Whirlpool WFD195 Instruction manual

GAS-FIRED WARM AIR FURNACE INSTALLATION INSTRUCTIONS
(Type FSP Category IV Direct or Nondirect Vent Air Furnace)
ATTENTION INSTALLATION 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 operations.
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.
PLACEHOLDER
FOR BAR CODE
Whirlpool Gold® Models
WGFM195, WFD195
WPIO-299H
These furnaces comply with requirements embodied in the
American National Stardard/National Standard of Canada ANSI
Z21.47 CSA-2.3 Gas Fired Central Furnaces.
NOTE: Please contact your distributor or our website for
applicable Specification Sheet referred to in this manual.
Tradewinds Distributing Company, LLC
14610 Breakers Drive
Jacksonville, Florida 32258
TABLE OF CONTENTS
GAS FURNACE SAFETY PRECAUTIONS ....................................3
Electrostatic Discharge (ESD) Precautions..................................4
PRODUCT DESCRIPTION AND APPLICATION ..........................4
Shipping Inspection .....................................................................4
To the Installer..............................................................................4
Important Note to the Owner Regarding Product Warranty .......4
Component Identification.............................................................5
Product Application......................................................................5
LOCATION REQUIREMENTS AND CONSIDERATIONS ............6
Clearances and Accessibility .......................................................7
Furnace Suspension ....................................................................8
Existing Furnace Removal ...........................................................8
Thermostat Location ....................................................................8
COMBUSTION AND VENTILATION AIR REQUIREMENTS........8
INSTALLATION POSITIONS.......................................................11
HORIZONTAL APPLICATIONS AND CONSIDERATIONS........11
General .......................................................................................11
Drain Trap and Lines ..................................................................11
Leveling ......................................................................................11
Alternate Vent/Flue Connections ...............................................11
Alternate Electrical and Gas Line Connections .........................12
Drain Pan....................................................................................12
Freeze Protection .......................................................................12
Furnace Suspension ..................................................................12
PROPANE GAS/HIGH ALTITUDE INSTALLATIONS .................13
VENT/FLUE PIPE AND COMBUSTION AIR PIPE......................13
General .......................................................................................13
Dual Certification: Nondirect/Direct Vent...................................13
Materials and Joining Methods..................................................13
Proper Vent/Flue and Combustion Air Piping Practices ...........14
Termination Locations................................................................14
Canadian Venting Requirements ...............................................14
Standard Furnace Connections.................................................15
Vent/Flue Pipe ............................................................................15
Combustion Air Pipe—Direct Vent Installations ........................15
Combustion Air Pipe—Nondirect Vent Installations..................15
Alternate Furnace Connections .................................................15
Alternate Vent/Flue Location......................................................16
Nondirect Vent (Single Pipe) Piping...........................................17
Vent/Flue Pipe Lengths and Diameters .....................................17
Vent/Flue Pipe Terminations ......................................................17
Direct Vent (Dual Pipe) Piping ....................................................18
Vent/Flue and Combustion Air Pipe Lengths and Diameters....18
Vent/Flue and Combustion Air Pipe Terminations ....................19
Vent/Intake Terminations for Installation of Multiple Direct Vent
Furnaces.....................................................................................20
Concentric Vent Termination .....................................................20
Side Wall Vent Kit.......................................................................21
CONDENSATE DRAIN LINES AND DRAIN TRAP .....................21
Standard Right or Left Side Drain Hose Connections...............21
Upright Installations—Trap on Right Side .................................21
Upright Installations—Trap on Left Side....................................22
Upright Drain Trap Mounting—Left or Right Side Panel ...........23
Horizontal Installations—Right Side Down................................23
Horizontal Installations—Left Side Down ..................................23
Horizontal Drain Trap Mounting—Left or Right Side Panel.......24
ELECTRICAL CONNECTIONS ....................................................24
Wiring Harness ...........................................................................24
115-Volt Line Connections.........................................................24
Junction Box Relocation............................................................25
24-Volt Thermostat Wiring .........................................................25
115-Volt Line Connection of Accessories (Humidifier and
2
Electronic Air Cleaner)................................................................25
GAS SUPPLY AND PIPING..........................................................26
High Altitude Derate ...................................................................26
Propane Gas Conversion ...........................................................26
Gas Control Valve.......................................................................27
Gas Piping Connections ............................................................27
Gas Piping Checks.....................................................................29
Propane Gas Tanks and Piping .................................................29
CIRCULATING AIR AND FILTERS ..............................................31
Ductwork—Airflow .....................................................................31
Bottom Return Air Opening—Upflow Models] ..........................31
Filters—Read This Section Before Installing the Return
Air Ductwork...............................................................................31
START-UP PROCEDURE AND ADJUSTMENT .........................33
Heat Anticipator Setting .............................................................33
Drain Trap Priming......................................................................33
Furnace Operation......................................................................33
Furnace Start-Up........................................................................33
Furnace Shutdown .....................................................................33
Gas Supply Pressure Measurement ..........................................33
Gas Manifold Pressure Measurement and Adjustment.............34
Gas Input Rate Measurement—Natural Gas Only.....................35
Temperature Rise .......................................................................35
Circulator Blower Speeds ..........................................................36
NORMAL SEQUENCE OF OPERATION .....................................36
Power Up....................................................................................36
Heating Mode—Mode DIP Switch Set to 1 STG Position.........36
Heating Mode—Mode DIP Switch Set to 2 STG Position.........36
Cooling Mode .............................................................................37
Fan Only Mode ...........................................................................37
Operational Checks....................................................................37
SAFETY CIRCUIT DESCRIPTION ...............................................37
General .......................................................................................37
Integrated Control Module .........................................................37
Primary Limit Control..................................................................37
Auxiliary Limit Control(s).............................................................37
Rollout Limit Control(s)...............................................................37
Pressure Switches......................................................................37
Flame Sensor..............................................................................37
MAINTENANCE ............................................................................38
Annual Inspection.......................................................................38
Filters ..........................................................................................38
Burners .......................................................................................38
Induced Draft and Circulator Blowers........................................38
Condensate Trap and Drain System (Qualified Servicer Only)..38
Flame Sensor (Qualified Servicer Only)......................................38
Igniter (Qualified Servicer Only)..................................................38
Flue Passages (Qualified Servicer Only) ....................................39
Before Leaving an Installation....................................................39
Repair and Replacement Parts ..................................................39
TROUBLESHOOTING ..................................................................39
Electrostatic Discharge (ESD) Precautions................................39
Fault Recall .................................................................................39
Resetting from Lockout..............................................................39
Diagnostic Chart.........................................................................40
BLOWER PERFORMANCE DATA...............................................42
WIRING DIAGRAM—WFD195 .....................................................44
WIRING DIAGRAM—WGFM195..................................................45
WIRING DIAGRAM—WGFM195..................................................46
WIRING DIAGRAM—WFD195 .....................................................47
ASSISTANCE OR SERVICE .........................................................48
GAS FURNACE SAFETY PRECAUTIONS
Please 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.
Recognize this symbol as a safety precaution.
WARNING
Hazards or unsafe practices could result in property
damage, product damage, severe personal injury or death.
CAUTION
Hazards or unsafe practices may result in property
damage, product damage, personal injury or death.
WARNING
The manufacturer 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.
WARNING
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.
WARNING
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 may be 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.
DANGER
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, service agency
or the gas supplier.
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.
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 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.
CO can cause serious illness including permanent brain
damage or death.
3
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
HIGH VOLTAGE!
To avoid property damage, personal injury or
death due electrical shock, the furnace must
be located so that the electrical components
are protected from water damage.
Electrostatic Discharge (ESD) Precautions
NOTE: Discharge static electricity accumulated in the body
before touching the unit. An electrostatic discharge can adversely
affect electrical components.
Use the following steps during furnace installations 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 noninstalled (ungrounded)
furnaces.
1. Disconnect all power to the furnace.
NOTE: 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 also.
3. Service the integrated control module or connecting wiring
after following the discharge process in Step 2.
NOTE: Do not recharge your body with static electricity by
moving or shuffling your feet or touching ungrounded
objects. If you touch an ungrounded object, repeat Step 2
before touching the control or wires.
4. Follow steps 1 through 3 before removing a new control from
its container or installing the control on a furnace. Return any
old or new controls to their containers before touching any
ungrounded object.
PRODUCT DESCRIPTION AND APPLICATION
■
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.
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 the delivery receipt of any visible damage
to the shipment or container.
2. Notify the carrier promptly and request an inspection.
3. With concealed damage, the carrier must be notified as soon
as possible—preferably within 5 days.
4. File the claim with the following support documents within a
9-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.
The carrier is responsible for making prompt inspection of the
damage and for a thorough investigation of each claim. The
distributor or manufacturer will not accept claims from dealers for
transportation damage.
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:
4
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Unit maximum external static pressure
Gas pressures
Btu input rating
Proper electrical connections
Circulating air temperature rise
Minimum or maximum CFM
Motor speed connections
Important Note to the Owner Regarding
Product Warranty
To receive the Lifetime Heat Exchanger Limited Warranty and the
10-Year Parts Limited Warranty, online registration must be
completed within 60 days of installation. Online registration is not
required in California or Quebec.
Full warranty details and instructions are available at
www.whirlpoolhvac.com.
Your warranty certificate is supplied as a separate document with
the unit installed by your contractor. Read the limited warranty
certificate carefully to determine what is and is not covered. Keep
the warranty certificate in a safe place. If you are unable to locate
the warranty certificate, please contact your installing contractor,
or contact customer service at 1-866-944-7575 to obtain a copy.
To register your unit, go to www.whirlpoolhvac.com. Click on the
manufacturer’s Comfort CommitmentTM Warranty link located at
the bottom center of the home page. Next, click on the Click
Here to Register Your Product link located at the top center of the
page, and complete the forms in the manner indicated.
WARNING
To prevent property damage, personal injury or death due
to fire, do not install the furnace in a mobile home, trailer
or recreational vehicle.
Component Identification
Upflow/Horizontal
E
Counterflow/Horizontal
F G
G
H
I J
E
Z
AA
J
K
L
*
*
*
*
*
*
*
A
*
B
AE
AD
AC
M
X
O
Y
P
R
R
S
N
Q
C
W
AB
V
T
U
O
N
Burner Compartment
K
C
S
T
AC
AE
P
Q
AD
CU
T FOR
DEHU
M
R
V
AB
W
R
S
T
T
M
B
L
AA
Z
I
A. Gas control valve
B. Gas line entrance (alternate)
C. Pressure switch
D. Gas manifold
E. Combustion air intake connection/
coupling
F. Hot surface igniter
G. Rollout limit switch
H. Burners
U
A
X
Y
S
Blower Compartment
Burner Compartment
C
*
Blower Compartment
AF
D
G
H
I. Flame sensor
Q. Electrical connection inlets (alternate)
J. Flue pipe connection/coupling
R. Coil front cover pressure tap
K. Flue pipe
S. Coil front cover drain port
L. Primary limit switch
T. Drain line penetrations
M. Gas line entrance
U. Drain trap
N. Flue pipe connection (alternate) V. Blower door interlock switch
O. Rubber elbow
W. Capacitor
P. Induced draft blower
X. 24-volt thermostat connections
G F
D
Y. Integrated control module (with
fuse and diagnostic LED)
Z. Transformer (40VA)
AA. Circulator blower
AB. Auxiliary limit switch
AC. Junction box
AD. Electrical connection inlets
AE. Coil front cover
AF. Combustion air inlet pipe
Product Application
This furnace is primarily designed for residential home-heating
applications.
IMPORTANT:
■ This furnace is not designed or certified for use in mobile
homes, trailers or recreational vehicles.
■ This furnace is not designed or certified for outdoor
applications.
■ The furnace must be installed indoors (for example, 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 nonindustrial
commercial applications:
■
■
■
■
Schools
Office buildings
Churches
Retail stores
■
■
■
■
Nursing homes
Hotels/motels
Common areas
Office areas
It must be installed according to the installation instructions
provided and according to 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 “makeup” air unit.
■ It must be installed with 2-pipe systems for combustion air,
especially if VOC’s or other contaminants are present in the
conditioned space.
■ All other warranty exclusions and restrictions apply.
This furnace is an ETL dual-certified appliance and is appropriate
for use with Natural or propane gas
NOTE: If you are using propane, a propane conversion kit is
required.
■
NOTE: In such applications, the furnace must be installed with
the following stipulations:
5
Dual certification means that the combustion air inlet pipe is
optional, and the furnace can be vented as a:
■ Nondirect vent (single pipe) central forced air furnace in
which combustion air is taken from the installation area or
from air ducted from the outside or a,
■ Direct vent (dual pipe) central forced air furnace in which all
combustion air supplied directly to the furnace burners
through a special air intake system outlined in these
instructions.
This furnace may be used as a construction site heater only if all
of the following conditions are met:
■ The vent system is permanently installed according to these
installation instructions.
■ A room thermostat is used to control the furnace. Fixed
jumpers that provide continuous heating cannot be used and
can cause long term equipment damage.
■ Return air ducts are provided and sealed to the furnace.
■ A return air temperature range between 60ºF and 80ºF (16ºC
and 27ºC) is maintained.
■ Air filters are installed in the system and maintained during
construction, replaced as appropriate during construction
and upon completion of construction.
■ The input rate and temperature rise are set according to 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 or CAN/CSA
B149.1 Installation Codes.
■ The furnace heat exchanger, components, duct system, air
filters and evaporator coils are thoroughly cleaned following
the final construction cleanup.
■ All furnace operating conditions (including ignition, input rate,
temperature rise and venting) are verified according to these
installation instructions.
NOTE: The Commonwealth of Massachusetts requires that the
following additional requirements must also be met:
■ Gas furnaces must be installed by a licensed plumber or gas
fitter.
■ A T-handle gas cock must be used.
■ If the unit is to be installed in an attic, the passageway to and
the service area around the unit must have flooring.
■
To ensure proper installation and operation, thoroughly read
this manual for specifics pertaining to the installation and
application of this product.
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.
WARNING
To prevent property damage, personal injury or death due
to fire, do not install the furnace in a mobile home, trailer
or recreational vehicle.
To ensure proper furnace operation, you must 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.
A copy of the National Fuel Gas Code (NFPA 54/ANSI Z223.1)
can be obtained from any of the following:
American National Standards Institute
1430 Broadway
New York, NY 10018
National Fire Protection Association
1 Batterymarch Park
Quincy, MA 02269
CSA International
8501 East Pleasant Valley
Cleveland, OH 44131
A copy of the CAN/CSA B149 Installation Codes can also be
obtained from:
CSA International
178 Rexdale Boulevard
Etobicoke, Ontario, Canada M9W 1R3
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.
LOCATION REQUIREMENTS AND CONSIDERATIONS
WARNING
■
Goodman 50
To prevent possible equipment damage, property damage,
personal injury or death, the following bullet points must
be observed when installing the unit.
Follow the instructions listed below when selecting a furnace
location. Refer also to the guidelines provided in “Combustion
and Ventilation Air Requirements.”
■ Centrally locate the furnace with respect to the proposed or
existing air distribution system.
■ Check that the temperature of the return air entering the
furnace is between 55°F and 100°F (13ºC and 38ºC) when the
furnace is heating.
6
■
Provide provisions for venting combustion products outdoors
through a proper venting system. Special consideration
should be given to the vent/flue pipe routing and the
combustion air intake pipe when applicable. Refer to
“Termination Locations” in “Vent/Flue Pipe and Combustion
Air Pipe” for appropriate termination locations and to
determine if the piping system from the furnace to the
termination can be accomplished within the guidelines given.
NOTE: The length of flue and/or combustion air piping can be
a limiting factor in the location of the furnace.
Locate the furnace so that the condensate flows downward
to the drain.
NOTE: Do not locate the furnace or its condensate drainage
system in any area subject to below freezing temperatures
without the proper freeze protection. Refer to “Condensate
Drain Lines and Trap” for further details.
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Check that 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.”
Set the furnace on a level floor to enable proper condensate
drainage. If the floor becomes wet or damp at times, place
the furnace above the floor on a concrete base sized
approximately 1¹⁄₂" (3.8 cm) larger than the base of the
furnace. Refer to “Horizontal Applications and
Considerations” for leveling of horizontal furnaces.
Check that the upflow or horizontal furnaces are not installed
directly on carpeting, or any other combustible material.
NOTE: The only combustible material allowed is wood.
A special accessory subbase must be used for the upright
counterflow unit installations over any combustible material
(including wood). Refer to subbase instructions for installation
details.
NOTE: A subbase will not be required if an air conditioning
coil is located beneath the furnace between the supply air
opening and the combustible floor.
Exposure to contaminated combustion air will result in safety
and performance-related problems.
NOTE: Do not install the furnace where the combustion air is
exposed to the following substances:
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
Masonry acid washing materials
Seal off a nondirect vent furnace if it is installed near an area
frequently contaminated by any of the above substances.
This protects the nondirect vent furnace from airborne
contaminants. To ensure that the enclosed nondirect vent
furnace has an adequate supply of combustion air, vent from
a nearby uncontaminated room or from outdoors. Refer to
“Combustion and Ventilation Air Requirements” for details.
If the furnace is used in connection with a cooling coil unit,
install the furnace upstream or in parallel with the cooling coil
unit. Premature heat exchanger failure will result if the cooling
coil unit 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" (45.7 cm) above the floor. Protect the
furnace from physical damage by vehicles.
If the furnace is installed horizontally, ensure the furnace
access doors are not on the “up/top” or “down/bottom” side
of the furnace. The furnace access doors must be vertical so
that the burners fire horizontally into the heat exchanger.
Do not connect the furnace to a chimney flue that serves a
separate appliance designed to burn solid fuel.
On counterflow installations, the air conditioning coil must be
downstream on the supply (positive) side of the furnace heat
exchanger.
Counterflow Installation Over a Noncombustible Floor
Before setting the furnace over the plenum opening, ensure
that the surface around the opening is smooth and level. A
tight seal should be made between the furnace base and
floor by using a silicone 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 for
your model for details). A special accessory subbase must be
used for upright counterflow unit installations over any
combustible material including wood. Refer to subbase
instructions for installation details. Follow the instructions with
the subbase for proper installation.
NOTES:
■ Do not install the furnace directly on carpeting, tile or
other combustible material other than wood flooring.
■ The subbase will not be required if an air conditioning coil
is installed between the supply air opening on the furnace
and the floor.
■
Clearances and Accessibility
Installations must adhere to the clearances to combustible
materials to which this furnace has been design-certified. The
minimum clearance information for this furnace is provided on
the unit’s clearance label. These clearances must be permanently
maintained.
Clearances must also accommodate an installation’s gas,
electrical, drain trap and drain line connections. If the alternate
vent/flue connection is used, additional clearance must be
provided to accommodate these connections. Refer to “Vent/
Flue Pipe and Combustion Air Pipe” for details.
NOTE: In addition to the required clearances to combustible
materials, a minimum of 24" (61 cm) service clearance must be
available in front of the unit.
A
A
B
B
B
Upflow
C
A. Top
B. Side
Counterflow
C
Horizontal
C. Bottom
A furnace installed in a confined space (for example, a closet or
utility room) must have 2 ventilation openings with a total
minimum free area of 0.25 sq. in. per 1,000 Btu/h of furnace input
rating. Refer to the Specification Sheet applicable to your model
for minimum clearances to combustible surfaces. One of the
ventilation openings must be within 12" (30.5 cm) of the top. The
other opening must be within 12" (30.5 cm) of the bottom of the
confined space. In a typical construction, the clearance between
the door and door frame is usually adequate to satisfy this
ventilation requirement.
Furnace Suspension
If suspending the furnace from rafters or joists, use ³⁄₈" threaded
rod and 2" x 2" x ¹⁄₈" (5.1 cm x 5.1 cm x 3.2 mm) angle iron as
shown in “Suspended Furnace” illustration. The length of rod will
depend on the application and the clearances necessary.
7
Suspended Furnace
B
A
C
H
G
F
E
A. ³⁄₈" (1 cm) diameter threaded
rod (6)
B. 8" (20.3 cm) minimum clearance
between center rod and furnace
cabinet to allow for circulator
blower removal.
C. Level furnace end to end, slight
forward tilt with front 0" to ³⁄₄"
(1.9 cm) below back.
D
D. Tilt outward to allow for door and
circulator blower removal.
E. Position as close as possible to
blower deck to allow for
circulator blower removal.
F. 2" x 2" x ¹⁄₈" (5.1 cm x 5.1 cm x
3.2 mm) angle iron (3)
G. Support nuts
H. Hold down nuts
Existing Furnace Removal
NOTE: When an existing furnace is removed from a venting
system serving other appliances, the venting system may be too
large to properly vent the remaining attached appliances.
