Goodman *CSS961205DN, *CSS960402BN, *CSS960804CN, *CSS960603BN, *MSS961205DN Installation Instructions Manual

I

NSTALLATION

I

NSTRUCTIONS FOR

TABLE OF CONTENTS

*MSS9* & *CSS9*

INGLE-STAGE

S

(T ype FSP CA TEGOR Y IV Direct

or Non Direct V ent Air Furnace)

These furnaces comply with requirements embodied in the American National Standard / National Standard of Canada ANSI Z21.47·CSA-2.3 Gas Fired Central Furnaces.

As a professional installer you have an obligation to know

the product better than the customer . This includes all safety precautions and related items.

Prior to actual installation, thoroughly familiarize yourself with this Instruction Manual. Pay special attention to all safety warnings. Often during installation or repair it is possible to place yourself in a position which is more hazardous than when the unit is in operation.

Remember, it is your responsibility to install the product safely and to know it well enough to be able to instruct a customer in its safe use.

Safety is a matter of common sense...a matter of thinking before acting. Most dealers have a list of specific good safety practices...follow them.

The precautions listed in this Installation Manual are intended as supplemental to existing practices. However, if there is a direct conflict between existing practices and the content of this manual, the precautions listed here take precedence.

RECOGNIZE THIS SYMBOL

AS A SAFETY PRECAUTION.

GAS F

Affix all manuals

adjacent to the unit.

URNACE

Installer:

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

SHIPPING INSPECTION............................................ 4

ELECTROST ATIC DISCHARGE (ESD) PRECAUTIONS.................... 4

TO THE INSTALLER ............................................. 5

PRODUCT APPLICATION ............................................. 5

LOCA TION REQUIREMENTS & CONSIDERATIONS......................... 6

C

LEARANCES AND ACCESSIBILITY ................................... 7

EXISTING FURNACE REMOVAL ..................................... 8

THERMOSTAT LOCATION .......................................... 9

COMBUSTION & VENTILATION AIR REQUIREMENTS ..................... 9

INSTALLATION POSITIONS ............................................ 9

HORIZONTAL APPLICATIONS & CONSIDERATIONS .......................10

FURNACE SUSPENSION ..........................................10

FRONT COVER PRESSURE SWITCH TUBE LOCATION ................10

DRAIN TRAP AND LINES ........................................10

LEVELING .....................................................10

ALTERNATE ELECTRICAL AND GAS LINE CONNECTIONS ..............10

DRAIN PAN ...................................................10

FREEZE PROTECTION ...........................................10

PROPANE GAS/HIGH ALTITUDE INST ALLATIONS .......................10

VENT/FLUE PIPE & COMBUSTION AIR PIPE .........................11

DUAL CERTIFICATION: NON-DIRECT/DIRECT VENT .................11

MATERIALS AND JOINING METHODS ..............................11

PROPER VENT/FLUE AND COMBUSTION AIR PIPING PRACTICES ......12

TERMINATION LOCATIONS ........................................12

CANADIAN VENTING REQUIREMENTS .............................. 13

STANDARD FURNACE CONNECTIONS ..............................13

VENT/INTAKE TERMINATIONS FOR INST ALLATION

OF MULTIPLE DIRECT VENT FURNACES .........................17

CONCENTRIC VENT TERMINATION.................................18

SIDE WALL VENT KIT..........................................18

CONDENSATE DRAIN LINES & DRAIN TRAP ..........................18

GENERAL DRAIN INFORMATION...................................19

FIELD SUPPLIED DRAIN .........................................19

UPFLOW MODEL INSTALLED VERTICALLY ..........................19

DRAIN EXITING RIGHT SIDE ..................................... 20

DRAIN EXITING LEFT SIDE ......................................20

UPFLOW MODEL INSTALLED HORIZONTALLY

WITH RIGHT SIDE DOWN ....................................20

UPFLOW MODEL INSTALLED HORIZONTALLY

WITH LEFT SIDE DOWN ......................................21

COUNTERFLOW MODEL INSTALLED VERTICALLY....................21

DRAIN EXITING LEFT SIDE ......................................21

DRAIN EXITING RIGHT SIDE ..................................... 21

COUNTERFLOW MODEL INSTALLED HORIZONTALLY

WITH RIGHT SIDE DOWN .....................................22

COUNTERFLOW MODEL INSTALLED HORIZONTALLY

WITH LEFT SIDE DOWN ......................................22

IOG-2009E 10/2015

5151 San Felipe Suite 500

Houston, TX 77056

www.goodmanmfg.com • www.amana-hac.com

is a registered trademark of Maytag Corporation or its related companies

ELECTRICAL CONNECTIONS .........................................23

WIRING HARNESS ..............................................23

115 VOLT LINE CONNECTIONS ..................................23

JUNCTION BOX RELOCATION.....................................24

24 VOL T THERMOSTAT WIRING ..................................24

SINGLE-STAGE HEATING THERMOSTAT APPLICATION ................24

FOSSIL FUEL APPLICATIONS......................................24

GAS SUPPLY AND PIPING ..........................................25

H

IGH ALTITUDE DERATE ........................................25

PROPANE GAS CONVERSION .....................................25

GAS PIPING CONNECTIONS ......................................26

PROPANE GAS TANKS AND PIPING ...............................28

CIRCULA TING AIR & FIL TERS .......................................29

DUCT WORK - AIR FLOW .......................................29

CHECKING DUCT STATIC ........................................29

BOTTOM RETURN AIR OPENING [UPFLOW MODELS]...............30

FILTERS - READ THIS SECTION

BEFORE INSTALLING THE RETURN AIR DUCT WORK..............31

HORIZONTAL INSTALLATIONS .....................................33

STARTUP PROCEDURE & ADJUSTMENT ..............................33

DRAIN TRAP PRIMING ..........................................33

FURNACE OPERATION ...........................................33

GAS SUPPLY PRESSURE MEASUREMENT ...........................34

GAS MANIFOLD PRESSURE MEASUREMENT AND ADJUSTMENT ........34

GAS INPUT RATE MEASUREMENT (NATURAL GAS ONLY) ...........35

TEMPERATURE RISE ............................................36

CIRCULATOR BLOWER SPEEDS ...................................36

BLOWER HEAT OFF DELAY TIMINGS .............................37

NORMAL SEQUENCE OF OPERATION .................................37

POWER UP ...................................................37

HEA TING MODE ...............................................37

COOLING MODE ...............................................37

FAN ONLY MODE .............................................38

OPERA TIONAL CHECKS ............................................38

AFETY CIRCUIT DESCRIPTION ......................................38

S

INTEGRATED CONTROL MODULE .................................38

PRIMARY LIMIT .................................................38

AUXILIAR Y LIMIT ...............................................38

ROLLOUT LIMIT ...............................................38

PRESSURE SWITCHES ...........................................38

FLAME SENSOR ................................................38

TROUBLESHOOTING ...............................................38

E

LECTROST ATIC DISCHARGE (ESD) PRECAUTIONS...................38

DIAGNOSTIC CHART ............................................39

RESETTING FROM LOCKOUT .....................................39

MAINTENANCE ...................................................39

ANNUAL INSPECTION ...........................................39

FILTERS .......................................................40

BURNERS .....................................................40

INDUCED DRAFT AND CIRCULATOR BLOWERS ......................41

CONDENSATE TRAP AND DRAIN SYSTEM

(QUALIFIED SERVICER ONLY).................................41

FLAME SENSOR (QUALIFIED SERVICER ONLY) .....................41

FLUE PASSAGES (QUALIFIED SERVICER ONLY).....................41

BEFORE LEAVING AN INSTALLA TION .................................41

REPAIR AND REPLACEMENT PARTS ..................................41

TROUBLESHOOTING CHART ........................................42

TROUBLESHOOTING CHART ........................................43

AIRFLOW ........................................................44

*MSS92*** & *CSS92***A* .................................. 44

*MSS96*** & *CSS96***A* .................................. 45

WIRING DIAGRAM ................................................46

*MSS92*** & *CSS92***A* .................................. 46

*MSS96*** & *CSS96***A* .................................. 47

SPECIAL INSTRUCTIONS FOR PRODUCTS

INSTALLED IN THE STATE OF MASSACHUSETTS ......................48

G

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

INSTALL OR PERFORM SERVICE ON THIS UNIT, YOU ASSUME RESPONSIBILITY FOR ANY PERSONAL INJURY OR PROPERTY DAMAGE WHICH MAY RESULT

M

ANY JURISDICTIONS REQUIRE A LICENSE TO INSTALL OR SERVICE HEATING AND AIR CONDITIONING EQUIPMENT

WARNING

2

. IF

YOU

.

S

AFETY

C

ONSIDERATIONS

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

This furnace is manufactured for use with natural gas. It may be field converted to operate on L.P. gas by using the appropriate L.P. conversion kit listed in the PROPANE GAS/ HIGH ALTITUDE INST ALLATIONS section of this manual

Install this furnace only in a location and position as speci-

LOCATION REQUIREMENTS & CONSIDERA TIONS sec-

fied in tion and INSTALLATION POSITIONS section of this manual.

Provide adequate combustion and ventilation air to the furnace as specified in

COMBUSTION & VENTILATION AIR RE-

QUIREMENTS section of this manual.

Combustion products must be discharged to the outdoors. Connect this furnace to an approved vent system only, as specified in VENT/FLUE PIPE & COMBUSTION AIR PIPE section of this manual.

Never test for gas leaks with an open flame. Use a commercially available soap solution made specifically for the detection of leaks to check all connections, as specified in GAS SUPPLY AND PIPING section of this manual.

Always install a furnace to operate within the furnace’ s intended temperature-rise range with a duct system which has external static pressure within the allowable range, as specified on the furnace rating plate and OPERATIONAL CHECKS section of these instructions.

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

A gas-fired furnace for installation in a residential garage must be installed as specified in the LOCATION REQUIRE- MENTS AND CONSIDERA TIONS section of this manual.

This furnace may be used as a construction site heater only if certain conditions are met. These conditions are listed in the PRODUCT APPLICATION section of this manual.

WARNING

TO

PREVENT PERSONAL INJURY OR DEATH DUE TO IMPROPER

INSTALLATION, ADJUSTMENT, ALTERA TI ON, SERVICE OR MAINTENANCE REFER TO THIS MANUAL INFORMATIO N, CONSULT 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 RESU LT 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 GAS:

D

O NOT TRY TO LIGHT ANY APPLIANCE



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

I

F YOU CANNOT REACH YOUR GAS SUPPLIER, CALL THE FIRE



DEPARTMENT

I

NSTALLATION AND SERVICE MUST BE PERFORMED BY A QUALIFIED

INSTALLER, SERVICE AGENCY OR THE GAS SUPPLIER

.

OLLOW THE GAS SUPPLIER’S INSTRUCTIONS

.

WARNING

T

HIS PRODUCT CONTAI NS 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 REPRODUCTIVE HARM

.

WARNING

H

EATING UNIT SHOULD NOT BE UTILIZED WITHOUT REASONABLE ROUT INE, INSPECTION, MAINTENANCE AND SUPERVISION BUILDING IN WHICH ANY SUCH DEVICE IS LOCATED WILL BE VACAN T CARE SHOULD BE TAKEN THAT SUCH DEVICE IS ROUT INELY INSPECTED MAINTAINED AND MONITORED. IN THE EVENT THAT THE BUILDING MAYBE EXPOSED TO FREEZING TEMPERATURES AND WILL BE VACAN T 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 EXPOSED TO FREEZING TEMPERATURES AND WILL BE VACAN T, ANY HYDRONIC COIL UNITS SHOULD BE DRAINED AS WELL AND, IN SUCH CASE, ALTERNATIVE HEAT SOURCES SHOULD BE UTILIZED

.

. IF

THE

,

CAUTION

FROZE N AND BURST WATER PIPE HAZAR D F

AILURE TO PROTECT AGAINST THE RISK OF FREEZING MAY RESULT IN

PROPERTY DAMAGE

S

PECIAL PRECAUTIONS AREA WHICH MAY DROP BELOW FREEZING OPERATION OR DAMAGE TO EQUIPMENT ENVIRONMENT HAS THE POTENTIAL OF FREEZING, THE DRAIN TRAP AND DRAIN LINE MUST BE PROTECTED HEATERS, ELECTRIC HEAT TAPE AND/OR RECOMMENDED FOR THESE INSTALLATIONS

.

MUST BE

MADE IF INSTALLING FURNACE IN AN

. T

HIS CAN CAUSE IMPROPER

. IF

THE FURNACE

. THE

USE OF ACCESSORY DRAIN TRAP

RV

ANTIFREEZE IS

.

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

.

Drain trap must be primed at time of installation. Trap is internally partitioned; add water to both inlet ports until water appears at both sides of the outlet opening. Failure to prime trap at time of installation may have a negative effect on combustion quality and pressure switch action.

3

Advertencia especial para la instalación de calentadores ó manejadoras de aire en áreas cerradas como e stacionamientos ó cuartos de servicio.

RISQUE D'E MP OI SONNEMENT AU

MONOXYDE DE CARBONE

Cett e v entilation es t nécessaire pour éviter le danger d'intox ication au CO pouvant surv en ir si un ap pareil produisant du mon ox yde de carb one continue de fonctionner au sein de la zon e confinée.

Le monoxy de de des

dommag es per man ents au cerve au et me m e la mor t.

carbone peut causer des maladies graves telles que

CO can cause serious illness inc l uding permanent brain damag e or death.

B10259-216

Las emisiones de monóxido de carbono pue den circular a través del aparato cuando se opera en cu alq uier modo.

El monóxido de ca rbono puede ca usa r enfe rm e dades severas como daño cerebra l permanente ó mu ert e.

B10259-216

SHIPPING INSPECTION

All units are securely packed in shipping containers tested according to International Safe Transit Association specifications. The carton must be checked upon arrival for external damage. If damage is found, a request for inspection by carrier’s agent must be

S

HOULD OVERHEAT ING 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

made in writing immediately . The furnace must be carefully inspected on arrival for damage and

bolts or screws which may have come loose in transit. In the event of damage the consignee should:

1. Make a notation on delivery receipt of any visible damage to shipment or container .

2. Notify carrier promptly and request an inspection.

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

3. With concealed damage, carrier must be notified as soon as possible - preferably within five days.

4. File the claim with the following support documents within a nine month statute of limitations.

• Original or certified copy of the Bill of Lading, or indemnity bond.

• Original paid freight bill or indemnity in lieu thereof.

• Original or certified copy of the invoice, showing trade and other discounts or reductions.

• Copy of the inspection report issued by carrier’ s representative at the time damage is reported to carrier.

WARNING

B10259-216

,

.

,

.

The carrier is responsible for making prompt inspection of damage and for a thorough investigation of each claim. The distributor or manufacturer will not accept claims from dealers for transportation damage.

ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS

NOTE: Discharge your 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.

4

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.

TO THE INSTALLER

Before installing this unit, please read this manual thoroughly to familiarize yourself with specific items which must be adhered to, including but not limited to: unit maximum external static pressure, gas pressures, BTU input rating, proper electrical connections, circulating air temperature rise, minimum or maximum CFM,

TO

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

WARNING

.

and motor speed connections.

P

RODUCT APPLICA TION

This furnace is primarily designed for residential home-heating 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 as a two-pipe systems for combustion air .

• 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. Bi-metal thermostats, or any thermostat affected by vibration, must not be used

during construction.

• 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 replaced daily during construction and upon completion of construction.

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

• The furnace must be installed as a two pipe system, using 100% outside air for combustion during construction.

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

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

• Furnace doors must be in place on the furnace while the furnace is operating in any mode.

