INSTALLATION INSTRUCTIONS
FOR
*(D, M)VC8 GAS FURNACE
(CATEGORY I )
Installer: Affix all manuals adjacent to the unit.
These furnaces comply with requirements embodied in the American National Standard / National Standard of Canada ANSI Z21.47·CSA2.3 Gas Fired Central Furnaces.
RECOGNIZE THIS SYMBOL AS A SAFETY PRECAUTION.
ATTENTION INSTALLING PERSONNEL
As a professional installer, you have an obligation to know the product better than the customer.
This includes all safety precautions and related items.
Prior to actual installation, thoroughly familiarize yourself with this Instruction Manual.
Pay special attention to all safety warnings. Often during installation or repair, it is possible to place yourself
in a position which is more hazardous than when the unit is in operation.
Remember, it is your responsibility to install the product safely and to know it well enough
to be able to instruct a customer in its safe use.
Safety is a matter of common sense...a matter of thinking before acting.
Most dealers have a list of specific, good safety practices...follow them.
The precautions listed in this Installation Manual are intended as supplemental to existing practices.
However, if there is a direct conflict between existing practices and the content of this manual,
the precautions listed here take precedence.
NOTE: Please contact your distributor or our website listed below
for the applicable Specification Sheet referred to in this manual.
WARNING
GOODMAN WILL NOT BE RESPONSIBLE FOR ANY INJURY OR PROPERTY DAMAGE ARISING FROM IMPROPER SERVICE OR SERVICE PROCEDURES. IF YOU INSTALL OR PERFORM SERVICE ON THIS UNIT, YOU ASSUME RESPONSIBILITY FOR ANY PERSONAL INJURY OR PROPERTY DAMAGE WHICH MAY RESULT. MANY JURISDICTIONS REQUIRE A LICENSE TO INSTALL OR SERVICE HEATING AND AIR CONDITIONING EQUIPMENT.
IO-429A
6/2013
5151 San Felipe Suite 500 • Houston, TX 77056
www.goodmanmfg.com • www.amana-hac.com
© 2011 - 2013 Goodman Manufacturing Company, L.P.
is a registered trademark of Maytag Corporation or its related companies and is used under license. All rights reserved.
Table of Contents
SAFETY CONSIDERATIONS ........................................................................................................................................................... 4
ADDITIONAL SAFETY CONSIDERATIONS ................................................................................................................................... 5
SHIPPING INSPECTION ........................................................................................................................................................ 5
ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS ................................................................................................................... 6
TO THE INSTALLER ............................................................................................................................................................ 6
PRODUCT DESCRIPTION ............................................................................................................................................................. 6
FEATURES ........................................................................................................................................................................ 6
PRODUCT APPLICATION .............................................................................................................................................................. 6
LOCATION REQUIREMENTS AND CONSIDERATIONS ............................................................................................................................. 7
CLEARANCES AND ACCESSIBILITY ......................................................................................................................................... 9
INSTALLATION POSITIONS ..................................................................................................................................................... 9
HORIZONTAL INSTALLATION (*MVC8 MODELS ONLY) ............................................................................................................... 9
FURNACE SUSPENSION ...................................................................................................................................................... 9
EXISTING FURNACE REMOVAL .............................................................................................................................................. 9
THERMOSTAT LOCATION ....................................................................................................................................................... 9
COMBUSTION AND VENTILATION AIR REQUIREMENTS ...................................................................................................................... 10
EXTERIOR MASONRY CHIMNEYS .................................................................................................................................................. 11
(CATEGORY I FURNACES ONLY) .................................................................................................................................................. 11
CHECKLIST SUMMARY ...................................................................................................................................................... 12
CHECK 1 - PROPER CHIMNEY TERMINATION. ........................................................................................................................ 12
CHECK 2 - ANY SOLID OR LIQUID FUEL APPLIANCES VENTED INTO THIS CHIMNEY CHANNEL ....................................................... 13
CHECK 3 - CHIMNEY CROWN CONDITION. ........................................................................................................................... 13
CHECK 4 - DEBRIS IN CLEANOUT. ...................................................................................................................................... 13
CHECK 5 - LINER CONDITION. .......................................................................................................................................... 13
CHECK 6 - DILUTION AIR. ............................................................................................................................................... 14
CHECK 7 - COMPLETE THE INSTALLATION. ............................................................................................................................ 14
FIX 1 - LINER TERMINATION .............................................................................................................................................. 14
FIX 2 -CHANGE VENTING ARRANGEMENTS ........................................................................................................................... 14
FIX 3 - REBUILD THE CROWN ........................................................................................................................................... 15
FIX 4 - RELINING ............................................................................................................................................................ 15
ELECTRICAL CONNECTIONS ....................................................................................................................................................... 15
WIRING HARNESS ........................................................................................................................................................... 16
115 VOLT LINE CONNECTIONS .......................................................................................................................................... 16
JUNCTION BOX RELOCATION ............................................................................................................................................. 16
24 VOLT THERMOSTAT WIRING .......................................................................................................................................... 17
SINGLE-STAGE HEATING THERMOSTAT APPLICATION ................................................................................................................ 17
24 VOLT DEHUMIDISTAT WIRING ........................................................................................................................................ 18
FOSSIL FUEL APPLICATIONS .............................................................................................................................................. 18
115 VOLT LINE CONNECTION OF ACCESSORIES (HUMIDIFIER AND ELECTRONIC AIR CLEANER) .................................................... 18
24 VOLT HUMIDIFIER ....................................................................................................................................................... 19
AUXILIARY ALARM SWITCH ............................................................................................................................................... 19
GAS SUPPLY AND PIPING .......................................................................................................................................................... 19
HIGH ALTITUDE DERATE ................................................................................................................................................... 20
PROPANE GAS CONVERSION .............................................................................................................................................. 20
GAS PIPING CONNECTIONS ............................................................................................................................................... 20
UPFLOW INSTALLATIONS .................................................................................................................................................... 21
COUNTERFLOW INSTALLATIONS ........................................................................................................................................... 21
GAS PIPING CHECKS ....................................................................................................................................................... 22
PROPANE GAS TANKS AND PIPING ...................................................................................................................................... 22
CIRCULATING AIR AND FILTERS .................................................................................................................................................. 23
CHECKING DUCT STATIC ................................................................................................................................................... 23
FILTERS - READ THIS SECTION BEFORE INSTALLING THE RETURN AIR DUCTWORK .................................................................... 24
UPRIGHT INSTALLATIONS ................................................................................................................................................... 24
CIRCULATION AIR FILTERS ................................................................................................................................................ 24
HORIZONTAL INSTALLATIONS ............................................................................................................................................... 24
2
Table of Contents
START-UP PROCEDURE AND ADJUSTMENT ................................................................................................................................... 24
HEAT ANTICIPATOR SETTING ............................................................................................................................................... 24
FURNACE OPERATION ....................................................................................................................................................... 24
GAS SUPPLY PRESSURE MEASUREMENT .............................................................................................................................. 25
GAS MANIFOLD PRESSURE MEASUREMENT AND ADJUSTMENT .................................................................................................. 26
GAS INPUT RATE MEASUREMENT (NATURAL GAS ONLY) ........................................................................................................... 27
TEMPERATURE RISE ......................................................................................................................................................... 27
CIRCULATOR BLOWER SPEEDS .......................................................................................................................................... 28
BLOWER HEAT OFF DELAY TIMINGS .................................................................................................................................... 30
COMFORTNET™ SYSTEM .......................................................................................................................................................... 30
OVERVIEW ..................................................................................................................................................................... 30
FOSSIL FUEL APPLICATIONS .............................................................................................................................................. 31
CTK0* WIRING ............................................................................................................................................................. 31
COMFORTNET™ COMPATIBLE FURNACE WITH NON-COMFORTNET COMPATIBLE SINGLE-STAGE AIR CONDITIONER .............................. 32
COMFORTNET™ SYSTEM ADVANCED FEATURES ............................................................................................................................. 32
THERMOSTAT MENU ......................................................................................................................................................... 32
DIAGNOSTICS .................................................................................................................................................................. 32
FURNACE ADVANCED FEATURES MENUS (ACCESSED THROUGH COMMUNICATING THERMOSTAT) ..................................................... 33
NETWORK TROUBLESHOOTING ........................................................................................................................................... 34
SYSTEM TROUBLESHOOTING .............................................................................................................................................. 34
NORMAL SEQUENCE OF OPERATION ............................................................................................................................................ 34
POWER UP .................................................................................................................................................................... 34
HEATING MODE ............................................................................................................................................................... 35
COOLING MODE ............................................................................................................................................................. 36
FAN ONLY MODE ............................................................................................................................................................ 36
OPERATIONAL CHECKS ............................................................................................................................................................. 36
SAFETY CIRCUIT DESCRIPTION ................................................................................................................................................... 37
INTEGRATED CONTROL MODULE ......................................................................................................................................... 37
PRIMARY LIMIT ................................................................................................................................................................ 37
AUXILIARY LIMIT ............................................................................................................................................................. 37
ROLLOUT LIMIT .............................................................................................................................................................. 37
PRESSURE SWITCHES ...................................................................................................................................................... 37
FLAME SENSOR .............................................................................................................................................................. 37
TROUBLESHOOTING ................................................................................................................................................................. 37
ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS ................................................................................................................. 37
DIAGNOSTIC CHART ......................................................................................................................................................... 37
FAULT RECALL ................................................................................................................................................................ 37
RESETTING FROM LOCKOUT .............................................................................................................................................. 38
MAINTENANCE ......................................................................................................................................................................... 38
ANNUAL INSPECTION ........................................................................................................................................................ 38
FILTERS ........................................................................................................................................................................ 38
BURNERS ...................................................................................................................................................................... 38
INDUCED DRAFT AND CIRCULATOR BLOWERS ....................................................................................................................... 39
FLAME SENSOR (QUALIFIED SERVICER ONLY) ...................................................................................................................... 39
FLUE PASSAGES (QUALIFIED SERVICER ONLY) ..................................................................................................................... 39
BEFORE LEAVING AN INSTALLATION .............................................................................................................................................. 39
REPAIR AND REPLACEMENT PARTS .............................................................................................................................................. 39
TROUBLESHOOTING CHART ....................................................................................................................................................... 40
STATUS CODES ....................................................................................................................................................................... 45
AIR FLOW DATA ...................................................................................................................................................................... 46
DIP SWITCHES ....................................................................................................................................................................... 47
*MVC8, *DVC8 WIRING DIAGRAM ........................................................................................................................................... 48
3
SAFETY CONSIDERATIONS
WARNING
IF THE INFORMATION IN THESE INSTRUCTIONS IS NOT FOLLOWED EXACTLY, A FIRE OR EXPLOSION MAY RESULT CAUSING PROPERTY
DAMAGE , PERSONAL INJURY OR LOSS OF LIFE.
DO NOT STORE OR USE GASOLINE OR OTHER FLAMMABLE VAPORS AND LIQUIDS IN THE VICINITY OF THIS OR ANY OTHER APPLIANCE.
WHAT TO DO IF YOU SMELL GAS:
DO NOT TRY TO LIGHT ANY APPLIANCE.
DO NOT TOUCH ANY ELECTRICAL SWITCH; DO NOT USE ANY PHONE IN YOUR BUILDING.
IMMEDIATELY CALL YOUR GAS SUPPLIER FROM A NEIGHBOR’S PHONE. FOLLOW THE GAS SUPPLIER’S INSTRUCTIONS.
IF YOU CANNOT REACH YOUR GAS SUPPLIER, CALL THE FIRE DEPARTMENT.
INSTALLATION AND SERVICE MUST BE PERFORMED BY A QUALIFIED INSTALLER, SERVICE AGENCY OR THE GAS SUPPLIER.
Adhere to the following warnings and cautions when installing,
adjusting, altering, servicing, or operating the furnace. To ensure proper installation and operation, thoroughly read this
manual for specifics pertaining to the installation and application of this product.
This furnace is manufactured for use with natural gas. It may
be field converted to operate on L.P. gas by using the appropriate L.P. conversion kit listed in the PROPANE GAS/HIGH ALTITUDE INSTALLATIONS section of this manual
Install this furnace only in a location and position as specified
in LOCATION REQUIREMENTS & CONSIDERATIONS section and INSTALLATION POSITIONS section of this manual.
Provide adequate combustion and ventilation air to the furnace
as specified in COMBUSTION & VENTILATION AIR REQUIREMENTS section of this manual.
WARNING
THIS PRODUCT CONTAINS OR PRODUCES A CHEMICAL OR CHEMICALS WHICH MAY CAUSE SERIOUS ILLNESS OR DEATH AND WHICH ARE KNOWN TO THE STATE OF CALIFORNIA TO CAUSE CANCER, BIRTH DEFECTS OR OTHER REPRODUCTIVE HARM.
Combustion products must be discharged to the outdoors.
Connect this furnace to an approved vent system only, as specified in VENT/FLUE PIPE & COMBUSTION AIR PIPE section
of this manual.
WARNING
Never test for gas leaks with an open flame. Use a commercially available soap solution made specifically for the detection of leaks to check all connections, as specified in GAS
SUPPLY AND PIPING section of this manual.
HEATING UNIT SHOULD NOT BE UTILIZED WITHOUT REASONABLE, ROUTINE, INSPECTION , MAINTENANCE AND SUPERVISION. IF THE BUILDING IN WHICH ANY SUCH DEVICE IS LOCATED WILL BE VACANT, CARE SHOULD BE TAKEN THAT SUCH DEVICE IS ROUTINELY INSPECTED, MAINTAINED AND MONITORED. IN THE EVENT THAT THE BUILDING MAYBE EXPOSED TO FREEZING TEMPERATURES AND WILL BE VACANT, ALL WATER‐BEARING PIPES SHOULD BE DRAINED, THE BUILDING SHOULD BE PROPERLY WINTERIZED, AND THE WATER SOURCE CLOSED . IN THE EVENT THAT THE BUILDING MAY BE EXPOSED TO FREEZING TEMPERATURES AND WILL BE VACANT, ANY HYDRONIC COIL UNITS SHOULD BE DRAINED AS WELL AND, IN SUCH CASE , ALTERNATIVE HEAT SOURCES SHOULD BE UTILIZED.
Always install a furnace to operate within the furnace’s intended
temperature-rise range with a duct system which has external
static pressure within the allowable range, as specified on the
furnace rating plate and OPERATIONAL CHECKS section of
these instructions.
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.
WARNING
A gas-fired furnace for installation in a residential garage must
be installed as specified in the LOCATION REQUIREMENTS
AND CONSIDERATIONS section of this manual.
TO PREVENT POSSIBLE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH DUE TO ELECTRICAL SHOCK , THE FURNACE MUST BE LOCATED TO PROTECT THE ELECTRICAL COMPONENTS FROM WATER.
This furnace may be used as a construction site heater only if
certain conditions are met. These conditions are listed in the
PRODUCT APPLICATION section of this manual.
WARNING
TO PREVENT PERSONAL INJURY OR DEATH DUE TO IMPROPER INSTALLATION, ADJUSTMENT, ALTERATION, SERVICE OR MAINTENANCE, REFER TO THIS MANUAL . FOR ADDITIONAL ASSISTANCE OR INFORMATION, CONSULT A QUALIFIED INSTALLER, SERVICER AGENCY OR THE GAS SUPPLIER.
4
WARNING
TO PREVENT PERSONAL INJURY OR DEATH DUE TO ASPHYXIATION, THIS FURNACE MUST BE CATEGORY I VENTED. DO NOT VENT USING CATEGORY III VENTING.
PROVISIONS MUST BE MADE FOR VENTING COMBUSTION PRODUCTS OUTDOORS THROUGH A PROPER VENTING SYSTEM. THE LENGTH OF FLUE PIPE COULD BE A LIMITING FACTOR IN LOCATING THE FURNACE.
ADDITIONAL SAFETY CONSIDERATIONS
•
•
CARBON MONOXIDE POISONING HAZARD
Special Warning for Installation of Furnace or Air Handling Units in
Enclosed Areas such as Garages, Utility Rooms or Parking Areas
Carbon monoxide producing devices (such as an automobile, space
heater, gas water heater, etc.) should not be operated in enclosed areas
such as unventilated garages, utility rooms or parking areas because of
the danger of carbon monoxide (CO) poisoning resulting from the exhaust
emissions. If a furnace or air handler is installed in an enclosed area such
as a garage, utility room or parking area and a carbon monoxide producing
device is operated therein, there must be adequate, direct outside
ventilation.
This furnace is approved for Category I Venting only.
Provisions must be made for venting combustion
products outdoors through a proper venting system.
The length of flue pipe could be a limiting factor in
locating the furnace.
SHIPPING INSPECTION
All units are securely packed in shipping containers tested
according to International Safe Transit Association specifications. The carton must be checked upon arrival for external
damage. If damage is found, a request for inspection by carrier’s
agent must be made in writing immediately.
This ventilation is necessary to avoid the danger of CO poisoning which
can occur if a carbon monoxide producing device continues to operate in
the enclosed area. Carbon monoxide emissions can be (re)circulated
throughout the structure if the furnace or air handler is operating in any
mode.
The furnace must be carefully inspected on arrival for damage
and bolts or screws which may have come loose in transit. In
the event of damage the consignee should:
1. Make a notation on delivery receipt of any visible damage
to shipment or container.
2. Notify carrier promptly and request an inspection.
3. With concealed damage, carrier must be notified as soon
as possible - preferably within five days.
4. File the claim with the following support documents within
a nine month statute of limitations.
•
Original or certified copy of the Bill of Lading, or
indemnity bond.
•
Original paid freight bill or indemnity in lieu thereof.
•
Original or certified copy of the invoice, showing trade
and other discounts or reductions.
•
Copy of the inspection report issued by carrier’s
representative at the time damage is reported to carrier.
CO can cause serious illness including permanent brain damage or death.
B10259-216
WARNING
SHOULD OVERHEATING OCCUR OR THE GAS SUPPLY FAIL TO SHUT OFF, TURN OFF THE MANUAL GAS SHUTOFF VALVE EXTERNAL TO THE FURNACE BEFORE TURNING OFF THE ELECTRICAL SUPPLY.
WARNING
POSSIBLE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH DUE TO FIRE, EXPLOSION, SMOKE, SOOT, CONDENSATION, ELECTRICAL SHOCK OR CARBON MONOXIDE MAY RESULT FROM IMPROPER INSTALLATION, REPAIR OPERATION, OR MAINTENANCE OF THIS PRODUCT.
The carrier is responsible for making prompt inspection of damage and for a thorough investigation of each claim. The distributor or manufacturer will not accept claims from dealers for transportation damage.
WARNING
TO PREVENT PERSONAL INJURY OR DEATH DUE TO IMPROPER INSTALLATION, ADJUSTMENT, ALTERATION, SERVICE OR MAINTENANCE, REFER TO THIS MANUAL . FOR ADDITIONAL ASSISTANCE OR INFORMATION, CONSULT A QUALIFIED INSTALLER, SERVICER AGENCY OR THE GAS SUPPLIER.
Keep this literature in a safe place for future reference.
WARNING
THIS UNIT MUST NOT BE USED AS A “CONSTRUCTION HEATER” DURING THE FINISHING PHASES OF CONSTRUCTION ON A NEW STRUCTURE. THIS TYPE OF USE MAY RESULT IN PREMATURE FAILURE OF THE UNIT DUE TO EXTREMELY LOW RETURN AIR TEMPERATURES AND EXPOSURE TO CORROSIVE OR VERY DIRTY ATMOSPHERES.
5
ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS
This product may also be installed with the ComfortNet thermostat and a non-ComfortNet compatible single stage air conNOTE: Discharge body’s static electricity before touching unit. ditioning unit. However, this reduces the benefits of the
An electrostatic discharge can adversely affect electrical com- ComfortNet system as the enhancements will only apply to the
ponents.
furnace.
Use the following precautions during furnace installation and
servicing to protect the integrated control module from damage. By putting the furnace, the control, and the person at the
same electrostatic potential, these steps will help avoid exposing the integrated control module to electrostatic discharge.
This procedure is applicable to both installed and non-installed
(ungrounded) furnaces.
1. Disconnect all power to the furnace. Do not touch the
integrated control module or any wire connected to the
control prior to discharging your body’s electrostatic
charge to ground.
2. Firmly touch a clean, unpainted, metal surface of the
furnaces near the control. Any tools held in a person’s
hand during grounding will be discharged.
3. Service integrated control module or connecting wiring
following the discharge process in step 2. Use caution
not to recharge your body with static electricity; (i.e., do
not move or shuffle your feet, do not touch ungrounded
objects, etc.). If you come in contact with an ungrounded
object, repeat step 2 before touching control or wires.
4. Discharge your body to ground before removing a new
control from its container. Follow steps 1 through 3 if
installing the control on a furnace. Return any old or
new controls to their containers before touching any
ungrounded object.
PRODUCT APPLICATION
This furnace is primarily designed for residential home-heating
applications. It is NOT designed or certified for use in mobile
homes, trailers or recreational vehicles. Neither is it designed
or certified for outdoor applications. The furnace must be installed indoors (i.e., attic space, crawl space, or garage area
provided the garage area is enclosed with an operating door).
This furnace can be used in the following non-industrial commercial applications:
Schools, Office buildings, Churches, Retail stores,
Nursing homes, Hotels/motels, Common or office areas
In such applications , the furnace must be installed with the
following stipulations:
•
It must be installed per the installation instructions
provided and per local and national codes.
•
It must be installed indoors in a building constructed
on site.
•
It must be part of a ducted system and not used in a
free air delivery application.
•
It must not be used as a “make-up” air unit.
•
All other warranty exclusions and restrictions apply.
This furnace may be used as a construction site heater ONLY
if the following conditions are met:
•
The vent system is permanently installed per these
installation instructions.
•
A room thermostat is used to control the furnace. Fixed
jumpers that provide continuous heating CANNOT be
used.
•
Return air ducts are provided and sealed to the furnace.
•
A return air temperature range between 60ºF (16ºC)
and 80ºF (27ºC) is maintained.
•
Air filters are installed in the system and maintained
during construction, replaced as appropriate during
construction, and upon completion of construction are
replaced.
•
The input rate and temperature rise are set per the
furnace rating plate.
•
100% outside air is provided for combustion air
requirements during construction. Temporary ducting
can be used.
NOTE: Do not connect the temporary duct directly to
the furnace. The duct must be sized for adequate
combustion and ventilation in accordance with the
latest edition of the National Fuel Gas Code NFPA 54/
ANSI Z223.1 orCAN/CSA B149.1 Installation Codes.
