ICP F8MTL, G8MTL Installation Insrtuctions

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Page 1

These instructions must be read and understood completely before attempting 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

Signal Words in Manuals

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

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.

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

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.

Signal Words on Product Labeling

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

CAUTION - Hazards or unsafe practices which may result in or product labels. minor personal injury or product or property damage, z_ Safety-alert symbol

NOTE - Used to highlight suggestions which wilt result in en-

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

hanced installation, reliability, or operation, ats, be alert to the potential for personal injury.

TABLE OF CONTENTS

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

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

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

Safety .......................................................... 4

General Installation ............................................... 4

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

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

LOCATION ....................................................... 6

AIR FOR COMBUSTION AND VENTILATION .......................... 7

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

Upflow Installation ............................................. 10

Downflow Installation .......................................... 10

Horizontal Installation ........................................... 11

Filter Arrangement ............................................ 14

Air Ducts .................................................... 14

Gas Piping ................................................... 16

Electrical Connections ......................................... 18

Venting ...................................................... 22

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

General ....................................................... 31

Start-Up Procedures ............................................ 31

Adjustments ................................................... 32

Check Safety Controls ........................................... 36

Checklist ...................................................... 36

SERVICE AND MAINTENANCE PROCEDURES .................... 40

Introduction .................................................. 40

Care and Maintenance ......................................... 41

Sequence of Operation ........................................ 45

Wiring Diagrams .............................................. 48

Troubleshooting .............................................. 49

PERSONAL INJURY, AND/OR PROPERTY DAMAGE HAZARD

Failure to carefully read and follow this warning could result in equipment malfunction, property damage,

3ersonal 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

3rocedures 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.

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 .

IS0 9001

Portions of the text and tables are reprinted from NFPA 54/ANSI Z223.1-20096), with permission of National Fire Protection Association, Quincy, MA 02269 and American Gas Association, Washington, DO 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.

Printedin U.S.A. 441 01 2101 02 Aug. 2012

INSTALLER: Affixthese instructions on or adjacent tothe furnace. CONSUMER: Retain these instructions for future reference.

Page 2

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Figure 1 - Dimensional Drawing

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BOTrOM RE11JRN [11kl]

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.

VEHTING(6PLACE8)

[511O1

81DEINLET

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Table 1 - Dimensions

FURNACE SIZE

0451412 0701412 0901714

1102122

1352422

135size furnace require a 5-in. or 6-in. (127 or 152mm) vent. Use a vent adapter between furnace and vent stack.

CABINET WIDTH

IN (mm)

14-3/16 (360) 14-3/16 (360)

17-1/2 (445)

21 (533)

24-1/2 (622)

OUTLET WIDTH

IN (rnm)

12-9/16 (319) 12-9/16 (319)

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

22-7/8 (581)

TOP AND BOTTOM

FLUE COLLAR

IN (mm)

9-5/16 (237)

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

15-1/16 (383)

BOTTOM INLET

WIDTH

IN (mm)

12-11/16 (322) 12-11/16 (322)

16 (406)

19-1/2 (495)

23 (584)

1 [_1._] p_4]

VENT

CONNECTION

SIZE

IN (mm)

4 (102) 4 (102)

4 (102)*

L11/4

SHIP

LB (KG)

107 (49) 115 (52)

127(58)

152 (69) 163 (74)

441 01 2101 02

Page 3

SAFETY CONSIDERATIONS

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

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

Improper installation, adjustment, alteration, service, maintenance, or use could 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

Improper installation or misapplication of furnace may require excessive servicing or cause premature component failure.

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.

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 servicin,q furnaces.

Improper installation, adjustment, alteration, service, maintenance, or use can cause explosion, fire, electrical

shock, or other conditions which may cause death, personal injury, or property damage. Consult a qualified installer, service agency, or your distributor or branch for information or

assistance. The qualified installer or agency must use factory-authorized kits or accessories when modifying this product. Refer to the individual instructions packaged with

the kits or accessories when installing. Follow all safety codes. Wear safety glasses, protective clothing, and work gloves. Have a fire extinguisher available. Read these instructions thoroughly and follow all warnings or

cautions include in literature and attached to the unit. Consult local building codes, the current editions of the National Fuel

Gas Code (NFGC) NFPA 54/ANSI Z223.1 and the National Electrical Code (NEC) NFPA 70.

Recognize safety information. This is the safety-alert symbol /_. When you see this symbol on the unit 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 hazards which could result in personal injury or death. CAUTION is used to identify unsafe practices which

may result in minor personal injury or product and property

damage. NOTE is used to highlight suggestions which will result in enhanced installation, reliability, or operation.

product and property damage. NOTE is used to highlight suggestions which will 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 specified in the "Location" section of these instructions.

3. Provide adequate combustion and ventilation air to the furnace space as specified in "Air for Combustion and

Ventilation" section.

4. Combustion products must be discharged outdoors. Connect this furnace to an approved vent system only,

as specified in the "Venting" section of these instructions.

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

specified in the "Gas Piping" section.

6. Always install furnace to operate within the furnace's intended 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

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. See "Air Ducts" section.

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 instructions.

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 installation 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 construction.

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

inches (914 mm) horizontally from the furnace. See NFPA 90B or local code for further requirements.

13. These furnaces SHALL NOT be installed directly on carpeting, 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, EN24X or

when the manufacturer's coil casing model number NAEA is used. See Figure2 for clearance to

combustible construction information.

441 01 2101 02 3

Page 4

INTRODUCTION

F8MTL & G8MTL 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. These furnaces shall not be installed directly on carpeting,

tile, or any other combustible material other than wood flooring. For downflow installations, a factory accessory floor

base must be used when installed on combustible materials and wood flooring. This special base is not required when this

Figure 2 - Clearances to Combustibles

furnace is installed on the manufacturer's coil model numbers END4X, ENW4X, or when the manufacturer's coil casing

model number NAEA is used. See Figure 2 for clearance to combustible material information.

This furnace is designed for minimum continuous return-air temperature of 60°F (16°O) db or intermittent operation down

to 55_'F (13°O) 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. (SeeFigure 3)

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

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

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

serious injury or death,

Read and follow instructions and precautions in User's Information Manual

provided with this furnace. Installation and service must be performed by a qualified service agency or the gas

supplier.

_k. CAUTION

Check entire gas assembly for leaks after 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 local codes, follow the National

Fuel Gas Code ANSI Z223.1 / NFPA54 or CSA B-149. 1 Gas Installation Code.

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

air. See manufacturer's installation information provided with this appliance.

I OPERATION I

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.

MINIMUM INCHES CLEARANCE TO COMBUSTIBLE CONSTRUCTION

I INSTALLATION

This forced air furnace is This furnace is approved for

equipped for use with natural UPFLOW, DOWNFLOW, and gas at altitudes 0 - 10,000 ft Clearancearrows

(O - 3,050m), do not changewith

An accessory kit, supplied by furnaceorientation,

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 Clearancein inches a Type B-1 Vent and may be Vent Clearance to combustibles: vented in common with other For SingleWallvents 6 inches (6 pc).

gas fired appliances. ForType B-1 vent type 1 inch (1 pc).

MINIMUM INCHES CLEARANCE TO

COMBUSTIBLE CONSTRUCTION

DOWNFLOW POSITIONS:

1" Installation on non-combustible floors only.

For Installation on combustible flooring only when installed on special base, Part No. KGASB0201ALL or 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 of the Top and two Sides of the furnace jacket, and building joists, studs or framing.

HORIZONTAL installations.

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

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:

Step 1 m Safety

National Fuel Gas Code (NFGC) NFPA 54-2009/ANSI

Z223.1-2009 and the Installation Standards, Warm Air

Heating and Air Conditioning Systems ANSI/NFPA 90B

Step 2 m 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

4 441 01 2101 02

for only the NFGC, contact the American Gas Association, 400 N. Capitol Street, N.W., Washington DC 20001

(www.AGA.org)

Figure 3 - Return Air Temperature

- - MAX 80 °F/27 °C

FRONT

MIN 60°F/16°0

A06745

Page 5

Step 3 m Combustion and Ventilation Air Section 9.3 of the NFGC, NFPA 54/ANSI Z223.1-2009 Air

for Combustion and Ventilation Step 4 m 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.

Step 5 _ 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

Step 6 _ Gas Piping and Gas Pipe Pressure Testing

NFPA 54 / ANSI Z223.1-2009; chapters 5, 6, 7, and 8 and National Plumbing Codes

Step 7 _ Electrical Connections National Electrical Code (NEC) ANSI/NFPA 70-2008

Step 8 _ Venting NFGC; NFPA 54/ANSI Z223.1-2009 chapters 12 and 13

ELECTROSTATIC DISCHARGE (ESD)

PRECAUTIONS PROCEDURE

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 furnace chassis which is close to the control. Tools

held in a person's hand during grounding will be satisfactorily discharged.

Figure 4 - Multipoise Orientations

THE BLOWER IS LOCATED

TO THE RIGHT OF THE

BURNER SECTION, AND

AIR CONDITIONED AIR IS

DISCHARGED TO THE LEFT.