• Damage or repairs due to failure to comply with these requirements are not covered under the warranty.

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.

5

• 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 (NFP A 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 National Fire Protection Association CSA International

25 West 43rd Street, 4th Floor 1 Batterymarch Park 8501 East Pleasant V alley

New Y ork, NY 10036 Quincy , MA 02169-7471 Independence, 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

L

OCA TION REQUIREMENTS

& C

ONSIDERA TIONS

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

WARNING

WARN ING

TO

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

.

,

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 V ent/Flue Pipe and Combustion Air Pipe -T ermination 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 Condensate Drain Lines and T rap 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 Ventilation 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 .

• 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 carbon tetrachloride water softening chemicals swimming pool chemicals deicing salts or chemicals halogen type refrigerants printing inks cleaning solutions (such as perchloroethylene)

6

paint removers varnishes hydrochloric acid

b

ible fl

cements and glues antistatic fabric softeners for clothes dryers masonry acid washing materials

• Seal off a non-direct vent furnace if it is installed near an area frequently contaminated by any of the above substances. This protects the non-direct vent furnace from airborne contaminants. T o ensure that the enclosed non-direct vent furnace has an adequate supply of combustion air , vent from a nearby uncontaminated room or from outdoors. R efer to the Combustion and Ventilation Air Requirements for details.

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

NOTES:

• For servicing or cleaning, a 24” front clearance is required.

• Unit connections (electrical, flue and drain) may necessitate greater clearances than the minimum clearances listed above.

• In all cases, accessibility clearance must take precedence over clearances from the enclosure where accessibility clearances are greater .

NOTES:

• For servicing or cleaning, a 24” front clearance is required.

• Unit connections (electrical, flue and drain) may necessitate greater clearances than the minimum clearances listed above.

• In all cases, accessibility clearance must take precedence over clearances from the enclosure where accessibility clearances are greater .

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 alternat e combustion air intake or vent/flue connections are used additional clearance must be provided to accommodate these connections. Refer to V ent/Flue Pipe and Combustion Air Pipe for details.

*M SS[92 & 96]* MINIM UM CLEA RA NCES TO COMBUSTIBLE M A TERIAL S

(INCHES)

POSITION* SIDES REAR FRONT BOTTOM FLUE TOP

Upflow 0" 0" 3" C 0" 1"

Horizontal 6" 0" 3" C 0" 6"

C = If placed on combustibl e floor, floo r MUST be wood on ly.

*CSS[92 & 96]* MINIMUM CLEARANCES TO COMBUSTIBLE MATERIALS

(INCHES)

POSITION* SIDES REAR FRONT BOTTOM FLUE TOP

Counterflow0"0"3"NC0"1"

Horizontal 6" 0" 3" C 0" 6"

C = If placed on combustibl e f loor, floor MUST be wood only. NC = For i nstallation on non -combustible floors only. A combustible su bba se

m ust

e used for installations on combust

ooring.

7

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.

TOP

SIDE SIDE SIDE

BOTTOM

Upflow Counterflow Horizontal

Figure 1

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. In a typical construction, the clearance between the door and door frame is usually adequate to satisfy this ventilation requirement.

EXISTING FURNACE REMOVAL

NOTE: When an existing furnace is removed from a venting system 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 American National Standard/National Standard of Canada for Gas-

Fired Central Furnaces ANSI Z21.47, 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. T urn on clothes dryers and any appliance not connected to the venting system. T urn 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. T est 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 P ropane 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.

8

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.

C

OMBUSTION

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.

& V

ENTILA TION 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

.

,

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.

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 B1491-05 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.

I

NST ALLATION POSITIONS

Figure 2A Figure 2B Figure 2C

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 horizontal 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

Recommended Installation Positions

9

be attached to the back of the furnace. Contact your distributor for proper airflow requirements and number of required ductwork connections. Refer to “R ecommended Installation Positions” figure for appropriate installation positions, ductwork connections, and resulting airflow arrangements.

H

ORIZONT AL APPLICATIONS

& C

ONSIDERA TIONS

When installing a furnace horizontally, additional consideration must be given to the following:

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"

XX

(3

ANGLE IRON

PLACES

)

FRONT COVER PRESSURE SWITCH TUBE LOCATION

When an upflow model is installed horizontally with left side down or a counterflow model is installed horizontally with right side down, the front cover pressure switch tube must be re-located to the lower port of the collector box cover .

1. R emove tube from front cover pressure switch and collector box cover .

2. R emove rubber plug from bottom collector box port and install on top collector box port.

3. Locate 24” x 1/4” tube in parts bag.

4. Install one end on front cover pressure switch.

5. R oute tube to lower port on collector box cover and cut off excess tubing.

Figure 3

DRAIN T RAP 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 5.5” 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 T rap 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. For proper flue pipe drainage, the furnace must be level lengthwise from end to end. The furnace should have a slight tilt from back to front with the access doors downhill from the back panel approximately 1/2 to 3/4 inches. The slight tilt allows the heat exchanger condensate, generated in the recuperator coil, to flow forward to the recuperator coil front cover .

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 T rap and Lines.

P

ROP ANE GAS/HIGH ALTITUDE INST ALLATIONS

This furnace is shipped from the factory configured for natural gas at standard altitude. Propane gas installations require an orifice and spring change to compensate for the energy content difference between natural and propane gas.

10

High altitude installations may require both a pressure switch and an orifice/spring change. These changes are necessary to compensate for the natural reduction in the density of both the gas fuel and the combustion air at higher altitude.

For installations above 7000 feet, please refer to the furnace Specification Sheets for required kit(s).

Contact the distributor for a tabular listing of appropriate manufacturer’ s kits for propane gas and/or high altitude installations. 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 .

V

ENT/FLUE PIPE

& C

OMBUSTION AIR PIPE

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.

In addition to PVC and ABS pipe and fittings, Innoflue® by Centrotherm Eco Systems and PolyP ro® by M&G Duravent are also approved vent and combustion air materials for installations in the U.S.A. and Canada. Manufacturers Installation instructions for these products must be followed. These products have specific instructions for installing, joining and terminating. Do not mix materials or components of one manufacturer with materials or components of another manufacturer.

All furnaces are built with 2" vent / intake pipe and connectors. For furnaces requiring installation of 3" pipe, the transition from 2" to 3" should be done as close to the furnace as practically possible.

WARN ING

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

Gas Altitude Ki t Orifice

Natural None #45 3.5" w. c. 1.9" w.c. None

0-7000

Propane LPM-07*

1

LPM-07* supports both Honeywell and White-Rodgers 1 -stage valves

In Canada, gas furnaces are only certified to 4500 feet.

NOTE:

. ALL

CONVERSIONS MUST BE PERFORMED BY A

.

Ma n i f ol d Pr essure

High

Stage

1

1.25mm 1 0.0" w.c. 6.0" w.c. None

Low

Stage

. THE

Pressure

Switch

Change

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

.

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.

MATERIALS AND JOINING METHODS

T wo-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 used. Fittings must be DWV type fittings meeting ASTM D2665 and ASTM D3311. Carefully follow the manufacturer ’s instructions for cutting, cleaning, and solvent cementing of PVC.

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

.

11

WARNING

.,

SPARKS, OPEN

.

The use of Schedule 40 PVC cellular core DWV meeting ASTM F891-1 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.

For Canadian installations; all PVC pipe, fittings and joining materials must be UL S636 listed. 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 center line 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.

Some models require the use of 3” pipe. Do not transition from a 2” to 3” pipe in a horizontal section of pipe as this may create a water trap.

PREFERRED

ACCEPTABLE

NO TRANSITION ON HORIZONTAL PLANE, THIS CREATES A WA TER TRAP AND

TRANSITION NO LESS THAN 45 DEGREES TO HORIZONTAL PLANE TO AVOID CREATING A WATER TRAP IN VENT PIPING.

Figure 4 Figure 5 Figure 6

RESTRICTS FLUE GASES

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. Allowances should be made for minor expansion and contraction due to temperature variations. For this reason, particular care must be taken to secure piping when a long run is followed by a short offset of less than 40 inches.

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 freezing temperatures below 35°F 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 concerning the appropriate location of vent/flue pipe and combustion air intake pipe (when applicable) terminations. Refer to Non-Direct V ent (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.

• V ent 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.

12

• 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

Non-Direct Vent

&

Direct Vent

Vent/Flue Terminations

Non-Direct Vent

Vent/Flue Termination

No Terminations Above Walkway

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.

Grade or Highest

Anticipated

Snow Level

3' min.

Forced Air

Inlet

<10'

Vent/Flue Termination

12"

12" min.

Direct Vent

12" min.

4' min.

4'

min.

12"

min.

Non-Direct Vent

Vent/Flue Termin atio n

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

Vent Termination Clearances

Figure 7

NOTE: In Canada, the Canadian Fuel Gas Code takes precedence over the preceding termination restrictions.

CANADIAN VENTING REQUIREMENTS

In Canada, venting must conform to the requirements of the current CAN/CSA-B149.1-05 Installation Code. Use only CSA-listed, ULCS636 compliant two- or three-inch diameter PVC or ABS pipe, solvent cement, and fittings throughout. The certified piping should be clearly marked with the ULC Std “S636” on the pipe and fittings. Carefully follow the pipe manufacturers’ instructions for cutting, cleaning, and solvent cementing PVC and/or ABS.

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-tight, 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.

V ent/Flue Pipe The vent pipe outlet is sized to accept 2” pipe. Secure vent/flue pipe directly into the

furnace fitting with the appropriate glue. Alternately, a small section of 2" pipe may be glued in the furnace socket and a rubber coupling installed to allow removal for future service. Combustion Air and V ent piping should be routed in a manner to avoid contact with refrigerant lines, metering devices, condensate drain lines, etc. If necessary, clearances may be increased by creating an offset using two 45 degree elbows (Figure 8A). This joint can be rotated on the fitting to establish maximum clearance between refrigerant lines, metering devices, and condensate drain lines, etc. This joint is the equivalent of one 90 deg. elbow when considering elbow count.

NOTE: For non-direct vent installations, a minimum of one 90° elbow should be in- stalled on the combustion air intake coupling to guard against inadvertent blockage.

DIRECT VENT INSTALLATIONS

On upflow units secure the combustion air intake pipe to the air intake coupling by using a take apart rubber coupling supplied with the furnace or a plastic coupling. Also, the intake coupling may be inverted to allow the intake pipe to be glued directly to it. After inverting the coupling, secure it to the furnace top with screws. O n 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. The combustion air intake pipe can also be secured directly to the counterflow unit air intake pipe coupling.

45 DEGREE

ELBOWS

Increased Clearance Configuration

Figure 8A

13

COMBUSTION AIR INT AKE OPTION: The RF000142 coupling (Figure 8B) can be secured directly to the furnace intake coupling if condensation is a concern. If the RF000142 is used on the combustion air inlet, it must be installed with the arrow pointing up. It should be noted, the combustion air will actually be moving in a direction opposite of the arrow on the RF000142 coupling. It must have a field supplied, trapped drain tube free-draining to proper condensate disposal location. A loop in the drain tube can serve as a trap. The unused RF000142 drain fitting should be capped.

NON-DIRECT VENT INSTALLATIONS

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

ALTERNATE VENT/FLUE LOCATION

E

DGES OF SHEET METAL HOLES MAY BE SHARP

The alternate vent/flue location is the large hole directly in line with the induced draft blower outlet. T o use the alternate vent/flue location refer to the following steps and the “Alternate Vent/Flue Location” figure. To use an alternate vent location on a counterflow / horizontal model, a special kit is required.

NOTE: In the horizontal left installation position, a means of condensate collection must be provided to keep vent pipe condensate from entering the draft inducer housing. If the vent drain elbow is eliminated from the installation, an RF000142 kit must be used.

PRECAUTION WHEN REMOVING HOLE PLUGS

Insert flange. Cut 2 ½” long.

R 000142F

WARNING

Figure 8B

. USE

.

VENT-DRAIN

GLOVES AS A

1. R emove the four screws from the vent pipe flange on top the furnace.

2. R emove the internal elbow and vent pipe

3. Cut 2 1/2" from the flange .

4. R emove plastic plug in line with the inducer outlet

5. Install cut end of the flanged section and connect to inducer with rubber coupling supplied with furnace.

6. Install screws removed in step 1 securing flange to cabinet.

WARN ING

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

,

-

,

ALTERNATE COMBUSTION AIR PROVISION

(Upflow / Horizontal models only)

When using the alternate venting location, either in a horizontal left side down installation or a vertical installation using down – venting, an alternate combustion air opening can be used. A locating dimple is located on the right side of the furnace cabinet. The locating dimple is 1 7/8" measured from the front edge of the cabinet in line with the knock out. To use the alternate combustion air location:

1. R emove screws and combustion air flange from cabinet.

2. Insert cabinet plug in unused combustion air hole.

3. Drill a pilot hole at the cabinet dimple (size dictated by knockout tool used).

THE

RUBBER ELBOW IS MOUNTED EXTERNALLY TO THE FURNACE CABINET EXTREME CARE MUST BE TAKEN TO ADEQUATELY SUPPORT FIELD SUPPLIED VENT/FLUE PIPING, AS DAMAGE CAN RESULT IN LEAKS CAUSING BODILY INJURY OR DEATH DUE TO EXPOSURE TO FLUE GASES INCLUDING CARBON MONOXIDE

14

Figure 9

E R E H

T U

C

Figure 10

Vent/Flue Pipe Cuts

WARNING

RUBBER ELBOW IS NOT DESIGNED TO SUPPORT A LOAD

. W

HEN THE

,

-

,

4. Use a knockout tool to create a 3" diameter hole

5. Install combustion air flange and secure with screws

BE

removed in step one.

SURE NOT TO DAMAGE INTERNAL WIRING OR OTHER COMPONENTS

WHEN REIN STALLING COUPLING AND SCREWS

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.

Although non-direct vent installations do not require a combustion 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

(For Installations At or Above 7,000 Feet using 3” Venting)

NOTE: If either a 90 degree or 45 degree elbow is used for termination, it must be pointed downward.

Refer to the Direct and Non-Direct V ent T able for applicable length, elbows, and pipe diameter for construction of the vent/flue pipe system of a non-direct 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.

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 fol-

lowing figure. Refer to V ent/Flue Pipe and Combustion Air Pipe - T ermination 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 V ent/Flue Pipe and Combustion Air Pipe. T o secure the pipe passing through the wall and prohibit damage to piping connections, a coupling should be installed on either side of the wall and solvent cemented to a length of pipe connecting the two couplings. The length of pipe should be the wall thickness plus the depth of the socket fittings to be installed on the inside and ou tside of the wall. The wall penetration should be sealed with silicone caulking material.

