• PROPOSITION 65 WARNING: This product
contains chemicals known to the state of
California to cause cancer, birth defects or
other reproductive harm.
• This furnace is not approved for installation
in mobile homes. Installing this furnace in
a mobile home could cause fi re, property
damage, and/or personal injury.
ATTENTION INSTALLERS:
It is your responsibility to know this product better than your
customer. This includes being able to install the product according
to strict safety guidelines and instructing the customer on how to
operate and maintain the equipment for the life of the product.
Safety should always be the deciding factor when installing this
product and using common sense plays an important role as well.
Pay attention to all safety warnings and any other special notes
highlighted in the manual. Improper installation of the furnace
or failure to follow safety warnings could result in serious injury,
death, or property damage.
These instructions are primarily intended to assist qualifi ed
individuals experienced in the proper installation of this appliance.
Some local codes require licensed installation/service personnel
for this type of equipment. Please read all instructions carefully
before starting the installation. Return these instructions to the
customer’s package for future reference.
WARNING:
FIRE OR EXPLOSION HAZARD
• Failure to follow safety warnings exactly
could result in serious injury or property
damage.
• Installation and service must be performed
by a qualifi ed installer, service agency or
the gas supplier.
• Do not store or use gasoline or other
fl ammable vapors and liquids in the
vicinity of this or any other appliance.
WHAT TO DO IF YOU SMELL GAS
• Do not try to light any appliance.
• Do not touch any electrical switch; do not
use any phone in your building.
• Leave the building immediately.
• Immediately call your gas supplier from a
neighbor’s phone. Follow the gas supplier’s
instructions.
• If you cannot reach your gas supplier, call
the fi re department.
DO NOT DESTROY THIS MANUAL.
KEEP IN A SAFE PLACE FOR FUTURE REFERENCE.
Page 2
TABLE OF CONTENTS
SAFETY INFORMATION .............................................3
REQUIREMENTS AND CODES ..................................4
GENERAL INSTRUCTIONS ........................................4
Combustion Air Quality ...........................................4
Operation of Furnace During Construction .............5
Installation in a Garage ...........................................5
Cleaning of Burners ..............................................23
Cleaning of Flue Passages ...................................23
Heat Exchanger and Burner Maintenance ............24
SAFETY INFORMATION
Safety markings are used frequently throughout this
manual to designate a degree or level of seriousness and
should not be ignored. WARNING indicates a potentially
hazardous situation that if not avoided, could result in
personal injury or death. CAUTION indicates a potentially
hazardous situation that if not avoided, may result in minor
or moderate injury or property damage.
Gas Information .....................................................32
Table 6 - Gas Flow Rates.................................32
Table 7 - Gas Pipe Capacities .........................32
Table 8 - High Altitude Deration Chart for
Propane Gas .....................................33
Table 9 - Natural Gas Heating Values ..............33
Table 10 - High Altitude Deration Chart for
Nat. Gas - High Heating Values .......34
Table 11 - High Altitude Deration Chart for
Nat. Gas - Low Heating Values........34
Location of Furnace Components .........................35
Figure 19 - Upfl ow/Horizontal Gas Furnace
Components ..................................35
Figure 20 - Downfl ow Gas Furnace
Components ..................................35
INSTALLATION/PERFORMANCE CHECKLIST .......36
WARNING:
The safety information listed below must be
followed during the installation, service, and
operation of this furnace. Failure to follow safety
recommendations could result in possible
damage to the equipment, serious per
injury or death
• Use only with type of gas approved for this furnace.
Refer to the furnace rating plate.
• Install this furnace only in a location and position as
specifi ed in Table 1 (page 6).
• Provide adequate combustion and ventilation air to the
furnace space as specifi ed on pages 7 - 9.
• Combustion products must be discharged outdoors.
Connect this furnace to an approved vent system only,
as specifi ed on pages 9 - 10.
• Never test for gas leaks with an open fl ame. Use a
commercially available soap solution to check all
connections. See page 15.
• This furnace is designed to operate with a maximum
external pressure rise of 0.5 inches of water column.
Consult Tables 4 - 5 (pages 28 - 30), and the rating
plate for the proper circulating air fl ow and temperature
rise. It is important that the duct system be designed to
handle the desired fl ow rate and temperature rise. An
improperly designed duct system can result in nuisance
shutdowns, and comfort or noise issues.
• When supply ducts carry air circulated by the furnace
to areas outside the space containing the furnace, the
return air shall also be handled by duct(s) sealed to
the furnace casing and terminating outside the space
containing the furnace. See page 11.
• This furnace may be used for temporary heating of
buildings or structures under construction. See the
guidelines listed on page 5.
• A gas-fi red furnace for installation in a residential garage
must be installed as specifi ed on page 5.
.
sonal
3
Page 4
REQUIREMENTS and CODES
This furnace must be installed in accordance with
these instructions, all applicable local building codes
and the current revision of the National Fuel Gas Code
(NFPA54/ANSI Z223.1) or the Natural Gas and Propane
Installation Code, CAN/CGA B149.1.
GENERAL INSTRUCTIONS
Combustion Air Quality
CAUTION:
Combustion air must not be drawn from a
corrosive atmosphere.
Additional codes listed below are for reference
purposes only and do not necessarily have
jurisdiction over local or state codes. Always
consult with local authorities before installing any
gas appliance.
Combustion and Ventilation Air
• US: National Fuel Gas Code (NFGC), Air for
Combustion and Ventilation
• CANADA: Natural Gas and Propane Installation Codes
(NSCNGPIC), Venting Systems and Air Supply for
Appliances
Duct Systems
• US and CANADA: Air Conditioning Contractors
Association (ACCA) Manual D, Sheet Metal and
Air Conditioning Contractors National Association
(SMACNA), or American Society of Heating,
Refrigeration, and Air Conditioning Engineers
(ASHRAE) Fundamentals Handbook
Electrical Connections
• US: National Electrical Code (NEC) ANSI/NFPA 70
• CANADA: Canadian Electrical Code CSA C22.1
Gas Piping and Gas Pipe Pressure Testing
• US: NFGC and National Plumbing Codes
• CANADA: NSCNGPIC
General Installation
• US: Current edition of the NFGC and the NFPA 90B.
For copies, contact the National Fire Protection
Association Inc., Batterymarch Park, Quincy, MA
02269; or American Gas Association, 400 N. Capitol,
N.W., Washington DC 20001 or www.NFPA.org
• CANADA: NSCNGPIC. For a copy, contact Standard
Sales, CSA International, 178 Rexdale Boulevard,
Etobicoke (Toronto), Ontario, M9W 1R3 Canada
To maximize heat exchanger life, the combustion air
must be free of chemicals that can form corrosive acidic
compounds in the combustion gases. The recommended
source of combustion air is to use outdoor air. However,
the use of indoor air in most applications is acceptable
except as listed:
• If the furnace is installed in a confi ned space, it is
required that the necessary combustion air come from
the outdoors by way of attic, crawl space, air duct, or
direct opening. For Installations in confi ned spaces,
see pages 7 - 8 for combustion air requirements.
• Installations in these locations may require outdoor air
for combustion, due to chemical exposures:
Commercial buildings
Buildings with indoor pools
Furnaces installed in laundry rooms
Furnaces installed in hobby or craft rooms
Furnaces installed near chemical storage areas
• Exposure to the following substances in the combustion
air supply may require outdoor air for combustion:
Permanent wave solutions
Chlorinated waxes and cleaners
Chlorine based swimming pool chemicals
Water softening chemicals
De-icing salts or chemicals
Carbon tetrachloride
Halogen type refrigerants
Cleaning solvents (perchloroethylene)
Printing inks, paint removers, varnishes, etc.
Hydrochloric acid
Cements and glues
Antistatic fabric softeners
Masonry acid washing materials
Safety
• US: (NFGC) NFPA 54–1999/ANSI Z223.1 and the
Installation Standards, Warm Air Heating and Air
Conditioning Systems ANSI/NFPA 90B.
• CANADA: CAN/CGA-B149.1 and .2–M00 National
Standard of Canada. (NSCNGPIC)
4
Page 5
Operation of Furnace During Construction
Installation in a Garage
CAUTION:
Failure to follow these instructions will void the
factory warranty and may signifi cantly reduce
the life or the performance of the furnace,
and/or result in other unsafe conditions. It is
the responsibility of the installing contractor
to insure these provisions are met.
Operating gas furnaces in construction environments can
cause a variety of problems with the furnace. Proper use
of commercial portable space heating equipment during
construction is recommended. This gas furnace may be
used during construction if it is not in violation of any
applicable codes and the following criteria are met:
• The installation must meet all applicable codes. The
furnace must be permanently installed according to
the instructions with the furnace including electrical
supply, gas supply, duct work and venting. The furnace
must be controlled by a thermostat properly installed
according to the instructions supplied with the furnace
and thermostat. The installation must include a properly
installed fi lter in the return air system with no by-pass
air. The fi lter must be inspected frequently and replaced
when necessary.
• Combustion air must be supplied from outside the
structure and located such that dust and gases
from construction activity are not introduced into the
combustion system.
• Provisions must be made to insure that condensate
does not freeze in the furnace or condensate drain lines
during operation and during idle times; for example,
overnight if turned off. (Condensing furnaces only)
• Before occupying the structure: The fi lter must be
replaced or cleaned, the duct work must be inspected
and cleaned of any construction debris, and the furnace
must be cleaned and/or repaired if found to be dirty,
damaged, or malfunctioning in any way by a qualifi ed
HVAC technician. The furnace shall be inspected and
approved by applicable local authority even if this
requires redundant inspections.
• Serial numbers for furnaces used during construction
must be submitted in writing (fax and email also
acceptable). This information will be used to track the
long-term affects of the use during construction on
furnaces. Proof of this submittal shall be available for
the fi nal inspection of the furnace prior to occupancy.
• This furnace is designed to operate with return air
temperatures in ranges normally found in occupied
residences, including setbacks. Minimum continuous
return temperature must not be below 60° F (15° C).
Occasionally a temporary return temperature of 55° F
(12° C) is acceptable. However, operation with a return
temperature below 55° F (12° C) is not allowed.
WARNING:
Do not place combustible materials on or
against the furnace cabinet or within 6 inches
of the vent pipe. Do not place combustible
materials, including gasoline or any other
fl ammable vapors and liquids, in the vicinity
of the furnace.
This gas-fi red furnace may be installed in a residential
garage with the provision that the burners and igniter
are located no less than 18 inches (457mm) above the
fl oor. The furnace must be located or protected to prevent
physical damage by vehicles.
Heating Load
The furnace should be sized to provide the design heating
load requirement. Heating load estimates can be made
using approved methods available from Air Conditioning
Contractors of America (Manual J); American Society of
Heating, Refrigerating, and Air Conditioning Engineers;
or other approved engineering methods. Excessive
oversizing of the furnace could cause the furnace
and/or vent to fail prematurely.
The ductwork should be appropriately sized to the capacity
of the furnace to ensure its proper airfl ow rating. For
installations above 2,000 ft., the furnace should have a
sea level input rating large enough that it will meet the
heating load after deration for altitude.