The following vent testing procedure is reproduced from the
American National Standard/National Standard of Canada for
Gas-Fired Central Furnaces ANSI Z21.4, 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:
1. Seal any unused openings in the venting system.
2. Inspect the venting system for proper size and horizontal
pitch, as required by the National Fuel Gas Code, ANSI
Z223.1 or the Natural Gas and Propane Installation Code,
CSA B149.1-05 and these instructions. Determine that there
is no blockage or restriction, leakage, corrosion and other
deficiencies which could cause an unsafe condition.
3. As far as practical, close all building doors and windows and
all doors between the space in which the appliance(s)
connected to the venting system are located and other
spaces of the building.
4. Close fireplace dampers.
5. Turn on clothes dryers and any appliance not connected to
the venting system. Turn on any exhaust fans, such as range
hoods and bathroom exhausts, so they shall operate at
maximum speed. Do not operate a summer exhaust fan.
6. Follow the lighting instructions. Place the appliance being
inspected in operation. Adjust thermostat so appliance shall
operate continuously.
7. Test for leaking from draft hood appliances at the draft hood
relief opening after 5 minutes of main burner operation. Use
the flame of a match or candle.
8. 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.
9. If improper venting is observed during any of the above tests,
the venting system must be corrected in accordance with the
National Fuel Gas Code ANSI Z223.1/NFPA 54 and/or
National Gas and Propane Installation Code CSA B149.1-05.
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 National Gas and
Propane Installation Code CSA B149.1-05.
Thermostat Location
The thermostat should be placed approximately 5 ft (1.5 m) from the
floor on a vibration-free, inside wall in an area having good air
circulation.
NOTE: Do not install the thermostat where it may be influenced
by any of the following:
■ 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
Consult the instructions packaged with the thermostat for
mounting instructions and further precautions.
COMBUSTION AND VENTILATION AIR REQUIREMENTS
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.
Improved construction and additional insulation in buildings have
reduced heat loss by reducing air infiltration and escape around
doors and windows. These changes have helped in reducing
heating/cooling costs but have created a problem supplying
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 starving appliances
for air.
8
House depressurization can cause back drafting or improper
combustion of gas-fired appliances, thereby exposing building
occupants to gas combustion products that could include carbon
monoxide.
If this furnace is to be installed in the same space with other gas
appliances, such as a water heater, ensure there is an adequate
supply of combustion and ventilation air for the other appliances.
Refer to the latest edition of the National Fuel Gas Code NFPA
54/ANSI Z223.1 or CAN/CSA B149 Installation Codes or
applicable provisions of the local building codes for determining
the combustion air requirements for the appliances.
Most homes will require outside air to 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.
The following information on air for combustion and ventilation is
reproduced from the National Fuel Gas Code NFPA 54/ANSI
Z223.1 Section 5.3.
5.3.1 General:
a) The provisions of 5.3 apply to gas utilization equipment
installed in buildings and which require air for
combustion, ventilation and dilution of flue gases from
within the building. They do not apply to (1) direct vent
equipment which is constructed and installed so that all
air for combustion is obtained from the outside
atmosphere and all flue gases are discharged to the
outside atmosphere, or (2) enclosed furnaces which
incorporate an integral total enclosure and use only
outside air for combustion and dilution of flue gases.
b) Equipment shall be installed in a location in which the
facilities for ventilation permit satisfactory combustion of
gas, proper venting and the maintenance of ambient
temperature at safe limits under normal conditions of use.
Equipment shall be located so as not to interfere with
proper circulation of air. When normal infiltration does not
provide the necessary air, outside air shall be introduced.
c) In addition to air needed for combustion, process air shall
be provided as required for: cooling of equipment or
material, controlling dew point, heating, drying, oxidation
or dilution, safety exhaust, odor control and air for
compressors.
d) In addition to air needed for combustion, air shall be
supplied for ventilation, including all the air required for
comfort and proper working conditions for personnel.
e) While all forms of building construction cannot be
covered in detail, air for combustion, ventilation and
dilution of flue gases for gas utilization equipment vented
by natural draft normally may be obtained by application
of one of the methods covered in 5.3.3 and 5.3.4.
f) Air requirements for the operation of exhaust fans,
kitchen ventilation systems, clothes dryers and fireplaces
shall be considered in determining the adequacy of a
space to provide combustion air requirements.
5.3.2 Equipment Located in Unconfined Spaces:
In unconfined spaces (see definition below) in buildings,
infiltration may be adequate to provide air for combustion
ventilation and dilution of flue gases. However, in buildings of
tight construction (for example, weather stripping, heavily
insulated, caulked, vapor barrier, etc.), additional air may need to
be provided using the methods described in 5.3.3-b or 5.3.4.
Equipment Located in Confined Spaces: All Air from Inside
Building. See 5.3.3-a.
NOTE: Each opening must have a free area of not less than
1 sq. in. (6.5 cm2) per 1,000 Btu of the total input rating of all
equipment in the enclosure, but not less than 100 sq. in.
(645.2 cm2).
A
B
D
C
B
A. Chimney or gas vent
B. Opening(s)
C. Water heater
D. Furnace
b) All Air from Outdoors: The confined space shall be
provided with 2 permanent openings, one commencing
within 12" (30.5 cm) of the top and one commencing
within 12" (30.5 cm) of the bottom of the enclosure. The
openings shall communicate directly, or by ducts, with
the outdoors or spaces (crawl or attic) that freely
communicate with the outdoors.
1. When directly communicating with the outdoors, each
opening shall have a minimum free area of 1 sq. in.
(6.5 cm2) per 4,000 Btu/h of total input rating of all
equipment in the enclosure.
Equipment Located in Confined Spaces: All Air from
Outdoors—Inlet Air from Ventilated Crawl Space and
Outlet Air to Ventilated Attic. See 5.3.3-b.
NOTE: The inlet and outlet air openings must each have a free
area of not less than 1 sq. in. (6.5 cm2) per 4,000 Btu of the total
input rating of all equipment in the enclosure.
Space, Unconfined.
A
For purposes of this Code, a space whose volume is not less
than 50 cu ft per 1,000 Btu/h of the aggregate input rating of all
appliances installed in that space. Rooms communicating
directly with the space in which the appliances are installed
through openings not furnished with doors, are considered a part
of the unconfined space.
B
5.3.3 Equipment Located in Confined Spaces:
a) All Air from Inside the Building: The confined space shall
be provided with 2 permanent openings communicating
directly with an additional room(s) of sufficient volume so
that the combined volume of all spaces meets the criteria
for an unconfined space. The total input of all gas
utilization equipment installed in the combined space
shall be considered in making this determination. Each
opening shall have a minimum free area of 1 sq. in.
(6.5 cm2) per 1,000 Btu/h of the total input rating of all gas
utilization equipment in the confined space, but not less
than 100 sq. in (645.2 cm2). One opening shall be within
12" (30.5 cm) of the top and one within 12" (30.5 cm) of
the bottom of the enclosure.
C
G
F
D
H
E
A. Chimney or gas vent
B. Ventilation louvers
(each end of attic)
C. Outlet air
D. Inlet air
E. Ventilation louvers for
unheated crawl space
F. Water heater
G. Furnace
H. Alternate air inlet
9
2. When communicating with the outdoors through vertical
ducts, each opening shall have a minimum free area of
1 sq. in. (6.5 cm2) per 4,000 Btu/h of total input rating of
all equipment in the enclosure.
4. When ducts are used, they shall be of the same crosssectional area as the free area of the openings to which
they connect. The minimum dimension of rectangular air
ducts shall not be less than 3" (7.6 cm).
Equipment Located in Confined Spaces: All Air from
Outdoors Through Ventilated Attic. See 5.3.3-b.
Equipment Located in Confined Spaces: All Air from
Outdoors—Single Air Opening. See 5.3.3-b.
NOTE: The inlet and outlet air openings must each have a free
area of not less than 1 sq. in. (6.5 cm2) per 4,000 Btu of the total
input rating of all equipment in the enclosure.
NOTE: The single opening must each have a free area of not less
than 1 sq. in. (6.5 cm2) per 3,000 Btu of the total input rating of all
equipment in the enclosure, but not less than the sum of the
areas of all vent connectors in the confined space.
A
B
A
B
C
F
E
D
E
D
C
A. Chimney or gas vent
B. Ventilation louvers
(each end of attic)
C. Outlet air
D. Inlet air duct (ends 12"
[30.5 cm] above floor)
E. Water heater
F. Furnace
3. When communicating with the outdoors through
horizontal ducts, each opening shall have a minimum free
area of 1 sq. in. (6.5 cm2) per 2,000 Btu/h of total input
rating of all equipment in the enclosure.
Equipment Located in Confined Spaces: All Air from
Outdoors. See 5.3.3-b.
NOTES:
■ The air duct openings must each have a free area of not less
than 1 sq. in. (6.5 cm2) per 2,000 Btu of the total input rating
of all equipment in the enclosure.
■ If the appliance room is located against an outside wall and
the air openings communicate directly with the outdoors,
each opening shall have a free area of not less than 1 sq. in.
(6.5 cm2) per 4,000 Btu/h of the total input rating of all
appliances in the enclosure.
A
A. Chimney or gas vent
B. Opening
C. Alternate opening location
D. Water heater
E. Furnace
5. When directly communicating with the outdoors, the
single opening shall have a minimum free area of 1 sq. in.
(6.5 cm2) per 3,000 Btu/h of total input rating of all
equipment in the enclosure.
5.3.4 Specially Engineered Installations:
The requirements of 5.3.3 shall not necessarily govern when
special engineering, approved by the authority having
jurisdiction, provides an adequate supply of air for combustion,
ventilation, and dilution of flue gases.
5.3.5 Louvers and Grilles:
In calculating free area in 5.3.3, consideration shall be given to
the blocking effect of louvers, grilles or screens protecting
openings. Screens used shall not be smaller than ¹⁄₄" (6.4 mm)
mesh. If the area through a design of louver or grille is known, it
should be used in calculating the size of opening required to
provide the free area specified. If the design and free area is not
known, it may be assumed that wood louvers will have 20 to
25 percent free area and metal louvers and grilles will have 60 to
75 percent free area. Louvers and grilles shall be fixed in the open
position or interlocked with the equipment so that they are
opened automatically during equipment operation.
5.3.6 Special Conditions Created by Mechanical
Exhausting or Fireplaces:
B
E
D
C
A. Chimney or gas vent
B. Outlet air duct
C. Inlet air duct
10
D. Water heater
E. Furnace
Operation of exhaust fans, ventilation systems, clothes dryers or
fireplaces may create conditions requiring special attention to
avoid unsatisfactory operation of installed gas utilization
equipment. Air from Inside Building. See 5.3.3-a.
INSTALLATION POSITIONS
This furnace may be installed in an upright position or horizontal
on either the left or right side panel.
NOTE: Do not install this furnace on its back.
For upright upflow furnaces, the return air ductwork may be
attached to the side panel(s) and/or base pan.
For horizontal upflow furnaces, the return air ductwork must be
attached to the base pan.
For both the upright or horizontal counterflow furnaces, the
return air ductwork must be attached to the base pan (top end of
the blower compartment).
NOTE: Do not attach the ductwork to the back of the furnace.
For upflow installations requiring 1,800 CFM or more, use either
2 side returns or a bottom return or a combination of side and
bottom.
Contact your local distributor for the proper airflow requirements
and the number of required ductwork connections. See the
“Recommended Installation Positions” illustrations for the
appropriate installation positions, ductwork connections and the
resulting airflow arrangements.
HORIZONTAL APPLICATIONS AND CONSIDERATIONS
General
Horizontal applications, in particular, may dictate many of the
installation’s specifics such as airflow direction, ductwork
connections, flue and combustion air pipe connections, etc. The
basic application of this furnace as a horizontal furnace differs
only slightly from an upright installation.
When installing a furnace horizontally, additional consideration
must be given to the following:
■ Drain trap and lines
■ Leveling the furnace
■ Alternate vent/flue and combustion air connections
■ Alternate electrical and gas line connections
■ Drain pan
■ Freeze protection
■ Furnace suspension.
Horizontal Furnace
A
C
B
I
F
D
H
G
E
A. Alternate vent/flue location
B. Level end-to-end
C. Level side-to-side or slightly
tilted—doors 0" to ³⁄₄" (1.9 cm)
below back panel
D. Drain line—¹⁄₄" (6.4 mm) per
foot downward slope
E. 36" (91.4 cm) minimum service
clearance
F. 4³⁄₄" (12.1 cm) minimum drain trap
clearance
G. Supports at both ends and middle
H. Drain pan
I. Gas line with 3" (7.6 cm) minimum
drip leg
Additionally, the appropriate downward piping slope must be
maintained from the drain trap to the drain location.
Refer to “Condensate Drain Trap and Lines” for further details. If
the drain trap and drain line will be exposed to temperatures near
or below freezing, adequate measures must be taken to avoid
condensate from freezing.
Leveling
Leveling ensures proper condensate drainage from the heat
exchanger and induced draft blower. For proper flue pipe
drainage, the furnace must be level lengthwise from end to end.
The furnace should also be level from back to front, or have a
slight tilt with the access doors sloping downward ³⁄₄" (1.9 cm)
lower than the back panel. The slight tilt allows the heat
exchanger condensate, generated in the recuperator coil, to flow
forward to the recuperator coil front cover.
Alternate Vent/Flue Connections
In horizontal installations, provisions for alternate vent/flue piping
are available for upflow furnaces with left discharge and
counterflow furnaces with right air discharge. This configuration
allows the vent/flue and combustion air piping to be run vertically
through the side of the furnace. Refer to the “Recommended
Installation Positions” illustrations for further details. The
standard piping connections may also be used in these positions.
See “Vent/Flue Pipe and Combustion Air Pipe” for details
concerning the conversion to the alternate vent/flue connections.
When using the horizontal alternate vent configuration, you must
use the RF000142 vent drain kit. See “Alternate Flue/Vent
Location” illustration.
NOTE: Alternate vertical piping connections cannot be used
when an upflow furnace is installed with the supply air
discharging to the right, or when a counterflow furnace is
installed with the supply air discharging to the left. In either case,
use the standard flue and combustion air piping connections.
Alternate Flue/Vent Location
A
B
C
Drain Trap and Lines
In horizontal applications, the condensate drain trap is secured to
the furnace side panel, suspending it below the furnace. A
minimum clearance of 4³⁄₄" (12.1 cm) below the furnace must be
provided for the drain trap.
A. Vent/Drain
B. Airflow
C. Field supplied drain hose
11
NOTES:
■ The field supplied drain hose is connected from the vent/
drain connection to the condensate drain line with a field
supplied connector.
■ Make a small loop in the drain hose to serve as a P-trap.
Recommended Installation Positions—Horizontal
Counterflow—Right Side Panel Discharge
B
Recommended Installation Positions—Upright Upflow
A
C
A
B
A. Bottom return duct connection C. Air discharge
B. Alternate flue pipe location
Recommended Installation Positions—Horizontal
Upflow—Right Side Panel Discharge
C
C
B
D
A. Air discharge
B. Alternate flue pipe location
A
C. Side return duct connections
D. Bottom return duct connection
Recommended Installation Positions—Upright
Counterflow
A
A. Bottom return duct connection
B. Air discharge
Recommended Installation Positions—Horizontal
Counterflow—Left Side Panel Discharge
B
A
B
A. Air discharge
B. Bottom return duct connection
Alternate Electrical and Gas Line Connections
This furnace has provisions allowing for electrical and gas line
connections through either side panel.
In horizontal applications, the connections can be made either
through the top or bottom of the furnace.
C
A. Bottom return duct connection
B. Alternate flue and combustion air pipe locations
C. Air discharge
Recommended Installation Positions—Horizontal
Upflow—Left Side Panel Discharge
B
Drain Pan
A drain pan must be provided if the furnace is installed above a
conditioned area.
The drain pan must cover the entire area under the furnace (and
air conditioning coil, if applicable).
Freeze Protection
Refer to “Horizontal Applications and Conditions—Drain Trap and Lines.”
A
C
A. Air discharge
C. Bottom return duct connection
B. Alternate flue pipe location
12
Furnace Suspension
If the furnace is installed in a crawl space, it must be suspended from
the floor joist or supported by a concrete pad.
NOTE: Never install the furnace on the ground or allow it to be
exposed to water. Refer to “Location Requirements and
Considerations—Furnace Suspension” for further details.
PROPANE GAS/HIGH ALTITUDE INSTALLATIONS
WARNING
Possible property damage, personal injury or death may
occur if the correct conversion kits are not installed. The
appropriate kits must be applied to ensure safe and proper
furnace operation. All conversions must be performed by
a qualified installer or service agency.
This furnace is shipped from the factory configured for Natural
gas at standard altitude. Propane gas installations require an
orifice change to compensate for the energy content difference
between Natural and propane gas.
High altitude installations may require both a pressure switch and
an orifice/spring change. These changes are necessary to
compensate for the natural reduction in the density of both the
gas fuel and the combustion air at higher altitude.
For installations above 7,000 ft (2,133.6 m), refer to your
distributor for required kit(s).
Gas
Altitude
Natural
Kit
0 to
None
7,000 ft
Propane (2,133.6 m) LPM-05
LPM-06
Pressure
Manifold Switch
Orifice Pressure Change
#43
3.5" W.C.
None
#55
10.0" W.C. None
NOTES:
■ In Canada, gas furnaces are only certified to 4,500 ft
(1,371.6 m).
■ LPM-05 supports White-Rodgers 2-stage valve only.
■ LPM-06 supports both Honeywell and White-Rodgers
2-stage valves.
Contact the distributor for a tabular listing of appropriate
manufacturer’s kits for propane gas and/or high altitude
installations. The indicated kits must be used to insure proper
furnace operation. All conversions must be performed by a
qualified installer or service agency.
VENT/FLUE PIPE AND COMBUSTION AIR PIPE
General
WARNING
Failure to follow these instructions can result in bodily
injury or death. Carefully read and follow all instructions
given in this section.
WARNING
Upon completion of the furnace installation, carefully
inspect the entire flue system both inside and outside of
the furnace to assure it is properly sealed. Leaks in the
flue system can result in serious personal injury or death
due to exposure to flue products, including carbon
monoxide.
A condensing gas furnace achieves its high level of efficiency by
extracting almost all of the heat from the products of combustion
and cooling them to the point where condensation takes place.
Because of the relatively low flue gas temperature and water
condensation requirements, PVC pipe is used as venting
material.
NOTES:
■ This furnace must not be connected to Type B, BW or L vent
or vent connector, and must not be vented into any portion of
a factory-built or masonry chimney except when used as a
pathway for PVC as described later in this section.
■ Do not common vent this appliance with another appliance or
use a vent which is used by a solid fuel appliance.
■ Do not use commercially available “no hub connectors” other
than those shipped with this product.
It is the responsibility of the installer to follow the manufacturers’
recommendations and to verify that all vent/flue piping and
connectors are compatible with furnace flue products.
Additionally, it is the responsibility of the installer to ensure that all
piping and connections possess adequate structural integrity and
support to avoid flue pipe separation, shifting or sagging during
furnace operation.
Dual Certification: Nondirect/Direct Vent
This furnace is dual certified and may be installed as a nondirect
vent (single pipe) or direct vent (dual pipe) appliance. A nondirect
vent installation requires only a vent/flue pipe, while a direct vent
installation requires both a vent/flue pipe and a combustion air
intake pipe. Refer to the appropriate section for details
concerning piping size, length, number of elbows, furnace
connections and terminations.
Materials and Joining Methods
WARNING
To avoid bodily injury, fire or explosion, solvent cements
must be kept away from all ignition sources (for example,
sparks, open flames and excessive heat) as they are
combustible liquids. Avoid breathing cement vapors or
contact with skin and/or eyes.
2" or 3" (5.1 cm or 7.6 cm) nominal diameter PVC Schedule
40 pipe meeting ASTM D1785, PVC primer meeting ASTM F656
and PVC solvent cement meeting ASTM D2564 specifications
must be used. Fittings must be DWV type fittings meeting ASTM
D2665 and ASTM D3311. Carefully follow the pipe
manufacturer’s instructions for cutting, cleaning and solvent
cementing of PVC.
The use of Schedule 40 PVC Cellular Core (Foam Core) plastic
pipe is also acceptable as a flue/vent and intake pipe material.
PVC primer meeting ASTM F656 and PVC solvent cement
meeting ASTM D2564 specifications must be used. Fittings must
be DWV type fittings meeting ASTM D2665 and ASTM D3311.
13
Carefully follow¹⁄₂" (1.3 cm) thick closed-cell foam. Also all vent/
flue piping exposed outdoors in excess of the terminations
shown in this manual (or in unheated areas) must be insulated
with ¹⁄₂" (1.3 cm) thinck closed_ the manufactures instructions for
cutting, cleaning and solvent cementing of PVC.
