Goodman GKS9 User Manual

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Page 1

GKS9

-F

IRED

ARM

URNACE

INSTALLATION INSTRUCTIONS

This furnace is shipped from the factory as a Dedicated Upflow. A “Blocked Drain Kit” is available and MUST

BE USED if the furnace is installed Horizontal Left or Horizontal Right. Check the Serial/Rating Plate on the

furnace for the Kit part number.

Installer: Affix all manuals adjacent to the unit.

(T ype FSP CATEGORY IV Direct or Non Direct Vent Air Furnace)

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

RECOGNIZE THIS SYMBOL AS A SAFETY PRECAUTION.

ATTENTION INSTALLING PERSONNEL

As a professional installer you have an obligation to know the product better than the customer. This includes all safety

precautions and related items.

Prior to actual installation, thoroughly familiarize yourself with this Instruction Manual. Pay special attention to all safety

warnings. Often during installation or repair it is possible to place yourself in a position which is more hazardous than

when the unit is in operation.

Remember, it is your responsibility to 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.

*NOTE: Please contact your distributor or our

website for the applicable Specification Sheet

referred to in this manual.

IO-300J 12/10

Goodman Manufacturing Company , L.P.

5151 San Felipe, Suite 500, Houston, TX 77056

www.goodmanmfg.com

Page 2

Table of Contents

I. Component Identification ............................................................................................................................................... 5

II. Safety .............................................................................................................................................................................. 6

ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS ................................................................................................... 6

III. Product Application ...................................................................................................................................................... 6

IV . Location Requirement s & Considerations.................................................................................................................. 7

GENERAL ......................................................................................................................................................... 7

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

URNACE SUSPENSION ........................................................................................................................................ 8

XISTING FURNACE REMOVAL .............................................................................................................................. 8

HERMOSTAT LOCATION ....................................................................................................................................... 9

V. Combustion & Ventilation Air Requirements ............................................................................................................... 9

VI. Installation Positions ...................................................................................................................................................11

VII. Horizontal Applications & Considerations ................................................................................................................11

GENERAL ........................................................................................................................................................11

RAIN TRAP AND LINES .....................................................................................................................................11

EVELING ........................................................................................................................................................11

LTERNATE VENT/FLUE CONNECTION .....................................................................................................................11

LTERNATE ELECTRICAL AND GAS LINE CONNECTIONS ............................................................................................ 12

RAIN PAN ..................................................................................................................................................... 12

REEZE PROTECTION ........................................................................................................................................ 12

URNACE SUSPENSION ...................................................................................................................................... 12

VIII. Propane Gas /High Altitude Installations............................................................................................................... 12

IX. Vent/Flue Pipe & Combustion Air Pipe ..................................................................................................................... 12

GENERAL ....................................................................................................................................................... 12

UAL CERTIFICA TION : NON-DIRECT/DIRECT VENT ................................................................................................... 13

ATERIALS AND JOINING METHODS ..................................................................................................................... 13

ROPER VENT/FLUE AND COMBUSTION AIR PIPING PRACTICES ................................................................................. 13

ERMINATION LOCATIONS ................................................................................................................................... 13

ANADIAN VENTING REQUIREMENTS..................................................................................................................... 14

TANDARD FURNACE CONNECTIONS ..................................................................................................................... 14

LTERNATE FURNACE CONNECTIONS ..................................................................................................................... 14

ON-DIRECT VENT (SINGLE PIPE) PIPING ............................................................................................................ 15

IRECT VENT (DUAL PIPE) PIPING ...................................................................................................................... 16

ENT/INTAKE TERMINATIONS FOR INSTALLATION OF MULTIPLE DIRECT VENT FURNACES .................................................. 18

ONCENTRIC VENT TERMINATION ......................................................................................................................... 18

IDE WALL VENT KIT........................................................................................................................................ 18

X. Condensate Drain Lines & Drain Trap........................................................................................................................ 18

GENERAL ....................................................................................................................................................... 18

PRIGHT INST ALLATIONS ..................................................................................................................................... 18

ORIZONTAL INSTALLA TIONS ................................................................................................................................21

XI. Electrical Connections................................................................................................................................................ 22

WIRING HARNESS ............................................................................................................................................ 22

OLT LINE CONNECTIONS ............................................................................................................................ 23

115 V

OLT THERMOSTAT WIRING ............................................................................................................................ 23

24 V

XII. Gas Supply and Piping.............................................................................................................................................. 23

GENERAL ....................................................................................................................................................... 23

AS PIPING CONNECTIONS ................................................................................................................................24

ROPANE GAS TANKS AND PIPING...................................................................................................................... 26

XIII. Circulating Air & Filters ............................................................................................................................................ 26

DUCTWORK - AIR FLOW ..................................................................................................................................... 26

OTTOM RETURN AIR OPENING [UPFLOW MODELS]............................................................................................... 27

ILTERS - READ THIS SECTION BEFORE INSTALLING THE RETURN AIR DUCTWORK ....................................................... 27

PRIGHT INST ALLATIONS ..................................................................................................................................... 27

ORIZONTAL INSTALLA TIONS ................................................................................................................................28

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Table of Contents

XIV. Startup Procedure & Adjustment............................................................................................................................. 28

HEA T ANTICIPAT OR SETTING ................................................................................................................................28

RAIN TRAP PRIMING ....................................................................................................................................... 28

URNACE OPERATION ......................................................................................................................................... 28

AS SUPPLY PRESSURE MEASUREMENT .............................................................................................................. 28

AS MANIFOLD PRESSURE MEASUREMENT AND ADJUSTMENT .................................................................................. 29

AS INPUT RATE MEASUREMENT (NA TURAL GAS ONLY) ......................................................................................... 29

EMPERATURE RISE ......................................................................................................................................... 30

IRCULATOR BLOWER SPEEDS ........................................................................................................................... 30

XV. Normal Sequence of Operation................................................................................................................................ 30

POWER UP ..................................................................................................................................................... 30

EATING MODE ............................................................................................................................................... 30

OOLING MODE .............................................................................................................................................. 31

AN ONLY MODE............................................................................................................................................. 31

XVI. Operational Checks .................................................................................................................................................. 31

BURNER FLAME ............................................................................................................................................... 31

XVII. Safety Circuit Description ....................................................................................................................................... 31

GENERAL ....................................................................................................................................................... 31

NTEGRATED CONTROL MODULE .......................................................................................................................... 31

RIMARY LIMIT ................................................................................................................................................ 31

UXILIARY LIMIT............................................................................................................................................... 31

OLLOUT LIMIT ................................................................................................................................................ 31

RESSURE SWITCHES ........................................................................................................................................ 31

LAME SENSOR ............................................................................................................................................... 31

XVIII. Troubleshooting...................................................................................................................................................... 32

ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS ................................................................................................. 32

IAGNOSTIC CHART .......................................................................................................................................... 32

ESETTING FROM LOCKOUT ............................................................................................................................... 32

XIX. Maintenance ............................................................................................................................................................. 32

ANNUAL INSPECTION .......................................................................................................................................... 32

ILTERS .......................................................................................................................................................... 32

URNERS ....................................................................................................................................................... 33

NDUCED DRAFT AND CIRCULATOR BLOWERS ......................................................................................................... 33

ONDENSATE TRAP AND DRAIN SYSTEM (QUALIFIED SERVICER ONLY)...................................................................... 33

LAME SENSOR (QUALIFIED SERVICER ONLY) ...................................................................................................... 33

GNITER (QUALIFIED SERVICER ONLY).................................................................................................................. 33

LUE PASSAGES (QUALIFIED SERVICER ONLY) ..................................................................................................... 33

XX. Before Leaving an Installation ................................................................................................................................. 33

XXI. Repair & Replacement Parts ................................................................................................................................... 33

APPENDIX

Troubleshooting Chart ...................................................................................................................................................... 34

GKS9 Wiring Diagram ...................................................................................................................................................... 36

WARN ING

OODMAN WILL NOT BE RESPONSIBLE FOR ANY INJURY OR PROPERTY DAMAGE ARISING FROM IMPROPER SERVICE OR SERVICE PROCEDURES YOU ASSUME RESPONSIBILITY FOR ANY PERSONAL INJURY OR PROPERTY DAMAGE WHICH MAY RESULT REQUIRE A LICENSE TO INSTALL OR SERVICE HEATING AND AIR CONDITIONING EQUIPMENT

. IF

YOU INSTALL OR PERFORM SERVICE ON THIS UNIT

. M

ANY JURISDICTIONS

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WARN ING

THE INFORMATION IN THESE INSTRUCTIONS IS NOT FOLLOWED EXACTLY, A FIRE OR EXPLOSION MAY RESULT CAUSING PROPERTY DAMAGE, PERSONAL INJURY OR LOSS OF LIFE

- D

O NOT STORE OR USE GASOLINE OR OTHER FLAMMABLE VAPORS

AND LIQUIDS IN THE VICINITY OF THIS OR ANY OTHER APPLIANCE

- WHAT T O D O IF YO U SMELL GA S:

* D

O NOT TRY TO LIGHT ANY APPLIANCE

* D

- I

NSTALLATION AND SERVICE MUST BE PERFORMED BY A QUALIFIED INSTALLER, SERVICE AGENCY OR THE GAS SUPPLIER

O NOT TOUCH ANY ELECTRICAL SWITCH; DO NOT USE

ANY PHONE IN YOUR BUILDING

MMEDIATELY CALL YOUR GAS SUPPLIER FROM A

* I

NEIGHBORS PHONE INSTRUCTIONS

F YOU CANNOT REACH YOUR GAS SUPPLIER, CALL THE

* I

FIRE DEPARTMENT

. F

OLLOW THE GAS SUPPLIERS

WARN ING

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

CARBON MONOXIDE POI SONING HAZARD

Special Warning for Installation of Furnace or Air Handling Units in Enclosed Areas such as Garages, Utility Rooms or Parking Areas

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.

TRANSPORTATION DAMAGE

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.

Keep this literature in a safe place for future reference.

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

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

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

B10259-216

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I. COMPONENT IDENTIFICATION

BLOWER COMPARTMENT BURNER COMPARTMENT

1 Gas Valve 2 Gas Line Entrance (Alternate) 3 Combustion Air Intake Connection / “Coupling” 4 Hot Surface Igniter 5 Burners 6 Rollout Limit 7 Flame Sensor 8 Flue Pipe Connection / “Coupling” 9 Flue Pipe (Internal) 10 Primary Limit 11 Pressure Switch 12 Gas Line Entrance 13 Rubber Elbow 14 Flue Pipe Connection (Alternate) 15 Induced Draft Blower

Upflow/Horizontal

16 Electrical Connection Inlets (Alternate) 17 Coil Front Cover Drain Port 18 Drain Line Penetrations 19 Blower Door Interlock Switch 20 24-Volt Thermostat Connections 21 Integrated Control Module

22 Transformer (40 VA) 23 Circulator Blower 24 Auxiliary Limit 25 Gas Manifold 26 Junction Box 27 Coil Front Cover 28 Drain Trap 29 Electrical Connection Inlets

(with fuse and diagnostic LED)

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II. SAFETY

Please adhere to the following warnings and cautions when installing, adjusting, altering, servicing, or operating the furnace.

