Page 1
installation instructions
395CAV
and operating instructions
UPFLOW GAS-FIRED
INDUCED-COMBUSTION FURNACES
NOTE: Read the entire instruction manual before starting the
installation.
This symbol → indicates a change since the last issue.
Index Page
SAFETY CONSIDERATIONS.....................................................1
Clearances From Combustible Materials.................................1
Dimensional Drawing...............................................................2
ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS
PROCEDURE........................................................................2-3
INTRODUCTION..........................................................................3
LOCATION....................................................................................3
General......................................................................................3
Location Relative to Cooling Equipment ................................3
Hazardous Locations.................................................................3
AIR FOR COMBUSTION AND VENTILATION...................3-5
Unconfined Space.....................................................................4
Confined Space......................................................................4-5
FILTER ARRANGEMENT .......................................................5-6
LEVELING LEGS (IF REQUIRED).........................................5-6
GAS PIPING...............................................................................6-7
ELECTRICAL CONNECTIONS..................................................7
115-v Wiring.............................................................................7
24-v Wiring...............................................................................7
Accessories................................................................................7
VENTING ......................................................................................7
START-UP, ADJUSTMENT, AND SAFETY CHECK.........7-14
General...................................................................................7-8
Sequence Of Operation .......................................................8-11
Heating Mode............................................................................9
Cooling Mode......................................................................9-11
Continuous Blower Mode.......................................................11
Heat Pump Mode....................................................................11
Start-Up Procedures................................................................11
Adjustments .......................................................................11-14
Set Gas Input Rate ............................................................11-13
Set Temperature Rise..............................................................13
Set Thermostat Heat Anticipator............................................14
Check Safety Controls .................................................................14
Checklist.......................................................................................14
SAFETY CONSIDERATIONS
Installing and servicing heating equipment can be hazardous due to
gas and electrical components. Only trained and qualified personnel should install, repair, or service heating equipment.
Untrained personnel can perform basic maintenance functions
such as cleaning and replacing air filters. All other operations must
be performed by trained service personnel. When working on
heating equipment, observe precautions in the literature, on tags,
and on labels attached to or shipped with the unit and other safety
precautions that may apply.
→
Follow all safety codes. In the United States, follow all safety
codes including the National Fuel Gas Code (NFGC) NFPA No.
54-1992/ANSI Z223.1-1992. In Canada, refer to the current
edition of the National Standard of Canada CAN/CGA-B149.1-
Series G
Cancels: II 395C-40-9 II 395C-40-10
1-96
®
and .2-M95 Natural Gas and Propane Installation Codes (NSCNGPIC). Wear safety glasses and work gloves. Have fire extinguisher available during start-up and adjustment procedures and
service calls.
Recognize safety information. This is the safety-alert symbol
When you see this symbol on the furnace and in instructions or
manuals, be alert to the potential for personal injury.
Understand the signal words DANGER, WARNING, and CAUTION. These words are used with the safety-alert symbol. DANGER identifies the most serious hazards which will result in severe
personal injury or death. WARNING signifies a hazard which
could result in personal injury or death. CAUTION is used to
identify unsafe practices which would result in minor personal
injury or product and property damage.
These instructions cover minimum requirements and conform to
existing national standards and safety codes. In some instances,
these instructions exceed certain local codes and ordinances,
especially those that may not have kept up with changing residential construction practices. We require these instructions as a
minimum for a safe installation.
TABLE 1—MINIMUM CLEARANCES FROM
COMBUSTIBLE MATERIALS (IN.)
UNIT SIZE 045 AND 070 091-155
Sides Single-Wall Vent 1 0
Type B-1 Double-Wall Vent 0 0
Back 00
Plenum Top 11
Vent Single-Wall Vent 6 6
Type B-1 Double-Wall Vent 1 1
Front Single-Wall Vent 6 6
Type B-1 Double-Wall Vent 3 3
Service 30 30
NOTES:
1. Provide 30-in. front clearance for servicing. An open door in front of the unit
can meet this requirement.
2. A minimum clearance of 3 in. must be provided in front of the unit for
combustion air and proper operation.
ama
CANADIAN GAS ASSOCIATION
APPROVED
R
.
—1—
Page 2
39 7⁄8″
28 1⁄2″
FLUE COLLAR
7
⁄8-IN. DIA HOLE
POWER ENTRY
7
⁄8-IN. DIA
ACCESSORY
1 3⁄4-IN. DIA HOLE
GAS ENTRY
1
⁄2-IN. DIA HOLE
THERMOSTAT
WIRE ENTRY
2 1⁄16″
1″
5 3⁄8″
5 13⁄16″
2 3⁄8″
12 5⁄16″
AIRFLOW
A
D
13
⁄16″
5 3⁄8″
5 13⁄16″
2 3⁄8″
2 11⁄16″
2 1⁄16″
1″
7
⁄8-IN. DIA
POWER ENTRY
1 1⁄2-IN. DIA
R.H. GAS ENTRY
7
⁄8-IN. DIA ACCESSORY
1
⁄2-IN. DIA THERMOSTAT
WIRE ENTRY
19″
OUTLET
13
⁄16″
SIDE INLET
TYP 1″
11
11
⁄16″
24 5⁄16″
AIR INLET
3″
NOTES:
11
⁄16″
E
1. Two additional 7⁄8-in. dia knockouts are located in the top plate.
⁄16″
5
TYP
⁄8″
SIDE INLET
231⁄4″
SIDE RETURN
DUCT LOCATION
2. Minimum return-air opening at furnace:
a. For 800 CFM–16-in. round or 141⁄2 x 12-in. rectangle.
b. For 1200 CFM–20-in. round or 141⁄2 x 191⁄2-in. rectangle.
c. For 1600 CFM–22-in. round or 141⁄2 x 231⁄4-in. rectangle.
d. For airflow requirements above 1800 CFM, use both side inlets,
a combination of 1 side inlet and the bottom, or the bottom only.
Fig. 1—Dimensional Drawing
TABLE 2—DIMENSIONS (IN.)
UNIT SIZE A D E VENT CONN SHIP. WT (LB)
024045 14-3/16 12-9/16 12-11/16 4 122
036045 14-3/16 12-9/16 12-11/16 4 124
024070 14-3/16 12-9/16 12-11/16 4 132
036070 14-3/16 12-9/16 12-11/16 4 134
042091 17-1/2 15-7/8 16 4 150
048091 21 19-3/8 19-1/2 4 154
036110 17-1/2 15-7/8 16 4 160
048111 21 19-3/8 19-1/2 4 166
060111 24-1/2 22-7/8 23 4 184
048135 21 19-3/8 19-1/2 5 178
060135 24-1/2 22-7/8 23 5 194
060155 24-1/2 22-7/8 23 5 204
141⁄2″
3
⁄4″
1
1″
A88367
ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS
PROCEDURE
CAUTION: Electrostatic discharge can affect electronic
components. Take precautions during furnace installation
and servicing to protect the furnace electronic control.
Precautions will prevent electrostatic discharges from
personnel and hand tools which are held during the
procedure. These precautions will help to avoid exposing
the control to electrostatic discharge by putting the
furnace, the control, and the person at the same electro-
static potential.
1. Disconnect all power to the furnace. DO NOT TOUCH
THE CONTROL OR ANY WIRE CONNECTED TO THE
CONTROL PRIOR TO DISCHARGING YOUR BODY’S
ELECTROSTATIC CHARGE TO GROUND.
2. Firmly touch a clean, unpainted, metal surface of the
furnace chassis which is close to the control. Tools held in
a person’s hand during grounding will be satisfactorily
discharged.
3. After touching the chassis you may proceed to service the
control or connecting wires as long as you do nothing that
recharges your body with static electricity (for example; DO
NOT move or shuffle your feet, DO NOT touch ungrounded objects, etc.).