As an alternative to PVC pipe, primer, solvent cement and fittings,
ABS materials which are in compliance with the following
specifications may be used. 2" or 3" (5.1 cm or 7.6 cm) ABS
Schedule 40 pipe must meet ASTM D1527 and, if used in
Canada, must be CSA listed. Solvent cement for ABS to ABS
joints must meet ASTM D2235 and, if used in Canada, must be
CSA listed.
The solvent cement for the PVC to ABS transition joint must meet
ASTM D3138.
Fittings must be DWV type fittings meeting ASTM D2661 and
ASTM D3311 and, if used in Canada, must be CSA listed.
Carefully follow the manufacturers’ instructions for cutting,
cleaning, and solvent cementing PVC and/or ABS.
All 90° elbows must be medium radius (¹⁄₄ bend DWV) or long
radius (long sweep ¹⁄₄ bend DWV) types conforming to ASTM
D3311. A medium radius (¹⁄₄ bend DWV) elbow measures 3¹⁄₁₆"
(7.8 cm) minimum from the plane of one opening to the centerline
of the other opening for 2" (5.1 cm) diameter pipe, and 4⁹⁄₁₆"
(11.6 cm) minimum for 3" (7.6 cm) pipe.
Proper Vent/Flue and Combustion Air Piping
Practices
Adhere to these instructions to ensure safe and proper furnace
performance. The length, diameter and number of elbows of the
vent/flue pipe and combustion air pipe (when applicable) affects
the performance of the furnace and must be carefully sized. All
piping must be installed in accordance with local codes and
these instructions.
Piping must be adequately secured and supported to prohibit
sagging, joint separation and/or detachment from the furnace.
Horizontal runs of vent/flue piping must be supported every 3 ft
to 5 ft (91.4 cm to 1.5 m) and must maintain a ¹⁄₄" (6.4 mm) per
foot downward slope, back toward the furnace, to properly return
condensate to the furnace’s drain system. Allowances should be
made for minor expansion and contraction due to temperature
variations. For this reason, particular care must be taken to
secure piping when a long run is followed by a short offset of less
than 40" (101.6 cm).
Precautions should be taken to prevent condensate from freezing
inside the vent/flue pipe and/or at the vent/flue pipe termination.
All vent/flue piping exposed to freezing temperatures below 35ºF
(2ºC) for extended periods of time must be insulated with ¹⁄₂"
(1.3 cm) thick closed-cell foam. Also, all vent/flue piping exposed
outdoors in excess of the terminations shown in this manual (or in
unheated areas) must be insulated with ¹⁄₂" (1.3 cm) thick closedcell foam. Inspect piping for leaks prior to installing insulation.
Termination Locations
NOTE: Refer to “Location Requirements and Considerations” for
combustion air contaminant restrictions.
The following bullets and illustration describe the restrictions
concerning the appropriate location of vent/flue pipe and
combustion air intake pipe (when applicable) terminations. Refer
to “Nondirect Vent (Single Pipe) Piping” and “Direct Vent (Dual
Pipe) Piping” located in this section for specific details on
termination construction.
■ All terminations (flue and/or intake) must be located at least
12" (30.5 cm) above ground level or the anticipated snow
level.
14
■
■
■
■
■
■
Vent terminations (nondirect and direct vent) must terminate
at least 3 ft (91.4 cm) above any forced air inlet located within
10 ft (3 m).
NOTE: This provision does not apply to the combustion air
intake termination of a direct vent application.
The vent termination of a nondirect vent application must
terminate at least 4 ft (121.9 cm) below, 4 ft (121.9 cm)
horizontally from or 12" (30.5 cm) above any door, window or
gravity air inlet into any building.
The vent termination of a direct vent application must
terminate at least 12" (30.5 cm) from any opening through
which flue gases may enter a building (door, window or
gravity air inlet).
The vent termination of vent pipe run vertically through a roof
must terminate at least 12" (30.5 cm) above the roof line (or
the anticipated snow level) and be at least 12" (30.5 cm) from
any vertical wall (including any anticipated snow buildup).
A vent termination shall not terminate over public walkways
or over an area where condensate or vapor could create a
nuisance or hazard or could be detrimental to the operation
of regulators, relief valves or other equipment.
The combustion air intake termination of a direct vent
application should not terminate in an area which is
frequently dusty or dirty.
Vent Termination Clearances
A
B
C
J
D
E
I
D
E
H
E
G
E
B
F
A. Nondirect vent and direct vent
vent/flue terminations
B. Nondirect vent—vent/flue
terminations
C. No terminations above walkway
D. 4" (10.2 cm) minimum)
E. 12" (30.5 cm) minimum
F. Direct vent—vent/flue
termination
G. Forced air inlet
H. Grade or highest anticipated
snow level
I. 3" (7.6 cm) minimum
J. Less than 10 ft (3 m)
NOTE: In Canada, the Canadian Fuel Gas Code takes
precedence over the preceding termination restrictions.
Canadian Venting Requirements
In Canada, venting must conform to the requirements of the
current CAN/CSA-B149.1-05 Installation Code. Use only CSAlisted, ULC-S636 compliant 2" or 3" (5.1 cm or 7.6 cm) diameter
PVC or ABS pipe, solvent cement and fittings throughout. The
certified piping should be clearly marked with the ULC Std
“S636” on the pipe and fittings.
Carefully follow the pipe manufacturers’ instructions for cutting,
cleaning and solvent cementing PVC and/or ABS.
The vent can be run through an existing unused chimney
provided the space between the vent pipe and the chimney is
insulated and closed with a weather-tight, corrosion-resistant
flashing.
Standard Furnace Connections
It is the responsibility of the installer to ensure that the piping
connections to the furnace are secure, airtight and adequately
supported.
As shipped, attachment “couplings” for vent/flue and combustion
air intake pipe connections are provided on the furnace’s top
cover (upflow) or base pan (counterflow).
To use the standard connections, field-supplied vent/flue pipe
and combustion air intake pipe (when applicable) should be
secured directly to the furnace at these locations.
Combustion Air Pipe—Nondirect Vent Installations
A minimum of one 90° elbow should be installed on the
combustion air intake coupling to guard against inadvertent
blockage.
Standard Connection—Upflow
D
B
C
Vent/Flue Pipe
A
Vent/flue pipe can be secured to the vent/flue coupling using the
rubber coupling and worm gear hose clamps provided with this
furnace. See “Standard Connections” illustration. The rubber
coupling allows separation of the vent/flue pipe from the furnace
during servicing. Combustion air and vent piping should be
routed in a manner to avoid contact with refrigerant lines,
metering devices, condensate drain lines, etc. If necessary,
clearances may be increased by utilizing two 45º long-sweep
elbows and creating an “S” joint to provide additional space at
connection locations. This joint can be rotated on the fitting to
establish maximum clearance between refrigerant lines, metering
devices, condensate drain lines, etc. This joint is the equivalent of
one 90º elbow when considering elbow count.
Increased Clearance Configuration
A. 90º PVC elbow (nondirect vent only) C. Rubber coupling with worm
gear hose clamps
B. Combustion air pipe (direct vent
only)
D. Vent/flue pipe
Standard Connection—Counterflow
B
A
D
C
B
A
A. Vent pipe
B. 45º long-sweep elbows
NOTES:
■ Do not use other commercially available “no hub connectors”
due to possible material conflicts.
■ The vent/flue pipe can also be secured using a PVC or ABS
elbow or coupling using the appropriate glue (see “Materials
and Joining Methods”).
■ For nondirect vent installations, a minimum of one 90° elbow
should be installed on the combustion air intake coupling to
guard against inadvertent blockage.
Combustion Air Pipe—Direct Vent Installations
On upflow units, secure the combustion air intake pipe directly to
the air intake coupling. On counterflow units secure the
combustion air intake pipe to the air intake coupling using the
rubber coupling and worm gear hose clamps provided with the
unit. The counterflow rubber coupling allows service removal of
air intake piping internal to the furnace blower compartment.
NOTE: Because of probable material conflicts, do not use other
commercially available “no hub connectors.” The combustion air
intake pipe can also be secured directly to the counterflow unit
air intake pipe coupling.
A. 90º PVC elbow (nondirect vent only) C. Rubber couplings with
worm gear hose clamps
B. Combustion air pipe (direct vent
only)
D. Vent/flue pipe
Alternate Furnace Connections
If the standard locations are undesirable for a specific installation,
alternate side panel locations are available for both combustion
air inlet and vent/flue pipe connections. These locations may be
of particular benefit to upright upflow installations requiring
additional access to an A coil, or to upright counterflow
installations requiring additional access to a filter or electronic air
cleaner, or to horizontal installations desiring vent/flue (and
combustion air intake) piping run vertically from the side of the
cabinet.
15
NOTE: Standard and alternate locations can be combined (for
example, an installation may use the standard combustion air
intake location but use the alternate vent/flue location or vice
versa), if needed.
WARNING
Edges of sheet metal holes may be sharp. Use gloves as
a precaution when removing hole plugs.
Alternate Vent/Flue Location
The alternate vent/flue location is the large hole directly in line
with the induced draft blower outlet. To use the alternate vent/flue
location, refer to the following steps and the “Alternate Vent/Flue
Location” illustration.
NOTE: Counterflow instructions follow the upflow instructions.
Upflow Units
1. Remove and save the 4 screws securing the vent/flue
coupling to the furnace top panel.
Counterflow Units
Remove and save the 4 screws securing the vent/flue
coupling to the furnace base pan. Also remove the 3 screws
securing the furnace’s internal vent/flue piping to the blower
deck.
Upflow and Counterflow Units
2. Loosen the worm gear hose clamps on the rubber elbow and
detach the rubber elbow from both the induced draft blower
and the vent/flue pipe.
3. Remove the vent/flue pipe from the furnace.
Upflow Units
4. Cut the vent/flue pipe 3³⁄₄" (9.5 cm) from the flanged end of
the pipe. See “Vent/Flue Pipe Cuts” illustration.
NOTE: The section of pipe attached to the coupling will reach
through the side panel to the induced draft blower.
5. Discard remaining pipe and elbows.
Relocate and install the plastic plug in the standard vent/flue
location (base pan).
Plug remaining hole in the blower deck with the plastic plug
included in the drain kit bag.
Upflow and Counterflow Units
8. Insert the cut section of the vent/flue pipe and coupling into
the alternate vent/flue location.
9. Attach the vent/flue pipe and coupling to the induced draft
blower using a rubber coupling and worm gear hose clamps
provided in the drain kit bag.
10. Secure the coupling to the cabinet using the screws removed
in Step 1 or with field-supplied ³⁄₈" #8 self-drilling screws.
WARNING
The rubber elbow is not designed to support a load.
When the
rubber elbow is mounted externally to the
Placeholder
furnace cabinet, extreme care must be taken to adequately
support field-supplied vent/flue piping, as damage can
result in leaks causing bodily injury or death due to
exposure to flue gases, including carbon monoxide.
11. For upright installations, externally mount the rubber elbow to
the vent/flue coupling using a worm gear hose clamp.
12. Secure the field-supplied vent/flue piping to the rubber elbow
using a worm gear hose clamp.
NOTE: Use of the alternate vent/flue location for upright
installations, requires the drain trap to be installed on the
same side of the furnace as the flue pipe.
13. For horizontal installations, externally secure the field
supplied vent/flue pipe directly to the vent/flue coupling using
a PVC or ABS coupling or elbow.
Alternate Vent/Flue Location—Upflow
A
B
Counterflow Units
Cut the vent/flue pipe 3³⁄₄" (9.5 cm) from the blower deck
coupling. See “Vent/Flue Pipe Cuts” illustration
Save vent/flue pipe attached to the blower deck coupling for
use in the alternate location.
Discard remaining pipe and elbows.
C
D
E
Vent/Flue Pipe Cuts
A
B
C
A. Vent/flue pipe
B. Screw locations (4)
C. Plastic plug—alternate vent/flue location
D. Rubber elbow
E. Induced draft
blower
Alternate Vent/Flue Location—Counterflow/Upright
(Upflow Similar)
A
A. Flange
B. Cut location
C. 3³⁄₄" (9.5 cm)
B
C
Upflow Units
D
6. Remove the plastic plug from the alternate vent/flue location.
7. Relocate and install the plastic plug in the standard vent/flue
location (top cover).
Counterflow Units
Remove the plastic plug from the alternate vent/flue location.
16
A. Plastic plug from drain kit bag
B. Vent/flue pipe
C. Rubber elbow
D. Induced draft blower
Alternate Vent/Flue Location—Counterflow
A
B
Nondirect Vent (Single Pipe) Maximum Allowable Length
of Vent/Flue Pipe—ft (m)
Number of Elbows
C
D
E
F
A. Vent/flue pipe
B. Screw locations (4)
C. Screw locations (3)
Models
Pipe—in.
(kBtu_Tons) (cm)
A
A. Rubber coupling
B. Vent/flue pipe
B
C
3
4
5
6
7
8
045_3
2 or 2¹⁄₂
68 65 62 59 56 53 50
(5.12 or 6.4) (21) (20) (19) (18) (17) (16) (15)
070_3
2 or 2¹⁄₂
68 65 62 59 56 53 50
(5.12 or 6.4) (21) (20) (19) (18) (17) (16) (15)
070_4
2 or 2¹⁄₂
46 43 40 Not Recommended
(5.12 or 6.4) (14) (13) (12)
D. Plastic plug—alternate vent/flue location
E. Rubber elbow
F. Induced draft blower
Alternate Vent/Flue Location—Upflow /Horizontal
(Counterflow Similar)
2
3 (7.6)
68 65 62 59 56 53 50
(21) (20) (19) (18) (17) (16) (15)
NOTES:
■ One 90º elbow should be secured to the combustion air
intake connection.
■ Minimum requirement for each vent/flue pipe is 5 ft (1.5 m)
and 1 elbow/tee.
■ Tee used in the vent/flue termination must be included when
determining the number of elbows in the piping system.
■ 2¹⁄₂" or 3" (6.4 cm or 7.6 cm) diameter pipe can be used in
place of 2" (5.1 cm) diameter pipe.
■ Increased clearance configurations using two 45º long-sweep
elbows should be considered equivalent to one 90º elbow.
C. Induced draft blower
Vent/Flue Pipe Terminations
■
Nondirect Vent (Single Pipe) Piping
Nondirect vent installations require only a vent/flue pipe. The vent
pipe can be run horizontally with an exit through the side of the
building or run vertically with an exit through the roof of the
building. The vent can also be run through an existing unused
chimney; however, it must extend a minimum of 12" (30.5 cm)
above the top of the chimney. The space between the vent pipe
and the chimney must be closed with a weather-tight, corrosionresistant flashing. For details concerning connection of the vent/
flue pipe to the furnace, refer to “Vent Pipe Installation and
Combustion Air—Standard Furnace Connections” or “Vent Pipe
Installation and Combustion Air—Alternate Furnace
Connections” for specific details.
Refer to the following “Nondirect Vent (Single Pipe) Piping—Vent/
Flue Pipe Terminations” for specific details on termination
construction.
Although nondirect vent installations do not require a combustion
air intake pipe, a minimum of one 90° elbow should be attached
to the furnace’s combustion air intake if an upright installation
uses the standard intake location, or a horizontal installation uses
the alternate air intake location. This elbow will guard against
inadvertent blockage of the air intake.
■
Vent/Flue Pipe Lengths and Diameters
■
Refer to the following tables for applicable length, elbows and
pipe diameter for construction of the vent/flue pipe systems of a
nondirect vent (single pipe) installation. In addition to the vent/
flue pipe, a single 90º elbow should be secured to the
combustion air intake to prevent inadvertent blockage. The tee
used in the vent/flue termination must be included when
determining the number of elbows in the piping system.
■
■
■
■
■
■
■
■
The vent/flue pipe may terminate vertically, as through a roof,
or horizontally, as through an outside wall.
Vertical vent/flue pipe terminations should be as shown in
“Vertical Vent Termination (Single Pipe)” illustration. Refer to
“Termination Locations” in this section for details concerning
location restrictions.
The penetration of the vent through the roof must be sealed
tight with proper flashing such as is used with a plastic
plumbing vent.
Horizontal vent/flue pipe terminations should be as shown in
“Horizontal Vent Termination (Single Pipe)” illustration. Refer
to “Termination Locations” in this section for details
concerning location restrictions.
A 2³⁄₈" (6.1 cm) diameter wall penetration is required for 2"
(5.1 cm) diameter pipe.
A 3" (7.6 cm) diameter hole is required for a 2¹⁄₂" (6.4 cm)
pipe.
A 3¹⁄₂" (8.9 cm) diameter hole is required for 3" (7.6 cm)
diameter pipe.
To secure the pipe passing through the wall and prohibit
damage to the piping connections, a coupling should be
installed on either side of the wall and solvent cemented to a
length of pipe connecting the 2 couplings.
The length of pipe should be the wall thickness plus the
depth of the socket fittings to be installed on the inside and
outside of the wall.
The wall penetration should be sealed with silicone caulking
material.
In a basement installation, the vent/flue pipe can be run
between joist spaces.
NOTE: If the vent pipe must go below a joist and then up into
the last joist space to penetrate the header, two 45° elbows
should be used to reach the header rather than two 90°
elbows.
17
Vertical Vent Termination (Single Pipe)
Standard Horizontal Vent Termination (Single Pipe)—
Above Highest Anticipated Snow Level
A
A
B
B
C
A. 12" (30.5 cm) minimum from wall
B. Vent/flue tee or 90º elbow turned down
C. 12" (30.5 cm) minimum to roof or highest anticipated snow level
A. Tee
B. 12" (30.5 cm) minimum to roof or
highest anticipated snow level
Alternate Vertical Vent Termination (Single Pipe)
A
B
A. 90º medium radius elbows
B. 12" (30.5 cm) minimum to roof or
highest anticipated snow level
Standard Horizontal Vent Termination (Single Pipe)
B
A
C
D
G
H
F
E
A. Inside building
B. Wall
C. Outside building
D. Tee or 90º elbow turned
down
18
E. 12" (30.5 cm) minimum to ground or
highest anticipated snow level
F. 12" (30.5 cm) minimum from wall
G. Coupling
H. Elbow or coupling
Direct Vent (Dual Pipe) Piping
The inlet air screens provided in the installation instruction packet
are available for the installer to use in the inlet of the combustion
air pipe to prevent animals from building nests in the combustion
air pipe. Installation of screens, while strongly recommended, is
not required and will not affect performance of the furnace.
Direct vent installations require both a combustion air intake and
a vent/flue pipe. The pipes may be run horizontally and exit
through the side of the building or run vertically and exit through
the roof of the building.
The pipes may be run through an existing unused chimney;
however, they must extend a minimum of 12" (30.5 cm) above the
top of the chimney. The space between the pipes and the
chimney must be closed with a weathertight, corrosion resistant
flashing. Both the combustion air intake and vent/flue pipe
terminations must be in the same atmospheric pressure zone.
See “Termination Locations,” or “Concentric Vent Termination” in
this section for specific details on termination constructions. For
details concerning connection of pipes to the furnace, refer to the
“Standard Furnace Connections” or “Alternate Furnace
Connections” in this section.
Vent/Flue and Combustion Air Pipe
Lengths and Diameters
Refer to the following chart for applicable length, elbows and
pipe diameter for construction of the vent/flue and combustion
air intake pipe systems of a direct vent (dual pipe) installation.
The number of elbows tabulated represents the number of
elbows and/or tees in each vent/flue and combustion air intake
pipe. Elbows and/or tees used in the terminations must be
included when determining the number of elbows in the piping
systems.
If the combustion air intake pipe is to be installed above a
finished ceiling or other area where dripping of condensate will
be objectionable, insulation of the combustion air pipe may be
required. Use ¹⁄₂" (1.3 cm) thick closed-cell foam insulation where
required.
