Goodman GCSS96, GMSS92, GMSS96 Installation Manual

I

NSTALLATION

I

NSTRUCTIONS FOR

*MSS9* & *CSS9*

INGLE-STAGE

S

(Type FSP CATEGORY IV Direct

or Non Direct Vent Air Furnace)

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

GAS F

URNACE

O

NLY PERSONNEL THAT HAVE BEEN TRAINED TO INSTALL, ADJUST, SERVICE OR

REPAIR (HEREINAFTER

SHOULD SERVICE THE EQUIPMENT

FOR ANY INJURY OR PROPERTY DAMAGE ARISING FROM IMPROPER SERVICE OR

SERVICE PROCEDURES

FOR ANY INJURY OR PROPERTY DAMAGE WHICH MAY RESULT

JURISDICTIONS THAT REQUIRE ONE OR MORE LICENSES TO SERVICE THE EQUIPMENT

SPECIFIED IN THIS MANUAL, ONLY LICENSED PERSONNEL SHOULD SERVICE THE

EQUIPMENT

THE EQUIPMENT SPECIFIED IN THIS MANUAL, OR ATTEMPTING TO INSTALL, ADJUST

SERVICE OR REPAIR THE EQUIPMENT SPECIFIED IN THIS MANUAL WITHOUT PROPER

TRAINING MAY RESULT IN PRODUCT DAMAGE, PROPERTY DAMAGE, PERSONAL

INJURY OR DEATH

, “

SERVICE

”)

THE EQUIPMENT SPECIFIED IN THIS MANUAL

. THE

MANUFACTURER WILL NOT BE RESPONSIBLE

. IF

YOU SERVICE THIS UNIT, YOU ASSUME RESPONSIBILITY

. IN

ADDITION, IN

. I

MPROPER INSTALLATION, ADJUSTMENT, SERVICING OR REPAIR OF

.

TABLE OF CONTENTS

,

Installer:

Affix all manuals

adjacent to the unit.

As a professional installer you have an obligation to know

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

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

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

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

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

RECOGNIZE THIS SYMBOL

AS A SAFETY PRECAUTION.

*NOTE: Please contact your distributor or our website for

the applicable Specification Sheet referred to in this manual.

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

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

ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS .................... 4

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

PRODUCT A PPLICATION ............................................. 5

LOCATION REQUIREMENTS & CONSIDERATIONS ......................... 6

CLEARANCES AND A CCESSIBILITY ................................... 7

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

THERMOSTAT LOCATION .......................................... 8

COMBUSTION & VENTILATION A IR REQUIREMENTS ..................... 8

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

HORIZONTAL A PPLICATIONS & CONSIDERATIONS ........................ 9

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

FRONT COVER PRESSURE SWITCH TUBE L OCATION ................. 9

DRAIN TRAP AND LINES ......................................... 9

LEVELING ...................................................... 9

ALTERNATE ELECTRICAL AND GAS L INE C ONNECTIONS .............. 10

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

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

PROPANE GAS/HIGH A LTITUDE INSTALLATIONS ....................... 10

VENT/FLUE PIPE & COMBUSTION A IR PIPE ......................... 10

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

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

PROPER VENT/FLUE AND COMBUSTION A IR PIPING PRACTICES ...... 11

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

CANADIAN VENT PIPE & COMBUSTION A IR PIPE R EQUIREMENTS ..... 13

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

VENT/INTAKE T ERMINATIONS FOR INSTALLATION OF MULTIPLE DIRECT

VENT FURNACES ............................................... 18

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

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

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

GENERAL DRAIN I NFORMATION ................................... 19

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

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

IOG-2009K 11/2017

5151 San Felipe Suite 500

Houston, TX 77056

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

is a registered trademark of Maytag Corporation or its related companies

DRAIN EXITING RIGHT S IDE ..................................... 19

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

UPFLOW MODEL INSTALLED HORIZONTALLY WITH RIGHT SIDE DOWN 20 UPFLOW MODEL INSTALLED HORIZONTALLY WITH LEFT SIDE DOWN .21 UPFLOW MODEL INSTALLED HORIZONTALLY WITH LEFT SIDE DOWN -

ALTERNATE .................................................... 21

COUNTERFLOW MODEL INSTALLED V ERTICALLY ....................22

DRAIN EXITING L EFT SIDE (SEE F IGURE 26) ..................... 22

DRAIN EXITING RIGHT SIDE (SEE FIGURE 27) .................... 22

COUNTERFLOW MODEL INSTALLED HORIZONTALLY WITH RIGHT SIDE

DOWN (SEE FIGURE 28) ...................................... 23

COUNTERFLOW MODEL INSTALLED HORIZONTALLY

LEFT SIDE DOWN ..................................... 23

WITH

ELECTRICAL CONNECTIONS ......................................... 24

WIRING HARNESS .............................................. 24

115 VOLT LINE CONNECTIONS .................................. 24

JUNCTION BOX RELOCATION ..................................... 25

24 VOLT T HERMOSTAT WIRING .................................. 25

SINGLE-STA GE HEATING THERMOSTAT A PPLICATION ................ 25

FOSSIL FUEL A PPLICATIONS ...................................... 25

TWINNING ....................................................26

GAS SUPPLY AND PIPING .......................................... 26

HIGH A LTITUDE D ERATE ........................................ 27

PROPANE GAS CONVERSION ..................................... 27

GAS PIPING C ONNECTIONS ......................................27

PROPANE GAS TANKS AND PIPING ............................... 29

CIRCULATING A IR & FILTERS ....................................... 30

DUCT WORK - AIR FLOW ....................................... 30

CHECKING DUCT S TATIC ........................................ 30

BOTTOM RETURN AIR OPENING [UPFLOW MODELS] ............... 31

FILTERS - READ THIS S ECTION B EFORE I NSTALLING

THE RETURN A IR DUCT WORK ............................... 31

HORIZONTAL INSTALLATIONS ..................................... 32

STARTUP PROCEDURE & ADJUSTMENT .............................. 32

DRAIN TRAP P RIMING .......................................... 32

FURNACE OPERATION ........................................... 32

GAS SUPPLY PRESSURE M EASUREMENT ........................... 33

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

GAS INPUT RAT E MEASUREMENT (NATURAL GAS O NLY) ...........34

TEMPERATURE RISE ............................................34

CIRCULATOR BLOWER SPEEDS ...................................35

BLOWER HEAT OFF DELAY TIMINGS ............................. 35

NORMAL SEQUENCE OF OPERATION .................................35

POWER UP ................................................... 35

HEATING M ODE ............................................... 35

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

FAN ONLY MODE ............................................. 36

OPERATIONAL C HECKS ............................................ 36

SAFETY CIRCUIT DESCRIPTION ...................................... 36

INTEGRATED CONTROL MODULE ................................. 36

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

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

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

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

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

TROUBLESHOOTING ............................................... 36

ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS ................... 36

DIAGNOSTIC CHART ............................................ 37

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

MAINTENANCE ................................................... 37

ANNUAL INSPECTION ........................................... 37

FILTERS ....................................................... 37

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

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

CONDENSATE TRAP AND DRAIN SYSTEM (QUALIFIED SERVICER ONLY)38

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

FLUE PASSAGES (QUALIFIED SERVICER ONLY)..................... 38

BEFORE LEAVING AN I NSTALLATION ................................. 38

REPAIR AND R EPLACEMENT PARTS .................................. 38

TROUBLESHOOTING CHART ........................................ 39

TROUBLESHOOTING CHART ........................................ 40

AIRFLOW .................................................... 41-42

*MSS92*** & *CSS92***A* .................................. 41

*MSS96*** & *CSS96***A* .................................. 42

WIRING DIAGRAM ................................................ 43

*MSS92*** & *CSS92***A* ............................... 43

WIRING DIAGRAM ................................................ 44

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

(WITH PCBBF138 CONTROL) .......................... 44

WIRING DIAGRAM ................................................ 45

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

(WITH PCBBF140 CONTROL) .......................... 45

SPECIAL INSTRUCTIONS FOR PRODUCTS I NSTALLED

THE STAT E OF M ASSACHUSETTS ............................... 47

IN

2

S

AFETY

C

ONSIDERATIONS

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

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

Install this furnace only in a location and position as specified in LOCATION REQUIREMENTS & CONSIDERATIONS sec- tion and INSTALLATION POSITIONS section of this manual.

Provide adequate combustion and ventilation air to the furnace as specified in COMBUSTION & VENTILATION AIR RE-

QUIREMENTS section of this manual.

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

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

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

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

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

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

WARNING

TO

PREVENT PERSONAL INJURY OR DEATH DUE TO IMPROPER

INSTALLATION, ADJUSTMENT, ALTERATION, SERVICE OR MAINTENANCE

REFER TO THIS MANUAL

INFORMATION, CONSU LT A QUALIFIED INSTALLER, SERVICER AGENCY OR

THE GAS SUPPLIER

. FOR

ADDITIONAL ASSISTANCE OR

.

WARNING

IF

THE INFORMATION IN THESE INSTRUCTIONS IS NOT FOLLOWED EXACTLY, A FIRE OR EXPLOSION MAY RESULT CAUSING PROPERTY DAMAGE

,

PERSONAL INJURY OR LOSS OF LIFE

DO

NOT STORE OR USE GASOLINE OR OTHER FLAMMABLE VAPORS AND

LIQUIDS IN THE VICINITY OF THIS OR ANY OTHER APPLIANCE

.

WHAT TO DO IF YOU SMELL 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

.

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

.

. IF

THE

,

CAUTION

FROZEN AND BURST WATER PIPE HAZARD F

AILURE TO PROTECT AGAINST THE RISK OF FREEZING MAY RESULT IN

PROPERTY DAMAGE

S

PECIAL PRECAUTIONS

AREA WHICH MAY DROP BELOW FREEZING

OPERATION OR DAMAGE TO EQUIPMENT

ENVIRONMENT HAS THE POTENTIAL OF FREEZING, THE DRAIN TRAP AND

DRAIN LINE MUST BE PROTECTED

HEATERS, ELECTRIC HEAT TAPE AND/OR

RECOMMENDED FOR THESE INSTALLATIONS

.

MUST BE

MADE IF INSTALLING FURNACE IN AN

. T

HIS CAN CAUS E IMPROPER

. IF

THE FURNACE

. THE

USE OF ACCESSORY DRAIN TRAP

RV

ANTIFREEZE IS

.

WARNING

TO

PREVENT POSSIBLE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH DUE TO ELECTRICAL SHOCK, THE FURNACE MUST BE LOCATED TO PROTECT THE ELECTRICAL COMPONENTS FROM WATER

.

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

3

Advertencia especial para la instalación de calentadores ó manejadoras de aire en ár eas cerradas com o estacionamientos ó cuartos de servi cio.

RISQUE D'EMPOISONNEMENT AU

MONOXYDE DE CARBONE

Las emis iones de monóxido d e carbono pueden circular a trav és del aparato cuan do se opera en cualquier mod o.

CO can cause serious illness inc luding permane nt b rain damage or death.

B10259-216

El monóxido de carbono pu ede causar enfe rmedade s severa s como daño cerebral permane nte ó muerte.

SHIPPING I NSPECTION

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.

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.

ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS

NOTE: Discharge your body’s static electricity before touching

unit. An electrostatic discharge can adversely affect electrical components.

Use the following precautions during furnace installation and servicing to protect the integrated control module from damage. By putting the furnace, the control, and the person at the same

Cette ventilation est nécessaire pour éviter le danger d'intoxication au CO pouvant survenir si un ap pareil produis ant du monoxy de de carb one continue de fonctionner au sein de la zone confin ée.

B10259-216

Le monoxy de de des

dommag es permanen ts au cerv eau et meme la mort.

carbone peut causer des maladies graves telles que

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

P

OSSIBLE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH DUE TO

FIRE, EXPLOSION, SMOKE, SOOT, CONDENSATIO N, ELECTRICAL SHOCK

OR CARBO N MONOXIDE MAY RESULT FROM IMPROPER INSTALLATION

REPAIR OPERATION, OR MAINTENANCE OF THIS PRODUCT

.

electrostatic potential, these steps will help avoid exposing the integrated control module to electrostatic discharge. This procedure is applicable to both installed and non-installed (ungrounded) furnaces.

