ICP N8MSL0451408A1, N8MSL0451412A1, N8MSL0701408A1, N8MSL0701412A1, N8MSL0701716A1 Installation Guide

...

These instructions must be read and understood completely before attempting installation.

Safety Labeling and Signal Words

DANGER, WARNING, CAUTION, and NOTE Signal Words in Manuals

The signal words DANGER, WARNING, CAUTION, and NOTE The signal word WARNING is used throughout this manual inthe are used to identify levels of hazard seriousness. The signal word following manner:

DANGER isonly 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 The signal word CAUTION is used throughout this manual in the manual that may apply to the product, following manner:

DANGER - Immediate hazards which will result in severe person-

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

severe personal injury or death. CAUTION - Hazards or unsafe practices which may result in or product labels.

minor personal injury or product or property damage.

NOTE - Used to highlight suggestions which wilt result in en- z_ Safety-alert symbol hanced installation, reliability, or operation. When you see this symbol on the unit and in instructions or manu-

TABLE OF CONTENTS

DIMENSIONS ............................................... 3

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

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

CODES AND STANDARDS ................................... 5

SAFETY ................................................ 5

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

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

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

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

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

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

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

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

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

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

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

UPFLOW INSTALLATION ................................. 10

DOWNFLOW INSTALLATION ............................. 11

FILTER ARRANGEMENT ................................. 12

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

AIR DELIVERY - CFM .................................... 14

ELECTRICAL CONNECTIONS ............................ 20

115-V WIRING .......................................... 20

J-BOX RELOCATION .................................... 20

ELECTRICAL CONNECTION TO J-BOX .................... 20

ELECTRICAL DATA ...................................... 21

24-V WIRING ........................................... 22

ACCESSORIES ......................................... 22

VENTING .................................................. 23

GENERAL VENTING REQUIREMENTS ..................... 23

MASONRY CHIMNEY REQUIREMENTS .................... 24

APPLIANCE APPLICATION REQUIREMENTS ............... 26

ADDITIONAL VENTING REQUIREMENTS .................. 26

SIDEWALL VENTING .................................... 27

START-UP, ADJUSTMENT, AND SAFETY CHECK ............... 30

GENERAL .............................................. 30

START-UP PROCEDURES ............................... 30

ADJUSTMENTS ......................................... 31

SPEED SELECTION ..................................... 32

CHECK SAFETY CONTROLS ............................. 33

CHECKLIST ............................................ 34

ORIFICE SIZE AND MANIFOLD PRESSURE ................ 35

SERVICE AND MAINTENANCE PROCEDURES ................. 39

CARE AND MAINTENANCE ................................... 39

SEQUENCE OF OPERATION ................................. 43

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

TROUBLESHOOTING GUIDE ................................. 45

Signal Words on Product Labeling

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

als, be alert to the potential for personal injury.

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

For verification of certification for individual

IS09001

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.

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

products, go to www.ahridirectory.org .

Portionsofthe text and tables are reprintedfrom NFPA54/ANSI Z223.t -20096), with permission of National FireProtectionAssociation, Quincy, MA02269 and American Gas Association,Washing-

ton, DC 20001. This reprinted material is not the complete and official position of the NFPAor ANSI, onthe referencedsubiect, which is represented only by the standard in itsentirety,

PrintedinU.S.A. 441 01 1402 02 May. 2012

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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.

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Table 1--Dimensions - In. (mm)

OUTLET

FURNACE SIZE

N8MSN & N8MSL

0451408 0451412 0701408 0701412 0701716

0901714 0902116 0902120 1101712 1102116

1102122 1352116 1352422 1552420

"135 and 155 size furnaces require a 5 or 6-in. (127 or 152 ram) vent. installation requirements.

CABINET WIDTH

IN (mm)

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

17-1/2 (445) 17-1/2 (445)

21 (533) 21 (533)

17-1/2 (445)

21 (533) 21 (533)

21 (533)

24-1/2 (622)

24-1/2 (622) 22-7/8 (581)

WIDTH

IN (mm)

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

15-7/8 (403) 15-7/8 (403)

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

19-3/8 (492)

22-7/8 (581)

Use a vent adapter between furnace and vent stack. See Installation Instructions for complete

SAFETY CONSIDERATIONS

FIRE, EXPLOSION, ELECTRICAL SHOCK, AND

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

injury, death, or property damage. Improper installation, adjustment, alteration, service,

maintenance, or use can cause carbon monoxide poisoning, explosion, fire, electrical shock, or other

conditions which may cause personal injury or property damage. Consult a qualified service agency,

local gas supplier, or your distributor or branch for information or assistance. The qualified service

agency must use only factory-authorized and listed

kits or accessories when modifying this product.

FURNACE RELIABILITY HAZARD

Failure to follow this caution may result in unit

component damage. Application of this furnace should be indoors with

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

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

TOP AND

BOTTOM

FLUE COLLAR

IN (mm)

9-5/16 (237) 9-5/16 (237)

9-5/16 (237)

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

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

13-5/16 (338) 15-1/16 (383) 15-1/16 (383) 23 (584) 4 (102)* 170 (77)

BOTTOM

WIDTH

IN (mm)

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

16 (406) 16 (406)

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

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

19-1/2 (495)

23 (584)

VENT

CONNECTION

SIZE*

IN (mm)

4 (102) 4 (102)

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

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

4 (102)* 4 (102)*

SHIP WT

LB(KG)

104 (47) 107 (49)

111(50)

115 (52)

126 (57)

127 (58)

140 (64) 146 (66) 135 (61) 146 (66) 152 (69)

149 (68) 163 (74)

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.

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 instruc- tions.

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

441 01 1402 02 3

whichhasanexternalstaticpressurewithintheallow- ablerange,asspecifiedinthe"Start-Up,Adjustments,

andSafetyCheck"section.Seefurnaceratingplate.

7.Whenafurnaceisinstalledsothatsupplyductscarry aircirculatedbythefurnacetoareasoutsidethespace

containingthefurnace,thereturnairshallalsobe handledbyduct(s)sealedtothefurnacecasingand

terminatingoutsidethespacecontainingthefurnace.

See"AirDucts"section.

8.Agas-firedfurnaceforinstallationinaresidentialgar- agemustbeinstalledasspecifiedinthewarningboxin

the"Location"section.

9.Thefurnacemaybe usedfor constructionheat providedthatthefurnaceinstallationandoperation

complieswiththefirstCAUTIONintheLOCATIONsec-

tionoftheseinstructions.

10.TheseMultipoiseGas-FiredFurnacesare CSA (formerlyA.G.A.andC.G.A.)design-certifiedforuse

withnaturalandpropanegases(seefurnacerating

plate)andforinstallationinalcoves,attics,basements, closets,utilityrooms,crawlspaces,andgarages.The

furnaceisfactory-shippedforusewithnaturalgas.A

CSA(A.G.A.andC.G.A.)listedaccessorygasconver-

sionkitisrequiredtoconvertfurnaceforusewithpro-

panegas.

11.SeeFigure1 forrequiredclearancesto combustible construction.

12.Maintaina1-in.(25mm)clearancefromcombustible materialstosupplyairductworkfora distanceof36in.

Figure 2 - Clearances to Combustibles

(914mm)horizontallyfromthefurnace.SeeNFPA90B

orlocalcodeforfurtherrequirements.

13.ThesefurnacesSHALLNOTbeinstalleddirectlyon carpeting,tile,oranyothercombustiblematerialother

thanwoodflooring.In downflowinstallations,factory accessoryfloorbaseMUSTbeusedwheninstalledon

combustiblematerialsandwoodflooring.Specialbase

isnotrequiredwhenthisfurnaceisinstalledonmanu-

facturer'scoilmodelnumbersEND4X,ENW4Xor whencoilcasingmodelnumberNAEAis used.See

Figure1forclearancetocombustibleconstructionin-

formation.

INTRODUCTION

N8MSN & N8MSL 4-way multipoise Category I fan-assisted furnace is CSA 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.

This furnace is designed for minimum continuous return-air temperature of 60°F (16°0) db or intermittent operation down to 55_'F (13°0) db such as when used with a night setback

thermostat. Return-air temperature must not exceed 80°F

(27°0) db. Failure to follow these return-air temperature limits

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

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

serious injury or death,

Read and follow instructions and

arecautions in User's Information Manual erovided with this furnace. Installation

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

_IL CAUTION

Check entire gas assembly for leaks after

lighting this appliance.

I INSTALLATION I

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 previsions 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

This forced air furnace is This furnace is approved for

equipped for use with natural HORIZONTAL installations, gas at altitudes 0 - 10,000 ft

(0 - 3,050m), Clearancearrows

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 VentOlearancetocombustibles: vented in common with other For Single Wall vents 6 inches (6 po).

gas fired appliances. For Type B-1vent type 1 inch (1 po).

DOWNFLOW POSITIONS:

1" Installation on non-combustible floors only.

For Installation on combustible flooring only when installed on special base, Part No. KGASB0201ALL or NAHAO1101SB, Coil Assembly, Part No. CAR, CAP, CNPV, CNRV, END4X, ENW4X, WENC, WTNC, WENW OR WTNW.

18 inches front clearance required for alcove.

* 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.

I INSTALLATION I

UPFLOW, DOWNFLOW, and

do not change with

MINIMUM INCHES CLEARANCE TO

COMBUSTIBLE CONSTRUCTION

IIIIIIIIIHMIMHI

336996-101 REV. C

4 441 01 1402 02

Figure 3 - Return Air Temperature

MAX 8OoF/27 oO

FRONT

"< :/ MIN 60°F/16°C

A06745

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

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

CODES AND STANDARDS

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

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

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 --Safety

National Fuel Gas Code (NFGC) NFPA 54-2009/ANSI Z223.1-2009 and the Installation

Standards, Warm Air Heating and Air Conditioning Systems ANSl/NFPA 90B

Step 2--General Installation

Current edition of the NFGC and the NFPA 90B. For copies, contact the National Fire Protection Associ-

ation Inc., Batterymarch Park, Quincy, MA 02269; (www.NFPA.org) or for only the NFGC, contact the

American Gas Association, 400 N. Capitol Street,

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

Step 3 --Combustion and Ventilation Air

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

Step 4--Duct Systems

Air Conditioning Contractors Association (ACCA)

Manual D, Sheet Metal and Air Conditioning Con-

tractors National Association (SMACNA), or Americ-

an Society of Heating, Refrigeration, and Air Condi-

tioning Engineers (ASHRAE) 2001 Fundamentals

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

--Acoustical Lining and Fibrous GlassStep 5

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

NFGC; 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

FURNACE RELIABILITY HAZARD

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

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.

1. Disconnect all power to the furnace. Multiple discon- nects 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 wilt be satis- factorily discharged.

3. After touching the chassis, you may proceed to service the control or connecting wires as long as you do noth-

ing to recharge your body with static electricity (for ex- ample; 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, un-

painted metal surface of the furnace again before touching control or wires.

5. Use this procedure for installed and uninstatled (un- grounded) furnaces.

6. Before removing a new control from its container, dis- charge 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 fur- nace. Put all used and new controls into containers be-

fore touching ungrounded objects.

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

441 01 1402 02 5

LOCATION

CARBON MONOXIDE POISONING AND UNIT

DAMAGE HAZARD

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

Figure 4 - Multipoise Orientations

THE BLOWER IS LOCATED

TOTHE RIGHT OFTHE

BURNERSECTION, AND

AiR CONDITIONED AIR IS

DISCHARGEDTO THE LEFT.

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. This furnace must:

be installed so the electrical components are protec-

ted from water.

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

Downflow installations require use of a factory-ap- proved floor base, coil model numbers END4X,

ENW4X or coil casing model number NAEA when installed on combustible materials or wood flooring.

(Refer to SAFETY CONSIDERATIONS). be located as close to the chimney or vent and at-

tached to an air distribution system. Refer to Air

Ducts section.

AIRFLOW

THE BLOWER IS

LOCATED BELOWTHE

BURNERSECTION, AND

CONDITIONED AIR IS

DISCHARGED UPWARD.

LOCATEDABOVETHE

BURNER SECTION, AND

THE BLOWER IS '_7

CONDITIONEDAIR IS

DISCHARGED DOWNWARD

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

ances shown on the furnace clearance to combust- ible label.

The following types of furnace installations may re- quire OUTDOOR AIR for combustion due to chemic-

al exposures: Commercial buildings

Buildings with indoor pools Laundry rooms

Hobby or craft rooms, and Chemical storage areas

If air is exposed to the following substances, it should not be

used for combustion air, and outdoor air may be required for combustion:

Permanent wave solutions Chlorinated waxes and cleaners

Chlorine based swimming pool chemicals

AIRFLOW

_ HORIZONTAL RIGH_AIRF L_C w

THE BLOWER IS

LOCATED TO THE LEFT

OF THE BURNER SECTION,

AND CONDiTiONED AIR IS

DISCHARGED TO THE RIGHT.

A02097

Water softening chemicals

De-icing salts or chemicals Carbon tetrachloride

Halogen type refrigerants Cleaning solvents (such as perchloroethylene)

Printing inks, paint removers, varnishes, etc. Hydrochloric acid

Cements and glues

Antistatic fabric softeners for clothes dryers

Masonry acid washing materials

All fuel-burning equipment must be supplied with air for fuel combustion. Sufficient air must be provided to avoid negative

pressure in the equipment room or space. A positive seal must be made between the furnace cabinet and the

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

6 441 01 1402 02

FIRE, INJURY OR DEATH HAZARD

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

When the furnace is installed in a residential garage, the burners and ignition sources must be located at

least 18 in. (457 mm) above the floor. The furnace must be located or protected to avoid damage by

vehicles. When the furnace is installed in a public

garage, airplane hangar, or other building having a hazardous atmosphere, the furnace must be installed in accordance with the NFPA 54/ANSI Z223.1-2009. (See Figure 5)

Figure 5 - Installation in a Garage

18-1N. (457.2 mm)

MINIMUM TO BURNERS

A93044

PERSONAL INJURY AND/OR PROPERTY DAMAGE HAZARD

Failure to follow this caution may result in furnace

component damage. This gas furnace may be used for heating buildings

under construction provided that:

-The furnace is permanently installed with all electrical wiring, piping, venting and ducting installed according to these installation instructions. A return air duct is provided, sealed to the furnace casing, and terminated outside the space containing the furnace. This prevents a negative pressure condition as created by the circulating air blower, causing a flame

rollout and/or drawing combustion products into the

structure.

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

structure without thermostatic control.

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

prevents the entrainment of drywall dust into combustion air, which can cause fouling and plugging of furnace components.

-The temperature of the return air to the furnace is maintained between 55°F (13°C) and 80°F (27°C), with no evening setback or shutdown. The use of the

furnace while the structure is under construction is deemed to be intermittent operation per our

installation instructions.

-The air temperature rise is within the rated rise range on the furnace rating plate, and the gas input rate has been set to the nameplate value.

-The filters used to clean the circulating air during the

construction process must be either changed or thoroughly cleaned prior to occupancy.

-The furnace, ductwork and filters are cleaned as necessary to remove drywall dust and construction

debris from all HVAC system components after construction is completed.

-Verify proper furnace operating conditions including ignition, gas input rate, air temperature rise, and

venting according to these installation instructions.

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)

Figure 6 - Prohibit Installation on Back

BACK

A02054

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.

AIR FOR COMBUSTION AND

VENTILATION

Provisions for adequate combustion, ventilation, and dilution air must be provided in accordance with:

Section 9.3 of the NFPA 54/ANSI Z223.1-2009, Air

for Combustion and Ventilation, and applicable pro- visions of the local building codes.

441 01 1402 O2 7

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

ventilation air opening, to the outdoors.

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.