Direct Vent (Dual Pipe) Maximum Allowable Length of Vent/Flue and Combustion Air Intake Pipe—ft (m)
Number of Elbows
Unit Input (Btu)
Termination Style
Pipe—in. (cm)
2
3
045_3
Standard
2 or 2¹⁄₂ (5.12 or 6.4)
68 (20.7)
65 (19.8) 62 (18.9) 59 (18)
56 (17.1) 53 (16.2) 50 (15.2)
Alternate
2 or 2¹⁄₂ (5.12 or 6.4)
55 (16.8)
52 (15.8) 49 (14.9) 46 (14)
43 (13.1) 40 (12.2) 37 (11.3)
Standard
2 or 2¹⁄₂ (5.12 or 6.4)
68 (20.7)
65 (19.8) 62 (18.9) 59 (18)
56 (17.1) 53 (16.2) 50 (15.2)
Alternate
2 or 2¹⁄₂ (5.12 or 6.4)
55 (16.8)
52 (15.8) 49 (14.9) 46 (14)
43 (13.1) 40 (12.2) 37 (11.3)
Standard
2 or 2¹⁄₂ (5.12 or 6.4)
46 (14)
43 (13.1) 40 (12.2)
Not Recommended
3 (7.6)
68 (20.7)
65 (19.8) 62 (18.9) 59 (18)
56 (17.1) 53 (16.2) 50 (15.2)
2 or 2¹⁄₂ (5.12 or 6.4)
33 (10.1)
30 (9.2)
Not Recommended
3 (7.6)
54 (16.5)
51 (15.5) 48 (14.6) 45 (13.7) 42 (12.8) 39 (11.9) 36 (11)
Standard
3 (7.6)
68 (20.7)
65 (19.8) 62 (18.9) 59 (18)
56 (17.1) 53 (16.2) 50 (15.2)
Alternate
3 (7.6)
55 (16.8)
52 (15.8) 49 (14.9) 46 (14)
43 (13.1) 40 (12.2) 37 (11.3)
Standard
3 (7.6)
68 (20.7)
65 (19.8) 62 (18.9) 59 (18)
56 (17.1) 53 (16.2) 50 (15.2)
Alternate
3 (7.6)
55 (16.8)
52 (15.8) 49 (14.9) 46 (14)
43 (13.1) 40 (12.2) 37 (11.3)
Standard
3 (7.6)
68 (20.7)
65 (19.8) 62 (18.9) 59 (18)
56 (17.1) 53 (16.2) 50 (15.2)
Alternate
3 (7.6)
55 (16.8)
52 (15.8) 49 (14.9) 46 (14)
43 (13.1) 40 (12.2) 37 (11.3)
070_3
070_4
Alternate
090_4
090_5
115_5
NOTES:
■ Minimum length of each vent/flue and combustion air intake
pipe is 5 ft (1.5 m) and one elbow/tee.
■ Elbows and/or tees used in the terminations must be
included when determining the number of elbows in the
piping system.
■
■
4
5
27 (8.2)
6
7
8
2¹⁄₂" (6.4 cm) or 3" (7.6 cm) diameter pipe can be used in
place of 2" (5.1 cm) diameter pipe.
Increased clearance configurations using two 45º long-sweep
elbows should be considered equivalent to one 90º elbow.
Vent/Flue and Combustion Air Pipe Terminations
The vent/flue and combustion air pipes may terminate vertically,
as through a roof, or horizontally, as through an outside wall.
Vertical pipe terminations should be as shown in “Vertical
Terminations (Dual Pipe)” illustration. Refer to “Termination
Locations” in this section for details concerning location
restrictions. The penetrations through the roof must be sealed
tight with the proper flashing such as is used with a plastic
plumbing vent.
Vertical Vent Terminations (Dual Pipe)
D
E
B
A
H
C
G
Horizontal terminations should be as shown in “Standard
Horizontal Vent Terminations (Dual Pipe)” illustration. Refer to
“Termination Locations” in this section for location restrictions.
■ A 2³⁄₈" (6.1 cm) diameter wall penetration is required for 2"
(5.1 cm) diameter pipe.
■ A 3" (7.6 cm) diameter hole is required for a 2¹⁄₂" (6.4 cm)
pipe.
■ A 3¹⁄₂" (8.9 cm) diameter hole is required for 3" (7.6 cm)
diameter pipe.
■ To secure the pipe passing through the wall and prohibit
damage to the piping connections, a coupling should be
installed on either side of the wall and solvent cemented to a
length of pipe connecting the 2 couplings.
■ The length of pipe should be the wall thickness plus the
depth of the socket fittings to be installed on the inside and
outside of the wall.
■ The wall penetration should be sealed with silicone caulking
material.
F
A. 12" (30.5 cm) minimum
B. Combustion air intake pipe
C. 90º medium radius elbows
D. Tee
E. Vent/flue pipe
F. 24" (61 cm) maximum, 3" (7.6 cm)
minimum
G. Screen
H. 12" (30.5 cm) minimum to roof or
highest anticipated snow level
19
Standard Horizontal Vent Terminations (Dual Pipe)
Alternate Horizontal Terminations (Dual Pipe)—Above
Highest Anticipated Snow Level
B
A
A
C
A
E
G
D
G
F
D
F
B
D
C
E
A. 24" (61 cm) maximum, 3"
D. 12" (30.5 cm) minimum to roof or
(7.6 cm) minimum
highest anticipated snow level
B. 12" (30.5 cm) minimum from E. Combustion air intake
wall
F. Screen
C. Vent/flue tee
G. 90º medium radius elbow
Alternate Horizontal Vent Terminations (Dual Pipe)
B
A
■
C
H
G
F
E
A. 90º medium radius elbow
B. Vent/flue pipe
C. 12" (30.5 cm) minimum
from wall
D. Screen
A. 90º medium radius elbow
B. Flue/vent pipe
C. 24" (61 cm) maximum, 3"
(7.6 cm)
D. Combustion air intake
E. 12" (30.5 cm) minimum to roof or
highest anticipated snow level
F. 24" (61 cm) maximum radius
G. Screen
In a basement installation, the vent/flue pipe can be run
between joist spaces.
NOTE: If the vent pipe must go below a joist and then up into
the last joist space to penetrate the header, two 45° elbows
should be used to reach the header rather than two 90°
elbows.
Vent/Intake Terminations for Installation of
Multiple Direct Vent Furnaces
D
E. 12" (30.5 cm) minimum to roof or
highest anticipated snow level
F. Combustion air intake
G. 24" (61 cm) maximum, 3" (7.6 cm)
minimum
H. 24" (61 cm) maximum radius
Standard Horizontal Terminations (Dual Pipe)—Above
Highest Anticipated Snow Level
If more than one direct vent furnace is to be installed vertically
through a common roof top, maintain the same minimum
clearances between the exhaust vent and air intake terminations
of adjacent furnaces as with the exhaust vent and air intake
terminations of a single furnace.
If more than one direct vent furnace is to be installed horizontally
through a common side wall, maintain the clearances as shown
in “Horizontal Venting of Multiple Furnaces” illustration. Always
terminate all exhaust vent outlets at the same elevation and
always terminate all air intakes at the same elevation.
Horizontal Venting of Multiple Furnaces
C
A
B
B
B
D
A
F
C
GF
H
F
E
E
D
H
G
E
A
A. Support straps
B. 24" (61 cm) maximum, 3"
(7.6 cm) minimum
C. 12" (30.5 cm) minimum from wall
D. Vent/flue tee
E. 12" (30.5 cm) minimum to roof or
highest anticipated snow level
F. Screen
G. 90º medium radius elbow
H. Combustion air intake
A. 90º medium radius elbows
B. Flue/vent pipes
C. 12" (30.5 cm) minimum
D. 12" (30.5 cm) minimum to roof or
highest anticipated snow level
E. Screens
F. 24" (61 cm) maximum, 3"
(7.6 cm) minimum
G. 3" (7.6 cm) minimum
H. Combustion air intakes
Concentric Vent Termination
Refer to the directions provided with the Concentric Vent Kit
(DCVK) for installation specifications.
20
Side Wall Vent Kit
This kit is to be used with 2" or 3" (5.1 cm or 7.6 cm) direct vent
systems. The vent kit must terminate outside the structure and
may be installed with the intake and exhaust pipes located sideby-side or with one pipe above the other.
NOTE: This kit is not intended for use with single pipe (nondirect
vent) installations.
Refer to the directions furnished with the Side Wall Vent Kit (Part
Number 0170K00000S) for installation specifications.
CONDENSATE DRAIN LINES AND DRAIN TRAP
A condensing gas furnace achieves its high level of efficiency by
extracting almost all of the heat from the products of combustion
and cooling them to the point where condensation takes place.
The condensate which is generated must be piped to an
appropriate drain location.
In upright installations, the furnace’s drain hoses may exit either
the right or left side of the furnace.
NOTE: If the alternate vent/flue outlet is utilized in an upright
installation, the drain trap and drain connections must be located
on the same side as the alternate vent/flue outlet.
In horizontal installations, the drain hoses will exit through the
bottom (down side) of the furnace with the drain trap suspended
beneath the furnace. The field-supplied drain system must be in
accordance with all local codes and the instructions in the
following sections.
Follow the bullets listed below when installing the drain system.
Refer to the following sections for specific details concerning
furnace drain trap installation and drain hose hookups
NOTES:
■ The drain trap supplied with the furnace must be used.
■ The drain line between the furnace and drain location must
be constructed of ³⁄₄" (1.9 cm) PVC or CPVC.
■ The drain line between the furnace and drain location must
maintain a ¹⁄₄" (6.4 mm) per foot downward slope toward the
drain.
■ Do not trap the drain line in any other location than at the
drain trap supplied with the furnace.
■ Do not route the drain line outside where it may freeze.
■ If the drain line is routed through an area which may see
temperatures near or below freezing, precautions must be
taken to prevent the condensate from freezing within the
drain line.
■ If an air conditioning coil is installed with the furnace, a
common drain may be used. An open tee must be installed in
the drain line near the cooling coil to relieve positive air
pressure from the coil’s plenum. This is necessary to prohibit
any interference with the function of the furnace’s drain trap.
Upright Installations—Trap on Right Side
In an upright installation, drain hoses are connected to drain
ports on the rubber elbow and the recuperator coil front cover.
The drain lines are then routed through the right side panel and
into the drain trap secured to the outside of the cabinet.
NOTE: Refer to “Alternate Vent/Flue Hose Connections” for
upright installations using an alternate vent/flue outlet,
1. Remove the rubber plug/cap from the right side of the front
cover drain port.
2. Secure Hose A to the front cover drain port with a red hose
clamp.
3. Route Hose A to the rear side panel grommet hole.
4. Cut and remove ¹⁄₄" (6.4 cm) from the end of the drain port on
the rubber elbow.
5. Insert Tube 1 into the rubber elbow drain port and secure with
the silver hose clamp. Angle Tube 1 outward toward the front
of the furnace.
6. Cut 17³⁄₄" (45.1 cm) from the long end of Hose B and discard.
7. Secure the remaining Hose B to Tube 1 with a green hose
clamp.
8. Route the other end of Hose B to the front right side panel
grommet hole.
NOTE: For details concerning the mounting of the drain trap,
refer to “Upright Drain Trap Mounting.”
9. Insert the short end of each Tube 2 through the side panel
grommet holes.
10. Secure the tubes to Hose A and Hose B with the green hose
clamps.
NOTE: Ensure hoses and tubes maintain a downward slope
for proper drainage and that they are not kinked or binding.
Upright Standard Connections—Right Side Upflow
(Counterflow Similar)
A
Standard Right or Left Side
Drain Hose Connections
All installation positions require the use of the drain trap, hoses,
tubes and clamps. The following quantity of hoses, tubes, and
hose clamps are provided with the unit.
B
C
D
E
F G
H
Hose and Tube Identification
A
B
M
C
H
G
A. Drain trap
B. Hose A
C. Hose B
F
E
D. Tube 2 (2)
E. Tube 1
F. Red hose clamp (1)
D
A. Right side panel
B. Rubber elbow
C. Rubber elbow drain
port
D. Silver hose clamp
L
K
J
E. Tube 1
F. Hose B
G. Side panel
grommet holes
H. Tubes 2
I
I. Drain trap
J. Green hose clamps (3)
K. Hose A
L. Red hose clamp
M. Front cover drain port
G. Silver hose clamp (1)
H. Green hose clamps (3)
21
Alternate Vent/Flue Drain Hose Connections
Upright Installations—Trap on Left Side
Upright installations using the alternate vent/flue outlet will
require right side only drain hoses to be connected as follows.
Refer to “Vent/Flue Pipe and Combustion Air Pipe” for details on
alternate vent/flue pipe connection.
1. Remove the rubber plug/cap from the right-side drain port on
the front cover. Save the rubber plug/cap for later use.
2. Secure Hose A to the drain port on the front cover with a red
hose clamp.
3. Route Hose A to the rear right side panel grommet hole.
4. Remove the grommet from the front right side panel drain
hole.
5. Seal the hole in the grommet with the large end of the rubber
plug/cap removed in Step 1.
6. Reinstall the grommet and rubber plug into the side panel
drain hole.
7. Cut ¹⁄₄" (6.4 cm) from the end of the drain port on the
externally mounted rubber elbow. Discard cut portion.
8. Insert Tube 1 into the rubber elbow drain port and secure with
a silver hose clamp.
NOTE: Angle tube toward drain trap.
9. Cut 17⁷⁄₈" (45.4 cm) from the long end of Hose B. Discard cut
portion.
10. Secure the remaining end of Hose B to the exposed end of
Tube 1 with a green hose clamp.
11. Route Hose B toward the right side panel grommet holes.
12. Insert the short end of one Tube 2 through the rear right side
panel grommet drain hole.
13. Secure Tube 2 to Hose A with a green hose clamp.
14. Insert the short end of the remaining Tube 2 into Hose B from
the rubber elbow and secure with a green hose clamp.
15. Ensure that the hoses and tubes maintain a downward slope
for proper drainage and are not kinked or binding.
NOTE: For left side trap installation, grommets must be moved to
the left side of the furnace and the plugs installed on the right
side of the furnace.
1. Remove the rubber plug/cap from the left side of the front
cover drain port.
2. Secure Hose A to the front cover drain port with a red hose
clamp.
3. Route Hose A to the rear side panel grommet hole.
4. Cut and remove ¹⁄₄" (6.4 cm) from the end of the drain port on
the rubber elbow.
5. Insert Tube 1 into the rubber elbow drain port and secure with
the silver hose clamp. Angle Tube 1 outward toward the front
of the furnace.
6. Cut X" from the long end of Hose B and discard. Refer to the
following table for the appropriate length to cut.
7. Secure the remaining Hose B to Tube 1 with a green hose
clamp.
8. Route the other end of Hose B to the front left side panel
grommet hole.
NOTE: Long Hose B must always be connected to Tube 1 and
the elbow and not on the front cover.
9. Insert the short end of each Tube 2 through the side panel
grommet holes.
10. Secure the tubes to Hose A and Hose B with the green hose
clamps.
NOTE: Ensure hoses and tubes maintain a downward slope
for proper drainage and that they are not kinked or binding.
Upright Standard Connections—Left Side Upflow
(Counterflow Similar)
A
M
Alternate Upright Upflow Connections—Right Side Only
(Counterflow Similar)
L
K
J
I
B
A
C
D
H
E
F
G
F
H
L
K
J
A. Front cover drain port
B. Rubber elbow (externally mounted)
C. Rubber elbow drain port
D. Silver hose clamp
E. Tube 1
F. Green hose clamps (3)
I
G. Hose B
H. Side panel grommet holes
I. Drain trap
J. Tubes 2 (2)
K. Hose A
L. Red hose clamp
B
C
D
E
F
A. Left side panel
B. Rubber elbow
C. Rubber elbow
drain port
D. Silver hose clamp
F G
E. Tube 1
I. Tube 2 (2)
F. Green hose clamps (3) J. Side panel drain holes
G. Hose B
K. Hose A
H. Drain trap
L. Red hose clamp
M. Front cover drain port
Cabinet Width—in. Models
(kBtu/Tons)
(cm)
X Length to Cut from
Long End of Hose B
17¹⁄₂" (44.5 cm)
45_30
7" (17.8 cm)
21" (53.4 cm)
70_40
3¹⁄₂" (8.9 cm)
24¹⁄₂" (62.3 cm)
090_50
None
115_50
22
Upright Drain Trap Mounting—Left or Right Side
Panel
1. Insert the drain tubes into the drain trap and position the
drain trap against the side panel.
NOTE: Drain tubes must reach the bottom of the drain trap.
2. Secure the drain trap to the side panel at the mounting holes
(dimples or crosshairs on counterflow models) located below
the grommet drain holes.
3. Attach the PVC drain line to the drain trap outlet with either a
90° elbow or coupling.
Horizontal Installations—Right Side Down
Horizontal installations with the right side down require that the
drain hoses be connected to the right side front cover drain port
and the rubber elbow drain port.
NOTE: On counterflow models, relocation of the front cover
pressure switch hose is required.
Make connections as follows:
1. Remove the rubber plug/cap from the right side of the front
cover drain port.
NOTE: On counterflow furnaces, relocate the front cover
pressure switch hose connection from the left side pressure
tap to the right (down) side tap to guard against blocked drain
conditions. Cut the hose to appropriate length to minimize
sagging. Plug the left (unused) pressure tap with the plug
removed from right side.
2. Secure Hose A to the front cover drain tap with a red hose
clamp.
3. Route Hose A to the rear right (down) side panel grommet
holes.
4. Cut ¹⁄₄" (6.4 cm) from the end of the drain port on the
externally mounted rubber elbow. Discard cut portion.
5. Insert Tube 1 into the rubber elbow drain port and secure with
a silver hose clamp.
NOTE: Angle tube outward toward front of furnace.
6. Cut 17³⁄₄" (45.1 cm) from the long end of Hose B. Discard cut
portion.
7. Secure the remaining end of Hose B to exposed end of Tube
1 with a green hose clamp.
8. Route Hose B to the front right (down) side panel grommet
holes.
9. Cut 5¹⁄₂" (14 cm) straight length from the long end of each
Tube 2. Discard the radius pieces.
10. Insert approximately 1" (2.5 cm) of each Tube 2 through the
right (down) side panel grommet holes.
11. Secure the tubes to Hose A and Hose B using the green hose
clamps.
NOTE: Ensure that the hoses and tubes maintain a
downward slope for proper drainage and are not kinked or
bound.
For details concerning the mounting of the drain trap, refer to
“Horizontal Drain Trap Mounting” in “Condensate Drain Lines and
Drain Trap.”
Horizontal Upflow Connections—Right Side Down
(Counterflow Similar)
B
A
M
L
K
H
J
D
C
HG F E
I
A. Front cover drain port
B. Front cover pressure
tap
C. Right side panel
D. Rubber elbow
E. Rubber elbow drain
port
F. Silver hose clamp
G. Tube 1
H. Green hose clamps (3)
I. Drain trap
J. Tubes 2
K. Hose B
L. Hose A
M. Red hose clamp
Horizontal Installations—Left Side Down
Horizontal installations with the left side panel down will require
the drain hoses to be connected to the left side front cover drain
port and the side drain port on the rubber elbow.
1. Remove the rubber plug/cap from the front cover left (down)
side drain port.
2. Relocate the front cover pressure switch hose connection
from the right side (as shipped) pressure tap to the left (down)
side tap.
NOTE: The pressure switch hose must be connected to the
down side to guard against blocked drain conditions. Cut the
hose to the appropriate length to minimize sagging. Plug the
right (unused) pressure tap with the rubber plug removed
from the left side.
3. Secure Hose A to the front cover drain port with a red hose
clamp.
4. Route Hose A to the rear left (down) side panel grommet
holes.
NOTE: For left side drainage, grommets must be relocated to
the left side panel.
5. Remove the rubber cap from the side drain port on the rubber
elbow.
6. Secure the short end of Hose B to the rubber elbow side
drain port using a green hose clamp.
NOTES:
■ For left side drainage, route Hose B to the far left (down)
side panel grommet holes.
■ Horizontal left side connections (when using a new side
port drain elbow) does not require connecting a hose to
the induced draft blower housing.
7. Cut 5¹⁄₂" (14 cm) straight length from the long end of each
Tube 2. Discard radius ends.
8. Insert approximately 1" (2.5 cm) of each Tube 2 through the
left side panel grommet hole.
9. Secure the tubes to Hose A and Hose B with the green hose
clamps.
NOTE: Tube must reach bottom of trap.
NOTE: Ensure that the hoses and tubes maintain a downward
slope for proper drainage and are not kinked or bound.
For details concerning the mounting of the drain trap, refer to
“Horizontal Drain Trap Mounting” in this section.
23
Horizontal Upflow Connections—Left Side Down
(Counterflow Similar)
A
B
C
C
D
E
J
I
A. Front cover drain port
B. Hose B
C. Green hose clamps (3)
D. Side panel grommet holes
E. Tubes 2
H
G C
DE
Horizontal Drain Trap Mounting—Left or Right
Side Panel
1. Position the drain trap against the side panel with the drain
tubes inserted into the trap.
NOTE: The trap may be orientated with the outlet facing
either the furnace’s top cover or base pan.
2. Secure the drain trap to the side panel at the dimples or
crosshairs located on either side of the grommet drain holes.
3. Confirm that the tubes reach the bottom of the drain trap and
that all of the hoses maintain a downward slope and are not
kinked or binding.
4. Attach the PVC drain line to the drain trap outlet with either a
90° elbow or coupling.