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

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

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

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

4

B10259-216

,

TO THE INSTALLER

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

P

RODUCT APPLICATION

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

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

Schools, Office buildings, Churches, Retail stores, Nursing

homes, Hotels/motels, Common or office areas

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

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

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

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

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

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

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

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

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

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

Gas furnaces manufactured on or after May 1, 2017 are not permitted to be used in Canada for heating of buildings or structures under construction.

In the U.S.A., this furnace may be used as a construction site heater ONLY if all of the following conditions are met:

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

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

metal thermostats, or any thermostat affected by vibration, must not be used during construction.

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

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

• Air filters are installed in the system and replaced daily during construction and upon completion of construction.

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

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

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

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

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

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

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

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

• A T-handle gas cock must be used.

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

To ensure proper furnace operation, install, operate and maintain the furnace in accordance with these installation and operation instructions, all local building codes and ordinances.

In their absence, follow the latest edition of the National Fuel Gas Code (NFPA 54/ANSI Z223.1), and/or CAN/CSA B149.1-15 Installation Codes, local plumbing or waste water codes, and other applicable codes.

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

.

5

A copy of the National Fuel Gas Code (NFPA 54/ANSI Z223.1)

can be obtained from any of the following:

American National Standards Institute

23 West 43rd Street, 4th Floor

New York, NY 10036

National Fire Protection Association

1 Batterymarch Park

Quincy, MA 02169-7471

CSA International

8501 East Pleasant Valley

Independence, OH 441311

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

A copy of the CAN/CSA B149.1-15 Installation Codes can also

be obtained from:

CSA International

178 Rexdale Boulevard

Etobicoke, Ontario, Canada M9W 1R3

L

OCATION REQUIREMENTS

& C

ONSIDERATIONS

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

WARNING

TO

PREVENT POSSIBLE EQUIPMENT DAMAGE, PROPERTY DAMAGE

PERSONAL INJURY OR DEATH, THE FOLLOWING BULLET POINTS MUST BE

OBSERVED WHEN INSTALLING THIS UNIT

.

,

WARNING

P

OSSIBLE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH DUE TO

FIRE, EXPLOSION, SMOKE, SOOT, CONDENSATIO N, ELECTRICAL SHOCK

OR CARBO N MONOXIDE MAY RESULT FROM IMPROPER INSTALLATION

REPAIR OPERATION, OR MAINTENANCE OF THIS PRODUCT

.

,

• Centrally locate the furnace with respect to the

proposed or existing air distribution system.

• Ensure the temperature of the return air entering the

furnace is between 55°F and 100°F when the furnace is heating.

• Provide provisions for venting combustion products

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

air piping can be a limiting factor in the location of the furnace.

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

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

Combustion and Ventilation Air Requirements.

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

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

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

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

permanent wave solutions chlorinated waxes or cleaners

chlorine-based carbon tetrachloride water softening chemicals

swimming pool chemicals deicing salts or chemicals halogen type refrigerants printing inks cleaning solutions (such as perchloroethylene) paint removers varnishes hydrochloric acid cements and glues antistatic fabric softeners for clothes dryers masonry acid washing materials

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

6

• If the furnace is used in connection with a cooling coil

b

ible fl

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

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

a “C” width coil may be installed with a “B” width furnace.

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

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

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

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

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

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

• Counterflow Installation over a combustible floor. If installation over a combustible floor becomes necessary, use an accessory subbase (see Specification Sheet applicable for your model for details.) A special accessory subbase must be used for upright counterflow unit installations over any combustible material including wood. Refer to subbase instructions for installation details. Follow the instructions with the subbase for proper installation. Do not install the furnace directly on carpeting, tile, or other combustible material other than wood flooring. (NOTE: The subbase will not be required if an air conditioning coil is installed between the supply air opening on the furnace and the floor.)

*M SS[92 & 96]* MINIM UM CLEARANCES TO COMBUSTIBLE M ATERIALS

(INCHES)

POSITION* SIDES REAR FRONT BOTTOM FLUE TOP

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

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

C = I f placed on combustible floor, floor MUST be wood only.

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

(INCHES)

POSITION* SID ES REA R FRONT BOTTOM FLUE TOP

Counterflow0"0"3"NC0"1"

Horizont al 6" 0" 3" C 0" 6"

C = If placed on combustible floor , floor MUST be wood only .

NC = For installation on non-combustible floors only. A combustible subbase must

e used for installations on combust

TOP

SIDE SIDE SIDE

BOTTOM

Upflow Counterflow Horizontal

Figure 1

ooring.

TOP

BOTTOM

CLEARANCES AND ACCESSIBILITY

NOTES:

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

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

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

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

NOTE: In addition to the required clearances to combustible materials, a minimum of 24 inches service clearance must be available in front of the unit.

A furnace installed in a confined space (i.e., a closet or utility room) must have two ventilation openings with a total minimum free area of 0.25 square inches per 1,000 BTU/hr of furnace input rating. Refer to Specification Sheet applicable to your model

7

for minimum clearances to combustible surfaces. One of the ventilation openings must be within 12 inches of the top; the other opening must be within 12 inches of the bottom of the confined space. In a typical construction, the clearance between the door and door frame is usually adequate to satisfy this ventilation requirement.

EXISTING FURNACE REMOVAL

NOTE: When an existing furnace is removed from a venting

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

The following vent testing procedure is reproduced from the

American National Standard/National Standard of Canada for Gas-Fired Central Furnaces ANSI Z21.47, CSA-2.3 latest edition Section 1.23.1.

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

1. Seal any unused openings in the venting system.

2. Inspect the venting system for proper size and horizontal pitch, as required by the National Fuel Gas Code, ANSI Z223.1 or the Natural Gas and Propane Installation Code, CSA B149.1-15 and these instructions. Determine that there is no blockage or restriction, leakage, corrosion and other deficiencies which could cause an unsafe condition.

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

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

If resizing is required on any portion of the venting system, use the appropriate table in Appendix G in the latest edition of the National Fuel Gas Code ANSI Z223.1 and/or CSA B149.1-15 Installation Codes.

THERMOSTAT LOCATION

WARNING

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

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

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

• Hot or cold air from registers.

• Radiant heat from the sun.

• Light fixtures or other appliances.

• Radiant heat from a fireplace.

• Concealed hot or cold water pipes, or chimneys.

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

Consult the instructions packaged with the thermostat for

mounting instructions and further precautions.

. M

OST HOMES REQUIRE OUTSIDE AIR BE

.

,

4. Close fireplace dampers.

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

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

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

8. If improper venting is observed during any of the above tests, the venting system must be corrected in accordance with the National Fuel Gas Code ANSI Z223.1/ NFPA 54 and/or National Gas and Propane Installation Code CSA B149.1-15.

C

OMBUSTION

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

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

If this furnace is to be installed in the same space with other gas appliances, such as a water heater, ensure there is an adequate supply of combustion and ventilation air for the other appliances. Refer to the latest edition of the National Fuel Gas Code NFPA 54/ANSI Z223.1 or CAN/CSA B1491-15 Installation Codes or applicable provisions of the local building codes for determining the combustion air requirements for the appliances.

& V

ENTILATION AIR REQUIREMENTS

8

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

I

NSTALLATION POSITIONS

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

H

ORIZONTAL APPLICATIONS

& C

ONSIDERATIONS

FRONT COVER PRESSURE SWITCH TUBE LOCATION

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

1. Remove tube from front cover pressure switch and collector box cover.

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

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

4. Install one end on front cover pressure switch.

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

DRAIN TRAP AND LINES

In horizontal applications the condensate drain trap is secured to the furnace side panel, suspending it below the furnace. A minimum clearance of 5.5” below the furnace must be provided for the drain trap. Additionally, the appropriate downward piping slope must be maintained from the drain trap to the drain location. Refer to Condensate Drain Trap and Lines for further de- tails. If the drain trap and drain line will be exposed to temperatures near or below freezing, adequate measures must be taken to prevent condensate from freezing.

2" 2" 3/8"

ANGLE IRON

XX

(3

PLACES

)

Figure 2

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

FURNACE S USPENSION

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

LEVELING

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

ALTERNATE VENT/FLUE AND COMBUSTION AIR CONNECTONS

In horizontial installations provisions for alternate flue and combustion air piping are available for upflow furnaces with left discharge and counterflow furnaces with right air discharge. This configuration allows thye flue and combustion air piping to be run vertically through the side of the furnace. Refer to the “Recommended Installation Positions” figure for further detail. The standard piping connections may also be used in these positions. Refer to Vent/Flue Pipe and Combustion Air Pipe for details concerning the conversion to the alternate vent/flue and combustion air connections.

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

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

9

FREEZE PROTECTION

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

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

Alternate Vent/Flue Location

Figure 3A

Figure 3B

Figure 3C

Recommended Installation Positions

ALTERNATE ELECTRICAL AND GAS LINE CONNECTIONS

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

Manifold P ress ure

Gas Altitude Kit Orifice

Nat ural No ne # 45 3.5" w.c. 1.9" w.c. No ne

0-7000

Propane LPM -07*

1

LPM -07* suppo rts bot h Honeywell and White-Rodgers 1-stage valves

In Canada, gas furnac es are o nly cert ified to 4500 feet.

NOTE:

P

ROPANE GAS/HIGH ALTITUDE INSTALLATIONS

1

1.25mm 10.0" w.c. 6.0" w.c. None

High

Stage

Low

Stage

Pressure

Swit ch

Change

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

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

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

For furnaces being converted to LP gas, it is strongly recommended that a LPLP03 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.

Contact the distributor for a tabular listing of appropriate manufacturer’s kits for propane gas and/or high altitude installations. The indicated kits must be used to insure safe and proper furnace operation. All conversions must be performed by a qualified installer, or service agency.

DRAIN PAN

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

V

ENT/FLUE PIPE

& C

OMBUSTION AIR PIPE

This manual will refer to the pipe that discharges products of combustion to the outdoors as the “vent” pipe or “flue” pipe. The pipe that supplies air for combustion to the furnace will be referred to as the “intake” pipe or “combustion air” pipe. A condensing gas furnace achieves its high level of efficiency by extracting almost all of the heat from the products of combustion and cooling them to the point where condensation

10

takes place. Because of the relatively low flue gas temperature and water condensation requirements, PVC or ABS pipe is typically used as venting and intake pipe materials. In Canada ABS is not an approved vent pipe material but it is permissable to use as combustion air pipe material.

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

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

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

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

MATERIALS AND JOINING METHODS

Two-three-inch nominal diameter PVC Schedule 40 pipe meeting ASTM D1785, PVC primer meeting ASTM F656, and PVC solvent cement meeting ASTM D2564 specifications must be used. Fittings must be DWV type fittings meeting ASTM D2665 and ASTM D3311. Carefully follow the manufacturer’s instructions for cutting, cleaning, and solvent cementing of PVC.

The use of Schedule 40 PVC cellular core DWV meeting ASTM F891-1 or ABS cellular core (Foam Core) plastic pipe is also acceptable as a flue/vent and intake pipe material. PVC primer meeting ASTM F656 and PVC solvent cement meeting ASTM D2564 specifications must be used. Fittings must be DWV type fittings meeting ASTM D2665 and ASTM D3311. Carefully follow the manufactures instructions for cutting, cleaning and solvent cementing of PVC.

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

NOTE: Requirement does not apply to the combustion air pipe.

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

WARNING

U

PON COMPLETION OF THE FURNACE INSTALLATION, CAREFULLY

INSPECT THE ENTIRE FLUE SYSTEM BOTH INSIDE AND OUTSIDE OF THE

FURNACE TO ASSURE IT IS PROPERLY SEALED

SYSTEM CAN RESULT IN SERIOUS PERSONAL INJURY OR DEATH DUE TO

EXPOSURE TO FLUE PRODUCTS, INCLUDING CARBO N MONOXIDE

. L

EAKS IN THE FLUE

.