*MSS9* / *CSS9 Direct Vent (2-Pipe) & Non-Direct Vent (1-Pipe)

Maximum Allowable Length of Vent/FLue Pipe

MODEL

*MSS920402BN

*MSS920603BN

*MSS920803BN

*MSS920804CN

*MSS920805CN

*MSS921004CN

*MSS921005CN

*MSS921205DN

*CSS920402BN

*CSS920603BN

*CSS920804CN

*CSS921005CN

7,000 ft altitude or above use 3" pipe

*MSS920402BN - add 20' of 2" pipe for upfl ow p osition

^

*M SS920803BN - add 10' o f 2" pipe for upflow position, add 66' of 3" pipe for upflow position

^

*M SS920804CN - add 25' of 2" pipe for upflow position, add 58' of 3" pipe for upflow position

^

^ *M SS920805CN - add 15' of 2" pipe for upflow position, add 58' of 3" pipe for upflow position

MODEL

*MSS960402BN

*MSS960603BN

*MSS960803BN

*MSS960804CN

*MSS960805CN

*MSS961005CN

*MSS961205DN

*CSS960402BN

*CSS960603BN

*CSS960804CN

*CSS961005CN

*CSS961205DN

7,000 ft altitude or above use 3" pipe ^ *M SS960402BN - add 25' of 2" pipe for upflow position

*M SS960803BN - add 20' of 2" pipe for upflow position

^

PIPE

12345678

SIZE

145 140 135 130 125 120 115 110

2

^

3 168 161 154 147 140 133 126 119 25550454035302520 3 127 120 113 106 99 92 85 78

30 25 20 15 10 5 N/A N/A

2

^

72 65 58 51 44 37 30 23

3

^

30 25 20 15 10 5 N/A N/A

2

^

72 65 58 51 44 37 30 23

3

^

40 35 30 25 20 15 10 5

2

^

37265585144373023 26055504540353025 3 168 161 154 147 140 133 126 119 23025201510 5N/AN/A 3 113 106 99 92 85 78 71 64 2 N/A N/A N/A N/A N/A N/A N/A N/A 36558514437302316 2 100 95 90 85 80 75 70 65 3 137 130 123 116 109 102 95 88 26055504540353025 3 127 120 113 106 99 92 85 78 2353025201510 5N/A 3 160 153 146 139 132 125 118 111 2 N/A N/A N/A N/A N/A N/A N/A N/A 3 127 120 113 106 99 92 85 78

PIPE

12345678

SIZE

100 95 90 85 80 75 70 65

2

^

3 168 161 154 147 140 133 126 119 24540353025201510 3 168 161 154 147 140 133 126 119

35 30 25 20 15 10 5 N/A

2

^

3 168 161 154 147 140 133 126 119 26055504540353025 3 113 106 99 92 85 78 71 64 24540353025201510 3 120 113 106 99 92 85 78 71 240353025201510 5 3 151 144 137 130 123 116 109 102 2 N/A N/A N/A N/A N/A N/A N/A N/A 3 158 151 144 137 130 123 116 109 2 100 95 90 85 80 75 70 65 3 137 130 123 116 109 102 95 88 24540353025201510 3 168 161 154 147 140 133 126 119 240353025201510 5 3 120 113 106 99 92 85 78 71 2 N/A N/A N/A N/A N/A N/A N/A N/A 3 113 106 99 92 85 78 71 64 2 N/A N/A N/A N/A N/A N/A N/A N/A 3 110 103 96 89 82 75 68 61

CAUTION

.

Number of Elbows

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

15

DOWN VENTING UPFLOW MODEL FURNACES ONL Y

Use alternate vent & combina tion a ir locations

Vent Pipe

r

o

l

F

Combustion Air Pipe

Field Supplied Drain Tee on Vent Pipe

e

c

a

p

s

l

w

a

r

C

/

t

n

e

m

e

s

a

B

All piping and fittings must be joined per material manufacturer’s specifications

to prevent separation and flue gas leaks.

Condensate trapped to prevent flue g as from escaping and routed to field supplied condensate disposa l

Both Pipes Terminated Outside Structure

1/4” per foot min. slope

6’ MAX.

Figure 11

TEE (OPTIONAL)

12" MIN.

COMBUSTION AIR INTAKE

(OPTIONAL)

*Not requ ire d for

single pipe installation

E

N

I

L

F

O

R

A

M

”

6

9

12” MIN TO ROOF OR HIGHEST ANTICIPA TED SNOW LEVEL

ELBOWS

Figure 12

STRAIGHT

Figure 13

12” MIN HEIGHT DIFFERENCE

.

N

I

M

”

3

-

.

X

16

VENT/FLUE TEE (

TURNED DO WN or

90° ELBOW TURNED

12" MIN. ABOVE

HIGHEST ANTI CIP A TED

SNOW LEVEL

or

45° EL B OW

DOWN

OPTIONAL)

Horizontal Termination (Single Pipe)

Above Highest Anticipated Snow Level

Figure 14

DIRECT VENT (DUAL PIPE) PIPING

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 Locations or Concentric Vent Termination for specific details on termination 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.

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 (V ent/Flue & Combustion Air Intake) pipe. Elbows and/or tees used in the terminations must be included when determining the number of elbows in the piping systems.

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.

90º OR 45°

ELBOW

10”- 24”

6” MAX

4” MIN

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 V ent/Flue Pipe and Combustion Pipe - T er - mination 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.

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

Center to center = 10” min / 24” max. V ertical separation: 0” - 24” V ent termination from wall = 8” min / 12” max. Combustion air intake from wall = 6” max.

V ent and intake clearance to ground or anticipated snow level = 12” min.

VENT/INTAKE TERMINATIONS FOR INSTALLATION OF MULTIPLE DIRECT VENT FURNACES

If more than one direct vent furnace is to be installed vertically through a common roof top, maintain the same

12" MIN. TO GRADE OR HIGHEST ANTICIPATED

SNOW LEVE L

Standard Horizontal Terminations (Dual Pipe)

Figure 15

90° ELBOWS

3” - 24”

12" MIN. ABOVE

HIGHEST ANTICIPATED

SNOW LEVEL

Alternate Horizontal Vent Termination (Dual Pipe)

Figure 16

17

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.

90° ELBOWS

3”MIN 24”MAX

3”-24” BETWEEN PIPES

12" MIN. ABOVE

HIGHEST ANTICIPATED

SNOW LEVEL

Combustion Air Intake may also be snorkeled

to obtain 12” min ground clearance.

Alternate Vent Termination Above Anticipated Snow Level

(Dual Pipe)

Figure 17

3” MIN

12” MIN TO GRADE OR HIGHEST ANT ICIPATED SNOW LEVEL

Termination of Multiple Direct Vent Furnaces

Figure 18

12” MIN SEPARATION

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.

Horizontal Installation

CONCENTRIC VENT TERMINATION

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

SIDE WALL VENT KIT

This kit is to be used with 2” or 3” direct vent systems. The vent kit must terminate outside the structure and may be installed with the intake and exhaust pipes located side-by-side or with one pipe above the other . These kits are NOT intended for use with single pipe (non-direct vent) installations.

Refer to the directions furnished with the Side Wall V ent Kit (p/n 0170K00000S or 0170K00001S) for installation specifications.

C

ONDENSA TE DRAIN LINES

A condensing gas furnace achieves its high level of efficiency by extracting heat from the products of combustion to the point where condensation takes place. The condensate must be collected in the furnace drain trap and routed to an appropriate drain location in compliance with local and national codes.

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.

& D

RAIN TRAP

18

Vertical Installation

Side Wall Vent Kit

Figure 19

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

• The drain trap must be primed at time of installation.

• The drain line between furnace and drain location must meet local and nation codes.

• 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.

• 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.

GENERAL DRAIN INFORMATION

All furnace models come with a factory installed drain trap. For vertical installations, the trap will remain in the factory position except for a counterflow when the installer desires the drain to exit the right side. All furnace models installed horizontally require the trap to be relocated. Many drain hoses have a built–in grommet which will provide a cabinet seal when installed. See instructions below for your model and installation position. NOTE: Both sides of the drain trap must be

primed prior to initial furnace start up

FIELD SUPPLIED DRAIN

Drain the furnace and air conditioning coil if applicable, in compliance with code requirements. In horizontal or counterflow installations, a field installed rubber coupling will allow the drain trap to be removed for cleaning. The drain trap must be primed before initial furnace start up. When an air conditioning coil drain is connected to the field supplied furnace drain, it must be vented. An open tee must be installed at a height no higher than the bottom of the furnace collector box to prevent air conditioning condensate from backing up into the furnace, if the common drain was blocked.

UPFLOW MODEL INSTALLED VERTICALLY

The trap and factory installed hoses remain as shipped. The furnace drain may exit either the right or left side of the furnace cabinet. Both sides of the cabinet have two .875” diameter holes which can be used interchangeably for drain and low voltage wiring purposes. If a higher drain exit is needed, a .875” diameter hole may be added in the area shown in Figure

21. Any unused cabinet opening must be sealed. Do not allow drain hose to sag or trap water.

#1

#4

#2

#5

3

#

Acceptable

areafor

drain hole.

Side Cut-Out

12”

3”

Righ t side shown.

Figure 21

19

#11

Figure 20

#8

#10

100 Degree Elbow

Coupling

#7

#9

6

#

NOTE: Hoses are model specific

and not all hoses will be shipped with all models.

DRAIN EXITING RIGHT SIDE

1. Locate and Install the 45º pipe / hose drain coupling from the outside of the cabinet (barbed end goes in the cabinet) through hole in the right side of the cabinet and secure with two field supplied #8 selftapping screws (see Figure 22).

2. Locate the long drain hose #3 and cut at line “A” .

3. Install large end of hose #3 to trap outlet and secure with 1.25" clamp.

4. Install smaller end of hose #3 on 45º elbow and secure with 1" clamp.

5. Refer to Field Supplied Drain section for instructions on field supplied / installed drain on outlet of furnace trap.

Hose #1

Hose #2

DRAIN EXITING LEFT SIDE

1. Install the 45 degree pipe / hose drain coupling from the outside of the cabinet (barbed end goes in the

45 degree barb-pipe

adapter

45 degree barb-pipe adapter

cabinet) through the hole in the left side of the cabinet and secure with two field supplied #8 selftapping screws (see Figure 22).

2. Locate the long drain hose #3 and cut at “B” line for a 17.5" cabinet; cut at line “C” for a 21" cabinet; do not cut for a “D” width cabinet.

Installer selects right or left side drain

and installs this hose accordingly.

Figure 22

3. Install large end of hose #3 to trap outlet and secure with 1.25" clamp.

4. Install smaller end of hose #3 on 45º elbow and secure with 1" clamp.

5. Refer to Field Supplied Drain section for instructions on field supplied / installed drain on outlet of furnace trap.

UPFLOW MODEL INSTALLED HORIZONTALLY WITH RIGHT SIDE DOWN

Minimum 5 1/2" clearance is required for the drain trap beneath the furnace.

1. Remove the clamps from both ends of the drain hoses.

2. Remove the two screws holding the drain trap to the blower deck.

3. Remove the trap and two hoses from the blower deck

4. Remove the two plugs from the right side of the cabinet and install them in the blower deck.

5a.(Draining the Vent Elbow ) Locate hose #2 (factory installed)

and cut 1” away from the 45 degree bend, discard the 45 degree section. Insert hose #2 from outside the cabinet through the cabinet drain hole nearest the top, secure it to the barbed fitting in the elbow with a red clamp.

5b. (Option for draining the vent elbow) The RF000142 drain

coupling may be used in conjunction with the steps in 5a if water is not draining effectively from the internal vent pipe.

Hose #11

The RF000142 may be installed externally to the furnace cabinet on a short PVC stub in the vent outlet fitting. The unused drain port on the RF000142 must be capped. A field

Figure 23

installed drain tube attached to the RF000142 must be trapped to prevent flue gas from escaping.

6. (Draining the Collector Box) Install the non-grommet end of hose #11 from outside the cabinet in the bottom drain hole. Install on collector box and secure with a silver clamp.

7. Use two silver clamps and secure the hoses to drain trap. The trap outlet faces the front of the furnace. Secure the trap to the cabinet using two screws removed in step 2 by inserting the two screws through the large set of holes in the top mounting tabs of the trap into the two predrilled holes in the side of the cabinet.

8. Refer to Field Supplied Drain section for instructions on field supplied / installed drain on outlet of furnace trap.

Hose #2

20

UPFLOW MODEL INSTALLED HORIZONTALLY WITH LEFT SIDE DOWN

Minimum 5 1/2" clearance is required for the drain trap beneath the furnace. *Also see Front Cover Pressure Switch Tube Location on page 10.

1. Remove the clamps from the two drain tubes on the trap.

2. Remove the two screws holding the drain trap to the blower deck.

3. Remove the trap and hoses from the blower deck .

4. Remove the two plugs from the left side of the cabinet and install them in the blower deck.

5. (Draining the Vent Elbow) Locate hose #6. Measuring from the non-grommet end; cut off and discard 1 ½” for a “D” width cabinet, 5” for a “C” width cabinet, 8 ½” for a “B” width cabinet.

6. Remove the rubber plug from vent – drain elbow side port. Place hose #6 on the vent – drain elbow side port and secure with a silver clamp .

7. Place cap on vent – drain elbow barb fitting and secure

with red clamp

8. Locate hose #5 and cut 3” from the non-grommet end. Discard the section without the grommet.

9. Insert the cut end of tube #5 through the lower cabinet drain hole.

10.Connect hose #6 & hose #5 using 100º elbow and secure with two red clamps

11.(Draining the Collector Box) Install the non-grommet end of hose #11 from outside the cabinet in the bottom drain hole. Install on collector box and secure with a silver clamp.

12.Use two silver clamps and secure the hoses to drain trap. The trap outlet faces the front of the furnace. Secure the trap to the cabinet using two screws removed in step 2 by inserting the two screws through the large set of holes in the top mounting tabs of the trap into the two predrilled holes in the side of the cabinet.

13.Place cap on vent – drain elbow barb fitting and secure with red clamp.

14.Refer to Field Supplied Drain section for instructions on field supplied / installed drain on outlet of furnace trap.

Hose #6

Hose #5

Hose #11

Figure 24

COUNTERFLOW MODEL INSTALLED VERTICALLY

The furnace drain may exit the right or left side of the furnace cabinet (left side preferred) T rap and factory installed hoses remain as shipped if the drain will exit the left side of the cabinet. Draining from the right side requires relocation of the trap to outside the cabinet.

DRAIN EXITING LEFT SIDE

1. Install a field supplied rubber coupling secured with a 1 1/4” clamp to enable removing the trap for future cleaning. Alternately, a PVC fitting may be glued on the trap outlet.

2. Install drain per local and National codes.

DRAIN EXITING RIGHT SIDE

1. Remove hose clamps and hoses from trap.

2. Remove trap.

3. (Draining the Vent Elbow) Insert the non-grommet end hose #10 into the cabinet back drain hole. Secure on vent – drain elbow barb

fitting with a red clamp.

4. Insert 100º elbow into the cut end and secure with red clamp.

5. (Draining the Collector Box) Insert non-grommet end of hose #9 into the cabinet front drain hole and secure on collector box drain port with a silver clamp.

6. Mate the drain trap inlets to the hoses and secure with silver clamps.

21

Hose #5 x 2

Hose #4 x 2

Figure 25

7. Line up the trap mounting holes with the pre-drilled holes in the furnace and secure with 2 screws removed in step

2.

8. Refer to Field Supplied Drain section for instructions on field supplied / installed drain on outlet of furnace trap.

COUNTERFLOW MODEL INSTALLED HORIZONTALLY WITH RIGHT SIDE DOWN

Minimum 5 1/2" clearance is required for the drain trap beneath the furnace.

*Also see Front Cover Pressure Switch T ube Location on page

10.

1. Remove hose clamps and hoses from trap.

2. Remove trap.

3. (Draining the Collector Box) From outside the cabinet, insert the non-grommet end hose #8 into the back drain hole.

4. Secure to collector box drain port using a silver clamp.

5. (Draining the Vent Elbow) From outside the cabinet, insert the non-grommet end of hose #7 into the front cabinet drain hole and secure on the vent – drain elbow barb fitting using a red clamp

6. Mate the trap inlets to the hoses, the outlet of the trap must face the original bottom of the furnace. Secure with silver clamps.

7. Fasten the drain trap to the cabinet with two screws removed in step 2

8. Refer to Field Supplied Drain section for instructions on field supplied / installed drain on outlet of furnace trap.

Figure 26

COUNTERFLOW MODEL INSTALLED HORIZONTALLY WITH LEFT SIDE DOWN

Minimum 5 1/2" clearance is required for the drain trap beneath the furnace.