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 sq./in, of free

area per 2,000 Btuh (1,100 mm2/kW) of combined input for all gas appliances in the space per

Figure 7 and Table 2.

d. TWO OPENINGS OR VERTICAL DUCTS require 1

sq./in, of free area per 4,000 Btuh (550 mm2/kW) for combined input of all gas appliances in the

space per Figure 7 and Table 2.

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.

3. ONE OUTDOOR OPENING requires: a. 1 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

b. Not less than the sum of the areas of all vent con-

nectors in the space.

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.

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 cu/ft, per 1,000 Btuh input rating for all

gas appliances installed in the space.

Spaces having less than 50 cu/ft, per 1,000 Btuh

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. require the OUTDOOR COMBUSTION AIR METHOD.

Spaces having at least 50 cu/ft, 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 combus- tion, ventilation, and dilution of flue gases using per-

manent horizontal or vertical duct(s) or opening(s) dir- ectly communicating with the outdoors or spaces that

CARBON MONOXIDE 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.

freely communicate with the outdoors.

Table 2--Minimum Free Area Re(

TWO HORIZONTAL DUCTS SINGLE DUCT OR OPENING

FURNACE (1 SQ. IN./2,000 BTUH) (1 SQ. IN./3,000 BTUH)

INPUT (1,100 SQ. MM/KW) (734 SQ. MM/KW)

(BTUH) Free Area of Round Duct Free Area of Round Duct Free Area of Round Duct

Opening and Duct Dia. Opening and Duct Dia. Opening 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) 22.0 (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) 44.0 (28387) 8 (203) 33 (21290) 7 (178)

154,000 77 (49677) 10 (254) 51.3 (33096) 9 (229) 38.5 (24839) 8 (203)

uired for Each Combustion Air Opening of Duct to Outdoors

TWO OPENINGS OR VERTICAL

DUCTS

(1 SQ. IN./4,000 BTUH)

(550 SQ. MM/KW)

EXAMPLES: Determining Free Area

FURNACE WATER HEATER TOTAL INPUT

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

66,000 + 40,000 (106,000 divided by 3,000) = 35.3 Sq. In.for a Single Duct or Opening 88,000 + 30,000 (118,000 divided by 2,000) = 59.0 Sq. In. for each of two Horizontal Ducts

8 441 01 1402 02

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

OTHER THAN FAN-ASSISTED TOTAL FAN-ASSISTED TOTAL

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

30 40 50 44 66 88 110 132 154

ACH Space Volume Ft3 (M3)

0.60 (29.7) (39.6) (49.5) (31.1) (46.7) (62.2) (77.8) (93.4) (109.0)

0.50 (35.6) (47.5) (59.4) (37.3) (56.0) (74.7) (93.4) (112.1 ) (130.8)

0.40 (44.5) (59.4) (74.3) (46.7) (70.0) (93.4) (116.8) (140.1 ) (163.5)

0.30 (59.4) (79.2) (99.1) (62.2) (93.4) (124.5) (155.7) (186.8) (218.0)

0.20 (89.1) (118.9) (148.6) (93.4) (140.1 ) (186.8) (233.6) (280.3) (327.0)

0.10 (178.3) (237.8) (297.3) (186.8) (280.3) (373.7) (467.2) (560.6) (654.1)

0.00 NP NP NP NP NP NP NP NP NP

NP = Not Permitted

Figure 7 -- Air for Combustion, Ventilation, and Dilution

1,050 1,400 1,750 1,100 1,650 2,200 2,750 3,300 3,850

1,260 1,680 2,100 1,320 1,980 2,640 3,300 3,960 4,620

1,575 2,100 2,625 1,650 2,475 3,300 4,125 4,950 5,775

2,100 2,800 3,500 2,200 3,300 4,400 5,500 6,600 7,700

3,150 4,200 5,250 3,300 4,950 6,600 8,250 9,900 11,550

6,300 8,400 10,500 6,600 9,900 13,200 16,500 19,800 23,100

Figure 8 - Air for Combustion, Ventilation, and Dilution

OUTDOORS

for Outdoors

SQ IN. PER 4000 BTUH*

from Indoors

VENT THROUGH ROOF

(305mm) 12" MAX

1 SQ IN. PER 2000

BTUH*

DUCTS

OUTDOORS

1 SQ IN. PER 2000 BTUH*

(305mm)

CIRCULATING AIR DUCTS

TO PER 4000

OUTDOORS BTUH*

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

NOTE: Use any ofthe following combinations of openings:

A&BC&DD&EF&G

1 SQ IN.

12_X (305mm)

1 SQ IN.

PER

4000

BTUH*

O3 rr

O O

F-

1 SQ IN.

PER

4000

BTUH*

12" (305mm)

MAX

The Standard Method:

1. The space has no less volume than 50 cu/ft, per 1,000 Btuh of the maximum input ratings for all gas appli-

ances installed in the space and

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

A03174

I I

INTERIOR

HEATED

SPACE

CIRCULATING AIR DUCTS

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

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

Table 3 - Minimum Space Volumes were determined by

using the following equations from the National Fuel Gas Code ANSI 7223.1-2009/NFPA 54-2009, 9.3.2.2:

1. For other than fan-assisted appliances, such as a draft hood-equipped water heater:

12" AX(305mm)

2_ 1 SQ IN.

BTUH* IN DOOR

i PER 1000

OR WALL

UNCONFINED

W SPACE

-4,

_: 6" MIN (152mm) co (FRONT)0

_z 1 SQ IN.

PER 1000

_ BTUH* IN DOOR

OR WALL

L 12"MAX(305ram)

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

1. Less than 0.40 ACH and

Vo'" m e Other: A-A0_ _k,T000 "a_/h r"#

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

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

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

V°lumeFan = ACH _000 Btu/hrJ

15ft3 f[ ]fan ="_

space.

441 01 1402 02 9

A03t 75

A04002

A04003

If: Iother= combinedinputof all otherthanfan-assisted

appliancesinBtuh/hr

Ifan= combinedinputof all fan-assistedappliancesin Btuh/hrACH=airchangesperhour(ACHshallnotexceed

0.60.)Thefollowingrequirementsapplyto theStandard MethodandtotheKnownAirInfiltrationRateMethod.

1.Adjoiningroomscanbeconsideredpartofaspaceif: a.Therearenocloseabledoorsbetweenrooms.

b.Combiningspacesonsamefloorlevel.Eachopen-

ingshallhavefreeareaofatleast1in.2/1,000Btuh (2,000mm2/kW)ofthetotalinputratingofallgas

appliancesinthespace,butnotlessthan100in.2

(0.06m2).Oneopeningshallcommencewithin12 in.(300mm)oftheceilingandthesecondopening

shallcommencewithin12in.(300mm)ofthefloor. Theminimumdimensionofairopeningsshallbeat

least3in.(80mm).(SeeFigure8)

c.Combiningspaceondifferentfloorlevels.The

volumesofspacesondifferentfloorlevelsshallbe consideredascommunicatingspacesifconnected

byoneormorepermanentopeningsindoorsor floorshavingfreeareaofatleast2in.2/1,000Btuh

(4,400mm2/kW)oftotalinputratingofallgasappli-

ances.

2.Anatticorcrawlspacemaybeconsideredaspacethat freelycommunicateswiththeoutdoorsprovidedthere

areadequatepermanentventilationopeningsdirectly tooutdoorshavingfreeareaofat least1-in.2/4,000

Btuhoftotalinputratingforallgasappliancesinthe

space.

3.InspacesthatusetheIndoorCombustionAirMethod,

infiltrationshouldbeadequatetoprovideairforcom- bustion,permanentventilationand dilutionof flue

gases.However,inbuildingswithunusuallytightcon-

struction,additionalairMUSTbeprovidedusingthe

methodsdescribedintheOutdoorCombustionAir Methodsection.

UnusuallytightconstructionisdefinedasConstructionwith:

a.Wallsandceilingsexposedtotheoutdoorshavea

continuous,sealedvaporbarrier.Openingsaregas- ketedorsealedand

b.Doorsandopenablewindowsareweatherstripped

and

c.Otheropeningsarecaulkedorsealed.Thesein-

cludejointsaroundwindowanddoorframes, betweensoleplatesandfloors,betweenwall-ceil-

ingjoints,betweenwallpanels,atpenetrationsfor

plumbing,electricalandgaslines,etc.

CombinationofIndoorandOutdoorAir

1.IndooropeningsshallcomplywiththeIndoorCom- bustionAirMethodbelowand,

2.Outdooropeningsshallbelocatedasrequiredinthe OutdoorCombustionAir Methodmentionedprevi-

ouslyand,

3.Outdooropeningsshallbesizedasfollows:

a.CalculatetheRatioofallIndoorSpacevolumedi-

videdbyrequiredvolumeforIndoorCombustion AirMethodbelow.

b.OutdooropeningsizereductionFactoris1minus

theRatioina.above.

c.MinimumsizeofOutdooropeningsshallbethesize

requiredinOutdoorCombustionAirMethod abovemultipliedbyreductionFactorinb.above. Theminimumdimensionofairopeningsshallbe

notlessthan3in.(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 bot- tom filler panel. (See Figure 9.)

Figure 9 -- Removing Bottom Closure Panel

BOTTOM CLOSURE

PANEL

BOTTOM FILLER PANEL

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.

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.

10 441 01 1402 02

Figure 10 - Leveling Legs Figure 11 - Floor and Plenum Opening Dimensions

(8mm)

(44mm)

1 3/4"

(44mm)

(8mm)

5/16 _

(8mm)

(44mm) 1 3/4"

(44mm) I 3/4'_.

A89014

Leveling Legs (If Desired) 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. (In- stall flat washer if desired.)

4. Adjust outside nut to provide desired height, and tight- en inside nut to secure arrangement.

5. Reinstall bottom closure panel if removed.

DOWNFLOW INSTALLATION NOTE: For downflow applications, this furnace is approved

for use on combustible flooring when any one of the following 3 accessories are used:

Downflow combustible floor subbase Coil model number END4X or ENW4X

Coil casing model number NAEA

1. Determine application being installed from Table 4.

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

3. Construct plenum to dimensions specified in Table 4 and Figure 11.

4. If downflow subbase is used, install as shown in Figure 12. If coil model numbers END4X, ENW4X or

coil casing model number NAEA is used, install as shown in Figure 13.

A96283

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 box. 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)

Figure 12 - Furnace, Plenum, and Subbase Installed on

a Combustible Floor

FURNACE

(OR COIL CASING

WHEN USED)

COMBUSTIBLE

FLOORING

DOWNFLOW

SUBBASE

SHEET METAL

PLENUM

__ FLOOR __

OPENING

A96285

441 01 1402 02 11

Figure 13 - Furnace, Plenum, and Coil or Coil Casing

Installed on a Combustible Floor

FURNACE

APPROVED

COIL ASSEMBLY

COIL BOX

COMBUSTIBLE

FLOORING

\\\\_

_f,=====SHEET METAL =====.=_

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 bot- tom filler panel. (See Figure 9)

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

3. Remove bottom closure panel.

4. Reinstall bottom filler panel and screws.

HORIZONTAL INSTALLATION

FIRE, EXPLOSION, AND CARBON MONOXIDE POISONING HAZARD

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

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

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

The furnace can be installed horizontally in an attic or 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.

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

PLENUM

FLOOR

OPENING

A08556

each bottom corner. To prevent screws from pulling out, use 2 #8 x 3/4-in. (19 mm) screws into the side and 2 #8 x 3/4-in.

(19 mm) screws in the bottom of the furnace casing for each

strap. (See Figure 15 and Figure 16) If the screws are attached to ONLY the furnace sides and not

the bottom, the straps must be vertical against the furnace 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 crawl space 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 mm) piece of sheet metal for flame roll-out protection in front of burner area for furnaces closer than 12 inches (305 mm) above the

combustible deck or suspended furnaces closer than 12 inches (305 mm) to joists. The sheet metal MUST extend underneath the furnace casing by 1 in. (25 mm) with the door

removed. The bottom closure panel on furnaces of widths 17-1/2 in.

(445 mm) and larger may be used for flame roll-out protection when bottom of furnace is used for return air connection. See Figure 17 for proper orientation of roll-out

shield.

Bottom Return Air Inlet

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

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

1. Tilt or raise furnace and remove 2 screws holding bot- tom 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) is used without a bottom return air inlet.

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

FILTER ARRANGEMENT

CARBON MONOXIDE AND POISONING HAZARD

Failure to follow this warning could result in personal injury, death and/or property damage. 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. This furnace requires 1 in. (25 mm) external filter rack. Refer to the instructions supplied with external filter rack for

assembly and installation options.

12 441 01 1402 02

Table 4_Opening Dimensions - In. (mm)

FURNACE

CASING

WIDTH

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

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

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

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

Downflow Applications on Combustible Flooring with Coil END4X, 12-5/16 19 13-5/16 20

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

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

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

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

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

Downflow Applications on Combustible Flooring with Coil END4X, 15-1/2 19 16-1/2 20

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

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

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

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

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

Downflow Applications on Combustible Flooring with Coil END4X, 19 19 20 20

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

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

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

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

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

Downflow Applications on Combustible Flooring with Coil EN D4X, 22-1/2 19 23-1/2 20

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

APPLICATION

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

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

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

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

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

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

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

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

PLENUM OPENING FLOOR OPENING

A B C D

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. NOTE: Flexible connections should be used between

ductwork and furnace to prevent transmission of vibration. Ductwork passing through unconditioned space should be insulated and sealed to enhance system performance. When air conditioning is used, a vapor barrier is recommended.

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

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

Ductwork Acoustical Treatment

NOTE: Metal duct systems that do not have a 90 degree elbow and 10 ft. (3 M) of main duct to the first branch take-off may require internal acoustical lining. As an alternative,

fibrous ductwork may be used if constructed and installed in

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

fibrous ductwork shall comply with NFPA 90B as tested by UL

Standard 181 for Class 1 Rigid air ducts. Supply Air Connections For a furnace not equipped with a cooling coil, the outlet duct

shall be provided with a removable access panel. This opening shall be accessible when the furnace is installed and

shall be of such a size that the heat exchanger can be

viewed for possible openings using light assistance or a

probe can be inserted for sampling the air stream. The cover attachment shall prevent leaks.

441 01 1402 02 13

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

FURNACE RETURN-AIR SPEED EXTERNAL STATIC PRESSURE (in, w,c,)

SIZE INLET 0,1 0,2 0,3 0,4 0,5 0,6 0,7 0,8 0,9 1,0

0451408A or Med-Low 865 830 790 745 690 625 545 440 250 195

0451412A or Med-Low 1360 1300 1240 1175 1115 1040 950 850 725 575

0701408A or Med-Low 835 815 790 755 710 660 590 480 325 205

0701412A or M ed-Low 1320 1280 1240 1205 1140 1075 995 905 790 620

0701716A or Med-Low 1550 1520 1475 1430 1375 1310 1240 1155 1070 970

0901714B or Med-High 1515 1485 1440 1380 1300 1220 1115 990 830 600

0902116A or Med-Low 1740 1700 1650 1590 1525 1440 1335 1195 1010 820

0902120A or M ed-Low 2230 2170 2110 2050 1985 1890 1780 1660 1525 1360

1101712A or Med-Low 1475 1435 1395 1335 1285 1185 1070 890 725 450

1102116A or Med-Low 1745 1710 1650 1560 1450 1340 1205 1090 865 605

1102122A or Med-Low 2140 2100 2050 1990 1935 1865 1760 1670 1545 14t0

1352116A or Med-Low 1790 1755 1705 1640 1550 1465 1295 1145 945 775

1352422A or Side & Med-Low 2120 2075 1995 1970 1905 1835 1735 1645 1515 1325

1552420A or Med-Low 2155 2125 2075 2015 1935 1830 1780 1635 1485 1365

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

filter rack. Todetermine airflow performance without this filter,assume an additional 0.1 in. w.c. available external static pressure.

