315AAV/JAV
Variable Speed
Induced---Combustion Deluxe
4---Way Multipoise Furnace
Installation Start--up, Operating, and
Service and Maintenance,
Instructions Series 140/E
SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . . . . . . . 2
Check Safety Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
CODES AND STANDARDS . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SERVICE AND MAINTENANCE PROCEDURES . . . . . . . 46
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
General Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Care and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Combustion and Ventilation Air . . . . . . . . . . . . . . . . . . . . . . 4
Sequence of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Duct Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Acoustical Lining and Fibrous Glass Duct . . . . . . . . . . . . . . . 4
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Gas Piping and Gas Pipe Pressure Testing . . . . . . . . . . . . . . . 4
Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
ama
Venting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS
PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
ISO 9001:2000
LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
AIR FOR COMBUSTION AND VENTILATION . . . . . . . . . 8
CERTIFIED
Outdoor Combustion Air Method . . . . . . . . . . . . . . . . . . . . 9
The Standard Method: . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
REGISTERED
Combination of Indoor and Outdoor Air . . . . . . . . . . . . . 10
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Bottom Return Air Inlet . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Side Return Air Inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
NOTE: Read the entire instruction manual before starting the
installation.
Portions of the text and tables are reprinted from NFPA 54/ANSI
Z223.1--2006E, with permission of National Fire Protection
Association, Quincy, MA 02269 and American Gas Association,
Washington DC 20001. This reprinted material is not the
complete and official position of the NFPA or ANSI on the
referenced subject, which is represented only by the standard in
its entirety.
Leveling Legs (If Desired) . . . . . . . . . . . . . . . . . . . . . . . . 11
Bottom Return Air Inlet . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Suspended Furnace Support . . . . . . . . . . . . . . . . . . . . . . . 11
Platform Furnace Support . . . . . . . . . . . . . . . . . . . . . . . . . 11
Roll--Out Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Bottom Return Air Inlet . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Side Return Air Inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
General Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Ductwork Acoustical Treatment . . . . . . . . . . . . . . . . . . . . 13
Supply Air Connections . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Upflow and Horizontal Furnaces . . . . . . . . . . . . . . . . . . . 14
Downflow Furnaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Return Air Connections . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Downflow Furnaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Upflow and Horizontal Furnaces . . . . . . . . . . . . . . . . . . . 18
START--UP, ADJUSTMENT, AND SAFETY CHECK . . . . . 34
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Start--Up Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
1
SAFETY CONSIDERATIONS
!
DANGER identifies the most serious hazards which will result in
severe personal injury or death. WARNING signifies a hazard
which could result in personal injury or death. CAUTION is used
to identify hazards which may result in minor personal injury or
product and property damage. NOTE is used to highlight
suggestions which will result in enhanced installation, reliability,
or operation.
1. Use only with type of gas approved for this furnace. Refer
to the furnace rating plate.
2. Install this furnace only in a location and position as specified in the “Location” section of these instructions.
3. Provide adequate combustion and ventilation air to the
furnace space as specified in “Air for Combustion and
Ventilation” section.
4. Combustion products must be discharged outdoors. Connect this furnace to an approved vent system only, as specified in the “Venting” section of these instructions.
5. Never test for gas leaks with an open flame. Use a commercially available soap solution made specifically for the
detection of leaks to check all connections, as specified in
the “Gas Piping” section.
6. Always install furnace to operate within the furnace’s intended temperature--rise range with a duct system which
has an external static pressure within the allowable range,
as specified in the “Start--Up, Adjustments, and Safety
Check” section. See furnace rating plate.
7. When a furnace is installed so that supply ducts carry air
circulated by the furnace to areas outside the space containing the furnace, the return air shall also be handled by
duct(s) sealed to the furnace casing and terminating outside the space containing the furnace. See “Air Ducts” section.
8. A gas--fired furnace for installation in a residential garage
must be installed as specified in the warning box in the
“Location” section.
9. The furnace may be used for construction heat provided
that the furnace installation and operation complies with
the first CAUTION in the LOCATION section of these instructions.
10. These Multipoise Gas--Fired Furnaces are CSA (formerly
A.G.A. and C.G.A.) design--certified for use with natural
and propane gases (see furnace rating plate) and for installation in alcoves, attics, basements, closets, utility rooms,
crawlspaces, and garages. The furnace is factory--shipped
for use with natural gas. A CSA (A.G.A. and C.G.A.) listed accessory gas conversion kit is required to convert furnace for use with propane gas.
11. See Fig. 1 for required clearances to combustible construction.
12. Maintain a 1--in. (25 mm) clearance from combustible materials to supply air ductwork for a distance of 36 in. (914
mm) horizontally from the furnace. See NFPA 90B or local code for further requirements.
13. These furnaces SHALL NOT be installed directly on carpeting, tile, or any other combustible material other than
wood flooring. In downflow installations, factory accessory floor base MUST be used when installed on combustible materials and wood flooring. Special base is not required when this furnace is installed on manufacturer’s
Coil Assembly Part No. CAPVP, CAPMP, or CNPVP, or
when Coil Box Part No. KCAKC is used. See Fig. 1 for
clearance to combustible construction information.
WARNING
FIRE, EXPLOSION, ELECTRICAL SHOCK, AND
CARBON MONOXIDE POISONING HAZARD
Failure to follow this warning could result in dangerous
operation, personal injury, death, or property damage.
315A
Improper installation, adjustment, alteration, service,
maintenance, or use can cause carbon monoxide poisoning,
explosion, fire, electrical shock, or other conditions which
may cause personal injury or property damage. Consult a
qualified service agency, local gas supplier, or your
distributor or branch for information or assistance. The
qualified service agency must use only factory--authorized
and listed kits or accessories when modifying this product.
!
CAUTION
FURNACE RELIABILITY HAZARD
Failure to follow this caution may result in unit component
damage.
Application of this furnace should be indoors with special
attention given to vent sizing and material, gas input rate,
air temperature rise, unit leveling, and unit sizing.
Installing and servicing heating equipment can be hazardous due
to gas and electrical components. Only trained and qualified
personnel should install, repair, or service heating equipment.
Untrained personnel can perform basic maintenance functions
such as cleaning and replacing air filters. All other operations
must be performed by trained service personnel. When working
on heating equipment, observe precautions in literature, on tags,
and on labels attached to or shipped with furnace and other safety
precautions that may apply.
These instructions cover minimum requirements and conform to
existing national standards and safety codes. In some instances,
these instructions exceed certain local codes and ordinances,
especially those that may not have kept up with changing
residential construction practices. We require these instructions as
a minimum for a safe installation.
!
CAUTION
CUT HAZARD
Failure to follow this caution may result in personal injury.
Sheet metal parts may have sharp edges or burrs. Use care
and wear appropriate protective clothing, safety glasses and
gloves when handling parts, and servicing furnaces.
Wear safety glasses and work gloves. Have fire extinguisher
available during start--up and adjustment procedures and service
calls.
. When you see this symbol on
This is the safety--alert symbol
the furnace and in instructions or manuals, be alert to the potential
for personal injury.
Understand the signal words DANGER, WARNING, and
CAUTION. These words are used with the safety--alert symbol.
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315A
A08471
Fig. 1 -- Clearances to Combustibles
3
INTRODUCTION
Boulevard, Etobicoke (Toronto), Ontario, M9W 1R3
Canada
Combustion and Ventilation Air
The Series 140/E 4--way multipoise Category I fan--assisted
furnace is CSA (formerly A.G.A. and C.G.A.) design--certified. A
Category I fan--assisted furnace is an appliance equipped with an
integral mechanical means to either draw or force products of
combustion through the combustion chamber and/or heat
exchanger. The furnace is factory--shipped for use with natural
gas. This furnace is not approved for installation in mobile
homes, recreational vehicles, or outdoors.
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US: Section 9.3 NFPA 54/ANSI Z223.1--2006 , Air
for Combustion and Ventilation .
CANADA: Part 7 of CAN/CSA--B149.1--05, Venting
Systems and Air Supply for Appliances
Duct Systems
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US and CANADA: Air Conditioning Contractors Association (ACCA) Manual D, Sheet Metal and Air
Conditioning Contractors National Association
(SMACNA), or American Society of Heating, Refrigeration, and Air Conditioning Engineers (ASHRAE)
2001 Fundamentals Handbook Chapter 34 or 2000
HVAC Systems and Equipment Handbook Chapters 9
and 16.
Acoustical Lining and Fibrous Glass Duct
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/ 27 C
315A
80
US and CANADA: current edition of SMACNA and
NFPA 90B as tested by UL Standard 181 for Class I
Rigid Air Ducts
Gas Piping and Gas Pipe Pressure Testing
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60
/ 16 C
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CANADA: CAN/CSA--B149.1--05 Parts 4, 5, 6, and 9
and Appendices A, B, E and H.
Electrical Connections
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A06745
Fig. 2 -- Return Air Temperature
This furnace is designed for minimum continuous return--air
temperature of 60_F (15_C) db or intermittent operation down to
55_F (13_C)db such as when used with a night setback
thermostat. Return--air temperature must not exceed 80_F (27_C)
db. Failure to follow these return--air temperature limits may
affect reliability of heat exchangers, motors, and controls. (See
Fig. 2.)
For accessory installation details, refer to the applicable
instruction literature.
NOTE: Remove all shipping brackets and materials before
operating the furnace.
CAUTION
Failure to follow this caution may result in unit component
damage.
Electrostatic discharge can affect electronic components.
Take precautions during furnace installation and servicing
to protect the furnace electronic control. Precautions will
prevent electrostatic discharges from personnel and hand
tools which are held during the procedure. These
precautions will help to avoid exposing the control to
electrostatic discharge by putting the furnace, the control,
and the person at the same electrostatic potential.
1. Disconnect all power to the furnace. Multiple disconnects
may be required. DO NOT TOUCH THE CONTROL OR
ANY WIRE CONNECTED TO THE CONTROL PRIOR
TO
DISCHARGING
YOUR
BODY’S
ELECTROSTATIC CHARGE TO GROUND.
2. Firmly touch the clean, unpainted, metal surface of the furnace chassis which is close to the control. Tools held in a
person’s hand during grounding will be satisfactorily discharged.
3. After touching the chassis, you may proceed to service the
control or connecting wires as long as you do nothing to
recharge your body with static electricity (for example;
DO NOT move or shuffle your feet, do not touch ungrounded objects, etc.).
CANADA: CSA B149.1--00 National Standard of
Canada Natural Gas and Propane Installation Code
(CAN/CSA--B149.1--05)
General Installation
CANADA: CAN/CSA--B149.1--05. For a copy, contact Standard Sales, CSA International, 178 Rexdale
CANADA: Canadian Electrical Code CSA C22.1
FURNACE RELIABILITY HAZARD
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NFPA 54/ANSI Z223.1--2006 and the Installation
Standards, Warm Air Heating and Air Conditioning
Systems ANSI/NFPA 90B .
US: Current edition of the NFGC and the NFPA 90B.
For copies, contact the National Fire Protection Association Inc., Batterymarch Park, Quincy, MA 02269;
(www.NFPA.org) or for only the NFGC, contact the
American Gas Association, 400 N. Capitol Street,
N.W., Washington, DC 20001 (www.AGA.org.) .
US: National Electrical Code (NEC) ANSI/
NFPA70--2006 .
ELECTROSTATIC DISCHARGE (ESD)
PRECAUTIONS PROCEDURE
Follow all national and local codes and standards in addition
to these instructions. The installation must comply with
regulations of the serving gas supplier, local building, heating,
plumbing, and other codes. In absence of local codes, the
installation must comply with the national codes listed below and
all authorities having jurisdiction.
In the United States and Canada, follow all codes and standards
for the following:
Safety
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Venting
US: NFPA 54/ANSI Z223.1--2006; chapters 12 and 13 .
CANADA: CAN/CSA--B149.1--05 Part 8 and Appendix C
CODES AND STANDARDS
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US: NFPA 54/ANSI Z223.1--2006 ; chapters 5, 6, and
7 and National Plumbing Codes .
4
(664mm)
26-1/8"
(FLUE COLLAR)
(733mm)
28-7/8"
(641mm)
25-1/4"
22-9/16"
(573mm)
A
JUNCTION BOX
LOCATION
D
F
5-15/16"
(22mm)
7/8" DIA
ACCESSORY
13/16"
(21mm)
4-13/16"
(122mm)
2-7/16"
(62mm)
1-5/16"
(33mm)
1-1/8"
(29mm)
8-9/16"
(217mm)
1/2" DIA THERMOSTAT
WIRE ENTRY
AIRFLOW
19"
(483mm)
OUTLET
1/2" DIA. K.O.THERMOSTAT
WIRE ENTRY (13mm)
1-3/4" DIA.RIGHT HAND
GAS ENTRY (44mm)
13/16"
(21mm)
9-5/8"
11/16" 7-3/4"
(17mm) (197mm)(244mm)
11-1/2"
(292mm)
3-15/16"
LEFT HAND GAS
ENTRY
33-5/16"
(846mm)
ALTERNAT E
JUNCTION BOX
LOCATIONS (TYP)
24-7/8"
(632mm)
7/8" DIA. K.O. WIRE ENTRY
(22mm)
VENT OUTLET
5 PLACES (TYP)
7/8" DIA. ACCESSORY
7/8" DIA. ACCESSORY
(22mm)
14-7/8"
(378mm)
11/16"
(17mm)
(549mm)
21-5/8"
BOTTOM INLET
1-11/16"
(43mm)
5-1/2"
(140mm)
E
11/16"
(17mm)
3-3/4"
(95mm)
24"
CASING
(610mm)
1-1/2" (38mm)
(560mm)
22-1/16"
SIDE INLET
315A
5-1/2" (140mm)
1-1/4"
(32mm)
1"
(25mm)
A04037
NOTES:
1. Two additional 7/8 ---in. (22 mm) diameter holes are located in the top plate.
2. Minimum return ---air openings at furnace, based on metal duct. If flex duct is used, see flex duct manufacturer’s recommendations for equivalent diameters.
a. For 800 CFM ---16 ---in. (406 mm) round or 14 1/2 x 12 ---in. (368 x 305 mm) rectangle.
b. For 1200 CFM ---20 ---in. (508 mm) round or 14 1/2 x 19 1/2 ---in. (368 x 495 mm) rectangle.
c. For 1600 CFM ---22 ---in. (559 mm) round or 14 1/2 x 22 1/16 ---in. (368 x 560mm) rectangle.
d. For airflow requirements above 1800 CFM, see Air Delivery table in Product Data literature for specific use of single side inlets. The use of both side inlets, a
combination of 1 side and the bottom, or the bottom only will ensure adequate return air openings for airflow requirements above 1800 CFM.
Fig. 3 -- Dimensional Drawing
Table 1 – Dimensions -- In. (mm)
FURNACE SIZE
A
CABINET
WIDTH
IN. (mm)
D
SUPPLY --AIR WIDTH
IN. (mm)
E
RETURN--AIR WIDTH
IN. (mm)
F
CENTER LINE TOP AND
BOTTOM FLUE COLLAR
IN. (mm)
FLUE
COLLAR*
IN. (mm)
SHIP WT.
LB (KG)
FILTER MEDIA
CABINET SIZE
IN. (mm)
12 ---9/16
12 ---11/16
9 ---5/16 (237)
4 (102)
127 (58)
16 (406)
(319)
(322)
15 ---7/8
090 ---16/048090
17 ---1/2 (445)
16 (406)
11 ---9/16 (294)
4 (102)
151 (68)
16 (406)
(403)
19 ---3/8
110 ---20/060110
21 (533)
19 ---1/2 (495)
13 ---5/16 (338)
4 (102)
163 (74)
20 (508)
(492)
22 ---7/8
135 ---22/066135
24 ---1/2 (622)
23 (584)
15 ---1/16 (383)
4 (102)†
177 (80)
24 (610)
(581)
22 ---7/8
155 ---22/066155
24 ---1/2 (622)
23 (584)
15 ---1/16 (383)
4 (102)†
183 (83)
24 (610)
(581)
*5 in. or 6 in. (127 or 152 mm) vent connector may be required in some cases.
{5 in. (127 mm) or larger vent is required. Use a 4 ---5 (102 ---127 mm) or 4 ---6 (102 ---152 mm) in. vent adapter between furnace and vent connector.
070 ---12/036070
14 ---3/16
(360)
LOCATION
4. If you touch ungrounded objects (and recharge your body
with static electricity), firmly touch a clean, unpainted
metal surface of the furnace again before touching control
or wires.
5. Use this procedure for installed and uninstalled (ungrounded) furnaces.
6. Before removing a new control from its container, discharge your body’s electrostatic charge to ground to protect the control from damage. If the control is to be installed in a furnace, follow items 1 through 4 before
bringing the control or yourself in contact with the furnace. Put all used and new controls into containers before
touching ungrounded objects.
7. An ESD service kit (available from commercial sources)
may also be used to prevent ESD damage.
GENERAL
This multipoise furnace is shipped in packaged configuration.
Some assembly and modifications are required when used in any
of the four applications shown in Fig. 4.
NOTE:
For high--altitude installations, the high--altitude
conversion kit MUST be installed at or above 5500 ft. (1676 M)
above sea level. Obtain high--altitude conversion kit from your
area authorized distributor.
5
THE BLOWER IS
LOCATED BELOW THE
BURNER SECTION, AND
CONDITIONED AIR IS
DISCHARGED UPWARD.
315A
THE BLOWER IS LOCATED
TO THE RIGHT OF THE
BURNER SECTION, AND
AIR CONDITIONED AIR IS
DISCHARGED TO THE LEFT.
THE BLOWER IS
LOCATED TO THE LEFT
OF THE BURNER SECTION,
AND CONDITIONED AIR IS
DISCHARGED TO THE RIGHT.
THE BLOWER IS
LOCATED ABOVE THE
BURNER SECTION, AND
CONDITIONED AIR IS
DISCHARGED DOWNWARD
A02097
Fig. 4 -- Multipoise Orientations
If air is exposed to the following substances, it should not be used
for combustion air, and outdoor air may be required for
combustion:
This furnace must:
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be installed so the electrical components are protected
from water.
