ICP F8MVL0701412A1, F8MVL0901716A1, F8MVL1102120A1, F8MVL1352422A1, G8MVL0701412A1 Installation Guide

...

These instructions must be read and understood completely before attemptin 9 installation.

Safety Labeling and Signal Words

DANGER, WARNING, CAUTION, and NOTE

The signal words DANGER, WARNING, CAUTION, and NOTE

are used to identify levels of hazard seriousness. The signal word DANGER is only used on product labels to signify an immediate

hazard. The signal words WARNING, CAUTION, and NOTE will be used on product labels and throughout this manual and other manual that may apply to the product.

DANGER - Immediate hazards which will result in severe person- al injury or death.

WARNING - Hazards or unsafe practices which could result in severe personal injury or death.

CAUTION - Hazards or unsafe practices which may result in minor personal injury or product or property damage.

NOTE - Used to highlight suggestions which wilt result in en- hanced installation, reliability, or operation.

TABLE OF CONTENTS

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

INTRODUCTION ........................................ 4

CODES AND STANDARDS ............................... 4

SAFETY ................................................ 4

GENERAL INSTALLATION ................................ 5

COMBUSTION AND VENTILATION AIR .................... 5

DUCT SYSTEMS ........................................ 5

ACOUSTICAL LINING AND FIBROUS GLASS DUCT ......... 5

GAS PIPING AND GAS PIPE PRESSURE TESTING ......... 5

ELECTRICAL CONNECTIONS ............................ 5

VENTING .............................................. 5

LOCATION ............................................. 5

MINIMUM FREE AREA REQUIRED ........................ 7

AIR FOR COMBUSTION AND VENTILATION ................ 8

INSTALLATION .......................................... 10

OPENING DIMENSIONS ................................. 12

AIR DUCTS ............................................. 13

GAS PIPING ............................................ 17

ELECTRICAL CONNECTIONS ............................ 18

24-V WIRING ........................................... 20

ACCESSORIES ......................................... 20

VENTING .............................................. 20

CHIMNEY INSPECTION CHART ........................... 25

START-UP, ADJUSTMENT, AND SAFETY CHECK ........... 31

Signal Words in Manuals

The signal word WARNING is used throughout this manual inthe following manner:

The signal word CAUTION is used throughout this manual in the following manner:

Signal Words on Product Labeling

Signal words are used in combination with colors and/or pictures or product labels.

Safety-alert symbol

When you see this symbol on the unit and in instructions or manu-

als, be alert to the potential for personal injury.

Use of the AHRI Certified TM Mark indicates a manufacturer's participation in the program. For

verification of certification for individual products, go to www.ahridirectory.org .

PERSONAL INJURY, AND/OR PROPERTY DAMAGE HAZARD

Failure to carefully read and follow this warning could result in equipment malfunction, property damage, personal injury and/or death. Installation or repairs made by unqualified persons could result in equipment malfunction, property damage, personal injury and/or death.

The information contained in this manual is intended for

use by a qualified service technician familiar with safety procedures and equipped with proper tools and test

instruments. Installation must conform with local building codes and

with the Natural Fuel Gas Code (NFCG) NFPA 54/ANSI Z223.1, and National standards of Canada

CAN/CSA-B149.1 and .2 Natural Gas and Propane Installation Codes.

INSTALLER: Affix these instructions on or adjacent to the furnace.

IS0 9001

Portions of the text and tables are reprinted from NFPA 54/ANSi Z223.t -2012_c3, with permission of National Fire Protection Association, Quincy, MA 02269 and American Gas Association, WasNng- ton, DC 20001. This reprinted material is not the complete and official position of the NFPA or ANSI, on the referenced subject, which is represented only by the standard in its entirety.

CONSUMER: Retain these instructions for future reference.

Printedin U.S.A. 441 01 2122 00 6/6/2014

Figure 1 - Dimensional Drawing

118/16

r,.= I2

2"t=V4 ['a_71

1-51/2,, NR FLOW

THERMO_rATWIRE

[540.5] [1_71

21.o 8,1

BoI"rOMINLET

2_N

rrzl.2]

[7_

TOPOF CAmNG

;::-,

[12.7]

_57_

I14t_1

i I

1--

T 11_.=]

oo/16 -- [=4S.Sl f

l 41B/16

=7a/4 ¢ 7/e

pt ,.7] I_=]

_W16

['_0.TJ

"r_ I_ CAImNG

LOCATION

618/18

[172.S]

ST_

[I_.S] S_--

5 7/10 [14&S1

[1N'lql 111/111_

_ [4L21

I,-

_86/8

it1=]-_1 /_

I " " ; / [_,.Tj

//THERMO_'FAT WIREB_ITRY / F¢1_/4

' F¢I=

]

_¢7/o

[22.=]

ACCESSORY

_.L_-%.,e 1

[,v_.o| m_=4] /

L1,7

[4&S]

147/8

la_.a]

(eo'rH=DE_

D-_-J _ 8/4

BOITOM RE11JRN [likl]

WIDTH

NOTES:

1. Two additional 7/8-in. (22 mm) diameter holes are located in the top plate.

2. Minimum return-air openings at furnace, based on metal duct. If flex duct is used, see flex duct manufacturer's recommendations for equivalent diameters.

a. For 800 CFM-16-in. (406 mm) round or 14 1/2 x 12-in. (368 x 305 mm) rectangle.

b. For 1200 CFM-20-in. (508 mm) round or 14 1/2 x 19 1/2-in. (368 x 495 mm) rectangle. c. For 1600 CFM-22-in. (559 mm) round or 14 1/2 x 22 1/16-in. (368 x 560mm) rectangle. d. For airflow requirements above 1800 CFM, see Air Delivery table in Product Data literature for specific use of single side inlets. The use of both side inlets, a

combination of 1 side and the bottom, or the bottom only will ensure adequate return air openings for airflow requirements above 1800 CFM.

VENTINO(5PLACE8)

Table I - Dimensions - In. (mm)

CABINET

FURNACE SIZE

0451412B 0701716B 0902116B

1102122B 1352422B

* 135 size furnace require a 5 in, or 6 in. (127 or 152 mm) vent. Use

2 Specifications are subject to change without notice. 441 01 2122 00

WIDTH

IN. (ram)

14-3/16 (360)

17-1/2 (445)

21 (533) 21 (533)

24-1/2 (622)

OUTLET

WIDTH

IN. (ram)

12-0/16 (319)

15-7/8 (403) 19-3/8 (492) 19-3/8 (492)

22-7/8 (581)

TOP AND BOTTOM

FLUE COLLAR

IN. (ram)

9-5/16 (237) 11-9/16 (294) 13-5/16 (338) 13-5/16 (338)

15-1/16 (383)

vent adapter between furnace and vent stack.

h_ 22 1/16

BOTTOM INLET

WIDTH

IN. (ram)

12-11/16 (322)

16 (406) 19-1/2 (495) 19-1/2 (495)

23 (584)

[r,m

81DEINLET

(eo'm mDES)

CONNECTION

L1 1/4

1 Ira.el [1_4]

VENT

SIZE

IN. (ram)

4 (102) 4 (102) 4 (102) 4 (102)

4 (102)*

SHIP WT.

LB (KG)

107 (49) 126 (57) 140 (64) 152 (69)

163 (74)

SAFETY CONSIDERATIONS

FIRE, EXPLOSION, ELECTRICAL SHOCK, AND CARBON MONOXIDE POISONING HAZARD

Failure to follow this warning could result in dangerous operation, personal injury,death, or property damage.

Improper installation, adjustment, alteration, service, maintenance, or use can cause carbon monoxide

poisoning, explosion, fire, electrical shock, or other conditions which may cause personal injury or property damage. Consult a qualified service agency, local gas supplier, or your distributor or branch for information or assistance. The qualified service agency must use only factory-authorized and listed

kits or accessories when modifying this product.

FURNACE RELIABILITY HAZARD

Failure to follow this caution may result in unit component damage.

Application of this furnace should be indoors with

special attention given to vent sizing and material, gas input rate, air temperature rise, unit leveling, and

unit sizing.

Installing and servicing heating equipment can be hazardous

due to gas and electrical components. Only trained and

qualified personnel should install, repair, or service

heating equipment, Untrained personnel can perform basic maintenance functions such as cleaning and replacing air

filters. All other operations must be performed by trained service personnel. When working on heating equipment,

observe precautions in literature, on tags, and on labels

attached to or shipped with furnace and other safety

precautions that may apply.

These instructions cover minimum requirements and conform to existing national standards and safety codes. In some

instances, these instructions exceed certain local codes and ordinances, especially those that may not have kept up with changing residential construction practices. We require these

instructions as a minimum for a safe installation.

CUT HAZARD

Failure to follow this caution may result in personal injury.

Sheet metal parts may have sharp edges or burrs.

Use care and wear appropriate protective clothing, safety glasses and gloves when handling parts, and servicing furnaces.

Wear safety glasses, protective clothing and work gloves.

Have fire extinguisher available during start-up and

adjustment procedures and service calls. This is the safety-alert symbol z_. When you see this symbol

on the furnace and in instructions or manuals, be alert to the potential for personal injury.

Understand the signal words DANGER, WARNING, and CAUTION. These words are used with the safety-alert

symbol. DANGER identifies the most serious hazards which will result in severe personal injury or death. WARNING

signifies a hazard which could result in personal injury or death. CAUTION is used to identify hazards which may result

in minor personal injury or product and property damage. NOTE is used to highlight suggestions which wilt result in

enhanced installation, reliability, or operation.

1. Use only with type of gas approved for this furnace. Refer to the furnace rating plate.

2. Install this furnace only in a location and position as spe- cified in the "Location" section of these instructions.

3. Provide adequate combustion and ventilation air to the fur-

nace space as specified in "Air for Combustion and Ventil-

ation" section.

4. Combustion products must be discharged outdoors. Con-

nect this furnace to an approved vent system only, as spe-

cified in the "Venting" section of these instructions.

5. Never test for gas leaks with an open flame. Use a com- mercially available soap solution made specifically for the

detection of leaks to check all connections, as specified in the "Gas Piping" section.

6. Always install furnace to operate within the furnace's inten- ded temperature-rise range with a duct system which has

an external static pressure within the allowable range, as specified in the "Start-Up, Adjustments, and Safety Check"

section. See furnace rating plate.

7. When a furnace is installed so that supply ducts carry air circulated by the furnace to areas outside the space con-

taining the furnace, the return air shall also be handled by duct(s) sealed to the furnace casing and terminating out-

side the space containing the furnace. See "Air Ducts" sec- tion.

8. A gas-fired furnace for installation in a residential garage must be installed as specified in the warning box in the

"Location" section.

9. The furnace may be used for construction heat provided that the furnace installation and operation complies with

the first CAUTION in the LOCATION section of these in- structions.

10. These Multipoise Gas-Fired Furnaces are CSA (formerly A.G.A. and C.G.A.) design-certified for use with natural

and propane gases (see furnace rating plate) and for in- stallation in alcoves, attics, basements, closets, utility

rooms, crawlspaces, and garages. The furnace is factory-

shipped for use with natural gas. A CSA (A.G.A. and C.G.A.) listed accessory gas conversion kit is required to

convert furnace for use with propane gas.

11. See Figure 2 for required clearances to combustible con- struction.

12. Maintain a 1-in. (25 mm) clearance from combustible ma- terials to supply air ductwork for a distance of 36 in. (914

mm) horizontally from the furnace. See NFPA 90B or local code for further requirements.

13. These furnaces SHALL NOT be installed directly on car- peting, tile, or any other combustible material other than

wood flooring. In downflow installations, factory accessory floor base MUST be used when installed on combustible

materials and wood flooring. Special base is not required when this furnace is installed on manufacturer's coil model

numbers END4X, ENW4X or coil casing model number NAEA. See Figure 2 for clearance to combustible con-

struction information.

441 01 2122 O0 Specifications are subject to change without notice. 3

Figure 2 - Clearances to Combustibles

Improper adjustment, alteration, service, maintenance, or installation can cause

serious injury or death.

Read and follow instructions and

_recautions in User's Information Manual _rovided with this furnace. Installation

and service must be performed by a qualified service agency or the gas

supplier.

_, CAUTION

Check entire gas assembly for leaksafter lighting this appliance.

I INSTALLATION

1. This furnace must be installed in accordance with the manufacturer's

instructions and local codes. In the

absence of localcodes, follow the National

FuelGas Code ANSI Z223.1 / NFPA54

or CSA B-149.1 Gas Installation Code.

2. Thisfurnace must be installed so there are provisions for combustion and ventilation

air. Seemanufacturer's installation information provided with this appliance.

This furnace is equipped with manual reset limit switch(es) in burner compartment to

protect against overheat conditions that can result from inadequate combustion air

supply or blocked vent conditions.

1. Do not bypass limit switches.

2. If a limit opens, call a quallified serviceman to correct the condition and reset limit switch.

I INSTALLATION I

MINIMUMINCHESCLEARANCETOCOMBUSTIBLECONSTRUCTION

This forced air furnace is equipped for use with natural gas at altitudes 0 - 10,000 ft

(0 - 3,050m).

An accessory kit, supplied by the manufacturer, shall be used

to convert to propane gas use or may be required for some

natural gas applications.

This furnace is for indoor

installation in a building

constructed on site.

This furnace may be installed on combustible flooring in alcove or closet at minimum clearance

as indicated by the diagram from combustible material.

This furnace may be used with a Type B-1 Vent and may be

vented in common with other gas fired appliances.

UPFLOW, DOWNFLOW, and

I his furnace is approved for

HORIZONTAL installations.

VentClearanceto combustibles:

ForSingleWallvents6 inches(613o). ForTypeB-1venttype 1inch(1pc).

Clearancearrows donotchangewith

Clearanceininches

MINIMUMINCHESCLEARANCETO

COMBUSTIBLECONSTRUCTION

DOWNFLOWPOSITIONS:

Installation on non-combustible floors only. For Installation on combustible flooring only when installed on special

base, Part No. KGASBO201ALLor NAHA01101SB, Coil Assembly, Part No. CAR,CAP, CNPV,CNRV,END4X, ENW4X,WENC, WTNC,

WENW OR WTNW. 18 inches front clearance required for alcove.

-k Indicates supply or return sides when furnace is in the horizontal position. Line contact only permissible between lines formed by intersections ofthe Top and two Sides of the furnace jacket, and building joists, studs or framing.

I IIIIIIIIIIIIIIIIII

• 336996-101 REV. C

INTRODUCTION

F8MVL & G8MVL 4-way multipoise Category I fan-assisted

furnace is CSA (formerly A.G.A. and C.G.A.) design-certified. A Category I fan-assisted furnace is an appliance equipped

with an integral mechanical means to either draw or force

products of combustion through the combustion chamber and/or heat exchanger. The furnace is factory-shipped for use with natural gas. This furnace is not approved for installation in

mobile homes, recreational vehicles, or outdoors.

Figure 3 - Return Air Temperature

- - MAX 80'_F/27'_C

This furnace is designed for minimum continuous return-air temperature of 60°F (15°O) db or intermittent operation down to 55"F (13°C)db such as when used with a night setback thermostat. Return-air temperature must not exceed 80_'F (27°0) db. Failure to follow these return-air temperature limits

may affect reliability of heat exchangers, motors, and controls. (See Figure 3)

For accessory installation details, refer to the applicable instruction literature.

NOTE: Remove all shipping brackets and materials before operating the furnace.

CODES AND STANDARDS

Follow all national and local codes and standards in addition to these instructions. The installation must comply

with regulations of the serving gas supplier, local building, heating, plumbing, and other codes. In absence of local

FRONT

codes, the installation must comply with the national codes listed below and all authorities having jurisdiction.

In the United States, follow all codes and standards for the following:

MIN 60°F/16°0

Safetv

NFPA 54/ANSI Z223.1-2012 and the Installation Standards, Warm Air Heating and Air Conditioning Systems ANSI/NFPA

A06745

4 Specifications are subject to change without notice. 441 01 2122 00

90B.

General Installation

Current edition of the NFGC and the NFPA 90B. For copies,

contact the National Fire Protection Association Inc.,

Batterymarch Park, Quincy, MA 02269; (www.NFPA.org) or for

only the NFGC, contact the American Gas Association, 400 N.

Capitol Street, N.W., Washington, DO 20001 (www.AGA.org).

Combustion and Ventilation Air

Section 9.3 NFPA 54/ANSI Z223.1-2012, Air for Combustion and Ventilation.

Duct Systems

Air Conditioning Contractors Association (ACCA) Manual D,

Sheet Metal and Air Conditioning Contractors National Association (SMACNA), or American Society of Heating,

Refrigeration, and Air Conditioning Engineers (ASHRAE) 2001

Fundamentals Handbook Chapter 34 or 2000 HVAC Systems and Equipment Handbook Chapters 9 and 16.

Acoustical Lining and Fibrous Glass Duct

Current edition of SMACNA and NFPA 90B as tested by UL

Standard 181 for Class I Rigid Air Ducts

Gas Piping and Gas Pipe Pressure Testing

NFPA 54/ANSI Z223.1-2012 ; chapters 5, 6, and 7 and

National Plumbing Codes.

Electrical Connections

National Electrical Code (NEC) NFPA 70-2011.

Venting

NFPA 54/ANSI Z223.1-2012; chapters 12 and 13.

ELECTROSTATIC DISCHARGE (ESD)

PRECAUTIONS PROCEDURE

FURNACE RELIABILITY HAZARD

Failure to follow this caution may result in unit component

damage.

Electrostatic discharge can affect electronic components. Take precautions during furnace installation and servicing to protect the furnace electronic control.

Precautions will prevent electrostatic discharges from personnel and hand tools which are held during the procedure. These precautions will help to avoid exposing the control to electrostatic discharge by putting the furnace, the control, and the person at the same

electrostatic potential.

Figure 4 - Multipoise Orientations

THE BLOWER IS LOCATED

1. Disconnect all power to the furnace. Multiple disconnects may be required. DO NOT TOUCH THE CONTROL OR

ANY WIRE CONNECTED TO THE CONTROL PRIOR TO

DISCHARGING YOUR BODY'S ELECTROSTATIC

CHARGE TO GROUND.

2. Firmly touch the clean, unpainted, metal surface of the fur-

nace chassis which is close to the control. Tools held in a

person's hand during grounding will be satisfactorily dis- charged.

3. After touching the chassis, you may proceed to service the control or connecting wires as long as you do nothing to

recharge your body with static electricity (for example; DO NOT move or shuffle your feet, do not touch ungrounded

objects, etc.).

4. If you touch ungrounded objects (and recharge your body with static electricity), firmly touch a clean, unpainted metal

surface of the furnace again before touching control or wires.

5. Use this procedure for installed and uninstatled (ungroun- ded) furnaces.

6. Before removing a new control from its container, dis- charge your body's electrostatic charge to ground to pro- tect the control from damage. If the control is to be installed

in a furnace, follow items 1 through 4 before bringing the control or yourself in contact with the furnace. Put all used and new controls into containers before touching ungroun- ded objects.

7. An ESD service kit (available from commercial sources) may also be used to prevent ESD damage.

LOCATION

GENERAL This multipoise furnace is shipped in packaged configuration.

Some assembly and modifications are required when used in any of the four applications shown in Figure 4.

NOTE: For high-altitude installations, the high-altitude conversion kit MUST be installed at or above 5500 ft. (1676 M) above sea level. Obtain high-attitude conversion kit from your

area authorized distributor.

AIRFLOW

THE BLOWER IS

LOCATED BELOW THE

BURNER SECTION, AND

CONDITIONEDAIR IS

DISCHARGEDUPWARD.

BURNER SECTION, AND

AIRCONDITIONEDAIR IS

DISCHARGEDTOTHE LEFT.

TOTHE RIGHT OFTHE f__.

HORIZONTALRIGHT [_

I .X AIRFLOW

THE BLOWER IS

LOCATEDABOVETHE

BURNER SECTION, AND

CONDITIONEDAIR IS

DISCHARGEDDOWNWARD AIRFLOW

441 01 2122 00 Specifications are subject to change without notice. 5

LOCATED TO THE LEFT

OF THE BURNER SECTION,

AND CONDITIONED AIR IS

THE BLOWER IS

DISCHARGED TO THE RIGHT.

A02097

This furnace must:

• be installed so the electrical components are protec- ted from water.

• not be installed directly on any combustible material other than wood flooring for upflow applications.

Downflow installations require use of a factory-ap-

proved floor base or coil model numbers END4X,

ENW4X or coil casing model number NAEA when installed on combustible materials or wood flooring (refer to SAFETY CONSIDERATIONS).

• be located close to the chimney or vent and attached to an air distribution system. Refer to Air Ducts sec-

tion.

• be provided ample space for servicing and cleaning. Always comply with minimum fire protection clear-

ances shown on the furnace clearance to combust-

ible construction label.

The following types of furnace installations may require

OUTDOOR AIR for combustion due to chemical exposures:

• Commercial buildings

• Buildings with indoor pools

• Laundry rooms

• Hobby or craft rooms, and

• Chemical storage areas

If air is exposed to the following substances, it should not be used for combustion air, and outdoor air may be required for

combustion:

• Permanent wave solutions

• Chlorinated waxes and cleaners

• Chlorine based swimming pool chemicals

• Water softening chemicals

• De-icing salts or chemicals

• Carbon tetrachloride

• Halogen type refrigerants

• Cleaning solvents (such as perchloroethylene)

• Printing inks, paint removers, varnishes, etc.

• Hydrochloric acid

• Cements and glues

• Antistatic fabric softeners for clothes dryers

• Masonry acid washing materials

All fuel-burning equipment must be supplied with air for fuel

combustion. Sufficient air must be provided to avoid negative pressure in the equipment room or space. A positive seal must

be made between the furnace cabinet and the return-air duct

to prevent pulling air from the burner area and from draft safeguard opening.

FIRE, INJURY OR DEATH HAZARD

Failure to follow this warning could result in personal injury, death and/or property damage.

When the furnace is installed in a residential garage, the

burners and ignition sources must be located at least 18 in. (457 mm) above the floor. The furnace must be

located or protected to avoid damage by vehicles. When

the furnace is installed in a public garage, airplane

hangar, or other building having a hazardous atmosphere, the furnace must be installed in accordance with the NFPA 54/ANSI Z223.1-2012. (See

Figure 5)

Figure 5 - Installation in a Garage

18-IN. (457.2 mm)

MINIMUM TO BURNERS

A93044

FIRE HAZARD

Failure to follow this warning could result in personal injury, death and/or property damage.

Do not install the furnace on its back or hang furnace with control compartment facing downward. Safety control operation will be adversely affected. Never

connect return-air ducts to the back of the furnace.

(See Figure 6)

LOCATION RELATIVE TO COOLING EQUIPMENT

The cooling coil must be installed parallel with, or on the downstream side of the unit to avoid condensation in the heat

exchangers. When installed parallel with the furnace, dampers or other flow control must prevent chilled air from entering the

furnace. If the dampers are manually operated, they must be equipped with means to prevent operation of either unit unless

the damper is in the full-heat or full-cool position.

6 Specifications are subject to change without notice. 441 01 2122 00

PERSONAL INJURY AND/OR PROPERTY DAMAGE HAZARD

Improper use or installation of this furnace may result in

premature furnace component failure. This gas furnace may be used for heating buildings under construction provided that:

-The furnace is permanently installed with all electrical wiring, piping, venting and ducting installed according to

these installation instructions. A return air duct is provided, sealed to the furnace casing, and terminated

outside the space containing the furnace. This prevents a

negative pressure condition as created by the circulating air blower, causing a flame rollout and/or drawing combustion products into the structure.

-The furnace is controlled by a thermostat. It may not be "hot wired" to provide heat continuously to the structure

without thermostatic control.

-Clean outside air is provided for combustion. This is to minimize the corrosive effects of adhesives, sealers and

other construction materials. It also prevents the entrainment of drywall dust into combustion air, which can cause fouling and plugging of furnace components.

-The temperature of the return air to the furnace is maintained between 55°F (13°C) and 80°F (27°C), with

no evening setback or shutdown. The use of the furnace while the structure is under construction is deemed to be

intermittent operation per our installation instructions.

-The air temperature rise is within the rated rise range on the furnace rating plate, and the gas input rate has been set to the nameplate value. -The filters used to clean the circulating air during the construction process must be either changed or thoroughly cleaned prior to occupancy.

-The furnace, ductwork and filters are cleaned as

necessary to remove drywall dust and construction debris from all HVAC system components after construction is completed.

-Verify proper furnace operating conditions including

ignition, gas input rate, air temperature rise, and venting according to these installation instructions.

Figure 6 - Prohibit Installation on Back

BACK J

A02054

Table 2 - Minimum Free Area Required for Each Combustion Air opening of Duct to Outdoors

TWO HORIZONTAL DUCTS SINGLE DUCT OR OPENING TWO OPENINGS OR VERTICAL DUCTS

FURNACE (1 SQ. IN./2,O00 BTUH) (1,100 SQ. MM/KW) (1 SQ. IN./3,O00 BTUH) (734 SQ. MM/KW) (1 SQ. IN./4,O00 BTUH) (550 SQ. MM/KW)

INPUT Free Area of Opening Round Duct Free Area of Opening Round Duct Free Area of Opening Round Duct

(BTUH) and Duct Dia. and Duct Dia. and Duct Dia.