WARNING

F

AILURE TO FOLLOW THESE INSTRUCTIONS CAN RESULT IN BODILY

INJURY OR DEATH

GIVEN IN THIS SECTION

. C

AREFULLY READ AND FOLLOW ALL INSTRUCTIONS

.

DUAL CERTIFICATION: NON-DIRECT/DIRECT VENT

This furnace is dual certified and may be installed as a non-direct vent (single pipe) or direct vent (dual pipe) appliance. A non-

direct vent installation requires only a vent/flue pipe, while a direct vent installation requires both a vent/flue pipe and a com-

bustion air intake pipe. Refer to the appropriate section for details concerning piping size, length, number of elbows, furnace connections, and terminations.

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

PROPER VENT/FLUE AND COMBUSTION AIR PIPING PRACTICES

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

WARNING

TO

AVOID BODILY INJURY, FIRE OR EXPLOSION, SOLVENT CEMENTS

MUST BE KEPT AWAY FROM ALL IGNITION SOURCES (I.E

FLAMES, AND EXCESSIVE HEAT) AS THEY ARE COMBUSTIBLE LIQUIDS

VOID BREATHING CEMENT VAPORS OR CONTACT WITH SKIN AND/OR

A

EYES

.

.,

SPARKS, OPEN

.

11

PREFERRED

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

TERMINATION LOCATIONS

Figure 4

ACCEPTABLE

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

Figure 5

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

Figure 6

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

Piping must be adequately secured and supported to prohibit sagging, joint separation, and/or detachment from the furnace. Horizontal runs of vent/flue piping must be supported every three to five feet and must maintain a 1/4 inch per foot downward slope, back towards the furnace, to properly return condensate to the furnace’s drain system. Allowances should be made for minor expansion and contraction due to temperature variations. For this reason, particular care must be taken to secure piping when a long run is followed by a short offset of less than 40 inches.

Non-Direct Vent

&

Direct Vent

Vent/Flue Terminations

Non-Direct Vent

Vent/Flue Termination

No Terminations Above Walkway

Grade or Highest

Anticipated Snow Leve l

3' min.

Forced Air

Inlet

<10'

12"

12" min.

Direct Vent

Vent/Flue Termination

4' min.

4'

min.

12"

min.

Non-Direct Vent

Vent/Flue Termination

Vent Termination Clearances

Figure 7

NOTE: Refer to Location Requirements and Considerations for combustion air contaminant restrictions.

The following bullets and diagram describe the restrictions concerning the appropriate location of vent/flue pipe and combustion air intake pipe (when applicable) terminations. Refer to

Non-Direct Vent (Single Pipe) Piping and Direct Vent (Dual Pipe) Piping located in this section for specific details on termination

construction.

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

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

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

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

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

12

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

• A vent termination shall not terminate over public walkways

or over an area where condensate or vapor could create a nuisance or hazard or could be detrimental to the operation of regulators, relief valves, or other equipment.

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

NOTE: In Canada, the current edition of CAN/CSA B149.1-15 takes precendence over the preceding termination restriction.

CANADIAN VENT PIPE & COMBUSTION AIR PIPE REQUIRE-

MENTS

All installations in Canada must conform to the requirements of CAN/CSA B149.1 -15 code. All vent components, including primer and cement, must be listed to ULC S636. The certified pipe and fittings should be clearly marked with the ULC standard “S636”. The primer and cement used must be of the same manufacturer as the vent system. For Royal Pipe System 636; use GVS-65 Primer (Purple) and GVS-65 PVC Solvent Cement. For IPEX System 636, use PVC/CPVC Primer, Purple or clear. Use PVC Solvent Cement (Gray).

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

The safe operation, as defined by ULC S636, of the vent system is based on following these installation instructions, the vent system manufacturer’s installation instructions, and proper use of primer and cement. It is recommended under this standard, that the vent system be checked once a year by qualified service personnel. All fire stops and roof flashings used with this system must be UL listed. Acceptability under CAN/CSA B149.1-15 is dependent upon full compliance with all installation instructions. Consult the authority having jurisdiction (gas inspection authority, municipal building department, fire department, etc.) before installation to determine the need to obtain a permit. *IPEX System 636™ is a

trademark of IPEX Inc.

Carefully follow the pipe manufacturers’ instructions for cutting, cleaning, and solvent cementing PVC and/or ABS.

The vent can be run through an existing unused chimney provided the space between the vent pipe and the chimney is insulated and closed with a weather-tight, corrosion-resistant flashing.

STANDARD FURNACE CONNECTIONS

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

VENT/FLUE P IPE

The vent pipe outlet is sized to accept 2” pipe. Secure vent/ flue pipe directly into the furnace fitting with the appropriate glue. Alternately, a small section of 2" pipe may be glued in the furnace socket and a rubber coupling installed to allow removal for future service. Combustion Air and Vent piping should be routed in a manner to avoid contact with refrigerant lines, metering devices, condensate drain lines, etc. If necessary, clearances may be increased by creating an offset using two 45 degree elbows (Figure 8A).

45 DEGREE

ELBOWS

Increased Clearance Configuration

Figure 8A

This joint can be rotated on the fitting to establish maximum clearance between refrigerant lines, metering devices, and condensate drain lines, etc. This joint is the equivalent of one 90 deg. elbow when considering elbow count.

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

WARNING

E

DGES OF SHEET METAL HOLES MAY BE SHARP

PRECAUTION WHEN REMOVING HOLE PLUGS

C

OMBUSTION AIR PIPE

DIRECT V ENT I NSTALLATIONS

On upflow units secure the combustion air intake pipe to the air intake coupling by using a take apart rubber coupling supplied with the furnace or a plastic coupling. Also, the intake coupling may be inverted to allow the intake pipe to be glued directly to it. After inverting the coupling, secure it to the furnace top with screws. On counterflow units secure the com- bustion air intake pipe to the air intake coupling using the rubber coupling and worm gear hose clamps provided with the unit. The

13

.

. USE

GLOVES AS A

counterflow rubber coupling allows service removal of air intake piping internal to the furnace blower compartment. The combustion air intake pipe can also be secured directly to the counterflow unit air intake pipe coupling.

VENT-DRAIN

Figure 8B

NON-DIRECT VENT INSTALLATIONS

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

WARNING

THE

RUBBER ELBOW IS NOT DESIGNED TO SUPPORT A LOAD

RUBBER ELBOW IS MOUNTED EXTERNALLY TO THE FURNACE CABINET

EXTREME CARE MUST BE TAKEN TO ADEQUATELY SUPPORT FIELD

SUPPLIED VENT/FLUE PIPING, AS DAMAGE CAN RESULT IN LEAKS

CAUSING BODILY INJURY OR DEATH DUE TO EXPOSURE TO FLUE GASES

INCLUDING CARBON MONOXIDE

. W

HEN THE

,

-

,

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

Insert flange. Cut 2 ½” long.

R 000142F

ALTERNATE VENT/FLUE LOCATION

The alternate vent/flue location is the large hole directly in line with the induced draft blower outlet. To use the alternate vent/ flue location refer to the following steps and the “Alternate Vent/ Flue Location” figure. This option is not available with counterflow models.

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

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

2. Remove the internal elbow and vent pipe

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

4. Remove plastic plug in line with the inducer outlet

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

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

CAUTION

Figure 9

BE

SURE NOT TO DAMAGE INTERNAL WIRING OR OTHER COMPONENTS

WHEN REINSTALLING COUPLING AND SCREWS

Figure 10

14

.

ALTERNATE COMBUSTION AIR PROVISION

(Upflow / Horizontal models only)

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

1. Remove screws and combustion air flange from cabinet.

2. Insert cabinet plug in unused combustion air hole.

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

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

5. Install combustion air flange and secure with screws removed in step one.

Number of Elbows

MODEL

*MSS920403AN

*MSS920402BN

*MSS920603BN

*MSS920803BN

*MSS920804CN

*MSS920805CN

*MSS921004CN

*MSS921005CN

*MSS921205DN

*CSS920402BN

*CSS920603BN

*CSS920804CN

*CSS921005CN

7,000 ft altitude or above use 3" pipe

*MSS920402BN - add 20' of 2" pipe for upflow position

^

*MSS920803BN - add 10' of 2" pipe f or upflow position, add 66' of 3" pipe f or upflow position

^

*MSS920804CN - add 25' of 2" pipe for upflow position, add 58' of 3" pipe for upf low position

^

PIPE

12345678

SIZE

2 7570656055504540 3 114 107 100 93 86 79 72 65

2^ 145 140 135 130 125 120 115 110

3 168 161 154 147 140 133 126 119 2 5550454035302520 3 127 120 113 106 99 92 85 78

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

2

^

72 65 58 51 44 37 30 23

3

^

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

2

^

72 65 58 51 44 37 30 23

3

^

40 35 30 25 20 15 10 5

2

^

3 7265585144373023 2 6055504540353025 3 168 161 154 147 140 133 126 119 2 3025201510 5N/AN/A 3 113 106 99 92 85 78 71 64 2 N/A N/A N/A N/ A N/A N/A N/A N/A 3 6558514437302316 2 100 95 90 85 80 75 70 65 3 137 130 123 116 109 102 95 88 2 6055504540353025 3 127 120 113 106 99 92 85 78 2 353025201510 5N/A 3 160 153 146 139 132 125 118 111

2 N/A N/A N/A N/ A N/A N/A N/A N/A

3 127 120 113 106 99 92 85 78

MODEL

*MSS960403AN

*MSS960402BN

*MSS960603BN

*MSS960803BN

*MSS960804CN

*MSS960805CN

*MSS961004CN

*MSS961005CN

*MSS961205DN

*CSS960402BN

*CSS960603BN

*CSS960804CN

*CSS961005CN

*CSS961205DN

PIPE

12345678

SIZE

2 7570656055504540 3 114 107 100 93 86 79 72 65 2 100 95 90 85 80 75 70 65 3 168 161 154 147 140 133 126 119 2 4540353025201510 3 168 161 154 147 140 133 126 119

35 30 25 20 15 10 5 N/A

2

^

3 168 161 154 147 140 133 126 119 2 6055504540353025 3 113 106 99 92 85 78 71 64 2 4540353025201510 3 120 113 106 99 92 85 78 71 2 N/A N/A N/A N/A N/A N/A N/A N/A 3 144 137 130 123 116 109 102 95 2 40353025201510 5 3 151 144 137 130 123 116 109 102 2 N/A N/A N/A N/A N/A N/A N/A N/A 3 158 151 144 137 130 123 116 109 2 100 95 90 85 80 75 70 65 3 137 130 123 116 109 102 95 88 2 4540353025201510 3 168 161 154 147 140 133 126 119 2 40353025201510 5 3 120 113 106 99 92 85 78 71 2 N/A N/A N/A N/A N/A N/A N/A N/A 3 113 106 99 92 85 78 71 64

2 N/A N/A N/A N/A N/A N/A N/A N/A

3 110 103 96 89 82 75 68 61

Non-Direct Vent (Single Pipe) Piping

Non-direct vent installations require only a vent/flue pipe. The vent pipe can be run horizontally with an exit through the side of the building or run vertically with an exit through the roof of the building. The vent can also be run through an existing unused chimney; however, it must extend a minimum of 12 inches above the top of the chimney. The space between the vent pipe and the chimney must be closed with a weather-tight, corrosion-resistant flashing.

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

VENT/FLUE PIPE LENGTHS AND DIAMETERS

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

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

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

15

VENT/FLUE PIPE T ERMINATIONS

A

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

The vent/flue pipe may terminate vertically, as through a roof, or horizontally, as through an outside wall.

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

Horizontal vent/flue pipe terminations should be as shown in the following figure. Refer to Vent/Flue Pipe and Combustion Air Pipe. To secure the pipe passing through the wall and prohibit damage to piping connections, a coupling should be installed on either side of the wall and solvent cemented to a length of pipe connecting the two couplings. The length of pipe should be the wall thickness plus the depth of the socket fittings to be installed on the inside and outside of the wall. The wall penetration should be sealed with silicone caulking material.

