Payne PG8MAA048070, PG8MAA066110, PG8MAA066110AAJA, PG8MAA048070AAJA, PG8MAA048090AAJA Installation Guide

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Installation, Start-Up Operating and

Service and Maintenance Instructions

Series G

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

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

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

Safety ......................................... 4

General Installation ............................... 4

Combustion and Ventilation Air ..................... 4

Duct Systems ................................... 5

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

Gas Piping and Gas Pipe Pressure Testing ............. 5

Electrical Connections ............................ 5

Venting ........................................ 5

LOCATION ....................................... 5

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

INSTALLATION .................................. 10

Bottom Return Air Inlet .......................... 10

Side Return Air Inlet ............................. 10

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

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

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

Platform Furnace Support ......................... 12

Roll-Out Protection ............................. 12

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

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

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

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

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

Return Air Connections .......................... 19

115-V Wiring .................................. 21

J-box Relocation ............................... 21

Electrical Connection to J-Box ..................... 21

Power Cord Installation in Furnace J-Box ............ 22

BX Cable Installation in Furnace J-Box .............. 22

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

Accessories .................................... 24

General Venting Requirements ..................... 24

Masonry Chimney Requirements ................... 25

Appliance Application Requirements ................ 27

Sidewall Venting ................................ 27

START-UP, ADJUSTMENT, AND SAFETY CHECK ..... 32

General ....................................... 32

Start-Up Procedures ............................. 32

Adjustments ................................... 37

Check Safety Controls ........................... 37

Checklist ...................................... 38

SERVICE AND MAINTENANCE PROCEDURES ....... 43

Introduction ................................... 43

Care and Maintenance ........................... 44

Sequence of Operation ........................... 47

Wiring Diagrams ............................... 48

Troubleshooting ................................ 48

PARTS REPLACEMENT INFORMATION GUIDE ....... 51

Always Ask For

Use of tile AIIR[ Cmlified rv Mark indicates a manulilcturer's pallicipation in the program. ]or

verification of cellification lbr individual products, go to www.ahridJreclory.org.

ISO9001

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

Portions of the text and tables are reprinted from NFPA 54/ANSI Z223.1-2012©, 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.

SAFETY CONSIDERATIONS

FIRE, EXPLOSION, ELECTRICAL SHOCK, AND

CARBON MONOXIDE POISONING HAZARD

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

Improper installation, adjustment, alteration, service, maintenance, or use can cause carbon monoxide poisoning, explosion, fire, electrical shock, or other conditions which may cause personal iniury 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.

FURNACE RELIABILITY HAZARD Failure to follow this caution may result in unit component

damage. 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.

CUT HAZARD Failure to follow this caution may result in personal iniury.

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.

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. Have a fire extinguisher available. Read these

instructions thoroughly and follow all warnings or cautions include in literature and attached to the unit. Consult local

building codes, the current editions of the National Fuel Gas Code (NFGC) NFPA 54/ANSI Z223.1 and the National

Electrical Code (NEC) NFPA 70.

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 iniury.

Understand the signal words DANGER, WARNING, and CAUTION. These words are used with the safety-alert symbol.

DANGER identifies the most serious hazards which will result in severe personal iniury or death. WARNING signifies hazards

which could result in personal iniury or death. CAUTION is used to identify unsafe practices which may result in minor

personal iniury or product and property damage. NOTE is used to highlight suggestions which will result in enhanced

installation, reliability, or operation.

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 spe- cified 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 products must be discharged outdoors. Con- nect this furnace to an approved vent system only, as spe-

cified in the "Venting" section of these instructions.

5. Never test for gas leaks with an open flame. Use a com- mercially 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 in- tended 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 con- taining the furnace, the return air shall also be handled by

duct(s) sealed to the furnace casing and terminating out- side the space containing the furnace. See "Air Ducts" sec-

tion.

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 in- structions.

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 install- ation in alcoves, attics, basements, closets, utility rooms,

crawlspaces, and garages. The furnace is factory-shipped for use with natural gas. A CSA (A.G.A. and C.G.A.) lis-

ted accessory gas conversion kit is required to convert fur- nace for use with propane gas.

11. See Fig. 1 for required clearances to combustible construc- tion.

12. Maintain a 1-in. (25 mm) clearance from combustible ma- terials to supply air ductwork for a distance of 36 in. (914

mm) horizontally from the furnace. See NFPA 90B or loc- al code for further requirements.

13. These furnaces SHALL NOT be installed directly on car- peting, tile, or any other combustible material other than

wood flooring. In downflow installations, factory access- ory floor base MUST be used when installed on combust-

ible materials and wood flooring. Special base is not re- quired when this furnace is installed on manufacturer's

Coil Assembly Part No. CNPV, CNRV, CAR or CAP or when Coil Box Part No. KCAKC is used. See Fig. 1 for

clearance to combustible construction information.

f_7/8

1/16

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BOTTOM_T

NOTES:

1. Two additional 7/8-in. (22 mm) 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. (406 mm) round or 14 1/2 x 12-in. (368 x 305 mm) rectangle.

(b.) For 1200 CFM-20-in. (508 mm) round or 14 1/2 x 19 1/2-in. (368 x 495 mm) rectangle,

(c.) For 1600 CFM-22-in. (559 mm) round or 14 1/2 x 22 1/16-in. (368 x 560mm) 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.

FURNACE SIZE A B C D VENT SHIP WT

CABINET OUTLET TOP & BOTTOM BOTTOM CONNECTION LB (KG)

WIDTH WIDTH FLUE COLLAR INLET WIDTH SIZE

045 - 08/024045 045 - 12/036045 070 - 08/024070

070 - 12/036070 070 - 16/048070 090 - 14/042090 090 - 16/048090 090 - 20/080090

110-12/038110 110-16/048110 110-22/088110 135-16/048135 135 -22/088135

155 -20/080155

"135 and 155 size furnaces require a 5 or 6-in. complete installation requirements.

14-3/16 (360) 12-9/16 (319) 9-5/16 (237) 12-11/16 (322) 4 (102) 104 (47) 14-3/16 (360) 12-9/16 (319) 9-5/16 (237) 12-11/16 (322) 4 (102) 107 (49) 14-3/16 (360) 12-9/16 (319) 9-5/16 (237) 12-11/16 (322) 4 (102) 111 (50) 14-3/16 (360) 12-9/16 (319) 9-5/16 (237) 12-11/16 (322) 4 (102) 115 (52)

17-1/2 (445) 15-7/8 (403) 11-9/16 (294) 16 (406) 4 (102) 126 (57) 17-1/2 (445) 15-7/8 (403) 11-9/16 (294) 16 (406) 4 (102) 127 (58)

21 (533) 19-3/8 (492) 13-5/16 (338) 19-1/2 (495) 4 (102) 140 (64) 21 (533) 19-3/8 (492) 13-5/16 (338) 19-1/2 (495) 4 (102) 146 (66)

17-1/2 (445) 15-7/8 (403) 11-9/16 (294) 16 (406) 4 (102) 135 (61)

21 (533) 19-3/8 (492) 13-5/16 (338) 19-1/2 (495) 4 (102) 146 (66) 21 (533) 19-3/8 (492) 13-5/16 (338) 19-1/2 (495) 4 (102) 152 (69)

21 (533) 19-3/8 (492) 13-5/16 (338) 19-1/2 (495) 4 (102)* 149 (68) 24-1/2 (622) 22-7/8 (581) 15-1/16 (383) 23 (584) 4 (102)* 163 (74) 24-1/2 (622) 22-7/8 (581) 15-1/16 (383)

(127 or

152 mm) vent. Use a vent adapter between furnace and vent stack. See Installation Instructions for

LOCATION

Fig. 1 - Dimensional Drawing

[15.1_

I N_N

23 (584) 4 (102)* 170 (77)

A10290

improper adjustment, alteration, service, maintenance, or installation can cause serious injury or death.

Read and follow instructions and precautions in User's Information Manual

provided with this furnace. Installation

and service must be performed by a

qualified service agency or the gas

supplier.

Check entire gas assembly for leaks after lighting this appliance.

iNSTALLATION

1. This furnace must be installed in accordance with the manufacturer's

instructions and local codes. In the absence of local codes, follow the National

Fuel Gas Code ANSI Z223.1 / NFPA54 or CSA B-149. 1 Gas Installation Code.

2. This furnace must be installed so there are provisions for combustion and ventilation

air. See manufacturer's installation information provided with this appliance.

OPERATION

This furnace is equipped with manual reset limit switch(es) in burner compartment to

protect against overheat conditions that can result from inadequate combustion air

supply or blocked vent conditions.

1. Do not bypass limit switches.

2. If a limit opens, call a quallified serviceman to correct the condition

and reset limit switch.

Fig. 2 - Clearances to Combustibles

MiNiMUMiNCHESCLEARANCETO COMBUSTIBLECONSTRUCTION

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 combustible material.

This furnace may be used with

a Type B-1 Vent and may be vented in common with other

gas fired appliances.

This furnace is approved for UPFLOW, DOWNFLOW, and

HORIZONTAL installations.

Clearancearrows donotchangewith

furnaceorientation.

Clearancein inches

Vent Clearance to combustibles:

For SingleWall vents 6 inches(6po). ForType B-1venttype I inch(1 po).

MINIMUM INCHES CLEARANCE TO

COMBUSTIBLE CONSTRUCTION

DOWNFLOWPOSiTiONS:

Installation on non-combustible floors only. For Installation on combustible flooring only when installed on special

base, Part No. KGASB0201ALL or NAHA01101SB, Coil Assembly, Part No. CAR, CAP, CNPV, CNRV, END4X, ENW4X, WENC, WTNC,

WENW OR WTNW. 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.

IIIIIIIIIIIIIIIIIIIIIIIIIII

336996-161 REV. C

A10269

! MAX80°F/27C

FRONT

__ :_ MIN60°F/16C

A06745

Fig. 3 - Return Air Temperature

INTRODUCTION

This 4-way nmltipoise 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 (16 °C) db or intermittent operation down to 55°F (13°C) db such as when used with a night setback

thermostat. Return-air temperature must not exceed 80 °F (27 ° C) db. Failure to follow these return-air temperature limits may

affect reliability of heat exchangers, motors, and controls. (See Fig. 3.)

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 nmst 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, follow all

codes and standards for the following:

Step 1 mSafety

National Fuel Gas Code (NFGC) NFPA 54-2012/AN- SI Z223.1-2012 and the Installation Standards, Warm

Air Heating and Air Conditioning Systems ANSI/

NFPA 90B

Step 2

Step 3

Step 4

Step 5

mGeneral Installation

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).

mCombustion and Ventilation Air

Section 9.3 of the NFGC, NFPA 54 / ANSI Z223.1-2012 Air for Combustion and Ventilation

_Duct Systems

Air Conditioning Contractors Association (ACCA)

Manual D, Sheet Metal and Air Conditioning Contract- ors National Association (SMACNA), or American

Society of Heating, Refrigeration, and Air Condition- ing Engineers (ASHRAE) 2001 Fundamentals Hand-

book Chapter 34 or 2000 HVAC Systems and Equip-

ment Handbook Chapters 9 and 16.

---Acoustical Lining and Fibrous Glass

Duct

• 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 Testing

• NFGC; NFPA 54 / ANSI Z223.1-2012 chapters 5, 6, 7

and 8 and National Plumbing Codes

Step 7 _Electrical Connections

• National Electrical Code (NEC) ANSI/NFPA 70-2011

Step 8 inVenting

• NFGC NFPA 54 / ANSI Z223.1-2012; chapters 12

and 13

ELECTROSTATIC DISCHARGE (ESD)

PRECAUTIONS PROCEDURE

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 be 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 fur- nace chassis which is close to the control. Tools held in a

person's hand during grounding will be satisfactorily dis- charged.

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 un-

grounded 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.

5. Use this procedure for installed and uninstalled (ungroun- 1 ded) furnaces.

6. Before removing a new control from its container, dis- charge your body's electrostatic charge to ground to pro- tect the control from damage. If the control is to be in-

stalled in a furnace, follow items 1 through 4 before bringing the control or yourself in contact with the fur-

nace. Put all used and new controls into containers before touching ungrounded objects.

7. An ESD service kit (available from commercial sources) may also be used to prevent ESD damage.

LOCATION

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.

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:

• be installed so the electrical components are protected from water.

not be installed directly on any combustible material other than wood flooring for upflow applications.

