Nordyne TA-072C-16B, TA-072C-12B, TA-120C-16B, TA-100C-20B, TA-120C-20B Installation Instructions Manual

...

Page 1

Gas Furnaces

Installation Instructions

*TA Full Size Series High Efficiency (Upflow/Horizontal) Two-Stage Furnace with Fixed Speed Blower *TK Full Size Series High Efficiency (Downflow) Two-Stage Furnace

with Fixed Speed Blower

*TA 80+ Upflow/Horizontal *TK 80+ Downflow

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.

FOR YOUR SAFETY:

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

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.

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.

Page 2

Page 3

Table of Contents

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

Upflow/Horizontal Models ....................................................................................................... 4

Downflow Models .................................................................................................................... 5

Capacities-Furnace Airflow Data ........................................................................................... 7

Safety Information ............................................................................................................................. 8

Installation Requirements ............................................................................................................ 6-8

Supply Air Plenum Installation .................................................................................................. 8-10

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

Installation on a Combustible Floor .................................................................................... 10

Venting and Combustion Air Requirements ................................................................................ 12

General ................................................................................................................................. 12

Installation in an Unconfined Space ................................................................................... 12

Installation in a Confined Space ......................................................................................... 13

Horizontal Furnace Installation ................................................................................... 13

Air From Inside ............................................................................................................. 14

Outdoor Air Using Vertical Ducts ................................................................................ 14

Air Directly Through an Exterior Wall .......................................................................... 15

Outdoor Air Using A Crawl Space and Ventilated Attic ............................................ 15

Outdoor Air Through Horizontal Ducts ....................................................................... 15

Venting Requirements .................................................................................................................... 15

General ................................................................................................................................. 15

Category I - Common Venting ............................................................................................. 16

Category III - Horizontal Venting ......................................................................................... 17

Horizontal Venting for *TK Models ............................................................................. 18

Horizontal Power Venting .................................................................................................... 19

Vent Termination Clearance ................................................................................................ 20

Location of Outdoor Terminations ....................................................................................... 20

Horizontal Installation .................................................................................................. 20

Flexible Vent Systems .......................................................................................................... 21

Circulating Air Supply .................................................................................................................... 21

General ................................................................................................................................. 21

Return Air .............................................................................................................................. 21

Gas Supply and Piping .................................................................................................................. 23

General ................................................................................................................................. 23

Leak Check .....................................................................................................................

High-Altitude Application ...................................................................................................... 24

Conversion ............................................................................................................................ 25

Natural Gas High Altitude Conversion ................................................................................ 25

LP/Propane Gas Sea Level and High Altitude Conversion .............................................. 25

Electrical Wiring ............................................................................................................................. 26

General ................................................................................................................................. 26

Line Voltage Wiring .............................................................................................................. 27

Low Voltage Wiring ............................................................................................................... 28

Start-up & Adjustments .................................................................................................................. 29

General ................................................................................................................................. 29

Start-Up Procedures .............................................................................................................29

Verifying and Adjusting Firing Rate .................................................................................... 29

Verifying and Adjusting Temperature Rise .................................................................... 29-30

Verifying Burner Operation .................................................................................................. 31

Verifying Operation of Supply Air Limit Switch ................................................................... 32

Wiring Diagram ................................................................................................................................ 34

Description of Components ........................................................................................................... 34

Maintenance..................................................................................................................................... 35

Vent System .......................................................................................................................... 36

Air Filter(s) .............................................................................................................................. 36

Lubrication ............................................................................................................................ 37

Blower Compartment ............................................................................................................ 37

Heat Exchanger and Burner Maintenance ......................................................................... 37

Cleaning of Flue Passages ................................................................................................. 37

Cleaning of Burners .............................................................................................................38

System Operation Information ...................................................................................................... 38

General ................................................................................................................................. 38

Sequence of Operation ....................................................................................................... 38

Heating Mode ............................................................................................................... 38

Cooling Mode ............................................................................................................... 38

Fan Mode ..................................................................................................................... 39

Furnace Fails to Operate ..................................................................................................... 39

Installation/Performance Checklist ............................................................................................. 40

...... 23

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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)

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

7/8 Cut-out for Electric

Connection

1 1/4D

X 3

Cut-out for

Gas Connection

Figure 1A. Upflow Unit Dimensions

FURNACE DIMENSIONS AND

SHIPPING WEIGHTS

High Low Dimensions Shipping

Model Input Input A B C Flue Outlet Weight D

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

060(*)-08A 60,000 42,000 14 1/4 12 3/4 3 1/4 4 120 11 3/4 060(*)-12A 60,000 42,000 14 1/4 12 3/4 3 1/4 4 132 11 3/4

072(*)-12 72,000 50,400 19 3/4 18 1/4 3 3/4 4 135 11 3/4

072(*)-16 72,000 50,400 19 3/4 18 1/4 3 3/4 4 152 11 3/4

096(*)-12 96,000 67,000 19 3/4 18 1/4 3 3/4 4 135 11 3/4

096(*)-16 96,000 67,000 19 3/4 18 1/4 3 3/4 4 152 11 3/4

096(*)-20 96,000 67,000 19 3/4 18 1/4 3 3/4 4 174 11 3/4

120(*)-16C 120,000 84,000 22 1/2 21 3 3/ 4 4 174 20

120(*)-20C 120,000 84,000 22 1/2 21 3 3/ 4 4 182 20

Note: (*) Can be C or N

Table 1A. Upflow Furnace Dimensions and Shipping Weights

Page 5

3/4"

FURNACE SPECIFICATIONS - Downflow Models

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"

DOWNFLOW FURNACE MODELS

27 1/8"

15 1/2"

(Bottom Opening)

10 1/4"

Figure 1B. Downflow Unit Dimensions

FURNACE DIMENSIONS AND

25"

Cut - out for

Gas Connection

Model High Low Shipping

Number Input Input A B C Weights

*TK (Btuh) (Btuh) inches inches inches (lbs)

060(*)-08 60,000 42,000 14 1/4 12 3/4 5 1/2 134 060(*)-12 60,000 42,000 14 1/4 12 3/4 5 1/2 134 072(*)-12 72,000 50,400 19 3/4 18 1/4 11 135 072(*)-16 72,000 50,400 19 3/4 18 1/4 11 147 096(*)-12 96,000 67,000 19 3/4 18 1/4 11 180 096(*)-16 96,000 67,000 19 3/4 18 1/4 11 180 096(*)-20 96,000 67,000 19 3/4 18 1/4 11 182 120(*)-16 120,000 84,000 19 3/4 18 1/4 11 180 120(*)-20 120,000 84,000 19 3/4 18 1/4 11 182

Note: (*) Can be C or N

Table 1B. Downflow Furnace Dimensions and Shipping Weights

SHIPPING WEIGHTS

D ime nsions

Page 6

CAPACITIES —Furnace Airflow Data

)

External Static Pressure (Inches Water Col umn)

0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8

790 55 / 37 785 56 / 38 760 58 / 39 750 59 / 40 720 61 / 41 685 65 / 43 655 68 /45 610 73 / 48

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

1360 34 / 21 1345 33 / 22 1310 32 / 22 1260 35 / 23 1205 37 / 24 1155 39 / 25 1095 40 / 27 1030 43 / 28

1165 37 / 24 1155 38 / 25 1135 39 / 26 1095 40 / 27 1045 43 / 28 1010 44 / 29 955 46 / 31 880 51 / 33

High‡

790 55 / 37 785 56 / 38 760 58 / 39 750 59 / 40 720 61 / 41 685 65 / 43 655 68 /45 610 73 / 48

1360 34 / 21 1345 33 / 22 1310 32 / 22 1260 35 / 23 1205 37 / 24 1155 39 / 25 1095 40 / 27 1030 43 / 28

1165 37 / 24 1155 38 / 25 1135 39 / 26 1095 40 / 27 1045 43 / 28 1010 44 / 29 955 46 / 31 880 51 / 33

1645 32 / 21 1575 34 / 22 1490 36 / 24 1395 40 / 23 1305 41 / 27 1230 43 / 30 1030 52 / 35 815 64 / 43

