Nordyne 045N-23ASK, 054N-23ASK, 045C-23ASK, 054C-23ASA, 054C-23ASK Installation Instructions Manual

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Page 1

GAS FURNACES

Installation Instructions

Single Stage High Efﬁ ciency Furnaces

80+ AFUE

*SA Upﬂ ow/Horizontal Model *SK Downﬂ ow Model

WARNING:

• PROPOSITION 65 WARNING: This product contains chemicals known to the state of California to cause cancer, birth defects or other reproductive harm.

• This furnace is not approved for installation in mobile homes. Installing this furnace in a mobile home could cause ﬁ re, property damage, and/or personal injury.

ATTENTION INSTALLERS:

It is your responsibility to know this product better than your customer. This includes being able to install the product according to strict safety guidelines and instructing the customer on how to operate and maintain the equipment for the life of the product. Safety should always be the deciding factor when installing this product and using common sense plays an important role as well. Pay attention to all safety warnings and any other special notes highlighted in the manual. Improper installation of the furnace or failure to follow safety warnings could result in serious injury, death, or property damage.

These instructions are primarily intended to assist qualiﬁ ed individuals experienced in the proper installation of this appliance. Some local codes require licensed installation/service personnel for this type of equipment. Please read all instructions carefully before starting the installation. Return these instructions to the customer’s package for future reference.

WARNING:

FIRE OR EXPLOSION HAZARD

• Failure to follow safety warnings exactly could result in serious injury or property damage.

• Installation and service must be performed by a qualiﬁ ed installer, service agency or the gas supplier.

• Do not store or use gasoline or other ﬂ ammable vapors and liquids in the vicinity of this or any other appliance.

WHAT TO DO IF YOU SMELL GAS

• Do not try to light any appliance.

• Do not touch any electrical switch; do not

use any phone in your building.

• Leave the building immediately.

• Immediately call your gas supplier from a

neighbors phone. Follow the gas suppliers instructions.

• If you cannot reach your gas supplier, call

the ﬁ re department.

DO NOT DESTROY.

KEEP IN A SAFE PLACE FOR FUTURE REFERENCE.

Page 2

TABLE OF CONTENTS

SAFETY INFORMATION .............................................4

REQUIREMENTS AND CODES .................................. 4

GENERAL INSTRUCTIONS ........................................ 5

Combustion Air Quality ...........................................5

Operation of Furnace During Construction .............5

Installation in a Garage ...........................................6

Heating Load ...........................................................6

Clearances to Combustible Materials .....................6

COMBUSTION AIR REQUIREMENTS ........................6

General Information ................................................6

Installation in a Conﬁ ned Space ..............................7

Outdoor Air Using Vertical Ducts ........................7

Outdoor Air Using Horizontal Ducts ...................7

VENTING REQUIREMENTS ......................................12

Category I Venting .................................................12

Horizontal Venting ..................................................13

Flexible Vent Systems ............................................13

CIRCULATING AIR REQUIREMENTS ......................13

Plenums and Air Ducts ..........................................13

Supply Air Connections .........................................14

Upﬂ ow/Horizontal Furnaces ..............................14

Downﬂ ow Furnaces ...........................................14

Return Air Connections .........................................14

Upﬂ ow/Horizontal Furnaces ..............................14

Side Return Installations ................................14

Bottom Return Installations ............................14

Outdoor Air Using a Crawl Space or

Vented Attic ........................................................7

Air Directly Through an Exterior Wall .................8

Alternate Method of Providing Air from

Outside ...............................................................8

Air From Inside ...................................................8

Installation in an Unconﬁ ned Space ........................ 8

FURNACE INSTALLATION .........................................9

General Requirements ............................................ 9

Upﬂ ow Installation ................................................... 9

Side Return Air Inlet ...........................................9

Bottom Return Air Inlet .......................................9

Horizontal Installation ..............................................9

Bottom Panel Removal .....................................10

Downﬂ ow Furnaces ...........................................14

Acoustical Treatments............................................14

GAS SUPPLY AND PIPING .......................................15

Leak Check ...........................................................15

High-Altitude Application .......................................15

Conversion to LP/Propane ....................................16

ELECTRICAL WIRING ...............................................17

Low Voltage Wiring ................................................17

Line Voltage Wiring ................................................17

Grounding ..............................................................18

Twinning .................................................................18

START-UP & ADJUSTMENTS ...................................18

Pre-Start Checklist ................................................18

Downﬂ ow Installation ............................................10

Installation on a Concrete Slab ........................10

Start-Up Procedures ..............................................18

Verifying and Adjusting Input Rate ........................18

Page 3

Verifying and Adjusting Temperature Rise .............19

Electrical Information.............................................29

Verifying Burner Operation ....................................19

Verify Operation of the Supply Air

Limit Switch ...........................................................20

OPERATING SEQUENCE .........................................20

Heating Cycle ........................................................20

Cooling Cycle ........................................................20

Fan Mode ..............................................................20

MAINTENANCE .........................................................20

Air Filters ...............................................................20

Blower Compartment ............................................21

Cleaning of Burners ..............................................21

Cleaning of Flue Passages ...................................21

Heat Exchanger and Burner Maintenance ............22

Table 4 - Wire length and Voltage Specs ..........29

Table 5 - Control Board Fault Codes ................29

Figure 17 - Wiring Diagram ..............................30

Gas Information .....................................................31

Table 6 - Gas Flow Rates.................................31

Table 7 - Gas Pipe Capacities .........................31

Table 8 - High Altitude Deration Chart for

Propane Gas .....................................32

Table 9 - Natural Gas Heating Values ..............32

Table 10 - High Altitude Deration Chart for

Nat. Gas -High Heating Values ........33

Table 11 - High Altitude Deration Chart for

Nat. Gas -Low Heating Values.........33

Location of Furnace Components .........................35

Lubrication ............................................................22

Vent System ..........................................................22

TROUBLESHOOTING ...............................................22

DESCRIPTION OF COMPONENTS ..........................23

FIGURES AND TABLES ............................................23

Table 1 - Minimum Clearances to Combustible

Materials ............................................23

Furnace Dimensions .............................................24

Figure 15 - Upﬂ ow/Horizontal Furnaces ...........24

Figure 16 - Downﬂ ow Furnaces........................25

Airﬂ ow Data ...........................................................26

Table 2 - Upﬂ ow/Horizontal Gas Furnaces .......26

Table 3 - Downﬂ ow Gas Furnaces ....................28

Figure 18 - Upﬂ ow/Horizontal Gas Furnace

Components ..................................35

Figure 19 - Downﬂ ow Gas Furnace

Components ..................................35

INSTALLATION/PERFORMANCE CHECKLIST .......36

Page 4

SAFETY INFORMATION

Safety markings are used frequently throughout this

manual to designate a degree or level of seriousness and should not be ignored. WARNING indicates a potentially hazardous situation that if not avoided, could result in personal injury or death. CAUTION indicates a potentially hazardous situation that if not avoided, may result in minor or moderate injury or property damage.

WARNING:

The safety information listed below must be followed during the installation, service, and operation of this furnace. Failure to follow safety recommendations could result in possible damage to the equipment, serious per

injury or death

sonal

REQUIREMENTS and CODES This furnace must be installed in accordance with

these instructions, all applicable local building codes and the current revision of the National Fuel Gas Code (NFPA54/ANSI Z223.1) or the Natural Gas and Propane Installation Code, CAN/CGA B149.1.

Additional codes listed below are for reference purposes only and do not necessarily have jurisdiction over local or state codes. Always consult with local authorities before installing any gas appliance.

Combustion and Ventilation Air

• US: National Fuel Gas Code (NFGC), Air for Combustion and Ventilation

• CANADA: Natural Gas and Propane Installation Codes (NSCNGPIC), Venting Systems and Air Supply for Appliances

• Use only with type of gas approved for this furnace. Refer to the furnace rating plate.

• Install this furnace only in a location and position as speciﬁ ed in Table 1 (page 23).

• Provide adequate combustion and ventilation air to the furnace space as speciﬁ ed on Pages 6 - 8.

• Combustion products must be discharged outdoors. Connect this furnace to an approved vent system only, as speciﬁ ed on Pages 12 - 13.

• Never test for gas leaks with an open ﬂ ame. Use a commercially available soap solution to check all connections (Page 15).

• This furnace is designed to operate with a maximum external pressure rise of 0.5 inches of water column. Consult Tables 2 and 3 (pages 26 - 28), and the rating plate for the proper circulating air ﬂ ow and temperature rise. It is important that the duct system be designed to handle the desired ﬂ ow rate and temperature rise. An improperly designed duct system can result in nuisance shutdowns, and comfort or noise issues.

• When 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.

• This furnace may be used for temporary heating of buildings or structures under construction. See the guidelines listed on page 5.

• A gas-ﬁ red furnace for installation in a residential garage must be installed as speciﬁ ed on Page 6.

Duct Systems

• US and CANADA: Air Conditioning Contractors Association (ACCA) Manual D, Sheet Metal and Air Conditioning Contractors National Association (SMACNA), or American Society of Heating, Refrigeration, and Air Conditioning Engineers (ASHRAE) Fundamentals Handbook

Electrical Connections

• US: National Electrical Code (NEC) ANSI/NFPA 70

• CANADA: Canadian Electrical Code CSA C22.1

Gas Piping and Gas Pipe Pressure Testing

• US: NFGC and National Plumbing Codes

• CANADA: NSCNGPIC

General Installation

• US: Current edition of the NFGC and the NFPA 90B. For copies, contact the National Fire Protection Association Inc., Batterymarch Park, Quincy, MA 02269; or American Gas Association, 400 N. Capitol, N.W., Washington DC 20001 or www.NFPA.org

• CANADA: NSCNGPIC. For a copy, contact Standard Sales, CSA International, 178 Rexdale Boulevard, Etobicoke (Toronto), Ontario, M9W 1R3 Canada

Safety

• US: (NFGC) NFPA 54–1999/ANSI Z223.1 and the Installation Standards, Warm Air Heating and Air Conditioning Systems ANSI/NFPA 90B.

• CANADA: CAN/CGA-B149.1 and .2–M00 National Standard of Canada. (NSCNGPIC)

Page 5

GENERAL INSTRUCTIONS Combustion Air Quality

CAUTION:

Combustion air must not be drawn from a corrosive atmosphere.

To maximize heat exchanger life, the combustion air must be free of chemicals that can form corrosive acidic compounds in the combustion gases. The recommended source of combustion air is to use outdoor air. However, the use of indoor air in most applications is acceptable except as listed:

• If the furnace is installed in a conﬁ ned space, it is required that the necessary combustion air come from the outdoors by way of attic, crawl space, air duct, or direct opening. See Installation in a Conﬁ ned Space section (pages 7 - 8) for combustion air requirements.

• Installations in these locations may require outdoor air

for combustion, due to chemical exposures:

Commercial buildings Buildings with indoor pools Furnaces installed in laundry rooms Furnaces installed in hobby or craft rooms Furnaces installed near chemical storage areas

• Exposure to the following substances in the combustion air supply may require outdoor air for combustion:

Permanent wave solutions Chlorinated waxes and cleaners Chlorine based swimming pool chemicals Water softening chemicals De-icing salts or chemicals Carbon tetrachloride Halogen type refrigerants Cleaning solvents (perchloroethylene) Printing inks, paint removers, varnishes, etc. Hydrochloric acid Cements and glues Antistatic fabric softeners Masonry acid washing materials

Operation of Furnace During Construction

CAUTION:

Failure to follow these instructions will void the factory warranty and may signiﬁ cantly reduce the life or the performance of the furnace, and/or result in other unsafe conditions. It is the responsibility of the installing contractor to insure these provisions are met.

Operating gas furnaces in construction environments can cause a variety of problems with the furnace. Proper use of commercial portable space heating equipment during construction is recommended. This gas furnace may be used during construction if it is not in violation of any applicable codes and the following criteria are met:

• The installation must meet all applicable codes. The furnace must be permanently installed according to the instructions supplied with the furnace including electrical supply, gas supply, duct work and venting. The furnace must be controlled by a thermostat properly installed according to the instructions supplied with the furnace and thermostat. The installation must include a properly installed ﬁ lter in the return air system with no by-pass air. The ﬁ lter must be inspected frequently and replaced when necessary.

• Combustion air must be supplied from outside the structure and located such that dust and gases from construction activity are not introduced into the combustion system.

• Provisions must be made to insure that condensate does not freeze in the furnace or condensate drain lines during operation and during idle times; for example, overnight if turned off. (Condensing furnaces only)

• Before occupying the structure: The ﬁ lter must be replaced or cleaned, the duct work must be inspected and cleaned of any construction debris, and the furnace must be cleaned and/or repaired if found to be dirty, damaged, or malfunctioning in any way by a qualiﬁ ed HVAC technician. The furnace shall be inspected and approved by applicable local authority even if this requires redundant inspections.

• Serial numbers for furnaces used during construction must be submitted in writing (fax and email also acceptable). This information will be used to track the long-term affects of the use during construction on furnaces. Proof of this submittal shall be available for the ﬁ nal inspection of the furnace prior to occupancy.