Clearances to Combustible Materials
This furnace is Design Certifi ed in the U.S. and Canada
by CSA International for the minimum clearances to
combustible materials listed in Table 1 (page 6). To obtain
model number and specifi c clearance information, refer
to the furnace rating plate, located inside of the furnace
cabinet.
Access for positioning and servicing the unit must be
considered when locating unit. The need to provide
clearance for access to panels or doors may require
clearance distances over and above the requirements.
Allow 24 inches minimum clearance from the
front of the unit. However 36 inches is strongly
recommended.
5
Page 6
INSTALLATION CLEARANCES to COMBUSTIBLE MATERIALS
For UPFLOW, HORIZONTAL & DOWNFLOW FURNACES
Left Side ...................................0 InchesVent ............................................. 1 InchTop ...........................................0 Inches
Right Side ................................0 InchesBack .........................................0 InchesFront.......................................4 Inches
UPFLOW APPLICATION
TOP
HORIZONTAL APPLICATION
SIDE
DOWNFLOW APPLICATION
TOP
†
TOP
LEFT SIDE
BOTTOM
†
Allow 24 in. minimum clearance for servicing. Recommended clearance is 36 in.
NOTE: The furnace is listed for installation on combustible or non-combustible fl ooring. However, wood is the only combustible
fl ooring allowed for installation. Downfl ow models must use the appropriate subase kit when installing over a wood fl oor
RIGHT SIDE
SIDE
Table 1. Minimum Clearances to Combustible Materials
WARNING:
BOTTOM
LEFT SIDE
BOTTOM
RIGHT SIDE
.
CARBON MONOXIDE POISONING HAZARD
Failure to follow the steps outlined below for each appliance connected to the venting system
being placed into operation could result in carbon monoxide poisoning or death. The following
steps shall be followed with each individual appliance connected to the venting system being
placed in operation, while all other appliances connected to the venting system are not in
operation:
1. Seal any unused openings in the venting system.
2. Inspect the venting system for proper size and horizontal pitch, as required in the National
Fuel Gas Code, ANSI Z223. 1/NFPA 54 or the CSA B149.1, Natural Gas and Propane Installation
Codes and these instructions. Determine that there is no blockage or restriction, leakage,
corrosion and other defi ciencies which could cause an unsafe condition.
3. As far as practical, close all building doors and windows and all doors between the space
in which the appliance(s) connected to the venting system are located and other spaces
of the building.
4. Close fi replace dampers.
5. Turn on clothes dryers and any appliance not connected to the venting system. Turn on
any exhaust fans, such as range hoods and bathroom exhausts, so they are operating at
maximum speed. Do not operate a summer exhaust fan.
6. Follow the lighting instructions. Place the appliance being inspected into operation. Adjust
the thermostat so appliance is operating continuously.
7. Test for spillage from draft hood equipped appliances at the draft hood relief opening after
5 minutes of main burner operation. Use the fl ame of a match or candle.
8. If improper venting is observed during any of the above tests, the venting system must
be corrected in accordance with the National Fuel Gas Code, ANSI Z223.1/NFPA 54 and/or CSA B149.1, Natural Gas and Propane Installation Codes.
9. After it has been determined that each appliance connected to the venting system properly
vents when tested as outlined above, return doors, windows, exhaust fans, fi replace
dampers and any other gas-fi red burning appliance to their previous conditions of use.
6
Page 7
COMBUSTION AIR REQUIREMENTS
General Information
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.
WARNING:
Furnace installation using methods other than
those described in the following sections must
comply with the National Fuel Gas Code (NFGC)
and all applicable local codes.
• Instructions for determining the adequacy of combustion
air for an installation can be found in the current revision
of the NFGC (ANSI Z223.1 / NFPA54). Consult local codes for special requirements. These requirements
are for US installations as found in the NFGC.
• The requirements in Canada (B149.1) are structured
differently. Consult with B149.1 and local code offi cials
for Canadian installations.
Provisions must be made during the installation of
this furnace that provide an adequate supply of air for
combustion.
CAUTION:
Exhaust fans, clothes dryers, fi replaces and
other appliances that force air from the house
to the outdoors can create a negative pressure
inside the house, resulting in improper furnace
operation or unsafe conditions such as fl ame roll
out. It is imperative that suffi cient air exchange
with the outdoors is provided to prevent
depressurization. Additional information about
how to test for negative pressure problems can
be found in the NFGC.
NOTE: Air openings on top of the furnace and openings in
closet doors or walls must never be restricted. If the furnace
is operated without adequate air for combustion, the fl ame
roll-out switch will open, turning off the gas supply to the
burners. This safety device is a manually reset switch.
DO NOT install jumper wires across these switches
to defeat their function or reset a switch without
identifying and correcting the fault condition.
If a switch must be replaced, use only the correct sized
part specifi ed in the Replacement Parts List provided
online.
The required sizing of these openings is determined by
whether inside or outside air is used to support combustion,
the method by which the air is brought to the space, and
by the total input rate of all appliances in the space. In
all cases, the minimum dimension of any combustion air
opening is 3 inches.
Air From Inside
If combustion air is taken from the heated space, the
two openings must each have a free area of at least one
square inch per 1,000 Btuh of total input of all appliances
in the confi ned space, but not less than 100 square
inches of free area (Figure 1). See example.
Example:
If the combined input rate of all appliances is less
than or equal to 100,000 Btuh, each opening must
have a free area of at least 100 square inches. If the
combined input rate of all appliances is 120,000 Btuh,
each opening must have a free area of at least 120
square inches.
Vent or
Chimney
NOTES:
Each opening must
be at least 100 sq. in.
or 1 sq. in. per 1,000
Btuh of total input rating,
whichever is greater.
Openings must start at
no more than 12 inches
from the top and bottom
of the enclosure.
A confi ned space is an area with volume less than 50
cubic feet per 1,000 Btuh of the combined input rates of
all appliances drawing combustion air from that space.
Furnace closets, small equipment rooms and garages are
confi ned spaces. Furnaces installed in a confi ned space
Figure 1. Combustion Air Drawn from Inside
Outdoor Air from a Crawl Space or Vented Attic
When the openings can freely exchange air with the
outdoors, each opening shall have a minimum free area
of 1 square inch per 4,000 Btuh of total appliance input.
The openings shall exchange directly, or by ducts, with
the outdoor spaces (crawl or attic) that freely exchange
with the outdoors (Figure 2, page 8).
7
Page 8
Ventilation louvers
Vent or
Chimney
Attic
Insulation
at each end of attic
Outlet air duct must be
at least 1 sq. in. per
4,000 Btuh of total
input rating. Must
Water
Heater
Furnace
extend above attic
insulation
Inlet air duct must be at
least 1 sq. in. per 4,000
Btuh of total input rating.
Crawl Space
Ventilated Louvers for
unheated crawl space
Figure 2. Combustion Air Drawn from a Crawl
Space or Vented Attic
Outdoor Air Using Vertical Ducts
If combustion air is taken from outdoors through vertical
ducts, the openings and ducts must have a minimum
free area of one square inch per 4,000 Btuh of total
appliance input. In installations drawing combustion air
from a ventilated attic, both air ducts must extend above
the attic insulation (Figure 3).
Vent or
Chimney
12" Max
-
-
-
-
-
-
-
-
-
-
-
See
Note
-
-
-
-
-
-
-
-
-
12" Max
Total Input Rating
(Btuh)
Water Heater
-
-
-
-
-
-
Air Duct
-
Furnace
-
-
-
-
-
-
-
-
Air Duct
-
Minimum Free Area
(Each Opening)
-
-
-
-
NOTE: Each
-
-
-
-
-
opening to
outside must
be at least 1
sq. in. per 2,000
Btuh of total
Outdoor Air Using Horizontal Ducts
If combustion air is taken from outdoors through horizontal
ducts, the openings and ducts must have a minimum free
area of one square inch per 2,000 Btuh of total appliance
input (Figure 4).
8
Air Directly Through An Exterior Wall
If combustion air is provided directly through an exterior
wall, the two openings must each have free area of at
least one square inch per 4,000 Btuh of total appliance
input (Figure 5).
to outside must be at
least 1 sq. in. per
4,000 Btuh of total
input rating.
Round Duct
Diameter
Figure 5. Combustion Air Drawn from Outside
Through an Exterior Wall
Page 9
Alternate Method of Providing Air from Outside:
If acceptable under local Codes, it is permitted to
provide outside air using one opening (See NFGC).
Generally, confi ned spaces must have two openings
in the space for combustion air. One opening must
be within 12 inches of the ceiling, and the other
must be within 12 inches of the fl oor. However, an
alternative method recently adopted by the NFGC
uses one opening within 12 inches of the top of the
space. This method may be used if it is acceptable
to the local codes.
The following conditions must be met:
1. The opening must start within 12” of the top of the
structure and connect with the out of doors through
vertical or horizontal ducts or be ducted to a crawl
or attic space that connects with the out of doors.
2. The opening must have a minimum free area of 1
sq. in. per 3,000 Btu per hour of the total input rating
of all equipment located in the enclosure.
3. The free area must not be less than the sum of all
the areas of the vent connectors in the enclosure.
Installation In An Unconfi ned Space
An unconfi ned space is an area including all rooms not
separated by doors with a volume greater than 50 cubic
feet per 1,000 Btuh of the combined input rates of all
appliances which draw combustion air from that space.
In general, a furnace installed in an unconfi ned space will
not require outside air for combustion. However, in homes
built for energy effi ciency (low air change rates), it may
be necessary to provide outside air to ensure adequate
combustion and venting, even though the furnace is
located in an unconfi ned space. See example.
Example:
A space with a water heater rated at 45,000 Btuh
input and a furnace rated at 75,000 Btuh requires a
volume of 6,000 cubic feet [50 x (45 + 75) = 6,000] to
be considered unconfi ned. If the space has an 8 foot
ceiling, the fl oor area of the space must be 750 square
feet (6,000 / 8 = 750).
VENTING REQUIREMENTS
WARNING:
Upon completion of the furnace installation,
carefully inspect the entire fl ue system both
inside and outside the furnace to assure it is
properly sealed. Leaks in the fl ue system can
result in serious personal injury or death due
to exposure of fl ue products, including carbon
monoxide.
• This furnace must be vented in compliance with
the current revision of the National Fuel Gas Code
(ANSI-Z223.1/NFPA54) and the instructions
provided below. Consult local codes for special
requirements.
• In Canada, venting shall conform to the requirements of
the current (CAN/CGA B149.1 or .2) installation codes.
Consult local codes for special requirements.
Category I Venting
This furnace is listed as a Category I vented appliance.
Category I furnaces generally operate with a slight
negative pressure (draft) and must be vented vertically or
near vertical. Additionally it is important to guard against
excessive condensation.
• Category I furnace installations must be connected to a
factory built chimney or vent complying with a recognized
standard, or a masonry or concrete chimney lined with
a lining material acceptable to the authority having
jurisdiction.
WARNING:
Venting into an unlined masonry chimney or
concrete chimney is prohibited. This may result
in improper draft and excess condensation
forming in the chimney.
