Nordyne TA UPFLOW, TK DOWNFLOW Installation Instructions Manual

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Page 1

TWO-STAGE NONCONDENSING GAS FURNACES WITH FIXED & VARIABLE SPEED BLOWERS - 80+ AFUE

Installation Instructions

*TA UPFLOW / HORIZONTAL MODEL

WARNING:

FIRE OR EXPLOSION HAZARD

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

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

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

WHAT TO DO IF YOU SMELL GAS

• Do not try to light any appliance.

• Do not touch any electrical switch; do not use any phone in your building.

• Leave the building immediately.

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

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

*TK DOWNFLOW MODEL

AVERTISSEMENT

RISQUE D’INCENDIE OU D’ EXPLOSION

• Le non-respect des avertissements de sécurité pourrait entraîner des blessures graves, la mort ou des dommages matériels.

• L’installation et l’entretien doivent être effectués par un installateur qualifié, un organisme de service ou le fournisseur de gazstaller, service agency or the gas supplier.

• Ne pas entreposer ni utiliser de l’essence ni d’autres vapeurs ou liquides inﬂ ammables dans le voisinage de cet appareil, ni de tout

autre appareil.

QUE FAIRE S’IL Y A UNE ODEUR DE GAZ

• Ne pas tenter d’allumer aucun appareil.

• Ne toucher à aucun interrupteur électrique; n’utiliser aucun téléphone dans le bâtiment.

• Évacuer l’immeuble immédiatement.

• Appeler immédiatement le fournisseur de gaz en employant le téléphone d’un voisin. Respecter à la lettre les instructions du fournisseur de gaz.

• Si personne ne répond, appeler le service des incendies.

DO NOT DESTROY THIS MANUAL. KEEP IN A SAFE PLACE FOR FUTURE REFERENCE.

Page 2

TABLE OF CONTENTS

IMPORTANT SAFETY INFORMATION .......................3

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

Combustion Air Quality .............................................4

Operation of Furnace During Construction ...............4

Installation in a Garage ............................................4

Clearances to Combustible Materials ....................... 5

Heating Load ............................................................5

COMBUSTION AIR & VENTING REQUIREMENTS ....6

General Information .................................................7

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

Air From Inside ...................................................7

Outdoor Air from a Crawl Space or

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

Outdoor Air Using Vertical Ducts ........................8

Outdoor Air Using Horizontal Ducts ...................8

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

Alternate Method of Providing Air from

Outside ...............................................................9

Installation in an Unconﬁ ned Space .........................9

Category I Venting ....................................................9

Horizontal Venting ..................................................10

Flexible Vent Systems ............................................ 10

CIRCULATING AIR REQUIREMENTS ......................11

Plenums & Air Ducts ..............................................11

Supply Air Connections ..........................................11

Upﬂ ow / Horizontal Furnaces ...........................11

Downﬂ ow Furnaces ..........................................11

Return Air Connections ..........................................11

Upﬂ ow / Horizontal Furnaces ...........................11

Side Return Installations .............................11

Bottom Return Installations ........................12

Downﬂ ow Furnaces ..........................................12

Acoustical Treatments ............................................12

FURNACE INSTALLATION .......................................12

General Requirements ........................................... 12

Upﬂ ow Installation .................................................. 12

Side Return Air Inlet ......................................... 12

Bottom Return Air Inlet ..................................... 12

Downﬂ ow Installation .............................................. 12

Installation on a Concrete Slab ........................ 13

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

Pressure Switches ................................................. 14

Bottom Panel Removal ........................................... 14

Alternate Bottom Panel Removal ..................... 14

GAS SUPPLY & PIPING ............................................15

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

High-Altitude Application ........................................16

Conversion to LP / Propane ...................................18

ELECTRICAL WIRING ...............................................18

Line Voltage Wiring ................................................19

Grounding ..............................................................19

Thermostat / Low Voltage Connections .................19

Single Stage AC & Single Stage Heat

Thermostat .......................................................20

Single Stage AC & Two - Stage Heat

Thermostat .......................................................20

Two - Stage AC & Two - Stage Heat

Thermostat .......................................................20

Autostaging for Single Stage Thermostats .............20

Autostaging for Two-Stage Thermostats ................21

Heat Anticipator ......................................................21

Dehumidiﬁ cation Options .......................................21

Blower Speed Conﬁ guration ...................................21

Fixed Speed Blowers ........................................21

Variable Speed Blowers ....................................21

START-UP & ADJUSTMENTS ...................................22

Pre-Start Checklist .................................................22

Start-Up Procedures ..............................................22

Verifying & Adjusting Input Rate ............................22

Verifying & Adjusting Temperature Rise .................23

Verifying Burner Operation ....................................23

Verify Operation of the Supply Air Limit Switch ......23

OPERATING SEQUENCE .........................................23

Heating Cycle .........................................................23

Cooling Cycle .........................................................24

Fan Mode ...............................................................24

MAINTENANCE .........................................................24

Air Filters ................................................................25

Blower Compartment .............................................25

Cleaning of Burners ...............................................25

Cleaning of Flue Passages ....................................25

Heat Exchanger & Burner Maintenance .................26

Lubrication ..............................................................26

Vent System ...........................................................26

DESCRIPTION OF COMPONENTS ..........................26

TROUBLESHOOTING ...............................................27

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FIGURES & TABLES .................................................28

Figure 20 - Furnace Dimensions ...................... 28

Airﬂ ow Data ............................................................29

Table 5 - Heating / Cooling Airﬂ ows and

Temperature Rises - Fixed

Table 6 -

Variable Speed ....................................31

Table 7 -

Variable Speed....................................32

Electrical Information ...........................................33

Figure 21 - Two-Stage Fixed Speed Motor

Control Board ..................................33

Figure 22 - Two-Stage Variable Speed

Motor Control Board ........................33

Figure 23 - Two-Stage Furnace Control Board ..33 Figure 24 - Wiring Diagram - Two Stage Fixed

Speed Upﬂ ow/Horiz. Furnaces ........34

Figure 25 - Wiring Diagram - Two Stage Fixed

Speed Downﬂ ow Furnaces .............35

Figure 26 - Wiring Diagram - Two Stage Variable

Speed Upﬂ ow/Horiz. Furnaces .......36

Figure 27 - Wiring Diagram - Two Stage Variable

Speed Downﬂ ow Furnaces .............37

Gas Information ...................................................38

Table 8 - Gas Flow Rates ..................................38

Table 9 - Gas Pipe Capacities ...........................38

Table 10 - High Altitude Deration Chart for

Propane Gas ....................................39

Table 11 - Natural Gas Heating Values .............39

Table 12 - High Altitude Deration Chart for

Nat. Gas - High Heating Value .........40

Table 13 - High Altitude Deration Chart for

Nat. Gas - Low Heating Value ..........40

Location of Furnace Components ........................41

Figure 28 - Upﬂ ow / Horizontal Gas Furnace

Components ...................................42

INSTALLATION / PERFORMANCE CHECKLIST .....44

Nominal CFM & Temperature Rises -

Nominal Cooling / Heat Pump CFM -

Speed ......30

IMPORTANT SAFETY INFORMATION

Please read all instructions before servicing this equipment. Pay attention to all safety warnings and any other special notes highlighted in the manual. Safety markings are used frequently throughout this manual to designate a degree or level of seriousness and should not be ignored. WARNING indicates a potentially hazardous situation that if not avoided, could result in personal injury or death. CAUTION indicates a potentially hazardous situation that if not avoided, may result in minor or moderate injury or property damage.

REQUIREMENTS & CODES

WARNING:

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

• This furnace must be installed in accordance with these instructions, all applicable local building codes and the current revision of the National Fuel Gas Code (NFPA54/ANSI Z223.1) or the Natural Gas and Propane Installation Code, CAN/CGA B149.1.

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

• Install this furnace only in a location and position as speciﬁ ed on page 5.

• Provide adequate combustion and ventilation air to the furnace space as speciﬁ ed on pages 6 - 10.

• Combustion products must be discharged outdoors. Connect this furnace to an approved vent system only, as speciﬁ ed on pages 9 - 10.

• Never test for gas leaks with an open ﬂ ame. Use a commercially available soap solution to check all connections. See pages 15 - 16.

• This furnace is designed to operate with a maximum external pressure rise of 0.5 inches of water column. Consult Tables 5 - 7 (pages 30 - 32), and the rating plate for the proper circulating air ﬂ ow and temperature rise. It is important that the duct system be designed to handle the desired ﬂ ow rate and temperature rise. An improperly designed duct system can result in nuisance shutdowns, and comfort or noise issues.

• When supply ducts carry air circulated by the furnace to areas outside the space containing the furnace, the return air shall also be handled by duct(s) sealed to the furnace casing and terminating outside the space containing the furnace. See pages 11 - 12.

• This furnace may be used for temporary heating of buildings or structures under construction. See the guidelines listed on pages 4 - 5.

• A gas-ﬁ red furnace for installation in a residential garage must be installed as speciﬁ ed on page 5.

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

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Combustion Air Quality

CAUTION:

Combustion air must not be drawn from a corrosive atmosphere.

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

• If the furnace is installed in a conﬁ ned space, it is required that the necessary combustion air come from the outdoors by way of attic, crawl space, air duct, or direct opening. For Installations in conﬁ ned spaces, see pages 7 - 8 for combustion air requirements.

• Installations in these locations may require outdoor air for combustion, due to chemical exposures:

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

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

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

Operation of Furnace During Construction

CAUTION:

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

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

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

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

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

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

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

Installation in a Garage

WARNING:

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

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

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Clearances to Combustible Materials

This furnace is Design Certiﬁ ed in the U.S. and Canada by CSA International for the minimum clearances to combustible materials. NOTE: The furnace is listed for installation on combustible or non-combustible ﬂ ooring. However, wood is the only combustible ﬂ ooring allowed for installation. Downﬂ ow models must use the appropriate subase kit when installing over a wood ﬂ oor. To obtain model number and speciﬁ c clearance information, refer to the furnace rating plate, located inside of the furnace cabinet.

Access for positioning and servicing the unit must be considered when locating unit. The need to provide clearance for access to panels or doors may require clearance distances over and above the requirements.

Allow 24 inches minimum clearance from the front of the unit. However 36 inches is strongly recommended.

See Table 1 for minimum clearance requirements.

CLEARANCES TO COMBUSTIBLE MATERIALS

Left Side..................0 Inches Top ..........................0 Inches

†

Right Side ...............0 Inches Front ......................

Vent ......................... 0 Inches Back ........................0 Inches

†

Allow 24 in. minimum clearance for servicing. Recommended

clearance is 36 in.

UPFLOW & DOWNFLOW

APPLICATIONS

BACK

TOP

LEFT SIDE

FRONT

VENT

RIGHT SIDE

HORIZONTAL

APPLICATIONS

TOP

VENT

SIDE

4 Inches

FRONT

BOTTOM

Table 1. Minimum Clearances to

Combustible Materials

Heating Load

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

oversizing of the furnace could cause the furnace and/or vent to fail prematurely. The ductwork should

be appropriately sized to the capacity of the furnace to ensure its proper airﬂ ow rating.

Two-stage furnaces operate at two input rates to better meet heating loads. The lower heating rate (low ﬁ re) is 65% of the high ﬁ re rate. The greatest degree of control over the furnace can be gained by controlling it with a two stage thermostat. This allows the thermostat to directly request either high or low ﬁ re. However, it is possible to operate the furnace using a single stage thermostat. In this application the furnace control can be set to increase from low to high ﬁ re, based on a timer. See Autostaging for Single Stage Thermostats (page 20).

Furnaces are properly sized to meet the expected maximum heating load. But this load occurs infrequently. So, during more moderate weather, the furnace is likely to use low ﬁ re a considerable part of the time. This is normal and has the beneﬁ t of quieter and more efﬁ cient operation.

The information listed below is for reference purposes only and does not necessarily have jurisdiction over local or state codes. Always consult with local authorities before installing

any gas appliance.

Combustion and Ventilation Air

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

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

Duct Systems

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

Electrical Connections

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

• CANADA: Canadian Electrical Code CSA C22.1

Gas Piping and Gas Pipe Pressure Testing

• US: NFGC and National Plumbing Codes

• CANADA: NSCNGPIC

General Installation

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

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

Safety

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

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

For installations above 2,000 ft., the furnace should have a sea level input rating large enough that it will meet the heating load after deration for altitude.

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COMBUSTION AIR & VENTING REQUIREMENTS

WARNING:

CARBON MONOXIDE POISONING HAZARD

Failure to follow the steps outlined below for each appliance connected to the venting system being placed into operation could result in carbon monoxide poisoning or death.

The following steps shall be followed with each individual appliance connected to the venting system being placed in operation, while all other appliances connected to the venting system are not in operation:

1. Seal any unused openings in the venting system.

2. Inspect the venting system for proper size and horizontal pitch, as required in the National

Fuel Gas Code, ANSI Z223.1/NFPA 54 or the CSA B149.1, Natural Gas and Propane Installation Codes and these instructions.

Determine that there is no blockage or restriction, leakage, corrosion and other deﬁ ciencies which could cause an unsafe condition.