1. Remove hose clamps and hoses from trap.

2. Remove trap.

3. Remove plugs from left side of cabinet and install in blower deck.

4. (Draining the Collector Box) Locate hose #4 and place the radius end on the collector box drain port, secure with a silver clamp.

5. Locate hose #2, insert from outside the cabinet in the drain hole closest to the front of the cabinet, insert a coupling and secure with a red clamp.

6. Mate coupling to hose #4 and secure with a red clamp.

7. (Draining the Vent Elbow) Remove plug from vent – drain elbow side port.

8. Locate hose #4 and place radius end on the side port of vent – drain elbow and secure with a red clamp.

9. Install cap on vent drain elbow barb fitting and secure

with red clamp.

10.Insert PVC pipe into hose #4 and secure with a red clamp.

11.Locate hose #5, insert it from outside the cabinet in the drain hole farthest from the front of the cabinet.

12.Insert 100º elbow in hose #5 and secure with a red clamp.

22

Hose #8

Hose #4

Drain Port

Hose #7

Figure 27

Hose #4

Hose #5 x2

Figure 28

13.Locate another hose #5 cut a 5.25" straight section and discard the radius end.

14.Connect the 5.25’ straight section to the 100º elbow and the PVC pipe and secure with red clamps.

15.Mate trap inlets and hoses and secure with silver clamps, drain trap outlet must point to the original bottom of the furnace.

16.Secure trap to furnace using two screws removed in step 2.

17.Refer to Field Supplied Drain section for instructions on field supplied / installed drain on outlet of furnace trap.

E

LECTRICAL CONNECTIONS

WIRING HARNESS

The wiring harness is an integral part of this furnace. 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.

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 left side (right side for counterflows) electrical connection with the junction box located inside the burner compartment. T o 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. T o relocate the junction box, follow the steps shown in the Junction Box Relocation section.

HIGH VOLTAGE !

TO

AVOID THE RISK OF ELECTRICAL SHOCK, WIRING TO

THE UNIT MUST BE POLARIZED AND GROUNDED

HIGH VOLTAGE !

TO

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

.

L

ABEL ALL WIRES PRIOR TO DISCONNECTION WHEN SERVICING CONTROLS OPERATION

. W

IRING ERRO RS CAN CAUSE IMPROPER AND DANGEROUS

. V

ERIFY PROPER OPERATION AFTER SERVICING

WARNING

.

WARNING

CAUTION

.

115 VOLT LINE VOLTAGE CONNECTION OF ACCESSORIES (HUMIDIFIER AND ELECTRONIC AIR CLEANER - 96% MODELS ONLY)

The furnace integrated control module is equipped with line voltage accessory terminals for controlling power to an optional fieldsupplied humidifier and/or electronic air cleaner .

The accessory load specifications are as follows: T urn 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 humidifier and electronic air cleaner hot terminals are identified as HUM and EAC. The humidifier and electronic air cleaner neutral terminals are identified as NEUTRAL. All field wiring must conform to applicable codes. Connections should be made as shown. (See Figure 29.)

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.

23

The integrated control module single humidifier terminal (HUM) is energized with 115 volts whenever the induced draft blower is energized. This terminal can also be used to provide 115 volt power to a humidifier transformer. The remaining primary transformer wire would be connected to the Line N on the control board. Th e i nte grated control module electronic air cleaner terminals (EAC) are energized with 115 volts whenever the circulator blower is energized.

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

JUNCTION BOX RELOCATION

WARNING

HIGH VOLTAGE !

TO

Line voltage connections can be made through either the right or left side panel. The furnace is shipped config-

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

.

ured for a left side electrical connection. To make electrical connections through the opposite side of

Humidi fier 1.0 A m p m ax i mu m at 120 V A C

Elect ronic A ir Cleaner 1.0 A m p m ax i mu m at 120 V A C

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.

T o 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. T o 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.

WARNING

E

DGES OF SHEET METAL HOLES MAY BE SHARP

PRECAUTION WHEN REMOVING HOLE PLUGS

WARNING

. USE

.

Figure 29

GLOVES AS A

24 VOLT THERMOSTAT WIRING

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 V A transformer to facilitate use with most cooling equipment. Consult the wiring diagram, located on the blower compartment door , for further details of 115 V olt and 24 Volt wiring.

SINGLE-STAGE HEATING THERMOSTAT APPLICATION

A single-stage thermostat with only one heating stage is needed to control this furnace.

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 com-

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

.

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

ATIONAL ELECTRICAL CODE

N

24

.

,

bined 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).

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.

GAS S

UPPLY AND PIPING

IMPORTANT NOTE

W

IRE ROUTING MUST NOT INTERFERE WITH CIRCULATOR BLOWER

OPERATION, FILTER REMOVAL OR ROUTINE MAINTENANCE

R

Room

Thermostat

.

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.

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.

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.

HIGH ALTITUDE DERATE

When this furnace is installed at high altitude, the appropriate High Altitude orifice kit must be applied. This is required due to the natural reduction in the density of both the gas fuel and combustion air as altitude increases. The kit will provide the proper design certified input rate within the specified altitude range.

High altitude kits are purchased according to the installation altitude and usage of either natural or propane gas. Consult the furnace Specification Sheet for appropriate kits.

R

Y C

Remote Condensing Unit

(Single-Stage Cooling)

Figure 30

Furnace Integrated

Control Module

WARNING

HIGH VOLTAGE !

TO

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

.

CAUTION

TO

PREVENT UNRELIABLE OPERATION OR EQUIPM EN T DAMAGE, THE

GAS MANIFOLD PRESSURE MUST BE AS SPECIFIED ON THE UNIT RATING PLATE

. O

NLY MINOR ADJUSTMENTS SHOULD BE MADE BY ADJUSTING

THE GAS VALVE PRESSURE REGULATOR

.

Do not derate the furnace by adjusting the manifold pressure to a lower pressure than specified on the furnace rating plate. The combination of the lower air density and a lower manifold pressure will prohibit the burner orifice from drawing the proper amount of air into the burner . This may cause incomplete combustion, flashback, and possible yellow tipping.

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, NFP A 54/ANSI Z223.1, and information provided by the gas supplier to determine the proper orifice size.

A different pressure switch may be required at high altitude regardless of the BTU/ft3 content of the fuel used. Consult the furnace Specification Sheet for pressure switch.

PROPANE GAS CONVERSION

This unit is configured for natural gas. To operate this furnace on L.P. gas, an LPM-07 LP Conversion kit must be used. The indicated kit must be used to insure safe and proper furnace operation. All conversions must be performed by a qualified installer,

or service agency .

GAS VALVE

This unit is equipped with a 24 volt gas valve controlled during furnace operation by the integrated control module. As shipped, the valve is configured for natural gas. The valve is field convertible for use with propane gas by replacing the regulator spring with a

25

propane gas spring from an appropriate manufacturer’ s propane gas conversion kit. T aps for measuring the gas supply pressure and manifold pressure are provided on the valve.

The gas valve has a manual ON/OFF control located on the valve itself. This control may be set only to the “ON” or “OFF” position. Refer to the lighting instructions label or Startup Procedure & Ad- justment for use of this control during start up and shut down periods.

GAS PIPING CONNECTIONS

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

WARNING

. THE

CONVERSIONS MUST BE PERFORMED BY A

.

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, NFP A 54/ANSI Z223.1.

T o 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.

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

WARNING

.

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 gauge

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

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 =

Heating Value of Gas (BTU/Cubic Foot)

Natural Gas Capacity of Pipe

In Cubic Feet of Gas Per Hour (CFH)

be downstream of the manual shutoff valve, between the shutoff valve and the furnace.

• 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.

26

• 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.

Alternate

Gas Line

Location

Manifold

Burners

Gas Valve

*Ground

Joint

Pipe

Union

*NOTE: Union may be inside furnace cabinet where allowed by local codes.

Manual Shut Off Valve (upstream from ground joint pipe union)

*Ground Joint Pipe Union

Drip Leg

Grommet in Standard Gas Line Hole

UPFLOW

Figure 31

Manual Shut Off V alve

(upstream from Alternate Union Location

Grommet in

Standard Gas Line Hole

ground joint pipe union)

Drip Leg

Plug in Alternate Gas Line Hole

Manual Shut Off Valve (upstream from ground joint pipe union)

*Ground

Joint

Pipe Unio n

Grommet

in Standard

Gas Line

Hole

Drip Leg

Burners

*NOTE: Union may be inside furnace cabinet where allowed by local codes.

COUNTERFLOW

Figure 32

Manual Shut Off Valve (upstream from ground joint pipe union)

Alternate Gas Line Location

*Ground Joint Pip e Union

Plug in Alternate Gas Line Hole

Gas Valve

Burners

Plug in Main Gas Line Hole

Manifold

Gas

Valve

Drain Trap

UPFLOW - HORIZONTAL LEFT

Figure 33

COUNTERFLOW - HORIZONTAL RIGHT

Figure 34

Gas Piping Connections

27

The gas piping may enter the left or right side of the furnace cabinet. The installer must supply rigid pipe 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. 1/2” NPT pipe and fittings are required. For models with an “L” shaped manifold, a 4 1/2” long nipple is required. For models with a hook shaped manifold, a 2” long nipple is required.

A semi-rigid connector to the gas piping can be used outside the cabinet per local codes. From the elbow , the length of pipe and the fittings required will vary by the side chosen, location of union and cabinet width. The union may be placed inside or outside of the cabinet.

GAS PIPING CHECKS

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

WARNING

piping system with test pressures equal to or less than 1/2 psig

TO

(3.48 kPA).

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

OR OPEN FLAME TO TEST FOR LEAKS

.

PROPANE GAS TANKS AND PIPING

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 Considerations 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

at the furnace manifold with all gas appliances in operation. Maintaining proper gas pressure depends on three main factors:

WARNING

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

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, rec-

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

.

IF

ommended 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. Always use a pipe thread sealant approved for all gases.

Refer to the illustration for typical propane gas installations and

First Stage Regulator

5 to 15 PSIG (20 PS IG M ax .)

Continuous

11" W.C.

piping.

28

200 PSIG Maximum

Propane Gas Installation (Typ.)

Figure 35

Second Stage Regulator

C

IRCULATING AIR

& F

ILTERS

DUCT WORK - AIR FLOW

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 V entilating 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 attached to the back of the furnace. For upflow installations requiring 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. T o 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.

N

T otal 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. T ape up the test hole after your test is complete. The negative pressure must be read between the filter and the furnace blower.

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.

T o 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.

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

.

WARNING

29

Example: static reading from return duct = -.1" w .c. static reading from supply duct = .3" w .c. total external static pressure on this system = .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.

The temperature rise of the furnace must be within the temperature rise range listed on the furnace rating plate.

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.

E

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

CUT USING TIN SNIPS

Checking Static Pressure

(80% Furnace Shown, 90% Similar)

Figure 36

WARN ING

. USE

GLOVES AS A

.

PRESS OUT BY HAND

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.

CUT FOUR CORNERS AFTER REMOVING SHEET METAL

Duct Flange Cut Outs

Figure 37

SCRIBE LINES OUTLINING DUCT FLANGES

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.

30

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. Damage or repairs due to the installation of the furnace without filters is not covered under the warranty .

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 the Filter Sizing Chart to determine filter area requirements.

Filter Sizing Chart

Model Minimum Recommended Filter Size^

*MSS9*0402BN* 1 - 16 X 25 Side or Bottom *MSS9*0603BN* 1 - 16 X 25 Side or Bottom *MSS9*0803BN* 1 - 16 X 25 Side or Bottom *MSS9*0804CN* 1 - 16 X 25 Side or Bottom *MSS9*0805CN* 1 - 20 X 25 Bottom / 2 - 16 X 25 Side Return *MSS921004CN* 1 - 16 X 25 Side or Bottom *MSS9*1005CN* 1 - 20 X 25 Bottom / 2 - 16 X 25 Side Return *MSS9*1205DN* 1 - 20 X 25 Bottom / 2 - 16 X 25 Side Return

*CSS9*0402BN* 2 - 10 X 20 or 1 - 16 X 25 Top Return *CSS9*0603BN* 2 - 10 X 20 or 1 - 16 X 25 Top Return *CSS9*0804CN* 2 - 10 X 20 or 1 - 16 X 25 Top Return *CSS9*1005CN* 2 - 14 X 20 or 1 - 20 X 25 Top Return *CSS 961205DN* 2 - 14 X 20 or 1 - 20 X 25 Top Return

^ Other size filters of equal or greater dimensions may be used, filters may also be centrally located.

Change filters before occupants take ownership of a new home!

Consider installing an air cleaner with deep-pleated media filter at the time of furnace installation. A deep-pleated filter with a MERV rating of 8 (minimum) will often provide better filtration to protect equipment and the air distribution system than a standard 1" filter and often has lower static pressure loss than a 1" filter . Also a deep-pleated filter will typically require less frequent replacement intervals. A void using highly restrictive 1" filters which produce static pressure loss greater than .25" W .C. In some installations the minimum filter size required (consult filter sizing chart above) will not lend itself to a filter installation on the side of the furnace. The installation of a centrally installed air cleaner cabinet or a return duct filter installation may offer more practicality .

Clean Comfort™ brand MERV 11 air cleaners have 5¼” media filters and are available in the following configurations. Consult your distributor for information on our complete line of IAQ Clean Comfort™ products.

31

Air Cleaner

Installation Location

Maximum

Heating Airflow

Filter (Media)

Dimensions

Part Number

Air Cleaner

Family

Sid e or bo t tom retu rn 1200 CF M 16 in X 20 in x 5¼ " AM11 - 162 0- 5 Sid e or bo t tom retu rn 1600 CF M 16 in X 25 in x 5¼ " AM11 - 162 5- 5

AM11-5

Sid e or bo t tom retu rn 1600 CF M 20 in X 20 in x 5¼ " AM11 - 202 0- 5 Sid e or bo t tom retu rn 2000 CF M 20 in X 25 in x 5¼ " AM11 - 202 5- 5

Sid e return

2 X 1600 CFM 2, 16 in X 25 in x 5¼ " AM11 - 3225-5 AM11-3225

(f or 2 sep arate returns) Sid e retu rn ( Rig ht an g le) 2000 CFM 20 in X 25 in x 5¼" A M11-2025- 5RA AM11-5RA Bottom retu rn (p latfo rm) 2000 CFM 20 in X 25 in x 5¼ " AM11-2832- 5PP Bottom retu rn (p latfo rm) 2000 CFM 20 in X 25 in x 5¼ " AM11-2843- 5PP

AM11-5PP

AM11-5 AM11-5RA AM11-5PP

Family Family Family

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 figures show possible filter locations.

CENTRAL

RETURN

GRILLE

EXTERNA L FILTER

FILTER

AIR FLOW

SIDE RETURN

RACK KIT

(EITHER SIDE)

FILTER

ACCESS

DOOR

RETURN

DUCT

FILTER SUPPORT BRACKET

(Field Supplied)

FI

LT

E

R

E

LT

I

F

CENTRAL

RETURN

GRILLE

Possible Upright Upflow

Filter Locations

Figure 38

AIR FLOW

Possible Upright Counterflow

Filter Locations

Figure 39

32

HORIZONTAL INSTALLATIONS

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

S

TARTUP PROCEDURE

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.

& A

DJUSTMENT

DRAIN TRAP PRIMING

The drain trap MUST be primed prior to furnace startup. T o prime, fill both sides of the drain trap with water. This ensures proper furnace drainage upon startup and prohibits the possibility of flue gases escaping through the drain system.