44,000 22 (14194) 6 (152) 14.7 (9484) 5 (127) 11 (7096) 4 (102) 66,000 33 (21290) 7 (178) 22 (14193) 6 (152) 16.5 (10645) 5 (127)

88,000 44 (28387) 8 (203) 29.3 (18903) 7 (178) 22 (14193) 6 (152) 110,000 55 (35484) 9 (229) 36.7 (23677) 7 (178) 27.5 (17742) 6 (152) 132,000 66 (42580) 10 (254) 44 (28387) 8 (203) 33 (21290) 7 (178)

Sq. In. (Sq. mm) In. (mm) Sq. In. (Sq. mm) In. (mm) Sq. In. (Sq. mm) In. (mm)

EXAMPLES: Determining Free Area

FURNACE WATER HEATER TOTAL INPUT

110,000 + 30,000 (140,000 divided by 4,000) = 35.0 Sq. In. for each two Vertical Ducts or Openings

66,000 + 40,000 (106,000 divided by 3,000) = 35.3 Sq. In. for a Single Duct or Opening

88,000 + 30,000 (118,000 divided by 2,000) = 59.0 Sq. In. for each of two Horizontal Ducts

441 01 2122 O0 Specifications are subject to change without notice. 7

Table 3 - Minimum Space Volumes for 100% Combustion, Ventilation, and Dilution from Indoors

OTHER THAN FAN-ASSISTED TOTAL FAN-ASSISTED TOTAL

(1,000'S BTUH GAS INPUT RATE) (1,000'S BTUH GAS INPUT RATE)

30 40 50 44 66 88 110 132

ACH Space Volume Ft3 (M3)

0.60 1,050 (29.7) 1,400 (39.6) 1,750 (49.5) 1,100 (31.1) 1,650 (46.7) 2,200 (62.2) 2,750 (77.8) 3,300 (93.4)

0.50 1,260 (35.6) 1,680 (47.5) 2,100 (59.4) 1,320 (37.3) 1,980 (56.0) 2,640 (74.7) 3,300 (93.4) 3,960 (112.1)

0.40 1,575 (44.5) 2,100 (59.4) 2,625 (74.3) 1,650 (46.7) 2,475 (70.0) 3,300 (93.4) 4,125 (116.8) 4,950 (140.1)

0.30 2,100 (59.4) 2,800 (79.2) 3,500 (99.1) 2,200 (62.2) 3,300 (93.4) 4,400 (124.5) 5,500 (155.7) 6,600 (186.8)

0.20 3,150 (89.1) 4,200 (118.9) 5,250 (148.6) 3,300 (93.4) 4,950 (140.1) 6,600 (186.8) 8,250 (233.6) 9,900 (280.3)

0.10 6,300 (178.3) 8,400 (237.8) 10,500 (297.3) 6,600 (186.8) 9,900 (280.3) 13,200 (373.7) 16,500 (467.2) 19,800 (560.6)

0.00 NP NP NP NP NP NP NP NP

NP = Not Permitted

AIR FOR COMBUSTION AND

VENTILATION

Provisions for adequate combustion, ventilation, and dilution

air must be provided in accordance with:

• U.S. Installations: Section 9.3 of the NFPA 54/ANSI Z223.1-2012, Air for Combustion and Ventilation and applicable provisions of the local building codes.

FURNACE CORROSION HAZARD Failure to follow this caution may result in furnace

damage.

Air for combustion must not be contaminated by halogen

compounds, which include fluoride, chloride, bromide, and iodide. These elements can corrode heat

exchangers and shorten furnace life. Air contaminants are found in aerosol sprays, detergents, bleaches, cleaning solvents, salts, air fresheners, and other

household products.

CARBON MONOXIDE POISONING HAZARD

Failure to follow this warning could result in personal injury or death.

The operation of exhaust fans, kitchen ventilation fans, clothes dryers, attic exhaust fans or fireplaces could

create a NEGATIVE PRESSURE CONDITION at the furnace. Make-up air MUST be provided for the

ventilation devices, in addition to that required by the furnace. Refer to the Carbon Monoxide Poisoning Hazard warning in the venting section of these instructions to determine if an adequate amount of make-up air is

available.

The requirements for combustion and ventilation air depend

upon whether or not the furnace is located in a space having a

volume of at least 50 cubic feet per 1,000 Btuh input rating for all gas appliances installed in the space.

• Spaces having less than 50 cubic feet per 1,000 Btuh

require the OUTDOOR COMBUSTION AIR METH-

OD.

Figure 7 - Air for Combustion, Ventilation, and Dilution

for Outdoors

A-- 1 SQ IN.

DUCTS _ J/ BTUH*

PER 4000

(30Smm)12"MAX/ I I D I I I I 12"

1SQIN. _ _zCO VENT L.J MAX (305mm)

PER2000 IBI _b ITHROUGH I I F[]_

BTUH* _ _ ROOF T

©_ PER

TO i'.:_ _ : a

DUCTS Ili °°

OUTDOORS

f ................. _ ....

PER2000 ,I, ...... _ L_T

BTUH* T " I1 [7_

__ __ • J

:, I I _

/ linCOlN.

/I II

lS o.

PER

BTUH*

(30_mm)12"MAX C _' I_ (30_mm)

' ' i i 12"MAX I A

CIRCULATING AIR DUCTS _.

*Minimum dimensions of 3-in, (76 mm),

NOTE: Use any of the following combinations of openings:

A&BC&DD&EF&G

• Spaces having at least 50 cubic feet per 1,000 Btuh may use the INDOOR COMBUSTION AIR, STAND-

ARD or KNOWN AIR INFILTRATION METHOD.

Outdoor Combustion Air Method

1. Provide the space with sufficient air for proper combustion, ventilation, and dilution of flue gases using permanent hori-

zontal or vertical duct(s) or opening(s) directly communic- ating with the outdoors or spaces that freely communicate

with the outdoors.

2. Figure7 illustrates how to provide TWO OUTDOOR OPENINGS, one inlet and one outlet combustion and vent-

ilation air opening, to the outdoors.

a. One opening MUST commence within 12 in. (300

mm) of the ceiling and the second opening MUST commence within 12 in. (300 mm) of the floor.

b. Size openings and ducts per Figure 7 and Table 2.

DUCT]- "X_ISQIN.

J TO PER 4000

OUTDOORS BTUH*

AO3174

8 Specifications are subject to change without notice. 441 01 2122 00

c. TWO HORIZONTAL DUCTS require 1 sq. in. (645

sq. mm) of free area per 2,000 Btuh (1,100 mm2/kW)

of combined input for all gas appliances in the space per Figure 7 and Table 2.

d. TWO OPENINGS OR VERTICAL DUCTS require 1

sq. in. (645 sq. mm) of free area per 4,000 Btuh (550

mm2/kW) for combined input of all gas appliances in

the space per Figure 7 and Table 2.

ONE OUTDOOR OPENING requires:

a. 1 sq. in. (645 sq. mm) of free area per 3,000 Btuh

(734 mm2/kW) for combined input of atl gas appli-

ances in the space per Table 2 and

Not less than the sum of the areas of atl vent con- nectors in the space.

Figure

8 - Air for Combustion, Ventilation, and Dilution

from Indoors

CIRCULATING AiR

DUCTS

I I I

1 1 1

INTERIOR

HEATED

SPACE

i i

CIRCULATING AIR DUCTS

I ENT THROUGH ROOF

I I I I I I

I I I

(305ram)

Gz_ ------1 SQ IN.

PER t000 BTUH* IN DOOR

OR WALL

UNCONFINED SPACE

6" MIN (152mm) (FRONT)0

1 SQ IN.

PER 1000

: BTUH* IN DOOR

-- OR WALL

L 12" MAX (305ram)

CARBON MONOXIDE POISONING HAZARD Failure to follow this warning could result in personal

injury or death. Many homes require air to be supplied from outdoors

for furnace combustion, ventilation, and dilution of flue

gases.

The furnace combustion air supply must be provided in accordance with this instruction manual.

The Standard Method:

1. The space has no less volume than 50 cubic feet per

1,000 Btuh of the maximum input ratings for all gas appli-

ances installed in the space and

2. The air infiltration rate is not known to be less than 0.40 air changes per hour (ACH).

The Known Air Infiltration Rate Method shall be used, if the infiltration rate is known to be:

1. Less than 0.40 ACH and

2. Equal to or greater than 0.10 ACH

Infiltration rates greater than 0.60 ACH shall not be used. The minimum required volume of the space varies with the number

of ACH and shall be determined per Table 3 or Equations 1 and 2. Determine the minimum required volume for each

appliance in the space and add the volumes together to get the total minimum required volume for the space.

Table 3 - Minimum Space Volumes were determined by using the following equations from the National Fuel Gas Code

ANSI Z228.1-2012/NFPA 54-2012, 9.8.2.2:

1. For other than fan-assisted appliances, such as a draft

hood-equipped water heater:

Volume _ 21ft3 f" [other =_

Other ACH _000 Btu/hr)

A04002

2. For fan-assisted appliances such as this furnace:

* Minimum opening size is 100 sq in, (64516 sq, mm)with minimum dimensions of 3 in, (76 ram)

1 Minimum of 3 in, (76 mm) when type-B1 vent is used.

A03175

Volume

Fan

ACH 005 Btu/hr)

The opening shall commence within 12 in. (300 mm) of the

ceiling. Appliances in the space shall have clearances of at least 1 in. (25 mm) from the sides and back and 6 in. (150

mm) from the front. The opening shall directly communicate

with the outdoors or shall communicate through a vertical or

horizontal duct to the outdoors or spaces (crawl or attic) that

freely communicate with the outdoors.

Indoor Combustion Air© NFPA & AGA Standard and Known-Air-Infiltration Rate Methods

Indoor air is permitted for combustion, ventilation, and dilution, if the Standard or Known-Air-Infiltration Method is

used.

If: Iother = combined input of atl other than fan-assisted appliances in Btuh/hr

Ifan = combined input of all fan-assisted appliances in Btuh/hr ACH = air changes per hour (ACH shall not exceed 0.60.)

The following requirements apply to the Standard Method and to the Known Air Infiltration Rate Method.

1. Adjoining rooms can be considered part of a space if:

a. There are no closeable doors between rooms. b. Combining spaces on same floor level. Each open-

ing shall have free area of at least 1 in.2/1,000 Btuh (2,000 mm2/kW) of the total input rating of all gas

appliances in the space, but not less than 100 in.2 (0.06 m2). One opening shall commence within 12

in. (300 mm) of the ceiling and the second opening shall commence within 12 in. (300 mm) of the floor.

The minimum dimension of air openings shall be at least 3 in. (80 mm). (See Figure 8)

441 01 2122 00 Specifications are subject to change without notice. 9

A04003

c. Combining space on different floor levels. The

volumes of spaces on different floor levels shall be

considered as communicating spaces if connected by one or more permanent openings in doors or

floors having free area of at least 2 in.2/1,000 Btuh

(4,400 mm2/kW) of total input rating of all gas appli-

ances.

2. An attic or crawlspace may be considered a space that freely communicates with the outdoors provided there are

adequate permanent ventilation openings directly to out- doors having free area of at least 1-in.2/4,000 Btuh of total

input rating for all gas appliances in the space.

3. In spaces that use the Indoor Combustion Air Method, infiltration should be adequate to provide air for combus-

tion, permanent ventilation and dilution of flue gases. However, in buildings with unusually tight construction, ad-

ditional air MUST be provided using the methods de- scribed in the Outdoor Combustion Air Method section.

4. Unusually tight construction is defined as Construction with:

a. Walls and ceilings exposed to the outdoors have a

continuous, sealed vapor barrier. Openings are gas- keted or sealed and

b. Doors and openable windows are weatherstripped

and

c. Other openings are caulked or sealed. These in-

clude joints around window and door frames, between sole plates and floors, between wall-ceiling

joints, between wall panels, at penetrations for

plumbing, electrical and gas lines, etc.

Combination of Indoor and Outdoor Air

1. Indoor openings shall comply with the Indoor Combus- tion Air Method below and,

2. Outdoor openings shall be located as required in the Out- door Combustion Air Method mentioned previously and,

3. Outdoor openings shall be sized as follows:

a. Calculate the Ratio of all Indoor Space volume di-

vided by required volume for Indoor Combustion Air Method below.

b. Outdoor opening size reduction Factor is 1 minus

the Ratio in a. above.

c. Minimum size of Outdoor openings shall be the size

required in Outdoor Combustion Air Method above multiplied by reduction Factor in b. above. The min-

imum dimension of air openings shall be not less

than 3 in. (80 mm).

INSTALLATION

UPFLOW INSTALLATION

Bottom Return Air Inlet

These furnaces are shipped with bottom closure panel

installed in bottom return-air opening. Remove and discard

this panel when bottom return air is used. To remove bottom

closure panel, perform the following:

1. Tilt or raise furnace and remove 2 screws holding bottom filler panel. (See Figure 9)

2. Rotate bottom filler panel downward to release holding tabs.

3. Remove bottom closure panel.

4. Reinstall bottom filler panel and screws.

Side Return Air Inlet

These furnaces are shipped with bottom closure panel

installed in bottom return-air opening. This panel MUST be in place when only side return air is used.

Figure 9 - Removing Bottom Closure Panel

BOTTOM

CLOSURE

PANEL

BOTTOM FILLER PANEL

NOTE: Side return-air openings can be used in UPFLOW and most HORIZONTAL configurations. Do not use side

return-air openings in DOWNFLOW configuration. Leveling Legs (If Desired) In upflow position with side return inlet(s), leveling legs may be

used. (See Figure 10) Install field-supplied, 5/16 X 1-1/2 in. (8 X 38 mm) (max) corrosion-resistant machine bolts,

washers and nuts. NOTE: Bottom closure must be used when leveling legs are

used. It may be necessary to remove and reinstall bottom closure panel to install leveling legs. To remove bottom closure panel, see Item 1 in Bottom Return Air Inlet section in Step 1

above. To install leveling legs:

1. Position furnace on its back. Locate and drill a hole in each bottom corner of furnace. (See Figure 10)

Figure 10- Leveling Legs

(Smm)

1 3/4'

(44ram)

1 3/4"

(44mm)

(Smm)

5/16"

(Smm)

(44mm) 1 3/4"

(44mm) 1 3/4'{"_.,

A89014

2. For each leg, install nut on bolt and then install bolt with

nut in hole. (Install flat washer if desired.)

3. Install another nut on other side of furnace base. (Install flat washer if desired.)

4. Adjust outside nut to provide desired height, and tighten

inside nut to secure arrangement.

10 specificationsaresubjecttochangewithout notice. 441 01 2122 00

5. Reinstall bottom closure panel if removed. DOWNFLOW INSTALLATION

NOTE: For downflow applications, this furnace is approved for use on combustible flooring when any one of the following two

accessories are used:

• Downflow combustible floor subbase

• Coil model numbers END4X or ENW4X

• Coil casing model number NAEA

1. Determine application being installed from Table 4.

2. Construct hole in floor per Table 4 and Figure 11.

sides and not pull away from the furnace sides, so that the strap attachment screws are not in tension (are loaded in

shear) for reliable support. Platform Furnace Support Construct working platform at location where all required

furnace clearances are met. (See Figure 3 and Figure 17) For furnaces with 1-in. (25 mm) clearance requirement on side,

set furnace on non-combustible blocks, bricks or angle iron. For crawlspace installations, if the furnace is not suspended

from the floor joists, the ground underneath furnace must be level and the furnace set on blocks or bricks.

Figure 11 - Floor and Plenum Opening Dimensions

3. Construct plenum to dimensions specified in Table 4 and

Figure 11.

4. If downflow subbase is used, install as shown in

Figure 12. If coil model numbers END4X, ENW4X or coil casing model number NAEA are used, install as shown in Figure 13.

NOTE: It is recommended that the perforated supply-air duct

flanges be completely folded over or removed from furnace when installing the furnace on a factory-supplied cased coil or

coil casing. To remove the supply-air duct flange, use wide duct pliers or hand seamers to bend flange back and forth until it breaks off. Be careful of sharp edges. (See Figure 14)

Bottom Return Air Inlet

These furnaces are shipped with bottom closure panel

installed in bottom return-air opening. Remove and discard

this panel when bottom return air is used. To remove bottom

closure panel, perform the following:

1. Tilt or raise furnace and remove 2 screws holding bottom

filler panel. (See Figure 9)

2. Rotate bottom filler panel downward to release holding

tabs.

3. Remove bottom closure panel.

4. Reinstall bottom filler panel and screws. HORIZONTAL INSTALLATION

Roll-Out Protection

Provide a minimum 17-3/4-in. X 22-in. (451 X 559 mm) piece of sheet metal for flame roll-out protection in front of burner

area for furnaces closer than 12-in. (305 mm) above the combustible deck or suspended furnaces closer than 12-in.

(305 mm) to joists. The sheet metal MUST extend underneath the furnace casing by 1-in. (25 mm)with the door removed.

The bottom closure panel on furnaces of widths 17-1/2-in. (445 mm) and larger may be used for flame roll-out protection

when bottom of furnace is used for return air connection. See

FIRE, EXPLOSION, AND CARBON MONOXIDE POISONING HAZARD

Failure to follow this warning could result in personal injury, death, or property damage.

Do not install the furnace on its back or hang furnace with control compartment facing downward. Safety

control operation will be adversely affected. Never connect return-air ducts to the back of the furnace.

The furnace can be installed horizontally in an attic or

crawlspace on either the left-hand (LH) or right-hand (RH)

side. The furnace can be hung from floor joists, rafters or trusses or installed on a non-combustible platform, blocks,

bricks or pad. Suspended Furnace Support

The furnace may be supported under each end with threaded

rod, angle iron or metal plumber's strap as shown. (See Figure 15 and Figure 16) Secure angle iron to bottom of

furnace as shown. Heavy-gauge sheet metal straps

(plumber's straps) may be used to suspend the furnace from

Figure 17 for proper orientation of roll-out shield.

Bottom Return Air Inlet

These furnaces are shipped with bottom closure panel installed in bottom return-air opening. Remove and discard

this panel when bottom return air is used. To remove bottom closure panel, perform the following:

1. Tilt or raise furnace and remove two screws holding bottom filler panel. (See Figure 9)

2. Rotate bottom filler panel downward to release holding tabs.

3. Remove bottom closure panel.

4. Reinstall bottom filler panel and screws.

Side Return Air Inlet These furnaces are shipped with bottom closure panel

installed in bottom return-air opening. This panel MUST be in place when side return air inlet(s) are used without a bottom

return air inlet. Not all horizontal furnaces are approved for side return air

connections (See Figure 20)

each bottom corner. To prevent screws from pulling out, use 2

#8 x in. screws into the side and 2 #8 x in. screws in the

bottom of the furnace casing for each strap. (See Figure 15

and Figure 16)

If the screws are attached to ONLY the furnace sides and not

the bottom, the straps must be vertical against the furnace

441 01 2122 00 Specifications are subject to change without notice.

A96283

Figure 12 - Furnace, Plenum, and Subbase Installed on a Figure 13 - Furnace, Plenum, and Coil or Coil Casing In-

Combustible Floor stalled on a Combustible Floor

FURNACE

(OR COIL CASING

WHEN USED)

FURNACE

APPROVED

COIL ASSEMBLY

COIL BOX

,------ COMBUSTIBLE

FLOORING

SUBBASE

SHEET METAL

PLENUM

__ FLOOR __

OPENING

j_ COMBUSTIBLE _'X

FLOORING

SHEET METAL

PLENUM

FLOOR

OPENING

A96285

Table 4 - Opening Dimensions - In. (mm)

FURNACE

CASING

WIDTH

APPLICATION

IN. (mm)

Upflow Applications on Combustible or Noncombustible 12-11/16 21-5/8 13-5/16 22-1/4

Flooring (subbase not required) (322) (549) (338) (565)

Downflow Applications on Noncombustible Flooring 12-9/16 19 13-3/16 19-5/8

14-3/16 (subbase not required) (319) (483) (335) (498)

(360) Downflow applications on Combustible Flooring 11-13/16 19 13-7/16 20-5/8

(subbase required) (284) (483) (34t) (600)

Downflow Applications on Combustible Flooring with Coil 12-5/16 19 13-5/16 20

END4X, ENW4X or Coil Casing NAEA (subbase not required) (319) (483) (338) (508)

Upflow Applications on Combustible or Noncombustible 16 21-5/8 16-5/8 22-1/4

Flooring (subbase not required) (406) (549) (422) (565)

Downflow Applications on Noncombustible Flooring 15-7/8 19 16-1/2 19-5/8

17-1/2 (subbase not required) (403) (483) (419) (498)

(445) Downflow Applications on Combustible Flooring 15-1/8 19 16-3/4 20-5/8

(subbase required) (384) (483) (425) (600)

Downflow Applications on Combustible Flooring with Coil 15-1/2 19 16-1/2 20

END4X, ENW4X or Coil Casing NAEA (subbase not required) (394) (483) (419) (508)

Upflow Applications on Combustible or Noncombustible 19-1/2 21-5/8 20-1/8 22-1/4

Flooring (subbase not required) (495) (549) (511) (565)

Downflow Applications on Noncombustible Flooring 19-3/8 19 20 19-5/8

21 (subbase not required) (492) (483) (508) (498)

(533) Downflow Applications on Combustible Flooring 18-5/8 19 20-1/4 20-5/8

(subbase required) (473) (483) (514) (600)

Downflow Applications on Combustible Flooring with Coil 19 19 20 20

END4X, ENW4X or Coil Casing NAEA (subbase not required) (483) (483) (508) (508)

Upflow Applications on Combustible or Noncombustible 23 21- 1/8 23-5/8 22-1/4

Flooring (subbase not required) (584) (537) (600) (565)

Downflow Applications on Noncombustible Flooring 22-7/8 19 23-1/2 19-5/8

24-1/2 (subbase not required) (581) (483) (597) (498)

(622) Downflow Applications on Combustible Flooring 22-1/8 19 23-3/4 20-5/8

(subbase required) (562) (483) (603) (600)

Downflow Applications on Combustible Flooring with Coil 22-1/2 19 23-1/2 20

END4X, ENW4X or Coil Casing NAEA (subbase not required) (572) (483) (597) (508)

PLENUM OPENING FLOOR OPENING

A B C D

A08556

12 specificationsaresubjecttochangewithout notice. 441 01 2122 00

Filter Arrangement

CARBON MONOXIDE POISONING HAZARD

Failure to follow this warning could result in personal injury, or death.

Never operate a furnace without a filter or with filter access door removed.

There are no provisions for an internal filter rack in these furnaces. A field-supplied accessory external filter rack is

required.

Refer to the instructions supplied with the external filter rack for assembly and installation options. AIR DUCTS

General Requirements The duct system should be designed and sized according to

accepted national standards such as those published by: Air

Conditioning Contractors Association (ACCA), Sheet Metal and Air Conditioning Contractors National Association

(SMACNA) or American Society of Heating, Refrigerating and Air Conditioning Engineers (ASHRAE) or consult The Air

Systems Design Guidelines reference tables available from your local distributor. The duct system should be sized to

handle the required system design CFM at the design external static pressure. The furnace airflow rates are provided in Table

12 Air Delivery-CFM (with Filter). When a furnace is installed so that the supply ducts carry air circulated by the furnace to

areas outside the space containing the furnace, the return air shall also be handled by duct(s) sealed to the furnace casing and terminating outside the space containing the furnace.

Secure ductwork with proper fasteners for type of ductwork

used. Seal supply- and return-duct connections to furnace with code approved tape or duct sealer.

NOTE: Flexible connections should be used between

ductwork and furnace to prevent transmission of vibration.

Ductwork passing through unconditioned space should be insulated to enhance system performance. When air

conditioning is used, a vapor barrier is recommended. Maintain a 1-in. (25 mm) clearance from combustible

materials to supply air ductwork for a distance of 36-in. (914 mm) horizontally from the furnace. See NFPA 90B or local

code for further requirements. Ductwork Acoustical Treatment

NOTE: Metal duct systems that do not have a 90 degree elbow and 10 ft. (3 M) of main duct to the first branch take-off

may require internal acoustical lining. As an alternative, fibrous ductwork may be used if constructed and installed in

accordance with the latest edition of SMACNA construction standard on fibrous glass ducts. Both acoustical lining and

fibrous ductwork shall comply with NFPA 90B as tested by UL Standard 181 for Class 1 Rigid air ducts.

Supply Air Connections For a furnace not equipped with a cooling coil, the outlet duct

shall be provided with a removable access panel. 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 possible openings using light assistance or a probe can be inserted for sampling the air stream. The cover attachment

shall prevent leaks. Upflow and Horizontal Furnaces

Connect supply-air duct to flanges on furnace supply-air outlet. Bend flange upward to 90 ° with wide duct pliers. (See

Figure 14) The supply-air duct must be connected to ONLY the furnace supply-outlet-air duct flanges or air conditioning

coil casing (when used). DO NOT cut main furnace casing side to attach supply air duct, humidifier, or other accessories.

All accessories MUST be connected to duct external to furnace main casing.

NOTE: For horizontal applications, the top most flange may be bent past 90 ° to allow the evaporator coil to hang on the flange temporarily while the remaining attachment and sealing of the coil are performed.

Figure 14 - Duct Flanges

UPFLOW DOWN FLOW HORIZONTAL

YES

441 01 2122 O0 specificationsaresubjecttochangewithout notice. 13

YES

120°_

MIN

YES

A02020

UTER DOOF

ASSEMBLY

8" (203mm) MIN FOR DOOR REMOVAL

Figure 15 - Horizontal Unit Suspension

4 REQ.

l / 1/4"(6mm) THREADED ROD

1" (25mm) SQUARE, 1-1/4"xl-1/4"xt/8" (32x32x3mm)

ANGLE IRON OR UNI-STRUT MAY BE USED

SECURE ANGLE IRON TO BOTTOM OF FURNACE WiTH 3 #8 xS/4'' (19ram) SCREWS

TYPICAL FOR 2 SUPPORTS

(2) HEX NUTS, (2) WASHERS & (2) LOCK WASHERS REQ. PER ROD

Figure 16 - Horizontal Suspension with Straps

OUTER DOOR

ASSEMBLY X II

A10130

22 GAUGE GALVANIZED STRAPS TYPICAL

FOR 4 STRAPS

AIR

BACK OF FURNACE

METHOD 1 FOLD ALL STRAPS UNDER FURNACE AND SECURE WTH

(4) #8 x 3/4 (19 ram) SHEET METAL SCREWS 12SCREWS IN SIDE AND 2 SCREWS IN BOTTOM).

METHOD 2 USE (4) #8 x 3/4 (19 ram) SHEET

METAL SCREWS FOR EACH STRAR THE STRAPS SHQULD BE VERTICAL AGAINST THE FURNACE SIDES AND NOT PULL AWAY FROM THE FURNACE SIDES.

AIR OPENING

14 specificationsaresubjecttochangewithout notice. 441 01 2122 00

A10131

Figure 17 - Typical Attic Installation

LINE CONTACT ONLY PERMISSIBLE BETWEEN

LINES FORMED BY INTERSECTIONS OF THE TOP AND TWO SIDES OF THE FURNACE JACKET AND BUILDING JOISTS,

STUDS, OR FRAMING.