• This furnace is designed to operate with return air temperatures in ranges normally found in occupied residences, including setbacks. Minimum continuous return temperature must not be below 60° F (15° C). Occasionally a temporary return temperature of 55° F (12° C) is acceptable. However, operation with a return temperature below 55° F (12° C) is not allowed.

Page 6

Installation in a Garage

WARNING:

Do not place combustible materials on or against the furnace cabinet or within 6 inches of the vent pipe. Do not place combustible materials, including gasoline or any other ﬂ ammable vapors and liquids, in the vicinity of the furnace.

This Gas-ﬁ red furnace may be installed in a residential garage with the provision that the burners and igniter are located no less than 18 inches (457mm) above the ﬂ oor. The furnace must be located or protected to prevent physical damage by vehicles.

Heating Load

The furnace should be sized to provide the design heating load requirement. Heating load estimates can be made using approved methods available from Air Conditioning Contractors of America (Manual J); American Society of Heating, Refrigerating, and Air Conditioning Engineers; or other approved engineering methods. Excessive

oversizing of the furnace could cause the furnace and/or vent to fail prematurely. In addition, the ductwork

should be appropriately sized to the capacity of the furnace to ensure its proper airﬂ ow rating. For installations above 2,000 ft., the furnace should have a sea level input rating large enough that it will meet the heating load after deration for altitude.

Clearances to Combustible Materials

This furnace is Design Certiﬁ ed in the U.S. and Canada by CSA International for the minimum clearances to combustible materials listed in Table 1 (page 23). To obtain model number and speciﬁ c clearance information, refer to the furnace rating plate, located inside of the furnace cabinet.

COMBUSTION AIR REQUIREMENTS General Information

WARNING:

Furnace installation using methods other than those described in the following sections must comply with the National Fuel Gas Code (NFGC) and all applicable local codes.

• Instructions for determining the adequacy of an installation can be found in the current revision of the NFGC (ANSI Z223.1 / NFPA54). Consult local codes for special requirements. These requirements are for US installations as found in the NFGC.

• The requirements in Canada (B149.1) are structured differently. Consult with B149.1 and local code ofﬁ cials for Canadian installations.

• Additional reference information for US and Canadian installations can be found in the Combustion and Ventilation Air section (page 4).

Provisions must be made during the installation of this furnace that provide an adequate supply of air for combustion.

CAUTION:

Exhaust fans, clothes dryers, ﬁ replaces and other appliances that force air from the house to the outdoors can create a negative pressure inside the house, resulting in improper furnace operation or unsafe conditions such as ﬂ ame roll out. It is imperative that sufﬁ cient air exchange with the outdoors is provided to prevent depressurization. Additional information about how to test for negative pressure problems can be found in the NFGC.

Access for positioning and servicing the unit must be considered when locating unit. The minimum required clearance from the front of the unit for servicing is 24 inches. The minimum required clearance for positioning is 30 inches from the front of the unit. The recommended clearance from the front of the unit is 36 inches. The need to provide clearance for access to panels or doors may require clearance distances over and above the requirements.

NOTE: Air openings on top of the furnace and openings in closet doors or walls must never be restricted. If the furnace is operated without adequate air for combustion, the ﬂ ame roll-out switch will open, turning off the gas supply to the burners. This safety device is a manually reset switch.

DO NOT install jumper wires across these switches to defeat their function or reset a switch without identifying and correcting the fault condition.

If a switch must be replaced, use only the correct sized part speciﬁ ed in the Replacement Parts List provided online.

Page 7

Installation In A Conﬁ ned Space

A conﬁ ned space is an area with volume less than 50 cubic feet per 1,000 Btuh of the combined input rates of all appliances drawing combustion air from that space. Furnace closets, small equipment rooms and garages are conﬁ ned spaces. Furnaces installed in a conﬁ ned space which supply heated air to areas outside the space must draw return air from outside the space and must have the return air ducts tightly sealed to the furnace.

The required sizing of these openings is determined by whether inside or outside air is used to support combustion, the method by which the air is brought to the space, and by the total input rate of all appliances in the space. In all cases, the minimum dimension of any combustion air opening is 3 inches.

Outdoor Air Using Vertical Ducts If combustion air is taken from outdoors through vertical ducts, the openings and ducts must have a minimum free area of one square inch per 4,000 Btuh of total appliance input. In installations drawing combustion air from a ventilated attic, both air ducts must extend above the attic insulation (Figure 1).

Ventilation Louvers at each end of attic

Vent or Chimney

Water Heater

Attic

Insulation

Furnace

Outlet Air Duct must be at least 1 sq. in. per 4,000 Btuh of total input rating.

Inlet and Outlet Ducts must extend above attic insulation.

Inlet Air Duct must be at least 1 sq. in. per 4,000 Btuh of total input rating.

12" Max

Total Input Rating

(Btuh)

Minimum Free Area

(Each Opening)

Round Duct

Diameter

40,000 100 sq. In 12 inches 60,000 100 sq. In 12 inches

80,000 100 sq. In 12 inches 100,000 100 sq. In 12 inches 120,000 120 sq. In 13 inches 140,000 140 sq. In 14 inches 160,000 160 sq. In 15 inches

Figure 1. Combustion Air Drawn from Outside

Through Vertical Ducts

Outdoor Air Using Horizontal Ducts If combustion air is taken from outdoors through horizontal ducts, the openings and ducts must have a minimum free area of one square inch per 2,000 Btuh of total appliance input (Figure 2).

Vent or

Chimney

12" Max

See

Note

12" Max

Total Input Rating

(Btuh)

40,000 10 sq. In 5 inches 60,000 15 sq. In 6 inches

80,000 20 sq. In 7 inches 100,000 25 sq. In 8 inches 120,000 30 sq. In 9 inches 140,000 35 sq. In 10 inches 160,000 40 sq. In 10 inches

Water Heater

Air Duct

Furnace

Air Duct

Minimum Free Area

(Each Opening)

NOTE: Each

opening to outside must be at least 1 sq. in. per 2,000 Btuh of total

input rating.

Round Duct

Diameter

Figure 2. Combustion Air Drawn from Outside

Through Horizontal Ducts

Outdoor Air from a Crawl Space or Vented Attic When the openings can freely exchange air with the outdoors, each opening shall have a minimum free area of 1 square inch per 4,000 Btuh of total appliance input. The openings shall exchange directly, or by ducts, with the outdoor spaces (crawl or attic) that freely exchange with the outdoors (Figure 3).

Ventilation louvers

Chimney

Attic Insulation

Water Heater

Vent or

at each end of attic

Furnace

Outlet air duct must be at least 1 sq. in. per 4,000 Btuh of total input rating. Must extend above attic insulation

Inlet air duct must be at least 1 sq. in. per 4,000 Btuh of total input rating.

Crawl Space

Ventilated Louvers for unheated crawl space

Figure 3. Combustion Air Drawn from a Crawl

Space or Vented Attic

Page 8

Air Directly Through An Exterior Wall If combustion air is provided directly through an exterior wall, the two openings must each have free area of at least one square inch per 4,000 Btuh of total appliance input (Figure 4).

Vent or

12" Max

See Note

12" Max

Total Input Rating

(Btuh)

40,000 10 sq. In 4 inches 60,000 15 sq. In 5 inches

80,000 20 sq. In 5 inches 100,000 25 sq. In 6 inches 120,000 30 sq. In 6 inches 140,000 35 sq. In 7 inches 160,000 40 sq. In 8 inches

Chimney

Furnace

Water Heater

Minimum Free Area

(Each Opening)

NOTE: Each opening

to outside must be at least 1 sq. in. per 4,000 Btuh of total input rating.

Round Duct

Diameter

Figure 4. Combustion Air Drawn from Outside

Through an Exterior Wall

Alternate Method of Providing Air from Outside: If acceptable under local Codes, it is permitted to provide outside air using one opening (See NFGC).

Air From Inside

If combustion air is taken from the heated space, the two openings must each have a free area of at least one square inch per 1,000 Btuh of total input of all appliances in the conﬁ ned space, but not less than 100 square inches of free area (Figure 5). For example, if the combined input rate of all appliances is less than or equal to 100,000 Btuh, each opening must have a free area of at least 100 square inches. If the combined input rate of all appliances is 120,000 Btuh, each opening must have a free area of at least 120 square inches.

Vent or

Chimney

NOTES: Each opening must be at least 100 sq. in. or 1 sq. in. per 1,000 Btuh of total input rating, whichever is greater.

Openings must start at no more than 12 inches from the top and bottom of the enclosure.

Water Heater

Total Input Rating

(Btuh)

40,000 100 sq. In 12 inches 60,000 100 sq. In 12 inches

80,000 100 sq. In 12 inches 100,000 100 sq. In 12 inches 120,000 120 sq. In 13 inches 140,000 140 sq. In 14 inches 160,000 160 sq. In 15 inches

Minimum Free Area

(Each Opening)

12" Max.

Furnace

See Notes

12” Max.

See

Notes

Round Duct

Diameter

Figure 5. Combustion Air Drawn from Inside

Generally, conﬁ ned spaces must have two openings in the space for combustion air. One opening must be within 12 inches of the ceiling, and the other must be within 12 inches of the ﬂ oor. However, an alternative method recently adopted by the NFGC uses one opening within 12 inches of the top of the space. This method may be used if it is acceptable to the local codes.

The following conditions must be met:

1. The opening must start within 12” of the top of the structure and connect with the out of doors through vertical or horizontal ducts or be ducted to a crawl or attic space that connects with the out of doors.

2. The opening must have a minimum free area of 1

sq. in. per 3,000 Btu per hour of the total input rating of all equipment located in the enclosure.

3. The free area must not be less than the sum of all

the areas of the vent connectors in the enclosure.

Installation In An Unconﬁ ned Space

An unconﬁ ned space is an area including all rooms not separated by doors with a volume greater than 50 cubic feet per 1,000 Btuh of the combined input rates of all appliances which draw combustion air from that space.

In general, a furnace installed in an unconﬁ ned space will not require outside air for combustion. However, in homes built for energy efﬁ ciency (low air change rates), it may be necessary to provide outside air to ensure adequate combustion and venting, even though the furnace is located in an unconﬁ ned space. See example.

Example: A space with a water heater rated at 45,000 Btuh input and a furnace rated at 75,000 Btuh requires a volume of 6,000 cubic feet [50 x (45 + 75) = 6,000] to be considered unconﬁ ned. If the space has an 8 foot ceiling, the ﬂ oor area of the space must be 750 square feet (6,000 / 8 = 750).

Page 9

FURNACE INSTALLATION

General Requirements

*SA series gas furnaces are shipped ready for installation in the upﬂ ow or horizontal right or left positions. Only the *SK series gas furnace may be used for downﬂ ow operation.

• The furnace must be leveled at installation and attached to a properly installed duct system. See Table 1 (page

23) for the required clearances needed to move the furnace to its installation point (hallways, doorways, stairs, etc).

• The furnace must be installed so that all electrical components are protected from water.

• The furnace must be installed upstream from a refrigeration system.

• Additional reference information for US and Canadian installations can be found in the General Installation section (page 4).

Upﬂ ow Installation

The *SA series gas furnace may be installed directly on combustible wood ﬂ ooring or supports. This furnace

must not be installed directly on carpeting, tile, or any combustible material other than wood ﬂ ooring.

For venting guidelines and speciﬁ cations, see Venting Requirements section (pages 12 - 13).

Access for positioning and servicing must be considered when locating the unit. See Table 1 (page 23) for clearance speciﬁ cations.

If the furnace is to be installed in an attic, it is required that a drip pan be placed under the furnace. If the installation is on a combustible platform (Figure 6), it is recommended that the drip pan extend at least 12 inches past the top and front of the furnace.

WARNING:

The furnace must not be installed directly on carpeting, tile, or any combustible material other than wood ﬂ ooring.

It is recommended for further reduction of ﬁ re hazard that cement board or sheet metal be placed between the furnace and the combustible ﬂ oor and extend 12 inches beyond the front of the door and top of the furnace.

Note: Line Contact

Is Permissible

Type “B” Vent

Gas Inlet

Side Return Air Inlet *SA series gas furnaces are shipped with the bottom panel installed (Figure 15, page 24). If the upﬂ ow furnace is installed with side return air, the bottom panel must not be removed.

Bottom Return Air Inlet *SA series gas furnaces are shipped with the bottom panel installed. If the upﬂ ow furnace is installed with bottom return air, the bottom panel must be removed. See Bottom Panel Removal on page 10.

Horizontal Installation

The *SA series gas furnace can be installed horizontally in an attic, basement, crawl space or alcove (Figure 6). It can also be suspended from a ceiling in a basement or utility room in either a right to left airﬂ ow or left to right airﬂ ow as shown in Figure 7.

*SA series furnaces are shipped with the bottom panel installed. If the furnace is installed horizontally, remove the bottom panel from the furnace before attaching the duct system. See Bottom Panel Removal on page 10.

