Nordyne 072C-16, 096C-12, 096C-16, 096C-20, 120C-16 Installation Instructions Manual

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Residential Gas Furnaces

Installation Instructions

80+ High Efficiency Upflow/Horizontal and Downflow with Variable Speed Blower

*RA 80+ Upflow

WARNING:

Improper installation, adjustment, alteration, service, or maintenance can cause injury or property damage. Refer to this manual. For assistance or additional information consult a qualified installer, service agency, or the gas supplier.

DO NOT DESTROY. PLEASE READ CAREFULLY AND KEEP IN A SAFE PLACE FOR FUTURE REFERENCE.

These instructions are primarily intended to assist qualified individuals experienced in the proper installation of this appliance. Some local codes require licensed installation/service personnel for this type of equipment. Read all instructions carefully before starting the installation.

FOR YOUR SAFETY

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

*RK 80+ Downflow

FOR YOUR SAFETY

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.

• Immediately call your gas supplier from a neighbor's phone. Follow the gas supplier's instructions.

• If you cannot reach your gas supplier, call the fire department.

• Extinguish any open flame.

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Page 3

Table of Contents

Furnace Specifications ....................................................................................................................................................... 4-5

Unit Dimensions and Shipping Weights ....................................................................................................... 4-5

Capacities-Furnace Airflow Data ..................................................................................................................... 6

Safety Information ............................................................................................................................................ 7

Installation Requirements ..................................................................................................................................................... 7

Requirements and Codes ................................................................................................................................ 7

Location............................................................................................................................................................ 7

Clearances to Combustibles ........................................................................................................................... 7

Venting and Combustion Air Requirements ................................................................................................................... 8-13

General ............................................................................................................................................................ 8

Installation in an Unconfined Space ................................................................................................................ 8

Installation in a Confined Space ...................................................................................................................... 8

Horizontal Furnace Installation ........................................................................................................... 1 0

Air From Inside .................................................................................................................................... 11

Outdoor Air Using Vertical Ducts ........................................................................................................ 12

Air Directly Through an Exterior Wall ................................................................................................. 1 2

Outdoor Air Using A Crawl Space and Ventilated Attic ...................................................................... 12

Outdoor Air Through Horizontal Ducts ............................................................................................... 12

Venting Requirements .................................................................................................................................................... 13-19

General .......................................................................................................................................................... 13

Category I - Common Venting ....................................................................................................................... 13

Category III - Horizontal Venting .................................................................................................................... 15

Horizontal Venting for Upflow Models ................................................................................................ 15

Horizontal Power Venting ................................................................................................................... 17

Location of Outdoor Terminations ................................................................................................................. 17

Horizontal Installation ......................................................................................................................... 17

Flexible Vent Systems .................................................................................................................................... 1 9

Circulating Air Supply ..................................................................................................................................................... 19-20

General .......................................................................................................................................................... 19

Return Air ....................................................................................................................................................... 19

Gas Supply and Piping .................................................................................................................................................... 20-22

General .......................................................................................................................................................... 20

Leak Check .................................................................................................................................................... 21

Conversion ..................................................................................................................................................... 2 1

High-Altitude Application ............................................................................................................................... 21

Natural Gas High Altitude Conversion .......................................................................................................... 22

LP/Propane Gas Sea Level and High Altitude Conversion .......................................................................... 22

Electrical Wiring .............................................................................................................................................................. 22-24

General .......................................................................................................................................................... 22

Line Voltage Wiring ........................................................................................................................................ 23

Low Voltage Wiring ........................................................................................................................................ 24

Start-up & Adjustments ....................................................................................................................................................... 24

General .......................................................................................................................................................... 24

Start-Up Procedures ...................................................................................................................................... 24

Verifying and Adjusting Firing Rate ............................................................................................................... 24

Configuring the Blower .................................................................................................................................. 25

Selecting Airflow ............................................................................................................................................ 25

Verifying and Adjusting Temperature Rise .................................................................................................... 26

Verifying Burner Operation ............................................................................................................................ 27

Verifying Operation of Supply Air Limit Switch .............................................................................................. 27

Description of Components ................................................................................................................................................ 28

Wiring Diagram ..................................................................................................................................................................... 30

Maintenance .................................................................................................................................................................... 29-31

Vent System ................................................................................................................................................... 29

Air Filter(s) ...................................................................................................................................................... 29

Lubrication ..................................................................................................................................................... 29

Blower Compartment ..................................................................................................................................... 29

Heat Exchanger and Burner Maintenance .................................................................................................... 29

Cleaning of Flue Passages ............................................................................................................................ 31

Installation/Performance Checklist .................................................................................................................... Back Cover

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FURNACE SPECIFICATIONS - Upflow/Horizontal Models

3/4

7/8

3/4

X 3

Cut-out for

Gas Connection

Cut-out for

Electric Connection

25 1/4

Return

Air Opening

(Side)

FLUE

OUTLET

3/4 3/4

1 1/4

Return Air Opening

(Bottom)

1 1/4D

Unit Shown in Upflow Position Rotate 90˚ Clockwise or Counter Clockwise for Horizontal Application

X 3

Gas Connection

7/8 Cut-out for Electric

Connection

Cut-out for

Figure 1a. Upflow Unit Dimensions

FURNACE DIMENSIONS AND

SHIPPING WEIGHTS

Furnace Dimensions Shipping

Model Input A B C Flue Outlet Weight D

*RA (Btuh) (in.) (in.) (in.) (in.) (lbs) (IN.)

072C-16 72,000 19 3/4 18 1/4 3 3/4 4 152 17 1/4

096C-12 96,000 19 3/4 18 1/4 3 3/4 4 163 17 1/4

096C-16 96,000 19 3/4 18 1/4 3 3/4 4 163 17 1/4

096C-20 96,000 22 1/2 21 3 3/4 4 174 20

120C-16 120,000 19 3/4 18 1/4 3 3/4 4 174 17 1/4

120C-20 120,000 22 1/2 21 3 3/4 4 182 20

144C-20 144,000 22 1/2 21 4 1/4 5 194 20

Table 1a. Upflow Furnace Dimensions and Shipping Weights

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FURNACE SPECIFICATIONS - Downflow Models

3/4"

23 5/8"

19 3/4"

4" Dia. Vent

3/4"

43"

3/4"

24 1/2"

Cut-out for Electric

Connection

Both sides

25"

Cut-out for Gas Connection

1-1/2 x 3-1/2 (both sides)

19 3/4"

(Bottom Opening)

27 7/8"

27 1/8"

15 1/2"

(Bottom Opening)

10 1/4"

Figure 1B. Downflow Unit Dimensions

DOWNFLOW FURNACE MODELS

25"

Cut - out for

Gas Connection

FURNACE DIMENSIONS AND

Model Furnace Shipping

Number Input A B C Weights

*RK (Btuh) inches inches inches (lbs)

060C-12 60,000 14 1/4 12 3/4 5 1/2 134 072C-12 72,000 14 1/4 12 3/4 5 1/2 135 072C-16 72,000 19 3/4 18 1/4 11 147 096C-12 96,000 19 3/4 18 1/4 11 154 096C-16 96,000 19 3/4 18 1/4 11 156 120C-20 120,000 19 3/4 18 1/4 11 182

Table 1B. Downflow Furnace Dimensions and Shipping Weights

SHIPPING WEIGHTS

Dime nsions

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CAPACITIES —Furnace Airflow Data

CFM SWITCH NUMBER

LOW HIGH 1 2 3 4

500 720 0 0 0 1 550 800 0 0 0 0 610 880 0 0 1 0 650 945 1 0 0 1 72010501000 80011551010

90013050101 1000 1450 0 1 0 0 1060 1530 1 1 0 1 1100 1595 0 1 1 0 1170 1700 1 1 0 0 1290 1870 1 1 1 0

NOTE: 0 = OFF 1 = ON

Table 1. Cooling/Heat Pump Airflow Settings

720 900 1056 1200 1350 1500 1656 1800 7 6

Switches

1 0 0

0 0 0

567

Nominal Air-Flo

1 0 1

0 0 1

1 1 0

Nominal A/C and HP

Capacity

2.5 TON

3 TON

3.5 TON

4 TON

5 TON

0 1 0

1 1 1

2 TON

0 1 1

72,000 59

90,000 63

96,000 67 59 108,000 67 120,000 66 126,000 69 62

80+% 92+%

144,000 71

80,000 67 100,000 73 65 120,000 71

Temperature Rise °F (Recommended settings are

NOTE: 0 = OFF 1 = ON

Notes:

1. Recommended temperature rises are highlighted in bold.

2. Airflow rates of 1800 CFM or more require two return air connections. Data is for operation with filter(s).

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

4. Temperature rises that are shaded grey are for reference only. These conditions are not recommended.

5. For single stage cooling, the indoor blower will operate at the CFM listed in the high column.

Table 2. Heating Airflow Settings

49 44

53 59

47 53 48

52 47

54 49

56 64

51 59

53 49

Bold

)

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SAFETY INFORMATION

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

2. Install this furnace only in a location and position as specified on Table 3 of these instructions.

3. Provide adequate combustion and ventilation air to the furnace space as specified on Pages 11 through 14.

4. Combustion products must be discharged outdoors. Connect this furnace to an approved vent system only, as specified on Pages 13 through 14.