WARN ING

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

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

. FOR

ADDITIONAL

WARN ING

HIGH VOLTAGE!

O AVOID PROPERTY DAMAGE, PERSONAL INJURY OR

DEATH DUE TO ELECTRICAL SHOCK, THE FURNACE MUST BE LOCATED TO PROTECT THE ELECTRICAL COMPONENTS FROM WATER

WARN ING

NOT UTILIZE THE HEATING UNIT WITHOUT REASONABLE ROUTINE INSPECTION, MAINTENANCE AND SUPERVISION BUILDING THAT IS OR WILL BE VACANT, CARE SHOULD BE TAKEN TO ROUTINELY INSPECT, MAINTAIN AND MONITOR THE UNIT EVENT THAT THE BUILDING MAY BE EXPOSED TO FREEZING TEMPERATURES AND WILL BE VACANT, DRAIN ALL WATER-BEARING PIPES, PROPERLY WINTERIZE THE BUILDING, AND TURN OFF ALL WATER SOURCES FREEZING TEMPERATURES AND IS VACANT, ANY HYDRONIC COIL UNITS SHOULD ALSO BE DRAINED AND AN ALTERNATIVE HEAT SOURCES UTILIZED

. IN

THE EVENT THAT THE BUILDING IS EXPOSED TO

. IF

THE UNIT IS IN A

. IN

THE

ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS

NOTE: Discharge static electricity accumulated in the body before

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

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

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

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

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

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

III. PRODUCT APPLICA TION

This furnace is primarily designed for residential home-heating applications. It is NOT designed or certified for use in mobile homes, trailers or recreational vehicles. This unit is NOT designed or certified for outdoor applications. The furnace must be installed indoors (i.e., attic space, crawl space, or garage area provided the garage area is enclosed with an operating door). This furnace can be used in the following non-industrial commercial applications:

Schools, Office buildings, Churches, Retail stores Nursing homes, Hotels/motels, Common or office areas

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

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

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

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

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

• It must be installed with two-pipe systems for combustion air, especially if VOC’s or other contaminants are present in the conditioned space.

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

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

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

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

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

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

• A room thermostat is used to control the furnace. Fixed jumpers that provide continuous heating CANNOT be used.

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

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

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

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

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

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NOTE: Do not connect the temporary duct directly to the furnace. The duct must be sized according to the instructions under Section V, Combustion and Ventilation

Air Requirements, Section 5.3.3.

• The furnace heat exchanger, components, duct system,

air filters and evaporator coils are thoroughly cleaned following final construction clean up.

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

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

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

• A T-handle gas cock must be used.

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

To ensure proper installation and operation, thoroughly read this manual for specifics pertaining to the installation and application of this product.

WARN ING

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

WARN ING

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

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 ANSI Z223.1, and/or CAN/CSA B149.1-05 Installation Codes, local plumbing or waste water codes, and other applicable codes. A copy of the National Fuel Gas Code ANSI Z223.1 can be obt ained from any of the following:

American National Standards Institute 1430 Broadway New York, NY 10018

National Fire Protection Association 1 Batterymarch Park Quincy, MA 02269

CSA International 8501 East Pleasant Valley Cleveland, OH 44131

A copy of the CAN/CSA B149.1-05 Installation Codes can also be obtained from:

CSA International 178 Rexdale Boulevard Etobicoke, Ontario, Canada M9W 1R3

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

IV . LOCATION REQUIREMENTS & CONSIDERA TIONS

GENERAL

WARNING

PREVENT POSSIBLE EQUIPMENT DAMAGE, PROPERTY DAMAGE PERSONAL INJURY OR DEATH, THE FOLLOWING BULLET POINTS MUST BE OBSERVED WHEN INSTALLING THE UNIT

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

tion and Ventilation Air Requirements.

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

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

• 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 Section IX, 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 Section X, 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 Section V,

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 Section VII, 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.

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

chlorinated waxes or cleaners chlorine-based swimming pool chemicals water softening chemicals deicing salts or chemicals carbon tetrachloride halogen type refrigerants cleaning solutions (such as perchloroethylene) printing inks paint removers varnishes hydrochloric acid

Page 8

cements and glues antistatic fabric softeners for clothes dryers and 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 Section V, Combustion and Ventilation Air Requirements for details.

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

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

• If the furnace is installed horizontally, the furnace access doors must be vertical so that the burners fire horizontally into the heat exchanger. Do not install the unit with the access doors on the “up/top” or “down/bottom” side of the furnace.

CLEARANCES AND ACCESSIBILITY

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 vent/flue connections are used additional clearance must be provided to accommodate these connections. Refer to Section IX, 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.

TOP

SIDE SIDE

BOTTOM

Upflow Horizontal

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

FURNACE SUSPENSION

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

PROVIDE 8" MINMUM CLEARANCE BETWEEN

CENTER ROD AND FURNACE CABINET

TO ALLOW FOR CIRCULATOR BLOWER REMOVAL

3/8" DIAMETER

THREADED ROD

(6 PLACES)

HOLD DOWN

NUTS

SUPPORT

NUTS

2"X2"X1/8" ANGLE IRON

(3 PLACES)

POSITION AS CLOSE AS POSSIBLE TO BLOWER DECK TO ALLOW FOR

CIRCULATOR BLOWER REMVOAL

ASSURE FURNACE IS LEVEL FROM

END TO END AND HAS A SLIGHT FORWARD TILT WITH THE FRONT

OF THE FURNACE 0"-3/4"

BELOW THE BACK OF THE FURNACE

TILT OUTWARD TO ALLOW FOR

DOOR AND CIRCULATOR BLOWER

REMOVAL

Suspended Furnace

EXISTING FURNACE REMOVAL

NOTE: When an existing furnace is removed from a venting system

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

The following vent testing procedure is reproduced from the American National Standard/National Standard of Canada for Gas-Fired Central Furnaces ANSI Z21.47·CSA-2.3 Section 1.23.1.

The following steps shall be followed with each appliance connected to the

venting system placed in operation, while any other appliances connected to the venting system are not in operation:

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

required by the National Fuel Gas Code, ANSI Z223.1 or the CSA B149.1-05 Installation Codes and these instructions. Determine that there is no blockage or restriction, leakage, corrosion and other deficiencies which could cause an unsafe condition;

c. In so far as practical, close all building doors and windows and all

doors between the space in which the appliance(s) connected to the venting system are located and other spaces of the building. Turn on clothes dryers and any appliance not connected to the venting system. Turn on any exhaust fans, such as range hoods and bathroom exhausts, so they shall operate at maximum speed. Do not operate a summer exhaust fan. Close fireplace dampers;

d. Follow the lighting instructions. Place the appliance being inspected

in operation. Adjust thermostat so appliance shall operate continuously;

e. Test for draft hood equipped spillage at the draft hood relief opening

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

f. After it has been determined that each appliance connected to the

venting system properly vents when tested as outlined above, return doors, windows, exhaust fans, fireplace dampers and any other gas burning appliance to their previous conditions of use;

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

common venting system must be corrected.

Corrections must be in accordance with the latest edition of the National Fuel Gas Code ANSI Z223.1 and/or CSA B149.1-05 Inst allation Codes.

Page 9

If resizing is required on any portion of the venting system, use the

appropriate table in Appendix G in the latest edition of the National Fuel Gas Code ANSI Z223.1 and/or CSA B149.1-05 Installation Codes.

THERMOSTAT LOCATION

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

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

cabinets.

• Hot or cold air from registers.

• Radiant heat from the sun.

• Light fixtures or other appliances.

• Radiant heat from a fireplace.

• Concealed hot or cold water pipes, or chimneys.

• Unconditioned areas behind the thermostat, such as an

outside wall.

DRAFTS OR DEAD SPOTS

-BEHIND DOORS

-IN CORNERS

-UNDER CABINETS

Thermostat Influences

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

V . COMBUSTION & VENTILA TION AIR REQUIREMENTS

WARN ING

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

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.

1. Headaches-Nausea-Dizziness, Flu-Like Symptoms.

2. Excessive humidity-heavily frosted windows or a moist “clammy” feeling in the home.

3. Smoke from a fireplace will not draw up the chimney.

4. Flue gases that will not draw up the appliance vent pipe.

. M

OST HOMES REQUIRE OUTSIDE

HOT

COLD

ENTILATION

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 ANSI Z223.1 (Section 5.3), or CSA B149.1-05 Installation Codes (Sections 7.2,

7.3, or 7.4), or applicable provisions of the local building codes for determining the combustion air requirements for the appliances. Most homes will require outside air be supplied to the furnace area by means of ventilation grilles or ducts connecting directly to the outdoors or spaces open to the outdoors such as attics or crawl spaces.

The following information on air for combustion and ventilation is reproduced from the National Fuel Gas Code ANSI Z223.1 Section 5.3.

5.3.1 General:

(a) The provisions of 5.3 apply to gas utilization equipment installed in

buildings and which require air for combustion, ventilation and dilution of flue gases from within the building. They do not apply to (1) direct vent equipment which is constructed and installed so that all air for combustion is obtained from the outside atmosphere and all flue gases are discharged to the outside atmosphere, or (2) enclosed furnaces which incorporate an integral total enclosure and use only outside air for combustion and dilution of flue gases.

(b) Equipment shall be installed in a location in which the facilities for

ventilation permit satisfactory combustion of gas, proper venting and the maintenance of ambient temperature at safe limits under normal conditions of use. Equipment shall be located so as not to interfere with proper circulation of air. When normal infiltration does not provide the necessary air, outside air shall be introduced.

vided as required for: cooling of equipment or material, controlling dew point, heating, drying, oxidation or dilution, safety exhaust, odor control, and air for compressors.

(d) In addition to air needed for combustion, air shall be supplied for

ventilation, including all air required for comfort and proper working conditions for personnel.

(e) While all forms of building construction cannot be covered in detail,

air for combustion, ventilation and dilution of flue gases for gas utilization equipment vented by natural draft normally may be obtained by application of one of the methods covered in 5.3.3 and

5.3.4.

(f) Air requirements for the operation of exhaust fans, kitchen ventila-

tion systems, clothes dryers, and fireplaces shall be considered in determining the adequacy of a space to provide combustion air requirements.

5.3.2 Equipment Located in Unconfined Spaces:

In unconfined spaces (see definition below) in buildings, infiltration may be adequate to provide air for combustion ventilation and dilution of flue gases. However, in buildings of tight construction (for example, weather stripping, heavily insulated, caulked, vapor barrier, etc.), additional air may need to be provided using the methods described in 5.3.3b or 5.3.4.