If the furnace is to be suspended from the ceiling, it will be necessary to use steel straps around each end of the furnace. The straps should be attached to the furnace with sheet metal screws and to the rafters with bolts. The furnace could also be suspended by an angle iron frame bolted to the rafters (Figure 7).

Coil Plenum

Electrical Supply

Connection

Combustible Platform

Figure 6. *SA Horizontal Installation on a Platform

Figure 7. *SA Horizontal Installation

Suspended in Attic or Crawl Space

Page 10

Bottom Panel Removal

To remove the bottom panel (Figure 8) from the upﬂ ow

furnace, perform the following steps:

1. Remove the blower door (1) from bottom of furnace.

2. Disconnect the wiring harness (2) from the

connector.

3. Remove two screws (3) securing the blower assembly

(4) to the furnace.

4. Carefully pull the blower assembly (4) out thru the

front of the furnace.

5. Remove all screws (5) securing bottom panel (6) to

bottom of furnace and front brace (7).

6. Lift up and slide bottom panel (6) out through front of

furnace.

7. Reinstall the blower assembly (4) in reverse order it

was removed.

Bottom Panel

Downﬂ ow Installation

The *SK series gas furnace is certiﬁ ed for installation on combustible ﬂ ooring. This furnace must not be installed

directly on carpeting, tile, or any combustible material other than wood ﬂ ooring. For venting guidelines and

speciﬁ cations, see Venting Requirements section (page

12).

WARNING:

Failure to install the downﬂ ow sub-base kit may result in ﬁ re, property damage or personal injury.

To install the furnace on combustible ﬂ ooring, a special sub-base is required. Downﬂ ow sub-base kits are factory supplied accessories and are listed according to the cabinet letter of the furnace. For ‘A’ size cabinets use Sub-Base kit #902974 only. For ‘B’, ‘C’, and ‘D’ size cabinets use Kit #904911. Please follow the instructions provided with the kit.

WARNING:

The downﬂ ow sub-base kit must not be installed directly on carpeting, tile, or any combustible material other than wood ﬂ ooring.

A downﬂ ow sub-base kit is not necessary if the furnace

Blower Assembly

is installed on a factory or site-built cased air conditioning coil. However, the plenum attached to the coil casing must be installed so that its surfaces are at least 1” from combustible construction.

Installation on a concrete slab.

1. Create an opening in the ﬂ oor according to the dimensions in Figure 9.

2. Position the plenum and the furnace as shown in Figure 10 (page 11).

Opening in concrete floor

“A”

“B”

Figure 8. Removal of Bottom Panel

*SK MODEL

NUMBERS:

054-23A

072-24B

090-24B

108-35C

126-45D

Figure 9. Cutout Dimensions

Dimension

“A”

⅝

⅛

⅝

Dimension

“B”

¼ ¼ ¼ ¼ ¼

Page 11

Concrete

Floor

Figure 10. Furnace on a Concrete Slab

Furnace

Sheet

Metal

Plenum

WARNING:

CARBON MONOXIDE POISONING HAZARD

Failure to follow the steps outlined below for each appliance connected to the venting system

being placed into operation could result in carbon monoxide poisoning or death.

The following steps shall be followed with each individual appliance connected to the venting system being placed in operation, while all 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 in the National

Fuel Gas Code, ANSI Z223. 1/NFPA 54 or the CSA B149.1, Natural Gas and Propane Installation Codes and these instructions. Determine that there is no blockage or restriction, leakage,

corrosion and other deﬁ ciencies 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 ﬁ replace dampers.

5. Turn on clothes dryers and any appliance not connected to the venting system. Turn on any exhaust fans, such as range hoods and bathroom exhausts, so they are operating at maximum speed. Do not operate a summer exhaust fan.

6. Follow the lighting instructions. Place the appliance being inspected into operation. Adjust the thermostat so appliance is operating continuously.

7. Test for spillage from draft hood equipped appliances at the draft hood relief opening after 5 minutes of main burner operation. Use the ﬂ ame 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 CSA B149.1, Natural Gas and Propane Installation Codes.

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, ﬁ replace dampers and any other gas-ﬁ red burning appliance to their previous conditions of use.

Page 12

VENTING REQUIREMENTS

WARNING:

Upon completion of the furnace installation, carefully inspect the entire ﬂ ue system both inside and outside the furnace to assure it is properly sealed. Leaks in the ﬂ ue system can result in serious personal injury or death due to exposure of ﬂ ue products, including carbon monoxide.

• This furnace must be vented in compliance with the current revision of the National Fuel Gas Code (ANSI-Z223.1/NFPA54) and the instructions provided below. Consult local codes for special

requirements.

• In Canada, venting shall conform to the requirements of the current (CAN/CGA B149.1 or .2) installation codes.

Consult local codes for special requirements.

• Additional reference information for US and Canadian installations can be found in the Combustion and Ventilation Air section (page 4).

Category I Venting

This furnace is listed as a Category I vented appliance. Category I furnaces generally operate with a slight negative pressure (draft) and must be vented vertically or near vertical. Additionally it is important to guard against excessive condensation.

• Category I furnace installations must be connected to a factory built chimney or vent complying with a recognized standard, or a masonry or concrete chimney lined with a lining material acceptable to the authority having jurisdiction.

WARNING:

Venting into an unlined masonry chimney or concrete chimney is prohibited. This may result in improper draft and excess condensation forming in the chimney.

• This furnace may be vented with a dedicated venting system or common vented with other Category I appliances. The vent system dimensions and material must conform to the NFGC or local Codes. Generally, this means using Type B vent pipe or a lined masonry chimney. When consulting the vent sizing tables in the NFGC, the MAX capacity of the vent must be greater than the furnaces high ﬁ re rate. The MIN capacity must be lower than the low ﬁ re rate. If the venting system is inappropriate for the furnace, the venting system will need to be modiﬁ ed to comply with NFGC or local codes.

• The venting system should be designed to have the minimum number of elbows or turns. All horizontal runs shall slope upwards from the furnace at ¼ inch per running foot of vent. Supports for the vent pipe must be installed a minimum of every ﬁ ve feet along the vent run to ensure no displacement after installation. Under no circumstances shall any portion of the vent system extend into or pass through any return air duct, supply air duct, or plenum.

• Single wall vent connectors may be used under the limited capacity ranges found in the vent sizing tables. It is recommended that Type B double wall vent be used for the connector whenever possible. An existing masonry chimney should be inspected and relined if necessary.

• In the U.S., this furnace must never be vented to a chimney or ﬂ ue that services a ﬁ replace or other appliance designed to burn solid fuel. If the furnace vent is to be connected to a chimney serving a ﬁ replace, the ﬁ replace must be sealed off from the chimney. In Canada, common venting with a ﬁ replace is permitted. Consult B149.1 and your local code authority.

• Single wall metal vertical vents shall not be used for Category I venting. The furnace vent, if metal, may be insulated if local codes allow. Any part of the vent system, metal vent only, not exposed to weather, but which are exposed to temperatures below 35° F (1°C) must be insulated to prevent condensation. All vent insulation shall be foil backed ﬁ berglass of one inch minimum thickness.

• Sheet metal fasteners should be used to secure the vent pipe to the furnace ﬂ ue. However, the NFGC lists that alternative vent products may be attached according to the vent manufacturers instructions.

• When an existing furnace is removed from a vent system serving other appliances, the existing vent system may no longer be sized to properly vent the remaining appliances. An improperly sized venting system can result in the formation of condensate, leakage, or spillage. The existing vent system should also be checked to make sure it remains in compliance with NFGC. If it isn’t, the vent system must be brought into compliance before installing the furnace.

Page 13

Horizontal Venting

CIRCULATING AIR REQUIREMENTS

WARNING:

Horizontal vent systems must be sealed with a high temperature sealant that can withstand temperatures of 450° F. Recommended sealants: Dow Corning Sealant 736 RTV; GE 106 RTV; High Tech Ind., High TEMP RED.

This furnace is not approved for horizontal venting without the use of an add-on power venter. Power venters establish negative pressure in the vent piping and the furnace operates as if connected to a Category I vertical vent. The power venter is only for use when exhausting through an exterior wall.

The power venter must be installed according to the instructions provided by the power venter manufacturer and applicable requirements of local codes. For Canadian installations please refer to the Canadian Installation Code (CAN/CGA-B149.1 or 2) and/or local codes.

The outlet of the vent must be at least 12 inches above the highest expected snow accumulation.

Flexible Vent Systems

Flexible venting systems are approved for use providing they are listed for the application and meet all local Code requirements. These systems are primarily used to line existing masonry chimneys. They must be sized to the application according to the sizing tables in the National Fuel Gas Code, including the required 20% reduction in maximum capacity.

Flexible venting systems are permitted to be used as the vent connector. However, great care must be taken to ensure that there are no sags in the venting system which could accumulate condensate. The ﬂ exible vent system must be supported at no more than 5 foot intervals and maintain a minimum slope of ¼ inch per foot of horizontal run.

WARNING:

Do not allow combustion products to enter the circulating air supply. Failure to prevent the circulation of combustion products into the living space can create potentially hazardous conditions including carbon monoxide poisoning that could result in personal injury or death.

All return ductwork must be secured to the furnace with sheet metal screws. For installations in conﬁ ned spaces, all return ductwork must be adequately sealed. When return air is provided through the bottom of the furnace, the joint between the furnace and the return air plenum must be air tight.

The surface that the furnace is mounted on must provide sound physical support of the furnace with no gaps, cracks or sagging between the furnace and the ﬂ oor or platform.

Return air and circulating air ductwork must not be connected to any other heat producing device such as a ﬁ replace insert, stove, etc. This may result in ﬁ re, explosion, carbon monoxide poisoning, personal injury, or property damage.

Plenums and Air Ducts

• Plenums and air ducts must be installed in accordance

with the Standard for the Installation of Air Conditioning and Ventilating Systems (NFPA No. 90A) or the Standard for the Installation of Warm Air Heating and Air Conditioning Systems (NFPA No. 90B). Additional reference information for US and Canadian installations can be found in the Duct Systems section (page 4).

• Table 2 and Table 3 (pages 26-28) contain the airﬂ ow and

temperature rise data. If the maximum airﬂ ow is 1,600 CFM or more, it is recommended that two openings be used for return air on upﬂ ow furnaces. Downﬂ ow furnaces can only use one return opening.

• It is recommended that the outlet duct contain a removable

access panel. The opening should be accessible when the furnace is installed in service and shall be of a size that smoke or reﬂ ected light may be observed inside the casing to indicate the presence of leaks in the heat exchanger. The cover for the opening shall be attached in such a manner as to prevent leaks.

• If outside air is used as return air to the furnace for

ventilation or to improve indoor air quality, the system must be designed so that the return air is not less than 60° F (15° C) during operation. If a combination of indoor and outdoor air is used, the ducts and damper system

Page 14

must be designed so that the return air supply to the furnace is equal to the return air supply under normal, indoor return air applications.

• When a cooling system is installed which uses the furnace blower to provide airﬂ ow over the indoor coil, the coil must be installed downstream (on the outlet side) of the furnace or in parallel with the furnace.

• If a cooling system is installed in parallel with the furnace, a damper must be installed to prevent chilled air from entering the furnace and condensing on the heat exchanger. If a manually operated damper is installed, it must be designed so that operation of the furnace is prevented when the damper is in the cooling position and operation of the cooling system is prevented when the damper is in the heating position.

Supply Air Connections

The supply air must be delivered to the heated space by duct(s) secured to the furnace casing, running full size and without interruption. It is good practice to seal all connections and joints with industrial grade sealing tape or liquid sealant. Requirements for sealing ductwork vary from region to region. Consult with local codes for requirements speciﬁ c to your area.

Upﬂ ow and Horizontal Furnaces To attach the supply air duct to the furnace, bend the furnace ﬂ anges (Figure 15, page 24) upward 90° with a pair of wide duct pliers. Position the duct on top of the furnace and secure together with sheet metal screws. The screws must penetrate the sheet metal casing and furnace ﬂ ange. Tape or seal all seams if required by local code.

Downﬂ ow Furnaces To attach the supply air duct to the downﬂ ow furnace, position the furnace over the duct and secure together with sheet metal screws. The screws must penetrate the duct and furnace casing.

Return Air Connections

In applications where the supply ducts carry heated air to areas outside the space where the furnace is installed, the return air must be delivered to the furnace by duct(s) secured to the furnace casing, running full size and without interruption. It is good practice to seal all connections and joints with industrial grade sealing tape or liquid sealant. Requirements for sealing ductwork vary from region to region. Consult with local codes for requirements speciﬁ c to your area.

Upﬂ ow and Horizontal Furnaces For upﬂ ow installations, the return air ductwork may be connected to the left side, right side, or bottom. The bottom panel (Figure 15, page 24) must be installed for left or right return air. NOTE: Do not use the back of the

furnace for return air.