5. Never test for gas leaks with an open flame. Use a commercially available soap solution made specifically for the detection of leaks to check all connections, as specified on Page 17 of these instructions.

6. Always install furnace to operate within the furnace’s intended temperature-rise range with a duct system which has an external static pressure within the allowable range, as specified on Table 2 of these instructions. See furnace rating plate.

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

8. A gas-fired furnace for installation in a residential garage must be installed as specified on Page 6 of these instructions.

9. The furnace is not to be used for temporary heating of buildings or structures under construction.

WARNING:

This furnace is not approved for installation in mobile homes. Installation in a mobile home could cause fire, property damage, and/or personal injury.

Location

Upflow gas furnaces are shipped ready for installation in the upflow or horizontal right or left positions. The furnace must be installed on a level surface, located as close to the vent (or chimney) and as close to the center of the air distribution system as possible. See Table 1 for overall dimensions to determine the required clearances in hallways, doorways, stairs, etc. to allow the furnace to be moved to the installation point. The furnace must be installed so that all electrical components are protected from water. The furnace must be installed upstream from a refrigeration system. This furnace is not to be used for temporary heating of buildings or structures under construction.

Clearances to Combustibles

This furnace is Design Certified by CSA International for the minimum clearances to combustible material listed in Table 3. Refer to the furnace rating plate, located inside of the furnace cabinet, for the specific model number and clearance information.

INSTALLATION REQUIREMENTS

Requirements and Codes

This furnace must be installed in accordance with these instructions, all applicable local building codes, current revision of the National Fuel Gas Code (ANSI-Z223.1), and in Canada with the CAN/CGA - B149 installation code. The current revision of the National Fuel Gas Code is available from:

American National Standards Institute, Inc.

1430 Broadway

New York, New York 10018

Additional helpful publications are:

NFPA-90A - Installation of

Air Conditioning and Ventilating Systems

NFPA-90B - Warm Air Heating

and Air Conditioning Systems

These publications are available from:

National Fire Protection Association, Inc. Batterymarch Park Quincy, Massachusetts 02269

Access for positioning and servicing the unit must be considered when locating unit. 24 inches is the minimum required clearance from the front of the unit for servicing it. 30 inches is the minimum required clearance from the front of the unit for positioning it. 36 inches is the

recommended clearance from the front of the unit.

Please note that a panel or door can be located such that the minimum clearance on the rating plate is satisfied, but that panel or door must be removable and allow the appropriate clearance for your installation.

This furnace is certified for use on wood flooring. This furnace must not be installed directly on carpeting, tile, or any combustible material other than wood flooring.

A gas-fired furnace installed in a residential garage must be installed so the burners and the igniter are located not less than 18 inches (457 mm) above the floor, and the furnace must be located or protected to avoid physical damage by vehicles.

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WARNING:

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

VENTING AND COMBUSTION AIR REQUIREMENTS

General

Provisions must be made in the installation of this furnace to provide an adequate supply of air for combustion. Detailed instructions for determining the adequacy of an installation can be found in the current revision of the National Fuel Gas Code (ANSI Z223.1 / NFPA54) or in applicable local building codes. Consult local codes for special requirements. For Canadian installations consult Canadian Installations Codes and (CAN/CGA B149.1 or .2).If the furnace is operated with inadequate air for combustion one of the flame roll-out switches located in the burner compartment or the vent switch will open, turning off the gas supply to the burners. These safety devices are manually reset switches. DO NOT install jumper wires across these switches to defeat their function. DO NOT reset a switch without identifying and correcting the fault condition. If a switch must be replaced, use only the correct part specified in the Replacement Parts List.

Air openings in the furnace door, warm air registers, and return air grilles must not be restricted.

3. The following types of installation 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 also 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 (such as perchloroethylene)

• Printing inks, paint removers, varnishes, etc.

• Hydrochloric acid

• Cements and glues

• Antistatic fabric softeners for clothes dryers

• Masonry acid washing materials

WARNING:

Furnace installation using methods other than those described in the following sections must comply with the National Fuel Gas Code and all applicable local codes to provide sufficient combustion air for the furnace.

CAUTION:

Combustion air must not be drawn from a corrosive atmosphere.

To maximize heat exchanger life, the combustion air must be free of chemicals which form corrosive acidic compounds in the combustion gases.

Combustion Air Quality

The recommended source of combustion air is to use the outdoor air supply. However, the use of indoor air in most applications is acceptable except as follows:

1. If the furnace is installed in a confined space it is recommended that the necessary combustion air come from the outdoors by way of attic, crawl space, air duct, or direct opening.

2. If outdoor combustion air is used, there must be no exposure to the installations or substances listed in Item 3 below.

Installation In An Unconfined Space

An unconfined 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.

For example, a space including 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 unconfined. If the space has an 8 foot ceiling, the floor area of the space must be 750 square feet (6,000 / 8 = 750). In general, a furnace installed in an unconfined space will not require outside air for combustion. However, in “tight” buildings (with weather stripping and caulk to reduce infiltration), it may be necessary to provide outside air to ensure adequate combustion and venting, even though the furnace is located in an unconfined space.

Installation In A Confined Space

A confined space is an area with volume less than 50 cubic feet per 1,000 Btuh of the combined input rates of all

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appliances drawing combustion air from that space. Furnace closets, small equipment rooms and garages are confined spaces. Furnaces installed in a confined 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. A confined space

must have two openings into 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 floor. 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.

Downflow Warning (*RK Models):

The design of the downflow furnace is certified for natural or propane gas and for installation on non-combustible flooring. A special combustible floor sub-base is required when installing on a combustible floor. Failure to install the sub-base may result in fire, property damage and personal injury. The special downflow sub-bases are factory supplied accessories, part numbers 902677 and 902974. When the furnace is installed on a factory or site-built cased air conditioning coil, the sub-base is not necessary. However, the plenum attached to the coil casing must be installed such that its surfaces are at least 1" from combustible construction.

Supply Air Plenum Installation

A. Installation on a concrete slab. - *RK

1. Construct a hole in the floor per the dimensions in Figure 2.

2. Place the plenum and the furnace as shown in Figure

B. Installation on a combustible floor. - *RK

1. Cut and frame the hole in the floor per the dimensions in Figure 4.

2. Place sub-base for combustible floors over the hole with its duct collar extended downward. Attach the supply air plenum to the base in a manner which will assure 1" clearance to the flooring or other combustible construction. Place furnace on the combustible base as shown in Figure 6.

3. When a factory or site built cased coil is provided beneath the furnace the sub-base for combustible floors is not necessary. However, the plenum attached to the cased coil must be installed such that its surfaces are at least 1" from the flooring or other combustible construction.

Horizontal Furnace Installation

This furnace can be installed horizontally in an attic, basement, crawl space or alcove. It can be suspended from a ceiling in a basement or utility room in either a right to left airflow or left to right airflow. (See Figure 2.)

CAUTION:

The downflow sub-base must not be installed directly on carpeting, tile, or any combustible material other than wood flooring.

WARNING:

If the furnace is to be suspended from the ceiling, it will be necessary to use steel straps around each end of the furnace. These 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.

Note: Line Contact is Permissible

Type “B” Vent

Coil Plenum

Electrical

Supply

Connection

Figure 2. Horizontal installation on a Platform

Gas Inlet

Combustible Platform

Louver Door

Page 10

Upflow Furnace Models

LEFT SIDE

UPFLOW APPLICATION

TOP

RIGHT SIDE

BOTTOM

HORIZONTAL APPLICATION

TOP

LEFT SIDE

BOTTOM

HORIZONTAL INSTALLATION CLEARANCES

Vent Connector

Type

LEFT SIDE

RIGHT SIDE

VENT

BACK

BOTTOM

TOP

FRONT

*** Allow 24" minimum clearance for servicing. The

recommended clearance is 36".

Standard Single

Wall Metal Vent

1" 1" 0" 0" 6" 1" 0" 0" 0" 0" 5" 0"

4"*** 4"***

RIGHT SIDE

Type B-1 Double

Wall Metal Vent

UPFLOW/DOWNFLOW INSTALLATION CL EARANCES

Vent Connector

Type

LEFT SIDE

RIGHT SIDE

VENT

BACK

BOTTOM

TOP

FRONT

Standard Single

Wall Metal Vent

0" 0"

5"* 0"

6" 1" 0" 0"

0"** 0"**

1" 1"

4"*** 4"***

Type B-1 Double

Wall Metal Vent

* For Downflow furnace installations only,

right side minimum clearance is 0".

** For Downflow furnace installations only,

furnace must be installed on noncombustible flooring.

*** Allow 24" minimum clearance for servicing.

The recommended clearance is 36".