FURNACE OPERATION

Purge gas lines of air prior to startup. Be sure not 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, high altitude, etc.) have been appropriately installed.

FURNACE STARTUP

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

2. T urn 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 in the Safety Considerations on page 3 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. T urn on the electrical power to the furnace.

11. Adjust the thermostat to a setting above room temperature.

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

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

.

CAUTION

FURNACE SHUTDOWN

1. Set the thermostat to the lowest setting. The integrated control will close the gas valve and extinguish flame. Following a 15 second delay , the induced draft blower will

be de-energized. The indoor blower will shut down when the time delay expires (selectable on 96% models).

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 .

33

GAS SUPPLY PRESSURE MEASUREMENT GAS PRESSURE TEST

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. T o measure the gas supply pressure, use the following procedure.

Gas Valve ON/OF F Selector Switch

Inlet Pressure

OUTLET

Regulator Cover S crew

Outlet Pressure

INLET

OUTLET

INLET

White-Rodgers Model 36J22

Figure 40A

White-Rodgers Model 36J22

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

Connected to Manometer

Figure 40B

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. See White-Rodgers 36J22 gas valve figure for location of inlet pressure tap.

NOTE: If measuring gas pressure at the drip leg, a field-supplied hose barb fitting must be installed prior to making the hose connection. If using the inlet pressure tap on the White-Rodgers 36J22 gas valve, then use the 36G/J Valve P ressure Check Kit, Part No. 0151K00000S.

3. T urn ON the gas 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 Inlet Gas Supply Pressure table.

Gas Range Nominal

Natural 3.2 - 3. 8" w. c. 3.5" w.c.

Propane 9.7 - 10. 3" w. c. 10.0" w. c.

Mani f old Gas Pressure

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. T urn OFF any unnecessary gas appliances stated in step 3.

GAS MANIFOLD PRESSURE MEASUREMENT AND ADJUSTMENT

Gas Line

Gas Shutoff Valve

Only small variations in gas pressure should be made by adjusting the gas valve pressure regulator. The manifold pressure must be measured with the burners operating. T o measure and adjust the manifold pressure, use the following procedure.

34

Gas Line To Furnace

Open To Atmosphere

Drip Leg Cap With Fitting

Manometer Hose

Manometer

Measuring Inlet Gas Pressure (Alt. Method)

Figure 41

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

2. T urn off all electrical power to the system.

3. Outlet pressure tap connections: White-Rodgers 36J22 valve: Back outlet pressure test screw (inlet/outlet pressure tap) out one turn (counterclockwise, not

more than one turn).

4. Attach a hose and manometer to the outlet pressure tap (White-Rodgers valve).

5. T urn ON the gas supply .

6. T urn on power and close thermostat “R” and “W” contacts to provide a call for heat.

7. Measure the gas manifold pressure with burners firing. Adjust manifold pressure using the Manifold Gas Pressure table shown on this page.

8. Remove regulator cover screw from the outlet pressure regulator adjust tower and turn screw clockwise to increase pressure or counterclockwise to decrease pressure. Replace regulator cover screw.

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

.

CAUTION

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

10.Remove the manometer hose from the hose barb fitting or outlet pressure tap.

11.Replace outlet pressure tap: White-Rodgers 36J22 valve: T urn outlet pressure test screw in to seal pressure port (clockwise, 7 in-lb minimum).

12.T urn on electrical power and gas supply to the system.

13.Close thermostat contacts “R” and “W” to energize the valve.

Using a leak detection solution or soap suds, check for leaks at outlet or screw (White-Rodgers valve). Bubbles forming indicate a leak. SHUT OFF GAS AND REPAIR ALL LEAKS IMMEDIATELY!

NOTE: For gas to gas conversion, consult your dealer for appropriate conversion.

GAS INPUT RATE MEASUREMENT (NATURAL GAS ONLY)

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

1. T urn OFF the gas supply to all other gas-burning appliances except the furnace.

2. While the furnace is operating at high fire rate, time and record one complete revolution of the gas meter dial, measuring the smallest quantity , usually the dial that indicates 1/2 cu. ft. per revolution. You will use this number to calculate the quantity of gas in cubic ft. if the furnace would consume if it ran steadily for one hour (3600 seconds).

3. If the 1/2 cu. ft. dial was used, multiply your number x 2. EXAMPLE: If it took 23 seconds to complete one revolution of the 1/2 ft. dial (23 x 2 = 46).

This tells us that at this rate, it would take 46 seconds to consume one cu. ft. of gas. 3600 / 46 = 78. This tells us that in one hour, the furnace would consume 78 cu. ft. of gas. The typical value range for 1 cu. ft. of natural gas is around 1000 BTU. Check with your gas utility, if possible. In this

example, the furnace is consuming 78,000 BTUH.

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.

35

4. Turn ON gas to and relight all other appliances turned off in step 1. Be certain that all appliances are functioning properly and that all pilot burners are operating.

TEMPERATURE RISE

SUPPLY AIR

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) position.

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

RETURN AIR

exchanger.

3. Subtract the return air temperature from the supply air temperature to determine the air temperature rise. Allow

Temperature Rise Measurement

Figure 42

adequate time for thermometer readings to stabilize.

4. Adjust temperature rise by adjusting the circulator blower speed. Increase blower speed to reduce temperature rise. Decrease blower speed to increase temperature rise. Refer to Startup Procedure and Adjustment -Circulator Blower Speeds for speed changing details.

CIRCULATOR BLOWER SPEEDS

This furnace is equipped with a multi-speed circulator blower . This blower provides ease in adjusting blower speeds. The Specification Sheet applicable to your model provides an airflow table, showing the relationship between airflow (CFM) and external static pressure (E.S.P.), for the proper selection of heating and cooling speeds.

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 .

TO

AVOID PERSONAL INJUR Y OR DEATH DUE TO ELECTRICAL SHOCK

TURN

OFF

POWER TO THE FURN A CE BEFORE CHANGING SPEED TAPS

30,000/12,000 = 2.5 Tons

2. Determine the proper air flow for the cooling system. Most cooling systems are designed to work with air volume 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

WARNING

,

.

3. Select the heating speed for your model from the heating speed chart in the Specification Sheet. The selected speed must provide a temperature rise within the rise range listed with the particular model.

T o adjust the circulator blower speed, proceed as follows:

1. T urn OFF power to the furnace.

2. Select the heating and cooling blower speeds that match the installation requirements from the airflow table in the Specification Sheet.

3. Relocate desired motor leads to the circulator blower heat and cool speed terminals on the integrated control module. (T erminals are identified as HEAT and COOL). If heating and cooling blower speeds are the same, a jumper wire must be used between the heat and cool terminals.

4. Connect all unused blower motor leads to the “PARK” terminals on the integrated control module. Any leads not connected to the “P ARK” terminals must be taped.

5. T urn ON power to furnace.

6. Verify proper temperature rise as outlined in the Temperature Rise section of Startup Procedure and Adjustment.

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.

36

BLOWER HEAT OFF DELAY TIMINGS

The integrated control module on 96% models provides a selectable heat off delay function. The heat off delay period may be set to 100 or 150 seconds by cutting the jumper 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 integrated control board on 92% models has a fixed blower off delay of 150 seconds.

N

ORMAL SEQUENCE OF OPERATION

POWER UP

The normal power up sequence is as follows:

• 115 V AC power applied to furnace.

• Integrated control module performs internal checks.

• LED will flash once at power up then remain on.

• Integrated control module monitors safety circuits continuously.

• Furnace awaits call from thermostat.

HEATING MODE

The normal operational sequence in heating mode is as follows:

• R and W thermostat contacts close, initiating a call for heat.

• Integrated control module performs safety circuit checks.

• Induced draft blower is energized for a 15-second prepurge.

• P ressure switch contacts are closed.

• 96% models 115 VAC HUM terminal is energized.

• Igniter warm up begins upon presence of closed pressure switch contacts.

• Gas valve opens at end of igniter warm up period, delivering gas to burners and establishing flame.

• Integrated control module monitors flame presence. Gas valve will remain open only if flame is detected.

• Circulator blower is energized on heat speed following a thirty (30) second blower on delay.

• 96% models 115 VAC EAC terminal is energized.

• Furnace runs, integrated control module monitors safety circuits continuously.

• R and W thermostat contacts open, completing the call for heat.

• Gas valve closes, extinguishing flame.

• Induced draft blower is de-energized following a fifteen second post purge.

• 96% models HUM terminal is de-energized.

• For 96% Models: Circulator blower continues running for the selected heat off delay period Factory set at 150 seconds.

• EAC terminal is de-energized For 92% Models: The blower off delay is 150 seconds (non-adjustable).

• Furnace awaits next call from thermostat.

COOLING MODE

The normal operational sequence in cooling mode is as follows:

• R,Y, G thermostat thermostat contacts close, initiating a call for cool.

• Integrated control module performs safety circuit checks.

• Outdoor fan and compressor are energized.

• Circulator blower is energized on the cool speed.

• 96% models 115 VAC EAC terminal is energized.

• Furnace circulator blower and outdoor cooling unit run their appropriate speeds, integrated control module monitors safety circuits continuously .

• R,Y, G thermostat contacts open, completing the call for cool.

• Outdoor fan and compressor are de-energized.

• Circulator blower continues running during a cool off delay period of 45 seconds.

• Furnace awaits next call from thermostat.

37

FAN ONLY MODE

The normal operational sequence in fan only mode is as follows:

• R and G thermostat contacts close, initiating a call for fan.

• Integrated control module performs safety circuit checks.

• Circulator blower is energized on heat speed.

• 96% models 115 VAC EAC terminal is energized.

• Circulator blower runs, integrated control module monitors safety circuits continuously.

• R and G thermostat contacts open, completing the call for fan.

• Circulator blower is de-energized.

• EAC terminal is de-energized.

• Furnace awaits next call from thermostat.

O

PERA TIONAL CHECKS

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.

S

AFETY 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 CONTROL MODULE

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.

PRIMARY LIMIT

The primary limit control is located on the partition panel and monitors heat exchanger compartment temperatures. It is a normallyclosed (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), manual-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.

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

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

38

integrated control module to electrostatic discharge. This procedure is applicable to both installed and uninstalled (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 furnace away from 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.

DIAGNOSTIC CHART

Refer to the Diagnostic C odes chart for assistance in determining the source of unit operational problems.

FAULT RECALL (96% Models Only)

The last five fault codes stored can be displayed on the diagnostic LED. When the control is in standby mode (no call for heat or cool), press the F AUL T RECALL switch for approximately two seconds or until the diagnostic LED turns off. R elease the switch and the LED will remain off for two seconds. Then the fault codes will display beginning with the most recent fault first with a two second pause between codes. After the stored fault codes have all displayed, the LED will remain off for two seconds and then turn on to indicate return to normal status. While displaying the stored fault codes, the control will ignore any new call for heat, cool or fan.

FAULT CODE RESET (96% Models Only)

The stored fault codes can be erased from memory . When the control is in standby mode (no call for heat or cool), press the F AUL T RECALL switch for five to ten seconds or until the diagnostic LED begins to rapid flash. When the switch is released, the LED will turn off for two seconds to indicate the codes are erased. After two seconds the LED will turn on to indicate return to normal status. If the switch is held pressed for over ten seconds the rapid flash will stop and the LED will be on to indicate return to normal status.

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 fault code displayed. I f t he 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 Chart for aid in determining the cause.

M

AINTENANCE

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. R epair 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 sense.

HIGH VOLTAGE !

TO

AVOID PERSONAL INJURY OR DEATH DUE TO

ELECTRICAL SHOCK, DISCONNECT ELECTRICAL POWER

BEFORE

PERFORMING ANY SERVICE OR MAINTENANCE

WARNING

.

39

• 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.

FILTERS 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. When replacing a filter, it must be replaced with a filter of the same type and size.

FILTER REMOVAL

Depending on the installation, differing filter arrangements can be applied. Filters can be installed in either the central return register or a side panel external filter rack (upflow only). A media air filter or electronic air cleaner can be used as an alternate filter . Follow the filter sizes given in the Recommended Minimum Filter size table to ensure proper unit performance.

DIAGNOSTIC CODES

1 flash, then pause System lockout 2 flashes, then pause Pressure switch stuck closed 3 flashes, then pause Pressure switch stuck open 4 flas hes, then pause Open limit switch

5 flas hes, then pause

6 flashes, then paus e Open rollout switch / open control board fuse 7 flashes, then paus e Low flame sense sig nal 8 flashes, then paus e Igniter relay fault Continuous flashing 115 Volt AC power reversed OFF Control failure ON Norm al operation

The LED will also flash once at power-up.

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

T o remove filters from an external filter rack in an upright upflow installation, follow the directions provided with external filter rack kit.

HORIZONTAL UNIT FILTER REMOVAL

Filters in horizontal installations are located in the central return register or the ductwork near the furnace. T o remove:

1. T urn OFF electrical power to furnace.

2. Remove filter(s) from the central return register or ductwork.

3. Replace filter(s) by reversing the procedure for removal.

4. T urn ON electrical power to furnace.

MEDIA AIR FILTER OR ELECTRONIC AIR CLEANER REMOVAL

Follow the manufacturer’ s directions for service.

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.

Burner Flame

Figure 43

40

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 motor windings 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 emery cloth or steel wool. Following cleaning, the flame sense signal should be as indicated in the Specifications Sheet.

FLUE PASSAGES (QUALIFIED SERVICER ONLY)

The heat exchanger flue passageways should be inspected at the beginning of each heating season.

B

EFORE LEA VING AN INST ALLATION

• Cycle the furnace with the thermostat at least three times. V erify cooling and fan only operation.

• Review the Owner ’s Manual with the homeowner and discuss proper furnace operation and maintenance.

• Leave literature packet near furnace.

R

EP AIR AND REPLACEMENT PAR TS

• When ordering any of the listed functional parts, be sure to provide the furnace model, manufacturing, and serial numbers

with the order .

• Although only functional parts are shown in the parts list, all sheet metal parts, doors, etc. may be ordered by description.

• Parts are available from your distributor.

Functional Parts ListGas V alve Blower Motor Gas Manifold Blower Wheel Natural Gas Orifice Blower Mounting Bracket Propane Gas Orifice Blower Cutoff Igniter Blower Housing Flame Sensor Pressure Switch Rollout Limit Switch Door Switch Primary Limit Switch Auxiliary Limit Switch Coil Front Cover Integrated Control Module Transformer Door Switch Induced Draft Blower Heat Exchanger with Recuperator Coil

41

T

ROUBLESHOOTING CHAR T

Symptoms of Abnormal

Operation

•Furnace fails to operate.

•Integrated control module diagnostic LED provides no signal.

•LED is Steady On.

Associated LED Code

NONE

ON

2

Fault

Description(s)

•No 115 volt power to furnace, or no 24 volt power to integrated control module.

•Blown fuse or circuit breaker.

•Integrated control module has an internal fault.

• Normal Operation

Possible Causes

•Manual disconnect switch OFF, door switch open, or 24 volt wires improperly connected or loose.

•Blown fuse or circuit breaker.

•Integrated control module has an internal fault.

• Normal Operation

CONTINUOUS

ON

•Furnace fails to operate.

•Integrated control module diagnostic LED is flashing ONE (1) flash.

1

1 FLASH

•Furnace lockout due to an excessive number of ignition “retries” (3 total)1.

•Failure to establish flame. Cause 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.

•Loss of flame after establishment. 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.

•Furnace fails to operate.

•Integrated control module diagnostic LED is flashing TWO (2) flashes.

•Induced draft blower runs continuously with no further furnace operation.