ENTRY

VENT

17 3/4" (451 mm)OVERALL 4 3/4" (121mm) UNDER DOOR 1" (25mm) UNDER FURNACE

EXTEND OUT 12" (305mm) FROM FACE OF DOOR

EQUIPMENT MANUAL

SHUT-OFF GAS VALVE

SEDIMENT UNION

TRAP

Downflow Furnaces

Connect supply-air duct to supply-air outlet on furnace. Bend

flange inward past 90 ° with wide duct pliers (See Figure 14) The supply-air duct must be connected to ONLY the furnace

supply outlet or air conditioning coil casing (when used). When

installed on combustible material, supply-air duct must be

Figure 18 - Upflow Return Air Configurations and Restrictions

_0-1N.(762mm)

MIN WORK AREA

*WHEN USED WITH SINGLE WALL VENT

CONNECTIONS

A10164

connected to ONLY the accessory subbase or a factory approved air conditioning coil casing. DO NOT cut main

furnace casing to attach supply side air duct, humidifier, or other accessories. All accessories MUST be connected to

duct external to furnace casing.

RETURN _

AIR

AIR _! ) RESTRICTIONS

RETURN T UPFLOW

RETURN AIR

UPFLOW RETURN AIR CONFIGURATIONS AND RESTRICTIONS

AiR FLOW MODELS RETURN AiR RETURN AiR RETURN AIR RETURN AiR

5 TONS AND YES YES YES YES GREATER *

ALL OTHER MODELS YES YES YES YES

• 2000 CFM AND GREATER AT ,6 ESP HI COOLING SPEED

<::: %-

RETURN

AIR

CONNECTION 1 CONNECTION 2 CONNECTION 3 COMBiNATiONS ONLY ONLY ONLY OF 1,2, AND 3

441 01 2122 00 specificationsaresubjecttochangewithout notice. 15

/\_x SIDERETURNAIR

\xJ NOT PERMI_ED FOR

AIR

RETURN

'\// "_ SIDERETURN AIR

/' 066,060, -22-20

• NOTE:RESTRICTIONSAME FOR AIR HORIZONALLEFT

Figure 19 - Downflow Return Air Configurations and Restrictions

DOWNFLOW RETURN AIR CONFIGURATIONS AND RESTRICTIONS

AmR FLOW MODELS RETURN AmR RETURN AIR RETURN AiR RETURN AIR

5 TONS AND YES NO NO NO GREATER *

ALL OTHER MODELS YES NO NO NO

CONNECTION 1 CONNECTION 2 CONNECTION 3 COMBINATIONS ONLY ONLY ONLY OF 1, 2, AND 3

Figure 20 - Horizontal Return Air Configurations and Restrictions

RETURN

AIR

066,060,-22-2O AIRFLOWMODELS

.....i,

iiii

HORIZONAL RETURN AIR RESTRICTIONS

HORIZONTAL RETURN AIR CONFIGURATIONS AND RESTRICTIONS

AiR FLOW MODELS RETURN AIR RETURN AIR RETURN AIR RETURN AIR

5 TONS AND YES NO NO NO GREATER *

ALL OTHER MODELS YES YES YES YES

• 2000 CFM AND GREATER AT .6 ESP HI COOLING SPEED

CONNECTION 1 CONNECTION 2 CONNECTION 3 COMBINATIONS ONLY ONLY ONLY OF 1,2, AND 3

16 specificationsaresubjecttochangewithout notice. 441 01 2122 00

Return Air Connections

FIRE HAZARD

A failure to follow this warning could cause personal injury, death and/or property damage.

Never connect return-air ducts to the back of the furnace. Follow instructions below.

Downflow Furnaces

The return-air duct must be connected to return-air opening

(bottom inlet) as shown in Figure 1. DO NOT cut into casing

sides (left or right). Side opening is permitted for only upflow and certain horizontal furnaces. Bypass humidifier

connections should be made at ductwork or coil casing sides exterior to furnace. (See Figure 19)

Upflow and Horizontal Furnaces

The return-air duct must be connected to bottom, sides (left or

right), or a combination of bottom and side(s) of main furnace casing as shown in Figure 1. Bypass humidifier may be

attached into unused return air side of the furnace casing.

(See Figure 18 and Figure20) Not all horizontal furnace models are approved for side return air connections. (See Figure 20) GAS PIPING

FIRE OR EXPLOSION HAZARD Failure to follow this warning could result in personal

injury, death, and/or property damage. Never purge a gas line into a combustion chamber.

Never test for gas leaks with an open flame. Use a commercially available soap solution made specifically for the detection of leaks to check all connections. A fire

or explosion may result causing property damage, personal injury or loss of life.

FIRE OR EXPLOSION HAZARD Failure to follow this warning could result in personal

injury, death, and/or property damage. Use proper length of pipe to avoid stress on gas

control manifold and a gas leak.

Installations must be made in accordance with all authorities having jurisdiction. If possible, the gas supply line should be a

separate line running directly from meter to furnace. NOTE: In the state of Massachusetts:

1. Gas supply connections MUST be performed by a li- censed plumber or gas fitter.

2. When flexible connectors are used, the maximum length shall not exceed 36 in. (915 mm).

3. When lever handle type manual equipment shutoff valves are used, they shall be T-handle valves.

4. The use of copper tubing for gas piping is NOT approved by the state of Massachusetts.

Refer to Table 5 for recommended gas pipe sizing. Risers must be used to connect to furnace and to meter. Support all

gas piping with appropriate straps, hangers, etc. Use a minimum of 1 hanger every 6 ft. (1.8 M). Joint compound (pipe

dope) should be applied sparingly and only to male threads of joints. Pipe dope must be resistant to the action of propane

gas.

Table 5 - Maximum Capacity of Pipe*

NOMINAL

IRON

PIPE SIZE

IN. (aM)

1/2 (12.7)

3/4 (19.0)

1 (25.4)

1-1/4

(31.8)

1-1/2

(38.1)

* Cubic ft of gas per hr for gas pressures of 0,5 psig (14- in, W,C,) or less and a pressure drop of 0.5-In. W.C. (based on a 0.60 specific gravity gas). Ref: Table 6

and 9.2 NFGC.

INTERNAL

DIA.

IN. (aM)

0.622 (158)

0.824 (20.9)

1.049 (26.6)

1.380 (35.0) 580

1.610 (40.9) 2100 1460 1180 990 900

LENGTH OF PIPE - FT (M)

10 20 30 40 50

(3.0) (6.0) (9.1) (12,1) (15.2)

175 120 97 82 73

360 250 200 170 151 680 465 375 320 285

1400 950 770 660

FIRE OR EXPLOSION HAZARD

A failure to follow this warning could result in personal

injury, death, and/or property damage. If local codes allow the use of a flexible gas appliance

connector, always use a new listed connector. Do not use a connector which has previously served another

gas appliance. Black iron pipe shall be installed at the furnace gas control valve and extend a minimum of 2-in. (51 mm) outside the furnace.

FURNACE DAMAGE HAZARD

Failure to follow this caution may result in furnace

FIRE OR EXPLOSION HAZARD Failure to follow this warning could result in personal

injury, death, and/or property damage. Gas valve inlet and/or inlet pipe must remain capped

damage. Connect gas pipe to furnace using a backup wrench

to avoid damaging gas controls and burner misatignment.

until gas supply line is permanently installed to protect the valve from moisture and debris. Also, install a sediment trap in the gas supply piping at the inlet to the gas valve.

Gas piping must be installed in accordance with national and local codes. Refer to current edition of NFGC in the U.S.

An accessible manual equipment shutoff valve MUST be installed external to furnace casing and within 6 ft. (1.8 M) of

furnace. A 1/8-in. (3 mm) NPT plugged tapping, accessible for test gauge connection, MUST be installed immediately

upstream of gas supply connection to furnace and downstream of manual equipment shutoff valve.

441 01 2122 00 specificationsaresubjecttochangewithout notice. 17

NOTE: The furnace gas control valve inlet pressure tap connection is suitable to use as test gauge connection providing test pressure DOES NOT exceed maximum 0.5 psig (14-1n. W.C.) stated on gas control valve. (See Figure 49)

Some installations require gas entry on right side of furnace (as viewed in upflow). (See Figure 21)

Install a sediment trap in riser leading to furnace as shown in Figure 22. Connect a capped nipple into lower end of tee. Capped nipple should extend below level of furnace gas controls. Place a ground joint union between furnace gas

control valve and exterior manual equipment gas shutoff valve.

A 1/8-in. (3 ram) NPT plugged tapping, accessible for test

gauge connection, MUST be installed immediately upstream of gas supply connection to furnace and downstream of manual equipment shutoff valve.

Piping should be pressure and leak tested in accordance with

the current addition of the NFGC in the United States, local, and national plumbing and gas codes before the furnace has

been connected. After all connections have been made, purge lines and check for leakage at furnace prior to operating

furnace.

If pressure exceeds 0.5 psig (14-1n. W.C.), gas supply pipe must be disconnected from furnace and capped before and

during supply pipe pressure test. Iftest pressure is equal to or less than 0.5 psig (14-1n. W.C.), turn off electric shutoff switch located on furnace gas control valve and accessible manual equipment shutoff valve before and during supply pipe

pressure test. After all connections have been made, purge lines and check for leakage at furnace prior to operating

furnace. The gas supply pressure shall be within the maximum and

minimum inlet supply pressures marked on the rating plate

with the furnace burners ON and OFF.

Figure 21 - Burner and Manifold

TOP VIEW OF BURNER AND MANIFOLD ASSEMBLY

I_ LI J_ I L_ To Gas

7_ j supply

2" (51ram)Nipple /_

Street Etbov7

t-Gas Valve

A08551

ELECTRICAL CONNECTIONS

ELECTRICAL SHOCK, FIRE OR EXPLOSION HAZARD

Failure to follow safety warnings could result in dangerous operation, serious injury, death or property damage. Improper servicing could result in dangerous operation,

serious injury, death or property damage.

• Before servicing, disconnect all electrical power to furnace.

• When servicing controls, label all wires prior to disconnecting. Reconnect wires correctly.

• Verify proper operation after servicing.

ELECTRICAL SHOCK HAZARD

Failure to follow this warning could result in personal injury or death.

Blower access panel door switch opens 115-v power to control. No component operation can occur. Do not bypass or close switch with panel removed.

See Figure 25 for field wiring diagram showing typical field 115-v wiring. Check all factory and field electrical connections

for tightness. Field-supplied wiring shall conform with the limitations of 63°F

(33°0) rise.

ELECTRICAL SHOCK AND FIRE HAZARD

Failure to follow this warning could result in personal injury, death, or property damage.

The cabinet MUST have an uninterrupted or unbroken

ground according to NEC NFPA 70-2011 or local codes to minimize personal injury if an electrical fault should occur.

This may consist of electrical wire, conduit approved for

electrical ground or a listed, grounded power cord (where permitted by local code) when installed in accordance with existing electrical codes. Refer to the power cord manufacturer's ratings for proper wire gauge. Do not use gas piping as an electrical ground.

Figure 22 - Typical Gas Pipe Arrangement

FURNACE MAY NOT OPERATE HAZARD

GAS

sUPPLY

MANUALJ II SHUTOFF _[ =

VALVE

SEDIMENT_

(REQUIRED).,_'_ f

TRAP /

UNION---j

Failure to follow this caution may result in intermittent

furnace operation.

Furnace control must be grounded for proper operation or

else control will lock out. Control must remain grounded through green/yellow wire routed to gas valve and manifold bracket screw.

115-V Wirinq Verify that the voltage, frequency, and phase correspond to

that specified on unit rating plate. Also, check to be sure that service provided by utility is sufficient to handle load imposed

by this equipment. Refer to rating plate or Table 6 for equipment electrical specifications.

U,S, Installations: Make all electrical connections in accordance with National Electrical Code (NEC) NFPA

A02035

18 specificationsaresubjecttochangewithout notice. 441 01 2122 00

70-2011 and any local codes or ordinances that might apply.

Table 6 - Electrical Data

VOLTS-

HERTZ-

FURNACE SIZE

0451412B 0701716B 0902116B 1102122B 1352422B

* Permissible limits of the voltage range at which the unit operates satisfactorily.

# Unit ampacity = 125 percent of largest operating component's full load amps plus 100 percent of all other potential operating components' (EAC, humidifier, etc.) full load amps. 1"Time-delay type is recommended.

SLength shown is as measured 1 way along wire path between furnace and service panel for maximum 2 percent voltage drop.

PHASE

115-60-1 115-60-1

115-60-1 115-60-1 115-60-1

OPERATING

VOLTAGE RANGE

Max. Min.

127 104 127 104

127 104 127 104 127 104

MAX. UNIT

AMPS

8.0

9.6

10.2

13.0

UNIT

AMPAClTY

10.8

12.8

13.4

16.8

MIN. WIRE SIZE AWG

14 14

14 12 12

MAX. WIRE

LENGTH - FT"(M)_:

34 (10.4)

28 (8.5) 27 (8.2)

34 (10.4) 34 (10.4)

MAX. FUSE OR

CKT BKR AMPS 1"

15 15

15 2O 2O

1. Select and remove a hole knockout in the casing where the electrical box is to be installed.

NOTE: Check that duct on side of furnace will not interfere

FIRE HAZARD

Failure to follow this warning could result in personal injury, death, or property damage.

Do not connect aluminum wire between disconnect switch and furnace. Use only copper wire.

with installed electrical box.

2. Remove the desired electrical box hole knockout and posi- tion the hole in the electrical box over the hole in the fur-

nace casing.

3. Fasten the electrical box to casing by driving two field-sup- plied screws from inside electrical box into casing steel.

Use a separate, fused branch electrical circuit with a properly

Figure 23 - Relocating J-Box

sized fuse or circuit breaker for this furnace. See Table 6 for wire size and fuse specifications. A readily accessible means

of electrical disconnect must be located within sight of the

furnace.

NOTE: Proper polarity must be maintained for 115-v wiring. If

FACTORY INSTALLED

LOCATION

ALTERNATE FIELD

LOCATION

polarity is incorrect, control LED status indicator light will flash rapidly and furnace wilt NOT operate.

J-Box Relocation

NOTE: If factory location of J-Box is acceptable, go to next

section (ELECTRICAL CONNECTION to J-Box).

NOTE: On 14-in. (356 mm) wide casing models, the J-Box shall not be relocated to other side of furnace casing when the vent pipe is routed within the casing.

1. Remove and save two screws holding J-Box. (See Figure 23)

NOTE: The J-Box cover need not be removed from the

J-Box in order to move the J-Box. Do NOT remove green

ground screw inside J-Box. (See Figure 23)

2. Cut wire tie on loop in furnace wires attached to J-Box.

3. Move J-Box to desired location.

4. Fasten J-Box to casing with the two screws removed in Step 1.

5. Route J-Box wires within furnace away from sharp edges, rotating parts and hot surfaces.

Electrical Connection to J-Box Electrical Box on Furnace Casing Side (See Figure 24)

4. Remove and save two screws holding J-Box. (See

Figure 23)

5. Pull furnace power wires out of 1/2-in. (12 mm) diameter hole in J-Box. Do not loosen wires from strain-relief wire-

tie on outside of J-Box.

6. Route furnace power wires through holes in casing and

electrical box and into electrical box.

7. Pull field power wires into electrical box.

8. Remove cover from furnace J-Box.

9. Route field ground wire through holes in electrical box and

casing, and into furnace J-Box.

FIRE OR ELECTRICAL SHOCK HAZARD Failure to follow this warning could result in personal

injury, death, or property damage.

10. Reattach furnace J-Box to furnace casing with screws re-

moved in Step 4.

11. Secure field ground wire to J-Box green ground screw.

If field-supplied manual disconnect switch is to be mounted on furnace casing side, select a location

where a drill or fastener cannot damage electrical or

gas components.

441 01 2122 00 specificationsaresubjecttochangewithout notice. 19

Figure 24 - Field-Supplied Electrical Box on Furnace

Casing

12. Complete electrical box wiring and installation. Connect line voltage leads as shown in Figure 24. Use best prac-

tices (NEC in U.S. for wire bushings, strain relief, etc.

13. Reinstall cover to J-Box. Do not pinch wires between cov- er and bracket.

Power Cord Installation in Furnace J-Box NOTE: Power cords must be able to handle the electrical

requirements listed in Table 5. Refer to power cord manufacturer's listings.

1. Remove cover from J-Box.

2. Route listed power cord through 7/8-in. (22 mm) diameter hole in J-Box.

3. Secure power cord to J-Box bracket with a strain relief bushing or a connector approved for the type of cord used.

4. Secure field ground wire to green ground screw on J-Box bracket.

5. Connect line voltage leads as shown in Figure 25.

6. Reinstall cover to J-Box. Do not pinch wires between cov- er and bracket.

BX Cable Installation in Furnace J-Box

1. Remove cover from J-Box.

2. Route BX cable into 7/8-in. (22 mm) J-Box.

diameter hole in

3. Secure BX cable to J-Box bracket with connectors ap- proved for the type of cable used.

4. Secure field ground wire to green ground screw on J-Box bracket.

5. Connect line voltage leads as shown in Figure 25.

6. Reinstall cover to J-Box. Do not pinch wires between cov- er and bracket.

24-V Wiring Make field 24-v connections at the 24-v terminal strip. (See

Figure 25 - Figure 33) Connect terminal Y/Y2 as shown in Figure 27 - Figure 33 for proper cooling operation. Use only

AWG No. 18, color-coded, copper thermostat wire. The 24-v circuit contains an automotive-type, 3-amp. fuse

located on the control. Any direct shorts during installation, service, or maintenance could cause this fuse to blow. If fuse

replacement is required, use ONLY a 3-amp. fuse of identical size.

ACCESSORIES

1. Electronic Air Cleaner (EAC) Connect an accessory Electronic Air Cleaner (if used) us-

ing 1/4-in female quick connect terminals to the two male 1/4-in quick-connect terminals on the control board

marked EAC-1 and EAC-2. The terminals are rated for

115VAC, 1.0 amps maximum and are energized during

blower motor operation. (See Figure 26)

2. Humidifier (HUM) Connect an accessory 24 VAC, 0.5 amp. maximum humid-

ifier (if used) to the 1/4-in male quick-connect HUM ter-

minal and COM-24V screw terminal on the control board thermostat strip. The HUM terminal is energized when

blower is energized in heating. (See Figure 26)

NOTE: DO NOT connect furnace control HUM terminal to H terminal on humidity sensing thermostat, or similar device. See

the humidity sensing thermostat, instructions for proper connection.

VENTING

The furnace shall be connected to a listed factory built chimney or vent, or a clay-tile lined masonry or concrete chimney. Venting into an unlined masonry chimney or

concrete chimney is prohibited. When an existing Category I furnace is removed or replaced,

the original venting system, may no longer be sized to properly vent the attached appliances. An improperly sized Category I

venting system could cause the formation of condensate in the furnace and vent, leakage of condensate and combustion

products, and spillage of combustion products into the living space.

20 Specifications are subject to change without notice. 441 01 2122 00

Figure 25 - Example of Field Wiring Diagram

.... FIELD 24-VOLT WIRING

.... FIELD 115-, 208/230-, 460-VOLT WIRING

-- FACTORY 24-VOLT WIRING FACTORY 115-VOLT WIRING

NOTE 2

r 11-STAGE

FIVE-- J('w) _ _ _ _ ITHERMOSTAT

.... "_. I Y "T_ Y I TERM NALS FED-SUPPLIED

vvFm__ I I I { 1 FUSED DISCONNECT

THREE-WIRE _ I I I _

HEATING- "_ ' ' _ ' '

ONLY _ II _ tt

/_ _ 4^,oh I I I { l PHASE

==__===] 208/280-

==._Q===L VOLT

115-VOLT FIELD-

SUPPLIED

FUSED

DISCONNECT

JUNCTION BOX @

CONTROL

BOX @

_ L____i£ L

CONDENSING

UNIT

24-VOLT

TERMINAL

BLOCK

FURNACE

NOTES: 1. Connect Y/Y2-terminal as shown for proper operation.

2. Some thermostats require a "C" terminal connection as shown.

3. Ifany ofthe original wire, as supplied, must be replaced, use same type or equivalent wire.

Figure 26 - Example of Variable Speed Furnace Control for Variable Speed ECM Blower Motor

I-_J'J - -I (SINGLE

==_===_.= =.._=== JPHASE

I - GNDI

208/230- OR 460-VOLT

A95236

SW1 SETUP MODEL PLUG OUTDOOR AIR CONDITIONING (A/C) & HUMIDIFIER

SWITCHES AND CONNECTOR AIR TEMP CONTINUOUS FAN (CF) TERMINAL (24-VAC

BLOWER OFF- CONNECTOR AIRFLOW SETUP SWITCHES 0.5 AMP MAX.)

DELAY _ /

COMMUNICATION

CONNECTOR

24-V THERMOSTAT I

STATusTAI:cD: '_:: 1

PL1 - LOW VOLTAGE MAIN \

HARNESS CONNECTOR

3-AMP FUSE

TRANSFORMER 24-VAC

CONNECTIONS

HUM

oii -

FUSE 3-AMP _"

.._EUTRAL-L_ / El _"10 O _"113P'L2

ACRDJ

[]

_OAT /

FLASH

UPGRADE

CONNECTOR

(FACTORY

ONLY)

LO., IV0t#*4 FZ00 WW I

ACRDJ - AIR

CONDITIONING

RELAY DISABLE

JUMPER

115-VAC (L2) NEUTRAL

CONNECTIONS

115-VAC (L1) LINE EAC-1 TERMINAL iGNiTER & INDUCER VERSION

VOLTAGE CONNECTIONS (115-VAC 1.0 AMP MAX.) MOTOR CONNECTOR

PL2 - HOT SURFACE SOFTWARE

441 01 2122 00 Specifications are subject to change without notice. 21

L14F003

CARBON MONOXIDE POISONING HAZARD Failure to follow the steps outlined below for each

appliance connected to the venting system being placed into operation could result in carbon monoxide poisoning or death.

The following steps shall be followed for each appliance connected to the venting system being placed into operation, while all other appliances connected to the venting system are not in operation:

1. Seal any unused openings in venting system.

2. Inspect the venting system for proper size and horizontal pitch, as required in the National Fuel Gas Code, NFPA 54/ANSI Z223.1-2012 and these

instructions. Determine that there is no blockage or restriction, leakage, corrosion and other deficiencies,

which could cause an unsafe condition.

3. As far as practical, close all building doors and

windows and all doors between the space in which the appliance(s) connected to the venting system

are located and other spaces of the building.

4. Close fireplace dampers.

5. Turn on clothes dryers and any appliance not connected to the venting system. Turn on any

exhaust fans, such as range hoods and bathroom exhausts, so they are operating at maximum speed.

Do not operate a summer exhaust fan.

6. Follow the lighting instructions. Place the appliance being inspected into operation. Adjust the thermostat

so appliance is operating continuously.

7. Test for spillage from draft hood equipped

appliances at the draft hood relief opening after 5

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

8. If improper venting is observed during any of the

above tests, the venting system must be corrected in accordance with the National Fuel Gas Code, NFPA 54/ANSI Z223.1-2012.

9. After it has been determined that each appliance connected to the venting system properly vents

when tested as outlined above, return doors, windows, exhaust fans, fireplace dampers and any

other gas-fired burning appliance to their previous conditions of use.

13 in the United States, the local building codes, and furnace and vent manufacturers' instructions.

The following information and warning must be considered in addition to the requirements defined in the NFGC.

CARBON MONOXIDE POISONING HAZARD Failure to follow this warning could result in personal

injury or death. Do not bypass the draft safeguard switch, as an

unsafe condition could exist which must be corrected.

1. If a vent (common or dedicated) becomes blocked, the fur- nace will be shut off by the draft safeguard switch located

on the vent elbow.

2. Two-stage furnaces require Type B vent connectors out-

side the casing in all configurations. Single wall vent con-

nector may be used inside the furnace casing with the

transition to Type B vent outside the furnace casing. Size the connector so that the FAN-Min vent connector capa- city is equal to or lower than the low fire rate of the furnace and the FAN-Max vent connector capacity is equal to or

higher than the furnace high fire rate.

3. Do not vent this Category I furnace into a single wall dedic-

ated or common vent. The dedicated or common vent is considered to be the vertical portion of the vent system

that terminates outdoors.

4. Vent connectors serving Category I furnaces shall not be

connected into any portion of a mechanical draft system operating under positive pressure.

5. Do not vent this appliance with any solid fuel burning appli-

ance.

6. Category I furnaces must be vented vertically or nearly

vertically unless equipped with a listed mechanical venter. See SIDEWALL VENTING section.

7. Do not vent this appliance into an unlined masonry chim- ney. Refer to Chimney Inspection Chart, Figure 34.

Figure 27 - Variable Speed Furnace with Single Stage Air

Conditioner

ICP THERMOSTAT VARIABLE SPEED SINGLE--STAGE

NOTE 5

FURNACE AIR CONDITIONER

.F- q

These furnaces are design-certified as Category I furnaces in accordance with ANSI Z21.47-2012/CSA 2.3-2012 and

operate with a non-positive vent static pressure to minimize the potential for vent gas leakage. Category I furnaces operate with a flue loss not less than 17 percent to minimize the

NOTE 4

potential for condensation in the venting system. These furnaces are approved for common venting and multistory

venting with other fan assisted or draft hood equipped appliances in accordance with the NFGC, the local building

D HUM

codes, and furnace and vent manufacturers' instructions. Vent system or vent connectors may need to be resized. Vent

systems or vent connectors must be sized to approach

minimum size as determined using appropriate table found in the current edition of NFGC.

