Intertek MVM97 Series, CVM97 Series Installation Instructions Manual

Download

NSTALLATION

NSTRUCTIONS FOR

*MVM97 & *CVM97

ODULATING

(Type FSP CATEGORY IV Direct

or Non Direct Vent Air Furnace)

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

As a professional installer you have an obligation to know

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

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

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

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

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

RECOGNIZE THIS SYMBOL

AS A SAFETY PRECAUTION.

*NOTE: Please contact your distributor or our website for

the applicable Specification Sheet referred to in this manual.

GAS F

Affix all manuals

adjacent to the unit.

URNACE

Installer:

TABLE OF CONTENTS

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

HIPPING INSPECTION ............................................ 4

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

O THE INSTALLER ............................................. 5

PRODUCT DESCRIPTION ..................................... 5

EATURES ...................................................... 5

PRODUCT APPLICATION ..................................... 6

LOCATION REQUIREMENTS & CONSIDERATIONS ......... 7

CLEARANCES AND A CCESSIBILITY ................................... 8

XISTING FURNACE REMOVAL ..................................... 9

HERMOSTAT LOCATION ......................................... 10

COMBUSTION & VENTILATION AIR REQUIREMENTS..... 10

INSTALLATION POSITIONS ................................. 14

HORIZONTAL APPLICATIONS & CONSIDERATIONS ...... 14

FURNACE SUSPENSION .......................................... 14

RONT COVER PRESSURE SWITCH TUBE LOCATION ................. 15

DRAIN TRAP AND LINES ......................................... 15

EVELING ..................................................... 15

LTERNATE ELECTRICAL AND GAS L INE CONNECTIONS .............. 15

DRAIN PAN .................................................... 15

FREEZE PROTECTION ............................................ 15

PROPANE GAS/HIGH ALTITUDE INSTALLATIONS ........ 15

VENT/FLUE PIPE & COMBUSTION AIR PIPE .............. 16

DUAL CERTIFICATION: NON-DIRECT/DIRECT VENT ................. 16

MATERIALS AND JOINING METHODS ............................... 16

PROPER VENT/FLUE AND COMBUSTION A IR PIPING PRACTICES ....... 17

TERMINATION LOCATIONS ........................................ 17

SPECIAL VENTING REQUIREMENTS FOR INSTALLATIONS IN C ANADA .... 19

STANDARD FURNACE CONNECTIONS ............................... 19

COMBUSTION A IR PIPE .......................................... 19

VENT/INTAKE T ERMINATIONS F OR I NSTALLATION

MULTIPLE DIRECT VENT FURNACES ....................... 23

CONCENTRIC VENT TERMINATION ................................. 23

SIDE WALL VENT KIT .......................................... 23

CONDENSATE DRAIN LINES & DRAIN TRAP .............. 23

GENERAL DRAIN I NFORMATION ................................... 23

FIELD SUPPLIED DRAIN ......................................... 24

UPFLOW MODEL INSTALLED VERTICALLY .......................... 24

DRAIN EXITING RIGHT S IDE ...................................... 24

DRAIN EXITING LEFT SIDE ....................................... 24

UPFLOW MODEL INSTALLED HORIZONTALLY

WITH

RIGHT SIDE DOWN .................................. 25

UPFLOW MODEL INSTALLED HORIZONTALLY

WITH

LEFT S IDE DOWN ................................... 25

IOG-2007A 11/14

5151 San Felipe Suite 500

Houston, TX 77056

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

T ABLE OF CONTENTS

DRAIN EXITING RIGHT S IDE ...................................... 26

PFLOW MODEL INSTALLED HORIZONTALLY

WITH LEFT SIDE DOWN - ALTERNATE ...................... 26

OUNTERFLOW MODEL INSTALLED VERTICALLY .................... 26

C D

RAIN EXITING LEFT SIDE ....................................... 26

COUNTERFLOW MODEL INSTALLED HORIZONTALLY

WITH

RIGHT SIDE DOWN .................................. 27

OUNTERFLOW MODEL INSTALLED HORIZONTALLY

LEFT S IDE DOWN ................................... 27

WITH

ELECTRICAL CONNECTIONS ............................... 28

WIRING HARNESS .............................................. 28

115 VOLT LINE CONNECTIONS .................................. 28

UNCTION BOX RELOCATION ..................................... 28

J 24 V

OLT THERMOSTAT WIRING .................................. 29

SINGLE-STA GE HEATING THERMOSTAT A PPLICATION ................. 30

OLT DEHUMIDISTAT WIRING ................................. 30

24 V F

OSSIL FUEL A PPLICATIONS ...................................... 31

LINE VOLTAGE ACCESSORIES

(ELECTRONIC AIR CLEANER AND HUMIDIFIER) ................ 31

24 VOLT HUMIDIFIER ........................................... 31

GAS SUPPLY AND PIPING .......................................... 31

HIGH A LTITUDE DERATE ......................................... 32

PROPANE G AS C ONVERSION ...................................... 32

GAS PIPING C ONNECTIONS ....................................... 32

PROPANE GAS TANKS AND PIPING ................................ 35

CIRCULATING A IR & FILTERS ....................................... 36

DUCT WORK - AIR FLOW ....................................... 36

CHECKING DUCT STATIC ......................................... 36

BOTTOM RETURN AIR OPENING [UPFLOW MODELS] ............... 37

FILTERS - READ THIS SECTION BEFORE INSTALLING

THE RETURN A IR DUCT WORK ............................. 37

UPRIGHT INSTALLATIONS ......................................... 38

HORIZONTAL INSTALLATIONS ...................................... 38

STARTUP PROCEDURE & ADJUSTMENT ................... 38

HEATING OPERATION WITH CTK01 THERMOSTAT (COMMUNICATING).39 HEATING OPERATION WITH CTK02**, CTK03** & CTK04**

THERMOSTAT (MODULATING COMMUNICATING) ................ 40

CONDENSATE DRAIN T RAP PRIMING ............................... 40

FURNACE OPERATION ........................................... 40

GAS SUPPLY PRESSURE M EASUREMENT ............................ 41

GAS MANIFOLD PRESSURE MEASUREMENT ......................... 42

GAS INPUT RAT E M EASUREMENT (NATURAL GAS O NLY) ............ 42

TEMPERATURE RISE ............................................. 43

CIRCULATOR BLOWER SPEEDS .................................... 44

BLOWER HEAT OFF DELAY TIMINGS .............................. 45

OMFORTNET™ SYSTEM ........................................ 45

C O

VERVIEW .................................................... 45

AIRFLOW CONSIDERATIONS ....................................... 46

OSSIL FUEL A PPLICATIONS ...................................... 46

DIP SWITCHES ............................................... 47

CTK0* W

OMFORTNET™ SYSTEM ADVANCED FEATURES ..................... 48

C N

ETWORK TROUBLESHOOTING .................................... 49

IRING .............................................. 48

SYSTEM TROUBLESHOOTING ...................................... 49

AULT RECALL SEQUENCE ....................................... 49

F F

AULT CLEAR SEQUENCE:....................................... 50

NORMAL SEQUENCE OF OPERATION ...................... 50

OWER UP .................................................... 50

P H

EATING MODE ................................................ 50

COOLING MODE ............................................... 50

AN ONLY MODE .............................................. 51

F O

PERATIONAL CHECKS .......................................... 51

SAFETY CIRCUIT DESCRIPTION .................................... 51

FURNACE CONTROL B OARD ...................................... 51

PRIMARY LIMIT ................................................. 51

AUXILIARY LIMIT ................................................ 51

ROLLOUT LIMIT ................................................ 52

PRESSURE SWITCHES ............................................ 52

FLAME SENSOR ................................................ 52

TROUBLESHOOTING ........................................ 52

ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS ................... 52

DIAGNOSTIC CHART ............................................. 52

RESETTING FROM LOCKOUT ..................................... 52

MAINTENANCE ............................................... 53

ANNUAL INSPECTION ............................................ 53

FILTERS ....................................................... 53

BURNERS ...................................................... 53

INDUCED DRAFT AND CIRCULATOR BLOWERS ....................... 54

CONDENSATE TRAP AND DRAIN SYSTEM (QUALIFIED SERVICER ONLY)54

FLAME SENSOR (QUALIFIED SERVICER ONLY) ..................... 54

BEFORE LEAVING AN INSTALLATION ...................... 54

REPAIR AND REPLACEMENT PARTS........................ 54

TROUBLESHOOTING CODES ............................... 55

WIRING DIAGRAM ........................................... 61

SPECIAL INSTRUCTIONS FOR PRODUCTS INSTALLED

IN THE STATE OF MASSACHUSETTS ................... 62

OODMAN WILL NOT BE RESPONSIBLE FOR ANY INJURY OR PROPERTY DAMAGE ARISING FROM IMPROPER SERVICE OR SERVICE PROCEDURES

INSTALL OR PERFORM SERVICE ON THIS UNIT, YOU ASSUME RESPONSIBILITY FOR ANY PERSONAL INJURY OR PROPERTY DAMAGE WHICH MAY RESULT

ANY JURISDICTIONS REQUIRE A LICENSE TO INSTALL OR SERVICE HEATING AND AIR CONDITIONING EQUIPMENT

WARNING

. IF

YOU

SAFETY CONSIDERATIONS

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

This furnace is manufactured for use with natural gas. It may be field converted to operate on L.P. gas by using the

appropriate L.P. conversion kit listed in the PROPANE GAS/ HIGH ALTITUDE INST ALLATIONS section of this manual

Install this furnace only in a location and position as speci-

fied in LOCA TION REQUIREMENTS & CONSIDERATIONS sec- tion and INSTALLATION POSITIONS section of this manual.

Provide adequate combustion and ventilation air to the

furnace as specified in COMBUSTION & VENTILATION AIR

REQUIREMENTS section of this manual.

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

specified in VENT/FLUE PIPE & COMBUSTION AIR PIPE

section of this manual.

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

in GAS SUPPLY AND PIPING section of this manual.

Always install a furnace to operate within the furnace’s intended temperature-rise range with a duct system which has external static pressure within the allowable range,

as specified on the furnace rating plate and OPERATIONAL CHECKS section of these instructions.

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

A gas-fired furnace for installation in a residential garage

must be installed as specified in the LOCATION REQUIRE- MENTS AND CONSIDERATIONS section of this manual.

This furnace may be used as a construction site heater only if certain conditions are met. These conditions are

listed in the PRODUCT APPLICATION section of this manual.

WARNING

PREVENT PERSONAL INJURY OR DEATH DUE TO IMPROPER INSTALLATION, ADJUSTMENT, ALTERA TI ON, SERVICE OR MAINTENANCE REFER TO THIS MANUAL INFORMATIO N, CONSULT A QUALIFIED INSTALLER, SERVICER AGENCY OR THE GAS SUPPLIER

. FOR

ADDITIONAL ASSISTANCE OR

WARNING

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

PERSONAL INJURY OR LOSS OF LIFE

NOT STORE OR USE GASOLINE OR OTHER FLAMMABLE VAPORS AND

LIQUIDS IN THE VICINITY OF THIS OR ANY OTHER APPLIANCE

WHAT TO DO IF YOU SMELL GAS:

O NOT TRY TO LIGHT ANY APPLIANCE



O NOT TOUCH ANY ELECTRICAL SWITCH; DO NOT USE ANY PHONE



IN YOUR BUILDING

MMEDIATELY CALL YOUR GAS SUPPLIER FROM A NEIGHBOR’S



PHONE

. F

F YOU CANNOT REACH YOUR GAS SUPPLIER, CALL THE FIRE



DEPARTMENT

NSTALLATION AND SERVICE MUST BE PERFORMED BY A QUALIFIED

INSTALLER, SERVICE AGENCY OR THE GAS SUPPLIER

OLLOW THE GAS SUPPLIER’S INSTRUCTIONS

WARNING

HIS PRODUCT CONTAI NS OR PRODUCES A CHEMICAL OR CHEMICALS WHICH MAY CAUSE SERIOUS ILLNESS OR DEATH AND WHICH ARE KNOWN TO THE STATE OF CALIFORNIA TO CAUSE CANCER, BIRTH DEFECTS OR OTHER REPRODUCTIVE HARM

WARNING

EATING UNIT SHOULD NOT BE UTILIZED WITHOUT REASONABLE ROUT INE, INSPECTION, MAINTENANCE AND SUPERVISION BUILDING IN WHICH ANY SUCH DEVICE IS LOCATED WILL BE VACAN T CARE SHOULD BE TAKEN THAT SUCH DEVICE IS ROUT INELY INSPECTED MAINTAINED AND MONITORED. IN THE EVENT THAT THE BUILDING MAYBE EXPOSED TO FREEZING TEMPERATURES AND WILL BE VACAN T ALL WATER-BEARING PIPES SHOULD BE DRAINED, THE BUILDING SHOULD BE PROPERLY WINTERIZED, AND THE WATER SOURCE CLOSED. IN THE EVENT THAT THE BUILDING MAY BE EXPOSED TO FREEZING TEMPERATURES AND WILL BE VACAN T, ANY HYDRONIC COIL UNITS SHOULD BE DRAINED AS WELL AND, IN SUCH CASE, ALTERNATIVE HEAT SOURCES SHOULD BE UTILIZED

. IF

THE

CAUTION

FROZE N AND BURS T WATER PIPE HAZ AR D

AILURE TO PROTECT AGAINST THE RISK OF FREEZING MAY RESULT IN

PROPERTY DAMAGE

PECIAL PRECAUTIONS

AREA WHICH MAY DROP BELOW FREEZING OPERATION OR DAMAGE TO EQUIPMENT ENVIRONMENT HAS THE POTENTIAL OF FREEZING, THE DRAIN TRAP AND DRAIN LINE MUST BE PROTECTED HEATERS, ELECTRIC HEAT TAPE AND/OR RECOMMENDED FOR THESE INSTALLATIONS

MUST BE

MADE IF INSTALLING FURNACE IN AN

. T

HIS CAN CAUSE IMPROPER

. IF

THE FURNACE

. THE

USE OF ACCESSORY DRAIN TRAP

ANTIFREEZE IS

WARNING

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

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

Advertenci a e spe cia l p ara la instalación de cale nt ad o res ó manejadoras de aire en áreas cerradas como esta cionamientos ó cuartos de servicio .

RISQUE D'E MPO ISO N NEM EN T AU

MONOXYDE DE CARBONE

Las emis ion es de monóxido de carbono pueden circ ula r a través del aparat o c uando se opera en cualquier modo.

CO can cause serious illness including permanent brain damag e or death.

B10259-216

El monóx i do de carbono puede causar enfermedades severas como daño cerebral permanente ó muerte.

WARNING

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

B10259-216

HOULD OVERHEAT ING OCCUR OR THE GAS SUPPLY FAIL TO SHUT OFF TURN OFF THE MANUAL GAS SHUTOFF VALVE EXTERNAL TO THE FURNACE BEFORE TURNING OFF THE ELECTRICAL SUPPLY

Cett e v entilation est nécessaire pour éviter le danger d'int oxication au CO pouvant survenir si un appareil produisant du monoxyde de carbon e continue de fonction ne r au sein de la zone confiné e .

Le monoxyde de des

dommages permanents au cerveau et meme la mort.

carbone peut causer des maladies graves telles que

B10259-216

WARNING

SHIPPING INSPECTION

All units are securely packed in shipping containers tested according to International Safe Transit Association specifications. The carton must be checked upon arrival for external damage. If damage is found, a request for inspection by carrier’s agent must be made in writing immediately.

The furnace must be carefully inspected on arrival for damage and bolts or screws which may have come loose in transit. In the event of damage the consignee should:

1. Make a notation on delivery receipt of any visible damage to shipment or container.

2. Notify carrier promptly and request an inspection.

3. With concealed damage, carrier must be notified as soon as possible - preferably within five days.

4. File the claim with the following support documents within a nine month statute of limitations.

• Original or certified copy of the Bill of Lading, or indemnity bond.

• Original paid freight bill or indemnity in lieu thereof.

• Original or certified copy of the invoice, showing trade and other discounts or reductions.

• Copy of the inspection report issued by carrier’s representative at the time damage is reported to carrier.

The carrier is responsible for making prompt inspection of damage and for a thorough investigation of each claim. The distributor or manufacturer will not accept claims from dealers for transportation damage.

ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS

NOTE: Discharge your body’s static electricity before touching unit. An electrostatic discharge can adversely affect electrical

components.

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

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

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

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

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

TO THE INSTALLER

Before installing this unit, please read this manual thoroughly to familiarize yourself with specific items which must be adhered to, including but not limited to: unit maximum external static pressure, gas pressures, BTU input rating, proper electrical connections,

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

WARNING

circulating air temperature rise, minimum or maximum CFM, and motor speed connections.

RODUCT DESCRIPTION

FEATURES

This furnace is a part of the ComfortNet™ family of products. The CTK family of thermostat kits allow this furnace to be installed as part of a digitally communicating system. The ComfortNet system provides automatic airflow configuration, enhanced setup features, and enhanced diagnostics. It also reduces the number of thermostat wires to a maximum of four. It may be also installed as part of a non-communicating system using a standard 24 VAC thermostat.

This product may be installed with the ComfortNet thermostat and a non-ComfortNet compatible single stage air conditioning unit. However, this reduces the benefits of the ComfortNet system as the enhancements will only apply to the furnace.

The modulating furnace operation is based off of negative pressure created by the draft inducer. The furnace control board receives commands from the room thermostat. The furnace control board then controls the RPM of the (3 phase) inducer by varying the frequency and voltage to the inducer. This is known as variable frequency drive (VFD). The inducer, pressure switches, and gas valve are linked by pneumatic tubing. The gas valve modulates based on this negative pressure.

30 13

Both Sides

UPFLOW/HORIZONTAL

Figure 1

14 3

9 12

27 23

COUNTERFLOW/HORIZONTAL

Figure 2

1 Gas Valve 17 Electrical Connection Inlets (Alternate) 2 Gas Line Entrance (Alternate) 18 Coil Front Cover Pressure Tap 3 Pressure Switch(es) 19 Coil Front Cover Drain Port 4 Gas Manifold 20 Drain Line Penetrations 5 Combustion Air Intake Connection 21 Drain Trap 6 Hot Surface Igniter 22 Blower Door Interlock Switch 7 Rollout Limit 23 Inductor (Not All Models) 8 Burners 24 Integrated Control Module

(with fuse and diagnostic LED)

9 Flame Sensor 25 24 Volt Thermostat Connections 10 Flue Pipe Connection 26 Transformer (40 VA) 11 Flue Pipe 27 ECM Variable Speed Circulator Blower 12 Primary Limit 28 Auxiliary Limit 13 Gas Line Entrance 29 Junction Box 14 Flue Pipe Connection (Alternate) NK 30 Electrical Connection Inlets 15 Rubber Elbow 31 Coil Front Cover 16 Variable-Speed Induced Draft Blower 32 "H" Fitting

RODUCT APPLICATION

This furnace is primarily designed for residential home-heating applications. It is NOT designed or certified for use in mobile homes,

trailers or recreational vehicles. Neither is it designed or certified for outdoor applications. The furnace must be installed indoors

(i.e., attic space, crawl space, or garage area provided the garage area is enclosed with an operating door).

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

Schools, Office buildings, Churches, Retail stores,

Nursing homes, Hotels/motels, Common or office areas

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

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

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

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

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

This product is dual certified. Dual certification means that the combustion air inlet pipe is OPTIONAL and the furnace can be vented as a:

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

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

• All other warranty exclusions and restrictions apply This furnace is an ETL dual-certified appliance and is appropriate for use

with natural or propane gas (NOTE: If using propane, a propane conversion kit is required).

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

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

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

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

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

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

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

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

NOTE: Do not connect the temporary duct directly to the furnace. The duct must be sized for adequate combustion and

ventilation in accordance with the latest edition of the National Fuel Gas Code NFPA 54/ANSI Z223.1 or CAN/CSA B149.1

Installation Codes.

• The furnace heat exchanger, components, duct system, air filters and evaporator coils are thoroughly cleaned following final

construction clean up.

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

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

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

• A T-handle gas cock must be used.

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

To ensure proper furnace operation, install, operate and maintain the furnace in accordance with these installation and operation instructions, all local building codes and ordinances. In their absence, follow the latest edition of the National Fuel Gas

Code (NFPA 54/ANSI Z223.1), and/or CAN/CSA B149.1 Installation Codes, local plumbing or waste water codes, and other applicable codes.

A copy of the National Fuel Gas Code (NFPA 54/ANSI Z223.1) can be obtained from any of the following:

American National Standards Institute National Fire Protection Association CSA International

25 West 43rd Street, 4th Floor 1 Batterymarch Park 8501 East Pleasant Valley

New York, NY 10036 Quincy, MA 02169-7471 Independence, OH 44131

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

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

CSA International

178 Rexdale Boulevard

Etobicoke, Ontario, Canada M9W 1R3

OCA TION REQUIREMENTS

& C

ONSIDERA TIONS

Follow the instructions listed below and the guidelines provided in the Combustion and Ventilation Air Requirements section when

selecting a furnace location.