TO THE INSTALLER
Before installing this unit, please read this manual thoroughly
to familiarize yourself with specific items which must be adhered to, including but not limited to: unit maximum external
static pressure, gas pressures, BTU input rating, proper electrical connections, circulating air temperature rise, minimum or
maximum CFM, and motor speed connections, and venting.
These furnaces are designed for Category I venting only.
WARNING
TO PREVENT PROPERTY DAMAGE, PERSONAL INJURY OR DEATH DUE TO FIRE, DO NOT INSTALL THIS FURNACE IN A MOBILE HOME, TRAILER, OR RECREATIONAL VEHICLE.
PRODUCT DESCRIPTION
FEATURES
This furnace is a part of the ComfortNet™ family of products.
The CTK0* ComfortNet thermostat kit allows this furnace to be
installed as part of a digitally communicating system. The
ComfortNet system provides automatic airflow configuration,
enhanced setup features, and enhanced diagnostics. It also
reduces the number of thermostat wires to a maximum of four.
It may be also installed as part of a “legacy” system using a
standard 24 VAC thermostat.
6
•
The furnace heat exchanger, components, duct
system, air filters and evaporator coils are thoroughly
cleaned following final construction clean up.
All furnace operating conditions (including ignition, input
rate, temperature rise and venting) are verified
according to these installation instructions.
In the USA, this furnace MUST be installed in accordance with
the latest edition of the ANSI Z223.1 booklet entitled “National
Fuel Gas Code” (NFPA 54), and the requirements or codes of
•
the local utility or other authority having jurisdiction. In Canada,
this furnace must be installed in accordance with the current
CAN/CGA-B149.1 & 2 Gas Installation Codes, local plumbing
or waste water codes and other applicable codes. Additional
NOTE: The Commonwealth of Massachusetts requires that the helpful publications available from the NFPA are, NFPA 90A following additional requirements must also be met:
Installation of Air Conditioning and Ventilating System and NFPA
90B - Warm Air Heating and Air Conditioning System.
•
Gas furnaces must be installed by a licensed plumber
or gas fitter.
All venting shall be in accordance with PART 7, Venting of Equip•
A T-handle gas cock must be used.
ment, of the National Fuel Gas Code, ANSI Z223.1, or appli•
If the unit is to be installed in an attic, the passageway
cable local building and/or air conditioning codes. These pubto and the service area around the unit must have
lications are available from:
flooring.
National Fire Protection Association, Inc.
1 Batterymarch Park, Quincy, MA 02269
WARNING
NOTE: Furnaces with NOx screens meet the California NOx
emission standards and California seasonal efficiency standards. ANNUAL inspections of the furnace and its vent system
is strongly recommended.
TO PREVENT PROPERTY DAMAGE, PERSONAL INJURY OR DEATH DUE TO FIRE, DO NOT INSTALL THIS FURNACE IN A MOBILE HOME, TRAILER, OR RECREATIONAL VEHICLE.
LOCATION REQUIREMENTS AND CONSIDERATIONS
To ensure proper furnace operation, install, operate and
maintain the furnace in accordance with these installation and operation instructions, all local building codes
and ordinances. In their absence, follow the latest edition of
the National Fuel Gas Code (NFPA 54/ANSI Z223.1), and/or
CAN/CSA B149 Installation Codes, local plumbing or waste
water codes, and other applicable codes.
Your unit model type determines which installation procedures
must be used. For *MVC8 models, you must follow instructions for Horizontal Left, Horizontal Right or Upflow installations only. These furnaces are not approved for Downflow installations.
Downflow models *DVC8 ARE NOT APPROVED FOR HORIA copy of the National Fuel Gas Code (NFPA 54/ANSI Z223.1) ZONTAL OR UPFLOW INSTALLATIONS. For these models,
use only the instructions for downflow installation only.
can be obtained from any of the following:
American National Standards Institute
1430 Broadway
WARNING
New York, NY 10018
TO PREVENT POSSIBLE EQUIPMENT DAMAGE, PROPERTY DAMAGE, National Fire Protection Association
PERSONAL INJURY OR DEATH, THE FOLLOWING BULLET POINTS MUST BE 1 Batterymarch Park
OBSERVED WHEN INSTALLING THIS UNIT.
Quincy, MA 02269
Follow the instructions listed below when selecting a furnace
location. Refer also to the guidelines provided in Section V,
Combustion and Ventilation Air Requirements.
•
Centrally locate the furnace with respect to the
A copy of the CAN/CSA B149 Installation Codes can also be
proposed or existing air distribution system.
obtained from:
CSA International
178 Rexdale Boulevard
Etobicoke, Ontario, Canada M9W 1R3
CSA International
8501 East Pleasant Valley
Cleveland, OH 44131
The rated heating capacity of the furnace should be greater
than or equal to the total heat loss of the area to be heated.
The total heat loss should be calculated by an approved method
or in accordance with “ASHRAE Guide” or “Manual J-Load Calculations” published by the Air Conditioning Contractors of
America.
7
•
•
•
•
•
•
Ensure the temperature of the return air entering the
furnace is between 55°F and 100°F when the furnace
is heating.
Provisions must be made for venting combustion
products outdoors through a proper venting system.
The length of flue pipe could be a limiting factor in
locating the furnace.
Ensure adequate combustion air is available for the
furnace. Improper or insufficient combustion air can
expose building occupants to gas combustion products
that could include carbon monoxide. Refer to
Combustion and Ventilation Air Requirements section.
The furnace must be level. If the furnace is to be set on
a floor that may become wet or damp at times, the
furnace should be supported above the floor on a
concrete base sized approximately 1-1/2" larger than
the base of the furnace.
Ensure upflow or horizontal furnaces are not installed
directly on carpeting, or any other combustible material.
The only combustible material allowed is wood.
Exposure to contaminated combustion air will result
in safety and performance-related problems. Do not
install the furnace where the combustion air is exposed
to the following substances:
•
•
•
Vent Pipe Clearance to Combustibles6" using Single Wall Connector or 1"
using B-1 vent.
chlorinated waxes or cleaners
chlorine-based swimming pool chemicals
water softening chemicals
deicing salts or chemicals
carbon tetrachloride
halogen type refrigerants
cleaning solutions (such as perchloroethylene)
printing inks
paint removers
varnishes
hydrochloric acid
cements and glues
antistatic fabric softeners for clothes dryers
and masonry acid washing materials
•
•
•
•
For counterflow installations, the air conditioning coil
must be downstream from the heat exchanger of the
furnace.
Counterflow installation over a noncombustible floor.
Before setting the furnace over the plenum opening,
ensure the surface around the opening is smooth and
level. A tight seal should be made between the furnace
base and floor by using a silicon rubber caulking
compound or cement grout.
Counterflow installation over a combustible floor. If
installation over a combustible floor becomes
necessary, use an accessory subbase (see
Specification Sheet applicable to your model for details).
A special accessory subbase must be used for upright
counterflow unit installations over any combustible
material including wood. Follow the instructions with
the subbase for proper installations. Do not install the
furnace directly on carpeting, tile, or other combustible
material other than wood flooring. (NOTE: The subbase
will not be required if an air conditioning coil is installed
between the supply air opening on the furnace and
the floor.
Top - 1"
Back - 0"
Side
Clearance - 1"
If the furnace is used in connection with a cooling unit,
install the furnace upstream or in parallel with the
cooling unit coil. Premature heat exchanger failure
will result if the cooling unit coil is placed ahead of the
furnace.
If the furnace is installed in a residential garage,
position the furnace so that the burners and ignition
source are located not less than 18 inches (457 mm)
above the floor. Protect the furnace from physical
damage by vehicles.
If the furnace is installed horizontally, the furnace
access doors must be vertical so that the burners fire
horizontally into the heat exchanger. Do not install
the unit with the access doors on the “up/top” or “down/
bottom” side of the furnace.
Do not connect this furnace to a chimney flue that
serves a separate appliance designed to burn solid
fuel.
Front Clearance - 3"
•
•
•
8
Adequate combustion/ventilation air must be supplied
to the closet.
Furnace must be completely sealed to floor or base.
Combustion/ ventilation air supply pipes must
terminate 12" from top of closet and 12" from floor of
closet. DO NOT remove solid base plate for side
return.
Return air ducts must be completely sealed to the
furnace and terminate outside the enclosure surfaces.
CLEARANCES AND ACCESSIBILITY
EXISTING FURNACE REMOVAL
Unobstructed front clearance of 24" for servicing is recom- NOTE: When an existing furnace is removed from a venting
system serving other appliances, the venting system may be
mended.
too large to properly vent the remaining attached appliances.
VE N T
TO P
B1-V EN T
SIN G LE
1"
6"
SID ES
FR O N T
B AC K
1"
3"
0"
(P LEN U M )
The following vent testing procedure is reproduced from the
American National Standard/National Standard of Canada
for Gas-Fired Central Furnaces ANSI Z21.47-Latest Edition, CSA-2.3-Latest Edition Section 1.23.1. The following
steps shall be followed with each appliance connected to the
venting system placed in operation, while any other appliances
connected to the venting system are not in operation:
a. Seal any unused openings in the venting system;
b. Inspect the venting system for proper size and
horizontal pitch, as required by the National Fuel Gas
Code, ANSI Z223.1 or the CAN/CSA B149 Installation
Codes and these instructions. Determine that there is
no blockage or restriction, leakage, corrosion and other
deficiencies which could cause an unsafe condition;
c. In so 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. 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 shall
operate at maximum speed. Do not operate a summer
exhaust fan. Close fireplace dampers;
d. Follow the lighting instructions. Place the appliance
being inspected in operation. Adjust thermostat so
appliance shall operate continuously;
e. Test for draft hood equipped appliance spillage at the
draft hood relief opening after 5 minutes of main burner
operation. Use the flame of a match or candle;
f. 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
burning appliance to their previous conditions of use;
g. If improper venting is observed during any of the above
tests, the common venting system must be corrected.
1"
Top clearance for horizontal configuration - 1"
INSTALLATION POSITIONS
An upflow furnace may be installed in an upright position or
horizontal on either the left or right side panel. Do not install
this furnace on its back. For vertically installed upflow furnaces,
return air ductwork may be attached to the side panel(s) and/or
basepan. For horizontally installed upflow furnaces, return air
ductwork must be attached to the basepan. For counterflow
furnaces, return ductwork must be attached to the top end of
the blower compartment.
NOTE: Ductwork must never be attached to the back of the
furnace.
HORIZONTAL INSTALLATION (*MVC8 MODELS ONLY)
Line contact to framing is permitted when installed in the horizontal configuration. Line contact is defined as the portion of
the cabinet that is formed by the intersection of the top and
side. ACCESSIBILITY CLEARANCE, WHERE GREATER,
SHOULD TAKE PRECEDENCE OVER MINIMUM FIRE PROTECTION CLEARANCE. A gas-fired furnace for installation in
a residential garage must be installed so that the ignition source
and burners are located not less than eighteen inches (18")
above the floor and is protected or located to prevent physical
damage by vehicles. A gas furnace must not be installed directly on carpeting, tile, or other combustible materials other
than wood flooring.
FURNACE SUSPENSION
If suspending the furnace from rafters or joist, use 3/8" threaded
rod and 2”x2”x3/8” angle iron as shown below. The length of
rod will depend on the application and the clearances necessary.
Corrections must be in accordance with the latest edition of
the National Fuel Gas Code NFPA 54/ANSI Z223.1 and/or CAN/
CSA B149 Installation Codes.
If resizing is required on any portion of the venting system, use
the appropriate table in Appendix G in the latest edition of the
National Fuel Gas Code ANSI Z223.1 and/or CAN/CSA B149
Installation Codes.
THERMOSTAT LOCATION
In an area having good air circulation, locate the thermostat
about five feet high on a vibration-free inside wall. Do not install
the thermostat where it may be influenced by any of the following:
Suspended Furnace
9
•
•
•
•
•
•
•
Drafts, or dead spots behind doors, in corners, or under
cabinets.
Hot or cold air from registers.
Radiant heat from the sun.
Light fixtures or other appliances.
Radiant heat from a fireplace.
Concealed hot or cold water pipes, or chimneys.
Unconditioned areas behind the thermostat, such as
an outside wall.
This furnace must use indoor air for combustion. It cannot be
installed as a direct vent (i.e., sealed combustion) furnace.
Most homes will require outside air be supplied to the furnace
area by means of ventilation grilles or ducts connecting directly
to the outdoors or spaces open to the outdoors such as attics
or crawl spaces.
CATEGORY I VENTING (VERTICAL VENTING)
WARNING
TO PREVENT POSSIBLE PERSONAL INJURY OR DEATH DUE TO ASPHYXIATION, THIS FURNACE MUST BE CATEGORY I VENTED. DO NOT VENT USING CATEGORY III VENTING.
HOT
COLD
Thermostat Influences
Category I Venting is venting at a non-positive pressure. A
furnace vented as Category I is considered a fan-assisted appliance and the vent system does not have to be “gas tight.”
NOTE: Single stage gas furnaces with induced draft blowers
draw products of combustion through a heat exchanger allowing, in some instances, common venting with natural draft appliances (i.e. water heaters). All installations must be vented in
accordance with National Fuel Gas Code NFPA 54/ANSI Z223.1
- latest edition. In Canada, the furnaces must be vented in accordance with the National Standard of Canada, CAN/CSA
B149.1 and CAN/CSA B149.2 - latest editions and amendments.
Consult the instructions packaged with the thermostat for mount- NOTE: The vertical height of the Category I venting system
must be at least as great as the horizontal length of the venting
ing instructions and further precautions.
system.
COMBUSTION AND VENTILATION AIR REQUIREMENTS
WARNING
TO PREVENT POSSIBLE PERSONAL INJURY OR DEATH DUE TO ASPHYXIATION, COMMON VENTING WITH OTHER MANUFACTURER’S INDUCED DRAFT APPLIANCES IS NOT ALLOWED.
WARNING
TO AVOID PROPERTY DAMAGE, PERSONAL INJURY OR DEATH, SUFFICIENT FRESH AIR FOR PROPER COMBUSTION AND VENTILATION OF FLUE GASES MUST BE SUPPLIED. MOST HOMES REQUIRE OUTSIDE AIR BE SUPPLIED INTO THE FURNACE AREA.
The minimum vent diameter for the Category I venting system
is as shown:
MINIMUM VENT
Improved construction and additional insulation in buildings have
MODEL
UPFLOW
COUNTERFLOW
reduced heat loss by reducing air infiltration and escape around
060
4
inch
4 inch
doors and windows. These changes have helped in reducing
080
4
inch
4 inch
heating/cooling costs but have created a problem supplying
100
5
inch
4 inch
combustion and ventilation air for gas fired and other fuel burning appliances. Appliances that pull air out of the house (clothes
dryers, exhaust fans, fireplaces, etc.) increase the problem by Under some conditions, larger vents than those shown above
may be required or allowed. When an existing furnace is restarving appliances for air.
moved from a venting system serving other appliances, the
House depressurization can cause back drafting or improper venting system may be too large to properly vent the remaining
combustion of gas-fired appliances, thereby exposing building attached appliances.
occupants to gas combustion products that could include carUpflow or Horizontal units are shipped with the induced draft
bon monoxide.
blower discharging from the top of the furnace. (“Top” is as
If this furnace is to be installed in the same space with other viewed for an upflow installation.) The induced draft blower can
gas appliances, such as a water heater, ensure there is an be rotated 90 degrees for Category I venting. For horizontal
adequate supply of combustion and ventilation air for the other installations, a four inch single wall pipe can be used to extend
appliances. Refer to the latest edition of the National Fuel Gas the induced draft blower outlet 1/2” beyond the furnace cabinet.
Code NFPA 54/ANSI Z223.1 or CAN/CSA B149 Installation THIS PRODUCT IS NOT DESIGNED FOR COUNTERCLOCKCodes or applicable provisions of the local building codes for WISE INDUCED DRAFT BLOWER ROTATION.
determining the combustion air requirements for the appliances.
10
Vent the furnace in accordance with the National Fuel Gas
Code NFPA 54/ANSI Z223.1 - latest edition. In Canada, vent
the furnace in accordance with the National Standard of Canada,
CAN/CSA B149.1 and CAN/CSA B149.2 - latest editions and
amendments.
WARNING
NEVER ALLOW THE PRODUCTS OF COMBUSTION, INCLUDING CARBON MONOXIDE, TO ENTER THE RETURN DUCTWORK OR CIRCULATION AIR SUPPLY.
Venting
THIS FURNACE IS NOT DESIGN CERTIFIED TO BE HORIZONTALLY VENTED.
EXTERIOR MASONRY CHIMNEYS
(CATEGORY I FURNACES ONLY)
To rotate the induced draft blower clockwise, you will need to
An exterior masonry chimney is defined as a “Masonry” chimpurchase one (0270F01119) chimney transition bottom kit.
ney exposed to the outdoors on one or more sides below the
1. Disconnect electrical power from the furnace.
roof line.” The ability to use a clay lined masonry chimney
2. Disconnect the induced draft blower power leads, flue
depends on a parameter not associated with interior chimneys.
pipe, and pressure switch tubing.
This variable is the geographic location of the installation. Re3. Remove the round cutout from the right side of the wrapper.
searchers have discovered that the winter design temperatures
4. Remove and save the four screws that fasten the induced
have a direct impact on the suitability of this type of venting. In
draft blower to the flue collector box.
most situations, the existing masonry chimneys will require a
5. Remove and save the three screws that hold the chimney
properly sized metallic liner.
assembly to the induced draft blower.
WARNING
6. Remove and save the four screws that fasten the chimney
top to the chimney bottom.
POSSIBILITY OF PROPERTY DAMAGE, PERSONAL INJURY OR DEATH 7. Remove the chimney transition bottom from the transition
DAMAGING CONDENSATION CAN OCCUR INSIDE MASONRY CHIMNEYS bottom kit.
WHEN A SINGLE FAN‐ASSISTED CATEGORY I APPLIANCE (80% AFUE 8. Install the chimney top with the four screws retained
FURNACE) IS VENTED WITHOUT ADEQUATE DILUTION AIR. DO NOT from step 6 onto the new chimney transition bottom from
CONNECT AN 80% FURNACE TO A MASONRY CHIMNEY UNLESS THE the transition bottom kit.
FURNACE IS COMMON VENTED WITH A DRAFT HOOD EQUIPPED 9. Install chimney assembly with the three screws retained
APPLIANCE OR THE CHIMNEY IS LINED WITH A METAL LINER OR TYPE B from step 5 onto the induced draft blower.
METAL VENT. ALL INSTALLATIONS USING MASONRY CHIMNEYS MUST BE 10. Reinstall the induced draft blower rotating it 90 degrees
SIZED IN ACCORDANCE WITH THE APPROPRIATE VENTING TABLES. IF AN clockwise from the original upflow configuration using
80% FURNACE IS COMMON VENTED WITH A DRAFT HOOD EQUIPPED the four screws retained in step 3. Ensure the gasket
APPLIANCE, THE POTENTIAL FOR CONDENSATION DAMAGE MAY STILL located between the induced draft blower and the collector
EXIST WITH EXTREMELY COLD CONDITIONS, LONG VENT CONNECTORS, box is rotated accordingly.
EXTERIOR CHIMNEYS, OR ANY COMBINATION OF THESE CONDITIONS. THE RISK OF CONDENSATION DAMAGE IS BEST AVOIDED BY USING 11. Reconnect the induced draft blower power leads. NOTE:
MASONRY CHIMNEY AS A PATHWAY FOR PROPERLY SIZED METAL LINER If the wires are not long enough, pull extra wire from the
wire bundle in the blower compartment.
OR TYPE B METAL VENT.
12. Reconnect the flue pipe, and the pressure switch tubing.
Ensure that all wires and the pressure switch tubing is
at least one inch from the flue pipe, or any other hot
surface.
13. Restore power to furnace.
Counterflow units are shipped with the induced draft blower
discharging from the top of the furnace. (“Top” as viewed for a
counterflow installation.)
Vent the furnace in accordance with the National Fuel Gas
Code NFPA54/ANSI Z223.1-latest edition. In Canada, vent the
furnace in accordance with the national standard of Canada,
CAN/CSA B149.1 and CAN/CSA B149.2- latest editions and
amendments.
11
Wash
Proper Chimney
Termination?
(Check 1)
Roof Line
Clay Tile Size: 8" x 8" x12"
(Each x 24" Length)
Attic Floor
1/2" to 1" Air Space
Second Floor
Chimney channel
free of solid and
liquid fuel
appliances?
(Check 2)
Change venting
arrangements
(Fix 2)
Crown in good
condition
(Check 3)
Rebuild crown
(Fix 3)
and/or Reline
(Fix 4)
Cleanout free of
debris?
(Check 4)
Reline
(Fix 4)
Liner in good
condition?
(Check 5)
Reline
(Fix 4)
Dilution air
available?
(Check 6)
Reline
(Fix 4)
Throat
Damper
First Floor
Breech
Clean Out
F.A.F. Vent
Connector
Fan Assisted
Forced Air
Furnace
Water Heater
Vent Connector
Natural Draft
Water Heater
Basement Floor
Typical Multiple Flue Clay Tile Chimney
CHECKLIST SUMMARY
This checklist serves as a summary of the items to be checked
before venting an 80+ furnace into a masonry chimney. In addition, we recommend that a qualified serviceman use this checklist to perform a yearly inspection of the furnace venting system.
This checklist is only a summary. For detailed information on
each of the procedures mentioned, see the paragraph referenced with each item.
This inspection is based upon a draft topical report, “Masonry
Chimney Inspection and Relining”, issued by the Gas Research
Institute. While not yet finalized, we believe this report represents the best information on this subject which is currently
available.
Complete the
installation.
(Check 7)
CHECK 1 - PROPER CHIMNEY TERMINATION.
A masonry chimney used as a vent for gas fired equipment
must extend at least three feet above the highest point where it
passes through the roof. It must extend at least two feet higher
than any portion of a building within a horizontal distance of 10
feet. In addition, the chimney must terminate at least 3 feet
above any forced air inlet located within 10 feet. The chimney
must extend at least five feet above the highest connected equipment draft hood outlet or flue collar.
