Tempstar F8MTL, G8MTL Installation Instructions Manual

Download

Page 1

INSTALLATION INSTRUCTIONS

80% Two−Stage, PSC Motor

Category I, Gas Furnace

F8MTL & G8MTL

These instructions must be read and understood completely before attempting installation.

Safety Labeling and Signal Words

DANGER, WARNING, CAUTION, and NOTE Signal Words in Manuals

The signal words DANGER, WARNING, CAUTION, and NOTE are used to identify levels of hazard seriousness. The signal word DANGER is only used on product labels to signify an immediate hazard. The signal words WARNING, CAUTION, and NOTE will be used on product labels and throughout this manual and other manual that may apply to the product.

DANGER − Immediate hazards which will result in severe person- al injury or death.

WARNING − Hazards or unsafe practices which could result in severe personal injury or death.

CAUTION − Hazards or unsafe practices which may result in minor personal injury or product or property damage.

NOTE − Used to highlight suggestions which will result in en- hanced installation, reliability, or operation.

The signal word WARNING is used throughout this manual in the following manner:

WARNING

The signal word CAUTION is used throughout this manual in the following manner:

CAUTION

Signal Words on Product Labeling

Signal words are used in combination with colors and/or pictures or product labels.

Safety−alert symbol

When you see this symbol on the unit and in instructions or manuals, be alert to the potential for personal injury.

TABLE OF CONTENTS

SAFETY CONSIDERATIONS 3......................................

INTRODUCTION 4................................................

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

STEP 1 — SAFETY 4..............................................

STEP 2 — GENERAL INSTALLATION 4..............................

STEP 3 — COMBUSTION AND VENTILATION AIR 5...................

STEP 4 — DUCT SYSTEMS 5......................................

STEP 5 — ACOUSTICAL LINING AND FIBROUS GLASS DUCT 5........

STEP 6 — GAS PIPING AND GAS PIPE PRESSURE TESTING 5........

STEP 7 — ELECTRICAL CONNECTIONS 5...........................

STEP 8 — VENTING 5.............................................

ELECTROSTATIC DISCHARGE PRECAUTIONS PROCEDURE 5........

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

AIR FOR COMBUSTION ANDVENTILATION 7........................

MINIMUM FREE AREA REQUIRED 8................................

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

TABLE 6 – MAXIMUM CAPACITY OF PIPE 17..........................

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

STEP 1 — GENERAL 31............................................

STEP 2 — START−UP PROCEDURES 31.............................

STEP 3 — ADJUSTMENTS 32.......................................

ALTITUDE DERATE MULTIPLIER FOR U.S.A. 32.......................

STEP 4 — CHECK SAFETY CONTROLS 36...........................

STEP 5 — CHECKLIST 36...........................................

SERVICE AND MAINTENANCE PROCEDURES 40.....................

STEP 1 — INTRODUCTION 40.......................................

STEP 2 — CARE AND MAINTENANCE 41.............................

FILTER SIZE INFORMATION 43......................................

STEP 3 — SEQUENCE OF OPERATION 45............................

STEP 4 — WIRING DIAGRAMS 47...................................

STEP 5 — TROUBLESHOOTING 47..................................

Use of the AHRI Certified TM Mark indicates a manufacturer’s participation in the program. For verification of certification for individual products, go to www.ahridirectory.org .

WARNING

PERSONAL INJURY, AND/OR PROPERTY DAMAGE HAZARD

Failure to carefully read and follow this warning could result in equipment malfunction, property damage, personal injury and/or death. Installation or repairs made by unqualified persons could result in equipment malfunction, property damage, personal injury and/or death. The information contained in this manual is intended for use by a qualified service technician familiar with safety procedures and equipped with proper tools and test instruments. Installation must conform with local building codes and with the Natural Fuel Gas Code (NFCG) NFPA 54/ANSI Z223.1, and National standards of Canada CAN/CSA−B149.1 and .2 Natural Gas and Propane Installation Codes.

INSTALLER: Affix these instructions on or adjacent to the furnace. CONSUMER: Retain these instructions for future reference.

Portions of the text and tables are reprinted from NFPA 54 /ANSI Z223.1−2012©, with permission of National Fire Protection Association, Quincy, MA 02269 and American Gas Association, Washington, DC 20001. This reprinted material is not the complete and official position of the NFPA or ANSI, on the referenced subject, which is represented only by the standard in its entirety.

Printed in U.S.A. 441 01 2101 05 5/2/2016

Page 2

Figure 1 − Dimensional Drawing

VENT

SHIP

NOTES:

1. Two additional 7/8-in. (22 mm) diameter holes are located in the top plate.

2. Minimum return-air openings at furnace, based on metal duct. If flex duct is used, see flex duct manufacturer's recommendations for equivalent diameters. a. For 800 CFM-16-in. (406 mm) round or 14 1/2 x 12-in. (368 x 305 mm) rectangle. b. For 1200 CFM-20-in. (508 mm) round or 14 1/2 x 19 1/2-in. (368 x 495 mm) rectangle. c. For 1600 CFM-22-in. (559 mm) round or 14 1/2 x 22 1/16-in. (368 x 560mm) rectangle. d. For airflow requirements above 1800 CFM, see Air Delivery table in Product Data literature for specific use of single side inlets. The use of both side inlets, a combination of 1 side and the bottom, or the bottom only will ensure adequate return air openings for airflow requirements above 1800 CFM.

Table 1 – Dimensions

A B C D

FURNACE SIZE

CABINET WIDTH

IN (mm)

OUTLET WIDTH

IN (mm)

0451412 14−3/16 (360) 12−9/16 (319) 9−5/16 (237) 12−11/16 (322) 4 (102) 107 (49) 0701412 14−3/16 (360) 12−9/16 (319) 9−5/16 (237) 12−11/16 (322) 4 (102) 115 (52) 0901714 17−1/2 (445) 15−7/8 (403) 11−9/16 (294) 16 (406) 4 (102) 127 (58) 1102122 21 (533) 19−3/8 (492) 13−5/16 (338) 19−1/2 (495) 4 (102) 152 (69)

Specifications are subject to change without notice.

TOP AND BOTTOM

FLUE COLLAR

IN (mm)

BOTTOM INLET

WIDTH

IN (mm)

CONNECTION

IN (mm)

VENT

SIZE

LB (KG)

441 01 2101 05

Page 3

SAFETY CONSIDERATIONS

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

Failure to follow this warning could result in dangerous operation, serious injury, death, or property damage.

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

FURNACE RELIABILITY HAZARD

Improper installation or misapplication of furnace may require excessive servicing or cause premature component failure.

Application of this furnace should be indoors with special attention given to vent sizing and material, gas input rate, air temperature rise, unit leveling, and unit sizing.

CUT HAZARD

Failure to follow this caution may result in personal injury.

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

servicing furnaces. Improper installation, adjustment, alteration, service, maintenance, or use can cause explosion, fire, electrical shock, or other conditions which may cause death, personal injury, or property damage. Consult a qualified installer, service agency, or your distributor or branch for information or assistance. The qualified installer or agency must use factory−authorized kits or accessories when modifying this product. Refer to the individual instructions packaged with the kits or accessories when installing. Follow all safety codes. Wear safety glasses, protective clothing, and work gloves. Have a fire extinguisher available. Read these instructions thoroughly and follow all warnings or cautions include in literature and attached to the unit. Consult local building codes, the current editions of the National Fuel Gas Code (NFGC) NFPA 54/ANSI Z223.1 and the National Electrical Code (NEC) NFPA 70. Recognize safety information. This is the safety−alert symbol

. When you see this symbol on the unit and in instructions or manuals, be alert to the potential for personal injury. Understand the signal words DANGER, WARNING, and CAUTION. These words are used with the safety−alert symbol. DANGER identifies the most serious hazards which will result in severe personal injury or death. WARNING signifies hazards which could result in personal injury or death. CAUTION is used to identify unsafe practices which

may result in minor personal injury or product and property

WARNING

CAUTION

damage. NOTE is used to highlight suggestions which will result in enhanced installation, reliability, or operation.

product and property damage. NOTE is used to highlight suggestions which will result in enhanced installation, reliability, or operation.

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

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

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

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

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

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

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

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

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

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

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

12. Maintain a 1−in. (25 mm) clearance from combustible materials to supply air ductwork for a distance of 36 inches (914 mm) horizontally from the furnace. See NFPA 90B or local code for further requirements.

13. These furnaces SHALL NOT be installed directly on carpeting, tile, or any other combustible material other than wood flooring. In downflow installations, factory accessory floor base MUST be used when installed on combustible materials and wood flooring. Special base is not required when this furnace is installed on manufacturer’s coil model numbers END4X, EN24X or when the manufacturer’s coil casing model number NAEA is used. See Figure 2 for clearance to combustible construction information.

441 01 2101 05

Specifications are subject to change without notice.

Page 4

INTRODUCTION

F8MTL & G8MTL 4−way multipoise Category I fan−assisted furnace is CSA (formerly A.G.A. and C.G.A.) design−certified. A Category I fan−assisted furnace is an appliance equipped with an integral mechanical means to either draw or force products of combustion through the combustion chamber and/or heat exchanger. The furnace is factory−shipped for use with natural gas. This furnace is not approved for installation in mobile homes, recreational vehicles, or outdoors.

These furnaces shall not be installed directly on carpeting, tile, or any other combustible material other than wood flooring. For downflow installations, a factory accessory floor base must be used when installed on combustible materials and wood flooring. This special base is not required when this

Figure 2 − Clearances to Combustibles

furnace is installed on the manufacturer’s coil model numbers END4X, ENW4X, or when the manufacturer’s coil casing model number NAEA is used. See Figure 2 for clearance to combustible material information.

This furnace is designed for minimum continuous return−air temperature of 60F (16C) db or intermittent operation down to 55F (13C) db such as when used with a night setback thermostat. Return−air temperature must not exceed 80F (27C) db. Failure to follow these return−air temperature limits may affect reliability of heat exchangers, motors, and controls. (SeeFigure 3)

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

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

CODES AND STANDARDS

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

with regulations of the serving gas supplier, local building, heating, plumbing, and other codes. In absence of local codes, the installation must comply with the national codes listed below and all authorities having jurisdiction.

In the United States, follow all codes and standards for the following:

Step 1 — Safety

National Fuel Gas Code (NFGC) NFPA 54−2012/ANSI Z223.1−2012 and the Installation Standards, Warm Air Heating and Air Conditioning Systems ANSI/NFPA 90B

Step 2 — General Installation

Current edition of the NFGC and the NFPA 90B. For copies, contact the National Fire Protection Association Inc., Batterymarch Park, Quincy, MA 02269; (www.NFPA.org) or

Specifications are subject to change without notice.

for only the NFGC, contact the American Gas Association, 400 N. Capitol Street, N.W., Washington DC 20001 (www.AGA.org)

Figure 3 − Return Air Temperature

80F/27C

60F/16C

A06745

441 01 2101 05

Page 5

Step 3 — Combustion and Ventilation Air

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

Step 4 — Duct Systems

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

Step 5 — Acoustical Lining and Fibrous Glass Duct

Current edition of SMACNA and NFPA 90B as tested by UL Standard 181 for Class I Rigid Air Ducts

Step 6 — Gas Piping and Gas Pipe Pressure Testing

NFPA 54 / ANSI Z223.1−2012; chapters 5, 6, 7, and 8 and National Plumbing Codes

Step 7 — Electrical Connections

National Electrical Code (NEC) NFPA 70−2011

Step 8 — Venting

NFGC; NFPA 54 / ANSI Z223.1−2012 chapters 12 and 13

ELECTROSTATIC DISCHARGE (ESD)

PRECAUTIONS PROCEDURE

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

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

Figure 4 − Multipoise Orientations

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

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

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

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

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

CAUTION

FURNACE RELIABILITY HAZARD

Improper installation or service of furnace may cause premature furnace component failure.

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

THE BLOWER IS LOCATED

TO THE RIGHT OF THE

BURNER SECTION, AND

AIR CONDITIONED AIR IS

DISCHARGED TO THE LEFT.

THE BLOWER IS

LOCATED ABOVE THE

BURNER SECTION, AND

CONDITIONED AIR IS

DISCHARGED DOWNWARD

441 01 2101 05

Specifications are subject to change without notice.

THE BLOWER IS

LOCATED BELOW THE

BURNER SECTION, AND

CONDITIONED AIR IS

DISCHARGED UPWARD.

THE BLOWER IS

LOCATED TO THE LEFT

OF THE BURNER SECTION,

AND CONDITIONED AIR IS

DISCHARGED TO THE RIGHT.

A02097

Page 6

LOCATION

GENERAL

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

NOTE: For high−altitude installations, the high−altitude conversion kit MUST be installed at or above 5500 ft. (1676 M) above sea level. Obtain high−altitude conversion kit from your area authorized distributor.

This furnace must:  be installed so the electrical components are protected from

water.

NOTE: For downflow applications, this furnace is approved for use on combustible flooring when any one of the following are used:

Downflow combustible factory−approved floor subbase Coil model numbers EAM4X, EDM4X, EMA4X, END4X

or ENW4X

Coil casing model number NAEA

 be located close to the chimney or vent and attached to an

air distribution system. Refer to Air Ducts section.

 be provided ample space for servicing and cleaning. Always

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

The following types of furnace installations may require OUTDOOR AIR for combustion due to chemical exposures:

 Commercial buildings  Buildings with indoor pools  Laundry rooms  Hobby or craft rooms, and  Chemical storage areas

 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

All fuel−burning equipment must be supplied with air for fuel combustion. Sufficient air must be provided to avoid negative pressure in the equipment room or space. A positive seal must be return−air duct to and from draft safeguard

made between the furnace cabinet and the

prevent pulling air from the burner area

opening.

FIRE, INJURY OR DEATH HAZARD

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

When the furnace is installed in a residential garage, the burners and ignition sources must be located at least 18 inches (457 mm) above the floor. The furnace must be located or protected to avoid damage by vehicles. When the furnace is installed in a public garage, airplane hangar, or other building having a hazardous atmosphere, the furnace must be installed in accordance with the NFGC. (See Figure 5)

WARNING

Figure 5 − Installation in a Garage

CARBON MONOXIDE POISONING AND UNIT DAMAGE HAZARD

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

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

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

for combustion:

 Permanent wave solutions  Chlorinated waxes and cleaners  Chlorine based swimming pool chemicals

WARNING

18−IN. (457.2 mm)

MINIMUM TO BURNERS

A93044

FIRE HAZARD

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

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

WARNING

Specifications are subject to change without notice.

