Rheem RGPE series, RGLE series Installation Instructions Manual

Page 1

INSTALLATION INSTRUCTIONS

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

RECOGNIZE THIS SYMBOL AS AN INDICATION OF IMPORTANT SAFETY INFORMATION!

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 until authorized by the gas supplier or fire department.

— 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 injury, property

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.

ISO 9001:2008

FOR RGPE UPFLOW, HORIZONTAL, RGLE DOWNFLOW 2 STAGE, 80+ GAS FURNACES

COMMUNICATING

THERMOSTATS

INSTALLATION

SEE PAGE 84

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.

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.

SUPERSEDES 92-24161-77-01

92-24161-77-02

Page 2

IMPORTANT: All Manufacturer 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 gas.

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 airconditioning 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.

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.

TABLE OF CONTENTS

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

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

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

IMPORTANTINFORMATION ABOUT EFFICIENCYANDINDOORAIR QUALITY...................................6

RECEIVING.....................................................................................................................................................7

LOCATION REQUIREMENTSANDCONSIDERATIONS.......................................................................................7

LOCATION.......................................................................................................................................................7

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

SITE SELECTION.........................................................................................................................................10

DUCTING......................................................................................................................................................10

COMBUSTIONAND VENTILATION AIR ...............................................................................................................12

COMBUSTIONAIR REQUIREMENTS........................................................................................................12

VENTING.................................................................................................................................................................16

GENERAL INFORMATION...........................................................................................................................16

DRAFTINDUCER.........................................................................................................................................16

FURNACE CATEGORY INFORMATION.....................................................................................................16

IMPORTANTAPPLICATIONNOTES...........................................................................................................16

B-1 VERTICALVENTING.............................................................................................................................17

SPECIAL VENT SYSTEMS..........................................................................................................................17

POWERVENT SYSTEMS...........................................................................................................................18

EXISTING VENT SYSTEMS........................................................................................................................18

GAS SUPPLYAND PIPING....................................................................................................................................19

GAS SUPPLY................................................................................................................................................19

GAS PIPING..................................................................................................................................................19

GAS PRESSURE..........................................................................................................................................20

LP CONVERSION.........................................................................................................................................20

SETTING GAS PRESSURE.........................................................................................................................21

ADJUSTING OR CHECKINGFURNACE INPUT.......................................................................................22

ELECTRICALWIRING............................................................................................................................................23

ELECTRICALCHECKS........................................................................................................................24

ACCESSORIES.......................................................................................................................................................25

FIELDINSTALLEDOPTIONACCESSORIES............................................................................................25

OTHERACCESSORIES AVAILABLE..........................................................................................................27

RXGW-B01 CHIMNEYADAPTER...............................................................................................................27

TYPICAL WIRING FOR SELECTACCESSORIESFOR COMMUNICATING RESIDENTIAL

SYSTEMS............................................................................................................................................27

80+ HIGH ALTITUDE INSTRUCTIONS.......................................................................................................29

LP GAS..........................................................................................................................................................29

ORIFICE ORDERING INFORMATION........................................................................................................29

ALTERNATE METHOD FOR CANADIAN HIGH-ALTITUDE DERATE......................................................29

AIRFLOW.................................................................................................................................................................31

INTEGRATED FURNACE CONTROL...................................................................................................................33

24 VAC THERMOSTAT INPUTS..................................................................................................................33

SPECIAL CONFIGURATION–COMMUNICATINGTHERMOSTATW/NON-COMM. CONDENSER......34

24 VAC FROM TRANSFORMERCONNECTIONS....................................................................................34

FUSE.............................................................................................................................................................34

115 VAC TERMINALS...................................................................................................................................34

INDUCED DRAFTMOTOROUTPUT.........................................................................................................34

NEUTRALTERMINALS................................................................................................................................35

ELECTRONICAIR CLEANER OUTPUT.....................................................................................................35

HUMIDIFIEROUTPUT.................................................................................................................................35

15-PIN MATE-N-LOK CONNECTOR...........................................................................................................35

COMMUNICATING ECM MOTOR COMMUNICATIONS CONNECTION.................................................36

SPARK IGNITIONTRANSFORMER...........................................................................................................37

R-J11 CONNECTOR.....................................................................................................................................37

COMMUNICATIONS NETWORK CONNECTION......................................................................................37

COMMUNICATIONS L.E.D.’S......................................................................................................................37

LEARNBUTTON...........................................................................................................................................38

MEMORY CARD CONNECTOR..................................................................................................................38

MEMORY CARD...........................................................................................................................................38

REPLACINGTHE FURNACE CONTROL...................................................................................................41

DIPSWITCHES.............................................................................................................................................44

SW1...............................................................................................................................................................44

SW2...............................................................................................................................................................46

FURNACE OPERATION USINGNON-COMMUNICATING SIINGLE-STAGE AND TWO-STAGE

THERMOSTATS......................................................................................................................................46

SW3-1AND SW3-2.......................................................................................................................................47

BIAS / TERMINATION ..................................................................................................................................48

DUALSEVEN-SEGMENT DIAGNOSTICDISPLAY ...................................................................................48

FAULT CODE BUFFER................................................................................................................................48

CLEARING DIAGNOSTICFAULT CODES FROM THE BUFFER.............................................................48

COMMUNICATING SYSTEMS....................................................................................................................49

START-UP PROCEDURES....................................................................................................................................57

IGNITOR PLACEMENT, ALIGNMENT& LOCATION.................................................................................57

TO START THE FURNACE..........................................................................................................................57

TO SHUT DOWN THE FURNACE..............................................................................................................57

SEQUENCE OF OPERATION.....................................................................................................................57

ADJUSTING OR CHECKINGFURNACE INPUT.......................................................................................59

MAINTENANCE.......................................................................................................................................................60

FILTERS ........................................................................................................................................................60

SYSTEM OPERATION INFORMATION......................................................................................................62

ANNUAL INSPECTION................................................................................................................................62

LUBRICATION...............................................................................................................................................62

REPLACEMENTPARTS..............................................................................................................................62

NOx MODELS...............................................................................................................................................62

TROUBLESHOOTING............................................................................................................................62-63

WIRING DIAGRAM.......................................................................................................................................79

THERMOSTATS......................................................................................................................................................80

NON-COMMUNICATINGTHERMOSTATS.................................................................................................80

SEQUENCE OF OPERATION.....................................................................................................................80

COMMUNICATING THERMOSTATS.....................................................................................................................84

Page 3

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 horizontally 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 subdivision can not be met at the 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 mounted 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 equipment. The sign shall read, in print size no less than one-half (1/2) inch in size,

“GASVENT DIRECTLY BELOW. KEEP CLEAR OF ALL OBSTRUCTIONS”.

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 carbon 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 adopted by the Board; and

2. Product Approved side wall horizontally 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.

(c) MANUFACTURER REQUIREMENTS – GAS EQUIPMENT VENTING SYSTEM PROVIDED. When the manufacturer of Product Approved side wall horizontally vented gas equipment provides a venting system design or venting system components with the equipment, 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 fueled equipment does not provide 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 installation instructions.

(e) A copy of all installation instructions for all ProductApproved side wall horizontally 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.

WARNING

INSTALLTHIS 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, OR WITH 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 INSTALLTHIS 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 ONLYWITH TYPE OF GAS APPROVED FOR THIS FURNACE. REFER TO THE FURNACE RATING PLATE.

Page 4

WARNING

WHENTHIS FURNACE IS INSTALLED IN A RESIDENTIAL GARAGE,IT MUST BE INSTALLED SO THE BURNERS AND IGNITION SOURCE ARE LOCATED NO LESSTHAN 18 INCHES ABOVETHE FLOOR.THIS ISTO REDUCETHE RISK OF IGNITING FLAMMABLEVAPORS WHICH MAY BE PRESENT IN A GARAGE. ALSO,THE FURNACE MUST BE LOCATED OR PROTECTEDTO AVOID PHYSICAL DAMAGE BY VEHICLES. FAILURETO FOLLOWTHESE 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 FOLLOWINGTEMPORARY INSTALLATION REQUIREMENTS ARE MET. INSTALLATION MUST COMPLY WITH ALL INSTALLATION INSTRUCTIONS INCLUDING:

• PROPERVENT 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 RATING PLATE MARKING;

• MEANS FOR PROVIDING OUTDOOR AIR REQUIRED FOR COMBUSTION;

• 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, ACCORDINGTOTHE INSTRUCTIONS.

WARNING

DO NOT JUMPER OR OTHERWISE BYPASS OVERTEMPERATURE OR ANY OTHER LIMITS OR SWITCHES ONTHE FURNACE. IF ONE OF THESE LIMITS OR SWITCHES SHOULDTRIP OR OPEN,THE USER ISTO BE INSTRUCTEDTO CALL A QUALIFIED INSTALLER, SERVICE AGENCY OR THE GAS SUPPLIER. FOR MANUALLY RESETABLE SWITCHES,THE USER IS FURTHER INSTRUCTEDTO NEVER RESETTHE SWITCH, BUTTO CALL A QUALIFIED TECHNICIAN. MANUAL RESET SWITCHES MAY REQUIRE FURTHER CORRECTIVE ACTIONS. FAILURETO FOLLOWTHIS WARNING COULD RESULT IN CARBON MONOXIDE POISONING, SERIOUS INJURY OR DEATH. IFTHE UNIT IS INSTALLED IN A CLOSET,THE DOOR MUST BE CLOSEDWHEN MAKINGTHIS CHECK. INSTALLERS ANDTECHNICIANS ARE INSTRUCTEDTO 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 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 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 INTHE EQUIPMENT AND DUCT MUST BE SEALED TO LIMIT THE MIGRATION OF TOXIC FUMES AND ODORS INCLUDING CARBON MONOXIDE FROM MIGRATING INTOTHE 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 FURNACE TO OPERATE WITHIN THE FURNACE'S INTENDED TEMPERATURE-RISE RANGE WITH A DUCT SYSTEM WHICH HAS AN EXTERNAL STATIC PRESSURE WITHIN THE ALLOWABLE RANGE, AS SPECIFIED IN DUCTING SECTION OF THESE INSTRUCTIONS. SEE ALSO FURNACE RATING PLATE.

WARNING

WHEN A FURNACE IS INSTALLED SO THAT SUPPLY DUCTS CARRY AIR CIRCULATED BY THE 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 WITHTHE 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 DAMAGETOTHE 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

Before beginning any troubleshooting procedure, complete the following installation checklist. A furnace malfunction is sometimes caused by an improper installation. By completing this checklist, the problem may be found and corrected. Make copies of the checklist and complete one for every Low Profile Furnace service call for your records.

INSTALLATION CHECKLIST

(Refer to this manual for specifics.) GAS SUPPLY

Adequate pipe size No gas leaks Proper supply and manifold gas pressure (check with an accurate U-tube manometer with the furnace and all other

gas appliances operating.)

ELECTRICAL

Correct thermostat and subbase Thermostat model Subbase model Correct thermostat mode and setting Correct line supply voltage Correct power supply polarity is required with electronic ignition Correct furnace ground to electrical panel DC microamp (∝A) flame signal (hot surface ignition units) Correct control voltage Measure and set heat anticipator amperage Air conditioning low voltage wires connected to terminals “Y” “C” - not with wire nuts

VENTING

Correct vent pipe diameter and length (according to CSA tables) Vent connection size Correct venting material (according to CSA tables) Correct lining for masonry chimneys Adequate clearance from combustibles Proper negative pressure reading in the vent Vent pipe secured to induced draft blower housing

COMBUSTION AIR

Proper source of combustion air Optional attic combustion air pull Correct combustion air opening size Non-attic combustion air pull

FURNACE INSTALLATION

Adequate clearance from combustibles Adequate clearance for service Proper air temperature rise (See furnace rating plate) External static pressure inches w.c. Correct filter(s) Correct cooling coil or accessories (if equipped) Adequate supply and return air ducting ReturnAir Duct Size SupplyAir Duct Size Air ducts sealed to prevent leakage

Page 6

GENERAL INFORMATION

The RGPE/RGLE series furnaces are design certified by CSA for use with natural and propane gasesas follows:

As a CategoryI furnace, it may be vented vertically with type B-1 vent pipe and alsomay be common vented as described in these instructions.

This furnace should be installed in accordancewith the American National Standard Z223.1 - latest edition booklet entitled “National Fuel Gas Code” (NFPA

54) (in Canada, CSAB149.1 and .2 Installation Codes for gas burning appliances), and the requirements or codes of the localutility or other authorityhaving jurisdiction including local plumbing or wastewater codes.

The NationalAppliance Energy ConservationAct (NAECA) of 1987 states that any gas furnace manufacturedafter January 1, 1992, must have a minimumAnnual Fuel Utilization Efficiency (AFUE) of 78%.The higher the AFUE percentage the more usableheat energy the consumer gets for every dollar of fuel purchased.This is similarto the EPA's minimum gas mileage requirement for automobiles. It gives the consumera relativelyeasy way to make direct efficiency comparisons between differentfurnace brands and styles.

A high AFUE value, which translates into a low operating cost, is not the only concern thatconsumers have. Theyalso want a furnace with a reasonable installed cost. They want a furnace that provides them with comfort – their main concern.And they expecta furnace with exceptional reliability and longevity.

Gas furnace manufacturers are always striving to provide consumers with the best furnace value. The Low Profile Furnace addresses all those consumer needs. It gives exceptionalefficiency with a low installationcost. It delivers the comfort the customer wants along with the reliability they expect.

The key to all these customer benefits is the furnace's heat exchanger.The materialsused to construct the furnace in general and the heatexchanger in particular make it a rugged,long lasting unit. The unique heat exchanger design provides the customer with a furnace only 34 inches high.This gives the consumer a unit easily installed in almost every location that accepts all customary accessories.

With the introduction of higherefficiency furnaces, special attention mustbe paid to the venting system.Only listed venting systems may be used as stated in the installation instructions and the National

Fuel Gas Code, ANSI Z223.1 (NFPA 54), or the Canadian CAN/CGA B149.1 and B149.2 InstallationCodes for Gas Burning Appliances.Sincefurnace tech-

nology and ventingrequirements are changing, awarenessof local, state, and federal codes and industry changes is imperative.

NOTE: Always perform a proper heat loss calculation beforespecifying the furnace size. This ensures that the furnace is sized to adequately, economically, heat the building and provide the correct airflow for yourapplication.

IMPORTANT:PROPERAPPLICATION, INSTALLATION AND MAINTENANCE OF THIS FURNACE ISA MUST IF CONSUMERSARE TO RECEIVE THE FULLBENEFITS FOR WHICH THEY HAVE PAID.

Additionalhelpful publications available from the “NationalFire Protection Association” are: NFPA-90A– Installation ofAir Conditioning and Ventilating Systems 1985 or latestedition.NFPA90B – WarmAir Heating and Air Conditioning Systems 1984.

Thesepublications are availablefrom:

National Fire Protection Association,

Inc. Batterymarch Park Quincy, MA 02269

CSA-INTERNATIONAL 178 Rexdale Blvd. Etobicoke (Toronto), Ontario Canada M9W, 1R3

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.

