Nordyne TC Upflow/Horizontal, TL Downflow Installation Instructions Manual

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Page 1

GAS FURNACES

Installation Instructions

Two-Stage Condensing Furnaces With Fixed and Variable Speed Blowers

95.1% AFUE

*TC Upﬂ ow/Horizontal Model

WARNING:

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

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

ATTENTION INSTALLERS:

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

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

*TL Downﬂ ow 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

neighbors phone. Follow the gas suppliers instructions.

• If you cannot reach your gas supplier, call

the ﬁ re department.

DO NOT DESTROY.

KEEP IN A SAFE PLACE FOR FUTURE REFERENCE.

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TABLE OF CONTENTS

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

Upﬂ ow/Horizontal Furnaces ..............................15

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

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

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

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

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

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

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

COMBUSTION AIR REQUIREMENTS ........................8

General Information .................................................8

Direct Vent Furnaces ................................................ 8

Conventional Furnaces - Conﬁ ned Spaces ..............8

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

Outdoor Air from a Crawl Space or

Vented Attic...........................................................8

Outdoor Air Using Vertical Ducts ..........................9

Outdoor Air Using Horizontal Ducts ......................9

Air Directly Through an Exterior Wall .................. 10

Alternate Method of Providing Air from

Outside ............................................................... 10

Conventional Furnaces - Unconﬁ ned Spaces ........ 10

VENTING REQUIREMENTS ...................................... 10

Vent Pipe Material .................................................. 11

Vent Pipe Length and Diameter ............................. 11

Vent Pipe Installation .............................................. 12

Outdoor Terminations - Horizontal Venting ............. 12

Outdoor Terminations - Vertical Venting ................. 13

Vent Freezing Protection ........................................ 13

Condensate Disposal ............................................. 14

Existing Installations ............................................... 14

CIRCULATING AIR REQUIREMENTS ...................... 14

Plenums and Air Ducts ........................................... 14

Supply Air Connections .......................................... 15

Upﬂ ow/Horizontal Furnaces ............................... 15

Downﬂ ow Furnaces ............................................15

Side Return Installations ..............................15

Bottom Return Installations ..........................15

Downﬂ ow Furnaces ............................................15

Acoustical Treatments ............................................15

FURNACE INSTALLATION .......................................16

General Requirements ...........................................16

Direct Vent (2 - Pipe) Applications ..........................16

Upﬂ ow Installation ..................................................16

Side Return Air Inlet ...........................................16

Bottom Return Air Inlet .......................................16

Downﬂ ow Installation ..............................................16

Installation on a Concrete Slab ..........................16

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

Bottom Panel Removal ...........................................17

Alternate Bottom Panel Removal .......................18

Vent and Inducer Assembly Options ......................18

Inducer Assembly Rotation ....................................18

Accessories ............................................................19

Finish Flange ......................................................19

Rubber Grommets ..............................................19

PVC Tee, Reducer, & Hose Barb ........................19

Condensate Drain Lines .....................................20

GAS SUPPLY AND PIPING .......................................20

Leak Check ...........................................................20

High-Altitude Application ........................................22

Conversion to LP/Propane .....................................22

ELECTRICAL WIRING ...............................................23

Fixed Speed Blower Applications ..........................23

Variable Speed Blower Applications ......................23

Wiring Conﬁ gurations ............................................24

Single Stage AC and Single Stage Heat

Thermostat .........................................................24

Single Stage AC and Two - Stage Heat

Thermostat .........................................................24

Return Air Connections ..........................................15

Two - Stage AC and Two - Stage Heat

Thermostat .........................................................24

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Autostaging for Single Stage Thermostats .............24

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

Autostaging for Two-Stage Thermostats .................25

Dehumidiﬁ cation Options ........................................25

Line Voltage Wiring .................................................25

Low Voltage Wiring .................................................25

Grounding ...............................................................25

Twinning ..................................................................26

START-UP & ADJUSTMENTS ...................................27

Pre-Start Checklist..................................................27

Start-Up Procedures ...............................................27

Verifying and Adjusting Input Rate .........................27

Verifying and Adjusting Temperature Rise ..............28

Verifying Burner Operation .....................................28

Verifying Operation of the Supply Air

Limit Switch ............................................................28

OPERATING SEQUENCE .........................................28

Heating Cycle .........................................................28

Cooling Cycle .........................................................29

Fan Mode ................................................................29

Table 11 - Gas Flow Rates .................................38

Table 12 - Gas Pipe Capacities ..........................38

Table 13 - High Altitude Deration Chart for

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

Table 14 - Natural Gas Heating Values ..............39

Table 15 - High Altitude Deration Chart for

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

Table 16 - High Altitude Deration Chart for

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

Electrical Information .............................................41

Figure 29 - Two-Stage Fixed Speed Motor

Control Board ....................................41

Figure 30 - Two-Stage Variable Speed

Motor Control Board ..........................41

Figure 31 - Two-Stage Furnace Control Board ....41

Figure 32 - Wiring Diagram - Two Stage Fixed

Speed Upﬂ ow/Horiz. Furnaces .........42

Figure 33 - Wiring Diagram - Two Stage Fixed

Speed Downﬂ ow Furnaces ...............43

TROUBLESHOOTING ...............................................29

DESCRIPTION OF COMPONENTS ..........................30

MAINTENANCE .........................................................30

Air Filters ................................................................30

Blower Compartment ..............................................30

Cleaning of Burners ................................................31

Heat Exchanger and Burner Maintenance .............31

Lubrication ..............................................................31

Vent System ...........................................................31

FRENCH TRANSLATIONS ........................................32

FIGURES AND TABLES ............................................34

Figure 28 - Furnace Dimensions ........................34

Airﬂ ow Data ...........................................................35

Table 8 - Heating/Cooling Airﬂ ows and

Temperature Rises - Fixed

Table 9 -

Nominal CFM and Temperature Rises -

Speed .......35

Variable Speed .....................................36

Figure 34 - Wiring Diagram - Two Stage Variable

Speed Upﬂ ow/Horiz. Furnaces .........44

Figure 35 - Wiring Diagram - Two Stage Variable

Speed Downﬂ ow Furnaces ...............45

Venting Information .................................................46

Table 17 -

Vent Termination Clearances .............46

Figure 36 - Horizontal and Vertical Venting ........47

Figure 37 - Upﬂ ow Options .................................48

Figure 38 - Horizontal Options ..........................49

Figure 39 - Downﬂ ow Options ............................50

Location of Furnace Components .........................51

Figure 40 - Upﬂ ow/Horizontal Gas Furnace

Components ....................................51

Figure 41 - Downﬂ ow Gas Furnace

Components ....................................51

INSTALLATION/PERFORMANCE CHECKLIST .......52

Table 10 -

Nominal Cooling/Heat Pump CFM -

Variable Speed .....................................37

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SAFETY INFORMATION

Safety markings are used frequently throughout this

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

WARNING:

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

injury or death

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

• Install this furnace only in a location and position as speciﬁ ed in Table 1 (page 7).

• Provide adequate combustion and ventilation air to the furnace space as speciﬁ ed on pages 8 - 10.

• Provide adequate clearances around the vent air intake terminal as speciﬁ ed in Figures 6 - 9 (pages 12 - 13).

• Combustion products must be discharged outdoors. Connect this furnace to an approved vent system only, as speciﬁ ed on pages 10 - 14.

• Never test for gas leaks with an open ﬂ ame. Use a commercially available soap solution to check all connections. See page 20.

• This furnace is designed to operate with a maximum external pressure rise of 0.5 inches of water column. Consult Tables 8 - 10 (pages 35 - 37), and the rating plate for the proper circulating air ﬂ ow and temperature rise. It is important that the duct system be designed to provide the correct ﬂ ow rates and external pressure 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 in the conditioned space. See page 14.

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

• This furnace may be used for temporary heating of buildings or structures under construction. See the guidelines listed on pages 5 - 6.

sonal

REQUIREMENTS and CODES This furnace must be installed in accordance with

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

The Commonwealth of Massachusetts requires compliance with regulation 248 CMR 4.00 and 5.00 for installation of through – the – wall vented gas appliances as follows:

1. For direct-vent appliances, mechanical-vent heating appliances or domestic hot water equipment, where the bottom of the vent terminal and the air intake is installed below four feet above grade the following requirements must be satisﬁ ed:

a.) A carbon monoxide (CO) detector and alarm shall

be placed on each ﬂ oor level where there are bedrooms. The detector shall comply with NFPA 720 (2005 Edition) and be mounted in the living area outside the bedroom(s).

b.) A (CO) detector shall be located in the room that

houses the appliance or equipment and shall:

• Be powered by the same electrical circuit as the appliance or equipment. Only one service switch shall power the appliance and the (CO) detector;

• Have battery back-up power;

• Meet ANSI/UL 2034 Standards and comply with NFPA 720 (2005 Edition); and Approved and listed by a Nationally Recognized Testing Laboratory as recognized under 527 CMR.

c.) A Product-approved vent terminal must be used,

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

d.) A metal or plastic identiﬁ cation plate shall be

mounted at the exterior of the building, four feet directly above the location of vent terminal. The plate shall be of sufﬁ cient size, easily read from a distance of eight feet away, and read “Gas Vent Directly Below”.

2. For direct-vent appliances, mechanical-vent heating appliances or domestic hot water equipment where the bottom of the vent terminal and the air intake is installed above four feet above grade the following requirements must be satisﬁ ed: a.) A (CO) detector and alarm shall be placed on

each ﬂ oor level where there are bedrooms. The detector shall comply with NFPA 720 (2005 Edition) and be mounted in the living area outside the bedroom(s).

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b.) The (CO) detector shall:

• Be located in the room that houses the appliance or equipment;

• Be hard-wired or battery powered or both.

• Shall comply with NFPA 720 (2005 Edition).

c.) A product-approved vent terminal must be used, and

if applicable, a product-approved air intake must be used. Installation shall be in strict compliance with the manufacturer’s instr uctions. A copy of the installation instructions shall remain with the appliance or equipment at the completion of the installation.

Additional 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)

GENERAL INSTRUCTIONS Combustion Air Quality

CAUTION:

Combustion air must not be drawn from a corrosive atmosphere.

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

• If the furnace is installed as a single pipe installation 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 8 - 10 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.

Page 6

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

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

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

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

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

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

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

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.

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.

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 23).

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.

Installation in a Garage

WARNING:

FIRE AND EXPLOSION HAZARD

Can result in serious injury or death.

Do not store or use gasoline or other ﬂ ammable vapors and liquids in the vicinity of this or any other appliance. Storage of or use of gasoline or other ﬂ ammable vapors or liquids in the vicinity of this or any appliance can result in serious injury or death.

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.

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 material listed in Table 1 (page 7). 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.

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INSTALLATION CLEARANCES to COMBUSTIBLE MATERIALS

For UPFLOW, HORIZONTAL & DOWNFLOW FURNACES

Left Side ...................................0 Inches Vent ............................................. 1 Inch Top ...........................................1 Inches

Right Side ................................0 Inches Back .........................................0 Inches Front.......................................4 Inches

UPFLOW APPLICATION

TOP

HORIZONTAL APPLICATION

SIDE

DOWNFLOW APPLICATION

TOP

†

TOP

LEFT SIDE

BOTTOM

†

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

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

RIGHT SIDE

SIDE

Table 1. Minimum Clearances to Combustible Materials

WARNING:

BOTTOM

LEFT SIDE

BOTTOM

RIGHT SIDE

CARBON MONOXIDE POISONING HAZARD

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

being placed into operation could result in carbon monoxide poisoning or death. The following steps shall be followed with each individual appliance connected to the venting system being placed in operation, while all other appliances connected to the venting system are not in operation:

1. Seal any unused openings in the venting system.

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

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

corrosion and other deﬁ ciencies which could cause an unsafe condition.

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

4. Close ﬁ replace dampers.

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

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

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

8. If improper venting is observed during any of the above tests, the venting system must be corrected in accordance with the National Fuel Gas Code, ANSI Z223.1/NFPA 54 and/or CSA B149.1, Natural Gas and Propane Installation Codes.

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

Page 8

COMBUSTION AIR REQUIREMENTS General Information

WARNING:

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

• Instructions for determining the adequacy of 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.