Side Return Installations

To attach the return air duct to the left or right side of the furnace, punch out the four knockouts (Figure 15) from the preferred side of the furnace. Using sharp metal cutters, cut an opening between all four knockouts to expose the blower assembly. Position the return air duct over the opening in the side and secure together with sheet metal screws. The screws must penetrate the duct and furnace casing.

WARNING:

The solid base of the furnace must be in place when the furnace is installed with side return air ducts. Removal of all or part of the base could cause circulation of combustible products into the living space and create potentially hazardous conditions, including carbon monoxide poisoning that could result in personal injury or death.

Bottom Return Installations

The bottom panel (Figure 15) must be removed from the bottom of the furnace for bottom return air. If bottom panel is still installed, go to page 9 for removal instructions. Position the furnace over the return air duct and secure together with sheet metal screws. The screws must penetrate the duct and furnace casing.

Downﬂ ow Furnaces To attach the return air duct to the furnace, bend the furnace ﬂ anges (Figure 16, page 25) upward 90° with a pair of wide duct pliers. Position the duct on top of the furnace and secure together with sheet metal screws. The screws must penetrate the sheet metal casing and furnace ﬂ ange. Tape or seal all seams if required by local code.

Acoustical Treatments

Damping ducts, ﬂ exible vibration isolators, or pleated media-style ﬁ lters on the return air inlet of the furnace may be used to reduce the transmission of equipment noise eminating from the furnace. These treatments can produce a quieter installation, particularly in the heated space. However, they can increase the pressure drop in the duct system. Care must be taken to maintain the proper maximum pressure rise across the furnace, temperature rise and ﬂ ow rate. This may mean increasing the duct size and/or reducing the blower speed. These treatments must be constructed and installed in accordance with NFPA and SMACNA construction standards. Consult with local codes for special requirements. For best sound performance, be sure to install all the needed gaskets and grommets around penetrations into the furnace, such as for electrical wiring.

Page 15

GAS SUPPLY AND PIPING

All gas piping must be installed in compliance with local codes and utility regulations.

In the absence of local codes the gas line installation must comply with the latest edition of the National Fuel Gas Code (ANSI Z223.1) or (CAN/CGA B149.1 or .2) Installation Codes. Additional reference information for US and Canadian installations can be found in the Gas Piping and Gas Pipe Pressure Testing section (page 4).

Shut-Off Valve

(See Note)

Dripleg

Upflow Models - Left Side Entry

Automatic

Gas Valve

(with manual

shut-off)

Manifold

IMPORTANT NOTES:

• Some local regulations require the installation of a manual

main shut-off valve and ground joint union external to the furnace as depicted in Figure 11. The shut-off valve should be readily accessible for service and/or emergency use. Consult the local utility or gas supplier for additional requirements regarding placement of the manual main gas shut-off.

• Gas piping must never run in or through air ducts,

chimneys, gas vents, or elevator shafts.

• Compounds used on threaded joints of gas piping must

be resistant to the actions of LP propane gas.

• The main gas valve and main power disconnect to the

furnace must be properly labeled by the installer in case emergency shutdown is required.

• Flexible gas connectors are not recommended for this

type of furnace but may be used if allowed by local jurisdiction. The ﬂ exible gas connector must be agency approved and certiﬁ ed for the type of gas being used. Only new ﬂ exible connectors may be used. Do not reuse

old ﬂ exible gas connectors.

• A drip leg should be installed in the vertical pipe run to

the unit (Figure 11).

Table 7 (page 31) lists gas pipe capacities for standard pipe sizes as a function of length in typical applications based on nominal pressure drop in the line.

The furnace may be installed for either left or right side gas entry. When connecting the gas supply, provide clearance between the gas supply line and the entry hole in the furnace casing to avoid unwanted noise and/or damage to the furnace. A typical gas service hookup is shown in Figure 11.

Leak Check

WARNING:

FIRE OR EXPLOSION HAZARD Never test for gas leaks with an open ﬂ ame. Check all connections using a commercially available soap solution. A ﬁ re or explosion may result causing property damage, personal injury or loss of life. Failure to follow the safety warnings exactly could result in serious injury, death or property damage.

Ground Joint

Union

Burner

Assembly

Downflow Models - Right Side Entry

Automatic

Gas Valve

(with manual

shut-off)

2 Street

Elbows

Burner

Assembly

Note: Some utilities require Shut- Off Valve to be 4 to 5 feet above floor.

Manifold

Shut-Off Valve

(See Note)

Dripleg

Ground Joint

Union

Figure 11. Typical Gas Connection

After the gas piping to the furnace is complete, all connections must be tested for gas leaks. This includes pipe connections at the main gas valve, emergency shutoff valve and ﬂ exible gas connectors (if applicable). The soap and water solution can be applied on each joint or union using a small paintbrush. If any bubbling is observed, the connection is not sealed adequately and must be retightened. Repeat the tightening and soap check process until bubbling ceases.

IMPORTANT NOTE: When pressure testing gas supply lines at pressures greater than 1/2 psig (14 inch W.C.), the gas supply piping system must be disconnected from the furnace to prevent damage to the gas control valve. If the test pressure is less than or equal to 1/2 psig (14 inch W.C.), close the manual shut-off valve.

High Altitude Application

High altitude conversion with this furnace depends on the installation altitude and the heating value of the gas. The installation of this furnace at altitudes above 2,000 feet must meet the requirements of the National Fuel Gas Code or local jurisdiction. In Canada, the requirements for high altitude are different and governed by CGA B149.1. Please consult your local code authority.

Page 16

WARNING:

The reduction of input rating necessary for high altitude installation may only be accomplished with factory supplied oriﬁ ces. Do not attempt to drill out oriﬁ ces in the ﬁ eld. Improperly drilled oriﬁ ces may cause ﬁ re, explosion, carbon monoxide poisoning, personal injury or death.

The furnaces are shipped from the factory with oriﬁ ces and gas regulator settings for natural gas operation at sea level altitudes. At 2000 feet, the NFGC requires that this appliance be derated 4% for each 1,000 feet of altitude. For example, at 2,000 feet the input needs to be reduced 8% , at 3,000 feet (12%) and etc. This deration is in reference to the input rate and gas heating value at sea level.

To derate the furnace requires knowing the heating value of the gas at the installation site. Heating values at particular job sites vary for two reasons:

1. The chemical mixture of the gas varies from region to region and is expressed as the “sea level heating value”.

2. The heating value varies by altitude. For this reason, especially in high altitude areas, the local gas utility speciﬁ es the heating value at the residence’s gas meter as the “local value”.

For added ﬂ exibility, two tables have been provided for natural gas installations with HIGH or LOW heating values at sea level. Tables 10 and 11 (page 33) contain the oriﬁ ce sizes and manifold pressure to use at various altitudes. Table 10 (High) is for natural gas installations with a heating value of more than 1,000 Btu per cubic foot and Table 11 (Low) is for less than 1,000 Btu per cubic foot. To determine which table to use:

1. Consult the local utility for the local heating value at your installation site.

2. From Table 9 (page 32), ﬁ nd your local heating value as supplied by the utility company. Follow down the column and stop at your altitude level.

3. If your sea level heating value is HIGH, use Table 10 or if it’s LOW, use Table 11 (page 33).

After changing the regulator pressure or the oriﬁ ces, it is required that you measure the gas input rate. This may be accomplished in the usual way, by clocking the gas meter and using the local gas heating value. See Verifying and Adjusting the Input Rate section (page 18).

IMPORTANT NOTE: Observe the action of the burners to make sure there is no yellowing, lifting or ﬂ ashback of the ﬂ ame.

Conversion to LP/Propane

WARNING:

The furnace was shipped from the factory equipped to operate on natural gas. Conversion to LP/propane gas must be performed by qualiﬁ ed service personnel using a factory supplied conversion kit. Failure to use the proper conversion kit can cause ﬁ re, explosion, property damage, carbon monoxide poisoning, personal injury, or death.

IMPORTANT NOTE: When converting a low NOx furnace from Natural gas to LP/propane gas, it is necessary to remove the NOx Bafﬂ es from the furnace.

Conversion to LP/propane is detailed in the installation instructions provided with the conversion kit. Generally, this will require the replacement of the burner oriﬁ ces and the spring found under the cap screw on the pressure regulator. In the U.S. if installation is above 2,000 ft., refer to Table 8 (page 32) to determine the correct oriﬁ ce size and manifold pressure. When conversion is complete, verify the manifold pressure and input rate are correct as listed in the Tables. Approved conversion kits are listed below:

• The United States LP/Propane Gas Sea Level and High Altitude Conversion Kit (P/N 904914) is for LP/propane conversion in the United States at altitudes between zero and 10,000 ft. above sea level. Please follow the instructions provided with the kit.

• The Canadian LP/Propane Gas Sea Level and High Altitude Conversion Kit (P/N 904915) is for LP/propane conversions in Canada at altitudes between zero and 4,500 ft. above sea level. Please follow the instructions

provided with the kit.

INSTALLATION EXAMPLE

Elevation: ................................................5,000 feet

Type of Gas: .........................................Natural Gas

Local Heating Value of Gas: ............................750

From Table 9, ﬁ nd 750 and follow down the column, stop at the 5,000 feet row. The heating value listed is LOW. Table 11 will be used to determine oriﬁ ce size and manifold pressure.

Page 17

ELECTRICAL WIRING

WARNING:

To avoid electric shock, personal injury, or death, turn off the electric power at the disconnect or the main service panel before making any electrical connections.

• Electrical connections must be in compliance with all applicable local codes and the current revision of the National Electric Code (ANSI/NFPA 70).

• For Canadian installations the electrical connections and grounding shall comply with the current Canadian Electrical Code (CSA C22.1 and/or local codes).

• Additional reference information for US and Canadian installations can be found in the Electrical Connections section (page 4).

IMPORTANT NOTE: If replacing any of the original wires supplied with the furnace, the replacement wire must be copper wiring and have a temperature rating of at least 105° F (40° C). For electrical requirements, refer to the furnace nameplate or Table 4 (page 29).

Low Voltage Wiring

The thermostat must be installed according to the instructions supplied by the thermostat manufacturer. Low voltage connections (24 VAC) from the thermostat are wired to the terminal strip on the integrated control in the furnace. See Figure 12 for proper connections for heating only (two-wire) and heating/cooling (four-wire) applications. Recommended minimum wire gauge for thermostat wiring is shown in Table 4.

The thermostat must not be installed on an outside wall or any other location where its operation may be adversely affected by radiant heat from ﬁ replaces, sunlight, or lighting ﬁ xtures, and convective heat from warm air registers or electrical appliances.

A/C CONDENSING UNIT

CONDENSING UNIT CONTROL BOX

EXPANSION PORT (MOTOR CONNECTION)

COM

ROOM

THERMOSTAT

Connect

R & W

For Heating

Only

NOTE: The “Y” terminal on the control board must be connected to the thermostat for proper cooling mode operation.

FIELD WIRING LOW VOLTAGE CONNECTION

R C Y G W

NEUTRAL LEADS

3 AMP FUSE

NEUTRALS

RCYGW

24V

SPEED

SELECT

FAN

HUM

STATUS

COOL

HEAT

FLAME

BLOWER

OFF

DELAY

XFMR

HIGH

EAC

ELECTRONIC AIR CLEANER

HUMIDIFIER TAP

RED GREEN YELLOW

180 120

90 60

LOW

MOTOR SPEED TAPS (NOT USED)

Figure 12. Low Voltage Field, Four-wire

Heating/Cooling Applications

Line Voltage Wiring

It is recommended that the line voltage (115 VAC) to the furnace be supplied from a dedicated branch circuit containing the correct fuse or circuit breaker for the furnace (Table 4).

IMPORTANT NOTE: An electrical disconnect must be installed readily accessible from and located within sight of the furnace. See Figure 13 or the wiring diagram label inside of the control door. Any other wiring methods must be acceptable to authority having jurisdiction.

Field Supplied Fused Service

Panel

Field Supplied Disconnect w/in Sight of Furnace

Junction Box (may be int. or ext. to the furnace). These connections can be made in the field supplied disconnect at the furnace.

The six pin terminal marked “Expansion Port” is not used in the single stage furnace as shipped from the factory. It is used for the furnace control board to communicate to a ﬁ xed speed or variable speed high efﬁ ciency motor that may be optionally installed. Please contact your distributor for the proper upgrade motor kit.

IMPORTANT NOTE: Set the heat anticipator according to the instructions supplied by the thermostat manufacturer.

To determine the heat anticipator setting:

1. Add the current draw of the system components; or

2. Measure the current ﬂ ow on the thermostat R-W circuit

after the circulating blower motor has started.

Black (Hot)

White (Neutral)

Green or Bare

(Ground)

Field Line Voltage Wiring

Ground

Black

White

Black

White

Ground

Field Supplied

Panel Connector

Factory Line Voltage Wiring

Black

White

Ground

Figure 13. Line Voltage Field Wiring

CAUTION:

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

Page 18

IMPORTANT NOTE: Proper line voltage polarity must be maintained in order for the control system to operate correctly. Verify the incoming neutral line is connected to the white wire and the incoming “hot” line is connected to the black wire. The furnace will not operate unless the polarity and ground are properly connected as shown in Figure 13 (page 17).