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not be installed directly on any combustible material
other than wood flooring (refer to SAFETY
CONSIDERATIONS).
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be located close to the chimney or vent and attached to
an air distribution system. Refer to Air Ducts section.
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be provided ample space for servicing and cleaning.
Always comply with minimum fire protection clearances shown on the furnace clearance to combustible
construction label.
!
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WARNING
CARBON MONOXIDE POISONING / COMPONENT
DAMAGE HAZARD
Failure to follow this warning could result in personal injury
or death and unit component damage.
Chlorinated waxes and cleaners
Chlorine based swimming pool chemicals
Water softening chemicals
De--icing salts or chemicals
Carbon tetrachloride
Halogen type refrigerants
Cleaning solvents (such as perchloroethylene)
Printing inks, paint removers, varnishes, etc.
Hydrochloric acid
Cements and glues
Antistatic fabric softeners for clothes dryers
Masonry acid washing materials
All fuel--burning equipment must be supplied with air for fuel
combustion. Sufficient air must be provided to avoid negative
pressure in the equipment room or space. A positive seal must be
made between the furnace cabinet and the return--air duct to
prevent pulling air from the burner area and from draft safeguard
opening.
Corrosive or contaminated air may cause failure of parts
containing flue gas, which could leak into the living space.
Air for combustion must not be contaminated by halogen
compounds, which include fluoride, chloride, bromide, and
iodide. These elements can corrode heat exchangers and
shorten furnace life. Air contaminants are found in aerosol
sprays, detergents, bleaches, cleaning solvents, salts, air
fresheners, and other household products. Do not install
furnace in a corrosive or contaminated atmosphere. Make
sure all combustion and circulating air requirements are met,
in addition to all local codes and ordinances.
!
WARNING
FIRE, INJURY OR DEATH HAZARD
Failure to follow this warning could result in personal
injury, death and/or property damage.
The following types of furnace installations may require
OUTDOOR AIR for combustion due to chemical exposures:
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Permanent wave solutions
When the furnace is installed in a residential garage, the
burners and ignition sources must be located at least 18 in.
(457 mm) above the floor. The furnace must be located or
protected to avoid damage by vehicles. When the furnace is
installed in a public garage, airplane hangar, or other
building having a hazardous atmosphere, the furnace must
be installed in accordance with the NFPA 54/ANSI
Z223.1--2006 or CAN/CSA--B149.1--05. (See Fig. 5.)
Commercial buildings
Buildings with indoor pools
Laundry rooms
Hobby or craft rooms, and
Chemical storage areas
6
!
CAUTION
PERSONAL INJURY AND/OR PROPERTY
DAMAGE HAZARD
Improper use or installation of this furnace may result in
premature furnace component failure. This gas furnace may
be used for heating buildings under construction provided
that:
18-IN. (457.2 mm)
MINIMUM TO BURNERS
A93044
Fig. 5 -- Installation in a Garage
!
--The furnace is controlled by a thermostat. It may not be
“hot wired” to provide heat continuously to the structure
without thermostatic control.
WARNING
--Clean outside air is provided for combustion. This is to
minimize the corrosive effects of adhesives, sealers and
other construction materials. It also prevents the
entrainment of drywall dust into combustion air, which can
cause fouling and plugging of furnace components.
FIRE HAZARD
Failure to follow this warning could result in personal
injury, death and/or property damage.
--The temperature of the return air to the furnace is
maintained between 55_F (13_C) and 80_F (27_C), with
no evening setback or shutdown. The use of the furnace
while the structure is under construction is deemed to be
intermittent operation per our installation instructions.
Do not install the furnace on its back or hang furnace with
control compartment facing downward. Safety control
operation will be adversely affected. Never connect
return--air ducts to the back of the furnace. (See Fig. 6.)
--The air temperature rise is within the rated rise range on
the furnace rating plate, and the gas input rate has been set
to the nameplate value. --The filters used to clean the
circulating air during the construction process must be
either changed or thoroughly cleaned prior to occupancy.
LOCATION RELATIVE TO COOLING EQUIPMENT
The cooling coil must be installed parallel with, or on the
downstream side of the unit to avoid condensation in the heat
exchangers. When installed parallel with the furnace, dampers or
other flow control must prevent chilled air from entering the
furnace. If the dampers are manually operated, they must be
equipped with means to prevent operation of either unit unless
the damper is in the full--heat or full--cool position.
--The furnace, ductwork and filters are cleaned as necessary
to remove drywall dust and construction debris from all
HVAC system components after construction is completed.
--Verify proper furnace operating conditions including
ignition, gas input rate, air temperature rise, and venting
according to these installation instructions.
A02054
Fig. 6 -- Prohibit Installation on Back
7
315A
--The furnace is permanently installed with all electrical
wiring, piping, venting and ducting installed according to
these installation instructions. A return air duct is provided,
sealed to the furnace casing, and terminated outside the
space containing the furnace. This prevents a negative
pressure condition as created by the circulating air blower,
causing a flame rollout and/or drawing combustion
products into the structure.
Table 2 – Minimum Free Area Required for Each Combustion Air opening of Duct to Outdoors
FURNACE
INPUT
(BTUH)
44,000
66,000
88,000
110,000
132,000
154,000
TWO HORIZONTAL DUCTS
(1 SQ. IN./2,000 BTUH) (1,100 SQ. MM/KW)
Free Area of Opening
Round Duct
and Duct
Dia.
Sq. In. (Sq. mm)
In. (mm)
22 (14194)
6 (152)
33 (21290)
7 (178)
44 (28387)
8 (203)
55 (35484)
9 (229)
66 (42580)
10 (254)
77 (49677)
10 (254)
SINGLE DUCT OR OPENING
(1 SQ. IN./3,000 BTUH) (734 SQ. MM/KW)
Free Area of Opening
Round Duct
and Duct
Dia.
Sq. In. (Sq. mm)
In. (mm)
14.7 (9484)
5 (127)
22 (14193)
6 (152)
29.3 (18903)
7 (178)
36.7 (23677)
7 (178)
44 (28387)
8 (203)
51.3 (33096)
9 (229)
TWO OPENINGS OR VERTICAL DUCTS
(1 SQ. IN./4,000 BTUH) (550 SQ. MM/KW)
Free Area of Opening
Round Duct
and Duct
Dia.
Sq. In. (Sq. mm)
In. (mm)
11 (7096)
4 (102)
16.5 (10645)
5 (127)
22 (14193)
6 (152)
27.5 (17742)
6 (152)
33 (21290)
7 (178)
38.5 (24839)
8 (203)
EXAMPLES: Determining Free Area
315A
FURNACE
WATER HEATER
TOTAL INPUT
110,000
+
30,000
=
(140,000 divided by 4,000)
=
35.0 Sq. In. for each two Vertical Ducts or Openings
66,000
+
40,000
=
(106,000 divided by 3,000)
=
35.3 Sq. In. for a Single Duct or Opening
88,000
+
30,000
=
(118,000 divided by 2,000)
=
59.0 Sq. In. for each of two Horizontal Ducts
Table 3 – Minimum Space Volumes for 100% Combustion, Ventilation, and Dilution from Indoors
OTHER THAN FAN-ASSISTED TOTAL
(1,000’S BTUH GAS INPUT RATE)
FAN-ASSISTED TOTAL
(1,000’S BTUH GAS INPUT RATE)
30
40
50
110
132
154
1,750
(49.5)
66
88
Space Volume Ft3 (M3)
1,100
1,650
2,200
(31.1)
(46.7)
(62.2)
0.60
1,050
(29.7)
1,400
(39.6)
2,750
(77.8)
3,300
(93.4)
3,850
(109.0)
0.50
1,260
(35.6)
1,680
(47.5)
2,100
(59.4)
1,320
(37.3)
1,980
(56.0)
2,640
(74.7)
3,300
(93.4)
3,960
(112.1)
4,620
(130.8)
0.40
1,575
(44.5)
2,100
(59.4)
2,625
(74.3)
1,650
(46.7)
2,475
(70.0)
3,300
(93.4)
4,125
(116.8)
4,950
(140.1)
5,775
(163.5)
0.30
2,100
(59.4)
2,800
(79.2)
3,500
(99.1)
2,200
(62.2)
3,300
(93.4)
4,400
(124.5)
5,500
(155.7)
6,600
(186.8)
7,700
(218.0)
0.20
3,150
(89.1)
4,200
(118.9)
5,250 (148.6)
3,300
(93.4)
4,950
(140.1)
6,600
(186.8)
8,250
(233.6)
9,900
(280.3)
11,550
(327.0)
0.10
6,300
(178.3)
8,400
(237.8)
10,500
(297.3)
6,600
(186.8)
9,900
(280.3)
13,200
(373.7)
16,500
(467.2)
19,800
(560.6)
23,100
(654.1)
0.00
NP
NP
NP
NP
NP
NP
NP
NP
NP
ACH
44
NP = Not Permitted
AIR FOR COMBUSTION AND
VENTILATION
!
Provisions for adequate combustion, ventilation, and dilution air
must be provided in accordance with:
S
S
CARBON MONOXIDE POISONING HAZARD
Failure to follow this warning could result in personal
injury or death.
U.S. Installations: Section 9.3 of the NFPA 54/ANSI
Z223.1--2006 , Air for Combustion and Ventilation and
applicable provisions of the local building codes.
The operation of exhaust fans, kitchen ventilation fans,
clothes dryers, attic exhaust fans or fireplaces could create a
NEGATIVE PRESSURE CONDITION at the furnace.
Make--up air MUST be provided for the ventilation devices,
in addition to that required by the furnace. Refer to the
Carbon Monoxide Poisoning Hazard warning in the venting
section of these instructions to determine if an adequate
amount of make--up air is available.
Canadian Installations: Part 8 of the CAN/CSA-B149.1--05, Venting Systems and Air Supply for Appliances and all authorities having jurisdiction.
!
WARNING
CAUTION
FURNACE CORROSION HAZARD
The requirements for combustion and ventilation air depend upon
whether or not the furnace is located in a space having a volume
of at least 50 cubic feet per 1,000 Btuh input rating for all gas
appliances installed in the space.
Failure to follow this caution may result in furnace damage.
Air for combustion must not be contaminated by halogen
compounds, which include fluoride, chloride, bromide, and
iodide. These elements can corrode heat exchangers and
shorten furnace life. Air contaminants are found in aerosol
sprays, detergents, bleaches, cleaning solvents, salts, air
fresheners, and other household products.
S
8
Spaces having less than 50 cubic feet per 1,000 Btuh
require the OUTDOOR COMBUSTION AIR
METHOD.
A
1 SQ IN.
PER
4000
BTUH*
INTERIOR
HEATED
SPACE
1 SQ IN.
PER
4000
BTUH*
E
12″ (305mm)
MAX
C
DUCT
TO
OUTDOORS
12" MAX (305mm)
1 SQ IN.
PER 1000
BTUH* IN DOOR
OR WALL
UNCONFINED
SPACE
6" MIN (152mm)
(FRONT)Ü
1 SQ IN.
PER 1000
BTUH* IN DOOR
OR WALL
G
12" MAX (305mm)
12″ MAX
(305mm)
CIRCULATING AIR DUCTS
VENT THROUGH ROOF
CLEARANCE IN FRONT OF COMBUSTION AIR
OPENINGS SHALL BE AT LEAST 3 IN.
1 SQ IN.
PER 2000
BTUH*
(305mm) 12″ MAX
F
OUTDOORS
DUCTS
TO
OUTDOORS
CIRCULATING
AIR DUCTS
B
12″ (305mm)
MAX
D
VENT
THROUGH
ROOF
CLEARANCE IN FRONT
OF COMBUSTION AIR
OPENINGS SHALL BE
AT LEAST 3 IN.
(76mm)
(305mm) 12″ MAX
1 SQ IN.
PER 2000
BTUH*
CIRCULATING AIR
DUCTS
CIRCULATING AIR DUCTS
1 SQ IN.
PER 4000
BTUH*
* Minimum opening size is 100 sq in. (64516 sq. mm)with minimum dimensions
of 3 in. (76 mm)
† Minimum of 3 in. (76 mm) when type-B1 vent is used.
*Minimum dimensions of 3--- in. (76 mm).
NOTE: Use any of the following combinations of openings:
A&BC&DD&EF&G
A03175
A03174
Fig. 7 -- Air for Combustion, Ventilation, and Dilution for
Outdoors
Fig. 8 -- Air for Combustion, Ventilation, and Dilution from
Indoors
Spaces having at least 50 cubic feet per 1,000 Btuh
may use the INDOOR COMBUSTION AIR,
STANDARD or KNOWN AIR INFILTRATION
METHOD.
Outdoor Combustion Air Method
1. Provide the space with sufficient air for proper combustion, ventilation, and dilution of flue gases using permanent horizontal or vertical duct(s) or opening(s) directly
communicating with the outdoors or spaces that freely
communicate with the outdoors.
2. Fig. 7 illustrates how to provide TWO OUTDOOR
OPENINGS, one inlet and one outlet combustion and
ventilation air opening, to the outdoors.
a. One opening MUST commence within 12 in. (300
mm) of the ceiling and the second opening MUST
commence within 12 in. (300 mm) of the floor.
b. Size openings and ducts per Fig. 7 and Table 2.
c. TWO HORIZONTAL DUCTS require 1 sq. in. (645
sq. mm) of free area per 2,000 Btuh (1,100 mm2/kW)
of combined input for all gas appliances in the space
per Fig. 7 and Table 2.
d. TWO OPENINGS OR VERTICAL DUCTS require 1
sq. in. (645 sq. mm) of free area per 4,000 Btuh (550
mm2/kW) for combined input of all gas appliances in
the space per Fig. 7 and Table 2.
3. ONE OUTDOOR OPENING requires:
a. 1 sq. in. (645 sq. mm) of free area per 3,000 Btuh
(734 mm2/kW) for combined input of all gas appliances in the space per Table 2 and
b. Not less than the sum of the areas of all vent connectors in the space.
The opening shall commence within 12 in. (300 mm) of the
ceiling. Appliances in the space shall have clearances of at least 1
in. (25 mm) from the sides and back and 6 in. (150 mm) from the
front. The opening shall directly communicate with the outdoors
or shall communicate through a vertical or horizontal duct to the
outdoors or spaces (crawl or attic) that freely communicate with
the outdoors.
Indoor Combustion AirE NFPA & AGA
Standard and Known--Air--Infiltration Rate Methods
Indoor air is permitted for combustion, ventilation, and dilution,
if the Standard or Known--Air--Infiltration Method is used.
S
!
WARNING
CARBON MONOXIDE POISONING HAZARD
Failure to follow this warning could result in personal
injury or death.
Many homes require air to be supplied from outdoors
for furnace combustion, ventilation, and dilution of flue
gases.
The furnace combustion air supply must be provided in
accordance with this instruction manual.
The Standard Method:
1. The space has no less volume than 50 cubic feet per 1,000
Btuh of the maximum input ratings for all gas appliances
installed in the space and
2. The air infiltration rate is not known to be less than 0.40
air changes per hour (ACH).
9
315A
1 SQ IN.
PER 4000
BTUH*
DUCTS
TO
OUTDOORS
315A
The Known Air Infiltration Rate Method shall be used, if the
infiltration rate is known to be:
1. Less than 0.40 ACH and
2. Equal to or greater than 0.10 ACH
Infiltration rates greater than 0.60 ACH shall not be used. The
minimum required volume of the space varies with the number of
ACH and shall be determined per Table 3 or Equations 1 and 2.
Determine the minimum required volume for each appliance in
the space and add the volumes together to get the total minimum
required volume for the space.
Table 3 -- Minimum Space Volumes were determined by using
the following equations from the National Fuel Gas Code ANSI
Z223.1--2006/NFPA 54--2006, 9.3.2.2:
1. For other than fan--assisted appliances, such as a draft
hood--equipped water heater:
Volume
Other
3
I other
= 21ft
ACH 1000 Btu/hr
A04002
2. For fan--assisted appliances such as this furnace:
Volume
Fan
3
I fan
= 15ft
ACH 1000 Btu/hr
A04003
If: Iother = combined input of all other than fan--assisted
appliances in Btuh/hr
Ifan = combined input of all fan--assisted appliances in Btuh/hr
ACH = air changes per hour (ACH shall not exceed 0.60.)
The following requirements apply to the Standard Method and
to the Known Air Infiltration Rate Method.
1. Adjoining rooms can be considered part of a space if:
a. There are no closeable doors between rooms.
b. Combining spaces on same floor level. Each opening
shall have free area of at least 1 in.2/1,000 Btuh (2,000
mm2/kW) of the total input rating of all gas appliances
in the space, but not less than 100 in.2 (0.06 m2). One
opening shall commence within 12 in. (300 mm) of
the ceiling and the second opening shall commence
within 12 in. (300 mm) of the floor. The minimum
dimension of air openings shall be at least 3 in. (80
mm). (See Fig. 8.)
c. Combining space on different floor levels. The
volumes of spaces on different floor levels shall be
considered as communicating spaces if connected by
one or more permanent openings in doors or floors
having free area of at least 2 in.2/1,000 Btuh (4,400
mm2/kW) of total input rating of all gas appliances.
2. An attic or crawlspace may be considered a space that
freely communicates with the outdoors provided there are
adequate permanent ventilation openings directly to outdoors having free area of at least 1--in.2/4,000 Btuh of total
input rating for all gas appliances in the space.
3. In spaces that use the Indoor Combustion Air Method,
infiltration should be adequate to provide air for combustion, permanent ventilation and dilution of flue gases.
However, in buildings with unusually tight construction,
additional air MUST be provided using the methods described in the Outdoor Combustion Air Method section.
4. Unusually tight construction is defined as Construction
with:
a. Walls and ceilings exposed to the outdoors have a continuous, sealed vapor barrier. Openings are gasketed or
sealed and
b. Doors and openable windows are weatherstripped and
c. Other openings are caulked or sealed. These include
joints around window and door frames, between sole
plates and floors, between wall--ceiling joints, between
wall panels, at penetrations for plumbing, electrical
and gas lines, etc.