1410 38 / 25 1350 39 / 26 1280 42 / 28 1215 44 / 29 1130 47 / 32 1010 53 / 35 845 63 / 42 680 78 / 52

1140 47 / 31 1105 48 / 32 1055 51 / 34 980 54 / 36 910 58 / 40 795 67 / 44 640 83 / 55 525 - / 68

1870 28 / 18 1845 29 / 19 1790 30 / 20 1735 31 / 20 1665 32 / 21 1580 33 / 22 1500 35 / 23 1400 38 / 25

Low**

High‡

Low**

High‡

1480 36 / 24 1450 37 / 24 1420 38 / 25 1380 39 / 26 1325 40 / 27 1265 42 / 28 1190 45 / 30 1075 50 / 33

1030 52 / 34 1010 53 / 35 990 54 / 36 950 56 / 37 915 58 / 39 865 61 / 41 775 69 / 46 690 77 / 51

815 65 / 43 765 69 / 46 720 72 / 50 670 79 / 53 620 86 / 57 560 95 / 63 515 - / 69 440 - / 81

Low**

1495 50 / 30 1430 52 / 31 1360 55 / 32 1275 58 / 35 1210 61 / 37 1090 68 / 40 925 80 / 48 740 - / 60

High‡

1345 55 / 33 1300 57 / 34 1240 60 / 36 1185 63 / 38 1115 66 / 40 975 76 / 45 880 84 / 67 675 - / 65

970 76 / 46 940 78 / 47 920 80 / 48 860 86 / 51 780 95 / 57 690 - / 65 575 - / 77 455 - / -

1935 38 / 23 1895 39 / 24 1835 40 / 24 1775 42 / 25 1715 43 / 26 1640 45 / 28 1555 47 / 30 1440 51 / 31

1660 44 / 27 1635 45 / 27 1600 46 / 28 1565 47 / 28 1525 49 / 29 1465 50 / 30 1400 53 / 32 1335 55 / 33

1390 53 / 32 1375 54 / 32 1330 55 / 33 1320 56 / 33 1290 56 / 34 1245 57 / 35 1200 59 / 37 1110 66 / 40

1180 63 / 37 1165 64 / 38 1140 65 / 39 1120 66 / 40 1095 67 / 41 1060 69 / 42 1015 73 / 44 970 76 / 46

2310 31 / 18 2255 32 / 19 2205 33 / 20 2155 34 / 20 2070 35 / 21 2015 35 / 22 1920 36 / 23 1840 40 / 24

High‡

Low**

High‡

2040 36 / 21 2010 37 / 22 1960 38 / 23 1900 39 / 24 1875 40 / 25 1815 41 / 25 1755 42 / 26 1650 45 / 27

1760 42 / 25 1735 43 / 25 1710 43 / 26 1665 44 / 27 1620 45 / 27 1565 47 / 28 1495 49 / 30 1410 52 / 31

1285 57 / 35 1275 58 / 36 1250 59 / 37 1225 60 / 38 1180 63 / 38 1135 65 / 39 1085 68 / 40 1065 69 / 42

Low**

1980 45 / 27 1945 45 / 28 1910 46 / 28 1860 48 / 29 1795 50 / 30 1720 52 / 31 1640 54 / 33 1545 58 / 35

High‡

1675 52 / 31 1665 53 / 32 1640 54 / 32 1610 55 / 33 1565 57 / 34 1515 59 / 35 1460 61 / 37 1375 64 / 39

1410 63 / 37 1395 64 / 38 1380 65 / 39 1360 66 / 40 1340 67 / 41 1310 68 / 42 1260 70 / 43 1185 75 / 45

1205 - / 44 1190 - / 45 1175 - / 45 1160 - / 46 1140 - / 47 1115 - / 48 1085 - / 49 1050 - / 51

2400 37 / 22 2360 37/ 23 2310 38 / 24 2255 40 / 24 2200 41 / 24 2140 42 / 25 2070 43 / 26 1990 45 / 27

2105 41 / 25 2095 42 / 25 2075 43 / 25 2060 43 / 26 2015 44 / 27 1960 45 / 27 1910 46 / 28 1845 49 / 29

1750 51 / 31 1745 51 / 31 1740 52 / 31 1720 52 / 31 1710 52 / 31 1680 53 / 32 1645 54 / 32 1600 56 / 33

1520 59 / 33 1515 59 / 33 1510 60 / 34 1500 60 / 35 1490 61 / 36 1475 61 / 37 1450 61 / 37 1425 62 / 38

Low**

High‡

Low**

2. TEMPERATUR E RISES IN THE TABL E ARE APPROXIMATE. ACTUAL TEMPERATURE RISES MAY VARY

3. TEMPERATURE RISES AND AIRFLOWS FOR EXTERNAL STATIC PRESSURES GREATER THAN 0.5 ARE FOR RFERENCE ONLY.

THESE CONDITIONS ARE NOT RECOMMENDED.

4. TEMPERATURE RISES ARE DISPLAYED AS HIGH FIRE / LOW FIRE

NOTES: 1. AIRFLOW RATES OF 1800 CFM OR MORE REQUIRE TWO RETURN AIR CONNECTIONS. DATA IS FOR OPERATION WITH FILTERS(S

*TA (Btuh) Speed HP

Model Heating

Number Input Motor Motor

060-08A 60,000 Med* 1/3

060-12A 60,000 Med* 1/3

80+ UPFLOW/HORIZONTAL FURNACE MODELS

Low**

072-12B 72,000 Med* 1/3

Med-Low*

072-16B 72,000 Med-High 1/2

Low**

096-12B 96,000 Med* 1/3

Med-Low*

096-16B 96,000 Med-High 1/2

Table 2A. Furnace Airflow Data

Med-Low*

096-20B 96,000 Med-High 3/4

120-16C 120,000 Med-High 1/2

Med-Low*

120-20C 120,000 Med-High 3/4

‡ = FACTORY SET COOLING

* = FACT ORY SET HIGH FIRE

** = FACTORY SET LOW FIRE

Page 7

)

CAPACITIES —Furnace Airflow Data (Continued)

External Static Pressure (Inches Water Column)

0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8

1420 31 / 20 1380 32 / 21 1340 33 / 22 1300 34 / 23 1235 36 / 24 1185 37 / 25 1110 40 / 26 1045 42 / 28

High‡

1215 36 / 23 1195 37 / 24 1175 38 / 25 1145 39 / 26 1105 40 / 27 1050 42 / 28 995 45 / 29 960 46 / 31

1/3

Med*

820 54 / 36 815 54 / 36 810 55 / 37 800 55 / 37 770 57 / 38 745 59 / 40 715 62 / 41 665 67 / 45

Low** High‡

CFM Ri se CFM Ri se CFM Rise CFM Rise CFM Rise CFM Rise CFM Ri se CFM Rise

1420 31 / 20 1380 32 / 21 1340 33 / 22 1300 34 / 23 1235 36 / 24 1185 37 / 25 1110 40 / 26 1045 42 / 28

1215 36 / 23 1195 37 / 24 1175 38 / 25 1145 39 / 26 1105 40 / 27 1050 42 / 28 995 45 / 29 960 46 / 31

1/3

Med*

820 54 / 36 815 54 / 36 810 55 / 37 800 55 / 37 770 57 / 38 745 59 / 40 715 62 / 41 665 67 / 45

Low** High‡

1655 32 / 21 1580 34 / 22 1500 35 / 24 1440 37 / 24 1355 40 / 26 1260 42 / 28 1155 46 / 31 980 54 / 36

1440 37 / 25 1400 38 / 25 1355 39 / 26 1285 42 / 28 1225 44 / 29 1145 46 / 31 1010 53 / 35 855 62 / 41

1015 52 / 35 1000 53 / 36 965 55 / 37 920 58 / 38 865 61 / 41 790 67 / 45 680 78 / 52 540 99 / 66

1985 27 / 18 1945 27 / 18 1900 28 / 18 1850 29 / 19 1780 30 / 20 1715 31 / 21 1640 33 / 22 1545 35 / 23