—2—
Page 3
4. If you touch ungrounded objects (recharge your body with
static electricity), firmly touch furnace again before touching control or wires.
5. Use this procedure for installed and uninstalled (ungrounded) furnaces.
6. Before removing a new control from its container, discharge your body’s electrostatic charge to ground to protect
the control from damage. If the control is to be installed in
a furnace, follow items 1 through 5 before bringing the
control or yourself into contact with the furnace. Put all
used AND new controls into containers before touching
ungrounded objects.
7. An ESD service kit (available from commercial sources)
may also be used to prevent ESD damage.
INTRODUCTION
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The Model 395CAV, Series G Furnace is available in sizes 45,000
through 155,000 Btuh input capacities.
The design of the upflow gas-fired furnace is A.G.A./C.G.A.
certified for natural and propane gas and for installation on
combustible flooring, in alcoves, attics, basements, closets, or
utility rooms. The design of this furnace line is not A.G.A./C.G.A.
certified for installation in mobile homes, recreation vehicles, or
outdoors.
Before installing the furnace, refer to the current edition of the
NFGC. Canadian installations must be installed in accordance with
NSCNGPIC and all authorities having jurisdiction. For further
information, the NFGC is available from National Fire Protection
Association Inc., Batterymarch Park, Quincy, MA 02269; American Gas Association, 1515 Wilson Boulevard, Arlington, VA
22209; or from Literature Distribution.
Installation must conform to the regulations of the serving gas
supplier and the local building, heating, and plumbing codes in
effect in the area in which the installation is made, or in the
absence of local codes with the requirements of the NFGC.
CAUTION: Application of this furnace should be indoors with special attention given to vent sizing and
material, gas input rate, air temperature rise, and unit
sizing. Improper installation or misapplication of the
furnace can require excessive servicing or cause premature component failure.
This furnace is designed for a minimum continuous return-air
temperature of 60°F db or an intermittent operation down to 55°F
db such as when used with a night setback thermostat. Return-air
temperature must not exceed a maximum of 85°F db.
WARNING: Improper installation, adjustment, alteration, service, maintenance, or use can cause carbon
monoxide poisoning, explosion, fire, electrical shock, or
other conditions which may cause personal injury or
property damage. Consult a qualified installer, service
agency, local gas supplier, or your distributor or branch
for information or assistance. The qualified installer or
agency must use only factory-authorized and listed kits or
accessories when modifying this product. Failure to
follow this warning can cause electrical shock, fire,
personal injury, or death.
For accessory installation details, refer to the applicable instruction
literature.
NOTE: Remove all shipping brackets and materials before
operating the furnace.
I. LOCATION
A. General
CAUTION: Do not install furnace in a corrosive or
contaminated atmosphere. Make sure all combustion and
circulating air requirements are met, in addition to all
local codes and ordinances.
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CAUTION: Do not use this furnace during construction
when adhesives, sealers, and/or new carpets are being
installed. If the furnace is required during construction,
use clean outside air for combustion and ventilation.
Compounds of chlorine and fluorine when burned with
combustion air form acids which cause corrosion of the
heat exchangers and metal vent system. Some of these
compounds are found in paneling and dry wall adhesives,
paints, thinners, masonry cleaning materials, and many
other solvents commonly used in the construction process.
Excessive exposure to contaminated combustion air will
result in safety and performance related problems.
This furnace must be installed so the electrical components are
protected from water. This furnace shall not be installed directly on
carpeting, tile, or any combustible material other than wood
flooring.
Locate furnace as close to the chimney/vent and as near the center
of the air distribution system as possible. The furnace should be
installed as level as possible.
When a furnace is installed so that the supply ducts carry air to
areas outside the space containing the furnace, the return air must
also be handled by a duct(s) sealed to the furnace casing and
terminating outside the space containing the furnace.
Provide ample space for servicing and cleaning. Always comply
with the minimum fire protection clearances shown on the unit
rating plate.
B. Location Relative to Cooling Equipment
The cooling coil must be installed parallel with or on the
downstream side of the unit to avoid condensation in the heat
exchangers. When installed parallel with a furnace, dampers or
other means used to control the flow of air must prevent chilled air
from entering the unit. If the dampers are manually operated, they
must be equipped with means to prevent operation of either unit
unless the damper is in the full-heat or full-cool position.
C. Hazardous Locations
When the furnace is installed in a residential garage, it must be
installed so that the burners and ignition source are located at least
18 in. above the floor. The furnace should be protected from
physical damage by vehicles. When a furnace is installed in public
garages, airplane hangars, or other buildings having hazardous
atmospheres, the unit must be installed in accordance with the
recommended good practice requirements of the National Fire
Protection Association, Inc.
II. AIR FOR COMBUSTION AND VENTILATION
Provisions for adequate combustion and ventilation air must be
provided in accordance with Section 5.3 of the NFGC, Air for
Combustion and Ventilation, or applicable provisions of the local
building codes.
Canadian installations must be installed in accordance with NSCNGPIC and all authorities having jurisdiction.
—3—
Page 4
CAUTION: Air for combustion must not be contaminated by halogen compounds, which include fluoride,
chloride, bromide, and iodide. These elements are found
in aerosol sprays, detergents, bleaches, cleaning solvents,
salts, air fresheners, and other household products.
SUPPLY
AIR
VENT THROUGH ROOF
All fuel-burning equipment must be supplied with air for combustion of the fuel. Sufficient air MUST be provided to ensure there
will not be a negative pressure in the equipment room or space. In
addition, a positive seal MUST be made between the furnace
cabinet and the return-air duct to prevent pulling air from the
burner area and draft safeguard opening.
CAUTION: The operation of exhaust fans, kitchen ventilation fans, clothes dryers, or fireplaces could create a
NEGATIVE PRESSURE CONDITION at the furnace.
Make-up air MUST BE PROVIDED for the ventilation
devices, in addition to that required by the furnace.
The requirements for combustion and ventilation air depend upon
whether the furnace is located in an unconfined or confined space.
A. Unconfined Space
An unconfined space must have at least 50 cubic ft for each 1000
Btuh of input for all the appliances (such as furnaces, clothes
dryer, water heaters, etc.) in the space.
For Example:
395CAV FURNACE
INPUT BTUH
44,000 293
66,000 440
88,000 587
110,000 733
132,000 880
154,000 1026
MINIMUM SQ FT WITH
7-1/2 FT CEILING
If the unconfined space is constructed unusually tight, air for
combustion and ventilation MUST come from either the outdoors
or spaces freely communicating with the outdoors. Combustion
and ventilation openings must be sized the same as for a confined
space. A minimum opening with a total of at least 1 sq in. per 5000
Btuh of total input rating for all equipment must be provided.
Return air must not be taken from the room unless an equal or
greater amount of air is supplied to the room.
B. Confined Space
A confined space has volume less than 50 cu ft per 1000 Btuh of
the total input rating for all appliances installed in that space. A
confined space MUST have 2 permanent openings, 1 within 12 in.
of the ceiling and the other within 12 in. of the floor. (See Fig. 2.)
NOTE: In determining the free area of an opening, the blocking
effect of the louvers, grilles, and screens must be considered. If the
free area of a louver or grille design is unknown, it may be
assumed that wood louvers have a 20 percent free area, and metal
louvers or grilles have a 60 percent free area. Screens, when used,
must not be smaller than 1/4-in. mesh. Louvers and grilles must be
constructed so they cannot be closed.
The size of the openings depends upon whether the air comes from
inside or outside of the structure.
1. All air from inside the structure:
a. Each opening MUST have at least 1 sq in. of free area
per 1000 Btuh of the total input for all equipment within
the confined space, but not less than 100 sq in. per
opening. (See Fig. 2.)
12″ MAX
1 SQ IN.
PER 1000
BTUH* IN DOOR
OR WALL
INTERIOR
HEATED
SPACE
RETURN AIR
* Minimum opening size is 100 square in. with
minimum dimensions of 3-In.
