAGE !

TO

AVOID PERSONAL INJURY OR DEATH DUE TO
ELECTRICAL SHOCK, DISCONNECT ELECTRICAL POWER
BEFORE SERVICING OR CHANGING ANY ELECTRICAL
WIRING

.

The furnace integrated control module is equipped with line volt­age accessory terminals for controlling power to an electronic air
cleaner.

The accessory load specifications are as follows. (The furnace
control board also has a set of dry contacts for humidifier
connection.)

Humidifier 1.0 Amp maximum at 120 VAC

Electronic Air Cleaner 1.0 Amp maximum at 120 VAC

Turn OFF power to the furnace before installing any accessories.
Follow the humidifier or air cleaner manufacturers’ instructions for
locating, mounting, grounding, and controlling these accesso­ries. Accessory wiring connections are to be made through the
1/4" quick connect terminals provided on the furnace integrated
control module. The Electronic air cleaner hot terminal is iden­tified as EAC. It is necessary to remove the protective tab on
the board cover to access the EAC Terminal. The EAC neu­tral terminal is identified as NEUTRAL. A line voltage hu­midifier may be connected between one of the HUM con­tacts and NEUTRAL. The other HUM contact must be fed
from the L1 terminal.

All field wiring must conform to applicable codes. Connections
should be made as shown in the following figure.

If it is necessary for the installer to supply additional line voltage
wiring to the inside of the furnace, the wiring must conform to all
local codes, and have a minimum temperature rating of 105°C.
All line voltage wire splices must be made inside the furnace
junction box.

The integrated furnace control HUM (dry contacts) are closed
whenever the inducer is energized in a non-communicating
installation. When used with a CTK02** communicating ther­mostat, the HUM terminals are closed whenever there is a
call for humidity. The integrated control module electronic air
cleaner terminals (EAC) are energized with 115 volts whenever
the circulator blower is energized.

24 VOLT HUMIDIFIER

A 24 volt humidifier can be powered by feeding one of the
HUM terminals with a field installed wire from the R terminal
or by connecting to the NO side of the low fire pressure switch.

Gas Supply and Piping

The furnace rating plate includes the approved furnace gas input
rating and gas types. The furnace must be equipped to operate
on the type of gas applied. This includes any conversion kits
required for alternate fuels and/or high altitude.

CAUTION

TO

PREVENT UNRELIABLE OPERATION OR EQUIPM EN T DAMAGE, THE
INLET GAS SUPPLY PRESSURE MUST BE AS SPECIFIED ON THE UNIT
RATING PLATE WITH ALL OTHER HOUSEHOLD GAS FIRED APPLIANCES
OPERATING

.

Inlet gas supply pressures must be maintained within the ranges
specified in the following table. The supply pressure must be
constant and available with all other household gas fired appli­ances operating. The minimum gas supply pressure must be
maintained to prevent unreliable ignition. The maximum must not
be exceeded to prevent unit overfiring.

NEUTRAL

L1

UX OUT

AUX IN

Accessories Wiring

40

Inlet Gas Supply Pressure
Natural Gas Minimum: 4.5" w.c. Maximum: 10.0" w.c.
Propane Gas Minimum: 11.0" w.c. Maximum: 13.0" w.c.

HIGH ALTITUDE

The modulating furnace is approved up to 10,000 ft altitude.
Do not derate the furnace by adjusting the manifold pressure to

a lower pressure.
In some areas the gas supplier may artificially derate the gas in

an effort to compensate for the effects of altitude. If the gas is
artificially derated, the appropriate orifice size must be determined
based upon the BTU/ft3 content of the derated gas and the alti­tude. Refer to the National Fuel Gas Code, NFPA 54/ANSI Z223.1,
and information provided by the gas supplier to determine the
proper orifice size.

.

OPERATION

PROPANE GAS CONVERSION

WARNING

P

OSSIBLE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH MAY
OCCUR IF THE CORRECT CONVERSION KITS ARE NOT INSTALLED
APPROPRIATE KITS MUST BE APPLIED TO ENSURE SAFE AND PROPER
FURNACE OPERATION
QUALIFIED INSTALLER OR SERVICE AGENCY

. ALL

CONVERSIONS MUST BE PERFORMED BY A

.

. THE

This unit is configured for natural gas. The appropriate
manufacturer’s propane gas conversion kit, must be applied for
propane gas installations.

LP KIT

MODEL

LPKMOD060UF *MVM960603BX
LPKMOD080UF *MVM960805CX

LPKMOD100UF *MVM961005DX
LPKMOD115UF *MVM961155DX

LPKMOD060CF *CVM960604CX
LPKMOD080CF *CVM960805DX

LPKMOD 100C F *CVM961005DX

(*= A or G)

The indicated kits must be used to insure safe and proper furnace
operation. All conversions must be performed by a qualified in­staller, or service agency.

GAS PIPING CONNECTIONS

WARNING

TO

AVOID POSSIBLE UNSATISFACTORY OPERATION OF EQUIPMEN T
DAMAGE DUE TO UNDERFIRIN G OR EQUIPM EN T, USE THE PROPER SIZE
OF NATURAL/PROPANE GAS PIPING NEEDED WHEN RUNNING PIPE FROM
THE METER/TANK TO THE FURNACE

.

When sizing a trunk line, be sure to include all appliances which
will operate simultaneously when sizing a trunk line.

The gas piping supplying the furnace must be properly sized based
on the gas flow required, specific gravity of the gas, and length of
the run. The gas line installation must comply with local codes,
or in their absence, with the latest edition of the National Fuel
Gas Code, NFPA 54/ANSI Z223.1.

Natural Gas Capacity of Pipe

Length of Nominal Black Pipe Size

Pipe in Feet 1/2" 3/4" 1" 1 1/4" 1 1/2"

10 132 278 520 1050 1600
20 92 190 350 730 1100
30 73 152 285 590 980
40 63 130 245 500 760
50 56 115 215 440 670
60 50 105 195 400 610
70 46 96 180 370 560
80 43 90 170 350 530
90 40 84 160 320 490

100 38 79 150 305 460

(Pressure 0.5 psig or less and pressure drop of 0.3" W.C.; Based on

0.60 Specific Gravity Gas)
BTUH Furnace Input

CFH =

Heat i ng Value of Gas (BTU/Cubic Foot)

In Cubic Feet of Gas Per Hour (CFH)

To connect the furnace to the building’s gas piping, the installer
must supply a ground joint union, drip leg, manual shutoff valve,
and line and fittings to connect to gas valve. In some cases, the
installer may also need to supply a transition piece from 1/2" pipe
to a larger pipe size.

The following stipulations apply when connecting gas piping. Re­fer to Gas Piping Connections figure for typical gas line connec­tions to the furnace.

• Gas piping must be supported external to the furnace
cabinet so that the weight of the gas line does not
distort the burner rack, manifold or gas valve.

• Use black iron or steel pipe and fittings for building
piping. Where possible, use new pipe that is properly
chamfered, reamed, and free of burrs and chips. If old
pipe is used, be sure it is clean and free of rust, scale,
burrs, chips, and old pipe joint compound.

• Use pipe joint compound on male threads ONLY. Al­ways use pipe joint compound (pipe dope) that is AP­PROVED FOR ALL GASSES. DO NOT apply com­pound to the first two threads.

• Use ground joint unions.

• Install a drip leg to trap dirt and moisture before it can
enter the gas valve. The drip leg must be a minimum
of three inches long.

• Install a 1/8" NPT pipe plug fitting, accessible for test
gage connection, immediately upstream of the gas
supply connection to the furnace.

• Always use a back-up wrench when making the con­nection to the gas valve to keep it from turning. The
orientation of the gas valve on the manifold must be
maintained as shipped from the factory. Maximum
torque for the gas valve connection is 375 in-lbs; ex­cessive over-tightening may damage the gas valve.

• Install a manual shutoff valve between the gas meter
and unit within six feet of the unit. If a union is in­stalled, the union must be downstream of the manual
shutoff valve, between the shutoff valve and the furnace.

41

A

OPERATION

GAS LINE

PLUG IN

GAS LINE

HOLE

PIPE UNION

BURNERS

MANIFOLD

GROUND JOINT

PIPE UNION

GAS VALVE

GAS VALVE

BURNERS

MANUAL SHUT-OFF VALVE

(UPSTREAM FROM GROUND

JOINT PIPE UNION)

DRIP LEG

GROM M E T IN STAN DA RD

GAS LINE HOLE

MANUAL

SHUT OFF VALVE

(UPST R EAM FROM

PIPE UNION)

HEIGHT REQUIRED

BY LOCAL CODE

GROMMET

IN STANDARD

GAS LINE HOLE

DRIP LEG

DRIP LEG

BURNERS

GAS VALVE

PLUG IN

LTE RNATE

GAS LINE

GAS VALVE

BURNERS

HOLE

PLUG IN ALTERNA T E

GAS LINE HOL E

ALTERNATE GAS

LINE LOCATION

MANIFOLD

HORIZONTAL [UPFLOW MODEL]

42

DRAIN TRAP

Gas Piping Connections

ALTERNATE GAS

LINE LOCATION

DRAIN TRAP

MANIFOLD

PLUG IN ALTERNA T E
GAS LINE HOLE

HORIZONTAL[COUNTERFLOW]

OPERATION

• Tighten all joints securely.

• Connect the furnace to the building piping by one of the
following methods:

– Rigid metallic pipe and fittings.
– Semi-rigid metallic tubing and metallic fittings.

Aluminum alloy tubing must not be used in exterior lo­cations. In order to seal the grommet cabinet penetra­tion, rigid pipe must be used to reach the outside of the
cabinet. A semi-rigid connector to the gas piping may
be used from there.

• Use listed gas appliance connectors in accordance with
their instructions. Connectors must be fully in the same
room as the furnace.

• Protect connectors and semirigid tubing against physi­cal and thermal damage when installed. Ensure alumi­num-alloy tubing and connectors are coated to protect
against external corrosion when in contact with ma­sonry, plaster, or insulation, or subjected to repeated
wetting by liquids such as water (except rain water),
detergents, or sewage.

DIRECT/STANDARD INLET PIPING

GAS PIPING CHECKS

Before placing unit in operation, leak test the unit and gas con­nections.

WARNING

TO

AVOID THE POSSIBILITY OF EXPLOSION OR FIRE, NEVER USE A MATCH

OR OPEN FLAME TO TEST FOR LEAKS

Check for leaks using an approved chloride-free soap and water
solution, an electronic combustible gas detector, or other ap­proved testing methods.

NOTE: Never exceed specified pressures for testing. Higher
pressure may damage the gas valve and cause subsequent
overfiring, resulting in heat exchanger failure.

Disconnect this unit and shutoff valve from the gas supply piping
system before pressure testing the supply piping system with
pressures in excess of 1/2 psig (3.48 kPa).

Isolate this unit from the gas supply piping system by closing its
external manual gas shutoff valve before pressure testing supply
piping system with test pressures equal to or less than 1/2 psig
(3.48 kPA).

.

PROPANE GAS TANKS AND PIPING

WARNING

E

DGES OF SHEET METAL HOLES MAY BE SHARP

PRECAUTION WHEN REMOVING HOLE PLUGS

When gas piping enters directly to the gas valve through the stan­dard inlet hole, the installer must supply straight pipe with a ground

joint union to reach the exterior of the furnace. The rigid pipe must
be long enough to reach the outside of the cabinet to seal the
grommet cabinet penetration. A semi-rigid connector to the gas
piping can be used outside the cabinet per local codes.

.

. USE

GLOVES AS A

INDIRECT/ALTERNATE INLET PIPING

When gas piping enters indirectly to the gas valve through the
alternate gas inlet hole the following fittings (starting from the gas

valve) to reach the outside of the cabinet must be supplied:

• Close nipple.

• 90 degree elbow.

• 2½ inch nipple.

• 90 degree elbow.

• Straight pipe, with a ground joint union, to reach the exterior

of the furnace. The rigid pipe must be long enough to reach
the outside of the cabinet so as to seal the grommet cabinet
penetration. A semi-rigid connector to the gas piping can be
used outside the cabinet per local codes.

WARNING

IF

THE GAS FURNACE IS INSTALLED IN A BASEMENT, AN EXCAVATED
AREA OR CONFI NED SPACE, IT IS STRO NGLY RECOMMENDED TO
CONTA CT A PROPANE SUPPLIER TO INSTALL A GAS DETECTING WARNING
DEVICE IN CASE OF A GAS LEAK

S

INCE PROPANE GAS IS HEAVIER THAN AIR, ANY LEAKING GAS CAN

•

SETTLE IN ANY LOW AREAS OR CONFI NED SPACES

•

ROPANE GAS ODORANT MAY FADE, MAKING THE GAS UNDETECTABLE

P

EXCEPT WITH A WARNING DEVICE

A gas detecting warning system is the only reliable way to detect
a propane gas leak. Rust can reduce the level of odorant in pro­pane gas. Do not rely on your sense of smell. Contact a local
propane gas supplier about installing a gas detecting warning
system. If the presence of gas is suspected, follow the instruc­tions listed in the Safety Precautions section of this manual.

All propane gas equipment must conform to the safety standards
of the National Board of Fire Underwriters, NBFU Manual 58.

For satisfactory operation, propane gas pressure must be 10”
WC + .5” WC a t the furnace manifold with all gas appliances in
operation. Maintaining proper gas pressure depends on three main
factors:

1. Vaporization rate, depending on temperature of the liq­uid, and “wetted surface” area of the container or con­tainers.

.

.

.

43

OPERATION

2. Proper pressure regulation. (Two-stage regulation is
recommended for both cost and efficiency).

3. Pressure drop in lines between regulators, and be­tween second stage regulator and the appliance. Pipe
size will depend on length of pipe run and total load of
all appliances.

Complete information regarding tank sizing for vaporization, rec­ommended regulator settings, and pipe sizing is available from
most regulator manufacturers and propane gas suppliers.

Since propane gas will quickly dissolve white lead and most stan­dard commercial compounds, special pipe dope must be used.
Shellac-based compounds resistant to the actions of liquefied
petroleum gases such as Gasolac®, Stalactic®, Clyde’s® or
John Crane® are satisfactory.

Refer to the following illustration for typical propane gas installa­tions and piping.

Sizing Between Second or Second Stage Regulator & Appliance*

Maximum Propane Capacities listed are based on 1/2" W.C. pressure drop at 11" W.C. setting.
Capacities in 1,000 BTU/hour.

Pipe or
Tubing
Length

Feet

10 39 92 199 329 501 275 567 1,071 2,205 3,307
20 26 62 131 216 346 189 393 732 1,496 2,299
30 21 50 107 181 277 152 315 590 1,212 1,858
40 19 41 90 145 233 129 267 504 1,039 1,559
50 18 37 79 131 198 114 237 448 913 1,417
60 16 35 72 1,211 187 103 217 409 834 1,275

80 13 29 62 104 155 89 185 346 724 1,066
100 11 26 55 90 138 78 162 307 630 976
125 10 24 48 81 122 69 146 275 567 866
150 9 21 43 72 109 63 132 252 511 787
200 8 19 39 66 100 54 112 209 439 665
250 8 17 36 60 93 48 100 185 390 590

*Data in accordance with NFPA pamphlet No. 54

Tubing Size, O.D. Type L

3/8" 1/2" 5/8" 3/4" 7/8" 1/2" 3/4" 1" 1-1/4" 1-1/2"

Nominal Pipe Size

Schedule 40

Propane Gas Piping Chart II

Circulating Air & Filters

DUCT WORK - AIR FLOW

200 PSIG
Maximum

5 to 15 PSIG
(20 PS IG Max.)

Continuous

Second Stage
Regulator

11" W.C.

First Stage
Regulator

Propane Gas Installation (Typ.)

Sizing Between First and Second Stage Regulator*

Maximum Propane Capacities listed are based on 2 psig pressure drop at 10 psig setting.
Capacities in 1,000 BTU/h ou r.

Pipe or
Tubing
Length

Feet

10 730 1,700 3,200 5,300 8,300 3,200 7,500
20 500 1,100 220 3,700 5,800 2,200 4,200
30 400 920 2,000 2,900 4,700 1,800 4,000
40 370 850 1,700 2,700 4,100 1,600 3,700
50 330 770 1,500 2,400 3,700 1,500 3,400
60 300 700 1,300 2,200 3,300 1,300 3,100

80 260 610 1,200 1,900 2,900 1,200 2,600
100 220 540 1,000 1,700 2,600 1,000 2,300
125 200 490 900 1,400 2,300 900 2,100
150 190 430 830 1,300 2,100 830 1,900
175 170 400 780 1,200 1,900 770 1,700
200 160 380 730 1,100 1,800 720 1,500

To convert to capacities at 15 psig settings - multiply by 1.130
To convert to capacities at 5 psig setti n gs - multiply by 0.879

Tubing Size, O.D. Type L

3/8" 1/2" 5/8" 3/4" 7/8" 1/2" 3/4"

Nominal Pipe Size

Schedule 40

Propane Gas Piping Chart I

WARNING

N

EVER ALLOW THE PRODUCTS OF COMBUSTION, INCLUDING CARB ON
MONOXIDE, TO ENTER THE RETU RN DUCT WORK OR CIRCULATION AIR
SUPPLY

.

Duct systems and register sizes must be properly designed for
the CFM and external static pressure rating of the furnace. De­sign the ductwork in accordance with the recommended meth­ods of “Air Conditioning Contractors of America” Manual D.

Install the duct system in accordance with Standards of the Na­tional Board of Fire Underwriters for the Installation of Air Condi­tioning, Warm Air Heating and Ventilating Systems. Pamphlets
No. 90A and 90B.

A closed return duct system must be used, with the return duct
connected to the furnace. NOTE: Ductwork must never be at-
tached to the back of the furnace. For upflow installations requir-
ing 1800 CFM or more, use either two side returns or bottom
return or a combination of side /bottom. Flexible joints may be
used for supply and return connections to reduce noise transmis­sion. To prevent the blower from interfering with combustion air or
draft when a central return is used, a connecting duct must be
installed between the unit and the utility room wall. Never use a
room, closet, or alcove as a return air chamber.