Space, Unconfined.

For purposes of this Code, a space whose volume is not less than 50 cubic feet per 1,000 BTU per hour of the aggregate input rating of all appliances installed in that space. Rooms communicating directly with the space in which the appliances are installed through openings not furnished with doors, are considered a part of the unconfined space.

5.3.3 Equipment Located in Confined Spaces:

(a) All Air from Inside the Building: The confined space shall be pro-

vided with two permanent openings communicating directly with an additional room(s) of sufficient volume so that the combined volume of all spaces meets the criteria for an unconfined space. The total input of all gas utilization equipment installed in the combined

Page 10

space shall be considered in making this determination. Each open-

ing shall have a minimum free area of 1 square inch per 1,000 BTU per hour of the total input rating of all gas utilization equipment in the confined space, but not less than 100 square inches. One opening shall be within 12 inches of the top and one within 12 inches of the bottom of the enclosure.

NOTE: Each opening must have a free area of not less than one square inch per 1 000 BT U of the total input rating of all equ i p ment in the enclosure, but not less than 100 square inches.

Chimney or Gas Vent

Opening

Chimney o r Gas Vent

Ventilation louvers (each end of attic)

NOTE: Th e inlet and ou tlet air openings must each have a free area of not less than one square inch per 4000 BTU of the total input rating of all equipment in the enclosure.

Outlet A i r

Furnace

Water Heater

Inlet air duct [ends 1 ft (300 mm) above floor]

Water Heater

Furnace

Opening

Equipment Located in Confined Spaces; All Air from Inside

Building. See 5.3.3-a.

(b) All Air from Outdoors: The confined space shall be provided with

two permanent openings, one commencing within 12 inches of the top and one commencing within 12 inches of the bottom of the enclosure. The openings shall communicate directly, or by ducts, with the outdoors or spaces (crawl or attic) that freely communicate with the outdoors.

1. When directly communicating with the outdoors, each opening shall have a minimum free area of 1 square inch per 4,000 BTU per hour of total input rating of all equipment in the enclosure.

Chimney or Gas Vent

Ventil ation louver s (each end of attic)

NOTE: Th e inlet and outlet ai r openings must each have a free area of not less than one square inch per 4000 BTU of the total inpu t rating of all equipmen t in the enclosure.

Outlet Air

Water Heater

lternate

air inlet

Furnace

Ventilation louvers for unheated crawl space

Inlet Air

Equipment Located in Confined Spaces; All Air from Outdoors—

Inlet Air from Ventilated Crawl Space and Outlet Air to Ventilated

Attic. See 5.3.3-b

2. When communicating with the outdoors through vertical ducts, each opening shall have a minimum free area of 1 square inch per 4,000 BTU per hour of total input rating of all equipment in the enclosure.

Equipment Located in Confined Spaces; All Air from Outdoors

Through Ventilated Attic. See 5.3.3-b.

3. When communicating with the outdoors through horizontal ducts, each opening shall have a minimum free area of 1 square inch per 2,000 BTU per hour of total input rating of all equipment in the enclosure.

Chimney or Gas Vent

NOTE: The air duct openings must have a free area of not less than one square inch per 2000 BTU of the total input rating of all equipment in the

Outlet air duct

Water Heater

Furnace

Inlet air duct

*If the appliance room is located against an outside wall and the air openings communicate directly with the outdoors, each opening shall have a free area of not less than one square inch per 4,000 BTU per hour of the total input rating of all appliances in the enclosure.

enclosure*.

Equipment Located in Confined Spaces; All Air from Outdoors.

See 5.3.3-b.

4. When ducts are used, they shall be of the same cross-sectional area as the free area of the openings to which they connect. The minimum dimension of rectangular air ducts shall not be less than 3 inches.

NOTE: The single opening must have a free area of not less than one square inch per 3000 BTU of the total input rating of al l e quipment in the enclosure, but not less than the sum of the areas of all vent connectors in the confined space.

Chimney or Gas Vent

Water

Furnace

Heater

Alternate Opening Location

Opening

Equipment Located in Confined Spaces; All Air from Outdoors -

Single Air Opening. See 5.3.3-b.

Page 11

5. When directly communicating with the outdoors, the single opening shall have a minimum free area of 1 square inch per 3,000 BTU per hour of total input rating of all equipment in the enclosure.

5.3.4 Specially Engineered Installations:

The requirements of 5.3.3 shall not necessarily govern when special engineering, approved by the authority having jurisdiction, provides an adequate supply of air for combustion, ventilation, and dilution of flue gases.

5.3.5 Louvers and Grilles:

In calculating free area in 5.3.3, consideration shall be given to the blocking effect of louvers, grilles or screens protecting openings. Screens used shall not be smaller than 1/4 inch mesh. If the area through a design of louver or grille is known, it should be used in calculating the size of opening required to provide the free area specified. If the design and free area is not known, it may be assumed that wood louvers will have 20-25 percent free area and metal louvers and grilles will have 60-75 percent free area. Louvers and grilles shall be fixed in the open position or interlocked with the equipment so that they are opened automatically during equipment operation.

5.3.6 Special Conditions Created by Mechanical Exhausting or Fireplaces:

Operation of exhaust fans, ventilation systems, clothes dryers, or fireplaces may create conditions requiring special attention to avoid unsatisfactory operation of installed gas utilization equipment. Air from Inside Building. See 5.3.3-a.

VI. INSTALLA TION POSITIONS

NOTE: This furnace is shipped from the factory as a Dedicated Upflow. A “Blocked Drain Kit” (0270K00012) is available and MUST BE USED if the furnace is installed Horizontal Left or Horizontal

Right. 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. 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.

VII. HORIZONTAL APPLICA TIONS & CONSIDERA TIONS

FURNACE MUST BE LEVEL

ALTERNATE VENT/FLUE LOCATION

GAS LINE WITH DRIP LEG (3" MINIMUM)

DRAIN PAN

FURNACE MUST BE SUPPORTED AT BOTH ENDS AND MIDDLE

FROM END TO END

4 3/4" MINIMUM DRAIN TRAP CLEARANCE

DRAIN LINE WITH 1/4" PER FOOT DOWNWARD SLOPE

36" MINIMUM SERVICE CLEARANCE REQUIRED

FURNACE MUST BE LEVEL OR SLIGHTLY TILTED FORWARD WITH THE DOORS 0" - 3/4" BELOW THE BACK PANEL

Horizontal Furnace

DRAIN TRAP AND LINES

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

LEVELING

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

ALTERNATE VENT/FLUE CONNECTION

In horizontal installations provisions for alternate flue piping are available for upflow furnaces with left discharge. This configuration allows the flue piping to be run vertically through 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 Section IX, Vent/Flue Pipe and Combustion Air Pipe for details concerning the conversion to the alternate vent/flue connections.

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

NOTE: This furnace is shipped from the factory as a Dedicated Upflow. A “Blocked Drain Kit” is available and MUST BE USED if the furnace is installed Horizontal Left or Horizontal Right. Check the Serial/ Rating Plate on the furnace for the Kit P/N.

GENERAL

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

Page 12

AIR

DISCHA RGE

Side

Return

Duct

Connection

UPFLOW UPRIGHT

ALTERNATE FL UE PIPE LOCATIONS

AIR

DISCHA RGE

UPFLOW HORIZONTAL

LEFT AIR DISCHARGE

Bottom Return

Duct

Connection

UPFLOW HORIZONTAL

RIGHT AIR DISCHARGE

Bottom

Return

Duct

ALTERNATE FL UE PIPE LOCATIONS

Side

Return

Duct

Connection

Bottom Return

Duct

Connection

DISCHA RGE

AIR

Recommended Installation Positions

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

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

ALTERNATE ELECTRICAL AND GAS LINE CONNECTIONS

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

DRAIN PAN

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

FREEZE PROTECTION

Refer to Section VII, Horizontal Applications and Conditions - Drain Trap and Lines.

FURNACE SUSPENSION

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. Refer to

Section IV, Location Requirements and Considerations - Furnace Suspension for further details.

VIII. PROPANE GAS /HIGH AL TITUDE INST ALLATIONS

WARN ING

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 A QUALIFIED INSTALLER OR SERVICE AGENCY

. ALL

CONVERSIONS MUST BE PERFORMED BY

This furnace is shipped from the factory configured for natural gas at standard altitude. Propane gas installations require an orifice

. THE

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 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 your distributor for required kit(s).

Altitude Gas Kit Orifice

Manifold

Pressure

Natural None #43 3.5" w .c.

0-7000

Propa ne

Supports Wh ite-Rodgers 1-s tag e valve only

Supports bo th Honey w ell and White-Rodgers 1- stage valv es

LPT-00* LPT-03*

#55 10.0" w.c.

NOTE: In Canada, gas fur naces are certifie d to 4500 feet.

Pressure

Switch

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.

IX. VENT/FLUE PIPE & COMBUSTION AIR PIPE

GENERAL

WARN ING

AILURE TO FOLLOW THESE INSTRUCTIONS CAN RESULT IN BODILY INJURY OR DEATH INSTRUCTIONS GIVEN IN THIS SECTION

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 FLUE SYSTEM CAN RESULT IN SERIOUS PERSONAL INJURY OR DEATH DUE TO EXPOSURE TO FLUE PRODUCTS, INCLUDING CARBON MONOXIDE

A condensing gas furnace achieves its high level of efficiency by extracting almost all of the heat from the products of combustion and cooling them to the point where condensation takes place. Because of the relatively low flue gas temperature and water condensation requirements, PVC pipe is used as venting material. This furnace must not be connected to T ype 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

. C

AREFULLY READ AND FOLLOW ALL

WARN ING

. L

EAKS IN THE

None

Page 13

responsibility of the installer to ensure that all piping and connections possess adequate structural integrity and support to prevent flue pipe separation, shifting, or sagging during furnace operation.

DUAL CERTIFICATION: NON-DIRECT/DIRECT VENT

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

MATERIALS AND JOINING METHODS

WARNING

O AVOID BODILY INJURY, FIRE OR EXPLOSION, SOLVENT CEMENTS MUST BE

KEPT AWAY FROM ALL IGNITION SOURCES (I.E., SPARKS, OPEN FLAMES, AND EXCESSIVE HEAT) AS THEY ARE COMBUSTIBLE LIQUIDS. CEMENT VAPORS OR CONTACT WITH SKIN AND/OR EYES.

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. 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-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 joint s 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 D331 1 and, if used in Canada, must be CSA listed. Carefully follow the pipe manufacturers’ instructions for cutting, cleaning, and solvent cementing PVC and/or ABS. All 90° elbows must be medium radius (1/4 bend DWV) or long radius (Long sweep 1/4 bend DWV) types conforming to ASTM D3311. A medium radius (1/4 bend DWV) elbow measures 3 1/ 16” minimum from the plane of one opening to the centerline of the other opening for 2” diameter pipe, and 4 9/16” minimum for 3” pipe.