•Integrated control module diagnostic LED is flashing THREE (3) flashes.

2

2 FLASHES

3

3 FLASHES

• Pressure switch circuit is closed.

• Induced draft blower is not operating.

• Pressure switch circuit not closed.

• Induced draft blower is operating.

•Induced draft blower pressure switch contacts sticking.

•Shorts in pressure switch circuit.

•Pressure switch hose blocked, pinched or connected improperly.

•Blocked flue and/or inlet air pipe, blocked drain system, or weak induced draft blower.

•Incorrect pressure switch setpoint or malfunctioning switch contacts.

•Loose or improperly connected wiring.

1

Integrated control module will automatically attempt to reset from lockout after one hour.

2

LED Flash code will cease if power to the control module is interrupted through the disconnect or door switch.

42

Corrective Action

•Assure 115 and 24 volt power to furnace integrated control module.

•Check integrated control module fuse (3A). Replace if necessary.

•Check for possible shorts in 115 and 24 volt circuits. Repair as necessary.

•Replace bad integrated control module.

•None

•Locate and correct gas interruption.

•Check front cover pressure switch operation (hose, wiring, contact operation). Correct if necessary.

•Replace or realign igniter.

•Check flame sense signal. Sand sensor if coated and/or oxidized.

•Check flue piping for blockage, proper length, elbows, and termination.

•Verify proper induced draft blower performance.

•Replace induced draft blower pressure switch.

•Repair short.

•Inspect pressure switch hose. Repair, if necessary,

•Inspect flue and/or inlet air piping for blockage, proper length, elbows, and termination. Check drain system. Correct as necessary.

•Correct pressure switch setpoint or contact motion.

•Tighten or correct wiring connection.

Cautions &

Notes

•Turn power OFF prior to repair.

•Replace grated

inte-

control module fuse with 3A automotive fuse.

•Read precautions in “Electrostatic Discharge” section of manual.

• Normal Operation

•Turn power OFF prior to repair.

•Igniter is fragile, handle with care.

•Sand flame sensor with emery cloth.

•See “Vent/ Flue Pipe” section for piping details.

•Turn power OFF prior to repair.

•Replace pressure switch with proper replacement part.

•Turn power OFF prior to repair.

•Replace pressure switch with proper replacement part.

T

ROUBLESHOOTING CHAR T

Symptoms of Abnormal

Operation

•Circulator blower runs continuously. No furnace operation.

•Integrated control module diagnostic LED is flashing FOUR (4) flashes.

Associated LED Code

4

4 FLASHES

2

Fault

Description(s)

•Primary or auxiliary limit circuit is open.

Possible Causes Corrective Action

•Faulty pirmary or auxiliary limit switch.

•Insufficient conditioned air over the heat exchanger. Blocked filters, restrictive ductwork, improper circulator blower speed, or failed circulator blower.

•Loose or improperly connected wiring.

•Check primary/ auxiliary limit. Replace if necessary.

•Check filters and ductwork for blockage. Clean filters or remove obstruction.

•Check circulator blower speed and performance. Correct speed or replace blower if necessary.

•Tighten or correct wiring connection.

•Induced draft blower and circulation blower runs continuously. No furnace operation.

•Integrated control module diagnostic LED is flashing FIVE (5) flashes.

•Furnace fails to operate.

•Integrated control module diagnostic LED is flashing SIX (6) flashes.

•No furnace operation.

5

5 FLASHES

6 FLASHES

6

•Flame sensed with no call for heat.

•Rollout limit open.

•Integrated control module fuse is blown.

•Short to ground in flame sense circuit.

•Flame rollout.

•Misaligned burners, blocked flue and/or air inlet pipe, or failed induced draft blower.

•Loose or improperly connected wiring.

•Short in 24 volt AC control circuits or safety circuits.

•Faulty rollout limit.

•Correct short at flame sensor or in flame sensor wiring.

•Check burners for proper alignment.

•Check flue and air inlet piping for blockage, proper length, elbows, and termination. Correct as necessary.

•Check rollout limit. Replace if necessary.

•Check induced draft blower for proper performance. Replace, if necessary.

•Tighten or correct wiring connection.

•Normal furnace operation.

•Integrated control module diagnostic LED is flashing SEVEN (7) flashes.

7

7 FLASHES

•Flame sense microamp signal is low.

•Flame sensor is coated/oxidized.

•Flame sensor incorrectly positioned in burner flame.

•Lazy burner flame due to improper gas

•Sand flame sensor.

•Inspect for proper sensor alignment.

•Compare current gas pressure to rating plate info. Adjust as needed.

pressure or combustion air.

•Furnace not operating.

•Integrated control module diagnostic LED is flashing EIGHT (8) flashes.

7

8

8 FLASHES

•Problem with igniter circuit.

•Improperly connected igniter.

•Bad igniter.

•Poor unit ground.

•Poor burner ground.

•Faulty integrated control module.

•Furnace fails to operate.

•Integrated control module diagnostic LED is flashing continuously.

•LED is steady on.

2

LED Flash code will cease if power to the control module is interrupted through the disconnect or door switch.

C

CONTINUOUS/

RAPID FLASH

STEADY ON

•Polarity of 115 or 24 volt power is reversed.

•Normal operation.

•Polarity of 115 volt AC power to furnace or integrated control module is reversed.

•Orange and gray wires to transformer are reversed.

•Poor unit ground.

•Check and correct wiring from integrated control module to igniter .

•Replace bad igniter.

•Check & correct unit ground wire.

•Replace bad integrated control module.

•Review wiring diagram to correct polarity .

•Reverse orange and gray wires going to transformer.

•Verify proper ground. Correct if necessary .

43

Cautions and

Notes

•Turn power OFF prior to repair.

•Replace primary/ auxiliary limit with proper replacement part.

•Replace blower with correct replacement part.

•Turn power OFF prior to repair.

•See “Vent/Flue Pipe” section for piping details.

•Replace induced draft blower with correct replacement part.

•Replace integrated control module fuse with 3A automotive fuse.

•Read precautions in “Electrostatic Discharge” section of manual.

•Replace rollout limit with correct replacement part.

•Turn power OFF prior to repair.

•Clean flame sensor with steel wool.

•See “Vent/Flue Pipe” section for piping details.

•See rating plate for proper gas pressure.

•Turn power OFF prior to repair.

•Replace igniter w/ proper replacment part.

•Read precautions in “Electrostatic Discharge” section of manual.

•Turn power OFF prior to repair.

A

IRFLOW

*MSS920402BN

*MSS920603BN

*MSS920803BN

*MSS920804CN

*MSS920805CN

*MSS921004CN

*MSS921005CN

*MSS921205DN

*CSS920402BN

*CSS920603BN

*CSS920804CN

*CSS921005CN

*MSS92*** & *CSS92***A*

0.1 0.2 0.3 0.4 0.5

AC CFM R ISE CFM RIS E CFM R ISE CFM RIS E CFM R ISE CFM CFM CFM

HIGH 3.0 1498 N/A 1446 N/A 1368 N/A 1302 N/A 1227 N/A 1145 1059 954

MED 2.5 1223 N/A 1182 N/A 1153 30 1099 31 1051 32 982 901 813

MED-LO 2.0 983 35 971 35 945 36 919 37 878 39 813 746 659

LOW 1.5 816 42 794 43 758 45 734 46 678 50 637 597 523

HIGH 3.0 1494 N/A 1428 36 1362 38 1294 39 1231 42 1162 1076 972

MED 2.5 1203 42 1178 43 1147 45 1101 46 1045 49 986 927 831

MED-LO 2.0 977 52 965 53 939 54 904 57 866 59 801 763 639

LOW 1.5 801 64 786 65 751 N/A 714 N/A 714 N/A 680 635 596

HIGH 3.0 1459 47 1397 49 1339 51 1270 54 1202 57 1107 1049 952

MED 2.5 1191 57 1166 58 1137 60 1086 63 1033 N/A 973 889 797

MED-LO 2.0 985 N/A 967 N/A 932 N/A 900 N/A 859 N/A 805 731 620

LOW 1.5 808 N/A 785 N/A 758 N/A 726 N/A 679 N/A 629 590 513

HIGH 5.0 2115 N/A 2050 N/A 1973 35 1915 36 1810 38 1695 1587 1467

MED 4.0 1802 38 1739 39 1725 40 1665 41 1612 42 1532 1443 1320

MED-LO 3.5 1517 45 1509 45 1496 46 1475 46 1441 47 1388 1304 1205

LOW 3.0 1213 56 1225 56 1216 56 1194 57 1179 58 1135 1084 1005

HIGH 5.0 2284 30 2231 31 2170 31 2103 32 2037 33 1945 1836 1750

MED 4.0 1865 37 1869 36 1775 38 1732 39 1684 40 1619 1548 1480

MED-LO 3.5 1594 43 1571 43 1530 45 1492 46 1454 47 1414 1355 1293

LOW 3.0 1411 48 1366 50 1325 51 1296 53 1251 54 1200 1147 1096

HIGH 5.0 2082 41 1997 43 1943 44 1847 46 1749 49 1669 1560 1443

MED 4.0 1823 47 1782 48 1711 50 1659 51 1574 54 1513 1402 1305

MED-LO 3.5 1565 54 1545 55 1529 56 1487 57 1441 59 1365 1287 1196

LOW 3.0 1261 N/A 1237 N/A 1242 N/A 1216 N/A 1179 N/A 1145 1098 1034

HIGH 5.0 2137 40 2073 41 2031 42 1949 44 1879 45 1811 1734 1625

MED 4.0 1793 48 1754 49 1704 50 1648 52 1590 54 1534 1451 1371

MED-LO 3.5 1558 55 1518 56 1477 58 1425 60 1376 62 1316 1242 1170

LOW 3.0 1370 62 1325 64 1288 N/A 1237 N/A 1191 N/A 1134 1086 1024

HIGH 5.0 2256 45 2192 47 2133 48 2054 50 1986 51 1907 1834 1718

MED 4.0 1805 57 1762 58 1722 59 1677 61 1618 63 1563 1507 1441

MED-LO 3.5 1565 65 1513 N/A 1480 N/A 1415 N/A 1392 N/A 1346 1269 1198

LOW 3.0 1368 N/A 1326 N/A 1278 N/A 1238 N/A 1208 N/A 1165 1093 1052

HIGH 3.0 1400 N/A 1331 N/A 1263 N/A 1189 N/A 1106 31 1020 941 843

MED 2.5 1204 N/A 1176 N/A 1121 30 1072 32 1002 34 927 853 740

MED-LO 2.0 1020 33 998 34 968 35 923 37 880 39 820 739 652

LOW 1.5 841 41 827 41 797 43 766 44 727 47 680 634 556

HIGH 3.0 1668 31 1335 38 1288 40 1207 42 1133 45 1061 955 845

MED 2.5 1224 42 1182 43 1139 45 1088 47 1015 50 948 859 759

MED-LO 2.0 1030 50 1005 51 988 52 942 54 893 57 830 751 666

LOW 1.5 859 60 830 62 815 63 789 65 751 N/A 693 629 556

HIGH 4.0 1770 39 1645 41 1610 42 1528 45 1437 47 1340 1251 1141

MED 3.5 1690 40 1615 42 1531 45 1470 46 1393 49 1308 1196 1099

MED-LO 3.0 1612 42 1540 44 1472 46 1398 49 1306 52 1223 1132 1010

LOW 2.5 1396 49 1339 51 1304 52 1250 55 1170 58 1092 1010 906

HIGH 4.0 1793 48 1699 50 1610 53 1533 56 1461 58 1363 1247 1146

MED 3.5 1693 50 1622 53 1552 55 1467 58 1390 61 1320 1205 1083

MED-LO 3.0 1632 52 1546 55 1493 57 1415 60 1332 64 1257 1148 1054

LOW 2.5 1429 60 1380 62 1334 64 1258 N/A 1199 N/A 1136 1041 942

0.6 0.7 0.8

1. CFM in chart is without filter(s). Filters do not ship with this furnace, but must be provided by the installer. If the furnace requires two return filters, this chart assumes both filters are installed.

2. All furnaces ship as high speed cooling and medium-speed heating. Installer must adjust blower cooling & heating speed as needed.

3. For most jobs, about 400 CFM per ton when cooling is desirable.

4. INSTALLATION IS TO BE ADJUSTED TO OBTAIN TEMPERATURE RISE WITHIN THE RANGE SPECIFIED ON THE RATING PLATE.

5. The chart is for information only. For satisfactory operation, external static pressure must not exceed value shown on rating plate. The shaded area indicates ranges in excess of maximum external static pressure allowed when heating. The data for 0.6" w.c. to 0.8" w.c. is shown for air conditioning purposes only.

6. At higher altitudes, a properly derated unit will have approximately the same temperature rise at a particular CFM, while the ESP at that CFM will be lower.

44

A

IRFLOW

*MSS960402BN

*MSS960603BN

*MSS960803BN

*MSS960804CN

*MSS960805CN

*MSS961005CN

*MSS961205DN

*CSS960402BN

*CSS960603BN

*CSS960804CN

*CSS961005CN

*CSS961205DN

*MSS96*** & *CSS96***A*

AC CFM RISE CFM RISE CFM RISE CFM RISE CFM RISE CFM CFM CFM

0.3 0.4 0.50.1 0.2

HIGH 3.0 1478 N/A 1418 25 1354 26 1290 28 1208 29 1129 1040 930

MED 2.5 1299 27 1265 28 1225 29 1167 30 1112 32 1033 949 841

MED-LO 2.0 1081 33 1064 33 1039 34 997 36 945 38 886 819 722

LOW 1.5 966 37 951 37 925 38 892 40 861 41 808 750 666 HIGH 3.0 1432 37 1374 39 1319 40 1237 43 1157 46 1063 958 854

MED 2.5 1289 41 1250 43 1204 44 1142 47 1066 50 981 897 789

MED-LO 2.0 1080 49 1057 50 1022 52 980 54 926 58 861 785 700

LOW 1.5 967 55 945 56 919 58 879 61 844 63 789 712 632 HIGH 3.0 1620 44 1561 46 1478 48 1401 51 1322 54 1239 1150 1052

MED 2.5 1538 46 1476 48 1401 51 1332 53 1250 57 1166 1083 992

MED-LO 2.0 1446 49 1388 51 1333 53 1258 57 1197 59 1112 1037 937

LOW 1.5 1246 57 1217 58 1165 61 1128 63 1067 N/A 994 938 840 HIGH 4.0 1746 41 1671 43 1589 45 1516 47 1447 49 1371 1295 1160

MED 2.5 1190 60 1179 60 1151 62 1138 62 1090 65 1042 970 879

MED-LO 2.0 894 N/A 877 N/A 867 N/A 870 N/A 863 N /A 831 764 671

LOW 1.5 624 N /A 595 N/A 620 N/A 620 N/A 610 N /A 604 571 519 HIGH 5.0 2233 32 2159 33 2086 34 2024 35 1941 37 1850 1753 1651

MED 4.0 1820 39 1778 40 1742 41 1695 42 1638 43 1551 1485 1384

MED-LO 3.5 1571 45 1535 46 1497 48 1446 49 1402 51 1338 1280 1204

LOW 3.0 1361 52 1333 53 1290 55 1255 N/A 1208 N/A 1171 1104 1051 HIGH 5.0 2157 41 2087 43 2028 44 1953 46 1858 48 1775 1661 1558

MED 4.0 1907 47 1852 48 1800 49 1738 51 1675 53 1605 1514 1410

MED-LO 3.5 1608 55 1580 56 1493 60 1501 59 1440 62 1367 1296 1219

LOW 3.0 1390 N/A 1344 N/A 1326 N/A 1268 N/A 1227 N/A 1194 1132 1071 HIGH 5.0 2204 48 2144 50 2080 51 1991 54 1914 56 1817 1724 1595