-- Indicates unstable operating conditions.

Bottom High 1035 995 945 895 835 770 675 565 390 195

Side(s) Low 760 720 680 635 580 520 445 345 220 195 Bottom High 1440 1375 1305 1240 1160 1070 975 870 730 560

Side(s) Low 1250 1210 1160 1100 1040 965 885 790 670 520 Bottom High 1030 1005 965 925 870 810 740 645 465 280

Side(s) Low 725 700 675 635 595 545 460 350 250 -- Bottom High 1425 1375 1320 1265 1200 1125 1035 940 830 655

Side (s) Low 1200 1175 1145 1105 1050 990 920 840 725 555 Bottom High 1755 1700 1635 1505 1570 1435 1350 1260 1160 1055

Side(s) Low 1355 1340 1310 1280 1240 1190 1125 1060 975 890 Bottom High 1650 1600 1535 1465 1385 1285 1175 1055 895 645

Side(s) Low 1205 1180 1160 1120 1065 1005 925 810 630 510 Bottom High 1940 1880 1805 1720 1635 1540 1425 1290 1090 830

Side(s) Low 1505 1505 1480 1440 1375 1300 1190 1045 890 740

Bottom Only M ed-Low 2170 2110 2040 1970 1895 1785 1675 1565 1420 1260

Both Sides High 2530 2450 2365 2270 2165 2065 1940 1805 1670 1505

1 Side & Bottom Low 1895 1890 1845 1815 1755 1685 1600 1480 1350 1180

1 Side Only Med-Low 2105 2145 2070 2010 1940 1845 1735 1620 1475 1325

Bottom High 1600 1550 1490 1425 1355 1260 1135 990 785 530

Side(s) Low 1315 1295 1265 1220 1155 1080 985 810 675 440 Bottom High 1980 1915 1835 1750 1655 1495 1365 1185 965 700

Side(s) Low 1530 1515 1470 1400 1310 1215 1095 990 830 670

Bottom Only Med-Low 2135 2100 2060 2000 1930 1860 1765 1670 1555 1425

Bottom, Sides High .... 2355 2285 2190 2090 1965 1850 1705 1535

1 Side & Bottom Low 1855 1840 1815 1775 1725 1675 1600 1510 1405 1290

1 Side Only M ed-Low 2030 2025 2000 1950 1905 1850 1750 1660 1555 1425

Bottom High 2065 2000 1930 1835 1710 1590 1420 1235 1025 835

Side (s) Low 1480 1480 1480 1450 1380 1295 1160 1005 855 670

Bottom Only M ed- Low 2130 2080 2025 1960 1880 1795 1690 1550 1405 1255

Bottom, Sides High .... 2355 2280 2160 2065 1930 1805 1655 1465

Bottom Low 1860 1830 1800 1755 1725 1630 1530 14t5 1280 1140

1 Side Only M ed-Low 2070 2015 1970 1935 1855 1765 1655 1550 1445 1265

Bottom Only M ed-Low 2115 2095 2055 2005 1940 1845 1820 1675 1525 1390

Both Sides High .... 2375 2285 2185 2105 1995 1870 1720 1555

1 Side & Bottom Low 1800 1790 1770 1735 1695 1640 1570 1465 1345 1225

1 Side Only Med-Low 2140 2085 2020 1950 1850 1745 1695 1545 14t5 1290

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

High 2405 2310 2220 2130 2025 1920 1790 1660 1530 1350

Low 1920 1875 1835 1780 1715 1630 1535 1420 1275 1135

High 2475 2395 2300 2200 2090 1985 1865 1730 1585 1425

Low 1850 1860 1810 1770 1715 1650 1555 1445 1310 1150

High 2485 24t 5 2340 2255 2160 2060 1950 1840 1720 1565

Low 1855 1840 1815 1775 1725 1675 1600 1510 1405 1290

High 2495 2440 2370 2290 2205 2120 2015 1910 1775 1625

Low -- 1735 1725 1695 1650 1595 1535 1455 1335 1230

High 2445 2365 2280 2190 2085 1980 1850 1705 1520 1355

Low 1860 1830 1800 1755 1705 1630 1530 14t5 1280 1140

High .... 2215 2130 2030 1920 1795 1675 1540 1385

Low 1860 1830 1800 1755 1725 1630 1530 14t5 1280 1140

High 2465 2430 2375 2305 2215 2110 2000 1865 1715 1530

Low 1800 1790 1770 1735 1695 1640 1570 1465 1345 1225

High .... 2260 2180 2070 1975 1865 1740 1595 1440

Low 1800 1790 1770 1735 1695 1640 1570 1465 1345 1225

14 441 01 1402 02

Figure 14 - Duct Flanges

UPFLOW

YES

/ t\ /\

120'_ YES 120°_ YES 120°_

MIN MIN MIN

NO NO NO

DOWNFLOW HORIZONTAL

I ......

YES

Figure 15 - Horizontal Unit Suspension

4 REQ,

/ /4" (6mm) THREADED ROD

YES

A02020

OUTER DOOR ASSEMBLY

8" (203mm) MtN FOR DOOR REMOVAL

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

SECURE ANGLE IRON TO BOTTOM

OF FURNACE WITH 3 #8 x3/4'' (19mm) SCREWS

TYPICAL FOR 2 SUPPORTS

1" (25ram) SQUARE, 1-1/4"x1-1/4"x1/8" (32x32x3mm)

ANGLE IRON OR UNI-STRUT MAY BE USED

A10130

441 01 1402 02 15

Figure 16 - Horizontal Suspension with Straps

22 GAUGE GALVANIZED STRAPS TYPICAL

FOR 4 STRAPS

/OPENING

AIR

OUTER DOOR ASSEMBLY

[ //

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

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

METAL SCREWS FOR EACH STRAR THE STRAPS SHOULD BE VERTICAL AGAINST THE FURNACE

FROM THE FURNACE SIDES AND NOT PULL AWAY

SIDES.

BACK OF FURNACE

METHOD 1 FOLD ALL STRAPS UNDER FURNACE AND SECURE WTH

(4) #8 x 3/4 (t9 mm) SHEET METAL SCREWS (2 SCREWS IN SiDE AND 2 SCREWS

iN BOTTOM).

TYPE-B VENT

A10131

173/4" (451 mm)OVERALL

43/4" (121mm) UNDER DOOR

1" (25mm) UNDER FURNACE

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

30-IN. (762mm)

MIN WORK AREA *WHEN USED WITH

SINGLE WALL VENT CONNECTIONS

EQUIPMENT MANUAL

SHUT-OFF GAS VALVE

SEDIMEN1

TRAP

UNWON

A10164

16 441 01 1402 02

Figure 18 - Upflow Return Air Configurations and Restrictions

i ¸_

RETURN i

AIR

RETURN

AIR

UPFLOW RETURN AiR CONFiGURATiONS AND RESTRICTIONS

AIR _!_ RESTRICTIONS

RETURN T UPFL©W

RETURN AIR

AIR FLOW MODELS RETURN AIR RETURN AIR RETURN AIR RETURN AIR |

5 TONS AND YES YES YES YES | GREATER *

ALL OTHER MODELS YES YES YES YES

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

RETURN

AiR

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

Figure 19 - Downflow Return Air Configurations and Restrictions

_1_ RETURN

AIR

]

AIR

RETURN i

• NOTE: RESTRICTION SAME FOR HORIZONAL LEFT

DOWNFLOWRETURNAJRCONRGURATIONSANDRESTRICq]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

Figure 20 - Horizontal Return Air Configurations and Restrictions

RETURN

........................(/ ........................

,@_ SIDERETURN AIR _ NOTPERMI_ED FOR

066,060,-22-2O AIR FLOWMODELS

AIR

II II II

I'\ /_lt_ _ SIDE RETURN AIR

, / _M NOT PERM _ED FOR

/" 066,060, _2_0

AIR FLOW MODELS

AaR RESTRICTIONS

i RETURN RETURNAIR

,r3_

_ HORIZONTAL RETURN AIR CONFIGURATIONS AND RESTRICTIONS

HORIZONAL

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

CONNECTmON 1 CONNECTION 2 CONNECTmON 3 COMBJNATmONS ONLY ONLY ONLY OF 1,2, AND 3

441 01 1402 02 17

Upflow and Horizontal Furnaces

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

Figure 14) The supply-air duct must be connected to ONLY the furnace supply-outlet-air duct flanges or air conditioning coil casing (when used). DO NOT cut main furnace casing

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

furnace main casing.

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

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 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.

FIRE HAZARD

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

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

Return Air Connections

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

(bottom inlet) as shown in Figure 19. DO NOT cut into casing sides (left or right). Side opening is permitted for only upflow

and most horizontal furnaces. (See Figure 19) Bypass

humidifier connections should be made at ductwork or coil casing sides exterior to furnace.

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 18 and Figure 20. 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

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.

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

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

control manifold and a gas leak.

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

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

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

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

2. When flexible connectors are used, the maximum length shall not exceed 36 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 ap-

proved 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.

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 (38.1)

* Cubic ft. of natural gas per hr for gas pressures of 0.5 psig (14-in. w.c,) or

less and a pressure drop of 0.5-in. w,c. (based on a 0.60 specific gravity gas). Ref: Table 6 and ANSI Z223-2009/NFPA 54-2009.

INTERNAL LENGTH OF PIPE - FT (M)

DIA.

'N. (MM) 110/ 1620/ 1930/ 11401/ 115502/

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 990 900

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.

18 441 01 1402 02

FURNACE OVERHEAT HAZARD

Failure to follow this caution may result in unit

component damage. Connect gas pipe to gas valve using a backup

wrench to avoid damaging gas controls and burner misatiqnment.

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

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

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

NOTE: The furnace gas valve inlet pressure tap connection is suitable to use as test gauge connection providing test

pressure DOES NOT exceed maximum 0.5 psig (14-in. w.c.) stated on gas control valve. (See Figure 41)

Figure 21 - Burner and Manifold

TOP VIEW OF BURNER AND MANIFOLD ASSEMBLY

Piping should be pressure and leak tested in accordance with NFGC, 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-in. 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-in. 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.

Figure 23 - Relocating J-Box

FACTORY INSTALLED

LOCATION

ALTERNATE

FIELD LOCATION

2" (51 ram)Nipple

Street

t-Gas Valve

Figure 22 - Typical Gas Pipe Arrangement

GAS--

SUPPLY j'"_

MANUALJ II SHUTOFF _ _

VALVE

(REQUIRED)_ "1_ }_

SEDIMENT-- /

TRAP /

UNION.-.J

Supply

A08551

Figure 24 - Field-Supplied Electrical Box on Furnace

Casing

A02035

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

Install a sediment trap in riser leading to furnace as shown in Figure 22. Connect a capped nipple into lower end of tee.

Capped nipple should extend below level of furnace gas controls. Place a ground joint union between furnace gas control valve and exterior manual equipment gas shutoff valve. A 1/8-in. (3 mm) NPT plugged tapping, accessible for test gauge connection, MUST be installed immediately

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.

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

441 01 1402 02 19

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 26 for field wiring diagram showing typical field

115-v wiring. Check all factory and field electrical

connections for tightness.

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.

FURNACE MAY NOT OPERATE 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.

Make all electrical connections in accordance with National Electrical Code (NEC) ANSI/NFPA 70-2008 and any local

codes or ordinances that might apply.

NOTE: Proper polarity must be maintained for 115-v wiring. If polarity is incorrect, control LED status indicator light will flash a status code 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-in. (356 mm) wide casing models, the J-Box

shall not be relocated to other side of furnace casing when the vent pipe is routed within the casing.

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

NOTE: The J-Box cover need not be removed from the J-Box in order to move the J-Box. Do NOT remove green

ground screw inside J-Box. The ground screw is not threaded into the casing flange and can be lifted out of the clearance hole in casing while swinging the front edge of the J-Box outboard of the casing.

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

3. Move J-Box to desired location.

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

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

ELECTRICAL CONNECTION TO J-BOX Field-Supplied Electrical Box on Furnace J-Box Bracket See

Figure 24.

1. Remove cover from furnace J-Box.

2. Attach electrical box to furnace J-Box bracket with at

least two field-supplied screws through holes in elec-

trical box into holes in bracket. Use blunt-nose screws that will not pierce wire insulation.

3. Route furnace power wires through holes in electrical box and J-Box bracket, and make field-wire connec-

tions in electrical box. Use best practices (NEC in U.S.) for wire bushings, strain relief, etc.

4. Route and secure field ground wire to green ground screw on J-Box bracket.

5. Connect line voltage leads as shown in Figure 26.

6. Reinstall cover to J-Box. Do not pinch wires between cover and bracket. Electrical Box on Furnace Casing

Side See Figure 24.

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.

FIRE HAZARD

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

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

Use a separate, fused 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 furnace.

20 441 01 1402 02

1. Select and remove a hole knockout in the caslng 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.RemoveandsavetwoscrewsholdingJ-Box.(See Figure23)

5.Pullfurnacepowerwiresoutof1/2-in.(12mm)diamet- erholeinJ-Box.Donotloosenwiresfromstrain-relief

wire-tieonoutsideofJ-Box.

6.Routefurnacepowerwiresthroughholesincasingand electricalboxandintoelectricalbox.

7.Pullfieldpowerwiresintoelectricalbox.

8.RemovecoverfromfurnaceJ-Box.

9.Routefieldgroundwirethroughholesinelectricalbox andcasing,andintofurnaceJ-Box.

10.ReattachfurnaceJ-Boxtofurnacecasingwithscrews removedinStep4.

11.SecurefieldgroundwiretoJ-Boxgreengroundscrew.

Table 7--Electrical Data

VOLTS-

FURNACE

SIZE

0451408A 0451412A

0701408A 0701412A 0701716A 0901714B 0902116A

0902120A

1101712A 1102116A 1102122A 1352116A 1352422A

1552420A

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

# Unit ampacity = 125 percent of largest operating component's full load amps plus 100 percent of all other potential operating components'

load amps.

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

HERTZ-

PHASE

115-60-1 115-60-1

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

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

115-60-1

12. Complete electrical box wiring and installation. Connect line voltage leads as shown in Figure 26. Use best

practices (NEC) 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-in. (22 mm) dia-

OPERATING

VOLTAGE RANGE

Maximum* Minimum*

127 104 127 104

127 104 127 104 127 104 127 104 127 104

127 104 127 104 127 104 127 104 127 104 127 104

127 104

MAXIMUM

UNIT

AMPS

5.2

7.2

5.1

7.2

9.5

8.2

10.0

14.1

8.6

10.2

15.1

10.5

14.5

15.4

UNIT

AMPAClTY

7.26

9.79

7.14

9.72

12.60

10.83

13.09

18.20

11.27

13.34

19.42

13.63

18.72

19.83

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 ap- proved for the type of cable used.

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

5. Connect line voltage leads as shown in Figure 26.

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

MAXIMUM

WIRE

LENGTH

FT. (M)$

49 (15) 37 (12) 51 (16)

38 (12)

29 (9)

34 (10)

28 (9)

31 (9)

32 (10)

27 (9) 29 (8) 27 (8)

30 (9)

29 (9)

MAXIMUM

FUSE OR

CKT BKR

AMPSt

meter 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 26.