VOID BREATHING

PROPER VENT/FLUE AND COMBUSTION AIR PIPING PRACTICES

Adhere to these instructions to ensure safe and proper furnace performance. The length, diameter, and number of elbows of the vent/flue pipe and combustion air pipe (when applicable) affects the performance of the furnace and must be carefully sized. All piping must be installed in accordance with local codes and these instructions. Piping must be adequately secured and supported to prohibit sagging, joint separation, and/or detachment from the furnace. Horizontal runs of vent/flue piping must be supported every three to five feet and must maintain a 1/4 inch per foot downward slope, back towards the furnace, to properly return condensate to the furnace’s drain system. Allowances should be made for minor expansion and contraction due to temperature variations. For this reason, particular care must be taken to secure piping when a long run is followed by a short offset of less than 40 inches. Precautions should be taken to prevent condensate from freezing inside the vent/flue pipe and/or at the vent/flue pipe termination. It is our recommendation that all vent/flue piping exposed to temperatures below 35°F for extended periods of time should 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) should be insulated with 1/2” thick closed cell foam. Inspect piping for leaks prior to installing insulation.

TERMINATION LOCATIONS

NOTES: Refer to Section IV, Location Requirements and

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

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

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

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

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

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

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

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

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

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

Non-Direct Vent

Direct Vent

Vent/Flue Terminations

Non-Direct Vent

Vent/Flue Termination

No Terminations Above Walkway

Grade or Highest

Anticipated Snow Level

3' min.

Forced Air

Inlet

<10'

12"

12" min.

Direct Vent

Vent/Flue Termination

Vent Termination Clearances

4' min.

min.

12"

min.

Non-Direct Vent

Vent/Flue Termination

Page 14

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

CANADIAN VENTING REQUIREMENTS

In Canada, venting must conform to the requirements of the current CAN/CSA-B149.1-05 Installation Code. Use only CSA-listed, ULC-S636 compliant two-three-inch diameter PVC or ABS pipe, solvent cement, and fittings throughout. The certified piping should be clearly marked with the ULC Std “S636” on the pipe and fittings. Carefully follow the pipe manufacturers’ instructions for cutting, cleaning, and solvent cementing PVC and/or ABS. The vent can be run through an existing unused chimney provided the space between the vent pipe and the chimney is insulated and closed with a weather-tight, corrosion-resistant flashing.

STANDARD FURNACE C ONNECTIONS

It is the responsibility of the installer to ensure that the piping connections to the furnace are secure, airtight, and adequately supported. As shipped, attachment “couplings” for vent/flue and combustion air intake pipe connections are provided on the furnace’s top cover (upflow). To use the standard connections, field supplied vent/flue pipe and combustion air intake pipe (when applicable) should be secured directly to the furnace at these locations.

VENT/FLUE PIPE

Vent/flue pipe can be secured to the vent/flue coupling using the rubber coupling and worm gear hose clamps provided with this furnace (see “Standard Connections” figure). The rubber coupling allows separation of the vent/flue pipe from the furnace during servicing. Combustion Air and Vent piping should be routed in a manner to avoid contact with refrigerant lines, metering devices, condensate drain lines, etc. If necessary, clearances may be increased by utilizing two 45 deg. Long-Sweep Elbows and creating an “S” joint to provide additional space at connection locations. 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.

COMBUSTION AIR PIPE

DIRECT VENT INSTALLATIONS

On upflow units secure the combustion air intake pipe directly to the air intake coupling. NOTE: Because of probable material conflicts, do not use other commercially available “no hub connectors”.

NON-DIRECT VENT INSTALLATIONS

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

(DIRECT VE NT O N LY)

90 PVC

ELBOW

(NON-DIRECT VENT)

COMBUSTION

AIR PIPE

RUBBER

COUPLING

WITH WORM

GEAR CLAM PS

UPFLOW

VENT/FLUE

PIPE

(NON-DIRECT VENT)

STANDARD CONNECTIONS

ALTERNATE FURNACE CONNECTIONS

If the standard locations are undesirable for a specific installation, alternate side panel locations are available for vent/flue pipe connections. These locations may be of particular benefit to upright upflow installations requiring additional access to an A coil or to horizontal installations desiring vent/flue piping run vertically from the side of the cabinet. NOTE: Standard and alternate locations can be combined (i.e., an installation may use the standard combustion air intake location but use the alternate vent/flue location), if needed.

V E N

45 DEGREE

LONG-SWEEP

ELBOWS

Increased Clearance Configuration

NOTE: Do not use other commercially available “no hub connec-

tors” due to possible material conflicts. The vent/flue pipe can also be secured using a PVC or ABS elbow or coupling using the appropriate glue (see Section IX, Materials and Joining Methods.

WARN ING

DGES OF SHEET METAL HOLES MAY BE SHARP

PRECAUTION WHEN REMOVING HOLE PLUGS

. USE

GLOVES AS A

ALTERNATE VENT/FLUE LOCATION

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

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

2. Loosen the worm gear hose clamps on the rubber elbow and detach it from both the induced draft blower and the vent/flue pipe.

3. Remove the vent/flue pipe from the furnace.

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

Page 15

FLANGE

(

)2345

3.75"

CUT HERE

Vent/Flue Pipe Cuts

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

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

WARN ING

THE

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

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

8. For horizontal installations, externally secure the fieldsupplied vent/flue pipe directly to the vent/flue coupling using a PVC or ABS coupling or elbow.

UPFLOW

SECURE TO

ID BLOWER WITH

RUBBER COUPLING

AND HOSE

CLAMPS

REMOVE

PIPE

REMOVE

4 SCREWS

REMOVE

AND RELOCATE

DETACH RUBBER

ELBOW FROM

ID BLOWER AND

VENT/FLUE

PIPE

SECURE TO

CABINET WITH

SCREWS

. W

HEN

NON-DIRECT VENT (SINGLE PIPE) PIPING

Non-direct vent installations require only a vent/flue pipe. The vent pipe can be run horizontally with an exit through the side of the building or run vertically with an exit through the roof of the building. The vent can also be run through an existing unused chimney; however, it must extend a minimum of 12 inches above the top of the chimney. The space between the vent pipe and the chimney must be closed with a weather-tight, corrosion-resistant flashing. For details concerning connection of the vent/flue pipe to the furnace, refer to Section IX, Vent/Flue Pipe and Combustion Air -

Standard Furnace Connections or Alternate Furnace Connections for specific details. Refer to the following Non-Direct Vent (Single Pipe) Piping - Vent/Flue Pipe Terminations for specific details on

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

VENT/FLUE PIPE LENGTHS AND DIAMETERS

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

Non-Dir ect Ve nt (Singl e Pipe)

Maximum Allowable Length of Vent/Flue Pipe (ft)

Models

(kBTU_Tons)

Pipe

Size

in.

(4)

Number of Elbows

04 5_3 2 or 2 1/ 2 68 65 62 5 9 56 53 5 0 070_3

070_4

090_4

090_5

2 or 2 1/236333027242118

3 68656259565350

2 or 2 1/255524946434037

3 68656259565350

2 or 2 1/237343128252219

3 68656259565350

2 or 2 1/239363330272421

3 68656259565350

115_5 3 68656259565350

1) One 90° elbow should be secured to the combustion air intake connection.

2) Minimum requirement for each vent pipe is five (5) feet in length and one elbow/tee.

3) Tee used in the vent/flue termination must be included when determining the number of elbows in the piping system.

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

5) Increased Clearance Configurations using (2) 45 deg. Long Sweep elbows should be considered equivalent to one 90 deg. elbow.

VENT/FLUE PIPE TERMINATIONS

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 Section IX, Vent/Flue Pipe and Combustion Air Pipe - Termination Locations for details concerning location

(3) (5)

(1) (2)

UPFLOW/HORIZONTAL

Alternate Vent/Flue Location

Page 16

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 Section IX, Vent/Flue Pipe and Combus- tion Air Pipe - Termination Locations for details concerning location restrictions. A 2 3/8” diameter wall penetration is required for 2” diameter pipe. A 3” diameter hole is required for a 2 1/2” pipe and a 3 1/2” diameter hole is required for 3” diameter pipe. 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. In a basement installation, the vent/flue pipe can be run between joist spaces. If the vent pipe must go below a joist and then up into the last joist space to penetrate the header, two 45° elbows should be used to reach the header rather than two 90° elbows.

TEE

WALL

INSIDE

ELBOW OR COUPLING

OUTSIDE

COUPLING

MIN.

FROM WALL

12"

90°ELBOW

12"

TO GROUND OR

HIGHEST ANTICIPATED

SNOW LEVEL

Horizontal Termination (Single Pipe)

12" MIN.

VENT/FLUE T E E

90° ELBOW TURNED

DOWN

TEE

TURNED

DOWN

12 " Min To

Roof Or

Highest Anticipated

Snow Level

Vertical Termination (Single Pipe)

12 " Min To

Roof Or

Highest Anticipate d

Snow Level

Vertical Termination (Single Pipe)

90º

MEDIUM RADIUS

ELBOWS

12" MIN.

TO ROOF OR

HIGHEST ANTICIPATED SNOW LEVEL

Horizontal Termination (Single Pipe)

Above Highest Anticipated Snow Level

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 Section IX, Vent/Flue and Combustion Air Pipe - Termi- nation Locations or Concentric Vent Termination for specific details on termination construction. For details concerning connection of pipes to the furnace, refer to the Section IX, Vent/Flue Pipe

and Combustion Pipe - Standard Furnace Connections or Alternate Furnace Connections.

VENT/FLUE AND COMBUSTION AIR PIPE LENGTHS AND 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. Use 1/2” thick closed cell foam insulation such as Armaflex or Insultube where required.

Alternate Vertical Termination (Single Pipe)

Page 17

Direct Vent (Dual Pipe)

Maxi m um All owable Len gth of Vent/F l ue & Combustion

Air Intake Pipe (ft)

Unit Input

(Btu)

Vent/Flue /A ir In take

Termination

Pipe

Size

Number of El bows

(4)

(1)(2) (3)(5)

(in.) 2345678

045_3

Standard 2 or 2 1/2 68 65 62 59 56 53 50 Alternate 2 or 2 1/25552 4946434037 Standard 2 or 2 1/2 36 33 30 27 24 21 18

070_3

Alt ernate 2 or 2 1/2 23 20 17 14 11 8 5 Standard 3 68 65 62 59 56 53 50 Alternate 3 55 52 49 46 43 40 37 Standard 2 or 2 1/2 55 52 49 46 43 40 37

070_4

Alternate 2 or 2 1/24239 3633302724 Standard 3 68 65 62 59 56 53 50 Alternate 3 55 52 49 46 43 40 37 Standard 2 or 2 1/2 37 34 31 28 25 22 19

090_4

Alt ernate 2 or 2 1/2 24 21 18 15 12 9 6 Standard 3 68 65 62 59 56 53 50 Alternate 3 55 52 49 46 43 40 37 Standard 2 or 2 1/2 39 36 33 30 27 24 21

090_5

Alternate 2 or 2 1/22623 20171411 8 Standard 3 68 65 62 59 56 53 50 Alternate 3 55 52 49 46 43 40 37

115_5

Standard 3 68 65 62 59 56 53 50 Alternate 3 55 52 49 46 43 40 37

1) One 90° elbow should be secured to the combustion air intake connection.

