Goodman VC8, DVC80603B, DVC80805C, DVC81005C, MVC80604B Installation Instructions Manual

I

NST ALLATION

I

NSTRUCTIONS

(CA TEGORY I )

Installer: Affix all manuals adjacent to the unit.

These furnaces comply with requirements em­bodied in the American National S tandard / Na­tional Standard of Canada ANSI Z21.47·CSA-

2.3 Gas Fired Central Furnaces.

RECOGNIZE THIS SYMBOL AS A SAFETY PRECAUTION.

FOR

*(D, M)VC8 G

AS

F

URNACE

ATTENTION INSTALLING PERSONNEL

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 inst all 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.

NOTE: Please contact your distributor or our website listed below

for the applicable Specification Sheet referred to in this manual.

WARN ING

G

OODMANWILLNOTBERESPO NSIBLEFORANYINJURYORPROPERTY

DAMAGEARISINGFROMIMPROPERSERVICEORSERVICEPROCEDURES

FYOUINSTALLORPERFORMSERVICEONTHISUNIT,YOUASSUME

I

RESPO NSIBILITYFORANYPERSONALINJURYORPROPERTYDAMAGE

WHICHMAYRESULT

INSTALLORSERVICEHEATINGANDAIRCONDITIONINGEQUIPMENT

.M

ANYJURISDICTIONSREQUIREALICENSETO


.







.

IO-418C
5/2012

5151 San Felipe Suite 500 • Houston, TX 77056

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

© 2011 - 2012 Goodman Manufacturing Company, L.P.

Table of Contents

ADDITIONAL SAFETY CONSIDERATIONS ................................................................................................................... 5

S

HIPPING INSPECTION ......................................................................................................................................... 5

ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS .................................................................................................. 5

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

IMPORTANT NOTE TO THE OWNER REGARDING PRODUCT WARRANTY............................................................................ 5

P

RODUCT DESCRIPTION .............................................................................................................................................. 6

EATURES ........................................................................................................................................................ 6

F

P

RODUCT APPLICATION ............................................................................................................................................... 6

L

OCATION REQUIREMENTS AND CONSIDERATIONS ............................................................................................................ 7

LEARANCES AND ACCESSIBILITY .......................................................................................................................... 8

C

INST ALLATION POSITIONS ..................................................................................................................................... 8

HORIZONTAL INSTALLATION (*MVC8 MODELS ONLY)............................................................................................... 8

FURNACE SUSPENSION ....................................................................................................................................... 9

EXISTING FURNACE REMOVAL .............................................................................................................................. 9

THERMOST AT LOCA TION....................................................................................................................................... 9

C

OMBUSTION AND VENTILATION AIR REQUIREMENTS ....................................................................................................... 10

E

XTERIOR MASONRY CHIMNEYS .................................................................................................................................11

(C

ATEGORY I FURNACES ONLY) .................................................................................................................................11

HECKLIST SUMMARY .......................................................................................................................................11

C

CHECK 1 - PROPER CHIMNEY TERMINATION.......................................................................................................... 12

CHECK 2 - ANY SOLID OR LIQUID FUEL APPLIANCES VENTED INTO THIS CHIMNEY CHANNEL .......................................... 12

CHECK 3 - CHIMNEY CROWN CONDITION............................................................................................................. 13

CHECK 4 - DEBRIS IN CLEANOUT. ...................................................................................................................... 13

CHECK 5 - LINER CONDITION. ........................................................................................................................... 13

CHECK 6 - DILUTION AIR. ................................................................................................................................. 13

CHECK 7 - COMPLETE THE INSTALLATION. ............................................................................................................ 13

FIX 1 - LINER TERMINATION .............................................................................................................................. 14

FIX 2 -CHANGE VENTING ARRANGEMENTS ............................................................................................................ 14

FIX 3 - REBUILD THE CROWN ............................................................................................................................ 14

FIX 4 - RELINING ............................................................................................................................................ 14

E

LECTRICAL CONNECTIONS ....................................................................................................................................... 15

IRING HARNESS............................................................................................................................................ 15

W

115 VOLT LINE CONNECTIONS ........................................................................................................................... 15

JUNCTION BOX RELOCATION .............................................................................................................................. 16

24 VOLT THERMOSTAT WIRING ........................................................................................................................... 16

SINGLE-ST AGE HEATING THERMOST AT APPLICATION ............................................................................................... 17

24 VOLT DEHUMIDISTAT WIRING ......................................................................................................................... 17

FOSSIL FUEL APPLICA TIONS............................................................................................................................... 18

115 VOLT LINE CONNECTION OF ACCESSORIES (HUMIDIFIER AND ELECTRONIC AIR CLEANER) ...................................... 18

24 VOLT HUMIDIFIER ........................................................................................................................................ 19

G

AS SUPPLY AND PIPING......................................................................................................................................... 19

IGH ALTITUDE DERA TE..................................................................................................................................... 19

H

PROPANE GAS CONVERSION ............................................................................................................................. 19

GAS PIPING CONNECTIONS ............................................................................................................................... 19

UPFLOW INSTALLATIONS .................................................................................................................................... 20

COUNTERFLOW INSTALLA TIONS ............................................................................................................................ 21

GAS PIPING CHECKS ....................................................................................................................................... 21

PROPANE GAS TANKS AND PIPING ..................................................................................................................... 21

C

IRCULATING AIR AND FILTERS ................................................................................................................................... 22

HECKING DUCT STATIC .................................................................................................................................... 22

C

FILTERS - READ THIS SECTION BEFORE INSTALLING THE RETURN AIR DUCTWORK ...................................................... 23

UPRIGHT INSTALLATIONS .................................................................................................................................... 23

CIRCULA TION AIR FILTERS .................................................................................................................................. 23

HORIZONTAL INSTALLA TIONS ............................................................................................................................... 23

2

Table of Contents

ST ART-UP PROCEDURE AND ADJUSTMENT ..................................................................................................................... 23

EAT ANTICIPAT OR SETTING ................................................................................................................................23

H

FURNACE OPERA TION ....................................................................................................................................... 23

AS SUPPLY PRESSURE MEASUREMENT ............................................................................................................. 24

G
G

AS MANIFOLD PRESSURE MEASUREMENT AND ADJUSTMENT .................................................................................. 25

GAS INPUT RATE MEASUREMENT (NATURAL GAS ONLY) ........................................................................................ 26

TEMPERATURE RISE ........................................................................................................................................ 26

CIRCULATOR BLOWER SPEEDS .......................................................................................................................... 26

LOWER HEAT OFF DELAY TIMINGS .................................................................................................................. 29

B

C

OMFORTNET™ SYSTEM ........................................................................................................................................ 29

VERVIEW ..................................................................................................................................................... 29

O

FOSSIL FUEL APPLICATIONS............................................................................................................................... 30

CTK0* WIRING ............................................................................................................................................. 30

COMFORTNET™ SYSTEM ADVANCED FEATURES .................................................................................................... 31

NETWORK TROUBLESHOOTING ............................................................................................................................. 33

SYSTEM TROUBLESHOOTING .............................................................................................................................. 33

N

ORMAL SEQUENCE OF OPERATION ........................................................................................................................... 34

OWER UP .................................................................................................................................................... 34

P

HEATING MODE ............................................................................................................................................... 34

COOLING MODE.............................................................................................................................................. 35

FAN ONLY MODE ............................................................................................................................................ 35

O

PERATIONAL CHECKS ............................................................................................................................................ 35

S

AFETY CIRCUIT DESCRIPTION ................................................................................................................................... 36

NTEGRATED CONTROL MODULE .......................................................................................................................... 36

I

PRIMARY LIMIT ............................................................................................................................................... 36

AUXILIARY LIMIT .............................................................................................................................................. 36

ROLLOUT LIMIT ............................................................................................................................................... 36

PRESSURE SWITCHES ....................................................................................................................................... 36

FLAME SENSOR .............................................................................................................................................. 36

T

ROUBLESHOOTING ................................................................................................................................................. 36

LECTROSTATIC DISCHARGE (ESD) PRECAUTIONS ................................................................................................ 36

E

DIAGNOSTIC CHART ......................................................................................................................................... 36

FAUL T RECALL ................................................................................................................................................ 37

RESETTING FROM LOCKOUT .............................................................................................................................. 37

M

AINTENANCE ........................................................................................................................................................ 37

NNUAL INSPECTION ......................................................................................................................................... 37

A

FIL TERS ......................................................................................................................................................... 37

BURNERS ....................................................................................................................................................... 38

INDUCED DRAFT AND CIRCULATOR BLOWERS ......................................................................................................... 38

FLAME SENSOR (QUALIFIED SERVICER ONLY) ..................................................................................................... 38

FLUE PASSAGES (QUALIFIED SERVICER ONL Y) .................................................................................................... 38

B

EFORE LEAVING AN INSTALLATION............................................................................................................................. 38

R

EPAIR AND REPLACEMENT PARTS ............................................................................................................................ 38

ROUBLESHOOTING CHART ....................................................................................................................................... 39

T

TATUS CODES ....................................................................................................................................................... 44

S

IR FLOW DATA ...................................................................................................................................................... 45

A

DIP SWITCHES ....................................................................................................................................................... 45

*MVC8, *DVC8 WIRING DIAGRAM .......................................................................................................................... 46

3

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.

WARNING

TO

PREVENTPERSONALINJURYORDEATHDUETOIMPROPER

INSTALLATION,ADJUSTMENT,ALTERATION,SERVICEORMAINTENANCE

REFERTOTHISMANUAL

INFORMATION,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RESULTCAUSINGPROPERTY
DAMAGE

,

PERSONALINJURYORLOSSOFLIFE

DO

NOTSTOREORUSEGASO LINE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CONTAINSORPRODUCESACHEMICALORCHEMICALS
WHICHMAYCAUSESERIOUSILLNESSORDEATHANDWHICHARE
KNOWNTOTHESTATEOFCALIFORNIATOCAUSECANCER,BIRTH
DEFECTSOROTHERREPRODUCTIVEHARM

.



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,

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

CARBON MONOX IDE POI SONING HAZARD

Spec ial Warning f o r In s ta llation of F ur nace or Air Han dl i n g Units in
Enclosed Areas such as Garages, Utility Rooms or Parking Areas

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

This ventilation is necessary to avoid the danger of CO poisoning which
can occur if a carbon monoxide producing device continues to operate in
the enclosed area. Car bon monoxide emissio ns can be (re)circulated
through out the stru cture if the furnace or air handler is operating in any
mode.

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

B10259-216

-

WARNING

S

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

.

,



WARNING

WARNING

H

EATINGUNITSHOULDNOTBEUTILIZEDWITHOUTREASONABLE

ROUTINE,INSPECTION,MAINTENANCEANDSUPERVISION

BUILDINGINWHICHANYSUCHDEVICEISLOCATEDWILLBEVACANT

CARESHOULDBETAKENTHATSUCHDEVICEISROUTINELYINSPECTED

MAINTAINEDANDMONITORED.INTHEEVENTTHATTHEBUILDING

MAYBEEXPOSEDTOFREEZINGTEMPERATURESANDWILLBEVACANT

ALLWATER‐BEARINGPIPESSHOULDBEDRAINED,THEBUILDINGSHOULD

BEPROPERLYWINTERIZED,ANDTHEWATERSOURCECLOSED.INTHE

EVENTTHATTHEBUILDINGMAYBEEXPOSEDTOFREEZING

TEMPERATURESANDWILLBEVACANT,ANYHYDRONICCOILUNITS

SHOULDBEDRAINEDASWELLAND,INSUCHCASE,ALTERNATIVEHEAT

SOURCESSHOULDBEUTILIZED

.

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

P

.IF

THE

OSSIBLEPROPERTYDAMAGE,PERSONALINJURYORDEATHDUETO

FIRE,EXPLOSION,SMOKE,SOOT,CONDENSATION,ELECTRICALSHOCK

,



ORCARBO NMONOXIDEMAYRESULTFROMIMPROPERINSTALLATION

REPAIROPERATION,ORMAINTENANCEOFTHISPRODUCT

.





,

,

,



,





TO

PREVENTPERSONALINJURYORDEATHDUETOIMPROPER

INSTALLATION,ADJUSTMENT,ALTERATION,SERVICEORMAINTENANCE



REFERTOTHISMANUAL

INFORMATION,CONSULTAQUALIFIEDINSTALLER,SERVICERAGENCYOR

THEGASSUPPLIER

.

WARNING

.FOR

ADDITIONALASSISTANCEOR



,









WARNING

T

HISUNITMUSTNOTBEUSEDASA“CONSTRUCTIONHEATER”DURING

THEFINISHINGPHASESOFCONSTRUCTIONONANEWSTRUCTURE



.

TYPEOFUSEMAYRESU LTINPREMATUREFAILUREOFTHEUNITDUETO

EXTREMELYLOWRETU RNAIRTEMPERATURESANDEXPOSURETO



CORROSIVEORVERYDIRTYATMOSPHERES

.



.T

HIS







4

WARN ING

TO

PREVENTPERSONALINJURYORDEATHDUETOASPHYXIATION,THIS

FURNACEMUSTBECATEGORY

ATEGORY

C
P

ROVISIONSMUSTBEMADEFORVENTINGCOMBUSTIONPRODUCTS

OUTDOORSTHROUGHAPROPERVENTINGSYSTEM

FLUEPIPECOULDBEALIMITINGFACTORINLOCATINGTHEFURNACE

III

VENTING

I

VENTED

.DO

NOTVENTUSING

.

.THE

LENGTHOF









.

ADDITIONAL SAFETY CONSIDERATIONS

• This furnace is approved for Category I Venting only .

• Provisions must be made for venting combustion
products outdoors through a proper venting system.
The length of flue pipe could be a limiting factor in
locating the furnace.

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 made in writing immediately .

This procedure is applicable to both installed and non-installed
(ungrounded) furnaces.

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

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

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

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

TO THE INSTALLER

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.

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 .

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.

Keep this literature in a safe place for future reference.

ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS

NOTE: Discharge body’s static electricity before touching unit.

An electrostatic discharge can adversely affect electrical com­ponents.

Use the following precautions during furnace installation and
servicing to protect the integrated control module from dam­age. By putting the furnace, the control, and the person at the
same electrostatic potential, these steps will help avoid expos­ing the integrated control module to electrostatic discharge.

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, and motor speed connections, and venting.
These furnaces are designed for Category I venting only.

IMPORTANT NOTE TO THE OWNER REGARDING PRODUCT
WARRANTY

Your warranty certificate is supplied as a separate document
with the unit installed by your contractor. Read the limited war­ranty certificate carefully to determine what is and is not cov­ered and keep the warranty certificate in a safe place. If you are
unable to locate the warranty certificate please contact your
installing contractor or contact customer service (877-254-4729)
to obtain a copy.

IMPORT ANT: T o receive the Lifetime Heat Exchanger Limited
Warranty (good for as long as you own your home) and the 10­year Parts Limited Warranty, online registration must be com­pleted within 60 days of installation. Online registration is not
required in California or Quebec. Complete warranty details
available from your local dealer or, for Goodman® brand prod­ucts, visit www.goodmanmfg.com, and for Amana® brand prod­ucts, visit www.amana-hac.com.

To register your Goodman® brand unit, go to
www.goodmanmfg.com and click “Warranty Registration”. Com­plete the registration as prompted.

T o register your Amana® brand unit, go to www.amana-hac.com
and click on “Warranty Registration”. Complete the registra­tion as prompted.

5

Product limited warranty certificates for models currently in pro­duction can be viewed at www.goodmanmfg.com or www.amana­hac.com. If your model is not currently in production or does
not appear on the website, please contact your installing con­tractor or contact customer service at (877-254-4729) to obtain
a copy of your warranty certificate.

Each product overview page contains a Product Warranty link;
by clicking on it you will be able to view the limited warranty
coverage for that specific product. T o view warranty registration
information, click on the Product Warranty text on the left navi­gation panel on the home page of each website. The Online
Product Registration pages are located in this same section.

WARNING

TO

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

P

RODUCT DESCRIPTION

.





FEATURES

This furnace is a part of the ComfortNet™ family of products.
The CTK0* ComfortNet thermostat kit allows this furnace to be
installed as part of a digitally communicating system. The
ComfortNet system provides automatic airflow configuration,
enhanced setup features, and enhanced diagnostics. It also
reduces the number of thermostat wires to a maximum of four.
It may be also installed as part of a “legacy” system using a
standard 24 V AC thermostat.

This product may also be installed with the ComfortNet ther­mostat and a non-ComfortNet compatible single stage air con­ditioning unit. However, this reduces the benefits of the
ComfortNet system as the enhancements will only apply to the
furnace.

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.

• All other warranty exclusions and restrictions apply .

This furnace may be used as a construction site heater ONLY
if 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.

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

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

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

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

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

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

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

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

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

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

• A T -handle gas cock must be used.

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

WARNING

TO

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

.





6

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 (NFP A 54/ANSI Z223.1)
can be obtained from any of the following:

American National Standards Institute

1430 Broadway

New York, NY 10018

National Fire Protection Association

1 Batterymarch Park

Quincy , MA 02269

L

OCA TION REQUIREMENTS AND CONSIDERA TIONS

Y our unit model type determines which installation procedures
must be used. For *MVC8 models, you must follow instruc­tions for Horizontal Left, Horizontal Right or Upflow installa­tions only . These furnaces are not approved for Downflow in­stallations.
Downflow models *DVC8 ARE NOT APPROVED FOR HORI-
ZONT AL OR UPFLOW INST ALLA TIONS. For these models,
use only the instructions for downflow installation only .