441 01 2101 05

Page 7

Figure 6 − Prohibit Installation on Back

A02054

CAUTION

PROPERTY DAMAGE HAZARD

Improper use or installation of this furnace may cause premature component failure. This gas furnace may be used for construction heat provided that:

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

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

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

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

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

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

−The furnace, ductwork and filters are cleaned as necessary to remove drywall dust and construction debris from all HVAC system components after construction is completed. −Verify proper furnace operating conditions including ignition, gas input rate, air temperature rise, and venting according to these installation instructions.

LOCATION RELATIVE TO COOLING EQUIPMENT

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

AIR FOR COMBUSTION AND

VENTILATION

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

U.S. installations: Section 9.3 of the NFPA 54 /A ANSI Z223.1−2012, Air for Combustion and Ventilation, and applicable provisions of the local building codes.

CAUTION

FURNACE CORROSION HAZARD

Failure to follow this caution may result in furnace damage.

Air for combustion must not be contaminated by halogen compounds, which include fluoride, chloride, bromide, and iodide. These elements can corrode heat exchangers and shorten furnace life. Air contaminants are found in aerosol sprays, detergents, bleaches, cleaning solvents, salts, air fresheners, and other household products.

CARBON MONOXIDE POISONING HAZARD

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

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

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

 Spaces having less than 50 cubic feet per 1,000 Btuh

require the Outdoor Combustion Air Method.

 Spaces having at least 50 cubic feet per 1,000 Btuh may

use the Indoor Combustion Air, Standard or Known Air

Infiltration Method.

Outdoor Combustion Air Method

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

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

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

of the ceiling and the second opening MUST

commence within 12 in. (300 mm) of the floor. b. Size openings and ducts per Figure 7 and Table 2. c. TWO HORIZONTAL DUCTS require 1 −in

area per 2,000 Btuh (1,100 mm

input for all gas appliances in the space per Figure 7

and Table 2.

WARNING

/kW) of combined

of free

441 01 2101 05

Specifications are subject to change without notice.

Page 8

d. TWO OPENINGS OR VERTICAL DUCTS require 1

−in

of free area per 4,000 Btuh (550 mm2/kW) for

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

connectors in the space. combined input of all gas appliances in the space per Figure 7 and Table 2

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

/kW) for combined input of all gas appliances in

the space per Table 2 and

Table 2 – Minimum Free Area Required for Each Combustion Air opening of Duct to Outdoors

FURNACE

INPUT

(BTUH)

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

110,000 55 (35484) 9 (229) 36.7 (23677) 7 (178) 27.5 (17742) 6 (152)

TWO HORIZONTAL DUCTS SINGLE DUCT OR OPENING TWO OPENINGS OR VERTICAL DUCTS

(1 SQ. IN./2,000 BTUH) (1,100 SQ. MM/KW) (1 SQ. IN./3,000 BTUH) (734 SQ. MM/KW) (1 SQ. IN./4,000 BTUH) (550 SQ. MM/KW)

Free Area of Opening

and Duct

Sq. In. (Sq. mm)

Round Duct

Dia.

In. (mm)

Free Area of Opening

and Duct

Sq. In. (Sq. mm)

Round Duct

Dia.

In. (mm)

Free Area of Opening

and Duct

Sq. In. (Sq. mm)

Round Duct

Dia.

In. (mm)

EXAMPLES: Determining Free Area

FURNACE WATER HEATER TOTAL INPUT

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

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

88,000 + 30,000 = (118,000 divided by 2,000) = 59.0 Sq. In. for each of two Horizontal Ducts

Figure 7 − Air for Combustion, Ventilation, and Dilution

for Outdoors

1 SQ IN.

12 ″ MAX

(305mm)

PER 4000 BTUH*

1 SQ IN .

BTUH*

1 SQ IN .

BTUH*

1 SQ IN. PER 4000 BTUH*

12 ″

(305mm)

MAX

PER

4000

OUTDOORS

PER 4000

12 ″

(305mm)

MAX

A03174

DUCTS

O UTDOORS

(305mm)

12 ″ MAX

1 SQ IN. PER 2000 BTUH*

DUCT S

OUTDOORS

1 SQ IN. PER 2000 BTUH*

(305mm)

12 ″ MAX

CIRCULA TING AIR DUCT S

*Minimum dimensions of 3−in. (76 mm). Note: Use any of the following combinations of openings: A & B C & D D & E F & G

AIR DUCTS

C IRCULA TING

OF COMB USTION AIR

CLEARANCE IN FRONT

VENT THR OUGH R OOF

(76mm)

AT LEAST 3 IN .

OPENINGS SHALL BE

DUCT

OUTDOORS

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

Figure 8 − Air for Combustion, Ventilation, and Dilution

from Indoors

CIRCULATING AIR

DUCTS

INTERIOR

HEATED

SPACE

CIRCULATING AIR DUCTS

* Minimum opening size is 100 sq in. (64516 sq. mm) with minimum dimensions of 3 in. (76 mm) † Minimum of 3 in. (76 mm) when type‐B1 vent is used.

VENT THROUGH ROOF

12" MAX

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

UNCONFINED SPACE

(152mm)

6" MIN (FRONT)

1 SQ IN. PER 1000 BTUH* IN DOOR

OPENINGS SHALL BE AT LEAST 3 IN.

OR WALL

CLEARANCE IN FRONT OF COMBUSTION AIR

12" MA X

(305mm)

A03175

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

Indoor air is permitted for combustion, ventilation, and

dilution, if the Standard or Known−Air−Infiltration Method is used.

Specifications are subject to change without notice.

441 01 2101 05

Page 9

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

CARBON MONOXIDE POISONING HAZARD

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

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

The Standard Method:

1. The space has no less volume than 50 cubic feet per 1,000 Btuh of the maximum input ratings for all gas appliances installed in the space and

ACH

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

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

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

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

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

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

0.00 NP NP NP NP NP NP NP NP NP

ACH = Air Changes/Hour NP = Not Permitted

WARNING

Table 3 – Minimum Space Volumes for 100% Combustion, Ventilation, and Dilution from Indoors

OTHER THAN FAN−ASSISTED TOTAL

(1,000s BTUH GAS INPUT RATE)

30 40 50 44 66 88 110 132 154

Space Volume (ft.3)

air changes per hour (ACH).

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

1. Less than 0.40 ACH and

2. Equal to or greater than 0.10 ACH

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

FAN −ASSISTED TOTAL

(1,000s BTUH GAS INPUT RATE)

Table 3−Minimum Space Volumes were determined by

using the following equations from the National Fuel Gas Code ANSI Z223.1−2012/NFPA 54−2012, 9.3.2.2:

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

Volume

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

Volume

If: I

= combined input of all other than fan−assisted

other

fan

ACH = air changes per hour (ACH shall not exceed 0.60.)

The following requirements apply to the Standard Method and to the Known Air Infiltration Rate Method.

appliances in Btuh/hr

= combined input of all fan−assisted appliances in

Btuh/hr

1. Adjoining rooms can be considered part of a space if: a. There are no closeable doors between rooms. b. Combining spaces on same floor level. Each opening

shall have free area of at least 1 in. mm in the space, but not less than 100 in. opening shall commence within 12 in. (300 mm) of the

Other

Fan

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

21ft ACH

15ft ACH

other

1000 Btu/hr

fan

1000 Btu/hr

/1,000 Btuh (2,000

(0.06 m2). One

A04002

A04003

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

c. Combining space on different floor levels. The

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

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

2. An attic or crawlspace may be considered a space that freely communicates with the outdoors provided there are adequate permanent ventilation openings directly to outdoors having free area of at least 1−in.2/4,000 Btuh of total input rating for all gas appliances in the space.

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

a. Walls and ceilings exposed to the outdoors have a

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

b. Doors and openable windows are weatherstripped

and

c. Other openings are caulked or sealed. These include

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

/1,000 Btuh (4,400

441 01 2101 05

Specifications are subject to change without notice.

Page 10

Combination of Indoor and Outdoor Air

1. Indoor openings shall comply with the Indoor Combustion Air Method below and,

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

3. Outdoor openings shall be sized as follows: a. Calculate the Ratio of all Indoor Space volume divided

by required volume for Indoor Combustion Air Method below.

b. Outdoor opening size reduction Factor is 1 minus the

Ratio in a. above.

c. Minimum size of Outdoor openings shall be the size

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

INSTALLATION

UPFLOW INSTALLATION Bottom Return Air Inlet

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

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

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

3. Remove bottom closure panel.

4. Reinstall bottom filler panel and screws.

Side Return Air Inlet

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

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

Figure 9 − Removing Bottom Closure Panel

BOTTOM CLOSURE PANEL

BOTTOM FILLER PANEL

Leveling Legs (If Desired)

In upflow position with side return inlet(s), leveling legs may be used. (See Figure 10) Install field−supplied, 5/16 x 1−1/2 in. (8 x 38 mm) (max) corrosion−resistant machine bolts, washers and nuts.

NOTE: Bottom closure must be used when leveling legs are used. It may be necessary to remove and reinstall bottom closure panel to install leveling legs. To remove bottom

closure panel, see item 1 in Bottom Return Air Inlet section in Step 1 above.

To install leveling legs:

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

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

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

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

5. Reinstall bottom closure panel if removed.

Figure 10 − Leveling Legs

″

(8mm)

″

1 3 / 4 ″

(44mm)

/ 4 ″

(44mm)

(8mm)

″

(8mm)

″

(44mm)

4 ″

A89014

(44mm)

DOWNFLOW INSTALLATION NOTE: For downflow applications, this furnace is approved

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

Downflow combustible factory−approved floor subbase Coil model numbers EAM4X, EDM4X, EMA4X, END4X

or ENW4X

Coil casing model number NAEA

1. Determine application being installed from Table 4.

2. Construct hole in floor per Table 4 and Figure 13.

3. Construct plenum to dimensions specified in Table 4 and Figure 13.

4. If downflow subbase is used, install as shown in Figure 11. If coil model numbers END4X, ENW4X or coil casing model number NEAE is used, install as shown in Figure 12.

NOTE: It is recommended that the perforated supply−air duct flanges be completely folded over or removed from furnace when installing the furnace on a factory−supplied cased coil or coil casing. To remove the supply−air duct flange, use wide duct pliers or hand seamers to bend flange back and forth until it breaks off. Be careful of sharp edges. (See Figure 14)

Specifications are subject to change without notice.

441 01 2101 05

Page 11

Figure 11 − Furnace, Plenum, and Subbase installed on

a Combustible Floor

FURNACE

(OR COIL CASING

WHEN USED)

COMBUSTIBLE

FLOORING

DOWNFLOW

SUBBASE

SHEET METAL

PLENUM

FLOOR

OPENING

HORIZONTAL INSTALLATION

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

Figure 13 − Floor and Plenum Opening Dimensions

B D

A96283

A96285

Figure 12 − Furnace, Plenum, and Coil or Coil Casing

Installed on a Combustible Floor

FURNACE

APPROVED

COIL ASSEMBLY

COIL BOX

COMBUSTIBLE

FLOORING

SHEET METAL

PLENUM

FLOOR

OPENING

A08556

Bottom Return Air Inlet

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

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

3. Remove bottom closure panel.

4. Reinstall bottom filler panel and screws.

441 01 2101 05

Specifications are subject to change without notice.

WARNING

FIRE, EXPLOSION, AND CARBON MONOXIDE POISONING HAZARD

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

Suspended Furnace Support

The furnace may be supported under each end with threaded rod, angle iron or metal plumber’s strap as shown. (See Figure 15 and Figure 16) Secure angle iron to bottom of furnace as shown. Heavy−gauge sheet metal straps (plumber’s straps) may be used to suspend the furnace from each bottom corner. To prevent screws from pulling out, use two (2) #8 x 3/4−in. (19 mm) screw into the side and 2 #8 x 3/4−in. (19 mm) screw in the bottom of the furnace casing for each strap. (See Figure 15 and Figure 16)

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

Platform Furnace Support

Construct working platform at location where all required furnace clearances are met. (See Figure 2 and Figure 17) For furnaces with 1−in. (25 mm) clearance requirement on side, set furnace on non−combustible blocks, bricks or angle iron. For crawlspace installations, if the furnace is not suspended from the floor joists, the ground underneath furnace must be level and the furnace set on blocks or bricks.

Roll−Out Protection

Provide a minimum 17−3/4−in. x 22−in. (451 x 559 mm) piece of sheet metal for flame roll−out protection in front of burner area for furnaces closer than 12 inches (305 mm) above the

Page 12

combustible deck or suspended furnaces closer than 12 inches (305 mm) to joists. The sheet metal MUST extend underneath the furnace casing by 1 in. (25 mm) with the door removed.

The bottom closure panel on furnaces of widths 17−1/2 in. (445 mm) and larger may be used for flame roll−out protection when bottom of furnace is used for return air connection. See Figure 17 for proper orientation of roll−out shield.