†
Minimum of 3-In. when type-B1 vent is used.
UNCONFINED
SPACE
CONFINED
SPACE
6″ MIN
(FRONT)
1 SQ IN.
PER 1000
BTUH* IN DOOR
OR WALL
12″ MAX
A89012
Fig. 2—Air For Combustion and Ventilation (Inside Air)
For Example:
395CAV FURNACE
INPUT BTUH
44,000 100
66,000 100
88,000 100
110,000 110
132,000 132
154,000 154
FREE AREA PER OPENING
(SQ IN.)
b. If the building is constructed unusually tight, a perma-
nent opening directly communicating with the outdoors
should be provided. This opening shall have a minimum
free area of 1 sq in. per 5000 Btuh of total input rating
for all equipment in the enclosure.
c. If the furnace is installed on a raised platform to provide
a return-air plenum, and return air is taken directly from
the hallway or space adjacent to the furnace, all air for
combustion must come from outdoors.
2. All air from outside the structure:
a. If combustion air is taken from outdoors through vertical
ducts, the openings and ducts MUST have at least 1 sq
in. of free area per 4000 Btuh of the total input for all
equipment within the confined space. (See Fig. 3.)
b. If combustion air is taken from the outdoors through
horizontal ducts, the openings and ducts MUST have at
least 1 sq in. of free area per 2000 Btuh of the total input
for all equipment within the confined space.
†
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Page 5
For Example:
395CAV FURNACE
INPUT BTUH
44,000 11.0 4
66,000 16.5 5
88,000 22.0 6
110,000 27.5 6
132,000 33.0 7
154,000 38.5 7
FREE AREA PER OPENING
(SQ IN.)
For Example:
395CAV FURNACE
INPUT BTUH
44,000 22.0 6
66,000 33.0 7
88,000 44.0 8
110,000 55.0 9
132,000 66.0 10
154,000 77.0 10
FREE AREA PER OPENING
(SQ IN.)
c. When ducts are used, they must be of the same cross-
sectional area as the free area of the openings to which
they connect. The minimum dimension of rectangular
ducts must not be less than 3 in. (See Fig. 3.)
ROUND PIPE
(IN. DIA)
ROUND PIPE
(IN. DIA)
WARNING: Do not install the furnace on its back;
safety control operation will be adversely affected. Never
connect return-air ducts to the back of the furnace. A
failure to follow this warning can cause a fire, personal
injury, or death.
III. FILTER ARRANGEMENT
The factory-supplied filter(s) is shipped in the blower compartment. Determine location for the filter and relocate filter retaining
wire if necessary. See Fig. 4 for side return application and Fig. 5
for bottom return application. See Table 3 to determine correct
filter size for desired filter location. Table 3 indicates filter size,
location, and quantity shipped with the furnace.
WASHABLE
FILTER
FILTER
RETAINER
DUCTS
A
B
TO
SUPPLY
AIR
D
VENT
THROUGH
ROOF
CONFINED
C
DUCT
TO
OUTDOORS
OUTDOORS
12″ MAX
1 SQ IN.
PER 2000
BTUH*
DUCTS
TO
OUTDOORS
1 SQ IN.
PER 2000
BTUH*
12
″ MAX
RETURN AIR
*Minimum dimensions of 3-In.
Use any of the following
NOTE:
combinations of openings:
A & B C & D D & E F & G
Fig. 3—Air For Combustion and Ventilation
(Outside Air)
SPACE
E
12″ MAX
1 SQ IN.
PER 4000
BTUH*
F
1 SQ IN.
BTUH*
1 SQ IN.
BTUH*
G
1 SQ IN.
PER 4000
BTUH*
12″
MAX
PER
4000
OUTDOORS
PER
4000
12″
MAX
A89013
A93045
Fig. 4—Side Filter Arrangement
(Control Removed for Clarity)
For bottom air-return applications, filter may need to be cut to fit
some furnace casing widths. A bottom closure panel is factory
installed in the bottom of the furnace. When bottom return inlet is
desired, remove and discard the bottom closure panel. Remove
side clip(s) and install in hole. Two sets of hardware are needed for
furnaces in 24-1/2-in. wide casings using 2 filters for bottom
return. All hardware is provided for filter installation.
NOTE: Furnaces with a 17-1/2-in. wide casing require an additional procedure when locating the filter for bottom return-air
application. Field fabricate a sheet metal filler strip1X3X24-1/2
in. and install it along side of the filter as shown in Fig. 5. Drive
2 screws through the casing side and into the filler strip to secure
it in place. Filter should rest on the top of the filler strip when
installed.
WARNING: Never operate unit without a filter or with
filter access door removed. Failure to follow this warning
can cause fire, personal injury, or death.
IV. LEVELING LEGS (IF REQUIRED)
When the furnace is used with side inlet(s) and leveling legs are
required, refer to Fig. 6, and install field-supplied, corrosionresistant 5/16-in. machine bolts and nuts.
NOTE: The maximum length of the bolt should not exceed 1-1/2
in.
1. Lay furnace on its back. Locate and drill 5/16-in. diameter
hole in each bottom corner of furnace as shown in Fig. 6.
2. Install nut on bolt and install bolt and nut in hole. (Install
flat washer if desired.)
3. Install another nut on other side of furnace base. (Install flat
washer if desired.)
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Page 6
171⁄2-IN. WIDE
CASINGS ONLY:
INSTALL FIELD-SUPPLIED
FILTER FILLER STRIP
UNDER FILTER.
3″
1
24
/2″
1″
FILTER
SUPPORT
241⁄2-IN. WIDE
CASINGS ONLY:
CUT AND FOLD
FACTORY-PROVIDED
FILTERS AS SHOWN
TO DESIRED SIZE.
WASHABLE
FILTER
FILTER
RETAINER
A96030
Fig. 5—Bottom Filter Arrangement
(Control Removed for Clarity)
TABLE 3—FILTER INFORMATION (IN.)
FURNACE
CASING WIDTH
14-3/16 (1) 16 X 25 X 1† (1) 14 X 25 X 1 Cleanable
17-1/2 (1) 16 X 25 X 1† (1) 16 X 25 X 1 Cleanable
21 (1) 16 X 25 X 1 (1) 20 X 25 X 1† Cleanable
24-1/2 (2) 16 X 25 X 1† (1) 24 X 25 X 1 Cleanable
* Filters can be field modified by cutting the frame as marked and folding to the
desired size. Alternate sizes can be ordered from your distributor or dealer.
† Factory-provided with the furnace.
FILTER SIZE*
Side Return Bottom Return
FILTER TYPE
4. Adjust outside nut to provide desired height, and tighten
inside nut to secure arrangement.
V. GAS PIPING
Gas piping must be installed in accordance with national and local
codes. Refer to the current edition of the NFGC. Canadian
installations must be installed in accordance with NSCNGPIC and
all authorities having jurisdiction.
Refer to Table 4 for the recommended gas pipe size. Risers must
be used to connect to the furnace and the meter.
5
⁄16″
5
⁄16″
1 3⁄4″
3
⁄4″
1
5
⁄16″
5
⁄16″
1 3⁄4″
1 3⁄4″
Fig. 6—Leveling Leg Installation
TABLE 4—MAXIMUM CAPACITY OF PIPE*
NOMINAL IRON
PIPE SIZE
(IN.)
1/2 0.622 175 120 97 82 73
3/4 0.824 360 250 200 170 151
1 1.049 680 465 375 320 285
1-1/4 1.380 1400 950 770 660 580
1-1/2 1.610 2100 1460 1180 990 900
* Cubic ft of gas per hr for gas pressures of 0.5 psig (14-in. wc) or less, and a
pressure drop of 0.5-in. wc (based on a 0.60 specific gravity gas). Ref: Table
10-2 NFPA 54-1992.