• This furnace may be vented with a dedicated venting
system or common vented with other Category I
appliances. The vent system dimensions and material
must conform to the NFGC or local Codes. Generally,
this means using Type B vent pipe or a lined masonry
chimney. When consulting the vent sizing tables in the
NFGC, the MAX capacity of the vent must be greater
than the furnaces high fi re rate. The MIN capacity must
be lower than the low fi re rate. If the venting system
is inappropriate for the furnace, the venting system
will need to be modifi ed to comply with NFGC or local
codes. The minimum diameter of any vent pipe is 4
inches.
• The venting system should be designed to have the
minimum number of elbows or turns. All horizontal runs
shall slope upwards from the furnace at ¼ inch per
running foot of vent. Supports for the vent pipe must
9
Page 10
be installed a minimum of every fi ve feet along the vent
run to ensure no displacement after installation.Under
no circumstances shall any portion of the vent system
extend into or pass through any return air duct, supply
air duct, or plenum.
• Single wall vent connectors may be used under the
limited capacity ranges found in the vent sizing tables.
It is recommended that Type B double wall vent be
used for the connector whenever possible. An existing
masonry chimney should be inspected and relined if
necessary.
• In the U.S., this furnace must never be vented to
a chimney or fl ue that services a fi replace or other
appliance designed to burn solid fuel. If the furnace
vent is to be connected to a chimney serving a fi replace,
the fi replace must be sealed off from the chimney. In
Canada, common venting with a fi replace is permitted.
Consult B149.1 and your local code authority.
• Single wall metal vertical vents shall not be used for
Category I venting. The furnace vent, if metal, may be
insulated if local codes allow. Any part of the vent system,
metal vent only, not exposed to weather, but which are
exposed to temperatures below 35° F (1°C) must be
insulated to prevent condensation. All vent insulation
shall be foil backed fi berglass of one inch minimum
thickness.
• Sheet metal fasteners should be used to secure the vent
pipe to the furnace fl ue. However, the NFGC states that
alternative vent products may be attached according to
the vent manufacturers instructions.
• When an existing furnace is removed from a vent system
serving other appliances, the existing vent system may no
longer be sized to properly vent the remaining appliances.
An improperly sized venting system can result in the
formation of condensate, leakage, or spillage. The
existing vent system should also be checked to make
sure it remains in compliance with NFGC. If it isn’t, the
vent system must be brought into compliance before
installing the furnace.
Horizontal Venting
WARNING:
Horizontal vent systems must be sealed with
a high temperature sealant that can withstand
temperatures of 450° F. Recommended sealants:
Dow Corning Sealant 736 RTV; GE 106 RTV;
High Tech Ind., High TEMP RED.
This furnace is not approved for horizontal venting
without the use of an add-on power venter. Power venters
establish negative pressure in the vent piping and the
furnace operates as if connected to a Category I vertical
vent. The power venter is only for use when exhausting
through an exterior wall.
The power venter must be installed according to the
instructions provided by the power venter manufacturer
and applicable requirements of local codes. For Canadian
installations please refer to the Canadian Installation Code
(CAN/CGA-B149.1 or 2) and/or local codes.
The outlet of the vent must be at least 12 inches above
the highest expected snow accumulation.
Flexible Vent Systems
Flexible venting systems are approved for use providing
they are listed for the application and meet all local Code
requirements. These systems are primarily used to line
existing masonry chimneys. They must be sized to the
application according to the sizing tables in the National
Fuel Gas Code, including the required 20% reduction in
maximum capacity.
Flexible venting systems are permitted to be used as the
vent connector. However, great care must be taken to
ensure that there are no sags in the venting system which
could accumulate condensate. The fl exible vent system
must be supported at no more than 5 foot intervals and
maintain a minimum slope of ¼ inch per foot of horizontal
run.
10
Page 11
CIRCULATING AIR REQUIREMENTS
WARNING:
Do not allow combustion products to enter the
circulating air supply. Failure to prevent the
circulation of combustion products into the
living space can create potentially hazardous
conditions including carbon monoxide
poisoning that could result in personal injury
or death.
All return ductwork must be secured to
the furnace with sheet metal screws. For
installations in confi ned spaces, all return
ductwork must be adequately sealed. When
return air is provided through the bottom of the
furnace, the joint between the furnace and the
return air plenum must be air tight.
must be designed so that the return air supply to the
furnace is equal to the return air supply under normal,
indoor return air applications.
• When a cooling system is installed which uses the
furnace blower to provide airfl ow over the indoor coil,
the coil must be installed downstream (on the outlet
side) of the furnace or in parallel with the furnace.
• If a cooling system is installed in parallel with the
furnace, a damper must be installed to prevent chilled air
from entering the furnace and condensing on the heat
exchanger. If a manually operated damper is installed,
it must be designed so that operation of the furnace is
prevented when the damper is in the cooling position
and operation of the cooling system is prevented when
the damper is in the heating position.
• It is good practice to seal all connections and joints
with industrial grade sealing tape or liquid sealant.
Requirements for sealing ductwork vary from region to
region. Consult with local codes for requirements specifi c
to your area.
The surface that the furnace is mounted on must
provide sound physical support of the furnace
with no gaps, cracks or sagging between the
furnace and the fl oor or platform.
Return air and circulating air ductwork must
not be connected to any other heat producing
device such as a fi replace insert, stove, etc.
This may result in fi re, explosion, carbon
monoxide poisoning, personal injury, or
property damage.
Plenums and Air Ducts
• Plenums and air ducts must be installed in accordance
with the Standard for the Installation of Air Conditioning
and Ventilating Systems (NFPA No. 90A) or the
Standard for the Installation of Warm Air Heating and
Air Conditioning Systems (NFPA No. 90B).
• Tables 4 - 5 (pages 28 - 30) contain the maximum
airfl ow and temperature rise data for each furnace input
rate. If the maximum airfl ow is 1,600 CFM or more, it is
recommended that two openings be used for return air
on upfl ow furnaces. Downfl ow furnaces can only use
one return opening.
• It is recommended that the outlet duct contain a removable
access panel. The opening should be accessible when
the furnace is installed in service and shall be of a size
that smoke or refl ected light may be observed inside
the casing to indicate the presence of leaks in the heat
exchanger. The cover for the opening shall be attached
in such a manner as to prevent leaks.
• If outside air is used as return air to the furnace for
ventilation or to improve indoor air quality, the system
must be designed so that the return air is not less than
60° F (15° C) during operation. If a combination of indoor
and outdoor air is used, the ducts and damper system
Supply Air Connections
The supply air must be delivered to the heated space by
duct(s) secured to the furnace casing, running full size
and without interruption.
Upfl ow and Horizontal Furnaces
To attach the supply air duct to the furnace, bend the
furnace fl anges (Figure 17, page 27) upward 90° with a pair
of wide duct pliers. Position the duct on top of the furnace
and secure together with sheet metal screws. The screws
must penetrate the sheet metal casing and furnace fl ange.
Tape or seal all seams if required by local code.
Downfl ow Furnaces
To attach the supply air duct to the downfl ow furnace,
position the furnace over the duct and secure together
with sheet metal screws. The screws must penetrate the
duct and furnace casing.
Return Air Connections
In applications where the supply ducts carry heated air
to areas outside the space where the furnace is installed,
the return air must be delivered to the furnace by duct(s)
secured to the furnace casing, running full size and without interruption.
Upfl ow and Horizontal Furnaces
For upfl ow installations, the return air ductwork may
be connected to the left side, right side, or bottom. The
bottom panel (Figure 17) must be installed for left or right
return air. NOTE: Do not use the back of the furnace
for return air.
11
Page 12
Side Return Installations
To attach the return air duct to the left or right side of
the furnace, punch out the four knockouts from the side
of the furnace (Figure 17, page 27). Using sharp metal
cutters, cut an opening between all four knockouts to
expose the blower assembly. Position the return air duct
over the opening in the side and secure together with
sheet metal screws. The screws must penetrate the duct
and furnace casing.
WARNING:
The solid base of the furnace must be in
place when the furnace is installed with side
return air ducts. Removal of all or part of the
base could cause circulation of combustible
products into the living space and create
potentially hazardous conditions, including
carbon monoxide poisoning that could result
in personal injury or death.
FURNACE INSTALLATION
*SA series gas furnaces are shipped ready for installation
in the upfl ow or horizontal right or left positions. Only
the *SK series gas furnace may be used for downfl ow
operation.
General Requirements
• The fur nace must be leveled at installation and attached
to a properly installed duct system. See Table 1
(page 6) for the required clearances needed to move
the furnace to its installation point (hallways, doorways,
stairs, etc).
• The furnace must be installed so that all electrical
components are protected from water.
• The furnace must be installed upstream from a
refrigeration system. (If applicable)
• The furnace requires special venting materials and
installation procedures. See pages 9 -10 for venting
guidelines and specifi cations.
Upfl ow Installation
Bottom Return Installations
The bottom panel (Figure 17) must be removed from the
bottom of the furnace for bottom return air. If bottom panel
is still installed, go to page 14 for removal instructions.
Position the furnace over the return air duct and secure
together with sheet metal screws. The screws must penetrate the duct and furnace casing.
Downfl ow Furnaces
To attach the return air duct to the furnace, bend the
furnace fl anges (Figure 17) upward 90° with a pair of
wide duct pliers. Position the duct on top of the furnace
and secure together with sheet metal screws. The screws
must penetrate the sheet metal casing and furnace fl ange.
Tape or seal all seams if required by local code.
Acoustical Treatments
Damping ducts, fl exible vibration isolators, or pleated
media-style fi lters on the return air inlet of the furnace
may be used to reduce the transmission of equipment
noise eminating from the furnace. These treatments can
produce a quieter installation, particularly in the heated
space. However, they can increase the pressure drop in
the duct system. Care must be taken to maintain the proper
maximum pressure rise across the furnace, temperature
rise and fl ow rate. This may mean increasing the duct
size and/or reducing the blower speed. These treatments
must be constructed and installed in accordance with
NFPA and SMACNA construction standards. Consult
with local codes for special requirements.For best sound
performance, be sure to install all the needed gaskets and
grommets around penetrations into the furnace, such as
for electrical wiring.
WARNING:
The furnace must not be installed directly on
carpeting, tile, or any combustible material other
than wood fl ooring.
Side Return Air Inlet
*SA series gas furnaces are shipped with the bottom panel
installed (Figure 17). If the upfl ow furnace is installed with
side return air, the bottom panel must not be removed.
Bottom Return Air Inlet
*SA series gas furnaces are shipped with the bottom panel
installed. If the upfl ow furnace is installed with bottom
return air, the bottom panel must be removed. See Bottom
Panel Removal on page 14.
Horizontal Installation
WARNING:
The furnace must not be installed directly on
carpeting, tile, or any combustible material other
than wood fl ooring.
The *SA series gas furnace can be installed horizontally
(Figure 6, page 13) in an attic, basement, crawl space
or alcove. It can also be suspended from a ceiling in a
basement or utility room in either a right to left airfl ow or
left to right airfl ow as shown in Figure 7.