12
If the chimney does not meet these termination requirements, Appliances which burn propane (sometimes referred to as LP
but all other requirements in the checklist can be met, it may (liquefied petroleum)) gas are considered gas-fired appliances.
be possible for a mason to extend the chimney. If this will not
CHECK 3 - CHIMNEY CROWN CONDITION.
be practical, see Fix 1.
10' or Less
2' Min.
Damage from condensate usually shows up first in the crown.
If any of the following trouble signs are present, the condition of
the crown is not satisfactory:
a) Crown leaning
b) Bricks missing
c) Mortar missing
d) Tile liner cracked
e) No tile liner
f) Salt staining at mortar joints. (White stains, and mortar
becomes sandy and/or erodes.)
2' Min.
3' Min.
Wall or
Parapet
Chimney
For problems a, b, or c, see Fix 3. If problems d, e, or f are
present, see Fix 4. IMPORTANT: It may be necessary to follow
both Fix 3 and Fix 4.
10' or Less
CHECK 4 - DEBRIS IN CLEANOUT.
2' Min.
3' Min.
A cleanout (dropleg) must be present such that the upper edge
of the cleanout cover is at least 12 inches below the lower edge
of the lowest chimney inlet opening.
Chimney
A chimney without a cleanout could become partially blocked
by debris. If no cleanout is present, the chimney must be relined (Fix 4). Remove the cleanout cover, and examine the
cleanout for debris. If significant amounts of any of the following
are found:
•
Fuel oil residue
•
Bricks
•
Mortar or sand
•
Pieces of the tile liner
•
Rusted pieces of the metallic liner - reline the chimney
(Fix 4).
Termination 10 Feet Or Less From Ridge, Wall or Parapet
More than 10’
3’ Min.
Wall or
Parapet
NOTE: No Height
above parapet
required when distance
from walls or parapet is
more than 10 feet.
More than 10’
10’
Chimney
CHECK 5 - LINER CONDITION.
If a metal liner is present, it must be checked. It cannot be
assumed that all existing metal liners are correctly installed
and in good condition.
Height above any
roof surface within
10 feet horizontally.
Remove the lowest existing vent connector, and examine the
inside of the elbow or tee at the base of the liner. A small amount
of soot may be considered acceptable, provided the installer
vacuums it away. If rusted pieces of the liner have collected
here, the metal liner must be removed and replaced (Fix 4).
Ridge
2” Min.
3’ Min.
Next, gently tap the inside of the liner with a Phillips screwdriver. If the screwdriver perforates the liner, or if the tapping
does not sound like metal hitting metal, the liner must be removed and replaced (Fix 4).
Chimney
Termination More Than 10 Feet From Ridge, Wall or Parapet
CHECK 2 - ANY SOLID OR LIQUID FUEL APPLIANCES VENTED
INTO THIS CHIMNEY CHANNEL
Remember that all appliances must be vented inside the liner.
Venting one appliance inside the liner and another appliance
Solid fuel appliances include fireplaces, wood stoves, coal fur- outside the liner is not acceptable.
naces, and incinerators.
Liquid fuel appliances include oil furnaces, oil-fired boilers and
oil-fired water heaters.
13
Next, use a flashlight and small mirror to sight up the liner. B CHECK 7 - COMPLETE THE INSTALLATION.
vent must be supported so as to not come into direct contact
with the chimney walls or tile liner. If it is not, it can probably be If Checks 1 through 6 have been satisfactory, and the liner is an
rehung so as to be acceptable. A thimble or fire stop may be acceptable size as determined by the tables in National Fuel
Gas Code NFPA 54/ANSI Z223.1 - latest edition and in the
helpful here.
National Standard of Canada, CAN/CSA B149.1 and CAN/CSA
Flexible liners should be hung straight or nearly straight. If it is B149.2 - latest editions and amendments, then the clay tile
spiraled in the chimney and in good condition, it should be liner can probably be used as a vent for the gas appliances.
rehung. To do this, break the top seal; pull up and cut off the However, the installer must keep in mind the following factors
excess liner length, and refit the top seal. Use caution when which may render the tile liner unsuitable for use as a vent:
doing this, as the cut edges of flexible liners may be sharp.
•
Extremely cold weather
The surfaces of the liner must be physically sound. If gaps or
•
Long vent connectors
holes are present, the metal liner must be removed and re•
Masonry chimneys with no air gap between the liner
placed (Fix 4). Finally, confirm that the metal liner is the corand the bricks. (In practice, this can be difficult to
rect size for the appliances to be installed. Use the GAMA
detect.)
tables and rules.
•
Exterior chimneys (The tables in National Fuel Gas
If a metal liner is not present, a clay tile liner must be present,
Code NFPA 54/ANSI Z223.1 - latest edition and in the
or the chimney must be lined (Fix 4).
National Standard of Canada, CAN/CSA B149.1 and
CAN/CSA B149.2 - latest editions and amendments
Use a flashlight and small mirror at the cleanout or vent conassume interior chimneys.)
nector to inspect the clay tile liner. If any of the following problems are present:
If, in the judgment of the local gas utility, installer, and/or local
•
Tile sections misaligned
codes; one or more of the above factors is likely to present a
problem, the chimney must be relined (Fix 4).
•
Tile sections missing
•
Gaps between tile sections
•
Signs of condensate drainage at the cleanout or vent
connectors
•
Mortar protruding from between tile sections
•
Use of sewer pipe or drainage pipe rather than an
approved fire clay tile reline the chimney (Fix 4).
FIX 1 - LINER TERMINATION
Any cap or roof assembly used with a liner must be approved
by the liner manufacturer for such use. The liner and cap/roof
assembly must then terminate above the roof in accordance
with the manufacturer’s instructions.
Next, measure the size of the liner. It may be possible to do
this from the cleanout. The liner must be at least as large as
the minimum size established by the tables in National Fuel
Gas Code NFPA 54/ANSI Z223.1 - latest edition and in the
National Standard of Canada, CAN/CSA B149.1 and CAN/CSA
B149.2 - latest editions and amendments. If the liner is too
small or too large, then the chimney must be relined (Fix 4).
In some cases, a shorter extension above the roof may be
possible with a liner than would be required with a masonry
chimney.
For further information on relining, see Fix 4.
FIX 2 -CHANGE VENTING ARRANGEMENTS
If the masonry chimney has more than one channel, it may be
possible to vent the gas appliances into one channel and vent
CHECK 6 - DILUTION AIR.
the solid or liquid fuel appliance(s) into another channel(s). Do
not vent an 80+ Furnace inside of a metal liner with other appliIf gas-fired appliances are to be vented into a clay tile liner, a
ances vented outside the liner.
source of dilution air is required.
Alternatively, the homeowner may agree to discontinue use of
Dilution air cannot be obtained through:
the fireplace (solid fuel appliance). If so, the tile liner must be
•
Induced draft appliances
cleaned to remove creosote buildup. The fireplace opening must
then be permanently sealed.
•
Natural draft appliances with vent dampers
Sufficient dilution air can ordinarily be obtained through the draft If oil-fired appliance(s) are being replaced by gas-fired
hood of a natural draft appliance only if the appliance’s vent appliance(s), the tile liner must first be cleaned to remove the
connector does not include a vent damper. If dilution air will not fuel oil residue.
be available, the chimney must be relined (Fix 4).
If none of the above options is practical, the furnace may need
to be vented vertically with a B Vent.
Under some conditions, a 90%+ furnace could be installed rather
than an 80% furnace. The 90%+ furnace can be vented horizontally or vertically through PVC pipe.
14
For sizing of flexible liners, see Note 22 and the tables in the
National Fuel Gas Code NFPA 54/ANSI Z223.1 - latest edition
If the chimney crown is damaged, a qualified mason must re- and in the National Standard of Canada, CAN/CSA B149.1 and
pair it in accordance with nationally recognized building codes CAN/CSA B149.2 - latest editions and amendments.
or standards. One such standard which may be referenced is
the Standard for Chimneys, Fireplaces, Vents, and Solid Fuel To install the liner, read and follow the liner manufacturer’s instructions and your local codes. Excess liner length should be
Burning Appliances, ANSI/NFPA 211.
pulled out of the chimney and cut off. Use caution when doing
FIX 4 - RELINING
this, as the cut edges of flexible liners may be sharp. Do not
spiral excess liner inside of the chimney. Support the liner as
Relining options include B vent and flexible liners.
recommended by the liner manufacturer.
If the chimney has diagonal offsets, B vent probably cannot be
Some manufacturers of flexible liners offer an insulation sleeve
used.
designed to be added to the liner before it is installed in the
If B vent is to be used, it must be supported adequately. Sup- chimney. (Poured insulation, either vermiculite or other materiports (such as fire stops or thimbles) must be used to prevent als, is no longer recommended.) Insulation will need to be added
the B vent from coming into direct contact with the tile liner or to the flexible liner if:
•
It is required by the liner manufacturer’s instructions.
chimney walls. Direct contact would result in higher heat loss,
with an increased possibility of poor venting system perfor•
The previous liner was properly sized and installed,
mance.
and suffered from condensation damage.
•
It is required by your local building codes.
It is not acceptable to vent one appliance inside the B vent and
other appliances outside. The excess space between the B Even if none of those three conditions exist which require addivent and the chimney walls must be covered at the top of the tional liner insulation, the installer may wish to consider it if:
chimney by a weatherproof, corrosion resistant flashing.
•
The local climate is very cold.
FIX 3 - REBUILD THE CROWN
The B vent should then be topped with a listed vent cap. The
listed vent cap will, when installed per the manufacturer’s instructions, prevent problems due to rain, birds, or wind effects.
•
•
The chimney is very tall.
The vent connectors used are very long or have a large
number of elbows.
Local experience indicates that flexible liners installed
without insulation are likely to have condensation
problems.
•
A B-vent installed as described in this section is considered to
be an enclosed vent system, and the sizing tables in National
Fuel Gas Code NFPA 54/ANSI Z223.1 - latest edition and in
the National Standard of Canada, CAN/CSA B149.1 and CAN/ Insulation must be selected and installed in accordance with
CSA B149.2 - latest editions and amendments may be used. the liner manufacturer’s instructions.
If a flexible liner is to be used, it must be made of the proper Finally, cap the chimney and terminate the liner in accordance
materials:
with the liner manufacturer’s instructions.
•
For most residential applications, an aluminum liner
ELECTRICAL CONNECTIONS
should be acceptable.
•
If the combustion air supplied to the furnace will be
contaminated with compounds containing chlorine or
WARNING
fluorine, a liner of AL 29-4C stainless steel should be
HIGH VOLTAGE !
used. Common sources of chlorine and fluorine
TO AVOID THE RISK OF ELECTRICAL SHOCK, WIRING TO compounds include indoor swimming pools and
THE UNIT MUST BE POLARIZED AND GROUNDED .
chlorine bleaches, paint strippers, adhesives, paints,
varnishes, sealers, waxes (which are not yet dried)
and solvents used during construction and remodeling.
WARNING
Various commercial and industrial processes may also
HIGH VOLTAGE !
be sources of chlorine/fluorine compounds.
TO AVOID PERSONAL INJURY OR DEATH DUE TO •
Heavier gauge 300 and 400 series stainless steel liners
ELECTRICAL SHOCK, DISCONNECT ELECTRICAL POWER were developed for use with oil or solid fuel appliances.
BEFORE SERVICING OR CHANGING ANY ELECTRICAL They are not suitable for use with gas-fired appliances.
WIRING.
Flexible liners specifically intended and tested for gas
applications are listed in the UL “Gas and Oil
Equipment Directory”. (UL Standard 1777).
CAUTION
LABEL ALL WIRES PRIOR TO DISCONNECTION WHEN SERVICING CONTROLS. WIRING ERRORS CAN CAUSE IMPROPER AND DANGEROUS OPERATION. VERIFY PROPER OPERATION AFTER SERVICING .
15
Line voltage connections can be made through either the right
or left side panel. The furnace is shipped configured for a right
side electrical connection. To make electrical connections
through the opposite side of the furnace, the junction box must
be relocated to the left side prior to making electrical connections. To relocate the junction box, perform the following steps.
WARNING
HIGH VOLTAGE !
TO AVOID THE RISK OF INJURY, ELECTRICAL SHOCK OR DEATH, THE FURNACE MUST BE ELECTRICALLY GROUNDED IN ACCORDANCE WITH LOCAL CODES OR IN THEIR ABSENCE, WITH THE LATEST EDITION OF THE NATIONAL ELECTRIC CODE.
WARNING
WIRING HARNESS
The wiring harness is an integral part of this furnace. Field
alteration to comply with electrical codes should not be required. Wires are color coded for identification purposes. Refer to the wiring diagram for wire routings. If any of the original
wire as supplied with the furnace must be replaced, it must be
replaced with wiring material having a temperature rating of at
least 105° C. Any replacement wiring must be a copper conductor.
115 VOLT LINE CONNECTIONS
Before proceeding with electrical connections, ensure that the
supply voltage, frequency, and phase correspond to that specified on the unit rating plate. Power supply to the furnace must
be NEC Class 1, and must comply with all applicable codes.
The furnace must be electrically grounded in accordance with
local codes or, in their absence, with the latest edition of The
National Electric Code, ANSI NFPA 70 and/or The Canadian
Electric Code CSA C22.1.
TO PREVENT PERSONAL INJURY OR DEATH DUE TO ELECTRIC SHOCK, DISCONNECT ELECTRICAL POWER BEFORE INSTALLING OR SERVICING THIS UNIT.
1. Remove both doors from the furnace.
2. Remove and save the screws holding the junction box to
the right side of the furnace.
3. Models that have the junction box located in the burner
or blower compartment will need to move the junction
box directly over.
4. Attach the junction box to the left side of the furnace,
using the screws removed in step 2.
5. Check the location of the wiring. Confirm that it will not
be damaged by heat from the burners or by the rotation
of the fan. Also confirm that wiring location will not
interfere with filter removal or other maintenance.
After the junction box is in the desired location, use washers to
connect field-supplied conduit to the junction box in accordance
with NEC and local codes. Connect hot, neutral, and ground
wires as shown in the furnace wiring diagram. The wires and
Use a separate fused branch electrical circuit containing prop- ground screw are located in the furnace junction box.
erly sized wire, and fuse or circuit breaker. The fuse or circuit NOTE: In downflow applications the power leads should be
breaker must be sized in accordance with the maximum over- routed through the supplied wire tabs when locating junction
current protection specified on the unit rating plate. An electri- box to the left side.
cal disconnect must be provided at the furnace location.
Low voltage wires may be connected to the terminal strip.
Connect hot, neutral, and ground wires as shown in the wiring
IMPORTANT NOTE: To avoid possible equipment malfunction,
diagram located on the unit’s blower door.
route the low voltage wires to avoid interference with filter reLine polarity must be observed when making field connections. moval or other maintenance.
Line voltage connections can be made through either the right
or left side panel. The furnace is shipped configured for a right
WARNING
side electrical connection with the junction box located inside
HIGH VOLTAGE !
the burner compartment (blower compartment for downflows).
TO AVOID THE RISK OF INJURY, ELECTRICAL SHOCK OR To make electrical connections through the opposite side of
DEATH, THE FURNACE MUST BE ELECTRICALLY the furnace, the junction box must be relocated to the other
GROUNDED IN ACCORDANCE WITH LOCAL CODES OR IN side of the burner (or blower) compartment prior to making
THEIR ABSENCE, WITH THE LATEST EDITION OF THE electrical connections. To relocate the junction box, follow the
NATIONAL ELECTRIC CODE.
steps shown below.
NOTE: Wire routing must not to interfere with circulator blower
To ensure proper unit grounding, the ground wire should run
operation, filter removal, or routine maintenance.
from the furnace ground screw located inside the furnace junction box all the way back to the electrical panel. NOTE: Do
JUNCTION BOX RELOCATION
not use gas piping as an electrical ground. To confirm proper
unit grounding, turn off the electrical power and perform the
WARNING
following check.
EDGES OF SHEET METAL HOLES MAY BE SHARP. USE GLOVES AS A PRECAUTION WHEN REMOVING HOLE PLUGS.
16
1. Measure resistance between the neutral (white)
connection and one of the burners.
2. Resistance should measure 10 ohms or less.
R
Furnace Integrated
Control Module
R
This furnace is equipped with a blower door interlock switch
which interrupts unit voltage when the blower door is opened for
servicing. Do not defeat this switch.
NEU
Y
C
Dehumidistat
[Optional]
Remote
Condensing Unit
(Single-Stage Cooling)
24 VOLT THERMOSTAT WIRING
IMPORTANT NOTE
NOTE: To apply a single-stage Heating Thermostat, the thermostat
selector switch on the Integrated Control Module must be set on
single-stage.
WIRE ROUTING MUST NOT INTERFERE WITH CIRCULATOR BLOWER OPERATION, FILTER REMOVAL OR ROUTINE MAINTENANCE.
A REMOVABLE PLUG CONNECTOR IS PROVIDED WITH THE CONTROL TO MAKE THERMOSTAT WIRE CONNECTIONS. THIS PLUG MAY BE REMOVED, WIRE CONNECTIONS MADE TO THE PLUG, AND REPLACED. IT IS STRONGLY RECOMMENDED THAT YOU DO NOT CONNECT MULTIPLE WIRES INTO A SINGLE TERMINAL. WIRE NUTS ARE RECOMMENDED TO ENSURE ONE 18 AWG WIRE IS USED FOR EACH TERMINAL . FAILURE TO DO SO MAY RESULT IN INTERMITTENT OPERATION.
Thermostat - Single -Stage Heating with Single-Stage
Cooling
_______________________
R
Furnace Integrated
Control Module
R
IMPORTANT NOTE
Y
WHEN USING A NON‐COMMUNICATING THERMOSTAT, DIP SWITCHES S1‐3 MUST BE SET TO MATCH THE THERMOSTAT TYPE. WHEN USING A 2‐STAGE THERMOSTAT, SET S1‐3 TO ON. WHEN USING A SINGLE STAGE THERMOSTAT, SET S1‐3 TO OFF. S1‐4 SHOULD BE USED ONLY WHEN A SINGLE STAGE THERMOSTAT IS CONNECTED . SEE SINGLE‐
STAGE HEATING THERMOSTAT APPLICATION SECTION FOR DETAILS.
C
NEU
Remote
Condensing Unit
(Single-Stage Cooling)
Dehumidistat
[Optional]
Thermostat - Two-Stage Heating with Single-Stage Cooling
_______________________
As a two-stage non-communicating furnace, the furnace integrated control module provides terminals for both “W1” and “W2”,
and “Y1” and “Y2” thermostat connections. This allows the
furnace to support the following system applications: ‘TwoStage Heating Only’, ‘Two-Stage Heating with Single Stage Cooling’, and ‘Two-Stage Heating with Two-Stage Cooling’. Refer to
the following figures for proper connections to the integrated
control module.
Low voltage connections can be made through either the right
or left side panel. Thermostat wiring entrance holes are located
in the blower compartment. The following figure shows connections for a “heat/cool system”.
This furnace is equipped with a 40 VA transformer to facilitate
use with most cooling equipment. Consult the wiring diagram,
located on the blower compartment door, for further details of
115 Volt and 24 Volt wiring.
NOTE: For single stage cooling applications, a jumper must
be located between Y1 and Y2 at the furnace control in order
to achieve the desired single stage cooling airflow. Use of
ramping profiles and dehumidification features requires a jumper
between Y1 and O and Y1 and DEHUM, respectively.
NOTE: Thermostat “R” required if outdoor unit is equipped with
a Comfort Alert™ module or if the outdoor unit is a part of the
ComfortNet™ family of equipment AND is wired as a noncommunicating system.
Y2
W1
W2
Y2
W1
W2
Furnace Integrated
Control Module
NEU
Y2
Dehumidistat
[Optional]
Remote
Condensing Unit
(Two-Stage Cooling)
Thermostat - Two-Stage Heating with Two-Stage Cooling
Thermostat Wiring Diagrams
SINGLE-STAGE HEATING THERMOSTAT APPLICATION
A single-stage thermostat with only one heating stage may
be used to control this furnace. The application of a singlestage thermostat offers a timed transition from low to high
fire. The furnace will run on low stage for a fixed period of time
before stepping up to high stage to satisfy the thermostat’s
call for heat. The delay period prior to stepping up can be set
at either a fixed 5 minute time delay or a load based variable
time between 1 and 12 minutes (AUTO mode). If the AUTO
mode is selected, the control averages the cycle times of the
previous three cycles and uses the average to determine the
time to transition from low stage to high stage.
17
To use a single-stage thermostat, turn off power to the furnace, FOSSIL FUEL APPLICATIONS
move the thermostat selection DIP switch to the OFF position.
Set the desired transition time by setting the transition delay This furnace can be used in conjunction with a heat pump in a
DIP switch to the desired ON/OFF position. Turn power back fossil fuel application. A fossil fuel application refers to a combined gas furnace and heat pump installation which uses an
on. Refer to the following figure.
outdoor temperature sensor to determine the most cost effiOFF
ON
Move to the ON position
Heat OFF Delay
cient means of heating (heat pump or gas furnace).
to select two-stage
thermostat or OFF to
select single stage
thermostat
DIP Switches
3
Thermostat
4
Stage Delay
Move to the ON position
to select Auto transition
delay or OFF for 5 minute
transition delay
S1
24 VOLT DEHUMIDISTAT WIRING
A heat pump thermostat with three stages of heat is required to
properly use a two-stage furnace in conjunction with a heat
pump. Refer to the fossil fuel kit installation instructions for
additional thermostat requirements.
Strictly follow the wiring guidelines in the fossil fuel kit installation instructions. All furnace connections must be made to the
furnace two-stage integrated control module and the “FURNACE” terminal strip on the fossil fuel control board.
The optional usage of a dehumidistat allows the furnace’s cir115 VOLT LINE CONNECTION OF ACCESSORIES (HUMIDIFIER
culator blower to operate at a slightly lower speed (85% of
desired speed) during a combined thermostat call for cooling AND ELECTRONIC AIR CLEANER)
and dehumidistat call for dehumidification. This can be done
WARNING
through an independent dehumidistat or through a thermostat’s
DEHUM terminal (if available). This lower blower speed enhances
HIGH VOLTAGE !
dehumidification of the conditioned air as it passes through the
TO AVOID PERSONAL INJURY OR DEATH DUE TO AC coil. For proper function, a dehumidistat applied to this
ELECTRICAL SHOCK, DISCONNECT ELECTRICAL POWER furnace must operate on 24 VAC and utilize a switch which
BEFORE SERVICING OR CHANGING ANY ELECTRICAL opens on humidity rise. Refer to the “Thermostat Wiring DiaWIRING.
grams” figure for additional wiring details.