High‡

1680 32 / 21 1650 32 / 21 1625 33 / 22 1600 33 / 22 1560 34 / 23 1505 35 / 23 1420 37 / 25 1330 40 / 27

1450 36 / 24 1410 37 / 25 1390 38 / 26 1370 39 / 26 1345 40 / 27 1305 41 / 28 1245 43 / 29 1160 46 / 31

1215 44 / 29 1190 45 / 30 1175 45 / 30 1170 45 / 31 1145 46 / 31 1115 48 / 32 1070 49 / 33 1020 52 / 35

Low**

1950 38 / 33 1885 39 / 23 1815 40 / 24 1765 42 / 25 1685 44 / 26 1600 46 / 27 1535 48 / 29 1425 52 / 31

High‡

1700 43 / 25 1665 44 / 26 1630 45 / 27 1580 47 / 28 1540 48 / 27 1475 50 / 30 1410 52 / 32 1330 55 / 33

1/2

Med-High

1430 51 / 30 1425 51 / 31 1395 52 / 32 1380 53 / 32 1335 55 / 33 1295 57 / 34 1230 60 / 36 1150 64 / 38

Med-Low*

1230 60 / 36 1225 60 / 36 1215 61 / 36 1190 62 / 37 1165 63 / 38 1130 65 / 39 1110 66 / 40 1070 69 / 42

1950 38 / 33 1885 39 / 23 1815 40 / 24 1765 42 / 25 1685 44 / 26 1600 46 / 27 1535 48 / 29 1425 52 / 31

Low** High‡

1700 43 / 25 1665 44 / 26 1630 45 / 27 1580 47 / 28 1540 48 / 27 1475 50 / 30 1410 52 / 32 1330 55 / 33

1/2

Med-High*

1430 51 / 30 1425 51 / 31 1395 52 / 32 1380 53 / 32 1335 55 / 33 1295 57 / 34 1230 60 / 36 1150 64 / 38

Med-Low**

1230 60 / 36 1225 60 / 36 1215 61 / 36 1190 62 / 37 1165 63 / 38 1130 65 / 39 1110 66 / 40 1070 69 / 42

Low

2100 35 / 20 2070 36 / 21 2010 37 / 22 1945 38 / 23 1905 39 / 23 1840 40 / 24 1790 41 / 25 1710 43 / 26

High‡

1830 40 / 23 1805 41 / 24 1760 42 / 25 1725 43 / 36 1680 44 / 27 1635 45 / 28 1555 47 / 29 1480 50 / 30

3/4

Med-High

1580 47 / 27 1550 48 / 28 1520 49 / 29 1490 50 / 30 1455 51 / 31 1395 53 / 32 1355 55 / 33 1280 57 / 35

Med-Low*

1175 63 / 37 1155 64 / 38 1120 65 / 39 1100 67 / 40 1070 69 / 41 1035 71 / 42 990 45 / 44 930 79 / 48

1950 46 / 27 1885 47 / 28 1815 48 / 29 1765 50 / 30 1685 53 / 31 1600 55 / 33 1535 58 / 35 1425 62 / 38

Low** High‡

1700 53 / 31 1665 53 / 32 1630 55 / 33 1580 56 / 34 1540 57 / 34 1475 60 / 36 1410 63 / 38 1330 67 / 40

1/2

Med-High

1430 63 / 37 1425 62 / 38 1395 64 / 39 1380 65 / 40 1335 66 / 41 1295 68 / 42 1230 72 / 43 1150 77 / 46

Med-Low*

1230 71 / 43 1225 72 / 44 1215 73 / 45 1190 74 / 46 1165 76 / 46 1130 78 / 47 1110 80 / 48 1070 83 / 49

2100 42 / 25 2070 43 / 26 2010 44 / 26 1945 46 / 27 1905 47 / 28 1840 48 / 29 1790 49 / 30 1710 52 / 31

Low** High‡

1830 48 / 28 1805 49 / 29 1760 50 / 30 1725 51 / 31 1680 53 / 32 1635 54 / 33 1555 57 / 34 1480 60 / 35

3/4

Med-High

1580 56 / 33 1550 57 / 34 1520 58 / 35 1490 59 / 36 1455 61 / 36 1395 63 / 38 1355 65 / 39 1280 71 / 42

Med-Low*

1175 75 / 45 1155 77 / 46 1120 79 / 47 1100 80 / 48 1070 83 / 50 1035 85 / 51 990 90 / 54 930 95 / 57

Low**

2. TEMPERATUR E RISES IN THE TABL E ARE APPROXIMATE. ACTUAL TEMPERATURE RISES MAY VARY

3. TEMPERATURE RISES AND AIRFLOWS FOR EXTERNAL STATIC PRESSURES GREATER THAN 0.5 ARE FOR RFERENCE ONLY.

THESE CONDITIONS ARE NOT RECOMMENDED.

4. TEMPERATURE RISES ARE DISPLAYED AS HIGH FIRE / LOW FIRE

NOTES: 1. AIRFLOW RATES OF 1800 CFM OR MORE REQUIRE TWO RETURN AIR CONNECTIONS. DATA IS FOR OPERATION WITH FILTERS(S

*TK (Btuh) Speed HP

Model Heating

Number Input Motor Motor

060-08A 60,000

060-12A 60,000

80+ DOWNFLOW FURNACE MODELS

Low**

072-12B 72,000 Med* 1/3

Med-Low*

072-16B 72,000 Med-High 1/2

100-12B 100,000

100-16B 100,000

Table 2B. Furnace Airflow Data

100-20B 100,000

120-16B 120,000

120-20B 120,000

‡ = FACTORY SET COOLING

* = FACT ORY SET HIGH FIRE

** = FACTORY SET LOW FIRE

Page 8

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 12 through 17.

4. Combustion products must be discharged outdoors. Connect this furnace to an approved vent system only, as specified on Pages 14 through 20.

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 23 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 11 of these instructions.

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

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

IMPORTANT NOTE

The Commonwealth of Massachusetts requires compliance with regulation 248 CMR

4.00 and 5.00 for installation of through – the – wall vented gas appliances as follows:

(a) For direct-vent appliances, mechanical-

vent heating appliances or domestic hot water equipment, where the bottom of the vent terminal and the air intake is installed below four feet above grade the following requirements must be satisfied:

1. If there is not one already present, on each floor level where there are bedroom(s), a carbon monoxide detector and alarm shall be placed in the living area outside the bedroom(s). The carbon monoxide detector shall comply with NFPA 720 (2005 Edition).

2. A carbon monoxide detector shall be located in the room that houses the appliance or equipment and shall:

a. Be powered by the same electrical

circuit as the appliance or equipment such that only one service switch services both the appliance

and the carbon monoxide detector; b. Have battery back-up power; c. Meet ANSI/UL 2034 Standards and

comply with NFPA 720 (2005 Edi-

tion); and d. Have been approved and listed by a

Nationally Recognized Testing Labo-

ratory as recognized under 527

CMR.

3. A Product-approved vent terminal must be used, and if applicable, a Productapproved air intake must be used. Installation shall be in strict compliance with the manufacturer’s instructions. A copy of the installation instructions shall remain with the appliance or equipment at the completion of the installation.

4. A metal or plastic identification plate shall be mounted at the exterior of the building, four feet directly above the

Page 9

location of vent terminal. The plate shall be of sufficient size to be easily read from a distance of eight feet away, and read “Gas Vent Directly Below”.

(b) For direct-vent appliances, mechanical-

vent heating appliances or domestic hot water equipment where the bottom of the vent terminal and the air intake is installed above four feet above grade the following requirements must be satisfied:

2. A carbon monoxide detector shall:

a. Be located in the room that houses

the appliance or equipment;

b. Be either hard-wired or battery pow-

ered or both; and

c. Shall comply with NFPA 720 (2005

Edition).

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 *TK gas furnace is for downflow operation only. 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.

Access for positioning and servicing the unit must be considered when locating unit. Twenty four inches is the minimum required clearance from the front of the unit for servicing it. Thirty inches is the minimum required clearance from the front of the unit for positioning it. Thirty Six

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.