*SA series furnaces are shipped with the bottom panel
installed. If the furnace is installed horizontally, remove the
bottom panel from the furnace before attaching the duct
system. See Bottom Panel Removal on page 14.
12
Page 13
Downfl ow Installation
Electrical Supply
Connection
Type “B” Vent
Coil Plenum
Gas Inlet
Combustible
Platform
Figure 6. *SA Horizontal Installation on a Platform
Nuts (x2)
Lag
Threaded
Rod
Washer
and
Lockwasher
Nuts (x2)
Bolt
Figure 7. *SA Horizontally Suspended
in Attic or Crawl Space
If the furnace is to be installed in an attic, it is required that
a drip pan be placed under the furnace. If the installation
is on a combustible platform (Figure 6), it is recommended
that the drip pan extend at least 12 inches past the top
and front of the furnace.
If the furnace will be suspended from the ceiling, assemble
a support frame (Figure 7) using slotted iron channel and
full threaded rod. Fasten the frame together with nuts,
washers, and lockwashers. Secure the support frame to the
rafters with lag bolts. The furnace can also be suspended
using steel straps around each end of the furnace. The
straps should be attached to the furnace with sheet metal
screws and to the rafters with bolts.
It is recommended for further reduction of fi re hazard
that cement board or sheet metal be placed between the
furnace and the combustible fl oor and extend 12 inches
beyond the front of the door and top of the furnace.
WARNING:
The furnace must not be installed directly on
carpeting, tile, or any combustible material other
than wood fl ooring.
WARNING:
Failure to install the downfl ow sub-base kit
may result in fi re, property damage or personal
injury.
To install the furnace on combustible fl ooring, a special
sub-base is required. Downfl ow sub-base kits are factory
supplied accessories and are listed according to the cabinet
letter of the furnace. For ‘A’ size cabinets use Sub-Base
kit #902974 only. For ‘B’, ‘C’, and ‘D’ size cabinets use
Kit #904911. Please follow the instructions provided
with the kit.
WARNING:
The downfl ow sub-base kit must not be installed
directly on carpeting, tile, or any combustible
material other than wood fl ooring.
A downfl ow sub-base kit is not necessary if the furnace
is installed on a factory or site-built cased air conditioning
coil. However, the plenum attached to the coil casing
must be installed so that its surfaces are at least 1” from
combustible construction.
Installation on a concrete slab.
1. Create an opening in the fl oor according to the
dimensions in Figure 8.
2. Position the plenum and the furnace as shown in
Figure 9 (page 14).
Opening in concrete floor
“A”
“B”
*SK MODEL
NUMBERS:
054-23A13
072-24B16
090-24B16
108-35C20
126-45D23
Dimensions shown in Inches.
Dimension
“A”
1/4
5/8
5/8
1/8
5/8
Dimension
“B”
19
1/4
19
1/4
19
1/4
19
1/4
19
1/4
Figure 8. Cutout Dimensions
13
Page 14
Concrete
Furnace
Floor
Sheet
Metal
Plenum
Figure 9. Furnace on a Concrete Slab
Bottom Panel Removal
The steps listed below describe how to remove the bottom
panel from the furnace. See Figure 10.
1. Remove the door (1) from the blower compartment.
2. Disconnect the blower motor wiring harness (2) from
the control board.
3. Remove two screws (3) securing the blower assembly
(4) to the furnace.
4. Carefully pull the blower assembly (4) out thru the
front of the furnace.
5. Remove all screws (5) securing bottom panel (6) to
bottom of furnace and front brace (7).
6. Lift up and slide bottom panel (6) out through front of
furnace.
7. Reinstall the blower assembly (4) in reverse order.
Alternate Bottom Panel Removal
If the bottom panel cannot be removed using the previous
instructions, the steps below are an alternate method for
removing the bottom panel. See Figure 11.
1. Remove the door (1) from the blower compartment .
2. Remove all screws securing the bottom panel (2) to
the front brace (3).
3. Remove two screws (4) securing the furnace cabinet
to the blower deck (5).
4. Remove all screws (6) securing the furnace cabinet
to the bottom panel (2).
5. Remove the screw (7) securing the bottom corner of the
furnace cabinet to the front brace (3).
6. Carefully spread the bottom corner of the furnace
cabinet outwards while sliding the bottom panel (2)
out through the front of the furnace.
7. Reassemble the furnace in reverse order.
4
1
5
7
6
1
3
4
6
2
7
Figure 10. Bottom Panel Removal
2
3
Figure 11. Alternate Removal Method
5
14
Page 15
GAS SUPPLY AND PIPING
All gas piping must be installed in compliance with local
codes and utility regulations. In the absence of local
codes the gas line installation must comply with the latest
edition of the National Fuel Gas Code (ANSI Z223.1) or
(CAN/CGA B149.1 or .2) Installation Codes.
IMPORTANT NOTES:
• Some local codes require the installation of a
manual main shut-off valve and ground joint union
external to the furnace as shown in Figure 12
(page 16). The shut-off valve should be readily
accessible for service and/or emergency use.
Consult the local utility or gas supplier for additional
requirements regarding placement of the manual
main gas shut-off.
• Gas piping must never run in or through air ducts,
chimneys, gas vents, or elevator shafts.
• Compounds used to seal joints on gas piping must
be resistant to the actions of LP propane gas.
• The main gas valve and main power disconnect to
the furnace must be properly labeled by the installer
in case emergency shutdown is required.
• Flexible gas connectors are not recommended for
this type of furnace but may be used if allowed by
local jurisdiction. The fl exible gas connector must
be agency approved and certifi ed for the type of
gas being used. Only new fl exible connectors may
be used. Do not reuse old fl exible gas connectors.
• A drip leg should be installed in the vertical pipe
run to the unit (Figure 12).
Table 7 (page 32) lists gas pipe capacities for standard
pipe sizes as a function of length in typical applications
based on nominal pressure drop in the line.
The furnace may be installed for either left or right side
gas entry. When connecting the gas supply, provide
clearance between the gas supply line and the entry hole
in the furnace casing to avoid unwanted noise and/or
damage to the furnace. Typical gas hookups are shown
in Figure 12.
Leak Check
WARNING:
FIRE OR EXPLOSION HAZARD
Never test for gas leaks with an open fl ame.
Check all connections using a commercially
available soap solution. A fi re or explosion
may result causing property damage, personal
injury or loss of life. Failure to follow the safety
warnings exactly could result in serious injury,
death or property damage.
After the gas piping to the furnace is complete, all
connections must be tested for gas leaks. This includes
pipe connections at the main gas valve, emergency shutoff
valve and fl exible gas connectors (if applicable). The soap
and water solution can be applied on each joint or union
using a small paintbrush. If any bubbling is observed,
the connection is not sealed adequately and must be
retightened. Repeat the tightening and soap check process
until bubbling ceases.
IMPORTANT NOTE: When pressure testing gas supply
lines at pressures greater than 1/2 psig (14 inch W.C.),
the gas supply piping system must be disconnected
from the furnace to prevent damage to the gas control
valve. If the test pressure is less than or equal to 1/2
psig (14 inch W.C.), close the manual shut-off valve.
High Altitude Application
High altitude conversion with this furnace depends on the
installation altitude and the heating value of the gas. The
installation of this furnace at altitudes above 2,000 feet
must meet the requirements of the National Fuel Gas
Code or local jurisdiction. In Canada, the requirements for
high altitude are different and governed by CGA B149.1.
Please consult your local code authority.
WARNING:
The reduction of input rating necessary for high
altitude installation may only be accomplished
with factory supplied orifi ces. Do not attempt
to drill out orifi ces in the fi eld. Improperly
drilled orifi ces may cause fi re, explosion,
carbon monoxide poisoning, personal injury
or death.
The furnaces are shipped from the factory with orifi ces
and gas regulator settings for natural gas operation at sea
level altitudes. At 2000 feet, the NFGC requires that this
appliance be derated 4% for each 1,000 feet of altitude.
For example, at 2,000 feet the input needs to be reduced
8%, at 3,000 feet (12%), etc. This deration is in reference
to the input rate and gas heating value at sea level.
To derate the furnace requires knowing the heating value of
the gas at the installation site. Heating values at particular
job sites vary for two reasons:
1. The chemical mixture of the gas varies from region
to region and is expressed as the “sea level heating
value”.
2. The heating value varies by altitude. For this reason,
especially in high altitude areas, the local gas utility
specifi es the heating value at the residence’s gas
meter as the “local value”.
For added fl exibility, two tables have been provided for
natural gas installations with HIGH or LOW heating
values at sea level. Tables 10 and 11 (page 34) contain
the orifi ce sizes and manifold pressure to use at various
altitudes. Table 10 (High) is for natural gas installations
15
Page 16
UPFLOW MODELS
1
RCYGW
STATUS
24V
See
Note
8
FAN
COOL
HEAT
FLAME
63
9
180
BLOWER
2
120
5
8
OFF
90
1
4
7
DELAY
60
L1A
63
2
5
1
4
XFMR
HIGH
LOW
HUM
EAC
MH
ML
L1
NEUTRALS
1
RCYGW
24V
FAN
COOL
HEAT
63
9
2
5
8
1
4
7
L1A
63
2
5
1
4
XFMR
HUM
L1
NEUTRALS
See
STATUS
FLAME
Note
180
BLOWER
120
OFF
90
DELAY
60
HIGH
LOW
EAC
MH
ML
8
4
3
7
5
2
6
Left Side Entry
2
6
Right Side Entry
5
3
DOWNFLOW MODELS
See
Note
8
3
5
(1) Automatic Gas Valve
(w/ manual shut-off)
RCYGW
63
9
2
5
8
1
4
7
L1A
63
2
5
1
4
NEUTRALS
2
Left Side Entry
(2) Burner Assembly(3) Dripleg(4) Elbow
24V
STATUS
FAN
COOL
HEAT
FLAME
180
BLOWER
120
OFF
90
DELAY
60
XFMR
HIGH
LOW
HUM
EAC
MH
ML
L1
7
1
6
ITEM # and COMPONENT
RCYGW
24V
63
9
2
5
8
1
4
7
L1A
63
2
5
1
4
HUM
NEUTRALS
1
4
2
6
Right Side Entry
STATUS
FAN
COOL
HEAT
FLAME
180
BLOWER
120
OFF
90
DELAY
60
XFMR
HIGH
LOW
EAC
MH
ML
L1
See
Note
8
3
5
(5) Ground Joint Union(6) Manifold(7) Plug(8) Shut - Off Valve
NOTE: Some utilities require Shut- Off Valve to be 4 to 5 feet above fl oor.
16
Figure 12. Typical Gas Connections
Page 17
with a heating value of more than 1,000 Btu per cubic foot
and Table 11 (Low) is for less than 1,000 Btu per cubic
To determine which table to use:
foot.
and manifold pressure. When conversion is complete, verify
the manifold pressure and input rate are correct as listed
in the Tables. Approved conversion kits are listed below:
1. Consult the local utility for the local heating value at
your installation site.
2. From Table 9 (page 33), fi nd your local heating value
as supplied by the utility company. Follow down the
column and stop at your altitude level.