CHECKING DUCT STATIC

Refer to your furnace rating plate for the maximum ESP (ex­ternal duct static) rating.

Total external static refers to everything external to the fur­nace cabinet. Cooling coils, filters, ducts, grilles, registers
must all be considered when reading your total external static
pressure. The supply duct pressure must be read between
the furnace and the cooling coil. This reading is usually taken
by removing the “A” shaped block off plate from the end on
the coil; drilling a test hole in it and reinstalling the block off
plate. Take a duct static reading at the test hole. Tape up the
test hole after your test is complete. The negative pressure
must be read between the filter and the furnace blower.

44

OPERATION

Too much external static pressure will result in insufficient
air that can cause excessive temperature rise. This can cause
limit switch tripping and heat exchanger failure.

To determine total external duct static pressure, proceed as
follows;

1. With clean filters in the furnace, use a draft gauge (in­clined manometer) to measure the static pressure of the
return duct at the inlet of the furnace. (Negative Pres­sure)

2. Measure the static pressure of the supply duct. (Positive
Pressure)

3. The difference between the two numbers is .4” w.c.

Example:

static reading from return duct = -0.1" w.c.
static reading from supply duct = 0.3" w.c.
total external static pressure on this system = 0.4"

w.c.
NOTE: Both readings may be taken simultaneously and

read directly on the manometer if so desired. If an air condi­tioner coil or Electronic Air Cleaner is used in conjunction
with the furnace, the readings must also include theses com­ponents, as shown in the following drawing.

4. Consult proper tables for the quantity of air.

If the total external static pressure exceeds the maximum
listed on the furnace rating plate, check for closed dampers,
registers, undersized and/or oversized poorly laid out duct
work.

BOTTOM RETURN AIR OPENING [UPFLOW MODELS]

The bottom return air opening on upflow models utilizes a “lance
and cut” method to remove sheet metal from the duct opening in
the base pan. To remove, simply press out the lanced sections
by hand to expose the metal strips retaining the sheet metal over
the duct opening. Using tin snips, cut the metal strips and re­move the sheet metal covering the duct opening. In the corners
of the opening, cut the sheet metal along the scribe lines to free
the duct flanges. Using the scribe line along the duct flange as a
guide, unfold the duct flanges around the perimeter of the opening
using a pair of seamer pliers or seamer tongs. NOTE: Airflow
area will be reduced by approximately 18% if duct flanges are not
unfolded. This could cause performance issues and noise is­sues.

WARNING

E

DGES OF SHEET METAL HOLES MAY BE SHARP
PRECAUTION WHEN REMOVING SHEET METAL FROM RETURN AIR
OPENINGS

.

CUT USING TIN SNIPS

. USE

GLOVES AS A

PRESS OUT BY HAND

Checking Static Pressure

CUT FOUR CORNERS
AFTER REMOVING SHEET
METAL

SCRIBE LINES OUTLINING
DUCT FLANGES

Duct Flange Cut Outs

When the furnace is used in connection with a cooling unit, the
furnace should be installed in parallel with or on the upstream
side of the cooling unit to avoid condensation in the heating ele­ment. With a parallel flow arrangement, the dampers or other
means used to control the flow of air must be adequate to prevent
chilled air from entering the furnace and, if manually operated,
must be equipped with means to prevent operation of either unit
unless the damper is in the full heat or cool position.

When the furnace is installed without a cooling coil, it is recom­mended that a removable access panel be provided in the outlet
air duct. This opening shall be accessible when the furnace is
installed and shall be of such a size that the heat exchanger can
be viewed for visual light inspection or such that a sampling probe
can be inserted into the airstream. The access panel must be
made to prevent air leaks when the furnace is in operation.

When the furnace is heating, the temperature of the return air
entering the furnace must be between 55°F and 100°F.

45

OPERATION

FILTERS - READ THIS SECTION BEFORE INSTALLING THE RETURN
AIR DUCT WORK

Filters must be used with this furnace. Discuss filter maintenance
with the building owner. Filters do not ship with this furnace, but
must be provided, sized and installed externally by the installer.
Filters must comply with UL900 or CAN/ULCS111 standards. If
the furnace is installed without filters, the warranty will be voided.

On upflow units, guide dimples locate the side return cutout loca­tions. Use a straight edge to scribe lines connecting the dimples.
Cut out the opening on these lines. NOTE: An undersized open­ing will cause reduced airflow.

Refer to Minimum Filter Area tables to determine filter area re­quirements.

COO LING AI RFLOW REQU IRE MENT (CFM)

600 800 1000 1200 1400 1600 2000

0603__XA --- --- 627* 627* 672 768 --­0805__XA --- --- --- 836* 836* 836* 960

Input

Airflow

1005__XA
1155__XA

0604__XA --- --- 320* 320* 336 384 --­0805__XA

Input

Airflow

1005__XA

--- --- --- 940* 940* 940* 960

COO LING AI RFLOW REQU IRE MENT (CFM)

600 800 1000 1200 1400 1600 2000

--- --- --- 427* 427* 427* 480

*Minimum filter area dictated by heating airflow requirement.

Permanent Minimum Filter Area (sq. in)

[Based on a 600 ft/min filter face velocity]

COOLING AIRFLOW REQUIREMENT (CFM)

600 800 1000 1200 1400 1600 2000

0603__XA --- --- 564* 564* 672 768

UPFLOW

COUNTERFLOW

UPFLOW

UPRIGHT INSTALLATIONS

Depending on the installation and/or customer preference, differ­ing filter arrangements can be applied. Filters can be installed in
the central return register or a side panel external filter rack kit
(upflows). As an alternative a media air filter or electronic air
cleaner can be used as the requested filter.

The following figure shows possible filter locations.

AIR FLOW

CENTRAL

RETURN

GRILLE

SIDE RETURN

EXTERNAL FILTER

FILTER

RETURN

(Field Supplied)

(EITHER SIDE)

FILTER

ACCESS

DOOR

DUCT

FILTER

SUPPORT

BRACKET

RACK KIT

FILTER

Possible Upright Upflow

FILT

ER

R

E

T

L

I

F

CENTRAL

RETURN

GRILLE

0805__XA --- --- --- 752* 752* 768 960

Input

Airflow

1005__XA
1155__XA

0604__XA --- --- 641* 641* 672 768 --­0805__XA

Input

Airflow

1005__XA

--- --- --- 940* 940* 940* 960

COUNTERFLOW

COOLING AIRFLOW REQUIREMENT (CFM)

600 800 1000 1200 1400 1600 2000

--- --- --- 854* 854* 854* 960

*Minimum filter area dictated by heating airflow requirement.

Disposable Minimum Filter area (sq. in)

[Based on 300 ft/min filter face velocity]

46

AIR FLOW

Possible Upright Counterflow

Filter Locations

OPERATION

HORIZONTAL INSTALLATIONS

Filters must be installed in either the central return register or in
the return air duct work.

IGNITION

(80%)

Startup Procedure & Adjustment

Furnace must have a 115 VAC power supply properly connected
and grounded. Proper polarity must be maintained for correct
operation. In addition to the following start-up and adjustment
items, refer to further information in Operational Checks section.

100%

IGNITION

(80%)

78%

57%

MIN.

2 MINS.

Operation with Conventional 1-Stage Thermostat

(DIP switch selections 1-Stage heat)

Call for heat, thermostat energizes W1 on IFC (W2 input is
ignored).

After a successful Light Off Sequence and expiration of the
Ignition Stabilization Period:

• After 2 minutes, the IFC increases to 57% at a rate of
1% per second

• After 10 total minutes, the IFC increases to 78% at a
rate of 1% per second.

• After 20 total minutes, the IFC increases to 100% at a
rate of 1% per second for the remainder of the call for
heat.

• The circulator is adjusted to the appropriate CFM, cor­responding to the current firing rate.

UNIT CALL FOR HEAT ENDS

10 MINS.

8 MINS.

70%

10 MINS.

60%

50%

2 MINS.

MIN.

8 MINS.

Operation with Conventional 2-Stage Thermostat

(DIP switch selects 2-stage heat)

Call for 1st-Stage Heat - Thermostat contacts close R to W1.

After a successful Light Off Sequence and expiration of the
Ignition Stabilization Period:

• The IFC adjusts to the low firing rate.

• After 2 minutes, the IFC increases to 50% fort he next
8 minutes.

• Thereafter, the IFC will increase 10%, at a rate of 1%
per second, every 10 minutes for the remainder of the
call for heat (See above figure).

• The circulator is adjusted to the appropriate CFM, cor­responding to the current firing rate.

47

OPERATION

90%

IGNITION

(80%)

70%

60%

50%

MIN.

Operation with Conventional 2-Stage Thermostat

(DIP switch selects 2-stage heat)

2 MINS.

8 MINS.

Call for 2nd-Stage Heat - Thermostat contacts close R to W1
and W2.

After a successful Light Off Sequence and expiration of the
Ignition Stabilization Period:

• The IFC adjusts to the low firing rate.

• After 2 minutes, the IFC increases to 80%.

• Thereafter, the IFC will increase 10%, at a rate of 1%
per second, every 10 minutes for the remainder of the
call for heat.

• The circulator is adjusted to the appropriate CFM, cor­responding to the current firing rate.

UNIT CALL FOR HEAT ENDS

CALL FOR
2ND STAGE HEAT

OPERATION

IGNITION

100%

(80%)

78%

50%

2 MINS.

MIN.

10 MINS.

• The IFC remains at the current firing rate until the 1st­Stage call for heat is satisfied.

HEATING OPERATION WITH CTK01 THERMOSTAT (COMMUNI-

CATING)

• When the Thermostat Heat Setup DIP switch is set to
2-Stage heat, the IFC operation will be compatible with
a CTK01communicating thermostat.

• When a call for heat is sent, the furnace will go through
the Light Off Sequence, After the successful Light Off
Sequence and expiration of the Ignition Stabilization
Period:

• The IFC adjusts to the low firing rate.

• After 2 minutes, the IFC accepts the specific Heat
Requested Demand.

• If the differential is equal to or less than 2 degrees, the
IFC will follow the conventional 2-Stage algorithm,
equivalent to a W1 request..

• If the heat differential is greater than 2 degrees, the
IFC will follow the conventional 2-Stage algorithm,
equivalent to a W2 request.

• The circulator will operate per the heat airflow profile.

HEATING OPERATION WITH CTK02** THERMOSTAT (MODU

COMMUNICATING)

LATING

• When the Thermostat Heat Setup DIP switch is set to
1-Stage heat, the IFC operation will be compatible with
a modulating communicating thermostat (CTK02**).

• When a call for heat is sent, the furnace will go through
the Light Off Sequence, After the successful Light Off
Sequence and expiration of the Ignition Stabilization
Period:

• The IFC adjusts to the low firing rate.

• After 2 minutes, the IFC accepts the specific Heat
Requested Demand.

• If the differential is 2 degrees or less, the Heat Current
Demand Status will show 50%.

• If the specific Heat Requested Demand is above 2 de­grees, the Heat Current Demand Status will track the
specific Heat Requested Demand.

• The circulator will operate per the heat airflow profile.

HEAT ANTICIPATOR SETTING

The heat anticipator in the room thermostat must be correctly
adjusted to obtain the proper number of cycles per hour and to
prevent “overshooting” of the setting. Set the heat anticipator
setting to 0.7 amps. Follow the thermostat manufacturer’s in­structions on how to adjust the heat anticipator setting.

Call for 2nd-Stage Heat with 1st-Stage call for heat call in
progress, with conventional 2-Stage Thermostat.

• The IFC increases the firing rate to 100% at a rate of
1% per second for the remainder of the W2 call.

• The circulator is adjusted to the appropriate CFM, cor­responding to the current firing rate.

Call for 2nd-Stage Heat satisfied; Call for 1st-Stage Heat re­mains.

48

DRAIN TRAP PRIMING

The drain trap must be primed prior to furnace startup. To prime,
fill the drain trap with water. This ensures proper furnace drainage
upon startup and prohibits the possibility of flue gases escaping
through the drain system. Air conditioning condensate may be
drained into the furnace trap. Please see requirements in
Condensate Drain Lines & Drain Trap section.

OPERATION

FURNACE OPERATION

Purge gas lines of air prior to startup. Be sure not to purge lines
into an enclosed burner compartment.

Check for leaks using an approved chloride-free soap and water
solution, an electronic combustible gas detector, or other ap­proved method. Verify that all required kits (propane gas, etc.)
have been appropriately installed.

FURNACE STARTUP

1. Close the manual gas shutoff valve external to the fur­nace.

2. Turn off the electrical power to the furnace.

3. Set the room thermostat to the lowest possible setting.

4. Remove the burner compartment door.

NOTE: This furnace is equipped with an ignition device which
automatically lights the burner. Do not try to light the burner by
hand.

5. Move the furnace gas valve manual control to the OFF
position.

6. Wait five minutes then smell for gas. Be sure check
near the floor as some types of gas are heavier than
air.

7. If you smell gas after five minutes, immediately follow
the Safety Instructions on page 5 of this manual. If
you do not smell gas after five minutes, move the fur­nace gas valve manual control to the ON position.

8. Replace the burner compartment door.

9. Open the manual gas shutoff valve external to the fur­nace.

10. Turn on the electrical power to the furnace.

1 1. Adjust the thermostat to a setting above room tem-

perature.

12. After the burners are lit, set the thermostat to desired
temperature.

FURNACE SHUTDOWN

1. Set the thermostat to the lowest setting.
The integrated control will close the gas valve and ex-

tinguish flame. Following a 15 second delay , the in­duced draft blower will be de-energized. After a 120,
150, 180 or 210-second delay period (field selectable
delay OFF [90, 120, 150, 180] plus 30-second ramp
down), the circulator blower de-energizes.

2. Remove the burner compartment door and move the
furnace gas valve manual control to the OFF position.

3. Close the manual gas shutoff valve external to the fur­nace.

4. Replace the burner compartment door.

GAS SUPPLY PRESSURE MEASUREMENT

CAUTION

TO

PREVENT UNRELIABLE OPERATION OR EQUIPM EN T DAMAGE, THE
INLET GAS SUPPLY PRESSURE MUST BE AS SPECIFIED ON THE UNIT
RATING PLATE WITH ALL OTHER HOUSEHOLD GAS FIRED APPLIANCES
OPERATING

.

The line pressure supplied to the gas valve must be within the
range specified below. The supply pressure can be measured at
the gas valve inlet pressure boss or at a hose fitting installed in
the gas piping drip leg. The supply pressure must be measured
with the burners operating. To measure the gas supply pressure,
use the following procedure.

PS

CONNECTION

ATMOSPHERE

PORT

FLOW

DIRECTION

Honeywell Model VR9205R

2-PIN

m

o

t

e

r

e

p

t

n

M

o

O

t

A

m

e

o

s

h

p

r

e

i

o

a

e

m

n

M

t

e

n

a

s

o

e

H

e

r

Outlet

Pressure

Tap

1/8 NPT

POWER
CONNECTOR

Inlet
Pressure
Tap
1/8 NPT

Honeywell Model VR9205R Connected to Manometer

49

OPERATION

1. Turn OFF gas to furnace at the manual gas shutoff
valve external to the furnace.

2. Connect a calibrated water manometer (or appropriate
gas pressure gauge) at either the gas valve inlet pres­sure boss or the gas piping drip leg. See Honeywell
VR9205R gas valve figure for location of inlet pressure
boss.

NOTE: If measuring gas pressure at the drip leg or Honeywell
VR9205R gas valve, a field-supplied hose barb fitting must be
installed prior to making the hose connection.

3. Turn ON the gas supply and operate the furnace and
all other gas consuming appliances on the same gas
supply line.

Field Test Mode is intended to help a service person
troubleshoot and check out an installed appliance.
T o enter Field Test Mode the Fault Recall Push-But-

ton
must be pressed twice within a 5 second period at

any
time during a heating cycle, at which time the display
will show “Ft”. While the display is showing “Ft”,

pressing and holding the Fault Recall Push-Button for
3 seconds will enable the field test mode and override
the normal firing rate sequence at a rate of 100% for 5
minutes or until the end of the call for heat. The dis­play will show the normal “Hi” while the control is firing
at 100%. If the Fault Recall Push-Button has not
been pressed within 5 seconds of displaying “Ft” the
display will revert back to normal.

4. Measure furnace gas supply pressure with burners firing.
Supply pressure must be within the range specified in the
Inlet Gas Supply Pressure table.

Inlet Gas Supply Pressure
Natural Gas Minimum: 4.5" w.c. Maximum: 10.0" w.c.
Propane G a s Minimum: 11.0" w.c. Maximum: 13.0" w.c.

If supply pressure differs from table, make the necessary adjust­ments to pressure regulator, gas piping size, etc., and/or con­sult with local gas utility.

5. Turn OFF gas to furnace at the manual shutoff valve and
disconnect manometer. Reinstall plug before turning on
gas to furnace.

6. Turn OFF any unnecessary gas appliances stated in step

3.

Gas Line

Gas
Shutoff
Valve

Gas Line
To Furnace

Open To
Atmosphere

Drip Leg Cap
With Fitting

Manomete r Hose

Manometer

Measuring Inlet Gas Pressure (Alt. Method)

GAS MANIFOLD PRESSURE MEASUREMENT

CAUTION

TO

PREVENT UNRELIABLE OPERATION OR EQUIPM EN T DAMAGE, THE
GAS MANIFOLD PRESSURE MUST BE AS SPECIFIED ON THE UNIT RATING
PLATE

. GAS

VALVE IS FACTORY SET AND DOES

F

IELD ADJUSTMENT

. DO

NOT ATTEM PT TO ADJUST VALVE

NOT

REQUIRE ANY

.

The manifold pressure must be measured with the burners oper­ating. To measure the manifold pressure, use the following
procedure.

1. Turn OFF gas to furnace at the manual gas shutoff valve
external to the furnace.

2. Turn off all electrical power to the system.

3. Outlet pressure tap connections: Remove the outlet pres­sure boss plug. Install an 1/8" NPT hose barb fitting into the
outlet pressure tap.