2) Minimum requirement for each vent pipe is five (5) feet in length and one elbow/tee.

3) Tee used in the vent/flue termination must be included when determining the number of elbows in the piping system.

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

5) Increased Clearance Configurations using (2) 45 deg. Long Sweep elbows should be considered equivalent to one 90 deg. elbow.

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 Section IX, Vent/Flue Pipe and Combustion Pipe - Termination 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/FLUE

12" MIN.

COMBUSTION

AIR INTA KE

Horizontal terminations should be as shown in the following figure. Refer to Section IX, Vent/Flue Pipe and Combustion Pipe - Termination Location for location restrictions. A 2 3/8” diameter wall penetration is required for 2” diameter pipe. A 3” diameter hole is required for a 2 1/2” pipe and a 3 1/2” diameter hole is required for 3” diameter pipe. 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 pipe connecting the two couplings. The pipe length 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.

12" MIN

12" MIN. ABOVE

HIGHEST ANTICIP ATED

SNOW LE VEL

12" MIN. ABOVE

HIGHES T AN TICIPA TED

SNOW LE VEL

3" MIN

24" MAX

90º

MEDIUM RADIUS

ELBOW

3" MIN

24" MAX

Standard Horizontal Terminations (Dual Pipe)

90° MEDIUM RADIUS ELBOW

24" MAX

3" MIN

24" MAX

AIR INTAKE

12" M IN. ABOVE

HIGHEST ANTICIPATED

SNOW LEVEL

Alternate Horizontal Vent Termination (Dual Pipe)

12" MIN

ENT/FLUE

TEE

12" MIN. ABOVE

HIGHEST ANTICIPATED

SNOW LEVE L

SUPPORT

STRAPS

COMBUSTION AIR INTAKE.

90° MEDIUM RADIUS ELBOWS

3" MIN.

24" MAX.

12" MIN. ABOVE

HIGHEST ANTICIPATED

SNOW LEVEL

12" MIN.

TO ROOF OR

HIGHEST ANTICIPATED SNOW LEVEL

Standard Horizontal Terminations Above Anticipated Snow

Level (Dual Pipe)

Vertical Terminations (Dual Pipe)

Page 18

Vent

12" Min.

24" Max.

12" Min. Above Highest Anticipated Snow Level

3" Min.

Air Intake

Alternate Vent Termination Above Anticipated Snow Level

(Dual Pipe)

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

VENT/INTAKE TERMINATIONS FOR INSTALLATION OF 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.

ents

3" Min.

24" Max.

12" MIN. ABOVE

HIGHEST ANTICIPATED

3" Min.

SNOW LE VEL

3" Min.

Air Intakes

90° Medium Radius Elbows

24" Max.

Horizontal Venting Of Multiple Units

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. This kit is NOT intended for use with single pipe (indirect vent) installations.

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

X. CONDENSATE DRAIN LINES & DRAIN TRAP

GENERAL

A condensing gas furnace achieves its high level of efficiency by extracting almost all of the heat from the products of combustion and cooling them to the point where condensation takes place.

The condensate which is generated must be piped to an appropriate drain location. In upright installations, the furnace’s drain hoses may exit either the right or left side of the furnace. NOTE: If the alternate vent/flue outlet is utilized in an upright installation, the drain trap and drain connections must be located on the same side as the alternate vent/flue outlet. In horizontal installations, the drain hoses will exit through the bottom (down side) of the unit with the drain trap suspended beneath the furnace. The field-supplied drain system must be in accordance with all local codes and the instructions in the following sections.

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

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

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

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

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

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

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

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

UPRIGHT INSTALLATIONS

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

NOTE: Refer to Section X, Condensate Drain Lines and Drain Trap

- Alternate Vent/Flue Hose Connections for upright installations

using an alternate vent/flue outlet.

STANDARD RIGHT OR LEFT SIDE DRAIN HOSE CONNECTIONS

Upright installations using the standard vent/flue outlet require drain hoses to be connected as follows. The following quantity of hoses, tubes, and hose clamps are provided with the unit.

HOSE A QTY: 1

HOSE B

DRAIN TRAP QTY: 1

GREEN HOSE CLAMPS QTY : 3

RED HOSE CLAMP QTY: 1

TUBE 1 QTY: 1

SILVER HOSE CLAMP QTY : 1

Hose and Tube Identification

1. Remove the rubber plug/cap from the front cover drain port (right or left side, depending on the intended drain trap mounting).

QTY : 1

TUBE 2 QTY : 2

Page 19

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

NOTE: For left side drainage, grommets will have to be relocated to left side panel.

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

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

5. Right side drains Cut 17 3/4 inches from the long end (end opposite the

bend) of Hose B. Save the part with the bend and discard the 17 3/4 inch piece that was cut. Secure the remaining hose to Tube 1 with a green hose clamp. Route the other end of Hose B to front right side panel grommet hole.

Left side drains Cut “X” inches from the long end of Hose B and discard.

Refer to table for appropriate length to cut. Secure remaining hose to Tube 1 with a green hose clamp. Route other end of Hose B to front left side panel grommet hole.

Cabinet Width

(inches)

17 1/2

24 1/2 None

Models

(kBTU_Tons)

045_30 070_30 070_40 090_40 090_50 115_50

RIGHT SIDE

PANEL

RUBBER

ELBOW

RUBBER ELBOW

DRAIN P ORT

"X" Length to Cut From Long

End of Hose B

7 inches

3 1/2 inches

FRONT CO VE R

DRAIN P ORT

Upright “Standard” Connections - Right Side

LEFT

SIDE PANEL

FRONT COV ER

DRAIN PORT

RED HOSE

CLAMP

HOSE A

SIDE PANEL

DRAIN

HOLES

TUBE(S) 2

DRAIN

TRAP

RED HOSE

CLAMP

HOSE

GREEN

HOSE

CLAMPS

(3 PLACES)

SILVER HOSE CLAMP

TUBE 1

HOSE

SIDE PANE L

GROMMET

HOLES

TUBE(S) 2

DRAIN TRAP

RUBBER

ELBOW

DRAIN PORT

SILVER HOSE

TUBE 1

GREEN HOSE

CLAMPS

(3 PLACES)

HOSE B

RUBBER

ELBOW

CLAMP

Upright “Standard” Connections - Left Side

Page 20

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

For details concerning mounting of the drain trap, refer to Section

X, Condensate Drain Lines and Drain Trap - Upright Drain Trap Mounting.

ALTERNATE VENT/FLUE DRAIN HOSE CONNECTIONS

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

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

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

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

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

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

6. Cut 17 7/8 inches from the long end of Hose B and discard.

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

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

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

For details concerning mounting of the drain trap, refer to the following section.

UPRIGHT DRAIN TRAP MOUNTING (LEFT OR RIGHT SIDE PANEL)

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

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

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

Upright “Alternate” Connections - Right Side Only

Page 21

HORIZONTAL INSTALLATIONS

NOTE: This furnace is shipped from the factory as a Dedicated

Upflow. A “Blocked Drain Kit” is available and

MUST BE USED if the furnace is installed Horizontal Left or Horizontal Right. Check the Serial/ Rating Plate on the furnace for the Kit P/N.

RIGHT SIDE DOWN

WARN ING

BLOCKED DRAIN KIT IS REQUIRED FOR HORIZONTAL INSTALLATIONS WITH THE RIGHT SIDE OR LEFT SIDE DOWN PROTECTS AGAINST A BLOCKED CONDENSATE DRAIN PROPERLY INSTALL THE KIT COULD LEAD TO BODILY INJURY OR DEATH DUE TO CARBON MONOXIDE EXPOSURE

RED HOSE

HOSE A

HOSE B

SIDE PANEL

GROMMET

HOLES

. THE

. F

AILURE TO

FRONT COVER DRAIN PO RT

CLAMP

KIT

NOTE: This furnace is shipped from the factory as a Dedicated

Upflow. A “Blocked Drain Kit” is available and

MUST BE USED if the furnace is installed Horizontal Left or Horizontal Right. Check the Serial/ Rating Plate on the furnace for the Kit P/N.

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

1. Remove the rubber plug/cap from the coil front cover drain port.

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

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

FRONT COVER

PRESSURE

TAP

RUBBER

ELBOW

TUBES 2

RUBBER ELBOW

SILVER HOSE

DRAIN TRAP

GREEN

HOSE

CLAMP

TUBE 1

(3 PLACES)

Horizontal Connections - Right Side Down

DRAFT BLOWER

FRONT COVER

PRESSURE

TAP

LEFT SIDE

PANEL

FRONT COVER

DRAIN PORT

RED HOSE CLAMP

SIDE PANEL

GROMMET

HOLES

RIGHT

SIDE

PANEL

DRAIN PORT

CLAMP

INDUCED

DRAIN PORT

HOSE B

HOSE A

GREEN HOSE

CLAMPS

(3 PLACES)

TUBE(S) 2

DRAIN TRAP

Horizontal Connections - Left Side Down

Page 22

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

5. Cut 17 3/4 inches from the long end (end opposite the bend) of Hose B. Save the part with the bend and discard the 17 3/4 inch piece that was cut.

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

7. Cut 5 1/2 inches straight length from the long end (end with taper) of each Tube 2. Save the 5 1/2” long pieces and discard the pieces with the bends.

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

9. A “Blocked Drain Kit” MUST be installed for right side down installations. The kit includes a front cover pressure switch that must be used to protect against a blocked drain condition. Install the front cover pressure switch per the instructions included with the “Blocked Drain Kit”. Failure to install the “Blocked Drain Kit” will void the warranty and could lead to bodily injury or death.

For details concerning mounting of the drain trap, refer to Section

X, Condensate Drain Lines and Drain Trap - Horizontal Drain Trap Mounting (Left or Right Side Panel).

LEFT SIDE DOWN

WARN ING

. THE

KIT

. F

AILURE TO

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

7. A “Blocked Drain Kit” MUST be installed for left side down installations. The kit includes a front cover pressure switch that must be used to protect against a blocked drain condition. Install the front cover pressure switch per the instructions included with the “Blocked Drain Kit”. Failure to install the “Blocked Drain Kit” will void the warranty and could lead to bodily injury or death.

For details concerning mounting of the drain trap, refer to Section

X, Condensate Drain Lines and Drain Trap - Horizontal Drain Trap Mounting (Left or Right Side Panel).