3. If your sea level heating value is HIGH, use Table 10
or if it’s LOW, use Table 11 (page 34).
Type of Gas: .........................................Natural Gas
Local Heating Value of Gas: ............................750
From Table 9, fi nd 750 and follow down the column,
stop at the 5,000 feet row. The heating value listed is
LOW. Table 11 will be used to determine orifi ce size and
manifold pressure.
After changing the regulator pressure or the orifi ces, it is
required that you measure the gas input rate. This may be
accomplished in the usual way, by clocking the gas meter
and using the local gas heating value. See Verifying and
Adjusting the Input Rate section (page 20).
IMPORTANT NOTE: Observe the action of the burners
to make sure there is no yellowing, lifting or fl ashback
of the fl ame.
Conversion to LP/Propane
WARNING:
The furnace was shipped from the factory
equipped to operate on natural gas. Conversion
to LP/propane gas must be performed by
qualifi ed service personnel using a factory
supplied conversion kit. Failure to use the
proper conversion kit can cause fi re, explosion,
property damage, carbon monoxide poisoning,
personal injury, or death.
IMPORTANT NOTE: When converting a low NOx furnace
from Natural gas to LP/propane gas, it is necessary
to remove the NOx Baffl es from the furnace.
• The United States LP/Propane Gas Sea Level and High
Altitude Conversion Kit (P/N 904914) is for LP/propane
conversion in the United States at altitudes between
zero and 10,000 ft. above sea level. Please follow the instructions provided with the kit.
• The Canadian LP/Propane Gas Sea Level and High
Altitude Conversion Kit (P/N 904915) is for LP/propane
conversions in Canada at altitudes between zero and
4,500 ft. above sea level. Please follow the instructions
provided with the kit.
ELECTRICAL WIRING
WARNING:
To avoid electric shock, personal injury, or death,
turn off the electric power at the disconnect
or the main service panel before making any
electrical connections.
• Electrical connections must be in compliance with all
applicable local codes and the current revision of the
National Electric Code (ANSI/NFPA 70).
• For Canadian installations the electrical connections
and grounding shall comply with the current Canadian
Electrical Code (CSA C22.1 and/or local codes).
CAUTION:
Label all wires prior to disconnection when
servicing controls. Wiring errors can cause
improper and dangerous operation. Verify
proper operation after servicing.
IMPORTANT NOTE: If replacing any of the original
wires supplied with the furnace, the replacement wire
must be copper wiring and have a temperature rating
of at least 105° F (40° C). For electrical specifi cations,
refer to the furnace nameplate or Table 2 (page 18).
Line Voltage Wiring
It is recommended that the line voltage (115 VAC) to
the furnace be supplied from a dedicated branch circuit
containing the correct fuse or circuit breaker for the
furnace (Table 2).
Conversion to LP/propane is detailed in the installation
instructions provided with the conversion kit. Generally,
this will require the replacement of the burner orifi ces and
the spring found under the cap screw on the pressure
regulator. In the U.S. if installation is above 2,000 ft., refer
to Table 8 (page 33) to determine the correct orifi ce size
IMPORTANT NOTES:
An electrical disconnect must be installed readily
accessible from and located within sight of the furnace.
See Figure 13 (page 18) or the wiring diagram label
inside of the control door. Any other wiring methods
must be acceptable to authority having jurisdiction.
17
Page 18
Proper line voltage polarity must be maintained in
order for the control system to operate correctly.
Verify the incoming neutral line is connected to the
white wire and the incoming “hot” line is connected
to the black wire. The furnace will not operate unless
the polarity and ground are properly connected as
shown in Figure 13.
Low Voltage Wiring
The thermostat must be installed according to the
instructions supplied by the thermostat manufacturer. Low
voltage connections (24 VAC) from the thermostat are
wired to the terminal strip on the integrated control in the
furnace. See Figure 14 (page 19) for proper connections
for heating only (two-wire) and heating/cooling (four-wire)
applications. Recommended minimum wire gauge for
thermostat wiring is shown in Table 2.
The thermostat must not be installed on an outside wall or
any other location where its operation may be adversely
affected by radiant heat from fi replaces, sunlight, or lighting
fi xtures, and convective heat from warm air registers or
electrical appliances.
The six pin terminal marked “Expansion Port” is not used
in the single stage furnace as shipped from the factory. It
is used for the furnace control board to communicate to
a fi xed speed or variable speed high effi ciency motor that
may be optionally installed. Please contact your distributor
for the proper upgrade motor kit.
Time-delay fuses or HACR-type circuit breakers are required.
Thermostat Wire Gauge
Furnace
Input
(Btuh)
2455 ft.25 ft.
2290 ft.45 ft.
20140 ft.70 ft.
18225 ft.110 ft.
Cabinet
Width
(in.)
Nominal
Electrical
Supply
Maximum
Operating
Voltage
NOTES:
2 - wire
(Heating)
Minimum
Operating
Voltage
Recommended Thermostat Wire Length
Maximum
Furnace
Amperes
Minimum
Wire
Gauge
4 or 5 wire
(Cooling)
Fuse or Circuit
Breaker Amps
Table 2. Wire Length and Voltage Specifi cations
Field Supplied
Fused Service
Panel
Field Supplied
Disconnect w/in
Sight of Furnace
Junction Box (may be int. or ext.
to the furnace). These connections
can be made in the field supplied
disconnect at the furnace.
Maximum
σ
Black (Hot)
White (Neutral)
Green or Bare
(Ground)
Ground
Field Line Voltage Wiring
Factory Line Voltage Wiring
18
Black
White
Ground
Black
White
Field Supplied
Panel Connector
Figure 13. Line Voltage Field Wiring
Black
White
Ground
Page 19
IMPORTANT NOTE: Set the heat anticipator according
to the instructions supplied by the thermostat
manufacturer.
To determine the heat anticipator setting:
1. Add the current draw of the system components; or
2. Measure the current fl ow on the thermostat R-W circuit
after the circulating blower motor has started.
A/C CONDENSING UNIT
CONDENSING UNIT
CONTROL BOX
EXPANSION PORT
(MOTOR CONNECTION)
COM
ROOM
THERMOSTAT
Connect
R & W
For Heating
Only
NOTE: The “Y” terminal
on the control board
must be connected to the
thermostat for proper
cooling mode operation.
FIELD WIRING
LOW VOLTAGE
CONNECTION
R
C
Y
G
W
NEUTRAL LEADS
3 AMP
FUSE
63
9
5
8
4
7
6
3
2
5
1
4
NEUTRALS
RCYGW
2
1
24V
SPEED
SELECT
FAN
HUM
STATUS
COOL
HEAT
FLAME
180
BLOWER
120
OFF
DELAY
60
XFMR
HIGH
LOW
EAC
MH
ML
L1
ELECTRONIC AIR CLEANER
HUMIDIFIER TAP
RED
GREEN
YELLOW
90
MOTOR SPEED TAPS
(NOT USED)
Figure 14. Low Voltage Field, Four-wire
Heating/Cooling Applications
Twinning
Single stage G7 furnaces are not supplied with a builtin twinning capability. Other valuable features and
enhancements were made to the new control that made it
necessary to remove the twinning capability. All standard
two-stage furnaces equipped with the fi xed speed iSEER™
motor include a twinning terminal on the blower control
board.
However, if both single stage G7 furnaces are upgraded
to the fi xed speed iSEER ™ blower, the twin terminal on
the blower control boards (Figure 15) may be used to
twin the single stage furnaces only if the following criteria
are met:
• Both furnaces and motors must be the same size.
• Both motors must be on the same speed for cooling
and heating.
• Both furnaces must have a common return duct and
common supply plenum.
• Both furnaces must be on the same leg of power.
IMPORTANT NOTE: G7 furnaces equipped with
variable speed iSEER ™ motors may not be twinned
under any circumstances.
Please contact your furnace distributor for technical
details.
THERMOSTAT
WG
YR
Grounding
WARNING:
To minimize personal injury, the furnace cabinet
must have an uninterrupted or unbroken electrical
ground. The controls used in this furnace require
an earth ground to operate properly. Acceptable
methods include electrical wire or conduit
approved for ground service. Do not use gas
piping as an electrical ground!
R
C
Y
G
W
FURNACE
BOARD
FSHE
BOARD
TWIN TERMINAL
A/C
UNIT
FURNACE 1FURNACE 2
Figure 15. Single Stage Twinning
R
C
Y
G
W
FURNACE
BOARD
FSHE
BOARD
TWIN TERMINAL
19
Page 20
START-UP AND ADJUSTMENTS
Pre-Start Check List
√ Verify the polarity of the connections are correct, the
line voltage power leads are securely connected and
the furnace is properly grounded.
√ Verify the thermostat wires (R, W, Y, and G) are
securely connected to the correct leads on the
terminal strip of the circuit board.
√ Verify the gas line service pressure does not exceed
10.0 inches of W.C., and is not less than 4.5 inches
W.C. for natural gas. For LP gas the line service
pressure must not exceed 14 in. W.C., and must not
be less than 11.0 in. W.C.
√ Verify the roll-out and manual reset switch is closed. If
necessary, press the red button to reset a switch. DO
NOT install a jumper wire across a switch to defeat
its function. If a switch reopens on startup, DO NOT
reset the switch without identifying and correcting the
fault condition.
√ Verify the blower door is in place, closing the door
switch in the line voltage circuit.
√ Verify the gas line has been purged and all connections
are leak free.
Start-up Procedures
Do not perform these steps until all of the checks in the
previous steps have been completed:
1. Set the thermostat to the lowest setting.
2. Turn off all electrical power to the furnace.
3. Follow the Operating Instructions on the label attached
to the furnace.
4. Set the thermostat above room temperature and verify
the Operating Sequence (Page 21).
5. After 5 minutes of operation, set the thermostat
below room temperature and verify steps 9 - 10 of
the Operating Sequence.
Example:
• Time for 1 revolution of a gas meter with a 1
cubic ft dial = 40 seconds.
• From Table 6 read 90 cubic ft gas per hr.
• Local heating value of the gas (obtained from
gas supplier) = 1,040 Btu per cubic ft.
• Input rate = 1,040 x 90 = 93,600 Btuh.
6. The manifold pressure must be set to the appropriate
value for each installation by a qualifi ed installer,
service agency or the gas supplier.
WARNING:
Do not attempt to drill the gas orifi ces. Use
only factory supplied orifices. Improperly
drilled orifi ces may cause fi re, explosion,
carbon monoxide poisoning, personal injury
or death.
a.) Obtain the manifold pressure setting required for
this installation by referring to Table 8 (page 33)
for Propane or Tables 10 or 11 for Natural Gas
(page 34).
b.) Remove the regulator capscrew (Figure 16) from
the INLET side of the regulator.
c.) Slowly turn the adjustment screw inside the regulator
to obtain the appropriate manifold pressure.
NOTE: Turning the screw clockwise increases
the pressure and turning the screw counterclockwise decreases the pressure. To prevent
backing the screw all the way out from the valve,
turn the screw slowly.
d.) Replace and tighten the regulator capscrew over
the adjustment screw.