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

COMBUSTION AIR INTAKE

(OPTIONAL)

*Not requ ired for

single pipe installation

E

N

I

L

F

O

R

12” MIN TO ROOF OR HIGHEST ANTICIPATED SNOW LEVEL

TEE (OPTIONAL)

M

”

6

9

Figure 12

12” MIN HEIGHT DIFFERENCE

M

”

3

-

.

X

A

.

N

I

DOWN VENTING UPFLOW MODEL FURNACES ONLY

Combustion Air Pipe

Field Supplied Drain Tee on Vent Pipe

w

a

r

C

/

t

n

e

m

e

s

a

B

ll piping and fittings must be joined per material manufacturers specifications

e

c

a

p

s

l

Condensate trapped to prevent flue gas from escaping and routed to field supplied condensate disposal

to prevent separation and flue gas leaks.

Figure 11

Use alternate vent & combination air locations

Vent Pi pe

Floor

6’ Max.

1/4” per foot min. slope to furnace

ELBOWS

STRAIGHT

Figure 13

12" MIN.

VENT/FLUE TEE (

TURNED DO WN or

90° ELBOW TURNED

1 2" MIN . ABOVE

HIGHEST ANTICIPATED

SNOW LEVEL

or

45° EL BOW

DOWN

OPTIONAL)

Horizontal Termination (Single Pipe)

Above Highest Anticipated Snow Level

Figure 14

16

10”- 24”

6” MAX

4” MIN

90° ELBOWS

3” - 24”

90º OR 45°

ELBOW

12" MIN. TO GRADE OR HIGHEST ANTICIPATED

SNOW LEVEL

Standard Horizontal Terminations (Dual Pipe)

Figure 15

DIRECT VENT (DUAL PIPE) PIPING

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

and Combustion Pipe - Standard Furnace Connections or Alter- nate Furnace Connections.

12" MIN. ABOVE

HIGHEST ANTICIPATED

SNOW LEVEL

Alternate Horizontal Vent Termination (Dual Pipe)

Figure 16

VENT/FLUE & COMBUSTION AIR PIPE LENGTHS & DIAMETERS

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

If the combustion air intake pipe is to be installed above a finished ceiling or other area where dripping of condensate will be objectionable, insulation of the combustion air pipe may be required.

90° ELBOWS

3”-24” BETWEEN PIPES

17

12" MIN. ABOVE

HIGHEST ANT ICIPATED

SNOW LEVEL

Combustion Air Intake may also be snorkeled

to obtain 12” min ground clearance.

Alternate Vent Termination Above Anticipated Snow Level

(Dual Pipe)

Figure 17

Use 1/2” thick closed cell foam insulation such as Armaflex™ or Insultube™ where required.

VENT/FLUE AND COMBUSTION AIR PIPE TERMINATIONS

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

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

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

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

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

3”MIN 24”MAX

12” MIN SEPARATION

3” MIN

12” MIN TO GRADE OR HIGHEST ANTICIPATED SNOW LEVEL

Termination of Multiple Direct Vent Furnaces

Figure 18

VENT/INTAKE TERMINATIONS FOR INSTALLATION OF MULTIPLE DIRECT VENT FURNACES

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

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

Horizontal Installation

Vertical Installation

Side Wall Vent Kit

Figure 19

CONCENTRIC VENT TERMINATION

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

SIDE WALL VENT KIT

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

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

C

ONDENSATE DRAIN LINES

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

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

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

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

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

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

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

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

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

& D

RAIN TRAP

18

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

Acceptable

area for

drain hole.

#1

#4

6

#

#2

#7

#9

#5

#11

Figure 20

#8

3

#

#10

Coupling

100 Degree Elbow

NOTE: Drain components shown for information purposes only.

12”

3”

Side Cut-Out

Right side shown.

Figure 21

FIELD SUPPLIED DRAIN

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

UPFLOW MODEL INSTALLED VERTICALLY

The trap and factory installed hoses remain as shipped. The furnace drain may exit either the right or left side of the furnace cabinet. Both sides of the cabinet have two .875” diameter holes which can be used interchangeably for drain and low voltage wiring purposes. If a higher drain exit is needed, a .875” diameter hole may be added in the area shown in Figure 21. Any unused cabinet opening must be sealed. Do not allow drain hose to sag or trap water.

GENERAL DRAIN INFORMATION

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

NOTE: Both sides of the drain trap must be primed prior

to initial furnace start up

DRAIN EXITING RIGHT SIDE

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

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

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

19

Hose #1

Hose #2

45 degree barb-pipe

adapter

Installer selects right or left side drain

and installs this hose accordingly.

Figure 22

45 degree barb-pipe adapter

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

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

DRAIN EXITING LEFT SIDE

1. Install the 45 degree pipe / hose drain coupling from the outside of the cabinet (barbed end goes in the cabinet) through the hole in the left side of the cabinet and secure with two field supplied #8 self-tapping screws (see Figure 22).

2. Locate the long drain hose #3 and cut at “B” line for a

17.5" cabinet; cut at line “C” for a 21" cabinet; do not cut for a “D” width cabinet.

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

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

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

Hose #11

Figure 23

Hose #2

UPFLOW MODEL INSTALLED HORIZONTALLY WITH RIGHT SIDE DOWN

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

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

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

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

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

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

6. For models *MSS920403AN and *MSS960403AN; locate the hose #2 (factory installed) and cut 1.5 length from the end of the hose. Insert hose #2 from outside the cabinet through the cabinet’s drain hole nearest to the top. Secure it to the barbed fitting in the elbow with a red clamp.

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

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

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

20

UPFLOW MODEL INSTALLED HORIZONTALLY WITH LEFT SIDE DOWN

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

*Also see Front Cover Pressure Switch Tube Location on page

10.

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

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

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

Hose #6

Hose #5

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

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

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

7. Unused vent-drain elbow drip leg port must be sealed

to prevent flue gases from escaping. Insert the rubber plug removed in step 6 into the unused elbow drain port. Inserting a blunt tool such as a 3/16’’ Allen wrench into the center of the rubber plug will stretch the plug and allow complete insertion.

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

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

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

11. (Draining the Collector Box) Remove cap from left side collector box drain port (bottom in horizontal left position) and install it on right side (top) collector box drain port.

Hose #11

Figure 24

12. Install the non-grommet end of hose #11 from outside the cabinet in the upper drain hole. Install on collector box and secure with a silver clamp.

13. Use two silver clamps and secure the hoses to drain trap. The trap outlet faces the front of the furnace. Secure the trap to the cabinet using two screws removed in step 2 by inserting the two screws through the large set of holes in the top mounting tabs of the trap into the two predrilled holes in the side of the cabinet. [Removed: Place cap on vent...]

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

UPFLOW MODEL INSTALLED HORIZONTALLY WITH LEFT SIDE DOWN - ALTERNATE

*Also see Front Cover Pressure Switch Tube Location on Page 10.

1. (Draining the RF000142 Coupling) Locate hose #2 (factory installed). Cut off and discard the 45° radius end.

2. Install 90°radius end of hose #2 on RF000142 drain outlet and secure with a red clamp.

3. Insert coupling in hose #2 and secure with a red clamp.

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

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

6. Insert 100 degree elbow in the cut end of hose #5.

7. Locate hose #6. Using red clamps, connect between the coupling and 100 degree elbow, cutting off excess tubing.

8. (Draining the Collector Box) Remove cap from left side collector box drain port (bottom in horizontal left position) and install it on right side (top) collector box drain port and secure with a red clamp.

9. Install the non-grommet end of hose #11 from outside the cabinet in the upper drain hole. Install on collector box and secure with a silver clamp.

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

21

Insert flange. Cut 2 ½” long.

R 000142F

Figure 25

COUNTERFLOW MODEL INSTALLED VERTICALLY

DRAIN EXITING RIGHT SIDE (SEE FIGURE 27)

1. Remove hose clamps and hoses from trap.

2. Remove trap.

3. (Draining the Vent Elbow) Insert the non-grommet end hose #10 into the cabinet back drain hole. Insert a coupling into the drip leg of the vent-drain elbow and secure with a silver clamp. Secure hose #10 on vent drain elbow barb fitting with a silver clamp.

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

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

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

2.

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

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

DRAIN EXITING LEFT SIDE (SEE FIGURE 26)

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

2. Install drain per local and National codes.

Figure 27

WARNING

HIGH VOLTAGE !

TO

AVOID PERSONAL INJURY OR DEATH DUE TO

ELECTRICAL SHOCK, DISCONNECT ELECTRICAL POWER

BEFORE SERVICING OR CHANGING ANY ELECTRICAL

WIRING

.

CAUTION

L

ABEL ALL WIRES PRIOR TO DISCONNECTION WHEN SERVICING

CONTROLS

OPERATION

. W

IRING ERRORS CAN CAUSE IMPROPER AND DANGEROUS

. V

ERIFY PROPER OPERATION AFTER SERVICING

.

Hose #4 x 3

Figure 26

Hose #5

WARNING

HIGH VOLTAGE !

TO

AVOID THE RISK OF ELECTRICAL SHOCK, WIRING TO

THE UNIT MUST BE POLARIZED AND GROUNDED

22

.

COUNTERFLOW MODEL INSTALLED HORIZONTALLY WITH RIGHT SIDE DOWN (SEE FIGURE 28)

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

NOTE: For horizontal installations, some of the required hoses are found in the factory-installed hose assemblies. Remove the hose clamps to obtain the respective hoses needed for installation, and install per the following directions.

1. Remove the drain trap and factory installed drain tube assemblies.

2. Remove two 1’’ plugs from right side of cabinet.

3. (Draining the Collector Box) From outside the cabinet, insert the non-grommet end hose #7 into the back drain hole and secure to collector box drain port using a silver clamp.

4. (Draining the Vent Elbow) Insert the straight barbed coupling into the vent - drain elbow drip leg and secure with a red clamp.

1. Remove the factory installed drain trap and hose assemblies. Leave the 100° elbow inserted and clamped in the vent-drain elbow.

2. Remove two 1”plugs from left side of cabinet

3. (Draining the Collector Box) Remove the cap from the left side of the collector box drain port (bottom in horizontal left position) and install it on right side drain port.

4. Place radius end of hose #4 (factory installed) on the collector box drain port and secure with a silver clamp.

5. Insert hose #2 from outside the cabinet in the front drain hole.

6. Connect hose #4 & hose #2 together using a straight barbed coupling and two gold clamps (factory installed).

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

8. The unused vent-drain elbow drip leg port must be plugged to prevent flue gases from escaping. Insert rubber plug removed in step 7 into the 100° elbow. (Inserting a blunt tool such as a 3/16’’ Allen wrench into the center of the rubber plug will stretch the plug and allow complete insertion)

Hose #4

Hose #8

Hose #7

Figure 28

5. From outside the cabinet, insert the non-grommet end of hose #8 into the front cabinet drain hole and secure on the vent - drain elbow barb fitting using a red clamp.

6. Place the drain hoses on the trap inlets and secure with silver clamps. The outlet of the trap must face the original botom of furnace.

7. Using the two sheet metal screws provided in the cabinet, secure the trap to the furnace.

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

Hose #7

COUNTERFLOW MODEL INSTALLED HORIZONTALLY WITH LEFT SIDE DOWN (SEE FIGURE 29)

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

*Also see Front Cover Pressure Switch Tube Location on page

10.

Hose #4

9. Place radius end of hose #4 on the side port of vent – drain elbow and secure with a gold clamp.

10. Insert a ½” diameter PVC pipe (factory installed) into hose #4 and secure with a gold clamp.

11. Insert the non-grommet end of hose #5 (factory installed) from outside the cabinet in the back drain hole.

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

Hose #5

Figure 29

Hose #2

23

13. Locate hose #4 and cut a cut off a 4” straight section and discard the radius end.

14. Connect the 4” straight section of hose #4 to the 100º elbow and the PVC pipe and secure with red clamps.

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

of the furnace.