4. Attach a hose and manometer to the outlet pressure
barb fitting.

5. Turn ON the gas supply.

6. Turn on power and close thermostat “R” and “W1” con­tacts to provide a call for low stage heat.

7. Modulating furnaces light at 80% of max input. For natu­ral gas the expected manifold pressure at ignition will be
in a range of 1.8" - 2.5" WC. For LP gas the range will be

5.8" - 6.8" WC.
NOTE: Measure the gas manifold pressure with the burn-

ers firing. After every time the main power is turned off
and back on, the furnace will enter a calibration routine
on the next call for heat The inducer will ramp up and

down during the calibration routine. After calibration, the
furnace will proceed to ignition cycle.

50

OPERATION

8. Field Test Mode is intended to help a service person
troubleshoot and check out an installed appliance by
bringing the furnace up to High fire (100% input), by-pass­ing the normal modulating routine.

To enter Field Test Mode the Fault Recall Push-Button
must be pressed twice within a 5 second period at any
time during a heating cycle, at which time the display will
show “Ft”. While the display is showing “Ft”, pressing
and holding the Fault Recall Push-Button for 3 seconds
will enable the field test mode and override the normal
firing rate sequence at a rate of 100% for 5 minutes or
until the end of the call for heat. The display will show the
normal “Hi” while the control is firing at 100%. If the Fault
Recall Push-Button has not been pressed within 5 sec­onds of displaying “Ft” the display will revert back to nor­mal.

NOTE: Gas valve is factory set and does NOT require
any field adjustment. Do NOT attempt to adjust valve.

9. Turn off all electrical power and gas supply to the sys­tem.

10.Remove the manometer hose from the hose barb fitting.

11.Remove the 1/8" NPT hose barb fitting from the outlet
pressure tap. Replace the outlet pressure boss plug and
seal with a high quality thread sealer.

12.Turn on electrical power and gas supply to the system.

13.Close thermostat contacts “R” and “W1/W2” to energize
the valve.

Using a leak detection solution or soap suds, check for leaks at
outlet pressure boss plug. Bubbles forming indicate a leak. SHUT
OFF GAS AND REPAIR ALL LEAKS IMMEDIATELY!

NOTE: For natural gas to LP conversion, consult the furnace
Specification Sheet.

Manifold Gas Pressu re

Gas

Natural High Stage 3.2 - 3.8" w.c. 3.5 " w.c.

Propane Hi g h Sta g e 9.5 - 10 .5" w.c. 10.0" w .c.

Rang e Nominal

GAS INPUT RATE MEASUREMENT (NATURAL GAS ONLY)

The gas input rate to the furnace must never be greater than that
specified on the unit rating plate. To measure natural gas input
using the gas meter, use the following procedure.

1. Turn OFF the gas supply to all other gas-burning appli-

ances except the furnace.

2. While the furnace is operating, time and record one

complete revolution of the smallest gas meter dial.

3. Calculate the number of seconds per cubic foot (sec/

ft3) of gas being delivered to the furnace. If the dial is a
one cubic foot dial, divide the number of seconds re­corded in step 2 by one. If the dial is a two cubic foot
dial, divide the number of seconds recorded in step 2
by two.

4. Calculate the furnace input in BTUs per hour (BTU/hr).
Input equals the sum of the installation’s gas heating
value and a conversion factor (hours to seconds) di­vided by the number of seconds per cubic foot. The
measured input must not be greater than the input indi­cated on the unit rating plate.

EXAMPLE:
Installation’s gas heating (HTG) value: 1,000 BTU/ft

3

(Obtained from gas supplier)
Installation’s seconds per cubic foot: 34 sec/ ft

3

Conversion Factor (hours to seconds): 3600 sec/hr
Input = (Htg. value x 3600) ÷ seconds per cubic foot
Input = (1,000 BTU/ft3 x 3600 sec/hr) ÷ 34 sec/ ft

3

Input = 106,000 BTU/hr

NOTE: The final manifold pressure cannot vary by more than ±

0.3” w.c. for Natural and

+ 0.5” for LP from the specified setting.
Consult your local gas supplier if additional input rate adjustment
is required.

5. Turn ON gas to and relight all other appliances turned

off in step 1. Be certain that all appliances are func-

tioning properly and that all pilot burners are operating.
T emperature Rise
Temperature rise must be within the range specified on the unit

rating plate. An incorrect temperature rise may result in condens­ing in or overheating of the heat exchanger. An airflow and tem­perature rise table is provided in the Specification Sheet appli­cable to your model. Determine and adjust temperature rise as
follows:

1. Operate furnace with burners firing for approximately

ten minutes. Ensure all registers are open and all duct

dampers are in their final (fully or partially open) posi-

tion.

2. Place thermometers in the return and supply ducts as

close to the furnace as possible. Thermometers must

not be influenced by radiant heat by being able to “see”

the heat exchanger.

3. Subtract the return air temperature from the supply air

temperature to determine the air temperature rise. Al-

low adequate time for thermometer readings to stabi-

lize.

4. Adjust temperature rise by adjusting the circulator

blower speed. Increase blower speed to reduce tem-

perature rise. Decrease blower speed to increase tem-

perature rise. Refer to Startup Procedure and

Adjustment -Circulator Blower Speeds for speed

changing details.

51

OPERATION

Temperature Rise Measurement

SUPPLY
AIR

RETUR N
AIR

2. Determine the proper air flow for the cooling system.
Most cooling systems are designed to work with air
flows between 350 and 450 CFM per ton. Most manu­facturers recommend an air flow of about 400 CFM per
ton.

Example: 2.5 tons X 400 CFM per ton = 1000 CFM

The cooling system manufacturer’s instructions must be checked
for required air flow. Any electronic air cleaners or other devices
may require specific air flows, consult installation instructions of
those devices for requirements.

3. Knowing the furnace model, locate the high stage cool­ing air flow charts in the Specification Sheet applicable
to your model. Look up the cooling air flow determined
in step 2 and find the required cooling speed and ad­justment setting.

Example: A *MVM960603BX furnace installed with a

2.5 ton air conditioning system. The air flow needed is
1000 CFM. Looking at the cooling speed chart for
*MVM960603BX, find the air flow closest to 1000 CFM.
A cooling airflow of 1000 CFM can be attained by se­lecting the cooling speed “C” and the adjustment to
“normal”.

CIRCULATOR BLOWER SPEEDS

WARNING

TO

AVOID PERSONAL INJURY OR DEATH DUE TO ELECTRICAL SHOCK

TURN

OFF

POWER TO THE FURNACE BEFORE CHANGING SPEED TAPS

,

.

This furnace is equipped with a multi-speed circulator blower.
This blower provides ease in adjusting blower speeds. The
heating blower speed is shipped set at “B”, and the cooling blower
speed is set at “D”. These blower speeds should be adjusted by
the installer to match the installation requirements so as to pro­vide the correct heating temperature rise and correct cooling CFM.

Use the dual 7-segment LED display adjacent to the DIP switches
to obtain the approximate airflow quantity. The airflow quantity is
displayed as a number on the display, rounded to the nearest
100 CFM. The display alternates airflow delivery indication and
the operating mode indication.

Example: The airflow being delivered is 1225 CFM. The display
indicates 12. If the airflow being delivered is 1275, the display
indicates 13.

1. Determine the tonnage of the cooling system installed
with the furnace. If the cooling capacity is in BTU/hr di­vide it by 12,000 to convert capacity to TONs.

Example: Cooling Capacity of 30,000 BTU/hr.
30,000/12,000 = 2.5 T ons

4. Continuous fan speed is selectable at 25%, 50%, 75%
or 100% of the furnace’s maximum airflow capability .

Example: If the furnace’s maximum airflow capability
is 2000 CFM, the continuous fan speed will be 0.25 x
2000 or 500 CFM.

5. Locate the blower speed selection DIP switches on the
integrated control module. Select the desired “cooling”
speed tap by positioning switches 1 and 2 appropri­ately . Select the desired “adjust” tap by positioning
switches 9 and 10 appropriately . Refer to the DIP
switch chart for switch positions and their correspond­ing taps. V erify CFM by noting the number displayed
on the dual 7-segment LED display .

6. The multi-speed circulator blower also offers several
custom ON/OFF ramping profiles. These profiles may
be used to enhance cooling performance and increase
comfort level. The ramping profiles are selected using
DIP switches 7 and 8. Refer to the following figure for
switch positions and their corresponding taps. Refer to
the bullet points below for a description of each ramp­ing profile. Verify CFM by noting the number displayed
on the dual 7-segment LED display .

52

DIP Switches

---

--- ---

--- --- ---

ON --- ---

--- --- --- ---

OFF --- --- ---

--- --- --- --- ---

OFF --- --- --- ---

--- --- --- --- --- ---

OFF

--- --- --- --- --- --- --- ---

Dip Switch

--- --- --- --- --- --- --- --- --- ---

OFF OFF

OFF ON

ON

ON ---

123456789101112131415161718

A OFF OFF --- --- --- --- --- --- --- --- --- --- --- --- -- - --- --- ---

--- --- --- --- --- --- --- --- --- --- --- ---

--- --- --- --- --- --- --- --- --- --- --- --- --- ---

--- --- --- --- --- --- --- --- --- --- --- --- --- --- --- ---

ON OFF

ON ON

B ON OFF --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- ---

C OFF ON --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- ---

D

A --- --- OFF OFF - -- --- --- --- --- --- --- --- --- --- -- - --- --- ---

B------

C --- --- OFF ON --- --- --- --- --- --- --- --- --- --- --- --- --- ---

ON OFF

D --- --- ON ON --- --- --- --- --- --- --- --- --- --- --- --- --- ---

A --- --- --- --- OFF OFF --- --- --- --- --- --- --- --- --- --- --- ---

B --- --- --- ---

OFF OFF

--- --- --- --- --- --- --- --- --- --- --- --- --- ON

--- --- --- --- --- --- --- --- --- --- --- --- ---

C --- --- --- --- OFF ON --- --- --- --- --- --- --- --- --- --- --- ---

D --- --- --- --- ON O N --- --- --- --- --- --- --- --- --- --- --- ---

A --- --- --- --- --- ---

B --- --- --- --- --- --- ON OFF --- --- --- --- --- --- --- --- --- ---

C --- --- --- --- --- --- OFF ON --- --- --- --- --- --- --- --- --- ---

D --- --- --- --- --- --- ON ON --- --- --- --- --- --- --- --- --- ---

2-Stage

Plus 10% --- --- --- --- --- --- --- --- ON OFF --- --- --- --- --- --- --- ---

Minus 10% --- --- --- --- --- --- --- --- OFF ON --- --- --- --- --- --- --- ---

0 Tri m Adjust --- --- --- --- --- -- - --- ---

90 Seconds --- --- --- --- -- - --- --- --- --- --- OFF OFF --- --- --- --- --- ---

0 Tri m Adjust --- --- --- --- --- -- - --- --- ON ON --- -- - --- --- --- --- - - - - - -

120 Seconds --- --- --- --- --- --- --- --- --- --- ON OF F --- -- - --- --- --- ---

150 Seconds --- --- --- --- --- --- --- --- --- ---

180 Seconds --- --- --- --- --- --- --- --- --- --- ON ON --- --- --- --- --- ---

1-Stage

2 Stage Stat --- --- --- --- --- --- --- --- --- --- - -- --- ON --- --- --- --- ---

1 Sta ge Stat --- --- --- --- --- --- --- --- --- --- --- ---

Compressor

Enabled --- --- --- --- --- --- --- --- --- --- --- --- --- --- ON

Disabled --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- OFF

Disabled --- --- --- --- --- --- --- --- --- --- --- --- --- ---

Compressor

Enabled --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- ---

Enabled --- --- --- --- --- --- --- --- --- --- --- --- --- --- ---

Disabled --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- OFF

Enabled --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- -- - ---

Disabled --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- OFF

Tap

Purpose Function

Switch

Cooling

Speed Tap

Bank

Speed

Heating

1

Continuous

Tap

Fan

Speed

Cooling

Ramping

Taps

Adjust

2

Delay

Hea t Off

T-Stat Heat

Compressor

Bias

Dehum

3

Pull Up

Pull Down

Not applicable (Indicates factory setting)

---

Communic ating thermostats are used onl y with Bi as, Pull Up, Pull Dow n dip sw itc hes.

53

OPERATION

• Profile A provides only an OFF delay of one (1) minute at
100% of the cooling demand airflow.

OFF

100% CFM 100% CFM

OFF

1 min

• Profile B ramps up to full cooling demand airflow by first
stepping up to 50% of the full demand for 30 seconds. The
motor then ramps to 100% of the required airflow. A one (1)
minute OFF delay at 100% of the cooling airflow is provided.

OFF

50% CFM

1/2 min

100% CFM

100% CFM

OFF

1 min

• Profile C ramps up to 85% of the full cooling demand air­flow and operates there for approximately 7 1/2 minutes.
The motor then steps up to the full demand airflow. Profile C
also has a one (1) minute 100% OFF delay.

OFF

100% CFM

OFF

• Profile D ramps up to 50% of the demand for 1/2 minute,
then ramps to 85% of the full cooling demand airflow and
operates there for approximately 7 1/2 minutes. The motor
then steps up to the full demand airflow. Profile D has a 1/2
minute at 50% airflow OFF delay.

OFF

OFF

7. Select the heating speed for your model from the heating
speed chart in the Specification Sheet. The “adjust” setting
(already established by the cooling speed selection) deter­mines which set of speeds are available. The selected speed
must provide a temperature rise within the rise range listed
with the particular model.

8. Select the desired “heating” speed tap by positioning switches
3 and 4 appropriately. Refer to figure above. Verify CFM by
noting the number displayed on the dual 7-segment LED
display.

In general lower heating speeds will: reduce electrical consump­tion, lower operating sound levels of the blower, and increase the
outlet air temperature delivered to the home. The speeds avail­able allow the blower performance to be optimized for the particu­lar homeowner’s needs.

DIP SWITCHES

There are 18 DIP switches on the modulating furnace IFC.
Switches are located in 3 rows, each having 6 switches.
Switches are numbered from 1 to 18. The “ON” position is
“UP’. The chart shows all 18 DIP switches, their function and
their factory position.

Switches 1 & 2 Select cooling speed A, B, C or D. Factory
setting is D (both switches up in the “ON” position. These
switches are ignored when using a CTK0* communicating
thermostat.

Switches 3 & 4 Select heating speed A, B, C or D. Factory
setting is B (3 ON, 4 OFF) These switches are ignored
when using a CTK0* communicating thermostat.

Switches 5 & 6 Select continuous fan speed A, B, C or D.
Factory setting is B (5 ON, 6 OFF) These selections are
based off of percentages of the maximum CFM that each
model furnace is rated for; A = 25%, B = 50%, C = 75%, D
= 100%. These switches are ignored when using a CTK0*
communicating thermostat.

Switches 7 & 8 Select cooling ramping profiles A, B, C or
D. Factory setting is A (both switches down in the “OFF”
position).Each ramping profile provides a different routine for
the indoor blower motor to follow in a call for cooling. Rather
than bringing the motor up to cooling speed immediately,
ramping profiles bring the motor up to cooling speed in stages.

NOTE: Reductions in CFM for ramping are not added to re-
ductions in CFM for DEHUM. Example; CFM is reduced for
the fist several minutes of a cooling call by 15%, if a call for
DEHUM is present during this CFM reduction; CFM will not
be reduced by another 15%. Rather, after the ramping time
period has expired, the CFM would continue at the 15% re­duction to satisfy the DEHUM request. These switches are
ignored when using a CTK0* communicating thermostat .

Switches 9 & 10 Select CFM Trim Adjustment. Choices
are 0%, + 10%, -10%. Factory setting is A. Trim adjust­ments add or subtract from the CFM selections made by
heat and cool CFM selections. Trim adjustments affect cool­ing, and heating fan speeds. These switches are ignored when
using a CTK0* communicating thermostat .

Switches 11 & 12 Select fan off delay in heat. Choices are
90, 120, 150, or 180 seconds. Factory setting is C, 150 sec­onds. These switches are ignored when using a CTK0* com­municating thermostat.

Switch 13 Selects thermostat type for heating. Factory
setting for this switch is OFF, this is the correct setting for a
conventional single stage stat or a CTK02** communicating­modulating stat. To use a conventional two stage heating
thermostat or a CTK0* thermostat, move this switch to the
ON position.

54

OPERATION

Switch 14 Selects compressor setup for cooling. Factory

position is OFF. This is the correct position for a single stage
condensing unit. In this position, Y from the room thermostat
would connect to Y1 on the IFC. Full CFM selected by
switches 1 & 2 will be delivered during a Y1 call. If using a
two stage outdoor unit, move this switch to the ON position
and wire Y1 from the room stat to Y1 on the IFC, wire Y2 on
the room stat to Y2 on the IFC. This switch is ignored when
using a CTK0* communicating thermostat.

Switch 15 Selects DEHUM. Enabling this feature will re­duce CFM in a call for cooling by 15%. Factory position is
OFF, in this position DEHUM is disabled. To use this feature
the DIP switch must be turned to the ON position and a nor­mally closed dehumidistat be used. This switch is ignored
when using a CTK0* communicating thermostat.

Switches 16, 17, 18 These are system switches critical to
the ClimateTalk™ communicating network and must be left
in the factory enabled ON position.

Pressure Switch Calibration Routine The modulating
furnace must go through a pressure switch calibration rou­tine before it can begin its first heat cycle. This is performed
automatically by the furnace and requires no action on the
part of the installer other than to have the system compo­nents installed completely and correctly. On the initial power
up, or any time that power to the furnace is switched off then
back on again and a call for heat is applied, the furnace will
go through a calibration routine. During the calibration rou­tine the IFC runs the induced draft blower at different speeds
to determine the opening and closing points of the pressure
switches. It records this information and uses it as reference
points for determining the draft inducer speeds for all gas
input rates from 35% - 100%.

Before beginning a calibration routine, the IFC will check that
both pressure switches are in the open position.