F
F. Drain trap
G. Hose A
H. Red hose clamps
I. Front cover drain port
J. Left side panel
ELECTRICAL CONNECTIONS
WARNING
HIGH VOLTAGE!
To avoid the risk of electrical shock, wiring to
the unit must be polarized and grounded.
WARNING
HIGH VOLTAGE!
To avoid personal injury or death due to
electrical shock, disconnect electrical
power before servicing or changing any
electrical wiring.
CAUTION
Label all wires prior to disconnection when servicing
controls. Wiring errors can cause improper and dangerous
operation. Verify proper operation after servicing.
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.
24
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.
Use a separate fused-branch electrical circuit containing properly
sized wire, and fuse or circuit breaker. The fuse or circuit breaker
must be sized in accordance with the maximum overcurrent
protection specified on the unit rating plate. An electrical
disconnect must be provided at the furnace location.
NOTE: Line polarity must be observed when making field
connections.
Connect hot, neutral and ground wires as shown in the wiring
diagram located on the unit’s blower door. For direct vent
applications, the cabinet opening to the junction box must be
sealed air tight using either an UL Listed/CSA approved bushing
such as Heyco Liquid Tight or by applying non-reactive UL
Listed/CSA approved sealant to bushing.
Line polarity must be observed when making field connections.
Line voltage connections can be made through either the right or
left side panel. The furnace is shipped configured for a left side
(right side for counterflows) electrical connection with the
junction box located inside the burner compartment.
To make electrical connections through the opposite side of the
furnace, the junction box must be relocated to the other side of
the burner compartment prior to making electrical connections.
To relocate the junction box, follow the steps shown in “Junction
Box Relocation.”
NOTE: Wire routing must not to interfere with circulator blower
operation, filter removal, or routine maintenance.
Junction Box Relocation
24-Volt Thermostat Wiring
WARNING
Edges of sheet metal holes may be sharp. Use gloves as
a precaution when removing hole plugs.
1. Remove the burner compartment door.
2. Remove and save the 2 screws securing the junction box to
the side panel.
3. Relocate junction box and associated plugs and grommets to
opposite side panel.
4. Secure with screws removed in Step 2.
Junction Box Relocation
NOTE: Wire routing must not interfere with circulator blower
operation, filter removal or routine maintenance.
Low voltage connections can be made through either the right or
left side panel. Thermostat wiring entrance holes are located in
the blower compartment. Wire routing must not interfere with
circulator blower operation, filter removal or routine maintenance.
Refer to the following illustration for thermostat connections to
the integrated control module terminal strip.
Thermostat Diagram
B
B
Y
A
W
W
R
Y
C
Y
R
G
G
W
R
C
W
R
G
D
Y
C
C
*
*
*
*
*
*
*
A
B
A. Standard junction box location
B. Alternate junction box location
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 (NEC).
To ensure proper unit grounding, the ground wire should run from
the furnace ground screw located inside the furnace junction box
all the way back to the electrical panel.
NOTE: Do not use gas piping as an electrical ground.
To confirm proper unit grounding, turn off the electrical power
and perform the following check.
1. Measure the resistance between the neutral (white)
connection and one of the burners.
2. Resistance should measure 10 ohms or less.
This furnace is equipped with a blower door interlock switch
which interrupts the unit voltage when the blower door is opened
for servicing.
NOTE: Do not defeat this switch.
A. Heating room thermostat
B. Furnace
C. Heating and cooling room thermostat
D. Remote condensing unit
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: To apply a single-stage heating thermostat, the
thermostat selector switch on the integrated control module must
be set on single-stage.
115-Volt Line Connection of Accessories (Humidifier
and Electronic Air Cleaner)
WARNING
HIGH VOLTAGE!
To avoid personal injury or death due to
electrical shock, disconnect electrical
power before servicing or changing any
electrical wiring.
The furnace integrated control module is equipped with line
voltage accessory terminals for controlling power to an optional
field-supplied electronic air cleaner.
The accessory load specifications are as follows:
Electronic Air Cleaner
1.0 Amp maximum at 120 VAC
NOTES:
■ Turn off power to the furnace before installing any
accessories.
■ Follow the 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 terminals are identified as
EAC-H.
■ The electronic air cleaner neutral terminals are identified as
NEUTRAL.
■ All field wiring must conform to applicable codes.
■ Connections should be made as shown in the “Optional
Accessories Wiring” illustration.
25
Optional Accessories Wiring
All line voltage wire splices must be made inside the furnace
junction box.
The integrated control module electronic air cleaner terminals
(EAC) are energized with 115 volts whenever the circulator blower
is energized.
Electronic
Air Cleaner
EAC-H
24-Volt Humidifier
120 VAC Hot and
Park Terminals
120 VAC
Neutral Terminals
12-Pin Connector
Integrated
Control
Module
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.
The yellow wire connected to the induced draft blower pressure
switch is powered anytime the pressure switch is closed and
provides 24 VAC humidifier control.
1. Remove the yellow wire and connect the supplied brown
jumper wire to the pressure switch terminal.
2. Reconnect the yellow wire to the “piggyback” terminal on the
brown jumper.
3. Connect the 24 VAC line of the humidifier to the stripped end
of the brown wire.
NOTES:
■ Using a wire connector or a field-supplied quick connect
terminal can make this connection.
■ The wiring must conform to all local and national codes.
4. Connect the COM side of the humidifier to the B/C terminal
on the furnace control board (or to the COM side of the
24 VAC transformer).
NOTE: Do not connect 115-volt humidifier to these terminals.
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
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 Inlet Gas Supply Pressure chart. 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 avoid unreliable ignition. The maximum
must not be exceeded to keep the furnace from overfiring.
Inlet Gas Supply Pressure
Natural gas
5.0" W.C. minimum; 10.0" W.C. maximum
Propane gas
11.0" W.C. minimum; 13.0" W.C. maximum
High Altitude Derate
When this furnace is installed at high altitude, the appropriate
high altitude orifice kit must be applied. This is required due to
the natural reduction in the density of both the gas fuel and
combustion air as altitude increases. The kit will provide the
proper design-certified input rate within the specified altitude
range.
High altitude kits are purchased according to the installation
altitude and usage of either Natural or propane gas. Contact your
distributor for a tabular listing of appropriate altitude ranges and
corresponding manufacturer’s high altitude (Natural, propane
gas, and/or pressure switch) kits.
26
NOTE: Do not derate the furnace by adjusting the manifold
pressure to a lower pressure than specified on the furnace rating
plate. The combination of the lower air density and a lower
manifold pressure will prohibit the burner orifice from drawing the
proper amount of air into the burner. This may cause incomplete
combustion, flashback and possible yellow tipping.
In some areas the gas supplier may artificially derate the gas in
an effort to compensate for the effects of altitude. If the gas is
artificially derated, the appropriate orifice size must be
determined based upon the Btu/ft3 content of the derated gas
and the altitude. Refer to the National Fuel Gas Code, NFPA 54/
ANSI Z223.1, and information provided by the gas supplier to
determine the proper orifice size.
A different pressure switch may be required at high altitude
regardless of the Btu/ft3 content of the fuel used. Contact your
distributor for a tabular listing of appropriate altitude ranges and
corresponding manufacturer’s pressure switch kits.
Propane Gas Conversion
WARNING
Possible property damage, personal injury or death may
occur if the correct conversion kits are not installed. The
appropriate kits must
be applied to ensure safe and proper
Placeholder
furnace operation. All conversions must be performed by
a qualified installer or service agency.
This furnace is configured for Natural gas. The appropriate
manufacturer’s propane gas conversion kit, must be applied for
propane gas installations. See “Propane Gas and/or High Altitude
Installations.”
Gas Control Valve
This furnace is equipped with a 24-volt gas control valve
controlled during the furnace operation by the integrated control
module. As shipped, the gas control valve is configured for
Natural gas. The gas control valve is field-convertible for use with
propane gas by replacing the regulator spring with a propane gas
spring from an appropriate manufacturer’s propane gas
conversion kit. Taps for measuring the gas supply pressure and
manifold pressure are provided on the valve.
The gas control valve has a manual On/Off control located on the
gas control valve itself. This control may be set only to the On or
Off position.
Refer to the lighting instructions label or see “Start-Up Procedure
and Adjustment” for use of this control during the start-up and
shutdown periods.
Gas Piping Connections
CAUTION
To avoid possible unsatisfactory operation or equipment
damage due to underfiring of equipment, use the proper
size of Natural/propane
gas piping needed when running
Placeholder
pipe from the meter/tank to the furnace.
When sizing a trunk line, be sure to include all appliances which
will operate simultaneously when sizing a trunk line.
The gas piping supplying the furnace must be properly sized
based on the gas flow required, specific gravity of the gas and
the length of the run. The gas line installation must comply with
local codes, or in their absence, with the latest edition of the
National Fuel Gas Code, NFPA 54/ANSI Z223.1.
Natural Gas Capacity of Pipe—Cu ft of Gas Per Hour (CFH)
Length of Nominal Black Pipe Size
Pipe—
¹⁄₂ "
³⁄₄ "
1"
1¹⁄₄ "
ft (m)
1¹⁄₂ "
10 (3)
132
278
520
1,050
1,600
20 (6.1)
92
190
350
730
1,100
30 (9.2)
73
152
285
590
980
40 (12.2)
63
130
245
500
760
50 (15.2)
56
115
215
440
670
60 (18.3)
50
105
195
400
610
70 (21.3)
46
96
180
370
560
80 (24.4)
43
90
170
350
530
90 (27.4)
40
84
160
320
490
100 (30.5)
38
79
150
305
460
Pressure 0.5 psig or less and pressure drop of 0.3" W.C.; based
on 0.60 specific gravity gas
Btu/h Furnace Input
CFH =
Heating Value of Gas (Btu/cu ft
To connect the furnace to the building’s gas piping, the installer
must supply a ground joint union, drip leg, manual shutoff valve
and line and fittings to connect to the gas control valve. In some
cases, the installer may also need to supply a transition piece
from ¹⁄₂" (1.3 cm) pipe to a larger pipe size.
The following stipulations apply when connecting gas piping.
Refer to “Gas Piping Connections” illustrations for typical gas line
connections to the furnace.
■ Use black iron or steel pipe and fittings for building piping.
■ Where possible, use new pipe that is properly chamfered,
reamed and free of burrs and chips.
NOTE: If old pipe is used, be sure it is clean and free of rust,
scale, burrs, chips and old pipe joint compound.
■ Use pipe joint compound (pipe dope) on male threads only.
■ Always use pipe joint compound (pipe dope) that is approved
for all gases.
NOTE: Do not apply compound to the first 2 threads.
■ Use ground joint unions.
■ Install a drip leg to trap dirt and moisture before it can enter
the gas control valve. The drip leg must be a minimum of 3"
(7.6 cm) long.
■ Install a ¹⁄₈" NPT pipe plug fitting, accessible for test gage
connection, immediately upstream of the gas supply
connection to the furnace.
■ Always use a backup wrench when making the connection to
the gas control valve to keep it from turning.
NOTE: The orientation of the gas control valve on the
manifold must be maintained as shipped from the factory.
■ Maximum torque for the gas control valve connection is
375 in-lbs.
NOTE: Excessive overtightening may damage the gas control
valve.
■ Install a manual shutoff valve between the gas meter and the
furnace within 6 ft (1.8 m) of the furnace.
■ 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:
1. Rigid metallic pipe and fittings.
2. Semirigid metallic tubing and metallic fittings.
NOTE: Aluminum alloy tubing must not be used in exterior
locations. In order to seal the grommet cabinet penetration,
rigid pipe must be used to reach the outside of the cabinet. A
semirigid connector to the gas piping may be used from
there.
■ Use UL Listed/CSA approved gas appliance connectors in
accordance with their instructions.
■ Gas connectors must be fully in the same room as the
furnace.
■ Protect gas connectors and semirigid 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, insulation or subjected to repeated wetting
by liquids such as water (except rain water), detergents or
sewage.
27
Gas Piping Connections—Upflow
B
C
Gas Piping Connections—Horizontal Upflow
D
C
E
D
A
E
B
A
J
J
F
I H G
I
H
A. Alternate gas line location
B. Manifold
C. Gas control valve
D. Burners
E. Manual shutoff valve (upstream
from ground joint pipe union)
F. Height required by local codes
G. Drip leg
H. Ground joint pipe union
I. Grommet in standard gas line hole
J. Plug in alternate gas line hole
Gas Piping Connections—Counterflow
G
A. Gas control valve
B. Ground joint pipe union
C. Manual shutoff valve (upstream
from ground joint pipe union)
D. Drip leg
E. Grommet in standard gas line hole
F
F. Drain trap
G. Plug in alternate gas line hole
H. Alternate gas line location
I. Manifold
J. Burners
Gas Piping Connections—Horizontal Counterflow
C
A
D
B
A
B
E
J
I
C
H
J
G
F
A. Manual shutoff valve (upstream
from ground joint pipe union)
B. Alternate gas line location
C. Plug in alternate gas line hole
D. Gas control valve
E. Manifold
D
E
F. Burners
G. Grommet in standard gas line hole
H. Ground joint pipe union
I. Drip leg
J. Height required by local codes
I
F
H
G
A. Gas control valve
B. Ground joint pipe union
C. Manual shutoff valve (upstream
from ground joint pipe union)
D. Drip leg
E. Grommet in standard gas line hole
F. Drain trap
G. Plug in alternate gas line hole
H. Alternate gas line location
I. Manifold
J. Burners
NOTES:
■ When the gas line is in the alternate location, swap the
position of the plug and grommet.
■ The drip leg may terminate with a ¹⁄₂" x ¹⁄₈" pipe plug to
accommodate line gas pressure measurement.
28
Direct/Standard Inlet Piping
Propane Gas Tanks and Piping
WARNING
WARNING
Edges of sheet metal holes may be sharp. Use gloves as
a precaution when removing hole plugs.
When gas piping enters directly to the gas control valve through
the standard inlet hole, the installer must supply straight pipe
with a ground joint union to reach the exterior of the furnace. The
rigid pipe must be long enough to reach the outside of the
cabinet to seal the grommet cabinet penetration. A semirigid
connector to the gas piping can be used outside the cabinet per
local codes.
Indirect/Alternate Inlet Piping
When gas piping enters indirectly to the gas control valve through
the alternate gas inlet hole, the following ¹⁄₂" pipe fittings (starting
from the gas control valve) must be supplied to reach the outside
of the cabinet:
■ 90º street elbow
■ 2¹⁄₂" pipe nipple
■ 90º elbow
■ Straight pipe
NOTE: The straight pipe must be long enough to reach the
outside of the cabinet so as to seal the grommet cabinet
penetration and to install the ground joint union outside of the
cabinet. A semirigid connector to the gas piping can be used
outside the cabinet per local codes.
Gas Piping Checks
Before placing the furnace in operation, leak test the furnace and
gas connections.
WARNING
To avoid the possibility of explosion or fire, never use a
match or open flame to test for leaks.
Check for leaks using an approved chloride-free soap and water
solution, an electronic combustible gas detector, or other
approved testing methods.
NOTES:
■ Never exceed specified pressures for testing. Higher pressure
may damage the gas control valve and cause subsequent
overfiring, resulting in heat exchanger failure.
■ Disconnect this unit and external manual shutoff valve from
the gas supply piping system before pressure testing the
supply piping system with pressures in excess of ¹⁄₂ psig
(3.48 kPa).
■ Isolate this unit from the gas supply piping system by closing
the external manual gas shutoff valve before pressure testing
supply piping system with test pressures equal to or less than
¹⁄₂ psig (3.48 kPa).
If the gas furnace is installed in a basement, and
Placeholder
excavated area or a 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 can
settle in low areas or confined spaces.
— Propane gas odorant may fade, making the gas
undetectable except with a warning device.
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.
All propane gas equipment must conform to the safety standards
of the National Board of Fire Underwriters, NBFU Manual 58.
For satisfactory operation, propane gas pressure must be 11"
W.C. at the furnace manifold with all gas appliances in operation.
Maintaining proper gas pressure depends on 3 main factors:
■ Vaporization rate, depending on temperature of the liquid and
“wetted surface” area of the container or containers.
■ Proper pressure regulation. Two-stage regulation is
recommended for both cost and efficiency.
■ Pressure drop in the lines between the regulators, and
between 2nd stage regulator and the appliance. Pipe size will
depend on the length of the pipe run and the total load of all
appliances.
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
liquefied petroleum gases, such as Gasolac®, Stalactic®, Clyde’s®
or John Crane® are satisfactory.
Refer to “Propane Gas Installation—Typical” for typical propane
gas installations and piping.
Propane Gas Installation—Typical
A
B
D
E
C
A. 1st stage regulator
B. 5 to 15 psig (20 psig maximum)
C. 200 psig maximum
D. 2nd stage regulator
E. Continuous 11" W.C.
29
Sizing Between 1st and 2nd Stage Regulator*
Maximum propane capacities listed are based on 2 psig pressure drop at 10 psig setting. Capacities in 1,000 Btu/h.
Propane Gas Piping Chart I
Tubing Size, O.D. Type L
Nominal Pipe Size Schedule 40
Pipe or Tubing Length—ft (m) ³⁄₈"
¹⁄₂"
⁵⁄₈"
³⁄₄"
⁷⁄₈"
¹⁄₂"
³⁄₄"
10 (3)
730
1,700
3,200
5,300
8,300
3,200
7,500
20 (6.1)
500
1,100
2,200
3,700
5,800
2,200
4,200
30 (9.2)
400
920
2,000
2,900
4,700
1,800
4,000
40 (12.2)
370
850
1,700
2,700
4,100
1,600
3,700
50 (15.2)
330
770
1,500
2,400
3,700
1,500
3,400
60 (18.3)
300
700
1,300
2,200
3,300
1,300
3,100
80 (24.4)
260
610
1,200
1,900
2,900
1,200
2,600
100 (30.5)
220
540
1,000
1,700
2,600
1,000
2,300
125 (38.1)
200
490
900
1,400
2,300
900
2,100
150 (45.7)
190
430
830
1,300
2,100
830
1,900
175 (53.3)
170
400
780
1,200
1,900
770
1,700
200 (61)
160
380
730
1,100
1,800
720
1,500
To convert to capacities at 15 psig settings—multiply by 1.13. To convert to capacities at 5 psig settings—multiply by 0.879.
Sizing Between Single or 2nd Stage Regulator and Appliance*
Maximum Propane Capacities Listed are Based on ¹⁄₂" W.C. pressure drop at 11" W.C. setting. Capacities in 1,000 Btu/h.
Propane Gas Piping Chart II
Tubing Size, O.D. Type L
Nominal Pipe Size Schedule 40
Pipe or Tubing Length—ft (m) ³⁄₈"
¹⁄₂"
⁵⁄₈"
³⁄₄"
⁷⁄₈"
1¹⁄₈
¹⁄₂"
³⁄₄"
1"
1¹⁄₄"
1¹⁄₂"
10 (3)
39
92
199
329
501
935
275
567
1,071
2,205
3,307
20 (6.1)
26
62
131
216
346
630
189
393
732
1,496
2,299
30 (9.2)
21
50
107
181
277
500
152
315
590
1,212
1,858
40 (12.2)
19
41
90
145
233
427
129
267
504
1,039
1,559
50 (15.2)
18
37
79
131
198
376
114
237
448
913
1,417
60 (18.3)
16
35
72
121
187
340
103
217
409
834
1,275
80 (24.4)
13
29
62
104
155
289
89
185
346
724
1,066
100 (30.5)
11
26
55
90
138
255
78
162
307
630
976
125 (38.1)
10
24
48
81
122
224
69
146
275
567
866
150 (45.7)
9
21
43
72
109
202
63
132
252
511
787
200 (61)
8
19
39
66
100
187
54
112
209
439
665
250 (76.2)
8
17
36
60
93
172
48
100
185
390
590
*Data in accordance with NFPA pamphlet Number 54.
30
CIRCULATING AIR AND FILTERS
Ductwork—Airflow
Duct systems and register sizes must be properly designed
for the CFM and external static pressure rating of the furnace.
Design the ductwork in accordance with the recommended
methods of “Air Conditioning Contractors of America”
Manual D.
■ Install the duct system in accordance with Standards of the
National Board of Fire Underwriters for the Installation of Air
Conditioning, Warm Air Heating and Ventilating Systems.
Pamphlets No. 90A and 90B.
■ A closed return duct system must be used, with the return
duct connected to the furnace.
NOTE: Ductwork must never be attached to the back of the
furnace.
■ Flexible joints may be used for supply and return connections
to reduce noise transmission.
■ To prevent the blower from interfering with combustion air or
draft when a central return is used, a connecting duct must
be installed between the unit and the utility room wall.
■ Never use a room, closet or alcove as a return air chamber.
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.
