Rheem RGFE, RGJF, RGGE Installation Instructions Manual

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Page 1

INSTALLATION INSTRUCTIONS

FOR RGFE UPFLOW, RGGE DOWNFLOW & RGJF DEDICATED HORIZONTAL HIGH EFFICIENCY MODULATING CONDENSING GAS FURNACES

RGJF

RGFE

RGGE

SEE PAGE 112

SEE PAGE 122

This Memory Card must be removed (broken away) from the furnace control when the control is replaced. The card must be inserted into the connector at J15 of the replacement control. Failure to retain this memory card with the furnace when replacing the furnace control could result in no operation when the furnace control is replaced.

MODULATING THERMOSTAT

INSTALLATION

MODULATING

COMMUNICATING

THERMOSTAT

INSTALLATION

ISO 9001:2008

WARNING

DO NOT EXCHANGE MEMORY CARDS BETWEEN 2 OR MORE DIFFERENT FURNACES. DOING SO COULD RESULT IN UNEXPECTED OPERATION – INCLUDING INADEQUATE AIRFLOW DURING HEATING (AND OTHER MODES) OR A LOSS OF HEAT.

RECOGNIZE THIS SYMBOL AS AN INDICATION OF IMPORTANT SAFETY INFORMATION!

IF THE INFORMATION IN THESE INSTRUCTIONS IS NOT FOLLOWED EXACTLY, A FIRE OR EXPLOSION MAY RESULT, CAUSING PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.

THESE INSTRUCTIONS ARE INTENDED AS AN AID TO QUALIFIED SERVICE PERSONNEL FOR PROPER INSTALLATION, ADJUSTMENT AND OPERATION OF THIS UNIT. READ THESE INSTRUCTIONS THOROUGHLY BEFORE ATTEMPTING INSTALLATION OR OPERATION. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN IMPROPER INSTALLATION, ADJUSTMENT, SERVICE OR MAINTENANCE, POSSIBLY RESULTING IN FIRE, ELECTRICAL SHOCK, CARBON MONOXIDE POISONING, EXPLOSION, PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.

PROPOSITION 65 WARNING: THIS PRODUCT CONTAINS CHEMICALS KNOWN TO THE STATE OF CALIFORNIA TO CAUSE CANCER, BIRTH DEFECTS OR OTHER REPRODUCTIVE HARM.

— Do not store or use gasoline or other flammable vapors and liquids, or other combustible materials

in the vicinity of this or any other appliance.

— WHAT TO DO IF YOU SMELL GAS

• Do not try to light any appliance.

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

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

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

• Do not return to your home u

— DO NOT RELY ON SMELL ALONE TO DETECT LEAKS. DUE TO VARIOUS FACTORS, YOU MAY NOT

BE ABLE TO SMELL FUEL GASES.

• U.L. recognized fuel gas and CO detectors are recommended in all applications, and their installation should be in accordance with the manufacturer’s recommendations and/or local laws, rules regulations, or customs.

— Improper installation, adjustment, alteration, service or maintenance can cause injur

damage or death. Refer to this manual. Installation and service must be performed by a qualified installer, service agency or the gas supplier. In the commonwealth of Massachusetts, installation must be performed by a licensed plumber or gas fitter for appropriate fuel.

ntil authorized by the gas supplier or fire department.

y, property

92-24161-75-00

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IMPORTANT: All Rheem products meet current Federal OSHA Guidelines for safety. California Proposition 65 warnings are required for certain products, which are not covered by the OSHA standards.

California's Proposition 65 requires warnings for products sold in California that contain, or produce, any of over 600 listed chemicals known to the State of California to cause cancer or birth defects such as fiberglass insulation, lead in brass, and combustion products from natural ga

All “new equipment” shipped for sale in California will have labels stating that the product contains and/or produces Proposition 65 chemicals. Although we have not changed our processes, having the same label on all our products facilitates manufacturing and shipping. We cannot always know “when, or if” products will be sold in the California market.

You may receive inquiries from customers about chemicals found in, or produced by, some of our heating and air-cond

itioning equipment, or found in natural gas used with some of our products. Listed below are those chemicals and substances commonly associated with similar equipment in our industry and other manufacturers.

• Glass Wool (Fiberglass) Insulation

• Carbon Monoxide (CO)

• Formaldehyde

• Benzene

More details are available at the Websites for OSHA (Occupational Safety and Health Administration), at www.osha.gov

and the State of

California's OEHHA (Office of

Environmental Health Hazard

Assessment), at www.oehha.org. Consumer education is important since the chemicals and substances on the list are found in our daily lives. Most consumers are aware that products present safety and health risks, when improperly used, handled and maintained.

Installation Instructions are updated on a regular basis. This is done as product changes occur or if new information becomes available. In this publication, an arrow ➤ denotes changes from the previous edition or additional new material.

TABLE OF CONTENTS

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

INSTALLATION CHECK LIST...................................................................................................................................5

GENERAL INFORMATION .......................................................................................................................................6

IMPORTANT INFORMATION ABOUT EFFICIENCY AND INDOOR AIR QUALITY..............................................8

LOCATION REQUIREMENTS AND CONSIDERATIONS.......................................................................................9

CLEARANCE-ACCESSIBILITY....................................................................................................................10

SITE SELECTION .........................................................................................................................................11

DIMENSIONS AND CLEARANCE TO COMBUSTIBLES...........................................................................12

UPFLOW MODELS.............................................................................................................................12

DOWNFLOW MODELS......................................................................................................................13

HORIZONTAL MODELS.....................................................................................................................14

DUCTING ......................................................................................................................................................15

SUPPLYAIR SENSOR .................................................................................................................................17

VENTING AND COMBUSTION AIR PIPING.........................................................................................................18

INSTALLATION WITH PRE-EXISTING VENT SYSTEMS..........................................................................18

JOINING PIPE AND FITTINGS....................................................................................................................19

CEMENTING JOINTS...................................................................................................................................19

NON-DIRECT VENT PIPE INSTALLATION ...........................................................................................................20

DIRECT VENT PIPE INSTALLATION ....................................................................................................................24

CONCENTRIC TERMINATIONS..................................................................................................................26

HORIZONTALTERMINATIONS...................................................................................................................28

CONDENSATE DRAIN / OPTIONAL NEUTRALIZER ..........................................................................................34

CONVERTING DOWNFLOW/HORIZONTAL MODELS TO HORIZONTAL CONFIGURATION.........................36

GAS SUPPLYAND PIPING ....................................................................................................................................39

GAS VALVE...................................................................................................................................................40

LP CONVERSION.........................................................................................................................................42

ELECTRICAL WIRING............................................................................................................................................45

ACCESSORIES.......................................................................................................................................................47

ELECTRONIC AIR CLEANER......................................................................................................................47

HUMIDIFICATIONAND DEHUMIDIFICATION............................................................................................47

OTHER ACCESSORIES ..............................................................................................................................49

TYPICAL WIRING ACCESSORIES FOR COMMUNICATING RESIDENTIAL SYSTEMS............49-50

HIGH ALTITUDE INSTALLATIONS ........................................................................................................................51

LP GAS AT HIGH ALTITUDE ELEVATIONS................................................................................................53

ZONING SYSTEMS......................................................................................................................................54

INSTALLATION WITH NON-COMMUNICATING, HIGH-EFFICIENCY PREMIUM COOLING

SYSTEMS ...................................................................................................................................................54

INTEGRATED FURNACE CONTROL ...................................................................................................................55

CONNECTORS AND COMPONENTS OF FURNACE CONTROL ...........................................................55

SPECIAL CONFIGURATION – COMM T-STAT AND NON-COMM CONDENSER ..................................56

MEMORY CARD...........................................................................................................................................60

RULES FOR WRITING, DISTRIBUTION AND ARBITRATION OF MULTIPLE COPIES OF

FURNACE SHARED DATA FOR COMMUNICATING-CAPABLE FURNACES ..............................60

REPLACING THE FURNACE CONTROL...................................................................................................63

DIPSWITCHES .............................................................................................................................................66

FURNACE OPERATION USING NON-COMMUNICATING MODULATING,

MODULATING AND TWO-STAGE T-STATS.....................................................................................69

COMMUNICATING SYSTEMS....................................................................................................................73

WIRING FOR COMMUNICATIONS...................................................................................................73

STARTUP FOR SYSTEMS CONFIGURED WITH COMMUNICATIONS........................................74

CONTINUOUS FAN OPERATION IN COMMUNICATING MODE...................................................75

ACTIVE FAULT CODES WITH COMMUNICATING SYSTEMS.......................................................75

FURNACE USER MENUS ...........................................................................................................................75

STATUS 1 ............................................................................................................................................76

STATUS 2 ............................................................................................................................................78

2 WK HIST...........................................................................................................................................78

LIFE HIST............................................................................................................................................79

FAULT HISTORY.................................................................................................................................79

UNIT INFO...........................................................................................................................................79

SETUP.................................................................................................................................................79

DIPSWITCH.........................................................................................................................................80

DUAL-FUEL OPERATION ............................................................................................................................80

START-UP PROCEDURES ....................................................................................................................................81

SEQUENCE OF OPERATION.....................................................................................................................83

SETTING INPUT RATE................................................................................................................................83

MAINTENANCE.......................................................................................................................................................84

TROUBLESHOOTING CHART ..............................................................................................................................87

NORMAL OPERATING CODES (TABLE 20) ........................................................................................................89

FURNACE FAULT CODES WITH DESCRIPTIONS AND SOLUTIONS (TABLE 21)..................................90-105

WIRE DIAGRAM – STEPPER / SERVO MODULATING VALVE (FUEL CODES HA OR HB).........................106

WIRE DIAGRAM – SOLENOID CONTROLLED MODULATING VALVE (FUEL CODES HG OR HH)............107

THERMOSTATS ....................................................................................................................................................108

NON-COMMUNICATING THERMOSTATS...............................................................................................108

THERMOSTAT WIRING (WITH WIRING DIAGRAMS) ............................................................................109

APPLICATIONS.....................................................................................................................................................112

MODULATING, TOUCH-SCREEN, NON-COMMUNICATING THERMOSTAT ((-)HC-TST412MDMS)..112

COMMUNICATING THERMOSTATS.........................................................................................................122

(-)HC-TST501CMMS PROGRAMMABLE COMMUNICATING THERMOSTAT............................124

(-)HC-TST550CMMS FULL COLOR, PROGRAMMABLE COMMUNICATING THERMOSTAT...128

IMPORTANT: To insure proper installation and operation of this product, completely read all instructions prior to attempting to assemble, install, operate, maintain or repair this product. Upon unpacking of the furnace, inspect all parts for damage prior to installation and start-up.

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SAFETY INFORMATION

IMPORTANT!

THE COMMONWEALTH OF MASSACHUSETTS REQUIRES COMPLIANCE WITH REGULATION 248 CMR 4.00 AND 5.00 FOR INSTALLATION OF THROUGH-THE-WALL VENTED GAS APPLIANCES AS FOLLOWS:

(a) For all side wall horizontally vented

gas fueled equipment installed in every dwelling, building or structure used in whole or in part for residential purposes, including those owned or operated by the Commonwealth and where the side

wall exhaust vent termination is less than

seven (7) feet above finished grade in the area of the venting, including but not limited to decks and porches, the following requirements shall be satisfied:

1. INSTALLATION OF CARBON MONOXIDE DETECTORS. At the time of

installation of the side wall horizontal

vented gas fueled equipment, the installing plumber or gasfitter shall observe that a hard wired carbon

monoxide detector with an alarm and

battery back-up is installed on the floor level where the gas equipment is to be installed. In addition, the installing plumber or gasfitter shall observe that a battery operated or hard wired carbon

monoxide detector with an alarm is

installed on each additional level of the dwelling, building or structure served by

the side wall horizontal vented gas

fueled equipment. It shall be the responsibility of the property owner to secure the services of qualified licensed professionals for the installation of hard wired

carbon monoxide detectors. a. In the event that the side wall horizon-

tally vented gas fueled equipment is installed in a crawl space or an attic, the

hard wired carbon monoxide detector

with alarm and battery back-up may be

installed on the next adjacent floor level.

b. In the event that the requirements of this subdi time of completion of installation, the owner shall have a period of thirty (30) days to comply with the above requirements; provided, however, that during said thirty (30) day period, a battery

operated carbon monoxide detector with

an alarm shall be installed.

2. APPROVED CARBON MONOXIDE DETECTORS. Each carbon monoxide

detector as required in accordance with the above provisions shall comply with NFPA 720 and be ANSI/UL 2034 listed and IAS certified.

3. SIGNAGE. A metal or plastic identification plate shall be permanently mount-

ed to the exterior of the building at a

minimum height of eight (8) feet above

grade directly in line with the exhaust vent terminal for the horizontally vented

gas fueled heating appliance or equip-

ment. The sign shall read, in print size no less than one-half (1/2) inch in size,

“GAS VENT DIRECTLY BELOW. KEEP CLEAR OF ALL OBSTRUCTIONS”.

vision can not be met at the

4. INSPECTION. The state or local gas

inspector of the side wall horizontally

vented gas fueled equipment shall not approve the installation unless, upon inspection, the inspector observes car-

bon monoxide detectors and signage

installed in accordance with the provisions of 248 CMR 5.08(2)(a) 1 through

4. (b) EXEMPTIONS: The following equip-

ment is exempt from 248 CMR

5.08(2)(a)1 through 4:

1. The equipment listed in Chapter 10 entitled “Equipment Not Required To Be Vented” in the most current edition of NFPA 54 as a

2. Product Approved side wall horizon-

tally vented gas fueled equipment installed in a room or structure separate from the dwelling, building or structure used in whole or in part for residential purposes.

wall horizontally vented gas equipment

provides a venting system design or venting system components with the equip

ment, the instructions provided by the manufacturer for installation of the equipment and the venting system shall include:

1. Detailed instructions for the installation of the venting system design or the venting system components; and

2. A complete parts list for the venting system design or venting system.

(d) MANUFACTURER REQUIREMENTS – GAS EQUIPMENT VENTING SYSTEM NOT PROVIDED. When the manufacturer of a Product

Approved side wall horizontally vented

gas fue the parts for venting the flue gases, but identifies “special venting systems”, the following requirements shall be satisfied by the manufacturer:

1. The referenced “special venting system” instructions shall be included with the appliance or equipment installation instructions; and

2. The “special venting systems” shall be Product Approved by the Board, and the instructions for that system shall include a parts list and detailed in tion instructions.

(e) A copy of all installation instructions for all Product Approved side wall hori-

zontally vented gas fueled equipment,

all venting instructions, all parts lists for venting instructions, and/or all venting design instructions shall remain with the appliance or equipment at the completion of the installation.

dopted by the Board; and

led equipment does not provide

stalla-

WARNING

INSTALL THIS FURNACE ONLY IN A LOCATION AND POSITION AS SPECIFIED IN THE LOCATION REQUIREMENTS AND CONSIDERATIONS SECTION OF THESE INSTRUCTIONS. PROVIDE ADEQUATE COMBUSTION AND VENTILATION AIR TOTHE FURNACE SPACE AS SPECIFIED IN THE VENTING SECTION OF THESE INSTRUCTIONS.

WARNING

PROVIDE ADEQUATE COMBUSTION AND VENTILATION AIR TO THE FURNACE SPACE AS SPECIFIED IN THE COMBUSTION AND VENTILATION AIR SECTION OF THESE INSTRUCTIONS.

WARNING

COMBUSTION PRODUCTS MUST BE DISCHARGED OUTDOORS. CONNECT THIS FURNACE TO AN APPROVEDVENT SYSTEM ONLY, AS SPECIFIED IN VENT PIPE INSTALLATION SECTION OF THESE INSTRUCTIONS.

WARNING

NEVER TEST FOR GAS LEAKS WITH AN OPEN FLAME. USE A COMMERCIALLY AVAILABLE SOAP SOLUTION MADE SPECIFICALLY FOR THE DETECTION OF LEAKS TO CHECK ALL CONNECTIONS, AS SPECIFIED IN GAS SUPPLY AND PIPING SECTION OF THESE TION INSTRUCTIONS.

WARNING

THIS FURNACE IS NOT APPROVED OR RECOMMENDED FOR INSTALLATION ON ITS BACK, WITH ACCESS DOORS FACING UPWARDS, ORWITH SUPPLY AIR DISCHARGING TO THE RIGHTHAND SIDE WHEN FACING THE FRONT OF THE FURNACE. SEE FIGURES 6 AND 7 FOR PROPER INSTALLATION OF HORIZONTAL MODELS.

WARNING

DO NOT INSTALL THIS FURNACE IN A MOBILE HOME!! THIS FURNACE IS NOT APPROVED FOR INSTALLATION IN A MOBILE HOME. DOING SO COULD CAUSE FIRE, PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.

WARNING

USE ONLY WITH TYPE OF GAS APPROVED FORTHIS FURNACE. REFER TO THE FURNACE RATING PLATE.

Page 4

WARNING

WHEN THIS FURNACE IS INSTALLED IN A RESIDENTIAL GARAGE, IT MUST BE INSTALLED SO THE BURNERS AND IGNITION SOURCE ARE LOCATED NO LESS THAN 18 INCHES ABOVE THE FLOOR. THIS ISTO REDUCE THE RISK OF IGNITING FLAMMABLE VAPORS WHICH MAY BE PRESENT IN A GARAGE. ALSO,THE FURNACE MUST BE LOCATED OR PROTECTED TO AVOID PHYSICAL DAMAGE BY VEHICLES. FAILURETO FOLLOW THESE WARNINGS CAN CAUSE A FIRE OR EXPLOSION, RESULTING IN PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.

WARNING

USE OF THIS FURNACE IS ALLOWED DURING CONSTRUCTION IF THE FOLLOWING TEMPORARY INSTALLATION REQUIREMENTS ARE MET. INSTALLATION MUST COMPLY WITH ALL INSTALLATION INSTRUCTIONS INCLUDING:

• PROPER VENT INSTALLATION;

• FURNACE OPERATING UNDER THERMOSTATIC CONTROL;

• RETURN AIR DUCT SEALED TO THE FURNACE;

• AIR FILTERS IN PLACE;

• SET FURNACE INPUT RATE AND

TEMPERATURE RISE PER RAT-

ING PLATE MARKING;

• MEANS FOR PROVIDING OUT-

DOOR AIR REQUIRED FOR COM-

BUSTION;

• RETURN AIR TEMPERATURE

MAINTAINED BETWEEN 55°F

(13°C) AND 80°F (27°C); AND;

• CLEAN FURNACE, DUCT WORK

AND COMPONENTS UPON SUBSTANTIAL COMPLETION OF THE CONSTRUCTION PROCESS, AND VERIFY FURNACE OPERATING CONDITIONS INCLUDING IGNITION, INPUT RATE,TEMPERATURE RISE AND VENTING, ACCORDINGTO THE INSTRUCTIONS.

WARNING

DO NOT JUMPER OR OTHERWISE BYPASS OVERTEMPERATURE OR ANY OTHER LIMITS OR SWITCHES ON THE FURNACE. IF ONE OF THESE LIMITS OR SWITCHES SHOULD TRIP OR OPEN, THE USER IS TO BE INSTRUCTED TO CALL A QUALIFIED INSTALLER, SERVICE AGENCY OR THE GAS SUPPLIER. FOR MANUALLY RESETABLE SWITCHES,THE USER IS FURTHER INSTRUCTED TO NEVER RESET THE SWITCH, BUT TO CALL A QUALIFIED TECHNICIAN. MANUAL RESET SWITCHES MAY REQUIRE FURTHER CORRECTIVE ACTIONS. FAILURE TO FOLLOWTHIS WARNING COULD RESULT IN CARBON MONOXIDE POISONING, SERIOUS INJURY OR DEATH. IF THE UNIT IS INSTALLED IN A CLOSET,THE DOOR MUST BE CLOSED WHEN MAKINGTHIS CHECK. INSTALLERS AND TECHNICIANS ARE INSTRUCTED TO REPLACE ANY LIMIT OR SAFETY SWITCH/DEVICE ONLY WITH IDENTICAL REPLACEMENT PARTS.

WARNING

DUCT LEAKS CAN CREATE AN UNBALANCED SYSTEM AND DRAW POLLUTANTS SUCH AS DIRT, DUST, FUMES AND ODORS INTO THE HOME CAUSING PROPERTY DAMAGE. FUMES AND ODORS FROM TOXIC, VOLATILE OR FLAMMABLE CHEMICALS, AS WELL AS AUTOMOBILE EXHAUST AND CARBON MONOXIDE (CO), CAN BE DRAWN INTOTHE LIVING SPACETHROUGH LEAKING DUCTS AND UNBALANCED DUCT SYSTEMS CAUSING PERSONAL INJURY OR DEATH (SEE FIGURE 5).

• IF AIR-MOVING EQUIPMENT OR

DUCTWORK IS LOCATED IN GARAGES OR OFF-GARAGE STORAGE AREAS - ALL JOINTS, SEAMS, AND OPENINGS IN THE EQUIPMENT AND DUCT MUST BE SEALED TO LIMIT THE MIGRATION OF TOXIC FUMES AND ODORS INCLUDING CARBON MONOXIDE FROM MIGRATING INTO THE LIVING SPACE.

• IF AIR-MOVING EQUIPMENT OR

DUCTWORK IS LOCATED IN SPACES CONTAINING FUEL BURNING APPLIANCES SUCH AS WATER HEATERS OR BOILERS ALL JOINTS, SEAMS, AND OPENINGS IN THE EQUIPMENT AND DUCT MUST ALSO BE SEALED TO PREVENT DEPRESSURIZATION OF THE SPACE AND POSSIBLE MIGRATION OF COMBUSTION BYPRODUCTS INCLUDING CARBON MONOXIDE INTOTHE LIVING SPACE.

WARNING

ALWAYS INSTALL FURNACETO OPERATE WITHIN THE FURNACE'S INTENDED TEMPERATURE-RISE RANGE WITH A DUCT SYSTEM WHICH HAS AN EXTERNAL STATIC PRESSURE WITHIN THE ALLOWABLE RANGE, AS SPECIFIED IN DUCTING SECTION OF THESE INSTRUCTIONS. SEE ALSO FURNACE RATING PLATE.

WARNING

WHEN A FURNACE IS INSTALLED SO THAT SUPPLY DUCTS CARRY AIR CIRCULATED BYTHE FURNACETO 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 CONTAININGTHE FURNACE.

NOTICE

IMPROPER INSTALLATION, OR INSTALLATION NOT MADE IN ACCORDANCE WITH THE CSA INTERNATIONAL (CSA) CERTIFICATION OR THESE INSTRUCTIONS, CAN RESULT IN UNSATISFACTORY OPERATION AND/OR DANGEROUS CONDI-TIONS AND ARE NOT COVERED BY THE UNIT WARRANTY.

NOTICE

IN COMPLIANCE WITH RECOGNIZED CODES, IT IS RECOMMENDED THAT AN AUXILIARY DRAIN PAN BE INSTALLED UNDER ALL EVAPORATOR COILS OR UNITS CONTAINING EVAPORATOR COILS THAT ARE LOCATED IN ANY AREA OF A STRUCTURE WHERE DAMAGE TO THE BUILDING OR BUILDING CONTENTS MAY OCCUR AS A RESULT OF AN OVERFLOW OF THE COIL DRAIN PAN OR A STOPPAGE IN THE PRIMARY CONDENSATE DRAIN PIPING. SEE ACCESSORIES SECTION OF THESE INSTRUCTIONS FOR AUXILIARY HORIZONTAL OVERFLOW PAN INFORMATION (MODEL RXBM).

WARNING

DO NOT EXCHANGE MEMORY CARDS BETWEEN 2 OR MORE DIFFERENT FURNACES. DOING SO COULD RESULT IN UNEXPECTED OPERATION – INCLUDING INADEQUATE AIRFLOW DURING HEATING (AND OTHER MODES OR A LOSS OF HEAT).

Page 5

INSTALLATION CHECK LIST

REFER TO INSTALLATION INSTRUCTIONS

GAS SUPPLY

Adequate pipe size

Correct supply pressure (during furnace operation)

Manifold pressure

No gas leaks

ELECTRICAL

115 V.A.C. supply (Single Circuit)

Polarity observed

Furnace properly grounded (Earth ground)

Adequate wire size

FURNACE INSTALLATION

Adequate clearance to combustibles

Adequate clearance for service (at front)

DUCT STATIC PRESSURE

in. w.c. on heating speed

in. w.c. on cooling spe

Air temperature rise

CONDENSATE LINE

Trap filled with water

Vented

Sloped toward drain

Condensate drain line hoses connected and clamped

TERMINATIONS – DIRECT VENT

VERTICAL

Intake – 12" min. above roof/snow level

Correct relationship – exhaust to intake

VERTICAL – CONCENTRIC (RXGY-E03A)

Intake – 12" min. above roof/snow level

HORIZONTAL – STANDARD (RXGY-D02, -D02A, -D03,

-D03A)

Correct relationship – exhaust to intake

12" min. above grade/snow level

ORIZONTAL – ALTERNATE (RXGY-D02, -D02A, -D03,

-D03A, -D04 OR -D04A)

Correct relationship – exhaust to intake

Above anticipated snow level

HORIZONTAL – CONCENTRIC (RXGY-E03A)

12" min. above grade/snow level

Intake “Y” rotated above center

Exhaust sloped toward furnace

VENTING – NON-DIRECT VENT (VERTICAL ONLY)

in. diameter – exhaust pipe

ft. of pipe – exhaust

no. of elbows

TERMINATION – NON-DIRECT VENT (VERTICAL ONLY)

12" min. above roof/snow level

Freeze protection (if necessary)

______ Neutralizer (if needed)

VENTING – DIRECT VENT

in. diameter – intake pipe

in. diameter – exhaust pipe

ft. of pipe – intake air

no. of elbows – intake air

ft. of pipe – exhaust pipe

no. of elbows – exhaust pipe

HORIZONTAL – STANDARD

12" min. above grade/snow level

HORIZONTAL – ALTERNATE

Above anticipated snow level

Model #

Serial #

Date

of installation

Page 6

GENERAL INFORMATION

The RGFE, RGGE and RGJF series furnaces are design-certified by CSA for use with natural and L.P. gases as follows:

• As direct vent, central forced air

furnaces with all combustion air supplied directly to the furnace burners through a special air intake system outlined in these instructions.

• As non-direct, central forced air fur-

nace taking combustion air from the installation area or using air ducted from the outside.

• IMPORTANT: Proper application,

installation and maintenance of this

furnace are required if consumers are to receive the full benefits for which they have paid.

Install this furnace in accordance with the American National Standard Z223.1 – latest edition entitled “National Fuel Gas Code” (NFPA54, 90A and 90B) and requirements or codes of the local utilities or other

authorities having jurisdiction. This is

available from the following: National Fire Protection

Association, Inc. Batterymarch Park Quincy, MA 02269

CSA International - U.S. 8501 East Pleasant Valley Road Cleveland, Ohio, 44131

Canadian installations must be installed in accordance with CSA, local installation codes and

authorities having jurisdiction.

CSA is available from: CSA International - Canada

178 Rexdale Blvd.

Etobicoke (Toronto), Ontario, Canada M9W-1R3

FIGURE 1

UPFLOW FURNACE RGFE (GAS VALVE MAY BE DIFFERENT THAN SHOWN)

➤ FIGURE 2

DOWNFLOW FURNACE RGGE (GAS VALVE MAY BE DIFFERENT THAN SHOWN)

ITEM

NO. PART NAME

1 CONDENSATE TRAP

2 DOOR SWITCH

3 JUNCTION BOX

4 TRANSFORMER

5 PRESSURE SWITCH ASSEMBLY

6 EXHAUST TRANSITION

7 CONNECTOR

8 MAIN LIMIT

9 EXHAUST AIR PIPE

10 VENT CAP SHIPPING PLUG

11 FLAME SENSOR

12 OVERTEMPERATURE SWITCH

ITEM

NO. PART NAME

13 TOP PLATE

14 BURNER

15 IGNITER

16 COMBUSTION AIR INLET

17 GAS VALVE

18 INDUCED DRAFT BLOWER

19 POWER FACTOR CHOKE

20 INTEGRATED FURNACE CONTROL

21 BLOWER MOTOR

22 BLOWER HOUSING

ITEM

NO. PART NAME

1 GAS VALVE

2 PRESSURE SWITCH ASSEMBLY

3 BLOWER HOUSING

4 POWER FACTOR CHOKE

5 BLOWER MOTOR

6 DOOR SWITCH

7 JUNCTION BOX

8 COMBUSTION AIR INLET

9 HALC

10 TOP PLATE

11 VENT CAP SHIPPING PLUG

ST-A1123-01_1 ST-A1123-01_2

12 OUTLET AIR PIPE

ITEM

NO. PART NAME

13 INTEGRATED FURNACE CONTROL

14 TRANSFORMER

15 INDUCED DRAFT BLOWER

16 CONNECTOR

17 EXHAUST TRANSITION

18 CONDENSATE TRAP

19 IGNITER

20 OVERTEMPERATURE SWITCH

21 BURNER

22 FLAME SENSOR

Page 7

➤ FIGURE 3

DEDICATED HORIZONTAL FURNACE RGJF (GAS VALVE MAY BE DIFFERENT THAN SHOWN)

ITEM

NO. PART NAME

1 GAS VALVE

2 CAPACITOR (FOR INDUCER)

3 LOW PRESSURE SWITCH

4 HIGH PRESSURE SWITCH

5 BLOWER HOUSING

6 POWER FACTOR CHOKE

7 BLOWER MOTOR

8 DOOR SWITCH

9 JUNCTION BOX

10 COMBUSTION AIR INLET

11 HALC

12 TOP PLATE

13 VENT CAP PLUG

ITEM

NO. PART NAME

14 OUTLET AIR PIPE

15 INTEGRATED FURNACE CONTROL

16 TRANSFORMER

17 INDUCED DRAFT BLOWER

18 CONNECTOR

19 EXHAUST TRANSITION

20 CONDENSATE TRAP

21 IGNITER

22 OVERTEMPERATURE SWITCH

23 BURNER

24 FLAME SENSOR

25 FACTORY-INST

ALLED STREET ELBOW

ST-A107801.S01

Page 8

IMPORTANT INFORMATION ABOUT EFFICIENCY AND INDOOR AIR QUALITY

Central cooling and heating equipment is only as efficient as the duct system that carries the cooled or heated air. To maintain efficiency, comfort and good indoor air quality, it is important to have the proper balance between the air being supplied to each room and the air returning to the cooling and heating equipment.

Proper balance and sealing of the duct system improves the efficiency of the heating andair conditioning system and improves the indoor air quality of the home by reducing the amount of airborne pollutants that enter homes from spaces where the ductwork and / or equipment is located. The manufacturer and the U.S. Environmental Protection Agency’s Energy Star Program recommend that central duct systems be checked by a qualified contractor for proper balance and sealing.

WARNING

DUCT LEAKS CAN CREATE AN UNBALANCED SYSTEM AND DRAW POLLUTANTS SUCH AS DIRT, DUST, FUMES AND ODORS INTOTHE HOME CAUSING PROPERTY DAMAGE. FUMES AND ODORS FROM TOXIC,VOLATILE OR FLAMMABLE CHEMICALS, AS WELL AS AUTOMOBILE EXHAUST AND CARBON MONOXIDE (CO), CAN BE DRAWN INTO THE LIVING SPACE THROUGH LEAKING DUCTS AND UNBALANCED DUCT SYSTEMS CAUSING PERSONAL INJURY OR DEATH (SEE FIGURE

4).

• IF AIR-MOVING EQUIPMENT OR

DUCTWORK IS LOCATED IN SPACES CONTAINING FUEL BURNING APPLIANCES SUCH AS WATER HEATERS OR BOILERS - ALL JOINTS, SEAMS, AND OPENINGS IN THE EQUIPMENT AND DUCT MUST ALSO BE SEALED TO PREVENT DEPRESSURIZATION OF THE SPACE AND POSSIBLE MIGRATION OF COMBUSTION BYPRODUCTS INCLUDING CARBON MONOXIDE INTO THE LIVING SPACE.

NOTICE

IMPROPER INSTALLATION,OR

INSTALLATION NOT MADE IN ACCORDANCE WITH THE CSA INTERNATIONAL (CSA) CERTIFICATION OR THESE INSTRUCTIONS, CAN RESULT IN UNSATISFACTORY OPERATION AND/OR DANGEROUS CONDI-TIONS AND ARE NOT COVERED BY THE UNIT WARRANTY.

NOTICE

IN COMPLIANCE WITH RECOGNIZED CODES, IT IS RECOMMEND-

ED THAT AN AUXILIARY DRAIN PAN BE INSTALLED UNDER ALL EVAPORATOR COILS OR UNITS CONTAINING EVAPORATOR COILS THAT ARE LOCATED IN ANY AREA OF A STRUCTURE WHERE DAMAGE TO THE BUILDING OR BUILDING CON-

TENTS MAY OCCUR AS A RESULT

OF AN OVERFLOW OF THE COIL

DRAIN PAN OR A STOPPAGE IN THE

PRIMARY CONDENSATE DRAIN PIP-

ING. SEE ACCESSORIES SECTION

OF THESE INSTRUCTIONS FOR

AUXILIARY HORIZONTAL OVER-

FLOW PAN INFORMATION (MODEL

RXBM).

FIGURE 4

MIGRATION OF DANGEROUS SUBSTANCES, FUMES, AND ODORS INTO LIVING SPACES

RECEIVING

Immediately upon receipt, all cartons

and contents should be inspected for

transit damage. Units with damaged

cartons should be opened immedi-

ately. If damage is found, it should

be noted on the delivery papers, and

a damage claim filed with the last carrier.

• After unit has been delivered to

job site, remove carton taking care

not to damage unit.

• Check the unit rating plate for unit

size, electric heat, coil, voltage,

phase, etc. to be sure equipment

matches what is required for the

job specification.

• Read the entire instructions before

starting the installation.

• Some building codes require extra

cabinet insulation and gasketing when unit is installed in attic applications.

• If

installed in an unconditioned space, apply caulking around the power wires, control wires, refrigerant tubing and condensate line where they enter the cabinet. Seal the power wires on the inside

where they exit conduit opening.

Caulking is required to prevent air leakage into and condensate from

forming inside the unit, control box,

and on electrical controls.

• Install the unit in such a way as to

allow necessary access to the coil/filter rack and blower/control compartment.

• Install the unit in a level position to

ensure proper condensate drainage. Make sure unit is level in both directions within 1/8”.

• Install the unit in accordance with

any local code which may apply and the national codes. Latest edi-

tions are available from: “National Fire Protection Association, Inc., Batterymarch Park, Quincy, MA

02269.” These publications are:

• ANSI/NFPA No. 70-(Latest Edition)

National Electrical Code.

• NFPA90A Installation of Air

Conditioning and Ventilating Systems.

• NFPA90B Installation of warm air

heating and air conditioning systems.

• The equipment has been evaluat-

ed in accordance with the Code of Federal Regulations, Chapter XX, Part 3280.