Combination of Indoor and Outdoor Air
1. Indoor openings shall comply with the Indoor Combustion Air Method below and,
2. Outdoor openings shall be located as required in the Outdoor Combustion Air Method mentioned previously and,
3. Outdoor openings shall be sized as follows:
a. Calculate the Ratio of all Indoor Space volume divided
by required volume for Indoor Combustion Air
Method below.
b. Outdoor opening size reduction Factor is 1 minus the
Ratio in a. above.
c. Minimum size of Outdoor openings shall be the size
required in Outdoor Combustion Air Method above
multiplied by reduction Factor in b. above. The minimum dimension of air openings shall be not less than
3 in. (80 mm).
INSTALLATION
UPFLOW INSTALLATION
Bottom Return Air Inlet
These furnaces are shipped with bottom closure panel installed in
bottom return--air opening. Remove and discard this panel when
bottom return air is used. To remove bottom closure panel,
perform the following:
1. Tilt or raise furnace and remove 2 screws holding bottom
filler panel. (See Fig. 9.)
2. Rotate bottom filler panel downward to release holding
tabs.
3. Remove bottom closure panel.
4. Reinstall bottom filler panel and screws.
Side Return Air Inlet
These furnaces are shipped with bottom closure panel installed in
bottom return--air opening. This panel MUST be in place when
only side return air is used.
A02098
Fig. 9 -- Removing Bottom Closure Panel
NOTE: Side return--air openings can be used in UPFLOW and
most HORIZONTAL configurations. Do not use side return--air
openings in DOWNFLOW configuration.
10
Leveling Legs (If Desired)
In upflow position with side return inlet(s), leveling legs may be
used. (See Fig. 10.) Install field--supplied, 5/16 X 1--1/2 in. (8 X
38 mm) (max) corrosion--resistant machine bolts, washers and
nuts.
NOTE: Bottom closure must be used when leveling legs are
used. It may be necessary to remove and reinstall bottom closure
panel to install leveling legs. To remove bottom closure panel, see
Item 1 in Bottom Return Air Inlet section in Step 1 above.
To install leveling legs:
1. Position furnace on its back. Locate and drill a hole in
each bottom corner of furnace. (See Fig. 10.)
2. For each leg, install nut on bolt and then install bolt with
nut in hole. (Install flat washer if desired.)
3. Install another nut on other side of furnace base. (Install
flat washer if desired.)
4. Adjust outside nut to provide desired height, and tighten
inside nut to secure arrangement.
5. Reinstall bottom closure panel if removed.
DOWNFLOW INSTALLATION
NOTE: For downflow applications, this furnace is approved for
use on combustible flooring when any one of the following 3
accessories are used:
S
S
Special Base, KGASB
5/ 16″
(8mm)
(8mm)
5/ 16″
1 3/4″
(44mm)
1 3/4″
(44mm)
(8mm)
5/16″
5/ 16″
(44mm) 1 3/ 4″
3/
(44mm) 1 4″
A89014
Fig. 10 -- Leveling Legs
HORIZONTAL INSTALLATION
Cased Coil Assembly Part No. CPVP, CAPMP or
CNPVP
Coil Box Part No. KCAKC
1. Determine application being installed from Table 4.
2. Construct hole in floor per Table 4 and Fig. 11.
3. Construct plenum to dimensions specified in Table 4 and
Fig. 11.
4. If downflow subbase, KGASB is used, install as shown in
Fig. 12. If Coil Assembly Part No. CPVP, CAPMP or
CNPVP Coil Box Part No. KCAKC is used, install as
shown in Fig. 13.
NOTE: It is recommended that the perforated supply--air duct
flanges be completely folded over or removed from furnace when
installing the furnace on a factory--supplied cased coil or coil box.
To remove the supply--air duct flange, use wide duct pliers or
hand seamers to bend flange back and forth until it breaks off. Be
careful of sharp edges. (See Fig. 14.)
Bottom Return Air Inlet
These furnaces are shipped with bottom closure panel installed in
bottom return--air opening. Remove and discard this panel when
bottom return air is used. To remove bottom closure panel,
perform the following:
1. Tilt or raise furnace and remove 2 screws holding bottom
filler panel. (See Fig. 9.)
2. Rotate bottom filler panel downward to release holding
tabs.
3. Remove bottom closure panel.
4. Reinstall bottom filler panel and screws.
315A
(8mm)
!
S
WARNING
FIRE, EXPLOSION, AND CARBON MONOXIDE
POISONING HAZARD
Failure to follow this warning could result in personal
injury, death, or property damage.
Do not install the furnace on its back or hang furnace with
control compartment facing downward. Safety control
operation will be adversely affected. Never connect
return--air ducts to the back of the furnace.
The furnace can be installed horizontally in an attic or crawlspace
on either the left--hand (LH) or right--hand (RH) side. The furnace
can be hung from floor joists, rafters or trusses or installed on a
non--combustible platform, blocks, bricks or pad.
Suspended Furnace Support
The furnace may be supported under each end with threaded rod,
angle iron or metal plumber’s strap as shown. (See Fig. 15 and
16.) Secure angle iron to bottom of furnace as shown.
Heavy--gauge sheet metal straps (plumber’s straps) may be used
to suspend the furnace from each bottom corner. To prevent
screws from pulling out, use 2 #8 x in. screws into the side and 2
#8 x in. screws in the bottom of the furnace casing for each strap.
(See Fig. 15 and 16.)
If the screws are attached to ONLY the furnace sides and not the
bottom, the straps must be vertical against the furnace sides and
not pull away from the furnace sides, so that the strap attachment
screws are not in tension (are loaded in shear) for reliable support.
Platform Furnace Support
Construct working platform at location where all required furnace
clearances are met. (See Fig. 2 and 17.) For furnaces with 1--in.
(25 mm) clearance requirement on side, set furnace on
non--combustible blocks, bricks or angle iron. For crawlspace
installations, if the furnace is not suspended from the floor joists,
the ground underneath furnace must be level and the furnace set
on blocks or bricks.
11
FURNACE
(OR COIL CASING
WHEN USED)
A
COMBUSTIBLE
FLOORING
PLENUM
OPENING
D
B
DOWNFLOW
SUBBASE
FLOOR
OPENING
SHEET METAL
PLENUM
FLOOR
OPENING
315A
C
A96285
A96283
Fig. 12 -- Furnace, Plenum, and Subbase Installed on a
Combustible Floor
Fig. 11 -- Floor and Plenum Opening Dimensions
Roll--Out Protection
Provide a minimum 17--3/4--in. X 22--in. (451 X 559 mm) piece
of sheet metal for flame roll--out protection in front of burner area
for furnaces closer than 12--in. (305 mm) above the combustible
deck or suspended furnaces closer than 12--in. (305 mm) to joists.
The sheet metal MUST extend underneath the furnace casing by
1--in. (25 mm)with the door removed.
The bottom closure panel on furnaces of widths 17--1/2--in. (445
mm) and larger may be used for flame roll--out protection when
bottom of furnace is used for return air connection. See Fig. 17
for proper orientation of roll--out shield.
Bottom Return Air Inlet
These furnaces are shipped with bottom closure panel installed in
bottom return--air opening. Remove and discard this panel when
bottom return air is used. To remove bottom closure panel,
perform the following:
1. Tilt or raise furnace and remove two screws holding bottom filler panel. (See Fig. 9.)
2. Rotate bottom filler panel downward to release holding
tabs.
3. Remove bottom closure panel.
4. Reinstall bottom filler panel and screws.
Side Return Air Inlet
These furnaces are shipped with bottom closure panel installed in
bottom return--air opening. This panel MUST be in place when
side return air inlet(s) are used without a bottom return air inlet.
FURNACE
APPROVED
COIL ASSEMBLY
OR
COIL BOX
COMBUSTIBLE
FLOORING
SHEET METAL
PLENUM
FLOOR
OPENING
A08556
Fig. 13 -- Furnace, Plenum, and Coil Assembly or Coil Box
Installed on a Combustible Floor
Not all horizontal furnaces are approved for side return air
connections (See Fig. 20.)
12
Table 4 – Opening Dimensions -- In. (mm)
14–3/16
(360)
17–1/2
(445)
21
(533)
24--- 1/2
(622)
Upflow Applications on Combustible or Noncombustible Flooring (KGASB subbase not required)
Downflow Applications on Noncombustible Flooring (KGASB
subbase not required)
Downflow applications on combustible flooring (KGASB subbase required)
Downflow Applications on Combustible Flooring with CNPV,
CNRV, CAR or CAP Coil Assembly or KCAKC coil box (KGASB
subbase not required)
Upflow Applications on Combustible or Noncombustible Flooring (KGASB subbase not required)
Downflow Applications on Noncombustible Flooring (KGASB
subbase not required)
Downflow applications on combustible flooring (KGASB subbase required)
Downflow Applications on Combustible Flooring with CNPV,
CNRV, CAR or CAP Coil Assembly or KCAKC coil box (KGASB
subbase not required)
Upflow Applications on Combustible or Noncombustible Flooring (KGASB subbase not required)
Downflow Applications on Noncombustible Flooring (KGASB
subbase not required)
Downflow applications on combustible flooring (KGASB subbase required)
Downflow Applications on Combustible Flooring with CNPV,
CNRV, CAR or CAP Coil Assembly or KCAKC coil box (KGASB
subbase not required)
Upflow Applications on Combustible or Noncombustible Flooring (KGASB subbase not required)
Downflow Applications on Noncombustible Flooring (KGASB
subbase not required)
Downflow applications on Combustible flooring (KGASB subbase required)
Downflow Applications on Combustible Flooring with CNPV,
CNRV, CAR or CAP Coil Assembly or KCAKC coil box (KGASB
subbase not required)
Filter Arrangement
!
PLENUM OPENING
APPLICATION
WARNING
CARBON MONOXIDE POISONING HAZARD
Failure to follow this warning could result in personal
injury, or death.
Never operate a furnace without a filter or with filter access
door removed.
There are no provisions for an internal filter rack in these
furnaces. An external filter rack is required.
This furnace is shipped with a factory--supplied Media Filter
Cabinet. The Media Filter Cabinet uses either a factory--supplied
standard 3/4--in. (19 mm) filter or 4--in. (102 mm) wide Media
Filter which can be purchased separately.
Refer to the instructions supplied with Media Cabinet for
assembly and installation options.
AIR DUCTS
General Requirements
The duct system should be designed and sized according to
accepted national standards such as those published by: Air
Conditioning Contractors Association (ACCA), Sheet Metal and
Air Conditioning Contractors National Association (SMACNA)
or American Society of Heating, Refrigerating and Air
Conditioning Engineers (ASHRAE) or consult The Air Systems
Design Guidelines reference tables available from your local
distributor. The duct system should be sized to handle the
FLOOR OPENING
A
B
C
D
12--- 11/16
(322)
12--- 9/16
(319)
11--- 13/16
(284)
21--- 5/8
(549)
19
(483)
19
(483)
13--- 5/16
(338)
13--- 3/16
(335)
13--- 7/16
(341)
22--- 1/4
(565)
19--- 5/8
(498)
20--- 5/8
(600)
12--- 5/16
(319)
19
(483)
13--- 5/16
(338)
20
(508)
16
(406)
15--- 7/8
(403)
15--- 1/8
(384)
21--- 5/8
(549)
19
(483)
19
(483)
16--- 5/8
(422)
16--- 1/2
(419)
16--- 3/4
(425)
22--- 1/4
(565)
19--- 5/8
(498)
20--- 5/8
(600)
15--- 1/2
(394)
19
(483)
16--- 1/2
(419)
20
(508)
19--- 1/2
(495)
19--- 3/8
(492)
18--- 5/8
(473)
21--- 5/8
(549)
19
(483)
19
(483)
20--- 1/8
(511)
20
(508)
20--- 1/4
(514)
22--- 1/4
(565)
19--- 5/8
(498)
20--- 5/8
(600)
19
(483)
19
(483)
20
(508)
20
(508)
23
(584)
22--- 7/8
(581)
22--- 1/8
(562)
21--- 1/8
(537)
19
(483)
19
(483)
23--- 5/8
(600)
23--- 1/2
(597)
23--- 3/4
(603)
22--- 1/4
(565)
19--- 5/8
(498)
20--- 5/8
(600)
22--- 1/2
(572)
19
(483)
23--- 1/2
(597)
20
(508)
required system design CFM at the design external static pressure.
The furnace airflow rates are provided in Table 5--Air
Delivery--CFM (With Filter). When a furnace is installed so that
the supply ducts carry air circulated by the furnace to areas
outside the space containing the furnace, the return air shall also
be handled by duct(s) sealed to the furnace casing and
terminating outside the space containing the furnace.
Secure ductwork with proper fasteners for type of ductwork used.
Seal supply-- and return--duct connections to furnace with code
approved tape or duct sealer.
NOTE: Flexible connections should be used between ductwork
and furnace to prevent transmission of vibration.
Ductwork passing through unconditioned space should be
insulated to enhance system performance. When air conditioning
is used, a vapor barrier is recommended.
Maintain a 1--in. (25 mm) clearance from combustible materials
to supply air ductwork for a distance of 36--in. (914 mm)
horizontally from the furnace. See NFPA 90B or local code for
further requirements.
Ductwork Acoustical Treatment
NOTE: Metal duct systems that do not have a 90 degree elbow
and 10 ft. (3 M) of main duct to the first branch take--off may
require internal acoustical lining. As an alternative, fibrous
ductwork may be used if constructed and installed in accordance
with the latest edition of SMACNA construction standard on
fibrous glass ducts. Both acoustical lining and fibrous ductwork
shall comply with NFPA 90B as tested by UL Standard 181 for
Class 1 Rigid air ducts.
13
315A
FURNACE
CASING
WIDTH
IN. (mm)
Supply Air Connections
For a furnace not equipped with a cooling coil, the outlet duct
shall be provided with a removable access panel. This opening
shall be accessible when the furnace is installed and shall be of
such a size that the heat exchanger can be viewed for possible
openings using light assistance or a probe can be inserted for
sampling the air stream. The cover attachment shall prevent leaks.
Upflow and Horizontal Furnaces
Connect supply--air duct to flanges on furnace supply--air outlet.
Bend flange upward to 90_ with wide duct pliers. (See Fig. 14.)
The supply--air duct must be connected to ONLY the furnace
supply--outlet--air duct flanges or air conditioning coil casing
(when used). DO NOT cut main furnace casing side to attach
supply air duct, humidifier, or other accessories. All accessories
MUST be connected to duct external to furnace main casing.
NOTE: For horizontal applications, the top most flange may be
bent past 90_ to allow the evaporator coil to hang on the flange
temporarily while the remaining attachment and sealing of the
coil are performed.
DOWNFLOW
UPFLOW
HORIZONTAL
90û
90û
YES
315A
YES
120û
MIN
YES
YES
YES
120û
MIN
NOT
RECOMMENDED
YES
120û
MIN
NOT
RECOMMENDED
NOT
RECOMMENDED
A02329
Fig. 14 -- Duct Flanges
/4" (6 mm) THREADED ROD
4 REQ.
1
OUTER DOOR
ASSEMBLY
SECURE ANGLE
IRON TO BOTTOM
OF FURNACE WITH
3 #8 x 3/4" (19 mm) SCREWS
TYPICAL FOR 2 SUPPORTS
8” (203 mm) MIN FOR
DOOR REMOVAL
1" (25 mm) SQUARE, 11/4" x 11/4" x 1/4"
(32 x 32 x 6 mm) ANGLE IRON
OR UNI-STRUT MAY BE USED
(2) HEX NUTS, (2) WASHERS & (2) LOCK WASHERS
REQ. PER ROD
A02345
Fig. 15 -- Horizontal Unit Suspension
14
315A
METHOD 2
USE (42) #8 x 3/4 (19 mm) SHEET
METAL SCREWS TYPICAL
FOR EACH STRAPS.THE
STRAPS SHOULD BE
VERTICAL AGAINST THE
FURNACE SIDES AND NOT
PULL AWAY FROM THE
FURNACE SIDES.
METHOD 1
FOLD ALL STRAPS UNDER
FURNACE AND SECURE WTH
(42) #8 x 3/4 (19 mm) SHEET METAL SCREWS
(2 SCREWS IN SIDE AND 2 SCREWS
IN BOTTOM).
A03176
Fig. 16 -- Horizontal Suspension with Straps
LINE CONTACT ONLY PERMISSIBLE BETWEEN
LINES FORMED BY INTERSECTIONS OF
THE TOP AND TWO SIDES OF THE FURNACE
JACKET AND BUILDING JOISTS,
STUDS, OR FRAMING.
17 3/4″ (451mm)OVERALL
4 3/4″ (121mm) UNDER DOOR
1″ (25mm) UNDER FURNACE
GAS
ENTRY
TYPE-B
EXTEND OUT 12″ (305mm)
VENT
FROM FACE OF DOOR
)
m
5 2m
1
(
IN*
6″ M
30-IN. (762mm)
MIN WORK AREA * WHEN USED WITH
SINGLE WALL VENT
CONNECTIONS
17 3/4″ (451mm)
SHEET
METAL
)
mm
559
22″ (
EQUIPMENT MANUAL
SHUT-OFF GAS VALVE
SEDIMENT
TRAP
UNION
A03177
Fig. 17 -- Typical Attic Installation
Downflow Furnaces
Connect supply--air duct to supply--air outlet on furnace. Bend
flange inward past 90_ with wide duct pliers (See Fig. 14.) The
supply--air duct must be connected to ONLY the furnace supply
outlet or air conditioning coil casing (when used). When installed
on combustible material, supply--air duct must be connected to
ONLY the accessory subbase, KGASB0201ALL, or a factory
approved air conditioning coil casing. DO NOT cut main furnace
casing to attach supply side air duct, humidifier, or other
accessories. All accessories MUST be connected to duct external
to furnace casing.