Downflow installations require use of a factory-ap- proved floor base or coil assembly when installed on combustible materials or wood flooring. (Refer to

SAFETY CONSIDERATIONS).

THE BLOWER IS LOCATED

TOTHE RIGHT OFTHE

BURNER SECTION, AND

AIR CONDiTiONED AiR IS

DISCHARGED TO THE LEFT.

AIRFLOW

THE BLOWER IS

LOCATED BELOW THE

BURNER SECTION, AND

CONDiTiONED AIR IS

DISCHARGED UPWARD.

HORIZONTAL LEFT

THE BLOWER IS

LOCATED ABOVE THE

BURNER SECTION, AND

CONDITIONED AIR IS

DISCHARGED DOWNWARD

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

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

• be provided ample space for servicing and cleaning. Always comply with minimum fire protection clear-

ances shown on the furnace clearance to combustible label.

• The following types of furnace installations may re-

quire OUTDOOR AIR for combustion due to chemical exposures:

• Commercial buildings

• Buildings with indoor pools

• Laundry rooms

• Hobby or craft rooms, and

• Chemical storage areas

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

combustion:

• Permanent wave solutions

• Chlorinated waxes and cleaners

• Chlorine based swimming pool chemicals

• Water softening chemicals

• De-icing salts or chemicals

• Carbon tetrachloride

• Halogen type refrigerants

_AIRFLOW

Fig. 4 - Multipoise Orientations

HORIZONTAL RIGH-'_AIR FL_OW

THE BLOWER IS

LOCATED TO THE LEFT

OF THE BURNER SECTION,

AND CONDiTiONED AIR IS

DISCHARGED TO THE RIGHT.

A02097

• Cleaning solvents (such as perchloroethylene)

• Printing inks, paint removers, varnishes, etc.

• Hydrochloric acid

• Cements and glues

• Antistatic fabric softeners for clothes dryers

• Masonry acid washing materials

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.

FIRE AND EXPLOSION HAZARD Failure to follow this warning could result in personal

iniury, death, and/or property damage. 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. (See Fig. 5.)

PERSONALINJURYAND/ORPROPERTY DAMAGEHAZARD

Failureto 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 nfininfize 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.

FIRE HAZARD Failure to follow this warning could result in personal

iniury, 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. 60

BACK J

A02054

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.

AIR FOR COMBUSTION AND

VENTILATION

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

• Section 9.3 of the NFPA 54 / ANSI Z223.1-2012, Air for Combustion and Ventilation, and applicable provi-

sions of the local building codes.

18-IN. (457.2 mm)

MINIMUM TO BURNERS

Fig. 5 - Installation in a Garage

FURNACE CORROSION HAZARD Failure to follow this caution may result in furnace damage.

Air for combustion nmst not be contanfinated by halogen compounds, which include fluoride, chloride, bronfide, and iodide. These elements can corrode heat exchangers and

shorten furnace life. Air contanfinants are found in aerosol sprays, detergents, bleaches, cleaning solvents, salts, air

fresheners, and other household products.

A93044

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 deternfine 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.

• Spaces having less than 50 cu/ft, per 1,000 Btuh re- quire the OUTDOOR COMBUSTION AIR METHOD.

• Spaces having at least 50 cu/fl, 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 combus- tion, ventilation, and dilution of flue gases using perman- ent 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.

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

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

f. Size openings and ducts per Fig. 7 and Table 1.

g. 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

Table 1.

h. 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 1.

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 1 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 ram) of the ceiling. Appliances in the space shall have clearances of at least 1

in. (25 ram) from the sides and back and 6 in. (150 ram) from the front. The opening shall directly communicate with the outdoors or shall conmmnicate 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 pernfitted 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 iniury.

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.

Table 1--Minimum Free Area Required for Each Combustion Air Opening of Duct to Outdoors

TWO HORIZONTAL DUCTS SINGLE DUCT OR OPENING

FURNACE (1 SQ. IN./2,000 BTUH) (1 SQ. IN./3,000 BTUH) (1 SQ. IN./4,000 BTUH)

INPUT (1,100 SO. MMiKW) (734 SO. MMiKW) (550 SO. MMiKW)

(BTUH) Free Area of Open- Round Duct Free Area of Open- Round Duct Free Area of Open- Round Duct

ing and Duct Dia. ing and Duct Dia. ing and Duct Dia.

Sq. In. (Sq. ram) In. (ram) Sq. In. (Sq. ram) In. (ram) Sq. In. (Sq. ram) In. (ram)

44,000 22 (14194) 6 (152) 14.7 (9484) 5 (127) 11 (7096) 4 (102) 66,000 33 (21290) 7 (178) 22.0 (14193) 6 (152) 16.5 (10645) 5 (127) 88,000 44 (28387) 8 (203) 29.3 (18903) 7 (178) 22 (14193) 6 (152)

110,000 55 (35484) 9 (229) 36.7 (23677) 7 (178) 27.5 (17742) 6 (152) 132,000 66 (42580) 10 (254) 44.0 (28387) 8 (203) 33 (21290) 7 (178)

154,000 77 (49677) 10 (254) 51.3 (33096) 9 (229) 38.5 (24839) 8 (203)

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

TWO OPENINGS OR VERTICAL

DUCTS

Table 2--Minimum Space Volumes for 100 % Combustion, Ventilation, and Dilution from Indoors

OTHER THAN FAN-ASSISTED TOTAL FAN-ASSISTED TOTAL

(1,000'S BTUH GAS INPUT RATE) (1,000'S BTUH GAS INPUT RATE)

30 40 50 44 66 88 110 132 154

ACH Space Volume Ft3 (M 3)

0.60 (29.7) (39.6) (49.5) (31.1) (46.7) (62.2) (77.8) (93.4) (109.0)

0.60 (35.6) (47.5) (59.4) (37.3) (56.0) (74.7) (93.4) (112.1) (130.8)

0.40 (44.5) (59.4) (74.3) (46.7) (70.0) (93.4) (116.8) (140.1) (163.5)

0.30 (59.4) (79.2) (99.1) (62.2) (93.4) (124.5) (155.7) (186.8) (218.0)

0.20 (89.1) (118.9) (148.6) (93.4) (140.1) (186.8) (233.6) (280.3) (327.0)

0.10 (178.3) (237.8) (297.3) (186.8) (280.3) (373.7) (467.2) (560.6)

0.00 NP NP NP NP NP NP NP

NP = Not Permitted

1,050 1,400 1,750 1,1 O0 1,650 2,200 2,750 3,300 3,850

1,260 1,680 2,1 O0 1,320 1,980 2,640 3,300 3,960 4,620

1,575 2,1 O0 2,625 1,650 2,475 3,300 4,125 4,950 5,775

2,1 O0 2,800 3,500 2,200 3,300 4,400 5,500 6,600 7,700

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

6,300 8,400 10,500 6,600 9,900 13,200 16,500 19,800 23,1 O0

NP NP

1 SQ IN.

OUTDOORS

PER 4000 BTUH*

CIRCULATINGDucTsAIR !

1 1 1 II

I I I I I

VENT THROUGH ROOF

(654.1) 0

(305mm) 12"MAX I _J

lSQiN _11:1

PER2000 IIB

BTUi"

DUCTS

OUTiOORS _

PER 2000 _ I:IAI BTUH* T

305mm 12"MAX | .

*Minimum dimensions of 3-in. (76 mm). NOTE: Use any of the following combinations of openings:

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

CIRCULATING AIR DUCTS

A&BC&DD&EF&G

TO PER 4000

OUTDOORS BTUH*

Outdoors

12" MAX

(305mm)

1 SQ IN.

12_ (305mm)

SO IN. PER

4000

3TUH*

cO n-

F-

SQ IN. PER

4000

BTUH*

12" (305mm) MAX

A03174

:305mm)

1 SQ IN. PER 1000

BTUH* IN DOOR ORWALL

INTERIOR

HEATED

SPACE

i i

CIRCULATING AIR DUCTS

* Minimum opening size is 100 sq in. (64516 sq. mm)with minimum dimensions of 3 in. (76 mm)

1-Minimum of 3 in. (76 mm) when type-B1 vent is used.

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

Indoors

UNCONFINED SPACE

6" MIN (152mm) (FRONT)0

1 SQ IN. PER 1000 BTUH* IN DOOR

-- ORWALL

L 12" MAX(305mm)

A03175

The Standard Method:

1. The space has no less volume than 50 cu/fl, 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 deternfined per TaMe 2 or Equations I and 2. Deternfine 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.

Table 2 - Minimum Space Volumes were deternfined by using the following equations from the National Fuel Gas Code ANSI Z223.1-2012/NFPA 54-2012, 9.3.2.2:

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

Volume - 21ft3 L_ !°ther

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

Volume _ 15ft 3 _ I fan

If: Iother = combined input of all other than fan-assisted

appliances in Btuh/hr Ifan = 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 closeaMe doors between rooms.

b. Combining spaces on same floor level. Each opening

c. Combining space on different floor levels. The

2. An attic or crawlspace may be considered a space that freely conmmnicates with the outdoors provided there are

adequate permanent ventilation openings directly to out- doors having free area of at least 1-in.2/4,000 Btuh of total

input rating for all gas appliances in the space.

3. In spaces that use the Indoor Combustion Air Method, in- filtration should be adequate to provide air for combus-

tion, permanent ventilation and dilution of flue gases.

Other ACH H000 Btu/hr

A04002

Fan ACH 000 Btu/hr

A04003

shall have free area of at least I in.2/1,000 Btuh (2,000 mm2/kW) of the total input rating of all gas appliances in the space, but not less than 100 in. 2 (0.06 m2). One

opening shall commence within 12 in. (300 ram) of the ceiling and the second opening shall commence

within 12 in. (300 ram) of the floor. The minimum dimension of air openings shall be at least 3 in. (80

ram). (See Fig. 8.)

volumes of spaces on different floor levels shall be considered as conmmnicating spaces if connected by

one or more permanent openings in doors or floors having free area of at least 2 in.2/1,000 Btuh (4,400 mm2/kW) of total input rating of all gas appliances.

However, in buildings with unusually tight construction, additional air MUST be provided using the methods de-

scribed in the Outdoor Combustion Air Method section.

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 of 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 nfinus the

Ratio in a. above.

c. Minimum size of Outdoor openings shall be the size

required in Outdoor Combustion Air Method above nmltiplied by reduction Factor in b. above. The nfin-

imum dimension of air openings shall be not less than 3 in. (80 mm).

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. 90

Bottom Closure Panel

Bottom Filler Panel

A10273

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. (8 x

38 ram) (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.

(8mm)

I 3/4'

(44mm)

1 3/4"

(44mm)

4. If downflow subbase, KGASB is used, install as shown in Fig. 12. If Coil Assembly Part No. CNPV, CNRV, CAR,

or CAP or Coil Box Part No. KCAKC is used, install as shown in Fig. 13.

(8mm)

5/16"

(8mm)

(44mm) 1 3/4"

(44mm) I 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 INSTALLATION NOTE: For downflow applications, this furnace is approved for

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

• Special Base, KGASB

• Cased Coil Assembly Part No. CNPV, CNRV, CAR, or CAP

• Coil Box Part 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 4 and Fig. 11.

A96283

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. 140

FURNACE

(OR COIL CASING

WHEN USED)

COMBUSTIBLE

FLOORING \

SUBBASE

SHEET METAL

PLENUM

FLOOR

OPENING

A96285

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

Combustible Floor

FURNACE

APPROVED

COIL ASSEMBLY

COIL BOX

COMBUSTIBLE

FLOORING

\\\\_

SHEET METAL _

PLENUM

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

Installed on a Combustible Floor

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.)

2. Rotate bottom filler panel downward to release holding

tabs.

3. Remove bottom closure panel.

4. Reinstall bottom filler panel and screws.

HORIZONTAL INSTALLATION

FLOOR

OPENING 12

A08556

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 170 For furnaces with 1-in, (25 ram) clearance requirement on side, set furnace on non-

combustible 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, (451 x 559 ram) piece of

sheet metal for flame roll-out protection in front of burner area for furnaces closer than 12 inches (305 ram) above the

combustible deck or suspended furnaces closer than 12 inches (305 ram) to joists, The sheet metal MUST extend underneath the

furnace casing by 1 in, (25 ram) with the door removed, The bottom closure panel on furnaces of widths 17-1/2 in, (445

ram) 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

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, 90

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

FIRE, EXPLOSION, AND CARBON MONOXIDE POISONING HAZARD

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

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 3/4-in. (19 ram) screws into

the side and 2 #8 x 3/4-in. (19 ram) screws in the bottom of the furnace casing for each strap. (See Fig. 15 and 16.)