16. Using the two sheet metal screws provided in the cabinet, secure the trap to the furnace.

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

E

LECTRICAL CONNECTIONS

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

WARNING

E

DGES OF SHEET METAL HOLES MAY BE SHARP

PRECAUTION WHEN REMOVING HOLE PLUGS

.

. USE

GLOVES AS A

WIRING HARNESS

The wiring harness is an integral part of this furnace. Wires are color coded for identification purposes. Refer to the wiring diagram for wire routings. If any of the original wire as supplied with the furnace must be replaced, it must be replaced with wiring material having a temperature rating of at least 105° C. Any replacement wiring must be a copper conductor.

115 VOLT LINE CONNECTIONS

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

WARNING

HIGH VOLTAGE !

TO

AVOID PERSONAL INJURY OR DEATH DUE TO

ELECTRICAL SHOCK, DISCONNECT ELECTRICAL POWER

BEFORE SERVICING OR CHANGING ANY ELECTRICAL

WIRING

.

Humidifier 1.0 Am p maximum at 120 VA C

Elec tronic A ir Cleaner 1.0 Amp maximum at 120 VAC

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

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

WARNING

TO

PREVENT PERSONAL INJURY OR DEATH DUE TO ELECTRIC SHOCK

DISCONNECT ELECTRICAL POWER BEFORE INSTALLING OR SERVICING THIS

UNIT

.

,

WARNING

HIGH VOLTAGE !

TO

AVOID THE RISK OF INJURY, ELECTRICAL SHOCK OR

DEATH, THE FURNACE MUST BE ELECTRICALLY

GROUNDED IN ACCORDANCE WITH LOCAL CODES OR IN

THEIR ABSENCE, WITH THE LATEST EDITION OF THE

N

ATIONAL ELECTRIC CODE

.

WARNING

TO

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

FURNACE MUST BE ELECTRICALLY GROUNDED IN ACCORDANCE WITH

LOCAL CODES OR, IN THEIR ABSENCE, WITH THE LATEST EDITION OF THE

ATIONAL ELECTRICAL CODE

N

.

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

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

The accessory load specifications are as follows:

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

24

control module. The humidifier and electronic air cleaner hot terminals are identified as HUM and EAC. The humidifier and electronic air cleaner neutral terminals are identified as NEUTRAL. All field wiring must conform to applicable codes. Connections should be made as shown. (See Figure 29.)

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

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

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

JUNCTION BOX RELOCATION

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

24 VOLT THERMOSTAT WIRING

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

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

WARNING

HIGH VOLTAGE !

TO

AVOID PERSONAL INJURY OR DEATH DUE TO

ELECTRICAL SHOCK, DISCONNECT ELECTRICAL POWER

BEFORE SERVICING OR CHANGING ANY ELECTRICAL

WIRING

.

LINE VOLTAGE CONNECTIONS CAN BE MADE THROUGH EITHER THE RIGHT

LEFT SIDE PANEL. THE FURNACE IS SHIPPED CONFIGURED FOR A LEFT

OR

ELECTRICAL CONNECTION. TO MAKE ELECTRICAL CONNECTIONS

SIDE

THROUGH

BE

CONNECTIONS

FOLLOWING

THE OPPOSITE SIDE OF THE FURNACE, THE JUNCTION BOX MUST

RELOCATED TO THE LEFT SIDE PRIOR TO MAKING ELECTRICAL

. TO RELOCATE THE JUNCTION BOX, PERFORM THE

STEPS.

1. Remove the burner compartment door.

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

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

IMPORTANT NOTE

W

IRE ROUTING MUST NOT INTERFERE WITH CIRCULATOR BLOWER

OPERATION, FILTER REMOVAL OR ROUTINE MAINTENANCE

.

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.

SINGLE-STAGE HEATING THERMOSTAT APPLICATION

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

Figure 30

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).

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.

25

PARK

E13

E11

K3

1

W

E9

R82

W22

K2

HEAT

E8

COOL

E1

W13

R35

R

HT OFF DLY

150

CUT

100

SW1.1

FOR

SECSEC

SW1.2

SW1.3

SW1.4

R9

SW2

FAULT

R522

RECALL

W27

R24

R12

5206A

R6

R15

W3

R16

DS1

R23

R18

R17

R11

CONDENSOR CONTACTOR COILS

NOTES:

1. ISOLATING RELAY MAY BE ELIMINATED IF LINE VOLTAGE SUPPLY TO FURNACES IS THE SAME PHASE . TO VERIFY PHASING: A) VERIFY SOURCE IS EXACTLY THE SAME EITHER L1, L2, OR L3 FROM THE SAME TRANSFORMER OR B) CHECK WITH SCOPE OR PHASE METER C) IF IN DOUBT USE RELAY

2. IF ISOLATING RELAY IS NOT USED, CONNECT FURNACE

LINE-H

EAC-H

E10

E29

RV1

W21

C15

FP

E14

E32

1VDC=1UA

R36

R39

R43 W20

R49

W18

R2

1

R3

R29

U1

TP14

R558

TP12

W11

PARK

XFMR-H

E16

E15

K1

W16

W9

R52

R51

R50

Q9

E12

R70

R90

6

R69

R67

R57

W19

L1

R53

R63

R41

W14

R44

W10

R27

R33

HUM-H

E28

K6

W26

W12

C14

R79

R81

R78

W32

R74

W28

W29

R95

R61

R75

F1

W4

CR13

W5

E33

R54

RV2

K4

W8

C11

C13

E31

W6

E17

E25

E18

E19

1

E20

E21

2

E23

K5

R73

R94

E34

W2

3

6

RV3

W7

LINE NEUTRAL

E24

R60

R58

W24

E30

TWINNING

R91

W30

E22

1

2

45

89

7

1112

10

AUTOMATIC IGNITI ON SYSTEM

R65

R13

W25

E7

CGRWY

PARK

E13

E11

K3

1

W

E9

R82

W22

K2

HEAT

E8

COOL

E1

W13

R35

R

HT OFF DL Y

150

CUT

100

SW1.1

FOR

SEC

SW1.2

SW1.3

SW1.4

SW2

FAULT

R522

RECALL

W27

R24

R12

5206A

RELAY

R6

R15

W3

R16

R23

R18

R17

R11

ISOLATING

(SEE NOTES)

R9

LINE-H

EAC-H

E10

E29

RV1

W21

C15

FP

E32

1VDC=1UA

R36

R39

R43 W20

R49

W18

R2

1

R3

R29

TP14

R558

DS1

TP12

W11

XFMR-H

E16

E15

K1

W16

W9

R52

E14

R51

R50

Q9

E12

R70

R90

6

R69

R67

R57

W19

L1

R53

R63

U1

R41

W14

R44

W10

R27

R33

HUM-H

E28

K6

W26

W12

C14

R79

R81

R78

W32

R74

W28

W29

R95

R61

R75

F1

W4

CR13

W5

E33

R54

RV2

K4

W8

C11

C13

E31

W6

E17

E25

E18

E19

1

E20

E21

2

E23

K5

R73

R94

E34

W2

3

6

RV3

W7

LINE NEUTRAL

E24

R60

R58

W24

E30

TWINNING

R91

W30

E22

1

2

45

89

7

1112

10

AUTOMATIC IGNITION SYSTEM

R65

R13

W25

E7

CGRWY

ROOM THERMOSTAT

TWINNING

Furnaces may be twinned without the use of a twinning kit. Furnaces must be the same model and equipped with PCBBF140 control boards. Follow the diagram provided in this manual. Connection of the “twin” terminals of each control together will allow simultaneous operation of two or more furnace indoor blowers to operate synchronously on a common duct system. Field installed low voltage thermostat wiring, 3/16" terminals are required to make this connection. An isolating relay (24 VAC coil & N/O SPST) contacts is also required if the furnaces are not fed from the same line voltage phase. A pulsing DC signal is used to share the call for fan operation between furnaces. The duration of the pulse width determines the speed that

the reading control will energize its blower motor.

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

.

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

GAS S

UPPLY AND PIPING

INLET GAS SUPPLY PRESSURE

Natural Gas Mi nimum: 4.5" w.c. Maximum: 10.0" w.c.

Propane Gas Minimum: 11.0" w.c. Maximum: 13.0" w.c.

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

R

Room

Thermostat

R

Furnace Integrated

Control Module

Y C

Remote Condensing Unit

(Single-Stage Cooling)

Figure 31

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.

26

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 DERATE

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

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

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

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

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

PROPANE GAS CONVERSION

This unit is configured for natural gas. To operate this furnace on L.P. gas, an LPM-07 LP Conversion kit must be used.

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

GAS VALVE

This unit is equipped with a 24 volt gas valve controlled during furnace operation by the integrated control module. As shipped, the valve is configured for natural gas. The valve is field convertible for use with propane gas by replacing the regulator spring with a propane gas spring from an appropriate manufacturer’s propane gas conversion kit. Taps for measuring the gas supply pressure and manifold pressure are provided on the valve.

GAS PIPING CONNECTIONS

The gas piping supplying the furnace must be properly sized based on the gas flow required, specific gravity of the gas, and length of the run. The gas line installation must comply with local codes, or in their absence, with the latest edition of the National Fuel Gas Code, NFPA 54/ANSI Z223.1 or CAN/CSA B149.1-15 in Canada.

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

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

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

• Use black iron or steel pipe and fittings for building piping.

Where possible, use new pipe that is properly chamfered, reamed, and free of burrs and chips. If old pipe is used, be sure it is clean and free of rust, scale, burrs, chips, and old pipe joint compound.

• Use pipe joint compound on male threads ONLY. Always

use pipe joint compound (pipe dope) that is APPROVED FOR ALL GASSES. DO NOT apply compound to the first two threads.

• Use ground joint unions.

• Install a drip leg to trap dirt and moisture before it can

enter the gas valve. The drip leg must be a minimum of three inches long.

• Install a 1/8" NPT pipe plug fitting, accessible for test

gauge connection, immediately upstream of the gas supply connection to the furnace.

• Always use a back-up wrench when making the connection

to the gas valve to keep it from turning. The orientation of the gas valve on the manifold must be maintained as shipped from the factory. Maximum torque for the gas valve connection is 375 in-lbs; excessive over-tightening may damage the gas valve.

• Install a manual shutoff valve between the gas meter and

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

• Tighten all joints securely.

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

27

Natural Gas Capacity of Pipe

Length of Nominal Black Pipe Size

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

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

100 38 79 150 305 460

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

0.60 Specific Gravity Gas)

BTUH Furnace Input

CFH =

Heating Value of Gas ( BTU/Cubic Foot)

In Cubic Feet of Gas Per Hour (CFH)

• Connection method must be in compliance with all local

and national codes. US: National Fuel Gas Code (NFGC) NFPA 54-2012/ANSI Z223.1-2012 and the Installation Standards, Warm Air Heating and Air Conditioning Systems ANSI/NFPA 90B.

In Canada, CANADA: National Standard of Canada, Natural Gas and Propane Installation Code (NSCNGPIC) CSA B149.1-15.

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

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

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

• Use listed gas appliance connectors in accordance with

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

• Protect connectors and semirigid tubing against physical

and thermal damage when installed. Ensure aluminumalloy 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.

The gas piping may enter the left or right side of the furnace cabinet. The installer must supply rigid pipe long enough to reach the outside of the cabinet to seal the grommet cabinet penetration. A semi-rigid connector to the gas piping can be used outside the cabinet per local codes. 1/2” NPT pipe and fittings are required. For models with an “L” shaped manifold, a 4 1/2” long nipple is required. For models with a hook shaped manifold, a 2” long nipple is required.

Alternate

Gas Line

Location

Manifold

Burners

Gas Valve

*Ground

Joint

Pip e

Union

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

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

*Ground Joint Pip e Union

Drip Leg

Grommet in Standard Gas Line Hole

UPFLOW

Figure 32

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

*Ground

Joint

Pip e U ni on

Grommet

in Standard

Gas Line

Hole

Drip Leg

Gas Valve

Burners

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

COUNTERFLOW

Figure 33

Alternate Gas Line Location

*Ground Joint Pipe Union

Plug in Alternate Gas Line Hole

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

28

Alternate Union Location

Grommet in

Standard Gas Line Hole

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

Drip Leg

Plug in Alternate Gas Line Hole

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).