· The IFC powers the draft inducer at a predetermined
speed and checks to see if the LPS has closed

· If the LPS is not closed the IFC will increase the draft
inducer RPM in small steps until it detects a closed
LPS.

· The IFC then begins to reduce RPM until it detects
that the LPS is open.

· It records the RPM point where the LPS went open

· The IFC then increases the inducer RPM by a large
predetermined step and checks to see if the HPS is
closed.

· If the HPS is not closed the IFC will increase the draft
inducer RPM in small steps until it detects a closed
HPS.

System

Ai r Cond itione r +

Furnace

He at Pum p +

Furnace

Furn ac e + Non-

Comm 1stg Air

Conditioner

S ystem O p e rating

Mode

Cooling Air Conditioner

Heati ng Furnace

Continuous Fan Thermostat

Co oling He at Pump

Heat Pum p H e ati ng

Only

Auxiliary He ating Fur nace

Continuous Fan Thermostat

Co oling Fur nace

Heati ng Furnace

Continuous Fan Thermostat

Airflow Deman d S our ce

He a t P ump

For example, assume the system is an air conditioner
matched with a furnace. With a call for low stage cooling,
the air conditioner will calculate the system’s low stage cool­ing airflow demand. The air conditioner will then send a fan
request along with the low stage cooling airflow demand to
the furnace. Once received, the furnace will send the low
stage cooling airflow demand to the ECM motor. The ECM
motor then delivers the low stage cooling airflow. See the
applicable ComfortNet air conditioner or heat pump installa­tion manual for the airflow delivered during cooling or heat
pump heating.

In continuous fan mode, the CTK0* thermostat provides the
airflow demand. The CTK02** thermostat may be configured
for one of threecontinuous fan speed settings allow for 25%,
50% or 75% airflow, based on the furnaces’ maximum airflow
capability. During continuous fan operation, the thermostat
sends a fan request along with the continuous fan demand to
the furnace. The furnace, in turn, sends the demand to the
ECM motor. The ECM motor delivers the requested continu­ous fan airflow.

FOSSIL FUEL APPLICATIONS

This furnace can be used in conjunction with a ComfortNet™
compatible heat pump in a fossil fuel application. A fossil fuel
application refers to a combined gas furnace and heat pump in­stallation which uses an outdoor temperature sensor to deter­mine the most cost efficient means of heating (heat pump or gas
furnace). When used with the CTK0* thermostat, the fur­nace/heat pump system is automatically configured as a fossil
fuel system. The balance point temperature may be adjusted
via the CTK0* thermostat advanced user menus (see CTK0*
instructions for additional information).

55

OPERATION

CTK0* WIRING

NOTE: Refer to Electrical Connections for 115 volt line

connections to the furnace.
NOTE: A removable plug connector is provided with the control

to make thermostat wire connections. This plug may be removed,
wire connections made to the plug, and replaced. Multiple wires
imust be twisted together prior to inserting into the plug connector.
Failure to do so may result in intermittent operation.

Typical 18 AWG thermostat wire may be used to wire the sys­tem components. One hundred (100) feet is the maximum length
of wire between indoor unit and outdoor unit, or between indoor
unit and thermostat. Wire runs over (100) feet require larger
gauge wire.

FOUR-WIRE INDOOR AND OUTDOOR WIRING

Typical ComfortNet wiring will consist of four wires between the
indoor unit and outdoor unit and between the indoor unit and ther­mostat. The required wires are: (a) data lines, 1 and 2; (b) ther­mostat “R” (24 VAC hot) and “C” (24 VAC common).

CTK0**

12RC

12RC

12RC

System Wiring using Four-Wires

Thermostat

ComfortNet Compatible Furnace
Integrated Control Module

ComfortNet Compatible AC/HP
Integrated Control Module

TWO-WIRE OUTDOOR, FOUR-WIRE INDOOR WIRING

Two wires can be utilized between the indoor and outdoor units.
For this wiring scheme, only the data lines, 1 and 2, are needed
between the indoor and outdoor units. A 40VA, 208/230 VAC to
24VAC transformer must be installed in the outdoor unit to pro­vide 24VAC power to the outdoor unit’s electronic control. The
transformer is included with the CTK01AA kit. See kit instruc­tions for mounting and wiring instructions. If using a CTK02 or
CTK01BA, an accessory transformer is available (TFK01).
Four wires are required between the indoor unit and thermostat.

• R powering Y1, O and G simultaneously

• The compressor and condenser fan are energized di­rectly from the Y1 terminal from the thermostat.

• The circulator is energized after cool fan on delay.

• If the ‘2 Stage Cooling’ DIP switch is set to:

• ON, then circulator will run at low cooling speed with
Y1 request

• OFF, then circulator will run at high cooling speed with
Y1 request (a Y2 request will be ignored)

• The circulator will operate according to one of the se­lectable ramping profiles.

• When the cool request is satisfied, the circulator is
de-energized per one of the selectable ramping pro­files.

2ND STAGE COOLING – CONVENTIONAL THERMOSTAT

• The ‘2 Stage Cooling’ DIP switch on the IFC must be
ON to enable 2 stage cooling control with a conven­tional thermostat.

• A call for 2nd stage cooling is signaled by the shorting
of R to Y2 while a valid call for first stage cooling ex­ists.

• After the cool fan on delay, the circulator is energized
at the low cooling speed when the 1st stage cool re­quest is detected and switches to high cooling speed
immediately after the 2nd stage cool request is detected.

• The circulator will be controlled according to the se­lected ramping profile.

• When the cool requests are satisfied, the circulator is
de-energized per the selected ramping profile.

COOLING OPERATION WITH A COMMUNICATING THERMOSTAT

CONVENTIONAL SINGLE STAGE A/C

AND

• The call for cooling will be communicated via the
ClimateTalk™ protocol.

• The Y1 terminal of the IFC becomes an output via the
on board Y1 relay

• The IFC does not provide short cycle protection.

• The circulator operates as commanded by the com­municating thermostat.

NOTE: Use of the CTK0* transformer is recommended if installing
a dual fuel/fossil fuel system. Failure to use the transformer in
the outdoor unit could result in over loading of the furnace
transformer.

1ST STAGE COOLING – CONVENTIONAL THERMOSTAT

• A call for cooling is signaled by:

• R powering Y1 and O simultaneously

56

COOLING OPERATION WITH A COMMUNICATING THERMOSTAT

OUTDOOR UNIT

AND

• The furnace receives the CFM demand from the com­municating outdoor unit.

CALL FOR COOL WITH CALL FOR HEAT PRESENT – DUAL
FUEL DEFROST OPERATION

• While in defrost, the standard light off sequence will be
followed. The IFC will then fire at 100% for the remain­der of the defrost call.

• While in defrost the circulator will use the selected
heat speed.

OPERATION

FAN MODE
CONVENTIONAL THERMOSTAT

Two seconds after G request becomes active without Y1 re­quest, IFC will run the circulator at the appropriate speed (as
selected by the DIP switches), unless circulator is running
as a result of Heat or Cool mode. The circulator speed re­quired by the heat or cool demand always has priority over G
speed.

COMMUNICATING THERMOSTAT

If a conventional G request is present without a heat or cool
request from the communicating thermostat, the circulator
will run at the selected fan speed.

HUMIDITY CONTROL
HUMIDIFIER OUTPUT – CONVENTIONAL THERMOSTAT

One set of isolated relay contacts are wired to a pair of termi­nals for connection to a humidifier. When the inducer is on
the IFC closes the humidifier relay contacts, except from the
calibration routine where the humidifier relay contacts are
always open.

HUMIDIFIER OUTPUT – COMMUNICATING THERMOSTAT

One set of isolated relay contacts are wired to a pair of termi­nals for connection to a humidifier. Upon receipt of a Humidi­fication Requested Demand the IFC will:

• Close the humidifier relay contacts

• Energize the circulator at the circulation speed (G
speed) unless the circulator is commanded to a differ­ent speed by a heat demand.

Dehumidification – Conventional Thermostat

• DEHUM functionality is enabled by a DIP switch set­ting.

• The IFC varies circulator speed operation based on the
DEHUM signal from the thermostat

• If 24VAC (R) is not connected to DEHUM (through a
Humidistat) and both Y1 and O terminals are ener­gized, then the IFC control reduces the cooling CFM
by 15%.

• If both Y1 and O terminals are not energized, the
DEHUM signal is ignored

• DEHUM is ignored during any heating request.

LEARN PUSH-BUTTON

Pressing the learn button re-sets the communicating net­work and allows the IFC to search for communicating equip­ment The press and release of the button starts the same
learning process as during power-up of the system.

CLIMATETALK™ COMMUNICATION LEDS

The IFC has two LEDs :

• Red communications LED – Indicates the status of
the network

• OFF is normal condition.

• 2 slow flashes on power-up: ON for ¼ second, OFF for
¾ second, ON for ¼ second, OFF.

• Continuous slow flash indicates communication fail­ure: ON for ¼ second, OFF for ¾ second…

• Green receive LED – Indicates network traffic

• Fast, sporadic flashes indicates normal bus commu­nication.

• ON solid indicates a Data 1 / Data 2 miswire.

Low

Model Tap

*CVM960604CX*

*CVM960805DX*

*CVM961005DX*

*MVM960603BX*

*MVM960805CX*

*MVM961005DX*

*MVM961155DX*

*100% CFM shown. CFM will vary proportionally with the g a s va lve
BTU/H input.

Stage

Cool
A 370 660 1220
B 540 860 1340

C 790 1150 1460
D 980 1470 1590

A 530 900 1600
B 730 1100 1710

C 930 1430 1800
D 1220 1880 1910

A 500 780 1730
B 740 1070 1770

C 920 1380 1840
D 1160 1780 1870

A 390 630 950
B 550 800 1050

C 680 1000 1170
D 800 1210 1270

A 540 830 1600
B 750 1090 1690

C 980 1460 1800
D 1210 1800 1890

A 510 790 1810
B 710 1100 1850

C 910 1410 1890
D 1160 1830 1940

A 510 790 1810
B 710 1100 1850

C 910 1410 1890
D 1160 1830 1940

Airflow Table

High

Stage

Cool

100%

Heat

*CFM

57

ABBREVIATIONS & DEFINITIONS

7. Select the heating speed for your model from the heat­ing speed chart in the Specification Sheet. The “ad­just” setting (already established by the cooling speed
selection) determines which set of speeds are avail­able. The selected speed must provide a temperature
rise within the rise range listed with the particular
model.

8. Select the desired “heating” speed tap by positioning
switches 3 and 4 appropriately . Refer to figure above.
V erify CFM by noting the number displayed on the dual
7-segment LED display .

In general lower heating speeds will: reduce electrical consump­tion, lower operating sound levels of the blower, and increase the
outlet air temperature delivered to the home. The speeds avail­able allow the blower performance to be optimized for the particu­lar homeowner’s needs.

BLOWER HEAT OFF DELAY TIMINGS

The integrated control module provides a selectable heat off de­lay function. The heat off delay period may be set to 90, 120, 150,
180 seconds using the DIP switches or jumper provided on the
control module. The delay is factory shipped at 150 seconds but
may be changed to suit the installation requirements and/or ho­meowner preference.

The indoor unit, outdoor unit and thermostat comprising a
ComfortNet system “communicate” digitally with one another, cre­ating a two-way communications path. The thermostat still sends
commands to the indoor and outdoor units. However, the ther­mostat may also request and receive information from both the
indoor and outdoor units. This information may be displayed on
the ComfortNet thermostat. The indoor and outdoor units also
interact with one another. The outdoor unit may send commands
to or request information from the indoor unit. This two-way digital
communications between the thermostat and subsystems (in­door/outdoor unit) and between subsystems is the key to unlock­ing the benefits and features of the ComfortNet system.

CTK0*
Thermostat

ComfortNet Compatible
Furnace Integrated
Control Module

ComfortNet Compatible

RC

AC/HP Integrated
Control Module

40V A Transformer

208/230 VAC

12RC

12RC

12

24 VAC

ComfortNet System

OVERVIEW

NOTE: DIP switch #13 MUST be set to match thermostat
type. To use the CTK01 communicating thermostat, DIP
switch #13 must be set to ON position. This is also the cor­rect setting for a non-communicating 2-stage thermostat. To
use the CTK02** modulating thermostat, check to make sure
DIP switch #13 is in the OFF position (factory position). This
is also the correct position when using a non-communicating
single stage thermostat.

The ComfortNet system is a system that includes a ComfortNet
compatible furnace and air conditioner or heat pump with a CTK0*
thermostat. A valid ComfortNet system could also be a compat­ible furnace, CTK0* thermostat and non-compatible, single stage
air conditioner. Any other system configurations are considered
invalid ComfortNet systems and must be connected as a tradi­tional (or non-communicating) system (see Electrical Connec-
tions for wiring connections).

A ComfortNet heating/air conditioning system differs from a non­communicating/traditional system in the manner in which the
indoor unit, outdoor unit and thermostat interact with one another.
In a traditional system, the thermostat sends commands to the
indoor and outdoor units via analog 24 VAC signals. It is a one­way communication path in that the indoor and outdoor units
typically do not return information to the thermostat.

System Wiring using Two-Wires between Furnace and AC/HP

and Four-Wires between Furnace and Thermostat

COMFORTNET COMPATIBLE FURNACE WITH NON-COMFORTNET

COMPATIBLE

Four wires are required between the furnace and thermostat. Two
wires are required between the furnace control and single stage
air conditioner. For this system configuration, the “Y1” terminal
on the integrated furnace control becomes an output rather than
an input. The “Y1” connection to the outdoor unit is made using
both 4-position thermostat connectors in the CTK0* kit. Re­move the red keying tabs from the on-board connector block and
position both 4-position connector such that “1”, “2”, “R”, “C”, and
“Y1” positions are filled.

12RC

12RC

SINGLE-STAGE AIR CONDITIONER

CTK0*
Thermostat

G

C Y

4-Position Connectors
from CTK0*
Thermostat Kit

W1 W2 Y1 Y2

ComfortNet Compatible

O

Non-ComfortNet Compatible
Single Stage AC

Furnace Integrated
Control Module

58

System Wiring between Furnace and Non-Communicating

Compatible Single Stage Air Conditioner

ABBREVIATIONS & DEFINITIONS

Pressure Switch Calibration Routine The modulating

furnace must go through a pressure switch calibration rou­tine before it can begin its first heat cycle. This is performed
automatically by the furnace and requires no action on the
part of the installer other than to have the system compo­nents installed completely and correctly. On the initial power
up, or any time that power to the furnace is switched off then
back on again and a call for heat is applied, the furnace will
go through a calibration routine. During the calibration rou­tine the IFC runs the induced draft blower at different speeds
to determine the opening and closing points of the pressure
switches. It records this information and uses it as reference
points for determining the draft inducer speeds for all gas
input rates from 35% - 100%.

Before beginning a calibration routine, the IFC will check that
both pressure switches are in the open position.

· The IFC powers the draft inducer at a predetermined
speed and checks to see if the LPS has closed.

· If the LPS is not closed the IFC will increase the draft
inducer RPM in small steps until it detects a closed
LPS.

• The IFC then begins to reduce RPM until it detects
that the HPS is open.

• It records the RPM point where the HPS went open.

• The IFC then adds a predetermined amount of draft
inducer RPM to both the recorded points.

• These new RPM points are the draft inducer speed for
35% (lowest input rate) and 100% (highest input rate).

The IFC then is able to control draft inducer speed
through the IFC-VFD throughout the entire range of
modulating operation.

100% (Max)

RPM

Closed
LPS

RPM 1

Time

35% (Minimum)

Inducer Calibration Routine

ABBREVIATIONS AND DEFINITIONS

• IFC: Integrated furnace control

• HSI: Hot surface element

Closed
HPS

RPM 2

• LPS: Low pressure switch

• IDB: Induced draft blower

• HPS: High pressure switch

• Variable Frequency Drive (VFD): Control of the in­duced draft blower is carried out by Variable Frequency
Drive. By varying the voltage and frequency to the draft
inducer, the RPM can be controlled. A section of the
IFC is dedicated to this task.

• Trial for Ignition Period (TFI): The period of time
between initiation of gas flow and the action to shut off
the gas flow in the event of failure to establish proof of
the supervised ignition source or the supervised main
burner flame.

• Gas Valve Sequence Period: The total period of time
of gas flow starting from the first initiation of gas to the
final action to shut off the gas before going to lockout.

• Ignition Activation Period (IAP): The period between
energizing the main gas valve and deactivation of the
ignition source prior to the end of TFI.

• Flame Recognition Period (FRP): The period be-
tween deactivation of the ignition source and the expi­ration of the TFI.

• Flame Failure Response Time (FFRT): The period
between loss of the supervised main burner flame and
the action to shut off the gas supply.

• Igniter Warm-up Time: The length of time allowed
for the hot surface igniter to heat up prior to the initia­tion of gas flow.

• Pre-purge Time: The period of time intended to allow
for the dissipation of any unburned gas or residual prod­ucts of combustion at the beginning of a furnace oper­ating cycle prior to initiating ignition. Beginning from
the moment the pressure switch is sensed closed and
lasting until the ignition source is energized.

• Inter-purge Time: The period of time intended to al­low for the dissipation of any unburned gas or residual
products of combustion, just prior to initiating ignition
retries during the Ignition Retries sequence.

• Post-purge Time: The period of time to allow for the
dissipation of any unburned gas or residual products
of combustion at the end of a furnace burner operating
cycle. Post-purge begins at the loss of flame sense.

• Ignition Stabilization Period – The period between
sensing of the main burner flame and the transition
from the Ignition Firing Rate to the Target Firing Rate.

• Ignition Recycles: The additional attempts within the
same thermostat cycle for ignition after loss of the su­pervised ignition source or the supervised main burner
flame.

• Ignition Retries: The additional attempts within the
same thermostat cycle for ignition when the supervised
main burner flame is not proven within the Trial for Igni­tion Period.

59

ABBREVIA TIONS & OPERATION

• Low Fire Rate: The lowest firing rate the IFC controls
to during a heating cycle.