FIGURE 1

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

Proper balance and sealing of the duct system improves the efficiency of the heating and air 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 SPACETHROUGH LEAKING DUCTS AND UNBALANCED DUCT SYSTEMS CAUSING PERSONAL INJURY OR DEATH (SEE FIGURE 1).

• 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

Page 7

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.

NOTICE

IN COMPLIANCE WITH RECOGNIZED CODES, IT IS RECOMMENDEDTHAT AN AUXILIARY DRAIN PAN BE INSTALLED UNDER ALL EVAPORATOR COILS OR UNITS CONTAINING EVAPORATOR COILS OR GAS FURNACES USED WITH EVAPORATOR COILS THAT ARE LOCATED IN ANY AREA OF A STRUCTURE WHERE DAMAGETO 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.

RECEIVING

Immediately upon receipt, all cartons and contents should be inspected for transit damage. Units with damaged cartons should be opened immediately. 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 editions are available from: “National Fire Protection Association, Inc., Batterymarch Park, Quincy, MA 02269.” These publications are:

• ANSI/NFPANo. 70-(Latest Edition) National Electrical Code.

• NFPA90AInstallation of Air Conditioning and Ventilating Systems.

• NFPA90B Installation of warm air heating and air conditioning systems.

• The equipment has been evaluated in accordance with the Code of Federal Regulations, Chapter XX, Part 3280.

LOCATION REQUIREMENTS AND CONSIDERATIONS

GENERAL INFORMATION

1. NOTE: This furnace is shipped with heat exchanger support brackets installed under the back of the heat exchanger.These may be removed before installation, but it is not required.

LOCATION

WARNING

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

2. IMPORTANT: This furnace is not approved or recommended for installation on its back, with access doors facing upwards.

3. This furnace is suitable for installation in buildings constructed on-site. This heating unit should be centralized with respect to the heat distribution system as much as practicable.

4. NOTE: These furnaces are approved for installation in attics, as well as alcoves, utility rooms, closets and crawlspaces.

5. IMPORTANT: Support this unit when

installed.Forattic or crawl space installation, horizontal furnaces may be installed on combustible wood flooring or by using support brackets. See Figure 2.

FIGURE 2

HORIZONTAL FURNACE INSTALLEDW/SUPPORT BRACKETS

EXHAUST VENT

NOTE: Do not block furnace access with support rods. Maintain clearances recommended in Figure 3. Allow enough space for proper service maintenance or replacement of the heat exchanger and blower assembly.

6. IMPORTANT: If installing in a util-

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

a. allow the largest part of the furb. allow any other appliance

nace to pass; or (such as a water heater) to

pass.

ST-A0799-01

Page 8

FIGURE 3

UPFLOW/HORIZONTAL DIMENSIONS

Ship.

/32

REDUCED CLEARANCE (IN.)

Back Top Front Vent

Left Right

A B C D E F

/16

➂ May be 1” with type B vent.

➀ May require 3” to 4” or 3” or 5” adapter.

➁ May be 0” with type B vent.

/2 0 3➁ 0 1 3 6➂ 105 lbs.

/2 0 3➁ 0 1 3 6➂ 115 lbs.

/2 0 0 0 1 3 6➂ 120 lbs.

/8 ➀ 15 2

/32 12

/2 16

/2 0 0 0 1 3 6➂ 140 lbs.

/2 2

/8 ➀ 15 2

/8 ➀ 18

/8 ➀ 22 2

/32 12

/32 14

/32 15

/2 16

/2 23

/16

/32

/16

ALTERNATE

GAS CONNECTION

/8 DIA.

OPTIONAL RETURN AIR CUTOUT

(EITHER SIDE) FOR USE WITH

EXTERNAL SIDE FILTER FRAME*

/32

RIGHT SIDE

FRONT

CLEARANCE TO COMBUSTIBLE MATERIAL (INCHES)

UPFLOW/HORIZONTAL MODELS

BOTTOM

TOP

RGPE Side Side Wgts.

Model

05 17

07(A) 17

/32

AIR

RETURN

AIR

SUPPLY

25.406

12 24

07(B),10 21 19

/32

SIGHT

GLASS

*Both sides for 1800 CFM or above.

AIRFLOW

/32

/16

GAS CONNECTION

LOW VOLTAGE

ELECTRICAL CONNECTION

OPTIONAL RETURN AIR CUTOUT

(EITHER SIDE) FOR USE WITH

EXTERNAL SIDE FILTER FRAME*

LEFT SIDE

IMPORTANT: This furnace is not approved or recommended for

installation on its back, with access doors facing upwards.

Page 9

FIGURE 4

DOWNFLOW DIMENSIONS

Ship.

Back Top Front Vent

REDUCED CLEARANCE (IN.)

/16

➂ May be 1” with type B vent.

➀ May require 3” to 4” or 3” or 5” adapter.

➁ May be 0” with type B vent.

/8 DIA.

/16

/8 DIA.

Left Right

A B C D E

CLEARANCE TO COMBUSTIBLE MATERIAL (INCHES)

Model

DOWNFLOW MODELS

RGLE Side Side Wgts.

/16

/8 0 0 0 1 3 6➂ 140 lbs.

/8 0 3➁ 0 1 3 6➂ 105 lbs.

/8 0 0 0 1 3 6➂ 120 lbs.

/8 ➀ 23

/8 ➀ 16

/8 ➀ 20

/32 12

/32 13

/32 15

/2 16

/2 23

12 24

07(A) 17

07(B),10 21 19

R.A.

SIGHT

GLASS

AIRFLOW

S.A.

AIR

SUPPLY

/16

TOP BOTTOM

AIR

RETURN

LOW VOLTAGE

/16

GAS CONNECTION

ELECTRIC CONNECTION

NOTE: IN DOWNFLOW CONFIGURATION, OPTIONAL AIR CUTOUT IS NOT PERMITTED.

COMBUSTIBLE FLOOR BASE REQUIRED IF FURNACE IS NOT INSTALLED ON COIL BOX.

Page 10

CLEARANCE – ACCESSIBILITY

The design of forced air furnaces with input ratings as listed in the tables on the following pages are certified by CSA 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.

ACCESSIBILITY CLEARANCES, WHERE GREATER, MUST TAKE PRECEDENCE OVER FIRE PROTECTION CLEARANCES.

WARNING

UPFLOW AND HORIZONTAL FURNACES MUST NOT BE INSTALLED DIRECTLY ON CARPETING, TILE OR OTHER COMBUSTIBLE MATERIAL OTHER THAN WOOD FLOORING. INSTALLATION ON A COMBUSTIBLE MATERIAL CAN RESULT IN FIRE CAUSING PROPERTY DAMAGE, SEVERE PERSONAL INJURY OR DEATH.

A gas-fired furnace for installation in a residential garage must be installed so that the burner(s) and the ignition source are located not less than 18” above the floor and the furnace is located or protected to avoid physical damage by vehicles.

WARNING

DOWNFLOW UNIT DESIGN IS CERTIFIED FOR INSTALLATION ON NONCOMBUSTIBLE FLOOR. A SPECIAL COMBUSTIBLE FLOOR SUB-BASE, FIGURE 5, IS REQUIRED WHEN INSTALLING ON A COMBUSTIBLE FLOOR. FAILURETO INSTALLTHE SUB-BASE MAY RESULT IN FIRE, PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.THIS SPECIAL BASE IS OFFERED AS AN ACCESSORY FROM THE FACTORY. SEE THE CLEARANCE LABEL LOCATED INSIDE THE FURNACE FOR THE APPROPRIATE MODEL NUMBER.

THE SPECIAL BASE IS NOT REQUIRED WHEN THE FURNACE IS INSTALLED ON TOP OF AN AIR CONDITIONING PLENUM.

SITE SELECTION

1. Select a site in the building near the center of the proposed, or existing, duct system.

2. Give consideration to the vent system piping when selecting the furnace location. Be sure the venting system can travel from the furnace to the termination with minimal length and elbows.

3. Locate the furnace near the existing gas piping. Or, 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 combustibles as shown in Figures 3 and 4.

CAUTION

WHEN COILS ARE INSTALLED ABOVE A FINISHED CEILING OR LIVING AREA, IT IS RECOMMENDED THAT AN AUXILIARY SHEET METAL CONDENSATE DRAIN PAN BE FABRICATED AND INSTALLED UNDER ENTIRE UNIT. FAILURETO DO SO CAN RESULT IN PROPERTY DAMAGE. RUN CONDENSATETO A LOCATION WHERE IT IS NOTICEABLE.

WARNING

COMBUSTIBLE MATERIAL MUST NOT BE PLACED ON OR AGAINST THE FURNACE JACKET OR WITHIN THE SPECIFIED CLEARANCES OF THE VENT PIPE. 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 AROUNDTHE FURNACE JACKET CAN CAUSE AN EXPLOSION OR FIRE RESULTING IN PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.THE FURNACE OWNER SHOULD BE CAUTIONED THATTHE FURNACE AREA MUST NOT BE USED AS A BROOM CLOSET OR FOR ANY OTHER STORAGE PURPOSES.

DUCTING

Proper air flow is required for the correct operation of this furnace. Too little air flow can cause erratic operation and can damage the heat exchanger. The duct system must carry the correct amount of air for heating and cooling. Position the unit to minimize long runs or runs with many turns and elbows.

Size and install the ducts according to acceptable industry standards and methods. The total static pressure drop (including evaporator coil, if used) of the entire system should not exceed 0.8” w.c. adequate space for unit filter. NOTE: Airflow external static pressure measurements do not include filter or coil.

IMPORTANT: Some high efficiency filters have a greater than normal resistance to air flow.This can adversely affect furnace operation. BE SURE TO CHECK AIR FLOW if using any filter other than the factory-provided filter.

NOTE: DO NOT take return air from bathrooms, kitchens, furnace rooms, garages, utility or laundry rooms, or cold areas.

IMPORTANT: Return air tempera- ture must be above 55°F during the heating season.

WARNING

NEVER ALLOW PRODUCTS OF COMBUSTION OR THE FLUE PRODUCTSTO ENTER THE RETURN AIR DUCTWORK, OR THE CIRCULATING AIR SUPPLY. ALL RETURN DUCTWORK MUST BE ADEQUATELY SEALED AND SECURED TO THE FURNACE WITH SHEET METAL SCREWS, AND JOINTS TAPED.WHEN A FURNACE IS MOUNTED ON A PLATFORM,WITH RETURN THROUGHTHE BOTTOM, IT MUST BE SEALED AIRTIGHT BETWEEN THE FURNACE AND THE RETURN AIR PLENUM. THE RETURN AIR PLENUM MUST BE PERMANENTLY ENCLOSED. NEVER USE A DOOR AS A PART OF THE RETURN AIR PLENUM. THE FLOOR OR PLATFORM MUST PROVIDE SOUND PHYSICAL SUPPORT OF THE FURNACE, WITHOUT SAGGING, CRACKS, GAPS, ETC., AROUND THE BASE AS TO PROVIDE A SEAL BETWEEN THE SUPPORT AND THE BASE.

Be sure to have

Page 11

FAILURE TO PREVENT PRODUCTS OF COMBUSTION FROM BEING CIRCULATED INTO THE LIVING SPACE CAN CREATE POTENTIALLY HAZARDOUS CONDITIONS, INCLUDING CARBON MONOXIDE POISONING THAT 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.

WARNING

BLOWER AND BURNERS MUST NEVER BE OPERATEDWITHOUT THE BLOWER DOOR IN PLACE.THIS IS TO PREVENT DRAWING GAS FUMES (WHICH COULD CONTAIN HAZARDOUS CARBON MONOXIDE) INTOTHE HOME THAT COULD RESULT IN PERSONAL INJURY OR DEATH.

UPFLOW UNITS

1. Set furnace in place and connect the return duct or return air cabinet to unit. Make the connection air-tight to prevent entraining combustion gases from any adjacent fuel-burning appliances. Unit return air may be connected on the sides or bottom of the return air compartment.

a. Openings in the side must be cut

out the full width of the knockouts on the unit. If using side return air,

THE BOTTOM base plate must be installed.

NOTE: Where the maximum airflow

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

b. If using bottom return air, place fur-

nace over return air plenum and seal furnace bottom to return air plenum.

WARNING

A SOLID METAL BASE PLATE, (SEE TABLE 1) MUST BE IN PLACE WHEN THE FURNACE IS INSTALLED WITH SIDE AIR RETURN DUCTS. FAILURE TO INSTALL A BASE PLATE COULD CAUSE PRODUCTS OF COMBUSTION TO BE CIRCULATED INTO THE LIVING SPACE AND CREATE POTENTIALLY HAZARDOUS CONDITIONS, INCLUDING CARBON MONOXIDE POISONING OR DEATH.

TABLE 1

FURNACE BASE BASE

WIDTH PLATE NO. PLATE SIZE

/2” RXGB-D17 151/8” x 239/16”

21” RXGB-D21 18

/2” RXGB-D24 255/8” x 239/16”

/8” x 239/16”

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

3. Connect the supply air plenum to the furnace plenum opening, or indoor coil.

NOTE: The RGLE has louvers to cool the inducer motor bearings.

DOWNFLOW UNITS

WARNING

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

FIGURE 5

COMBUSTIBLE FLOOR BASE (RXGC-B17, -B21, -B24)

1. Position the unit over the supply air plenum and connect.

a. If installing on a combustible

floor and not using an evapo- rator coil box, install the special combustible floor base. See Figure 5.

b. If summer air conditioning is

desired, position the indoor coil on the supply air side. Insure that no air can bypass this coil.

2. Connect the return air ducting to the return air opening at the top of the unit. Make the connection air tight to prevent entraining combustion gases from an adjacent fuel-burning appliance.

HORIZONTAL UNITS

1. Unit can be mounted left or right side airflow configuration.

2. Position the unit on adequate supports or by using support brackets (see Figure 2) and connect supply plenum and return.

3. 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.

4. Secure the four angle brackets shipped with the unit to the return air opening. See Figure 6. Connect the return air ducting to the return air opening at the top of the unit. Make the connection air tight to prevent entraining combustion gases from an adjacent fuel-burning appliance.

Page 12

FIGURE 6

HORIZONTAL RETURN AIR DUCT (LEFT-HAND AIRFLOW POSITION SHOWN)

AIRFLOW

RETURN

REAR VIEW

FOUR ANGLE BRACKETS ARE SHIPPED WITH EACH UNIT THAT CAN BE USED TO SECURE THE RETURN AIR DUCT TO A HORIZONTAL UNIT.

COMBUSTION AND VENTILATION AIR

IMPORTANT: This is not a direct vent furnace. Review venting instructions before installing.

• 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 may also require OUTDOOR AIR for combustion:

• Permanent wave solutions

• Chlorinated waxes and cleaners

• Chlorine-based swimming pool

chemicals

• Water softening chemicals

• De-icing salts or chemicals

• Carbon tetrachloride

• Halogen type refrigerants

• Cleaning solvents (such as

perchloroethylene)

• Printing inks, paint removers,

varnishes, etc.