Table 3. Minimum Clearances to Combustible Material

Downflow Furnace Models

DOWNFLOW APPLICATION

TOP

LEFT SIDE

BOTTOM

RIGHT SIDE

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Access for positioning and servicing must be considered when locating the unit. Refer to Table 3, Minimum Clearances to Combustible Material, for clearance specifications.

Keep all insulating materials away from the louvered door. Insulating materials may be combustible.

This furnace may be installed directly on combustible wood flooring or supports, if type "B-1" vent pipe is used (See Figure 4). It is recommended for further reduction of fire hazard that cement board or sheet metal be placed between the furnace and the combustible floor and extend 12 inches beyond the front of the louvered door.

18.75"

19.25"

Hole in

Floor

13.25"

19.25"

Hole in

Floor

WARNING:

Furnaces installed with combustion air drawn from a heated space which includes exhaust fans, fireplaces, or other devices that may produce a negative pressure should be considered confined space installations.

See the venting section for venting guidelines and specifications.

Air From Inside (See Figure 7)

If combustion air is taken from the heated space, the two openings must inch per 1,000 Btuh of total input of all appliances in the confined space, but not less than 100 square inches of free area. 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.

each

have a free area of at least one square

*RK 072-16; 096-12; 096-16;

120-20

*RK 060-12;

072-12

Figure 3a. Opening for Concrete Slab

Concrete

Furnace

Floor

Sheet

Metal

Plenum

Figure 3b. Furnace on a Concrete Slab

18.75"

13.25"

19.63"

Hole in

Floor

*RK 072-16;

096-12; 096-16; 120-20

Hole in

Floor

*RK 060-12;

072-12

19.63"

* Smaller dimensions for *RK

18.75"

or 13.25"*

16.75"

or 11.25"*

19.75"

or 14.25"*

1.50"

060-12; 072-12

9.25"

2.0"

28.38"

19.63"

1.58"

1 inch thick fiberglass 3 lb density

Figure 5. Downflow Sub-Base Dimensions

Downflow Sub-base

Furnace

Sheet

Metal

Plenum

Wood Floor

Figure 4. Opening in Wood Floor

Figure 6. Downflow Sub-Base Dimensions

Page 12

Outdoor Air Using Vertical Ducts (See Figure 8)

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.

If the unit is installed in an area with an exhaust fan, provide sufficient ventilation to prevent negative pressures from occurring in the room.

Vent or Chimney

Openings to adjacent space. Each opening must be at least 100 sq. in. or 1 sq. in. per 1000 Btuh of total input rating, whichever is greater. See minimum area per table.

The combustion air openings must not be restricted in any manner.

CAUTION:

Do not supply combustion air from an attic space that is equipped with power ventilation or any other device that may produce a negative pressure.

Air Directly Through An Exterior Wall (See Figure 9)

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 4000 Btuh of total appliance input.

12" Max.

Furnace

12" Max.

Water Heater

Total Input

Rating (Btu/hr)

40,000 60,000 80,000 100,000 120,000 140,000 160,000

Minimum

Free Area

(Each Opening)

100 sq. in. 100 sq. in. 100 sq. in. 100 sq. in. 120 sq. in. 140 sq. in. 160 sq. in.

Round Duct

Diameter

12" 12" 12" 12" 13" 14" 15"

Figure 7. Equipment in a Confined Space with all

Combustion Air Drawn from the Inside

Vent or Chimney

Attic Insulation

Furnace

Water Heater

a. All Combustion Air from Ventilated Attic.

Total Input

Rating (Btu/hr)

40,000 60,000 80,000 100,000 120,000 140,000 160,000

Minimum

Free Area

(Each Opening)

10 sq. in. 15 sq. in. 20 sq. in. 25 sq. in. 30 sq. in. 35 sq. in. 40 sq. in.

Ventilation Louvers at

each end of attic

Outlet Air Duct must

be at least 1 sq. in.

per 4,000 Btuh of total input rating.

Round Duct

Diameter

4" 5" 5" 6" 6" 7" 8"

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

Figure 8. Equipment in a Confined Space with all

Combustion Air Drawn from the Outside

through Vertical Ducts

Outdoor Air Using a Crawl Space and Ventilated Attic (See Figure 10)

When directly communicating 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 communicate directly, or by ducts, with the outdoor spaces (crawl or attic) that freely communicate with the outdoors.

Outdoor Air Using Horizontal Ducts (See Figure 11)

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.

Vent or Chimney

Each opening to outside must be at least 1 sq. in. per 4000 Btuh of total input rating.

12" Max

Furnace

12" Max

Total Input

Rating (Btuh)

40,000 60,000 80,000 100,000 120,000 140,000 160,000

Figure 9. Equipment in a Confined Space with all

Combustion Air Drawn from the Outside

through Exterior Wall

Water Heater

Minimum

Free Area

(Each Opening)

10 sq. in. 15 sq. in. 20 sq. in. 25 sq. in. 30 sq. in. 35 sq. in. 40 sq. in.

Round Duct

Diameter

4" 5" 5" 6" 6" 7"

Page 13

Vent or Chimney

Ventilation Louvers at each end of attic

Attic Insulation

Outlet Air Duct must be at least 1 sq. in. per 4000 Btuh of total input rating. Must extend above attic insulation.

Each opening to outside must be at least 1 sq. in. per 2000 Btuh of total input rating.

Vent or Chimney

Furnace

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

Water Heater

Ventilation Louvers for unheated crawl space

Crawl Space

Figure 10. Equipment in a Confined Space with All

Combustion Air Drawn from a

Crawl Space and Ventilated Attic

If the unit is installed in an area with an exhaust fan, provide sufficient ventilation to prevent negative pressures from occurring in the room.

The combustion air openings must not be restricted in any manner.

VENTING REQUIREMENTS

General

This furnace must be vented in compliance with, the current revision of the National Fuel Gas Code (ANSI-Z223.1/ NFPA54), with the instructions provided below.

12" Max

Rating (Btu/hr)

12" Max

Total Input

40,000 60,000 80,000 100,000 120,000 140,000 160,000

Furnace

Water Heater

(Each Opening)

Minimum

Free Area

20 sq. in. 30 sq. in. 40 sq. in. 50 sq. in. 60 sq. in. 70 sq. in. 80 sq. in.

Air Duct

Round Duct

Diameter

5" 6" 7" 8" 9" 10" 10"

Figure 11. Equipment in a Confined Space with all

Combustion Air Drawn from the Outside through

Horizontal Ducts

should be evenly spaced around the flue diameter, if possible.

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.

This furnace must never be vented to a chimney flue servicing a fireplace or other appliance designed to burn solid fuel. If the furnace vent is to be connected to a chimney serving a fireplace, the fireplace must be sealed off from the chimney.

For Category I furnace installations, the furnace shall 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. Venting into an unlined masonry

chimney or concrete chimney is prohibited.

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 ambient temperatures below 35° F must be insulated to prevent condensation. All vent insulation shall be foil backed fiberglass of one inch minimum thickness.

Three sheet metal fasteners (field supplied) should be used to secure the vent pipe to the furnace flue. These fasteners

Category I - Common Venting

When an existing furnace is removed from a venting system serving other appliances, the venting system is likely to be too large to properly vent the remaining appliances. An improperly sized venting system can result in the formation of condensate, leakage, spillage, etc.

The venting system should be designed to have the minimum number of elbows or turns. All horizontal runs shall be sloped upwards from the furnace at 1/4 inch per running foot of vent. Supports for the vent pipe must be installed a minimum of every five 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.

If the furnace is operated with blocked or restricted venting, the blocked vent switch located in the vent plate will open, turning off the gas supply to the burners. The blocked vent switch is a manually reset device. DO NOT install a jumper

Page 14

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 for each appliance connected to the venting system being placed into operation, while all other appliances connected to the venting system are not in operation:

1. Seal any unused openings in 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 deficiencies which could cause an unsafe condition.

3. As far as practical, close all building doors and windows and all doors between the space in which the appliance(s) connected to the venting system are located and other spaces of the building.

4. Close fireplace dampers.

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

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

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

8. If improper venting is observed during any of the above tests, the venting system must be corrected in accordance with the

or CSA B149.1, Natural Gas and Propane Installation Codes

National Fuel Gas Code, ANSI Z223.1/NFPA 54 and/

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

wire across this switch to defeat its function. DO NOT reset the switch without identifying and correcting the fault condition which caused the switch to trip. If this switch must be replaced, use only the part specified in the Replacement Parts List.

WARNING:

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

Category III: Horizontal Venting

NOTE: The reduced NOx models (eighth character N) are not approved as a Category III furnace for use with horizontal venting.