• High Firing Rate: The maximum firing rate that an
installed appliance can attain based on manifold ori­fices and the high pressure switch setting.

• Ignition Firing Rate: The target firing rate at which
the appliance always lights off. The appliance stays at
this firing rate until the Ignition Stabilization Period
expires. It then moves to the target firing rate called for
by the operating sequence.

• Target Firing Rate: The firing rate that the IFC con-
trols the inducer to attain at a given time in the operat­ing sequence.

• Heat Fan On Delay: The period between proof of the
supervised main burner flame and the activation of the
blower motor at the low heat speed.

• Heat Fan Off Delay: The period between the loss of
supervised main burner flame after the call for heat has
ended and the deactivation of the blower motor.

• 2nd Stage On Delay: This applies to systems config­ured for 1-stage thermostats. The length of time oper­ating in normal low fire mode before switching to mid
fire mode.

• Auto Restart Delay: The time delay waited before the
control is able to perform a new trial for ignition in the
case of Soft Lockout.

• Soft Lockout: A state caused a system fault such as
loss of flame or pressure switch failure .

• Hard Lockout: A state caused by a failure internal to
the control or by a system fault such as a flame rollout

• Fault Debouncing Time: The period between a sys­tem fault occurring and the IFC recognizing the fault
has occurred. This time varies depending on the spe­cific fault.

• Factory Shared Data: Data used by a ClimateTalk™
device for specific configuration parameters. This data
will be programmed in at the Goodman factory.

Heat Exchanger Prepurge 15 sec --­HSI Warm U p 17 sec Same for all trials
Ignition Acti vation Per iod 3 sec --­Flame Recognition Period 1 sec --­Trial F or Ignition 4 sec TFI = IAP + FRP
Gas Valve Sequence Period 12 sec --­I gni ti on Stab il iz ati on Per io d 10 sec ---

Flame Debounce Period 2 sec

Post-purge 29 sec --­Inter-purge 30 sec --­A uto Restart Delay 60 m in --­Ign ition Retries 2 3 trials total
Ignition Recycles – Flame Failure 2 3 flame los ses total
Flame Failure Response Time 2 sec max @ 1uA

Other Parameters

Low Fire Rate 35% % of target high fire rate
Ignition Fire Rate 80% % of target high fire rate
High Fire Rate 100% ---

Time it takes to debounce
flame presence or failure

---

Ignition Activation Chart

Ignition Retries:

When flame is not sensed during the Trial for Ignition Period:

• The valve is de-energized.

• The inducer remains energized at ignition speed dur­ing the Inter-purge Period.

• The circulator if already running remains energized at
the current CFM for the circulator fan off delay period.

• When the Inter-purge Period expires, the control pro­ceeds to the HSI Warm-up and then a new Trial for
Ignition is started again for up to a maximum of two
additional trials (3 attempts total). After the third Trial
for Ignition has failed to light the burner the IFC pro­ceeds to Soft Lockout through the Post-purge where
the inducer remains energized at the ignition speed.
Error code “E0” is flashed during the Soft Lockout pe­riod.

The retry count is cleared if flame is sensed for longer
than 10 seconds after exiting Trial for Ignition, or upon
exit of Soft Lockout.

Ignition Recycles:

When flame is established during Trial for Ignition, and then

lost:

• The gas valve is de-energized.

• The inducer moves to the ignition speed and holds for
the Inter-purge Period.

60

SERVICE & OPERATION

• The circulator if already running remains energized at
the current CFM for the circulator fan off delay period.

• When the Inter-purge Period expires, the control pro­ceeds to the HSI Warm-up and then a new Trial for
Ignition is started.

• A maximum of two recycles (3 flame losses) are al­lowed on a single call for heat before the control pro­ceeds to Soft Lockout through the Post-purge where
the inducer remains energized at the current speed.
Error code “E0” is flashed during the Soft Lockout pe­riod.

• The recycle count is not cleared until the current de­mand for heat is satisfied or upon exit of Soft Lockout.

Rollout Circuit Operation

If the manual reset rollout switch circuit opens during a heat-

ing cycle:

• The valve is immediately de-energized.

• The inducer will run for the Post-purge period at its
current speed

• If the circulator fan is on it will run for the normal fan off
delay at the current heat speed.

• An error code is logged and displayed indicating the
rollout switch circuit has opened.

• All future thermostat heat requests are ignored..
The IFC will remain in this state until the rollout switch

closes. Once the manual rollout switch has been re­set the IFC will clear the error code and return to nor­mal operation.

If the rollout switch circuit opens in any mode, other than
Heat, it will be ignored.

Limit Switch Operation

If the limit switch circuit is open during a heating cycle:

• The valve is immediately de-energized.

• The inducer will run for the Post-purge period at its
current speed.

• The circulator is immediately energized at high heat
speed. The IFC will remain in this state until the limit
switch circuit closes.

• The IFC logs and displays an error code indicating the
limit circuit is open.

• Once the limit switch circuit closes and a call for heat
is present, a new ignition sequence is started and the
circulator will remain energized for the selected fan off
delay. If the burner is lit before expiration of the se­lected fan off delay, the fan off timing is stopped and
the circulator will adjust to the speed requested by the
heating sequence.

Pressure Switch Configuration

• The IFC monitors the contacts of a SPST (single pole
single throw) low pressure switch with a set point that
ensures the switch will be closed at approximately 35%
of the firing rate of the furnace.

• The IFC monitors the contacts of a SPST high pres­sure switch with a set point that ensures the switch
will be closed at approximately 100% of the firing rate
of the furnace.

H Fitting

The H-fi tting

“conditions”

the ne gative

pressure
signal whic h
is applied t o

the gas valve

Restrictin g Orifi ce

Restrictin g Orifice

"H" Fitting

The low pressure switch assembly includes an H fitting as­sembly and tubing that provides pressure signals to the
Honeywell amplified gas/air gas valve. The H fitting contains
an orifice which conditions the negative air pressure control­ling the gas valve. This has the effect of allowing only smooth
changes in air pressure to reach the gas valve.

Low Pressure Switch Operation

• If a call for heat exists and the low pressure switch is
closed already (before the ignition sequence has be­gun), the IFC will wait 5 minutes. After the 5 minute
delay, and if the LPS is still closed, the IFC will log
and display an error code indicating the low pressure
switch is stuck closed. When the LPS is sensed open,
the IFC clears the error code and resumes normal op­eration.

If the ignition sequence has begun and the low pressure switch
fails to close within 30 seconds, the IFC logs and displays
an error code indicating the low pressure switch is stuck
open. The inducer continues to run for a total of 5 minutes,
at which time the IFC de-energizes the inducer and then at­tempts the Calibration routine immediately. If during the 5
minute interval LPS is sensed closed or call for heat is re­moved, the IFC clears the error code and resumes normal
operation.

If the limit switch circuit opens in any mode, other than Heat,
it will be ignored.

61

SERVICE & OPERATION

High Pressure Switch Operation

• High Pressure Switch action is used to determine the
inducer speed required to achieve the 100% firing rate
of the appliance. The determination is made by the
IFC during the calibration process.

• The HPS must remain closed during 100% fire opera­tion. If it opens during 100% fire operation, the IFC will
increase the inducer speed at a rate of 1% per sec in
an attempt to re-close the pressure switch up to the
maximum allowed RPM. If the HPS is re-closed suc­cessfully, the IFC will complete the Heat mode and
perform the Calibration routine on the next call for heat.
If the HPS remains open, the IFC will end the Heat
mode through the Post-purge and perform the Calibra­tion routine immediately (error code “E9” is flashed until
calibration routine is successful).

• High Pressure Switch check takes place during the
Calibration routine. If the switch is stuck open or closed
calibration will not be completed and the appropriate
error code will be logged and displayed.

Hot Surface Igniter Operation

The IFC energizes a relay to control the line voltage Hot Sur­face Igniter. The HSI warm up time will be fixed for all ignition
trials. Both the continuity of the igniter and the ability of the
relay to energize the igniter are continuously monitored dur­ing the Igniter Warm-up and Ignition Activation Periods.

ECM Motor

An Emerson® UltraTech® four wire indoor fan motor provides
supply air to the conditioned space. This is the same motor
used on Goodman & Amana previous generation communi­cating furnaces.

The ECM motor consists of two sections;

1. A motor body containing 3 phase motor windings

2. An electronic control module (end bell).
In the event of a non-operating motor; the following items

should be checked. There are two harnesses which connect
the blower motor to the IFC. The line voltage (5 Pin) harness
provides 115 volts directly off of the IFC L1 and neutral termi­nals on ½ hp ECM motors. On furnaces with ¾ and 1 HP
ECM motors, L1 is fed to the motor through an inductor coil.
The inductor coil conditions the power supply to the motor
smoothing out spikes and electrical noise. The low voltage
harness is a 4 wire harness that supplies 12 volts DC to
terminals 1 & 4 of the motor and communicating signals on
terminals 3 & 4.

W ARNING

THE

CONTROL MODULE CONTAINS COMPONENTS WHICH CAN HOLD AN
ELECTRICAL CHARGE FOR SEVERAL MINUTES
TAKEN APART, IT MUST BE ALLOWED TO DISSIPATE VOLTAGE BY
WAITING FIVE MINUTES BEFORE IT IS INSPECTED INTERNALLY
BELL CAN BE SEPARATED FROM THE MOTOR BODY BY REMOVING THE
THREE SCREWS WHICH JOIN THEM
THE INTERANL HARNESS CAN BE SEPARATED
AND MOTOR CAN THEN BE INSPECTED SEPARATELY

. O

. B

EFORE THE MOTOR IS

. THE

END

NCE THE SCREWS ARE REMOVED

. THE

CONTROL MODULE

.

,

The motor contains three windings of equal resistance + / ­10%. Resistance between windings is generally less than
10 ohms and will vary between models. To take this read­ing; the ohm meter leads are placed in the wiring harness,
previously disconnected from the internal control unit con­nector.

Inspect capacitors inside the control unit for bulging or swol­len caps. The end bell should be replaced if components
appear swollen or bulging. A functioning control unit should
have a phase to phase resistance of greater than 100K
between any two pins. A separated control unit is shown
below. To take this reading; the ohm meter leads are placed
in the end bell socket and not in the wiring harness.

3 Wire
Motor-to-Control Harness

3 Pin Connector

Motor
Connector

Beyond basic visual checks and voltage / resistance checks;
the Emerson ECM motor may be tested with an Emerson
UltraCheck-EZ™ diagnostic tool (Goodman Part UTT-01).
This tool will test the motor windings and also the commu­nicating module of the motor.

62

OPERA TIONAL CHECKS

LED LED St a tus Indication Po ss ible Caus es Corrective Action(s)

Red

Com munications

LED

Green

Receive

LED

Off • Normal condition • None • None

2 Flashes • Out-of-bo x reset • None

Rapid Flashing • Normal network traffic • Control is “talking” on

On Solid • Data 1/ Data 2 miss-wire

Operational Checks

BURNER FLAME

The burner flames should be inspected with the burner compart­ment door installed. Flames should be stable, quiet, soft, and
blue (dust may cause orange tips but they must not be yellow).
Flames should extend directly outward from the burners without
curling, floating, or lifting off. Flames must not impinge on the
sides of the heat exchanger firing tubes.

• Control power up

• Learn button depressed

• None

network as expected

• Data 1 and data 2 wires reversed
a t furn ac e , thermostat or
communicati ng compatible
outdoor AC/HP

• Sho r t betwee n dat a 1 and
data 2 wires.

• Sho r t betwee n dat a 1 or
data 2 wires and R
(24VAC) or C (24 VAC
common).

• Check commun icatio ns
wiring (da ta 1/ data 2
wires).

• Check wire connections at
terminal block

• Check data 1/ data 2
voltage s.

A memory chip is only required when all communicating com­ponents have been replaced with service parts containing no
shared data. If either an existing control board or ECM motor
needed to be replaced, the service part would upload the
necessary data from the remaining communicating compo­nent. In a fully communicating system, this would include
the communicating thermostat and communicating outdoor
unit control board as the necessary data is stored in all com­municating devices.

Check the
Burner Flames for:

1. Stable, soft and blue.

2. Not curling, floating
or lifting off.

Burner Flame

MEMORY CHIPS

Memory chips are a service only item and are not sent out
with new equipment. They are used only in the rare occur­rence where communicating equipment shared data needs
to be restored.

Memory chips should not be routinely installed at the time of
installation. A memory chip is not required when an individual
control board or motor is replaced.

A furnace void of shared data will not function in a legacy or a
fully communicating installation. The furnace display would
show “d0” indicating that there is no shared data in the fur­nace control board. If it is ever necessary to use a memory
chip, the specific memory chip for your furnace number must
be used.

63

OPERA TIONAL CHECKS

To use a memory chip;

1. Power down all HVAC equipment in the system.

2. As when handling any electronic components, discharge
any static electricity you may be carrying by touching
grounded metal.

3. Insert the memory card in the slot on the control board.

4. Power the system back up and allow a few minutes for
the network to establish communication between all de­vices.

5. Furnace control board will display “OP” or ‘ON” (depend­ing on board part number).

6. Check operation.

7. Memory chip can be left on the control board (recom­mended) or removed once equipment is powered down
again.

PRESSURE SWITCHES

The pressure switches are normally-open (closed during opera­tion) negative air pressure-activated switches. They monitor the
airflow (combustion air and flue products) through the heat ex­changer via pressure taps located on the induced draft blower
and the coil front cover. These switches guard against insuffi­cient airflow (combustion air and flue products) through the heat
exchanger and/or blocked condensate drain conditions.

FLAME SENSOR

The flame sensor is a probe mounted to the burner/manifold as­sembly which uses the principle of flame rectification to deter­mine the presence or absence of flame.

T roubleshooting

WARNING

Safety Circuit Description

A number of safety circuits are employed to ensure safe and
proper furnace operation. These circuits serve to control any
potential safety hazards and serve as inputs in the monitoring
and diagnosis of abnormal function. These circuits are continu­ously monitored during furnace operation by the integrated con­trol module.

INTEGRATED FURNACE CONTROL (IFC)

The integrated control module is an electronic device which, if a
potential safety concern is detected, will take the necessary pre­cautions and provide diagnostic information through an LED dis­play.

PRIMARY LIMIT

The primary limit control is located on the partition panel and
monitors heat exchanger compartment temperatures. It is a nor­mally-closed (electrically), automatic reset, temperature-activated
sensor. The limit guards against overheating as a result of insuf­ficient conditioned air passing over the heat exchanger.

AUXILIARY LIMIT

The auxiliary limit controls are located on or near the circulator
blower and monitors blower compartment temperatures. They
are a normally-closed (electrically), auto-reset sensors. These
limits guard against overheating as a result of insufficient condi­tioned air passing over the heat exchanger.

ROLLOUT LIMIT

The rollout limit controls are mounted on the burner/manifold as­sembly and monitor the burner flame. They are normally-closed
(electrically), manual-reset sensors. These limits guard against
burner flames not being properly drawn into the heat exchanger.

HIGH VOLTAGE !

TO

AVOID PERSONAL INJURY OR DEATH DUE TO

ELECTRICAL SHOCK, DISCONNECT ELECTRICAL POWER

BEFORE

Refer to the Troubleshooting Codes for assistance in determin­ing the source of unit operational problems. The dual 7-segment
LED display will display an error code that may contain a letter
and number. The error code may be used to assist in trouble­shooting the unit.

PERFORMING ANY SERVICE OR MAINTENANCE

RESETTING FROM LOCKOUT

Furnace lockout results when a furnace is unable to achieve igni­tion after three attempts during a single call for heat. It is charac­terized by a non-functioning furnace and a E 0 code displayed on
the dual 7-segment display. If the furnace is in “lockout”, it will (or
can be) reset in any of the following ways.

1. Automatic reset. The integrated control module will auto­matically reset itself and attempt to resume normal opera­tions following a one hour lockout period.

2. Manual power interruption. Interrupt 115 volt power to the
furnace.

3. Manual thermostat cycle. Lower the thermostat so that
there is no longer a call for heat for 1 -20 seconds then reset
to previous setting.

NOTE: If the condition which originally caused the lockout still
exists, the control will return to lockout. Refer to the
Troubleshooting Codes for aid in determining the cause.

.

64

MAINTENANCE

Maintenance

FILTERS

WARNING

TO

AVOID ELECTRICAL SHOCK, INJURY OR DEATH
DISCONNECT ELECTRICAL POWER BEFORE PERFORMING ANY
MAINTENANCE
HANDLE WITH CARE
WITH BARE FINGERS, ROUGH HANDLING OR VIBRATION
COUL D DAMAGE THE IGNITER RESU LTING IN PREMATURE
FAILURE
HANDLE THE IGNITER

. IF

YOU MUST HANDLE THE IGNITER

. T

OUCHING THE IGNITER ELEMENT

. O

NLY A QUALIFIED SERVICER SHOULD EVER

.

,

,

ANNUAL INSPECTION

The furnace should be inspected by a qualified installer, or service
agency at least once per year. This check should be performed at
the beginning of the heating season. This will ensure that all fur­nace components are in proper working order and that the heating
system functions appropriately. Pay particular attention to the
following items. Repair or service as necessary.

• Flue pipe system. Check for blockage and/or leakage.
Check the outside termination and the connections at and
internal to the furnace.

• Heat exchanger. Check for corrosion and/or buildup within
the heat exchanger passageways.

• Burners. Check for proper ignition, burner flame, and flame
signal.

• Drainage system. Check for blockage and/or leakage.
Check hose connections at and internal to furnace.

• Wiring. Check electrical connections for tightness and/or
corrosion. Check wires for damage.

• Filters.

CAUTION

TO

ENSURE PROPER UNIT PERFORMANCE, ADHERE TO THE FILTER SIZES

GIVEN IN THE RECOMMENDED MINIMUM FILTER SIZE TABLE OR

PECIFICATION SHEET APPLICABLE TO YOUR MODEL

S

.

FILTER MAINTENANCE

Improper filter maintenance is the most common cause of inad­equate heating or cooling performance. Filters should be cleaned
(permanent) or replaced (disposable) every two months or as re­quired.