General Venting Requirements

SENSOR

OUTDOOR

Follow all safety codes for proper vent sizing and installation

requirements, including local building codes, the National Fuel

See notes 1, 3, 4, and 5

Gas Code NFPA 54/ANSI Z223.1-2012 (NFGC), Parts 12 and

22 Specifications are subject to change without notice. 441 01 2122 O0

LO9F025

Figure 28 - Variable Speed Furnace with Two-Stage Air

Conditioner

Figure 30 - Variable Speed Furnace with Two-Stage Heat

Pump (Dual Fuel)

ICP THERMOSTAT VARIABLE SPEED TWO-STAGE

NOTE 5 -I--"_

FURNACE AIR CONDITIONER

F_q

r-_

NOTE4 _1-_- ]

B HUM

OUTDOOR

SENSOR

See notes 1, 3, 4, and 5

ICP THERMOSTAT VARIABLE SPEED TWO-,STAGE

FURNACE HEAT PUMP

NOTE 5

E_ ED

NOTE 4

0 HUM

OUTDOOR

SENSOR I

Figure 29 - Variable Speed Furnace with Single Stage

Heat Pump (Dual Fuel)

ICP THERMOSTAT VARIABLE SPEED SINGLE--STAGE

FURNACE HEAT PUMP

NOTE 5

F_q

E3-

NOTE 4

0 HUM

0_-

L0gF026

See notes 1,2, 3, 4, and 5

LOgF028

Figure 31 - Variable Speed Furnace and Humidifier Only

HUMIDITY SENSING VARIABLE SPEED

THERMOSTAT FURNACE

r-_ , [_

P • I

SPST | • I

RELAY

HUMIDIFIER

115 VAC _

See notes 6 and 7

OUTDOOR 1

SENSOR I

See notes 1,2, 3, 4, and 5

LOgF027

441 01 2122 O0 Specifications are subject to change without notice. 23

LOgF029

Figure 32 - AC with Variable Speed Furnace, Humidifier, Figure 33 - HP with Variable Speed Furnace, Humidifier,

and Dehumidification and Dehumidification

HUMIDITY SENSING

THERMOSTAT

VARIABLE SPEED

FURNACE

HUMIDITY SENSING

THERMOSTAT

VARIABLE SPEED

FURNACE

_ HUM

SPDT f

RELAY

HUMIDIFIER

115 VAC "-_

See notes 6 and 7

LOgF029

NOTES FOR FIGURES Figure 27 - Figure 33

1. Refer to outdoor equipment Installation Instructions for additional information and setup procedure.

2. Outdoor Air Temperature Sensor must be attached in all dual fuel applications.

3. Refer to ICP thermostat Installation Instructions for additional information and setup procedure.

4. When using a Humidity Sensing Thermostat, set DEHUMIDIFY OPTIONS to H DE-ENRGZD FOR DEHUM.

Optional connection. If wire is connected SWl-2 on VS furnace control should be set in ON position to allow ICP Thermostat to control the furnace staging.

6. HUM connection is 24 VAC and is energized when the blower turns on during a call for heat.

7. When connecting 115 VAC to humidifier use a separate 115 VAC supply.

8. When using a humidifier on a HP installation connect humidifier to hot water.

115 VAC _

See notes 7 and 8

L09F030

24 Specifications are subject to change without notice. 441 01 2122 O0

Figure 34 - Chimney Inspection Chart

CHIMNEY INSPECTION CHART

Foradditionalrequirementsrefertothe NationalFuelGas Code NFPA 54/ANSI Z223.1 and ANSI/NFPA 211

Chimneys,Fireplaces,Vents,and SolidFuel BurningAppliances

Crown

condition: Rebuild

Missing mortar crown.

or brick?

Is chimney

property lined with

clay tile line_

Yes

Is Repair

liner and top liner or top seal seal in good or reline chimney as

condition? necessary.

in cleanout?

Mortar, tile,

fuel oil residue?

Mortar

ortile

debris?

ve metal vent I ] No or liner.

Clay

tile misalignment,

missing sections,

Yes _,

gaps?

J_No _ instzuctionsfor / A _

/ _ _ application /

Reline

Repair

Remove mortar

and tile debris

_Not Suitable

Condensate

Chimney

exposed to

outdoors below

roof line?

{ Chimney is _.,

/'i,,_._ ..._h _._ .... _ _ .... Line chimney with property

<" __"L >- I_.,,_,e sized,listedflexiblemetal

_,_,L_u, ,,_u ,,,,_, U,/Yes I liner or Type-B vent per

",,,_lype-id ventY/ _, NFGC Vent

_./ I"'_Z;;_;';.;";_7"I vent manufacturer's

/ Is chimney _No . / PartCof

! V__II_/ '_o _himney adapter venting_Suitable

" _. = Rinnh_ / _ _ instructions for /

/ _ Sizing Tables and liner or

J.Yes L _ . Not Suitable

_ultable

I _,_,_,_'_ I Installation instructions.

adapter per

Install chimney

instructions.

441 01 2122 O0 Specifications are subject to change without notice. 25

A10133

Masonry Chimney Requirement

NOTE: These furnaces are CSA design-certified for use in

exterior tile-lined masonry chimneys with a factory accessory

Chimney Adapter Kit. Refer to the furnace rating plate for

correct kit usage. The Chimney Adapter Kits are for use with

ONLY furnaces having a Chimney Adapter Kit number marked

on the furnace rating plate.

If a clay tile-lined masonry chimney is being used and it is

exposed to the outdoors below the roof line, relining might be

required. Chimneys shall conform to the Standard for

Chimneys, Fireplaces, Vents, and Solid Fuel Burning Appliances ANSI/NFPA 211-2012 in the United States and

must be in good condition.

U.S.A.-Refer to Sections 13.1.8 and 13.2.20 of the NFPA 54/ANSI Z223.1-2012 or the authority having jurisdiction to

determine whether relining is required. If relining is required,

use a properly sized listed metal liner, Type-B vent, or a listed alternative venting design.

NOTE: See the NFPA 54/ANSI Z223.1-2012 13.1.9 and

13.2.20 regarding alternative venting design and the

exception, which cover installations such as our Chimney Adapter Kits which are listed for use with these furnaces.

The Chimney Adapter Kit is a listed alternative venting system for these furnaces. See the kit instructions for complete

details. This furnace is permitted to be vented into a clay tile-lined

masonry chimney that is exposed to the outdoors below the

roof line, provided:

1. Vent connector is Type-B double-wall, and

2. This furnace is common vented with at least 1 draft hood

equipped appliance, and

3. The combined appliance input rating is less than the max-

imum capacity given in Table 7, and

4. The input rating of each space heating appliance isgreater

than the minimum input rating given in Table 8 for the local 99% Winter Design Temperature. Chimneys having intern-

al areas greater than 38 sq. in. (24516 sq. mm) require fur- nace input ratings greater than the input ratings of these furnaces. See footnote at bottom of Table 8, and

5. The authority having jurisdiction approves.

If all of these conditions cannot be met, an alternative venting

design shall be used, such as the listed chimney adapter kit with a furnace listed for use with the kit, a listed chimney-lining

system, or a Type-B common vent.

Inspections before the sale and at the time of installation will

determine the acceptability of the chimney or the need for

repair and/or (re)lining. Refer to the Figure 34 to perform a

chimney inspection. If the inspection of a previously used tile-lined chimney:

a. Shows signs of vent gas condensation, the chimney

should be relined in accordance with local codes and the authority having jurisdiction. The chimney

should be relined with a listed metal liner, Type-B vent, or a listed chimney adapter kit shall be used to

reduce condensation. If a condensate drain is re- quired by local code, refer to the NFPA 54/ANSI

Z223.1-2012, Section 12.10 for additional informa- tion on condensate drains.

b. Indicates the chimney exceeds the maximum per-

missible size inthe tables, the chimney should be rebuilt or relined to conform to the requirements of

the equipment being installed and the authority hav-

ing jurisdiction.

A chimney without a clay tile liner, which is otherwise in good condition, shall be rebuilt to conform to ANSI/NFPA 211 or be

lined with a UL listed metal liner or UL listed Type-B vent. Relining with a listed metal liner or Type-B vent is considered

to be a vent-in-a-chase. If a metal liner or Type-B vent is used to line a chimney, no

other appliance shall be vented into the annular space between the chimney and the metal liner.

Exterior Masonry Chimney FAN + NAT

Installations with Type-B Double-Wall Vent

Connectors ©NFPA & AGA

Table 7 - Combined Appliance Maximum Input

Rating in Thousands of Btuh per Hour

VENT HEIGHT

FT (a) 12

6 (1.8)

8 (2.4) 10 (3.0) 15 (4.5) 20 (6.0)

30 (9.1)

INTERNAL AREA OF CHIMNEY

SQ. IN. (SQ. MM)

(7741)

74 8O 84

NR NR

19 28

(12258) (18064)

119 178 130 193 138 207 152 233

NR 250 NR NR

(24516)

257 279 299 334

368 4O4

Appliance Application Requirements

Appliance operation has a significant impact on the performance of the venting system. If the appliances are sized, installed, adjusted, and operated properly, the venting

system and/or the appliances should not suffer from condensation and corrosion. The venting system and all

appliances shall be installed in accordance with applicable listings, standards, and codes.

The furnace should be sized to provide 100 percent of the design heating load requirement plus any margin that occurs

because of furnace model size capacity increments. Heating load estimates can be made using approved methods available from Air Conditioning Contractors of America

(Manual J); American Society of Heating, Refrigerating, and Air-Conditioning Engineers; or other approved engineering

methods. Excessive oversizing of the furnace could cause the furnace and/or vent to fail prematurely.

When a metal vent or metal liner is used, the vent must be in good condition and be installed in accordance with the vent

manufacturer's instructions. To prevent condensation in the furnace and vent system, the

following precautions must be observed:

1. The return-air temperature must be at least 60°F db ex- cept for brief periods of time during warm-up from setback

at no lower than 55"F (13°C) db or during initial start-up from a standby condition.

2. Adjust the gas input rate per the installation instructions.

Low gas input rate causes low vent gas temperatures, causing condensation and corrosion in the furnace and/or venting system. Derating is permitted only for altitudes

above 2000 Ft. (610 M).

3. Adjust the air temperature rise to the midpoint of the rise range or slightly above. Low air temperature rise can

cause low vent gas temperature and potential for condens- ation problems.

4. Set the thermostat heat anticipator or cycle rate to reduce

short cycling.

26 Specifications are subject to change without notice. 441 01 2122 00

BURN HAZARD

Failure to follow this caution may result in personal injury.

Hot vent pipe is within reach of small children when installed in downflow position.

See the followinq instruction.

Table 8 - Minimum Allowable Input Rating of

Space-Heating Appliance in Thousands of Btuh per Hour

INTERNAL AREA OF CHIMNEY

VENT HEIGHT

FT, (M)

Local 99% Winter

8 10 15

Local 99% Winter

8 10

15 20 30

Local 99% Winter Design

6 NR

8 NR 10 NR 15 NR

20 NR 30 NR

Local 99% Winter Design Temperature: -11

Not recommended for any vent configuration.

*The 99.6% heating (db) temperatures found in the 1997 or 2001 ASHRAE Fundamentals Handbook, Climatic Design Information chapter, Table

1A (United States) and 2A (Canada) or the 2005 ASHRAE Fundamentals hand- book, Climatic Design Information chapter, and the CD-ROM included with the

2005 ASHRAE Fundamentals Handbook.

12 19 28 38

(7741) (12258) 18064) (24516)

Design Temperature: 17 to 26 degrees F

0 55

52 74

NR 90 NR NR

NR NR NR NR

Design Temperature:

NR 78 NR 94

NR 111 NR NR NR NR NR NR

SQ. IN. (SQ. MM)

Temperature:

NR NR NR NR

NR NR

lower

99 14t

111 154 125 169 167 212 212 258

NR 362

5 to 16 degrees F*

121 166 135 182 149 198

193 247

NR 293

NR 377

-10 to 4 degrees F* 145 196 159 213

175 231

NR 283 NR 333

NR NR

degrees F or

Air for combustion must not be contaminated by halogen

compounds which include chlorides, fluorides, bromides, and iodides. These compounds are found in many common home

products such as detergent, paint, glue, aerosol spray, bleach, cleaning solvent, salt, and air freshener, and can cause

corrosion of furnaces and vents. Avoid using such products in

the combustion-air supply. Furnace use during construction of the building could cause the furnace to be exposed to halogen

compounds, causing premature failure of the furnace or

venting system due to corrosion. Vent dampers on any appliance connected to the common

vent can cause condensation and corrosion in the venting system. Do not use vent dampers on appliances common

vented with this furnace.

Additional Venting Requirements A 4-in. (102 mm) round vent elbow is supplied with the

furnace. A 5-in. (127 mm) or 6- in. (152 mm) vent connector may be required for some model furnaces. A field-supplied

4-in. (102 mm) to 5-in. (127 mm) or 4-in. (102 mm) to 6-in. (152 mm) sheet metal increaser fitting is required when 5-in.

(127 mm) or 6-in. (152 mm) vent connector is used. See Figure 35 - Figure 47, Venting Orientation for approved vent

configurations. NOTE: Vent connector length for connector sizing starts at

furnace vent elbow. The 4-in. (102 mm) vent elbow is shipped for upflow configuration and may be rotated for other positions.

Remove the three screws that secure vent elbow to furnace, rotate furnace vent elbow to position desired, reinstall screws.

The factory-supplied vent elbow does NOT count as part of the number of vent connector elbows.

The vent connector can exit the furnace through one of five locations on the casing.

CUT HAZARD Failure to follow this caution may result in personal injury.

Sheet metal parts may have sharp edges or burrs. Use care and wear appropriate protective clothing, safety glasses and gloves when handling parts, and servicing

furnaces.

1. Attach the single wall vent connector to the furnace vent elbow, and fasten the vent connector to the vent elbow

with at least two field-supplied, corrosion-resistant, sheet metal screws located 180 ° apart.

NOTE: A flue extension is recommended to extend from the furnace elbow to outside the furnace casing. If flue extension

is used, fasten the flue extension to the vent elbow with at least two field-supplied, corrosion-resistant, sheet metal screws located 180 ° apart. Fasten the vent connector to the flue extension with at least two field-supplied, corrosion resistant sheet metal screws located 180° apart.

2. Vent the furnace with the appropriate connector as shown

in Figure 35 - Figure 47.

3. Determine the correct location of the knockout to be re- moved.

4. Use a hammer and screwdriver to strike a sharp blow between the tie points and work the slug back and forth

until the slug breaks free.

An accessory Vent Guard Kit is REQUIRED for downflow applications for use where the vent exits through the lower

portion of the furnace casing door. Refer to the Vent Guard Kit Instructions for complete details. See Specification Sheet for

accessory listing.

441 01 2122 00 Specifications are subject to change without notice. 27

Figure 35 - Upflow Application - Vent Elbow Up Figure 37 - Downflow Application - Vent Elbow Up then

Left

_o _ o_

SEE NOTES: 1,2,4,7,8,9 on the page following

these figures

A03208

Figure 36 - Upflow Application - Vent Elbow Right

Figure 38 - Downflow Application - Vent Elbow Up

SEE NOTES:1,2,3,4,5,7,8,9

on the page following these figures

A03210

_-o 037

SEE NOTES: 1,2,3,4,7,8,9 on the pages following

these figures

• .O _ _o

SEE NOTES: 1,2,4,5,7,8,9 on the page following

these figures

A03209

A03211

28 Specifications are subject to change without notice. 441 01 2122 00

Figure39 - Downflow Application - Vent Elbow Leftthen

Figure 41 - Horizontal Left Application - Vent Elbow Left

SEE NOTES: 1,2,4,7,8,9 on the page

following these figures

A03213

Figure 42 - Horizontal Left Application - Vent Elbow

Right then Up

SEE NOTES: 1,2,4,5,6,7,8,9,10

on the page following these figures

A03207

Figure 40 - Downflow Application - Vent Elbow Up then

Right

SEE NOTES:1,2,3,4,5,7,8,9 on the page following

these figures.

=o .

SEE NOTES: 1,2,4,5,7,8,9 on the page following these figures

A03214

Figure 43 - Horizontal Right Application - Vent Elbow

Right

SEE NOTES: 1,2,4,7,8,9 on the page following these figures

A03218

Figure 44 - Horizontal Left Application - Vent Elbow Up

A03212

o ,

:\ j

SEE NOTES: 1,2,4,5,7,8,9 on the page following these figures

A03215

29441 01 2122 O0 Specifications are subject to change without notice.

Figure 45 - Horizontal Left Application - Vent Elbow Figure 47 - Horizontal Right Application-Vent Elbow Left

Right ,,.

/-X

SEE NOTES: 1,2,4,5,7,8,9

SEE NOTES: 1,2,4,5,7,8,9 on the page

followingthesefigures

A03216

Figure 46 - Horizontal Right Application - Vent Elbow

Left then Up

VENTING NOTES FOR Figure 35 - Figure 47

1. For common vent, vent connector sizing and vent material:

United States--use the NFGC.

2. Immediately increase to 5-in. (102 mm) or 6-in. (152 mm) vent connector outside furnace casing when 5-in. (127

mm) vent connector is required, refer to Note 1 above.

3. Side outlet vent for upflow and downflow installations must use Type B vent immediately after exiting the furnace, ex- pect when Downfiow Vent Guard Kit is used in the

downflow position.

4. Type-B vent where required, refer to Note 1 above.

5. A 4-in.(102 mm) single-wall (26 ga. min.) vent must be used inside furnace casing and when the NAHB00301VC

Downflow Vent Guard Kit is used external to the furnace.

6. Accessory Downflow Vent Guard Kit is required in downflow installations with lower vent configuration.

SEE NOTES: 1,2,4,5,7,8,9 on the page following these figures

7. Chimney Adapter Kit may be required for exterior masonry chimney applications. Refer to Chimney Adapter Kit for

sizing and complete application details.

A03219

8. Secure vent connector to furnace elbow with (2) corrosion-

resistant sheet metal screws, spaced approximately 180 °

apart.

9. Secure all other single wall vent connector joints with (3) corrosion resistant screws spaced approximately 120 °

apart. Secure Type-B vent connectors per vent connector manufacturer's recommendations.

NOTE:

specified below. For all other applications, followFor the following applications, use the minimum vertical heights as

exclusively the National Fuel Gas Code.

MIN. VENT MIN. VERTICAL VENT

FURNACE FURNACE INPUT DIAMETER HEIGHT

ORIENTATION VENT ORIENTATION (BTUH/HR) IN. (mm)* FT, (M)**

Downflow Vent elbow left, then up Figure 39 132,000/110,OOO 5 (127) 12 (3.6)

Horizontal Left Vent elbow right, then up Figure 42 132,000 5 (127) 7 (2.1) Horizontal Left Vent Elbow up Figure 44 132,000 5 (127) 7 (2.1)

Downflow Vent elbow up then left Figure 37 110,OOO 5 (127) 10 (3.0) Downflow Vent elbow up, then right Figure 40 110,OOO 5 (127) 10 (3.0)

NOTE: All vent configurations must also meet National Fuel Gas Code venting requirements NFGC.

*4-in. (102 mm) inside casing or vent guard **Including 4 in. (102 mm) vent section(s)

A02068

The horizontal portion of the venting system shall slope

upwards not less than 1/4-in. per linear ft. (21 mm/m) from the

furnace to the vent and shall be rigidly supported every 5 ft.

(1.5 M) or less with metal hangers or straps to ensure there is no movement after installation.

Sidewall Venting This furnace is not approved for direct sidewall horizontal

venting. Per section 12.4.3 of the NFPA 54/ANSI Z223.1-2012, any

listed mechanical venter may be used, when approved by the authority having jurisdiction.

Select the listed mechanical venter to match the Btuh input of the furnace being vented. Follow all manufacturer's installation

requirements for venting and termination included with the listed mechanical venter.

30 Specifications are subject to change without notice. 441 01 2122 00

START-UP, ADJUSTMENT, AND SAFETY

CHECK

General

FIRE HAZARD

Failure to follow this warning could result in personal injury, death or property damage.

This furnace is equipped with manual reset limit switches in the gas control area. The switches open and shut off power to the gas valve, if a flame rollout or overheating condition occurs in the gas control area.

DO NOT bypass the switches. Correct problem before resetting the switches.

1. Maintain 115-v wiring and ground. Improper polarity will result in rapid flashing LED and no furnace operation.

2. Make thermostat wire connections at the 24-v terminal block on the furnace control. Failure to make proper con-

nections wilt result in improper operation. (See Figure 25 - Figure 33)

3. Gas supply pressure to the furnace must be greater than

4.5-1n. W.C. (0.16 psig ) but not exceed 14-1n. W.C. (0.5 psig).

4. Check all manual-reset switches for continuity.

5. Replace blower compartment door. Door must be in place to operate furnace.

6. Setup switch descriptions The variable speed furnace con- trol has DIP switches to select thermostat staging, blower

off delay timings, air flow selection and other operational or service related functions. (See Figure 26, Figure 55 and

Table 9)

FURNACE DAMAGE HAZARD

Failure to follow this caution may result in reduced

furnace life.

DO NOT redrill orifices. Improper drilling (burrs,

out-of-round holes, etc.) can cause excessive burner

noise and misdirection of burner flames. This can result in flame impingement of heat exchangers,

causing failures. (See Figure 49)

Figure 49 - Orifice Hole

BURNEJ

ORIFICE

Figure 50 - Amp. Draw Check with Ammeter

TERMINALS WITH THERMOSTAT REMOVED

(ANITICIPATOR, CLOCK, ETC., MUST BEOUT OF CIRCUIT.)

THERMOSTAT SUBBASE

A93059

CUT HAZARD Failure to follow this caution may result in personal injury.

Sheet metal parts may have sharp edges or burrs. Use care and wear appropriate protective clothing, safety

glasses and gloves when handling parts, and servicing furnaces.

Figure 48 - Redundant Automatic Gas Control Valve

ON/OFF SWITC _

1/25 NPT INLET i_ "-7

_- J_J _,"_ REGULATOR ADJUSTMENT

PRESSURE TAP __

1/25 NPT OUTLEJ

s A04167

FROM UNIT 24-V CONTROL TERMINALS

EXAMPLE: 5.0 AMPS ON AMMETER = 0.5 AMPS FOR THERMOSTAT

10 TURNS AROUND JAWS ANTICIPATOR SETTING

A96316

441 01 2122 00 Specifications are subject to change without notice. 31

Start-Up Procedures

FIRE OR EXPLOSION HAZARD

Failure to follow this warning could result in personal injury, death, and/or property damage.

Never purge a gas line into a combustion chamber. Never test for gas leaks with an open flame. Use a commercially available soap solution made specifically for the detection of leaks to check all connections. A fire or explosion may result causing property damage, personal injury or loss of life.

ELECTRICAL SHOCK HAZARD

Failure to follow this warning could result in personal injury, or death.

Blower access door switch opens 115-v power to control. No component operation can occur unless

switch is closed. Caution must be taken when manually closing this switch for service purposes.

Purge gas lines after all connections have been made.

Check gas lines for leaks.

To Begin Component Self-Test: Remove Blower Access Door. Disconnect the thermostat

R lead from furnace control board. Manually close blower door switch. Turn Setup DIP switch SWl-6 ON. (See

Figure 26, Figure 55 and Table 9)

NOTE: The furnace control allows all components, except the gas valve, to be run for short period of time. This feature helps diagnose a system problem in case of a component failure. Component test feature will not operate if any thermostat signal is present at the control.

Refer to service label attached to furnace or See Figure 51. Component test sequence is as follows:

a. Inducer motor starts on high-speed and continues to

run until Step d. of component test sequence.

b. Hot surface igniter is energized for 15 sec., then off. c. Blower motor operates for 15 sec. d. Inducer motor goes to low-speed for 10 sec., then

stops.

e. After component test is completed, one or more

status codes (heartbeat, 2+5) will flash. See com- ponent test section of service label (Figure 51) in

furnace for explanation of status codes.

NOTE: To repeat component test, turn setup switch SWl-6 OFF, then back ON.

4. Turn setup DIP switch SWl-6 OFF. Reconnect R lead to furnace control board, release blower door switch and rein-

stall blower access door.

5. Operate furnace per instruction on inner door.

6. Verify furnace shut down by lowering thermostat setting below room temperature.

7. Verify furnace restarts by raising thermostat setting above

room temperature.

Adjustments

FIRE HAZARD

Failure to follow this warning could result in personal injury, death and/or property damage.

DO NOT bottom out gas valve regulator adjusting

screw. This can result in unregulated manifold

pressure and result in excess overfire and heat exchanger failures.

32 Specifications are subject to change without notice. 441 01 2122 O0

RCL

LHT

LHR

C/E

CFM

TST

TWN

CFM

m-? m-?

v-i

m-?

SW1

IC] I-1

fq I-q I-1

I-1 fq

Irq

SW2

SETUP

SWITCH

SW1-1

SW1-2

SW1-3

SW1-4

SW1-5

SW1-6

SW1-7 &

SW1-8

SW2-1 Twining OFF

SW2-2

SW2-6, 7, 8 Airflow)

SW2-3, 4, 5

SWITCH NAME

Status Code Recovery

Low Heat Only (Adaptive Heat

Mode when SW1-2 is OFF)

Low Heat Rise

Adjustment

Comfort/Efficiency

Adjustment

CFM per ton adjust Component

Self Test Blower OFF

delay

CFM per ton

Adjustments OFF

AC (Cooling OFF

CF (Continuous Fan)

Table 9 - Furnace Setup Switch Description

NORMAL

POSITIOI_

or OFF

DESCRIPTION OF USE

Turn ON to retrieve up to 7 stored status codes for troubleshooting assistance

OFF

when R thermostat lead is disconnected. When SW1-2 is OFF allows two-stage operation with a single stage thermo-

stat. Turn ON when using two- stage thermostat to allow Low Heat operation

OFF

when R to W/W1 closes and High Heat operation when R to W/W1 and W2 close.

Turn ON to increase Low Heat airflow by 18 percent. This compensates for

OFF

increased return air temperature caused with bypass humidifier.

Turn ON to decrease Low Heat airflow by approximately 7 percent and High

Heat airflow by approximately 10 percent for maximum comfort.

OFF

Turn ON for 400 CFM per ton, Turn OFF for 350 CFM per ton. See also SW2. Turn ON to initiate Component Self Test for troubleshooting assistance when

OFF

R thermostat lead is disconnected. Turn OFF when Self Test is completed.