When the furnace is installed without a cooling coil, it is
recommended that a removable access panel be provided in the
outlet air duct. This opening shall be accessible when the furnace
is installed and shall be of such a size that the heat exchanger
can be viewed for 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.
When the furnace is heating, the temperature of the return air
entering the furnace must be between 55°F and 100°F (13ºC and
38ºC).
■
3. In the corners of the opening, cut the sheet metal along the
scribe lines to free the duct flanges.
4. Using the scribe line along the duct flange as a guide, unfold
the duct flanges around the perimeter of the opening using a
pair of seamer pliers or seamer tongs.
NOTE: Airflow area will be reduced by approximately 18% if
duct flanges are not unfolded. This could cause performance
issues and noise issues.
WARNING
Edges of sheet metal holes may be sharp. Use gloves as
a precaution when removing hole plugs.
Duct Flange Cutouts
A
B
D
C
A. Cut using tin snips.
B. Press out by hand.
Filters—Read This Section Before Installing the
Return Air Ductwork
■
■
■
Bottom Return Air Opening—Upflow Models
The bottom return air opening on upflow models utilizes a “lance
and cut” method to remove sheet metal from the duct opening in
the base pan.
1. To remove, simply press out the lanced sections by hand to
expose the metal strips retaining the sheet metal over the
duct opening.
2. Using tin snips, cut the metal strips and remove the sheet
metal covering the duct opening.
C. Scribe lines outlining duct flanges.
D. Cut 4 corners after removing sheet metal.
■
Filters must be used with this furnace. Discuss filter
maintenance with the building owner.
Filters do not ship with this furnace, but must be provided,
sized and installed externally by the installer.
Filters must comply with UL900 or CAN/ULCS111 standards.
If the furnace is installed without filters, the warranty will be
voided.
On upflow units, guide dimples locate the side return cutout
locations. Use a straight edge to scribe lines connecting the
dimples. Cut out the opening on these lines.
NOTE: An undersized opening will cause reduced airflow.
31
Refer to Minimum Filter Requirement charts to determine filter area requirements.
Minimum Filter Requirements Chart
Cooling Airflow Requirement (CFM)—Permanent Minimum Filter Area (sq. in.) Based On 600 ft (182.9 m)
Per Minute Filter Face Velocity
Input Airflow
600
800
1,000
1,200
1,400
1,600
2,000
0453BXA
194*
194
240
288
-
-
-
0703BXA
-
324*
324*
324*
336
-
-
0704CXA
-
-
291*
291*
336
384
-
0904CXA
-
-
432*
432*
432*
432*
-
0905DXA
-
-
-
388*
388*
388*
480
1155DXA
-
-
-
486*
486*
486*
486*
Cooling Airflow Requirement (CFM)—Permanent Minimum Filter Area (sq. in.) Based On 300 ft (91.4 m) Per
Minute Filter Face Velocity
0453BXA
388*
388*
480
576
-
-
-
0703BXA
-
647*
647*
647*
672
-
-
0704CXA
-
-
583*
583*
672
768
-
0904CXA
-
-
863*
863*
863*
863*
-
0905DXA
-
-
-
777*
777*
777*
960
1155DXA
-
-
-
971*
971*
971*
971*
*Minimum filter area dictated by heating airflow requirement.
Filter Locations—Possible Upright Counterflow
Upright Installations
Depending on the installation and/or customer preference, filters
can be installed in the central return register or a side panel
external filter rack kit (upflows). As an alternative, a media air filter
or electronic air cleaner can be used as the requested filter.
The following illustrations show possible filter locations.
A
B
B
Filter Locations—Possible Upright Upflow
F
C
A
B
C
E
B
B
D
A. Central return grille
B. Filter
C. Airflow
D. Side return external filter rack kit (either side)
D
A. Filter access door
B. Filter
C. Central return grille
D. Airflow
E. Filter support bracket (provided)
F. Return duct
Horizontal Installations
Filters must be installed in either the central return register or in
the return air ductwork.
32
START-UP PROCEDURE AND ADJUSTMENT
This 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.”
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
avoid 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.
Drain Trap Priming
The drain trap must be primed prior to the furnace start-up. To
prime, fill the drain trap with water.
This ensures proper furnace drainage upon start-up and avoids
the possibility of flue gases escaping through the drain system.
Furnace Operation
1. Purge the gas lines of air prior to start-up.
NOTE: Be sure not purge lines into an enclosed burner
compartment.
2. Check for leaks using an approved chloride-free soap and
water solution, an electronic combustible gas detector or
other approved method.
3. Verify that all required kits (propane gas, high altitude, etc.)
have been appropriately installed.
After a 100- to 150-second delay period (field-selectable), the
circulator blower de-energizes.
2. Remove the burner compartment door and move the furnace
gas control valve manual control to the Off position.
3. Close the manual gas shutoff valve external to the furnace.
4. Replace the burner compartment door.
Gas Supply Pressure Measurement
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 control valve must be within
the range specified below. The supply pressure can be measured
at the gas control 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 Control Valve—White-Rodgers 36G54 2-Stage
A
B
Furnace Start-Up
1. Close the manual gas shutoff valve external to the furnace.
2. Turn off the electrical power to the furnace.
3. Set the room thermostat to the lowest possible setting.
4. Remove the burner compartment door.
NOTE: This furnace is equipped with an ignition device which
automatically lights the burner. Do not try to light the burner by hand.
5. Move the furnace gas control valve manual control to the Off
position.
6. Wait 5 minutes, and then check for a gas odor.
NOTE: Check near the floor as some types of gas are heavier
than air.
7. If a gas odor is detected, follow the instructions in “Gas
Furnace Safety Precautions” in this manual.
8. If no gas odor is detected, move the furnace gas control valve
manual control to the On position.
9. Replace the burner compartment door.
10. Open the manual gas shutoff valve external to the furnace.
11. Turn on the electrical power to the furnace.
12. Adjust the thermostat to a setting above room temperature.
13. After the burners are lit, set the thermostat to the desired
temperature.
Furnace Shutdown
1. Set the thermostat to the lowest setting.
The integrated control will close the gas control valve and
extinguish the flame. Following a 15-second delay, the
induced draft blower will be de-energized.
C
A. Inlet
B. Outlet
C. On/Off selector switch
Gas Control Valve—White-Rodgers 36G54 Connected to
Manometer
B
A
C
D
E
F
K
L
J
A. Open to atmosphere
B. Manometer hose
C. Outlet pressure boss
D. High-fire regulator adjust
E. Regulator vent
F. Low-fire regulator adjust
I HG
G. Coaxial coil terminal (M)
H. Common terminal (C)
I. High-fire coil terminal (HI)
J. On/Off selector switch
K. Inlet pressure boss
L. Manometer
33
Gas Control Valve—Honeywell VR9205 2-Stage
A
If the supply pressure differs from chart, make the necessary
adjustments to the pressure regulator, gas piping size, etc., and/
or consult with local gas utility.
5. Turn off the gas supply to the furnace at the manual shutoff
valve.
6. Disconnect the manometer.
7. Reinstall plug before turning on gas supply to furnace.
8. Turn off any unnecessary gas appliances started in Step 3.
B
Measuring Inlet Gas Pressure Alternate Method
D
A. Regulator vent
B. High-fire regulator adjust
C
C. Low-fire regulator adjust
D. On/Off selector switch
A
B
Gas Control Valve—Honeywell VR9205 Connected to
Manometer
C
C
B
A
D
D
E
G
F
i
E
F
A. Gas supply line
B. Gas shutoff valve
C. Gas supply line to furnace
D. Open to atmosphere
E. Manometer
F. Manometer hose
G. Drip leg cap with fitting
H
Gas Manifold Pressure Measurement and
Adjustment
G
A. Open to atmosphere
B. Manometer hose
C. Common terminal (C)
D. High-fire coil terminal (HI)
E. Low-fire coil terminal (LO)
F. ¹⁄₈" NPT inlet pressure tap
G. ¹⁄₈" NPT outlet pressure tap
H. Manometer
1. Turn off the 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 control valve inlet pressure
boss or the gas piping drip leg. See Gas Control Valve—
Honeywell VR9205 Connected to Manometer or Gas Control
Valve—White-Rodgers 36G54 Connected to Manometer for
location of inlet pressure boss/tap.
NOTE: If measuring the gas pressure at the drip leg or on the
Honeywell VR9205 gas control valve, a field-supplied hose barb
fitting must be installed prior to making the hose connection. If
using the inlet pressure boss on the White-Rodgers 36G54 gas
control valve, then use the 36G Valve Pressure Check Kit, Part
Number 0151K00000S.
3. Turn on the gas supply and operate the furnace and all other
gas consuming appliances on the same gas supply line.
4. Measure the furnace gas supply pressure with burners firing.
NOTE: Supply pressure must be within the range specified in the
Inlet Gas Supply Pressure chart.
Inlet Gas Supply Pressure
Natural Gas
Minimum: 5.0" W.C.Maximum: 10.0" W.C.
Propane Gas
Minimum: 11.0" W.C.Maximum: 13.0" W.C.
34
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 control valve pressure regulator.
Only small variations in gas pressure should be made by
adjusting the gas control valve pressure regulator. The manifold
pressure must be measured with the burners operating. To
measure and adjust the manifold pressure, use the following
procedure.
1. Turn off the gas supply to furnace at the manual gas shutoff
valve external to the furnace.
2. Turn off all electrical power to the system.
3. Outlet pressure tap connections:
■ Honeywell VR9205 valve: Remove the outlet pressure
boss plug. Install an ¹⁄₈" NPT hose barb fitting into the
outlet pressure tap.
■ White-Rodgers 36G54 valve: Back outlet pressure test
screw (inlet/outlet pressure boss) out one turn
(counterclockwise, not more than one turn).
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.
8. Adjust manifold pressure using the following Manifold Gas
Pressure chart.
9. Remove the regulator cover screw from the low (LO) outlet
pressure regulator adjust tower.
10. Turn the screw clockwise to increase pressure or
counterclockwise to decrease pressure.
11. Replace regulator cover screw.
12. Close thermostat R and W2 contacts to provide a call for
high-stage heat.
13. Remove the regulator cover screw from the high (HI) outlet
pressure regulator adjust tower.
14. Turn the screw clockwise to increase pressure or
counterclockwise to decrease pressure.
15. Replace the regulator cover screw.
16. Turn off all electrical power and gas supply to the system.
17. Remove the manometer hose from the hose barb fitting or
outlet pressure boss.
18. Replace the outlet pressure tap:
■ 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.
■ White-Rodgers 36G54 valve: Turn the outlet pressure test
screw in to seal pressure port (clockwise, 7 in-lb
minimum).
19. Turn on electrical power and gas supply to the system.
20. Close the thermostat contacts R and W1/W2 to energize the
valve.
21. Using a leak detection solution or soap suds, check for leaks
at the outlet pressure boss plug (Honeywell valve) or screw
(White-Rodgers valve). Bubbles forming indicate a leak.
IMPORTANT: If a leak is detected, turn off gas immediately
and repair all leaks.
NOTE: For gas-to-gas conversion, consult your dealer for
appropriate conversion.
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): 3,600 sec/h
Input = (Htg. value x 3,600) ÷ seconds per cubic foot
Input = (1,000 Btu/ft3 x 3,600 sec/h) ÷ 34 sec/ft3
Input = 106,000 Btu/h
This measured input must not be greater than the input indicated
on the unit rating plate.
5. Turn on the gas supply to all other appliances turned off in
Step 1.
6. Ensure that all appliances are functioning properly and that all
pilot burners are lit and operating.
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
10 minutes.
2. Ensure that all registers are open and all duct dampers are in
their final (fully or partially open) position.
3. Place thermometers in the return and supply ducts as close
to the furnace as possible. Thermometers must not be
influenced by radiant heat from the heat exchanger.
Temperature Rise Measurement
Rise = Supply air temperature - Return air temperature
A
B
C
Manifold Gas Pressure
Gas
Natural
Propane
Range
Nominal
Low Stage
1.7" to 2.3" W.C.
2.0" W.C.
High Stage
3.2" to 3.8" W.C.
3.5" W.C.
Low Stage
5.7" to 6.3" W.C.
6.0" W.C.
High Stage
9.7" to 10.3" W.C. 10.0" W.C.
D
E
Gas Input Rate Measurement—Natural Gas Only
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.
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 2 cubic foot dial, divide the number of
seconds recorded in Step 2 by 2.
4. Calculate the furnace input in Btu per hour (Btu/h). 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.
A. Heat exchanger radiation
“line of sight”
B. Supply air
C. Supply air temperature
D. Return air temperature
E. Return air
4. Subtract the return air temperature from the supply air
temperature to determine the air temperature rise. Allow
adequate time for thermometer readings to stabilize.
5. Adjust the temperature rise by adjusting the circulator blower
speed. Increase blower speed to reduce temperature rise.
Decrease blower speed to increase temperature rise. Refer to
“Circulator Blower Speeds” for speed changing details.
35
Circulator Blower Speeds
WARNING
To prevent premature failure of heat exchanger, property
damage, personal injury or death, do not adjust the limit
control (factory set).
This furnace is equipped with a multispeed 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 cooling blower speed is set at
High and the heating blower speed is set as indicated in the
Specification Sheet applicable to your model. 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.
To adjust the circulator blower speed, proceed as follows:
1. Turn off the power to the furnace.
2. Select the heating and cooling blower speeds that match the
installation requirements from the airflow table in the
Specification Sheet.
3. Relocate the desired motor leads to the circulator blower heat
and cool speed terminals on the integrated control module.
(Terminals are identified as LO HEAT-H, HI HEAT-H and
COOL-H (hot)). If a heating speed and the cooling blower
speed are the same, a jumper wire must be used between the
heat and cool terminals.
4. Connect all of the unused blower motor leads to the “PARK”
terminals on the integrated control module. Any leads not
connected to the “PARK” terminals must be taped.
5. Turn on the power to furnace.
6. Verify the proper temperature rise as outlined in “Temperature
Rise.”
Circulator Blower Speeds
Low
Red
Medium Low
Orange
Medium
Blue
High
Black
Common/Neutral
White
NORMAL SEQUENCE OF OPERATION
Power Up
The normal power up sequence is as follows:
■ 115 VAC power applied to furnace.
■ Integrated control module performs internal checks.
■ Integrated control module LED will light.
■ Integrated control module monitors safety circuits
continuously.
■ Furnace awaits call from thermostat.
Heating Mode—Mode DIP Switch Set to
1 STG Position
The normal operational sequence in heating mode is as follows:
■ R and W thermostat contacts close, initiating a call for heat.
■ Integrated control module performs safety circuit checks.
■ Induced draft blower is energized for a 15-second prepurge
period causing the pressure switch contacts to close.
■ Igniter warm-up begins after 15-second prepurge expires.
■ Low-stage and high-stage gas control valves open at the end
of the igniter warm-up period, delivering gas to the burners
and establishing flame.
■ Integrated control module monitors flame presence. Gas
control valve will remain open only if flame is detected.
■ Circulator blower is energized on high heat speed following a
fixed 30-second blower on delay. Electronic air cleaner
terminals are energized with circulator blower.
■ Furnace operates; integrated control module monitors safety
circuits continuously.
■ R and W thermostat contacts open, completing the call for
heat.
■ Gas control valve closes, extinguishing flame.
■ Induced draft blower is de-energized following a 15-second
post purge.
■
36
The circulator blower remains at high-heat speed for
30 seconds. The circulator blower then switches to low-heat
speed for the remainder of the selected heat-off delay period.
For example, the selected heat-off delay period is
150 seconds. The circulator blower operates at high heat for
30 seconds and at low speed for 150 - 30 = 120 seconds.
Heating Mode—Mode DIP Switch Set to
2 STG Position
The normal operational sequence in heating mode is as follows:
■ R and W thermostat contacts close, initiating a call for heat.
■ Integrated control module performs safety circuit checks.
■ Induced draft blower is energized for a 15-second prepurge
period causing the pressure switch contacts to close.
■ Igniter warm-up begins after 15-second prepurge expires.
■ Low-stage and high-stage gas control valves open at the end
of the igniter warm-up period, delivering gas to the burners
and establishing flame.
■ High-stage gas control valve closes after 5 seconds;
low-stage gas control valve remains open.
■ Integrated control module monitors flame presence. Gas
control valve will remain open only if flame is detected.
■ Circulator blower is energized on low-heat speed following a
fixed 30-second blower on delay. Electronic air cleaner
terminals are energized with circulator blower.
■ Furnace is now operating in low-stage heating mode.
■ Furnace operates; integrated control module monitors safety
circuits continuously.
■ If low-stage delay period expires, control will shift operation
from low-stage heating mode operation to high-stage heating
mode operation. Control will energize circulator blower
high-heat speed and high-stage gas control valve.
■ Furnace is now operating in high-stage heating mode.
■ R and W thermostat contacts open, completing the call for
heat.
■ Induced draft blower is de-energized following a 15-second
post purge.
■ Circulator blower is de-energized following a heat-off delay
period (selectable 100 to 150 seconds; factory-set at
150 seconds).
■
If the furnace is operating in the low-stage heating mode
when thermostat contacts open, circulator blower remains at
low-heat speed for the selected delay off period.
If the furnace is operating in high-stage heating mode when
the thermostat contacts open, the circulator blower remains
at high-heat speed for the selected heat-off delay period. The
circulator blower then switches to low-heat speed for the
remainder of the selected heat-off delay period. For example,
the selected heat-off delay period is 150 seconds. The
circulator blower operates at high heat for 30 seconds and at
low speed for 150 - 30 = 120 seconds.
Furnace awaits the next call from thermostat.
Cooling Mode
The normal operational sequence in cooling mode is as follows:
■ R and Y thermostat contacts close, initiating a call for cool.
■ Integrated control module performs safety circuit checks.
■ Outdoor fan and compressor are energized.
■ Circulator blower is energized on cool speed following a fixed
5-second on delay. Electronic air cleaner terminals are
energized with circulator blower.
■ Furnace circulator blower and outdoor cooling unit run;
integrated control module monitors safety circuits
continuously.
■ R and Y thermostat contacts open, completing the call for
cool.
■ Outdoor fan and compressor are de-energized.
■ Circulator blower is de-energized following a fixed 45-second
cool off delay period. Electronic air cleaner terminals are
de-energized.
■ Furnace awaits the next call from thermostat.
■
■
■
■
■
■
Integrated control module performs safety circuit checks.
Circulator blower is energized on low-heat speed. Electronic
air cleaner terminals are energized.
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
terminals are de-energized.
Furnace awaits the next call from thermostat.
Operational Checks
Burner Flame
The burner flames should be inspected with the burner
compartment door installed. A sight glass is provided for
inspection purposes. Flames should be stable, quiet, soft and
blue (dust may cause orange tips but must not be yellow). The
flames should extend directly outward from the burner without
curling, floating or lifting off. Flames must not impinge on the
sides of the heat exchanger firing tubes.
Burner Flame
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.
Check the burner flames for good adjustment, a stable, soft and
blue flame that is not curling, floating or lifting off.
SAFETY CIRCUIT DESCRIPTION
General
A number of circuits are employed to ensure 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 Control
The primary limit control is located on the partition panel and
monitors heat exchanger compartment temperatures. It is a
normally closed (electrically), automatic reset, temperatureactivated sensor. The limit guards against overheating as a result
of insufficient conditioned air passing over the heat exchanger.
Auxiliary Limit Control(s)
The auxiliary limit control(s) are located on or near the circulator
blower and monitors blower compartment temperatures. They
are normally-closed (electrically), manual-reset sensors.
These limits guard against overheating as a result of insufficient
conditioned air passing over the heat exchanger.
Rollout Limit Control(s)
The rollout limit control(s) 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.
Pressure Switches
The pressure switches are normally-open (closed during
operation), negative air pressure-activated switches. They
monitor the airflow (combustion air and flue products) through
the heat exchanger via pressure taps located on the induced
draft blower and the coil front cover. These switches guard
against insufficient airflow (combustion air and flue products)
through the heat exchanger and/or blocked condensate drain
conditions.
Flame Sensor
The flame sensor is a probe mounted on the burner/manifold
assembly which uses the principle of flame rectification to
determine the presence or absence of flame.
37
MAINTENANCE
WARNING
HIGH VOLTAGE!
To avoid personal injury or death due to
electrical shock, 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 the furnace.
2. Remove the filter(s) from the central return register or
ductwork.
3. Replace the filter(s) by reversing the procedure for removal.
4. Turn on electrical power to the furnace.
Annual Inspection
The furnace should be inspected by a qualified installer, or
service agency at least once per year. This check should be
performed at the beginning of the heating season. This will
ensure that all furnace components are in proper working order
and that the heating system functions appropriately. Pay
particular attention to the following items. Repair or service as
necessary.
■ 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
sense.
