Lennox 80G1DF, A80DF Installation Instructions Manual

INSTALLATION INSTRUCTIONS
A80DF & 80G1DF
Warm Air Gas Furnace
Downflow Air Discharge
This manual must be left with the homeowner for future reference.
This is a safety alert symbol and should never be ignored. When you see this symbol on labels or in manuals, be alert to the potential for personal injury or death.
CAUTION
As with any mechanical equipment, personal injury can result from contact with sharp sheet metal edges. Be careful when you handle this equipment.
WARNING
Improper installation, adjustment, alteration, service or maintenance can cause property damage, personal injury or loss of life. Installation and service must be performed by a licensed professional installer (or equivalent), service agency or the gas supplier.
TABLE OF CONTENTS
Unit Dimensions ............................................................ 2
A80DF & 80G1DF Parts Arrangement .......................... 3
A80DF & 80G1DF Gas Furnace ................................... 4
Shipping and Packing List ............................................ 4
Safety Information ......................................................... 4
Use of Furnace as a Construction Heater .................... 5
General ......................................................................... 6
Combustion, Dilution, Ventilation Air ............................. 6
Setting Equipment ........................................................ 9
Filters .......................................................................... 12
Duct System ................................................................ 12
Venting ........................................................................ 12
Gas Piping .................................................................. 21
*506528-01*
Electrical ..................................................................... 22
Unit Start-Up ............................................................... 27
Heating Sequence of Operation ................................. 28
Gas Pressure Adjustment ........................................... 28
Control Settings .......................................................... 28
High Altitude ................................................................ 29
Other Unit Adjustments ............................................... 29
Service ........................................................................ 31
Planned Service .......................................................... 34
Control Diagnostic Codes ........................................... 34
Troubleshooting .......................................................... 34
Repair Parts List ......................................................... 35
Manufactured By
Allied Air Enterprises, Inc.
A Lennox International, Inc. Company
215 Metropolitan Drive
West Columbia, SC 29170
506528-01 Page 1 of 37Issue 1035
A80DF & 80G1DF Unit Dimensions - inches (mm)
FRONT VIEW
Model
A801DF/80G1DF
045-08 045-12 070-08 070-12
090-12 090-16
110-12 110-16 110-20
135-20
in.
14-1/2
17-1/2
21
24-1/2
SIDE VIEW
A
mm
368
446
533
622
13-3/8
16-3/8
19-7/8
23-3/8
B
in.
mm
340
416
504
546
19-1/2
C
in.
13
16
23
mm
330
406
495
584
in.
4-3/4
6-1/4
9-3/4
D
mm
121
159
8
203
248
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BLOWER ASSEMBLY
CONTROL BOX
FLUE CHASE
A80DF & 80G1DF
Expanded View
INTERNAL FLUE PIPE ASSEMBLY
BURNER BOX ASSEMBLY
CABINET
HEAT EXCHANGER
COMBUSTION AIR INDUCER
GAS VALVE
ACCESS PANEL
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Figure 1
A80DF & 80G1DF Gas Furnace
The A80DF & 80G1DF gas furnace is shipped ready for installation in the downflow position.
The furnace is equipped for installation in natural gas applications. A conversion kit (ordered separately) is required for use in propane/LP gas applications.
This unit can be installed as either a Direct Vent or a Non-Direct Vent gas central furnace
NOTE: In Direct Vent installations, combustion air is taken from outdoors and flue gases are discharged outdoors. In Non-Direct Vent installations, combustion air is taken from indoors and flue gases are discharged outdoors.
Shipping and Packing List
1 - Assembled Gas Furnace 1 - Bag assembly containing the following:
2 - Screws 3 - Wire nuts 1 - Snap bushing 1 - Snap Plug 1 - Wire tie 1 - Vent warning label 1 - Owner’s manual and warranty card
Check equipment for shipping damage. If you find any damage, immediately contact the last carrier.
Please refer to the technical specification sheets for available accessories.
Safety Information
CAUTION
As with any mechanical equipment, personal injury can result from contact with sharp sheet metal edges. Be careful when you handle this equipment.
Certifications
These units are CSA International certified to ANSI Z21.47.