WARNING

TO

PREVENTPOSSIBLEEQUIPMENTDAMAGE,PROPERTYDAMAGE

PERSONALINJURYORDEATH,THEFOLLOWINGBULLETPOINTSMUSTBE

OBSERVEDWHENINSTALLINGTHISUNIT

.

,



CSA International

8501 East Pleasant V alley

Cleveland, OH 44131

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

CSA International

178 Rexdale Boulevard

Etobicoke, Ontario, Canada M9W 1R3

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.

In the USA, this furnace MUST be installed in accordance with
the latest edition of the ANSI Z223.1 booklet entitled “National
Fuel Gas Code” (NFP A 54), and the requirement s or codes of
the local utility or other authority having jurisdiction. In Canada,
this furnace must be installed in accordance with the current
CAN/CGA-B149.1 & 2 Gas Installation Codes, local plumbing
or waste water codes and other applicable codes. Additional
helpful publications available from the NFP A are, NFPA 90A ­Installation of Air Conditioning and Ventilating System and NFP A
90B - Warm Air Heating and Air Conditioning System.

All venting shall be in accordance with P ART 7, V enting of Equip­ment, of the National Fuel Gas Code, ANSI Z223.1, or appli­cable local building and/or air conditioning codes. These pub­lications are available from:

National Fire Protection Association, Inc.

1 Batterymarch Park, Quincy , MA 02269

Follow the instructions listed below when selecting a furnace
location. Refer also to the guidelines provided in Section V,

Combustion and Ventilation Air Requirements.

• 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.

• Provisions must be made for venting combustion
products outdoors through a proper venting system.
The length of flue pipe could be a limiting factor in
locating the furnace.

• 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 section.

• The furnace must be level. If the furnace is to be set
on a floor that may become wet or damp at times, the
furnace should be supported above the floor on a
concrete base sized approximately 1-1/2" larger than
the base of the furnace.

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

NOTE: Furnaces with NOx screens meet the California NOx
emission standards and California seasonal efficiency stan­dards. ANNUAL inspections of the furnace and its vent system
is strongly recommended.

7

V

• 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:

chlorinated waxes or cleaners

chlorine-based swimming pool chemicals

water softening chemicals
deicing salts or chemicals

carbon tetrachloride

halogen type refrigerants

cleaning solutions (such as perchloroethylene)

printing inks

paint removers

varnishes

hydrochloric acid

cements and glues

antistatic fabric softeners for clothes dryers

and masonry acid washing materials

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

• 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, the furnace
access doors must be vertical so that the burners fire
horizontally into the heat exchanger. Do not install
the unit with the access doors 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.

• For counterflow installations, the air conditioning coil
must be downstream from the heat exchanger of the
furnace.

• 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 silicon 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 to your model for details).
A special accessory subbase must be used for upright
counterflow unit installations over any combustible
material including wood. Follow the instructions with
the subbase for proper installations. 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.

ent Pipe Clearance to Combu stibles­6" using Single Wall Connector or 1"
using B-1 vent.

Top - 1"

Back - 0"

Side
Clearance - 1"

Front Clearance - 3"

• Adequate combustion/ventilation air must be supplied
to the closet.

• Furnace must be completely sealed to floor or base.
Combustion/ ventilation air supply pipes must
terminate 12" from top of closet and 12" from floor of
closet. DO NOT remove solid base plate for side
return.

• Return air ducts must be completely sealed to the
furnace and terminate outside the enclosure surfaces.

CLEARANCES AND ACCESSIBILITY

Unobstructed front clearance of 24" for servicing is recom-
mended.

VENT

B1-VENT SINGLE

1" 6" 1" 3" 0" 1"

Top clearance for horizontal configuration - 1"

SIDES FRONT BACK

TOP

(PLENUM)

INSTALLATION POSITIONS

An upflow 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 vertically installed upflow furnaces,
return air ductwork may be attached to the side panel(s) and/
or basepan. For horizontally installed upflow furnaces, return
air ductwork must be attached to the basepan. For counterflow
furnaces, return ductwork must be attached to the top end of
the blower compartment.

NOTE: Ductwork must never be attached to the back of the
furnace.

HORIZONTAL INSTALLATION (*MVC8 MODELS ONLY)

Line contact to framing is permitted when installed in the hori­zontal configuration. Line contact is defined as the portion of
the cabinet that is formed by the intersection of the top and
side. ACCESSIBILITY CLEARANCE, WHERE GREATER,
SHOULD T AKE PRECEDENCE OVER MINIMUM FIRE PRO­TECTION CLEARANCE. A gas-fired furnace for installation in

8

a residential garage must be installed so that the ignition source
and burners are located not less than eighteen inches (18")
above the floor and is protected or located to prevent physical
damage by vehicles. A gas furnace must not be installed di­rectly on carpeting, tile, or other combustible materials other
than wood flooring.

FURNACE SUSPENSION

If suspending the furnace from rafters or joist, use 3/8" threaded
rod and 2”x2”x3/8” angle iron as shown below. The length of
rod will depend on the application and the clearances neces­sary.

Suspended Furnace

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-Latest Edi­tion, 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:

a. Seal any unused openings in the venting system;
b. Inspect the venting system for proper size and

horizontal pitch, as required by the National Fuel Gas
Code, ANSI Z223.1 or the CAN/CSA B149 Installation
Codes and these instructions. Determine that there is
no blockage or restriction, leakage, corrosion and other
deficiencies which could cause an unsafe condition;

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

d. Follow the lighting instructions. Place the appliance

being inspected in operation. Adjust thermostat so
appliance shall operate continuously;

e. T est for draft hood equipped appliance spillage at the

draft hood relief opening after 5 minutes of main burner
operation. Use the flame of a match or candle;

f. 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;

g. If improper venting is observed during any of the above

tests, the common venting system must be corrected.

Corrections must be in accordance with the latest edition of
the National Fuel Gas Code NFP A 54/ANSI Z223.1 and/or CAN/
CSA B149 Installation Codes.

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 CAN/CSA B149
Installation Codes.

THERMOSTAT LOCATION

In an area having good air circulation, locate the thermostat
about five feet high on a vibration-free inside wall. 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.

HOT
COLD

Thermostat Influences

Consult the instructions packaged with the thermostat for mount­ing instructions and further precautions.

9

C

OMBUSTION AND VENTILA TION AIR REQUIREMENTS

WARN ING

TO

AVOIDPROPERTYDAMAGE,PERSONALINJURYORDEATH

SUFFICIENTFRESHAIRFORPROPERCOMBUSTIONANDVENTILATIONOF

FLUEGASESMUSTBESUPPLIED

SUPPLIEDINTOTHEFURNACEAREA

.M

OSTHOMESREQUIREOUTSID EAIRBE

.

,





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

NOTE: The vertical height of the Category I venting system
must be at least as great as the horizontal length of the venting
system.

WARNING

TO

PREVENTPOSSIBLEPERSONALINJURYORDEATHDUETO

ASPHYXIATION,COMMONVENTINGWITHOTHERMANUFACTURER’S

INDUCEDDRAFTAPPLIANCESISNOTALLOWED

.





The minimum vent diameter for the Category I venting system
is as shown:

MINIMUM VENT

MODEL

UPFLOW COUNTERFLOW

06 0 4 in c h 4 inc h
08 0 4 in c h 4 inc h
10 0 5 in c h 4 inc h

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 B149 Installation
Codes or applicable provisions of the local building codes for
determining the combustion air requirements for the appliances.

This furnace must use indoor air for combustion. It cannot be
installed as a direct vent (i.e., sealed combustion) furnace.

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.

CATEGORY I VENTING (VERTICAL VENTING)

WARN ING

TO

PREVENTPOSSIBLEPERSONALINJURYORDEATHDUETO

ASPHYXIATION,THISFURNACEMUSTBECATEGORY

VENTUSINGCATEGORY

III

VENTING

.

Category I Venting is venting at a non-positive pressure. A
furnace vented as Category I is considered a fan-assisted ap­pliance and the vent system does not have to be “gas tight.”
NOTE: Single stage gas furnaces with induced draft blowers
draw products of combustion through a heat exchanger allow­ing, in some instances, common venting with natural draft ap­pliances (i.e. water heaters). All inst allations must be vented in
accordance with National Fuel Gas Code NFP A 54/ANSI Z223.1

- latest edition. In Canada, the furnaces must be vented in ac­cordance with the National Standard of Canada, CAN/CSA
B149.1 and CAN/CSA B149.2 - latest editions and amendments.

I

VENTED



.DO

NOT



Under some conditions, larger vents than those shown above
may be required or allowed. When an existing furnace is re-
moved from a venting system serving other appliances, the
venting system may be too large to properly vent the remaining
attached appliances.

Upflow or Horizontal units are shipped with the induced draft
blower discharging from the top of the furnace. (“Top” is as
viewed for an upflow installation.) The induced draft blower can
be rotated 90 degrees for Category I venting. For horizontal
installations, a four inch single wall pipe can be used to extend
the induced draft blower outlet 1/2” beyond the furnace cabinet.

THIS PRODUCT IS NOT DESIGNED FOR COUNTERCLOCK­WISE INDUCED DRAFT BLOWER ROT A TION.

Vent the furnace in accordance with the National Fuel Gas
Code NFP A 54/ANSI Z223.1 - latest edition. In Canada, vent
the furnace in accordance with the National Standard of Canada,
CAN/CSA B149.1 and CAN/CSA B149.2 - latest editions and
amendments.

Venting

THIS FURNACE IS NOT DESIGN CERTIFIED TO BE HORI­ZONT ALL Y VENTED.

To rotate the induced draft blower clockwise, you will need to
purchase one (0270F01 1 19) chimney transition bottom kit.

1. Disconnect electrical power from the furnace.

2. Disconnect the induced draft blower power leads, flue
pipe, and pressure switch tubing.

3. Remove the round cutout from the right side of the wrapper.

4. Remove and save the four screws that fasten the induced
draft blower to the flue collector box.

5. Remove and save the three screws that hold the chimney
assembly to the induced draft blower .

6. Remove and save the four screws that fasten the chimney
top to the chimney bottom.

7. Remove the chimney transition bottom from the transition
bottom kit.

10

8. Install the chimney top with the four screws retained
from step 6 onto the new chimney transition bottom from
the transition bottom kit.

9. Install chimney assembly with the three screws retained
from step 5 onto the induced draft blower .

10.Reinstall the induced draft blower rotating it 90 degrees
clockwise from the original upflow configuration using
the four screws retained in step 3. Ensure the gasket
located between the induced draft blower and the collector
box is rotated accordingly .

1 1. Reconnect the induced draft blower power leads. NOTE:

If the wires are not long enough, pull extra wire from the
wire bundle in the blower compartment.

12. Reconnect the flue pipe, and the pressure switch tubing.
Ensure that all wires and the pressure switch tubing is
at least one inch from the flue pipe, or any other hot
surface.

13.Restore power to furnace.

Counterflow units are shipped with the induced draft blower
discharging from the top of the furnace. (“T op” as viewed for a
counterflow installation.)

Vent the furnace in accordance with the National Fuel Gas
Code NFP A54/ANSI Z223.1-latest edition. In Canada, vent the
furnace in accordance with the national standard of Canada,
CAN/CSA B149.1 and CAN/CSA B149.2- latest editions and
amendments.

WARNING

P

OSSIBILITYOFPROPERT YDAMAGE,PERSONALINJURYORDEATH

DAMAGINGCONDENSATIONCANOCCURINSIDEMASONRYCHIMNEYS

WHENASINGLEFAN‐ASSISTEDCATEGORY

FURNACE)ISVENTEDWITHOUTADEQUATEDILUTIONAIR

CONNECTAN

FURNACEISCOMMONVENTEDWITHADRAFTHOODEQUIPPED

APPLIANCEORTHECHIMNEYISLINEDWITHAMETALLINERORTYPE

METALVENT

SIZEDINACCORDANCEWITHTHEAPPROPRIATEVENTINGTABLES

80%

APPLIANCE,THEPOTENTIALFORCONDENSATIONDAMAGEMAYSTILL

EXISTWITHEXTREMELYCOLDCONDITIONS,LONGVENTCONNECTORS

EXTERIORCHIMNEYS,ORANYCOMBINATIONOFTHESECONDITIONS

HERISKOFCONDENSATIONDAMAGEISBESTAVOIDEDBYUSING

T

MASONRYCHIMNEYASAPATHWAYFORPROPERLYSIZEDMETALLINER

ORTYPE

80%

FURNACETOAMASONRYCHIMNEYUNLESSTHE

.ALL

INSTALLATIONSUSINGMASONRYCHIMNEYSMUSTBE

FURNACEISCOMMONVENTEDWITHADRAFTHOODEQUIPPED

B

METALVENT

.

Clay Tile Size: 8" x 8" x12"

I

APPLIANCE

Wash

(Each x 24" Length)

1/2" to 1" Air Space

(80%AFUE

.DO

Roof Line

Attic Floor

NOT



.IFAN







B

.










,



WARN ING

N

EVERALLOWTHEPRODUCTSOFCOMBUSTION,INCLUDINGCARBO N

MONOXIDE,TOENTERTHERETURNDUCTWORKORCIRCULATIONAIR

SUPPLY

.

E

XTERIOR MASONRY CHIMNEYS

(C

ATEGORY

I F

URNACES ONLY

)





An exterior masonry chimney is defined as a “Masonry” chim­ney exposed to the outdoors on one or more sides below the
roof line.” The ability to use a clay lined masonry chimney
depends on a parameter not associated with interior chimneys.
This variable is the geographic location of the installation. Re­searchers have discovered that the winter design temperatures
have a direct impact on the suitability of this type of venting. In
most situations, the existing masonry chimneys will require a
properly sized metallic liner.

Second Floor

Throat

Damper

Breech

Fan Assisted

Clean Out

Typical Multiple Flue Clay Tile Chimney

Forced Air
Furnace

F.A .F. Ven t
Connector

First Floor

Water Heater
Vent Connector

Natural Draft
Wate r Heate r

Basement Floor

CHECKLIST SUMMARY

This checklist serves as a summary of the items to be checked
before venting an 80+ furnace into a masonry chimney . In addi­tion, we recommend that a qualified serviceman use this check­list to perform a yearly inspection of the furnace venting sys­tem.

This checklist is only a summary . For det ailed information on
each of the procedures mentioned, see the paragraph refer­enced with each item.

This inspection is based upon a draft topical report, “Masonry
Chimney Inspection and Relining”, issued by the Gas Research
Institute. While not yet finalized, we believe this report repre­sents the best information on this subject which is currently
available.

11

Proper Chimney

Termination?

(Check 1)

If the chimney does not meet these termination requirements,
but all other requirements in the checklist can be met, it may
be possible for a mason to extend the chimney . If this will not
be practical, see Fix 1.

10' or Less

Chimney channel

free of solid and

liquid fuel

appliances?

(Check 2)

Crown in good

condition

(Check 3)

Cleanout free of

debris?

(Check 4)

Liner in good

condition?

(Check 5)

Change venting

arrangements

(Fix 2)

Rebuild crown

(Fix 3)

and/or Reline

(Fix 4)

Reline
(Fix 4)

Reline
(Fix 4)

2' Min.

Termination 10 Feet Or Less From Ridge, Wall or Parapet

2' Min.

Wall or
Parapet

Chimney

10' or Less

2' Min.

Chimney

More than 10’

3' Min.

3' Min.

3’ Min.

Dilution air

available?
(Check 6)

Reline
(Fix 4)

Complete the

installation.

(Check 7)

CHECK 1 - PROPER CHIMNEY TERMINATION.

A masonry chimney used as a vent for gas fired equipment
must extend at least three feet above the highest point where it
passes through the roof. It must extend at least two feet higher
than any portion of a building within a horizontal distance of 10
feet. In addition, the chimney must terminate at least 3 feet
above any forced air inlet located within 10 feet. The chimney
must extend at least five feet above the highest connected equip­ment draft hood outlet or flue collar.

NOTE:

No Height

above parapet

Wall or
Parapet

Ridge

Termination More Than 10 Feet From Ridge, Wall or Parapet

required when distance
from walls o r parapet is
more than 10 feet.

More than 10’

Chimney

10’

2” Min.

Chimney

Height above any
roof surface within
10 feet horizontally.

3’ Min.

CHECK 2 - ANY SOLID OR LIQUID FUEL APPLIANCES VENTED

THIS CHIMNEY CHANNEL

INTO

Solid fuel appliances include fireplaces, wood stoves, coal fur­naces, and incinerators.

12

Liquid fuel appliances include oil furnaces, oil-fired boilers and
oil-fired water heaters.

Appliances which burn propane (sometimes referred to as LP
(liquefied petroleum)) gas are considered gas-fired appliances.

CHECK 3 - CHIMNEY CROWN CONDITION.

Damage from condensate usually shows up first in the crown.
If any of the following trouble signs are present, the condition of
the crown is not satisfactory:

a) Crown leaning
b) Bricks missing
c) Mortar missing
d) Tile liner cracked
e) No tile liner
f ) Salt staining at mortar joints. (White stains, and mortar

becomes sandy and/or erodes.)

For problems a, b, or c, see Fix 3. If problems d, e, or f are
present, see Fix 4. IMPORT ANT : It may be necessary to follow
both Fix 3 and Fix 4.

CHECK 4 - DEBRIS IN CLEANOUT.

A cleanout (dropleg) must be present such that the upper edge
of the cleanout cover is at least 12 inches below the lower edge
of the lowest chimney inlet opening.

A chimney without a cleanout could become partially blocked
by debris. If no cleanout is present, the chimney must be re­lined (Fix 4). Remove the cleanout cover, and examine the
cleanout for debris. If significant amounts of any of the following
are found:

• Fuel oil residue

• Bricks

• Mortar or sand

• Pieces of the tile liner

• Rusted pieces of the metallic liner - reline the chimney
(Fix 4).