Verifying and Adjusting Input Rate
IMPORTANT NOTE: The input rate must not exceed
the rate shown on the furnace rating plate. At altitudes
above 2,000 feet, it must not exceed that on the rating
plate less 4% for each 1,000 feet.
The input rate must be verifi ed for each installation to
prevent over-fi ring of the furnace. To determine the exact
input rate, perform the following procedures:
1. Shut off all other gas fi red appliances.
2. Start the furnace and run it for at least 3 minutes.
3. Measure the time (in seconds) required for the gas
meter to complete one revolution.
4. Convert the time per revolution to cubic feet of gas
per hour using Table 6 (page 32).
5. Multiply the gas fl ow rate in cubic ft per hr by the
heating value of the gas in Btu per cubic ft to obtain
the input rate in Btuh See example above.
20
Capscrew
Figure 16. Regulator Capscrew
Verifying and Adjusting Temperature Rise
Confi rm the temperature rise through the furnace is
within the limits specifi ed on the furnace rating plate. Any
temperature rise outside the specifi ed limits could result
in premature failure of the heat exchanger.
Page 21
WARNING:
To prevent electric shock, personal injury, or
death, disconnect the electric power before
performing any maintenance.
1. Place ther mometers in the return and supply air stream
as close to the furnace as possible. The thermometer
on the supply air side must be shielded from direct
radiation from the heat exchanger to avoid false
readings.
2. Adjust all registers and duct dampers to the desired
position and run the furnace for 10 to 15 minutes before
taking any temperature readings. The temperature
rise is the difference between the supply and return
air temperatures.
For typical duct systems, the temperature rise will fall
within the limits specifi ed on the rating plate with the
blower speed at the factory recommended setting. If the
measured temperature rise is outside the specifi ed limits,
it may be necessary to change the speed of the blower.
NOTE: Lowering the blower speed will increase the
temperature rise and a higher blower speed will decrease
the temperature rise.
The furnace is equipped with a multi-speed motor. Heating,
cooling, and fan speed selection is made by moving the
switch on the integrated control located in the furnace.
Verifying Burner Operation
CAUTION:
The door over the burners may only be open
for inspection purposes only. The door must be
installed during unattended operation.
1. Remove the burner compartment door.
2. Set the thermostat above room temperature and
observe the ignition sequence. NOTE: The burner
fl ame should carry over immediately between all
burners without lifting off, curling, or fl oating. The
fl ames should be blue, without yellow tips.
3. After validating the fl ame, change the thermostat
setting to below room temperature.
4. Verify the burner fl ame is completely extinguished.
5. Replace the burner compartment door.
Verify Operation of the Supply Air Limit Switch
Note: A properly functioning limit switch should turn off
the gas valve when the return is blocked (time depends
on how well the return air is blocked). The circulating air
and combustion blowers should continue to run when the
limit switch opens.
1. Verify the blower door is securely mounted in place
and that there is power to the furnace.
2. Block the return airfl ow to the furnace by installing a close-off plate in place of or upstream of the
fi lter(s).
3. Set the thermostat above room temperature and
observe the Operating Sequence.
4. Remove the close-off immediately after the limit switch
opens. If the furnace continues to operate with no return air, set the thermostat below room temperature,
shut off the power to the furnace, and replace the limit
switch.
OPERATING SEQUENCE
The operating sequences for the heating, cooling, and fan
modes are described below. Refer to the fi eld and furnace
wiring diagrams: (Figure 13, page 18), (Figure 14, page
19) and (Figure 18, page 31).
Heating Cycle
1. The thermostat calls for heat by energizing the W
terminal with 24VAC.
2. The control verifi es the pressure switch is open.
3. If the pressure switch is open, the control energizes
the inducer and waits for the pressure switch to close.
The pressure switch must close within 10 seconds.
4. The control runs the inducer for a 30 second prepurge.
5. The control energizes the igniter output for the
appropriate warm-up time limit.
6. The control energizes the main gas valve for 3
seconds.
7. If the fl ame proved and ignites the gas, the control
de-energizes the igniter. The gas valve and inducer
remains energized. The control goes to blower on
delay.
8. If fl ame is present, the control energizes the blower
on the selected HEAT speed 30 seconds after the
gas valve opened. The gas valve and inducer remain
energized.
9. When the thermostat demand for heat is satisfi ed, the
control de-energizes the gas valve. The inducer output
remains on for a 30 second post-purge period.
10. Blower off timing begins when the thermostat is
satisfi ed. The control will operate at the selected HEAT
speed of 60, 90, 120, or 180 seconds. If the blower
off delay jumper is not present, the fan should still
operate for 120 seconds at the selected HEAT speed.
The Indoor blower motor is de-energized after a blower
off delay as selected by the movable jumper.
21
Page 22
Cooling Cycle
1. The thermostat calls for cooling by energizing the Y
terminal with 24VAC.
2. The control energizes the blower in the cooling speed
and sends 24VAC to the contactor in the condensing
unit.
3. When the thermostat removes the call for cooling,
the contactor in the outdoor condensing unit is deenergized and the control continues to run the fan for
a period of 60 seconds.
Fan Mode
• When the thermostat energizes the G terminal for
continuous fan (without calling for heat or cooling), the
indoor fan is energized on the selected FAN speed.
• If a call for cooling occurs during continuous fan, the
blower will switch over to the selected COOL speed.
• If the W terminal receives a call for heat during continuous
fan, the blower will de energize.
• A call for fan is ignored while in lockout.
TROUBLESHOOTING
If the furnace fails to operate check the following:
• Is the thermostat operating properly?
• Are the blower compartment door(s) in place?
• Is the furnace disconnect closed?
• Has the circuit breaker tripped or the control board
fuse burned open?
• Is the gas turned on?
• Are any manual reset switches open?
• Is the fi lter dirty or plugged?
• Is the fl ame sensor coated? (Remove and clean with
steel wool).
• Are all the LED’s on the furnace control board constantly
ON? If not, refer to Table 3 or the wiring diagram (Figure
18, page 31) to determine fault condition.
IMPORTANT NOTE: The furnace will lock out after 5
failed attempts for ignition and will try again every
hour if the call for heat remains.
• If the Inducer Blower is operating, and items above
have been verifi ed, check the Blower Limit Switch and
reset if necessary. See Figure 19 or 20 (page 35) for
component location.
• If the furnace operates when the Blower Limit Switch is
reset, contact a qualifi ed service technician to identify
and repair the problem.
• If the furnace still doesn’t operate, check the Flame
Roll-out Switches and reset if necessary. See Figure
19 or 20 for component location.
• If the furnace operates when the Flame Rollout Switch
is reset, contact a qualifi ed service technician to identify
and repair the problem.
22
Diagnostic DescriptionGreen LEDRed LED
Control Fault (No Power)OffOff
L1/Neutral Polarity FaultFlashFlash
1 Hour LockoutAlternating Flash
Normal OperationOnOn
Pressure Switch Closed FaultOnFlash
Pressure Switch Open FaultFlashOn
Open Limit Switch FaultFlashOff
Motor FaultOnOff
Diagnostic DescriptionYellow LED
Low Flame Sensor SignalContinuous Flash
Flame PresentOn
Table 3. Control Board Fault Conditions
MAINTENANCE
WARNING:
These maintenance instructions are primarily
intended to assist qualified technicians
experienced in the proper maintenance and
operation of this appliance.
Proper maintenance is most important to achieve the best
performance from a furnace. Follow these instructions for
years of safe, trouble free operation.
• Always reinstall the doors on the furnace after servicing
or cleaning/changing the fi lters. Do not operate the
furnace without all doors and covers in place.
• Verify the thermostat is properly installed and is not being
affected by drafts or heat from lamps or other appliances.
• To achieve the best performance and minimize equipment
failure it is recommended that a yearly maintenance
checkup be performed. At a minimum, this check should
include the following items:
Air Filter(s)
WARNING:
Never operate the furnace without a fi lter in
place. Dust and lint can build up on internal
components, resulting in loss of effi ciency,
equipment damage, and possible fi re.
Note: Air fi lter(s) are not supplied with the furnace as
shipped from the factory. The installer must provide a
high velocity fi lter and rack for a fi lter in the return air
duct adjacent to the furnace, or in a return air grill to the
furnace.It is recommended that fi lters be cleaned or
replaced monthly. New or newly renovated homes may
require more frequent changing until the construction
dust has minimized.
Page 23
Filters designed to remove smaller particles such as
pollen, may require additional maintenance. Filters for
side return and bottom return applications are available
from most local distributors.
Blower Compartment
Dirt and lint can create excessive loads on the motor
resulting in higher than normal operating temperatures
and shortened service life. It is recommended that the
blower compartment be cleaned of dirt or lint that may
have accumulated in the compartment or on the blower
and motor as part of the annual inspection.
Cleaning of Burners
If the burners must be cleaned, follow steps 1 - 12. See
Figures 19 and 20 (page 35) for component location.
1. Shut off gas supply to the furnace at the meter or at
a manual valve in the supply piping.
2. Turn off all power to the furnace and set the thermostat
to its lowest setting.
3. Remove the burner door from the furnace.
4. Turn the gas control switch to the OFF position.
5. Disconnect the wires from the gas valve, igniter, fl ame
sensor, and fl ame rollout switch.
6. Using two wrenches, separate the ground-joint union
in the gas supply piping at the furnace.
7. Remove the piping between the gas valve and the
ground-joint union. (If applicable).
8. Remove all screws securing the burner assembly to
the furnace.
9. Carefully remove the burner assembly from the furnace.
DO NOT DAMAGE THE IGNITER WHILE REMOVING
THE BURNER ASSEMBLY.
10. Inspect the burners for accumulated dust or debris.
If necessary carefully clean them with a soft wire
brush and a vacuum cleaner. DO NOT DAMAGE THE
IGNITER WHILE CLEANING THE BURNER.
11. Replace all the parts in reverse order that they were
removed.
12. Follow the lighting instructions found on the furnace
door to return the furnace to operation. Verify proper
operation after servicing.
Cleaning Of Flue Passages
If the fl ue passages must be cleaned, follow the steps
below. See Figures 19 and 20 for component location.
1. Shut off the gas supply to the furnace at the meter or
at the manual valve in the gas supply piping.
2. Turn off all power to the furnace and set the thermostat
to the lowest temperature setting.
3. Remove the blower door from the furnace.
4. Turn the gas control switch to the OFF position.
CAUTION:
Label all wires prior to disconnection when
servicing controls. Wiring errors can cause
improper and dangerous operation.
5. Disconnect the wires from the gas valve, fl ame sensor,
inducer, fl ame roll-out switch, limit switch, pressure
switch and igniter.
6. Remove the silicone rubber tube from the inducer.
7. Using two wrenches, separate the ground-joint union
in the gas supply piping at the furnace.
8. Remove the piping between the gas valve and the
ground-joint union. (If applicable).
9. Remove all screws securing the burner assembly to
the furnace.
10. Carefully remove the burner assembly from the furnace.
DO NOT DAMAGE THE IGNITER WHILE REMOVING
THE BURNER ASSEMBLY.