Page 9

LOCATION REQUIREMENTS AND CONSIDERATIONS

GENERAL INFORMATION

CAUTION

DO NOT USE THIS FURNACE DURING CONSTRUCTION IF AIR LADEN CORROSIVE COMPOUNDS ARE PRESENT SUCH AS CHLORINE AND FLUORINE. OTHERWISE, PROVISIONS MUST BE TAKEN TO PROVIDE CLEAN, UNCONTAMINATED COMBUSTION AND VENTILATION AIR TO THE FURNACE. FURNACE COMBUSTION AND VENTILATION AIR CONTAMINATED WITHTHESE COMPOUNDS FORMS ACIDS DURING COMBUSTION WHICH CORRODES THE HEAT EXCHANGER AND COMPONENT PARTS. SOME OF THESE CONTAMINANTS ARE FOUND IN, BUT NOT LIMITED TO, PANELING, DRY WALL, ADHESIVES, PAINTS, STAINS, VARNISHES, SEALERS, AND MASONRY CLEANING MATERIALS.

WARNING

DO NOT INSTALL THIS FURNACE IN A MOBILE HOME!! THIS FURNACE IS NOT APPROVED FOR INSTALLATION IN A MOBILE HOME. DOING SO COULD CAUSE FIRE, PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.

WARNING

WHEN THIS FURNACE IS INSTALLED IN A RESIDENTIAL GARAGE, IT MUST BE INSTALLED SO THE BURNERS AND IGNITION SOURCE ARE LOCATED NO LESS THAN 18 INCHES ABOVE THE FLOOR. THIS IS TO REDUCE THE RISK OF IGNITING FLAMMABLE VAPORS WHICH MAY BE PRESENT IN A GARAGE. ALSO,THE FURNACE MUST BE LOCATED OR PROTECTED TO AVOID PHYSICAL DAMAGE BY VEHICLES. FAILURE TO FOLLOWTHESE WARNINGS CAN CAUSE A FIRE OR EXPLOSION, RESULTING IN PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.

1. IMPORTANT: If installing the unit

over a finished ceiling or living

area, be certain to install an auxil-

iary condensate drain pan under the entire unit. Extend this auxil- iary drain pan under any evaporator coil installed with the furnace and the open portion of the con-

densate drain assembly. See

“Condensate Drain/Neutralizer”

section for more details.

2. IMPORTANT: If using a cooling

evaporator coil with this furnace. Be sure the air passes over the

heat exchanger before passing

over the cooling coil. The cooled air passing over the warm ambient

air inside the heat exchanger

tubes can cause condensation inside the sion and eventual failure.

3. IMPORTANT: Install the furnace

level. If it is not level, condensate cannot drain properly, possibly causing furnace shut down.

NOTE: These furnaces are approved for installation in attics, as well as alcoves, utility rooms, closets and crawlspaces. Make provisions to pre-

vent freezing of condensate.

4. IMPORTANT: If this furnace is

installed in a garage, attic or any other unconditioned space, a selfregulating heat tape must be installed around the condensate trap and along the entire length of the condensate drain in the unconditioned space.

The heat tape should meet the following requirements:

a. The heat tape must be UL listed. b. Install the heat tape per the

c. The heat tape should be rated

FIGURE 5

DOWNFLOW HORIZONTAL FURNACE WITH HEAT TAPE ON CONDENSATETRAP

DRAIN PIPE

A086701

tubes resulting in corro-

manufacturer’s instructions for the entire length of drain pipe in the unconditioned space.

at 3 or 5 watts per foot at 120V.

SUPPLY AIR

HEAT TAPE

TRAP

5. IMPORTANT: If installing in a

utility room, be sure the door is wide enough to:

a. allow the largest part of the

furnace to pass; or

b. allow any other appliance

(such as a water heater) to pass.

6. Install the furnace level and plumb. If it is not level, condensate cannot drain properly, possibly causing furnace to shut down.

IMPORTANT: Do not attempt to twin the modulating furnace. The characteristics of the ECM blower motor preclude twinning applications.

RETURN AIR

Page 10

FIGURE 6

DOWNFLOW/HORIZONTAL FURNACE INSTALLED IN HORIZONTAL POSITION W/SUPPORT BRACKETS

THIS FURNACE IS NOT APPROVED OR RECOMMENDED FOR INSTALLATION ON ITS BACK, WITH ACCESS DOORS FACING UPWARDS, ORWITH SUPPLY AIR DISCHARGING TO THE RIGHT

GAS PIPE

TRAP

CAUTION

SUPPLY AIR

INTAKE VENT

ELECTRICAL CONDUIT

EXHAUST VENT

RETURN AIR

E FOLLOWING MODELS INCLUDE THE ADDITIONAL BRACKET (WHICH MUST BE REMOVED) ON THE BLOWER ASSEMBLY:

RGFE/RGGE/RGJF-09EZCMS RGFE/RGGE/RGJF-10EZCMS RGFE/RGGE/RGJF-12ERCMS

HAND SIDE WHEN FACING THE FRONT OF THE FURNACE.

SEE FIGURES 6 AND 7 FOR PROPER INSTALLATION OF HORIZONTAL MODELS.

FIGURE 7

REMOVING SHIPPING BRACKET

CLEARANCE ACCESSIBILITY

The design of forced air furnaces with models as listed in the tables under Figures 9 and 10 are certified by CSA Laboratories for the clearances to combustible materials shown in inches.

See name/rating plate and clearance label for specific model number and clearance information.

Service clearance of at least 24 inches is recommended in front of all furnaces.

FOR PURPOSES OF SERVICING THIS APPLIANCE, ACCESSIBILITY CLEARANCES, WHERE GREATER, SHOULD TAKE PRECEDENCE OVER FIRE PROTECTION CLEARANCES.

A086801

WARNING

FURNACES MUST NOT BE INSTALLED DIRECTLY ON CARPET, TILE OR OTHER COMBUSTIBLE MATERIAL. INSTALLATION ON A COMBUSTIBLE MATERIAL OTHER THAN WOOD FLOORING MAY RESULT IN FIRE CAUSING DAMAGE, PERSONAL INJURY OR DEATH.

-GGE FURNACES MAY NOT

BE INSTALLED DIRECTLYTO A COMBUSTIBLE FLOOR. A SPECIAL FLOOR BASE IS REQUIRED.

-GFE upflow furnaces and -GGE downflow furnaces are designed and certified for installation on combustible (wood only) floors.

-GGE downflow furnaces may be installed on a cased evaporator coil mounted on a combustible (wood only) floor or (for installations without an evaporator coil) installed on a special base for combustible floors mounted to a combustible (wood only) floor.The nece

ssary floor base for installing a -GGE furnace in the downflow configuration to a combustible (wood only) floor is an accessory sold through finished goods. Following is a list of floor base models by furnace input size (see Figure 8).

RGGE

Furnace Special Base For

BTU’s Combustible Floors

60, 75 RXGC-B17

90, 105 RXGC-B21

120 RXGC-B24

Upflow furnaces are shipped with a bottom closure panel installed. When bottom return air is used, remove the panel by removing the two screws attaching the panel to the front base angle. See filter section for details (see Figure 12).

92-24379-01

CAUTION

SOME MODELS HAVE A SHIPPING BRACKET INSTALLED TO PROTECT THE BLOWER ASSEMBLY DURING SHIPPING.

LOCATE AND REMOVE THE SHIPPING BRACKET FROM THE SIDE OF THE BLOWER HOUSING BEFORE OPERATING UNIT. SEE FIGURE 7.

Page 11

FIGURE 8

BASE FOR COMBUSTIBLE FLOORS

SITE SELECTION

1. Select a site in the building near

the center of the proposed, or exist-

ing, duct system.

2. Give consideration to the vent system piping when selecting the furnace location. Vent from the furnace to the termination with minimal length and elbows.

3. Locate the furnace near the exist-

ing gas piping. If running a new gas

line, locate the furnace to minimize

the length and elbows in the gas piping.

4. Locate the furnace to maintain proper clearance to combu as shown in Figures 9, 10 & 11.

stibles

WARNING

COMBUSTIBLE MATERIAL MUST NOT BE PLACED ON OR AGAINST THE FURNACE JACKET. THE AREA AROUND THE FURNACE MUST BE KEPT CLEAR AND FREE OF ALL COMBUSTIBLE MATERIALS INCLUDING GASOLINE AND OTHER FLAMMABLE VAPORS AND LIQUIDS. PLACEMENT OF COMBUSTIBLE MATERIALS ON, AGAINST OR AROUND THE FURNACE JACKET CAN CAUSE AN EXPLOSION OR FIRE RESULTING IN PROPERTY DAMAGE, PERSONAL INJURY OR DEATH. THE HOMEOWNER SHOULD BE CAUTIONED THAT THE FURNACE A USED AS A BROOM CLOSET OR FOR ANY OTHER STORAGE PURPOSES.

REA MUST NOT BE

Page 12

FIGURE 9

PHYSICAL DIMENSIONS AND CLEARANCE TO COMBUSTIBLES, UPFLOW MODELS

A039201

RGFE

UPFLOW MODELS

AIRFLOW

NOTE: For 1800 or more CFM, both side

returns must be used when not using a

bottom return configuration.

AO39201

Page 13

FIGURE 10

DIMENSIONS AND CLEARANCES TO COMBUSTIBLES, DOWNFLOW MODELS

RGGE

(Downflow Configuration)

FOR MODELS INSTALLED AS DOWNFLOW ONLY

AIRFLOW

Page 14

FIGURE 11



DIMENSIONS AND CLEARANCES TO COMBUSTIBLES, HORIZONTAL MODELS

NOTE: For 1800 or more CFM, both side

returns must be used when not using a

FACING THE FRONT OF THE FUR-

ONLY BE INSTALLED SO AS WHEN

IMPORTANT:THIS FURNACE MAY

NACE, SUPPLY AIR IS DIS-

CHARGED ON THE LEFT HAND

SIDE.

(RETURN)(SUPPLY)

bottom return configuration.

INSTALLED AS

configuration.)

(FUEL CODE HB ONLY)

HORIZONTAL ONLY

RGJF (ALL) & RGGE

on RGGE models – only

(Be sure to check the fuel code

furnaces with HB fuel codes

can be installed in horizontal

AIRFLOW

Page 15

DUCTING

Proper airflow is required for the correct operation of this furnace. Too little airflow can cause erratic operation and can damage the heat

exchanger. The supply and return duct

must carry the correct amount of air for heating and cooling if summer air conditioning is used.

Size the ducts according to acceptable

industry standards and methods. The total static pressure drop of the supply

and return duct should not exceed 0.2"

w.c.

WARNING

NEVER ALLOWTHE PRODUCTS OF COMBUSTION FROMTHE FLUE TO ENTER THE RETURN AIR DUCTWORK ORTHE CIRCULATED AIR SUPPLY. ALL RETURN DUCTWORK MUST BE ADEQUATELY SEALED AND SECURED TO THE FURNACE

WITH SHEET METAL SCREWS;

AND JOINTS,TAPED. SECURE ALL OTHER DUCT JOINTS WITH APPROVED CONNECTIONS AND SEAL AIRTIGHT.WHEN A FURNACE IS MOUNTED ON A PLATFORM WITH RETURN THROUGH THE BOTTOM, IT MUST BE SEALED AIRTIGHT BETWEEN THE FURNACE ANDTHE RETURN AIR PLENUM.THE FLOOR OR PLATFORM MUST PROVIDE PHYSICAL SUPPORT OFTHE FURNACEWITHOUT SAGGING, CRACKS, OR GAPS AROUND THE BASE, PROVIDING A SEAL BETWEEN THE SUPPORT AND THE BASE.

FAILURE TO PREVENT PRODUCTS OF COMBUSTION FROM BEING CIRCULATED INTOTHE LIVING SPACE CAN CREATE POTENTIALLY HAZARDOUS CONDITIONS, INCLUDING CARBON MONOXIDE POISONINGTHAT COULD RESULT IN PERSONAL INJURY OR DEATH.

DO NOT, UNDER ANY CIRCUMSTANCES, CONNECT RETURN OR SUPPLY DUCTWORK TO OR FROM ANY OTHER HEAT PRODUCING DEVICE SUCH AS A FIREPLACE INSERT, STOVE, ETC. DOING SO MAY RESULT IN FIRE, CARBON MONOXIDE POISONING, EXPLOSION, PERSONAL INJURY OR PROPERTY DAMAGE.

IMPORTANT: Some high efficiency filters

have a greater than normal resistance to airflow. This can adversely affect furnace operation. Be sure to check airflow if using any filter other than the factory-provided filter.

UPFLOW UNITS

1. Position the unit to minimize long

runs of duct or runs of duct with many turns and elbows.

WARNING

UPFLOW FURNACE: BASE PLATE MUST BE INSTALLED IN THE FURNACE BOTTOM WHEN USING SIDE AIR RETURN. FAILURE TO INSTALL A BASE PLATE COULD CAUSETHE PRODUCTS OF COMBUSTION TO CIRCULATE INTOTHE LIVING SPACE AND CREATE POTENTIALLY HAZARDOUS CONDITIONS, INCLUDING CARBON MONOXIDE POISONING OR DEATH.

A SOLID METAL

2. Open the return air compartment.

a. If using side return air, do not

remove the bottom base.

b. Cut an opening in the side .

The opening should be cut the full width of the knockouts on the

unit.

NOTE: When using side return, return air plenums, RXGR-C17B, C21B and C24B are available from the factory.

c. Remove the bottom base, if

using bottom return air. Remove the panel by removing the two screws attaching the base to the front base angle. See Figure 12.

NOTE: Where the maximum

airflow is 1800 CFM or more, both sides or the bottom must be used for return air.

3. Connect the return duct or return air cabinet to the unit. Make the connection air tight to prevent entra

ining combustion gases from

an adjacent fuel-burning appli-

ance.

4. Be sure to have adequate

space for the unit filter. NOTE: DO NOT take return air

from bathrooms, kitchens, furnace rooms, garages, utility or laundry rooms, or cold areas. DO NOT use a rear air return.

5. If summer air conditioning is desired, position the indoor coil on the supply air side of the unit. Insure that no air can bypass this coil.

6. Connect the supply air plenum to the furnace plenum opening.

IMPOR

TANT: If a flexible duct

connector must be used, it MUST be rated for a minimum temperature of 250°F. continuous.

FIGURE 12

BOTTOM PANEL REMOVAL

NOTE: FILTERAND FILTER-ROD ARE SHIPPED ON TOP OF SOLID BOTTOM. REMOVE FILTER AND FILTER ROD TO ACCES SOLID BOTTOM

ADS-5422-01

Page 16

DOWNFLOW UNITS

1. Position the unit to minimize long

runs of duct or runs of duct with many turns and elbows.

2. If summer air conditioning is desired, position the indoor coil on the supply air side of the unit. Insure that no air can bypass this coil.

3. If installing on a combustible floor

and not using an air conditioning plenum, install the special base for

combustible floors. See Figure 8.

WARNING

THE DOWNFLOW FURNACE DESIGN IS CERTIFIED FOR INSTALLATION ON A NON-COMBUSTIBLE FLOOR USE THE SPECIAL BASE SPECIFIED ON THE FURNACE CLEARANCE LABEL. FAILURE TO INSTALLTHE SPECIAL BASE MAY RESULT IN FIRE, PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.THIS SPECIAL BASE IS SHIPPED FROM THE FACTORY AS AN ACCESSORY.

4. Connect the furnace to the supply air plenum.

5. Connect the return air ducting to the return air opening at the top of the unit. Make the connection air tight to prevent entraining combus-

tion gases from an adjacent fuel-

burning appliance.

6. Be sur

eto have adequate space

for the unit filter. NOTE: DO NOT take return air

from bathrooms, kitchens, furnace rooms, garages, utility or laundry rooms, or cold areas.

 Return air can come from : (1) outside the building, (2) from return air ducting from several inside rooms, or (3) a combination of the two. When using

outside air, design and adjust the sys-

tem to maintain a return air temperature above 55°F during the heating season. If return air comes from both inside and outside the building, design the ducting system with a diverting damper so that the volume of return air entering the furnace equals that which would normally enter thr furnace. Any duct opening pulling return air from the outside must not be any higher nor closer than 10 feet to the fur-

nace exhaust vent.

ough the return air intake of the

Page 17

SUPPLY AIR SENSOR

Each furnace comes shipped from the factory with a supply air sensor. Install the sensor, in the supply air plenum trunk, with two, field supplied, #8 sheet metal screws, using the following guidelines:

1. 12” downstream of the evaporator coil, if installed.

2. If no evaporator coil is used, locate the sensor out of direct line-of-site of the heat exchanger and not closer than 18” downstream of the furnace outlet.

3. Attach the supply air sensor wires onto the terminals marked “SA Sensor” on the integrated furnace control board (See Figure 13).

4. Do not extend the supply-air sensor

wire. NOTE: Improper placement of the

supply air sensor can adversely affect furnace temperature rise.

NOTE: In downflow circumstances where building construction does not allow for the placement of the sensor to fall within these parameters, the supply air sensor should not be connected. This means that the furnace will run under default parameters. When running under default parameters, the “82” code will appear for 90 seconds. After that, the fault code will be stored in the control board’s memory and will show only upon power cycling. Default airflow

parameters can be manually adjusted.

See section discussing Integrated Furnace Control (IFC) board in this manual.

For communicating systems, the supply air se off so that a fault code will not be displayed at all. This can be done in the furnace setup menu of a communicating thermostat. See the section of this manual titled Communicating Systems under sub-section titled Furnace User Menus (Setup).

nsor input can be turned

FIGURE 13

SUPPLY AIR SENSOR TERMINALS

Page 18

VENTING AND COMBUSTION AIR PIPING

GENERAL INFORMATION

WARNING

READ AND FOLLOW ALL INSTRUCTIONS IN THIS SECTION. FAILURETO PROPERLY VENT THIS FURNACE OR PROTECT IT FROM INADEQUATE COMBUSTION AIR CAN CAUSE CARBON MONOXIDE POISONING, AN EXPLOSION OR FIRE, RESULTING IN PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.

OVERTEMPERATURE SAFETY SWITCHES

Furnaces are equipped with safety switches in the burner compartment to protect against over temperature conditions. If a switch is tripped, it must be manually reset.

WARNING

DO NOT JUMPER OVERTEMPERATURE OR ANY OTHER SAFETY SWITCHES! IF ONE OF THESE OVER TEMPERATURE SWITCHES SHOULD TRIP, CALL A QUALIFIED INSTALLER, SERVICE AGENCY OR THE GAS SUPPLIER. DO NOT RESET THE SWITCHES WITHOUTTAKING CORRECTIVE ACTION. FAILURE TO DO SO CAN RESULT IN CARBON MONOXIDE POISONING OR DEATH. IF THIS UNIT IS INSTALLED IN A CLOSET, THE DOOR MUST BE CLOSEDWHEN MAKING THIS CHECK.

REPLACETHE OVER TEMPERATURE SAFETY SWITCHES ONLY WITH THE IDENTICAL REPLACEMENT PART.

WARNING

IN CANADA, PRODUCTS CERTIFIED FOR INSTALLATION AND INTENDED TO BE VENTEDWITH PLASTIC VENT SYSTEMS (PVC, CPVC) MUST USE VENT SYSTEMS THAT ARE CERTIFIED TO THE STANDARD FOR TYPE BH GAS VENTING SYSTEMS, ULC S636.

THE COMPONENTS OF THE CERTIFIED MATERIAL MUST NOT BE INTERCHANGED WITH OTHER VENT SYSTEMS OR UNLISTED PIPE/FITTINGS.

PLASTIC COMPONENTS AND SPECIFIED PRIMERS AND GLUES OF THE CERTIFIED SYSTEM MUST BE FROM A SINGLE SYSTEM MANUFACTURER AND NOT INTERMIXED WITH OTHER SYSTEM MANUFACTURER’S PARTS.

NOTE: INLET AIR PIPING IS NOT CONSIDERED TO BE A PART OF THE “VENTING SYSTEM”.THE REQUIREMENT THATVENT MATERIAL BE CERTIFIED TO ULC S636 DOES NOT APPLY TO INLET AIR PIPING.

INSTALLATION WITH PRE-EXISTING VENT SYSTEMS

When the installation of this furnace

replaces an existing furnace that is

removed from a vent system serving other appliances (such as a water

heater), the existing vent system is likely

to be too large to proper remaining attached appliances.

Follow the steps below with each appliance remaining connected to the original common vent system. Place the appliance to be tested in operation, while the other appliances remaining connected to the common vent system are not in operation. Test the operation of each appliance individually by the following method.

1. Permanently seal any unused openings in the common venting system.

2. Visually inspect the venting system f

or proper size and horizontal pitch

and determine that there is no blockage, restriction, leakage, corrosion or other deficiencies which could cause an unsafe condition.

3. If practical, close all building doors, windows and all doors between the space where the appliances remaining connected to the common venting system are located. Turn on clothes dryers and any appliance not connected to the

ly vent the

common venting system. Turn

on any exhaust fans, such as

range hoods and ba

exhausts, so they will operate at maximum speed. Do not operate a summer exhaust fan. Close

fireplace dampers.

4. Follow the lighting instructions. Place the appliance being

inspected into operation. Adjust

the thermostat so the appliance will operate continuously.

5. Test for spillage at the draft hood relief opening after 5 minutes of main burner operation. Use the flame of a match or candle, or smoke from a cigarette, cigar or pipe.

6. After it has been determined each appliance that remains connected to the common venting system properly vents (when tested as outlined above), return

doors, windows, exhaust fans,

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

7. If improper venting is observed during any of the above tests,

resize the common venting sys-

tem. Refer to latest edition of the National Fuel Gas Code ANSI Z223.1, or the CSA-GAMA venting tables for Category I furnaces

NOTE: For U.S. installations only. Schedule 40 ABS-DWV pipe and fittings may be used as an alternate to PVC pipe for the combustion air inlet and vent pipes.

NOTE: For U.S. installations only. Cellular core PVC is also approved for use. It must be schedule 40 PVC-DWV cellular pipe manufactured under ASTM F-891.

throom

that

Page 19

JOINING PIPE AND FITTINGS

WARNING

PVC SOLVENT CEMENTS AND PRIMERS ARE HIGHLY FLAMMABLE. PROVIDE ADEQUATE VENTILATION AND DO NOT ASSEMBLE COMPONENTS NEAR HEAT SOURCE OR AN OPEN FLAME. DO NOT SMOKE. AVOID SKIN OR EYE CONTACT. OBSERVE ALL CAUTIONS AND WARNINGS PRINTED ON MATERIAL CONTAINERS. FAILURETO FOLLOW THESE GUIDELINES MAY RESULT IN FIRE, EXPLOSION OR ASPHYXIATION CAUSING PERSONAL INJURY OR DEATH.

All pipe, fittings, solvent cement, primers and procedures must conform to American National Standard Institute and American Society for Testing and Materials (ANSI/ASTM) standards as shown below:

IMPORTANT: The plastic combustion air and venting components are MADE of PVC. If using ABS piping, ensure that the solvent cement is compatible for

joining PVC to ABS components or use

a mechanical connection that can withstand the vent temperatures and is corrosion resistant.

CEMENTING JOINTS

Properly seal all joints in the PVC vent

using the following materials and procedures:

PVC CLEANER-PRIMER AND PVC MEDIUM-BODY SOLVENT CEMENT

IMPORTANT: After cutting pipe, remove all ragged edges and burrs. This is important to prevent increase in pressure drop throughout the system.

1. Cut pipe end square. Chamfer edge of pipe. Clean fitting socket and

pipe joint area of all dirt, grease and

moisture.

2. After checking pipe and socket for proper fit, wipe socket cleaner-primer. Apply a liberal coat of primer to inside surface of socket and outside of pipe. READ INSTRUCTIONS INCLUDED WITH THE PRIMER FOR PROPER INSTALLATION.

and pipe with

3. Apply a thin coat of cement evenly in the socket. Quickly apply a heavy coat of cement to the pipe end and insert pipe into fitting with a slight twisting movement until it bottoms out.

NOTE: Cement must be fluid; if not, recoat.

4. Hold the pipe in the fitting for 30 seconds to prevent the tapered socket from pushing the pipe out of the fitting.

5. Wipe all excess cement from the joint with a rag. Allow 15 minutes

before handling. Cure time varies according to fit, temperature and humidity.

NOTE: Stir the solvent cement frequently while using. Use a natural bristle, one inch wide brush or the applicator supplied with the can.

IMPORTANT: For Proper Installation DO NOT use solvent cement that has become curdled, lumpy or thickened. DO NOT thin. Observe shelf precautions printed on containers. For application below 32°F, use only low-temperature-type solvent cement.

For correct installation of the vent pipe, follow the instructions provided by the manufacturers of the pipe, primer and solvent.

PIPE & FITTING MATERIAL

Schedule 40 PVC (Pipe) D1785 Schedule 40 PVC (Cellular Core Pipe) F891 Schedule 40 PVC (Fittings) D2466 SDR-21PVC (Pipe) D2241 SDR-26 PVC (Pipe) D2241 Schedule 40 ABS Cellular Core DWV (Pipe) F628 Schedule 40 ABS (Pipe) D1527 Schedule 40 ABS (Fittings) D2468 ABS-DWV (Drain Waste & Vent)

(Pipe & Fittings) PVC-DWV (Drain Waste & Vent)

(Pipe & Fittings)

ASTM

SPECIFICATION

D2661

D2665

Page 20

NON-DIRECT VENT PIPE INSTALLATION

(FOR VERTICALTERMINATIONS ONLY)

COMBUSTION AIR

WARNING

ALWAYS PROVIDE THIS FURNACE AND ANY OTHER FUEL BURNING APPLIANCE WITH ENOUGH FRESH AIR FOR PROPER COMBUSTION AND VENTILATION OF THE FLUE GASES. MOST BUILDING CODES REQUIRE THAT OUTSIDE AIR BE SUPPLIED INTO THE FURNACE AREA. FAILURE TO DO SO CAN CAUSE DEATH FROM CARBON MONOXIDE POISONING.

Provide adequate facilities for combustion and ventilation air in accordance with section 5.3, Air for Combustion and Ventilation of the National Fuel Gas Code, ANS Z223.1 - latest edition; CAN/CGA B149.1 and .2, or applicable provisions of the local building codes. These combustion and ventilation facilities must not be obstructed.

IMPORTANT: Air for combustion and ventilation must not come from a corrosive atmosphere. Any furnace failure due to corrosive elements in

the atmosphere is excluded from

warranty coverage.

The following types of installation (but not limited to the following) REQUIRE OUTDOOR AIR for combustion, d

to chemical exposures:

• Commercial buildings

• Buildings with indoor pools

• Furnaces installed in laundry

rooms

• Furnaces in hobby or craft rooms

• Furnaces installed near chemical

storage areas.

Exposure to the following substances

in the combustion air supply (but not limited to the following) also REQUIRE OUTDOOR AIR for combustion:

• Permanent wave solutions

• Chlorinated waxes and cleaners

• Chlorine-based swimming pool

chemicals

• Water softening chemica

• De-icing salts or chemicals

• Carbon Tetrachloride

• Halogen type refrigerants

• Cleaning solvents (such as per-

chloroethylene)

• Printing inks, paint removers,

varnishes, etc.

• Hydrochloric acid

• Cements and glues

• Anti-static fabric softeners for

clothes dryers

• Masonry acid washing materials

Combustion air must be free of acid forming chemicals such as sulphur, fluorine, and chlorine. These elements are found in aerosol sprays, detergents, bleaches, cl vents, air fresheners, paint and varnish removers, refrigerants and many other commercial and household products. Vapors from these products when burned in a gas flame form acid compounds. The acid compounds increase the dew point temperature of the flue products and produce highly corrosive condensate.

eaning sol-

WARNING

ALL FURNACE INSTALLATIONS MUST COMPLY WITHTHE NATIONAL FUEL GAS CODE AND LOCAL CODES TO PROVIDE ADEQUATE COMBUSTION AND VENTILATION AIR FOR THE FURNACE. FAILURE TO DO SO CAN RESULT IN EXPLOSION, FIRE, PROPERTY DAMAGE, CARBON MONOXIDE POISONING, PERSONAL INJURY OR DEATH.

Combustion air requirements are determined by whether the furnace is in an open (unconfined) area or in a confined space such as a closet or small room.

FURNACE LOCA UNCONFINED SPACE

Using indoor air for combustion.

An unconfined space must have at least 50 cubic feet for each 1,000 BTUH of the total input for all appliances in the space. Here are a

few examples of the room sizes

required for different inputs. The

sizes are based on 8 foot ceilings.

See Table 1.

TABLE 1

UNCONFINED SPACE DIMENSIONS

BTUH Minimum Sq. Feet Typical Room Size

Input With 8 foot Ceiling

60,000 375 15' x 25' OR 19' x 20'

75,000 469 15' x 32' OR 20' x 24'

90,000 563 20' x 28' OR 24' x 24'

105,000 657 20' x 33' OR 26' x 25'

120,000 750 25' x 30' OR 24' x 32'

If the open space containing the furnace is in a building constructed to severely limit outside air infiltration (contemporary energy efficient construction methods), o still be required for the furnace to operate and vent properly. Outside

air openings should be sized the

same as for a confined space.

TED IN AN

utside air may

Page 21

FURNACE LOCATED IN A CONFINED SPACE.

A confined space (any space smaller than shown before as “unconfined”) must have openings into

the space, which are located in accordance with the requirements set forth in the following subsections A and B. The open-

ings must be sized by how they

connect to the heated area or to the outside, and by the input of all appliances in the space.

If the confined space is within a building with tight construction, combustion air must be taken fro

m outdoors or areas freely communicating with the outdoors.

TABLE 2

INDOOR AIR OPENING DIMENSIONS

BTUH Free Area

Input Each Opening

60,000 100 square inches

75,000 100 square inches

90,000 100 square inches

105,000 105 square inches

120,000 120 square inches

FIGURE 14

AIR FROM HEATED SPACE

A. USING INDOOR AIR FOR

COMBUSTION

IMPORTANT: DO NOT take air from

a heated space with a fireplace,

exhaust fan or other device that may

produce a negative pressure.

If combustion air is taken from the heated area (see Figure 14), the openings must each have at least

100 square inches of free area.

Each opening must have at least

one square inch of free area for each 1,000 BTUH of total input in

the space. See Table 2.

B. USING OUTDOOR AIR FOR

COMBUSTION

IMPORTANT: Do not take air from

an attic space that is equipped with power ventilation.

The confined space must communicate with the outdoors in accordance with Methods 1 or 2. The minimum dimension of air openings shall not be less than 3 inches. Where ducts are used, they shall be of the same cross-sectional area as the free area of the openings to which they connect.

Method 1 Two permanent openings, one locat-

ed within 12 inches of the top and one located within 12 inches of the bottom of the enclosure, shall be pro-

vided. The openings shall communi-

cate directly, or by ducts, with the out-

doors or spaces (crawl or attic) that

freely communicate with the out-

doors.

a. Where directly communicating

with the outdoors or where communicating to the outdoors through vertical ducts as shown in Figure 15, each opening shall have a minimum free area of 1 square inch for each 4000 BTUH of total appliance input rating in the enclosure. See Table 3.

A077501

TABLE 3

VERTICAL OUTDOOR AIR OPENING DIMENSIONS

BTUH Free Area Round Pipe

Input Each Opening Size

60,000 15.00 square inches 5"

75,000 18.75 square inches 5"

90,000 22.50 square inches 6"

105,000 26.25 square inches 6"

120,000 30.00 square inches 7"

Page 22

b. Where communicating with out-

doors through horizontal ducts,

each opening shall have a minimum free area of 1 square inch for each 2000 BTUH of total input rating of all equipment in the enclosure. See Table 4 and Figure 16.

TABLE 4

HORIZONTAL OUTDOOR AIR OPENING DIMENSIONS

BTUH Free Area Round Pipe

Input Each Opening Size

60,000 30.00 square inches 7"

75,000 37.50 square inches 7"

90,000 45.00 square inches 8"

105,000 52.50 square inches 9"

120,000 60.00 square inches 9"

Method 2 One permanent opening, located within 12 inches of the top of the enclosure, shall be permitted where the equipment has clearances of at least 1 inch from the sides and back and 6 inches from the front of the appliance. The opening shall directly communicate with the outdoors or communicate through a vertical or

horizontal duct to the outdoors or

spaces (crawl or attic) that freely communicate with the outdoors, and shall have a minimum free area of:

a. One square inch for each 3000

BTUH of the total input rating of all equipment located in the enclosure (see Table 5), and

Combustion air openings must not be restricted in any manner.

CONSULT LOCAL CODES FOR SPECIAL REQUIREMENTS.

FIGURE 15

AIR FROM ATTIC/CRAWL SPACE

A077601

FIGURE 16

OUTSIDE AIR USING A HORIZONTAL INLET & OUTLET

b. Not less than the sum of the

areas of all vent connectors in the confined space.

If the unit is installed where there is

an exhaust fan, sufficient ventilation

must be provided to prevent the

exhaust fan from creating a negative

pressure.

TABLE 5

VERTICAL OR HORIZONTAL OUTDOOR AIR OPENING DIMENSIONS

BTUH Free Area Round Pipe

Input Each Opening Size

60,000 20.00 square inches 6" 75,000 25.00 square inches 6"

90,000 30.00 square inches 7" 105,000 35.00 square inches 7" 120,000 40.00 square inches 8"

A077701

Page 23

INSTALLATION GUIDELINES

IMPORTANT: When installed as a non-

direct furnace, only vertical terminations

are allowed. Do not use horizontal termi-

nations when the furnace is installed with a non-direct vent.

All exhaust vent piping must be installed

in compliance with Part 7, Venting of Equipment, of the latest edition of the National Fuel Gas Code NFPA 54/ANSI A223.1, or CAN/CGA-B149.1 and .2, local codes or ordinances and these instructions.

7. The minimum vent length is 5 feet.

8. All piping through the roof is 2".

When using 3" pipe, reduce to 2" within 18" of the inside of the roof.

9. Vertical through-the-roof installations do not require any special vent termination. Use 2" PVC

pipe extending a minimum of 12

inches above the anticipated level of snow accumulation.

10. Elbows must be a mini

mum of

15” apart.

11. No screens may be used to cover combustion air or

exhaust.

VENTING GUIDELINES - Non-

Direct

Vent

1. IMPORTANT: Do not common vent

with any other appliance. Do not install in the same chase or chimney with a metal or high temperature plastic pipe from another gas or fuel-burning appliance unless the required minimum clearances to combustibles are maintained between the PVC pipe and other pipes.

2. Use only medium or long radius

sweep elbows, such as PVC-DWV elbows.

NOTE: For upflow and downflow

installations, extend the exhaust

pipe a minimum of 18" vertically above t

he furnace cabinet before

turning the vent.

3. Vertical vent piping is preferred.

4. Install all horizontal piping as fol-

lows:

• Slope horizontal vent piping

upward a minimum of 1/4" per foot of run so that condensate drains toward the furnace.

• Support horizontal vent piping at

least every four feet. No sags or dips are permitted.