CARBON MONOXIDE AND POISONING HAZARD

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

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

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

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

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

the Product Data Sheet for accessory list. Refer to the instructions supplied with external filter rack for

assembly and installation options.

Table 3--Opening Dimensions - In. (mm)

FURNACE

CASING

APPLICATION

WIDTH

Upflow Applications on Combustible or Noncombustible Floor- 12-11/16 21-5/8 13-5/16 22-1/4

Downflow Applications on Noncombustible Flooring (KGASB 12-9/16 19 13-3/16 19-5/8

14-3/16 Downflow applications on combustible flooring (KGASB sub- 11 - 18/16 19 18- 7/16 20- 5/8

(360) base required) (284) (483) (341) (600)

Downflow Applications on Combustible Flooring with CNPV,

CNRV, CAR, or CAP Coil Assembly or KCAKC coil box

Upflow Applications on Combustible or Noncombustible Floor- 16 21 -5/8 16-5/8 22-1/4

Downflow Applications on Noncombustible Flooring (KGASB 15-7/8 19 16-1/2 19-5/8

17-1/2 Downflow applications on combustible flooring (KGAS B su b- 15-1/8 19 16-3/4 20-5/8

(445) base required) (384) (483) (425) (600)

Downflow Applications on Combustible Flooring with CNPV,

CNRV, CAR, or CAP Coil Assembly or KCAKC coil box

Upflow Applications on Combustible or Noncombustible Floor- 19-1/2 21-5/8 20-1/8 22-1/4

Downflow Applications on Noncombustible Flooring (KGASB 19-3/8 19 20 19-5/8

21 Downflow applications on combustible flooring (KGASB sub- 18-5/8 19 20-1/4 20-5/8

(533) base required) (473) (483) (514) (600)

Downflow Applications on Combustible Flooring with CNPV,

CNRV, CAR, or CAP Coil Assembly or KCAKC coil box

Upflow Applications on Combustible or Noncombustible Floor- 23 21 - 1/8 28- 5/8 22-1/4

Downflow Applications on Noncombustible Flooring (KGASB 22-7/8 19 28-1/2 19-5/8

24-1/2 Downflow applications on Combustible flooring (KGAS B su b- 22-1/8 19 28- 3/4 20-5/8

(622) base required) (562) (483) (603) (600)

Downflow Applications on Combustible Flooring with CNPV,

CNRV, CAR, or CAP Coil Assembly or KCAKC coil box

ing (KGASB subbase not required) (322) (549) (338) (565)

subbase not required) (819) (483) (335) (498)

(KGASB subbase not required) (819) (483) (338) (508)

ing (KGASB subbase not required) (406) (549) (422) (565)

subbase not required) (403) (483) (419) (498)

(KGASB subbase not required) (394) (483) (419) (508)

ing (KGASB subbase not required) (495) (549) (511) (565)

subbase not required) (492) (483) (508) (498)

(KGASB subbase not required) (483) (483) (508) (508)

ing (KGASB subbase not required) (584) (537) (600) (565)

subbase not required) (581) (483) (597) (498)

(KGASB subbase not required) (572) (483) (597) (508)

PLENUM OPENING FLOOR OPENING

A B C D

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

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

19 19 20 20

22-1/2 19 28-1/2 20

AIR DUCTS 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 4 - 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. (25 ram) clearance from combustible materials to supply air ductwork for a distance of 36 in. (914 ram) 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. (3 M) 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.

Table4--Air Delivery - CFM (with Filter)*

FURNACE RETURN-AIR SPEED EXTERNAL STATIC PRESSURE (In. W.C.)

SiZE INLET 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0

045-08/ Bottom or High 1035 995 945 895 835 770 675 565 390 195

024048 Side(s) Med - High 865 830 790 745 690 625 545 440 250 195

045-12/ Bottom or High 1440 1375 1305 1240 1160 1070 975 870 730 560

036045 Side(s) Med - High 1360 1300 1240 1175 1115 1040 950 850 725 575

070-08/ Bottom or High 1030 1005 965 925 870 810 740 645 465 280

024070 Side(s) Med- High 835 815 790 755 710 660 590 480 325 205

070-12/ Bottom or High 1425 1375 1320 1265 1200 1125 1035 940 830 655

036070 Side(s) Med- High 1320 1280 1240 1205 1140 1075 995 905 790 620

070-16/ Bottom or High 1755 1700 1635 1570 1505 1435 1350 1260 1160 1055

048070 Side(s) Med- High 1550 1520 1475 1430 1375 1310 1240 1155 1070 970

090-14/ Bottom or High 1605 1570 1535 1465 1385 1285 1175 1055 895 645

042090 Side(s) Med - High 1470 1445 1410 1380 1300 1220 1115 990 830 600

090-16/ Bottom or High 1940 1880 1805 1720 1635 1540 1425 1290 1090 830

048090 Side(s) Med - High 1740 1700 1650 1590 1525 1440 1335 1195 1010 820

Bottom Only Med - High 2170 2110 2040 1970 1895 1785 1675 1565 1420 1260

090-20/ Both Sides or 1 High 2530 2450 2365 2270 2165 2065 1940 1805 1670 1505

060090 Side & Bottom Med - High 2230 2170 2110 2050 1985 1890 1780 1660 1525 1360

1Side Only Med - High 2105 2145 2070 2010 1940 1845 1735 1620 1475 1325

110-12/ Bottom or High 1600 1550 1490 1425 1355 1260 1135 990 785 530

036110 Side(s) Med- High 1475 1435 1395 1335 1285 1185 1070 890 725 450

110-16/ Bottom or High 1980 1915 1835 1750 1655 1495 1365 1185 965 700

048110 Side(s) Med-High 1745 1710 1650 1560 1450 1340 1205 1090 865 605

Bottom Only Med- High 2135 2100 2060 2000 1930 1860 1765 1670 1555 1425

110-22/

066110 or 1 Side & Bot- Med-High 2140 2100 2050 1990 1935 1865 1760 1670 1545 1410

A filter is required for each return-air inlet. Airflow performance included 3/4-in. (19 mm) washable filter media such as contained in factory-authorized ac-

cessory filter rack. To determine airflow performance without this filter, assume an additional 0.1 In. W.C. available external static pressure.

-- Indicates unstable operating conditions.

Bottom Sides High .... 2355 2285 2190 2090 1965 1850 1705 1535

tom Med - Low 1855 1840 1815 1775 1725 1675 1600 1510 1405 1290

1Side Only Med - High 2030 2025 2000 1950 1905 1850 1750 1660 1555 1425

Med - Low 760 720 680 635 580 520 445 345 220 195

Med - Low 1250 1210 1160 11O0 1040 965 885 790 670 520

Med - Low 725 700 675 635 595 545 460 350 250 - -

Med - Low 1200 1175 1145 1105 1050 990 920 840 725 555

Med - Low 1355 1340 1310 1280 1240 1190 1125 1060 975 890

Med- Low 1310 1295 1265 1230 1195 1120 1025 915 710 565

Med - Low 1505 1505 1480 1440 1375 1300 1190 1045 890 740

High 2405 2310 2220 2130 2025 1920 1790 1660 1530 1350

Med - Low 1920 1875 1835 1780 1715 1630 1535 1420 1275 1135

Med - Low 1895 1890 1845 1815 1755 1685 1600 1480 1350 1180

High 2475 2395 2300 2200 2090 1985 1865 1730 1585 1425

Med - Low 1850 1860 1810 1770 1715 1650 1555 1445 1310 1150

Med - Low 1315 1295 1265 1220 1155 1080 985 810 675 440

Med- Low 1530 1515 1470 1400 1310 1215 1095 990 830 670

High 2485 2415 2340 2255 2160 2080 1950 1840 1720 1565

Med - Low 1855 1840 1815 1775 1725 1675 1600 1510 1405 1290

High 2495 2440 2370 2290 2205 2120 2015 1910 1775 1625

Med - Low - - 1735 1725 1695 1650 1595 1535 1455 1335 1230

Table 5---Air Delivery - CFM (with Filter)* (Continued)

FURNACE RETURN-AIR SPEED EXTERNAL STATIC PRESSURE (In. W.C.)

SIZE iNLET 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0

135-16/ Bottom or High 2065 2000 1930 1835 1710 1590 1420 1235 1025 835

048135 Side(s) Med - High 1790 1755 1705 1640 1550 1465 1295 1145 945 775

Bottom Only Med - High 2130 2080 2025 1960 1880 1795 1690 1550 1405 1255

135-22/

066135 or 1 Side & Bot- Med-High 2120 2075 1995 1970 1905 1835 1735 1645 1515 1325

155-20/ Both Sides Or 1 High .... 2375 2285 2185 2105 1995 1870 1720 1555

060155 Side & Bottom Med-High 2155 2125 2075 2015 1935 1830 1780 1635 1485 1365

A filter is required for each return-air inlet. Airflow performance included 3/4-in. (19 mm) washable filter media such as contained in factory-authorized ac-

cessory filter rack. To determine airflow performance without this filter, assume an additional 0.1 In. W.C. available external static pressure.

-- Indicates unstable operating conditions.

Bottom, Sides High .... 2355 2280 2160 2065 1930 1805 1655 1465

tom Med - Low 1860 1830 1800 1755 1725 1630 1530 1415 1280 1140

1 Side Only Med-High 2070 2015 1970 1935 1855 1765 1655 1550 1445 1265

Bottom Only Med - High 2115 2095 2055 2005 1940 1845 1820 1675 1525 1390

1Side Only Med - High 2140 2085 2020 1950 1850 1745 1695 1545 1415 1290

Med - Low 1480 1480 1480 1450 1380 1295 1160 1005 855 670

High 2445 2365 2280 2190 2085 1980 1850 1705 1520 1355

Med - Low 1860 1830 1800 1755 1705 1630 1530 1415 1280 1140

High .... 2215 2130 2030 1920 1795 1675 1540 1385

Med - Low 1860 1830 1800 1755 1725 1630 1530 1415 1280 1140

High 2465 2430 2375 2305 2215 2110 2000 1865 1715 1530

Med - Low 1800 1790 1770 1735 1695 1640 1570 1465 1345 1225

High .... 2260 2180 2070 1975 1865 1740 1595 1440

Med - Low 1800 1790 1770 1735 1695 1640 1570 1465 1345 1225

U PFLOW DOWN FLOW HO REZO NTAL

[......

YES

120°_ MIN

YES

YES 120°_ YES 120°_ YES

NO NO NO

/\ /\

MIN MIN

Fig. 14 - Duct Flanges

YES

A02020

ASSEMBLY

8" (203mm) MtN

FOR DOOR REMOVAL

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

_/4"(6mm) THREADED ROD 4 REQ.

SECURE ANGLE

IRON TO BOTTOM

OF FURNACE WiTH 3 #8 x3/4'' (19mm) SCREWS

TYPICAL FOR 2 SUPPORTS

1" (25ram) SQUARE, 1-1/4"x1-1/4"x1/8" (32x32x3mm) ANGLE IRON OR UNI-STRUT MAY BE USED

OUTER DGOR ASSEMB_

A10130

Fig. 15 - Horizontal Unit Suspension

22 GAUGE GALVANIZED STRAPS TYPICAL

FOR 4 STRAPS

METHOD 2

BACK OF FURNACE

METHOD 1 FOLD ALL STRAPS UNDER FURNACE AND SECURE WTH

(4) #8 x 3/4 (t9 ram) SHEET METAL SCREWS (2 SCREWS IN SIDE AND 2 SCREWS

IN BOTTOM).

USE (4) #8 x 3/4 (19 ram) SHEET METAL SCREWS FOR EACH

STRAR THE STRAPS SHOULD BE VERTICAL AGAINST THE FURNACE SIDES AND NOT PULL AWAY FROM THE FURNACE SIDES.

Fig. 16 - Horizontal Suspension with Straps

A10131

LINECONTACTONLYPERMISSIBLEBETWEEN LINESFORMEDBYINTERSECTIONSOF

THETOPANDTWOSIDESOFTHEFURNACE

JACKETANDBUILDINGJOISTS, STUDS,ORFRAMING.