BURNERS

Visually inspect the burner flames periodically during the heating
season. Turn on the furnace at the thermostat and allow several
minutes for flames to stabilize, since any dislodged dust will alter
the flames normal appearance. Flames should be stable, quiet,
soft, and blue (dust may cause orange tips but they must not be
yellow). They should extend directly outward from the burners
without curling, floating, or lifting off. Flames must not impinge on
the sides of the heat exchanger firing tubes.

INDUCED DRAFT AND CIRCULATOR BLOWERS

The bearings in the induced draft blower and circulator blower
motors are permanently lubricated by the manufacturer. No fur­ther lubrication is required. Check openings on motor housing
for accumulation of dust which may cause overheating. Clean as
necessary.

CONDENSATE TRAP AND DRAIN SYSTEM (QUALIFIED SERVICER
ONLY)

Annually inspect the drain tubes, drain trap, and field-supplied
drain line for proper condensate drainage. Check drain system
for hose connection tightness, blockage, and leaks. Clean or
repair as necessary.

FLAME SENSOR (QUALIFIED SERVICER ONLY)

Under some conditions, the fuel or air supply can create a nearly
invisible coating on the flame sensor. This coating acts as an
insulator causing a drop in the flame sense signal. If the flame
sense signal drops too low the furnace will not sense flame and
will lock out. The flame sensor should be carefully cleaned by a
qualified servicer using steel wool.

65

SERVICING

SERVICING

S-1 CHECKING VOL T AGE ................................. 67

S-2 CHECKING WIRING..................................... 67

S-3A THERMOSTA T AND WIRING ....................... 67

S-3B HEATING ANTICIP A TOR/ CYLCE RA TE....... 68

S-4 CHECKING TRANSFORMER

AND CONTROLCIRCUIT........................... 68

S-300 CHECKING PRIMARY LIMIT CONTROL ...... 68

S-30 CHECKING AUXILIARY LIMIT CONTROL..... 68

S-302 CHECKING FLAME ROLLOUT CONTROL... 69

S-303 INDUCED DRAFT BLOWER MOTOR ......... 69

S-304 CHECKING MODULATING GAS VALVE..... 69

S-304ACHECKING INDUCTOR COIL....................... 69

S-305 CHECKING MAIN BURNERS ...................... 71

S-306 CHECKING ORIFICES ................................. 71

S-307 CHECKING GAS PRESSURE ..................... 71

S-308 CHECKING HOT SURFACE IGNITOR.......... 72

S-309 CHECKING FOR FLASHBACK .................... 72

S-310 CHECKING PRESSURE CONTROL ............ 72

S-311 HIGH ALTITUDE APPLICA TION .................... 73

S-312 CHECKING FOR DELA YED IGNITION........ 73

S-313 CHECKING INTEGRATED

IGNITION CONTROL BOARDS ............... 73

S-314 CHECKING FLAME SENSOR ................... 7 4

66

SERVICING

S-1 CHECKING VOLTAGE

WARNING

HIGH VOLTAGE
D

ISCONNECT ALL POWER BEFORE SERVICI NG OR

CHANGING ANY E LECTRI CAL WI RING.
SOURCES MAY BE PRESENT.
PROPERTY DAMAGE, PERS ONAL INJURY OR DEATH.

MULTIPLE POWER

FAILURE TO DO SO MAY CAUSE

1. Remove the blower door to gain entry to the Junction
Box.

2. Remove cover from the Junction Box and gain access to
incoming power lines.

With Power ON:

WARNING

INE VOLTAGE NOW PRESENT

L

3. Using a voltmeter, measure the voltage across the hot
and neutral connections. Line voltage should measure
115 +/- 10%. Measure from black (hot) to ground should
also read 115 volts +/- 10%. Measuring from white (neu­tral) to ground should read 0 volts

NOTE: To energize the furnace, the Door Interlock Switch
must be engaged at this point.

4. No reading - indicates open wiring, open line voltage

fuse, no power, or faulty Door Interlock Switch from
unit to fused disconnect service. Repair as needed.

5. With proper voltage at line voltage connectors, ener-

gize the furnace blower motor by jumpering terminals
R to G on the integrated ignition control.

6. With the blower motor in operation, the voltage should

be 1 15 volts ± 10 percent.

7. If the reading falls below the minimum voltage, check

the line wire size. Long runs of undersized wire can
cause low voltage. If wire size is adequate, notify the
local power company of the condition.

8. After completing check and/or repair , replace Junction

Box cover and reinstall the service panel doors.

9. Turn on electrical power and verify proper unit opera-

tion.

S-2 CHECKING WIRING

WARNING

DISCONNECT ALL POWER BEFORE SERVICING.

1. Check wiring visually for signs of overheating, damaged
insulation and loose connections.

2. Use an ohmmeter to check continuity of any suspected
open wires.

3. If any wires must be replaced, replace with AWM, 105°C.
2/64 thick insulation of the same gauge or its equivalent.

CHECKING THERMOSTAT, WIRING
AND ANTICIPATOR

S-3A THERMOSTAT AND WIRING

WARNING

DISCONNECT ALL POWER BEFORE SERVICING.

1. Remove the blower compartment door to gain access to
the thermostat low voltage wires located at the furnace
integrated control module terminals.

2. Remove the thermostat low voltage wires at the furnace
control panel terminal board.

3. Jumper terminals R to W on the integrated ignition con­trol.

With Power On (and Door Interlock Switch closed):
NOTE: For this test, DIP switch #13 must be in OFF posi-

tion.)

WARNING

LINE VOLTAGE NOW PRESENT

4. Induced Draft Motor must run and pull in pressure

switch.

5. If the hot surface ignitor heats and at the end of the ig-

nitor warm-up period the gas valve opens and the
burners ignite, the trouble is in the thermostat or wir­ing.

6. With power off, check the continuity of the thermostat

and wiring. Repair or replace as necessary .

If checking the furnace in the air conditioning mode, pro-

ceed as follows.

7. With power off, Jumper terminals R to Y (or Y1 or Y2

for two-stage models) to G .

8. Turn on the power .

9. If the furnace blower motor starts and the condensing

unit runs, then the trouble is in the thermostat or wir­ing. Repair or replace as necessary .

10. After completing check and/or repair of wiring and

check and/or replacement of thermostat, reinstall
blower compartment door.

1 1. Turn on electrical power and verify proper unit opera-

tion.

67

SERVICING

S-3B HEATING ANTICIPATOR/ CYLCE RATE

Older heating thermostats may have an adjustable anticipa­tor. This is a wire wound adjustable heater which is ener­gized during the "ON" cycle to help prevent overheating of
the conditioned space.

The anticipator is a part of the thermostat and if it should fail
for any reason, the thermostat must be replaced.

Other thermostats have a cycle rate adjustment to adjust
cycles per hour. This should be set to match system type.

S-4 CHECKING TRANSFORMER AND CONTROL

CIRCUIT

A step-down transformer 120 volt primary to 24 volt second­ary, 40 VA (Heating and Cooling Models) supplies ample
capacity of power for either operation.

WARNING

HIGH VOLTAGE
D

ISCO NN E CT ALL POWER BEFORE SERVI CING OR

CHANGING ANY ELECTRICAL WIRING.
SOURCES MAY BE PRESENT.
PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.

MULT IPLE POWER

FAILURE TO DO SO MAY CAUSE

1. Remove blower compartment door to gain access to the
thermostat low voltage wires located at the furnace inte­grated control module.

2. Remove the thermostat low voltage wires at the furnace
integrated control module terminals.

With Power On (and Door Interlock Switch closed

WARNING

S-300 CHECKING PRIMARY LIMIT CONTROL

All modulating furnaces use a nonadjustable, automatic re­set, bi-metal type limit control. The primary limit control is
located on the front panel of the furnace between heat ex­changer tubes. This is a normally closed control.

WARNING

HIGH VOLTAGE

ISCO NN E CT ALL POWER BEFORE SERVI CING OR

D

CHANGING ANY ELECTRICAL WIRING.
SOURCES MAY BE PRESENT.
PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.

MULT IPLE POWER

FAILURE TO DO SO MAY CAUSE

1. Turn off all voltage sources

2. Remove the two wires from the limit switch

3. Using an ohmmeter, check for a closed circuit across
the two limit contacts (this will be the same reading
that you see by touching your two meter leads to­gether)

S-301 CHECKING AUXILIARY LIMIT CONTROL

Automatic Reset Auxiliary Limit Located in Blower Hous­ing

Modulating furnaces use an auxiliary limit(s) (automatic re­set) control connected in series with the main limit switch.
If its temperature should be exceeded, it will open, interrupt­ing the voltage in the limit circuit. The auxiliary limit is lo­cated on the side of the blower housing. This is a normally
closed switch. To check auxiliary limits; perform the follow­ing steps.

LINE VOLTAGE NOW PRESENT

3. Use a voltmeter, check voltage across terminals R
and C. Must read 24 V AC.

4. No voltage indicates faulty transformer, open fuse, bad
wiring, bad splice, or open door interlock switch.

5. Check transformer primary voltage at incoming line
voltage connections, fuse, splices, and blower door in­terlock switch.

6. If line voltage is available to the primary side of trans­former and not at secondary side, the transformer is
inoperative. Replace.

7. After completing check and/or replacement of trans­former and check and/or repair of control circuit, rein­stall blower compartment door .

8. Turn on electrical power and verify proper unit opera­tion.

68

WARNING

HIGH VOLTAGE
D

ISCO NNECT ALL POWER BEFORE SERVI CING OR

CHANGING ANY ELECTRICAL WIRING.
SOURCES MAY BE PRESENT.
PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.

MULTIPLE POWER

FAILURE TO DO SO MAY CAUSE

1. Turn off all power sources

2. Remove the two wires from the auxiliary limit switch

3. Using an ohmmeter, check for a closed circuit across
the two limit contacts (this will be the same reading
that you see by touching your two meter leads to­gether)

SERVICING

AUXILIARY LIMIT
CONTROL

BLOWER HOUSING

AUXILIARY LIMIT
CONTROL

Auxiliary Limit Control Location

S-302 CHECKING FLAME ROLLOUT CON-

TROL

A temperature activated manual reset control is mounted to
the manifold assembly on modulating furnace, as shown in
the following illustration.

FLAME
ROLLOUT
SWITCHES

*

*

*

*

2

*

**

Flame Rollout Switch Location

(90% Upflow Furnace Shown, Counterflow Similar)

WARNING

HIGH VOLTAGE
D

ISCO NN E CT ALL POWER BEFORE SERVI CING OR

CHANGING ANY ELECTRICAL WIRING.
SOURCES MAY BE PRESENT.
PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.

1. Turn off all power sources

2. Remove the two wires from the roll out switch

3. Using an ohmmeter, check for a closed circuit across
the two roll out switch contacts (this will be the same
reading that you see by touching your two meter leads
together).

MULT IPLE POWER

FAILURE TO DO SO MAY CAUSE

S-303 INDUCED DRAFT BLOWER MOTOR

Induced Draft Blower (IDB)

All modulating furnace models use a three phase induced
draft blower to draw flue gases through the heat exchanger .
The inducer uses ball bearings and is permanently
lubricated. This motor is driven at varying speeds by the
VFD (variable frequency drive) section of the IFC. The IFC
takes typical single phase power supplied to the furnace
and converts it to a three phase supply to operate the draft
inducer at the desired speed. The windings of the induced
draft motor will have equal resistance +/- 5%. Normal
resistance readings at room temperature will range from
14-17 ohms. The voltage supplied by the IFC to drive the
induced draft blower will vary from 15-1 10 volts A/C between
any two windings. This would be read between any two of
the three power wires between the IFC and the induced
draft blower . This voltage to the IBD will vary between furnace
models and is dependant on what percentage of maximum
fire is being called for. The power wires are colored red,
white and black. A green colored ground wire is also
present.

S-304 CHECKING MODULATING GAS VALVE

Gas ValveModulating furnaces use a 24 VAC pneumati­cally operatedgas valve by Honeywell. The valve is ener­gized by the inte-grated furnace control on a call for heat,
wired in series through the front-cover pressure switch. The
firing rate percentage is determined by the negative pres­sure created by the operation of the draft inducer. The gas
valve is factory set and non-adjustable in the field. Do not
remove the seal covering the regulator screws or attempt to
adjust either of the regulator screws. Even though the modu­lating gas valve is non-adjustable in the field, gas industry
procedure dictates that the installing / servicing technician
should know that the appliance is operating as designed
before leaving newly installed or serviced equipment. The
gas valve is equipped with 1/8 NPT fittings to access both
the inlet and manifold gas pressures. To do a manifold gas
pressure check, the furnace can be operated in field test
mode. This mode will quickly bring the furnace up to high
fire. To enter field test mode; during a call for heat, press
the fault recall button twice within a five second period; when
the dual seven segment displays show Ft, press the fault
recall button again to enter field test mode.The furnace will
stay in field test for five minutes or until the call for heat is
satisfied. Gas valve orientation must be such that the switch
is facing out towards the front of the furnace.

S-304A CHECKING INDUCTOR COIL

Wired in series with ¾ and 1 HP ECM motors; the inductor
coil conditions the power supply to the motor, smoothing
out spikes and electrical noise. With voltage applied to one
side of the inductor coil, the output voltage to the motor
should be the same as incoming voltage.

69

SERVICING

MODULATING FURNACE PNEUMATIC TUBING DIAGRAM

Front Cover

Pressur e Sw itch

Black Tee

MUST

be left open

Low & High Pressure Switch Assembly

with “H” Fitting

+ Port is Open

to the Atmosphere

Modulating

Gas Valve

Negative (-)

Port on Gas Valve

For representation only. Ac tual unit may vary in appearance.

70

Upflow Model Shown

SERVICING

S-305 CHECKING MAIN BURNERS

The main burners are used to provide complete combustion
of various fuels in a limited space, and transfer this heat of
the burning process to the heat exchanger.

Proper ignition, combustion, and extinction are primarily due
to burner design, orifice sizing, gas pressure, primary and
secondary air, vent and proper seating of burners.

Depending on the size of the furnace, each furnace will
havefrom three to five inshot burners. Burners are precisely
constructed of aluminized steel and designed to provide
proper ignition and flame stability. When converting a modu­lating furnace to L.P. gas, the factory installed burners must
be replaced by burners that come in the L.P. kit.

WARNING

D

IS CONNECT

In checking main burners, look for signs of rust, oversized
and undersized carry over ports restricted with foreign ma­terial, etc, refer to Beckett Burner drawing.

ALL G

AS AND ELECTRICAL POWER SUPPLY.

A

GAS
STREAM

B

The length of Dimension "A" determines the angle of Gas
Stream "B".

DENT OR
BURR

GAS

STREAM

B

A dent or burr will cause a severe deflection of the gas stream.

S-307 CHECKING GAS PRESSURE

Gas Supply Pressure Measurement

CAUTION

Beckett Burner

S-306 CHECKING ORIFICES

A fixed gas orifice is used in all Goodman® brand & Amana
brand furnaces. That is an orifice which has a fixed bore
and position as shown in the following drawing.

No resizing should be attempted until all factors are taken
into consideration such as inlet and manifold gas pressure,
alignment, and positioning, specific gravity and BTU con­tent of the gas being consumed.

Orifices should be treated with care in order to prevent dam­age. They should be removed and installed with a box-end
wrench in order to prevent distortion. In no instance should
an orifice be peened over and redrilled.

T

O PREVENT UNRELIABL E OPERATI ON OR E QUIPMENT DAMAGE, T HE
INLET GAS SUPPLY PRESSURE MUST BE AS SPECIFIED ON THE UNIT
RATING PLATE WITH ALL OTHER HOUSEHOLD GAS FIRED APPLIANCES
OPERATING.

Gas inlet and manifold pressures should be checked in ac­cordance to the type of fuel being consumed.

The line pressure supplied to the gas valve must be within
the range specified below. The supply pressure can be mea­sured at the gas valve inlet pressure tap or at a hose fitting
installed in the gas piping drip leg. The supply pressure must

®

be measured with the burners operating. To measure the
gas supply pressure, use the following procedure.

WARNING

D

ISCONNECT ELECTRICAL POWER AND SHUT OFF GAS SUPPLY.

1. After turning off gas to furnace at the manual gas shutoff
valve external to the furnace, remove burner compart­ment door to gain access to the gas valve.

2. Connect a calibrated water manometer (or appropriate
gas pressure gauge) at either the gas valve inlet pres­sure tap or the gas piping drip leg as shown in the follow­ing figures.

71

SERVICING

GAS LINE

GAS SHUTOFF VALVE

GAS LINE
TO FURNACE

OPEN TO
ATMOSPHERE

DRIP L E G CAP
WITH FITTING

MANOMETER HOSE

MANOMETER

Measuring Inlet Gas Pressure

(Alternate Method)

3. Turn ON the gas and electrical power supply and oper­ate the furnace and all other gas consuming appliances
on the same gas supply line.

4. Measure furnace gas supply pressure with burners fir­ing. Supply pressure must be within the range specified
in the following table.

T o test manifold pressure the furnace must be put into
“field test mode” to bring the furnace up to 100% input.

5. Disconnect manometer after turning off gas at manual
shutoff valve. Reinstall plug before turning on gas to fur­nace.

6. Turn OFF any unnecessary gas appliances started in
step 3.

7. Turn on gas to furnace and check for leaks. If leaks are
found, repair and then reinstall burner compartment door.

8. Turn on electrical power and verify proper unit operation.

The gas valve is factory set and non-adjustable in the field.
Do not remove the seal covering the regulator screws or
attempt to adjust either of the regulator screws. Even though
the modulating gas valve is non-adjustable in the field, gas
industry procedure dictates that the installing / servicing tech­nician should know that the appliance is operating as de­signed before leaving newly installed or serviced equipment.
The gas valve is equipped with 1/8 NPT fittings to access
both the inlet and manifold gas pressures. To do a manifold
gas pressure check the furnace can be operated in field
test mode. This mode will quickly bring the furnace up to
high fire. To enter field test mode; during a call for heat,
press the fault recall button twice within a five second pe­riod; when the dual seven segment displays show Ft, press
the fault recall button again to enter field test mode. The
furnace will stay in field test for five minutes or until the call
for heat is satisfied. Gas valve orientation must be such that
the switch is facing out towards the front of the furnace.