HORIZONTAL DRAIN TRAP MOUNTING (LEFT OR RIGHT SIDE PANEL)

NOTE: This furnace is shipped from the factory as a Dedicated Upflow . A “Blocked Drain Kit” is available and MUST BE USED if the furnace is installed Horizontal Left or Horizontal Right. Check the Serial/ Rating Plate on the furnace for the Kit P/N.

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

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

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

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

XI. ELECTRICAL CONNECTIONS

WARN ING

NOTE: This furnace is shipped from the factory as a Dedicated

Upflow. A “Blocked Drain Kit” is available and MUST BE USED if the furnace is installed Horizontal Left or Horizontal Right. Check the Serial/ Rating Plate on the furnace for the Kit P/N.

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

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

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

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

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

5. Cut 5 1/2 inches straight length from the long end (end with taper) of each Tube 2. Save the 5 1/2” long pieces and discard the pieces with the bends.

HIGH VOLTAGE! T

O AVOID THE RISK OF ELECTRICAL SHOCK, WIRING TO

THE UNIT MUST BE POLARIZED AND GROUNDED

WARN ING

HIGH VOLTAGE!

O AVOID PERSONAL INJURY OR DEATH DUE TO

ELECTRICAL SHOCK, DISCONNECT ELECTRICAL POWER BEFORE SERVICING OR CHANGING ANY ELECTRICAL WIRING

CAUTION

ABEL ALL WIRES PRIOR TO DISCONNECTION WHEN SERVICING CONTROLS DANGEROUS OPERATION SERVICING

. W

IRING ERRORS CAN CAUSE IMPROPER AND

. V

ERIFY PROPER OPERATION AFTER

WIRING HARNESS

The wiring harness is an integral part of this furnace. Field alteration to comply with electrical codes should not be required. Wires are color-coded for identification purposes. Refer to the wiring diagram for wire routings. If any of the original wire as supplied

Page 23

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 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 N.E.C. Class 1, and must comply with all applicable codes. The furnace must be electrically grounded in accordance with local codes or, in their absence, with the latest edition of The National Electric Code, ANSI NFPA 70 and/or The Canadian Electric Code CSA C22.1. Use a separate fused branch electrical circuit containing properly sized wire, and fuse or circuit breaker. The fuse or circuit breaker must be sized in accordance with the maximum overcurrent protection specified on the unit rating plate. An electrical disconnect must be provided at the furnace location.

NOTE: Line polarity must be observed when making field connections.

WARN ING

UPRIGHT UPFLOW INSTALLATIONS, THE DRAIN TRAP MUST BE MOUNTED ON THE OPPOSITE SIDE OF THE UNIT FROM THE JUNCTION BOX

. T

HIS WILL REDUCE THE RISK OF WATER REACHING THE

JUNCTION BOX IN THE EVENT OF A BLOCKED DRAIN CONDITION

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 a UL approved bushing such as Heyco Liquid Tight or by applying a UL approved non-reactive sealant to bushing. Line polarity must be observed when making field connections. Line voltage connections can be made through either the right or left side panel. The furnace is shipped configured for a left side electrical connection with the junction box located inside the burner compartment. To make electrical connections through the opposite side of the furnace, the junction box must be relocated to the other side of the burner compartment prior to making electrical connections. To relocate the junction box, follow the steps shown below.

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

WARN ING

DGES OF SHEET METAL HOLES MAY BE SHARP

PRECAUTION WHEN REMOVING HOLE PLUGS

1. Remove the burner compartment door.

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

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

. USE

GLOVES AS A

STANDARD

JUNCTION BOX

LOCATION

***

ALTERNATE

JUNCTION BOX

LOCATION

Junction Box Relocation

WARNING

HIGH VOLTAGE! T

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

ATIONAL ELECTRIC CODE

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

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

2. Resistance should measure 10 ohms or less.

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

24 VOLT THERMOSTAT WIRING

NOTE: Wire routing must not interfere with circulator blower

operation, filter removal, or routine maintenance. Low voltage connections can be made through either the right or

left side panel. Thermostat wiring entrance holes are located adjacent to the junction box locations in the blower compartment. Wire routing must not to interfere with circulator blower operation, filter removal, or routine maintenance. Refer to the following figure for thermostat connections to the integrated control module terminal strip.

W R

HEATING

ROOM

THERMOSTAT

R G C

FURNACE

HEATING AND

COOLING ROOM

THERMOSTAT

Y W R

G C

FURNACE

Y C

REMOTE

CONDENSIN G

UNIT

Thermostat Diagram

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.

XII. GAS SUPPL Y AND PIPING

GENERAL

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.

Page 24

CAUTION

PREVENT UNRELIABLE OPERATION OR EQUIPMENT DAMAGE, THE GAS MANIFOLD PRESSURE MUST BE AS SPECIFIED ON THE UNIT RATING PLATE ADJUSTING THE GAS VALVE PRESSURE REGULATOR

. O

NLY MINOR ADJUSTMENTS SHOULD BE MADE BY

Inlet gas supply pressures must be maintained within the ranges specified below. 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.

Inlet Gas Supply Pressure

Natural Gas

Propane Gas

Minimum:5.0" W.C. Maximum :10.0" W.C. Minimum:11.0" W.C. Maximum :13.0" W.C.

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. Contact your distributor for a tabular listing of appropriate altitude ranges and corresponding manufacturer’s high altitude (Natural, Propane Gas, and/or Pressure Switch) 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, 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/ft

content of the fuel used. Contact your distributor for a tabular listing of appropriate altitude ranges and corresponding manufacturer’s pressure switch kits.

PROPANE GAS CONVERSION

WARN ING

. ALL

CONVERSIONS MUST BE PERFORMED BY

. THE

This unit is configured for natural gas. The appropriate manufacturer’s propane gas conversion kit, must be applied for propane gas installations. Refer to the Section VIII, Propane Gas / High Altitude Installations section for details.

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. 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 Section XIV, Startup Pro- cedure & Adjustment for use of this control during start up and shut down periods.

GAS PIPING CONNECTIONS

GENERAL

CAUTION

AVOID POSSIBLE UNSATISFACTORY OPERATION OR 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

When sizing a trunk line, be sure to include all appliances which will operate simultaneously when sizing a trunk line. The gas piping supplying the furnace must be properly sized based on the gas flow required, specific gravity of the gas, and length of the run. The gas line installation must comply with local codes, or in their absence, with the latest edition of the National Fuel Gas Code, ANSI Z223.1.

Natural Gas Capacity of Pipe

Length of Nominal Black Pipe Size

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

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

100 38 79 150 305 460

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

0.60 Specific Gravity Gas) BTUH Furnace Input

CFH =

Heat i ng Value of Gas (BT U/Cu bi c Foot)

In Cubic Feet of Gas Per Hour (CFH)

To connect the furnace to the building’s gas piping, the installer must supply a ground joint union, drip leg, manual shutoff valve, and line and fittings to connect to gas valve. In some cases, the installer may also need to supply a transition piece from 1/2" pipe to a larger pipe size. The following stipulations apply when connecting gas piping. Refer to Gas Piping Connections figure for typical gas line connections to the furnace.

• 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.

Page 25

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

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

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

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

• Install a manual shutoff valve between the gas meter and

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

• Tighten all joints securely.

• Connect the furnace to the building piping by one of the

following methods:

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

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

• Use listed gas appliance connectors in accordance with

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

• Protect connectors and semirigid tubing against physical

and thermal damage when installed. Ensure 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.

GAS VALVE

ALTERNATE

GAS LINE LOCATI ON

PLUG IN

ALTERNATE

GAS LINE

HOLE

MANIFOLD

PIPE UNION

BURNERS

UPFLOW

MANUAL SHUT-OF F VALVE

(UPSTREAM F ROM GROUND

GROUND JOINT

PIPE U NION

GAS VALVE

BURNERS

ALTER NATE GA S

LINE LOCATION

MANIFOLD

JOINT PIPE UNION)

DRIP LEG

GROMMET IN STAND ARD

GAS LINE HOLE

PLUG IN A LTERNATE

GAS LINE HOLE

HORIZONTAL [UPFLOW MODEL]

NOTES: 1. WHEN GAS LINE IS IN THE ALTERNATE

LOCATION, SWAP THE POSITION OF THE PLUG AND GROMMET

Gas Piping Connections

WARNING

DGES OF SHEET METAL HOLES MAY BE SHARP

PRECAUTION WHEN REMOVING HOLE PLUGS

GROMMET

. USE

MANUAL

SHUT OFF VALVE

(UPSTREAM FR OM

GROUND JOINT

PIPE UNION)

HEIGHT REQUIRED

BY LOCAL CODE

DRIP LE G

GLOVES AS A

GROUND JOINT PIPE UNION

IN STA ND ARD

GAS LINE HO LE

DRAIN TRAP

2. DRIP LEG MAY TERMINATE WITH A 1/2" X 1/8" PIPE PLUG TO ACCOMMODATE LINE GAS PRESSURE MEASUREMENT.

DIRECT/STANDARD INLET PIPING

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

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

INDIRECT/ALTERNATE INLET PIPING

When gas piping enters indirectly to the gas valve through the alternate gas inlet hole the following 1/2 inch pipe fittings (starting

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

• 1 - 90 degree street elbow.

• 1 - 2-1/2 inch pipe nipple.

• 1 - 90 degree elbow.

• 1 - Straight pipe

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

GAS PIPING CHECKS

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

Page 26

WARN ING

AVOID THE POSSIBILITY OF EXPLOSION OR FIRE, NEVER USE A

MATCH OR OPEN FLAME TO TEST FOR LEAKS

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

First Stage Regulator

200 PSIG Maximum

5 to 15 PSIG (20 PSIG Max.)

Second Stage Regulator

Continuous

11" W.C.

NOTE: Never exceed specified pressures for testing. Higher

pressure may damage the gas valve and cause subsequent overfiring, resulting in heat exchanger failure.

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

PROPANE GAS TANKS AND PIPING

WARN ING

THE GAS FURNACE IS INSTALLED IN A BASEMENT, AN EXCAVATED AREA OR A 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 AS CAN

SETTLE IN ANY LOW AREAS OR CONFINED SPACES

• P

ROPANE GAS ODORANT MAY FADE, MAKING THE GAS

NDETECTABLE EXCEPT FOR WITH A WARNING DEVICE

A gas detecting warning system is the only reliable way to detect a propane gas leak. Rust can reduce the level of odorant in propane gas. Do not rely on your sense of smell. Contact a local propane gas supplier about installing a gas detecting warning system. If the presence of gas is suspected, follow the instructions on Page 4 of this manual. All propane gas equipment must conform to the safety standards of the National Board of Fire Underwriters, NBFU Manual 58. For satisfactory operation, propane gas pressure must be 11 inch w.c. 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.

Complete information regarding tank sizing for vaporization, recommended regulator settings, and pipe sizing is available from most regulator manufacturers and propane gas suppliers. Since propane gas will quickly dissolve white lead and most standard commercial compounds, special pipe dope must be used. Shellac-based compounds resistant to the actions of liquefied petroleum gases such as Gasolac

, Stalactic®, Clyde’s® or John Crane® are satisfactory. Refer to the following illustration for typical propane gas installations.