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 (ungrounded) furnaces.

6. Before removing a new control from its container, discharge your body's electrostatic charge to ground to

protect 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 ungrounded objects.

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

FURNACE RELIABILITY HAZARD

Improper installation or service of furnace may cause premature furnace component failure.

Electrostatic discharge can affect electronic components. Follow the Electrostatic Discharge Precautions Procedure listed below 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.

AIRFLOW

THE BLOWER IS

LOCATED BELOW THE

BURNER SECTION, AND

CONDITIONED AIR IS

DISCHARGED UPWARD.

THE BLOWER IS

LOCATED ABOVE TH E

BURNER SECTION, AND

CONDITIONED AIR IS

DISCHARGED DOWNWARD

441 01 2101 O2 5

HORIZONTAL RIGHT [_>

AIRFLOW

LOCATED TO THE LEFT

OF THE BURNER SECTION,

AND CONDITIONED AIR IS

THE BLOWER IS

DISCHARGED TO THE RIGHT.

A02097

Page 6

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-attitude 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. This furnace must:

• be installed so the electrical components are protected from water.

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

installations require use of a factory-approved floor base, coil model numbers END4X, ENW4X, or the manufacturer's 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 section.

• be provided ample space for servicing and cleaning. Always

comply with minimum fire protection clearances shown on

the furnace clearance to combustible 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

• 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 inches (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 NFGC. (See Figure 5)

Figure 5 - Installation in a Garage

CARBON MONOXIDE POISONING AND UNIT

DAMAGE HAZARD

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

Corrosive or contaminated air may cause failure of parts containing flue gas, which could leak into the living space. 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.

Do not install furnace in a corrosive or contaminated atmosphere. Make sure all combustion and

circulating air requirements are met, in addition to all local codes and ordinances.

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

18-iN. (457.2 mm)

MINIMUMTO 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)

6 441 01 2101 02

Page 7

Figure 6 - Prohibit Installation on Back

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 /A ANSI Z223.1-2009, Air for Combustion and Ventilation, and applicable provisions of the local building codes.

BACK J

A02054

PROPERTY DAMAGE HAZARD

Improper use or installation of this furnace may cause premature component failure. This gas furnace may be used for construction heat 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 roll-out 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.

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.

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 Carbon Monoxide Poisoning Hazard warning in 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 atl gas appliances installed in the space.

• Spaces having less than 50 cubic feet per 1,000 Btuh require the Outdoor Combustion Air Method.

• Spaces having at least 50 cubic feet per 1,000 Btuh may use the Indoor Combustion Air, Standard 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 horizontal or vertical duct(s) or opening(s) directly communicating with the outdoors or spaces that freely communicate with the outdoors.

2. Figure 7 illustrates how to provide TWO OUTDOOR OPENINGS, one inlet and one outlet combustion and

ventilation 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. c. TWO HORIZONTAL DUCTS require 1 -in 2 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.

441 01 2101 O2 7

Page 8

d. TWO OPENINGS OR VERTICAL DUCTS require 1

-in 2 of free area per 4,000 Btuh (550 mm2/kW) for

b. Not less than the sum of the areas of all

connectors in the space.

combined input of all gas appliances in the space per

Figure 7 and Table 2

3. ONE OUTDOOR OPENING requires: a. One square inch of free area per 3,000 Btuh (734

mm2/kW) for combined input of all gas appliances in the space per Table 2 and

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.

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

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)

EXAMPLES: Determining Free Area

FURNACE WATERHEATER 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

vent

Figure 7 - Air for Combustion, Ventilation, and Dilution

for Outdoors

1 SQ IN.

SQ IN. PER

400O

BTUH*

cO rr

1 SQ IN.

PER

4OOO

BTUH*

12" (305mm) MAX

(305mm) 12" MAX

1 SQIN. A PER 2000 BTUH*

DUCTS

OUTDOORS

1 SQ IN. PER 2000

BTUH*

(305mm) 12" MAX

DUCT,' PER 4000

TO BTUH*

OUTDOORS

D 12_X (305mm)

VENT THROUGH

ROOF

CIRCULATING AIR DUCTS

TO PER 4O00

OUTDOORS BTUH*

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

Note: Use any of the following combinations of openings:

A&BC&DD&EF&G

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.

1 SQ IN.

A03174

Figure 8 - Air for Combustion, Ventilation, and Dilution

from Indoors

DUCTS

CIRCULATING AiR !

I I I I I I I I I I

I I I I I

INTERIOR

HEATED

SPACE

i i

CIRCULATING AIR DUCTS

* 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.

VENT THROUGH ROOF

12" AX(305mm)

o *

_ 1 SQ IN.

• PER 1000 BTUH* iN DOOR ORWALL

UNCONFINED SPACE

6" MIN (152mm) (FRONT)0

1 SQ iN. PER 1000

_: BTUH* iN DOOR

_-----OR WALL

12" MAX (305mm)

A03175

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.

8 441 01 2101 02

Page 9

CARBONMONOXIDE POISONING HAZARD

Failure to follow this warning could result in death

and/or personal injury.

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

appliances installed in the space and

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

OTHER THAN FAN-ASSISTED TOTAL FAN-ASSISTED TOTAL

ACH

0.60 1,050

0.50 1,260

0.40 1,575

0.30 2,100

0.20 3,150

0.10 6,300

0.00 NP

ACH =Air Changes/Hour NP = NotPermitted

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

Code ANSI Z223.1-2009/NFPA 54-2009, 9.3.2.2:

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

draft hood-equipped water heater:

Volume _ 21ft3 (f= [other ='_

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

Volume

If:

Iother

= combined input of all other than fan-assisted

Ifan

= combined input of all fan-assisted appliances in

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 opening

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

(1,000s BTUH GAS INPUT RATE) (1,000s BTUH GAS INPUT RATE)

30 40 50 44 66 88 110 132 154

S _ace Volume (ft.3)

1,400 1,750 1,100 1,650 2,200 2,750 3,300 3,850

1,680 2,100 1,320 1,980 2,640 3,300 3,960 4,620 2,100 2,625 1,650 2,475 3,300 4,125 4,950 5,775 2,800 3,500 2,200 3,300 4,400 5,500 6,600 7,700 4,200 5,250 3,300 4,950 6,600 8,250 9,900 11,550 8,400 10,500 6,600 9,900 13,200 16,500 19,800 23,100

NP NP NP NP NP NP NP NP

Other ACH _000 Btu/hrJ

A04002

FaR

ACH 000 Btu/hrJ

A04003

appliances in Btuh/hr

Btuh/hr

2. The air infiltrationrate 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.

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

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 appliances.

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

are adequate permanent ventilation openings directly to outdoors having free area of at least 1-in.2/4,000 Btuh of total input rating for all gas appliances in the

space.

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

combustion, permanent ventilation and dilution of flue gases. However, in buildings with unusually tight

construction, additional air MUST be provided using the methods described in the Outdoor Combustion Air

Method section. Unusually tight construction is defined as Construction with:

a. Walls and ceilings exposed to the outdoors have a

continuous, sealed vapor barrier. Openings are gasketed or sealed and

b. Doors and openable windows are weatherstripped

and

c. Other openings are caulked or sealed. These include

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

Combustion Air Method below and,

441 01 2101 02 9

Page 10

2.Outdooropeningsshallbelocatedasrequiredinthe Outdoor CombustionAir Methodmentioned

previouslyand,

3.Outdooropeningsshallbesizedasfollows:

a.CalculatetheRatioofallIndoorSpacevolumedivided

by requiredvolumefor IndoorCombustionAir

Methodbelow.

b.OutdooropeningsizereductionFactoris1minusthe

Ratioina.above.

c.MinimumsizeofOutdooropeningsshallbethesize

requiredinOutdoorCombustionAirMethodabove

multipliedby reductionFactorin b. above.The minimumdimensionofairopeningsshallbenotless

than3in.(80mm).

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.

NOTE: Side return-air openings can be used in UPFLOW

and most HORIZONTAL configurations. Do not use side

return-air openings in DOWNFLOW configuration.

Figure 9 - Removing Bottom Closure Panel

BOTTOM CLOSURE

PANEL

BOTTOM FILLER PANEL

Levelinq Leqs (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)

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

5. Reinstall bottom closure panel if removed.

Figure 10 - Leveling Legs

(Smm)

(44ram)

I 3/4"

(44mm)

(Smm)

(44mm) 1 3/4"

(44mm) 1

A89014

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 13.

3. Construct plenum to dimensions specified in Table 4

and Figure 13.

4. If downflow subbase is used, install as shown in Figure 11. If coil model numbers END4X, ENW4X or

coil casing model number NEAE is used, install as shown in Figure 12.

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)

10 441 01 2101 02

Page 11

Figure 11 - Furnace, Plenum, and Subbase installed on

a Combustible Floor

FURNACE

(OR COIL CASING

WHEN USED)

COMBUSTIBLE

FLOORING

SUBBASE

SHEET METAL

PLENUM

FLOOR

OPENING

HORIZONTAL INSTALLATION

The furnace can be installed horizontally in an attic or crawl

space 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.