Grounding

WARNING:

To minimize personal injury, the furnace cabinet must have an uninterrupted or unbroken electrical ground. The controls used in this furnace require an earth ground to operate properly. Acceptable methods include electrical wire or conduit

approved for ground service. Do not use gas piping as an electrical ground!

Twinning

Single stage G7 furnaces are not supplied with a builtin twinning capability. Other valuable features and enhancements were made to the new control that made it necessary to remove the twinning capability. All standard two-stage furnaces equipped with the ﬁ xed speed iSEER™ motor include a twinning terminal on the blower control board.

However, if both Single stage G7 furnaces are upgraded to the ﬁ xed speed iSEER ™ blower, the twin terminal on the blower control boards may be used. Alternately, offthe-shelf furnace twinning kits such as Johnson Controls (P/N 2TC03700124) may be used. Using this control also provides the additional feature of two-stage operation by individually controlling the heat section of each furnace. Contact your furnace distributor for technical details.

G7 furnaces equipped with variable speed iSEER ™ motors may not be twinned under any circumstances.

START-UP AND ADJUSTMENTS Pre-Start Check List

√ Verify the polarity of the connections are correct, the

line voltage power leads are securely connected and the furnace is properly grounded.

√ Verify the thermostat wires (R, W, Y, and G) are

securely connected to the correct leads on the terminal strip of the circuit board.

√ Verify the gas line service pressure does not exceed

10.0 inches of W.C., and is not less than 4.5 inches W.C. for natural gas. For LP gas the line service pressure must not exceed 14 in. W.C., and must not be less than 11.0 in. W.C.

√ Verify the roll-out and manual reset switch is closed.

If necessary, press the red button to reset a switch.

Note: DO NOT install a jumper wire across a switch to defeat its function. If a switch reopens on

startup, DO NOT reset the switch without identifying and correcting the fault condition.

√ Verify the blower door is in place, closing the door

switch in the line voltage circuit.

√ Verify the gas line has been purged and all connections

are leak free.

Start-up Procedures

Do not perform these steps until all of the checks in the

previous steps have been completed:

1. Set the thermostat to the lowest setting.

2. Turn off all electrical power to the furnace.

3. Follow the Operating Instructions on the label attached to the furnace.

4. Set the ther mostat above room temperature and verify the Operating Sequence (Page 20).

5. After 5 minutes of operation, set the thermostat below room temperature and verify steps 9-10 of the Operating Sequence (page 20).

Verifying and Adjusting Input Rate IMPORTANT NOTE: The input rate must not exceed the rate shown on the furnace rating plate. At altitudes above 2,000 feet, it must not exceed that on the rating plate less 4% for each 1,000 feet.

The input rate must be veriﬁ ed for each installation to

prevent over-ﬁ ring of the furnace. To determine the exact input rate, perform the following procedures:

1. Shut off all other gas ﬁ red appliances.

2. Start the furnace and run it for at least 3 minutes.

3. Measure the time (in seconds) required for the gas meter to complete one revolution.

4. Convert the time per revolution to cubic feet of gas per hour using Table 6 (page 31).

5. Multiply the gas ﬂ ow rate in cubic ft per hr by the heating value of the gas in Btu per cubic ft to obtain the input rate in Btuh or see the example (page 19).

Page 19

Example:

• Time for 1 revolution of a gas meter with a 1 cubic ft dial = 40 seconds.

• From Table 6 read 90 cubic ft gas per hr.

• Local heating value of the gas (obtained from gas supplier) = 1,040 Btu per cubic ft.

• Input rate = 1,040 x 90 = 93,600 Btuh.

6. The manifold pressure must be set to the appropriate value for each installation by a qualiﬁ ed installer, service agency or the gas supplier.

WARNING:

Do not attempt to drill the gas oriﬁ ces. Use only factory supplied orifices. Improperly drilled oriﬁ ces may cause ﬁ re, explosion, carbon monoxide poisoning, personal injury or death.

a.) Obtain the manifold pressure setting required for

this installation by referring to Table 8 for Propane or Tables 10 or 11 for Natural Gas (pages 32-33).

b.) Remove the regulator capscrew (Figure 14) from

the INLET side of the regulator.

c.) Slowly turn the adjustment screw inside the regulator

to obtain the appropriate manifold pressure.

NOTE: Turning the screw clockwise increases the pressure and turning the screw counterclockwise decreases the pressure. To prevent backing the screw all the way out from the valve, turn the screw slowly.

d.) Replace and tighten the regulator capscrew over

the adjustment screw.

Verifying and Adjusting Temperature Rise

Conﬁ rm the temperature rise through the furnace is within the limits speciﬁ ed on the furnace rating plate. Any temperature rise outside the speciﬁ ed limits could result in premature failure of the heat exchanger.

WARNING:

To prevent electric shock, personal injury, or death, disconnect the electric power before performing any maintenance.

1. Place thermometers in the return and supply air stream as close to the furnace as possible. The thermometer on the supply air side must be shielded from direct radiation from the heat exchanger to avoid false readings.

2. Adjust all registers and duct dampers to the desired position and run the furnace for 10 to 15 minutes before taking any temperature readings. The temperature rise is the difference between the supply and return air temperatures.

For typical duct systems, the temperature rise will fall within the limits speciﬁ ed on the rating plate with the blower speed at the factory recommended setting. If the measured temperature rise is outside the speciﬁ ed limits, it may be necessary to change the speed of the blower. NOTE: Lowering the blower speed will increase the temperature rise and a higher blower speed will decrease the temperature rise.

The furnace is equipped with a multi-speed motor. Heating, cooling, and fan speed selection is made by moving the switch on the integrated control located in the furnace.

Verifying Burner Operation

Capscrew

Figure 14. Regulator Capscrew

CAUTION:

The door over the burners may only be open for inspection purposes only. The door must be installed during unattended operation.

1. Remove the burner compartment door.

2. Set the thermostat above room temperature and observe

the ignition sequence. NOTE: The burner ﬂ ame should carry over immediately between all burners without lifting off, curling, or ﬂ oating. The ﬂ ames should be blue, without yellow tips.

3. After validating the ﬂ ame, change the thermostat setting

to below room temperature.

4. Verify the burner ﬂ ame is completely extinguished.

5. Replace the burner compartment door.

Page 20

Verify Operation of the Supply Air Limit Switch

Note: A properly functioning limit switch should turn off

the gas valve when the return is blocked (time depends on how well the return air is blocked). The circulating air and combustion blowers should continue to run when the limit switch opens.

1. Verify the blower door is securely mounted in place and that there is power to the furnace.

2. Block the return airﬂ ow to the furnace by installing a close-off plate in place of or upstream of the ﬁ lter(s).

3. Set the thermostat above room temperature and observe the Operating Sequence.

4. Remove the close-off immediately after the limit switch opens. If the furnace continues to operate with no return air, set the thermostat below room temperature, shut off the power to the furnace, and replace the limit switch.

OPERATING SEQUENCE

The operating sequences for the heating, cooling, and fan modes are described below. Refer to the ﬁ eld and furnace wiring diagrams: (Figures 12-13, page 17) and (Figure 17, page 30).

for 120 seconds at the selected HEAT speed. The Indoor blower motor is de-energized after a blower off delay as selected by the movable jumper.

Cooling Cycle

1. The thermostat calls for cooling by energizing the Y terminal with 24VAC.

2. The control energizes the blower in the cooling speed and sends 24VAC to the contactor in the condensing unit.

3. When the thermostat removes the call for cooling, the contactor in the outdoor condensing unit is deenergized and the control continues to run the fan for a period of 60 seconds.

Fan Mode

• When the thermostat energizes the G terminal for

continuous fan (without calling for heat or cooling), the indoor fan is energized on the selected FAN speed.

• If a call for cooling occurs during continuous fan, the

blower will switch over to the selected COOL speed.

• If the W terminal receives a call for heat during continuous

fan, the blower will de energize.

• A call for fan is ignored while in lockout.

MAINTENANCE

Heating Cycle

1. The thermostat calls for heat by energizing the W terminal with 24VAC.

2. The control veriﬁ es the pressure switch is open.

3. If the pressure switch is open, the control energizes the inducer and waits for the pressure switch to close. The pressure switch must close within 10 seconds.

4. The control runs the inducer for a 30 second prepurge.

5. The control energizes the igniter output for the appropriate warm-up time limit.

6. The control energizes the main gas valve for 3 seconds.

7. If the ﬂ ame proved and ignites the gas, the control de-energizes the igniter. The gas valve and inducer remains energized. The control goes to blower on delay.

8. If ﬂ ame is present, the control energizes the blower on the selected HEAT speed 30 seconds after the gas valve opened. The gas valve and inducer remain energized.

9. When the thermostat demand for heat is satisﬁ ed, the control de-energizes the gas valve. The inducer output remains on for a 30 second post-purge period.

10. Blower off timing begins when the thermostat is satisﬁ ed. The control will operate at the selected HEAT speed of 60, 90, 120, or 180 seconds. If the blower off delay jumper is not present, the fan should still operate

WARNING:

These maintenance instructions are primarily intended to assist qualified technicians experienced in the proper maintenance and operation of this appliance.

Proper maintenance is most important to achieve the best performance from a furnace. Follow these instructions for years of safe, trouble free operation.

• Always replace the doors on the furnace after servicing or cleaning/changing the ﬁ lters. Do not operate the

furnace without all doors and covers in place.

• Verify the thermostat is properly installed and is not being affected by drafts or heat from lamps or other appliances.

• To achieve the best performance and minimize equipment failure it is recommended that a yearly maintenance checkup be performed. At a minimum, this check should include the following items:

Air Filter(s)

WARNING:

Never operate the furnace without a ﬁ lter in place. Dust and lint in the return air can build up on internal components, resulting in loss of efﬁ ciency, equipment damage, and possible ﬁ re.

Page 21

Note: Air ﬁ lter(s) are not supplied with the furnace as shipped from the factory. The installer must provide a high velocity ﬁ lter and rack for a ﬁ lter in the return air duct adjacent to the furnace, or in a return air grill to the furnace. replaced monthly. New or newly renovated homes may require more frequent changing until the construction dust has minimized.

Filters designed to remove smaller particles such as pollen, may require additional maintenance. Filters for side return and bottom return applications are available from most local distributors.

Blower Compartment

Dirt and lint can create excessive loads on the motor resulting in higher than normal operating temperatures and shortened service life. It is recommended that the blower compartment be cleaned of dirt or lint that may have accumulated in the compartment or on the blower and motor as part of the annual inspection.

Cleaning of Burners

If the burners must be cleaned, follow steps 1-12. See Figure 18 and 19 (page 35) for component location.

1. Shut off gas supply to the furnace at the meter or at

2. Turn off all power to the furnace and set the thermostat

3. Remove the burner door from the furnace.

4. Turn the gas control switch to the OFF position.

5. Disconnect the wires from the gas valve, igniter, ﬂ ame

6. Using two wrenches, separate the ground-joint union

7. Remove the piping between the gas valve and the

8. Remove all screws securing the burner assembly to

9. Carefully remove the burner assembly from the furnace.

10. Inspect the burners for accumulated dust or debris.

11. Replace all the parts in reverse order that they were

12. Follow the lighting instructions found on the furnace

It is recommended that ﬁ lters be cleaned or

a manual valve in the supply piping.

to its lowest setting.

sensor, and ﬂ ame rollout switch.

in the gas supply piping at the furnace.

ground-joint union. (If applicable).

the furnace.

DO NOT DAMAGE THE IGNITER WHILE REMOVING THE BURNER ASSEMBLY.

If necessary carefully clean them with a soft wire brush and a vacuum cleaner. DO NOT DAMAGE THE

IGNITER WHILE CLEANING THE BURNER.

removed.

door to return the furnace to operation. Verify proper operation after servicing.

Cleaning Of Flue Passages

If the ﬂ ue passages must be cleaned, follow the steps below. See Figures 18 and 19 for component location.

1. Shut off the gas supply to the furnace at the meter or

at the manual valve in the gas supply piping.

2. Turn off all power to the furnace and set the thermostat

to the lowest temperature setting.

3. Remove the blower door from the furnace.

4. Turn the gas control switch to the OFF position.

CAUTION:

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

5. Disconnect the wires from the gas valve, ﬂ ame sensor,

inducer, ﬂ ame roll-out switch, limit switch, pressure switch and igniter.

6. Remove the silicone rubber tube from the inducer.

7. Using two wrenches, separate the ground-joint union

in the gas supply piping at the furnace.

8. Remove the piping between the gas valve and the

ground-joint union. (If applicable).

9. Remove all screws securing the burner assembly to

the furnace.

10. Carefully remove the burner assembly from the furnace.

DO NOT DAMAGE THE IGNITER WHILE REMOVING THE BURNER ASSEMBLY.