In the USA, installation of gas furnaces must conform with local building codes. In the absence of local codes, units must be installed according to the current National Fuel Gas Code (ANSI-Z223.1). The National Fuel Gas Code is available from the following address: American National
Standards Institute, Inc., 11 West 42nd Street, New York, NY 10036.
Clearances
Adequate clearance must be made around the air openings into the vestibule area. In order to ensure proper unit operation, combustion and ventilation air supply must be provided according to the current National Fuel Gas Code. Vent installations must be consistent with the venting tables (in this instruction) and applicable provisions of local building codes.
This furnace is CSA International certified for installation clearances to combustible material as listed on the unit nameplate and in the tables in figures 8 and 10. Accessibility and service clearances must take precedence over fire protection clearances.
DANGER
DANGER OF EXPLOSION!
There are circumstances in which odorant used with LP/ Propane gas can lose its scent. In case of a leak, LP/ Propane gas will settle close to the floor and may be difficult to smell. An LP/Propane leak detector should be installed in all LP applications.
WARNING
Improper installation, adjustment, alteration, service or maintenance can cause property damage, personal injury or loss of life. Installation and service must be performed by a licensed professional installer (or equivalent), service agency or the gas supplier.
NOTE: For installation on combustible floors, the furnace shall not be installed directly on carpeting, tile, or other combustible material other than wood flooring.
Installed Locations
For installation in a residential garage, the furnace must be installed so that the burner(s) and the ignition source are located no less than 18 inches (457 mm) above the floor. The furnace must be located or protected to avoid physical damage by vehicles. When a furnace is installed in a public garage, hangar, or other building that has a hazardous atmosphere, the furnace must be installed according to recommended good practice requirements and current National Fuel Gas Code.
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Temperature Rise
NOTE: Furnace must be adjusted to obtain a temperature
rise within the range specified on the unit nameplate. Failure to do so may cause erratic limit operation and may result in premature heat exchanger failure.
This furnace may be installed in alcoves, closets, attics, basements, garages, and utility rooms in the upflow or horizontal position.
This furnace design has not been certified for installation in mobile homes, recreational vehicles, or outdoors.
This furnace must be installed so that its electrical components are protected from water.
Installed in Combination with a Cooling Coil
When this furnace is used with cooling units, it shall be installed in parallel with, or on the upstream side of, cooling units to avoid condensation in the heating compartment. See Figure 2. With a parallel flow arrangement, a damper (or other means to control the flow of air) must adequately prevent chilled air from entering the furnace. If the damper is manually operated, it must be equipped to prevent operation of either the heating or the cooling unit, unless it is in the full HEAT or COOL setting. See Figure 2.
Heating Unit Installed Parallel to Air Handler Unit
Use of Furnace as a Construction Heater
These units are not recommended for construction heating during any phase of construction. Very low return air temperature, harmful vapors and operation of the unit with clogged or misplaced filters will damage the unit.
These units may be used for heating of buildings or structures under construction, if the following conditions are met:
The vent system must be permanently installed per these installation instructions.
A room thermostat must control the furnace. The use of fixed jumpers that will provide continuous heating is not allowed.
The return air duct must be provided and sealed to the furnace.
Return air temperature range between 60°F (16°C) and 80°F (27°C) must be maintained.
Air filters must be installed in the system and must be maintained during construction.
Air filters must be replaced upon construction completion.
Figure 2
When installed, this furnace must be electrically grounded according to local codes. In addition, in the United States, installation must conform with the current National Electric Code, ANSI/NFPA No. 70. The National Electric Code (ANSI/ NFPA No. 70) is available from the following address:
National Fire Protection Association 1 Battery March Park Quincy, MA 02269
NOTE: This furnace is designed for a minimum continuous return air temperature of 60° F (16°C) or an intermittent operation down to 55° F (13°C) dry bulb for cases where a night setback thermostat is used. Return air temperature must not exceed 85° F (29°C) dry bulb.
The input rate and temperature rise must be set per the furnace rating plate.
One hundred percent (100%) outdoor air must be provided for combustion air requirements during construction. Temporary ducting may supply outdoor air to the furnace. Do not connect duct directly to the furnace. Size the temporary duct following these instructions in section for Combustion, Dilution and Ventilation Air in a confined space with air from outside.