To install/connect a dehumidistat:
1. Turn OFF power to furnace.
2. To enable the dehumidify function on the integrated control
module, set the dehumidification ENABLE dipswitch from
OFF to ON.
3. Secure the dehumidistat neutral wire (typically the white
lead) to the terminal marked “DEHUM” on the furnace
integrated control module.
4. Secure the dehumidistat hot wire (typically the black
lead) to the terminal marked “R” on the furnace integrated
control module.
5. Secure the dehumidistat ground wire (typically the green
lead) to the ground screw on the furnace junction box.
NOTE: Ground wire may not be present on all
dehumidistats.
6. Turn ON power to furnace.
The furnace integrated control module is equipped with line
voltage accessory terminals for controlling power to an optional
field-supplied humidifier and/or electronic air cleaner.
The accessory load specifications are as follows:
Humidifier
Electronic Air Cleaner
1.0 Amp maximum at 120 VAC
1.0 Amp maximum at 120 VAC
Turn OFF power to the furnace before installing any accessories.
Follow the humidifier or air cleaner manufacturers’ instructions for
locating, mounting, grounding, and controlling these accessories.
Accessory wiring connections are to be made through the 1/4"
quick connect terminals provided on the furnace integrated control
module. The Electronic air cleaner hot terminal is identified as
EAC. It is necessary to remove the protective tab on the board
cover to access the EAC Terminal. The EAC neutral terminal
is identified as NEUTRAL. A line voltage humidifier may be
connected between one of the HUM contacts and NEUTRAL.
Once the switch is set, the dehumidify function is enabled dur- The other HUM contact must be fed from the L1 terminal.
ing a combination call for cooling (T-Stat) and dehumidification All field wiring must conform to applicable codes. Connections
(DEHUM-Stat).
should be made as shown in the following figure.
OFF ON
1
DEHUM
2
TRIM ENABLE
Move to the ON position
to enable dehumidification
S5
18
HUM-IN
HUM-OUT
NEUTRAL
24 VOLT HUMIDIFIER
A 24 volt humidifier can be powered by feeding one of the HUM
terminals with a field installed wire from the R terminal or by
connecting to the NO side of the low fire pressure switch.
Accessories Wiring
If it is necessary for the installer to supply additional line voltage wiring to the inside of the furnace, the wiring must conform
to all local codes, and have a minimum temperature rating of
105°C. All line voltage wire splices must be made inside the
furnace junction box.
The integrated furnace control HUM (dry contacts) are closed
whenever the inducer is energized in a non-communicating installation. When used with a CTK02** communicating thermostat, the HUM terminals are closed whenever there is a call for
humidity. The integrated control module electronic air cleaner terminals (EAC) are energized with 115 volts whenever the circulator
blower is energized.
In addition, the control is equipped with a dedicated humidification relay which is available through ¼ inch terminals HUM-IN
and HUM-OUT. Similar to the HUM terminal, when utilizing
legacy connections, this relay will be closed during normal
heating operation (115VAC must be present on the HUM-IN
terminal to take advantage of HUM-OUT). However, the control
can provide additional humidification features when wired to a
communicating thermostat (1, 2, R, C connections). If the
communicating thermostat is not capable of providing a humidification call, this dedicated relay will function exactly as
mentioned above with a legacy setup. If the communicating
thermostat is capable of providing a humidification call the user
is now provided with 3 modes of operations which can be selected within the thermostat user menu.
1. ON: Humidifier is turned on with a heat demand.
2. OFF: Humidifier remains off (relay never closes).
AUXILIARY ALARM SWITCH
The control is equipped with a 24VAC Auxiliary Alarm Input (12
inch purple wire attached to pin 6 of 15 pin connector) which
can be utilized with communicating mode setups (typically used
for condensate switch wiring but could be used with compatible C02 sensors or Fire Alarms).
Legacy mode use
In a legacy system (Non-communicating), this auxiliary alarm
input is not operational. Any auxiliary alarm switch must be
used to interrupt Y1 signal either to IFC or to UC.
Communication mode use
This feature can be activated or deactivated through the thermostat user menus. By default, an AUX switch is normally
closed and opens when the water level in the evaporator coil
base pan reaches a particular level. The control will respond by
turning off the outdoor compressor and display the proper fault
codes. If the AUX switch is detected closed for 30 seconds,
normal operation resumes and error messages are no longer
displayed. Installer must wire control voltage (24VAC) to AUX
switch to ensure the Auxiliary Alarm Input has 24VAC during
normal operation.
GAS SUPPLY AND PIPING
The furnace rating plate includes the approved furnace gas input rating and gas types. The furnace must be equipped to
operate on the type of gas applied. This includes any conversion kits required for alternate fuels and/or high altitude.
CAUTION
3. IND: Humidifier will cycle with humidification demand, independent of heat demand. This mode allows the user to
select one of 4 fan speeds (25, 50, 75, and 100%).
TO PREVENT UNRELIABLE OPERATION OR EQUIPMENT DAMAGE, THE INLET GAS SUPPLY PRESSURE MUST BE AS SPECIFIED ON THE UNIT RATING PLATE WITH ALL OTHER HOUSEHOLD GAS FIRED APPLIANCES OPERATING.
Inlet gas supply pressures must be maintained within the ranges
specified in the following table. The supply pressure must be
constant and available with all other household gas fired appliances operating. The minimum gas supply pressure must be
maintained to prevent unreliable ignition. The maximum must
not be exceeded to prevent unit overfiring.
19
NOTE: Do not remove the gas valve inlet plug before the gas This unit is configured for natural gas. The appropriate
line is installed. Replace if water or debris has been introduced. manufacturer’s propane gas conversion kit, must be applied for
propane gas installations. Refer to the “Propane Gas and/or
High Altitude Installations” section for details.
INLET GAS SUPPLY PRESSURE
Natural Gas
Minimum: 4.5" w.c.
Maximum: 10.0" w.c.
Propane Gas
Minimum: 11.0" w.c.
Maximum: 13.0" w.c.
NOTE: Adjusting the minimum supply pressure below the limits
in the above table could lead to unreliable ignition. Gas input to
the burners must not exceed the rated input shown on the
rating plate. Overfiring of the furnace can result in premature
heat exchanger failure. Gas pressures in excess of 13 inches
water column can also cause permanent damage to the gas
valve.
If converting to LP gas, it is recommended that an LPLP0* kit
also be installed. The use of this kit will prevent the furnace
from firing when the LP gas supply pressure is too low to support proper combustion.
Consult the furnace Specification Sheet for a listing of appropriate manufacturer’s kits for propane gas and/or high altitude installations. The indicated kits must be used to insure safe and
proper furnace operation. All conversions must be performed
by a qualified installer, or service agency.
GAS PIPING CONNECTIONS
At all altitudes, the manifold pressure must be within 0.3 inches
w.c. of that listed in the Specification Sheet applicable to your
model for the fuel used. At all altitudes and with either fuel, the
air temperature rise must be within the range listed on the furnace nameplate. Should this appliance be converted to LP,
refer to the instructions included in the factory authorized LP
conversion kit.
WARNING
TO AVOID POSSIBLE UNSATISFACTORY OPERATION OF EQUIPMENT DAMAGE DUE TO UNDERFIRING OR EQUIPMENT, USE THE PROPER SIZE OF NATURAL /PROPANE GAS PIPING NEEDED WHEN RUNNING PIPE FROM THE METER/TANK TO THE FURNACE.
HIGH ALTITUDE DERATE
When sizing a trunk line, be sure to include all appliances
IMPORTANT NOTE: The furnace will naturally derate itself with which will operate simultaneously.
altitude. Do not attempt to increase the firing rate by changing The gas piping supplying the furnace must be properly sized
orifices or increasing the manifold pressure. This can cause based on the gas flow required, specific gravity of the gas, and
poor combustion and equipment failure.
length of the run. The gas line installation must comply with
High altitude installations may require both a pressure switch local codes, or in their absence, with the latest edition of the
and an orifice change. These changes are necessary to com- National Fuel Gas Code, NFPA 54/ANSI Z223.1.
pensate for the natural reduction in the density of both the gas
fuel and the combustion air at higher altitude.
For installations above 7000 feet, please refer to your distributor for required kit(s).
Gas
Altitude
Natural
Propane
0-7000
Kit
Orifice
None
#45
LPM-06
#55
Manifold Pressure
Pressure
High Stage Low Stage Switch Change
3.5" w.c.
1.9" w.c.
None
10.0" w.c.
6.0" w.c.
None
NOTE: In Canada, gas furnaces are only certified to 4500 feet.
Natural Gas Capacity of Pipe
In Cubic Feet of Gas Per Hour (CFH)
Length of
Nominal Black Pipe Size
Pipe in Feet
1/2"
3/4"
1"
1 1/4"
10
132
278
520
1050
20
92
190
350
730
30
73
152
285
590
40
63
130
245
500
50
56
115
215
440
60
50
105
195
400
70
46
96
180
370
80
43
90
170
350
90
40
84
160
320
100
38
79
150
305
(Pressure 0.5 psig or less and pressure drop of 0.3" W.C.; Based on
0.60 Specific Gravity Gas)
1 1/2"
1600
1100
980
760
670
610
560
530
490
460
Consult the furnace Specification Sheet for appropriate
CFH = BTUH Furnace Input
Heating Value of Gas (BTU/Cubic Foot)
manufacturer’s kits for propane gas and/or high altitude installations. The indicated kits must be used to insure safe and
proper furnace operation. All conversions must be performed To connect the furnace to the building’s gas piping, the installer
by a qualified installer, or service agency.
must supply a ground joint union, drip leg, manual shutoff valve,
and line and fittings to connect to gas valve. In some cases,
PROPANE GAS CONVERSION
the installer may also need to supply a transition piece from 1/
2" pipe to a larger pipe size.
WARNING
The following stipulations apply when connecting gas piping.
POSSIBLE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH MAY •
Gas piping must be supported external to the furnace
OCCUR IF THE CORRECT CONVERSION KITS ARE NOT INSTALLED . THE cabinet so that the weight of the gas line does not
APPROPRIATE KITS MUST BE APPLIED TO ENSURE SAFE AND PROPER distort the burner rack, manifold or gas valve.
FURNACE OPERATION . ALL CONVERSIONS MUST BE PERFORMED BY A QUALIFIED INSTALLER OR SERVICE AGENCY.
20
•
•
•
•
•
•
•
•
•
Use black iron or steel pipe and fittings for the building
piping.
Use pipe joint compound on male threads only. Pipe
joint compound must be resistant to the action of the
fuel used.
Use ground joint unions.
Install a drip leg to trap dirt and moisture before it can
enter the gas valve. The drip leg must be a minimum
of three inches long.
Install a 1/8" NPT pipe plug fitting, accessible for test
gage connection, immediately upstream of the gas
supply connection to the furnace.
Use two pipe wrenches when making connection to
the gas valve to keep it from turning. The orientation
of the gas valve on the manifold must be maintained
as shipped from the factory.
Install a manual shutoff valve between the gas meter
and unit within six feet of the unit. If a union is installed,
the union must be downstream of the manual shutoff
valve, between the shutoff valve and the furnace.
Tighten all joints securely.
Connect the furnace to the building piping by one of
the following methods:
–
–
Rigid metallic pipe and fittings.
–
Use listed gas appliance connectors in accordance
with their instructions. Connectors must be fully in
the same room as the furnace.
–
Semi-rigid metallic tubing and metallic fittings.
Aluminum alloy tubing must not be used in exterior
locations.
Protect connectors and semi-rigid tubing against
physical and thermal damage when installed.
Ensure aluminum-alloy tubing and connectors are
coated to protect against external corrosion when
in contact with masonry, plaster, or insulation, or
subjected to repeated wetting by liquids such as
water (except rain water), detergents, or sewage.
Gas line
entrance
Right side
gas entrance
(alternate)
General Furnace Layout
UPFLOW INSTALLATIONS
When the gas piping enters through the right side of the furnace, the installer must supply the following fittings (starting
from the gas valve):
•
Close nipple.
•
90 degree elbows.
•
Straight pipe to reach the exterior of the furnace .
A ground joint union, drip leg, and manual shutoff valve must
also be supplied by the installer. In some cases, the installer
may also need to supply a transition piece from 1/2" to another
pipe size.
When the gas piping enters through the left side of the furnace,
the installer must supply the following fittings (starting from the
gas valve):
•
90 degree elbow.
•
Straight pipe to reach the exterior of the furnace.
•
A ground joint union, drip leg, and manual shutoff valve
must also be supplied by the installer. In some cases,
the installer may also need to supply a transition piece
from 1/2 inch to another pipe size.
COUNTERFLOW INSTALLATIONS
When the gas piping enters through the left side of the furnace,
the installer must supply a straight pipe and a 90 degree elbow
to reach the exterior of the furnace.
A ground joint union, drip leg and manual shutoff valve must
also be supplied by the installer. In most cases, the installer
may also need to supply a transition piece from ½” to another
pipe size. When the gas piping enters through the right side of
the furnace, the installer must supply the following fittings (starting at the gas valve):
•
Close Nipple
•
90 Degree Elbow
•
Straight Pipe to Reach Exterior of Furnace.
21
For satisfactory operation, propane gas pressure must be 10
inch WC at the furnace manifold with all gas appliances in
Before placing unit in operation, leak test the unit and gas con- operation. Maintaining proper gas pressure depends on three
nections.
main factors:
1. Vaporization rate, depending on temperature of the liquid,
WARNING
and “wetted surface” area of the container or containers.
TO AVOID THE POSSIBILITY OF EXPLOSION OR FIRE, NEVER USE A MATCH 2. Proper pressure regulation. (Two-stage regulation is
OR OPEN FLAME TO TEST FOR LEAKS.
recommended for both cost and efficiency).
GAS PIPING CHECKS
3. Pressure drop in lines between regulators, and between
second stage regulator and the appliance. Pipe size will
depend on length of pipe run and total load of all
appliances.
Check for leaks using an approved chloride-free soap and water solution, an electronic combustible gas detector, or other
approved testing methods.
Complete information regarding tank sizing for vaporization, recommended regulator settings, and pipe sizing is available from
most regulator manufacturers and propane gas suppliers.
Since propane gas will quickly dissolve white lead and most
standard commercial compounds, special pipe dope must be
used. Shellac-based compounds resistant to the actions of
NOTE: Never exceed specified pressures for testing. Higher liquefied petroleum gases such as Gasolac®, Stalactic ®,
pressure may damage the gas valve and cause subsequent Clyde’s® or John Crane® are satisfactory.
overfiring, resulting in heat exchanger failure.
Refer to the following illustration for typical propane gas instalDisconnect this unit and shutoff valve from the gas supply pip- lations and piping.
ing system before pressure testing the supply piping system
5 to 15 PSIG
with pressures in excess of 1/2 psig (3.48 kPa).
First Stage
(20 PSIG Max.)
Regulator
This unit must be isolated from the gas supply system by closing its manual shutoff valve before pressure testing of gas supply piping system with test pressures equal to or less than 1/2
psig (3.48 kPa).
Continuous
11" W.C.
200 PSIG
Maximum
Second Stage
Regulator
PROPANE GAS TANKS AND PIPING
WARNING
IF THE GAS FURNACE IS INSTALLED IN A BASEMENT, AN EXCAVATED AREA OR CONFINED SPACE , IT IS STRONGLY RECOMMENDED TO CONTACT A PROPANE SUPPLIER TO INSTALL A GAS DETECTING WARNING DEVICE IN CASE OF A GAS LEAK.
• SINCE PROPANE GAS IS HEAVIER THAN AIR, ANY LEAKING GAS CAN
SETTLE IN ANY LOW AREAS OR CONFINED SPACES.
• PROPANE GAS ODORANT MAY FADE, MAKING THE GAS UNDETECTABLE
EXCEPT WITH A WARNING DEVICE.
Propane Gas Installation (Typ.)
PROPANE GAS PIPING CHARTS
Sizing Between First and Second Stage Regulator*
Maximum Propane Capacities listed are based on 2 psig pressure drop at 10 psig setting.
Capacities in 1,000 BTU/hour.
A gas detecting warning system is the only reliable way to
detect a propane gas leak. Rust can reduce the level of odorant
in propane gas. Do not rely on your sense of smell. Contact a
local propane gas supplier about installing a gas detecting
warning system. If the presence of gas is suspected, follow
the instructions on Page 3 of this manual.
All propane gas equipment must conform to the safety standards of the National Board of Fire Underwriters, NBFU Manual
58.
22
Pipe or
Tubing
Length,
Feet
10
20
30
40
50
60
80
100
125
150
175
200
Nominal Pipe Size
Schedule 40
Tubing Size, O.D. Type L
3/8"
1/2"
5/8"
3/4"
7/8"
1/2"
3/4"
730
500
400
370
330
300
260
220
200
190
170
160
1,700
1,100
920
850
770
700
610
540
490
430
400
380
3,200
2,200
2,000
1,700
1,500
1,300
1,200
1,000
900
830
780
730
5,300
3,700
2,900
2,700
2,400
2,200
1,900
1,700
1,400
1,300
1,200
1,100
8,300
5,800
4,700
4,100
3,700
3,300
2,900
2,600
2,300
2,100
1,900
1,800
3,200
2,200
1,800
1,600
1,500
1,300
1,200
1,000
900
830
770
720
7,500
4,200
4,000
3,700
3,400
310
2,600
2,300
2,100
1,900
1,700
1,500
When the furnace is heating, the temperature of the return air
entering the furnace must be between 55°F and 100°F.
Sizing Between Second Stage and Appliance Regulator*
Maximum Propane Capacities listed are based on 2 psig pressure drop at 10 psig setting.
Capacities in 1,000 BTU/hour.
Pipe or
Tubing
Length,
Feet
10
20
30
40
50
60
80
100
125
150
200
250
Nominal Pipe Size
Schedule 40
Tubing Size, O.D. Type L
3/8"
1/2"
5/8"
3/4"
7/8"
1-1/8"
1/2"
3/4"
1"
39
26
21
19
18
16
13
11
10
9
8
8
92
62
50
41
37
35
29
26
24
21
19
17
199
131
107
90
79
72
62
55
48
43
39
36
329
216
181
145
131
121
104
90
81
72
66
60
501
346
277
233
198
187
155
138
122
109
100
93
935
630
500
427
376
340
289
255
224
202
187
172
275
189
152
129
114
103
89
78
69
63
54
48
567
393
315
267
237
217
185
162
146
132
112
100
1,071
732
590
504
448
409
346
307
275
252
209
185
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 a duct sealed
to the furnace casing and terminating outside the space containing the furnace.
1-1/4" 1-1/2"
2,205
1,496
1,212
1,039
91
834
724
630
567
511
439
390
3,307
2,299
1,858
1,559
1,417
1,275
1,066
976
866
787
665
590
CHECKING DUCT STATIC
Refer to your furnace rating plate for the maximum ESP (external duct static) rating.
Total external static refers to everything external to the furnace
cabinet. Cooling coils, filters, ducts, grilles, registers must all
be considered when reading your total external static presWARNING
sure. The supply duct pressure must be read between the furnace and the cooling coil. This reading is usually taken by
NEVER ALLOW THE PRODUCTS OF COMBUSTION, INCLUDING CARBON removing the “A” shaped block off plate from the end on the
MONOXIDE, TO ENTER THE RETURN DUCT WORK OR CIRCULATION AIR coil; drilling a test hole in it and reinstalling the block off plate.
SUPPLY.
Take a duct static reading at the test hole. Tape up the test
Duct systems and register sizes must be properly designed for hole after your test is complete. The negative pressure must be
the CFM and external static pressure rating of the furnace. read between the filter and the furnace blower.
Ductwork should be designed in accordance with the recom- Too much external static pressure will result in insufficient air
mended methods of “Air Conditioning Contractors of America” that can cause excessive temperature rise. This can cause
Manual D.
limit switch tripping and heat exchanger failure.
CIRCULATING AIR AND FILTERS
A duct system must be installed in accordance with Standards To determine total external duct static pressure, proceed as
of the National Board of Fire Underwriters for the Installation of follows;
Air Conditioning, Warm Air Heating and Ventilating Systems.
1. With clean filters in the furnace, use a draft gauge (inclined
Pamphlets No. 90A and 90B.
manometer) to measure the static pressure of the return
A closed return duct system must be used, with the return duct
duct at the inlet of the furnace. (Negative Pressure)
connected to the furnace. NOTE: Ductwork must never be
attached to the back of the furnace. For installations requiring 2. Measure the static pressure of the supply duct. (Positive
Pressure)
more than 1800 CFM, use a bottom return or two sided return.
Supply and return connections to the furnace may be made
3. The difference between the two numbers is .4” w.c.
with flexible joints to reduce noise transmission. To prevent the
blower from interfering with combustion air or draft when a cen- Example:
tral return is used, a connecting duct must be installed between the unit and the utility room wall. A room, closet, or static reading from return duct = -.1" w.c.
alcove must not be used as a return air chamber.
static reading from supply duct = .3" w.c.
When the furnace is used in connection with a cooling unit, the
furnace should be installed in parallel with or on the upstream
side of the cooling unit to avoid condensation in the heating
element. With a parallel flow arrangement, the dampers or other
means used to control the flow of air must be adequate to
prevent chilled air from entering the furnace and, if manually
operated, must be equipped with means to prevent operation of
either unit unless the damper is in the full heat or cool position.
total external static pressure on this system = .4" w.c.
NOTE: Both readings may be taken simultaneously and read
directly on the manometer if so desired. If an air conditioner
coil or Electronic Air Cleaner is used in conjunction with the
furnace, the readings must also include theses components,
as shown in the following drawing.
4. Consult proper tables for the quantity of air.
When the furnace is installed without a cooling coil, it is recIf the total external static pressure exceeds the maximum listed
ommended that a removable access panel be provided in the
on the furnace rating plate, check for closed dampers, regisoutlet air duct. This opening shall be accessible when the furters, undersized and/or oversized poorly laid out duct work.
nace is installed and shall be of such a size that the heat
exchanger can be viewed for visual light inspection or such that
a sampling probe can be inserted into the airstream. The access panel must be made to prevent air leaks when the furnace
is in operation.