Bottom Return Air Inlet

Table 4 – Opening dimensions − In. (mm)

FURNACE

CASING

APPLICATION

WIDTH

Upflow Applications on Combustible or Noncombustible Flooring

(subbase not required)

Downflow Applications on Noncombustible Flooring

14–3/16

(376)

Downflow Applications on Combustible Flooring (subbase required)

(subbase not required)

Downflow Applications on Combustible Flooring with Coil END4X,

ENW4X or Coil Casing NAEA (subbase not required)

Upflow Applications on Combustible or Noncombustible Flooring

(subbase not required)

Downflow Applications on Noncombustible Flooring

17–1/2

(445)

Downflow Applications on Combustible Flooring (subbase required)

(subbase not required)

Downflow Applications on Combustible Flooring with Coil

END4X, ENW4X or Coil Casing NAEA (subbase not required)

Upflow Applications on Combustible or Noncombustible Flooring

(subbase not required)

Downflow Applications on Noncombustible Flooring with Coil

(533)

END4X, ENW4X or Coil Casing NAEA (subbase not required)

Downflow Applications on Combustible Flooring

(subbase required)

Downflow Applications on Combustible Flooring with Coil END4X,

ENW4X or Coil Casing NAEA (subbase not required)

Figure 14 − Duct Flanges

UPFLOW DOWNFLOW HORIZONTAL

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

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

3. Remove bottom closure panel.

4. Reinstall bottom filler panel and screws.

Side Return Air Inlet

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

PLENUM OPENING FLOOR OPENING

A B C D

12−11/16

(322)

12−9/16

(319)

11−13/16

(284)

12−5/16

(319)

(406)

15−7/8

(403)

15−1/8

(384)

15−1/2

(394)

19−1/2

(495)

19−3/8

(492)

18−5/8

(473)

(483)

21−5/8

(549)

(483)

21−5/8

(549)

(483)

21−5/8

(549)

(483)

13−5/16

(338)

13−3/16

(335)

13−7/16

(341)

13−5/16

(338)

16−5/8

(422)

16−1/2

(419)

16−3/4

(425)

16−1/2

(419)

20−1/8

(511)

(508)

20−1/4

(514)

(508)

22−1/4

(565)

19−5/8

(498)

20−5/8

(600)

(508)

22−1/4

(565)

19−5/8

(498)

20−5/8

(600)

(508)

22−1/4

(565)

19−5/8

(498)

20−5/8

(600)

(508)

120° MIN

90°

YES

120°

MIN

Specifications are subject to change without notice.

YES

120°

MIN

90°

YES

A02020

441 01 2101 05

Page 13

OUTER DOOR A S SEMBLY

8" (203mm) FOR DOOR REMOVAL

MIN

Figure 15 − Horizontal Unit Suspension

4 " (6mm) THREADED ROD

4 REQ.

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

SECURE ANGLE IRON TO BOTTOM OF FURNACE WITH

/4" (19mm) SCREWS

3 #8 x TYPICAL FOR 2 SUPPORTS

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

Figure 16 − Horizontal Suspension with Straps

METHOD 2 USE (4) #8 x 3/4 (19 mm) SHEET METAL SCREWS FOR EACH STRAP. THE STRAPS SHOULD BE VERTICAL AGAINST THE FURNACE SIDES AND NOT PULL AWAY FROM THE FURNACE SIDES.

A10130

441 01 2101 05

METHOD 1 FOLD ALL STRAPS UNDER FURNACE AND SECURE WTH (4) #8 x 3/4 (19 mm) SHEET METAL SCREWS (2 SCREWS IN SIDE AND 2 SCREWS IN BOTTOM).

Specifications are subject to change without notice.

A10131

Page 14

LINE CONT A CT ONL Y PERMISSIBLE BETWEEN LINES FORMED BY INTERSECTIONS OF THE T OP AND TW O SIDES OF THE FURNA CE JA CKET AND BUILDING JOISTS , STUDS , OR FRAMING.

EQUIPMENT MANU AL

SHUT -OFF GAS VA LV E

Figure 17 − Typical Attic Installation

SHEET MET AL

GAS ENTR Y

17 3 / 4 ″

(559mm)

″

(451mm)

6 ″

M IN

TYPE-B VENT

(152mm)

30-IN . (762mm) MIN WORK AREA

17 3 / 4 ″

(451mm)

4 3 / 4 ″

(121mm)

1 ″

(25mm)

EXTEND OUT 12 ″ FR OM FA CE OF DOOR

* WHEN USED W ITH SINGLE W ALL VEN T CONNECTIONS

OVERALL

UNDER DOOR

UNDER FURNACE

(305mm)

SEDIMENT

TRAP

UNION

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

FILTER ARRANGEMENT

WARNING

CARBON MONOXIDE POISONING HAZARD

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

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

There are no provisions for an internal filter rack in these furnaces. A field−supplied, accessory external filter rack is required.

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

AIR DUCTS General Requirements

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

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

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

A10164

NOTE: Flexible connections should be used between ductwork and furnace to prevent transmission of vibration.

Ductwork passing through unconditioned space should be insulated to enhance system performance. When air conditioning is used, a vapor barrier is recommended.

Maintain a 1−in. (25 mm) clearance from combustible materials to supply air ductwork for a distance of 36 in. (914 mm) horizontally from the furnace. See NFPA 90B or local code for further requirements.

Ductwork Acoustical Treatment NOTE: Metal duct systems that do not have a 90 elbow and

10 ft. (3 M) of main duct to the first branch take−off may require internal acoustical lining. As an alternative, fibrous ductwork may be used if constructed and installed in accordance with the latest edition of SMACNA construction standard on fibrous glass ducts. Both acoustical lining and fibrous ductwork shall comply with NFPA 90B as tested by UL Standard 181 for Class 1 Rigid air ducts.

Supply Air Connections

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

Upflow and Horizontal Furnaces

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

A02329

Specifications are subject to change without notice.

441 01 2101 05

Page 15

Table 5 – Air Delivery − CFM (With Filter)*

FURNACE

SIZE

0451412

0701412

0901714

1102422

*A filter is required for each return−air inlet. Airflow performance included 3/4−in. (19 mm) washable filter media such as contained in factory−authorized accessory filter rack. To determine airflow performance without this filter, assume an additional 0.1 In. W.C. available external static pressure.

−− Indicates unstable operating conditions.

RETURN-AIR

INLET

Bottom or

Side(s)

Bottom or

Side(s)

Bottom or

Side(s)

Bottom Only

Bottom Sides or

1 Side & Bottom

1Side Only

SPEED

High

Med-High

Medium

Med-Low

Low

High

Med-High

Medium

Med-Low

Low

High

Med-High

Med-Low

Low

High

Med-High

Medium

Med-Low

Low

High

Med-High--2205--2175

High

Med-High

Medium

Med-Low

Low

0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0

1465 1295 1150 1030

860 1440 1180 1015

885

695 1650 1515 1385 1205 2530 2225 1895 1565 1320

2485 2155 1830 1520 1275

1400 1260 1120 1010

835 1400 1165 1020

885

700 1600 1485 1360 1180 2460 2190 1885 1555 1295

2430 2135 1830 1505 1260

EXTERNAL STATIC PRESSURE (IN. W.C.)

1325 1210 1085

980

810 1355 1150 1010

880

700 1535 1440 1320 1160 2380 2135 1865 1535 1265 2415 2120 2360 2100 1810 1490 1240

1250 1155 1040

945

780 1300 1125

990

865

690 1465 1380 1260 1120 2285 2075 1820 1505 1235 2330 2065 2270 2040 1780 1470 1210

1175 1090

985 895

745 1240 1085

965

845

670 1385 1300 1195 1065 2200 1995 1770 1465 1205 2235 1975 2175 1970 1730 1430 1180

1085 1015

920 835

700 1170 1030

925

815

640 1285 1220 1120 1005 2085 1910 1700 1410 1160 2125 1900 2070 1885 1665 1385 1135

980 930 835 765 635

1090

970 875 770

600 1175 1115 1025

925 1970 1805 1610 1350 1105 1995 1790 1950 1790 1595 1330 1090

860 830 740 685 555

1000

890 800 700 540

1055

990 915

810 1835 1695 1520 1265 1035 1860 1685 1825 1680 1505 1250 1025

725 700 620 570 445 890 785 700 605 460 895 830 710

630 1695 1565 1410 1175

950 1735 1580 1685 1560 1395 1165

930

560 545 510 345 260 745 645 560 475 345 645 600 565

510 1545 1430 1290 1050

870 1605 1460 1535 1420 1275 1055

840

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

Downflow Furnaces

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

Return Air Connections

WARNING

FIRE HAZARD

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

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

Downflow Furnaces

The return−air duct must be connected to return−air opening (bottom inlet) as shown in Figure 1. DO NOT cut into casing sides (left or right). Side opening is permitted for only upflow and most horizontal furnaces. Bypass humidifier connections

should be made at ductwork or coil casing sides exterior to furnace. (See Figure 19)

Upflow and Horizontal Furnaces

The return−air duct must be connected to bottom, sides (left or right), or a combination of bottom and side(s) of main furnace casing as shown in Figure 1. Bypass humidifier may be attached into unused return air side of the furnace casing. (See Figure 18 and Figure 20) Not all horizontal furnaces are approved for side return air connections. (See Figure 20)

GAS PIPING

WARNING

FIRE OR EXPLOSION HAZARD

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

Never purge a gas line into a combustion chamber. Never test for gas leaks with an open flame. Use a commercially available soap solution made specifically for the detection of leaks to check all connections. A fire or explosion may result causing property damage, personal injury or loss of life.

WARNING

FIRE OR EXPLOSION HAZARD

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

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

441 01 2101 05

Specifications are subject to change without notice.

Page 16

WARNING

FIRE OR EXPLOSION HAZARD

Failure to protect gas valve inlet from water and debris could result in death, personal injury and/or property damage.

Gas valve inlet and/or inlet pipe must remain capped until gas supply line is permanently installed to protect the valve from moisture and debris. Also, install a sediment trap in the gas supply piping at the inlet to the gas valve.

Figure 18 − Upflow Return Air Configurations and Restrictions

5 TONS AND

GREATER

2000 CFM AND GREATER AT .6 ESP HI COOLING SPEED

Figure 19 − Downflow Return Air Configurations and Restrictions

5 TONS AND

GREATER

* 2000 CFM AND GREATER AT .6 ESP HI COOLING SPEED

Specifications are subject to change without notice.

441 01 2101 05

Page 17

Figure 20 − Horizontal Return Air Configurations and Restrictions

5 TONS AND

GREATER

* 2000 CFM AND GREATER AT .6 ESP HI COOLING SPEED

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

WARNING

Table 6 – Maximum Capacity of Pipe

NOMINAL

IRON PIPE

SIZE

IN. (MM)

1/2 (12.7)

3/4 (19.0)

1( 25.4)

1‐1/4

(31.8)

1‐1/2

(38.1)

* Cubic ft. of natural gas per hr for gas pressures of 0.5 psig (14−In. W.C.) or

less and a pressure drop of 0.5−In. W.C. (based on a 0.60 specific gravity gas). Ref: Table 6 and NFPA54/ANSI Z223.1−2012.

INTERNAL

DIA.

IN. (MM)

0.622 (158)

0.824

(20.9)

1.049 (26.6)

1.380 (35.0)

1.610 (40.9)

LENGTH OF PIPE - FT. (M)

(3.0)20(6.0)30(9.1)40(12.1)50(15.2)

175 120 97 82 73

360 250 200 170 151

680 465 375 320 285

1400 950 770 660 580

2100 1460 1180 990 900

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

NOTE: In the state of Massachusetts:

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

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

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

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

Refer to Table 6 for recommended gas pipe sizing. Risers must be used to connect to furnace and to meter. Support all gas piping with appropriate straps, hangers, etc. Use a minimum of 1 hanger every 6 ft. (1.8 M). Joint compound (pipe dope) should be applied sparingly and only to male threads of joints. Pipe dope must be resistant to the action of propane gas.

FIRE OR EXPLOSION HAZARD

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

If local codes allow the use of a flexible gas appliance connector, always use a new listed connector. Do not use a connector which has previously served another gas appliance. Black iron pipe shall be installed at the furnace gas control valve and extend a minimum of 2 in. (51 mm) outside the furnace.

CAUTION

FURNACE DAMAGE HAZARD

Failure to follow this caution may result in furnace damage.

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

An accessible manual equipment shutoff valve MUST be installed external to furnace casing and within 6 ft. of furnace. A 1/8−in. (3 mm) NPT plugged tapping, accessible for test gauge connection, MUST be installed immediately upstream of gas supply connection to furnace and downstream of manual equipment shutoff valve.

NOTE: The furnace gas control valve inlet pressure tap connection is suitable to use as test gauge connection providing test pressure DOES NOT exceed maximum 0.5 psig (14−In. W.C.) stated on gas control valve. (See Figure 48) Some installations require gas entry on right side of furnace (as viewed in upflow). (See Figure 21)

441 01 2101 05

Specifications are subject to change without notice.

Page 18

Figure 21 − Burner and Manifold

2” (51mm)

Street Elbow

A08551

Install a sediment trap in riser leading to furnace as shown in Figure 22. Connect a capped nipple into lower end of tee. Capped nipple should extend below level of furnace gas controls. Place a ground joint union between furnace gas control valve manifold and exterior manual equipment gas shutoff valve.

Figure 23 − Field Wiring Diagram

Figure 22 − Typical Gas Pipe Arrangement

GAS SUPPLY

MANUAL SHUTOFF VALVE (REQUIRED)

SEDIMENT TRAP

UNION

A02035

A 1/8−in. (3 mm) NPT plugged tapping, accessible for test gauge connection, MUST be installed immediately upstream of gas supply connection to furnace and downstream of manual equipment shutoff valve. Piping should be pressure and leak tested in accordance with NFGC in the United States, local, and national plumbing and gas codes before the furnace has been connected. After all connections have been made, purge lines and check for leakage at furnace prior to operating furnace. If pressure exceeds 0.5 psig (14−In. W.C.), gas supply pipe must be disconnected from furnace and capped before and during supply pipe pressure test. If test pressure is equal to or less than 0.5 psig (14−In. W.C.), turn off electric shutoff switch located on furnace gas control valve and accessible manual equipment shutoff valve before and during supply pipe pressure test. After all connections have been made, purge lines and check for leakage at furnace prior to operating furnace. The gas supply pressure shall be within the maximum and minimum inlet supply pressures marked on the rating plate with the furnace burners ON and OFF.

Specifications are subject to change without notice.

ELECTRICAL CONNECTIONS

WARNING

ELECTRICAL SHOCK, FIRE OR EXPLOSION HAZARD

Failure to follow safety warnings could result in dangerous operation, serious injury, death or property damage. Improper servicing could result in dangerous operation, serious injury, death or property damage.

 Before servicing, disconnect all electrical

power to furnace.

 When servicing controls, label all wires prior

to disconnecting. Reconnect wires correctly.

 Verify proper operation after servicing.

441 01 2101 05

Page 19

WARNING

CAUTION

ELECTRICAL SHOCK HAZARD

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

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

See Figure 23 for field wiring diagram showing typical field 115 −v wiring. Check all factory and field electrical connections for tightness.

Field−supplied wiring shall conform with the limitations of 63F (33C) rise.