Manifold pressure for natural gas is pre-set to be between

3.2” WC to 3.8”WC. If the furnace has been converted to LP
gas, the manifold pressure will be 9.7”WC to 10.3”W.

Manifold Gas Pressure

Natural Gas

Propane Gas

3.5" w.c.

10.0" w.c.

S-308 CHECKING HOT SURFACE IGNITOR

Modulating furnaces use a 115 volt silicon nitride hot sur­face igniter. This is the familiar and reliable 0131F00008S
igniter with 17 second warm up time. At room temperature
the igniter has a resistance range of 37 - 68 ohms. The
H.S.I. isconnected electrically to the IFC by a 3/16" push­on connection.

S-309 CHECKING FOR FLASHBACK

Flashback will also cause burning in the burner venturi, but
is caused by the burning speed being greater than the gas­air flow velocity coming from a burner port.

Flashback may occur at the moment of ignition, after a burner
heats up or when the burner turns off. The latter is known as
extinction pop.

Since the end results of flashback and delayed ignition can
be the same (burning in the burner venturi) a definite attempt
should be made to determine which has occurred. If flash­back should occur, check for the following:

1. Improper gas pressure - adjust to proper pressure (See
S-307 CHECKING GAS PRESSURE)..

2. Check burner for proper alignment and/or replace burner.

3. Improper orifice size - check orifice for obstruction.

S-310 CHECKING PRESSURE CONTROL

The pressure control is a safety device to prevent the com­bustion cycle from occurring with inadequate venting caused
by a restricted or blocked vent pipe on the modulating fur­nace. Also on the modulating furnaces there is a pressure
control that will prevent the combustion cycle from occur­ring with inadequate condensate drainage due to a partial or
blocked recuperator coil or drain.

WARNING

HIGH VOLTAGE

ISCONNECT ALL POWER BEFORE SERVI CING OR

D

INSTALLI NG THIS UNIT.
BE PRESENT.
DAMAGE, PERS ONAL I NJURY OR D EATH.

1. Remove burner compartment door to gain access to pres­sure switch(es).

2. Remove wires from the pressure switch(es) electrical ter­minals.

3. Using a VOM check from common terminal to NO (Nor­mally Open) - should read open.

MULTIPLE POWER SOURCES MAY

FAILURE TO DO SO MAY CAUSE PROPERTY

72

SERVICING

If switch reads as above proceed to Step 4, otherwise re­place control.

4. Remove the pressure control hose from the control and
interconnect with an inclined manometer as shown in
the following figures.

MODULATING FURNACE PNEUMATIC TUBING DIAGRAM

Front Cover

Pressure Switch

be left open

Low & High Pressure Switch Assembly

Black Tee

MUST

with “H” Fitting

+ Port is Open

to the Atmosphere

Modulating

Gas Valve

Negative (-)

Port on Gas Valve

S-313 CHECKING INTEGRATED IGNITION

CONTROL BOARDS

NOTE: Failure to earth ground the furnace, reversing the

neutral and hot wire connection to the line (polarity), or a
high resistance connection in the neutral line may cause
the control to lockout due to failure to sense flame.

WARNING

T

O AVOID THE RISK OF ELECTRICAL SHOCK, WIRING TO THE UNIT
MUST BE PROPERLY POLARIZED AND GROUNDED.
BEFORE PERFORMING SERVICE LISTED BELOW.

The ground wire must run from the furnace all the way back
to the electrical panel. Proper grounding can be confirmed
by disconnecting the electrical power and measuring resis­tance between the neutral (white) connection and the burner
closest to the flame sensor. Resistance should be less than
10 ohms.

The ignition control is a combination electronic and electro­mechanical device and is not field repairable. Complete unit
must be replaced.

D

ISCONNECT POWER

Upflow Model Shown

For represent atio n onl y. Actual unit may vary in app ear a nce .

S-311 HIGH ALTITUDE APPLICATION

Modulating furnaces are approved up to 10,000 ft alti­tude. No kit or changes are needed.

S-312 CHECKING FOR DELAYED IGNITION

Delayed ignition is a delay in lighting a combustible mix­ture of gas and air which has accumulated in the combus­tion chamber.

When the mixture does ignite, it may explode and/or rollout
causing burning in the burner venturi.

If delayed ignition should occur, the following should be
checked:

1. Improper gas pressure - adjust to proper pressure (See
S-307 CHECKING GAS PRESSURE).

2. Improper burner positioning - burners should be in lo­cating slots, level front to rear and left to right.

3. Carry over (lighter tube or cross lighter) obstructed ­clean.

4. Main burner orifice(s) deformed, or out of alignment to
burner - replace.

WARNING

INE VOLTAGE NOW PRESENT

L

These tests must be completed within a given time frame
due to the operation of the ignition control.

The ignition control is capable of diagnosing many furnace
failures to help in troubleshooting. The PCBKF200 and
PCBKF201 controls utilize a dual, 7-segment LED display
to indicate diagnostic codes.

When the control is powered up normally the light will be on
continuously. The PCBKF200 and PCBKF201displays will
indicate "ON" when powered and in standby mode.

This can be used to test for 120 volts and 24 volts to the
control since both must be present for the light to be on. If
this step fails, check for 120 volts to the control and check
the transformer and its associated wiring. If this step is suc­cessful give the control a call for heat and wait five (5) sec­onds or until the furnace goes into lockout. If the control
detects a failure it will now be shown on the diagnostic indi­cator light/display. Refer to the Abnormal Operation section
in the Sequence of Operation section of this manual for more
detail on failure codes

The indicator light/display may be viewed by looking through
the sight glass in the blower compartment door. The failure
codes are retrieved via an on-board, momentary push button
switch. Pressing the button for 2-5 seconds will force the
failure codes to be displayed on the diagnostic indicator.

73

SERVICING

S-314 CHECKING FLAME SENSOR

A flame sensing device is used in conjunction with the igni­tion control module to prove combustion. If proof of flame is
not present the control will de-energize the gas valve and
"retry" for ignition or lockout.

WARNING

HIGH VOLTAGE

ISCONNECT ALL POWER BEFORE SERVI CING OR

D

INSTALLI NG THIS UNIT.
BE PRESENT.
DAMAGE, PERSONAL INJURY OR DEATH.

Flame signal is continuously monitored by the IFC. The flame
rod, flame rod wire, and proper grounding are all critical to
proving the presence of flame. Because of the design of the
Honeywell flame proving system, reading flame signal with a
microamp meter will not provide reliable and consistent re­sults and is therefore not a recommended practice. The IFC
has a built in warning (E6) if flame signal is approaching the
low threshold.

MULTIPLE POWER SOURCES MAY

FAILURE TO DO SO MAY CAUSE PROPERTY

NOTE: Contaminated fuel or combustion air can create a

nearly invisible coating on the flame sensor. This coating
works as an insulator causing a loss in the flame sense
signal. If this situation occurs the flame sensor must be
cleaned with steel wool.

74

Troubleshooting

O

E0

E1

E2

Notes & Cautions

repair.

“Electrostatic Discharge”

section of manual.

x Turn power OFF prior to

x Read precautions in

module with current

x Replace integrated control

replacement parts.

x Turn power OFF prior to

repair.

with care.

x Igniter is fragile, handle

wool.

section for piping details.

x Clean flame rod with steel

x See “Vent/Flue Pipe”

x Turn power OFF prior to

repair.

with correct replacement

x Replace pressure switch

part.

repair.

with correct replacement

part.

blower with correct

replacement part.

assemble/install H fitting

x Turn power OFF prior to

x Replace pressure switch

x Replace induced draft

in factory configuration.

x Take care to

Corrective Actions

interruption.

switch operation (hose, wiring,

contact operation). Correct if

necessary. Make sure furnace is

draining properly.

sensor if coated and/or oxidized.

proper length, elbows, and

termination.

x Assure proper wiring to furnace

blower performance.

and integrated control module.

x Verify power to the furnace and

integrated control module is

stable and within specifications.

x Replace bad integrated control

module.

x Locate and correct gas

x Check front cover pressure

x Replace or realign igniter.

x Check flame sense signal. Sand

x Check flue piping for blockage,

x Verify proper induced draft

x Replace low stage pressure

switch.

x Repair short in wiring.

Repair/replace if necessary.

piping for blockage, proper

length, elbows, and termination.

necessary.

performance. Correct as

necessary.

or contact motion.

x Inspect pressure switch hose.

x Inspect flue and/or inlet air

x Check drain system. Correct as

x Check induced draft blower

connection.

x Correct pressure switch set point

x Tighten or correct wiring

x Clean H fitting.

Possible Causes

may be no gas to burners, front

cover pressure switch stuck open,

bad igniter or igniter alignment,

improper orifices, or

coated/oxidized or improperly

connected flame sensor.

Cause may be interrupted gas

supply, lazy burner flames

(improper gas pressure or

restriction in flue and/or

combustion air piping), front

cover pressure switch opening, or

improper induced draft blower

performance.

contacts sticking.

x Failure to establish flame. Cause

x Improper wiring to the furnace

or integrated control module.

EE

x Normal operation x None x Normal operation

x Loss of flame after establishment.

wiring.

x Low stage pressure switch

x Shorts in pressure switch circuit

E1

pinched, or connected improperly.

blocked drain system or weak

induced draft blower.

or malfunctioning switch

contacts.

wiring.

x Pressure switch hose blocked

x Blocked flue and/or inlet air pipe,

x Incorrect pressure switch set point

x Loose or improperly connected

blocked.

x Inducer not running.

x H fitting atmospheric port

ComfortNet

Thermostat Only

Fault Description

LED Codes

Diagnostic/Status

FAULT

Message Code

INTERNAL

module has an internal

x Integrated control

if

Thermostat)

None None

LOCKOUT E0

an excessive number of

ignition “retries” or

flame “recycles” (3

fault

x Normal operation

n

O

n

x Furnace lockout due to

total).

E0

error code.

PS1

CLOSED

switch circuit is closed at

x Low stage pressure

E1

start of heating cycle.

error code.

PS1 OPEN E2

switch circuit is not

closed.

x Low stage pressure

E2

error code.

Symptoms of Abnormal Operation

(Non-communicating & ComfortNet™

provides IF error code..

icon illuminated

x ComfortNet thermostat “Call for Service”

x ComfortNet thermostat scrolls “Check

Furnace” message

x LED display indicates

x Furnace fails to operate

x Furnace fails to operate

x Integrated control module LED display

icon illuminated.

provides

x ComfortNet thermostat “Call for Service”

x Integrated control module LED display

x ComfortNet thermostat scrolls “Check

Furnace” message.

icon illuminated.

x ComfortNet thermostat “Call for Service”

x ComfortNet thermostat scrolls “Check

Furnace” message.

with no further furnace operation.

x Induced draft blower runs continuously

provides

x Furnace fails to operate.

x Integrated control module LED display

icon illuminated.

x ComfortNet thermostat “Call for Service”

x ComfortNet thermostat scrolls “Check

Furnace” message.

provides

x Integrated control module LED display

75

Troubleshooting

E3

E4

E

E5

E6

Notes & Cautions

repair.

applicable to your model

for allowable rise range

and proper circulator

x Turn power OFF prior to

x See Specification Sheet

speed.

repair.

x Turn power OFF prior to

x Turn power OFF prior to

repair.

x Turn power OFF prior to

repair.

x Turn power OFF prior to

repair.

automotive type

x Replace fuse with 3-amp

x Turn power OFF prior to

repair.

steel wool.

x Clean flame sensor with

x See "Vent/Flue Pipe"

section for piping details.

gas pressure.

x See rating plate for proper

Corrective Actions

blockage. Clean filters or

remove obstruction.

and performance. Correct speed

or replace blower motor if

necessary.

connection.

x Check filters and ductwork for

x Check circulator blower speed

x Tighten or correct wiring

in flame sensor wiring.

x Correct short at flame sensor or

x Check for lingering flame.

x Verify proper operation of gas

valve. Replace if necessary.

x Reset system power and verify

inducer is running properly.

x Replace inducer or integrated

control module, if necessary.

exchanger.

x Line up burners.

x Check for flame disturbance on

roll out when blower comes on.

x Install jumper.

x Inspect float switch.

x Line up orifice plate.

x Remove Blockage from heat

voltage wiring

coated/oxidized.

alignment.

blockage, proper length, elbows,

and termination.

x Clean flame sensor if

x Inspect for proper sensor

x Check inlet air piping for

rating plate. Adjust as needed.

x Compare current gas pressure to

Possible Causes

the heat exchanger. Blocked

filters, restrictive ductwork,

improper circulator blower speed,

or failed circulator blower motor.

x Insufficient conditioned air over

E3

wiring.

x Loose or improperly connected

circuit.

x Short to ground in flame sense

x Lingering burner flame.

x Slow closing gas valve.

E4

x Lingering Inducer motor

EC

overcurrent detected.

x Orifice plate out of position.

x Blocked heat exchanger.

Ed

x Burners out of alignment.

x Defective heat exchanger.

aux out.

x Open circuit between aux in or

EF

x Missing jumper.

x Open float switch..

x Short in low voltage wiring x Locate and correct short in low

Not

Displayed

.positioned in burner flame.

improper gas pressure or

x Lazy burner flame due to

combustion air.

x Flame sensor is coated/oxidized.

x Flame sensor incorrectly

E6

ComfortNet

Thermostat Only

Fault Description

LED Codes

Diagnostic/Status

Message Code

Thermostat)

HIGH

LIMIT

x Primary limit.

E3

OPEN

error code.

IMPROPER

x Flame sensed when it

E4

FLAME

should not be present.

error code.

OR

FAULT

INDUCER

x Inducer motor

overcurrent fault.

EC

INDUCER

LOCKOUT

OPEN

ROLLOUT

switch is open

x Manual reset rollout

Ed

d error code.

OPEN

AUXILIARY

x Open auxiliary input.

EF

Not

Displayed

x Open Fuse

E5

error code.

WEAK

x Flame sense micro amp

E6

FLAME

signal is low

error code.

Symptoms of Abnormal Operation

(Non-communicating & ComfortNet™

furnace operation.

provides

x Circulator blower runs continuously. No

icon illuminated.

x Integrated control module LED display

x ComfortNet thermostat “Call for Service”

x ComfortNet thermostat scrolls “Check

Furnace” message.

runs continuously. No furnace operation.

provides

icon illuminated.

x Induced draft blower and circulator blower

x Integrated control module LED display

x ComfortNet thermostat “Call for Service”

x ComfortNet thermostat scrolls “Check

Furnace” message.

x Furnace fails to operate

76

provides EC error code.

x Integrated control module LED display

x ComfortNet thermostat “Call for Service”

icon illuminated.

x ComfortNet thermostat scrolls “Check

Furnace” message.

provides

x No furnace operation.

x Integrated control module LED display

provides Ef error code.

x No furnace operation.

x Integrated control module LED display

provides

x No furnace operation.

Power”.

x Integrated control module LED display

x ComfortNet thermostat displays “Battery

provides

x Normal furnace operation.

x Integrated control module LED display

E8

E9

EA

0

Troubleshooting

Notes & Cautions

repair.

with correct replacement

x Turn power OFF prior to

part.

x Replace pressure switch

x Turn power OFF prior to

repair.

with correct replacement

part.

x Replace pressure switch

x Replace induced draft

blower with correct

replacement part.

x Turn power OFF prior to

repair.

x Turn power OFF prior to

repair

specific model.

BEFORE turning power

ON. Memory card may be

removed after data is

loaded.

removing memory card.

x Use memory card for the

x Insert memory card

x Turn power OFF before

x Error code will be cleared

once data is loaded.

Corrective Actions

Repair/replace if necessary.

piping for blockage, proper

length, elbows, and termination.

Check drain system. Correct as

necessary.

performance. Correct as

necessary.

or contact motion.

switch.

x Replace high stage pressure

x Inspect pressure switch hose.

x Repair short in wiring

x Inspect flue and/or inlet air

x Check induced draft blower

connection.

correct polarity.

x Correct pressure switch set point

x Tighten or correct wiring

necessary.

x Review wiring diagram to

x Verify proper ground. Correct if

x Check and correct wiring.

x Populate shared data set using

memory card.

Possible Causes

pinched, or connected

improperly.

blocked drain system or weak

induced draft blower.

point or malfunctioning switch

contacts.

contacts sticking.

wiring.

x High stage pressure switch

x Shorts in pressure switch circuit

E8

x Pressure switch hose blocked

x Blocked flue and/or inlet air pipe,

x Incorrect pressure switch set

wiring.

x Loose or improperly connected

x Polarity of 115 volt AC power to

EA

furnace or integrated module is

reversed.

x Reversed unit ground.

x Furnace does not contain any

d0

shared data.

ComfortNet

Thermostat Only

Fault Description

LED Codes

Diagnostic/Status

Thermostat)

Message Code

PS2

CLOSED

switch circuit is closed at

x High stage pressure

E8

PS2 OPEN E9

switch circuit is not

closed.

operating.

start of heating cycle.

operating.

low stage only

x Furnace is operating on

x High stage pressure

x Induced draft blower is

low stage only

x Induced draft blower is

x Furnace is operating on

E9

error code.

error code.

REVERSED

x Polarity of 115 volt AC

PLTY

is reversed

EA

error code.

DATA

NO NET

x Data not yet on network.

d0

error code.