• Hydrochloric acid

• Cements and glues

• Antistatic fabric softeners for

clothes dryers

• Masonry acid washing materials

WARNING

THIS FURNACE AND ANY OTHER FUEL-BURNING APPLIANCE MUST BE PROVIDED WITH ENOUGH FRESH AIR FOR PROPER COMBUSTION AND VENTILATION OF THE FLUE GASES. MOST HOMES WILL REQUIRETHAT OUTSIDE AIR BE SUPPLIED INTO THE FURNACE AREA. FAILURETO DO SO CAN CAUSE DEATH FROM CARBON MONOXIDE POISONING.

Adequate facilities for providing air for combustion and ventilation must be provided in accordance with section

5.3, Air for Combustion and Ventilation, of the National Fuel Gas Code, ANSI, Z223.1 latest edition or CSA B149.1 and .2 or, applicable provisions for the local building codes, and not obstructed so as to prevent the flow of air to the furnace.

COMBUSTION AIR REQUIREMENTS

IMPORTANT: Air for combustion and ventilation must not come from a corrosive atmosphere. Any failure due to corrosive elements in the atmosphere is excluded from warranty coverage.

The following types of installation may require OUTDOOR AIR for combustion, due to chemical exposures:

FIGURE 7

AIR FROM HEATED SPACE

Page 13

Combustion air must be free of acid forming chemicals; such as sulphur, fluorine and chlorine. These elements are found in aerosol sprays, detergents, bleaches, cleaning solvents, 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 are highly corrosive after they condense.

WARNING

ALL FURNACE INSTALLATIONS MUST COMPLYWITH THE NATIONAL FUEL GAS CODE AND LOCAL CODES TO PROVIDE ADEQUATE COMBUSTION AND VENTILATION AIR FOR THE FURNACE. FAILURE TO DO SO CAN CREATE HAZARDOUS CONDITIONS RESULTING IN PROPERTY DAMAGE, BODILY INJURY OR DEATH FROM SMOKE, FIRE OR CARBON MONOXIDE.

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. See Figures 7 and 8.

EXAMPLE 1. FURNACE LOCATED IN AN 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 appli ances

in the space. Here are a few

examples of the room sizes required for different inputs. The sizes are based on 8 foot ceilings.

BTUH Minimum Sq. Feet Typical Room Size

Input With 8' Ceiling With 8' Ceiling

50,000 312 14*x24* or 18*x18*

75,000 469 15*x31* or 20*x24* 100,000 625 20*x31* or 25*x25* 125,000 833 23*x34* or 26*x30*

If the open space containing the furnace is in a building with tight construction (contemporary construction), outside air may still be required for the furnace to operate and vent properly. Outside air openings should be sized the same as for a confined space.

FIGURE 8

AIR FROM ATTIC/CRAWL SPACE

EXAMPLE 2. FURNACE LOCATED IN A CONFINED SPACE

A confined space (any space smaller than shown above 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. Size the openings by how they are connected to the heated area or to the outside, and by the input of all appliances in the space.

If confined space is within a building with tight construction, combustion air must be taken from outdoors or area freely communicating with the outdoors.

A. USING INDOOR AIR FOR COM-

BUSTION, ALL OF THE MODELS

IMPORTANT: Air should not be taken 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 heat-

ed area, 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. Here are some examples of typical openings required.

Btuh Free Area

Input Each Opening

100,000 100 Square Inches

AIR INTAKE PIPE CONNECTION (RGPE UPFLOW/HORIZONTAL ONLY)

A double-elbow may be installed to top inlet air opening, BUT IS NOT REQUIRED.This will help to prevent accidental blockage of the intake opening. Reference Figure 9 for proper elbow diameter.

NOTE: Inlet is specifically designed

to prevent material from being pulled into furnace. If elbows are not used, the intake opening must be kept clean and free of debris.

It is also acceptable to run the condensate drain (or refrigerant) line access over the air intake hole as long as a 1" minimum clearance is maintained.

B. USING OUTDOOR AIR FOR

COMBUSTION, ALL OF THE MODELS

IMPORTANT: Never take com- bustion air from an attic space that is equipped with power ventilation.

The confined space must communicate with the outdoors according to Methods 1 and 2. The minimum air opening dimension shall not be less than 3 inches. When using ducts, they shall be of the same cross-sectional area as the free area of the openings to which they connect.

Page 14

FIGURE 9

COMBUSTION AIR FITTING – NON-ATTIC COMBUSTION AIR PULL, RGPE ONLY

ATTACH OPTIONAL DOUBLE ELBOW TO TOP INLET AIR OPENING TO PREVENT ACCIDENTALBLOCKAGE OF INTAKE OPENING. THIS IS NOT A REQUIREMENT. (SEE PREVIOUS PAGE.) SINGLE ELBOW IS ALLOWED BUT MAY NOT PREVENT DEBRIS FROM BEING DROPPED INTO THE FURNACE.

EXHAUST

PVC DOUBLE ELBOW

6" MININUM CLEARANCE

#8 SCREWS

6" MIN.

GROUND OR SHELF SURFACE

NOTE: PREDRILL HOLES FOR SCREWS TO PREVENT CRACKING.

METALFLUE PIPE ONLY

#8 SCREWS

B: Method 1 Provide two permanent openings,

one located within 12 inches of the top and one located within 12 inches of the bottom of the enclosure. Each opening shall communicate directly, or by ducts, with the outdoors or spaces (crawl or attic) that freely communicate with the outdoors.

a. Where directly communicating

with the outdoors or where communicating to the outdoors through VERTICAL DUCTS, each opening shall have a minimum free area of 1 square inch for each 4000 BTUH of total appliance input rating in the enclosure. Here are typical duct sizes:

VERTICAL OUTDOOR AIR OPENING DIMENSIONS

BTUH Free Area Round

Input Each Opening Pipe Size

50,000 12.50 sq. inches 4”

75,000 18.75 sq. inches 5” 100,000 25.00 sq. inches 6” 125,000 31.25 sq. inches 7”

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 for all equipment in the enclosure. Here are typical duct sizes:

HORIZONTAL OUTDOOR AIR OPENING DIMENSIONS

BTUH Free Area Round

Input Each Opening Pipe Size

50,000 25.00 sq. inches 6”

75,000 37.50 sq. inches 7” 100,000 50.00 sq. inches 8” 125,000 62.50 sq. inches 9”

B: 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 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, AND

b. Not less than the sum of the

areas of all vent connectors in the confined space.

IMPORTANT: If the furnace is in a location with an exhaust fan, there must be sufficient ventilation to prevent the exhaust fan from creating a negative pressure in the room.

Combustion air openings must NOT BE RESTRICTED in any manner.

CONSULT LOCAL CODES FOR SPECIAL REQUIREMENTS.

Page 15

B: Method 3, RGPE only For the optimum in quiet operation, attic

air may be brought directly to the furnace.

IMPORTANT: In applications using Method 3 for combustion air, the attic must be ventilated by gable or soffit vents. See Figure 8.

It is not required to provide any permanent openings as described in Method 1

or Method 2.

CAUTION

COMBUSTION AIR INTAKES CANNOT BE TERMINATED OUTSIDE. DOING SO CAN CAUSE IMPROPER

FIGURE 10

OUTSIDE AIR USING A HORIZONTAL INLET & OUTLET

OPERATION OF THE FURNACE

If attic combustion air is used, the inlet air opening at the furnace must be protected from accidental blockage. Install a 90° elbow pointing horizontally at the top of inlet air pipe. See Figure 11 (maximum of 2, 22

⁄2°, 45° or 90°

elbows, allowed).

NOTE: Maximum length of pipe that may be used for combustion air is 10 feet with two elbows. Lengths of more than 10 feet can result in nuisance pressure switch trips.

FIGURE 11

COMBUSTION AIR FITTING – OPTIONAL ATTIC COMBUSTION AIR PULL, RGPE ONLY

ATTACH A 90° ELBOW TO TOP INLET AIR OPENING TO PREVENT ACCIDENTALBLOCKAGE OF INTAKE OPENING.

PVC ELBOW

EXHAUST

ATTIC SPACE

METALFLUE PIPE ONLY

INDOOR SPACE

10 FT. MAX.

CAUTION

12" MIN. FROM TOP OF INSULATION

INCLUDING HORIZONTALDIRECTION

#8 SCREW

INSULATION

6" MINIMUM CLEARANCE

PVC COUPLER

USE OF SHEET METAL AIR INTAKE PIPE INSTEAD OF PVC MAY RESULT IN NOISE ISSUES.

NOTE: PREDRILL HOLES FOR SCREWS TO PREVENT CRACKING.

#8 SCREWS

Page 16

VENTING

GENERAL INFORMATION

The furnace must be vented in accordance with these instructions, National Fuel Gas Code, ANSI Z223.1 and/or the Natural Gas Installation Code, CSAB149.1 & .2 and requirements or codes of the local utility or other authority having jurisdiction.

WARNING

DEVICES ATTACHED TOTHE FLUE OR VENT FOR THE PURPOSE OF REDUCING HEAT LOSS UP THE CHIMNEY HAVE NOT BEEN TESTED AND HAVE NOT BEEN INCLUDED IN THE DESIGN CERTIFICATION OF THIS FURNACE. WE, THE MANUFACTURER, CANNOT AND WILL NOT BE RESPONSIBLE FOR INJURY OR DAMAGE CAUSED BYTHE USE OF SUCH UNTESTED AND/OR UNCERTIFIED DEVICES, ACCESSORIES OR COMPONENTS.

DRAFT INDUCER

WARNING

VENT PIPE ATTACHING HOLES MUST BE PREDRILLED IN THE DRAFT INDUCER COLLAR TO PREVENT DAMAGINGTHE INDUCER. DRILL 1/8” DIAMETER HOLES THROUGHTHE VENT PIPE AND COLLAR AND USE #8 SCREWS TO ATTACH. SEE FIGURE 12. FAILURE TO FOLLOWTHIS WARNING CAN CAUSE RECIRCULATION OF FLUE PRODUCTS CAUSING CARBON MONOXIDE POISONING RESULTING IN PERSONAL INJURY OR DEATH.

FIGURE 12

ATTACHINGTO DRAFT INDUCER COLLAR

FURNACE CATEGORY INFORMATION

This furnace is shipped as a Category I type induced draft furnace. A Category I furnace operates with a nonpositive vent pressure and has a vent gas temperature at least 140°F above the dew point of the vent gases. A Category I type may be a draft hood equipped furnace or have a fan assisted combustion system (induced draft). The inducer is used to pull flue products through the combustion chamber and as they leave the furnace, most of the energy has been dissipated. The buoyant effect of the flue gases provides venting to the outdoors.

During the off cycle, the inducer is off and there is very little flow through the vent, cooling the vent. During the on cycle there is no dilution airflow, as with a draft hood type furnace. Although the vent heats up rapidly without dilution air, the flue products contain more water vapor, which results in a higher dew point temperature. It is most important that you follow the guidelines in these instructions to prevent the possible formation of condensation in the venting system.

As a Category I furnace it may be vented vertically with type B-1 vent pipe and also may be common vented, as described in these instructions.

A0991-01

IMPORTANT APPLICTION NOTES

When the furnace is used as a replacement, the existing vent system should be inspected to assure that there are no obstructions, blockage, or any signs of corrosion and is properly sized for use with this furnace.

NOTE: When the vent table permits more than one diameter of pipe for a connector or vent, the smallest permitted diameter must be used.

Vent pipe may be type “B-1,” either rigid or suitable flexible construction that carries a u.l. listing.

Common venting is allowed with vertical B-1 vent systems, and lined masonry chimneys. Follow the National Fuel Gas Code, ANSI Z223.1 and/or the Natural Gas Installation Code, CSA-B149.1 & .2 for proper installation practices.

NOTE: Follow combustion air instructions as outlined in this manual.

Single wall vent connectors to “B-1 vent or masonry chimneys” may be used under the guidelines of the National Fuel Gas Code, ANSI Z223.1 and/or the Natural Gas Installation Code, CSA-B149.1 & .2.

The entire length of the vent connector shall be readily accessible for inspection, cleaning and replacement.

Page 17

“B-1” VERTICAL VENTING

Type “B-1” vents must be installed in accordance with the terms of their listings and the vent manufacturer’s instructions.

“B-1” vents must be supported and spaced in accordance with their listings and the manufacturer’s instructions. All vents must be supported to maintain their minimum clearances from combustible material.

VERTICAL VENTING

Categorized

Input Size Required

50K 3”

75K *4” 100K *4” 125K *5”

*NOTE: All furnaces have a 3” vent connection as shipped from the factory. A 3” to 4” or 3” to 5” vent transition is required on all but the 50,000 BTUH models when vertically vented or common vented with metal vent pipes. THE VENT TRANSITION CONNEC-

TION MUST BE MADE ATTHE FURNACE VENT EXIT. It must originate with an adapter

if required, at the furnace flue collar and terminate either in a listed cap or roof assembly. When common venting, the vent connector size may differ from the above diameters depending on application. See ANSI Z21.47-1993/CSA-2.3-M93 or latest edition tables.

VERTICAL VENT SYSTEMS:

1. A gas vent shall terminate above the roof surface with a listed cap or listed roof assembly. Gas vents 12 inches in size or smaller with listed caps shall be permitted to be terminated in accordance with Figure 13, provided they are at least 8 feet from a vertical wall or similar obstruction. All other gas vents shall terminate not less than 2 feet above the highest point where they pass through the roof and at least 2 feet higher than any portion of a building within 10 feet.

2. A type B-1 gas vent shall terminate at least 5 feet in vertical height above the highest connected equipment draft hood or flue collar.

3. Must rise

/4” per foot away from the furnace on horizontal runs and be supported with straps or hangers so it has no sags or dips. Supports at 4 foot intervals and at all elbows are recommended.

4. The vent connector must be mechanically fastened to the outlet collar of the furnace with at least (2) sheet metal screws except vent connectors that are B-1 material. These shall be assembled in accordance with the manufacturer’s instructions. See Figure 12.

Furnace Vent

FIGURE 13

TYPICAL VENTING WITH “B-1”VENT

5. Any angle greater than 45 degrees from the vertical is considered horizontal. The total horizontal distance of a vent plus the horizontal vent connector serving draft-hood equipped appliances shall not be greater than 75 percent of the vertical height of the vent.

NOTE: Refer to the National Fuel Gas Code, ANSI Z223.1 and/or the Natural Gas Installation Code, CSA-B149.1 & .2.

Single appliance venting of a fan assisted furnace into a tile-lined masonry chimney is prohibited. The chimney must be lined with either Type B vent or with a listed, single wall, metal lining system. Reference National Fuel Gas Code, ANSI Z223.1 and/or the Natural Gas Installation Code, CSA-B149.1 & .2. See Figure 14 for typical B-1 vent chase.

WARNING

DO NOT CONNECT THIS FURNACETO A CHIMNEY USED TO VENT A SOLID FUEL APPLIANCE (WOOD OR COAL).VENTING WITH A SOLID FUEL APPLIANCE CAN LEAD TO IMPROPER FUNCTIONING OF THE UNIT, AND DUE TO SOOTING,THE POSSIBILITY OF FIRE RESULTING IN PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.