17 3/4" (451 mm)OVERALL

43/4 '' (121mm) UNDER DOOR

1" (25mm) UNDER FURNACE

EQUIPMENTMANUAL

SHU_OFFGASVALVE

SEDIMENT

TRAP

SUPPLY T,_

ENTRY VENT

30-IN. (762mm)

MIN WORK AREA *WHEN USED WITH

EXTEND OUT 12" (305mm) FROM FACE OF DOOR

SINGLE WALL VENT CONNECTIONS

UNION

A10164

Fig. 17 - Typical Attic Installation

AIR

RETURN

UPFLOW RETURN AIR CONFIGURATIONS AND RESTRICTIONS

AIR FLOW MODELS RETURN AIR RETURN AiR RETURN AIR RETURN AIR

066.060, -22 AND YES YES YES YES

-20 MODELS ALL OTHER MODELS YES YES YES YES

UPFLOW

RETURN AIR

RESTRICTIONS

Fig. 18 - Upflow Return Air Configurations and Restrictions

CONNECTION 1 CONNECTmON 2 CONNECTION 3 COMBINATIONS ONLY ONLY ONLY OF 1,2, AND 3

A02075

RETURN

(_ RETURN

AIR

DOWNFLOWRETURNAIRCONFIGURATIONSANDRESTRiCTiONS

AIR FLOW MODELS RETURN AIR RETURN AIR RETURN AIR RETURN AIR

066.060, -22 AND YES NO NO NO

-20 MODELS ALL OTHER MODELS YES NO NO NO

Fig. 19 - Downflow Return Air Configurations and Restrictions

RETURN

AIR

CONNECTION 1 CONNECTION 2 CONNECTION 3 COMBINATIONS ONLY ONLY ONLY OF 1,2, AND 3

A02163

_ NOT PERMITTED FOR

066,060, -22-20 AIR FLOW MODELS

II III

"l II IIIRET, #N II III

= SIDE RETURN AIR

b/ll©NOTPERMITTEDFOR IVI

0660602_oELS

I_ _l _VV -- HORIZONAL

* NOTE: RESTRICTION _. HORIEONAL LEFT

SAME FOR AIR RESTRICTIONS

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

RETURN RETURN AIR

\% HORIZONTAL RETURN AIR CONFIGURATIONS AND RESTRICTIONS

AIR FLOW MODELS RETURN AIR RETURN AIR RETURN AIR RETURN AIR

066.060, -22 AND YES NO NO NO

-20 MODELS ALL OTHER MODELS YES YES YES YES

CONNECTION 1 CONNECTION 2 CONNECTION 3 COMBINATIONS ONLY ONLY ONLY OF 1, 2, AND 3

temporarily while the remaining attachment and sealing of the coil are performed.

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 factory-approved accessory subbase or a factory-approved air conditioning coil casing. DO NOT cut main

furnace casing to attach supply side air duct, humidifier, or other

A02162

accessories.AllaccessoriesMUSTbeconnectedto duct external

to furnace casing.

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 Furnaces

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.

Up flow and Horizontal Furnaces 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 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 specifcally for the detection of leaks to check all connections. A fire or explosion may result causing property damage, personal injury or loss of

life.

Refer to Table 5 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. (1.8 M) 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 5--Maximum Capacity of Pipe

NOMINAL

IRON PIPE

SIZE

IN. (MM)

1/2 (12.7)

3/4 (19.0)

1 (25.4)

1-1/4

(31.8)

1-1/2

(38.1)

Cubic ft. of natural gas per hr for gas pressures of 0.5 psig (14-1n. W.C.)

or less and a pressure drop of 0.5-In. W.C. (based on a 0.60 specific gravity gas). Ref: Table 6 and ANSI Z223-2012/NFPA 54-2012.

INTERNAL LENGTH OF PIPE - FT (M)

DIA.

IN. (MM) (3.0) (6.0) (9.1) (12.1) (15.2)

0.622 (158) 175 120 97 82 73

0.824

(20.9) 360 250 200 170 151

1.049

(26.6) 680 465 375 320 285

1.380

(35.0) 1400 950 770 660 580

1.610

(40.9) 2100 1460 1180 990 900

10 20 30 40 50

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. (51 mm) 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.

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.

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 li- censed 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.

An accessible manual equipment shutoff valve MUST be installed external to furnace casing and within 6 ft. (1.8 M) of

furnace. A 1/8-in. (3 mm) 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.

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. W.C.) stated on gas control valve. (See Fig. 42.)

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. (3 mm) 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.

90 ° Elbow

2"(51 ram) Nipple

Street Elbow

TOP VIEW OF BURNER AND MANIFOLD ASSEMBLY Ins

Supply

L Gas Valve

Facto_

GAS SUPPLY

MAN UAL SHUTOFF VALVE

(

SEDIMENT TRAP

Fig. 22 - Typical Gas Pipe Arrangement

Fig. 21 - Burner and Manifold

UNION

A08551

A02035

A10291

Fig. 23 - Relocating J-Box

A10141

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

Piping should be pressure and leak tested in accordance with

NFGC, local, and 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. W.C.), gas supply pipe nmst 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. W.C.), 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. 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

ELECTRICAL SHOCK HAZARD Failure to follow this warning could result in personal

injury or death. Blower access panel door switch opens l15-v power to

control. No component operation can occur. Do not bypass or close switch with panel removed.

See Fig. 26 for field wiring diagram showing typical field l15-v wiring. Check all factory and field electrical connections for

tightness.

ELECTRICALSHOCKANDFIREHAZARD Failureto follow this warning could result in personal

iniury, death, or property damage. The cabinet MUST have an uninterrupted or unbroken

ground according to NEC ANSI/NFPA 70-2011 or local codes to minimize personal iniury 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.

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.

llS-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 6 for equipment electrical specifications.

Make all electrical connections in accordance with National Electrical Code (NEC) ANSI/NFPA 70-2011 and any local codes

or ordinances that might apply.

FIRE HAZARD

Failure to follow this warning could result in personal iniury, 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 6 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 l15-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). NOTE: On 14-in. (356 mm) 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 two screws removed in Step

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.) for wire bushings, strain relief, etc.

4. Route and 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. Electrical Box on Furnace Casing Side

See Fig. 24.

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.

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

2. Remove the desired electrical box hole knockout and posi- tion the hole in the electrical box over the hole in the fur-

nace casing.

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

steel.

4. Remove and save two screws holding J-Box. (See Fig. 23 .)

5. Pull furnace power wires out of 1/2-in. (12 mm) diameter hole in J-Box. Do not loosen wires from strain-relief

wire-tie on outside of J-Box.

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

7. Pull field power wires into electrical box.

8. Remove cover from furnace J-Box.

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

10. Reattach furnace J-Box to furnace casing with screws re- moved in Step 4.

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

Table6--Electrical Data

FURNACE SIZE

045=08/024045 115-60-1 5.2 7.26 045=12/036045 115-60-1 7.2 9.79

070=08/024070 115-60-1 5.1 7.14 070=12/036070 115-60-1 7.2 9.72

070=16/048070 115-60-1 9.5 12.60 090=14/042090 115-60-1 8.6 11.39

090=16/048090 115-60-1 10.0 13.09 090 = 20/060090 115-60-1 14.1 18.2 110=12/036110 115-60-1 8.6 11.27

110=16/048110 115-60-1 10.2 13.34 110=22/066110 115-60-1 15.1 19.42

135=16/048135 115-60-1 10.5 13.63 135=22/066135 115-60-1 14.5 18.72 155=20/060155 115-60-1 15.4 19.83

Permissible limits of the voltage range at which the unit operates satisfactorily.

# 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.

1-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.

VOLTS- HERTZ-

PHASE

OPERATING VOLTAGE

RANGE

Maximum* Minimum*

127 104 127 104

127 104 127 104 127 104

127 104 127 104

127 104 127 104 127 104

127 104 127 104

MAXIMUM

UNIT AMPS

UNiT

AMPACITY#

MAXIMUM

WiRE

LENGTH FT.

(M)$

49 (14.9) 37 (11.2)

51 (15.5) 38 (11.5)

29 (8.8) 32 (9.7)

28 (8.5) 31 (9.4)

32 (9.7) 27 (8.2)

29 (8.8) 27 (8.2)

30 (9.1) 29 (8.8)

12. Complete electrical box wiring and installation. Connect line voltage leads as shown in Fig. 26. Use best practices

(NEC) for wire bushings, strain relief, etc.

13. 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 6. Refer to power cord manufacturer's listings.

1. Remove cover from J-Box.

2. Route listed power cord through 7/8-in. (22 ram) 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. 26.

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

BX CABLE INSTALLATION IN FURNACE J-BOX

1. Remove cover from J-Box.

2. Route BX cable into 7/8-inch (22 ram) diameter hole in J-Box.

3. Secure BX cable to J-Box bracket with connectors ap- proved 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.

MAXIMUM

FUSE OR MINIMUM

CKT BKR WIRE

AMPSI" GAUGE

15 14 15 14

15 14 15 14 15 14

15 14 15 14

20 12

15 14 15 14

20 12

15 14

20 12 20 12

BLOWER OFF-DELAY

J2 JUMPER

24-V THERMOSTAT

TERMINALS

3-AMP FUSE

LED OPERATION &

DIAGNOSTIC LIGHT

115-VAC(L2)N EL

CONNECTIONS

L2 ____

TWINNING AND/OR COMPONENTTEST

TERMINAL

HUMIDIFIER TERMINAL

(24-VAC 0.5 AMP MAX.)

TRANSFORMER 24-VAC

CONNECTIONS

PL1 -LOW VOLTAGE MAIN

HARNESS CONNECTOR

TERMINAL

1.0 AMP MAX.)

;PARE SPARE-2 SPARE-3

NOTE 2

THREE-WIRE --_ _ i i

HEATING-ONLY _ "_ _--',

FIVEWIRE @@

BLOWER DOOR SWITCH _ _

@_J '', ,

C _ ----t--J

O I N I T I

115-V FIELD- AUXILIARY O _---

SUPPLIED J-BOX L @

DISCONNECT @

FURNACE

Fig. 26 - Heating and Cooling Application Wiring Diagram with Single Stage Thermostat

R@ L

24-V

TERMINAL

BLOCK

115 VAC (L1) LINE

VOLTAGE CONNECTION

Fig. 25 - Furnace Control

THERMOSTAT TERMINALS FIELD-SUPPLIED

I I I I

NOTE 1 I

NOTES: 1.

I-T

_ _, O--H--Q

TWO WiRE

ConnectY-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.

PL2 1

PL2-HOT SURFACE

IGNITER & INDUCER

MOTOR CONNECTOR

.... FIELD 24-V WIRING

.... FIELD 115-, 208/230-, 460-VWIRING

-- FACTORY 24-V WIRING FACTORY 115-V WIRING

DISCONNECT

@ii_il

CONDENSING UNIT

208/230-OR 460-V

THREE

PHASE

208/230-V SINGLE

PHASE

Al1619

A99440

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) us-

ing l/4-in female quick connect terminals to the two male l/4-in quick-connect terminals on the control board

marked EAC-I 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 hu-

midifier (if used) to the l/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. 24.)

NOTE: A field-supplied, l15-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 humidity sensing thermostat, zone

controller or similar device. See humidity sensing thermostat, 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. GENERAL VENTING REQUIREMENTS

Follow all safety codes for proper vent sizing and installation requirements, including local building codes, the National Fuel Gas Code ANSI Z223.1-2012/NFPA 54-2012 (NFGC), Parts 12

and 13, 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 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.

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 Z21.47-2012/CSA 2.3-2012 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, 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.

CARBON MONOXIDE POISONING HAZARD

Failure to follow this warning could result in personal iniury 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 fur-

nace will be shut off by the draft safeguard switch located on the vent elbow.

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. Do not vent this appliance with any solid fuel burning ap- pliance.

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 china- ney. 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 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 211-2012 and must be in good condition. U.S.A.-Refer to NFPA 54/ANSI Z223.1-2012 Sections 13.1.8

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 NFPA 54 / ANSI Z223.1-2012, 13.1.8 and

13.2.20 regarding alternative venting design and the Exception, which cover installations such as the Chimney Adapter Kits 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. See the Product Data Sheet for accessory list.