5. Insulate all vent runs through unconditioned spaces where below-

freezing temperatures are expected,

with 1" thick medium density, foil

ced fiber glass or equivalent

Rubatex/Armaflex insulation. For horizontal runs where water may collect and freeze, wrap the vent

pipe with self-regulating, 3 or 5 Watt heat tape. The heat tape must be U.L. listed and installed per the manufacturer’s instructions.

6. All piping between the furnace and the roof penetration is 2" or 3" as specified in Table 6. Table 6 lists the

maximum allowable exhaust vent

pipe length for the number of elbows used, based on the furnace

size.

PORTANT: Use Only standard

vertical terminations when installing the modulating furnace as a nondirect vent appliance.

➤ TABLE 6

NON-DIRECT VENT APPLICATIONS

MAXIMUM ALLOWABLE LENGTH IN FEET OF EXHAUST PIPE

UPFLOW FURNACES RGFE

NUMBER OF ELBOWS

22°, 45° OR 90°

MEDIUM / LONG RADIUS ONLY

1-2 3-4 5-6

40'

120'

20' 120' 110' 110'

35'

120'

15' 120' 105' 105'

30'

120'

10'

120'

95' 95'

FURNACE

INPUT

60,000

75,000

90,000 105,000 120,000

PIPE SIZE

(VERTICAL VENT

TERMINATIONS

ONLY)

TERMINATION

2" 3" 2" 3" 3" 3"

STANDARD STANDARD STANDARD STANDARD STANDARD STANDARD

3" 45' 35' 30'STANDARD

DOWNFLOW AND HORIZONTAL FURNACES RGGE AND RGJF

FURNACE

INPUT

PIPE SIZE

(VERTICAL VENT

TERMINATIONS

ONLY)

TERMINATION

STANDARD

60,000

3" 2"

STANDARD STANDARD

75,000

90,000 105,000 120,000

NOTES:

1. N.R. - NOT RECOMMENDED.

2. MAXIMUM OF 6 ELBOWS MAY BE USED. DO NOT COUNT ELBOWS IN ALTERNATE TERMINATION KIT. MEDIUM OR LONG SWEEP ELBOWS MAY BE USED.

3. A 45 OR 22.5 DEGREE ELBOW IS CONSIDERED ONE ELBOW.

4. CONCENTRIC TERMINATION NO. RXGY-E03A IS FOR THRU-THE-ROOF OR THRU-THE-WALL VENTING.

5. USE KITS RXGY-D02 OR D02A (2") OR RXGY-D03 OR D03A (3") FOR STANDARD OR ALTERNATE THRU-THE-WALL VENTING.

6. USE KITS RXGY-D04 OR D04A FOR ALTERNATE VENTING OF 120,000 BTUH UNITS

7. NO SCREENS MAY BE USED TO COVER COMBUSTION AIR AND EXHAUST.

* A = 17

B = 21” CABINET WIDTH

3" 3" 3" 40' 35' 30'STANDARD

⁄2” CABINET WIDTH

STANDARD STANDARD STANDARD

NUMBER OF ELBOWS

22°, 45° OR 90°

MEDIUM / LONG RADIUS ONLY

1-2 3-4 5-6

30'

120'

20'

120'

90' 45'

25'

120'

15'

120'

80' 40'

WITH LONG RUNS.

20'

120'

10'

120'

75' 35'

Page 24

DIRECT VENT PIPE INSTALLATION

WARNING

READ AND FOLLOW ALL INSTRUCTIONS IN THIS SECTION. FAILURETO PROPERLY VENT THIS FURNACE CAN CAUSE CARBON MONOXIDE POISONING OR AN EXPLOSION OR FIRE, RESULTING IN PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.

Direct vent installations require a dedicated combustion air and venting system. All air for combustion is taken from outside and all combustion products are discharged to the outdoors.

Therefore, no ventilation or combustion air openings are required.

INSTALLATION GUIDELINES

All exhaust piping must be installed in

compliance with Part 7, “Venting of Equipment,” of the latest edition of the National Fuel Gas Code NPFA 54, 90A and 90B ANSI Z223.1-, local codes or ordinances and these instructions.

1. IMPORTANT: Do not common

vent with any other appliance. Do not install in the same chase or chimney with a metal or high temperature plastic pipe from another gas or fuel-burning appliance unless the required minimum clearances to maintained between the approved PVC pipe and other pipes.

2. Use only medium or long radius

sweep elbows.

NOTE: For all installations. Extend

the combustion air exhaust pipe a

minimum of 18" vertically above the furnace cabinet before turning the vent.

3. Vertical piping is preferred.

4. Install all horizontal piping as fol-

lows:

• Slope horizontal vent piping

upward a minimum of 1/4" per foot of run so that condensate drains toward the furnace.

• Support h

least every four feet. No sags or dips are permitted.

combustibles are

orizontal vent piping at

➤ TABLE 7

DIRECT VENT APPLICATIONS

MAXIMUM ALLOWABLE LENGTH IN FEET OF EACH EXHAUST PIPE AND INTAKE PIPE

UPFLOW RGFE FURNACES

NUMBER OF ELBOWS

FURNACE

INPUT

60,000

75,000

90,000

105,000

120,000

PIPE SIZE

TERMINATION

STANDARD

CONCENTRIC

ALTERNATE

STANDARD

CONCENTRIC

ALTERNATE

STANDARD STANDARD

CONCENTRIC

ALTERNATE

STANDARD

CONCENTRIC

ALTERNATE

STANDARD

CONCENTRIC

ALTERNATE

STANDARD

CONCENTRIC

ALTERNATE ALTERNATE

VENT

TERMINATION KIT

RECOMMENDED

RXGY-D02A/G02A

RXGY-E03A/G02A

RXGY-D02A

RXGY-D03A/G02A

RXGY-E03A/G02A

RXGY-D03A RXGY-D02A/G02A RXGY-D0

3A/G02A

RXGY-E03A/G02A

RXGY-D03A RXGY-D03A/G02A

RXGY-E03A/G02A

RXGY-D03A RXGY-D03A/G02A

RXGY-E03A/G02A

RXGY-D03A

RXGY-D03/G02A

RXGY-E03A/G02A

RXGY-D03A

RXGY-D04A

⁄2°, 45° OR 90°

MEDIUM / LONG

RADIUS ONLY

1-2 5-6

3-4

40'

35'

25'

30'

120'

105'

110'

15'

20'

120'

100'

95'

110' 105' 95'

50' 40' 35'

110' 105' 95'

50' 40' 35'

45' 35' 30'

105' 95' 90'

DOWNFLOW AND DOWNFLOW/HORIZONTAL RGGE AND RGJF

NUMBER OF ELBOWS

FURNACE

INPUT

60,000

75,000

90,000

105,000

120,000

NOTES:

1. N.R. - NOT RECOMMENDED.

2. MAXIMUM OF 6 ELBOWS MAY BE USED. DO NOT COUNT ELBOWS IN ALTERNATE TERMINATION KIT. MEDIUM OR LONG SWEEP ELBOWS MAY BE USED.

3. A 45 OR 22.5 DEGREE ELBOW IS CONSIDERED ONE ELBOW.

4. CONCENTRIC TERMINATION NO. RXGY-E03 IS FOR THRU-THE-ROOF OR THRU-THE-WALL VENTING.

5. USE KITS RXGY-DO2 (2") OR RXGY-D03 (3") FOR STANDARD OR ALTERNATE THRU-THE-WALL VENTING.

6. USE KITS RXGY-D04 FOR ALTERNATE VENTING OF 120,000 BTUH UNITS WITH LONG RUNS.

7. NO SCREENS MAY BE USED TO COVER COMBUSTION AIR AND EXHAUST.

* A = 171⁄2” CABINET WIDTH

B = 21” CABINET WIDTH

** ALTERNATE VENT NOT PERMITTED ON DOWNFLOW/HORIZONTAL MODELS.

PIPE SIZE

TERMINATION

STANDARD

CONCENTRIC

STANDARD

CONCENTRIC

STANDARD

CONCENTRIC

STANDARD

CONCENTRIC

STANDARD

CONCENTRIC

STANDARD

CONCENTRIC

STANDARD

CONCENTRIC

VENT

TERMINATION KIT

RECOMMENDED

RXGY-D02A/G02A

RXGY-E03A/G02A

RXGY-D03A/G02A

RXGY-E03A/G02A

RXGY-D02A/G02A

RXGY-E03A/G02A

RXGY-D03A/G02A

RXGY-E03A/G02A

GY- D03A/G02A

RXGY-E03A/G02A

RXGY-D03A/G02A

RXGY-E03A/G02A

RXGY-D03A/G02A

RXGY-E03A/G02A

⁄2°, 45° OR 90°

MEDIUM / LONG

RADIUS ONLY

1-2 5-6

3-4

30' 25' 20'

30' 25' 20' 120' 120' 120' 120' 120' 120'

15'

20'

15'

20'

120'

70'

60'

70'

60'

45'

40'

45'

40'

35'

40'

35'

30'

20'

120'

100'

10'

120'

85'

10'

10' 120' 120'

55'

35'

30'

Page 25

FIGURE 17

STANDARD VERTICAL DIRECT VENTING UPFLOW MODEL SHOWN (TYPICAL FOR DOWNFLOW/HORIZONTAL MODELS)

DETAIL A

EXHAUST TERMINATION

12”

NOTES:

THE COMBUSTION AIR PIPE

MUST TERMINATE IN THE SAME PRESSURE ZONE AS THE EXHAUST PIPE.

INCREASE THE 12-IN. MINIMUM

TO KEEP TERMINAL OPENING ABOVE ANTICIPATED LEVEL OF SNOW ACCUMULATIONWHERE APPLICABLE.

WHEN 3-IN. DIAM. PIPE IS USED,

REDUCE TO 2-IN. DIAMETER BEFORE PENETRATING ROOF. A MAXIMUM OF 18 IN. OF 2-IN. PIPE MAY BE USED BEFORE PASSINGTHROUGH ROOF.

SUPPORT VERTICAL PIPE EVERY 6

FEET. EXHAUSTTERMINATION - TERMINATE

THE LAST 12 INCHES WITH 2” PVC PIPE ON 90,000 AND 120,000 BTUH MODELS. REDUCE AND TERMINATE THE LAST 12 INCHES WITH 1 PIPE ON 60,000 THROUGH 75,000 BTUH MODELS.

SEE DETAIL A.

/2” PVC

5. Insulate all vent runs through unconditioned spaces where

below-freezing temperatures are expected with 1" thick medium

density, foil faced fiber glass or

equivalent Rubatex/Armaflex insulation. For horizontal runs where

water may collect, wrap the vent pipe with self-regulating, 3 or 5 Watt heat tape. The heat tape must be U.L. listed and installed per the manufacturer’s instructions.

6. All piping between the furnace and the roof or outside wall pe tration is 2" or 3" as specified in

Table 7. Table 7 lists the maxi-

mum allowable length for the

exhaust vent pipe and intake air

pipe for the number of elbows used, based on the type of termi-

nation and furnace size.

7. The minimum vent length is 5 feet.

8. All piping through the roof or outside wall is 2". When using 3"

pipe, reduce to 2" within 18" of the inside of the roof or outside wall (except 120,000 BTUH model using the RXGY-D04 or D04A Horizontal Vent Kit).

9. Terminate the vent using one of the following termination options.

ne-

10. Elbows must be a minimum of 15” apart.

11. No screens may be used to cover

combustion air or exhaust.

VERTICAL TERMINATIONS

STANDARD VERTICAL TERMINATIONS

Combustion Air Piping um-radius sweep elbows to keep the inlet downward and prevent the entry of rain. The inlet opening of the com-

bustion air termination must be a minimum of 12" above the anticipated level of snow accumulation.

Exhaust Vent Piping

must terminate at least 12 inches above the combustion air termination inlet. The 2" vent pipe used to penetrate the roof must be reduced to 1 1/2" PVC for the last 12" for the 60,000 and 75,000 BTUH furnace models. No reduction of the 2" pipe is necessary for the 90,000 through 120,000 BTUH

models. The maximum length of the exposed vent pipe above the roof is

30".

(See Figure 16)

: Use two medi-

: The exhaust vent

ST-A0407-00

Page 26

CONCENTRIC TERMINATIONS

CONCENTRIC VENT KIT NO. RXGY-E03A (SEE FIGURE 18)

This kit is for vertical and horizontal

intake air/vent runs. One 5-in. diameter hole is required for installation. See Figure 18 for the general layout. Complete installation instructions are included with the kit.

FIGURE 18

CONCENTRIC VENT KIT NO. RXGY-E03A (DIRECT VENT INSTALLATIONS)

ITEM No. DESCRIPTION

1 2.5 24 33 43 5 PVC RAINCAP

" PVC PIPE SCHEDULE 40 -- 37.125" LONG " PVC PIPE SCHEDULE 40 -- 24" LONG " x3" x4" SPECIAL CONCENTRIC FITTING " x 45° STREET ELBOW (FIELD SUPPLIED)

NOTE: The following IPEX brand concentric terminations (System 636) may be purchased in the field

and used in

place of factory supplied kits: 3” Concentric Kit – Item # 196006

VERTICAL INSTALLATION

MAINTAIN 12 IN. MINIMUM CLEARANCE ABOVE HIGHEST ANTICIPATED SNOW LEVEL. MAXIMUM OF 24 IN. ABOVE ROOF.

HORIZONTAL INSTALLATION

FIELD-SUPPLIED STRAP

NOTE: AIR INTAKE NOT

ORIENTATION SENSITIVE.

1" MAXIMUM

NOTE: Drain tee is not needed for the inlet pipe.

Page 27

INSTALLATION – RXGY-G02A Side Wall Vent

INSTALLATION – RXGY-G02 Side Wall Vent

This termination for horizontal venting only. This termination for direct vent application only.

Important: Do no install on the prevailing winter wind side of the structure Note: Multi-venting-No common venting.

FIGURE 19

VENT KIT INSTALLATION OPTIONS

?? ? ?

EXHAUST

AIR INTAKE

NOTE: Install the vent and air intake piping into the vent plate openings. Seal all gaps between the pipes and wall. Be Sure To Use Silicone Sealant to seal the vent pipe to the vent cap to permit field disassembly for annual inspection and cleaning. Also seal all pipe penetrations in wall. To prevent possibility of condensate freeze-up or recirculation, do not install vent kits one above the other.

FIGURE 20

TYPICAL INSTALLATION

For 90000 thru 120000 BTUH modelsreduce to a length between 12 inches and 30 inches of 2 inch pipe. For 60000 thru 75000 BTUH modelswhen 3 inch pipe is used: reduce last 30 inches to 18 inches of 2 inch pipe and 12 inches of 1-1/2 inch pipe to maintain velocity. Note: Vent should protrude a maximum of 2-1/4” beyond vent plate. Air intake should protrude a maximum of 1inch beyond vent plate.

Seal all wall cavities

ST-A1075

Page 28

HORIZONTAL TERMINATIONS

STANDARD HORIZONTAL TERMINA-

(SEE FIGURE 21)

TIONS

NOTE: All furnaces with horizontal air intakes (except those using horizontal

concentric vent kit RXGY-E03A) must have a drain tee assembly and trap

installed in the combustion air pipe as close to the furnace as possible. This is to drain any water that may enter the combustion air pipe to prevent it from entering the furnace vestibule area.

These parts are included in horizontal

vent kits RXGY-D02A, RXGY-D03A and RXGY-D04A.

NOTE: The combustion air and exhaust terminations must be at least 12 inches above grade or anticipated snow levels.

Use alternate horizontal terminations

when termination locations are limited and higher snow levels are anticipated.

NOTE: Ensure the location of the combustion air inlet with respect to the

exhaust vent terminal complies with

Figure 21, detail C.

Combustion Air Piping

: Use a 2" PVC coupling with a wind deflector vane (provided) installed as follows:

1. Install a 2" coupling to the combustion air pipe at the outside wall to prevent the termination from being pushed inward.

2. Cut a 2 1/4" length of 2" PVC pipe and connect this to the coupling.

3. Connect another 2" coupling to the end of the 2 1/4" length of pipe. Terminate this outer coupling 4 inches from the wall.

4. Attach the vane in the final 2" coupling in the vertical position with PVC cement.

IMPORTANT: To insure proper furnace operation, install the vane in the vertical position as shown in Figure 21, Detail B. Failure to install the vane properly can result in nuisance tripping of the pressure switch.

Exhaust Vent Piping: 60,000 and 75,000 BTUH models: Install a 2" to 1 1/2" reducer coupling at the outside wall to prevent the termination from being pushed inward. Reduce the 2" vent pipe used to penetrate the wall to 1 1/2" PVC for the last 12" of the run.

Terminate the 1 1/2" PVC exhaust

vent at least 12 inches from the outside wall.

90,000 through 120,000 BTUH models: Install a 2" coupling at the

outside wall to prevent the termination from being pushed inward. No reduction of the 2" pipe used to penetrate the wall is necessary.

Terminate the 2" PVC exhaust vent

at least 12 inches from the outside wall.

FIGURE 21

STANDARD HORIZONTAL DIRECT VENTING UPFLOW MODEL SHOWN (TYPICAL FOR DOWNFLOW/HORIZONTAL MODELS)

NOTES:

SUPPORT HORIZONTAL

➀

PIPE EVERY FOUR FEET. WHEN 3 IN. PIPE IS USED REDUCE TO

➁

2 IN. BEFORE PENETRATING OUTSIDE WALL.

18 IN. MAXIMUM. 2 IN. DIAMETER

➂

PIPE MAY BE USED INSIDE THE WALL.

DETAIL“A” - EXHAUSTTERMINATION

➃

TERMINATETHE LAST 12 INCHES WITH 2” PVC PIPE ON 90,000 AND 120,000 BTUH MODELS. REDUCE AND TERMINATE THE LAST 12 INCH-

/2” PVC PIPE ON 60,000

ES WITH 1 THROUGH 75,000 BTUH MODELS.

INCREASE THE 12 IN. MINIMUM

➄

ABOVE GRADE TO KEEP TERMINAL OPENINGS ABOVE ANTICIPATE D LEVEL OF SNOW ACCUMULATION WHERE APPLICABLE.

DETAIL“B”, INSTALLWIND DEFLEC-

➅

TOR VANE IN 2 IN. PVC COUPLING IN VERTICAL POSITION USING PVC SOLVENT.

THE COMBUSTION AIR TERMINATION MUST BE IN THE SAME PRESSURE ZONE AS THE EXHAUSTTERMINATION.

EXHAUST/INTAKE RELATIONSHIP

DETAIL C

NO SCREENS OR ELBOWS AT THE END OF THE PIPES

DETAIL C

DETAIL A

12”

EXHAUST TERMINATION

COMBUSTION AIR TERMINATION

DETAIL B

ST-A0407-00

Page 29

ALTERNATE HORIZONTAL TERMINATIONS (See Figure 22)

NOTE: This method is not permitted

on modulation downflow/horizontal

(RGGE or RGJF) models.

NOTE: The combustion air and

exhaust terminations must be at least

12 inches above grade or anticipated

snow levels. Alternate horizontal ter-

minations allow the combustion air

and exhaust terminations to be raised a maximum of 60 inches above the

wall penetrations to maintain the required clearance.

NOTE: If combustion air vent pipe is extended more than 24 inches, insulate the vent pipe between the two outside 90° elbows with closed cell

insulation such as rubatex, armaflex

or equivalent.

NOTE: Ensure the location of the combustion air inlet with respect to

the exhaust vent terminal complies

with Figure 22.

Combustion Air Piping

: Use a 2" PVC elbow with a wind deflector vane (provided) installed as follows:

1. Install a 2" elbow to the combustion air pipe at the outside wall to prevent the termination from being pushed inward.

2. Cut an adequate length of 2" PVC pipe as needed to clear the anticipated snow level and connect this to the elbow.

3. Connect another 2" elbow to the end of the pipe such that the inlet is facing away from the wall. This outer coupling must terminate 4 inches from the wall.

4. Attach

the vane in the final 2" elbow in the vertical position with PVC solvent.

IMPORTANT: To insure proper furnace operation, the supplied vane must be installed in the vertical position as shown in Figure 21, Detail B.

FIGURE 22

ALTERNATE HORIZONTAL DIRECT VENTTERMINATION

SEE DETAIL A

3" MAX. NOTE: 3-1/2" MAX. WHEN D04 KIT IS USED.

EXHAUST VENT 21/2" PVC FOR MODELS WITH 120,000 BTUH INPUT (KIT NO. RXGY-D04A)

2" PVC FOR MODELS WITH INPUTS OF 90,000 THRU 120,000 BTUH. REDUCE TO 11/2" FOR MODELS WITH INPUTS OF 60,000 AND 75,000 BTUH. ELBOWS AND RISERS ARE 2" PVC.

12" FROM WALL

PIPE SUPPORT STRAP

DETAIL C

EXHAUST/INTAKE RELATIONSHIP

NOTE: If combustion air vent pipe is extended more

than 24 inches, insulate the vent pipes between the two outside 90° elbows with closed cell insulation

such as rubatex, armaflex, or equivalent.

Exhaust Vent Piping

1. Install a 2" elbow to the exhaust vent

pipe at the outside wall to prevent the termination from being pushed inward.

2. Cut an adequate length of 2" PVC pipe as needed to insure proper loca-

tion of the exhaust vent termination

with respect to the combustion air inlet and connect this to the elbow.

3. Connect another 2" elbow to the end of the pipe such that the inlet is facing away from the wall.

INTAKEVENT 21/2" PVC FOR MODELS WITH 120,000 BTUH INPUT.

2" PVC ELBOWS AND RISER MODELS WITH INPUTS OF 75,000 THRU 120,000 BTUH.

USE KIT NO. RXGY-D02 OR D02A WHEN 2" PIPE IS USED BETWEEN FURNACE AND OUTSIDE WALL. USE KIT NO. RXGY-D03 OR D03A WHEN 3" PIPE IS USED.

DETAIL A

EXHAUST VENT FOR

MODELS WITH INPUT OF

60,000 AND 75,000 BTU

I339

Exhaust Vent Termination:

60,000 and 75,000 BTUH models: Reduce the 2" vent pipe used to

penetrate the wall and extend the

terminations to 1 1/2" PVC for the last 12" of the run. Install a 2" to 1 1/2" reducer bushing in the last 2" elbow. Connect a length of 1 1/2"

PVC pipe such that the exhaust vent

terminates at least 12 inches from the outside wall. See Figure 22, Detail A.

90,000 through 120,000 BTUH models: No reduction of the 2" pipe used

to penetrate the wall is necessary.

Terminate the 2" PVC exhaust vent

at least 12 inches from the outside wall.

120,000 BTUH model with the RXGY-D04A Horizontal Vent Kit:

Venting and terminations install the

same as above except the 2" pipe

and connectors are replaced with 2 1/2" pipe and connectors.

Page 30

LOCATION REQUIREMENTS HORIZONTAL DIRECT VENTS

CAUTION

THE COMBUSTION PRODUCTS AND MOISTURE IN THE FLUE GASES WILL CONDENSE AS THEY LEAVETHE TERMINATION. THE CONDENSATE CAN FREEZE ON THE EXTERIOR WALL, UNDER THE EAVES AND ON SURROUNDING OBJECTS. SOME DISCOLORATIONTOTHE EXTERIOR OF THE BUILDING IS TO BE EXPECTED. HOWEVER, IMPROPER LOCATION OR INSTALLATION CAN RESULT IN STRUCTURAL OR EXTERIOR FINISH DAMAGETOTHE BUILDING AND MAY RECIRCULATE PRODUCTS OF COMBUSTION INTOTHE COMBUSTION AIR TERMINAL AND FREEZE.

NOTE: In Canada vent terminations

must be in accordance with the current CSA-B149 Gas Installation Code and/or local codes.

The vent must be installed with the following minimum clearances. See Figures 23 and 24.

1. Locate the bottom of the vent terminal and the air inlet at least 12 inches above grade. Increase the 12-in. minimum to keep the terminal openings above the level of snow accumulation, where applicable.

2. Do not terminate the vent over public walkways or over an area where condensate or vapor could create a

nuisance or hazard.

3. Locate the vent terminal at least one foot from any opening through which flue gases could enter a building.

4. Locate the vent terminal at least 3 feet above any forced air inlet

located within 10 feet, except the

combustion air inlet of a direct vent appliance.

5. Allow the vent terminal minimum

horizontal clearance of 4 feet from

electric meters, gas meters, regulators and relief equipment.

6. Locate the furnace combustion air inlet a sufficient distance from the vent of any other gas or fuel burning appliance or electric clothes dryer to prevent recirculation of the flue gases into the furnace com-

bustion air inlet. The only exception

to this requirement is the case of multiventing two or more furnaces, which is covered in the section on multiventing in these instructions.

In addition to the minimum clearances listed above, the ven be governed by the following guidelines.

1. Do not terminate under any kind of patio or deck. If running the vent under a deck, insulate it to insure

no condensate freezes and blocks

the pipe. The insulation must be waterproof.

For vent considerations, the edge of the deck must be considered the outside wall.

2. Do not terminate behind any area that may allow the flue products to become stagnant and recirculate.

3. Do not locate on the side of a building with pre winds. This will help prevent mois-

ture from freezing on walls and

overhangs (under eaves).

4. Do not extend vent directly

through brick or masonry surfaces. Use a rust-resistant sheet metal or plastic backing plate behind vent. See Figure 15.

5. Do not locate too close to shrubs as condensate may stunt or kill them.

FIGURE 23

MOISTURE ZONES

t location should

vailing winter

6. Minimum vertical clearances of 1 foot are recommended for over-

hangs up to 1 foot horizontal.

The vertical clearance should be increased equ

tional increase in horizontal overhang to a maximum vertical

clearance of 6 feet.

7. Caulk all cracks, seams and

joints within 6 feet horizontally

as well as 6 feet above and below vent. See Figure 23.

8. Painted surfaces must be sound and in good condition with no cracking, peeling, etc. Painted surfaces will require maintenance.

9. Do not expose 3" x 2" reducer/

bushing to outdoor ambient temperatures.

ally for each addi-

MULTIVENTING

IF VENTINGTWO OR MORE FURNACES NEAR EACH OTHER IS REQUIRED, EACH FURNACE MUST BE INDIVIDUALLY VENTED – NO COMMON VENTING IS PERMITTED. See Figures 25 and 26 for posi-

tioning of the terminations. When

2 FT. SQ. SHEET METAL PLATE ON BRICK OR MASONRY SURFACE RECOMMENDED, BUT NOT REQUIRED BY CODE.

Page 31

FIGURE 24

DIRECT VENTTERMINAL CLEARANCES

US Installations

National Fuel Gas Code

Canadian Installations

US Installations

Natural Gas and Propane Installation Code

Canadian Installations

Page 32

FIGURE 25

TWO FURNACE VENTINGTHROUGH ROOF

FIGURE 26

TWO FURNACE VENTINGTHROUGH WALL

TWO-PIPE VENTING

EXHAUST VENT MODELS 06-07 TO BE REDUCED TO 1-1/2” PVC LAST 12”.

3” MININUM 24” MAXIMUM

CONCENTRIC VENTING

8” MININUM 24” MAXIMUM

TWO-PIPE VENTING

3” MININUM 24” MAXIMUM

CONCENTRIC VENTING

SEE CONCENTRIC

MINIMUM 12" ABOVE AVERAGE

SNOW ACCUMULATION. MAXIMUM

OF 24 IN. ABOVE ROOF.

VENT SECTION ON PAGE 23 FOR MORE INFORMATION.

more than two furnaces are to be vented, there must be at least 4 feet between the first two furnaces and the third, etc.

CONNECTING TO FURNACE

IMPORTANT: Clean and deburr all

pipe cuts. The shavings must not be

allowed to block the exhaust, inlet or

condensate drain pipes. IMPORTANT: When indoor combus-

tion air is used, the inlet air opening at the furnace must be protected from accidental blockage. On downflow models, install a doub top inlet air opening. See Figure 30.

le elbow in the

MAXIMUM 1"

DISTANCE

FROM WALL

8” MININUM 24” MAXIMUM

UPFLOW MODELS

The exhaust air pipe connection is a 2-in. female PVC pipe fitting extend-

ing through the left nace top plate. See Figure 27. This opening has a protective cap which

should be removed just prior to installing the exhaust pipe. When 2-

in. pipe is used, connect it directly to this fitting. When 3-in. pipe is used, connect a 2 to 3-in. coupling to this fitting with a short piece of 2-in. PVC pipe.

The inlet combustion air connection is at the right An alternate combustion inlet air connection may be made on the right

side of the jacket. The alternate con-

side of the fur-

side of the top plate.

6' MINIMUM

10' RECOMMENDED

MINIMUM 12"

ABOVE GRADE

SEE CONCENTRIC VENT SECTION ON PAGE 23 FOR MORE INFORMATION.

nection opening has a plastic cap. A combustion inlet air connection fitting is supplied with the furnace and it must be installed in the furnace by screwing it into the opening. Make sure the rubber “O-ring” supplied with the furnace is used with this fitting. See Figure 27.

IMPORTANT: When using indoor combustion air, the furnace air opening must be protected from accidental blockage. In pointing downward on the side or a double elbow pointing downward in the top opening. See Figure 28.

stall a 2-inch 90° elbow

Page 33

➤DOWNFLOW/HORIZONTAL

MODELS

NOTE: Combustion air inlet and exhaust

outlet air pipes are reversed for down-

flow and horizontal models from that of

upflow.

The exhaust pipe connection is a 2-in. PVC pipe fitting extending through the

right side of the furnace top cover. This opening has a protective cap which

should be removed just prior to installing the exhaust pipe. When 2-in. pipe is

used, connect it directly to this fitt When 3-in. pipe is used, connect with a 2- to 3-in. coupling directly to the 2-in. pipe.

The combustion inlet air connection is a

2-in. extruded hole on the left side of the

top plate. When a 2-in. pipe is used, attach a 2-in. PVC coupling over this hole with RTV sealant and also add two sheet metal screws through the coupling

into the extrusion to secure it in place,

and add the required piping. When 3-in. pipe is required, use a 2- to 3-in. cou-

pling and add the required piping. S

Figure 29. IMPORTANT: Always pre-drill holes

before securing with screws. Using selftapping screws without first pre-drilling causes the PVC fitting to crack.

ing.

FIGURE 27

UPFLOW COMBUSTION AIR AND VENT PIPE CONNECTION (GAS VALVE MAY BE DIFFERENT THAN SHOWN)

TOP PLATE

VENT CAP/PLUG

OUTLET AIR PIPE

EXHAUST TRANSITION

CONNECTOR

CONDENSATE TRAP

FIGURE 28

DOWNFLOW COMBUSTION AIR AND VENT PIPE CONNECTION (GAS VALVE MAY BE DIFFERENT THAN SHOWN)

NOTE:

ATTACH COUPLING TO EXTRUDED COLLAR WITH TWO SCREWS. PUT BEAD OF SILICONE AROUND BASE

BEFORE MOUNTING COUPLING.

COMBUSTION

AIR CHASE

“O” RING

TOP PLATE

COUPLING

COMBUSTION AIR ADAPTER

NOTE:

WHEN COMBUSTION AIR INLET IS IN OPTIONAL POSITION SWAP LOCATION OF INLET AIR ADAPTER AND “O” RING WITH PLUG.

PLUG OPT. COMBUSTION AIR INLET POSITION

INDUCED DRAFT BLOWER

A1119-01_1

VENT CAP/PLUG

EXHAUST AIR PIPE - PVC

CONNECTOR

FIGURE 29

UPFLOW MODELS -- COMBUSTION AIR FITTING

INDUCED DRAFT

BLOWER

OUTLET AIR PIPE

EXHAUST TRANSITION

A1119-01_2

➤ FIGURE 30

DOWNFLOW/HORIZONTAL MODELS COMBUSTION AIR AND VENT PIPE CONNECTION

Page 34

CONDENSATE DRAIN/OPTIONAL NEUTRALIZER

GENERAL INFORMATION

CAUTION

DO NOT RUN DRAIN OUTDOORS. FREEZING OF CONDENSATE CAN CAUSE PROPERTY DAMAGE.

IMPORTANT: Do not connect into a com-

mon drain line with an air conditioner evaporator coil drain located below the furnace. A blocked or restricted drain line can result in overflow of the coil pan and negate the furnace blocked-drain shutoff control.

➤ IMPORTANT: If installing the unit over a finished ceiling or living area, be certain

to install an auxiliary condensate drain pan under the entire unit extending out

under the condensate tee. With the mini-

mum 5

⁄2" riser for upflow models

or 13⁄4" for downflow models installed above the tee, a blocked drain will result in overflow from the riser. if the furnace is installed in an attic, crawlspace or other

area where freezing temperatures may occur, the furnace drain can freeze while

shut off for long periods of time. If required by local codes, install a con-

densate neutralizer cartridge in the drain line. Install cartridge in horizontal position

only.Also install an overflow line if routing to a floor drain (see Figures 31 & 32). If available, install a condensate pump that is resistant to acidic water. Pumps are available from your local distributor. If pump used is not resistant to acidic water,

a condensate neutralizer must be used

ahead of the pump. The condensate

pump must have an auxiliary safety

switch to prevent operation of the furnace and resulting overflow of condensate in the event of pump failure. The safety switch must be wired through the “R” circuit only (low voltage) to provide operation in either heating or cooling modes.

When selecting neutralizer cartridges and

condensate pumps, use the following data:

CONDENSATE PRODUCTION: MAX (ALL MODELS) = 1-2 gallons per hr.

FIGURE 31

UPFLOW CONDENSATE DRAIN (GAS VALVE MAY BE DIFFERENT THAN SHOWN)

➤ FIGURE 32

DOWNFLOW CONNECTION (GAS VALVE MAY BE DIFFERENT THAN SHOWN)

A1120.01_1

pH LEVEL:

3.2 - 4.5 using OUTDOOR air

2.2 - 4.5 using INDOOR air (neutral pH = 7.0)

UPFLOW MODELS

The condensate drain trap is located in the blower compartment on the left- hand

side of the jacket. A short piece of1⁄2-in.

PVC pipe and a1⁄2-in. tee are provided. Connect the1⁄2-in. pipe to the elbow on the trap and the tee to this pipe so that the open end is upward. Run a drain tube from the bottom of the tee to a floor drain or condensate pump.

IMPORTANT: If installing the unit over a finished ceiling or living area, be certain

to install an auxiliary condensate drain pan under the entire unit extending out

under the condensate tee.

A1120.01_2

Page 35

IMPORTANT: There are two options when choosing a height for the condensate riser:

CONDENSATE OVERFLOW:With a

⁄2 inch riser installed above the tee,

a blocked drain will result in overflow from the riser.

FURNACE SHUTDOWN: To cause the furnace to shut down when a blocked drain is present, install a riser which is a minimum of 10

⁄16”. If the

furnace is installed in an attic, crawlspace or other area where freezing temperatures may occur, the furnace drain can freeze while shut off for long periods of time.

Use a solvent cement that is compatible with PVC material. Cut the drain hoses to the appropriate length and connect to the trap with hose clamps. Tighten the clamps with pliers and check for leaks after attaching.