ELECTRICAL SHOCK AND FIRE HAZARD

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

The cabinet MUST have an uninterrupted or unbroken ground according to NEC NFPA 70−2011 or local codes to minimize personal injury if an electrical fault should occur. This may consist of electrical wire, conduit approved for electrical ground or a listed, grounded power cord (where permitted by local code) when installed in accordance with existing electrical codes. Refer to the power cord manufacturer’s ratings for proper wire gauge. Do not use gas piping as an electrical ground.

WARNING

FURNACE MAY NOT OPERATE HAZARD

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

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

115−V WIRING

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

Table 7 – Electrical Data

FURNACE

SIZE

0451412 115 −60−1 127 104 7.1 9.67 38 (11.5) 15 14 0701412 115 −60−1 127 104 7.3 9.90 37 (11.2) 15 14 0901714 115 −60−1 127 104 8.2 10.84 34 (10.3) 15 14 1102122 115−60−1 127 104 13.7 17.60 32 (9.7) 20 12

* Permissible limits of the voltage range at which the unit operates satisfactorily. # Unit ampacity = 125% of largest operating component’s full load amps plus 100% of all other potential operating components (EAC, humidifier, etc.) full load amps.

 Time−delay type is recommended.  Length shown is as measured 1 way along wire path between unit and service panel for maximum 2% voltage drop.

U.S. Installations: Make all electrical connections in accordance with National Electrical Code (NEC) NFPA 70−2011 and any local codes or ordinances that might apply.

FIRE HAZARD

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

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

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

NOTE: Proper polarity must be maintained for 115−v wiring. If polarity is incorrect, control LED status indicator light will flash status code of 10 and furnace will NOT operate.

VOLTS− HERTZ−

PHASE

WARNING

OPERATING VOLTAGE

RANGE

MAX* MIN.*

MAX UNIT

AMPS

UNIT

AMPACITY#

J−BOX RELOCATION NOTE: If factory location of J−Box is acceptable, go to next

section (ELECTRICAL CONNECTION TO J−BOX). NOTE: On 14” wide casing models, the J−Box shall not be

relocated to other side of furnace casing when the vent pipe is routed within the casing.

1. Remove and save two screws holding J−Box. (See Figure 24)

NOTE: The J−Box cover need not be removed from the J−Box in order to move the J−Box. Do NOT remove green ground screw inside J−Box.

2. Cut wire tie on loop in furnace wires attached to J−Box.

3. Move J−Box to desired location.

4. Fasten J−Box to casing with the two screws removed in Step 1.

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

MAXIMUM

WIRE

LENGTH

FT. (M)‡

MAXIMUM

FUSE OR CKT BKR

AMPS†

MINIMUM

WIRE

GAUGE

441 01 2101 05

Specifications are subject to change without notice.

Page 20

Figure 24 − Relocating J−Box

FACTORY INSTALLED LOCATION

ALTERNATE FIELD LOCATION

ELECTRICAL CONNECTION TO J−BOX

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

Electrical Box on Furnace Casing Side. See Figure 25

WARNING

FIRE OR ELECTRICAL SHOCK HAZARD

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

If field−supplied manual disconnect switch is to be mounted on furnace casing side, select a location where a drill or fastener cannot damage electrical or gas components.

Figure 25 − Field−Supplied Electrical Box on Furnace

Casing

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

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

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

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

4. Remove and save two screws holding J−Box. (See Figure 24)

5. Pull furnace power wires out of 1/2−inch (12 mm) diameter hole in J−Box. Do not loosen wires from strain−relief wire−tie on outside of J−Box.

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

7. Pull field power wires into electrical box.

8. Remove cover from furnace J−Box.

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

10. Reattach furnace J−Box to furnace casing with screws removed in Step 4.

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

12. Complete electrical box wiring and installation. Connect line voltage leads as shown in Figure 23. Use best practices (NEC in U.S. for wire bushings, strain relief, etc.

13. Reinstall cover to J−Box. Do not pinch wires between cover and bracket.

POWER CORD INSTALLATION IN FURNACE J−BOX NOTE: Power cords must be able to handle the electrical

requirements listed in Table 7. Refer to power cord manufacturer’s listings.

1. Remove cover from J−Box.

2. Route listed power cord through 7/8−inch (22 mm) diameter hole in J−Box.

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

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

5. Connect line voltage leads as shown in Figure 23.

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

BX. CABLE INSTALLATION IN FURNACE J−BOX

1. Remove cover from J−Box.

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

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

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

5. Connect line voltage leads as shown in Figure 23.

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

24−V WIRING

Make field 24−v connections at the 24−v terminal strip. (See Figure 23) Connect terminal Y/Y2 as shown in Figure 26−Figure 32 for proper cooling operation. Use only AWG No. 18, color−coded, copper thermostat wire.

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

Specifications are subject to change without notice.

441 01 2101 05

Page 21

Figure 26 − Two−Stage Furnace with Single−Speed Air

Conditioner

Figure 27 − Two−Stage Furnace with Two−Stage Air

Conditioner

Figure 28 − Two−Stage Furnace with Single−Stage Heat

Pump (Dual Fuel)

Figure 29 − Two−Stage Furnace with Two−Stage Heat

Pump (Dual Fuel)

441 01 2101 05

Specifications are subject to change without notice.

Page 22

Figure 30 − Two−Stage Furnace and Humidifier Only

Figure 31 − AC with Two−Stage Furnace, Humidifier, and

Dehumidification

Figure 32 − HP with Two−Stage Furnace, Humidifier, and

Dehumidification

For Figure 26 − Figure 32

1. Refer to outdoor equipment Installation Instructions for additional information and setup procedure.

2. Outdoor Air Temperature Sensor must be attached in all dual fuel application.

3. Refer to ICP thermostat Installation Instructions for additional information and setup procedure.

4. When using a Humidity Sensing Thermostat, set DEHUMIDIFY OPTIONS to H DE−ENRGZD FOR DEHUM

5. Optional connection for Two−Stage: If wire is connected, SW1−1(TT) on furnace control should be set to ON position to allow ICP Thermostat to control the furnace staging.

6. HUM 24VAC terminal 24 VAC and is energized when the low pressure switch closes during a call for heat.

7. When connecting 115 VAC to humidifier use a separate 115 VAC supply.

8. When using a humidifier on a HP installation, connect humidifier to hot water.

ACCESSORIES

1. Electronic Air Cleaner (EAC): Connect an accessory Electronic Air Cleaner (if used) using 1/4−in female quick connect terminals to the two male 1/4−in quick−connect terminals on the control board marked EAC 1 AMP and NEUTRAL. The terminals are rated for 115VAC, 1.0 amps maximum and are energized during blower motor operation. (See Figure 33)

2. Humidifier (HUM 24VAC and HUM)

a. HUM 24VAC: Connect an accessory 24 VAC, 0.5

amp maximum humidifier (if used) to the ¼−in male quick−connect HUM 24VAC terminal and C screw terminal on the control board thermostat strip. The HUM 24VAC terminal is energized when there is a call for heat (W) and the pressure switch (PRS) closes. (See Figure 33 and Figure 55).

b. HUM: connect an accessory 115VAC (EAC and.

HUM and 1 amp maximum combined) humidifier (if used) to the ¼−in male quick connect HUM terminal and NEUTRAL ¼−in QUICK CONNECT. THE hum terminal is energized when the inducer motor is energized (IDR). (See Figure 33 and Figure 55).

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

NOTE: DO NOT connect furnace control HUM 24VAC terminal to H (humidifier) terminal on humidity sensing thermostat, or similar device. See humidity sensing thermostat, thermostat, or controller manufacturer’s instructions for proper connection.

VENTING

The furnace shall be connected to a listed factory built chimney or vent or a clay−tile lined masonry or concrete chimney. Venting into an unlined masonry chimney or concrete chimney is prohibited. When an existing Category I furnace is removed or replaced, the original venting system may no longer be sized to properly vent the attached appliances. An improperly sized Category I venting system could cause the formation of condensate in the furnace and vent, leakage of condensate and combustion products, and spillage of combustion products into the living space.

Specifications are subject to change without notice.

441 01 2101 05

Page 23

Figure 33 − Furnace Control−PSC Blower Motor

24−V THERMOSTAT

TERMINALS

3−AMP FUSE

LED OPERATION & DIAGNOSTIC LIGHT

115 −VAC (L2) NEUTRAL

CONNECTIONS

BLOWER SPEED

SELECTION TERMINALS

SETUP SWITCHES THERMOSTAT TYPE AND HEAT

OFF−DELAY

TT OFF DLY

HUM

24VAC

COM/BLUE

24VAC/RED

SPARE1 SPARE2

SPARE1

SPARE2

EAC TERMINAL (115 VAC 1.0 AMP MAX.)

TWINNING AND/OR COMPONENT TEST

SW1

EAC 1 AMP

TERMINAL

HUM

XFMR

HUMIDIFIER TERMINAL 115 −VAC

P2−HOT SURFACE IGNITOR (HSI) &

115 VAC (L1) LINE VOLTAGE CONNECTION

INDUCER MOTOR CONNECTOR

HUMIDIFIER TERMINAL (24−VAC 0.5 AMP MAX)

TRANSFORMER 24VAC CONNECTIONS

P1 − LOW VOLTAGE MAIN HARNESS CONNECTOR

L09F023

441 01 2101 05

Specifications are subject to change without notice.

Page 24

WARNING

CARBON MONOXIDE POISONING HAZARD

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

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

1. Seal any unused openings in venting system.

2. Inspect the venting system for proper size and horizontal pitch, as required in the National Fuel Gas Code, ANSI Z223.1/NFPA 54, and these instructions. Determine that there is no blockage or restriction, leakage, corrosion and other deficiencies, which could cause an unsafe condition.

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

4. Close fireplace dampers.

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

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

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

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

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

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

GENERAL VENTING REQUIREMENTS

Follow all safety codes for proper vent sizing and installation requirements, including local building codes, the National Fuel Gas Code ANSI Z223.1−2012/NFPA 54−2012 (NFGC), Parts 12 and 13 in the United States, the local building codes, and furnace and vent manufacturers’ instructions.

These furnaces are design−certified as Category I furnaces in accordance with ANSI Z21.47−2012/CSA 2.3−2012 and operate with a non−positive vent static pressure to minimize the potential for vent gas leakage. Category I furnaces operate with a flue loss not less than 17% to minimize the potential for condensation in the venting system. These furnaces are approved for common venting and multi−story venting with other fan assisted or draft hood equipped appliances in accordance with the NFCG, local building codes, and furnace and vent manufacturers’ instructions.

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

CARBON MONOXIDE POISONING HAZARD

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

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

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

2. Two−stage furnaces require Type B vent connectors outside the casing in all configurations. Single wall vent connector may be used inside the furnace casing with the transition to Type B vent outside the furnace casing. Size the connector so that the FAN−Min vent connector capacity is equal to or lower than the low fire rate of the furnace and the FAN−Max vent connector capacity is equal to or higher than the furnace high fire rate.

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

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

5. Do not vent this appliance with any solid fuel burning appliance.

6. Category I furnaces must be vented vertically or nearly vertically unless equipped with a listed mechanical venter. See the SIDEWALL VENTING section.

7. Do not vent this appliance into an unlined masonry chimney. Refer to Chimney Inspection Chart, Figure 34.

MASONRY CHIMNEY REQUIREMENTS NOTE: These furnaces are CSA design−certified for use in

exterior tile−lined masonry chimneys with a factory accessory Chimney Adapter Kit. Refer to the furnace rating plate for correct kit usage. The Chimney Adapter Kits are for use with ONLY furnaces having a Chimney Adapter Kit number marked on the furnace rating plate.

If a clay tile−lined masonry chimney is being used and it is exposed to the outdoors below the roof line, relining might be required. Chimneys shall conform to the Standard for Chimneys, Fireplaces, Vents, and Solid Fuel Burning Appliances ANSI/NFPA 211−2012 in the United States and must be in good condition.

U.S.A.−Refer to Sections 13.1.8 and 13.2.20 of the NFPA 54 / ANSI Z223.1−2012 or the authority having jurisdiction to determine whether relining is required. If relining is required, use a properly sized listed metal liner, Type−B vent, or a listed alternative venting design.

NOTE: See the NFPA 54 / ANSI Z223.1−2012, 13.1.8 and

13.2.20 regarding alternative venting design and the exception, which cover installations such as the Chimney Adapter Kits which are listed for use with these furnaces. The Chimney Adapter is listed alternative venting system for these furnaces. See the kit instructions for complete details.

WARNING

Specifications are subject to change without notice.

441 01 2101 05

Page 25

Figure 34 − Chimney Inspection Chart

441 01 2101 05

Specifications are subject to change without notice.

A10133

Page 26

The Chimney Adapter Kit is a listed alternative venting system for these furnaces. See the kit instructions for complete details.

This furnace is permitted to be vented into a clay tile−lined masonry chimney that is exposed to the outdoors below the roof line, provided:

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

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

3. The combined appliance input rating is less than the maximum capacity given in Table 8, and

4. The input rating of each space heating appliance is greater than the minimum input rating given in Table 9 for the local 99% Winter Design Temperature. Chimneys having internal areas greater than 38 in (24516 mm2)require furnace input ratings greater than the input ratings of these furnaces. See footnote at bottom of Table 9, and

5. The authority having jurisdiction approves.

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

Inspections before the sale and at the time of installation will determine the acceptability of the chimney or the need for repair and/or (re)lining. Refer to Figure 34 to perform a chimney inspection. If the inspection of a previously used tile−lined chimney:

a. Shows signs of vent gas condensation, the chimney

should be relined in accordance with local codes and the authority having jurisdiction. The chimney should be relined with a listed metal liner, Type−B vent, or a listed chimney adapter kit shall be used to reduce condensation. If a condensate drain is required by local code, refer to the NFPA 54 / ANSI Z223.1−2012, Section 12.10 for additional information on condensate drains.

b. Indicates the chimney exceeds the maximum

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

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

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

Exterior Masonry Chimney FAN + NAT

Installations with Type−B Double

−Wall Vent

Connectors ENFPA & AGA

Table 8 – Combined Appliance Maximum Input Rating in

Thousands of BTUH per Hour

INTERNAL AREA OF CHIMNEY

VENT HEIGHT

FT. (M)

6 (1.8) 74 119 178 257

8 (2.4) 80 130 193 279 10 (3.0) 84 138 207 299 15 (4.5) NR 152 233 334

20 (6.0) NR NR 250 368 30 (9.1) NR NR NR 404

(7741)19(12258)28(18064)38(24516)

SQ. IN. (SQ. MM)

Table 9 – Minimum Allowable Input Rating of

Space−Heating Appliance in Thousands of BTUH per

Hour

INTERNAL AREA OF CHIMNEY

VENT HEIGHT (FT)

Temperature: 17 to 26_F (-8 to -3_C)

6 (1.8) 0 55 99 141

8 (2.4) 52 74 111 154

10 (3.0) NR 90 125 169

15 (4.6) NR NR 167 212

20 (6.1) NR NR 212 258

30 (9.1) NR NR NR 362

Temperature: 5 to 16_F* (-15 to -9_C)

6 (1.8) NR 78 121 166

8 (2.4) NR 94 135 182

10 (3.0) NR 111 149 198

15 (4.6) NR NR 193 247

20 (6.1) NR NR NR 293

30 (9.1) NR NR NR 377

Temperature: -10 to 4_F* (-23 to -16_C)

6 (1.8) NR NR 145 196

8 (2.4) NR NR 159 213

10 (3.0) NR NR 175 231

15 (4.6) NR NR NR 283

20 (6.1) NR NR NR 333

30 (9.1) NR NR NR NR

Temperature: -11_F (-24_C) or lower

Not recommended for any vent configuration.