SPECIAL VENT SYSTEMS (SVS)

IMPORTANT: It is THE FURNACE MANUFACTURER’s position now that new pipe used in a category III vent application, including Selkirk’s Selvent™ II HTPV product, should cease immediately.

installations of any HTPV

Page 18

POWER VENT SYSTEMS

When vertical venting is not possible, the only acceptable method for horizontal venting is with the use of Tjernlund model GPAK-1TR or Field Controls models SWG-4R power venter. Type B vent pipe and fittings must be used. Common venting is not permitted

All application and installation instructions supplied with the power venter must be followed.

Please address all questions regarding power venter installation, agency listings and furnace model compatibility to:

Tjernlund Products, Inc. (800) 255-4208 or (612) 426-2993

Field Controls L.L.C. (800) 742-8368 or (919) 522-0214

RXGW-B01 CHIMNEY ADAPTER

IMPORTANT: CHIMNEY ADAPTER IS CERTIFIED FOR USE ON UPFLOW (RGPE) ONLY.

This appliance is CSA certified for use with RXGW-B01 Chimney Adapter. Refer to Kit Installation Instructions 92-101682-01.

EXISTING VENT SYSTEMS

IMPORTANT RETROFIT VENTING INSTRUCTIONS

If this furnace is a replacement installation, ALWAYS INSPECT the existing vent system to be sure there are no obstructions, blockages, or signs of corrosion.

When the existing furnace is removed from a venting system serving other appliances, the venting is likely to be too large to properly vent the remaining attached appliances.

The following steps shall be followed with each appliance that remains connected to the common venting system, while the other appliances that remain connected to the common venting systems are not in operation.

NOTE:When the vent table permits more than one diameter of pipe for a connector or vent, the smallest permitted diameter must be used.

1. Seal any unused openings in the common venting system.

2. Visually inspect the venting system for 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. Insofar as is 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 common venting system. Turn on any exhaust fans, such as range hoods and bathroom 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 that 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, the common venting system must be resized. Refer to National Fuel Gas Code, ANSI Z223.1 and/or the Natural Gas Installation Code, CSA-B149.1 & .2.

FIGURE 14

DEDICATED VENTING THROUGH CHIMNEY WITH “B-1”VENT

Page 19

GAS SUPPLY AND PIPING

GAS SUPPLY

WARNING

THIS FURNACE IS EQUIPPED ATTHE FACTORY FOR USE ON NATURAL GAS ONLY. CONVERSIONTO LP GAS REQUIRES A SPECIAL KIT AVAILABLE FROMTHE DISTRIBUTOR. FAILURETO 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, changes 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. In the commonwealth of Massachusetts, installation must be performed by a licensed plumber or gas fitter for appropriate fuel.

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 detector manufacturer’s recommendations and/or local laws, rules, regulations or customs.

FIGURE 15

GAS PIPING INSTALLATION

MANUAL GAS VALVE

(IN CLOSED POSITION)

4 TO 5 FEET

ABOVE FLOOR

REQ'D BY SOME

UTILITIES

DRIP LEG

4 TO 5 FEET

ABOVE FLOOR

REQ'D BY SOME

UTILITIES

DRIP LEG

GAS PIPE INSTALLATION

UPFLOW & DOWNFLOW

UNION

HORIZONTAL

MANUAL GAS VALVE (IN CLOSED POSITION)

FLAME SENSOR

BURNERS

FLAME SENSOR

DUCT

UNION

GAS VALVE

MANIFOLD

DIRECT SPARK IGNITOR

GAS PIPING (SEE FIGURE 15)

Install the gas piping according to all local codes, state codes and regulations of the utility company, whichever holds jurisdiction.

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 manual gas

valve must be adequate in size to prevent undue pressure drop and never smaller than the pipe size to the combination gas valve on the furnace. Refer to Table 2 for the recom-

mended pipe size for natural gas and Table 3 for LP gas pipe sizes.

IMPORTANT: It is permissible to run flexible gas connector inside the unit to a piece of black pipe. If local codes

DIRECT SPARK IGNITOR

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 limits flexible gas connectors to a maximum of 36”.

Install a ground joint union outside the cabinet to easily remove the control valve assembly. Install a manual shut-off valve in the gas line outside the cabinet. The valve should be readi-

ly accessible to turn the gas 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.

MANIFOLD

GAS VALVE

IMPORTANT: When making gas pipe connections, use a back-up wrench to prevent any twisting of the control assembly and gas valve.Do not overtighten the connection.

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

IMPORTANT: ENSURE that the fur- nace gas control valve not be subjected to high gas line supply pressures.

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

testing that exceeds 1/2 PSIG (14” W.C.) (3.48 kPa).

Page 20

GAS PRESSURE

IMPORTANT: Natural gas supply pressure should operate between 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.

NOTE: Do not exceed a gas pressure of 13” w.c.

WARNING

ELEVATIONS ABOVE 2000 FT REQUIRETHATTHE FURNACE INPUT RATING BE ADJUSTED ANDTHAT THE SIZE OFTHE 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.

WARNING

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

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

LP CONVERSION

NOTE: For installation, see specific LP kit installation instructions. Orifice must be ordered for the correct elevation.

NOTE:Order the correct LP conversion kit from the local distributor. Furnace conversion to LP gas must be performed by a qualified technician.

More information found in the high altitude and orifice section.

NOx MODELS

When converting furnaces equipped with NOx inserts to LP gas, remove the NOx insert assemblies. Steps for removal are listed below:

1. Turn off all electrical power and the gas supply to the furnace.

2. Remove the burner door from the furnace.

3. Remove the igniter assembly –

handle with care.

4. Remove the two screws attaching the NOx insert retainer brackets to the center panel. Pull the retainer rod.

5. Put the two screws back into the holes in the center panel.

6. Re-install the igniter and burner assemblies.

7. Replace burner door.

8. Turn on electrical power and gas supply to the unit.

NOTE:Some NOx models may have one less NOx insert.

Page 21

SETTING GAS PRESSURE

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 90100125 150

1/2 275 189 152 129 114 103 96 89 83 78 69 63 3/4 567 393315 267 237 217 196 182 173 162 146 132

11,071 732 590504 448 409 378 346 322 307 275 252 1-1/4 2,205 1,496 1,212 1,039913 834 771 724 677 630567 511 1-1/2 3,307 2,299 1,858 1,559 1,417 1,275 1,1811,086 1,023 976 866

787

2 6,221 4,331 3,465 2,9922,646 2,394 2,205 2,047 1,9211,811 1,606 1,496

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

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

The maximum gas supply pressure to the furnace should be 10.5” w.c. natural gas, or 13” w.c. LP gas. The minimum supply gas pressure to the gas valve should be 5" w.c. natural gas or 11" w.c. LP gas. A properly calibrated manometer is required for accurate gas pressure measurements.

Supply Gas Pressure Measurement.

A line pressure tap is on the inlet side of the gas valve.

1. With gas shut off to the furnace at the manual gas valve outside the unit, remove the input pressure tap plug.

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

3. Turn on the gas supply and operate the furnace and all other gasfired units on the same gas line as the furnace.

4. Adjust the line gas pressure to supply:

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 pressure tap plug.

7. Turn gas on, and check for leaks.

NATURAL GAS:

If the supply gas line pressure is above the operating range, install an in-line gas regulator to the furnace. If supply gas line pressure is below the operating range, either remove any restrictions in the gas supply piping or enlarge the gas pipe. See Table 2.

LP GAS:

If the supply gas line pressure is above the operating range, have the LP supplier reduce the line pressure at the regulator. If supply gas line pressure is below operating range, have the LP supplier adjust the line pressure at the regulator. See Table 3.

NOTE: Depending on the amount of LP vapor and the outdoor ambient temperature, the LP storage tank may require supplemental heat to maintain proper pressure levels. Ensure LP storage tank does not drop below 15% capacity during heating season.

FIGURE 16

TYPICAL HOSE CONNECTION TO LINE PRESSURETAP

TABLE 2

NATURALGAS 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/FT3)

TABLE 3

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

Page 22

ADJUSTING OR CHECKING FURNACE INPUT

NATURAL GAS:

The maximum gas supply pressure to the furnace should be 10.5” W.C. for natural gas. The minimum gas supply pressure for purposes of input adjustment to the furnace should be 5” W.C.

A properly calibrated manometer or gauge is required for accurate gas pressure readings.

1. When adjusting the furnace input, the high fire input should be checked. The high fire manifold pressure should be 3.5' W.C. Follow these steps to be sure the furnace is high fire mode:

a. With a single stage thermostat,

the furnace runs for 12 minutes on low fire before shifting to high fire. To be certain that it is on high fire, jump terminals “W” and “W2” on the control board in the blower compartment.

b. With a two stage thermostat, set

the thermostat to its highest setting to keep the furnace operating in the high fire mode.

2. To adust high fire manifold pressure, remove the adjustment cover screw on the outlet end of the gas valve and turn the adjustment screw clockwise to increase the pressure and counterclockwise to reduce the pressure. Replace the cover screw securely.

3. The low fire manifold pressure should be 1.7" W.C. As mentioned above, the furnace remains in the low fire mode for 12 minutes upon a heat call with a single stage thermostat. With a two stage thermostat, disconnect the thermostat lead to the “W2” terminal on the control board and the furnace will remain in the low fire mode. To adjust the pressure, remove the regulator cover, on top of the valve, and adjust as noted under Step 2, above. After the adjustment replace the screw cover securely.

NOTE: Use a 3/32⬙ allen wrench for

making the pressure adjustment.

LP GAS:

Furnaces for use on LP gas, the LP gas supply pressure must be set between

11.0” and 13.0” W.C. by means of the tank or branch supply regulators. The furnace manifold pressure should be set at 10” W.C. at the gas control valve. For elevations up to 7,000 feet, rating plate input ratings apply. For high altitudes (elevations 7,000 and over) and for any necessary major changes in the gas flow rate the orifice spud must be changed.

TO CHANGE ORIFICE SPUDS:

1. Shut off the manual main gas valve and remove the gas manifold.

2. Replace the orifice spuds.

3. Reassemble in reverse order.

4. Turn the gas supply back on and check for leaks.

5. Check for proper operation and set to proper manifold pressure.

TABLE 4

METER TIME IN MINUTES AND SECONDS FOR NORMAL

INPUT RATING OF FURNACES EQUIPPED FOR NATURAL OR LP GAS

INPUT

BTU/HR

50,000

75,000

100,000

125,000

150,000

Input BTU/HR =

METER

CU. FT.

SIZE

ONE 15112 1 15 1 18 3 20 TEN 10 50 12 00 12 30 13 12 30 00

ONE 0 44 0 48 0 50 0 53 20 TEN 7 12 80819 8 48 20 0

ONE 0 33 0 36 0 38 0 40 1 30 TEN 5 24 60615 6 36 15 0

ONE 0 26 0 29 0 30 0 32 1 12 TEN 4 19 4 48 50517 12 0

ONE 0 31 0 24 0 25 0 26 10 TEN 3 36 40410 4 20 10 0

Heating Value of Gas (BTU/Ft3) x 3600 x correction factor Time in Seconds (for 1 cu.ft.) of Gas

HEATING VALUE OF GAS BTU PER CU. FT.

900 1000 1040 1100 2500

MIN. SEC. MIN. SEC. MIN. SEC. MIN. SEC. MIN. SEC.

Check of input is important to prevent over firing of the furnace beyond its design-rated input. NEVER SET INPUT ABOVE THAT SHOWN ON THE RATING PLATE.

TO CHECK FURNACE INPUT:

1. Make certain that all other gas appliances are shut off, with the exception of pilot burners.

2. Start the furnace

3. Time the meter to measure the time required to burn one cubic foot of gas.

4. Use Table 4 to determine input rate.

Page 23

ELECTRICAL WIRING

WARNING

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

WARNING

THE CABINET MUST HAVE AN UNINTERRUPTED GROUND ACCORDINGTO 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 CONNECTTHE GROUNDWIRE CAN CAUSE ELECTRICAL SHOCK RESULTING IN PERSONAL INJURY OR DEATH.

ate wiring diagramlocated on the inside cover of the furnacecontrol box and in these instructions.

NOTE:The electrical junction box may be moved to the right sideif necessary. A knockout is provided.Seal the opposite holewith plugprovided.

WARNING

L1TERMINAL AND NEUTRALTERMINAL POLARITY MUST BE OBSERVED WHENMAKINGFIELD CONNECTIONS TOTHE FURNACE. FAILURETO DO SOWILL EXPOSE LIVEWIRING IN THE BLOWER COMPARTMENTWHEN THE DOOR IS REMOVED.TOUCHING THESE LIVE CIRCUITS COULD RESULT IN PERMANENT INJURY OR DEATH FROMELECTRICALSHOCK.

FIGURE 17

JUNCTION BOX LOCATION

UPFLOW/HORIZONTAL

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

Association, Inc. Batterymarch Park Quincy, MA 02269

Canadian StandardsAssociation 178 Rexdale Boulevard Rexdale, Ontario, Canada M9W 1R3

WARNING

THIS FURNACE IS EQUIPPED WITH A BLOWER DOOR SAFETY SWITCH. DO NOT DISABLETHIS SWITCH. FAILURETO FOLLOW THISWARNING 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 furnace rating plate. Maximum over-current protection is 15 amperes.

Use a separate,fused branch electrical circuitcontaininga properly sizedfuse or circuitbreaker. Connect this circuitdirectly fromthe main switchbox to an electrical disconnect that is readily accessible and locatedwithin arm’s reach (2 ft.)of the furnace. Connect fromthe electrical disconnectto the junction boxon the left sideof the furnace, inside the blower compartment. See Figure 17.For the proper connection,refer to the appropri-

DOWNFLOW

Page 24

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 any 120 VAC terminal to any neutral 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 voltage polarity, or phasing, 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 check the building wiring.

ControlVoltage Check

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

2. Call for heat at the thermostat. (Does not include communicating thermostats.)

3. With the unit operating, use a voltmeter to measure the voltage from control voltage terminal “W” to terminal “C” on the furnacecontrol board.

4. The voltage should be a nominal 24 volts (Acceptable 18-30 VAC).

This test should be made with the unit

in full operation.

Page 25

ACCESSORIES

FIELD-INSTALLED OPTION ACCESSORIES

TWINNING: Most installations of (-)GPE/ (-)GLE furnaces cannot be twinned. However, a few exceptions exist for installations with some commercial evaporator coils. Consult the installation instructions of the coil to see if the furnace(s) can be twinned. If so, a twinning kit will be required and the part number for the kit can be found in the installation instructions for the coil.

ELECTRONIC AIR CLEANER

Line voltage power is supplied from the screw terminal “EAC”, see Figure 18, and a line voltageneutral 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 50 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 100 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 furnaceand 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.