11a. Remove all screws securing the inducer assembly

to the vent pipe running out of the furnace (*SA upﬂ ow/horizontal models only).

11b. Remove all screws securing the combustion air tube

assembly to the vent pipe running out of the furnace. (*SK downﬂ ow models only).

12. Remove all screws securing the inducer assembly

to the collector pan.

13a. Carefully remove the inducer assembly and combus-

tion tube assembly from the furnace. DO NOT BREAK

THE SEALS AT EACH END OF THE COMBUSTION AIR TUBE. (*SK downﬂ ow models only).

13b. Carefully remove the inducer assembly from the

furnace (*SA upﬂ ow/horizontal models only).

14. Remove all screws securing the collector pan to the

furnace.

15. Remove the collector pan and gasket from the

furnace.

16. Attach a round wire brush to a length of high grade

stainless steel cable. Attach the other end of the cable to a variable speed reversible drill. Slowly insert and rotate the cable into the top portion of the heat exchanger. Operate the drill alternating between

Page 22

forward and reverse, working the cable in and out several times to obtain sufﬁ cient cleaning. Repeat this sequence for each heat exchanger tube.

17. Remove all loosened debris from the heat exchanger tubes using a vacuum cleaner.

18. Using a bright light, check the condition of the upper and lower sections of the heat exchanger tubes.

19. Inspect the burners for accumulated dust or debris. If burners must be cleaned, see Cleaning of Burners (page 22).

20. Replace all the parts in reverse order that they were removed.

21. Check gaskets for damage. Replace if needed.

22. Follow the lighting instructions found on the furnace door to return the furnace to operation. Verify proper operation after servicing.

Heat Exchanger and Burner Maintenance

The furnace should operate for many years without soot buildup in the ﬂ ue passageways, however, the ﬂ ue, vent system, and burners should be inspected and cleaned (if required) by a qualiﬁ ed service technician annually to ensure continued safe operation. Pay attention to any deterioration from corrosion or other sources.

Lubrication

The bearings in the blower motor and inducer blower used in these furnaces are pre-lubricated and sealed by the manufacturer. No further oiling of the bearings is required for the life of the motor.

Vent System

WARNING:

Holes in the vent pipe or heat exchanger can cause combustion products to enter the home. Replace the vent pipe or heat exchanger if leaks are found. Failure to prevent the circulation of combustion products into the living space can create potentially hazardous conditions including carbon monoxide poisoning that could result in personal injury or death.

TROUBLESHOOTING If the furnace fails to operate check the following:

• Is the thermostat operating properly?

• Are the blower compartment door(s) in place?

• Is the furnace disconnect closed?

• Has the circuit breaker tripped or the control board fuse burned open?

• Is the gas turned on?

• Are any manual reset switches open?

• Is the ﬁ lter dirty or plugged?

• Is the ﬂ ame sensor coated? (Remove and clean with steel wool).

• Are all the LED’s on the furnace control board constantly

ON? If not, refer to Table 5 (page 29) or the wiring diagram (Figure 17, page 30) to determine fault condition.

IMPORTANT NOTE: The furnace will lock out after 5 failed attempts for ignition and will try again every hour if the call for heat remains.

• If the Inducer Blower is operating, and items above

have been veriﬁ ed, check the Blower Limit Switch and reset if necessary. See Figure 18 or 19 (page 35) for component location.

• If the furnace operates when the Blower Limit Switch is

reset, contact a qualiﬁ ed service technician to identify and repair the problem.

• If the furnace still doesn’t operate, check the Flame

Roll-out Switches and reset if necessary. See Figure 18 or 19 for component location.

• If the furnace operates when the Flame Rollout Switch

is reset, contact a qualiﬁ ed service technician to identify and repair the problem.

Check the vent pipe and/or chimney to ensure that it is not corroded or blocked by debris. Any corroded section of vent pipe must be replaced, and any obstruction or blockage must be removed prior to operating the furnace.

Page 23

DESCRIPTION OF COMPONENTS

The descriptions below are various functional components that affect the operation and shutting down of this furnace. Some of these components and their locations are shown in Figures 18 and 19. If any component of the furnace must be replaced, use only factory authorized replacement parts speciﬁ ed in the Replacement Parts List provided online.

Blower Limit Switch

Blower switches prevent operation when blower is not operational.

Flame Sensor

The ﬂ ame sensor veriﬁ es when a ﬂ ame has carried over from the igniter to the opposite end burner. If no ﬂ ame is detected, the furnace will shut down within 4 seconds.

Flame Roll-Out Switch

The ﬂ ame roll-out switch veriﬁ es that the burner ﬂ ames are drawn into the heat exchanger tubes. If the burner ﬂ ames are not properly drawn into the heat exchanger, the ﬂ ame roll-out switch will close the gas valve and initiate the shutdown cycle.

Gas Valve

The gas valve controls the ﬂ ow of gas to the burners. When the gas valve is energized it automatically opens and regulates the gas pressure in the manifold.

Inducer Assembly

The inducer assembly vents products of combustion to the outside.

Pressure Switch

The pressure switch veriﬁ es that the inducer is drawing the combustion gases through the heat exchanger. If the ﬂ ame is not properly drawn into the heat exchanger tube, the rollout switch or the ﬂ ame sensor will shut the furnace down.

Supply Air Limit Switch

The supply air limit switch prevents the air temperature leaving the furnace from exceeding the maximum allowable outlet air temperature.

FIGURES AND TABLES

UPFLOW, DOWNFLOW & HORIZONTAL INSTALLATION CLEARANCES*

Left Side 0 In.

Right Side 0 In.

Vent 1 In.

Back 0 In.

Top 1 In.

Front 4 In.**

* These are the listed clearances to combustible materials.

** Allow 24 in. minimum clearance for servicing. Recommended clearance is 36 in.

The furnace is listed for installation on combustible or non-combustible ﬂ ooring. However, wood is the only combustible ﬂ ooring allowed for installation. Downﬂ ow models must use the appropriate subase kit when installing over a wood ﬂ oor.

UPFLOW APPLICATION

TOP

HORIZONTAL APPLICATION

SIDE

DOWNFLOW APPLICATION

TOP

LEFT SIDE

BOTTOM

Table 1. Minimum Clearances to Combustible Material

RIGHT SIDE

TOP

SIDE

BOTTOM

LEFT SIDE

BOTTOM

RIGHT SIDE

Page 24

⅞

“D”

Dimension

⅝

“C”

Dimension

“B”

Dimension

“A”

Dimension

(†)-23A

*SA

Model #’s

045

054(†)-23A

⅛

⅞

(†)-24B

072

090(†)-24B

(†)-35C

072

⅞

⅜

21 14

090(†)-35C

FURNACE DIMENSIONS

⅛

22 ⅞ 23

NOTES:

(†)-35C

108

(†)-45D

126

(†) can be C or N

22 ¼

Dimensions shown in Inches.

21 ⁄

22 ¾

⅝ X 3 ½ X 45°

HOLE FOR GAS

22 ½

(BOTH SIDES)

4 KNOCKOUTS

RIGHT SIDE

TOP VIEW

FRONT BRACE

FLANGES

PANEL

BOTTOM

TYPE B

ACCEPTS 4”

BOTTOM VIEW

Ø ⅞ HOLE FOR

VENT PIPE

THERMOSTAT

25 ⅜

ELECTRIC

Ø ⅞ HOLE FOR

1 ⅝ X 3 ½

ELECTRIC

HOLE FOR GAS

Ø ⅞ HOLE FOR

29 ½

LEFT SIDE

23 ½

Figure 15. *SA 80+ High Efﬁ ciency Upﬂ ow/Horizontal Furnaces

Page 25

“D”

Dimension

“C”

Dimension

“B”

Dimension

¼ 10 ¾ 12 ⅝ 12 ⅞

“A”

Dimension

*SK

(†)-23A

Model #’s

054

TOP VIEW

17 ½ 11 ¾ 15 ⅞ 16 ⅛

072(†)-24B

⅜ 19 ⅝

21 14

(†)-35C

108

090(†)-24B

FLANGES

NOTES:

½ 15 ¼ 22 ⅞ 23 ⅛

126(†)-45D

(†) can be C or N

Dimensions shown in Inches.

Ø ⅞ HOLE

FOR THERMOSTAT

1 ⅝ X 3 ½ X 45°

Ø ⅞ HOLE

FOR ELECTRIC

22 ½

29 ½

HOLE FOR GAS

RIGHT SIDE

TYPE B

VENT PIPE

ACCEPTS 4”

FRONT BRACE

BOTTOM VIEW

18 ⅝

Ø ⅞ HOLE

FOR ELECTRIC

22 ½

FOR GAS

1 ⅝ X 3 ½ HOLE

⅜

LEFT SIDE

Figure 16. *SK 80+ High Efﬁ ciency Downﬂ ow Furnaces

Page 26

Model

Number

SA045(†)-23A

Bottom Return

Side Return

SA045(†)-23A

SA054(†)-23A

Bottom Return

Side Return

SA054(†)-23A

SA072(†)-24B

Bottom Return

Side Return

SA072(†)-24B

SA090(†)-24B

Bottom Return

Side Return

SA090(†)-24B

SA072(†)-35C

Bottom Return

Side Return

SA072(†)-35C

or 2 Sides

Side + Bottom

SA072(†)-35C

Heating

Input

(Btuh)

45,000

54,000

72,000

90,000

72,000

AIRFLOW DATA

UPFLOW / HORIZONTAL GAS FURNACES

Motor Speed

High* 1,260 26 1,205 28 1,145 29 1,080 31 1,025 33 960 35 890 37 825 40

Med-High 955 35 950 35 940 35 935 36 925 36 860 39 800 42 725 46

Med-Low** 825 40 800 42 760 44 730 46 690 48 650 51 600 56 530 63

Low 655 51 630 53 610 55 580 57 550 61 520 64 480 69 435 77

High* 1,350 25 1,290 26 1,225 27 1,155 29 1,100 30 1,025 33 950 35 885 38

Med-High 1,025 33 1,015 33 1,005 33 1,000 33 990 34 920 36 855 39 775 43

Med-Low** 885 38 855 39 815 41 780 43 740 45 695 48 640 52 565 59

Low 700 48 675 49 655 51 620 54 590 56 555 60 515 65 465 72

High* 1,260 32 1,205 33 1,145 35 1,080 37 1,025 39 960 42 890 45 825 48

Med-High** 955 42 950 42 940 43 935 43 925 43 860 47 800 50 725 55

Med-Low 825 48 800 50 760 53 730 55 690 58 650 62 600 67 530 75

Low 655 61 630 63 610 66 580 69 550 73 520 77 480 83 435 92

High* 1,350 30 1,290 31 1,225 33 1,155 35 1,100 36 1,025 39 950 42 885 45

Med-High** 1,025 39 1,015 39 1,005 40 1,000 40 990 40 920 43 855 47 775 52

Med-Low 885 45 855 47 815 49 780 51 740 54 695 58 640 63 565 71

Low 700 57 675 59 655 61 620 65 590 68 555 72 515 78 465 86

High* 1,685 32 1,640 33 1,605 33 1,565 34 1,515 35 1,475 36 1,415 38 1,345 40

Med-High 1,330 40 1,295 41 1,275 42 1,245 43 1,215 44 1,185 45 1,135 47 1,070 50

Med-Low** 1,175 45 1,155 46 1,125 47 1,100 48 1,075 50 1,045 51 1,010 53 955 56

Low 930 57 895 60 885 60 850 63 825 65 800 67 770 69 740 72

High* 1,770 30 1,720 31 1,685 32 1,645 32 1,590 34 1,550 34 1,485 36 1,415 38

Med-High 1,400 38 1,360 39 1,340 40 1,310 41 1,275 42 1,245 43 1,190 45 1,125 47

Med-Low** 1,235 43 1,215 44 1,180 45 1,155 46 1,130 47 1,100 48 1,060 50 1,005 53

Low 975 55 940 57 930 57 890 60 865 62 840 63 810 66 775 69

High* 1,610 41 1,575 42 1,530 44 1,485 45 1,440 46 1,385 48 1,340 50 1,275 52

Med-High** 1,295 51 1,260 53 1,235 54 1,220 55 1,175 57 1,135 59 1,095 61 1,015 66

Med-Low 1,155 58 1,130 59 1,100 61 1,070 62 1,035 64 1,015 66 965 69 920 72

Low 880 76 860 78 830 80 800 83 765 87 740 90 675 99 660 101

High* 1,690 39 1,655 40 1,610 41 1,560 43 1,510 44 1,455 46 1,405 47 1,340 50

Med-High** 1,360 49 1,325 50 1,300 51 1,280 52 1,235 54 1,190 56 1,150 58 1,065 63