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

(7741)19(12258)28(18064)38(24516)

Local 99% Winter Design

SQ. IN. (SQ. MM)

Specifications are subject to change without notice.

441 01 2101 05

Page 27

APPLIANCE APPLICATION REQUIREMENTS

Appliance operation has a significant impact on the performance of the venting system. If the appliances are sized, installed, adjusted, and operated properly, the venting system and/or the appliances should not suffer from condensation and corrosion. The venting system and all appliances shall be installed in accordance with applicable listings, standards, and codes.

The furnace should be sized to provide 100% of the design heating load requirement plus any margin that occurs because of furnace model size capacity increments. Heating load estimates can be made using approved methods available from Air Conditioning Contractors of America (Manual J); American Society of Heating, Refrigerating, and Air−Conditioning Engineers; or other approved engineering methods. Excessive over−sizing of the furnace could cause the furnace and/or vent to fail prematurely. When a metal vent or metal liner is used, the vent must be in good condition and be installed in accordance with the vent manufacturer’s instructions.

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

To prevent condensation in the furnace and vent system, the following precautions must be observed:

1. The return−air temperature must be at least 60F (15C) db except for brief periods of time during warm−up from setback at no lower than 55F (13C) db or during initial start−up from a standby condition.

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

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

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

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

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

ADDITIONAL VENTING REQUIREMENTS

A 4 in. (102 mm) round vent elbow is supplied with the furnace. A 5 in. or 6 in. (127 or 152 mm) vent connector may

be required for some model furnaces. A field−supplied 4 in. to 5 in. (102 to 127 mm) or 4 in. to 6 in. (102 mm to 152 mm) sheet metal increaser fitting is required when 5 in. or 6 in. (127 or 152 mm) vent connector is used. See Figure 35−Figure 47 Venting Orientation for approved vent configurations.

See Venting Notes after orientation figures.

Figure 35 − Upflow Application−Vent Elbow Up

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

A03208

Figure 36 − Upflow Application−Vent Elbow Right

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

A03209

441 01 2101 05

Specifications are subject to change without notice.

Page 28

Figure 37 − Downflow Application−Vent Elbow Up then

Left

Figure 39 − Downflow Application−Vent Elbow Left then

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

Figure 38 − Downflow Application−Vent Elbow Up

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

A03210

A03211

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

A03207

Figure 40 − Downflow Application−Vent Elbow Up then

Right

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

A03212

Specifications are subject to change without notice.

441 01 2101 05

Page 29

Figure 41 − Horizontal Left Application − Vent Elbow Left

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

A03213

Figure 42 − Horizontal Left Application − Vent Elbow

Right then Up

Figure 45 − Horizontal Left Application − Vent Elbow

Right

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

A03216

Figure 46 − Horizontal Right Application − Vent Elbow

Left then Up

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

A03214

Figure 43 − Horizontal Right Application − Vent Elbow

Right

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

A03218

Figure 44 − Horizontal Left Application − Vent Elbow Up

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

A03219

Figure 47 − Horizontal Right Application−Vent Elbow Left

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

A02068

Venting Notes for Figure 35 − Figure 47

1. For common vent, vent connector sizing and vent material: United States−−use the NFGC.

2. Immediately increase to 5−in. or 6−in. (127 or 152 mm) vent connector outside furnace casing when 5−in. (127 mm) vent connector is required, refer to Note 1 above.

3. Side outlet vent for upflow and downflow installations must use Type B vent immediately after exiting the furnace, except when Downflow Vent Guard Kit, is used in the downflow position.

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

441 01 2101 05

A03215

Specifications are subject to change without notice.

Page 30

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

5. Four−in. (102 mm) single−wall (26 ga. min.) vent must be used inside furnace casing and when the Downflow Vent Guard Kit is used external to the furnace.

6. Accessory Downflow Vent Guard Kit, required in downflow installations with lower vent configuration.

7. Chimney Adapter Kit may be required for exterior masonry chimney applications. Refer to Chimney Adapter Kit for sizing and complete application details.

NOTE: For the following applications, use the minimum vertical heights as specified below. For all other applications, follow exclusively the National Fuel Gas Code

FURNACE

ORIENTATION

Downflow

*4 in. (102 mm) inside casing or vent guard **Including 4 in. (102 mm) vent section(s) NOTE: All vent configurations must also meet National Fuel Gas Code venting requirements NFGC.

CAUTION

CUT HAZARD

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

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

NOTE: Vent connector length for connector sizing starts at furnace vent elbow. The 4−in. (102 mm) vent elbow is shipped for upflow configuration and may be rotated for other positions. Remove the 3 screws that secure vent elbow to furnace, rotate furnace vent elbow to position desired, re−install screws. The factory−supplied vent elbow does NOT count as part of the number of vent connector elbows.

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

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

NOTE: A flue extension is recommended to extend from the furnace elbow to outside the furnace casing. If flue extension is used, fasten the flue extension to the vent elbow with at least two field−supplied, corrosion−resistant, sheet metal screws located 180 apart. Fasten the vent connector to the flue extension with at least two field−supplied, corrosion resistant sheet metal screws located 180 apart.

2. Vent the furnace with the appropriate connector as shown in Figure 35−Figure 47.

VENT

ORIENTATION

Vent elbow left, then

up Figure 39

Vent elbow up then

left Figure 37

Vent elbow up, then

right Figure 40

FURNACE

INPUT(BTUH/HR)

110,000 5 (127) 12 (3.6)

110,000 5 (127) 10 (3.0)

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

9. Secure all other single wall vent connector joints with (3) corrosion resistant screws spaced approximately 120 apart. Secure Type−B vent connectors per vent connector manufacturer’s recommendations.

MINIMUM VENT

DIAMETER

IN. (mm)*

3. Determine the correct location of the knockout to be removed.

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

CAUTION

BURN HAZARD

Failure to follow this caution may cause personal injury.

Hot vent pipe is within reach of small children when installed in downflow position.

See the following instruction.

An accessory Vent Guard Kit is REQUIRED for downflow applications where the vent exits through the lower portion of the furnace casing. (See Figure 39) Refer to the Vent Guard Kit Instructions for complete details.

The horizontal portion of the venting system shall slope upwards not less than 1/4−in. per linear ft. (6 mm/.3 M) from the furnace to the vent and shall be rigidly supported every 5 ft. (1.5 M) or less with metal hangers or straps to ensure there is no movement after installation.

SIDEWALL VENTING This furnace is not approved for direct sidewall horizontal

venting. In the U.S.: Per section 12.4.3 of the NFPA 54 / ANSI

Z223.1−2012, any listed mechanical venter may be used, when approved by the authority having jurisdiction.

Select the listed mechanical venter to match the Btuh input of the furnace being vented. Follow all manufacturer’s installation requirements for venting and termination included with the listed mechanical venter.

MINIMUM VERTICAL

VENT HEIGHT

FT. (M)**

Specifications are subject to change without notice.

441 01 2101 05

Page 31

START−UP, ADJUSTMENT, AND SAFETY

CHECK

Step 1 — General

FIRE HAZARD

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

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

1. Maintain 115−v wiring and ground. Improper polarity will result in status code 10 and no furnace operation.

2. Make thermostat wire connections at the 24−v terminal block on the furnace control. Failure to make proper connections will result in improper operation. (See Figure 33)

WARNING

Table 10 – Two−Stage Furnace Setup Switch Description

3. Gas supply pressure to the furnace must be greater than 4.5−In. W.C. (0.16 psig ) but not exceed 14−In. W.C. (0.5 psig).

CAUTION

CUT HAZARD

Failure to follow this caution may result in personal injury.

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

4. Check all manual−reset switches for continuity.

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

6. Setup switch descriptions The two−stage furnace has DIP switches used to select thermostat staging and heat off delay timings. For switch locations on Furnace control board, See Figure 33 and Figure 55.

7. Setup switch descriptions − See Table 10.

SETUP

SWITCH NO.

SW1-1 Thermostat Type OFF

SW2-2 Heat OFF delay OFF

SW3-3 Heat OFF delay ON

Table 11 – Two−Stage Furnace Blower OFF Delay Setup

DESIRED HEATING MODE

BLOWER OFF DELAY (SEC.)

90 OFF OFF

120 * OFF ON

150 ON OFF 180 ON ON

* Factory setting

SWITCH

NAME

Switch

SETUP

SWITCH

SW1-2

FACTORY

POSITION

SETUP

SWITCH

SW1-3

Step 2 — Start−Up Procedures

FIRE OR EXPLOSION HAZARD

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

441 01 2101 05

WARNING

Specifications are subject to change without notice.

DESCRIPTION

When OFF, allows Two-stage operation with a single stage thermo

stat. Turn ON when using two-stage thermostat to allow Low Heat

operation when R to W/W1 closes and High Heat operation when R

Control heat OFF delay time. Used in conjunction with SW1-3.

Control heat OFF delay time. Used in conjunction with SW1-2.

ELECTRICAL SHOCK HAZARD

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

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

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

2. Check gas lines for leaks.

3. To Begin Component Self−Test: Remove blower access door. Disconnect the thermostat R lead from furnace control board. Manually close blower door switch. Short (jumper) the C terminal on control to the TEST/TWIN 3/16−in. (8 mm) quick−connect terminal on control until the LED goes out (approximately 2 sec). Gas valve and humidifier will not be turned on. Remove jumper from terminals. (See Figure 33)

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

Refer to service label attached to furnace or See Figure 51. Component test sequence is as follows:

OF USE

to W/W1 and W2 close.

See Table 14.

WARNING

Page 32

a. LED will display previous status code 4 times.

NOTE: If no previous code is present, go directly to b.

b. Inducer motor starts on high−speed and continues to

run until Step g of component test sequence.

c. Hot surface igniter is energized for 15 sec., then off. d. Blower motor operates on LO−HEAT speed for 10 sec. e. Blower motor operates on HI−HEAT speed for 10 sec.

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

g. Inducer motor goes to low−speed for 10 sec., then

stops.

h. Reconnect R lead to furnace control board, release

blower door switch and re−install blower door.

4. Operate furnace per instruction on inner door.

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

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

Step 3 — Adjustments

WARNING

FIRE HAZARD

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

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

CAUTION

FURNACE DAMAGE HAZARD

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

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

Low NOx models in downflow or horizontal positions MUST use Table 16 (21,000 BTUH per burner). See input listed on rating plate.

a. Obtain average yearly gas heat value (at installed

altitude) from local gas supplier.

b. Obtain average yearly gas specific gravity from local

gas supplier.

c. Find installation altitude in Table 15 or 16.

Table 12 – Altitude Derate Multiplier for U.S.A.

ALTITUDE

FT. (M)

0–2000

(0-610)

2001–3000 (610-914)

3001–4000

(914-1219)

4001–5000

(1219-1524)

5001–6000

1524-1829)

6001–7000

(1829-2134)

7001–8000

(2134-2438)

8001–9000

(2438-2743)

9001–10,000

(2743-3048)

* Derate multiplier factors are based on midpoint altitude for altitude range.

PERCENT

OF DERATE

0 1.00

8–12 0.90

12–16 0.86

16–20 0.82

20–24 0.78

24–28 0.74

28–32 0.70

32–36 0.66

36–40 0.62

DERATE MULTIPLIER

FACTOR*

d. Find closest natural gas heat value and specific

gravity in Table 15 or 16

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

intersection to find orifice size and low−and high−heat manifold pressure settings for proper operation.

f. Check and verify burner orifice size in furnace.

NEVER ASSUME ORIFICE SIZE. ALWAYS CHECK AND VERIFY.

g. Replace orifice with correct size, if required by Table

15 or 16. Use only factory−supplied orifices. See EXAMPLE 1.

Furnace gas input rate on rating plate is for installations at altitudes up to 2000 ft. (610 M). Furnace input rate must be within +/−2% of furnace rating plate input. For altitudes above 5500 ft. (1676 M), a field−supplied high altitude pressure switch is required.

1. Determine the correct gas input rate. The input rating for altitudes above 2,000 ft. (610 M) must be reduced by 4% for each 1,000 ft. (305 M) above sea level. For installations below 2000 ft. (610 M), refer to the unit rating plate. For installations above 2000 ft. (610 M), multiply the input on the rating plate by the derate multiplier in Table 11 for the correct input rate.

2. Determine the correct orifice and manifold pressure adjustment. All models in all positions except Low NOx models in downflow and horizontal positions use Table 15 (22,000 BTUH per burner).

Specifications are subject to change without notice.

EXAMPLE 1: (0−2000 ft. / 0−610 M altitude) For 22,000 Btuh per burner application, use Table 15. Heating value = 1000 Btuh/cu ft. Specific gravity = 0.62 Therefore: Orifice No. 43* Manifold pressure: 3.7−In. W.C. for high−heat

1.6−In. W.C. for low−heat * Furnace is shipped with No. 43 orifices. In this example all main burner orifices are the correct size and do not

need to be changed to obtain proper input rate.