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

4. Close ﬁ replace dampers.

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

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

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

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

Gas Code, ANSI Z223.1/NFPA 54 and/or CSA B149.1, Natural Gas and Propane Installation Codes.

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

AVERTISSEMENT:

RISQUE D’EMPOISONNEMENT AU

MONOXYDE DE CARBONED

Le non-respect des consignes suivantes portant

sur chacun des appareils raccordés au système d’évacuation mis en service pourrait entraîner l’empoisennement au monoxyde de carbone ou la mort. Les consignes suivantes doivent être observées pour chaque appareil raccordé au système d’évacuation mis en service si les autres appareils raccordés au système ne sont pas en service:

1. Sceller toute ouverture non utilisée de la systéme d’évacuation;

2. S’assurer que la systéme d’évacuation présente des dimensions et une pente horizontale conformes à la norme ANSI Z223.1/NFPA 54, intitulée National Fuel Gas Code ou aux codes d’installation CSA-B149.1, ainsi qu’aux présentes instructions. S’assurer que la systéme d’évacuation n’est pas bloquée, restreinte, corrodée, qu’elle ne fuit pas et qu’elle ne présente aucun autre défaut potentiellement dangereux;

3. Dans la mesure du possible, fermer toutes les portes et fenêtres du bâtiment, et toutes les portes entre la pièce où se trouve l’appareil raccordé à la systéme d’évacuation et les autres pièces du bâtiment.

4. Fermer les registres des foyers;

5. Mettre en service les sécheuses et tout autre appareil qui n’est pas raccordé à la systéme d’évacuation. Faire fonctionner à régime maximal tout ventilateur d’évacuation, tel que les hottes de cuisinière et les ventilateurs de salles de bains. Ne pas mettre en service les ventilateurs d’été.

6. Respecter les instructions d’allumage. Mettre en service l’appareil à l’essai. Régler le thermostat de manière à ce que l’appareil fonctionne sans interruption;

7. Vériﬁ er s’il y a débordement à l’oriﬁ ce d’évacuation du coupe tirage des appareils dotés d’un coupe tirage 5 minutes après l’allumage du brûleur principal. Utiliser la ﬂ amme d’une allumette ou d’une chandelle.

8. Si l’on constate, au cours de l’un des essais qui précèdent, que l’évacuation est déﬁ ciente, corriger le système d’évacuation conformément à la norm ANSI Z223.1/NFPA 54, National Fuel Gas Code, et (ou) aux codes d’installation CSA B149.1.

9. Après avoir déterminé que tous les appareils raccordés à la systéme d’évacuation évacuent correctement tel que prescrit ci-dessus, rouvrir les portes et les fenêtres et remettre les ventilateurs d’évacuation, les registres de foyers et tout autre appareil fonctionnant au gaz à leur état de fonctionnement initial.

Page 7

General Information

WARNING:

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

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

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

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

the method by which the air is brought to the space, and by the total input rate of all appliances in the space. In all cases, the minimum dimension of any combustion air opening is 3 inches.

Air From Inside

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

Example:

If the combined input rate of all appliances is less than or equal to 100,000 Btuh, each opening must have a free area of at least 100 square inches. If the combined input rate of all appliances is 120,000 Btuh, each opening must have a free area of at least 120 square inches.

CAUTION:

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

NOTE: Air openings on top of the furnace and openings

in closet doors or walls must never be restricted. If the furnace is operated without adequate air for combustion, the ﬂ ame roll-out switch will open, turning off the gas supply to the burners. This safety device is a manually reset switch. DO NOT install jumper wires across these

switches to defeat their function or reset a switch without identifying and correcting the fault condition.

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

Installation In A Conﬁ ned Space

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

Vent or

Chimney

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

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

Water Heater

Total Input Rating

(Btuh)

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

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

Minimum Free Area

(Each Opening)

12" Max.

Furnace

See Notes

12” Max.

See

Notes

Round Duct

Diameter

Figure 1. Combustion Air Drawn from Inside

Outdoor Air from a Crawl Space or Vented Attic

When the openings can freely exchange air with the outdoors, each opening shall have a minimum free area of 1 square inch per 4,000 Btuh of total appliance input. The openings shall exchange directly, or by ducts, with the outdoor spaces (crawl or attic) that freely exchange with the outdoors (Figure 2, page 8).

The required sizing of these openings is determined by whether inside or outside air is used to support combustion,

Page 8

Ventilation louvers

Vent or

Chimney

Attic Insulation

at each end of attic

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

Wate r Heater

Crawl Space

Furnace

Ventilated Louvers for unheated crawl space

extend above attic insulation

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

Figure 2. Combustion Air Drawn from a Crawl

Space or Vented Attic

Outdoor Air Using Vertical Ducts

If combustion air is taken from outdoors through vertical ducts, the openings and ducts must have a minimum free area of one square inch per 4,000 Btuh of total appliance input. In installations drawing combustion air from a ventilated attic, both air ducts must extend above the attic insulation (Figure 3).

Ventilation Louvers at each end of attic

Vent or Chimney

Water Heater

Attic

Insulation

Furnace

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

Inlet and Outlet Ducts must extend above attic insulation.

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

12" Max

Total Input Rating

(Btuh)

Minimum Free Area

(Each Opening)

Round Duct

Diameter

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

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

Figure 3. Combustion Air Drawn from Outside

Through Vertical Ducts

Outdoor Air Using Horizontal Ducts

If combustion air is taken from outdoors through horizontal ducts, the openings and ducts must have a minimum free area of one square inch per 2,000 Btuh of total appliance input (Figure 4).

Vent or

Chimney

12" Max

See

Note

12" Max

Total Input Rating

(Btuh)

Air Duct

Furnace

Air Duct

Water Heater

Minimum Free Area

(Each Opening)

NOTE: Each

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

input rating.

Round Duct

Diameter

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

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

Figure 4. Combustion Air Drawn from Outside

Through Horizontal Ducts

Air Directly Through An Exterior Wall

If combustion air is provided directly through an exterior wall, the two openings must each have free area of at least one square inch per 4,000 Btuh of total appliance input (Figure 5).

Vent or

12" Max

See Note

12" Max

Total Input Rating

(Btuh)

40,000 10 sq. In 4 inches

60,000 15 sq. In 5 inches

80,000 20 sq. In 5 inches

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

Figure 5. Combustion Air Drawn from Outside

Chimney

NOTE: Each opening

Furnace

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

Water Heater

Minimum Free Area

(Each Opening)

Through an Exterior Wall

Round Duct

Diameter

Page 9

Alternate Method of Providing

Air from Outside:

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

The following conditions must be met:

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

2. The opening must have a minimum free area of 1 sq. in. per 3,000 Btu per hour of the total input rating of all equipment located in the enclosure.

3. The free area must not be less than the sum of all the areas of the vent connectors in the enclosure.

Installation In An Unconﬁ ned Space

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

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

Example:

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

Category I Venting

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

WARNING:

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

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

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

Consult local codes for special requirements.

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

WARNING:

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

• This furnace may be vented with a dedicated venting system or common vented with other Category I appliances. The vent system dimensions and material must conform to the NFGC or local Codes. Generally, this means using Type B vent pipe or a lined masonry chimney. When consulting the vent sizing tables in the NFGC, the MAX capacity of the vent must be greater than the furnaces high ﬁ re rate. The MIN capacity must be lower than the low ﬁ re rate. If the venting system is inappropriate for the furnace, the venting system will need to be modiﬁ ed to comply with NFGC or local codes. The minimum diameter of any vent pipe is 4

inches.

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

Page 10

extend into or pass through any return air duct, supply air duct, or plenum.

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

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

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

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

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

Horizontal Venting

WARNING:

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

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

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

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

Flexible Vent Systems

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

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

Page 11

CIRCULATING AIR REQUIREMENTS

WARNING:

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

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

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

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

Plenums and Air Ducts

• Plenums and air ducts must be installed in accordance with the Standard for the Installation of Air Conditioning and Ventilating Systems (NFPA No. 90A) or the Standard for the Installation of Warm Air Heating and Air Conditioning Systems (NFPA No. 90B).

• Tables 5 - 7 (pages 29 - 32) contain the maximum airﬂ ow and temperature rise data for ﬁ xed and variable speed motors. If the maximum airﬂ ow is 1,600 CFM or more, it is recommended that two openings be used for return air on upﬂ ow furnaces. Downﬂ ow furnaces can only use one return opening.

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

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

furnace is equal to the return air supply under normal, indoor return air applications.

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

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

• It is good practice to seal all connections and joints with industrial grade sealing tape or liquid sealant. Requirements for sealing ductwork vary from region to region. Consult with local codes for requirements speciﬁ c to your area.

Supply Air Connections

The supply air must be delivered to the heated space by duct(s) secured to the furnace casing, running full size and without interruption.

Upﬂ ow and Horizontal Furnaces

To attach the supply air duct to the furnace, bend the furnace ﬂ anges (Figure 20, page 28) upward 90° with a pair of wide duct pliers. Position the duct on top of the furnace and secure together with sheet metal screws. The screws must penetrate the sheet metal casing and furnace ﬂ ange. Tape or seal all seams if required by local code.

Downﬂ ow Furnaces

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

Return Air Connections

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

Upﬂ ow and Horizontal Furnaces

For upﬂ ow installations, the return air ductwork may be connected to the left side, right side, or bottom. The bottom panel (Figure 20) must be installed for left or right return air. NOTE: Do not use the back of the furnace

for return air.

Side Return Installations

To attach the return air duct to the left or right side of the furnace, punch out the four knockouts (Figure 20) from the preferred side of the furnace. Using sharp metal

Page 12

cutters, cut an opening between all four knockouts to expose the blower assembly. Position the return air duct over the opening in the side and secure together with sheet metal screws. The screws must penetrate the duct and furnace casing.

WARNING:

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

Bottom Return Installations

The bottom panel (Figure 20) must be removed from the bottom of the furnace for bottom return air. If bottom panel is still installed, go to page 14 for removal instructions. Position the furnace over the return air duct and secure together with sheet metal screws. The screws must penetrate the duct and furnace casing.

Downﬂ ow Furnaces

To attach the return air duct to the furnace, bend the furnace ﬂ anges (Figure 20) upward 90° with a pair of wide duct pliers. Position the duct on top of the furnace and secure together with sheet metal screws. The screws must penetrate the sheet metal casing and furnace ﬂ ange. Tape or seal all seams if required by local code.

Acoustical Treatments

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

FURNACE INSTALLATION

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

General Requirements

• The furnace must be leveled at installation and attached to a properly installed duct system. See Table 1 (page 5) for the required clearances needed to move the furnace to its installation point (hallways, doorways, stairs, etc).

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

• The furnace must be installed upstream from a refrigeration system. (If applicable)

• The furnace requires special venting materials and installation procedures. See pages 11 - 12 for venting guidelines and speciﬁ cations.

Upﬂ ow Installation

WARNING:

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

Side Return Air Inlet

*TA series gas furnaces are shipped with the bottom panel installed (Figure 20). If the upﬂ ow furnace is installed with side return air, the bottom panel must not be removed.

Bottom Return Air Inlet

*TA series gas furnaces are shipped with the bottom panel installed. If the upﬂ ow furnace is installed with bottom return air, the bottom panel must be removed (See Bottom Panel Removal on page 14).

Downﬂ ow Installation

WARNING:

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

WARNING:

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

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

with the kit.

Page 13

WARNING:

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

Concrete

Floor

Furnace

A downﬂ ow sub-base kit is not necessary if the furnace is installed on a factory or site-built cased air conditioning coil. However, the plenum attached to the coil casing must be installed so that its surfaces are at least 1” from combustible construction.

Installation on a concrete slab

1. Create an opening in the ﬂ oor according to the dimensions in Figure 6.

2. Position the plenum and the furnace as shown in Figure 7.

Opening in concrete floor

“A”

“B”

Cabinet Size Dim. “A” Dim. “B”

A 13 B C D

NOTE: Dimensions shown in Inches.

1/4

19 1/4 16 5/8 19 1/4 20 1/8 19 1/4 23 5/8 19 1/4

Sheet

Metal

Plenum

Figure 7. Furnace on a Concrete Slab

Note: Line Contact

Is Permissible

Gas Inlet

Type “B” Vent

Airflow

Coil Plenum

Electrical Supply

Connection

Combustible Platform

Figure 8. *TA Horizontally Installed on a Platform

Figure 6. Cutout Dimensions

Horizontal Installation

WARNING:

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

The *TA series gas furnace can be installed horizontally in an attic, basement, crawl space or alcove (Figure 8). It can also be suspended from a ceiling in a basement or utility room in either a right to left airﬂ ow or left to right airﬂ ow as shown in Figure 9.

*TA series furnaces are shipped with the bottom panel installed. If furnace is installed horizontally, remove the bottom panel from the furnace before attaching the duct system. See Bottom Panel Removal on page 14.

If installing the furnace in an attic, it is required that a drip pan be placed under the furnace. If the installation is on a combustible platform (Figure 8), it is recommended that the drip pan extend at least 12 inches past the top and front of the furnace.