This condensing furnace is certiﬁ ed for installation either as a Direct Vent (2-pipe) or Conventional (1-pipe) appliance. Direct Vent appliances draw combustion air from the outdoors and vent combustion products back outside. Installation with air taken from around the furnace is often referred to as Conventional installation - i.e. only the vent (exhaust) pipe is provided.

Provisions must be made during the installation of this furnace that provide an adequate supply of air for combustion. The combustion air from the outside needs to be clear of chemicals that can cause corrosion. The inlet pipe should not be placed near corrosive chemicals such as those listed on page 6.

Another important consideration when selecting one or two pipe installation is the quality of the Indoor air which can sometimes be contaminated with various household chemicals . These chemicals can cause severe corrosion in the furnace combustion system. A 2-pipe installation has the additional advantage that it isolates the system from the effects of negative pressure in the house.

CAUTION:

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

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.

Direct Vent Furnaces

Direct Vent (2-pipe) furnaces draw combustion air directly from the outdoors and then vent the combustion products back outside, isolating the entire system from the indoor space. It is important to make sure that the whole system is sealed and clearances to combustibles are maintained regardless of the installation being in a conﬁ ned or unconﬁ ned space.

Conventional Furnaces - Conﬁ ned Spaces

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. Ducts must have cross - sectional area at least as large as the free area of their respective openings to the furnace space. Attics or crawl spaces must connect freely with the outdoors if they are the source of air for combustion and ventilation.

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

Air From Inside If combustion air is taken from the heated space, the two openings must each have a free area of at least one square inch per 1,000 Btuh of total input of all appliances in the conﬁ ned space, but not less than 100 square inches of free area (Figure 1, page 10).

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.

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,

Page 9

Vent or

Chimney

Vent or

Chimney

Ventilation Louvers at each end of attic

Attic

Insulation

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

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.

Total Input Rating

(Btuh)

Water Heater

Minimum Free Area

(Each Opening)

12” Max.

Furnace

See

Notes

See

Notes

12” Max.

Round Duct

Diameter

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

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

Figure 1. Combustion Air Drawn from 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).

Ducts must extend above

Water Heater

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

Furnace

Minimum Free Area

(Each Opening)

attic insulation.

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

12" Max

Round Duct

Diameter

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). Ducts must have cross - sectional area at least as large as the free area of their respective openings to the furnace space.

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 (Figure 3).

Vent or

Chimney

Ventilation Louvers (each end of attic)

Water Heater

Inlet Air

---------

NOTE: Air openings shall

each have a free area of not less than one square inch per 4,000 Btuh of the total input rating of all equipment in the enclosure.

---------

Furnace

Alternate

Air Inlet

Outlet Air

---------

Ventilation Louvers For Unheated Crawl Space

Figure 2. Combustion Air Drawn from a Crawl

Space or Vented Attic

Vent or

Chimney

Water Heater

Air Duct

Furnace

Air Ducts must be at least 1 sq. in. per 2,000 Btuh of total input rating.

Air Duct

Total Input Rating

(Btuh)

Minimum Free Area

(Each Opening)

Round Duct

Diameter

40,000 20 sq. In 5 inches 60,000 30 sq. In 6 inches

80,000 40 sq. In 7 inches 100,000 50 sq. In 8 inches 120,000 60 sq. In 9 inches 140,000 70 sq. In 10 inches 160,000 80 sq. In 10 inches

Figure 4. Combustion Air Drawn from Outside

Through Horizontal Ducts

Page 10

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

Chimney

See

Note

See

Note

12" Max.

Total Input Rating

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

12"

Max

(Btuh)

40,000 10 sq. In 4 inches 60,000 15 sq. In 5 inches 80,000 20 sq. In 5 inches

Water Heater

Minimum Free Area

(Each Opening)

NOTE: Each opening to outside

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

Furnace

Round Duct

Diameter

Figure 5. Combustion Air Drawn from Outside

Through an Exterior Wall

Conventional Furnaces - Unconﬁ ned Spaces

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

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

Example:

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

VENTING REQUIREMENTS

• 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.

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.

WARNING:

This furnace must not be vented with other appliances, even if that appliance is of the condensing type. Common venting can result in severe corrosion of other appliances or their venting and can allow combustion gases to escape through such appliances or vents. Do not vent the furnace to a ﬁ replace chimney or building chase.

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 is classiﬁ ed as a “Category IV” appliance, which requires special venting materials and installation procedures.

Page 11

This section speciﬁ es installation requirements for Conventional (1-pipe) and Direct Vent (2-pipe) piping. For 1- pipe installations, install vent piping as described in this section and provide air for combustion and ventilation according to pages 8 - 10. Table 2 contains the maximum length of vent and combustion air piping for either type of installation.

Material ....................................... Standard

Schedule 40PVC ............................D1785

PVC-DWV ....................................... D2665

SDR-21 & SDR-26 ..........................D2241

ABS-DWV ....................................... D2661

Schedule 40 ABS ............................ F628

Foam/Cellular Core PVC ................ F891

Category IV appliances operate with positive vent pressure and therefore require vent systems which are thoroughly sealed. They also produce liquid condensate, which is slightly acidic and can cause severe corrosion of ordinary venting materials. Furnace operation can be adversely affected by restrictive vent and combustion air piping.

The inducer assembly on this furnace can be rotated to vent the ﬂ ue products out of the left or right side of the furnace. This increases the ﬂ exibility of which direction the vent pipe can exit the furnace.

Vent Pipe Material

Vent and combustion air pipe and ﬁ ttings must be one of the following materials in the list and must conform to the indicated ANSI/ASTM standards. Cement must conform to ASTM Standard D2564 for PVC and Standard D2235 for ABS. PVC primer must meet standard ASTM F656. When joining PVC piping to ABS, use PVC solvent cement. (See procedure speciﬁ ed in ASTM Standard D3138)

FURNACE

MODELS

(BTU)

FURNACE

INSTALLATION

SINGLE VENT PIPE LENGTH (FT.)

with 1 long radius elbow**

OUTLET

2” Diameter

In Canada, all plastic vent pipes and ﬁ ttings including any cement, cleaners, or primers must be certiﬁ ed as a system to ULC S636. However this requirement does not apply to the ﬁ nish ﬂ anges or piping internal to the furnace.

Vent Pipe Length and Diameter

In order for the furnace to operate properly, the combustion air and vent piping must not be excessively restrictive.

• The venting system should be designed to have the minimum number of elbows or turns.

• All horizontal runs must slope upwards from the furnace at 1/4 inch minimum per running foot of vent.

• Transition to the ﬁ nal vent diameter should be done as close to the furnace outlet as practical.

• Always use the same size or a larger pipe for combustion air that is used for the exhaust vent.

Table 2 indicates the maximum allowable pipe length for a furnace of known input rate, when installed with piping

DUAL VENT PIPE LENGTH (ft.)

with 1 long radius elbow on each pipe**

OUTLET

3” Diameter

INLET/OUTLET

2” Diameter

INLET/OUTLET

3” Diameter

Upﬂ ow 90 90 90 90

60,000

80,000

100,000

120,000

1. Subtract 2.5 ft. for each additional 2 inch long radius elbow, 5 ft. for each additional 2 inch short radius elbow, 3.5 ft. for each additional 3 inch long radius elbow, and 7 ft. for each additional 3 inch short radius elbow. Subtract 5 ft for each 2” tee and 8 ft for each 3” tee. Two 45 degree elbows are equivalent to one 90 degree elbow.

2. The length of pipe needed between the inducer and the ﬁ nish ﬂ ange on downﬂ ow models is 15”.

3. This table applies for elevations from sea level to 2,000 ft. For higher elevations, decrease pipe lengths by 8% per 1,000 ft of altitude.

Horizontal 50 90 50 90

Downﬂ ow 30 90 30 90

Upﬂ ow 90 90 90 90

Horizontal 30 90 30 90

Downﬂ ow 30 90 30 90

Upﬂ ow 60 90 60 90

Horizontal 30 90 30 90

Downﬂ ow 30 90 25 90

Upﬂ ow N/A 90 N/A 90

Horizontal N/A 90 N/A 90

Downﬂ ow N/A 90 N/A 90

*NOTES:

Table 2. Vent Pipe Lengths

Page 12

of selected diameter and number of elbows. To use the table, the furnace input rate, the centerline length and the number of elbows on each pipe must be known.

When estimating the length of vent runs, consideration must be made to the effect of elbows and other ﬁ ttings. This is conveniently handled using the idea of “equivalent length”. This means the ﬁ ttings are assigned a linear length that accounts for the pressure drop they will cause. For example: a 2” diameter, long radius elbow is worth the equivalent of 2.5 feet of linear run. A 90 degree tee is worth 7 ft.

The equivalent lengths of tees and various elbows are listed in Table 2. Measure the linear length of the vent run and then add in the equivalent length of each ﬁ tting. The total length, including the equivalent ﬁ tting lengths, must be less than the maximum length speciﬁ ed in Table 2.

on either side of the exterior wall (Figure 36). These couplings may be required by local code.

• If breakable connections are required in the combustion air inlet pipe (if present) and exhaust vent piping, then straight neoprene couplings for 2” or 3” piping with hose clamps can be used. These couplings can be ordered through your local furnace distributor. To install a coupling:

1. Slide the rubber coupling over the end of the pipe

that is attached to the furnace and secure it with one of the hose clamps.

2. Slide the other end of the rubber coupling onto

the other pipe from the vent.

3. Secure the coupling with the second hose clamp,

ensuring that the connection is tight and leak free.

Condensing furnace combustion products have very little buoyancy, so Table 2 is to be used without consideration of any vertical rise in the piping.

Vent Pipe Installation

CAUTION:

Combustion air must not be drawn from a corrosive atmosphere.

This furnace has been certiﬁ ed for installation with zero clearance between vent piping and combustible surfaces. However, it is good practice to allow space for convenience in installation and service.

• The quality of outdoor air must also be considered. Be sure that the combustion air intake is not located near a source of solvent fumes or other chemicals which can cause corrosion of the furnace combustion system. (See list of substances on page 5).

• Route piping as direct as possible between the furnace and the outdoors. Longer vent runs require larger diameters. Vent piping must be sloped upwards 1/4” per foot in the direction from the furnace to the terminal. This is to ensure that any condensate ﬂ ows back to the condensate disposal system.

• If a Direct Vent (2-pipe) system is used, the combustion air intake and the vent exhaust must be located in the same atmospheric pressure zone. This means both pipes must exit the building through the same portion of exterior wall or roof as shown in Figures 6 - 9 (pages 12 - 13) and Figure 36 (page 47).

• Piping must be mechanically supported so that its weight does not bear on the furnace. Pipe supports must be installed a minimum of every 5 feet along the vent run to ensure no displacement after installation. Supports may be at shorter intervals if necessary to ensure that there are no sagging sections that can trap condensate. It is recommended to install couplings along the vent pipe,

Outdoor Terminations - Horizontal Venting

Vent and combustion air intake terminations shall be installed as depicted in Figures 6 & 7 (page 13) and in accordance with these instructions:

• Vent termination clearances must be consistent with the NFGC, ANSI 2223.1/NFPA 54 and/or the CSA B149.1, Natural Gas and Propane Installation Code. Table 15 (page 44) lists the necessary distances from the vent termination to windows and building air intakes.

• All minimum clearances must be maintained to protect building materials from degradation by ﬂ ue gases as shown in Figure 7.

• Vent and combustion air intake terminations must be located to ensure proper furnace operation and conformance to applicable codes. A vent terminal must be located at least 3 feet above any forced air inlet located within 10 feet. This does not apply to the combustion air inlet of a direct vent (two pipe) appliance. In Canada, CSA B149.1, takes precedence over these instructions. See Table 17 (page 46).

• For optimal performance, vent the furnace through a wall that experiences the least exposure to winter winds.

• The vent termination shall be located at least 3 ft. horizontally from any electric meter, gas meter, regulator and any relief equipment. These distances apply ONLY

Mounting Kit

Faceplate Secured

to Wall with Screws

Typical Both Pipes

Combustion

Air Inlet

Exhaust Vent Left Side Option

Exhaust

Inlet

12" Min. to Maximum

Expected Snow Level

Typical Both Pipes

90°

Elbow

8" min. 36" max.

Both Sides

Exhaust Vent

Right Side Option

Figure 6. Inlet and Exhaust Pipe Clearances

Page 13

to U.S. installations. In Canada, CSA B149.1, takes precedence over these instructions.

• Do not install the vent terminal such that exhaust is directed into window wells, stairwells, under decks or into alcoves or similar recessed areas, and do not terminate above any public walkways.

• If venting horizontally, a side wall vent kit is available according to the pipe diameter size of the installation. For 2 inch pipe use side wall vent kit #904617, and for 3 inch pipe use kit #904347. Please follow the

instructions provided with the kit.

• Concentric vent termination kits are available for use with these furnaces. For 2 Inch pipe use kit #904177 and for 3 inch pipe use kit # 904176. Please follow the

instructions provided with the kit.

• When the vent pipe must exit an exterior wall close to the grade or expected snow level where it is not possible to obtain clearances shown in Figure 6, a riser may be provided as shown in Figure 8. Insulation is required to prevent freezing of this section of pipe. See Table 3 for vent freezing protection.

Outdoor Terminations - Vertical Venting

Termination spacing requirements from the roof and from each other are shown in Figure 9.

The roof penetration

must be properly ﬂ ashed and waterproofed with a plumbing roof boot or equivalent ﬂ ashing. Vent and combustion air piping may be installed in an existing chimney which is not in use provided that:

• Both the exhaust vent and air intake run the length of the chimney.

• The top of the chimney is sealed and weatherproofed.

• The termination clearances shown in Figure 9 are maintained.

• No other gas ﬁ red or fuel-burning equipment is vented through the chimney.

90° Elbow

12” Above Maximum

Expected Snow Level

(Typ. Both pipes)

Exhaust Vent

Combustion Air

Direct vent terminal 50,000 Btuh or less

9 In.

Note 2

Mechanical draft vent terminal

NOTES:

1. All dimensions shown are minimum requirements.

2. Exterior vent terminations must be located at least 12 In above the maximum expected snow level.

4ft.

Note 2

4 ft.

Mechanical draft vent terminal

12 in.

Note 2

Mechanical

draft vent

terminal

Less

than 10 ft.

3 ft.

Forced Air Inlet

Direct vent terminal -

more than 50,000 Btuh

Figure 7 Vent Locations

12" Min.

19" Max.

(See Note)

12" Above

Maximum Expected

Support

Outside

Wall

NOTE: Vent Configuration to Provide 12" Minimum height above Snow Level.

Snow Level

1/2" Armaflex Insulation or Equivalent (if required)

Figure 8. Alternate Horizontal Vent Installation

8" Min.

36" Max.

Plumbing Vent

Roof Boot

(Typ. Both Pipes)

Figure 9. Vertical Vent Termination

Vent Freezing Protection

• When the vent pipe is exposed to temperatures below freezing (i.e., when it passes through unheated spaces, chimneys, etc.) the pipe must be insulated with 1/2 inch thick sponge rubber insulation, Armaﬂ ex-type insulation or equivalent. Insulating pipe is important to avoid condensate icing.

• Table 3 lists the maximum length of ﬂ ue pipe that can travel through an unconditioned space or an exterior space. The total vent length must not exceed the lengths noted in Table 2 (page 11). For Canadian installations, please refer to the Canadian Installation Code (CAN/ CGA-B149.1 or 2) and/or local codes.

Maximum Flue Pipe Length

Winter Design

Temperature

Without Insulation

in Unconditioned and

Exterior Spaces

With Insulation

(feet)

(feet)*

20 45 70

020 70

-20 10 60

* = Insulation thickness greater than 3/8 inch, based on an R value of 3.5 (ft x F x hr) / (BTU x in.)

Table 3. Vent Protection

Page 14

• For extremely cold climates or for conditions of short furnace cycles (i.e. set back thermostat conditions) the last 18 inches of vent pipe can be reduced. It is acceptable to reduce from 3” to 2-1/2”, 3” to 2”, or 2” to 1-1/2” if the total vent length is at least 15 feet in length, the vent length is within the parameters speciﬁ ed in Table 2 (page

11). The restriction should be counted as 3 equivalent feet. Smaller vent pipes are less susceptible to freezing, but must not be excessively restrictive. The length of the 2 inch pipe must not be longer than 18 inches.

• If furnace is installed horizontally, make sure the drainage port on the in-line drain assembly is pointed downward to ensure proper drainage of condensate. See Figure 33 - 34 on pages 44- 45.

• To prevent debris or creatures from entering the combustion system, a protective screen may be installed over the combustion air intake opening. The screens hole size must be large enough to prevent air restriction.

Condensate Disposal

The method for disposing of condensate varies according to local codes. Consult your local code or authority having jurisdiction.

Each of the condensate drain lines must be J-trapped using ﬁ eld supplied parts. After the condensate lines are J-trapped, they may be combined together into a single run to the drain. The drain lines must be routed downward to ensure proper drainage from furnace.

Neutralizer kit P/N 902377 is available for use with this furnace. Please follow the instructions provided with

the kit.

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.

Existing Installations

When an existing furnace is removed from a vent system serving other appliances, the existing vent system may not be sized properly to vent the remaining appliances (For example: water heater). An improperly sized venting system can result in the formation of condensate, leakage, or spillage. The existing vent system should be checked to make sure it is in compliance with NFGC and must be brought into compliance before installing the furnace.

NOTE: If replacing an existing furnace, it is possible you will encounter an existing plastic venting system that is subject to a Consumer Product Safety Commission recall. The pipes involved in the recall are High Temperature Plastic Vent (HTPV). If your venting system contains these pipes DO NOT reuse this venting system! This recall does not apply to other plastic vent pipes, such as white PVC or CPVC. Check for details on the CPSC website or call their toll-free number (800) 758-3688.

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 8 - 10 (pages 35 - 37) 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 way 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

Page 15

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 28, page 34) 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 cabinet.

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 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 28) must be installed for left or right return air. NOTE: Do not use the back of the furnace

for return air.

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 cabinet.

WARNING:

The solid base of the furnace must be in position 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 28) must be removed from the bottom of the furnace for bottom return air. If bottom panel is installed, go to page 15 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 cabinet.

Downﬂ ow Furnaces To attach the return air duct to the fur nace, bend the furnace ﬂ anges (Figure 28, page 34) 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 cabinet 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

Side Return Installations

To attach the return air duct to the left or right side of the furnace, punch out the four knockouts (Figure 28) from the preferred side of the furnace. Using sharp metal cutters, cut an opening between all four knockouts to expose

Page 16

FURNACE INSTALLATION

*TC series gas furnaces offer a wide range of installation options, including installation in the upﬂ ow or horizontal positions with either right, left, or upﬂ ow return air. The *TL series gas furnaces may only be installed as a down ﬂ ow application.

General Requirements

• The furnace must be leveled at installation and attached to a properly installed duct system. See Table 1 (page 7) 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 cabinet plug must always be used to close the hole in the side of the furnace when rotating the inducer.

• The furnace requires special venting materials and installation procedures. See pages 10 -14 for venting guidelines and speciﬁ cations.

Direct Vent (2-Pipe) Applications

It is important that Direct Vent (2-pipe) systems maintain an airtight ﬂ ow path from the air inlet to the ﬂ ue gas outlet. The furnace ships from the factory with two holes in the cabinet for the air inlet and ﬂ ue gas outlet. In certain conﬁ gurations, it is necessary to remove and relocate a plastic cap in the furnace cabinet. If changing the position of the air inlet and ﬂ ue gas outlet, it is required that the previous hole be closed off with the plastic cap to maintain air tightness in the furnace. The hole locations for *TC and *TL furnaces are shown in Figure 28 (page 34).

Upﬂ ow Installation

WARNING:

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

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 ‘B’, ‘C’, and ‘D’ size cabinets use Kit #904911. Please follow the instructions provided

with the kit.

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 10.

2. Position the plenum and the furnace as shown in Figure 11 (page 17).

Opening in concrete floor

“A”

“B”

Side Return Air Inlet *TC series gas furnaces are shipped with the bottom panel installed (Figure 28). If the upﬂ ow furnace is installed using both side return air inlets, the bottom panel must not be removed. The bottom panel must be in place if the bottom of the furnace is not being used as a return.

Bottom Return Air Inlet If the *TC series gas furnace is installed using the bottom as a return air inlet and 1 side return, the bottom panel (Figure 28) must be removed.

Cabinet Size Dim. “A” Dim. “B”

‘B’

‘C’

‘D’

Figure 10. Cutout Dimensions

⅝ ⅛ ⅝

¼ ¼ ¼

Page 17

Concrete

Floor

Furnace

Sheet

Metal

Plenum

Figure 11. Furnace on a Concrete Slab

Horizontal Installation

WARNING:

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

The *TC series gas furnace can be installed horizontally (Figure 12) in an attic, basement, crawl space or alcove. It can also be suspended from a ceiling in a basement or utility room in either a right to left airﬂ ow or left to right airﬂ ow as shown in Figure 13.

*TC 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 section.

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 12), it is recommended that the drip pan extend at least 12 inches past the top and front of the furnace.

If the furnace will be suspended from the ceiling, assemble a support frame (Figure 13) using slotted iron channel and full threaded rod. Fasten the frame together with nuts,

Nuts (x2)

Lag Bolt

Threaded

Rod

Washer

and

Lockwasher

Nuts (x2)

Figure 13. *TC Horizontally Suspended

in Attic or Crawl Space

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.

Bottom Panel Removal

The steps listed below describe how to remove the bottom

panel from the furnace. See Figure 14.

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

2. Disconnect the blower motor wiring harness (2) from the control board.

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

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

Electrical Supply

Connection

Coil Plenum

Combustion Air

One-Pipe Installation Shown

Airflow

Condensate Drain Lines Must Be Trapped

With J-Trap or Field Supplied Loop.

Figure 12. *TC Horizontal installation on a Platform

Exhaust Pipe

Vented to Outside

Combustible

Platform

Figure 14. Bottom Panel Removal

Page 18

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

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

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

Alternate Bottom Panel Removal If the bottom panel cannot be removed using the previous instructions, the steps below are an alternate method for removing the bottom panel. (See Figure 15).

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

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

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

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

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

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

7. Reassemble the furnace in reverse order.

Conventional (1 Pipe)

Vent Upﬂ ow

Right Option 1 N/A N/A Option 9

Up N/A Option 5 Option 6 Option 10

Left Option 2 N/A N/A Option 11

Vent Upﬂ ow

Right Option 3 N/A N/A Option 12

Up N/A Option 7 Option 8 Option 13

Left Option 4 N/A N/A Option 14

†

Requires a 2 inch PVC endcap.

Horiz. Right

Direct Vent (2-pipe)

Horiz. Right

Horiz.

Left

Horiz.

Left

Downﬂ ow

†

Downﬂ ow

†

Table 4. Vent and Inducer Blower Options

Inducer Assembly Rotation

WARNING:

Inducer rotation must be completed before the furnace is connected to gas and electric. If both utilities have been connected, follow the shutdown procedures printed on the furnace label and disconnect the electrical supply.

Figure 15. Alternate Removal Method

Vent and Inducer Assembly Options

To increase installation ﬂ exibility, the inducer assembly can be rotated to 2 different positions. Each variation has slightly different requirements with regard to condensate disposal and, in some cases, the need to seal the furnace cabinet. IMPORTANT NOTE: The Inducer Assembly

must never be positioned to vent downwards on horizontal installs.

CAUTION:

It is good practice to label all wires prior to disconnection. Wiring errors can cause improper and dangerous operation.

1. Disconnect the electrical harness (1) from the inducer assembly (2). See Figure 16.

2. Remove the inducer assembly ground wire (3) from the blower deck (4) or door.

3. Remove four screws (5) securing the inducer assembly (2) to the header box (6).

4. Remove drain tube from inline drain assembly.

5. Rotate the inducer assembly (2) to its new position.

Before using Table 4 (page 19) the number of pipes (1-pipe or 2-pipe) connected to the furnace must be known. Find the proper furnace style (upﬂ ow, horizontal, or downﬂ ow) and then the side that the pipes will exit from the furnace. Finally select the option that properly matches your installation type from Figures 37 - 39 (pages 48 - 50).I

Figure 16. Inducer Assembly Rotation

Page 19

6. Secure the inducer assembly (2) to the header box (6) by reinstalling the four screws (5) and the extra screw provided in the parts package.

7. Remove the cabinet plug (7) from side of furnace and reinstall in hole on opposite side of cabinet.

8. If applicable, install condensate drain on the in-line drain assembly. See Figures 37-39 (pages 48 - 50).

9. Reconnect the electrical harness (1) to the inducer assembly (2).

10. Reconnect the inducer assembly ground wire (3) to the blower deck (4) or door.

11. Verify proper operation as detailed on the furnace label.

Accessories

The components in Figures 17 - 19 are included in the extra parts bag supplied with the purchase of *TC/ *TLfurnaces. Depending on your particular installation, some of these components are optional and may not be used. Please refer to the descriptions and accompanying ﬁ gures when installing these items.

Finish Flange (Fig. 17) The ﬁ nish ﬂ ange must be installed to vent the combustion air pipe through the top of the furnace. NOTE: For proper installation it is important that the pipe and screw holes in the ﬁ nish ﬂ ange, gasket, and cabinet are aligned.

1. Position ﬂ ange gasket over hole in the furnace cabinet.

2. Position ﬁ nish ﬂ ange on top of the ﬂ ange gasket.

3. Secure ﬂ ange and gasket to cabinet with three ﬁ eld supplied sheet metal screws.

rubber grommet should be installed in the 1 5/8” hole prior to running the gas pipe into the cabinet. No sealants are required.

The 3/4” rubber grommet is used if venting out the left side of the cabinet and the drain tube is routed through the blower deck. Remove the plastic plug from the hole and install the grommet before routing the drain tube.

ø 2 1/4” Rubber

Grommet

ø 7/8” Rubber

Ø 3/4” Rubber

Grommet

Figure 18. Rubber Grommets

PVC TEE, Reducer, and Hose Barbs (Fig. 19)

IMPORTANT NOTES: Before permanently installing these components, it is recommended you dry-ﬁ t them ﬁ rst to ensure proper ﬁ t and alignment with other vent pipes.

The PVC items shown in Figure 19 (page 20) are not supplied with *TL furnaces.

The 2” PVC tee, reducer, and hose barb are used when the inducer is rotated to vent out thru the left or right side of the furnace cabinet.

Inlet Air

Finish Flange

Flange Gasket

Figure 17. Finish Flanges

Rubber Grommets (Fig. 18) The 2 1/4” rubber grommet is used to seal the opening between the furnace cabinet and the 2” PVC vent pipe. The rubber grommet should be installed in the 3” hole prior to running the vent pipe out of cabinet. No sealants are required.

The 7/8” rubber grommet is used to seal the opening between the furnace cabinet and the gas pipe. The

The 1/2” x 3/4” hose barb can be used to route the condensate drain to the outside of the cabinet. It must be installed from inside the cabinet with the threaded end inserted thru the 1 1/16” hole. See Figure 28

2” PVC Pipe from

Inline Drain Assembly

(Not Included)

2” PVC TEE

2” x 1/2” PVC

Reducer

1/2” x 1/2”

Hose Barb

1/2” x 3/4”

Hose Barb

Figure 19. PVC Tee (2”), Reducer and Hose Barb

Page 20

(page 34) for hole location The condensate drain should be connected to the barbed end. Attach 1” PVC drain line to the threaded end.

drain lines on the outside of the residence be wrapped with an industry approved insulation or material allowed by local code.

1. Install the 1/2” x 1/2” hose barb on the 2” PVC reducer. Do not over tighten! NOTE: Use an adequate amount of Teﬂ on tape on the threads. Do not use liquid sealants.

2. Install the reducer on one end of the PVC tee. Use appropriate primer and cement to permanently bond the reducer and tee together.

3. Install the tee on the 2” vent pipe that is extending out the side of the cabinet. Use appropriate primer and cement to permanently bond them together.

4. Verify all connections and joints for tight ﬁ t and proper alignment with other vent pipes.

Condensate Drain Lines The placement of the condensate drain lines will depend on the conﬁ guration selected in Table 4 (page 18). The drain lines can be routed out the left or right side of the furnace, but must maintain a downward slope to ensure proper condensate drainage. The J-trap may need to be rotated to the side that matches your setup in Figures 37 - 39 (pages 48 - 50). To rotate the J-trap, loosen the clamp on the drain tube, rotate the J-trap to either side, and retighten the clamp.

Four general rules apply:

• Each condensate drain line must be separately trapped

using a J-Trap or ﬁ eld supplied loop.

• There must always be a drain attached to the collector

at the outlet of the secondary heat exchanger.

• There must always be a drain at the outlet of the inducer

assembly.

• There must always be a drain at the lowest point of the

venting system.

GAS SUPPLY AND PIPING

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

IMPORTANT NOTES:

• Some local regulations require the installation of a manual main shut-off valve and ground joint union external to the furnace as depicted in Figure 20. 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 shutoff.

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

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

• 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. 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 as shown in Figure 20.

Table 12 (page 38) lists gas ﬂ ow capacities for standard pipe sizes as a function of length in typical applications based on nominal pressure drop in the line.

Exceptions and clariﬁ cations to the general rules:

• In some cases, the lowest point in the vent system is where it connects to the inducer (Options 6 & 8). In this case one drain at this location is sufﬁ cient.

• If the vent exits the furnace horizontally, the vent may be turned vertically with a tee. The drip leg formed by the tee must include a drain (Options 1-4, 9, 11, 12, 14).

• In certain cases, it is permitted to drain the inducer back into the top drain of the collector (Options 1, 3, 5, 7, 9, 10, 12, & 13). To ensure proper drainage of condensate, make sure the drain line does not sag or becomes twisted. The drain tube supplied with the furnace may need to be trimmed.

IMPORTANT NOTE: If the furnace is installed in an area where temperatures fall below freezing, special precautions must be made for insulating condensate drain lines that drain to the outdoors. If condensate freezes in the lines, this will cause improper operation or damage to the furnace. It is recommended that all

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 20 (page 21).

Leak Check

WARNING:

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

Page 21

UPFLOW MODELS

Note “A”

See

Note “A”

See

Note “B”

Left Side Entry

DOWNFLOW MODELS

See

Note “B”

Right Side Entry

See

Note “A”

See

Note “A”

See

Note “B”

Left Side Entry

See

Note “B”

Right Side Entry

ITEM # and COMPONENT

(1) Automatic Gas Valve

(w/ manual shut-off)

(2) Burner Assembly (3) Dripleg

(4) Elbow (5) Ground Joint Union (6) Manifold

(7) Pipe Nipple (8 inch) (8) Plug (9) Shut - Off Valve

NOTE A: Some utilities require Shut- Off Valve to be 4 to 5 feet above ﬂ oor. NOTE B: Inducer assembly omitted for clarity of pipe installation.

Figure 20. Typical Gas Connections

Page 22

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

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

WARNING:

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

The furnaces are shipped from the factory with oriﬁ ces and gas regulator settings for natural gas operation at sea level altitudes. At 2000 feet, the NFGC requires that this appliance be derated 4% for each 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.

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, particularly in high altitude areas, the local gas utility usually 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 15 and 16 (page 40) contain the oriﬁ ce sizes and manifold pressure to use at various altitudes. Table 15 (HIGH) is for natural gas installations with a

heating value of more than 1,000 Btu per cubic foot and Table 16 (LOW) is for less than 1,000 Btu per cubic foot. To determine which table to use:

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

2. From Table 14 (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 15 or if it’s LOW, use Table 16. See example.

INSTALLATION EXAMPLE

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

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

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

From Table 14, ﬁ nd 750 and follow down the column, stop at the 5,000 feet row. The heating value listed is LOW. Table 16 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 and Adjusting the Input Rate section (page 27).

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

Conversion to LP/Propane

WARNING:

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

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.

Approved conversion kits are listed below. Please follow the instructions provided with each kit.

• 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 2,000 ft. and 10,000 ft. above sea level.

Page 23

• 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.

In the U.S., if installation is above 2,000 ft., refer to Table 13 (page 39) to determine the correct oriﬁ ce size and regulator pressure. When conversion is complete, verify the manifold pressure and input rate are correct as listed in the tables.

ELECTRICAL WIRING

WARNING:

ELECTRICAL SHOCK, FIRE OR EXPLOSION HAZARD

Failure to follow safety warnings exactly could result in dangerous operation, serious injury, death 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.

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

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

Fixed Speed Blower Applications NOTE: This section applies only to furnaces with model

numbers sufﬁ xed with two numbers, followed by a letter, such as 35C or 45D. If your model has sufﬁ x VA, VB, VC, or VD, please consult the Variable Speed Blower Application section.

The ﬁ xed speed motor control board (Figure 29) 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 8 (page 35).

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 page 25 for additional dehumidiﬁ cation options.

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.

Variable Speed Blower Applications

NOTE: This section applies only to models ending with

the sufﬁ xes VA, VB, VC, or VD.

The variable speed motor control board (Figure 30, page

41) has a set of dip switches for setting the base 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, see Table 9 (page 36) for heating or Table 10 (page 37) for cooling.

IMPORTANT NOTE: If replacing any of the original wires supplied with the furnace, the replacement wire must be copper wiring and have a temperature rating of at least 105°F (40°C). For electrical speciﬁ cations, refer to the furnace nameplate or Table 5 (page 26).

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 29, page 41) controls the torque and the variable speed motor control board (Figure 30) controls the airﬂ ow at a constant CFM. Both boards use the same furnace control board (Figure 29).

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 page 25 for additional dehumidiﬁ cation options.

CAUTION:

The variable speed control board is also used by other appliances. Many of the terminals and connections on the board are for other appliances and are not used in the two stage application. The only two-stage ﬁ eld connection to this board is the DHUM terminal, used to reduce the blower speed during cooling. See page 26.

Page 24

Wiring Conﬁ gurations

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

Single Stage AC and Single Stage Thermostat (Fig. 21) This option does not use the full two-stage control capability of the furnace, but the possibility of timed autostaging is available. See Autostaging for Single Stage Thermostats.

• Connect the thermostat’s W output (Figure 21) to the

furnace control boards W1 terminal. This allows the furnace to always run in low output mode.

• Always connect the thermostat C and R to the furnace

control board C and R.

• For cooling, connect the thermostats Y signal to the

furnace control board Y/Y2 terminal.

• Field supplied wires should also connect Y/Y2 and C

to the outdoor unit’s Y and C terminals.

ROOM THERMOSTAT

(SINGLE STAGE)

Y/Y2

TWO STAGE FURNACE BOARD

DHUM

A/C CONDENSING UNIT

Y C

(SINGLE STAGE)

DHUM

HIGH EFFICIENCY

BLOWER MOTOR

CONTROL BOARD

Figure 21. Wiring Conﬁ guration 1

Single Stage AC and Two Stage Thermostat (Fig. 22) This option uses the full two stage heating capability of the furnace with a single stage outdoor unit:

• Connect the thermostat’s W1 and W2 outputs to the

furnace control board’s W1 and W2 terminals.

• Always connect the thermostat C and R to the furnace

control board C and R

• For cooling, connect the thermostats Y signal to the

furnace control board Y/Y2 terminal.

• Field supplied wires should also connect Y/Y2 and C

to the outdoor unit’s Y and C terminals.

ROOM THERMOSTAT

(TWO - STAGE)

R DHUMC

Y C

A/C CONDENSING UNIT

(SINGLE STAGE)

DHUM

HIGH EFFICIENCY

BLOWER MOTOR

CONTROL BOARD

Two-Stage AC and Two-Stage Thermostat (Fig. 23) This option uses the full two stage heating capability of the furnace with a two stage outdoor unit:

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

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

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

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

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

ROOM THERMOSTAT

(TWO STAGE)

Y/Y2

TWO STAGE FURNACE BOARD

DHUM

Y2 Y1 C

A/C CONDENSING UNIT

(TWO STAGE)

DHUM

HIGH EFFICIENCY

BLOWER MOTOR

CONTROL BOARD

Figure 23. Wiring Conﬁ guration 3

Autostaging for Single Stage Thermostats

The Autostaging feature included on all G7 2-stage furnaces makes 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 start in low ﬁ re, but after a period of time jump to high ﬁ re, until the heating load is met. See Low Voltage Wiring (page 25).

Autostaging options are selected using the Autostage jumper (Figure 31, page 41) located near the thermostat screw terminal block. On the circuit board, Autostage jumper pins are electrically connected on the circuit board to R, W1, and W2 such that:

1. When the Autostage jumper is in the “SHORT” position,

R is connected to W2. Setting the Autostage jumper in the “SHORT” position is the same as jumping R to W2. This connection 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.

2. When the Autostage jumper is in the “LONG” position,

W1 and W2 are connected. Setting the Autostage jumper in the “LONG” position is the same as jumpering W1 and W2 together. The control board knows that Autostaging (at 12 minutes, the “LONG” setting) is active when 24vac inputs from both W1 and W2 are received at the same time.

Y/Y2

TWO STAGE FURNACE BOARD

Figure 22. Wiring Conﬁ guration 2

Page 25

Autostaging for Two-Stage Thermostats

The Autostage setting on the furnace control board (Figure

31) is disabled when shipped from the factory. This feature will be not used when paired with a two-stage thermostat. The Autostage Jumper (P7) must be kept on the NONE setting to allow the thermostat to adjust stages.

IMPORTANT NOTE: An electrical disconnect must be installed readily accessible from and located within sight of the furnace. See Figure 25 (page 26) or the wiring diagram label inside of the control door. Any other wiring methods must be acceptable to authority having jurisdiction.

Please note that on certain thermostats, even without the Autostage jumper in the “LONG” position, W1 and 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 and 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.

Dehumidiﬁ cation Options

Both motor control boards (Figures 29 & 30, page 41) have a DHUM connection that causes 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:

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 (Figure 24).

2. If using a separate humidistat, connect the DHUM and R terminals on the humidistat to the DHUM and 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 and DHUM terminals on the motor 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

CONTROL BOARD

DHUM

HUMIDISTAT

Figure 24. DHUM Wiring Conﬁ guration 7

Line Voltage Wiring

It is recommended that the line voltage (115 VAC) to the furnace be supplied from a dedicated branch circuit containing the correct fuse or circuit breaker for the furnace (Table 5, page 26).

CAUTION:

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

IMPORTANT NOTE: Proper line voltage polarity must be maintained in order for the control system to operate correctly. Verify the incoming neutral line is connected to the white wire and the incoming “hot” line is connected to the black wire. The furnace will not operate unless the polarity and ground are properly connected as shown in Figure 25.

Low Voltage Wiring

The thermostat must be installed according to the instructions supplied by the thermostat manufacturer. Low voltage connections (24 VAC) from the thermostat are wired to the terminal strip on the integrated control in the furnace. Recommended minimum wire gauge for thermostat wiring is shown in Table 5.

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

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

To determine the heat anticipator setting:

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

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

after the circulating blower motor has started.

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!

Page 26

Furnace

Input

(Btuh)

60,000

Cabinet

Width

(in.)

17 ½

Nominal

Electrical

Supply

Maximum Operating

Voltage

Minimum

Operating

Voltage

Maximum

Furnace

Amperes

Minimum

Wire

Gauge

115-60-1 127 103 7.0 14 15

80,000 21 115-60-1 127 103 9.4 14 20

100,000 21 115-60-1 127 103 9.4 14 20

120,000

115-60-1 127 103 12.5 14 25

** Time-delay fuses or HACR-type circuit breakers are required.

Recommended Thermostat Wire Length

Thermostat Wire Gauge

24 55 ft. 25 ft.

22 90 ft. 45 ft.

20 140 ft. 70 ft.

18 225 ft. 110 ft.

2 - wire

(Heating)

4 or 5 wire

(Cooling)

Table 5. Wire Length and Voltage Speciﬁ cations

Maximum

Fuse or Circuit

Breaker Amps**

Field Supplied

Fused Service

Panel

Black (Hot)

White (Neutral)

Field Supplied Disconnect w/in Sight of Furnace

Black

White

Green or Bare

(Ground)

Ground

Field Line Voltage Wiring Factory Line Voltage Wiring

Figure 25. Line Voltage Field Wiring

Twinning

The control boards on ﬁ xed speed furnaces are capable of being twinned to other furnace of the same series, only if the following criteria are met:

• The circuit boards are the same.

• The thermostat wires and the 1/4 inch thick quick-connect

terminals marked “TWIN” (Figure 26) on the furnace controls must be connected together.

• The fuses must remain installed on each board.

• Twinned furnaces must be properly grounded according

to local codes.

• The autostage jumper must be set to the same pin

setting on both furnace control boards.

Ground

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

Black

White

Field Supplied

Panel Connector

THERMOSTAT

W1 G

R C Y

G W1 W2

FURNACE

BOARD

FSHE

BOARD

TWIN TERMINAL

A/C

UNIT

FURNACE 1 FURNACE 2

Black

White

Ground

FURNACE

TWIN TERMINAL

R C Y

G W1 W2

BOARD

FSHE

BOARD

Note: Variable speed furnaces cannot be twinned.

Figure 26. Twinning

Page 27

START-UP AND ADJUSTMENTS Pre-Start Check List

√ Verify the polarity of the connections are correct, the

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

√ Verify that all needed thermostat wires are securely

connected to the correct leads on the terminal strip of the circuit board. See Figures 21 - 23 (page 24).

√ Verify the gas line service pressure does not exceed

10.0 inches of water column, 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 button to reset the switch. DO

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

reset the switch without identifying and correcting the fault condition.

√ 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.

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 input rate in Btuh. See example.

Example:

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

• From Table 11 read 90 cubic ft gas per hr.

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

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

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

WARNING:

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

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 28.

5. After 5 minutes of operation, set the thermostat below room temperature and verify steps 11 & 12 of the Operating Sequence.

Verifying and Adjusting Input Rate

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

The input rate must be veriﬁ ed for each installation to

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

1. Shut off all other gas ﬁ red appliances.

2. Start 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 11 (page 38).

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

this installation by referring to Table 13 (page 39) for Propane or Tables 15 or 16 for Natural Gas (page 40).

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 27) on the side of the regulator to adjust the full input setting. IMPORTANT

NOTE: Turning the adjusting screw clockwise increases the pressure and counterclockwise reduces the pressure.

d.) Reinstall plastic cap after adjustment is complete.

HI Input

Adjusting Screw

Lo Input Adjusting Screw

Figure 27. HI and LO Input Adjusting Screws

Page 28

Verifying and Adjusting Temperature Rise

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

1. Place thermometers in the return and supply air

stream as close to the furnace as possible. To avoid false readings, the thermometer on the supply air side must be shielded from direct radiation from the heat exchanger.

2. Adjust all registers and duct dampers to the desired

position and run the furnace for 10 to 15 minutes on high ﬁ re before taking any temperature readings. The temperature rise is the difference between the supply and return air temperatures.

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

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

Verifying Burner Operation

CAUTION:

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

1. Remove the burner compartment door.

2. Set the thermostat above room temperature and

observe the ignition sequence. 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 flame characteristics, change

thermostat setting to below room temperature.

4. Verify burner ﬂ ame is completely extinguished.

5. Replace the burner compartment door.

Verifying Operation of the Supply Air Limit Switch

Note: A properly functioning limit switch should turn off

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

1. Check the blower door and verify that it is securely

mounted in place and that there is power to the furnace.

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

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

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

OPERATING SEQUENCE

The operating sequences for the heating, cooling, and fan modes are described below. Refer to the ﬁ eld and furnace wiring diagrams: (Figures 21 - 23, page 24), (Figures 32

- 35, pages 42 - 45) and (Figure 25, page 26).

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 induced draft 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 re. 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.

Page 29

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 deenergized and the control continues to run the fan for a period of 60 seconds.

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!)

• Is there blockage in the condensate drain switch? Also verify that there is no double trapping of condensate.

• Is the secondary heat exchanger free of debris and clogs?

• Is evaporator coil clean and free of debris (If applicable).

Fan Mode

• When the thermostat energizes the G terminal for

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

• If a call for cooling occurs during continuous fan, the blower will switch over to the selected COOL speed.

• If the W terminal receives a call for heat during continuous fan, the blower will de energize.

• A call for fan is ignored while in lockout.

• The blower will operate at 50% of the selected high cooling speed for continuous fan operation.

• Are all the LED’s on the furnace and motor control boards constantly ON? If not, refer to Tables 6 - 7 to determine fault condition.

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

• If the Inducer Blower is operating, and items above have been veriﬁ ed, check the Blower Limit Switch (Figure 40 or 41, page 51) 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 40 or 41) 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.

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 6. Furnace Control Board Fault Conditions

Green

LED

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

Table 7. Motor Control Board Fault Conditions

Red LED

Page 30

DESCRIPTION OF COMPONENTS

The descriptions below are various functional components that affect the operation and shutting down of this furnace. Some of these components and their locations are shown in Figures 40 and 41 (page 51). 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

The Blower switch prevents furnace operation when blower is not operational.

Condensate Drain Switch

The Condensate Drain Switch will shut down the furnace if the condensate drain from the Collector Pan becomes clogged.

Flame Sensor

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

Flame Roll-Out Switch

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

Gas Valve

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

Inducer Assembly

The inducer assembly vents products of combustion to the outside.

Pressure Switch

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

Supply Air Limit Switch

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

MAINTENANCE

WARNING:

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

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

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

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

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

Air Filter(s)

WARNING:

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

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

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

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.

Page 31

Cleaning of Burners

If the burners must be cleaned, follow the steps below and see Figure 40 or 41 (page 51) 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 it’s lowest setting.

3. Remove the burner door from the furnace.

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

5. Disconnect the wires from the gas valve, igniter, ﬂ ame sensor, and ﬂ ame rollout switch.

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

7. Remove the piping between the Gas Valve and the ground-joint union. (If applicable).

8. Remove all screws securing the Manifold Assembly to the Burner Box.

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 from which they were removed.

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

Heat Exchanger and Burner Maintenance

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

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 inlet pipe (if applicable) and outlet pipe to ensure they are not blocked by debris. Any damaged section of vent pipe must be replaced, and any obstruction or blockage must be removed prior to operating the furnace.

Page 32

FRENCH TRANSLATIONS

The following are French translations of important warning statements found within this manual.

AVERTISSEMENT:

RISQUE D’EMPOISONNEMENT AU MONOXYDE DE CARBONED Le non-respect des consignes suivantes portant sur chacun des appareils raccordés au système d’évacuation mis en service pourrait entraîner l’empoisennement au monoxyde de carbone ou la mort. Les consignes suivantes doivent être observées pour chaque appareil raccordé au système d’évacuation mis en service si les autres appareils raccordés au système ne sont pas en service:

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

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

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

4. Fermer les registres des foyers;

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

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

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

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

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

Page 33

AVERTISSEMENT:

RISQUE D’INCENDIE OU D’ EXPLOSION

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

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

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

QUE FAIRE S’IL Y A UNE ODEUR DE GAZ

• Ne pas tenter d’allumer aucun appareil.

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

• Évacuer l’immeuble immédiatement.

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

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

AVERTISSEMENT:

RISQUE D’INCENDIE ET D’EXPLOSION

Risque de blessures graves ou de mort.

Ne pas entreposer ni utiliser de l’essence ni d’autres vapeurs ou liquides inﬂ ammables dans le voisinage de cet appareil, ni de tout autre appareil. Le fait d’entreposer ou d’utiliser de l’essence ou d’autres liquides ou vapeurs inﬂ ammables à proximité de cet appareil ou de tout autre appareil peut causer des blessures graves ou la mort.

AVERTISSEMENT:

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

Le non-respect des avertissements de sécurité pourrait entraîner un fonctionnement dangereux de l’appareil, des blessures graves, la mort ou des dommages matériels.

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

• Couper toute alimentation électrique au

générateur d’air chaud avant de prodéder aux travaux d’entretein.

• Au moment de l’entretien des commandes,

étiquetez tous les ﬁ ls avant de les débrancher. S’assurer de les raccorder correctement.

• S’assurer que l’appareil fonctionne

adéquatement aprés l’entretien.

AVERTISSEMENT:

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

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

Page 34

FIGURES AND TABLES

*TC 95.1% Upﬂ ow/Horizontal Furnace

FRONT

BRACE

BOTTOM

PANEL

23 1/2

INLET AIR

BOTTOM

VIEW

Ø 7/8 HOLE FOR THERMOSTAT

Ø 7/8 HOLE FOR

ELECTRIC

Ø 1 5/8 HOLE

FOR GAS

17 7/8

Ø 1 1/16 HOLE

Ø 3” HOLE

FOR VENT

34 1/2

22 1/4

25 3/8

22 1/2

PIPE

17 1/4

LEFT SIDE

TOP VIEW

FLANGES

3 ¼

Ø 7/8 HOLE FOR

THERMOSTAT

Ø 3” HOLE FOR

VENT PIPE

Upﬂ ow/Horz.

Cabinets

‘B’ Cabinet ‘C’ Cabinet ‘D’ Cabinet

Dim.

“A”

17 ½ 15 ⅞ 16 ⅛

21 19 ⅜ 19 ⅝

24 ½ 22 ⅞ 23 ⅛

NOTES:

Dimensions shown in inches.

Ø 7/8 HOLE

FOR ELECTRIC

22 1/2

Ø1 5/8 HOLE FOR GAS

4 KNOCKOUTS

24 7/8

(BOTH SIDES)

Ø 1 1/16 HOLE

RIGHT SIDE

Dim.

“B”

Dim.

“C”

1 1/4

*TL 95.1% Downﬂ ow Furnace

FRONT BRACE

BOTTOM

VIEW

18 1/2

2 3/4

Ø 7/8 HOLE FOR ELECTRIC

1 5/8 X 3 1/2 HOLE FOR GAS

16 1/2

10 1/4

Ø 1 1/16 HOLE

34 1/2

Ø 3” HOLE

FOR VENT

24 1/8

22 1/4

25 1/2

22 1/2

PIPE

LEFT SIDE

FLUE

TOP VIEW

FLANGES

Downﬂ ow

Cabinets

‘B’ Cabinet ‘C’ Cabinet ‘D’ Cabinet

Dim.

“A”

Dim.

“B”

Dim.

“C”

17 ½ 15 ⅞ 16 ⅛

21 19 ⅜ 19 ⅝

24 ½ 22 ⅞ 23 ⅛

NOTES:

Dimensions shown in inches.

INLET AIR

1/2

Ø 7/8 HOLE FOR

THERMOSTAT

Ø 7/8 HOLE FOR

22 1/4

ELECTRIC

Ø 1 5/8 HOLE

FOR GAS

25 Ø 3” HOLE FOR VENT PIPE

22 1/2

25 3/8

17 1/4

Ø 1 1/16 HOLE

RIGHT SIDE

29 1/2

17 7/16

Figure 28. Furnace Dimensions

Page 35

AIRFLOW DATA

*TC/TL FURNACES WITH FIXED SPEED BLOWERS

Model

Number

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.

Heating Input

*TC/TL-060D-*B

*TC/TL-80D-*C

*TC/TL-100D-*C

*TC/TL-120D-*D

(Btuh)

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

0100

1 1 0 0 725 73

0 0 1 0 810 65

1 0 1 0 940 56 890 59 845 62 795 66 750 70 700 75

0 1 1 0 990 53 945 56 905 58 860 61 820 64 775 68 735 72 690 76

1 1 1 0 1,055 50 1,015 52 970 54 930 57 890 59 845 62 805 66 760 69

0 0 0 1 1,135 47 1,095 48 1,055 50 1,010 52 960 55 930 57 890 59 850 62

60,000

1 0 0 1 1,185 45 1,145 46 1,105 48 1,065 50 1,030 51 990 53 950 56 910 58

0 1 0 1 1,250 42 1,210 44 1,170 45 1,135 47 1,095 48 1,055 50 1,020 52 980 54

1 1 0 1 1,290 41 1,255 42 1,220 43 1,180 45 1,145 46 1,110 48 1,075 49 1,040 51

0 0 1 1 1,315 40 1,275 41 1,240 43 1,200 44 1,160 45 1,120 47 1,085 49 1,045 51

1 0 1 1 1,350 39 1,315 40 1,280 41 1,245 42 1,205 44 1,170 45 1,135 47 1,100 48

0 1 1 1 1,390 38 1,350 39 1,315 40 1,275 41 1,240 43 1,200 44 1,160 45 1,125 47

1 1 1 1 1,420 37 1,380 38 1,345 39 1,310 40 1,270 42 1,235 43 1,200 44 1,160 45

0 0 0 0 1,125 55 1,040 68 960 73 880 80 795 89

1 0 0 0 1,205 58 1,120 63 1,040 68 960 73 875 80 795 89

0 1 0 0 1,305 54 1,225 57 1,150 61 1,070 66 995 71 915 77 840 84

1 1 0 0 1,430 49 1,350 52 1,270 55 1,190 59 1,110 63 1,030 68 950 74 865 81

0 0 1 0 1,525 46 1,450 49 1,375 51 1,300 54 1,225 57 1,150 61 1,075 65 1,000 70

1 0 1 0 1,620 43 1,540 46 1,465 48 1,390 51 1,315 54 1,240 57 1,165 60 1,090 65

0 1 1 0 1,695 42 1,620 43 1,545 46 1,465 48 1,390 51 1,315 54 1,235 57 1,160 61

1 1 1 0 1,770 40 1,700 41 1,630 43 1,555 45 1,485 47 1,410 50 1,340 53 1,265 56

0 0 0 1 1,875 38 1,805 39 1,730 41 1,655 43 1,580 45 1,510 47 1,435 49 1,340 53

80,000

1 0 0 1 1,905 37 1,840 38 1,775 40 1,710 41 1,640 43 1,575 45 1,510 47 1,445 49

0 1 0 1 1,980 36 1,910 37 1,845 38 1,780 40 1,715 41 1,650 43 1,580 45 1,515 46

1 1 0 1 2,025 35 1,960 36 1,895 37 1,830 38 1,765 40 1,700 41 1,635 43 1,570 45

0 0 1 1 2,085 34 2,025 35 1,960 36 1,900 37 1,840 38 1,775 40 1,715 41 1,655 43

1 0 1 1 2,135 33 2,070 34 2,010 35 1,945 36 1,880 37 1,815 39 1,750 40 1,685 42

0 1 1 1 2,200 32 2,145 33 2,090 34 2,035 35 1,980 36 1,925 37 1,870 38 1,820 39

1 1 1 1 2,280 31 2,225 32 2,170 32 2,115 33 2,065 34 2,010 35 1,955 36 1,900 37

0 0 0 0 1,125 78 1,040 85

1 0 0 0 1,205 73 1,120 79 1,040 85

0 1 0 0 1,305 67 1,225 72 1,150 76 1,070 82 995 88

1 1 0 0 1,430 62 1,350 65 1,270 69 1,190 74 1,110 79 1,030 85

0 0 1 0 1,525 58 1,450 61 1,375 64 1,300 68 1,225 72 1,150 76 1,075 82 1,000 88

1 0 1 0 1,620 54 1,540 57 1,465 60 1,390 63 1,315 67 1,240 71 1,165 76 1,090 81

0 1 1 0 1,695 52 1,620 54 1,545 57 1,465 60 1,390 63 1,315 67 1,235 71 1,160 76

1 1 1 0 1,770 50 1,700 52 1,630 54 1,555 57 1,485 59 1,410 62 1,340 66 1,265 70

0 0 0 1 1,875 47 1,805 49 1,730 51 1,655 53 1,580 56 1,510 58 1,435 61 1,340 66

100,000

1 0 0 1 1,905 46 1,840 48 1,775 50 1,710 51 1,640 54 1,575 56 1,510 58 1,445 61

0 1 0 1 1,980 44 1,910 46 1,845 48 1,780 49 1,715 51 1,650 53 1,580 56 1,515 58

1 1 0 1 2,025 43 1,960 45 1,895 46 1,830 48 1,765 50 1,700 52 1,635 54 1,570 56

0 0 1 1 2,085 42 2,025 43 1,960 45 1,900 46 1,840 48 1,775 50 1,715 51 1,655 53

1 0 1 1 2,135 41 2,070 42 2,010 44 1,945 45 1,880 47 1,815 48 1,750 50 1,685 52

0 1 1 1 2,200 40 2,145 41 2,090 42 2,035 43 1,980 44 1,925 46 1,870 47 1,820 48

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 46

0 0 0 0 1,395 76 1,350 78 1,305 81 1,260 84 1,210 87 1,165 91 1,120 94

1 0 0 0 1,465 72 1,420 74 1,375 77 1,330 79 1,290 82 1,245 85 1,200 88 1,155 91

0 1 0 0 1,555 68 1,510 70 1,470 72 1,425 74 1,380 76 1,340 79 1,295 82 1,250 84

1 1 0 0 1,625 65 1,585 67 1,540 69 1,500 70 1,460 72 1,415 75 1,375 77 1,335 79

0 0 1 0 1,690 62 1,650 64 1,610 66 1,570 67 1,530 69 1,485 71 1,445 73 1,405 75

1 0 1 0 1,760 60 1,715 62 1,670 63 1,625 65 1,575 67 1,530 69 1,485 71 1,440 73

0 1 1 0 1,835 58 1,790 59 1,745 60 1,695 62 1,650 64 1,605 66 1,555 68 1,510 70

1 1 1 0 1,885 56 1,840 57 1,790 59 1,745 60 1,700 62 1,655 64 1,610 66 1,565 67

0 0 0 1 1,945 54 1,900 56 1,850 57 1,805 58 1,760 60 1,710 62 1,665 63 1,620 65

120,000

1 0 0 1 1,950 54 1,905 55 1,860 57 1,820 58 1,775 59 1,735 61 1,690 62 1,650 64

0 1 0 1 2,075 51 2,030 52 1,990 53 1,945 54 1,900 56 1,855 57 1,810 58 1,770 60

1 1 0 1 2,125 50 2,085 51 2,040 52 2,000 53 1,955 54 1,910 55 1,870 56 1,825 58

0 0 1 1 2,170 49 2,130 50 2,090 51 2,045 52 2,005 53 1,965 54 1,925 55 1,880 56

1 0 1 1 2,215 48 2,180 48 2,140 49 2,105 50 2,070 51 2,035 52 2,000 53 1,965 54

0 1 1 1 2,225 47 2,165 49 2,100 50 2,040 52

1111 2,170 49 2,120 50 2,065 51

0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8

Table 8. Heating / Cooling Airﬂ ows (CFM) and Temperature Rises (°F)

External Static Pressure (in.W.C.)

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)

Page 36

“B” CABINET

*TC/TL FURNACES WITH VARIABLE SPEED BLOWERS

Switch Settings For Heat

(0 = OFF, 1 = ON)

1234 CFM Temp Rise (°F)

1000 1,000 53

1001 1,100 48

1010 1,200 44

1011 1,300 41

1100 1,400 38

1101 1,500 35

1110 1,600 33

1111 1,700 31

*TC/TL-060D-*B

Input (BTU) 60,000

Switch Settings For Heat

(0 = OFF, 1 = ON)

1234CFMTemp Rise (°F) CFM Temp Rise (°F)

#0001,000 70 1,000 88

#0011,115 63 1,115 79

“C” CABINET

“D” CABINET

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. # Switch not used- can be 0 or 1.

#0101,230 57 1,230 72

#0111,345 52 1,345 65

#1001,460 48 1,460 60

#1011,575 45 1,575 56

#1101,690 42 1,690 52

#1111,805 39 1,805 49

Switch Settings For Heat

(0 = OFF, 1 = ON)

1234 CFM Temp Rise (°F)

#000 1,500 70

#001 1,615 65

#010 1,730 61

#011 1,845 57

#100 1,960 54

#101 2,075 51

#110 2,190 48

#111 2,305 46

Notes:

*TC/TL-080D-*C

Input (BTU) 80,000

*TC/TL-120D-*D

Input (BTU) 120,000

*TC/TL-100D-*C

Input (BTU) 100,000

Table 9. Nominal Heating Airﬂ ows (CFM) and Temperature Rises (°F)

Page 37

*TC/TL FURNACES WITH VARIABLE SPEED BLOWERS

“B” CABINET

Switch Settings

(0 = OFF, 1 = ON)

HEAT COOL

CFM

Nominal A/C and HP

Capacity

1-4 5 6 7 8 LOW HIGH

1 0 0 0 0 485 700

1 0 0 0 1 525 760

1 0 0 1 0 565 820

1 0 0 1 1 605 880

1 0 1 0 0 650 940

1 0 1 0 1 690 1,000

1 0 1 1 0 730 1,060

1 0 1 1 1 775 1,120

1 1 0 0 0 815 1,180

1 1 0 0 1 855 1,240

3 TON

1 1 0 1 0 895 1,300

1 1 0 1 1 940 1,360

1 1 1 0 0 980 1,420

1 1 1 0 1 1,020 1,480

3.5 TON

1 1 1 1 0 1,065 1,540

1 1 1 1 1 1,105 1,600

2 TON

2.5 TON

*TC/TL FURNACES WITH VARIABLE SPEED BLOWERS

“C” CABINET

Switch Settings

(0 = OFF, 1 = ON)

HEAT COOL HEAT COOL

CFM

Nominal A/C and

HP Capacity

*TC/TL FURNACES WITH VARIABLE SPEED BLOWERS

“D” CABINET

Switch Settings

(0 = OFF, 1 = ON)

CFM

1-4 5 6 7 8 LOW HIGH 1-4 5 6 7 8 LOW HIGH

# 0 0 0 0 705 1,025

# 0 0 0 1 750 1,090

# 0 0 1 0 795 1,155 # 0 0 1 0 1,020 1,480

# 0 0 1 1 840 1,220 # 0 0 1 1 1,050 1,520

3 TON

# 0 1 0 0 885 1,285

# 0 0 0 0 965 1,400

# 0 0 0 1 995 1,440

2.5 TON

# 0 1 0 0 1,075 1,560

# 0 1 0 1 930 1,350 # 0 1 0 1 1,105 1,600

# 0 1 1 0 975 1,415

3.5 TON

# 0 1 1 0 1,130 1,640

# 0 1 1 1 1,020 1,480 # 0 1 1 1 1,160 1,680

# 1 0 0 0 1,065 1,545 # 1 0 0 0 1,185 1,720

# 1 0 0 1 1,110 1,610 # 1 0 0 1 1,215 1,760

# 1 0 1 0 1,155 1,675

4 TON

# 1 0 1 0 1,240 1,800

# 1 0 1 1 1,200 1,740 # 1 0 1 1 1,270 1,840

# 1 1 0 0 1,245 1,805 # 1 1 0 0 1,295 1,880

# 1 1 0 1 1,290 1,870 # 1 1 0 1 1,325 1,920

5 TON

# 1 1 1 0 1,335 1,935 # 1 1 1 0 1,350 1,960

# 1 1 1 1 1,380 2,000 # 1 1 1 1 1,380 2,000

Nominal A/C and HP

Capacity

3.5 TON

4 TON

5 TON

# Switch not used - can be 0 or 1

Table 10. Nominal Cooling/Heat Pump Airﬂ ows (CFM) for Variable Speed Furnaces

Page 38

TIME FOR ONE

REVOLUTION

(SECONDS)

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

GAS INFORMATION

GAS FLOW RATES (CUBIC FEET PER HOUR)

CUBIC FEET PER

REVOLUTION

OF GAS METER

1 5 10 1 5 10

TIME FOR ONE

REVOLUTION

(SECONDS)

CUBIC FEET PER

REVOLUTION

OF GAS METER

Table 11. Gas Flow Rates

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

FOR NATURAL GAS (SPECIFIC GRAVITY - 0.60)

NOMINAL BLACK

IRON PIPE

DIAMETER (IN.)

½ ¾

1 520 350 285 245 215 195 180 170

1 ¼ 1,050 730 590 500 440 400 370 350

1 ½ 1,600 1,100 890 760 670 610

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

10 20 30 40 50 60 70 80

130 90 75 65 55 50 45 40

280 190 150 130 115 105 95 90

Cubic Feet Per Hour Required =

LENGTH OF PIPE RUN (FT)

NOTES

Input To Furnace (Btu/hr)

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

Table 12. Black Iron Gas Pipe Capacities

Page 39

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

Table 13. High Altitude Deration Chart for Propane Gas

PROPANE GAS

INPUT (BTU) and STAGE

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

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

55 55 55 55 ORIFICE SIZE

4.2 10.0 4.2 10.0 4.2 10.0 4.2 10.0 MANIFOLD PRESSURE

55 55 55 55 ORIFICE SIZE

4.2 9.0 4.2 9.0 4.2 9.0 4.2 9.0 MANIFOLD PRESSURE

55 55 55 55 ORIFICE SIZE

4.2 8.5 4.2 8.5 4.2 8.5 4.2 8.5 MANIFOLD PRESSURE

56 56 56 56 ORIFICE SIZE

4.2 10.0 4.2 10.0 4.2 10.0 4.2 10.0 MANIFOLD PRESSURE

56 56 56 56 ORIFICE SIZE

4.2 9.0 4.2 9.0 4.2 9.0 4.2 9.0 MANIFOLD PRESSURE

56 56 56 56 ORIFICE SIZE

4.2 8.5 4.2 8.5 4.2 8.5 4.2 8.5 MANIFOLD PRESSURE

ALTITUDE

ABOVE

SEA LEVEL

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

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

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

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

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

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

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

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

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

LOCAL HEATING VALUE, BTU PER CUBIC FOOT

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

Table 14. Natural Gas Heating Values

Page 40

NATURAL GAS - 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) and STAGE

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

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

45 45 45 45 ORIFICE SIZE

1.7 3.5 1.7 3.5 1.7 3.5 1.7 3.5 MANIFOLD PRESSURE

45 45 45 45 ORIFICE SIZE

1.7 3.3 1.7 3.3 1.7 3.3 1.7 3.3 MANIFOLD PRESSURE

45 45 45 45 ORIFICE SIZE

1.7 3.1 1.7 3.1 1.7 3.1 1.7 3.1 MANIFOLD PRESSURE

45 45 45 45 ORIFICE SIZE

1.7 2.9 1.7 2.9 1.7 2.9 1.7 2.9 MANIFOLD PRESSURE

45 45 45 45 ORIFICE SIZE

1.7 2.8 1.7 2.8 1.7 2.8 1.7 2.8 MANIFOLD PRESSURE

48 48 48 48 ORIFICE SIZE

1.7 3.5 1.7 3.5 1.7 3.5 1.7 3.5 MANIFOLD PRESSURE

48 48 48 48 ORIFICE SIZE

1.7 3.3 1.7 3.3 1.7 3.3 1.7 3.3 MANIFOLD PRESSURE

48 48 48 48 ORIFICE SIZE

1.7 3.0 1.7 3.0 1.7 3.0 1.7 3.0 MANIFOLD PRESSURE

48 48 48 48 ORIFICE SIZE

1.7 2.8 1.7 2.8 1.7 2.8 1.7 2.8 MANIFOLD PRESSURE

Table 15. High Altitude Deration Chart for Natural Gas - High Heating Value

NATURAL GAS - 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

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

1.7 3.5 1.7 3.5 1.7 3.5 1.7 3.5 MANIFOLD PRESSURE

1.7 3.4 1.7 3.4 1.7 3.4 1.7 3.4 MANIFOLD PRESSURE

1.7 3.2 1.7 3.2 1.7 3.2 1.7 3.2 MANIFOLD PRESSURE

1.7 3.1 1.7 3.1 1.7 3.1 1.7 3.1 MANIFOLD PRESSURE

1.7 2.9 1.7 2.9 1.7 2.9 1.7 2.9 MANIFOLD PRESSURE

1.7 3.5 1.7 3.5 1.7 3.5 1.7 3.5 MANIFOLD PRESSURE

1.7 3.3 1.7 3.3 1.7 3.3 1.7 3.3 MANIFOLD PRESSURE

1.7 3.1 1.7 3.1 1.7 3.1 1.7 3.1 MANIFOLD PRESSURE

INPUT (BTU) and STAGE

45 45 45 45 ORIFICE SIZE

48 48 48 48 ORIFICE SIZE

Table 16. High Altitude Deration Chart for Natural Gas - Low heating Value

Page 41

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 29. Two-Stage Fixed Speed

Motor Control Board

AUTO

STAGE

NONE

SHORT

LONG

FUSE

Y/Y2

THERMOSTAT CONNECTIONS

293

EXPANSION

PORT

MOTOR WIRE

HARNESS

FOR WIRING TO THE

MOTOR CONTROL

BOARD

EXPANSION

PORT

GREEN

RED

YELLOW

(FLAME)

OFF

90 120 180

BLOWER

DELAY

STATUS

W_OUT

Y/Y2_OUT

Y1_OUT

OUTPUT TERMINALS

H_OUT

OUTPUT

HUMIDIFIER

FIELD USE

EXPANSION PORT

CONNECTION TO

FURNACE CONTROL

Figure 30. Two-Stage Variable Speed

NOT FOR

BOARD

STATUS LIGHTS

RED

CONNECTION TO

IQ THERMOSTAT

GREEN

FAN SPEED

(IF APPLICABLE)

1 2 345 6 7

OFF ON

HEAT

MOTOR WIRING

Motor Control Board

COOL

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

14325

EAC

XMFR

LINE

HUM

Figure 31. Two-Stage Furnace Control Board

NEUTRALS

LINE- N

XMFR-N

LINE- N

Page 42

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

123 123

PAR T O F

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

RCY/Y2 W2GW1Y1

VIOLET

SWITCH

VIOLET

SWITCH

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

DELAY

BLUE

FLAME SENSOR

BROWN

RED

12345

LINE- N

XMFR-N

14325

HUM

LINE

XMFR

EAC

WHITE

BLACK

VENT LIMIT

(ON SELECT

BLUEBLUE

FLAME

ROLL-OUT

SUPPLY

AIR LIMIT

ORANGE

YELLOW

MODELS)

GREEN

WHITE

BLUE BLUE

BLACK

BLUE

BLACK

DOOR

SWITCH

BLACK

BLACK 120V

WHITE (NEUTRAL)

WHITE

GROUND

INDUCER

GREEN

BLACK WHITE

RED

BLACK

1 1

2 2

IGNITOR

123

LEGEND:

FIELD WIRING

LOW VOLTAGE

HIGH VOLTAGE

Figure 32. Wiring Diagram for Two-Stage, Fixed Speed Upﬂ ow Furnaces

Page 43

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

MOTOR

RED

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.

BLACK

WHITE

120 V

24 V

BLK W/ WHITE STRIPES

WHITE W/ BLK STRIPES

1234

LOW

SWITCH

PRESSURE

HIGH

SWITCH

PRESSURE

BLACK

WHITE

W RX TX COM C R

RCY/Y2 W2GW1Y1

ORANGE

VIOLET

GREEN

BLACK

LINE- N

XMFR-N

DELAY

BLWR OFF

RED

BLUE

FLAME SENSOR

GAS

YELLOW

BROWN

VALVE

14325

HUM

LINE

XMFR

EAC

WHITE BLACK

VENT LIMIT

(ON SELECT

BLUE

FLAME

ROLL-OUT

BLUE

SUPPLY

AIR LIMIT

MODELS)

WHITE

BLACK

WHITE

DOOR

SWITCH

GROUND

(NEUTRAL)

BLACK 120V

GREEN

BLACK WHITE

RED

BLACK

INDUCER

IGNITOR

123

LEGEND:

FIELD WIRING

LOW VOLTAGE

HIGH VOLTAGE

Figure 33. Wiring Diagram for Two-Stage, Fixed Speed Downﬂ ow Furnaces

Page 44

CFM

112233445566778899

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

MOTOR

123

RED

123

RED

MOTOR PART OF

BLACK

MOTOR CHOKE

(ON 3/4 AND 1HP

MOTORS ONLY)

BLACK

BLOWER

LIMIT

0409

7109180

BLACK

WHITE

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

BLACK

GNDSENDHUM Y1

L1-OUT

L1-IN

L2-IN

WHITE

PWM

MODE

SPEED

COOL

HEAT

FAN SPEED

L2-OUT

W RX TX COM C R

RCY/Y2 W2GW1Y1

FAULT

COMMON

LIMIT

BLOWER

12345

RED

ORANGE

YELLOW

RED

ORANGE

YELLOW

12345

BLUE

GREEN

BLUE

GREEN

BLUE

¢7109187¤

BLACK

WHITE

BLUE BLUE

BLACK

WHITE

IGNITOR

BLACK WHITE

RED

BLACK

123

BLACK

INDUCER

BLACK

123

DX-

DX+

OPEN

GREEN

GND

RED

Y1Y/Y2W

DELAY

BLWR OFF

BLUE

LINE- N

XMFR-N

HUM

LINE

XMFR

EAC

WHITE BLACK

BROWN

14325

This wiring diagram shows connections and

termination required for the blower kit only.

Use in addition to the wiring diagram for the

furnace.

LOW

ORANGE

MODELS)

(ON SELECT

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 Upflow Furnaces

application.

CONDENSATE

Figure 34. Wiring Diagram for Two-Stage, Variable Speed Upﬂ ow Furnaces

ORANGE

SWITCH

PRESSURE

HIGH

ORANGE

SWITCH

PRESSURE

VIOLET

SWITCH

PRESSURE

VIOLET

SWITCH

PRESSURE

VIOLET

GREEN

GAS

DOOR

WHITE

SWITCH

BLACK

BLACK 120V

WHITE (NEUTRAL)

GREEN

GROUND

LEGEND:

FIELD WIRING

LOW VOLTAGE

HIGH VOLTAGE

MODELS)

VENT LIMIT

BLUE

(ON SELECT

FLAME

ROLL-OUT

SUPPLY

AIR LIMIT

RED

BROWN

BLUE

FLAME SENSOR

YELLOW

BROWN

VALVE

Page 45

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

PART OF

BLACK

WHITE

LIMIT

BLUE

BLACK

BLOWER

WHITE

DECK LIMIT

LIMIT

CFM

MOTOR

RED

123 123

MOTOR

PWM

FAULT

MODE

SPEED

COOL

HEAT

FAN SPEED

L2-OUT

OPEN

COMMON

GREEN

OPEN

GNDSEN

DHUM

L1OUT

L1-IN

L2-IN

RED

8 7 6 5 4 3 2 1

DX-

DX+

ORANGE

WHITE

BLACK

RED

YELLOW

GND

Y1Y/Y2W

WHITE

ORANGE

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 35. 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 46

VENTING INFORMATION

VENT TERMINAL

Clearance Location

Clearance above grade, veranda, porch, deck, balcony, or

A =

maximum expected snow level.

B = Clearance to window or door that may be opened.

C = Clearance to permanently closed window

Vertical clearance to ventilated sofﬁ t located above the

D =

terminal within a horizontal distance of 2 feet (61cm) from the center line of the terminal.

E = Clearance to unventilated sofﬁ t.

F = Clearance to outside corner.

G = Clearance to inside corner.

Clearance to each side of center line extended above

H =

meter/regulator assembly.

I = Clearance to service regulator vent outlet. 3 feet (1.83m)

Clearance to non-mechanical air supply inlet to building

J =

or the combustion air inlet to any other appliance.

K = Clearance to mechanical air supply inlet. 6 feet (1.83m)

Clearance above paved sidewalk or driveway located on

L =

public property.

M = Clearance under veranda, porch, deck, or balcony.

a In accordance with the current CSA B149.1 Natural Gas and Propane Installation Guide Code b In accordance with the current ANSI Z223.1 / NFPA 54 Natural Fuel Gas Code c A vent shall not terminate directly above a sidewalk or paved driveway that is located between two single family dwellings and serves both dwellings. d Permitted only if veranda, porch, deck, or balcony is fully open on a minimum of two sides beneath the ﬂ oor.

For clearances not speciﬁ ed in ANSI Z223.1 / NFPA 54 or CSA B149.1, the following statement shall be included: “Clearance in accordance with local installation codes, and the

requirements of the gas supplier and the manufacturers installation instructions”

AIR SUPPLY INLET

CANADIAN INSTALLATIONS

Direct Vent (2-pipe) &

Conventional Vent (1-pipe)

Furnaces

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

6 inches (15cm) for

appliances < 10,000 Btuh (3kW) 12 inches (30cm) for appliances

10,000 Btuh - 100,000 Btuh (30kW)

36 inches (91cm) for

appliances > 100,000 Btuh (30Kw)

***

*** *** ***

3 feet (91cm) within a height 15 feet

above the meter/regulator assembly

6 inches (15cm) for

appliances < 10,000 Btuh (3kW) 12 inches (30cm) for appliances

10,000 Btuh - 100,000 Btuh (30kW)

36 inches (91cm) for

appliances > 100,000 Btuh (30Kw)

7 feet (2.13m)

12 inches (30cm)

NOTES:

AREA WHERE TERMINAL IS NOT PERMITTED

Direct Vent

(2-pipe) Furnaces

6 inches (15cm) for

appliances < 10,000 Btuh (3kW)

9 inches (23cm) for appliances

10,000 Btuh - 50,000 Btuh (30kW)

12 inches (30cm) for

appliances > 50,000 Btuh (30Kw)

** **

6 inches (15cm) for

appliances < 10,000 Btuh (3kW)

9 inches (23cm) for appliances

10,000 Btuh - 50,000 Btuh (30kW)

12 inches (30cm) for

appliances > 50,000 Btuh (30Kw)

3 feet (91cm) above if within

10 feet (3m) horizontally

Table 17. Vent Termination Clearances

US INSTALLATIONS

Conventional Vent

(1-pipe) Furnaces

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

1 ft. (300mm) above opening

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

1 ft. (300mm) above opening

3 ft. (91cm) above if within

10 feet (3m) horizontally

7 ft. (2.13m)

Page 47

HORIZONTAL VENTING

(2-Pipe Shown)

90°

Elbow

Combustion Air

Straps or Other Suitable

Supports at minimum of 5 ft. Intervals

Seal/Caulk

Around Pipes

at Building

90°

Elbow

Straight Neoprene Coupling with 2 Hose Clamps* (Optional)

VERTICAL VENTING

(2-Pipe Shown)

Support System on

Vertical Rise

90° Elbow

Upward Pitch - 1/4” per foot

First Support Placed as Close to Furnace Connection as Possible

Exhaust Vent

PVC TEE, Reducer,

and 1/2” x 1/2” Hose Barb

Condensate

Drain Line

First Support as Close

to Furnace as Possible

Outlet Exhaust Vent

See Table 2 for PVC Pipe Lengths (Field Supplied)

Wall

Support System on

Vertical Rise

7”

Normal

Snow Level

12” Min.

Straight Neoprene

Combustion Air

Couplings with 2

Hose Clamps

90° Elbow

PVC TEE, Reducer,

Exhaust Vent

and 1/2” x 1/2” Hose Barb

Condensate

Drain Line

See Table 2 for PVC Pipe Lengths

(Field Supplied)

Figure 36. Horizontal and Vertical Venting

Combustion Air

Upward Pitch

1/4” per foot

90°

Elbow

Exhaust Vent

Condensate

Drain Line

Page 48

1 Pipe Upflow

Inlet Air

Option

Exhaust Vent

PVC TEE

and Reducer

Plug

See View -A-

VIEW -A-

Inline Drain

NOTES:

1.) All drain lines must be trapped with J-Trap or field supplied loop.

2.) Drain line traps may be positioned inside or outside the cabinet.

Header

Box

Drain

and Reducer

Drain Line

Attached to

3/4 x 1/2

Hose Barb

PVC TEE

Inlet Air

Exhaust Vent

See View -B-

(This drain not needed

if “X” is less than 6”.)

VIEW -B-

Header

Box Drain

Inline Drain

(Tubing is routed thru

the blower deck and

side of cabinet.)

Option

Plug

See

View -B-

Plug

Inlet Air

Option

See View -A-

2 Pipe Upflow

Exhaust Vent

PVC TEE

and Reducer

PVC TEE

and Reducer

Drain Line

Attached to

3/4 x 1/2

Hose Barb

Figure 37. Upﬂ ow Options

Exhaust Vent

Inlet Air

Option

Plug

See View -B-

Page 49

1 Pipe Horizontal

Option

See View -C-

Exhaust Vent

Inlet Air

Plug

See View -D-

Inline Drain

VIEW -C-

Option

Exhaust Vent

Plug

See View -D-

VIEW -D-

Header Box

Drain

All drain lines must be trapped with J-Trap or field supplied loop.

2 Pipe Horizontal

Option

See View -C-

Exhaust Vent

Plug

Inlet Air

Figure 38. Horizontal Options

Inline

Drain

Inlet Air

See View -D-

Option

Header Box

Drain

Exhaust Vent

Plug

See View -D-

Page 50

1 Pipe Downflow

Option

Plug

VIEW -E-

PVC

Inlet Air

Cap

See View -E-

PVC TEE

and Reducer

Exhaust Vent

Drain Line

Attached to

1/2 x 1/2

Hose Barb

Option

Plug

See

View -F-

Inlet Air

Exhaust

See Table 2 for

2” PVC Pipe Length

(Field Supplied)

Plug

PVC TEE

and Reducer

Drain Line Attached

to 1/2 x 1/2 Hose Barb

VIEW -F-

PVC

Inlet Air

Option

Cap

Plug

Exhaust Vent

See View -G-

VIEW -G-

Header Box

Inline

Drain

NOTES:

1.) All drain lines must be trapped with J-Trap or field supplied loop.

2.) Drain line traps may be positioned inside or outside the cabinet.

2 Pipe Downflow

Option

Plug

PVC

Inlet Air

Cap

See View -E-

PVC TEE

and Reducer

Exhaust Vent

Drain Line

Attached to

1/2 x 1/2

Hose Barb

Option

Plug

See

View -F-

Inline Drain

Header Box

Inlet Air

Exhaust

Inline Drain - This drain

Drain

See Table 2 for

2” PVC Pipe Length

(Field Supplied)

Plug

PVC TEE

and Reducer

Drain Line Attached

to 1/2 x 1/2 Hose Barb

not needed if “X”

is less than 6”.

Option

Exhaust Vent

Header Box

PVC

Inlet Air

Cap

See View -G-

Drain

Plug

Figure 39. Downﬂ ow Options

Page 51

LOCATION OF FURNACE COMPONENTS

AIR

FLOW

ITEM COMPONENT NAME

1. Blower Assembly

2. Blower Door Switch

3. Burner Assembly

4. Finish Flange

5. Flame Roll-Out Switch

6. Flame Sensor

7. Furnace Control Board

8. Gas Manifold

9. Gas Valve

10. Igniter

11. Inducer Assembly

12. Inducer Limit Switch

13. Inline Drain Assembly

14.

15. Motor Control Board

16. Motor Control Box

17. Pressure Switches

18. Transformer

Motor Choke

(C and D cabinets only)

AIR FLOW

Figure 40.

ITEM COMPONENT NAME

1. Blower Assembly

Blower Door Switch

(behind blower panel)

3. Burner Assembly

4. Finish Flanges

5. Flame Roll-Out Switch

6. Flame Sensor

7. Furnace Control Board

8. Gas Manifold

9. Gas Valve

10. Igniter

11. Inducer Assembly

12. Inducer Limit Switch

13. Inline Drain Assembly

14.

Motor Choke (C and D cabinets only)

15. Motor Control Board

16. Pressure Switches

17. Transformer

Upﬂ ow/Horizontal Gas Furnace Components

AIR

FLOW

Figure 41. Downﬂ ow

Gas Furnace Components

Page 52

INSTALLATION/PERFORMANCE CHECK LIST

INSTALLER NAME:

CITY _______________ STATE _____________

INSTALLATION ADDRESS:

CITY _______________ STATE _____________

UNIT MODEL #

UNIT SERIAL # ____________________________

Minimum clearances per Table 1 (page 7)?

Has the owner’s infor mation been reviewed with the home-owner?

YES NO

ELECTRICAL SYSTEM:

Electrical connections tight? YES NO

Line voltage polarity correct? YES NO

Supply Voltage: ______________________ VOLTS

Has the thermostat been calibrated?

Is the thermostat level? YES NO

Is the heat anticipator setting correct?

GAS SYSTEM:

Gas Type: (circle one)

Gas pipe connections leaktested?

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

Is there adequate fresh air supply for combustion and ventilation?

YES NO

Natural

Gas

YES NO

Propane

Has the literature package been left near the furnace?

Installation Altitude: ____________________ (FT.)

YES NO

Deration Percentage: ___________________ (%)

Furnace Input: _______________________ (Btuh)

Supply Air Temperature: ________________ (° F)

Return Air Temperature: _________________(° F)

Temperature Rise: _____________________(° F)

VENTING SYSTEM:

Vent free from restrictions? YES NO

Filter(s) secured in place? YES NO

Filter(s) clean? YES NO

Flue connections tight? YES NO

Is there proper draft? YES NO

O’Fallon, MO

¢7090475¤

7090470

7090470(Replaces 708810A)

Speciﬁ cations and illustrations subject to change

without notice or incurring obligations.

Printed in U.S.A. (05/09)