INTERNAL
DIAMETER
(IN.)
LENGTH OF PIPE (FT)
10 20 30 40 50
CAUTION: If a flexible connector is required or allowed by the authority having jurisdiction, black iron
pipe shall be installed at the gas valve and extend a
minimum of 2 in. outside the furnace casing.
Piping should be pressure tested in accordance with local and
→
national plumbing and gas codes before the furnace has been
attached. If the pressure exceeds 0.5 psig (14-in. wc), the gas
supply pipe must be disconnected from the furnace and capped
before the pressure test. If the test pressure is equal to or less than
0.5 psig (14-in. wc), turn off electric shutoff switch located on the
gas valve before the test. It is recommended that the ground joint
union be loosened before pressure testing. After all connections
have been made, purge the lines and check for leakage with
regulated gas supply pressure.
Install a sediment trap in the riser leading to the furnace. The trap
can be installed by connecting a tee to the riser leading from the
furnace. Connect a capped nipple into the lower end of the tee. The
capped nipple should extend below the level of the gas controls.
(See Fig. 7.)
Apply joint compound (pipe dope) sparingly and only to the male
threads of each joint. The compound must be resistant to the action
of propane gas.
→
An accessible manual shutoff valve MUST be installed upstream
of the furnace gas controls and within 72 in. of the furnace. A
1/8-in. NPT plugged tapping, accessible for test gage connection,
MUST be installed immediately upstream of the gas supply
connection to the furnace and downstream of the manual shutoff
valve. Place ground joint union between the gas control manifold
and the manual shutoff valve.
A89014
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Page 7
GAS
SUPPLY
MANUAL
SHUTOFF
VALVE
(REQUIRED)
→
WARNING: The cabinet MUST have an uninterrupted
or unbroken ground according to NEC, ANSI/NFPA
70-1996 and Canadian Electrical Code, CSA C22.1 or
local codes to minimize personal injury if an electrical
fault should occur. This may consist of electrical wire or
conduit approved for electrical ground when installed in
accordance with existing electrical codes. Do not use gas
piping as an electrical ground. Failure to follow this
warning could result in electrical shock, fire, or death.
SEDIMENT
TRAP
UNION
→
VI. ELECTRICAL CONNECTIONS
A. 115-v Wiring
Refer to the unit rating plate or Table 5 for equipment electrical
requirements. The control system requires an earth ground for
proper operation.
Make all electrical connections in accordance with the National
→
Electrical Code (NEC) ANSI/NFPA 70-1996 and local codes or
ordinances that might apply. For Canadian installations, all electrical connections must be made in accordance with CSA C22.1
Canadian Electrical Code, or authorities having jurisdiction.
Fig. 7—Typical Gas Pipe Arrangement
WARNING: Use the proper length of pipes to avoid
stress on the gas control manifold. Failure to follow this
warning can result in a gas leak, causing fire, explosion,
personal injury, or death.
CAUTION: Connect the gas pipe to the furnace using a
backup wrench to avoid damaging gas controls.
WARNING: Never purge a line into a combustion
chamber. Never use matches, candles, flame, or other
sources of ignition for the purpose of checking leakage.
Use a soap-and-water solution to check for leakage.
Failure to follow this warning can cause a fire, explosion,
personal injury, or death.
CAUTION: Do not connect aluminum wire between
disconnect switch and furnace. Use only copper wire.
A89417
The auxiliary junction box (J-box) can be moved to the left-hand
side of the furnace when a left-side power supply is desired.
Remove the 2 screws holding the auxiliary J-box. Mount the J-box
on the left-hand side of the furnace (holes have been pre-drilled in
casing). When moved, tuck the wiring harness behind the clip
provided to keep extra wire lengths out of the way.
NOTE: Proper polarity must be maintained for 115-v wiring. If
polarity is incorrect, control board fault code indicator light will
flash rapidly and the furnace will not operate.
B. 24-v Wiring
Make field 24-v connections at the 24-v terminal strip. (See Fig.
9.) Connect terminal Y as shown in Fig. 8 for proper cooling
operation. Use only AWG No. 18, color-coded, copper thermostat
wire.
The 24-v circuit contains an automotive-type, 3-amp fuse located
on the main control board. Any direct shorts during installation,
service, or maintenance could cause this fuse to blow. If fuse
replacement is required, use ONLY a 3-amp fuse of identical size.
C. Accessories
1. Electronic Air Cleaner (EAC)
Two spring clamp terminals (for 12 gage maximum, solid
or stranded wire), marked EAC-1 and EAC-2 are provided
for EAC connection. (See Fig. 9.) These terminals are
energized with 115-v, (1-amp maximum) during blower
motor operation. To connect EAC power leads to furnace
control center, strip approximately 1/8 in. of insulation from
wire. Open terminal by depressing switch arm with a
screwdriver or finger, and insert wire as shown in Fig. 10.
2. Humidifier (HUM)
Screw terminals (HUM and Com) are provided for 24-v
humidifier connection. The terminals are energized with
24-v 0.5-amp maximum after inducer motor prepurge
period.
NOTE: A field-supplied, 115-v controlled relay connected to
EAC terminals may be added if humidifier operation is desired
during blower operation.
VII. VENTING
→
Refer to the National or Local Installation Code such as; National
Fuel Gas Code Z223.1-1992, or the Canadian Installation Code,
CAN B149.1- and .2-M95, for proper vent sizing and installation
requirements. Use the enclosed Venting Tables for Category I
Fan-Assisted Furnaces for a quick, easy reference. The horizontal
portion of the venting system shall maintain a minimum of 1/4-in.
upward slope per linear ft and it shall be rigidly supported every 5
ft or less with hangers or straps to ensure that there will be no
movement after installation.
VIII. START-UP, ADJUSTMENT, AND SAFETY CHECK
A. General
NOTE: Proper polarity must be maintained for 115-v wiring. If
polarity is incorrect, control board fault indicator light will flash
rapidly and furnace will not operate.
—7—
Page 8
BLK
WHT
WHT
GND
115-VOLT FIELD-
SUPPLIED
FUSED
DISCONNECT
THREE-WIRE
BLK
AUXILIARY
J-BOX
FIVE
WIRE
NOTE 2
WCR GY
THERMOSTAT
TERMINALS
HEATING-
ONLY
W
R
GND
CONTROL
BOX
FURNACE
G
C
Y
24-VOLT
TERMINAL
BLOCK
NOTE 1
CONDENSING
UNIT
TWO
WIRE
NOTES: Connect Y-terminal as shown for proper operation.
1.
2.
Some thermostats require a "C" terminal connection as shown.
3.
If any of the original wire, as supplied, must be replaced, use
same type or equivalent wire.
Fig. 8—Heating and Cooling Application Wiring Diagram
FIELD 24-VOLT WIRING
FIELD 115-, 208/230-, 460-VOLT WIRING
FACTORY 24-VOLT WIRING
FACTORY 115-VOLT WIRING
FIELD-SUPPLIED
FUSED DISCONNECT
208/230- OR
460-VOLT
THREE
PHASE
208/230-
VOLT
SINGLE
GND
PHASE
A95241
TABLE 5—ELECTRICAL DATA
UNIT SIZE
024045 115—60—1 127 104 6.0 14 47 15
036045 115—60—1 127 104 8.3 14 34 15
024070 115—60—1 127 104 5.9 14 47 15
036070 115—60—1 127 104 8.7 14 32 15
042091 115—60—1 127 104 9.0 14 31 15
048091 115—60—1 127 104 10.4 14 27 15
036110 115—60—1 127 104 8.0 14 35 15
048111 115—60—1 127 104 10.1 14 28 15
060111 115—60—1 127 104 14.4 12 31 20
048135 115—60—1 127 104 10.1 14 28 15
060135 115—60—1 127 104 13.3 12 33 20
060155 115—60—1 127 104 14.0 12 31 20
* Permissible limits of the voltage range at which the unit operates satisfactorily.