Med-Low 1,215 55 1,190 56 1,155 58 1,125 59 1,090 61 1,065 63 1,015 66 965 69

Low 925 72 900 74 870 77 840 79 800 83 775 86 710 94 695 96

High* 1,950 27 1,865 29 1,790 30 1,715 31 1,630 33 1,550 34 1,475 36 1,390 38

Med-High 1,860 29 1,780 30 1,710 31 1,635 33 1,575 34 1,500 36 1,415 38 1,325 40

Med-Low** 1,300 41 1,240 43 1,200 44 1,160 46 1,120 48 1,065 50 995 54 910 59

Low 1,165 46 1,115 48 1,060 50 1,025 52 985 54 940 57 890 60 825 65

High* 2,030 26 1,940 27 1,860 29 1,785 30 1,695 31 1,615 33 1,535 35 1,445 37

Med-High 1,935 28 1,850 29 1,780 30 1,700 31 1,340 40 1,560 34 1,470 36 1,380 39

Med-Low** 1,350 40 1,290 41 1,250 43 1,205 44 1,165 46 1,110 48 1,035 52 945 56

Low 1,215 44 1,160 46 1,105 48 1,065 50 1,025 52 980 54 925 58 860 62

High* 2,050 26 1,960 27 1,880 28 1,800 30 1,710 31 1,630 33 1,550 34 1,460 37

Med-High 1,955 27 1,870 29 1,800 30 1,715 31 1,655 32 1,575 34 1,485 36 1,390 38

Med-Low** 1,365 39 1,300 41 1,260 42 1,220 44 1,175 45 1,120 48 1,045 51 955 56

Low 1,225 44 1,170 46 1,115 48 1,075 50 1,035 52 985 54 935 57 865 62

0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8

CFM Rise CFM Rise CFM Rise CFM Rise CFM Rise CFM Rise CFM Rise CFM Rise

External Static Pressure (Inches Water Column)

Table 2. *SA - 80% AFUE, Single Stage, Upﬂ ow/Horizontal Gas Furnaces

Page 27

Model

Number

(†) Can be C or N

* Factory Set Cooling Speed

** Factory Set Heating Speed

Heating

Input

(Btuh)

SA090(†)-35C

Bottom Return

Side Return

SA090(†)-35C

or 2 Sides

Side + Bottom

SA090(†)-35C

SA108(†)-35C

Bottom Return

Side Return

SA108(†)-35C

or 2 Sides

Side + Bottom

SA108(†)-35C

Bottom only

or 2 openings

SA126(†)-45D

Side Return

SA126(†)-45D

Motor

Speed

High* 1,940 34 1,860 36 1,790 37 1,710 39 1,625 41 1,540 43 1,450 46 1,355 49

Med-High** 1,820 37 1,760 38 1,695 39 1,620 41 1,545 43 1,466 45 1,380 48 1,280 52

Med-Low 1,290 52 1,245 54 1,200 56 1,155 58 1,110 60 1,060 63 995 67 915 73

90,000

Low 1,145 58 1,110 60 1,070 62 1,035 64 1,000 67 950 70 905 74 835 80

High* 2,020 33 1,935 34 1,860 36 1,780 37 1,690 39 1,600 42 1,510 44 1,410 47

Med-High** 1,895 35 1,830 36 1,765 38 1,685 40 1,610 41 1,525 44 1,435 46 1,330 50

Med-Low 1,345 50 1,295 51 1,250 53 1,200 56 1,155 58 1,100 61 1,035 64 950 70

90,000

Low 1,190 56 1,155 58 1,115 60 1,075 62 1,040 64 980 68 940 71 870 77

High* 2,040 33 1,955 34 1,880 35 1,795 37 1,705 39 1,620 41 1,525 44 1,425 47

Med-High** 1,910 35 1,850 36 1,780 37 1,700 39 1,625 41 1,540 43 1,450 46 1,345 50

Med-Low 1,355 49 1,310 51 1,260 53 1,215 55 1,165 57 1,115 60 1,050 63 960 69

90,000

Low 1,205 55 1,165 57 1,125 59 1,085 61 1,050 63 1,000 67 950 70 875 76

High* 2,205 36 2,150 37 2,095 38 2,030 39 1,970 41 1,900 42 1,830 44 1,740 46

Med-High** 2,050 39 1,995 40 1,955 41 1,895 42 1,840 43 1,775 45 1,700 47 1,610 50

Med-Low 1,700 47 1,680 48 1,645 49 1,610 50 1,565 51 1,525 52 1,460 55 1,375 58

108,000

Low 1,390 58 1,370 58 1,355 59 1,320 61 1,300 62 1,270 63 1,225 65 1,175 68

High* 2,295 35 2,235 36 2,180 37 2,110 38 2,050 39 1,975 41 1,900 42 1,810 44

Med-High** 2,130 38 2,075 39 2,035 39 1,970 41 1,915 42 1,845 43 1,765 45 1,675 48

Med-Low 1,770 45 1,750 46 1,710 47 1,675 48 1,630 49 1,585 50 1,520 53 1,430 56

108,000

Low 1,445 55 1,425 56 1,410 57 1,375 58 1,350 59 1,320 61 1,275 63 1,225 65

High* 2,315 35 2,260 35 2,200 36 2,130 38 2,070 39 1,995 40 1,925 42 1,825 44

Med-High** 2,155 37 2,095 38 2,055 39 1,990 40 1,930 41 1,865 43 1,785 45 1,690 47

Med-Low 1,785 45 1,765 45 1,725 46 1,690 47 1,645 49 1,600 50 1,535 52 1,445 55

108,000

Low 1,460 55 1,440 56 1,425 56 1,385 58 1,365 59 1,335 60 1,285 62 1,235 65

High* 2,255 41 2,200 42 2,125 44 2,065 45 2,010 46 1,935 48 1,855 50 1,755 53

Med-High** 2,075 45 2,025 46 1,970 47 1,940 48 1,875 50 1,810 52 1,750 53 1,680 56

Med-Low 1,720 54 1,695 55 1,655 56 1,630 57 1,580 59 1,520 61 1,455 64 1,390 67

126,000

Low 1,360 69 1,375 68 1,365 68 1,315 71 1,310 71 1,300 72 1,260 74 1,230 76

High* 2,230 42 2,180 43 2,105 44 2,045 46 1,990 47 1,915 49 1,835 51 1,740 54

Med-High** 2,055 45 2,005 47 1,950 48 1,920 49 1,855 50 1,790 52 1,735 54 1,665 56

Med-Low 1,705 55 1,680 56 1,640 57 1,615 58 1,565 60 1,505 62 1,440 65 1,375 68

126,000

Low 1,345 69 1,360 69 1,350 69 1,300 72 1,230 76 1,290 72 1,250 75 1,220 77

UPFLOW / HORIZONTAL GAS FURNACES

External Static Pressure (Inches Water Column)

0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8

CFM Rise CFM Rise CFM Rise CFM Rise CFM Rise CFM Rise CFM Rise CFM Rise

NOTES:

1. Two openings are recommended for airﬂ ows above 1,600 CFM if ﬁ lter(s) is(are) adjacent to furnace

2. Temperature rises in the table are approximate. Actual temperature rises may vary.

3. Temperature rises shaded in gray are for reference only. These conditions are not recommended

Table 2. Continued

Page 28

DOWNFLOW GAS FURNACES

Model

Number

(†) Can be C or N 1. Temperature rises in the table are approximate. Actual temperature rises may vary.

* Factory Set Cooling Speed

** Factory Set Heating Speed

Heating

Input

(Btuh)

54,000

SK054(†)-23A

72,000

SK072(†)-24B

90,000

SK090(†)-24B

108,000

SK108(†)-35C

126,000

SK126(†)-45D

Motor

Speed

High* 1,375 29 1,340 30 1,300 31 1,270 31 1,225 33 1,175 34 1,115 36 1,035 39

Med-High 1,155 35 1,130 35 1,110 36 1,085 37 1,055 38 1,015 39 975 41 910 44

Med-Low** 790 51 775 52 765 52 750 53 730 55 700 57 665 60 610 66

Low 650 62 640 63 630 63 610 66 590 68 565 71 530 75 480 83

High* 1,610 33 1,590 34 1,575 34 1,560 34 1,540 35 1,495 36 1,460 37 1,415 38

Med-High 1,295 41 1,275 42 1,260 42 1,250 43 1,220 44 1,195 45 1,170 46 1,120 48

Med-Low** 1,155 46 1,135 47 1,115 48 1,095 49 1,065 50 1,040 51 1,015 53 980 54

Low 910 59 885 60 860 62 835 64 810 66 785 68 765 70 735 73

High* 1,675 40 1,655 40 1,640 41 1,620 41 1,590 42 1,560 43 1,520 44 1,475 45

Med-High 1,330 50 1,315 51 1,300 51 1,280 52 1,255 53 1,230 54 1,200 56 1,150 58

Med-Low** 1,180 56 1,165 57 1,150 58 1,135 59 1,115 60 1,090 61 1,060 63 1,010 66

Low 940 71 925 72 900 74 880 76 850 78 825 81 795 84 760 88

High* 2,395 33 2,335 34 2,285 35 2,230 36 2,200 36 2,140 37 2,080 38 2,000 40

Med-High 2,190 37 2,135 37 2,115 38 2,080 38 2,030 39 1,975 41 1,915 42 1,810 44

Med-Low** 1,785 45 1,770 45 1,740 46 1,725 46 1,685 47 1,645 49 1,615 50 1,565 51

Low 1,145 70 1,110 72 1,070 75 1,035 77 1,000 80 950 84 905 88 835 96

High* 2,445 38 2,395 39 2,385 39 2,330 40 2,275 41 2,225 42 2,130 44 2,015 46

Med-High 2,195 43 2,170 43 2,140 44 2,120 44 2,090 45 2,030 46 1,975 47 1,855 50

Med-Low** 1,795 52 1,780 52 1,770 53 1,760 53 1,725 54 1,690 55 1,655 56 1,610 58

Low 1,480 63 1,475 63 1,450 64 1,440 65 1,440 65 1,415 66 1,405 66 1,375 68

0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8

CFM Rise CFM Rise CFM Rise CFM Rise CFM Rise CFM Rise CFM Rise CFM Rise

2. Temperature rises shaded gray are for reference only. These conditions are not recommended.

External Static Pressure (Inches Water Column)

Notes

Table 3. *SK - 80% AFUE, Single Stage, Downﬂ ow Gas Furnaces

Page 29

ELECTRICAL INFORMATION

Furnace

Model Number *SA/*SK

045(†)-23A 45,000

054(†)-23A 54,000

072(†)-24B 72,000

072(†)-35C 72,000 21 115-60-1 127 103 9.0 14 15

090(†)-24B 90,000

090(†)-35C 90,000 21 115-60-1 127 103 9.0 14 15 108(†)-35C 108,000 21 115-60-1 127 103 9.0 14 15

126(†)-45D 126,000

(†) can be “C” or “N” ** Time-delay fuses or HACR-type circuit breakers are required.

Thermostat Wire Gauge

Furnace

Input

(Btuh)

24 55 ft. 25 ft. 22 90 ft. 45 ft. 20 140 ft. 70 ft. 18 225 ft. 110 ft.

Cabinet

Width

(in.)

¼ ¼

Nominal

Electrical

Supply

115-60-1 127 103 6.3 14 15

115-60-1 127 103 9.7 14 20

115-60-1 127 103 15.2 12 30

Maximum

Operating

Voltage

NOTES:

2 - wire

(Heating)

Minimum

Operating

Voltage

Recommended Thermostat Wire Length

Maximum

Furnace

Amperes

Minimum

Wire

Gauge

4 or 5 wire

(Cooling)

Fuse or Circuit

Breaker Amps**

Maximum

Table 4. Wire Length and Voltage Speciﬁ cations

Diagnostic Description Green LED Red LED

Control Fault (No Power) Off Off

L1/Neutral Polarity Fault Flash Flash

1 Hour Lockout Alternating Flash

Normal Operation On On

Pressure Switch Closed Fault On Flash

Pressure Switch Open Fault Flash On

Open Limit Switch Fault Flash Off

Diagnostic Description Yellow LED

Low Flame Sensor Signal Continuous Flash

Flame Present On

Table 5. Control Board Fault Conditions

Page 30

112233445566778899

BLUE

Green LED Red LED

Control Fault (No Power) Off Off

L1 / Neutral Polarity Fault Flash Flash

1 Hour Lockout

Normal Operation On On

Pressure Switch Closed Fault On Flash

Pressure Switch Open Fault Flash On

Open Limit Switch Fault Flash Off

Low Flame Sensor Signal

Flame Present

Diagnostic Description

FAULT CONDITIONS

Diagnostic Description

Yellow LED

Continuous Flash

Alternating Flash

BLUE

PRESSURE

ORANGE

PRESSURE

FLAME

BLUE

VENT

BLUE

SWITCH

MODELS)

(ON SELECT

SWITCH

ROLL-OUT

MODELS)

(ON SELECT

LIMIT SWITCH

BLOWER

LIMIT

WHITE

120 V

WHITE W/ BLK STRIPES

24 V

BLACK

BLK W/ WHITE STRIPES

1234

BLUE

BLACK

WHITE

1234

ORANGE

BLUE

TO OUTDOOR UNIT

MHMLLOW

HIGH

HEAT

COOL

FAN

COM

24V

RCYGW

3 AMP FUSE

RED

GREEN

YELLOW

GREEN

DELAY

BLWR OFF

123

456

789

4 SPEED MOTOR

RED

BLACK

LOW

HIGH

EAC

XFMR

HUM

NEUTRALS

BLACK

BLUE

ORANGE

RED

WHITE

BLACK

RED

ORANGE

BLUE

BLACK

WHITE

BLACK

WHITE

BLACK

DOOR

SWITCH

GREEN

L1A

123

456

YELLOW

SUPPLY

AIR LIMIT

SINGLE STAGE

Refer to the Installation Instructions

provided with the furnace for the

proper heating and cooling speeds

For 80+ and 90+

Single Stage Furnaces

for your application.