15
315A
A02075
Fig. 18 -- Upflow Return Air Configurations and Restrictions
A02163
Fig. 19 -- Downflow Return Air Configurations and Restrictions
A02162
Fig. 20 -- Horizontal Return Air Configurations and Restrictions
16
Table 5 – Air Delivery -- CFM (With Filter)*
070--- 12
††
Operating Mode
Low Heat
High Heat
††
††
090--- 16
1--- 1/2--- Ton Cooling
2--- Ton A/C Cooling
2--- 1/2--- Ton A/C Cooling
3--- Ton A/C Cooling
3--- 1/2--- Ton A/C Cooling
Maximum
Low Heat
High Heat
††
††
110--- 20***
1--- 1/2--- Ton A/C Cooling
2--- Ton A/C Cooling
2--- 1/2--- Ton A/C Cooling
3--- Ton A/C Cooling
3--- 1/2--- Ton A/C Cooling
4--- Ton A/C Cooling
Maximum
Low Heat
High Heat
††
††
††
135--- 22
2--- Ton A/C Cooling
2--- 1/2--- Ton A/C Cooling
3--- Ton A/C Cooling
3--- 1/2--- Ton A/C Cooling
4--- Ton A/C Cooling
5--- Ton A/C Cooling
6--- Ton A/C Cooling
Maximum
Low Heat
High Heat
††
††
††
155--- 22
2--- Ton A/C Cooling
2--- 1/2--- Ton A/C Cooling
3--- Ton A/C Cooling
3--- 1/2--- Ton A/C Cooling
4--- Ton A/C Cooling
5--- Ton A/C Cooling
6--- Ton A/C Cooling
Maximum
Low Heat
High Heat
††
††
††
2--- Ton A/C Cooling
2--- 1/2--- Ton A/C Cooling
3--- Ton A/C Cooling
3--- 1/2--- Ton A/C Cooling
4--- Ton A/C Cooling
5--- Ton A/C Cooling
6--- Ton A/C Cooling
Maximum
735 (615)†
1180
(1060)†
525
700
875
1050
1225
1400
985 (825)†
1210
(1090)†
525
700
875
1050
1225
1400
1600
1320
(1110)†
1475
(1330)†
700
875
1050
1225
1400
1750
2100
2200
1700
(1430)†
1915
(1725)†
700
875
1050
1225
1400
1750
2100
2200
1715
(1440)†
1970
(1775)†
700
875
1050
1225
1400
1750
2100
2200
External
Static
Pressure
Range*
(in. wc)
External Static Pressure (ESP) (IN WC)
0.1
0.2
0.3
0.4
0.5
0--- 0.50
735
735
735
735
0--- 1.0
1160
1165
1175
1180
1180
0--- 0.50‡
0--- 0.50‡
0--- 1.0‡
0--- 1.0‡
0--- 1.0
0--- 1.0
515
690
875
1050
1220
1395
500
680
875
1050
1225
1400
500
675
875
1050
1225
1400
490
680
870
1050
1225
1400
485
675
865
1050
1225
1395
0.6
0.7
0.8
0.9
1
1180
1180
1180
1180
1175
855
1050
1220
1385
850
1045
1205
1370
835
1035
1190
1340
825
1020
1185
1300
820
1000
1170
1245
AIRFLOW (CFM)
725
0--- 1.0
950
970
985
985
985
985
985
985
985
980
0--- 1.0
1190
1205
1210
1210
1210
1210
1210
1210
1210
1200
0--- 0.50‡
0--- 0.50‡
0--- 1.0‡
0--- 1.0‡
0--- 1.0
0--- 1.0
0--- 1.0
525
680
815
1005
1190
1350
1595
520
680
845
1005
1200
1370
1600
525
680
845
1015
1200
1390
1600
495
675
855
1035
1205
1390
1600
475
670
850
1040
1205
1400
1595
850
1040
1215
1390
1555
845
1035
1205
1380
1505
835
1030
1200
1380
1465
820
1025
1185
1360
1430
805
1010
1170
1340
1390
0--- 1.0
1275
1295
1315
1320
1320
1320
1320
1320
1320
1315
0--- 1.0
1460
1465
1475
1475
1475
1475
1475
1475
1465
1465
0--- 0.50‡
0--- 0.50‡
0--- 0.50‡
0--- 1.0‡
0--- 1.0‡
0--- 1.0‡
0--- 1.0
0--- 1.0
700
875
1050
1225
1400
1750
2100
2200
700
875
1050
1225
1400
1750
2100
2190
700
875
1050
1225
1400
1750
2100
2190
700
875
1050
1225
1400
1750
2100
2180
700
875
1050
1225
1400
1750
2090
2155
1225
1400
1750
2075
2145
1225
1400
1750
2055
2125
1225
1400
1750
2040
2100
1225
1400
1740
2005
2080
1225
1400
1725
1970
2020
0--- 1.0
1700
1700
1700
1700
1700
1695
1700
1695
1685
1670
0--- 1.0
1900
1905
1915
1915
1915
1915
1915
1915
1915
1915
0--- 0.50‡
0--- 0.50‡
0--- 0.50‡
0--- 1.0‡
0--- 1.0‡
0--- 1.0‡
0--- 1.0
0--- 1.0
700
870
1010
1155
1395
1740
2075
2180
700
870
1030
1180
1400
1750
2085
2195
700
865
1050
1200
1400
1750
2090
2200
700
865
1050
1210
1400
1750
2100
2200
665
865
1050
1220
1400
1735
2100
2200
1225
1400
1740
2100
2200
1225
1400
1735
2090
2185
1225
1390
1730
2080
2165
1225
1375
1715
2055
2140
1225
1355
1700
2025
2095
0--- 1.0
1715
1715
1715
1715
1715
1705
1710
1705
1705
1695
0--- 1.0
1955
1965
1965
1970
1970
1970
1970
1970
1970
1960
0--- 0.50‡
0--- 0.50‡
0--- 0.50‡
0--- 1.0‡
0--- 1.0‡
0--- 1.0‡
0--- 1.0
0--- 1.0
700
865
1015
1160
1385
1745
2055
2175
700
875
1020
1185
1400
1750
2070
2190
700
875
1035
1215
1400
1750
2080
2200
700
865
1045
1225
1400
1750
2085
2200
680
865
1050
1225
1400
1745
2095
2200
1225
1400
1740
2100
2200
1225
1395
1745
2100
2200
1225
1395
1745
2100
2200
1225
1380
1740
2090
2180
1225
1360
1735
2065
2160
*Actual external static pressure (ESP) can be determined by using the fan laws (CFM 2 proportional to ESP); such as, a system with 1180 CFM
at 0.5 ESP would operate at cooling airflow of 1050 CFM at 0.4 ESP and low--- heating airflow of 735 CFM at 0.19 ESP.
{Comfort airflow values are shown in parenthesis. Comfort airflow is selected when the low--- heat rise adjustment switch (SW1--- 3) is OFF and
the comfort/efficiency switch (SW1--- 4) is ON.
}Ductwork must be sized for high--- heating CFM within the operational range of ESP.
**Wattage data provided is for the circulating blower with bottom return and does not include draft inducer, accessories, or gas controls.
{{Operation within the blank areas of the chart is not recommended because high--- heat operation will be above 1.0 ESP.
***All airflows on 110 size furnace are 5% less on side return only installations.
17
315A
Unit Size
CFM
Airflow
Setting
Return Air Connections
!
WARNING
FIRE HAZARD
A failure to follow this warning could cause personal injury,
death and/or property damage.
315A
Never connect return--air ducts to the back of the furnace.
Follow instructions below.
Downflow Furnaces
The return--air duct must be connected to return--air opening
(bottom inlet) as shown in Fig. 3. DO NOT cut into casing sides
(left or right). Side opening is permitted for only upflow and
certain horizontal furnaces. Bypass humidifier connections
should be made at ductwork or coil casing sides exterior to
furnace. (See Fig. 19.)
Upflow and Horizontal Furnaces
The return--air duct must be connected to bottom, sides (left or
right), or a combination of bottom and side(s) of main furnace
casing as shown in Fig. 3. Bypass humidifier may be attached
into unused return air side of the furnace casing. (See Fig. 18 and
20.) Not all horizontal furnace models are approved for side
return air connections. (See Fig. 20.)
GAS PIPING
!
NOTE: In the state of Massachusetts:
1. Gas supply connections MUST be performed by a licensed plumber or gas fitter.
2. When flexible connectors are used, the maximum length
shall not exceed 36 in. (915 mm).
3. When lever handle type manual equipment shutoff valves
are used, they shall be T--handle valves.
4. The use of copper tubing for gas piping is NOT approved
by the state of Massachusetts.
Refer to Table 6 for recommended gas pipe sizing. Risers must be
used to connect to furnace and to meter. Support all gas piping
with appropriate straps, hangers, etc. Use a minimum of 1 hanger
every 6 ft. (1.8 M). Joint compound (pipe dope) should be
applied sparingly and only to male threads of joints. Pipe dope
must be resistant to the action of propane gas.
Table 6 – Maximum Capacity of Pipe
NOMINAL
IRON PIPE
SIZE
IN. (MM)
WARNING
50
(15.2)
73
360
250
200
170
151
1 ( 25.4)
1.049 (26.6)
680
465
375
320
285
1-1/4
(31.8)
1.380 (35.0)
1400
950
770
660
580
1-1/2
(38.1)
1.610 (40.9)
2100
1460
1180
990
900
WARNING
CAUTION
FURNACE DAMAGE HAZARD
Use proper length of pipe to avoid stress on gas control
manifold and a gas leak.
Gas piping must be installed in accordance with national and
local codes. Refer to current edition of NFGC in the U.S. and the
CAN/CSA--B149.1--05 in Canada.
Installations must be made in accordance with all authorities
having jurisdiction. If possible, the gas supply line should be a
separate line running directly from meter to furnace.
0.824 (20.9)
!
Failure to follow this warning could result in personal
injury, death, and/or property damage.
Gas valve inlet and/or inlet pipe must remain capped until
gas supply line is permanently installed to protect the valve
from moisture and debris. Also, install a sediment trap in the
gas supply piping at the inlet to the gas valve.
40
(12.1)
82
If local codes allow the use of a flexible gas appliance
connector, always use a new listed connector. Do not use a
connector which has previously served another gas
appliance. Black iron pipe shall be installed at the furnace
gas control valve and extend a minimum of 2--in. (51 mm)
outside the furnace.
FIRE OR EXPLOSION HAZARD
Failure to follow this warning could result in personal
injury, death, and/or property damage.
30
(9.1)
97
A failure to follow this warning could result in personal
injury, death, and/or property damage.
WARNING
FIRE OR EXPLOSION HAZARD
20
(6.0)
120
FIRE OR EXPLOSION HAZARD
Never purge a gas line into a combustion chamber. Never
test for gas leaks with an open flame. Use a commercially
available soap solution made specifically for the detection
of leaks to check all connections.
WARNING
0.622(158)
3/4 (19.0)
!
Failure to follow this warning could result in personal
injury, death, and/or property damage.
!
1/2 (12.7)
10
(3.0)
175
* Cubic ft of gas per hr for gas pressures of 0.5 psig (14--- in. wc) or less and
a pressure drop of 0.5--- in wc (based on a 0.60 specific gravity gas). Ref:
Table 9.2 NFGC.
FIRE OR EXPLOSION HAZARD
!
LENGTH OF PIPE --- FT (M)
INTERNAL
DIA.
IN. (MM)
Failure to follow this caution may result in furnace damage.
Connect gas pipe to furnace using a backup wrench to
avoid damaging gas controls and burner misalignment.
An accessible manual equipment shutoff valve MUST be
installed external to furnace casing and within 6 ft. (1.8 M) of
furnace. A 1/8--in. (3 mm) NPT plugged tapping, accessible for
test gauge connection, MUST be installed immediately upstream
of gas supply connection to furnace and downstream of manual
equipment shutoff valve.
NOTE: The furnace gas control valve inlet pressure tap
connection is suitable to use as test gauge connection providing
test pressure DOES NOT exceed maximum 0.5 psig (14--in. wc)
stated on gas control valve. (See Fig. 55.)
Some installations require gas entry on right side of furnace (as
viewed in upflow). (See Fig. 21 and 22)
Install a sediment trap in riser leading to furnace as shown in Fig
23. Connect a capped nipple into lower end of tee. Capped nipple
should extend below level of furnace gas controls. Place a ground
18
GAS
SUPPLY
MANUAL
SHUTOFF
VALVE
(REQUIRED)
SEDIMENT
TRAP
UNION
A02035
Fig. 23 -- Typical Gas Pipe Arrangement
ELECTRICAL CONNECTIONS
!
WARNING
ELECTRICAL SHOCK HAZARD
Failure to follow this warning could result in personal
injury or death.
Blower access panel door switch opens 115--v power to
control. No component operation can occur. Do not
bypass or close switch with panel removed.
2” (51mm)
A05028
Fig. 21 -- Right Side Gas Entry Example 1
See Fig. 25 for field wiring diagram showing typical field 115--v
wiring. Check all factory and field electrical connections for
tightness.
Field--supplied wiring shall conform with the limitations of 63_F
(33_C) rise.
!
90∞ Elbow
WARNING
ELECTRICAL SHOCK AND FIRE HAZARD
Failure to follow this warning could result in personal
injury, death, or property damage.
The cabinet MUST have an uninterrupted or unbroken
ground according to NEC ANSI/NFPA 70--2006 and
Canadian Electrical Code CSA C22.1 or local codes to
minimize personal injury if an electrical fault should occur.
This may consist of electrical wire, conduit approved for
electrical ground or a listed, grounded power cord (where
permitted by local code) when installed in accordance with
existing electrical codes. Refer to the power cord
manufacturer’s ratings for proper wire gauge. Do not use
gas piping as an electrical ground.
2” (51 mm) Nipple
Street Elbow
Gas Valve
A02327
Fig. 22 -- Right Side Gas Entry Example 2
!
CAUTION
FURNACE MAY NOT OPERATE HAZARD
Failure to follow this caution may result in intermittent
furnace operation.
Furnace control must be grounded for proper operation or
else control will lock out. Control must remain grounded
through green/yellow wire routed to gas valve and manifold
bracket screw.
19
315A
joint union between furnace gas control valve and exterior
manual equipment gas shutoff valve.
A 1/8--in. (3 mm) NPT plugged tapping, accessible for test gauge
connection, MUST be installed immediately upstream of gas
supply connection to furnace and downstream of manual
equipment shutoff valve.
Piping should be pressure and leak tested in accordance with the
current addition of the NFGC in the United States or CAN/
CSA--B149.1--05 in Canada, local, and national plumbing and
gas codes before the furnace has been connected. After all
connections have been made, purge lines and check for leakage at
furnace prior to operating furnace.
If pressure exceeds 0.5 psig (14--in. wc), gas supply pipe must be
disconnected from furnace and capped before and during supply
pipe pressure test. If test pressure is equal to or less than 0.5 psig
(14--in. wc), turn off electric shutoff switch located on furnace gas
control valve and accessible manual equipment shutoff valve
before and during supply pipe pressure test. After all connections
have been made, purge lines and check for leakage at furnace
prior to operating furnace.
The gas supply pressure shall be within the maximum and
minimum inlet supply pressures marked on the rating plate with
the furnace burners ON and OFF.
115--V Wiring
Verify that the voltage, frequency, and phase correspond to that
specified on unit rating plate. Also, check to be sure that service
provided by utility is sufficient to handle load imposed by this
equipment. Refer to rating plate or Table 7 for equipment
electrical specifications.
U.S. Installations: Make all electrical connections in accordance
with National Electrical Code (NEC) ANSI/NFPA 70--2006 and
any local codes or ordinances that might apply.
Canadian Installations: Make all electrical connections in
accordance with Canadian Electrical Code CSA C22.1 or
authorities having jurisdiction.
!
WARNING
FIRE HAZARD
Failure to follow this warning could result in personal
injury, death, or property damage.
Do not connect aluminum wire between disconnect
switch and furnace. Use only copper wire.
Use a separate, fused branch electrical circuit with a properly
sized fuse or circuit breaker for this furnace. See Table 7 for wire
size and fuse specifications. A readily accessible means of
electrical disconnect must be located within sight of the furnace.
315A
Table 7 – Electrical Data
FURNACE
SIZE
VOLTS--HERTZ--PHASE
OPERATING
VOLTAGE RANGE
Max.
Min.
MAX. UNIT
AMPS
UNIT
AMPACITY
#
MAX. WIRE
LENGTH --- FT (M)}
MAX. FUSE OR
CKT BKR AMPS {
MIN.
WIRE
GAUGE
070 ---12/036070
115 ---60 ---1
127
104
9.0
11.99
30 (9.0)
15
14
090 ---16/048090
115 ---60 ---1
127
104
9.6
12.56
29 (8.8)
15
14
110 ---20/060110
115 ---60 ---1
127
104
15.1
19.33
29 (8.8)
20
12
135 ---22/066135
115 ---60 ---1
127
104
14.9
19.13
30 (9.0)
20
12
155 ---22/066155
115 ---60 ---1
127
104
15.0
19.23
29 (8.8)
20
12
* Permissible limits of the voltage range at which the unit operates satisfactorily.
# Unit ampacity = 125 percent of largest operating component’s full load amps plus 100 percent of all other potential operating components’ (EAC, humidifier,
etc.) full load amps.
{Time ---delay type is recommended.
}Length shown is as measured 1 way along wire path between furnace and service panel for maximum 2 percent voltage drop.
NOTE: Proper polarity must be maintained for 115--v wiring. If
polarity is incorrect, control LED status indicator light will flash
rapidly and furnace will NOT operate.
J--Box Relocation
NOTE: If factory location of J--Box is acceptable, go to next
section (ELECTRICAL CONNECTION to J--Box).
NOTE: On 14--in. (356 mm) wide casing models, the J--Box
shall not be relocated to other side of furnace casing when the
vent pipe is routed within the casing.
1. Remove and save two screws holding J--Box. (See Fig.
24.)
NOTE: The J--Box cover need not be removed from the J--Box
in order to move the J--Box. Do NOT remove green ground
screw inside J--Box. The ground screw is not threaded into the
casing flange and can be lifted out of the clearance hole in casing
while swinging the front edge of the J--Box outboard of the
casing.