† Time-delay fuse is recommended.
‡ Length shown is as measured 1 way along wire path between unit and service panel for maximum 2 percent voltage drop.
VOLTS—
HERTZ—
PHASE
The furnace must have a 115-v power supply properly connected
and grounded. Proper polarity must be maintained for correct
operation. Thermostat wire connections at R, W, C, and Y must be
made at the 24-v terminal block on the control board. The gas
service pressure must not exceed 0.5 psig (14-in. wc), but must be
no less than 0.16 psig (4.5-in. wc).
CAUTION: This furnace is equipped with a manual
reset limit switch or fuse link in the gas control area. The
OPERATING
VOLTAGE RANGE
Maximum* Minimum*
MAXIMUM
UNIT AMPS
MINIMUM
WIRE GAGE
MAXIMUM
WIRE LENGTH (FT)‡
The blower compartment door must be in place to complete the
115-v circuit to the furnace.
B. Sequence of Operation
CAUTION: Furnace control must be grounded for
proper operation, or control will lockout. Control is
grounded through green wire routed to gas valve and
burner bracket screw.
switch or fuse link opens and shuts off power to the gas
valve if a flame rollout or overheating condition occurs in
the gas control area. DO NOT bypass the switch. Correct
inadequate combustion air supply problem and reset the
switch or replace the fuse link.
Using the schematic diagram shown in Fig. 11, follow the
sequence of operation through the different modes. Read and
follow the wiring diagram very carefully.
NOTE: If there is a power interruption and any thermostat call,
the control initiates a 90-sec blower only on period before starting
Before operating the furnace, check each manual reset switch for
another cycle.
continuity. If necessary, press the button to reset the switch.
MAXIMUM
FUSE OR
HACR-TYPE CKT
BKR AMPS†
—8—
Page 9
BLOWER OFF DELAY
ADJUSTMENT SWITCH
115-VAC (L1)
POWER
SUPPLY
HOT SURFACE
CONNECTOR
TEST/TWIN
SEC-1
3-AMP FUSE
COOL
HEAT
IGNITOR
G
R
Y
W
Com
24V
HUM
115-VAC (L2) NEUTRAL
CONNECTION
INDUCER MOTOR
CONNECTOR
Fig. 9—Control Board
24V THERMOSTAT
TERMINALS
HUMIDIFIER TERMINAL
(24-VAC 0.5 AMP MAX)
LED OPERATION &
DIAGNOSTIC LIGHT
HARNESS CONNECTOR
24V TRANSFORMER SEC-2
SPARE 1
BLOWER SPEED
SELECTION TERMINALS
SPARE 2
EAC 1 (BLACK)
EAC-ELECTRONIC AIR CLEANER
TERMINALS (115-VAC 1.5 AMP MAX)
EAC 2 (WHITE)
A93052
Fig. 10—EAC Terminals on Control Board
1. Heating mode
When the wall thermostat "calls for heat," the R-W circuit
closes. The furnace control performs a self-check, verifies
the pressure switch contacts are open, and starts inducer
motor.
a. Prepurge period—As the inducer motor comes up to
speed, the pressure switch contacts close to begin a
15-sec prepurge period.
b. Ignitor warm-up—At the end of the prepurge period, the
ignitor is energized for a 17-sec ignitor warm-up period.
c. Ignition sequence—When the ignitor warm-up period is
completed, the gas valve opens, permitting gas flow to
the burners where it is ignited. After 5 sec, the ignitor is
de-energized and a 2-sec flame-sensing period begins.
A93053
d. HUM terminal is energized with the gas valve. See
accessories in the Electrical Connections section.
e. Flame-sensing—When burner flame is sensed, the con-
trol begins the blower on delay period and continues
holding the gas valve open. If burner flame is not sensed,
the control closes the gas valve and repeats ignition
cycle.
NOTE: Ignition sequence will repeat 3 additional time before a
lockout occurs. Lockout automatically resets after 3 hrs, or can be
manually reset by turning 115v off (not at thermostat) for 3 sec
minimum, then on again.
f. Blower on delay—Forty sec after burner flame is proven,
the blower motor is energized on heating speed. Simultaneously, the humidifier and electronic air cleaner
terminals (HUM and Com for humidifier, EAC-1 and
EAC-2 for electronic air cleaner) are energized. If jumper
is on pin 6 and pin 9, blower on delay is 60 sec.
g. Blower off delay—When the thermostat is satisfied, the
circuit between R-W is broken, de-energizing the gas
valve stopping gas flow to the burners. The blower
motor and EAC remain energized 90, 135, 180, or 225
sec (depending on the blower off-time selection). The
furnace is factory set for a 135-sec blower off delay.
h. Post-purge—The inducer motor remains energized 5 sec
after the burners are extinguished. If jumper is on pin 6
and pin 9, the post-purge period is 15 sec.
2. Cooling mode
When the thermostat "calls for cooling," R-G and R-Y
circuits close. The R-Y circuit starts the outdoor condensing
—9—
Page 10
L2
CAP
BLWM
START
SCHEMATIC DIAGRAM
(NATURAL GAS & PROPANE)
NOTE #4
EQUIPMENT GROUND
OL
LO
HI
MED LO
MED HI
COM
NOTE #8
HEAT
SPARE-2
COM
COOL
SPARE-1
HI/LO
EAC-1
TO 115VAC FIELD DISCONNECT
NEUTRAL
L1
ILK
PRS
ALS
NOTE #12
(WHEN USED)
DSS
ORN
OM
GRY
W
C
SW1
SW2
OFF
DELAY
BLOWER
NOTE #9
(NOT ON ALL MODELS)
PCB
YEL
HUM
TEST/TWIN
SELECTION CHART
BLOWER OFF DELAY
BLU
LED
90 SEC
L1
BLWR
FRS1 FRS2
RED
135 SEC
3-P
1-M
1
2
3
PL1
180 SEC
GV
LS
WHT
4
HSIR
FL
(WHEN USED)
FSE
5
6
225 SEC
EAC-2
87
9
IDM
HSI
1
2
1
PR2
PL52
1
PL2
115VAC
PR1
IDR
NOTE #5
2-C
GRN
WHT
BLK
TRAN
RED
BLU
RED
SEC-2
SEC-1
HI/LO
RELAY
NOT USED
PL3
2
3
24VAC
TRAN
NOTE #6
FU1
TEST/TWIN
GRN
WHT (COM)
24 VAC-3A
CAP
BRN
START
OL
NOTE #8
BLK (HI)
YEL (MED HI)
SPARE-1
FUSE
COOL
FU1
SPEED
SELECT
BLOWER
GVR
HSIR IDR BLW R
FL
PRS
NOTE #11
ALS
LS
FRS1 FRS2
(WHEN USED
1
7
SEC-2
SEC-1
GVR-2
HUM
NOTE #12
BRN
BLWM
RED (LO)
BLU (MED LO)
1.5 AMP
SPARE-2
EAC-1
EAC-2
HEAT
OM
L2
C
PR2
123
PL3
2
1
PL2
PR1
VAC
L1
120
PL1
4
GVR
HI/LO
BLWR
IDR
HSIR
R
W
NOTE #4
FUSED DISCONNECT
SWITCH (WHEN REQ’D)
JB
BLK
ILK
WHT
WHT (COM)
WHT
BLK
BLK
BLK
WHT
PL5
12
WHT
2-C
(WHEN USED)
GV
DSS
3-P
1-M
2
3
GVR-1
CPU
L1
NEUTRAL
FU2
GRN
WHT
BLK
GRN
IDM
BLK
HSI
8
Y
NOTE #5
FSE
6
5
G
PCB PRINTED CIRCUIT BOARD
PL1 9-CIRCUIT CONNECTOR
PL2 2-CIRCUIT PCB CONNECTOR
ALS AUXILIARY LIMIT SWITCH, OVERTEMP. -MANUAL RESET, SPST-(N.C.)