11a. Remove all screws securing the inducer assembly
to the vent pipe running out of the furnace
(*SA upfl ow/horizontal models only).
11b. Remove all screws securing the combustion air tube
assembly to the vent pipe running out of the furnace.
(*SK downfl ow models only).
12. Remove all screws securing the inducer assembly
to the collector pan.
13a. Carefully remove the inducer assembly and combus-
tion tube assembly from the furnace. DO NOT BREAK
THE SEALS AT EACH END OF THE COMBUSTION
AIR TUBE. (*SK downfl ow models only).
13b. Carefully remove the inducer assembly from the
furnace (*SA upfl ow/horizontal models only).
14. Remove all screws securing the collector pan to the
furnace.
15. Remove the collector pan and gasket from the
furnace.
16. Attach a round wire brush to a length of high grade
stainless steel cable. Attach the other end of the
cable to a variable speed reversible drill. Slowly insert
and rotate the cable into the top portion of the heat
exchanger. Operate the drill alternating between
forward and reverse, working the cable in and out
several times to obtain suffi cient cleaning. Repeat
this sequence for each heat exchanger tube.
17. Remove all loosened debris from the heat exchanger
tubes using a vacuum cleaner.
18. Using a bright light, check the condition of the upper
and lower sections of the heat exchanger tubes.
19. Inspect the burners for accumulated dust or debris.
If burners must be cleaned, see Cleaning of
Burners.
23
Page 24
20. Replace all the parts in reverse order that they were
removed.
21. Check gaskets for damage. Replace if needed.
22. Follow the lighting instructions found on the furnace
door to return the furnace to operation. Verify proper
operation after servicing.
Heat Exchanger and Burner Maintenance
The furnace should operate for many years without soot
buildup in the fl ue passageways, however, the fl ue, vent
system, and burners should be inspected and cleaned
(if required) by a qualifi ed service technician annually
to ensure continued safe operation. Pay attention to any
deterioration from corrosion or other sources.
Lubrication
The bearings in the blower motor and inducer blower used
in these furnaces are pre-lubricated and sealed by the
manufacturer. No further oiling of the bearings is required
for the life of the motor.
Vent System
WARNING:
Holes in the vent pipe or heat exchanger can
cause combustion products to enter the home.
Replace the vent pipe or heat exchanger if leaks
are found. Failure to prevent the circulation
of combustion products into the living space
can create potentially hazardous conditions
including carbon monoxide poisoning that
could result in personal injury or death.
Check the vent pipe and/or chimney to ensure that it is not
corroded or blocked by debris. Any corroded section of vent
pipe must be replaced, and any obstruction or blockage
must be removed prior to operating the furnace.
DESCRIPTION OF COMPONENTS
The descriptions below are various functional components
that affect the operation and shutting down of this furnace.
Some of these components and their locations are shown
in Figures 19 and 20 (page 35).If any component of the
furnace must be replaced, use only factory authorized
replacement parts specifi ed in the Replacement Parts
List provided online.
Blower Limit Switch
Blower switches prevent operation when blower is not
operational.
Flame Sensor
The fl ame sensor verifi es when a fl ame has carried over
from the igniter to the opposite end burner. If no fl ame is
detected, the furnace will shut down within 4 seconds.
Flame Roll-Out Switch
The fl ame roll-out switch verifi es that the burner fl ames
are drawn into the heat exchanger tubes. If the burner
fl ames are not properly drawn into the heat exchanger, the
fl ame roll-out switch will close the gas valve and initiate
the shutdown cycle.
Gas Valve
The gas valve controls the fl ow of gas to the burners.
When the gas valve is energized it automatically opens
and regulates the gas pressure in the manifold.
Inducer Assembly
The inducer assembly vents products of combustion to
the outside.
Pressure Switch
The pressure switch verifi es that the inducer is drawing
the combustion gases through the heat exchanger. If
the fl ame is not properly drawn into the heat exchanger
tube, the rollout switch or the fl ame sensor will shut the
furnace down.
24
Supply Air Limit Switch
The supply air limit switch prevents the air temperature
leaving the furnace from exceeding the maximum
allowable outlet air temperature.
Page 25
FRENCH TRANSLATIONS
The following are French translations of important warning statements found within this manual.
AVERTISSEMENT:
RISQUE D’EMPOISONNEMENT AU MONOXYDE DE CARBONED
Le non-respect des consignes suivantes portant sur chacun des appareils raccordés au système
d’évacuation mis en service pourrait entraîner l’empoisennement au monoxyde de carbone
ou la mort. Les consignes suivantes doivent être observées pour chaque appareil raccordé
au système d’évacuation mis en service si les autres appareils raccordés au système ne sont
pas en service:
1. Sceller toute ouverture non utilisée de la systéme d’évacuation;
2. S’assurer que la systéme d’évacuation présente des dimensions et une pente horizontale conformes à la norme ANSI Z223.1/NFPA 54, intitulée National Fuel Gas Code ou aux
codes d’installation CSA-B149.1, ainsi qu’aux présentes instructions. S’assurer que la
systéme d’évacuation n’est pas bloquée, restreinte, corrodée, qu’elle ne fuit pas et qu’elle
ne présente aucun autre défaut potentiellement dangereux;
3. Dans la mesure du possible, fermer toutes les portes et fenêtres du bâtiment, et toutes
les portes entre la pièce où se trouve l’appareil raccordé à la systéme d’évacuation et les
autres pièces du bâtiment.
4. Fermer les registres des foyers;
5. Mettre en service les sécheuses et tout autre appareil qui n’est pas raccordé à la systéme
d’évacuation. Faire fonctionner à régime maximal tout ventilateur d’évacuation, tel que
les hottes de cuisinière et les ventilateurs de salles de bains. Ne pas mettre en service les
ventilateurs d’été.
6. Respecter les instructions d’allumage. Mettre en service l’appareil à l’essai. Régler le
thermostat de manière à ce que l’appareil fonctionne sans interruption;
7. Vérifi er s’il y a débordement à l’orifi ce d’évacuation du coupe tirage des appareils dotés
d’un coupe tirage 5 minutes après l’allumage du brûleur principal. Utiliser la fl amme d’une
allumette ou d’une chandelle.
8. Si l’on constate, au cours de l’un des essais qui précèdent, que l’évacuation est défi ciente,
corriger le système d’évacuation conformément à la norm ANSI Z223.1/NFPA 54, National
Fuel Gas Code, et (ou) aux codes d’installation CSA B149.1.
9. Après avoir déterminé que tous les appareils raccordés à la systéme d’évacuation évacuent correctement tel que prescrit ci-dessus, rouvrir les portes et les fenêtres et remettre
les ventilateurs d’évacuation, les registres de foyers et tout autre appareil fonctionnant
au gaz à leur état de fonctionnement initial.
25
Page 26
AVERTISSEMENT:
RISQUE D’INCENDIE OU D’ EXPLOSION
• Le non-respect des avertissements de
sécurité pourrait entraîner des blessures
graves, la mort ou des dommages matériels.
• L’installation et l’entretien doivent être
effectués par un installateur qualifi é, un
organisme de service ou le fournisseur
de gazstaller, service agency or the gas
supplier.
• Ne pas entreposer ni utiliser de l’essence ni
d’autres vapeurs ou liquides infl ammables
dans le voisinage de cet appareil, ni de tout
autre appareil.
QUE FAIRE S’IL Y A UNE ODEUR DE GAZ
• Ne pas tenter d’allumer aucun appareil.
• Ne toucher à aucun interrupteur électrique;
n’utiliser aucun téléphone dans le bâtiment.
• Évacuer l’immeuble immédiatement.
• Appeler immédiatement le fournisseur de
gaz en employant le téléphone d’un voisin.
Respecter à la lettre les instructions du
fournisseur de gaz.
• Si personne ne répond, appeler le service des
incendies.
AVERTISSEMENT:
RISQUE D’INCENDIE ET D’EXPLOSION
Risque de blessures graves ou de mort.
Ne pas entreposer ni utiliser de l’essence ni
d’autres vapeurs ou liquides infl ammables
dans le voisinage de cet appareil, ni de tout
autre appareil. Le fait d’entreposer ou d’utiliser
de l’essence ou d’autres liquides ou vapeurs
infl ammables à proximité de cet appareil ou de
tout autre appareil peut causer des blessures
graves ou la mort.
AVERTISSEMENT:
RISQUE DE CHOC ÉLECTRIQUE, D’INCENDIE
OU D’EXPLOSION
Le non-respect des avertissements de sécurité pourrait entraîner un fonctionnement dangereux de l’appareil, des blessures graves, la
mort ou des dommages matériels.
Un entretein incorrect pourrait entraîner un
fonctionnement dangereux de l’appareil, des
blessures graves, la mort ou des dommages
matériels.
• Couper toute alimentation électrique au
générateur d’air chaud avant de prodéder aux
travaux d’entretein.
• Au moment de l’entretien des commandes,
étiquetez tous les fi ls avant de les débrancher.
S’assurer de les raccorder correctement.
• S’assurer que l’appareil fonctionne
adéquatement aprés l’entretien.
AVERTISSEMENT:
Ne jamais utiliser une fl amme nue por vérifi er la
présence des fuites de gaz. Pour la vérifi cation
de tous les joints, utiliser plutôt une solution
savonneuse commerciale fabriquée spécifi quement pur la détection des fuites de gaz.
Un incendie ou une explosion peut entraîner
des dommages matériels, des blessures ou
la mort.
Le non-respect des avertissements de sécurité
pourrait d’entraîner des blessures graves, la
mort ou des dommages matériels.
26
Page 27
FIGURES AND TABLES
*SA 80+ Upfl ow Furnace
D
FRONT
BRACE
BOTTOM
PANEL
23 1/2
BOTTOM VIEW
25 3/8
Ø 7/8 HOLE FOR
ELECTRIC
4 KNOCKOUTS
(BOTH SIDES)
34 1/2
1 1/4
23
28
LEFT SIDE
15
1
ACCEPTS 4”
TYPE B
VENT PIPE
1 5/8 X 3 1/2
HOLE FOR GAS
23
TOP VIEW
23
C
FLANGES
B
A
*SA Model #’s Dim. “A” Dim. “B” Dim. “C” Dim. “D”
045
19
(†)-23A
054(†)-23A
(†)-24B
072
090(†)-24B
(†)-35C
072
090(†)-35C
108
(†)-35C
(†)-45D24
126
1/4
10
11
3/4
3/4
14
17
1/2
211419
1/2
15
1/4
12
15
22 7/823
NOTES:
(†) “C” = Standard Models
“N” = 80% Low NOx Models
Ø 7/8 HOLE FOR
THERMOSTAT
Ø 7/8 HOLE FOR
ELECTRIC
29 1/2
22 1/2
Dimensions shown in Inches.