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

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

• Provide provisions for venting combustion products outdoors through a proper venting system. Special consideration should be given to vent/flue pipe routing and combustion air intake

PREVENT POSSIBLE EQUIPM EN T DAMAGE, PROPERTY DAMAGE PERSONAL INJURY OR DEATH, THE FOLLOWING BULLET POINTS MUST BE OBSERVED WHEN INSTALLING THIS UNIT

WARNING

pipe when applicable. Refer to V ent/Flue Pipe and Combustion Air Pipe -T ermination Locations for appropriate termination

locations and to determine if the piping system from furnace to termination can be accomplished within the guidelines

given. NOTE: The length of flue and/or combustion air piping

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

• Locate the furnace so condensate flows downwards to the

WARNING

drain. Do not locate the furnace or its condensate drainage

system in any area subject to below freezing temperatures without proper freeze protection. Refer to Condensate Drain Lines and T rap for further details.

• Ensure adequate combustion air is available for the furnace. Improper or insufficient combustion air can expose building

occupants to gas combustion products that could include carbon monoxide. Refer to Combustion and Ventilation Air

Requirements.

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

Horizontal Applications and Considerations for leveling of horizontal furnaces.

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

• A special accessory subbase must be used for upright counterflow unit installations over any combustible material (including

wood). Refer to subbase instructions for installation details. (NOTE: A subbase will not be required if an air conditioning coil

is located beneath the furnace between the supply air opening and the combustible floor.

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

permanent wave solutions chlorinated waxes or cleaners chlorine-based swimming pool chemicals water softening chemicals deicing salts or chemicals carbon tetrachloride halogen type refrigerants cleaning solutions (such as perchloroethylene) printing inks paint removers varnishes hydrochloric acid cements and glues antistatic fabric softeners for clothes dryers

and masonry acid washing materials

• Isolate a non-direct furnace from an area contaminated by any of the above substances. This protects the non- direct vent furnace from airborne contaminants. To ensure that the enclosed non-direct vent furnace has an adequate

supply of combustion air, air must be ducted in from a nearby uncontaminated room or from outdoors. Refer to the

Combustion and V entilation Air Requirements for details.

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

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

width as the furnace or may be one size larger than the furnace. Example: a “C” width coil may be installed with

a “B” width furnace.

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

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

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

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

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

• Counterflow Installation over a noncombustible floor. Before setting the furnace over the plenum opening, ensure the

surface around the opening is smooth and level. A tight seal should be made between the furnace base and floor by using a silicone rubber caulking compound or cement grout.

• Counterflow Installation over a combustible floor . If installation over a combustible floor becomes necessary, use an accessory

subbase (see Specification Sheet applicable for your model for details.) A special accessory subbase must be used for upright counterflow unit installations over any combustible material including wood. Refer to subbase instructions for installation details. Follow the instructions with the subbase for proper installation. Do not install the furnace directly on carpeting, tile,

or other combustible material other than wood flooring. (NOTE: The subbase will not be required if an air conditioning coil

is installed between the supply air opening on the furnace and the floor.)

CLEARANCES AND ACCESSIBILITY

NOTES:

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

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

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

greater.

*MVM97* MINIMUM CLEARANCES TO COMBUSTIBLE MATERIALS

(INCHES)

POSITION* FRONT SIDES REAR TOP FLUE FLOOR

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

Horizont al Alco ve 6" 0" 4" 0" C

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

NOTES:

ible fl

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

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

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

*CVM97* MINIMUM CLEARANCES TO COMBUSTIBLE MATERIALS

(INCHES)

POSITION* SIDES REAR FRONT BOTTOM FLUE TOP

Counterflow0"0"3"NC0"1"

Hor izontal 6" 0" 3" C 0" 6"

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

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

e used for inst allations on combust

ooring.

Installations must adhere to the clearances to combustible materials to which this furnace has been design certified. The minimum

TOP

clearance information for this furnace is provided on the unit’s clearance label. These clearances must be permanently maintained.

SIDE SIDE SIDE

Clearances must also accommodate an installation’s gas, electrical, and drain trap and drain line connections.

NOTE: In addition to the required clearances to combustible mate-

rials, a minimum of 24 inches service clearance must be available

BOTTOM

Upflow Cou nterflow Horizontal

BOTTOM

in front of the unit.

Figure 3

EXISTING FURNACE REMOVAL

NOTE: When an existing furnace is removed from a venting system serving other appliances, the venting system may be too large to

properly vent the remaining attached appliances.

The following vent testing procedure is reproduced from the American National Standard/National Standard of Canada for

Gas-Fired Central Furnaces ANSI Z21.4, CSA-2.3 latest edition Section 1.23.1.

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

1. Seal any unused openings in the venting system;

2. Inspect the venting system for proper size and horizontal pitch, as required by the National Fuel Gas Code, ANSI Z223.1 or the Natural Gas and Propane Installation Code, CSA B149.1-05 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 shall operate at maximum speed. Do not operate a summer exhaust fan.

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

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

8. If improper venting is observed during any of the above tests, the venting system must be corrected in accordance with the National Fuel Gas Code ANSI Z223.1/NFPA 54 and/or National Gas and Propane Installation Code CSA B149.1-05.

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

If resizing is required on any portion of the venting system, use the appropriate table in Appendix G in the latest edition of the National Fuel Gas Code ANSI Z223.1 and/or CSA B149.1-05 Installation Codes.

THERMOSTAT LOCATION

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

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

• Hot or cold air from registers.

• Radiant heat from the sun.

• Light fixtures or other appliances.

• Radiant heat from a fireplace.

• Concealed hot or cold water pipes, or chimneys.

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

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

OMBUSTION

& V

ENTILATION AIR REQUIREMENTS

Improved construction and additional insulation in buildings have

WARNING

reduced heat loss by reducing air infiltration and escape around doors and windows. These changes have helped in reducing heating/cooling costs but have created a problem supplying combustion and ventilation air for gas fired and other fuel burning appliances. Appliances that pull air out of the house (clothes dryers,

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

. M

OST HOMES REQUIRE OUTSIDE AIR BE

exhaust fans, fireplaces, etc.) increase the problem by starving appliances of air.

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

When the furnace is installed as a direct vent (2-pipe system) furnace, no special provisions for air for combustion are required. However, if this furnace is to be installed in the same space with other gas appliances, such as a water heater, ensure there is an adequate supply of combustion and ventilation air for the other appliances. Refer to the latest edition of the National Fuel Gas Code NFPA 54/ANSI Z223.1 or CAN/CSA B149 Installation Codes or applicable provisions of the local building codes for determining the combustion air requirements for the appliances.

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

The following information on air for combustion and ventilation is reproduced from the National Fuel Gas Code NFP A 54/ANSI Z223.1 Section 9.3.

9.3* Air for Combustion and Ventilation.

9.3.1 General.

9.3.1.1 Air for combustion, ventilation, and dilution of flue gases for appliances installed in buildings shall be obtained by application of one of the

methods covered in 9.3.2 through 9.3.6. Where the requirements of 9.3.2 are not met, outdoor air shall be introduced in accordance with methods covered in 9.3.3 through 9.3.6.

Exception No. 1: This provision shall not apply to direct vent appliances.

9.3.1.2 Appliances of other than natural draft design and other than Category 1 vented appliances shall be provided with combustion, ventilation, and dilution air in accordance with the appliance manufacturer’s instructions.

9.3.1.3 Appliances shall be located so as not to interfere with proper circulation of combustion, ventilation, and dilution air.

9.3.1.4 Where used, a draft hood or a barometric draft regulator shall be installed in the same room or enclosure as the appliance served so as to prevent

any difference in pressure between the hood or regulator and the combustion air supply.

9.3.1.5 Makeup air requirements for the operation of exhaust fans, kitchen ventilation systems, clothes dryers, and fireplaces shall be considered in determining the adequacy of a space to provide combustion air requirements.

9.3.2 Indoor Combustion Air. The required volume of indoor air shall be determined in accordance with the method in 9.3.2.1 or 9.3.2.2 except that where the air infiltration rate is known to be less than 0.40 ACH, the method in 9.3.2.2 shall be used. The total required volume shall be the sum of the required volume calculated for all appliances located within the space. Rooms communicating directly with the space in which the appliances are installed through openings not furnished with doors, and through combustion air openings sized and located in accordance with 9.3.2.3, are considered a part of the required volume.

9.3.2.1* Standard Method. The minimum required volume shall be 50 ft

9.3.2.2* Known Air Infiltration Rate Method. Where the air infiltration rate of a structure is known, the minimum required volume shall be determined

as follows: (1) For appliances other than fan-assisted, calculate using the following equation:

Required Volume

> ________ _________

other

21 ft

ACH 1000 Btu/hr

other

(

)

per 1,000/Btu/hour (4.8m3/kW).

(2) For fan-assisted appliances, calculate using the following equation:

Required Volume

where:

I I ACH = air change per hour (percent of volume of space exchanged per hour, expressed as a decimal)

(3) For purposes of this calculation, an infiltration rate greater than 0.60 ACH shall not be used in the equations in 9.3.2.2(1) and 9.3.2.2(2).

9.3.2.3 Indoor Opening Size and Location. Openings used to connect indoor spaces shall be sized and located in accordance with the following:

(1)*Combining spaces on the same story. Each opening shall have a minimum

(2) Combining spaces in different stories. The volumes of spaces in different

= all appliances other than fan-assisted input in Btu per hour

other

= fan-assisted appliances input in Btu per hour

fan

free area of 1 in. all appliances in the space but not less than 100 in.2 (0.60m2). One opening shall commence within 12 in. (300 mm) of the top, and one opening shall commence within 12 in. (300 mm) of the bottom, of the enclosure [see Figure A.9.3.2.3(1)]. The minimum dimension of air openings shall be not less than 3 in. (80 mm).

stories shall be considered as communicating spaces where such spaces are connected by one or more openings in doors or floors having a total minimum free area of 2 in.2/1000 Btu/hr (4400 mm2/kW) of total input rating of all appliances.

> ________ _________

fan

/1000Btu/hr (2200 mm2/kW) of the total input rating of

15 ft

ACH 1000 Btu/hr

fan

)(

9.3.3 Outdoor Combustion Air. Outdoor combustion air shall be provided through opening(s) to the outdoors in accordance with the methods in 9.3.3.1 or 9.3.3.2. The minimum dimension of air openings shall not be less than 3 in. (80 mm).

9.3.3.1 T wo Permanent Openings Method. Two permanent openings, one commencing within 12 in. (300 mm) of the top and one commencing within 12 in. (300 mm) of the bottom, of the enclosure shall be provided. The openings shall communicate directly , or by ducts, with the outdoors or spaces that freely communicate with the outdoors, as follows:

Figure A.9.2.3.3.(1) All Combustion Air from Adjacent

Indoor Spaces through Indoor Combustion Air Openings.

(1)*Where directly communicating with the outdoors or where communicating to the outdoors through vertical ducts, each opening shall have a minimum

free area of 1 in.

/4000 Btu/hr (550 min2/kW) of total input rating of all appliances in the enclosure. [See Figure A.9.3.3.1(1)(a) and Figure

A.9.3.3.1(1)(b).]

Figure A.9.3.3.1(1)(a) All Combustion Air From Outdoors -

Inlet Air from Ventilated Crawl Space and Outlet Air to Ventilated Attic.

(2)* Where communicating with the outdoors through horizontal ducts, each

opening shall have a minimum free area of 1 in.2/2000 Btu/hr (1100 min2/ kW) of total input rating of all appliances in the enclosure. [See Figure

A.9.3.3.1(2).]

9.3.3.2* One Permanent Opening Method. One permanent openings, commencing within 12 in. (300 mm) of the top of the enclosure, shall be provided. The appliance shall have clearances of at least 1 in. (25 mm) from the sides and back and 6 in. (150 mm) from the front of the appliance. The opening shall directly communicate with the outdoors or shall communicate through a vertical or horizontal duct to the outdoors or spaces that freely communicate with the outdoors (see Figure A.9.3.3.2) and shall have a minimum free area of the following: (1) 1 in.

/3000 Btu/hr (700 mm2 per kW) of the total input rating of all appliances

located in the enclosure, and

(2) Not less than the sum of the areas of all vent connectors in the space.

Figure A.9.3.3.1(1)(b) All Combustion Air From Outdoors through Ventilated Attic.

Figure A.9.3.3.1(2) All Combustion Air From Outdoors

through Horizontal Ducts.

Figure A.9.3.3.2 All Combustion Air

From Outdoors through Single Combustion Air Opening.

9.3.4 Combination Indoor and Outdoor Combustion Air. The use of a combination of indoor and outdoor combustion air shall be in accordance with

(1) through (3) (see example calculation in Annex J]:

(1) Indoor Openings: Where used, openings connecting the interior spaces shall comply with 9.3.2.3. (2) Outdoor Opening(s) Location. Outdoor opening(s) shall be located in accordance with 9.3.3. (3) Outdoor Opening(s) Size. The outdoor opening(s) size shall be calculated in accordance with the following:

(a) The ratio of the interior spaces shall be the available volume of all communicating spaces divided by the required volume. (b) The outdoor size reduction factor shall be 1 minus the ratio of interior spaces. (c) The minimum size of outdoor opening(s) shall be the full size of outdoor opening(s) calculated in accordance with 9.3.3, multiplied by the

reduction factor. The minimum dimension of air openings shall not be less than 3 in. (80 mm).

9.3.5 Engineered Installations. Engineered combustion air installations shall provide an adequate supply of combustion, ventilation, and dilution air and shall be approved by the authority having jurisdiction.

9.3.6 Mechanical Combustion Air Supply. Where all combustion air is provided by a mechanical air supply system, the combustion air shall be supplied form outdoors at the minimum rate of 0.35 ft

/min per 1000 Btu/hr (0.034 m3/min per kW) for all appliances located within the space.

9.3.6.1 Where exhaust fans are installed, additional air shall be provided to replace the exhausted air .

9.3.6.2 Each of the appliances served shall be interlocked to the mechanical air supply system to prevent main burner operation where the mechanical air

supply system is not in operation.

9.3.6.3 Where combustion air is provided by the building’ s mechanical ventilation system, the system shall provide the specified combustion air rate in addition to the required ventilation air.

9.3.7 Louvers, Grilles, and Screens.

9.3.7.1 Louvers and Grilles. The required size of openings for combustion, ventilation, and dilution air shall be based on the net free area of each opening.

Where the free area through a design of louver or grille or screen is known, it shall be used in calculating the size opening required to provide the free area specified. Where the louver and grille design and free area are not known, it shall be assumed that wood louvers will have 25 percent free area, and metal louvers and grilles will have 75 percent free area. Nonmotorized louvers and grilles shall be fixed in the open position.

9.3.7.2 Minimum Scree Mesh Size. Screens shall not be smaller than 1/4 in. mesh.

9.3.7.3 Motorized Louvers. Motorized louvers shall be interlocked with the appliance so they are proven in the full open position prior to main burner

ignition and during main burner operation. Means shall be provided to prevent the main burner form igniting should the louver fail to open during burner startup and to shut down the main burner if the louvers close during burner operation.

9.3.8 Combustion Air Ducts. Combustion air ducts shall comply with 9.3.8.1 through 9.3.8.8.

9.3.8.1 Ducts shall be constructed of galvanized steel or a material having equivalent corrosion resistance, strength, and rigidity .

Exception: Within dwellings units, unobstructed stud and joist spaces shall not be pr ohibited from conveying combustion air, provided that not more than one fireblock is removed.

9.3.8.2 Ducts shall terminate in an unobstructed space, allowing free movement of combustion air to the appliances.

9.3.8.3 Ducts shall serve a single space.

9.3.8.4 Ducts shall not serve both upper and lower combustion air openings where both such openings are used. The separation between ducts servicing

upper and lower combustion air openings shall be maintained to the source of combustion air.

9.3.8.5 Ducts shall not be screened where terminating in an attic space.

9.3.8.6 Horizontal upper combustion air ducts shall not slope downward toward the source of combustion air.

9.3.8.7 The remaining space surrounding a chimney liner, gas vent, special gas vent, or plastic piping installed within a masonry, metal, or factory built

chimney shall not be used to supply combustion air.

Exception: Direct vent appliances designed for installation in a solid fuel-burning fireplace where installed in accordance with the manufacture’s installation instructions.

9.3.8.8 Combustion air intake openings located on the exterior of the building shall have the lowest side of the combustion air intake openings located at least 12 in. (300 mm) vertically from the adjoining grade level.

NST ALLATION POSITIONS

A/GMVM97 models may be installed upflow or horizontally with left or right side down. A/GCVM97 models may be installed downflow or horizontally with left or right side down.

Do not install this furnace on its back. For upright upflow furnaces, return air ductwork may be attached to the side panel(s) and/ or basepan. For horizontal upflow furnaces, return air ductwork must be attached to the basepan. For both upright or horizontal

counterflow furnaces, return ductwork must be attached to the basepan (top end of the blower compartment). NOTE:

Ductwork

must never be attached to the back of the furnace. Refer to “Recommended Installation Positions” figure for appropriate installation positions, ductwork connections, and resulting airflow arrangements.

Figure 4B

Figure 4A

ORIZONT AL APPLICA TIONS

& C

ONSIDERA TIONS

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

FURNACE SUSPENSION

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

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

Recommended Installation Positions

2" 2" 3/8"

PLACES

ANGLE IRON

)

Figure 4C

Figure 5

FRONT COVER PRESSURE SWITCH TUBE LOCATION

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

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

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

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

4. Install one end on front cover pressure switch.

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

DRAIN T RAP AND LINES

In horizontal applications the condensate drain trap is secured to the furnace side panel, suspending it below the furnace. A minimum clearance of 5 1/2 inches below the furnace must be provided for the drain trap. Additionally, the appropriate downward piping slope

must be maintained from the drain trap to the drain location. Refer to Condensate Drain T rap and Lines for further details. If the drain

trap and drain line will be exposed to temperatures near or below freezing, adequate measures must be taken to prevent condensate from freezing.

LEVELING

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

ALTERNATE ELECTRICAL AND GAS LINE CONNECTIONS

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

DRAIN PAN

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

FREEZE PROTECTION

Refer to Horizontal Applications and Conditions - Drain T rap and Lines.

ROP ANE GAS/HIGH ALTITUDE INST ALLATIONS

WARNING

This furnace is shipped from the factory configured for natural gas up to 10,000 ft. altitude. Propane conversions require the proper LP kit to compensate for the energy content difference between natural and propane gas.

For furnaces being converted to LP gas, it is strongly recommended that a LPLP03 kit also be installed. The use of this kit will prevent the furnace from firing when the LP gas supply pressure is too low to support proper combustion.

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

OSSIBLE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH MAY OCCUR IF THE CORRECT CONVERSION KITS ARE NOT INSTALLED APPROPRIATE KITS MUST BE APPLIED TO ENSURE SAFE AND PROPER FURNACE OPERATION QUALIFIED INSTALLER OR SERVICE AGENCY

Altitude Kit

Natural None #45

0-10,000

Propane LPM-09 1.25MM

. ALL

CONVERSIONS MUST BE PERFORMED BY A

Manifold Pressure

OrificeGas

High

Stage

3.5" w.c. 1" w.c. None

10.0" w.c. 2.6" w.c. None

Low Stage (50% firing

. THE

Pressure

rate)

Switch Change

In Canada, ga s furnaces are only certified to 4500 feet.

NOTE:

ENT/FLUE PIPE

& C

OMBUSTION AIR PIPE

WARNING

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

AILURE TO FOLLOW THESE INSTRUCTIO N S CAN RESU LT IN BODILY INJURY OR DEATH GIVEN IN THIS SECTION

. C

AREFULLY READ AND FOLLOW ALL INSTRUCTIONS

cause of the relatively low flue gas temperature and water condensation requirements, PVC or ABS pipe is used as venting material.

In addition to PVC and ABS pipe and fittings, Innoflue

by Centrotherm Eco Systems and PolyPro® by M&G Duravent are also approved vent and combustion air materials for installations in the U.S.A. and Canada. Manufacturers Installation instructions for these products must be followed. These products have specific instructions for installing, joining and terminat-

PON COMPLETION OF THE FURNACE INSTALLATION, CAREFULLY INSPECT THE ENTIRE FLUE SYSTEM BOTH INSIDE AND OUTSIDE OF THE FURNACE TO ASSURE IT IS PROPERLY SEALED SYSTEM CAN RESU LT IN SERIOUS PERSONAL INJURY OR DEATH DUE TO EXPOSURE TO FLUE PRODUCTS, INCLUDING CARBON MONOXIDE

WARNING

. L

EAKS IN THE FLUE

ing. Do not mix materials or components of one manufacturer with materials or components of another manufacturer.

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

This furnace must not be connected to Type B, BW, or L vent or vent connector, and must not be vented into any portion of a factory built or masonry chimney except when used as a pathway for PVC as described later in this section. Never common vent this appliance with another appliance or use a vent which is used by a solid fuel appliance.