23
MINIMUM FILTER SIZES for DISPOSABLE FILTERS
FURNACE INPUT (BTU/hr)
FILTER SIZE
60K
610 in
80K
813 in2
100K
889 in2
2
DISPOSABLE NOMINAL 300 F.P.M. FACE VELOCITY
HORIZONTAL INSTALLATIONS
Filters must be installed in either the central return register or
in the return air duct work.
START-UP PROCEDURE AND ADJUSTMENT
Checking Static Pressure
(80% Furnace Shown, 90% Similar)
FILTERS - READ THIS SECTION BEFORE INSTALLING THE
RETURN AIR DUCTWORK
Furnace must have a 115 VAC power supply properly connected
and grounded. Proper polarity must be maintained for correct
operation. In addition to the following start-up and adjustment
items, refer to further information in Operational Checks section.
HEAT ANTICIPATOR SETTING
The heat anticipator in the room thermostat must be correctly
adjusted to obtain the proper number of cycles per hour and to
prevent “overshooting” of the setting. Set the heat anticipator
setting to 0.7 amps. Follow the thermostat manufacturer’s
instructions on how to adjust the heat anticipator setting.
Filters must be used with this furnace. Discuss filter mainteFURNACE OPERATION
nance with the building owner. Filters do not ship with this
furnace, but must be provided by the installer. Filters must com- Purge gas lines of air prior to startup. Be sure not purge lines
ply with UL900 or CAN/ULCS111 standards. If the furnace is into an enclosed burner compartment.
installed without filters, the warranty will be voided.
Check for leaks using an approved chloride-free soap and water solution, an electronic combustible gas detector, or other
NOTE: An undersized opening will cause reduced airflow. The approved method. Verify that all required kits (propane gas,
bottom return is set up as a knock out.
high altitude, etc.) have been appropriately installed.
UPRIGHT INSTALLATIONS
FURNACE STARTUP
Depending on the installation and/or customer preference, dif- 1. Close the manual gas shutoff valve external to the furnace.
fering filter arrangements can be applied. Filters can be in- 2. Turn off the electrical power to the furnace.
stalled in the central return register or a side panel external 3. Set the room thermostat to the lowest possible setting.
filter rack kit (upflows), or the ductwork above a downflow fur- 4. Remove the burner compartment door.
nace. As an alternative, a media air filter or electronic air cleaner NOTE: This furnace is equipped with an ignition device which
can be used as the primary filter.
automatically lights the burner. Do not try to light the burner by
hand.
CIRCULATION AIR FILTERS
5. Move the furnace gas valve manual control to the OFF
position.
One of the most common causes of a problem in a forced air
heating system is a blocked or dirty filter. Circulating air filters 6. Wait five minutes then smell for gas. Be sure check
must be inspected monthly for dirt accumulation and replaced
near the floor as some types of gas are heavier than air.
if necessary. Failure to maintain clean filters can cause prema- 7. If you smell gas after five minutes, immediately follow
ture heat exchanger failure.
the Safety Instructions on page 2 of this manual. If you
do not smell gas after five minutes, move the furnace
A new home may require more frequent replacement until all
gas valve manual control to the ON position.
construction dust and dirt is removed. Circulating air filters are
8.
Replace
the burner compartment door.
to be installed in the return air duct external to the furnace
9. Open the manual gas shutoff valve external to the furnace.
cabinet.
10. Turn on the electrical power to the furnace.
11. Adjust the thermostat to a setting above room
temperature.
24
7. After completion of the 5-minute timer or test mode termination, whichever is earlier, the system will return to normal
operation, either continuing an existing heat demand or going
to the idle state.
12. After the burners are lit, set the thermostat to desired
temperature.
FURNACE SHUTDOWN
1. Set the thermostat to the lowest setting.
The integrated control will close the gas valve and
extinguish flame. Following a 15 second delay, the
induced draft blower will be de-energized. After a 120,
150, 180 or 210-second delay period (field selectable
delay OFF [90, 120, 150, 180] plus 30-second ramp
down), the circulator blower de-energizes.
2. Remove the burner compartment door and move the
furnace gas valve manual control to the OFF position.
3. Close the manual gas shutoff valve external to the furnace.
4. Replace the burner compartment door.
CAUTION
TO PREVENT UNRELIABLE OPERATION OR EQUIPMENT DAMAGE, THE INLET GAS SUPPLY PRESSURE MUST BE AS SPECIFIED ON THE UNIT RATING PLATE WITH ALL OTHER HOUSEHOLD GAS FIRED APPLIANCES OPERATING.
The line pressure supplied to the gas valve must be within the
range specified below. The supply pressure can be measured
at the gas valve inlet pressure boss or at a hose fitting installed
in the gas piping drip leg. The supply pressure must be measured with the burners operating. To measure the gas supply
pressure, use the following procedure.
GAS SUPPLY PRESSURE MEASUREMENT
GAS PRESSURE TEST
NOTE: When removing a valve adjustment screw or a
pressure boss, use a T-25 or 3/16” flathead screwdriver.
DO NOT USE POWER TOOLS.
INLET
OUTLET
This test is to be used for field test mode only, and it will allow
gas valve pressure to be checked at 100% firing rate.
1. If both ‘FAULT RECALL’ and ‘LEARN’ push buttons are
pressed for greater than 1 second, the display will blank to
indicate the push buttons are pressed. Within 5 seconds,
both push buttons should be released. If any push button is
not released, the test mode will not activate. The display
will return to normal.
2. Once the push buttons are released, the display will flash
“Ft” to indicate the push buttons are released and successful entry into test mode has been achieved.
Gas Valve On/Off
Selector Switch
White-Rodgers Model 36G54 (Two-Stage)
Open to
Atmosphere
Manometer
Hose
Outlet
Pressure Boss
3. The control will force a high capacity demand. If a low capacity demand is already being serviced, it will be forced to
high capacity.
High Fire Regulator
Adjust
Regulator
Vent
Low Fire
Regulator
Adjust
4. The display will continue to flash “Ft” until high capacity
(100%) is achieved. Once achieved, the display will show
“Ft” without flashing. A 5-minute timer will be started to allow sufficient opportunity for the gas pressure to be tested.
Inlet
Pressure
Boss
Manometer
5. If a call for heat is given or removed during the test, the
system will still operate until the 5 minute test time is complete.
White-Rodgers Model 36G54 Connected to Manometer
6. During test mode, if both push buttons are pressed for
greater than 1 second, the display will blank to indicate
push buttons are pressed. If both push buttons are released
within 5 seconds, the test mode will terminate and the system will return to normal operation. Otherwise, the test mode
will continue uninterrupted.
25
High Fire Coil
Coaxial Coil
Terminal (HI)
Terminal (M)
Common
On/Off Switch
Terminal(C)
Regulator
Vent
Gas Valve On/Off
Selector Switch
High Fire
Regulator
Adjust
Low Fire
Regulator
Adjust
INLET GAS SUPPLY PRESSURE
Natural Gas
Minimum: 4.5" w.c.
Maximum: 10.0" w.c.
Propane Gas
Minimum: 11.0" w.c.
Maximum: 13.0" w.c.
If supply pressure differs from table, make the necessary adjustments to pressure regulator, gas piping size, etc., and/or
consult with local gas utility.
5. Turn OFF gas to furnace at the manual shutoff valve and
disconnect manometer. Reinstall plug before turning on
gas to furnace.
6. Turn OFF any unnecessary gas appliances stated in
step 3.
Honeywell Model VR9205 (Two-Stage)
Gas Line
Manometer
Hose
Open to
Atmosphere
Common
Terminal(C)
High Fire Coil
Terminal (HI)
Gas
Shutoff
Valve
Low Fire Coil
Terminal (LO)
Gas Line
To Furnace
i
Open To
Atmosphere
Inlet Pressure Tap
1/8 NPT
Drip Leg Cap
With Fitting
Manometer
Manometer Hose
Manometer
Outlet Pressure Tap
1/8 NPT
Honeywell Model VR9205 Connected to Manometer
Measuring Inlet Gas Pressure (Alt. Method)
GAS MANIFOLD PRESSURE MEASUREMENT AND ADJUSTMENT
1. Turn OFF gas to furnace at the manual gas shutoff valve
external to the furnace.
2. Connect a calibrated water manometer (or appropriate
gas pressure gauge) at either the gas valve inlet pressure
boss or the gas piping drip leg. See Honeywell VR9205
gas valve figure or White-Rodgers 36G54 gas valve figure
for location of inlet pressure boss.
CAUTION
TO PREVENT UNRELIABLE OPERATION OR EQUIPMENT DAMAGE, THE GAS MANIFOLD PRESSURE MUST BE AS SPECIFIED ON THE UNIT RATING PLATE. ONLY MINOR ADJUSTMENTS SHOULD BE MADE BY ADJUSTING THE GAS VALVE PRESSURE REGULATOR.
Only small variations in gas pressure should be made by adNOTE: If measuring gas pressure at the drip leg or Honeywell justing the gas valve pressure regulator. The manifold pressure
VR9205 gas valve, a field-supplied hose barb fitting must be must be measured with the burners operating. To measure
installed prior to making the hose connection. If using the inlet and adjust the manifold pressure, use the following procedure.
pressure boss on the White-Rodgers 36G54 gas valve, then 1. Turn OFF gas to furnace at the manual gas shutoff valve
external to the furnace.
use the 36G Valve Pressure Check Kit, Goodman Part No.
0151K00000S.
2. Turn off all electrical power to the system.
3. Turn ON the gas supply and operate the furnace and all
3. Outlet pressure tap connections:
other gas consuming appliances on the same gas supply
a. Honeywell VR9205 valve: Remove the outlet pressure
line.
boss plug. Install an 1/8" NPT hose barb fitting into
4. Measure furnace gas supply pressure with burners firing.
the outlet pressure tap.
Supply pressure must be within the range specified in
b. White-Rodgers 36G54 valve: Back outlet pressure test
the Inlet Gas Supply Pressure table.
screw (inlet/outlet pressure boss) out one turn
(counterclockwise, not more than one turn).
26
4. Attach a hose and manometer to the outlet pressure
barb fitting (Honeywell valve) or outlet pressure boss
(White-Rodgers valve).
5. Turn ON the gas supply.
6. Turn on power and close thermostat “R” and “W1”
contacts to provide a call for low stage heat.
7. Measure the gas manifold pressure with burners firing.
Adjust manifold pressure using the Manifold Gas
Pressure table shown below.
8. Remove regulator cover screw from the low (LO) outlet
pressure regulator adjust tower and turn screw clockwise
to increase pressure or counterclockwise to decrease
pressure. Replace regulator cover screw.
9. Close thermostat “R” and “W2” contacts to provide a
call for high stage heat.
10. Remove regulator cover screw from the high (HI) outlet
pressure regulator adjust tower and turn screw clockwise
to increase pressure or counterclockwise to decrease
pressure. Replace regulator cover screw.
11. Turn off all electrical power and gas supply to the system.
12. Remove the manometer hose from the hose barb fitting
or outlet pressure boss.
13. Replace outlet pressure tap:
a. Honeywell VR9205 valve: Remove the 1/8" NPT hose
barb fitting from the outlet pressure tap. Replace the
outlet pressure boss plug and seal with a high quality
thread sealer.
b. White-Rodgers 36G54 valve: Turn outlet pressure test
screw in to seal pressure port (clockwise, 7 in-lb
minimum).
14. Turn on electrical power and gas supply to the system.
15. Close thermostat contacts “R” and “W1/W2” to energize
the valve.
2. While the furnace is operating, time and record one
complete revolution of the smallest gas meter dial.
3. Calculate the number of seconds per cubic foot (sec/ft3)
of gas being delivered to the furnace. If the dial is a one
cubic foot dial, divide the number of seconds recorded in
step 2 by one. If the dial is a two cubic foot dial, divide
the number of seconds recorded in step 2 by two.
4. Calculate the furnace input in BTUs per hour (BTU/hr).
Input equals the sum of the installation’s gas heating
value and a conversion factor (hours to seconds) divided
by the number of seconds per cubic foot. The measured
input must not be greater than the input indicated on the
unit rating plate.
EXAMPLE:
Installation’s gas heating (HTG) value: 1,000 BTU/ft3
(Obtained from gas supplier)
Installation’s seconds per cubic foot: 34 sec/ ft3
Conversion Factor (hours to seconds): 3600 sec/hr
Input = (Htg. value x 3600) ÷ seconds per cubic foot
Input = (1,000 BTU/ft3 x 3600 sec/hr) ÷ 34 sec/ ft3
Input = 106,000 BTU/hr
Minor changes to the input rate may be accomplished through
manifold pressure adjustments at the gas valve. Refer to Section XIV, Startup Procedure and Adjustment - Gas Manifold
Pressure Measurement and Adjustment for details. NOTE:
The final manifold pressure cannot vary by more than ± 0.3”
w.c. from the specified setting. Consult your local gas supplier
if additional input rate adjustment is required.
5. Repeat steps 2 through 4 on high stage.
6. Turn ON gas to and relight all other appliances turned off
in step 1. Be certain that all appliances are functioning
properly and that all pilot burners are operating.
Using a leak detection solution or soap suds, check for leaks
at outlet pressure boss plug (Honeywell valve) or screw (WhiteRodgers valve). Bubbles forming indicate a leak. SHUT OFF
GAS AND REPAIR ALL LEAKS IMMEDIATELY!
NOTE: For gas to gas conversion, consult your dealer for
appropriate conversion.
M anifold Gas Pressure
Gas
Range
Natural
Low Stage 1.6 - 2.2" w .c.
High Stage 3.2 - 3.8" w .c.
Propane
Low Stage 5.7 - 6.3" w .c.
High Stage 9.7 - 10.3" w .c.
Nom inal
1.9" w .c.
3.5" w .c.
6.0" w .c.
10.0" w .c.
GAS INPUT RATE MEASUREMENT (NATURAL GAS ONLY)
TEMPERATURE RISE
Temperature rise must be within the range specified on the unit
rating plate. An incorrect temperature rise may result in condensing in or overheating of the heat exchanger. An airflow and
temperature rise table is provided in the Specification Sheet
applicable to your model. Determine and adjust temperature
rise as follows:
1. Operate furnace with burners firing for approximately ten
minutes. Ensure all registers are open and all duct
dampers are in their final (fully or partially open) position.
2. Place thermometers in the return and supply ducts as
close to the furnace as possible. Thermometers must
not be influenced by radiant heat by being able to “see”
the heat exchanger.
The gas input rate to the furnace must never be greater than
that specified on the unit rating plate. To measure natural gas
input using the gas meter, use the following procedure.
1. Turn OFF the gas supply to all other gas-burning
appliances except the furnace.
27
3. Subtract the return air temperature from the supply air
temperature to determine the air temperature rise. Allow
adequate time for thermometer readings to stabilize.
4. Adjust temperature rise by adjusting the circulator blower
speed. Increase blower speed to reduce temperature rise.
Decrease blower speed to increase temperature rise.
Refer to Startup Procedure and Adjustment -Circulator
Blower Speeds for speed changing details.
This furnace is equipped with a multi-speed circulator blower.
This blower provides ease in adjusting blower speeds. The
Specification Sheet applicable to your model provides an airflow table, showing the relationship between airflow (CFM) and
external static pressure (E.S.P.), for the proper selection of
heating and cooling speeds. The heating blower speed is
shipped set at “B”, and the cooling blower speed is set at “D”.
These blower speeds should be adjusted by the installer to
match the installation requirements so as to provide the correct heating temperature rise and correct cooling CFM.
HEAT EXCHANGER
RADIATION "LINE OF SIGHT"
SUPPLY
AIR
TSUPPLY
RISE =
TSUPPLY
-
TRETURN
Use the dual 7-segment LED display adjacent to the dipswitches
to obtain the approximate airflow quantity. The airflow quantity
is displayed as a number on the display, rounded to the nearest 100 CFM. The display alternates airflow delivery indication
and the operating mode indication.
TRETURN
RETURN
AIR
Example: The airflow being delivered is 1225 CFM. The display indicates 12. If the airflow being delivered is 1275, the
display indicates 13.
1. Determine the tonnage of the cooling system installed
with the furnace. If the cooling capacity is in BTU/hr divide
it by 12,000 to convert capacity to TONs.
Example: Cooling Capacity of 30,000 BTU/hr.
30,000/12,000 = 2.5 Tons
Temperature Rise Measurement
CIRCULATOR BLOWER SPEEDS
WARNING
TO AVOID PERSONAL INJURY OR DEATH DUE TO ELECTRICAL SHOCK, TURN OFF POWER TO THE FURNACE BEFORE CHANGING SPEED TAPS.
Speed Selection Dip Switches
Cool
Selection
Switches
TAP
Adjust
Selection
Switches
Profile
Selection
Switches
Model
Heat
Selection
Switches
735
805
875
945
1050
1150
1250
1350
*DVC80805C***
A
B
C
D
520
715
910
1170
800
1100
1400
1800
945
1015
1085
1155
1350
1450
1550
1650
60 sec/100% *DVC81005C***
A
B
C
D
553
748
943
1203
850
1150
1450
1850
1085
1155
1225
1260
1550
1650
1750
1800
*MVC80604B***
A
B
C
D
390
520
715
910
600
800
1100
1400
875
945
1015
1085
1250
1350
1450
1550
*MVC80805C***
A
B
C
D
520
715
910
1170
800
1100
1400
1800
1050
1120
1190
1260
1500
1600
1700
1800
*MVC81005C***
A
B
C
D
520
715
910
1170
800
1100
1400
1800
1210
1225
1245
1260
1725
1750
1775
1800
S4- 3 S4- 4
OFF OFF
OFF
OFF
B
ON
OFF
ON
ON
OFF
C
OFF
ON OFF
ON
OFF
ON
OFF
ON
D
ON
ON
ON
ON
ON
ON
ON
Profiles
High Stage
Heat
600
800
1000
1200
OFF OFF OFF
ON
Low Stage
Heat
390
520
650
780
S3- 1 S3- 2 S3- 3 S3- 4 S4-1 S4-2
OFF
High Stage
Cool
A
B
C
D
OFF
OFF
Low Stage
Cool
*DVC80603B***
A
ON
Tap
Pre-Run
Short-Run
OFF Delay
A
-------
--------
B
-------
30 sec/50%
C
-------
7.5 min/82%
60 sec/100%
D
30 sec/50%
7.5 min/82%
30 sec/50%
60 sec/100%
To Set Airflow: (1) Select model and desired High Stage Cooling Airflow. Determine
the corresponding tap (A, B, C, or D). Set dip switches S3-1* and S3-2* to the
appropriate ON / OFF positions. (2) Select model and desired High Stage Heating
Airflow. Determine the corresponding tap (A, B, C, or D). Set dip switches S4-3* and
S4-4* to the appropriate ON / OFF positions. (3) Selecting Airflow Adjustment Factor:
For 0% trim set S5-2* to OFF (trim disabled). If trim is desired set S5-2* to ON (trim
enabled) and set S3-3* and S3-4* to appropriate ON / OFF positions. Tap A is +5%,
Tap B is -5%, Tap C is +10%, Tap D is -10%.
To Set Comfort Mode: Select Desired Comfort Mode profile (see profiles above). Set
dip switches S4-1* and S4-2* to the appropriate ON / OFF positions.
Dehumidification: To enable, set switch S5-1* to ON. Cooling airflow will be reduced
to 85% of nominal value during cool call. To disable, set switch S5-1* to OFF.
Continuous Fan Speed: Set dip switches S5-3* and S5-4* to select one of 4
continuous fan speeds (25%, 50%, 75%, or 100%). " See installation manual
for details"
*the “S” number refers to one of four labeled dip switch section each containing 4
individual dip switches. The following number refers to the individual labeled dip
switch within that section
0140F01170
NOTE: Airflow data shown applies to legacy mode operation only. For a fully communicating system, please see the
outdoor unit’s installation instructions for cooling and pump heating airflow data. See ComfortNet™ System - Airflow
Consideration section for details.
28
•
2. Determine the proper air flow for the cooling system.
Most cooling systems are designed to work with air flows
between 350 and 450 CFM per ton. Most manufacturers
recommend an air flow of about 400 CFM per ton.
Example: 2.5 tons X 400 CFM per ton = 1000 CFM
Profile A provides only an OFF delay of one (1) minute
at 100% of the cooling demand airflow.
100% CFM
OFF
100% CFM
OFF
1 min
The cooling system manufacturer’s instructions must be
checked for required air flow. Any electronic air cleaners or
• Profile B ramps up to full cooling demand airflow by
other devices may require specific air flows, consult installafirst stepping up to 50% of the full demand for 30 seconds.
tion instructions of those devices for requirements.
The motor then ramps to 100% of the required airflow. A
3. Knowing the furnace model, locate the high stage cooling
one (1) minute OFF delay at 100% of the cooling airflow
air flow charts in the Specification Sheet applicable to
is provided.
your model. Look up the cooling air flow determined in
step 2 and find the required cooling speed and adjustment
100% CFM
100% CFM
setting.
50% CFM
OFF
OFF
Example: A *MVC80604BX furnace installed with a 2.5
1/2 min
1 min
ton air conditioning system. The air flow
needed is 1000 CFM. Looking at the cooling
speed chart for *MVC80604BX, find the air
• Profile C ramps up to 85% of the full cooling demand
flow closest to 1000 CFM. A cooling airflow
airflow and operates there for approximately 7 1/2
of 990 CFM can be attained by setting the
minutes. The motor then steps up to the full demand
cooling speed to “C” and the adjustment to
airflow. Profile C also has a one (1) minute 100% OFF
-10% trim.
delay.
4. Continuous fan speeds that provide 25, 50, 75 and 100%
of the furnace’s maximum airflow capability are
100% CFM
OFF
OFF
selectable via dip switches S5- 3, 4.
Example: If the furnace’s maximum airflow capability
is 2000 CFM and 25% continuous fan speed
is selected, the continuous fan speed will
Switch Bank: S3
be 0.25 x 2000 CFM = 500 CFM.
DIP Switch No.
Cooling
5. Locate the blower speed selection DIP switches on the
Airflow
1
2
integrated control module. Select the desired “cooling”
A
OFF
OFF
speed tap by positioning switches 1 and 2 appropriately.
B
ON
OFF
Select the desired “adjust” tap by positioning switches
C
OFF
ON
3 and 4 appropriately. To enable adjustments and select
D*
ON
ON
-5, 5, -10 or 10% trim, you must set dipswitch S5-2 to
(*Indicates factory setting)
ON. If S5-2 is in the OFF position, you will receive 0%
trim. Refer to the following figure for switch positions
Switch Bank: S3
and their corresponding taps. Verify CFM by noting the
DIP Switch No.
number displayed on the dual 7-segment LED display.