Blower Off Delay time - adjustable 90 seconds to 180 seconds. See table in

Adjustments section or refer to unit wiring diagram. Allows for selection of furnace Main (OFF) or Secondary (ON) when Twinned

furnace setup is required. See kit instructions for further directions on installa- tion and setup.

Allows additional CFM per ton selections when used with SWl-5 325 CFM per ton (nominal) when SW2-2 ON and SW1-5 OFF

350 CFM per ton (nominal) when SW2-2 OFF and SWl-5 OFF 370 CFM per ton (nominal) when SW2-2 ON and SWl-5 ON

400 CFM per ton (nominal) when SW2-2 OFF and SW1-5 ON

See Air Delivery Tables for model specific CFM vs. static pressure

The AC setup switches select desired cooling or high stage cooling (two stage units) airflow. See Cooling Air Delivery Tables for specific switch set-

tings. The CF setup switches select desired Continuous Fan Airflow The CF switch position is the low cooling airflow selection for two stage cool-

OFF

ing units.

The CFM values are shown in the Air Delivery Tables below for SW2 settings.

SW2-3, 4, 5 cannot be set for airflow higher than SW 2-6, 7, 8. See Continuous Fan Air Flow Table for specific switch settings.

Table 10 - Airflow Selection (based on 350 CFM/ton) for A/C (SW2-6, 7, 8) and *OF (SW2-3, 4, 5)

NoI- -I

sw2 OFF

rlrlrlrlrlrlrlrlON

8 7 6 5 _ 3 2 1

MODEL SIZE

045-12 070-16 090-16

"110-22 "135-22

SW2

A/C (8 7 6)

CF (5 4 3)

DEF DEF DEF

DEF DEF

OFF

SW2

A/C (8 7 6)

CF (5 4 3)

OFF

5252

5252 5252

7002

SW2

A/C (8 Z 6)

CF (5 4 3)

7OO 7OO 7OO

875 875

OFF

SW2

A/C (8 7 6)

CF (5 4 3)

875 875 875

1050 1050

OFF

A/C (8 7 6)

CF _ 4 3)

10501

1050 1050

1225 1225

1. Default A/C airflow when A/C switches (SW2-6, 7, 8) are in OFF position

2. Default continuous fan airflow when OF switches (SW2-3, 4, 5) are in OFF position * Continuous fan (OF) airflow for 110 and 135 models is the same as 0902116

NOTE: OF airflow wilt not be higher than the selected A/C airflow

SW2

OFF

SW2

A/C (8 7 6)

CF (5 4 3)

1150 1225 1225

1400 1400

OFF

SW2

A/C (8 7 6)

CF (5 4 3)

1150

14001 14001

17501 17501

OFF

SW2

A/C (_87 6)

CF (b_4__S)

1150 1650 1750

1925 1925

OFF

441 01 2122 00 Specifications are subject to change without notice. 33

Table 11 - Air Conditioning (A!C) SW2-6, 7, 8 or *Continuous-Fan (CF) SW2-3, 4, 5 Airflow Selection Chart

MODEL

SIZE

045 070 090 110 135

MODEL

SIZE

O45 O7O O9O 110 135

SW2

A/C

-- OFF

nMn

876

DEF DEF DEF DEF DEF

-- OFF

nnn

876

DEF DEF DEF DEF DEF

BASED ON 400 CFM/TON

A/C

sw2 -- OFF sw2 .... sw2 ....

nng

87_ ON

6002 6002 6002

8002 8002

A/C

ngn

8760N

800 800

800 1000 1000

BASED ON 370 CFM/TON

A/C

sw2 -- OFF sw2 -- OFF sw2 --

nng

878 ON ON

5552 5552 5552

7402 7402

_C _C

nun ngg

876 8780N

740 925

925 1110

OFI

SETUP SWITCH

OF( sw2--

sw2 -- OFF

SW1-5 ON

gnn

8760N

1000 1000 1000 1200 1200

SETUP SWITCH SW1-5 ON

OFF

8_60N

12001

1200 1200

1400 1400

A/C

sw2 -- DFF

sw2 -- OFF

gnn

876 3N

11101

1110 1110

1295 1295

& SW2-2 OFF

A/C

3FF

878 )N

1314 1400 1400 1600 1600

& SW2-2 ON

A/C

8780N

1215 1295 1295 1480 1480

A/C

sw2 -- OFF

8780N

1314

16001 16001 20001 20001

A/C

sw2 -- DFF

67_ 3N

1215

14801 14801 18501 18501

A/C

sw2 DFF

_ 3N

1343

1926 2000 2200 2200

A/C

sw2 -- OFF

8780N

1242

1781

1850 2035 2035

MODEL

SIZE

O45 O7O O9O 110 135

MODEL

SIZE

O45 O7O O9O 110 135

BASED ON 350 CFM/TON

A/C A/C

sw2--3FF sw2--DFF

nnn nl)g

876 ON 878 ON

DEF 5252 DEF 5252 DEF 5252 DEF 7002 DEF 7002

BASED ON 325 CFM/TON

SW2

A/C

nnn

876

DEF DEF DEF DEF DEF

OFF

A/C

sw2 -- OFF

nng

876 ON

4882 4882 4882

6502

SETUP SWITCH SW1-5 OFF & SW2-2

A/C

-- OFF sw2 --

SW2

878

700 700 700 875 875

A!C

sw2 DFF sw2

8763N

650 650 650 813 813

OFF

sw2 OFF

8160N

875 875

875 1050 1050

10501

1050 1050 1225 1225

SETUP SWITCH

A/C

876 DN

813

975

3FF

sw2 -- OFF

9751

975

975 1138 1138

87_ ON

SW1-5 OFF

A/C

_7_ON

OFF (Factory Default)

sw2 -- OFF

8760N

1150 1225 1225 1400 1400

& SW2-2 ON

A/C

sw2 -- OFF

876 9N

1067 1138 1138 1300 1300

A/C

sw2 OFF

87_ ON

sw2 -- OFF

1150 1175

14001 1685 14001 1750 17501 1925 17501 1925

A/C

sw2 -- OFF

8780N

sw2 -- OFF

1067

13001 13001 16251 16251

A/C

_'8 ON

A/C

878C) N

1091 1565 1625 1788 1788

1. Default A/C airflow when A/C switches (SW2-6, 7, 8) are in OFF position

2. Default continuous fan airflow when OF switches (SW2-3, 4, 5) are in OFF position * Continuous fan (OF) airflow for 110 and 135 models is the same as 0902116

NOTE: OF airflow wilt not be higher than the selected A/C airflow

34 Specifications are subject to change without notice. 441 01 2122 00

Unit

Size

045 - 12

Unit

Size

070-16

Unit

Size

090-16

Unit

Size

110-22

Unit

Size

135-22

See CFM Notes following,

Table 12 -Air Delivery - CFM (with filter)*

COOLING 4 AND HEATING AIR DELIVERY - CFM (Bottom Return 5 With Filter)

(SW1-5 and SW2-2 set to OFF, except as indicated. See notes 1 and 2,)

Cooling Switch Settings External Static Pressure (ESP)

SW2-8

OFF OFF

ON ON

Cooling Switch Settings External Static Pressure (ESP)

SW2-8

OFF OFF

ON ON

Cooling Switch Settings External Static Pressure (ESP)

SW2-8

OFF OFF

ON ON

Cooling Switch Settings External Static Pressure (ESP)

SW2-8

OFF OFF

ON ON

Cooling Switch Settings External Static Pressure (ESP)

SW2-8

OFF OFF

ON ON

SW2-7 SW2-6

OFF OFF OFF ON

ON OFF

ON ON OFF OFF OFF ON

ON OFF

ON ON

Maximum CIg Airflow z

High Heat Airflow _

Low Heat Airflow _

SW2-7 SW2-6

OFF OFF OFF ON

ON OFF

ON ON OFF OFF

OFF ON

ON OFF

ON ON

Maximum CIg Airflow z 1890 1850 1810 1750 1685 1615 1545 1475 1395 1275

High Heat Airflow _ 1540 1490 1450 14t0 1365 1320 1275 1235 1190 1140

Low Heat Airflow _ 1370 1320 1275 1225 1180 1135 1085 1040 995 950

SW2-7

OFF OFF

ON OFF

OFF

Maximum CIg Airflow z

High Heat Airflow _

Low Heat Airflow _

SW2-7

OFF OFF

ON OFF OFF

Maximum CIg Airflow z

High Heat Airflow _

Low Heat Airflow _

SW2-7 SW2-6

OFF OFF OFF ON

ON OFF

ON ON OFF OFF

OFF ON

ON OFF

ON ON

Maximum CIg Airflow z

High Heat Airflow _

Low Heat Airflow _

SW2-6

OFF

SW2-6

OFF

0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 I 1.0

1190 1140 1100 1065 1020 985 905 800 665 I 525

620 560 520 455 410 355 305 255 See note 4 795 755 705 670 615 585 530 490 440 405

1020 955 930 890 840 805 755 715 645 490 1190 1140 1100 1065 1020 985 905 800 665 525

1455 1390 1325 1255 1175 1085 1000 880 755 575 1455 1390 1325 1255 1175 1085 1000 880 755 575

915 860 825 790 735 700 650 610 550 450 780 730 685 635 585 545 495 450 400 370

0.1 0.2 0.3

1615 1570 1530

64O 840 775 700

1045 980 920 1220 1175 1120

1390 1335 1290 1615 1570 1530 1890 1850 1810

Io.41o. 0.6o.7o.81o.911.o1490 1450 1405 1365 1325 1280 1210

See note 4

640 See note 4 860 805 750 690 640 See note 4

1075 1025 970 925 875 820 775 1245 1200 1155 1105 1055 1015 970

1490 1450 1405 1365 1325 1280 1210 1750 1685 1615 1545 1475 1395 1275

o.lo.2o.31o.41o. o.6o.7o.81o.911.o1625 1580 1535 1490 1445 1390 1325 1215 1070 910

555 See note 4

845 770 670 595 See note 4 1010 950 880 790 725 670 580 See note 4 1210 1155 1105 1035 970 910 850 800 730 660

1405 1360 1305 1255 1185 1130 1070 1015 960 875 1625 1580 1535 1490 1445 1390 1325 1215 1070 910

2095 2010 1935 1855 1770 1675 1540 1300 1120 940 2095 2010 1935 1855 1770 1675 1540 1300 1120 940

1735 1685 1630 1580 1520 1455 1375 1235 1085 915 1230 1175 1125 1055 995 930 875 820 755 690

o.lo.2o.31o.41o. o.6o.7o.81o.911.o2055 2000 1950 1900 1840 1790 1740 1675 1625 1565

855 755 See note 4 1060 985 875 800 700 See note 4

1250 1180 1095 1025 925 860 775 715 See note 4 1445 1380 1320 1235 1175 1100 1035 955 900 825 1685 1630 1560 1505 1445 1375 1320 1265 1195 1140

2055 2000 1950 1900 1840 1790 1740 1675 1625 1565 2465 24t5 2365 2305 2230 2140 2045 1925 1805 1655 2465 24t5 2365 2305 2230 2140 2045 1925 1805 1655

2105 2055 2005 1955 1895 1850 1795 1735 1665 1580

1740 1685 1620 1560 1505 1440 1385 1325 1260 1205

2040 1985 1930 1880 1830 1775 1715 1660 1595 1510

o.lo.2o.31o.41o. o.6o.7o.81o.911.o

850 740 See note 4 1040 960 865 755 See note 4

1245 1170 1080 1005 920 835 750 See note 4 1450 1385 1305 1245 1180 1085 1015 935 880 805

1670 1605 1540 1480 1425 1350 1280 1220 1135 1070

2040 1985 1930 1880 1830 1775 1715 1660 1595 1510 2520 2455 2405 2350 2290 2195 2090 1965 1815 1615

2520 2455 2405 2350 2290 2195 2090 1965 1815 1615 2260 2205 2150 2100 2045 1985 1925 1855 1745 1600 2005 1950 1895 1845 1790 1735 1675 1620 1550 1475

441 01 2122 O0 Specifications are subject to change without notice. 35

Air Delivery-CFM Notes

1. Nominal 350 CFM/ton cooling airflow is delivered with SW1-5 and SW2-2 set to OFF. Set both SW1-5 and SW2-2 to ON for +7% airflow (nominal 370 CFM/ton). Set SW1-5 to ON and SW2-2 to OFF for +15% airflow (nominal 400 CFM/ton). Set SW2-2 to ON and SW1-5 to OFF for -7% airflow (nominal 325 CFM/ton).

2. Maximum cooling airflow is achieved when switches SW2-6, SW2-7, SW2-8 and SW1-5 are set to ON, and SW2-2 is set to OFR

3. All heating CFM's are when low heat rise adjustment switch (SW1-3) and comfort/efficiency adjustment switch (SW1-4) are both set to OFR

4. Ductwork must be sized for high-heating CFM within the operational range of ESP. Operation within the blank areas of the chart is not recommend- ed because high-heat operation will be above 1.0 ESP.

5. All airflows on 21" casing size furnaces are 5% less on side return only installations.

6. Side returns for 24.5" casing sizes require two sides, or side and bottom, to allow sufficient airflow at the return of the furnace.

Figure 51 - Service Label

u=Lu

O:z:

uJ_

_ 340686-101 REV. A

36 Specifications are subject to change without notice. 441 01 2122 O0

Furnace gas input rate on rating plate is for installations at

altitudes up to 2000 Ft. (610 M). Furnace input rate must be within +/-2 percent of furnace rating plate input. For altitudes above 5500 Ft. (1676 M), a field-supplied high altitude

pressure switch is required.

1. Determine the correct gas input rate. The input rating for altitudes above 2,000 ft. (610 M) must be reduced by 4 percent for each 1,000 ft. (305 M) above

sea level. For installations below 2000 Ft. (610 M), refer to the unit

rating plate. For installations above 2000 Ft. (610 M), mul- tiply the input on the rating plate by the de-rate multiplier in Table 13 for the correct input rate.

Table 13 -Altitude Derate Multiplier for U.S.A.

ALTITUDE PERCENT DERATE MULTIPLIER

FT,(M) OF DERATE FACTOR*

0-2000

(0-610)

2001-3000

(610-914)

3001-4000 (914-1219) 4001-5000

(1219-1524)

5001-6000

1524-1829)

6001-7000

(1829-2134)

7001-8000

(2134-2438)

8001-9000

(2438-2743)

9001-10,000 36-40 0.62

(2743-3048)

0 1.00

8-12 0.90

12-16 0.86

16-20 0.82

20-24 0.78

24-28 0.74

28-32 0.70

32-36 0.66

2. Determine the correct orifice and manifold pressure adjust- ment. All models in all positions except Low NOx models in

downflow and horizontal positions use Table 15 (22,000 Btuh per burner.) Low NOx models in downflow or hori-

zontal positions must use Table 17 (21,000 Btuh per burn- er.) See input listed on rating plate.

a. Obtain average yearly gas heat value (at installed

altitude) from local gas supplier.

b. Obtain average yearly gas specific gravity from local

gas supplier.

c. Find installation altitude in Table 15 or 17. d. Find closest natural gas heat value and specific

gravity in Table 15 or 17.

e. Follow heat value and specific gravity lines to point

of intersection to find orifice size and low-and high- heat manifold pressure settings for proper operation.

f. Check and verify burner orifice size in furnace. NEV-

ER ASSUME ORIFICE SIZE. ALWAYS CHECK AND

VERIFY.

NOTE: If orifice hole appears damaged or it is suspected to have been redrilted, check orifice hole with a numbered drill bit of correct size. Never redrilt an orifice. A burr-free and

squarely aligned orifice hole is essential for proper flame

characteristics.

g. Replace orifice with correct size, if required by Table

15 or 17. Use only factory-supplied orifices. See EXAMPLE 1.

EXAMPLE 1:0-2000 ft. (0-610 M) altitude For 22,000 Btuh per burner application use Table 15.

Heating value = 1000 Btuh/cu ft. Specific gravity = 0.62

Therefore: Orifice No. 43*

Manifold pressure: 3.7-1n. W.C. for high-heat

1.6-In. W.C. for low-heat

* Furnace is shipped with No. 43 orifices. In this example all

main burner orifices are the correct size and do not need to be changed to obtain proper input rate.

3. Adjust manifold pressure to obtain low fire input rate. (See

Figure 48)

a. Turn gas valve ON/OFF switch to OFF. b. Remove manifold pressure tap plug from gas valve.

c. Connect a water column manometer or similar

device to manifold pressure tap. d. Turn gas valve ON/OFF switch to ON. e. Move setup SWl--2 on furnace control to ON posi-

tion to lock furnace in low-heat operation. (See Ta-

ble 9)

f. Manually close blower door switch.

g. Jumper R and W/W1 thermostat connections on

control to start furnace. (See Figure 26) h. Remove regulator adjustment cap from low heat gas

valve pressure regulator (See Figure 48) and turn

low-heat adjusting screw (3/16 or smaller flat-tipped

screwdriver) counterclockwise (out) to decrease in-

put rate or clockwise (in) to increase input rate.

NOTE: DO NOT set low-heat manifold pressure less than

1.4-1n. W.C. or more than 1.7-1n. W.C. for natural gas. If manifold pressure is outside this range, change main burner

orifices.

i. Install low-heat regulator adjustment cap. j. Move setup switch SW1-2 to off position after com-

pleting low-heat adjustment. k. Leave manometer or similar device connected and

proceed to Step 4.

4. Adjust manifold pressure to obtain high fire input rate. (See Figure 48)

a. Jumper R to W/W1 and W2 thermostat connections

on furnace control. This keeps furnace locked in high-heat operation.

b. Remove regulator adjustment cap from high-heat

gas valve pressure regulator (See Figure 48) and turn high heat adjusting screw (3/16-in. or smaller

flat-tipped screwdriver) counterclockwise (out) to decrease input rate or clockwise (in) to increase in-

put rate.

NOTE: DO NOT set high-heat manifold pressure less than

3.2-1n. W.C. or more than 3.8 In. W.C. for natural gas. If

manifold pressure is outside this range, change main burner orifices to obtain manifold pressure in this range.

c. When correct input is obtained, replace caps that

conceal gas valve regulator adjustment screws. Main burner flame should be clear blue, almost

transparent.

d. Remove jumpers R to W/W1 and R to W2.

441 01 2122 00 Specifications are subject to change without notice. 37

5. Verify natural gas input rate by clocking meter. a. Turn off all other gas appliances and pilots served

by the meter.

b. Move setup switch SWl-2 to ON position. This

keeps furnace locked in low-heat operation.

c. Jumper R to W/W1. d. Run furnace for 3 minutes in low-heat operation.

e. Measure time (in sec) for gas meter to complete 1

revolution and note reading. The 2 or 5 cubic feet dial provides a more accurate measurement of gas

flow.

f. Refer to Table 14 for cubic ft. of gas per hr.

g. Multiply gas rate cu ft./hr by heating value (Btuh/cu

ft.) to obtain input. If clocked rate does not match

required input from Step 1, increase manifold pres- sure to increase input or decrease manifold pressure to decrease input. Repeat steps b through e until

correct low-heat input is achieved. Re-install low

heat regulator seal cap on gas valve.

h. Move setup switch SWl-2 to OFF position and

jumper R to W/W1, and W2. This keeps furnace

locked in high-heat operation. Repeat items d through g for high-heat operation.

6. Set Temperature Rise NOTE: Blower access door must be installed when taking

temperature rise reading. Leaving blower access door off will

result in incorrect temperature measurements.

FURNACE DAMAGE HAZARD

Failure to follow this caution may result in shorten

furnace life. Set air temperature rise within limits specified on the

rating plate to prevent reduced life of furnace components. Operation is within a few degrees of the mid-point of rise range when setup switch SWl-4 is

OFR

NOTE: Temperature rise can be determined for low-heat operation by placing setup switch SW1-2 on furnace control in ON position. For high-heat operation, place setup switch SW1-2 in OFF position and jumper R-W2 on furnace control. DO NOT forget to return setup switch to OFF position and remove R-W2 jumper upon completion of testing.

c. This furnace is capable of automatically providing

proper airflow to maintain the temperature rise within the range specified on furnace rating plate. Iftem- perature rise is outside this range, proceed as fol-

lows:

(1.) Check gas input for low- and high-heat opera-

tion. (2.) Check derate for altitude if applicable. (3.) Check all return and supply ducts for excessive

restrictions causing static pressure greater than

0.5-In. W.C.

(4.) Ensure Low Heat Rise Adjust switch SWI-3 on

furnace control is in ON position when a bypass

humidifier is used. (See Figure 26 for switch

location.) (5.) Make sure proper model plug is installed.

d. Remove thermostat jumpers and release blower

access door switch.

e. Repeat Steps a through c as required to adjust for

high heat temperature rise.

f. When correct high heat input rate and temperature

rise is achieved, turn gas valve ON/OFF switch to

OFR g. Release blower access door switch. h. Remove manometer or similar device from gas

valve.

i. Re-install manifold pressure tap plug in gas valve.

(See Figure 48)

FIRE HAZARD

Failure to follow this warning could result in personal injury, death, and/or property damage.

Reinstall manifold pressure tap plug in gas valve to prevent gas leak.

UNITDAMAGE HAZARD

Failure to follow this caution may result in overheating

the heat exchangers or condensing flue gases in heat

j. Remove thermostat jumper wire from furnace control

board. k. Turn gas valve ON/OFF switch to ON.

exchanger areas not designed for condensate.

Temperature rise must be within limits specified on

unit rating plate. Operation is within a few degrees of midpoint of rise range when setup switch SWl-4 is

OFR

When setup switch SWl-4 is ON, operation will be near the

high end of the rise range for improved comfort.

Furnace must operate within ranges of temperature rise specified on the furnace rating plate. Determine air temperature rise as follows:

a. Place thermometers in return and supply ducts as

near furnace as possible. Be sure thermometers do not see heat exchanger so that radiant heat does

not affect readings. This practice is particularly im- portant with straight-run ducts.

b. When thermometer readings stabilize, subtract re-

FURNACE OVERHEATING HAZARD

Failure to follow this caution may result in reduced

furnace life.

Recheck temperature rise. It must be within limits specified on the rating plate. Recommended operation is at the mid-point of rise range or slightly

above.

I. Proceed to Step 6, "Set Blower Off Delay" before

installing blower access door.

7. Set Blower Off Delay a. Remove blower access door if installed.

b. Turn Dip switch SW-7 or SW-8 ON or OFF for de-

sired blower off delay. (See Table 9 and Figure 26 and Figure 55)

turn-air temperature from supply-air temperature to

determine air temperature rise.

38 Specifications are subject to change without notice. 441 01 2122 O0

8. Set thermostat heat anticipator. a. Mechanical thermostat. Set thermostat heat anticip-

ator to match the amp. draw of the electrical com-

ponents in the R-W/W1 circuit. Accurate amp. draw readings can be obtained at the wires normally con- nected to thermostat subbase terminals, R and W.

The thermostat anticipator should NOT be in the

circuit while measuring current.

(1.) Set SW1-2 switch on furnace control board to

ON.

(2.) Remove thermostat from subbase or from wall. (3.) Connect an amp. meter as shown in Figure 50.

across the R and W subbase terminals or R and W wires at wall.

(4.) Record amp. draw across terminals when fur-

nace is in low heat and after blower starts.

(5.) Set heat anticipator on thermostat per thermo-

stat instructions and install on subbase or wall.

(6.) Turn SW1-2 switch OFF. (7.) Install blower access door.

b. Electronic thermostat: Set cycle rate for 3 cycles per

hr.

9. Set Airflow for Air Conditioning - Low Speed and High Speed Cooling

The ECM blower can be adjusted for a range of airflow for

Table 14 - Gas Rate (CU ft./hr)

SECONDS G

FOR 1 REVOLUTION

10 11

12 13 14

15 16

17 18 19

2O 21 22

23 24 25

26 27 28

29 3O

31 32 33

34 35 36

37 38 39

4O 41

42 43 44

45 46 47

48 49

1 Cu

SIZE OF TEST DIAL SECONDS

2 Cu Ft, 5 Cu Ft, FOR 1 REVOLUTION

Ft. 1 Cu Ft. 360 327

30O 277 257

24O 225

212 2OO 189

180 171 164

157 150 144

138 133 129

124 120

116 113

109 106

103 100

97 95 92

90 88

86 84 82

80 78 76

75 73

720 1800 50 72 144 655 1636 51 71 141

600 1500 52 69 138 555 1385 53 68 136 514 1286 54 67 133

480 1200 55 65 131 450 1125 56 64 129

424 1059 57 63 126 400 1000 58 62 124 379 947 59 61 122

360 900 60 60 120 343 857 62 58 116 327 818 64 56 112

313 783 66 54 109 300 750 68 53 106 288 720 70 51 103

277 692 72 50 100 267 667 74 48 97 257 643 76 47 95

248 621 78 46 92 240 600 80 45 90

232 581 82 44 88 225 563 84 43 86 218 545 86 42 84

212 529 88 41 82 206 514 90 40 80 200 500 92 39 78

195 486 94 38 76 189 474 96 38 75 185 462 98 37 74

180 450 100 36 72 176 439 102 35 71

172 429 104 35 69 167 419 106 34 68 164 409 108 33 67

160 400 110 33 65 157 391 112 32 64 153 383 116 31 62

150 375 120 30 60 147 367

Low Speed or High Speed cooling. See Table 12 Air Deliv- ery - CFM (With Filter ). Depending on the model size, the cooling airflow can be adjusted from 1.5 tons nominal cool-

ing to 3.5, to 4 or 2 to 6 tons of nominal cooling based on 350 cfm ton.

The cooling airflow is adjusted by turning Setup switches A/C SW2-6, SW2-7 and SW2-8 or OF (SW2-3, SW2-4, and SW2-5) either ON or OFF. Select the required airflow from Table 12. Table 10 is based on 350 CFM per ton. For airflow at 400 CFM per ton, turn Setup SWl-5 ON (See Table 9 and Figure 26 and Figure 55)

NOTE: 6 ton airflow will truncate at 2200 cfm on applicable models. For a complete explanation of cooling airflow, refer to the section titled "Sequence of Operation."