Downflow Warning (*TK 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 subbase may result in fire, property damage and personal injury. The special downflow subbases are factory supplied accessories, part numbers 902974, 902677, 904108 and 904165. 904165 is an adjustable sub-base kit and it can be used in all cabinet sizes. 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.

CAUTION:

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

Page 10

Upflow Furnace Models

UPFLOW APPLICATION

TOP

LEFT

BOTTOM

RIGHT

HORIZONTAL APPLICATION

SIDE

TOP

SIDE

Downflow Furnace Models

BOTTOM

INSTALLATION CLEARANCES

Vent Connector

Type

LEFT SIDE

RIGHT SIDE

VENT

BACK

BOTTOM

TOP

FRONT

Standard Single

Wall Metal Vent

0" 0" 0" 0" 6" 1" 0" 0" 0"** 0"** 1" 1" 4"*** 4"***

Type B-1 Double

Wall Metal Vent

** For Downflow furnace installations only, furnace

must be installed on non-combustible flooring.

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

recommended clearance is 36".

Table 3. Minimum Clearances to Combustible Material

LEFT SIDE

TOP

RIGHT SIDE

BOTTOM

Page 11

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.

Supply Air Plenum Installation

A. Installation on a concrete slab. - *TK

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

2. Place the plenum and the furnace as shown in Figure 3.

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.

18.75"

19.25"

Hole in

Floor

*TK 072 *TK 100 *TK 120

13.25"

19.25"

Hole in

Floor

*TK 060

Figure 2. Opening for Concrete Slab

B. Installation on a combustible floor. - *TK

For downflow furnace installation, this furnace is approved for use on combustible flooring when NORDYNE combustible floor sub-base kit #904165 is used.

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

2. Install the sub-base according to the installation instructions. (See Figure 5)

18.75"

or 13.25”*

16.75"

1.50"

9.25"

28.38"

2.0"

19.63"

Concrete

Floor

Furnace

Sheet

Metal

Plenum

Figure 3. Furnace on a Concrete Slab

18.75"

20.63"

Hole in

Floor

*TK 072 *TK 100 *TK 120

13.25"

20.63"

Hole in

Floor

*TK 060

Figure 4. Opening in Wood Floor

1.58"

1 inch thick fiberglass 3 lb density

19.75"

or 14.25”*

*Smaller dimension for *TK60

Figure 5. Downflow Sub-Base

Dimensions

Downflow

Sub-base

Furnace

Sheet

Metal

Plenum

Wood

Floor

Figure 6. Furnace with Coil Assembly

on a Wood Floor

Page 12

3. 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 surface is at least 1” from combustible material in Figure 6.

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.

When determining combustion air space, the full rate input of this two-stage furnace must be used.

Combustion Air Quality

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

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 Out- door 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

CAUTION:

Combustion air must not be drawn from a corrosive atmosphere.

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.

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

Page 13

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 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.

The *TA series furnace may be installed directly on combustible wood flooring or supports, if type "B-1" vent pipe is used (See Figure 8). 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.

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.

Horizontal Furnace Installation

The *TA series furnaces 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 Figures 7 and

8.)

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. (See Figure 7.)

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.

Figure 7. *TA Horizontal Installation

Suspended in Attic or Crawl Space

Note: Line Contact is Permissible

Type “B” Vent

Coil Plenum

Electrical

Supply

Connection

Gas Inlet

Combustible Platform

Louver Door

Figure 8. *TA Horizontal installation on a

Platform

Page 14

See the venting section for venting guidelines and specifications.

Air From Inside (See Figure 9)

If combustion air is taken from the heated

each

space, the two openings must

have a free area of at least one square 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 com-

bined input rate of all appliances is 120,000 Btuh, each opening must have a free area of at least 120 square inches.

Outdoor Air Using Vertical Ducts (See Figure 10) 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.

Water Heater

Total Input

Rating (Btu/hr)

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

Vent or Chimney

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.

Furnace

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.

12" Max.

Round Duct

Diameter

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

Figure 9. 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.

Inlet Air Duct must be at least 1 sq. in.

Round Duct

Diameter

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

Inlet and Outlet

Ducts must

extend above

attic insulation.

per 4,000 Btuh of

total input rating.

12" Max

Figure 10. Equipment in a Confined

Space with all Combustion Air Drawn

from the Outside through Vertical Ducts

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.

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.

Vent or Chimney

Each openin to out mu 1 sq. in. per 4000 Btuh of total input ratin

side

st be at lea

12" Max

Total Input

Rating (Btuh)

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

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.

Furnace

Round Duct

Diameter

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

Figure 11. Equipment in a Confined

Space with all Combustion Air Drawn

from the Outside through Exterior Wall

Page 15

Air Directly Through An Exterior Wall

(See Figure 11)

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.

Outdoor Air Using a Crawl Space and Ventilated

Attic (See Figure 12)

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 13)

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.

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.

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 acceptance to the authority having jurisdiction. Venting into an

unlined masonry chimney or concrete chimney is prohibited.

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. Single wall metal vents shall not be used for Category I venting, Category I furnaces must be vented vertically or near vertically.

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.

Vent or Chimney

Furnace

Water Heater

Ventilation Louvers for unheated crawl space

Ventilation Louvers at each end of attic

Attic Insulation

Crawl Space

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

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

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.

Vent or

Furnace

Water Heater

(Each Opening)

Chimney

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"

side

st be at lea

12" Max

Rating (Btu/hr)

Each openin to out mu 1 sq. in. per 2000 Btuh of total input ratin

12" Max

Total Input

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

Figure 12. Equipment in a Confined

Space with All Combustion Air Drawn

from a Crawl Space and Ventilated Attic

Figure 13. Equipment in a Confined Space

with all Combustion Air Drawn from the

Outside through Horizontal Ducts

Page 16

Three sheet metal fasteners (field supplied) should be used to secure the vent pipe to the furnace flue. These fasteners should be evenly spaced around the flue diameter, if possible.

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

WARNING:

improperly sized venting system can result in the formation of condensate, leakage, spillage, etc.

The steps outlined in the warning below shall be followed with each individual appliance connected to the vent system placed in operation, while all other appliances connected to the vent system are not in operation:

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

Natural Gas and Propane Installation Codes

mine 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

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, fireplace dampers and any other gas-fired burning appliance to their previous conditions of use.

National Fuel Gas Code, ANSI Z223. 1/NFPA 54 or the CSA B149.1,

and these instructions. Deter-

National Fuel Gas Code,

Page 17

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 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

appliances. When venting horizontal, this is 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. NOTE: No bleed tube is required for the *RA

045(C,N)-08 model.

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 14.)

Pressure

Switch

Bleed Tube

Sensor

Tubes

NOTE: The reduced NOx models (eighth

character N) are not approved as a Category III (Category III) furnace for use with horizontal venting.

The furnaces are approved for use with 3"

single wall AL29-4C 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

Collector Pan

Figure 14. *TA Bleed Tube Installation

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

15.)

3. Bypass the vent switch by removing both wires from the vent switch and attaching them to the wire nut. (See Figure 16.)

Page 18

Collector Pan

Cover Plate

Covered Vent

Nut

Collar Hole

Figure 15. Vent Collar Detail

Switch

Limit

Blue

Switch

Flame

Roll-Out

Switch

Vent Limit

Blue

Wire Nut

Figure 16. Limit Circuit Wiring

Horizontal Venting: *TK Models:

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.)

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

17.)

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 18.)

4. Remove and discard the restrictor plate and screw from the transition assembly. (See Figure 18.)

5. Install and seal a 4" to 3" reducer to the transition. (See Figure 19.) Attach the new high temperature vent pipe to the reducer.

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.

Bleed Tube

Orifice

Pressure

Switch

Figure 17. *TK Bleed Tube Installation

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 20.)

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.

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.

Combustion

Tube

Remove

and

Discard

Screw

Restrictor

Plate

Transition

Inducer

Figure 18. *TK Horizontal

Vent Modification

Page 19

Special 3"

AL29-4C Stainless

Steel

Vent Pipe

with this furnace. 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.