Nuts (x2)

Lag

Threaded

Rod

Washer

and

Lockwasher

Nuts (x2)

Bolt

Figure 9. *TA Horizontally Suspended in Attic

If suspending the furnace from the ceiling, assemble a support frame (Figure 9) using slotted iron channel and full threaded rod. Fasten the frame together with nuts, washers, and lockwashers. Secure the support frame to the rafters with lag bolts. The furnace can also be suspended using steel straps around each end of the furnace. The straps should be attached to the furnace with sheet metal screws and to the rafters with bolts.

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

Page 14

Pressure Switches

Figure 10 displays the proper routing of pressure switch tubing for *TA & *TK furnaces. On both furnaces, the tubing connects at one end of the pressure switch and is routed directly to the static tap on the inducer assembly. NOTE: The control board in the *TA illustration has been omitted for clarity of tubing installation. There is no need to remove the control board to install your pressure switch tube.

Figure 10. Pressure Switch Tubing for *TA & *TK Furnaces

56 7 4

12 3

Bottom Panel Removal

The steps listed below describe how to remove the bottom panel from the furnace. See Figure 11.

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

2. Disconnect the wiring harness (2) from the connector.

3. Remove two screws (3) securing the blower assembly (4) to the furnace.

4. Carefully pull the blower assembly (4) out thru the front of the furnace.

5. Remove all screws (5) securing bottom panel (6) to bottom of furnace and front brace (7).

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

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

Alternate Bottom Panel Removal

If the bottom panel cannot be removed using the previous instructions, the steps below are an alternate method for removing the bottom panel. See Figure 12.

1. Remove the door (1) from the blower compartment .

2. Remove all screws securing the bottom panel (2) to the front brace (3).

3. Remove two screws (4) securing the furnace cabinet to the blower deck (5).

4. Remove all screws (6) securing the furnace cabinet to the bottom panel (2).

5. Remove the screw (7) securing the bottom corner of the furnace cabinet to the front brace (3).

6. Carefully spread the bottom cor ner of the furnace cabinet outwards while sliding the bottom panel (2) out through the front of the furnace.

7. Reassemble the furnace in reverse order.

Figure 11. Bottom Panel Removal

Figure 12. Alternate Removal Method

Page 15

GAS SUPPLY & PIPING

WARNING:

FIRE OR EXPLOSION HAZARD

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

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

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

WHAT TO DO IF YOU SMELL GAS

• Do not try to light any appliance.

• Do not touch any electrical switch; do not use any phone in your building.

• Leave the building immediately.

• Immediately call your gas supplier from

a neighbor’s phone. Follow the gas supplier’s instructions.

• If you cannot reach your gas supplier, call

the ﬁ re department.

• All gas piping must be installed in compliance with local codes and utility regulations. In the absence of local codes the gas line installation must comply with the latest edition of the National Fuel Gas Code (ANSI Z223.1) or (CAN/CGA B149.1 or .2) Installation Codes.

• 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. See Figure 13 (page 17).

• Gas piping must never run in or through air ducts, chimneys, gas vents, or elevator shafts.

• Compounds used to seal joints on gas piping must be resistant to the actions of LP propane gas.

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

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

• A drip leg should be installed in the vertical pipe run to the unit. See Figure 13.

AVERTISSEMENT:

RISQUE D’INCENDIE OU D’ EXPLOSION

• Le non-respect des avertissements de sécurité pourrait entraîner des blessures graves, la mort ou des dommages matériels.

• L’installation et l’entretien doivent être effectués par un installateur qualifié, un organisme de service ou le fournisseur de gazstaller, service agency or the gas supplier.

• Ne pas entreposer ni utiliser de l’essence ni d’autres vapeurs ou liquides inﬂ ammables dans le voisinage de cet appareil, ni de tout autre appareil.

QUE FAIRE S’IL Y A UNE ODEUR DE GAZ

• Ne pas tenter d’allumer aucun appareil.

• Ne toucher à aucun interrupteur électrique; n’utiliser aucun téléphone dans le bâtiment.

• Évacuer l’immeuble immédiatement.

• Appeler immédiatement le fournisseur de gaz en employant le téléphone d’un voisin. Respecter à la lettre les instructions du fournisseur de gaz.

• Si personne ne répond, appeler le service des incendies.

Table 9 (page 38) lists gas pipe capacities for standard pipe sizes as a function of length in typical applications based on nominal pressure drop in the line.

The furnace may be installed for either left or right side gas entry. When connecting the gas supply, provide clearance between the gas supply line and the entry hole in the furnace casing to avoid unwanted noise and/or damage to the furnace. Typical gas hookups are shown in Figure 13.

Leak Check

WARNING:

FIRE OR EXPLOSION HAZARD

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

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

Page 16

AVERTISSEMENT:

RISQUE D’INDENDIE OU D’EXPLOSION

appliance be derated 4% for each 1000 feet of altitude. For example, the input needs to be reduced 8% at 2,000 feet, 12% at 3,000 feet, etc. This deration is in reference to the input rate and gas heating value at sea level.

Le non-respect des avertissements de sécurité pourrait d’entraîner des blessures graves, la mort ou des dommages matériels.

Ne jamais utiliser une ﬂ amme nue por vériﬁ er la présence des fuites de gaz. Pour la vériﬁ cation de tous les joints, utiliser plutôt une solution savonneuse commerciale fabriquée spéciﬁ quement pur la détection des fuites de gaz. Un incendie ou une explosion peut entraîner des dommages matériels, des blessures ou la mort.

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

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

High Altitude Application

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

WARNING:

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

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

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

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

For added ﬂ exibility, two tables have been provided for natural gas installations with HIGH or LOW heating values at sea level. Tables 12 and 13 (page 40) contain the oriﬁ ce sizes and manifold pressure to use at various altitudes. Table 12 (HIGH) is for natural gas installations with a heating value of more than 1,000 Btu per cubic foot and Table 13 (LOW) is for less than 1,000 Btu per cubic foot. To determine which table to use:

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

2. From Table 11 (page 39), ﬁ nd your local heating value as supplied by the utility company. Follow down the column and stop at your altitude level.

3. If your sea level heating value is HIGH, use Table 12 or if it’s LOW, use Table 13.

Installation Example

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

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

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

From Table 11, ﬁ nd 750 and follow down the column, stop at the 5,000 feet row. The heating value listed is LOW. Table 13 will be used to determine oriﬁ ce size and manifold pressure.

After changing the regulator pressure or changing the oriﬁ ces, it is required that you measure the gas input rate. This may be accomplished in the usual way, by clocking the gas meter and using the local gas heating value. See Verifying & Adjusting the Input Rate section (page 22).

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

The furnaces are shipped from the factory with oriﬁ ces and gas regulator settings for natural gas operation at sea level altitudes. At 2000 feet, the NFGC requires that this

Page 17

UPFLOW MODELS

Note “A”

See

Note “A”

Left Side Entry

Right Side Entry

DOWNFLOW MODELS

See

Note “A”

See

Note “A”

Left Side Entry

Right Side Entry

COMPONENTS:

(1) Automatic Gas Valve

(w/ manual shut-off)

(2) Burner Assembly (3) Dripleg (4) Elbow

(5) Ground Joint Union (6) Manifold (7) Plug (8) Shut - Off Valve

NOTE: Some utilities require Shut- Off Valve to be 4 to 5 feet above ﬂ oor.

Figure 13. Typical Gas Connections

Page 18

Conversion to LP / Propane

ELECTRICAL WIRING

WARNING:

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

Conversion to LP / Propane is detailed in the installation instructions provided with the conversion kit. Generally, this will require the replacement of the burner oriﬁ ces and the spring/stem assembly in the pressure regulator. In the U.S. if installation is above 2,000 ft., refer to Table 10 (page 39) to determine the correct oriﬁ ce size and regulator pressure. See example below.

Installation Example

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

Type of Gas: .........................................Propane Gas

Input BTUH of Furnace: ................................80,000

From Table 10 , ﬁ nd 5,000 and follow across the row, stop at the 80,000 feet column. At ﬁ rst stage, the manifold pressure listed is 4.2, but at 2nd stage the pressure is

10.0. The listed oriﬁ ce size is 56.

When conversion is complete, verify the manifold pressure and input rate are correct as listed in the Tables. Approved conversion kits are listed below:

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

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

instructions provided with the kit.

WARNING:

ELECTRICAL SHOCK, FIRE OR EXPLOSION HAZARD

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

Improper servicing could result in dangerous operation, serious injury, death or property damage.

• Before servicing, disconnect all electrical power to furnace.

• When servicing controls, label all wires prior to disconnecting. Reconnect wires correctly.

• Verify proper operation after servicing.”

AVERTISSEMENT:

RISQUE DE CHOC ÉLECTRIQUE, D’INCENDIE OU D’EXPLOSION

Le non-respect des avertissements de sécurité pourrait entraîner de l’appareil, dommages matériels.

Un entretein incorrect pourrait entraîner un fonctionnement dangereux de l’appareil, des blessures graves, la mort ou des dommages

matériels

• Couper toute alimentation électrique au générateur d’air chaud avant de prodéder aux travaux d’entretein.

• Au moment de l’entretien des commandes, étiquetez tous les ﬁ ls avant de les débrancher. S’assurer de les raccorder correctement.

• S’assurer que l’appareil fonctionne adéquatement aprés l’entretien.

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

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

un fonctionnement dangereux

des blessures graves, la mort ou des

Line Voltage Wiring

It is recommended that the line voltage (115 VAC) to the furnace be supplied from a dedicated branch circuit containing the correct fuse or circuit breaker for the furnace. See Table 2 (page 19).

Page 19

IMPORTANT NOTES:

• An electrical disconnect must be installed readily accessible from and located within sight of the furnace. See Figure 14 or the wiring diagram label inside of the control door. Any other wiring methods must be acceptable to authority having jurisdiction.

• Proper line voltage polarity must be maintained in order for the control system to operate correctly. Verify the incoming neutral line is connected to the white wire and the incoming “hot” line is connected to the black wire. See Figure 17. The furnace will not operate unless the polarity and ground are properly connected.

• If replacing any of the original wires supplied with the furnace, the replacement wire must be copper wiring and have a temperature rating of at least 105°F (40° C). For electrical speciﬁ cations, refer to the furnace nameplate or Table 2.

Grounding

WARNING:

To minimize personal injury, the furnace cabinet must have an uninterrupted or unbroken electrical ground. The controls used in this furnace require an earth ground to operate properly. Acceptable methods include electrical wire or conduit approved for ground service. Do not use gas piping as an electrical ground!

Thermostat / Low Voltage Connections

• The furnace is designed to be controleed by a 24 VAC thermostat. The thermostat’s wiring must comply with the current provisions of the NEC (ANSI/NFPA 70) and with applicable local codes having jurisdiction.

• NORDYNE no longer supports twinning of two stage furnaces. Please contact your furnace distributor for details.

Furnace

Input

(Btuh)

60,000

80,000 100,000 100,000 21 115-60-1 127 103 10.4 14 20 120,000 21 115-60-1 127 103 10.4 14 20 140,000

Thermostat Wire Gauge

Cabinet

Width

(in.)

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

Nominal

Electrical

Supply

115-60-1 127 103 7.9 14 15 115-60-1 127 103 7.9 14 15 115-60-1 127 103 7.9 14 15

115-60-1 127 103 13.4 14 30

Maximum Operating

Voltage

2 - wire - Heating 4 or 5 wire - Cooling

Minimum

Operating

Voltage

Recommended Thermostat Wire Length

Maximum

Furnace

Amperes

Minimum

Wire

Gauge

* Time-delay fuses or circuit breakers are required.

Table 2. Wire Length & Voltage Speciﬁ cations

Field Supplied Fused Service

Panel

Field Supplied Disconnect w/in Sight of Furnace

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

Maximum

Fuse or Circuit

Breaker Amps*

Black (Hot)

White (Neutral)

Green or Bare

(Ground)

Ground

Field Line Voltage Wiring Factory Line Voltage Wiring

Black

White

Ground

Black

White

Field Supplied

Panel Connector

Figure 14. Line Voltage Field Wiring

Black

White

Ground

Page 20

• The thermostat must be installed according to the instructions supplied by the thermostat manufacturer. Low voltage connections (24 VAC) from the thermostat are wired to the terminal strip on the integrated control in the furnace. Recommended minimum wire gauge for thermostat wiring is shown in Table 2.

• The thermostat should be mounted about 5 feet above the ﬂ oor on an inside wall. DO NOT install the thermostat on an outside wall or any other location where its operation may be adversely affected by radiant heat from ﬁ replaces, sunlight, or lighting ﬁ xtures, and convective heat from warm air registers or electrical appliances. Refer to the thermostat manufacturer’s instruction sheet for detailed mounting information.

• Depending on the type of air conditioning unit and thermostat used, both blower applications utilize three basic wiring conﬁ gurations:

Single Stage AC & Single Stage Thermostat

This option does not use the full two-stage control capability of the furnace, but the possibility of timed autostaging is available. See also Autostaging for Single Stage Thermostats:

• Connect the thermostat’s W output to the furnace control boards W1 terminal. This allows the furnace to always run in low output mode. See Figure 15.