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

MINIMUM

GAUGE

15 15

15 15 15 15 15

15 15

2O 2O

(EAC, humidifier, etc.) full

WIRE

14 14

14 14 14 14 14

12 14 14 12 14 12

441 01 1402 02 21

Figure 25 - Furnace Control

HEAT TWINNING AND/OR

J2 JUMPER

24-V THERMOSTAT

TERMINALS

3-AMP FUSE

LED OPERATION & DIAGNOSTIC LIGHT

115-VAC (L2) NEUTRAL

CONNECTIONS

BLOWER SPEED s _ ........... 115VA! EAC_ ...... ,M ,ND_HS,

SELECT'ON TER_ !O_N_AG:ET, O N iA! V_ACRx1M._A' 1THI_E_M/!_cFAIE R p_-HoOT (tNUDRFcACE/G_ (H S ,) & , N D U C ER

OFF-DELAY COMPONENT TEST

TERMINAL

TRANSFORMER 24-MAC CONNECTIONS

HARNESS CONNECTOR

owvoT

Figure 26 - Heating and Cooling Application Wiring Diagram with Single Stage Thermostat

NOTE 2

FIVEWIRE _ l(_ (_ (_

THREE-WIRE_ _.---'_---_-

HEATING-ONLY _'_ _f -T- _-

BLOWER DOOR SWITCH"-_ "__

115-V FIELD- AUXILIARY O _c_ __ -, SUPPLIED

DISCONNECT _ NOTE 1

J-BOX L ('_ ....... _,

24-V

TERMINA

BLOCK

FURNACE

NOTES:I.

24-V WIRING

Make field 24-v connections at the 24-v terminal strip. (See Figure 25) Connect terminal Y as shown in Figure 26 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.

- - - FIELD24-VWIRING

= = = FIELD 115-, 208/230-, 460-V WIRING

-- FACTORY 24-V WIRING FACTORY 115-V WiRiNG

(_ (_ ] THERMOSTAT

TERMINALS

, ?i_ii!iiiii!iiiiiiii_i}_

i_iiiiiiiiiiiiiiii_!_

FIELD-SUPPLIED DISCONNECT

460-V THREE

1208/230- OR

PHASE

SINGLE

PHASE

} 208/230-V

=4 CONDENSING

L TWO UNIT

WIRE

Connect Y-terminal in furnace as shown for proper blower operation.

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

If any of the original wire, as supplied, must be replaced, use

same type or equivalent wire.

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 1 AMP and NEUTRAL. The termin- als are rated for 115 VAC, 1.0 amps maximum and are

energized during blower motor operation. (See

Figure 24)

22 441 01 1402 02

2.Humidifier(HUM24VACandHUM) a. HUM24VAC:Connectanaccessory24

VAC,0.5ampmaximumhumidifier(ifused)tothe

1/4-inmalequick-connectHUM24VACterminal andCscrewterminalonthecontrolboardthermo-

statstrip.TheHUM24VACterminalisenergized whenthereisacallforheat(W)andthepressure

switch(PRS)closes.(SeeFigure24andFigure48). b. HUM:Connectanaccessory115VAC(EAC

andHUMare1ampmaximumcombined)humidifier (ifused)tothe]A-inchmalequickconnectHUM

terminalandNEUTRAL]A-inchquickconnect.The

HUMterminalisenergizedwhentheinducermotor isenergized(IDR).(SeeFigure24andFigure48).

NOTE:Afield-supplied,115-vcontrolledrelayconnectedto EACterminalsmaybe addedif humidifieroperationis desiredduringbloweroperation.

NOTE: DONOTconnectfurnacecontrolHUM24VAC terminalto H (humidifier)terminalon humiditysensing

thermostat,or similardevice.See humiditysensing thermostat,thermostat,or controllermanufacturer's

instructionsforproperconnection.

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. 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, local building codes, and furnace and vent

manufacturers' instructions.

CARBON MONOXIDE POISONING HAZARD

Failure to follow the steps outlined below for each appliance

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

The following steps shall be followed for each appliance connected to the venting system being placed into operation,

while all other appliances connected to the venting system are not in operation:

1. Seal any unused openings in venting system.

2. Inspect the venting system for proper size and horizontal pitch, as required in the National Fuel Gas Code, 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.

These furnaces are design-certified as Category I furnaces in

accordance with ANSI Z21.47-2009/CSA 2.3-2009 and operate with a non-positive vent static pressure to minimize

the potential for vent gas leakage. Category I furnaces

operate with a flue loss not less than 17 percent to minimize

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

venting with other fan assisted or draft hood equipped

appliances in accordance with the NFGC, the local building 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 cou d 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. Do not connect this Category I furnace into a single- wall dedicated or common vent. The dedicated or com-

mon vent is considered to be the vertical portion of the vent system that terminates outdoors.

3. Vent connectors serving Category I furnaces shall not be connected into any portion of a mechanical draft system operating under positive pressure.

441 01 1402 02 23

4.Donotventthisappliancewithanysolidfuelburning appliance.

5.CategoryIfurnacesmustbeventedverticallyornearly verticallyunlessequippedwithalistedpowerventer.

6.Donotventthisapplianceintoanunlinedmasonry chimney.RefertoChimneyInspectionChart.

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

exterior clay 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

numbers 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 and must be in good

condition.

U.S.A.-Refer to NFPA 54/ANSI Z223.1-2009 Sections 13.1.8 and 13.2.20 of the NFGC 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 Kit is 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. Chim-

neys having internal areas greater than 38 in2 (24516

mm2) require furnace input ratings greater than the in- put 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 these furnaces, which are listed for use with the kit, a

listed chimney-lining system, or a Type-B common vent. Inspections before the sale and at the time of installation will determine the acceptability of the chimney or the need for

repair and/or (re)lining. Refer to the Chimney Inspection Chart to perform a chimney inspection. If the inspection of a

previously used tile-lined chimney:

a. Shows signs of vent gas condensation, the chim-

ney 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 per-

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

the equipment being installed and the authority hav- ing jurisdiction.

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

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

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

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

24 441 01 1402 02

Figure 27 - 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

Crown

condition: Rebuild

Missing mortar crown.

or brick?

Is chimney

property lined with

clay tile liner?

Is Repair

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

condition? necessary.

Yes Repair

in cleanout? Mortar

Mortar, tile, or tile

fuel oil residue? debris?

Clay

tile misalignment,

missing sections,

gaps?

Remove metal vent

or liner.

Yes

Reline

Part B of

instructionsfor

Remove mortar

and tile debris

Not Suitable

Condensate

Chimney

exposed to

outdoors below

roof line?

lined with properly

sized, listed liner or

Yes

Ischimney

to bededicated to

a single

furnace?

adapter per

Install chimney I

instructions. _lot Suitable

Part Col

instructions for

application

Line chimney with property

sized, listed flexible metal

liner or Type-B vent per

NFGC Vent

Sizing Tables and liner or

vent manufacturer's

Installation instructions.

3uitable

adapter per

1stall chimney I

instructions.

A10133

441 01 1402 02 25

APPLIANCE APPLICATION REQUIREMENTS

Appliance operation has a significant impact on the performance of the venting system. If the appliances are

sized, installed, adjusted, and operated properly, the venting system and/or the appliances should not suffer from

condensation and corrosion. The venting system and all appliances shall be installed in accordance with applicable

listings, standards, and codes.

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

because of furnace model size capacity increments. Heating

load estimates can be made using approved methods

available from Air Conditioning Contractors of America

(Manual J); American Society of Heating, Refrigerating, and

Air-Conditioning Engineers; or other approved engineering methods. Excessive oversizing of the furnace could cause

the furnace and/or vent to fail prematurely. When a metal vent or metal liner is used, the vent must be in

good condition and be installed in accordance with the vent manufacturer's instructions.

To prevent condensation in the furnace and vent system, the following precautions must be observed:

1. The return-air temperature must be at least 60°F (16°0) db except for brief periods of time during warm-

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

2. Adjust the gas input rate per the installation instruc- tions. Low gas input rate causes low vent gas temper- atures, causing condensation and corrosion in the fur-

nace and/or venting system. Derating is permitted only

for altitudes above 2000 ft. (610 M).

3. Adjust the air temperature rise to the midpoint of the

rise range or slightly above. Low air temperature rise can cause low vent gas temperature and potential for condensation problems.

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

Table 8_ EXTERIOR MASONRY CHIMNEY FAN + NAT INSTALLATIONS WITH TYPE-B DOUBLE WALL VENT

CONNECTORS ©NFPA & AGA Combined Appliance

Maximum Input

Rating in Thousands of Btuh per Hour

INTERNALAREA OF CHIMNEY

VENT HEIGHT

FT, (i)

6 (1.8)

8(2.4)

10(3.0) 15(4.5)

20 (6.0) 30 (9.1)

(7741)

80 84

NR NR NR

SQ. IN. (SQ. MM)

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-Heat-

ing Appliance in Thousands of Btuh per Hour

INTERNAL AREA OF CHIMNEY

VENT HEIGHT

FT. (M) 12 19 28 38

(7741) (12258) 18064) (24516)

Local 99% Winter Design Temperature: 17 to 26 degrees F

6 0 55 99 141

8 52 74 111 154 10 NR 90 125 169 15 NR NR 167 212

20 NR NR 212 258 30 NR NR NR 362

Local 99% Winter Design Temperature: 5 to 16 degrees F*

6 NR 78 121 166

8 NR 94 135 182 10 NR 111 149 198

15 NR NR 193 247 20 NR NR NR 293 30 NR NR NR 377

Local 99% Winter Design Temperature: -10 to 4 degrees F*

6 NR NR 145 196

8 NR NR 159 213

10 NR NR 175 231 15 NR NR NR 283 20 NR NR NR 333

30 NR NR NR NR

Local 99% Winter Design Temperature: -11 °F (ld°C) or

Not recommended for any vent configuration.

*The 99.6% heating db temperatures found in the 1997 or 2001 ASHRAE Fundamentals Handbook, Climatic Design Information chapter, Table 1A

(United States) and 2A (Canada) or the 2005 ASHRAE Fundamentals hand-

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

SQ, IN. (SQ, MM)

lower

Air for combustion must not be contaminated by halogen compounds which include chlorides, fluorides, bromides, and

iodides. These compounds are found in many common home products such as detergent, paint, glue, aerosol spray,

bleach, cleaning solvent, salt, and air freshener, and can cause corrosion of furnaces and vents. Avoid using such products in the combustion-air supply. Furnace use during

construction of the building could cause the furnace to be exposed to halogen compounds, causing premature failure of

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

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

vented with this furnace.

ADDITIONAL VENTING REQUIREMENTS

A 4-in. (102 mm) round vent elbow is supplied with the furnace. A 5-in. (127 mm) or 6-in. (152 mm) vent connector

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

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

Figure 28 - Figure 40 Venting Orientation for approved vent configurations.

NOTE: Vent connector length for connector sizing starts at furnace vent elbow. The 4-in. (102 mm) vent elbow is shipped for upflow configuration and may be rotated for other positions. Remove the 3 screws that secure vent elbow to furnace, rotate furnace vent elbow to position desired,

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

26 441 01 1402 02

Theventconnectorcanexitthecabinetof thefurnace throughoneoffivelocations.

1.Attachthesinglewaltventconnectortothefurnace ventelbow,andfastentheventconnectortothevent

elbowwithatleasttwofield-supplied,corrosion-resist- ant,sheetmetalscrewslocated180°apart.

NOTE:Aflueextensionisrecommendedtoextendfromthe furnaceelbowtooutsidethefurnacecasing.Ifflueextension

isused,fastentheflueextensiontotheventelbowwithat leasttwofield-supplied,corrosion-resistant,sheetmetal screwslocated180° apart.Fastentheventconnectortothe flueextensionwithat leasttwofield-supplied,corrosion resistantsheetmetalscrewslocated180°apart.

2.Ventthefurnacewiththeappropriateconnectoras shownin Figure28- Figure40.

CUTHAZARD

Failure to follow this caution may result in personal injury. Sheet metal parts may have sharp edges or

burrs. Use care and wear appropriate protective clothing,

safety glasses and gloves when handling parts and servicing furnaces.

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

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

until the slug breaks free.

BURN HAZARD

Failure to follow this caution may cause personal injury.

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

instruction.

An accessory Vent Guard Kit is REQUIRED for downflow

applications for use where the vent exits through the lower portion of the furnace casing door. Refer to the Vent Guard Kit

Instructions for complete details.

The horizontal portion of the venting system shall slope

upwards not tess than 1/4-in. (6 mm) per linear ft. (21 mm/m)

from the furnace to the vent and shall be rigidly supported

every 5 ft. (1.5 M) or less with metal hangers or straps to ensure there is no movement after installation.

SIDEWALL VENTING

This furnace is not approved for direct sidewall horizontal venting.

Per section 12.4.3 of the NFPA 54 / ANSI Z223.1-2009, any listed mechanical venter may be used, when approved by the

authority having jurisdiction. Caution!! for the following applications, use the minimum

vertical vent heights as specified below.

For all other applications, follow exclusively the national fuel gas code.

Table lO_Minimum Vent Heights

FURNACE ORIENTATION DIAMETER IN, VENT HEIGHT

Downflow Vent Elbow left, 132,000 5 (127) 12 (3.6)

Horizontal Left then up Figure 35 132,000

Horizontal Left Figure 36 132,000 5 (127) 7 (2.2)

Horizontal Left Figure 36 154,000 5 (127) 7 (2.2)

Downflow Vent elbow up then left

Downflow Vent elbow up, then right

4 in. (102 mm) inside casing or vent uard

** Including 4 in. (102 mm) vent section (s) NOTE: All vent configurations must also meet National Fuel Gas Code (NFGC) venting requirements

NOTE: For all unlisted vent configurations, refer to National Fuel Gas Code (NFGC) venting requirements.

VENT FURNACE

ORIENTATION INPUT (BTUH/HR) (mm)* FT, (M)**

154,000

then up Figure 32 110,000 (3 ton only)

Vent Elbow right, 154,000 5 (127) 7 (2.2)

Vent Elbow up 154,000

Vent Elbow up

Figure 30 110,000 (3 ton only) 5 (127) 10 (3.0)

Figure 33 110,000 (3 ton only) 5 (127) 10 (3.0)

MINIMUM VENT MINIMUM VERTICAL

441 01 1402 02 27

Figure 28 - Upflow Application-Vent Elbow Up Figure 30 - Downflow Application-Vent Elbow Up then

Left

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

these figures

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

A03208

Figure 29 -- Upflow Application-Vent Elbow Right

on the page following

these figures

Figure 31 -- Downflow Application-Vent Elbow Up

A03210

.j,

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

on the pages following these figures

A03209

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

A03211

28 441 01 1402 02

Figure 32 - Downflow Application-Vent Elbow Left then

Figure 35 - Horizontal Left Application-Vent Elbow

Ric

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

following these figures

A032t 4

Figure 36 -- Horizontal Left Application-Vent Elbow Up

SEE NOTES: 1,2,4,5,8,7,8,9,t0

on the page following these figures

A03207

Figure 33 -- Downflow Application-Vent Elbow Up then

Right

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

these figures.

A032t 2

Fi_iure 34 -- Horizontal Left Application-Vent Elbow Left

. o.

/ _

,\/,

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

following these figures

Figure 37 -- Horizontal Left Application-Vent Elbow

Right

S--,/

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

following these figures

Figure 38 -- Horizontal Right Application-Vent Elbow

Right

A03215

A03216

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

following these figures

A03213

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

following these figures

A03218

441 01 1402 02 29

Figure 39 - Horizontal Right Application-Vent Elbow

Left then Up

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

A03219

Figure 40 -- Horizontal Right Application-Vent Elbow

Left

. J

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

START-UP, ADJUSTMENT, AND SAFETY

CHECK

Step 1 --General

FIRE HAZARD

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

This furnace is equipped with manual reset limit

switches in the gas control area. The switches open and shut off power to the gas valve if a flame rollout or overheating condition occurs in the gas control area. DO NOT bypass the switches. Correct inadequate combustion air supply problem before resetting the

switches.