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 max- imum capacity given in Table 7, and

4. The input rating of each space heating appliance is greater than the minimum input rating given in Table 8 for the

local 99% Winter Design Temperature. Chimneys having internal areas greater than 38 in2 (24516 mm 2) require fur-

nace input ratings greater than the input ratings of these furnaces. See footnote at bottom of Table 8, 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 con-

densation. If a condensate drain is required by local code, refer to the NFPA 54 / ANSI Z223.1-2012, Sec-

tion 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 equip-

ment being installed and the authority having jurisdic- tion.

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 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.

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

Rebuild

crown.

Is chimney No

property lined with

clay tile liner?

Yes

IS liner and top seal in good

condition?

Clay

tile misalignment,

missing sections,

gaps?

Condensate

drainage at bottom

of chimney?

N_ Reline

Remove mortar

and tile debris

_'es

_Suitable h

/[_No "'_ instructions for / _ _ "

/ _ _ application /

/_,_ ,,,_÷h_,_,, _ V_ .... Line chimney with property

__'_. _'_ I bUlIaD,e sized, listed flexible metal

-._,L_u, ._ ..... ._' _'/Yes t liner orTyp_ B vent per

"_ype-_ venv/ _lr NFGC Vent

/ _ Sizing Table. _ and liner or

_i[ a_rP_c_rioPner........ Installahon,

1Yes = ".............. . Nor _uJraDle

bultable

a ey i

'n_'o_n_ mn eY vent manL

a pe pe i

Chimney

exposed to

outdoors below

roof line?

Chimney is

acceptable for use.

/ Iq r.himn_/ _ r,l_ / Part C of

__himney adapter ventin_e

" _ asinale / I I " _ instructions for / I

._s _ furnace? / I t _ application / [

Install chimney

adapter per instructions.

Fig. 27 - Chimney Inspection Chart

A10133

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 following precautions must be observed:

1. The return-air temperature must be at least 60°F (16°C) db except for brief periods of time during warm-up from

setback at no lower than 55°F (13°C) 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, caus-

ing condensation and corrosion in the furnace and/or vent- ing system. Derating is permitted only for altitudes above

2000 ft. (610 M).

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.

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. (102 mm) round vent elbow is supplied with the furnace.

A 5-in. (127 mm) or 6-in. (152 mm) vent connector may be required for some model furnaces. A field-supplied 4-in. (102

mm) to 5-in. (127 mm) or 4-in. (102 mm) to 6-in. (152 mm) sheet metal increaser fitting is required when 5-in. (127 mm) or

6-in. (152 mm) vent connector is used. See Fig. 28 - 40 Venting Orientation for approved vent configurations.

NOTE: Vent connector length for connector sizing starts at furnace vent elbow. The 4-in. (102 mm) 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 cabinet of the furnace through one of 5 locations.

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.

NOTE: An accessory flue extension is available to extend from the furnace elbow to outside the furnace casing. See the Product Data Sheet for accessory list. 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. 28 - 40.

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. Determine the correct location of the knockout to be re- moved.

4. Use a hammer and screwdriver to strike a sharp blow between the tie points and work the slug back and forth

until the slug breaks free.

BURN HAZARD

Failure to follow this caution may cause personal iniury. Hot vent pipe is within reach of small children when

installed in downflow position. See the following instruction.

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

Instructions for complete details. See the Product Data Sheet for accessory list.

The horizontal portion of the venting system shall slope upwards not less than l/4-in. (6 mm) per linear ft. (21 mm/m) from the

furnace to the vent and shall be rigidly supported every 5 ft. (1.5 M) 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.

Per section 12.4.3 of the NFPA 54 / ANSI Z223.1-2012, any listed mechanical venter may be used, when approved by the

authority having jurisdiction.

Table7--ExteriorMasonryChimneyFan+ Nat Installations

with Type-B Double Wall Vent Connectors ©NFPA & AGA

Combined Appliance Maximum Input

Rating in Thousands of Btuh per Hour

VENT HEIGHT

FT. (M)

6 (1.8)

8 (2.4) 10 (3.0) 15 (4.5) 20 (6.0)

30 (9.1)

Table 8--Minimum Allowable Input Rating of Space-Heat-

ing Appliance in Thousands of Btuh per Hour

VENT HEIGHT SQ, IN. (SQ, MM)

FT. (M) 12 19 28 38

Local 99% Winter Design Temperature: 17 to 25 degrees F

5 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 352

Local 99% Winter Design Temperature: 5 to 16 degrees F*

6 NR 78 121 166

8 NR 94 135 182 10 NR 111 149 198

15 NR NR 193 247 20 NR NR NR 293 30 NR NR NR 377

Local 99% Winter Design Temperature: -10 to 4 degrees F*

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

Local 99% Winter Design Temperature: -11 °F (16°C) or

Not recommended for any vent configuration.

*The 99.6% heating db temperatures found in the 1997 or 2001 ASHRAE Fundamentals Handbook, Climatic Design Information chapter, Table 1A (United States) or the 2005 ASHRAE Fundamentals handbook, Climatic Design Information chapter, and the CD-ROM included with the 2005

ASHRAE Fundamentals Handbook.

INTERNAL AREA OF CHIMNEY

SQ. IN. (SQ. MM)

12 19

(7741) (12258)

74 119 80 130 84 138

NR 152 NR NR NR NR

(18064)

178 193 207

233 25O

(24516)

INTERNAL AREA OF CHIMNEY

(7741) (12258) 18084) (24516)

lower

257 279 299

334 368 404

Table 9--Minimum Vent Heights

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 VENT FURNACE

ORIENTATION ORIENTATION iNPUT (BTUH/HR) IN. (rnm)* FT. (M)**

Vent elbow left, then 154,000

Downfiow up Fig. 32 110,000(036/- 12 only)

Horizontal Left then up Fig. 35 132,000 5 (127) 7 (.65)

Horizontal Left Fig. 36 132,000 5 (127) 7 (,65)

Horizontal Left Vent elbow right

Downfiow left Fig. 30 (036/-12 only) 5 (127) 10 (3.0)

Downfiow right Fig. 33 (036/-12 only) 5 (127) 10 (3.0)

4 in. (102 mm) inside casino or vent guard

** Including 4 in. (102 mm) vent section (s) NOTE: All vent configurations must also meet National Fuel Gas Code (NFGC) venting requirements NOTE: For all unlisted vent configurations, refer to National Fuel Gas Code (NFGC) venting requirements.

Vent elbow right, 154,000

Vent Elbow up 154,000

Fig. 37 154,000 5 (127) 7 (.65)

Vent elbow up then 110,000

Vent elbow up, then 110,000

132,000 5 (127) 12 (3.6)

MiNiMUM VENT MiNiMUM VERTICAL VENT

DIAMETER HEIGHT

_ o_

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

Fig. 28 - Upflow Application-Vent Elbow Up

A03208

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

A03209

Fig. 29 - Upflow Application-Vent Elbow Right

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

these figures

I x\

I Ooj<i i

SEE NOTES: 1,2,4,5,6,7,8,9,t0 on the page following these figures

A03210

Fig. 30 - Downflow Application-Vent Elbow Up then Left

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

these figures

A03211

Fig. 31 - Downflow Application-Vent Elbow Up

A03207

Fig. 32 - Downflow Application-Vent Elbow Left then Up

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

these figures.

A03212

Fig. 33 - Downflow Application-Vent Elbow Up then Right

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

Fig. 34 - Horizontal Left Application-Vent Elbow Left

A03213

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

Fig. 35 - Horizontal Left Application-Vent Elbow Right

then Up

° /A i

,\/,

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

following these figures

Fig. 36 - Horizontal Left Application-Vent Elbow Up

A03214

A03215

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

Fig. 38 - Horizontal Right Application-Vent Elbow Right

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

Fig. 39 - Horizontal Right Application-Vent Elbow Left

then Up

A03218

A03219

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

Fig. 37 - Horizontal Left Application-Vent Elbow Right

A03216

Fig. 40 - Horizontal Right Application-Vent Elbow Left

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

NOTES FOR FIGURES 28 - 40

1. For common vent, vent connector sizing and vent material, use the NFGC.

2. Immediately increase to 5-in. (127 mm) or 6-in. (152 mm) vent connector outside furnace casing when 5-in. (127 mm) vent connector is required, 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 field-approved Downflow Vent Guard Kit, is used in the downflow position. See Product Data Sheet for accessory list.

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

5. A 4-in. (102 mm) single-wall (26 ga. minimum) vent must be used inside furnace casing and when the field-approved Downflow Vent Guard Kit is used external to the furnace. See Product Data Sheet for accessory list.

6. Accessory Downflow Vent Guard Kit required in downflow installations with lower vent configuration. See Product Data Sheet for accessory list.

7. Chimney Adapter Kit may be required for exterior masonry chimney applications. Refer to Chimney Adapter Kit for sizing and complete application details. See Product Data Sheet for accessory list.

8. Secure vent connector to furnace elbow with (2) corrosion-resistant sheet metal screws, spaced approximately 180 ° apart.

9. Secure all other single wall vent connector joints with (3) corrosion resistant screws spaced approximately 120 ° apart. Secure Type-B vent connect- ors per vent connector manufacturer's recommendations.

10. The total height of the vent and connector shall be at least seven ft. (2.1 M) 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. 31.)

A02068

START-UP, ADJUSTMENT, AND SAFETY

CHECK

Step 1 mGeneral

FIRE HAZARD

Failure to follow this warning could result in personal iniury, 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 con-

nections will result in improper operation, (See Fig. 26,)

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

4,5-In, W,C, (0,16 psig ) but not exceed 14-In, W,C, (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.

Step 2 reStart-Up Procedures

ELECTRICALSHOCK HAZARD Failure to follow this warning could result in personal

iniury, or death. Blower access door switch opens l15-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. 45.

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.

Step 3 --Adjustments

FIRE AND EXPLOSION HAZARD

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

Never test for gas leaks with an open flame. Use a commercially available soap solution made specifically for

the detection of leaks to check all connections. A fire or explosion may result causing property damage, personal

iniury or loss of life.

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

2. Check gas lines for leaks.

Table 10--Altitude Derate Multiplier for U.S.A.

ALTITUDE PERCENT DERATEMULTIPLIER

FT.(M) OF DERATE FACTOR*

0-2000

(0-610)

2001-3000

(610-914 /

3001-4000

(914-1219)

4001-5000

(1219-1524)

5001-6000

1524-1829)

6001-7000

(1829-2134)

7001-8000

(2134-2438)

0 1.00

8-12 0.90

12-16 0.86

16-20 0.82

20-24 0.78

24-28 0.74

28-32 0.70

8001-9000

(2438-2743) 9001-10,000 38-40 0.82

(2743 -3048) * Derate multiplier factors are based on midpoint altitude for altitude range.

FIRE HAZARD Failure to follow this warning could result in iniury, 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.

43.)

Furnace gas input rate on rating plate is for installations at altitudes up to 2000 ft. (610 M). Furnace input rate must be

within +/-2 percent of furnace rating plate input.

1. Determine the correct gas input rate. The input rating for altitudes above 2,000 ft. (610 M) must

be reduced by 4 percent for each 1,000 ft. (305 M) above sea level. For installations below 2000 ft., refer to the unit

rating plate. For installations above 2000 ft. (610 M), mul- tiply the input on the rating plate by the derate multiplier in Table 10 for the correct input rate.

2. Determine the correct orifice and manifold pressure adjust- ment. There are two different orifice and manifold adjust-

ment tables. All models in all positions, except Low NOx models in downflow or horizontal positions, use Table 14

(22,000 Btuh/Burner). Low NOx models in the downflow or horizontal positions

must use Table 15 (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 14 or 15.

d. Find closest natural gas heat value and specific gravity

in Table 14 or 15.

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.

g. Replace orifice with correct size if required by Table

14 or 15. Use only factory-supplied orifices. See EXAMPLE 2.

32-38 0.86

EXAMPLE 2:(0-2000 ft. (0-610 M) altitude) For 22,000 Btuh per burner application use Table 14.

Heating value = 1000 Btuh/cu ft. Specific gravity = 0.62

Therefore: Orifice No. 43" Manifold pressure: 3.7-In. W.C.

*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. 42.)

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. W.C. or more than 3.8-In. W.C. for natural gas at sea level. If manifold pressure is outside this range, change main burner orifices or refer

Table 14 or 15. 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 12 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 fol- lows:

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 par- ticularly important with straight-run ducts,

b. When thermometer readings stabilize, subtract return-

air temperature from supply-air temperature to determ- ine 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:

• Gas input for heating operation.

• Derate for altitude if applicable.