Adjust Taps
3
4
6. The multi-speed circulator blower also offers several
custom ON/OFF ramping profiles. These profiles may
+5%*
OFF
OFF
be used to enhance cooling performance and increase
-5%
ON
OFF
comfort level. The ramping profiles are selected using
10%
OFF
ON
DIP switches S4- 1, 2. Refer to the following figure for
-10%
ON
ON
switch positions and their corresponding taps. Refer to
(*Indicates factory setting)
the bullet points below for a description of each ramping
NOTE: To enable adjustments and select -5, 5, -10 or 10%
profile. Verify CFM by noting the number displayed on
trim, you must set dip switch S5-2 to ON. If S5-2 is in the
the dual 7-segment LED display.
OFF position, you will receive 0% trim.
Switch Bank: S4
Ramping
Profiles
DIP Switch No.
1
2
A*
OFF
OFF
B
ON
OFF
C
OFF
ON
D
ON
ON
(*Indicates factory setting)
29
•
Profile D ramps up to 50% of the demand for 1/2 minute,
then ramps to 85% of the full cooling demand airflow
and operates there for approximately 7 1/2 minutes. The
motor then steps up to the full demand airflow. Profile D
has a 1/2 minute at 50% airflow OFF delay.
OFF
Sw itch Bank : S1
Heat OFF Delay
1
2
OFF
OFF
120 seconds
ON
OFF
150 seconds*
OFF
ON
90 seconds
OFF
DIP Sw itch No.
180 seconds
ON
ON
(*Indicates f actory setting)
Heat Off Delay Dipswitches
7. Select the heating speed for your model from the heating
speed chart in the Specification Sheet. The adjust setting
(already established by the cooling speed selection)
determines which set of speeds are available. The
selected speed must provide a temperature rise within
the rise range listed with the particular model.
Example: If the *MVC80604BX is set for 1210 CFM
on cooling, the “ADJUST” is set to “+” (plus).
The four heating speeds available are “A
Plus”, “B Plus”, “C Plus”, and “D Plus”. “A
Plus” has a rise of 38°F for both stages
which is within the 20-50°F rise range for
the *MVC80604BX . This setting will keep
electrical consumption to a minimum. Set
the “Heat” speed DIP switches to “A”.
Switch Bank: S4
DIP Switch No.
Heating
Airflow
3
4
A
OFF
OFF
B*
ON
OFF
COMFORTNET™ SYSTEM
OVERVIEW
The ComfortNet system is a system that includes a ComfortNet
compatible furnace and air conditioner or heat pump with a
CTK0* thermostat. A valid ComfortNet system could also be a
compatible furnace, CTK0* thermostat and non-compatible,
single stage air conditioner. Any other system configurations
are considered invalid ComfortNet systems and must be connected as a traditional (or legacy) system (see Electrical Connections for wiring connections).
A ComfortNet heating/air conditioning system differs from a noncommunicating/traditional system in the manner in which the
indoor unit, outdoor unit and thermostat interact with one another. In a traditional system, the thermostat sends commands
to the indoor and outdoor units via analog 24 VAC signals. It is
a one-way communication path in that the indoor and outdoor
units typically do not return information to the thermostat.
In a ComfortNet system, the indoor unit, outdoor unit, and thermostat comprising a ComfortNet system “communicate” digiC
OFF
ON
tally with one another. creating a two-way communications path.
D
ON
ON
The thermostat still sends commands to the indoor and out(*Indicates factory setting)
door units. However, the thermostat may also request and
receive information from both the indoor and outdoor units. This
8. Select the desired “heating” speed tap by positioning
information may be displayed on the CTK0* thermostat. The
switches S4- 3, 4 appropriately. Refer to figure above.
indoor and outdoor units also interact with one another. The
Verify CFM by noting the number displayed on the dual
outdoor unit may send commands to or request information
7-segment LED display.
from the indoor unit. This two-way digital communications between the thermostat and subsystems (indoor/outdoor unit) and
In general lower heating speeds will: reduce electrical consumpbetween subsystems is the key to unlocking the benefits and
tion, lower operating sound levels of the blower, and increase
features of the ComfortNet system.
the outlet air temperature delivered to the home. The speeds
available allow the blower performance to be optimized for the Two-way digital communications is accomplished using only
particular homeowner’s needs.
two wires. The thermostat and subsystem controls are power
with 24 VAC. Thus, a maximum of 4 wires between the equipBLOWER HEAT OFF DELAY TIMINGS
ment and thermostat is all that is required to operate the sysThe integrated control module provides a selectable heat off tem.
delay function. The heat off delay period may be set to 90, 120,
150, 180 seconds using the DIP switches or jumper provided AIRFLOW CONSIDERATIONS
on the control module. The delay is factory shipped at 150 Airflow demands are managed differently in a fully communiseconds but may be changed to suit the installation require- cating system than they are in a non-communicating wired
ments and/or homeowner preference. Refer to the following fig- system. The system operating mode (as determined by the
ures for switch positions and corresponding delay times.
thermostat) determines which unit calculates the system airflow demand. If the indoor unit is responsible for determining
the airflow demand, it calculates the demand and sends it to
30
the ECM motor. If the outdoor unit or thermostat is responsible for determining the demand, it calculates the demand
and transmits the demand along with a fan request to the
indoor unit. The indoor unit then sends the demand to the
ECM motor. The table below lists the various ComfortNet systems, the operating mode, and airflow demand source.
System
Air Conditioner +
Furnace
Heat Pump +
Furnace
Furnace + NonComm 1stg Air
Conditioner
System
Operating Mode
Airflow Dem and
Source
Cooling
Air Conditioner
Heating
Furnace
Continuous Fan
Thermostat
FOSSIL FUEL APPLICATIONS
This furnace can be used in conjunction with a ComfortNet™ compatible heat pump in a fossil fuel application. A fossil fuel application refers to a combined gas furnace and heat pump installation
which uses an outdoor temperature sensor to determine the most
cost efficient means of heating (heat pump or gas furnace). When
used with the CTK0* thermostat, the furnace/heat pump system is automatically configured as a fossil fuel system. The
balance point temperature may be adjusted via the CTK0* thermostat advanced user menus (see CTK0* instructions for additional information).
CTK0* WIRING
Cooling
Heat Pump
Heat Pump Heating
Only
Heat Pump
Auxiliary Heating
Furnace
Continuous Fan
Thermostat
Cooling
Furnace
Heating
Furnace
Continuous Fan
Thermostat
NOTE: A removable plug connector is provided with the control
to make thermostat wire connections. This plug may be
removed, wire connections made to the plug, and replaced. It
is STRONGLY recommended that you do not connect multiple
wires into a single terminal. Wire nuts are recommended to
ensure one 18 AWG wire is used for each terminal. Failure to
do so may result in intermittent operation.
Typical 18 AWG thermostat wire may be used to wire the system components. One hundred (100) feet is the maximum
length of wire between indoor unit and outdoor unit, or between
indoor unit and thermostat. Wire runs over (100) feet require
larger gauge wire.
FOUR-WIRE INDOOR AND OUTDOOR WIRING
Typical ComfortNet wiring will consist of four wires between the
indoor unit and outdoor unit and between the indoor unit and
For example, assume the system is an air conditioner matched thermostat. The required wires are: (a) data lines, 1 and 2; (b)
with a furnace. With a call for low stage cooling, the air con- thermostat “R” (24 VAC hot) and “C” (24 VAC common).
ditioner will calculate the system’s low stage cooling airflow
CTK0*
demand. The air conditioner will then send a fan request along
1 2 R C Thermostat
with the low stage cooling airflow demand to the furnace. Once
received, the furnace will send the low stage cooling airflow
ComfortNet Compatible Furnace
1 2 R C Integrated Control Module
demand to the ECM motor. The ECM motor then delivers the
low stage cooling airflow. See the applicable ComfortNet air
conditioner or heat pump installation manual for the airflow
ComfortNet Compatible AC/HP
1 2 R C
delivered during cooling or heat pump heating.
Integrated Control Module
In continuous fan mode, the CTK0* thermostat provides the
airflow demand. The thermostat may be configured for a low,
medium, or high continuous fan speed. The low, medium, and
high fan speeds correspond to 25%, 50%, and 75%, respectively, of the furnaces’ maximum airflow capability. During continuous fan operation, the thermostat sends a fan request along
with the continuous fan demand to the furnace. The furnace,
in turn, sends the demand to the ECM motor. The ECM motor
delivers the requested continuous fan airflow.
System Wiring using Four-Wires
TWO-WIRE OUTDOOR, FOUR-WIRE INDOOR WIRING
Two wires can be utilized between the indoor and outdoor units.
For this wiring scheme, only the data lines, 1 and 2, are needed
required between the indoor and outdoor units. A 40VA, 208/
230 VAC to 24VAC transformer must be installed in the outdoor unit to provide 24VAC power to the outdoor unit’s electronic control. See the instruction manual provided with the
thermostat for wiring instructions.
31
NOTE: Use of a transformer is recommended if installing a dual COMFORTNET™ SYSTEM ADVANCED FEATURES
fuel/fossil fuel system. Failure to use the transformer in the
outdoor unit could result in over loading of the furnace transformer. The ComfortNet system permits access to additional system
information, advanced setup features, and advanced diagnosCTK0*
Thermostat
tic/troubleshooting features. These advanced features are or1 2 R C
ganized into a menu structure. The menus are accessed and
navigated by means of the CTK0* thermostat. For details, see
ComfortNet Compatible
1 2 R C Furnace Integrated
the thermostat instruction sheet.
Control Module
40VA Transformer
1
2
R C
ComfortNet Compatible
AC/HP Integrated
Control Module
24 VAC
208/230 VAC
System Wiring using Two-Wires between Furnace and AC/HP
and Four-Wires between Furnace and Thermostat
THERMOSTAT MENU
If this furnace is installed with a communicating compatible
heat pump, the system is recognized as a dual fuel system.
The balance point temperature should be set via the thermostat advanced menu.
DIAGNOSTICS
Accessing the furnace’s diagnostics menu provides ready ac-
COMFORTNET™ COMPATIBLE FURNACE WITH NONcess to the last six faults detected by the furnace. Faults are
COMFORTNET COMPATIBLE SINGLE-STAGE AIR CONDITIONER stored most recent to least recent. Any consecutively repeated
Four wires are required between the furnace and thermostat. Two
wires are required between the furnace control and single stage air
conditioner. For this system configuration, the “Y1” terminal on the
integrated furnace control becomes an output rather than an input.
The “Y1” connection to the outdoor unit is made using both 4position thermostat connectors in the CTK0* kit. Remove the red
keying tabs from the on-board connector block and position both
4-position connectors such that “1”, “2”, “R”, “C”, and “Y1” positions
are filled.
CTK0*
Thermostat
1
2
R
C
1
2
R C G
C
fault is stored a maximum of three times. Example: A clogged
return air filter causes the furnace limit to trip repeatedly. The
control will only store this fault the first three consecutive times
the fault occurs. Navigate to the diagnostics menu as described
in the thermostat installer manual.
NOTE: It is highly recommended that the fault history be cleared
when performing maintenance or servicing the furnace.
4-Position Connectors
from CTK0*
Thermostat Kit
W1 W2 Y1
Y
Y2
O
ComfortNet Compatible
Furnace Integrated
Control Module
Non-ComfortNet Compatible
Single Stage AC
System Wiring between Furnace and Non-Communicating
Compatible Single Stage Air Conditioner
32
FURNACE ADVANCED FEATURES MENUS (ACCESSED THROUGH COMMUNICATING THERMOSTAT)
CONFIGURATION
Submenu Item
Number of Heat Stages (HT STG)
Indication (for Display Only; not User Modifiable)
Displays the number of furnace heating stages
Input Rate (BTU/HR)
Motor HP (1/2, ¾, or 1 MTR HP)
Displays the furnace input rate in kBtu/hr
Displays the furnace indoor blower motor horsepower
DIAGNOSTICS
Submenu Item
Indication/User Modifiable Options
Comments
Fault 1 (FAULT #1)
Most recent furnace fault
For dis play only
Fault 2 (FAULT #2)
Next m ost recent furnace fault
For dis play only
Fault 3 (FAULT #3)
Next m ost recent furnace fault
For dis play only
Fault 4 (FAULT #4)
Next m ost recent furnace fault
For dis play only
Fault 5 (FAULT #5)
Next m ost recent furnace fault
For dis play only
Fault 6 (FAULT #6)
Least recent furnace fault
For dis play only
Clear Fault History (CLEAR)
NO or YES
Selecting “YES” c lears the fault
history
NOTE: Consecutively repeated faults are shown a maximum of 3 times
IDENTIFICATION
Submenu Item
Model Number (MOD NUM)
Indication (for Display Only; not User Modifiable)
Displays the furnace model number
Serial Number (SER NUM)
Software (SOFTWARE)
Displays the furnace serial number (Optional)
Displays the application software revision
SET-UP
Submenu Item
Heat Airflow Trim (HT TRM)
Heat ON Delay (HT ON
Heat OFF Delay (HT OFF)
User Modifiable Options
-10% to +10% in 2% increments,
default is 0%
5, 10, 15, 20, 25, or 30 seconds,
default is 30 seconds
30, 60, 90, 120, 150, or 180 seconds,
default is 150 seconds
Comments
Trims the heating airflow by the selected
amount.
Selects the indoor blower heat ON delay
Selects the indoor blower heat OFF delay
Heat Airflow (HT ADJ)
1, 2, 3, or 4
Selects the nominal heating airflow (see
Startup Procedure and Adjustment –
Circulator Blower Speeds for addition
information)
Auxiliary Alarm
ON / OFF
Enable or Disable Auxiliary Alarm Input
ON / OFF / IND
Select Humidity Relay Functionality. ON Humidifier is turned on with heat demand.
OFF - Humidifier remains off. IND - Humidifier
will cycle with humidification demand
(independent of an active heat demand)
1, 2, 3, 4
Select Humidity Fan Speed (this option is
enabled when Humidity Setting of IND is
selected). 1 - 25%, 2 - 50%, 3 - 75%, 4 100% of maximum airflow.
Humidity Setting
Humidity Fan Speed
33
STATUS
Submenu Item
Mode (MODE)
CFM (CFM)
Indication (for Display Only; not User Modifiable)
Displays the current furnace operating mode
Displays the airflow for the current operating mode
NON-COMM (APPLIES ONLY TO A COMMUNICATING COMPATIBLE FURNACE MATCHED
WITH A NON-COMMUNICATING COMPATIBLE SINGLE STAGE AIR CONDITIONER)
Submenu Item
Cool Airflow (CL CFM)
User Modifiable Options
18, 24, 30, 36, 42, 48, or 60, default
is 18
Comments
Selects the airflow for the noncommunicating compatible single stage AC
unit
Cool Airflow Trim (CL TRM)
-10% to +10% in 2% increments,
default is 0%
Selects the airflow trim amount for the noncommunicating compatible single stage AC
unit
Cool Airflow Profile (CL PRFL)
A, B, C, or D, default is A
Selects the airflow profile for the noncommunicating compatible single stage AC
unit
Cool ON Delay (CL ON)
5, 10, 20, or 30 seconds, default is
5 seconds
Selects the indoor blower ON delay for the
non-communicating compatible single
stage AC unit
Cool OFF Delay (CL OFF)
30, 60, 90, or 120 seconds, default
is 30 seconds
Selects the indoor blower OFF delay for the
non-communicating compatible single
stage AC unit
•
NETWORK TROUBLESHOOTING
Communications is achieved by taking the difference between
two dc signals. The signals and transmission lines are referred to as “data 1” and “data 2”. Each transmission line is
biased to approximately 2.5Vdc. During data reception/transmission, the data lines vary between +5V and ground. (When
data 1 is increasing towards +5V, data 2 is decreasing towards ground and when data 1 is decreasing towards ground,
data 2 is increasing towards +5V. Typically, the data 1 line is
approximately 2.6Vdc and the data 2 transmission line is approximately 2.3Vdc. The voltage difference between data 1
and data 2 is typically 0.2 to 0.6 Vdc.
Learn button – Used to reset the network. Depress
the button for approximately 2 seconds to reset the
network.
SYSTEM TROUBLESHOOTING
NOTE: Refer to the instructions accompanying the CT
compatible outdoor AC/HP unit for troubleshooting information.
Refer to the Troubleshooting Chart in the back of this manual
for a listing of possible furnace error codes, possible causes
and corrective actions.
The ComfortNet system is a fully communicating system, and NORMAL SEQUENCE OF OPERATION
thus, constitutes a network. Occasionally the need to troubleshoot the network may arise. The integrated furnace control POWER UP
has some on-board tools that may be used to troubleshoot the
network. These tools are: red communications LED, green The normal power up sequence is as follows:
• 115 VAC power applied to furnace.
receive (Rx) LED, and learn button.
•
Red communications LED – Indicates the status of
• Integrated control module performs internal checks.
the network. The table below indicates the LED status
• Integrated control module displays 8 8 on dual 7-segment
and the corresponding potential problem.
display LED’s.
•
Green receive LED – Indicates network traffic. The
• Integrated control module monitors safety circuits
table below indicates the LED status and the
continuously.
corresponding potential problem.
• Furnace awaits call from thermostat. Dual 7-segment
LED’s display O while awaiting call from thermostat.
34
LED
Description
Possible Cause
Corrective Action
Normal condition
None
None
None
1 Flash
Communications
Failure
Communications
Failure
•Depress Learn Button
•Verify that bus BIAS and
TERM dipswitches are in
the ON position.
•Depress once quickly for
a power-up reset
•Depress and hold for 2
seconds for an out-of-box
reset
2 Flashes
Out-of-box reset
•Control power up
•Learn button depressed
None
None
Off
•Nopower
•Communications
error
•No power to furnace
•Open fuse
•Communications error
•Check fuses and circuit
breakers; replace/reset
•Replace blown fuse
•Check for shorts in low
voltage wiring in furnace/
system
•Reset network by
depressing learn button
•Check data 1/ data 2
voltages
•Turn power OFF prior to
repair
1 Steady
Flash
No network
found
•Broken/ disconnected
data wire(s)
•Furnace is installed
as a legacy/ traditional
system
•Check communications
wiring (data 1/ data 2
wires)
•Check wire connections
at terminal block
•Verify furnace installation
type (legacy/ traditional
or communicating) Check
data 1/ data 2 voltages
•Turn power OFF prior to
repair
•Verify wires at terminal
blocks are securely
twisted together prior to
inserting into terminal
block
•Verify data1 and data
voltages as described
above
Rapid
Flashing
Normal network
traffc
Control is “talking” on
network as expected
None
None
On Solid
Data 1/ Data 2
miss-wire
•Data 1 and data 2 wires
reversed at furnace,
thermostat, or CT™
compatible outdoor AC/
HP
•Short between data 1
and data 2 wires
•Short between data 1
or data 2 wires and R
(24VAC) or C (24VAC
common)
•Check communications
wiring (data 1/ data 2
wires)
•Check wire connections
at terminal block
•Check data 1/ data 2
voltages
•Turn power OFF prior to
repair
•Verify wires at terminal
blocks are securely
twisted together prior to
inserting into terminal
block
•Verify data1 and data
voltages as described
above
Red
Communications
LED
Green Receive
LED
HEATING MODE
• Gas valve opens at end of igniter warm up period, delivering
The normal operational sequence in heating mode is as follows:
• R and W1 (or R and W1/W2) thermostat contacts close,
initiating a call for heat.
• Integrated control module performs safety circuit checks.
• Induced draft blower is energized on high speed for a 15•
•
Comments
Off
gas to burners and establishing flame.
• Integrated control module monitors flame presence. Gas
valve will remain open only if flame is detected.
• If the thermostat call is for low heat, gas valve and induced
draft blower will continue on low stage. If the call is for
high heat, the gas valve and induced draft blower will
change to high stage.
second prepurge. Humidifier terminal is energized with
induced draft blower.
Induced draft blower steps to low speed following
prepurge. Low stage pressure switch contacts are
closed.
Igniter warm up begins upon step to low speed and
presence of closed low stage pressure switch contacts.
• Circulator blower is energized on heat speed following a
•
35
thirty (30) second blower on delay. The circulator blower
requires thirty seconds to ramp up to full speed.
Electronic air cleaner terminal is energized with circulator
blower.
Furnace is now operating on the specified stage called
for by the two-stage thermostat.
• Furnace runs, integrated control module monitors safety
•
• R and Y1/G or Y2/G thermostat contacts open,
circuits continuously.
If the two-stage thermostat changes the call from low
heat to high heat, the integrated control module will
immediately switch the induced draft blower, gas valve,
and circulator blower to their high stage settings.
completing the call for cool.
Outdoor fan and compressor are de-energized.
•
• Circulator blower continues running during a cool off delay
• If the two-stage thermostat changes the call from high
heat to low heat, the control will immediately switch the
induced draft blower and gas valve to their low stage
settings. The circulator blower will remain on high
heating speed for thirty (30) seconds before switching to
the low heat circulating speed.
• R and W1 (or R and W1/W2) thermostat contacts open,
completing the call for heat.
• Gas valve closes, extinguishing flame.
• Induced draft blower is de-energized following a fifteen
•
•
FAN ONLY MODE
The normal operational sequence in fan only mode is as follows:
• R and G thermostat contacts close, initiating a call for
fan.
• Integrated control module performs safety circuit checks.
• Circulator blower is energized on continuous fan speed
second post purge. Humidifier terminals are de-energized.
• Circulator blower continues running for the selected heat
(25, 50, 75 or 100% of the furnace’s maximum airflow
capability. Fan speed selected by dip switches.) following
a five (5) second delay. Electronic air cleaner terminal
is energized.
off delay period (90, 120, 150 or 180 seconds). The
speed run during this period depends on the last heat
call provided by the thermostat.
If the last call for heat was a call for low heat, the air
circulator motor will run on low heat speed for the duration
of the heat off delay period (90, 120, 150 or 180 seconds).
If the last call for heat was a call for high heat, the air
circulating motor will run on the high heating speed for
thirty (30) seconds and then switch to the low heating
speed for the balance of the heat off delay period (60,
90, 120 or 150 seconds).
• Circulator blower and electronic air cleaner terminal is
de-energized.
period. The OFF delay time and airflow level are
determined by the selected ramping profile.
Electronic air cleaner terminal and circulator blower are
de-energized.