The furnaces are approved for use with 3" single wall AL294C stainless steel vent pipe in horizontal vent applications. This pipe is available from the following manufacturers:

Z-FLEX Inc. - vent brand name (Z-VENT) Heat-fab Inc. - vent brand name (Saf-T Vent) Flex-L International - vent brand name (Star-34 Vent)

This vent pipe must be used for the entire length of the vent run. The installation must be in accordance with all instructions supplied by the vent manufacturer for use on Category III appliances. When venting horizontal, this is

Page 15

Cut

Sensor

Tubes

Pressure

Switch

Bleed Tube

Bleed Tube Orifice

Switch

Limit

Blue

Switch

Flame

Roll-Out

Switch

Vent

Limit

Figure 14. Limit Circuit Wiring

Blue

Wire Nut

Collector Pan

Figure 12. Bleed Tube Installation

defined as a Category III furnace, the vent pressure is positive, and the venting system must be sealed in both horizontal and vertical runs.

For horizontal venting installations in both the United States and Canada the transition assembly must be modified by adding a bleed tube to the pressure switch tube and bypassing the vent switch. All model furnaces will require Vent Kit #903196 for horizontal venting.

Horizontal Venting For Upflow Models:

1. Remove the rubber tubing from the pressure switch sensor tube and the collector pan sensor tube. Cut 1/2 inch from one end of the rubber sensor tube, fold in half and cut along the bend line. Discard the 1/2 inch long piece of tubing. Select the correct bleed tube using the table supplied with vent kit #903196 and place the other two pieces of tubing on both ends of the bleed tube. Do not cover the hole in the bleed tube. Place the assembly back on the pressure switch sensor tube and the collector pan sensor tube. (See Figure 12.)

cover the hole(s) on the vent collar assembly. Tighten the nut securely while holding the cover plate in position. (See Figure 13.)

3. Bypass the vent switch by removing both wires from the vent switch and attaching them to the wire nut. (See Figure 14.)

CAUTION:

Do not drill holes through the vent pipe or fittings on a horizontal vented furnace. Do not use sheet metal screws, or rivets. Drilling, screws, or rivets will cause leaks.

The components of the horizontal vent system must not be penetrated with screws, rivets, or other devices, either when joining pipes and fittings or using support straps. All joints must be sealed with high temperature silicone before locking bands are installed. If the lengths of pipe must be cut, the joint must still be sealed with silicone and the locking band used. When installing the condensate tube be sure to form a trap by means of a 3" loop filled with water. (See Figure 15.)

Horizontal Venting: *RK Models:

2. Remove the nut and restrictor plate from the vent collar assembly and discard the restrictor plate. Select the appropriate dilution cover plate as noted with vent kit #903196. Fit the clearance hole in the cover plate over the weld stud. The cover plate must

Covered Vent

Nut

Figure 13. Vent Collar Detail

Collar Hole

Cover Plate

1. By-pass the vent switch, located on blower compartment door, by removing both wires from the switch. Remove wire terminals, strip wires and tie together in a wire nut. (See Figure 16.)

/4" Per

Wall Thimble

(For combustible

wall material)

Locking Band

Termination

Te e

Outside

Wall

Support

0-6'

Locking Band

Te e

Drain

Plug

Foot Rise

3" Dia. Loop

90˚ Elbow

Figure 15. Typical Horizontal Vent Installation

Page 16

2. Remove the rubber tubing from the pressure switch sensor tube and the collector pan sensor tube. Cut the tubing approximately 3" from one end. Select the appropriate dilution cover plate as noted with vent kit #903196. Insert the bleed tube into the tubing. Do not cover the hole in the bleed tube. Place the tubing assembly back on the pressure switch sensor tube and collector pan sensor tube. (See Figure 16.)

3. To gain access to the restrictor plate, remove and discard the combustion tube from the transition assembly. Insure the seal between inducer and transition assembly is not broken. (See Figure 17.)

4. Remove and discard the restrictor plate and screw from the transition assembly. (See Figure 17.)

5. Install and seal a 4" to 3" reducer to the transition. (See Figure 18.) Attach the new high temperature vent pipe to the reducer.

NOTE: The direction of the male-female joints from the drain tee to the termination tee is opposite to standard gas appliance venting. The male end of the pipes point towards the furnace.

1. Apply an adhesive bead around the outside of the pipe approximately 1/4" from the end of the pipe. This includes the first fitting or pipe attached to the furnace.

2. Push the pipe and fitting together while twisting the pipe or fitting. Twisting the pipe or fitting spreads the adhesive completely within the fitting socket.

3. When the pipe is at the socket bottom, inspect the joint. Look for a complete, uninterrupted ring of adhesive material around the pipe at the fitting socket. Additional adhesive or rotation of the pipe or fitting may be required for a complete seal. The

Keep the number of pipe fittings to a minimum. Maintain a minimum of 6 inches of air space between the vent and combustibles at all times, this includes inside and outside the building.

Collector Pan

Bleed Tube

Orifice

Pressure

Switch

Combustion

Tube

Remove

and

Discard

Screw

Restrictor

Plate

Transition

Inducer

Figure 17. *RK Horizontal

Vent Modification

Special 3"

AL29-4C Stainless Steel

Vent Pipe

Figure 16. *RK Bleed Tube Installation

4" to 3" Reducer

Transition

Figure 18. *RK Reducer Installation

Page 17

complete adhesive material ring provides the seal required for the positive pressure vent.

4. All vent systems must include a tee and drain plug for collection and disposal of condensate. The drain tee must be installed within the first 5 feet of vent run to protect the furnace.

5. All horizontal sections must have a slope toward the drain tee of not less than 1/4" per foot to prevent the collection of condensate at any location other than at the tee.

6. Horizontal runs must be supported with 3/4" pipe strap at a maximum of 5 foot intervals and at each point where an elbow is used.

Installation Instructions are provided with the kit. Installation must conform to those instructions and applicable requirements of local codes.

WARNING:

The entire vent system must be sealed with a high temperature sealant which will withstand temperatures of 450°F. Recommended sealants: Dow Corning Sealant 736 RTV; GE 106 RTV; High Tech Ind., High TEMP RED.

Location of Outdoor Terminations

7. Maintain a 6 inch minimum air space to combustibles from all sections of the stainless steel vent system, except when a wall thimble is used.

Horizontal Power Venting

— The Tjerlund GPAK-1TN

horizontal kit is certified for use with *RA, *RK Series furnaces. The kit includes a power venter, a side-wall vent hood and a barometric draft control. It has an electrical interlock to assure that the furnace will not operate when the power venter is off.

The kit is for use only when exhaust is through an exterior wall, normally with horizontal vent piping. The power venter establishes negative pressure in the vent piping and the furnace operates as if connected to Category I vertical venting.

Horizontal Venting Requirements

Furnace

Model Number Pipe Reducer Maximum Max. Feet

*RA Size Needed # Elbows Vent Pipe

072C-12 3" 4" to 3" 4 35 096C-12 3" 4" to 3" 4 35 096C-16 3" 4" to 3" 4 35 096C-20 3" 4" to 3" 4 35 120C-16 3" 4" to 3" 4 35 120C-20 3" 4" to 3" 4 35 144C-20 3" 4" to 3" 3 30

Note: Special 5" to 4" Reducer Kit, p/n 902249 required for model number *RA144C-20.

Furnace

Model Number Pipe Reducer Maximum Max. Feet

*RK Size Needed # Elbows Vent Pipe

060C-12 3" 4" to 3" 4 35 072C-12 3" 4" to 3" 4 35 072C-16 3" 4" to 3" 4 35 096C-12 3" 4" to 3" 4 35 096C-16 3" 4" to 3" 4 35 120C-20 3" 4" to 3" 4 35

Table 4. Horizontal Venting Requirements

Horizontal Installation

The vent termination tee must be installed with the following minimum clearances. (See Figure 19.) Vent Termination clearances shall be consistant with the National Fuel Gas Code, ANSI 2223.1/NFPA 54 and/or the CSA B149.1, Natural Gas and Propane Installation Code.

All minimum clearances specified must be maintained to protect building material from degradation by flue gases.

1. The termination tee must be 12 inches above snow level or grade level which ever is higher. See Figure 14 for alternate method to achieve 12" above snow level.

2. The minimum distance from any door, (openable) window, or gravity air inlet is 4 ft. below, 4 ft. horizontally, or 1 ft. above.

3. The vent termination shall be a minimum of 3 ft. above any forced air inlet within 10 ft. (See Figure 19.)

4. Recommended minimum distance from an inside corner formed by two exterior walls is 6 ft., but is not required.

5. The minimum distance from gas or electric meter(s) is 4 ft.

6. Avoid areas where condensate drainage may cause problems such as above planters, patios, or adjacent to windows where the steam from the flue gases may cause fogging. Do not terminate above any public walkway.

7. Select the point of wall penetration where the minimum 1/4 inch per foot of upward slope can be maintained.

8. When penetrating a noncombustible wall, the hole through the wall must be large enough to maintain the pitch, pipe clearance for passage, and provide for proper sealing. Penetrating a combustible wall requires the use of a wall thimble. (See Figure 20.) A 6-1/2 inch square framed opening is required to insert the thimble halves. The thimble is adjustable to varying wall thickness and is held in place by applying sealant to the male sleeve before assembly. Also run a bead of sealant around the outer wall thimble.