BLWR BLOWER MOTOR RELAY, SPST-(N.O.)
LEGEND
NOT USED
PL3 3-CIRCUIT IDM CONNECTOR
BLWM BLOWER MOTOR
A95335
322869-101 REV. C
NOT USED
9
OM
C
PL5 2-CIRCUIT HSI/PCB CONNECTOR
PRS PRESSURE SWITCH, SPST-(N.O.)
CAP CAPACITOR
CPU MICROPROCESSOR AND CIRCUITRY
DSS DRAFT SAFEG UARD SWITCH
NOTES:
TEST/TWIN COMPONENT TEST & TWIN TERMINAL
EAC-1 ELECTRONIC AIR CLEANER CONNECTION (115 VAC 1.5 AMP MAX.)
optimum speed selection.
1. If any of the original equipment wire is replaced use wire rated for 105°C.
2. Inducer (IDM) and blower (BLWM) motors contain internal auto-reset thermal overload switches (OL).
3. Blower motor speed selections are for average conditions, see installation instructions for details on
4. Use only copper wire between the disconnect switch and the furnace junction box (JB).
5. This wire must be connected to furnace sheetmetal for control to detect flame.
JUNCTION
UNMARKED TERMINAL
PCB TERMINAL
FACTORY WIRING (115VAC)
TRAN TRANSFORMER-115VAC/24VAC
(FIELD INSTALLED & SUPPLIED)
EAC-2 ELECTRONIC AIR CLEANER CO NNECTION (COMMON)
FL FUSIBLE LINK
FRS FLAME ROLLOUT SW. -MANUAL RESET, SPST-(N.C.)
FSE FLAME PROVING ELECTRODE
FU1 F USE, 3 AMP, AUTOMOTIVE BLADE TYPE, FACTORY INSTALLED
FU2 FUSE OR CIRCUIT BREAKER CURRENT INTERRUPT DE VI CE
GV GAS VALVE- REDUNDANT OPERATORS
GVR GAS VALVE RELAY, DPST-(N.O.)
(135 seconds only on some models)
after three hours.
6. Replace only with a 3 amp fuse.
7. Yellow lead not on all motors.
8. Blower-on delay, gas heating 45 seconds, cooling or heat pump 2 seconds.
9. Blower-off delay, gas heating 90, 135, 180 or 225 seconds, cooling or heat pump 90 seconds.
FACTORY WIRING (24VAC)
FIELD WIRING (115VAC)
FIELD WIRING (24VAC)
CONDUCTOR ON PCB
HI/LO BLOWER MOTOR SPEED CHANGE RELAY, SPDT
HSI HOT SURFACE IGNITOR (115 VAC)
HSIR HOT SURFACE IGNITOR RELAY, SPST-(N.O.)
HUM 24VAC HUMIDIFIER CONNECTION (.5 AMP. MAX.)
IDM INDUCED DRAFT MOTOR
models only.
10. Ignition-lockout will occur after four consecutive unsuccessful trials-for-ignition. Control will auto-reset
11. When used auxiliary limit switch (ALS) is on downflow models only. When used FL is on upflow
12. Some models may have spade quick connect terminals.
FIELD WIRING TERMINAL
FIELD GROUND
EQUIPMENT GROUND
FIELD SPLICE
PLUG RECEPTACLE
IDR INDUCED DRAFT RELAY, SPST-(N.O.)
ILK BLOWER ACCESS PANEL IN TE R LOCK SWITCH, SPST-(N.O.)
JB JUNCTION BOX
LED LIGHT-EMITTING DIODE FOR STATUS CODES
LGPS LOW GAS PRESSURE SWITCH, SPST-(N.O.)
LS LIMIT SWITCH, AUTO RESET, SPST(N.C.)
OL AUTO-RESET INTERNAL MOTOR OVERLOAD TEMP. SW.
→ Fig. 11—Unit Wiring Diagram
—10—
Page 11
unit and the combined R-Y and R-G circuits start the
furnace blower motor on cooling speed. The EAC-1 terminal is energized with 115v when the blower is operating on
cooling speed.
When the thermostat is satisfied, R-G and R-Y circuits are
broken. The furnace blower and EAC continue operating on
cooling speed for an additional 90 sec.
3. Continuous blower mode
NOTE: EAC-1 terminal is energized with 115v whenever blower
operates.
When the R-G circuit is made, the blower motor operates on
heating speed. During a call for heat, the blower stops,
allowing the furnace heat exchangers to heat up more
quickly, then restarts at the end of the 40-sec blower on
delay period. If jumper is on pin 6 and pin 9, the blower on
delay is 60 sec.
The blower reverts to continuous operation after the heating
cycle is completed.
When the thermostat "calls for cooling," the blower operates on cooling speed. When the thermostat is satisfied, the
blower operates an additional 90 sec before reverting back
to continuous operation on heating speed.
4. Heat pump mode
When installed with a heat pump, the furnace control
automatically changes the timing sequence to avoid long
blower off time during demand defrost cycles. When the
W-Y or W-Y-G thermostat inputs are received at the same
time, the control changes the blower to heating speed or
starts the blower if it was off, and begins a heating cycle.
The blower remains on until the end of the prepurge period,
then shuts off until the end of the ignition warm-up and trial
for ignition periods (a total of 24 sec). The blower then
comes back on at heating speed.
When the W input signal disappears, the control begins the
normal inducer post-purge period and the blower changes to
cooling speed after a 1-sec delay. If the W-Y-G signals
disappear at the same time, the blower remains on for the
selected heating blower off delay period and the inducer
goes through its normal post-purge period. If the W-Y
inputs should disappear, leaving the G signal input, the
control goes into continuous blower and the inducer remains on for the normal post-purge period.
Anytime the control senses false flame, the control locks
out of the heating mode. This occurs because the control
cannot sense the W input due to the false flame signal, and
as a result, sees only the Y input and goes into cooling
mode, blower off delay. All other control functions remain
in standard format.
NOTE: EAC-1 terminal is energized whenever blower operates.
HUM terminal is only energized when gas valve is energized
C. Start-up Procedures
1. Purge gas lines—After all connections have been made,
purge the lines and check for leaks.
WARNING: Never purge a line into a combustion
chamber. Never use matches, candles, flame, or other
sources of ignition for the purpose of checking leakage.
Use a soap-and-water solution to check for leakage.
Failure to follow this warning can cause fire, explosion,
personal injury, or death.
2. Component test—The furnace control board allows all
components, except gas valve, to be run for a short period
of time.
This feature helps diagnose a system problem in case of a
component failure. To initiate component test procedure,
short (jumper) the TEST 1/4-in. quick connect terminal on
control board (adjacent to diagnostic light) and the Com
terminal on thermostat connection block for approximately
2 sec. (See Fig. 9.)
NOTE: Component test feature will not operate if any thermostat
signal is present at control board.
Component test sequence is as follows.
a. Momentarily jumper TEST and Com terminals until
LED goes off.
b. LED will display previous fault 4 times.
c. Inducer motor operates for 10 sec, then stops.
d. Hot surface ignitor is energized for 15 sec, then de-
energized.
e. Blower motor operates on cooling speed for 10 sec, then
stops.
f. Blower motor operates on heating speed for 10 sec, then
stops.
3. To operate furnace, follow procedures on operating instructions label attached to furnace.
4. With furnace operating, set thermostat below room temperature and observe that furnace goes off. Set thermostat
above room temperature and observe that furnace restarts.
D. Adjustments
1. Set gas input rate.
There are 2 methods of adjusting the gas input rate. The
preferred method is by using Table 6 and following the
instructions in item a. The second method is by clocking the
gas meter and using the instructions in item b.