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

DUAL CERTIFICATION: NON-DIRECT/DIRECT VENT

This furnace is dual certified and may be installed as a non-direct

vent (single pipe) or direct vent (dual pipe) appliance. A non-direct vent installation requires only a vent/flue pipe, while a direct vent

installation requires both a vent/flue pipe and a combustion air intake pipe. Refer to the appropriate section for details concerning piping size, length, number of elbows, furnace connections, and terminations.

AVOID BODILY INJURY, FIRE OR EXPLOSION, SOLVENT CEMENTS MUST BE KEPT AWAY FROM ALL IGNITION SOURCES (I.E FLAMES, AND EXCESSIVE HEAT) AS THEY ARE COMBUSTIBLE LIQUIDS

VOID BREATHING CEMENT VAPO RS OR CONTA CT WITH SKIN AND/OR

EYES

WARNING

SPARKS, OPEN

MATERIALS AND JOINING METHODS

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

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

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

As an alternative to PVC pipe, primer, solvent cement, and fittings, ABS materials which are in compliance with the following specifications may be used: Two-or-three-inch solid wall ABS Schedule 40 pipe must meet ASTM D1527 and, if used in Canada, must be CSA listed or, two-or-three-inch cellular core ABS Schedule 40 pipe must meet ASTM F628 and, if used in Canada, must be CSA listed. Solvent cement for ABS to ABS joints must meet ASTM D2235 and, if used in Canada, must be CSA listed. The solvent cement for the PVC to ABS transition joint must meet ASTM D3138. Fittings must be DWV type fittings meeting ASTM D2661 and ASTM D3311 and, if used in Canada, must be CSA listed. Carefully follow the manufacturers’ instructions for cutting, cleaning, and solvent cementing PVC and/or ABS.

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

The use of two short radius 45 degree elbows is permitted to provide clearance to refrigerant piping above the furnace.

PROPER VENT/FLUE AND COMBUSTION AIR PIPING PRACTICES

Adhere to these instructions to ensure safe and proper furnace performance. The length, diameter, and number of elbows of the vent/flue pipe and combustion air pipe (when

PREFERRED

applicable) affects the performance of the furnace and must be carefully sized. All piping must be installed in accordance with local codes and these instructions.

Piping must be adequately secured and supported to prohibit sagging, joint separation, and/or detachment from the furnace. Horizontal runs of vent/flue and combustion air piping must be properly supported. PVC pipe supports must be no more than 5' apart. For ABS pipe, supports must be no more than 3' apart. Horizontal pipe runs must maintain a 1/4 inch per foot downward slope, back towards the furnace, to properly return condensate to the furnace’s drain system.

Precautions should be taken to prevent condensate from freezing inside the vent/flue pipe and/or at the vent/flue pipe termination. All vent/flue piping exposed to temperatures below 35°F for extended periods of time must be insulated with 1/2” thick closed cell foam. Also, all vent/flue piping exposed outdoors in excess of the termina-

Figure 6

tions shown in this manual (or in unheated areas) must be insulated with 1/2” thick closed cell foam. Inspect piping for leaks prior to installing insulation.

TERMINATION LOCATIONS

NOTE: Refer to Location Requirements and Considerations for combustion air

contaminant restrictions.

ACCEPT ABLE

TRANSITION NO LESS THAN 45 DEGREES TO HORIZONTAL PLANE T O AVO ID CREATING A W ATER TRAP IN VENT PIPING.

The following bullets and diagram describe the restrictions concerning the appropriate location of vent/flue pipe and combustion air intake pipe (when applicable) termina-

tions. Refer to Non-Direct V ent (Single Pipe) Piping and Direct Vent (Dual Pipe) Piping

located in this section for specific details on termination construction.

• All terminations (flue and/or intake) must be located at least 12 inches above

Figure 7

ground level or the anticipated snow level.

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

NOTE: This provision does not apply to the combustion air intake

termination of a direct vent application.

• The vent termination of a direct vent application must terminate

at least 12 inches from any opening through which flue gases may enter a building (door, window, or gravity air inlet).

• The vent termination running vertically through a roof must

NO TRANSITION ON HOR IZON TAL PLANE, THIS CREATES A WATER TRAP AND RESTRICTS FLUE GASES

terminate at least 12 inches above the roof line (or the anticipated snow level) and be at least 12 inches from any vertical wall (including any anticipated snow build up).

• A vent termination shall not terminate over public walkways or over an area where condensate or vapor could create a nuisance

Figure 8

or hazard or could be detrimental to the operation of regulators, relief valves, or other equipment.

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

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

DIRECT VENT TERMINAL CLEARANCES

A= Clearance above grade,

veranda, porch, deck or balcony. (See 1.24.6-i(9)b.)

B= Clearance to window or

door that may be opened.

C= Clearance to permanently

closed window.

D= Vertical clearance to ventilated soffit

located above the terminal within a horizontal distance of 2 feet (61 cm) from the center line of the terminal.

E= Clearance to unventilated sof fi t. * * F= Clearance to outside corner. * * G= Clearance to inside corner. * * H= Clearance to each side of cen te r

line exten ded ab o ve meter / regulator assembly.

Canadian Installations

12 in. (30 cm) 12 in. (30 cm)

6 in. (15 cm) for appliances 10,000 Btuh (3 kW), 12 in. (30 cm) for appliances > 10,000 Btuh (3 kW) and 100,000 Btuh (30 kW), 36 in. (91 cm) for appliances > 100,000 Btuh (30 kW).

3 ft. (91 cm) within a heig h t 15 ft. (4.5 m) above the meter/regulator assembly.

U.S. Installations

6 in. (15 cm) for appliances 10,000 Btuh (3 kW), 9 in. (23 cm) for appliances > 10,000 Btuh (3 kW) and 50,000 Btuh (15 kW), 12 in. (30 cm) for appliances > 500,000 Btuh (15 kW).

V X

I= Clearance to service

regulator vent outlet.

J= Clearance to nonmechanical air

supply inlet to building or the combustion air inlet to any other appliance.

K= Clearance to a mechanical

air supply inlet.

L= Clearance above paved sidewalk or

paved driveway located on public property.

M= Clearance under veranda, porch,

deck or balcony.

1 In accordance with the current CSA B149.1, Natural Gas and Propane Installation Code.

2 In accordance with the current ANSI Z223.1/NFPA 54, National Fuel Gas Code.

† A vent shall not terminate directly above a sidewalk or paved driveway that is located between two single family dwellings and serves

both dwellings.

‡ Permitted only if veranda, porch, deck or balcony is fully open on a minimum of two sides beneath the floor.

* For clearances not specified in ANSI Z223.1/NFPA 54 or CSA B149.1, the following statement shall be included:

“Clearance in accordance with local installation codes and the requirements of the gas supplier and the manufacturer’s installation instruction.”

Canadian Installations

3 ft. (91 cm). *

6 in. (15 cm) for appliances 10,000 Btuh (3 kW), 12 in. (30 cm) for appliances > 10,000 Btuh (3kW) and 100,000 Btuh (30 kW), 36 in. (91 cm) for appliances > 100,000 Btuh (30 kW).

6 ft. (1.83 m) 3 ft. (91 cm) above if within

7 ft. (2.13m) † *

12 in. (30 cm) ‡ *

U.S. Installations

6 in. (15 cm) for appliances 10,000 Btuh (3 kW), 9 in. (23 cm) for appliances > 10,000 Btuh (3kW) and 50,000 Btuh (15 kW), 12 in. (30 cm) for appliances > 50,000 Btuh (15 kW).

10 ft. (3 m) horiz ontally.

OTHER THAN DIRECT VENT TERMINAL CLEARANCES

A= Clearance above grade,

veranda, porch, deck or balcony. (See 1.24.6-i(9)b.)

B= Clearance to window or

door that may be opened.

C= Clearance to permanently

closed window.

D= Vertical clearance to ventilated soffit

located above the terminal within a horizontal distance of 2 feet (61 cm) from the center line of the terminal.

E= Clearance to unventilated soffit. * * F= Clearance to outside corner. * * G= Clearance to inside corner. * * H= Clearance to each side of center

line extended above meter/regulator assembly.

Canadian Installations

12 in. (30 cm) 12 in. ( 30 cm )

6 in. (15 cm) for appliances 10,000 Btuh (3 kW), 12 in. (30 cm) for appliances > 10,000 Btuh (3 kW) and 100,000 Btuh (30 kW), 36 in. (91 cm) for appliances > 100,000 Btuh (30 kW).

3 ft. (91 cm) within a height 15 ft. (4.5 m) above the meter/regulator assembly.

U.S. Installations

4 ft. (1.2 m) below or to side of opening; 1 ft. (300 m) above opening.

I= Clearance to sevice

regulator vent outlet.

J= Clearance to nonmechanical air

supply inlet to building or the combustion air inlet to any other appliance.

K= Clearance to a mechanical

air supply inlet.

L= Clearance above paved sidewalk or

paved driveway located on public property.

M= Clearance under veranda, porch,

deck or balcony.

1 In accordance with the current CSA B149.1, Natural Gas and Propane Installation Code.

2 In accordance with the current ANSI Z223.1/NFPA 54, National Fuel Gas Code.

† A vent shall not terminate directly above a sidewalk or paveable driveway that is located between two single family dwellings and serves

both dwelling.

‡ Permitted only if veranda, porch, deck or balcony is fully open on a minimum of two sides beneath the floor.

* For clearances not specified in ANSI Z223.1/NFPA 54 or CSA B149.1, the following statement shall be included:

“Clearance in accordance with local installation codes and the requirements of the gas supplier and the manufacturer’s installation instruction.”

Canadian Installations

3 ft. (91 cm). *

6 in. (15 cm) for appliances 10,000 Btuh (3 kW), 12 in. (30 cm) for appliances > 10,000 Btuh (3kW) and 100,000 Btuh (30 kW), 36 in. (91 cm) for appliances > 100,000 Btuh (30 kW).

6 ft. (1.83 m) 3 ft. (91 cm) above if within

7 ft. (2.13m) † 7 ft. (2.13m)

12 in. (30 cm) ‡ *

U.S. Installations

4 ft. (1.2 m) below or to side of opening; 1 ft. (300 m) above opening.

10 ft. (3 m) horizontally.

SPECIAL VENTING REQUIREMENTS FOR INSTALLATIONS IN CANADA

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

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

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

ment, etc.) before installation to determine the need to obtain a permit. *IPEX System 636™ is a trademark of IPEX Inc.

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

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

STANDARD FURNACE CONNECTIONS

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

VENT PIPE CONNECTION

The vent pipe outlet is sized to accept 2” pipe. Secure vent/flue pipe directly into the furnace fitting with the appropriate glue. Alternately, a small section of 2" pipe may be glued in the furnace socket and a rubber coupling installed to allow removal for future service. Combustion Air and Vent piping should be routed in a manner to avoid contact with refrigerant lines, metering devices, condensate drain lines, etc. If necessary, clearances may be increased by creating an offset using two 45 degree elbows. This joint can be rotated on the fitting to establish maximum clearance between refrigerant lines, metering devices, and condensate drain lines, etc. This joint is the equivalent of one 90 deg. elbow when considering elbow count.

COMBUSTION AIR PIPE

DIRECT VENT INSTALLATIONS

On upflow units secure the combustion air intake pipe to the air intake coupling by using a

take apart rubber coupling supplied with the furnace or a plastic coupling. Also, the intake coupling may be inverted to allow the intake pipe to be glued directly to it. After

inverting the coupling, secure it to the furnace top with screws. On counterflow units

secure the combustion air intake pipe to the air intake coupling using the rubber coupling and worm gear hose clamps provided with the unit. The counterflow rubber coupling allows service removal of air intake piping internal to the furnace blower compartment. The combustion air intake pipe can also be secured directly to the counterflow unit air intake pipe coupling.

45 DEGREE

ELBOWS

Increased Clearance

Figure 9A

VENT-DRAIN

COMBUSTION AIR INT AKE OPTION: The RF000142 coupling can be secured directly to the

furnace intake coupling if condensation is a concern. If the RF000142 is used on the combustion air inlet, it must be installed with the arrow pointing up. It should be noted, the combustion air will actually be moving in a direction opposite of the arrow on the RF000142 coupling. It must have a field supplied, trapped drain tube free-draining to proper condensate disposal location. A loop in the drain tube can serve as a trap. The unused RF000142 drain fitting should be capped.

NON-DIRECT VENT INSTALLATIONS

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

WARNING

DGES OF SHEET METAL HOLES MAY BE SHARP

PRECAUTION WHEN REMOVING HOLE PLUGS

Figure 9B

. USE

GLOVES AS A

ALTERNATE VENT/FLUE LOCATION

The alternate vent/flue location is the large hole directly in line with

the induced draft blower outlet. To use the alternate vent/flue location on an upflow / horizontal model, refer to the following steps and the “Alternate Vent/Flue Location” figure. To use an alternate vent location on a counterflow / horizontal model, a special kit is required.

NOTE: In the horizontal left installation position, a means of

condensate collection must be provided to keep vent pipe condensate from entering the draft inducer housing. If the ventdrain elbow is eliminated from the installation; an RF000142 kit must be used.

1. Remove screws from vent flange.

2. Remove internal elbow and vent pipe.

3. Cut pipe 2 1/2” from flange.

4. Remove cabinet plug adjacent to inducer outlet and install an original cabinet vent hole.

5. Install RF000142 coupling on inducer outlet.

6. Install flanged vent section removed in step 2 & secure with clamps.

7. Secure flange to cabinet using screws removed in step 1.

R 000142F

ALTERNATE COMBUSTION AIR PROVISION

(Upflow / Horizontal models only)

Insert flange. Cut 2 ½” long.

Figure 10

E R E H

T U C

When using the alternate venting location, either in a horizontal left side down installation or a vertical installation using down – venting, an alternate combustion

DOWN VENTING UPFLOW MODEL FURNACES ONLY

Use alternate vent & combination air locations

Ven t Pi pe

Combustion Air Pipe

Field Supplied Drain Tee on Vent Pipe

All piping and fittings m us t be joined per material manu fa c turer’s sp e cifications

to prevent separation and flue gas leaks.

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

Figure 12

Vent/Flue Pipe Cuts

Figure 11

6’ MAX.

Both Pipes Terminated Outside Struc ture

1/4” per foot min. slope

air opening can be used. A locating dimple is located on the right side of the furnace cabinet. The locating dimple is 1 7/8" measured from the front edge of the cabinet in line with the knock out. To use the alternate combustion air location:

1. Remove screws and combustion air flange from cabinet.

2. Insert cabinet plug in unused combustion air hole.

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

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

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

VENT/FLUE PIPE LENGTHS AND DIAMETERS

Refer to the following table for applicable length, elbows, and pipe diameter for construction of the vent/flue pipe system. The tee used in the vent/flue termination must be counted as an elbow when determining the number of elbows in the piping system.

1) Maximum allowable limits listed on individual lengths for inlet and flue and NOT a combination.

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

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

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

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

*MVM97/*CVM97 Direct Vent (2 - Pipe) and Non-Direct Vent (1- Pipe)

Maximum Allowa ble Length of Vent /Flue P ipe & Combustion Air Pipe (ft)

Uni t

Pipe Size

Input

(Btu)

60,000

80,000

80,000 3 250 243 236 229 222 215 208 201 194

100,000

100,000 3 250 243 236 229 222 215 208 201 194

120,000

120,000 3 220 213 206 199 192 185 178 171 164

(4)

(in.)

or 2 1/2

012345678

250 245 240 235 230 225 220 215 210

90 85 80 75 70 65 60 55 50

75 70 65 60 55 50 45 40 35

Number o f Elbows

(3) (5)

(6)

(1) (2)

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

VENT/FLUE PIPE TERMINATIONS

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

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

Vertical vent/flue pipe terminations should be as shown in the following figure. Refer to Vent/Flue Pipe and Combustion Air Pipe - T ermination Locations for details concerning location restrictions. The penetration of the vent through the roof must be sealed tight

with proper flashing such as is used with a plastic plumbing vent.

Horizontal vent/flue pipe terminations should be as shown in the following figure. Refer to V ent/Flue Pipe and Combustion Air Pipe

- T ermination Locations for details concerning location restrictions. The wall penetration should be sealed with silicone caulk-

ing material.

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

TEE (OPTIONAL)

COMBUSTION AIR INTAKE

(OPTIONAL)

*Not required for

single pipe installation

INTAKE

SCREEN

OPTIONAL

”

12” MIN TO ROOF OR HIGHEST ANTICIPATED SNOW LEVEL

Figure 13

12” MIN HEIGHT DIFFERENCE BETWEEN INTAKE AND VENT

”

ELBOWS

STRAIGHT

Figure 14

12" MIN.

VENT/FLUE & COMBUSTION AIR PIPE LENGTHS & DIAMETERS

If there is a difference between the vent and combustion air pipes, count the pipe with the most fittings. Elbows and/or tees used in the terminations must be included when determining the number of elbows in the piping systems.

If the combustion air intake pipe is to be installed above a finished ceiling or other area where dripping of condensate will be objectionable, insulation of the combustion air pipe may be required. Use 1/2” thick closed cell foam insulation such as Armaflex™ or Insultube™ where required.

VENT/FLUE TEE (

TURNED DOWN or

90° ELBOW TURNED

12" MIN. ABOVE

HIGHEST ANTI CIPATED

SNOW LE VEL

45° ELBO W

DOWN

OPTIONAL)

Horizontal Termination (Single Pipe)

Above Highest Anticipated Snow Level

Figure 15

10”- 24”

6” MAX

4” MIN

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

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

or anticipated snow level = 12” min.

90° ELBOWS

3” - 24”

AIR INTAKE

SCREEN

(OPTIONAL)

12" MIN. ABOVE

HIGHEST ANTICIPATED

SNOW LEVEL

Alternate Horizontal Vent Termination (Dual Pipe)

Figure 17

90º OR 45°

ELBOW

SCREEN

(OPTIONAL)

12" MIN. TO GRADE OR HIGHEST ANTICIPATED

SNOW LEVEL

Standard Horizontal Terminations (Dual Pipe)

Figure 16

90° ELBOWS

3”-24” BETWEEN PIPES

AIR INTAKE

SCREEN

(OPTIONAL)

12" MIN. ABOVE

HIGHEST ANTICIPATED

SNOW LEVEL

Figure 18

Combustion Air Intake may also be snorkeled to obtain 12” min ground clearance.

Alternate Vent Termination Above Anticipated Snow Level

(Dual Pipe)

VENT/INTAKE TERMINATIONS FOR INSTALLATION OF MULTIPLE DIRECT VENT FURNACES

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

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

CONCENTRIC VENT TERMINATION

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

SIDE WALL VENT KIT

This kit is to be used with 2” or 3” direct vent systems. The vent kit must terminate outside the structure and may be installed with the intake and exhaust pipes located side-by-side or with one pipe above the other. These

kits are NOT intended for use with single pipe (indirect vent) installations.

3” - 24”

12” MIN SEPA RATION

3” MIN

OPTIONAL INTAKE SCREENS

Termination of Multiple Direct Vent Furnaces

Horizontal Installation

12” MIN TO GRADE OR HIGHEST ANTICIPATED SNOW LEVEL

Figure 19

Refer to the directions furnished with the Side Wall Vent Kit (p/n 0170K00000S or 0170K000001S) for installation specifications.

ONDENSA TE DRAIN LINES

& D

RAIN TRAP

Vertical Installation

Side Wall Vent Kit

Figure 20

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

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

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

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

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

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

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

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

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

GENERAL DRAIN INFORMATION

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

installed. See following instructions for your model and installation position. NOTE: Both sides of the drain trap must be

primed prior to initial furnace start up

FIELD SUPPLIED DRAIN

Drain the furnace and air conditioning coil if applicable, in compliance with code requirements. In horizontal or counterflow installations, a field installed rubber coupling will allow the drain trap to be removed for cleaning. The drain trap must be primed before initial furnace start up. When an air conditioning coil drain is connected to the field supplied furnace drain, it must be vented.

UPFLOW MODEL INSTALLED VERTICALLY

The trap and factory installed hoses remain as shipped. The furnace drain may exit either the right or left side of the furnace cabinet.

DRAIN EXITING RIGHT SIDE

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

22).

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

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

1.25" clamp.

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

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

NOTE: Hoses are model specific

#11

Figure 21

#10

100 Degree Elbow

Hose #1

Hose #2

Coupling

DRAIN EXITING LEFT SIDE

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

22).

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

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

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

1.25” clamp.

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

45 degree

barb-pipe

adapter

45 degree barb-pipe adapter

Installer selects right or left side drain

and installs this hose accordingly.

Figure 22

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

UPFLOW MODEL INSTALLED HORIZONTALLY WITH RIGHT SIDE DOWN

Minimum 5 3/8" clearance is required for the drain trap beneath the furnace.

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

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

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

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

Hose #11

5. (Draining the Vent Elbow ) Locate hose #5 and cut it at line “C”. Install the cut end of hose #5 from outside the cabinet

Figure 23

through the cabinet drain hole nearest the top. Secure it to the barbed fitting in the elbow with a red clamp.