• Always connect the thermostat C & R to the furnace control board C & R.

• For cooling, connect the thermostat’s Y signal to the furnace control board’s Y / Y2 terminal.

• Field supplied wires should also connect Y / Y2 & C to the outdoor unit’s Y & C terminals.

ROOM THERMOSTAT

(SINGLE STAGE)

DHUM

Y C

A/C CONDENSING UNIT

(SINGLE STAGE)

DHUM

HIGH EFFICIENCY

BLOWER MOTOR

CONTROL BOARD

ROOM THERMOSTAT

(TWO - STAGE)

Y/Y2

TWO STAGE FURNACE BOARD

R DHUMC

Y C

A/C CONDENSING UNIT

(SINGLE STAGE)

DHUM

HIGH EFFICIENCY

BLOWER MOTOR

CONTROL BOARD

Figure 16. Wiring Conﬁ guration 2

Two-Stage AC & Two-Stage Thermostat

This option uses the full two-stage heating capability of the furnace with a two-stage outdoor unit. See Figure 17.

• Connect the thermostat’s W1 & W2 outputs to the furnace control board’s W1 & W2 terminals.

• Always connect the thermostat C & R to the furnace control board C & R.

• For cooling, connect the thermostat’s Y & Y1 signals to the furnace control board’s Y / Y2 & Y1 terminal’s.

• Field supplied wires should also connect Y / Y2 & Y1 signals to the outdoor unit’s Y & Y1 terminals.

• Connect terminal C to the outdoor unit’s C.

ROOM THERMOSTAT

(TWO STAGE)

Y/Y2

TWO STAGE FURNACE BOARD

Figure 17. Wiring Conﬁ guration 3

DHUM

Y2 Y1 C

A/C CONDENSING UNIT

(TWO STAGE)

DHUM

HIGH EFFICIENCY

BLOWER MOTOR

CONTROL BOARD

Y/Y2

TWO STAGE FURNACE BOARD

Figure 15. Wiring Conﬁ guration 1

Single Stage AC & Two-Stage Thermostat

This option uses the full two-stage heating capability of the furnace with a single stage outdoor unit. See Figure 16.

• Connect the thermostat’s W1 & W2 outputs to the furnace control board’s W1 & W2 terminals.

• Always connect the thermostat C & R to the furnace control board C & R.

• For cooling, connect the thermostat’s Y signal to the furnace control board’s Y / Y2 terminal.

• Field supplied wires should also connect Y / Y2 & C to the outdoor unit’s Y & C terminals.

Autostaging for Single Stage Thermostats

The Autostaging feature included on all G7 2-stage furnaces make it possible to use a single stage thermostat and still receive some of the beneﬁ ts of 2-stage furnace operation. If Autostage is enabled, the furnace will drop to LOW ﬁ re after initially starting in HIGH ﬁ re. After a period of time (8 or 12 minutes) the furnace will then stage up to HIGH ﬁ re, until the heating load is met. See Figure 15 and the Low Voltage Wiring section (page 19).

Autostaging options are selected using the autostage jumper located near the thermostat terminal block. See Figure 23 (page 33). When the autostage jumper is moved from NONE to SHORT or LONG, the following occurs during a call for heat:

Page 21

1. Setting the Autostage jumper in the SHORT position

signals the control to utilize an 8 minute delay between LOW ﬁ re and HIGH ﬁ re when a call for heat is supplied via 24V signal to W1. This setting is the same as jumping R to W2

2. Setting the Autostage jumper in the LONG position

signals the control to utilize an 12 minute delay between LOW ﬁ re and HIGH ﬁ re when a call for heat is supplied via 24V signal to W1. This setting is the same as jumping W1 to W2

control board together with a ﬁ eld supplied wire. This option causes the blower to run at a reduced CFM for 10 minutes after a call for cooling.

MOTOR

HUMIDISTAT

DHUM

CONTROL BOARD

DHUM

Figure 18. DHUM Wiring Conﬁ guration

Autostaging for Two-Stage Thermostats

The Autostage setting on the furnace control board (Figure 23, page 33) is disabled when shipped from the factory. This feature will be not used when paired with a two-stage thermostat. The autostage jumper setting (P7) must be kept on NONE to allow the thermostat to adjust stages.

Please note that on certain thermostats, even without the autostage jumper in the LONG position, W1 & W2 may be energized at exactly the same time when a recovery from a set-back begins, the user adjusts the set point, or the system is powered on. If W1 & W2 are energized at exactly the same time for any reason, the control will operate in the autostage LONG (12 minute) mode. If the autostage jumper is in the NONE position and autostaging is activated unexpectedly for any of the reasons listed, it will return to normal, staged operation after the completion of the heating cycle.

Heat Anticipator

Set the heat anticipator according to the instructions supplied by the thermostat manufacturer. To determine the heat anticipator setting:

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

2. Measure the current ﬂ ow on the thermostat R & W

circuit after the circulating blower motor has started.

Dehumidiﬁ cation Options

Both motor control boards (Figures 21 & 22, page 33) have a DHUM connection that allows the system to increase the amount of humidity that is removed from the circulating air. This is accomplished by reducing the CFM and allowing the cooling coil to become colder. This will only occur when there is a call for cooling. There are many ways that this can be electrically wired.

Blower Speed Conﬁ guration

Two-stage furnaces use high efﬁ ciency circulating air motors that come in two variations and both are controlled differently. The ﬁ xed speed motor control board (Figure 21, page 33) controls the torque and the variable speed motor control board (Figure 22,) controls the airﬂ ow at a constant CFM. Both boards use the same furnace control board.

Fixed Speed Blowers

NOTE: This section applies only to furnaces with model numbers sufﬁ xed with two numbers, followed by a letter, such as 35C1 or 45D1. If your model has sufﬁ x VA1, VB1, VC1, or VD1, please consult the Variable Speed Blower Application section.

The ﬁ xed speed motor control board (Figure 21) contains a set of dip switches for setting the blower speed. Use pins 1 to 4 to set the blower speed for heating and pins 5 to 8 to set the speed for cooling. To determine the appropriate switch settings for your installation, refer to Table 5 (pages 29 - 30).

For thermostats with a dehumidiﬁ er output, use a ﬁ eld supplied wire to connect the thermostat’s dehumidiﬁ er output to the terminal marked DHUM. The thermostat should be set so that the DHUM output should be high (positive) when dehumidiﬁ cation is needed. See also Dehumidiﬁ cation Options section.

CAUTION:

The terminal marked “Y1_IN” on the variable speed motor control board is not an output to drive the outdoor unit. DO NOT connect Y1_IN on the motor control board to the outdoor unit.

1. If the room thermostat incorporates a humidity sensor

and DHUM output, connect the DHUM on the thermostat to the DHUM terminal on the motor control board. See Figure 18.

2. If using a separate humidistat, connect the DHUM & R

terminals on the humidistat to the DHUM & R terminals on the motor control board. In this option, the DHUM output of the humidistat must be set to be normally open and closed when there is a call for humidiﬁ cation.

3. If a humidistat is not available, it is an acceptable option

to connect the R & DHUM terminals on the motor

Variable Speed Blowers

NOTE: This section applies only to models ending with the sufﬁ xes VA1, VB1, VC1, or VD1.

The variable speed motor control board (Figure 22) has a set of dip switches for setting the base blower speed (CFM). Use pins 1 to 4 to set the blower speed for heating and pins 5 to 8 to set the speed for cooling. To determine the appropriate switch settings for your installation, see Table 6 (page 31) for heating or Table 7 (page 32) for cooling.

Page 22

Use ﬁ eld supplied wire to connect the thermostat’s dehumidiﬁ er output to the terminal marked DHUM. The thermostat should be set so that the DHUM output is high (positive) when dehumidiﬁ cation is needed. See also Dehumidiﬁ cation Options section (page 21)

CAUTION:

The variable speed control board is used by other appliances. Many of the terminals and connections on the board are for other appliances and are not used in twostage applications. The only two-stage ﬁ eld connection to this board is the DHUM terminal, used to reduce blower speed during cooling.

START-UP & ADJUSTMENTS

Pre-Start Check List

 Verify the polarity of the connections are correct, the

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

 Verify that all needed thermostat wires are securely

connected to the correct leads on the terminal strip of the circuit board. See Figures 15 - 17 (page 20).

 Verify the gas line service pressure does not exceed

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

11.0 in. W.C.

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

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

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

reset the switch without identifying and correcting the fault condition.

 Verify the blower door is in place, closing the door switch

in the line voltage circuit.

 Verify the gas line has been purged and all connections

are leak free.

Start-up Procedures

Do not perform these steps until all of the checks in the previous steps have been completed:

1. Set the thermostat to the lowest setting.

2. Turn off all electrical power to the furnace.

3. Follow the Operating Instructions on the furnace label.

4. Set the thermostat above room temperature and verify

the Operating Sequence. See page 23.

5. After 5 minutes of operation, set the thermostat below

room temperature and verify steps 11 - 12 of the Operating Sequence (page 24).

the rating plate less 4% for each 1,000 feet. To determine the exact input rate, perform the following procedures:

1. Shut off all other gas ﬁ red appliances.

2. Start and run the furnace in high ﬁ re for at least 3 minutes.

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

4. Convert the time per revolution to cubic feet of gas per hour using Table 8 (page 38).

5. Multiply the gas ﬂ ow rate in cubic feet per hr by the heating value of the gas in Btu per cubic ft to obtain the ﬁ ring rate in Btuh. See example.

Example:

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

• From Table 8 read 90 cubic ft gas per hr.

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

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

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

WARNING:

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

a.) Remove plastic cap from pressure regulator. b.) Obtain the manifold pressure setting required

for this installation by referring to Table 10 (page

39) for Propane or Tables 12 or 13 (page 40) for Natural Gas.

c.) Using an Allen wrench, turn the the LO Input

Adjusting Screw on the LO side of the regulator to adjust the reduced input setting or turn the HI Input Adjusting Screw (Figure 19) on the side of the regulator to adjust the full input setting.

HI Input

Adjusting Screw

Lo Input Adjusting Screw

Verifying & Adjusting Input Rate

The input rate must be veriﬁ ed for each installation to prevent over-ﬁ ring of the furnace. NOTE: The input rate must not exceed the rate shown on the furnace rating plate. At altitudes above 2,000 feet, it must not exceed that on

Figure 19. HI & LO Input Adjusting Screws

Page 23

NOTE: Turning the adjusting screw clockwise

increases the pressure and counterclockwise reduces the pressure.

d.) Reinstall plastic cap after adjustment is complete.

Verifying & Adjusting Temperature Rise

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

WARNING:

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

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

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

Verifying Operation of the Supply Air Limit Switch

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

1. Check the blower door for secure mounting and that there is power to the furnace.

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

3. Set the ther mostat above room temperature and observe the Operating Sequence.

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

OPERATING SEQUENCE

The operating sequences for the heating, cooling, and fan modes are described below. Refer to the ﬁ eld and furnace wiring diagrams: (Figure 14, page 19) , (Figures 15 - 17, page 22), & (Figures 24 - 27, pages 34 - 37).

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

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

Verifying Burner Operation

CAUTION:

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

1. Remove the burner compartment door.

2. Set the ther mostat above room temperature and observe the ignition sequence. The burner ﬂ ame should carry over immediately between all burners without lifting off, curling, or ﬂ oating. The ﬂ ames should be blue, without yellow tips.

3. After validating ﬂ ame characteristics, change thermostat setting to below room temperature.

4. Verify burner ﬂ ame is completely extinguished.

5. Replace the burner compartment door.

Heating Cycle

1. The thermostat calls for heat by energizing the W1

terminal with 24VAC.

2. The control checks to see the pressure switch is open. If the switch is closed, the furnace will shut down for 5 minutes before retrying

3. If the pressure switch is open, the control energizes the inducer motor and waits for the pressure switch to close. The pressure switch must close within 12 seconds.

4. The control runs the inducer for a 30 second pre-purge time.

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

6. The furnace always ignites the burners in high ﬁ re. If the call for heat is for low rate, the furnace will move down to low ﬁ re after the ﬂ ames stabilize.

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

8. The control energizes the blower on the selected HEAT speed 30 seconds after the gas valve opened. The gas valve and inducer remain energized.

9. If there is a call for high ﬁ re, the gas valve moves to the high ﬁ re position and the blower speeds are increased. The furnace will remain in high ﬁ re until the demand for heat is satisﬁ ed.

10. If autostaging is enabled (single stage thermostat) the

demand for heat has lasted more than the selected time, the furnace automatically moves up to high ﬁ r e .

Page 24

Autostage times are either SHORT (8 minutes), LONG (12 minutes), or OFF, depending on the Jumper (P7) setting on the furnace control board.

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

12. The circulating air blower will continue to run for the selected Blower Off Delay(P5). This may be 60, 90, or 120 seconds depending on the jumper setting on the furnace control board.

Cooling Cycle

1. The thermostat calls for cooling by energizing the Y/Y2

or Y1 terminal with 24VAC.

2. The control energizes the blower in the cooling speed

and sends 24VAC to the contactor in the condensing unit.