4" to 3" Reducer

Transition

Figure 19. *TK Reducer Installation

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 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.

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 Pipe Reducer Maximum Max. Feet

Input Size Needed # Elbows Vent Pipe

60,000 3" 4" to 3" 4 35 72,000 3" 4" to 3" 4 35 96,000 3" 4" to 3" 4 35

120,000 3" 4" to 3" 4 30

Table 4. Horizontal

Venting Requirements

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.

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.

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-

1 horizontal kit is certified for use

(For combustible

/4" Per

Wall Thimble

wall material)

90˚ Elbow

0-6'

Locking Band

Te e

Drain

Plug

Support

Foot Rise

3" Dia. Loop

Figure 20. Typical Horizontal Vent

Installation

Locking Band

Termination

Te e

Outside

Wall

Page 20

Location of Outdoor Terminations

Horizontal Installation

The vent termination tee must be installed with the following minimum clearances. (See Figure

21.) Vent termination clearances shall be con-

sistent with the

National Fuel Gas Code, ANSI

2223.1/NFPA 54 and/or the CSA B149.1, Natural Gas and Propane Installation Code.

VENT TERMINAL

Clearance abov e grade, veranda, porch,

A =

deck, or balc ony

Clearance t o window or door that may be

B =

opened

Clearance t o permanently closed window

C =

Vertical c learance to ventilat ed sof fit

D =

locat ed above t he terminal within a horizont al dis tanc e of 2 feet (61 cm) from the center line of the terminal Clearance to unventilated soff it

E =

Clearance t o outside corne

F =

Clearance t o inside corner

G =

Clearance to each side of c enter line

H =

extended above met er/re Clearance t o service regulator vent outlet 3 feet (1.83 m)

I =

Clearance t o nonmechanical air supply inlet

J =

to building or the combust ion air inlet to any other appliance

Clearance t o a mechanical air supply inlet 6 feet (1. 83 m) 3 feet (91 c m) above if wit hin 10 feet (3 m)

K =

Clearance abov e paved sidewalk or paved

L =

driveway located on public property

Clearance under v eranda, porch deck, or

M =

balcony

ulator as sembl

AIR SUPPLY INLET

Canadian Installations

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

6 inches (15 cm) for applianc es ≤ 10,000 Btuh (3 kW), 12 inc hes (30 c m) for appliances > 10,000 B tuh (3 k W) and ≤ 100,00 Btuh (30 kW), 36 inches (91 cm) for appliances >100,00 Bt uh (30 kW)

3 feet (91 cm) wit hin a height 15 feet above t he meter/re

6 inches (15 cm) for applianc es ≤ 10,000 Btuh (3 kW), 12 inc hes (30 c m) for appliances > 10,000 B tuh (3 k W) and ≤ 100,00 Btuh (30 kW), 36 inches (91 cm) for appliances >100,00 Bt uh (30 kW)

7 feet (2.13 m) † 7 feet (2. 13 m)

12 inches (30 cm) ‡

AREA WHERE TERMINAL IS NOT PERMITTED

** ** **

ulator as sembl

US Installations

4 feet (1. 2 m) below or to s ide of opening; 1 foot (300 mm) above opening

horizont ally

In accordance with the current CSA B149.1 Natural Gas and Propane 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 statement shall be included:

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

Figure 21. Vent Termination Clearances for Other Than Direct Vent Furnaces

manufacturer’s installation instructions.”

Page 21

All minimum clearances specified must be maintained to protect building materials 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 22 for alternate method to achieve 12" above snow level.

2. 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.

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

4. 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 22.) 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.

5. 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.

6. 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.

7. 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 23.)

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).

Use Wall Thimble at Vent Points

Termination Tee

Support vent pipe every 5 feet

Figure 22. Alternate Horizontal

Vent Installation

Ground Level

Combustible

Wall Thimble

(Inner Half)

3" Vent

Pipe

Inner Shield 41/2" Dia.

Combustible

Inside

Wall

Inside

Wall

Outer Overlapping Shield 6

Wall Thimble Outer Half

Locking Band

Inner Overlapping Shield 63/8" Dia.

12" Min

Outside Combustible Wall

Figure 23. Typical Termination

/2" Dia.

Protective

Screen

3" Termination

Te e

Page 22

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 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.

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.

For Upflow/Horizontal 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 pages of these instructions, contains the airflow data for each furnace model. Where maximum airflow is 1800 CFM or more, two openings must be used for return air.

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

Manifold

Burner Assembly

Figure 24. Typical Gas

Service Connection

Downflow Models- Right Side Entry

Shut-Off Valve

Some utilities

require Shut-Off

Valve to be

4 to 5 feet

above floor

Dripleg

Burner Assembly

Manifold

Automatic Gas

Valve (with manual

shut-off)

Ground Joint Union

Page 23

1/2

130907565555045403/4

280

190

150

130

115

10595901520

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

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.

lation must comply with the latest edition of the National Fuel Gas Code (ANSI Z223.1) or (CAN/ CGA B149.1 or .2) Installation Codes.

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.

Leak Check

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.

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 24. 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 instal-

CAPACITY OF BL ACK I RON GAS PIPE (CU. FT. PE R HOUR)

FOR NATURAL GAS (SPECIFIC GRAVITY - 0.60)

NOMINAL LENGTH OF PIPE RUN

BLACK IRON (feet)

PIPE DIAMETER

(in.) 1020304050607080

The cub ic f eet per hour list ed in t he table above m ust b e greater t han the c ubic feet per hour of g as fl ow required by the f urnace.

To determ ine t he cubic feet per hour of gas f low required b y the furnace, div ide the input rat e of the furnace by the heat ing value of the gas :

Cubic Feet P er Hour Required Input T o Furnace (Btu/ hr)

Heating V alue of Gas (Btu /Cu. Ft .)

Table 5. Capacity of Black Iron Gas Pipe

(cu. ft. per hour) for Natural Gas

(specific gravity = .60)

Page 24

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.

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.

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

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.

MANIFOLD PRESSURE ADJUSTMENT

Manifold pressures for low and high stages are independently adjustable. Adjustment tap locations on the valve are shown in Figure 25. Manifold pressure would be adjusted below procedure:

- Turn off gas shut off valve outside furnace.

- Install manometer on the gas valve at the outlet pressure tap.

- Turn on the shut off. Run furnace at high fire and set manifold pressure. Also set manifold pressure while running at low fire (refer to Tables 7 and 8.)

- Ensure plug is tight after removing manometer.

HIGH STAGE ADJUSTMENT UNDER VENT CAP

2-STAG E OPERATOR

INLET PRESSURE TAP 1/8 NPT

(Honeywell shown)

(4) QUICK DISCONNECT TERMINALS

1ST STAG E REGULATOR COVER REGULATOR ADJUST BENEATH THIS SCREW

VENT (.330 DIA. +DFT. POST) ACCEPTS 5/16” HOSE CONNECTION

2ND STAG E REGULATOR COVER REGULATOR ADJUST BENEATH THIS SCREW

(White Rodgers shown)

Figure 25. Gas Valve

VENT FITTING FOR 90 PLUS EFFICIENT APPLIANCES

LOW STAGE ADJUSTMENT UNDER VENT CAP

OUTLET PRESSURE TAP 1/8 NPT

INLET PRESSURE POST SET SCREW: 3/32” HEX HEAD (.339 DIA. +DFT.) ACCEPT S 5/18” HOSE CONNECTION

CONTROL LABEL

OUTLET PRESSURE POST SET SCREW: 3/32” HEX HEAD (.339 DIA. +DFT.) ACCEPT S 5/18” HOSE CONNECTION

Page 25

)

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

(

)

(

)

(

)