Furnace awaits next call from thermostat.
• Circulator blower runs, integrated control module
monitors safety circuits continuously.
• R and G thermostat contacts open, completing the call
for fan.
• Circulator blower is de-energized. Electronic air cleaner
terminal is de-energized.
• Furnace awaits next call from thermostat.
OPERATIONAL CHECKS
• Circulator blower ramps down to OFF during the 30
The burner flames should be inspected with the burner compartment door installed. Flames should be stable, quiet, soft,
• Furnace awaits next call from thermostat.
and blue (dust may cause orange tips but they must not be
yellow). Flames should extend directly outward from the burnCOOLING MODE
ers without curling, floating, or lifting off. Flames must not
The normal operational sequence in cooling mode is as fol- impinge on the sides of the heat exchanger firing tubes.
lows:
• R and Y1/G or Y2/G thermostat contacts close, initiating
a call for cool.
• Integrated control module performs safety circuit checks.
seconds following the heat off delay period.
Check the
Burner Flames for:
1. Stable, soft and blue.
2. Not curling, floating
or lifting off.
• Outdoor fan and compressor are energized to their
•
•
appropriate speed.
Circulator blower is energized on the appropriate cool
speed at the level and time determined by the selected
ramping profile. Electronic air cleaner terminal is
energized with circulator blower.
Furnace circulator blower and outdoor cooling unit run
their appropriate speeds, integrated control module
monitors safety circuits continuously.
Burner Flame
36
SAFETY CIRCUIT DESCRIPTION
A number of safety circuits are employed to ensure safe and
proper furnace operation. These circuits serve to control any
potential safety hazards and serve as inputs in the monitoring
and diagnosis of abnormal function. These circuits are continuously monitored during furnace operation by the integrated
control module.
INTEGRATED CONTROL MODULE
The integrated control module is an electronic device which, if
a potential safety concern is detected, will take the necessary
precautions and provide diagnostic information through an LED.
PRIMARY LIMIT
The primary limit control is located on the partition panel and
monitors heat exchanger compartment temperatures. It is a
normally-closed (electrically), automatic reset, temperature-activated sensor. The limit guards against overheating as a result
of insufficient conditioned air passing over the heat exchanger.
AUXILIARY LIMIT
The auxiliary limit controls are located on or near the circulator
blower and monitors blower compartment temperatures. They
are a normally-closed (electrically), auto-reset sensors. These
limits guard against overheating as a result of insufficient conditioned air passing over the heat exchanger.
Use the following precautions during furnace installation and
servicing to protect the integrated control module from damage. By putting the furnace, the control, and the person at the
same electrostatic potential, these steps will help avoid exposing the integrated control module to electrostatic discharge.
This procedure is applicable to both installed and uninstalled
(ungrounded) furnaces.
1. Disconnect all power to the furnace. Do not touch the
integrated control module or any wire connected to the
control prior to discharging your body’s electrostatic
charge to ground.
2. Firmly touch a clean, unpainted, metal surface of the
furnace away from the control. Any tools held in a
person’s hand during grounding will be discharged.
3. Service integrated control module or connecting wiring
following the discharge process in step 2. Use caution
not to recharge your body with static electricity; (i.e., do
not move or shuffle your feet, do not touch ungrounded
objects, etc.). If you come in contact with an ungrounded
object, repeat step 2 before touching control or wires.
4. Discharge your body to ground before removing a new
control from its container. Follow steps 1 through 3 if
installing the control on a furnace. Return any old or
new controls to their containers before touching any
ungrounded object.
DIAGNOSTIC CHART
ROLLOUT LIMIT
WARNING
The rollout limit controls are mounted on the burner/manifold
assembly and monitor the burner flame. They are normallyclosed (electrically), manual-reset sensors. These limits guard
against burner flames not being properly drawn into the heat
exchanger.
HIGH VOLTAGE !
TO AVOID PERSONAL INJURY OR DEATH DUE TO ELECTRICAL SHOCK, DISCONNECT ELECTRICAL POWER BEFORE PERFORMING ANY SERVICE OR MAINTENANCE.
PRESSURE SWITCHES
Refer to the Troubleshooting Chart at the end of this manual for
assistance in determining the source of unit operational probThe pressure switches are normally-open (closed during oplems. The dual 7-segment LED display will display an error
eration) negative air pressure-activated switches. They monicode that may contain a letter and number. The error code may
tor the airflow (combustion air and flue products) through the
be used to assist in troubleshooting the unit.
heat exchanger via pressure taps located on the induced draft
blower and the coil front cover. These switches guard against FAULT RECALL
insufficient airflow (combustion air and flue products) through
the heat exchanger and/or blocked condensate drain condi- The ignition control is equipped with a momentary push-button
switch that can be used to display the last six faults on the
tions.
dual 7-segment LED’s. The control must be in Standby Mode
FLAME SENSOR
(no thermostat inputs) to use the feature. Depress the switch
for approximately 2 seconds. Release the switch when the
The flame sensor is a probe mounted to the burner/manifold
assembly which uses the principle of flame rectification to de- LED’s are turned off. The last six faults will be displayed most
recent to least recent on the dual 7-segment LED’s.
termine the presence or absence of flame.
NOTE: Consecutively repeated faults are stored a maximum of
three times. Example: A clogged return air filter causes the
furnace limit to trip repeatedly. The control will only store this
fault the first three consecutive times the fault occurs.
TROUBLESHOOTING
ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS
NOTE: Discharge body’s static electricity before touching unit.
An electrostatic discharge can adversely affect electrical
components.
37
RESETTING FROM LOCKOUT
FILTERS
Furnace lockout results when a furnace is unable to achieve
ignition after three attempts during a single call for heat. It is
characterized by a non-functioning furnace and a E 0 code displayed on the dual 7-segment display. If the furnace is in “lockout”, it will (or can be) reset in any of the following ways.
1. Automatic reset. The integrated control module will
automatically reset itself and attempt to resume normal
operations following a one hour lockout period.
2. Manual power interruption. Interrupt 115 volt power to
the furnace.
3. Manual thermostat cycle. Lower the thermostat so that
there is no longer a call for heat for 1 -20 seconds then
reset to previous setting.
CAUTION
TO ENSURE PROPER UNIT PERFORMANCE, ADHERE TO THE FILTER SIZES GIVEN IN THE RECOMMENDED MINIMUM FILTER SIZE TABLE OR SPECIFICATION SHEET APPLICABLE TO YOUR MODEL.
FILTER MAINTENANCE
Improper filter maintenance is the most common cause of inadequate heating or cooling performance. Filters should be
cleaned (permanent) or replaced (disposable) every two months
or as required. When replacing a filter, it must be replaced with
a filter of the same type and size.
FILTER REMOVAL
NOTE: If the condition which originally caused the lockout still
exists, the control will return to lockout. Refer to the Diagnostic Depending on the installation, differing filter arrangements can
Chart for aid in determining the cause.
be applied. Filters can be installed in either the central return
register or a side panel external filter rack (upflow only). A
MAINTENANCE
media air filter or electronic air cleaner can be used as an alternate filter. Follow the filter sizes given in the Recommended
WARNING
Minimum Filter size table to ensure proper unit performance.
TO AVOID ELECTRICAL SHOCK, INJURY OR DEATH, DISCONNECT ELECTRICAL POWER BEFORE PERFORMING ANY MAINTENANCE. IF YOU MUST HANDLE THE IGNITER, HANDLE WITH CARE. TOUCHING THE IGNITER ELEMENT WITH BARE FINGERS, ROUGH HANDLING OR VIBRATION COULD DAMAGE THE IGNITER RESULTING IN PREMATURE FAILURE. ONLY A QUALIFIED SERVICER SHOULD EVER HANDLE THE IGNITER.
To remove filters from an external filter rack in an upright upflow
installation, follow the directions provided with external filter
rack kit.
HORIZONTAL UNIT FILTER REMOVAL
Filters in horizontal installations are located in the central return register or the ductwork near the furnace.
To remove:
1. Turn OFF electrical power to furnace.
2. Remove filter(s) from the central return register or
The furnace should be inspected by a qualified installer, or serductwork.
vice agency at least once per year. This check should be per3. Replace filter(s) by reversing the procedure for removal.
formed at the beginning of the heating season. This will ensure
4. Turn ON electrical power to furnace.
that all furnace components are in proper working order and
that the heating system functions appropriately. Pay particular MEDIA AIR FILTER OR ELECTRONIC AIR CLEANER REMOVAL
attention to the following items. Repair or service as necesFollow the manufacturer’s directions for service.
sary.
ANNUAL INSPECTION
•
•
•
•
•
•
Flue pipe system. Check for blockage and/or leakage.
Check the outside termination and the connections at
and internal to the furnace.
Heat exchanger. Check for corrosion and/or buildup
within the heat exchanger passageways.
Burners. Check for proper ignition, burner flame, and
flame signal.
Drainage system. Check for blockage and/or leakage.
Check hose connections at and internal to furnace.
Wiring. Check electrical connections for tightness and/
or corrosion. Check wires for damage.
Filters.
BURNERS
Visually inspect the burner flames periodically during the heating season. Turn on the furnace at the thermostat and allow
several minutes for flames to stabilize, since any dislodged
dust will alter the flames normal appearance. Flames should
be stable, quiet, soft, and blue (dust may cause orange tips
but they must not be yellow). They should extend directly
outward from the burners without curling, floating, or lifting off.
Flames must not impinge on the sides of the heat exchanger
firing tubes.
38
INDUCED DRAFT AND CIRCULATOR BLOWERS
BEFORE LEAVING AN INSTALLATION
The bearings in the induced draft blower and circulator blower
motors are permanently lubricated by the manufacturer. No further lubrication is required. Check motor windings for accumulation of dust which may cause overheating. Clean as necessary.
• Cycle the furnace with the thermostat at least three
•
•
FLAME SENSOR (QUALIFIED SERVICER ONLY)
Under some conditions, the fuel or air supply can create a
nearly invisible coating on the flame sensor. This coating acts
as an insulator causing a drop in the flame sense signal. If the
flame sense signal drops too low the furnace will not sense
flame and will lock out. The flame sensor should be carefully
cleaned by a qualified servicer using emery cloth or steel wool.
Following cleaning, the flame sense signal should be as indicated in the Specifications Sheet.
times. Verify cooling and fan only operation.
Review the Owner’s Manual with the homeowner and
discuss proper furnace operation and maintenance.
Leave literature packet near furnace.
REPAIR AND REPLACEMENT PARTS
• When ordering any of the listed functional parts, be sure
to provide the furnace model, manufacturing, and serial
numbers with the order.
• Although only functional parts are shown in the parts
list, all sheet metal parts, doors, etc. may be ordered by
description.
• Parts are available from your distributor.
FLUE PASSAGES (QUALIFIED SERVICER ONLY)
The heat exchanger flue passageways should be inspected at
the beginning of each heating season. If necessary, clean the
passageways as outlined in the following steps.
1. Turn OFF the electrical power and gas supply to the
furnace.
2. Disconnect the gas line and remove the burner/ manifold
assembly by removing the screws securing the assembly
to the partition panel.
3. Disconnect the flue pipe system from the induced draft
blower.
4. Remove the induced draft blower and collector box cover.
5. Clean the primary heat exchanger tubes using a wire
brush attached to a length of high grade stainless steel
cable, such as drain cleanout cable. Attach a variable
speed reversible drill to the other end of the cable. Slowly
rotate the cable with the drill and insert it into one of the
heat exchanger tubes. While reversing the drill, work
the cable in and out several times to obtain sufficient
cleaning. Repeat for each tube.
6. Clean residue from furnace using a vacuum cleaner.
7. Replace the parts removed in the previous steps in
reverse order.
8. Turn on electrical power and gas to furnace. Check for
leaks and proper unit operation.
9. Severe heat exchanger fouling is an indication of an
operational problem. Perform the checks listed in
Startup Procedure and Adjustments to reduce the
chances of repeated fouling.
Functional Parts ListGas Valve
Gas Manifold
Natural Gas Orifice
Propane Gas Orifice
Igniter
Flame Sensor
Rollout Limit Switch
Primary Limit Switch
Pressure Switch
Induced Draft Blower
Door Switch
39
Blower Motor
Blower Wheel
Blower Mounting Bracket
Blower Cutoff
Blower Housing
Inductor
Heat Exchanger
Auxiliary Limit Switch
Integrated Control Module
Transformer
TROUBLESHOOTING CHART
Symptoms of Abnormal Diagnostic/
Operation (Legacy &
Status LED
ComfortNet™ Thermostat)
Codes
Fault Description
• No 115 power to
furnace or no 24 volt
power to integrated
control module
• Blown fuse or circuit
breaker
• Integrated control
module has an
internal fault
ComfortNet™
Thermostat Only
Message
Code
INTERNAL
FAULT
EE
None
None
Possible Causes
Corrective Actions
Notes & Cautions
• Manual disconnect switch
OFF, door switch open or
24 volt wire improperly
connected or loose
• Blown fuse or circuit
breaker
• Integrated control module
has an internal fault
• Assure 115 and 24
volt power to furnace
and integrated control
module.
• Check integrated control
module fuse (3A).
Replace if necessary.
• Check for possible
shorts in 115 and 24
volt circuits. Repair as
necessary.
• Replace bad integrated
control module.
• Turn power OFF prior
to repair.
• Replace integrated
control module fuse
with 3A automotive
fuse.
• Read precautions
in “Electrostatic
Discharge” section of
manual.
• Replace control with
correct replacement
part
• Normal operation
• None
• Normal operation
• Locate and correct gas
interruption.
• Check front cover
pressure switch operation
(hose, wiring, contact
operation). Correct if
necessary.
• Replace or realign igniter.
• Check fame sense
signal. Sand sensor if
coated and/or oxidized.
• Check fue piping for
blockage, proper length,
elbows, and termination.
• Verify proper induced
draft blower performance.
• Turn power OFF prior
to repair.
• Igniter is fragile,
handle with care.
• Sand fame sensor
with emery cloth.
• See “Vent/Flue Pipe”
section for piping
details.
• Furnace fails to operate
• Integrated control module
LED display provides no
signal.
• ComfortNet™ thermostat
“Call for Service” icon
illuminated
• ComfortNet™ thermostat
scrolls “Check Furnace”
message
None
• LED display indicates On
On
• Normal operation
• Furnace fails to operate
• Integrated control module
LED display provides E0
error code.
• ComfortNet™ thermostat
“Call for Service” icon
illuminated.
• ComfortNet™ thermostat
scrolls “Check Furnace”
message.
E0
• Furnace lockout
due to an excessive
number of ignition
“retries” (3 total)
LOCKOUT
E0
• Failure to establish fame.
Cause may be no gas
to burners, front cover
pressure switch stuck
open, bad igniter or igniter
alignment, improper
orifces, or coated/oxidized
or improperly connected
fame sensor.
• Loss of fame after
establishment. Cause
may be interrupted gas
supply, lazy burner fames
(improper gas pressure
or restriction in fue and/
or combustion air piping),
front cover pressure switch
opening, or improper
induced draft blower
performance.
• Furnace fails to operate.
• Integrated control module
LED display provides E1
error code.
• ComfortNet™ thermostat
“Call for Service” icon
illuminated.
• ComfortNet™ thermostat
scrolls “Check Furnace”
message.
E1
• Low stage pressure
switch circuit is
closed at start of
heating cycle.
PS1
CLOSED
E1
• Low stage pressure switch • Replace low stage
contacts sticking.
pressure switch.
• Shorts in pressure switch • Repair short in wiring.
circuit wiring.
40
• Turn power OFF prior
to repair.
• Replace pressure
switch with proper
replacement part.
TROUBLESHOOTING CHART
Symptoms of Abnormal
Operation (Legacy
& ComfortNet™
Thermostat)
Diagnostic/
Status LED
Codes
Fault Description
ComfortNet™
Thermostat Only
Message
Code
Possible Causes
Corrective Actions
Notes & Cautions
• Induced draft blower
runs continuously with no
further furnace operation.
• Integrated control module
LED display provides E2
error code.
• ComfortNet™ thermostat
“Call for Service” icon
illuminated.
• ComfortNet™ thermostat
scrolls “Check Furnace”
message.
E2
• Low stage
pressure switch
circuit is not
closed.
PS1 OPEN
E2
• Pressure switch hose
blocked pinched, or
connected improperly.
• Blocked fue and/or inlet
air pipe, blocked drain
system or weak induced
draft blower.
• Incorrect pressure
switch set point or
malfunctioning switch
contacts.
• Loose or improperly
connected wiring.
• Inspect pressure switch
hose. Repair/replace if
necessary.
• Inspect fue and/or inlet
air piping for blockage,
proper length, elbows,
and termination. Check
drain system. Correct as
necessary.
• Check induced draft
blower performance.
Correct as necessary.
• Correct pressure switch
set point or contact
motion.
• Tighten or correct wiring
connection.
• Turn power OFF prior
to repair.
• Replace pressure
switch with proper
replacement part.
• Replace induced draft
blower with proper
replacement part.
• Circulator blower
runs continuously. No
furnace operation.
• Integrated control
module LED display
provides E3 error code.
• ComfortNet™
thermostat “Call
for Service” icon
illuminated.
• ComfortNet™
thermostat scrolls
“Check Furnace”
message.
E3
• Primary limit or
auxiliary limit
circuit is open.
• Rollout limit
circuit is open.
HIGH LIMIT
OPEN
E3
• Insuffcient conditioned
air over the heat
exchanger. Blocked
flters, restrictive
ductwork, improper
circulator blower
speed, or failed
circulator blower motor.
• Flame rollout.
• Misaligned burners,
blocked fue and/or
air inlet pipe, or failed
induced draft blower.
• Loose or improperly
connected wiring.
• Check flters and
ductwork for blockage.
Clean flters or remove
obstruction.
• Check circulator
blower speed and
performance. Correct
speed or replace blower
motor if necessary.
• Check burners for
proper alignment.
• Check fue and air inlet
piping for blockage,
proper length, elbows,
and termination.
Correct as necessary.
• Check induced draft
blower for proper
performance. Replace if
necessary.
• Tighten or correct
wiring connection.
• Turn power OFF
prior to repair.
• See Specifcation
Sheet applicable
to your model* for
allowable rise range
and proper circulator
speed.
• See "Vent/Flue Pipe"
section for piping
details.
• Induced draft blower
and circulator blower
runs continuously. No
furnace operation.
• Integrated control
module LED display
provides E4 error code.
• ComfortNet™
thermostat “Call
for Service” icon
illuminated.
• ComfortNet™
thermostat scrolls
“Check Furnace”
message.
E4
• Flame sensed
with no call for
heat.
IMPROPER
FLAME
E4
• Short to ground in
fame sense circuit.
• Lingering burner fame.
• Slow closing gas valve.
• Correct short at fame
sensor or in fame
sensor wiring.
• Check for lingering
fame.
• Verify proper operation
of gas valve.
• Turn power OFF
prior to repair.
• No furnace operation.
• Integrated control
module LED display
provides E5 error code.
• ComfortNet™
thermostat displays
“Battery Power”
E5
• Open Fuse
• Locate and correct
short in low voltage
wiring
• Turn power OFF
prior to repair.
• Replace fuse with
3-amp automotive
type
• Normal furnace
operation.
• Integrated control
module LED display
provides E6 error code.
E6
• Flame sense
micro amp signal
is low
• Sand fame sensor if
coated/oxidized.
• Inspect for proper
sensor alignment.
• Check inlet air piping
for blockage, proper
length, elbows, and
termination.
• Compare current gas
pressure to rating plate.
Adjust as needed.
• Turn power OFF
prior to repair.
• Sand fame sensor
with emery cloth.
• See "Vent/Flue Pipe"
section for piping
details.
• See rating plate for
proper gas pressure.
Not
Displayed
WEAK
FLAME
Not
• Short in low voltage
Displayed
wiring
E6
41
• Flame sensor is
coated/oxidized.
• Flame sensor
incorrectly positioned
in burner fame.
• Lazy burner fame
due to improper gas
pressure or combustion
air.
TROUBLESHOOTING CHART
Symptoms of Abnormal
Operation (Legacy
& ComfortNet™
Thermostat)
Diagnostic/
Status LED
Codes
Fault Description
ComfortNet™
Thermostat Only
Possible Causes
Message
Code
IGNITER
FAULT
E7
• Improperly connected
igniter.
• Shorted igniter.
• Poor unit ground.
• Igniter relay fault on
integrated control
module.
Corrective Actions
• Furnace fails to operate.
• Integrated control
module LED display
provides E7 error code.
• ComfortNet™
thermostat “Call
for Service” icon
illuminated.
• ComfortNet™
thermostat scrolls
“Check Furnace”
message.
E7
• Problem with
igniter circuit.
• Furnace fails to operate
on high stage; furnace
operates normally on low
stage.
• Integrated control module
LED display provides E8
error code.
E8
• High stage
pressure switch
circuit is closed
at start of heating
cycle.
• Induced draft
blower is
operating.
• Furnace is
operating on low
stage only
PS2 CLOSED
E8
• High stage pressure
• Replace high stage
switch contacts sticking.
pressure switch.
• Shorts in pressure
• Repair short in wiring
switch circuit wiring.
• Furnace fails to operate
on high stage; furnace
operates normally on low
stage.
• Integrated control module
LED display provides E9
error code.
E9
• High stage
pressure switch
circuit is not
closed.
• Induced draft
blower is
operating.
• Furnace is
operating on low
stage only
PS2 OPEN
E9
• Pressure switch hose
blocked pinched, or
connected improperly.
• Blocked fue and/or inlet
air pipe, blocked drain
system or weak induced
draft blower.
• Incorrect pressure
switch set point or
malfunctioning switch
contacts.
• Loose or improperly
connected wiring.
• Inspect pressure switch
hose. Repair/replace if
necessary.
• Inspect fue and/or inlet
air piping for blockage,
proper length, elbows,
and termination. Check
drain system. Correct as
necessary.
• Check induced draft
blower performance.
Correct as necessary.
• Correct pressure switch
set point or contact
motion.
• Tighten or correct wiring
connection.
• Furnace fails to operate.
• Integrated control module
LED display provides EA
error code.
• ComfortNet™ thermostat
“Call for Service” icon
illuminated.
• ComfortNet™ thermostat
scrolls “Check Furnace”
message.
EA
• Polarity of 115 volt
AC is reversed
REVERSED
PLTY
EA
• Polarity of 115 volt AC
power to furnace or
integrated module is
revered.