2. Cut wire tie on loop in furnace wires attached to J--Box.
3. Move J--Box to desired location.
4. Fasten J--Box to casing with the two screws removed in
Step 1.
See Fig. 24.
5. Route J--Box wires within furnace away from sharp edges,
rotating parts and hot surfaces.
Electrical Connection to J--Box
Field--Supplied Electrical Box on Furnace J--Box Bracket
See Fig. 25.
1. Remove cover from furnace J--Box.
2. Attach electrical box to furnace J--Box bracket with at least
two field--supplied screws through holes in electrical box
into holes in bracket. Use blunt--nose screws that will not
pierce wire insulation.
3. Route furnace power wires through holes in electrical box
and J--Box bracket, and make field--wire connections in
electrical box. Use best practices (NEC in U.S. and CSA
C22.1 in Canada) for wire bushings, strain relief, etc.
4. Route and secure field ground wire to green ground screw
on J--Box bracket.
5. Connect line voltage leads as shown in Fig. 25.
6. Reinstall cover to J--Box. Do not pinch wires between
cover and bracket.
Electrical Box on Furnace Casing Side
See Fig. 25.
20
TWO
315A
A02099
Fig. 24 -- Relocating J--Box
!
WARNING
FIRE OR ELECTRICAL SHOCK HAZARD
Failure to follow this warning could result in personal
injury, death, or property damage.
If field--supplied manual disconnect switch is to be mounted
on furnace casing side, select a location where a drill or
fastener cannot damage electrical or gas components.
1. Select and remove a hole knockout in the casing where the
electrical box is to be installed.
NOTE: Check that duct on side of furnace will not interfere with
installed electrical box.
2. Remove the desired electrical box hole knockout and position the hole in the electrical box over the hole in the furnace casing.
3. Fasten the electrical box to casing by driving two field-supplied screws from inside electrical box into casing
steel.
4. Remove and save two screws holding J--Box. (See Fig.
24.)
5. Pull furnace power wires out of 1/2--in. (12 mm) diameter
hole in J--Box. Do not loosen wires from strain--relief
wire--tie on outside of J--Box.
6. Route furnace power wires through holes in casing and
electrical box and into electrical box.
7. Pull field power wires into electrical box.
8. Remove cover from furnace J--Box.
9. Route field ground wire through holes in electrical box
and casing, and into furnace J--Box.
10. Reattach furnace J--Box to furnace casing with screws removed in Step 4.
11. Secure field ground wire to J--Box green ground screw.
12. Complete electrical box wiring and installation. Connect
line voltage leads as shown in Fig. 25. Use best practices
(NEC in U.S. and CSA C22.1 in Canada) for wire bushings, strain relief, etc.
13. Reinstall cover to J--Box. Do not pinch wires between
cover and bracket.
A03221
Fig. 25 -- Field--Supplied Electrical Box on Furnace Casing
Power Cord Installation in Furnace J--Box
NOTE: Power cords must be able to handle the electrical
requirements listed in Table 6. Refer to power cord
manufacturer’s listings.
1. Remove cover from J--Box.
2. Route listed power cord through 7/8--in. (22 mm) diameter
hole in J--Box.
3. Secure power cord to J--Box bracket with a strain relief
bushing or a connector approved for the type of cord used.
4. Secure field ground wire to green ground screw on J--Box
bracket.
5. Connect line voltage leads as shown in Fig. 26.
6. Reinstall cover to J--Box. Do not pinch wires between
cover and bracket.
BX Cable Installation in Furnace J--Box
1. Remove cover from J--Box.
2. Route BX cable into 7/8--in. (22 mm) diameter hole in
J--Box.
3. Secure BX cable to J--Box bracket with connectors approved for the type of cable used.
4. Secure field ground wire to green ground screw on J--Box
bracket.
5. Connect line voltage leads as shown in Fig. 26.
6. Reinstall cover to J--Box. Do not pinch wires between
cover and bracket.
24--V Wiring
Make field 24--v connections at the 24--v terminal strip. (See Fig.
26.) Connect terminal Y/Y2 as shown in Fig. 28--35 for proper
cooling operation. Use only AWG No. 18, color--coded, copper
thermostat wire.
The 24--v circuit contains an automotive--type, 3--amp. fuse
located on the control. Any direct shorts during installation,
service, or maintenance could cause this fuse to blow. If fuse
replacement is required, use ONLY a 3--amp. fuse of identical
size.
21
ACCESSORIES
1. Electronic Air Cleaner (EAC)
Connect an accessory Electronic Air Cleaner (if used) using 1/4--in female quick connect terminals to the two male
1/4--in quick--connect terminals on the control board
marked EAC--1 and EAC--2. The terminals are rated for
115VAC, 1.0 amps maximum and are energized during
blower motor operation. (See Fig. 27.)
2. Humidifier (HUM)
Connect an accessory 24 VAC, 0.5 amp. maximum humidifier (if used) to the 1/4--in male quick--connect HUM
terminal and COM--24V screw terminal on the control
board thermostat strip. The HUM terminal is energized
when blower is energized in heating. (See Fig. 27.)
NOTE: DO NOT connect furnace control HUM terminal to
HUM (humidifier) terminal on Thermidistat, Zone Controller or
similar device. See ThermidistatE, Zone Controller, thermostat,
or controller manufacturer’s instructions for proper connection.
VENTING
The furnace shall be connected to a listed factory built chimney
or vent, or a clay--tile lined masonry or concrete chimney. Venting
into an unlined masonry chimney or concrete chimney is
prohibited.
When an existing Category I furnace is removed or replaced, the
original venting system, may no longer be sized to properly vent
the attached appliances. An improperly sized Category I venting
system could cause the formation of condensate in the furnace
and vent, leakage of condensate and combustion products, and
spillage of combustion products into the living space.
315A
FIELD 24-VOLT WIRING
FIELD 115-, 208/230-, 460-VOLT WIRING
FACTORY 24-VOLT WIRING
FACTORY 115-VOLT WIRING
NOTE 2
W
FIVE
WIRE
C
Y
R
G
1-STAGE
THERMOSTAT
TERMINALS
FIELD-SUPPLIED
FUSED DISCONNECT
THREE-WIRE
HEATINGONLY
BLK
BLK
W2
WHT
WHT
COM
208/230- OR
460-VOLT
THREE
PHASE
W/W1
GND
115-VOLT FIELD- JUNCTION
SUPPLIED
BOX
FUSED
CONTROL
DISCONNECT
BOX
NOTE 1
Y/Y2
R
GND
208/230VOLT
SINGLE
PHASE
CONDENSING
UNIT
G
24-VOLT
TERMINAL
BLOCK
FURNACE
NOTES: 1. Connect Y/Y2-terminal as shown for proper operation.
2. Some thermostats require a "C" terminal connection as shown.
3. If any of the original wire, as supplied, must be replaced, use
same type or equivalent wire.
A95236
Fig. 26 -- Field Wiring Diagram
22
115 VAC Output to
HSI & Inducer
ECM Motor harness
Connector
VS HSI HI LO
Future Use
PL3
PL2
W2 Y1 DHUM G
Com W/W1 Y/Y2
24V
R
EAC-1
STATUS
CODE
315A
NEUTRAL-L2
EAC-2
LEDS
SEC-2 SEC-1
PL1
COMM
SW-1
PL4
SW3
CF
L1
12 Pin Inline
Connector
FUSE 3-AMP
PL7
ACRDJ
PL9
HUM
OAT
24 VAC Hum Output
(0.5 AMP MAX)
ACRDJ Jumper
A B C D
Model Plug
1-AMP@115 VAC
115 VAC EAC Input
(1.0 AMP MAX)
SW4
115 VAC Input
Transformer
Primary & 120
VAC to ECM
Motor
Neutral Leads and
EAC 2 (Neutral)
SW2
AC
Set up Switches SW1, 1
thru 8
24 VAC Output
Fuse, 3 Amp
A/C & Constant Air Flow
Switches
Status Code Light
A02018
Fig. 27 -- Variable Speed Furnace Control for ECM Blower Motor
23
!
WARNING
CARBON MONOXIDE POISONING HAZARD
315A
Failure to follow the steps outlined below for each
appliance connected to the venting system being placed into
operation could result in carbon monoxide poisoning or
death.
The following steps shall be followed for each appliance
connected to the venting system being placed into
operation, while all other appliances connected to the
venting system are not in operation:
1. Seal any unused openings in venting system.
2. Inspect the venting system for proper size and
horizontal pitch, as required in the National Fuel Gas
Code, NFPA 54/ANSI Z223.1--2006 or the CSA
B149.1, Natural Gas and Propane Installation Code
and these instructions. Determine that there is no
blockage or restriction, leakage, corrosion and other
deficiencies, which could cause an unsafe condition.
3. As far as practical, close all building doors and
windows and all doors between the space in which
the appliance(s) connected to the venting system are
located and other spaces of the building.
4. Close fireplace dampers.
5. Turn on clothes dryers and any appliance not
connected to the venting system. Turn on any
exhaust fans, such as range hoods and bathroom
exhausts, so they are operating at maximum speed.
Do not operate a summer exhaust fan.
6. Follow the lighting instructions. Place the appliance
being inspected into operation. Adjust the thermostat
so appliance is operating continuously.
7. Test for spillage from draft hood equipped
appliances at the draft hood relief opening after 5
minutes of main burner operation. Use the flame of a
match or candle.
8. If improper venting is observed during any of the
above tests, the venting system must be corrected in
accordance with the National Fuel Gas Code, NFPA
54/ANSI Z223.1--2006 and/or CSA B149.1, Natural
Gas and Propane Installation Code.
9. After it has been determined that each appliance
connected to the venting system properly vents when
tested as outlined above, return doors, windows,
exhaust fans, fireplace dampers and any other
gas--fired burning appliance to their previous
conditions of use.
A00275
Fig. 28 -- Two--Stage Furnace with Single--Speed
Air Conditioner
!
WARNING
CARBON MONOXIDE POISONING HAZARD
Failure to follow this warning could result in personal
injury or death.
Do not bypass the draft safeguard switch, as an unsafe
condition could exist which must be corrected.
1. If a vent (common or dedicated) becomes blocked, the furnace will be shut off by the draft safeguard switch located
on the vent elbow.
2. Two--stage furnaces require Type B vent connectors outside the casing in all configurations. Single wall vent connector may be used inside the furnace casing with the
transition to Type B vent outside the furnace casing. Size
the connector so that the FAN--Min vent connector capacity is equal to or lower than the low fire rate of the furnace and the FAN--Max vent connector capacity is equal
to or higher than the furnace high fire rate.
3. Do not vent this Category I furnace into a single wall dedicated or common vent. The dedicated or common vent is
considered to be the vertical portion of the vent system
that terminates outdoors.
4. Vent connectors serving Category I furnaces shall not be
connected into any portion of a mechanical draft system
operating under positive pressure.
5. In the US: Do not vent this appliance with any solid fuel
burning appliance.
In Canada: Check with the authority having jurisdiction
for approval on use with solid fuel burning appliance.
6. Category I furnaces must be vented vertically or nearly
vertically unless equipped with a listed mechanical venter.
See SIDEWALL VENTING section.
7. Do not vent this appliance into an unlined masonry chimney. Refer to Chimney Inspection Chart, Fig. 36.
Vent system or vent connectors may need to be resized. Vent
systems or vent connectors must be sized to approach minimum
size as determined using appropriate table found in the current
edition of NFGC or CAN/CSA--B149.1--05.
General Venting Requirements
Follow all safety codes for proper vent sizing and installation
requirements, including local building codes, the National Fuel
Gas Code NFPA 54/ANSI Z223.1--2006 (NFGC), Parts 10 and
13 in the United States or the National Standard of Canada,
Natural Gas and Propane Installation Code CSA--B149.1--00
(CAN/CSA--B149.1--05) Section 8 and Appendix C in Canada,
the local building codes, and furnace and vent manufacturers’
instructions.
The following information and warning must be considered in
addition to the requirements defined in the NFGC or the
CAN/CSA--B149.1--05.
24
315A
See notes 2, 5, 8, 10, 11 and 12
on the page following these figures
See notes 1, 2, 3, 4, 6, 8, 9, 10, 12, 13 and 15
on the page following these figures
A03179
A03178
Fig. 29 -- Two--Stage Furnace with Two--Speed Air Conditioner
Fig. 31 -- Two--Stage Furnace with Two--Speed Heat Pump
(Dual Fuel)
See notes 1, 2, 4, 11, 14, 15, and 16
on the page following these figures
See notes 1, 2, 4, 6, 7, 9, 10, 11, and 15
on the page following these figures
A03180
A03181
Fig. 30 -- Two--Stage Furnace with Single--Speed Heat Pump
(Dual Fuel)
Fig. 32 -- Dual--Fuel Thermostat with Two--Stage Furnace
and Single--Speed Heat Pump
25
315A
7
See notes 2, 11, and 12 on the
page following these figures
See notes 1, 2, 3, 4, 12, 13, 14, 15, and 17
on the page following these figures
A03182
A03183
Fig. 33 -- Dual--Fuel Thermostat with Two--Stage Furnace
and Two--Speed Heat Pump
Fig. 34 -- Two--Stage Thermostat with Two--Stage Furnace
and Two--Speed Air Conditioner
See notes 1 and 2 on the page
following these figures
A03184
Fig. 35 -- Single--Stage Thermostat with Two--Stage Furnace and Two--Speed Air Conditioner
26
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
27
315A
1.
2.
3.
NOTES FOR FIGURES 28--35
Heat pump MUST have a high pressure switch for dual fuel applications.
Refer to outdoor equipment Installation Instructions for additional information and setup procedure.
If the heat pump date code is 1501E or earlier, select the “ZONE” position on the two--speed heat pump control. Heat pumps having
date codes 1601E and later do not have or require a “ZONE” selection.
Outdoor Air Temperature Sensor must be attached in all dual fuel applications.
Dip switch No. 1 on Thermidistat should be set in OFF position for air conditioner installations. This is factory default.
Dip switch No. 1 on Thermidistat should be set in ON position for heat pump installations.
Dip switch No. 2 on Thermidistat should be set in OFF position for single--speed compressor operation. This is factory default.
Dip switch No. 2 on Thermidistat should be set in ON position for two--speed compressor operation.
Configuration Option No. 10 “Dual Fuel Selection” must be turned ON in all dual fuel applications.
NO connection should be made to the furnace HUM terminal when using a Thermidistat.
Optional connection: If wire is connected, dip switch SW1--2 on furnace control should be set in ON position to allow Thermidistat/
Thermostat to control furnace staging.
Optional connection: If wire is connected, ACRDJ jumper on furnace control should be removed to allow Thermidistat/Thermostat to
control outdoor unit staging.
Furnace must control its own high--stage heating operation via furnace control algorithm.
The RVS Sensing terminal “L” should not be connected. This is internally used to sense defrost operation.
DO NOT SELECT the “FURNACE INTERFACE” or “BALANCE POINT” option on the two--speed heat pump control board. This
is controlled internally by the Thermidistat/Dual Fuel Thermostat.
Dip switch D on Dual Fuel Thermostat should be set in OFF position for single--speed compressor operation. This is factory default.
Dip switch D on Dual Fuel Thermostat should be set in ON position for two--speed compressor operation.
CHIMNEY INSPECTION CHART
For additional requirements refer to the National Fuel Gas Code NFPA 54/ANSI Z223.1 and ANSI/NFPA 211
Chimneys, Fireplaces, Vents, and Solid Fuel Burning Appliances in the U.S.A. or to the Canadian
installation Code CSA-B149.1 in Canada.
Crown
condition:
Missing mortar
or brick?
Rebuild
crown.
Yes
315A
No
Is chimney
property lined with
clay tile liner?
No
Yes
Is
liner and top
seal in good
condition?
No
Repair
liner or top seal
or reline chimney as
necessary.
Reline
Repair
Yes
Debris
in cleanout?
Yes
Mortar, tile, metal vent,
fuel oil residue?
Mortar
or tile
debris?
No Remove metal vent
or liner.
Clay
tile misalignment,
missing sections,
gaps?
Yes
Remove mortar
and tile debris
No
Yes
No
No
Consult
Part B of
chimney adapter venting
instructions for
application
suitability.
Is chimney
lined with properly
sized, listed liner or
Type-B vent?
Condensate
drainage at bottom
of chimney?
Yes
Suitable
Yes
Install chimney
adapter per
instructions.
No
Yes
Chimney
exposed to
outdoors below
roof line?
Yes
Is chimney
to be dedicated to
a single
furnace?
Not Suitable
Not Suitable
Consult
Part C of
chimney adapter venting
instructions for
application
suitability
No
Line chimney with property
sized, listed flexible metal
liner or Type-B vent per
NFGC or NSCNGPIC Vent
Sizing Tables and liner or
vent manufacturer’s
Installation instructions.
Suitable
Install chimney
adapter per
instructions.
No
Chimney is
acceptable for use.
A03206
Fig. 36 -- Chimney Inspection Chart
28
lined with a UL listed (ULC listed in Canada) metal liner or UL
listed Type--B vent. Relining with a listed metal liner or Type--B
vent is considered to be a vent--in--a--chase.
If a metal liner or Type--B vent is used to line a chimney, no other
appliance shall be vented into the annular space between the
chimney and the metal liner.
Exterior Masonry Chimney FAN + NAT
Installations with Type--B Double--Wall Vent
Connectors ENFPA & AGA
Table A—Combined Appliance Maximum Input
Rating in Thousands of Btuh per Hour
VENT HEIGHT
FT (M)
6 (1.8)
8 (2.4)
10 (3.0)
15 (4.5)
20 (6.0)
30 (9.1)
INTERNAL AREA OF CHIMNEY
SQ. IN. (SQ. MM)
12
19
28
38
(7741)
(12258)
(18064)
(24516)
74
119
178
257
80
130
193
279
84
138
207
299
NR
152
233
334
NR
NR
250
368
NR
NR
NR
404
Appliance Application Requirements
Appliance operation has a significant impact on the performance
of the venting system. If the appliances are sized, installed,
adjusted, and operated properly, the venting system and/or the
appliances should not suffer from condensation and corrosion.