Manif old Press ure Set ting (in WC) Full Input

Low Input

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

Manif old Press ure Set ting (in WC) Full Input

Low Input

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

Manif old Press ure Set ting (in WC) Full Input

Low Input

zero to

Elev ation

2000 to

1999

3.5 3.5 3.5

1.7 1.7 1.7

Elev ation

2000 to

1999

3.5 3.5 3.5

1.7 1.7 1.7

Elev ation

2000 to

1999

3.5 3.5 3

1.7 1.7 1.5

feet above sea level

5000 to

4999

feet above sea level

5000 to

4999

feet above sea level

5000 to

4999

5999

6000 to

7999

3.5 3.0

1.7 1.6

6000 to

7999

3.2 2.8

1.6 1.5

6000 to

7999

2.8 2.5

1.4 1.3

8000 to

10000

8000 to

10000

8000 to

10000

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

For a LP Gas Sea Level Heating Value of 2,500 Btu/hr.

zero to

Manif old Press ure Setting (in WC) Full Input

Low Input

Elev ation (feet above sea level

2000 to

1999

10 8.5 10

5.5 5.5 6.5

4999

5000 to

5999

6000 to

7999

8000 to

10000

98.5

6.5 6.5

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

Furnace Ratin

Plate Input (Btu/h)

Orifice Drill Size Orifice Drill Size

Nat LP

60,000 45 55 60,000 45 56 72,000 43 54 72,000 43 55 96,000 43 54 96,000 43 55

120,000 43 54 120,000 43 55

Table 8. Natural and LP Gas Orifice Sizes

for Elevations between zero and 4999 ft.

Above Sea Level

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.

Furnace Ratin

Plate Input (Btu/h)

Nat LP

Table 9. Natural and LP gas Orifice Sizes

for Elevations between 5000 and 10,000

ft. Above Sea Level

LP/Propane Gas Conversion

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

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.

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

Page 26

zero and 5000 ft. above sea level, a, #54 drill size orifice should be used depending upon the rated firing rate of the unit (see Table 8 or 9). However for installations above 5000 ft. above sea level, a # 55 drill size orifice should be used. After changing the orifices, use Table 7 to determine the appropriate manifold pressure for your 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.

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 904404.

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 904405.

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.

Furna ce Furnace C abinet N omina l Max imum Minimum Max imum Minimum Maximum

Model Num ber Input Width Elec tr ica l Operating Ope rating Furna ce Wire Fuse or Cir cuit

*TA ,*TK (Btu/hr) (in.) Supply Voltage Voltage Amperes Gauge Brea ke r Amps* *

060(†)-08A 60,000 14. 25 115-60-1 127 103 7.1 14 15 060(†)-12A 60,000 14. 25 115-60-1 127 103 7.1 14 15 072(†)-12B 72,000 19. 75 115-60-1 127 103 7.1 14 15 072(†)-16B 72,000 19. 75 115-60-1 127 103 9.0 14 15 096(†)-12B 100,000 19.75 115-60-1 127 103 7.1 14 15 096(†)-16B 100,000 19.75 115-60-1 127 103 9.0 14 15 096(†)-20B 100,000 19.75 115-60-1 127 103 14.5 12 20 120(†)-16B 120,000 19.75 115-60-1 127 103 9.0 14 15 120(†)-20B 120,000 19.75 115-60-1 127 103 14.5 12 20 120(†)-16C 120,000 22.50 115-60-1 127 103 9.0 14 15 120(†)-20C 120,000 22.50 115-60-1 127 103 12.2 12 20

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.

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

Thermostat Wire Gauge Recommended Thermostat Wire Length

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

2-wire 4 or 5-wire

(heating) (cooling)

Table 10. Electrical Data

Page 27

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 35.)

CAUTION:

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

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. Accept-

able 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 26.

Field Supplied

Fused Service

Panel

Black (Hot)

White (Neutral)

Green or Bare

(Ground)

Field Supplied

Panel Connector

Black White

Ground

Field Supplied Disconnect Within Sight of Furnace

Ground

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.

Figure 26. Line Voltage Field Wiring

A/C Condensing Unit

Condensing Unit

Control Box

Blower Off

3 Amp

Fuse

Flame Signal Light

Status Light

HEAT

M1M2M3

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

24 V

EAC

HUM

Neutrals

Unused Motor Leads

HUM

63 52 41

Timing

(Yellow)

(Red)

COOL

EAC

Field Line Voltage Wiring

Factory Line Voltage Wiring

6090120

180

TWIN

XFMR

Figure 27. Low Voltage Field, Four-wire Heating/Cooling Applications

Page 28

Low Voltage Wiring

Staging Configurations

These furnaces are factory configured to operate on high fire only, but can be field converted to operate as two-stage furnaces.

NOTE: T efficiency, the furnace should be operated in the factory configuration (high fire only as described in part 2.)

Two stage thermostat configuration

1. installation a two stage heating thermostat is used. CAUTION: Disconnect yellow wire with black stripe from low firing of gas valve. Remove female connector from yellow/black wire and strip insulation from end. Connect stripped yellow wire with black stripe to (W2) from the thermostat. (See Figure 28). The first stage bulb (W1) is connected to W on the furnace control board. On a call for first stage heat, the furnace will operate at low fire and the blower will run at a lower speed. On a call for second stage heat, the furnace will operate at high fire and the blower will run at a higher speed. The furnace will stage between low fire, high fire, and off depending on the thermostat signal.

O achieve full rated capacity and

– For this

High fire only configuration

– As shipped from the factory, the low and high terminals on the gas valve. are connected in parallel (See Figure 29). This defeats the staging feature and the furnace operates on high fire only. All of the burners will operate on a call for heat and the variable speed blower will operate at a higher speed.

Low fire only configuration

– For this installation,

the high terminal is disconnected (See Figure

30). This defeats the staging feature and the furnace operates on low fire only. The furnace will run at reduced firing rate and the variable speed blower will operate at a lower speed.

Outdoor ambient dependent configuration

4. For this installation, the high and low terminals are connected in parallel with an outdoor thermostat (open on rise style) in series with the high terminal (See Figure 31). CAUTION: DO NOT CONNECT W2 from outdoor thermostat to the furnace wiring when using the outdoor ambient dependent configuration. When the outdoor temperature is above the set point, the outdoor thermostat opens keeping the high terminal closed. The furnace operates in the low fire mode at a lower blower speed. When the

–

Legend

Field Wiring

Factory Wiring:

Low Voltage High Voltage

AIR CONDITIONER

CONDENSING UNIT

CLOSED END CONNECTOR

DO NOT REMOVE

BROWN

YELLOW

LO C

N.O

N.C

24V

DPST

RELAY

TWO STAGE ROOM

THERMOSTAT

BROWNBROWN

YELLOW/BLACK

YELLOW

RED - LOW FIRE

BLUE - HIGH FIRE

CONTROL BOARD

HUM

ORANGE

INTEGRATED

COOL

HEAT

EAC

PRESENT ON ALL MODELS

BLACK

YELLOW

BROWN

XFMR

THESE WIRES ARE NOT

WHITE

YG W

963 852

3 OR 4 SPEED

MOTOR

RED

ORANGE

BLUE

BLACK

Figure 28. Two Stage Configuration

Page 29

outdoor thermostat closes, the high fire on gas valve opens and the furnace operates in the high fire mode at higher blower speed.

Timed staging configuration

– For this installation, the low and high on the gas valve are connected in parallel with a delay on make timer (two wire style) in series with the low fire gas valve (See Figure 32). CAUTION: DO NOT CONNECT W2 from thermostat to the furnace wiring when using timed stage configuration. When the low fire on the gas valve is energized, the furnace operates in the low fire mode at a lower blower speed and the timer begins its delay function. If the room thermostat is not satisfied before the timer activates, the furnace will stage to high fire and the blower will operate at a higher speed until the room thermostat is satisfied.

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 control board in the furnace. See Figures 28-32 for the proper connections for heating only (four wire) and heating/cooling (five 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.

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 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.

To check the heat anticipator setting either:

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

2. Measure the current flow on the thermostat RW 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:

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

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.