• Poor unit ground
• Review wiring diagram to • Turn power OFF prior
to repair.
correct polarity.
• Verify proper ground.
Correct if necessary.
• Check and correct
wiring.
• Integrated control
module LED display EF
error code.
• ComfortNet™ thermostat
“Call for Service” .
EF
• Aux switch open
Aux Alarm
Fault
EF
• High water level in the
evaporation coil.
• Check overfow pan and
service.
• Turn power OFF prior
to service.
• Furnace fails to operate.
• Integrated control module
LED display provides d0
error code.
• ComfortNet™ thermostat
“Call for Service” icon
illuminated.
• ComfortNet™ thermostat
scrolls “Check Furnace”
message.
d0
• Data not yet on
network.
NO NET
DATA
d0
• Furnace does not
• Populate shared data
contain any shared data.
set using memory card.
• Turn power OFF prior
to repair
• Use memory card for
the specifc model.
• Insert memory card
BEFORE turning
power ON. Memory
card may be removed
after data is loaded
and power is turned
off.
• Error code will be
cleared once data is
42
• Check and correct
wiring from integrated
control module to
igniter.
• Replace shorted igniter.
• Check and correct unit
ground wiring.
• Check igniter output
from control. Replace if
necessary.
Notes & Cautions
• Turn power OFF
prior to repair.
• Replace igniter with
correct replacement
part.
• Replace control with
correct replacement
part.
• Turn power OFF prior
to repair.
• Replace pressure
switch with proper
replacement part.
• Turn power OFF prior
to repair.
• Replace pressure
switch with proper
replacement part.
• Replace induced draft
blower with proper
replacement part.
TROUBLESHOOTING CHART
Symptoms of Abnormal
Diagnostic/
Operation (Legacy
Status LED Fault Description
& ComfortNet™
Codes
Thermostat)
ComfortNet™
Thermostat Only
Message
Code
Possible Causes
Corrective Actions
Notes & Cautions
• Operation different than
expected or no operation.
• Integrated control
module LED display
provides d4 error code.
• ComfortNet™ thermostat
“Call for Service” icon
illuminated.
• ComfortNet™ thermostat
scrolls “Check Furnace”
message.
d4
• Invalid memory
card data.
INVALID MC
DATA
d4
• Shared data set on
memory card has been
rejected by integrated
control module
• Furnace fails to operate.
• Integrated control
module LED display
provides b0 error code.
• ComfortNet™ thermostat
“Call for Service” icon
illuminated.
• ComfortNet™ thermostat
scrolls “Check Furnace”
message.
b0
MOTOR NOT
• Circulator blower
RUN
motor is not
running when it
should be running.
b0
• Loose wiring connection • Tighten or correct wiring
at circulator motor
connection.
power leads or
• Verify continuous
circulator motor power
circuit through inductor.
leads disconnected.
Replace if open or short
• Open circuit in inductor
circuit.
or loose wiring
• Check circulator blower
connection at inductor
motor. Replace if
(3/4 Hp and 1 Hp
necessary.
models only).
• Failed circulator blower
motor.
• Furnace fails to operate.
• Integrated control
module LED display
provides b1 error code.
• ComfortNet™ thermostat
“Call for Service” icon
illuminated.
• ComfortNet™ thermostat
scrolls “Check Furnace”
message.
b1
• Integrated control
module has lost
communications
with circulator
blower motor.
MOTOR
COMM
b1
• Loose wiring connection • Tighten or correct wiring • Turn power OFF prior
at circulator motor
connection.
to repair
control leads.
• Check circulator blower • Replace circulator
• Failed circulator blower
motor. Replace if
motor with correct
motor.
necessary.
replacement part.
• Failed integrated control • Check integrated control • Replace integrated
module.
module. Replace if
control module with
necessary.
correct replacement
part.
• Furnace fails to operate.
• Integrated control
module LED display
provides b2 error code.
• ComfortNet™ thermostat
“Call for Service” icon
illuminated.
• ComfortNet™ thermostat
scrolls “Check Furnace”
message.
b2
• Circulator blower
motor horse
power in shared
data set does not
match circulator
blower motor
horse power.
MOTOR
MISMATCH
b2
• Incorrect circulator
• Verify circulator blower if
blower motor in furnace.
motor horse power is the
same specifed for the
• Incorrect shared data
specifc furnace model.
set in integrated control
Replace if necessary.
module.
• Verify shared data set is
correct for the specifc
model. Re-populate data
using correct memory
card if required.
• Turn power OFF prior
to repair
• Replace motor with
correct replacement
part.
• Use memory card for
the specifc model
• Insert memory card
BEFORE turning
power ON. Memory
card may be removed
after data is loaded
and power is turned
off.
• Error code will be
cleared once shared
data and motor horse
power match.
• Furnace operates at
reduced performance.
• Airfow delivered is less
than expected.
• Integrated control
module LED display
provides b3 error code.
b3
• Circulator blower
motor is operating
in a power,
temperature, or
speed limiting
condition.
MOTOR
LIMITS
b3
•
•
•
•
• Turn power OFF prior
to repair.
43
Blocked flters.
Restrictive ductwork.
Undersized ductwork.
High ambient
temperatures.
• Verify shared data set is • Turn power OFF prior
correct for the specifc
to repair
model. Re-populate data • Use memory card for
using correct memory
the specifc model.
card if required.
• Insert memory card
BEFORE turning
power ON. Memory
card may be removed
after data is loaded
and power is turned
off.
• Error code will be
cleared once data is
loaded and power is
turned off.
• Check flters for
blockage. Clean flters
or remove obstruction.
• Check ductwork for
blockage. Remove
obstruction. Verify all
registers are fully open.
• Verify ductwork is
appropriately sized for
system. Resize/replace
ductwork if necessary.
• See "III. Product
Description" and "IV.
Location Requirements
& Considerations"
furnace installation
requirements.
• Turn power OFF prior
to repair
• Replace inductor with
correct replacement
part.
• Replace circulator
motor with correct
replacement part.
TROUBLESHOOTING CHART
Symptoms of Abnormal
Diagnostic/
Operation (Legacy
Status LED Fault Description
& ComfortNet™
Codes
Thermostat)
• Furnace fails to operate.
• Integrated control
module LED display
provides b4 error code.
• ComfortNet™ thermostat
“Call for Service” icon
illuminated.
• ComfortNet™ thermostat
scrolls “Check Furnace”
message.
b4
• Furnace fails to operate.
• Integrated control
module LED display
provides b5 error code.
• ComfortNet™ thermostat
“Call for Service” icon
illuminated.
• ComfortNet™ thermostat
scrolls “Check Furnace”
message.
b5
• Furnace fails to operate.
• Integrated control
module LED display
provides b6 error code.
• ComfortNet™ thermostat
“Call for Service” icon
illuminated.
• ComfortNet™ thermostat
scrolls “Check Furnace”
message.
b6
• Furnace fails to operate.
• Integrated control
module LED display
provides b7 error code.
• ComfortNet™ thermostat
“Call for Service” icon
illuminated.
• ComfortNet™ thermostat
scrolls “Check Furnace”
message.
b7
• Furnace operates at
reduced performance or
operates on low stage
when high stage is
expected.
• Integrated control
module LED display
provides b9 error code.
b9
• Circulator blower
motor senses
a loss of rotor
control.
ComfortNet™
Thermostat Only
Possible Causes
Corrective Actions
Notes & Cautions
Message
Code
MOTOR
TRIPS
b4
• Turn power OFF prior
to repair
b5
• Turn power OFF prior
to repair.
• Replace motor with
correct replacement
part.
• Replace wheel with
correct replacement
part.
• Circulator blower
motor senses
high current.
• Circulator blower MOTOR LCKD
ROTOR
motor fails to start
10 consecutive
times.
•
• Circulator blower
motor shuts down
for over or under
voltage condition.
• Circulator blower
motor shuts
down due to
over temperature
condition on
power module.
• Circulator blower
motor does not
have enough
information to
operate properly.
Motor fails to start
40 consecutive
times.
• Airflow is lower
than demanded.
MOTOR
VOLTS
b6
• Turn power OFF prior
to repair
•
•
•
MOTOR
PARAMS
b7
•
•
•
LOW ID
AIRFLOW
B9
44
• Blocked filters.
• Restrictive ductwork.
• Undersized ductwork.
• Check filters for
blockage. Clean filters
or remove obstruction.
• Check ductwork for
blockage. Remove
obstruction. Verify all
registers are fully open.
• Verify ductwork is
appropriately sized for
system. Resize/replace
ductwork if necessary.
• Turn power OFF prior
to repair.
STATUS CODES
INTERNAL CONTROL FAULT/NO POWER
O
E
E
E
n
NORMAL OPERATION
0
1
2
LOCKOUT DUE TO EXCESSIVE RETRIES
LOW STAGE PRESSURE SWITCH STUCK CLOSED AT START OF HEATING CYCLE
LOW STAGE PRESSURE SWITCH STUCK OPEN
E 3
E 4
OPEN HIGH LIMIT SWITCH
E 5
E 6
OPEN FUSE
E 7
E 8
IGNITER FAULT OR IMPROPER GROUNDING
E 9
E A
HIGH STAGE PRESSURE SWITCH STUCK OPEN
E F
d 0
d 4
AUXILIARY SWITCH OPEN
b
b
b
b
0
1
2
FLAME DETECTED WHEN NO FLAME SHOULD BE PRESENT
LOW FLAME SIGNAL
HIGH STAGE PRESSURE SWITCH STUCK CLOSED AT START OF HEATING CYCLE
REVERSED 115 VAC POLARITY
DATA NOT YET ON NETWORK
INVALID MEMORY CARD DATA
BLOWER MOTOR NOT RUNNING
BLOWER COMMUNICATION ERROR
BLOWER HP MIS-MATCH
3
b 4
BLOWER MOTOR OPERATING IN POWER, TEMPERATURE, OR SPEED LIMIT
b 5
b 6
b 7
b 9
C 1
C 2
BLOWER MOTOR LOCKED ROTOR
BLOWER MOTOR CURRENT TRIP OR LOST ROTOR
OVER/UNDER VOLTAGE TRIP OR OVER TEMPERATURE TRIP
INCOMPLETE PARAMETERS SENT TO MOTOR
LOW INDOOR AIRFLOW
LOW STAGE COOL
HIGH STAGE COOL
P 1
P 2
L 0
HIGH STAGE HEAT PUMP HEAT
H I
HIGH STAGE GAS HEAT
F
1 2
LOW STAGE HEAT PUMP HEAT
LOW STAGE GAS HEAT
CONTINUOUS FAN
CFM/100; ALTERNATES WITH
C 1 , C 2, L O , H I
P 1,P 2
45
,
F
0140F01169 REV A
AIR FLOW DATA
Speed Selection Dip Switches
Cool
Selection
Switches
TAP
Adjust
Selection
Switches
Profile
Selection
Switches
S3- 1 S3- 2 S3- 3 S3- 4 S4-1
S4-2
Model
Heat
Selection
Switches
High Stage
Cool
Low Stage
Heat
High Stage
Heat
A
B
C
D
390
520
650
780
600
800
1000
1200
735
805
875
945
1050
1150
1250
1350
*DVC80805C***
A
B
C
D
520
715
910
1170
800
1100
1400
1800
945
1015
1085
1155
1350
1450
1550
1650
60 sec/100% *DVC81005C***
A
B
C
D
553
748
943
1203
850
1150
1450
1850
1085
1155
1225
1260
1550
1650
1750
1800
*MVC80604B***
A
B
C
D
390
520
715
910
600
800
1100
1400
875
945
1015
1085
1250
1350
1450
1550
*MVC80805C***
A
B
C
D
520
715
910
1170
800
1100
1400
1800
1050
1120
1190
1260
1500
1600
1700
1800
*MVC81005C***
A
B
C
D
520
715
910
1170
800
1100
1400
1800
1210
1225
1245
1260
1725
1750
1775
1800
S4- 3 S4- 4
OFF
OFF OFF OFF
OFF OFF
OFF
OFF
B
ON
OFF
C
D
Profiles
Low Stage
Cool
*DVC80603B***
A
ON
OFF
ON
OFF
ON
OFF
OFF
ON OFF
ON
OFF
ON
OFF
ON
ON
ON
ON
ON
ON
ON
ON
ON
Tap
Pre-Run
Short-Run
OFF Delay
A
-------
--------
B
-------
30 sec/50%
C
-------
7.5 min/82%
60 sec/100%
D
30 sec/50%
7.5 min/82%
30 sec/50%
60 sec/100%
To Set Airflow: (1) Select model and desired High Stage Cooling Airflow. Determine
the corresponding tap (A, B, C, or D). Set dip switches S3-1* and S3-2* to the
appropriate ON / OFF positions. (2) Select model and desired High Stage Heating
Airflow. Determine the corresponding tap (A, B, C, or D). Set dip switches S4-3* and
S4-4* to the appropriate ON / OFF positions. (3) Selecting Airflow Adjustment Factor:
For 0% trim set S5-2* to OFF (trim disabled). If trim is desired set S5-2* to ON (trim
enabled) and set S3-3* and S3-4* to appropriate ON / OFF positions. Tap A is +5%,
Tap B is -5%, Tap C is +10%, Tap D is -10%.
To Set Comfort Mode: Select Desired Comfort Mode profile (see profiles above). Set
dip switches S4-1* and S4-2* to the appropriate ON / OFF positions.
Dehumidification: To enable, set switch S5-1* to ON. Cooling airflow will be reduced
to 85% of nominal value during cool call. To disable, set switch S5-1* to OFF.
Continuous Fan Speed: Set dip switches S5-3* and S5-4* to select one of 4
continuous fan speeds (25%, 50%, 75%, or 100%). " See installation manual
for details"
*the “S” number refers to one of four labeled dip switch section each containing 4
individual dip switches. The following number refers to the individual labeled dip
switch within that section
0140F01170
NOTE: Airflow data shown applies to non-communicating mode operation only. For a fully communicating
system, please see the outdoor unit’s installation instructions for cooling and pump heating airflow data. See
ComfortNet™ System - Airflow Consideration section for details.
46
DIP SWITCHES
Switch Bank
Purpose
Heating Off Delay
S1
Thermostat Setup
Cooling Airflow
S3
Trim
Ramping Profile
S4
Heating Airflow
Dehum
Trim
S5
Continuous Fan
Function
90
120
150
180
2 Stage Stat
2 Stage Stat
1 Stg Stat 5 min delay
1 Stg Stat auto delay
A
B
C
D
Add 5%
Minus 5%
Add 10%
Minus 10%
A
B
C
D
A
B
C
D
Disabled
Enabled
Disabled
Enabled
25%
50%
75%
100%
47
1
Off
On
Off
On
Off
On
Off
On
Off
On
Off
On
Dip Switch
2
3
Off
Off
On
On
On
On
Off
Off
Off
Off
On
On
Off
On
Off
On
Off
Off
On
On
Off
On
Off
On
4
On
Off
Off
On
Off
Off
On
On
Off
Off
On
On
Off
On
Off
On
Off
On
Off
On
Off
Off
On
On
*MVC8, *DVC8 WIRING DIAGRAM
TO
115 VAC/ 1 Ø /60 HZ
POWER SUPPLY WITH
OVERCURRENT
PROTECTION DEVICE
GND
C
BK
WH
3
2
PM
1
DISCONNECT
TO 115VAC/ 1 Ø /60 HZ POWER SUPPLY WITH
OVERCURRENT PROTECTION DEVICE
YL
WARNING:
DISCONNECT POWER
BEFORE SERVICING.
WIRING TO UNIT
MUST BE PROPERLY
POLARIZED AND
GROUNDED.
BL
WH
BR
OR
RD
PU
CHASSIS GROUND
AUTO RESET PRIMARY
LIMIT CONTROL
PU
PU
3
1
N
DISCONNECT
DOOR
SWITCH
JUNCTION BOX
INDUCTOR COIL
70kBTU,90kBTU,
115kBTU MODELS
ONLY
GN
INDUCED
DRAFT
BLOWER
WH
RD
BK
2
GND
L
INDOOR
AIR
CIRCULATOR
BLWR
GND
HUM-IN
GND
BURNER COMPARTMENT
LINE
AUTO RESET
AUXILIARY
LIMIT CONTROL
5 CIRCUIT CONNECTOR
HUM
HUMIN
HUMOUT
NEUTRAL
OR
BK
EAC
LINE
BK
FS
5
4
SEE NOTE 6
INTEGRATED CONTROL MODULE
BK
RD
WH
PU
BLOWER COMPARTMENT
3
NEUTRAL
HUMIDIFIER
HUM-OUT
YL
ELECTRONIC
AIR CLEANER
HEAT AF
YL
RD
14
15
10
11
12
7
8
9
4
5
6
DEHUM ENABLE
TRIM ENABLE
CONT FAN
HEAT OFF DLY
RD
T-STAT
1
2
IGN
HOT SURFACE
IGNITER
FUSE 3 A
BL
3
FLAME SENSOR
115 VAC
1
24
VAC
115
VAC
40 VA
TRANSFORMER
DIAGNOSTIC
LED'S
TO +VDC
Y1
PSO (7)
W1
LOW FIRE PRESS.
SWITCH
24V HUM.
PS1 (2)
C
NO
W2
PS2 (12)
TO
MICRO
Y2
NO
C
HIGH FIRE
PRESS. SWTICH
O
Y1
Y2
G
W2
C
W1
1
R
2
DEHUM
MANUAL RESET ROLLOUT
LIMIT CONTROLS
G
WH
AUTO RESET PRIMARY
LIMIT CONTROL
AUTO RESET AUXILIARY LIMIT
CONTROLS
HLO (10)
HLI (1)
O
DEHUM
FUSE
MVL (13)
24 V THERMOSTAT CONNECTIONS
BL
24V HUM.
WH
ECM MTR RD
HARNESS
40 VA
TRANSFORMER
24 VAC
RD
2
NEUTRAL
TH (4)
R
BK
PU
YL
24 V
3A
4
3
SEE
NOTE 5
NEUTRAL
IND LO
FS
TWO-STAGE
INTEGRATED
CONTROL
MODULE
RD
13
NEUTRAL
ID
BLWR
1
24V THERMOSTAT CONNECTIONS
BR
DIP SWITCHES
BL
WH
COOL PRFL
NEUTRAL
IND HI
2
4 CIRCUIT MOTOR
CONNECTOR
GN
BL
TRIM %
NEUTRAL
HUMIDIFIER
HUM
EAC
LINE
COOL AF
PM
MVH (14)
C
HI
MVC (8)
C
GAS
VALVE
GND (5)
GY
BK
4
BK
5
4
3
2
1
BK
GR
PK
BK
TO
R
WH
GND
TR (11)
BK
3
2
1
INTEGRATED CONTROL MODULE
HIGH VOLTAGE!
DISCONNECT ALL POWER BEFORE SERVICING OR INSTALLING THIS UNIT.
MULTIPLE POWER SOURCES MAY BE PRESENT. FAILURE TO DO SO MAY
CAUSE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.
WH
FLAME
SENSOR
MANUAL RESET ROLLOUT LIMIT
CONTROLS
WARNING:DISCONNECT
POWER BEFORE
SERVICING. WIRING
TO UNIT MUST BE
PROPERLY POLARIZED
AND GROUNDED.
N
NO
HIGH FIRE
PRESSURE SWITCH
GAS VALVE
(HONEY WELL)
C
L
BK
C
NO
TWO STAGE
HI
JUNCTION BOX
YL
SWITCH
2 CIRCUIT
CONNECTOR
BL
LOW FIRE
PRESSURE
YL
2 1
24V HUM.
WH
BR
SWITCH ASSEMBLY
HOT
SURFACE
IGNITER
YL
YL
RD
ID BLOWER TWO-STAGE PRESSURE
GND (4)
+ VDC (1)
GND
CIRCULATOR
BLOWER
INDUCTOR COIL
BLOWER
COMPARTMENT
DOOR SWITCH
(OPEN WHEN
DOOR OPEN)
INDOOR
AIR
CIRCULATOR
BLWR
RX (2)
TO
MICRO
TX (3)
AUX
INTEGRATED CONTROL MODULE
HUMIDIFIER
NOTES:
1. SET HEAT ANTICIPATOR ON ROOM THERMOSTAT AT 0.7 AMPS.
2. MANUFACTURER'S SPECIFIED REPLACEMENT PARTS MUST BE USED WHEN SERVICING.
3. IF ANY OF THE ORIGINAL WIRE AS SUPPLIED WITH THE FURNACE MUST BE REPLACED,
IT MUST BE REPLACED WITH WIRING MATERIAL HAVING A TEMPERATURE RATING OF
AT LEAST 105 $ C. USE COPPER CONDUCTORS ONLY.
4. UNIT MUST BE PERMANENTLY GROUNDED AND CONFORM TO N.E.C. AND LOCAL CODES.
5. TO RECALL THE LAST 6 FAULTS, MOST RECENT TO LEAST RECENT, DEPRESS SWITCH FOR MORE
THAN 2 SECONDS WHILE IN STANDBY (NO THERMOSTAT INPUTS)
6. HUMIDIFIER INSTALLATION OPTIONS: USE HUM TERMINAL TO RUN HUMIDIFIER DURING HEAT CALL
(COMMUNICATING OR LEGACY MODES). USE HUM-IN AND HUM-OUT TERMINALS TO RUN
HUMIDIFIER DURING HEAT CALL ( COMMUNICATING MODE OR LEGACY MODE) OR INDEPENDENTLY
FROM HEAT CALL (COMMUNICATING MODE ONLY - SETUP IS DONE WITHIN COMMUNICATING
THERMOSTAT)
COLOR CODES:
PK PINK
BR BROWN
WH WHITE
BL BLUE
GY GRAY
RD RED
YL YELLOW
OR ORANGE
PU PURPLE
GN GREEN
BK BLACK
LOW VOLTAGE (24V)
LOW VOLTAGE FIELD
HI VOLTAGE (115V)
HI VOLTAGE FIELD
JUNCTION
TERMINAL
INTERNAL TO
INTEGRATED CONTROL
PLUG CONNECTION
EQUIPMENT GND
FIELD GND
FIELD SPLICE
SWITCH (TEMP.)
IGNITER
SWITCH (PRESS.)
OVERCURRENT
PROT. DEVICE
0140F01168-B
Wiring is subject to change. Always refer to the wiring diagram on the unit for the most up-to-date wiring.
48