MED 4.0 1938 55 1914 56 1849 58 1778 60 1713 62 1645 1548 1454

MED-LO 3.5 1651 65 1624 66 1574 68 1529 70 1475 72 1409 1331 1236

LOW 3.0 1427 75 1382 N/A 1345 N/A 1311 N/A 1272 N/A 1215 1159 1066 HIGH 3.0 1425 25 1345 26 1271 28 1198 30 1138 31 1051 945 864

MED 2.5 1254 28 1218 29 1155 31 1107 32 1040 34 952 869 761

MED-LO 2.0 1082 33 1051 34 1007 35 965 37 910 39 841 770 660

LOW 1.5 889 40 872 41 829 43 815 44 765 46 711 659 585 HIGH 3.0 1348 40 1283 42 1217 44 1151 46 1086 49 1014 931 844

MED 2.5 1188 45 1139 47 1098 49 1039 51 986 54 916 834 758

MED-LO 2.0 1015 53 985 54 945 56 909 59 858 62 804 733 655

LOW 1.5 821 65 814 N/A 788 N/A 765 N/A 720 N/A 677 640 564 HIGH 4.0 1736 41 1613 44 1578 45 1498 47 1409 50 1314 1226 1119

MED 3.5 1657 43 1583 45 1501 47 1441 49 1366 52 1282 1173 1077

MED-LO 3.0 1581 45 1510 47 1443 49 1371 52 1280 56 1199 1110 990

LOW 2.5 1369 52 1313 54 1278 56 1225 58 1147 62 1071 990 888 HIGH 5.0 2018 44 1953 46 1877 47 1788 50 1735 51 1659 1556 1448

MED 4.0 1826 49 1749 51 1660 54 1566 57 1496 59 1415 1335 1220

MED-LO 3.5 1618 55 1539 58 1476 60 1406 63 1340 66 1275 1194 1093

LOW 3.0 1402 63 1354 66 1296 69 1242 N/A 1173 N/A 1108 1042 965 HIGH 5.0 2123 50 2053 52 2000 53 1916 56 1832 58 1739 1646 1561

MED 4.0 1912 56 1844 58 1770 60 1708 62 1619 66 1543 1436 1349

MED-LO 3.5 1684 63 1622 66 1578 68 1503 71 1442 74 1374 1302 1204

LOW 3.0 1493 71 1436 74 1371 N/A 1319 N/A 1264 N/A 1208 1153 1061

0.6 0.7 0.8

1. CFM in chart is without filter(s). Filters do not ship with this furnace, but must be provided by the installer. If the furnace requires two return filters, this chart assumes both filters are installed.

2. All furnaces ship as high speed cooling and medium-speed heating. Installer must adjust blower cooling & heating speed as needed.

3. For most jobs, about 400 CFM per ton when cooling is desirable.

4. INSTALLATION IS TO BE ADJUSTED TO OBTAIN TEMPERATURE RISE WITHIN THE RANGE SPECIFIED ON THE RATING PLATE.

5. The chart is for information only. For satisfactory operation, external static pressure must not exceed value shown on rating plate. The shaded area indicates ranges in excess of maximum external static pressure allowed when heating. The data for 0.6" w.c. to 0.8" w.c. is shown for air conditioning purposes only.

6. At higher altitudes, a properly derated unit will have approximately the same temperature rise at a particular CFM, while the ESP at that CFM will be lower.

45

W

IRING

HIGH VOLTAGE!

Disconnect ALL power before servicing or installing this unit. Multiple

D

IAGRAM

R

2

V

4

C

A

F

E

I

D

R

I

M

U

H

V

2

V

T

2

E

4

H

R

M

O

C

N

T

N

E

C

S

E

A

.

S

.

N

L

.

C

D

N

G

B

R

B

C

L

O

B

W

R

E

U

R

N

E

B

R

power sources may be present. Failure to do so may cause property

damage, personal injury or death.

D

R

O

W

H

I

D P S

2

C

O

C H

O

U

S I

G



T

E

A

S

F

O 1

F

L

A



2

A

L

F



3

F

L

A



4

F

L

A



5

A

L

F

L

6

F

A

L

6

F



F

L

7

A



8

F

L

A



N

O

C

R

O

L

C

O

C

L

Y

E

L

R

O

R

A

U

R

U

P

N

G

R

E

K

A

B

L

C

B

4

T

S

A

O

T

O

I

N

S

1

5

V

W

R

I

E

2

W

R

C

G

Y

S

E

F

U

I

E

N

T

G

A

T

R

N

O

R

C

T

M

O

D

U

L

A

I

N

T

G

D

C

S

O

D

L

E

1

5

V

C

A

D

N

T

H

P

R

A

O

A

-

H

L

O

C

A

O

H

T

E

W

H

B

K

(

H

B

M

L

(

M

R

O

(

L

R

D

(

U

L

I

R

C

B

L

O

W

P

A

C

I

R

O

T

M

O

C

O

B R W

R

I N

T R

N

I

D

S S S S S S

S S

S

I

T

O

O N

P

E

K

T

P

A

M

N

R

T

E

T

A

M

N

T

R

P

E

M

D

N

G

K

B

W

H

I

N

D

L

O

B

O

U

A

R

T

R

A

M

R

P

I

O

R

C

N

T

N

C

O

L

W

R

O

E

2

4

U

R

S

E

U

H

I

N

F T

N

L

M

H

T

C

T

I

C

U

O

C

T

E

R

A

C

E

R

E

S

A

G

N

O

Y

=

N

M

R

=

C

O

T

N

H

=

S

Y

S

T

E

H

E

S

=

E

P

R

H

S

E

S

E

P

R

=

H

E

S

=

P

E

N

O

H

E

S

=

A

M

L

F

H

E

S

H

=

E

S

=

N

E

P

O

H

E

S

=

F

L

7

A

E

S

=

H

F

L

8

A

D

I

P

U

A

R

O

U

S

/

P

K

S

:

E

D

R

B

W

G

E

B

L

E

N

G

Y D

R

O

Y

G

C

A

C

K

B

D

E L

E

M

R

E

T

K

H

-

I

)

D

E

L

D

O

W

)

R

T

O

A

R

E

D

E

U

C

W

R

E

S

T

I

M

I

Y

L

O

L

V

A

C

F

E

I

D

R

I

2

C

M

I

L

V

A

V

L

O

A

O

R

L

M

C

O

L

S

U

R

E

S

U

R

E

H

G

I

H

S

E

N

L

O

R

E

H

S

E

H

S

F

A

L

K

N

I

P

O

R

B

H

W

H

B

U

L

G

R

A

E

D

R

4

0

A

V

R

E

R

O

M

F

R

T

N

A

S

W

H

R

O

1

3

2

K

P

4

6

5

Y

G

XFMR-H

L

S

I

A

N

H

-

L

I

E

N

R

D

W

)

D

T

F

R

A

L

Y

N

A

R

U

E

M

S

L

E

A

T

N

E

G

I

S

L

(

R

B

Y

G

E

P

E

R

A

N

O

T

I

R

U

L

E

I

A

F

R

T

O

E

K

(

T

U

R

S

W

T

S

C

I

H

S

T

C

I

H

W

S

L

I

M

I

T

O

H

I

E

W

S

O

/

P

N

T

U

O

E

C

S

F

O

L

W

=

S

=

C

H

E

C

K

S

V

H

=

E

S

E

R

O

N

W

N

1

.

2

.

I

T

E

3

.

E

H

Y

4

.

5

.

O

R

8

9

7

L

B

R

1

2

G

D

R

2

1

P

K

G

1

0

L

Y

O

R

Y

115 VAC NEUTRAL

TERMINALS

K

B

R

B

H

W

H

W

WH

L

Y

A

X

A

Y

M

I

L

U

I

R

I

T

I

L

K

B

R

O

C

O

N

I

S

E

U

T T

U

T

N

A

M

N

I

G

R

E

T

E

S

E

T

M

N

A

I

F

A

V

L

O

B A

S

T

N

U

T

I

L

N

T

R

C

O

S

U

P

H

W

H

U

P

L

B

R

O

K

P

I

T

M

L

O

T

L

I

U

L

4

0

T

R

O

N

L

C

O

N

D

E

D

E

X

E

C

S

E

O

K

L

C O

K

P

C

E

N

A

L

G

A

S

V

S

L

E

F

U

O

R

A

N

S

G

E

I

R

T

E

R

O

D

1

5

1

S

E

: H

A

C

E

I

T

A

T

N

U

C

F

A

T

R

S

U

'

F

T

O

N

E

H

O

Y

T

E

N

A

I

P

M

G

W

S

E

P

R

E

D

P

O

R

V

O

D

I

E

P

B

U

M

T

S

R

(

O

R

L

)

C

N

S

O

T

B

)

T

U

K

G

N

D

R

O

T

F

N

C

O

U

R

S

R

E

P

)

D

V

E

L

E

R

O

R

P

G

M

P

I

V

A

C

O

R

T

L

I

P

A

R

N

O

I

R

A

O

P

T

S

P

E

C

D

F

R

E

I

P

I

E

L

R

I

A

R

I

G

I

N

E

W

A

L

G

N

I

R

A

T

U

R

A

E

T

E

O

H

S

U

B

L

D

E

D

A

T

O

H

C

R

E

C

T

H

R

G

Y

L

T

N

E

N

A

E

M

R

B C D (

L

B

PK

GR

RD

YL

BL

OR

D

G

R

E

V

R W

E

S

I

C

H

T

R

O

U

N

I

D

N

G

Y

E

A

H

M

R

T

S

M

O

P

C

A

E

A

T

E

R

N

M

S

I

S

D

P

T

E

L

W

U

P

O

E

S

T

A

L

F

T

A

1

U

T

S

J

S

N

Y

T

I

B

E

D

T

P

M

I

E

G

T

E

N

R

E

A

U

O

D

N

C

E

A

D

N

*MSS92*** & *CSS92***A*

R

E

W

O

L

T

E

M

A

T

N

P

R

O

M

T

I

C

R

W

H

O

S

O

E

P

N

W

E

H

N

D

)

O

P

O

N

E

R

C

24V THERMOSTAT CONNECTIONS N.E. C. CLASS 2 WIRE

BK

G

O

T

Y

R

C

I

M

O

W

R

(

)

H

3

T

-

X

R

H

F

M

INTEGRATED CO NTROL MODULE

GY

BR

I

N

L

E

H

-

R

O

D S

I

W

T

C

G

N

I

N

R

A

W

P

T

C

E

N

O

N

C

S

I

D

S

B

E

V

R

F

O

G

T

O

N

I

N

U

I

W

R

E

S

U

B

T

M

Y

L

R

E

P

O

R

P

I

R

O

A

P

D

Z

L

E

D

N

D

O

G

A

N

U

R

1

O

T

V

O

U

N

I

J

O

T

N

C

L

B

X

B

O

W

H

R

G

D

N

G

B

K

E

L

M

A

F

S

O

E

N

S

R

2

V

O

L

W

O

L

W

V

I

H

V

I

A

R

N

G

I

T

E

G

U

P

L

.

P

M

0

A

7

S

A

.

T

U

M

S

T

B

E

U

E

S

E

F

H

U

T

N

R

A

C

E

0

5

U

C

.

P

S

C

°

P

O

E

A

T

O

M

E

T

R

L

A

L

A

T

R

U

E

I

S

N

E

A

O

N

T

E

F

M

.

N

R

O

4

(

E

V

O

T

L

A

G

D

E

L

G

E

I

T

A

F

O

L

G

E

T

L

A

(

1

5

O

1

V

L

I

E

O

T

D

M

E C D

.

C

D

T

F

L

A

G

C

N

I

U

O

T

N

J

M

R

T

E

I

N

A

I

N

E

R

T

A

L

T

O

C

N

R

E

D

T

O

N

O

T

O

E

C

I

C

H

S

W

E

N

E

N

I

V

R

C

I

A

C

S

E

U

L

T

R

B

P

D

N

O

U

C

R

C

T

S

R

O

A

L

T

L

S

A

N

E

I

H

T

O

E

C

H

R

C

R

C

T

E

T

C

O

C

A

L

O

L

D

.

N

A

M

U

I

H

I

F

I

D

)

6

(

T

R

N

(

)

G

D

8

V

M

C

(

9

)

N O

V

M

(

2

)

1

T

E

O

V

R

O

R

C

F

N

P

T

R

I

S

C

E

W

E

S

R

S

U

)

0

1

(

P

S

)

4

(

O

S

P

7

(

)

L

I

H

1

(

L

)

O

H

A

I

L

O

1

)

R

1

(

2

O

)

R

5

(

1

A

M

A

L

N

U

R

I

CON

T

M

L

I

(

G

LEC

S

N

I

2

1

A

F

E

M

L

F

S

N

G

I

N

I

D

H

:

W

O

N

I

C

I I

T

.

D

V

5

1

C

R

E

W S P

R

U

T

S

O

H

I

G

T

I

N

I

D

R

W

B

L

C

O

L

C

R

I

U

C

B

L

H

-

T

A

E

H

N

U

C

J

N

O

T

O

B

I

R

E

.

G

L

Ø

/

0

H

6

/

A

C

1

P

R

U

E

R

T

N

I

N

R

G

N

A

:

I

D

S

C

I

E

C

G

N

I

W

V

R

.

I

O

P

L

Y

L

R

E

P

D

C

O

I

S

N

E

)

L

O

L

N

G

.

R

B

P

S

E

U

L

T

M

I

T

,

D

E

.

N

Y

O

L

I

T

O

E

R

U

Q

N

I

R

E

N

E

M

T

O

O D

E

S

I

N

L

.

M

G

F

C

.

N

I

T

N

G

A

I

L C

O

ETROL

(

T

R

A

V

A

E

N

C

T

R

D

O

P T

E

N

G

Z

I

E

S

W O

C

E

O

E

N

O

C

D

C

R

Y

N

T

R

O

L

S

T

L

U

O

S

)

O

L

O

N

4

0KB

)

T

U

C

0

4

V

A

R

S

N

T

F

O

C

R

S

O

E

R

O

D

S

I

N

W

E

R

S

U

P

N

D

O

E

C

I

V

T

R

E

W

O

P

T

C

E

M

S

U

T

I

N

T

O

U

E

D

N

G

A

O

R

G

N

U

T

P

M

E

N

Q

I

F

D

I

E

L

I

E

D

P

F

L

S

W

T

C

I

H

(

E

T

I

N

G

I

T

H

C

P

R

I

E

(

E

V

R

U

C

E

P

R

V

D

.

O

E

T

R

I

W

T

N

I

H

D

W

E

R

H

U

X

T

I

M

E

S

T

ROL

O

N

V

4

5

S

F

A

E

R

A

L

W

X

N

Z

O

N

O

N

I

R

A

C

T

S

A

S

G

D

A

E

R

T

L

U

E

R

D

O

M

T

L

O

2

C

A

G

S

V

E

V

A

L

1

M

I

E

D

W

R

B

L

O

S

P

E

S

R

U

E

R

S

W

I

C

T

H

O

N

T

A

U

TOR

E

S

E

P

R

M

R

A

I

Y

T

I

M

I

L

N

T

R

C

O

L

E

M

R

INTEGRATED CONTROL MODULE

LINE NEUTRALS

N

O

C

N

E

T

C

Y

T

L

H

W

I

C

I

E

B

F

E

O

R

B

E

T U

E

D

N

.

D

TO115 VAC / 1Ø / 60HZ

POWERSUPPLYWITH

OVERCURRENT PROTECTION

DEVICE

N D

L

D

N

G

D

N

G

E

C

I

L

)

P

.