10. Set Airflow For Continuous Fan/Low Speed Cooling Airflow The ECM blower motor can be adjusted for continuous fan speeds different than heating or cooling fan speed. See Table 12 Air Delivery - CFM (With Filter). Select the re-

quired continuous fan airflow from Table 11. The continuous fan speed is also the fan speed for low speed cooling when furnace is used with a 2-speed cool-

ing unit. Adjust the Continuous Fan CFM to match the air- flow required for low speed cooling. Select the required air- flow from Table 12. For airflow at 400 CFM per ton, turn Setup SW1-5 ON (See Table 11) The airflow selected for

low speed cooling will also be the airflow used for continu- ous fan.

SIZE OF TEST DIAL

2 Cu Ft.

5 Cu Ft.

360 355

346 34O 333

327 321

316 310 305

300 29O 281

273 265 257

25O 243 237

231 225

22O 214 2O9

2O5 2OO

196 192

188 184

180 178

173 170 167

164 161 155

150

441 01 2122 00 Specifications are subject to change without notice. 39

Table 15 - Orifice Size and Manifold Pressure (In. W.C.) for Gas Input Rate

(Tabulated Data Based on 22,000 Btuh High-Heat/14,500 Btuh for Low-Heat per Burner, Derated 4 Percent for Each 1000 Ft.

(305 M) Above Sea Level)

SPECIFIC GRAVITY OF NATURAL GAS

0.60

0.62 0.64

Orifice Manifold Orifice Manifold

No. Pressure No. Pressure

42 3.7/1.6 41 3.5/1.5 42 3.5/1.5 42 3.7/1.6

42 3.4/1.5 42 3.5/1.5 42 3.2/1.4 42 3.3/1.4

43 3.7/1.6 43 3.8/1.7 43 3.5/1.5 43 3.6/1.6 43 3.4/1.5 43 3.5/1.5

43 3.2/1.4 43 3.3/1.4 44 3.5/1.5 43 3.2/1.4

High/Low High/Low

ALTITUDE RANGE

FT. (U)

0 to

USA 2000

(oto61o)

AVG. GAS

HEAT VALUE

AT ALTITUDE

(BTUH/CU FT.)

900 925

950

975 1000 1025

1050 1075

1100

Orifice No.

42 42

43 43

44 44

0.58

Manifold Orifice Manifold

Pressure No. Pressure

High/Low High/Low

3.5/1.5 42 3.6/1.6

3.3/1.4 42 3.4/1.5

3.8/1.7 42 3.3/1.4

3.6/1.6 43 3.8/1.6

3.5/1.5 43 3.6/1.6

3.3/1.4 43 3.4/1.5

3.6/1.6 43 3.2/1.4

3.4/1.5 44 3.5/1.5

3.3/1.4 44 3.4/1.5

SPECIFIC GRAVITY OF NATURAL GAS

ALTITUDE RANGE

FT. (U)

200t to

USA 3000 (610

to 914)

AVG. GAS

HEAT VALUE

AT ALTITUDE

(BTUH/CU FT.)

8OO

825

85O

875

900

925

950

975 1000

Orifice No.

0.58 Manifold Orifice Manifold Orifice Pressure Orifice

Pressu re Pressu re Pressu re

0.60 0.62 0.64 Manifold Manifold

High/Low No. High/Low No. High/Low No. High/Low

42 42

43 43

43 44

44 44 45

3.4/1.5 42 3.5/1.5 42 3.6/1.6 42 3.7/1.6

3.2/1.4 42 3.3/1.4 42 3.4/1.5 42 3.5/1.5

3.7/1.6 43 3.8/1.6 42 3.2/1.4 42 3.3/1.4

3.5/1.5 43 3.6/1.6 43 3.7/1.6 43 3.8/1.7

3.3/1.4 43 3.4/1.5 43 3.5/1.5 43 3.6/1.6

3.5/1.5 43 3.2/1.4 43 3.3/1.4 43 3.4/1.5

3.4/1.5 44 3.5/1.5 44 3.6/1.6 43 3.2/1.4

3.2/1.4 44 3.3/1.4 44 3.4/1.5 44 3.5/1.5

3.7/1.6 45 3.8/1.7 44 3.2/1.4 44 3.4/1.5 SPECIFIC GRAVITY OF NATURAL GAS

ALTITUDE RANGE

FT. (U)

3001 to

4000

USA (914 to

1219)

AVG. GAS

HEAT VALUE

AT ALTITUDE

(BTUH/CU FT.)

775 8OO

825 85O

875 9OO

925 95O

Orifice No.

0.58

Manifold Manifold Manifold

Pressu re Pressu re Pressu re

High/Low No. High/Low No. High/Low No. High/Low

42 43

43 43

44 44

45 46

3.2/1.4 42 3.3/1.4 42 3.4/1.5 42 3.5/1.5

3.6/1.6 43 3.8/1.6 42 3.2/1.4 42 3.3/1.4

3.4/1.5 43 3.5/1.5 43 3.7/1.6 43 3.8/1.6

3.2/1.4 43 3.3/1.4 43 3.4/1.5 43 3.6/1.5

3.5/1.5 44 3.6/1.6 43 3.3/1.4 43 3.4/1.5

3.3/1.4 44 3.4/1.5 44 3.5/1.5 43 3.2/1.4

3.8/1.6 44 3.2/1.4 44 3.3/1.5 44 3.4/1.5

3.8/1.6 45 3.7/1.6 45 3.8/1.7 44 3.3/1.4

0.60 0.62 0.64

Manifold

Orifice Orifice Pressure Orifice

SPECIFIC GRAVITY OF NATURAL GAS

ALTITUDE RANGE

FT. (U)

4001 to

5000

USA (1219 to

1524)

AVG. GAS

HEAT VALUE

AT ALTITUDE

(BTUH/CU FT.)

75O 775 8OO

825 85O

875 9OO 925

Orifice No.

0.58 Manifold Orifice Manifold Orifice Pressure Orifice

Pressu re Pressu re Pressu re

0.60 0.62 0.64 Manifold Manifold

High/Low No. High/Low No. High/Low No. High/Low

43 43 43

44 44

45 46 46

3.6/1.6 43 3.8/1.6 42 3.2/1.4 42 3.3/1.4

3.4/1.5 43 3.5/1.5 43 3.6/1.6 43 3.8/1.6

3.2/1.4 43 3.3/1.4 43 3.4/1.5 43 3.5/1.5

3.4/1.5 44 3.6/1.5 43 3.2/1.4 43 3.3/1.4

3.2/1.4 44 3.4/1.5 44 3.5/1.5 44 3.6/1.6

3.7/1.6 45 3.8/1.7 44 3.3/1.4 44 3.4/1.5

3.7/1.6 46 3.8/1.7 45 3.7/1.6 44 3.2/1.4

3.5/1.5 46 3.6/1.6 46 3.7/1.6 46 3.8/1.7 SPECIFIC GRAVITY OF NATURAL GAS

ALTITUDE RANGE

FT. (U)

5001 to

USA

6000

(1524 to

1829)

AVG. GAS

HEAT VALUE

AT ALTITUDE

(BTUH/CU FT.)

725 75O

775 8OO

825 85O 875

9OO

Orifice No.

0.58

Manifold Orifice Manifold Orifice Pressure Orifice

Pressu re Pressu re Pressu re

High/Low No. High/Low No. High/Low No. High/Low

43 43

44 44

46 46 47

3.4/1.5 43 3.5/1.5 43 3.6/1.6 43 3.7/1.6

3.2/1.4 43 3.3/1.4 43 3.4/1.5 43 3.5/1.5

3.4/1.5 44 3.5/1.5 43 3.2/1.4 43 3.3/1.4

3.2/1.4 44 3.3/1.4 44 3.4/1.5 44 3.5/1.5

3.8/1.7 45 3.8/1.6 44 3.2/1.4 44 3.3/1.4

3.6/1.6 46 3.7/1.6 46 3.8/1.7 45 3.8/1.6

3.8/1.7 46 3.5/1.5 46 3.6/1.6 46 3.7/1.6

3.6/1.6 47 3.8/1.6 46 3.4/1.5 46 3.5/1.5

0.60 0.62 0.64

Manifold Manifold

* Orifice numbers 43 are factory installed

40 Specifications are subject to change without notice. 441 01 2122 O0

Table 15 - Orifice Size and Manifold Pressure (In. W.C.) for Gas Input Rate (Con't.)

(Tabulated Data Based on 22,000 Btuh High-Heat/14,500 Btuh for Low-Heat per Burner, Derated 4 Percent for Each 1000 Ft.

Above Sea Level)

ALTITUDE AVG. GAS

RANGE HEAT VALUE

FT. (U) AT ALTITUDE

6001 to 725

USA

USA 700

USA

* Orifice numbers 43 are factory installed

7000 750

(1829 to 775

2134) 800

ALTITUDE

RANGE

FT. (U) (BTUH/CU FT.)

700t to 700

8000 725

(2134 to 750

2438) 775

ALTITUDE HEAT VALUE

RANGE AT ALTITUDE

8001 to

9000

(2438 to 725

2743) 750

ALTITUDE HEAT VALUE

RANGE AT ALTITUDE

9001 to 625

10,000 650

2743 to 675

3048) 700

(BTUH/CU FT.)

675 700

825 850

AVG. GAS

HEAT VALUE

AT ALTITUDE

650 675

800 825

AVG. GAS

(BTUH/CU FT.)

625 650

675

775

AVG. GAS

(BTUH/CU FT.)

600

725

Orifice

0.58 Manifold

No.

43 3.4/1.5 43 3.5/1.5 43 3.6/1.6 43 44 3.6/1.6 43 3.3/1.4 43 3.4/1.5 43 44 3.4/1.5 44 3.5/1.5 44 3.6/1.6 43

45 3.8/1.7 44 3.3/1.4 44 3.4/1.5 44 46 3.7/1.6 45 3.7/1.6 45 3.8/1.7 44

46 3.5/1.5 46 3.6/1.6 46 3.8/1.6 45 47 3.7/1.6 46 3.4/1.5 46 3.5/1.5 46 47 3.5/1.5 47 3.6/1.6 47 3.8/1.6 46

No.

44 44

45 46

46 47

47 48

No.

44 45

46 47

47 48

No.

45 46

47 47 48

Pressure High/Low

0.58 Manifold

Pressure High/Low

3.6/1.6

3.3/1.5

3.8/1.6

3.7/1.6

3.4/1.5

3.6/1.6

3.4/1.5

3.7/1.6

0.58 Manifold

Pressure High/Low

3.3/1.5

3.7/1.6

3.6/1.6

3.8/1.7

3.6/1.6

3.8/1.7

3.6/1.5

0.58 Manifold

Pressure High/Low

3.7/1.6

3.6/1.6

3.8/1.6

3.5/1.5

3.7/1.6

3.5/1.5

Check Safety Controls

The flame sensor, gas valve, and pressure switch were all

checked in the Start-up procedure section as part of normal operation.

1. Check Main Limit Switch This control shuts off combustion system and energizes

air-circulating blower motor, iffurnace overheats. By using this method to check limit control, it can be established that

limit is functioning properly and will operate if there is a re- stricted return-air supply or motor failure. If limit control

does not function during this test, cause must be determ- ined and corrected.

a. Run furnace for at least 5 minutes.

b. Gradually block off return air with a piece of card-

board or sheet metal until the limit trips.

c. Unblock return air to permit normal circulation. d. Burners will re-light when furnace cools down.

441 01 2122 O0 Specifications are subject to change without notice. 41

SPECIFIC GRAVITY OF NATURAL GAS

0.60 0.62

Orifice Orifice

No. No.

SPECIFIC GRAVITY OF NATURAL GAS

Orifice

No.

43 44

44 46

46 47

47 48

SPECIFIC GRAVITY OF NATURAL GAS

Orifice

No.

44 44

46 46

47 47

SPECIFIC GRAVITY OF NATURAL GAS

Orifice

No.

45 46

46 47 48

Manifold Manifold

Pressure Pressure

High/Low High/Low

0.60 Manifold

Pressure

High/Low

3.2/1.4

3.5/1.5

3.2/1.4

3.8/1.7

3.6/1.5

3.8/1.6

3.5/1.5

3.8/1.6

0.60 Manifold

Pressure

High/Low

3.5/1.5

3.2/1.4

3.8/1.6

3.5/1.5

3.7/1.6

3.5/1.5

3.7/1.6

0.60 Manifold

Pressure

High/Low

3.8/1.7

3.7/1.6

3.4/1.5

3.6/1.6

3.8/1.7

3.6/1.6

Check draft safeguard switch. The purpose of this control

Orifice

No.

43 3.4/1.5 44 3.6/1.6

44 3.3/1.4 45 3.7/1.6 46 3.7/1.6

46 3.4/1.5 47 3.7/1.6

47 3.4/1.5

Orifice

No.

44 3.6/1.6 44 3.3/1.4

45 3.7/1.6 46 3.6/1.6

47 3.8/1.7 47 3.6/1.6 48 3.8/1.7

Orifice

No.

44 3.3/1.4 46 3.8/1.7

46 3.6/1.5 47 3.7/1.6

47 3.5/1.5 48 3.7/1.6

is to cause the safe shutdown of the furnace during certain

blocked vent conditions.

a. Verify vent pipe is cool to the touch. b. Disconnect power to furnace and remove vent con-

nector from furnace vent elbow.

c. Restore power to furnace and set room thermostat

above room temperature.

d. After normal start-up, allow furnace to operate for 2

minutes, then block vent elbow in furnace 80 percent of vent area with a piece of flat sheet metal.

e. Furnace should cycle off within 2 minutes. If gas

does not shut off within 2 minutes, determine reason draft safeguard switch did not function properly and

correct condition.

f. Remove blockage from furnace vent elbow.

g. Switch will auto-reset when it cools.

0.62

Manifold

Pressure High/Low

Manifold Pressure High/Low

Manifold Pressure

High/Low

Orifice

No.

Orifice

No.

43 43

44 44

46 46

47 47

Orifice

No.

43 44

45 46

46 47

Orifice

No.

44 45

46 46 47

0.64 Manifold

Pressure

High/Low

3.7/1.6

3.5/1.5

3.2/1.4

3.5/1.5

3.2/1.4

3.7/1.6

3.6/1.6

3.4/1.5

0.64 Manifold

Pressure

High/Low

3.5/1.5

3.2/1.4

3.4/1.5

3.2/1.4

3.8/1.6

3.6/1.5

3.8/1.6

3.6/1.5

0.64 Manifold

Pressure

High/Low

3.2/1.4

3.4/1.5

3.8/1.7

3.7/1.6

3.5/1.5

3.7/1.6

3.5/1.5

0.64 Manifold

Pressure

High/Low

3.4/1.5

3.8/1.6

3.7/1.6

3.4/1.5

3.6/1.6

3.8/1.7

h. Re-install vent connector.

NOTE: Should switch remain open longer than 3 minutes,

furnace control board will lockout the furnace for 3 hours. To

reset furnace control board, turn thermostat below room

temperature or from HEAT to OFF and turn 115-v power OFF, then back ON.

3. Check Pressure Switch(es) This control proves operation of the draft inducer blower.

a. Turn off 115-v power to furnace.

b. Disconnect inducer motor lead wires from wire har-

ness.

c. Turn on 115-v power to furnace. d. Set thermostat to "call for heat" and wait 1 minute.

When pressure switch is functioning properly, hot surface igniter should NOT glow and control dia-

gnostic light flashes a status code 3. If hot surface igniter glows when inducer motor is disconnected,

shut down furnace immediately.

e. Determine reason pressure switch did not function

properly and correct condition.

f. Turn off 115-v power to furnace.

g. Reconnect inducer motor wires, replace outer door,

and turn on 115-v power.

h. Blower will run for 90 seconds before beginning the

call for heat again.

i. Furnace should ignite normally.

Checklist

1. Put away tools and instruments. Clean up debris.

2. Verify that switches SWl-1 and SWl-6 are OFF and other setup switches are set as desired. Verify that switches

SWl-7 and SWl-8 for the blower OFF DELAY are set as desired per Table 16.

Table 16- Blower Off Delay Setup Switch

SETUP SWITCH

DESIREDHEATING MODE (SW-7 AND -8) POSITION

BLOWER OFF DELAY (SEC,) SWl-7 SWl-8

90 OFF OFF 120 ON OFF 150 OFF ON 180 ON ON

3. Verify that blower and burner access doors are properly in- stalled.

4. Cycle test furnace with room thermostat.

5. Check operation of accessories per manufacturer's in- structions.

6. Review User's Guide with owner.

7. Attach literature packet to furnace.

SERVICE AND MAINTENANCE

PROCEDURES

Untrained personnel can perform basic maintenance functions

such as cleaning and replacing air filters. All other operations

must be performed by trained service personnel. A qualified ser-

vice person should inspect the furnace once a year.

ENVIRONMENTAL HAZARD

Failure to follow this caution may result in environmental pollution.

Remove and recycle all components or materials (i.e. oil, refrigerant, control board, etc.) before unit final disposal.

ELECTRICAL SHOCK, FIRE OR EXPLOSION HAZARD

Failure to follow this warning could result in personal injury or death, or property damage.

Before installing, modifying, or servicing system, main

electrical disconnect switch must be in the OFF position and install a lockout tag. There may be more

than one disconnect switch. Lock out and tag switch with a suitable warning label. Verify proper operation after servicing.

ELECTRICAL OPERATION HAZARD Failure to follow this caution may result in improper

furnace operation or failure of furnace.

Label all wires prior to disconnection when servicing

controls. Wiring errors can cause improper and dangerous operation.

General These instructions are written as if the furnace is installed in

an upflow application. An upflow furnace application is where the blower is located below the combustion and controls

section of the furnace, and conditioned air is discharged upward. Since this furnace can be installed in any of the 4

positions shown in Figure 4, you must revise your orientation to component location accordingly.

Electrical Controls and Wirinq

ELECTRICAL SHOCK HAZARD

Failure to follow this warning could result in personal injury or death.

There may be more than one electrical supply to the furnace. Check accessories and cooling unit for additional electrical supplies that must be shut off

during furnace servicing. Lock out and tag switch with

a suitable warning label.

FIRE, INJURY OR DEATH HAZARD Failure to follow this warning could result in personal

injury, death and/or property damage.

The ability to properly perform maintenance on this

equipment requires certain knowledge, mechanical skills, tools, and equipment. If you do not possess these, do not attempt to perform any maintenance on this equipment other than those procedures

recommended in the User's Manual.

42 Specifications are subject to change without notice. 441 01 2122 O0

The electrical ground and polarity for 115-v wiring must be properly maintained. Refer to Figure25 for field wiring

information and to Figure 55 for furnace wiring information. NOTE: If the polarity is not correct, the STATUS LED on the

control wilt flash status code 10 and prevent the furnace from heating. The control system also requires an earth ground for proper operation of the control and flame-sensing electrode.

The 24-v circuit contains an automotive-type, 3-amp. fuse located on the control. (See Figure 26) Any shorts of the 24-v

wiring during installation, service, or maintenance will cause this fuse to blow. If fuse replacement is required, use ONLY a

3-amp. fuse. The control LED turn off when fuse needs to be

replaced. Proper instrumentation is required to service electrical

controls. The control in this furnace is equipped with a Status Code LED (Light-Emitting Diode) to aid in installation,

servicing, and troubleshooting. Status codes can be viewed at the sight glass in blower access door. The amber furnace

control LED is either flashing a heartbeat (bright-dim), on-solid, or flashing a status code. For an explanation of status codes, refer to service label located on blower access door or Figure51, and the

troubleshooting guide which can be obtained from your

distributor. See Figure 56, a brief Troubleshooting Guide.

For 2-Stage Variable Speed ECM Controls the stored status codes wilt NOT be erased from the control memory, when 115- or 24-v power is interrupted. The control wilt store up to

the last 7 Status Codes in order of occurrence.

1. To retrieve status codes, proceed with the following: NOTE: NO thermostat signal may be present at control, and

atl blower-OFF delays must be completed.

a. Leave 115-v power to furnace turned on.

b. Remove outer access door. c. Look into blower access door sight glass for current

amber LED status. Removing blower access door will open blower access door switch and terminate

115-v power to control so that status code is not

displayed.

d. Remove blower access door.

NOTE: The Status Codes cannot be retrieved by disconnecting the limit switch or draft safeguard switch. To retrieve Status Codes, follow the procedure below.

2. Turn Setup Switch, SWl-1 "ON."

3. Manually close blower access door switch.

4. Control will flash up to 7 Status Codes.

5. The last Status Code, or 8th Code, flashing heartbeat briefly.

6. Turn SWl-1 "OFF."

7. The Amber LED wilt flash heartbeat (bright-dim) continu- ously to indicate proper operation.

8. Release blower access door switch, install blower access door and replace outer door or refer to the SERVICE label

on the front of the blower access door for more informa- tion.

Component Self-Test Component Test can ONLY be initiated by performing the

following:

1. Remove outer access door.

2. Remove blower access door.

3. Remove the wire from the "R" terminal of the control board.

4. Turn Setup Switch, SW-I-6 "ON."

5. Manually close blower access door switch. Blower access door switch opens 115-v power to control. No component operation can occur unless switch is closed. Caution must be taken when manually closing this switch for

service purposes.

6. Component Test sequence will function as follows: a. Inducer motor starts on high-speed and continues to

run until Step (d.) of component test sequence.

b. Hot surface igniter is energized for 15 sec, then

deenergized. c. Blower operates for 10 sec, then turns off. d. Inducer motor goes to low-speed for 10 seconds,

then turns off. e. After component test is completed, one or more

status codes (heartbeat, 2+5) will flash. See com-

ponent test section of service label for explanation of

status codes.

NOTE: To repeat component test, turn setup switch SWl-6 OFF then back ON.

f. Turn setup switch SWl-6 OFF.

7. RELEASE BLOWER ACCESS DOOR SWITCH, reattach wire to "R" terminal on furnace control board, replace blower access door, and replace outer access door.

CARE AND MAINTENANCE

FIRE OR EXPLOSION HAZARD Failure to follow this warning could result in personal

injury, death and/or property damage. Never store anything on, near, or in contact with the

furnace, such as:

8. Spray or aerosol cans, rags, brooms, dust mops, vacuum cleaners, or other cleaning tools.

9. Soap powders, bleaches, waxes or other cleaning compounds, plastic or plastic containers,

gasoline, kerosene, cigarette lighter fluid, dry cleaning fluids, or other volatile fluids.

10. Paint thinners and other painting compounds, paper bags, or other paper products. Exposure to

these materials could lead to corrosion of the heat exchangers.

For continuing high performance and to minimize possible furnace failure, periodic maintenance must be performed on

this furnace. Consult your local dealer about proper frequency of maintenance and the availability of a maintenance contract.

ELECTRICAL SHOCK AND FIRE HAZARD

Failure to follow this warning could result in personal injury, death, and/or property damage.

Turn off the gas and electrical supplies to the furnace

before performing any maintenance or service. Follow

the operating instructions on the label attached to the furnace.

ELECTRICALSHOCKHAZARD

Failure to follow this warning could result in personal injury, or death.

Blower access door switch opens 115-v power to

furnace control. No component operation can occur

unless switch is closed. Exercise caution to avoid electrical shock from exposed electrical components

CARBON MONOXIDE POISONING AND FIRE

HAZARD

Failure to follow this warning could result in personal injury, death and/or property damage.

Never operate furnace without a filter or with filter

access door removed.

when manually closing this switch for service

purposes.

441 01 2122 O0 Specifications are subject to change without notice. 43

Table 17 - Orifice Size and Manifold Pressure (In. W.C.) for Gas Input Rate

(Tabulated Data Based on 21,000 Btuh High-Heat/14,500 Btuh for Low-Heat Per Burner, Derated 4 Percent for Each 1000 Ft.

(305 M) Above Sea level)

SPECIFIC GRAVITY OF NATURAL GAS

0.60

Orifice

No.

42 43

43 43

43 44

44 44 45

Manifold

Pressure

High/Low

3.3/1.6

3.8/1.8

3.6/1.7

3.4/1.6

3.3/1.6

3.6/1.7

3.4/1.6

3.2/1.5

3.7/1.8

Orifice

No.

42 3.4/1.6 42 3.2/1.5

43 3.7/1.8 43 3.5/1.7 43 3.4/1.6

43 3.2/1.5 44 3.5/1.7

44 3.3/1.6 44 3.2/1.5

SPECIFIC GRAVITY OF NATURAL GAS

0.60

Orifice

No.

42 43

43 43 44

44 45

46 46

Manifold

Pressure

High/Low

3.2/1.5

3.7/1.7

3.5/1.6

3.3/1.6

3.5/1.7

3.3/1.6

3.8/1.8

3.6/1.7

Orifice

No.

42 3.3/1.6 43 3.8/1.8

43 3.6/1.7 43 3.4/1.6

43 3.2/1.5 44 3.5/1.6

44 3.3/1.6 45 3.8/1.8

46 3.8/1.8

SPECIFIC GRAVITY OF NATURAL GAS

0.60

Orifice

No.

43 43

43 44

44 45

46 46

Manifold

Pressure

High/Low

3.7/1.7

3.4/1.6

3.2/1.5

3.5/1.7

3.3/1.6

3.8/1.8

3.7/1.8

3.5/1.7

Orifice

No.

43 3.8/1.8 43 3.5/1.7

43 3.3/1.6 44 3.6/1.7

44 3.4/1.6 44 3.2/1.5 45 3.7/1.8

46 3.7/1.7

SPECIFIC GRAVITY OF NATURAL GAS

0.60

Orifice

No.

43 43 44

44 45

46 46 47

Manifold

Pressure

High/Low

3.4/1.6

3.2/1.5

3.4/1.6

3.2/1.5

3.7/1.8

3.7/1.7

3.5/1.7

3.7/1.8

Orifice

No.

43 3.5/1.7 43 3.3/1.6

44 3.6/1.7 44 3.4/1.6

45 3.8/1.8 46 3.8/1.8

46 3.6/1.7 47 3.8/1.8

SPECIFIC GRAVITY OF NATURAL GAS

0.60

Orifice

No.

43 44

44 46 46

47 47

Manifold

Pressure

High/Low

3.2/1.5

3.4/1.6

3.2/1.5

3.8/1.8

3.6/1.7

3.8/1.8

3.6/1.7

3.4/1.6

Orifice

No.