The venting system and all appliances shall be installed in
accordance with applicable listings, standards, and codes.
The furnace should be sized to provide 100 percent of the design
heating load requirement plus any margin that occurs because of
furnace model size capacity increments. Heating load estimates
can be made using approved methods available from Air
Conditioning Contractors of America (Manual J); American
Society of Heating, Refrigerating, and Air--Conditioning
Engineers; or other approved engineering methods. Excessive
oversizing of the furnace could cause the furnace and/or vent to
fail prematurely.
When a metal vent or metal liner is used, the vent must be in
good condition and be installed in accordance with the vent
manufacturer’s instructions.
To prevent condensation in the furnace and vent system, the
following precautions must be observed:
1. The return--air temperature must be at least 60_F db except
for brief periods of time during warm--up from setback at
no lower than 55_F (13_C) db or during initial start--up
from a standby condition.
2. Adjust the gas input rate per the installation instructions.
Low gas input rate causes low vent gas temperatures, causing condensation and corrosion in the furnace and/or venting system. Derating is permitted only for altitudes above
2000 Ft. (610 M).
3. Adjust the air temperature rise to the midpoint of the rise
range or slightly above. Low air temperature rise can cause
low vent gas temperature and potential for condensation
problems.
4. Set the thermostat heat anticipator or cycle rate to reduce
short cycling.
!
CAUTION
BURN HAZARD
Failure to follow this caution may result in personal injury.
Hot vent pipe is within reach of small children when
installed in downflow position.
See the following instruction.
29
315A
Masonry Chimney Requirement
NOTE: These furnaces are CSA design--certified for use in
exterior tile--lined masonry chimneys with a factory accessory
Chimney Adapter Kit. Refer to the furnace rating plate for correct
kit usage. The Chimney Adapter Kits are for use with ONLY
furnaces having a Chimney Adapter Kit number marked on the
furnace rating plate.
If a clay tile--lined masonry chimney is being used and it is
exposed to the outdoors below the roof line, relining might be
required. Chimneys shall conform to the Standard for Chimneys,
Fireplaces, Vents, and Solid Fuel Burning Appliances
ANSI/NFPA 211--2006 in the United States and to a Provincial or
Territorial Building Code in Canada (in its absence, the National
Building Code of Canada) and must be in good condition.
U.S.A.--Refer to Sections 13.1.9 and 13.2.20 of the NFPA
54/ANSI Z223.1--2006 or the authority having jurisdiction to
determine whether relining is required. If relining is required, use
a properly sized listed metal liner, Type--B vent, or a listed
alternative venting design.
NOTE:
See the NFPA 54/ANSI Z223.1--2006 13.1.9 and
13.2.20 regarding alternative venting design and the exception,
which cover installations such as our Chimney Adapter Kits
KGACA02014FC and KGACA02015FC, which are listed for
use with these furnaces.
The Chimney Adapter Kit is a listed alternative venting system
for these furnaces. See the kit instructions for complete details.
Canada (and U.S.A.)--This furnace is permitted to be vented into
a clay tile--lined masonry chimney that is exposed to the outdoors
below the roof line, provided:
1. Vent connector is Type--B double--wall, and
2. This furnace is common vented with at least 1 draft hood
equipped appliance, and
3. The combined appliance input rating is less than the maximum capacity given in Table A, and
4. The input rating of each space heating appliance is greater
than the minimum input rating given in Table B for the
local 99% Winter Design Temperature. Chimneys having
internal areas greater than 38 sq. in. (24516 sq. mm) require furnace input ratings greater than the input ratings of
these furnaces. See footnote at bottom of Table B, and
5. The authority having jurisdiction approves.
If all of these conditions cannot be met, an alternative venting
design shall be used, such as the listed chimney adapter kit with a
furnace listed for use with the kit, a listed chimney--lining system,
or a Type--B common vent.
Inspections before the sale and at the time of installation will
determine the acceptability of the chimney or the need for repair
and/or (re)lining. Refer to the Fig. 34 to perform a chimney
inspection. If the inspection of a previously used tile--lined
chimney:
a. Shows signs of vent gas condensation, the chimney
should be relined in accordance with local codes and
the authority having jurisdiction. The chimney should
be relined with a listed metal liner, Type--B vent, or a
listed chimney adapter kit shall be used to reduce condensation. If a condensate drain is required by local
code, refer to the NFPA 54/ANSI Z223.1--2006, Section 12--10 for additional information on condensate
drains.
b. Indicates the chimney exceeds the maximum permissible size in the tables, the chimney should be rebuilt or
relined to conform to the requirements of the equipment being installed and the authority having jurisdiction.
A chimney without a clay tile liner, which is otherwise in good
condition, shall be rebuilt to conform to ANSI/NFPA 211 or be
Table B—Minimum Allowable Input Rating of
Space--Heating Appliance in
Thousands of Btuh per Hour
The vent connector can exit the door through one of five
locations on the door.
!
INTERNAL AREA OF CHIMNEY
315A
VENT HEIGHT
FT. (M)
SQ. IN. (SQ. MM)
12
19
28
38
(7741)
(12258) 18064)
(24516)
Local 99% Winter Design Temperature: 17 to 26 degrees F
6
0
55
99
141
8
52
74
111
154
10
NR
90
125
169
15
NR
NR
167
212
20
NR
NR
212
258
30
NR
NR
NR
362
Local 99% Winter Design Temperature: 5 to 16 degrees F*
6
NR
78
121
166
8
NR
94
135
182
10
NR
111
149
198
15
NR
NR
193
247
20
NR
NR
NR
293
30
NR
NR
NR
377
Local 99% Winter Design Temperature: --- 10 to 4 degrees F*
6
NR
NR
145
196
8
NR
NR
159
213
10
NR
NR
175
231
15
NR
NR
NR
283
20
NR
NR
NR
333
30
NR
NR
NR
NR
Local 99% Winter Design Temperature: --- 11 degrees F or
lower
Not recommended for any vent configuration.
*The 99.6% heating (db) temperatures found in the 1997 or 2001
ASHRAE Fundamentals Handbook, Climatic Design Information chapter,
Table 1A (United States) and 2A (Canada) or the 2005 ASHRAE Fundamentals handbook, Climatic Design Information chapter, and the CD --ROM included with the 2005 ASHRAE Fundamentals Handbook.
Air for combustion must not be contaminated by halogen
compounds which include chlorides, fluorides, bromides, and
iodides. These compounds are found in many common home
products such as detergent, paint, glue, aerosol spray, bleach,
cleaning solvent, salt, and air freshener, and can cause corrosion
of furnaces and vents. Avoid using such products in the
combustion--air supply. Furnace use during construction of the
building could cause the furnace to be exposed to halogen
compounds, causing premature failure of the furnace or venting
system due to corrosion.
Vent dampers on any appliance connected to the common vent
can cause condensation and corrosion in the venting system. Do
not use vent dampers on appliances common vented with this
furnace.
Additional Venting Requirements
A 4--in. (102 mm) round vent elbow is supplied with the furnace.
A 5--in. (127 mm) or 6-- in. (152 mm) vent connector may be
required for some model furnaces. A field--supplied 4--in. (102
mm) to 5--in. (127 mm) or 4--in. (102 mm) to 6--in. (152 mm)
sheet metal increaser fitting is required when 5--in. (127 mm) or
6--in. (152 mm) vent connector is used. See Fig. 37--49, Venting
Orientation for approved vent configurations.
NOTE: Vent connector length for connector sizing starts at
furnace vent elbow. The 4--in. (102 mm) vent elbow is shipped
for upflow configuration and may be rotated for other positions.
Remove the three screws that secure vent elbow to furnace, rotate
furnace vent elbow to position desired, reinstall screws. The
factory--supplied vent elbow does NOT count as part of the
number of vent connector elbows.
CAUTION
CUT HAZARD
Failure to follow this caution may result in personal injury.
Sheet metal parts may have sharp edges or burrs. Use care
and wear appropriate protective clothing, safety glasses and
gloves when handling parts, and servicing furnaces.
1. Attach the single wall vent connector to the furnace vent
elbow, and fasten the vent connector to the vent elbow
with at least two field--supplied, corrosion--resistant, sheet
metal screws located 180_ apart.
NOTE: An accessory flue extension KGAFE0112UPH is
available to extend from the furnace elbow to outside the furnace
casing. If flue extension is used, fasten the flue extension to the
vent elbow with at least two field--supplied, corrosion--resistant,
sheet metal screws located 180_ apart. Fasten the vent connector
to the flue extension with at least two field--supplied, corrosion
resistant sheet metal screws located 180_ apart.
2. Vent the furnace with the appropriate connector as shown
in Fig 37--49.
3. Orient the door to determine the correct location of the
door knockout to be removed.
4. Use aviation--type tin snips to remove the correct
U--shaped knockout in door.
NOTE: A number of techniques can be used to remove these
knockouts as seen in Fig. 50 through 54. The knockout in the
bottom of the door is unique due to its flanging and is not easily
removed by first cutting the two tie points at the edge of the door,
using aviation--type tin snips. (See Fig. 50.) A sharp blow to the
rounded end of the knockout (See Fig. 51.) will separate more tie
points and allow the knockout to be pulled loose. (See Fig. 52.)
Remove any burrs and sharp edges.
For the rectangular J--box knockout, use tin snips along the door
edge and use a sharp blow with a hammer to remove the
knockout.
Remove any burrs and sharp edges.
For the knockouts in the other locations on the door (top and
sides), tin snips can also be used along the door edges; however,
the preferred method is to use a hammer and screwdriver to strike
a sharp blow (See Fig. 53.) directly to the knockout tie points or
use a hammer in the upper left corner of the desired knockout.
(See Fig. 54.) Remove any burrs and sharp edges.
NOTE: If a knockout does not come out after two sharp blows,
pull and snip as needed to remove the knockout. Additional
blows may cause damage to the door.
An accessory Vent Guard Kit, KGAVG0101DFG is REQUIRED
for downflow applications for use where the vent exits through
the lower portion of the furnace casing door. Refer to the Vent
Guard Kit Instructions for complete details.
30
315A
SEE NOTES: 1,2,4,7,8,9
on the page following
these figures
SEE NOTES:1,2,3,4,5,7,8,9
on the page following
these figures
A03208
A03210
Fig. 37 -- Upflow Application -- Vent Elbow Up
Fig. 39 -- Downflow Application -- Vent Elbow Up then Left
SEE NOTES: 1,2,4,5,7,8,9
on the page following
these figures
SEE NOTES: 1,2,3,4,7,8,9
on the pages following
these figures
A03209
A03211
Fig. 38 -- Upflow Application -- Vent Elbow Right
Fig. 40 -- Downflow Application -- Vent Elbow Up
31
SEE NOTES: 1,2,4,7,8,9 on the page
following these figures
A03213
315A
Fig. 43 -- Horizontal Left Application -- Vent Elbow Left
SEE NOTES: 1,2,4,5,6,7,8,9,10
on the page following these figures
A03207
Fig. 41 -- Downflow Application -- Vent Elbow Left then Up
SEE NOTES: 1,2,4,5,7,8,9 on the page
following these figures
A03214
Fig. 44 -- Horizontal Left Application -- Vent Elbow Right
then Up
SEE NOTES:1,2,3,4,5,7,8,9
on the page following
these figures.
SEE NOTES: 1,2,4,7,8,9 on the page
following these figures
A03212
A03218
Fig. 42 -- Downflow Application -- Vent Elbow Up then Right
Fig. 45 -- Horizontal Right Application -- Vent Elbow Right
32
SEE NOTES: 1,2,4,5,7,8,9 on the page
following these figures
SEE NOTES: 1,2,4,5,7,8,9 on the page
following these figures
A03219
Fig. 48 -- Horizontal Right Application -- Vent Elbow Left
then Up
SEE NOTES: 1,2,4,5,7,8,9
SEE NOTES: 1,2,4,5,7,8,9 on the page
following these figures
A02068
A03216
Fig. 49 -- Horizontal Right Application--Vent Elbow Left
Fig. 47 -- Horizontal Left Application -- Vent Elbow Right
Caution!! For the following applications, use the minimum vertical heights as specified below.
For all other applications, follow exclusively the National Fuel Gas Code.
FURNACE
ORIENTATION
Downflow
Horizontal Left
Horizontal Left
Horizontal Left
Downflow
Downflow
VENT ORIENTATION
FURNACE INPUT
(BTUH/HR)
MIN. VENT
DIAMETER
IN. (mm)*
MIN. VERTICAL VENT
HEIGHT
FT. (M)**
Vent elbow left, then up
Fig. 37
Vent elbow right, then up
Fig. 40
Vent Elbow up
Fig. 41
Vent elbow right
Fig. 42
Vent elbow up then left
Fig. 35
Vent elbow up, then right
Fig. 38
154,000 132,000
110,000(036/--- 12 only)
5 (127)
12 (3.6)
154,000 132,000
5 (127)
7 (2.1)
154,000 132,000
5 (127)
7 (2.1)
154,000
5 (127)
7 (2.1)
110,000 (036/--- 12 only)
5 (127)
10 (3.0)
110,000 (036/--- 12 only)
5 (127)
10 (3.0)
NOTE: All vent configurations must also meet National Fuel Gas Code venting requirements NFGC.
*4 ---in. (102 mm) inside casing or vent guard
**Including 4 in. (102 mm) vent section(s)
33
315A
A03215
Fig. 46 -- Horizontal Left Application -- Vent Elbow Up
1.
2.
3.
4.
5.
6.
7.
8.
9.
315A
10.
Venting Notes for Fig. 37--49
For common vent, vent connector sizing and vent material: United States----use the NFGC Canada----use the CAN/CSA--B149.1--05
Immediately increase to 5--in. (102 mm) or 6--in. (152 mm) vent connector outside furnace casing when 5--in. (127 mm) vent connector is required, refer to Note 1 above.
Side outlet vent for upflow and downflow installations must use Type B vent immediately after exiting the furnace, except when
KGAVG0101DFG, Downflow Vent Guard Kit, is used in the downflow position.
Type--B vent where required, refer to Note 1 above.
A 4--in.(102 mm) single--wall (26 ga. min.) vent must be used inside furnace casing and when the KGAVG0101DFG Downflow Vent
Guard Kit is used external to the furnace.
Accessory Downflow Vent Guard Kit, KGAVG0101DFG required in downflow installations with lower vent configuration.
Chimney Adapter Kit may be required for exterior masonry chimney applications. Refer to Chimney Adapter Kit, KGACA02014FC
or KGACA02015FC, for sizing and complete application details.
Secure vent connector to furnace elbow with (2) corrosion--resistant sheet metal screws, spaced approximately 180_ apart.
Secure all other single wall vent connector joints with (3) corrosion resistant screws spaced approximately 120_ apart. Secure Type--B
vent connectors per vent connector manufacturer’s recommendations.
The total height of the vent and connector shall be at least seven feet for the 154,000 Btuh gas input rate model when installed in a
downflow application with furnace elbow turned to left side with the connector elbow outside furnace casing pointing upward. (See
Fig. 39.)
The horizontal portion of the venting system shall slope upwards
not less than 1/4--in. per linear ft. (21 mm/m) from the furnace to
the vent and shall be rigidly supported every 5 ft. (1.5 M) or less
with metal hangers or straps to ensure there is no movement after
installation.
Sidewall Venting
This furnace is not approved for direct sidewall horizontal
venting.
In the U.S.: Per section 12.4.3.1 of the NFPA 54/ANSI
Z223.1--2006, any listed mechanical venter may be used, when
approved by the authority having jurisdiction.
In Canada: Per section 8.24.2 of the CAN/CSA--B149.1--05,
any listed mechanical venter may be used, when approved by the
authority having jurisdiction.
Select the listed mechanical venter to match the Btuh input of the
furnace being vented. Follow all manufacturer’s installation
requirements for venting and termination included with the listed
mechanical venter.
1. Maintain 115--v wiring and ground. Improper polarity will
result in rapid flashing LED and no furnace operation.
2. Make thermostat wire connections at the 24--v terminal
block on the furnace control. Failure to make proper connections will result in improper operation. (See Fig. 26.)
3. Gas supply pressure to the furnace must be greater than
4.5--in. wc (0.16 psig ) but not exceed 14--in. wc (0.5
psig).
4. Check all manual--reset switches for continuity.
5. Replace blower compartment door. Door must be in place
to operate furnace.
6. Setup switch descriptions The variable speed furnace control has DIP switches to select thermostat staging, blower
off delay timings, air flow selection and other operational
or service related functions. (See Fig. 27, 59 and Table 8.)
!
START--UP, ADJUSTMENT, AND SAFETY
CHECK
CUT HAZARD
Failure to follow this caution may result in personal injury.
General
!
CAUTION
Sheet metal parts may have sharp edges or burrs. Use care
and wear appropriate protective clothing, safety glasses and
gloves when handling parts, and servicing furnaces.
WARNING
FIRE HAZARD
Failure to follow this warning could result in personal injury,
death or property damage.
This furnace is equipped with manual reset limit switches in
the gas control area. The switches open and shut off power to
the gas valve, if a flame rollout or overheating condition
occurs in the gas control area. DO NOT bypass the switches.
Correct problem before resetting the switches.