3. Adjust manifold pressure to obtain low fire input rate. (See Figure 48)

a. Turn gas valve ON/OFF switch to OFF. b. Remove manifold pressure tap plug from gas valve.

441 01 2101 05

Page 33

c. Connect a water column manometer or similar device

to manifold pressure tap.

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

Figure 48 − Redundant Automatic Gas Control Valve

A06667

e. Move setup switch TT (SW1−1) on furnace control to

ON position to lock furnace in low−heat operation. (See Figure 33 and Table 10)

f. Manually close blower door switch.

g. Jumper R and W/W1 thermostat connections on

control to start furnace. (See Figure 33)

h. Remove regulator adjustment cap from low−heat gas

valve pressure regulators. (See Figure 48) Turn low−heat adjusting screw (3/16 in. (5 mm) or smaller flat tipped screwdriver) counterclockwise (out) to decrease input rate or clockwise (in) to increase input rate.

NOTE: DO NOT set low−heat manifold pressure less than

1.4−In. W.C. or more than 1.7−In. W.C. for natural gas. If manifold pressure is outside this range, change main burner orifices.

i. Install low−heat regulator adjustment cap. j. Leave manometer or similar device connected and

proceed to Step 4.

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

4. Verify natural gas low−heat input rate by clocking meter.

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

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

the meter.

b. Run for 3 minutes in low−heat operation. c. Measure time (in sec) for gas meter to complete 1

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

Figure 49 − Orifice Hole

BURNER

ORIFICE

A93059

d. Refer to Table 12 for cubic ft. of gas per hr. e. Multiply gas rate cu ft. /hr by heating value (Btuh/cu

ft. ) to obtain input. If clocked rate does not match required input from Step 1, increase manifold pressure to increase input or decrease manifold pressure to decrease input. Repeat steps b through e until correct low heat input is achieved. Re−install low−heat regulator seal cap on gas valve.

5. Set low−heat temperature rise. The furnace must operate within the temperature rise ranges specified on the furnace rating plate. Do not exceed temperature rise ranges specified on unit rating plate for high−and low−heat. Determine the temperature rise as follows:

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

ELECTRICAL SHOCK HAZARD

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

Disconnect 115−v electrical power before changing speed tap.

a. Verify unit is running in low heat per Step 3. Place

thermometers in return and supply ducts as close to furnace as possible. Be sure thermometers do not see radiant heat from heat exchangers. Radiant heat affects temperature rise readings. This practice is particularly important with straight−run ducts.

b. When thermometer readings stabilize, subtract

return−air temperature from supply−air temperature to determine air temperature rise.

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

(1.) Gas input for low heat operation. (2.) Derate for altitude if applicable. (3.) Return and supply ducts for excessive

WARNING

restrictions causing static pressures greater than

0.50−In. W.C.

441 01 2101 05

Specifications are subject to change without notice.

Page 34

Table 13 – Gas Rate (cu ft. /hr)

SECONDS

FOR

REVOLUTION

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

SIZE OF TEST DIAL

1 CU FT. 2 CU FT. 5 CU FT. 1 CU FT. 2 CU FT. 5 CU FT.

c. Adjust air temperature rise by adjusting blower speed.

Increase blower speed to reduce temperature rise. Decrease blower speed to increase temperature rise. For low heat, speed selection can be low (factory setting), med−low, or med (5−speed blowers only).

d. Remove Blower Access door and remove thermostat

jumpers.

e. To change motor speed selection for low heat, remove

blower motor lead from control LO−HEAT terminal. (See Figure 33) Select desired blower motor speed lead from one of the other terminals and relocate it to the LO−HEAT terminal. (See Table 13 for lead color identification). Reconnect original lead to SPARE terminal.

f. Repeat steps a through e.

CAUTION

FURNACE OVERHEATING HAZARD

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

Recheck temperature rise. It must be within limits specified on the rating plate. Recommended operation is at the midpoint of rise range or slightly above.

g. When correct low heat input rate and temperature rise

is achieved, proceed to Step 6.

6. Adjust Manifold Pressure to Obtain High Heat Rate

SECONDS

FOR

REVOLUTION

SIZE OF TEST DIAL

a. Remove high fire regulator adjustment cap from gas

valve pressure regulator.

b. Jumper R, W/W1 and W2 thermostat connections on

control to run furnace in high heat. (See Figure 33)

c. d. Turn high−heat adjusting screw (3/16−in. (5 mm) or

smaller flat tipped screwdriver) counterclockwise (out) to decrease input rate or clockwise (in) to increase

rate. d. Re−install high−fire adjustment caps. e. Leave manifold or similar device connected and

proceed to Step 7.

NOTE: DO NOT set high−heat manifold pressure less than

3.2−In. W.C. or more than 3.8−In. W.C. for natural gas. If manifold pressure is outside this range, change main burner orifices.

7. Verify natural gas high heat input rate by clocking meter.

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

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

the meter. b. Run for 3 minutes in high−heat operation. c. Measure time (in sec) for gas meter to complete 1

revolution and note reading. d. Refer to Table 12 for cubic ft. of gas per hr. e. Multiply gas rate cu ft. /hr by heating value (Btuh/cu

ft.) to obtain input.

Specifications are subject to change without notice.

441 01 2101 05

Page 35

NOTE: Using the 2 cu. ft. or 5 cu. ft. gas meter dial provides greater accuracy in verifying gas input rate.

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

8. Set high heat temperature rise. Jumper R to W/W1 and W2 to check high−gas−heat temperature rise. Do not exceed temperature rise ranges specified on furnace rating plate for high heat. The furnace must operate within the temperature rise ranges specified on the furnace rating plate. Determine the air temperature rise as follows:

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

a. Verify the furnace is operating in high heat per Step

6. Place thermometers in return and supply ducts as close to furnace as possible. Be sure thermometers do not see radiant heat from heat exchangers. Radiant heat affects temperature rise readings. This practice is particularly important with straight−run ducts.

b. When thermometer readings stabilize, subtract

return−air temperature from supply−air temperature to determine air temperature rise.

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

(1.) Gas input for low−and high−heat operation. (2.) Derate for altitude if applicable. (3.) Return and supply ducts for excessive

restrictions causing static pressures greater than

0.50−In. W.C.

(4.) Dirty filter.

c. Adjust air temperature rise by adjusting blower speed.

Increase blower speed to reduce temperature rise. Decrease blower speed to increase temperature rise. For high heat, speed selection can be med−high, med (5−speed blowers only), or med−low (factory setting).

ELECTRICAL SHOCK HAZARD

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

Disconnect 115−v electrical power before changing speed tap.

d. To change motor speed selection for high heat,

remove blower motor lead from control HI−HEAT terminal. (See Figure 33) Select desired blower motor speed lead from one of the other terminals and relocate it to the HI−HEAT terminal. DO NOT use the low−heat tap that was already set. (See Table 13 for lead color identification). Reconnect original lead to SPARE terminal.

e. Repeat steps a thru d.

f. When correct high heat input rate and temperature rise

is achieved, turn gas valve ON/OFF switch to OFF. g. Remove Blower Access Door. h. Remove manometer or similar device from gas valve.

i. Re−install manifold pressure tap plug in gas valve.

(See Figure 49)

441 01 2101 05

WARNING

Specifications are subject to change without notice.

FIRE HAZARD

Failure to reinstall manifold pressure tap plug in gas valve could result in personal injury, property damage or death.

Reinstall manifold pressure tap plug in gas valve to prevent gas leak.

j. Remove thermostat jumper wire from furnace control

board.

k. Turn TT switch OFF or leave ON if using a two−stage

thermostat.

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

m. Proceed to Step 9, “Set Heat Off Delay” before

installing blower access door.

FURNACE OVERHEATING HAZARD

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

Recheck temperature rise. It must be within limits specified on the rating plate. Recommended operation is at the midpoint of rise range or slightly above.

9. Set Heat Off Delay a. Remove Blower Access Door if installed. b. Turn Dip switch 2 and 3 ON or OFF for desired blower

off delay. (See Table 14 and Figure 34)

10. Set thermostat heat anticipator. a. Mechanical thermostat − Set thermostat heat

anticipator to match the amp. draw of the electrical components in the R−W/W1 circuit. Accurate amp. draw readings can be obtained at the wires normally connected to thermostat subbase terminals, R and W. The thermostat anticipator should NOT be in the circuit while measuring current.

(1.) Set TT switch on furnace control board to ON. (2.) Remove thermostat from sub−base or from wall. (3.) Connect an amp. meter as shown in Figure 50

(4.) Record amp. draw across terminals when

(5.) Set heat anticipator on thermostat per thermostat

(6.) Turn TT switch OFF or leave ON if using a

(7.) Install blower access door.

b. Electronic thermostat: Set cycle rate for 3 cycles per

hr.

11. Set airflow CFM for cooling Select the desired blower motor speed lead for cooling airflow. See Table 5−Air Delivery−CFM (With Filter). See Table 13 for lead color identification.

WARNING

CAUTION

across the R and W subbase terminals or R and W wires at wall.

furnace is in low heat and after blower starts.

instructions and install on subbase or wall.

two−stage thermostat.

Page 36

Table 14 – Speed Selection

COLOR SPEED AS SHIPPED

White Common BLW

Black High COOL

Yellow Med-High SPARE

Orange† Med SPARE

Blue Med-Low HI-HEAT Red Low* LO HEAT

* Continuous−blower speed−as shipped default  Not all models equipped with 5 speed motors

Figure 50 − Amp. Draw Check with Ammeter

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

HOOK-AROUND AMMETER

R Y W G

10 TURNS

FROM UNIT 24-V CONTROL TERMINALS

EXAMPLE:

5.0 AMPS ON AMMETER 10 TURNS AROUND JAWS

0.5 AMPS FOR THERMOSTAT

ANTICIPATOR SETTING

A96316

Step 4 — Check Safety Controls

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

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

a. Run furnace for at least 5 minutes. b. Gradually block off return air with a piece of cardboard

or sheet metal until the limit trips.

c. Unblock return air to permit normal circulation.

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

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

a. Verify vent pipe is cool to the touch. b. Disconnect power to furnace and remove vent

connector from furnace vent elbow.

c. Restore power to furnace and set room thermostat

above room temperature.

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

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

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

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

f. Remove blockage from furnace vent elbow. g. Switch will auto−reset when it cools. h. Re−install vent connector.

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

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

a. Turn off 115−v power to furnace. b. Disconnect inducer motor lead wires from wire

harness. c. Turn on 115−v power to furnace. d. Set thermostat to “call for heat” and wait 1 minute.

When pressure switch is functioning properly, hot

surface igniter should NOT glow and control will flash

a status code 3. If hot surface igniter glows when

inducer motor is disconnected, shut down furnace

immediately. e. Determine reason pressure switch did not function

properly and correct condition.

f. Turn off 115−v power to furnace.

g. Reconnect inducer motor wires, replace outer door,

and turn on 115−v power. h. Blower will run for 90 seconds before beginning the

call for heat again.

i. Furnace should ignite normally.

Step 5 — Checklist

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

2. Verify that switches for TT and heat off−delay are blower off−delay are selected as desired.

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

4. Cycle test furnace with room thermostat.

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

6. Review User’s Guide with owner.

7. Attach literature packet to furnace.

Specifications are subject to change without notice.

441 01 2101 05

Page 37

Table 15 – Orifice Size* and Manifold Pressures (in. w.c.) for Gas Input Rate

441 01 2101 05

Specifications are subject to change without notice.

A10184

Page 38

Table 15 − Orifice Size and Manifold Pressures (in. w.c.) for Gas Input Rate (cont.)

A10184A

Specifications are subject to change without notice.

441 01 2101 05

Page 39

Table 16 – Orifice Size* and Manifold Pressures (in. w.c.) for Gas Input Rate

441 01 2101 05

Specifications are subject to change without notice.

A10185

Page 40

Table 16 − Orifice Size* and Manifold Pressures (in. w.c.) for Gas Input Rate (cont.)

SERVICE AND MAINTENANCE

PROCEDURES

Untrained personnel can perform basic maintenance functions such as cleaning and replacing air filters. All other operations must be performed by trained service personnel. A qualified service person should inspect the furnace once a year.

WARNING

FIRE, PERSONAL INJURY AND UNIT DAMAGE HAZARD

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

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

CAUTION

ENVIRONMENTAL HAZARD

Failure to follow this caution may result in environmental pollution.

Remove and recycle all components or materials (i.e. oil, refrigerant, control board, etc.) before unit final disposal.

A10185A

ELECTRICAL SHOCK, FIRE OR EXPLOSION HAZARD

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

Before installing, modifying, or servicing system, main electrical disconnect switch must be in the OFF position and install a lockout tag. There may be more than one disconnect switch. Lock out and tag switch with a suitable warning label. Verify proper operation after servicing.

UNIT OPERATION HAZARD

Failure to follow this caution may result in improper unit operation or failure of unit components.

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

Step 1 — Introduction

GENERAL

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

WARNING

CAUTION

Specifications are subject to change without notice.

441 01 2101 05

Page 41

ELECTRICAL CONTROLS AND WIRING

ELECTRICAL SHOCK HAZARD

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

There may be more than one electrical supply to the furnace. Check accessories and cooling unit for additional electrical supplies that must be shut off during furnace servicing. Lock out an tag switch with a suitable warning label.

The electrical ground and polarity for 115−v wiring must be properly maintained. Refer to Figure 23 for field wiring information and to Figure 55 for furnace wiring information.

NOTE: If the polarity is not correct, the STATUS LED on the control will flash a status code 10 and prevent the furnace from heating. The control system also requires an earth ground for proper operation of the control and flame−sensing electrode.

The 24−v circuit contains an automotive−type, 3−amp. fuse located on the control. (See Figure 31) Any shorts of the 24−v wiring during installation, service, or maintenance will cause this fuse to blow. If fuse replacement is required, use ONLY a 3−amp. fuse. The control LED will be off when fuse needs to be replaced.

Proper instrumentation is required to service electrical controls. The control in this furnace is equipped with a Status Code LED (Light−Emitting Diode) to aid in installation, servicing, and troubleshooting. Status codes can be viewed at the sight glass in blower access door. The furnace control LED is either ON continuously, flashing a heartbeat or a status code.

For an explanation of status codes, refer to service label located on blower access door or Figure 51, and the troubleshooting guide which can be obtained from your distributor.