43 3.3/1.6 44 3.5/1.7

44 3.3/1.6 45 3.8/1.8

46 3.7/1.8 46 3.5/1.7

47 3.7/1.8 47 3.5/1.7

0.62

Manifold

Pressure High/Low

Manifold

Pressure High/Low

Manifold

Pressure High/Low

Manifold Pressure High/Low

Manifold Pressure

High/Low

Orifice

No.

42 42

43 43

43 44 44

Orifice

No.

42 42

43 43 43

44 44

44 45

Orifice

No.

42 43

43 43

44 44

45 46

Orifice

No.

43 43 43

44 44

45 46 46

Orifice

No.

43 43

44 44 46

46 46

0.64 Manifold

Pressure High/Low

3.5/1.7

3.3/1.6

3.8/1.8

3.7/1.7

3.5/1.7

3.3/1.6

3.2/1.5

3.4/1.6

3.3/1.6

0.64 Manifold

Pressure High/Low

3.4/1.6

3.2/1.5

3.7/1.8

3.5/1.7

3.3/1.6

3.6/1.7

3.4/1.6

3.2/1.5

3.7/1.8

0.64 Manifold

Pressure High/Low

3.2/1.5

3.7/1.7

3.4/1.6

3.2/1.5

3.5/1.7

3.3/1.6

3.8/1.8

0.64 Manifold

Pressure High/Low

3.6/1.7

3.4/1.6

3.2/1.5

3.5/1.6

3.3/1.6

3.7/1.8

3.5/1.7

0.64 Manifold

Pressure High/Low

3.4/1.6

3.2/1.5

3.4/1.6

3.2/1.5

3.8/1.8

3.6/1.7

3.4/1.6

3.7/1.7

ALTITUDE RANGE

FT. (U)

0 to

USA 2000

(oto61o)

ALTITUDE RANGE

FT. (U)

200t to

USA 3000 (610

to 914)

ALTITUDE RANGE

FT. (U)

3001 to

USA 4OOO(914

ALTITUDE RANGE

USA

ALTITUDE RANGE

USA

to 1219)

FT. (U)

4001 to

5000

(1219 to

1524)

FT. (U)

5001 to

6000

(1524 to

1829)

AVG. GAS

HEAT VALUE

AT ALTITUDE

(BTUH/CU FT.)

900 925

950 975

1000 1025

1050 1075 1100

AVG. GAS

HEAT VALUE

AT ALTITUDE

(BTUH/CU FT.)

800 825

850 875 900

925 950

975

1000

AVG. GAS

HEAT VALUE

AT ALTITUDE

(BTUH/CU FT.)

775 800

825 850

875 900

925 950

AVG. GAS

HEAT VALUE

AT ALTITUDE

(BTUH/CU FT.)

750 775 800

825 850

875 900 925

AVG. GAS

HEAT VALUE

AT ALTITUDE

(BTUH/CU FT.)

725 750

775 800 825

850 875

900

Orifice

No.

42 43

43 43

44 44

44 45 46

Orifice

No.

43 43

43 43 44

44 45

46 46

Orifice

No.

43 43

44 44

45 46

46 46

Orifice

No.

43 44 44

45 46

46 47 47

Orifice

No.

44 44

45 46 46

47 47

0.58 Manifold

Pressure

High/Low

3.2/1.5

3.7/1.8

3.5/1.7

3.3/1.6

3.6/1.7

3.4/1.6

3.3/1.6

3.8/1.8

0.58 Manifold

Pressure

High/Low

3.8/1.8

3.5/1.7

3.3/1.6

3.2/1.5

3.4/1.6

3.2/1.5

3.7/1.8

3.5/1.7

0.58 Manifold

Pressure

High/Low

3.5/1.7

3.3/1.6

3.6/1.7

3.4/1.6

3.8/1.8

3.6/1.7

3.4/1.6

0.58 Manifold

Pressure

High/Low

3.3/1.6

3.6/1.7

3.3/1.6

3.8/1.8

3.5/1.7

3.8/1.8

3.6/1.7

0.58 Manifold

Pressure

High/Low

3.5/1.7

3.3/1.6

3.7/1.8

3.5/1.7

3.7/1.8

3.5/1.7

3.8/1.8

44 Specifications are subject to change without notice. 441 01 2122 O0

Table 17 - Orifice Size and Manifold Pressure (In. W.C.) for Gas Input Rate (Con't.)

(Tabulated Data Based on 21,000 Btuh High-Heat/14,500 Btuh for Low-Heat Per Burner, Derated 4 Percent for Each 1000 Ft.

(305 M) Above Sea level)

ALTITUDE RANGE HEAT VALUE

FT. (U) AT ALTITUDE

6001 to 725

USA

ALTITUDE RANGE HEAT VALUE

USA

ALTITUDE RANGE HEAT VALUE

USA 700

ALTITUDE RANGE HEAT VALUE

USA

* Orifice numbers 43 are factory installed

7000 750

(1829 to 775

2134) 800

FT. (U) AT ALTITUDE

700t to 700

8000 725

(2134 to 750

2438) 775

FT. (U) AT ALTITUDE

8001 to

9000

(2438 to 725

2743) 750

FT. (U) AT ALTITUDE

9001 to 625

10,000 650

(2743 to 675

3048) 700

AVG. GAS

(BTUH/CU FT.)

675 700

825 850

AVG. GAS

(BTUH/CU FT.)

650 675

800 825

AVG. GAS

(BTUH/CU FT.)

625 650

675

775

AVG. GAS

(BTUH/CU FT.)

600

725

0.58

Orifice

No.

44 3.5/1.7 43 3.2/1.5 43 3.3/1.6 43 44 3.3/1.6 44 3.4/1.6 44 3.5/1.7 43 45 3.7/1.8 45 3.8/1.8 44 3.3/1.6 44

46 3.6/1.7 46 3.8/1.8 45 3.7/1.8 45 46 3.4/1.6 46 3.5/1.7 46 3.6/1.7 46

47 3.6/1.7 47 3.8/1.8 46 3.4/1.6 46 47 3.4/1.6 47 3.5/1.7 47 3.6/1.7 47 48 3.7/1.7 48 3.8/1.8 47 3.4/1.6 47

Orifice

No.

44 45

46 47

47 48

48 48

Orifice

No.

45 46

47 47

48 48

Orifice

No.

46 47

47 48 48

Manifold

Pressure

High/Low

0.58 Manifold

Pressure

High/Low

3.3/1.6

3.7/1.8

3.6/1.7

3.8/1.8

3.5/1.7

3.8/1.8

3.6/1.7

3.3/1.6

0.58 Manifold

Pressure

High/Low

3.7/1.8

3.6/1.7

3.8/1.8

3.5/1.7

3.7/1.8

3.5/1.7

3.8/1.8

0.58 Manifold

Pressure

High/Low

3.6/1.7

3.7/1.8

3.4/1.6

3.6/1.7

3.4/1.6

3.7/1.8

CUT HAZARD

Failure to follow this caution may result in personal injury.

Sheet metal parts may have sharp edges or burrs. Use care and wear appropriate protective clothing, safety glasses and gloves when handling parts, and servicing

furnaces.

The minimum maintenance on this furnace is as follows:

1. Check and clean air filter each month or more frequently if required. Replace if torn.

2. Check blower motor and wheel for cleanliness each heat- ing and cooling season. Clean as necessary.

3. Check electrical connections for tightness and controls for proper operation each heating season. Service as neces- sary.

SPECIFIC GRAVITY OF NATURAL GAS

0.60 0.62

Orifice Orifice

No. No.

SPECIFIC GRAVITY OF NATURAL GAS

Orifice

No.

44 45

46 46

47 47

48 48

SPECIFIC GRAVITY OF NATURAL GAS

Orifice

No.

45 46

46 47

48 48

SPECIFIC GRAVITY OF NATURAL GAS

Orifice

No.

46 47

47 48 48

Manifold Manifold

Pressure Pressure

High/Low High/Low

0.60 Manifold

Pressure

High/Low

3.4/1.6

3.8/1.8

3.7/1.8

3.5/1.7

3.7/1.8

3.4/1.6

3.7/1.8

3.5/1.6

0.60 Manifold

Pressure

High/Low

3.8/1.8

3.7/1.8

3.4/1.6

3.6/1.7

3.8/1.8

3.6/1.7

3.4/1.6

0.60 Manifold

Pressure

High/Low

3.7/1.8

3.8/1.8

3.6/1.7

3.8/1.8

3.5/1.7

3.8/1.8

Orifice

No.

44 3.5/1.7 44 3.3/1.6

46 3.8/1.8 46 3.6/1.7 47 3.8/1.8

47 3.6/1.7 48 3.8/1.8

48 3.6/1.7

Orifice

No.

44 3.3/1.6 46 3.8/1.8

46 3.5/1.7 47 3.7/1.8

47 3.5/1.7 48 3.7/1.8 48 3.5/1.7

Orifice

No.

46 3.8/1.8 46 3.5/1.7

47 3.7/1.8 47 3.4/1.6

48 3.6/1.7 48 3.4/1.6

4. Inspect burner compartment before each heating season

for rust, corrosion, soot or excessive dust. If necessary,

have furnace and burner serviced by a qualified service

agency.

5. Inspect the vent pipe/vent system before each heating

season for rust, corrosion, water leakage, sagging pipes or broken fittings. Have vent pipes/vent system serviced by a qualified service agency.

6. Inspect any accessories attached to the furnace such as a humidifier or electronic air cleaner. Perform any service or

maintenance to the accessories as recommended in the accessory instructions.

0.62

Manifold

Pressure High/Low

Manifold Pressure High/Low

Manifold Pressure

High/Low

Orifice

No.

Orifice

No.

43 44

45 46

46 47

47 48

Orifice

No.

44 45

46 46

47 48

Orifice

No.

45 46

47 47 48

0.64 Manifold

Pressure High/Low

3.4/1.6

3.2/1.5

3.4/1.6

3.8/1.8

3.5/1.7

3.8/1.8

3.5/1.7

0.64 Manifold

Pressure High/Low

3.2/1.5

3.4/1.6

3.8/1.8

3.7/1.8

3.5/1.6

3.7/1.7

3.4/1.6

3.7/1.8

0.64 Manifold

Pressure High/Low

3.4/1.6

3.8/1.8

3.7/1.7

3.4/1.6

3.6/1.7

3.8/1.8

3.6/1.7

0.64 Manifold

Pressure High/Low

3.7/1.8

3.6/1.7

3.8/1.8

3.5/1.7

3.7/1.8

3.5/1.7

441 01 2122 O0 Specifications are subject to change without notice. 45

Table 18 - Filter Size Information - In. (mm)

SIDE

FURNACE CASING WIDTH RETURN

16 X 25 X 3/4

14-1/2 (368) (406 X 635 X 19)

16 X 25 X 3/4

17-1/2 (445) (406 X 635 X 19)

16 X 25 X 3/4

21 (533) (406 X 635 X 19)

16 X 25 X 3/4

24 (610) (406 X 635 X 19)

* Recommended

Cleaning and/or Replacing Air Filter

The air filter arrangement will vary depending on the application.

NOTE: If the filter has an airflow direction arrow, the arrow must point towards the blower.

CUT HAZARD

Failure to follow this caution may result in personal injury.

Sheet metal parts may have sharp edges or burrs. Use care and wear appropriate protective clothing, safety glasses and gloves when handling parts, and servicing

furnaces.

Blower Motor and Wheel

ELECTRICAL SHOCK HAZARD

Failure to follow this warning could result in personal injury or death.

Blower access door switch opens 115-v power to control. No component operation can occur unless

switch is closed. Caution must be taken when manually closing this switch for service purposes.

NOTE: The blower wheel should not be dropped or bent as balance will be affected.

The following steps should be performed by a qualified service agency.

To ensure long life and high efficiency, clean accumulated dirt and grease from blower wheel and motor annually.

The inducer and blower motors are pre-lubricated and require

no additional lubrication. These motors can be identified by the

absence of oil ports on each end of the motor.

Clean blower motor and wheel as follows:

1. Turn off electrical supply to furnace.

2. Remove outer door.

3. For downflow or horizontal furnaces having vent pipes within the furnace that pass in front of the blower access

door:

a. Disconnect vent connector from furnace vent elbow.

b. Disconnect and remove short piece of vent pipe

from within furnace.

FILTERSIZE

BOTTOM

RETURN

14 X 25 X 3/4

(356 X 635 X 19)

16 X 25 X 3/4

(406 X 635 X 19)

20 X 25 X 3/4

(508 X 635 X 19)

24 X 25 X 3/4

(610 X 635 X 19)

FILTER TYPE

Washable*

4. Remove 2 screws from blower access door and remove blower access door.

5. All factory wires can be left connected, but field thermostat connections may need to be disconnected depending on

their length and routing.

6. Remove 2 screws holding blower assembly to blower deck and slide blower assembly out of furnace.

7. Clean blower wheel and motor using a vacuum with soft brush attachment. Blower wheel blades may be cleaned

with a small paint or flux brush. Do not remove or disturb balance weights (clips) on blower wheel blades.

8. Vacuum any loose dust from blower housing, wheel and motor.

9. If a greasy residue is present on blower wheel, remove wheel from the blower housing and wash it with an appro-

priate degreaser. To remove wheel:

NOTE: Before disassembly, mark blower mounting arms, motor, and blower housing so motor and each arm is positioned at the same location during reassembly.

a. Disconnect ground wire attached to blower housing. b. Remove screws securing cutoff plate and remove

cutoff plate from housing.

c. Loosen set screw holding blower wheel on motor

shaft (160+/-20 in.-Ib, when assembling).

d. Remove bolts holding motor to blower housing and

slide motor out of wheel (40+/-10 in.-Ib, when reas- sembling).

e. Remove blower wheel from housing.

f. Clean wheel and housing.

10. Reassemble motor and blower by reversing steps 9a, through 9e. Be sure to reattach ground wire to the blower

housing.

11. Verify that blower wheel is centered in blower housing and set screw contacts the flat portion of the motor shaft.

Loosen set screw on blower wheel and reposition if neces-

sary.

12. Spin the blower wheel by hand to verify that the wheel does not rub on the housing.

13. Reinstall blower assembly in furnace.

14. Reinstall 2 screws securing blower assembly to blower deck.

15. Reconnect blower leads to furnace control. Refer to fur-

nace wiring diagram, and connect thermostat leads if pre-

viously disconnected.

16. To check blower for proper rotation:

a. Turn on electrical supply.

46 Specifications are subject to change without notice. 441 01 2122 O0

f. Hot surface igniter.

g. Flame-sensing electrode. h. Flame rollout switches.

ELECTRICALSHOCKHAZARD

Failure to follow this warning could result in personal injury, or death.

Blower access door switch opens 115-v power to

furnace control. No component operation can occur unless switch is closed. Exercise caution to avoid

electrical shock from exposed electrical components when manually closing this switch for service purposes.

b. Manually close blower access door switch.

NOTE: If R-W/W1 thermostat terminals are jumpered at the time blower access door switch is closed, blower will run for 90 sec before beginning a heating cycle.

c. Perform component self-test as shown at the bottom

of the SERVICE label, located on the front of blower

access door.

d. Verify blower is rotating in the correct direction

17. If furnace is operating properly, RELEASE BLOWER AC-

6. Remove screws that fasten the collector box assembly to the cell panel. Be careful not to damage the collector box.

Inducer assembly and elbow need not be removed from

collector box.

7. Disconnect gas line from gas manifold.

8. Remove the four screws that attach the burner assembly to the cell panel. The gas valve and individual burners

need not be removed from support assembly. Remove NOx baffles, if installed.

NOTE: Be very careful when removing burner assembly to avoid breaking igniter. See Figure 52-Figure 53 for correct

igniter location.

9. Using field-provided 25-caliber rifle cleaning brush, 36-in.

(914 mm) long, 1/4-in. (6 mm) diameter steel spring cable, a variable speed reversible electric drill, and vacuum cleaner, clean cells as follows:

Figure 52 - Igniter Position - Side View

CESS DOOR SWITCH. Remove any jumpers or reconnect any disconnected thermostat leads. Replace blower ac- cess door.

18. Downflow or horizontal furnaces with vent pipe through fur- nace only:

7.1 mm

9/32"--_

5/16"

7.9 mm

a. Install and connect short piece of vent pipe inside

furnace to existing vent.

b. Connect vent connector to vent elbow.

19. Reinstall outer door.

20. Turn on gas supply and cycle furnace through one com- plete heating and cooling cycle. Verify the furnace temper-

ature rise as shown in Adjustments Section. Adjust tem- perature rise as shown in Adjustments Section. If outdoor

temperature is below 70°F, turn off circuit breaker to out- door unit before running furnace in the cooling cycle. Turn outdoor circuit breaker on after completing cooling cycle.

Cleaning Heat Exchanger

Figure 53 - Igniter Position - Top View

The following steps should be performed by a qualified service agency:

NOTE: If the heat exchangers get a heavy accumulation of

soot and carbon, they should be replaced rather than trying to

clean them thoroughly. A build-up of soot and carbon indicates that a problem exists which needs to be corrected,

such as improper adjustment of manifold pressure, insufficient

or poor quality combustion air, incorrect size or damaged manifold orifice(s), improper gas, or a restricted heat exchanger. Action must be taken to correct the problem.

If it becomes necessary to clean the heat exchangers because of dust or corrosion, proceed as follows:

1. Turn OFF gas and electrical power to furnace.

2. Remove outer access door.

3. Disconnect vent connector from furnace vent elbow.

4. For downflow or horizontal furnace having an internal vent pipe, remove internal vent pipe within the casing.

5. Disconnect wires to the following components. Mark wires to aid in reconnection (be careful when disconnecting

wires from switches because damage may occur):

a. Draft safeguard switch.

b. Inducer motor. c. Pressure switches.

d. Limit overtemperature switch.

a. Remove metal screw fitting from wire brush to allow

insertion into cable.

b. Insert the twisted wire end of brush into end of

spring cable, and crimp tight with crimping tool or crimp by striking with balt-peen hammer. TIGHT-

NESS IS VERY IMPORTANT.

NOTE: The materials needed in item 9 can usually be purchased at local hardware stores.

(1.) Attach variable-speed, reversible drill to the end

of spring cable (end opposite brush).

(2.) Insert brush end of cable into the outlet opening

of cell and slowly rotate with drill. DO NOT force cable. Gradually insert cable into upper pass of cell. (See Figure 54)

e. Gas valve.

441 01 2122 O0 Specifications are subject to change without notice. 47

A05025

A05026

(3.) Work cable in and out of celt 3 or 4 times to ob-

tain sufficient cleaning. DO NOT pull cable with

great force. Reverse drill and gradually work cable out.

(4.) Insert brush end of cable in burner inlet opening

17. Set thermostat above room temperature and check fur- nace for proper operation.

18. Verify blower airflow and speed changes between heating

and cooling.

19. Check for gas leaks.

of cell, and proceed to clean 2 lower passes of cell in same manner as upper pass.

(5.) Repeat foregoing procedures until each cell in

furnace has been cleaned.

(6.) Using vacuum cleaner, remove residue from

each cell.

(7.) Using vacuum cleaner with soft brush attach-

ment, clean burner assembly.

(8.) Clean flame sensor with fine steel wool. (9.) Install NOx baffles (if removed).

Figure 54 - Cleaning Heat Exchanger Cell

FIRE OR EXPLOSION HAZARD Failure to follow this warning could result in personal

injury, death, and/or property damage. Never purge a gas line into a combustion chamber.

Never test for gas leaks with an open flame. Use a commercially available soap solution made specifically for the detection of leaks to check all connections. A fire or explosion may result causing property damage, personal injury or loss of life.

Sequence of Operation NOTE: Furnace control must be grounded for proper

operation or else control will lock out. Control is grounded through green/yellow wire routed to gas valve and burner box screw. Using the schematic diagram in Figure 55, follow the sequence of operation through the different modes. Read and follow the wiring diagram very carefully.

NOTE: If a power interruption occurs during a call for heat (W/W1 or W/Wl-and-W2), the control will start a 90-second blower-only ON period two seconds after power is restored, if the thermostat is still calling for gas heating. The amber LED

A91252

light will flash code 1+2 during the 90-second period, after which the LED will flash a heartbeat (bright-dim), as long as

(10.) Reinstall burner assembly. Center burners in cell

openings.

10. Remove old sealant from cell panel and collector box flange.

11. Spray releasing agent on the heat exchanger cell panel where collector box assembly contacts cell panel.

NOTE: A releasing agent such as a vegetable oil cooking

spray that does not contain corn oil, canola oil, halogenated

hydrocarbons or aromatic content, which may prevent an inadequate seal from occuring, and RTV sealant such as G.E.

RTV 162, G.E. RTV 6702, or Dow-Corning RTV 738 sealant are required. DO NOT substitute any other type of RTV sealant.

12. Apply new sealant to flange of collector box and attach to cell panel using existing screws, making sure all screws

are secure.

13. Reconnect wires to the following components (Use con- nection diagram on wiring label, if wires were not marked

for reconnection locations.):

a. Draft safeguard switch.

b. Inducer motor. c. Pressure switches.

d. Limit overtemperature switch. e. Gas valve.

f. Hot surface igniter.

g. Flame-sensing electrode. h. Flame rollout switches.

14. Reinstall internal vent pipe, if applicable.

15. Reinstall vent connector on furnace vent elbow. Securely fasten vent connector to vent elbow with 2 field-supplied, corrosion-resistant, sheet metal screws located 180°

apart.

no faults are detected. After the 90-second period, the furnace wilt respond to the thermostat normally.

The blower door must be installed for power to be conducted through the blower door interlock switch ILK to the furnace

control CPU, transformer TRAN, inducer motor IDM, blower motor BLWM, hot-surface igniter HSI, and gas valve GV.

1, Two-Stage Heating (Adaptive Mode) with Single-Stage

Thermostat

See Figure 25 thermostat connections NOTE: The low-heat only switch SWl-2 selects either the low-heat only operation mode when ON, (see item 2. below) or the adaptive heating mode when OFF in response to a call for heat. (See Table 9) When the W2 thermostat terminal is energized it will always cause high-heat operation when the R-to-W circuit is closed, regardless of the setting of the low-heat only switch. This furnace can operate as a two-stage furnace with a single-stage thermostat because the furnace control CPU includes a programmed adaptive sequence of controlled operation, which selects low-heat or high-heat operation. This selection is based upon the stored history of the length of previous gas-heating periods of the single-stage thermostat.

The furnace will start up in either low- or high-heat. If the furnace starts up in low-heat, the control CPU determines the low-heat on-time (from 0 to 16 minutes) which is permitted

before switching to high-heat. If the power is interrupted, the stored history is erased and the

control CPU will select low-heat for up to 16 minutes and then switch to high-heat, as long as the thermostat continues to

call for heat. Subsequent selection is based on stored history of the thermostat cycle times.

The wall thermostat "calls for heat", closing the R-to-W circuit. The furnace control performs a self-check, verifies the

low-heat and high-heat pressure switch contacts LPS and

16. Replace blower access door only if it was removed.

48 Specifications are subject to change without notice. 441 01 2122 00

HPS are open, and starts the inducer motor IDM in high-speed.

a. Inducer Prepurge Period

(1.) If the furnace control CPU selects low-heat op-

eration the inducer motor IDM comes up to

speed, the low-heat pressure switch LPS

closes, and the furnace control CPU begins a 15-second prepurge period. If the low-heat

pressure switch LPS fails to remain closed the inducer motor IDM will remain running at high-

speed. After the low-heat pressure switch re-

closes the furnace control CPU will begin a 15-second prepurge period, and continue to run

the inducer motor IDM at high-speed.

(2.) If the furnace control CPU selects high-heat

operation, the inducer motor IDM remains run- ning at high-speed, and the high-heat pressure

switch relay HPSR is de-energized to close the

NO contact. When sufficient pressure is avail-

able the high-heat pressure switch HPS closes, and the high-heat gas valve solenoid GV-HI is

energized. The furnace control CPU begins a 15-second prepurge period after the low-heat

pressure switch LPS closes. If the high-heat pressure switch HPS fails to close and the low-

heat pressure switch LPS closes, the furnace

will operate at low-heat gas flow rate until the

high-heat pressure switch closes for a maxim- um of 2 minutes after ignition.

b. Igniter Warm-Up -At the end of the prepurge peri-

od, the Hot-Surface Igniter HSI is energized for a 17-second igniter warm-up period.

c. Trial-For-Ignition Sequence -When the igniter

warm-up period is completed the main gas valve

relay contact GVR closes to energize the gas valve

solenoid GV-M. The gas valve solenoid GV-M per-

mits gas flow to the burners where it is ignited by the HSI. Five seconds after the GVR closes, a 2-second

flame proving period begins. The HSl igniter will re-

main energized until the flame is sensed or until the

2-second flame proving period begins. If the furnace

control CPU selects high-heat operation, the high- heat gas valve solenoid GV-HI is also energized.

d. Flame-Proving - When the burner flame is proved

at the flame-proving sensor electrode FSE, the in-

ducer motor IDM switches to low-speed unless the

furnace is operating in high-heat, and the furnace

control CPU begins the blower-ON delay period and continues to hold the gas valve GV-M open. If the

burner flame is not proved within two seconds, the control CPU will close the gas valve GV-M, and the control CPU wilt repeat the ignition sequence for up

to three more Trials-For-Ignition before going to

Ignition-Lockout. Lockout will be reset automatically

after three hours, or by momentarily interrupting 115 vac power to the furnace, or by interrupting 24 vac

power at SEC1 or SEC2 to the furnace control CPU (not at W/W1, G, R, etc.). If flame is proved when

flame should not be present, the furnace control

CPU will lock out of Gas-Heating mode and operate

the inducer motor IDM on high speed until flame is

no longer proved.

e. Blower-On delay - If the burner flame is proven the

blower-ON delays for low-heat and high-heat are

as follows:

Low-heat - 45 seconds after the gas valve GV-M is opened the blower motor BLWM is turned ON at

low-heat airflow. High-heat - 25 seconds after the gas valve GV-M

is opened the BLWM is turned ON at high-heat air- flow. Simultaneously, the humidifier terminal HUM

and electronic air cleaner terminal EAC-1 are ener- gized and remain energized throughout the heating

cycle.

f. Switching from Low- to High-Heat - If the furnace

control CPU switches from low-heat to high-heat, the furnace control CPU will switch the inducer motor

IDM speed from low to high. The high-heat pressure switch relay HPSR is de-energized to close the NC

contact. When sufficient pressure is available the high-heat pressure switch HPS closes, and the high-heat gas valve solenoid GV-HI is energized. The blower motor BLWM will transition to high-heat

airflow five seconds after the furnace control CPU switches from low-heat to high-heat.

g. Switching from High- to Low-Heat -The furnace

control CPU will not switch from high-heat to low- heat while the thermostat R-to-W circuit is closed

when using a single-stage thermostat.

h. Blower-Off Delay -When the thermostat is satis-

fied, the R to W circuit is opened, de-energizing the gas valve GV-M, stopping gas flow to the burners, and de-energizing the humidifier terminal HUM. The inducer motor IDM will remain energized for a 5-second post-purge period. The blower motor BL-

WM and air cleaner terminal EAC-1 will remain en- ergized at low-heat airflow or transition to low-heat

airflow for 90, 120, 150, or 180 seconds (depending on selection at blower-OFF delay switches). The furnace control CPU is factory-set for a 120-second blower-OFF delay.