CHECK 5 - LINER CONDITION.

If a metal liner is present, it must be checked. It cannot be
assumed that all existing metal liners are correctly installed
and in good condition.

Remove the lowest existing vent connector, and examine the
inside of the elbow or tee at the base of the liner. A small amount
of soot may be considered acceptable, provided the installer
vacuums it away. If rusted pieces of the liner have collected
here, the metal liner must be removed and replaced (Fix 4).

Next, gently tap the inside of the liner with a Phillips screw­driver. If the screwdriver perforates the liner, or if the tapping
does not sound like metal hitting metal, the liner must be re­moved and replaced (Fix 4).

Remember that all appliances must be vented inside the liner.
Venting one appliance inside the liner and another appliance
outside the liner is not acceptable.

Next, use a flashlight and small mirror to sight up the liner. B
vent must be supported so as to not come into direct contact
with the chimney walls or tile liner. If it is not, it can probably be
rehung so as to be acceptable. A thimble or fire stop may be
helpful here.

Flexible liners should be hung straight or nearly straight. If it is
spiraled in the chimney and in good condition, it should be
rehung. To do this, break the top seal; pull up and cut off the
excess liner length, and refit the top seal. Use caution when
doing this, as the cut edges of flexible liners may be sharp.

The surfaces of the liner must be physically sound. If gaps or
holes are present, the metal liner must be removed and re­placed (Fix 4). Finally , confirm that the metal liner is the cor­rect size for the appliances to be installed. Use the GAMA
tables and rules.

If a metal liner is not present, a clay tile liner must be present,
or the chimney must be lined (Fix 4).

Use a flashlight and small mirror at the cleanout or vent con­nector to inspect the clay tile liner. If any of the following prob­lems are present:

• Tile sections misaligned

• Tile sections missing

• Gaps between tile sections

• Signs of condensate drainage at the cleanout or vent
connectors

• Mortar protruding from between tile sections

• Use of sewer pipe or drainage pipe rather than an
approved fire clay tile reline the chimney (Fix 4).

Next, measure the size of the liner. It may be possible to do
this from the cleanout. The liner must be at least as large as
the minimum size established by the tables in National Fuel
Gas Code NFPA 54/ANSI Z223.1 - latest edition and in the
National Standard of Canada, CAN/CSA B149.1 and CAN/CSA
B149.2 - latest editions and amendments. If the liner is too
small or too large, then the chimney must be relined (Fix 4).

CHECK 6 - DILUTION AIR.

If gas-fired appliances are to be vented into a clay tile liner, a
source of dilution air is required.

Dilution air cannot be obtained through:

• Induced draft appliances

• Natural draft appliances with vent dampers

Sufficient dilution air can ordinarily be obtained through the draft
hood of a natural draft appliance only if the appliance’s vent
connector does not include a vent damper. If dilution air will not
be available, the chimney must be relined (Fix 4).

CHECK 7 - COMPLETE THE INSTALLATION.

If Checks 1 through 6 have been satisfactory , and the liner is an
acceptable size as determined by the tables in National Fuel
Gas Code NFPA 54/ANSI Z223.1 - latest edition and in the

13

National Standard of Canada, CAN/CSA B149.1 and CAN/CSA
B149.2 - latest editions and amendments, then the clay tile
liner can probably be used as a vent for the gas appliances.
However, the installer must keep in mind the following factors
which may render the tile liner unsuitable for use as a vent:

• Extremely cold weather

• Long vent connectors

• Masonry chimneys with no air gap between the liner
and the bricks. (In practice, this can be difficult to
detect.)

• Exterior chimneys (The tables in National Fuel Gas
Code NFP A 54/ANSI Z223.1 - latest edition and in the
National Standard of Canada, CAN/CSA B149.1 and
CAN/CSA B149.2 - latest editions and amendments
assume interior chimneys.)

If, in the judgment of the local gas utility , installer , and/or local
codes; one or more of the above factors is likely to present a
problem, the chimney must be relined (Fix 4).

FIX 1 - LINER TERMINATION

Any cap or roof assembly used with a liner must be approved
by the liner manufacturer for such use. The liner and cap/roof
assembly must then terminate above the roof in accordance
with the manufacturer’s instructions.

In some cases, a shorter extension above the roof may be
possible with a liner than would be required with a masonry
chimney .

For further information on relining, see Fix 4.

FIX 2 -CHANGE VENTING ARRANGEMENTS

FIX 3 - REBUILD THE CROWN

If the chimney crown is damaged, a qualified mason must re­pair it in accordance with nationally recognized building codes
or standards. One such standard which may be referenced is
the St andard for Chimneys, Fireplaces, V ents, and Solid Fuel
Burning Appliances, ANSI/NFPA 211.

FIX 4 - RELINING

Relining options include B vent and flexible liners.
If the chimney has diagonal offsets, B vent probably cannot be

used.
If B vent is to be used, it must be supported adequately . Sup-

ports (such as fire stops or thimbles) must be used to prevent
the B vent from coming into direct contact with the tile liner or
chimney walls. Direct contact would result in higher heat loss,
with an increased possibility of poor venting system perfor­mance.

It is not acceptable to vent one appliance inside the B vent and
other appliances outside. The excess space between the B
vent and the chimney walls must be covered at the top of the
chimney by a weatherproof, corrosion resistant flashing.

The B vent should then be topped with a listed vent cap. The
listed vent cap will, when installed per the manufacturer’s in­structions, prevent problems due to rain, birds, or wind effects.

A B-vent installed as described in this section is considered to
be an enclosed vent system, and the sizing tables in National
Fuel Gas Code NFPA 54/ANSI Z223.1 - latest edition and in
the National St andard of Canada, CAN/CSA B149.1 and CAN/
CSA B149.2 - latest editions and amendments may be used.

If the masonry chimney has more than one channel, it may be
possible to vent the gas appliances into one channel and vent
the solid or liquid fuel appliance(s) into another channel(s). Do
not vent an 80+ Furnace inside of a metal liner with other appli­ances vented outside the liner.

Alternatively , the homeowner may agree to discontinue use of
the fireplace (solid fuel appliance). If so, the tile liner must be
cleaned to remove creosote buildup. The fireplace opening must
then be permanently sealed.

If oil-fired appliance(s) are being replaced by gas-fired
appliance(s), the tile liner must first be cleaned to remove the
fuel oil residue.

If none of the above options is practical, the furnace may need
to be vented vertically with a B Vent.

Under some conditions, a 90%+ furnace could be installed rather
than an 80% furnace. The 90%+ furnace can be vented hori­zontally or vertically through PVC pipe.

If a flexible liner is to be used, it must be made of the proper
materials:

• For most residential applications, an aluminum liner
should be acceptable.

• If the combustion air supplied to the furnace will be
contaminated with compounds containing chlorine or
fluorine, a liner of AL 29-4C stainless steel should be
used. Common sources of chlorine and fluorine
compounds include indoor swimming pools and
chlorine bleaches, paint strippers, adhesives, paints,
varnishes, sealers, waxes (which are not yet dried)
and solvents used during construction and remodeling.
V arious commercial and industrial processes may also
be sources of chlorine/fluorine compounds.

• Heavier gauge 300 and 400 series stainless steel liners
were developed for use with oil or solid fuel appliances.
They are not suitable for use with gas-fired appliances.
Flexible liners specifically intended and tested for gas
applications are listed in the UL “Gas and Oil
Equipment Directory”. (UL S tandard 1777).

14

For sizing of flexible liners, see Note 22 and the tables in the
National Fuel Gas Code NFP A 54/ANSI Z223.1 - latest edition
and in the National Standard of Canada, CAN/CSA B149.1 and
CAN/CSA B149.2 - latest editions and amendments.

T o inst all the liner , read and follow the liner manufacturer’s in­structions and your local codes. Excess liner length should be
pulled out of the chimney and cut off. Use caution when doing
this, as the cut edges of flexible liners may be sharp. Do not
spiral excess liner inside of the chimney . Support the liner as
recommended by the liner manufacturer.

Some manufacturers of flexible liners offer an insulation sleeve
designed to be added to the liner before it is installed in the
chimney. (Poured insulation, either vermiculite or other materi­als, is no longer recommended.) Insulation will need to be added
to the flexible liner if:

• It is required by the liner manufacturer’s instructions.

• The previous liner was properly sized and installed,
and suffered from condensation damage.

• It is required by your local building codes.

Even if none of those three conditions exist which require addi­tional liner insulation, the installer may wish to consider it if:

• The local climate is very cold.

• The chimney is very tall.

• The vent connectors used are very long or have a large
number of elbows.

• Local experience indicates that flexible liners installed
without insulation are likely to have condensation
problems.

Insulation must be selected and installed in accordance with
the liner manufacturer’s instructions.

Finally , cap the chimney and terminate the liner in accordance
with the liner manufacturer’s instructions.

E

LECTRICAL CONNECTIONS

WARN ING

HIGHVOLTAGE!

TO

AVOIDTHERISKOFELECTRICALSHOCK,WIRINGTO

THEUNITMUSTBEPOLARIZEDANDGROUNDED



.

CAUTION

L

ABELALLWIRESPRIORTODISCONNECTIONWHENSERVICING

CONTROLS

OPERATION

.W

IRINGERRORSCANCAUSEIMPROPERANDDANGEROUS

.V

ERIFYPROPEROPERATIONAFTERSERVICING





.

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

.









WIRING HARNESS

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

115 VOLT LINE CONNECTIONS

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

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

Connect hot, neutral, and ground wires as shown in the wiring
diagram located on the unit’s blower door .

WARN ING

HIGHVOLTAGE!

TO

AVOIDPERSONALINJURYORDEATHDUETO

ELECTRICALSHOCK,DISCONNECTELECTRICALPOWER

BEFORESERVICINGORCHANGINGANYELECTRICAL

WIRING

.

Line polarity must be observed when making field connections.
Line voltage connections can be made through either the right
or left side panel. The furnace is shipped configured for a right







side electrical connection with the junction box located inside
the burner compartment (blower compartment for downflows).
To make electrical connections through the opposite side of
the furnace, the junction box must be relocated to the other
side of the burner (or blower) compartment prior to making
electrical connections. T o relocate the junction box, follow the
steps shown below.

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

15

JUNCTION BOX RELOCATION

WARN ING

E

DGESOFSHEETMETALHOLESMAYBESHARP

PRECAUTIO NWHENREMOVINGHOLEPLUGS

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

.

.USE

GLOVESASA



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

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

2. Resistance should measure 10 ohms or less.

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

WARN ING

TO

PREVENTPERSONALINJURYORDEATHDUETOELECTRICSHOCK

DISCONNECTELECTRICALPOWERBEFOREINSTALLINGORSERVICINGTHIS

UNIT

.

,



1. Remove both doors from the furnace.

2. Remove and save the screws holding the junction box to
the right side of the furnace.

3. Models that have the junction box located in the burner
or blower compartment will need to move the junction
box directly over.

4. Attach the junction box to the left side of the furnace,
using the screws removed in step 2.

5. Check the location of the wiring. Confirm that it will not
be damaged by heat from the burners or by the rotation
of the fan. Also confirm that wiring location will not
interfere with filter removal or other maintenance.

After the junction box is in the desired location, use washers to
connect field-supplied conduit to the junction box in accordance
with NEC and local codes. Connect hot, neutral, and ground
wires as shown in the furnace wiring diagram. The wires and
ground screw are located in the furnace junction box.

NOTE: In downflow applications the power leads should be
routed through the supplied wire tabs when locating junction
box to the left side.

Low voltage wires may be connected to the terminal strip.
IMPORT ANT NOTE: T o avoid possible equipment malfunction,

route the low voltage wires to avoid interference with filter re­moval or other maintenance.

WARN ING

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

ATIONALELECTRICCODE

N

.





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

24 VOLT THERMOSTAT WIRING

IMPORTANT NOTE

W

IREROUTINGMUSTNOTINTERFEREWITHCIRCULATORBLOWER

OPERATION,FILTERREMOVA LORROUTINEMAINTENANCE

REMOVA BLEPLUGCONNECTORISPROVIDEDWITHTHECONTROLTO

A

MAKETHERMOSTATWIRECONNECTIONS

WIRECONNECTIONSMADETOTHEPLUG,ANDREPLACED

STRONGLY

TERMINALBETWISTEDTOGETHERPRIORTOINSERTINGINTOTHEPLUG

CONNECTOR

OPERATION

RECOMMENDEDTHATMULTIPLEWIRESINTOASINGLE



.F

AILURETODOSOMAYRESULTININTERMITTENT

.

.T

HISPLUGMAYBEREMOVED

.ITIS

As a two-stage non-communicating furnace, the furnace inte­grated control module provides terminals for both “W1” and “W2”,
and “Y1” and “Y2” thermostat connections. This allows the
furnace to support the following system applications: ‘Two­Stage Heating Only’, ‘T wo-St age Heating with Single Stage Cool­ing’, and ‘Two-S tage Heating with T wo-S tage Cooling’. Refer to
the following figures for proper connections to the integrated
control module.

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

This furnace is equipped with a 40 V A transformer to facilitate
use with most cooling equipment. Consult the wiring diagram,
located on the blower compartment door , for further details of
1 15 V olt and 24 V olt wiring.

NOTE: For single stage cooling applications, a jumper must
be located between Y1 and Y2 at the furnace control in order
to achieve the desired single stage cooling airflow. Use of
ramping profiles and dehumidification features requires a jumper
between Y1 and O and Y1 and DEHUM, respectively .



.



,







16

NOTE: Thermostat “R” required if outdoor unit is equipped with
a Comfort Alert™ module or if the outdoor unit is a part of the
ComfortNet™ family of equipment AND is wired as a non­communicating system.

R

Furnace Integrated

Control Module

Dehumidistat

[Optional]

Y C

Remote

Condensing Unit

(Single-Stage Cooling)

R

NEU

NOTE: To apply a single-stage Heating Thermostat, the thermostat
selector switch on the Integrated Control Module must be set on
single-stage.

Thermostat - Single -Stage Heating with Single-Stage Cooling

_______________________

R

Furnace Integrated

Control Module

Dehumidistat

[Optional]

Y C

Remote

Condensing Unit

(Single-Stage Cooling)

R

NEU

Thermostat - Two-Stage Heating with Single-Stage Cooling

_______________________

Y2

Y2

Y2

Remote

Condensing Unit

(Two-Stage Cooling)

Thermostat - Two-Stage Heating with Two-Stage Cooling

Thermostat Wiring Diagrams

W1 W2

W1 W2

NEU

Furnace Integrated

Dehumidistat

[Optional]

Control Module

SINGLE-STAGE HEATING THERMOSTAT APPLICATION

A single-stage thermostat with only one heating stage may
be used to control this furnace. The application of a single­stage thermostat offers a timed transition from low to high
fire. The furnace will run on low stage for a fixed period of
time before stepping up to high stage to satisfy the
thermostat’s call for heat. The delay period prior to step­ping up can be set at either a fixed 5 minute time delay or a
load based variable time between 1 and 12 minutes (AUTO
mode). If the AUT O mode is selected, the control averages
the cycle times of the previous three cycles and uses the
average to determine the time to transition from low stage to
high stage.

T o use a single-st age thermostat, turn of f power to the fur­nace, move the thermostat selection DIP switch to the OFF
position. Set the desired transition time by setting the tran­sition delay DIP switch to the desired ON/OFF position.
Turn power back on. Refer to the following figure.

Heat OFF Delay
DIP Switches

ONOFF

3
4

Thermostat

Stage Delay

S1

Move to the ON position
to select two-stage
thermostat or OFF to
select single stage
thermostat

Move to the ON position
to select A u to transition
delay or OFF for 5 minute
transition delay

24 VOLT DEHUMIDISTAT WIRING

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

T o inst all/connect a dehumidistat:

1. Turn OFF power to furnace.

2. Secure the dehumidistat neutral wire (typically the
white lead) to the terminal marked “DEHUM” on the
furnace integrated control module.

3. Secure the dehumidistat hot wire (typically the black
lead) to the terminal marked “R” on the furnace
integrated control module.

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

17

5. Turn ON power to furnace.

NOFF

T o enable the dehumidify function on the integrated control mod­ule, set the dehumidification ENABLE dipswitch from OFF to
ON.

Once the switch is set, the dehumidify function is enabled dur­ing a combination call for cooling (T-S tat) and dehumidification
(DEHUM-Stat).

O

9

10

S5

DEHUM
Unused

Move to the ON position
to enable dehumidification

FOSSIL FUEL APPLICATIONS

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

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

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

115 VOLT LINE CONNECTION OF ACCESSORIES (HUMIDIFIER

ELECTRONIC AIR CLEANER)

AND

WARN ING

HIGHVOLTAGE!

TO

AVOIDPERSONALINJURYORDEATHDUETO

ELECTRICALSHOCK,DISCONNECTELECTRICALPOWER

BEFORESERVICINGORCHANGINGANYELECTRICAL

WIRING

.







module. The Electronic air cleaner hot terminal is identified as
EAC. It is necessary to remove the protective tab on the board
cover to access the EAC T erminal. The EAC neutral terminal
is identified as NEUTRAL. A line voltage humidifier may be
connected between one of the HUM contacts and NEUTRAL.
The other HUM contact must be fed from the L1 terminal.

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

Accessories Wiring

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 volt age wire splices must be made inside the
furnace junction box.

The integrated furnace control HUM (dry contacts) are closed
whenever the inducer is energized in a non-communicating in­stallation. When used with a CTK02** communicating thermo­stat, the HUM terminals are closed whenever there is a call for
humidity . The integrated control module electronic air cleaner ter­minals (EAC) are energized with 1 15 volts whenever the circulator
blower is energized.