34
A04129
Fig. 52 -- Knockout Pulled Loose
A04128
Fig. 51 -- Rounded End of Knockout
35
315A
A04127
Fig. 50 -- Using Tin Snips to Cut Tie Points
REGULATOR COVER SCREW
PLASTIC ADJUST SCREW
ON/OFF SWITCH
REGULATOR SPRING
1/2˝ NPT INLET
INLET
PRESSURE TAP
HIGH STAGE GAS
PRESSURE REGULATOR
ADJUSTMENT
LOW STAGE
GAS PRESSURE
REGULATOR ADJUSTMENT
315A
MANIFOLD
PRESSURE TAP
1/2˝ NPT OUTLET
A04130
A04167
Fig. 53 -- Hammer and Screwdriver Used for Knockout
Fig. 55 -- Redundant Automatic Gas Control Valve
BURNER
ORIFICE
A04131
A93059
Fig. 54 -- Remove Knockout with Hammer
Fig. 56 -- Orifice Hole
36
HOOK-AROUND
AMMETER
R Y W G
10 TURNS
FROM UNIT 24-V
CONTROL TERMINALS
EXAMPLE: 5.0 AMPS ON AMMETER
10 TURNS AROUND JAWS
= 0.5 AMPS FOR THERMOSTAT
ANTICIPATOR SETTING
Component test sequence is as follows:
a. Inducer motor starts on high--speed and continues to
run until Step d. of component test sequence.
b. Hot surface igniter is energized for 15 sec., then off.
c. Blower motor operates for 15 sec.
d. Inducer motor goes to low--speed for 10 sec., then
stops.
e. After component test is completed, one or more status
codes (11, 25, or 41) will flash. See component test
section of service label (Fig. 58) in furnace for explanation of status codes.
NOTE: To repeat component test, turn setup switch SW1--6
OFF, then back ON.
4. Turn setup DIP switch SW1--6 OFF. Reconnect R lead to
furnace control board, release blower door switch and reinstall blower access door.
5. Operate furnace per instruction on inner door.
6. Verify furnace shut down by lowering thermostat setting
below room temperature.
7. Verify furnace restarts by raising thermostat setting above
room temperature.
Adjustments
!
A96316
Fig. 57 -- Amp. Draw Check with Ammeter
FIRE HAZARD
Failure to follow this warning could result in personal
injury, death and/or property damage.
Start--Up Procedures
!
WARNING
DO NOT bottom out gas valve regulator adjusting screw.
This can result in unregulated manifold pressure and result
in excess overfire and heat exchanger failures.
WARNING
FIRE AND EXPLOSION HAZARD
Failure to follow this warning could cause personal injury,
death or property damage.
!
Never test for gas leaks with an open flame. Use a
commercially available soap solution made specifically for
detection of leaks to check all connections.
CAUTION
FURNACE DAMAGE HAZARD
Failure to follow this caution may result in reduced furnace
life.
!
WARNING
DO NOT redrill orifices. Improper drilling (burrs,
out--of--round holes, etc.) can cause excessive burner noise
and misdirection of burner flames. This can result in flame
impingement of heat exchangers, causing failures. (See Fig.
56.)
ELECTRICAL SHOCK HAZARD
Failure to follow this warning could result in personal
injury, or death.
Blower access door switch opens 115--v power to control.
No component operation can occur unless switch is closed.
Caution must be taken when manually closing this switch
for service purposes.
1. Purge gas lines after all connections have been made.
2. Check gas lines for leaks.
3. To Begin Component Self--Test:
Remove Blower Access Door. Disconnect the thermostat
R lead from furnace control board. Manually close blower
door switch. Turn Setup DIP switch SW1--6 ON. (See Fig.
27, 59 and Table 8.)
NOTE: The furnace control allows all components, except the
gas valve, to be run for short period of time. This feature helps
diagnose a system problem in case of a component failure.
Component test feature will not operate if any thermostat signal is
present at the control.
Refer to service label attached to furnace or See Fig. 58.
37
315A
THERMOSTAT SUBBASE
TERMINALS WITH
THERMOSTAT REMOVED
(ANITICIPATOR, CLOCK, ETC.,
MUST BE OUT OF CIRCUIT.)
Table 8 – Furnace Setup Switch Description
SETUP SWITCH
NO.
SWITCH NAME
SW1--- 1
Status Code Recovery
OFF
SW1--- 2
Adaptive Heat Mode
OFF
Low Heat Rise Adjust
OFF
SW1--- 3
SW1--- 5
Comfort/Efficiency Adjustment
CFM per ton adjust
OFF
SW1--- 6
Component Self--- Test
OFF
SW1--- 7
Blower OFF delay
ON or OFF
SW1--- 8
Blower OFF delay
ON or OFF
SW1--- 4
315A
NORMAL
POSITION
ON
DESCRIPTION OF USE
Turn ON to retrieve up to 7 stored status codes for troubleshooting assistance when R thermostat lead is disconnected.
Allows 2--- stage operation with a single stage thermostat. Turn ON when
using 2 stage thermostat to allow Low Heat operation when R to W/W1
closes and High Heat operation when R to W/W1 and W2 close.
Turn ON to increase Low Heat airflow by 18 percent. This compensates
for increased return air temperature caused with bypass humidifier.
Turn ON to decrease Low Heat airflow by 16 percent and High Heat
airflow 10 percent for maximum comfort.
Turn ON for 400 CFM per ton. Turn OFF for 350 CFM per ton.
Turn ON to initiate Component Self--- Test for troubleshooting assistance
when R thermostat lead is disconnected. Turn OFF when Self--- Test is
completed.
Control blower Off Delay time. Used in conjunction with SW1--- 8. See
Table 9.
Control blower Off Delay time. Used in conjunction with SW1--- 7. See
Table 9.
SERVICE
LED CODE
STATUS
If status code recall is needed disconnect the "R" thermostat lead, reset power, and put setup switch "SW1-1" in the ON
position. To cl ear the status code history put setup switch "SW1-1" in the ON position and jumper thermostat terminals "R",
CONTINUOUS OFF - Check for 115VAC at L1 and L2, and 24VAC at SEC-1 and SEC-2.
"W/W1", and "Y/Y2" simultaneously until status code #11 is flashed.
CONTINUOUS ON - Control has 24VAC power.
RAPID FLA SHING - Line voltage (115VAC) polarity reversed.
EACH OF THE FOLLOWING STATUS CODES IS A TWO DIGIT NUMBER WITH THE FIRST DIGIT DETERMINED BY THE NUMBER OF SHORT FLASHES AND THE SECOND DIGIT BY THE NUMBER OF LONG FLASHES.
11 NO PREVIOUS CODE - Stored status codes are erased automatically after 72
hours or as specified above.
12 BL OWER ON A FTER POWER UP (115 VAC or 24 VAC) -Blower runs for 90
seconds, if unit is powered up during a call for heat (R-W/W1 closed) or
(R-W/W1 opens) during blower on-delay period.
13 LIMIT CIRCUIT LOCKOUT - Lockout occurs if a limit, draft safeguard, flame
rollout, or blocked vent switch (if used) is open longer than 3 minutes or 10
successive limit trips occurred during high-heat. Control will auto reset after
three hours. Refer to status code #33.
14 IGNITION LOCKOUT - Control will auto-reset after three hours. Refer to status
code #34.
15 BL OWER MOTOR LOCKOUT - Indicates the blower failed to reach 250 RPM or
the blower failed to communicate within 30 seconds after being turned ON in two
successive heating cycles. Control will auto reset after 3 hours.
Refer to status code #41.
21 GAS HEAT ING LOCKOUT - Control will NOT auto reset. Check for:
- Mis-wired gas valve
-Defective control (valve relay)
22 ABNO RMAL FLAME-PROVING SIGNAL - Flame is proved while gas valve is
de-energized. Inducer will run until fault is cleared. Check for:
- Leaky gas valve
- Stuck-open gas valve
23 PRESSURE SWITCH DID NOT OPEN Check for:
- Obstructed pressure tubing
- Pressure switch stuck closed
24 SECONDARY VOLTAGE FUSE IS OPEN Check for: - Short circuit in secondary
voltage (24VAC) wiring.
25 INVAL ID MODEL SELECTION OR SETUP ERROR - Indicates either the model
plug is missing or incorrect or, setup switch "SW1-1" or "SW1-6" is positioned
improperly. If code flashes 4 times on power-up control is defaulting to model
selection stored in memory.Check for: -Thermostat call with SW1-1, SW1-6 or
both SW1-1 & SW1-6 ON. - Board date code 2103 or later required to recognize model
plug 007. - Proper model plug number and resistance values per wiring diagram
31 HIGH-HEAT PRESSURE SWITCH OR RELAY DID NOT CLOSE OR
REOPENED - Control relay may be defective. Refer to status code #32.
32 LOW-HEAT PRESSURE SWITCH DID NOT CLOSE OR REOPENED - If open
longer than five minutes, inducer shuts off for 15 minutes before retry. If opens
during blower on-delay period, blower will come on for the selected blower
off-delay. Check for: - Excessive wind
- Restricted vent - Proper vent sizing
32 Cont in ued: Check for:
- Low inducer voltage (115 VAC)
- Defective inducer motor
- Inadequate combustion air supply
- Defective pressure switch
- Low inlet gas pressure (if LGPS used)
- Low inducer voltage (115 VAC)
- Disconnected or obstructed pressure tubing
33 LIMIT CIRCUIT FAULT - Indicates a limit, draft safeguard, flame rollout, or
blocked vent switch (if used) is open or the furnace is operating in high-heat
only mode due to 2 successive low heat limit trips. Blower will run for 4
minutes or until open switch remakes whichever is longer. If open longer
than 3 minutes, code changes to lockout #13. If open less than 3 minutes
status code #33 continues to flash until blower shuts off. Flame rollout switch
and BVSS require manual reset.
Check for: - Loose blower wheel
- Restricted vent
- Proper vent sizing
- Excessive wind
- Dirty filter or restricted duct system
- Defective switch or connections
- Inadequate combustion air supply (Flame Roll-out Switch open)
34 IGNITION PROVING FAILURE - Control will try three more times before
lockout #14 occurs. If flame signal lost during blower on-delay period, blower
will come on for the selected blower off-delay. Check for:
- Oxide buildup on flame sensor (clean with fine steel wool)
- Proper flame sense microamps (.5 microamps D.C. min., 4.0 - 6.0 nominal)
- Manual valve shut-off - Low inlet gas pressure - Control ground continuity
- Gas valve defective or turned off
- Flame sensor must not be grounded
- Inadequate flame carryover or rough ignition
- Green/Ye llow wire MUST be connected to furnace sheet metal
41 BL OWER MOTOR FAUL T - Indicates the blower failed to reach 250 RPM
or the blower failed to communicate within the prescribed times limits. Thirty
seconds after being turned ON or ten seconds during steady-state operation.
43 LOW-HEAT PRESSURE SWITCH OPEN WHILE HIGH-HEAT PRESSURE
SWITCH IS CLOSED - Check for: - Mis-wired pressure switches
- Low-heat pressure switch stuck open - Low inlet gas pressure (if LGPS used)
- Disconnected or obstructed pressure tubing
45 CONTROL CIRCUITRY LOCKOUT Auto-reset after one hour lockout due to;
- Gas valve relay stuck open - Flame sense circuit failure - Software check error
Reset power to clear lockout. Replace control if status code repeats.
COMPONENT TEST
To i nitiate the component test sequence, shut
OFF the room thermostat or disconnect the "R"
thermostat lead. Reset power and then put setup
switch "SW1-6" in the ON position to start the
component test sequence. Once initiated the
furnace control will turn the inducer ON at highheat speed. The inducer motor will run for the
entire test. The hot surface igniter and blower
motor will be turned ON for 15 seconds each.
When the blower is turned OFF the inducer will
be switched to low-speed for 10 seconds. When
the component test is completed one or more of
the following codes will flash.
CODE
DESCRIPTION
11
Indicates the blower motor tested
OK. Visual check of inducer motor
and hot surface igniter required.
25
SETUP ERROR - Same as code 25 above.
41
BLOWER MOTOR FAUL T - Indicates
blower motor failed test. Check
blower, wiring, and furnace control.
To repe at component test turn setup switch
"SW1-6" OFF and then back ON. After component
test is completed put setup switch "SW1-6" in the
OFF position and reconnect the "R" thermostat
lead.
328787-101 REV. A
A04015
Fig. 58 -- Service Label
Furnace gas input rate on rating plate is for installations at
altitudes up to 2000 Ft. (610 M). Furnace input rate must be
within +/--2 percent of furnace rating plate input. For altitudes
above 5500 Ft. (1676 M), a field--supplied high altitude pressure
switch is required.
1. Determine the correct gas input rate.
In the U.S.A.: The input rating for altitudes above 2,000
ft. (610 M) must be reduced by 4 percent for each 1,000 ft.
(305 M) above sea level.
For installations below 2000 Ft. (610 M), refer to the unit
rating plate. For installations above 2000 Ft. (610 M),
multiply the input on the rating plate by the de--rate multiplier in Table 8 for the correct input rate.
In Canada: The input rating for altitudes from 2,000 (610
M) to 4,500 ft. (1372 M) above sea level must be derated
10 percent by an authorized Gas Conversion Station or
Dealer.
To determine correct input rate for altitude, see example
and use 0.90 as derate multiplier factor.
EXAMPLE 1
88,000 BTUH INPUT FURNACE INSTALLED AT 4300 Ft. (1310
M)
Derate
Furnace Input
Rate
Furnace Input
X
Multiplier
=
at Installation
Rate
at Sea Level
Factor
Altitude
88,000
X
0.90
=
79,200
2. Determine the correct orifice and manifold pressure adjustment. All models in all positions except Low NOx models
in downflow and horizontal positions use Table 12
(22,000 Btuh per burner.) Low NOx models in downflow
or horizontal positions must use Table 13 (21,000 Btuh
per burner.) See input listed on rating plate.
a. Obtain average yearly gas heat value (at installed
altitude) from local gas supplier.
b. Obtain average yearly gas specific gravity from local
gas supplier.
c. Find installation altitude in Table 12 or 13.
38
Table 9 – Altitude Derate Multiplier for U.S.A.
ALTITUDE
FT. (M)
0–2000
(0--- 610)
2001–3000
(610--- 914)
3001–4000
(914--- 1219)
4001–5000
(1219--- 1524)
5001–6000
1524--- 1829)
6001–7000
(1829--- 2134)
7001–8000
(2134--- 2438)
8001–9000
(2438--- 2743)
9001–10,000
(2743--- 3048)
PERCENT
OF DERATE
DERATE MULTIPLIER
FACTOR*
0
1.00
8–12
0.90
12–16
0.86
16–20
0.82
20–24
0.78
24–28
0.74
28–32
0.70
32–36
0.66
36–40
0.62
Table 10 – Blower Off Delay Setup Switch
DESIRED HEATING MODE
BLOWER OFF DELAY (SEC.)
90
120
150
180
SETUP SWITCH (SW --- 7 AND
--- 8) POSITION
SW1--- 7
SW1--- 8
OFF
OFF
ON
OFF
OFF
ON
ON
ON
EXAMPLE 2: 0–2000 ft. (0--610 M) altitude
For 22,000 Btuh per burner application use Table 12.
Heating value = 1000 Btuh/cu ft.
Specific gravity = 0.62
Therefore: Orifice No. 43*
Manifold pressure: 3.7--in. wc for high--heat
1.6--in. wc for low--heat
* Furnace is shipped with No. 43 orifices. In this example all main burner orifices are the correct size and do
not need to be changed to obtain proper input rate.
3. Adjust manifold pressure to obtain low fire input rate. (See
Fig. 55.)
a. Turn gas valve ON/OFF switch to OFF.
b. Remove manifold pressure tap plug from gas valve.
c. Connect a water column manometer or similar device
to manifold pressure tap.
d. Turn gas valve ON/OFF switch to ON.
e. Move setup SW1—2 on furnace control to ON position to lock furnace in low--heat operation. (See Table
8 and Fig. 25.)
f. Manually close blower door switch.
g. Jumper R and W/W1 thermostat connections on control to start furnace. (See Fig. 25.)
h. Remove regulator adjustment cap from low heat gas
valve pressure regulator (See Fig. 55.) and turn low-heat adjusting screw (3/16 or smaller flat--tipped
screwdriver) counterclockwise (out) to decrease input
rate or clockwise (in) to increase input rate.
NOTE: DO NOT set low--heat manifold pressure less than
1.4--in wc or more than 1.7--in. wc for natural gas. If manifold
pressure is outside this range, change main burner orifices.
i. Install low--heat regulator adjustment cap.
j. Move setup switch SW1--2 to off position after completing low--heat adjustment.
k. Leave manometer or similar device connected and
proceed to Step 4.
4. Adjust manifold pressure to obtain high fire input rate.
(See Fig. 55.)
a. Jumper R to W/W1 and W2 thermostat connections on
furnace control. This keeps furnace locked in high-heat operation.
b. Remove regulator adjustment cap from high--heat gas
valve pressure regulator (See Fig. 55) and turn high
heat adjusting screw (3/16--in. or smaller flat--tipped
screwdriver) counterclockwise (out) to decrease input
rate or clockwise (in) to increase input rate.
NOTE: DO NOT set high--heat manifold pressure less than
3.2--in. wc or more than 3.8 in. wc for natural gas. If manifold
pressure is outside this range, change main burner orifices to
obtain manifold pressure in this range.
c. When correct input is obtained, replace caps that conceal gas valve regulator adjustment screws. Main
burner flame should be clear blue, almost transparent
(See Fig. 61.)
d. Remove jumpers R to W/W1 and R to W2.
5. Verify natural gas input rate by clocking meter.
NOTE: Gas valve regulator adjustment caps must be in place for
proper input to be clocked.
a. Turn off all other gas appliances and pilots served by
the meter.
b. Move setup switch SW1--2 to ON position. This
keeps furnace locked in low--heat operation.
c. Jumper R to W/W1.
d. Run furnace for 3 minutes in low--heat operation.
e. Measure time (in sec) for gas meter to complete 1
revolution and note reading. The 2 or 5 cubic feet dial
provides a more accurate measurement of gas flow.
f. Refer to Table 11 for cubic ft. of gas per hr.
g. Multiply gas rate cu ft./hr by heating value (Btuh/cu
ft.) to obtain input. If clocked rate does not match required input from Step 1, increase manifold pressure to
increase input or decrease manifold pressure to decrease input. Repeat steps b through e until correct
low--heat input is achieved. Re--install low heat regulator seal cap on gas valve.
h. Move setup switch SW1--2 to OFF position and jumper R to W/W, and W2. This keeps furnace locked in
high--heat operation. Repeat items d through g for
high--heat operation.