DOWNFLOW MODELS IMPORTANT: There are two options

when choosing a height for the condensate riser:

CONDENSATE OVERFLOW:With a

⁄4 inch riser installed above the tee,

a blocked drain will result in overflow from the riser.

FURNACE SHUTDOWN: To cause the furnace to shut down when a blocked drain is present, install a riser which is a minimum of 5

⁄2”. If the fur-

nace is installed in an attic, crawlspace or other area where freezing temperatures may occur, the furnace drain can freeze while shut off for long periods of time.

Use a solvent cement that is compatible with PVC material.

RXGY-H01 CONVERTING TO LEFT DRAIN FOR DOWNFLOW MODELS

To convert downflow models to lefthand drain, a kit (RXGY-H01) must be ordered from the distributor. The kit includes a 24” piece of1⁄2” black PVC pipe, a 2” rubber grommet, a 1-5/8” plug and instructions. Note the location of the alternate drain hole as shown in Figure 34.

To convert to left side drainage, first remove the drainage hoses from the trap. Remove the trap from its mounting bracket, rotate it 180 degrees and mount in place with the drainage elbow pointing to the left. Reattach the drain hoses.

Remove the plug from the 2” alternate drain hole (see Figure 34) and replace it with the 2” rubber grommet supplied in the RXGY- H01 downflow alternate

diameter plug that is also supplied in the RXGY-H01 downflow alternate drain kit. Both the hole-plug and grommet must be in place to insure a good seal in the burner compartment.

A length of provided in the RXGY-H01 downflow alternate drain kit. Glue one end of the pipe to the elbow in the trap. Cut

the pipe so that it extends through

the alternate drain hole in the left side of the cabinet one inch (see Figure

34). Connect the1/2” PVC tee (supplied with the furnace) to the pipe with a 1-3/4” riser. Use the 1-5/8” plug supplied in the RXGY-H01 downflow alternate drain kit to seal the right side drainage hole.

IMPORTANT: Do not connect into a common drain line with an air conditioner evaporator coil drain located above the furnace. A blocked or restricted drain line can result in overflow of the coil pan and negate the furnace blocked-drain shutoff control.

drain kit. Also, remove the 1-5/8” grommet supplied in the primary drain hole and replace it with the 1-5/8”

FIGURE 33

UPFLOW OPPOSITE SIDE CONDENSATETRAP CONNECTION (NO KIT REQUIRED)

/2” black PVC pipe is also

REVERSING THE TRAP

UPFLOW MODELS

The trap may be moved to the right side for right-side drainage. Open the knockout for the drain on the right side of the cabinet. Remove the bracket holding the trap from the left side. Seal the left side drain hole with a plug provided in the cloth bag with the furnace. Position the mounting bracket and trap so that the drain elbow is centered in the hole on the right. See Figure 33.

Drill two holes in the cabinet to mount the bracket. Mount the trap and bracket to the right side with the drain elbow pointing through the knockout. Connect the above. Route the drain hoses behind

the top of the electric box, cut to the

appropriate length, and connect to the trap with hose clamps.

⁄2" pipe and tee as noted

ST-A1121-01

FIGURE 34

DOWNFLOW OPPOSITE SIDE CONDENSATE TRAP CONNECTION (REQUIRES RXGY-H01 KIT) (GAS VALVE MAY BE DIFFERENT THAN SHOWN)

ST-A1121-01

Page 36

CONVERTING DOWNFLOW/HORIZONTAL (RGGE WITH HB FUEL CODE ONLY) MODELS TO HORIZONTAL CONFIGU-

See additional instructions on page 38 for instructions on installing the trap for dedicated horizontal models (RGJF only)

CONDENSATE DRAIN FOR HORIZONTAL INSTALLATION

NOTE: Only RGGE models with HB fuel codes can be installed in the hori-

zontal configuration. All other fuel gas

codes must be installed as dedicated downflow configuration only.

Refer to Figure 36 for Steps 1-5.

1. This unit is shipped factory ready for downflow densate trap assembly and drain hoses require conversion for hori-

zontal installation. Remove the existing condensate trap with the

unit in the upright IMPORTANT: This furnace may

only be installed so that when facing the front of the furnace, supply air is discharged on the left hand side.

2. Remove the burner compartment door from the unit.

3. Remove the two screws from the

right side of the furnace jacket

which support the trap mounting bracket ➁. Remove the two plastic plugs on either side of the trap outlet hole and discard.

4. Remove the (L-shaped) clear vinyl drain tube ➂ from the top of the existing trap ➀.

Do no

from the furnace collector box.

5. Remove the ribbed drain tube ➃

from the existing trap ➀ and the exhaust transition ➄. Discard this

tube. Retain the clamps for future use. Additional clamps are provided in the parts bag if any clamps are damaged during conversion process.

NOTE: The following steps should take place with the furnace in the hori-

zontal position.

Refer to Figure 37 for Steps 6-11.

6. Locate the parts bag in the burner compartment. Inst plugs ➅ in the side of the jacket from bottom side up.

installation. The con-

position.

disconnect the short end

all two plastic

7. Fill the trap assembly ➆ with 1/2 cup of water.

8. Attach the gasket ➇ onto the trap assembly so that the gasket holes on the gasket line up with the holes on the trap assembly.

9. Insert the trap assembly with gas-

ket up through the existing hole in the jacket and secure from inside the jacket. Use two screws pro-

vided. Screw down into the two “ears” molded into either side of the trap. Snug the trap assembly against the furnace jacket com- pressing the gasket slightly to eliminate any air leaks. Do not overtighten!

10. Attach the black molded rubber 90° elbow ➈ to the straight spout on the trap top using a black nylon clamp ➉. Attach the other end of the rubber elbow to the

spout ➋ located on the exhaust transition ➄ using a black nylon clamp.

11. Attach the end of the ribbed tube ➂ to the 45° elbow molded into the top of the trap assembly using a black nylon clamp.

FIGURE 35

HORIZONTAL CONDENSATE DRAIN (GAS VALVE, MANIFOLD AND PRESSURE SWITCHES MAY BE DIFFERENT THAN SHOWN)

IMPORTANT: Tighten all clamp

connections with a pair of pliers and check for leaks after conversion is complete.

12. IMPORTANT: There are two options when choosing a height for the condensate riser:

CONDENSATE OVERFLOW: With a 1 above the tee, a blocked drain will result in overflow from the riser.

FURNACE SHUTDOWN: To cause the furnace to shut down when a blocked drain is present, install a riser which is a minimum of 5 in an attic, crawlspace or other

area where freezing tempera-

tures may occur, the furnace drain can freeze while shut off for long periods of time.

Use a solvent cement that is compatible with PVC material.

⁄4 inch riser installed

⁄2”. If the furnace is installed

ST-A1128-01

Page 37

I534

CONDENSATE TRAP CONVERSION FROM DOWNFLOW TO

HORIZONTAL INSTALLATION

FIGURE 37

HORIZONTAL POSITION: CONDENSATE TRAP INSTALLATION FOR HORIZONTAL

OPERATION

FIGURE 36

UPRIGHT POSITION: REMOVAL OF EXISTING DOWNFLOW CONDENSATE TRAP

Page 38

CONDENSATE DRAIN FOR HORIZONTAL (RGJF) INSTALLATION

WARNING

DEDICATED HORIZONTAL (RGJF) MODELS ARE SHIPPED WITHOUT A DRAIN TRAP ATTACHED. IT MUST BE ATTACHED (AS DESCRIBED BELOW) IN THE FIELD. FAILURE TO INSTALLTHE DRAIN TRAP AS DESCRIBED CAN CAUSETHE FURNACE TO SHUT DOWN UNEXPECTEDLY.

NOTE:The following steps should take place with the furnace in the horizontal position.

Refer to Figure 37 for Steps 1-8.

1. Locate the parts bag in the burner compartment.

2. Remove the red vinyl covers that cover the vent drain and heat

exchanger drain (see Figure 38).

3. Fill the trap assembly with a cup of water.

4. Attach the gasket onto the trap assembly so that the gasket holes on the gasket line up with the holes on the trap assembly.

5. Insert the trap assembly with gas-

ket up through the existing hole in the jacket and secure from inside the jacket. Use two screws pro-

vided. Screw down into the two “ears” molded into either side of the trap. Snug the trap assembly

against the furnace jacket com-

pressing the gasket slightly to eliminate any air leaks. Do not overtighten!

6. Attach the black molded rubber 90° elbow to the straight spout on the trap top using a black nylon clamp . Attach the other end of the rubber elbow to the

spout located on the exhaust

transition using a black nylon clamp.

7. Attach one end of the horizontal ribbed tube to the collector box.

Clamp the hose tight with black nylon clamp. Then attach the other end of the ribbed tube to the 45° elbow molded into the top of the trap assembly. Clamp the hose tight with black nylon clamp.

The horizontal ribbed tube is 6.7”

in length.

IMPORTANT: Tighten all clamp connections with a pair of pliers and check for leaks after conversion is complete.

8. IMPORTANT: There are two options when choosing a height for the condensate riser:

CONDENSATE OVERFLOW: With a 13⁄4 inch riser installed above the tee, a blocked drain will result in overflow from the riser.

FURNACE SHUTDOWN: To cause the furnace to shut down when a blocked drain is present, install a riser which is a minimum

of 5

⁄2”. If the furnace is installed

in an attic, crawlspace or other area where freezing temperatures may occur, the furnace drain can freeze while shut off for long periods of time. Provisions must be made to prevent freezing of condensate.

Use a solvent cement that is compatible with PVC material.

FIGURE 38

REMOVE VINYL CAPS BEFORE INSTALLINGTHE DRAIN SYSTEM. (-GJF MODELS ONLY)

NOTE: See location requirements

and combustion section for additional recommendations.

FILLING THE TRAP

FILL THE TRAP ASSEMBLY WITH WATER BEFORE OPERATINGTHE FURNACE. Do this by removing the

drain hose from the trap or from the connection to the secondary coil. Pour about a cup of water into the

vent trap. Any excess water flows into

the house drain when the trap is full.

REMOVE THESE RED VINYL COVERS TO INSTALL THE DRAIN SYSTEM

Page 39

GAS SUPPLY AND PIPING

GAS SUPPLY

WARNING

THIS FURNACE IS EQUIPPED AT THE FACTORY FOR USE ON NATURAL GAS ONLY. CONVERSION TO LP GAS REQUIRES A SPECIAL KIT AVAILABLE FROM THE DISTRIBUTOR. FAILURE TO USE THE PROPER CONVERSION KIT CAN CAUSE FIRE, CARBON MONOXIDE POISONING, EXPLOSION, PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.

See the conversion kit index supplied with the furnace. This index identifies the proper LP Gas Conversion Kit required for each particular furnace.

IMPORTANT: Any additions,

or conversions required for the furnace to satisfactorily meet the application should be made by a qualified installer, service agency or the gas supplier, using factory-specified or approved parts.

IMPORTANT: Connect this furnace only to gas supplied by a commercial utility.

IMPORTANT: A U.L. recognized

fuel gas and CO detector(s) are recommended in all applications, and their installation should be in accordance with the manufacturer’s recommendation

s and/or local laws, rules, regula-

tions or customs.

changes

FIGURE 39

GAS PIPING -- UPFLOW INSTALLATION (GAS VALVE MAY BE DIFFERENT THAN SHOWN)

MANUAL

GAS VALVE

4 TO 5 F T.

ABOVE FLOOR

REQ’D BY

SOME

UTILITIES.

GROMMET (IN NORMAL POSITION)

DRIP LEG

UNION

(TYPICAL INSTALLATION)

TOP VIEW OF GAS LINE AND VALVE

IN OPT. POSITION

BURNERS

GROMMET

NOTE: WHEN GAS LINE IS IN OPT. POSITION, SWAP LOCATION OF GROMMET AND PLUG.

OPTIONAL GAS LINE POSITION

GAS VALVE

MANIFOLD

PRESSURE TAP PLUG (IN NORMAL POSITION)

MANIFOLD

IMPORTANT: Do not run a flexible gas connector inside the unit.

➤ FIGURE 40

GAS PIPING -- HORIZONTAL INSTALLATION (GAS VALVE, MANIFOLD AND PRESSURE SWITCHES MAY BE DIFFERENT THAN SHOWN)

DRIP LEG

BURNERS

MANUAL GAS VALVE

INSTALLA UNION BETWEEN THE MANUAL GAS STOP AND THE MAIN GAS VALVE

GROMMET

GAS VALVE

NOTE: ONLY RGGE MODELS WITH FUEL CODE HB CAN BE INSTALLED HORIZONTALLY.

A1122-01_1

GAS PIPING

Install the gas piping according to all local codes and regulations of the utility company.

If possible, run a separate gas supply line directly from the meter to the furnace. Consult the local gas company for the location of the manual main shut-off valve. The gas line and man-

ual gas valve must be adequate in size to prevent undue pressure drop and never smaller than the pipe size

MANIFOLD

MANIFOLD PRESSURE TAP

A1122-01_2

➤ FIGURE 41

GAS PIPING — DOWNFLOW INSTALLATION (GASVALVE MAY BE DIFFERENT THAN SHOWN)

MANUAL GAS VALVE

4 TO 5 F T.

ABOVE FLOOR

REQ’D BY

SOME

UTILITIES.

GROMMET (IN NORMAL POSITION)

DRIP LEG

TOP VIEW OF GAS LINE AND VALVE

IN OPT. POSITION

UNION

BURNERS

GROMMET

NOTE: WHEN GAS LINE IS IN OPT. POSITION, SWAP LOCATION OF GROMMET AND PLUG.

OPTIONAL GAS LINE POSITION

GAS VALVE

PLUG (IN NORMAL POSITION)

MANIFOLD PRESSURE TAP

MANIFOLD

A1122-01_1

Page 40

to the combination gas valve on the furnace. Refer to Table 8 for the recom-

mended gas pipe size for natural gas

and Table 9 for L.P. See Figures 39, 40 & 41 for typical gas pipe connections.

Install a ground joint union between the manual gas stop and the main gas valve to easily remove the control valve assembly. Install a manual gas stop in the gas line outside the furnace cabinet. The gas stop should

be readily accessible to t supply on or off. Install a drip leg in the gas supply line as close to the furnace as possible. Always use a pipe compound resistant to the action of liquefied petroleum gases on all threaded connections.

IMPORTANT: When making gas pipe connections, use a back-up wrench to prevent any twisting of the control assembly and gas valve.

Any strains on the gas valve can change the position of the gas orifices in the burners. This can cause erratic furnace operation.

IMP

ORTANT: Do not run a flexible gas

connector inside the unit. 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 serviced another gas appliance. Massachusetts law requires

that all flexible gas connectors be less

than 36”. The gas pipe grommet in the cabinet

does not seal around a flexible gas con-

nector. It is important to have all openings in the cabinet burner compartment seale operation.

IMPORTANT: To insure a good seal, the

gas pipe that runs through the grommet must be 1/2” schedule 40 black pipe.

IMPORTANT: Ensure that the furnace

gas control valve is not subjected to

high gas line supply pressures (13.5” w.c. or above).

DISCONNECT the furnace and its individual shut-off valve from the gas supply piping during any pressure testing that

exceeds 1/2 PSIG (3.23 kPa or 13" w.c.).

d for proper furnace

urn the gas

GAS PRESSURE

Natural gas supply pressure should be 5" to 10.5" w.c. LP gas supply pressure should be 11" to 13" w.c.

This pressure must be maintained with all other gas-fired appliances in operation.

WARNING

NEVER PURGE A GAS LINE INTO THE COMBUSTION CHAMBER. NEVER USE MATCHES, FLAME OR ANY IGNITION SOURCE FOR CHECKING LEAKAGE. FAILURE TO ADHERE TO THISWARNING CAN CAUSE A FIRE OR EXPLOSION RESULTING IN PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.

To check for gas leakage, use an approved chloride-free soap and water solution, an electronic combustible gas detector, or other approved method.

GAS VALVE

This furnace has a 24-volt operated main solenoid valve. It has ports for measuring supply pressure and manifold pressure. A manual control is on the valve body. It can be set to only the

“ON” or “OFF” positions. IMPORTANT: Two different gas valves

are available with the modulating furnace. The type of valve used will affect the wire diagram, wire assemblies, lighting instructions, LP conversion kit and many other aspects of the furnace design. To determine the type of valve used on your furnace, consult the first two digits of the serial number.

By Serial Number (AKA fuel code)

HA or HB controlled modulating valve.

HG or HU controlled modulating valve.

See Figures 42 and 43.

FOR MODULATINIG FURNACES WITH THE STEPPER/SERVO CONTROLLED MODULATING VALVE, DO NOT ROUTE THE SPARK IGNITOR WIRE (ORANGE) NEAR THE GAS VALVE. DOING SO COULD RESULT IN A LOSS OF HEAT.

– The valve is a stepper/servo

– The valve is a solenoid-

WARNING

FIGURE 42

GAS VALVE STEPPER CONTROL-FUEL CODE HA OR HB

ON/OFF SWITCH

FIGURE 43

GAS VALVE SOLENOID CONTROL FUEL CODE HG OR HH

MANUAL CONTROL

Page 41

TABLE 8

NATURAL GAS PIPE CAPACITYTABLE (CU. FT./HR.)

Capacity of gas pipe of different diameters and lengths in cu. ft. per hr. with pressure drop of 0.3 in. and specific gravity of 0.60 (natural gas).

Nominal Length of Pipe, Feet Iron Pipe

Size, Inches 10 20 30 40 50 60 70 80

1/2 132 92 73 63 56 50 46 43 3/4 278 190 152 130 115 105 96 90

1 520 350 285 245 215 195 180 170 1-1/4 1,050 730 590 500 440 400 370 350 1-1/2 1,600 1,100 890 760 670 610 560 530

After the length of pipe has been determined, select the pipe size which will provide the minimum cubic

feet per hour required for the gas input rating of the furnace. By formula:

Cu. Ft. Per Hr. Required =

The gas input of the furnace is marked on the furnace rating plate. The heating value of the gas (BTU/FT3) may be determined by consulting the local natural gas utility or the LP gas supplier.

Gas Input of Furnace (BTU/HR)

Heating Value of Gas (BTU/FT

)

TABLE 9

LP GAS PIPE CAPACITY TABLE (CU. FT./HR.)

Maximum capacity of pipe in thousands of BTU per hour of undiluted liquefied petroleum gases (at 11

inches water column inlet pressure). (Based on a Pressure Drop of 0.5 Inch Water Column)

Nominal Length of Pipe, Feet Iron Pipe

Size, Inches 10 20 30 40 50 60 70 80 90 100 125 150

1/2 275 189 152 129 114 103 96 89 83 78 69 63 3/4 567 393 315 267 237 217 196 182 173 162 146 132

1 1,071 732 590 504 448 409 378 346 322 307 275 252 1-1/4 2,205 1,496 1,212 1,039 913 834 771 724 677 630 567 511 1-1/2 3,307 2,299 1,858 1,559 1,417 1,275 1,181 1,086 1,023 976 866 787

2 6,221 4,331 3,465 2,992 2,646 2,394 2,205 2,047 1,921 1,811 1,606 1,496

Example (LP): Input BTU requirement of unit, 150,000

Equivalent length of pipe, 60 ft. = 3/4" IPS required.

LP COPPER TUBE SIZING TABLE

Sizing between single or second stage (low pressure) regulator and appliance. Maximum capacity of pipe in thousands of BTU per hour of undiluted propane gases (at 11" w.c. setting).

Outside Diameter Copper Tubing, Type L 10 20 30 40 50 60 80 100 125 150

3/8" 49 34 27 23 20 19 16 14 11 10

1/2" 110 76 61 52 46 42 36 32 28 26

5/8" 206 141 114 97 86 78 67 59 52 48

3/4" 348 239 192 164 146 132 113 100 89 80

7/8" 536 368 296 253 224 203 174 154 137 124

Length of Pipe, Feet

Page 42

LP CONVERSION

IMPORTANT: LP gas from trucks used

to transport liquid-based fertilizers can

contain chemicals that will damage the furnace. Verify that your gas supplier does not use the same truck to transport materials other than LP.

This furnace is shipped from the facto-

ry for use on natural gas only. For use on LP gas, a proper conversion is required.

HG or HH Fuel Code trolled modulating valve): Conversion of the furnace for use on LP gas requires conversion kit RXGJ- FP07. This kit includes an LP gas valve.

HA or HB Fuel Code controlled modulating valve): Conversion of the furnace for use with LP gas requires conversion kit RXGJ- FP27. (Gas valve not required.)

CAUTION

ELEVATIONS ABOVE 2000 FT REQUIRE THATTHE FURNACE INPUT RATING BE ADJUSTED AND

THAT THE SIZE OF THE BURNER ORIFICES BE RE-CALCULATED BASED ON ELEVATION AND GAS HEATING VALUE.THE BURNER ORIFICES MAY (OR MAY NOT) NEED TO BE CHANGED. SEE THE SECTION TITLED “HIGH ALTITUDE INSTALLATIONS” OF THIS BOOK FOR INSTRUCTIONS.

NOTE: Order the correct LP conver-

sion kit available from the local distrib-

utor. Furnace conversion to LP gas

must be performed by a qualified

installer, service agency, or the gas

supplier.

To change orifice spuds for conversion

to LP:

1. Shut off the manual gas valve and disconnect the gas line at the union ahead of the unit gas valve.

(solenoid con-

(stepper/servo

2. Remove the gas valve and manifold assembly.

3. Replace the orifice spuds.

4. a. For servo (stepper) controlled

gas valve (fuel code HA or HB):

Install the jumper supplied with

the kit into the valve as shown in Figure 44. Make sure

that the

jumper connects the two pins

and verify by checking manifold pressure at high fire. It should

be approx. 11” w.c.

b. For solenoid controlled gas

valve (fuel code HG or HH): Remove the natural gas valve from the manifold assembly and replace with the LP valve included in the kit.

5. Re-attach the manifold assembly to the unit and connect the gas line to the gas valve.

6. Place the conversion label,

included in the kit, adjacent to

the CSA rating plate. Also for servo controlled gas valves only (fuel code HA or HB) be sure to install the label titled “LP” over

the hole where the jumper is

inserted in Item 4 above.

7. Check unit for leaks.

8. Follow lighting instructions to put the furnace into operation.

9. Check manifold pressure.

Consult Table 11, if there is any

question concerning orifice sizing.

FIGURE 44

SERVO CONTROLLED GAS VALVE SUPPLY PRESSURE TAP AND LP JUMPER WELL (FUEL CODE HA OR HB)

NOTE: REMOVE COVER TO

ADJUSTMENT WELL WHEN MAKING ADJUSTMENTS. REPLACE WHEN DONE.

NOTE: THE ADJUSTMENT WHEEL WILL NOT STOP ROTATING WHEN IT HITS THE MAXIMUM OR MINIMUM POSITION. INSTEAD IT WILL CONTINUE TO ROTATE TO THE OPPOSITE ADJUSTMENT. USE THE LETTERS ON THE WHEEL AS A GUIDE.

LP JUMPER WELL (INSERT JUMPER HERE)

SUPPLY PRESSURE TAP

ADJUSTMENT WELL

FIGURE 45

SOLENOID CONTROLLED GAS VALVE SUPPLY-LINE PRESSURE TAP (FUEL CODE: HG OR HH)

SUPPLY-LINE PRESSURE TAP

NOTE: LP orifices are included in

the kit but they may need to be

exchanged based on heating value

and/or elevation. LP orifices must be selected based on the altitude of the installation. See orifice chart.

OTE ABOUT LP CONVERSION

N OF STEPPER-CONTROLLED MODULATING GAS VALVE:

convert the stepper-controlled mod-

ulating gas valve, a jumper is

required to connect the two pins

inside the jumper well. It is possible to install the jumper such that the

pins are not connected. This is

incorrect. The jumper must connect the pins together inside the jumper

well. This can be confirmed by visual inspection and by verifying proper manifold pressure at high fire

(100%) after the jumper

is installed.

Manifold pressure should always be

Page 43

checked when converting the furnace for LP operation. Figures 46 and 47 below show the incorrect way and the

correct way to install the jumper. The jumper well is located next to the adjustment well (with “+” and “–” text

and two-headed arrow) and will be covered by a sticker or label. To con-

FIGURE 47

LP JUMPER INSTALLED ON SERVO MODULATING GAS VALVE WITH PINS PROPERLY CONNECTED. THIS IS CORRECT SURE THAT THE JUMPER CONNECTS THE TWO PINS TOGETHER AND VERIFY MANIFOLD GAS PRESSURE AT HIGH FIRE TO MAKE SURE THAT THE VALVE IS PROPERLY CONVERTED FOR LP GAS

vert to LP the label over the jumper

well will need to be removed.

FIGURE 46

LP JUMPER INSTALLED ON SERVO MODULATING GAS VALVE WITH PINS NOT CONNECTED. THIS IS INCORRECT SURE THAT THE JUMPER CONNECTS THE TWO PINS TOGETHER AND VERIFY MANIFOLD GAS PRESSURE AT HIGH FIRE TO MAKE SURE THE VALVE IS PROPERLY CONVERTED FOR LP GAS

. MAKE

SETTING GAS PRESSURE

A properly calibrated pressure gauge

JUMPER

IMPROPERLY

INSTALLED. NOTE THAT PINS ARE NOT CONNECTED.

or U-Tube manometer is required for accurate gas pressure measurements.

CAUTION

ELEVATIONS ABOVE 2000 FT REQUIRE THAT THE FURNACE INPUT RATING BE ADJUSTED AND THAT THE SIZE OF THE BURNER ORIFICES BE RE-CAL-

FIGURE 48

SERVO-CONTROLLED GAS VALVE MANIFOLD PRESSURE TAP LOCATION (FUEL CODE: HA OR HB)

. MAKE

JUMPER

PROPERLY

INSTALLED. NOTE THAT PINS ARE CONNECTED.

CULATED BASED ON ELEVATION AND GAS HEATING VALUE. THE BURNER ORIFICES MAY (OR MAY NOT) NEED TO BE CHANGED. SEE THE SECTION TITLED “HIGH ALTITUDE INSTALLATIONS” OF THIS BOOK FOR INSTRUCTIONS.

Supply Gas Pressure Measurement.

1. With gas shut off to the furnace at the manual gas valve outside the unit, remove the line pressure tap plug on the gas valve. See Figure 48.

2. Connect a U-Tube manometer to the pressure tap.

3. Turn on the gas supply and operate the furnace at 100% and all other gas-fired units on the same gas line as the furnace.

4. Note or adjust the supply-line

pressure to give: A. 5" - 10.5" w.c. for natural gas. B. 11" - 13" w.c. for LP gas.

5. Shut off the gas at the manual gas valve and remove the U-Tube manometer.

6. Replace the supply-line pressure tap plug before turning on the gas.

7. Check unit for

leaks.

If the supply-line pressure is above these ranges, install an in-line gas regulator to the furnace for natural gas units. With LP gas, have the LP supplier reduce the supply-line pressure at the regulator.

If supply-line pressure is below these ranges, either remove any restrictions in the gas supply piping or enlarge the gas pipe. See Tables 8 and 9. With LP gas, have the LP supplier adjust the supply-line pressure at the regulator.

FIGURE 49

SERVO CONTROLLED GAS VALVE PRESSURE ADJUSTMENT (FUEL CODE: HA OR HB)

NOTE: The adjust-

ment wheel will not stop rotating when

it hits the maximum

or minimum position. Instead, it will continue to rotate to the opposite

adjustment. Use

the letters on the wheel as a guide.

MANIFOLD TAP

CAUTION

ELEVATIONS ABOVE 2000 FT REQUIRE THAT THE FURNACE INPUT RATING BE ADJUSTED AND THAT THE SIZE OF THE BURNER ORIFICES BE RE-CALCULATED BASED ON ELEVATION AND GAS HEATING VALUE. THE BURNER ORIFICES MAY (OR MAY NOT) NEED TO BE CHANGED. SEE THE SECTION TITLED “HIGH ALTITUDE INSTALLATIONS” OF THIS BOOK FOR INSTRUCTIONS.

Page 44

➤ SERVO GAS VALVE (FUEL

➤ CODE: HA OR HB) MANIFOLD ➤ GAS PRESSURE ➤ MEASUREMENT/ADJUSTMENT.

1. With the gas to the unit shut off at the manual gas valve, remove the outlet pressure tap plug in the gas valve. See Figure 48.

2. Connect the positive pressure hose from a manometer to the pressure tap.

3. Note the manifold gas pressure to be:

A. 3.5" w.c. (±.3) for natural gas . B. 10.0" w.c. ( ±.5) for LP gas. NOTE: Make s

ure the unit is oper-

ating at maximum heating capacity (100%) before adjusting the mani-

fold pressure.

4. To adjust the pressure regulator,

NOTE: Only small variations in gas pressure should be made by

adjusting the pressure regulator.

NOTE: Allow up to 5 seconds for each change in manifold pressure.

5. Turn the adjustm

ent screw clockwise to increase pressure, or counterclockwise to decrease pressure. See Figure 49.

6. Check manifold gas pressure.

7. Repeat step 5 & 6 if needed.

8. Securely replace the regulator cap.

NOTE: Shut off gas at the manual gas valve and remove the U-Tube manometer.

9. Replace the manifold pressure tap plug before turning on the gas.

10. Check unit for leaks. insert a small slotted screwdriver into the opening at the top of the valve (see Figure 49).

FIGURE 50

SOLENOID CONTROLLED MANIFOLD PRESSURE TAP LOCATION (FUEL CODE HA OR HB)

REGULATOR CAP

OUTLET MANIFOLD PRESSURE TAP

➤ SOLENOID GAS VALVE (FUEL

➤ CODE: HG OR HH

) MANIFOLD

➤ GAS PRESSURE ➤ MEASUREMENT.

1. With the gas to the unit shut off at the manual gas valve, remove the outlet pressure tap plug in the gas valve. See Figure 50.

2. Connect the positive pressure hose from a manometer to the pressure tap.

3. Note the manifold gas pressure to be:

A. 3.5" w.c. (±.3) for natural gas .

B. 10.0" w.c. ( ±.5) for LP gas.

4. To adjust the pressure regulator,

remove the regulator cap.

TE: Only small variations in

gas pressure should be made by

adjusting the pressure regulator.

5. Turn the adjustment screw, using

⁄32" allen wrench, clockwise to

a increase pressure, or counterclockwise to decrease pressure. See Figure 51.

6. Check manifold gas pressure.

7. Repeat step 5 & 6 if needed.

8. Securely replace the regulator cap.

NOTE: Shut off gas at the manual gas valve and remove the UTube mano

meter.

9. Replace the manifold pressure tap plug before turning on the gas.

10. Check unit for leaks. NOTE: Do not use gas valve pres-

sure adjustment as a means to adjust temperature rise. The blower

motor will change speed to maintain a reasonably constant temperature rise.

FIGURE 51

SOLENOID CONTROLLED GAS VALVE PRESSURE ADJUSTMENT (3/32" ALLEN WRENCH) (FUEL CODE HH OR HG)

Page 45

ELECTRICAL WIRING

WARNING

TURN OFF ELECTRIC POWER AT FUSE BOX OR SERVICE PANEL BEFORE MAKING ANY ELECTRICAL CONNECTIONS. FAILURE TO DO SO CAN CAUSE ELECTRICAL SHOCK RESULTING IN PERSONAL INJURY OR DEATH.

WARNING

THE CABINET MUST HAVE AN UNINTERRUPTED GROUND ACCORDING TO THE LATEST EDITION OF THE NATIONAL ELECTRICAL CODE, ANSI/ NFPA70-, OR IN CANADA, THE CANADIAN ELECTRICAL CODE, CSA-C22.1 OR LOCAL CODES THAT APPLY. A GROUND SCREW IS PROVIDED IN THE JUNCTION BOX. FAILURE TO PROPERLY CONNECT THE GROUND WIRE CAN CAUSE ELECTRICAL SHOCK RESULTING IN PERSONAL INJURY OR DEATH.

WARNING

THIS FURNACE IS EQUIPPED WITH A BLOWER DOOR SAFETY SWITCH. DO NOT DISABLE THIS SWITCH. FAILURE TO FOLLOW THIS WARNING CAN RESULT IN ELECTRICAL SHOCK, PERSONAL INJURY OR DEATH.

IMPORTANT: The furnace must be

installed so that the electrical components are protected from water.

A grounding wire is provided to connect to the incoming grounding wire from line power. The furnace must be permanently grounded in accordance with all national and local codes.

Before proceeding with the electrical connections, be certain that the service panel voltage, frequency and phase corresponds to that specified on the fur-

nace rating plate. Maximum over-current

protection is 15 amperes. Use a separate, fused branch electrical

circuit containing a properly sized fuse or

circuit breaker. Connect this circuit directly

from the main switch box to an electrical

disconnect that is readily accessible and located within arm’s reach (2 ft.) of the furnace. Connect from the electrical dis-

connect to the junction box on the left

side of the furnace, inside the blower compartment. See Figure 52. For the proper connection, refer to the appropri-

ate wiring diagram located on the inside

cover of the furnace control box and in

these instructions.

NOTE: The electrical junction box may

be moved to the right side if necessary. A knockout is provided. Seal the opposite hole with plug provided.

WARNING

L1 TERMINAL AND NEUTRAL TERMINAL POLARITY MUST BE OBSERVED WHEN MAKING FIELD CONNECTIONS TO THE FURNACE. FAILURE TO DO SO WILL EXPOSE LIVE WIRING IN THE BLOWER COM THE DOOR IS REMOVED. TOUCHING THESE LIVE CIRCUITS COULD RESULT IN PERMANENT INJURY OR DEATH FROM ELECTRICAL SHOCK.

FIGURE 52

JUNCTION BOX LOCATION

UPFLOW MODELS

➤DOWNFLOW/

HORIZONTAL

MODELS

PARTMENT WHEN

Make all electrical connections in accordance with the latest edition of the National Electrical Code ANSI/NFPA70 – or in Canada, the Canadian Electrical Code Part 1CSA Standard C22.1 and local codes

having jurisdiction.

These may be obtained from: National Fire Protection

Associati Batterymarch Park Quincy, MA 02269

Canadian Standards Association

178 Rexdale Boulevard Rexdale, Ontario, Canada M9W 1R3

on, Inc.

Page 46

ELECTRICAL CHECKS

Line Power Check

The furnace must have a nominal 115 volt power supply for proper operation. If there is not a consistent power supply, contact a licensed electrician to correct the problem.

1. With the blower compartment door off, manually hold the push button door switch in.

2. Call for heat at the thermostat.

3. With the unit operating, use a voltmeter to measure the voltage from an

y 120 VAC terminal to any neu-

tral connection.

4. The voltage should be a nominal 115 volts (acceptable 105120VAC).

This test should be made with the unit in full operation.

Polarity Check

If line & neutral are reversed, a fault code (26) will be displayed at the furnace seven segment display (SSD) and at the communicating thermostat active fault display screen (communicating systems only).

Proper line ing, is a must for this furnace to operate. Use a volt meter to make this check.