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

The accessory load specifications are as follows:

Humidifier 1.0 Amp maximum at 120 VAC

Electronic Ai r Cleaner 1.0 Amp maximum at 120 VAC

Turn OFF power to the furnace before installing any accessories.
Follow the humidifier or air cleaner manufacturers’ instructions for
locating, mounting, grounding, and controlling these accessories.
Accessory wiring connections are to be made through the 1/4"
quick connect terminals provided on the furnace integrated control

18

24 VOLT HUMIDIFIER

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

GAS S

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.

TO

INLETGASSUPPLYPRESSUREMUSTBEASSPECIFIEDONTHEUNIT

RATINGPLATEWITHALLOTHERHOUSEHOLDGASFIREDAPPLIANCES

OPERATING

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

UPPL Y AND PIPING

CAUTION

PREVENTUNRELIABLEOPERATIONOREQUIPMENTDAMAGE,THE



.





For installations above 7000 feet, please refer to your distribu­tor for required kit(s).

Gas

Altitude Kit Orifice

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

Propane LPM-06 #55 10.0" w.c. 6.0" w.c. None

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

0-7000

Manifold Pressure Pressure

High StageLow Stage

Switch Change

Consult the furnace Specification Sheet for 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.

PROPANE GAS CONVERSION

WARNING

P

OSSIBLEPROPERTYDAMAGE,PERSONALINJURYORDEATHMAY

OCCURIFTHECORRECTCONVERSIONKITSARENOTINSTALLED

APPROPRIATEKITSMUSTBEAPPLIEDTOENSURESAFEANDPROPER

FURNACEOPERATION

QUALIFIEDINSTALLERORSERVICEAGENCY

.ALL

CONVERSIONSMUSTBEPERFORMEDBYA

.



.THE





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.

NOTE: Adjusting the minimum supply pressure below the limits
in the above table could lead to unreliable ignition. Gas input to
the burners must not exceed the rated input shown on the
rating plate. Overfiring of the furnace can result in premature
heat exchanger failure. Gas pressures in excess of 13 inches
water column can also cause permanent damage to the gas
valve.

At all altitudes, the manifold pressure must be within 0.3 inches
w.c. of that listed in the S pecification Sheet applicable to your
model for the fuel used. At all altitudes and with either fuel, the
air temperature rise must be within the range listed on the fur­nace nameplate. Should this appliance be converted to LP,
refer to the instructions included in the factory authorized LP
conversion kit.

HIGH ALTITUDE DERATE

IMPORT ANT NOTE: The furnace will naturally derate itself with

altitude. Do not attempt to increase the firing rate by changing
orifices or increasing the manifold pressure. This can cause
poor combustion and equipment failure.

This unit is configured for natural gas. The appropriate
manufacturer’s propane gas conversion kit, must be applied for
propane gas installations. Refer to the “Propane Gas and/or
High Altitude Installations” section for det ails.

If converting to LP gas, it is recommended that an LPLP0* kit
also be installed. The use of this kit will prevent the furnace
from firing when the LP gas supply pressure is too low to sup­port proper combustion.

Consult the furnace S pecification Sheet for a 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.

GAS PIPING CONNECTIONS

WARNING

TO

AVOIDPOSSIBLEUNSATISFACTORYOPERATIONOFEQUIPMENT

DAMAGEDUETOUNDERFIRINGOREQUIPMENT,USETHEPROPERSIZE

OFNATURAL/PROPANEGASPIPINGNEEDEDWHENRUNNINGPIPEFROM

THEMETER/TANKTOTHEFURNACE

.







High altitude installations may require both a pressure switch
and an orifice 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.

19

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

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.

Natural Gas Capacity of Pi pe

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.; B a sed on

0.60 Specific Gravity Gas)
BT UH Furnace I nput

CFH =

He at ing Value of Gas (BTU /Cubic Foot)

In Cubic Feet of Ga s P er Hour (CFH)

• 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.

– Use listed gas appliance connectors in accordance

with their instructions. Connectors must be fully in
the same room as the furnace.

– Protect connectors and semi-rigid 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.

Gas line
entrance

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.

• 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 the building
piping.

• Use pipe joint compound on male threads only. Pipe
joint compound must be resistant to the action of the
fuel used.

• Use ground joint unions.

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

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

• Use two pipe wrenches when making 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 .

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

• Tighten all joints securely.

Right side
gas entrance
(alternate)

General Furnace Layout

UPFLOW INSTALLATIONS

When the gas piping enters through the right side of the fur­nace, the installer must supply the following fittings (starting

from the gas valve):

• Close nipple.

• 90 degree elbows.

• Straight pipe to reach the exterior of the furnace .

A ground joint union, drip leg, and manual shutoff valve must
also be supplied by the installer. In some cases, the installer
may also need to supply a transition piece from 1/2" to another
pipe size.

When the gas piping enters through the left side of the furnace,
the installer must supply the following fittings (starting from the
gas valve):

• 90 degree elbow.

• Straight pipe to reach the exterior of the furnace.

• A ground joint union, drip leg, and manual shutoff valve
must also be supplied by the installer . In some cases,
the installer may also need to supply a transition piece
from 1/2 inch to another pipe size.

20

COUNTERFLOW INSTALLATIONS

When the gas piping enters through the left side of the furnace,
the installer must supply a straight pipe and a 90 degree elbow
to reach the exterior of the furnace.

A ground joint union, drip leg and manual shutoff valve must
also be supplied by the installer. In most cases, the installer
may also need to supply a transition piece from ½” to another
pipe size. When the gas piping enters through the right side of
the furnace, the installer must supply the following fittings (start­ing at the gas valve):

• Close Nipple

• 90 Degree Elbow

• Straight Pipe to Reach Exterior of Furnace.

GAS PIPING CHECKS

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

WARN ING

TO

AVOIDTHEPOSSIBILIT YOFEXPLOSIONORFIRE,NEVERUSEAMATCH

OROPENFLAMETOTESTFORLEAKS

.



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 on Page 3 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

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

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

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.

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).

This unit must be isolated from the gas supply system by clos­ing its manual shutoff valve before pressure testing of gas sup­ply piping system with test pressures equal to or less than 1/2
psig (3.48 kPa).

PROPANE GAS TANKS AND PIPING

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

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

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

200 PSIG
Maximum

5 to 15 PSIG
(20 PSIG Max.)

Continuous

Second Stage
Regulator

11" W.C.

First Stag e
Regulator

Propane Gas Installation (Typ.)

WARN ING

IF

THEGASFURNACEISINSTALLEDINABASEMENT,ANEXCAVATED

AREAORCONFINEDSPACE,ITISSTRONGLYRECOMMENDEDTO

CONTACT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CONFINEDSPACES

•

ROPANEGASODORANTMAYFADE,MAKINGTHEGASUNDETECTABLE

P



EXCEPTWITHAWARNINGDEVICE

.

.







.

21

PROPANE GAS PIPING CHARTS

Sizing Between First and Se c ond Stage Regulator*
Maximum Propane Capa cities listed are based on 2 psig pressure drop at 10 psig setting .
Capacities in 1,000 BTU/hour.

Pipe or

Tubing

Length,

Feet

10 730 1,700 3,200 5,300 8,300 3,200 7,500
20 500 1,100 2,200 3,700 5,800 2,200 4,200
30 400 920 2,000 2,900 4,700 1,800 4,000
40 370 850 1,700 2,700 4,100 1,600 3,700
50 330 770 1,500 2,400 3,700 1,500 3,400
60 300 700 1,300 2,200 3,300 1,300 310

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

Sizing Between Second Stage an d Appliance Regulator*
Maximum Propane Capacities listed are based on 2 psig pressure drop at 10 psig setting.
Capacities in 1,000 BTU/hour.

Pipe or
Tubing

Length,

Feet

10 39 92 199 329 501 935 275 567 1,071 2,205 3,307
20 26 62 131 216 346 630 189 393 732 1,496 2,299
30 21 50 107 181 277 500 152 315 590 1,212 1,858
40 19 41 90 145 233 427 129 267 504 1,039 1,559
50 18 37 79 131 198 376 114 237 448 91 1,417
60 16 35 72 121 187 340 103 217 409 834 1,275

80 13 29 62 104 155 289 89 185 346 724 1,066
100 11 26 55 90 138 255 78 162 307 630 976
125 10 24 48 81 122 224 69 146 275 567 866
150 9 21 43 72 109 202 63 132 252 511 787
200 8 19 39 66 100 187 54 112 209 439 665
250 8 17 36 60 93 172 48 100 185 390 590

C

IRCULA TING AIR AND FILTERS

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

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

Tubing Size, O.D. Type L

Tubing Size, O.D. Type L

Nominal Pipe Size

Schedule 40

Nominal Pipe Size

Schedule 40

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

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

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

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 a duct sealed
to the furnace casing and terminating outside the space con­taining the furnace.

CHECKING DUCT STATIC

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

WARN ING

N

EVERALLOWTHEPRODUCTSOFCOMBUSTION,INCLUDINGCARBO N

MONOXIDE,TOENTERTHERETURNDUCTWORKORCIRCULATIONAIR

SUPPLY

.





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

A duct system must be installed in accordance with S tandards
of the National Board of Fire Underwriters for the Installation of
Air Conditioning, Warm Air Heating and Ventilating Systems.
Pamphlets No. 90A and 90B.

A closed return duct system must be used, with the return duct
connected to the furnace. NOTE: Ductwork must never be
attached to the back of the furnace. For installations requiring
more than 1800 CFM, use a bottom return or two sided return.
Supply and return connections to the furnace may be made
with flexible joints 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. A room, closet, or
alcove must not be used as a return air chamber.

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. Tape 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.

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

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

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

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

22

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.

filter rack kit (upflows), or the ductwork above a downflow fur­nace. As an alternative, a media air filter or electronic air cleaner
can be used as the primary filter.

CIRCULATION AIR FILTERS

One of the most common causes of a problem in a forced air
heating system is a blocked or dirty filter. Circulating air filters
must be inspected monthly for dirt accumulation and replaced
if necessary . Failure to maintain clean filters can cause prema­ture heat exchanger failure.

A new home may require more frequent replacement until all
construction dust and dirt is removed. Circulating air filters are
to be installed in the return air duct external to the furnace
cabinet.

MINIMUM FILTER SIZES for DISPOSABLE FILTERS

FURNACE INPUT (BTU/hr) FILTER SIZE

60K
80K

100K

DISPOSABLE NOMINAL 300 F.P.M. FACE VELOCITY

610 in
813 in
889 in

2

2

2

HORIZONTAL INSTALLATIONS

Checking Static Pressure

(80% Furnace Shown, 90% Similar)

FILTERS - READ THIS SECTION BEFORE INSTALLING THE
RETURN AIR DUCTWORK

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 by the installer . Filters must com­ply with UL900 or CAN/ULCS1 11 standards. If the furnace is
installed without filters, the warranty will be voided.

NOTE: An undersized opening will cause reduced airflow . The
bottom return is set up as a knock out.

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

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

S

TART-UP PROCEDURE AND ADJUSTMENT

Furnace must have a 115 V AC 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.

HEAT ANTICIPATOR SETTING

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

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. Turn off the electrical power to the furnace.

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

4. Remove the burner compartment door .

23

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

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

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

7. If you smell gas after five minutes, immediately follow
the Safety Instructions on page 2 of this manual. If you
do not smell gas after five minutes, move the furnace
gas valve manual control to the ON position.

8. Replace the burner compartment door .

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

10.Turn on the electrical power to the furnace.

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

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

FURNACE SHUTDOWN

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

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

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

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

4. Replace the burner compartment door .

GAS SUPPLY PRESSURE MEASUREMENT

CAUTION

TO

PREVENTUNRELIABLEOPERATIONOREQUIPMENTDAMAGE,THE

INLETGASSUPPLYPRESSUREMUSTBEASSPECIFIEDONTHEUNIT

RATINGPLATEWITHALLOTHERHOUSEHOLDGASFIREDAPPLIANCES

OPERATING

.

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







t

e

r

n

o

a

m

e

o

m

Inlet
Pressure
Boss

e

t

e

r

M

o

H

s

e

Outlet

Pressure Boss

n

O

O

/

High Fire Regulator

Adjust

i

H

g

e

h

e

m

r

T

S

i

w

c

t

h

f

f

l

r

o

i

i

C

F

i

n

a

l

I

(

)

H

Common
Terminal(C)

o

C

e

r

T

Open to

Atmosphere

a

M

n

White-Rodgers Model 36G54 Connected to Manometer

High Fire

Regulator
Vent

Gas Valve On/Off
Selector Switch

Regulator
Adjust

Low Fire
Regulator
Adjust

Honeywell Model VR9205 (Two-Stage)

Common

e

m

e

t

e

n

M

t

p

O

p

h

s

t

A

m

o

M

a

a

o
e

r

e

i

e

t

r

n

o

e

m

r

n

o

e

o

H

s

Terminal(C)

High Fire Coil
Terminal (HI)

Low Fire Coil
Terminal (LO)

Inlet Pressure Tap
1/8 NPT

Regulator

Vent

Low Fire
Regulator
Adjust

a

a

x

o

l

i

C

i

n

a

l

M

(

m

l

i

)

INLET OUTLET

Gas Valve On/Off
Selector Switch

White-Rodgers Model 36G54 (Two-Stage)

Outlet Pressure Tap
1/8 NPT

Honeywell Model VR9205 Connected to Manometer

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

24

2. Connect a calibrated water manometer (or appropriate
gas pressure gauge) at either the gas valve inlet pressure
boss or the gas piping drip leg. See Honeywell VR9205
gas valve figure or White-Rodgers 36G54 gas valve figure
for location of inlet pressure boss.

NOTE: If measuring gas pressure at the drip leg or Honeywell
VR9205 gas valve, a field-supplied hose barb fitting must be
installed prior to making the hose connection. If using the inlet
pressure boss on the White-Rodgers 36G54 gas valve, then
use the 36G Valve Pressure Check Kit, Goodman Part No.
0151K00000S.

3. Turn 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.

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.

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

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

6. Turn OFF any unnecessary gas appliances stated in
step 3.

Gas Line

Gas
Shutoff
Valve

Gas Line
To Furnace

Open To
Atmosphere

Drip Leg Cap
With Fitting

Manometer Hose

Manometer

Measuring Inlet Gas Pressure (Alt. Method)

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. To measure
and adjust the manifold pressure, use the following procedure.

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

2. Turn off all electrical power to the system.

3. Outlet pressure tap connections:

a. Honeywell VR9205 valve: Remove the outlet pressure

boss plug. Install an 1/8" NPT hose barb fitting into
the outlet pressure tap.

b. White-Rodgers 36G54 valve: Back outlet pressure test

screw (inlet/outlet pressure boss) out one turn
(counterclockwise, not more than one turn).

4. Attach a hose and manometer to the outlet pressure
barb fitting (Honeywell valve) or outlet pressure boss
(White-Rodgers valve).

5. T urn ON the gas supply .

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

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

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

9. Close thermostat “R” and “W2” contacts to provide a
call for high stage heat.

10.Remove regulator cover screw from the high (HI) outlet
pressure regulator adjust tower and turn screw clockwise
to increase pressure or counterclockwise to decrease
pressure. Replace regulator cover screw.

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

12.Remove the manometer hose from the hose barb fitting
or outlet pressure boss.

13.Replace outlet pressure tap:

a. Honeywell VR9205 valve: Remove the 1/8" NPT hose

barb fitting from the outlet pressure tap. Replace the
outlet pressure boss plug and seal with a high quality
thread sealer.

b. White-Rodgers 36G54 valve: Turn outlet pressure test

screw in to seal pressure port (clockwise, 7 in-lb
minimum).

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

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

GAS MANIFOLD PRESSURE MEASUREMENT AND ADJUSTMENT

CAUTION

TO

PREVENTUNRELIABLEOPERATIONOREQUIPMENT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

.







25

Using a leak detection solution or soap suds, check for leaks

.

at outlet pressure boss plug (Honeywell valve) or screw (White­Rodgers valve). Bubbles forming indicate a leak. SHUT OFF
GAS AND REPAIR ALL LEAKS IMMEDIA TELY!
NOTE: For gas to gas conversion, consult your dealer for
appropriate conversion.

Mani fold Gas Pressure

Gas

Natural Low Stage 1.6 - 2.2" w .c. 1.9 " w.c.

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

Propane Low Stage 5.7 - 6.3" w .c. 6.0" w .c.

High Stage 9.7 - 10.3" w.c

Range Nom inal

10.0" w.c.

GAS INPUT RATE MEASUREMENT (NATURAL GAS ONLY)

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

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

2. While the furnace is operating, time and record one
complete revolution of the smallest gas meter dial.

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

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

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

(Obtained from gas supplier)
Installation’s seconds per cubic foot: 34 sec/ ft
Conversion Factor (hours to seconds): 3600 sec/hr
Input = (Htg. value x 3600) ÷ seconds per cubic foot
Input = (1,000 BTU/ft3 x 3600 sec/hr) ÷ 34 sec/ ft
Input = 106,000 BTU/hr

Minor changes to the input rate may be accomplished through
manifold pressure adjustments at the gas valve. Refer to Sec-

tion XIV, Startup Procedure and Adjustment - Gas Manifold
Pressure Measurement and Adjustment for details. NOTE:

The final manifold pressure cannot vary by more than ± 0.3”
w.c. from the specified setting. Consult your local gas supplier
if additional input rate adjustment is required.

5. Repeat steps 2 through 4 on high stage.

6. 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.

3

3

3

TEMPERATURE RISE

T emperature 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 exchanger.