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

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

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

Hose #5-Cut at “C”

UPFLOW MODEL INSTALLED HORIZONTALLY WITH LEFT SIDE DOWN

Minimum 5 3/8" clearance is required for the drain trap beneath the furnace. *Also see Front Cover Pressure Switch T ube Location on page 15.

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

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

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

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

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

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

7. Place cap on vent – drain elbow barb fitting and secure

with red clamp

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

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

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

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

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

13. Place cap on vent – drain elbow barb fitting and secure with red clamp.

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

Hose #6

Hose #5

Hose #11

Figure 24

UPFLOW MODEL INSTALLED HORIZONTALLY WITH LEFT SIDE DOWN - ALTERNATE

1. Install radius end of hose #5 on RF000142 coupling and secure with red clamp.

2. Insert coupling in hose #5.

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

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

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

6. Locate hose #6. Connect between the coupling and 100 degree elbow, cutting off excess tubing.

R 000142F

Insert flange. Cut 2 ½” long.

Figure 25

COUNTERFLOW MODEL INSTALLED VERTICALLY

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

DRAIN EXITING LEFT SIDE

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

2. Install drain per local and National codes.

DRAIN EXITING RIGHT SIDE

1. Remove hose clamps and hoses from trap.

2. Remove trap.

3. (Draining the Vent Elbow) Insert the non-grommet end hose #10 into the cabinet back drain hole. Secure on vent – drain elbow barb fitting with a red clamp.

4. Insert 100º elbow into the cut end and secure with red clamp.

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

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

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

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

Hose #5 x 2

Figure 27

Hose #4 x 2

Figure 26

COUNTERFLOW MODEL INSTALLED HORIZONTALLY WITH RIGHT SIDE DOWN

Minimum 5 3/8" clearance is required for the drain trap beneath the furnace.

*Also see Front Cover Pressure Switch T ube Location on page 15.

1. Remove hose clamps and hoses from trap.

2. Remove trap.

3. (Draining the Collector Box) From outside the cabinet, insert the non-grommet end hose #8 into the back drain hole.

4. Secure to collector box drain port using a silver clamp.

5. (Draining the Vent Elbow) From outside the cabinet, insert the non-grommet end of hose #7 into the front cabinet drain hole and secure on the vent – drain elbow barb fitting using a red clamp

6. Mate the trap inlets to the hoses, the outlet of the trap must face the original bottom of the furnace. Secure with silver clamps.

7. Fasten the drain trap to the cabinet with two screws removed in step 2

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

Hose #8

Figure 28

Drain Port

Hose #7

COUNTERFLOW MODEL INSTALLED HORIZONTALLY WITH LEFT SIDE

Hose #4

DOWN

Minimum 5 3/8" clearance is required for the drain trap beneath the furnace.

1. Remove hose clamps and hoses from trap.

2. Remove trap.

3. Remove plugs from left side of cabinet and install in blower deck.

4. (Draining the Collector Box) Locate hose #4 and place the radius end on the collector box drain port, secure with a silver clamp.

5. Locate hose #2, insert from outside the cabinet in the drain hole closest to the front of the cabinet, insert a coupling and secure with a red clamp.

6. Mate coupling to hose #4 and secure with a red clamp.

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

8. Locate hose #4 and place radius end on the side port of vent – drain elbow and secure with a red clamp.

9. Install cap on vent drain elbow barb fitting and secure with red clamp.

10. Insert PVC pipe into hose #4 and secure with a red clamp.

11. Locate hose #5, insert it from outside the cabinet in the drain hole farthest from the front of the cabinet.

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

13. Locate another hose #5 cut a 5.25" straight section and discard the radius end.

14. Connect the 5.25’ straight section to the 100º elbow and the PVC pipe and secure with red clamps.

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

16. Secure trap to furnace using two screws removed in step 2.

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

Hose #4

Hose #5 x2

Figure 29

LECTRICAL CONNECTIONS

WARNING

WIRING HARNESS

The wiring harness is an integral part of this furnace. Wires are color coded for identification purposes. Refer to the wiring dia-

HIGH VOLTAGE !

AVOID THE RISK OF ELECTRICAL SHOCK, WIRING TO

THE UNIT MUST BE POLARIZED AND GROUNDED

gram for wire routings. If any of the original wire as supplied with the furnace must be replaced, it must be replaced with wiring material having a temperature rating of at least 105° C. Any replacement wiring must be a copper conductor.

115 VOLT LINE CONNECTIONS

Before proceeding with electrical connections, ensure that the sup-

HIGH VOLTAGE !

AVOID PERSONAL INJURY OR DEATH DUE TO ELECTRICAL SHOCK, DISCONNECT ELECTRICAL POWER BEFORE SERVICING OR CHANGING ANY ELECTRICAL WIRING

WARNING

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

ABEL ALL WIRES PRIOR TO DISCONNECTION WHEN SERVICING CONTROLS OPERATION

. W

IRING ERRORS CAN CAUSE IMPROPER AND DANGEROUS

. V

ERIFY PROPER OPERATION AFTER SERVICING

CAUTION

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

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

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

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

JUNCTION BOX RELOCATION

WARNING

Line voltage connections can be made through either the right or left side panel. The furnace is shipped configured for a right side electrical connection. To make electrical connections through the opposite side of the furnace, the junction box must be relocated

PREVENT PERSONAL INJURY OR DEATH DUE TO ELECTRIC SHOCK DISCONNECT ELECTRICAL POWER BEFORE INSTALLING OR SERVICING THIS UNIT

to the left side prior to making electrical connections. To relocate the junction box, perform the following steps.

1. Remove the burner compartment door.

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

DGES OF SHEET METAL HOLES MAY BE SHARP

PRECAUTION WHEN REMOVING HOLE PLUGS

WARNING

. USE

GLOVES AS A

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

WARNING

HIGH VOLTAGE !

WARNING

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

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

ATIONAL ELECTRIC CODE

. US: National Ele ctrical Code (NEC) ANSI/NFPA 70-2011. In CANADA: Canadian Electrical Code CSA C22.1.

To ensure proper unit grounding, an earth ground wire must be connected between the furnace ground screw located inside

the furnace junction box and the electrical service panel. NOTE: Do not use gas piping as an electrical ground. To confirm

proper unit grounding, turn off the electrical power and perform the following check.

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

2. Resistance should measure 10 ohms or less.

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

24 VOLT THERMOSTAT WIRING

When installed with a non-communicating thermostat, the furnace integrated control module provides terminals for both “W1” and “W2”, and “Y1” and “Y2” thermostat connections. This allows the furnace to support the following system applications: ‘Two-Stage Heating Only’, ‘Two-Stage Heating with Single Stage Cooling’, and ‘Two-Stage Heating with Two-Stage Cooling’. Refer to the following figures for proper connections to the integrated control module.

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

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

NOTE: Use of cooling ramping profiles and dehum feature re-

quires a jumper between Y1 and O when a straight cooling unit is used.

The auxiliary contacts are shipped with a factory installed jumper. As an option, the auxiliary contacts may be wired to a normally closed float switch. In the event of open contacts, the gas heat and cooling will be disabled until the condition is corrected. These are 24 volt terminals powered internally, do not apply another voltage source to these terminals.

IRE ROUTING MUST NOT INTERFERE WITH CIRCULATOR BLOWER

OPERATION, FILTER REMOVAL OR ROUTINE MAINTENANCE

REMOVABLE PLUG CONNECTOR IS PROVIDED WITH THE FURNACE

CONTROL TO MAKE THERMOSTAT WIRE CONNECTIONS BE REMOVED, WIRE CONNECTIONS MADE TO THE PLUG, AND REPLACED BE JOINED WITH A WIRE NUT AND A SINGLE CONDUCTOR BE INSERTED UNDER THE TERMINAL SCREW INTERMITTENT OPERATION

STRONGLY

. IT IS

RECOMMENDED THAT MULTIPLE WIRES

. F

AILURE TO DO SO MAY RESULT IN

. T

HIS PLUG MAY

IMPORTANT NOTE

HEAT SET-UP DIP SWITCH DIP

MATCH THERMOSTAT TYPE THERMOSTAT ALSO THE CORRECT SETTING FOR A NON-COMMUNICATING THERMOSTAT MODULATING THERMOSTAT, CHECK TO MAKE SURE IN THE POSITION WHEN USING A NON-COMMUNICATING SINGLE-STAGE THERMOSTAT

, DIP

SWITCH

. TO

USE

OFF

POSITION (FACTORY POSITION

SWITCH

#13 MUST BE

. TO

USE THE

#13

MUST BE SET TO

CTK01

COMMUNICATING

POSITION

CTK02**, CTK03** OR CTK04**

DIP

SWITCH

). T

HIS IS ALSO THE CORRECT

SET TO

. T

STAGE

#13 IS

IMPORTANT NOTE

HERMOSTAT OMFORT ALERT™ MODULE OR IF THE OUTDOOR UNIT IS A PART OF

THE COMFORTNET™ FAMILY OF EQUIPM EN T

“R”

REQUIRED IF OUTDOOR UNIT IS EQUIPPED WITH A

DEHUM

HIS IS

Figure 30

1Y12

24 V TH ERMOSTAT CONNECTIONS

Low Voltage Connections with Auxiliary Terminals

AUX

THERMOSTAT

IMPORTANT NOTE

USE A SINGLE-STAGE HEAT THERMOSTAT

FURNACE CONTROL BOARD MUST BE SET TO THE

, DIP

SWITCH

OFF

#13 ON

POSITION

THE

Y C

Remote

Condensing Unit

(Single-Stage Cooling)

Thermostat - Single-Stage Heatingwith Single-Stage Cooling

NEU

Furnace Integrated

Control Module

Dehumidistat

[Optional]

Figure 31

Field installed jumper

to enable cooling

ramping profile when

using a straight

cooling unit.

Thermostat - Two-Stage Heating with Two-Stage Cooling

Remote

Condensing Unit

(Two-Stage Cooling)

W1 W2

NEU

Dehumidistat

[Optional]

Figure 33

SINGLE-STAGE HEATING THERMOSTAT APPLICATION

Furnace Integrated

Control Module

THERMOSTAT

Y C

Remote

Condensing Unit

(Single-Stage Cooling)

Thermostat - Two-Stage Heating with Single-Stage Cooling

NEU

Furnace Integrated

Control Module

Dehumidistat

[Optional]

Figure 32

IMPORTANT NOTE (COOLING SETUP)

SET DIP

COOLING THERMOSTAT

SWITCH

#14 TO ON

POSITION WHEN USING A

STAGE

A single-stage thermostat with only one heating stage may be used to control this furnace.

To use a single-stage thermostat, turn off power to the furnace, move the thermostat selection DIP switch to the OFF position. Turn power back on. Refer to the DIP switch chart in this manual.

24 VOLT DEHUMIDISTAT WIRING

The optional usage of a dehumidistat allows the furnace’s circulator blower to operate at a slightly lower speed (85% of desired speed) during a combined thermostat call for cooling and dehumidistat call for dehumidification. This can be done through an independent dehumidistat or through a thermostat’s DEHUM terminal (if available). This lower blower speed enhances dehumidification of the conditioned air as it passes through the AC coil. For proper function, a dehumidistat applied to this furnace must operate on 24 VAC

and utilize a switch which opens on humidity rise. Refer to the “Thermostat Wiring Diagrams” figure for additional wiring

details.

To install/connect a dehumidistat:

1. Turn OFF power to furnace.

2. Secure the dehumidistat neutral wire (typically the white lead) to the terminal marked “DEHUM” on the furnace integrated control module.

3. Secure the dehumidistat hot wire (typically the black lead) to the terminal marked “R” on the furnace integrated control module.

4. Secure the dehumidistat ground wire (typically the green lead) to the ground screw on the furnace junction box. NOTE:

Ground wire may not be present on all dehumidistats.

5. If the condenser is a straight cooling unit, install a jumper from Y1 to 0 on the furnace board.

6. Turn ON power to furnace.

To enable the dehumidify function on the integrated control module, set the dehumidification ENABLE DIP switch from OFF to ON.

Once the switch is set, the dehumidify function is enabled during a combination call for cooling (T-Stat) and dehumidification

(DEHUM-Stat). Refer to the DIP switch chart in the back section of this manual.

FOSSIL FUEL APPLICATIONS

This furnace can be used in conjunction with a heat pump in a fossil fuel application. A fossil fuel application refers to a combined gas furnace and heat pump installation which uses an outdoor temperature sensor to determine the most cost efficient means of heating (heat pump or gas furnace).

HIGH VOLTAGE !

AVOID PERSONAL INJURY OR DEATH DUE TO ELECTRICAL SHOCK, DISCONNECT ELECTRICAL POWER BEFORE SERVICING OR CHANGING ANY ELECTRICAL WIRING

WARNING

A heat pump thermostat with three stages of heat is required to

properly use a two-stage furnace in conjunction with a heat pump. Refer to the fossil fuel kit (AFE18-60A) installation instructions for additional thermostat requirements.

Strictly follow the wiring guidelines in the fossil fuel kit installation instructions. All furnace connections must be made to the furnace control board and the “FURNACE” terminal strip on the fossil fuel control board.

LINE VOLTAGE ACCESSORIES (ELECTRONIC A IR CLEANER AND HUMIDIFIER)

The furnace control board is equipped with line voltage accessory terminals for controlling power to an electronic air cleaner.

The accessory load specifications are as follows. (The furnace

HIGH VOLTAGE !

AVOID PERSONAL INJURY OR DEATH DUE TO ELECTRICAL SHOCK, DISCONNECT ELECTRICAL POWER BEFORE SERVICING OR CHANGING ANY ELECTRICAL WIRING

WARNING

control board also has a set of dry contacts for humidifier connection.)

Turn OFF power to the furnace before installing any accessories.

Humidifier 1.0 Amp maximum at 120 VAC

Electronic Air Cleaner 1.0 Amp maximum at 120 VAC

Follow the humidifier or air cleaner manufacturers’ instructions for locating, mounting, grounding, and controlling these accessories. Accessory wiring connections are to be made through the 1/4" quick connect terminals provided on the furnace integrated control

module. The Electronic air cleaner hot terminal is identified as EAC. It is necessary to remove the protective tab on the board cover to access the EAC Terminal. The EAC neutral terminal is identified as NEU-

TRAL. A line voltage humidifier may be connected between one of the HUM contacts and NEUTRAL. The other HUM contact must be fed from the L1 terminal.

All field wiring must conform to applicable codes. Connections should be made as shown in Figure 34.

If it is necessary for the installer to supply additional line voltage wiring to the inside of

NEUTRAL

the furnace, the wiring must conform to all local codes, and have a minimum temperature rating of 105°C. All line voltage wire splices must be made inside the furnace junction box.

The furnace control board HUM (dry contacts) are closed whenever the inducer is energized in a non-communicating installation. When used with a CTK02**, CTK03 or CTK04 communicating thermostat, the HUM terminals are closed whenever there is a call for humidity. The integrated control module electronic air cleaner terminals (EAC) are energized with 115 volts whenever the circulator blower is energized.

24 VOLT HUMIDIFIER

A 24 volt humidifier can be powered by feeding one of the HUM terminals with a field installed wire from the R terminal.

GAS S

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

UPPLY AND PIPING

AUX OUT

AUX IN

Accessories Wiring

Figure 34

CAUTION

PREVENT UNRELIABLE OPERATION OR EQUIPM EN T DAMAGE, THE INLET GAS SUPPLY PRESSURE MUST BE AS SPECIFIED ON THE UNIT RATING PLATE WITH ALL OTHER HOUSEHOLD GAS FIRED APPLIANCES OPERATING

Inlet gas supply pressures must be maintained within the ranges specified in the following table. The supply pressure must be constant and available with all other household gas fired appliances

Natural Gas Minimum: 4.5" w.c. Maximum: 10.0" w.c. Propane G a s Minimum: 11.0" w.c. Maximum: 13.0" w.c.

Inlet Gas Supply Pressure

operating. The minimum gas supply pressure must be maintained to prevent unreliable ignition. The maximum must not be exceeded to prevent unit overfiring.

HIGH ALTITUDE DERATE

In some areas the gas supplier may artificially derate the gas in an effort to compensate for the effects of altitude. If the gas is artificially derated, the appropriate orifice size must be determined based upon the BTU/ft3 content of the derated gas and the altitude. Refer to the National Fuel Gas Code, NFPA 54/ANSI Z223.1 or CAN/CSA B149.1 in Canada, and information provided by the gas supplier to determine the proper orifice size.

PROPANE GAS CONVERSION

As shipped, this unit is configured for natural gas. The LPM-09 is required to convert this furnace to operate on LP gas.

The correct kit must be used to insure safe and proper furnace operation. All conversions must be performed by a qualified in-

OSSIBLE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH MAY OCCUR IF THE CORRECT CONVERSIO N KITS ARE NOT INSTALLED APPROPRIATE KITS MUST BE APPLIED TO ENSURE SAFE AND PROPER FURN ACE OPERATION QUALIFIED INSTALLER OR SERVICE AGENCY

. ALL

staller, or service agency.

GAS VALVE

This unit is equipped with a 24 volt gas valve which modulates by pneumatic linkage to the combustion air blower. Taps for measuring the gas supply pressure and manifold pressure are provided on the valve. This is a non-convertible, non-adjustable gas valve equipped for natural gas.

WARNING

. THE

CONVERSIO NS MUST BE PERFORMED BY A

The gas valve has a manual ON/OFF control located on the valve itself. This control may be set only to the “ON” or “OFF” position.

Refer to the lighting instructions label or the Startup Procedure & Adjustment section of this manual for use of this control during

start up and shut down periods.

GAS PIPING CONNECTIONS

WARNING

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

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

The following stipulations apply when connecting gas piping. Re-

fer to Gas Piping Connections figure for typical gas line connec-

tions to the furnace.

• Gas piping must be supported external to the furnace

cabinet so that the weight of the gas line does not distort the burner rack, manifold or gas valve.

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

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

• Use pipe joint compound on male threads ONLY. Always use

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

• Use ground joint unions.

AVOID POSSIBLE UNSATISFACTORY OPERATION OF EQUIPMEN T DAMAGE DUE TO UNDERFIRIN G OR EQUIPM EN T, USE THE PROPER SIZE OF NATURAL/PROPANE GAS PIPING NEEDED WHEN RUNNING PIPE FROM THE METER/TANK TO THE FURNACE

Natural Gas Capacity of Pipe In Cubic Feet of Gas Per Hour (CFH)

Nominal ½¾11¼1½22½

Actual ID: 0.622 0.824 1.049 1.380 1.610 2.067 2.469

Length (ft)

10 170 360 678 1390 2090 4020 6400

20 118 247 466 957 1430 2760 4400

30 95 199 374 768 1150 2220 3530

40 81 170 320 657 985 1900 3020

50 72 151 284 583 873 1680 2680

60 65 1370 257 528 791 1520 2430

70 60 126 237 486 728 1400 2230

80 56 117 220 452 677 1300 2080

90 52 110 207 424 635 1220 1950

100 50 104 195 400 600 1160 1840 125 44 92 173 355 532 1020 1630 150 40 83 157 322 482 928 1480 175 37 77 144 296 443 854 1360 200 34 71 134 275 412 794 1270 250 30 63 119 244 366 704 1120

This chart refers to natural gas with an inlet pressure of less than 2 psi and a pressure drop of 0.5" W.C. Specific gravity is 0.60.

CFH = BTUH Furnace Input

Capacity in Cubic Feet of Gas per Hour

Heating Valve of Gas (BTU/Cubic Foot)

Pipe Size (in.)

• Install a drip leg to trap dirt and moisture before it can enter the gas valve. The drip leg must be a minimum of three inches

long.

• A line pressure test port is provided on the gas valve. If desired, install a 1/8" NPT pipe plug fitting, accessible for test

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

• Always use a back-up wrench when making the connection to the gas valve to keep it from turning. The orientation of the gas

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

• Install a manual shutoff valve between the gas meter and unit within six feet of the unit. If a union is installed, the union must

be downstream of the manual shutoff valve, between the shutoff valve and the furnace.

• Tighten all joints securely.

• Connection method must be in compliance with all local and national codes. US: National Fuel Gas Code (NFGC) NFPA

54-2012/ANSI Z223.1-2012 and the Installation Standards, Warm Air Heating and Air Conditioning Systems ANSI/NFPA 90B.

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

2010. Connect the furnace to the building piping by one of the following methods:

– Rigid metallic pipe and fittings. – Semi-rigid metallic tubing and metallic fittings. Aluminum alloy tubing must not be used in exterior locations. In order

to seal the grommet cabinet penetration, rigid pipe must be used to reach the outside of the cabinet. A semi-rigid connector to the gas piping may be used from there.

• Use listed gas appliance connectors in accordance with their instructions. Connectors must be fully in the same room as the

furnace.