The furnace heat exchanger, components, duct system, air filters and evaporator coils must be thoroughly cleaned following final construction clean-up.
All furnace operating conditions (including ignition, input rate, temperature rise and venting) must be verified according to these installation instructions.
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General
These instructions are intended as a general guide and do not supersede local codes in any way. Consult authorities having jurisdiction before installation.
In addition to the requirements outlined previously, the following general recommendations must be considered when installing one of these furnaces:
Place the furnace as close to the center of the air distribution system as possible. The furnace should also be located close to the chimney or vent termination point.
Do not install the furnace where drafts might blow directly into it. This could cause improper combustion.
Do not block the furnace combustion air openings with clothing, boxes, doors, etc. Air is needed for proper combustion and safe unit operation.
When the furnace is installed in an attic or other insulated space, keep insulation away from the furnace.
Combustion, Dilution & Ventilation Air
In the past, there was no problem in bringing in sufficient outdoor air for combustion. Infiltration provided all the air that was needed. In today’s homes, tight construction practices make it necessary to bring in air from outside for combustion. Take into account that exhaust fans, appliance vents, chimneys, and fireplaces force additional air that could be used for combustion out of the house. Unless outside air is brought into the house for combustion, negative pressure (outside pressure is greater than inside pressure) will build to the point that a downdraft can occur in the furnace vent pipe or chimney. As a result, combustion gases enter the living space creating a potentially dangerous situation.
In the absence of local codes concerning air for combustion and ventilation, use the guidelines and procedures in this section to install this furnaces to ensure efficient and safe operation. You must consider combustion air needs and requirements for exhaust vents and gas piping.
NOTE: The Commonwealth of Massachusetts stipulates these additional requirements:
Gas furnaces shall be installed by a licensed plumber or fitter only.
The gas cock must be “T handle” type.
When a furnace is installed in an attic, the passageway
to and service area surrounding the equipment shall be floored.
WARNING
Product Contains Fiberglass Wool.
Disturbing the insulation in this product during installation, maintenance, or repair will expose you to fiberglass wool. Breathing this may cause lung cancer. (Fiberglass wool is known to the State of California to cause cancer.)
Fiberglass wool may also cause respiratory, skin, and eye irritation.
To reduce exposure to this substance or for further information, consult material safety data sheets available from address shown below, or contact your supervisor.
Allied Air Enterprises, Inc. 215 Metropolitan Drive West Columbia, SC 29170
A portion of this information has been reprinted with permission from the National Fuel Gas Code (ANSI-Z223.1). This reprinted material is not the complete and official position of the ANSI on the referenced subject, which is represented only by the standard in its entirety.
WARNING
Insufficient combustion air can cause headaches, nausea, dizziness or asphyxiation. It will also cause excess water in the heat exchanger resulting in rusting and premature heat exchanger failure. Excessive exposure to contaminated combustion air will result in safety and performance related problems. Avoid exposure to the following substances in the combustion air supply:
Permanent wave solutions Chlorinated waxes and cleaners Chlorine base swimming pool chemicals Water softening chemicals De-icing salts or chemicals Carbon tetrachloride Halogen type refrigerants Cleaning solvents (such as perchloroethylene) Printing inks, paint removers, varnishes, etc. Hydrochloric acid Antistatic fabric softeners for clothes dryers Masonry acid washing materials
506528-01Page 6 of 37 Issue 1035
All gas fired appliances require air for the combustion process. If sufficient combustion air is not available, the furnace or other appliances will operate inefficiently and unsafely. Enough air must be provided to meet the needs of all fuelburning appliances and appliances such as exhaust fans which force air out of the house. When fireplaces, exhaust fans, or clothes dryers are used at the same time as the furnace, much more air is necessary to ensure proper combustion and to prevent a downdraft. Insufficient air causes incomplete combustion which can result in carbon monoxide.
In addition to providing combustion air, fresh outdoor air dilutes contaminants in the indoor air. These contaminants may include bleaches, adhesives, detergents, solvents and other contaminants which can corrode furnace components.
Equipment in Confined Space - All Air From Inside
The requirements for providing air for combustion and ventilation depend largely on whether the furnace is installed in an unconfined or a confined space.