Figure 13 - Floor and Plenum Opening Dimensions

A96283

A96285

Figure 12 - Furnace, Plenum, and Coil or Coil Casing

Installed on a Combustible Floor

FURNACE

APPROVED

COIL ASSEMBLY

COIL BOX

_ COMBUSTIBLE

FLOORING x

SHEET METAL ====.._

PLENUM

FLOOR

OPENING

A08556

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(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.

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.

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

two (2) #8 x 3/4-in. (19 mm) screw into the side and 2 #8 x

3/4-in. (19 mm) screw 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

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 2 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.

Roll-Out Protection

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

area for furnaces closer than 12 inches (305 mm) above the

441 01 2101 02 11

Page 12

combustibledeckorsuspendedfurnacescloserthan12

inches(305mm)tojoists.ThesheetmetalMUSTextend

underneaththefurnacecasingby1in.(25mm)withthedoor

removed.

Thebottomclosurepanelonfurnacesofwidths17-1/2in.

(445mm)andlargermaybe usedfor flameroll-out

protectionwhenbottomof furnaceis usedfor returnair connection.SeeFigure17forproperorientationofroll-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 (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 side return air inlet(s) are used without a bottom

return air inlet.

FURNACE

CASING

WIDTH

14-3/16

(376)

17-1/2

(445)

(533)

24-1/2

(622)

Table 4 - Opening dimensions - In.

APPLICATION

Upflow Applications on Combustible or Noncombustible Flooring

(subbase not required)

Downflow Applications on Noncombustible Flooring

(subbase not required)

Downflow Applications on Combustible Flooring (subbase required)

Downflow Applications on Combustible Flooring with Coil END4X,

ENW4X or Coil Casing NAEA (subbase not required)

Upflow Applications on Combustible or Noncombustible Flooring

(subbase not required)

Downflow Applications on Noncombustible Flooring

(subbase not required)

Downflow Applications on Combustible Flooring (subbase required)

Downflow Applications on Combustible Flooring with Coil

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

Upflow Applications on Combustible or Noncombustible Flooring

(subbase not required)

Downflow Applications on Noncombustible Flooring with Coil

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

Downflow Applications on Combustible Flooring

(subbase required)

Downflow Applications on Combustible Flooring with Coil END4X,

ENW4X or Coil Casing NAEA (subbase not required)

Upflow Applications on Combustible or Noncombustible Flooring

(subbase not required)

Downflow Applications on Noncombustible Flooring

(subbase not required)

Downflow Applications on Combustible Flooring (subbase required)

Downflow Applications on Combustible Flooring with Coil

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

Figure 14 - Duct Flanges

U PFLOW DOWN FLOW

(mm)

PLENUMOPENING

A B

12-11/16 21-5/8

(322) (549)

12-9/16 19

(319) (483)

11-13/16 19

(284) (483)

12-5/16 19

(319) (483)

16 21-5/8

(406) (549)

15- 7/8 19

(403) (483)

15-1/8 19

(384) (483)

15-1/2 19

(394) (483)

19-1/2 21-5/8

(495) (549)

19-3/8 19

(492) (483)

18-5/8 19

(473) (483)

19 19

(483) (483)

23 21-1/8

(584) (537)

22- 7/8 19

(581) (483)

22-1/8 19

(562) (483)

22-1/2 19

(572) (483)

HORIZONTAL

FLOOR OPENING

C D

13-5/16 22-1/4

(338) (565)

13-3/16 19-5/8

(335) (498)

13-7/16 20-5/8

(34t) (600)

13-5/16 20

(338) (508)

16-5/8 22-1/4

(422) (565)

16-1/2 19-5/8

(419) (498)

16-3/4 20-5/8

(425) (600)

16-1/2 20

(419) (508)

20-1/8 22-1/4

(511) (565)

20 19-5/8

(508) (498)

20 - 1/4 20- 5/8

(514) (600)

20 20

(508) (508)

23 - 5/8 22- 1/4

(600) (565)

23-1/2 19- 5/8

(597) (498)

23-3/4 20-5/8

(603) (600)

23 - 1/2 20

(597) (508)

12 441 01 2101 02

YES

YES YES

NO Q/1 NO

YES

120o\ YES

MIN

A02020

Page 13

Figure 15 - Horizontal Unit Suspension

4 REQ.

UTER DOOR

ASSEMBLY

8" (203mm) MIN FOR DOOR REMOVAL

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

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

SECURE ANGLE IRON TO BOTTOM

OF FURNACE WiTH 3 #8 xS/4'' (19ram) SCREWS

TYPICAL FOR 2 SUPPORTS

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

ANGLE IRON OR UNI-STRUT MAY BE USED

Figure 16 - Horizontal Suspension with Straps

OUTER DOOR

ASSEMBLY X III I

IIII

22 GAUGE GALVANIZED STRAPS TYPICAL

FOR 4 STRAPS

AIR

/OPENING

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.

BACK OF FURNACE

METHOD 1 FOLD ALL STRAPS UNDER

FURNACE AND SECURE WTH (4) #8 x 3/4 (19 ram) SHEET METAL SCREWS (2 SCREWS IN SIDE AND 2 SCREWS

IN BOTTOM).

A10130

AIR OPENING

441 01 2101 02 13

A10131

Page 14

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

EQUIPMENT MANUAL

SHUT-OFF GAS VALVE

SEDIMENT UNION

TRAP

Not all horizontal furnaces are approved for side return air

connections. (See Figure 20)

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 5-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.

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

1" (25mm) UNDER FURNACE

VENT

30-IN. (762mm)

MIN WORKAREA *WHEN USED WITH

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

SINGLE WALL VENT CONNECTIONS

A10164

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 _'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.

A02329

14 441 01 2101 02

Page 15

Table 5 - Air Delivery - CFM (With Filter)*

FURNACE

SIZE

0451412

0701412

0901714

1102422

1352422

rack. To determine airflow performance without this filter, assume an additional 0.1 In. W.C. available external static pressure.

-- Indicates unstable operating conditions.

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.

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 connected to ONLY the accessory combustible floor 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

INLET

Bottom or

Side(s)

Bottom or

Side(s)

Bottom or

Side(s)

Bottom Only

Bottom Sides or 1 Side & Bottom

1Side Only

Bottom

Only

Bottom Sides

1 Side & Bottom

1 Side Only

SPEED

High 1465 1400 1325 1250 1175 1085 980 860 725 560

Med-High 1295 1260 1210 1155 1090 1015 930 830 700 545

Medium 1150 1120 1085 1040 985 920 835 740 620 510

Med-Low 1030 1010 980 945 895 835 765 685 570 345

Low 860 835 810 780 745 700 635 555 445 260

High 1440 1400 1355 1300 1240 1170 1090 1000 890 745

Med-High 1180 1165 1150 1125 1085 1030 970 890 785 645

Medium 1015 1020 1010 990 965 925 875 800 700 560

Med-Low 885 885 880 865 845 815 770 700 605 475

Low 695 700 700 690 670 640 600 540 460 345

High 1650 1600 1535 1465 1385 1285 1175 1055 895 645

Med-High 1515 1485 1440 1380 1300 1220 1115 990 830 600

Med- Low 1385 1360 1320 1260 1195 1120 1025 915 710 565

Low 1205 1180 1160 1120 1065 1005 925 810 630 510

High 2530 2460 2380 2285 2200 2085 1970 1835 1695 1545

Med-High 2225 2190 2135 2075 1995 1910 1805 1695 1565 1430

Medium 1895 1885 1865 1820 1770 1700 1610 1520 1410 1290

Med-Low 1565 1555 1535 1505 1465 1410 1350 1265 1175 1050

Low 1320 1295 1265 1235 1205 1160 1105 1035 950 870

High .... 2415 2330 2235 2125 1995 1860 1735 1605

Med-High 2205 2175 2120 2065 1975 1900 1790 1685 1580 1460

High 2485 2430 2360 2270 2175 2070 1950 1825 1685 1535

Med-High 2155 2135 2100 2040 1970 1885 1790 1680 1560 1420

Medium 1830 1830 1810 1780 1730 1665 1595 1505 1395 1275

Med-Low 1520 1505 1490 1470 1430 1385 1330 1250 1165 1055

Low 1275 1260 1240 1210 1180 1135 1090 1025 930 840

High 2485 2400 2310 2215 2110 2000 1880 1725 1535 1355

Med-High 2195 2150 2090 2000 1920 1825 1720 1565 1405 1255

Med-Low 1880 1850 1820 1780 1715 1635 1540 1415 1290 1160

Low 1640 1635 1615 1585 1530 1465 1370 1255 1150 1040

High .... 2385 2305 2195 2085 1960 1825 1670 1465

Med-High 2180 2145 2060 2010 1945 1865 1765 1660 1515 1325

Med-Low 1880 1850 1820 1780 1715 1635 1540 1415 1290 1160

Low 1640 1635 1615 1585 1530 1465 1370 1255 1150 1040

High 2320 2250 2155 2055 1970 1855 1725 1600 1450 1280

Med-High 2125 2065 1995 1910 1815 1710 1610 1490 1340 1175

Med-Low 1845 1825 1765 1710 1650 1570 1475 1370 1240 1100

Low 1640 1620 1580 1540 1485 1410 1330 1220 1080 960

0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0

EXTERNAL STATIC PRESSURE (IN.W.C.)