■ 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
Filters
CAUTION
To ensure proper unit performance, adhere to the filter
sizes given in the Recommended Minimum Filter Size
chart or Specification Sheet applicable to your model.
NOTE: Please contact your distributor or our website for the
applicable Specification Sheet referred to in this manual.
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 2 months or
as required. When replacing a filter, it must be replaced with a
filter of the same type and size.
Media Air Filter or Electronic Air Cleaner Removal
Follow the manufacturer’s directions for service.
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.
Induced Draft and Circulator Blowers
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.
Condensate Trap and Drain System
(Qualified Servicer Only)
Annually inspect the drain tubes, drain trap and field-supplied
drain line for proper condensate drainage. Check drain system
for hose connection tightness, blockage and leaks. Clean or
repair as necessary.
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 1 to 6 microamps at
115 volts.
Filter Removal
Depending on the installation, differing filter arrangements can be
applied. Filters can be installed in either the central return register
or a side panel external filter rack (upflow only).
A media air filter or electronic air cleaner can be used as an
alternate filter. Follow the filter sizes given in the Recommended
Minimum Filter Size chart to ensure proper unit performance.
38
Igniter (Qualified Servicer Only)
If the igniter and the surrounding air are at about 70°F (21ºC) and
the igniter wires are not connected to any other electrical
components, the resistance of the igniter should not exceed
75 ohms. If it does, the igniter should be replaced.
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 below.
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, drain and pressure tap
hoses from the recuperator coil front cover.
5. Remove the recuperator coil front cover to expose the coil
tubes and turbulators.
6. Remove the recuperator coil turbulators individually by slowly
pulling each turbulator forward firmly.
7. Clean the recuperator coil tubes using a long handle wire
brush, such as a gun cleaning brush.
8. 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.
9. Clean the residue from the furnace by using a vacuum cleaner.
10. Replace the parts removed in the previous steps in reverse
order.
11. Turn on electrical power and gas to furnace. Check for leaks
and proper unit operation.
12. Severe heat exchanger fouling is an indication of an
operational problem. Perform the checks listed in “Start-Up
Procedure and Adjustments” to reduce the chances of
repeated fouling.
Before Leaving an Installation
■
■
■
Cycle the furnace with the thermostat at least 3 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.
Functional Parts List
■
Gas Control Valve
■
Blower Motor
■
Gas Manifold
■
Blower Wheel
■
Natural Gas Orifice
■
Blower Mounting Bracket
■
Propane Gas Orifice
■
Blower Cutoff
■
Igniter
■
Blower Housing
■
Flame sensor
■
Capacitor
■
Rollout Limit Switch
■
Heat Exchanger
■
Primary Limit Switch
■
Door Switch
■
Auxiliary Limit Switch
■
Coil Front Cover
■
Pressure Switch
■
Integrated Control Module
■
Induced Draft Blower
■
Transformer
TROUBLESHOOTING
Electrostatic Discharge (ESD) Precautions
Fault Recall
NOTE: Discharge static electricity accumulated in the body
before touching the unit. An electrostatic discharge can adversely
affect electrical components.
Use the following steps during furnace installations 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 also.
3. Service the integrated control module or connecting wiring
after following the discharge process in Step 2.
NOTE: Do not recharge your body with static electricity by
moving or shuffling your feet or touching ungrounded
objects. Repeat Step 2 if you touch an ungrounded object.
4. Follow steps 1 through 3 before removing a new control from
its container or installing the control on a furnace. Return any
old or new controls to their containers before touching any
ungrounded object.
The ignition control is equipped with a momentary pushbutton
switch that can be used to display the last 5 faults detected by
the control.
The control must be in Standby Mode (no thermostat inputs) to
use the feature. Depress the pushbutton switch for approximately
2 seconds.
Release the switch when the LED display is turned off. The
diagnostic LED will then display the flash codes associated with
the last 5 detected faults. The order of display is the most recent
fault to the least recent fault.
Resetting from Lockout
Furnace lockout results when a furnace is unable to achieve
ignition after 3 attempts during a single call for heat. It is
characterized by a nonfunctioning furnace and a 1-flash
diagnostic LED code. 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 1-hour lockout period.
2. Manual power interruption. Interrupt 115-volt power to the
furnace for 1 to 20 seconds.
3. Manual thermostat cycle. Lower the thermostat so that there
is no longer a call for heat for 1 to 20 seconds, and then reset
to previous setting.
NOTE: If the condition which originally caused the lockout still exists,
the control will return to lockout. Refer to the “Diagnostic Chart.”
39
Diagnostic Chart
WARNING
HIGH VOLTAGE!
To avoid personal injury or death due to electrical shock, disconnect electrical power
before performing any service or maintenance.
The red diagnostic LED blinks to assist in troubleshooting the uit. The number of blinks refers to a specific fault code.
Symptoms of
Abnormal
Operation
■
■
Furnace fails to
operate.
Integrated
control module
diagnostic LED
display
provides no
signal.
Associated
LED Code Fault Description Possible Causes
None
■
■
■
No 115-volt
power to
furnace, or no
24-volt power to
integrated
control module.
Blown fuse or
circuit breaker.
Internal fault in
Integrated
control module.
■
■
■
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.
Corrective Actions
■
■
■
■
■
LED display is
steady on
■
Furnace fails to
operate.
Integrated
control module
diagnostic LED
is flashing
1 flash.
■
■
40
Furnace fails to
operate.
Integrated
control module
diagnostic LED
is flashing 2
flashes.
Assure 115-volt power
to the furnace, and
24-volt power to
integrated control
module
Check integrated
control module fuse.
Replace with 3A
automotive fuse, if
necessary.
Check for possible
shorts in 115-volt and
24-volt circuits. Repair
as necessary.
Replace bad
integrated control
module.
■
■
■
■
Turn off power
prior to repair.
Replace
integrated control
module fuse with
3A automotive
fuse.
Read precautions
in “Electrostatic
Discharge”
section of manual.
Replace
integrated control
module with
current
replacement
parts.
Continuous
On
■
Normal
operation
■
Normal operation
■
None
■
Normal operation
1 flash
■
Furnace lockout
due to an
excessive
number of
ignition “retries”
(3 total).
■
Failure to establish
flame. No gas to
burners, front cover
pressure switch stuck
open, bad igniter or
igniter alignment,
improper orifices or
coated/oxidized or
improperly connected
flame sensor.
Loss of flame after
establishment.
Interrupted gas supply,
lazy burner flames
(improper gas pressure
or restriction in flue and/
or combustion air
piping), front cover
pressure switch
opening, or improper
induced draft blower
performance.
■
Locate and correct gas
interruption.
Check front cover
pressure switch
operation (hose, wiring,
contact operation).
Correct if necessary.
Replace or realign
igniter. Igniter is fragile,
handle gently.
Check flame sense
signal. Sand sensor if
coated and/or oxidized.
Check flue piping for
blockage, proper
length, elbows and
termination.
Verify proper induced
draft blower
performance.
■
Turn off power
prior to repair.
Igniter is fragile,
handle with care.
Sand flame
sensor with
emery cloth.
See “Vent/Flue
Pipe” section for
piping details.
Induced draft blower
pressure switch
contacts sticking.
Shorts in pressure
switch circuit.
■
Replace induced draft
blower pressure
switch.
Repair short.
■
■
■
Notes and
Cautions
2 flashes
■
■
Pressure switch
circuit is closed.
Induced draft
blower is not
operating.
■
■
■
■
■
■
■
■
■
■
■
■
Turn off power
prior to repair.
Replace pressure
switch with
correct
replacement part.
Symptoms of
Abnormal
Operation
■
■
Induced draft
blower runs
continuously
with no further
furnace
operation.
Integrated
control module
diagnostic LED
is flashing
3 flashes.
Associated
LED Code Fault Description Possible Causes
3 flashes
■
■
Pressure switch
circuit is not
closed.
Induced draft
blower is
operating.
■
■
■
■
Pressure switch hose
blocked, pinched or
connected improperly.
Blocked flue and/or inlet
air pipe, blocked drain
system or weak induced
draft blower.
Incorrect pressure
switch setpoint or
malfunctioning switch
contacts.
Loose or improperly
connected wiring.
Corrective Actions
■
■
■
■
■
■
■
Circulator
blower runs
continuously.
No furnace
operation.
Integrated
control module
diagnostic LED
is flashing
4 flashes.
4 flashes
■
Primary limit or
auxiliary limit
circuit is open.
■
■
■
Insufficient conditioned
air over the heat
exchanger. Blocked
filters, restrictive
ductwork, improper
circulator blower speed,
or failed circulator
blower.
Faulty primary limit
switch.
Loose or improperly
connected wiring.
■
■
■
■
■
■
■
■
Notes and
Cautions
Inspect pressure
switch hose. Repair/
replace, if necessary,
Inspect flue and/or
inlet air piping for
blockage, proper
length, elbows and
termination.
Check drain system.
Correct as necessary.
Correct pressure
switch setpoint or
contact motion.
Tighten or correct
wiring connection.
■
Check primary limit
switch. Replace if
necessary.
Check filters and
ductwork for blockage.
Clean filters or remove
obstruction.
Check circulator
blower speed and
performance. Correct
speed or replace
blower if necessary.
Tighten or correct
wiring connection.
■
■
■
■
■
Turn off power
prior to repair.
Replace pressure
switch with
correct
replacement part.
Replace induced
draft blower with
correct
replacement part.
Turn off power
prior to repair.
Replace primary
switch with
correct
replacement part.
Replace
circulator blower
with correct
replacement part.
Induced draft
blower and
circulator
blower runs
continuously.
No furnace
operation.
Integrated
control module
diagnostic LED
is flashing
5 flashes.
5 flashes
■
Flame sensed
with no call for
heat.
■
Short to ground in flame
sense circuit.
■
Correct short at flame
sensor or in flame
sensor wiring.
■
Turn off power
prior to repair.
No furnace
operation.
Integrated
control module
diagnostic LED
is flashing
6 flashes.
6 flashes
■
Rollout limit
switch open.
Integrated
control module
fuse is blown.
■
Flame rollout.
Misaligned burners,
blocked flue and/or air
inlet pipe or failed
induced draft blower.
Loose or improperly
connected wiring.
Short in 24-volt AC
control circuits or safety
circuits.
Faulty rollout limit
switch.
■
Check burners for
proper alignment.
Check flue and air inlet
piping for blockage,
proper length, elbows
and termination.
Correct as necessary.
Check rollout limit
switch. Replace if
necessary.
Check induced draft
blower for proper
performance. Replace
if necessary.
Tighten or correct
wiring connection.
Repair short in 24-volt
AC control/safety
circuit(s).
Replace integrated
control module fuse
(3A).
■
Turn off power
prior to repair.
Replace induced
draft blower with
correct
replacement part.
Replace
integrated control
module fuse with
3A automotive
fuse.
Read precautions
in “Electrostatic
Discharge”
section of
manual.
Replace rollout
limit switch with
correct
replacement part.
See “Vent/Fluie
Pipe” section for
piping details.
■
■
■
■
■
■
■
■
■
■
■
■
■
■
■
■
41
Symptoms of
Abnormal
Operation
■
■
Normal furnace
operation.
Integrated
control module
diagnostic LED
is flashing
7 flashes.
Associated
LED Code Fault Description Possible Causes
7 flashes
Flame sense
microamp signal
is low.
■
■
■
■
Notes and
Cautions
Corrective Actions
Flame sensor is coated/
oxidized.
Flame sensor incorrectly
positioned in burner
flame.
Lazy burner flame due to
improper gas pressure
or combustion air.
■
■
■
Sand flame sensor if
coated/oxidized.
Inspect for proper
sensor alignment.
Compare current gas
pressure to rating plate
info. Adjust as needed.
■
■
■
■
■
■
■
■
No furnace
operation
Integrated
control module
diagnostic LED
is flashing
8 flashes.
Induced draft
blower runs
continuously.
No furnace
operation.
Integrated
control module
diagnostic LED
is flashing
continuously.
8 flashes
Problem with
igniter circuit.
■
■
■
■
■
■
Continuous
flashes
Polarity of 115volt or 24-volt
power is
reversed.
■
■
■
■
Improperly connected
igniter.
Bad igniter.
Poor unit ground.
Poor burner ground.
Faulty integrated control
module.
Polarity of 115-volt AC
power to furnace or
integrated control
module is reversed.
Red and blue wires to
transformer are
reversed.
Poor unit ground.
■
■
■
■
■
■
■
Check and correct
wiring from integrated
control module to
igniter
Replace bad igniter.
Check and correct
furnace ground wiring
Replace faulty
integrated control
module.
■
Review wiring diagram
to correct polarity.
Verify proper ground.
Correct if necessary.
Reverse red and blue
wires connected to
transformer.
■
■
■
■
Turn off power
prior to repair.
Sand flame
sensor with
emery cloth.
See “Vent/Flue
Pipe” section for
piping details.
See rating plate
for proper gas
pressure.
Turn off power
prior to repair.
Replace igniter
with correct
replacement part.
Replace
integrated control
module with
correct
replacement part.
Read precautions
in “Electrostatic
Discharge”
section of
manual.
Turn off power
prior to repair.
BLOWER PERFORMANCE DATA
Blower Performance Data
CFM and Temperature Rise vs. External Static Pressure
Tons
AC at
0.5"
ESP
CFM
Rise CFM
Rise CFM
Rise CFM
Rise CFM
Rise CFM CFM CFM
High
3.0
1,352
29
1,318
30
1,260
31
1,202
33
1,128
35
1,044 955
853
Med
2.5
1,214
32
1,172
34
1,123
35
1,064
37
1,012
39
938
859
741
Med-Lo
2.0
997
40
994
40
960
41
923
43
884
45
817
741
611
Low
1.5
757
52
753
52
734
54
704
56
674
59
620
524
438
High
3.0
1,449
41
1,409
42
1,326
45
1,273
47
1,201
49
1,194 1,136 1,018
Med
2.5
1,192
50
1,172
51
1,141
52
1,094
54
1,046
57
973
904
793
Med-Lo
2.0
981
61
962
62
943
63
917
65
888
67
830
764
665
Low
1.5
750
79
730
81
714
83
692
86
657
90
620
570
502
Motor
Model—Heating
Speed as Shipped Speed
WGFM1950453BXA
(MED-HI)
WGFM1950703BXA
(MED-HI)
42
External Static Pressure (Inches Water Column)
0.1
0.2
0.3
0.4
0.6
0.5
0.7
0.8
Blower Performance Data
CFM and Temperature Rise vs. External Static Pressure
Tons
AC at
0.5"
ESP
CFM
Rise CFM
Rise CFM
Rise CFM
Rise CFM
Rise CFM CFM CFM
4.0
2,069
29
1,965
30
1,871
32
1,756
34
1,661
36
1,549 1,415 1,275
3.5
1,752
34
1,724
34
1,667
36
1,603
37
1,488
40
1,402 1,290 1,082
Med-Lo
3.0
1,437
41
1,437
41
1,417
42
1,369
43
1,320
45
1,256 1,140 984
Low
2.5
1,184
50
1,177
50
1,161
51
1,132
52
1,095
54
1,047 928
WGFM1950904CXA High
(MED-HI)
Med
4.0
1,970
40
1,874
42
1,757
45
1,667
48
1,566
51
1,431 1,334 1,182
3.5
1,713
46
1,650
48
1,572
50
1,510
52
1,418
56
1,313 1,211 1,079
Med-Lo
3.0
1,439
55
1,412
56
1,370
58
1,327
60
1,260
63
1,166 1,078 956
Low
2.5
1,183
67
1,155
69
1,122
74
1,108
72
1,062
75
1,011 931
High
5.0
2,147
37
2,114
37
2,057
39
2,030
39
1,978
40
1,889 1,784 1,713
Med
4.0
1,675
47
1,686
47
1,640
48
1,623
49
1,557
51
1,501 1,455 1,360
Med-Lo
3.5
1,489
53
1,470
54
1,436
55
1,4099 56
1,361
58
1,318 1,243 1,130
Low
3.0
1,307
61
1,265
63
1,234
64
1,203
66
1,168
68
1,096 1,053 991
High
5.0
2,134
46
2,103
47
2,029
48
1,941
51
1,906
51
1,818 1,733 1,625
Med
4.0
1,678
58
1,643
60
1,643
60
1,577
62
1,527
64
1,489 1,423 1,339
Med-Lo
3.5
1,453
68
1,440
68
1,426
69
1,363
72
1,349
73
1,314 1,253 1,205
Low
3.0
1,259
78
1,239
79
1,220
80
1,181
83
1,159
85
1,118 1,082 1,015
High
3.0
1,415
28
1,352
30
1,290
31
1,196
34
1,127
36
1,035 936
825
Med
2.5
1,221
33
1,178
34
1,127
36
1,073
38
1,007
40
932
834
733
Med-Lo
2.0
1,034
39
1,000
40
976
41
935
43
881
46
818
733
662
Low
1.5
860
47
845
48
812
50
783
51
740
54
682
619
534
High
3.0
1,431
42
1,368
44
1,296
47
1,228
49
1,150
53
1,055 962
860
Med
2.5
1,212
50
1,182
51
1,138
53
1,091
55
1,019
59
944
871
769
Med-Lo
2.0
1,002
60
978
62
956
63
921
66
878
69
825
738
647
Low
1.5
813
74
805
75
790
76
759
80
726
83
689
644
605
High
4.0
1,755
34
1,674
36
1,632
37
1,510
40
1,423
42
1,325 1,241 1,116
Med
3.5
1,656
36
1,585
38
1,536
39
1,429
42
1,355
45
1,268 1,145 1,059
Med-Lo
3.0
1,551
39
1,488
41
1,427
42
1,353
45
1,290
47
1,195 1,100 1,017
Low
2.5
1,286
47
1,258
48
1,241
49
1,185
51
1,112
54
1,067 983
High
4.0
1,734
46
1,652
49
1,578
51
1,508
53
1,413
57
1,336 1,248 1,154
Med
3.5
1,642
49
1,558
52
1,487
54
1,418
57
1,336
60
1,243 1,164 1,039
Med-Lo
3.0
1,522
53
1,458
55
1,396
58
1,321
61
1,253
64
1,182 1,101 986
Low
2.5
1,287
63
1,244
65
1,184
68
1,148
70
1,098
73
1,034 ‘953 849
High
5.0
2,189
37
2,109
38
2,025
40
1,948
41
1,862
43
1,757 1,644 1,537
Med
4.0
1,885
43
1,831
44
1,776
45
1,711
47
1,637
49
1,539 1,453 1,346
Med-Lo
3.5
1,665
48
1,627
50
1,584
51
1,524
53
1,462
55
1,400 1,323 1,220
Low
3.0
1,474
55
1,440
56
1,401
57
1,356
59
1,310
61
1,255 1,193 1,109
Motor
Model—Heating
Speed as Shipped Speed
WGFM1950704CXA High
(MED-HI)
Med
WGFM1950905DXA
(MED-HI)
WGFM1951155DXA
(MED-HI)
WFD1950453BXA
(MED-HI)
WFD1950703BXA
(MED-HI)
WFD1950704CXA
(MED-HI)
WFD1950904CXA
(MED-HI)
WFD1950905DXA
(MED-HI)
External Static Pressure (Inches Water Column)
0.1
0.2
NOTES:
1. CFM in chart is without filters. Filters do not ship with this
furnace, but must be provided by the installer. If the furnace
requires 2 return filters, this chart assumes both filters are
installed.
0.3
0.4
0.5
0.6
0.7
0.8
837
816
886
2. All furnaces ship as high-speed cooling and medium-speed
heating. Installer must adjust blower cooling and heating
speed as needed.
43
3. For most jobs, about 400 CFM per ton when cooling is
desirable.
4. Installation is to be adjusted to obtain temperature rise within
the range specified on the rating plate.
5. The chart is for information only. For satisfactory operation,
external static pressure must not exceed value shown on
rating plate. The shaded area indicates ranges in excess of
maximum external static pressure allowed when heating. The
data for 0.6" W.C. to 0.8" W.C. is shown for air conditioning
purposes only.
6. The above chart is for U.S. furnaces installed at 0 to 2,000 ft
(609.6 m). At higher altitudes, a properly de-rated unit will
have approximately the same temperature rise at a particular
CFM, while the ESP at that CFM will be lower.
WIRING DIAGRAM—WFD195
WARNING
HIGH VOLTAGE!
Disconnect ALL power before servicing.
Multiple power sources may be present.
Failure to do so may cause property damage, personal injury or death.
24VAC
Humidifier
Equipment GND
Field GND
Field Splice
Switch (Temp.)