Unconfined Space
An unconfined space is an area such as a basement or large equipment room with a volume greater than 50 cubic feet (1.42 m3) per 1,000 Btu (.29 kW) per hour of the combined input rating of all appliances installed in that space. This space also includes adjacent rooms which are not separated by a door. Though an area may appear to be unconfined, it might be necessary to bring in outdoor air for combustion if the structure does not provide enough air by infiltration. If the furnace is located in a building of tight construction with weather stripping and caulking around the windows and doors, follow the procedures in the air from outside section.
Confined Space
A confined space is an area with a volume less than 50 cubic feet (1.42 m3) per 1,000 Btu (.29 kW) per hour of the combined input rating of all appliances installed in that space. This definition includes furnace closets or small equipment rooms.
When the furnace is installed so that supply ducts carry air circulated by the furnace to areas outside the space containing the furnace, the return air must be handled by ducts which are sealed to the furnace casing and which terminate outside the space containing the furnace. This is especially important when the furnace is mounted on a platform in a confined space such as a closet or small equipment room. Even a small leak around the base of the unit at the platform or at the return air duct connection can cause a potentially dangerous negative pressure condition. Air for combustion and ventilation can be brought into the confined space either from inside the building or from outside.
NOTE: Each opening shall have a free area of at least one square inch per 1,000 Btu (645 mm² per .29 kW) per hour of the total input rating of all equipment in the enclosure, but not less than 100 square inches (64546 mm²).
Figure 3
Air from Inside
If the confined space that houses the furnace adjoins a space categorized as unconfined, air can be brought in by providing two permanent openings between the two spaces. Each opening must have a minimum free area of 1 square inch (645 mm2) per 1,000 Btu (.29 kW) per hour of total input rating of all gas fired equipment in the confined space. Each opening must be at least 100 square inches (64516 mm2). One opening shall be within 12 inches (305 mm) of the top of the enclosure and one opening within 12 inches (305 mm) of the bottom. See Figure 3.
Air from Outside
If air from outside is brought in for combustion and ventilation, the confined space must have two permanent openings. One opening shall be within 12 inches (305 mm) of the top of the enclosure and one opening within 12 inches (305 mm) of the bottom. These openings must communicate directly or by ducts with the outdoors or spaces (crawl or attic) that freely communicate with the outdoors or indirectly through vertical ducts. Each opening shall have a minimum free area of 1 square inch (645 mm2) per 4,000 Btu (1.17 kW) per hour of total input rating of all equipment in the enclosure. See Figures 4 and 5. When communicating with the outdoors through horizontal ducts, each opening shall have a minimum free area of 1 square inch (645 mm2) per 2,000 Btu (.56 kW) per total input rating of all equipment in the enclosure. See Figure 6.
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When ducts are used, they shall be of the same cross sectional area as the free area of the openings to which they connect. The minimum dimension of rectangular air ducts shall be no less than 3 inches (75 mm). In calculating free area, the blocking effect of louvers, grilles, or screens must be considered. If the design and free area of protective covering is not known for calculating the size opening required, it may be assumed that wood louvers will have 20 to 25 percent free area and metal louvers and grilles will have 60 to 75 percent free area. Louvers and grilles must be fixed in the open position or interlocked with the equipment so that they are opened automatically during equipment operation.
EQUIPMENT IN CONFINED SPACE - ALL AIR FROM OUTSIDE
(Inlet Air from Crawlspace &
Outlet Air to Ventilated Attic)
EQUIPMENT IN CONFINED SPACE
(ALL AIR FROM OUTSIDE)
NOTE: Each air duct opening shall have a free area of at least one square inch per 2,000 Btu (645 mm² per .59 kW) per hour of the total input rating of all equipment in the enclosure. If the equipment room is located against an outside wall and the air openings communicate directly with the outdoors, each opening shall have a free area of at least 1 square inch per 4,000 Btu (645 mm² per 1.17 kW) per hour of the total input rating of all other equipment in the enclosure.
NOTE: The inlet and outlet air openings shall each have a free area of at least one square inch per 4,000 Btu (645 mm² per 1.17 kW) per hour of the total input rating of all equipment in the enclosure.