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 most 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 Figure 20) Not all horizontal furnaces are approved for side return air connections. (See Figure 20)

GAS PIPING

Return Air Connections

accessoryfilter*A filter is required for each return-air inlet. Airflow performance included 3/4-in. (19 mm) washable filter media such as contained in factory-authorized

FIRE HAZARD

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.

441 01 2101 02 15

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.

Page 16

FIRE OR EXPLOSION HAZARD

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

Use proper length of pipe to avoid stress on gas control manifold and a gas leak.

Figure 18 - Upflow Return Air Configurations and Restrictions

UPFLOW RETURN AiR CONFiGURATiONS AND RESTRICTIONS

AIR FLOW MODELS RETURN AIR RETURN AIR RETURN AIR RETURN AIR

GREATER * 5 TONS AND YES YES YES YES

ALL OTHER MODELS YES YES YES YES

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

RETURN "i

AIR

RETURN

AiR

FIRE OR EXPLOSION HAZARD Failure to protect gas valve inlet from water and

debris could result in death, personal injury and/or property damage.

Gas valve inlet and/or inlet pipe must remain capped 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.

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

RETURN / UPFLOW

AiR / RETURN AIR

RESTRICTIONS

Figure 19 - Downflow Return Air Configurations and Restrictions

,FI_ RETURN

_J AI R

RETURN

AIR AIR

DOWNFLOWRETURNAIRCONFIGURATIONSANDRESTRICq]ONS

AIR FLOW MODELS RETURN AIR RETURN AIR RETURN AIR RETURN AIR

5 TONS AND YES NO NO NO GREATER *

ALL OTHER MODELS YES NO NO NO

• 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

16 441 01 2101 02

Page 17

Figure 20 - Horizontal Return Air Configurations and Restrictions

RETURN

AIR

_ SIDE RETURN AIR

_ NOT PERMITIED FOR

066,060, -22-2O AIR FLOW MODELS

..............................i

AIR

RETURN {

' ' ,/_ SIDERETURNAIR

/ 066,060,-22-20

AIR FLOW MODELS

......................_///.................................

HNORTzE6NRAELSTLREICFTTI......... ,_ ........ ICTIONS

J RETURN RETURN AIR

_s_ | 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

ii iiiiii/iiiii

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

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

Table 6 - Maximum Capacity of Pipe

NOMINAL

IRON PIPE

SIZE

IN. (MM)

1/2 (12.7)

3/4 (19.0)

1(25.4)

1-1/4

(31.8)

1-1/2 900

(38.1)

* Cubic ft. of natural gas per hr for gas pressures of 0.5 psig (14-1n. 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 NFPA54/ANSI Z223.1-2009.

INTERNAL LENGTH OF PIPE - FT. (M)

DIA. 10 20 30 40 50

IN. (MM) (3.0) (6.0) (9.1) (12.1) (15.2)

0.622 (158) 175 120 97 82 73

0.824

(20.9) 360 250 200 170 151

1.049

(26.6) 680 465 375 320 285

1.380

(35.0) 1400 950 770 660 580

1.610

(40.9) 2100 1460 1180 990

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 licensed plumber or gas fitter.

2. When flexible connectors are used, the maximum length shall not exceed 36 inches (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 6 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.

FIRE OR EXPLOSION HAZARD 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

damage.

Connect gas pipe to furnace using a backup wrench

to avoid damaging gas controls and burner

misatignment.

An accessible manual equipment shutoff valve MUST be

installed external to furnace casing and within 6 ft. 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.

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

441 01 2101 02 17

Page 18

Figure 21 - Burner and Manifold

TOP VIEW OF BURNER AND MANIFOLD ASSEMBLY

90 ° EIbow_

Supply

2" (51 mm)Nipple

L Gas Valve

A08551

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 manifold and exterior manual equipment gas shutoff valve.

Figure 23 - Field Wiring Diagram

NOTE2

Figure 22 - Typical Gas Pipe Arrangement

GAS

SUPPLY,Z'[

MANUALJ II SHUTOFF _ _

VALVE

(REQUIRED)jf*_.)_

SEDIMENT-- /

TRAP /

UNION---_

....................FIELD 24-VOLT WIRING

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

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

A02035

115-VOLT FIELD-

SUPPL}ED

FUSED

DISCONNECT

CONTROL

FURNACE

BOX

TERMINAL

BLOCK

NOTES: 1. Oor_r_ect Y!Y24erm hal as shown for proper operation.

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.

Piping should be pressure and leak tested in accordance with 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. If test 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.

CONDENSING

UNIT

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

3. If any of the original wire, as supplied, must be replace6, use same type or equivalent wire.

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. ELECTRICAL CONNECTIONS

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 23 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°C) rise.

18 441 01 2101 02

Page 19

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 ANSI/NFPA 70-2008 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.

Table 7 - Electrical Data

FURNACE MAY NOT OPERATE HAZARD

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 WIRING

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 7 for

equipment electrical specifications.

FURNACE

SIZE

0451412 115-60-1 7.1 9.67 14 0701412 115-60-1 7.3 9.90 14

0901714 115-60-1 8.2 10.84 14

1102122 115-60-1 13.7 17.60 12

1352422 115-60-1 14.5 18.61 12

* Permissible limits of the voltage range at which the unit operates satisfactorily. # Unit ampacity = 125% of largest operating component's full load amps plus 100% of all other potential operating components (EAC, humidifier, etc.) full load amps.

1-Time-delay type is recommended. $ Length shown is as measured 1 way along wire path between unit and service panel for maximum 2% voltage drop.

VOLTS-

HERTZ-

PHASE

U.S. Installations: Make all electrical connections in

accordance with National Electrical Code (NEC) ANSI/NFPA 70-2008 and any local codes or ordinances that might apply.

OPERATING VOLTAGE

RANGE

MAX* MIN.*

127 104 127 104

127 104

MAX UNIT

AMPS

UNIT

AMPACITY#

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.

MAXIMUM

WIRE

LENGTH

FT, (i)$

38 (11.5) 37 (11.2) 34 (10.3)

32 (9.7) 30 (9.1)

MAXIMUM

FUSE OR

CKT BKR

AMPSI

15 15

20 20

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

3. Move J-Box to desired location.

FIRE HAZARD

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

Do not connect aluminum wire between disconnect

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.

Figure 24 - Relocating J-Box

switch and furnace. Use only copper wire.

Use a separate branch electrical circuit with a properly sized fuse or circuit breaker for this furnace. See Table 7 for wire

size and fuse specifications. A readily accessible means of electrical disconnect must be located within sight of the

FACTORY INSTALLED

LOCATION

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

If polarity is incorrect, control LED status indicator light will flash status code of 10 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" 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 24)

MINIMUM

WIRE

GAUGE

ALTERNATE

FIELD LOCATION

441 01 2101 02 19

Page 20

ELECTRICAL CONNECTION TO J-BOX

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

Electrical Box on Furnace Casing Side, See Figure 25

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

injury, death, or property damage. 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.

Figure 25 - Field-Supplied Electrical Box on Furnace

Casing

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

with installed electrical box.

2. Remove the desired electrical box hole knockout and position the hole in the electrical box over the hole in

the furnace casing.

3. Fasten the electrical box to casing by driving two

field-supplied screws from inside electrical box into

casing steel.

4. Remove and save two screws holding J-Box. (See Figure 24)

5. Pull furnace power wires out of 1/2-inch (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.

10. Reattach furnace J-Box to furnace casing with screws removed in Step 4.

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

12. Complete electrical box wiring and installation. Connect line voltage leads as shown in Figure 23. Use best

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

13. Reinstall cover to J-Box. Do not pinch wires between

cover and bracket.

POWER CORD INSTALLATION IN FURNACE J-BOX

NOTE: Power cords must be able to handle the electrical requirements listed in Table 7. Refer to power cord

manufacturer's listings.

1. Remove cover from J-Box.

2. Route listed power cord through 7/8-inch (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 23.

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

BX, CABLE INSTALLATION IN FURNACE J-BOX

1. Remove cover from J-Box.

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

3. Secure BX cable to J-Box bracket with connectors approved 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 23.

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

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

Figure 23) Connect terminal Y/Y2 as shown in Figure 26-Figure 32 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.