Page 18

VENT TERMINAL

AIR SUPPLY INLET

AREA WHERE TERMINAL IS NOT PERMITTED

Clearance above grade, v eranda, porch,

A =

Canadian Installations

US Installations

12 inches (30 cm) 12 inches (30 cm)

deck, or balcony

Clearance to window or door that may be

B =

opened

6 inches (15 c m) f or appl ianc es ≤ 10,0 00 Btuh (3 kW), 12 inches (30 cm) for

4 feet (1.2 m) below or to side of opening;

1 foot (300 mm) above opening appliances > 10,000 Btuh (3 kW) and ≤ 100,00 Btuh (30 kW), 36 inches (91 cm) for appliances >100,00 Btuh (30 kW)

Clearance to permanently closed window

C =

Vertic al c learance to v entilat ed so ff it

D =

located above the terminal within a horizont al di st ance of 2 feet (61 c m) f rom

the center line of t he terminal Clearance to unventilated soffit

E =

Clearance to outside corner

F =

Clearance to inside corner

G =

Clearance to each side of c enter line

H =

extended above meter/regulator assembly Clearance to service regulator vent outlet 3 feet (1.83 m)

I =

Clearance to nonmechanical air supply inlet

J =

to building or the combustion air inlet to any other appliance

3 fe et (91 cm ) wit hin a height 15 f eet above the meter/regulator assembly

6 inches (15 c m) f or appl ianc es ≤ 10,000 Btuh (3 kW), 12 inches (30 cm) for appliances > 10,000 Btuh (3 kW) and ≤

** ** **

4 feet (1.2 m) below or to side of opening;

1 foot (300 mm) above opening

100,00 Btuh (30 kW), 36 inches (91 cm) for appliances >100,00 Btuh (30 kW)

Clearance to a mechanical air supply inlet 6 feet (1.83 m) 3 feet (91 cm) above if within 10 feet (3 m)

K =

horizontally

Clearance above paved sidewalk or paved

L =

7 feet (2.13 m) † 7 feet (2.13 m)

driveway located on public property

Clearance under veranda, porch deck, or

M =

balcony

12 inches (30 cm) ‡

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

In accordance with the current ANSI Z223.1 / NFPA 54 National Fuel Gas Code † A vent shall not terminate directly above a sidewalk or paved driveway that is located between two single family dwellings and serves both dwellings. ‡ Permitted only if veranda, porch, deck, or balcony is fully open on a minimum of two sides beneath the floor. * For clearances not specified in ANSI Z223.1 / NFPA 54 or CSA B149.1, one of the following statements shall be included:

“Clearance in accordance with local installation codes, and the requirements of the gas supplier

and the manufacturer’s installation instructions.”

Figure 19. Vent Termination Clearances

Page 19

9. The vent pipe must extend 1-1/4 inches through the outer thimble half for a combustible wall. Be sure to check this carefully before cutting the vent pipe.

10. Attach a 3 inch coupling to the end of the pipe that extends through the wall or thimble. This prevents the vent pipe from being pushed inward.

11. Cut an 8 inch minimum piece of vent pipe and connect the coupling to the termination tee. The inside of the tee must be a minimum of 12 inches from the outside of the wall. (See Figure 21.)

Flexible Vent Systems

Flexible gas vent is approved for use in vertical single vent or common vent installations only. The minimum distance to combustibles is 1" for type B insulated and 6" for single wall. The venting system must be installed in accordance with the local authorities, the vent manufacturer's instructions and the instructions listed below.

The flexible vent must be installed in accordance with the venting tables for vertical or common venting only. The vent system must be supported in horizontal runs with 3/4" pipe strap at a maximum of 5 foot intervals. All horizontal sections must have a slope toward the furnace of not less than 1/4" per foot. The vent must not sag, or have any bends greater than 90 degrees.

CIRCULATING AIR SUPPLY

General

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).

It is recommended that the outlet duct be provided with a removable access panel. This opening should be accessible when the furnace is installed in service and shall be of a size that smoke or reflected light may be observed inside the casing to indicate the presence of leaks in the heat

Use Wall Thimble at Vent Points

Combustible

Wall Thimble

(Inner Half)

3" Vent

Pipe

Inner Shield 41/2" Dia.

Combustible

Inside

Wall

Inside

Wall

Outer Overlapping

/2" Dia.

Shield 6

Wall Thimble Outer Half

Locking Band

Inner Overlapping Shield 63/8" Dia.

12" Min

Outside Combustible Wall

Protective

Screen

3" Termination

Tee

Figure 21. Typical Termination

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 50° F (10° C) during operation. If a combination of indoor and outdoor air is used, the ducts and damper system 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 airflow 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.

Return Air

In applications where the supply ducts carry heated air to areas outside the space in which the furnace is installed, the return air must be delivered to the furnace by duct(s) sealed to the furnace casing, running full size and without interruption.

Termination Tee

Support

Figure 20. Alternate Horizontal Vent Installation

Ground Level

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 products of combustion to be circulated into the living space and create potentially hazardous conditions, including carbon monoxide poisoning that could result in personal injury or death.

Page 20

WARNING:

Products of combustion must not be allowed to enter the return air ductwork or the circulating air supply. Failure to prevent products of combustion from being circulated 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 confined spaces, all return ductwork must be adequately sealed and joints must be taped. 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 floor or platform on which the furnace is mounted must provide sound physical support of the furnace with no gaps, cracks, or sagging between the furnace and the floor or platform.

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

For *RA installations: The return air ductwork may be connected to any or all of the following: left side return, right side return, or bottom return. NOTE: Do not use the back of the furnace for return air. Table 2 in the front of these instructions, contains the airflow data for this furnace model. Where maximum airflow is 1800 CFM or more, two openings must be used for return air.

GAS SUPPLY AND PIPING

General

This furnace may be installed for either left or right side gas entry. A typical gas service hookup is shown in Figure 22. When making the gas connection 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. All gas piping must be installed in compliance with local codes and utility regulations. Some local regulations require the installation of a manual main shut-off valve and ground joint union external to the furnace. 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. 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. If desirable an 1/8 inch NPT tap must be installed in the gas line to the unit for use when measuring the gas supply pressure. The tap should be readily accessible for service use. A drip leg should be installed in the vertical pipe run to the unit. Table 5 lists gas flow capacities for standard pipe sizes as a function of length in typical applications based on nominal pressure drop in the line.

IMPORTANT NOTES:

1. Gas piping must not be run in or through air ducts, chimneys, gas vents, elevator shafts, etc.

2. Compounds used on threaded joints of gas piping must be resistant to the actions of liquefied petroleum gases.

3. The main manual gas valve and main power disconnect to the furnace must be properly labeled by the installer in case emergency shutdown is required.

Upflow Models- Left Side Entry

Some utilities

require Shut-Off

Valve to be

4 to 5 feet

above floor

Dripleg

Shut-Off Valve

Automatic Gas

Valve (with manual

shut-off)

Ground Joint Union

Figure 22. Typical Gas Service Connection Upflow

Manifold

Burner Assembly

Downflow Models- Right Side Entry

Shut-Off Valve

Automatic Gas

Valve (with manual

shut-off)

Ground Joint Union

Burner Assembly

Manifold

Figure 23. Typical Gas Service Connection

Some utilities

require Shut-Off

Valve to be

4 to 5 feet

above floor

Dripleg

Page 21

LEAK CHECK

WARNING:

Fire or Explosion Hazard

Failure to follow the safety warnings exactly could result in serious injury, death or property damage.

Never test for gas leaks with an open flame. Use a commercially available soap solution made specifically for the detection of leaks to check all connections. A fire or explosion may result causing property damage, personal injury or loss of life.

High Altitude Application

High altitude application with this furnace can be field performed by a simple adjustment of manifold pressure, and if necessary changing the orifices. The changes required depend on the installation altitude and the heating value of the gas. The gas heating value based on sea level can be obtained from your local gas utility. The heating value of gas at high altitude is always lower than the sea level heating value. The heating values used in Tables 6 & 7 are based on sea level values.

Natural Gas High Altitude Conversion

All factory shipped furnaces are ready to operate between zero and 4999 ft. above sea level. For higher altitudes (between 5000 and 10,000 ft. above sea level), conversion can be achieved simply by adjusting the furnace manifold pressure as shown in Table 6.

After the gas piping to the furnace is complete, all connections must be tested for gas leaks. To check for leaks in gas piping systems, use only a soap and water solution or other approved method.

CAUTION:

Do not use matches, lighters, candles, or other sources of open flame to check for gas leaks.

IMPORTANT NOTE: When pressure testing the gas supply lines at pressures greater than 1/2 psig (14 inch W.C.), the furnace must be disconnected from the gas supply piping system 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.), the furnace must be isolated from the gas supply line by closing the manual shut-off valve.

Conversion

Conversion of this furnace to use LP/propane gas must be made by qualified service personnel, using only approved parts.