FIGURE 18

EAC AND HUMIDIFIER TERMINALS ON FURNACE CONTROL (IFC)

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 19

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)

FIGURE 20

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

An optional 24VAC humidistat can be installed as shown in Figures 19 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

Page 26

FIGURE 21

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

FIGURE 22

HUMIDISTAT USEDTO CONTROL DEHUMIDIFICATION IN COOLING ONLY (NO HUMIDIFIER) (FOR USE WITH NON-COMMUNICATINGTHERMOSTATS)

airflow will be permanently reduced by approximately 15% giving less than optimal performance and possibly causing problems. 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 condensers, 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

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. The latter thermostat should not be used if humidification control is required. To wire the furnace for humidification control using the former thermostat, refer to the wiring diagram in Figure 19(I). Be sure not

to install the

jumper between “R” and “HUM

STAT” on the furnace control. 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 operation during heating, refer to Figure 19 (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 humidification can be accomplished using a humidistat as shown in Figures 20 (II) or 21 (III). These figures show installation of a humidifier with external 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 HUMIDIFICATION 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 27

B2. WITH NON-COMMUNICATING

THERMOSTAT (REQUIRES OPTIONAL HUMIDISTAT).

Control of dehumidification only (no humidification) can be accomplished by installing an optional humidistat as shown in Figure 22 (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 permanently reduced by approximately 15%.

C. HUMIDIFICATION AND DEHUMIFI-

CATION CONTROL (REQUIRES OPTIONAL HUMIDIFIER).

C1. WITH COMMUNICATING

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 control using the former thermostat, refer to the wiring diagram in Figure 19 (I). Be sure not between “R” and “HUM STAT” on the furnace control. Installing this jumper will operate the humidifier any time

to install the jumper

THERMOSTAT AND ACCESSORIES FOR THERMOSTAT

Programmable Communicating:

(-)HC-TST501CMMS

Full-Color, Programmable Communicating:

(-)HC-TST550CMMS

Remote Sensor:

(For Thermostats Above Only)

F1451378

Thermostat Wall Plate ForThermostat HC-TST501CMMS Above Only:

F61-2600

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-COMMUNICATING

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 20 (II) or 21 (III). These figures show installation of a humidifier with external 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.

OTHER ACCESSORIES AVAILABLE

FOSSIL FUEL KIT (non-communicat-

ing systems only)

Use of a heat pump with the two stage furnace requires a heat pump thermostat used in conjunction with the fossil fuel kit. For proper operation use the following procedures:

a. With the RXPF-F01 kit, connectthe

thermostat “E” terminal, one side of the plenum switch, and the black wire from the fossil fuel kit to “W2” on the IFC.

b. For the RXPF-F02 kit, connect

“W” on the fossil fuel kit interface wiring board to “W2” on the IFC.

Regardless of which fossil fuel kit is used, when activated, the two stage furnace follows the sequence of operation for a single stage thermostat.

➢ IMPORTANT: ALWAYS FOLLOW THE MANUFACTURER’S FOSSIL FUEL KIT INSTRUCTIONS.

TWINNING: Most installations of (-)GPE and (-)GLE furnaces cannot be twinned. However, a few exceptions exist for installations with some commercial evaporator coils. Consult the installation instructions of the coil to see if the furnace can be twinned. If so, a twinning kit will be required and the part number for the kit can be found in the installation instructions for the coil.

RXGW-B01 CHIMNEY ADAPTER

IMPORTANT: Chimney adapter is certified for use on upflow only.

This appliance is CSA certified for use with RXGW-B01 chimney adapter. Refer to kit installation instructions 92-101682-01.

TYPICAL WIRING FOR SELECT 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.

Page 28

METHOD BLOWER

ACTIVATION

CONTACTS WIRING CONFIGURATION

NORMALLY

OPEN

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.

BLOWER

RUNS

(Y1)

NORMALLY

CLOSED

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

NORMALLY

OPEN

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.

BLOWER

DOES NOT

RUN

(Y2)

NORMALLY

CLOSED

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

OPERATION WITH SELECTED ACCESSORIES

Page 29

80+ HIGH ALTITUDE

THE MANIFOLD PRESSURE OF THIS APPLIANCE HAS

BEEN FIELD ADJUSTED TO OBTAIN THE CORRECT INPUT RATING FOR INSTALLATION AT ALTITUDES

BETWEEN 2,000 FEET AND 4,500 FEET ELEVATION.

LA PRESSION DU DISTRIBUTEUR D'ALIMENTATION

DE CET APPAREIL A ÉTÉ AJUSTÉ SUR LES LIEUX AFIN

D'OBTENIR LA BONNE PUISSANCE D'ENTRÉE POUR

UNE INSTALLATION ENTRE 2000 ET 4500 PIEDS

D'ALTITUDE.

92-24399-01-01

INSTRUCTIONS (TABLE 13)

CAUTION

INSTALLATION OFTHIS FURNACE AT ALTITUDES ABOVE 2000 FT (610 m) SHALL BE IN ACCORDANCE WITH LOCAL CODES, OR IN THE ABSENCE OF LOCAL CODES,THE NATIONAL FUEL GAS CODE, ANSI Z223.1/NFPA 54 OR NATIONAL STANDARD OF CANADA, NATURAL GAS AND PROPANE INSTALLATION CODE, CAN B149.1.

Furnaces can be ordered from the factory already converted for high altitude elevations. The factory option for high altitude elevations would be ordered as a 278 option (example: a 75k BTU upflow furnace which is factory converted for high altitude elevations would have the model number (-)GPE07EAMKR). These factory converted furnaces come with pressure switches for high-altitude elevations already attached. Also, different burner orifices are installed at the factory which are one drill size smaller (#43 DMS) than standard (-)GPE/(-)GLE gas furnaces (#42 DMS). The smaller orifice is installed to accommodate for average heating values expected in most high altitude areas and a required 4% per thousand feet reduction in input as specified by the National Fuel Gas Code (NFGC). Specific orifices should always

be recalculated for all high altitude installations as outlined below. Orifices should be changed, if necessary, based on gas heating value and elevation.

34" 80 Plus furnaces installed above 2,000 ft. require the furnace to be derated 4% per thousand feet.

IMPORTANT: Factory installed orifices are calculated and sized based on a sea level Natural Gas heating value of 1075 BTU per cubic ft.

NOTE:Orifices are available through your local distributor.

Reference Tables 11, 12 and 13 for appropriate orifice sizing.

NOTE:Keep any parts removed during LP conversion procedure stored with the product literature for future use.

The following are examples of orifice sizing using the National Fuel Gas Code Appendix F:

Example: 900 BTU/ft Natural Gas Heating Value

I/H = Q 25000 / 900 = 27.78 ft

I = Sea Level input (per burner): 25000 H = Sea Level Heating Value: 900 Q = 27.78 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 Seal Level: #40 From Table F.4 of National Fuel Gas

Code Handbook, 2002

Orifice required at 5000 ft. elevation (4% de-rate per thousand ft): #42

Regional

Orifice required at 8000 ft. elevation (4% de-rate per thousand ft.): #44

TABLE 11

LP GAS

Example: 1050 BTU/ft3 Regional Natural Gas Heating Value

I / H = Q 25000 / 1050 = 23.81ft

I = Sea Level input (per burner): 25000 H = Sea Level Heating Value: 1050 Q = 23.81 ft

Natural Gas per hour.

From Table F.1 of Natural Fuel Gas Code Handbook, 2002 (3.5⬙ w.c. col- umn).

Orifice required at Sea Level: #43 From Table F.4 of National Fuel Gas

Code Handbook, 2002

Orifice required at 5000 ft. elevation (4% de-rate per thousand ft.): #45

Orifice required at 8000 ft elevation (4% de-rate per thousand ft): #47

LP GAS (TABLE 11)

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

The NFGC 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 Rheem products. The National Fuel Gas Code LP orifices are based on an 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 recommendations. The Sea Level input

Altitude burner) 25000 Size

0 to 2000 ft. 25000 #54 2000ⴕ-3000ⴕ 24000 #54 3000ⴕ-4000ⴕ 23000 #54 4000ⴕ-5000ⴕ 22000 #54 5000ⴕ-6000ⴕ 21000 #54 6000ⴕ-7000ⴕ 20000 #54 7000ⴕ-8000ⴕ 19000 #55 8000ⴕ-9000ⴕ 18000 #55

9000ⴕ-10000ⴕ 17000 #55

sand ft. and the orifice size must be selected based on the reduced input in Table 11.

ORIFICE ORDERING INFORMATION

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 available 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

should still be reduced by 4% per thou-

TABLE 12

ALTERNATE METHOD FOR CANADIAN HIGH-ALTITUDE DERATE

NATURAL GAS LP GAS

ORIFICE

ALTITUDE

0’ - 2000’

2001’ - 4500’

INPUT

50,000

75,000 100,000 125,000 150,000

45,000

67,500

90,000 112,500 135,000

OUTPUT

40,000 60,000

80,000 100,000 120,000

36,000

54,000

72,000

90,000 108,000

SIZE

#42

MANIFOLD

PRESSURE

3.5” W.C.

2.9” W.C.

ALTITUDE

0’ - 2000’

2001’ - 4500’

FIGURE 23

MANIFOLD PRESSURE-CHANGE LABEL

INPUT

50,000

75,000 100,000 125,000 150,000

45,000

67,500

90,000 112,500 135,000

Input (per Orifice

ORIFICE

OUTPUT

40,000 60,000

80,000 100,000 120,000

36,000

54,000

72,000

90,000 108,000

SIZE

#54

MANIFOLD PRESSURE

10” W.C.

8.1” W.C.

Page 30

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

ELEVATION CHART (NFG recommended orifice based on 4% derate for each 1000 foot of elevation, based on the intersection of the

Heat

80 Plus

Cubic

Sea Level

orifice required at Sea Level and the elevation required below)

Value at

Foot at

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

25,000

3.5" W.C.

25,000 24,000 23,000 22,000 21,000 20,000 19,000 18,000 17,000 16,000

TABLE 13

37 30.63 816 37 37 38 39 39 40 41 42 42 43

38 29.25 855 38 38 39 40 41 41 42 42 43 43

39 28.2 887 39 39 40 41 41 42 42 43 43 44

40 27.03 925 40 40 41 42 42 42 43 43 44 44

41 25.98 962 41 41 42 42 42 43 43 44 44 45

Size

Orifice

80 Plus Models with 25,000 Btu's per Burner

SUPPLEMENTAL ORIFICE SIZE CHART

Sea Level

42 24.95 1002 42 42 42 43 43 43 44 44 45 46

43 22.39 1117 43 43 44 44 44 45 45 46 47 47

44 21.01 1190 44 44 45 45 45 46 47 47 48 48

Final Firing Rate per Burner

NOTE:

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.

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 (25,000 for 80 plus) by the Heat Value for the site to determine the Cubic Foot value at Sea Level, or divide 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 Level orifice for the site. To select the corre-

sponding high altitude orifice, locate the site elevation on the chart above and the orifice required at Sea 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 these two points on the chart above.

Page 31

ALTERNATE METHOD FOR CANADIAN

HIGH-ALTITUDE

DERATE

In Canada, unless an orifice change is specifically mandated by local codes, an alternate method of altitude deration through a reduction in manifold pressure is acceptable as described in Table 12. This information is based on a heating value of 1000 BTU per cubic feet of natural gas, and 2500 BTU per cubic feet of LP gas.

IMPORTANT: Actual input rates must be measured onsite with manifold pressure adjustment to ensure that an actual 10% reduction in input rate is achieved.

Once this field adjustment has been made, the label shown in Figure 23 must be affixed in a conspicuous location on the front of the furnace cabinet.

NOTE: This label is supplied in the information packet shipped with each furnace.

AIR FLOW

The importance of proper air flow over the heat exchanger cannot be over emphasized.

CAUTION

IT IS IMPORTANT THAT EACH DUCT SYSTEM BE SIZED AND INSTALLED FORTHE SPECIFIC APPLICATION BY PROPERLY APPLYINGTHE APPROPRIATE INDUSTRY ACCEPTED STANDARD. IF LESS THAN MINIMUM STANDARDS ARE APPLIED,THE EQUIPMENT USER COULD EXPECT TO EXPERIENCE HIGHER UTILITY BILLS,MAJOR COMPONENT FAILURE,VARYING DEGREES OF AIR NOISE OR OTHER UNSATISFACTORY ISSUES,OVERWHICHTHE MANUFACTURER HAS NO CONTROL.

One of the most common causes of heat exchanger failure is overheating due to low air flow.An air flow table is located inside the blower door and on the following pages.

FIGURE 24

TEMPERATURE RISE MEASUREMENT

FIGURE 25

TYPICAL FURNACE NAME PLATE

AIR CONDITIONING DIVISION

FORT SMITH, ARKANSAS

ZONING SYSTEMS

The manufacturer does not currently provide or support zoning.However, zoning systems can be installed with the system as long as the zoning equipment manufacturers specificationsand 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 air is routed 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 preventthe coil from icing with excess bypass cooling. Also, if the zoning equipment manufacturerprovides a limit switch (usually provided by

Page 32

the zoning manufacturer), this limit must be installed in the system to prevent the furnace from overheating.

TEMPERATURE RISE CHECK

To determineif the air flow is correct, make a temperature rise check.

1. Insert a thermometer in the supply air duct as close to the furnace as possible yet out of a direct line from the heat exchanger. See Figure 24.

2. Insert a thermometer in the return air duct as close to the furnace as possible.

3. Operate the furnace.

4. When the thermometer in the supply air duct stops rising (approximately five minutes), subtract the return air temperature from the supply air temperature. The difference is the temperature rise.

5. Compare the measured temperature rise to the approved temperature rise range listed on the furnace name plate. See product specification sheet and nameplate located on furnace.

If the measured temperature rise is above the approved range, either the air flow is too low or the manifold pressure needs to be adjusted. More air must be moved by speeding up the blower, by removing restrictions in the duct system, or by adding more supply or return air duct. If the measured temperature rise is below the approved range, either the air flow is too much or the manifold pressure needs to be adjusted. Use lower speed tap on the multi-speed blower.

IMPORTANT: The measured temperature rise should be in the middle of the range. See product specification sheet and name plate located on furnace.

IMPORTANT: Some high-efficiency filters have a greater than normal resistance to airflow. This can adversely affect furnace operation.BE SURETO CHECK AIRFLOW if using any filter other than factory-provided filter.

Page 33

INTEGRATED FURNACE CONTROL (I.F.C.)

(all must be on)

FIGURE 26

TWO-STAGE CLIMATE-TALK COMMUNICATING FURNACE CONTROL (RHEEM # 62-102784-01)

24 VACTHERMOSTAT (TSTAT) INPUTS (J4 & J6)

These connections are used with any traditional 24VAC one-stage or twostage thermostat. Fully communicating thermostats must be connected to the COMM NETWORK CONNECTION (see section titled

SSYYSSTTEEMMSS

details).

CCOOMMMMUUNNIICCAATTIINNGG

of this document for

22,, YY11,, YY22,, GG,, CC aanndd RR

WW11,, WW traditional nearly all HVAC equipment. Installation of the thermostat to these connections is straight-forward and simple.

thermostat inputs used in

are the

HHUUMM SSTTAATT to connect the output of a humidistat to the furnace control to control humidification and/or dehumidification. Optional equipment is required for these features. Please see the section titled

DEHUMIDIFICATION

ment for more details.