See Figure 56 for a brief Troubleshooting guide. The stored status codes will NOT be erased from the control

memory, if 115− or 24−v power is interrupted.

STATUS CODE RECOVERY AND COMPONENT TEST

To retrieve status code, proceed with the following: NOTE: No thermostat signal may be present at control, and

all blower−OFF delays must be completed. Perform component self−test as shown on the SERVICE

label, located on the of blower access door.

WARNING

Step 2 — Care and Maintenance

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

FIRE OR EXPLOSION HAZARD

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

Never store anything on, near, or in contact with the furnace, such as:

1. Spray or aerosol cans, rags, brooms, dust

mops, vacuum cleaners, or other cleaning tools.

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

3. Paint thinners and other painting compounds, paper bags, or other paper products. Exposure to these materials could lead to corrosion of the heat exchanger.

ELECTRICAL SHOCK AND FIRE HAZARD

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

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

CARBON MONOXIDE POISONING AND FIRE HAZARD

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

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

CUT HAZARD

Failure to follow this caution may result in personal injury.

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

The minimum maintenance on this furnace is as follows:

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

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

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

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

WARNING

CAUTION

441 01 2101 05

Specifications are subject to change without notice.

Page 42

Figure 51 − Service Label

Specifications are subject to change without notice.

441 01 2101 05

Page 43

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

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

Table 17 – Filter Size Information (in. / mm)

FURNACE

CASING WIDTH

14-1/2 (368)

17-1/2 (445)

21 (533)

24 (610)

* Recommended ** Some furnaces may have 2 filters.

16 x25 x 3/4

(406 x635 x 19)

16 x25 x 3/4

(406 x635 x 19)

16 x25 x 3/4

(406 x635 x 19)

16 x25 x 3/4

(406 x635 x 19)

SIDE

RETURN

FILTER SIZE

(356 x635 x 19)

(406 x635 x 19)

(508 x635 x 19)

(610 x635 x 19)

BOTTOM RETURN

14 x25 x 3/4

16 x25 x 3/4

20 x25 x 3/4

24 x25 x 3/4

FILTER

TYPE

Washable*

CLEANING AND/OR REPLACING AIR FILTER

The air filter arrangement will vary depending on the application.

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

CAUTION

CUT HAZARD

Failure to follow this caution may result in personal injury.

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

BLOWER MOTOR AND WHEEL

WARNING

ELECTRICAL SHOCK HAZARD

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

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

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

a. Disconnect vent connector from furnace vent elbow. b. Disconnect and remove short piece of vent pipe from

within furnace.

4. Remove two (2) screws from blower access door and remove blower access door.

5. All factory wires can be left connected, but field thermostat connections may need to be disconnected depending on their length and routing.

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

7. Clean blower wheel and motor using a vacuum with soft brush attachment. Blower wheel blades may be cleaned with a small paint or flux brush. Do not remove or disturb balance weights (clips) on blower wheel blades.

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

9. If a greasy residue is present on blower wheel, remove wheel from the blower housing and wash it with an appropriate degreaser. To remove wheel:

NOTE: Before disassembly, mark blower mounting arms, motor, and blower housing so motor and each arm is positioned at the same location during reassembly.

a. Disconnect capacitor wires (if equipped) and ground

wire attached to blower housing.

b. Remove screws securing cutoff plate and remove

cutoff plate from housing.

c. Loosen set screw holding blower wheel on motor shaft

(160+/−20 in.−lb. when reassembling).

d. Remove bolts holding motor to blower housing and

slide motor out of wheel (40+/−10 in.−lb. when reassembling).

e. Remove blower wheel from housing.

f. Clean wheel and housing.

10. Reassemble motor and blower by reversing steps 9a, through 9e. Be sure to reattach ground wire to the blower housing.

11. Verify that blower wheel is centered in blower housing and set screw contacts the flat portion of the motor shaft. Loosen set screw on blower wheel and reposition if necessary.

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

13. Reinstall blower assembly in furnace.

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

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

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

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

Clean blower motor and wheel as follows:

1. Turn off electrical supply to furnace.

2. Remove outer door.

441 01 2101 05

Specifications are subject to change without notice.

CAUTION

UNIT DAMAGE HAZARD

Failure to follow this caution may result in shortened heat exchanger life.

Heating fan speed(s) MUST be adjusted to provide proper air temperature rise as specified on the rating plate. Recommended operation is at the midpoint of the rise range or slightly above. Refer to “SET TEMPERATURE RISE” under START−UP, ADJUSTMENT, and SAFETY CHECK.

14. Reinstall 2 screws securing blower assembly to blower deck.

Page 44

15. Refer to furnace wiring diagram, and connect thermostat leads if previously disconnected.

16. To check blower for proper rotation: a. Turn on electrical supply. b. Manually close blower access door switch.

NOTE: If thermostat terminals are jumpered at the time blower access door switch is closed, blower will run for 90 sec before beginning a heating or cooling cycle.

c. Perform component self−test as shown at the bottom

of the SERVICE label, located on the front of blower access door.

d. Verify blower is rotating in the correct direction.

17. If furnace is operating properly, RELEASE BLOWER ACCESS DOOR SWITCH. Remove any jumpers or reconnect any disconnected thermostat leads. Replace blower access door.

WARNING

ELECTRICAL SHOCK HAZARD

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

Blower access door switch opens 115−v power to furnace control. No component operation can occur unless switch is closed. Exercise caution to avoid electrical shock from exposed electrical components when manually closing this switch for service purposes.

18. Downflow or horizontal furnaces with vent pipe through furnace only:

a. Install and connect short piece of vent pipe inside

furnace to existing vent.

b. Connect vent connector to vent elbow.

19. Reinstall outer door.

20. Turn on gas supply and cycle furnace through one complete heating and cooling cycle. Verify the furnace temperature rise as shown in Adjustments Section. Adjust temperature rise as shown in Adjustments Section. If outdoor temperature is below 70F (21C) turn off circuit breaker to outdoor unit before running furnace in the cooling cycle. Turn outdoor circuit breaker on after completing cooling cycle.

CLEANING HEAT EXCHANGER The following steps should be performed by a qualified

service agency: NOTE: If the heat exchangers get a heavy accumulation of

soot and carbon, they should be replaced rather than trying to clean them thoroughly. A build−up of soot and carbon indicates that a problem exists which needs to be corrected, such as improper adjustment of manifold pressure, insufficient or poor quality combustion air, incorrect size or damaged manifold orifice(s), improper gas, or a restricted heat exchanger. Action must be taken to correct the problem.

If it becomes necessary to clean the heat exchangers because of dust or corrosion, proceed as follows:

1. Turn OFF gas and electrical power to furnace.

2. Remove outer access door.

3. Disconnect vent connector from furnace vent elbow.

4. For downflow or horizontal furnace having an internal vent pipe, remove internal vent pipe within the casing.

5. Disconnect wires to the following components. Mark wires to aid in reconnection of (be careful when

disconnecting wires from switches because damage may occur):

a. Draft safeguard switch. b. Inducer motor. c. Pressure switches. d. Limit overtemperature switch. e. Gas valve.

f. Hot surface igniter. g. Flame−sensing electrode h. Flame rollout switches.

6. Remove screws that fasten the collector box assembly to the cell panel. Be careful not to damage the collector box. Inducer assembly and elbow need not be removed from collector box.

7. Disconnect gas line from gas manifold.

8. Remove the 5 screws that attach the burner assembly to the cell panel. The gas valve and individual burners need not be removed from support assembly. Remove NOx baffles if installed.

NOTE: Be very careful when removing burner assembly to avoid breaking igniter. See Figure 52 and Figure 53 for correct igniter location.

9. Using field−provided 25−caliber rifle cleaning brush, 36−in. (914 mm) long 1/4−in. (6 mm) diameter steel spring cable, a variable speed reversible electric drill, and vacuum cleaner, clean cells as follows:

a. Remove metal screw fitting from wire brush to allow

insertion into cable.

b. Insert the twisted wire end of brush into end of spring

cable, and crimp tight with crimping tool or crimp by striking with ball−peen hammer. TIGHTNESS IS VERY IMPORTANT.

Figure 52 − Igniter Position−Side View

A05025

NOTE: The materials needed in item 9 can usually be purchased at local hardware stores.

(1.) Attach variable−speed, reversible drill to the end

of spring cable (end opposite brush).

(2.) Insert brush end of cable into the outlet opening

of cell and slowly rotate with drill. DO NOT force cable. Gradually insert cable into upper pass of cell. (See Figure 54)

(3.) Work cable in and out of cell 3 or 4 times to obtain

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

Specifications are subject to change without notice.

441 01 2101 05

Page 45

(4.) Insert brush end of cable in burner inlet opening

of cell, and proceed to clean 2 lower passes of cell in same manner as upper pass.

(5.) Repeat foregoing procedures until each cell in

furnace has been cleaned.

(6.) Using vacuum cleaner, remove residue from

each cell.

(7.) Using vacuum cleaner with soft brush

attachment, clean burner assembly. (8.) Clean flame sensor with fine steel wool. (9.) Install NOx baffles (if removed.)

(10.) Reinstall burner assembly. Center burners in cell

openings.

10. Remove old sealant from cell panel and collector box flange.

11. Spray releasing agent on the heat exchanger cell panel where collector box assembly contacts cell panel.

NOTE: A releasing agent such as a vegetable oil cooking spray that does not contain corn oil, canola oil, halogenated hydrocarbons or aromatic content, which may prevent an inadequate seal from occuring, and RTV sealant such as G.E. RTV 162, G.E. RTV 6702, or Dow−Corning RTV 738 sealant are required. DO NOT substitute any other type of RTV sealant.

12. Apply new sealant to flange of collector box and attach to cell panel using existing screws, making sure all screws are secure.

13. Reconnect wires to the following components (Use connection diagram on wiring label, if wires were not marked for reconnection locations.):

a. Draft safeguard switch. b. Inducer motor.

c. Pressure switches.

d. Limit overtemperature switch. e. Gas valve.

f. Hot surface igniter. g. Flame−sensing electrode. h. Flame rollout switches.

14. Reinstall internal vent pipe, if applicable.

15. Reinstall vent connector on furnace vent elbow. Securely fasten vent connector to vent elbow with 2 field−supplied, corrosion−resistant, sheet metal screws located 180 apart.

Figure 53 − Igniter Position−Top View

A05026

16. Replace blower access door only, if it was removed.

17. Set thermostat above room temperature and check furnace for proper operation.

18. Verify blower airflow and speed changes between heating and cooling.

19. Check for gas leaks.

20. Replace outer access door.

441 01 2101 05

Specifications are subject to change without notice.

Figure 54 − Cleaning Heat Exchanger Cell

A91252

FIRE OR EXPLOSION HAZARD

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

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

WARNING

Step 3 — Sequence of Operation

NOTE: Furnace control must be grounded for proper

operation or control will lockout. Control is grounded through green wire connected to gas valve and burner bracket screw. Using the schematic diagram in Figure 55, follow the sequence of operation through the different modes. Read and follow the wiring diagram very carefully.

NOTE: If a power interruption occurs during a call for heat (W/W1 or W/W1−and−W2), the control will run the blower for the selected heat off−delay period two seconds after power is restored, if the thermostat is still calling for gas heating. The LED light will flash a status code 1+2 during this period, after which the LED will switch to a heartbeat, as long as no faults are detected. After this period, the furnace will respond to the thermostat normally.

The blower door must be installed for power to be conducted through the blower door interlock switch ILK to the furnace control CPU, transformer TRAN, inducer motor IDM, blower motor BLWM, hot−surface igniter HSI, and gas valve GV.

1. Two−Stage Heating with Single−Stage Thermostat (See Figure 23 or Figure 32 for thermostat connections)

NOTE: The thermostat type switch (TT) selects either the two−stage thermostat operation mode when ON, (see item 2) or the single stage thermostat operation mode when OFF in response to a call for heat. When the W2 thermostat terminal is energized it will always cause high−heat operation when the R to W circuit is closed, regardless of the setting of the thermostat type switch. This furnace can operate as a two−stage furnace with a single−stage thermostat because the furnace control CPU includes a programmed sequence of controlled operation, which selects low−heat for the first 12 minutes of operation then switches to high heat operation.

If the power is interrupted, the control CPU will operate in low heat for 12 minutes then it will switch to high−heat, as long as the thermostat continues to call for heat.

The wall thermostat “calls for heat”, closing the R to W circuit. The furnace control performs a self−check, verifies the low−heat and high−heat pressure switch contacts LPS and HPS are open, and starts the inducer motor IDM in high−speed. The HUM terminal is energized for a 115V humidifier (if used).

Page 46

a. Inducer Prepurge Period (see Figure 55 schematic

diagram)

(1.) Low heat (W/W1) the inducer motor IDM comes

up to high−speed, the low−heat pressure switch LPS closes. After the low−heat pressure switch closes the furnace control CPU will begin a 15−second prepurge period, and continue to run the inducer motor IDM at high−speed.