3. When the thermostat removes the call for cooling, the

contactor in the outdoor condensing unit is de-energized and the control continues to run the fan for a period of 60 seconds.

Fan Mode

• When the thermostat energizes the G terminal for

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

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

blower will switch over to the selected COOL speed.

• If the W ter minal receives a call for heat during continuous

fan, the blower will de energize.

• A call for fan is ignored while in lockout.

• The blower will operate at 50% of the selected high

cooling speed for continuous fan operation.

MAINTENANCE

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

WARNING:

ELECTRICAL SHOCK, FIRE OR EXPLOSION HAZARD

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

Improper servicing could result in dangerous operation, serious injury, death or property damage.

• Before servicing, disconnect all electrical power to furnace.

• When servicing controls, label all wires prior to disconnecting. Reconnect wires correctly.

• Verify proper operation after servicing.”

AVERTISSEMENT:

RISQUE DE CHOC ÉLECTRIQUE, D’INCENDIE OU D’EXPLOSION

Le non-respect des avertissements de sécurité pourrait entraîner de l’appareil, dommages matériels.

Un entretein incorrect pourrait entraîner un fonctionnement dangereux de l’appareil, des blessures graves, la mort ou des dommages

matériels

un fonctionnement dangereux

des blessures graves, la mort ou des

• Couper toute alimentation électrique au générateur d’air chaud avant de prodéder aux travaux d’entretein.

• Au moment de l’entretien des commandes, étiquetez tous les ﬁ ls avant de les débrancher. S’assurer de les raccorder correctement.

• S’assurer que l’appareil fonctionne adéquatement aprés l’entretien.

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

• Always reinstall the doors on the furnace after servicing or cleaning/changing the ﬁ lters. Do not operate the furnace without all doors and covers in place.

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

Page 25

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

Air Filter(s)

WARNING:

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

Note: Air ﬁ lter(s) are not supplied with the furnace as

shipped from the factory. The installer must provide a high velocity ﬁ lter and rack for a ﬁ lter in the return air duct adjacent to the furnace, or in a return air grill to the furnace. It is recommended that ﬁ lters be 1” or 2” thick and be cleaned or replaced monthly. New or newly renovated homes may require more frequent changing until the construction dust has minimized.

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

Blower Compartment

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

Cleaning of Burners

If the burners must be cleaned, follow the steps below and see Figure 28 (page 41) for component location.

1. Shut off 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 its lowest setting.

3. Remove the burner door from the furnace.

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

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

sensor, and ﬂ ame rollout switch.

CAUTION:

To prevent damage to the unit or internal components, it is recommended that two wrenches be used when loosening or tightening nuts. Do not over tighten!

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

in the gas supply piping at the furnace.

7. Remove the piping between the gas valve and the

ground-joint union. (If applicable).

8. Remove all screws securing the burner assembly to the furnace.

9. Carefully remove the burner assembly from the furnace.

DO NOT DAMAGE THE IGNITER WHILE REMOVING THE BURNER ASSEMBLY.

10. Inspect the burners for accumulated dust or debris.

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

IGNITER WHILE CLEANING THE BURNER.

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

removed.

12. Follow the lighting instructions found on the furnace

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

Cleaning Of Flue Passages

If the ﬂ ue passages must be cleaned, follow the steps below. See Figure 28 for component location.

1. Shut off the gas supply to the furnace at the meter or at the manual valve in the gas supply piping.

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

3. Remove the blower door from the furnace.

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

5. Disconnect the wires from the gas valve, ﬂ ame sensor, inducer, ﬂ ame roll-out switch, limit switch, pressure switch and igniter.

6. Remove the silicone rubber tube from the inducer.

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

8. Remove the piping between the gas valve and the ground-joint union. (If applicable).

9. Remove all screws securing the burner assembly to the furnace.

10. Carefully remove the burner assembly from the

furnace. DO NOT DAMAGE THE IGNITER WHILE

REMOVING THE BURNER ASSEMBLY.

11. *TA models - Remove all screws securing the inducer

assembly to the vent pipe running out of the furnace

*TK models - Remove all screws securing the

combustion air tube assembly to the vent pipe running out of the furnace.

12. Remove all screws securing the inducer assembly to

the collector pan.

13. *TA models - Carefully remove the inducer assembly

from the furnace.

*TK models - Carefully remove the inducer assembly

and combustion tube assembly from the furnace. DO

NOT BREAK THE SEALS AT EACH END OF THE COMBUSTION AIR TUBE.

14. Remove all screws securing the collector pan to the

furnace.

15. Remove the collector pan and gasket from the furnace.

Page 26

16. Attach a round wire brush to a length of high grade stainless steel cable. Attach the other end of the cable to a variable speed reversible drill. Slowly insert and rotate the cable into the top portion of the heat exchanger. Operate the drill alternating between forward and reverse, working the cable in and out several times to obtain sufﬁ cient cleaning. Repeat this sequence for each heat exchanger tube.

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

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

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

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

21. Check gaskets for damage. Replace if needed.

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

Heat Exchanger & Burner Maintenance

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

DESCRIPTION OF COMPONENTS

The descriptions below are various functional components that affect the operation and shutting down of this furnace. Some of these components and their locations are shown in Figure 28 (page 41). If any component of the furnace must be replaced, use only factory authorized replacement parts speciﬁ ed in the Replacement Parts List provided online.

Blower Limit Switch: Prevents operation when blower is not operational.

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

Flame Roll-Out Switch: Veriﬁ es that the burner ﬂ ames are drawn into the heat exchanger tubes. If the burner ﬂ ames are not properly drawn into the heat exchanger, the ﬂ ame roll-out switch will close the gas valve and initiate the shutdown cycle.

Gas Valve: Controls the ﬂ ow of gas to the burners. When the gas valve is energized it automatically opens and regulates the gas pressure in the manifold.

Inducer Assembly: Vents products of combustion to the outside.

Pressure Switch: Veriﬁ es that the inducer is drawing the combustion gases through the heat exchanger. The pressure switch prevents furnace operation with excessive ﬂ ue blockage or improper inducer operation.

WARNING:

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

Lubrication

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

Vent System

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

Supply Air Limit Switch: Prevents the air temperature leaving the furnace from exceeding the maximum allowable outlet air temperature.

Page 27

TROUBLESHOOTING

If the furnace fails to operate check the following:

• Is the thermostat operating properly?

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

• Is the furnace disconnect closed?

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

• Is the gas turned on?

• Are any manual reset switches open?

• Is the ﬁ lter dirty or plugged?

• Is the ﬂ ame sensor coated? (Remove and clean with steel wool. Do not use emery cloth or sandpaper!)

• Are all the LED’s on the furnace and motor control boards constantly ON? If not, refer to Tables 3 - 4 to determine fault condition.

Diagnostic Description Green LED Red LED

Control Fault (No Power) Off Off

L1/Neutral Polarity Fault Flash Flash

1 Hour Lockout Alternating Flash

Normal Operation On On

Pressure Switch Closed Fault On Flash

Pressure Switch Open Fault Flash On

Open Limit Switch Fault Flash Off

Motor Fault On Off

Diagnostic Description Yellow LED

Low Flame Sensor Signal Continuous Flash

Flame Present On

Table 3. Furnace Control Board Fault Conditions

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

• If the Inducer Blower is operating, and items above have been veriﬁ ed, check the Blower Limit Switch (Figure 28, page 41) and reset if necessary.

• If the furnace operates when the Blower Limit Switch is reset, contact a qualiﬁ ed service technician to identify and repair the problem.

• If the furnace still doesn’t operate, check the Flame Roll-out Switches (Figure 28) and reset if necessary.

• If the furnace operates when the Flame Rollout Switch is reset, contact a qualiﬁ ed service technician to identify and repair the problem.

Fixed

Speed

Furnaces

Variable

Speed

Furnaces

Diagnostic

Description

Control Fault (No Power) Off Off

Normal Operation On On

Motor Fault On Flash

Twin Fault (no motor fault) Flash On

Communications Fault Flash Flash

Control Fault (No Power) Off Off

Normal Operation On On

Motor Fault On Flash

Communications Fault Flash Flash

Green

LED

Table 4. Motor Control Board Fault Conditions

Red LED

Page 28

FIGURES & TABLES

*TA 80+ Upﬂ ow / Horizontal Furnace

Cabinet

Size

‘A’ Cabinet 14 1/4 10 3/4 12 5/8 12 7/8

‘B’ Cabinet 17 1/2 11 3/4 15 7/8 16 1/8

‘C’ Cabinet 21 14 19 3/8 19 7/8

‘D’ Cabinet 24 1/2 15 1/4 22 7/8 23 1/8

NOTE: Dimensions shown in Inches.

Dim.

-A-

Dim.

-B-

25 3/8

Electric

(Ø 7/8)

4 Knockouts

(both sides)

1 1/4

LEFT SIDE

Dim.

-C-

Dim.

-D-

(1 5/8 X 3 1/2)

Gas

TOP VIEW

FLANGES

Accepts 4” Type B Vent Pipe

FRONT VIEW

T-stat

(Ø 7/8)

Electric (Ø 7/8)

29 1/2

22 1/2

BOTTOM VIEW

Front Brace

Bottom

Panel

23 1/2

Gas

(1 5/8 X 3 1/2 X 45°)

RIGHT SIDE

22 1/4

21 3/4

34 1/2

22 3/4

*TK 80+ Downﬂ ow Furnace

Cabinet

Siz

‘A’ Cabinet 14 1/4 10 3/4 12 5/8 12 7/8

‘B’ Cabinet 17 1/2 11 3/4 15 7/8 16 1/8

‘C’ Cabinet 21 14 19 3/8 19 5/8

‘D’ Cabinet 24 1/2 15 1/4 22 7/8 23 1/8

NOTE: Dimensions shown in Inches.

Dim.

-A-

Dim.

-B-

34 1/2

(1 5/8 X 3 1/2)

Dim.

-C-

Electric

(Ø 7/8)

Gas

25 3/8

LEFT SIDE

Dim.

-D-

22 1/2

TOP VIEW

FLANGES

Accepts 4” Type B Vent Pipe

FRONT VIEW

T-stat

(Ø 7/8)

Electric (Ø 7/8)

29 1/2

BOTTOM VIEW

18 5/8

(1 5/8 X 3 1/2 X 45°)

22 1/2

Front

Brace

22 1/4

Gas

RIGHT SIDE

Figure 20. Furnace Dimensions

Page 29

AIRFLOW DATA

*TA / *TK FURNACES with FIXED SPEED BLOWERS

Model Number

Heating Input

(Btuh)

*TA / TK - 060C - 23A1

(60,000)

*TA / TK - 080C - 24B1

(80,000)

*TA - 100C - 24B1

(100,000)

Motor Switch Settings

(0 = OFF, 1 = ON)

1/5 2/6 3/7 4/8 CFM Rise CFM Rise CFM Rise CFM Rise CFM Rise CFM Rise CFM Rise CFM Rise

0000 1000

01006007455580510

110070563670666357060074

001077557740607056366567

10109004987051835538005676558730616956466067

01109504792048890508555282554795567655873061

11101,000 44 970 46 940 47 910 49 880 51 850 52 820 54 790 56

00011,075 41 1,045 43 1,015 44 985 45 960 46 925 48 900 49 870 51

10011,110 40 1,080 41 1,055 42 1,025 43 1,000 44 975 46 945 47 920 48

01011,170 38 1,140 39 1,115 40 1,090 41 1,060 42 1,035 43 1,010 44 985 45

11011,210 37 1,185 38 1,160 38 1,130 39 1,105 40 1,080 41 1,055 42 1,025 43

00111,520 29 1,225 36 1,200 37 1,175 38 1,150 39 1,120 40 1,095 41 1,070 42

10111,305 34 1,280 35 1,255 35 1,230 36 1,205 37 1,180 38 1,155 38 1,130 39

01111,350 33 1,230 36 1,305 34 1,285 35 1,260 35 1,240 36 1,215 37 1,195 37 11111,440 31 1,400 32 1,365 33 1,230 36 1,295 36 1,255 35 1,220 36 1,185 38

0000 1000

0100

110072582

001081073

1010940638906784570795757507970085

01109906094563905658606982072775767358169086

11101,055 56 1,015 58 970 61 930 64 890 67 845 70 805 74 760 78

00011,135 52 1,095 54 1,055 56 1,010 59 960 62 930 64 890 67 850 70

10011,185 50 1,145 52 1,105 54 1,065 56 1,030 58 990 60 950 62 910 65

01011,250 47 1,210 49 1,170 51 1,135 52 1,095 54 1,055 56 1,020 58 980 60

11011,290 46 1,255 47 1,220 49 1,180 50 1,145 52 1,110 53 1,075 55 1,040 57

00111,315 45 1,275 46 1,240 48 1,200 49 1,160 51 1,120 53 1,085 55 1,045 57

10111,350 44 1,315 45 1,280 46 1,245 48 1,205 49 1,170 51 1,135 52 1,100 54

01111,390 43 1,350 44 1,315 45 1,275 46 1,240 48 1,200 49 1,160 51 1,125 53 11111,420 42 1,380 43 1,345 44 1,310 45 1,270 47 1,235 48 1,200 49 1,160 51

0000 1000

0100

1100

0010

101094079890838458879593750 700 655 605

0110990759457890582860868209077596735 690

11101,055 70 1,015 73 970 76 930 80 890 83 845 88 805 92 760 97

00011,135 65 1,095 68 1,055 70 1,010 73 790 94 930 80 890 83 850 87

10011,185 63 1,145 65 1,105 67 1,065 70 1,030 72 990 75 950 78 910 81

01011,250 59 1,210 61 1,170 63 1,135 65 1,095 68 1,055 70 1,020 73 980 76

11011,290 57 1,255 59 1,220 61 1,180 63 1,145 65 1,110 67 1,075 69 1,040 71

00111,315 56 1,275 58 1,240 60 1,200 62 1,160 64 1,120 66 1,085 68 1,045 71

10111,350 55 1,315 56 1,280 58 1,245 59 1,205 61 1,170 63 1,135 65 1,100 67

01111,390 53 1,350 55 1,315 56 1,275 58 1,240 60 1,200 62 1,160 64 1,125 66 11111,420 52 1,380 54 1,345 55 1,310 57 1,270 58 1,235 60 1,200 62 1,160 64

0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8

NOTES:

1. Motor Switch Settings are for heating speeds using HEAT. switches 1, 2, 3, & 4 and cooling speeds using COOL switches 5, 6, 7, & 8.