1. With the blower compartment door off, manually hold the push button door switch in.

2. Use a voltmeter to measure the voltage from any 120 VAC terminal to any bare metal ground on the furnace.

3. The voltage should be a nominal 115 volts (acceptable 105120VAC).

4. Use a voltmeter to measure the voltage from any neutral terminal to the bare metal ground on the furnace.

5. The voltage should be less than

1.0 VAC.

6. If the voltage from any 120 VAC terminal to ground is less than 1.0 VAC volts and the voltage from a neutral to ground is a nominal 115 volts, the polarity is reversed.

7. To correct the problem, either reverse the hot and neutral wires to the furnace or have a licensed electrician che wiring.

Control Voltage Check

1. With the blower compartment

2. Call for heat at the thermostat.

3. With the unit operating, use a

voltage polarity, or phas-

ck the building

door off, manually hold the push button door switch in.

(Does not include communicating thermostats.)

voltmeter to measure the voltage from control voltage terminal “W”

Page 47

ACCESSORIES

FIELD-INSTALLED OPTION ACCESSORIES

TWINNING: Twinning is NOT permitted

on any modulating RGFE, RGGE or RGJF furnace model.

ELECTRONIC AIR CLEANER

Line voltage power is supplied from the screw terminal “EAC”, see Figure 53, and a line voltage neutral screw terminal on the control board. This will power the electronic air cleaner whenever the blower is operating and delivering the recommended minimum CFM. The 60 and 75 KBTU models, which are capable of a maximum delivery of 1200 CFM, will operate the electronic air cleaner at 500 CFM and above. The 90, 105 and 120 KBTU models, which are capable of

a maximum delivery of 2000 CFM, will

operate the electronic air cleaner at 800 CFM and above. These limits are set to

prevent excessive production of ozone

at the lower airflows of the modulating furnace and are based on average requirements of commercially available electronic air cleaners. Continuous fan speeds are selectable and some lower fan speeds may not deliver enough airflow to operate an electronic air cleaner. The IFC determines the minimum airflow necessary to operate an electronic air cleaner and will not turn on the electronic air cleaner unless the airflow is high enough for the EAC.

HUMIDIFICATION AND DEHUMIDIFICATION

HUMIDIFIER – The humidifier contacts (labeled “HUM OUT”) are “dry” contacts on the I.F.C. This means that the terminals are connected directly to the contacts of a board-mounted relay. The coil of the relay is controlled by the microprocessor of the IFC. The coil is engaged roughly any time the heat speed blower is engaged and (1) 24VAC is present on the thermostat terminal of the IFC labeled “HUM STAT” or (2) a communicating thermostat with humidification and dehumidification capability is installed with call for humidification present.

FIGURE 54

WIRING FOR OPTIONAL HUMIDIFICATION (AND DEHUMIDIFICATION WITH COMMUNICATING THERMOSTAT) WITH OPTIONAL HUMIDIFIER AND NO HUMIDISTAT (HUMIDIFICATION ACTIVE DURING ANY HEAT CALL) (FOR USE WITH COMMUNICATING AND NON-COMMUNICATING THERMOSTATS)

FIELD INSTALLED JUMPER FROM “R” TO “HUM STAT” TERMINALS

JUMPER SHOULD NOT BE INSTALLED WHEN USING A COMMUNICATING THERMOSTAT WITH HUMIDIFICATION AND DEHUMIDIFICATION CAPABILITIES.

An optional 24VAC humidistat can be installed as shown in Figures 54 thru 54 (II thru IV). With the optional humidistat, two separate conditions must be met before humidification can begin 1). There must be a call for heat and the blower must be engaged and 2.) The humidistat must determine that there is a need for humidification.

Note: Dipswitch SW2-1 (labeled “ODD”) enables (“ON”) or disables (“OFF”) dehumidification operation. However, it has no affect on humidification operation. If this switch is set to the “ON” position and no humidistat is installed, the cooling

NOTE: DO NOT USE COMMUNICATING THERMOSTAT MODEL (-)HC-TST501CMMS IF HUMIDITY CONTROL VIA THE THERMOSTAT IS NEEDED

FIGURE 53

EAC AND HUMIDIFIER TERMINALS ON FURNACE CONTROL (IFC)

FIGURE 55

WIRING FOR OPTIONAL DEHUMIDIFICATION WITH HUMIDIFICATION (WITH OPTIONAL HUMIDISTAT AND HUMIDIFIER) NOTE: CAN BE USED WITH COMMUNICATING OR NON-COMMUNICATING SYSTEMS

Page 48

FIGURE 56

WIRING FOR OPTIONAL DEHUMIDIFICATION OPERATION AND HUMIDIFICATION WITH OPTIONAL HUMIDIFIER (HUMIDIFIER WITH INTERNAL POWER SUPPLY) (FOR USE WITH NON-COMMUNICATING THERMOSTATS)

FIGURE 57

HUMIDISTAT USED TO CONTROL DEHUMIDIFICATION IN COOLING ONLY (NO HUMIDIFIER) (FOR USE WITH NON-COMMUNICATING THERMOSTATS)

airflow will be permanently reduced by

approximately 15% giving less than

optimal performance and possibly causing prob

lems. It is not recommended to leave this switch in the “ON” position without a humidistat installed.

Control of dehumidification in cooling and/or humidification in heating can be done with a variety of methods depending on whether there is a communicating thermostat or a humidistat available and depending on the type of operation desired.

With systems configured with communicating thermostats and co

ndensers, dehumidification is controlled by the condenser and is not affected by the position of dipswitch SW2-1 or the voltage (or lack of voltage) at the thermostat terminal labeled “HUM STAT”.

To determine which wiring diagram and method to use, select from the following configurations:

A. HUMIDIFICATION CONTROL ONLY

WITH NO DEHUMIDIFICATION (REQUIRES OPTIONAL HUMIDIFIER).

A1. WITH COMMUNICATING

umidification control is required. To wire the furnace for humidification control using the former thermostat, refer to the wiring diagram in Figure 54(I). Be sure not

to install the

jumper between “R” and “HUM

STAT” on the furnace con-

trol. Installing this jumper

will operate the humidifier any time there is a heat call.

Without the jumper, the

humidification call from the thermostat must be active and a heat call must be present with the blower running.

A2. WITH NON-COMMUNICAT-

ING THERMOSTAT

A2-1 CONTINOUS HUMID-

IFIER OPERATION DURING HEATING. For continuous humidifier o

peration during heating, refer to Figure 54 (I) and make sure to install

the jumper between

the thermostat terminals labeled “R” and “HUM STAT”. A separate humidistat is not required for this configuration and the humidifier will turn on whenever there is a call for heat and the blower is running.

A2-2 CONTROLED

HUMIDIFIER OPERATION USING A HUMIDISTAT (REQUIRES OPTIONAL HUMIDISTAT). Controlled humidificat

ion can be accomplished using a humidistat as shown in Figures 55 (II) or 56 (III). These figures show installation of a

humidifier with exter-

nal and internal power supplies respectively. Dehumidification operation will be disabled if the dipswitch SW2-1 is in the “OFF” position. If this switch is in the “ON” position, dehumidification control will be active.

B. DEHUMIDIFICATION CONTROL

WITH NO HUMIDIFIC

ATION

B1. For communicating ther-

mostats listed with this furnace, dehumidification is controlled automatically when selected at the thermostat and additional wiring is not necessary. The actual airflow demand (reduced for dehumidification) is requested of the furnace by the condenser.

Page 49

B2. WITH NON-COMMUNICATING

THERMOSTAT (REQUIRES OPTIONAL HUMIDISTAT). Control of dehumidification only (no humidification) can be accomplished by installing an op

tional humidistat as shown in Figure 57 (IV). The dipswitch SW2-1 must be set to the “ON” position. If this switch is not turned “ON”, dehumidification operation will not take place. Further, if this switch is “ON” and no humidistat is installed, airflow in cooling will be perma-

nently reduced by approximate-

ly 15%.

C. HUMIDIFICATION AND DEHUMIFI-

CATION CONTROL (REQUIRES OPTIONAL HUMIDIFIER).

C1. WITH COMM

THERMOSTAT Humidifier control is included with the (-)HC-TST412MDMS (modulating, non-communicating) and (-)HC-TST550CMMS (full-color communicating) model thermostats. However, it is not included with the (-)HCTST501CMMS model communicating thermostat. Do not purchase the latter thermostat if humidification control is required. To wire the furnace for humidification and dehumidification cont thermostat, refer to the wiring diagram in Figure 54 (I). Be sure not between “R” and “HUM STAT” on the furnace control.

Installing this jumper will oper-

ate the humidifier any time

UNICATING

rol using the former

to install the jumper

there is a heat call and dehumidification will never take place when in cooling. Without

the jumper, a humidification call

from the thermostat must be active and a heat call must be present with the blower running for the “HUM OUT” relay contacts to close.

C2. WITH NON-COMMU

THERMOSTAT (REQUIRES OPTIONAL HUMIDISTAT.) For non-communicating thermostats, an optional humidistat must be installed. Controlled humidification and dehumidification can be accomplished using a humidistat as shown in Figures 55 (II) or 56 (III). These figures show installation

of a humidifier with external and

internal power supplies respectively. Dehumidification operation will be disabled switch SW2-1 is in the “OFF” position. If this switch is in the “ON” position, dehumidification control will be active.

NICATING

if the dip-

OTHER ACCESSORIES AVAILABLE

These kits are available through the finished goods department.

CONCENTRIC VENT TERMINATION KIT

= RXGY-E03A

HORIZONTAL, TWO-PIPE TERMINATION KIT = RXGY-D02/D02A, RXGY-

D03/D03A, OR RXGY-D04/D04A

VENT TERMINATION KIT: RXGY-G02 CONDENSATE PUMP KIT: RXGY-B

NEUTRALIZER KIT: RXGY-A01 EXTERNAL BOTTOM FILTER RACK:

RXGF-CB

EXTERNAL SIDE FILTER RACK:

RXGF-CA These parts are available through

ProStock parts department.

ALTERNATE (LEFT-SIDE) DRAIN

KIT (DOWNFLOW MODELS ONLY):

RXGY-H01

TYPICAL WIRING ACCESSORIES FOR COMMUNICATING RESIDENTIAL SYSTEMS

detector and freeze protection

switch. There are two methods of connecting the switch to the system depending on the device configuration normally closed or normally open. The blower can run during a fault or the blower can shut off during a fault depending on how the system is connected. Please refer to local and/or state codes these devices. The following operation applies only when BOTH the condenser and thermostat are serial communicating devices. If the condenser is non-communicating (traditional, legacy 24VAC controlled) this diagram is not valid.

for installing

THERMOSTAT AND ACCESSORIES FOR THERMOSTAT

Programmable Modulating Thermostat:

(-)HC-TST412MDMS

Programmable Communicating Modulating:

(-)HC-TST501CMMS

Full-Color, Programmable Communicating Modulating:

(-)HC-TST550CMMS

Remote Sensor:

(For Thermostats Above Only)

F1451378

Thermostat Wall Plate For Thermostats Above Only:

F61-2600

Page 50

Typical Wiring Accessories for Communicating Residential Systems

The Rheem Serial Communicating (CC2) system allows accessories to be connected to shut down the system in the event of a fault. Typical devices that can be connected are the drain overflow switch, smoke detector and freeze protection switch. There are two methods of connecting the switch to the system depending on the device configuration normally closed or normally open. The blower can run during a fault or the blower can shut off during a fault depending on how the system is connected. Please refer to local and/or state codes for installing these devices. The following operation applies only when BOTH the condenser and thermostat are serial communicating devices. If the condenser is non- communicating (traditional, legacy 24VAC controlled) this diagram is not valid.

METHOD BLOWER

ACTIVATION

BLOWER

RUNS

(Y1)

CONTACTS WIRING CONFIGURATION

NORMALLY

OPEN

NORMALLY

CLOSED

When 24 VAC is applied to Y1 at the furnace control in a communicating system a SYSTEM BUSY message appears on the thermostat. When the SYSTEM BUSY message appears the outdoor unit will shut down and the indoor unit will continue to run at first stage cooling airflow.

If the device does not have normally open contacts an additional relay must be used for proper system operation.

BLOWER

DOES NOT

RUN

(Y2)

NORMALLY

OPEN

NORMALLY

CLOSED

When the device is connected to Y2 and a fault occurs the blower will shut down. The Y2 input can still be used with normally open or normally closed contacts.

If the device does not have normally open contacts an additional relay must be used for proper system operation.

Page 51

HIGH ALTITUDE INSTALLATIONS

RGFE/RGGE/RGJF -HIGH ALTITUDE CONVERSION

WARNING

FOR RGGE-06 AND RGJF-06 MODELS, A PRESSURE SWITCH CHANGE IS NOT NECESSARY AT ANY ELEVATION. FOR RGGE-07 & RGJF-07 MODELS, A PRESSURE SWITCH CHANGE IS REQUIRED AT E ABOVE 8,000 FT. FOR ALL OTHER RGFE/RGGE/RGJF FURNACES, A PRESSURE SWITCH CHANGE IS REQUIRED AT ELEVATIONS ABOVE 5,000 FT. THE APPROPRIATE HIGHELEVATION KIT WILL CONVERT THE FURNACE FOR USE ABOVE THE APPROPRIATE ELEVATION STATED HERE. DO NOT INSTALL THE -278 OPTION FURNACE OR THE HIGH ALTITUDE KIT BELOW THE STATED ELEVATION. DOING SO CAN CAUSE SERIOUS PERSONAL INJURY OR DEATH OR EQUIPMENT FAILURE.

HIGH ALTITUDE CONVERSION KITS

WARNING

FOR RGGE-06 & RGJF-06 MODELS, A PRESSURE SWITCH CHANGE IS NOT NECESSARY AT ANY ELEVATION. FOR RGGE-07 & RGJF-07 MODELS, A PRESSURE SWITCH CHANGE IS REQUIRED AT ELEVATIONS ABOVE 8,000 FT. FOR ALL OTHER RGFE/RGGE/RGJF FURNACES, A PRESSURE SWITCH CHANGE IS REQUIRED AT ELEVATIONS ABOVE 5,000 FT. THE APPROPRIATE HIGHELEVATION KIT WILL CONVERT THE FURNACE FOR USE ABOVE THE ELEVATION STATE INSTALL THE HIGH ALTITUDE KIT BELOW THE STATED ELEVATION. DOING SO CAN CAUSE SERIOUS PERSONAL INJURY OR DEATH OR EQUIPMENT FAILURE.

HIGH ALTITUDE FIELD CONVERSION KITS (RGFE MODELS)

MODEL INPUT(BTU) KIT NO.

RGFE-06XXXXX 60,000 RXGY-F34 RGFE-07XXXXX 75,000 RXGY-F35 RGFE-09XXXXX 90,000 RXGY-F36 RGFE-10XXXXX 105,000 RXGY-F37 RGFE-12XXXXX 120,000 RXGY-F38

LEVATIONS

D HERE. DO NOT

HIGH ALTITUDE FIELD CONVERSION KITS (RGGE & RGJF MODELS)

MODEL INPUT(BTU) KIT NO.

RGGE OR RGJF-06XXXXX 60,000 No Kit

RGGE OR RGJF-07XXXXX 75,000 RXGY-F23

RGGE OR RGJF-09XXXXX 90,000 RXGY-F24 RGGE OR RGJF-10XXXXX 105,000 RXGY-F25 RGGE OR RGJF-12XXXXX 120,000 RXGY-F26

Orifice Selection for High Altitude Applications

Natural Gas

CAUTION

INSTALLATION OF THIS FURNACE AT ALTITUDES ABOVE 2000 FT (610 m) SHALL BE IN ACCORDANCE WITH LOCAL CODES OR, IN THE ABSENCE OF LOCAL CODES, THE

IONAL FUEL GAS CODE, ANSI

NAT Z223.1/NFPA 54 OR NATIONAL STANDARD OF CANADA, NATURAL GAS AND PROPANE INSTALLATION CODE, CAN B149.1.

INSTALLATION OF THIS APPLIANCE AT OR ABOVE 5000 FT (1525 m) SHALL BE MADE IN ACCORDANCE WITH THE LISTED HIGH ALTITUDE CONVERSION KIT AVAILABLE FOR THIS FURNACE.

34” 90 Plus furnaces installed at high elevations require the installation of a high altitude kit for proper operation.

gh altitude kit consists of a high

The hi altitude pressure switch that replaces the high pressure switch of the furnace.

The pressure switch must be installed at elevations above those listed. Elevations above 2000 ft. require the furnace to be de-rated 4% per thousand feet. NOTE: Factory installed ori-

fices are calculated and sized based on

a sea level Natural Gas heating value of 1075 BTU per cubic ft. Region reduced heating values may nullify the

need to change orifices except at extreme altitudes. Table 10 shows

some quick conversions based on elevation and gas heating value. This table is combined and simplified from Tables F1 and F4 of the National Fuel Gas Code.

TABLE 10

Natural Gas Orifice Drill Size (4% per 1000 ft. De-Rate) IMPORTANT: For 90+ Furnaces only. Do not use this chart for any 80+ Furnace. Burner Input (per burner) 15,000 BTU @ Sea Level

Annual Avg. Heat

Value (btu per ft3)

Sea level 2000 to 3000 to 4000 to 5000 to 6000 to 7000 to 8000 to to 1999 ft 2999 ft 3999 ft 4999 ft 5999 ft 6999 ft 7999 ft 8999 ft

47 48 48 49 49 49 50 50

850

48 49 49 49 50 50 50 51

900

49 50 50 50 51 51 51 52

1000

50 51 51 51 51 52 52 52

1075

51 51 52 52 52 53 53 53

1170

Required

(8000 ft and above only)

EXAMPLES

The following are examples of orifice sizing using the National Fuel Gas Code Appendix F. For a simplified estimation of orifice size based on

heating value and elevation use Tables 10 and 11. However, calculations are the best method.

Example: 900 BTU/ft Natural Gas Heating Value

I / H = Q 15000 / 900 = 16.68 ft

I = Sea Level input (per burner): 15000 H = Sea Level Heatin Q = 16.68 ft

Natural Gas per hour.

From Table F.1 of National Fuel Gas Code Handbook, 2002 (3.5ⴖ w.c. col- umn) Orifice required at Sea Level: # 48

From Table F.4 of National fuel Gas

Code Handbook, 2002

Orifice required at 5000 ft. elevation (4% de-rate per thousand ft): # 50 Orifice required at 8000 ft. elevation (4% de-rate per thousand ft): # 51

Example: 1050 BTU/ft Natural Gas Heating Value

I / H = Q 15000 / 1050 = 14.63 ft

I = Sea Level input (per burner): 15000 H = Sea Level Heating Value: 1050 Q= 14.28 ft

Natural Gas.

From Table F.1 of National Fuel Gas code Handbook, 2002 (3.5ⴖ w.c. col- umn) Orifice required at Sea Level: # 50

From Table F.4 of National Fuel Gas

code Handbook, 2002

Orifice required at 5000 ft. elevation (4% de-rate per thousand ft): # 51 Orifice required at 8000 ft (4% de-rate per thousand ft): # 52

Regional

/hr

g Value: 900

Regional

/hr

. elevation

Page 52

0-999 1000-1999 2000-2999 3000-3999 4000-4999 5000-5999 6000-6999 7000-7999 8000-8999 9000-9999

ELEVATION CHART (National Fuel Gas Code recommended orifice based on 4% derate for each 1000 foot of elevation, based

on the intersection of the orifice required at Sea Level and the elevation required below)

Value at

per Burner

15,000 Btu’s

90 Plus Heat

Cubic

Foot at

3.5" W.C.

Sea Level

15,000 14,400 13,800 13,200 12,600 12,000 11,400 10,800 10,200 9,600

Size

Orifice

46 18.57 808 46 46 47 47 47 48 48 49 49 50

Sea

Level

NATURAL GAS QUICK REFERENCE CHART FOR ORIFICE SELECTION, AT 3.5" W.C. AND APPROXIMATE FINAL FIRING RATES

90 Plus ONLY models with 15,000 Btu's per Burner. DO NOT USE THIS CHART FOR ANY 80 PLUS MODEL.

TABLE 11

SUPPLEMENTAL ORIFICE SIZE CHART

47 17.52 856 47 47 48 48 49 49 49 50 50 51

48 16.36 917 48 48 49 49 49 50 50 50 51 51

49 15.2 987 49 49 50 50 50 51 51 51 52 52

Final Firing Rate per Burner

50 13.92 1078 50 50 51 51 51 51 52 52 52 53

51 12.77 1175 51 51 51 52 52 52 52 53 53 53

All calculations are performed by using the first three columns of information only. Before beginning any calculations, determine the

individual burner Btu size and heating value at Sea Level for the installation site. Each value shown in the Heat Value column is per

burner at 3.5" W.C.

NOTE:

Heat Value at Sea Level, for the location of the installation, is available from the Natural Gas Supplier to that site. Orifices for all altitudes are based

on Sea Level values.

Divide the individual burner capacity (15,000 for 90 plus) by the Heat Value for the site to determine the Cubic Foot value at Sea Level, or divide

Level from your calculation in the first column. The correct high altitude orifice that must be installed in each individual burner is the intersection of

burner capacity by the Cubic Foot value for the Heat Value. Once you have either the Cubic Foot Value or the Heat Value you can estimate the Sea

these two points on the chart above.

Level orifice for the site. To select the corresponding high altitude orifice, locate the site elevation on the chart above and the orifice required at Sea

Page 53

LP GAS AT HIGH ALTITUDE ELEVATIONS

LP Gas is a manufactured gas that has consistent heating value across most regions.

The National Fuel Gas Code (N.F.G.C.) guidelines are used with the following

exception:

The recommended LP Gas high altitude orifice selections differ slightly in that the NFGC LP orifice chart, as they are not accurate for the RGFE, RGGE or RGJF gas furnaces. The National Fuel Gas Code LP or

ifices are based on an

Orifice Ordering Informa

Orifice sizes are selected by adding the 2-digit drill size required in the orifice part number. Drill sizes available are 39 through 64; metric sizes avail-

able 1.10mm (-90) and 1.15mm (-91): Orifice Part Number 62-22175-(drill

size)

Example 1: #60 drill size orifice required

Part #62-22175-60

Example 2:

1.15mm drill size orifice required

Part #62-22175-91

11” of water column pressure at the orifice, which differs from products that use 10” of water column at the orifice. This difference requires a deviation

from the NFGC orifice size recommen-

dations. The Sea Level input should still be reduced by 4% per thousand ft. and

the orifice size must be selected based

on the reduced input selection shown in Table 12.

TABLE 12

LP Gas Orifice Drill Size and per burner de-rate by elevation based on 15,000 btu 90+ burners.

IMPORTANT: For 90+ Furnaces only. Do not use this chart for any 80+ Furnace.

Altitude burner) 15000 Size

0 to 2000 ft. 15000 1.15 mm (factory) 2001ⴕ to 3000ⴕ 13200 1.15 mm 3001ⴕ to 4000ⴕ 12600 1.10 mm 4001ⴕ to 5000ⴕ 12000 #58 5001ⴕ to 6000ⴕ 11400 #59 6001ⴕ to 7000ⴕ 1080 #60 7001ⴕ to 8000ⴕ 10200 #62 8001ⴕ to 9000ⴕ 9600 #63 9001ⴕ to 10000ⴕ 9000 #64

Input (per Orifice

tion

Page 54

ZONING SYSTEMS

The manufacturer does not currently

provide or support zoning with modulating furnace. However, zoning systems

can be installed with the system as long

as the zoning equipment manufacturers

specifications and installation instructions are met and followed.

The preferred zoning method is to use

a “bypass” system which is properly

installed for maximum efficiency. In these systems, excess

back through the system to be used again – this is opposed to a “dump”

system in which excess air is routed to a zone where it is expected that the extra heat or cooling would be least

noticed. If installed as a “bypass” system, the

installation must have an optional

freeze stat installed to prevent the coil from icing with excess bypass cooling. Also, if the zoning equipment manufac-

turer prov

ides a limit switch (usually

provided by the zoning manufacturer),

this limit must be installed in the system to prevent the furnace from overheating.

air is routed

FURNACE INSTALLATION WITH NON-COMMUNICATING HIGH-EFFICIENCY PREMIUM COOLING OR HEAT PUMP SYSTEMS

Furnace installation with Rheem/Ruud

-ASL or -ARL outdoor condensing units can provide high efficiency (up to 16 SEER) cooling operation when combined with proper evaporator coil. For listed cooling equipment combinations, see the -ARA or -ARL specification sheets and Tables 13 and 14 of this document. Using Tables 13 and 14 and literature provided with the cooling equipment, the installer needs to make sure that the proper evaporator coil, condensing coil and airflow is configured to achieve rated efficiency.

In accordance with Rheem/Ruud cooling equipment in do not install an evaporator coil or coil casing to the furnace which is smaller in width than the furnace cabinet.

stallation instructions,

UP TO 16 SEER COOLING OPERATION

Check the revision number of the integrated furnace control (IFC) to determine how best to configure your furnace for high SEER operation.

To achieve high SEER operation, turn dip switch #4 of bank SW2 to the “off” position (factory setting). This will enable the furnace operation for 16 SEER. Actual SEER values will vary and depend on the equipment combination. Consult the specifications sheets and installation instructions of the cooling equipment pur

chased for a listing of the SEER

ratings for a specific combination.

TABLE 13

AIRFLOW AND CONDENSER SELECTION – PREMIUM (NON-COMMUNICATING) COOLING SYSTEMS (1 STAGE COOL ONLY) (NOTE: SWITCH SW2-4 OF THE IFC MUST BE IN THE “OFF” POSITION FOR OPTIMUM PERFORMANCE)

TONS

2 -GFE/GGE-06 & -07 17.5" 800 -ARA-24 OFF ON OFF OFF

2-1/2 -GFE/GGE-06 & -07* 17.5" 1000 -ARA-30 ON OFF OFF OFF

3 -GFE/GGE-09 & -10* 21" 1200 -ARA-36 ON ON OFF OFF

3-1/2 -GFE/GGE-09 & -10* 21" 1400 -ARA-42 ON ON OFF OFF

3 -GFE/GGE-12 24.5" 1200 -ARA-36 ON ON OFF OFF

3-1/2 -GFE/GGE-12 24.5" 1400 -ARA-42 ON ON OFF OFF

Evaporator coil must be the same width as the furnace OR one size larger in width than the gas furnace. (See condenser spec. sheet, I&O and other literature for evaporator selection)

FURNACE

MODEL WIDTH

APPROX. AIRFLOW

(CFM)

CONDENSING

UNIT

MOD. FURNACE IFC DIP-SWITCH SETTINGS

SW-1,#1 SW-1,#2 SW-1,#3 SW-1,#4

TABLE 14

AIRFLOW AND CONDENSER SELECTION – PREMIUM (NON-COMMUNICATING) COOLING SYSTEMS (2 STAGE COOL) (NOTE: SWITCH SW2-4 OF THE IFC MUST BE IN THE “OFF” POSITION FOR OPTIMUM PERFORMANCE)

TONS

2 -GFE/GGE-06 & -07 17.5" 800 -ARL/ASL-24 OFF ON OFF OFF 3 -GFE/GGE-06 & -07 17.5" 1200 -ARL/ASL-36 OFF OFF OFF OFF 3 -GFE/GGE-09 & -10 21" 1200 -ARL/ASL-36 ON ON OFF OFF 3 -GFE/GGE-12 24.5" 1200 -ARL/ASL-36 ON ON OFF OFF 4 -GFE/GGE-09 & -10 21" 1600 -ARL/ASL-48 ON OFF OFF OFF 4 -GFE/GGE-12 24.5" 1600 -ARL/ASL-48 ON OFF OFF OFF 5 -GFE/GGE-12 24.5" 1800 -ARL/ASL-60 OFF OFF OFF OFF

Evaporator coil must be the same width as the furnace OR one size larger in width than the gas furnace. (See condenser spec. sheet, I&O and other literature for evaporator selection)

FURNACE

MODEL WIDTH

APPROX. AIRFLOW

(CFM)

CONDENSING

UNIT

MOD. FURNACE IFC DIP-SWITCH SETTINGS

SW-1,#1 SW-1,#2 SW-1,#3 SW-1,#4

Page 55

INTEGRATED FURNACE CONTROL (I.F.C.)

FIGURE 58

MODULATING CLIMATE-TALK COMMUNICATING FURNACE CONTROL (RHEEM # 62-102783-01)

BIAS/TERM (COMM ONLY) (all must be on)

24 VAC THERMOSTAT (TSTAT) INPUTS (J4 & J6)

These connections are used with any traditional 24VAC one-stage or twostage thermostat or the modulating, non-communicating, thermostat specified for this modulating furnace. Fully communicating thermostats must be connected to the COMM NETWORK CONNECTION (see section titled

COMMUNICATING SYSTEMS

document for details). Optimum heat-

of this

ing performance will be realized only

with the fully modulating thermostat (either communicating or non-communicating).

1, Y1, Y2, G, C and R

W tional thermostat inputs used in nearly all HVAC equipment. Installation of the thermostat to these connections is straight-forward and simple.

UM STAT connect the output of a humidistat to the furnace control to control humidification and/or dehumidification.

– This terminal is used to

are the tradi-

Optional equipment is required for these features. Please see the section titled

DEHUMIDIFICATION

ment for more details.

/W2

V nect the modulating signal (V) from a non-communicating, fully modulating thermostat specified for use with this furnace. It is used to transmit the firing rate (determined by the thermostat) to the furnace control. In addition, a traditional 24VAC signal from a two-stage thermostat ter-

HUMIDIFICTION AND

of this docu-

– This terminal is used to con-

Page 56

minal labeled “W2” can be connected to this terminal to activate the timed staging feature of this furnace.

Note: Do not apply 24vac to the V/W2

terminal (as with a jumper to R for diag-

nostic purposes) when a non-communicating, modulating thermostat is installed.

SPECIAL CONFIGURATION – COMMUNICATING THERMOSTAT AND FURNACE WITH A NON-COMMUNICATING CONDENSER

Y1 and Y2 used to connect directly to a non-communicating condenser when a communicating thermostat is installed to the furnace but a non-communicating condenser is installed in the system. While the optimum configuration is with a communicating condenser connected to the network, there may be installations where this is not desired. In these cases, the thermostat will be communicatin

and the furnace control will energize

the condenser as necessary (the addi-

– These terminals may be

g with the furnace control

tional relays have been added to the furnace control to allow this operation).

The thermostat connections labeled “Y1” and “Y2” on the I.F.C. are normally

inputs

to the furnace control to turn on

the blower when they are energized.

However, in this configuration, these (normally) inputs become

energize the condenser when a cooling

call has been sent from the communicating thermostat.

When this configuration is desired, use the wiring diagram in Figure 59 to connect the thermostat and condenser to the furnace control. For single stage

condensers, a jumper must be installed

between Y1 & Y2 at the furnace control.

NOTE: A heat pump condenser cannot be installed with this configuration.

is no control for the reversing

There valve.

outputs

24 VAC FROM TRANSFORMER (XFORMER) CONNECTIONS

These inputs are used to connect 24VAC from the furnace transformer to the furnace control (I.F.C.).

FUSE (F1)

A three-amp automotive-style (ATC blade type) fuse is supplied onboard the furnace control. This fuse should provide protection from short-circuits on the control board and associated 24 VAC wiring.

115 VAC TERMINALS

These terminals supply 115 VAC to the furnace control from the input at

the junction box of the furnace.

Additionally, spare terminals are provided for use with electronic air cleaners and other accessories as needed (Check the voltage rating of your equipment.)

INDUCED DRAFT MOTOR (INDUCER) OUTPUT (J2)

This four-pin Mate-n-Lok style connector is black in color and provides power to both the high and low speed inducer outputs. This connector on the IFC has female sockets so that it can not be confused with the four-pin connector used for motor control (which has male pins).

FIGURE 59

WIRING DIAGRAM – SPECIAL CONFIGURATION: COMMUNICATING THERMOSTAT AND FURNACE WITH NON-COMMUNICATING CONDENSER

NOTE: DEHUMIDIFICATION FUNCTION FROM A COMMUNICATING THERMOSTAT WILL NOT BE POSSIBLE WITH THIS CONFIGURATION.

ST-A1115-01, REV. 02

Page 57

For troubleshooting purposes, follow the wiring diagram and troubleshooting flowchart supplied in this manual and on the inside of the furnace blower door. Additionally, the pin designations for the connector are specified below:

in 1

to Inducer High Speed Output.

in 2

to Inducer Low Speed Output

in 3

is not used.

in 4

to Neutral.

NEUTRAL TERMINALS

These terminals connect 115VAC neutral to the furnace control from the input

at the junction box of the furnace.

Additionally, spare terminals are provided for use with electronic air cleaners, humidifiers and other accessories as needed (Check the voltage rating of your equipment.)

ELECTRONIC AIR CLEANER (E.A.C.) OUTPUT (J8)

This output is used to energize an elec-

tronic air cleaner. The output will provide 1.0 amp at 115 VAC. This output is

energized any time the blower motor is above 40% of maximum airflow capaci-

ty. Airflow below this value is not considered to be enough for a typical electronic air cleaner to perform properly.

For 1/2HP motors – Electronic air clean-

er is energized any time the blower is above 480 CFM (1200 CFM x 0.4)

For 1 HP motors - Electronic air cleaner

is energized any time the blower is above 800 CFM (2000 CFM x 0.4)

HUMIDIFIER OUTPUT (J8)

These outputs (two) are connected to the contacts of a control-mounted relay. In this sense, they are what are called “dry” contacts. That is, they provide no voltage, they are only used to close a circuit. The contacts can be used to close either a 24VAC or 115VAC circuit

either with a maximum of 1 amp

Details about the humidifier outputs and wiring diagrams can be found in the section titled

DEHUMIDIFICATION

HUMIDIFICATION AND

of this document.

current.

STEPPER GAS VALVE CONTROL (J16)

For furnaces equipped with a stepper modulating gas valve, a five-pin connector is used to control and sense the gas valve. The valve uses a PWM (Pulse Width Modulated) signal to control the firing rate. The duty cycle this signal is five percent less than the

expected firing rate. For example, if

the firing rate is 90%, the PWM to (and from) the valve will be 85% duty cycle. The connector also provides the

24VAC signal to energize the main

valve solenoid. Reference the wiring diagram for the furnace printed in this document or on the inside of the furnace blower door.

For troubleshooting purposes, follow the wiring flowchart supplied in this manual and on the inside of the furnace blower door. Additionally, the pin designations for the connector are specified below:

in 1

P connector Pin 1 (TH)

in 2

connector Pin 2 (RX) P

in 3

connector Pin 3 (TX) P

in 4

connector Pin 4 (COMMON) P

in 5

connector Pin 5 (MVTH)

diagram and troubleshooting

to stepper modulating gas valve

15-PIN MATE-N-LOK CONNECTOR (J1) (see Fig 58)

The 15-pin Mate-n-Lok style connector provides connections for a variety of inputs and outputs to the furnace control. For modulating furnaces with a solenoid-controlled modulating gas valve (HG or HH Fuel Codes) the 15pin connector provides power and control signals to the gas valve. Also, the flame

sense, pressure switches sense and limits sense (Main Limit, MRLC and HALC) are connected to the I.F.C. through this connector. Reference the wiring diagram for the furnace printed in this document or on the inside of the furnace blower door for pin assignments for troubleshooting.