R
G
BK
2nd
Stage
Delay
Mode
4
9
8
7
BU
11
10
Y
G
OR
OR
BR
24 VAC
11 5 VAC
Flame Sensor
W
FS
Hot Surface Igniter
IGN
Induced Draft
Blower
Y
OR
W
GY
OR
BU
BK
BR
Y
IND
H E LO
AT
-H
COOL-H
W
H I -H
AT
HE
OR
PR
Manual Reset
Auxiliary Limits
1. In upflow blower
deck
2. In counterflow
blower housing
BK
L INE-H
Junction Box
Door
Switch
W
W
Induced Draft Blower
WARNING:
Disconnect Power
Before Servicing.
Wiring to Unit Must
Be Properly Polarized
and Grounded.
W
Auto Reset
Primary Limit
Control
PR
Y
C
PK
Manual Reset Rollout Limit (Control(s)
Induced Draft
(Single Control On 45k Btu)
Blower Pressure 2 4 VAC
Humidifier
Switch
Front Cover
N Pressure Switch
C
OO
PM 1
GY
12-Circuit
Connector
GND
Hot
2
C
BR
Surface
Igniter
3
OR
HI
Gas Control Valve
Check codes for proper wiring and circuit protection before installation.
Disconnect
L
GND
N
To 115 VAC/10/60 Hz Power Supply
with Overcurrent Protection Device
OR
OR
Circulator
Blower
Electronic
Air Cleaner
E AC-H
GN D
Integrated Control Module
Line Neutrals
G
R
PK
R
Blower Compartment
O
Manual Reset Rollout
Limit Control(s)
(Single Control on 45k Btu)
LINE-H
Burner Compartment
Auto Reset
Primary
Limit
Control
RO1 (5)
XF MR-H
Capacitor
W
Manual Reset Auxiliary
Limit Controls
RO2 (11)
WH
1
Circulator
Blower
N
HLI (7)
R
Integrated Control Module
See Note 4
NO
C
PSO (4)
HLO (1 )
PK
2
Induced Draft
Blower Pressure
Switch
W
BK
B K (HI)
BU (ME D)
O R (M ED LO W )
R (LO W )
R
PS (1 0)
To
Micro
Y
Gas
Control
Valve
40 VA
Transformer
115 VAC Neutral
Terminals
XFMR-H
FS
C
NO
TH (3)
W
BR
G
GY
HEAT-H
GND
GY
PK
OR
12
OR
115 VAC HOT and PARK Terminals
COOL-H
1
5
R
*
*
2
6
GY
Heat
Off
Delay
Factory Settings Shown
Diagnostic
LED See Note 6
3
BU
44
24V Thermostat at Connections
OR
*
*
Reversed 115 VAC Polarity
Wiring is subject to change.
Always refer to the wiring
diagram on the unit for the
most up-to-date wiring.
HI
Front Cover
Pressure Switch
BK
ON OFF
High Voltage (115V)
Normal Operation
Control Failure
System Lockout (Retries Exceeded)
Pressure Switch Stuck Closed
Pressure Switch Stuck Open
Open High Limit Switch
Flame Sense without Gas Control Valve
Open Rollout Limit Switch or Open Fuse
Low Flame Signal
Check Igniter or Improper Grounding
W
Fuse
Low Voltage (24V)
Low Voltage Field
Steady On =
Off =
1
1 Flash =
2
2 Flashes =
3
3 Flashes =
4
4 Flashes =
5
5 Flashes =
6
6 Flashes =
7
7 Flashes =
8
8 Flashes =
C
Continuous/
Rapid Flashes =
C
MVL (2)
C
W Y
Integrated
Control
Module
BR
GND
GND (8)
M VC (9)
MVH (12)
BK
Symbol
GY
W
BK
R
BU
OR
Y
G
PK
A
V
BR
TR (6 )
40 VA
Transformer
PM
C
High Voltage Field
Junction
Terminal
Internal To
Integrated Control
Plug Connection
Integrated
Control Module
Humidifier
11 5 V A C
24V Thermostat
Connections
Pressure Switch
Overcurrent
Prot. Device
0
GY
24 VAC
Igniter
Color
Gray
White
Black
Red
Blue
Orange
Yellow
Green
Pink
Azure
Violet
Brown
Blower Compartment
Door SwitchT
(Open When
Door Open)
OR
R
WARNING: Disconnect Power Before Servicing.
Wiring to Unit Must Be Properly Polarized
and Grounded.
BU
Junction Box
GY
N
W
To 115 VAC/10/60 Hz
GN D Power Supply with
G
Overcurrent Protection
L Device
BK
Flame
Sensor
Disconnect
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 105ºC. Use copper conductors
only.
4. If heating and cooling blower speeds are not the same,
discard jumper before connecting blower leads. Unused
blower leads must be placed on “PARK” terminals of
integrated control or taped.
5. Furnace must be permanently grounded and conform to NEC
and local codes.
6. To recall the last 5 faults, most recent to least recent, depress
switch for more than 2 seconds in standby (no thermostat
inputs).
WIRING DIAGRAM—WGFM195
WARNING
HIGH VOLTAGE!
Disconnect ALL power before servicing.
Multiple power sources may be present.
Failure to do so may cause property damage, personal injury or death.
Blower Compartment
Door Switch
(Open When
Door Open)
OR
24 V AC
Humidifier
GY
24 VAC
1 15 V A C
24V Thermostat
Connections
R
G
BK
Fuse
Integrated
Control
Module
ON OFF
*
*
1
5
4
9
8
7
11
BL
OR
OR
BR
Manual Reset Rollout
Limit Control(s)
(Single Control on 45k Btu)
IGN
OR
BR
YL
IN D
HE LO
AT
-H
CO OL -H
W
OR
H I -H
AT
HE
GY
GND
BK
LINE -H
Junction Box
Door
Switch
W
W
Induced Draft Blower
WARNING:
Disconnect Power
Before Servicing.
Wiring to Unit Must
Be Properly Polarized
and Grounded.
W
Auto Reset
Primary Limit
Control
PR
BU
Y
C
O
R
PK
W
Induced Draft
Blower Pressure 24 VA C
Humidifier
Switch
PM
1
Manual Reset Rollout Limit (Control(s)
(Single Control On 45k Btu)
GY
N
C
2
HI
3
L
GND
N
WARNING: Disconnect Power Before Servicing.
Wiring to Unit Must Be Properly Polarized
and Grounded.
BU
Junction Box
Front Cover
Pressure Switch
W
GY
O
GND
C
Disconnect
To 115 VAC/10/60 Hz Power Supply
with Overcurrent Protection Device
OR
OR
12-Circuit
Connector
Hot
Surface
Igniter
Circulator
Blower
Electronic
Air Cleaner
E A C-H
Manual Reset
Auxiliary Limits
1. In upflow blower
deck
2. In counterflow
blower housing
Burner Compartment
Integrated Control Module
Line Neutrals
OR
RD
BU
BK
Induced Draft
Blower
Integrated Control Module
G
Y
PK
R
PR
N
115 V A C
FS
Blower Compartment
R
24 V A C
Hot Surface Igniter
Circulator
Blower
Reversed 115 VAC Polarity
Wiring is subject to change.
Always refer to the wiring
diagram on the unit for the
most up-to-date wiring.
RO 1 (5)
BK
W
Normal Operation
Control Failure
System Lockout (Retries Exceeded)
Pressure Switch Stuck Closed
Pressure Switch Stuck Open
Open High Limit Switch
Flame Sense without Gas Control Valve
Open Rollout Limit Switch or Open Fuse
Low Flame Signal
Check Igniter or Improper Grounding
Auto Reset
Primary
Limit
Control
RO 2 (11)
GY
WH
Capacitor
Steady On =
Off =
1
1 Flash =
2
2 Flashes =
3
3 Flashes =
4
4 Flashes =
5
5 Flashes =
6
6 Flashes =
7
7 Flashes =
8
8 Flashes =
C
Continuous/
Rapid Flashes =
0
Manual Reset Auxiliary
Limit Controls
R
XF MR -H
GY
BR
H LO (1)
LINE-H
B K (H I)
B U (M E D )
O R (M E D L O W )
R (LO W )
NO
C
PS O (4)
H LI (7)
Flame Sensor
1
HEAT-H
See Note 4
Induced Draft
Blower Pressure
Switch
W
WH
PU
2
Gas
Control
Valve
40 VA
Transformer
W
BR
P S (10)
To
Micro
T H (3)
115 VAC Neutral
Terminals
XFMR-H
FS
115 VAC HOT and PARK Terminals
G
Y
GY
OR
Diagnostic
LED See Note 6
GR
YL
R
*
GND
PR
OR
10
GY
Heat
Off
Delay
Factory Settings Shown
COOL-H
2
12
2nd
Stage
Delay
Mode
High Voltage (115V)
3
6
GY
24V Thermostat at Connections
OR
C
NO
Front Cover
Pressure Switch
BK
W
Igniter
Low Voltage (24V)
Low Voltage Field
MV L(2)
C
W Y
BK
High Voltage Field
Junction
Terminal
Internal To
Integrated Control
Plug Connection
HI
MV H (12)
PM
C
Pressure Switch
Overcurrent
Prot. Device
Symbol
GY
W
BK
R
BU
OR
Y
G
PK
A
V
BR
C
MV C (9)
Switch (Temp.)
Color
Gray
White
Black
Red
Blue
Orange
Yellow
Green
Pink
Azure
Violet
Brown
GND
G ND (8)
Equipment GND
Field GND
Field Splice
Integrated
Control Module
Humidifier
T R (6)
N
To 115 VAC/10/60 Hz
G
G N D Power Supply with
OR
Overcurrent Protection
L Device
BK
BR
Gas Control Valve
(Honeywell)
Flame
Sensor
Disconnect
Check codes for proper wiring and circuit protection before installation.
45
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 105ºC. Use copper conductors
only.
4. If heating and cooling blower speeds are not the same,
discard jumper before connecting blower leads. Unused
blower leads must be placed on “PARK” terminals of
integrated control or taped.
5. Furnace must be permanently grounded and conform to NEC
and local codes.
6. To recall the last 5 faults, most recent to least recent, depress
switch for more than 2 seconds in standby (no thermostat
inputs).
WIRING DIAGRAM—WGFM195
WARNING
HIGH VOLTAGE!
Disconnect ALL power before servicing.
Multiple power sources may be present.
Failure to do so may cause property damage, personal injury or death.
GY
24 VAC
115 VAC
24V Thermostat
Connections
C
BK
1
5
4
9
8
7
GY
2
115 VAC
Hot Surface Igniter
Induced Draft
Blower
OR
GY
OR
IND
HE LO
ATH
W
HI -H
AT
HE
OR
PR
Blower Compartment
Burner Compartment
EAC-H
Manual Reset
Auxiliary Limits
1. In upflow - blower
deck
2. In counterflow blower housing
GND
BK
Circulator
Blower
COOL-H
BR
Y
Integrated Control Module
Line Neutrals
Y
BK
IGN
Integrated Control Module
G
R
PK
R
Circulator Blower
Electronic
Air Cleaner
LINE-H
Junction Box
Door
Switch
W
W
Induced Draft Blower
Disconnect
W
Auto Reset
Primary Limit
Control
WARNING:
Disconnect Power
Before Servicing.
Wiring to Unit Must
Be Properly
N
GND
L
Polarized and
To 115 VAC/10/60 Hz Power Supply
Grounded.
PR
BU
Y
R
OR
OR
NO
W
C
PK
Manual Reset Rollout Limit (Control(s)
Induced Draft
(Single Control On 45 kBtu)
24 VAC
Blower Pressure Humidifier
Switch
Front Cover
NO Pressure Switch
C
PM 1
GY
2-Circuit
Connector
GND
Hot
C
BR
2
Surface
Igniter
OR
HI
3
Gas Control Valve
Check codes for proper wiring and circuit protection before installation.
46
Manual Reset Rollout
Limit Control(s)
(Single Control on 45k Btu)
24 VAC
FS
BK
BR
Reversed 115 VAC Polarity
Wiring is subject to change.
Always refer to the wiring
diagram on the unit for the
most up-to-date wiring.
RO1(5)
Auto Reset
Primary
Limit
Control
Flame Sensor
W
BU
Normal Operation
Control Failure
System Lockout (Retries Exceeded)
Pressure Switch Stuck Closed
Pressure Switch Stuck Open
Open High Limit Switch
Flame Sense without Gas Control Valve
Open Rollout Limit Switch or Open Fuse
Low Flame Signal
Check Igniter or Improper Grounding
RO2(11)
40 VA
Transformer
W
Steady On =
Off =
1
1 Flash =
2
2 Flashes =
3
3 Flashes =
4
4 Flashes =
5
5 Flashes =
6
6 Flashes =
7
7 Flashes =
8
8 Flashes =
C
Continuous/
Rapid Flashes =
Manual Reset Auxiliary
Limit Controls
R
XFMR-H
Capacitor
0
HLO(1)
W
W
BR
W
NO
C
TH(3)
1
LINE-H
BK (HI)
BU (MED)
OR(MED LOW)
R (LOW)
PS(10)
PSO(4)
HLI(7)
To
Micro
PK
XFMR-H
GND
OR
G
Y
GY
OR
HEAT-H
See
Note 4.
G
BR
R
Diagnostic LED See
Note 6.
115 VAC Hot and Park Terminals
COOL-H
Y
OR
FS
GY
W
BK
R
BU
OR
Y
G
PK
A
V
BR
BU
12 11 10
2nd
Stage
Delay*
Mode*
Heat
Off
Delay*
*Factory Settings Shown
Color Symbol
PK
OR
115 VAC Neutral
Terminals
High Voltage Field
Junction
Terminal
Internal To
Integrated Control
Plug Connection
2
6
24V Thermostatat Connections
ON OFF
3
GY
Induced Draft
Blower Pressure
Switch
Front Cover
Pressure Switch
BK
Integrated
Control
Module
High Voltage (115V)
Gray:
White:
Black:
Red:
Blue:
Orange:
Yellow:
Green:
Pink:
Azure:
Violet:
Brown:
OR
Fuse
Gas
HI Control
Valve
PM
C
MVL(2) NO
C
W
Igniter
Low Voltage (24V)
Low Voltage Field
C
MVH(12)
BK
Pressure Switch
Overcurrent
Prot. Device
GND
GND(8)
MVC(9)
G R W Y
Switch (Temperature)
Integrated
Control Module
Humidifier
TR(6)
40 VA
Transformer
Equipment GND
Field GND
Field Splice
Blower Compartment
Door Switch
(Open When
Door Open)
OR
24 VAC
Humidifier
with Overcurrent Protection Device
R
WARNING: Disconnect Power Before Servicing.
Wiring to Unit Must Be Properly Polarized
and Grounded.
BU
Junction Box
GY
N
To 115 VAC/10/60 Hz
GND Power Supply with
Overcurrent Protection
L Device
W
G
BK
Flame
Sensor
Disconnect
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 105ºC. Use copper conductors
only.
4. If heating and cooling blower speeds are not the same,
discard jumper before connecting blower leads. Unused
blower leads must be placed on “PARK” terminals of
integrated control or taped.
5. Furnace must be permanently grounded and conform to NEC
and local codes.
6. To recall the last 5 faults, most recent to least recent, depress
switch for more than 2 seconds in standby (no thermostat
inputs).
WIRING DIAGRAM—WFD195
WARNING
HIGH VOLTAGE!
Disconnect ALL power before servicing.
Multiple power sources may be present.
Failure to do so may cause property damage, personal injury or death.
24 VAC
Humidifier
24 VAC
MVL(2)
BK
3
Integrated
Control
Module
ON OFF
1
2
6
54
9
87
PR
OR
BU
12 11 10
2nd
Stage
Delay*
Mode *
Y
BR
R
W
115 VAC
Hot Surface Igniter
IGN
OR
BU
COOL-H
BR
HI -H
AT
HE
OR
PR
Blower Compartment
Line Neutrals
OR
R
HE LO
AT
-H
W
Y
IND
GY
Circulator
Blower
Integrated Control Module
Y
BK
Induced Draft
Blower
Integrated Control Module
G
GY
PK
R
Circulator
Blower
Electronic
Air Cleaner
EAC-H
LINE-H
Burner Compartment
Junction Box
GND
Door
Switch
BK
W
W
Induced Draft Blower
WARNING:
Disconnect Power
Before Servicing.
Wiring to Unit Must
Be Properly Polarized
and Grounded.
W
Auto Reset
Primary Limit
Control
Reversed 115 VAC Polarity
C
PK
Manual Reset Rollout Limit (Control(s)
Induced Draft
(Single Control On 45k Btu)
Blower Pressure 24 VAC
Humidifier
Switch
Front Cover
N Pressure Switch
C
O
PM 1
GY
2-Circuit
Connector
GND
Hot
2
HI
OR
Surface
3
Igniter
BR
C
Gas Control Valve (Honeywell)
Disconnect
GND
L
N
To 115 VAC/10/60 Hz Power Supply
with Overcurrent Protection Device
OR
N
O
W
PR
BU
Y
OR
R
Wiring is subject to change.
Always refer to the wiring
diagram on the unit for the
most up-to-date wiring.
Manual Reset Rollout
Limit Control(s)
(Single Control on 45 kBtu)
24 VAC
40 VA
Transformer
FS
BK
W
Normal Operation
Control Failure
System Lockout (Retries Exceeded)
Pressure Switch Stuck Closed
Pressure Switch Stuck Open
Open High Limit Switch
Flame Sense without Gas Control Valve
Open Rollout Limit Switch or Open Fuse
Low Flame Signal
Check Igniter or Improper Grounding
Induced
Draft Blower
Pressure
Switch
RO1(5)
GY
PR
2
NO
C
Flame Sensor
See Note 4
BR
R
XFMR-H
W
BR
HLO(1)
Auto Reset Primary
Limit Controls
RO2(11)
W
1
LINE-H
BK (HI)
BU (MED)
OR (MED LOW)
R (LOW)
W
C
NO
Front Cover
Pressure Switch
PS(10)
PSO(4)
HLI(7)
To
Micro
Y
TH(3)
115 VAC Neutral
Terminals
FS
HEAT-H
G
GY
OR
115 VAC HOT and PARK Terminals
G
OR
OR
GY
Heat
Off
Delay *
* Factory Settings Shown
Diagnostic
LED See Note 6
GY
Capacitor
0 Steady On =
Off =
1
1 Flash =
2 2 Flashes =
3 3 Flashes =
4 4 Flashes =
5 5 Flashes =
6 6 Flashes =
7 7 Flashes =
8 8 Flashes =
C Continuous/
Rapid Flashes =
24V Thermostat at Connections
OR
Fuse
GND
Gas
HI Control
PM Valve
Auxiliary
Limit Controls
MVH(12)
W
BK
COOL-H
C
GND
C
C G R W Y
XFMR-H
GY
W
BK
R
BU
OR
Y
G
PK
A
V
BR
Integrated
Control Module
Humidifier
TR(6)
GND(8)
MVC(9)
40 VA
Transformer
115 VAC
24V Thermostat
Connections
Low Voltage (24V)
Low Voltage Field
High Voltage (115V)
High Voltage Field
Junction
Terminal
Internal To
Integrated Control
Plug Connection
Color Symbol
Gray:
White:
Black:
Red:
Blue:
Orange:
Yellow:
Green:
Pink:
Azure:
Violet:
Brown:
GY
BK
Equipment GND
Field GND
Field Splice
Switch (Temperature)
Igniter
Pressure Switch
Overcurrent
Prot. Device
Blower Compartment
Door Switch
(Open When
Door Open)
OR
R
WARNING: Disconnect Power Before Servicing.
Wiring to Unit Must Be Properly Polarized
and Grounded.
BU
Junction Box
GY
N
W
G
GND
BK
Flame
Sensor
L
To 115 VAC/10/60 Hz
Power Supply with
Overcurrent Protection
Device
Disconnect
Check codes for proper wiring and circuit protection before installation.
47
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 105ºC. Use copper conductors
only.
4. If heating and cooling blower speeds are not the same,
discard jumper before connecting blower leads. Unused
blower leads must be placed on “PARK” terminals of
integrated control or taped.
5. Furnace must be permanently grounded and conform to NEC
and local codes.
6. To recall the last 5 faults, most recent to least recent, depress
switch for more than 2 seconds in standby (no thermostat
inputs).
ASSISTANCE OR SERVICE
If you need further assistance, you can write to the below
address with any questions or concerns:
Tradewinds Distributing Company, LLC
14610 Breakers Drive
Jacksonville, FL 32258
WPIO-299H
© 2010. All rights reserved.
Please include a daytime phone number in your correspondence.
Or call toll free: 1-866-944-7575.
®Registered Trademark/TM Trademark of Whirlpool, U.S.A.,
Manufactured under license by Tradewinds Distributing Company, LLC, Jacksonville, Florida.
Warranty provided by manufacturer. All other trademarks are owned by their respective companies.
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Printed in U.S.A.