• Protect connectors and semirigid tubing against physical and thermal damage when installed. Ensure aluminum-alloy tubing

and connectors are coated to protect against external corrosion when in contact with masonry, plaster, or insulation, or subjected to repeated wetting by liquids such as water (except rain water), detergents, or sewage.

Alternate

Gas Line

Location

Gas Valve

*Ground

Joint

Pip e

Union

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

Manifold

Burners

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

*Ground Joint Pip e Union

Drip Leg

Grommet in Standard Gas Line Hole

UPFLOW

Figure 35

Gas Piping Connections

*Ground

Joint

Pip e Union

Grommet

in Standard

Gas Line

Hole

Drip Leg

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

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

Alternate Gas Line Location

*Ground Joint Pipe Uni on

Plug in Alternate Gas Line Hole

Gas Valve

Burners

COUNTERFLOW

Figure 36

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

Alternate Union Location

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

Grommet in

Manifold

Gas

Val ve

Drain Trap

COUNTERFLOW - HORIZONTAL RIGHT

Figure 38

When gas line is in the alternate location, swap the position of the plug and grommet.

UPFLOW - HORIZONTAL LEFT

Figure 37

Standard Gas Line Hole

Burners

Drip leg may terminate with a 1/2” x 1/8” pipe plug to accommodate line gas pressure measurement.

The gas piping may enter the left or right side of the furnace cabinet. The installer must supply rigid pipe long enough to reach the outside of the cabinet to seal the grommet cabinet penetration. A semi-rigid connector to the gas piping can be used outside

DGES OF SHEET METAL HOLES MAY BE SHARP

PRECAUTION WHEN REMOVING HOLE PLUGS

WARNING

the cabinet per local codes. 1/2” NPT pipe and fittings are required. For models with an “L” shaped manifold, a 4 1/2” long nipple is required. For models with a hook shaped manifold, a 2” long nipple is required.

Drip Leg

Plug in Alternate Gas Line Hole

Plug in Main Gas Line Hole

. USE

GLOVES AS A

From the elbow, the length of pipe and the fittings required will vary by the side chosen, location of union and cabinet width. The union may be placed inside or outside of the cabinet.

GAS PIPING CHECKS

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

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

Check for leaks using an approved chloride-free soap and water

OR OPEN FLAME TO TEST FOR LEAKS

solution, an electronic combustible gas detector, or other approved testing methods.

NOTE: Never exceed specified pressures for testing. Higher pressure may damage the gas valve and cause subsequent overfiring,

resulting in heat exchanger failure.

Disconnect this unit and shutoff valve from the gas supply piping system before pressure testing the supply piping system with pressures in excess of 1/2 psig (3.48 kPa).

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

WARNING

PROPANE GAS TANKS AND PIPING

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

the Safety Precautions section of this manual.

All propane gas equipment must conform to the safety standards of the National Board of Fire Underwriters, NBFU Manual 58.

THE GAS FURNACE IS INSTALLED IN A BASEMENT, AN EXCAVATED AREA OR CONFI NED SPACE, IT IS STRO NGLY RECOMMENDED TO CONTA CT A PROPANE SUPPLIER TO INSTALL A GAS DETECTING WARNING DEVICE IN CASE OF A GAS LEAK

INCE PROPANE GAS IS HEAVIER THAN AIR, ANY LEAKING GAS CAN

•

SETTLE IN ANY LOW AREAS OR CONFI NED SPACES

•

ROPANE GAS ODORANT MAY FADE, MAKING THE GAS UNDETECTABLE

EXCEPT WITH A WARNING DEVICE

WARNING

CANADA: National Standard of Canada, Natural Gas and Propane Installation Code (NSCNGPIC) CSA B149.1—2010.

For satisfactory operation, propane gas pressure must be 10” WC + .5” WC at the furnace manifold with all gas appliances in operation. Maintaining proper gas pressure depends on three main factors:

1. Vaporization rate, depending on temperature of the liquid, and “wetted surface” area of the container or containers.

2. Proper pressure regulation. (Two-stage regulation is recommended for both cost and efficiency).

3. Pressure drop in lines between regulators, and between second stage regulator and the appliance. Pipe size will depend on length of pipe run and total load of all appliances.

Complete information regarding tank sizing for vaporization, recommended regulator settings, and pipe sizing is available from most regulator manufacturers and propane gas suppliers.

First Stage Regulator

5 to 15 PSIG (20 PS IG Max.)

Continuous

11" W.C.

Since propane gas will quickly dissolve white lead and most standard commercial compounds, special pipe dope must be used. Pipe dope used on propane gas installations must be approved for use with propane gas.

200 PSIG Maximum

Second Stage Regulator

Refer to the Figure 39 for typical propane gas installations and piping.

Sizing Between First and Second Stage Regulator*

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

Pipe or Tubing Length

Feet

10 730 1,700 3,200 5,300 8,300 3,200 7,500 20 500 1,100 220 3,700 5,800 2,200 4,200 30 400 920 2,000 2,900 4,700 1,800 4,000 40 370 850 1,700 2,700 4,100 1,600 3,700 50 330 770 1,500 2,400 3,700 1,500 3,400 60 300 700 1,300 2,200 3,300 1,300 3,100

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

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

Tubing Size, O.D. Type L

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

Propane Gas Piping Chart I

Nominal Pipe Size

Schedule 40

Propane Gas Installation (Typ.)

Figure 39

Sizing Between Second or Second Stage Regulator & Appliance*

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

Pipe or Tubing Length

Feet

10 39 92 199 329 501 275 567 1,071 2,205 3,307 20 26 62 131 216 346 189 393 732 1,496 2,299 30 21 50 107 181 277 152 315 590 1,212 1,858 40 19 41 90 145 233 129 267 504 1,039 1,559 50 18 37 79 131 198 114 237 448 913 1,417 60 16 35 72 1,211 187 103 217 409 834 1,275

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

*Data in accordance with NFPA pamphlet No. 54

Tubing Size, O.D. Type L

3/8" 1/2" 5/8" 3/4" 7/8" 1/2" 3/4" 1" 1-1/4" 1-1/2"

Nominal Pipe Size

Schedule 40

Propane Gas Piping Chart II

IRCULATING AIR

DUCT WORK - AIR FLOW

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

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

A closed return duct system must be used, with the return duct connected to the furnace. NOTE: Ductwork must never be attached to the back of the furnace. For upflow installations requiring 1800 CFM or more, use either two side returns or bottom return or a

combination of side and bottom. Flexible joints may be used for supply and return connections to reduce noise transmission. To prevent the blower from interfering with combustion air or draft when a central return is used, a connecting duct must be installed between the unit and the utility room wall. Never use a room, closet, or alcove as a return air chamber.

& F

ILTERS

WARNING

EVER ALLOW THE PRODUCTS OF COMBUSTION, INCLUDING CARB ON MONOXIDE, TO ENTER THE RETU RN DUCT WORK OR CIRCULATION AIR SUPPLY

CHECKING DUCT STATIC

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

Total external static refers to everything external to the furnace cabinet. Cooling coils, filters, ducts, grilles, registers must all be considered when reading your total external static pressure. The supply duct pressure must be read between the furnace and the cooling coil. This reading is usually taken by removing the “A” shaped block off plate from the end on the coil; drilling a test hole in it and reinstalling the block off plate. Take a duct static reading at the test hole. Tape up the test hole after your test is complete. The negative pressure must be read between the filter and the furnace blower.

Excessive external static pressure will result in insufficient air which can cause excessive temperature rise. This can cause limit switch tripping and heat exchanger failure.

To determine total external duct static pressure, proceed as follows;

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

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

3. The difference between the two numbers is your total external static pressure.

Example:

static reading from return duct = -0.1" W.C.

static reading from supply duct = +0.3" W.C.

total external static pressure on this system = 0.4" W.C.

NOTE: Both readings may be taken simultaneously and read directly

on the manometer if so desired. If an air conditioner coil or Electronic Air Cleaner is used in conjunction with the furnace, the readings must also include these components, as shown in the following drawing.

4. Consult proper tables for the quantity of air.

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

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

Checking Static Pressure

Figure 40

BOTTOM RETURN AIR OPENING [UPFLOW MODELS]

The bottom return air opening on upflow models utilizes a “lance and cut” method to remove sheet metal from the duct opening in the base pan. To remove, simply press out the lanced sections by hand to expose the metal strips retaining the sheet metal over the duct opening. Using tin snips, cut the metal strips and remove the sheet metal covering the duct opening. In the corners of the opening, cut the sheet metal along the scribe lines to free the duct flanges. Using the scribe line along the duct flange as a guide, bend the duct flanges around the perimeter of the opening using a pair of seamer pliers or seamer tongs.

NOTE: Airflow area will be reduced by approximately 18% if duct

flanges are not folded open. This could cause performance issues and noise issues.

DGES OF SHEET METAL HOLES MAY BE SHARP PRECAUTION WHEN REMOVING SHEET METAL FROM RETURN AIR OPENINGS

WARNING

. USE

GLOVES AS A

When the furnace is used in connection with a cooling unit, the furnace should be installed in parallel with or on the upstream side of the cooling unit to avoid condensation in the heating element. With a parallel flow

CUT USING TIN SNIPS

PRESS OUT BY HAND

arrangement, the dampers or other means used to control the flow of air must be adequate to prevent chilled air from entering the furnace and, if manually operated, must be equipped with means to prevent operation of either unit unless the damper is in the full heat or cool position.

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

CUT FOUR CORNERS AFTER REMOVING SHEET METAL

Duct Flange Cut Outs

Figure 41

SCRIBE LINES OUTLINING DUCT FLANGES

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

FILTERS - READ THIS SECTION BEFORE INSTALLING THE RETURN AIR DUCT

WORK

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

On upflow units, guide dimples locate the side return cutout locations. Use a straight edge to scribe lines connecting the dimples. Cut out the opening on

these lines. NOTE: An undersized opening will cause reduced airflow.

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

Change filters before occupants take ownership of a new home!

*MVM970603BN** 24 X 30

*MVM970803BN** 24 X 30

*MVM970804CN** 24 X 36

*MVM971005CN** 24 X 36

*MVM971205DN** (2) 20 X 25

*CVM970603BN** 20 X 25

*CVM970803BN** 24 X 30

*CVM970804CN** 24 X 30

*CVM971005CN** 24 X 36

[Based on 300 ft/min filter face velocity]

Filter Sizing Chart

Model Minimum Filter Size

UPRIGHT INSTALLATIONS

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

The following figure shows possible filter locations.

CENTRAL

RETURN

GRILLE

EXTERNAL FILTER

FILTER

AIR FLOW

SIDE RETURN

RACK KIT

(EITHER SIDE)

FILTER

ACCESS

DOOR

RETURN

DUCT

FILTER

SUPPORT

BRACKET

(Field Supplied)

Possible Upright Upflow

Figure 42

Possible Upright Counterflow

HORIZONTAL INSTALLATIONS

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

AIR FLOW

Filter Locations

Figure 43

CENTRAL

RETURN

GRILLE

TARTUP PROCEDURE

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

refer to further information in Operational Checks section.

& A

DJUSTMENT

IGNITION

100%

(80%)

78%

Call for heat, thermostat energizes W1 on the furnace control board (W2 input is ignored).

57%

8 MINS.

After a successful Light Off Sequence and expiration of the Ignition Stabilization Period:

• The furnace control board adjusts the firing rate to 35%

MIN.

2 MINS.

(low fire rate).

• After 2 minutes, the furnace control board increases the firing rate to 57% at a rate of 1% per second.

• After 10 total minutes, the furnace control board increases the firing rate to 78% at a rate of 1% per second.

Operation with Conventional 1-Stage Thermostat

(DIP switch selects 1-Stage heat)

Figure 44

• After 20 total minutes, the furnace control board increases to 100% at a rate of 1% per second for the remainder of the call for heat.

• The circulator fan is adjusted to the appropriate CFM, corresponding to the current firing rate.

UNIT CALL FOR HEAT ENDS

10 MINS.

Call for 1st-Stage Heat - Thermostat contacts close R to W1.

After a successful Light Off Sequence and expiration of the Ignition Stabilization Period:

• The furnace control board adjusts to the low firing rate.

• After 2 minutes, the furnace control board increases the firing rate to 50% for the next 8 minutes.

• Thereafter, the furnace control board will increase the firing rate 10%, at a rate of 1% per second, every 10 minutes for the remainder of the call for heat (See above figure).

• The circulator fan is adjusted to the appropriate CFM, corresponding to the current firing rate.

Call for 2nd-Stage Heat - Thermostat contacts close R to W1 and W2.

After a successful Light Off Sequence and expiration of the Ignition Stabilization Period:

• The furnace control board adjusts to the low firing rate of 35%.

• After 2 minutes, the furnace control board increases the firing rate to 80%.

• Thereafter, the IFC will increase the firing rate by 10%, at a rate of 1% per second, every 10 minutes for the remainder of the call for heat.

• The circulator fan is adjusted to the appropriate CFM, corresponding to the current firing rate.

IGNITION

(80%)

70%

10 MINS.

60%

50%

2 MINS.

MIN.

8 MINS.

Operation with Conventional 2-Stage Thermostat

(DIP switch selects 2-stage heat)

Figure 45

10 MINS.

IGNITION

90%

8 MINS.

(80%)

70%

60%

50%

2 MINS.

MIN.

Operation with Conventional 2-Stage Thermostat

Call for 2nd-Stage Heat with 1st-Stage call for heat call in progress, with conventional 2-Stage Thermostat.

(DIP switch selects 2-stage heat)

Figure 46

• The furnace control board increases the firing rate to 100% at a rate of 1% per second for the remainder of the W2 call.

• The circulator is adjusted to the appropriate CFM, corresponding to the current firing rate.

Call for 2nd-Stage Heat satisfied; Call for 1st-Stage Heat remains.

• The furnace control board remains at the current firing

IGNITION

100%

(80%)

78%

UNIT CALL FOR HEAT ENDS

rate until the 1st-Stage call for heat is satisfied.

HEATING OPERATION WITH CTK01 THERMOSTAT (COMMUNI-

CATING)

• When the Thermostat Heat Setup DIP switch is set to 2Stage heat, the furnace control board operation will be compatible with a CTK01 communicating thermostat.

• When a call for heat is sent, the furnace will go through the Light Off Sequence, at which time the Heat Current Demand Status will still show 0%. After the successful Light Off Sequence and expiration of the Ignition Stabilization Period:

• The furnace control board adjusts to the low firing rate.

• After 2 minutes, the furnace control board accepts the specific heat requested demand.

• If the differential is equal to or less than 2 degrees, the furnace control board will follow the conventional 2-Stage algorithm, equivalent to a W1 request and be reflected in the heat current demand status %.

50%

MIN.

2 MINS.

Figure 47

CALL FOR 2ND STAGE HEAT

• If the heat differential is greater than 2 degrees, the furnace control board will follow the conventional 2-Stage algorithm, equivalent to a W2 request and be reflected in the heat current demand status %.

• The circulator will operate per the heat airflow profile.

HEATING OPERATION WITH CTK02**, CTK03** & CTK04** THERMOSTAT (MODULATING COMMUNICATING)

• When the Thermostat Heat Setup DIP switch is set to 1-Stage heat, the furnace control board operation will be compatible with a modulating communicating thermostat (CTK02**, CTK03 or CTK04).

• The furnace control board adjusts to the low firing rate.

• After 2 minutes, the furnace control board accepts the specific Heat Requested Demand.

• If the differential is 2 degrees or less, the heat current demand status will show 50%.

• If the specific heat requested demand is above 2 degrees, the heat current demand status will track the specific heat requested demand.

• The circulator fan will operate per the heat airflow profile.

CONDENSATE DRAIN TRAP PRIMING

The drain trap MUST be primed prior to furnace startup. To prime, fill the drain trap with water. This ensures proper furnace

drainage upon startup and eliminates the possibility of flue gases escaping through the drain system. Please see requirements in

Condensate Drain Lines & Drain T rap section.

FURNACE OPERATION

Purge gas lines of air prior to startup. Be sure not to purge lines into an enclosed burner compartment. Follow NFPA 54, National Fuel gas Code 8.3 for proper purging methods. In Canada, follow approved purging methods in B149.1.

Check for leaks using an approved chloride-free soap and water solution, an electronic combustible gas detector, or other approved method. Verify that all required kits (propane gas, etc.) have been appropriately installed.

FURNACE STARTUP

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

2. Turn off the electrical power to the furnace.

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

4. Remove the burner compartment door.

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

by hand.

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

6. Wait five minutes then smell for gas. Be sure to check near the floor as propane is heavier than air,

7. If you smell gas after five minutes, immediately follow the Safety Considerations on page 4 of this manual. If you do

not smell gas after five minutes, move the furnace gas valve manual control to the ON position.

8. Replace the burner compartment door.

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

10. Turn on the electrical power to the furnace.

11. Adjust the thermostat to a setting above room temperature.

12. After the burners are lit, set the thermostat to desired temperature.

FURNACE SHUTDOWN

1. Set the thermostat to the lowest setting. The integrated control will close the gas valve and extinguish flame. After the blower off delay expires, the circulator blower

de-energizes.

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

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

4. Replace the burner compartment door.

GAS SUPPLY PRESSURE MEASUREMENT

Before placing a gas furnace or any gas appliance in operation, verify that the gas piping, gas fittings and all gas components are safe and free of leaks by means of an electronic combustible gas indicator and a gas meter dial test. Combustible gas indicators must be calibrated and verified at inter-

PREVENT UNRELIABLE OPERATION OR EQUIPM EN T DAMAGE, THE INLET GAS SUPPLY PRESSURE MUST BE AS SPECIFIED ON THE UNIT RATING PLATE WITH ALL OTHER HOUSEHOLD GAS FIRED APPLIANCES OPERATING

CAUTION

vals prescribed by the instrument manufacturer.

The line pressure supplied to the gas valve must be within the range specified in the Inlet Gas Supply Pressure table. The supply

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

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

2. Connect a calibrated water manometer (or appropriate gas pressure gauge) at either the gas valve inlet pressure tap or the gas piping drip leg. See Honeywell VR9205R gas valve figure for location of inlet pressure tap.

NOTE: If measuring gas pressure at the drip leg or Honeywell VR9205R

gas valve, a field-supplied hose barb fitting must be installed prior to making the hose connection.

3. Turn ON the gas supply, check for leaks and operate the furnace and all other gas consuming appliances on the same gas supply line.

NOTE: To bring furnace up to High Fire, see instructions for field test mode in GAS MANIFOLD PRESSURE MEASUREMENT

section.

4. Measure furnace gas supply pressure with burners firing. Supply

pressure must be within the range specified in the Inlet Gas Supply Pressure table.

Inlet Gas Supply Pressure Natural Gas Minimum: 4.5" w.c. Maximum: 10.0" w.c. Propane G a s Minimum: 11.0" w.c. Maximum: 13.0" w.c.

PRESSURE

SWITCH

CONNECTION

TMOSPHERE

PORT

FLOW

DIRECTION

2-PIN

POWER CONNECTOR

Inlet Pressure Tap 1/8 NPT

Figure 49A

Honeywell Model VR9205R

Figure 48

Outlet

Pressure

Tap

1/8 NPT

Figure 49B

Honeywell Model VR9205R Connected to Manometer

If supply pressure differs from table, make the necessary adjustments to pressure regulator, gas piping size, etc., and/or consult with local gas utility.

5. Turn OFF gas to furnace at the manual shutoff valve and disconnect manometer. Reinstall threaded plug before turning on gas to furnace.

6. Turn OFF any unnecessary gas appliances stated in step 3.

GAS MANIFOLD PRESSURE MEASUREMENT

Gas Line

Gas Shutoff Valve

Gas Line To Furnace

CAUTION

PREVENT UNRELIABLE OPERATION OR EQUIPM EN T DAMAGE, THE GAS MANIFOLD PRESSURE MUST BE AS SPECIFIED ON THE UNIT RATING PLATE

. GAS

VALVE IS FACTORY SET AND DOES

IELD ADJUSTMENT

. DO

NOT ATTEM PT TO ADJUST VALVE

NOT

REQUIRE ANY

Drip Leg Cap With Fitting

Manomete r Hose

Open To Atmosphere

The manifold pressure must be measured with the burners operating. To measure the manifold pressure, use the following procedure:

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

2. Turn off all electrical power to the system.

3. Outlet pressure tap connections: Remove the outlet pressure tap plug. Install

Measuring Inlet Gas Pressure (Alt. Method)

Manometer

Figure 50

an 1/8" NPT hose barb fitting into the outlet pressure tap. Refer to gas valve diagram on preceding page.

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

5. Turn ON the gas supply.

6. Turn on power and close thermostat “R” and “W1” contacts to provide a call for low stage heat.

7. Modulating furnaces light at 80% of max input. For natural gas, the expected manifold pressure at ignition will be in a range of 1.8” - 2.5” W.C. For LP gas, the range will be 5.8” - 6.8” W.C.

NOTE: Measure the gas manifold pressure with the burners firing. After every time the main power is turned off and back on, the furnace will enter a calibration routine on the next call for heat The inducer will ramp up and down during

the calibration routine. After calibration, the furnace will proceed to ignition cycle.