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

3. Data is shown without ﬁ lter

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

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

6. When in low stage, the circulating airﬂ ow (2-stage furnaces only) is 70% of the tables high value.

External Static Pressure (in.W.C.)

Table 5. Heating / Cooling Airﬂ ows (CFM) & Temperature Rises (° F)

Page 30

*TA / *TK FURNACES with FIXED SPEED BLOWERS

Model Number

Heating Input

(Btuh)

*TA / TK - 100C - 35C1

(100,000)

*TA / TK - 120C - 35C1

(120,000)

*TA / TK - 140C - 45D1

(140,000)

Motor Switch Settings

(0 = OFF, 1 = ON)

1/5 2/6 3/7 4/8 CFM Rise CFM Rise CFM Rise CFM Rise CFM Rise CFM Rise CFM Rise CFM Rise

0 0 0 0 1,125 66 1,040 71 960 77

1 0 0 0 1,205 61 1,120 66 1,040 71 960 77

0 1 0 0 1,305 57 1,225 60 1,150 64 1,070 69 995 74 915 81

1 1 0 0 1,430 52 1,350 55 1,270 58 1,190 62 1,110 67 1,030 72 950 78 865 86

0 0 1 0 1,525 49 1,450 51 1,375 54 1,300 57 1,225 60 1,150 64 1,075 69 1,000 74

1 0 1 0 1,620 46 1,540 48 1,465 51 1,390 53 1,315 56 1,240 60 1,165 64 1,090 68

0 1 1 0 1,695 44 1,620 46 1,545 48 1,465 51 1,390 53 1,315 56 1,235 60 1,160 64

1 1 1 0 1,770 42 1,700 44 1,630 45 1,555 48 1,485 50 1,410 53 1,340 55 1,265 59

0 0 0 1 1,875 40 1,805 41 1,730 43 1,655 45 1,580 47 1,510 49 1,435 52 1,340 55

1 0 0 1 1,905 39 1,840 40 1,775 42 1,710 43 1,640 45 1,575 47 1,510 49 1,445 51

0 1 0 1 1,980 37 1,910 39 1,845 40 1,780 42 1,715 43 1,650 45 1,580 47 1,515 49

1 1 0 1 2,025 37 1,960 38 1,895 39 1,830 40 1,765 42 1,700 44 1,635 45 1,570 47

0 0 1 1 2,085 36 2,025 37 1,960 38 1,900 39 1,840 40 1,775 42 1,715 43 1,655 45

1 0 1 1 2,135 35 2,070 36 2,010 37 1,945 38 1,880 39 1,815 41 1,750 42 1,685 44

0 1 1 1 2,200 34 2,145 35 2,090 35 2,035 36 1,980 37 1,925 38 1,870 40 1,820 41

1 1 1 1 2,280 32 2,225 27 2,170 34 2,115 35 2,065 22 2,010 37 1,955 38 1,900 39

0 0 0 0 1,125 79 1,040

1 0 0 0 1,205 74 1,120 79 1,040 85

0 1 0 0 1,305 68 1,225 73 1,150 77 1,070 83

1 1 0 0 1,430 62 1,350 66 1,270 70 1,190 75 1,110 80 1,030 86

0 0 1 0 1,525 58 1,450 61 1,375 65 1,300 68 1,225 73 1,150 77 1,075 83 1,000 89

1 0 1 0 1,620 55 1,540 58 1,465 61 1,390 64 1,315 68 1,240 72 1,165 76 1,090 82

0 1 1 0 1,695 52 1,620 55 1,545 58 1,465 61 1,390 64 1,315 68 1,235 72 1,160 77

1 1 1 0 1,770 50 1,700 52 1,630 55 1,555 57 1,485 60 1,410 63 1,340 66 1,265 70

0 0 0 1 1,875 47 1,805 49 1,730 51 1,655 54 1,580 56 1,510 59 1,435 62 1,340 66

1 0 0 1 1,905 47 1,840 48 1,775 50 1,710 52 1,640 54 1,575 56 1,510 59 1,445 62

0 1 0 1 1,980 45 1,910 47 1,845 48 1,780 50 1,715 52 1,650 54 1,580 56 1,515 59

1 1 0 1 2,025 44 1,960 45 1,895 47 1,830 49 1,765 50 1,700 52 1,635 54 1,570 57

0 0 1 1 2,085 43 2,025 44 1,960 45 1,900 47 1,840 48 1,775 50 1,715 52 1,655 54

1 0 1 1 2,135 42 2,070 43 2,010 44 1,945 46 1,880 47 1,815 49 1,750 51 1,685 53

0 1 1 1 2,200 40 2,145 41 2,090 43 2,035 44 1,980 45 1,925 46 1,870 48 1,820 49

1 1 1 1 2,280 39 2,225 40 2,170 41 2,115 42 2,065 43 2,010 44 1,955 45 1,900 47

0 0 0 0 1,395 74 1,350 77 1,305 79 1,260 82 1,210 86 1,165 89

1 0 0 0 1,465 71 1,420 73 1,375 75 1,330 78 1,290 80 1,245 83 1,200 86

0 1 0 0 1,555 67 1,510 69 1,470 71 1,425 73 1,380 75 1,340 77 1,295 80 1,250 83

1 1 0 0 1,625 64 1,585 65 1,540 67 1,500 69 1,460 71 1,415 73 1,375 75 1,335 78

0 0 1 0 1,690 61 1,650 63 1,610 64 1,570 66 1,530 68 1,485 70 1,445 72 1,405 74

1 0 1 0 1,760 59 1,715 60 1,670 62 1,625 64 1,575 66 1,530 68 1,485 70 1,440 72

0 1 1 0 1,835 57 1,790 58 1,745 59 1,695 61 1,650 63 1,605 65 1,555 67 1,510 69

1 1 1 0 1,885 55 1,840 56 1,790 58 1,745 59 1,700 61 1,655 63 1,610 64 1,565 66

0 0 0 1 1,945 53 1,900 55 1,850 56 1,805 57 1,760 59 1,710 61 1,665 62 1,620 64

1 0 0 1 1,950 53 1,905 54 1,860 56 1,820 57 1,775 58 1,735 60 1,690 61 1,650 63

0 1 0 1 2,075 50 2,030 51 1,990 52 1,945 53 1,900 55 1,855 56 1,810 57 1,770 59

1 1 0 1 2,125 49 2,085 50 2,040 51 2,000 52 1,955 53 1,910 54 1,870 55 1,825 57

0 0 1 1 2,170 48 2,130 49 2,090 50 2,045 51 2,005 52 1,965 53 1,925 54 1,880 55

1 0 1 1 2,215 47 2,180 48 2,140 48 2,105 49 2,070 50 2,035 51 2,000 52 1,965 53

0 1 1 1 2,225 47 2,165 48 2,100 49 2,040 51

1111 2,170 48 2,120 49 2,065 50

0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8

External Static Pressure (in.W.C.)

NOTES:

1. Motor Switch Settings are for heating speeds using HEAT switches 1, 2, 3, & 4 and cooling speeds using COOL switches 5, 6, 7, & 8.

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

3. Data is shown without ﬁ lter.

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

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

6. When in low stage, the circulating airﬂ ow is 70% of the tables high value. (2-stage furnaces only)

Table 5. Continued

Page 31

“A” CABINET

*TA / TK FURNACES with VARIABLE SPEED BLOWERS

Switch Settings For Heat

(0 = OFF, 1 = ON)

1 2 3 4 CFM Temp Rise (° F)

0 0 0 0 640 69

0 0 0 1 720 62

0 0 1 0 800 56

0 0 1 1 880 51

0 1 0 0 960 46

0 1 0 1 1,040 43

0 1 1 0 1,120 40

0 1 1 1 1,200 37

*TA / TK - 060C - VA1

Input (BTU) 60,000

“B” CABINET

“C” CABINET

Switch Settings For Heat

(0 = OFF, 1 = ON)

1 2 3 4 CFM Temp Rise (°F) CFM Temp Rise (° F)

1 0 0 0 1,000 59 1,000 74

1 0 0 1 1,100 54 1,100 67

1 0 1 0 1,200 49 1,200 62

1 0 1 1 1,300 46 1,300 57

1 1 0 0 1,400 42 1,400 53

1 1 0 1 1,500 40 1,500 49

1 1 1 0 1,600 37 1,600 46

1 1 1 1 1,700 35 1,700 44

Switch Settings For Heat

(0 = OFF, 1 = ON)

1 2 3 4 CFM Temp Rise (° F) CFM Temp Rise (° F)

# 0 0 0 1,000 74 1,000 89

# 0 0 1 1,115 66 1,115 80

# 0 1 0 1,230 60 1,230 72

# 0 1 1 1,345 55 1,345 66

# 1 0 0 1,460 51 1,460 61

# 1 0 1 1,575 47 1,575 56

# 1 1 0 1,690 44 1,690 53

# 1 1 1 1,805 41 1,805 49

*TA / TK - 080C - VB1

Input (BTU) 80,000

*TA / TK - 100C - VC1

Input (BTU) 100,000

*TA - 100C - VB1

Input (BTU) 100,000

*TA / TK - 120C - VC1

Input (BTU) 120,000

Switch Settings For Heat

(0 = OFF, 1 = ON)

1 2 3 4 CFM Temp Rise (° F)

# 0 0 0 1,500 69

# 0 0 1 1,615 64

“D” CABINET

# Switch not used - can be 0 or 1

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

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

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

# 0 1 0 1,730 60

# 0 1 1 1,845 56

# 1 0 0 1,960 53

# 1 0 1 2,075 50

# 1 1 0 2,190 47

# 1 1 1 2,305 45

Table 6. Nominal Heating Airﬂ ows (CFM) & Temperature Rise (° F)

*TA / TK - 140C - VD1

Input (BTU) 140,000

NOTES:

Page 32

*TA / TK FURNACES with VARIABLE SPEED BLOWERS

“A” CABINET

Switch Settings

(0 = OFF, 1 = ON)

HEAT COOL

1-4 5678LOWHIGH

0 0000 360 525

0 0001 400 580

0 0010 440 635

0 0011 475 690

0 0100 515 745

0 0101 550 800

0 0 1 1 0 590 855

0 0 1 1 1 630 910

0 1 0 0 0 665 965

0 1001 7051,020

0 1 0 1 0 740 1,075

0 1 0 1 1 780 1,130

0 1 1 0 0 820 1,185

0 1 1 0 1 855 1,240

0 1 1 1 0 895 1,295

0 1 1 1 1 930 1,350

CFM

Nominal A/C

& HP Capacity

2 TON

2.5 TON

3 TON

“B” CABINET

Switch Settings

(0 = OFF, 1 = ON)

HEAT COOL

1-4 5678LOWHIGH

1 0000 485 700

1 0001 525 760

1.5 TON

1 0010 565 820

1 0011 605 880

1 0100 650 940

1 0101 6901,000

1 0110 7301,060

1 0111 7751,120

1 1000 8151,180

1 1001 8551,240

1 1010 8951,300

1 1011 9401,360

1 1100 9801,420

1 11011,020 1,480

1 11101,065 1,540

1 11111,105 1,600

CFM

Nominal A/C

& HP Capacity

2 TON

2.5 TON

3 TON

3.5 TON

“C” CABINET

Switch Settings

(0 = OFF, 1 = ON)

HEAT COOL

1-4 5678LOWHIGH

# 0000 7051,025

# 0001 7501,090

# 0010 7951,155

# 0011 8401,220

# 0100 8851,285

# 0101 9301,350

# 0110 9751,415

# 01111,020 1,480

# 10001,065 1,545

# 10011,110 1,610

# 10101,155 1,675

# 10111,200 1,740

# 11001,245 1,805

# 11011,290 1,870

# 11101,335 1,935

# 11111,380 2,000

# Switch not used - can be 0 or 1

CFM

Nominal A/C

& HP Capacity

3.5 TON

4 TON

5 TON

“D” CABINET

Switch Settings

(0 = OFF, 1 = ON)