CUT HAZARD Failure to follow this caution may result in personal

injury. Sheet metal parts may have sharp edges or burrs.

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

Notes for Figure 33 - Figure 40

1. Forcommon vent, vent connectorsizing and vent material,use the NFGC.

2. Immediatelyincreaseto 5-in. (127 mm) or 6-in. (152mm) vent connector outside furnace casing when 5-in. (127 mm) vent

connector is required, refer to Note1 above.

3. Sideoutlet vent for upflow anddownflow installationsmust use Type B vent immediately after exitingthe furnace, exceptwhen

the DownflowVent Guard Kit,is usedin the downflow position

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

5. A 4-in. (102 mm) single-wall (26 ga. minimum) vent must be

used inside furnace casing and when the Downflow Vent Guard Kit is used external to the furnace.

6. Accessory Downflow Vent Guard Kit is required in downflow installationswith lowervent configuration.

7. Chimney Adapter Kit may be required for exterior masonry

chimney applications. Refer to Chimney Adapter Kitfor sizing andcomplete applicationdetails.

8. Securevent connectorto furnace elbowwith (2)corrosion-res- istantsheet metal screws, spaced approximately 180° apart.

9. Secureall othersingle wallvent connectorjoints with (3)corro- sion resistant screwsspaced approximately 120° apart. Secure

Type-B vent connectors per vent connector manufacturer's re- commendations.

A02068

1. Maintain 115-v wiring and ground. Improper polarity will result in flashing a status code 10 and no furnace

operation.

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

connections will result in improper operation. (See

Figure 26)

3. Gas supply pressure to the furnace must be greater than 4.5-in. w.c. (0.16 psig ) but not exceed 14-in. w.c.

(0.5 psig).

4. Check all manual-reset switches for continuity.

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

6. Replace outer door.

Step 2--Start-Up Procedures

FIRE AND 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.

1. Purge gas lines after all connections have been made.

2. Check gas lines for leaks.

30 441 01 1402 02

ELECTRICALSHOCKHAZARD

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

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

switch is closed. Caution must be taken when

manually closing this switch for service purposes.

3. To Begin Component Self-Test: Remove blower ac- cess door. Disconnect the thermostat R lead from the

furnace control board. Manually close the blower door switch. Short (jumper) the C terminal on control to the

TEST/TWIN 3/16-inch quick connect terminal on con- trol until LED goes out (approximately 2 sec). Gas

valve and humidifier will not be turned on. (See Figure 25)

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

Component test sequence is as follows: Refer to service label attached to furnace or see Figure 44.

a. LED will display previous status code 4 times.

NOTE: If no previous code is present, go directly to b.

b. Inducer motor starts and continues to run until Step

f of component test sequence. c. Hot surface igniter is energized for 15 sec., then off. d. Blower motor operates on HEAT speed for 10 sec. e. Blower motor operates on COOL speed for 10 sec.

f. Inducer motor stops.

g. Reconnect R lead to furnace control board, release

blower door switch and re-install blower door.

4. Operate furnace per instruction on door.

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

6. Verify furnace restarts by raising thermostat setting above room temperature.

Step 3--Adjustments

Table 11--Altitude Derate Multiplier for U.S.A.

ALTITUDE PERCENT DERATEMULTIPLIER

FT,(M) OF DERATE FACTOR*

0-2000

(0-610)

2001-3000

(610-914)

3001-4000

(914-1219)

4001-5000

(1219-1524)

5001-6000

1524-1829)

6001-7000

(1829-2134)

7001-8000

(2134-2438)

8001-9000

(2438-2743)

9001-10,000 36-40 0.62

(2743-3048)

* Derate multiplier factors are based on midpoint altitude for altitude ran( e.

0 1.00

8-12 0.90

12-16 0.86 16-20 0.82

20-24 0.78

24-28 0.74 28-32 0.70

32-36 0.66

FIRE HAZARD

Failure to follow this warning could result in injury,

death and/or property damage.

DO NOT bottom out gas valve regulator adjusting screw. This can result in unregulated manifold pressure and result in excess overfire and heat exchanger failures.

FURNACE DAMAGE HAZARD

Failure to follow this caution may result in reduced furnace life.

DO NOT redrill orifices. Improper drilling (burrs, out-of round holes, etc.) can cause excessive burner

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

causing failures. (See Figure 42)

Furnace gas input rate on rating plate is for installations at altitudes up to 2000 ft. (610 M). Furnace input rate must be

within +/-2 percent of furnace rating plate input.

1. Determine the correct gas input rate. The input rating for altitudes above 2,000 ft. (610 M)

must be reduced by 4 percent for each 1,000 ft. (305 M) above sea level. For installations below 2000 ft., refer to the unit rating plate. For installations above

2000 ft. (610 M), multiply the input on the rating plate by the derate multiplier in Table 11 for the correct input

rate.

2. Determine the correct orifice and manifold pressure ad- justment. There are two different orifice and manifold adjustment tables. All models in all positions, except

Low NOx models in downflow or horizontal positions, use Table 15 (22,000 Btuh/Burner).

Low NOx models in the downflow or horizontal posi- tions must use Table 16 (21,000 Btuh/Burner). See in-

put listed on rating plate. a. Obtain average yearly gas heat value (at installed

altitude) from local gas supplier.

b. Obtain average yearly gas specific gravity from loc-

al gas supplier.

c. Find installation altitude in Table 15 or 16. d. Find closest natural gas heat value and specific

gravity in Table 15 or 16.

e. Follow heat value and specific gravity lines to point

of intersection to find orifice size and manifold pres- sure settings for proper operation.

f. Check and verify burner orifice size in furnace.

NEVER ASSUME ORIFICE SIZE. ALWAYS CHECK

AND VERIFY.

g. Replace orifice with correct size if required by Table

15 or 16. Use only factory-supplied orifices. See EXAMPLE 2.

441 01 1402 02 31

EXAMPLE 2:(0-2000 ft. (0-610 M) altitude) For 22,000 Btuh per burner application use Table 15. Heating value = 1000 Btuh/cu ft.

Specific gravity = 0.62 Therefore: Orifice No. 43*

Manifold pressure: 3.7-in. w.c.

*Furnace is shipped with No. 43 orifices. In this example all main burner orifices are the correct size and do not need to

be changed to obtain proper input rate.

3. Adjust manifold pressure to obtain correct input rate. a. Turn gas valve ON/OFF switch to OFF.

b. Remove manifold pressure tap plug from gas valve.

(See Figure 41)

c. Connect a water column manometer or similar

device to manifold pressure tap.

d. Turn gas valve ON/OFF switch to ON. e. Manually close blower door switch.

f. Set thermostat to call for heat.

g. Jumper R and W thermostat connections on fur-

nace control board to start furnace.

h. Remove regulator seal cap and turn regulator ad-

justing screw counterclockwise (out) to decrease

input rate of clockwise (in) to increase input rate.

i. Install regulator seat cap.

j. Leave manometer or similar device connected and

proceed to Step 4.

NOTE: DO NOT set manifold pressure less than 3.2-in. w.c.

or more than 3.8-in. w.c. for natural gas at sea level. If manifold pressure is outside this range, change main burner

orifices or refer Table 15 or 16.

NOTE: If orifice hole appears damaged or it is suspected to have been redrilted, check orifice hole with a numbered drill

bit of correct size. Never redrill an orifice. A burr-free and squarely aligned orifice hole is essential for proper flame

characteristics.

4. Verify natural gas input rate by clocking meter.

NOTE: Gas valve regulator adjustment cap must be in place

for proper input to be clocked.

a. Turn off all other gas appliances and pilots served

by the meter.

b. Run furnace for 3 minutes in heating operation.

c. Measure time (in sec) for gas meter to complete 1

revolution and note reading. The 2 or 5 cubic feet

dial provides a more accurate measurement of gas

flow. d. Refer to Table 13 for cubic ft. of gas per hr. e. Multiply gas rate (cu ft./hr) by heating value (Btu/cu

ft.) to obtain input.

If clocked rate does not match required input from Step 1, increase manifold pressure to increase input or decrease

manifold pressure to decrease input. Repeat steps b through e until correct input is achieved. Reinstall regulator seat cap on gas valve.

5. Set temperature rise. The furnace must operate within the temperature rise ranges specified on the furnace

rating plate. Do not exceed temperature rise range

specified on unit rating plate. Determine the temperat-

ure rise as follows:

NOTE: Blower access door must be installed when taking temperature rise reading. Leaving blower access door off will

result in incorrect temperature measurements.

a. Place thermometers in return and supply ducts as

close to furnace as possible. Be sure thermometers do not see radiant heat from heat exchangers. Ra- diant heat affects temperature rise readings. This practice is particularly important with straight-run

ducts.

b. When thermometer readings stabilize, subtract re-

turn-air temperature from supply-air temperature to

determine air temperature rise. NOTE: Blower access door must be installed for proper temperature rise measurement.

NOTE: If the temperature rise is outside this range, first check:

Gas input for heating operation.

Derate for altitude if applicable.

Return and supply ducts for excessive restrictions

causing static pressures greater than 0.50-in. w.c.

Dirty filter.

ELECTRICAL SHOCK HAZARD

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

Disconnect 115-v electrical power before changing speed tap.

c. Adjust air temperature rise by adjusting blower

speed. Increase blower speed to reduce temperat-

ure rise. Decrease blower speed to increase tem-

perature rise.

d. Turn thermostat down below room temperature and

remove blower access door.

e. To change motor speed selection for heating, re-

move blower motor lead from control HEAT terminal

(See Figure 25) Select desired blower motor speed

lead from one of the other terminals and relocate it

to the HEAT terminal (See Table 12 for lead color

identification). Reconnect original lead to SPARE

terminal.

Table 12--Speed Selection

COLOR SPEED AS SHIPPED

White Common BLW

Black Hiqh COOL

Yellow1- Med-Hiqh SPARE

Blue Med-Low HEAT

Red Low SPARE

NOTE: 1- Yellow available on 4 speed motor only

f. Repeat steps a through e.

g. When correct input rate and temperature rise is

achieved, turn gas valve ON/OFF switch to OFF.

h. Remove manometer or similar device from gas

valve.

i. Reinstall manifold pressure tap plug in gas valve.

FIRE HAZARD

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

Reinstall manifold pressure tap plug in gas valve to prevent gas leak.

32 441 01 1402 02

j.Reinstallbloweraccessdoorifremoved.

k.TurngasvalveON/OFFswitchtoON.

FURNACE OVERHEATING HAZARD Failure to follow this caution may result in reduced

furnace life.

Recheck temperature rise. It must be within limits

specified on the rating plate. Recommended operation is at the midpoint of rise range or slightly above.

6. Set thermostat heat anticipator. a. Mechanical thermostat - Set thermostat heat anti-

cipator to match the amp. draw of the electrical components in the R-W circuit. Accurate amp. draw

readings can be obtained at the wires normally con- nected to thermostat subbase terminals, R and W.

The thermostat anticipator should NOT be in the circuit while measuring current. (1.) Remove ther-

mostat from subbase or from wall. (2.) Connect an amp. meter as shown in Figure 43 across the R

and W subbase terminals or R and W wires at wall. (3.) Record amp. draw across terminals when fur-

nace is in heating and after blower starts. (4.) Set heat anticipator on thermostat per thermo-

stat instructions and install on subbase or wall.

b. Electronic thermostat: Set cycle rate for 4 cycles

per hr.

7. Adjust heat off delay The heat off delay has 4 ad- justable settings from 90 sec to 180 sec. The heat off

delay jumpers are located on the furnace control board.

(See Figure 25) To change the heat off delay setting,

move the jumper from one set of pins on the control to the pins used for the selected heat off delay. Factory heat off delay setting is 120 sec.

8. Set airflow CFM for cooling Select the desired blower motor speed lead for cooling airflow. See Table 5-Air

Delivery-CFM (With Filter). See Table 12 for lead color identification.

Figure 41 - Gas Control Valve

Figure 42 - Orifice Hole

Figure 43 -- Amp, Draw Check With Ammeter

TERMINALS WITH THERMOSTAT REMOVED

(ANITICIPATOR, CLOCK, ETC., MUST BE OUT OF CIRCUIT.)

10 TURNS

FROM UNIT 24-V CONTROL TERMINALS

EXAMPLE: 5.0AMPSONAMMETER = 0.5AMPSFORTHERM©STAT

10 TURNS AROUND JAWS ANTiCiPATOR SETTING

SUBBASE

AMMETER

A93059

A96316

Step 4--Check Safety Controls

The flame sensor, gas valve, and pressure switch were all

checked in the Start-up procedure section as part of normal operation.

1. Check Main Limit Switch(es) This control shuts off combustion control system and energizes air-circulating blower motor, if furnace over-

heats. By using this method to check limit control, it can be established that limit is functioning properly and will

operate if there is a restricted duct system or motor fail- ure. If limit control does not function during this test,

cause must be determined and corrected. a. Run furnace for at least 5 minutes.

b. Gradually block off return air with a piece of card-

board or sheet metal until the limit trips.

A06666

c. Unblock return air to permit normal circulation. d. Burners will re-light when furnace cools down.

2. Check draft safeguard switch. The purpose of this control is to cause the safe shut-

down of the furnace during certain blocked vent condi- tions.

441 01 1402 02 33

a. Verify vent pipe is cool to the touch. b. Disconnect power to furnace and remove vent con-

nector from furnace vent elbow.

c. Restore power to furnace and set room thermostat

above room temperature.

d. After normal start-up, allow furnace to operate for 2

minutes, then block vent elbow in furnace 80 per- cent of vent area with a piece of flat sheet metal.

e. Furnace should cycle off within 2 minutes. If gas

does not shut off within 2 minutes, determine reas- on draft safeguard switch did not function properly

and correct condition.

f. Remove blockage from furnace vent elbow.

g. Switch will auto-reset when it cools.

h. Re-install vent connector.

NOTE: Should switch remain open longer than 3 minutes,

furnace control board will lockout the furnace for 3 hrs. To

reset furnace control board, turn thermostat below room temperature or from HEAT to OFF and turn 115-v power OFF, then back ON.

3. Check Pressure Switch This control proves operation of the draft inducer blower.

a. Turn off 115-v power to furnace. b. Disconnect inducer motor lead wires from wire har-

ness.

c. Turn on 115-v power to furnace.

d. Set thermostat to "call for heat" and wait 1 minute.

When pressure switch is functioning properly, hot surface igniter should NOT glow and control dia- gnostic light flashes a status code 3. If hot surface

igniter glows when inducer motor is disconnected, shut down furnace immediately.

e. Determine reason pressure switch did not function

properly and correct condition.

f. Turn off 115-v power to furnace.

g. Reconnect inducer motor wires, replace outer door,

and turn on 115-v power.

h. Blower will run for 90 sec and flash status code 1+2

before beginning the call for heat again.

i. Furnace should ignite normally.