Figure 4
EQUIPMENT IN CONFINED SPACE - ALL AIR FROM OUTSIDE
(All Air through Ventilated Attic)
Figure 6
NOTE: The inlet and outlet air openings shall each have a free area
of at least one square inch per 4,000 Btu (645 mm² per 1.17 kW) per hour of the total input rating of all equipment in the enclosure.
Figure 5
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Setting Equipment
WARNING
Do not install the furnace on its front or its back. Do not connect the return air ducts to the back of the furnace. Doing so will adversely affect the operation of the safety control devices, which could result in personal injury or death.
The gas furnace can be installed as shipped in either the upflow position or the horizontal position.
Select a location that allows for the required clearances that are listed on the unit nameplate. Also consider gas supply connections, electrical supply, vent connection, and installation and service clearances [24 inches (610 mm) at unit front]. The unit must be level.
NOTE: Units with 1/2 hp blower motors are equipped with three flexible legs and one rigid leg. See Figure 7. The rigid leg is equipped with a shipping bolt and a flat white plastic washer (rather than the rubber mounting grommet used with a flexible mounting leg). The bolt and washer
must be removed before the furnace is placed into operation. After the bolt and washer have been removed,
the rigid leg will not touch the blower housing.
Downflow Applications
Allow for clearances to combustible materials as indicated on the unit nameplate. Minimum clearances for closet or alcove installations are shown in Figure 8.
Downflow Application Installation Clearances
Figure 7
Units with 1/2 HP
Blower Motor.
* Front clearance In alcove Installation must be 24 in. (610 mm). Maintain a minimum of 24 in. (610 mm) for front service access. ‡ For installation on a combustible floor, do not install the furnace directly on carpeting, tile or other combustible materials other than wood flooring. † Left side requires 3 inches if a single wall vent is used on 14-1/2 inch cabinets.
Figure 8
Return Air
Return air must be brought in through the top of the furnace installed in an downflow application.
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Figure 9
WARNING
Improper installation of the furnace can result in personal injury or death. Combustion and flue products must never be allowed to enter the return air system or air in the living space. Use sheet metal screws and joint tape to seal return air system to furnace.
In platform installations with furnace return, the furnace should be sealed airtight to the return air plenum. A door must never be used as a portion of the return air duct system. The base must provide a stable support and an airtight seal to the furnace. Allow absolutely no sagging, cracks, gaps, etc.
For no reason should return and supply air duct systems ever be connected to or from other heating devices such as a fireplace or stove, etc. Fire, explosion, carbon monoxide poisoning, personal injury and/or property damage could result.
Installation on Non-Combustible Flooring (Figure 11)
1. Cut floor opening keeping in mind clearances listed on unit rating plate. Also keep in mind gas supply connections, electrical supply, flue and air intake connections and sufficient installation and servicing clearances. See Table 1 for correct floor opening size.
2. Flange warm air plenum and lower the plenum into the opening.
3. Set the unit over the plenum and seal the plenum to the unit.
4. Ensure that the seal is adequate.
NON-COMBUSTIBLE FLOOR OPENING SIZE
NOTE: Floor opening dimensions listed are 1/4 inch (6 mm) larger
than the unit opening. See dimension drawing on page 2.
Table 1
Installation Clearances
* Front
Back
Sides
Vent
Floor
* Front clearance in alcove installation must be 24 in. (610 mm). Maintain a minimum of 24 in. (610 mm) for front service access. † Allow proper clearances to accommodate condensate trap and vent pipe installation. ‡ The furnace may be installed on a combustible wood floor if an optional additive base is installed between the furnace and the combustivle floor.
0
0
0†
0
NC‡
Figure 11
Installation on Combustible Flooring (Figure 12)
1. When unit is installed on a combustible floor, a downflow combustible flooring base must be installed between the furnace and the floor. The base must be ordered separately. See Table 2 for opening size to cut in floor.
CAUTION
The furnace and combustible flooring base shall not be installed directly on carpeting, tile, or other combustible material other than wood flooring.
Figure 10
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COMBUSTIBLE FLOORING BASE OPENING SIZE
Table 2
Figure 12
2. After opening is cut, set the combustible flooring base into opening.
3. Check fiberglass strips on the combustible flooring base to make sure they are properly glued and positioned.
4. Lower supply air plenum into the combustible flooring base until plenum flanges seal against fiberglass strips.
er opening is
NOTE: Be careful not to damage fiberglass strips. Check for a tight seal.