• Return and supply ducts for excessive restrictions caus- ing static pressures greater than 0.50-In. W.C.

• Dirty filter.

ELECTRICALSHOCK HAZARD

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

Disconnect 115-v electrical power and install lockout tag 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 11 for lead color identification).

Reconnect original lead to SPARE terminal.

Table ll--Speed Selection

COLOR

White

Black

Yellow'i-

Blue*

Red*

1/5 HPmotor models: BLUEto HEAT,REDto SPARE Not available on 1/5 HP motors.

NOTE: Continuous blower isthe HEATspeed.

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 gas valve.

i. Reinstall manifold pressure tap plug in gas valve.

SPEED

Common

Hiqh

Med-Hiqh

Med - Low

Low

AS SHIPPED

BLW

COOL

SPARE SPARE

HEAT

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.

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 ther- mostat subbase terminals, R and W. The thermostat

anticipator should NOT be in the circuit while measur- ing current. (1.) Remove thermostat from subbase or

from wall. (2.) Connect an amp. meter as shown in Fig. 44 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.

7. Adjust blower off delay The blower off delay has 4 ad-

justable 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 4-Air De- livery-CFM (With Filter). See Table 11 for lead color

identification.

FIRE HAZARD

Failure to follow this warning could result in personal iniury, 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.

.............oR PCB _v _

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w u J1 RED I

Y TBB=NI I ......

R _ HUM _I I _.........

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FuIr_ _ - BLU _BLK

SEC-2 SEC-1 _, _ d

_,_o I I _ I ......./ .....

_ _ _ RED _ WriT

_ _ PRS _ _ ILGPS I I

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OTE_11/ >d II

_--_-- BLK PL3 GRN/YEL

B-- .... WHT B ,N)---- i WHT

2 i NEUTRAL _ EQUIPMENT GROUND

L COOL BLWM EAC-2

IbR HSI

SPARE-1 _ MEDLO CAP

(NATURAL & PROPANE GASES)

HEAT MED HI -

NOTE #5 START L2

...... -- •

I | FRS1 BSS (WHEN USED)

F U1 { NO PL14 - -_

FRS2 LS1 NOTE #10

)-- -- BVSS

w@ :P:_1 (WHEN USED}

RED I F I L

I i .......,¢___,"-"

"--L BHT/CLR BLOWER MOTOR SPEED CHANGE RELAY, SPDT LSI, 2 LIMIT SWITCH, AUTO-RESET, SPST (N.C.)

E BLWR SLOWER MOTOR RELAY, SPST - {NO.) OL AUTO-RESET INTERNAL MOTOR OVERLOAD

BLWM BLOWER MOTOR, PERMANENT - SPLIT - CAPACITOR TEMPERATURE SWITCH (N.Cg

C BUSS BLOCKED VENT SHUTOFF SWITCH, MANUAL- RESET SPST-(N C.) PCB PRINTED CIRCUIT BOARD CONTROL

CAP CAPACITOR PL 11-CIRCUIT PCB CONNECTOR CPU MICROPROCESSOR AND CIRCUITRY 2-CIRCUIT CONNECTOR

E .................... l................ T_NC) _23 2_IRCUIT HSl ..........

__ EAC-1 ELECTRONIC AIR CLEANER CONNECTION (115 VAC 1.0 AMP MAX) PRS PRESSURE SWITCH SPST-(N.O.)

SAC-2 ELECTRONIC AIR CLEANER CONNECTION (COMMON) TEST/TWIN COMPONENT TEST & TWIN TERMINAL FRS 12 FLAME ROLLOUT SW-MANUAL RESET SPST-(N C,)

FSE FLAME-PROVING ELECTRODE TRAN TRANSFORMER-If EVAC/24VAC FU 1 FUSE, 3 AMP, AUTOMOTIVE BLADE TYPE, FACTORY INSTALLED --0-- JUNCTION

FU 2 FUSE OR CIRCUIT BREAKER CURRENT INTERRUPT DEVICE O UNMARKED TERMINAL GND EQUIPMENT GROUND _ PCB CONTROL TERMINAL

GV GAS VALVE-REDUNDANT _ FACTORY WIRING (t 15VAC) GVR GAS VALVE RELAY, SPST-(N O ) FACTORY WIRING (24VAC)

HSI HOT SURFACE IGNITER (115 VAC) HSIR HOT SURFACE IGNITER RE Ay, SPST-(N O.) _- FIELD WIRING (lfl 5VAC)

HUM 24 MAC HUMIDIFIER CONNECTION (05 AMP MAX) .... FIELD WIRING (24VAC)

IDM INDUCED DRAFT MOTOR, SHADED-POLE CONDUC fOR ON CON [ROL PCB IOR INDUCED DRAFT MOTOR R Eb_,y, SPST-(N.O) _ FIELD WIRING SCREW TERMINAL

ILK DOWER ACCESS PANEL INTERLOCK SWITCH, SPSI-(N.O.) .j_. J1 BLOWER - OFF DELAY JUMPER SELECTOR - HEATING _ FIELD EARTH GROUND J2 BLOWER - OFF OELAY JUMPER - COOLING _ EQUIPMENT GROUND

JB JUNCTION BOX LED LIGHT-EMI_ING DIODE FOR STATUS CODES - RED _ FIELD SPLICE

LOPS LOW GAS PRESSURE SWITCH SPST-{N O.) _ )---_ PLUG RECEPTACLE

_,. 15. Low Speed Tap on 4 speed motor only. 339937-201 REV, A_

(FIELD INSTALLED & SUPPLIED)

WHT _' -r _2-_"

Fig. 41 - Wiring Diagram

/ PL1-5 _#3

--_::=> FL-_

C 4v PCB NOTE#5 I_PL-7

NOTES:

1. If any of the odginal equsment wre is replaced use wire rated for 105"C.

2. Use only copper wire between file disconnect switch ahd the furnace iWlction box (JB).

3. This wre must be connected to furnace sheet mefal for control to prove flame.

4. Symbols are eleetdcal representat on only.

5. Solid lines inside PCB are pdn_ed c_mtBt board conductors and are not included n legend.

6. Replace only with a 3 amp fuse.

7. Inducer (IDM) and blower (BLWM) motors contqin internal auto-reset thermal overload switches (eL). B. Neutral connections are intemhangeable within the NEUTRAL connector block.

9. Blower motor speed selections are for average conditions, see installaton instructions for details on optimum speed selection.

10. Factory connected when BUSS (Chimney Adaptel Accessory Kt) is not installed.

11. Factory connected when LOPS is not used.

12. Ignition-lockout will occur after fo_r consecutive unsuccessful tdals-for-ignition. ConBol will

auto-reset after three hours.

13. Blower-on delay: gas heating 25 seconds, cool ng or heat pump 2 seconds.

14. Blower-off delay: gas heating selections are 90,120,150 or 180 seconds, cooling or

heat pump 90 seconds or 5 seconds when J2 is out.

A13111

II _.,_ (WHEN USED) _q_

Fig. 42 - Gas Control Valve

A06666

THERMOSTAT SUBBASE TERMINALS WITH THERMOSTAT REMOVED

(ANITICIPATOR, CLOCK, ETC.,

MUST BE OUT OF CIRCUIT.)

HOOK-AR(

AMMETER

FROM UNIT 24-V

CONTROL TERMINALS

A93059

Fig. 43 - Orifice Hole

EXAMPLE: 5.0 AMPS ON AMMETER = 0.5 AMPS FOR THERMOSTAT

10 TURNS AROUND JAWS ANTICIPATOR SETTING

Fig. 44 - Amp. Draw Check With Ammeter

A96316

Step 4 reCheck 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 en- ergizes air-circulating blower motor, if furnace overheats.

By using this method to check limit control, it can be es- tablished 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.

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 l15-v power to furnace.

b. Disconnect inducer motor lead wires from wire har-

ness.

c. Turn on l15-v power to furnace.

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

When pressure switch is functioning properly, hot sur- face 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,

and turn on 115-v power.

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

for heat again.

i. Furnace should ignite normally.

5 mCheeklist

Step

Put away tools and instruments. ('lean up debris.

Verify that blower OFF-DELAY time is selected as de- sired.

3. Verify that blower and burner access doors are properly in- stalled.

4. Cycle test furnace with room thermostat.

5. Check operation of accessories per manufacturer's instruc- tions.

6. Review User's Guide with owner.

7. Attach literature packet to furnace.

SECONDS FOR 1

REVOLUTION

10 11 12 13 14 15

16 17 18 19

20 21 22 23 24

25 26 27 28 29

31 32

33 34

36 37

41 42 43 44

46 47

SIZE OF TEST DIAL

Cu Ft 360

327 300 277 257 24O

225 212 200 189 18O 171 164 157 15O

144 138 133 129 124 120 116 113

1O9 1O6 103 1O0

97 95 92 9O

88 86 84 82 8O 78 76 75 73

2 Cu Ft

720 655 600 555 514 480

450 424 4OO 379 360 343 327 313 300

288 277 267 257 248 24O 232 225

218 212 206 200

195 189 185 18O

176 172 167 164 16O 157 153 15O 147

Table 12--Gas Rate (cu ft./hr)

5Cu Ft

1800 1636 1500 1385 1286 1200

1125 1059 1000

947 9OO 857 818 783 75O

720 692 667 643 621 600 581 563

545 529 514 500 486 474 462 45O

439 429 419 4O9 400 391 383 375 367

SECONDS FOR 1

REVOLUTION

5O 51 52 53 54 55

56 57 58 59 60 62 64 66 68

70 72 74 76 78 8O 82 84

86 88 9O 92 94 96 98

100 102

104 106 108 110 112 116 120

SIZE OF TEST DIAL

1 Cu Ft

72 71 69 68 67 65

64 63 62 61 60 58 56 54 53

51 50 48 47 46 45 44 43

42 41 4O 39 38 38 37 36

35 35 34 33 33 32 31 3O

2 Cu Ft

144 141 138 136 133 131

129 126 124 122 120 116 112 1O9 1O6

103 1O0

97 95 92 9O 88 86

84 82 8O 78 76 75 74 72

71 69 68 67 65 64 62 6O

5Cu Ft

360 355 346 34O 333 327

321 316 310 305 300 290 281 273 265

257 250 243 237 231 225 220 214

209 205 200

196 192 188 184 18O

178 173 17O 167 164 161 155 15O

FURNACE CASING WIDTH

14-1/2 (368)

17-1/2 (445)

21 (533)

24 (610)

Recommended

** Some furnaces may have 2 filters.

Table

13--Filter Size Information (In. / mm)

FILTER SIZE

SIDE

RETURN

16 x25 x3/4

(406 x635 x19)

16 x25 x3/4

(406 x635 x19)

16 x25 x3/4

(406 x635 x19)

16 x25 x3/4

(406 x635 x19)

BOTTOM

RETURN

14 x25 x3/4

(356 x635 x19)

16 x25 x3/4

(406 x635 x19)

20 x25 x3/4

(508 x635 x19)

24 x25 x3/4

(610 x635 x19)

FILTER TYPE

Washable*

Table 14--Orifice Size* and Manifold Pressure (In. W.C.) for Gas Input Rate

(Tabulated data based on 22,000 btuh per burner, derated 4 percent for each 1000 ft. (305 M) above sea level)

AVG. GAS SPECIFIC GRAVITY OF NATURAL GAS

ALTITUDE RANGE HEAT VALUE 0.58 0.60 0.62 0.64

FT. (M) AT ALTITUDE Orifice Manifold Orifice Manifold Orifice Manifold Orifice Manifold

0 to 975 43 3.6 43 3.8 42 3.2 42 3.3

U.S.A, 1000 43 3.5 43 3.6 43 3.7 43 3.8

U.S.A, (610 to 900 43 3.3 43 3.4 43 3.5 43 3.6

U.S.A, 4000 850 43 3.2 43 3.3 43 3.4 43 3.6

U.S.A, 5000 825 43 3.0 43 3.1 43 3.2 43 3.3

Orifice numbers 43 are factory installed.