– T

his terminal is used

HUMIDIFICTION AND

of this docu-

Page 34

SPECIAL CONFIGURATION – COMMUNICATING THERMOSTAT AND FURNACE WITH A NONCOMMUNICATING CONDENSER

YY11 aanndd YY22 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 communicating with the furnace control and the furnace control will energize the condenser as necessary (the additional 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

iinnppuuttss

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.

– These terminals may be

to the furnace control to turn on

oouuttppuuttss

When this configuration is desired, use the wiring diagram in Figure 27 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. There is no control for the reversing valve.

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 on-board 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).

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:

FIGURE 27

WIRING DIAGRAM – SPECIAL CONFIGURATION: COMMUNICATING THERMOSTAT AND FURNACE WITH NON-COMMUNICATING CONDENSER

Page 35

PPiinn 11

to Inducer High Speed Output. PPiinn 22 PPiinn 33 PPiinn 44

Inducer Low Speed Output

not used.

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 electronic 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 capacity. 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 cleaner 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 current. Details about the humidifier outputs and wiring diagrams can be found in the section titled

AND DEHUMIDIFICATION

ument.

HUMIDIFICATION

of this doc-

15-PIN MATE-N-LOK CONNECTOR (J1) (see Fig 28)

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.

PPiinn 11

to F

lame Sense rod.

PPiinn 22

Overtemp Limit (MRLC)

Sense PPiinn 33 PPiinn 44

PPiinn 55

PPiinn 66

PPiinn 77 PPiinn 88

PPiinn 99

PPiinn 11

PPiinn 1111 PPiinn 11

PPiinn 11 PPiinn 11 PPiinn 11

Main Limit (LC) Sense

24 VAC to Limit Sense

Circuits

VAC out to Auxiliary Limit

(HALC- Heat

Control)

1st stage gas valve solenoid

valve main

2nd stage gas valve solenoid

Low Pressure Switch

sense.

High Pressure Switch

sense.

to Low and High Pressure

Switch 2

to Aux Input sense

to Ground on furnace cabi-

net

not used on this control

gas valve 24VAC common

Assisted Limit

solenoid 24VAC.

4VAC

Page 36

FIGURE 28

15-PIN CONNECTOR; J1 WITH PIN DESIGNATIONS

COMMUNICATING ECM MOTOR COMMUNICATIONS (CONTROL) CONNECTION (J10) (see Fig 28)

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.

PPiinn 11

to com

motor PPiinn 22

motor PPiinn 33

motor PPiinn 44

motor

municating blower

connector Pin 1 (+V)

to communicating blower

connector Pin 2 (TX)

to communicating blower

connector Pin 3 (RX)

to communicating blower

connector Pin 4 (C)

Page 37

FIGURE 29

FOUR-PIN MOTOR CONTROL CONNECTION; J10 WITH PIN ASSIGNMENTS.

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 29.

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 service diagnostic tool. Unfortunately, this tool 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.

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 communicating thermostat. (Except under one special circumstance where a com-

municating thermostat and non-communicating condenser are used. See Figure 27 and the section of this document titled SPECIAL CON-

FIGURATION – COMMUNICATING 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 27 for connections of the communications network.

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 38

installed. These L.E.D.’s will not energize 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 all points are connected 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”

(STATUS) (Red) L.E.D.

L.E.D. blinks ON, ¾ second OFF) upon power-up.

twice slowly (¼ second

something

––

This

LEARN BUTTON

Pressing the learn button for two seconds 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 reversed. 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 CONNECTOR (J15)

This connector is used to insert a memory 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 programmed 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 correct. This means, for example, furnace shared data for a 120KBTU upflow furnace could be installed and recognized as valid furnace shared data 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 question. 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

is defined as

is defined

but furnace shared data inside the furnace IFC microprocessor may be written or rewritten in the field through the network depending on the circumstances.

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 EXCESSIVE 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 microprocessor (a mirror of the most recent memory card with blower 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.

AATTTTAACCHHEEDD

1. An

physically connected to the furnace control and almost appears to be part of the furnace control itself. A photo is shown in Figure 30 and is how the furnace control with memory card is shipped from the factory.

memory card is

Page 39

FIGURE 30

AN ATTACHED MEMORY CARD

IINNSSEERRTTEEDD

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 31 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, as such,

FIGURE 31

IINNSSEERRTTEEDD

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

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 away 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. However, 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.

nnoo mmeemmoorryy ccaarrdd pprreesseenntt

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 include 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 40

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) a valid furnace 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 for any given 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 J15 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 alerted via 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.

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 thermostat (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).

oonnee mmeemmoorryy ccaarrdd pprreesseenntt

2. If (attached to IFC 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 CNFLCT),

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),

oorr

inserted in J15 of

and/or

V. is from an older furnace

and is missing critical newer furnace shared data (“d8” - OLD SHARED DATA),

furnace shared data from the network (if valid) is used to control the furnace (see description of “network” under “If

pprreesseenntt

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 alerted (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 present (in which 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.

nnoo mmeemmoorryy ccaarrdd

”

(item 1 above)).

(NO VALID SHARED

Page 41

ttwwoo mmeemmoorryy ccaarrddss pprreesseenntt

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

rryy ccaarrdd pprreesseenntt

above) are used. A fault code is not displayed anywhere unless warranted for the attached memory card per the rules outlined for

aanndd

inserted in J15

(outlined in 2

oonnee mmeemmoo--

oonnee mmeemmoorryy ccaarrdd pprreesseenntt

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

rryy ccaarrdd pprreesseenntt

above) are used. A fault code is not displayed anywhere unless warranted for the attached memory card per the rules outlined for

oonnee mmeemmoo--

(outlined in 2

oonnee mmeemmoorryy ccaarrdd pprreesseenntt

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

rryy ccaarrdd pprreesseenntt

above) are used. A fault code is not displayed anywhere unless warranted for the attached memory card per the rules outlined for

oonnee mmeemmoo--

(outlined in 2

oonnee mmeemmoorryy ccaarrdd pprreesseenntt

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

sseenntt

used. A fault code is not displayed anywhere unless warranted for the attached memory card per the rules outlined for

mmeemmoorryy ccaarrdd pprreesseenntt

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

ccaarrdd pprreesseenntt

above) are used. A fault code is not displayed anywhere unless warranted for the attached memory card per the rules outlined for

oonnee mmeemmoorryy ccaarrdd pprreesseenntt

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.

oonnee mmeemmoorryy ccaarrdd pprree--

(outlined in 2 above) are

oonnee

. Furnace

oonnee mmeemmoorryy

(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 not to remove the card 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 32). 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.

Page 42

FIGURE 32

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 43

FIGURE 33

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).

TETHER S ECURING ORIGINAL MEMORY C ARD TO F URNACE – DO

NOT CUT THIS TETHER OR REMOVE THE ORIGINAL MEMORY CARD FROM THE FURNACE WHEN REPLACING THE FURNACE CONTROL (I.F.C.)

Page 44

DIPSWITCHES

TIMED HEAT STAGING

NORMAL NO STAGING

TIMED STAGING

(-)GPE-05(-)BMKR (-)GPE-07(-)BRQR (-)GPE-10(-)BRMR (-)GLE-05(-)BMKR (-)GLE-07(-)BRQR (-)GLE-10(-)BRMR (-)GPE-07(-)AMKR (-)GPE-12(-)ARMR (-)GLE-07(-)AMKR (-)GLE-12(-)ARMR

1200 CFM 1600 CFM 2000 CFM

1000 CFM 1400 CFM 1600 CFM

800 CFM 1200 CFM 1400 CFM

600 CFM 1000 CFM 1200 CFM

NNOOTTEE:: does not recognize switch setting changes while energized.

The integrated furnace control

SW1

SW1-1 AND SW1-2 – COOLING AIRFLOW SELECT – These dipswitches

are used to select the appropriate cooling 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 airflow which is preset at the factory and not adjustable.

FIGURE 34

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 target 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-communicating systems can be adjusted approximately +/- 10% by using the cool trim adjustment dipswitches; SW1-5 and SW1-6. See Figure 34.

Cooling airflow for non-communicating 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 the low stage (1

stage) of cooling. See the tables in Figure 35. More information can be found in the section titled SW2 (SW2-6).

Consult the tables in Figures 34, 35 and 36 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 45

FIGURE 35

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 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

FURNACE COOLING AIRFLOW RATES, GPE-05, GPE-07(-)A, GLE-05 & GLE-07(-)A (1200 CFM Max) motor settings

(applies only to systems configured with non-communicating condenser).

SW1, Pos. 2 SW1, Pos. 1

Y2 Single

stage

Y1 Low 2

stage

Y1+Y2 High 2

stage

Notes

Low Airflow = approx. 50% of High-Stage Cooling (Could be used with condensers with two

compressors.)

HIGH SEER (16+) Premium

Cooling airflow (SW2, Position 4 is

OFF)

SW2, Pos. 4

ON OFF OFF

2000 CFM 1000 CFM 2000 CFM 5 Ton A/C

ON OFF ON

1600 CFM 800 CFM 1600 CFM 4 Ton A/C

ON ON OFF

1400 CFM 700 CFM 1400 CFM 3.5 Ton

ON ON ON

1200 CFM 600 CFM 1200 CFM 3 Ton

OFF OFF OFF

2000 CFM 1400 CFM 1800 CFM 5 Ton A/C

OFF OFF ON

1600 CFM 1200 CFM 1600 CFM 4 Ton A/C

OFF ON OFF

1275 CFM 1050 CFM 1400 CFM

3.5 Ton

OFF ON ON

1200 CFM 900 CFM 1200 CFM 3 Ton

Low Airflow = approx. 50% of

High-Stage (Could be

used with condensers with two

compressors.)

HIGH SEER (16+) Premium

Cooling airflow (SW2, Position 4 is

OFF)

SW2, Pos. 4

FURNACE COOLING AIRFLOW RATES, GPE-10, GPE-12, GLE-10 & GLE-12 (2000 CFM Max) motor settings

(applies only to systems configured with non-communicating condenser).

SW1, Pos. 2 SW1, Pos. 1

Y2 Single

stage

Y1 Low 2

stage

Y1+Y2 High 2

stage

Notes

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

FURNACE COOLING AIRFLOW RATES, GPE-05, GPE-07(-)A, GLE-05 & GLE-07(-)A (1200 CFM Max) motor settings

(applies only to systems configured with non-communicating condenser).

SW1, Pos. 2 SW1, Pos. 1

Y2 Single

stage

Y1 Low 2

stage

Y1+Y2 High 2

stage

Notes

Low Airflow = approx. 50% of High-Stage Cooling (Could be used with condensers with two

compressors.)

HIGH SEER (16+) Premium

Cooling airflow (SW2, Position 4 is

OFF)

SW2, Pos. 4

SW2, Pos. 4 SW1, Pos. 2 SW1, Pos. 1

Y2 Single

Stage

Y1 Low 2

Stage

Y1+Y2 High 2

Stage

ON OFF OFF 1600 CFM 800 CFM 1600 CFM 4 Ton A/C ON OFF ON 1400 CFM 700 CFM 1400 CFM 3.5 Ton A/C ON ON OFF 1200 CFM 600 CFM 1200 CFM 3 Ton A/C

ON ON ON 1000 CFM 500 CFM 1000 CFM 2.5 Ton A/C OFF OFF OFF 1600 CFM 1200 CFM 1600 CFM 4 Ton A/C OFF OFF ON 1400 CFM 1050 CFM 1400 CFM 3.5 Ton A/C OFFONOFF 1200 CFM 900 CFM 1200 CFM 3 Ton A/C OFF ON ON 1000 CFM 750 CFM 1000 CFM 2.5 Ton A/C

FURNACE COOLING AIRFLOW RATES, GPE-07(-)B & GLE-07(-)B (1600 CFM MAX) motor settings

Notes

Low Airflow = approx. 50% of Hi

h-Sta

(

Could be used with condensers with tw

compressors).

HIGH SEER (16+) Premium Cooling

airflow (SW2, Position 4 is OFF)

(applies only to systems configured with non-communicating condenser)

COOLING AIRFLOW SELECTIONS FOR NON-COMMUNICATING CONDENSERS

SW1-3 TIMED HEAT STAGING – This

switch permits the user to select between no timed staging (i.e. a two stage thermostat is connected) or timed staging with a single-stage thermostat. With the selection “ON,” the furnace will stage up to 100% heat after 12 minutes with a heat call on W1 only. This means that a 1-stage thermostat can be used to simulate 2-stage heating operation.

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”

⁄2 HP MOTORS = Approx. 600 CFM

⁄4 HP MOTORS = Approx. 800 CFM 1 HP MOTORS = Approx. 1000 CFM “ON”

⁄2 HP MOTORS = Approx. 1200 CFM

⁄4 HP MOTORS = Approx. 1600 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 = “ON”, SW1-6 = “ON” –

No adjustment.

Page 46

FIGURE 36

BLOWER OFF DELAY

OFF/OFF

HIGH HEAT = 80 SEC.

LOW HEAT = 110 SEC.

LOW COOL = 0 SEC.

HIGH COOL = 30 SEC.

ON/OFF

HIGH HEAT = 60 SEC.

LOW HEAT = 80 SEC.

LOW COOL = 0 SEC.

HIGH COOL = 0 SEC.

OFF/ON

HIGH HEAT = 120 SEC.

LOW HEAT = 150 SEC.

LOW COOL = 0 SEC.

HIGH COOL = 20 SEC.

ON/ON HIGH HEAT - 180 SEC. LOW HEAT = 180 SEC.

HIGH COOL = 0 SEC.

LOW COOL = 150 SEC.

USE GUIDE: A, B, C, D WILL INDICATE HEATING BLOWER OFF DELAYS IN “SETUP” USER MENU.

DIPSWITCH BANK SW2 TEST MODE SELECT

ST-A1117-02

SSwwiittcchh ((SSWW22--11)) CCaallll VVoollttaaggee aatt ““ HHUUMM”” AAccttiioonn 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” position. 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 dehumidification feature will become active and it will be necessary to install a humidistat to the “HUM STAT” terminal as discussed and shown in wiring diagrams in the section of this manual titled “

HUMIDIFICATION AND DEHUMIDIFI-

CATION

” of this document. Failure to install a humidistat to the “HUM STAT” terminal with dipswitch SW2-1 in the “ON” position will cause the cooling speed airflow to be reduced to the dehumidification speed..

SW2-2 and SW2-3 – BLOWER OFF DELAYS

Blower off delays in both heating and cooling are set with these two dipswitches. The selections are as follows (SW2-2/SW2-3):

OFF/OFF(default) = high heat = 80, low heat = 110 sec., Low Cool = 0 sec, High Cool - 30 sec.

ON/OFF = high heat = 60, low heat = 80 sec., Low Cool = 0 sec., High Cool = 0 sec.

ON/ON = highheat = 180, low heat = 180 sec., Low Cool = 0 sec., High Cool = 50 sec.

FURNACE OPERATION USING NON-COMMUNICATING SINGLE-STAGE, AND TWO-STAGE THERMOSTATS (CONSULT THE SECTION OF THIS DOCUMENT TITLED NON-COMMUNICATING THERMOSTATS FOR WIRING DIAGRAMS)

The furnace is capable of operating with a single-stage or a two-stage thermostat as well as the modulating thermostat or fully communicating thermostat specified for use with the furnace. Fully communicating thermostat functions and operations are explained in detail in the sections of this manual titled COMMUNICAT-

ING SYSTEMS and THERMOSTATS (under the sub-section titled COMMUNICATING THERMOSTATS).