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

HEAT EXCHANGER

RADIATION "LINE OF SIGHT"

SUPPLY
AIR

T

SUPPLY

RISE =

T

SUPPLY

T

-

RETURN

T

RETURN

RETURN
AIR

Temperature Rise Measurement

CIRCULATOR BLOWER SPEEDS

WARNING

TO

AVOIDPERSONALINJURYORDEATHDUETOELECTRICALSHOCK

TURN

OFF

POWERTOTHEFURNACEBEFORECHANGINGSPEEDTAPS

This furnace is equipped with a multi-speed circulator blower.
This blower provides ease in adjusting blower speeds. The
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. The heating blower speed is

,

.

26

shipped set at “B”, and the cooling blower speed is set at “D”.
These blower speeds should be adjusted by the installer to
match the installation requirements so as to provide the cor­rect heating temperature rise and correct cooling CFM.

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

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

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

Example: Cooling Capacity of 30,000 BTU/hr.

30,000/12,000 = 2.5 T ons

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

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

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

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

Example: A *MVC80604BX furnace installed with a 2.5

ton air conditioning system. The air flow
needed is 1000 CFM. Looking at the cooling
speed chart for *MVC80604BX, find the air
flow closest to 1000 CFM. A cooling airflow
of 990 CFM can be attained by setting the
cooling speed to “C” and the adjustment to
“-” (minus).

4. Continuous fan speed in legacy mode is 25% of the
furnace’s maximum airflow capability. For continuous
fan speed in communicating mode, see ComfortNet™
System Overview on page 29.

Example: If the furnace’s maximum airflow capability

is 2000 CFM, the continuous fan speed will
be 0.25 x 2000 CFM = 500 CFM.

5. Locate the blower speed selection DIP switches on the
integrated control module. Select the desired “cooling”
speed tap by positioning switches 1 and 2 appropriately .
Select the desired “adjust” tap by positioning switches
3 and 4 appropriately . Refer to the following figure for
switch positions and their corresponding taps. Verify
CFM by noting the number displayed on the dual 7­segment LED display .

6. The multi-speed circulator blower also offers several
custom ON/OFF ramping profiles. These profiles may
be used to enhance cooling performance and increase
comfort level. The ramping profiles are selected using
DIP switches 5 and 6. Refer to the following figure for
switch positions and their corresponding taps. Refer to
the bullet points below for a description of each ramping
profile. Verify CFM by noting the number displayed on
the dual 7-segment LED display .

Swit c h Ba nk: S4

Ramping

Profiles

A* OFF OFF

BONOFF
COFFON
DONON

(*Indicates factory setting)

DIP Switc h No.

56

• Profile A provides only an OFF delay of one (1) minute
at 100% of the cooling demand airflow.

OFF

100% CFM 100% CFM

1 min

• Profile B ramps up to full cooling demand airflow by
first stepping up to 50% of the full demand for 30 seconds.
The motor then ramps to 100% of the required airflow . A
one (1) minute OFF delay at 100% of the cooling airflow
is provided.

OFF

50% CFM

1/2 min

100% CFM

100% CFM

1 min

• Profile C ramps up to 85% of the full cooling demand
airflow and operates there for approximately 7 1/2
minutes. The motor then steps up to the full demand
airflow. Profile C also has a one (1) minute 100% OFF
delay.

OFF

100% CFM

OFF

OFF

OFF

27

Switch Bank: S3

Cooling

Airflow

AOFFOFF
BONOFF
COFFON

D* ON ON

(*Indicates fact ory setting)

Switc h Bank: S3

Adjust Taps

Normal* OFF OFF

10% ON OFF

-10% OFF ON

Normal ON ON

(*Ind i cates facto ry setting )

DIP Switch No.

12

DIP Switch No.

34

• Profile D ramps up to 50% of the demand for 1/2 minute,
then ramps to 85% of the full cooling demand airflow
and operates there for approximately 7 1/2 minutes. The
motor then steps up to the full demand airflow. Profile D
has a 1/2 minute at 50% airflow OFF delay .

7. Select the heating speed for your model from the heating
speed chart in the Specification Sheet. The adjust setting
(already established by the cooling speed selection)
determines which set of speeds are available. The
selected speed must provide a temperature rise within
the rise range listed with the particular model.

Example: The *MVC80604BX is set for 990 CFM on

cooling, the “ADJUST” is set to “+” (plus).
The four heating speeds available are “A
Plus”, “B Plus”, “C Plus”, and “D Plus”. “A
Plus” has a rise of 38°F for both stages
which is within the 20-50°F rise range for
the *MVC80604BX . This setting will keep
electrical consumption to a minimum. Set
the “Heat” speed DIP switches to “A”.

Switch Bank: S4

Heating

Airflow

AOFFOFF

B* ON OFF

COFFON
DONON

(*Indicates factory setting)

DIP Switch No.

78

OFF

Speed Selection Dip Switches

Cool Adjust Profile Heat
Selection Selection Selection Selection
Switches Switches Switches Switches

TAP 1 2 3 4 5 6 7 8
A OFF OFF OFF OFF OFF OFF OFF OFF
B ON OFF ON OFF ON OFF ON OFF

C OFF ON OFF ON OFF ON OFF ON
D ON ON ON ON ON ON ON ON

Profiles Pr e -Ru n Short-Run OFF Delay

A ------- -------- 60 sec/100%

B ------- 30 sec/50% 60 sec/100%
C ------- 7.5 min/82% 60 sec/100%

D 30 sec/50% 7.5 min/82% 30 sec /50%

To set airflow:

(1) Select model and desire d
hig h s tage cooling a i r flow. Dete rmine the corr espondin g ta p
( A, B, C, or D ). Set dip switches 1 and 2 to the appropriate
ON / OFF positions. (2) Select model and desired high stage
heating airflow. Determine the corres pon d ing tap ( A, B, C, or
D ). Set dip switches 7 and 8 to the appropriate ON / OFF
positions. (3) Select the airflow adjustment factor taps A and
D are 1; Tap B is +10%; Tap C -10%. Set dip switches 3 and 4
to the appropriate ON / OFF positions.

To set Comfort Mo d e:

Select desired Comfort Mode profile
(see profiles above). Set switches 5 and 6 to the appropriate
ON / OFF positions.

OFF

Model Tap Low Stage High Stage Low Stage High Stage
Cool Cool Heat Heat

390

*DVC80603B***

*DVC80805C***

*DVC81005C***

*MVC80604B***

*MVC80805C***

*MVC81005C ***

A

520

B

650

C

780

D

520

A

B
C
D

A
B
C
D

A
B
C
D

A
B
C
D

A
B

C
D

715
910

1170
553

748
943

1203

390
520

715
910

520

715
910

1170

520

715
910

1175

600

800
1000
1200

800

1100
1400
1800

850

1150

1450
1850

600
800

1100
1400

800

1100

1400
1800

800

1100

1400
1800

735

805

875

935

945

1015

1085

1155

1085

1155
1225
1260

875
945

1015

1085
1050

1120

1190
1260

1210

1225
1245
1260

1050

1150
1250
1350

1350
1450
1550
1650

1550
1650
1750
1800

1250
1350
1450
1550

1500
1600
1700
1800

1725

1750

1775

1800

NOTE: Airflow data shown applies to legacy mode operation only. For a fully communicating
system, please see the outdoor unit’s installation instructions for cooling and pump heating
airflow data. See ComfortNet™ System - Airflow Consideration section for details.

28

8. Select the desired “heating” speed tap by positioning
switches 7 and 8 appropriately . Refer to figure above.
Verify CFM by noting the number displayed on the dual
7-segment LED display .

In general lower heating speeds will: reduce electrical consump­tion, lower operating sound levels of the blower, and increase
the outlet air temperature delivered to the home. The speeds
available allow the blower performance to be optimized for the
particular homeowner’s needs.

BLOWER HEAT OFF DELAY TIMINGS

The integrated control module provides a selectable heat off
delay function. The heat off delay period may be set to 90, 120,
150, 180 seconds using the DIP switches or jumper provided
on the control module. The delay is factory shipped at 150
seconds but may be changed to suit the installation require­ments and/or homeowner preference. Refer to the following fig­ures for switch positions and corresponding delay times.

Switc h Bank: S1

DIP Switch No.

12

C

OMFORTNET

Heat OFF Delay

90 seconds O FF OFF

120 seconds ON OFF

15 0 seconds * OFF O N

180 seconds ON ON

(*Ind i cates facto ry setting )

Heat Off Delay Dipswitches

™ S

YSTEM

OVERVIEW

tween the thermostat and subsystems (indoor/outdoor unit) and
between subsystems is the key to unlocking the benefits and
features of the ComfortNet system.

Two-way digital communications is accomplished using only
two wires. The thermostat and subsystem controls are power
with 24 V AC. Thus, a maximum of 4 wires between the equip­ment and thermostat is all that is required to operate the sys­tem.

AIRFLOW CONSIDERATIONS

Airflow demands are managed differently in a fully communi­cating system than they are in a non-communicating wired
system. The system operating mode (as determined by the
thermostat) determines which unit calculates the system air­flow demand. If the indoor unit is responsible for determining
the airflow demand, it calculates the demand and sends it to
the ECM motor. If the outdoor unit or thermostat is respon­sible for determining the demand, it calculates the demand
and transmits the demand along with a fan request to the in­door unit. The indoor unit then sends the demand to the ECM
motor. The table below lists the various ComfortNet systems,
the operating mode, and airflow demand source.

System

Air Conditioner +

Furnace

System

Operating Mode

Cooling Air Conditioner

Heating Furnace

Continuous Fan Thermostat

Airflow Demand

Source

The ComfortNet system is a system that includes a ComfortNet
compatible furnace and air conditioner or heat pump with a
CTK 0* thermost at. A valid ComfortNet system could also be a
compatible furnace, CTK0* thermostat and non-compatible,
single stage air conditioner. Any other system configurations
are considered invalid ComfortNet systems and must be con­nected as a traditional (or legacy) system (see Electrical Con-
nections for wiring connections).

A ComfortNet heating/air conditioning system differs from a non­communicating/traditional system in the manner in which the
indoor unit, outdoor unit and thermostat interact with one an­other. In a traditional system, the thermost at sends commands
to the indoor and outdoor units via analog 24 V AC signals. It is
a one-way communication path in that the indoor and outdoor
units typically do not return information to the thermostat.

In a ComfortNet system, the indoor unit, outdoor unit, and ther­mostat comprising a ComfortNet system “communicate” digi­tally with one another. creating a two-way communications
path. The thermostat still sends commands to the indoor and
outdoor units. However , the thermostat may also request and
receive information from both the indoor and outdoor units. This
information may be displayed on the CTK0* thermostat. The
indoor and outdoor units also interact with one another. The
outdoor unit may send commands to or request information
from the indoor unit. This two-way digital communications be-

Cooling Heat Pump

Heat Pump +

Furnace

Furnace + Non-

Comm 1stg Air

Conditioner

Heat Pump Heating

Only

Auxil iary H eating Furnace

Continuous Fan Thermostat

Cooling Furnace

Heating Furnace

Continuous Fan Thermostat

Heat Pump

For example, assume the system is an air conditioner matched
with a furnace. With a call for low stage cooling, the air condi­tioner will calculate the system’s low stage cooling airflow
demand. The air conditioner will then send a fan request along
with the low stage cooling airflow demand to the furnace. Once
received, the furnace will send the low stage cooling airflow
demand to the ECM motor. The ECM motor then delivers the
low stage cooling airflow . See the applicable ComfortNet air
conditioner or heat pump installation manual for the airflow
delivered during cooling or heat pump heating.

29

In continuous fan mode, the CTK0* thermostat provides the
airflow demand. The thermostat may be configured for a low,
medium, or high continuous fan speed. The low, medium, and
high fan speeds correspond to 25%, 50%, and 75%, respec­tively , of the furnaces’ maximum airflow capability . During con­tinuous fan operation, the thermostat sends a fan request along
with the continuous fan demand to the furnace. The furnace,
in turn, sends the demand to the ECM motor. The ECM motor
delivers the requested continuous fan airflow.

FOSSIL FUEL APPLICATIONS

This furnace can be used in conjunction with a ComfortNet™ com­patible heat pump in a fossil fuel application. A fossil fuel applica­tion refers to a combined gas furnace and heat pump installation
which uses an outdoor temperature sensor to determine the most
cost efficient means of heating (heat pump or gas furnace). When
used with the CTK0* thermostat, the furnace/heat pump sys­tem is automically configured as a fossil fuel system. The
balance point temperature may be adjusted via the CTK0* ther­mostat advanced user menus (see CTK0* instructions for addi­tional information).

CTK0* WIRING

NOTE: Refer to Electrical Connections for 115 volt line

connections to the furnace.
NOTE: A removable plug connector is provided with the control

to make thermostat wire connections. This plug may be
removed, wire connections made to the plug, and replaced. It
is strongly recommended that multiple wires into a single
terminal be twisted together prior to inserting into the plug
connector. Failure to do so may result in intermittent operation.

Typical 18 A WG thermostat wire may be used to wire the sys­tem components. One hundred (100) feet is the maximum
length of wire between indoor unit and outdoor unit, or between
indoor unit and thermostat. Wire runs over (100) feet require
larger gauge wire.

FOUR-WIRE INDOOR AND OUTDOOR WIRING

Typical ComfortNet wiring will consist of four wires between the
indoor unit and outdoor unit and between the indoor unit and
thermostat. The required wires are: (a) data lines, 1 and 2; (b)
thermostat “R” (24 V AC hot) and “C” (24 V AC common).

CTK0*

12RC

12RC

Thermostat

ComfortNet Compatible Furnace
Integrated Control Module

TWO-WIRE OUTDOOR, FOUR-WIRE INDOOR WIRING

Two wires can be utilized between the indoor and out door units.
For this wiring scheme, only the data lines, 1 and 2, are needed
required between the indoor and outdoor units. A 40VA, 208/
230 VAC to 24VAC transformer must be installed in the out­door unit to provide 24VAC power to the outdoor unit’s elec­tronic control. The transformer is included with the CTK0* kit.
See kit instructions for mounting and wiring instructions. Four
wires are required between the indoor unit and thermostat. If
using a CTK02** in a dual fuel system, the accessory trans­former kit TFK01 should be used.

NOTE: Use of the CTK0* transformer is recommended if
installing a dual fuel/fossil fuel system. Failure to use the
transformer in the outdoor unit could result in over loading of
the furnace transformer.

CTK0*

12RC

12RC

40VA Transformer
(included in CTK01 kit)

208/230 VAC

System Wiring using Two-Wires between Furnace and AC/HP

and Four-Wires between Furnace and Thermostat

24 VAC

12

Thermostat

ComfortNet Compatible
Furnace Integrated
Control Module

RC

ComfortNet Compatible
AC/HP Integrated
Control Module

COMFORTNET COMPATIBLE FURNACE WITH NON-COMFORTNET

COMPATIBLE

Four wires are required between the furnace and thermostat. T wo
wires are required between the furnace control and single stage air
conditioner. For this system configuration, the “Y1” terminal on the
integrated furnace control becomes an output rather than an input.
The “Y1” connection to the outdoor unit is made using both 4­position thermostat connectors in the CTK0* kit. Remove the red
keying tabs from the on-board connector block and position both
4-position connectors such that “1”, “2”, “R”, “C”, and “Y1” positions
are filled.

12RC

12RC

SINGLE-STAGE AIR CONDITIONER

CTK0*
Thermostat

G

4-Position Connectors
from CTK0*
Thermostat Kit

W1 W2 Y1 Y2

O

ComfortNet Compatible
Furnac e Integrated
Control Module

12RC

System Wiring using Four-Wires

ComfortNet Compatible A C/ HP
Integrated Control Module

Non- Compatible

C Y

System Wiring between Furnace and Non-Communicating

Compatible Single Stage Air Conditioner

ComfortNet

Single Stage AC

30

COMFORTNET™ SYSTEM ADVANCED FEATURES

The ComfortNet system permits access to additional system
information, advanced setup features, and advanced diagnos­tic/troubleshooting features. These advanced features are or­ganized into a menu structure. The menus are accessed and
navigated as described in the following section.

ACCESSING AND NAVIGATING THE ADVANCED F EATURES MENUS

The advanced system features are accessed using the
ComfortNet thermostat. These advanced features are accessed
as follows:

• On the ComfortNet thermostat Home Screen Display ,
touch the Menu key to display additional key choices.

• Touch and hold the Installer Config key for
approximately 3 seconds to enter the Thermostat
Options Configuration menu.

• Touch and hold the Installer Config key again for
approximately 3 seconds to enter the Advanced
Installer Configuration menu.

Touch the + or _ to step through the list of installed equip­ment, including the thermostat. Touch the Installer Config
key to enter the submenus for the equipment displayed. The
text “WORKING” will be displayed in the scrolling display area
while the data is being retrieved. The first sub-menu is then
displayed. See tables below for listing of furnace submenus.

Touch the + or _ to step through the list of submenus and
view settings. If a setting can be adjusted, _ and + keys will

_

appear. Use the

or + keys to adjust the setting to the

desired value. Touch the + or _ to step to the next item.

“WORKING” will appear as the settings are being updated.
“DONE” will appear to indicate the change was accepted. If

the change is not accepted, the display will show “FAIL” then
revert to the Fault Screen.

Some parameters being displayed switch between the item
name and the item value. T ouch the Hold key to moment arily
stop the display from switching.

To exit an equipment submenu and revert back to the equip­ment menus, touch the Menu key. T ouch Menu again to revert
back to the Thermostat Options Menu. Touch the Run Sched-
ule key to step out of all menus and back to the CT thermostat
Home Screen Display .