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

Page 30

Legend

Field Wiring

Factory Wiring:

Low Voltage High Voltage

AIR CONDITIONER

CONDENSING UNIT

CLOSED END CONNECTOR

DO NOT REMOVE

BROWN

YELLOW

LO C

N.O

N.C

24V

DPST

RELAY

TWO STAGE ROOM

THERMOSTAT

BROWNBROWN

YELLOW/BLACK

YELLOW

RED - LOW FIRE

BLUE - HIGH FIRE

CONTROL BOARD

HUM

ORANGE

INTEGRATED

COOL

HEAT

EAC

PRESENT ON ALL MODELS

BLACK

YELLOW

BROWN

XFMR

THESE WIRES ARE NOT

WHITE

YG W

963 852

3 OR 4 SPEED

MOTOR

RED

ORANGE

BLUE

BLACK

Legend

Field Wiring

Factory Wiring:

Low Voltage High Voltage

Figure 29. High Fire Only Configuration

TWO STAGE ROOM

THERMOSTAT

AIR CONDITIONER

CONDENSING UNIT

CLOSED END CONNECTOR

DO NOT REMOVE

BROWN

YELLOW

LO C

N.O

N.C

24V

DPST

RELAY

YELLOW/BLACK

INTEGRATED

CONTROL BOARD

ORANGE

COOL

HEAT

HUM

YELLOW

RED - LOW FIRE

BLUE - HIGH FIRE

BROWNBROWN

YELLOW

BROWN

XFMR

EAC

THESE WIRES ARE NOT

PRESENT ON ALL MODELS

BLACK

WHITE

YG W

963

852

3 OR 4 SPEED

MOTOR

RED

ORANGE

BLUE

BLACK

Figure 30. Low Fire Only Configuration

Page 31

Legend

Field Wiring

Factory Wiring:

Low Voltage High Voltage

AIR CONDITIONER

CONDENSING UNIT

CLOSED END CONNECTOR

DO NOT REMOVE

BROWN

YELLOW

LO C

N.O

N.C

24V

DPST

RELAY

TWO STAGE ROOM

THERMOSTAT

BROWNBROWN

YELLOW/BLACK

ODT

YELLOW

RED - LOW FIRE

BLUE - HIGH FIRE

INTEGRATED

CONTROL BOARD

HUM

ORANGE

COOL

XFMR

HEAT

EAC

THESE WIRES ARE NOT

PRESENT ON ALL MODELS

BLACK

YELLOW

BROWN

YG W

963 852

3 OR 4 SPEED

MOTOR

RED

ORANGE

BLUE

BLACK

WHITE

Legend

Field Wiring

Factory Wiring:

Low Voltage High Voltage

Figure 31. Outdoor Ambient Dependent

TWO STAGE ROOM

THERMOSTAT

24V

DPST

YELLOW/BLACK

SDT

CONTROL BOARD

HUM

ORANGE

YELLOW

RED - LOW FIRE

BLUE - HIGH FIRE

BROWNBROWN

INTEGRATED

COOL

HEAT

EAC

PRESENT ON ALL MODELS

BLACK

YELLOW

BROWN

XFMR

THESE WIRES ARE NOT

AIR CONDITIONER

CONDENSING UNIT

CLOSED END CONNECTOR

DO NOT REMOVE

BROWN

YELLOW

LO C

N.O

N.C

RELAY

YG W

963

852

3 OR 4 SPEED

MOTOR

RED

ORANGE

BLUE

BLACK

WHITE

Figure 32. Timed Two Stage Configuration

Page 32

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:

Verifying and Adjusting Temperature Rise

Verify the temperature rise through the furnace is within the range specified on the furnace rating plate. Temperature rises outside the specified range could result in premature heat exchanger failure.

• 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.

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. For typical duct systems, the temperature rise will fall within the range specified on the rating plate with the blower speed at the factory recommended setting. If the temperature rise measured is outside the range specified, it may be necessary to change the blower speed. Lower blower speeds will increase the temperature rise and higher blower speeds will decrease the temperature rise. The furnace is equipped with a multi-speed motor. Heating and cooling speed selection is made by moving the leads located in the furnace (See Figure 33 blower relay). The wiring diagram on the furnace and Figure 35 show the speed taps for adjusting motor speed.

CAUTION:

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

YELLOW

N.O

N.C

24V

DPST

RELAY

Figure 33. Blower Relay

If it is desired that the blower operate at the same speed for heating and cooling, tape off the unused blower lead and install the jumper wire. The jumper wire should be connected between the “cool” terminal on the control board and the

3 OR 4 SPEED

MOTOR

CONTROL BOARD

HUM

INTEGRATED

COOL

HEAT

XFMR

EAC

ORANGE

6 PIN

PLUG

WHITE

RED

BLUE

BLACK

Page 33

appropriate terminal on the blower relay. Figure 33 shows high fire heating and cooling using the same blower speed.

The integrated control is factory set to start the circulating air blower 30 seconds after the gas valve is opened. The integrated control is factory wired to turn the blower motor off 120 seconds after the gas valve is closed. If necessary for comfort, the “off” time may be changed by adjusting the Blower Off jumper on the integrated control. See Figure 34 for blower on and off time adjustments.

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 ob-

serve 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 closeoff 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 circulating air and combustion blowers should continue to run when the limit switch opens. Remove the close-off immedi-

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

Blower Off

Timing

Flame Signal

Light (Yellow)

Status

Light (Red)

COOL

HEAT

EAC

120

180

XFMR

Electronic Air Tap

(.5A@ 120 VAC)

Figure 34. Integrated Control

Page 34

ately after the limit switch opens. If the furnace operates for more than four minutes with no return air, set the thermostat to a temperature below room temperature, shut off the power to the furnace, and replace the limit switch.

DESCRIPTION OF COMPONENTS

Figure 36 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

For Upflow and Downflow Series Residential Furnaces

BLOWER DECK

LIMIT SWITCH

YELLOW

BLUE

SINGLE OR

TWO STAGE ROOM

THERMOSTAT

BROWN

N.O

N.C

24V

DPST

RELAY

SUPPLY AIR

LIMIT SWITCH

WHITE (NEUTRAL)

CLOSED END CONNECTOR

DO NOT REMOVE

BROWN

Legend

Field Wiring

Factory Wiring:

Low Voltage High Voltage

Gas Valve

BLUE

AIR CONDITIONER

CONDENSING UNIT

BROWN

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

Ignition Failure (Check Ground)

115 VAC & Neutral Reversed or no Ground

False Flame or Gas Valve Relay Shorted Power Off

FAULT CONDITION Low Flame Sensor Signal

Flame Present

BLUE

BLACK 120V

GROUND

YELLOW/BLACK

STATUS

LIGHT

1 FLASH

2 FLASHES

3 FLASHES

4 FLASHES

5 FLASHES

Continuous

FLAME

YELLOW

LIGHT

Continuous

Flash

FLAME ROLL-OUT

SWITCH

YELLOW

RED (Low Fire)

BLUE (High-Fire)

RED

OFF

BLUE

SAFETY SWITCH

FLAME SENSOR

VENT

IGNITOR

INDUCER

BLUE

RED

YELLOW

112

ORANGE

WHITE W/BLK STRIPES

BLK W/ WHITE STRIPES

COM

24 V

Y G

852

BROWN

NEUTRALS

EAC

HUM

BLACK

WHITE

GREEN

3 AMP FUSE

HUM

PRESSURE

SWITCH

ORANGE

BLACK

TRANSFORMER

24 V

BLOWER OFF

COOL

XFMR

HEAT

EAC

THESE WIRES ARE NOT

PRESENT ON ALL MODELS

BLACK

WHITE

TWIN

BLACK

If any of the original wire as supplied with the furnace must be replaced, it must be replaced with wiring material having a temperature rating of at least 105° C.

Use copper conductors only.

BLOWER DOOR

SWITCH

WHITE

120 V

BLACK

FLAME

STATUS

3 OR 4 SPEED

MOTOR

BLACK

WHITE

RED

ORANGE

BLUE

BLACK 5

WD#7105460

Figure 35. Wiring Diagram for Upflow and Downflow Models

Page 35

GAS FLOW RATE (CUBIC FEET PER 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

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 rollout 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.