8. Field Test Mode is intended to help a service person troubleshoot and check out an installed appliance by bringing the furnace up to High fire (100% input), by-passing the normal modulating routing.

To enter Field Test Mode the Fault Recall Push-Button must be pressed twice within a 5 second period at any time

during a heating cycle, at which time the display will show “Ft”. While the display is showing “Ft”, pressing and holding the Fault Recall Push-Button for 3 seconds will enable the field test mode and override the normal firing rate sequence at a rate of 100% for 5 minutes or until the end of the call for heat. The display will show the normal “Hi” while the control is firing at 100%. If the Fault Recall Push-Button has not been pressed within 5 seconds of displaying “Ft” the display will revert back to normal.

NOTE: Gas valve is factory set and does NOT require

any field adjustment. Do NOT attempt to adjust valve.

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

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

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

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

13. Close thermostat contacts “R” and “W1/W2” to energize the valve.

Using an approved liquid gas leak detector solution, check for leaks at outlet pressure tap plug. Bubbles forming indicate a leak. SHUT OFF

Nat ur al H i gh Stage 3. 2 - 3.8" w.c . 3.5" w.c.

Propane High Stage 9.5 - 10.5" w.c. 10.0" w.c.

Manifold Gas Pr essu re

Gas

Range Nominal

GAS AND REPAIR ALL LEAKS IMMEDIATELY!

GAS INPUT RATE MEASUREMENT (NATURAL GAS ONLY)

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

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

2. While the furnace is operating at high fire rate, time and record one complete revolution of the gas meter dial measuring the smallest quantity, usually the dial that indicates 1/2 cu. ft. per revolution. You will use this number to calculate the quantity of gas in cubic ft. if the furnace would consume if it ran steadily for one hour (3600 seconds).

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

EXAMPLE: If it took 23 seconds to complete one revolution of the 1/2 ft. dial.

This tells us that at this rate, it would take 46 seconds to consume one cu. ft. of gas. 23 x 2 = seonds per cu. ft.

3600 (secs in 1 hour) / 46 = 78

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

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

NOTE: The final manifold pressure cannot vary by more than ± 0.3” w.c. for Natural and

+ 0.5” for LP from the

specified setting. Consult your local gas supplier if additional input rate adjustment is required.

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

TEMPERATURE RISE

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

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

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

3. Subtract the return air temperature from the supply air temperature to determine the air temperature rise. Allow adequate time for thermometer readings to stabilize.

4. Adjust temperature rise by adjusting the circulator blower speed. Increase blower speed to reduce temperature rise.

Decrease blower speed to increase temperature rise. Refer to Startup Procedure and Adjustment -Circulator Blower Speeds for speed changing details.

TEMPERATURE RISE

Model HI / LO

*MVM970603BXAA 20-50/25-55

*MVM970803BXAA 30-60/25-55

*MVM970804CXAA 25-55/25-55

*MVM971005CXAA 35-65/25-55

*MVM971205DXAA 35-65/30-60

*CVM970603BXAA 35-65/30-60

*CVM970803BXAA 35-65/35-65

*CVM970804CXAA 35-65/35-65

*CVM971005CXAA 35-65/30-60

SUPPLY AIR

RETURN AIR

Temperature Rise Measurement

Figure 51

CIRCULATOR BLOWER SPEEDS

This furnace is equipped with an ECM circulator blower. The heating blower speed is shipped set at “B”, and the cooling blower speed setting is “D”. These blower speeds should be adjusted by the installer to match the installation requirements so as to provide the correct heating temperature rise and correct cooling CFM.

Use the dual 7-segment LED display adjacent to the DIP switches to obtain the approximate airflow quantity. The airflow quantity is displayed as a number on the display, rounded to the nearest 100 CFM. The display alternates airflow delivery indication and the operating mode indication.

Example: The airflow being delivered is 1225 CFM. The display

indicates 12. If the airflow being delivered is 1275, the display indicates 13.

1. Determine the tonnage of the cooling system installed with the furnace. If the cooling capacity is in BTU/hr divide it by 12,000 to convert capacity to TONs.

Example: Cooling Capacity of 30,000 BTU/hr.

30,000/12,000 = 2.5 Tons

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

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

The cooling system manufacturer’s instructions must be checked for required air flow. Any electronic air cleaners or other devices may require specific quantity of air, consult installation instructions of those devices for requirements.

3. Knowing the furnace model, locate the high stage cooling air flow table. Look up the cooling air flow determined in step 2 and find the required cooling speed and adjustment setting.

Example: A *MVM970603BN furnace installed with a 2.5 ton

air conditioning system. The air flow needed is 1000 CFM. Looking at the cooling speed chart for *MVM970603BN, find the air flow closest to 1000 CFM. A cooling airflow of 1000 CFM can be attained by selecting the cooling speed “C” and the adjustment to “normal”.

WARNING

AVOID PERSONAL INJURY OR DEATH DUE TO ELECTRICAL SHOCK

TURN

OFF

POWER TO THE FURNACE BEFORE CHANGING SPEED TAPS

Low

Model Tap

*MVM970603BN*

*MVM970803BN*

*MVM970804CN*

*MVM971005CN*

*MVM971205DN*

*CVM970603BN

*CVM970803BN

*CVM970804CN*

*CVM971005CN*

*100% CFM shown. CFM will vary proportionally with the gas valve BTU/H input.

Stage

Cool

398 599 953 667

557 817 1059 740

C 696 1007 1158 808 D 810 1212 1260 881

403 629 1202 855

B 540 806 1316 923

705 1023 1389 1033

D 819 1230 1396 1063

513 789 1228 867

B 660 967 1337 939 C 791 1182 1430 1016

913 1375 1516 1077

A 564 820 1818 1256

784 1133 1870 1292

C 982 1464 1910 1316

1259 1736 1957 1358

A 547 867 1891 1329 B 831 1160 1940 1362

1020 1467 1968 1390

D 1278 1910 2028 1440

433 656 938 687

B 541 790 950 751

686 972 986 814

D 806 1195 992 874

A 405 624 1057 758

B 549 808 1146 815

C 678 994 1256 882

D 784 1177 1349 946

556 837 1234 889

714 1022 1325 944

C 838 1206 1442 1019 D 991 1475 1528 1068

524 784 1759 1209

B 744 1078 1797 1249

927 1388 1840 1277

D 1185 1766 1881 1300

High Stage

Cool

100%

Heat *CFM

Low heat

CFM for

2 stage

4. Continuous fan speed is selectable at 25%, 50%, 75% or 100% of the furnace’s maximum airflow capability.

Example: If the furnace’s maximum airflow capability is 2000 CFM, the continuous fan speed at 25% will be 0.25 x 2000 or

500 CFM.

5. Locate the blower speed selection DIP switches on the integrated control module. Select the desired “cooling” speed tap by positioning switches 1 and 2 appropriately. Select the desired “adjust” tap by positioning switches 9 and 10 appropriately. Refer to the DIP switch chart for switch positions and their corresponding taps. Verify CFM by noting the number displayed on the dual 7-segment LED display.

6. The multi-speed circulator blower also offers several custom ON/OFF ramping profiles for cooling. These profiles may be used to enhance cooling performance and increase comfort level. The ramping profiles are selected using DIP switches 7 and 8. Refer to the bullet points below for a description of each ramping profile. Verify CFM by noting the number displayed on the dual 7-segment LED display.

• Profile A provides only an OFF delay of one (1) minute at 100%

of the cooling demand airflow.

OFF

100% CFM 100% CFM

OFF

1 min

Figure 52A

• Profile B ramps up to full cooling demand airflow by first

stepping up to 50% of the full demand for 30 seconds. The motor then ramps to 100% of the required airflow. A one (1)

OFF

50% CFM

1/2 min

100% CFM

1 min

minute OFF delay at 100% of the cooling airflow is provided.

Figure 52B

• Profile C ramps up to 85% of the full cooling demand airflow

and operates there for approximately 7 1/2 minutes. The motor

OFF

100% CFM

then steps up to the full demand airflow. Profile C also has a one (1) minute 100% OFF delay.

Figure 52C

• Profile D ramps up to 50% of the demand for 1/2 minute, then

ramps to 85% of the full cooling demand airflow and operates

OFF

there for approximately 7 1/2 minutes. The motor then steps up to the full demand airflow. Profile D has a 1/2 minute at 50% airflow OFF delay.

Figure 52D

Airflow Tables

7. Select the heating speed for your model from the heating speed table in this manual. The “adjust” setting (already established by the cooling speed selection) determines which set of speeds are available. The selected speed must provide a temperature rise within the rise range listed with the particular model.

8. Select the desired “heating” speed tap by positioning switches 3 and 4 appropriately. Refer to the airflow table. Verify CFM by noting the number displayed on the dual 7-segment LED display.

OFF

In general, lower heating speeds will reduce electrical consumption, lower operating sound levels of the blower, and increase the outlet

air temperature delivered to the home. The speeds available allow the blower performance to be optimized for the particular needs of the installation.

BLOWER HEAT OFF DELAY TIMINGS

The integrated control module provides a selectable heat off delay function. The heat off delay period may be set to 90, 120, 150, 180 seconds using the DIP switches or jumper provided on the control module. The delay is factory shipped at 150 seconds but may be changed to suit the installation requirements and/or homeowner preference. Refer to the DIP switch chart in the back section of this manual for switch positions and corresponding delay times.

OMFORTNET

™ S

YSTEM

OVERVIEW

NOTE: DIP switch #13 MUST be set to match thermostat type. T o use the CTK01 communicating thermostat, DIP switch #13 must be set to ON position. This is also the correct setting for a non-communicating 2-stage thermostat. T o use the CTK02**, CTK03** or CTK04** modulating thermostat, check to make sure DIP switch #13 is in the OFF position (factory position). This is also the correct position when using a non-communicating single stage thermostat.

The ComfortNet system is a system that includes a ComfortNet compatible furnace and air conditioner or heat pump with a CTK0* thermostat. A valid ComfortNet system could also be a compatible furnace, CTK0* thermostat and non-compatible, single stage air conditioner. Any other system configurations are considered invalid ComfortNet systems and must be connected as a traditional (or

non-communicating) system (see Electrical Connections for wiring connections).

A ComfortNet heating/air conditioning system differs from a non-communicating/traditional system in the manner in which the indoor unit, outdoor unit and thermostat interact with one another. In a traditional system, the thermostat sends commands to the indoor and outdoor units via analog 24 VAC signals. It is a one-way communication path in that the indoor and outdoor units typically do not return information to the thermostat.

The indoor unit, outdoor unit and thermostat comprising a ComfortNet system “communicate” digitally with one another, creating a two-way communications path. The thermostat still sends commands to the indoor and outdoor units. However, the thermostat may also request and receive information from both the indoor and outdoor units. This information may be displayed on the ComfortNet thermostat. The indoor and outdoor units also interact with one another. The outdoor unit may send commands to or request information from the indoor unit. This two-way digital communications between the thermostat and subsystems (indoor/ outdoor unit) is the key to unlocking the benefits and features of the ComfortNet system.

Two-way digital communications is accomplished using only two wires. The thermostat and subsystem controls are powered with 24 VAC. Thus, a maximum of 4 wires between the equipment and thermostat is all that is required to operate the system.

AIRFLOW CONSIDERATIONS

Airflow demands are managed differently in a communicating

system than they are in a non-communicating wired system. The system operating mode (as determined by the thermostat) determines which unit calculates the system airflow demand. If the furnace is responsible for determining the airflow demand, it calculates the demand and sends it to the ECM motor. If the outdoor unit or thermostat is responsible for determining the demand, it calculates the demand and transmits the demand along with a fan request to the indoor unit. The furnace then sends the demand to the ECM motor. The following table lists the various ComfortNet systems, the operating mode, and airflow demand source.

For example, assume the system is an air conditioner matched with a furnace. With a call for low stage cooling, the air conditioner will calculate the system’s low stage cooling airflow demand. The air conditioner will then send a fan request along with the low stage cooling airflow demand to the furnace. Once received, the furnace will send the low stage cooling airflow demand to the ECM motor. The ECM motor then delivers the low stage cooling airflow. See the applicable ComfortNet air conditioner or heat pump installation manual for the airflow delivered during cooling or heat pump heating.

System

Ai r Cond itio n er +

Furnace

He at Pum p +

Furnace

Furnac e + Non-

Comm 1stg Air

Conditioner

S ystem Operati ng

Mode

Cooling Air Conditioner

Heating Furnace

Continuous Fan Thermostat

Cooling Heat Pump

Heat Pum p He at ing

Only

Auxiliary Heating Furnace

Continuous Fan Thermostat

Cooling Furnace

Heating Furnace

Continuous Fan Thermostat

Airflow Deman d S our ce

He a t P ump

In continuous fan mode, the CTK0* thermostat provides the airflow demand. The thermostat may be configured for one of three continuous fan speed settings allow for 25%, 50% or 75% airflow, based on the furnaces’ maximum airflow capability. During continuous fan operation, the thermostat sends a fan request along with the continuous fan demand to the furnace. The furnace, in turn, sends the demand to the ECM motor. The ECM motor delivers the requested continuous fan airflow.

FOSSIL FUEL APPLICATIONS

This furnace can be used in conjunction with a ComfortNet™ compatible heat pump in a fossil fuel application. A fossil fuel application refers to a combined gas furnace and heat pump installation which uses an outdoor temperature sensor to determine the most cost efficient means of heating (heat pump or gas furnace). When used with the CTK0* thermostat, the furnace/heat pump system is automatically configured as a fossil fuel system. The balance point temperature may be adjusted via the CTK0* thermostat advanced user menus (see CTK0* instructions for additional information).

DIP S

S 2

DIP Switch

WITCHES

* or CTK02, CTK03, CTK04

** or CTK01

1 2 3 4 5 6 7 8 9 101112131415161718

A OFF O FF --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- ---

B ON O FF --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- ---

C OFF O N --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- ---

D ON ON --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- ---

A --- --- O FF O FF --- --- --- --- --- --- --- --- --- --- --- --- --- ---

B --- --- ON OFF --- --- --- --- --- --- --- --- --- --- --- --- --- ---

C --- --- O FF O N --- --- --- --- --- --- --- --- --- --- --- --- --- ---

D --- --- O N O N --- --- --- --- --- --- --- --- --- --- --- --- --- ---

A --- --- --- --- O FF O FF --- --- --- --- --- --- --- --- --- --- --- ---

B --- --- --- --- ON OFF --- --- --- --- --- --- --- --- --- --- --- ---

C --- --- --- --- O FF ON --- --- --- --- --- --- --- --- --- --- --- ---

D --- --- --- --- O N O N --- --- --- --- --- --- --- --- --- --- --- ---

A --- --- --- --- --- --- OFF OFF --- --- --- --- --- --- --- --- --- ---

B --- --- --- --- --- --- ON O FF --- --- --- --- --- --- --- --- --- ---

C --- --- --- --- --- --- OFF O N --- --- --- --- --- --- --- --- --- ---

D --- --- --- --- --- --- O N O N --- --- --- --- --- --- --- --- --- ---

Plus 10% --- --- --- --- --- --- --- --- O N OFF --- --- --- --- --- --- --- ---

M inus 10% --- --- --- --- --- --- --- --- OFF O N --- --- --- --- --- --- --- ---

90 Se c ond s --- --- --- --- --- --- --- --- --- --- O FF O FF --- --- --- --- --- ---

120 Se c onds --- --- --- --- --- --- --- --- --- --- O N OFF --- --- --- --- --- ---

150 Se c onds --- --- --- --- --- --- --- --- --- --- OFF ON --- --- --- --- --- ---

180 Se c onds --- --- --- --- --- --- --- --- --- --- O N ON --- --- --- --- --- ---

0 Trim Adju st --- --- --- --- --- --- --- --- OFF OFF --- --- --- --- --- --- --- ---

Fan

Tap

Speed

Heating

Continuous

Bank

Cooling

Speed Tap

Purpose Function

Switch

Speed

Tap

Cooling

Ramping

0 Trim Adju st --- --- --- --- --- --- --- --- O N ON --- --- --- --- --- --- --- ---

Taps

Adjust

Heat Off

1 Stage Stat* --- --- --- --- --- --- --- --- --- --- --- --- OFF --- --- --- --- ---

2 Stage Stat** --- --- --- --- --- --- --- --- --- --- --- --- ON --- --- --- --- ---

Delay

T-St at H eat

--- --- --- --- --- --- --- --- --- --- --- --- --- O N --- --- --- ---

--- --- --- --- --- --- --- --- --- --- --- --- --- OFF --- --- --- ---

age

tage

Compressor

Enabled --- --- --- --- --- --- --- --- --- --- --- --- --- --- ON --- --- ---

Disable d --- --- --- --- --- --- --- --- --- --- --- --- --- --- OFF --- --- ---

Compressor

Dehum

Enabled --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- ON --- ---

Disable d --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- OFF --- ---

Disable d --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- OFF ---

Bias

Pu ll U p

Enabled --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- ON

Enabled --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- ON ---

Disable d --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- OFF

Pull Down

Not applicable (Indicates factory setting)

---

Communicating thermostats are used only with Bias, Pull Up, Pull Down dip switches.

CTK0* WIRING NOTE: Refer to Electrical Connections for 115 volt line connections to the furnace.

NOTE: A removable plug connector is provided with the control to make thermostat wire connections. This plug may be removed,

wire connections made to the plug, and replaced. It is that multiple wires into a single terminal be twisted together prior to inserting into the plug connector. Failure to do so may result in intermittent operation.

Typical 18 AWG thermostat wire may be used to wire the system components. One hundred (100) feet is the maximum length of wire between indoor unit and outdoor unit, or between indoor unit and thermostat. Wire runs over (100) feet require larger gauge wire.

FOUR-WIRE INDOOR AND OUTDOOR WIRING

strongly recommended

12RC

CTK0* Thermostat

ComfortNet Compatible Furnace Integrated Control Module

ComfortNet Compatible AC/HP Integrated Control Module

Typical ComfortNet™ wiring will consist of four wires between the indoor unit and

System Wiring using Four-Wires outdoor unit and between the indoor unit and thermostat. The required wires are: (a) data lines, 1 and 2; (b) thermostat “R” (24 VAC hot) and “C” (24 VAC common).

12RC

CTK0* Thermostat

TWO-WIRE OUTDOOR, FOUR-WIRE INDOOR WIRING

ComfortNet Com pat ible Furnace Integrated Control Module

ComfortNet Compatible

AC/HP Integra ted Control Module

As few as two wires can be utilized between the indoor and outdoor units. For this wiring scheme, only the data lines, 1 and 2, are needed between the indoor and outdoor units. A 40VA, 208/ 230 VAC to 24VAC transformer must be installed in the outdoor unit to provide 24VAC power to the outdoor unit’s electronic control. The transformer is included in selected communicating

40VA Transformer (included in CTK01 kit)

208/230 VAC

24 VAC

12RC

thermostat kits. See kit instructions for mounting and wiring instructions. Four wires are required between the indoor unit and thermostat. If using a communicating thermostat kit that does not include a transformer in a dual fuel system, the accessory transformer kit TFK01 should be used.

NOTE: Use of the accessory transformer is recommended if

installing a dual fuel/fossil fuel system. Failure to use the

System Wiring using Two-Wires between Furnace and AC/HP

and Four-Wires between Furnace and Thermostat

CTK0* Thermostat

12RC

4-Position Connectors from CTK0* Thermostat Kit

transformer in the outdoor unit could result in over loading of the furnace transformer.

12RC

W1 W2 Y1 Y2

ComfortNet Compatible Furnace Int egrate d Control Module

COMFORTNET™ COMPATIBLE FURNACE WITH NON-COMFORTNET

COMPATIBLE

Four wires are required between the furnace and thermostat. Two wires are required between the furnace control and single stage air conditioner. For this system configuration, the “Y1” terminal on the integrated furnace control becomes an output rather than an input. The “Y1” connection to the outdoor unit is made using both of the 4-position thermostat connectors in the CTK0* kit. Remove the red keying tabs from the on-board connector block and position both 4-position connector such that “1”, “2”, “R”, “C”, and “Y1” positions are filled.

SINGLE-STAGE AIR CONDITIONER

Non- Compatible

C Y

System Wiring between Furnace and Non-

Communicating Compatible Single Stage Air Conditioner

ComfortNet

Single Stage AC

COMFORTNET™ SYSTEM ADVANCED F EATURES

The ComfortNet system permits access to additional system information, advanced setup features, and advanced diagnostic/ troubleshooting features. These advanced features are organized into a menu structure. The menus are accessed and navigated as described in the instructions provided with the communicating control.

DIAGNOSTICS

Accessing the furnace’s diagnostics menu provides ready access to the last ten faults detected by the furnace. Faults are stored most recent to least recent. Any consecutively repeated fault is stored a maximum of three times. Example: A clogged return air

filter causes the furnace limit to trip repeatedly. The control will only store this fault the first three consecutive times the fault

occurs.