2000

(0 to

610) 1025 43 3.3 43 3.4 43 3.5 43 3.6

2001 to 850 43 3.7 43 3.8 42 3.2 42 3.3

3000 875 43 3.5 43 3.6 43 3.7 43 3.8

914) 925 43 3.1 43 3.2 43 3.3 43 3.4

3001 to 825 43 3.4 43 3.5 43 3.7 43 3.8

(914 to 875 43 3.0 43 3.1 43 3.3 43 3.4

1219) 900 43 2.9 43 3.0 43 3.1 43 3.2

4001 to 800 43 3.2 43 3.3 43 3.4 43 3.5

(1219 to 850 43 2.8 43 2.9 43 3.0 43 3.1

1524) 875 43 2.7 43 2.8 43 2.9 43 2.9

(BTU/CU FT.) No. Pressure No. Pressure No. Pressure No. Pressure

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

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

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

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

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

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

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

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

Table 14-Orifice Size* and Manifold Pressure (In. W.C.) for Gas Input Rate (Continued)

(Tabulated data based on 22,000 btuh per burner, derated 4 percent for each 1000 ft. (305 M) above sea level)

AVG. GAS SPECiFiC GRAVITY OF NATURAL GAS

ALTITUDE RANGE HEAT VALUE 0.58 0.60 0.62 0.64

FT. (M) AT ALTITUDE

(BTU/CU FT.) No. Pressure No. Pressure No. Pressure No. Pressure

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

5001 to 775 43 3.0 43 3.1 43 3.2 43 3.3

U.S.A. (1524

U.S.A. (1829

U.S.A. (2134

U.S.A.

6000 800 43 2.8 43 2.9 43 3.0 43 3.1

1829) 850 43 2.5 43 2.5 43 2.6 43 2.7

6001 to 725 43 2.9 43 3.0 43 3.1 43 3.2

7000 750 43 2.7 43 2.8 43 2.9 43 3.0

2134) 800 43 2.4 43 2.5 43 2.6 43 2.7

7001 to 700 43 2.7 43 2.8 43 2.9 43 3.0

8000 725 43 2.5 43 2.6 43 2.7 43 2.8

2438) 775 43 2.2 43 2.3 43 2.4 43 2.4

8001 to 650 43 2.7 43 2.8 43 2.9 43 3.0

9000 675 43 2.5 43 2.6 43 2.7 43 2.8

(2438

2743) 725 43 2.2 43 2.2 43 2.3 43 2.4

9001 to 625 43 2.5 43 2.6 43 2.6 43 2.7

10,000 650 43 2.3 43 2.4 43 2.4 43 2.5

(2743 675 43 2.1 43 2.2 43 2.3 43 2.3

3048) 700 48 3.7 43 2.0 43 2.1 43 2.2

825 43 2.6 43 2.7 43 2.8 43 2.9

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

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

775 43 2.6 43 2.7 43 2.7 43 2.8

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

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

750 43 2.4 43 2.4 43 2.5 43 2.6

800 43 2.1 43 2.1 43 2.2 43 2.3 825 48 3.7 43 2.0 43 2.1 43 2.2 625 43 2.9 43 3.0 43 3.1 43 3.2

700 43 2.3 43 2.4 43 2.5 43 2.6

750 43 2.0 43 2.1 43 2.2 43 2.2 600 43 2.7 43 2.8 43 2.9 43 3.0

725 48 3.5 48 3.6 48 3.7 43 2.0 775

48 3.6 48 3.7 43 2.0 43 2.1

__ct_

Table 15--Orifice Size* and Manifold Pressure (In. W.C.) for Gas Input Rate

(Tabulated data based on 21,000 btuh per burner, derated 4 percent for each 1000 ft. (305 M) above sea level)

SPECiFiC GRAVITY OF NATURAL GAS

ALTITUDE AVG, GAS 0.58 0.60 0.62 0.64

RANGE HEAT VALUE FT. (M) AT ALTITUDE Orifice Manifold Orifice Manifold Orifice Manifold Orifice Manifold

(BTU/CU FT.) No. Pressure No. Pressure No. Pressure No. Pressure

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

U,S,A. 1000 44 3.6 43 3.3 43 3.4 43 3.5

U,S,A. 3000 900 43 3.0 43 3.1 43 3.2 43 3.3

U,S,A. 4000 850 43 2.9 43 3.0 43 3.1 43 3.2

U,S,A. 5000

* Orifice numbers 43 are factor" installed.

0 to 2000 (0 to 610)

2001 to 875 43 312 43 3.3 43 314 43 315

(610 to

914) 925 43 2.8 43 2.9 43 3.0 43 3.1

3001 to 825 43 3.1 43 3.2 43 3.3 43 3.4

(914 to 875 43 2.8 43 2.9 43 3.0 43 3.1

1219) 900 43 2.6 43 2.7 43 2.8 43 2.9

4001 to

(1219 to

1524)

975 43 3.3 43 3.4 43 3.5 43 3.7

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 11 O0 46 3.8 45 3.7 44 3.2 44 3.3

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

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

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

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

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

Table 15--Orifice Size* and Manifold Pressure (In. W.C.) for Gas Input Rate (Continued)

(Tabulated data based on 21,000 btuh per burner, derated 4 percent for each 1000 ft. (305 M) above sea level)

ALTITUDE HEAT VALUE

RANGE AT

FT. (M) ALTITUDE Orifice Manifold Orifice Manifold Orifice Manifold Orifice Manifold

5001 to

U.S.A. (1524 to 825 43 2.4 43 2.5 43 2.5 43 2.6

U.S.A. (1829 to 775 43 2.3 43 2.4 43 2.5 43 2.6

U.S.A. (2134 to 750 43 2.1 43 2.2 43 2.3 43 2.4

U.S.A.

U.S.A,

6000 800 43 2.5 43 2.6 43 2.7 43 2.8

1829) 850 43 2.2 43 2.3 43 2.4 43 2.5

6001 to

7000 750 43 2.5 43 2.6 43 2.7 43 2.8

2134) 800 43 2.2 43 2.3 43 2.3 43 2.4

7001 to

8000 725 43 2.3 43 2.4 43 2.5 43 2.5

2438) 775 43 2.0 43 2.1 43 2.2 43 2.2

8001 to

9000 675 43 2.3 43 2.4 43 2.4 43 2.5

(2438 to 700 43 2.1 43 2.2 43 2.3 43 2.3

2743) 725 48 3.7 43 2.0 43 2.1 43 2.2

9001 to

10,000 650 43 2.1 43 2.2 43 2.2 43 2.3

(2743 to 675 48 3.6 48 3.8 43 2.1 43 2.1

3048) 700 48 3.4 48 3.5 48 3.6 48 3.7

AVG. GAS SPECIFIC GRAVITY OF NATURAL GAS

0.58 0.60 0.62 0.64

(BTU/CU FT.) No. Pressure No. Pressure No. Pressure No. Pressure

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

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

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

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

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

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

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

750 48 3.5 48 3.6 48 3.7 43 2.0 600 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

725 49 3.7 49 3.8 48 3.4 48 3.5 775 49 3.8 48 3.4 48 3.5 48 3.6

If status code recall is needed, briefly remove then reconnect one main limit _re to display stored status code. On RED LED boards do not remove power or blower door before initiating status cede recall. After

status code recat[ is completed component test _[[ cocor. LED CODE STATUS

EACH OF THE FOLLOWING STATUS CODES IS A ]WO DIGIT NUMBER WITH THE FI RST DIGIT DETERMI NED 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 31 PRESSURE SWITCH DID NOT CLOSE OR REOPENED - If open longer than five minutes

RED LED boards stored status codes can also be erased when power inducer shuts off for 15 minutes before retry, Check for: - Excessive wind (115 VAC or 24 VAC) to ceetret is ieterrupted. - Proper vent sizing - Defective inducer motor

12 BLOWER ON AFTER POWER UP (115 VAC or 24 VAC) -Btewer runs for 90 seconds, - Low inducer vettage (115VAC) - Defective pressure switch

if unit is powered up during a call for heat (R-W ctosed) or R-W opens during blower - Inadequate combustion air supply - Disconnected or obstructed pressure tubing on-delay. - Low inlet gas pressure (if LGPS used) - Restricted vent

13 LIMIT CIRCUIT LOCKOUT - Lockotrl occurs if the timit, draft safeguard, flame rottout, or If it opens during btower on-detay period, btower will come on for the seIected btower

blocked vent switch (if used) is open longer than 3 minutes, off-delay.

- Control wiii auto reset after three hours. - Refer to #33. 33 LIMIT CIRCUIT FAULT - Indicates a timit, draft safeguard, flame roHout, or blocked vent

14 IGNITION LOCKOUT - Control wilt aLrie-reset after three hours, Refer to #34. switch (if used) is open, Blower wilt run for 4 minutes or until open switch remakes 21 GAS HEATING LOCKOUT - Control wilt NOT auto reset, whichever is longer, If open toeger than 3 minutes, code changes to lockout #13.

Check for: - Mis-wired gas valve -Defective control (valve reIay) If open tess than 3 mieutes status code #33 continues to flash untiI blower shuts Off.

22 ABNORMAL FLAME-PROVING SIGNAL - Flame is proved while gas valve is de- Ftame reHeut switch and BVSS require manual reset, Check for: - Restricted vent

energized. Inducer wiii run until fault is cleared. Check for: - Leaky gas valve - Proper vent sizing - Loose blower wheel. - Excessive wind

- Stuck-open gas valve - Dirty filter or restricted duct system.

23 PRESSURE SWITCH DID NOT OPEN Check for: - Defective blower motor or capacitor. - Defective switch or connections.

- Obstructed pressure tubing, - Pressure switch stuck closed, - Inadequate combustion air supply (Flame Roll-out Switch open),

24 SECONDARY VOLTAGE FUSE IS OPEN Check for: 34 IGNITION PROVING FAILURE - Control wilt try three more times before lockout #14

- Short circuit in secondary voltage (24VAC) wiring, occurs, If flame signal test during blower on-delay period, blower wilt come on for the

COMPONENT TEST

To initiate the component test sequence, shut OFF the room thermostat or disconnect the "R" I thermostat lead. Briefly short the TEST/TWIN terminal to the "Corn 24V" terminal. Status LED

wiii flash code and then turn ON the inducer motor. The inducer motor wilt rue for the entire I

component test. The hot surface ignitor, blower motor fan speed (oe AMBER LED boards only) Newer motor-heat speed, and blower motor-coot speed wilt be turned ON for 10-15 I

seconds each. Gas Valve and Humidifier wilt not be turned on.

_ 327596-101 REV. B

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 vottage (115VAC) polarity reversed, If twinned, refer to twinning kit instructions,

selected blower eff-dalay. Check for: - Ftame sensor must net be grounded

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

- Proper flame sense microamps (.5 microamps D.C. mie., 4.0 - 6.0 nominal).

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

- Defective Hot Surface Ignitor - Control ground continuity

- Low intet 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 - Ftame sense circuit faiIure - Software check error Reset power to clear lockout, Replace control if status code repeats.

Fig. 45 - Service Label

SERVICE AND MAINTENANCE

PROCEDURES

A04223

FIRE, EXPLOSION, ELECTRICAL SHOCK HAZARD

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

Before servicing, disconnect all electrical power and install lockout tag 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.

ENVIRONMENTAL HAZARD Failure to follow this caution may result in environmental

pollution. Remove and recycle all components or materials (i.e. oil,

refrigerant, et.) before unit final disposal.

Step 1 reintroduction

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 WIRING

ELECTRICAL SHOCK HAZARD Failure to follow this warning could result in personal

iniury or death. Before installing, modifying, or servicing system, main

electrical disconnect switch must be in the OFF position and install a lockout tag. 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. Lockout and tag switch with a suitable warning label. Verify proper operation after 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. 41 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 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. 45 and the troubleshooting guide which can be obtained from your distributor. The furnace control

will store 1 status code for 72 hrs. See Fig. 49, a brief Troubleshooting Guide.

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 l15-v power to furnace turned on.

b. Remove outer access door.

c. Look into blower access door sight glass for current

LED status.

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.

2 mCare and Maintenance

Step

FIRE OR EXPLOSION HAZARD

Failure to follow this warning could result in personal iniury, 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.

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.

ELECTRICAL SHOCK AND FIRE HAZARD

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

Turn off the gas and electrical supplies to the unit and install lockout tag 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 iniury, death and/or property damage.

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

CUT HAZARD Failure to follow this caution may result in personal iniury.

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 FILTER 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.

CUTHAZARD Failureto follow this caution may result in personal iniury.

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.

Media cabinet filter procedures: NOTE: Media cabinet or 3/4-in. (19 ram) filter rack are

accessories and are not included from the factory.

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 3/4-in. (19 ram) 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 13 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.