20 441 01 2101 02

Page 21

Figure 26 - Two-Stage Furnace with Single-Speed Air

ICP THERMOSTAT TWO-STAGE SINGLE-,STAGE

Conditioner

FURNACE AIR CONDITIONER

NOTE 5

F_q

F_q Fq

[]

Figure 28 - Two-Stage Furnace with Single-Stage Heat

Pump (Dual Fuel)

ICP THERMOSTAT TWO-STAGE SINGLE-STAGE

NOTE 5

F_q E_

FURNACE HEAT PUMP

F_q F_q

NOTE4

SENSOR

OUTDOOR ]__]

Seenotesl, 3,4, and5

Figure 27 - Two-Stage Furnace with Two-Stage Air

ICP THERMOSTAT TWO-,STAGE TWO-STAGE

C_- C_-

EZ_

Conditioner

FURNACE AIR CONDITIONER

NOTE5

F_q F_q

-E3

[]

E35

NOTE4

E2_

D HUM24VAC

EZ} EZ_

See notes 1, 2, 3, 4, 5, and 8

Figure 29 - Two-Stage Furnace with Two-Stage Heat

ICP THERMOSTAT TWO-STAGE TWO-STAGE

NOTE 5 _F_" _

OUTDOOR

SENSOR I

Pump (Dual Fuel)

FURNACE HEAT PUMP

C_-

E2_

E25

NOTE4

C_-

D HUM

24VAC

E2_

NOTE4 _['_'q

p-q

HUM

24VAC

OUTDOOR

SENSOR

See notes 1, 3, 4, and 5

EZ} E_5

See notes 1,2, 3, 4, 5, and 8

441 01 2101 02 21

OUTDOOR

SENSOR I

Page 22

Figure 30 - Two-Stage Furnace and Humidifier Only

HUMIDITY SENSING

THERMOSTAT

HUMIDIFIER

TWO-STAGE

FURNACE

Figure 32 - HP with Two-Stage Furnace, Humidifier, and

Dehumidification

HUMIDITY SENSING TWO-,STAGE

THERMOSTAT FURNACE

See note 7

Figure 31 - AC with Two-Stage Furnace, Humidifier, and

HUMIDITY SENSlNG

THERMOSTAT

Dehumidification

"RNO--STAG E

FURNAC E

-0

SPDT f

RELAY

HUMIDIFIER

See notes 6 and 7

SPOTil

RELAY

HUMIDIFIER i

See note 7

For Figure 26 - Figure 32

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 application.

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

5. Optional connection for Two-Stage: If wire is connected, SWl-I(TT) on furnace control should be set to ON position to allow ICP Thermostat to control

the furnace staging.

6. HUM 24VAC terminal is 24 VAC and is energized when the low pressure switch closes during a call for heat.

7. When connecting 115VAC to humidifier use a separate

115 VAC supply.

8. When using a humidifier on a HP installation, connect

humidifier to hot water.

22 441 01 2101 02

Page 23

ACCESSORIES

1. Electronic Air Cleaner (EAC): Connect an accessory Electronic Air Cleaner (if used) using 1/4-in female

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

EAC 1AMP and NEUTRAL. The terminals are rated for

115VAC, 1.0 amps maximum and are energized during

blower motor operation. (See Figure 33)

2. Humidifier (HUM 24VAC and HUM) a. HUM 24VAC: Connect an accessory 24 VAC, 0.5

amp maximum humidifier (if used) to the X-in male quick-connect HUM 24VAC terminal and C screw

terminal on the control board thermostat strip. The

HUM 24VAC terminal is energized when there is a call for heat (W) and the pressure switch (PRS)

closes. (See Figure 33 and Figure 55).

b.. HUM: connect an accessory 115VAC (EAC and

HUM and 1 amp maximum combined) humidifier (if used) to the ¼-in male quick connect HUM terminal and NEUTRAL X-in QUICK CONNECT. THE hum

terminal is energized when the inducer motor is

energized (IDR). (See Figure 33 and Figure 55).

Figure 33 - Furnace ControI-PSC Blower Motor

SETUP SWITCHES THER-

MOSTAT TYPE AND HEAT

OFF-DELAY _

-- wo o_

NOTE: A field-supplied, 115-v controlled relay connected to EAC terminals may be added if humidifier operation is desired during blower operation.

NOTE: DO NOT connect furnace control HUM 24VAC

terminal to H (humidifier) terminal on humidity sensing thermostat, or similar device. See humidity sensing

thermostat, thermostat, or controller manufacturer's

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.

TWINNING AND/OR COMPONENT TEST

TERMINAL

24-V THERMOSTAT

TERMINALS

3-AMP FUSE -

LED OPERATION & DIAGNOSTIC LIGHT

115-VAC (L2) NEUTRAL

CONNECTIONS

SELECTION TERMINALS

HUMIDIFIER TERMINAL (24-VAC 0,5 AMP MAX)

F'_ TRANSFORMER 24VAC

//7 CONNECTIONS

HARNESS CONNECTOR

_ _IVI_ _ P1 - LOW VOLTAGE_MAIN

BHI/LOR

P2-HQT SURFACE IGNITOR (HSI) & INDUCER MOTOR CONNECTOR

TER L 115 VAC (L1) LINE

(115 VAC 1,0 AMP MAX,) VOLTAGE CONNECTION

L09F023

441 01 2101 02 23

Page 24

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

injury or death. 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, ANSI Z223.1/NFPA 54, 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, ANSI Z223.1/NFPA 54.

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.

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 NFGC.

GENERAL VENTING REQUIREMENTS

Follow all safety codes for proper vent sizing and installation requirements, including local building codes, the National

Fuel Gas Code ANSI Z223.1-2009/NFPA 54-2009 (NFGC), Parts 12 and 13 in the United States, the local building codes,

and furnace and vent manufacturers' instructions. These furnaces are design-certified as Category I furnaces in

accordance with ANSI Z21.47-2006/CSA 2.3-2006 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% to minimize the

potential for condensation in the venting system. These furnaces are approved for common venting and multi-story

venting with other fan assisted or draft hood equipped appliances in accordance with the NFCG, 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 furnace will be shut off by the draft safeguard switch

located on the vent elbow.

2. Two-stage furnaces require Type B vent connectors outside the casing in all configurations. Single wall vent

connector 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 capacity 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 dedicated 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 appliance.

6. Category I furnaces must be vented vertically or nearly vertically unless equipped with a listed mechanical

venter. See the SIDEWALL VENTING section.

7. Do not vent this appliance into an unlined masonry chimney. Refer to Chimney Inspection Chart,

Figure 34.

MASONRY CHIMNEY REQUIREMENTS 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 211-2009 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 Z223.1-2009 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 Z223.1-2009, 13.1.8 and

13.2.20 regarding alternative venting design and the exception, which cover installations such as the Chimney Adapter Kits which are listed for use with these furnaces. The Chimney Adapter is listed alternative venting system for these furnaces. See the kit instructions for complete details.

24 441 01 2101 02

Page 25

Figure 34 - Chimney Inspection Chart

CHIMNEY INSPECTION CHART

For additional requirements refer to the National Fuel Gas Code NFPA 54/ANSI Z223.1 and ANSI/NFPA 211

Chimneys, Fireplaces, Vents, and Solid Fuel Burning Appliances

Rebuild

Crown.

prol_rct_ilim_Ywith -_ No

_ Reline

sale ing...cod _or reline chimney as/

residue? debris_''_t Mr'°;;ar?

_ve metal vent [ J No

or liner. J

Clay

tile misalignment, missing sections,

Yes

gaps?

Condensate

at bottom

Chimney

exposed to

outdoors below

roof line?

_,- __perl.y _ ]Suitable sized, listed flexible metal

_b_ '_O '__ _chimney adapter ventingS_le

• _ .... _-_n,_ .... J"__ in§tructions for -_

Yes _ f"ur_a_e-? / _ applicatlon /

Remove mortar

and tile debris

_Not Suitable

_LNo _ instructions for / A_ b

/ _ _ application

.,_,=_^._ ,.._. _L^.,,. _ _ .... Line chimney with property

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

",_ype-u vent'._,,,/ _ NFGC Vent

/ _ Sizing Tables and liner or

_./ I"'_;_-_;,;';,T;_;;7'I vent manu

.[Yes L _ . Not Suitable

Is chimney _No . _ Part C of

Suitable

I i_;_ I Installationil

suitabili , ,

chimney]

I adapter per / I instructions. /

441 01 2101 02 25

A10133

Page 26

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 maximum capacity given in Table 8, and

4. The input rating of each space heating appliance is greater than the minimum input rating given in Table 9

for the local 99% Winter Design Temperature.

Chimneys having internal areas greater than 38 in2 (24516 mm2)require furnace input ratings greater than

the input ratings of these furnaces. See footnote at

bottom of Table 9, 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 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 required by

local code, refer to the NFPA 54/ANSI Z223.1-2009,

Section 12.10 for additional information on condensate drains.

b. Indicates the chimney exceeds the maximum

permissible size in the tables, the chimney should be

rebuilt or relined to conform to the requirements of the

equipment being installed and the authority having jurisdiction.