NOTE: It is highly recommended that the fault history be cleared when performing maintenance or servicing the furnace.

NETWORK TROUBLESHOOTING

The indoor control is equipped with a bank of three DIP switches that provide biasing and termination functions for the communications transmission lines. The outdoor control in the communicating compatible unit is equipped with a bank of two DIP switches that provide termination functions for the communications transmission lines. Communications errors will result if these switches are not correctly set. Note that the ON position is the correct position for all bias and pull up/pull down DIP switches.

The ComfortNet™ system is a fully communicating system, and thus, constitutes a network. Occasionally the need to troubleshoot the network may arise. The furnace control board has some on-board tools that may be used to troubleshoot the network. These tools are: red communications LED, green receive (Rx) LED, and learn button.

• Red communications LED – Indicates the status of the network. The table below indicates the LED status and the corresponding potential problem.

• Green receive LED – Indicates network traffic. The table below indicates the LED status and the corresponding potential problem.

• Learn button – Used to reset the network. Depress the button for approximately 2 seconds to reset the network.

SYSTEM TROUBLESHOOTING

NOTE: Refer to the instructions accompanying the ComfortNet compatible outdoor AC/HP unit for troubleshooting information.

Refer to the Troubleshooting Codes for a listing of possible furnace error codes, possible causes and corrective actions.

FAULT RECALL SEQUENCE

• Only allowed in standby mode while display is showing ON.

• Hold fault recall push-button for 2-5 seconds (until display is blank) and then release.

• Display will then be blank for 2 seconds before displaying faults stored in history.

• All faults are displayed one time, from most recent to least recent.

• A Maximum of 3 consecutive faults of the same type will be logged.

• Each error is displayed for 2 seconds, with a blank screen for 1 second in between.

• When all errors have been displayed, the display returns to ON.

LED LED Status Indication Possible Caus es Corrective Action (s) Notes & Cautions

Red

Communications

LED

Green

Receive

LED

Off • Normal condition • None • None • None

2 Flashes • Out-of-box reset • None • None

Rapi d Flashing • Norma l network traff ic • Control is “talking” on

On Solid • Data 1/ Data 2 miss-

wir e

• Control power up

• Learn button depress ed

network as expected

• Data 1 and data 2 wires revers ed

at furnace, thermostat or

communicating compatible

outdoor AC/HP

• Short between data 1 and

data 2 wires.

• Short between data 1 or

data 2 wires and R

(24VAC) or C (24VAC

common).

• None • None

•Check communications

wiring (data 1/ data 2

wires).

•Check wire connections at

terminal block

•Check data 1/ data 2

voltages.

•Turn power OFF prior to

repair.

• Verify wires at terminal

blocks are s ecurely twisted

together prior to ins erting

into terminal block.

•Verify data 1 and data

voltages as described abov e

FAULT CLEAR SEQUENCE:

• Only allowed in standby mode, while display is showing ON.

• Hold fault recall push-button for 5-10 seconds (until display starts flashing “—”) and then release.

• All faults in the history will have been cleared, and display returns to ON.

• If you hold the button for longer than 10 seconds, the display will return to ON and the faults will not be cleared.

ORMAL SEQUENCE OF OPERATION

POWER UP

The normal power up sequence is as follows:

• 115 VAC power applied to furnace.

• Integrated control module performs internal checks.

• Integrated control module monitors safety circuits continuously.

• Furnace awaits call from thermostat. Dual 7-segment LED’s display O while awaiting call from thermostat.

HEATING MODE

The normal operational sequence in heating mode is as follows:

• Thermostat contacts close, initiating a call for heat.

• Integrated control module performs safety circuit checks.

• Induced draft blower is energized on high speed for a 15-second prepurge.

• Induced draft blower steps to low speed following prepurge. Low stage pressure switch contacts are closed.

• Igniter warm up begins upon step to low speed and presence of closed low stage pressure switch contacts.

• Gas valve opens at end of igniter warm up period, delivering gas to burners and establishing flame.

• Integrated control module monitors flame presence. Gas valve will remain open only if flame is detected.

• The percentage of heating demand is sent from the furnace control board to determine what RPM the draft inducer

should run at. A higher percentage demand will drive the inducer RPM higher. This will cause the gas valve to modulate higher. The burner will modulate based on the inducer speed

• Circulator blower is energized on heat speed following a thirty (30) second blower on delay. The circulator blower CFM will

increase or decrease with gas valve modulation. Electronic air cleaner terminal is energized with circulator blower.

• Furnace is now operating on the specified stage called for by the thermostat.

• Furnace runs, integrated control module monitors safety circuits continuously.

• If the two-stage thermostat changes the call from low heat to high heat, the integrated control module will immediately switch

the induced draft blower, gas valve, and circulator blower to their high stage settings.

• The thermostat contacts open, completing the call for heat.

• Gas valve closes, extinguishing flame.

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

• Circulator blower continues running for the selected heat off delay period (90, 120, 150 or 180 seconds). The speed run during

this period depends on the last heat call provided by the thermostat. If the last call for heat was a call for high heat, the air circulating motor will run on the high heating speed for thirty (30) seconds

and then switch to the low heating speed for the balance of the heat off delay period (60, 90, 120 or 150 seconds).

• Circulator blower and electronic air cleaner terminal is de-energized.

• Circulator blower ramps down to OFF during the 30 seconds following the heat off delay period.

• Furnace awaits next call from thermostat.

COOLING MODE

The normal operational sequence in cooling mode is as follows:

• R and Y1/G or Y2/G thermostat contacts close, initiating a call for cool.

• Integrated control module performs safety circuit checks.

• Outdoor fan and compressor are energized to their appropriate speed.

• Circulator blower is energized on the appropriate cool speed at the level and time determined by the selected ramping profile.

Electronic air cleaner terminal is energized with circulator blower.

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

circuits continuously.

• R and Y1/G or Y2/G thermostat contacts open, completing the call for cool.

• Outdoor fan and compressor are de-energized.

• Circulator blower continues running during a cool off delay period. The OFF delay time and airflow level are determined by the

selected ramping profile.

• Electronic air cleaner terminal and circulator blower are de-energized.

• Furnace awaits next call from thermostat.

FAN ONLY MODE

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

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

• Integrated control module performs safety circuit checks.

• Circulator blower is energized on continuous fan speed (25%, 50%, 75% or 100% DIP switch selectable when using a

conventional thermostat). Electronic air cleaner terminal is energized.

• The furnace control board HUM dry contacts close.

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

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

• Circulator blower is de-energized. Electronic air cleaner terminal is de-energized.

• Furnace awaits next call from thermostat.

PERA TIONAL CHECKS

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

AFETY CIRCUIT DESCRIPTION

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

Check t he Burner Flames for:

1. Stable, soft and blue.

2. Not curling, floating or lifting off.

Burner Flame

Figure 53

FURNACE CONTROL BOARD

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

PRIMARY LIMIT

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

AUXILIARY LIMIT

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

ROLLOUT LIMIT

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

PRESSURE SWITCHES

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

FLAME SENSOR

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

ROUBLESHOOTING

ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS

NOTE: Discharge body’s static electricity before touching unit. An electrostatic discharge can adversely affect electrical components.

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

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

DIAGNOSTIC CHART

Refer to the T roubleshooting Codes for assistance in determining

the source of unit operational problems. The dual 7-segment LED display will display an error code that may contain a letter and number. The error code may be used to assist in troubleshooting the unit.

HIGH VOLTAGE !

AVOID PERSONAL INJURY OR DEATH DUE TO

ELECTRICAL SHOCK, DISCONNECT ELECTRICAL POWER

BEFORE

PERFORMING ANY SERVICE OR MAINTENANCE

WARNING

RESETTING FROM LOCKOUT

Furnace lockout results when a furnace is unable to achieve ignition after three attempts during a single call for heat. It is character-

ized by a non-functioning furnace and a E 0 code displayed on the dual 7-segment display. If the furnace is in “lockout”, it will (or can

be) reset in any of the following ways.

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

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

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

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

AINTENANCE

WARNING

ANNUAL INSPECTION

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

AVOID ELECTRICAL SHOCK, INJURY OR DEATH DISCONNECT ELECTRICAL POWER BEFORE PERFORMING ANY MAINTENANCE HANDLE WITH CARE WITH BARE FINGERS, ROUGH HANDLING OR VIBRATION COUL D DAMAGE THE IGNITER RESU LTING IN PREMATURE FAILURE HANDLE THE IGNITER

. IF

YOU MUST HANDLE THE IGNITER

. T

OUCHING THE IGNITER ELEMENT

. O

NLY A QUALIFIED SERVICER SHOULD EVER

• Flue pipe system. Check for blockage and/or leakage. Check the outside termination and the connections at and internal to the furnace.

• Heat exchanger. Check for corrosion and/or buildup within the heat exchanger passageways.

• Burners. Check for proper ignition, burner flame, and flame signal.

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

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

• Filters.

• Use a combustion analyzer to check CO2 level after 5 minutes of run time.

FILTERS

CAUTION

FILTER MAINTENANCE

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

ENSURE PROPER UNIT PERFORMANCE, ADHERE TO THE FILTER SIZES

GIVEN IN THE RECOMMENDED MINIMUM FILTER SIZE TABLE OR

PECIFICATION SHEET APPLICABLE TO YOUR MODEL

FILTER REMOVAL

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

To remove filters from an external filter rack in an upright upflow installation, follow the directions provided with external filter rack kit.

HORIZONTAL UNIT FILTER REMOVAL

Filters in horizontal installations are located in the central return register or the ductwork near the furnace.

To remove:

1. Turn OFF electrical power to furnace.

2. Remove filter(s) from the central return register or ductwork.

3. Replace filter(s) by reversing the procedure for removal.

4. Turn ON electrical power to furnace.

MEDIA AIR FILTER OR ELECTRONIC AIR CLEANER REMOVAL

Follow the manufacturer’s directions for service.

BURNERS

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

INDUCED DRAFT AND C IRCULATOR BLOWERS

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

CONDENSATE TRAP AND DRAIN SYSTEM (QUALIFIED SERVICER ONLY)

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

FLAME SENSOR (QUALIFIED SERVICER ONLY)

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

EFORE LEA VING AN INST ALLATION

• Cycle the furnace with the thermostat at least three times. Verify cooling and fan only operation.

• Review the Owner’s Manual with the homeowner and discuss proper furnace operation and maintenance.

• Leave literature packet near furnace.

EP AIR AND REPLACEMENT PAR TS

• When ordering any of the listed functional parts, be sure to provide the furnace model, manufacturing, and serial numbers

with the order.

• Although only functional parts are shown in the parts list, all sheet metal parts, doors, etc. may be ordered by description.

• Parts are available from your distributor.

Functional Parts List-

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

ROUBLESHOOTING CODES

Turn power OFF prio r t o repair.

Read precautions in “Electrostatic

Discharge” se ct ion of manual.

R epla c e integr ated c ontro l m odule

•

Assure proper wiring to furnace and

•

w ith current replac ement part s .

•

integra ted c ontrol module .

Verify power to the furnace and

integra ted c ontrol module is s table and

within spe c ifications.

Replace bad in tegr ated control modul e.

•

Turn power OFF prio r t o repair.

Igniter is fragile, handle with care.

•••

Lo c ate and correct gas int erruption.

Che ck front cover pre s sure switch

•

Turn power OFF prio r t o repair.

Replace pre ssure switch w ith correct

Clean flame rod with steel wool.

See “Vent/Flue Pipe” section for

piping details.

•

operation (hose, wiring, contact

operation). Correct if necessary. Make

sure furnace is draining properly.

Replace or realign igniter.

Check flame sense signal. Sand sensor

if coated and/or oxidized.

Ch eck flue piping fo r blockage , proper

length, elbows, and termination.

Verify prope r i ndu c ed draft blower

•

performance.

•

replacement part.

•

Replace lo w stage pressure switch.

Repair short in w iring.

•

Turn power OFF prio r t o repair.

Replace pre ssure switch w ith correct

replacement part.

R epla c e induced dr aft blower with

correct replac ement part.

Take care t o assemble/ install H fitting

•

blo c k age, proper length, elbow s , a nd

in fac tor y configur ation.

•

termination.

Che ck drain system. Corre ct as

necessary.

Check induced draft blow er

performance. Correct as necessary.

Correct pressure switch set point or

•

contact motion.

•

Inspect pressure switch hose.

Repair/replace if nece ssary.

Inspect flue and/or inlet air piping for

•

Turn power OFF prio r t o repair.

See Specification Sheet applicable to

your mo del for allowable rise ra nge

and proper circulator speed.

•

Che ck filters and ductwork for

blo c k age. Cle an filters or remove

obstruction.

Check circulator blower speed and

performance. Correct speed or replace

blower moto r if necessary.

Tighten or correct wiring connection.

Clean H fitting.

•

Tighten or correct wiring connection.

•

Possible Causes Corrective Actions Notes & Cautions

Low stage pre s sure switch

contacts sticking.

Shorts in pres sure switch circuit

integra ted c ontrol module .

EE • Improper wiring to the furnace or

ComfortNet

T hermostat Only

Fault

FAULT

Message Code

INTERNAL

Description

control module

has an internal

fault

•Integrated

& Status

Diagnostic

LED Codes

Failure to establish flame. Cause

may be no gas to burners, front

cover pressure switch stuck ope n,

ba d igniter or i gniter alignment,

improper orifices, or

coated/oxidized or improperly

connected flame sensor.

Loss of flame after establishment.

Cause may be interrupted gas

supply, lazy burner flames

(improper gas pre ssure o r

re stric tion in flue a nd/or

combustio n a ir piping), front cover

pressure switch opening, or

imprope r i nduced dr aft blower

•

LOCKOUT E0 •

due to a n

excessive

number o f

ignition “retries”

or flame

“recycles” (3

• Normal operation None None • Normal operation • None • Normal operation

•Furnace lockout

error code.

total).

performance.

wiring.

•

E1 •

PS1

CLOSED

pressure switch

circuit is closed

at start of

• Low stage

erro r code.

Pressure switch hose blocked

pinched, or conne c ted im p r ope r ly.

Blocked flue and/o r in let air pipe,

blocked dra in syste m o r w eak

induced draft blower.

Incorrect pressure switch set point

or malfunctio ning s w itch cont acts .

Loose or improperly connected

wiring.

Induc er not r u nnin g.

•

E2 •

PS1

OPEN

heating cycle.

pressure switch

circuit is not

closed.

• Low stage

H fitt ing atmo s pheric port blocked.

•

error code.

Insufficient conditioned air over

the he at ex c hanger. Blo c ked

filte rs, re st rict ive ductw o rk,

improper circulator blower speed,

or failed circulator blower motor.

Loose or improperly connected

wiring.

•

E3 •

LIMIT

OPEN

• Primary limit. HIGH

error code.

(Non-communicating

& ComfortNet™ T hermostat)

Furnace fails to operate

Integrat ed cont rol module LED

display provides IF e rro r co de.

ComfortNet thermostat “Call for

Service” icon illum i nated

ComfortNet thermostat scrolls

“Check Furnace” message

Furnace fails to operate

Integrat ed cont rol module LED

display provides

ComfortNet thermostat “Call for

Service” icon illuminated.

ComfortNet thermostat scrolls

•

Symptoms of Abnormal Operation

•

• LED display indicates

•

“Check Furnace” message.

•

Induc ed draft blow er runs

continuously with no furth er

furnace operation.

Integrat ed cont rol module LED

display provides

ComfortNet thermostat “Call for

Service” icon illuminated.

ComfortNet thermostat scrolls

Furnace fails to operate.

Integrat ed cont rol module LED

display provides

ComfortNet thermostat “Call for

Service” icon illuminated.

ComfortNet thermostat scrolls

“Check Furnace” message.

•

“Check Furnace” message.

•

Circula tor blowe r runs continuously.

No furnace operation.

Integrat ed cont rol module LED

display provides

ComfortNet thermostat “Call for

Service” icon illuminated.

ComfortNet thermostat scrolls

•

“Check Furnace” message.

•

TROUBLESHOOTING CODES

• Turn power O F F pr ior to repair.

Correct short at flame sensor or

in flame sensor wiring.

Che ck for lingering flame.

Verify proper operation of gas

•

valve . Replace if necessary.

•

Reset system power a nd ve rify

inducer is run ning pr operly.

•

Turn pow e r O FF prior t o re pa ir.

Replace fuse with 3- amp automotive

• Turn power O F F pr ior to repair.

Replace inducer or integrated

control module, if nec essar y .

•

Line up or ifice plate .

Remove Blockage from heat

exchanger.

Line up burner s.

•

• Turn power O F F pr ior to repair.

Check for flame disturbance on

roll out when blower comes on.

Ins t all jumpe r .

•

Inspect float switch.

•

type

•

low volt age wiring.

Turn pow e r O FF prior t o re pa ir.

Clean flame sensor with steel wool.

•••

Clean flame sensor if coated/oxidized.

Inspect for proper sensor alignment.

•

See "Vent/Flue Pipe" section for

piping details.

See rating plate for proper gas

pressure.

Turn pow e r O FF prior t o re pa ir.

Replace pre ssure switch w ith correct

•

Ch eck inlet air pip ing for blockage,

proper length, elbows, and termination.

Compare current gas pressure to r ating

plate. Adjust as needed.

•

replacement part.

•

Replace high st age pres s ur e swit c h.

Repair short in w iring

•

Possible Causes Corrective Actions Notes & Cautions

Short to ground in flame sense

circuit.

Linge r ing burn er flam e.

Slow closing gas valve.

•

E4 •

ComfortNet

T hermostat Only

Fault

FLAME

Message Code

IMPROPER

Description

when it should

not be present.

•Flame sensed

& Status

Diagnostic

LED Codes

error code .

overcurrent detected.

EC • Linger ing I ndu cer mot or

INDUCER

LOCKOUT

FAULT OR

overcurrent

fault.

• Induc er motor

Orifice plate out of position.

Ed •

ROLLOUT

•Manual reset

Blocked heat exchanger.

•••

OPEN

ro llout sw itch is

Burners out of alignment.

Defective heat exchanger.

open.

error code .

Open circuit between aux in or aux

out.

Missing jumper.

Open float switch.

• Short in low voltage wiring • Locate and correct short in

•

EF •

OPEN

AUXILIARY

input.

• Open a ux ili ary

Displayed

• Open Fuse . No t Displayed No t

error code .

Flame sensor is coated/oxidized.

Flame sensor incorrectly

positioned in burner flame.

La z y b ur n er fla m e due to improper

gas pressure or combustion air.

High stage pressure sw itch

contacts sticking.

Shorts in pres sure switch circuit

•

E6 •

WEAK

FLAME

micro amp

signal is lo w.

•Flame sense

error code .

wiring.

•

E8 •

PS2

CLOSED

High stage

pressure switch

circuit is closed

at start of

heating cyc le.

Induc ed draft

blower is

operating.

Furnace is

operating on

•

low stage only

•

error code .

(Non-communicating

& ComfortNet™ T hermostat)

Induced draft blower and circulator

blo wer runs continuous ly . No

furnace operation.

Integrat ed cont rol module LED

display provides

ComfortNet thermostat “Call for

Service” icon illuminated.

ComfortNet thermostat scrolls

“Check Furnace” message.

Furnace fails to operate

Integrat ed cont rol module LED

display pro vide s EC error code.

ComfortNet thermostat “Call for

Service” icon illuminated.

ComfortNet thermostat scrolls

Symptoms of Ab normal Operation

•

“Check Furnace” message.

•

No furnace operation.

Integrat ed cont rol module LED

display provides

•

No furnace operation.

Integrat ed cont rol module LED

display provides Ef error code.

No furnace operation.

Integrat ed cont rol module LED

display provides

ComfortNet thermostat displays

“Batte ry Po w er”.

Normal furnace operation.

Integrat ed cont rol module LED

•

display provides

•

Furnace fails to operate on high

stage; furnace operates normally

on low stage.

Integrat ed cont rol module LED

•

display provides

•

TROUBLESHOOTING CODES

Turn pow er OFF prior to re pair.

Replace pressure switch with correct

replacement part.

•

Replace high sta ge pre ss ur e switch.

Repair short in wiring

•

Turn pow er OFF prior to re pair.

Replace pressure switch with correct

replacement part.

Replace induced draft blower with

•

Inspect pressure switch hose.

•

correct replacement part.

•

Repa ir/replace if necessary.

Inspect flue and/or inlet air piping for

blockage, proper length, elbows, and

termination. Che ck drain system.

Correct as necessary.

C heck induced draft blow er

performance. Correct as necessary.

•

Corre ct pressure sw itch set point or

•

• Turn pow er OFF prior to re pair.

contact motion.

Tighten o r c orre ct wiring connectio n.

Review wiring diagra m t o correct

polarity.

Verify proper ground. Correct if

•

necessary.

•

Turn pow er OFF prior to re pair.

Use me mo ry ca rd for the specific

model.

Insert memo ry ca rd BEFOR E t urning

powe r ON. Memory card may be

removed after data is loaded.