6. Slide filter into cabinet.

7. Replace filter cabinet door.

8. Turn on electrical supply to furnace. BLOWER MOTOR AND WHEEL

ELECTRICALSHOCK 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. 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. All factory wires can be left connected, but field thermo- stat connections may need to be disconnected depending

on their length and routing.

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

7. 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.

8. Vacuum any loose dust from blower housing, wheel and motor.

9. If a greasy residue is present on blower wheel, remove wheel from the blower housing and wash it with an appro-

priate 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 reas- sembling).

e. Remove blower wheel from housing.

f. Clean wheel and housing.

10. Reassemble motor and blower by reversing steps 9f through 9a, finishing with 9a. Be sure to reattach ground

wire to the blower housing.

11. 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 neces- sary.

12. Spin the blower wheel by hand to verify that the wheel does not rub on the housing.

13. Reinstall blower assembly in furnace.

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 nfidpoint of the rise range or slightly above. Refer to SET TEMPERATURE RISE under START-UP, ADJUSTMENT, and SAFETY

CHECK.

14. Connect thermostat leads if previously disconnected.

15. To check blower for proper rotation:

a. Turn on electrical supply.

ELECTRICALSHOCK HAZARD Failure to follow this warning could result in personal

iniury, or death. Blower access door switch opens l15-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.

b. Manually close blower access door switch.

NOTE: If thermostat ternfinals 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

16. If furnace is operating properly, RELEASE BLOWER ACCESS DOOR SWITCH. Remove any jumpers or re-

connect any disconnected thermostat leads. Replace blower access door.

17. 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,

18. Reinstall casing door.

19. Turn on gas supply and cycle furnace through one com- plete heating and cooling cycle. Verify the furnace temper-

ature rise as shown in Adjustments Section. Adjust tem- perature rise as shown in Adjustments Section. If outdoor

temperature is below 70 °F, (21 ° C) 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 EXCHANGER 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 discon-

necting wires from switches because damage may occur):

a. Draft safeguard switch,

b. Inducer motor.

c. Pressure switch(es).

d. Linfit 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.

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. 46 and 47 for correct igniter

location.

9. Using field-provided 25-caliber rifle cleaning brush, 36-in. (914 ram) long, 1/4 in. (6 ram) diameter steel

spring caMe, 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 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 variaMe-speed, reversible drill to the end of spring caMe (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. 48.) (3) Work cable in and out of cell 3 or 4 times to obtain sufficient

cleaning. DO NOT pull cable with great force. Reverse drill and gradually work caMe out.

9132-

7.1 mm

A05025

Fig. 46 - Igniter Position-Side View

1-7/8

(47.6 mm)

A05026

Fig. 47 - Igniter Position-Top View

A01050

Fig. 48 - Cleaning Heat Exchanger Cell

(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 con- nection 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 ° 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.

FIRE OR EXPLOSION HAZARD

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

Never test for gas leaks with an open flame. Use a commercially available soap solution made specifically for

the detection of leaks to check all connections. A fire or explosion may result causing property damage, personal

injury or loss of life,

19. Check for gas leaks.

20. Replace outer access door.

Step 3 mSequence 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. 41, 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 t\_r 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 amber 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 thermo-

stat "calls for heat," closing the R-to-W circuit. The fur- nace 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 in-

stalled 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 re- lay 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 prov- ing period begins. The HSI igniter will remain ener-

gized 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 fact- ory-set for a 120-second blower-OFF delay.

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 cir- cuits are opened. The outdoor unit will stop, and the fur-

nace 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.)

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 ener-

gized as long as the blower motor BLWM is energized. During a call for heat, the blower BLWM will stop during igniter warm-up (17 see), ignition, and blower-ON delay

(25 see), 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 addi- tional 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 opera-

tion.

Heat Pump When installed with a heat pump, the furnace control auto-

matically 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 in-

ducer 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 disap- pear, leaving the G signal, the blower motor BLWM will

continue running the blower motor at HEAT speed after the selected blower-OFF delay period is completed.

Step 4 reWiring Diagrams Refer to Fig. 25 and 41 for wiring diagrams.

Step 5 mTroubleshooting Refer to the service label. (See Fig. 45-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 @propriate arrow to the next item.

The Guide will help to identify the problem or failed component. After replacing any component, verify correct operation

sequence.

START

Is LED status on?

light

YES

,_ls there 115V at Lt and L2?

,-,_,_ Is door switch closed?

-,_,_,_ Is door switch closed? I

_ YES

I ls there 24V at SEC-1 and SEC-2?

_ YES

Replace furnace control,

pause?ISLED status light blinking rapidly without a

" Is LED status light blinking ON/OFF slowly

w th a comb nat on of short and ong flashes? I y

YES

_" Determine status code, The status code isa

2 digit number with the first digit determined _' by the number of short flashes and the second _° d g t by the number of ong f ashes?

T _YES _Was there a previous status code _" wasG°tofashedsecti°nbelow for the status code that F I

Check for correct line voltage polarity. If units are twinned, check for proper low-voltage

(24V) transformer phasing.

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 #t t (t short and ! 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 boards only) HEAT speed, and COOL speed will run for t0 t5 seconds each.

Gas valve and humidifier will not be turned on.

other than #tt?

_ YES

I Isthere t15V going to switch?

_ YES

l [ Replace door switch.

•_ Replace transformer.

___ oes the control respond to W, Y1 (if present)

Y/Y2, and G (24V) thermostat signals?

V YES

to check operation. Status codes are erased after 72 hours, On RED LED boards stored status codes can also be erased whenever

I Run system through a heating or cooling cycle

(t 15V or 24V) is interrupted.

I Replace furnace control,

-"_ Is circuit breaker closed? p

II YES

J Check for continuity in wire from circuit breaker

I I Close circuit breaker and go back to START. I_

to furnace, I

Check room thermostat or I interconnecting cable,

' NO

___ls 24V present at W '¢1 (if present) Y/Y2 or I

G thermostat terminals on the furnace control? I

, YES

Disconnect all the thermostat wires from the I

furnace centre, I

___ oes the problem repeat when using

a jumper wire?

_ NO

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,

A02106a

NO PREVIOUS CODE - Stored codes 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.

BLOWER ON AFTER POWER UP - (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.

3133PRESSURE SWITCH DID NOT CLOSE

OR REOPENED - tf open longer than 5

minutes, inducer shuts off for 15 minutes

before retry, tf opens during blower on- delay period, blower will come on for the selected blower oft-delay. Check for:

- Proper vent sizing.

--€,

- Low inducer voltage (115V).

- Low inlet gas pressure (if LGPS used).

- Inadequate combustion air supply,

- Disconnected or obstructed pressure tubing.

- Defective inducer motor.

- Defective pressure switch.

- Excessive wind.

- Restricted vent.

Unplug igniter harness from control and initiate another component test sequence. Check for 115V between pin 1and NEUTRAL-L2 on

the control. Was 115V present for the 15 second period?

CONTROL CIRCUITRY LOCKOUT

Auto-reset after 1 hour lockout due to:

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 inthe harness and igniter.

Replace defective component.

LIMIT CIRCUIT LOCKOUT- Lockout 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.

IGNITION LOCKOUT- System failed to ignite gas and prove flame in 4 attempts.

Control will auto-reset after 3 hours. See status code 34.

GAS HEATING LOCKOUT-Turn off power and wait 5 minutes to retry.

Check for:

- Stuck closed gas valve relay on control.

- Miswire or short to gas valve wire.

ABNORMAL FLAME-PROVING SIGNAL Flame is proved while gas valve is de- energized. Inducer will run until fault is

cleared. Check for:

- Stuck open or leaky gas valve.

PRESSURE SWITCH DID NOT OPEN I

Check for:

- Obstructed pressure tube.

- Pressure switch stuck closed.

SECONDARY VOLTAGE FUSE IS OPEN Check for:

- Short circuit in secondary voltage (24V) wiring including thermostat leads.

Disconnect thermostat leads to isolate short circuit.

LIMIT CIRCUIT FAULT- indicates the limit, draft safeguard, flame rollout, or

blocked vent switch* (if used) is open. Blower will run for 4 minutes or until open switch remakes whichever is longer, tf

open longer than 3 minutes, code changes to lockout #13. tf open less

than 3 min. status code #33 continues to flash until blower shuts off. Flame

rollout switch and BVSS requires manual reset. Check for:

- Dirty filter or restricted duct system.

- Loose blower wheel.

- Defective switch or connections.

- Defective blower motor or capacitor.

- Inadequate combustion air supply (flame rollout switch open).

- Restricted vent.

- Proper vent sizing.

- Excessive wind.

IGNITION PROVING FAILURE- tf flame

is not sensed during the trial for ignition period, the control will repeat the ignition

sequence 3 more times before lockout #14 occurs, tf flame signal is lost during

the blower on-delay period, blower will

come on for the selected blower oft-delay.

Check the following items first before

proceeding to the next step.

- Gas valve turned off.

- Manual shut-oft valve.

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

- Flame sensor must not be grounded.

To determine whether the problem is in the gas valve, igniter, or flame sensor the

system can be operated in the component test mode to check the igniter. First

remove the R thermostat connection from the control and initiate the component test sequence. Does the igniter glow

orange/white by the end of the 15 second warm-up period?

* Blocked vent switch used in Chimney Adapter Kit

Reconnect the R thermostat lead and set

thermostat to call for heat. Connect voltmeter across gas valve connections. Does gas valve

receive 24V?

YES

Does gas valve open and allow gas to flow?

YES

I Do the main burners ignite?

YES

I Do the main burners stay on?

Repeat call for heat and check flame sensor current during trial for ignition period, ts the

DC microamps below 0.5?

YES

Clean flame sensor with fine steel wool and I

recheck current. Nominal current is 4.0 to 6.0 microamps.

I Is current near typical value?

__YES

Will main burners ignite and stay on?

J YES

I Fixed" I

._..O_t Check connections. If OK, replace control.

Replace valve.

NOel Check that all gas valves are turned on.

Check for:

- Inadequate flame carryover or rough ignition.

Proper firing rate.

- Low inlet gas pressure. Blocked or incorrect carry- over gap.

(.045" nominal)

Allow blower to come on and repeat test to

check for intermittent operation.

Check connections and retry, tf current is near typical value (4.0-6.0 nominal) and

burners will not stay on, replace control.

__.._ Replace electrode.

!_._ Replace furnace control.

PARTS REPLACEMENT INFORMATION GUIDE

CASING GROUP Outer door Blower door

Top filler plate

Bottom filler plate Bottom enclosure

ELECTRICAL GROUP Control bracket

Junction box Linfit switch(es)

Circuit board Door switch

Transformer Wiring harness l15v

Wiring harness 24v

BLOWER GROUP

Blower housing Blower cutoff

Blower motor Blower wheel

Capacitor (where used) Capacitor strap (where used)

Grommet Power choke (where used)

GAS CONTROL GROUP Manifold

Burner assembly Orifice

Flame sensor Hot surface igniter

Gas valve Manual reset linfit switches

Burner support assembly

HEAT EXCHANGER GROUP Heat exchanger cell

Cell panel Lox NOx baffle (California models only)

INDUCER GROUP Housing assembly

Pressure switch Inducer motor

Inducer wheel Vent elbow assembly

Draft safeguard switch

TO OBTAIN INFORMATION ON PARTS: Consult your installing dealer or classified section of your local telephone directory under "Heating Equipment" or "Air Conditioning Contractors and Systems" headings for dealer listing by brand name or contact:

PAYNE HEATING & COOLING

Consumer Relations Department

P.O. Box 4952

Syracuse, New York 13221-4952

1-800-417-2963

Example of Model Number

MODEL VARIATION VARIATION

PG8M A A 036 070 A E JA

WARNING: Improper installation, adjustment, alteration, service, or maintenance can cause personal injury, property damage, or death. Consult a qualified installer, service agency, or your local gas supplier for information or assistance. The qualified installer or service agency

must use only factory-authorized replacement parts, kits, or accessories when modifying this product.

ELECTRICAL MAJOR COOLING HEATING MINOR

SUPPLY SERIES SIZE SIZE SERIES

Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations.

Edition Date: 08_13

Catalo_ No: IM-PG8J-17

Replaces: IM PG8J 16

Payne PG8MAA048070, PG8MAA066110, PG8MAA066110AAJA, PG8MAA048070AAJA, PG8MAA048090AAJA Installation Guide

Specifications and Main Features

Frequently Asked Questions

User Manual