WARNING:

This furnace was equipped at the factory for use with natural gas only. A special kit, supplied by the manufacturer, is required to convert the furnace to operate on LP/propane gas. Failure to use the proper conversion kit can cause fire, explosion, property damage, carbon monoxide poisoning, personal injury, or death.

LP/Propane Gas Sea Level and High Altitude Conversion

IMPORTANT NOTE: When converting a low NOx furnace

from natural gas to LP/Propane, it is necessary to remove the NOx baffles from the furnace.

Conversion of this furnace to utilize LP/propane gas must be made by qualified service personnel, using factory authorized or approved parts. Conversion to LP/propane gas can be accomplished by first replacing the natural gas orifices with the appropriate LP/propane orifices shown in Table 8 or 9. Note: for installations between zero and 5000 ft. above sea level, a #54 or #55 drill size orifice should be used depending upon the rated firing rate of the unit (see

CAPA CITY OF BLACK I RON G AS P IP E (CU . FT . P ER HO UR)

FOR NATURAL GAS (SP ECI FIC GRAVITY - 0. 60)

NOMINAL LENGTH OF PIPE RUN

BLACK IRON (feet)

PIPE DIAMETER

(in.) 1020304050607080

1/2 130 90 75 6 5 55 50 45 40

3/4 280 190 150 130 115 105 95 90

1 520 350 285 245 215 195 180 170

1 1/4 1050 730 590 500 440 400 370 350

1 1/2 1600 1100 890 760 670 610 560 530

The cubic feet per hour listed in the table above must be greater than the cubic fee per hour of gas flow required by the furnace.

To determine the cubic feet per hour of gas flow required by the furnace, divide the input rate of the furnace by the heating value of the gas:

Cu bic Fe et Per H our R equi red = Inp ut To Fu rnace (Btu/h r)

He ating Value o f Gas (Btu/C u. Ft.)

Table 5. Capacity of Black Iron Gas Pipe

(cu. ft. per hour) for Natural Gas (specific gravity = .60)

Page 22

)

For a Natural Gas Sea Level Heating Value of 800 to 899 Btu/cu.ft.

Elevation (feet above sea level)

zero to

1999

Manifold Pressure Setting (in WC)

For a Natural Gas Sea Level Heating Value of 900 to 999 Btu/cu.ft.

Manifold Pressure Setting (in WC)

For a Natural Gas Sea Level Heating Value of 1,000 to 1,100 Btu/cu.ft.

Manifold Pressure Setting (in WC)

Table 6. Manifold Pressure (in WC) for Natural Gas at Various Altitudes

3.5 3.5 3.5

zero to

1999

3.5 3.5 3.5

zero to

1999

3.5 3.5

2000 to

4999

Elevation (feet above sea level)

2000 to

4999

Elevation (feet above sea level)

2000 to

4999

5000 to

5999

5000 to

5999

5000 to

5999

3.0 2.8 2.5

Elevation (feet above sea level

0 to 2,000 to 5,000 to 6,000 to 8,000 to

1,999 4,999 5,999 7,999 10,000

Manifold Press ure in (WC) for an LP Gas Heating Value of 2,500 Btu/hr.

10.0 8.5 10.0 9.0 8.5

6000 to

7999

3.5 3.0

6000 to

7999

3.2 2.8

6000 to

7999

8000 to

10000

8000 to

10000

8000 to

10000

Table 7. Manifold Pressure (in WC) for LP/Propane Gas at Various Altitudes

Table 8 or 9). However for installations above 5000 ft. above sea level, a # 55 or #56 drill size orifice should be used. After changing the orifices, use Table 7 to determine the appropriate manifold pressure for your installation.

Conversion to LP/propane, sea level, and high altitude is detailed in the installation instructions provided with the conversion kit. Approved conversion kits are listed below

United States LP/Propane Gas Sea Level and High Altitude Conversion Kit - P/N 904090

This kit is for LP/propane conversion in the United States at altitudes between zero and 10,000 ft. above sea level. Follow the installation instructions supplied with the kit for proper installation.

Canadian LP/Propane Gas Sea Level and High Altitude Conversion Kit - P/N 904091

This kit is for LP/propane conversions in Canada at altitudes between zero and 4500 ft. above sea level. Follow the installation instructions supplied with the kit for proper installation.

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 WIRING

General

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

For Canadian installations the electrical connections and grounding shall be done in accordance with the current Canadian Electrical Code (CSA C22.1, Part 1 and/or local codes). If any of the original wire as supplied with the furnace must be replaced, it must be replaced with wire having a temperature rating of at least 105°C. Refer to the furnace nameplate and Table 10 for electrical requirements.

Page 23

Furnace Rating Furnace Rating

Plate Input (Btu/h)

Orifice Drill Size Orifice Drill Size

Nat LP

Plate Input (Btu/h)

72000 43 54 72000 43 55

96000 43 54 96000 43 55 120000 43 54 120000 43 55 144000 43 54 144000 43 55

Nat LP

Table 8. Natural and LP Gas Orifice Sizes for Elevations

between zero and 4999 ft. Above Sea Level

Line Voltage Wiring

The line voltage (115 volt) to the furnace must be supplied from a dedicated branch circuit containing the correct fuse or circuit breaker for the furnace. (See Table 10.) An electrical disconnect must be installed to be readily accessible from and located within sight of the furnace. (See the Wiring Diagram label in the furnace and Figure 22.)

CAUTION:

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

Verify proper operation after servicing.

Furnace Furnace Cabinet Nominal Maximum Minimum Maximum Minimum Maximum

Model Number Input Width Electrical Operating Operating Furnace Wire Fuse or Circuit

*RA/*RK (Btu/hr) (in.) Supply Voltage Voltage Amperes Gauge Breaker Amps*

Table 9. Natural and LP gas Orifice Sizes for Elevations

between 5000 and 10,000 ft. Above Sea Level

The furnace cabinet must have an uninterrupted, unbroken ground to minimize injury should an electrical fault condition occur. The controls used in this furnace require an earth ground to operate properly. Acceptable methods for grounding are electrical wire or conduit approved for electrical ground service. Do not use gas piping as an electrical ground.

IMPORTANT NOTE: Proper line voltage polarity must be maintained in order for the control system to operate correctly. Verify that the incoming neutral line is connected to the white wire and the incoming “hot” line is connected to the black wire. These furnaces will not operate unless the polarity and ground are properly connected. See Figure

22.

072(†)-16 72,000 19.75 115-60-1 127 103 9.0 14 15 096(†)-12 96,000 19.75 115-60-1 127 103 7.1 14 15 096(†)-16 96,000 19.75 115-60-1 127 103 9.0 14 15 096(†)-20 96,000 22.50 115-60-1 127 103 12.2 12 20 120(†)-16 120,000 19.75 115-60-1 127 103 9.0 14 15 120(†)-20 120,000 22.50 115-60-1 127 103 12.2 12 20 144(†)-20 144,000 22.50 115-60-1 127 103 12.2 12 20

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

Thermostat Wire Gauge Recommended Thermostat Wire Length

2-wire 4 or 5-wire

(heating) (cooling)

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

Table 10. Electrical Data

Page 24

Low Voltage Wiring

Install the thermostat per the manufacturer’s instructions. The low voltage (24 volt) connections from the thermostat are made at the terminal strip on the integrated control in the furnace. See Figure 18 for the proper connections for heating only (two-wire) and heating/cooling (four-wire) applications. The recommended minimum wire gauge for thermostat wiring is shown in Table 10.

The thermostat must not be installed on an outside wall or any other location where its operation may be adversely affected. Adverse affects include radiant loading from fireplaces, sunlight, or lighting fixtures, and convective loading from warm air registers or electrical appliances.

To determine the heat anticipator setting either:

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

2. Measure the current flow on the thermostat R-W circuit after the circulating blower motor has started.

Set the heat anticipator according to the thermostat manufacturer’s instructions for heat anticipator settings.

START-UP AND ADJUSTMENTS

General

Prior to start-up, verify that:

a switch to defeat its function. If a switch reopens on start-up, DO NOT reset the switch without identifying and correcting the fault condition which caused the switch to trip.

5. The blower door is in place, closing the door switch in the line voltage circuit.

6. The gas line has been purged and all connections are leak tight.

Start-up Procedures

After all of the above checks have been made:

1. Set the thermostat to the lowest setting.

2. Close the disconnect(s) to provide line voltage to the furnace.

3. Follow the procedures given on the operating instruction label attached to the furnace.

4. Set the thermostat above room temperature and verify the operating sequence. (See the Sequence of Operation).

5. After the furnace has run for approximately five minutes, set the thermostat below room temperature and verify steps (9) through (11) of the Sequence of

Operation.

1. The line voltage power leads are securely connected, that the polarity of the connections is correct, and that the furnace is properly grounded.

2. The thermostat wires (R, W, Y, and G) are securely connected to the correct leads on the terminal strip of the circuit board.

3. The gas line service pressure does not exceed 10.0 in. water column (0.36 psig), and is not less than 4.5 in. water column (0.16 psig) for natural gas. For LP gas the line service pressure must not exceed 14 in. water column (0.51 psig), and must not be less than

11.0 in. w.c. (0.40 psig).