HEAT COOL

1-4 5678LOWHIGH

# 0000 9651,400

# 0001 9951,440

2.5 TON

3 TON

# 00101,020 1,480

# 00111,050 1,520

# 01001,075 1,560

# 01011,105 1,600

# 01101,130 1,640

# 01111,160 1,680

# 10001,185 1,720

# 10011,215 1,760

# 10101,240 1,800

# 10111,270 1,840

# 11001,295 1,880

# 11011,325 1,920

# 11101,350 1,960

# 11111,380 2,000

# Switch not used - can be 0 or 1

CFM

Nominal A/C & HP

Capacity

3.5 TON

4 TON

5 TON

Table 7. Nominal Cooling / Heat Pump Airﬂ ows (CFM) for Variable Speed Furnaces

Page 33

ELECTRICAL INFORMATION

NOT USED

RCY1

CONNECTION TO

DHUM

TWIN

FAN SPEED

1 2 345 6 7

OFF ON

HEAT

THERMOSTAT

COOL

TERMINAL TO

CONNECTION

TWIN FURNACES

FURNACE CONTROL

RED

STATUS

GREEN

BOARD

NOT USED

Figure 21. Two-Stage Fixed Speed

Motor Control Board

AUTO

STAGE

NONE

SHORT

LONG

Y/Y2

THERMOSTAT CONNECTIONS

EXPANSION

PORT

MOTOR WIRE

HARNESS

FOR WIRING TO THE

MOTOR CONTROL

BOARD

EXPANSION

PORT

GREEN

RED

W_OUT

Y/Y2_OUT

Y1_OUT

OUTPUT TERMINALS

H_OUT

OUTPUT

HUMIDIFIER

FIELD USE

EXPANSION PORT

CONNECTION TO

FURNACE CONTROL

NOT FOR

BOARD

RED

STATUS LIGHTS

CONNECTION TO

IQ THERMOSTAT

(IF APPLICABLE)

RED

GREEN

1 2 345 6 7

OFF ON

MOTOR WIRING

FAN SPEED

COOL

HEAT

HARNESS

L2-OUT

L1-IN

L1-OUT

OUTPUT

DEHUMIDIFIER

DHUM_IN

Y1_IN

SENSOR

GROUND

L2-IN

FOR USE

WITH IQ

OUTDOOR

UNITS

INPUT TERMINALS

INPUTS

293

BLOWER

FUSE

14325

EAC

XMFR

LINE

HUM

Figure 23. Two-Stage Furnace Control Board

YELLOW

(FLAME)

OFF

DELAY

NEUTRALS

XMFR-N

90 120 180

LINE- N

STATUS

Figure 22. Two-Stage Variable Speed

Motor Control Board

Page 34

112233445566778899

RED

Green LED Red LED

Control Fault (No Power) Off Off

L1 / Neutral Polarity Fault Flash Flash

1 Hour Lockout

Normal Operation On On

Pressure Switch Closed Fault On Flash

Pressure Switch Open Fault Flash On

Open Limit Switch Fault Flash Off

Low Flame Sensor Signal

Flame Present

Diagnostic Description

FAULT CONDITIONS

Diagnostic Description

Yellow LED

Continuous Flash

Alternating Flash

Motor Fault On Off

RED

PAR T O F

123 123

MOTOR

BLUE

MOTOR

TORQUE

PWM

NONE

MODE

SPEED

COMMON

GND

WHITE

BLACK

COOL

FAN SPEED

BLUE

HEAT

DEHUM

R C Y1 TWIN

MOTOR CHOKE

MOTORS ONLY)

(ON 3/4 AND 1HP

12345

BROWN

RED

ORANGE

YELLOW

BLACKBLACK

GREEN

BLUE

BLACK

WHITE

0409

7109160

¢710916+¤

LIMIT

BLOWER

BLACK

VIOLET

WHITE

ORANGE

PRESSURE

RX TX COM C R

VIOLET

SWITCH

VIOLET

SWITCH

RCY/Y2 W2GW1Y1

GREEN

BROWN

GAS

VALVE

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.

BLACK

WHITE

120 V

24 V

BLK W/ WHITE STRIPES

WHITE W/ BLK STRIPES

1234

This wiring diagram shows connections and

termination required for the blower kit only.

Use in addition to the wiring diagram for the

furnace.

SWITCH

PRESSURE

LOW

WIRING DIAGRAM

For 80+ and 90+ 2-Stage Fixed Speed Upflow Furnaces

Refer to the Installation Instructions

provided with the kit for the proper

heating and cooling speeds for your

application.

MODELS)

(ON SELECT

CONDENSATE

ORANGE

PRESSURE

HIGH

ORANGE

SWITCH

YELLOW

BROWN

BLWR OFF

RED

LIMIT

BLOWER

XMFR-N

DELAY

BLUE

FLAME SENSOR

BROWN

RED

12345

LINE- N

14325

HUM

LINE

XMFR

EAC

WHITE BLACK

VENT LIMIT

(ON SELECT

BLUEBLUE

FLAME

ROLL-OUT

SUPPLY

AIR LIMIT

ORANGE

YELLOW

MODELS)

WHITE

GREEN

BLUE

BLACK

BLUE BLUE

BLACK

WHITE

DOOR

SWITCH

GREEN

GROUND

BLACK 120V

WHITE (NEUTRAL)

BLACK WHITE

RED

BLACK

INDUCER

1 1

2 2

IGNITOR

123

LEGEND:

FIELD WIRING

LOW VOLTAGE

HIGH VOLTAGE

Figure 24. Wiring Diagram for Two-Stage, Fixed Speed Upﬂ ow Furnaces

Page 35

112233445566778899

RED

Green LED Red LED

Control Fault (No Power) Off Off

L1 / Neutral Polarity Fault Flash Flash

1 Hour Lockout

Normal Operation On On

Pressure Switch Closed Fault On Flash

Pressure Switch Open Fault Flash On

Open Limit Switch Fault Flash Off

Low Flame Sensor Signal

Flame Present

Diagnostic Description

FAULT CONDITIONS

Diagnostic Description

Yellow LED

Continuous Flash

Alternating Flash

Motor Fault On Off

RED

PART OF

RED

MOTOR

123 123

WHITE

BLACK

8 7 6 5 4 3

MOTOR

TORQU E

2 1

ORANGE

7 6

WHITE

BLACK

RED

3 2

YELLOW

LIMIT

BLOWER

LIMIT

BLOWER DECK

7109170

BLUE

¢7109171¤

COOL

HEAT

0409

PWM

NONE

MODE

SPEED

COMMON

GND

FAN SPEED

R C Y1 TWINDEHUM

MOTOR CHOKE

(ON 3/4 AND 1HP

MODELS ONLY)

BLACK BLACK

LIMIT

BLOWER

BLACK

WHITE

BLUE

WHITE

ORANGE

YELLOW

RED

BLACK

ORANGE

RED

BLACK

WHITE

BLUE

BLACK

WHITE

YELLOW

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.

This wiring diagram shows connections and

termination required for the blower kit only.

Use in addition to the wiring diagram for the

furnace.

WIRING DIAGRAM

Refer to the Installation Instructions

provided with the kit for the proper

heating and cooling speeds for your

For 80+ and 90+ 2-Stage Fixed Speed Downflow Furnaces

application.

WHITE

WHITE W/ BLK STRIPES

120 V

24 V

BLACK

BLK W/ WHITE STRIPES

LOW

HIGH

1234

SWITCH

PRESSURE

SWITCH

PRESSURE

BLACK

WHITE

W RX TX COM C R

RCY/Y2 W2GW1Y1

ORANGE

VIOLET

GREEN

GAS

BLACK

LINE- N

XMFR-N

DELAY

BLWR OFF

BLUE

14325

HUM

LINE

XMFR

EAC

WHITE

BLACK

MODELS)

VENT LIMIT

(ON SELECT

BLUE

FLAME

ROLL-OUT

BLUE

SUPPLY

AIR LIMIT

WHITE

BLACK

WHITE

DOOR

SWITCH

GROUND

(NEUTRAL)

BLACK 120V

GREEN

RED

YELLOW

BROWN

FLAME SENSOR

VALVE

BLACK WHITE

RED

BLACK

INDUCER

IGNITOR

123

LEGEND:

FIELD WIRING

LOW VOLTAGE

HIGH VOLTAGE

Figure 25. Wiring Diagram for Two-Stage, Fixed Speed Downﬂ ow Furnaces

Page 36

FLAME

ROLL-OUT

SUPPLY

AIR LIMIT

PRESSURE

SWITCH

PRESSURE

SWITCH

PRESSURE

SWITCH

PRESSURE

SWITCH

FLAME SENSOR

GAS

VALVE

LINE- N

XMFR-N

LINE

XMFR

EAC

HUM

LINE- N

14325

COM

IGNITOR

DOOR

SWITCH

RCY/Y2 W2GW1Y1

LOW

HIGH

BLOWER

LIMIT

BLOWER

LIMIT

CFM

MOTOR

GNDSENDHUM Y1

L2-OUT

L2-IN

L1-IN

L1-OUT

Y1Y/Y2W

SPEED

COMMON

PWM

MODE

OPEN

FAULT

GND

DX-

DX+

RED

GREEN

24 V

120 V

WHITE

BLACK

WHITE W/ BLK STRIPES

BLK W/ WHITE STRIPES

1234

INDUCER

123

BLACK

WHITE

BLACK

112233445566778899

12345

COOL

FAN SPEED

HEAT

BLWR OFF

DELAY

RED

PAR T O F

MOTOR

123

BLUE

BLACK

WHITE

BLACK

WHITE

BLACK

WHITE

RED

GREEN

BROWN

YELLOW

VIOLET

ORANGE

VENT LIMIT

(ON SELECT

MODELS)

BLACK 120V

WHITE (NEUTRAL)

GROUND

CONDENSATE

(ON SELECT

MODELS)

BLACK

VIOLET

For 80+ and 90+ 2-Stage Variable Speed Upflow Furnaces

WIRING DIAGRAM

7109180

FIELD WIRING

LEGEND:

LOW VOLTAGE

HIGH VOLTAGE

Refer to the Installation Instructions

provided with the kit for the proper

heating and cooling speeds for your

application.

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.

This wiring diagram shows connections and

termination required for the blower kit only.

Use in addition to the wiring diagram for the

furnace.

¢7109187¤

Green LED Red LED

Control Fault (No Power) Off Off

L1 / Neutral Polarity Fault Flash Flash

1 Hour Lockout

Normal Operation On On

Pressure Switch Closed Fault On Flash

Pressure Switch Open Fault Flash On

Open Limit Switch Fault Flash Off

Low Flame Sensor Signal

Flame Present

Diagnostic Description

FAULT CONDITIONS

Diagnostic Description

Yellow LED

Continuous Flash

Alternating Flash

Motor Fault On Off

0409

ORANGE

MOTOR CHOKE

(ON 3/4 AND 1HP

MOTORS ONLY)

BLUE BLUE

BLACK

WHITE

BLACK

WHITE

BROWN

RED

ORANGE

YELLOW

GREEN

BLUE

BROWN

RED

ORANGE

YELLOW

GREEN

BLUE

Figure 26. Wiring Diagram for Two-Stage, Variable Speed Upﬂ ow Furnaces

Page 37

Green LED Red LED

Control Fault (No Power) Off Off

L1 / Neutral Polarity Fault Flash Flash

1 Hour Lockout

Normal Operation On On

Pressure Switch Closed Fault On Flash

Pressure Switch Open Fault Flash On

Open Limit Switch Fault Flash Off

Low Flame Sensor Signal

Flame Present

Diagnostic Description

FAULT CONDITIONS

Diagnostic Description

Yellow LED

Continuous Flash

Alternating Flash

Motor Fault On Off

112233445566778899

RED

PAR T O F

BLACK

WHITE

LIMIT

BLUE

ORANGE

BLACK

BLOWER

WHITE

DECK LIMIT

LIMIT

CFM

MOTOR

RED

123 123

MOTOR

GNDSEN

PWM

MODE

COOL

FAN SPEED

DHUM

L1OUT

L1-IN

L2-OUT

L2-IN

FAULT

SPEED

HEAT

OPEN

COMMON

GREEN

OPEN

RED

DX+

8 7 6 5 4 3 2 1

DX-

ORANGE

7 6

WHITE

BLACK

RED

3 2

YELLOW

GND

Y1Y/Y2W

WHITE

YELLOW

RED

BLACK

0409

7109190

¢710919=¤

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.

BLACK

WHITE

120 V

24 V

BLK W/ WHITE STRIPES

WHITE W/ BLK STRIPES

1234

This wiring diagram shows connections and

termination required for the blower kit only.

Use in addition to the wiring diagram for the

furnace.