Burners

Manifold

Gas

Valve

Drain Trap

UPFLOW - HORIZONTAL LEFT

Figure 34

Plug in Main Gas Line Hole

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

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

WARNING

TO

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

OR OPEN FLAME TO TEST FOR LEAKS

.

WARNING

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

.

PROPANE GAS TANKS AND PIPING

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

COUNTERFLOW - HORIZONTAL RIGHT

Figure 35

GAS PIPING CHECKS

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

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

58.

CANADA: National Standard of Canada, Natural Gas and Propane Installation Code (NSCNGPIC) CSA B149.1-15.

5 to 15 PSIG (20 PS IG Max .)

Figure 36

Continuous

Second S tage Regulator

11" W. C.

29

First Stage Regulator

200 PSIG Maximum

Propane Gas Installation (Typ.)

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

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.

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;

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

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

WARNING

N

EVER ALLOW THE PRODUCTS OF COMBUSTION, INCLUDING CARBO N

MONOXIDE, TO ENTER THE RETURN DUCT WORK OR CIRCULATION AIR

SUPPLY

.

C

IRCULATING AIR

& F

ILTERS

DUCT WORK - AIR FLOW

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

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

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

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

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

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

Example:

Difference is 4

-1

static reading from return duct = -.1" w.c.

static reading from supply duct = .3" w.c.

total external static pressure on this system = .4" w.c.

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

4. Consult proper tables for the quantity of air.

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

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

0

1 2

3

CHECKING DUCT STATIC

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

Total external static refers to everything external to the furnace cabinet. Cooling coils, filters, ducts, grilles, registers must all be considered when reading your total external static pressure. The supply duct pressure must be read between

30

Digital

Manometer

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.

Checking Static Pressure

(80% Furnace Shown, 90% Similar)

Figure 37

WARNING

E

DGES OF SHEET METAL HOLES MAY BE SHARP

PRECAUTION WHEN REMOVING SHEET METAL FROM RETURN AIR

OPENINGS

.

. USE

GLOVES AS A

BOTTOM RETURN AIR OPENING [UPFLOW MODELS]

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

CUT USING TIN SNIPS

PRESS OUT BY HAND

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

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

Filters must be used with this furnace. Discuss filter maintenance with the building owner. Filters do not ship with this furnace, but must be provided, sized and installed externally by the installer. Filters must comply with UL900 or CAN/ULCS111 standards. Damage or repairs due to the installation of the furnace without filters is not covered under the warranty.

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

Refer to the Filter Sizing Chart to determine filter area requirements.

Filter Sizing Chart

Model Minimum Recommended Filter Size^

*MSS9*0403AN* 1 - 16 X 25 Side or 1 - 14 x 25 Bottom

*MSS9*0402BN 1 - 16 X 25 Side or Bottom

*MSS9*0603BN* 1 - 16 X 25 Side or Bottom

*MSS9*0803BN* 1 - 16 X 25 Side or Bottom

*MSS9*0804CN* 1 - 16 X 25 Side or Bottom

*MSS9*0805CN* 1 - 20 X 25 Bottom / 2 - 16 X 25 Side Return

*MSS9*1004CN* 1 - 16 X 25 Side or Bottom

*MSS9*1005CN* 1 - 20 X 25 Bottom / 2 - 16 X 25 Side Return

*MSS9*1205DN* 1 - 20 X 25 Bottom / 2 - 16 X 25 Side Return

CUT FOUR CORNERS AFTER REMOVING SHEET METAL

Duct Flange Cut Outs

Figure 38

SCRIBE LINES OUTLINING DUCT FLANGES

*CSS 9*0402BN* 2 - 10 X 20 or 1 - 16 X 25 Top Return

*CSS 9*0603BN* 2 - 10 X 20 or 1 - 16 X 25 Top Return

*CSS 9*0804CN* 2 - 10 X 20 or 1 - 16 X 25 Top Return

*CSS 9*1005CN* 2 - 14 X 20 or 1 - 20 X 25 Top Return

*CSS 961205DN* 2 - 14 X 20 or 1 - 20 X 25 Top Return

^ Lar ge r filte rs may b e us ed, filt er s may also b e c en t rally lo c at ed .

Change filters before occupants take ownership of a new home!

31

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

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

Air Cleaner

Installation Location

Si de o r botto m return 1200 CFM 16 i n X 20 in x 5¼" AM11-1620-5

Si de o r botto m return 1600 CFM 16 i n X 25 in x 5¼" AM11-1625-5

Si de o r botto m return 1600 CFM 20 i n X 20 in x 5¼" AM11-2020-5

Si de o r botto m return 2000 CFM 20 i n X 25 in x 5¼" AM11-2025-5

Si de re turn

(fo r 2 se para te re turns )

Si de re turn (Ri ght a ngle ) 2000 CFM 20 in X 25 i n x 5¼" AM11-2025-5RA AM11-5RA

Botto m return (pla tform) 2000 CFM 20 i n X 25 in x 5¼" AM11-2832-5PP

Botto m return (pla tform) 2000 CFM 20 i n X 25 in x 5¼" AM11-2843-5PP

AM11-5 AM11-5RA AM11-5PP

Family Family Family

Maximu m

Heating Airflow

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

Filter (Media)

Dimensions

Part Number

Air Cleaner

Family

AM11-5

AM11-5PP

FILTER

ACCESS

DOOR

F

I

RETURN

DUCT

FILTER SUPPORT BRACKET

(Field Supplied)

L

T

E

R

AIR FLOW

R

E

T

L

I

F

CENTRAL

RETURN

GRILLE

Possible Upright Counterflow

Filter Locations

HORIZONTAL INSTALLATIONS

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

S

TA RTU P PROCEDURE

& A

DJUSTMENT

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

DRAIN TRAP PRIMING

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

FURNACE OPERATION

Upright Installations

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

The following figures show possible filter locations.

AIR FLOW

CENTRAL

RETURN

GRILLE

SIDE RETURN

EXTERNAL FILTER

FILTER

RACK KIT

(EITHER SIDE)

FILTER

Purge gas lines of air prior to startup. Be sure not purge lines into an enclosed burner compartment. Follow NFPA 54, National Fuel Gas Code 8.1 for proper purging methods. In Canada, follow approved purging methods in B149.1-15.

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.

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

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

.

Possible Upright Upflow

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

32

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

7. If you smell gas after five minutes, immediately follow the safety instructions in the Safety Considerations on page 3 of this manual. If you do not smell gas after five minutes, move the furnace gas valve manual control to the ON position.

8. Replace the burner compartment door.

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

10. 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. The indoor blower will shut down when the time delay expires (selectable on 96% models).

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

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

4. Replace the burner compartment door.

GAS SUPPLY PRESSURE MEASUREMENT

GAS PRESSURE TEST

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

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

2. Connect a calibrated water manometer (or appropriate gas pressure gauge) at either the gas valve inlet pressure tap or the gas piping drip leg. See White-Rodgers 36J22 gas valve figure for location of inlet pressure tap.

Gas Valve ON/OFF Selector Switch

Inlet Pressure

OUTLET

White-Rodgers Model 36J22

Connected to Manometer

INLET

NOTE: If measuring gas pressure at the drip leg, a field-

suppliedhose barb fitting must be installed prior to making the hose connection. If using the inlet pressure tap on the WhiteRodgers 36J22 gas valve, then use the 36G/J Valve Pressure Check Kit, 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.

Manifold Gas Pressure

Gas Range Nominal

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

Propane 9.7 - 10.3" w.c. 10.0" w.c.

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.

OUTLET

Regulator Cover Screw

INLET

Outlet Pressure

White-Rodgers Model 36J22

Measuring Inlet Gas Pressure (Alt. Method)

Figure 39

33

GAS MANIFOLD PRESSURE MEASUREMENT AND ADJUSTMENT

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: White-Rodgers 36J22 valve: Back outlet pressure test screw

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

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

5. Turn ON the gas supply.

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

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

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

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

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

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

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

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

Using a leak detection solution or soap suds, check for leaks at outlet or screw (White-Rodgers valve). Bubbles forming indicate a leak. SHUT OFF GAS AND REPAIR ALL LEAKS IMMEDIATELY! NOTE: For gas to gas conversion, consult your dealer for appropriate conversion.

indicates 1/2 cu. ft. per revolution. You will use this number to calculate the quantity of gas in cubic ft. if the furnace would consume if it ran steadily for one hour (3600 seconds).

3. If the 1/2 cu. ft. dial was used, multiply your number x 2.

EXAMPLE: If it took 23 seconds to complete one revolution of the 1/2 ft. dial (23 x 2 = 46).

This tells us that at this rate, it would take 46 seconds to consume one cu. ft. of gas. 3600 / 46 = 78.

This tells us that in one hour, the furnace would consume 78 cu. ft. of gas.

The typical value range for 1 cu. ft. of natural gas is around 1000 BTU. Check with your gas utility, if possible. In this example, the furnace is consuming 78,000 BTUH.

NOTE: The final manifold pressure cannot vary by more than ± 0.3” w.c. for Natural and + 0.5” for LP from the specified setting. Consult your local gas supplier if additional input rate adjustment is required.

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

TEMPERATURE RISE

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

1. Operate furnace with burners firing for approximately ten minutes. Ensure all registers are open and all duct dampers are in their final (fully or partially open) position.

2. Place thermometers in the return and supply ducts as close to the furnace as possible. Thermometers must not be influenced by radiant heat by being able to “see” the heat exchanger.

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

.

GAS INPUT RATE MEASUREMENT (NATURAL GAS ONLY)

The actual gas input rate to the furnace must never be greater than that specified on the unit rating plate. To 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 at high fire rate, time and record one complete revolution of the gas meter dial, measuring the smallest quantity, usually the dial that

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.

34

SUPPLY AIR

RETURN AIR

If heating and cooling blower speeds are the same, a jumper wire must be used between the heat and cool terminals.

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

5. Turn ON power to furnace.

6. Verify proper temperature rise as outlined in the

Temperature Rise section of Startup Procedure and Adjustment.

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

BLOWER HEAT OFF DELAY TIMINGS

Temperature Rise Measurement

Figure 40

CIRCULATOR BLOWER SPEEDS

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

WARNING

TO

AVOID PERSONAL INJURY OR DEATH DUE TO ELECTRICAL SHOCK

TURN

OFF

POWER TO THE FURNACE BEFORE CHANGING SPEED TAPS

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 Tons

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

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

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

To adjust the circulator blower speed, proceed as follows:

1. Turn OFF power to the furnace.

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

3. Relocate desired motor leads to the circulator blower heat and cool speed terminals on the integrated control module. (Terminals are identified as HEAT and COOL).

,

.

The integrated control module on 96% models provides a selectable heat off delay function. The heat off delay period may be set to 100 or 150 seconds by cutting the jumper on the control module. The delay is factory shipped at 150 seconds but may be changed to suit the installation requirements and/or homeowner preference.

The integrated control board on 92% models has a fixed blower off delay of 150 seconds.

N

ORMAL SEQUENCE OF OPERATION

POWER UP

The normal power up sequence is as follows:

• 115 VAC power applied to furnace.

• Integrated control module performs internal checks.

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

• Integrated control module monitors safety circuits continuously.

• Furnace awaits call from thermostat.

HEATING MODE

The normal operational sequence in heating mode is as follows:

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

• Gas valve closes, extinguishing flame.

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

• 96% models HUM terminal is de-energized.

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

• EAC terminal is de-energized For 92% Models: The blower off delay is 150 seconds

(non-adjustable).

• Furnace awaits next call from thermostat.

COOLING MODE

The normal operational sequence in cooling mode is as follows:

35

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

• Integrated control module performs safety circuit checks.