Symptoms of Abnormal Operation

(Non-communicating & ComfortNet™

furnace operates normally on low stage.

x Furnace fails to operate on high stage;

x Integrated control module LED display

provides

furnace operates normally on low stage.

provides

x Furnace fails to operate on high stage;

x Integrated control module LED display

icon illuminated.

x ComfortNet thermostat “Call for Service”

x ComfortNet thermostat scrolls “Check

Furnace” message.

provides d

icon illuminated.

x ComfortNet thermostat “Call for Service”

x ComfortNet thermostat scrolls “Check

Furnace” message.

x Furnace fails to operate.

x Integrated control module LED display

provides

x Furnace fails to operate.

x Integrated control module LED display

77

Troubleshooting

4

0

1

2

3

Notes & Cautions

Corrective Actions

Possible Causes

Only

ComfortNetThermostat

repair

x Turn power OFF prior to

for the specific model. Re-

populate data using correct

x Verify shared data set is correct

has been rejected by integrated

control module

x Shared data set on memory card

d4

DATA

Message Code

INVALID MC

x Use memory card for the

specific model.

x Insert memory card

memory card if required.

BEFORE turning power

ON. Memory card may be

removed after data is

loaded.

removing memory card.

once data is loaded.

repair

correct replacement part.

with correct replacement

part.

repair

with correct replacement

part.

module with correct

replacement part.

repair

correct replacement part.

specific model

BEFORE turning power

ON. Memory card may be

removed after data is

loaded.

x Turn power OFF before

x Error code will be cleared

x Turn power OFF prior to

x Replace inductor with

connection.

through inductor. Replace if

circulator motor power leads or

RUN

open or short circuit.

x Verify continuous circuit

circulator motor power leads

disconnected.

x Open circuit in inductor or loose

x Tighten or correct wiring

x Loose wiring connection at

b0

MOTOR NOT

x Replace circulator motor

x Turn power OFF prior to

x Replace circulator motor

x Replace integrated control

x Turn power OFF prior to

x Replace motor with

x Use memory card for the

x Insert memory card

Replace if necessary.

connection.

01 Emerson tester

x Check circulator blower motor.

x Tighten or correct wiring

wiring connection at inductor

(3/4 Hp and 1 Hp models only).

circulator motor control leads.

x Failed circulator blower motor.

x Loose wiring connection at

b1

COMM

MOTOR

x Check blower motor with UTT-

x Failed circulator blower motor.

x Failed integrated control module.

module. Replace if necessary.

x Check integrated control

horse power is the same

specified for the specific furnace

x Verify circulator blower motor

in furnace.

x Incorrect circulator blower motor

b2

MOTOR

MISMATCH

model. Replace if necessary.

integrated control module.

x Incorrect shared data set in

x Verify shared data set is correct

for the specific model. Re-

populate data using correct

memory card if required.

x Turn power OFF before

removing memory card.

x Error code will be cleared

once shared data and

motor horse power match.

x Turn power OFF prior to

x Check filters for blockage.

x Blocked filters.

b3

MOTOR

repair.

Clean filters or remove

obstruction.

x Restrictive ductwork.

x Undersized ductwork.

LIMITS

Remove obstruction. Verify all

x Check ductwork for blockage.

x High ambient temperatures.

registers are fully open.

sized for system. Resize/replace

ductwork if necessary.

"Location Requirements &

Considerations" for furnace

x Verify ductwork is appropriately

installation requirements.

x See "Product Description" and

78

Fault Description

LED Codes

Diagnostic/Status

Symptoms of Abnormal Operation

(Non-communicating & ComfortNet™

Thermostat)

data.

x Invalid memory card

d4

error code.

operation.

provides d

icon illuminated.

x Operation different than expected or no

x Integrated control module LED display

x ComfortNet thermostat “Call for Service”

x ComfortNet thermostat scrolls “Check

Furnace” message.

is not running when it

should be running.

x Circulator blower motor

b0

error code.

provides b

x Furnace fails to operate.

icon illuminated.

x Integrated control module LED display

x ComfortNet thermostat “Call for Service”

x ComfortNet thermostat scrolls “Check

Furnace” message.

module has lost

communications with

circulator blower motor.

x Integrated control

b1

error code.

provides b

x Furnace fails to operate.

icon illuminated.

x Integrated control module LED display

x ComfortNet thermostat “Call for Service”

x ComfortNet thermostat scrolls “Check

Furnace” message.

horse power in shared

data set does not match

circulator blower motor

x Circulator blower motor

horse power.

b2

error code.

provides b

icon illuminated.

x ComfortNet thermostat “Call for Service”

x ComfortNet thermostat scrolls “Check

Furnace” message.

x Furnace fails to operate.

x Integrated control module LED display

x Circulator blower motor

b3

x Furnace operates at reduced performance.

is operating in a power,

temperature, or speed

limiting condition.

error code.

provides b

x Airflow delivered is less than expected.

x Integrated control module LED display

4

5

6

7

9

Troubleshooting

Notes & Cautions

repair.

x Turn power OFF prior to

Corrective Actions

grills/registers, duct system, and

furnace air inlet/outlet for

blockages.

x Check filters, filter

x Turn power OFF prior to

x Check circulator blower for

repair

obstructions. Remove and

replacement part.

x Replace motor with correct

repair/replace wheel/motor if

necessary.

x Replace wheel with correct

x Check circulator blower motor

replacement part.

shaft rotation and motor.

Replace motor if necessary.

x Turn power OFF prior to

x Check power to furnace. Verify

repair.

line voltage to furnace is within

the range specified on the

furnace rating plate.

x See "Product Description" and

"Location Requirements &

Considerations" for furnace

installation requirements.

x Turn power OFF prior to

x Check integrated control module.

repair.

Verify control is populated with

replacement part(s).

x Replace with correct

correct shared data set. See data

errors above for details.

x Use memory card for the

x Check for locked rotor condition

specific model.

(see error code above for

details).

x Turn power OFF prior to

x Check filters for blockage.

repair.

Clean filters or remove

obstruction.

Remove obstruction. Verify all

registers are fully open.

sized for system. Resize/replace

x Check ductwork for blockage.

ductwork if necessary.

x Verify ductwork is appropriately

Possible Causes

ComfortNet

Thermostat Only

Fault Description

LED Codes

Diagnostic/Status

x Abnormal motor loading, sudden

b4

MOTOR

Message Code

x Circulator blower motor

change in speed or torque, sudden

TRIPS

senses a loss of rotor

b4

blockage of furnace air inlet or

outlet.

filters, very restrictive ductwork,

blockage of furnace air inlet or

outlet.

housing.

x High loading conditions, blocked

control.

senses high current.

x Circulator blower motor

bearings.

x Obstruction in circulator blower

x Seized circulator blower motor

b5

ROTOR

MTR LCKD

fails to start 10

consecutive times.

x Circulator blower motor

b5

x High AC line voltage to furnace.

x Failed circulator blower motor.

x Low AC line voltage to furnace.

x High ambient temperatures.

b6

VOLTS

MOTOR

shuts down for over or

under voltage condition.

x Circulator blower motor

x Circulator blower motor

shuts down due to over

temperature condition on

b6

power module.

module.

x Error with integrated control

x Motor has a locked rotor

b7

MOTOR

PARAMS

does not have enough

information to operate

x Circulator blower motor

b7

condition.

properly.

x Blocked filters.

x Restrictive ductwork.

x Undersized ductwork.

b9

LOW ID

AIRFLOW

consecutive times.

x Airflow is lower than

demanded.

x Motor fails to start 40

b9

Thermostat)

error code.

Symptoms of Abnormal Operation

(Non-communicating & ComfortNet™

provides b

icon illuminated.

x ComfortNet thermostat “Call for Service”

x ComfortNet thermostat scrolls “Check

Furnace” message.

x Furnace fails to operate.

x Integrated control module LED display

error code.

provides b

x Furnace fails to operate.

icon illuminated.

x Integrated control module LED display

x ComfortNet thermostat “Call for Service”

x ComfortNet thermostat scrolls “Check

Furnace” message.

error code.

error code.

error code.

provides b

icon illuminated.

x ComfortNet thermostat “Call for Service”

x ComfortNet thermostat scrolls “Check

Furnace” message.

x Furnace fails to operate.

x Integrated control module LED display

provides b

x Furnace fails to operate.

icon illuminated.

x Integrated control module LED display

x ComfortNet thermostat “Call for Service”

x ComfortNet thermostat scrolls “Check

Furnace” message.

x Furnace operates at reduced performance.

provides b

x Integrated control module LED display

79

Status Codes

80

NO POWER
NORMAL OPERATIO N

On

INDICATES AIRFL OW, FO LL OWED BY CFM

A

BLOWER MO TO R NOT RUNNING

b0

BLOWE R CO M M UNICATION ERROR

b1

BLOWER HP MIS-MATCH

b2

BLOWER MO TO R O PERATING IN POWER, TEMPERATURE, OR SPEED LIMIT

b3

BLOWER M OTOR CURRENT TRIP O R L O ST ROTOR

b4

BLOWER MO TO R LO CKED ROTOR

b5

BLOWER OVER/ UNDER VOLTAGE TRIP OR OVER TEM PERATURE TRIP

b6

INCOMPLETE PARAMETERS SENT TO MOTOR

b7

LOW INDO OR AIRFLOW

b9

CLIMATETALK COMPRESSOR COOLING / CONVENTIO NAL COMPRESSOR COOLI NG

C

WHEN 1-STAG E CO MPRESSOR I S SE T UP
LOW STAGE CO OL

C1

HIGH STAGE COOL

C2

CLIMA TETAL K CO M PRESSOR COOLING W I TH DEHUM I FICATION / CONVENTIONAL
COMP RESSOR COOLING W ITH DEHUMIDIF I CA TION WHEN 1-STA GE

d

COMPRESSOR IS SET UP
DATA NOT YET ON NETWORK

d0

CONVENTIONAL 1-STAGE COMPRESSOR COOLING WITH DEHUM I DI FI CAT ION WHEN

d1

2-STAGE COMPRESSOR I S SET UP
CONVENTIONAL 2-STAGE COMPRESSOR COOLING WITH DEHUM I DI FI CAT ION WHEN

d2

2-STAGE COMPRESSOR I S SET UP
INVALID MEMORY CARD DATA

d4

DEFROST DEM AND

dF

LOCKO UT DUE TO EXCESSIVE RETRIES O R RECY CL ES

E0

LOW STAGE PRESSURE SWITCH STUCK CLOSED AT START OF HEATING CYCLE

E1

LOW STAGE PRESSURE SWITCH STUCK OPEN

E2

OPEN HIG H LIMI T SWI TCH

E3

FLAM E DET ECT ED W HEN NO FLAME SHOULD BE PRESE NT

E4

OPEN FUSE

E5

LOW FLAM E SIGNAL

E6

IGNITER FAULT OR IMPROPER GROUNDING

E7

HIGH STAGE PRESSURE SWITCH STUCK CLOSED AT START OF HEATING CY CLE

E8

HIGH STAGE PRESSURE SWITCH STUCK OPEN

E9

REVERSED 115 VAC POLARITY

EA

INDUCER MOTOR O VERCURRENT FAULT

EC

ROLLO UT SWI TCH OPEN

Ed

AUXILIARY INPUT OPEN

EF

CONTINUOUS F AN

F

FIELD TEST MODE

Ft

INDICATES GAS HEAT, FO L LOWED BY PERCENTAGE OF DEM AND

H

HIGH HEAT = 100%

HI

INTERNAL FAULT

IF

CLIMATETALK COMPRESSOR HEATING / CONVENTI O NAL COMPRESSOR HEATING

P

WHEN 1-STAG E CO MPRESSOR I S SE T UP
CONVENTIO NAL 1-STAGE COM PRESSOR HEATING

P1

WHEN 2-STAG E CO MPESSOR I S SE T UP
CONVENTIO NAL 2-STAGE COM PRESSOR HEATING

P2

WHEN 2-STAG E CO MPESSOR I S SE T UP
% OF HI GH HEA T

50

Wiring Diagram

T

O

H

A

F

R

U

S

E

T

I

N

G

I

1

2

RD

WH

HIGH VOLTAGE!

Disconnect ALL power before servicing or installing this unit. Multiple

power sources may be present. Failure to do so may cause property

damage, personal injury or death.

C

E

A

H

WH

WH

WH

:

S

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T

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1

A

M

.

2

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3

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.

5

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0140F00863-B

*MVM96_A*, *CVM96_A*

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(

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PRESS. SWITCH

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INT EGRATED CO NTROL MODULE

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N

O

5

4

L

O

R

T

N

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K

P

Y

R

A

M

I

L

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N

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N

T

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S

E

Y

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L

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L

B

M

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S

A

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Y

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N

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I

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)

U

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k

C

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D

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S

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R

O

R

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V

C

T

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W

R

O

BR

H

OR

OR

PU

ID BLOWER

CONNECTOR

1
2

3

BL

FLAME

SENSOR

FURNACE CONTROL MODULE

D

I

COOL TAPS

HEAT TAPS

FAN TAPS

RAMPING

ADJUST

DELAY

COOL SETUP

HEAT SETUP

PULL U P

DEHUM

BIAS

E

S

U

F

V

4

A

2

3

R

T

M

M

K

B

S

S

E

N

R

T
C

H

F
E
M

5

0
S

D

L
,

B

L

B

D

R

Y

G

4

3

2

1

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T

A

L

U

C

R

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C

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R

N

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R

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A

P

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C

I

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N

A

R

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N

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H

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.

C

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L

R

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Y

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G

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C

I

V

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R
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C

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A

N

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G

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R

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D

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C

A

L

P

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R

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B

T

T

A

G

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V

A

H

L

A

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R

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S

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A

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S

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H

T

MODULATING INTE RGRATED

G

N

A

O

S

C

I

T

L

E

D

'

S

HEAT OFF

DIP SW IT C HES

PULL DOWN

R

2Y11

T

H

4

V

2

5
4

3
2
1

R

E

W

O

L

B

R

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M

R

M

E

O

H

T

N

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M

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C

A

L

P

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R

D

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P

P

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S

A

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B

T

S

U

M

T

I

,

R

U

T

A

R

E

P

M

E

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S

R

O

T

C

U

D

N

A

D

E

D

N

U

O

R

G

C

E

R

T

S

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M

,

S

H

T

E

R

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M

R

A

)

S

T

U

P

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I

1

GY

1

2

OR

3

W1

W2

G

C

R

E

A

M

T

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S

T

N

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N

K

B

H

W

R

G

K

P

WH

A

7

.

0

T

A

T

A

T

S

S

U

M

S

T

R

A

P

T

E

H

T

H

T

I

W

I

W

D

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C

A

L

P

E

R

A

F

O

G

N

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T

A

R

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.

Y

L

N

M

R

O

F

N

O

C

D

N

S

A

E

L

O

T

T

N

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S

D

N

O

C

E

S

2

N

2

OR

45

6

OR

Y2

C

E

O

T

I

G

.

S

P

M

E

B

T

H

T
T

O

T

T

L

I

H

W

LINE

H

S

I

E

C

A

HUM

3

7

89

DEH UM

O

N

S

D

N

E

NEUTRAL

RD

BK

4

BR

BR

10

11

12

A

U

X

YL

BL

RD

BK

GY

BK

L

I

O

C

R

O

T

C

U

D

N

I
7

1

1

,

U

T

B

k

0

9

,

U

T

B

k

0

D

O

M

U

T

B

k

5

S

L

E

Y

L

N

O

D

O

C

R

O

L

O

C

K

N

I

P

K

P

W

O

R

B

R

B

I

H

W

H

W

E

U

L

B

L

B

Y

A

R

G

Y

G

D

E

R

D

R

O

L

L

E

Y

L

Y

N

A

R

O

R

O

R

U

P

U

P

P
E

E

R

G

R

G

C

A

L

B

K

B

JUNCTION BOX

K

E

R

E

R

H

F

S

B

H

W

A

E

M

A

L

R

O

S

N

E

CHASSIS

GROUND

BL

W

DISCONNECT POWER
BEFORE SERVICING
WIRING TO UNIT
MUST BE PROPERLY
POLARIZED AND

N

U

O

R

G

T

C

E

N

N

O

C

S

I

D

Ø /60 HZ PO WER SUPPLY WITHTO 11 5VAC/1

OVERCURRENT PROTECT ION DEVICE

:

G

N

I

N

R

.

D

E

D

O

O

R

D

T

H

W

C

S

I

R

I

N

C

O

C

T

I

D

O

U

L

U

T

U

0

k

7

k

B

T

9

0

,

,

B

5

1

k

1

B

T

U

M

O

D

S

L

E

Y

L

O

N

GR

E

N

L

INTEGRATED CONTROL MODULE

I

C

A

E

3

2

1

U

M

H

G

N

I

S

F

BK

I

L

N

E

40 VA

TRANSFORMER

4

2

C

A

V

GY

5

1

1

C

A

V

H

W

H

W

K

B

R

E

W

O

L

B

T

N

E

M

T

R

A

P

M

O

C

H

C

T

I

W

S

R

O

O

D

N

E

H

W

N

E

P

O

(

)

N

E

P

O

R

O

O

D

:

S

E

N

E

T

W

E

G

E

L
N

K

A

T

L

W

O

O

V

L

A

T

L

W

O

O

L

V

E

G

A

T

L

O

V

I

H

E

G

A

T

L

O

V

I

H

N

O

I

T

C

N

U

J

L

A

N

I

M

R

E

T

T

L

A

N

R

E

T

N

I
N

E

T

A

R

G

E

T

I

N

N

O

C

G

U

L

P

3

U

A

F

S

E

R

T

5

R

24V THERMOSTAT CONNECTIONS

1

Y

W

1

W

2

T
M

2

Y

G

O

DEHUM

24V HUM.

C

O

T

R

O

T

M

I

C

R

I

N

E

T

G

R

M

O

D

U

E

L

D

L

E

I

F

E

G

)

V

4

2

(

E

G

)

V

5

1

1

(

E

I

F

D

L

O

O

R

T

N

O

C

D

N

O

I

T

C

E

(

A
C

O

O

D

T

V

+

C

3

)

(

(

6

)

2

)

(

1

)

2

(

O

H

I

G

H

O

C

R

I

P

R

S

E

1

1

)

(

8

)

(

7

)

(

0

1

)

(
G

N

D

TR (9)

G

N

D

D

V

+

C

R

X

(

2

T

3

(

)

X

O

E

T

A

D

C

O

N

R

O

T

L

L

Wiring is subject to change. Always refer to the wiring diagram on the unit for the most up-to-date wiring.

81