Step 5--Checklist

1. Put away tools and instruments. Clean up debris.

2. Verify that heat off-delay time is selected as desired.

3. Verify that blower and burner access doors are prop- erly installed.

4. Cycle test furnace with room thermostat.

5. Check operation of accessories per manufacturer's in- structions.

6. Review User's Guide with owner.

7. Attach literature packet to furnace.

Table 13--Gas Rate (cu ft./hr)

SECONDS FOR 1

REVOLUTION

10 360 720 1800 50 72 11 327 655 1636 51 71 12 300 600 1500 52 69 13 277 555 1385 53 68 14 257 514 1286 54 67 15 240 480 1200 55 65 16 225 450 1125 56 64

17 212 424 1059 57 63 18 200 400 1000 58 62

19 189 379 947 59 61 20 180 360 900 60 60 21 171 343 857 62 58 22 164 327 818 64 56 23 157 313 783 66 54 24 150 300 750 68 53

25 144 288 720 70 51 26 138 277 692 72 50 27 133 267 667 74 48 28 129 257 643 76 47 29 124 248 621 78 46 30 120 240 600 80 45 31 116 232 581 82 44 32 113 225 563 84 43 33 109 218 545 86 42

34 106 212 529 88 41 35 103 206 514 90 40 36 100 200 500 92 39 37 97 195 486 94 38 38 95 189 474 96 38 39 92 185 462 98 37 40 90 180 450 100 36 41 88 176 439 102 35

42 86 172 429 104 35 43 84 167 419 106 34 44 82 164 409 108 33 45 80 160 400 110 33 46 78 157 391 112 32 47 76 153 383 116 31 48 75 150 375 120 30 49 73 147 367

SIZE OFTEST DIAL

Cu Ft 2 Cu Ft 5 Cu Ft

SECONDS FOR 1

REVOLUTION 1 Cu Ft

SIZE OF TEST DIAL

2 Cu Ft 5 Cu Ft

144 360 14t 355 138 346 136 340 133 333 131 327 129 321

126 316 124 310 122 305 120 300

116 290

112 281 109 273 106 265

103 257 100 250

97 243 95 237 92 231 90 225 88 220 86 214 84 209

82 205 80 200 78 196 76 192 75 188 74 184 72 180 71 178

69 173 68 170 67 167 65 164 64 161 62 155 60 150

34 441 01 1402 02

FURNACE CASING WIDTH

14-1/2 (368) Washable* 17-1/2 (445) Washable*

21 (533) Washable* 24 (610) Washable*

Recommended

** Some furnaces mayhave 2 filters.

Table 15--Orifice Size* and Manifold Pressure in. w.c. for Gas Input Rate

(Tabulated data based on 22,000 btuh per burner, derated 4 percent for each 1000 ft. (305 M) above sea level)

AVG. GAS

ALTITUDE RANGE HEAT VALUE

FT. (i) AT ALTITUDE

(BTU/CU FT.)

900 925

950 975

1000 1025

1050

U.S.A.

0 to

2000

(oto

610)

1075

1100

800 825

2001 to

3000

U.S.A. (6t0 to

914)

850 875

900 925

950 975

1000

775 800

3001 to

U.S.A. 4000

(914 to

1219)

825 850

875 900

925 950

750 775

4001 to

U.S.A. 5000

(1219 to

1524)

800 825

850 875 900

925 725

750

5001 to

U.S.A. 6000

(1524 to

1829)

775 800

825 850

875 900

675 700

6001 to

U.S.A. 7000

(1829 to

2134)

725 750

775 800

825 850

Orifice numbers 43are factory installed.

Table 14_Filter Size Information - in.(mm)

SIDE RETURN BOTTOM RETURN

16 x 25 x 3/4 (406 x 635 x 19) 14 x 25 x 3/4 (356 x 635 x 19)

16 x 25 x3/4 (406 x 635 x 19) 16 x 25 x 3/4 (406 x 635 x 19) 16 x 25 x3/4 (406 x 635 x 19) 20 x 25 x 3/4 (508 x 635 x 19)

16 x 25 x3/4 (406 x 635 x 19) 24 x 25 x 3/4 (610 x 635 x 19)

0,58 0,60 0,62

Orifice Manifold Orifice Manifold Orifice Manifold

No, Pressure No, Pressure No, Pressure

42 3.5 42 3.6 42 3.7 42 3.3 42 3.4 42 3.5

43 3.8 42 3.3 42 3.4 43 3.6 43 3.8 42 3.2

43 3.5 43 3.6 43 3.7 43 3.3 43 3.4 43 3.5

44 3.6 43 3.2 43 3.4 44 3.4 44 3.5 43 3.2

44 3.3 44 3.4 44 3.5 42 3.4 42 3.5 42 3.6

42 3.2 42 3.3 42 3.4 43 3.7 43 3.8 42 3.2

43 3.5 43 3.6 43 3.7 43 3.3 43 3.4 43 3.5

43 3.1 43 3.2 43 3.3 43 2.9 43 3.0 43 3.1 43 2.8 43 2.9 43 3.0

43 2.6 43 2.7 43 2.8 42 3.2 42 3.3 42 3.4

43 3.6 43 3.8 42 3.2 43 3.4 43 3.5 43 3.7

43 3.2 43 3.3 43 3.4 43 3.0 43 3.1 43 3.3

43 2.9 43 3.0 43 3.1 43 2.7 43 2.8 43 2.9 43 2.6 43 2.7 43 2.8

43 3.6 43 3.8 42 3.2 43 3.4 43 3.5 43 3.6

43 3.2 43 3.3 43 3.4 43 3.0 43 3.1 43 3.2

43 2.8 43 2.9 43 3.0 43 2.7 43 2.8 43 2.9 43 2.5 43 2.6 43 2.7

43 2.4 43 2.5 43 2.6 43 3.4 43 3.5 43 3.6

43 3.2 43 3.3 43 3.4 43 3.0 43 3.1 43 3.2

43 2.8 43 2.9 43 3.0 43 2.6 43 2.7 43 2.8

43 2.5 43 2.5 43 2.6 43 2.3 43 2.4 43 2.5 43 2.2 43 2.3 43 2.3

43 3.4 43 3.5 43 3.6 43 3.1 43 3.3 43 3.4

43 2.9 43 3.0 43 3.1 43 2.7 43 2.8 43 2.9

43 2.6 43 2.7 43 2.7 43 2.4 43 2.5 43 2.6

43 2.3 43 2.3 43 2.4 43 2.1 43 2.2 43 2.3

FILTER SIZE

SPECIFIC GRAVITY OF NATURAL GAS

Orifice

No,

41 42

42 42

43 43

43 42

42 42

43 43

43 43 43

43 42

42 43

43 43

43 43 43

42 43

43 43

43 43 43

43 43

43 43 43

43 43

FILTER TYPE

0,64

Manifold

Pressure

3.5

3.7

3.5

3.3

3.8

3.6

3.5

3.3

3.2

3.7

3.5

3.3

3.8

3.6

3.4

3.2

3.1

2.9

3.5

3.3

3.8

3.6

3.4

3.2

3.0

2.8

3.3

3.8

3.5

3.3

3.1

2.9

2.8

2.6

3.7

3.5

3.3

3.1

2.9

2.7

2.6

2.4

3.7

3.5

3.2

3.0

2.8

2.7

2.5

2.4

441 01 1402 02 35

Table 15-Orifice Size* and Manifold Pressure in. w.c. for Gas Input Rate (Continued)

(Tabulated data based on 22,000 btuh per burner, derated 4 percent for each 1000 ft. (305 M) above sea level)

ALTITUDE RANGE

FT. (i)

700t to

U.S.A.

U.S.A. (2743 to

* Orifice numbers 43 are factory installed.

8000

(2134 to

2438)

8001 to

9000

(2438 to

2743)

9001 to

10,000

3048)

AVG. GAS SPECIFIC GRAVITY OF NATURAL GAS

HEAT VALUE 0.58 0.60 0.62 0.64

AT ALTITUDE Orifice Manifold Orifice Manifold Orifice Manifold Orifice Manifold

(BTU/CU FT.) No. Pressure No. Pressure No. Pressure No. Pressure

850 43 3.1 43 3.2 43 3.4 43 3.5 675 43 2.9 43 3.0 43 3.1 43 3.2

700 43 2.7 43 2.8 43 2.9 43 3.0 725 43 2.5 43 2.6 43 2.7 43 2.8

750 43 2.4 43 2.4 43 2.5 43 2.6 775 43 2.2 43 2.3 43 2.4 43 2.4

800 43 2.1 43 2.1 43 2.2 43 2.3 825 48 3.7 43 2.0 43 2.1 43 2.2

625 43 2.9 43 3.0 43 3.1 43 3.2 650 43 2.7 43 2.8 43 2.9 43 3.0

675 43 2.5 43 2.6 43 2.7 43 2.8 700 43 2.3 43 2.4 43 2.5 43 2.6

725 43 2.2 43 2.2 43 2.3 43 2.4 750 43 2.0 43 2.1 43 2.2 43 2.2

600 43 2.7 43 2.8 43 2.9 43 3.0 625 43 2.5 43 2.6 43 2.6 43 2.7

650 43 2.3 43 2.4 43 2.4 43 2.5 675 43 2.1 43 2.2 43 2.3 43 2.3

700 48 3.7 43 2.0 43 2.1 43 2.2 725 48 3.5 48 3.6 48 3.7 43 2.0 775 48 3.6 48 3.7 43 2.0 43 2.1

36 441 01 1402 02

(Tabulated data based on 21,000 btuh per burner, derated 4 percent for each 1000 ft. (305 M) above sea level)

ALTITUDE

RANGE

FT. (M)

U.S.A.

U.S.A. 3000

U.S.A.

* Orifice numbers 43 are facton

0 to 2000 (0 to 610)

2001 to

(6t 0 to

914)

3001 to

4000

(914 to

1219)

4001 to

5000

(1219 to

1524)

5001 to

6000

(1524 to

1829)

6001 to

7000

(1829 to

2134)

Table 16--Orifice Size* and Manifold Pressure in. w.c. for Gas Input Rate

SPECIFIC GRAVITY OF NATURAL GAS

AVG, GAS 0,58 0,60 0,62 0,64

HEAT VALUE

AT ALTITUDE Orifice Manifold Orifice Manifold Orifice Manifold Orifice Manifold

(BTU/CU FT.) No, Pressure No, Pressure No, Pressure No, Pressure

900 42 3.2 42 3.3 42 3.4 42 3.5 925 43 3.7 43 3.8 42 3.2 42 3.3

950 43 3.5 43 3.6 43 3.7 43 3.8 975 43 3.3 43 3.4 43 3.5 43 3.7

1000 44 3.6 43 3.3 43 3.4 43 3.5 1025 44 3.4 44 3.6 43 3.2 43 3.3

1050 44 3.3 44 3.4 44 3.5 43 3.2 1075 45 3.8 44 3.2 44 3.3 44 3.4

1100 46 3.8 45 3.7 44 3.2 44 3.3

800 43 3.8 42 3.2 42 3.3 42 3.4 825 43 3.5 43 3.7 43 3.8 42 3.2 850 43 3.3 43 3.5 43 3.6 43 3.7

875 43 3.2 43 3.3 43 3.4 43 3.5 900 43 3.0 43 3.1 43 3.2 43 3.3

925 43 2.8 43 2.9 43 3.0 43 3.1 950 43 2.7 43 2.8 43 2.9 43 2.9

975 43 2.5 43 2.6 43 2.7 43 2.8

1000 43 2.4 43 2.5 43 2.6 43 2.7

775 43 3.5 43 3.7 43 3.8 42 3.2

800 43 3.3 43 3.4 43 3.5 43 3.7 825 43 3.1 43 3.2 43 3.3 43 3.4

850 43 2.9 43 3.0 43 3.1 43 3.2 875 43 2.8 43 2.9 43 3.0 43 3.1

900 43 2.6 43 2.7 43 2.8 43 2.9 925 43 2.5 43 2.6 43 2.7 43 2.7

950 43 2.4 43 2.4 43 2.5 43 2.6

750 43 3.3 43 3.4 43 3.5 43 3.6 775 43 3.1 43 3.2 43 3.3 43 3.4

800 43 2.9 43 3.0 43 3.1 43 3.2 825 43 2.7 43 2.8 43 2.9 43 3.0

850 43 2.6 43 2.7 43 2.8 43 2.8 875 43 2.4 43 2.5 43 2.6 43 2.7

900 43 2.3 43 2.4 43 2.5 43 2.5 925 43 2.2 43 2.2 43 2.3 43 2.4

725 43 3.1 43 3.2 43 3.3 43 3.4 750 43 2.9 43 3.0 43 3.1 43 3.2 775 43 2.7 43 2.8 43 2.9 43 3.0

800 43 2.5 43 2.6 43 2.7 43 2.8 825 43 2.4 43 2.5 43 2.5 43 2.6

850 43 2.2 43 2.3 43 2.4 43 2.5 875 43 2.1 43 2.2 43 2.3 43 2.3

900 43 2.0 43 2.1 43 2.1 43 2.2

675 43 3.1 43 3.2 43 3.3 43 3.4 700 43 2.9 43 3.0 43 3.1 43 3.2

725 43 2.7 43 2.8 43 2.9 43 2.9 750 43 2.5 43 2.6 43 2.7 43 2.8

775 43 2.3 43 2.4 43 2.5 43 2.6

800 43 2.2 43 2.3 43 2.3 43 2.4 825 43 2.1 43 2.1 43 2.2 43 2.3

850 48 3.7 43 2.0 43 2.1 43 2.1

installed.

441 01 1402 02

Table 16--Orifice Size* and Manifold Pressure in. w.c. for Gas Input Rate (Continued)

(Tabulated data based on 21,000 btuh per burner, derated 4 percent for each 1000 ft. (305 M) above sea level)

ALTITUDE

HEAT VALUE

RANGE

AVG. GAS SPECIFIC GRAVITY OF NATURAL GAS

FT. (i)

ALTITUDE Orifice Manifold Orifice Manifold Orifice Manifold Orifice

(BTU/CU FT.) No. Pressure No. Pressure No. Pressure No.

700t to

U.S.A.

8000

(2134to

2438)

8001to

U.S.A.

9000

(2438to

2743)

9001to

10,000

U.S.A.

(2743to

3048)

* Orifice numbers 43 are factory installed.

0.58 0.60 0.62

650 43 2.9 43 3.0 43 3.1 43 675 43 2.7 43 2.7 43 2.8 43

700 43 2.5 43 2.6 43 2.6 43 725 43 2.3 43 2.4 43 2.5 43

750 43 2.1 43 2.2 43 2.3 43 775 43 2.0 43 2.1 43 2.2 43

800 48 3.6 48 3.7 43 2.0 43 825 48 3.3 48 3.5 48 3.6 48

625 43 2.7 43 2.7 43 2.8 43 650 43 2.5 43 2.5 43 2.6 43

675 43 2.3 43 2.4 43 2.4 43 700 43 2.1 43 2.2 43 2.3 43

725 48 3.7 43 2.0 43 2.1 43 750 48 3.5 48 3.6 48 3.7 43

600 43 2.4 43 2.5 43 2.6 43 625 43 2.3 43 2.3 43 2.4 43

650 43 2.1 43 2.2 43 2.2 43 675 48 3.6 48 3.8 43 2.1 43

700 48 3.4 48 3.5 48 3.6 48 725 49 3.7 49 3.8 48 3.4 48

775 49 3.8 48 3.4 48 3.5 48

Figure 44 - Service Label

0.64 Manifold

Pressure

3.2

2.9

2.7

2.5

2.4

2.2

2.1

3.7

2.9

2.7

2.5

2.3

2.2

2.0

2.7

2.5

2.3

2.1

3.7

3.5

3.6

To performstatus code recall/componenttest, the control mustbe in idle mode(no calls for heat,cool, or fan with the blower off) displayinga "Heartbeat". Status code recall/component test can be performed in one oftwo ways.:

SERVICE

1. Briefly (2-3 seconds) connectthe TEST/TWINterminalto the "C"thermostat terminalwith ajumper wire, (NOTE: Ifconnected for morethan 4-5 seconds status code 10will flash but itwill net overwrite the previousstatus code),

2. Briefly removethen reconnectonelimit wire (main, rollout, or draft-safeguard switch), (NOTE: Iflimitwire isdisconnected for more than 4-5seconds status code 4 will flash and the previous status code willbe lost).