For troubleshooting purposes, follow the wiring diagram and troubleshooting flowchart supplied in this manual and on the i blower door. Additionally, the pin designations for the connector are specified below:

in 1

in 2

in 3

in 4

in 5

in 6

in 7

in 8

in 9

in 10

in 11

in 12

in 13

in 14

in 15

nside of the furnace

to Flame Sense rod. to Overtemp Limit (MRLC)

Sense to Main Limit (LC) Sense to 24 VAC to Limit Sense

Circuits

24 VAC out to Auxiliary Limit

(HALC- Heat Assisted Limit Control)

Solenoid-controlled modulating gas valve main solenoid 24VAC (not used on furnaces with stepper (servo) modulating gas valve).

is not used on the production control.

to Low Pressure Switch sense.

to High Pressure Switch sense.

to Low and High Pressure Switch 24VAC

to Aux Input sense

to Ground on furnace cabinet

Solenoid-controlled modulating gas valve control circuit (not used on furnaces with stepper (servo) modulating gas valve).

Solenoid-controlled modulating gas valve main solenoid 24VAC common (not used on furnaces with stepper (servo) modulating gas valve).

Page 58

FIGURE 60

15-PIN CONNECTOR; J1 WITH PIN DESIGNATIONS

COMMUNICATING ECM MOTOR COMMUNICATIONS (CONTROL) CONNECTION (J10) (see Fig 58)

This connector sends and receives messages to and from the blower motor

through a single peer-to-peer network. The blower motor does not communicate on the same communications buss as the furnace, condenser and thermostat. Further, a different communications protocol is used.

For troubleshooting purposes, follow the wiring

flowchart supplied in this manual and on the inside of the furnace blower door. Additionally, the pin designations for the connector are specified below:

diagram and troubleshooting

in 1

to communicating blower

motor connector Pin 1 (+V)

in 2

to communicating blower

motor connector Pin 2 (TX)

in 3

to communicating blower

motor connector Pin 3 (RX)

in 4

to communicating blower

motor connector Pin 4 (C)

Page 59

FIGURE 61

FOUR-PIN MOTOR CONTROL CONNECTION; J10 WITH PIN ASSIGNMENTS.

WARNING: Do not route the orange igniter wire within 2ⴖ of the gas valve. Noise from the wire could cause failed ignition and loss of heat.

SPARK IGNITION TRANSFORMER (XFORMER) (T1)

The spark ignition transformer resides on the furnace control (older generations of the modulating furnace have the spark transformer mounted to a separate ignition control). The transformer

provides spark energy at approximately 60 hz frequency and a minimum of

12KV. The transformer can be seen in Figure 61.

WARNING

DO NOT ROUTE THE ORANGE IGNITER WIRE WITHIN 2ⴖ OF VALVE. DOING SO COULD CAUSE FAILED IGNITIONS AND LOSS OF HEAT.

THE GAS

R-J11 CONNECTOR (J-11)

WARNING

DO NOT CONNECT A TELEPHONE OR PHONE LINE TO THE CONNECTOR (JACK) AT POSITION J-11. DOING SO COULD CAUSE

IRREPRABLE DAMAGE TO EITHER THE FURNACE CONTROL (I.F.C.) OR THE TELEPHONE (OR TELEPHONE LINE) OR BOTH.

This connector is used to program the furnace control at the factory. It can also be used to connect a field ser

iagnostic tool. Unfortunately, this tool

d was not available at the time of this publication but should be available in the future. Otherwise, this connection is not to be used in the field. It should never be connected to a telephone line or a telephone. Doing so could damage the furnace control or the telephone (or telephone lines) or both.

vice

COMMUNICATIONS NETWORK CONNECTION

These connections are used when installing a communicating thermostat specified for use with this furnace. Further, normally, thermostat connections will not be made at the 24 V Thermostat Inputs when using a com-

municating thermostat. (Except under

one special circumstance where a communicating thermostat and noncommunicating condenser are used. See Figure 59 and the section of this document titled SPECIAL CON-

FIGURATION – THERMOSTAT AND FURNACE WITH A NON-COMMUNICATING CONDENSER.)

The terminal labeled “1” on the furnace control connects directly to the terminal labeled “1” on the thermostat and “1” on the condenser. The remaining connections follow the same pattern.

Follow the wiring diagram in Figure 59 for connections of the communications network.

COMMUNICATING

COMMUNICATIONS L.E.D.’s (Light Emitting Diodes)

Note: The “RX” and “STAT” L.E.D.’s will not operate unless a communicating thermostat is

Page 60

installed. These L.E.D.’s will not ener-

gize if a traditional 24V thermostat

only is used to control the furnace.

“RX” (Green) L.E.D. – This L.E.D. indi-

cates that communications is being

sensed to or from (i.e.:

the network is trying to communicate)

other components (e.g. a condenser) on

the network. This L.E.D. will blink randomly any time a message is received by the furnace control. If no blinking is seen within five minutes, it can be assumed that there is not valid communications established. Check wiring to make sure that a

properly.

Further, if this L.E.D. is on continuously,

it is an indication that mis-wiring has occurred. Most probably, connections “1” and “2” are reversed. Double-check the wiring and make sure that the wire connected to pin “1” on the condenser is the same wire connected to pin “1” on the thermostat and the furnace control. The same follows for the wires to pins “2”, “R” and “C”.

“STAT”

L.E.D. blinks twice slowly (¼ second

ON, ¾ second OFF) upon power-up.

(STATUS) (Red) L.E.D.–This

something

ll points are connected

LEARN BUTTON

Pressing the learn button for two sec-

onds will cause the green “RX” L.E.D. to blink rapidly (for a short period) to indicate an attempt at communications. If the L.E.D. does not blink, communications can not be established. The problem may be that the wires at the J9 connector “1” and “2” on the I.F.C. may be re

versed. Check to make sure that

wiring is from “1” on the IFC leads to “1” on the thermostat and condenser (if present) and the same follows for connections “2”, “R” and “C”.

MEMORY CARD CONNEC-

TOR (J15)

This connector is used to insert a mem-

ory card.

MEMORY CARD

A memory card is defined as an electronic card that carries a copy of the furnace shared data.

RULES FOR WRITING, DISTRIBUTION AND ARBITRATION OF MULTIPLE

COPIES OF FURNACE SHARED DATA

FOR COMMUNICATING-CAPABLE

FURNACES

Furnace shared data data specific to a given furnace that is critical for proper furnace operation. More specifically, it is data which defines the operation of the furnace and is unique to a given furnace platform and model. The most critical of these data are the coefficients that control the blower operation (i.e. define the blower speedtorque operation). Because of this, each furnace control is pr with furnace shared data for that model furnace only. The furnace shared data from any given furnace can NOT be transferred to another furnace for any reason. Doing so can adversely affect operation of the furnace. Further, if no furnace shared data is present, the furnace will not operate in any mode and a fault will be displayed.

Valid Furnace Shared Data as furnace shared data for the furnace series in question with the correct motor horsepower. However, it is impossible for the furnace control to determine if the furnace shared data is matched to the furnace input BTU’s if the motor horsepower is cor-

rect. This means, for example, fur-

nace shared data for a 120KBTU upflow furnace could be installed and

recognized as valid furnace shared

ta in a 90KBTU downflow furnace. VALID FURNACE SHARED DATA simply means that there is no motor horsepower conflict and that the furnace shared data is for the series of furnace in question. VALID FURNACE SHARED DATA is data that will be used by the furnace control with no fault reported. VALID FURNACE SHARED DATA may not necessarily mean that the furnace shared data is correct for the furnace in ques

tion. The input BTU’s could

still be incorrect and this is why it is

important to never exchange memory

cards from one furnace to another. Furnace shared data is programmed

into the furnace control microprocessor and attached memory card at the factory. The attached memory card cannot be programmed in the field but furnace shared data inside the furnace IFC microprocessor may be written or rewritten in the field through the network depending on the circumstances.

is defined as

ogrammed

is defined

WARNING

DO NOT REPLACE THE FURNACE CONTROL OR MEMORY CARD OF THE FURNACE WITH A FURNACE CONTROL OR MEMORY CARD OF ANOTHER FURNACE OR ANOTHER COMPONENT (E.G.: A MEMORY CARD FROM A CONDENSER OR AIR HANDLER). THE WRONG FURNACE CONTROL OR MEMORY CARD MAY SPECIFY PARAMETERS WHICH WILL MAKE THE FURNACE RUN AT UNDESIRED CONDITIONS INCLUDING (BUT NOT NECESSARILY LIMITED TO) REDUCED AIRFLOW DURING HEATING CAUSING EXCE UNDESIRED OPERATION OF THE MAIN LIMIT CONTROL. FURTHER, THE MEMORY CARD IS SPECIFIC TO THE MODEL NUMBER AND BTU INPUT RATING FOR A SPECIFIC FURNACE AND THIS INFORMATION SHOULD NOT BE TRANSPORTED FROM ONE FURNACE (OR COMPONENT) TO ANOTHER.

The memory card is the default memory location to be used first when there is any conflict. If the

memory card has been replaced with a card that has data for another furnace, the furnace will assume the identity of the “other” furnace. In all cases, the memory card has the final say about the data to use. It is only when the memory card is not present, is corrupt or specifies a motor larger or smaller than what is found in the furnace that the furnace control will use the data stored in the micro most recent memory card with blow-

er size matching that found in the

furnace). The hierarchy of data to be used in the event of a lost card or conflict is listed in order of importance below.

1. An

processor (a mirror of the

ATTACHED

physically connected to the furnace control and almost appears to be part of the furnace control itself. A photo is shown in Figure 62 below and is this is how the furnace control with memory card is shipped from the factory.

memory card is

SSIVE

Page 61

FIGURE 62

AN ATTACHED MEMORY CARD

INSERTED

2. An

memory card is one that has been inserted into connector J15 of the furnace control and is shown in the photo in Figure 63 below. A memory card will not be inserted in this connector from the factory and the connector is designed only to be used to install a memory card to a replacement furnace control in the field.

Replacement IFC’s (furnace controls) from ProStock do NOT contain any furnace shared data and

FIGURE 63

INSERTED

AN FURNACE CONTROL BELOW. REPLACEMENT FURNACE CONTROLS FROM PROSTOCK WILL INCLUDE THIS ATTACHED CARD (BELOW) EXCEPT WITHOUT THE ELECTRONIC COMPONENTS WHICH ARE SHOWN HERE SURFACE-MOUNTED TO THE CARD.

MEMORY CARD. NOTE THAT A BLANK CARD IS STILL SEEN ATTACHED TO THE

, as such,

will not operate the furnace until furnace shared data is loaded in the field either via the original memory card or via redundant copies stored on various components in a communicating network (the latter applies only to installations configured as communicating systems and NOT to so-called legacy (24VAC) controlled systems).

When the furnace control is replaced, the original memory card must be broken a

way from the origi-

nal furnace control (IFC) and retained with the furnace. When the new IFC is installed, the original memory card will be inserted into connector J15 of the IFC to impart the critical furnace shared data to the replacement control. Note that in this circumstance there will be essentially two furnace shared data cards; one attached to the furnace control and one inserted into connector J15. Howe

ver, the attached card has no furnace shared data as replacement controls ordered from ProStock will not contain any furnace shared data on the memory card or in the microprocessor and memory cards cannot be written (or rewritten) in the field.

no memory card present

1. If a. Furnace shared data from the

“network” is used. Furnace network shared data is defined as a redundant copy (or copies) of the critical furnace shared data stored at various places and components on the communicating network.

The “network” can be defined as follows:

I. The “network” can be the

furnace control itself if it was programmed at the factory and the memory card has been removed for some reason.

II. The “network” can be a fur-

nace control which has had a valid card previously (either attached or inserted) and removed for some reason.

III. The “network” can be a fur-

nace control attached to a communicating condenser and/or thermostat which has copies of the furnace shared data that can be retrieved by the furnace control.

IV. A furnace control sent as a

replacement part will have no furnace shared data either in the microprocessor or on the memory card. The replacement control does not i

nclude a valid memory card. The furnace shared data can be added by:

1. Inserting a valid memory

card (e.g. the original memory card sent with the original furnace con-

, –

Page 62

trol or a valid replacement memory card ordered from ProStock.

2. by attaching the furnace control to a communicating network (e.g. a condenser and thermostat) which was previously connected to (and operating with nace control with valid furnace shared data.

Regardless, the memory card of a replacement control cannot be programmed or reprogrammed in the field with furnace shared data and will always remain blank. In fact, this card does not even contain the electronic components necessary to turn it into a valid memory card.

V. Replacement memory cards

with the appropriate furnace shared data fo model can be ordered from Pro-Stock. In the event that the original memory card is lost, the original furnace control has been replaced and there is no furnace shared data on the network (or the furnace is not part of a communicating network (i.e.: is not connected to a communicating condenser and thermostat)), the replacement memory card must be ordered and installed into the connector at J1

5 to give the furnace valid furnace shared data. The furnace will not operate properly without the correct furnace shared data. When no furnace shared data is present (either at the memory card or on the network) a “d1” (NO SHARED DATA) fault code will be displayed at both the thermostat active fault screen and at the furnace control (I.F.C.) sevensegment displays. Also, the homeowner will be alerte the communicating thermostat with either a CHECK SYSTEM or CHECK FURNACE error message displayed on the main screen.

If the original memory card is lost, it should be replaced even if there is valid furnace shared data on the network. The valid furnace shared data on the network should only be considered as a backup to the memory card.

) a valid fur-

r any given

d via

b. If valid furnace shared data is

available from the network and no memory card is present, a “d4” (MEM CARD INVALID) fault is displayed at the communicating thermostat active fault screen and at the furnace seven-segment displays when in standby mode only (see fault code priority list). The homeowner is not alerted (level 1 fault).

c. If no furnace shared data is pre-

sent on the network and a memory card

is either not present or the shared data on the memory card is not valid, a “d1” (NO SHARED DATA) fault is displayed at both the communicating thermostat active fault screen and at the furnace seven-segment displays provided a higher priority fault code is not also present (in which case the higher priority fault is displayed) (see fault code priority list). The homeowner is alerted via the communicating (level 2 fault).

d. If furnace shared data from the

memory card is not valid or is not present and shared data from network can be used, the appropriate fault (d4, d5, d6, d7 or d8 – see fault codes in this manual) is displayed at the communicating thermostat active fault screen and at the furnace seven-segment displays during standby mode only. The homeowner is not alerted (level 1 fault).

one memory card present

2. If (attached to IFC orinserted in J15 of the IFC), furnace shared data from the memory card (if valid) will be used to write (or re-write) the network furnace shared data and furnace shared data from card will be used. If the data on that card is not valid,:

a. If furnace shared data on the

memory card

I. is corrupt or invalid (“d4” –

MEM CARD INVALID”),

and/or

II. is for another component or

different furnace series (“d5” – CARD-HARD

and/or

III. does not match the horsepow-

er of the attached motor (“d6”BLWR HP CNFLCT),

and/or

IV. does not support the motor

manufacturer of the motor present (“d7” - BLWR MFG CNFLCT),

thermostat

CNFLCT),

and/or

V. is from an older furnace

and is missing critical newer furnac (“d8” - OLD SHARED DATA),

furnace shared data from the network (if valid) is used to control the furnace (see description of “network” under “If

present

Furnace shared data on the network will not be written or re-written from the memory card. If the furnace shared data on the network is valid, the appropriate fault for the memory card will be displayed at the active fault screen of the communicating thermostat and at the furnace sevensegment displays when in standby mode only (see fault code priority list). The homeowner will not be alert

ed (level 1 fault).

b. If neither the furnace shared

data on the memory card is valid nor the furnace shared data on the network is valid, the fault code status is elevated. The homeowner is alerted via the communicating thermostat (level 2 fault) and the fault code

DATA) is displayed at the communicating thermostat active fault screen and at the furnace seven-segment displays provided a

higher priority fault is not also present (in which case the higher priority fault is displayed) (see fault code priority list).

c. If no furnace shared data is

available on either the memory card or the network, the fault code “d1” (NO SHARED DATA) is displayed at the communicating thermostat active fault screen and at the furnace seven-segment displays provided a higher priority fault is not also prese case the higher priority fault is displayed) (see fault code priority list). The homeowner is alerted via the communicating thermostat (level 2 fault). Furnace shared data on the network will not be written or re-written from the memory card.

e shared data

no memory card

”

(item 1 above)).

(NO VALID SHARED

nt (in which

Page 63

two memory cards present

3. If (attached to IFC of IFC), the memory card inserted into J15 “wins” and its furnace shared data is used and written to the network (if valid) unless:

a. If no furnace shared data is pre-

sent on the memory card inserted in J15, the furnace shared data from the attached memory card is used and the rules for

ry card present

above) are used. A fault code is not displayed anywhere unless warranted for the attached memory card per the rules outlined for

and

inserted in J15

(outlined in 2

one memo-

one memory card present

Furnace shared data is not written to the network unless the furnace shared data on the attached memory card is valid.

b. If furnace shared data on the

memory card inserted in J15 is corrupt (“d4” – MEM CARD INVALID), the furnace shared data from the attached memory card is used and the rules for

ry card present

above) are used. A fault code is not displayed anywhere unless warranted for the attached memory card per the rules outlined for

one memo-

(outlined in 2

one memory card present

Furnace shared data is not written to the network unless the furnace shared data on the attached memory card is valid.

c. If furnace shared data on the

inserted memory card is a motor mismatch (“d6” - BLWR HP CNFLCT), the furnace shared data from the attached memory card is used and the rules for

ry card present

above) are used. A fault code is not displayed anywhere unless warranted for the attached memory card per the rules outlined for

one memo-

(outlined in 2

one memory card present

Furnace shared data is not written to the network unless the furnace shared data on the attached memory card is valid.

–

d. If furnace shared data on the

inserted memory card does not support the motor manufacturer of the motor present (“d7” - BLWR MFG CNFLCT), the furnace shared data from the attached memory card is used and the rules for

sent

used. A fault code is not displayed anywhere unless warranted for the attached memory card per the rules outlined for

memory card present

shared data is not written to the network unless the furnace shared data on the attached memory card is valid.

e. If furnace shared data on the

inserted memory card is from an older furnace and is missing critical newer furnace shared data (“d8” – OLD SHARED DATA), the furnace shared data from the attached memory card is used and the rules for

card present

above) are used. A fault code is not displayed anywhere unless warranted for the attached memory card per the rules outlined for

one memory card present

Furnace shared data is not written to the network unless the furnace shared data on the attached memory card is valid.

4. Furnace shared data is never written to any memory card (attached or inserted) in the field. There is no way to write to a memory card in the field. If a new memory card is needed, it must be ordered from ProStock parts replacements.

one memory card pre-

(outlined in 2 above) are

one

. Furnace

one memory

(outlined in 2

REPLACING THE FURNACE CONTROL

In the event that the furnace control must be replaced, the memory card must be broken away (detached) from the original furnace control and retained with the furnace. A plastic tether with a note wrapped around the tether is used to remind the technician no from the furnace. The card can be broken away easily by putting pressure on the control board at dipswitch bank SW-3 with the left hand and pulling forward on the upper right-hand corner of the card with the furnace control still in place on the control board mounting plate (see Figure 64). The card will break free from the furnace control. Use this card to insert into the memory card connector labeled J15 of the replacement control board. Failure to save and connect the memory card properly to the replacement control may result in no operation or undesired operation of the furnace.

When replacing the furnace control, be sure to match the dipswitch settings of the original control on the replacement.

DO NOT CUT THE PLASTIC WIRE TIE USED AS A TETHER TO THE ATTACHED, BREAK-AWAY MEMORY CARD. DOING SO WILL DEFEAT THE PURPOSE OF RETAINING THE MEMORY CARD – WHICH COULD LEAD TO A LOSS OF CRITICAL DATA NECESSARY TO OPERATE THE FUR NACE. THE CARD MUST STAY WITH THE FURNACE – EVEN WHEN THE FURNACE CONTROL (IFC) MUST BE REPLACED.

NEVER USE A CONTROL BOARD TAKEN FROM ANOTHER FURNACE AS A REPLACEMENT CON TROL FOR THIS FURNACE. FURNACE CONTROLS TAKEN FROM OTHER FURNACES MAY CONTAMINATE THE NETWORK WITH THE WRONG SHARED DATA WHICH CAN ONLY BE FIXED BY REPLACING THE MEMORY CARD WITH THE ORIGINAL MEMORY CARD FROM YOUR FURNACE OR A REPLACEMENT MEMORY CARD DESIGNED FOR YOUR FURNACE.

t to remove the card

Page 64

FIGURE 64

REMOVE THE MEMORY CARD WHEN REPLACING THE FURNACE CONTROL. THIS PHOTO SHOWS THE CORRECT WAY TO REMOVE THE MEMORY CARD. DO NOT CUT THE TETHER.

For communicatinig systems as a final

confirmation of the correct shared data the model number should be verified by checking the furnace user menu under the sub menu titled “Unit Info.” Make sure that the model number displayed in the menu matches the model number on the rating label. (NOTE: Wild cards

will be shown in parenthesis. Example:

RGFLE/F)-06(E/N)MCKS.)

Page 65

FIGURE 65

ON A REPLACEMENT FURNACE CONTROL THE ORIGINAL MEMORY CARD FROM THE ORIGINAL FURNACE CONTROL SHOULD BE INSERTED INTO CONNECTOR J11 OF THE REPLACEMENT CONTROL. DOING THIS WILL GIVE THE REPLACEMENT CONTROL ITS IDENTITY. NOTE THAT THERE WILL BE TWO MEMORY CARDS – THE ORIGINAL (INSERTED INTO J11) AND THE REPLACEMENT (STILL ATTACHED TO THE REPLACEMENT FURNACE CONTROL).

Page 66

DIPSWITCHES

NOTE:

does not recognize switch setting

changes while energized.

SW1

SW1-1 AND SW1-2 – COOLING AIR-

FLOW SELECT – These dipswitches

are used to select the appropriate cool-

ing airflow based on the amount

required. The switch settings do not

affect cooling airflow when installed with

a fully communicating condenser. In

that case, the condenser supplies the

information for cooling ai

preset at the factory and not adjustable.

The integrated furnace control

rflow which is

FIGURE 66

DIPSWITCH BANK SW1

For non-communicating systems or communicating systems with a noncommunicating condenser (see section titled SPECIAL CONFIGURATION –

COMMUNICATING THERMOSTAT AND FURNACE WITH A NON-COMMUNICATING CONDENSER of this

document), the target cooling airflow

will be determined by the adjustments

of SW1-1 and SW1-2. Furnaces with

½ HP motors will have a maximum tar-

get airflow setting of 1200 CFM. Furnace with 1

HP motors will have a

maximum target airflow setting of 2000

CFM. The airflow achieved may be less than the target if the static pressure across the furnace is over 0.6” wc. Consult the cooling equipment instructions and documents for target airflow

and adjust accordingly.

Cooling airflow for non-communicat-

ing systems can be adjusted approximately +/- 10% by using the cool trim adjustment dipswitches;

SW1-5 and SW1-6. See Figure 66. Cooling airflow for non-communicat-

ing systems is also affected by the settings of dipswitch position SW2-6. This switch will determine the appropriate amount of airflow to be used for t

he low stage (1

stage) of cooling. See the tables in Figure 67. More information can be found in the section titled SW2 (SW2-6).

Consult the tables in Figures 66, 67 and 68 for target airflow settings and

adjustments based on the positions

of the dipswitches SW1-1, SW1-2, SW1-5, SW1-6 and SW2-6.

Page 67

FIGURE 67

COOLING AIRFLOW SELECTIONS FOR NON-COMMUNICATING CONDENSERS

MODULATING FURNACE COOLING AIRFLOW RATES, 1/2 HP (1200 CFM Max) motor settings

(applies only to systems configured with non-communicating condenser).

SW2, Pos. 6

OFF OFF OFF 1200 CFM 900 CFM 1200 CFM 3 Ton A/C OFF OFF ON 1000 CFM 750 CFM 1000 CFM 2.5 Ton OFF ON OFF 800 CFM 600 CFM 800 CFM 2 Ton A/C

OFF ON ON 600 CFM 450 CFM 600 CFM

SW1, Pos. 2 SW1, Pos. 1

ON OFF OFF 1200 CFM 600 CFM 1200 CFM 3 Ton A/C ON OFF ON 1000 CFM 500 CFM 1000 CFM 2.5 Ton ON ON OFF 800 CFM 400 CFM 800 CFM 2 Ton A/C

ON ON ON 600 CFM 300 CFM 600 CFM

YH Single

stage

MODULATING FURNACE COOLING AIRFLOW RATES, 1 HP (2000 CFM Max) motor settings

(applies only to systems configured with non-communicating condenser).

SW2, Pos. 6

OFF OFF OFF OFF OFF ON OFF ON OFF OFF ON ON

SW1, Pos. 2 SW1, Pos. 1

ON OFF OFF ON OFF ON ON ON OFF ON ON ON

YH Single

stage

2000 CFM 1000 CFM 2000 CFM 5 Ton A/C 1600 CFM 800 CFM 1600 CFM 4 Ton A/C

1400 CFM 700 CFM 1400 CFM 3.5 Ton 1200 CFM 600 CFM 1200 CFM 3 Ton 2000 CFM 1400 CFM 1800 CFM 5 Ton A/C 1600 CFM 1200 CFM 1600 CFM 4 Ton A/C 1275 CFM 1050 CFM 1400 CFM 1200 CFM 900 CFM 1200 CFM 3 Ton

SW1-3 HEAT RISE ADJUST – This dipswitch is used to select desired temperature rise in the heating mode. The heat rise wi

ll always be closer to the target if the supply air sensor is properly installed (see sub-section in this section titled “SA SENSOR” below).

“OFF” will yield the maximum heat rise.

(Target heat rise is 65°F but this value may vary slightly between low and high fire. Temp. rise will always be closer to the target if the “SA SENSOR” is properly installed.)

“ON” will increase the airflow to yield the minimum heat rise. (Target heat rise is 55°F but this value may vary slightly between low and high fire. Temp. rise will always be closer to the target if the “SA SENSOR” is properly installed.)

YL Low 2

stage

YL+YH High 2

stage

YL+YH High 2

stage

3.5 Ton

Notes

Low Heat Airflow = approx. 50% of

High-Stage Cooling (Could be

used with condensers with two

compressors.)

HIGH SEER (16+) Premium

Cooling airflow (SW1, Position 6 is

Low Heat Airflow = approx. 50% of

High-Stage Cooling (Could be used with condensers with two

Cooling airflow (SW1, Position 6 is

ON)

Notes

compressors.)

HIGH SEER (16+) Premium

ON)

SW1-4 FAN SPEED SELECT – This dipswitch is used to select the continuous fan speed when the furnace is configured with a non-communicating thermostat.

“OFF”

½ HP MOTORS = Approx. 600 CFM

1 HP MOTORS = Approx. 1000 CFM

“ON”

½ HP MOTORS = Approx. 1200 CFM

1 HP MOTORS = Approx. 2000 CFM

SW1-5 AND SW1-6 – COOLING AND HEAT-PUMP AIRFLOW ADJUSTMENT – These dipswitches

are used to adjust the cooling and

heat-pump airflow for non-communicating systems slightly based on the user’s preference.

SW1-5 = “OFF”, SW1-6

= “OFF” –

No adjustment.

SW1-5 = “ON”, SW1-6 = “OFF” –

+10% adjustment.

SW1-5 = “OFF”, SW1-6 = “ON” – -

10% adjustment.

SW1-5 = “OFF”, SW1-6 = “OFF” –

No adjustment.

Page 68

FIGURE 68

of full rate (minimum fire and 2-stage operation). This is accomplished by setting the Test Switches as indicated in Table XX below.

Table XX - SW2-2 and SW2-3 MODE SELECTION SETTINGS

Mode

Switch SW2-2

Position

Switch SW2-3

Position

Modulating/ Single-

Stage

OFF OFF

Test 40%

ON OFF

Test 100%

OFF ON

Two-Stage

ON ON

DIPSWITCH BANK SW2 TEST MODE SELECT

Switch (SW2-1) Call Voltage at “ HUM” Action ON COOL 24 Normal Cool (c or C)

ON COOL 0 Dehum Cool (cd or Cd) ON Heat 24 Hum Contacts Closed. ON Heat 0 Hum Contacts Open. OFF COOL 24 Normal Cool (c or C) OFF COOL 0 Normal Cool (c or C) OFF Heat 24 Hum Contacts Closed. OFF Heat 0 Hum Contacts Open.

SW2

SW2-1 = ODD “ON” or “OFF” select.

This switch will ignore the input from the 24 volt terminal labeled “HUM STAT” during cooling when in the “OFF” posi-

tion. However, the “HUM STAT” input is

always read in the heating mode to turn on and off the humidifier relay.

When in the “ON” position, the dehumid-

ification feature will become active and it will be necessary to install a humidistat to the “HUM STAT” terminal as dis-

SW2-2 and SW2-3 FURNACE TEST and OPERATING

MODES

FURNACE TEST SWITCHES The Test Switches (SW2) will place the

IFC into a test mode, operating the furnace at continuous input rates of either

100% of full rate (maximum fire) or

40% of full rate (minimum fire). This is accomplished by setting the Test Switches as indicated in Table 15 below.

cussed and shown in wiring diagrams in the section of this manual titled “

HUMIDIFICATION AND DEHUMIDIFI-

CATION

install a humidistat to the “HUM STAT”

” of this document. Failure to

TABLE 15

SW2-2 AND SW2-3 MODE SELECTION SETTINGS

terminal with dipswitch SW2-1 in the

“ON” position will cause the cooling speed airflow to be reduced to the dehumidification speed..

To enter the Furnace Test Mode, proceed as follows:

1 Switch the 115 volt power to the

furnace OFF.

Do not change

settings with control energized. 2 Remove furnace blower door. 3 Position Test Switches SW2-2

and SW2-3 for the desired test

mode. 4 Replace furnace blower door.

5. Switch the 115 volt power to the

furnace ON.

6. Set the thermostat mode to

HEAT, adjust the setpoint at least

4°F above room temperature to

demand a call for heating. When the furnace is powered with

the test switches in a position other than modulating/single-stage or in 2stage mode,

the first call for heat

within the first hour after power-up

Note: The “Test 40%” and “Test 100%” settings will time out and become invalid one hour after power reset.

Page 69

will instruct the furnace to perform as follows:

1 Normal ignition sequence 2 A calibration cycle will be perform

unless the Test Switches are set for Test 40%. The LED status indicator will flash “H” or “h” during the calibration cycle.

NOTE: The supply air sensor (field

installed) is required for the furnace calibration cycle. If the air sensor is faulty, or not properly connected, the furnace will not attempt a calibration cycle and will operate on factory default parameters pre-programmed into the micropro

cessor.

After calibration, the furnace will then

adjust to the desired Test capacity. This

allows time for the technician to check

steady-state operation and evaluate fur-

nace performance.

The furnace will operate at the fixed

Test capacity until one of the following conditions:

A. The thermostat is satisfied and the

call for heat is removed.

B. The furnace has been in test mode

continuously for sixty minute

which time the furnace control (IFC)

will exit the test mode and proceed to

normal heating operation as configured. Test mode can not be activated again unless line voltage power to the furnace is cycled off and back on. This is true even if the dipswitches remain configured to the test settings.

o set the furnace for normal oper-

ation:

1 Set the thermostat mode to OFF.

Always allow furnace to complete the cool down cycle.

2 Switch the 115 volt power to the fur-

nace OFF.

with control energized. 3 Remove furnace blower door. 4 Position dipswitches SW2-2 and

SW2-3 for modulating/single-stage

mode or 2-stage mode. 5 Replace furnace blower door.

6. Switch the 115 volt power to the fur-

nace ON.

7. Set the thermostat as desired.

o not change settings

s, at

FURNACE OPERATION USING NON-COMMUNICATING MODULATING, SINGLE-STAGE, AND TWO-

STAGE THERMOSTATS (CONSULT THE SECTION OF THIS DOCUMENT TITLED NON-COMMUNICATING THERMOSTATS FOR WIRING DIAGRAMS)

The modulating furnace is capable of

operating with a single-stage or a two-

stage thermostat as well as the modu-

lating thermostat or fully communicating

thermostat specified for use with the

furnace. Fully communica

stat functions and operations are

explained in detail in the sections of

this manual titled COMMUNICATING

SYSTEMS and THERMOSTATS (under

the sub-section titled COMMUNICAT-

ING THERMOSTATS).

Based on the dipswitch settings of

SW2-2 and SW2-3, the furnace will

operate with either single-stage or two-

stage thermostats as a modulating sys-

tem using an algorithm that utilizes

three distinct firing ra

and 100% of the furnace heating

capacity (See below for operation of

each). See Figure 68 to determine

which dipswitch settings are necessary

for operation with a modulating, single-

stage or two-stage thermostat.

See the section of this document titled

THERMOSTATS (under the sub-sec-

tion titled NON-COMMUNICATING

THERMOSTATS) for information on

how to wire the thermostats for each of

the configu

In non-communicating systems, the

heating cycle is always initiated by a 24

volt signal on W1. When the controller

senses 24 volts on W1, the following

sequence occurs:

MODULATING FUNCTION:

(Modulating function with a non-com-

municating thermostat only applies

when both switches

are in the “ OFF” position

communicating modulating thermostat

(specified for use with the furnace) is

installed as shown in Figure 88.)

After the warm-up period, the furnace

will respond to the thermostat demand

by adjusting the gas valve pressure

and blower speed between 40% and

100% of maximum heating capacity.

rations below.

ting thermo-

tes; 40%, 65%

W2-2 and SW2-3

and a non-

TWO-STAGE FUNCTION:

(Two-stage function only applies when both switches SW2-3 are in the “ ON” position and a two-stage thermostat is installed as shown in Figure 90.)

After the blower on-delay period, the furnace will respond to the thermo-

stat demand by adjusting the gas

valve pressure and blower heating speeds to the “W” signal values. “W1” only = 40% gas valve pressure and blower heating speed. “W2” = 65% gas valve pressure and blower heating speed for the first five minutes and 100% thereafter. Also, i the call for heat ends, the furnace terminates at the present rate.

SINGLE-STAGE FUNCTION (“W” signal only) :

(Single-stage function only applies when both switches SW2-3 are in the “ OFF” position and a single-stage thermostat is installed as shown in Figure 89.)

After the blower on-delay period, the furnace will respond to the thermostat demand by altering the gas valve pressure and blower speed as follows:

hase 1: furnace capacity (gas valve output and blower speed)

hase 2:

P furnace capacity (gas valve output and blower speed)

hase 3:

P of furnace capacity (gas valve output and blower speed)

OTE:

N ing any phase, the furnace will terminate immediately at the firing rate of that phase.