The gas valve regulator has been nominally set at 3.5-in. wc
for natural gas. When adjusting input rate, do not set
manifold pressure above 3.8-in. wc or below 3.2-in. wc.
a. Check gas input rate using Table 6.
(1.) Obtain average yearly heat value for local gas
supply.
(2.) Obtain average yearly specific gravity for local gas
supply.
(3.) Verify furnace model. Table 6 can only be used for
model 395CAV Furnaces.
(4.) Check and verify orifice size in furnace. NEVER
ASSUME THE ORIFICE SIZE. ALWAYS
CHECK AND VERIFY.
(5.) Find natural gas heat value and specific gravity in
Table 6.
(6.) Follow heat value and specific gravity lines to point
of intersection. Find orifice size and manifold pressure settings for proper operation at given natural
gas conditions.
EXAMPLE:
Heat value 1070
Btu/cu ft specific gravity 0.58
Therefore; Orifice No. 44*
Manifold pressure 3.3-in. wc
*The furnace is shipped with No. 43 orifices.
Therefore, in this example all main burner orifices must be
changed and manifold pressure must be adjusted.
(7.) Proceed to item c to adjust manifold pressure.
—11—
Page 12
GAS
HEAT
VALUE
(BTU/CU FT)
860
875
890
905
920
935
950
965
980
995
1010
1025
1040
1055
1070
1085
1100
TABLE 6—MODEL 395CAV ORIFICE SIZE AND MANIFOLD PRESSURE FOR CORRECT INPUT RATE
(Tabulated Data Based on Altitude Up to 2000 Ft and 22,000 Btuh Per Burner)
SPECIFIC GRAVITY OF NATURAL GAS
0.56 0.58 0.60 0.62 0.64 0.66 0.68 0.70 0.72
Orf
Mnfld
No.
Press.
41
42
—
42
—
—
42
—
—
42
—
—
43—3.8—42—3.2—42—3.3—42—3.4—41423.2
43—3.7—43—3.8—42—3.2—42—3.3—42—3.4—41423.2
43—3.6—43—3.7—43—3.8—42—3.2—42—3.3—42—3.4—41423.2
43—3.4—43—3.6—43—3.7—43—3.8—42—3.2—42—3.3—42—3.4—41423.2
44433.8
44433.7
44—3.6—44433.7
44—3.5—44433.6
44—3.4—44—3.5—44433.6
44—3.3—44—3.4—44—3.5—44433.6
44—3.2—44—3.3—44—3.4—44—3.5—44433.7
45—3.8—44—3.2—44—3.3—44—3.4—44—3.6—44433.7
45—3.7—45—3.8
Orf
No.
3.2
41
3.6
42
—
—
3.4
41
—
42
—
—
3.3
42
—
—
—
—
3.2
42
—
—
—
—
3.342—
3.24443
Mnfld
Orf
Press.
3.3
3.7
—
3.2
3.6
—
3.4
—
—
3.3
—
—
3.5—43—3.6—43—3.7—43—3.8—42—3.2—42—3.3—42—3.4—41423.2
3.8
3.443—
3.34443
3.24443
3.444—
No.
41
42
40
41
42
—
41
42
—
42
—
—
Mnfld
Press.
Orf
Mnfld
No.
Press.
3.4
41
3.8
40
3.2
—
3.3
41
3.7
42
—
40
3.2
41
3.6
42
—
—
3.4
41
—
42
—
—
3.5—43—3.6—43—3.7—43—3.8—42—3.2—42—3.3—42—3.4
3.8
3.443—
3.7
3.343—
3.24443
3.2—44—3.4—44—3.5—44—3.6—44433.7
Orf
Mnfld
Orf
No.
Press.
3.5
41
3.3
—
3.4
3.8
3.2
3.3
3.7
—
3.2
3.6
—
3.5—43—3.6—43—3.7—43—3.8—42—3.2—42—3.3
3.4—43—3.5—43—3.6—43—3.7—43—3.8—43—3.2
3.7
3.343—
3.24443
3.7
39
3.2
40
3.4
41
3.5
40
3.3
—
—
41
3.4
42
3.8
—
—
41
3.3
42
3.7
—
—
3.54142
3.4—43—3.5—43—3.6—43—3.7—43—3.8
3.8
3.343—
3.24443
No.
41
39
40
41
39
40
41
40
—
41
42
—
Mnfld
Press.
Orf
Mnfld
Orf
No.
Press.
3.8
39
3.3
3.5
3.6
3.2
3.4
3.5
3.2
—
3.4
3.8
—
3.3
3.74142
3.54142
3.4—43—3.5—43—3.6—43—3.7
3.8
3.343—
2.34443
3.4
40
3.6
—
—
41
3.8
39
3.3
40
3.5
41
3.6
40
3.3
—
—
41
3.5
40
3.2
—
—
3.4
3.84140
3.3
3.74142
3.54142
3.4—43—3.5—43—3.6
3.8
3.343—
3.24443
No.
38
39
40
39
40
—
41
39
40
41
40
—
Mnfld
Press.
3.2
3.5
3.7
3.3
3.6
3.7
3.2
3.4
3.6
3.3
3.5
3.24140
3.4
3.84140
3.3
3.64142
3.54142
—
—
3.4—43—3.5
3.8
3.343—
Orf
No.
38
39
40
38
39
40
41
39
40
41
39
40
Mnfld
Press.
3.3
3.6
3.8
3.2
3.4
3.7
3.8
3.3
3.5
3.7
3.2
3.4
3.6
3.3
3.5
3.2
3.4
3.7
3.3
3.6
3.5
—
—
—
—
—
—
—
3.4
—
b. Check gas input rate by clocking gas meter.
(1.) Obtain average yearly heat value for local gas
supply.
(2.) Check and verify orifice size in furnace. NEVER
ASSUME THE ORIFICE SIZE. ALWAYS
CHECK AND VERIFY.
CAUTION: DO NOT redrill burner orifices. Improper
drilling (burrs, out of round, etc.) can cause excessive
burner operating noise and misdirection of burner flames.
This could result in flame impingement on burners and
heat exchanger surfaces, leading to potential failures.
(3.) Turn off all other gas appliances and pilots.
(4.) Start furnace and let run for 3 minutes.
(5.) Measure time (in sec) for gas meter to complete 1
revolution.
(6.) Refer to Table 7 for cu ft of gas per hr.
(7.) Multiply gas rate (cu ft/hr) by heating value (Btu/cu
ft).
EXAMPLE:
Btu heating input = Btu/cu ft X cu ft/hr
Heating value of gas = 1070 Btu/cu ft
Time for 1 revolution of 2 cu ft dial = 72 sec
Gas rate = 100 X 1070 = 107,000 Btuh
(8.) Measured gas input should not exceed gas input on
unit rating plate.
(9.) Proceed to item c to adjust manifold pressure.
c. Adjust gas input.
(1.) Remove regulator adjustment seal cap. (See Fig.
12.)
(2.) Turn adjusting screw counterclockwise to decrease
input. Turn screw clockwise to increase input. DO
NOT set manifold pressure less than 3.2-in. wc or
more than 3.8-in. wc for natural gas. Make any
major adjustments by changing main burner orifices.
—12—
Page 13
TABLE 7—GAS RATE CU FT/HR
SECONDS
FOR 1
REVOLUTION
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
SIZE OF
TEST DIAL
1
cu ft2cu ft5cu ft
360
720
655
600
555
514
480
450
424
400
379
360
343
327
313
300
288
277
267
257
248
240
232
225
218
212
206
200
195
189
185
180
176
172
167
164
160
157
153
150
147
1800
1636
1500
1385
1286
1200
1125
1059
100
947
900
857
818
783
750
720
692
667
643
621
600
581
563
545
529
514
500
486
474
462
450
439
429
419
409
400
391
383
375
367
327
300
277
257
240
225
212
200
189
180
171
164
157
150
144
138
133
129
124
120
116
113
109
106
103
100
97
95
92
90
88
86
84
82
80
78
76
75
73
SECONDS
FOR 1
REVOLUTION
50
51
52
53
54
55
56
57
58
59
60
62
64
66
68
70
72
74
76
78
80
82
84
86
88
90
92
94
96
98
100
102
104
106
108
110
112
116
120
(3.) When correct input is obtained, replace regulator
seal cap. Main burner flame should be clear blue,
almost transparent. (See Fig. 13.)