Figure 17. Wiring Diagram for Upﬂ ow and Downﬂ ow Furnaces

GROUND

THERMOSTAT

FLAME SENSOR

GAS

VALV E

IGNITOR

INDUCER

BLACK 120V

WHITE (NEUTRAL)

LEGEND:

FIELD WIRING

LOW VOLTAGE

HIGH VOLTAGE

WD#710731-C

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.

Use copper conductors only.

Page 31

TIME FOR

ONE REVOLUTION

(SECONDS)

10 360 1,800 3,600 66 55 273 545 12 300 1,500 3,000 68 53 265 529 14 257 1,286 2,571 70 51 257 514 16 225 1,125 2,250 72 50 250 500 18 200 1,000 2,000 74 49 243 486 20 180 900 1,800 76 47 237 474 22 164 818 1,636 78 46 231 462 24 150 750 1,500 80 45 225 450 26 138 692 1,385 82 44 220 439 28 129 643 1,286 84 43 214 429 30 120 600 1,200 86 42 209 419 32 113 563 1,125 88 41 205 409 34 106 529 1,059 90 40 200 400 36 100 500 1,000 92 39 196 391 38 95 474 947 94 38 191 383 40 90 450 900 96 38 188 375 42 86 429 857 98 37 184 367 44 82 409 818 100 36 180 360 46 78 391 783 102 35 176 353 48 75 375 750 104 35 173 346 50 72 360 720 106 34 170 340 52 69 346 692 108 33 167 333 54 67 333 667 110 33 164 327 56 64 321 643 112 32 161 321 58 62 310 621 114 32 158 316 60 60 300 600 116 31 155 310 62 58 290 581 118 31 153 305 64 56 281 563 120 30 150 300

GAS INFORMATION

GAS FLOW RATES (CUBIC FEET PER HOUR)

CUBIC FEET PER REVOLUTION

OF GAS METER

1 5 10 1 5 10

TIME FOR

ONE REVOLUTION

(SECONDS)

CUBIC FEET PER REVOLUTION

OF GAS METER

Table 6. Gas Flow Rates

CAPACITY OF BLACK IRON GAS PIPE (CU. FT. PER HOUR)

FOR NATURAL GAS (SPECIFIC GRAVITY - 0.60)

NOMINAL BLACK

IRON PIPE

DIAMETER (IN.)

½ ¾

1 520 350 285 245 215 195 180 170

1 ¼ 1,050 730 590 500 440 400 370 350

1 ½ 1,600 1,100 890 760 670 610

The cubic feet per hour listed in the table above must be greater than the cubic feet per hour of gas ﬂ ow required by the furnace. To determine the cubic feet per hour of gas ﬂ ow required by the furnace, divide the input rate of the furnace by the heating value (from gas supplier) of the gas.

10 20 30 40 50 60 70 80

130 90 75 65 55 50 45 40

280 190 150 130 115 105 95 90

Cubic Feet Per Hour Required =

LENGTH OF PIPE RUN (FT)

NOTES

Input To Furnace (Btu/hr)

Heating Value of Gas (Btu/Cu. Ft.)

Table 7. Black Iron Gas Pipe Capacities

Page 32

ALTITUDE ABOVE

SEA LEVEL

0 to 1,999 FT

PROPANE GAS

INPUT (BTU)

45,000 54,000 72,000 90,000 108,000 126,000

57 56 56 56 56 56 ORIFICE SIZE

10.0 10.0 10.0 10.0 10.0 10.0 MANIFOLD PRESSURE

2,000 to 2,999 FT

3,000 to 4,999 FT

5,000 to 5,999 FT

6,000 to 7,999 FT

8,000 to 10,000 FT

57 56 56 56 56 56 ORIFICE SIZE

9.0 9.0 9.0 9.0 9.0 9.0 MANIFOLD PRESSURE

57 56 56 56 56 56 ORIFICE SIZE

8.5 8.5 8.5 8.5 8.5 8.5 MANIFOLD PRESSURE

59 57 57 57 57 57 ORIFICE SIZE

10.0 10.0 10.0 10.0 10.0 10.0 MANIFOLD PRESSURE

59 57 57 57 57 57 ORIFICE SIZE

9.0 9.0 9.0 9.0 9.0 9.0 MANIFOLD PRESSURE

59 57 57 57 57 57 ORIFICE SIZE

8.5 8.5 8.5 8.5 8.5 8.5 MANIFOLD PRESSURE

Table 8. High Altitude Deration Chart for Propane Gas

ALTITUDE ABOVE

SEA LEVEL

2,000 FT LOW LOW LOW LOW LOW LOW HIGH HIGH HIGH

3,000 FT LOW LOW LOW LOW LOW LOW HIGH HIGH HIGH

4,000 FT LOW LOW LOW LOW LOW HIGH HIGH HIGH HIGH

5,000 FT LOW LOW LOW LOW LOW HIGH HIGH HIGH HIGH

6,000 FT LOW LOW LOW LOW HIGH HIGH HIGH HIGH HIGH

7,000 FT LOW LOW LOW LOW HIGH HIGH HIGH HIGH HIGH

8,000 FT LOW LOW LOW HIGH HIGH HIGH HIGH HIGH HIGH

9,000 FT LOW LOW LOW HIGH HIGH HIGH HIGH HIGH HIGH

10,000 FT LOW LOW HIGH HIGH HIGH HIGH HIGH HIGH HIGH

650 700 750 800 850 900 950 1,000 1,050

LOCAL HEATING VALUE (BTU PER CUBIC FOOT)

Table 9. Natural Gas Heating Values

Page 33

ALTITUDE ABOVE

SEA LEVEL

0 to 1,999 FT

NATURAL GAS - HIGH HEATING VALUE

INPUT (BTU)

45,000 54,000 72,000 90,000 108,000 126,000

49 47 47 47 47 47 ORIFICE SIZE

3.5 3.5 3.5 3.5 3.5 3.5 MANIFOLD PRESSURE

2,000 to 2,999 FT

3,000 to 3,999 FT

4,000 to 4,999 FT

5,000 to 5,999 FT

6,000 to 6,999 FT

7,000 to 7,999 FT

8,000 to 8,999 FT

9,000 to 9,999 FT

Table 10. High Altitude Deration Chart for Natural Gas - High Heating Value

ALTITUDE ABOVE

SEA LEVEL

0 to 1,999 FT

49 47 47 47 47 47 ORIFICE SIZE

2.9 3.2 3.2 3.2 3.2 3.2 MANIFOLD PRESSURE

49 47 47 47 47 47 ORIFICE SIZE

2.8 3.0 3.0 3.0 3.0 3.0 MANIFOLD PRESSURE

49 47 47 47 47 47 ORIFICE SIZE

2.6 2.8 2.8 2.8 2.8 2.8 MANIFOLD PRESSURE

49 47 47 47 47 47 ORIFICE SIZE

2.5 2.7 2.7 2.7 2.7 2.7 MANIFOLD PRESSURE

51 49 49 49 49 49 ORIFICE SIZE

3.3 3.5 3.5 3.5 3.5 3.5 MANIFOLD PRESSURE

51 49 49 49 49 49 ORIFICE SIZE

3.0 3.3 3.3 3.3 3.3 3.3 MANIFOLD PRESSURE

51 49 49 49 49 49 ORIFICE SIZE

2.8 3.0 3.0 3.0 3.0 3.0 MANIFOLD PRESSURE

51 49 49 49 49 49 ORIFICE SIZE

2.6 2.8 2.8 2.8 2.8 2.8 MANIFOLD PRESSURE

NATURAL GAS - LOW HEATING VALUE

INPUT (BTU)

45,000 54,000 72,000 90,000 108,000 126,000

49 47 47 47 47 47 ORIFICE SIZE

3.5 3.5 3.5 3.5 3.5 3.5 MANIFOLD PRESSURE

2,000 to 2,999 FT

3,000 to 3,999 FT

4,000 to 4,999 FT

5,000 to 5,999 FT

6,000 to 6,999 FT

7,000 to 7,999 FT

8,000 to 8,999 FT

9,000 to 9,999 FT

49 47 47 47 47 47 ORIFICE SIZE

3.5 3.5 3.5 3.5 3.5 3.5 MANIFOLD PRESSURE

49 47 47 47 47 47 ORIFICE SIZE

3.1 3.3 3.3 3.3 3.3 3.3 MANIFOLD PRESSURE

49 47 47 47 47 47 ORIFICE SIZE

2.9 3.1 3.1 3.1 3.1 3.1 MANIFOLD PRESSURE

49 47 47 47 47 47 ORIFICE SIZE

2.7 2.9 2.9 2.9 2.9 2.9 MANIFOLD PRESSURE

49 47 47 47 47 47 ORIFICE SIZE

2.6 2.8 2.8 2.8 2.8 2.8 MANIFOLD PRESSURE

51 49 49 49 49 49 ORIFICE SIZE

3.4 3.4 3.4 3.4 3.4 3.4 MANIFOLD PRESSURE

51 49 49 49 49 49 ORIFICE SIZE

3.1 3.2 3.2 3.2 3.2 3.2 MANIFOLD PRESSURE

51 49 49 49 49 49 ORIFICE SIZE

2.9 2.9 2.9 2.9 2.9 2.9 MANIFOLD PRESSURE

Table 11. High Altitude Deration Chart for Natural Gas - Low Heating Value

Page 34

Page 35

LOCATION OF FURNACE COMPONENTS

ITEM

10.

11.

12.

13.

COMPONENT NAME

Blower Assembly

Blower Door Switch

Burner Assembly

Control Board

Flame Sensor

Gas Manifold

Gas Valve

Igniter

Inducer Assembly

Limit Switch

Pressure Switch

Roll-Out Switch

Transformer

9 8 7

63 5 4

NEUTRALS

RCYGW

STATUS

24V

FAN

COOL

HEAT

FLAME

180

BLOWER

120

OFF

DELAY

L1A 2

XFMR

HIGH

LOW

HUM

EAC

ITEM

10.

11.

12.

13.

14.

COMPONENT NAME

Blower Assembly

Blower Door Switch

Burner Assembly

Combustion Tube

Control Board

Flame Sensor

Gas Manifold

Gas Valve

Igniter

Inducer Assembly

Limit Switch

Pressure Switch

Roll-Out Switch

Transformer

Figure 18.

Upﬂ ow/Horizontal Gas Furnace

9 8 7

63 5 4

5 4

NEUTRALS

RCYGW

STATUS

24V

FAN

COOL

HEAT

FLAME

180

BLOWER

120

OFF

DELAY

L1A 2

XFMR

HIGH

LOW

HUM

EAC

Figure 19. Downﬂ ow

Gas Furnace

Page 36

INSTALLATION/PERFORMANCE CHECK LIST

INSTALLER NAME:

CITY _______________ STATE _____________

INSTALLATION ADDRESS:

CITY _______________ STATE _____________

UNIT MODEL #

UNIT SERIAL # ____________________________

Minimum clearances per Table 1 (page 23)?

Has the owner’s information been reviewed with the home-owner?

YES NO

ELECTRICAL SYSTEM:

Electrical connections tight? YES NO

Line voltage polarity correct? YES NO

Supply Voltage: ______________________ VOLTS

Has the thermostat been calibrated?

Is the thermostat level? YES NO

Is the heat anticipator setting correct?

GAS SYSTEM:

Gas Type: (circle one)

Gas pipe connections leak tested?

Gas Line Pressure: __________________ (in - W.C.)

Is there adequate fresh air supply for combustion and ventilation?

YES NO

Natural

Gas

YES NO

Propane

Has the literature package been left near the furnace?

YES NO

Installation Altitude: ____________________ (FT.)

Deration Percentage: ___________________ (%)

Furnace Input: _______________________ (Btuh)

Supply Air Temperature: ________________ (° F)

Return Air Temperature: ________________ (° F)

Temperature Rise: ____________________ (° F)

VENTING SYSTEM:

Vent free from restrictions? YES NO

Filter(s) secured in place? YES NO

Filter(s) clean? YES NO

Flue connections tight? YES NO

Is there proper draft? YES NO

O’Fallon, MO

¢708807>¤

708807D

708807D (Replaces 708807C)

Speciﬁ cations and illustrations subject to change

without notice or incurring obligations.

Printed in U.S.A. (09/08)