(2.) High Heat (W/W1+W2) the inducer motor IDM

comes up to high speed and the high−heat pressure switch relay HPSR is de−energized to close the NC contact. When sufficient pressure is available, the high−heat pressure switch HPS closes, and the high−heat gas valve solenoid GV−HI is energized. After LPS closes, 24VAC power is supplied for a field−installed humidifier at the HUM 24VAC terminal and the furnace control CPU begins a 15−second prepurge period. If the high−heat pressure switch HPS fails to close and the low−heat pressure switch LPS closes, the furnace will operate at low−heat gas flow rate until the high−heat pressure switch closes for a maximum of 2 minutes after ignition. If HPS doesn’t close after 2 minutes from LPS closing, GV is turned off and heat off delay is completed. Then a new cycle will begin if a call for heat remains.

b. Igniter Warm−Up−At the end of the prepurge period,

the (Hot Surface Igniter) HSI is energized for a 17−second igniter warm−up period.

c. Trial−for−Ignition Sequence−When the igniter

warm−up period is completed the main gas valve relay contacts GVR close to energize the gas valve solenoid GV−M, the gas valve opens. The gas valve solenoid GV−M permits gas flow to the burners where it is ignited by the HSI. 5 sec after the GVR closes, a 2−sec flame proving period begins. The HSI igniter will remain energized until the flame is sensed or until the 2−sec flame proving period begins. If the furnace control CPU operates in high−heat operation, the high

−heat gas valve solenoid GV−HI is also

energized.

d. Flame−Proving−When the burner flame is proved at

the flame−proving sensor electrode FSE, the inducer motor IDM switches to low−speed unless running at high−heat, and the furnace control CPU begins the blower−ON delay period and continues to hold the gas valve GV−M open. If the burner flame is not proved within two seconds, the control CPU will close the gas valve GV−M, and the control CPU will repeat the ignition sequence for up to three more Trials−For−Ignition before going to Ignition− Lockout. Lockout will be reset automatically after three hours, or by momentarily interrupting 115 vac power to the furnace, or by interrupting 24 vac power at 24VAC or COM to the furnace control CPU (not at W/W1, G, R, etc.). If flame is proved when flame should not be present, the furnace control CPU will lock out of Gas−Heating mode and operate the inducer motor IDM on high speed until flame is no longer proved.

e. Blower On Delay−If the burner flame is proven, the

blower on delay for low−heat and high−heat are as follows: Low−Heat−45 seconds after the gas valve GV−M is energized the blower motor (BLWM) is energized at LO HEAT speed. High−Heat−25 seconds after the gas valve GV−M is energized the BLWM is energized at HI HEAT speed. Simultaneously, the electronic air cleaner (EAC 1 AMP) terminal is energized and remains energized as long as the BLWM is energized.

f. Switching from Low−to High−Heat−If the furnace

control CPU switches from low−heat to high−heat, the

g. Switching from High− to Low−Heat−The furnace

h. Heat−Off Delay−When the thermostat is satisfied, the

2. Two −Stage Thermostat and Two−Stage Heating (See Figure 31 for thermostat connections)

NOTE: In this mode the TT switch (SW1−1) must be ON to select the two−stage thermostat mode in response to closing the thermostat R−to−W1 circuit. Closing the thermostat R−to−W1−and−W2 circuits always causes high−heat operation, regardless of the setting of the thermostat type.

The wall thermostat “calls for heat”, closing the R−to−W1 circuit for low−heat or closing the R−to−W1 and−W2 circuits for high−heat. The furnace control performs a self−check, verifies the low−heat and high−heat pressure switch contacts LPS and HPS are open, and starts the inducer motor IDM in high−speed.

The start up and shut down functions and delays described in item 1. above apply to the two−stage heating mode as well, except for switching from low− to high−heat and vice versa.

a. Switching from Low− to High−Heat−If the

b. Switching from High− to Low−Heat−If the

3. Cooling Mode−The thermostat “calls for cooling.” a. Single−Speed Cooling−

Specifications are subject to change without notice.

furnace control CPU will switch the inducer motor IDM speed from low to high. The high−heat pressure switch relay HPSR is de−energized to close the NC contact. When sufficient pressure is available the high−heat pressure switch HPS closes, and the high−heat gas valve solenoid GV−HI is energized. The blower motor BLWM will switch to HI HEAT speed 5 seconds after the furnace control CPU switches from low−heat to high−heat.

control CPU will not switch from high−heat to low−heat while the thermostat R−to−W circuit is closed when using a single stage thermostat.

R to W circuit is opened, de−energizing the gas valve GV−M, stopping gas flow to the burners, and de−energizing the humidifier terminal HUM 24VAC. The inducer motor IDM will remain energized for a 5−second post−purge period then turn off, also turning off HUM for 115V humidifier. The blower motor BLWM and air cleaner terminal EAC 1 AMP will remain energized for 90, 120, 150, or 180 seconds (depending on selection at heat−off delay switches). The furnace control CPU is factory−set for a 120−second heat−off delay.

thermostat R−to− W1 circuit is closed and the R−to−W2 circuit closes, the furnace control CPU will switch the inducer motor IDM speed from low to high. The high−heat pressure switch relay HPSR is de−energized to close the NC contact. When sufficient pressure is available the high−heat pressure switch HPS closes, and the high−heat gas valve solenoid GV−HI is energized. The blower motor BLWM will switch to HI HEAT speed five seconds after the R−to−W2 circuit closes.

thermostat R−to−W2 circuit opens, and the R−to−W1 circuit remains closed, the furnace control CPU will switch the inducer motor IDM speed from high to low. The high−

heat pressure switch relay HPSR is energized to open the NC contact and de−energize the high−heat gas valve solenoid GV−HI. When the inducer motor IDM reduces pressure sufficiently, the high−heat pressure switch HPS will open. The gas valve solenoid GV−M will remain energized as long as the low−heat pressure switch LPS remains closed. The blower motor BLWM will switch to LO HEAT speed 5 seconds after the R−to−W2 circuit opens.

(See Figure 23 for thermostat connections) The thermostat closes the R−to−G−and−Y circuits. The R−to−Y circuit starts the outdoor unit, and the furnace control R−to−G−and−Y/Y2 circuits start the

441 01 2101 05

Page 47

furnace blower motor BLWM on cool speed. The electronic air cleaner terminal EAC 1 AMP is energized with 115 vac when the blower motor BLWM is operating. When the thermostat is satisfied, the R−to−G and−Y circuits are opened. The outdoor unit will stop, and the furnace blower motor BLWM will continue operating on the COOL speed for an additional 90 seconds. Jumper Y/Y2 to DHUM to reduce the cooling off−delay to 5 seconds. (See Figure 24)

b. Two−Speed Cooling

The thermostat closes the R−to−G−and−Y1 circuits for low−cooling or closes the R−to−G−and−Y1−and−Y2 circuits for high−cooling. The R−to−Y1 circuit starts the outdoor unit on low−cooling speed, and the furnace control R−to−G−and−Y1 circuit starts the furnace blower motor BLWM on low−cool speed (same speed as LO HEAT). The R−to−Y1−and−Y2 circuits start the outdoor unit on high−cooling speed, and the furnace control R−to−G−and−Y1 and −Y2 circuits start the furnace blower motor BLWM on COOL speed. The electronic air cleaner terminal EAC 1 AMP is energized with 115 vac whenever the blower motor BLWM is operating. When the thermostat is satisfied, the R−to−G−and opened. The outdoor unit stops, and the furnace blower BLWM and electronic air cleaner terminal EAC 1 AMP will remain energized for an additional 90 seconds. Jumper Y1 to DHUM to reduce the cooling off−delay to 5 seconds. (See Figure 33)

4. Dehumidify Mode

5. Continuous Blower Mode

−Y1 or R−to−G−and−Y1−and−Y2 circuits are

(See Figure 26 − Figure 32 for humidity sensing thermostat connections) The dehumidification output, H on the humidity sensing thermostat should be connected to the furnace control thermostat terminal DHUM. When there is a dehumidify demand, the DHUM input is activated, (24 vac signal is removed from the H input terminal). In other words, the DHUM input logic is reversed. The DHUM input is turned ON when no dehumidify demand exists.

Activation/Deactivation

Once 24 vac is detected by the furnace control on the DHUM input, the furnace control operates enables the dehumidify mode. If the DHUM input is off for more than 48 hours, the furnace control disables the dehumidify mode. The cooling operation described in item 3. above also applies to operation with a humidity sensing thermostat. The exceptions are listed below:

a. Low cooling − When the R−to−G−and−Y1 circuit is

closed and there is a demand for dehumidification,the furnace blower motor BLWM will continue running at low−cool speed (same speed as LO HEAT).

b. High cooling −When the R−to−G−and−Y/Y2 circuit is

closed and there is a demand for dehumidification,the furnace blower motor BLWM will drop the blower speed from COOL to HI HEAT for a maximum of 10 minutes before reverting back to COOL speed. If there is still a demand for dehumidification after 20 minutes, the furnace control CPU will drop the blower speed back to HI HEAT speed. This alternating 10−minute cycle will continue as long as there is a call for cooling.

c. Cooling off−delay − When the “call for cooling” is

satisfied and there is a demand for dehumidification, the cooling blower−off delay is decreased from 90 seconds to 5 seconds.

When the R−to−G circuit is closed by the thermostat, the blower motor BLWM will operate on continuous−blower speed LO HEAT speed. Terminal EAC 1 AMP is energized as long as the blower motor BLWM is energized. During a call for heat, the blower BLWM will stop during igniter warm−up (17 seconds), ignition (7 seconds), and blower−ON delay (45 seconds in low−heat, and 25 seconds in high−heat), allowing the furnace heat exchangers to heat up more

quickly, then restarts at the end of the blower−ON delay period at LO HEAT or HI HEAT speed respectively. The blower motor BLWM will revert to continuous−blower speed after the heating cycle is completed. In high−heat, the furnace control CPU will hold the blower motor BLWM at HI HEAT speed during the selected blower−OFF delay period before reverting to continuous−blower speed. When the thermostat “calls for low−cooling”, the blower motor BLWM will operate at low−cool speed (same speed as LO HEAT). When the thermostat “calls for high−cooling”, the blower motor BLWM will operate at COOL speed. When the thermostat is satisfied, the blower motor BLWM will operate an additional 90 seconds on COOL speed before reverting back to continuous−blower speed. When the R−to−G circuit is opened, the blower motor BLWM will continue operating for an additional 5 seconds, if no other function requires blower motor BLWM operation.

6. Heat Pump (See Figure 26 − Figure 32 for thermostat connections) When installed with a heat pump, the furnace control automatically changes the timing sequence to avoid long blower off times during demand defrost cycles. When the R−to−W/W1−and−Y1 or R−to−W/W1−and−Y1−and−G circuits are energized the furnace control CPU will switch to or turn on the blower motor BLWM at low−cool speed (same speed as LO HEAT), and begin a low−heat cycle. The blower motor BLWM will remain on until the end of the prepurge period, then shut off for 24 seconds then come back on at LO HEAT speed. When the W/W1 input signal disappears, the furnace control begins a normal inducer post−purge period and the blower remains running at LO HEAT speed. If the R−to− W/W1−and−Y1−and−G signals disappear at the same time, the blower motor BLWM will remain on for the selected heat−off delay period. If the R−to−W/W1−and−Y1 signals disappear, leaving the G signal, the blower motor BLWM will remain on for the selected heat−off delay period then switch to continuous−blower speed. When the R−to−W/W1−and−Y/Y2, R−to−W/W1−and− Y/Y2− and−G, R−to−W/W1−and−Y1−and−Y/Y2, or R−to−W/W1−and− Y1−and−Y/Y2−and−G circuits are energized the furnace control CPU will switch to or turn on the blower motor BLWM at COOL speed, and begin a high−heat cycle. The blower motor BLWM will remain on until the end of the prepurge period, then shut off for 24 seconds then come back on at HI HEAT speed. When the W/W1 input signal disappears, the furnace control begins a normal inducer post−purge period and the blower switches to COOL speed after a 3 second delay. If the R−to−W/W1−and−Y/Y2−and−G or R−to−W/W1−and−Y1−and− Y/Y2 disappear at the same time, the blower motor BLWM will remain on for the selected heat−off delay period If the R−to−W/W1−and−Y/Y2 or R−to−W/W1− and−Y1−and−Y/Y2 signals disappear, leaving the G signal, the blower motor BLWM will remain on for the selected heat−off delay period then switch to continuous−blower speed.

−and−G signals

Step 4 — Wiring Diagrams

Refer to wiring diagram, Figure 55.

Step 5 — Troubleshooting

Refer to the service label. (See Figure 51 —Service Label)

441 01 2101 05

Specifications are subject to change without notice.

Page 48

Figure 55 − Wiring Diagram

Specifications are subject to change without notice.

337797−201 Rev. B

441 01 2101 05

Page 49

Figure 56 − Troubleshooting Guide − Two −Speed

441 01 2101 05

Specifications are subject to change without notice.

Page 50

NOTE:

NUMBER IN UPPER LEFT HAND

CORNER REPRESENTS FLASH CODE

Specifications are subject to change without notice.

441 01 2101 05

Page 51

PARTS REPLACEMENT INFORMATION GUIDE

CASING GROUP

Outer door Blower door Top filler plate Bottom filler plate Bottom enclosure

ELECTRICAL GROUP

Control bracket Junction box Limit switch(es) Circuit board Door switch Transformer Wiring harness 115v

BLOWER GROUP

Blower housing Blower cutoff Blower motor Blower wheel Capacitor (where used) Capacitor strap (where used) Grommet Power choke (where used)

GAS CONTROL GROUP

Manifold Burner assembly Orifice Flame sensor Hot surface igniter Gas valve Manual reset limit switches

HEAT EXCHANGER GROUP

Heat exchanger cell Cell panel Lox NOx baffle (California models

only)

INDUCER GROUP

Housing assembly Pressure switch Inducer motor Inducer wheel Vent elbow assembly

Wiring harness 24v

MODEL NUMBER IDENTIFICATION GUIDE

DIGIT POSITION 1 2 3 4 5 6,7,8 9,10 11,12 13 14 F or G= Mainline F 8 M T L 045 14 12 A 1 N = Entry 8 = 80% AFUE EFFICIENCY M = Multiposition POSITION

V = Variable Speed Blower Motor − ECM

X = ECM Blower Motor S = Single−stage T = Two−stage TYPE N = Standard L = Low Nox FEATURE 045 = 45,000 BTU/hr 070 = 70,000 BTU/hr 090 = 90,000 BTU/hr 110 = 110,000 BTU/hr HEAT INPUT 14 = 143/16” 17 = 171/2” 21 = 21” 24 = 241/2” CABINET WIDTH 08 = 800 CFM 12 = 1200 CFM 14 = 1400 CFM 16 = 1600 CFM 20 = 2000 CFM 22 = 2200 CFM COOLING AIRFLOW

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

Have available the product/model number and the serial number located on the unit rating plate to ensure correct replacement parts. WARNING: Improper installation, adjustment, alteration, service, or maintenance can cause personal injury, property damage, or death.

Consult a qualified installer, service agency, or your local gas supplier for information or assistance. The qualified installer or service agency must use only factory−authorized replacement parts, kits, or accessories when modifying this product.

SALES (MAJOR) REVISION DIGIT

ENGINEERING (MINOR) REVISION DIGIT

International Comfort Products

Consumer Relations Department

P.O. Box 128

Lewisburg, TN 37091, USA

931−270−4100

441 01 2101 05

Specifications are subject to change without notice

Page 52

Lewisburg, TN 37091 USA

Specifications are subject to change without notice

441 01 2101 01