• Outdoor fan and compressor are energized.

• Circulator blower is energized on the cool speed.

• 96% models 115 VAC EAC terminal is energized.

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

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

• Outdoor fan and compressor are de-energized.

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

• Furnace awaits next call from thermostat.

FAN ONLY MODE

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

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

• Integrated control module performs safety circuit checks.

• Circulator blower is energized on heat speed.

• 96% models 115 VAC EAC terminal is energized.

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

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

• Circulator blower is de-energized.

• EAC terminal is de-energized.

• Furnace awaits next call from thermostat.

O

PERATIONAL CHECKS

The burner flames should be inspected with the burner compartment door installed. Flames should be stable, quiet, soft, and blue (dust may cause orange tips but they must not be yellow). Flames should extend directly outward from the burners without curling, floating, or lifting off. Flames must not impinge on the sides of the heat exchanger firing tubes.

S

AFETY CIRCUIT DESCRIPTION

A number of safety circuits are employed to ensure safe and proper furnace operation. These circuits serve to control any potential safety hazards and serve as inputs in the monitoring and diagnosis of abnormal function. These circuits are continuously monitored during furnace operation by the integrated control module.

INTEGRATED CONTROL MODULE

The integrated control module is an electronic device which, if a potential safety concern is detected, will take the necessary precautions and provide diagnostic information through an LED.

PRIMARY LIMIT

The primary limit control is located on the partition panel and monitors heat exchanger compartment temperatures. It is a 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), manual-reset sensors. These limits guard against overheating as a result of insufficient conditioned air passing over the heat exchanger.

ROLLOUT LIMIT

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

PRESSURE SWITCHES

The pressure switches are normally-open (closed during operation) negative air pressure-activated switches. They monitor the airflow (combustion air and flue products) through the heat exchanger via pressure taps located on the induced draft blower and the coil front cover. These switches guard against insufficient airflow (combustion air and flue products) through the heat exchanger and/or blocked condensate drain conditions.

FLAME SENSOR

The flame sensor is a probe mounted to the burner/manifold assembly which uses the principle of flame rectification to determine the presence or absence of flame.

T

ROUBLESHOOTING

ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS

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

An electrostatic discharge can adversely affect electrical components.

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

36

objects, etc.). If you come in contact with an ungrounded object, repeat step 2 before touching control or wires.

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

DIAGNOSTIC CHART

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

FAULT RECALL (96% Models Only)

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

WARNING

HIGH VOLTAGE !

TO

AVOID PERSONAL INJURY OR DEATH DUE TO

ELECTRICAL SHOCK, DISCONNECT ELECTRICAL POWER

BEFORE

FAULT CODE RESET (96% Models Only)

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

PERFORMING ANY SERVICE OR MAINTENANCE

.

RESETTING FROM LOCKOUT

Furnace lockout results when a furnace is unable to achieve ignition after three attempts during a single call for heat. It is characterized by a non-functioning furnace and a fault code displayed. If the furnace is in “lockout”, it will (or can be) reset in any of the following ways.

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

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

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

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

M

AINTENANCE

ANNUAL INSPECTION

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

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

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

• Filters.

FILTERS

FILTER MAINTENANCE

Improper filter maintenance is the most common cause of inadequate heating or cooling performance. Filters should be cleaned (permanent) or replaced (disposable) every two months or as required. When replacing a filter, it must be replaced with a filter of the same type and size.

FILTER REMOVAL

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

To 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.

To 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.

37

MEDIA AIR FILTER OR ELECTRONIC AIR CLEANER REMOVAL

FLAME SENSOR (QUALIFIED SERVICER ONLY)

Follow the manufacturer’s directions for service.

DIAG NOSTIC CODES

1 flash, then pause System lockout

2 flashes, then pause Pressure switch stuck closed

3 flashes, then pause Pressure switch stuck open

4 flashes , then pause Open limit switch

5 flashes , then pause

6 flashes , then pause Open rollout switch / open control board fuse

7 flashes , then pause Low flame sense sig nal

8 flashes , then pause Igniter relay fault

Continuous flashing 115 Volt AC power reversed

OFF Control failure

ON Normal operation

The LED will also flash once at power-up.

Flame has been sensed when no flame

should be present (no call for heat)

BURNERS

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

INDUCED DRAFT AND CIRCULATOR BLOWERS

The bearings in the induced draft blower and circulator blower motors are permanently lubricated by the manufacturer. No further lubrication is required. Check motor windings for accumulation of dust which may cause overheating. Clean as necessary.

Burner Flame

Figure 41

CONDENSATE TRAP AND DRAIN SYSTEM (QUALIFIED SERVICER ONLY)

Under some conditions, the fuel or air supply can create a nearly invisible coating on the flame sensor. This coating acts as an insulator causing a drop in the flame sense signal. If the flame sense signal drops too low the furnace will not sense flame and will lock out. The flame sensor should be carefully cleaned by a qualified servicer using emery cloth or steel wool. Following cleaning, the flame sense signal should be as indicated in the Specifications Sheet.

FLUE PASSAGES (QUALIFIED SERVICER ONLY)

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

B

EFORE LEAVING 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.

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

Annually inspect the drain tubes, drain trap, and field-supplied drain line for proper condensate drainage. Check drain system for hose connection tightness, blockage, and leaks. Clean or repair as necessary.

38

T

ROUBLESHOOTING CHART

Symptoms of Abnormal

Operation

•Furnace fails to operate.

•Integrated control module diagnostic LED provides no signal.

•LED is Steady On.

•Furnace fails to operate.

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

•Furnace fails to operate.

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

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

•Integrated control module diagnostic LED is flashing

THREE (3) flashes.

Associated

LED Code

NONE

ON

CONTINUOUS

ON

1

1 FLASH

2

2 FLASHES

3

2

3 FLASHES

2

Description(s)

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

•Blown fuse or circuit breaker.

•Integrated control module has an internal fault.

• Normal Operation

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

• Pressure switch circuit is closed.

• Induced draft blower is not operating.

• Pressure switch circuit not closed.

• Induced draft blower is operating.

Fault

Possible Causes

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

•Blown fuse or circuit breaker.

•Integrated control module has an internal fault.

• Normal Operation

•Failure to establish flame. Cause may be no gas to burners, front cover pressure switch stuck open, bad igniter or igniter alignment, improper orifices, or coated/oxidized or improperly connected flame sensor.

•Loss of flame after establishment. Cause may be interrupted gas supply, lazy burner flames (improper gas pressure or restriction in flue and/or combustion air piping), front cover pressure switch opening, or improper induced draft blower performance.

•Induced draft blower pressure switch contacts sticking.

•Shorts in pressure switch circuit.

•Pressure switch hose blocked, pinched or connected improperly.

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

•Incorrect pressure switch setpoint or malfunctioning switch contacts.

•Loose or improperly connected wiring.

Corrective Action

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

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

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

•Replace bad integrated control module.

•None

•Locate and correct gas interruption.

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

•Replace or realign igniter.

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

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

•Verify proper induced draft blower performance.

•Replace induced draft

blower pressure switch.

•Repair short.

•Inspect pressure switch hose. Repair, if necessary,

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

•Correct pressure switch setpoint or contact motion.

•Tighten or correct wiring connection.

Cautions &

Notes

•Turn power OFF prior to repair.

•Replace grated

inte-

control module fuse with 3A automotive fuse.

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

• Normal Operation

•Turn power OFF prior to repair.

•Igniter is fragile, handle with care.

•Sand flame sensor with emery cloth.

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

•Turn power OFF prior to repair.

•Replace pressure switch with proper replacement part.

•Turn power OFF prior to repair.

•Replace pressure switch with proper replacement part.

1

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

2

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

39

T

ROUBLESHOOTING CHART

Symptoms of Abnormal

Operation

•Circulator blower runs continuously. No furnace operation.

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

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

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

• Furnace fails to operate.

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

• No furnace operation.

• Normal furnace operation.

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

• Furnace not operating.

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

• Circulating blowers not operating simultaneously. No blower operation.

• Furnace fails to operate.

• Integrated control module diagnostic LED is flashing continuously.

• LED is steady on.

2

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

Associated

LED Code

4

4 FLASHES

5

5 FLASHES

6

6 FLASHES

7

7 FLASHES

7

8

8 FLASHES

9

C

9 FLASHES

C

CONTINUOUS/

RAPID FLASH

STEADY ON

2

Fault

Description(s)

•Primary or auxiliary limit circuit is open.

• Flame sensed with no call for heat.

• Rollout limit open.

•Integrated control module fuse is blown.

• Flame sense microamp signal is low.

• Problem with igniter circuit.

•Twinning Fault

• Polarity of 115

or 24 volt power is reversed.

• Normal operation.

Possible Causes Corrective Action

•Faulty pirmary or auxiliary limit switch.

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

•Loose or improperly connected wiring.

• Short to ground in flame sense circuit.

• Flame rollout.

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

•Loose or improperly connected wiring.

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

• Faulty rollout limit.

• Flame sensor is coated/ oxidized.

• Flame sensor incorrectly positioned in burner flame.

• Lazy burner flame due to improper gas pressure or combustion air.

•Improperly connected igniter.

• Bad igniter.

• Poor unit ground.

•Poor burner ground.

•Faulty integrated control module.

• Furnace twin terminals not connected together by field wiring.

• Isolating relay not used or improperly installed

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

• Orange and gray wires to transformer are reversed.

• Poor unit ground.

•Check primary/auxiliary limit. Replace if necessary.

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

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

•Tighten or correct wiring connection.

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

• Check burners for proper alignment.

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

• Check rollout limit. Replace if necessary.

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

•Tighten or correct wiring connection.

• Sand flame sensor.

• Inspect for proper sensor alignment.

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

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

•Replace bad igniter.

•Check & correct unit ground wire.

•Replace bad integrated control module.

• Install field wiring connecting twin terminals, check continuity of wiring.

• Verify each furnace fan motor is operable without twinning connection.

•Wire per twinning diagram in this installation manual

•Review wiring diagram to

correct polarity.

• Reverse orange and gray

wires going to transformer.

•Verify proper ground.

Correct if necessary.

40

Cautions and

Notes

•Turn power OFF prior to repair.

•Replace primary/ auxiliary limit with proper replacement part.

•Replace blower with correct replacement part.

• Turn power OFF prior to repair.

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

•Replace induced draft blower with correct replacement part.

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

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

• Replace rollout limit with correct replacement part.

• Turn power OFF prior to repair.

• Clean flame sensor with steel wool.

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

• See rating plate for proper gas pressure.

• Turn power OFF prior to repair.

• Replace igniter w/proper replacment part.

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

• Verify line voltage supply is turned off before proceeding with corrections.

• Turn power OFF prior to repair.