After the status code is flashed4 times the componenttest will begin (see "ComponentTestSequence"below). I1noprevious status code is available the control will notflash a status code and will immediatelystartthe

componenttest. Storedstatus codesareerased automaticallyafter 72 hours.

EACH OF THE FOLLOWING STATUS CODES IS A SINGLE OR TWO DIGIT NUMBER WITH THE FIRST NUMBER DETERMINED BY THE NUMBER OF SHORT FLASHES AND THE

SECOND NUMBER AFTER THE PLUS (÷) SIGN IS THE NUMBER OF LONG FLASHES.

LED STATUS CODES

HEARTBEAT (bright-dim) -Control has 24VAC power

2 PRESSURESWITCHBID NOT OPEN Check for:

- Obstructed pressuretubing. - Pressure switch stuckclosed.

3 PRESSURESWITCH DIDNOT CLOSE OR REOPENED- Ifopen longer thanfive

minutes, inducershutsoff for 15 minutesbefore retry. Check for: - Excessivewind

- Proper ventsizing - Defectiveinducer motor

- Low inducervoltage (115VAC) - Defective pressure switch

- Inadequatecombustion air supply - Disconnectedor obstructed pressuretubing

- Low inletgas pressure(if LGPSused) - Restrictedvent If it opensduring blower on-delayperiod,blowerwillcome onfor the selected blower off-delay.

4 LIMIT CIRCUITFAULT. Indicates a limit, draft safeguard,flamerollout, or blocked vent switch

(ifused) is open. Blowerwillrunfor 4 minutesor until open switchremakeswhichever is longer. If open longer than 3 minutes, code changesto lockout #7, Ifopen lessthan3 minutesstatus

code#4 continues to flash untilblower shuts off. Flame rolloutswitchand BVSSrequire manualreset. Check for: - Restricted vent - Propervent sizing - Loose blowerwheel

- Excessivewind - Dirtyfilter or restricted ductsystem - Defective blower motor or capacitor

- Defectiveswitch or connections - Inadequate combustion airsupply (Flame Roll.out Switchopen)

5 ABNORMAL FLAME-PROVINGSIGNAL -Flame is proved while gas valve is de-energized.

Inducerwill rununtil fault is cleared, Check for: - Leakygas valve . Stuck.open gas valve

6 IGNITIONPROVINGFAILURE - Controlwill trythree moretimes before lockout #6+1occurs,

If flamesignallost during blower on-delay period, blower will come on for the selected blower off-delay. Check for: - Flamesensormust not be grounded

Gasvalve and humidifierwill notbeturned on. Components will be tested in sequenceas follows: Inducermotorwillrunfor entirecomponenttest,and the following componentsareON for 10- 15 secondseach individually; hot surface igniter, FAN (if equipped), HEATspeed,COOLspeed.

COMPONENT TEST SEQUENCE

6 Continued - Oxide buildup onflame sensor(cleanwith fine steelwool).

- Proper flame sensemicroamps (.5 microamps D,C. rain.,4,0- 6.0 nominal),

- Gas valve defective or gas valveturned off - Manualvalve shut-off - Lowinletgas pressure

- Defective Hot SurfaceIgniter - Controlgroundcontinuity - Inadequateflame carryover orrough ignition

- Green/Yellowwire MUST beconnected1ofurnacesheet metal.

7 LIMIT CIRCUITLOCKOUT - Lockoutoccurs if the limit, draft safeguard,flame rollout, orblockedvent

switch (ifused) is openlonger than 3 minutes. - Controlwillauto reset after three hours. - Referto #4.

8 GAS HEATING LOCKOUT - Controlwill NOT auto reset. Check for:

- Mis.-wiredgasvalve - Defectivecontrol(valve relay)

10 POLARITY - Linevoltage (115VAC)polarityreversed. - If twinned,refer to twinning kit instructions. 1+2 BLOWERON AFTER POWER UP (115VACor 24VAC) - Blower runs for 90 seconds, if unit is powered

upduring acallfor heat (R-W closed) or (R-W)opens during bloweron-delay. during bloweron-delay.

6+1 IGNITION LOCKOUT - Controlwill auto-resetafter three hours. Refer10#6. OFF SECONDARYVOLTAGE FUSEISOPEN Checkfor: - Door switch not closed

-115VACatL1 and Neutral,24VACat24VACRED and COM BLUE,24V Fuse3A

- Door switch not closed -Short circuitin secondary voltage(24VAC)wiring.

ON CONTROLCIRCUITRY LOCKOUT Auto-resetafter onehour lockoutdue to;

SOLID - Gasvalve relaystuck open - Flamesense circuit failure - Softwarecheckerror

Resetpowerto clear lockout. Replace control if statuscode repeats.

IIIIIIIIIIIIIIMIIIIIIIIIIIIIII

337016-101REV.A

38 441 01 1402 02

SERVICE AND MAINTENANCE

PROCEDURES

FIRE, EXPLOSION, ELECTRICAL SHOCK HAZARD

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

The ability to properly perform maintenance on this

equipment requires certain knowledge, mechanical

skills, tools, and equipment. If you do not possess these, do not attempt to perform any maintenance on

this equipment other than those procedures

recommended in the User's Manual.

ELECTRICAL SHOCK, FIRE OR EXPLOSION HAZARD

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

Before servicing, disconnect all electrical power to furnace and install a lock out tag. Verify proper operation after servicing.

ELECTRICAL OPERATION HAZARD Failure to follow this caution may result in improper

furnace operation.

Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation.

ENVIRONMENTAL HAZARD

Failure to follow this caution may result in

environmental pollution.

Remove and recycle all components or materials (i.e.

oil, refrigerant, et.) before unit final disposal.

Step 1 --Introduction

GENERAL

These instructions are written as if the furnace is installed in an upflow application. An upflow furnace application is where

the blower is located below the combustion and controls section of the furnace, and conditioned air is discharged

upward. Since this furnace can be installed in any of the 4 positions shown in Figure 4, you must revise your orientation

to component location accordingly.

ELECTRICAL CONTROLS AND WIRING

ELECTRICAL SHOCK HAZARD

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

Before installing, modifying, or servicing system, main electrical disconnect switch must be in the OFF position and install a lockout tag. There may be more than one electrical supply to the furnace. Check accessories and cooling unit for additional electrical supplies that must be shut off during furnace servicing. Lockout and tag switch with a suitable warning label. Verify proper operation

after servicing.

The electrical ground and polarity for 115-v wiring must be

properly maintained. Refer to Figure 26 for field wiring information and Figure 48 for furnace wiring information.

NOTE: If the polarity is not correct, the STATUS LED on the control will flash a status code 10 and prevent the furnace

from heating. The control system also requires an earth

ground for proper operation of the control and flame-sensing electrode.

The 24-v circuit contains an automotive-type, 3-amp. fuse

located on the control. (See Figure 25) Any shorts of the 24-v wiring during installation, service, or maintenance will cause

this fuse to blow. If fuse replacement is required, use ONLY a

3-amp. fuse. The control LED will be off when fuse needs to be replaced.

Proper instrumentation is required to service electrical controls. The control in this furnace is equipped with a Status

Code LED (Light-Emitting Diode) to aid in installation, servicing, and troubleshooting. It can be viewed through the

sight glass in blower access door. The furnace control LED is either ON continuously, flashing a heart beat, or a status

code. For an explanation of status codes, refer to service label

located on blower access door or Figure 44. See Figure 49 for a brief Troubleshooting Guide.

STATUS CODE RECOVERY AND COMPONENT TEST

To retrieve status code, proceed with the following:

NOTE: No thermostat signal may be present at control, and all blower-OFF delays must be completed.

Perform component self-test as shown on the SERVICE label, located on the of blower access door.

Step 2--Care and Maintenance

For continuing high performance and to minimize possible equipment failure, periodic maintenance must be performed on this equipment. Consult your local dealer about proper

frequency of maintenance and the availability of a

maintenance contract.

441 01 1402 02 39

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

injury, death and/or property damage. Never store anything on, near, or in contact with the

furnace, such as:

1. Spray or aerosol cans, rags, brooms, dust mops,

vacuum cleaners, or other cleaning tools.

2. Soap powders, bleaches, waxes or other cleaning compounds, plastic or plastic containers, gasoline, kerosene, cigarette lighter fluid, dry cleaning fluids, or

other volatile fluids.

3. Paint thinners and other painting compounds, paper bags, or other paper products.

ELECTRICAL SHOCK AND FIRE HAZARD

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

Turn off the gas and electrical supplies to the unit and install a lock out tag before performing any

maintenance or service. Follow the operating instructions on the label attached to the furnace.

CARBON MONOXIDE POISONING AND FIRE

HAZARD

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

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

CUT HAZARD Failure to follow this caution may result in personal

injury. Sheet metal parts may have sharp edges or burrs.

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

servicing furnaces.

The minimum maintenance on this furnace is as follows:

1. Check and clean air filter each month or more frequently if required. Replace if torn.

2. Check blower motor and wheel for cleanliness each heating and cooling season. Clean as necessary.

3. Check electrical connections for tightness and controls for

proper operation each heating season. Service as necessary.

4. Inspect burner compartment before each heating season

for rust, corrosion, soot or excessive dust. If necessary, have furnace and burner serviced by a qualified service agency.

5. Inspect the vent pipe/vent system before each heating

season for rust, corrosion, water leakage, sagging pipes or broken fittings. Have vent pipes/vent system serviced by a

qualified service agency.

6. Inspect any accessories attached to the furnace such as a humidifier or electronic air cleaner. Perform any service or

maintenance to the accessories as recommended in the accessory instructions. CLEANING AND/OR REPLACING AIR FILTER

The air filter arrangement will vary depending on the application. The filter is exterior to the furnace casing.

NOTE: If the filter has an airflow direction arrow, the arrow must point towards the blower.

CUT HAZARD Failure to follow this caution may result in personal

injury. Sheet metal parts may have sharp edges or burrs.

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

BLOWER MOTOR AND WHEEL

ELECTRICAL SHOCK HAZARD

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

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

switch is closed. Caution must be taken when manually

closing this switch for service purposes.

NOTE: The blower wheel should not be dropped or bent as balance will be affected.

The following steps should be performed by a qualified service agency.

To ensure long life and high efficiency, clean accumulated dirt and grease from blower wheel and motor annually.

The inducer and blower motors are pre-lubricated and require no additional lubrication. These motors can be

identified by the absence of oil ports on each end of the motor.

Clean blower motor and wheel as follows:

1. Turn off electrical supply to furnace.

2. Remove outer door.

3. For downflow or horizontal furnaces having vent pipes within the furnace that pass in front of the blower ac- cess door:

a. Disconnect vent connector from furnace vent elbow. b. Disconnect and remove short piece of vent pipe

from within furnace.

4. Remove 2 screws from blower access door and re- move blower access door.

5. All factory wires can be left connected, but field thermo- stat connections may need to be disconnected de-

pending on their length and routing.

6. Remove 2 screws holding blower assembly to blower deck and slide blower assembly out of furnace.

7. Clean blower wheel and motor using a vacuum with soft brush attachment. Blower wheel blades may be

cleaned with a small paint or flux brush. Do not remove or disturb balance weights (clips) on blower wheel

blades.

40 441 01 1402 02

8. Vacuum any loose dust from blower housing, wheel and motor.

9. If a greasy residue is present on blower wheel, remove wheel from the blower housing and wash it with an ap-

propriate degreaser. To remove wheel:

NOTE: Before disassembly, mark blower motor, and blower housing so motor and each arm is positioned at the same location during reassembly.

a. Disconnect capacitor wires and ground wire at-

tached to blower housing.

b. Remove screws securing cutoff plate and remove

cutoff plate from housing.

c. Loosen set screw holding blower wheel on motor

shaft (160+/-20 in.-Ib, when reassembling).

d. Remove bolts holding motor to blower housing and

slide motor out of wheel (40+/-10 in.-Ib, when reas- sembling).

e. Remove blower wheel from housing.

f. Clean wheel and housing.

10. Reassemble motor and blower by reversing steps 9f through 9a, finishing with 9a. Be sure to reattach

ground wire to the blower housing.

11. Verify that blower wheel is centered in blower housing and set screw contacts the flat portion of the motor

shaft. Loosen set screw on blower wheel and reposi- tion if necessary.

12. Spin the blower wheel by hand to verify that the wheel does not rub on the housing.

13. Reinstall blower assembly in furnace.

UNIT DAMAGE HAZARD

Failure to follow this caution may result in shortened heat

exchanger life.

Heating fan speed(s) MUST be adjusted to provide proper air temperature rise as specified on the rating plate. Recommended operation is at the midpoint of the

rise range or slightly above. Refer to SET TEMPERATURE RISE under START-UP, ADJUSTMENT, and SAFETY CHECK.

14. Connect thermostat leads if previously disconnected.

15. To check blower for proper rotation: a. Turn on electrical supply.

ELECTRICALSHOCKHAZARD

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

Blower access door switch opens 115-v power to

furnace control. No component operation can occur

unless switch is closed. Exercise caution to avoid electrical shock from exposed electrical components

when manually closing this switch for service purposes.

b. Manually close blower access door switch.

NOTE: If thermostat terminals are jumpered at the time blower access door switch is closed, blower wilt run for 90 sec before beginning a heating or cooling cycle.

c. Perform component self-test as shown on the

SERVICE label, located on the blower access door.

441 01 1402 02

16. If furnace is operating properly, RELEASE BLOWER ACCESS DOOR SWITCH. Remove any jumpers or re-

connect any disconnected thermostat leads. Replace blower access door.

17. Downflow or horizontal furnaces with vent pipe through furnace only:

a. Install and connect short piece of vent pipe inside

furnace to existing vent.

b. Connect vent connector to vent elbow.

18. Reinstall casing door.

19. Turn on gas supply and cycle furnace through one complete heating and cooling cycle. Verify the furnace temperature rise as shown in Adjustments Section. Ad-

just temperature rise as shown in Adjustments Section. If outdoor temperature is below 70°F, (21°C) turn off

circuit breaker to outdoor unit before running furnace in the cooling cycle. Turn outdoor circuit breaker on after

completing cooling cycle.

CLEANING HEAT EXCHANGER

The following steps should be performed by a qualified

service agency: NOTE: If the heat exchangers get a heavy accumulation of

soot and carbon, they should be replaced rather than trying to clean them thoroughly. A heavy build-up of soot and carbon indicates that a problem exists which needs to be corrected, such as improper adjustment of manifold pressure, insufficient or poor quality combustion air, incorrect size or damaged manifold orifice(s), improper gas, or a restricted heat exchanger. Action must be taken to correct the problem.

If it becomes necessary to clean the heat exchangers because of dust or corrosion, proceed as follows:

1. Turn OFF gas and electrical power to furnace.

2. Remove outer access door.

3. Disconnect vent connector from furnace vent elbow.

4. For downflow or horizontal furnace having an internal vent pipe, remove internal vent pipe within the casing.

5. Disconnect wires to the following components. Mark wires to aid in reconnection of (be careful when discon-

necting wires from switches because damage may oc- cur):

a. Draft safeguard switch. b. Inducer motor.

c. Pressure switch(es). d. Limit overtemperature switch.

e. Gas valve.

f. Hot surface igniter.

g. Flame-sensing electrode. h. Flame rollout switches.

i. Remove NOx baffles on low NOx models.

6. Remove screws that fasten the collector box assembly to the cell panel. Be careful not to damage the collector

box. Inducer assembly and elbow need not be re- moved from collector box.

7. Disconnect gas line from gas manifold.

8. Remove the 5 screws that attach the burner assembly to the cell panel. The gas valve and individual burners

need not be removed from support assembly.