Clean Display

Installer

Config

Set Time

Schedu le

Run

Set

Schedule

Upon entering the advanced menus, the Advanced Fault Menu
is displayed. The display will change to the Fault Screen and
indicate any faults that may be present in the indoor or outdoor
equipment. If a fault is present, the Fault Screen will show the
equipment and an error code with a description of the fault.

Touch _ or + keys to view the fault status of any remaining
equipment. The text “NO F AUL TS” will be scrolled if no errors
are present.

Call for Service

Menu

Advanced

Run

Schedule

Call for Service

Menu

Advanced

Run

Schedule

THERMOSTAT MENU

If this furnace is installed with a communicating compatible
heat pump, the system is recognized as a dual fuel system.
The balance point temperature should be set via the thermo­stat advanced menu. Navigate to the THERMOSTAT menu.
Press the INST ALLER CONFIG key . Navigate to the SETUP
menu and press the INST ALLER CONFIG button. Navigate to
dF BAL PNT. Adjust the dual fuel system balance point using
the back/forward arrows.

DIAGNOSTICS

Accessing the furnace’s diagnostics menu provides ready ac­cess to the last six faults detected by the furnace. Faults are
stored most recent to least recent. Any consecutively repeated
fault is stored a maximum of three times. Example: A clogged
return air filter causes the furnace limit to trip repeatedly . The
control will only store this fault the first three consecutive times
the fault occurs. Navigate to the diagnostics menu as described
above in Accessing and Navigating the Advanced Features
Menus.

NOTE: It is highly recommended that the fault history be cleared
when performing maintenance or servicing the furnace.

31

FURNACE ADVANCED FEATURES MENUS

CONFIGURATION

Su bm enu Item Indi c a tion ( fo r Dis play Only; not User Mod if i able)

Num ber of Heat Stages (HT STG) Displays the number of furnace heating stages
Input Rate (BTU/HR) Displays the furnace input rate in kBtu/hr

Mot or HP (1/2, ¾, or 1 MTR HP) Disp lays the furnace indoor blower motor horsepower

DIAGNOST ICS

Sub menu Item I ndi cati on/ Us er Mod ifia bl e Opti ons Com m en ts

Fault 1 (F A ULT #1) Mos t recent fur nace fault For display only
Fault 2 (F A ULT #2) Next most rece nt fur nace fault For disp lay only
Fault 3 (F A ULT #3) Next most rece nt fur nace fault For disp lay only
Fault 4 (F A ULT #4) Next most rece nt fur nace fault For disp lay only
Fault 5 (F A ULT #5) Next most rece nt fur nace fault For disp lay only
Fault 6 (F A ULT #6) Least rec ent fur n ace fau l t For display only

Clear Fault Hist ory (CLEAR) NO or YES

NOTE:

Consecutively repeated faults are shown a maximum of 3 times

Se lectin g “YES” clear s the fault
history

IDENTIFICATION

Sub menu Item Indication (for Display Only; not User Modifiable)

Model Number (MOD NUM) Displays the furnace model number
Serial Number (SER NUM) Displays the furnace serial number (Optional)
Software (SOFTWARE) Displays the application software revision

SET-UP

Submenu Item User Mo difi able Opt ions Comments

H eat Airf low Trim (HT T RM ) -10% to +10% in 2% increments,

default is 0%

H eat ON Delay (HT ON 5, 10, 15, 20, 25, or 30 seconds,

default is 30 seconds

H eat OFF Delay (HT OFF ) 30, 60, 90, 120, 150, o r 180 seconds,

default is 150 seconds

H eat Airf low (HT ADJ) 1, 2, 3, or 4 Selects the nominal heati ng air flow (see

STA TUS

Submenu Item Indication (for Display Only; n o t User Modifiable)

Mode (MODE) Displays the current furnace operating mode
C FM (CFM) Dis play s the airflow for the current operati ng mode

Trims the heating airflow by the selected
amount.

Selects the indoor blower heat ON delay
Selects the indoor blower heat OFF delay

Startup Procedure and Adjustment –
Circulator Blower Speeds for addition

information)

32

NON-COMM (APPLIES ONLY TO A COMMUNICATING COMPATIBLE FURNACE MATCHED

WITH A NON-COMMUNICATI NG COMP ATIBL E S INGLE STAGE AIR CONDITI ONER)

Subme nu Ite m Use r Mod ifi ab le Option s Com ment s

Coo l Airf low (CL CFM ) 18, 24, 30, 36, 42 , 48, or 60, defa u lt

is 18

Se lec ts th e ai rfl o w fo r the non­communicating com patible single stage AC
unit

Co ol Airflow T rim (C L TRM) -10% to +10% in 2% increment s ,

d e fault is 0%

Selects the airflow trim amount for the non­communicating com patible single stage AC
unit

Co ol Airflow Pr ofile (CL PRFL) A, B, C, or D, default is A Sel ec ts the a ir flow profile for t he non-

communicating com patible single stage AC
unit

Co ol ON Delay (C L ON) 5 , 10, 20 , or 30 seconds , default is

5 seconds

Se lec ts th e in d oor blower ON dela y for the
non-communicating compatible single
st a g e A C un i t

C oo l OFF D ela y ( C L OFF) 30 , 60 , 90 , or 12 0 se c on ds , de f a u lt

is 30 se co nds

Selects the indoor blower OFF delay for the
non-communicating compatible single
st a g e A C un i t

NETWORK TROUBLESHOOTING

Communications is achieved by taking the difference between
two dc signals. The signals and transmission lines are re­ferred to as “data 1” and “data 2”. Each transmission line is
biased to approximately 2.5Vdc. During data reception/trans­mission, the data lines vary between +5V and ground. (When
data 1 is increasing towards +5V, data 2 is decreasing to­wards ground and when data 1 is decreasing towards ground,
data 2 is increasing towards +5V. Typically, the data 1 line is
approximately 2.6Vdc and the data 2 transmission line is ap­proximately 2.3Vdc. The voltage difference between data 1
and data 2 is typically 0.2 to 0.6 Vdc.

The indoor control is equipped with a bank of three dipswitches
that provide biasing and termination functions for the commu­nications transmission lines. The outdoor control in the com­municating compatible unit is equipped with a bank of two

The ComfortNet system is a fully communicating system, and
thus, constitutes a network. Occasionally the need to trouble­shoot the network may arise. The integrated furnace control
has some on-board tools that may be used to troubleshoot the
network. These tools are: red communications LED, green
receive (Rx) LED, and learn button.

• Red communications LED – Indicates the status of
the network. The table below indicates the LED status
and the corresponding potential problem.

• Green receive LED – Indicates network traffic. The
table below indicates the LED status and the
corresponding potential problem.

• Learn button – Used to reset the network. Depress
the button for approximately 2 seconds to reset the
network.

SYSTEM TROUBLESHOOTING

dipswitches that provide termination functions for the commu­nications transmission lines. Communications errors will re­sult if these switches are not correctly set. The figure below
indicates the switch position for the bias and termination dip
switches. Note that the ON position is the correct position for
all bias and termination dipswitches.

ONOFF
1
2
3

BIAS
BIAS

TERM

NOTE: Refer to the instructions accompanying the CT
compatible outdoor AC/HP unit for troubleshooting information.

Refer to the Troubleshooting Chart in in the back of this manual
for a listing of possible furnace error codes, possible causes
and corrective actions.

Indoor Unit BIAS and TERMINA TION Dip Switches

33

LED LED

Status

Off

1 Flash •

Red

Communications

LED

2 Flashes

Off

1 Steady

Flash

Green Receive

LED

Rapid

Flashing
On Solid

Indication Possible Causes Correct ive Action(s) Notes & Cautions

• Normal condition • Non e • None • None
Communications

Failure

•

Out-of-box reset

• No power

• Communications

error

•

No networ k foun d • Bro ken/ di sconnected

• Normal network
traffic

• Data 1/ Data 2
miss-wire

• Communications
Failure

• Control power up

• Learn button
depressed

No power to furnace

• Open fuse

• Communications error

data wire(s)

• Furnac e is installed as
a non communicating /
traditional system

• Control is “talking” on
netw or k a s expected

• Data 1 and data 2
wires reversed at
furnace, thermostat,
or Com f o rt Net

compatible

outdoor AC/HP

• Short between data 1
and data 2 wires

• Short between data 1
or data 2 wi r es and R
(24VAC) or C (24VAC
common)

Depress Learn Button

• Verify th at bus BIAS
and TERM
dipswitches are in t he
ON position.

• None • None

• Check fuses and
circuit breakers;
replace/reset

• Replac e b lo wn fuse

• Check for shorts in
low voltage wiring in
furnace/system

• Reset network by
depressing learn
button

• Check data 1/ data 2
voltages

• Check
communications
wiring (data 1/ data 2
wires)

• Check wi re
conn ections at
terminal block

• Verif y f urnace
installation type
(non communicating /
traditional
or communicating)

Check da ta 1/ data 2

•
voltages

• None • None

• Check
communications
wiring (data 1/ data 2
wires)

• Check wire
connections at
terminal block

• Check da ta 1/ data 2
voltages

• Depress once
quickly for a power­up rese t

• Depress and hold
for 2 secon ds for
an out- of-box reset

• Turn po wer OFF
prior to repair

• Turn po wer OFF
prior to repair

• Verify wires at
terminal blocks are
securely t wiste d
together prior to
inserting into
terminal block

• Ver ify data 1 and
data voltages as
descri be d above

• Turn power OFF
prior to repair

• Verif y wi res at
terminal blocks are

securely twisted
together prior to
inserting into
terminal block

• Ver ify data 1 and
data vo lt ag e s as
descri be d above

N

ORMAL SEQUENCE OF OPERA TION

POWER UP

The normal power up sequence is as follows:

• 115 V AC power applied to furnace.

• Integrated control module performs internal checks.

88

• Integrated control module displays

88

8

8 on dual 7-segment

88

88

display LED’s.

• Integrated control module monitors safety circuits

continuously.

• Furnace awaits call from thermostat. Dual 7-segment

LED’s display

OO

O while awaiting call from thermostat.

OO

HEATING MODE

The normal operational sequence in heating mode is as fol­lows:

• R and W1 (or R and W1/W2) thermostat contacts close,

initiating a call for heat.

• Integrated control module performs safety circuit checks.

• Induced draft blower is energized on high speed for a 15-

second prepurge. Humidifier terminal is energized with
induced draft blower.

• Induced draft blower steps to low speed following

prepurge. Low stage pressure switch contacts are
closed.

• Igniter warm up begins upon step to low speed and

presence of closed low stage pressure switch contacts.

34

• 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.

• If the thermostat call is for low heat, gas valve and induced

draft blower will continue on low stage. If the call is for
high heat, the gas valve and induced draft blower will
change to high stage.

• Circulator blower is energized on heat speed following a

thirty (30) second blower on delay . The circulator blower
requires thirty seconds to ramp up to full speed.
Electronic air cleaner terminal is energized with circulator
blower.

• Furnace is now operating on the specified stage called

for by the two-stage thermostat.

• Furnace runs, integrated control module monitors safety

circuits continuously.

• If the two-stage thermostat changes the call from low

heat to high heat, the integrated control module will
immediately switch the induced draft blower, gas valve,
and circulator blower to their high stage settings.

• If the two-stage thermostat changes the call from high

heat to low heat, the control will immediately switch the
induced draft blower and gas valve to their low stage
settings. The circulator blower will remain on high
heating speed for thirty (30) seconds before switching to

the low heat circulating speed.

• R and W1 (or R and W1/W2) 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. Humidifier terminals are de-energized.

• Circulator blower continues running for the selected heat

off delay period (90, 120, 150 or 180 seconds). The
speed run during this period depends on the last heat
call provided by the thermostat.

If the last call for heat was a call for low heat, the air
circulator motor will run on low heat speed for the duration
of the heat off delay period (90, 120, 150 or 180 seconds).

If the last call for heat was a call for high heat, the air
circulating motor will run on the high heating speed for
thirty (30) seconds and then switch to the low heating
speed for the balance of the heat off delay period (60,
90, 120 or 150 seconds).

• Circulator blower and electronic air cleaner terminal is

de-energized.

• Circulator blower ramps down to OFF during the 30

seconds following the heat off delay period.

• Furnace awaits next call from thermostat.

COOLING MODE

The normal operational sequence in cooling mode is as fol­lows:

• R and Y1/G or Y2/G thermostat contacts close, initiating

a call for cool.

• Integrated control module performs safety circuit checks.

• Outdoor fan and compressor are energized to their

appropriate speed.

• Circulator blower is energized on the appropriate cool

speed at the level and time determined by the selected
ramping profile. Electronic air cleaner terminal is
energized with circulator blower.

• Furnace circulator blower and outdoor cooling unit run

their appropriate speeds, integrated control module
monitors safety circuits continuously .

• R and Y1/G or Y2/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. The OFF delay time and airflow level are
determined by the selected ramping profile.

• Electronic air cleaner terminal and circulator blower are
de-energized.

• Furnace awaits next call from thermostat.

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 continuous fan speed

(25% of the furnace’s maximum airflow capability)
following a five (5) second delay . Electronic air cleaner
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. Electronic air cleaner

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.

35

Check the
Burner Flames for:

1. Stable, soft and blue.

2. Not curling, floating
or lifting off.

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

Burner Flame

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
normally-closed (electrically), automatic reset, temperature-ac­tivated sensor. The limit guards against overheating as a result
of insufficient conditioned air passing over the heat exchanger .

AUXILIARY LIMIT

The auxiliary limit controls are located on or near the circulator
blower and monitors blower compartment temperatures. They
are a normally-closed (electrically), auto-reset sensors. These
limits guard against overheating as a result of insufficient con­ditioned air passing over the heat exchanger.

ROLLOUT LIMIT

The rollout limit controls are mounted on the burner/manifold
assembly and monitor the burner flame. They are normally­closed (electrically), manual-reset sensors. These limits guard
against burner flames not being properly drawn into the heat
exchanger.

NOTE: Discharge body’s static electricity before touching unit.
An electrostatic discharge can adversely affect electrical
components.

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

WARNING

HIGHVOLTAGE!

TO

AVOIDPERSONALINJURYORDEATHDUETO

ELECTRICALSHOCK,DISCONNECTELECTRICALPOWER

BEFORE

PERFORMINGANYSERVICEORMAINTENANCE





.

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.

Refer to the T roubleshooting Chart at the end of this manual for
assistance in determining the source of unit operational prob­lems. The dual 7-segment LED display will display an error
code that may contain a letter and number . The error code may
be used to assist in troubleshooting the unit.

36

FAULT RECALL

The ignition control is equipped with a momentary push-button
switch that can be used to display the last six faults on the
dual 7-segment LED’s. The control must be in S t andby Mode
(no thermostat inputs) to use the feature. Depress the switch
for approximately 2 seconds. Release the switch when the
LED’s are turned off. The last six faults will be displayed most
recent to least recent on the dual 7-segment LED’s.

NOTE: Consecutively repeated faults are stored a maximum of
three times. Example: A clogged return air filter causes the
furnace limit to trip repeatedly . The control will only store this
fault the first three consecutive times the fault occurs.

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

EE

characterized by a non-functioning furnace and a

00

E

0 code dis-

EE

00

played on the dual 7-segment display. If the furnace is in “lock­out”, it will (or can be) reset in any of the following ways.

1. Automatic reset. The integrated control module will
automatically reset itself and attempt to resume normal
operations following a one hour lockout period.

2. Manual power interruption. Interrupt 115 volt power to
the furnace.

3. Manual thermostat cycle. Lower the thermostat so that
there is no longer a call for heat for 1 -20 seconds then
reset to previous setting.

NOTE: If the condition which originally caused the lockout still
exists, the control will return to lockout. Refer to the Diagnostic
Chart for aid in determining the cause.

M

AINTENANCE

WARN ING

TO

AVOIDELECTRICALSHOCK,INJURYORDEATH

DISCONNECTELECTRICALPOWERBEFOREPERFORMINGANY

MAINTENANCE

HANDLEWITHCARE

WITHBAREFINGERS,ROUGHHANDLINGORVIBRATION

COULDDAMAGETHEIGNITERRESULTINGINPREMATURE

FAILURE

HANDLETHEIGNITER

.IF

YOUMUSTHANDLETHEIGNITER

.T

OUCHINGTHEIGNITERELEMENT

.O

NLYAQUALIFIEDSERVICERSHOULDEVER

.

,



,









ANNUAL INSPECTION

The furnace should be inspected by a qualified installer , or ser­vice agency at least once per year. This check should be per­formed at the beginning of the heating season. This will ensure
that all furnace components are in proper working order and
that the heating system functions appropriately . Pay particular
attention to the following items. Repair or service as neces­sary.

• Flue pipe system. Check for blockage and/or leakage.
Check the outside termination and the connections at
and internal to the furnace.

• Heat exchanger. Check for corrosion and/or buildup
within the heat exchanger passageways.

• Burners. Check for proper ignition, burner flame, and
flame signal.

• Drainage system. Check for blockage and/or leakage.
Check hose connections at and internal to furnace.

• Wiring. Check electrical connections for tightness and/
or corrosion. Check wires for damage.

• Filters.

FILTERS

CAUTION

TO

ENSUREPROPERUNITPERFORMANCE,ADHERETOTHEFILTERSIZES

GIVENINTHERECOMMENDEDMINIMUMFILTERSIZETABLEOR

PECIFICATIONSHEETAPPLICABLETOYOURMODEL

S

.

FILTER MAINTENANCE

Improper filter maintenance is the most common cause of in­adequate heating or cooling performance. Filters should be
cleaned (permanent) or replaced (disposable) every two months
or as required. 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.

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. Turn 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. Turn ON electrical power to furnace.