4. The roll-out and vent safety manual reset switches are closed. If necessary, press the red button to reset a switch. DO NOT install a jumper wire across

Field Supplied Fused Service

Panel

Black (Hot)

White (Neutral)

Green or Bare

(Ground)

Ground

Field Supplied

Panel Connector

Black White

Field Supplied Disconnect Within Sight of Furnace

Black White

Ground

Figure 22. Line Voltage Field Wiring

Verifying and Adjusting Firing Rate

The firing rate must be verified for each installation to prevent over-firing the furnace.

IMPORTANT NOTE: The firing rate must not exceed the rate shown on the furnace rating plate. At altitudes above 2000 feet it must not exceed that on the rating plate less 4% for each 1000 feet.

Follow the procedure below to determine the firing rate.

1. Shut off all other gas fired appliances.

2. Start the furnace and allow it to run for at least three minutes.

Field Line Voltage

Black White

Ground

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

Wiring

Factory Line Voltage Wiring

Page 25

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 11.

5. Multiply the gas flow rate in cubic feet per hour by the heating value of the gas in Btu per cubic foot to obtain the firing rate in Btu per hour. Example:

• Time for 1 revolution of a gas meter with a 1 cubic

foot dial = 40 seconds.

• From Table 11 read 90 cubic feet per hour of gas.

• Heating value of the gas (obtained from gas

supplier) = 1040 Btu per cubic foot.

• Firing rate = 1040 x 90 = 93,600 Btuh.

6. Adjustments to the firing rate can be made by adjusting the gas manifold pressure. See the High Altitude Application section for additional information of firing rate at elevations above 2000 ft.

The manifold pressure must be set to the appropriate value for your installation. Refer to either Table 6 for natural gas or Table 7 for LP/propane gas to verify the manifold pressure setting required for your particular installation. To adjust the manifold pressure, remove the regulator cap and turn the adjusting screw clockwise to increase pressure or counterclockwise to reduce pressure. Replace the regulator cap after adjustments are complete.

CAUTION:

Do not re-drill the burner orifices. If the orifice size must be changed, use only new orifices.

Configuring the Blower

The variable speed blower kit is equipped with a microprocessor-controlled variable speed motor that is pre-programmed to deliver optimum airflow in a variety of conditions and system configurations. Before operation, the variable speed blower kit must be configured to match the unit with the system, system options, and climatic conditions. With the variable speed blower kit installed and configured properly, the furnace will respond directly to gradually change speed in response to changes in system variables such as the thermostat settings, duct static, filter, etc. The variable speed blower kit is configured by setting the 7 switches located on the motor control board as described below.

IMPORTANT:

The variable speed blower kit has been designed to give the installer maximum flexibility to optimize system performance, efficiency, and comfort. Because there are so many ways to configure the kit it is important to read and follow these instructions carefully.

Selecting Heat Airflow

The heating airflow is selected by setting switches 5, 6 , and 7 as displayed on Figure 21. Refer to Table 2 and select a nominal rise based on the furnace nominal efficiency and input. Follow the table column up to find the switch setting and nominal air-flow. Be sure that the selected rise is within the specification of the furnace as shown on the furnace rating label. For single stage cooling, follow the high airflow column.

A/C Condensing Unit

Condensing Unit

Control Box

R Y G W

Connect

R & W

For

Heating

Only

Room

Thermostat

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

FIELD WIRING

Low Voltage Connections

R C Y G W

COM

3 Amp

24 V

EAC

HUM

Neutrals

Unused Motor Leads

HUM

63 52 41

Blower Off

Fuse

Flame Signal Light

Status Light

HEAT

M1M2M3

Timing

(Yellow)

(Red)

COOL

EAC

XFMR

6090120

180

Figure 23. Low Voltage Field, Four-wire Heating/Cooling Applications

Page 26

Selecting The Cooling/Heat Pump Airflow

In order to select the appropriate airflow for AC and HP operation the nominal system capacity must be known. The nominal system capacity is ALWAYS the nominal capacity of the outdoor unit. In some cases the nominal system capacity is not the same as the nominal capacity of the indoor coil.

The cooling/heat pump airflow is selected by setting switches 1 through 4 on the motor control board located in the blower control panel. All airflows for other modes of operation (except gas heat) are determined by this setting. Table 1 shows the airflow values versus the airflow selector switch settings, and the range of airflow settings recommended for each nominal system capacity.

NOTE: The CFM values listed on Table 2 are not dependent on duct static pressure. The motor automatically compensates for changes in duct static pressure (within the limits of the motor).

For Two Stage Cooling:

The furnace is supplied with the yellow "Y1" and blue "Y2" connections attached to the control board. When installing this furnace with a two stage condensing unit, remove the blue "Y2" wire from the control board and connect to the

thermostat. Connect a field supplied wire from the yellow "Y1" to the thermostat and the condensing unit, and another wire from "Y2" on the thermostat to "Y2" on the condenser. (See Figure 23).

For maximum capacity and energy efficiency, generally, a selection at or near the top of the CFM range for that nominal capacity is best. For maximum dehumidification, select an airflow near the middle or bottom of the CFM range for that nominal capacity.

IMPORTANT NOTE: When installing a 2-stage heat pump with a fossil fuel kit, the transformer in the furnace MUST be upgraded to one with a 60VA rating (Part No. 904077).

NOTE: If coil icing is observed, the cooling/heat pump airflow selected may be too low. Double-check to be sure the setting selected is within the range shown in Table 1. Also check to be sure the system is properly charged (see outdoor unit installation instructions). If icing continues to occur, raise the selected airflow one or two steps.

Verifying and Adjusting Temperature Rise

Verify the temperature rise through the furnace is within the range specified on the furnace rating plate. Temperature

GAS FLOW RATE (CUBIC FEE T PE R HOUR)

TIME FOR TIME FOR

ONE REVOLUTION ONE REVOLUTION

(SECONDS) 1 5 10 (SECONDS) 1 5 10

10 360 1800 3600 66 55 273 545 12 300 1500 3000 68 53 265 529 14 257 1286 2571 70 51 257 514 16 225 1125 2250 72 50 250 500 18 200 1000 2000 74 49 243 486 20 180 900 1800 76 47 237 474 22 164 818 1636 78 46 231 462 24 150 750 1500 80 45 225 450 26 138 692 1385 82 44 220 439 28 129 643 1286 84 43 214 429 30 120 600 1200 86 42 209 419 32 113 563 1125 88 41 205 409 34 106 529 1059 90 40 200 400 36 100 500 1000 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

CUBIC FEET PER REVOLUTION OF

METER

CUBIC FEET PER REVOLUTION OF

METER

Table 11. Gas Flow Rate

Page 27

rises outside the specified range could result in premature heat exchanger failure.

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

TWO STAGE CONDENSING UNIT

THERMOSTAT

CONDENSING

UNIT

YELLOW

123456789

Figure 23. Connections for Two Stage Cooling

REMOVE BLU

WIRE FROM

Y TERMINAL

FURNACE

BOARD

BLUE

10111213141516

WARNING:

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

Verifying Burner Operation

To verify operation of the burners, make sure that the furnace door is in place and that there is power to the furnace. Set the thermostat to a temperature above room temperature and observe the ignition sequence. The burner flame should carry over immediately between all burners. The flames should be blue, without yellow tips. Flames should extend from each burner without lifting off, curling, or floating. After verifying satisfactory flame characteristics, set the thermostat to a temperature below room temperature and verify that the burner flame extinguishes completely

Verify Operation of the Supply Air Limit Switch

To verify operation of the supply air limit switch, make sure that the blower door is in place and that there is power to the furnace. Block the return airflow to the furnace by installing a close-off plate in place of or upstream of the filter(s). Set the thermostat to a temperature above room temperature and verify that the Sequence of Operation is as described in these instructions. The limit switch should function to turn off the gas valve within approximately four minutes (the exact time depending on the efficiency of the close-off in blocking the return air to the furnace). The combustion blower should continue to run when the limit switch opens. Remove the close-off immediately after the limit switch opens. If the furnace operates for more than four minutes with no return air, set the thermostat to a

Blue Y2

Yellow (short) Y1

Red R

Grey C

Green G

12 3 4 765

AC/HP

SPEEDS

HTG

Figure 24. Connections to Furnace Circuit Board

Yellow (long) GAS VALVE

Black L1

White NEUTRAL

5711

To Motor Plugs

Page 28

temperature below room temperature, shut off the power to the furnace, and replace the limit switch.

DESCRIPTION OF COMPONENTS

Figure 27 shows the location of each of the functional components described below. Also, refer to the Sequence of Operation Section of this manual . If any component of the furnace must be replaced, use only factory authorized replacement parts. See the Replacement Parts List for the factory authorized replacement for each component.

Flame Sensor

The flame sensor acts to prove that flame has carried over from the igniter to the opposite end burner. If no flame is sensed, the furnace will shut down within 7 seconds of ignition.