Figure 13
Return Air Opening - Downflow Units
Return air may be brought in only through the top opening of a furnace installed in the downflow position. The following steps should be taken when installing plenum:
1. Bottom edge of plenum should be flanged with a hemmed edge (See Figure 14 or 15).
2. Sealing strips should be used to ensure an airtight seal between the cabinet and the plenum.
3. In all cases, plenum should be secured to top of furnace using sheet metal screws.
4. Make certain that an adequate seal is made.
5. Set the furnace over the plenum.
6. Ensure that the seal between the furnace and plenum is adequate.
Installation on Cooling Coil Cabinet (Figure 13)
NOTE: Downflow combustible flooring kit is not used.
1. Refer to reverse flow coil installation instructions for correctly sized opening in floor and installation of cabinet.
2. When cooling cabinet is in place, set and secure the furnace according to the instructions that are provided with the cooling coil. Secure the furnace to the cabinet.
3. Seal the cabinet and check for air leaks.
506528-01 Page 11 of 37Issue 1035
Figure 14
Figure 15
Filters
This unit is not equipped with a filter or rack. A field provided high velocity filter is required for the unit to operate properly.
Venting
A 4 inch diameter flue transition is factory installed on the combustion air inducer outlet of all models.
A filter must be in place any time the unit is operating.
Duct System
Use industry approved standards (such as those published by Air Conditioning Contractors of America or American Society of Heating, Refrigerating and Air Conditioning Engineers) to size and install the supply and return air duct system. This will result in a quiet and low static system that has uniform air distribution.
NOTE: Do not operate the furnace in the heating mode with an external static pressure that exceeds 0.8 inches w.c. Higher external static pressures may cause erratic limit operation.
Supply Air Plenum
If the furnace is installed without a cooling coil, a removable access panel must be installed in the supply air duct. The access panel should be large enough to permit inspection (either by smoke or reflected light) of the heat exchanger for leaks after the furnace is installed. The furnace access panel must always be in place when the furnace is operating and it must not allow leaks into the supply air duct system.
Return Air Plenum
IMPORTANT
The unit will not vent properly with the flue transition pointed down in the 6 o’clock position.
The combustion air inducer may be rotated clockwise or counterclockwise by 90° to allow for top or side vent discharge in all applications. When the unit is installed, the flue transition must be in the 9 o’clock, 12 o’clock or 6 o’clock position.
These series units are classified as fan assisted Category I furnaces when vertically vented according to the latest edition of National Fuel Gas Code (NFPA 54 / ANSI Z223.1) in the USA. A fan assisted Category I furnace is an appliance equipped with an integral mechanical means to either draw or force combustion products through the combustion chamber and/or heat exchanger. This unit is not approved for use with horizontal venting.
NOTE: Use these instructions as a guide. They do not supersede local codes. This furnace must be vented according to all local codes these installation instructions, and the provided venting tables in these instructions.
NOTE: Return air must not be drawn from a room where this furnace, or any other gas fueled appliance (i.e., water heater), or carbon monoxide producing device (i.e., wood fireplace) is installed.
When return air is drawn from a room, a negative pressure is created in the room. If a gas appliance is operating in a room with negative pressure, the flue products can be pulled back down the vent pipe and into the room. This reverse flow of the flue gas may result in incomplete combustion and the formation of carbon monoxide gas. This toxic gas might then be distributed throughout the house by the furnace duct system.
The venting tables in this manual were extracted from the National Fuel Gas Code (NFPA 54 / ANSI Z223.1) and are provided as a guide for proper vent installation. Proper application, termination, construction and location of vents must conform to local codes having jurisdiction. In the absence of local codes, the NFGC serves as the defining document.
Refer to the tables and the venting information contained in these instructions to properly size and install the venting system.
IMPORTANT
Once the venting system is installed, attach the “Disconnected Vent” warning sticker to a visible area of the plenum near the vent pipe. See Figure 15. The warning sticker is provided in the bag assembly. Order kit 66W04 for additional stickers.
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