22 1/4
25
21 3/4
22 3/4
1 5/8 X 3 1/2 X 45°
HOLE FOR
GAS
RIGHT SIDE
5/8
7/8
3/8
12
16
19
7/8
1/8
7/8
1/8
*SK 80+ Downfl ow Furnace
D
FRONT
BRACE
18 5/8
BOTTOM VIEW
Ø 7/8 HOLE
FOR ELECTRIC
34 1/2
1 5/8 X 3 1/2 HOLE
FOR GAS
LEFT SIDE
25 3/8
28
ACCEPTS 4”
VENT PIPE
22 1/2
7
TYPE B
23
TOP VIEW
C
FLANGES
B
A
*SK Model #’s Dim. “A” Dim. “B” Dim. “C” Dim. “D”
(†)-23A14 1/410 3/412 5/812 7/8
054
(†)-24B
072
090
(†)-24B
(†)-35C
108
19
(†)-45D24 1/215 1/422 7/823 1/8
126
(†) “C” = Standard Models
“N” = 80% Low NOx Models
FOR THERMOSTAT
FOR ELECTRIC
Ø 7/8 HOLE
Ø 7/8 HOLE
17 1/211 3/415 7/816 1/8
211419 3/819 5/8
NOTES:
Dimensions shown in Inches.
22 1/4
25
1 5/8 X 3 1/2 X 45°
29 1/2
HOLE FOR GAS
22 1/2
7
RIGHT SIDE
Figure 17. Furnace Dimensions
27
Page 28
Model
Number
SA045(†)-23A
Bottom Return
Side Return
SA045(†)-23A
SA054(†)-23A
Bottom Return
Side Return
SA054(†)-23A
SA072(†)-24B
Bottom Return
Side Return
SA072(†)-24B
SA090(†)-24B
Bottom Return
Side Return
SA090(†)-24B
SA072(†)-35C
Bottom Return
Side Return
SA072(†)-35C
or 2 Sides
Side + Bottom
SA072(†)-35C
Heating
Input
(Btuh)
45,000
45,000
54,000
54,000
72,000
72,000
90,000
90,000
72,000
72,000
72,000
AIRFLOW DATA
*SA - UPFLOW / HORIZONTAL GAS FURNACES - 80% AFUE,
CAPACITY OF BLACK IRON GAS PIPE (CU. FT. PER HOUR)
FOR NATURAL GAS (SPECIFIC GRAVITY - 0.60)
NOMINAL BLACK
IRON PIPE
DIAMETER (IN.)
1/213090756555504540
3/42801901501301151059590
1520350285245215195180170
1 1/41,050730590500440400370350
1 1/21,6001,100890760670610
The cubic feet per hour listed in the table above must be greater than the cubic feet per hour of gas fl ow required by the
furnace. To determine the cubic feet per hour of gas fl ow required by the furnace, divide the input rate of the furnace by the
heating value (from gas supplier) of the gas.
1020304050607080
Cubic Feet Per Hour Required =
LENGTH OF PIPE RUN (FT)
NOTES
Input To Furnace (Btu/hr)
Heating Value of Gas (Btu/Cu. Ft.)
Table 7. Black Iron Gas Pipe Capacities
Page 33
ALTITUDE ABOVE
SEA LEVEL
0 to 1,999 FT
PROPANE GAS
INPUT (BTU)
45,00054,00072,00090,000108,000126,000
575656565656ORIFICE SIZE
10.010.010.010.010.010.0MANIFOLD PRESSURE
2,000 to 2,999 FT
3,000 to 4,999 FT
5,000 to 5,999 FT
6,000 to 7,999 FT
8,000 to 10,000 FT
575656565656ORIFICE SIZE
9.09.09.09.09.09.0MANIFOLD PRESSURE
575656565656ORIFICE SIZE
8.58.58.58.58.58.5MANIFOLD PRESSURE
595757575757ORIFICE SIZE
10.010.010.010.010.010.0MANIFOLD PRESSURE
595757575757ORIFICE SIZE
9.09.09.09.09.09.0MANIFOLD PRESSURE
595757575757ORIFICE SIZE
8.58.58.58.58.58.5MANIFOLD PRESSURE
Table 8. High Altitude Deration Chart for Propane Gas
ALTITUDE ABOVE
SEA LEVEL
2,000 FTLOWLOWLOWLOWLOWLOWHIGHHIGH HIGH
3,000 FTLOWLOWLOWLOWLOWLOWHIGHHIGH HIGH
4,000 FTLOWLOWLOWLOWLOWHIGHHIGHHIGH HIGH
5,000 FTLOWLOWLOWLOWLOWHIGHHIGHHIGH HIGH
6,000 FTLOWLOWLOWLOWHIGHHIGHHIGH HIGH HIGH
7,000 FTLOWLOWLOWLOW HIGHHIGHHIGHHIGH HIGH
8,000 FTLOWLOWLOWHIGH HIGHHIGHHIGH HIGH HIGH
9,000 FTLOWLOWLOWHIGH HIGHHIGHHIGH HIGH HIGH
10,000 FTLOWLOWHIGH HIGH HIGHHIGHHIGH HIGH HIGH
6507007508008509009501,000 1,050
LOCAL HEATING VALUE (BTU PER CUBIC FOOT)
Table 9. Natural Gas Heating Values
33
Page 34
ALTITUDE ABOVE
SEA LEVEL
0 to 1,999 FT
NATURAL GAS - HIGH HEATING VALUE
INPUT (BTU)
45,00054,00072,00090,000108,000126,000
494747474747ORIFICE SIZE
3.53.53.53.53.53.5MANIFOLD PRESSURE
2,000 to 2,999 FT
3,000 to 3,999 FT
4,000 to 4,999 FT
5,000 to 5,999 FT
6,000 to 6,999 FT
7,000 to 7,999 FT
8,000 to 8,999 FT
9,000 to 9,999 FT
Table 10. High Altitude Deration Chart for Natural Gas - High Heating Value
ALTITUDE ABOVE
SEA LEVEL
0 to 1,999 FT
494747474747ORIFICE SIZE
2.93.23.23.23.23.2MANIFOLD PRESSURE
494747474747ORIFICE SIZE
2.83.03.03.03.03.0MANIFOLD PRESSURE
494747474747ORIFICE SIZE
2.62.82.82.82.82.8MANIFOLD PRESSURE
494747474747ORIFICE SIZE
2.52.72.72.72.72.7MANIFOLD PRESSURE
514949494949ORIFICE SIZE
3.33.53.53.53.53.5MANIFOLD PRESSURE
514949494949ORIFICE SIZE
3.03.33.33.33.33.3MANIFOLD PRESSURE
514949494949ORIFICE SIZE
2.83.03.03.03.03.0MANIFOLD PRESSURE
514949494949ORIFICE SIZE
2.62.82.82.82.82.8MANIFOLD PRESSURE
NATURAL GAS - LOW HEATING VALUE
INPUT (BTU)
45,00054,00072,00090,000108,000126,000
494747474747ORIFICE SIZE
3.53.53.53.53.53.5MANIFOLD PRESSURE
2,000 to 2,999 FT
3,000 to 3,999 FT
4,000 to 4,999 FT
5,000 to 5,999 FT
6,000 to 6,999 FT
7,000 to 7,999 FT
8,000 to 8,999 FT
9,000 to 9,999 FT
494747474747ORIFICE SIZE
3.53.53.53.53.53.5MANIFOLD PRESSURE
494747474747ORIFICE SIZE
3.13.33.33.33.33.3MANIFOLD PRESSURE
494747474747ORIFICE SIZE
2.93.13.13.13.13.1MANIFOLD PRESSURE
494747474747ORIFICE SIZE
2.72.92.92.92.92.9MANIFOLD PRESSURE
494747474747ORIFICE SIZE
2.62.82.82.82.82.8MANIFOLD PRESSURE
514949494949ORIFICE SIZE
3.43.43.43.43.43.4MANIFOLD PRESSURE
514949494949ORIFICE SIZE
3.13.23.23.23.23.2MANIFOLD PRESSURE
514949494949ORIFICE SIZE
2.92.92.92.92.92.9MANIFOLD PRESSURE
Table 11. High Altitude Deration Chart for Natural Gas - Low Heating Value
34
Page 35
LOCATION OF FURNACE COMPONENTS
ITEM
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
COMPONENT NAME
Blower Assembly
Blower Door Switch
Burner Assembly
Control Board
Flame Sensor
Gas Manifold
Gas Valve
Igniter
Inducer Assembly
Limit Switch
Pressure Switch
Roll-Out Switch
Transformer
9
10
13
12
8
2
7
63
5
4
9
8
NEUTRALS
4
RCYGW
STATUS
24V
FAN
COOL
HEAT
FLAME
63
180
BLOWER
2
120
5
OFF
90
1
4
DELAY
60
L1A
2
1
XFMR
HIGH
LOW
HUM
EAC
MH
ML
L1
7
11
5
6
3
1
ITEM
COMPONENT NAME
1.Blower Assembly
2.
Blower Door Switch
(behind blower panel)
3.Burner Assembly
4.Combustion Tube
5.Control Board
6.Flame Sensor
7.Gas Manifold
8.Gas Valve
9.Igniter
10.Inducer Assembly
11.Limit Switch
12.Pressure Switch
13.Roll-Out Switch
14.
Transformer
Figure 19.
Upfl ow/Horizontal Gas Furnace
1
2
4
10
11
13
9
9
8
7
63
5
4
63
5
4
2
1
NEUTRALS
RCYGW
STATUS
24V
FAN
COOL
HEAT
FLAME
180
BLOWER
2
120
OFF
90
1
DELAY
60
L1A
XFMR
HIGH
LOW
HUM
EAC
MH
ML
L1
14
12
8
6
7
3
5
Figure 20. Downfl ow
Gas Furnace
35
Page 36
INSTALLATION/PERFORMANCE CHECK LIST
INSTALLER NAME:
CITY _______________STATE _____________
INSTALLATION ADDRESS:
CITY _______________STATE _____________
UNIT MODEL #
UNIT SERIAL # ____________________________
Minimum clearances per
Table 1 (page 6)?
Has the owner’s information
been reviewed with the
home-owner?
YESNO
YESNO
ELECTRICAL SYSTEM:
Electrical connections tight?YESNO
Line voltage polarity correct?YESNO
Supply Voltage: ______________________ VOLTS
Has the thermostat been
calibrated?
Is the thermostat level?YESNO
Is the heat anticipator setting
correct?
GAS SYSTEM:
Gas Type: (circle one)
Gas pipe connections leak
tested?
Gas Line Pressure: __________________ (in - W.C.)
Is there adequate fresh
air supply for combustion
and ventilation?
YESNO
YESNO
Natural
Gas
YESNO
YESNO
Propane
Has the literature package
been left near the
furnace?
YESNO
Installation Altitude: ____________________ (FT.)
Deration Percentage: ___________________ (%)
Furnace Input: _______________________ (Btuh)
Supply Air Temperature: ________________ (° F)
Return Air Temperature: ________________ (° F)
Temperature Rise: ____________________ (° F)
VENTING SYSTEM:
Vent free from restrictions?YESNO
Filter(s) secured in place?YESNO
Filter(s) clean?YESNO
Flue connections tight?YESNO
Is there proper draft?YESNO
O’Fallon, MO
¢709044#¤
7090440
7090440(Replaces 708807D)
Specifi cations and illustrations subject to change
without notice or incurring obligations.
Printed in U.S.A. (05/09)
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