Based on the dipswitch settings of SW1-3, the furnace will operate with either single-stage or two-stage thermostats.

See the section of this document titled THERMOSTATS (under the sub-section titled NON-COMMUNI- CATING THERMOSTATS) for information on how to wire the thermostats for each of the configurations below.

Page 47

In non-communicating systems, the

Low

Adjustment

Mid-Rise

1st Hi

Adjustment

2nd Hi

Adjustment

Low

Adjustment

Mid-Rise

1st Hi

Adjustment

2nd Hi

Adjustment

B- SW3-1,2 =

ON/OFF

A- SW3-1,2 =

OFF/OFF

C- SW3-1,2 =

OFF/ON

D- SW3-1,2 =

ON/ON

B- SW3-1,2 =

ON/OFF

A- SW3-1,2 =

OFF/OFF

C- SW3-1,2 =

OFF/ON

D- SW3-1,2 =

ON/ON

Approx.

Temp Rise

Approx.

Temp Rise

Approx.

Temp Rise

Approx.

Temp Rise

Approx.

Temp Rise

Approx.

Temp Rise

Approx.

Temp Rise

Approx.

Temp Rise

(-)GPE-05(-)BMKR 20°-50°F

27°F 35°F 43°F 45°F

25°-55°F

32°F 40°F 48°F 55°F

(-)GPE-07(-)AMKR 20°-50°F

27°F 35°F 43°F 50°F

30°-60°F

37°F 45°F 53°F 56°F

(-)GPE-07(-)BRQR 20°-50°F

27°F 35°F 43°F 50°F

25°-55°F

32°F 40°F 48°F 55°F

(-)GPE-10(-)BRMR 25°-55°F

32°F 40°F 48°F 55°F

30°-60°F

37°F 45°F 53°F 60°F

(-)GPE-12(-)ARMR 30°-60°F

37°F 45°F 53°F 60°F

35°-65°F

42°F 50°F 58°F 65°F

(-)GLE-07(-)AMK

20°-50°F 30°F 35°F 45°F 50°F 30°-60°F 37°F 45°F 53°F 60°F

(-)GLE-07(-)BRQ

20°-50°F 27°F 35°F 43°F 50°F 25°-55°F 32°F 40°F 48°F 55°F

(-)GLE-10(-)BRM

25°-55°F 32°F 40°F 48°F 55°F 30°-60°F 37°F 45°F 53°F 60°F

(-)GLE-12(-)ARM

30°-60°F 37°F 45°F 53°F 60°F 35°-65°F 42°F 50°F 58°F 58°F

UPFLOWDOWNFLW

High Fire

Model

Low Fire

Published

Low Temp

Rise Range

Published High Temp Rise Range

heating cycle is always initiated by a 24 volt signal on W1. When the controller senses 24 volts on W1, the following sequence occurs:

TWO-STAGE FUNCTION SW1-3 = OFF:

After the blower on-delay period, the furnace will respond to the thermostat demand by adjusting the gas valve pressure and blower heating speeds to the “W” signal values. “W1” only = low gas valve pressure and blower heating speed. “W2” = high gas valve pressure and blower heating speed.

SINGLE-STAGE FUNCTION (“W” signal only) :

(Single-stage function only applies when switch SW1 is on and a single-stage thermostat is installed as shown in Figure 48.)

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:

PPhhaassee 11::

0 to 7 minutes = Low of furnace capacity (gas valve output and blower speed)

PPhhaassee 22:: nace ca

After 7 minutes = 100% of fur-

pacity (gas valve output and

blower speed)

NNOOTTEE:: any ph

If the call for heat ends during

ase, the furnace will terminate immediately at the firing rate of that phase.

SSWW22--44 leave dip

- For most cooling operation, 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.

Placing SW2-4 in the “ON” position will establish the low (Y1) cooling airflow at ½ of the max cool (Y2) airflow. This setting will be useful with cooling systems where two compressors are used to control two cooling stages (one compressor for first stage and two compressors for second stage).

SW3-1 and SW3-2

HEATING AIRFLOW ADJUSTMENTS The furnace is shipped from the factory

with low and high fire heating airflows. These are set from the factory to let the furnace operate at the mid-point of the temperature rise range. The temperature may vary slightly due to furnace input and voltage variations.

The airflow can be slightly adjusted to the homeowner’s taste. This is done with dipswitches SW3-1 and SW3-2 of the furnace control board. There is one adjustment below nominal (heat rise is less than nominal – air is warmer). Some models do not have all three adjustments. Figure 37 shows the approximate heat rise based on the adjustments of dipswitch SW3-1 and SW3-2.

WARNING

IT IS THE INSTALLER’S RESPONSIBILITY TO VERIFY THAT THE TEMPERATURE RISE DOES NOT EXCEED THE PUBLISHED RISE RANGE OF THE FURNACE. THE RISE RANGE MUST ALWAYS BE CHECKED AT BOTH

LOW AND HIGH FIRE BEFORE LEAVING THE JOBSITE. IF THE TEMPERATURE IS OUTSIDE THE SPECIFIED RANGE, AN ADJUSTMENT TO THESE DIPSWITCHES MUST BE MADE TO CORRECT THE HEAT RISE.

FIGURE 37

HEAT RISE ADJUST – DIPSWITCHES SW3-1 AND SW3-2

Page 48

SW4

FIGURE 38

DIPSWITCH BANK SW4 TERMINATION AND BIAS SELECTIONS

ST-A1117-04

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. llaattiioonnss,, aallll tthhrreeee ooff tthhee ddiippsswwiittcchheess iinn bbaannkk SSWW44 mmuusstt bbee iinn tthhee ““ OONN”” ppoossii-- ttiioonn.. IIff nnoott,, tthhee ssyysstteemm mmaayy nnoott bbee aabbllee ttoo ccoommmmuunniiccaattee..

FFoorr ccuurrrreenntt iinnssttaall

DUAL SEVEN-SEGMENT DIAGNOSTIC DISPLAY

The dual seven-segment diagnostic display will either display the status of the system (e.g. “H” for Heat) or a diagnostic 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, the fault 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 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 1049, the decimal will 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”).

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 displayed is the number of days since each 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 SW3-2 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 display 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 Fault Hist selection. The seven-segment displays will again operate as described above.

Either procedure will clear the fault codes in the fault buffer displayed at the dual seven-segment displays on the I.F.C. And at the Fault History user menu on communicating thermostats.

on, off, on, off

Page 49

TABLE 16

LIST OF FAULT CODES AND NORMAL OPERATION CODES

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. The fault buffer can also be cleared at the user menu under “FAULT HIST” in the sub-menu titled “CLEAR FAULT HISTORY”.

Either procedure will clear the fault codes in the buffer displayed at the dual seven-segment displays on the I.F.C. AND

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.

at the Fault History user menu on communicating thermostats.

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 recommended 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 communicating connections or communications may not be properly established.

Figure 39 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 and C) be installed from the furnace to the condenser.

Page 50

FIGURE 39

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

SSTTAARRTT--UUPP PPRROOCCEEDDUURREESS

Once the communicating wiring is properly installed and the furnace is connected to line voltage, the system can be turned on. The thermostat will display the following text:

“SEARCHING”

is displayed several times for several 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 complete. If these messages are not displayed within 30 minutes after energizing the system, communications 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 order 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 51

When the system has found all necessary 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 necessary adjustments.

NOTE: When a communicating condenser is installed with the system, a capital “C” will be displayed at the furnace seven-segment display for both low & high cooling stages.

CONTINUOUS FAN OPERATION IN

CCOOMMMMUUNNIICCAATTIINNGG MMOODDEE Cont

inuous fan operation will always

depend o

n 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 (75KBTU), 700 CFM for

⁄4 HP (75KBTU (wide) and 50 KBTU) and 1000 CFM for 1 HP motors (100KBTU). 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 cooling 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 default values are reset in the furnace “SETUP” user menu, the continuous fan CFM will be restored to factory default (Max = 600 CFM for

⁄2 HP, 700 CFM for 3⁄4 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 condenser sends a fan demand to the furnace control.

ACTIVE FAULT CODES WITH COMMUNICATING SYSTEMS

Two levels of fault codes exist: (1) Noncritical 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) operations from proceeding. Detailed explanations 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 configuring 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 operation instructions for that thermostat.

Navigating the user menus is straight-forward. The menu follows the logic tree shown in Figure 40 (a & b).

NOTE: There may be a delay of several seconds when accessing he user menus or sub-menus. This is normal.

Page 52

FIGURE 40a

HIGH LOW

LO HEAT HIGH HEAT

LO HEAT HRS

LO HEAT CYCLES

HI HEAT HRS

HI HEAT CYCLES

BLOWER HOURS

BLOWER CYCLES

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 information for various parameters and permit some installation options to be selected.

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.

“STATUS 1” menu – This menu gives information about the status of certain furnace components and features.

➤

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

– Indicates the 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 unexpectedly when opened.

Page 53

FIGURE 40b

1 STG.

OFF

BLOWER OFF DELAY

OFF ON

HIGH HEAT HRS

LOW HEAT HRS

LOW HEAT CYCLES

HIGH HEAT CYCLES

BLOWER HOURS

TOTAL DAYS PWRD

HEAT ADJ

A B C D

B C D

BLOWER OFF DELAY

LOW HIGH

MENU TREE – CONTINUED

➤ ➤

➤

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 control 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

– Indicates the firing rate of the gas valve. This value can be low or high depending on the thermostat demand.

8. GAS VLV RELAY

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

– Indicates the

➤

ON, flame should be present.

9. FLAME

ence 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.

10. BLOWER CFM

CFM that the furnace control

– Indicates the pres-

– Indicates the

Page 54

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 and features.

11.. MMOODDEE

aa.. MMOODD HHEEAATT –– bb.. AACC –– cc.. FFAANN OONNLLYY ––

dd.. HHPP ––

2. MO

3. MOTOR RPM

4. MAXIMUM CFM

5. BLOWER CFM

6. TEMP DIFF

a. If the Supply Air Sensor (S.A.S.)

b. If the S.A.S. is not

– Indicates the current state of operation of the furnace. The possibilities are listed below:

t operation

Hea

Air

conditioning operation.

operation.

Heat-pump operation.

TOR MFGR – Indicates the manufacturer of the main air-circulating blower motor. At the time of this publication there are two possibilities; GenteQ (formerly GE) for Regal Beloit (formerly GE) and EMERSON.

of the main circulating air blower.

maximum CFM that the main circulating air blower can deliver.

put of airflow in CFM of the main circulating air blower.

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 the 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 to Celsius units. A few other different conditions that apply to this menu item are:

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.

“SUPPLY AIR SENS” in “SETUP”

Continuous fan

– Indicates the RPM

– Indicates the

– Indicates the out-

* – Indicates the differ-

be changed

turned on (see

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

“SUPPLY AIR SENS” in “SETUP” menu below) and a sensor is perature will be displayed in the “TEMP DIFF” selection.

d. If the S.A.S. is

“SUPPLY AIR SENS” in “SETUP” menu below) and a sensor is 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

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 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

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.

turned on (see

attached, a valid tem-

turned on (see

attached (or not

* – Indicates the

be changed to

* – Indicates the

b. If the S.A.S. is not turned on

(see “SUPPLY AIR SENS” in “SETUP” menu below) and a sensor is 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 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 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

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. LO HT HRS

number of hours of operation of low gas heat in the last 14 days.

22.. LLOO HHTT CCYYCCLLSS number of cycles of operation of low gas heat in the last 14 days.

33.. HHII HHTT HHRRSS ber of hours of operation of high gas heat in the last 14 days.

44.. HHII HHTT CCYYCCLLSS number of cycles of operation of

high gas heat in the last 14 days.

55.. BBLLOOWWEERR HHRRSS number of hours of continuous fan operation in the last 14 days.

66.. BBLLOOWWEERR CCYYCCLLSS 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.

attached, a valid

attached (or not

– Indicates when

– Indicates the

– Indicates the num-

– Indicates the

turned on (see

– Indicates

Page 55

LLIIFFEE HHIISSTT

“ 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.

11.. TTOOTTAALL DDAAYYSS PPWWRRDD the total number of days that the furnace has been powered. This number is not affected by any thermostat operation.

22.. LLOO HHTT HHRRSS of hours of operation of low gas heat over the life of the furnace.

33.. LLOO HHTT CCYYCCLLSS ber of cycles of operation of low gas heat over the life of the furnace.

44.. HHII HHTT HHRRSS of hours of operation of high gas heat over the life of the furnace.

55.. HHII HHTT CCYYCCLLSS ber of cycles of operation of high gas heat over the life of the furnace.

66.. BBLLOOWWEERR HHRRSS number of hours of continuous fan operation over the life of the furnace.

77.. BBLLOOWWEERR CCYYCCLLSS 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.

FFAAUULLTT HHIISSTTOORRYY

“ gives information recent faults experienced by the furnace. The most recent fault is displayed upon entering the menu. Three seconds later the text “DAYS“ is displayed 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 viewing 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 displayed in the order 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”.

menu – This menu gives

”

– Indicates

– Indicates the number

– Indicates the num-

– Indicates the number

– Indicates the num-

– Indicates the

menu – This menu

”

about the six most

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 of “DAYS 10” is displayed to indicate the number of days since the fault occurred.

UUNNIITT IINNFFOO

“ information

11.. MMOODDEELL NNUUMMBBEERR ((MMNN))

22.. SSEERRIIAALL NNUUMMBBEERR ((SSNN))

33.. SSOOFFTTWWAARREE VVEERRSS.. SSEETTUUPP

“ the field adjustment of certain parameters 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.

11.. HHEEAATT AADDJJ

22.. BBLLOOWWEERR OOFFFF DDEELLAAYY

33.. SSUUPPPPLLYY AAIIRR SSEENNSS

” menu – This menu permits

the adjustment of the heat airflow. Operation of this selection is exactly as with the dipswitches at SW3 at the furnace control. The heat rise can be changed by increasing or decreasing the airflow slightly. Adjustments are A, B, C & D as shown in Figures 37 & 40.

The default factory setting for the low heat adjustment is “A”.

selection permits the adjustment of the heating blower off delay in communicating mode. The selections are A, B, C and D. The actual timings for the blower off delay are described in Figure 36 as selections A-D of dipswitches SW2-2 and SW2-3.

The default factory setting for the blower off delay is “A”.

tion 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

– This menu gives

” menu

about the furnace.

- This selection permits

- This

– This selec-

descriptions for these items in the “STATUS 2” menu 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”.

NNOOTTEE:: 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.

55.. FFIIXXEEDD FFIIRREE RRAATTEE ture 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 low and high.

6. RESET ALL DFLTS

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

“DIPSWITCH” menu – This menu

permits viewing of the dipswitch selections. It is a way to read the

FOR DUAL-FUEL

– This fea-

– This

Page 56

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 selections do not generally affect operation of 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.