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

Table 8 - Combined Appliance Maximum Input Rating in

Thousands of BTUH per Hour

VENT HEIGHT

FT. (M)

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 )

8O 84

NR NR NR

19 28

(12258) (18064)

119 178 130 193 138 207 152 233

NR 250 NR NR

(24516)

257 279 299

334 368

404

Table 9 - Minimum Allowable Input Rating of

Space-Heating Appliance in Thousands of BTUH per

Hour

INTERNAL AREA OF CHIMNEY

VENT HEIGHT (FT)

Temperature: 17 to 26°F (-8 to -3°C)

6 (1.8) 0 55 99 141 8 (2.4) 52 74 111 154

10 (3.0) NR 90 125 169 15 (4.6) NR NR 167 212

20 (6.1) NR NR 212 258 30 (9.1) NR NR NR 362

Temperature: 5 to 16°F * (-15 to -9°C)

6 (1.8) NR 78 121 166 8 (2.4) NR 94 135 182

10 (3.0) NR 111 149 198 15 (4.6) NR NR 193 247

20 (6.1) NR NR NR 293 30 (9.1) NR NR NR 377

Temperature: -10 to 4°F * (-23 to -16°C)

6 (1.8) NR NR 145 196 8 (2.4) NR NR 159 213

10 (3.0) NR NR 175 231 15 (4.6) NR NR NR 283

20 (6.1) NR NR NR 333 30 (9.1) NR NR NR NR

Temperature: -11 °F (-24°C) or lower

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) or the 2005 ASHRAE Fundamentals handbook, Climatic

Design Information chapter, and the CD-ROM included with the 2005 ASHRAE Fundamentals Handbook.

12 19 28 38

(7741) (12258) (18064) (24516)

Local 99% Winter Design

SQ, IN. (SQ, MM)

26 441 01 2101 02

Page 27

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% 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 over-sizing 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.

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 (15°0) db except for brief periods of time during

warm-up from setback at no lower than 55_'F (13°0) 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

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 condensation problems.

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

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. or 6 in. (127 or 152 mm) vent connector may

be required for some model furnaces. A field-supplied 4 in. to 5 in. (102 to 127 mm) or 4 in. to 6 in. (102 mm to 152 mm)

sheet metal increaser fitting is required when 5 in. or 6 in. (127 or 152 mm) vent connector is used. See

Figure 35-Figure 47 Venting Orientation for approved vent configurations.

See Venting Notes after orientation figures.

Figure 35 - Upflow Application-Vent Elbow Up

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

these figures

A03208

Figure 36 - Upflow Application-Vent Elbow Right

if¸,¸}

,j,

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

these figures

A03209

441 01 2101 02 27

Page 28

Figure 37 - Downflow Application-Vent Elbow Up then

Left

Figure39 - DownflowApplication-Vent Elbow Left then

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

Figure 38 - Downflow Application-Vent Elbow Up

- = .

!'/ ix'

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

these figures

A03210

A03211

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.

A03212

28 441 01 2101 02

Page 29

Page 30

Page 31

Page 32

Page 33

Page 34

Page 35

Page 36

Page 37

Page 38

Page 39

Page 40

Page 41

Page 42

Page 43

Page 44

Page 45

(4.)Insertbrushendofcableinburnerinletopening

ofcell,andproceedtoclean2lowerpassesofcell insamemannerasupperpass.

(5.)Repeatforegoingproceduresuntileachcellin

furnacehasbeencleaned.

(6.)Usingvacuumcleaner,removeresiduefrom

eachcell.

(7.)Usingvacuumcleanerwith soft brush

attachment,cleanburnerassembly.

(8.)Cleanflamesensorwithfinesteelwool. (9.)InstallNOxbaffles(ifremoved.)

(10.)Reinstallburnerassembly.Centerburnersincell

openings.

10.Removeoldsealantfromcellpanelandcollectorbox flange.

11.Sprayreleasingagentontheheatexchangercellpanel wherecollectorboxassemblycontactscellpanel.

NOTE:A releasingagentsuchasavegetableoilcooking spraythatdoesnotcontaincornoil,canolaoil,halogenated hydrocarbonsoraromaticcontent,whichmaypreventan inadequateseatfromoccuring,andRTVsealantsuchas G.E.RTV162,G.E.RTV6702,orDow-CorningRTV738

sealantarerequired.DONOTsubstituteanyothertypeof RTVsealant.

12.Applynewsealanttoflangeofcollectorboxandattach tocellpanelusingexistingscrews,makingsureall screwsaresecure.

13.Reconnectwiresto thefollowingcomponents(Use connectiondiagramonwiringlabel,ifwireswerenot markedforreconnectionlocations.):

a.Draftsafeguardswitch. b.Inducermotor. c.Pressureswitches.

d.Limitovertemperatureswitch. e.Gasvalve.

f.Hotsurfaceigniter.

g.Flame-sensingelectrode. h.Flamerolloutswitches.

14.Reinstallinternalventpipe,ifapplicable.

15.Reinstallvent connectoron furnaceventelbow. Securelyfastenventconnectortoventelbowwith2

field-supplied,corrosion-resistant,sheetmetalscrews located180° apart.

Figure 53 - Igniter Position-Top View

A05026

16. Replace blower access door only, if it was removed.

17. Set thermostat above room temperature and check furnace for proper operation.

18. Verify blower airflow and speed changes between heating and cooling.

19. Check for gas leaks.

20. Replace outer access door.

Figure 54 - Cleaning Heat Exchanger Cell

A91252

FIRE OR EXPLOSION HAZARD

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

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.

Step 3 m Sequence of Operation NOTE: Furnace control must be grounded for proper

operation or control will lockout. Control is grounded through green wire connected to gas valve and burner bracket screw. Using the schematic diagram in Figure55, 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 run the blower for

the selected heat off-delay period two seconds after power is

restored, if the thermostat is still calling for gas heating. The LED light wilt flash a status code 1+2 during this period, after

which the LED will switch to a heartbeat, as long as no faults are detected. After this period, the furnace will 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 with Single-Stage Thermostat (See Figure 23 or Figure 32 for thermostat

connections)

NOTE: The thermostat type switch (TT) selects either the

two-stage thermostat operation mode when ON, (see item 2)

or the single stage thermostat operation mode when OFF in response to a call for heat. 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 thermostat type switch. This furnace can operate as a

two-stage furnace with a single-stage thermostat because the furnace control CPU includes a programmed sequence of

controlled operation, which selects low-heat for the first 12 minutes of operation then switches to high heat operation.

If the power is interrupted, the control CPU will operate in low heat for 12 minutes then it will switch to high-heat, as long as

the thermostat continues to call for heat. 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 HPS are open, and starts the inducer motor IDM in

441 01 2101 02 45

Page 46

high-speed. The HUM terminal is energized for a 115V humidifier (if used).

a. Inducer Prepurge Period (see Figure 55 schematic

diagram)

(1.) Low heat (W/W1) the inducer motor IDM comes

up to high-speed, the low-heat pressure switch

LPS closes. After the low-heat pressure switch

closes the furnace control CPU will begin a

15-second prepurge period, and continue to run

the inducer motor IDM at high-speed.

(2.) High Heat (W/WI+W2) the inducer motor IDM

comes up to high speed and the high-heat pressure switch relay HPSR is de-energized to close the NO contact. When sufficient pressure

is available, the high-heat pressure switch HPS

closes, and the high-heat gas valve solenoid GV-HI is energized. After LPS closes, 24VAC power is supplied for a field-installed humidifier

at the HUM 24VAC terminal and the furnace control CPU begins a 15-second prepurge

period. 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 maximum of 2 minutes after ignition.

If HPS doesn't close after 2 minutes from LPS

closing, GV is turned off and heat off delay is completed. Then a new cycle will begin if a call

for heat remains.

b. Igniter Warm-Up-At the end of the prepurge period,

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 contacts GVR close to energize the gas valve solenoid GV-M, the gas valve opens. The gas valve solenoid

GV-M permits gas flow to the burners where it is

ignited by the HSI. 5 sec after the GVR closes, a 2-sec

flame proving period begins. The HSI igniter will

remain energized until the flame is sensed or until the 2-sec flame proving period begins. If the furnace control CPU operates in 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 inducer motor IDM switches to low-speed unless running at

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 will 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 24VAC or COM 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 wilt 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 delay for low-heat and high-heat are as follows: Low-Heat-45 seconds after the gas valve GV-M is energized the blower motor (BLWM) is energized at LO HEAT speed.

High-Heat-25 seconds after the gas valve GV-M is energized the BLWM is energized at HI HEAT speed. Simultaneously, the electronic air cleaner (EAC 1 AMP) terminal is energized and remains energized as

long as the BLWM is energized.

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 switch to HI HEAT speed 5 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. Heat-Off Delay-When the thermostat is satisfied, 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 24VAC. The inducer motor IDM will remain energized for a 5-second post-purge period then turn off, also turning off HUM for 115V humidifier. The blower motor

BLWM and air cleaner terminal EAC 1 AMP will remain energized for 90, 120, 150, or 180 seconds

(depending on selection at heat-off delay switches).

The furnace control CPU is factory-set for a

120-second heat-off delay.

2. Two-Stage Thermostat and Two-Stage Heating (See Figure 31 for thermostat connections)

NOTE: In this mode the TT switch (SWI-1) must be ON to select the two-stage thermostat 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 thermostat type.