MEDIA AIR FILTER OR ELECTRONIC AIR CLEANER REMOVAL

Follow the manufacturer’s directions for service.





37

BURNERS

Visually inspect the burner flames periodically during the heat­ing season. Turn on the furnace at the thermostat and allow
several minutes for flames to stabilize, since any dislodged
dust will alter the flames normal appearance. Flames should
be stable, quiet, soft, and blue (dust may cause orange tips
but they must not be yellow). They should extend directly
outward from the burners without curling, floating, or lifting off.
Flames must not impinge on the sides of the heat exchanger
firing tubes.

INDUCED DRAFT AND CIRCULATOR BLOWERS

9. Severe heat exchanger fouling is an indication of an
operational problem. Perform the checks listed in
Startup Procedure and Adjustments to reduce the
chances of repeated fouling.

B

EFORE LEA VING AN INSTALLATION

• Cycle the furnace with the thermostat at least three

times. Verify 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.

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.

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. If necessary , clean the
passageways as outlined below .

1. Turn OFF the electrical power and gas supply to the
furnace.

2. Disconnect the gas line and remove the burner/ manifold
assembly by removing the screws securing the assembly
to the partition panel.

3. Disconnect the flue pipe system from the induced draft
blower.

4. Remove the induced draft blower and collector box cover.

5. Clean the primary heat exchanger tubes using a wire
brush attached to a length of high grade stainless steel
cable, such as drain cleanout cable. Att ach a variable
speed reversible drill to the other end of the cable. Slowly
rotate the cable with the drill and insert it into one of the
heat exchanger tubes. While reversing the drill, work
the cable in and out several times to obtain sufficient
cleaning. Repeat for each tube.

6. Clean residue from furnace using a vacuum cleaner.

7. Replace the parts removed in the previous steps in
reverse order.

8. Turn on electrical power and gas to furnace. Check for
leaks and proper unit operation.

R

EPAIR AND REPLACEMENT PARTS

• 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 List-

Gas V alve Blower Motor
Gas Manifold Blower Wheel
Natural Gas Orifice Blower Mounting Bracket
Propane Gas Orifice Blower Cutoff
Igniter Blower Housing
Flame Sensor Inductor
Rollout Limit Switch Heat Exchanger

Primary Limit Switch Auxiliary Limit Switch

Pressure Switch Integrated Control Module
Induced Draft Blower Transformer
Door Switch

38

T

O

E0

E1

E2

ROUBLESHOOTING

C

HART

Notes & Cautions

repair.

module fuse with 3A

automotive fuse.

“Electrostatic Discharge”

section of manual.

x Turn power OFF prior to

x Replace integrated control

x Read precautions in

module with current

x Replace integrated control

replacement parts.

x Turn power OFF prior to

repair.

with care.

x Igniter is fragile, handle

emery cloth.

section for piping details.

x Sand flame sensor with

x See “Vent/Flue Pipe”

x Turn power OFF prior to

repair.

with correct replacement

part.

x Replace pressure switch

x The board checks for an

open pressure switch when

repair.

with correct replacement

part.

blower with correct

a call for heat is received.

It will only power the

inducer and proceed with

the call for heat if the

pressure switch is open.

x Turn power OFF prior to

x Replace pressure switch

replacement part.

x Replace induced draft

Corrective Actions

interruption.

switch operation (hose, wiring,

contact operation). Correct if

necessary.

sensor if coated and/or oxidized.

proper length, elbows, and

termination.

furnace and integrated control

x Assure 115 and 24 volt power to

module.

fuse (3A). Replace if necessary.

and 24 volt circuits. Repair as

necessary.

module.

x Locate and correct gas

x Check integrated control module

x Check for possible shorts in 115

x Replace bad integrated control

x Check front cover pressure

x Replace or realign igniter.

x Check flame sense signal. Sand

x Check flue piping for blockage,

x Verify proper induced draft

blower performance.

x Replace low stage pressure

switch.

between ignition attempts if

furnace is equipped with

PCBKF101 control board. Look

for cause of no ignition – gas

supply, gas valve switch off,

x Repair short in wiring.

x Disregard E1 code shown

improper gas manifold pressure,

Repair/replace if necessary.

piping for blockage, proper

length, elbows, and termination.

necessary.

performance. Correct as

necessary.

or contact motion.

improper L.P. conversion.

x Inspect pressure switch hose.

x Inspect flue and/or inlet air

x Check drain system. Correct as

x Check induced draft blower

connection.

x Correct pressure switch set point

x Tighten or correct wiring

Possible Causes

may be no gas to burners, front

cover pressure switch stuck open,

bad igniter or igniter alignment,

improper orifices, or

coated/oxidized or improperly

connected flame sensor.

Cause may be interrupted gas

supply, lazy burner flames

(improper gas pressure or

restriction in flue and/or

combustion air piping), front

cover pressure switch opening, or

improper induced draft blower

performance.

contacts sticking.

wiring.

control will detect a closed

pressure switch after a failed

ignition attempt and before the

next attempt and may display a

door switch open or 24 volt wire

improperly connected or loose

x Blown fuse or circuit breaker

x Integrated control module has an

internal fault

x Manual disconnect switch OFF,

EE

x Normal operation x None x Normal operation

x Failure to establish flame. Cause

x Loss of flame after establishment.

x Low stage pressure switch

x Shorts in pressure switch circuit

x Board timing with PCBKF101

E1

misleading E1 code.

pinched, or connected improperly.

blocked drain system or weak

induced draft blower.

or malfunctioning switch

contacts.

x Pressure switch hose blocked

x Blocked flue and/or inlet air pipe,

x Incorrect pressure switch set point

wiring.

x Loose or improperly connected

ComfortNet

Thermostat Only

Fault Description

LED Codes

Diagnostic/Status

Message Code

INTERNAL

x No 115 power to furnace

None

Thermostat)

FAULT

or no 24 volt power to

integrated control

module

x Blown fuse or circuit

breaker

None None

LOCKOUT E0

an excessive number of

module has an internal

fault

x Integrated control

x Normal operation

n

O

n

ignition “retries” (3 total)

x Furnace lockout due to

E0

error code.

PS1

CLOSED

switch circuit is closed at

x Low stage pressure

E1

start of heating cycle.

error code.

PS1 OPEN E2

switch circuit is not

closed.

x Low stage pressure

E2

error code.

Symptoms of Abnormal Operation

(Non-Communicating & ComfortNet™

provides no signal.

icon illuminated

x ComfortNet thermostat “Call for Service”

x ComfortNet thermostat scrolls “Check

Furnace” message

x Furnace fails to operate

x Integrated control module LED display

provides

x LED display indicates

x ComfortNet thermostat “Call for Service”

x Furnace fails to operate

x Integrated control module LED display

icon illuminated.

x ComfortNet thermostat scrolls “Check

Furnace” message.

x Furnace fails to operate.

icon illuminated.

x ComfortNet thermostat “Call for Service”

x ComfortNet thermostat scrolls “Check

Furnace” message.

with no further furnace operation.

x Induced draft blower runs continuously

provides

x Integrated control module LED display

icon illuminated.

x ComfortNet thermostat “Call for Service”

x ComfortNet thermostat scrolls “Check

Furnace” message.

provides

x Integrated control module LED display

39

T

E3

E4

E5

E6

E7

ROUBLESHOOTING

Notes & Cautions

repair.

applicable to your model

x Turn power OFF prior to

for allowable rise range

x See Specification Sheet

Corrective Actions

blockage. Clean filters or

remove obstruction.

x Check filters and ductwork for

and performance. Correct speed

x Check circulator blower speed

C

HART

and proper circulator

speed.

section for piping details.

x See "Vent/Flue Pipe"

or replace blower motor if

necessary.

alignment.

for blockage, proper length,

elbows, and termination. Correct

as necessary.

proper performance. Replace if

x Check burners for proper

x Check flue and air inlet piping

necessary.

x Check induced draft blower for

connection.

x Tighten or correct wiring

repair.

x Turn power OFF prior to

in flame sensor wiring.

x Correct short at flame sensor or

x Check for lingering flame.

x Verify proper operation of gas

valve.

x Turn power OFF prior to

repair.

emery cloth.

section for piping details.

gas pressure.

repair.

correct replacement part.

repair.

automotive type

x Turn power OFF prior to

x Sand flame sensor with

x See "Vent/Flue Pipe"

x See rating plate for proper

x Replace fuse with 3-amp

coated/oxidized.

alignment.

voltage wiring

x Sand flame sensor if

blockage, proper length, elbows,

x Inspect for proper sensor

x Check inlet air piping for

x Turn power OFF prior to

and termination.

integrated control module to

rating plate. Adjust as needed.

x Check and correct wiring from

x Compare current gas pressure to

x Replace igniter with

igniter.

x Replace shorted igniter.

correct replacement part.

x Replace control with

wiring.

x Check and correct unit ground

control. Replace if necessary.

x Check igniter output from

Possible Causes

ComfortNet

Thermostat Only

Fault Description

LED Codes

Diagnostic/Status

E3

HIGH

Message Code

x Insufficient conditioned air over

x Primary limit or

E3

the heat exchanger. Blocked

filters, restrictive ductwork,

LIMIT

OPEN

auxiliary limit circuit is

open.

improper circulator blower speed,

x Rollout limit circuit is

or failed circulator blower motor.

x Flame rollout.

open.

x Misaligned burners, blocked flue

and/or air inlet pipe, or failed

induced draft blower.

wiring.

x Loose or improperly connected

circuit.

x Short to ground in flame sense

x Lingering burner flame.

x Slow closing gas valve.

E4

FLAME

IMPROPER

call for heat.

x Flame sensed with no

E4

x Short in low voltage wiring x Locate and correct short in low

Not

Displayed

Not

Displayed

x Open Fuse

E5

x Flame sensor is coated/oxidized.

x Flame sensor incorrectly

E6

WEAK

FLAME

signal is low

x Flame sense micro amp

E6

positioned in burner flame.

improper gas pressure or

combustion air.

x Lazy burner flame due to

x Improperly connected igniter.

E7

IGNITER

x Problem with igniter

x Shorted igniter.

FAULT

circuit.

E7

control module.

x Poor unit ground.

x Igniter relay fault on integrated

Thermostat

Symptoms of Abnormal Operation

(Non-Communicating & ComfortNet™

error code.

furnace operation.

provides

icon illuminated.

x Circulator blower runs continuously. No

x Integrated control module LED display

x ComfortNet thermostat “Call for Service”

x ComfortNet thermostat scrolls “Check

Furnace” message.

error code.

runs continuously. No furnace operation.

provides

x Induced draft blower and circulator blower

icon illuminated.

x Integrated control module LED display

x ComfortNet thermostat “Call for Service”

x ComfortNet thermostat scrolls “Check

Furnace” message.

error code.

provides

x No furnace operation.

x Integrated control module LED display

x ComfortNet thermostat displays “Battery

Power”.

x Normal furnace operation.

error code.

provides

x Integrated control module LED display

x Furnace fails to operate.

x Integrated control module LED display

error code.

provides

icon illuminated.

x ComfortNet thermostat “Call for Service”

x ComfortNet thermostat scrolls “Check

Furnace” message.

40

T

E8

E9

EA

0

ROUBLESHOOTING

C

HART

Notes & Cautions

repair.

with correct replacement

x Turn power OFF prior to

part.

x Replace pressure switch

x Turn power OFF prior to

repair.

with correct replacement

part.

x Replace pressure switch

x Replace induced draft

blower with correct

replacement part.

x Turn power OFF prior to

repair.

x Turn power OFF prior to

repair

specific model.

BEFORE turning power

ON. Memory card may be

removed after data is

loaded.

removing memory card.

x Use memory card for the

x Insert memory card

x Turn power OFF before

x Error code will be cleared

once data is loaded.

Corrective Actions

Repair/replace if necessary.

piping for blockage, proper

length, elbows, and termination.

Check drain system. Correct as

necessary.

performance. Correct as

necessary.

or contact motion.

switch.

x Replace high stage pressure

x Inspect pressure switch hose.

x Repair short in wiring

x Inspect flue and/or inlet air

x Check induced draft blower

connection.

correct polarity.

x Correct pressure switch set point

x Tighten or correct wiring

necessary.

x Review wiring diagram to

x Verify proper ground. Correct if

x Check and correct wiring.

x Populate shared data set using

memory card.

Possible Causes

pinched, or connected

improperly.

blocked drain system or weak

induced draft blower.

point or malfunctioning switch

contacts.

contacts sticking.

wiring.

x High stage pressure switch

x Shorts in pressure switch circuit

E8

x Pressure switch hose blocked

x Blocked flue and/or inlet air pipe,

x Incorrect pressure switch set

wiring.

x Loose or improperly connected

x Polarity of 115 volt AC power to

EA

furnace or integrated module is

revered.

x Poor unit ground

x Furnace does not contain any

d0

shared data.

ComfortNet

Thermostat Only

Fault Description

LED Codes

Diagnostic/Status

PS2

Message Code

Thermostat

CLOSED

switch circuit is closed at

x High stage pressure

E8

PS2 OPEN E9

switch circuit is not

closed.

operating.

start of heating cycle.

operating.

low stage only

x Furnace is operating on

x High stage pressure

x Induced draft blower is

low stage only

x Induced draft blower is

x Furnace is operating on

E9

error code.

error code.

REVERSED

x Polarity of 115 volt AC

PLTY

is reversed

EA

error code.

DATA

NO NET

x Data not yet on network.

d0

error code.

Symptoms of Abnormal Operation

(Non-Communicating & ComfortNet™

x Furnace fails to operate on high stage;

furnace operates normally on low stage.

provides

x Integrated control module LED display

x Furnace fails to operate on high stage;

furnace operates normally on low stage.

provides

x Integrated control module LED display

icon illuminated.

x ComfortNet thermostat “Call for Service”

x ComfortNet thermostat scrolls “Check

Furnace” message.

x Furnace fails to operate.

provides d

icon illuminated.

x ComfortNet thermostat “Call for Service”

Furnace” message.

x ComfortNet thermostat scrolls “Check

x Integrated control module LED display

provides

x Furnace fails to operate.

x Integrated control module LED display

41

T

4

0

1

2

3

ROUBLESHOOTING

C

HART

Notes & Cautions

Corrective Actions

Possible Causes

Only

ComfortNetThermostat

repair

x Turn power OFF prior to

x Use memory card for the

for the specific model. Re-

populate data using correct

x Verify shared data set is correct

has been rejected by integrated

control module

x Shared data set on memory card

d4

DATA

Message Code

INVALID MC

specific model.

x Insert memory card

memory card if required.

BEFORE turning power

ON. Memory card may be

removed after data is

loaded.

removing memory card.

once data is loaded.

repair

correct replacement part.

with correct replacement

part.

repair

with correct replacement

part.

module with correct

replacement part.

repair

correct replacement part.

specific model

BEFORE turning power

ON. Memory card may be

removed after data is

loaded.

x Turn power OFF before

x Error code will be cleared

x Turn power OFF prior to

x Tighten or correct wiring

x Loose wiring connection at

b0

MOTOR NOT

connection.

circulator motor power leads or

RUN

x Replace inductor with

x Replace circulator motor

through inductor. Replace if

open or short circuit.

x Verify continuous circuit

circulator motor power leads

disconnected.

x Open circuit in inductor or loose

x Turn power OFF prior to

x Replace circulator motor

x Replace integrated control

x Turn power OFF prior to

x Replace motor with

x Use memory card for the

x Insert memory card

Replace if necessary.

connection.

Replace if necessary.

x Check circulator blower motor.

x Tighten or correct wiring

wiring connection at inductor

(3/4 Hp and 1 Hp models only).

circulator motor control leads.

x Failed circulator blower motor.

x Loose wiring connection at

b1

COMM

MOTOR

module. Replace if necessary.

x Check circulator blower motor.

x Check integrated control

x Failed circulator blower motor.

x Failed integrated control module.

horse power is the same

specified for the specific furnace

x Verify circulator blower motor

in furnace.

x Incorrect circulator blower motor

x Incorrect shared data set in

b2

MOTOR

MISMATCH

model. Replace if necessary.

for the specific model. Re-

populate data using correct

memory card if required.

x Verify shared data set is correct

integrated control module.

x Turn power OFF before

removing memory card.

x Error code will be cleared

once shared data and

motor horse power match.

x Turn power OFF prior to

x Check filters for blockage.

x Blocked filters.

b3

MOTOR

repair.

Clean filters or remove

obstruction.

x Restrictive ductwork.

x Undersized ductwork.

LIMITS

Remove obstruction. Verify all

x Check ductwork for blockage.

x High ambient temperatures.

registers are fully open.

sized for system. Resize/replace

ductwork if necessary.

"Location Requirements &

Considerations" for furnace

x Verify ductwork is appropriately

installation requirements.

x See "Product Description" and

Fault Description

LED Codes

Diagnostic/Status

Symptoms of Abnormal Operation

(Non-Communicating & ComfortNet™

data.

x Invalid memory card

d4

x Circulator blower motor

is not running when it

should be running.

b0

module has lost

communications with

circulator blower motor.

x Integrated control

b1

x Circulator blower motor

horse power in shared

data set does not match

circulator blower motor

horse power.

b2

x Circulator blower motor

is operating in a power,

temperature, or speed

limiting condition.

b3

Thermostat

error code.

operation.

provides d

icon illuminated.

x Operation different than expected or no

x Integrated control module LED display

x ComfortNet thermostat “Call for Service”

x ComfortNet thermostat scrolls “Check

Furnace” message.

x Furnace fails to operate.

error code.

provides b

icon illuminated.