11.. CCOOOOLL AAIIRRFFLLOOWW 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.

22.. TTIIMMEEDD SSTTAAGGIINNGG FFEEAATTUURREE OFF – 2 Stage Operation ON – Timed Staging W/1 Stage Thermostat

33.. HHEEAATT AADDJJ selected at SW3, positions 1 and 2. It is the adjustment of the high heat rate airflow. See the section of this manual titled “DIPSWITCH” under “SW3” for details and selections.

44.. FFAANN SSPPDD SSEELLEECCTT fan speed selected. See the section of this manual titled “DIPSWITCH” under “SW1” (SW1-4) for details and selections.

– Displays the

–

– Displays the value

– Displays the

55.. AACC--HHPP AADDJJ 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.

66.. OONN DDEEMMAANNDD DDEEHHUUMM the dehumidification feature on or off. See the section of this manual titled “DIPSWITCH” under “SW2” (SW2-1) for details and selections.

77.. AACC HHPP SSTTGG MMUULLTT for adjustment to the airflow for low-stage of cooling and heat-pump 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. Dualfuel systems will display “ Pump heat operation at the furnace control’s (I.F.C.) dual seven-segment displays. During defrost mode, “ 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.

– Adjusts the cooling

– Toggles

– This allows

” for Heat-

” will

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.

NOTE:

TION, 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.

FOR DUAL-FUEL OPERA-

Page 57

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 41.

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 proper ventilation, it 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 negative pressure switch, a “no heat call” would result.

FIGURE 41

OPTIMUM IGNITOR LOCATION

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.

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.

Page 58

TABLE 17

NORMAL OPERATION CODES

Page 59

• The controller sends a spark signal to spark across the electrodes.

• The main solenoid on the gas valve are energized (low fire) 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 low rate through the warm-up period - 20 seconds (aka Blower Off Delay).

Heating Cycle Response

➤ TWO-STAGE FUNCTION – NON-

COMMUNICATING SYSTEMS ONLY:

(Two-stage function only applies when SW1-3 is in the “OFF” position and a two-stage thermostat is installed as shown in Figure 49.)

After the warm-up period, the furnace will respond to the thermostat demand by adjusting the gas valve and blower heating speeds to the “W” signal values. “W” only = low gas valve pressure and blower heating speed. “W2” = high gas valve pressure and blower heating speed 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 7 minutes = Low fire furnace capacity (gas valve output and blower speed)

Phase 2: After 7 minutes = 100% of furnace 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.

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 will shut down and return to the proper off cycle operation.

ADJUSTING OR CHECKING FURNACE INPUT

NATURAL GAS:

The maximum gas supply pressure to the furnace should be 10.5” W.C. for natural gas. The minimum gas supply pressure for purposes of input adjustment to the furnace should be 5” W.C.

A properly calibrated manometer or gauge is required for accurate gas pressure readings.

1. When adjusting the furnace input, the high fire input should be checked. The high fire manifold pressure should be 3.5' W.C. Follow these steps to be sure the furnace is high fire mode:

a. With a single stage thermostat, the

furnace runs for 12 minutes on low fire before shifting to high fire. To be certain that it is on high fire, jump terminals “W” and “W2” on the control board in the blower compartment.

b. With a two stage thermostat, set

the thermostat to its highest setting to keep the furnace operating in the high fire mode.

TABLE 18

METER TIME IN MINUTES AND SECONDS FOR NORMAL

INPUT RATING OF FURNACES EQUIPPED FOR NATURAL OR LP GAS

INPUT

BTU/HR

50,000

75,000

100,000

125,000

150,000

Input BTU/HR =

METER

CU. FT.

SIZE

ONE 15112 1 15 1 18 3 20 TEN 10 50 12 00 12 30 13 12 30 00

ONE 0 44 0 48 0 50 0 53 20 TEN 7 12 80819 8 48 20 0

ONE 0 33 0 36 0 38 0 40 1 30 TEN 5 24 60615 6 36 15 0

ONE 0 26 0 29 0 30 0 32 1 12 TEN 4 19 4 48 50517 12 0

ONE 0 31 0 24 0 25 0 26 10 TEN 3 36 40410 4 20 10 0

Heating Value of Gas (BTU/Ft3) x 3600 x correction factor Time in Seconds (for 1 cu.ft.) of Gas

HEATING VALUE OF GAS BTU PER CU. FT.

900 1000 1040 1100 2500

MIN. SEC. MIN. SEC. MIN. SEC. MIN. SEC. MIN. SEC.

NOTE: Use a 3/32⬙ allen wrench for

making the pressure adjustment.

LP GAS:

Furnaces for use on LP gas, the LP gas supply pressure must be set between 11.0” and 13.0” W.C. by means of the tank or branch supply regulators. The furnace manifold pressure should be set at 10” W.C. at the gas control valve. For elevations up to 7,000 feet, rating plate input ratings apply. For high altitudes (elevations 7,000 and over) and for any necessary major changes in the gas flow rate the orifice spud must be changed.

TO CHANGE ORIFICE SPUDS:

1. Shut off the manual main gas valve and remove the gas manifold.

2. Replace the orifice spuds.

3. Reassemble in reverse order.

4. Turn the gas supply back on and check for leaks.

5. Check for proper operation and set to proper manifold pressure.

Check of input is important to prevent over firing of the furnace beyond its design-rated input. NEVER SET INPUT ABOVE THAT SHOWN ON THE RATING PLATE.

TO CHECK FURNACE INPUT:

1. Make certain that all other gas appliances are shut off, with the exception of pilot burners.

2. Start the furnace

3. Time the meter to measure the time required to burn one cubic foot of gas.

4. Use Table 4 to determine input rate.

Page 60

MAINTENANCE

WARNING

DISCONNECT MAIN ELECTRICAL POWER TO THE UNIT BEFORE ATTEMPTING ANY MAINTENANCE. FAILURE TO DO SO CAN CAUSE ELECTRICAL SHOCK RESULTING IN SEVERE PERSONAL INJURY OR DEATH.

FILTERS

Filter application and placement are critical to airflow, which may affect the heating and cooling system performance. Reduced airflow can shorten the life of the systems major components, such as motor, limits, elements, heat exchanger, evaporator coil or compressor. Consequently, we recommend that the return air duct system have only one filter location. The most common location will be inside the furnace or a filter base. For systems with a return air filter grill or multiple filter grills, can have a filter installed at each of the return air openings. DO NOT DOUBLE FILTER THE RETURN AIR DUCT SYSTEM. DO NOT FILTER THE SUPPLY AIR DUCT SYSTEM.

If high efficiency filters or electronic air cleaners are used in the system, it is important that the airflow is not reduced to maximize system performance and life. Always verify that the systems airflow is not impaired by the filtering sys-

TABLE 19 FILTER SIZES

UPFLOW FILTER SIZES AS SHIPPED

FURNACE INPUT BOTTOM SIDE

WIDTH BTUH SIZE SIZE

/2" 50, 75 153/4" X 25" 153/4" X 25" 1

21" 75, 100 19

/2" 125 223/4" X 25" 153/4" X 25" 1

/4" X 25" 153/4" X 25" 1

tem that has been installed, by performing a temperature rise and temperature drop test.

Keep the air filters clean at all times. Vacuum dirt from filter, wash with detergent and water, air dry thoroughly and reinstall.

See Table 19 and Figures 42 through 44 for proper filter sizes and locations.

1. 21”-100,000 BTUH unit requires removal of 3

/2” segment of filter and frame to get proper width for a side filter.

/2”-125,000 BTUH units require

2. 24 removal of 7” segment of filter and frame to get proper width for a side filter.

QUANTITY

*NOTE: Some filters must be ordered or resized to fit certain units and applications.

IMPORTANT: 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 circulated dust particles will be heated and charred by contact with the furnace heat exchanger. This sooty residue will soil ceilings, walls, drapes, carpets, and other household articles. Soot damage may also result when certain types of candles are burned, or candlewicks are left untrimmed.

FIGURE 42

FILTER RETAINING ROD

FILTER ROD 45-24095-01

Page 61

FIGURE 43

UPFLOW FILTER RETAINING ROD (SIDE RETURN)

CUT-OUT AND DRILL DETAIL

FILTER ROD SUPPORT ANGLE AE-60520-01

FILTER SUPPORT ANGLE AE-61883-01

FILTER AND ROD ASSEMBLY

FILTER ROD 45-24095-01

SOLID BOTTOM MAY BE ORDERED FROM THE FACTORY.

FIGURE 44

DOWNFLOW FILTER INSTALLATION

FILTER ROD SUPPORT ANGLE AE-60520-01

FILTER SUPPORT ANGLE (SEE ANGLE DETAIL) AE-61883-01

ROD & FILTER SUPPORT ANGLE ASSEMBLY

*BOTH SIDES FOR 1800 CFM OR ABOVE.

Page 62

SYSTEM OPERATION INFORMATION

Advise The Customer To:

1. Advise customer of filter location. Keep the air filters clean. The heating system will operate better, more efficiently 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 & bathroom exhaust fans.

5. Do not permit the heat generated by television, lamps or radios to influence the thermostat operation.

6 Except for the mounting platform,

keep all combustible articles three feet from the furnace and vent system.

7. 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.

WARNING

COMBUSTIBLE MATERIAL MUST NOT BE PLACED ON OR AGAINST THE FURNACE JACKET OR WITHIN THE SPECIFIED CLEARANCES OF THE VENT PIPE. 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 FURNACE OWNER SHOULD BE CAUTIONED THAT THE FURNACE AREA MUST NOT BE USED AS A BROOM CLOSET OR FOR ANY OTHER STORAGE PURPOSES.

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 paying particular attention to deterioration from corrosion or other sources.

WARNING

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.

• IMPORTANT: It is recommended that

at the beginning of the heating season and approximately midway in 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.

• IMPORTANT: It is also 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 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.

IMPORTANT: FOR Nox MODELS – At the beginning of the heating season a visual inspection of the Nox device should be made to ensure they have not become obstructed by insects nests or anything else which may effect performance.

LUBRICATION

The indoor blower motor and induced draft motor are prelubricated by the motor manufacturer and do not require further attention.

The motors 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. Air filters should be kept clean. Dirty filters can restrict airflow and results in motor overheating.

REPLACEMENT PARTS

Contact your local distributor for a complete parts list.

NOx MODELS

When converting furnaces equipped with NOx inserts to LP gas, remove the NOx insert assemblies.

TROUBLESHOOTING

Refer to Figure 45.

WIRING DIAGRAM

Figure 46 is a complete wiring diagram for the furnace.

Page 63

FIGURE 45

2-STAGE COMMUNICATING INTEGRATED

FURNACE CONTROL (IFC)

TROUBLESHOOTING GUIDE

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 = Installation & Operation Instructions Manual.

1) For communicating systems, go to the “setup” menu and set fixed fire rate to high. For legacy systems ensure W2 & W1 are properly connected and make sure both are energized w/ 240ac after the heat call is palced.

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”).

For Non-Comm. Systems.

“A capital H 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

Check W2 & connections,

replace or repair as

necessary

Check t-stat, replace if

necessary.

(pre-purge) IDM runs for 30 sec. at low speed?

Does IDM Run for 60 Sec. and then off

for five minutes with fault

45, 46 or 57 displayed?

- See FAULT CODES under “Troubleshooting” in I&O Manual.

ECM BLOWER “ON” DELAY

J16-4

J16-5 on IFC.

NOTE: 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”.

Note: If good flame is not sensed a fault code “11” or “13” will be displayed at SSD’s Note: “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).

CHECK :

- 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

Remove heat call by setting T-stat set point below room temperature. For communicating t-stats, go to “setup” menu and set fixed fire rate to low. For legacy systems, ensure low heat call w/ 24vac on W1and 0 VAC on W2. Initiate new heat call. Allow heat call to proceed through blower on delay. The burners drop from high fire to low rate and I.B.M. energizes at low heat CFM.

Be sure to note dip switch settings before troubleshooting.

For Comm. System

Lower case “h”

Capital “H”

-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

CHECK : AIRFLOW - ensure no restrictions, such as dirty filter, blower wheel, dampers

or closed registers, Etc. exist. LIMITS - 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. ROLLOUTS - 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. OVERFIRE - ensure furnace is not overfired (temp rise is above stated range). Check gas valve, proper orifice size, gas presure

CHECK :

-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

Does the IDM Start on Low Speed?

TROUBLESHOOTING CHART

Page 64

SSD = Seven Segment Display of Furnace control COMM. = Communication. I&O = Installation & Operation Instructions Manual.

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”).

For Non-Comm. Systems.

“A capital H is displayed at IFC SSD’S” ?

Dual SSD’S “ON” ?

92-22744-24-00

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

Check W2 & connections,

replace or repair as

necessary

Check t-stat, replace if

necessary.

(pre-purge) IDM runs for 30 sec. at low speed?

Does IDM Run for 60 Sec. and then off

for five minutes with fault

45, 46 or 57 displayed?

- See FAULT CODES under “Troubleshooting” in I&O Manual.

ECM BLOWER “ON” DELAY

J16-4

J16-5 on IFC.

NOTE: 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”.

Note: If good flame is not sensed a fault code “11” or “13” will be displayed at SSD’s Note: “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).

CHECK :

- 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

Check to make sure test mode dip switches are properly set.

- 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.

Does I. B. M. energize at low speed?

After Blower on delay, Does IDM switch to low speed and remain at low speed after switching?

Does furnace continue to operate at low fire until T-stat satisfied or heat call removed?

Ensure T-stat not switching to high fire or test mode not timing out (1 hour limit)

Fault code displayed?

See FAULT CODES under

troubelshooting in the I & O Manual

Does IDM Shut off after post purge?

Does I. B. M. shut off after 90 seconds? (plus slew)

Double check - is heat call

completely off at IFC?

** 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.

For Comm. System

Lower case “h”

Capital “H”

-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

CHECK : AIRFLOW - ensure no restrictions, such as dirty filter, blower wheel, dampers

CHECK :

-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.

Remove heat call by setting T-stat below room temp.

Remove power to furnace, open blower compartment and restore dip switches to original settings. Replace blower door. Restore power to unit.

- 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.

G0 T0

Does the IDM Start on Low Speed?

PROBLEM PERSISTS

REPEAT THIS SEQUENCE UNTIL TROUBLE- FREE OPERATION

FIGURE 45

TROUBLESHOOTING CHART – CONTINUED

Page 65

TABLE 20

FURNACE FAULT CODES EXPANDED W/DESCRIPTIONS AND SOLUTIONS

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 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. NOTE:To clear current fault codes in the furnace control buffer, turn dipswitch SW3-2 on, off, on, off, or off, on, off, on within 30 seconds. The right-most seven-segment display will ener-

gize 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. The fault buffer can also be cleared at the user menu under “FAULT HISTORY” in the sub-menu titled “CLEAR FAULT HISTORY”. Either procedure will clear the fault codes in the buffer displayed at the dual seven-segment displays on the I.F.C. AND 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.

indicates that the message displayed at the thermostat active fault screen will be CARD-HARD CNFLCT.

at the Fault History user menu on communicating thermostats.

FAULT CODES

Page 66