LOW

SWITCH

PRESSURE

W RX TX COM C R

BLACK

LINE- N

XMFR-N

DELAY

BLWR OFF

RCY/Y2 W2GW1Y1

14325

HUM

LINE

XMFR

EAC

ORANGE

YELLOW

RED

BLACK

WHITE

BLUE

BLACK

DOOR

SWITCH

WHITE

INDUCER

1 1

IGNITOR

2 2

123

WIRING DIAGRAM

Refer to the Installation Instructions

provided with the kit for the proper

heating and cooling speeds for your

For 80+ and 90+ 2-Stage Variable Speed Downflow Furnaces

application.

Figure 27. Wiring Diagram for Two-Stage, Variable Speed Downﬂ ow Furnaces

HIGH

SWITCH

PRESSURE

GAS

FLAME

FLAME SENSOR

VALVE

ROLL-OUT

SUPPLY

AIR LIMIT

GREEN

BLACK 120V

GROUND

WHITE (NEUTRAL)

LEGEND:

FIELD WIRING

LOW VOLTAGE

HIGH VOLTAGE

Page 38

GAS INFORMATION

TIME FOR

ONE REVOLUTION

(SECONDS)

10 360 1,800 3,600

12 300 1,500 3,000

14 257 1,286 2,571

16 225 1,125 2,250

18 200 1,000 2,000

20 180 900 1,800

22 164 818 1,636

24 150 750 1,500

26 138 692 1,385

28 129 643 1,286

30 120 600 1,200

32 113 563 1,125

34 106 529 1,059

36 100 500 1,000

38 95 474 947

40 90 450 900

42 86 429 857

44 82 409 818

46 78 391 783

48 75 375 750

50 72 360 720

52 69 346 692

54 67 333 667

56 64 321 643

58 62 310 621

60 60 300 600

62 58 290 581

64 56 281 563

GAS FLOW RATES

CUBIC FEET PER

REVOLUTION OF GAS METER 15 10

GAS FLOW RATES

TIME FOR

ONE REVOLUTION

(SECONDS)

66 55 273 545

68 53 265 529

70 51 257 514

72 50 250 500

74 49 243 486

76 47 237 474

78 46 231 462

80 45 225 450

82 44 220 439

84 43 214 429

86 42 209 419

88 41 205 409

90 40 200 400

92 39 196 391

94 38 191 383

96 38 188 375

98 37 184 367

100 36 180 360

102 35 176 353

104 35 173 346

106 34 170 340

108 33 167 333

110 33 164 327

112 32 161 321

114 32 158 316

116 31 155 310

118 31 153 305

120 30 150 300

CUBIC FEET PER

REVOLUTION OF GAS METER

15 10

Table 8. Gas Flow Rates (Cubic Feet per Hour)

GAS PIPE CAPACITIES

Nominal Pipe

Diameter (IN.)

1/2 130 90 75 65 55 50 45 40

3/4 280 190 150 130 115 105 95 90

1 520 350 285 245 215 195 180 170

1 1/4 1,050 730 590 500 440 400 370 350

1 1/2 1,600 1,100 890 760 670 610

10 20 30 40 50 60 70 80

Cubic Feet Per Hour Required =

Length of Pipe Run (Feet)

Input To Furnace (Btu/hr)

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

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

Table 9. Capacity of Black Iron Gas Pipe (cu. ft. per hour)

for Natural Gas w/ Speciﬁ c Gravity = 0.60

Page 39

PROPANE DERATION CHART

ALTITUDE ABOVE

SEA LEVEL

0 to 1,999 FT

2,000 to 2,999 FT

3,000 to 4,999 FT

5,000 to 5,999 FT

6,000 to 7,999 FT

8,000 to 10,000 FT

INPUT (BTU) & STAGE

60,000 80,000 100,000 120,000 140,000

1st 2nd 1st 2nd 1st 2nd 1st 2nd 1st 2nd

55 55 55 55 55 ORIFICE SIZE

4.2 10.0 4.2 10.0 4.2 10.0 4.2 10.0 4.2 10.0 MANIFOLD PRESSURE

55 55 55 55 55 ORIFICE SIZE

4.2 9.0 4.2 9.0 4.2 9.0 4.2 9.0 4.2 9.0 MANIFOLD PRESSURE

55 55 55 55 55 ORIFICE SIZE

4.2 8.5 4.2 8.5 4.2 8.5 4.2 8.5 4.2 8.5 MANIFOLD PRESSURE

56 56 56 56 56 ORIFICE SIZE

4.2 10.0 4.2 10.0 4.2 10.0 4.2 10.0 4.2 10.0 MANIFOLD PRESSURE

56 56 56 56 56 ORIFICE SIZE

4.2 9.0 4.2 9.0 4.2 9.0 4.2 9.0 4.2 9.0 MANIFOLD PRESSURE

56 56 56 56 56 ORIFICE SIZE

4.2 8.5 4.2 8.5 4.2 8.5 4.2 8.5 4.2 8.5 MANIFOLD PRESSURE

Table 10. High Altitude Deration Chart for Propane Gas

LOCAL HEATING VALUES FOR NATURAL GAS

ALTITUDE ABOVE

SEA LEVEL

2,000 FT LOW LOW LOW LOW LOW LOW

3,000 FT LOW LOW LOW LOW LOW LOW

4,000 FT LOW LOW LOW LOW LOW

5,000 FT LOW LOW LOW LOW LOW

6,000 FT LOW LOW LOW LOW

7,000 FT LOW LOW LOW LOW

8,000 FT LOW LOW LOW

9,000 FT LOW LOW LOW

10,000 FT LOW LOW

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

HIGH HIGH HIGH HIGH HIGH HIGH HIGH

BTU PER CUBIC FOOT

HIGH HIGH HIGH HIGH HIGH

HIGH HIGH HIGH HIGH HIGH HIGH HIGH HIGH HIGH HIGH HIGH HIGH HIGH HIGH HIGH HIGH HIGH

Table 11. Natural Gas Heating Values

HIGH HIGH HIGH

HIGH HIGH HIGH HIGH HIGH HIGH HIGH HIGH HIGH HIGH HIGH

Page 40

NATURAL GAS with HIGH HEATING VALUE

ALTITUDE ABOVE

SEA LEVEL

0 to 1,999 FT

2,000 to 2,999 FT

3,000 to 3,999 FT

4,000 to 4,999 FT

5,000 to 5,999 FT

6,000 to 6,999 FT

7,000 to 7,999 FT

8,000 to 8,999 FT

9,000 to 9,999 FT

INPUT (BTU) & STAGE

60,000 80,000 100,000 120,000 140,000

1st 2nd 1st 2nd 1st 2nd 1st 2nd 1st 2nd

45 45 45 45 45 ORIFICE SIZE

1.7 3.5 1.7 3.5 1.7 3.5 1.7 3.5 1.7 3.5 MANIFOLD PRESSURE

45 45 45 45 45 ORIFICE SIZE

1.7 3.3 1.7 3.3 1.7 3.3 1.7 3.3 1.7 3.3 MANIFOLD PRESSURE

45 45 45 45 45 ORIFICE SIZE

1.7 3.1 1.7 3.1 1.7 3.1 1.7 3.1 1.7 3.1 MANIFOLD PRESSURE

45 45 45 45 45 ORIFICE SIZE

1.7 2.9 1.7 2.9 1.7 2.9 1.7 2.9 1.7 2.9 MANIFOLD PRESSURE

45 45 45 45 45 ORIFICE SIZE

1.7 2.8 1.7 2.8 1.7 2.8 1.7 2.8 1.7 2.8 MANIFOLD PRESSURE

48 48 48 48 48 ORIFICE SIZE

1.7 3.5 1.7 3.5 1.7 3.5 1.7 3.5 1.7 3.5 MANIFOLD PRESSURE

48 48 48 48 48 ORIFICE SIZE

1.7 3.3 1.7 3.3 1.7 3.3 1.7 3.3 1.7 3.3 MANIFOLD PRESSURE

48 48 48 48 48 ORIFICE SIZE

1.7 3.0 1.7 3.0 1.7 3.0 1.7 3.0 1.7 3.0 MANIFOLD PRESSURE

48 48 48 48 48 ORIFICE SIZE

1.7 2.8 1.7 2.8 1.7 2.8 1.7 2.8 1.7 2.8 MANIFOLD PRESSURE

Table 12. High Altitude Deration Chart for Natural Gas - High Heating Value

NATURAL GAS with LOW HEATING VALUE

ALTITUDE ABOVE

SEA LEVEL

0 to 1,999 FT

2,000 to 2,999 FT

3,000 to 3,999 FT

4,000 to 4,999 FT

5,000 to 5,999 FT

6,000 to 6,999 FT

7,000 to 7,999 FT

8,000 to 8,999 FT

9,000 to 9,999 FT

60,000 80,000 100,000 120,000 140,000

1st 2nd 1st 2nd 1st 2nd 1st 2nd 1st 2nd

45 45 45 45 45 ORIFICE SIZE

1.7 3.5 1.7 3.5 1.7 3.5 1.7 3.5 1.7 3.5 MANIFOLD PRESSURE

45 45 45 45 45 ORIFICE SIZE

1.7 3.5 1.7 3.5 1.7 3.5 1.7 3.5 1.7 3.5 MANIFOLD PRESSURE

45 45 45 45 45 ORIFICE SIZE

1.7 3.4 1.7 3.4 1.7 3.4 1.7 3.4 1.7 3.4 MANIFOLD PRESSURE

45 45 45 45 45 ORIFICE SIZE

1.7 3.2 1.7 3.2 1.7 3.2 1.7 3.2 1.7 3.2 MANIFOLD PRESSURE

45 45 45 45 45 ORIFICE SIZE

1.7 3.1 1.7 3.1 1.7 3.1 1.7 3.1 1.7 3.1 MANIFOLD PRESSURE

45 45 45 45 45 ORIFICE SIZE

1.7 2.9 1.7 2.9 1.7 2.9 1.7 2.9 1.7 2.9 MANIFOLD PRESSURE

48 48 48 48 48 ORIFICE SIZE

1.7 3.5 1.7 3.5 1.7 3.5 1.7 3.5 1.7 3.5 MANIFOLD PRESSURE

48 48 48 48 48 ORIFICE SIZE

1.7 3.3 1.7 3.3 1.7 3.3 1.7 3.3 1.7 3.3 MANIFOLD PRESSURE

48 48 48 48 48 ORIFICE SIZE

1.7 3.1 1.7 3.1 1.7 3.1 1.7 3.1 1.7 3.1 MANIFOLD PRESSURE

INPUT (BTU) & STAGE

Table 13. High Altitude Deration Chart for Natural Gas - Low Heating Value

Page 41

LOCATION OF FURNACE COMPONENTS

12 3456 7

Main Air

Limit Switch

Inducer

Assembly

Transformer

Igniter

Blower Door Switch

Motor Control Box

Motor Choke

(C & D cabinets only)

Blower Assembly

(behind blower panel)

Motor Choke

(C & D cabinets only)

Blower Door Switch

(behind blower panel)

Roll-Out Switch

Upﬂ ow / Horizontal Furnace

Combustion Tube

Furnace Control Board Gas Valve

Pressure Switch

Flame Sensor

Gas Manifold

Burner Assembly

Motor Control Board

Blower Assembly

Furnace Control Board

56 7 4

12 3

Motor Control Board

Transformer

Pressure Switches

Inducer Assembly

Main Air Limit Switch

Igniter

Assembly

Burner

Roll-Out

Switch

Downﬂ ow Furnace

Figure 28. Furnace Components

Gas Valve

Gas Manifold

Flame

Sensor

Page 42

Page 43

Page 44

INSTALLATION / PERFORMANCE CHECK LIST

ATTENTION INSTALLERS:

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

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

INSTALLER NAME:

CITY: STATE:

INSTALLATION ADDRESS:

CITY: STATE:

ELECTRICAL SYSTEM:

Electrical connections tight? YES NO

Line voltage polarity correct? YES NO

Supply Voltage: ________________________________ VOLTS

Has the thermostat been calibrated? YES NO

Is the thermostat level? YES NO

Is the heat anticipator setting correct? YES NO

GAS SYSTEM:

Gas Type: (circle one)

Gas pipe connections leak tested? YES NO

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

Installation Altitude: ______________________________ (FT.)

Deration Percentage: ______________________________ (%)

Natural

Gas

Propane

UNIT MODEL #

UNIT SERIAL #

Minimum clearances per Table 1 (page 5)?

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

Has the literature package been left near the furnace?

YES NO

WARNING:

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

Furnace Input: _________________________________ (Btuh)

Supply Air Temperature: __________________________ (° F)

Return Air Temperature: __________________________ (° F)

Temperature Rise: _______________________________ (° F)

COMBUSTION AIR & VENTING SYSTEM:

Is there adequate fresh air supply for combustion and ventilation?

Vent free from restrictions? YES NO

Filter(s) secured in place? YES NO

Filter(s) clean? YES NO

Flue connections tight? YES NO

Is there proper draft? YES NO

YES NO

O’ Fallon, MO

¢709045)¤

709045A

709045A (Replaces 7090450)

Speciﬁ cations and illustrations subject to change

without notice or incurring obligations.

Printed in U.S.A. (03/10)