M

E

R

T

S

)

S

.

N

T

C

I

E

R

A

E

I

L

T

A

M

G

0

1

4

0

F

2

0

A

-

5

9

Wiring is subject to change. Always refer to the wiring diagram on the unit for the most up-to-date wiring.

46

W

IRING

HIGH VOLTAGE!

Disconnect ALL power before servicing or installing this unit. Multiple

D

IAGRAM

B

E

L

O

W

R

4

2

V

C

A

U

F

H

E

I

D

M

I

R

2

4

V

A

T

S

T

O

R

E

H

V

2

M

T

4

T

N

E

I

N

O

S

O

C

N

L

S

C

A

E

S

.

2

N

.

C

D

E

L

115 VA C HOT AND PARK TERMINAL S

G

N

D

R

B

R

A

C

L

O

B

W

C

O

R

E

C

O

R

N

U

R

B

power sources may be present. Failure to do so may cause property

damage, personal injury or death.

D

R

O

R

W

H

I

D

B

R

E

P S

W

2

C

I

R

C

O

N T

O

H

R

U

S I

G

N

I



A

D

S

T

E

O

F



F

L

1

A

S

F

L

2

A

S



F

L

3

A

S



L

4

F

A

S

F

L

5

A

S



F

L

6

F

L

A

S

6

A

S



F

L

S

7

A



F

S

L

8

A



C

N

O

I

T

C

R

O

C

O

L

Y

O

E

L

Y

L

N

O

A

R

O

P

U

P

U

R

P

G

E

R

N

G

E

K

C

A

L

B

K

B

W

C

A

I

G

D

COOL-H

P

M

G

N O

L

S

I

T

C

E

N

A

F T

E

Y

H

H H

H

H H

H H H

U

N

D

W

G

E

L

N

V

1

5

I

R

E

W

G

R

Y

F

E

S

U

R

I

E

N

T

G

A

T

N

O

R

O

C

L

D

U

M

O

I

T

C

S

O

N

HEAT-H

W

H

B

K

(

H

B

M

L

(

M

(

R

O

L

(

R

D

L

C

U

R

I

C

B

L

O

W

C

I

R

A

O

T

A

M

R

P

T

N

E

T

M

R

N

A

E

P

D

N

K

B

W

H

D

I

N

B

L

O

R

O

U

A

T

A

M

R

P

R

I

C

R

O

T

N

C

W

O

R

E

4

2

E

U

R

S

U

H

M

H

C

T

I

U

O

C

T

R

E

C R

A

G

S

O

=

N

O

R

M

=

C

N

O

T

=

S

T

E

Y

E

S

=

P

R

E

S

E

P

R

=

S

E

=

P

E

N

O

E

S

=

A

M

L

F

E

S

E

S

=

N

E

P

O

E

S

=

F

L

7

A

E

S

=

F

L

8

A

P

U

D

A

O

R

I

S

/

P

K

:

E

S

B

R

W

E

B

L

Y

G

D

R

O

G

Y

C

A

C

B

K

D

E L

E

EAC-H

I

)

D

)

E E

D

L

O

W

)

O

R

T

A

E

R

U

C

E

D

W

E

R

S

T

E

T

I

L

I

M

Y

L

A

V

C

E

I

R

F

I

D

C

2

I

M

L

V

A

O

L

A

L

O

R

M

L

O

C

R

U

E

S

E

R

U

S

G

H

I

H

N

E

S

O

R

L

S

H

E

S

H

E

F

A

L

N

P

I

K

B

R

O H

W

H

U

B

L

A

R

G R

E

D

4

0

A

V

T

R

E

R

O

R

M

A

F

N

S

W

H

R

O

123

K

P

4

65

Y

G

98

12

XFMR-H

LINE-H

R

D

O

)

W

B

T

D

F

R

A

L

Y

R

A

T

M

U

R

N

E

L

S

A

E

C

N

O

E

G

I

S

L

(

R

B

Y

G

E

R

P

A

N

O

T

I

R

U

L

F

A

E

I

E

I

T

R

E

(

T

R

U

O

K

T

U

T

S

C

I

H

S

W

S

U

T

S

C

T

I

H

W

L

I

T

I

M

T

H

I

U

E

W

O

T

S

O

C

N

/

O

U

P

T

N

E

A

L

O

F

S

L

=

W

S

=

C

H

E

C

K

I

G

E

H

S

=

R

E

V

E

T

O

N

W

1

.

E

S

.

M

A

2

E

I

T

.

F

I

3

E

A

H

Y

L

B

4

.

A

S N

U

5

.

R

O

7

L

B

11

10

L

Y

O

G

Y

R

D

TERMINALS

115 VAC NEUTRAL

HUM-N

H

W

2

1

K

O

P

O

L

N

E

S

C C

T

R

M

N

R

S T N

A

N I

V

W

O

T

I

W

K

B

P

K

L

Y

A

Y

I

A

X

R

L

U

C

S

O

N

L

T

R

O

U

P

H

W

H

U

P

L

B

R

K

I

M

O

I

T

L

U

C

R

N

L

T

)

T

U

R

B

O

T

0

N

L

K

4

G

N

D

C

N

O

F P

)

D

E

X

C

K

C

S

D

O

L

E

K

O

P

E

N

L

S

G

V

A

V

A

E

U

S

F

O

L

N

G

A

S

I

E

I

S

: H

U

Y

N

O

M

R

M

P

I

R

O

E

T

V

A

C

1

5

E

1

D

A

E

C

T

A

I

T

I

N

A

P

T

O

C

R

A

U

F

T

'

S

P

E

C

T

E

H

R

O

F

O

I

G

I

N

E

A

G

T

M

P

A

R

U

E

T

E

R

S

E

O

S

H

P

D

S

P

R

I

V

O

D

E

T

H

C

E

U

T

B

S

E

P

A

E

M

R

B

R

G

R

B

PK

H

WH

BL

L

I

T

I

M

OR

D

R

)

S

O

L

(

G

R

E

V

O

C

R

O

T

N

R

E

R

E

S

W

U

S

U

O

P

E

R

O

G

T

Y

O

I

A

R

L

P

R

H

N

T

O

M

O

E

I

F

A

R U O

N

R

E

R

I

D

P

E

C

L

A

M

E

I

W

R

S

P

L

E

U

S

A

P

R

T

E

N

A

I

T

F

O

A

G

J

U

D

E

A

T

S

E

B

D

L

T

I

G

N

R

E

H

C

E

T

A

E

T

N

L

Y

G

R

U

O

D

N

R

M

P

A

O

C

R

S

R

O

D (

O

N

E

W

P

R

O

D

BK

L

GR

RD

YL

GY

OR

BR

B

I

C

H

T

N

I

D

N

I

N

G

A

T

S

T

O

A

T

M

0

7

.

P

A

S

T

N

M

T

U

R

S

T F

I

T

D

I

E

L

H

E

H

W

T

5

1

L

0

E

T

S

A

.

°

C

U

E

L

R

T

S

L

Y

N

A

I

B

D

T

M

P

E

R

A

T

R

U

E R

F

O

N

E

C

O

A

D

N

*MSS96*** & *CSS96***A*

A

R

E

T

E

G

I

U

F

H

I

D

M

T

E

T

N

M

W

I

T

C

H

E

H

N

)

N

E

P

C

24V THERMOSTAT CONNECTIONS N.E.C. CLASS 2 WIRE

BK

G

O

T

Y

R

C

M

I

O

W

R

)

3

(

T

H

-

R

H

X

M

F

INTEGRATED CONTROL MODULE

E

A

I

L

N

H

-

E

R

O

D S

W

I

C

T

H

G

N

I

R

A

W

C

O

N

E

T

C

N

S

P

I

D

F

O

B

R

E

S

E

I

R

V

G

T

N

I

N

O

I

U

W

R

E

B

U

S

M

T

R

L

E

R

O

P

Y

D

Z

E

I

R

O

A

P

L

E

D

N

D

A

G

O

N

R

U

T

O

1

1 E

V

O

U

N

J

T

C

I

O

L

M

L

A

F

S

N

E

S

W

O

L O

L

W

H

I

H

E

G

T

L

P

M

P

A

S

B

U

E

S

U

R

N

A

S

E

C

O

T

O

M

R

S

I

E

O

T

M

N

X

B

O

H

W

R

G

D

N

G

B

K

E O

R

G

V

O

T

E

L

A

(

2

V

R

A G

U

.

E

C P

P

A

T N

A

E

.

N

4

O

L

D

L

E

I

F

E

G

T

A

(

1

)

E

5

1

G

V

T

L

A

O

D

E C D

.

D

L

I

L

E

F

T

E

A

G

N

J

U

I

O

T

C

N

E

R

I

A

T

N

M

I

N

E

R

L

T

O

A

N

E

D

T

W

M

H

C

L

C

O

R

T

N

O

C

N

O

E

C

I

T

H

E

S

V

R

N

C

E

I

G

N

I A

C

B

S

U

E

T

E

R

P

L

D

O

N

C

U

R

T

C

S

R

O

I

T

S

E

N

A

H

T

L

T

L

A

R

E

O

H

C

T

C

A

C

O

L

O

.

D

N

A

I

T

R

(

)

6

N

G

(

)

D

8

M

V

C

(

9

)

N O

M

V

(

2

)

1

V

C

E

F

O

T

O

R

N

E

I

R

S

P

E

S

W

T

R

S

U P P H

H

R

F

S

N

I

G

D

I

N

C

-

H

: O

W N

G

I

C T

D

.

V

5

C

R

W S P

C

S

)

(

0

1

)

4

(

O

S

7

(

L

)

I

O

L

1

(

)

A

I

L

)

1

2

(

O

)

5

1

(

O

M

U

A

N

L

R

L

I

M

O

T

I

T

C

N

(

S

I

N

G

L

C

O

E

2

1

F

L

A

M

E

O

H

T

S

R

U

T

I

N

G

I

D

B

L

W

R

I

U

F

H

I

D

M

C

O

L

C

R

I

C

U

L

B

H

-

T

A

E

H

E

L

E

C

R

T

A

I

L

C

E

R

C

B

T

N

O

N

O

I

U

X

J

R

E

.

G

L

Ø

/

0

H

6

Z

/

C

1

A

R

P

T

N

U

E

R

I

D

O

N

S

G

:

C

N

I

R

A

R

I

C

W

N

G

I

.

R

V

E

O

L

P

Y

L

R

O

R

E

P

E

N

O

I

S

C

D

)

L

.

R

S

U

E

T

E

T

B

M

I

E

D N

O

N

I

O

D

E

P

, L

L S

L

.

Y

E

R

U

Q

T

N

I

E

S

R

M

E

I

N

G

.

F

C

M

.

N

E

R

H

U

X

T

M

I

S

E

O

R N

4

V

5 S

A

F

E

R

I

E

A

L

R

W

O A

N

P

O

N

I

R

A

N

T

O

C

R

L

O

D

G

N

C

I

Y

A

L

R

I

C

O

N

E

T

R

O

L

S

)

(

T

O

L

R

C

A

V

C

A

E

S

N

C

E

R

T

R

O

C

I

N

E

R

D

O

W

C

T

E

N

C

E

G

T

Z

E

I

2

C

G

V

M

1

I

B

D

L

P

E

R

S

I

W O

N

C

U

T

O

A

L

R

S

O

R

I

P

M

I

L C

O

N

L

T

L

U

O

4

K

N

0

O

B

)

T

U

V

A

0

4

A

R

S

T

N

F

R

O

M

E

R

I

D

S

N

O

C

N

E

N

S

U

E

W

R

P

Y

L

P

D

O

E

T

C

N

I

E

I

V

B

R

E

W

O

P

T

D

R

O

E

F

S

M

B

T

U

E

T

I

N

U

G

N

D

E

R

O

U

D

N

A

DEVICE

N

G

N

D

T

C

S

C

A

S

O

L

N

G

M

T

E

N

D

P

I

U

E

Q

I

E

F

D

L

N

G

D

I

C

E

F

D

I

L

P

L

E

S

)

T

C

.

I

S

W

P

H

(

E

M

T

N

T

G

E

R

I

)

S

.

E

R

P

(

W

H

C

I

T

V

C

E

R

O

R

U

E

N

P

E

D

T

R

C

E

V

D

I

.

O

E

T

W

R

I

T

W

I

H

N

T

M

A

E

G

D

E

M

O

L

U

A

S

A

E

L

V

W

E

O

R

S

U

E

R

H

T

C

O

R

E

S

T

A

R

Y

T

R

O

L

INTEGRATED CONTROL MODULE

LINE NEUTRALS

T

C

T

H

I

E

.

D

TO115 VAC / 1Ø / 60HZ

POWER SUPPLY WITH

OVERCURRENT PROTECTION

R

L

A

I

0

1

4

0

F

0

2

0

A

-

6

0

Wiring is subject to change. Always refer to the wiring diagram on the unit for the most up-to-date wiring.

47

SPECIAL INSTRUCTIONS FOR PRODUCTS INSTALLED IN THE STATE OF MASSACHUSETTS

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

1. INST ALLATION OF CARBON MONOXIDE DETECTORS. At the time of installation of the side wall horizontal vented gas fueled equipment, the installing plumber or gasfitter shall observe that a hard wired carbon monoxide detector with an alarm and battery back-up is installed on the floor level where the gas equipment is to be installed. In addition, the installing plumber or gasfitter shall observe that a battery operated or hard wired carbon monoxide detector with

COMBUSTION AIR INTAKE.

DISTANCE BETWEEN

COMBUSTION AIR

INTAKE AND GRADE

an alarm is installed on each additional level of the dwelling, building or structure served by the side wall horizontal vented gas fueled equipment. It shall be the responsibility of the property owner to secure the services of qualified licensed professionals for the installation of hard wired carbon monoxide detectors

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

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

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

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

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

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

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

VENT/FLUE

TEE

DISTANCE BET WE EN

VENT AND GRADE

EXEMPTIONS

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

1. The equipment listed in Chapter 10 entitled “Equipment Not Required To Be Vented” in the most current edition of NFP A 54 as adopted by the Board; and

2. Product Approved side wall horizontally vented gas fueled equipment installed in a room or structure separate from the dwelling, building or structure used in whole or in part for residential purposes.

(c) MANUF ACTURER REQUIREMENTS - GAS EQUIPMENT VENTING SYSTEM PROVIDED. When the manufacturer of P roduct Approved side wall

horizontally vented gas equipment provides a venting system design or venting system components with the equipment, the instructions provided by the manufacturer for installation of the equipment and the venting system shall include:

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

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

(d) MANUF ACTURER REQUIREMENTS - GAS EQUIPMENT VENTING SYSTEM NOT PROVIDED. When the manufacturer of a Product Approved side

wall horizontally vented gas fueled equipment does not provide the parts for venting the flue gases, but identifies “special venting systems”, the following requirements shall be satisfied by the manufacturer:

5. The referenced “special venting system” instructions shall be included with the appliance or equipment installation instructions; and

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

(e) A copy of all installation instructions for all P roduct Approved side wall horizontally vented gas fueled equipment, all venting instructions,

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

NOTE: SPECIFICATIONS AND PERFORMANCE DATA LISTED HEREIN ARE SUBJECT TO CHANGE WITHOUT NOTICE.

5151 San Felipe Suite 500

Houston, TX 77056

www.goodmanmfg.com • www.amana-hac.com

48

Goodman CSS961205DN, CSS960402BN, CSS960804CN, CSS960603BN, *MSS961205DN Installation Instructions Manual

Specifications and Main Features

Frequently Asked Questions

User Manual