Flame Roll-Out Switch

The flame roll-out switch verifies that the burner flames are drawn into the heat exchanger tubes. If the burner flames are not properly drawn into the heat exchanger, the flame

roll-out switch will open. The circulating air blower (and combustion blower, if connected) will continue to operate if the flame roll-out switch opens.

Gas Valve

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

Pressure Switch

The pressure switch verifies that the inducer is drawing the combustion gases through the heat exchanger.

Supply Air Limit Switch

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

Vent Safety Switch

The vent safety switch shuts the furnace down if the vent becomes blocked or restricted.

Common

Leads

Connect

Neutral

Lead of

Electronic

Air Cleaner

and/or Humidifier

Here.

R C Y G W

EAC

HUM

Humidifier Tap

(.5A@ 120 VAC)

COM

24 V

Neutrals

3 Amp Fuse

Unused Motor

Leads

M1M2M3

HUM

Flame Signal Light (Yellow)

Status

Light (Red)

COOL

HEAT

These motor speed taps are

not used for variable speed models

XFMR

EAC

Electronic Air Tap

(.5A@ 120 VAC)

Figure 25. Integrated Control

Page 29

MAINTENANCE

It is recommended that the furnace be checked yearly. At a minimum, this check should include the following items.

WARNING:

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

WARNING:

Products of combustion must not be allowed to enter the living space. Failure to prevent products of combustion from being circulated into the living space can create potentially hazardous conditions including carbon monoxide poisoning that could result in personal injury or death.

Vent System

Check the vent pipe 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.

Air Filter(s)

The installer must provide a high velocity filter and rack for a filter in the return air duct adjacent to the furnace, or in a return air grill to the furnace. Filters should be changed or cleaned monthly during the heating season. New or newly renovated homes may require more frequent changing until the construction dust has been removed.

Filters for side return and bottom return applications are available from your local distributors.

Lubrication

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

Blower Compartment

The blower compartment should be cleaned monthly during the heating and cooling seasons to remove any dirt and lint that may have accumulated in the compartment or on the blower and motor. Dirt and lint can create excessive loads on the motor resulting in higher than normal operating temperatures and shortened service life.

Heat Exchanger and Burner Maintenance

The furnace should operate for many years without soot buildup in the flue passageways, however, the flue passageways, the vent system, and the burners should be inspected and cleaned (if required) by a qualified serviceman annually to ensure continued safe operation. Particular attention must be given to identify deterioration from corrosion or other sources.

WARNING:

Never operate the furnace without a filter in place. Dust and lint in the return air can build up on internal components, resulting in loss of efficiency, equipment damage, and possible fire.

Air filter(s) are not supplied with the furnace as shipped from the factory.

WARNING:

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

Page 30

For Upflow and Downflow Residential Furnace with Variable Speed Blower

BLACK

WHITE

120 V

180 120

90 60

24 V

WHITE W/ BLK STRIPES

BLK W/ WHITE STRIPES

BROWN

RED

YELLOW

FLAME SENSOR

GAS

VALVE

PRIMARY

IGNITOR

BLACK

INDUCER

BLUE

SWITCH

PRESSURE

VENT

(ALL MODELS)

SAFETY SWITCH

SWITCH

(ALL MODELS)

FLAME ROLL-OUT

SUPPLY AIR

LIMIT SWITCH

(ALL MODELS)

BLACK

WHITE

ORANGE ORANGE BLUE BLUE

WHITE (NEUTRAL)

BLOWER DOOR

SWITCH

GREEN

GROUND

BLACK 120V

TRANSFORMER

IS USED, SEE INSERT A

IF TWO STAGE CONDENSING UNIT

Legend

Factory Wiring:

Field Wiring

Low Voltage

High Voltage

THERMOSTAT

1234567

AIR CONDITIONER

CONDENSING UNIT

13 11 7 5

GREY

RED

BLUE

BROWN

YELLOW

123456789

VARIABLE

RED

ORANGE

10111213141516

SPEED

MOTOR

BLOWER

GREY

YELLOW

WHITE

BLUE

GREEN

YELLOW

replaced, it must be replaced with wiring material having a

temperature rating of at least 105˚ C.

appropriate heating and cooling speed settings for your application.

NOTES:

1. Use copper conductors only.

2. If any of the original wire as supplied with the furnace must be

BLACK

WHITE

VARIABLE SPEED

BLOWER CONTROL BOX

POWER FACTOR

CORRECTION CHOKE

12345

RED

LIGHT

STATUS

1 FLASH

2 FLASHES

3 FLASHES

FAULT CONDITION

Power On

Limit Circuit Open or External Load On "W"

Pressure Switch is Open with Inducer On

Pressure Switch is Closed with Inducer Off

BOARD

FURNACE

WIRE FROM

Y TERMINAL

REMOVE BLUE

THERMOSTAT

UNIT

CONDENSING

INSERT A: TWO STAGE CONDENSING UNIT

OFF

Continuous

4 FLASHES

5 FLASHES

Ignition Failure (Check Ground)

False Flame or Gas Valve Relay Shorted

Power Off

115 VAC & Neutral Reversed or no Ground

thermostat terminals after making the field thermostat connections.

3. Refer to the Installation Instructions provided with the furnace for the

4. Ensure that wires from the blower remain connected to the board

Flash

LIGHT

FLAME

YELLOW

Continuous

Low Flame Sensor Signal

Flame Present

FAULT CONDITION

16 15

BLUE

13 12 11

10 9 8 7 6 5 4 3

YELLOW

Figure 26. Wiring Diagram for Upflow and Downflow Models with Variable Speed Blower

Page 31

Cleaning Of Flue Passages

If the flue passages must be cleaned, follow the steps below. See Figure 27 for component location and identification.

1. Shut off the gas supply to the furnace either 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 louvered door from the furnace.

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

5. Disconnect the wires from the gas valve, igniter, flame sensor, combustion air motor, flame roll-out switch, blocked vent switch, over-temperature limit switch, pressure switch.

6. Remove the silicone rubber tube from the collector pan.

7. For *RA models: Remove the screws that hold the vent control assembly to the top panel.

8. Remove the nuts that hold the combustion air motor to the collector pan, and remove the complete combustion air blower and combustion tube assembly. BE CAREFUL NOT TO BREAK THE

SEALS AT EACH END OF THE COMBUSTION AIR TUBE.

9. Remove the screws that hold the collector pan in place, and remove the collector pan from the furnace.

10. Using wrenches, separate the ground-joint union in the gas supply piping at the furnace.

11. Remove the piping between the gas valve and the ground-joint union, if necessary.

CAUTION:

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

Upflow Models

12. Remove the screws that hold the burner assembly in place and remove the burner assembly. BE

EXTREMELY CAREFUL NOT TO DAMAGE THE IGNITER WHILE REMOVING THE BURNER ASSEMBLY.

Downflow Models

1 Igniter 2 Flame Sensor 3 Gas Valve 4 Roll-Out

Switch(s)

5 Pressure

Switch

6 Control Board 7 Blower Door

Switch

8 Vent Assembly

(Upflow Models)

9 Vent Switch

10 Low Voltage

Transformer 11 Burner Assembly 12 Supply Air Limit Switch 13 Blower Assembly 14 Inducer

Figure 27. Location of Major Components

4 1

15 Combustion Tube

w/insulation (Downflow Models)

16 Vent Transition

Assembly (Downflow Models)

Page 32

INSTALLATION/PERFORMANCE CHECK LIST

LOCATION __________________________ CITY _____________________________ STATE _______

INSTALLER __________________________ CITY _____________________________ STATE _______ UNIT MODEL NUMBER _______________________ UNIT SERIAL NUMBER _______________________

Minimum Clearances per Table 3? __________

Electrical Connections tight? _______________ Line Voltage Polarity correct? ______________ Supply Voltage: _____________ Volts Blower Motor HP: ___________

FUEL TYPE: Natural Gas __________ LP/Propane ______ Gas Piping Connections leak-tested? ________ Gas Line Pressure: _________ (in. water column, with furnace operating) Manifold Pressure: _________ (in. water column, with furnace operating) Is there adequate fresh air supply for combustion and ventilation? __________

Furnace Input: _________________ (Btuh) Supply Air Temperature: _________ (° F) Return Air Temperature: _________ (° F) Temperature Rise: _____________ (° F)

Are Flue Connections tight? _________________ Is there Proper Draft? ______________________ Is Vent free from restrictions? ________________

Is the Filter(s) secured in place? ______________ Is the Filter(s) clean? _______________________

Has the Thermostat been calibrated? __________ Is the Thermostat level? ____________________ Is the Heat Anticipator Setting correct? _________

Has the Owner's Information been reviewed with the homeowner? __________________________

Has the Literature Package been left near the furnace? ________________________________

O'Fallon, MO

¢708275=¤

708275A

708275A (Replaces 7082750)

Specifications and illustrations subject to change

without notice and without incurring obligations.

Printed in U.S.A. (09/03)