W2-4

S leave dip switch SW2-4 in the “OFF” position. This will enable the furnace operation with most two-stage, noncommunicating cooling equipment. Actual SEER values will vary and depend on the equipment combination. Consult the specifications sheets and installation instructions of the cooling equipment purchased for a listing of the SEER ratings for a specific combination.

0 to 5 minutes = 40% of

5 to 12 minutes = 65% of

After 12 minutes = 100%

If the call for heat ends dur-

- For most cooling operation,

W2-2 and

Page 70

FIGURE 69

DIPSWITCH BANK SW3 HEAT AIRFLOW ADJUSTMENT

NOTE: TO CLEAR FAULT CODES IN THE FURNACE CONTROL, TURN SWITCH # SW3-3 ON, OFF, ON, OFF OR OFF, ON, OFF, ON WITHIN 30 SECONDS. THE RIGHT-MOST SEVEN-SEGMENT DISPLAY WILL FLASH THE UPPER

AND LOWER HORIZONTAL MEMBERS ONCE AS CONFIRMATION THAT THE FAULTS HAVE BEEN CLEARED. BE SURE TO RETURN THE DIPSWITCH (SW3-3) TO ITS ORIGINAL POSITION AFTER CLEARING THE FAULTS.

Placing SW2-4 in the “ON” position will establish the low (Y1) cooling airflow at

½ of the max cool (Y2) airflow. This set-

ting will be useful with cooling systems where two compressors are used to control two cooling stag

es (one compressor for first stage and two compressors for second stage).

SW3

Dipswitch bank SW3 is used to fine-tune the airflow in the heating mode. The switches of bank SW3 can be set to

adjust either the minimum heat rate airflow or the maximum heat rate airflow or

both. Also, every firing rate in between

these points will be adjusted according-

ly.

SW3 will allow for airflow adjustments at

high altitude, improper temperature probe locations, or no temperature probe applications. If the temperature

rise range needs adjustment, the techni-

cian must use separate temperature probes to determine the rise range and

adjust the airflow using SW3’s dip

switches until the rise range is as close as possible to the target temperature

rise (65°F or 55°F – adjusted at dip-

switch SW1-3).

Three examples of airflow adjustment

are shown below. NOTE: All dip switches on SW3 will be

shipped in the “OFF” position.

xample 1

E PROBLEM: Temperature rise is too

high at 40% firing rate although it is within the published range at 100% firing rate.

SOLUTION: More airflow is needed to lower the temperature rise at 40%.

1) Set dip switches 4 and 5 of SW3 to the “ON” position. This will produce a

7.5% increase in blower output.

2) Allow furnace to run for several minutes at 40% firing rate until temperature probes reach equilibrium.

) If the temperature rise is still above

3 the published range, set switch 6 of SW3 to the “ON” position. This will

increase the airflow rate from +7.5% to +15% above the standard value.

FIGURE 70

EXAMPLE 1

SW3

100%

OFF

123456

STD

7.5% STD

7.5%

40%

A. Set switches 4 & 5 to “ON” position

to increase airflow by 7.5% at the 40% fire rate.

ADJ

15% ADJ

15%

SW3

100%

OFF

123456

STD

7.5% STD

7.5%

40%

B. If +7.5% is not enough, increase air-

flow by setting switch 6 to “ON” posi-

tion to give +15%.

ADJ

15% ADJ

15%

Page 71

EXAMPLE 2 PROBLEM: Temperature rise is too low

at 100% firing rate although it is within the published range at 40% firing rate.

SOLUTION: Less airflow is needed to increase temperature rise at 100%.

1) Set dip switch 1 of SW3 to the “ON” position, which overrides standard airflow.

2) Leave switches 2 and 3 in the “OFF” position to decrease airflow by 7.5%.

3) Allow furnace to run for several minutes at 100% rate

until temperature

probes reach equilibrium. 4) If the temperature rise is still below the published range, set switch 3 to the “ON” position. This will decrease the airflow rate from

7.5% to -15% below the standard value.

EXAMPLE 3 PROBLEM: Temperature rise is too low

at 40% firing rate and is too high at 100%.

SOLUTION: Less airflow is needed to increase temperature rise at 40% firing rate and more is needed to decrease temperature rise at 100%.

1) Set dip switch 4 of SW3 to the “ON” position to override standard airflow at 40% firing rate. Leave switches 5 and 6 in “OFF” position to decrease airflow by

7.5%.

2) Allow furnace to run for several minutes at 40% rate until temperature probes reach equilibrium.

3) If temperature rise is still lower than the published range, set switch 6 to the “ON” position to decrease the airflow rate from -7.5% to -15% below the standard value.

4) Set dip switches 1 to the “ON” position to override standard airflow at 100% firing rate. Set switch 2 to the “ON” position to increase airflow by 7.5%.

5) Allow furnace to run for several minutes at 100% rate until temperature probes reach equilibrium.

6) If temperature rise is still higher than the published range, set switch 3 to “ON” position to increase the airflow rate from 7.5% to 15% above the standard value.

FIGURE 71

EXAMPLE 2

SW3

100%

OFF

123456

STD

7.5% STD

7.5%

40%

A. Set switch #1 to “ON” position and

leave #2 and #3 in the “OFF” position to decrease airflow by 7.5% at the 100% fire rate.

ADJ

15%

ADJ

15%

SW3

100%

OFF

123456

STD

7.5% STD

7.5%

40%

B. If -7.5% is not enough, decrease

airflow by setting switch 3 to “ON” position to give -15%.

ADJ

15%

ADJ

15%

FIGURE 72

EXAMPLE 3

SW3

100%

OFF

123456

STD

7.5% STD

7.5% 40%

A. Set switch #4 to “ON” and leave #5 and

#6 set to “OFF” to decrease airflow by

7.5% at the 40% fire rate. If necessary, set switch #6 to “ON” to decrease airflow by 15%.

ADJ

15% ADJ

15%

SW3

100%

OFF

123456

STD

7.5%

STD

7.5% 40%

B. Set switches #1 and #2 to “ON” and

leave #3 set to “OFF” to increase airflow by 7.5% at the 100% fire rate. If necessary, set switch #3 to “ON” to increase airflow by 15%.

ADJ

15% ADJ

15%

Page 72

SW4

FIGURE 73

DIPSWITCH BANK SW4 TERMINATION AND BIAS SELECTIONS

BIAS / TERMINATION

These dipswitches will not be used for first generation controls. They are

designed to be used for future generations of ClimateTalk which may support multiple networks.

lations, all three of the dipswitches in

bank SW4 must be in the “ ON” posi-

tion. If not, the system may not be

able to communicate.

or current instal-

DUAL SEVEN-SEGMENT

DIAGNOSTIC DISPLAY

The dual seven-segment diagnostic dis-

play will either display the status of the

system (e.g. “H” for Heat) or a diagnos-

tic error code in the event of an active

fault. Fault and status codes and their

meanings can be determined from Table

16. For detailed information for each fault code refer to the TROUBLESHOOTING section of this manual. For communicating systems

code and a description can be found in the thermostat “Active Fault” display area. (See the section of this document titled “ACTIVE FAULT DISPLAY” under COMMUNICATING SYSTEMS for more information).

, the fault

The rightmost decimal on the display will blink one time for every 100 CFM of

expected airflow whenever the blower

is operating. If the value is actually less than 50 CFM above any increment of 100, the value will be rounded to the lesser 100 value and the lesser value

will be displayed. For example, if the

actual CFM is blink ten times. If the actual CFM value is 1051, the decimal will blink eleven times. For better resolution, a service tool or communicating thermostat is

required and the expected CFM can be

determined within a resolution of 10 CFM. (See the section of this manual titled “USER MENUS” under “STATUS 1” or “STATUS 2” submenu “BLOWER CFM”).

1049, the decimal will

FAULT CODE BUFFER

Upon power reset, the last five fault codes from the furnace will be displayed on the seven-segment display. These will be displayed in chronological order from newest (displayed first) to oldest (displayed last).

For communicating systems, the fault code buffer can also be read at the communicating thermostat inside the furnace User Menus. The most recent

six fault codes are stored. Also dis-

played is the number of days since eac

h fault code was recorded.

NOTE: The following fault codes will not be stored back-to-back in the fault buffer. These will only be stored in the buffer if the previous fault stored was a different fault. 82, 11, 45, 46 & 57.

CLEARING DIAGNOSTIC FAULT CODES FROM THE BUFFER

To clear the fault codes in the fault buffer, the dipswitch at position SW3-3 can be used. Turn the switch off, on, off, on or quickly within 30 seconds to reset the fault codes. When this is done, the right-most seven-segment dis-

play will energize the upper and lower horizontal segments for four

seconds as confirmation that the fault codes have been cleared from the buffer. Be sure to return the switch to the original position after clearing the faults.

Faults can also be cleared at the furnace User menu under the Hist selection. The seven-segment displays will again operate as described above.

on, off, on, off

Fault

Page 73

TABLE 16

LIST OF FAULT CODES AND NORMAL OPERATION CODES

(not displayed in communicating)

(displayed for both stages in communicating mode)

NOTE: To clear current fault codes in the furnace control buffer, turn dipswitch SW3-3 on, off, on, off,

or off, on, off, on within 30 seconds. The right-most seven-segment display will energize the upper and lower horizontal members for four seconds as confirmation that the faults have been cleared. Be

sure to return the dispswitch (SW3-3) to its original position after clearing the faults. NOTE: The following fault codes will not be stored back-to-back in the fault buffer. These will only be

stored in the buffer if the previous fault stored was a different fault. 82, 11, 45, 46 & 57.

COMMUNICATING SYSTEMS

The modulating furnace is capable of communicating with a thermostat and condenser to improve cooling and heat-pump airflow, displaying active faults and active furnace information at the thermostat and improved diagnostics and troubleshooting.

WIRING A FURNACE FOR COMMUNICATIONS.

Maximum wire lengths and notes

about wiring communicating systems are noted below.

MAXIMUM COMMUNICATING WIRE LENGTHS (1, 2, R & C)

Max Wire Length – Thermostat to

Furnace = 100 FT @ 18 AWG*

Max Wire Length – Furnace to

Condenser = 125 FT @ 18 AWG* Notes:

1. When using twisted pairs, be sure the wires connected to pins labeled “1” (recommended wire color = green) and “2” (recommended wire color = yellow) are a twisted pair.

2. Wires may be solid or stranded..

3. *Wire gage smaller than 18 AWG is not approved or recomm for this application.

4. When using existing wire from a

previous installation, be sure to trim the tip of the wire back past the insulation and strip a small amount of insulation from the

wire to expose clean new copper

for the communicating connections. Fresh copper must be

exposed when making the com-

municating connections or communications may not be properly established.

Figure 74 is the wiring diagram for connecting the furnace to an approved ClimateTalk communicating thermostat and approved Rheem or Ruud communicating condenser.

The only approved configuration is to install dedicated wires directly from the furnace to the thermostat and a separate set of dedicated wires directly from the furnace to the condenser. Note: The only approved configuration requires that four dedicated wires (1, 2, R be installed from the furnace to the condenser.

ended

and C)

Page 74

FIGURE 74

WIRING DIAGRAM – COMMUNICATING CONFIGURATION

ST-A-1114-01

STARTUP FOR SYSTEMS CONFIGURED WITH COMMUNICATIONS

WARNING

INSTALLATION OF LINE VOLTAGE AND GAS MUST BE PERFORMED ACCORDING TO INSTRUCTIONS WRITTEN IN THIS MANUAL. FAILURE TO DO SO COULD RESULT IN INJURY OR DEATH.

When the furnace is configured for communications, the components on the network (i.e. furnace, thermostat and condenser) must establish communications before engaging a heat (or other) thermostat demand. The procedure for establishing communications is automatic and is described below. Once communications is established, the start-up procedure will be the same as the general start-up instructions described in the section of this manual titled

START-UP PROCEDURES

Once the communicating wiring is properly installed and the furnace is connected to line voltage, the system can be turned on. The thermo-

stat will display the following text:

“SEARCHING”

is displayed several times for sever-

al seconds. Next, the text

“FURNACE FOUND”

and

“AIR CONDITIONER FOUND”

“HEAT PUMP FOUND”

(depending on which is installed in the system) will be displayed. The process can take

several minutes

(up to a maximum of 30) to com-

plete. If these messages are not displayed within 30 minutes after

energizing the system, communica-

tions can not be established. There are many reasons why communications may not be established – including improper settings of the “TERM” and “BIAS” switches (see BIAS / TERMINATION) and improper wiring (see WIRING A FURNACE FOR COMMUNICATIONS above).

The o

rder in which these messages

will be displayed will depend on

which components are energized

first. The order listed here assumes that the furnace and condenser are

energized at the same time. If not,

the order of display will be in the order that the components are turned on.

Page 75

When the system has found all neces-

sary components, the text area of the

communicating thermostat will go

blank. This is an indicator that the system is operating properly. Proceed by engaging a typical thermostat call to determine if operation is correct as described in

the section of this book titled START UP PROCEDURES” to test heating, cooling and fan operation and to make neces-

sary adjustments.

NOTE: When a communicating condenser is installed with the system, a capital “C” will be displayed at the fu

rnace seven-segment display for both low & high cooling stages.

CONTINUOUS FAN OPERATION IN

OMMUNICATING MODE

C Continuous fan operation will always

depend on the selection (Hi, Med, Low) made at the communicating thermostat

for the continuous fan speed (see installation instructions for the thermostat). However, during the first few operations of continuous fan, the blower speed will

be limited to a maximum of 600 CFM for

⁄2 HP motors (60KBTU and 75KBTU)

and 1000 CFM for 1 HP motors (90KBTU, 105KBTU and 120KBTU). This will continue until the high cooling call information is provided from the

condenser. Once the max cooling CFM

value has been transmitted by the condenser (condenser must reach high stage – in heat pump or cooling), the

continuous fan will then have a maximum CFM value equal to the max cool-

ing airflow from the condenser. The Hi, Med and Low selections for continuous

fan will be based on max CFM of

the condenser with Hi continuous fan speed equal to the high speed CFM of the

cooling/HP condenser. NOTE: When faults are cleared in the

furnace “SETUP” user menu, the continuous fan CFM will be restored to factory

default (Max = 600 CFM for 1/2 HP and

1200 CFM for 1 HP). These values will again be used to calculate continuous fan airflow until a cooling call has been established and a communicating conden

ser sends a fan demand to the fur-

nace control.

ACTIVE FAULT CODES WITH COMMUNICATING SYSTEMS

Two levels of fault codes exist: (1) Non-

critical and (2) Critical. In general a non-critical fault permits all (or nearly all) operations to proceed and a critical fault prevents all (or nearly all) opera-

tions from proceeding. Detailed expla-

nations are given for each fault code and how to diagnose and troubleshoot problems by fault code displayed in the “TROUBLSHOOTING” section of this manual.

Active faults of either level will be displayed at the thermostat in the “ACTIVE FAULT” area of the thermostat. To enter the furnace “ACTIVE FAULT” area using a communicating thermostat, see the installation and operation instructions for that thermostat.

FURNACE USER MENUS NOTICE:

ALL TEMPERATURE VALUES DISPLAYED IN USER MENUS ARE DISPLAYED IN DEGREES FAHRENHEIT AT ALL TIMES. THIS IS TRUE EVEN IF THE THERMOSTAT IS SELECTED TO CELCIUS (C.). USER MENUS CAN NOT DISPLAY TEMPERATURES IN CELCIUS.

Systems configured for communications will have some advantages over traditional control (24VAC thermostats) systems. One advantage is that a variety of information that can be useful for config

uring the furnace/ system and diagnostic/troubleshoot ing information can be displayed at the thermostat.

The bulk of this information can be found inside the user menus. The

procedure for entering (and exiting)

the user menus will vary depending on the thermostat or service tool that

is used. To enter, navigate or exit

the furnace “USER MENU”s using a communicating thermostat, see the installation and opera

tion instruc-

tions for that thermostat. Navigating the user menus is

straight-forward. The menu follows the logic tree shown in Figure 75 (a & b).

NOTE: There may be a delay of several seconds when accessing he user menus or sub-menus. This is normal.

Page 76

FIGURE 75a

MENU TREE

➤

NOTE: There may be a delay of several seconds when accessing user menus or submenus. This is normal.

➤

The thermostat menus give active infor-

mation for various parameters and permit some installation options to be selected.

Note: Supply Air (SA) and

(RA) temperature readings may not be

accurate in standby mode. These

should only be read and used when the

blower is running in heat, cool or other modes.

“STATUS 1” menu – This menu gives information about the status of certain furnace components and features.

Return Air

➤

1. MAIN LIMIT – Indicates the state of

the main limit – either opened or closed. The normal state is closed. An open limit can be an indicator of

excessive static pressure in the

ventilation duct.

2. MRLC INPUT

of the Manual Reset Limit Control (MRLC) – either opened or closed. The normal state is closed. These switches are sometimes referred to as “Roll-Out” controls or limits. When one or more of these limits has opened, a flame has rolled into

– Indicates the state

the vestibule. This event should rarely (if ever) happen but can

be an indicator that the exhaust

flue is blocked.

3. HALC INPUT

state of the Heat Assisted Limit Control (HALC) – either opened or closed. The normal state is closed. This limit switch is only

present on downflow/horizontal

models and can often be an indicator that the main blower

has stopped turning unexpect-

edly when opened.

– Indicates the

Page 77

FIGURE 75b

MENU TREE – CONTINUED

TOTAL DAYS PWRD

MOD HT HRS

MOD HT CYCLS

BLOWER HRS

BLOWER CYCLES

➤ ➤

➤

NOTE: There may be a delay of several seconds when accessing user menus or submenus. This is normal.

➤

➤ ➤

4. IDM OUTPUT

of the Induced Draft Motor (IDM) – OFF, HI or LO. The indication is the state at which the furnace con-

trol expects the motor to be. If the

indication is HI or LO and the motor is not turning, a number of problems could be the cause – including a non-functioning blower relay on the furnace control or a non functioning inducer.

5. FURN LO PR SW

state of the Low Pressure Control (LPC) (also known as low pressure switch) – either OPEN or CLOSED.

– Indicates the state

– Indicates the

6. FURN HI PR SW – Indicates the

state of the High Pressure Control (HPC) (also known as high pressure switch) – either OPEN or CLOSED.

7. GAS VLV PRCNT

– Indicates the firing rate of the modulating gas valve. This value can be any number between 40% and 100% depending on the thermostat demand.

8. GAS VLV RELAY

– Indicates the state of the gas valve relay –either ON or OFF. ON indicates that the

main gas valve solenoid is engaged. Any time the indication is ON, flame should be present.

9. FLAME

– Indicates the presence of a flame. The possibilities are “OFF”, “MARGINAL”, “GOOD” and “UNEXPECTED”. A marginal flame can be an indicator that the flame sense rod needs to be cleaned. “UNEXPECTED” flame is a serious condition and must be dealt with immediately by a professional, licensed HVAC technician.

Page 78

10. BLOWER CFM – Indicates the CFM

that the furnace control requests from the blower motor. This value

may vary somewhat from the actual values, but it should be very close. The value can also be tracked through the blinking decimal point on the seven segment displays at the furnace control (although with not as much resolution).

“STATUS 2” menu – This menu also gives information about the status of certain furnace components a

nd fea-

tures.

. MODE

– Indicates the current state

of operation of the furnace. The possibilities are listed below:

. MOD HEAT –

a b. AC – c

Air conditioning operation.

. FAN ONLY –

Heat operation

Continuous fan

operation.

. HP –

Heat-pump operation.

2. MOTOR MFGR – Indicates the

manufacturer of the main air-circu-

lating blower motor. At the time of

this publication there are two possi-

bilities; RGBLT for Regal Beloit (for-

merly GE) and EMERSON.

3. MOTOR RPM

– Indicates the RPM

of the main circulating air blower.

4. MAXIMUM CFM

– Indicates the

maximum CFM that the main circu-

lating air blower can deliver.

5. BLOWER CFM

– Indicates the output of airflow in CFM of the main circulating air blower.

6. TEMP DIFF

* – Indicates the differ-

ence between the outlet duct and

inlet duct air temperatures. This menu item may not be accurate when the Air Circulating Blower (ACB) is not turning.

When the outlet air (supply) temperature is greater than the inlet air (return) temperature, the thermostat

will display the text “RISE” with the

temperature value. Conversely, when the outlet air (supply) temperature is less than t

he inlet air

(return) temperature, the thermostat

will display the text “DROP” with the

temperature value. This temperature is displayed in

degrees F and can not

be changed to Celsius units. A few other different conditions that apply to this

menu item are: a. If the Supply Air Sensor (S.A.S.)

turned on (see “SUPPLY

is not AIR SENS” in “SETUP” menu below) and a sensor is not attached (or not sensed), NA will be displayed in the “TEMP DIFF” selection.

b. If the S.A.S. is not

turned on (see “SUPPLY AIR SENS” in “SETUP” menu below) and a

sensor is

attached, a valid temperature will be displayed in the “TEMP DIFF” selection.

c. If the S.A.S. is

turned on (see “SUPPLY AIR SENS” in “SETUP” menu below) and a sensor is

attached, a valid temperature will be displayed in the “TEMP DIFF” selection.

d. If the S.A.S. is

turned on (see “SUPPLY AIR SENS” in “SETUP” menu below) and a sensor is not

attached (or not

sensed), the text “FLT” (for

FauLT) is displayed in the “TEMP DIFF” selection

*ALL TEMPERATURES WITHIN THE USER MENUS CAN BE DISPLAYED ONLY IN FAHRENHEIT VALUES

Note: Supply Air (SA) and Return Air (RA) temperature readings may not be accurate in standby mode. These should only be read and used when the blower is running in heat, cool or other modes.

7. RETURN TEMP

* – Indicates the

temperature of the return air in the return air duct. This menu item may not be accurate when the Air Circulating Blower (ACB) is not turning. This value is sensed at the furnace control (IFC) and not at an

external sensor attached to the

control. If the temperature can not be sensed for some reason, the

text “FLT” will be displayed. This

temperature is displayed in degrees F and can not

be changed to

Celsius units *ALL TEMPERATURES CAN BE

DISPLAYED ONLY IN FAHRENHEIT VALUES

Note: Supply Air (SA) and Return Air (RA) temperature readings may not be accurate in standby mode. These should only be read and used when the blower is running in heat, cool or other modes.

8. SUPPLY TEMP

* – Indicates the

temperature of the supply air in the supply air duct. This menu item may not be accurate when the Air Circulating Blower (ACB) is not turning. This value is sensed at an

external sensor attached to the

control. This temperature is displayed in degrees F and can not changed to Celsius units. A few different conditions that apply to this menu item are:

a. If the Supply Air Sensor (S.A.S.)

turned on (see “SUPPLY

is not AIR SENS” in “SETUP” menu below) and a sensor is not

attached (or not sensed), NA will be displayed in the “SUPPLY TEMP” selection.

b. If the S.A.S. is not

(see “SUPPLY AIR SENS” in “SETUP” menu below) and a sensor is

attached, a valid temperature will be displayed in the “SUPPLY TEMP” selection.

c. If the S.A.S. is

“SUPPLY AIR SENS” in “SETUP” menu below) and a sensor is

attached, a valid temperature will be displayed in the “SUPPLY TEMP” selection.

d. If the S.A.S. is

“SUPPLY AIR SENS” in “SETUP” menu below) and a sensor is not

attached (or not

sensed), the text “FLT” (for

FauLT) is displayed in the “SUPPLY TEMP” selection.

*ALL TEMPERATURES CAN BE DISPLAYED ONLY IN FAHRENHEIT VALUES

Note: Supply Air (SA) and Return Air (RA) temperature readings may not be accurate in standby mode. These should only be read and used when the blower is running in heat, cool or other modes.

9. HUM OUTPUT

– Indicates when the humidifier output is turned on.

“2 WK HIST” menu – This menu gives information about the number of cycles and the amount of time spent in various modes of operation over the last 14 days.

NOTE: For both 2 WK & LIFE HIST, the value saved prior to power loss may not include information from the last hour of operation. This is because the information is only stored once every hour.

1. MOD HT HRS

– Indicates the number of hours of operation of gas heating operation rate in the last 14 days.

. MOD HT CYCLS

number of cycles of operation (i.e.: the number of times it turned on and off) of gas heat operation in the last 14 days.

. BLOWER HRS

number of hours of continuous fan operation in the last 14 days.

. BLOWER CYCLS

– Indicates the

the number of cycles of operation (i.e.: the number of times it turned on and off) of the continuous fan operation in the last 14 days.

turned on

turned on (see

– Indicates the

– Indicates

Page 79

IFE HIST

“

” menu – This menu gives information about the number of cycles and the amount of time spent in various modes of operation over the life of the furnace.

NOTE: For both 2 WK & LIFE HIST., the value saved prior to power loss may not include information from the last hour of operation. This is because the information is only stored once every hour.

. TOTAL DAYS PWRD

– Indicates the total number of days that the furnace has been powered. This number is not affected by any thermostat operation.

. MOD HT HRS

– Indicates the number of hours of operation of gas heating operation over the life of the furnace.

. MOD HT CYCLS

– Indicates the number of cycles of operation (i.e.: the number of times it turned on and off) of gas heat operation over the life of the furnace.

. BLOWER HRS

– Indicates the number of hours of continuous fan operation over the life of the furnace.

. BLOWER CYCLS

– Indicates the number of cycles of operation (i.e.: the number of times it turned on and off) of the continuous fan operation over the life of the furnace.

AULT HISTORY

“

” menu – This menu

gives information about the six most recent faults experienced by the fur-

nace. The most recent fault is displayed upon entering the menu. Three

seconds later the text “DAYS“ is dis-

played followed by a number. The number indicates the number of days since

that fault was experienced.

The faults can be viewed in order of occurrence. Pressing the down arrow key once will permit vie

wing of the next most recent fault. Pressing the key again will display the second most recent fault and so on.

If no fault present in the memory, the

text “NO FAULT” and “DAYS 0” will be

displayed. It is possible that there will

be less than six faults stored (if less than six faults have occurred since

installation or clearing of faults). In this

case, the existing faults will be dis-

played in the ord

er of occurrence and the remaining faults will be displayed as “NO FAULT” and “DAYS 0”.

The final item in this menu is “CLEAR FAULTS”. The options are “yES” and “no”. This item permits the faults to be

cleared so all six positions will display

“NO FAULT” and “DAYS 0”.

When faults are cleared, the right seven segment display on the furnace control will flash the upper and lower

horizontal bars once.

Note that the “FAULT HISTORY” only accumulates days when power is applied to the furnace control board.

For example, if a fault actually occurred

ten days ago and the furnace was not powered for two of the ten days, the

fault will be displayed with the text

“DAYS 8” instead o

f “DAYS 10” is displayed to indicate the number of days since the fault occurred.

NIT INFO

“

” menu – This menu gives

information about the furnace.

. MODEL NUMBER (MN)

2. SERIAL NUMBER (SN)

3. SOFTWARE VERS.

ETUP

“

” menu – This menu permits

the field adjustment of certain parame-

ters of the furnace. The selected values will be saved in memory even when power is lost and restored. The procedure for making changes in the furnace setup menu will vary depending on the thermostat or service tool that is used. To enter, navigate, make

changes to or exit the furnace “SETUP”

menu using a communicating thermostat, see

the installation and operation

instructions for that thermostat.

. HEAT RISE ADJ*

– The value of the heat rise can be changed to reflect the comfort of the homeowner. The value can be changed

between “NOM +10” (nominal or

mid temperature rise plus 10 degrees F) and “NOM” (nominal or mid temperature rise). Additional

adjustment can be to low and high

heating rates (and all points between) at the “MIN HEAT ADJ” and “MAX HEAT ADJ” menu items in items 2 and 3 below.

The temperature rise val

ues listed are for reference only. The actual measured temperature rise may be

different than expected by several

degrees. The default factory setting for the

heat rise is “NOM +10”.

*ALL TEMPERATURES CAN BE DISPLAYED ONLY IN FAHRENHEIT VALUES

. MIN HEAT ADJ

- This selection

permits the adjustment of the low

heat airflow. Operation of this

selection is exactly as with the dip-

switches at SW3 at the furnace control. The low heat rise can be changed by increasing or decreas-

ing the airflow slightly. Adjustments

are -15%, -7.5%, 0, +7.5% and +15%. Note that when a low heat adjustment is made, the low heat rate is adjusted and all

points between low a

nd high

heat will be adjusted proportionally with the greatest adjustment

on the low end and the least

adjustment on the high end.

IMPORTANT: Note that increasing the airflow will decrease the temperature rise and decreasing the airflow will increase the temperature rise. This may not be obvious at first.

The default factory setting for

the min heat adjustment is “0”.

. MAX HEAT ADJ

- This selection

permits the adjustment of the

high heat airflow. Operation of

this selection is exactly as with

the dipswitches at SW3 at the furnace control. The high heat rise can be changed by increasing or decreasing the airflow

slightly. Adjustments are -15%, -

7.5%, 0, +7.5% and +15%.

Note that when a high heat

adjustment is made, the high heat rate is adjusted and all

points between high and low

at will be adjusted proportion-

ally with the greatest adjustment

on the high end and the least

adjustment on the low end.

IMPORTANT: Note that increasing the airflow will decrease the temperature rise and decreasing the airflow will increase the temperature rise. This may not be obvious at first.

The default factory setting for

the max heat adjustment is “0”.

. SUPPLY AIR SENS

– This selection permits the disabling and enabling of the supply air sensor input. In many cases, it may not be possible to install this sensor. When this is the case, the selection can be changed to “OFF”. Selecting “on” or “OFF” will affect how the “TEMP RISE” (TEMPerature RISE) and “SUPPLY TEMP” values are displayed in the “STATUS 2” menu. See the descriptions for these items in the “STATUS 2” men

u descriptions

above for more information. Note that turning this selection

to “OFF” will prevent the “82” fault code (SA SENSOR FLT) from being displayed on powerup (or at any other time) and from logging in the fault buffer.

The default factory setting for the supply air sensor input is “on”.

Page 80

OTE:

FOR DUAL-FUEL OPERATION, THE SUPPLY AIR SENSOR MUST BE INSTALLED AND THE SELECTION FOR THIS SENSOR SET TO “ON” IN THE “SETUP” USER MENU UNDER THE SELECTION “SUPPLY AIR SENS” FOR DUAL-FUEL OPERATION. FAILURE TO INSTALL THE SENSOR AND TO TURN IT ON IN THE USER MENUS COULD CAUSE EXCESSIVE TRIPPING OF THE PRESSURE LIMIT CONTROLS ON THE AC SYSTEM.

. FIXED FIRE RATE

– This feature

will temporarily fix the gas heating

fire rate to the selection desired. The selected rate will be applied to the present heat call only. If there is no heat call already present when the selection is attempted, the system will not permit the firing rate to

be fixed at the user menu. The firing rate and blower will be fixed at the

selected rate for the duration of the

existinig heat call or a

maximum of two hours (whichever comes first). This feature should only be used for

installation, diagnostic, adjustment

and troubleshooting purposes by an

experienced licensed technician.

Selectable firing rates are 40%, 50%, 60%, 70%, 75%, 80%, 85%, 90% and 100%.

6. RESET ALL DFLTS

– This selection restores all items in the “SETUP” menu to the factory default selections. If “yES” is selected, all settings in this menu will be lost.

NOTE: When faults are cleared in the furnace “SETUP” user menu, the continuous fan CFM will also be restored to the factory default setting. (See Continuous Fan Operation in Communicating Mode.)

BELOW USER MENU IS USED FOR NON-COMMUNICATING SYSTEMS ONLY

SWITCH” menu – This menu per-

“DIP

mits viewing of the dipswitch selections. It is a way to read the dipswitch selections without the need of translating the settings manually.

Note: The “DIPSWITCH” menus will not be displayed at the thermostat. They are invisible to the thermostat and can not be displayed. These menus can only be viewed with the field service tool. The reason is that dipswitch selec-

do not generally affect operation of

tions the furnace when using the communicating mode of operation.

NOTE: The integrated furnace control

does not recognize switch setting changes while energized. To change

settings, remove power to the board by turning off the disconnect or switch to the furnace control or removing power at the breaker, make changes, then return power.

1. COOL AIRFLOW

– Displays the value of the cooling airflow selected. See the section of this manual titled “DIPSWITCH” under “SW1” (SW1-1 and SW1-2) for details and selections.

. HEAT RISE*

– Displays the value selected for the heat rise (either nominal or nominal plus ten degrees F). See the section of this manual titled “DIPSWITCH” under “SW1” (SW1-3) for details and selections.

*ALL TEMPERATURES CAN BE DISPLAYED ONLY IN FAHRENHEIT VALUES

. HI HEAT ADJ

– Displays the value

selected at SW3, positions 4 thru 6.

It is the adjustment of the high heat

rate airflow. See the section of this manual titled “DIPSWITCH” under “SW3” (SW3-4 thru SW3-6) for details and selections.

. LO HEAT ADJ

– Displays the value

selected at SW3, positions 1 thru 3.

It is the adjustment of the low heat

rate airflow. See the section of this manual titled “DIPSWITCH” under “SW3” (SW3-1 thru SW3-3) for details and selections.

. FAN SPD SELECT

– Displays the fan speed selected. See the section of this manual titled “DIPSWITCH” under “SW1” (SW3-4) for details and selections.

. AC-HP ADJ

– Adjusts the cooling

or heat-pump airflow slightly to

change or adjust the temperature

rise slightly. See the section of this manual titled “DIPSWITCH” under “SW1” (SW1-5 and SW1-6) for details and selections.

. ON DEMAND DEHUM

– Toggles the dehumidification feature on or off. See the section of this manual titled “DIPSWITCH” under “SW2” (SW2-1) for details and selections.

. TST MODE OR STG

– Displays the operation configuration based on the dipswitch selections. These

selections are explained in detail in

the section of this manual titled “DIPSWITCH” under “SW2” (SW22 and SW2-3). Further description follows:

STAGING

– (SW2-2 = OFF and SW2-3 = OFF) Represents either fully modulating operation (when valid signal is present) or staging operation when a single stage thermostat is connected.

STAGING

– (SW2-2 = ON and SW2-3 = ON) Represents timed staging operation with a two-stage thermostat.

0 PRCNT TEST

– (SW2-2 = ON and SW2-3 = OFF) Represents the mode of operation which will provide 40% heat rate for any heat call

– regardless of the rate transmit-

the thermostat. This

ted by mode ends automatically after the first 60 minutes of operation after power-up.

00 PRCNT TEST

– (SW2-2 = OFF and SW2-3 = ON) Represents the mode of operation which will provide 100% heat rate for any heat call – regardless of the rate transmitted by the thermostat. This mode ends automatically after the first 60 minutes of operation after power-up.

. AC HP STG MULT

– This allows

for adjustment to the airflow for

low-stage of cooling and heatpump operation. See the section of this manual titled “DIPSWITCH” under “SW2” (SW2-4) for details and selections.