ON AND
OFF SWITCH
SIZE OF
TEST DIAL
1
cu ft2cu ft5cu ft
72
144
141
138
136
133
131
129
126
124
122
120
116
112
109
106
103
100
97
95
92
90
88
86
84
82
80
78
76
75
74
72
71
69
68
67
65
64
62
60
360
355
346
340
333
327
321
316
310
305
300
290
281
273
265
257
250
243
237
231
225
220
214
209
205
200
196
192
188
184
180
178
173
170
167
164
161
155
150
71
69
68
67
65
64
63
62
61
60
58
56
54
53
51
50
48
47
46
45
44
43
42
41
40
39
38
38
37
36
35
35
34
33
33
32
31
30
GAS
PRESSURE
REGULATOR
ADJUSTMENT
BURNER FLAME
BURNER
MANIFOLD
Fig. 13—Burner Flame
e. Canadian installations only—The Canadian ratings are
approved for altitudes up to 2000 ft for natural and
propane gases. High-altitude ratings are from 2000 ft to
4500 ft above sea level. See Table 8 for nominal burner
orifice size. High-altitude rating includes a 10 percent
derate as required by Canadian standards.
TABLE 8—CANADIAN ORIFICE SIZE
GAS
SEA LEVEL
0—2000 FT
Natural 43 44
Propane 54 55
HIGH ALTITUDE
2000—4500 FT
2. Set temperature rise.
Furnace must operate within range of temperature rise
specified on the unit rating plate. Determine the air temperature rise as follows.
a. Place duct thermometers in return and supply ducts as
near furnace as possible. Be sure thermometers do not
"see" heat exchangers so that radiant heat will not affect
thermometer readings. This is particularly important
with straight-run ducts.
b. When thermometer readings stabilize, subtract return-air
temperature from supply-air temperature to determine
temperature rise.
c. Adjust air temperature rise by adjusting blower speed.
Increase blower speed to reduce temperature rise. Decrease blower speed to increase temperature rise.
A89020
INLET
PRESSURE TAP
MANIFOLD
PRESSURE TAP
Fig. 12—Redundant Automatic Gas Control Valve
→
d. High altitude—In the United States gas input on rating
plate is for altitudes up to 2000 ft. Ratings for altitudes
over 2000 ft must be 4 percent less for each 1000 ft
above sea level. To obtain the adjusted altitude rating,
adjust the manifold pressure (see item c) and replace the
main burner orifices as needed. Refer to National Fuel
Gas Code Appendix F, Table F-4 for proper orifice
sizing at high altitudes.
A95618
WARNING: Disconnect the electrical power before
changing the speed tap. A failure to follow this warning
can cause personal injury.
d. To change blower motor speed selections for heating
mode, remove blower motor lead from control board
HEAT terminal. (See Fig. 11.) Select desired blower
motor speed lead from 1 of the other terminals and
relocate it to HEAT terminal. See Table 9 for lead color
identification. Reconnect original lead on SPARE terminal.
CAUTION: Recheck temperature rise. It must be within
limits specified on unit rating plate. Recommended operation is at midpoint of rise or above.
—13—
Page 14
TABLE 9—SPEED SELECTOR
COLOR SPEED
Black High Cool
Yellow (When
present)
Blue Medium-Low Heat
Red Low Spare
White Common COM
Medium-High Spare
FACTORY-
ATTACHED TO
3. Set thermostat heat anticipator.
The thermostat heat anticipator must be set to match the
amp draw of the electrical components in the R-W circuit.
Accurate amp draw readings can be obtained at thermostat
subbase terminals R and W. Fig. 14 illustrates an easy
method of obtaining the actual amp draw. The amp reading
should be taken after the blower motor has started. See the
thermostat manufacturer’s instructions for adjusting the
heat anticipator and for varying the heating cycle length.
NOTE: When using an electronic thermostat, set the cycle rate for
3 cycles per hr.
THERMOSTAT SUBBASE
TERMINALS WITH
THERMOSTAT REMOVED
HOOK-AROUND
VOLT/AMMETER
R Y W G
10 TURNS
FROM UNIT 24-VOLT
TERMINAL BLOCK
The preferred method of checking the limit control is to
gradually block off the return air after the furnace has been
operating for a period of at least 5 minutes. As soon as the
limit has shut off the burners, the return-air opening should
be unblocked. By using this method to check the limit
control, it can be established that the limit is functioning
properly and operates if there is a motor failure.
2. Check draft safeguard switch.
The purpose of this control is to permit the safe shutdown
of the furnace during certain blocked vent conditions.
a. Disconnect power to furnace and remove vent connector
from furnace outlet collar. Be sure to allow time for vent
pipe to cool down before removing.
b. Restore power to furnace and set room thermostat above
room temperature.
c. After normal start-up, allow furnace to operate for 2
minutes, then block flue outlet 100 percent. Furnace
should cycle off within 2 minutes.
d. Remove blockage and reconnect vent pipe to furnace
outlet collar.
e. Wait 5 minutes and then reset draft safeguard switch.
3. Check pressure switch.
This control proves operation of draft inducer blower.
a. Turn off 115-v power to furnace.
b. Remove control door and disconnect inducer motor lead
wires from wire harness.
c. Turn on 115-v power to furnace.
d. Set thermostat to "call for heat" and wait 1 minute. When
pressure switch is functioning properly, hot surface
ignitor should NOT glow and control center diagnostic
light flashes a 31 fault. If hot surface ignitor glows when
inducer motor is disconnected, shut down furnace im-
mediately. Determine reason pressure switch did not
function properly and correct condition.
e. Turn off 115-v power to furnace.
f. Reconnect inducer motor wires, replace control door, and
turn on 115-v power.
EXAMPLE:
5.0 AMPS ON AMMETER
10 TURNS AROUND JAWS
= 0.5 AMPS FOR THERMOSTAT SETTING
A80201
Fig. 14—Amp Draw Check With Ammeter
E. Check Safety Controls
The flame sensor, gas valve, and pressure switch were all checked
in the Start-up Procedures section as part of normal operation.
1. Check primary limit control.
This control shuts off the combustion control system and
energizes the circulating-air blower motor if the furnace
overheats.
F. Checklist
1. Put away tools, instruments, and clean up debris.
2. Verify manual reset switches have continuity.
3. Ensure blower and control access doors are properly installed.
4. Cycle test furnace with room thermostat.
5. Check operation of accessories per manufacturer’s instructions.
6. Review User’s Manual with owner.
7. Leave literature packet near furnace.,
—14—
Page 15
SERVICE TRAINING
Packaged Service Training programs are an excellent way to increase your
knowledge of the equipment discussed in this manual, including:
• Unit Familiarization • Maintenance
• Installation Overview • Operating Sequence
A large selection of product, theory, and skills programs is available, using popular
video-based formats and materials. All include video and/or slides, plus companion
book.
Classroom Service Training plus "hands-on" the products in our labs can mean
increased confidence that really pays dividends in faster troubleshooting, fewer
callbacks. Course descriptions and schedules are in our catalog.
CALL FOR FREE CATALOG 1-800-962-9212
[ ] Packaged Service Training [ ] Classroom Service Training
A94328
—15—
Page 16
© 1996 BDP Co. • P.O. Box 70 • Indianapolis, IN 46206 Printed in U.S.A.
—16—
395c4010 Catalog No. BDP-3339-518
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