The wall thermostat "calls for heat", closing the R-to-W1 circuit for low-heat or closing the R-to-W1 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 two-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

thermostat 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-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 switch to HI HEAT speed five seconds after the

R-to-W2 circuit closes.

b. Switching from High- to Low-Heat-If the

thermostat R-to-W2 circuit opens, and the R-to-W1 circuit remains closed, the furnace control CPU wilt

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 will open. The gas valve solenoid GV-M will remain energized as long as the low-heat pressure switch LPS remains closed. The blower motor BLWM will switch to LO HEAT speed 5 seconds after the R-to-W2 circuit opens.

3. Cooling Mode-The thermostat "calls for cooling."

a. Single-Speed Cooling-

(See Figure 23 for thermostat connections)

The thermostat closes the R-to-G-and-Y circuits.

46 441 01 2101 02

Page 47

The R-to-Y circuit starts the outdoor unit, and the furnace control R-to-G-and-Y/Y2 circuits start the

furnace blower motor BLWM on cool speed. The electronic air cleaner terminal EAC 1 AMP is

energized with 115 vac when the blower motor BLWM is operating.

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 operating on the COOL speed for an additional 90 seconds. Jumper Y/Y2 to DHUM to reduce the cooling off-delay to 5

seconds. (See Figure 24)

b. Two-Speed Cooling

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 furnace control

R-to-G-and-Y1 circuit starts the furnace blower motor BLWM on low-cool speed (same speed as LO HEAT). The

R-to-Yl-and-Y2 circuits start the outdoor unit on high-cooling speed, and the furnace control R-to-G-and-Y1

and -Y2 circuits start the furnace blower motor BLWM on COOL speed. The electronic air cleaner terminal EAC 1 AMP

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 AMP will remain energized for an additional 90 seconds. Jumper Y1 to

DHUM to reduce the cooling off-delay to 5 seconds. (See Figure 33)

4. Dehumidify Mode (See Figure26 - Figure32 for humidity sensing

thermostat connections) The dehumidification output, H on the humidity sensing thermostat should be

connected to the furnace control thermostat terminal DHUM. When there is a dehumidify demand, the DHUM input is activated, (24 vac signal is removed

from the H input terminal). In other words, the DHUM input logic is reversed. The DHUM input is turned ON

when no dehumidify demand exists. Activation/Deactivation

Once 24 vac is detected by the furnace control on the DHUM input, the furnace control operates enables the dehumidify mode. If the DHUM input is off for more than 48 hours, the furnace control disables the dehumidify mode. The cooling operation described in item 3. above also applies 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 continue running at

low-cool speed (same speed as LO HEAT).

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 speed from COOL to HI HEAT for a maximum of 10 minutes before reverting back to COOL speed. If there is still a demand for dehumidification after 20 minutes,

the furnace control CPU will drop the blower speed back to HI HEAT speed. This alternating 10-minute cycle will continue as long as there is a call for cooling.

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.

5. Continuous Blower Mode

When the R-to-G circuit is closed by the thermostat, the blower motor BLWM will operate on continuous-blower speed LO HEAT speed. Terminal EAC 1 AMP is energized as long as the blower motor BLWM is energized. During a call for heat, the blower BLWM will stop during igniter warm-up (17 seconds), ignition (7 seconds), and blower-ON delay (45

seconds in low-heat, and 25 seconds in high-heat), allowing the furnace heat exchangers to heat up more quickly, then restarts at the end of the blower-ON delay period at LO HEAT or HI HEAT speed respectively. The

blower motor BLWM will revert to continuous-blower speed after the heating cycle is completed. In

high-heat, the furnace control CPU will hold the blower motor BLWM at HI HEAT speed during the selected blower-OFF delay period before reverting to

continuous-blower speed. When the thermostat "calls for low-cooling", the blower motor BLWM will operate at low-cool speed (same speed as LO HEAT). When the thermostat "calls for high-cooling", the blower motor BLWM will operate at COOL speed.

When the thermostat is satisfied, the blower motor BLWM will operate an additional 90 seconds on COOL

speed before reverting back to continuous-blower speed. When the R-to-G circuit is opened, the blower motor BLWM will continue operating for an additional 5 seconds, if no other function requires blower motor BLWM operation.

6. Heat Pump (See Figure 26 - Figure 32 for thermostat

connections) When installed with a heat pump, the furnace control automatically changes the timing sequence to avoid long blower off times during demand defrost cycles. When the R-to-W/W1 -and-Y1 or R-to-W/W1-and-Y1-and-G circuits are energized the

furnace control CPU will switch to or turn on the blower motor BLWM at low-cool speed (same speed as LO

HEAT), and begin a low-heat cycle. The blower motor BLWM will remain on until the end of the prepurge period, then shut off for 24 seconds then come back on at LO HEAT speed. When the W/W1 input signal disappears, the furnace control begins a normal inducer post-purge period and the blower remains running at LO HEAT speed. If the R-to-

W/Wl-and-Yl-and-G signals disappear at the same time, the blower motor BLWM will remain on for the selected heat-off delay period. If the R-to-W/Wl-and-Y1 signals disappear, leaving the G signal, the blower motor BLWM will remain on for the selected heat-off delay period then switch to continuous-blower speed.

When the R-to-W/W1 -and-Y/Y2, R-to-W/W1 -and- Y/Y2- and-G, R-to-W/Wl-and-Yl-and-Y/Y2, or R-to-W/Wl-and-Yl-and-Y/Y2-and-G circuits are energized the furnace control CPU will switch to or turn on the blower motor BLWM at COOL speed, and begin a high-heat cycle. The blower motor BLWM will remain on until the end of the prepurge period, then shut off for 24 seconds then come back on at HI HEAT speed.

When the W/W1 input signal disappears, the furnace control begins a normal inducer post-purge period and the blower switches to COOL speed after a 3 second delay. If the R-to-W/Wl-and-Y/Y2-and-G or R-to-W/W1 -and-Y1 -and- Y/Y2-and-G signals disappear at the same time, the blower motor BLWM will remain on for the selected heat-off delay period. If

the R-to-W/W 1-and-Y/Y2 or R-to-W/W1 - and-Yl-and-Y/Y2 signals disappear, leaving the G signal, the blower motor BLWM will remain on for the selected heat-off delay period then switch to continuous-blower speed.

Step 4 m Wiring Diagrams Refer to wiring diagram, Figure 55. Step 5 m Troubleshooting

Refer to the service label. (See Figure 51 --Service Label)

441 01 2101 02 47

Page 48

4_ Oo

.,,,& O

.,,,&

.,,,& o

.,,,&

o I'O

CONNECTION DIAGRAM

NOTE #3

=BRN

SELECT CHART

SW THERMOSTAT HEAT

TYPE OFF-DELAY

1 , 2 3

ON t-STG S?C

OFF

1 2 3 *

B-STG120

SEC.

°Ni 15D

OFF SEC. • O

o. tBO 1

OFF SEC.

• FACTORY SETTINGS cd

t_23 _ _ o

sS _I--

ON_ PLT w >

I OFFIE E III _ <o 0_o u-z

kW2 Y1 DHUM G C W/W1 Y/Y2 R STATUSCOGE

LED [

BHI/LOR BHT/CLR BLWR BLWM BVSS CAP CPU DSS EAC 1 AMP

FRS 1, 2 FSE FU1 FU2

GND GV GVR HPS HPSR HSl HSlR HUM 24VAC HUM IDM IDR IHI/LOR ILK

LED LGPS LPS LSl, 2 OL

LPCB

FUSEOR CIRCUIT

BREAKER &DISCONNECT

SWITCH(WHENREQ'D)

BLOWER MOTOR SPEED CHANGE RELAY, SPDT P1 BLOWER MOTOR SPEED CHANGE RELAY, SPDT P2 BLOWER MOTOR RELAY, SPST (M.D.) P4 BLOWER MOTOR, PERMANENT-SPLIT-CAPACITOR P5 BLOCKED VENT SHUTOFF SWITCH, MANUAL-RESET, SRST-(N.C.) PLT

CAPACITOR TRAM

MICROPROCESSOR AND CIRCUITRY TESTF[WlN DRAFT SAFE GUARD SWITCH. AUTO-RESET, SPST-(N.C.)

ELECTRONIC AIR CLEANER CONNECTION (EAC & HUM 1 AMP MAX.) FLAME ROLLOUT SW-MANUAL RESET, SPST-(N.C.) O

FLAME-PROVING ELECTRODE m FUSE, 3AMP, AUTOMOTIVE BLADE TYPE, FACTORY INSTALLED FUSE OR CIRCUIT BREAKER CURRENT INTERRUPT DEVICE

(FIELD SUPPLIED AND INSTALLED)

EQUIPMENT GROUND

GAS VALME-REDUNDANT

GAS VALVE RELAY, SPST-(N.O,) ....