Furnace” message.

x ComfortNet thermostat “Call for Service”

x ComfortNet thermostat scrolls “Check

x Integrated control module LED display

x Furnace fails to operate.

error code.

provides b

icon illuminated.

Furnace” message.

x ComfortNet thermostat “Call for Service”

x ComfortNet thermostat scrolls “Check

x Integrated control module LED display

x Furnace fails to operate.

error code.

provides b

icon illuminated.

x ComfortNet thermostat “Call for Service”

x ComfortNet thermostat scrolls “Check

Furnace” message.

x Integrated control module LED display

x Furnace operates at reduced performance.

error code.

provides b

x Airflow delivered is less than expected.

x Integrated control module LED display

42

T

4

5

6

7

9

ROUBLESHOOTING

C

HART

Notes & Cautions

x Turn power OFF prior to

repair.

x Turn power OFF prior to

repair

replacement part.

x Replace motor with correct

replacement part.

x Replace wheel with correct

x Turn power OFF prior to

repair.

x Turn power OFF prior to

repair.

replacement part(s).

x Replace with correct

x Use memory card for the

repair.

specific model.

x Turn power OFF prior to

Corrective Actions

grills/registers, duct system, and

furnace air inlet/outlet for

blockages.

x Check filters, filter

obstructions. Remove and

repair/replace wheel/motor if

necessary.

shaft rotation and motor.

Replace motor if necessary.

line voltage to furnace is within

the range specified on the

furnace rating plate.

x Check circulator blower for

x Check circulator blower motor

x Check power to furnace. Verify

x See "Product Description" and

"Location Requirements &

Considerations" for furnace

installation requirements.

Verify control is populated with

correct shared data set. See data

errors above for details.

x Check integrated control module.

x Check for locked rotor condition

(see error code above for

details).

x Check filters for blockage.

Clean filters or remove

obstruction.

Remove obstruction. Verify all

registers are fully open.

sized for system. Resize/replace

x Check ductwork for blockage.

ductwork if necessary.

x Verify ductwork is appropriately

Possible Causes

ComfortNet

Thermostat Only

Fault Description

LED Codes

Diagnostic/Status

x Abnormal motor loading, sudden

b4

MOTOR

Message Code

x Circulator blower motor

change in speed or torque, sudden

TRIPS

senses a loss of rotor

b4

blockage of furnace air inlet or

control.

outlet.

x Circulator blower motor

filters, very restrictive ductwork,

blockage of furnace air inlet or

outlet.

housing.

x High loading conditions, blocked

senses high current.

bearings.

x Obstruction in circulator blower

x Seized circulator blower motor

b5

ROTOR

MTR LCKD

fails to start 10

consecutive times.

x Circulator blower motor

b5

x High AC line voltage to furnace.

x Failed circulator blower motor.

x Low AC line voltage to furnace.

x High ambient temperatures.

b6

VOLTS

MOTOR

shuts down for over or

under voltage condition.

x Circulator blower motor

x Circulator blower motor

shuts down due to over

temperature condition on

b6

power module.

module.

x Error with integrated control

x Motor has a locked rotor

b7

MOTOR

PARAMS

does not have enough

information to operate

x Circulator blower motor

b7

condition.

properly.

x Blocked filters.

x Restrictive ductwork.

x Undersized ductwork.

b9

LOW ID

AIRFLOW

consecutive times.

x Airflow is lower than

demanded.

x Motor fails to start 40

b9

Thermostat

error code.

Symptoms of Abnormal Operation

(Non-Communicating & ComfortNet™

x Furnace fails to operate.

provides b

icon illuminated.

Furnace” message.

x Integrated control module LED display

x ComfortNet thermostat “Call for Service”

x ComfortNet thermostat scrolls “Check

x Furnace fails to operate.

error code.

provides b

icon illuminated.

x ComfortNet thermostat “Call for Service”

x ComfortNet thermostat scrolls “Check

x Integrated control module LED display

Furnace” message.

x Furnace fails to operate.

error code.

error code.

error code.

provides b

icon illuminated.

Furnace” message.

x ComfortNet thermostat “Call for Service”

x ComfortNet thermostat scrolls “Check

x Integrated control module LED display

x Furnace fails to operate.

provides b

icon illuminated.

x Integrated control module LED display

x ComfortNet thermostat “Call for Service”

x ComfortNet thermostat scrolls “Check

Furnace” message.

x Furnace operates at reduced performance

or operates on low stage when high stage is

expected.

provides b

x Integrated control module LED display

43

S

TATUS

C

ODES

INTERNAL CONTROL FAULT/NO POWER
NORMAL OPERATION

O

n

LOCKOUT DUE TO EXCESSIVE RETRIES

E 0

LOW STAGE PRESSURE SWITCH STUCK CLOSED AT START OF HEATING CYCLE

E 1

LOW STAGE PRESSURE SWITCH STUCK OPEN

E 2

OPEN HIGH LIMIT SWITCH

E 3

FLAME DETECTED WHEN NO FLAME SHOULD BE PRESENT

E 4

OPEN FUSE

E 5

LOW FLAME SIGNAL

E 6

IGNITER FAULT OR IMPROPER GROUNDING

E 7

HIGH STAGE PRESSURE SWITCH STUCK CLOSED AT START OF HEATING CYCLE

E 8

HIGH STAGE PRESSURE SWITCH STUCK OPEN

E 9

REVERSED 1 15 VAC POLARITY

E A

DATA NOT YET ON NETWORK

d 0

INVALID M EMO RY CARD DATA

d 4

BLOWER MOTOR NOT RUNNING

b 0

BLOWER COMMUNICATION ERROR

b 1

BLOWER HP MIS-MATCH

b 2

BLOWER MOTOR OPERATING IN POWER, TEMPERA T URE, OR SPE ED LIMIT

b 3

BLOWER MOTOR CURRENT TRIP OR LOST ROTOR

b 4

BLOWER MOTOR LOCKED ROTOR

b 5

OVER/UNDER VOLTAGE TRIP OR OVER TEMPERATURE TRIP

b 6

INCOMPLETE PA R A METERS SENT TO MOTOR

b 7

LOW INDOOR AIRFLOW

b 9

LOW STAGE COOL

C 1

HIGH STAGE COOL

C 2

LOW STAGE HEAT

L 0

HIGH STAGE HEAT

H I

CONTINUOUS FAN

F

CFM/100; ALTERNATES WITH , , , ,

1 2

C 1

C 2

L O

H I

F

44

AIR F

LOW

D

ATA

Speed Selection Dip Switches

Cool Adjust Profile Heat
Selection Selection Selection Selection
Switches Switches Switches Switches

TAP 1 2 3 4 5 6 7 8
A OFF OFF OFF OFF OFF OFF OFF OFF
B ON OFF ON OFF ON OFF ON OFF

C OFF ON OFF ON OFF ON OFF ON
D ON ON ON ON ON ON ON ON

Profiles Pre -Run Short-Run OFF Del ay

A ------- -------- 60 sec/100%
B ------- 30 sec/50% 60 sec/100%
C ------- 7.5 min/82% 6 0 sec /100%
D 30 sec/50% 7.5 min/82% 30 sec/50%

To set airflow:

(1) Select model and desired
high stage coolin g airflo w . De te rmin e the co rresponding tap
( A, B, C, or D ). Set dip switches 1 and 2 to the appropriate
ON / OFF positions. (2) Select model and desired high stage
heating airflow. Determine the co rresponding tap ( A, B, C, or
D ). Set dip switches 7 and 8 to the appropriate ON / OFF
positions. (3) Select the airflow adjustment f a c tor taps A and
D are 1; Tap B is +10%; Tap C -10%. Set dip switches 3 and 4
to the appropriate ON / OFF positions.

To set Comfort Mode:

Select desired Comfort Mode p rof ile
(see profiles above). Set switches 5 and 6 to the appropriate
ON / OFF positions.

Model Tap Low Stage High Stage Low Stage High Stage
Cool Cool Heat Heat

390
520
650
780

520

715
910

1170
553

748

943

1203

390
520

715
910

520

715
910

1170

520

715
910

1175

600

800
1000
1200

800

1100
1400
1800

850

1150

1450
1850

600
800

1100
1400

800

1100

1400
1800

800

1100

1400
1800

735
805
875
935

945

1015

1085

1155

1085

1155
1225
1260

875
945

1015

1085

1050

1120

1190
1260

1210
1225
1245
1260

*DVC80603B***

*DVC80805C** *

*DVC81005C***

*MVC80604B***

*MVC80805C***

*MVC81005C***

A

B
C
D

A

B
C
D

A
B
C
D

A
B
C
D

A
B
C
D

A
B

C
D

1050

1150
1250
1350

1350
1450
1550
1650

1550
1650
1750
1800

1250
1350
1450
1550

1500
1600
1700
1800

1725

1750

1775

1800

NOTE: Airflow data shown applies to non-communicating mode operation only. For a fully communicating
system, please see the outdoor unit’s installation instructions for cooling and pump heating airflow data. See
ComfortNet™ System - Airflow Consideration section for details.

DIP S

Switch

Bank

WITCHES

Purpose

He at OFF

Delay

S1

Thermostat

Setup

Bus BIAS BIAS ON* ON* --- --- --- --- --- --- --- ---

S2

S3

S4

S5

---

TERM Bus Termination --- --- ON* --- --- --- --- --- --- ---

Cooling

S peed T ap

A djus t T aps

Ramping

Profiles

Heating

S peed T ap

DEHUM

Not ap pl ic able

Func tion

9 0 s econds O FF OFF --- --- --- - -- --- --- --- ---

120 seconds ON OFF --- --- --- --- --- --- --- ---

150 seconds* OFF ON --- --- --- --- --- --- --- ---

180 seconds ON ON --- --- --- --- --- --- --- --­1 -Stage T-st at --- --- OFF --- --- --- --- --- --- --­2-S ta ge T-Sta t --- --- ON --- --- --- --- --- - -- ---

5 -M in Delay --- --- --- OF F --- --- --- --- - -- ---

A uto D elay --- --- --- ON --- --- --- --- --- ---

A OFF OFF --- --- --- --- --- --- --- --­B ON OFF --- --- --- --- --- --- --- --­C OFF ON --- --- --- --- --- --- --- ---

D* ON ON --- --- --- --- --- --- --- ---

Normal* --- --- OFF OFF --- --- --- --- --- ---

10% --- --- ON OFF --- --- --- --- --- ---

-10% --- --- OFF ON --- --- --- --- --- ---

Normal --- --- ON ON --- --- --- --- --- ---

A* --- --- --- --- OFF OFF --- --- --- ---

B --- --- --- --- ON OFF --- --- --- --­C --- --- --- --- OFF ON --- --- --- --­D --- --- --- --- ON ON --- --- --- --­A --- --- --- --- --- --- OFF OFF --- ---

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

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

Disabled* --- --- --- --- --- --- --- --- OFF Unused

Enabled --- --- --- --- --- --- --- --- ON Unused

12345678910

(*Indicates fa ctory se ttin g)

DIP Switch No .

45

*MVC8, *DVC8 W

YL

YL

ID BLOWER TWO-STAGE PRESSURE

SWITCH ASSEMBLY

HOT

SURFACE

IGNITER

2 CIRCUIT

2

1

CONNECTOR

BK

WH

.

MAY

UNIT

SO

THIS

DO

.

TO

DEATH

INSTALLING

AILURE

OR

. F

OR

INJURY

PRESENT

SERVICI NG

BE

MAY

PERSONAL

,

BEFORE

DAMAGE

SOURCES

POWER
ALL

POWER

PROPERTY

ULTIPLE

ISCONNECT

HIGH VOLTAGE!

D

CAUSE

M

NOTES:

1. SET HEAT ANTICIPATOR ON ROOM THERMOSTAT AT 0.7 AMPS.

2. MANUFACTURER'S SPECIFIED REPLACEMENT PARTS MUST BE
USED WHEN SERVICING.

3. 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. USE COPPER CONDUCTORS ONLY.

4. UNIT MUST BE PERMANENTLY GROUNDED AND CONFORM TO
N.E.C. AND LOCAL CODES.

5. TO RECALL THE LAST 6 FAULTS, MOST RECENT TO LEAST
RECENT, DEPRESS SWITCH FOR MORE THAN 2 SECONDS WHILE
IN STANDBY (NO THERMOSTAT INPUTS)

ECM MTR
HARNESS

BK

WH

RD

RD

LOW FIRE

PRESSURE

SWITCH

TWO STAGE

GAS VALVE

(HONEY WELL)

2

HI

3

BL

C

1

PM

MANUAL RESET ROLLOUT LIMIT

PU

AUTO RESET PRIMARY

LIMIT CONTROL

3

2

1

BURNER COMPARTMENT

BLOWER COMPARTMENT

EAC

BL

WH

BL

BR

14

13

RD

10

11

YL

RD

BL

GY

BK

3
2

1

CIRCULATOR
BLOWER

24 V

3 A

4

RD

YL

FUSE

8

7

5

4

1

2

5
4
3
2
1

C

NO

YL

WH

BR

CONTROLS

WH
RD
BK

HUM

NEUTRAL

BK

LINE

GN

YL

15

12

HEAT OFF

9

2ND STG DLY

6

3

SEE

NOTE 5

C

R

2

1

24 V THERMOSTAT CONNECTIONS

BK

WH

GR

PK

YL

HIGH FIRE

PRESSURE SWITCH

PU

FS

OR

COOL

ADJUST

DELAY

HEAT

DEHUM

UNUSED

DELAY

T-STAT

W2

W1

Y1

G

GND

24V HUM.

GND

AUTO RESET

AUXILIARY

LIMIT CONTROL

CONNECTOR

DIP SWITCHES

MODULE

DIAGNOSTIC

LED'S

Y2

RD

C

NO

RD

PU

INDUCED

DRAFT

BLOWER

PU

5 CIRCUIT CONNECTOR

5

4

3

2

1

4 CIRCUIT MOTOR

4

3

2

1

TWO-STAGE

INTEGRATED

CONTROL

DEHUM

O

BK

INDUCTOR COIL
70kBTU,90kBTU,

115kBTU MODELS

ONLY

COLOR CODES:

PK PINK
BR BROWN

WH WHITE
BL BLUE
GY GRAY
RD RED

YL YELLOW

OR ORANGE
PU PURPLE
GN GREEN
BK BLACK

BR

YL

WH

BK

40 VA

TRANSFORMER

JUNCTION BOX

WH

BL

FLAME

SENSOR

BK

CHASSIS GROUND

OR

GN

BL

RD

24
VAC

115
VAC

WH

WH

BK

BK

BLOWER
COMPARTMENT
DOOR SWITCH
(OPEN WHEN
DOOR OPEN)

LOW VOLTAGE (24V)

LOW VOLTAGE FIELD

HI VOLTAGE (115V)

HI VOLTAGE FIELD

INTERNAL TO

INTEGRATED CONTROL

PLUG CONNECTION

WH

DISCONNECT

OVERCURRENT PROTECTION DEVICE

WARNING:

DISCONNECT POWER
BEFORE SERVICING.
WIRING TO UNIT
MUST BE PROPERLY
POLARIZED AND
GROUNDED.

DOOR

SWITCH

INDUCTOR COIL
70kBTU,90kBTU,

115kBTU MODELS

ONLY

LINE

INTEGRATED CONTROL MODULE

LINE

FUSE 3 A

R

TO +VDC

24V THERMOSTAT CONNECTIONS

Y1

W1

W2

TO
MICRO

Y2

G

O

DEHUM

24V HUM.

C

TO

R

TO

MICRO

INTEGRATED CONTROL MODULE

JUNCTION

TERMINAL

GND

Ø /60 HZ POWER SUPPLY WITHTO 115VAC/ 1

L

CIRCULATOR

EAC

ELECTRONIC
AIR CLEANER

IND HI

IND LO

HUM

HUMIDIFIER

IGN

HOT SURFACE

FS

FLAME SENSOR

TH (4)

AUTO RESET AUXILIARY LIMIT

CONTROLS

HLO (10)

PSO (7)

PS1 (2)

NO

PS2 (12)

HIGH FIRE
PRESS. SWTICH

HLI (1)

MVL (13)

MVH (14)

MVC (8)

GND (5)

TR (11)

GND (4)

+ VDC (1)

RX (2)

TX (3)

HUMIDIFIER

SWITCH (PRESS.)

L

N

GND

JUNCTION BOX

INDOOR

AIR

BLWR

ID

BLWR

IGNITER

115 VAC

24 VAC

24V HUM.

NO

INDOOR

CIRCULATOR

BLWR

EQUIPMENT GND

FIELD SPLICE

SWITCH (TEMP.)

OVERCURRENT
PROT. DEVICE

IRING

TO
115 VAC/ 1

Ø /60 HZ
POWER SUPPLY WITH
OVERCURRENT
PROTECTION DEVICE

WARNING:DISCONNECT
POWER BEFORE
SERVICING. WIRING
TO UNIT MUST BE
PROPERLY POLARIZED
AND GROUNDED.

N

DISCONNECT

GND

NEUTRAL

NEUTRAL

NEUTRAL

NEUTRAL

NEUTRAL

NEUTRAL

40 VA
TRANSFORMER

AUTO RESET PRIMARY

LIMIT CONTROL

LOW FIRE PRESS.

SWITCH

C

C

MANUAL RESET ROLLOUT
LIMIT CONTROLS

PM

HI

C

GAS
VALVE

GND

AIR

FIELD GND

IGNITER

D

IAGRAM

INTEGRATED CONTROL MODULE

0140F00818 REV. B

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

46

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47

5151 San Felipe, Suite 500, Houston, TX 77056

© 201 1 - 2012 Goodman Manufacturing Comp any, L.P.

Goodman Manufacturing Company , L.P.

www.goodmanmfg.com

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