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.

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.

Pressure Switch

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

Page 36

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)

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.

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.

Upflow Models

1 4

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

Downflow

Models

10 Low Voltage

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

15 Combustion Tube

w/insulation (Downflow Models)

16 Vent Transition

Assembly (Downflow Models)

Figure 36. Location of Major Components

Page 37

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:

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.

Cleaning Of Flue Passages

If the flue passages must be cleaned, follow the steps below. See Figure 36 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 thethermostat 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, overtemperature limit switch, pressure switch.

CAUTION:

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

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

7. For *TA upflow 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.

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.

13. The furnace heat exchanger tubes can now be cleaned by the use of a round wire brush attached to a length of high grade stainless steel cable, such as drain cleanout cable. Attach variable speed reversible drill to the other end of the spring cable. Slowly rotate the cable with the drill and insert it into the top portion of the heat exchanger. While reversing the drill, work the cable in and out several times to obtain sufficient cleaning. Repeat this sequence for each heat exchanger tube.

14. When all heat exchanger tubes have been cleaned, any debris inside the tubes can be removed with the nozzle of a vacuum cleaner.

15. With a light, check the condition of the upper and lower sections of the heat exchanger tube.

16. Inspect the burners and clean them (if necessary) with a soft wire brush and/or the nozzle

Page 38

of a vacuum cleaner. BE EXTREMELY CARE-

FUL NOT TO DAMAGE THE IGNITER WHILE CLEANING THE BURNER.

17. Replace all the parts in reverse order from which they were removed.

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

Cleaning of Burners

If the burners must be cleaned, follow the steps below. See Figure 36 for component location and identification.

1. Shut off the gas supply to the furnace either 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 the lowest temperature setting.

3. Remove the upper louvered door from the furnace.

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

5. Disconnect the wires from the gas valve, igniter, and flame sensor.

6. Using 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 necessary.

8. 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.

9. Inspect the burners and clean them (if necessary) with a soft wire brush and/or the nozzle of a vacuum cleaner. BE EXTREMELY CARE-

FUL NOT TO DAMAGE THE IGNITER WHILE CLEANING THE BURNER.

10. Replace all the parts in reverse order from which they were removed.

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

SYSTEM OPERATION INFORMATION General

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

1. Do not place combustible materials on or against the furnace cabinet or within 6 inches of the vent pipe.

2. Do not store gasoline or any other flammable vapors and liquids in the vicinity of the furnace.

3. Change or replace the air filters monthly during

any period when the circulating blower is operating regularly.

4. Always replace the doors on the furnace after servicing or cleaning/changing the filters. Do not operate the furnace without all doors and covers in place.

5. Avoid operating the furnace when windows and doors are open.

6. Be sure that the thermostat is properly

installed and is not being affected by drafts or heat from lamps or other appliances.

Sequence of Operation

The operating sequences for the heating, cooling, and fan modes are described below. Refer to the field and furnace wiring diagrams; Figures 26, 27, 28, 29, 30, 31, 32, 33, 34 and 35.

Heating Mode:

1. On a call for heat the thermostat closes, applying 24 VAC to the W terminal on the control board.

2. The control board checks for continuity on the 24 VAC limit control circuit (over-temperature limit switch, flame rollout switches and blocked vent switch in series). If an open limit is detected the control board will energize the inducer and the conditioned air blower. All other system functions will be inoperable until the limit circuit closes. While the limit is open, the red LED will pulse at a rate of 1 blink per unit time.

3. The furnace control checks for continuity across the pressure switch (24 VAC). If the pressure switch is closed the heat mode sequence will not continue. If it remains closed for 10 seconds the red LED will blink 3 times repetitively until the fault condition clears.

4. The inducer is energized.

5. The pressure switch will close. If the pressure switch does not close after 10 seconds the fault LED will blink 2 times repetitively and the inducer will continue to run until the switch is closed.

6. The inducer will pre-purge for 30 seconds and then the igniter will start its warm-up as follows:

Initial Power up: After 30 seconds of igniter warm-up the gas valve (24 VAC) will then open. The igniter circuit will stay energized for 3 seconds after the gas valve opens.

After Initial Power up: The control has a programmed adaptive ignition feature which varies

Page 39

the warm-up period as follows: If ignition is successful the warm-up is reduced by 3seconds on each subsequent call for heat until ignition failure occurs. Upon ignition failure, the warm-up is increased by 3-seconds on the next try. If successful, the timing remains fixed at this level. In general, whenever ignition failure occurs the warm-up interval is increased by 3-seconds on the next try. And if successful, it remains there. Minimum and maximum warmup time limits are set at 6 and 54-seconds, respectively.

7. The furnace control must prove flame via the flame sensor 5 seconds after the gas valve opens. If flame is sensed, all burners are on and the igniter cools off. If no flame is sensed, the gas valve closes immediately and the inducer continues to run. A second trial for ignition (step 6) begins if no flame is sensed on the fifth try for ignition, the furnace control is locked and the red LED will blink 4 times repetitively. The thermostat must be opened for at least ten seconds to reset the furnace control after a lock out. Otherwise, the furnace will attempt another ignition sequence in 1 hour.

8. The furnace control energizes the circulating air blower on the heating speed 30 seconds after the gas valve circuit is energized .

9. When the thermostat has been satisfied, gas valve is de-energized.

10. The inducer is de-energized after a 30-second postpurge.

2. The furnace control energizes the circulating blower (115 VAC) on the cooling speed.

3. When the thermostat is satisfied, the G and Y terminals on the control board are de-energized opening the compressor contactor.

4. The circulating air blower is de-energized after a 90-second delay.

Fan Mode:

1. On a call for fan operation, the thermostat applies 24 VAC to the G terminal on the furnace control board.

2. The circulating air blower is energized immediately on the low heating speed.

3. If the furnace is operated in the continuous ON position at the thermostat and is then switched to AUTO, the circulating blower will operate for a specified delay (factory set at 120 seconds).

Furnace Fails to Operate If the furnace does not operate check the following:

1. Is the thermostat operating properly?

2. Are the blower compartment door(s) in place?

3. Is the furnace disconnect closed?

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

5. Is the gas turned on?

6. Are any manual reset switches open?

7. Is the filter dirty or plugged?

8. Is the flame sensor coated? (Remove and clean with emery cloth.)

11. The furnace control keeps the circulating air blower energized for 120 seconds (factory set) or 60, 90, or 180 seconds (field adjustable). (See Figure 34.)

12. Abnormal conditions: If a limit opens during operation, the inducer and circulating air blower continue to operate. The gas valve is deenergized immediately. The blowers continue to operate until the limit closes. When the limit closes the inducer blower is de-energized immediately. The circulating air blower continues to operate for the specified delay (factory set at 120 seconds).

Cooling Mode:

1. On a call for cooling the thermostat closes, applying 24 VAC to the G and Y terminals on the furnace control. This closes the compressor contactor.

If the furnace locks out after 5 attempts for ignition, it will try again every hour if a call for heat remains. If the inducer and circulating air blowers are operating, and items 1 through 8 have been checked, press the red reset button on the vent safety switch (See Figure 36). If the furnace operates after depressing the reset button, contact a qualified serviceman to identify and repair the problem.

If the furnace continues to not operate, depress the red reset buttons on the flame roll-out switches. (See Figure 36.) If the furnace operates after depressing the reset buttons, contact a qualified servicemen to identify and repair the problem.

Twinning

The two-stage furnace may not be twinned.

Page 40

INSTALLATION/PERFORMANCE CHECK LIST

LOCATION _________________ CITY ___________________ STATE ______________

INSTALLER ________________ CITY ___________________ STATE ______________

UNIT MODEL NUMBER ________________________________

UNIT SERIAL NUMBER _________________________________

Minimum Clearances per Table 1? _____

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? ___________

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? _________________________

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

Temperature Rise: ______________ (° F)

¢708509>¤

O'Fallon, MO

7085090

7085090 (Replaces 7084370)

Specifications and illustrations subject to change without

notice and without incurring obligations. Printed in

U.S.A. (11/05)