Turn power OF F before removing

memo ry card.

Error co de will be cleared once data

is loaded.

Turn pow er OFF prior to re pair

Use me mo ry ca rd for the specific

model.

Insert memo ry ca rd BEFOR E t urning

powe r ON. Memory card may be

removed after data is loaded.

Turn power OF F before removing

memo ry card.

Error co de will be cleared once data

•

Che ck and corre ct wiring.

•

memo ry ca rd.

• Populate shared data set using

•

the specific model. Re-populate

data using correct memory card if

required.

• Verify shared data set is correct for

is loaded.

•

Possibl e Cau ses Corrective Actions Notes & Cau tions

High stage pressure switch

contacts sticking.

Shorts in pressure switch circuit

wiring.

•

E8 •

ComfortNet

PS2

T h ermostat On l y

Fault

CLOSED

Message Code

Descrip tion

High stage

pressure switch

circuit is closed

at start of

heating cycle.

Indu c ed draft

blower is

operating.

•

Furnace is

•

& Status

Diagn ostic

LE D Codes

error code .

operating on

Pressure switch hose blocked

pinched, or connecte d i m p r operly .

Bloc k ed flue a nd/or inle t air pipe,

block ed drain sy s tem or w eak

induced draft blo wer.

Incorrect pres sure sw it ch se t po int

or malfunctioning switch conta cts.

Loose or improperly connected

•

E9 •

PS2

OPEN

low stage only

High stage

pressure switch

circ uit is not

closed.

•

Indu c ed draft

•

wiring.

•

blower is

operating.

Furnace is

operating on

•

error code .

Polarity of 11 5 volt AC powe r to

furnace or integrated module is

reversed.

Rever s ed unit ground.

•

EA •

PLTY

REVERSED

low stage only

115 v ol t A C i s

reversed

• Polarity of

error code.

shared data.

d0 • Furnace does not contain any

DATA

NO NET

on network.

•Data not yet

error code .

has been reject ed by inte gra t e d

control module

d4 • Shared data set on memory card

DATA

INVALID MC

card data.

• Invalid memory

error code .

(Non-communicating

& ComfortNet™ T h ermostat)

Furnace fails to operate on high

stage; furnace operates normally on

low stage.

Int egrated contro l module LED

Symptoms of Abnormal Op eration

•

display provides

•

Furnace fails to operate on high

stage; furnace operates normally on

low stage.

Int egrated contro l module LED

•

display provides

Furnace fails to operate.

Int egrated contro l module LED

display provides

ComfortNet thermostat “Call for

Service” ico n il lum i nated.

ComfortNet thermostat scrolls

“Check Furnace” message.

Furnace fails to operate.

Int egrated contro l module LED

display provides

ComfortNet thermostat “Call for

Service” ico n il lum i nated.

ComfortNet thermostat scrolls

•

“Check Furnace” message.

•

Operation different than expected or

no operation.

Int egrated contro l module LED

display provides

ComfortNet thermostat “Call for

Service” ico n il lum i nated.

ComfortNet thermostat scrolls

•

“Check Furnace” message.

•

TROUBLESHOOTING CODES

Turn po wer O FF pr i or t o repair

Re pla ce circulator motor with correct

Turn po wer O FF pr i or t o repair

Replace inductor with correct

replacement part.

Re pla ce circulator motor with correct

•

Corr e c ti v e Ac t i on s N ote s & C a u ti onsPossible Causes

Tighte n o r correct wiring connection.

•

replacement part.

•

Ver ify continuous c irc uit through

inductor. Replace if open or short

circuit.

Check circulator blower motor.

•

Replace if necessary.

•

replacement part.

•

Tighte n o r correct wiring connection.

Check blower motor with UTT-01

Emerson test er

•

Repla c e integrated co nt r ol module

with correct replacement part.

•

Check integrated control module.

Replace if necessary.

•

Turn po wer O FF pr i or t o repair

Replace motor with correct

replacement part.

Use memory card for the spe cific

model

Insert memo ry card BEFORE turning

powe r O N. Memo ry card may be

removed after data is loaded.

Turn pow e r OF F be fore remo ving

memory car d.

Error code w ill be cleare d once

shared data and motor horse power

match.

•

Verify circulator blower motor horse

power is the same specified for the

specific furnace m odel. Re place if

necessary.

Verify shared data set is correct for the

spe cific mo d el. Re - populate data

•

using correct memory card if required.

•

• Turn power O FF pr i or t o repair.

C heck filte r s for blockage. Cle an filters

or remove obstruct io n.

Che ck ductwork for blo c kage. Remo ve

obstruct ion. Verify all registers

are fully open.

Verify ductwork is appropriat ely sized

for system. R esize/replac e ductwo rk if

necessary.

See "Pro duct Descriptio n" and

•

"Loca tion Requireme nts

•

• Turn power O FF pr i or t o repair.

& Cons iderat ions" for furnace

inst allation requirements.

duct system, and furnace

a ir inlet/outlet for blockages.

• C heck filters, filter grills/register s ,

Loose wiring connection at

circulato r moto r control leads.

Failed circulator blower motor.

Loose wiring connection at

circulato r motor powe r leads or

circulato r motor powe r leads

disconnected.

Open circuit in induc tor or loose

w ir i ng connectio n at induct or (3/4

Hp and 1 Hp models only).

Failed circulator blower motor.

•

b0 •

ComfortNet

T h ermostat Onl y

MOTOR

Message Code

NOT RUN

Fault

Descrip ti on

motor is not

running when

it s hould be

• Circulator blower

running.

& Status

Diagnostic

LE D Codes

error code.

Faile d integrated c ontro l module.

•

b1 •

COMM

MOTOR

co nt r ol mo dule

has lost

commun ications

• Integrated

with circulator

error code.

Incorrect circulator blowe r motor in

furnace.

Incorrect sha red data set in

integrat ed contr ol module.

•

b2 •

MOTOR

MISMATCH

blower motor.

moto r horse

power in shared

dat a set does not

match circula tor

blower motor

• Circulator blower

horse powe r.

error code.

Blocked filte rs.

b3 •

MOTOR

• Circulator blower

Rest rictive ductwork.

Undersized ductwork.

•••

LIMITS

moto r is

operating in a

High ambient temperatures.

power,

temperature, or

speed lim iting

condition.

Abnor mal mo tor loading, s udden

change in speed or torque,

sudden blockage of furnace air

inlet or outlet.

H igh loading conditions, blocked

filters, very rest rict ive ductwo rk,

blockage of furnace air inlet or

outlet.

•

b4 •

TRIPS

MOTOR

Circulator blower

motor senses a

loss of rotor

control.

Circulator blower

moto r se nse s

•

high curre nt .

•

error code.

(Non-communicating

& ComfortNet™ Ther mostat)

Furnace fails to operate.

Integr ated c ontro l m odule LED

display pr ovides

ComfortNet thermostat “ Call for

Service” ico n il lum i nated.

ComfortNet thermostat scrolls

•

Symptoms of Abnormal Operation

•

“Check Furna c e” message.

•

ComfortNet thermostat “ Call for

Service” ico n il lum i nated.

ComfortNet thermostat scrolls

Furnace fails to operate.

Integr ated c ontro l m odule LED

display pr ovides

•

“Check Furna c e” message.

•

Furnace fails to operate.

Integr ated c ontro l m odule LE

display pr ovides

ComfortNet thermostat “ Call for

Service” ico n il lum i nated.

ComfortNet thermostat scrolls

•

“Check Furna c e” message.

•

Furnace operates at reduced

performance.

Airflow delivered is less than

expected.

Integr ated c ontro l m odule LED

•

display pr ovides

•

Furnace fails to operate.

Integr ated c ontro l m odule LED

display pr ovides

ComfortNet thermostat “ Call for

Service” ico n il lum i nated.

ComfortNet thermostat scrolls

•

“Check Furna c e” message.

•

TROUBLESHOOTING CODES

Turn power OF F prior to repair

Replace motor with correct

replacement part.

Replace wheel with correct

replacement part.

•

Check circulator blower for

obstruct ions. Remove and

repair /replace wheel/motor if necessary.

Check circulator blower motor shaft

•

• Turn pow er OF F prior to repair.

rotation and motor. Re place motor if

necessary.

Che ck power to furnace. Verify line

voltage to furnace is within the range

specified on the furnace rating plate.

See "Product Des c ription" and

•

Turn power OF F prior to repair.

Replace with correct replacement

part(s).

Use memory card for the spe cific

•

"Location Requirements &

Considerations" fo r furnace

installation requirements.

C heck integra ted c ontro l module.

•

model.

•

Verify control is populated with

correct shared data set. See data

errors abo ve for det ails.

Che ck fo r lo ck ed rotor condition

(see error code above for details).

•

• Turn pow er OF F prior to repair.

Check filters for blockage. Clean filters

or remove obstruction.

C heck duct wo r k for blockag e. Remove

obstruction. Verify all registers are fully

open.

Verify ductwork is appropriately sized

for system. Resize/replace ductwo rk if

•

necessary.

•

Possib le Cau ses Corrective Acti ons Notes & Cautions

Obstruction in circulator bl ower

housing.

Seized circulator blower motor

bearings.

Faile d circulator blower motor .

High AC line voltage to furnace.

Low AC line voltage to furnace.

•

b5 •

ComfortNet

T hermostat Only

Fault

ROTOR

Mess ag e Code

MTR LCKD

Descrip ti on

motor fails to

sta rt 10

consecutive

• Circulator blower

times.

& Status

Diagnostic

LE D Codes

error code .

High ambient temperatures.

•

b6 •

VOLTS

MOTOR

Circulator blower

mot or shuts

down for over or

unde r vo ltage

condition.

Circulator blower

mot or shuts

do wn due to

•

over temperature

•

error code .

Error with integrated control

module.

Mot or has a locked ro tor co nditio n.

•

b7 •

MOTOR

PARAMS

condition o n

po we r modul e.

Circulator blower

motor does not

have enough

infor m ation to

operate properly.

Motor fails to

•

start 40

•

error code .

Blocked filters.

Restrictive ductwork.

Undersized ductwork .

•

b9 •

LOW ID

AIRFLOW

consecutive

times.

than de m ande d.

• Airflo w is lo wer

error code .

(Non-communicating

& ComfortNet™ T hermostat)

Furnace fails to operate.

Integra ted control module LE D

display provides

ComfortNet thermostat “Call for

Service” icon illu mi nated.

ComfortNet thermostat scrolls

“Check Furnace” message.

Furnace fails to operate.

Integra ted control module LE D

display provides

ComfortNet thermostat “Call for

Service” icon illu mi nated.

ComfortNet thermostat scrolls

•

Symptoms of Abnormal Operation

•

“Check Furnace” message.

•

Furnace fails to operate.

Integrat ed cont rol module LED

display provides

ComfortNet thermostat “Call for

Service” icon illu mi nated.

ComfortNet thermostat scrolls

•

“Check Furnace” message.

•

Furnace operates at reduced

performance.

Integra ted control module LE D

display provides

•

STATUS CODES

NO POWER NORMAL OPERATION

INDICATES AIRFLOW, FOLLOWED BY CFM

BLOWER MOTOR NOT RUNNING

BLOWER COMMUNICATION ERROR

BLOWER HP MIS-MATCH

BLOWER MOTOR OPERATING IN POWER, TEMPERATURE, OR SPEED LIMIT

BLOWER MOTOR CURRENT TRIP OR LOST ROTOR

BLOWER MOTOR LOCKED ROTOR

BLOWER OVER/UNDER VOLTAGE TRIP OR OVER TEMPERATURE TRIP

INCOMPLETE PARAMETERS SENT TO MOTOR

LOW INDOOR AIRFLOW

CONVENTIONAL COMPRESSOR COOLING WHEN 1-STAGE COMPRESSOR IS SET UP

LOW STAGE COOL

HIGH STAGE COOL

CONVENTIONAL COMPRESSOR COOLING WITH DEHUMIDI FICATION WHEN 1-STAGE COMPRESSOR IS SET UP

DATA NOT YET ON NETWORK

CONVENTIONAL 1-STAGE COMPRESSOR COOLING WITH DEHUMIDI F ICATI ON W HEN 2-STAGE CO MPRESSO R IS SET UP

CONVENTIONAL 2-STAGE COMPRESSOR COOLING WITH DEHUMIDI F ICATI ON W HEN 2-STAGE CO MPRESSO R IS SET UP

INVALID MEMORY CARD DATA

DEFROST DEMAND

LOCKOUT DUE TO EXCESSIVE RETRIES OR RECYCLES

LOW STAGE PRESSURE SWITCH STUCK CLOSED AT START OF HEATING CYCLE

LOW STAGE PRESSURE SWITCH STUCK OPEN

OPEN HIGH LIMIT SWITCH

FLAME DETECTED WHEN NO FLAME SHOULD BE PRESENT

OPEN FUSE

LOW FLAME SIGNAL

IGNITER FAULT OR IMPROPER GROUNDING

HIGH STAGE PRESSURE SWITCH STUCK CLOSED AT START OF HEATING CYCLE

HIGH STAGE PRESSURE SWITCH STUCK OPEN

REVERSED 115 VAC POLARITY

INDUCER MOTOR OVERCURRENT FAULT

ROLLOUT SWITCH OPEN

AUXILIARY INPUT OPEN

CONTINUOUS FAN OR FURNACE PROVIDING AIR FOR COMMUNICATING OUTDOOR UNIT

FIELD TEST MODE

INDICATES GAS HEAT, FOLLOWED BY PERCENTAGE OF DEMAND

HIGH HEAT = 100%

INTERNAL FAULT

CONVENTIONAL COMPRESSOR HEATING WHEN 1-STAGE COMPRESSOR IS SET UP

CONVENTIONAL 1-STAGE COMPRESSOR HEATING WHEN 2-STAGE COMPESSOR IS SET UP

CONVENTIONAL 2-STAGE COMPRESSOR HEATING WHEN 2-STAGE COMPESSOR IS SET UP

% OF HIGH HEAT

CFM x 100, ALTERNATES WITH THERMOSTAT CALL & GAS HEAT OPERATING PERCENTAGE.

IRING DIAGRAM

HIGH VOLTAGE!

Disconnect ALL power before servicing or installing this unit. Multiple

power sources may be present. Failure to do so may cause property

damage, personal injury or death.

N 1 2

*MVM97_A*, *CVM97_A*

L 0

)

R O

LINE

HSI EAC

HUM

DEHUM

NEUTRAL

AUX

(ON SOME MODELS)

JUNCTION BOX

CHASSIS

GROUND

W M

DOOR

SWITCH

INDUCTOR COIL

(ON SOME MODELS)

INTEGRATED CONTROL MODULE

LINE

EAC

HUM

IGN

LINE

40 VA

TRANSFORMER

2 V

W B

GR GREEN

(

24V THERMOSTAT CONNECTIONS N.E.C. CLASS 2 WIRE

FUSE 3A

TO+VDC

MICRO

DEHUM

24V HUM.

MICRO

INTEGRATED CONTROL MODULE

)

(

)

(

)

SENSOR

HEAT SETUP

FLAME

COOL TAPS

RAMPING

COOL SETUP

)

HEAT TAPS

ADJUST

DEHUM

(

CONNECTOR

ID BLOWER

DIAGNOSTIC

LED’S

FAN TAPS

HEAT OFF

DELAY

PULL UP

BIAS

DIP SWITCHES

PULL DOWN

(

R U I

F W L U

N T

R W



T M

’S

(

MODULATING INTERGRATED

FURNACE CONTROL MODULE

2 N

P S

T A O D

)

W P

INDOOR

AIR

CIRCULATOR

BLWR

ELECTRONIC

AIR CLEANER

OPTIONAL

3 ID BLWR

HUMIDIFIER

OPTIONAL

HOT SURFACE

IGNITER

24 VAC

INDOOR

CIRCULATOR

BLWR

GND

MANUAL RESET ROLLOUT

FRONT COVER PRESS. SWITCH

AIR



JUNCTION BOX

TR (5)

AUTO RESET AUXILIARY LIMIT

CONTROLS

(3)

(6)

(12)

(2)

HIGH FIRE PRESS. SWITCH

(11)

(7)

(8)

(10)

GND (4)

TR (9)

GND (4)

+ VDC (1)

RX (2)

TX (3)



GND

NEUTRAL

40 VA TRANSFORMER

AUTO RESET PRIMARY

LIMIT CONTROL

LOW FIRE PRESS. SWITCH

LIMIT CONTROLS

GND

(

)

S M

GAS VALVE

INTEGRATED CONTROL MODULE

SPECIAL INSTRUCTIONS FOR PRODUCTS INSTALLED

THE STATE OF MASSACHUSETTS

For all side wall horizontally vented gas fueled equipment installed in every dwelling, building or structure used in whole or in part for residential purposes, including those owned or operated by the Commonwealth and where the side wall exhaust vent termination is less than seven (7) feet above finished grade in the area of the venting, including but not limited to decks and porches, the following requirements shall be satisfied:

VENT/FLUE

TEE

1. INSTALLATION OF CARBON MONOXIDE DETECTORS. At the time of installation of the side wall horizontal vented gas fueled equipment, the installing plumber or gasfitter shall observe that a hard wired carbon monoxide detector with an alarm

COMBUSTION AIR INTAKE.

DISTANCE BETWEEN

COMBUSTION AIR

INTAKE AND GRADE

DISTANCE BETWEEN

VENT AND GRADE

and battery back-up is installed on the floor level where the gas equipment is to be installed. In addition, the installing plumber or gasfitter shall observe that a battery operated or hard wired carbon monoxide detector with an alarm is installed on each additional level of the dwelling, building or structure served by the side wall horizontal vented gas fueled equipment. It shall be the responsibility of the property owner to secure the services of qualified licensed professionals for the installation of hard wired carbon monoxide detectors

a. In the event that the side wall horizontally vented gas fueled equipment is installed in a crawl space or an attic, the hard

wired carbon monoxide detector with alarm and battery back-up may be installed on the next adjacent floor level.

b. In the event that the requirements of this subdivision can not be met at the time of completion of installation, the owner

shall have a period of thirty (30) days to comply with the above requirements; provided, however, that during said thirty (30) day period, a battery operated carbon monoxide detector with an alarm shall be installed.

2. APPROVED CARBON MONOXIDE DETECTORS. Each carbon monoxide detector as required in accordance with the above provisions shall comply with NFPA 720 and be ANSI/UL 2034 listed and IAS certified.

3. SIGNAGE. A metal or plastic identification plate shall be permanently mounted to the exterior of the building at a minimum height of eight (8) feet above grade directly in line with the exhaust vent terminal for the horizontally vented gas fueled heating appliance or equipment. The sign shall read, in print size no less than one-half (1/2) inch in size, “GAS VENT

DIRECTLY BELOW. KEEP CLEAR OF ALL OBSTRUCTIONS”.

4. INSPECTION. The state or local gas inspector of the side wall horizontally vented gas fueled equipment shall not approve the installation unless, upon inspection, the inspector observes carbon monoxide detectors and signage installed in accordance with the provisions of 248 CMR 5.08(2)(a)1 through 4.

EXEMPTIONS

The following equipment is exempt from 248 CMR 5.08(2)(a)1 through 4:

1. The equipment listed in Chapter 10 entitled “Equipment Not Required To Be Vented” in the most current edition of NFPA 54 as adopted by the Board; and

2. Product Approved side wall horizontally vented gas fueled equipment installed in a room or structure separate from the dwelling, building or structure used in whole or in part for residential purposes.

side wall horizontally vented gas equipment provides a venting system design or venting system components with the equipment, the instructions provided by the manufacturer for installation of the equipment and the venting system shall include:

1. Detailed instructions for the installation of the venting system design or the venting system components; and

2. A complete parts list for the venting system design or venting system. (d) MANUFACTURER REQUIREMENTS - GAS EQUIPMENT VENTING SYSTEM NOT PROVIDED. When the manufacturer of a Product

Approved side wall horizontally vented gas fueled equipment does not provide the parts for venting the flue gases, but identifies “special venting systems”, the following requirements shall be satisfied by the manufacturer:

1. The referenced “special venting system” instructions shall be included with the appliance or equipment installation instructions; and

2. The “special venting systems” shall be Product Approved by the Board, and the instructions for that system shall include a parts list and detailed installation instructions.

(e) A copy of all installation instructions for all Product Approved side wall horizontally vented gas fueled equipment, all

venting instructions, all parts lists for venting instructions, and/or all venting design instructions shall remain with the appliance or equipment at the completion of the installation.

THIS PAGE LEFT INTENTIONALLY BLANK

NOTE: SPECIFICATIONS AND PERFORMANCE DATA LISTED HEREIN ARE SUBJECT TO CHANGE WITHOUT NOTICE.

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

Goodman Manufacturing Company, L.P.

5151 San Felipe Suite 500

Houston, TX 77056

Intertek MVM97 Series, CVM97 Series Installation Instructions Manual

Specifications and Main Features

Frequently Asked Questions

User Manual