A

IRFLOW

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

AC CFM RISE CFM RIS CFM RISE CFM RISE CFM RISE CFM CFM CFM

HIGH 3.0 1260 N/ A 1205 N/ A 1153 N/ A 1081 31 1023 33 94 6 871 790

*M SS920403A N

*M SS920402B N

*M SS920603B N

*M SS920803B N

*M SS920804CN

*M SS920805CN

*M SS921004C N

*M SS921005C NAA

*M SS921005C NAB

*M SS921205D N

*CSS920402B N

*CSS920603B N

*CSS920804CN

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

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

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

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

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

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

M ED 2.5 1156 N/ A 1115 N/ A 1074 31 1019 33 959 35 893 817 742

MED-

LOW 1.5 938 36 903 37 873 38 834 40 791 42 746 672 597 HIGH 3.0 1545 N/ A 1495 N/A 1438 N/ A 1369 N/ A 1295 N/ A 1212 1141 1034 M ED 2.5 1322 N/A 1290 N /A 1246 N /A 1209 N/ A 1149 30 1078 1013 921

M ED- 2.0 1099 31 1077 32 1048 33 1019 33 985 35 928 859 772

LOW 1.5 976 35 969 35 923 37 896 38 858 40 817 763 683 HIGH 3.0 1543 N/ A 1484 N/ A 1427 36 1363 37 1296 39 1209 1122 1020 M ED 2.5 1344 38 1315 39 1274 40 1223 42 1172 44 1097 1024 920

M ED- 2.0 1138 45 1108 46 1083 47 1046 49 1008 51 956 876 791

LOW 1.5 1002 51 987 52 962 N/A 929 N/A 899 N/ A 847 796 716 HIGH 3.0 1560 44 1505 45 1426 48 1366 50 1288 53 1194 1116 1006 M ED 2.5 1362 50 1313 52 1275 53 1225 56 1166 58 1097 1009 912

M ED- 2.0 1138 60 1116 61 1099 62 1053 65 1005 N/ A 948 876 779

LOW 1.5 1010 N/A 1004 N/A 966 N/ A 944 N/ A 900 N/A 851 783 690 HIGH 5.0 2053 N/A 1994 N/ A 1921 35 1827 37 1720 40 1614 1501 1344 M ED 4.0 1858 37 1811 38 1749 39 1676 41 1589 43 1500 1397 1264

M ED- 3.5 1538 44 1516 45 1494 46 1459 47 1400 49 1335 1239 1129

LOW 3.0 1256 54 1244 55 1216 56 1206 57 1170 58 1113 1063 987 HIGH 5.0 2256 30 2172 31 2107 32 2058 33 1959 35 1859 1762 1654 M ED 4.0 1980 34 1923 35 1882 36 1808 38 1722 40 1633 1559 1454

M ED- 3.5 1630 42 1593 43 1561 47 1523 49 1476 51 1432 1358 1270

LOW 3.0 1387 53 1332 54 1305 55 1258 N/A 1215 N /A 1159 1101 1032 HIGH 5.0 2059 41 1952 44 1900 45 1802 47 1703 50 1609 1470 1340 M ED 4.0 1860 46 1792 48 1733 49 1656 51 1576 54 1477 1367 1248

M ED- 3.5 1530 56 1505 57 1470 58 1452 59 1385 62 1305 1221 1097

LOW 3.0 1255 N /A 1253 N/A 1223 N /A 1203 N/A 1158 N/A 1111 1058 932 HIGH 5.0 2235 38 2166 39 2110 40 2021 42 1956 44 1855 1740 1618 M ED 4.0 1955 44 1921 44 1860 46 1808 47 1746 49 1645 1572 1461

M ED- 3.5 1658 51 1634 52 1590 54 1549 55 1494 57 1432 1359 1266

LOW 3.0 1418 60 1374 62 1348 63 1297 N A 1265 N /A 1219 1152 1106 HIGH 5.0 2489 N/A 2420 35 2330 37 2250 38 2183 39 2091 1963 1803 M ED 4.0 2102 41 2050 42 2005 42 1944 44 1880 45 1798 1693 1602

M ED- 3.5 1768 48 1723 49 1690 50 1624 52 1580 54 1493 1436 1339

LOW 3.0 1474 58 1429 60 1388 61 1370 62 1313 65 1253 1168 1082 HIGH 5.0 2355 43 2275 45 2177 47 2105 49 2014 51 1897 1770 1633 M ED 4.0 2050 50 1996 51 1957 52 1882 54 1815 56 1708 1598 1505

M ED- 3.5 1753 58 1703 60 1650 62 1601 64 1548 N /A 1461 1369 1264

LOW 3.0 1521 N /A 1451 N/ A 1409 N /A 1328 N /A 1298 N/ A 1237 1155 1042 HIGH 3.0 1512 N/A 1446 N/A 1375 N/ A 1301 N/ A 1222 N/A 1137 1033 940 M ED 2.5 1356 N/ A 1310 N/A 1261 N/A 1193 N/A 1122 30 1041 963 869

M ED- 2.0 1168 N /A 1133 30 1092 31 1053 32 984 35 929 858 753

LOW 1.5 1053 32 1006 34 976 35 934 36 887 38 811 754 663

HIGH 3.0 1431 36 1363 37 1303 39 1236 41 1168 44 1082 1003 910 M ED 2.5 1305 39 1251 41 1197 43 1148 45 1076 48 1012 931 842

M ED- 2.0 1141 45 1109 46 1070 48 1017 50 969 53 904 826 737

LOW 1.5 1041 49 996 51 962 53 913 56 876 58 807 729 658 HIGH 4.0 1881 36 1762 39 1703 40 1601 43 1516 45 1393 1310 1171 M ED 3.5 1758 39 1686 40 1628 42 1533 44 1441 47 1339 1249 1153

M ED- 3.0 1577 43 1523 45 1458 47 1400 49 1303 52 1228 1126 1030

LOW 2.5 1338 51 1306 52 1267 54 1215 56 1146 59 1086 1011 909

2.0 1028 33 993 34 959 35 915 36 866 39 810 742 671

0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8

41

A

IRFLOW

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

*MSS960403AN

*MSS960402BN

*MSS960603BN

*MSS960803BN

*MSS960804CN

*MSS960805CN

*MSS961004CN

*MSS961005CN

*MSS961205DN

*CSS960402BN

*CSS960603BN

*CSS960804CN

*CSS9 610 05CN

*CSS9 612 05DN

AC C FM RISE CFM RISE CFM RISE CFM RISE CFM RISE CFM CFM CFM

HI G H 3 . 0 12 0 7 2 9 115 3 3 0 1118 3 1 10 6 7 3 3 10 16 3 3 9 6 0 8 9 7 8 3 5

MED 2.5 1047 33 1019 34 987 35 951 36 908 38 862 813 753

MED-LO 2.0 900 39 8 77 40 842 41 8 14 42 774 45 739 687 634

LOW 1.5 8 0 2 43 78 0 4 5 757 4 6 721 4 8 6 9 2 50 6 48 6 07 570

HI G H 3 . 0 14 4 0 2 5 13 7 8 2 6 13 2 2 2 7 12 5 9 2 8 119 1 3 0 1114 10 2 8 9 2 2

MED 2.5 1292 28 1246 29 1206 29 1146 31 1094 33 1015 936 847

MED-LO

2.0 1125 32 1084 33 1038 34 1005 35 955 37 89 8 827 736

LOW 1.5 1018 35 988 36 950 37 911 39 869 41 818 747 66 3

HIGH 3.0 1446 37 1383 39 1307 41 1252 43 1182 45 1087 993 900

MED 2.5 1297 41 1258 42 1203 44 1141 47 1066 50 995 912 809

2.0 1111 48 1083 49 1046 51 1004 53 945 56 888 804 729 LOW 1.5 1004 53 973 55 947 56 911 59 860 62 801 737 645

HIGH 3.0 1520 47 1447 49 138 8 51 1307 54 1220 58 1126 1034 925

MED 2.5 1444 49 1381 51 1317 54 1245 57 1171 61 1083 993 889

2.0 1315 54 1268 56 1219 58 1152 62 1073 N/A 1008 919 817

LOW 1.5 1135 63 1106 64 1063 N/A 1017 N/A 970 N/A 912 828 751

HIGH 4.0 1937 37 1841 39 1768 40 1689 42 1573 45 1483 1369 1244

MED 3.5 1790 40 1711 42 1649 43 1559 46 1482 48 1382 1274 1172

3.0 1529 47 1499 47 1451 49 1405 51 1321 54 1254 1166 1058

L O W 2 . 5 12 4 8 N / A 12 2 3 N / A 12 10 N / A 115 8 N / A 112 6 N / A 10 7 2 10 13 9 3 0

HIGH 5.0 2109 34 2030 35 1970 36 1924 37 1831 39 1738 1647 1546

MED 4.0 1868 38 1815 39 1776 40 1706 42 1640 43 1556 1485 1385

3.5 1591 45 1550 46 1516 47 1465 49 1406 51 1351 1282 1199

L O W 3 . 0 13 6 0 5 2 13 0 6 5 4 12 8 0 N / A 12 3 4 N / A 119 2 N / A 113 7 10 8 0 10 12

HIGH 5.0 1960 45 1894 47 1812 49 1736 51 1634 54 1544 1473 13 60 MED 4.0 1740 51 1687 53 1617 55 1549 57 1490 60 1410 1321 1221

3.5 1491 60 1456 61 1402 63 1346 N/A 1281 N/A 1213 1145 1045

LOW 3.0 1239 N/A 1212 N/A 1178 N/A 1141 N/A 1098 N/A 1047 984 930

HIGH 5.0 2053 43 1992 45 1935 46 1869 48 1773 50 1686 1586 1475

MED 4.0 1884 47 1824 49 1754 51 1690 53 1623 55 1537 1449 1347

3.5 1614 55 1566 57 1519 59 1471 60 1413 63 1367 1296 1219

LOW 3.0 1390 N/A 1344 N/A 1326 N/A 1268 N/A 1227 N/A 1194 1132 1071

HIGH 5.0 2201 48 2129 50 2056 52 1997 53 1921 56 1844 1720 1588

MED 4.0 1967 54 1903 56 1843 58 1779 60 1708 62 1621 1534 1408

3.5 1675 64 1619 N/A 1574 N/A 1520 N/A 1457 N/A 1383 1305 1201

LOW 3.0 1444 N/A 1408 N/A 1345 N/A 1291 N/A 1249 N/A 1168 1105 1012

HIGH 3.0 1407 25 1336 27 1278 28 1220 29 1143 3 1 1055 945 869

MED 2.5 1295 27 1244 29 1192 30 1123 32 1068 33 994 912 806

2.0 1139 31 1096 32 1059 34 1016 35 954 37 885 806 714 LOW 1.5 1025 35 989 36 964 37 922 39 876 41 811 729 643

HIGH 3.0 1407 38 1336 40 1278 42 1220 44 1143 47 1055 945 869

MED 2.5 1295 41 1244 43 1192 45 1123 47 1068 50 994 912 806

2.0 1139 47 1096 49 1059 50 1016 52 954 56 885 806 714

LOW 1.5 1025 52 989 54 964 55 922 58 876 61 811 729 643

HIGH 4.0 179 5 4 0 1706 4 2 164 0 43 1534 4 6 144 2 4 9 13 59 1250 1141

MED 3.5 1712 42 1635 43 1550 46 1469 48 1380 52 1288 1184 1082

3.0 1544 46 1484 48 1418 50 1353 53 1265 56 1185 1093 987

LOW 2. 5 130 7 54 1273 56 122 9 58 118 6 6 0 1128 6 3 106 1 9 77 8 92

HIGH 5.0 1992 45 1921 46 1883 47 1791 50 1723 52 1626 1549 1437

M E D 4 . 0 18 4 1 4 8 17 8 0 5 0 17 3 0 5 1 16 5 3 5 4 15 8 6 5 6 15 0 2 14 10 13 15

3.5 1638 54 1582 56 1528 58 1476 60 1401 63 1336 1262 1161

LOW 3.0 1430 62 1380 64 1336 67 1278 70 1231 N/A 1162 1099 1019

HIGH 5.0 2123 50 2053 52 2000 53 1916 56 1832 58 1739 1646 1561

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

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

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

0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8

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

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

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

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

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

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

42

W

IRING

HIGH VOLTAGE!

Disconnect ALL power before servicing or installing this unit. Multiple

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45

THIS PAGE INTENTIONALLY LEFT BLANK

46

SPECIAL INSTRUCTIONS FOR PRODUCTS INSTALLED IN THE STATE OF MASSACHUSETTS

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

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

COMBUSTION AIR INTAKE.

DISTANCE BETWEEN

COMBUSTION AIR

INTAKE AND GRADE

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

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

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

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

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

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

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

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

VENT/FLUE

TEE

DISTANCE BETWEEN

VENT AND GRADE

EXEMPTIONS

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

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

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

(c) MANUFACTURER REQUIREMENTS - GAS EQUIPMENT VENTING SYSTEM PROVIDED. When the manufacturer of Product Approved side wall

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

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

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

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

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

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

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

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

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

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

5151 San Felipe Suite 500

Houston, TX 77056

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

47

5151 San Felipe Suite 500

Houston, TX 77056

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

is a registered trademark of Maytag Corporation or its related companies

48