DUAL-FUEL OPERATION IN COMMUNICATING MODE

Systems configured for dual-fuel operation will include a communicating condenser with a reversing valve. Dual-fuel systems will display

” for Heat-Pump heat operation

“ at the furnace control’s (I.F.C.) dual seven-segment displays. During

defrost mode, “

” will be displayed.

All other codes apply.

The balance point can be adjusted

at the thermostat for optimal operation. The balance point is the point below which gas heat will be used and above which heat-pump heat will be used.

For dual-fuel systems, to protect equipment, the supply air sensor must be installed. When

the supply air sensor is properly installed and the system is in defrost mode, the gas heat will only operate when the outlet air is below 110°F. When the

outlet air exceeds 110°F, the gas

valve is turned off and the Air Circulating Blower (ACB) continues to run. When the supply air temperature reaches 95°F, the gas heat will again be turned on. This cycle will continue until the call for defrost has ended.

OTE:

Page 81

START-UP PROCEDURES

IGNITOR PLACEMENT, ALIGNMENT & LOCATION

Ignition failure may be a result of improper ignitor alignment caused during a service call or other work done to the furnace in the field. When performing any work on the burner, heat

exchanger, etc., the technician must

check alignment of the spark ignitor. Misalignment of the ignitor could cause a failure to light or rough ignition. The correct ignitor alignment is shown in Figure 76.

TO START THE FURNACE

DIRECT SPARK IGNITION LIGHTING INSTRUCTIONS

This appliance is equipped with a directspark ignition device. This device lights the main burners each time the room thermostat calls for heat. See the lighting instructions on the furnace.

During initial start-up, it is not unusual for odor or smoke to come out of any room registers. To ensure prope

is recommended to open windows and

doors, before initial firing.

The furnace has a negative pressure

switch that is a safety during a call for

heat. The induced draft blower must pull a negative pressure on the heat

exchanger to close the negative pressure

switch. The induced draft blower must maintain at least the negative pressure switch set point for the furnace to operate. If the induced draft blower fails to

close or maintain the closing of the nega-

tive pressure switch, a “no heat call”

would result.

r ventilation, it

1. Remove the burner compartment control access door.

2. IMPORTANT: Be sure that the man- ual gas control has been in the “OFF” position for at least five minutes. Do not attempt to manually light the main burners.

3. Set the room thermostat to its lowest setting and turn off the furnace electrical power.

4. Turn the gas control knob to the “ON” position.

5. Replace the burner compartment

control access door.

WARNING

FAILURE TO REPLACE THE BURNER DOOR CAN CAUSE PRODUCTS OF COMBUSTION TO BE RELEASED INTO THE CONDITIONED AREA RESULTING IN PERSONAL INJURY OR DEATH.

6. Turn on the manual gas stop.

7. Turn on the furnace electrical power.

8. Turn thermostat to “Heat” mode and set the room thermostat at least 10°F above room temperature to light the main burners.

9. After the burners are lit, set the room thermostat to a desired temperature.

FURNACE TEST MODE

See the section of this manual titled “DIPSWITCH” under “SW-2” for details about test mode.

FIGURE 76

UPFLOW OPTIMUM IGNITOR LOCATION

DOWNFLOW/HORIZONTAL OPTIMUM IGNITOR LOCATION

Page 82

TABLE 17

NORMAL OPERATION CODES

CODE AT DUAL 7-SEGMENT DISPLAY OF IFC: 0

CODE AT DUAL 7-SEGMENT DISPLAY OF IFC

: H or h (steady on - not blinking)

DEHUMIDIFICATION MODE

CODE AT DUAL 7-SEGMENT DISPLAY OF IFC: Cd DESCRIPTION

: This code indicates that cooling is active with dehumidification active at the same time. When

dehumidification is active, the cooling airflow will be reduced in order to allow water to accumulate on the condenser thereb

removing humidity from the conditioned environment.

CODE AT DUAL 7-SEGMENT DISPLAY OF IFC

: F

COOLING MODE

DESCRIPTION: This code indicates the furnade is in cooling mode (any stage).

GAS HEAT MODE

FAN MODE

DESCRIPTION: The furnace is in continous fan mode.

HEAT PUMP HEAT MODE

DESCRIPTION: This code indicates the furnade is in heat-pump heating mode (dual-fuel systems only) (any stage).

CODE AT DUAL 7-SEGMENT DISPLAY OF IFC

: HP or hP

CODE

STANDBY MODE

DESCRIPTION: This code is displayed anytime there is no fault code to display and no thermostat call present. The

furnace is idle.

CODE AT DUAL 7-SEGMENT DISPLAY OF IFC

: C

DISPLAYED TEXT

H or h

(steady)

DESCRIPTION: This code indicates that the heat-pump is in deFrost mode (dual-fuel systems only) and furnace is

erating as supplemental heat at a fixed 65% of maximum gas heating capacity.

DEFROST MODE

CODE AT DUAL 7-SEGMENT DISPLAY OF IFC: dF

DESCRIPTION

DESCRIPTION: This code is displayed any time there is a call for gas heat. The lower-case "h" is displayed when the

furnace is calibrating. Calibration will occur during the first heat call after power reset or power-up. The calibration cycle allows the blower to be adjusted to deliver the proper airflow amount for a given heat rise at a given rate. Calibration takes more five minutes at a reduced input. Calibration will not occur if the SA sensor is not connected. If either (upper case "H" or lower-case "h" is blinking, it is an indication that a "V" signal is not present on a system that is noncommunicating. Blinking of this code will not be considered a fault if the thermostat chosen for use is noncommunicating and non-modulating. See fault codes "H" (blinking) and "h" (blinking) for more information.

CODE AT DUAL 7-SEGMENT DISPLAY OF IFC

NORMAL OPERATION CODES

Page 83

TO SHUT DOWN THE FURNACE

1. Set the room thermostat to its lowest setting and turn to “OFF” position.

2. Turn off the manual gas stop and turn off the electrical power to the furnace.

3. Remove the burner compartment control access door.

4. Shut off the gas to the main burners by turning the gas control knob to the “OFF” position.

5. Replace the burner compartment control access door.

WARNING

SHOULD OVERHEATING OCCUR OR THE GAS SUPPLY FAIL TO SHUT OFF, CLOSE THE MANUAL GAS VALVE FOR THE APPLIANCE BEFORE SHUTTING OFF THE ELECTRICAL SUPPLY. FAILURE TO DO SO CAN CAUSE AN EXPLOSION OR FIRE RESULTING IN PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.

SEQUENCE OF OPERATION

Heating Cycle Initiation

The heating cycle is always initiated by a 24 volt signal on W of the thermostat or, for communicating systems, a message is transmitted from the thermostat to the IFC. When the controller senses 24 volts on W or the communicated message for heat call, the following sequence occurs:

• High and low pressure switches are

checked to insure contacts are open.

• Inducer is powered on high speed for

a thirty (30) second prepurge.

• Pressure switches are monitored as

the inducer creates the vacuum to close the contacts.

• The modulating gas valve is set to the highest possible rate (no flow yet).

• The controller sends a spark signal to

spark across the electrodes.

• The main solenoids on the gas valve are energized allowing gas to flow to

the burners.

• When flame is proven, the ignition control is de-energized - 8 second maximum trial time.

• The gas valve maintains 100% rate

through the warm-up period - 20 seconds (aka Blower Off Delay).

Heating Cycle Response

MODULATING FUNCTION:

(“W” and “V” signal inputs, refer to dip

switch set SW2 on IFC) After the warm-up period, the furnace will respond to the thermostat demand

by adjusting the gas valve pressure

and blower speed anywhere between 40% to 100% heating capacity.

➤ TWO-STAGE FUNCTION – NON-

COMMUNICATING SYSTEMS ONLY:

(Two-stage function only applies when both SW2-2 and SW2-3 are in the

TABLE 18

METER TIME

METER TIME IN MINUTES AND SECONDS FOR NORMAL INPUT RATING OF FURNACES

INPUT SIZE

BTU/HR CU. FT. MIN. SEC. MIN. SEC. MIN. SEC. MIN. SEC. MIN. SEC.

60,000 TEN 9010 0 10 24 11 0 25 0

75,000 TEN 7 12 80819 8 48 20 0

90,000 TEN 60640 70720 16 40

105,000 TEN 5 10 5 40 60620 14 20

120,000 TEN 4 30 50510 5 30 12 30

Formula: Input BTU/HR = x C • F

“ON” position and a two-stage thermostat is installed as shown in Figure ??.)

After the warm-up period, the furnace will respond to the thermostat demand

by adjusting the gas valve pressure and

blower heating speeds to the “W” signal values. “W” only = 40% gas valve pressure and blower heating speed. “W2” = 65% gas valve pressure and blower heating speed for first five minutes and 100% thereafter. Also, if the call for heat ends, the furnace terminates at the present rate.

➤ SINGLE-STAGE FUNCTION – NON-

COMMUNICATING SYSTEMS ONLY:

(SW2-2 and SW2-3 must both be turned “off” for this operation.)

(“W” signal only)

After the warm-up period, the furnace will respond to the thermostat demand by altering the gas valve pressure and blower speed as follows:

Phase 1: 0 to 5 minutes = 40% of furnace

capacity (gas valve output and blower spee

Phase 2: 5 to 12 minutes = 65% of fur-

nace capacity (gas valve output and blower speed)

Phase 3: After 12 minutes = 100% of fur-

nace capacity (gas valve output and blower speed)

NOTE: If the call for heat ends during any

phase, the furnace will terminate immediately at the firing rate of that phase.

EQUIPPED FOR NATURAL OR LP GAS

METER

ONE 0 54 101316230

ONE 0 44 0 48 0 50 0 53 20

ONE 0 36 0 40 0 42 0 44 1 40

ONE 0 31 0 34 0 36 0 38 1 26

ONE 0 27 0 30 0 31 0 33 1 15

Where C • F =

HEATING VALUE OF GAS BTU PER CU. FT.

900 1000 1040 1100 2500 (LP)

DRY Heating Value of Gas (BTU/FT

Time in Seconds (for 1 cu. ft.) of Gas

Gas Pressure (inch • Hg) x 520 (˚F)

Gas Temperature (˚F) x 30 (inches • Hg)

) x 3600

SETTING INPUT RATE

Checking furnace input is important to prevent over firing beyond its design-rated input. NEVER SET INPUT ABOVE THAT SHOWN ON THE RATING PLATE. Use the following table or formula to determine input rate. Prior to checking the furnace input, make certain that all other gas appliances are shut off,

with the exception of pilot burners.

Time the meter with only the furnace in operation. Start the furnace, in Furnace Test Mode, 100% rate, and measure the time required to burn one cubic foot of gas.

The furnace is shipped from the fac-

tory with #50 orifices. They are sized

for natural gas having a heating value of 1075 BTU/cu. ft. and a specific gravity of .60. For high-altitude models (option 278) the furnace comes equipped with #51 orifices installed for elevations 5,000 to 5,999 ft. These orifices may still need to be changed based on both elevation and gas heating value. Consult the section of this book titled “High Altitude Installation” for details.

Since heating values vary geographically, the manifold pressure and/or

gas orifice size may need to be changed to adjust the furnace to its

nameplate input. The rate will also vary with altitude. Consult the local

Heating Cycle Termination

(“W” signal only, refer to dip switch set

SW2 on IFC) When the 24 volt signal is removed from W1 or, for communicatiing systems, a message is transmitted from the thermostat to the furnace to “end the heat call”, the heating cycle will end and the furnace

gas utility to obtain the yearly aver-

age heating value and orifice size

required to fire each individual burner at 15,000 BTUH. For high altitude installations, also consult the section of this manual titled “High Altitude Installations” for details on how to

calculate the correct orifice size.

will shut down and return to the proper off cycle operation.

Page 84

MAINTENANCE

WARNING

DISCONNECT MAIN ELECTRICAL POWER TO THE UNIT BEFORE ATTEMPTING ANY MAINTENANCE. FAILURE TO DO SO CAN CAUSE ELECTRICAL SHOCK RESULTING IN PERSONAL INJURY OR DEATH.

FILTERS

Keep the filters clean at all times. Remove the filter. Vacuum dirt from filter, wash with detergent and water, air dry thoroughly and reinstall.

NOTE: Some filters must be resized to fit

certain units and applications. See Table 19 and Figu

1. 21" - 90,000 & 105,000 BTUH units

2. 24

FIGURE 77

UPFLOW — FILTER REPLACEMENT

res 77, 78, 79, 80 & 81.

require removal of a 3

/2-in. segment of filter and frame to get the proper width for a side filter.

/2" - 120,000 BTUH unit requires removal of a 7" segment of filter and frame to get the proper width for a side filter.

TABLE 19

FILTER SIZES

UPFLOW FILTER SIZES

FURNACE INPUT BOTTOM SIDE

WIDTH KBTUH SIZE SIZE

171/2" 60 AND 75 153/4" X 25" 153/4" X 25" 1

21" 90 AND 105 19

/2" 120 223/4" X 25" 153/4" X 25" 1

/4" X 25" 153/4" X 25" 1

FIGURE 78

RESIZING FILTERS AND FRAME

FILTER MAINTENANCE

Instruct the user or homeowner on how to access the filters for regular maintenance.

Filter application and maintenance are critical to airflow, which may affect the heating and cooling system performance. Reduced airflow can

shorten the life of the system’s major

components, such as motor, limits,

heat exchanger, evaporator coil or

compressor. Consequently, it is recommended that the return air duct system have only one filter location. The most common location will be inside the furnace or a filter base. Systems with a return-air filter grille or multiple filter grilles, can have a filter installed at each of the return-air openings. Installers are instructed to show the homeowner or end user where the filter has been installed.

If high efficiency filters or electronic air cleaners are used in the system, it is important that the airflow is not

reduced in order to maximize system

performance and life. Always verify that the system’s airflow is not impaired by the filtering system that has been installed. This can be done by performing a temperature rise and temperature drop test.

Instruct the homeowner or end-user to keep the filter(s) clean at all times. Instruct them to vacuum dirt from the filter, wash with detergent and water, air dry thoroughly and reinstall.

ADS-5422-01

The installer may install a return-air filter in place of the furnace filter.

DO NOT DOUBLE-FILTER THE RETURN-AIR DUCT SYSTEM. DO NOT FILTER THE SUPPLY AIR DUCT SYSTEM.

QUANTITY

REMOVE SEGMENT TO SIZE AS REQUIRED

54-24094-01

Page 85

FIGURE 79

UPFLOW -- SIDE FILTER LOCATIONS

CUT-OUT AND DRILL DETAIL

FIGURE 80

DOWNFLOW -- FILTER INSTALLATION

AIRFLOW

ROD & FILTER SUPPORT ANGLE ASSEMBLY

FIGURE 81

HORIZONTAL -- FILTER INSTALLATION

AIRFLOW

I332

A087001.S01

A087101.S01

Page 86

CAUTION

DO NOT OPERATE THE SYSTEM WITHOUT FILTERS. A PORTION OF THE DUST ENTRAINED IN THE AIR MAY TEMPORARILY LODGE IN THE AIR DUCT RUNS AND AT THE SUPPLY REGISTERS. ANY RECIRCULATED DUST PARTICLES WILL BE HEATED AND CHARRED BY CONTACT WITH THE FURNACE HEAT EXCHANGER. THIS RESIDUE WILL SOIL CEILINGS, WALLS, DRAPES, CARPETS AND OTHER HOUSEHOLD ARTICLES.

LUBRICATION

IMPORTANT: Do Not attempt to lubri-

cate the bearings on the blower motor or the induced draft blower motor. Addition of lubricants can reduce the motor life and void the warranty.

The blower motor and induced d blower motor bearings are prelubricated by the manufacturer and do not require further attention.

The blower motor and induced draft blower motor must be cleaned periodically by a qualified installer, service agency, or the gas supplier to prevent the possibility of overheating due to an accumulation of dust and dirt on the

windings or on the motor exterior. The

air filters should be kept clean. As di filters can restrict airflow. The motor depends upon sufficient airflowing across and through it to keep from overheating.

raft

rty

SYSTEM OPERATION INFORMATION

Advise The Customer IMPORTANT: Replace all blower doors

and compartment covers after servicing the furnace. Do not operate the unit without all panels and doors securely in place.

1. Keep the air filters clean. The heating system will operate more effici

ently and more economically.

2. Arrange the furniture and drapes so that the supply air registers and the return air grilles are unobstructed.

3. Close doors and windows. This will reduce the heating load on the system.

4. Avoid excessive use of kitchen exhaust fans.

5. Do not permit the heat generated by television, lamps or radios to influence the thermostat operation.

6. Explain proper operation of the

system with constant air circulation.

ANNUAL INSPECTION

The furnace should operate for many

years without excessive scale build-up

in the flue passageways. However, it is recommended that a qualified installer, service agency, or the gas supplier annually inspect the flue passageways, the vent system and the main burners for continued safe operation. Pay particular attention to deterioration from corrosion or o

During the annual inspection, all electrical power to the furnace should be turned off and then restored. This will put the furnace into a calibration cycle on the initial call for heat. This is a five minute (or until the heat call is satisfied) cycle which allows the furnace to evaluate conditions It should be noted, that a calibration cycle will occur on the initial call for heat each t has been interrupted to the unit.

IMPORTANT: It is recommended that at

the beginning and at approximately half

way through the heating season, a visual inspection be made of the main burner flames for the desired flame appearance by a qualified installer, service agency or the gas supplier. If the flames are distorted and/or there is evidence of back pressure, check the vent and air system for blockage. If there is car-

bon and scale in the heat exchanger tubes, the heat exchanger assembly

should be replaced.

HOLES IN THE VENT PIPE OR HEAT EXCHANGER CAN CAUSE TOXIC FUMES TO ENTER THE HOME, RESULTING IN CARBON MONOXIDE POISONING OR DEATH. THE VENT PIPE OR HEAT EXCHANGER MUST BE REPLACED IF THEY LEAK.

ther sources.

ime after line voltage

inlet

WARNING

IMPORTANT: It is recommended that

at the beginning of the heating season, the flame sensor be cleaned with steel wool by a qualified installer, service agency or the gas supplier.

IMPORTANT: It is recommended that at the beginning of the heating season, the condensate trap be inspected for debris or blockage. A blocked condensate trap can cause water to back up into the primary heat

exchanger and lea

ping of the over temperature switches and/or pressure switches.

IMPORTANT: It is recommended that at the beginning of the heating sea-

son, the condensate neutralizer (if

used) be replaced by a qualified installer, service agency or the gas supplier.

IMPORTANT: Drain traps will often dry out over a summer. During annual inspection the service person must verify that the trap still has wate there is not enough water (or no water) in the trap, the service person must fill it to the appropriate level.

IMPORTANT: It is recommended that an annual inspection and cleaning of all furnace markings be made to assure legibility. Attach a replacement marking, which can be obtained through the distributor, if any are found to be illegible or missing.

d to nuisance trip-

r. If

REPLACEMENT PARTS

Contact your local distributor for a complete parts list.

TROUBLESHOOTING

Figure 82 is a troubleshooting flowcharts for the sequence of operation. Table 21 is for fault-code descriptions.

WIRING DIAGRAM

Figures 83 and 84 are complete wiring diagrams for the furnace and power sources.

Page 87

FIGURE 82

TROUBLESHOOTING CHART

MODULATING INTEGRATED

FURNACE CONTROL (IFC)

TROUBLESHOOTING GUIDE

1) Set DIP switches SW2-2 to “OFF” and SW2-3 to “ON” for test mode - high fire.

2) Set FAN switch to “AUTO” on T-stat.

3) Set thermostat to call for heat (set temp. differential to greater than 10°F).

4) “H” should be displayed at “SSD’s” and should Be on steady, if flashing check dip switches (Item “1”).

Dual SSD’S “ON”

Is thermostat heat call present? For 24 VAC (Non-Comm. T-stat., is 24 VAC on W1 and/or W2 of IFC. H or h should be displayed at SSD’S.

ECM = Constant CFM Blowers. (Electronically commutated motor) TSTAT = Thermostat. IDM = Induced Draft Motor (or Inducer). IFC = Integrated Furnace Control (or control board). PS = Pressure Switch(es). PFC = Power Factor Correction Choke. SE = Spark Electrode (s). SSD = Seven Segment Display of Furnace control COMM. = Communication. I&O = Instal

lation & Operation Instructions Manual.

For Comm. System

For Non-Comm. Systems.

“A capital

is displayed at IFC SSD’S”

Capital “H”

Lower case “h”

Is a modulating

T-stat connected?

2 Stg. or 1 Stg. Non Comm. T-stat

(pre-purge) IDM runs for 30 sec. at high speed?

Spark Electrodes (SE) Energize?

Does ECM blower start on high heat

speed 15-20 seconds after burners light?

Is a fault code displayed at IFC?

(After 10 Sec. a fault code will display anyway)

-Check line voltage at I.D.M.

-Check Wires And connections between I.D.M. and I.F.C.

-Ensure line voltage between J2, Pin 1 & J2, Pin 4 of I.F.C. (High IN Output).

-Check I.D.M. Capacitor.

Check t-stat, replace if

necessary.

Check “V” signal wires &

connections, replace or

repair as necessary

Does IDM Run for 60 Sec. and then off

PROBLEM PERSISTS

G0 T0

- Check all connections between I.F.C. & E.C.M. Motor.

- Check 24v to E.C.M. control (4pin connector, pin 1-4)

- Check Dip switch setting.

- Check P.F.C. choke.

- Check all wiring and connections to P.F.C choke.

- Check fault code display, see

- Check line voltage to motor (115VAC).

Note: IFC SSD’s will display “22, 33 or 23”.

H or h only

For 1st 10 Sec. only

for five minutes with fault

45, 48 or 57 displayed?

See I&O.

Does gas valve remain

energized?

“fault codes” in I & O.

Under ”Troubleshooting”

If good flame is not sensed a fault code

“11” or “13” will be displayed at SSD’s

“12” is low flame sense, furnace should

still operate well.

FAULT

in I & O Manual

- See FAULT CODES under “Troubleshooting” in I&O Manual.

J16-4

If IFC goes into lockout (”r” will be displayed at SSD’s), shut off main power to unit, wait 30 seconds then reset power or removed heat call and re-establish.

J16-5 on IFC.

Fault code

“45”, “46” or

“57” displayed

at SSD’s.

- ensure no restrictions, such as dirty filter, blower wheel,

dampers or closed registers, Etc. exist.

- ensure good wire and connections between I.F.C. and all limits. makes sure limits are not open when circulating air temperature is within a specific range.

- Ensure rollouts or overtemperature limits do not need to be

reset. make sure no flame rollout in burner compartment due to blocked flue

or heat exchanger or combustion restriction.

- ensure furnace is not overfired (temp rise is above stated

range). Check gas valve, proper orifice size, gas presure

Remove heat call by setting T-stat set point below room temperature. remove power to furnace and open blower door. Set dip switch SW2-2 to “ON” and SW2-3 to “OFF”. Replace furnace door, reset po furnace. Initiate new heat call. Allow heat call to proceed through blower on delay. The burners drop

from high fire to low (40%) rate and I.B.M. energizes at

low heat CFM.

wer to

-Grounding on I.F.C. in place and continuity between screw and field

-installed ground.

-Flame sense rod clean (clean if nessessary).

-Wire continunity between flame sense rod and J1, Pin1 on I.F.C.

-Flame carries across all burners, and all burners stay lit.

- Check test mode dip switches.

- Make sure test mode has not

expired (1 hour limit).

- Fault codes at IFC SSD - see FAULT CODES under troubleshooting in I&O manual.

- 24V Between IFC pins J16, Pin 4 & J16, Pin 5 of I.F.C.

- Make sure heat call present at T-stat.

- T-stat wires and connections

Page 88

SSD = Seven Segment Display of Furnace control COMM. = Communication. I&O = Instal

lation & Operation Instructions Manual.

3) Set thermostat to call for heat (set temp. differential to greater than 10°F).

4) “H” should be displayed at “SSD’s” and should Be on steady, if flashing check dip switches (Item “1”).

For Non-Comm. Systems.

“A capital

is displayed at IFC SSD’S”

Dual SSD’S “ON”

Is thermostat heat call present? For 24 VAC (Non-Comm. T-stat., is 24 VAC on W1 and/or W2 of IFC. H or h should be displayed at SSD’S.

Is a fault code displayed at IFC?

(After 10 Sec. a fault code will display anyway)

H or h only

For 1st 10 Sec. only

FAULT

Under ”Troubleshooting”

in I & O Manual

Is a modulating

T-stat connected?

Check “V” signal wires &

connections, replace or

repair as necessary

Check t-

stat, replace if

necessary.

(pre-purge) IDM runs for 30 sec. at high speed?

Does IDM Run for 60 Sec. and then off

for five minutes with fault

45, 48 or 57 displayed?

- See FAULT CODES under “Troubleshooting” in I&O Manual.

J16-4

J16-5 on IFC.

If IFC goes into lockout (”r” will be displayed at SSD’s), shut off main power to unit, wait 30 seconds then reset power or removed heat call and re-establish.

- Check all connections between I.F.C. & E.C.M. Motor.

- Check 24v to E.C.M. control (4pin connector, pin 1-4)

- Check Dip switch setting.

- Check P.F.C. choke.

- Check all wiring and connections to P.F.C choke.

- Check fault code display, see

“fault codes” in I & O.

- Check line voltage to motor (115VAC).

Does ECM blower start on high heat

speed 15-20 seconds after burners light?

Note: IFC SSD’s will display “22, 33 or 23”.

If good flame is not sensed a fault code

“11” or “13” will be displayed at SSD’s

“12” is low flame sense, furnace should

still operate well.

Fault code

“45”, “46” or

“57” displayed

at SSD’s.

- Check test mode dip switches.

- Make sure test mode has not

expired (1 hour limit).

- Fault codes at IFC SSD - see FAULT CODES under troubleshooting in I&O manual.

- 24V Between IFC pins J16, Pin 4 & J16, Pin 5 of I.F.C.

- Make sure heat call present at T-stat.

- T-stat wires and connections

wer to furnace. Initiate new heat call. Allow heat call to proceed through blower on delay. The burners drop

from high fire to low (40%) rate and I.B.M. energizes at

low heat CFM.

For Comm. System

Lower case “h”

Capital “H”

2 Stg. or 1 Stg. Non Comm. T-stat

-Check line voltage at I.D.M.

-Check Wires And connections between I.D.M. and I.F.C.

-Ensure line voltage between J2, Pin 1 & J2, Pin 4 of I.F.C. (High IN Output).

-Check I.D.M. Capacitor.

Spark Electrodes (SE) Energize?

See I&O.

Does gas valve remain

energized?

PROBLEM PERSISTS

- ensure no restrictions, such as dirty filter, blower wheel,

dampers or closed registers, Etc. exist.

- ensure good wire and connections between I.F.C. and all limits. makes sure limits are not open when circulating air temperature is within a specific range.

- Ensure rollouts or overtemperature limits do not need to be

reset. make sure no flame rollout in burner compartment due to blocked flue

or heat exchanger or combustion restriction.

- ensure furnace is not overfired (temp rise is above stated

range). Check gas valve, proper orifice size, gas presure

-Grounding on I.F.C. in place and continuity between screw and field

-installed ground.

-Flame sense rod clean (clean if nessessary).

-Wire continunity between flame sense rod and J1, Pin1 on I.F.C.

-Flame carries across all burners, and all burners stay lit.

G0 T0

FIGURE 82

TROUBLESHOOTING CHART – CONTINUED

After Blower on delay, Does IDM switch to low speed and remain a

t low speed after switching?

Does I. B. M. energize at low speed?

Does furnace continue to operate at low fire until T-stat satisfied or heat call removed?

Remove heat call by setting T-stat below room temp.

Does IDM Shut off after Twenty Second post purge?

Does I. B. M. shut off after 90 seconds? (plus slew)

Remove power to furnace, open blower compartment and restore dip switches to original settings. Replace blower door. Restore power to unit.

Check to make sure test mode dip switches are properly set.

Ensure T-stat not switching to high fire or test mode dips witches not timing out (1 hour limit)

Double check - is heat call

completely off at IFC?

troubelshooting in the I & O Manual

Fault code displayed?

See FAULT CODES under

- Check wire and all connections between I.F.C.J2 and I.D.M

- Check for 115 VAC on P2.

- Check I.D.M. capacitor.

- Check I.D.M. low speed. Replace if neccessary.

- Check all connections between IFC and ECM motor.

- Check 24V to ECM Motor. (low voltage connector, pins 1 & 4)

- Check P.F.C. Choke.

- Check all wiring and connections to P.F.C. choke.

- Check fault code display and see “fault codes” In I & O.

** System will attempt to light 4 times. Voltage Is present at gas valve for only 7 seconds during each ignition trial. System will enter a 1 hour lockout after 4 attempts.

92-22744-23-00

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TABLE 20

NORMAL OPERATION CODES

CODE

DISPLAYED TEXT

CODE AT DUAL 7-SEGMENT DISPLAY OF IFC

DESCRIPTION

NORMAL OPERATION CODES

CODE AT DUAL 7-SEGMENT DISPLAY OF IFC: 0

DESCRIPTION: This code is displayed anytime there is no fault code to display and no thermostat call present. The

furnace is idle.

CODE AT DUAL 7-SEGMENT DISPLAY OF IFC DESCRIPTION: This code is displayed any time there is a call for gas heat. The lower-case "h" is displayed when the

H or h

(steady)

CODE AT DUAL 7-SEGMENT DISPLAY OF IFC DESCRIPTION: This code indicates the furnade is in cooling mode (any stage).

CODE AT DUAL 7-SEGMENT DISPLAY OF IFC DESCRIPTION: This code indicates the furnade is in heat-pump heating mode (dual-fuel systems only) (any stage).

CODE AT DUAL 7-SEGMENT DISPLAY OF IFC DESCRIPTION: The furnace is in continous fan mode.

CODE AT DUAL 7-SEGMENT DISPLAY OF IFC: dF DESCRIPTION: This code indicates that the heat-pump is in deFrost mode (dual-fuel systems only) and furnace is

erating as supplemental heat at a fixed 65% of maximum gas heating capacity.

STANDBY MODE

GAS HEAT MODE

: H or h (steady on - not blinking)

COOLING MODE

: C

HEAT PUMP HEAT MODE

: HP or hP

FAN MODE

: F

DEFROST MODE

DEHUMIDIFICATION MODE

CODE AT DUAL 7-SEGMENT DISPLAY OF IFC: Cd DESCRIPTION

dehumidification is active, the cooling airflow will be reduced in order to allow water to accumulate on the condenser thereb

: This code indicates that cooling is active with dehumidification active at the same time. When

removing humidity from the conditioned environment.

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TABLE 21

FAULT CODES

DISPLAYED TEXT

DESCRIPTION

DESCRIPTION: This message will not be displayed at the furnace. It will be displayed at the condenser but it involves

the furnace. It is an indicator that the maximum airflow that can be supplied by the furnace is not enough capacity for the condenser.

CAUSE

: The condenser selected is too large for the airflow capacity of the furnace.

FAULT

CODE

NO SHARED DATA

DESCRIPTION: This code is displayed anytime there is no shared data at the furnace or (for communicating systems

only) on the network (e.g. at the condenser or thermostat). The shared data is electronically stored data that is used to define (among other things) blower operation. Without the shared data, the furnace can not function. Note that shared data may be available even if there is no card attached to the furnace control. A missing memory card will display fault code "d4" if shared data is available on the network.

STATUS

: This is a critical fault. The air conditioner (or heat pump) condenser will not operate in communicating

mode.

SOLUTION

SOLUTION: Replace the missing memory card into the connector labeled J15 on the furnace control (I.F.C.). If the

original card can not be found, a replacement card can be ordered from ProStock. Be sure to order the correct memory card for the furnace. Note: Furnace power must be cycled off and then on again after replacing the card or the shared data will not be read.

MESSAGES TO HOMEOWNER AT COMM. THERMOSTAT: "CALL FOR SERVICE " & "CHECK FURNACE".

CAUSE

STATUS

MESSAGE IN FAULT AREA OF COMMUNICATING THERMOSTATS: AIRFLOW MISMATCH

SOLUTION

: The condenser or furnace should be replaced with a condenser or furnace which will match the

necessary airflow requirements of the condenser. Check specification sheets for both the furnace and the condenser to determine airflow capacity needed and supplied.

MESSAGE IN FAULT AREA OF COMM. THERMOSTAT

: "NO SHARED DATA "

CODE AT DUAL 7-SEGMENT DISPLAY OF IFC & FAULT AREA OF COMM. THERMOSTAT

: d1

CODE AT DUAL 7-SEG DISPLAY OF HP/AC & FAULT AREA OF COMM. THERMOSTAT

: d3

MESSAGES TO HOMEOWNER AT COMMUNICATING THERMOSTATS

: "CALL FOR SERVICE " & "CHECK

FURNACE".

CAUSE

: Typically, the memory card will be missing from the furnace. In most cases, the cause of this fault will be the

loss or disconnection of the original memory card from the furnace control (or I.F.C.). When the furnace control (or I.F.C.) is replaced, the memory card must be broken away, saved and installed in the replacement control. This is explained in detail in the section of this book titled REPLACING THE FURNACE CONTROL.

STATUS

: This is a critical fault. The furnace will not operate in any mode.

AIRFLOW MISMATCH

EXPECTED OPERATION: No operation (including thermostat) will be permitted without the shared data. The shared

data defines the IBM (Indoor Blower Motor) speed-torque curve. Without this information, the IBM can not operate. Refer to the section of this manual titled "INTEGRATED FURNACE CONTROL" under the subsection titled "MEMORY CARD" for details on the hierarchy of use of multiple copies of shared data and distribution (among other details) of shared data.

EXPECTED OPERATION

: No cooling or heat-pump heating operation can take place. However, all other modes of

operation (including gas heat) should proceed as normal. Refer to the section of this manual titled "INTEGRATED FURNACE CONTROL" under the subsection titled "MEMORY CARD" for details on the hierarchy of use of multiple copies of shared data and distribution (among other details) of shared data.

CODE AT DUAL 7-SEGMENT DISPLAY OF IFC & FAULT AREA OF COMM. THERMOSTAT

MESSAGES TO HOMEOWNER AT COMM. THERMOSTAT

EXPECTED OPERATION

MESSAGE IN FAULT AREA OF COMM. THERMOSTAT

FURNACE FAULT CODES EXPANDED W/DESCRIPTIONS AND SOLUTIONS

Page 91

TABLE 21

FURNACE FAULT CODES EXPANDED W/DESCRIPTIONS AND SOLUTIONS – CONTINUED

FAULT CODES

NOTE: The text in the “DISPLAYED TEXT” box shows combinations of upper-case and lower-case letters. Upper-case letters are used

in the message displayed at the thermostat active fault screen. For example, the text CARD-HARDware CoNFLiCT indicates that the message displayed at the thermostat active fault screen will be CARD-HARD CNFLCT. NOTE: The following fault codes will not be stored back-to-back in the fault buffer. These will only be stored in the buffer if the previous fault stored was a different fault. 82, 11, 45, 46 & 57.

Page 92