Propane Gas Installation (Typ.)

Sizing Between First and Second Stage Regulator*

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

Pipe or Nominal Pipe Size Tubing Tubing Size, O.D. Type L Schedule 40

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

Feet

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

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

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

Propane Gas Piping Chart I

Sizing Between Single or Second Stage Regulator and Appliance*

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

Pipe or Nominal Pipe Size Tubing Tubing Size, O.D. Type L Schedule 40 Length, 3/8" 1/2" 5/8" 3/4" 7/8" 1-1/8" 1/2" 3/4" 1" 1-1/4" 1-1/2"

Feet

10 39 92 199 329 501 935 275 567 1,071 2,205 3,307 20 26 62 131 216 346 630 189 393 732 1,496 2,299 30 21 50 107 181 277 500 152 315 590 1,212 1,858 40 19 41 90 145 233 427 129 267 504 1,039 1,559 50 18 37 79 131 198 376 114 237 448 913 1,417 60 16 35 72 121 187 340 103 217 409 834 1,275

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

*Data in accordance with NFPA pamphlet NO. 54

Propane Gas Piping Chart II

XIII. CIRCULATING AIR & FIL TERS

DUCTWORK - 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 attached to the back of the furnace. 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.

NOTE: Two side openings or a side opening and bottom opening are required for airflow delivery of 1800 CFM and greater.

Page 27

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 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.

WARN ING

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

COOLING AIRFLOW REQUIREMENT (CFM)

600 800 1000 1200 1400 1600 2000

0453_XA 188* 192 240 288 --- --- ---

0703_XA --- 282 * 282* 282* 336 --- ---

0704_XA --- --- 26 0* 260* 336 384 --0904_XA --- --- 37 6* 376* 376* 384 ---

Input__Airflow

0905_XA --- --- --- 37 6* 376* 384 480

115_XA --- --- --- 47 0* 470* 470* 480

DGES OF SHEET METAL HOLES MAY BE SHARP

PRECAUTION WHEN REMOVING SHEET METAL FROM DUCT OPENING

CUT USING TIN SNIPS

CUT FOUR CORNERS AFTER REMOVING SHEET METAL

. USE

GLOVES AS A

PRESS OUT BY HAND

SCRIBE LINES OUTLINING DUCT FLAN GE S

Duct Flange Cut Outs

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

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

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

*Minimum filter area dictated by heating airflow requirement.

Permanent Minimum Filter Area (sq. in)

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

COOLI NG AIRFLOW REQUIREMENT (CFM)

600 800 1000 1200 1400 1600 2000

0453_XA 376* 384 480 576 --- --- --0703_XA --- 564* 564* 564* 672 --- ---

0704_XA --- --- 564* 564* 672 768 ---

0904_XA --- --- 752* 752* 752* 768 ---

Input__Airflow

0905_XA --- --- --- 752* 752* 768 800 1155_XA --- --- --- 940* 940* 940* 800

*Minimum filter area dictated by heating airflow requirement.

Disposable Minimum Filter area (sq. in)

[Based on 300 ft/min filter face velocity]

UPRIGHT INSTALLATIONS

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

The following figure shows possible filter locations.

AIR FLO W

CENTRAL

RETURN

GRILLE

SIDE RETURN

EXTERNAL FILTER

FILTER

RACK KIT

(EITHER SIDE)

FILTERS - READ THIS SECTION BEFORE INSTALLING THE RETURN AIR DUCTWORK

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

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

FILTER

Possible Upright Upflow

Filter Locations

Page 28

HORIZONTAL INSTALLATIONS

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

4. Replace the burner compartment door.

GAS SUPPLY PRESSURE MEASUREMENT

XIV . ST ARTUP PROCEDURE & ADJUSTMENT

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

HEAT ANTICIPATOR SETTING

The heat anticipator in the room thermostat must be correctly adjusted to obtain the proper number of cycles per hour and to prevent “overshooting” of the setting. Set the heat anticipator setting to

0.7 amps. Follow the thermostat manufacturer’s instructions on how to adjust the heat anticipator setting.

DRAIN TRAP PRIMING

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

FURNACE OPERATION

Purge gas lines of air prior to startup. Be sure not purge lines into an enclosed burner compartment. Check for leaks using an approved chloride-free soap and water solution, an electronic combustible gas detector, or other approved method. Verify that all required kits (propane gas, high altitude, etc.) have been appropriately installed.

FURNACE STARTUP

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

2. Turn off the electrical power to the furnace.

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

4. Remove the burner compartment door.

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



WARN ING

HIGHVOLTAGE!

ISCONNECTALLPOWERBEFORESERVICINGOR

INSTALLINGTHISUNIT

BEPRESENT

DAMAGE,PERSONALINJURYORDEATH

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 unit OFF. To measure inlet pressure, use the following procedure.

.F

.M

ULTIPLEPOWERSOURCESMAY

AILURETODOSOMAYCAUSEPROPERTY

Gas Valve

On/Off

Selector

Switch

OUTLET



Inlet Pres s ur e

Tap

INLET

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

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

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

7. If you smell gas after five minutes, immediately follow the instructions on page 4 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 draf t blower will be de-energized. After a 150-second delay period (fixed), the circulator blower will be de-energized.

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.

Pressure Regulator

Adjustment

(Under Cap Screw)

Outlet Pressure

Tap

White-Rodgers Model 36G22

Pressu re Regulator

Inlet Pressure Tap

(under cap screw)

Outlet Pressure Tap

Gas Valve On/Off Selector Switch

Honeywell Model VR8215 (Single-Stage)

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.

Page 29

3. Inlet pressure tap connections: a. Honeywell VR8215 Valve:

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

b. White-Rodgers 36G22 valve:

Back inlet pressure test screw (inlet pressure boss) out one turn (counterclockwise, not more than one turn).

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

fitting (Honeywell valve) or inlet pressure boss (WhiteRodgers 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. Using a leak detection solution or soap suds, check for

leaks at outlet pressure boss plug (Honeywell valve) or screw (White-Rodgers valve). Bubbles forming indicate a leak. SHUT OFF GAS AND REPAIR ALL LEAKS IMMEDIATELY!

8. Measure the gas supply pressure with burners firing. Adjust

supply pressure using the Inlet Gas Supply Pressure table shown below. If supply pressure reading differs from the table, make necessary adjustments to pressure regulator, gas piping size, etc., and/or consult with local gas utility.

Inlet Gas Supply Pressure

Natural Gas

Propane Gas

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

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

inlet pressure boss.

11. Replace inlet pressure tap: a. Honeywell VR8215 valve:

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

b. White-Rodgers 36G22 valve:

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

12. Retest for leaks. If bubbles form, shut down gas and repair

leaks immediately.

13. Turn ON electrical power and gas supply to the system.

14. Turn valve switch ON.

Minimum:5.0" W.C. Maximum :10.0" W.C. Minimum:11.0" W.C. Maximum :13.0" W.C.

GAS MANIFOLD PRESSURE MEASUREMENT AND ADJUSTMENT

CAUTION

TO

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

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

PLATE

.O

NLYMINORADJUSTMENTSSHOULDBEMADEBYADJUSTING

THEGASVALVEPRESSUREREGULATOR



WARNING

HIGHVOLTAGE!

ISCONNECTALLPOWERBEFORESERVICINGOR

INSTALLINGTHISUNIT

BEPRESENT

DAMAGE,PERSONALINJURYORDEATH

.F

.M

ULTIPLEPOWERSOURCESMAY

AILURETODOSOMAYCAUSEPROPERTY



Consult the appliance rating plate to ensure burner manifold pressure is as specified. If another outlet pressure is required, follow these steps.

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

2. Turn OFF all electrical power to the system.

3. Outlet pressure tap connections:

a. Honeywell VR8215 valve:

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

b. White-Rodgers 36G22 valve:

Back outlet pressure test screw (outlet pressure boss) out one turn (counterclockwise, not more than one turn).

4. Attach a hose and manometer to the outlet pressure barb fitting (Honeywell valve) or outlet pressure boss (WhiteRodgers 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. Using a leak detection solution or soap suds, check for leaks at outlet pressure boss plug (Honeywell valve) or screw (White-Rodgers valve). Bubbles forming indicate a leak. SHUT OFF GAS AND REPAIR ALL LEAKS IMMEDIATELY!

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

Manifold Gas Pressure

Natural Gas 3.5" w.c.

Propane Gas 10.0" w.c.

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

10. Turn OFF all electrical power and gas supply to the system.

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

12. Replace outlet pressure tap:

a. Honeywell VR8215 valve:

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

b. White-Rodgers 36G22 valve: Turn outlet pressure test

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

13. Turn ON electrical power and gas supply to the system.

14. Close thermostat contacts to provide a call for heat.



15. Retest for leaks. If bubbles form, SHUT OFF GAS AND REPAIR ALL LEAKS IMMEDIA TEL Y!

GAS INPUT RATE MEASUREMENT (NATURAL GAS ONLY)

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

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

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

This valve is shipped from the factory with the regulator preset (see control label).

Page 30

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

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

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

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

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

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

x 3600 sec/hr) ÷ 34 sec/ ft

Input = 106,000 BTU/hr

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

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

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

5. 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.

HEAT EXCHANGER

RADIATION "LINE OF SIGHT"

SUPPLY AIR

SUPPLY

RISE =

SUPPLY

RETURN

RETURN AI R

Temperature Rise Measurement

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 Section XIV, Startup Procedure and Adjustment -Circulator Blower Speeds for speed changing details.

CIRCULATOR BLOWER SPEEDS

WARN ING

PREVENT PREMATURE FAILURE OF HEAT EXCHANGER, PROPERTY DAMAGE, PERSONAL INJURY OR DEATH, DO NOT ADJUST THE LIMIT CONTROL (FACTORY-SET

This furnace is equipped with a multi-speed circulator blower. This blower provides ease in adjusting blower speeds. The Specification Sheet applicable to your model provides an airflow table, showing the relationship between airflow (CFM) and external static pressure (E.S.P .), for the proper selection of heating and cooling speeds. The cooling blower speed is shipped set on HIGH, and the heating blower speed is set as indicated in the Specification Sheet applicable to your model. These blower speeds should be adjusted by the installer to match the installation requirements so as to provide the correct heating temperature rise and correct cooling CFM.

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. (T erminals are identified as HEA T and COOL (hot)). 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 Section XIV, Startup Procedure and Adjustment - Temperature Rise.

Circulator Blower S

eeds

Low Red

Medium Low

Orange

Medium Blue

Common/Neutral

Black

White

XV . NORMAL SEQUENCE OF OPERA TION

POWER UP

The normal power up sequence is as follows:

• 115 VAC power applied to furnace.