HIGH-NEAT PRESSURE SWITCH, SPST-(N.O.) HIGH-HEAT PRESSURE SWITCH RELAY, SPST-(N,C.) HOT SURFACE IGNITER (115VAC) _) HOT SURFACE IGNITER RELAY, SPST-(N.O.) .-.L

24VAC HUMIDIFIER CONNECTION (0.5 AMP MAX.) ":

LINE VOLTAGE HUMIDIFIER CONNECTION (EAC & HUM I AMP MAX.) INDUCED DRAFT MOTOR, SHADED-POLE INDUCED DRAFT MOTOR RELAY. SPST-(N.O.)

INDUCER MOTOR SPEED CHANGE RELAY, SPDT ,,_ ),_ BLOWER ACCESS PANEL INTERLOCK SWITCH, SPST-(N.O.)

JUNCTION BOX

LIGHT-EMITING DIODE FOR STATUS CODES - GREEN LOW GAS PRESSURE SWITCH, SPST-(N.O.) LOW-HEAT PRESSURE SWITCH, SPST-(N.O.) LIMIT SWITCH, AUTO-RESET, SPST-(N.C.)

AUTO-RESET INTERNAL MOTOR OVERLOAD TEMPERATURE SWITCH-(N.C.)

PRINTED CIRCUIT BOARD CONTROL

(WHEN USED)

-, <_€_ P4 v,_rrl

i = _RED_ = RED

RED.

BW.

12-CIRCUIT PCB CONNECTOR 3-CIRCUIT PCB HSI & IDM CONNECTOR 3-CIRCUIT IDM CONNECTOR 2-CIRCUIT HSI CONNECTOR 3-CIRCUIT FACTORY TEST CONNECTOR

TRANSFORMER, 115VAC/24VAC

COMPONENT TEST & TWINNING TERMINAL JUNCTION

UNMARKED TERMINAL

PCB CONTROL TERMINAL

FACTORY POWER WIRING (115VAC)

FACTORY CONTROL WIRING (24VAC)

FIELD CONTROL WIRING (115VAC)

FIELD CONTROL WIRING (24VAC) CONDUCTOR ON CONTROL PCB

FIELD WIRING SCREW TERMINAL

FIELD EARTH GROUND

EQUIPMENT GROUND

FIELD SPLICE

PLUG RECEPTACLE

337797-201 REV. B

NOTES:

TESTiTV_N

(_ DHUM I (WHEN USED)

@Yt

_:_:>} P1-9

'_:)_ > P1-11

NOTE #5 I _ P1-7

1. If any of the original equipment wire is replaced use wire ratedfor 105°C.

2. Use only copper wire between the disconnect switch and the furnace junction box (JB). 3, This wire must be connected to furnace sheet metal for control to prove flame.

4. Symbols are electrical representation only.

5. Solid lines inside PCB are printed circuit board conductors and are not included in the legend.

6. Replace only with a 3 amp fuse.

7. Blower motor (BLWM) and inducer motor (IDM) contain internal auto-reset thermal overload switches (OL).

8. Neutral connections are interchangeable within the NEUTRAL connector block.

9. Blower motor speed selections are for average conditions see installation instructions for optimum selection,

10. Factory connected when BVSS (Chimney Adapter Kit) is not installed.

11. Factory connected when LGPS is not used.

12. Ignition lockout will occur after four consecutive unsuccessful trials-for-ignition. Control will auto-reset after three hours.

13. Blower-on delay: gas high-heat 25 seconds, gas low-heat 45 seconds, cooling or heat pump 2 seconds.

14. Blower off-delay: gas heating selections are 90, 120, 150, 180 seconds, cooling or heat pump 90 seconds or

I 5 seconds when DHUM is active, j

'11

._.

{I1

Page 49

t.O

START

Is LED status light ON solid, alternately

flashing bright-dim-bright-dim like a heartbeat, or flashing ON and OFF?

YES

I Is LED status light ON solid?

I Is LED status light alternately flashing

bright-dim-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, the number of long

flashes?

I o to section below for the flashed status

code.

Troubleshooting Guide - Two Stage

YES

Is there 115V at L1 and NEUTRAL?

YES

Is there 24V at 24VAC and COM?

YES

Is the 24V fuse open?

YES

Inspect secondary voltage (24V) wiring, including thermostat leads for short

circuit. Replace fuse

Replace furnace control.

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,

Is door switch closed? _ Close the door switch.

I I

YES

Is there 115V going to switch? _ Is circuit breaker closed?

YES

i e0,a o0oor witoh.I Ichec 'orcont'ou' in iro'ro oirouit ro orto,urn oo.

•_ Replace transformer.

I E4S

To recall a status code: Briefly (2 - 3 seconds) connect the TEST/TWIN terminal to the "C" thermostat fermi nal with a jumper wire to begin status code recovery and component test. If a previous status code is present, the code will repeat 4 times then go on to component test. If no previous code is present, a component test will begin without flashing any status codes. Component Test Sequence: Gas valve and humidifier will not be turned on.

Inducer motor will start in HIGH speed and

remain on HIGH until the end of the blower test, then shift to LOW speed for 7 to 15 seconds, the following components are on for 10 - 15 seconds each individually: hot surface igniter, blower speeds: LO HEAT, HI HEAT, COOL.

Was there a previous status code?

._ Does the control respond to W/W1, W2,

Y1, Y/Y2, and G (24V) thermostat signals?

YES

Run system through a Iowqqeat, high- heat, or cooling cycle to check operation.

Status codes are erased after 72 hours.

Replace furnace control.

I lose circuit breaker and go back to

START.

I Check room thermostat or

interconnecting cable.

INo

_ s 24V present at W/W1, W2, Y1, Y/Y2 or

G thermostat terminals on the furnace control?

YES

I I Disconnect all the thermostat wires from

the furnace control.

Does the problem repeat when using a

jumper wire?

The thermostat is not compatible with the furnace control. Either install a ballast

resistor, connect the C furnace control thermostat terminal to the thermostat, or replace the thermostat.

'11

01 0")

--I

III

(I) (D

Page 50

O1 O

ro o

o ro

PRESSURE SWITCH DID NOT OPEN - Check for:

- Obstructed pressure tube.

- Pressure switch stuck closed.

LOWq-IEAT 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. Blower will run for 4 min. or until open switch remakes whichever is longer. If open longer than 3 rain.code changes to lockout #7. If open less than 3 rain. 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)

- Defective blower motor

._ 7

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 1lame 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 electric switch ON?

- Manual shut--off valve open?

- Green/Yellow wire MUST be connected to furnace sheet metal.

- Flame sensor must not be grounded.

LIMIT CIRCUIT LOCKOUT - Lockout occurs if the limit, draft safeguard, flame rollout, or blocked vent switch (if used) is open longer than 3 minutes. Control will

auto-reset after 3 hours. Refer to status code #4.

GAS HEATING LOCKOUT - Control will 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.

HIGHq-IEAT PRESSURE SWITCH OR RELAY DID NOT CLOSE OR REOPENED -Check for:

- Control relay may be defective.

- Gas valve is miswired.

- Refer to status code #3.

POLARITY - Check for correct line voltage polarity. If units are twinned, check for proper low--voltage (24V) transformer phasing.

1 + 2 BLOWER ON AFTER POWER UP

(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-WA/Vl opens) during the blower on-delay period.

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.

To determine whether the problem is in the gas / valve, igniter, or flame sensor, the system can i'm be operated in component test mode. To check IN the igniter remove the R thermostat connection | from the control, reset power, start the | component test. Does the igniter glow I ,, orange/white bythe end of the 15 second warm- I Y

up period? F

I I

NOTE: NUMBER IN UPPER LEFT HAND CORNER REPRESENTS FLASH CODE

Unplug igniter harness from control and repeat component test. Check for 115V between connector P2 (HSI) and NEUTRAL4_2 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 current below 0.5 uA?

YES

Clean flame sensor with fine steel wool and recheck current. Nominal current is

4.0 to 6.0uA DC.

Is current near typical value?

YES

Will main burners ignite and stay on?

YES

Fixed.

Replace furnace control.

Check for continuity in the harness and igniter. Replace defective component.

Check connections. If OK,

replace control.

Check that gas valve electric

switch is turned on. Replace valve.

Check for:

- Inadequate flame carryover or rough ignition.

- Low inlet gas pressure.

- Proper firing rate.

- Air leakage around igniter bracket.

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--6.0uA DCnominal) and burners will not stay on, repeat check in highqqeat. 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.

Page 51

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

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

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

Vent elbow assembly

Wiring harness 24v

DIGIT POSITION F or G= Mainline

N = Entry 8 = 80% AFUE

M = Multiposition

V = Variable Speed Blower Motor -

]_CM 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 = 143/1¢'' 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 unit rating 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.

1 2 3

F 8 M

EFFICIENCY

POSITION

International Comfort Products, LLC

4 5

T L

TYPE

FEATURE

HEAT INPUT

Consumer Relations Department

P.O. Box 128

Lewisburg, TN 37091, USA

931-270-4100

6,7,8

045

CABINET WIDTH

9,10

COOLING AIRFLOW

SALES (MAJOR) REVISION DIGIT

ENGINEERING (MINOR) REVISION DIGIT

11,12

441 01 2101 02 specificationsaresubjecttochangewithout notice 51