2. Two-Stage Thermostat and Two-Stage Heating

See Figure 27-Figure 33 for thermostat connections. NOTE: In this mode the low-heat only switch SW1-2 must be

ON to select the low-heat only operation mode in response to closing the thermostat R-to-W1 circuit. Closing the thermostat R-to- Wl-and-W2 circuits always causes high-heat

operation, regardless of the setting of the low-heat only switch.

The walt thermostat "calls for heat", closing the R-to-W1 circuit for low-heat or closing the R-to-Wl-and-W2 circuits for high-heat. The furnace control performs a self-check,

verifies the low-heat and high-heat pressure switch contacts LPS and HPS are open, and starts the inducer motor IDM in high-speed.

The start up and shut down functions and delays described in item 1. above apply to the 2-stage heating mode as well, except for switching from low- to high-Heat and vice versa.

a. Switching from Low- to High-Heat - If the ther-

mostat R-to-W1 circuit is closed and the R-to-W2 circuit closes, the furnace control CPU will switch the inducer motor IDM speed from low to high. The

high-heat pressure switch relay HPSR is de-ener- gized to close the NC contact. When sufficient pres- sure is available the high-heat pressure switch HPS closes, and the high-heat gas valve solenoid GV-HI is energized. The blower motor BLWM will transition to high-heat airflow five seconds after the R-to-W2

circuit closes.

b. Switching from High- to Low-Heat -If the thermo-

stat R-to- W2 circuit opens, and the R-to-W1 cir- cuit remains closed, the furnace control CPU will

switch the inducer motor IDM speed from high to low. The high-heat pressure switch relay HPSR is energized to open the NC contact and de-energize the high-heat gas valve solenoid GV-HI. When the

inducer motor IDM reduces pressure sufficiently, the high-heat pressure switch HPS wilt open. The gas valve solenoid GV-M will remain energized as long as the low-heat pressure switch LPS remains

441 01 2122 00 Specifications are subject to change without notice. 49

closed. The blower motor BLWM will transition to low-heat airflow five seconds after the R-to-W2

circuit opens.

3. Cooling mode

The thermostat "calls for cooling".

a. Single-Speed Cooling-

See Figure 27 for thermostat connections

The thermostat closes the R-to-G-and-Y circuits. The R-to- Y circuit starts the outdoor unit, and the

R-to-G-and-Y/Y2 circuits start the furnace blower motor BLWM on cooling airflow. Cooling airflow is

based on the A/C selection shown in Table 10. The

electronic air cleaner terminal EAC-1 is energized with 115 vac when the blower motor BLWM is oper- ating.

When the thermostat is satisfied, the R-to-G-and-Y

circuits are opened. The outdoor unit will stop, and the furnace blower motor BLWM will continue operat-

ing at cooling airflow for an additional 90 seconds. Jumper Y/Y2 to DHUM to reduce the cooling off-

delay to 5 seconds. (See Figure 26)

b. Two-Stage Thermostat and Two-Speed Cooling

See Figure 28 for thermostat connections

The thermostat closes the R-to-G-and-Y1 circuits for

low-cooling or closes the R-to-G-and-Yl-and-Y2 circuits

for high-cooling. The R-to-Y1 circuit starts the outdoor unit on

low-cooling speed, and the R-to-G-and-Y1 circuit starts the furnace blower motor BLWM at low-cooling airflow which is the OF (continuous fan) selection as shown in Table 11. The

R-to-Yl-and-Y2 circuits start the outdoor unit on

high-cooling speed, and the R-to- G-and-Y/Y2 circuits start the furnace blower motor BLWM at high-cooling airflow.

High-cooling airflow is based on the A/C (air conditioning) selection shown in Table 10.

The electronic air cleaner terminal EAC-1 is energized with

115 vac whenever the blower motor BLWM is operating. When the thermostat is satisfied, the R-to-G-and-Y1 or

R-to- G-and-Yl-and-Y2 circuits are opened. The outdoor

unit stops, and the furnace blower BLWM and electronic air

cleaner terminal EAC-1 will remain energized for an additional 90 seconds. Jumper Y1 to DHUM to reduce the cooling

off-delay to 5 seconds. (See Figure 26)

4. Dehumidfy Mode

See Figure 27-Figure 33 for thermostat connections. The H output on the humidify sensing thermostat should

be connected to the furnace control thermostat terminal DHUM. When there is a dehumidify demand, the DHUM

input is activated, which means 24 vac signal is removed from the DHUM input terminal. In other words, the DHUM

input logic is reversed. The DHUM input is turned ON when no dehumidify demand exists. Activation/Deactiva-

tion Once 24 vac is detected by the furnace control on the DHUM input, the furnace control operates in dehumidify

mode. If the DHUM input is low for more than 48 hours, the furnace control reverts back to non-dehumidify mode.

The cooling operation described in item 3. above also ap- plies to operation with a humidity sensing thermostat. The

exceptions are listed below:

a. Low Cooling-When the R-to-G-and-Y1 circuit is

closed and there is a demand for dehumidification,

the furnace blower motor BLWM will drop the blower airflow to 90 percent of low-cooling airflow which is the OF (continuous fan) selection as shown in Table

10.

b. High-Cooling-When the R-to-G-and-Y/Y2 circuit

is closed and there is a demand for dehumidification,

the furnace blower motor BLWM will drop the blower airflow to 90 percent of high-cooling airflow. High-

cooling airflow is based on the A/C (air conditioning)

selection shown in Table 10.

c. Cooling off-delay-When the "call for cooling" is

satisfied and there is a demand for dehumidification, the cooling blower-off delay is decreased from 90

seconds to 5 seconds.

Continuous Blower Mode When the R-to-G circuit is closed by the thermostat, the

blower motor BLWM will operate at continuous blower air- flow. Continuous blower airflow selection is initially based on the CF (continuous fan) selection shown in Table 10.

Factory default is shown in Table 10. Terminal EAC-1 is

energized as long as the blower motor BLWM is energized.

During the initial call for heat, the furnace control CPU wilt

keep the blower motor BLWM at continuous blower airflow. The blower motor BLWM wilt remain ON until the main

burners ignite then shut OFF and remain OFF for the blower-ON delay (45 seconds in low-heat, and 25 seconds in high-heat), allowing the furnace heat ex-

changers to heat up more quickly, then restarts at the end of the blower-ON delay period at low-heat or high-heat airflow, respectively.

The blower motor BLWM will revert to continuous-blower airflow after the heating cycle is completed. In high-heat,

the furnace control CPU will drop the blower motor BLWM to low-heat airflow during the selected blower-OFF delay

period before transitioning to continuous-blower airflow. When the thermostat "calls for low-cooling", the blower

motor BLWM will switch to operate at low-cooling airflow. When the thermostat is satisfied, the blower motor BLWM will operate an additional 90 seconds at low-cooling air- flow before transitioning back to continuous-blower airflow.

When the thermostat "calls for high-cooling", the blower motor BLWM will operate at high cooling airflow. When the thermostat is satisfied, the blower motor BLWM will operate an additional 90 seconds at high-cooling airflow before transitioning back to continuous-blower airflow. When the

R-to-G circuit is opened, the blower motor BLWM wilt con- tinue operating for an additional 5 seconds, if no other function requires blower motor BLWM operation.

6. Heat pump See Figure 29 - Figure 33 for thermostat connections.

When installed with a heat pump, the furnace control auto- matically changes the timing sequence to avoid long

blower off times during demand defrost cycles. Whenever W/W1 is energized along with Y1 or Y/Y2, the furnace con-

trol CPU will transition to or bring on the blower motor BL- WM at cooling airflow, low-heat airflow, whichever is low-

est. The blower motor BLWM will remain on until the main burners ignite then shut OFF and remain OFF for 25

seconds before coming back on at heating airflow. When the W/W1 input signal disappears, the furnace control be-

gins a normal inducer post-purge period while changing the blower airflow. If Y/Y2 input is still energized the fur-

nace control CPU will transition the blower motor BLWM

airflow to cooling airflow. If Y/Y2 input signal disappears and the Y1 input is still energized the furnace control CPU

will transition the blower motor BLWM to low-cooling air- flow. If both the Y1 and Y/Y2 signals disappear at the

same time, the blower motor BLWM will remain on at low-

heat airflow for the selected blower-OFF delay period. At

the end of the blower- OFF delay, the blower motor BLWM will shut OFF unless G is still energized, in which case the

blower motor BLWM will operate at continuous blower air- flow.

7. Component test The furnace features a component test system to help dia-

gnose a system problem in the case of a component fail- ure. To initiate the component test procedure, ensure that

there are no thermostat inputs to the control and all time

50 Specifications are subject to change without notice. 441 01 2122 00

delays have expired. Turn on setup switch SWl-6. (See

Figure 26)

NOTE: The component test feature will not operate if the control is receiving any thermostat signals or until all time delays have expired.

The component test sequence is as follows:

a. The furnace control CPU turns the inducer motor ON

at high-heat speed and keeps it ON through step c.

b. After waiting 10 seconds the furnace control CPU

turns the hot surface igniter ON for 15 seconds, then

OFF.

c. The furnace control CPU then turns the blower mo-

tor BLWM on at 50% torque for 15 seconds, then

OFF.

d. After shutting the blower motor OFF the furnace con-

trol CPU switches the inducer to low-heat speed for

10 seconds, then OFF.

After the component test is completed, 1 or more status codes (heartbeat, 2+5) will flash. See component test section or Service Label (Figure 51) for explanation of status codes.

NOTE: To repeat component test, turn setup switch aWl-6 to OFF and then back ON.

Wiring Diagram Refer to wiring diagram Figure 55. Troubleshooting Refer to the service label. (See Figure 51--Service Label) The Troubleshooting Guide (See Figure 56) can be a useful

tool in isolating furnace operation problems. Beginning with the word "Start," answer each question and follow the appropriate arrow to the next item.

The Guide will help to identify the problem or failed component. After replacing any component, verify correct

operation sequence.

NOTE: The EAC terminals are energized when the blower is operating.

Figure 55 - Wiring Diagram

f CONNECTION DIAGRAM TO 115VAC FIELD- DISCONNECT SWITCH SCHEMATIC DIAGRAM

SAC-2 Elemmnic Air Cleaner Connecton (Common) PL10 2-Circuil HSI Connector i FACTORY CONTROL

FRS Flame Rolleut Sw. - Manual Reset, SPST-(N.C.) PL11 3 Circuit IDM Power Connector WIRING (24MAC) FSE Plame-prov ng Electrode PL12 1-Circuit I_ductor Splice Connector

FUSE F_se, 3 Amp Au ome Ne B ade Type, Fac cry _s a ed PL13 4-Circuit ECM Blower CTRL Connector WIRING (24VAC) GV Gas V_lve-reduodaM PL14 5-Circuit ECM Blower Power Connector

GVR Gas Valve Relay, DPST-(N.O.) PL16 3-Circuit PWM Connector CONDUCTOR ON HPS High-heat Pressure Switch, SPST (N.O.) aWl-1 Manual Swtch, Stalus Code Recall CONTROL HPSR High-bee Pressure Switch Relay, SPaT {N.C.) SW1-2 Manual Sw tch, Low Heat Only

Hal Hot S'Jfface Ign ter (115VAC) SW1-3 Manual Sw tch, Low Heat Rise Adj. (_ FIELD WIRING HSIR Hot Surface Ign ter Relay, SPST (N.O.) SWI4 Manual Swtch Comfod/Egy. Ad}. SCREW TERMINAL

RUM 24VAC Humidifier Connec on (0.5 Amp. Max.) SWl-5 Manual Sw tch, Cooling CFM/Ton HUMR Humidifier Relay, SPST (N.O.) SW1.,6 Manual Sw tch, Component Test /_/'7 GROUND IOM Inducod Drag Motor 2-Speed, Shaded Pole SWI-7,8 Manual Sw tches, Blower Off-Belay IOR IducedDragMo_orRelay, SPST-(N.O.) SW2-1 Manu_lSwitch, TwinNngMai_,(OFP)/Sec. {ON) ---( _- PLUGRECEPTCALE MILER Inducer Motor Speed Change Relay, SPDT SW2-2 Manual Switch Cooling CFMFFon ILK SlowerAccess Panel Interlock Swl_ch, SPST-(N.O,) SW2-3,4,5 Continuous Fan (Adj s_ab_ Ai_ow-CFM) IND I ductor (Note #7} SW2-6,7,8 Air Co_ditoNng (Adiustable N_ow-CFM) LED Light Erntting Dode for Stats Codes TRAN Transformer, 115VAC / 24MAC

LGPS Low Gas P_essure Switch SPST (N.O.)

.... FIELD CONTROL

/ EQUIPMENT

NOTES:

5. Solid Ines nside PCS are pdMed c rcuit board conductors and are rot included in legel,d.

6. Replace only wlih a 3 amp fuse.

7. Inductor istypically used with 3/4 hp and 1 hp SCM blowe_ motors. Review moto_ nstrucdons if replacing moto_ to see if Inductor is required.

8. Factory connected when (LGPS} not used.

11. Inducer motor (IDM) contains irtemal auto-reset thermal ovedood switch..

12. Factor,/connected when BVSS is not used. BVSS used when Chimney Adapeter Accessory Kt sinstalled.

13. Any of the 5 wges shown witMn the NEUTRAL L2 box can be com,ected to any _erminal within the box.

14. Slower motor (BLWM) s locked-rotor ovMoad protected by redundant electronic coM_ol c rcuits.

340750-201REV B

441 01 2122 OO Specifications are subject to change without notice. 51

START

Is AMBER LED status light ON solid,

alternately flashing bright-dim-bright-dim like a heartbeaL or flashing ON and OFF?

YES

Troubleshooting Guide - ICP Variable Speed

Is there 115Vat L1 and L2?

p I--_ Is door switch closedi YES

Is there 24V at SEC-1 and SEC-2?

I I-'_ I Is there 115V gOing tO switch?

_ YES

Close the door switch.

I-_ Is circuit breaker closed?

Is AMBER LED status light ON solid?

Is AMBER LED status light alternately flashing brighbdim-bright-dim like a heartbeat?

Determine status code. The status code is a single or two digit number with the first number determined by the number of

short flashes and the second number after the plus (+) sign is the number of

long flashes?

Go to section below for the status code that was flashed.

NO _ YES

._ Is the 24V fuse open?

4l YES

leads to isolate short circuit.

Replace fuse then disconnect thermostat

-4

Replace furnace control. I

Check to make sure that the correct model plug PL4 is installed. The wiring schematic shows all valid model plugs.

Is the correct model plug installed?

_ NO

Replace model plug PL4.

The last status code has cleared. To recall a previous status code disconnect

the R thermostat connection, reset power, and put setup switch SWI-1 in the ON position. The AMBER LED will

flash the status codes in the order of occurrence. Record status codes until

heartbeat flashes. After heartbeat flashes several times the status codes will repeat. Status codes are erased after 72 hours or can be manually erased

by putting setup switch SWI-1 in the ON position and jumpering R, W/W1, and Y/Y2 simultaneously until the heartbeat

flashes. When done put setup switch SWl-1 in the OFF position.

Was there a previous status code other than the heartbeat?

I I Replace do°r switch

-4

Replace transformer. ]

The control is locked out and will auto- reset after 1 hour. Lockout could be due to any of the following:

- Flame sense circuit failure.

- Gas valve relay stuck open.

- Software check error. Reset power to clear lockout. Replace control if code repeats.

Does the control respond to W/W1, W2, Y1, Y/Y2, and G (24V) thermostat

signals?

Run system through a low-heat, high- heat, or cooling cycle to check operation.

Status codes are erased after 72 hours or can be manually erased by putting

setup switch SWI-1 in the ON position andjumpering R, W/W1, and Y/Y2

simultaneously until the heartbeat flashes.

Replace furnace control.

YES

J Check for continuity in wire from circuit

breaker to furnace.

Close circuit breaker and go back to START.

Check room thermostat or interconnecting cable.

T.o

G thermostat terminals on the furnace

t_ s 24V present at W/W1, W2, Y1, Y/Y2 or

_ oes the problem reieat when using a

control?

YES

Disconnect all the thermostat wires from the furnace control.

jumper wire?

The thermostat is not compatible with the furnace control Either install a ballast

resistor, connect the Com24V thermostat terminal to the thermostat, or replace the

thermostat

"11

tj'l

0")

--I

=r o

._.

---41

___ 5

PRESSURE SWITCH DID NOT OPEN -

Check for:

- Obstructed pressure tube.

- Pressure switch stuck closed.

LOW-HEAT PRESSURE SWITCH DID NOT CLOSE OR REOPENED - If opens

during blower on-delay period, blower will come on for the selected blower off-delay.

If open longer than 5 minutes inducer shuts off for 15 minutes before retry. Check for:

- Proper vent sizing.

- Low inlet gas pressure (if LGPS used).

- Inadequate combustion air supply,

- Disconnected or obstructed pressure

tubing.

- Defective or miswired pressure switches

- Excessive wind.

- Restricted vent.

- Defective Inducer motor.

- Low inducer voltage (115 VAC)

LIMIT CIRCUIT FAULT - Indicates the

limit, draft safeguard, flame rollout, or

blocked vent switch (if used) is open or the furnace is operating in high-heat only

mode due to 2 successive low-heat limit trips. Blower will run for 4 min. or until open switch remakes whichever is longer.

If open longer than 3 min., code changes to lockout #7. If open less than 3 min. status code #4 continues to flash until

blower shuts off. Flame rollout and

blocked vent switch require manual reset. Check for:

Restricted vent. Loose blower wheel.

Defective switch or connections. Proper vent sizing. Dirty filter or restricted duct system,

Excessive wind.

Inadequate combustion air supply.

(Flame rollout switch open)

- Blower motor not operating

ABNORMAL FLAME-PROVING SIGNAL

Flame is proved while gas valve is de- energized. Inducer will run until fault is cleared. Check for:

- Stuck open or leaky gas valve.

IGNITION PROVING FAILURE - If flame is

not sensed during the trial for ignition

period, the control will repeat the ignition sequence 3 more times before lockout #6 +

1 occurs. If flame signal is lost during the

blower on-delay period, blower will come on for the selected blower off-delay. Check

the following before going to the next step.

- Gas valve turned off.

- Manual shut-off valve,

- Green/Yellowwire MUST be connected

to furnace sheet metal.

- Flame sensor must not be grounded.

occurs if the limit, draft safeguard, flame rollout, or blocked vent switch (if used) is open longer than 3 minutes or 10

"_t 7 LIMIT CIRCUIT LOCKOUT- Lockout

"_1 8 GAS HEATING LOCKOUT- Control will

q 9 HIGH-HEAT PRESSURE SWITCH OR

q 10 POLARITY- Check for correct line

"_I 1 +2 BLOWER ON AFTER POWER UP-

successive limit trips occurred during high- heat. Control will auto-reset after 3 hours.

Refer to status code #4.

NOT auto reset. Turn off power and wait 5 minutes to retry. Check for:

- Stuck closed gas valve relay on control.

- Miswire or short to gas valve wire.

RELAY DID NOT CLOSE OR REOPENED - Check for:

- Control relay may be defective.

- Gas valve is miswired.

- Refer to status code #3,

voltage polarity. If units are twinned, check for proper low-voltage (24V) transformer phasing.

(115V OR 24V) - Normal operation. Blower runs for 90 seconds, if unit is

powered up during a call for heat (R- W/W1 closed) or when (R-W/W1 opens) during the blower on-delay period.

2+5 INVALID MODEL SELECTION OR SETUP

ERROR - If status code 2 + 5 only flashes 4 times on power-up the control is missing its model plug PL4 and is defaulting to the

model selection stored in memory. If status code 2 + 5 flashes continuously it could indicate any of the following:

- Model plug PL4 is missing and there is no valid model stored in permanent memory. This will happen if you forget to install the

model plug PL4 on a service replacement

control.

- Thermostat call with SWl-1 ON.

- Thermostat call with SWl-6 ON.

- SWl-1 and SW1-6 both ON.

- Two different furnace models twinned.

- If replacing a control, be sure to use correct version (V##) located on control

board) Models supported should be listed

To determine whether the problem is in the gas | valve, igniter, or flame sensor the system can be operated in component test mode. To check the NC

igniter remove the R thermostat connection from the control reset power, and put setup switch SW1-6 in the ON position to start the

component test. Does the igniter glow orange/white by the end of the 15 second warm-

up period?

NOTE: NUMBER IN UPPER LEFT HAND CORNER REPRESENTS FLASH CODE

6+1

IGNITION LOCKOUT - System

failed to ignite gas and prove flame in 4 attempts. Control will

auto-reset after 3 hours. Refer to status code #6.

Unplug igniter harness from control and /--_ repeat component test by turning setup --

switch SW1-6 OFF and then back ON. Check for 115V between pin 3 and

NEUTRAL-L2 on the control. Was 115V present for the 15 second period?

Reconnect the R thermostat lead and set thermostat to call for heat. Connect

voltmeter across gas valve connections, Does gas valve receive 24V?

YES

Does gas valve open and allow gas to flow?

YES

Do the main burners ignite?

YES

Do the main burners stay on?

Repeat call for heat and check flame sensor current during trial for ignition

period. Is the DC microamps below 0.5?

Clean flame sensor with fine steel wool and recheck current. Nominal current is

4.0 to 6.0 microamps,

Is current near typical value?

Will main burners ignite and stay on?

Fixed.

[

YES

Replace furnace control.

Check for continuity in the harness and igniter. Replace

defective component.

Check connections, If OK, replace control.

Check that all gas valves are turned on. Replace valve.

Check for:

- Inadequate flame carryover or rough ignition.

- Low inlet gas pressure.

- Properfiring rate.

- Air leakage around igniter bracket.

YES

Allow blower to come on and repeat test to check for

intermittent operation.

Check connections and retry.

If current is near typical value (4.0_6.0 nominal) and burners will not stay on, repeat check

in high-heat. If burners will still not stay on replace control. If burners operate in

high-heat then switch to low- heat, check manifold pressure. If OK, check

burner carryover and flame sensor location.

Replace electrode,

Replace furnace control. I

PARTS REPLACEMENT INFORMATION GUIDE

CASING GROUP Outer door Blower door

Top filler plate Bottom filler plate

Bottom enclosure ELECTRICAL GROUP

Control bracket Junction box

Limit switch(es) Circuit board

Door switch Transformer

Wiring harness 115v Wiring harness 24v

DIGIT POSITION F or G= Mainline

N = Entry 8 = 80% AFUE

M = Multiposition

V = Variable Speed Blower Motor - ECM

X = ECM Blower Motor S = Single-stage

T = Two-stage

N = Standard L = Low Nox

045 = 45,000 BTU/hr 070 = 70,000 BTU/hr 090 = 90,000 BTU/hr 110 = 110,000 BTU/hr 135 = 135,000 BTU/hr

14 = 143/16" 17 = 171/2''

21 = 21" 24 = 241/2''

08 = 800 CFM 12 = 1200 CFM 14 = 1400 CFM 16 = 1600 CFM 20 = 2000 CFM 22 = 2200 CFM

TO OBTAIN INFORMATION ON PARTS: Consult your installing dealer or the classified section of your local telephone directory under the "Heating Equipment" or "Air Conditioning Contractors and Systems" headings for dealer listing by brand name, or contact:

Have available the product/model number and the serial number located on the unitrating plate to ensure correct replacement parts. WARNING: Improper installation, adjustment, alteration, service, or maintenance can cause personal injury, property damage, or death. Consult a qualified

installer, service agency, or your local gas supplier for information or assistance. The qualified installer or service agency must use only factory-authorized replacement parts, kits, or accessories when modifying this product.

BLOWER GROUP Blower housing

Blower cutoff Blower motor Blower wheel

Capacitor (where used) Capacitor strap (where used)

Grommet Power choke (where used)

GAS CONTROL GROUP Manifold

Burner assembly Orifice

Flame sensor Hot surface igniter

1 2

F 8

EFFICIENCY

Consumer Relations Department

Lewisburg, TN 37091 USA

POSITION

P.O. Box 128

931-270-4100

4 5

V L

TYPE

FEATURE

Vent elbow assembly

6,7,8

045

HEAT INPUT

CABINET WIDTH

SALES (MAJOR) REVISION DIGIT

Gas valve Manual reset limit switches

HEAT EXCHANGER GROUP

Heat exchanger cell Celt panel

Lox NOx baffle (California models only)

INDUCER GROUP Housing assembly

Pressure switch Inducer motor

Inducer wheel

9,10

COOLING AIRFLOW

ENGINEERING (MINOR) REVISION DIGIT

11,12

54 specificationsaresubjecttochangewithout notice 441 01 2122 00

Lewisburcj, TN 37091 USA

ICP F8MVL0701412A1, F8MVL0901716A1, F8MVL1102120A1, F8MVL1352422A1, G8MVL0701412A1 Installation Guide

Specifications and Main Features

Frequently Asked Questions

User Manual