• Integrated control module performs internal checks.

• Integrated control module LED will light.

• Integrated control module monitors safety circuits

continuously.

• Furnace awaits call from thermostat.

HEATING MODE

The normal operational sequence in heating mode is as follows:

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

Page 31

• Integrated control module performs safety circuit checks.

• Induced draft blower is energized for 15 second prepurge

period causing pressure switch contacts to close.

• Igniter warm up begins after 15 second prepurge expires.

• Gas valve opens at end of igniter warm up period, delivering

gas to burners and establishing flame.

• Integrated control module monitors flame presence. Gas

valve will remain open only if flame is sensed.

• Circulator blower is energized on heat speed following a

fixed thirty second blower on delay.

• Furnace runs, integrated control module monitors safety

circuits continuously.

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

heat.

• Gas valve closes, extinguishing flame.

• Induced draft blower is de-energized following a fifteen

second post purge.

• Circulator blower is de-energized following the heat off delay

period (fixed 150 seconds).

• Furnace awaits next call from thermostat.

COOLING MODE

The normal operational sequence in cooling mode is as follows:

• R and Y 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 cool speed following a

fixed five second on delay.

• Furnace circulator blower and outdoor cooling unit run,

integrated control module monitors safety circuits continuously.

• R and Y thermostat contacts open, completing the call for

cool.

• Outdoor fan and compressor are de-energized.

• Circulator blower is de-energized following a fixed forty five

second cool off delay period.

• 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.

• 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.

• Furnace awaits next call from thermostat.

XVI. OPERA TIONAL CHECKS

BURNER FLAME

The burner flames should be inspected with the burner compartment door installed. A sight glass is provided for inspection purposes. Flames should 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.

Check the burner flames for:

1. Good adjustment

2. Stable, soft and blue

3. Not curling, floating, or lifting off.

Burner Flame

XVII. SAFETY CIRCUIT DESCRIPTION

GENERAL

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, the module will take the necessary precautions and provide diagnostic information through an LED.

PRIMARY LIMIT

The primary limit control is located on the partition panel and monitors heat exchanger compartment temperatures. It is a normallyclosed (electrically), automatic reset, temperature-activated sensor. The limit guards against the overheating as a result of insufficient conditioned air passing over the heat exchanger.

AUXILIARY LIMIT

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

ROLLOUT LIMIT

The rollout limit controls are mounted on the burner/manifold assembly and monitor the burner flame. They are normally-closed (electrically), manual-reset, temperature-activated 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), single-pole single-throw, 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

Page 32

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.

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

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

XIX. MAINTENANCE

XVIII. TROUBLESHOOTING

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 ser-

vicing 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 furnaces near the control. Any tools held in a person’s hand during grounding will be discharged.

DIAGNOSTIC CHART

WARN ING

HIGH VOLTAGE! T

O AVOID PERSONAL INJURY OR DEATH DUE TO ELECTRICAL SHOCK, DISCONNECT ELECTRICAL POWER BEFORE PERFORMING ANY MAINTENANCE HANDLE THE IGNITER, HANDLE WITH CARE THE IGNITER ELEMENT WITH BARE FINGERS, ROUGH HANDLING OR VIBRATION COULD DAMAGE THE IGNITER RESULTING IN PREMATURE FAILURE SERVICER SHOULD EVER HANDLE THE IGNITER

. O

NLY A QUALIFIED

. IF

YOU MUST

. T

OUCHING

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.

HIGH VOLTAGE!

O AVOID PERSONAL INJURY OR DEATH DUE TO

ELECTRICAL SHOCK, DISCONNECT ELECTRICAL POWER BEFORE PERFORMAING ANY SERVICE OR MAINTENANCE

Refer to the Troubleshooting Chart at the end of this manual for assistance in determining the source of unit operational problems. The red diagnostic LED blinks to assist in troubleshooting the unit. The number of blinks refers to a specific fault code.

RESETTING FROM L OCKOUT

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 one flash diagnostic LED code. 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 for 1 - 20 seconds.

FILTERS

CAUTION

ENSURE PROPER UNIT PERFORMANCE, ADHERE TO THE FILTER

SIZES GIVEN IN THE RECOMMENDED MINIMUM FILTER SIZE TABLE OR

PECIFICATION SHEET APPLICABLE TO YOUR MODEL

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.

Page 33

To remove filters from an external filter rack in an upright upflow installation, follow the directions provided with external filter rack kit. For further details, see your distributor.

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.

MEDIA AIR FILTER OR ELECTRONIC AIR CLEANER REMOVAL

Follow the manufacturer’s directions for service.

BURNERS

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

INDUCED DRAFT AND CIRCULATOR BLOWERS

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

CONDENSATE TRAP AND DRAIN SYSTEM (QUALIFIED SERVICER ONLY)

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

FLAME SENSOR (QUALIFIED SERVICER ONLY)

Under some conditions, the fuel or air supply can create a nearly invisible coating on the flame sensor. This coating acts as an insulator causing a drop in the flame sense signal. If the flame sense signal drops too low the furnace will not sense flame and will lock out. The flame sensor should be carefully cleaned by a qualified servicer using emery cloth or steel wool. Following cleaning, the flame sense signal should be 1 to 6 microamps.

IGNITER (QUALIFIED SERVICER ONLY)

If the igniter and the surrounding air are at about 70°F and the igniter wires are not connected to any other electrical components, the resistance of the igniter should not exceed 200 ohms. If it does, the igniter should be replaced.

FLUE PASSAGES (QUALIFIED SERVICER ONLY)

The heat exchanger flue passageways should be inspected at the beginning of each heating season. If necessary, clean the passageways as outlined below.

4. Remove the induced draft blower and the drain and pressure tap hoses from the recuperator coil front cover.

5. Remove the recuperator coil front cover to expose the coil tubes and turbulators.

6. Remove the recuperator coil turbulators individually by slowly pulling each turbulator forward firmly.

7. Clean the recuperator coil tubes using a long handle wire brush, such as a gun cleaning brush.

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

9. Clean residue from furnace using a vacuum cleaner.

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

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

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

XX. BEFORE LEAVING AN INST ALLATION

• 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.

XXI. REP AIR & REPLACEMENT PARTS

• When ordering any of the listed functional parts, be sure to

provide the furnace model, manufacturing, and serial numbers with the order.

• Although only functional parts are shown in the parts list, all

sheet metal parts, doors, etc. may be ordered by description.

• Parts are available from your distributor.

Functional Parts List-

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

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

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

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

Page 34

Symptoms of Abnormal

Operation

• Furnace fails to operate.

• Integrated control module diagnostic LED provides no signal.

• LED is Steady On.

Associated

LED Code

NONE

CONTINUOUS

Troubleshooting Chart

Fault Description(s) Possible Causes

Fault Description(s) Possible Causes Corrective Action

• 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 • Normal Operation • None

• 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.

• 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.

Cautions and Notes

• Turn power OFF prior to repair.

• Replace

integrated control module fuse with 3A automotive fuse.

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

• Normal Operation

• 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.

1 FLASH

2 FLASHES

3 FLASHES

• 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.

• 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.

• 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.

• 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.

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

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

Page 35

Troubleshooting 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.

• Circulator blower runs continuously. No furnace operation.

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

Associated LED Code

4 FLASHES

5 FLASHES

6 FLASHES

Fault Description(s) Possible Causes Corrective Action Cautions and Notes

• Primary or auxiliary limit circuit is open.

•Faulty primary or auxiliary limit switch.

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

•Loose or improperly connected wiring.

• Check primary/auxiliary limit. Replace if necessary.

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

• Check circulator blower speed and performance. Correct speed

• Turn power OFF prior to repair.

• Replace primary/ auxiliary limit with proper replacement part.

• Replace blower with correct replacement part.

or replace blower if necessary.

• Tighten or correct wiring connection.

• Flame sensed with no call for heat.

• Short to ground in flame sense circuit.

•Correct short at flame sensor or in flame

• Turn power OFF prior to repair.

sensor wiring.

• Rollout limit circuit is open.

•Flame rollout.

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

•Loose or improperly connected wiring.

•Faulty rollout limit.

• 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.

• Turn power OFF prior to repair.

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

• Replace rollout limit with correct

replacement part.

• Replace induced draft blower with correct replacement part.

• Tighten or correct wiring connection.

• Normal furnace operation.

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

7 FLASHES

• Flame sense microamp signal is low.

•Flame sensor is coated/ oxidized.

•Flame sensor incorrectly positioned in burner flame.

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

• Sand flame sensor if coated/oxidized.

• Inspect for proper sensor alignment.

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

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

• Furnace fails to operate.

• Integrated control module diagnostic LED is flashing continuously.

CONTINUOUS/

RAPID FLASH

•Polarity of 115 or 24 volt power is reversed.

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

• Orange and gray wires to transformer are reversed.

• Review wiring diagram to correct polarity.

• Reverse orange and gray wires going to transformer.

• Poor unit ground.

• Verify proper ground. Correct if necessary.

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

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

• Turn power OFF prior to repair.

• Sand flame sensor with emery clot.

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

• See rating plate for proper gas pressure.

• Turn power OFF prior to repair.

Page 36

GKS9 WIRING DIAGRAM

MOSTAT AT 0.

C P

EED

"PAR

NDED

C H

WITH

COMPA D

(

OPEN WHEN

DOO

T 1

MINALS

TER

OPEN)

NTEGR

TS MUST BE U

USE

N H

ME,

NTE N

24V THERMOSTAT CONNECTIONS

E O

PER

INTEGRATED CONTROL MODULE

TION

AGE

AGE (115V

HEN

C ATE

MICRO

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)

DOO

TCH

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)

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DEATH

INSTALLING

AILURE

. F

INJURY

PRESENT

SERVICING

MAY

PERSONAL

BEFORE

DAMAGE

SOURCES

POWER ALL

POWER

PROPERTY

ULTIPLE

ISCONNECT

HIGH VOLTAGE!

CAUSE

DIAGN

LED

URNER

P SWI

HOT

STEADY ON = NORMAL OPERATION

211

XFMR-H

)

TERMINALS

115 VAC NEU TRA L

A AUXI I

LOWER

NUAL

Y LIMIT

W D

OFF = CONTROL FAILURE

1 FLASH =

2 FLASHES = PRESSURE SWITCH STUCK CLOSED

2 3

3 FLASHES = PRESSURE SWITCH STUCK OPEN

4 FLASHES = OPEN HIGH LIMIT

5 FLASHES = FLAME SENSE WITHOUT GAS VALVE

6 FLASHES =

CONTINUOUS/RAPID FLASHES = REVERSED 115 VAC POLARITY

COLOR

014

O P

URPLE

LACK

LOW

ODES

236

L B

RED

ES:

SET H

2. MANUFACT

LOW

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ATING A

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Ø /60 HZ POWER SUPPLY WITH

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ENT

MATERIAL

USE

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

Goodman GKS9 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual