Payne PG8J, PG8M Installation Instructions Manual

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Page 1

PG8J PG8M

SINGLE ---ST AGE DELUXE

INDUCED ---COMBUSTION

4--- WAY MULTI POIS E FURNACE

Installation Instructions

SAFETY CONSIDERATIONS 2........................

INTRODUCTION 3..................................

CODES AND STANDARDS 4..........................

Step 1 —Safety 4..................................

Step 2 —General Installation 4.......................

Step 3 —Combustion and Ventilation Air 4..............

Step 4 —Duct Systems 5............................

Step 5 —Acoustical Lining and Fibrous Glass Duct 5......

Step 6 —Gas Piping and Gas Pipe Pressure Testing 5......

Step 7 —Electrical Connections 5.....................

Step8—Venting 5................................

LOCATION 6.......................................

General 6........................................

Location Relative to Cooling Equipment 7..............

AIR FOR COMBUSTION AND VENTILATION 7.........

Outdoor Combustion Air Method 8....................

INSTALLATION 11..................................

Bottom Return Air Inlet 11..........................

Side Return Air Inlet 11.............................

Leveling Legs (If Desired) 11........................

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

Suspended Furnace Support 12.......................

Platform Furnace Support 13.........................

Roll--Out Protection 13.............................

Bottom Return Air Inlet 13..........................

Side Return Air Inlet 13.............................

General Requirements 13............................

Ductwork Acoustical Treatment 13....................

Supply Air Connections 13..........................

Return Air Connections 20..........................

115--V Wiring 22..................................

J--Box Relocation 22...............................

Electrical Connection to J--Box 22.....................

Power Cord Install. Furnace J--Box 23.................

BX Cable Install Furn. J--Box 23......................

24--V Wiring 25...................................

Accessories 25....................................

General Venting Requirements 25.....................

Masonry Chimney Requirements 26...................

Appliance Application Requirements 28................

Additional Venting Requirements 29...................

Sidewall Venting 30................................

START--UP, ADJUSTMENT, AND SAFETY CHECK 31.....

Step1—General 31...............................

Step 2 —Start--Up Procedures 31.....................

Step3—Adjustments 34............................

Step 4 —Check Safety Controls 37....................

Step 5 —Checklist 38..............................

SERVICE AND MAINTENANCE PROCEDURES 45.......

Step 1 —Introduction 45............................

Step 2 —Care and Maintenance 47

Step 3 —Sequence of Operation 49....................

Step 4 —Wiring Diagrams 50........................

Step 5 —Troubleshooting 50.........................

....................

ama

ISO 9001:2000

CERTIFIED

REGISTERED

NOTE: Read the entire instruction manual before starting the installation.

Portions of the text and tables are reprinted from NFPA 54/ANSI Z223.1--2006E, with permission of Nation Fire Protection Association, Quincy, MA 02269 and American Gas Association, Washington DC 20001. This reprinted material is not the complete and official position of the NFPA or ANSI on the referenced subject, which is represented only by the standard in its entirely.

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SAFETY CONSIDERATIONS

Improper installation, adjustment, alteration, service, maintenance, or use can cause explosion, fire, electrical shock, or other conditions which may cause death, personal injury, or property damage. Consult a qualified installer, service agency, or your distributor or branch for information or assistance. The qualified installer or agency must use factory-- authorized kits or accessories when modifying this product. Refer to the individual instructions packaged with the kits or accessories when installing.

Follow all safety codes. Wear safety glasses, protective clothing, and work gloves. Use quenching cloth for brazing operations. Have fire extinguisher available. Read these instructions thoroughly and follow all warnings or cautions included in literature and attached to the unit. Consult local building codes and National Electrical Code (NEC) for special requirements.

Recognize safety information. This is the safety--alert symbol When you see this symbol on the unit and in instructions or manuals, be alert to the potential for personal injury. Understand these signal wo rds; DANGER, WARNING, and CAUTION.

PG8J/M

These words are used with the safety--alert symbol. DANGER identifies the most serious hazards which will result in severe personal injury or death. WA R N IN G sig n ifies hazards which could result in personal injury or death. CAUTION is used to identify unsafe practices wh ich may result in minor personal injury or product and property damage. NOTE is used to highlight suggestions which will result in enhanced installation, reliability, or operation.

Installing and servicing heating equipment can be hazardous due to gas and electrical components. Only trained and qualified

personnel should install, repair, or service heating equipment.

Untrained personnel can perform basic maintenance functions such as cleaning and replacing air filters. All other operations must be performed by trained service personnel. When working on heating equipment, observe precautions in literature, on tags, and on labels attached to or shipped with furnace and other safety precautions that may apply.

These instructions cover minimum requirements and conform to existing national standards and safety codes. In some instances, these instructions exceed certain local codes and ordinances, especially those that may not have kept up with changing residential constructions practices. We require these instructions as a minimum for a safe installation.

CAUTION

FURNACE RELIABILITY HAZARD

Improper installation or misapplication of furnace may require excessive servicing or cause premature component failure. Application of this furnace should be indoors with special attention given to vent sizing and material, gas input rate, air temperature rise, unit leveling, and unit sizing.

CAUTION

CUT HAZARD

Failure to follow this caution may result in personal injury. Sheet metal parts may have sharp edges or burrs. Use care and wear appropriate protective clothing, safety glasses and gloves when handling parts and servicing furnaces.

FIRE, EXPLOSION, ELECTRICAL SHOCK, AND CARBON MONOXIDE POISONING HAZARD

Failure to follow this warning could result in personal injury, death, or property damage.

Improper installation, adjustment, alteration, service, maintenance, or use could cause carbon monoxide poisoning, explosion, fire, electrical shock, or other conditions which may cause personal injury or property damage. Consult a qualified service agency, local gas supplier, or your distributor or branch for information or assistance. The qualified service agency must use only factory--authorized and listed kits or accessories when modifying this product.

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

2. Install this furnace only in a location and position as specified in the “Location” section of these instructions.

3. Provide adequate combustion and ventilation air to the furnace space as specified in “Air for Combustion and Ventilation” section.

4. Combustion product must be discharged outdoors. Connect this furnace to an approved vent system only as specified in the “Venting” section of these instructions.

5. Never test for gas leaks with an open flame. Use a commercially available soap solution made specifically for the detection of leaks to check all connections, as specified in the “Gas Piping” section.

6. Always install furnace to operate within the furnace’s intended temperature--rise range with a duct system which has an external static pressure within the allowable range, as specified in the “Start-- Up, Adjustments, and Safety Check” section. See furnace rating plate.

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

8. A gas-- fired furnace for installation in a residential garage must be installed as specified in the warning box in the Location section.

9. The furnace may be used for construction heat provided that the furnace installation and operation complies with the first CAUTION in the LOCATION section of these instructions.

10. These Multipoise Gas-- Fired Furnaces are CSA (formerly A.G.A. and C.G.A.) design--certified for use with natural and propane gases (see furnace rating plate) and for installation in alcoves, attics, basements, closets, utility rooms, crawlspaces, and garages. The furnace is factory--shipped for use with natural gas. A CSA listed gas conversion kit is required to convert furnace for use with propane gas.

11. See Fig. 2 for required clearances to combustible construction.

12. Maintain a 1--in. clearance from combustible materials to supply air ductwork for a distance of 36 inches horizontally from the furnace. See NFPA 90B or local code for further requirements.

WARNING

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26-1/8"

(FLUE COLLAR)

5-15/16"

7/8" DIA

ACCESSORY

NOTES:

1. Two additional 7/8-in. diameter holes are located in the top plate.

2. Minimum return-air openings at furnace, based on metal duct. If flex duct is used, see flex duct manufacturer’s recommendations for equivalent diameters. a. For 800 CFM-16-in. round or 14 1/2 x 12-in. rectangle. b. For 1200 CFM-20-in. round or 14 1/2 x 19 1/2-in. rectangle. c. For 1600 CFM-22-in. round or 14 1/2 x 22-in. rectangle. d. For airflow requirements above 1800 CFM, see Air Delivery table in Product Data literature for specific use of single side inlets. The use of both side inlets a combination of 1 side and the bottom, or the bottom only will ensure adequate return air openings for airflow requirements above 1800 CFM.

1/2" DIA THERMOSTAT

33-5/16"

7/8" DIA. ACCESSORY

11/16"

28-7/8"

25-1/4"

22-9/16"

JUNCTION BOX LOCATION

WIRE ENTRY

3-15/16"

LEFT HAND GAS

ENTRY

21-5/8"

BOTTOM INLET

24"

CASING

1-11/16"

24-7/8"

5-1/2"

4-13/16"

8-9/16"

ALTERNATE

VENT OUTLET

3-3/4"

2-7/16" 1-5/16"

1-1/8"

13/16"

JUNCTION BOX

LOCATIONS (TYP)

5 PLACES (TYP)

5-1/2"

11/16"

AIRFLOW

19"

OUTLET

1/2" DIA. K.O.THERMOSTAT WIRE ENTRY

1-3/4" DIA.RIGHT HAND GAS ENTRY

7/8" DIA. K.O. WIRE ENTRY

7/8" DIA. ACCESSORY

1-1/2"

22-1/16"

SIDE INLET

13/16"

11/16"

14-7/8"

1-1/4"

7-3/4"

Fig. 1 --- Dimensional Drawing

9-5/8"

11-1/2"

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A04037

13. These furnaces SHALL NOT be installed directly on carpeting, tile, or any other combustible material other than wood flooring. In downflow installations, factory accessory floor base MUST be used when installed on combustible materials and wood flooring. Special base is not required when this furnace is installed on manufacturer’s Coil Assembly Part No. CAPV, CAPMP, or CNPVP, or when Coil Box Part No. KCAKC is used. See Fig. 2 for clearance to combustible construction information.

INTRODUCTION

Series 120/C 4--way multipoise Category I fan-- assisted furnace is CSA design--certified. A Category I fan--assisted furnace is an appliance equipped with an integral mechanical means to either draw or force products of combustion through the combustion chamber and/or heat exchanger. The furnace is factory--shipped for use with natural gas. This furnace is not approved for installation in mobile homes, recreational vehicles, or outdoors.

This furnace is designed for minimum continuous return-- air temperature of 60_F db or intermittent operation down to 55_F db such as when used with a night setback thermostat. Return-- air temperature must not exceed 85_F db. Failure to follow these

return--air temperature limits may affect reliability of heat exchangers, motors, and controls. (See Fig. 2.)

A02055

Fig. 2 --- Return Air Temperature

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PG8J/M

INSTALLATION

MINIMUM INCHES CLEARANCE TO COMBUSTIBLE CONSTRUCTION

This forced air furnace is equipped for use with

natural gas at altitudes 0-10,000 ft (0-3,050m).

An accessory kit, supplied by the manufacturer, shall be used to convert to propane gas use or may be required for some natural gas applications.

This furnace is for indoor installation in a building constructed on site.

This furnace may be installed on combustible flooring in alcove or closet at minimum clearance as indicated by the diagram from combusitble material.

This furnace may be used with a Type B-1 Vent and may be vented in common with other gas fired appliances.

pour utilisation avec gaz naturel et altitudes comprises entre 0-3,050m (0-10,000 pi).

Utiliser une trousse de conversion, fournie par le fabricant, pour passer au gaz propane ou pour certaines installations au gaz naturel.

Cette fournaise est prévue pour être installée dans un bâtiment construit sur place.

Cette fournaise peut être installée sur un plancher combustible dans une alcôve ou dans un garde-robe en respectant le minimum d'espace libre des matériaux combustibles, tel qu

indiqué sur le diagramme.

Cette fournaise peut être utilisée avec un conduit d au conduit ommun d 'autres appareils à gaz.

DISTANCE MINIMALE EN POUCES AUX CONSTRUCTIONS COMBUSTIBLES

This furnace is approved for UPFLOW, DOWNFLOW, and HORIZONTAL installations.

Cette fournaise est approuvée pour l 'installation HORIZONTALE et la circulation d 'air VERS LE HAUT et VERS LE BAS.

Clearance arrows do not change with furnace orientation.

TOP / PLENUM

Cette fournaise à air pulsé est équipée

BOTTOM

DESSOUS

†

Vent Clearance to combustibles:

For Single Wall vents 6 inches (6 po). For Type B-1 vent type 1 inch (1 po).

évacuation de Type B-1 ou connectée

Dégagement de l´évent avec combustibles:

Pour conduit d´évacuation à paroi simple 6 po (6 inches). Pour conduit d

évacuation de Type B-1 1 po (1 inch).

Les fléches de dégagement

l 'orientation de la fournaise.

DESSUS / CHAMBRED' AIR

MINIMUM INCHES CLEARANCE TO COMBUSTIBLE CONSTRUCTION

DOWNFLOW POSITIONS:

Installation on non-combusibible floors only.

†

For Installation on combustible flooring only when installed on special base, Part No. KGASB0201ALL,

Coil Assembly, Part No. CD5 or CK5, or Coil Casing, Part No. KCAKC.

18 inches front clearance required for alcove.

Indicates supply or return sides when furnace is in the horizontal position. Line contact only permissible

between lines formed by intersections of the Top and two Sides of the furnace jacket, and building joists, studs or framing.

DÉGAGEMENT MINIMUM EN POUCES AVEC ÉLÉMENTS

POUR LA POSITION COURANT DESCENDANT:

Pour l´installation sur plancher non combustible seulement.

†

Pour l

installation sur un plancher combustible seulement quand on utilise la base spéciale, pièce nº KGASB0201ALL, l nº KCAKC.

Dans une alcôve, on doit maintenir un dégagement à l

La poistion indiquée concerne le côté d

position horizontale.

Le contact n

deux côtés de la cherrise de la fournaise et les solives, montant sous cadre de charpente.

DE CONSTRUCTION COMBUSTIBLES

ensemble serpentin, pièce nº CD5 ou CK5, ou le carter de serpentin, pièce

entrée ou de retour quand la fournaise est dans la

est permis qu´entre les lignes formées par les intersections du dessus et des

avant de 18 po (450mm).

327590-101 REV. C

ne change pas avec

MIN

Clearance in inches Dégagement (po).

24"

MIN

For accessory installation details, refer to the applicable instruction literature.

NOTE: Remove all shipping brackets and materials before operating the furnace.

CODES AND STANDARDS

Follow all national and local codes and standards in addition to these instructions. The installation must comply with

regulations of the serving gas supplier, local building, heating, plumbing, and other codes. In absence of local codes, the installation must comply with the national codes listed below and all authorities having jurisdiction. In the United States and Canada, follow all codes and standards for the following:

Step 1 —Safety

US: National Fuel Gas Code (NFGC) NFPA

54--2006/ANSI Z223.1--2006 and the Installation Standards, Warm Air Heating and Air Conditioning Systems ANSI/NFPA 90B

Fig. 3 --- Clearances to Combustibles

S CANADA: CSA B149.1 --00 National Standard of

Canada Natural Gas and Propane Installation Codes (NSCNGPIC)

Step 2 —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; (www.NFPA.org) or for only the NFGC, contact the American Gas Association, 400 N. Capitol Street, N.W., Washington, DC 20001 (www.AGA.org).

S CANADA: NSCNGPIC. For a copy, contact Standard

Sales, CSA International, 178 Rexdale Boulevard, Etobicoke (Toronto), Ontario, M9W 1R3 Canada

Step 3 —Combustion and Ventilation Air

US: Section 9.3 of the NFGC, Air for Combustion and

Ventilation

A04123

Page 5

S CANADA: Part 7 of NSCNGPIC, Venting Sy stems

and Air Supply for Appliances

Step 4 —Duct Systems

US and CANADA: Air Conditioning Contractors As-

sociation (ACCA) Manual D, Sheet Metal and Air Conditioning Contractors National Association (SMACNA), or American Society of Heating, Refrigeration, and Air Conditioning Engineers (ASHRAE) 2001 Fundamentals Handbook Chapter 34 or 2000 HVAC Systems and Equipment Handbook Chapters 9 and 16.

Step 5 —Acoustical Lining and Fibrous Glass Duct

US and CANADA: current edition of SMACNA and

NFPA 90B as tested by UL Standard 181 for Class I Rigid Air Ducts

Step 6 —Gas Piping and Gas Pipe Pressure Testi ng

US: NFGC; chapters 5, 6, 7, and 12 and National

Plumbing Codes

S CANADA: NSCNGPIC Parts 3, 4, 5, and 8, and Ap-

pendices A, B, E, and H.

Step 7 —Electrical Connections

US: National Electrical Code (NEC) ANSI/NFPA

70--2006

S CANADA: Canadian Electrical Code CSA C22.1

Step 8 —Ven ti ng

US: NFGC; chapters 10 and 13

S S CANADA: NSCNGPIC Part 12 and Appendix C

ELECTROSTATIC DISCHARGE (ESD)

PRECAUTIONS PROCEDURE

CAUTION

FURNACE RELIABILITY HAZARD

Failure to follow this caution may result in furnace component damage.

Electrostatic discharge can affect electronic components. Follow the Electrostatic Discharge Precautions Procedure listed below during furnace installation and servicing to protect the furnace electronic control. Precautions will prevent electrostatic discharges from personnel and hand tools which are held during the procedure. These precautions will help to avoid exposing the control to electrostatic discharge by putting the furnace, the control, and the person at the same electrostatic potential.

1. Disconnect all power to the furnace. Multiple disconnects may b e required. DO NOT TOUCH THE CONTROL OR ANY WIRE CONNECTED TO THE CONTROL PRIOR TO DISCHARGING YOUR BODY’S ELECTROSTATIC CHARGE TO GROUND.

2. Firmly touch the clean, unpainted, metal surface of the furnace chassis which is close to the control. Tools held in a person’s hand during grounding will be satisfactorily discharged.

3. After touching the chassis, you may proceed to service the control or connecting wires as long as you do nothing to recharge your body with static electricity (for example; DO NOT move or shuffle your feet, do not touch ungrounded objects, etc.).

4. If you touch ungrounded objects (and recharge your body with static electricity), firmly touch a clean, unpainted metal surface of the furnace again before touching control or wires.

PG8J/M

THE BLOWER IS LOCATED

TO THE RIGHT OF THE

BURNER SECTION, AND

AIR CONDITIONED AIR IS

DISCHARGED TO THE LEFT.

THE BLOWER IS

LOCATED ABOVE THE

BURNER SECTION, AND

CONDITIONED AIR IS

DISCHARGED DOWNWARD

THE BLOWER IS

LOCATED BELOW THE

BURNER SECTION, AND

CONDITIONED AIR IS

DISCHARGED UPWARD.

THE BLOWER IS

LOCATED TO THE LEFT

OF THE BURNER SECTION,

AND CONDITIONED AIR IS

DISCHARGED TO THE RIGHT.

A02097

Fig. 4 --- Multipoise Orientations

Page 6

TABLE 1—DIMENSIONS (IN.)

FURNACE SIZE A

045 --- 08/024045 14--- 3/16 12--- 9/16 12--- 11/16 9--- 5/16 4 104 045 --- 12/036045 14--- 3/16 12--- 9/16 12--- 11/16 9--- 5/16 4 107 070 --- 08/024070 14--- 3/16 12--- 9/16 12--- 11/16 9--- 5/16 4 111 070 --- 12/036070 14--- 3/16 12--- 9/16 12--- 11/16 9--- 5/16 4 115 070 --- 16/048070 17- -- 1/2 15--- 7/8 16 11--- 9/16 4 126 090 --- 14/042090 17- -- 1/2 15--- 7/8 16 11--- 9/16 4 127 090 --- 16/048090 21 19---3/8 19 --- 1/2 13---5/16 4 140 090 --- 20/060090 21 19---3/8 19 --- 1/2 13---5/16 4 146 110 --- 12/036110 17- -- 1/2 15--- 7/8 16 11--- 9/16 4 135 110 --- 16/048110 21 19---3/8 19 --- 1/2 13---5/16 4 146 110 --- 22/066110 21 19---3/8 19 --- 1/2 13---5/16 4 152 135 --- 16/048135 21 19---3/8 19 --- 1/2 13---5/16 4 149 135 --- 22/066135 24- -- 1/2 22--- 7/8 23 15--- 1/16 4 163 155 --- 20/060155 24- -- 1/2 22--- 7/8 23 15--- 1/16 4 170

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* 5 --- in . o r 6 --- i n . v e n t c o n n e c t or m a y b e r eq u i r e d i n s o m e c a s es .

5. Use this procedure for installed and uninstalled (ungrounded) furnaces.

6. Before removing a new control from its container, discharge your body’s electrostatic charge to ground to protect the control from damage. If the control is to be installed in a furnace, follow items 1 through 4 before bringing the control or yourself in contact with the furnace. Put all used and new controls into containers before touching ungrounded objects.

7. An ESD service kit (available from commercial sources) mayalsobeusedtopreventESDdamage.

CABINET WIDTHDSUPPLY --- AIR

WIDTH (IN.)

LOCATION

GENERAL

This multipoise furnace is shipped in packaged configuration. Some assembly and modifications are required when used in any of the four applications shown in Fig. 4.

This furnace must:

S be installed so the electrical components are protected

from water.

S not be installed directly on any combustible material

other than wood flooring (refer to SAFETY CONSIDERATIONS).

S be located as close to the chimney or vent and attached

to an air distribution system. Refer to Air Ducts section.

S be provided ample space for servicing and cleaning.

Always comply with minimum fire protection clearances shown on the furnace clearance to combustible label.

S The following types of furnace installations may re-

quire OUTDOOR AIR for combustion due to chemical exposures:

S Commercial buildings S Buildings with indoor pools S Laundry rooms S Hobby or craft rooms, and

RETURN--- AIR

WIDTH (IN.)

CARBON MONOXIDE POISONING AND UNIT DAMAGE HAZARD

Failure to follow this warning could result in personal injury or death, and unit component damage.

Corrosive or contaminated air may cause failure of parts containing flue gas, which could leak into the living space. Air for combustion must not be contaminated by halogen compounds, which include fluoride, chloride, bromide, and iodide. These elements can corrode heat exchangers and shorten furnace life. Air contaminants are found in aerosol sprays, detergents, bleaches, cleaning solvents, salts, air fresheners, and other household products. Do not install furnace in a corrosive or contaminated atmosphere. Make sure all combustion and circulating air requirements are met, in addition to all local codes and ordinances.

All fuel--burning equipment must be supplied with air for fuel combustion. Sufficient air must be provided to avoid negative pressure in the equipment room or space. A positive seal must be made between the furnace cabinet and the return--air duct to prevent pulling air from the burner area and from draft safeguard opening.

C.L. TOP AND

BOTTOM FLUE

COLLAR (IN.)

WARNING

FLUE

COLLAR*

(IN.)

S Chlorine based swimming pool chemicals S Water softening chemicals S De--icing salts or chemicals S Carbon tetrachloride S Halogen type refrigerants S Cleaning solvents (such as perchloroethylene) S Printing inks, paint removers, varnishes, etc. S Hydrochloric acid S Cements and glues S Antistatic fabric softeners for clothes dryers S Masonry acid washing materials

S Chemical storage areas S Permanent wave solutions S Chlorinated waxes and cleaners

If air is exposed to the following substances, it should not be used for combustion air, and outdoor air may be required for combustion:

SHIP WT (LB)

Page 7

FIRE AND EXPLOSION HAZARD

Failure to follow this warning could result in personal injury, death, and/or property damage. or explosion.

When the furnace is installed in a residential garage, the burners and ignition sources must be located at least 18 inches above the floor. The furnace must be located or protected to avoid damage by vehicles. When the furnace is installed in a public garage, airplane hangar, or other building having a hazardous atmosphere, the furnace must be installed in accordance with the NFGC or NSCNGPIC. (See Fig. 5.)

PERSONAL INJURY AND/OR PROPERTY DAMAGE HAZARD

Failure to follow this caution may result in furnace component damage.

This gas furnace may be used for heating buildings under construction provided that:

--The furnace is permanently installed with all electrical wiring, piping, venting and ducting installed according to these installation instructions. A return air duct is provided, sealed to the furnace casing, and terminated outside the space containing the furnace. This prevents a negative pressure condition as created by the circulating air blower, causing a flame rollout and/or drawing combustion products into the structure.

--The furnace is controlled by a thermostat. It may not be hot wired to provide heat continuously to the structure without thermostatic control.

--Clean outside air is provided for combustion. This is to minimize the corrosive effects of adhesives, sealers and other construction materials. It also prevents the entrainment of drywall dust into combustion air, which can cause fouling and plugging of furnace components.

--The temperature of the return air to the furnace is maintained between 55_F(13_C) and 80_F(27_C), with no evening setback or shutdown. The use of the furnace while the structure is under construction is deemed to be intermittent operation per our installation instructions.

--The air temperature rise is within the rated rise range on the furnace rating plate, and the gas input rate has been set to the nameplate value.

--The filters used to clean the circulating air during the construction process must be either changed or thoroughly cleaned prior to occupancy.

--The furnace, ductwork and filters are cleaned as necessary to remove drywall dust and construction debris from all HVAC system components after construction is completed.

--Verify proper furnace operating conditions including ignition, gas input rate, air temperature rise, and venting according to these installation instructions.

WARNING

CAUTION

18-IN. MINIMUM

TO BURNERS

A93044

Fig. 5 --- Installation in a Garage

FIRE HAZARD

Failure to follow this warning could result in personal injury, death and/or property damage.

Do not install the furnace on its back or hang furnace with control compartment facing downward. Safety control operation will be adversely affected. Never connect return--air ducts to the back of the furnace. (See Fig. 6.)

Fig. 6 --- Prohibit Installation on Back

LOCATION RELATIVE TO COOLING EQUIPMENT

The cooling coil must be installed parallel with, or on the downstream side of the unit to avoid condensation in the heat exchangers. When installed parallel with the furnace, dampers or other flow control must prevent chilled air from entering the furnace. If the dampers are manually operated, they must be equipped with means to prevent operation of either unit unless the damper is in the full--heat or full--cool position.

WARNING

A02054

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Page 8

AIR FOR COMBUSTION AND

VENTILATION

Provisions for adequate combustion, ventilation, and dilution air must be provided in accordance with:

S U.S. installations: Section 9.3 of the NFGC, Air for

Combustion and Ventilation, and applicable provisions of the local building codes.

S Canadian installations: Part 7 of the NSCNGPIC, V ent-

ing Systems and Air Supply for Appliances, and all authorities having jurisdiction.

CAUTION

FURNACE CORROSION HAZARD

Failure to follow this caution may result in furnace damage. Air for combustion must not be contaminated by halogen compounds, which include fluoride, chloride, bromide, and iodide. These elements can corrode heat exchangers and

PG8J/M

shorten furnace life. Air contaminants are found in aerosol sprays, detergents, bleaches, cleaning solvents, salts, air fresheners, and other household products.

CARBON MONOXIDE POISONING HAZARD

Failure to follow this warning could result in personal injury or death.

The operation of exhaust fans, kitchen ventilation fans, clothes dryers, attic exhaust fans or fireplaces could create a NEGATIVE PRESSURE CONDITION at the furnace. Make--up air MUST be provided for the ventilation devices, in addition to that required by the furnace. Refer to Carbon Monoxide Poisoning Hazard warning in venting section of these instructions to determine if an adequate amount of make-- up air is available.

The requirements for combustion and ventilation air depend upon whether or not the furnace is located in a space having a volume of at least 50 cu/ft. per 1,000 Btuh input rating for all gas appliances installed in the space.

S Spaces having less than 50 cu/ft. per 1,000 Btuh re-

quire the OUTDOOR COMBUSTION AIR METHOD.

S Spaces having at least 50 cu/ft. per 1,000 Btuh may use

the INDOOR COMBUSTION AIR, STANDARD or KNOWN AIR INFILTRATION METHOD.

Outdoor Combustion Air Method

1. Provide the space with sufficient air for proper combustion, ventilation, and dilution of flue gases using permanent horizontal or vertical duct(s) or opening(s) directly communicating with the outdoors or spaces that freely communicate with the outdoors.

2. Fig. 7 illustrates how to provide TWO OUTDOOR OPENINGS, one inlet and one outlet combustion and ventilation air opening, to the outdoors.

a. One opening MUST commence within 12 in. (300

mm) of the ceiling and the second opening MUST commence within 12 in. (300 mm) of the floor.

b. Size openings and ducts per Fig. 7 and Table 2.

c. TWO HORIZONTAL DUCTS require 1 sq./in. of free

area per 2,000 Btuh (1,100 mm2/kW) of combined input for all gas appliances in the space per Fig. 7 and Tab l e 2.

WARNING

d. TWO OPENINGS OR VERTICAL DUCTS require 1

sq./in. of free area per 4,000 Btuh (550 mm2/kW) for combined input of all gas appliances in the space per Fig. 7 and Table 2.

3. ONE OUTDOOR OPENING requires: a. 1 square inch of free area per 3,000 Btuh (734

mm2/kW) for combined input of all gas appliances in the space per Table 2 and

b. Not less than the sum of the areas of all vent connect-

ors in the space.

The opening shall commence within 12 in. (300 mm) of the ceiling. Appliances in the space shall have clearances of at least 1 in. (25 mm) from the sides and back and 6 in. (150 mm) from the front. The opening shall directly communicate with the outdoors or shall communicate through a vertical or horizontal duct to the outdoors or spaces (crawl or attic) that freely communicate with the outdoors.

Indoor Combustion Air NFPA & AGA Standard and Known--Air--Infiltration Rate Methods

Indoor air is permitted for combustion, ventilation, and dilution, if the Standard or Known--Air--Infiltration Method is used.

CARBON MONOXIDE POISONING HAZARD

Failure to follow this warning could result in death and/or personal injury.

Many homes require air to be supplied from outdoors for furnace combustion, ventilation, and dilution of flue gases. The furnace combustion air supply must be provided in accordance with this instruction manual.

The Standard Method:

1. The space has no less volume than 50 cu/ft. per 1,000

Btuh of the maximum input ratings for all gas appliances installed in the space and

2. The air infiltration rate is not known to be less than 0.40

air changes per hour (ACH).

The Known Air Infiltration Rate Method shall be used, if the infiltration rate is known to be:

1. Less than 0.40 ACH and

2. Equal to or greater than 0.10 ACH

Infiltration rates greater than 0.60 ACH shall not be used. The minimum required volume of the space varies with the number of ACH and shall be determined per Table 3 or Equations 1 and 2. Determine the minimum required volume for each appliance in the space and add the volumes together to get the total minimum required volume for the space.

WARNING

Page 9

TABLE 2—MINIMUM FREE AREA REQUIRED FOR EACH COMBUSTION AIR OPENING OR DUCT TO OUTDOORS

TWO HORIZONTAL DUCTS

FURNACE

INPUT

(BTUH)

44,000 22 6 14.7 5 11 4 66,000 33 7 22 6 16.5 5

88,000 44 8 29.3 7 22 6 110,000 55 9 36.7 7 27.5 6 132,000 66 10 44 8 33 7 154,000 77 10 51.3 9 38.5 8

(1 SQ. IN./2,000 BTUH ) (1,100 SQ. MM/KW)

Free Area of Open -

ing a nd Duct

(Sq. In.)

Round Duct

(In. Dia)

SINGLE DUCT OR OPENING

(1 SQ. IN./3,000 BTUH ) (734 SQ. MM/KW)

Free Area of

Opening and Duct

(Sq. In.)

Round Duct

(In. Dia)

TWO OPENINGS OR VERTICAL DUCTS

(1 SQ. IN./4,000 BTUH ) (550 SQ. MM/KW)

Free Area of Open -

ing a nd Duct

(Sq. In.)

Round Duct

(In. Dia)

EXAMPLES: Determining Free Area

FURNACE WATER HEATER TOTAL INPUT

110,000 + 30,000 = (140,000 divided by 4,000) = 35.0 Sq. In. for each two Vertical Ducts or Openings

66,000 + 40,000 = (106,000 divided by 3,000) = 35.3 Sq. In. for a Single Duct or Opening 88,000

+ 30,000 = (118,000 divided by 2,000) = 59.0 Sq. In. for each of two Horizontal Ducts

TABLE 3—MINIMUM SPACE VOLUMES FOR 100% COMBUSTION, VENTILATION, AND DILUTION FROM INDOORS

OTHER THAN FAN---ASSISTED TO-

ACH

0.60 1,050 1,400 1,750 1,100 1,650 2,200 2,750 3,300 3,850

0.50 1,260 1,680 2,100 1,320 1,980 2,640 3,300 3,960 4,620

0.40 1,575 2,100 2,625 1,650 2,475 3,300 4,125 4,950 5,775

0.30 2,100 2,800 3,500 2,200 3,300 4,400 5,500 6,600 7,700

0.20 3,150 4,200 5,250 3,300 4,950 6,600 8,250 9,900 11,550

0.10 6,300 8,400 10,500 6,600 9,900 13,200 16,500 19,800 23,100

0.00 NP NP NP NP NP NP NP NP NP

(1,000’S BTUH GAS INPUT RATE)

30 40 50 44 66 88 110 132 154

TAL

SpaceVolume(ft.3)

FAN---ASSISTED TOTAL

(1000’S BTUH GAS INPUT RATE)

PG8J/M

Page 10

DUCTS

OUTDOORS

1 SQ IN. PER 4000 BTUH*

CIRCULATING AIR

DUCTS

VENT THROUGH ROOF

12″ MAX

1 SQ IN. PER 2000 BTUH*

DUCTS

OUTDOORS

PG8J/M

1 SQ IN. PER 2000 BTUH*

12″ MAX

CIRCULATING AIR DUCTS

Minimum dimensions of 3 in.

Use any of the following

NOTE:

combinations of openings: A & B C & D D & E F & G

AIR DUCTS

CIRCULATING

OPENINGS SHALL BE

OF COMBUSTION AIR

CLEARANCE IN FRONT

VENT THROUGH ROOF

AT LEAST 3 IN.

OUTDOORS

DUCT

12″ MAX

1 SQ IN. PER 4000 BTUH*

Fig. 7 --- Air for Combustion, Ventilation, and Dilution for

Outdoors

12″ MAX

1 SQ IN.

PER

4000

BTUH*

OUTDOORS

1 SQ IN.

PER 4000

BTUH*

12″ MAX

A03174

12" MAX

1 SQ IN. PER 1000 BTUH* IN DOOR OR WALL

INTERIOR

HEATED

SPACE

CIRCULATING AIR DUCTS

* Minimum opening size is 100 sq in. with minimum dimensions of 3 in.

†

Minimum of 3 in. . when type-B1 vent is used.

UNCONFINED SPACE

6" MIN (FRONT)

1 SQ IN. PER 1000 BTUH* IN DOOR

OPENINGS SHALL BE AT LEAST 3 IN.

OR WALL

CLEARANCE IN FRONT OF COMBUSTION AIR

†

12" MAX

A03175

Fig. 8 --- Air for Combustion, Ventilation, and Dilution From

Indoors

Table 3--Minimum Space Volumes were determined by using

the following equations from the National Fuel Gas Code ANSI Z223.1--2006/NFPA 54-- 2006,8.3.2.2:

1. For other than fan--assisted appliances, such as a draft hood--equipped water heater:

Volume

Other

21ft ACH

other

1000 Btu/hr

A04002

2. For fan--assisted appliances such as this furnace:

Volume

Fan

15ft ACH

fan

1000 Btu/hr

A04003

If:

other = combined input of all other than fan--assisted

appliances in Btuh/hr

fan = combined input of all fan--assisted appliances in Btuh/hr ACH = air changes per hour (ACH shall not exceed 0.60.) The following requirements apply to the Standard Method and to the Known Air Infiltration Rate Method.

1. Adjoining rooms can be considered part of a space if:

a. There are no closeable doors between rooms.

b. Combining spaces on same floor level. Each opening

shall have free area of at least 1 in.2/1,000 Btuh (2,000

/kW) of the total input rating of all gas appliances

mm in the space, but not less than 100 in.

(0.06 m2). One opening shall commence within 12 in. (300 mm) of the ceiling and the second opening shall commence within 12 in. (300 mm) of the floor. The minimum dimension of air openings shall be at least 3 in. (80 mm).(SeeFig.8.)

c. Combining space on different floor levels. The

volumes of spaces on different floor levels shall be considered as communicating spaces if connected by one or more permanent openings in doors or floors having free area of at least 2 in.

/kW) of total input rating of all gas appliances.

/1,000 Btuh (4,400

2. An attic or crawlspace may be considered a space that freely communicates with the outdoors provided there are adequate permanent ventilation openings directly to outdoors having free area of at least 1--in.

/4,000 Btuh of total

input rating for all gas appliances in the space.

3. In spaces that use the Indoor Combustion Air Method, infiltration should be adequate to provide air for combustion, permanent ventilation and dilution of flue gases. However, in buildings with unusually tight construction, additional air MUST be provided using the methods describedintheOutdoor Combustion Air Method section.

Page 11

Unusually tight construction is defined as Construction with:

a. Walls and ceilings exposed to the outdoors have a con-

tinuous, sealed vapor barrier. Openings are gasketed or sealed and

b. Doors and openable windows are weatherstripped and

c. Other openings are caulked or sealed. These include

joints around window and door frames, between sole plates and floors, between wall--ceiling joints, between wall panels, at penetrations for plumbing, electrical and gas lines, etc.

Combination o f Indoor and Outdoor Air

1. Indoor openings shall comply with the Indoor Combus- tion Air Method below and,

2. Outdoor openings shall be located as required in the Out- door Combustion Air Method mentioned previously and,

3. Outdoor openings shall be sized as follows:

a. Calculate the Ratio of all Indoor Space volume divided

by required volume for Indoor Combustion Air Method below.

b. Outdoor opening size reduction Factor is 1 minus the

Ratio in a. above.

c. Minimum size of Outdoor openings shall be the size

required in Outdoor Combustion Air Method above multiplied by reduction Factor in b. above. The minimum dimension of air openings shall be not less than 3in.(80mm).

INSTALLATION

UPFLOW INSTALLATION

Bottom Return Air Inlet

These furnaces are shipped with bottom closure panel installed in bottom return--air opening. Remove and discard this panel when bottom return air is used. To remove bottom closure panel, perform the following:

1. Tilt or raise furnace and remove 2 screws holding bottom filler panel. (See Fig. 9.)

A02098

Fig. 9 --- Removing Bottom Closure Panel

2. Rotate bottom filler panel downward to release holding tabs.

3. Remove bottom closure panel.

4. Reinstall bottom filler panel and screws.

Side Return Air Inlet

These furnaces are shipped with bottom closure panel installed in bottom return--air opening. This panel MUST be in place when only side return air is used.

NOTE: Side return--air openings can be used in UPFLOW and most HORIZONTAL configurations. Do not use side return--air openings in DOWNFLOW configuration.

In upflow position with side return inlet(s), leveling legs may be used. (See Fig. 10.) Install field--supplied, 5/16 X 1--1/2 in. (max) corrosion -- resistant machine bolts, washers and nuts.

NOTE: Bottom closure must be used when leveling legs are used. It may be necessary to remove and reinstall bottom closure panel to install leveling legs. To remove bottom closure panel, see Item 1. in Bottom Return Air Inlet section.

16″

1 3 4″

4″

16″

4″

1 3 4″

A89014

Fig. 10 --- Leveling Legs

Leveling Legs (If Desired)

To install leveling legs:

1. Position furnace on its back. Locate and drill a hole in each bottom corner of furnace. (See Fig. 10.)

2. For each leg, install nut on bolt and then install bolt and nut in hole. (Install flat washer if desired.)

3. Install another nut on other side of furnace base. (Install flat washer if desired.)

4. Adjust outside nut to provide desired height, and tighten inside nut to secure arrangement.

5. Reinstall bottom closure panel if removed.

DOWNFLOW INSTALLA

TION

NOTE: For downflow applications, this furnace is approved for

use on combustible flooring when any one of the following 3 accessories are used:

S Special Base, KGASB S Cased Coil Assembly Part No. CAPVP, CAPMP, or

CNPVP

S Coil Box P art No . KCAKC

1. Determine application being installed from Table 3.

2. Construct hole in floor per Table 3 and Fig. 11.

3. Construct plenum to dimensions specified in Table 3 and Fig. 11.

4. If downflow subbase, KGASB is used, install as shown in Fig. 12. If Coil Assembly Part No. CAPVP, CAPMP, or CNPVP o r Coil Box Part No. KCAKC is used, install as shown in Fig. 13.

PG8J/M

Page 12

FURNACE

CD5 OR CK5

COIL ASSEMBLY

OR KCAKC

COIL BOX

PLENUM

OPENING

FLOOR

PG8J/M

Fig. 11 --- Floor and Plenum Opening Dimensions

NOTE: It is recommended that the perforated supply--air duct

flanges be completely folded over or removed from furnace when installing the furnace on a factory--supplied cased coil or coil box. To remove the supply--air duct flange, use wide duct pliers or hand seamers to bend flange back and forth until it breaks off. Be careful of sharp edges. (See Fig. 14.)

FURNACE

(OR COIL CASING

WHEN USED)

COMBUSTIBLE

FLOORING

A96283

COMBUSTIBLE

FLOORING

SHEET METAL

PLENUM

FLOOR

OPENING

A04140

Fig. 13 --- Furnace, Plenum, and Coil Assembly or Coil Box

Installed on a Combustible Floor

Bottom Return Air Inlet

1. Tilt or raise furnace and remove 2 screws holding bottom filler panel. (See Fig. 9.)

2. Rotate bottom filler panel downward to release holding tabs.

3. Remove bottom closure panel.

4. Reinstall bottom filler panel and screws.

HORIZONTAL INSTALLA

WARNING

TION

DOWNFLOW

SUBBASE

SHEET METAL

PLENUM

FLOOR

OPENING

Fig. 12 --- Furnace, Plenum, and Subbase Installed on a

Combustible Floor

A96285

FIRE, EXPLOSION, AND CARBON MONOXIDE POISONING HAZARD

Failure to follow this warning could result in personal injury, death, or property damage.

The furnace can be installed horizontally in an attic or crawl space on either the left--hand (LH) or right--hand (RH) side. The furnace can be hung from floor joists, rafters or trusses or installed on a non--combustible platform, blocks, bricks or pad.

Suspended Furnace Support

The furnace may be supported under each end with threaded rod, angle iron or metal plumber’s strap as shown. (See Fig. 15 and

16.) Secure angle iron to bottom of furnace as shown. Heavy--gauge sheet metal straps (plumber’s straps) may be used to suspend the furnace from each bottom corner. To prevent screws from pulling out, use 2 #8 x .--in. screws into the side and 2 #8 x .--in. screws in the bottom of the furnace casing for each strap. (See Fig. 15 and 16.)

Page 13

If the screws are attached to ONLY the furnace sides and not the bottom, the straps must be vertical against the furnace sides and not pull away from the furnace sides, so that the strap attachment screws are not in tension (are loaded in shear) for reliable support.

Platform Furnace Support

Construct working platform at location where all required furnace clearances are met. (See Fig. 2 and 17.) For furnaces with 1--in. clearance requirement on side, set furnace on noncombustible blocks, bricks or angle iron. For crawl space installations, if the furnace is not suspended from the floor joists, the ground underneath furnace must be level and the furnace set on blocks or bricks.

Roll--Out Protection

Provide a minimum 17--3/4 in. X 22 in. piece of sheet metal for flame roll--out protection in front of burner area for furnaces closer than 12 inches above the combustible deck or suspended furnaces closer than 12 inches to joists. The sheet metal MUST extend underneath the furnace casing by 1 in. with the door removed.

The bottom closure panel on furnaces of widths 17--1/2 in. and larger may be used for flame roll--out protection when bottom of furnace is used for return air connection. See Fig. 17 for proper orientation of roll--out shield.

Bottom Return Air Inlet

1. Tilt or raise furnace and remove 2 screws holding bottom filler panel. (See Fig. 9.)

2. Rotate bottom filler panel downward to release holding tabs.

3. Remove bottom closure panel.

4. Reinstall bottom filler panel and screws.

Side Return Air Inlet

These furnaces are shipped with bottom closure panel installed in bottom return--air opening. This panel MUST be in place when side return air inlet(s) is used without a bottom return air inlet.

Not all horizontal furnaces are approved for side return air connections. (See Fig. 20.)

FILTER

ARRANGEMENT

CARBON MONOXIDE AND POISONING HAZARD

Failure to follow this warning could result in personal injury, death and/or property damage. Never operate a furnace without a filter or with filter access door removed.

WARNING

DUCTS

AIR

General Requirements

The duct system should be designed and sized according to accepted national standards such as those published by: Air Conditioning Contractors Association (ACCA), Sheet Metal and Air Conditioning Contractors National Association (SMACNA) or American Society of Heating, Refrigerating and Air Conditioning Engineers (ASHRAE) or consult The Air Systems Design Guidelines reference tables available from your local distributor. The duct system should be sized to handle the required system design CFM at the design external static pressure. The furnace airflow rates are provided in Table 5--AIR DELIVERY--CFM (With Filter).

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

Secure ductwork with proper fasteners for type of ductwork used. Seal supply-- and return--duct connections to furnace with code approved tape or duct sealer.

NOTE: Flexible connections should be used between ductwork and furnace to prevent transmission of vibration. Ductwork passing through unconditioned space should be insulated and sealed to enhance system performance. When air conditioning is used, a vapor barrier is recommended.

Maintain a 1--in. clearance from combustible materials to supply air ductwork for a distance of 36 in. horizontally from the furnace. See NFPA 90B or local code for further requirements.

Ductwork Acoustical Treatment

NOTE: Metal duct systems that do not have a 90 degree elbow

and 10 ft. of main duct to the first branch take--off may require internal acoustical lining. As an alternative, fibrous ductwork may be used if constructed and installed in accordance with the latest edition of SMACNA construction standard on fibrous glass ducts. Both acoustical lining and fibrous ductwork shall comply with NFPA 90B as tested by UL Standard 181 for Class 1 Rigid air ducts.

Supply Air Connections

For a furnace not equipped with a cooling coil, the outlet duct shall be provided with a removable access panel. This opening shall be accessible when the furnace is installed and shall be of such a size that the heat exchanger can be viewed for possible openings using light assistance or a probe can be inserted for sampling the air stream. The cover attachment shall prevent leaks.

PG8J/M

There are no provisions for an internal filter rack in these furnaces.

Refer to the instructions supplied with Media Cabinet for assembly and installation options.

A field--supplied accessory external filter rack is required.

This furnace requires KGAFR030ALL 1 in. external filter rack or a suitable field--supplied substitute, such as the media cabinet.

Refer to the instructions supplied with external filter rack for assembly and installation options.

Page 14

TABLE 4—OPENING DIMENSIONS (IN.)

PG8J/M

FURNACE

CASING

WIDTH

14–3/16

17–1/2

24 --- 1/2

APPLICATION

Upflow Applications on Combustible or Noncombustible Flooring (KGASB subbase not required) Downflow Applications on Noncombustible Flooring (KGASB subbase not required) Downflow applications on combustible flooring (KGASB sub-

base required)

Downflow Applications on Combustible Flooring with CD5 or CK5 Coil Assembly or KCAKC coil box (KGASB subbase not required) Upflow Applications on Combustible or Noncombustible Flooring (KGASB subbase not required) Downflow Applications on Noncombustible Flooring (KGASB subbase not required) Downflow applications on combustible flooring (KGASB sub-

base required)

Downflow Applications on Combustible Flooring with CD5 or CK5 Coil Assembly or KCAKC coil box (KGASB subbase not required)

PLENUM OPENING FLOOR OPENING

A B C D

12--- 11/16 21 ---5/8 13 ---5/16 22--- 1/4

12--- 9/16 19 13 ---3/16 19--- 5/8

11--- 13/16 19 13 --- 7/16 20--- 5/8

12--- 5/16 19 13 ---5/16 20

16 21--- 5/8 16 ---5/8 22 ---1/4

15--- 7/8 19 16--- 1/2 19--- 5/8

15--- 1/8 19 16--- 3/4 20--- 5/8

15--- 1/2 19 16--- 1/2 20

19--- 1/2 21 --- 5/8 20---1/8 22---1/4

19--- 3/8 19 20 19--- 5/8

18--- 5/8 19 20 --- 1/4 20 --- 5/8

19 19 20 20

23 21--- 1/8 23 ---5/8 22 ---1/4

22--- 7/8 19 23 --- 1/2 19 --- 5/8

22--- 1/8 19 23 --- 3/4 20 --- 5/8

22--- 1/2 19 23 --- 1/2 20

Page 15

TABLE 5—AIR DELIVERY -- CFM (WITH FILTER)*

FUR-

NACE

SIZE

024045

036045

024070

036070

048070

042090

048090

060090

036110

048110

066110

* A filter is required for each return--- air inlet. Airflow performance included 1 --- in. washable filter media such as contained in factory--- authorized accessory filter

rack. To determine airflow performance without this filter, assume an additional 0.1 in. wc available external static pressure.

------ Indicates unstable operating conditions.

RETURN--- AIR

INLET

Bottom or

Side(s)

Bottom or

Side(s)

Bottom or

Side(s)

Bottom or

Side(s)

Bottom or

Side(s)

Bottom or

Side(s)

Bottom or

Side(s)

Bottom Only

Both Sides or 1

Side & Bottom

1Side Only

Bottom or

Side(s)

Bottom or

Side(s)

Bottom Only

Bottom Sides or

1 Side & Bottom

1Side Only

SPEED

High

M e d --- H i g h

M e d --- L o w

High

M e d --- H i g h

M e d --- L o w

High

M e d --- H i g h

M e d --- L o w

High

M e d --- H i g h

M e d --- L o w

High

M e d --- H i g h

M e d --- L o w

High

M e d --- H i g h

M e d --- L o w

High

M e d --- H i g h

M e d --- L o w

High

M e d --- H i g h

M e d --- L o w

High

M e d --- H i g h

M e d --- L o w

High

M e d --- H i g h

M e d --- L o w

High

M e d --- H i g h

M e d --- L o w

High

M e d --- H i g h

M e d --- L o w

High

M e d --- H i g h

M e d --- L o w

High

M e d --- H i g h

M e d --- L o w

High

M e d --- H i g h

M e d --- L o w

0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0

1085

920

820 1440 1360 1250 1030

835

725 1425 1320 1200 1805 1630 1460 1650 1515 1385 2060 1790 1505 2405 2225 2020 2530 2285 1995 2475 2260 1950 1625 1510 1360 2035 1745 1530 2530 2230 1920

2235 1920 2540 2125

--- ---

1035

875

775 1375 1300 1210 1010

815

700 1375 1280 1175 1740 1585 1420 1600 1485 1360 1985 1765 1505 2310 2155 1955 2450 2215 1945 2395 2190 1910 1575 1470 1335 1965 1710 1515 2470 2205 1900

--- ---

220 1900 2495 2120 1795

EXTERNAL STATIC PRESSURE (IN. WC)

975 830

730 1305 1240 1160

980

790

675 1320 1240 1145 1670 1530 1385 1535 1440 1320 1915 1715 1480 2220 2080 1880 2365 2150 1900 2300 2110 1855 1515 1415 1295 1880 1650 1470 2400 2165 1880 2415 2155 1880 2430 2105 1790

915 770

680 1240 1175 1100

945

760

645 1265 1205 1105 1600 1470 1325 1465 1380 1260 1820 1645 1440 2130 1995 1805 2270 2075 1840 2200 2035 1795 1445 1355 1250 1790 1560 1400 2320 2110 1845 2350 2100 1845 2355 2060 1765

845 710

620 1160 1115 1040

900

720

600 1200 1140 1050 1530 1405 1280 1385 1300 1195 1720 1560 1375 2025 1895 1730 2165 1985 1770 2090 1940 1730 1355 1285 1180 1680 1450 1310 2220 2035 1795 2250 2040 1795 2265 2010 1720

770 640

555 1070 1040

965

845

675

555 1125 1075

990 1445 1330 1220 1285 1220 1120 1610 1470 1300 1920 1785 1630 2065 1890 1685 1985 1845 1650 1260 1185 1100 1495 1340 1215 2115 1950 1730 2145 1955 1730 2175 1940 1650

675 555 470 975 950 885 775 610 475

1035

995

920 1360 1255 1155 1175 1115 1025 1490 1345 1190 1790 1675 1535 1940 1780 1600 1865 1735 1555 1165 1070

985 1365 1205 1095 2000 1855 1650 2015 1850 1650 2065 1840 1585

565 440 360 870 850 790 680 490 390 940 905

840 1280 1170 1080 1055

990

915 1340 1195 1045 1660 1565 1420 1805 1660 1480 1730 1620 1445

990

890

810 1215 1090

990 1865 1740 1555 1875 1740 1555 1935 1730 1500

390 250 190 730 725 670 490 375 300 830 790

725 1180 1080

995

895

830

710 1135 1010

890 1530 1420 1275 1670 1525 1350 1585 1475 1310

785

725

--- ---

1075

955

830 1730 1615 1460 1715 1595 1460 1785 1615 1390

195

--- ---

--- --560 575 520 335 265

--- --655 620 555

1075

990 910 645 600 565 925 820 740

1350 1260 1135 1505 1360 1180 1425 1325 1150

--- ---

--- --875 750 670

1590 1485 1340 1560 1470 1340 1650 1485 1280

PG8J/M

Page 16

TABLE 5⎯ AIR DELIVERY -- CFM (WITH FILTER)* (CONTINUED)

FURNACE

SIZE

048135

066135

060155

PG8J/M

* A filter is required for each return--- air inlet. Airflow performance included 1 --- in. washable filter media such as contained in factory--- authorized accessory filter

rack. To determine airflow performance without this filter, assume an additional 0.1 in. wc available external static pressure.

------ Indicates unstable operating conditions.

RETURN--- AIR INLET

Bottom or

Side(s)

Bottom Only

Bottom, Sides or 1 Side & Bottom

1SideOnly

Bottom Only

Both Sides Or 1 Side & Bottom

1Side Only

UPFLO

90˚

SPEED

High

M e d --- H i g h

M e d --- L o w

High

M e d --- H i g h

M e d --- L o w

High

M e d --- H i g h

M e d --- L o w

High

M e d --- H i g h

M e d --- L o w

High

M e d --- H i g h

M e d --- L o w

High

M e d --- H i g h

M e d --- L o w

High

M e d --- H i g h

M e d --- L o w

W OWNFLOW

0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0

2090 1790 1545 2485 2195 1880

--- --“218 0 1880

--- --2135 1880 2465 2115 1800

--- --2155 1800

--- --2140 1800

2010 1755 1525 2400 2150 1850

--- --2145 1850

--- --2085 1850 2430 2105 1790

--- --2135 1790

--- --2095 1790

EXTERNAL STATIC PRESSURE (IN. WC)

1930 1705 1500 2310 2090 1820

2385 2060 1820

2245 2035 1820 2375 2075 1770 2375 2095 1770 2260 2040 1770

1835 1640 1450 2215 2000 1780

2305 2010 1780

2155 1975 1780 2305 2030 1735 2285 2040 1735 2180 1975 1735

1710 1550 1380 2110 1920 1715

2195 1945 1715

2055 1895 1715 2230 1980 1695 2200 1975 1695 2085 1890 1695

1590 1465 1315 2000 1825 1635

2085 1865 1635

1940 1795 1635 2110 1910 1640 2105 1895 1640 1975 1810 1640

HORIZONTAL

90˚

1470 1360 1215 1880 1720 1540

1960 1765 1540

1825 1685 1540 2000 1830 1570 1995 1790 1570 1865 1705 1570

1335 1210 1005 1725 1565 1415

1825 1660 1415

1695 1565 1415 1865 1725 1465 1870 1685 1465 1740 1595 1465

1025 945 855 1535 1405 1290

1670 1515 1290

1555 1445 1290 1725 1590 1345 1730 1550 1345 1605 1480 1345

835 785 670 1355 1255 1160

1465 1325 1160

1385 1265 1160 1545 1425 1225 1570 1400 1225 1455 1325 1225

120˚ MIN

YES

NOT RECOMMENDED

120˚

MIN

Fig. 14 --- Duct Flanges

YES

NOT RECOMMENDED

120˚

MIN

YES

NOT RECOMMENDED

A02329

Page 17

OUTER DOOR ASSEMBLY

8" MIN FOR DOOR REMOVAL

" THREADED ROD

4 REQ.

SECURE ANGLE IRON TO BOTTOM OF FURNACE WITH 3 #8 x TYPICAL FOR 2 SUPPORTS

" x 1

" x

" ANGLE IRON

1" SQUARE, 1 OR UNI-STRUT MAY BE USED

" SCREWS

PG8J/M

(2) HEX NUTS, (2) WASHERS & (2) LOCK WASHERS REQ. PER ROD

Fig. 15 --- Horizontal Unit Suspension

A05027

A02014

Fig. 16 --- Horizontal Suspension with Straps

Page 18

PG8J/M

LINE CONTACT ONLY PERMISSIBLE BETWEEN LINES FORMED BY INTERSECTIONS OF THE TOP AND TWO SIDES OF THE FURNACE JACKET AND BUILDING JOISTS, STUDS, OR FRAMING.

MANUAL SHUTOFF

GAS VALVE

SEDIMENT

TRAP

GAS ENTRY

″

MIN*

TYPE-B VENT

17 3/4″

SHEET METAL

″

Fig. 17 --- Typical Attic Installation

30-IN. MIN WORK AREA

17 3/4″ OVER ALL 4 3/4″ UNDER DOOR 1″ UNDER FURNACE

EXTEND OUT 12″ OUT FROM FACE OF DOOR

* WHEN USED WITH SINGLE WALL VENT CONNECTIONS

A02164

Fig. 18 --- Upflow Return Air configurations and Restrictions

A02075

Page 19

Fig. 19 --- Downflow Return Air Configurations and Restrictions

PG8J/M

A02163

Fig. 20 --- Horizontal Return Air Configurations and Restrictions

Upflow and Horizontal

Furnaces

Connect supply--air duct to flanges on furnace supply--air outlet. Bend flange upward to 90_ with wide duct pliers. (See Fig. 14.) The supply--air duct must be connected to ONLY the furnace supply--outlet-- air duct flanges or air conditioning coil casing (when used). DO NOT cut main furnace casing side to attach supply air duct, humidifier, or other accessories. All accessories MUST be connected to duct external to furnace main casing.

NOTE: For horizontal applications, the top--most flange may be bent past 90_ to allow the evaporator coil to hang on the flange temporarily while the remaining attachment and sealing of the coil are performed.

A02162

Downflow Furnaces

Connect supply--air duct to supply--air outlet on furnace. Bend flange inward past 90_ with wide duct pliers. (See Fig. 14.) The supply--air duct must be connected to ONLY the furnace supplyoutlet or air conditioning coil casing (when used). When installed on combustible material, supply--air duct must be connected to ONLY the accessory subbase KGASB0201ALL or a factory approved air conditioning coil casing. DO NOT cut main furnace casing to attach supply side air duct, humidifier, or other accessories. All accessories MUST be connected to duct external to furnace casing.

Page 20

FIRE HAZARD

A failure to follow this warning could result in personal injury, or death and/or property damage.

Never connect return--air ducts to the back of the furnace. Follow instructions below.

Return Air Connections

Downflow

The return--air duct must be connected to return--air opening (bottom inlet) as shown in Fig. 19. DO NOT cut into casing sides (left or right). Side opening is permitted for only upflow and most horizontal furnaces. (See Fig. 19.) Bypass humidifier connections should be made at ductwork or coil casing sides exterior to furnace.

Upflow and Horizontal

PG8J/M

The return--air duct must be connected to bottom, sides (left or right), or a combination of bottom and side(s) of main furnace casing as shown in Fig. 18 and 20. Bypass humidifier may be attached into unused return air side of the furnace casing. (See Fig. 18 and 20.)

Not all horizontal furnaces are approved for side return air connections. (See Fig. 20.)

GAS

Furnaces

PIPING

FIRE OR EXPLOSION HAZARD

Failure to follow this warning could result in personal injury, death, and/or property damage.

Never purge a gas line into a combustion chamber. Never test for gas leaks with an open flame. Use a commercially available soap solution made specifically for the detection of leaks to check all connections.

FIRE OR EXPLOSION HAZARD

Failure to follow this warning could result in personal injury, death, and/or property damage.

Use proper length of pipe to avoid stress on gas control manifold and a gas leak.

Gas piping must be installed in accordance with national and local codes. Refer to current edition of NFGC in the U.S., the NSCNGPIC in Canada.

Installations must be made in accordance with all authorities having jurisdiction. If possible, the gas supply line should be a separate line running directly from meter to furnace.

NOTE: In the state of Massachusetts:

1. Gas supply connections MUST be performed by a licensed plumber or gas fitter.

2. When flexible connectors are used, the maximum length shall not exceed 36 inches (915 mm).

3. When lever handle type manual equipment shutoff valves are used, they shall be T--handle valves.

4. The use of copper tubing for gas piping is NOT approved by the state of Massachusetts.

WARNING

Furnaces

WARNING

Refer to Table 6 for recommended gas pipe sizing. Risers must be used to connect to furnace and to meter. Support all gas piping with appropriate straps, hangers, etc. Use a minimum of 1 hanger every 6 ft. Joint compound (pipe dope) should be applied sparingly and only to male threads of joints. Pipe dope must be resistant to the action of propane gas.

TABLE 6—MAXIMUM CAPACITY OF PIPE*

NOMINAL

IRON PIPE

SIZE (IN.)

1/2 0.622 175 120 97 82 73

3/4 0.824 360 250 200 170 151

1 1.049 680 465 375 320 285

1 --- 1 / 4 1.380 1400 950 770 660 580

1 --- 1 / 2 1.610 2100 1460 1180 990 900

* Cubic ft. of natural gas per hr for gas pressures of 0.5 psig (14 --- in. wc)

or less and a pressure drop of 0.5 - --in. wc (based on a 0.60 specific gravity gas). Ref: Table 12.2 ANSI Z223---2006/NFPA 54 --- 2006.

FIRE OR EXPLOSION HAZARD

Failure to follow this warning could result in personal injury, death, and/or property damage.

If local codes allow the use of a flexible gas appliance connector, always use a new listed connector. Do not use a connector which has previously served another gas appliance. Black iron pipe shall be installed at the furnace gas control valve and extend a minimum of 2 in. outside the furnace.

FURNACE OVERHEAT HAZARD

Failure to follow this caution may result in unit component damage.

Connect gas pipe to gas valve using a backup wrench to avoid damaging gas controls and burner misalignment.

An accessible manual equipment shutoff valve MUST be installed external to furnace casing and within 6 ft. of furnace. A 1/8--in. NPT plugged tapping, accessible for test gauge connection, MUST be installed immediately upstream of gas supply connection to furnace and downstream of manual equipment shutoff valve.

INTERNAL

DIAMETER

LENGTH OF PIPE (FT.)

(IN.)

10 20 30 40 50

WARNING

CAUTION

Page 21

2" Nipple

Street Elbow

national plumbing and gas codes before the furnace has been connected. After all connections have been made, purge lines and check for leakage at furnace prior to operating furnace.

If pressure exceeds 0.5 psig (14--in. wc), gas supply pipe must be disconnected from furnace and capped before and during supply pipe pressure test. If test pressure is equal to or less than 0.5 psig (14--in. wc), turn off electric shutoff switch located on furnace gas control valve and accessible manual equipment shutoff valve before and during supply pipe pressure test. After all connections have been made, purge lines and check for leakage at furnace prior to operating furnace.

TWO

A05028

90° Elbow

PG8J/M

A02099

Fig. 23 --- Relocating J--Box

Gas Valve

A02327

Fig. 21 --- Burner and Manifold

NOTE: The furnace gas valve inlet pressure tap connection is

suitable to use as test gauge connection providing test pressure DOES NOT exceed maximum 0.5 psig (14--in. wc) stated on gas control valve. (See Fig. 47.)

Some installations require gas entry on right side of furnace (as viewed in upflow.) (See Fig. 21.)

Install a sediment trap in riser leading to furnace as shown in Fig

22. Connect a capped nipple into lower end of tee. Capped nipple should extend below level of furnace gas controls. Place a ground joint union between furnace gas control valve and exterior manual equipment gas shutoff valve. A 1/8--in. NPT plugged tapping, accessible for test gauge connection, MUST be installed immediately upstream of gas supply connection to furnace and downstream of manual equipment shutoff valve.

GAS SUPPLY

MANUAL SHUTOFF VALV E (REQUIRED

SEDIMENT TRAP

UNION

A03221

Fig. 24 --- Field--Supplied Electrical Box on Furnace Casing

The gas supply pressure shall be within the maximum and minimum inlet supply pressures marked on the rating plate with the furnace burners ON and OFF.

ELECTRICAL

CONNECTIONS

WARNING

Fig. 22 --- Typical Gas Pipe Arrangement

Piping should be pressure and leak tested in accordance with NFGC in the United States or NSCNGPIC in Canada, local, and

A02035

ELECTRICAL SHOCK HAZARD

Failure to follow this warning could result in personal injury or death.

Blower access panel door switch opens 115--v power to control. No component operation can occur. Do not bypass or close switch with panel removed.

Page 22

ELECTRICAL SHOCK AND FIRE HAZARD

Failure to follow this warning could result in personal injury, death, or property damage.

The cabinet MUST have an uninterrupted or unbroken ground according to NEC ANSI/NFPA 70--2006 and Canadian Electrical Code CSA C22.1 or local codes to minimize personal injury if an electrical fault should occur. This may consist of electrical wire, conduit approved for electrical ground or a listed, grounded power cord (where permitted by local code) when installed in accordance with existing electrical codes. Refer to the power cord manufacturer’s ratings for proper wire gauge. Do not use gas piping as an electrical ground.

PG8J/M

FURNACE MAY NOT OPERATE

Failure to follow this caution may result in intermittent furnace operation.

Furnace control must be grounded for proper operation or else control will lock out. Control must remain grounded through green/yellow wire routed to gas valve and manifold bracket screw.

See Fig. 26 for field wiring diagram showing typical field 115--v wiring. Check all factory and field electrical connections for tightness.

Field--supplied wiring shall conform with the limitations of 63_F (33_C) rise.

115--V WIRING

Verify that the voltage, frequency, and phase correspond to that specified on unit rating plate. Also, check to be sure that service provided by utility is sufficient to handle load imposed by this equipment. Refer to rating plate or Table 7 for equipment electrical specifications.

U.S. installations: Make all electrical connections in accordance with National Electrical Code (NEC) ANSI/NFPA 70--2006 and any local codes or ordinances that might apply.

Canadian installations: Make all electrical connections in accordance with Canadian Electrical Code CSA C22.1 or authorities having jurisdiction.

WARNING

CAUTION

NOTE: On 14 in. wide casing models, the J--Box shall not be relocated to other side of furnace casing when the vent pipe is routed within the casing.

1. Remove and save two screws holding J--Box. (See Fig.

23.)

NOTE: The J--Box cover need not be removed from the J-- Box in order to move the J-- Box. Do NOT remove green ground screw inside J--Box. The ground screw is not threaded into the casing flange and can be lifted out of the clearance hole in casing while swinging the front edge of the J--Box outboard of the casing.

2. Cut wire tie on loop in furnace wires attached to J--box.

3. Move J--Box to desired location.

4. Fasten J--Box to casing with 2 screws removed in Step 1.

5. Route J--Box wires within furnace away from sharp edges, rotating parts and hot surfaces.

ELECTRICAL CONNECTION TO J--BOX

Field--Supplied Electrical Box on Furnace J--Box Bracket See Fig. 24.

1. Remove cover from furnace J--Box.

2. Attach electrical box to furnace J--Box bracket with at least two field--supplied screws through holes in electrical box into holes in bracket. Use blunt--nose screws that will not pierce wire insulation.

3. Route furnace power wires through holes in electrical box and J--Box bracket, and make field--wire connections in electrical box. Use best practices (NEC in U.S. and CSA C22.1 in Canada) for wire bushings, strain relief, etc.

FIRE HAZARD

Failure to follow this warning could result in personal injury, death, or property damage.

Do not connect aluminum wire between disconnect switch and furnace. Use only copper wire.

Use a separate, fused branch electrical circuit with a properly sized fuse or circuit breaker for this furnace. See Table 7 for wire size and fuse specifications. A readily accessible means of electrical disconnect must be located within sight of the furnace.

NOTE: Proper polarity must be maintained for 115--v wiring. If polarity is incorrect, control LED status indicator light will flash rapidly and furnace will NOT operate.

J--BOX RELOCATION

NOTE: If factory location of J--Box is acceptable, go to next

section (ELECTRICAL CONNECTION TO J--BOX).

WARNING

Page 23

TABLE 7—ELECTRICAL DATA

FURNACE

SIZE

045--- 08/024045 1 1 5 --- 6 0 --- 1 127 104 5.4 7.54 49 15 14 045--- 12/036045 1 1 5 --- 6 0 --- 1 127 104 7.0 9.50 39 15 14 070--- 08/024070 1 1 5 --- 6 0 --- 1 127 104 5.0 7.06 52 15 14 070--- 12/036070 1 1 5 --- 6 0 --- 1 127 104 6.8 9.22 40 15 14 070--- 16/048070 1 1 5 --- 6 0 --- 1 127 104 9.5 12.60 29 15 14 090--- 14/042090 1 1 5 --- 6 0 --- 1 127 104 8.2 10.83 34 15 14 090--- 16/048090 1 1 5 --- 6 0 --- 1 127 104 10.0 13.13 28 15 14 090--- 20/060090 1 1 5 --- 6 0 --- 1 127 104 13.6 17.61 32 20 12 110--- 12/036110 1 1 5 --- 6 0 --- 1 127 104 8.2 10.75 34 15 14 110--- 16/048110 1 1 5 --- 6 0 --- 1 127 104 10.1 13.12 28 15 14 110--- 22/066110 1 1 5 --- 6 0 --- 1 127 104 14.8 18.99 30 20 12 135--- 16/048135 1 1 5 --- 6 0 --- 1 127 104 10.2 13.27 27 15 14 135--- 22/066135 1 1 5 --- 6 0 --- 1 127 104 14.4 18.55 30 20 12 155--- 20/060155 1 1 5 --- 6 0 --- 1 127 104 15.0 19.33 29 20 12

* Permissible limits of th e voltage range at which the unit operates satisfactoril y. # Unit ampacity = 125 percent of largest operating component’s full load amps plus 100 percent of all other potential operating components’ (EAC, humidifier,

etc.) full load amps.

{ Time --- delay type is recommended. } Length shown is as measured 1 way along wire path between unit and service panel for maximum 2 percent voltage drop.

V O L T S --H E R T Z ---

PHASE

NOTE: Check that duct on side of furnace will not interfere with installed electrical box.

4. Remove the desired electrical box hole knockout and position the hole in the electrical box over the hole in the furnace casing.

5. Fasten the electrical box to casing by driving two field supplied screws from inside electrical box into casing steel.

6. Remove and save two screws holding J--Box. (See Fig.

23.)

7. Pull furnace power wires out of 1/2-- inch diameter hole in J--Box. Do not loosen wires from strain--relief wire--tie on outside of J--Box.

8. Route furnace power wires through holes in casing and electrical box and into electrical box.

9. Pull field power wires into electrical box.

10. Remove cover from furnace J--Box.

11. Route and secure field ground wire to green ground screw on J--Box bracket.

12. Connect line voltage leads as shown in Fig. 26.

13. Reinstall cover to J--Box. Do not pinch wires between cover and bracket. Electrical Box on Furnace Casing Side See Fig. 24.

OPERATING VOLTAGE

RANGE

Maximum

Minimum*

MAXIMUM

UNIT

AMPS

UNIT

AMPACITY#

3. Reattach furnace J--Box to furnace casing with screws removedinStep4.

4. Secure field ground wire to J--Box green ground screw.

5. Complete electrical box wiring and installation. Connect line voltage leads as shown in Fig. 26. Use best practices (NEC in U.S. and CSA C22.1 in Canada) for wire bushings, strain relief, etc.

6. Reinstall cover to J--Box. Do not pinch wires between cover and bracket.

POWER CORD INSTALLATION IN FURNACE J--BOX

NOTE: Power cords must be able to handle the electrical

requirements listed in Table 5. Refer to power cord manufacturer’s listings.

1. Remove cover from J--Box.

2. Route listed power cord through 7/8-- in. diameter hole in J--Box.

3. Secure power cord to J--Box bracket with a strain relief bushing or a connector approved for the type of cord used.

4. Secure field ground wire to green ground screw on J--Box bracket.

5. Connect line voltage leads as shown in Fig. 25.

6. Reinstall cover to J--Box. Do not pinch wires between cover and bracket.

MAXIMUM

WIRE

LENGTH

(FT . )‡

MAXIMUM

FUSE OR CKT BKR

AMPS†

MINIMUM

WIRE

GAUGE

BX CABLE INSTALLATION IN FURNACE J--BOX

FIRE OR ELECTRICAL SHOCK HAZARD

Failure to follow this warning could result in personal injury, death, or property damage. If field--supplied manual disconnect switch is to be mounted on furnace casing side, select a location where a drill or fastener cannot damage electrical or gas components.

1. Select and remove a hole knockout in the casing where the electrical box is to be installed.

WARNING

1. Remove cover from J--Box.

2. Route BX cable into 7/8-- inch diameter hole in J--Box.

3. Secure BX cable to J--Box bracket with connectors approved for the type of cable used.

4. Secure field ground wire to green ground screw on J--Box bracket.

5. Connect line voltage leads as shown in Fig. 26.

6. Reinstall cover to J--Box. Do not pinch wires between cover and bracket.

2. Route field ground wire through holes in electrical box and casing, and into furnace J--Box.

PG8J/M

Page 24

BLOWER OFF-DELAY

J2 JUMPER

24-V THERMOSTAT

TERMINALS

G Com W Y R

24V

BLOWER OFF-DELAY

90 150

120 180

TWINNING AND/OR COMPONENT TEST

TERMINAL

HUMIDIFIER TERMINAL

(24-VAC 0.5 AMP MAX.)

3-AMP FUSE

LED OPERATION &

PG8J/M

DIAGNOSTIC LIGHT

115-VAC(L2)NEUTRAL

CONNECTIONS

BLOWER SPEED

SELECTION TERMINALS

COOL

HEAT

STATUS CODE LED

NUETRAL

BLW

COOL HEAT

SPARE-1

SPARE-2

TEST/TWIN

0.5 AMP@24VAC

FUSE 3-AMP

SEC-2 SEC-1

EAC-2 L2

SPARE-1 SPARE-2

PLT

HUM

PLT 1

1-AMP@

EAC-1

115VAC

EAC-1 TERMINAL

(115-VAC 1.0 AMP MAX.)

Fig. 25 --- Furnace Control

PR-1

PL2 1

115 VAC (L1) LINE

VOLTAGE CONNECTION

TRANSFORMER 24-VAC

CONNECTIONS

PL1-LOW VOLTAGE MAIN

HARNESS CONNECTOR

PL2-HOT SURFACE

IGNITER & INDUCER

MOTOR CONNECTOR

A02100

FIVE WIRE

THREE-WIRE

HEATING-ONLY

BLOWER DOOR SWITCH

BLK

WHT

115-V FIELD-

SUPPLIED

BLK

WHT

GND

AUXILIARY J-BOX

DISCONNECT

Fig. 26 --- Heating and Cooling application Wiring Diagram with 1--Stage Thermostat

GND

FURNACE

NOTE 2

O N

R O

COM

Y/Y2

24-V

TERMINAL

BLOCK

FIELD 24-V WIRING FIELD 115-, 208/230-, 460-V WIRING FACTORY 24-V WIRING FACTORY 115-V WIRING

WCR GY

THERMOSTAT TERMINALS

FIELD-SUPPLIED DISCONNECT

208/230- OR 460-V THREE PHASE

208/230-V SINGLE PHASE

NOTE 1

CONDENSING

GND

UNIT

TWO WIRE

NOTES: Connect Y-terminal in furnace as shown for proper blower operation.

Some thermostats require a "C" terminal connection as shown.

If any of the original wire, as supplied, must be replaced, use same type or equivalent wire.

A99440

Page 25

24--V WIRING

Make field 24--v connections at the 24-- v terminal strip. (See Fig.

25.) Connect terminal Y as shown in Fig. 26 for proper cooling operation. Use only AWG No. 18, color--coded, copper thermostat wire.

The 24--v circuit contains an automotive--type, 3 --amp. fuse located on the control. Any direct shorts during installation, service, or maintenance could cause this fuse to blow. If fuse replacement is required, use ONLY a 3--amp. fuse of identical size.

ACCESSORIES

1. Electronic Air Cleaner (EAC) Connect an accessory Electronic Air Cleaner (if used) using 1/4 -- in female quick connect terminals to the two male 1/4--in quick-- connect terminals on the control board marked EAC -- 1 and EAC-- 2. The terminals are rated for 115 VAC, 1.0 amps maximum and are energized during blower motor operation. (See Fig. 24.)

2. Humidifier (HUM) Connect an accessory 24 VAC, 0.5 amp. maximum humidifier (if used) to the 1/4--in male quick--connect HUM terminal and COM--24V screw terminal on the control board thermostat strip. The HUM terminal is energized when gas valve relay (GVR) is energized. (See Fig. 25.)

NOTE: A field--supplied, 115--v controlled relay connected to EAC terminals may be added if humidifier operation is desired during blower operation.

NOTE: DO NOT connect furnace control HUM terminal to HUM (humidifier) terminal on Thermidistatt, Zone Controller or similar device. See Thermidistatt, Zone Controller, thermostat, or controller manufacturer ’s instructions for proper connection.

VENTING

The furnace shall be connected to a listed factory built chimney or vent, or a clay -- tile lined masonry or concrete chimney. Venting into an unlined masonry chimney or concrete chimney is prohibited.

When an existing Category I furnace is removed or replaced, the original venting system may no longer be sized to properly vent the attached appliances. An improperly sized Category I venting system could cause the formation of condensate in the furnace and vent, leakage of condensate and combustion products, and spillage of combustion products into the living space.

Vent system or vent connectors may need to be resized. Vent systems or vent connectors, must be sized to approach minimum size as determined using appropriate table found in the NFGC or NSCNGPIC.

GENERAL VENTING REQUIREMENTS

Follow all safety codes for proper vent sizing and installation requirements, including local building codes, the National Fuel Gas Code ANSI Z223.1--2006/NFPA 54--2006 (NFGC), Parts 10 and 13 in the United States or the National Standard of Canada, Natural Gas and Propane Installation Code CSA --B149.1-- 00 (NSCNGPIC), Section 7 and Appendix C in Canada, the local building codes, and furnace and vent manufacturers’ instructions.

CARBON MONOXIDE POISONING HAZARD

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

1. Seal any unused openings in 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 CSA B149.1, Natural Gas and Propane Installation Code and these instructions. Determine that there is no blockage or restriction, leakage, corrosion and other deficiencies, which could cause an unsafe condition.

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

4. Close fireplace dampers.

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

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

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

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

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

These furnaces are design-- certified as Category I furnaces in accordance with ANSI Z21.47--2003/CSA 2.3--2003 and operate with a non-- positive vent static pressure to minimize the potential for vent gas leakage. Category I furnaces operate with a flue loss not less than 17 percent to minimize the potential for condensation in the venting system. These furnaces are approved for common venting and multistory venting with other fan assisted or draft hood equipped appliances in accordance with the NFGC or the NSCNGPIC, the local building codes, and furnace and vent manufacturers’ instructions.

The following information and warning must be considered in addition to the requirements defined in the NFGC and the NSCNGPIC.

WARNING

PG8J/M

CARBON MONOXIDE POISONING HAZARD

Failure to follow this warning could result in personal injury or death.

Do not bypass the draft safeguard switch, as an unsafe condition could exist which must be corrected.

1. If a vent (common or dedicated) becomes blocked, the furnace will be shut off by the draft safeguard switch located on the vent elbow.

Page 26

2. Do not connect this Category I furnace into a single--wall dedicated or common vent. The dedicated or common vent is considered to be the vertical portion of the vent system that terminates outdoors.

3. Vent connectors serving Category I furnaces shall not be connected into any portion of a mechanical draft system operating under positive pressure.

4. In the U.S.: Do not vent this appliance with any solid fuel burning appliance. In Canada: Check with the authority having jurisdiction for approval on use with solid fuel burning appliance.

5. Category I furnaces must be vented vertically or nearly vertically unless equipped with a listed power venter.

6. Do not vent this appliance into an unlined masonry chimney. Refer to Chimney Inspection Chart, Fig. 27.

MASONRY CHIMNEY REQUIREMENTS

NOTE: These furnaces are CSA design--certified for use in

exterior clay tile--lined masonry chimneys with a factory accessory Chimney Adapter Kit. Refer to the furnace rating plate

PG8J/M

for correct kit usage. The Chimney Adapter Kits are for use with ONLY furnaces having a Chimney Adapter Kit numbers marked on the furnace rating plate.

If a clay tile--lined masonry chimney is being used and it is exposed to the outdoors below the roof line, relining might be required. Chimneys shall conform to the Standard for Chimneys, Fireplaces, Vents, and Solid Fuel Burning Appliances ANSI/NFPA 211--2003 in the United States and to a Provincial or Territorial Building Code in Canada (in its absence, the National Building Code of Canada) and must be in good condition.

U.S.A.--Refer to Sections 13.1.9 and 13.2.20 of the NFGC or the authority having jurisdiction to determine whether relining is required. If relining is required, use a properly sized listed metal liner, Type--B vent, or a listed alternative venting design.

NOTE: See the NFGC, 13.1.9 and 13.2.20 regarding alternative venting design and the Exception, which cover installations such as the Chimney Adapter Kits KGACA02014FC and KGACA02015FC, which are listed for use with these furnaces. The Chimney Adapter Kit is listed alternative venting system for these furnaces. See the kit instructions for complete details.

Canada (and U.S.A.)--This furnace is permitted to be vented into a clay tile--lined masonry chimney that is exposed to the outdoors below the roof line, provided:

1. Vent connector is Type--B double--wall, and

2. This furnace is common vented with at least 1 draft hood equipped appliance, and

3. The combined appliance input rating is less than the maximum capacity given in Table A, and

4. The input rating of each space heating appliance is greater than the minimum input rating given in Table B for the local 99% Winter Design Temperature. Chimneys having internal areas greater than 38 sq./in. require furnace input ratings greater than the input ratings of these furnaces. See footnote at bottom of Table B, and

5. The authority having jurisdiction approves.

If all of these conditions cannot be met, an alternative venting design shall be used, such as the listed chimney adapter kit with these furnaces, which are listed for use with the kit, a listed chimney--lining system, or a Type--B common vent.

Inspections before the sale and at the time of installation will determine the acceptability of the chimney or the need for repair and/or (re)lining. Refer to the Fig. 27 to perform a chimney inspection. If the inspection of a previously used tile--lined chimney:

a. Shows signs of vent gas condensation, the chimney

should be relined in accordance with local codes and the authority having jurisdiction. The chimney should be relined with a listed metal liner, Type--B vent, or a listed chimney adapter kit shall be used to reduce condensation. If a condensate drain is required by local code, refer to the NFGC, Section 12.10 for additional information on condensate drains.

b. Indicates the chimney exceeds the maximum permiss-

ible size in the tables, the chimney should be rebuilt or relined to conform to the requirements of the equipment being installed and the authority having jurisdiction.

A chimney without a clay tile liner, which is otherwise in good condition, shall be rebuilt to conform to ANSI/NFPA 211 or be lined with a UL listed (ULC listed in Canada) metal liner or UL listed Type--B vent. Relining with a listed metal liner or Type--B vent is considered to be a vent-- in--a--chase.

If a metal liner or Type--B vent is used to line a chimney, no other appliance shall be vented into the annular space between the chimney and the metal liner.

Page 27

CHIMNEY INSPECTION CHART

For additional requirements refer to the National Fuel Gas Code NFPA 54/ANSI Z223.1 and ANSI/NFPA 211

Chimneys, Fireplaces, Vents, and Solid Fuel Burning Appliances in the U.S.A. or to the Canadian

installation Code CSA-B149.1 in Canada.

Crown

condition:

Missing mortar

or brick?

Is chimney

property lined with

clay tile liner?

Ye s

liner and top

seal in good

condition?

Ye s

Debris

in cleanout?

Mortar, tile, metal vent,

fuel oil residue?

Ye s

Rebuild

crown.

Repair

liner or top seal

or reline chimney as

necessary.

Repair

Mortar

or tile

debris?

Reline

Ye s

Remove mortar

and tile debris

PG8J/M

Clay tile misalignment, missing sections,

gaps?

Condensate

drainage at bottom

of chimney?

Chimney

exposed to

outdoors below

roof line?

Chimney is

acceptable for use.

Remove metal vent

or liner.

Ye s

lined with properly

sized, listed liner or

Ye s

Is chimney

Type-B vent?

Ye s

Is chimney

to be dedicated to

a single

furnace?

Consult

Part B of

chimney adapter venting

instructions for

application

suitability.

Suitable

Ye s

Install chimney

adapter per

instructions.

chimney adapter venting

Not Suitable

Consult

Part C of

instructions for

application

suitability

Line chimney with property

sized, listed flexible metal

liner or Type-B vent per

NFGC or NSCNGPIC Vent

Sizing Tables and liner or

vent manufacturer’s

Installation instructions.

Suitable

Install chimney

adapter per instructions.

A03206

Fig. 27 --- Chimney Inspection Chart

Page 28

APPLIANCE APPLICATION REQUIREMENTS

Appliance operation has a significant impact on the performance of the venting system. If the appliances are sized, installed,

adjusted, and operated properly, the venting system and/or the appliances should not suffer from condensation and corrosion. The venting system and all appliances shall be installed in accordance with applicable listings, standards, and codes.

The furnace should be sized to provide 100 percent of the design heating load requirement plus any margin that occurs because of furnace model size capacity increments. 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.

When a metal vent or metal liner is used, the vent must be in good condition and be installed in accordance with the vent manufacturer’s instructions.

To prevent condensation in the furnace and vent system, the

PG8J/M

following precautions must be observed:

1. The return--air temperature must be at least 60_F db except

for brief periods of time during warm--up from setback at no lower than 55_F db or during initial start--up from a standby condition.

2. Adjust the gas input rate per the installation instructions. Low gas input rate causes low vent gas temperatures, causing condensation and corrosion in the furnace and/or venting system. Derating is permitted only for altitudes above 2000 ft.

3. Adjust the air temperature rise to the midpoint of the rise range or slightly above. Low air temperature rise can cause low vent gas temperature and potential for condensation problems.

4. Set thermostat heat anticipator or cycle rate to reduce short cycling.

EXTERIOR MASONRY CHIMNEY FAN + NAT

INSTALLATIONS WITH TYPE--B DOUBLE--WALL

VENT CONNECTORS

TABLE A–COMBINED APPLIANCE MAXIMUM INPUT

RATING IN THOUSANDS OF BTUH PER HOUR

VENT

HEIGHT

(FT . )

6 74 119 178 257

8 80 130 193 279

10 84 138 207 299

15 NR 152 233 334

20 NR NR 250 368

30 NR NR NR 404

INTERNAL AREA OF CHIMNEY

(SQ. IN.)

12 19 28 38

TABLE B–MINIMUM ALLOWABLE INPUT RATING OF

SPACE--HEATING APPLIANCE IN THOUSANDS OF

BUT PER HOUR

VENT

HEIGHT

(FT . )

6 0 55 99 141

8 52 74 111 154

10 NR 90 125 169

15 NR NR 167 212

20 NR NR 212 258

30 NR NR NR 362

6 NR 78 121 166

8 NR 794 135 182

10 NR 111 149 198

15 NR NR 193 247

20 NR NR NR 293

30 NR NR NR 377

6 NR NR 145 196

8 NR NR 159 213

10 NR NR 175 231

15 NR NR NR 283

20 NR NR NR 333

30 NR NR NR NR

Temperature: --- 11 degrees F or lower

Not recommended for any vent configuration

* The 99% Winter Design Dry--- Bulb (db) temperatures are found in the

1993 ASHRAE Fundamentals Handbook, chapter 24 , Table 1 (United States) and 2 (Canada), or use the 99.6% heating db temperatures found in the 1997 or 2001 ASHRAE Fundamental s Handbook, Climatic Design Information chapter, Table 1A (United States) and 2A (Canada).

INTERNAL AREA OF CHIMNEY

(SQ. IN.)

12 19 28 38

Local 99% Winter Design

Temperature: 17 to 26 degrees F*

Local 99% Winter Design

Temperature: 5 to 16 degrees F*

Local 99% Winter Design

Temperature: --- 10 to 4 degrees F*

Local 99% Winter Design

Page 29

Fig. 28 --- Using Tin Snips to Cut Tie Points

Air for combustion must not be contaminated by halogen compounds which include chlorides, fluorides, bromides, and iodides. These compounds are found in many common home products such as detergent, paint, glue, aerosol spray, bleach, cleaning solvent, salt, and air freshener, and can cause corrosion of furnaces and vents. Avoid using such products in the combustion--air supply. Furnace use during construction of the building could cause the furnace to be exposed to halogen compounds, causing premature failure of the furnace or venting system due to corrosion.

Vent dampers on any appliance connected to the common vent can cause condensation and corrosion in the venting system. Do not use vent dampers on appliances common vented with this furnace.

ADDITIONAL VENTING REQUIREMENTS

A 4 in. round vent elbow is supplied with the furnace. A 5--in. or 6-- in. vent connector may be required for some model furnaces. A field--supplied 4--in.--to--5 -- in. or 4-- in.--to--6 -- in. sheet metal increaser fitting is required when 5--in. or 6--in. vent connector is used. See Fig. 33-- 44 Venting Orientation for approved vent configurations.

NOTE: Vent connector length for connector sizing starts at furnace vent elbow. The 4--in. vent elbow is shipped for upflow configuration and may be rotated for other positions. Remove the 3 screws that secure vent elbow to furnace, rotate furnace vent elbow to position desired, reinstall screws. The factory--supplied vent elbow does NOT count as part of the number of vent connector elbows.

The vent connector can exit the door through one of 5 locations on the door.

1. Attach the single wall vent connector to the furnace vent elbow, and fasten the vent connector to the vent elbow with at least two field--supplied, corrosion--resistant, sheet metal screws located 180_ apart.

A04127

NOTE: An accessory flue extension KGAFE0112UPH is available to extend from the furnace elbow to outside the furnace casing. If flue extension is used, fasten the flue extension to the vent elbow with at least two field--supplied, corrosion--resistant, sheet metal screws located 180_ apart. Fasten the vent connector to the flue extension with at least two field--supplied, corrosion resistant sheet metal screws located 180_ apart.

2. Vent the furnace with the appropriate connector as shown in Fig. 33--45.

CAUTION

CUT HAZARD

Failure to follow this caution may result in personal injury. Sheet metal parts may have sharp edges or burrs.

Use care and wear appropriate protective clothing, safety glasses and gloves when handling parts and servicing furnaces.

3. Orient the door to determine the correct location of the door cutout to be removed.

4. Use aviation--type tin snips to remove the correct U--shaped cut--out in door.

NOTE: If this furnace is equipped with knockouts in the door for the vent, a number of techniques can be used to remove these knockouts as seen in Fig. 28 through 32. The knockout in the bottom of the door is unique due to its flanging and is not easily removed by first cutting the two tie points at the edge of the door, using aviation--type tin snips. (See Fig. 28.) A sharp blow to the rounded end of the knockout (See Fig. 29.) will separate more tie points and allow the knockout to be pulled loose. (See Fig. 30.) Remove all burrs and sharp edges.

PG8J/M

Page 30

PG8J/M

Fig. 29 --- Rounded End of Knockout

For the knockouts in the other locations on the door (top and sides), tin snips can also be used along the door edges; however, the preferred method is to use a hammer and screwdriver to strike a sharp blow (See Fig. 31.) directly to the knockout tie points or use a hammer in the upper left corner of the desired knockout. (See Fig. 32.) Remove all burrs and sharp edges.

CAUTION

BURN HAZARD

Failure to follow this caution may cause personal injury.

Hot vent pipe is within reach of small children when installed in downflow position. See the following instruction.



A04129

Fig. 30 --- Knockout Pulled Loose

A04128

A04130

Fig. 31 --- Hammer and Screwdriver Used for Knockout

An accessory Vent Guard Kit, KGAVG0101DFG is REQUIRED for downflow applications for use where the vent exits through the lower portion of the furnace casing door. Refer to the Vent Guard Kit Instructions for complete details.

The horizontal portion of the venting system shall slope upwards not less than 1/4--in. per linear ft. (21 mm/m) from the furnace to the vent and shall be rigidly supported every 5 ft. or less with metal hangers or straps to ensure there is no movement after installation.

SIDEWALL VENTING

This furnace is not approved for direct sidewall horizontal venting.

In the U.S.: Per section 12.4.3.1 o f the NFGC, any listed mechanical venter may be used, when approved by the authority having jurisdiction.

In Canada: Per section 7.24.2 of the NSCNGPIC, any listed venters may be used, when approved by the authority having jurisdiction. Select the listed mechanical venter to match the Btuh input of the furnace being vented. Follow all manufacturer’s installation requirements for venting and termination included with the listed mechanical venter.

A04131

Fig. 32 --- Remove Knockout with Hammer

Page 31

START--UP, ADJUSTMENT, AND SAFETY

CHECK

Step 1 —General

FIRE HAZARD

Failure to follow this warning could result in personal injury, death and/or property damage.

This furnace is equipped with manual reset limit switches in the gas control area. The switches open and shut off power to the gas valve if a flame rollout or overheating condition occurs in the gas control area. DO NOT bypass the switches. Correct inadequate combustion air supply problem before resetting the switches.

CUT HAZARD

Failure to follow this caution may result in personal injury. Sheet metal parts may have sharp edges or burrs.

Use care and wear appropriate protective clothing, safety glasses, and gloves when handling parts and servicing furnaces.

1. Maintain 115--v wiring and ground. Improper polarity will result in rapid flashing LED and no furnace operation.

2. Make thermostat wire connections at the 24-- v terminal block on the furnace control. Failure to make proper connections will result in improper operation. (See Fig. 26.)

3. Gas supply pressure to the furnace must be greater than

4.5--in. wc (0.16 psig ) but not exceed 14--in. wc (0.5 psig).

4. Check all manual-- reset switches for continuity.

5. Install blower compartment door. Door must be in place to operate furnace.

6. Replace outer door.

WARNING

CAUTION

Step 2 —Start--Up Procedures

WARNING

ELECTRICAL SHOCK HAZARD

Failure to follow this warning could result in personal injury, or death.

Blower access door switch opens 115-- v power to control. No component operation can occur unless switch is closed. Caution must be taken when manually closing this switch for service purposes.

3. To Begin Component Self--Test: Remove blower access door. Disconnect the thermostat R lead from the furnace control board. Manually close the blower door switch. Short (jumper) the COM--24v terminal on control to the TEST/TWIN 3/16-- inch quick connect terminal on control until LED goes out (approximately 2 sec). Gas valve and humidifier will not be turned on. (See Fig. 25.)

NOTE: The furnace control allows all components, except the gas valve, to be run for short period of time. This feature helps diagnose a system problem in case of a component failure. Component test feature will not operate if any thermostat signal is present at the control.

Component test sequence is as follows: Refer to service label attached to furnace or see Fig. 50.

a. LED will display previous status code 4 times.

b. Inducer motor starts and continues to run until Step f

of component test sequence.

c. Hot surface igniter is energized for 15 sec., then off.

d. Blower motor operates on HEAT speed for 10 sec.

e. Blower motor operates on COOL speed for 10 sec.

f. Inducer motor stops.

g. Reconnect R lead to furnace control board, release

blower door switch and re--install blower door.

4. Operate furnace per instruction on door.

5. Verify furnace shut down by lowering thermostat setting below room temperature.

6. Verify furnace restarts by raising thermostat setting above room temperature.

WARNING

PG8J/M

FIRE AND EXPLOSION HAZARD

Failure to follow this warning could result in personal injury, death and or property damage.

Never purge a gas line into a combustion chamber. Never use matches, candles, flame, or other sources of ignition for the purpose of checking leakage. Use a soap--and--water solution to check for leakage.

1. Purge gas lines after all connections have been made.

2. Check gas lines for leaks.

Page 32

PG8J/M

SEE NOTES: 1,2,4,7,8,9 on the page following these figures

SEE NOTES: 1,2,4,5,7,8,9 on the page following these figures

Fig. 33 --- Upflow Application--Vent Elbow Up

SEE NOTES: 1,2,3,4,7,8,9 on the pages following these figures

Fig. 34 --- Upflow Application--Vent Elbow Right

A03208

A03209

A03211

Fig. 36 --- Downflow Application--Vent Elbow Up

SEE NOTES: 1,2,4,5,6,7,8,9,10 on the page following these figures

A03207

Fig. 37 --- Downflow Application--Vent Elbow Left then Up

SEE NOTES:1,2,3,4,5,7,8,9 on the page following these figures

Fig. 35 --- Downflow Application--Vent Elbow Up then Left

A03210

SEE NOTES:1,2,3,4,5,7,8,9 on the page following these figures.

Fig. 38 --- Downflow Application--Vent Elbow Up then Right

A03212

Page 33

SEE NOTES: 1,2,4,7,8,9 on the page following these figures

A03213

Fig. 39 --- Horizontal Left Application--Vent Elbow Left

SEE NOTES: 1,2,4,5,7,8,9 on the page following these figures

A03214

Fig. 40 --- Horizontal Left Application--Vent Elbow Right

then Up

SEE NOTES: 1,2,4,7,8,9 on the page following these figures

A03218

Fig. 43 --- Horizontal Right Application--Vent Elbow Right

SEE NOTES: 1,2,4,5,7,8,9 on the page following these figures

A03219

Fig. 44 --- Horizontal Right Application--Vent Elbow Left

then Up

PG8J/M

SEE NOTES: 1,2,4,5,7,8,9 on the page following these figures

Fig. 41 --- Horizontal Left Application--Vent Elbow Up

SEE NOTES: 1,2,4,5,7,8,9 on the page following these figures

Fig. 42 --- Horizontal Left Application--Vent Elbow Right

A03215

A03216

SEE NOTES: 1,2,4,5,7,8,9

A02068

Fig. 45 --- Horizontal Right Application--Vent Elbow Left

For common vent, vent connector sizing and vent material:

United States----Use the NFGC Canada -- -- use the NSCNGPIC

2. Immediately increase to 5--in. or 6-- in. vent connector outside

furnace casing when 5--in. vent connector is re quired, refer to Note 1 above.

3. Side outlet vent for upflow and downflow installations must use

Type B vent immediately after exiting the furnace, except when KGAVG0101DFG, Downflow Vent Guard Kit, is used in the downflow position

4. Type--B vent where required, refer to the Note 1 above.

5. Four--in. single-- wall (26 ga. minimum) vent must be used inside

furnace casing and when the KGAVG0101DFG Downflow Vent Guard Kit is used external to the furnace.

6. Accessory Down flow Vent Gua rd Kit, KGAVG0101DFG re-

quired in downflow installations with lower vent configuration.

7. Chimney Adapter Kit may be required for exterior masonry

chimney applications. Refer to Chimney Adapter Kit, KGACA02014FC or KGACA02015FC, for sizing and complete application details.

Page 34

CAUTION!! FOR THE FOLLOWING APPLICATIONS, USE THE MINIMUM VERTICAL VENT HEIGHTS AS SPECIFIED

BELOW.

FOR ALL OTHER APPLICATIONS, FOLLOW EXCLUSIVELY THE NATIONAL FUEL GAS CODE.

FURNACE

ORIENTATION

Downflow

Horizontal Left

Downflow

* 4 in. inside casing or vent guard ** Including 4 in. vent section (s)

NOTE: All vent configurations mu st also meet National Fuel Gas Code venting requirements NFGC

VENT

ORIENTATION

Vent elbow left, then

up Fig. 36

Vent elbow right,

then up Fig. 39

Vent Elbow up Fig.

Vent elbow right Fig.

Vent elbow up then

left Fig. 34

Vent elbow up, then

right Fig. 37

FURNACE

INPUT(BTUH/HR)

154,000 132,000

110,000(036/--- 12 only)

154,000 132,000 5 7

154,000 5 7

110,000 (036/ --- 12 only) 5 10

MINIMUM VENT

DIAMETER (IN.)*

5 12

MINIMUM VERTICAL VENT

HEIGHT (FT.)**

8. Secure vent connector to furnace elbow with (2) corrosion--res-

PG8J/M

istant sheet metal screws, spaced approximately 180° apart.

9. Secure all other single wall vent connector joints with (3) corro-

sion resistant screws spaced approximately 120° apart. Secure Type--B vent connectors per vent connector manufacturer’s recommendations.

10. The total height of the vent and connector shall be at least seven

ft. for the 154,000 Btuh gas input rate model when installed in a downflow application with furnace elbow turned to left side with the connector elbow outside furnace casing pointing upward. (See Fig. 36.)

Step 3 —Adjustments

FIRE HAZARD

Failure to follow this warning could result in injury, death and/or property damage.

DO NOT bottom out gas valve regulator adjusting screw. This can result in unregulated manifold pressure and result in excess overfire and heat exchanger failures.

FURNACE DAMAGE HAZARD

Failure to follow this caution may result in reduced furnace life.

DO NOT redrill orifices. Improper drilling (burrs, out--of round holes, etc.) can cause excessive burner noise and misdirection of burner flames. This can result in flame impingement of heat exchangers, causing failures. (See Fig.

48.)

Furnace gas input rate on rating plate is for installations at altitudes up to 2000 ft. Furnace input rate must be within +/--2 percent of furnace rating plate input.

1. Determine the correct gas input rate.

In the U.S.A.:

The input rating for altitudes above 2,000 ft. must be reduced by 4 percent for each 1,000 ft. above sea level. For installations below 2000 ft., refer to the unit rating plate. For installations above 2000 ft., multiply the input on the rating plate by the derate multiplier in Table 8 for the correct input rate.

In Canada:

The input rating must be derated by 10 percent for altitudes of 2,000 ft. to 4,500 ft. above sea level by an autho-

WARNING

CAUTION

rized Gas Conversion Station or Dealer. To determine correct input rate for altitude, see example 1 and use 0.90 as derate multiplier factor.

TABLE 8—ALTITUDE DERATE MULTIPLIER FOR

U.S.A.

ALTITUDE PERCENT DERATE MULTIPLIER

(FT.) OF DERATE FACTOR*

0–2000 0 1.00 2001–3000 8–12 0.90 3001–4000 12–16 0.86 4001–5000 16–20 0.82 5001–6000 20–24 0.78 6001–7000 24–28 0.74 7001–8000 28–32 0.70 8001–9000 32–36 0.66

9001–10,000 36–40 0.62

* Derate mul tiplier factors are based on midpoint altitude for altitude range.

EXAMPLE 1:

88,000 BTUH INPUT FURNACE INSTALLED AT 4300 FT.

Furnace Input

Rate at Sea Level

X Derate Multiplier

Factor

= Furnace Input

Rate at

Installation

Altitude

88,000 X 0.90 = 79,200

2. Determine the correct orifice and manifold pressure adjustment. There are two different orifice and manifold adjustment tables. All models in all positions, except Low NOx models in downflow or horizontal positions, use Table 12 (22,000 Btuh/Burner). Low NOx models in the downflow or horizontal positions must use Table 13 (21,000 Btuh/Burner). See input listed on rating plate.

a. Obtain average yearly gas heat value (at installed alti-

tude) from local gas supplier.

b. Obtain average yearly gas specific gravity from local

gas supplier.

c. Find installation altitude in Table 12 or 13.

d. Find closest natural gas heat value and specific gravity

in Table 12 or 13.

e. Follow heat value and specific gravity lines to point of

intersection to find orifice size and manifold pressure settings for proper operation.

f. Check and verify burner orifice size in furnace.

NEVER ASSUME ORIFICE SIZE. ALWAYS CHECK AND VERIFY.

Page 35

g. Replace orifice with correct size if required by Table

12 or 13. Use only factory--supplied orifices. See EXAMPLE 2.

EXAMPLE 2: (0--2000 ft. altitude)

For 22,000 Btuh per burner application use Table 12. Heating value = 1000 Btuh/cu ft. Specific gravity = 0.62 Therefore: Orifice No. 43* Manifold pressure: 3.7 --in. wc *Furnace is shipped with No. 43 orifices. In this example all main burner orifices are the correct size and do not need to be changed to obtain proper input rate.

3. Adjust manifold pressure to obtain correct input rate. a. Turn gas valve ON/OFF switch to OFF.

b. Remove manifold pressure tap plug from gas valve.

(See Fig. 47.)

c. Connect a water column manometer or similar device

to manifold pressure tap.

d. Turn gas valve ON/OFF switch to ON.

e. Manually close blower door switch.

f. Set thermostat to call for heat.

g. Jumper R and W thermostat connections on furnace

control board to start furnace.

h. Remove regulator seal cap and turn regulator adjusting

screw counterclockwise (out) to decrease input rate of clockwise (in) to increase input rate.

i. Install regulator seal cap.

j. Leave manometer or similar device connected and

proceed to Step 4.

NOTE: DO NOT set manifold pressure less than 3.2--in wc or more than 3.8--in. wc for natural gas at sea level. If manifold pressure is outside this range, change main burner orifices or refer Table 12 or 13.

NOTE: If orifice hole appears damaged or it is suspected to have been redrilled, check orifice hole with a numbered drill bit of correct size. Never redrill an orifice. A burr--free and squarely aligned orifice hole is essential for proper flame characteristics.

4. Verify natural gas input rate by clocking meter.

NOTE: Gas valve regulator adjustment cap must be in place for proper input to be clocked.

a. Turn off all other gas appliances and pilots served by

the meter.

b. Run furnace for 3 minutes in heating operation.

c. Measure time (in sec) for gas meter to complete 1 re-

volution and note reading. The 2 or 5 cubic feet dial provides a more accurate measurement of gas flow.

d. Refer to Table 10 for cubic ft. of gas per hr.

e. Multiply gas rate (cu ft./hr) by heating value (Btu/cu

ft.) to obtain input.

If clocked rate does not match required input from Step 1, increase manifold pressure to increase input or decrease manifold pressure to decrease input. Repeat steps b through e until correct input is achieved. Reinstall regulator seal cap on gas valve.

5. Set temperature rise. The furnace must operate within the

temperature rise ranges specified on the furnace rating plate. Do not exceed temperature rise range specified on unit rating plate. Determine the temperature rise as follows:

NOTE: Blower access door must be installed when taking temperature rise reading. Leaving blower access door off will result in incorrect temperature measurements.

a. Place thermometers in return and supply ducts as close

to furnace as possible. Be sure thermometers do not

see radiant heat from heat exchangers. Radiant heat affects temperature rise readings. This practice is particularly important with straight--run ducts.

b. When thermometer readings stabilize, subtract return--

air temperature from supply--air temperature to determine air temperature rise.

NOTE: Blower access door must be installed for proper temperature rise measurement.

NOTE: If the temperature rise is outside this range, first check:

1.) Gas input for heating operation.

2.) Derate for altitude if applicable.

3.) Return and supply ducts for excessive restrictions causing static pressures greater than 0.50--in. wc.

4.) Dirty filter.

WARNING

ELECTRICAL SHOCK HAZARD

Failure to follow this warning could result in personal injury or death. Disconnect 115--v electrical power before changing speed tap.

c. Adjust air temperature rise by adjusting blower speed.

Increase blower speed to reduce temperature rise. Decrease blower speed to increase temperature rise.

d. Turn thermostat down below room temperature and

remove blower access door.

e. To change motor speed selection for heating, remove

blower motor lead from control HEAT terminal (See Fig. 25.) Select desired blower motor speed lead from one of the other terminals and relocate it to the HEAT terminal (See Table 9 for lead color identification). Reconnect original lead to SPARE terminal.

TABLE 9—SPEED SELECTION

COLOR SPEED AS SHIPPED

White Common BLW

Black High COOL

Yellow{ M e d --- H i g h SPARE

Blue* M e d --- L o w SPARE

Red* Low HEAT

* 1/5 HP motor models: BLUE to HEAT, RED to SPARE { Not available on 1/5 HP motors. NOTE: Continuous blower is the HEAT speed.

f. Repeat steps a through e.

g. When correct input rate and temperature rise is

achieved, turn gas valve ON/OFF switch to OFF.

h. Remove manometer or similar device from g as valve.

i. Reinstall manifold pressure tap plug in gas valve.

FIRE HAZARD

Failure to follow this warning could result in personal injury, death and/or property damage. Reinstall manifold pressure tap plug in gas valve to prevent gas leak.

j. Reinstall blower access door if removed.

k. Turn gas valve ON/OFF switch to ON.

WARNING

PG8J/M

Page 36

PG8J/M

A08411

Fig. 46 --- Wiring Diagram

Page 37

EXAMPLE:

THERMOSTAT SUBBASE TERMINALS WITH THERMOSTAT REMOVED (ANITICIPATOR, CLOCK, ETC., MUST BE OUT OF CIRCUIT.)

R Y W G

10 TURNS

FROM UNIT 24-V CONTROL TERMINALS

5.0 AMPS ON AMMETER 10 TURNS AROUND JAWS

HOOK-AROUND AMMETER

0.5 AMPS FOR THERMOSTAT

ANTICIPATOR SETTING

PG8J/M

Fig. 47 --- Gas Control Valve

BURNER

ORIFICE

Fig. 48 --- Orifice Hole

6. Set thermostat heat anticipator.

a. Mechanical thermostat -- Set thermostat heat anticipat-

or to match the amp. draw of the electrical components in the R--W circuit. Accurate amp. draw readings can be obtained at the wires normally connected to thermostat subbase terminals, R and W. The thermostat anticipator should NOT be in the circuit while measuring current. (1.) Remove thermostat from subbase or from wall. (2.) Connect an amp. meter as shown in Fig. 48 across the R and W subbase terminals or R and W wires at wall. (3.) Record amp. draw across terminals when furnace is in heating and after blower starts. (4.) Set heat anticipator on thermostat per thermostat instructions and install on subbase or wall.

b. Electronic thermostat: Set cycle rate for 4 cycles per

hr.

A06666

A93059

A96316

Fig. 49 --- Amp. Draw Check With Ammeter

CAUTION

FURNACE OVERHEATING HAZARD

Failure to follow this caution may result in reduced furnace life. Recheck temperature rise. It must be within limits specified on the rating plate. Recommended operation is at the midpoint of rise range or slightly above

7. Adjust blower off delay The blower off delay has 4 adjustable settings from 90 sec to 180 sec. The blower off delay jumpers are located on the furnace control board. (See Fig. 25.) To change the blower off delay setting, move the jumper from one set of pins on the control to the pins used for the selected blower off delay. Factory off delay setting is 120 sec.

8. Set airflow CFM for cooling Select the desired blower motor speed lead for cooling airflow. See Table 5--Air Delivery--CFM (With Filter). See Table 9 for lead color identification.

Step 4 —Check Safety Controls

The flame sensor, gas valve, and pressure switch were all checked in the Start-- up procedure section as part of normal operation.

1. Check Main Limit Switch(es) This control shuts off combustion control system and energizes air--circulating blower motor, if furnace overheats. By using this method to check limit control, it can be established that limit is functioning properly and will operate if there is a restricted duct system or motor failure. If limit control does not function during this test, cause must be determined and corrected.

a. Run furnace for at least 5 minutes.

b. Gradually block off return air with a piece of card-

board or sheet metal until the limit trips.

c. Unblock return air to permit normal circulation.

d. Burners will re-- light when furnace cools down.

2. Check draft safeguard switch. The purpose of this control is to cause the safe shutdown of the furnace during certain blocked vent conditions.

Page 38

PG8J/M

TABLE 10—GAS RATE (CU FT./HR)

SECONDS FOR 1

REVOLUTION

10 360 720 1800 50 72 144 360 11 327 655 1636 51 71 141 355 12 300 600 1500 52 69 138 346 13 277 555 1385 53 68 136 340 14 257 514 1286 54 67 133 333 15 240 480 1200 55 65 131 327 16 225 450 1125 56 64 129 321 17 212 424 1059 57 63 126 316 18 200 400 1000 58 62 124 310 19 189 379 947 59 61 122 305 20 180 360 900 60 60 120 300 21 171 343 857 62 58 116 290 22 164 327 818 64 56 112 281 23 157 313 783 66 54 109 273 24 150 300 750 68 53 106 265 25 144 288 720 70 51 103 257 26 138 277 692 72 50 100 250 27 133 267 667 74 48 97 243 28 129 257 643 76 47 95 237 29 124 248 621 78 46 92 231 30 120 240 600 80 45 90 225 31 116 232 581 82 44 88 220 32 113 225 563 84 43 86 214 33 109 218 545 86 42 84 209 34 106 212 529 88 41 82 205 35 103 206 514 90 40 80 200 36 100 200 500 92 39 78 196 37 97 195 486 94 38 76 192 38 95 189 474 96 38 75 188 39 92 185 462 98 37 74 184 40 90 180 450 100 36 72 180 41 88 176 439 102 35 71 178 42 86 172 429 104 35 69 173 43 84 167 419 106 34 68 170 44 82 164 409 108 33 67 167 45 80 160 400 110 33 65 164 46 78 157 391 112 32 64 161 47 76 153 383 116 31 62 155 48 75 150 375 120 30 60 150 49 73 147 367

SIZE OF TEST DIAL

1CuFt 2CuFt 5CuFt 1CuFt 2CuFt 5CuFt

SECONDS FOR 1

REVOLUTION

SIZE OF TEST DIAL

a. Verify vent pipe is cool to the touch.

b. Disconnect power to furnace and remove vent con-

nector from furnace vent elbow.

c. Restore power to furnace and set room thermostat

above room temperature.

d. After normal start--up, allow furnace to operate for 2

minutes, then block vent elbow in furnace 80 percent of vent area with a piece of flat sheet metal.

e. Furnace should cycle off within 2 minutes. If gas does

not shut off within 2 minutes, determine reason draft safeguard switch did not function properly and correct condition.

f. Remove blockage from furnace vent elbow.

g. Switch will auto--reset when it cools.

h. Re--install vent connector.

NOTE: Should switch remain open longer than 3 minutes, furnace control board will lockout the furnace for 3 hrs. To reset furnace control board, turn thermostat below room temperature or from HEAT to OFF and turn 115v power OFF, then back ON.

3. Check Pressure Switch This control proves operation of the draft inducer blower.

a. Turn off 115--v power to furnace.

b. Disconnect inducer motor lead wires from wire har-

ness.

c. Turn on 115--v power to furnace.

d. Set thermostat to “call for heat” and wait 1 minute.

When pressure switch is functioning properly, hot surface igniter should NOT glow and control diagnostic light flashes a status code 32. If hot surface igniter glows when inducer motor is disconnected, shut down furnace immediately.

e. Determine reason pressure switch did not function

properly and correct condition.

f. Turn off 115--v power to furnace.

g. Reconnect inducer motor wires, replace outer door,

andturnon115--vpower.

h. Blower will run for 90 sec before beginning the call

for heat again.

i. Furnace should ignite normally.

Step 5 —Checklist

1. Put away tools and instruments. Clean up debris.

2. Verify that blower OFF-- DELAY time is selected as desired.

3. Verify that blower and burner access doors are properly installed.

4. Cycle test furnace with room thermostat.

5. Check operation of accessories per manufacturer’s instructions.

6. Review User’s Guide with owner.

7. Attach literature packet to furnace.

TABLE 11—FILTER SIZE INFORMATION (IN.)

FURNACE

CASING

WIDTH

14--- 1/2 16 X 25 X 1 (1) 14 X 25 X 1 Cleanable*

17--- 1/2 16 X 25 X 1 (1) 16 X 25 X 1 Cleanable*

21 16 X 25 X 1 (1) 20 X 25 X 1 Cleanable*

24** 16 X 25 X 1 (1) 24 X 25 X 1 Cleanable*

* Recommended ** Some furnaces may h ave 2 filters.

Side Return

FILT E R SIZE

Bottom

Return

FILTE R

TYPE

Page 39

TABLE 12—ORIFICE SIZE* AND MANIFOLD PRESSURE FOR GAS INPUT RATE

(TABULATED DATA BASED ON 22,000 BTUH PER BURNER, DERATED 4 PERCENT FOR EACH 1000 FT. ABOVE SEA

LEVEL)

AVG.. GAS

ALTITUDE RANGE

(FT . )

U.S.A.

and

Canada

ALTITUDE RANGE

U.S.A.

and

Canada

ALTITUDE RANGE

U.S.A.

Only

ALTITUDE RANGE

U.S.A.

Only

* Orifice numbers 43 are factory installed.

0to

2000

(FT . )

U.S.A.

Altitudes

2001 to 3000 or Canada

Altitudes

2000 to

4500

(FT . )

3001 to

4000

(FT . )

4001 to

5000

HEAT VALUE

(BTUH/CU

FT.)

900 42 3.5 42 3.6 42 3.7 41 3.5 925 42 3.3 42 3.4 42 3.5 42 3.7 950 43 3.8 42 3.3 42 3.4 42 3.5

975 43 3.6 43 3.8 42 3.2 42 3.3 1000 43 3.5 43 3.6 43 3.7 43 3.8 1025 43 3.3 43 3.4 43 3.5 43 3.6 1050 44 3.6 43 3.2 43 3.4 43 3.5 1075 44 3.4 44 3.5 43 3.2 43 3.3 1100 44 3.3 44 3.4 44 3.5 43 3.2

AVG.. GAS

HEAT VALUE

(BTUH/CU

FT.)

800 42 3.4 42 3.5 42 3.6 42 3.7

825 42 3.2 42 3.3 42 3.4 42 3.5

850 43 3.7 43 3.8 42 3.2 42 3.3

875 43 3.5 43 3.6 43 3.7 43 3.8

900 43 3.3 43 3.4 43 3.5 43 3.6

925 43 3.1 43 3.2 43 3.3 43 3.4

950 43 2.9 43 3.0 43 3.1 43 3.2

975 43 2.8 43 2.9 43 3.0 43 3.1 1000 43 2.6 43 2.7 43 2.8 43 2.9

AVG. GAS HEAT VALUE (BTU/CU FT.)

775 42 3.2 42 3.3 42 3.4 42 3.5 800 43 3.6 43 3.8 42 3.2 42 3.3 825 43 3.4 43 3.5 43 3.7 43 3.8 850 43 3.2 43 3.3 43 3.4 43 3.6 875 43 3.0 43 3.1 43 3.3 43 3.4 900 43 2.9 43 3.0 43 3.1 43 3.2 925 43 2.7 43 2.8 43 2.9 43 3.0 950 43 2.6 43 2.7 43 2.8 43 2.8

AVG. GAS HEAT VALUE (BTU/CU FT.)

750 43 3.6 43 3.8 42 3.2 42 3.3 775 43 3.4 43 3.5 43 3.6 43 3.8 800 43 3.2 43 3.3 43 3.4 43 3.5 825 43 3.0 43 3.1 43 3.2 43 3.3 850 43 2.8 43 2.9 43 3.0 43 3.1 875 43 2.7 43 2.8 43 2.9 43 2.9 900 43 2.5 43 2.6 43 2.7 43 2.8 925 43 2.4 43 2.5 43 2.6 43 2.6

0.58 0.60 0.62 0.64

Orifice

No.

Orifice

No.

Orifice

No.

Orifice

No.

Manifold

Pressure

0.58 0.60 0.62 0.64 Manifold

Pressure

0.58 0.60 0.62 0.64 Manifold

Pressure

0.58 0.60 0.62 0.64 Manifold

Pressure

SPECIFIC GRAVITY OF NATURAL GAS

Orifice

No.

SPECIFIC GRAVITY OF NATURAL GAS

Orifice

No.

SPECIFIC GRAVITY OF NATURAL GAS

Orifice

No.

SPECIFIC GRAVITY OF NATURAL GAS

Orifice

No.

Manifold Pressure

Orifice

No.

Orifice

No.

Orifice

No.

Orifice

No.

Manifold

Pressure

Manifold

Pressure

Manifold

Pressure

Manifold

Pressure

Orifice

No.

Orifice

No.

Orifice

No.

Orifice

No.

Manifold Pressure

PG8J/M

Page 40

TABLE 12–ORIFICE SIZE* AND MANIFOLD PRESSURE FOR GAS INPUT RATE (CONTINUED)

(TABULATED DATA BASED ON 22,000 BTUH PER BURNER, DERATED 4 PERCENT FOR EACH 1000 FT. ABOVE SEA

LEVEL)

PG8J/M

ALTITUDE

RANGE (FT.)

U.S.A.

Only

ALTITUDE

RANGE (FT.)

U.S.A.

Only

ALTITUDE

RANGE (FT.)

U.S.A.

Only

ALTITUDE

RANGE (FT.)

U.S.A.

Only

5001 to

6000

6001 to

7000

7001 to

8000

8001 to

9000

AVG. GAS

HEAT VALUE

AT ALTITUDE

(BTU/CU FT.)

725 43 3.4 43 3.5 43 3.6 43 3.7

750 43 3.2 43 3.3 43 3.4 43 3.5

775 43 3.0 43 3.1 43 3.2 43 3.3

800 43 2.8 43 2.9 43 3.0 43 3.1

825 43 2.6 43 2.7 43 2.8 43 2.9

850 43 2.5 43 2.5 43 2.6 43 2.7

875 43 2.3 43 2.4 43 2.5 43 2.6

900 43 2.2 43 2.3 43 2.3 43 2.4

AVG. GAS HEAT VALUE AT ALTITUDE (BTU/CU FT.)

675 43 3.4 43 3.5 43 3.6 43 3.7

700 43 3.1 43 3.3 43 3.4 43 3.5

725 43 2.9 43 3.0 43 3.1 43 3.2

750 43 2.7 43 2.8 43 2.9 43 3.0

775 43 2.6 43 2.7 43 2.7 43 2.8

800 43 2.4 43 2.5 43 2.6 43 2.7

825 43 2.3 43 2.3 43 2.4 43 2.5

850 43 2.1 43 2.2 43 2.3 43 2.4

AVG. GAS HEAT VALUE AT ALTITUDE (BTU/CU FT.)

650 43 3.1 43 3.2 43 3.4 43 3.5

675 43 2.9 43 3.0 43 3.1 43 3.2

700 43 2.7 43 2.8 43 2.9 43 3.0

725 43 2.5 43 2.6 43 2.7 43 2.8

750 43 2.4 43 2.4 43 2.5 43 2.6

775 43 2.2 43 2.3 43 2.4 43 2.4

800 43 2.1 43 2.1 43 2.2 43 2.3

825 48 3.7 43 2.0 43 2.1 43 2.2

AVG. GAS HEAT VALUE AT ALTITUDE (BTU/CU FT.)

625 43 2.9 43 3.0 43 3.1 43 3.2

650 43 2.7 43 2.8 43 2.9 43 3.0

675 43 2.5 43 2.6 43 2.7 43 2.8

700 43 2.3 43 2.4 43 2.5 43 2.6

725 43 2.2 43 2.2 43 2.3 43 2.4

750 43 2.0 43 2.1 43 2.2 43 2.2

775 48 3.6 48 3.7 43 2.0 43 2.1

0.58 0.60 0.62 0.64

Orifice No.

Manifold Pressure

0.58 0.60 0.62 0.64

Manifold Pressure

0.58 0.60 0.62 0.64

Manifold Pressure

0.58 0.60 0.62 0.64

Manifold Pressure

SPECIFIC GRAVITY OF NATURAL GAS

Orifice No.

Manifold Pressure

SPECIFIC GRAVITY OF NATURAL GAS

Manifold Pressure

SPECIFIC GRAVITY OF NATURAL GAS

Manifold Pressure

SPECIFIC GRAVITY OF NATURAL GAS

Manifold Pressure

Orifice No.

Manifold Pressure

Orifice No.

Manifold Pressure

Page 41

TABLE 12–ORIFICE SIZE* AND MANIFOLD PRESSURE FOR GAS INPUT RATE (CONTINUED)

(TABULATED DATA BASED ON 22,000 BTUH PER BURNER, DERATED 4 PERCENT FOR EACH 1000 FT. ABOVE SEA

LEVEL)

ALTITUDE RANGE

(FT . )

U.S.A.

Only

9001 to

10,000

AVG. GAS

HEAT VALUE

AT ALTITUDE

(BTU/CU FT.)

600 43 2.7 43 2.8 43 2.9 43 3.0

625 43 2.5 43 2.6 43 2.6 43 2.7

650 43 2.3 43 2.4 43 2.4 43 2.5

675 43 2.1 43 2.2 43 2.3 43 2.3

700 48 3.7 43 2.0 43 2.1 43 2.2

725 48 3.5 48 3.6 48 3.7 43 2.0

0.58 0.60 0.62 0.64

Orifice No.

Manifold Pressure

SPECIFIC GRAVITY OF NATURAL GAS

Orifice No.

Manifold Pressure

Orifice No.

Manifold Pressure

Orifice No.

Manifold Pressure

PG8J/M

Page 42

TABLE 13—ORIFICE SIZE* AND MANIFOLD PRESSURE FOR GAS INPUT RATE

(TABULATED DATA BASED ON 21,000 BTUH PER BURNER, DERATED 4 PERCENT FOR EACH 1000 FT. ABOVE SEA

LEVEL)

SPECIFIC GRAVITY OF NATURAL GAS

ALTITUDE RANGE (FT.)

U.S.A. and

Canada

ALTITUDE RANGE (FT.)

PG8J/M

U.S.A. and Canada

ALTITUDE RANGE (FT.)

U.S.A. Only

ALTITUDE RANGE (FT.)

U.S.A. Only

0 to 2000

U.S.A.

Altitudes

2001 to 3000 or Canada

Altitudes

2000 to

4500

3001 to

4000

4001 to

5000

AVG. GAS HEAT VALUE (BTU/CU FT.)

900 42 3.2 42 3.3 42 3.4 42 3.5 925 43 3.7 43 3.8 42 3.2 42 3.3 950 43 3.5 43 3.6 43 3.7 43 3.8

975 43 3.3 43 3.4 43 3.5 43 3.7 1000 44 3.6 43 3.3 43 3.4 43 3.5 1025 44 3.4 44 3.6 43 3.2 43 3.3 1050 44 3.3 44 3.4 44 3.5 43 3.2 1075 45 3.8 44 3.2 44 3.3 44 3.4 1100 46 3.8 45 3.7 44 3.2 44 3.3

AVG. GAS HE AT VA LU E (BTU/CU FT.)

800 43 3.8 42 3.2 42 3.3 42 3.4

825 43 3.5 43 3.7 43 3.8 42 3.2

850 43 3.3 43 3.5 43 3.6 43 3.7

875 43 3.2 43 3.3 43 3.4 43 3.5

900 43 3.0 43 3.1 43 3.2 43 3.3

925 43 2.8 43 2.9 43 3.0 43 3.1

950 43 2.7 43 2.8 43 2.9 43 2.9

975 43 2.5 43 2.6 43 2.7 43 2.8 1000 43 2.4 43 2.5 43 2.6 43 2.7

AVG. GAS HE AT VA LU E (BTU/CU FT.)

775 43 3.5 43 3.7 43 3.8 42 3.2

800 43 3.3 43 3.4 43 3.5 43 3.7

825 43 3.1 43 3.2 43 3.3 43 3.4

850 43 2.9 43 3.0 43 3.1 43 3.2

875 43 2.8 43 2.9 43 3.0 43 3.1

900 43 2.6 43 2.7 43 2.8 43 2.9

925 43 2.5 43 2.6 43 2.7 43 2.7

950 43 2.4 43 2.4 43 2.5 43 2.6

AVG. GAS HE AT VA LU E (BTU/CU FT.)

750 43 3.3 43 3.4 43 3.5 43 3.6

775 43 3.1 43 3.2 43 3.3 43 3.4

800 43 2.9 43 3.0 43 3.1 43 3.2

825 43 2.7 43 2.8 43 2.9 43 3.0

850 43 2.6 43 2.7 43 2.8 43 2.8

875 43 2.4 43 2.5 43 2.6 43 2.7

900 43 2.3 43 2.4 43 2.5 43 2.5

925 43 2.2 43 2.2 43 2.3 43 2.4

0.58 0.60 0.62 0.64

Orifice No.

Manifold Pressure

0.58 0.60 0.62 0.64 Manifold

Pressure

0.58 0.60 0.62 0.64 Manifold

Pressure

0.58 0.60 0.62 0.64 Manifold

Pressure

Orifice No.

SPECIFIC GRAVITY OF NATURAL GAS

Orifice No.

SPECIFIC GRAVITY OF NATURAL GAS

Orifice No.

SPECIFIC GRAVITY OF NATURAL GAS

Orifice No.

Manifold Pressure

Orifice No.

Manifold Pressure

Orifice No.

Manifold Pressure

Page 43

TABLE 13—ORIFICE SIZE* AND MANIFOLD PRESSURE FOR GAS INPUT RATE (CONTINUED)

(TABULATED DATA BASED ON 21,000 BTUH PER BURNER, DERATED 4 PERCENT FOR EACH 1000 FT. ABOVE SEA

LEVEL)

ALTITUDE

RANGE (FT.)

U.S.

Only

ALTITUDE

RANGE (FT.)

U.S.

Only

ALTITUDE

RANGE (FT.)

U.S.

Only

ALTITUDE

RANGE (FT.)

U.S.

Only

5001 to

6000

6001 to

7000

7001 to

8000

8001 to

9000

AVG. GAS HEAT

VALUE AT ALTI-

TUDE (BTU/CU

FT.)

725 43 3.1 43 3.2 43 3.3 43 3.4 750 43 2.9 43 3.0 43 3.1 43 3.2 775 43 2.7 43 2.8 43 2.9 43 3.0 800 43 2.5 43 2.6 43 2.7 43 2.8 825 43 2.4 43 2.5 43 2.5 43 2.6 850 43 2.2 43 2.3 43 2.4 43 2.5 875 43 2.1 43 2.2 43 2.3 43 2.3 900 43 2.0 43 2.1 43 2.1 43 2.2

AVG. GAS HEAT

VALUE AT ALTITUDE (BTU/CU

FT.)

675 43 3.1 43 3.2 43 3.3 43 3.4 700 43 2.9 43 3.0 43 3.1 43 3.2 725 43 2.7 43 2.8 43 2.9 43 2.9 750 43 2.5 43 2.6 43 2.7 43 2.8 775 43 2.3 43 2.4 43 2.5 43 2.6 800 43 2.2 43 2.3 43 2.3 43 2.4 825 43 2.1 43 2.1 43 2.2 43 2.3 850 48 3.7 43 2.0 43 2.1 43 2.1

AVG. GAS HEAT

VALUE AT ALTITUDE (BTU/CU

FT.)

650 43 2.9 43 3.0 43 3.1 43 3.2 675 43 2.7 43 2.7 43 2.8 43 2.9 700 43 2.5 43 2.6 43 2.6 43 2.7 725 43 2.3 43 2.4 43 2.5 43 2.5 750 43 2.1 43 2.2 43 2.3 43 2.4 775 43 2.0 43 2.1 43 2.2 43 2.2 800 48 3.6 48 3.7 43 2.0 43 2.1 825 48 3.3 48 3.5 48 3.6 48 3.7

AVG. GAS HEAT

VALUE AT ALTITUDE (BTU/CU

FT.)

625 43 2.7 43 2.7 43 2.8 43 2.9 650 43 2.5 43 2.5 43 2.6 43 2.7 675 43 2.3 43 2.4 43 2.4 43 2.5 700 43 2.1 43 2.2 43 2.3 43 2.3 725 48 3.7 43 2.0 43 2.1 43 2.2 750 48 3.5 48 3.6 48 3.7 43 2.0 775 49 3.8 48 3.4 48 3.5 48 3.6

Orifice No.

0.58 0.60 0.62 0.64 Manifold

Pressure

0.58 0.60 0.62 0.64 Manifold

Pressure

0.58 0.60 0.62 0.64 Manifold

Pressure

0.58 0.60 0.62 0.64 Manifold

Pressure

SPECIFIC GRAVITY OF NATURAL GAS

Orifice No.

Manifold Pressure

SPECIFIC GRAVITY OF NATURAL GAS

Manifold Pressure

SPECIFIC GRAVITY OF NATURAL GAS

Manifold Pressure

SPECIFIC GRAVITY OF NATURAL GAS

Manifold Pressure

Orifice No.

Manifold Pressure

Orifice No.

Manifold Pressure

PG8J/M

Page 44

TABLE 13—ORIFICE SIZE* AND MANIFOLD PRESSURE FOR GAS INPUT RATE (CONTINUED)

(TABULATED DATA BASED ON 21,000 BTUH PER BURNER, DERATED 4 PERCENT FOR EACH 1000 FT. ABOVE SEA

LEVEL)

SPECIFIC GRAVITY OF NATURAL GAS

Orifice No.

Manifold Pressure

Orifice No.

Manifold Pressure

ALTITUDE RANGE

(FT . )

AVG. GAS

HEAT VALUE

AT ALTITUDE

(BTU/CU FT.)

0.58 0.60 0.62 0.64

Orifice No.

Manifold Pressure

600 43 2.4 43 2.5 43 2.6 43 2.7 625 43 2.3 43 2.3 43 2.4 43 2.5

U.S.A.

Only

9001 to

10,000

650 43 2.1 43 2.2 43 2.2 43 2.3 675 48 3.6 48 3.8 43 2.1 43 2.1 700 48 3.4 48 3.5 48 3.6 48 3.7 725 49 3.7 49 3.8 48 3.4 48 3.5

PG8J/M

If st atus code recal l is needed, b riefly r emove then reconnect one main limit wire to di splay stored status code. On RED LED boar ds do not remove power or blower door before initi ating status code recall. After status code r ecall is completed c omponent test will occur.

EACH OF THE FOLLOWING STATUS CODES IS A TWO DIGIT NUMBER WITH THE FIRST DIGIT DETERMINED BY THE NUMBER OF SHORT FLASHES AND THE SECOND DIGIT BY THE NUMBER OF LONG FLASHES.

11 NO PREVIOUS CODE - Stored status code is erased automatically after 72 hours. On

RED LED boards stored status codes can al so be erased when power (115 VAC or 24 VAC) to control is interrupted.

12 BLOWER ON AFTE R POWER UP (115 VAC or 24 VAC) -Blower runs f or 90 seconds,

if unit is powered up during a call for heat (R-W closed) or R-W opens during blower on-delay.

13 LIMIT CIRCUIT LOCKOUT - Lockout occurs if the limit, draft saf eguard, flame rollout, or

blocked vent switch (if used) is open longer than 3 minutes.

- Control will auto reset after three hours. - Refer to #33.

14 IGNITION LOCKOUT - Control will auto-reset after three hours. Refer to #34. 21 GAS HEATING LOCKOUT - Control will NOT auto reset.

Check for: - Mis-w ired gas valve -Defective control (valve relay)

22 ABNORMAL FLAME-PROVING SIGNAL - Flame is prove d while gas valve is de-

energized. Inducer will run until fault is cleared. Check for: - Leaky gas valve

- Stuck-open gas valve

23 PRESSURE S WITCH DID NOT OPEN Check for:

- Obstructed pressure tubing. - Pressure switch stuck cl osed.

24 SECONDARY VOLT AGE FUSE IS OPEN Check for:

- Short circuit in secondary voltage (24VAC) wiring.

LED CODE

CONTINUOUS OFF - Check for 115VAC at L1 and L2, and 24VAC at SEC-1 and SEC-2. CONTINUOUS ON - Control has 24VAC power. RAPID FLASHING - Line voltage (115VAC) polarity reversed. If twinned, r efer to twinning kit instructio ns.

COMPONENT TEST

To initiate the component test sequence, shut OFF the room thermostat or disconnect the "R" thermostat lead. Briefly short the TEST/TWIN terminal to the "Com 24V" terminal. Status LED will flash code and then turn ON the inducer motor. The inducer motor will run for the entire component test. The hot surface ignitor , blower motor fan speed (on AMBER LED boards only) blower motor-heat speed, and blower motor-cool speed will be turned ON for 10-15 seconds each. Gas Valve and Humidifier will not be turned on.

327596-101 REV. B

SERVICE

STATUS

31 PRESSURE SWITCH DID NOT CLOSE OR REOPENED - If open longer than five minutes,

inducer shuts off for 15 minutes before retry. Check for: - Excessive wind

- Proper vent sizing - Defective inducer motor

- Low inducer voltage (115VAC) - Defectiv e pressure switch

- Inadequate combustion air supply - Disconnected or obstructed pres sure tubing

- Low inlet gas pressure (if LGPS used) - Restricted vent If it opens during blower on-delay period, bl ower will come on for the selected blower off-delay.

33 LIMIT CIRCUIT FAULT - Indicates a limit, draft safeguard, flame rollout, or blocked vent

switch (if used) is open. Blower will run for 4 minutes or until open swi tch remakes whichever is longer. If open longer than 3 minutes, code changes to lockout #13. If open less than 3 minutes status code #33 continues to flash unti l blower shuts off. Flame rollout switch and BVSS require manual reset. Check for: - Restricted vent

- Proper vent sizing - Loo se blower wheel. - Excessive wind

- Dirty filter or restricted duct system.

- Defective blower motor or capacitor. - Defective switch or connections.

- Inadequate combustion air supply (Flame Roll-out Switch open).

34 IGNITION PROVI NG FAILURE - Control will try three more times before lockout #14

occurs. If flame signal lost during blower on-delay period, blower will come on for the selected blower off-delay. Check for: - Flame sensor must not be grounded

- Oxide buildup on flame sensor (clean with fine steel wool).

- Proper flame sense microamps (.5 micr oamps D.C. min., 4.0 - 6.0 nomina l).

- Gas valve defective or gas valve turned off - Manual valve shut-off

- Defective Hot Surface I gnitor - Control ground continuity

- Low inlet gas pressure - Inadequate flame carryover or rough ignition

- Green/Yellow wire MUST be connected to furnace sheet metal

45 CONTROL CIRCUITRY LOCKOUT Auto-reset after one hour lockout due to;

- Gas valve relay stuck open - Flame sense circuit failure - Software check error Reset power to clear lockout. Replace control if status code repeats.

Orifice No.

Manifold Pressure

Fig. 50 --- Service Label

A04223

Page 45

SERVICE AND MAINTENANCE

PROCEDURES

FIRE, EXPLOSION, ELECTRICAL SHOCK HAZARD

Failure to follow this warning could result in personal injury, death and/or property damage.

The ability to properly perform maintenance on this equipment requires certain knowledge, mechanical skills, tools, and equipment. If you do not possess these, do not attempt to perform any maintenance on this equipment other than those procedures recommended in the User¡¯s Manual.

ELECTRICAL SHOCK, FIRE OR EXPLOSION HAZARD

Failure to follow this warning could result in personal injury or death, or property damage.

Before servicing, disconnect all electrical power to furnace. Verify proper operation after servicing.

ELECTRICAL OPERATION HAZARD

Failure to follow this caution may result in improper furnace operation.

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

Step 1 —Introduction

GENERAL

These instructions are written as if the furnace is installed in an upflow application. An upflow furnace application is where the blower is located below the combustion and controls section of the furnace, and conditioned air is discharged upward. Since this furnace can be installed in any of the 4 positions shown in Fig. 4, you must revise your orientation to component location accordingly.

ELECTRICAL CONTROLS AND

ELECTRICAL SHOCK HAZARD

Failure to follow this warning could result in personal injury or death.

There may be more than one electrical supply to the furnace. Check accessories and cooling unit for additional electrical supplies that must be shut off during furnace servicing.

The electrical ground and polarity for 115--v wiring must be properly maintained. Refer to Fig. 26 for field wiring information and to Fig. 46 for furnace wiring information.

NOTE: If the polarity is not correct, the STATUS LED on the control will flash rapidly and prevent the furnace from heating. The control system also requires an earth ground for proper operation of the control and flame-- sensing electrode.

The 24--v circuit contains an automotive--type, 3 --amp. fuse located on the control. (See Fig. 25.) Any shorts of the 24--v

WARNING

CAUTION

WIRING

WARNING

wiring during installation, service, or maintenance will cause this fuse to blow. If fuse replacement is required, use ONLY a 3--amp. fuse. The control LED will display status code 24 when fuse needs to be replaced.

Proper instrumentation is required to service electrical controls. The control in this furnace is equipped with a Status Code LED (Light--Emitting Diode) to aid in installation, servicing, and troubleshooting. It can be viewed through the sight glass in blower access door. The furnace control LED is either ON continuously, rapid flashing, or a code composed of 2 digits. The first digit is the number of short flashes, the second digit is the number of long flashes.

For an explanation of status codes, refer to service label located on blower access door or Fig. 50 and the troubleshooting guide which can be obtained from your distributor. The furnace control will store 1 status code for 72 hrs.

See Fig. 54, a brief Troubleshooting Guide. For Controls With a RED

The stored status code will be erased from the control memory, if 115-- or 24--v power is interrupted.

1. To retrieve status code, proceed with the following:

NOTE: NO thermostat signal may be present at control, and all blower--OFF delays must be completed.

a. Leave 115--v power to furnace turned on.

b. Remove outer access door.

c. Look into blower access door sight glass for current

LED status. Do not remove blower access door or terminate 115--v power to control or status code will be lost.

d. BRIEFLY remove insulated terminal wire from the

draft safeguard (DSS) switch until LED goes out (1 to 2 sec), then reconnect it.

2. When above items have been completed, the LED flashes status code 4 times. Record this status code for further troubleshooting.

3. Component self--test will begin. Refer to component TEST section for complete test sequence.

4. Check LED status.

5. Refer to SERVICE label on front of the blower access door for more information.

6. Check LED status. If no previous faults in history, control will flash status code 11.

7. If LED status indicates proper operation, RELEASE BLOWER ACCESS DOOR SWITCH, reattach wire to R terminal on furnace control board, replace blower access door, and replace burner access door.

LED

Step 2 —Care and Maintenance

FIRE OR EXPLOSION HAZARD

Failure to follow this warning could result in personal injury, death and/or property damage.

Never store anything on, near, or in contact with the furnace, such as: 1. Spray or aerosol cans, rags, brooms, dust mops, vacuum cleaners, or other cleaning tools.

2. Soap powders, bleaches, waxes or other cleaning compounds, plastic or plastic containers, gasoline, kerosene, cigarette lighter fluid, dry cleaning fluids, or other volatile fluids.

3. Paint thinners and other painting compounds, paper bags, or other paper products.

WARNING

PG8J/M

Page 46

For continuing high performance and to minimize possible equipment failure, periodic maintenance must be performed on this equipment. Consult your local dealer about proper frequency of maintenance and the availability of a maintenance contract.

WARNING

ELECTRICAL SHOCK AND FIRE HAZARD

Failure to follow this warning could result in personal injury, death or property damage.

Turn off the gas and electrical supplies to the unit before performing any maintenance or service. Follow the operating instructions on the label attached to the furnace.

CARBON MONOXIDE POISONING AND FIRE HAZARD

Failure to follow this warning could result in personal

PG8J/M

injury, death and/or property damage.

Never operate unit without a filter or with filter access door removed.

WARNING

Media cabinet filter procedures:

NOTE: Media cabinet or 1 in. filter rack are accessories and are

not included from the factory with standard furnace model.

1. Turn off electrical supply to furnace before removing filter access door.

2. Remove filter cabinet door.

3. Slide filter out of cabinet.

4. If equipped with permanent, washable 1--inch filter, clean filter by spraying cold tap water through filter in opposite direction of airflow. Rinse filter and let dry. Oiling or coating of the filter is not recommended. See Table 11 for size information.

5. If equipped with factory-- specified disposable media filter, replace only with media filter having the same part number and size. For expandable replacement media, refer to the instructions included with the replacement media. If equipped with accessory KGAFR0301ALL external filter rack, See Table 11.

6. Slide filter into cabinet.

7. Replace filter cabinet door.

8. Turn on electrical supply to furnace.

BLOWER MOTOR AND

WHEEL

WARNING

CAUTION

CUT HAZARD

Failure to follow this caution may result in personal injury.

Sheet metal parts may have sharp edges or burrs. Use care and wear appropriate protective clothing, safety glasses and gloves when handling parts and servicing furnaces.

The minimum maintenance on this furnace is as follows:

1. Check and clean air filter each month or more frequently if required. Replace if torn.

2. Check blower motor and wheel for cleanliness each heating and cooling season. Clean as necessary.

3. Check electrical connections for tightness and controls for proper operation each heating season. Service as necessary.

4. Inspect burner compartment before each heating season for rust, corrosion, soot or excessive dust. If necessary, have furnace and burner serviced by a qualified service agency.

5. Inspect the vent pipe/vent system before each heating season for rust, corrosion, water leakage, sagging pipes or broken fittings. Have vent pipes/vent system serviced by a qualified service agency.

6. Inspect any accessories attached to the furnace such as a humidifier or electronic air cleaner. Perform any service or maintenance to the accessories as recommended in the accessory instructions.

CLEANING AND/OR REPLACING AIR FIL

The air filter arrangement will vary depending on the application. The filter is exterior to the furnace casing.

NOTE: If the filter has an airflow direction arrow, the arrow must point towards the blower.

CAUTION

CUT HAZARD

Failure to follow this caution may result in personal injury.

Sheet metal parts may have sharp edges or burrs. Use care and wear appropriate protective clothing, safety glasses and gloves when handling parts and servicing furnaces.

TER

ELECTRICAL SHOCK HAZARD

Failure to follow this warning could result in personal injury or death.

Blower access door switch opens 115-- v power to control. No component operation can occur unless switch is closed. Caution must be taken when manually closing this switch for service purposes.

NOTE: The blower wheel should not be dropped or bent as balance will be affected.

The following steps should be performed by a qualified service agency.

To ensure long life and high efficiency, clean accumulated dirt and grease from blower wheel and motor annually.

The inducer and blower motors are pre--lubricated and require no additional lubrication. These motors can be identified by the absence of oil ports on each end of the motor.

Clean blower motor and wheel as follows:

1. Turn off electrical supply to furnace.

2. Loosen the thumbscrew on outer door and remove outer door.

3. For downflow or horizontal furnaces having vent pipes within the furnace that pass in front of the blower access door:

a. Disconnect vent connector from furnace vent elbow.

b. Disconnect and remove short piece of vent pipe from

within furnace.

4. Remove 2 screws from blower access door and remove blower access door.

5. Disconnect blower leads from furnace control. Record wire color and location for reassembly. All other factory wires can be left connected, but field thermostat connections may need to be disconnected depending on their length and routing.

6. Remove 2 screws holding control box to blower shelf.

7. Hang control box from front of furnace casing and away from blower compartment.

8. Remove 2 screws holding blower assembly to blower deck and slide blower assembly out of furnace.

Page 47

9. Clean blower wheel and motor using a vacuum with soft brush attachment. Blower wheel blades may be cleaned with a small paint or flux brush. Do not remove or disturb balance weights (clips) on blower wheel blades.

10. Vacuum any loose dust from blower housing, wheel and motor.

11. If a greasy residue is present on blower wheel, remove wheel from the blower housing and wash it with an appropriate degreaser. To remove wheel:

NOTE: Before disassembly, mark blower motor, and blower housing so motor and each arm is positioned at the same location during reassembly.

a. Disconnect capacitor wires and ground wire attached

to blower housing.

b. Remove screws securing cutoff plate and remove

cutoff plate from housing.

c. Loosen set screw holding blower wheel on motor shaft

(160+/--20 in.--lb. when reassembling).

d. Remove bolts holding motor to blower housing and

slide motor out of wheel (40+/--10 in.--lb. when reassembling).

e. Remove blower wheel from housing.

f. Clean wheel and housing.

12. Reassemble motor and blower by reversing steps 11f through 11a, finishing with 11a. Be sure to reattach ground wire to the blower housing.

13. Verify that blower wheel is centered in blower housing and set screw contacts the flat portion of the motor shaft. Loosen set screw on blower wheel and reposition if necessary.

14. Spin the blower wheel by hand to verify that the wheel does not rub on the housing.

15. Reinstall blower assembly in furnace.

16. Reinstall control box assembly in furnace.

CAUTION

UNIT DAMAGE HAZARD

Failure to follow this caution may result in shortened heat exchanger life.

Heating fan speed(s) MUST be adjusted to provide proper air temperature rise as specified on the rating plate. Recommended operation is at the midpoint of the rise range or slightly above. Refer to SET TEMPERATURE RISE under START--UP, ADJUSTMENT, and SAFETY CHECK.

NOTE: Refer to Table 9 for motor speed lead relocation if leads were not identified before disconnection.

17. Reconnect blower leads to furnace control. Refer to furnace wiring diagram, and connect thermostat leads if previously disconnected.

18. To check blower for proper rotation:

a. Turn on electrical supply.

b. Manually close blower access door switch.

NOTE: If thermostat terminals are jumpered at the time blower access door switch is closed, blower will run for 90 sec before beginning a heating or cooling cycle.

c. Perform component self--test as shown at the bottom

of the SERVICE label, located on the front of blower access door.

d. Verify blower is rotating in the correct direction

ELECTRICAL SHOCK HAZARD

Failure to follow this warning could result in personal injury, or death.

Blower access door switch opens 115--v power to furnace control. No component operation can occur unless switch is closed. Exercise caution to avoid electrical shock from exposed electrical components when manually closing this switch for service purposes.

19. If furnace is operating properly, RELEASE BLOWER ACCESS DOOR SWITCH. Remove any jumpers or reconnect any disconnected thermostat leads. Replace blower access door.

20. Downflow or horizontal furnaces with vent pipe through furnace only:

a. Install and connect short piece of vent pipe inside fur-

nace to existing vent.

b. Connect vent connector to vent elbow.

21. Reinstall casing door.

22. Turn on gas supply and cycle furnace through one complete heating and cooling cycle. Verify the furnace temperature rise as shown in Adjustments Section. Adjust temperature rise as shown in Adjustments Section. If outdoor temperature is below 70_F, turn off circuit breaker to outdoor unit before running furnace in the cooling cycle. Turn outdoor circuit breaker on after completing cooling cycle.

CLEANING HEAT

The following steps should be performed by a qualified service agency:

NOTE: If the heat exchangers get a heavy accumulation of soot

and carbon, they should be replaced rather than trying to clean them thoroughly. A heavy build--up of soot and carbon indicates that a problem exists which needs to be corrected, such as improper adjustment of manifold pressure, insufficient or poor quality combustion air, incorrect size or damaged manifold orifice( s), improper gas, or a restricted heat exchanger. Action must be taken to correct the problem.

If it becomes necessary to clean the heat exchangers because of dust or corrosion, proceed as follows:

1. Turn OFF gas and electrical power to furnace.

2. Remove outer access door.

3. Disconnect vent connector from furnace vent elbow.

4. For downflow or horizontal furnace having an internal vent pipe, remove internal vent pipe within the casing.

5. Disconnect wires to the following components. Mark wires to aid in reconnection of (be careful when disconnecting wires from switches because damage may occur):

a. Draft safeguard switch.

b. Inducer motor.

c. Pressure switch(es).

d. Limit overtemperature switch.

e. Gas valve.

f. Hot surface igniter.

g. Flame--sensing electrode.

h. Flame rollout switches.

i. Remove NOx baffles on low NOx models.

WARNING

EXCHANGER

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Page 48

9/32˝

5/16˝

PG8J/M

Fig. 51 --- Igniter Position--Side View

1-7/8”

Fig. 52 --- Igniter Position--Top View

Fig. 53 --- Cleaning Heat Exchanger Cell

6. Remove screws that fasten the collector box assembly to the cell panel. Be careful not to damage the collector box. Inducer assembly and elbow need not be removed from collector box.

7. Disconnect gas line from gas manifold.

8. Remove the 5 screws that attach the burner assembly to the cell panel. The gas valve and individual burners need not be removed from support assembly.

NOTE: Be very careful when removing burner assembly to avoid breaking igniter. See Fig. 51 and 52 for correct igniter location.

9. Using field--provided 25--caliber rifle cleaning brush, 36--in. long, 1/4 in. diameter steel spring cable, a variable speed, reversible electric drill, and vacuum cleaner, clean cells as follows:

a. Remove metal screw fitting from wire brush to allow

insertion into cable.

b. Insert the twisted wire end of brush into end of spring

cable, and crimp tight with crimping tool or crimp by

A05025

A05026

A01050

striking with ball--peen hammer. TIGHTNESS IS VERY IMPORTANT.

NOTE: The materials needed in item 9 can usually be purchased at local hardware stores.

(1.) Attach variable--speed, reversible drill to the end

of spring cable (end opposite brush).

(2.) Insert brush end of cable into the outlet opening

of cell and slowly rotate with drill. DO NOT force cable. Gradually insert cable into upper pass of cell. (See Fig. 60.)

(3.) Work cable in and out of cell 3 or 4 times to ob-

tain sufficient cleaning. DO NOT pull cable with great force. Reverse drill and gradually work cable out.

(4.) Insert brush end of cable in burner inlet opening

of cell, and proceed to clean 2 lower passes of cell in same manner as upper pass.

(5.) Repeat foregoing procedures until each cell in

furnace has been cleaned.

(6.) Using vacuum cleaner, remove residue from each

cell.

(7.) Using vacuum cleaner with soft brush attachment,

clean burner assembly.

(8.) Clean flame sensor with fine steel wool.

(9.) Install NOx baffles (if removed).

(10.) Reinstall burner assembly. Center burners in cell

openings.

10. Remove old sealant from cell panel and collector box flange.

11. Spray releasing agent on the heat exchanger cell panel where collector box assembly contacts cell panel.

NOTE: A releasing agent such as cooking spray or equivalent (must not contain corn or canola oil, aromatic or halogenated hydrocarbons or inadequate seal may occur) and RTV sealant (G.E. 162, 6702, or Dow--Corning 738) are needed before starting installation. DO NOT substitute any other type of RTV sealant. G.E. 162 (P771--9003) is available through RCD in 3--oz tubes.

12. Apply new sealant to flange of collector box and attach to cell panel using existing screws, making sure all screws are secure.

13. Reconnect wires to the following components. (Use connection diagram on wiring label, if wires were not marked for reconnection locations.):

a. Draft safeguard switch.

b. Inducer motor.

c. Pressure switch(es).

d. Limit over--temperature switch.

e. Gas valve.

f. Hot surface igniter. g. Flame--sensing electrode.

h. Flame rollout switches.

i. Install NOx baffles (if removed).

14. Reinstall internal vent pipe, if applicable.

15. Reinstall vent connector on furnace vent elbow. Securely fasten vent connector to vent elbow with 2 field--supplied, corrosion--resistant, sheet metal screws located 180¡ã apart.

16. Replace blower access door only, if it was removed.

17. Set thermostat above room temperature and check furnace for proper operation.

18. Verify blower airflow and speed changes between heating and cooling.

Page 49

FIRE OR EXPLOSION HAZARD

Failure to follow this warning could result in personal injury, death and/or property damage.

Never use a match or other open flame to check for gas leaks. Use a soap-- and--water solution.

19. Check for gas leaks.

20. Replace outer access door.

WARNING

Step 3 —Sequence of Operation

NOTE: Furnace control must be grounded for proper operation

or control will lock out. Control is grounded through green/yellow wire routed to gas valve and manifold bracket screw.

Using the schematic diagram in Fig. 46, follow the sequence of operation through the different modes. Read and follow the wiring diagram very carefully.

NOTE: If a power interruption occurs during a call for heat (W), the control will start a 90--sec blower--only ON period two seconds after power is restored, if the thermostat is still calling for gas heating. The red LED light will flash code 12 during the 90--sec period, after which the LED will be ON continuous, as long as no faults are detected. After the 90--sec period, the furnace will respond to the thermostat normally.

The blower door must be installed for power to be conducted through the blower door interlock switch ILK to the furnace control CPU, transformer TRAN, inducer motor IDM, blower motor BLWM, hot--surface igniter HSI, and gas valve GV.

1. Heating (See Fig. 26 for thermostat connections.) The wall thermostat “calls for heat” closing the R-- to--W circuit. The furnace control performs a self--check, verifies the pressure switch contacts PRS are open, and starts the inducer motor IDM.

a. Inducer Prepurge Period-- As the inducer motor

IDM comes up to speed, the pressure switch contacts PRS close, 24 VAC power is supplied for a field installed humidifier at the HUM terminal and the control begins a 15--sec prepurge period.

b. Igniter Warm--Up-- At the end of the prepurge period,

the Hot--Surface igniter HSI is energized for a 17--second igniter warm--up period.

c. Trial--for--Ignition Sequence-- When the igniter

warm-- up period is completed, the main gas valve relay contacts GVR close to energize the gas valve GV, the gas valve opens, The gas valve GV permits gas flow to the burners where it is ignited by the HSI. Five seconds after the GVR closes, a 2--second flame proving period begins. The HSI igniter will remain energized until the flame is sensed or until the 2--second flame proving period begins.

d. Flame--Proving-- When the burner flame is proved at

the flame--proving sensor electrode FSE, the furnace control CPU begins the blower--ON delay period and continues to hold the gas valve GV open. If the burner flame is not proved within two seconds, the control CPU will close the gas valve GV, and the control CPU will repeat the ignition sequence for up to three more Trials--For--Ignition before going to Ignition--Lockout. Lockout will be reset automatically after three hours or by momentarily interrupting 115 vac power to the furnace, or by interrupting 24 vac power at SEC1 or SEC2 to the furnace control CPU (not at W, G, R, etc.).

If flame is proved when flame should not be present, the furnace control CPU will lock out of Gas--Heating mode and operate the inducer motor IDM until flame is no longer proved.

e. Blower--On Delay-- If the burner flame is proven, the

blower motor is energized on HEAT speed 25 sec after the gas valve GV is energized. Simultaneously, the electronic air cleaner terminal EAC--1 is energized and remains energized as long as the blower motor BLWM is energized.

f. Blower--Off Delay-- When the thermostat is satisfied,

the R--to--W circuit is opened, de--energizing the gas valve GV, stopping gas flow to the burners, and de-energizing the humidifier terminal HUM. The inducer motor IDM will remain energized for a 5--second post--purge period. The blower motor BLWM and air cleaner terminal EAC--1 will remain energized for 90, 120, 150, or 180 seconds (depending on the blower-OFF delay selection). The furnace control CPU is factory--set for a 120--second blower--OFF delay.

2. Cooling Mode (See Fig. 26 for thermostat connections.) The thermostat closes the R--to--G-- and-- Y circuits. The R--to--Y circuit starts the outdoor unit, and the R--to--G and Y circuits start the furnace blower motor BLWM on COOL speed. The electronic air cleaner terminal EAC-- 1 is energized with 115 vac when the blower motor BLWM is operating. When the thermostat is satisfied, the R-- to--G--and--Y circuits are opened. The outdoor unit will stop, and the furnace blower motor BLWM will continue operating on the COOL speed for an additional 90 sec. Cut jumper J2 to reduce the cooling off--delay to 5 sec. (See Fig. 25.)

3. Continuous Blower Mode When the R--to--G circuit is closed by the thermostat, the blower motor BLWM will operate on continuous--blower speed (same as HEAT speed). Terminal EAC--1 is energized as long as the blower motor BLWM is energized. During a call for heat, the blower BLWM will stop during igniter warm--up (17 sec), ignition, and blower--ON delay (25 sec), allowing the furnace heat exchangers to heat up more quickly, then restarts at the end of the blower-- ON delay period at HEAT speed. When the thermostat “calls for cooling”, the blower motor BLWM will operate at COOL speed. When the thermostat is satisfied, the blower motor BLWM will operate an additional 90 sec, on COOL speed before reverting back to continuous blower speed. When the R--to--G circuit is opened, the blower motor BLWM will continue operating for an additional 5 sec, if no other function requires blower motor BLWM operation.

4. Heat Pump When installed with a heat pump, the furnace control automatically changes the timing sequence to avoid long blower off times during demand defrost cycles. When the R--to--Wand-- Y or R--to--W--and--Y--and--G circuits are energized the furnace control CPU will continue to turn on the blower motor BLWM at HEAT speed, and begin a heating cycle. The blower motor BLWM will remain on until the end of the prepurge period, then shut off for 24 sec then come back on at HEAT speed. When the W input signal disappears, the furnace control begins a normal inducer post-- purge period and the blower switches to COOL speed after a 3 sec delay. If the R--to--W--and-Y--and--G signals disappear at the same time, the blower motor BLWM will remain on for the selected blower-OFF delay period. If the R --to-- W --and-- Y signals disappear, leaving the G signal, the blower motor BLWM will

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Page 50

continue running the blower motor at HEAT speed after the selected blower--OFF delay period is completed.

Step 4 —Wiring Diagrams

Refer to Fig. 24 and 45 for wiring diagrams.

Step 5 —Troubleshooting

Refer to the service label. (See Fig. 50–Service Label.) The Troubleshooting Guide can be a useful tool in isolating furnace operation problems. Beginning with the word Start, answer each question and follow the appropriate arrow to the next item. The Guide will help to identify the problem or failed component. After replacing any component, verify correct operation sequence.

PG8J/M

Page 51

A02106a

Is door switch closed?

YES

Is circuit breaker closed?

Is there 115V going to switch?

YES

Check for continuity in wire from circuit breaker

to furnace.

Replace door switch.

Is 24V present at W, Y1 (if present), Y/Y2 or

G thermostat terminals on the furnace control?

YES

Disconnect all the thermostat wires from the

furnace control.

Check room thermostat or

Close circuit breaker and go back to START.

interconnecting cable.

Does the problem repeat when using

a jumper wire?

YES

The thermostat is not compatible with the

furnace control. Either install a ballast resistor,

connect the Com24V thermostat terminal to

the thermostat, or replace the thermostat.

PG8J/M

YES

Replace transformer.

Does the control respond to W, Y1 (if present),

Y/Y2, and G (24V) thermostat signals?

Run system through a heating or cooling cycle

to check operation. Status codes are erased

after 72 hours. On RED LED boards stored

status codes can also be erased whenever

(115V or 24V) is interrupted.

Replace furnace control.

YES

Is there 115V at L1 and L2?

YES

START

Is LED status light on?

YES

Is there 24V at SEC-1 and SEC-2?

Replace furnace control.

Check for correct line voltage polarity. If units

are twinned, check for proper low-voltage

(24V) transformer phasing.

YES

Is LED status light blinking rapidly without a

pause?

To recall status code briefly remove and reconnect one RED wire from the draft

safeguard switch to display stored status code. On RED LED control do not

remove power or blower access panel before initiating status code recall. You

can also recall the previous status code by momentarily shorting the TEST/TWIN

terminal to Com24V terminal until the LED goes out. LED will flash the status

code of the previous fault or status code #11 (1 short and 1 long flash) if there

was no previous fault. After the control repeats the code 4 times, the control

will go through a brief component test sequence. The inducer will start and run

for the entire component test. The HSI, blower motor FAN speed (AMBER LED

YES

Is LED status light blinking ON/OFF slowly

with a combination of short and long flashes?

Determine status code. The status code is a

2 digit number with the first digit determined

by the number of short flashes and the second

Was there a previous status code

boards only) HEAT speed, and COOL speed will run for 10 – 15 seconds each.

Gas valve and humidifier will not be turned on.

digit by the number of long flashes?

other than #11?

YES

Go to section below for the status code that

was flashed.

Page 52

Auto-reset after 1 hour lockout due to:

45 CONTROL CIRCUITRY LOCKOUT

- Flame circuit failure.

- Gas valve relay stuck open.

- Software check error.

Reset power to clear lockout. Replace

control if code repeats.

Replace furnace control.

Check for continuity in the harness and igniter.

Replace defective component.

Check connections. If OK, replace control.

Check that all gas valves are turned on.

Replace valve.

Check for:

- Inadequate flame carryover or rough

ignition.

- Low inlet gas pressure.

(.045 nominal)

- Proper firing rate.

- Blocked or incorrect carry- over gap.

Allow blower to come on and repeat test to

check for intermittent operation.

Check connections and retry. If current is

near typical value (4.0-6.0 nominal) and

burners will not stay on, replace control.

Replace electrode.

Replace furnace control.

PG8J/M

OR REOPENED  If open longer than 5

minutes, inducer shuts off for 15 minutes

31 PRESSURE SWITCH DID NOT CLOSE

Unplug igniter harness from control and initiate

another component test sequence. Check

before retry. If opens dur ing blower on-

delay period, blower will come on for the

selected blower off-delay. Check for:

tubing.

- Proper vent sizing.

- Low inlet gas pressure (if LGPS used).

- Inadequate combustion air supply.

- Disconnected or obstructed pressure

- Low inducer voltage (115V).

YES

for 115V between pin 1 and NEUTRAL-L2 on

the control. Was 115V present for the 15

second period?

Reconnect the R thermostat lead and set

thermostat to call for heat. Connect voltmeter

across gas valve connections. Does gas valve

- Defective inducer motor.

- Defective pressure switch.

- Excessive wind.

- Restricted vent.

limit, draft safeguard, flame rollout, or

blocked vent shutoff switch* (if used) is

open. Blower will run for 4 minutes or

33 LIMIT CIRCUIT FAULT  Indicates the

receive 24V?

until open switch remakes whichever is

YES

Does gas valve open and allow gas to flow?

longer. If open longer than 3 minutes,

code changes to lockout #13. If open

less than 3 min. status code #33

continues to flash until blower shuts off.

YES

Flame rollout switch and BVSS requires

manual reset. Check for:

- Dirty filter or restricted duct system.

YES

Do the main burners ignite?

- Defective blower motor or capacitor.

- Loose blower wheel.

- Defective switch or connections.

YES

Do the main burners stay on?

(flame rollout switch open).

- Inadequate combustion air supply

- Restricted vent.

- Proper vent sizing.

- Excessive wind.

YES

Repeat call for heat and check flame sensor

current during trial for ignition period. Is the

DC microamps below 0.5?

is not sensed during the trial for ignition

34 IGNITION PROVING FAILURE  If flame

Clean flame sensor with fine steel wool and

YES

period, the control will repeat the ignition

sequence 3 more times before lockout

#14 occurs. If flame signal is lost during

the blower on-delay period, blower will

come on for the selected blower off-delay.

YES

recheck current. Nominal current is 4.0 to 6.0

microamps.

Check the following items first before

proceeding to the next step.

Is current near typical value?

to furnace sheet metal.

- Gas valve turned off.

- Green/Yellow wire MUST be connected

- Flame sensor must not be grounded.

To determine whether the problem is in

the gas valve, igniter, or flame sensor the

- Manual shut-off valve.

system can be operated in the component

YES

Will main burners ignite and stay on?

test mode to check the igniter. First

remove the R thermostat connection from

Fixed.

the control and initiate the component

test sequence. Does the igniter glow

orange/white by the end of the 15 second

warm-up period?

Troubleshooting Guide

Fig. 54

are erased after 72 hours. On RED LED

boards stored status codes can also be

erased whenever power (115V or 24V)

is interrupted. Run system through a

heating or cooling cycle to check system.

(115V OR 24V)  Normal operation.

Blower runs for 90 seconds, if unit is

powered up during a call for heat (R-W

closed) or when (R-W opens) during the

blower on-delay period.

occurs if the limit, draft safeguard, flame

rollout, or blocked vent switch*(if used) is

open longer than 3 minutes. Control will

auto-reset after 3 hours. See code 33.

ignite gas and prove flame in 4 attempts.

Control will auto-reset after 3 hours.

See status code 34.

power and wait 5 minutes to retry.

Check for:

- Stuck closed gas valve relay on control.

- Miswire or short to gas valve wire.

Flame is proved while gas valve is de-

11 NO PREVIOUS CODE  Stored codes

12 BLOWER ON AFTER POWER UP 

13 LIMIT CIRCUIT LOCKOUT  Lockout

14 IGNITION LOCKOUT  System failed to

21 GAS HEATING LOCKOUT  Turn off

22 ABNORMAL FLAME-PROVING SIGNAL

Printed in U.S.A. Edition Date: 07/08

Manufacturer reserves the righ t to change, at any time, sp ecifications and designs without notice an d without obligatio ns.

energized. Inducer will run until fault is

cleared. Check for:

* Blocked vent shutoff switch used in Chimney Adapter Kit

wiring including thermostat leads.

Disconnect thermostat leads to isolate

- Stuck open or leaky gas valve.

Check for:

- Obstructed pressure tube.

- Pressure switch stuck closed.

23 PRESSURE SWITCH DID NOT OPEN

24 SECONDARY VOLTAGE FUSE IS OPEN

Check for:

- Short circuit in secondary voltage (24V)

short circuit.

C a t a l o g N o : I M -- P G 8 J -- 1 0

Replaces: IM--PG8J--09