NOTE: Be very careful when removing burner assembly to avoid breaking igniter. See Figure 45 and Figure 46 for correct igniter location.

9. Using field-provided 25-caliber rifle cleaning brush, 36-in. (914 mm) long, 1/4 in. (6 mm) diameter steel

spring cable, a variable speed reversible electric drill, and vacuum cleaner, clean cells as follows:

a. Remove metal screw fitting from wire brush to allow

insertion into cable.

b. Insert the twisted wire end of brush into end of

spring cable, and crimp tight with crimping tool or crimp by striking with batl-peen hammer.

TIGHTNESS IS VERY IMPORTANT.

NOTE: The materials needed in item 9 can usually be

purchased at local hardware stores.

(1) Attach variable-speed, reversible drill to the end of spring

cable (end opposite brush).

(2) Insert brush end of cable into the outlet opening of celt

and slowly rotate with drill. DO NOT force cable. Gradually

insert cable into upper pass of cell. (See Figure 47) (3) Work cable in and out of cell 3 or 4 times to obtain

sufficient cleaning. DO NOT pull cable with great force.

Reverse drill and gradually work cable out.

Figure 45 -- Igniter Position-Side View

7.1 rnm

5/16"

9/32"_

7.9 mm

A05025

Figure 46 - Igniter Position-Top View

A05026

Figure 47 -- Cleaning Neat Exchanger Cell

(4) Insert brush end of cable in burner inlet opening of cell,

and proceed to clean 2 lower passes of cell in same manner as upper pass.

(5) Repeat foregoing procedures until each cell in furnace

has been cleaned.

(6) Using vacuum cleaner, remove residue from each cell. (7) Using vacuum cleaner with soft brush attachment, clean

burner assembly.

(8) Clean flame sensor with fine steel wool. (9) Install NOx baffles (if removed).

(10) Reinstall burner assembly. Center burners in cell

openings.

10. Remove old sealant from cell panel and collector box flange.

11. Spray releasing agent on the heat exchanger cell panel where collector box assembly contacts cell panel.

NOTE: A releasing agent such as a vegetable oil cooking spray that does not contain corn oil, canola oil, halogenated hydrocarbons or aromatic content, which may prevent an inadequate seat from occuring, and RTV sealant such as

G.E. RTV 162, G.E. RTV 6702, or Dow-Corning RTV 738 sealant are required. DO NOT substitute any other type of

RTV sealant.

12. Apply new sealant to flange of collector box and attach to cell panel using existing screws, making sure all screws are secure.

13. Reconnect wires to the following components. (Use connection diagram on wiring label, if wires were not

marked for reconnection locations.): a. Draft safeguard switch.

b. Inducer motor.

c. Pressure switch(es).

d. Limit over-temperature switch. e. Gas valve.

f. Hot surface igniter.

g. Flame-sensing electrode. h. Flame rollout switches.

i. Install NOx baffles (if removed).

14. Reinstall internal vent pipe, if applicable.

15. Reinstall vent connector on furnace vent elbow. Se- curely fasten vent connector to vent elbow with 2 field- supplied, corrosion-resistant, sheet metal screws loc- ated 180° apart.

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

17. Set thermostat above room temperature and check fur-

nace for proper operation.

18. Verify blower airflow and speed changes between

heating and cooling.

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.

A0t050

42 441 01 1402 02

19. Check for gas leaks.

20. Replace outer access door.

Step 3--Sequence of Operation

NOTE: Furnace control must be grounded for proper

operation or control will lock out. Control is grounded through green/yellow wire routed to gas valve and manifold bracket

screw. Using the schematic diagram in Figure48, 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), the control will start a 90-sec blower-only ON period two seconds after power is restored, if the thermostat is still calling for gas heating. The GREEN LED light will flash code 1+2 during the 90-sec period, after which the LED will be flashing a heartbeat, as long as no faults are detected. After

the 90-sec 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. Heating (See Figure 26 for thermostat connections.) The wall

thermostat "calls for heat," closing the R-to-W circuit. The furnace control performs a self-check, verifies the pressure switch contacts PRS are open, and starts the

inducer motor IDM.

NOTE: There are two humidifier terminals available 24VAC (HUM 24VAC) and 115VAC (HUM). Confirm the correct

terminal to voltage is being used.

a. Inducer Prepurge Period- The inducer enable

relay contacts IDR close and allow 115 VAC to in- ducer motor and HUM terminal (not to be confused with the 24-v HUM 24 VAC terminal). As the in- ducer motor IDM comes up to speed, the pressure switch contacts PRS close, 24 VAC power is sup-

plied for a field installed humidifier at the HUM 24VAC terminal and the control begins a 15-sec prepurge period.

b. Igniter Warm-Up- At the end of the prepurge peri-

od, the Hot-Surface igniter HSI is energized for a 17-second igniter warm-up period.

c. Trial-for-Ignition Sequence- When the igniter

warm-up period is completed, the main gas valve relay contacts GVR close to energize the gas valve GV, the gas valve opens, The gas valve GV permits gas flow to the burners where it is ignited by the

HSI. Five seconds after the GVR closes, a 2-second flame proving period begins. The HSI igniter will remain energized until the flame is sensed or until the 2-second flame proving period begins.

d. Flame-Proving- When the burner flame is proved

at the flame-proving sensor electrode FSE, the furnace control CPU begins the blower-ON delay period and continues to hold the gas valve GV open. If the burner flame is not proved within two seconds, the control CPU will close the gas valve GV, and the control CPU will repeat the ignition se-

quence for up to three more Trials-For-Ignition be- fore 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, G, R, etc.) If flame is proved when flame should not be present, the fur- nace control CPU will lock out of Gas-Heating

mode and operate the inducer motor IDM until flame is no longer proved.

e. Blower-On Delay- If the burner flame is proven,

the blower motor is energized on HEAT speed 25 sec after the gas valve GV is energized.

Simultaneously, the electronic air cleaner terminal EAC 1 AMP is energized and remains energized as long as the blower motor BLWM is energized.

f. Heat-Off Delay- When the thermostat is satisfied,

the R-to-W circuit is opened, de-energizing the

gas valve GV, stopping gas flow to the burners, and de-energizing the 24-v humidifier terminal HUM

24VAC. The inducer motor IDM will remain ener- gized for a 5-second post-purge period. Then turn

off the inducer motor and HUM (115-v) humidifier

terminal. The blower motor BLWM and air cleaner terminal EAC 1 AMP will remain energized for 90,

120, 150, or 180 seconds (depending on the HEAT-OFF delay selection). The furnace control CPU is factory-set for a 120-second Heat-Off Delay.

2. Cooling Mode (See Figure 26 for thermostat connections.) The ther- mostat closes the R-to-G-and-Y circuits. The R-to-Y

circuit starts the outdoor unit, and the R-to-G and Y 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 addition-

al 90 sec. Cut jumper J2 to reduce the cooling off- delay to 5 sec. (See Figure 25)

3. Continuous Blower Mode When the R-to-G circuit is closed by the thermostat,

the blower motor BLWM will operate on continuous- blower speed (same as 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 sec), ignition, and blower-ON delay (25 sec), allowing the furnace heat exchangers

to heat up more quickly, then restarts at the end of the blower-ON delay period at HEAT speed.

When the thermostat "calls for cooling", the blower mo- tor BLWM will operate at COOL speed. When the ther-

mostat is satisfied, the blower motor BLWM will operate an additional 90 sec, 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 sec, if no other function requires blower motor BLWM opera-

tion.

4. Heat Pump 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-and-Y or R-to-W-and-Y-and-G

circuits are energized the furnace control CPU will con- tinue to turn on the blower motor BLWM at HEAT

speed, and begin a heating cycle. The blower motor BLWM will remain on until the end of the prepurge peri-

od, then shut off for 24 sec then come back on at HEAT speed. When the W input signal disappears, the fur-

nace control begins a normal inducer post-purge peri- od and the blower switches to COOL speed after a 3

sec delay. If the R-to-W-and-Y-and-G signals disap- pear at the same time, the blower motor BLWM will re-

main on for the selected blower-OFF delay period. If the R-to-W-and-Y signals disappear, leaving the G

signal, the blower motor BLWM will continue running the blower motor at HEAT speed after the selected

blower-OFF delay period is completed.

Step 4--Wiring Diagrams

Refer to Figure 25 and Figure 48 for wiring diagrams.

Step 5--Troubleshooting

Refer to the service label (See Figure 44 or Figure 49).

441 01 1402 02 43

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

FLAME-PROVING ELECTRODE TRAN FUSE, 3 AMP, AUTOMOTIVE BLADE TYPE. FACTORY INSTALLED

FUSE OR CIRCUIT BREAKER CURRENT INTERRUPT DEVICE

(FIELD INSTALLED & SUPPLIED) O

EQUIPMENT GROUND m GAS VALVE-REDUNDANT

GAS VALVE RELAY,SPST-(N.O.) HOT SURFACE IGNITER (115VAC) HOT SURFACE IGNITER RELAY, SPST-(N.0.) ° ° ° 24VAC HUMIDIFIER CONNECTION (0.5 AMP MAX.) LINE VOLTAGE HUMIDIFIER CONNECTION (EAC & HUM 1 AMP MAX.) " " " INDUCED DRAFT MOTOR, SHADED-POLE INDUCED DRAFT MOTOR RELAY.SPST-(N.O.) BLOWER ACCESS PANEL INTERLOCK SWITCH, SPST-(N.O.)

BLOWER - OFF DELAYJUMPER SELECTOR - HEATING BLOWER - OFF DELAv JUMPER- COOLING

JUNCTION BOX LIGHT-EMITTING DIODE FOR STATUS CODES - GREEN

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PCB PRINTED CIRCUITBOARD CONTROL P1 11-CIRCUIT PCB CONNECTOR

P2 2-CIRCUIT CONNECTOR P3 2-CIRCUIT HSl, CONNECTOR

PRS PRESSURE SWITCH, SRST-(N.O.) TEST/TWIN COMPONENT TEST &TWIN TERMINAL

TEMPERATURE SWITCH (N.C.)

TRANSFORMER-115VAC/24VAC

JUNCTION UNMARKED TERMINAL PCS CONTROL TERMINAL

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NOTES:

1. If any of the original equipment wire is replaced use wire rated for 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 legend. _ < ,,_

6. Replace only with a 3 amp fuse. _ u_

7. Inducer (IDM) and blower (BLWM) motors contqin internal auto-reset thermal overload switches (OL). _ ac

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

9. Blower motor speed selections are fer average conditions, see installation instructions fer details on _ o. 41_ optimum speed selection. _

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

11. Factory connected when LGPS is net used. _ eo ,,_

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auto-reset after three hours, m

13. Blower.on delay: gas heating 25 seconds, cooling or heat pump 2 seconds. _ '_

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

90 seconds or 5 seconds when J2 is cut.

15. Yellow Speed Tap on 4 speed motor only. _ "_

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Troubleshooting Guide -

light

START

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.

To recall a status code: Briefly (2 - 3 seconds) connect the TEST/TWIN terminal to the "C" thermostat terminal 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 and remain on until

the end of the blower test, then off. The following components are on for 10 -15 seconds each individually: hot surface igniter, blower speeds: FAN (if present), HEAT, COOL.

O IX)

Is LED status light ON solid, alternately flashing bright--dim-bright-dim like a heartbeat, or flashing ON and OFF?

[

I Is LED status ON solid?

bright_imJaright_im like a heartbeat?

I Is LED status light alternately flashing

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.

Single Stage

Is door switch closed?

YES

Is there 115V going to switch?

YES

I Replace door switch.

-_ Replace transformer.

Does the control respond to W, Y1, Y/Y2, and G (24V) thermostat signals?

_L YES

Run system through a heat, or cooling cycle to check operation. Status codes

are erased after 72 hours.

Close the door switch.

Is circuit breaker closed?

I I Check for continuity in wire from circuit

I I Close circuit breaker and go backto

i i Disconnect all the thermostat wires from

breaker to furnace.

START.

interconnecting cable.

I heck room thermostat or

thermostat terminals on the furnace Is 24V present at W, Y1, Y/Y2 or G

control?

the furnace control.

YES

I F

'11

--I

(I)

._.

III

i o to section below for the flashed statuscode.

I E--4S

Was there a previous status code?

4_ O1

I Replace furnace control.

F.o

jumper wire?

Does the problem repeat when using a

.°

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.

4_ Ob

2 PRESSURE SWITCH DID NOT OPEN -

Check for:

- Obstructed pressure tube.

- Pressure switch stuck closed.

3 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 min, 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

ABNORMAL FLAME-PROVING SIGNAL Flame is proved while gas valve is de-

energized. Inducer will run until fault is

._ 5

o re

cleared. Check for:

- Stuck open or leaky gas valve.

IGNITION PROVING FAILURE -If flame is

not sensed during the trial for ignition period, the control will repeat the ignition sequence 3 more times before lockout #6 +

1 occurs. If flame signal is lost during the blower on-delay period, blower will come on

for the selected blower off-delay. Check the following before going to the next step.

- Gas valve electric switch on?

- Manual shut-offvalve open?

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

- Flame sensor must not be grounded.

._ 7

LIMIT CIRCUIT LOCKOUT - Lockout occurs ifthe 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.

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--W/W1 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 be

operated in component test mode. To check the igniter, remove the R thermostat connection

from the control, reset power, start the component test. Does the igniter glow

orange/white by the end of the 15 second warm- up period?

NOTE: NUMBER IN UPPER LEFT HAND

CORNER REPRESENTS FLASH CODE

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 6.0 #A DC.

Is current near typical value?

YES

Will main burners ignite and stay on?

YES

Fixed.

Replace furnace control.

Check fer 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 fer:

- 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

(4.0-6.0_ DC nominal) and burners will not stay on,

replace control.

Replace electrode.

Replace furnace control.

I I

PARTS REPLACEMENT INFORMATION GUIDE

CASING GROUP Outer door

Blower door Top filler plate

Bottom filler plate Bottom enclosure

ELECTRICAL GROUP Control bracket

Junction box Limit switch(es)

Circuit board Door switch

Transformer Wiring harness 115v

Wiring harness 24v

DIGIT POSITION 1 2 3 4 5 6,7,8 9,10 11,12 13 14

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

N 8 M S L 045 14 12 A 1

N = Non-Branded 8 = 80% AFUE EFFICIENCY

M = Multiposition POSITION

V = Variable Speed Blower Motor - ECM

X = ECM Blower Motor S = Single-stage

T = Two-stage

N = Standard L = Low Nox

045 = 44,000 BTU/hr 070 = 66,000 BTU/hr 090 = 88,000 BTU/hr 110 = 110,000 BTU/hr 132 = 132,000 BTU/hr 155 = 154,000 BTU/hr 14 = 14-3/16" 17 = 17-1/2"

21 = 21" 24 = 24-1/2" 08 = 800 CFM (max)

12 = 1200 CFM (max) 14 = 1400 CFM (max) 16 = 1600 CFM (max) 20 = 2000 CFM (max) 22 = 2200 CFM (max)

SALES (MAJOR) REVISION DIGIT ENGINEERING (MINOR) REVISION DIGIT

TYPE

FEATURE

HEAT INPUT

CABINET WIDTH

NOMINAL MAXIMUM COOLING AIRFLOW @ .5 IN.W,C.

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.

441 01 1402 02 specificationsaresubjecttochangewithout notice 47

International Comfort Products, LLC

Consumer Relations Department

P.O. Box 128

Lewisburg, TN 37091, USA

931-270-4100

ICP N8MSL0451408A1, N8MSL0451412A1, N8MSL0701408A1, N8MSL0701412A1, N8MSL0701716A1 Installation Guide

Specifications and Main Features

Frequently Asked Questions

User Manual