6. Set Temperature Rise
39
315A
d. Find closest natural gas heat value and specific gravity
in Table 12 or 13.
e. Follow heat value and specific gravity lines to point of
intersection to find orifice size and low--and high--heat
manifold pressure settings for proper operation.
f. Check and verify burner orifice size in furnace.
NEVER ASSUME ORIFICE SIZE. ALWAYS
CHECK AND VERIFY.
NOTE: If orifice hole appears damaged or it is suspected to have
been redrilled, check orifice hole with a numbered drill bit of
correct size. Never redrill an orifice. A burr--free and squarely
aligned orifice hole is essential for proper flame characteristics.
g. Replace orifice with correct size, if required by Table
12 or 13. Use only factory--supplied orifices. See
EXAMPLE 2.
NOTE: Blower access door must be installed when taking
temperature rise reading. Leaving blower access door off will
result in incorrect temperature measurements.
!
e. Repeat Steps a through c as required to adjust for high
heat temperature rise.
f. When correct high heat input rate and temperature rise
is achieved, turn gas valve ON/OFF switch to OFF.
g. Release blower access door switch.
h. Remove manometer or similar device from gas valve.
i. Re--install manifold pressure tap plug in gas valve.
(See Fig. 55.)
CAUTION
FURNACE DAMAGE HAZARD
Failure to follow this caution may result in shorten furnace
life.
!
Set air temperature rise within limits specified on the rating
plate to prevent reduced life of furnace components.
Operation is within a few degrees of the mid--point of rise
range when setup switch SW1--4 is OFF.
315A
!
WARNING
FIRE HAZARD
Failure to follow this warning could result in personal
injury, death, and/or property damage.
Reinstall manifold pressure tap plug in gas valve to prevent
gas leak.
CAUTION
UNIT DAMAGE HAZARD
j. Remove thermostat jumper wire from furnace control
board.
k. Turn gas valve ON/OFF switch to ON.
Failure to follow this caution may result in overheating the
heat exchangers or condensing flue gases in heat exchanger
areas not designed for condensate.
Temperature rise must be within limits specified on unit
rating plate. Operation is within a few degrees of midpoint
of rise range when setup switch SW1--4 is OFF.
!
CAUTION
FURNACE OVERHEATING HAZARD
Failure to follow this caution may result in reduced furnace
life.
When setup switch SW1--4 is ON, operation will be near the high
end of the rise range for improved comfort.
Furnace must operate within ranges of temperature rise specified
on the furnace rating plate. Determine air temperature rise as
follows:
a. Place thermometers in return and supply ducts as near
furnace as possible. Be sure thermometers do not see
heat exchanger so that radiant heat does not affect
readings. This practice is particularly important with
straight--run ducts.
b. When thermometer readings stabilize, subtract
return--air temperature from supply--air temperature to
determine air temperature rise.
NOTE: Temperature rise can be determined for low--heat
operation by placing setup switch SW1--2 on furnace control in
ON position. For high--heat operation, place setup switch SW1--2
in OFF position and jumper R--W2 on furnace control. DO NOT
forget to return setup switch to OFF position and remove R--W2
jumper upon completion of testing.
c. This furnace is capable of automatically providing
proper airflow to maintain the temperature rise within
the range specified on furnace rating plate. If
temperature rise is outside this range, proceed as
follows:
(1.) Check gas input for low-- and high--heat
operation.
(2.) Check derate for altitude if applicable.
(3.) Check all return and supply ducts for excessive
restrictions causing static pressure greater than
0.5--in. wc.
(4.) Ensure Low Heat Rise Adjust switch SW1--3 on
furnace control is in ON position when a bypass
humidifier is used. (See Fig. 27 for switch
location.)
(5.) Make sure proper model plug is installed.
d. Remove thermostat jumpers and release blower access
door switch.
Recheck temperature rise. It must be within limits specified
on the rating plate. Recommended operation is at the
mid--point of rise range or slightly above.
l. Proceed to Step 6, “Set Blower Off Delay” before installing blower access door.
7. Set Blower Off Delay
a. Remove blower access door if installed.
b. Turn Dip switch SW--7 or SW--8 ON or OFF for desired blower off delay. (See Table 8 and Fig. 27 and
59.)
8. Set thermostat heat anticipator.
a. Mechanical thermostat. Set thermostat heat anticipator
to match the amp. draw of the electrical components in
the R--W/W1 circuit. Accurate amp. draw readings can
be obtained at the wires normally connected to thermostat subbase terminals, R and W. The thermostat
anticipator should NOT be in the circuit while measuring current.
(1.) Set SW1--2 switch on furnace control board to
ON.
(2.) Remove thermostat from subbase or from wall.
(3.) Connect an amp. meter as shown in Fig. 57
across the R and W subbase terminals or R and
W wires at wall.
(4.) Record amp. draw across terminals when furnace
is in low heat and after blower starts.
(5.) Set heat anticipator on thermostat per thermostat
instructions and install on subbase or wall.
(6.) Turn SW1--2 switch OFF.
(7.) Install blower access door.
b. Electronic thermostat: Set cycle rate for 3 cycles per
hr.
9. Set Airflow for Air Conditioning --Single Stage and High
Stage Cooling
The ECM blower can be adjusted for a range of airflows
40
for Low Speed or High Speed cooling. See Table 5--Air
Delivery -- CFM (With Filter ). Depending on the model
size, the cooling airflow can be adjusted from 1. tons nominal cooling to 3 ., to 4 or to 6 tons of nominal cooling
based on 350 cfm ton.
The cooling airflow is adjusted by turning Setup switches
SW2--1, SW2--2 and SW2--3 either ON or OFF. Select the
required airflow from Fig. 63. Fig. 63 is based on 350
CFM per ton. For airflow at 400 CFM per ton, turn Setup
SW1--5 ON (See Table 8 and Fig. 27 and 59.)
NOTE: 6 ton airflow will truncate at 2200 cfm on applicable
models. For a complete explanation of cooling airflow, refer to
the section titled “Sequence of Operation.”
10. Set Airflow For Continuous Fan/Low Speed Cooling Airflow The ECM blower motor can be adjusted for continu-
315A
ous fan speeds different than heating or cooling fan speed.
See Table 5 -- Air Delivery -- CFM (With Filter). Select the
required continuous fan airflow from Fig. 63.
The continuous fan speed is also the fan speed for low
speed cooling when furnace is used with a 2--speed cooling unit. Adjust the Continuous Fan CFM to match the
airflow required for low speed cooling. Select the required
airflow from Fig. 61. For airflow at 400 CFM per ton, turn
Setup SW1--5 ON (See Fig. 63.) The airflow selected for
low speed cooling will also be the airflow used for continuous fan.
The continuous fan speed can be further adjusted at the
thermostat using the “Comfort Fan” select function.
Changing the continuous fan speed at the thermostat
DOES NOT change the low speed cooling airflow selected at the control board.
41
315A
A08464
Fig. 59 -- Wiring Diagram
42
SECONDS G
FOR 1 REVOLUTION
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
1 Cu Ft.
360
327
300
277
257
240
225
212
200
189
180
171
164
157
150
144
138
133
129
124
120
116
113
109
106
103
100
97
95
92
90
88
86
84
82
80
78
76
75
73
SIZE OF TEST DIAL
2 Cu Ft.
5 Cu Ft.
720
1800
655
1636
600
1500
555
1385
514
1286
480
1200
450
1125
424
1059
400
1000
379
947
360
900
343
857
327
818
313
783
300
750
288
720
277
692
267
667
257
643
248
621
240
600
232
581
225
563
218
545
212
529
206
514
200
500
195
486
189
474
185
462
180
450
176
439
172
429
167
419
164
409
160
400
157
391
153
383
150
375
147
367
SECONDS
FOR 1 REVOLUTION
50
51
52
53
54
55
56
57
58
59
60
62
64
66
68
70
72
74
76
78
80
82
84
86
88
90
92
94
96
98
100
102
104
106
108
110
112
116
120
43
1 Cu Ft.
72
71
69
68
67
65
64
63
62
61
60
58
56
54
53
51
50
48
47
46
45
44
43
42
41
40
39
38
38
37
36
35
35
34
33
33
32
31
30
SIZE OF TEST DIAL
2 Cu Ft.
5 Cu Ft.
144
360
141
355
138
346
136
340
133
333
131
327
129
321
126
316
124
310
122
305
120
300
116
290
112
281
109
273
106
265
103
257
100
250
97
243
95
237
92
231
90
225
88
220
86
214
84
209
82
205
80
200
78
196
76
192
75
188
74
184
72
180
71
178
69
173
68
170
67
167
65
164
64
161
62
155
60
150
315A
Table 11 – Gas Rate (CU ft./hr)
Table 12 – Orifice Size and Manifold Pressure (In. wc) for Gas Input Rate
(Tabulated Data Based on 22,000 Btuh High--Heat/14,500 Btuh for Low--Heat per Burner, Derated 4 Percent for Each 1000 Ft.
(305 M) Above Sea Level)
ALTITUDE RANGE
FT. (M)
315A
USA
and
Cana
da
0 to
2000
(0 to 610)
ALTITUDE RANGE
FT. (M)
USA
and
Canada
U.S.A.
Altitudes
2001 to
3000 (610
to 914) or
Canada
Altitudes
2001 to
4500 (610
to 1372)
ALTITUDE RANGE
FT. (M)
USA
Only
3001 to
4000
(914 to
1219)
ALTITUDE RANGE
FT. (M)
USA
Only
4001 to
5000
(1219 to
1524)
AVG. GAS
HEAT VALUE
(BTUH/CU FT.)
900
925
950
975
1000
1025
1050
1075
1100
AVG. GAS
HEAT VALUE
(BTUH/CU FT.)
800
825
850
875
900
925
950
975
1000
AVG. GAS
HEAT VALUE
(BTUH/CU FT.)
775
800
825
850
875
900
925
950
0.58
Manifold
Orifice
Pressure
No.
High/Low
42
3.5/1.5
42
3.3/1.4
43
3.8/1.7
43
3.6/1.6
43
3.5/1.5
43
3.3/1.4
44
3.6/1.6
44
3.4/1.5
44
3.3/1.4
0.58
Orifice
No.
Manifold
Pressure
High/Low
42
42
43
43
43
44
44
44
45
3.4/1.5
3.2/1.4
3.7/1.6
3.5/1.5
3.3/1.4
3.5/1.5
3.4/1.5
3.2/1.4
3.7/1.6
0.58
Orifice
No.
Manifold
Pressure
High/Low
42
43
43
43
44
44
45
46
3.2/1.4
3.6/1.6
3.4/1.5
3.2/1.4
3.5/1.5
3.3/1.4
3.8/1.6
3.8/1.6
0.58
AVG. GAS
HEAT VALUE
(BTUH/CU FT.)
Orifice
No.
Manifold
Pressure
High/Low
750
775
800
825
850
875
900
925
43
43
43
44
44
45
46
46
3.6/1.6
3.4/1.5
3.2/1.4
3.4/1.5
3.2/1.4
3.7/1.6
3.7/1.6
3.5/1.5
* Orifice numbers 43 are factory installed
SPECIFIC GRAVITY OF NATURAL GAS
0.60
0.62
Manifold
Manifold
Orifice
Orifice
Pressure
Pressure
No.
No.
High/Low
High/Low
42
3.6/1.6
42
3.7/1.6
42
3.4/1.5
42
3.5/1.5
42
3.3/1.4
42
3.4/1.5
43
3.8/1.6
42
3.2/1.4
43
3.6/1.6
43
3.7/1.6
43
3.4/1.5
43
3.5/1.5
43
3.2/1.4
43
3.4/1.5
44
3.5/1.5
43
3.2/1.4
44
3.4/1.5
44
3.5/1.5
SPECIFIC GRAVITY OF NATURAL GAS
0.60
0.62
Manifold
Manifold
Orifice
Orifice
Pressure
Pressure
No.
No.
High/Low
High/Low
42
3.5/1.5
42
3.6/1.6
42
3.3/1.4
42
3.4/1.5
43
3.8/1.6
42
3.2/1.4
43
3.6/1.6
43
3.7/1.6
43
3.4/1.5
43
3.5/1.5
43
3.2/1.4
43
3.3/1.4
44
3.5/1.5
44
3.6/1.6
44
3.3/1.4
44
3.4/1.5
45
3.8/1.7
44
3.2/1.4
SPECIFIC GRAVITY OF NATURAL GAS
0.60
0.62
Manifold
Manifold
Orifice
Orifice
Pressure
Pressure
No.
No.
High/Low
High/Low
42
3.3/1.4
42
3.4/1.5
43
3.8/1.6
42
3.2/1.4
43
3.5/1.5
43
3.7/1.6
43
3.3/1.4
43
3.4/1.5
44
3.6/1.6
43
3.3/1.4
44
3.4/1.5
44
3.5/1.5
44
3.2/1.4
44
3.3/1.5
45
3.7/1.6
45
3.8/1.7
SPECIFIC GRAVITY OF NATURAL GAS
0.60
0.62
Manifold
Manifold
Orifice
Orifice
Pressure
Pressure
No.
No.
High/Low
High/Low
43
43
43
44
44
45
46
46
3.8/1.6
3.5/1.5
3.3/1.4
3.6/1.5
3.4/1.5
3.8/1.7
3.8/1.7
3.6/1.6
44
42
43
43
43
44
44
45
46
3.2/1.4
3.6/1.6
3.4/1.5
3.2/1.4
3.5/1.5
3.3/1.4
3.7/1.6
3.7/1.6
Orifice
No.
41
42
42
42
43
43
43
43
43
0.64
Manifold
Pressure
High/Low
3.5/1.5
3.7/1.6
3.5/1.5
3.3/1.4
3.8/1.7
3.6/1.6
3.5/1.5
3.3/1.4
3.2/1.4
0.64
Orifice
No.
Manifold
Pressure
High/Low
42
42
42
43
43
43
43
44
44
3.7/1.6
3.5/1.5
3.3/1.4
3.8/1.7
3.6/1.6
3.4/1.5
3.2/1.4
3.5/1.5
3.4/1.5
0.64
Orifice
No.
Manifold
Pressure
High/Low
42
42
43
43
43
43
44
44
3.5/1.5
3.3/1.4
3.8/1.6
3.6/1.5
3.4/1.5
3.2/1.4
3.4/1.5
3.3/1.4
0.64
Orifice
No.
Manifold
Pressure
High/Low
42
43
43
43
44
44
44
46
3.3/1.4
3.8/1.6
3.5/1.5
3.3/1.4
3.6/1.6
3.4/1.5
3.2/1.4
3.8/1.7
Table 12 -- Orifice Size and Manifold Pressure (In. wc) for Gas Input Rate (Con’t.)
(Tabulated Data Based on 22,000 Btuh High--Heat/14,500 Btuh for Low--Heat per Burner, Derated 4 Percent for Each 1000 Ft.
Above Sea Level)
USA
Only
5001 to
6000
(1524
to
1829)
ALTITUDE
RANGE
FT. (M)
USA
Only
6001 to
7000
(1829
to
2134)
ALTITUDE
RANGE
FT. (M)
USA
Only
7001 to
8000
(2134
to
2438)
ALTITUDE
RANGE
FT. (M)
USA
Only
8001 to
9000
(2438
to
2743)
USA
Only
9001 to
10,000
2743 to
3048)
AVG. GAS
HEAT VALUE
AT ALTITUDE
(BTUH/CU FT.)
725
750
775
800
825
850
875
900
AVG. GAS
HEAT VALUE
AT ALTITUDE
(BTUH/CU FT.)
675
700
725
750
775
800
825
850
0.58
Manifold
Orifice
Pressure
No.
High/Low
43
3.4/1.5
43
3.2/1.4
44
3.4/1.5
44
3.2/1.4
46
3.8/1.7
46
3.6/1.6
47
3.8/1.7
47
3.6/1.6
0.58
Manifold
Orifice
Pressure
No.
High/Low
43
3.4/1.5
44
3.6/1.6
44
3.4/1.5
45
3.8/1.7
46
3.7/1.6
46
3.5/1.5
47
3.7/1.6
47
3.5/1.5
AVG. GAS
HEAT VALUE
AT ALTITUDE
(BTUH/CU FT.)
Orifice
No.
650
675
700
725
750
775
800
825
44
44
45
46
46
47
47
48
AVG. GAS
HEAT VALUE
AT ALTITUDE
(BTUH/CU FT.)
625
650
675
700
725
750
775
600
625
650
675
700
725
* Orifice numbers 43 are factory installed
0.58
Manifold
Pressure
High/Low
3.6/1.6
3.3/1.5
3.8/1.6
3.7/1.6
3.4/1.5
3.6/1.6
3.4/1.5
3.7/1.6
0.58
Manifold
Orifice
Pressure
No.
High/Low
44
3.3/1.5
45
3.7/1.6
46
3.6/1.6
47
3.8/1.7
47
3.6/1.6
48
3.8/1.7
48
3.6/1.5
45
3.7/1.6
46
3.6/1.6
47
3.8/1.6
47
3.5/1.5
48
3.7/1.6
48
3.5/1.5
SPECIFIC GRAVITY OF NATURAL GAS
0.60
0.62
Manifold
Manifold
Orifice
Orifice
Pressure
Pressure
No.
No.
High/Low
High/Low
43
3.5/1.5
43
3.6/1.6
43
3.3/1.4
43
3.4/1.5
44
3.5/1.5
43
3.2/1.4
44
3.3/1.4
44
3.4/1.5
45
3.8/1.6
44
3.2/1.4
46
3.7/1.6
46
3.8/1.7
46
3.5/1.5
46
3.6/1.6
47
3.8/1.6
46
3.4/1.5
SPECIFIC GRAVITY OF NATURAL GAS
0.60
0.62
Manifold
Manifold
Orifice
Orifice
Pressure
Pressure
No.
No.
High/Low
High/Low
43
3.5/1.5
43
3.6/1.6
43
3.3/1.4
43
3.4/1.5
44
3.5/1.5
44
3.6/1.6
44
3.3/1.4
44
3.4/1.5
45
3.7/1.6
45
3.8/1.7
46
3.6/1.6
46
3.8/1.6
46
3.4/1.5
46
3.5/1.5
47
3.6/1.6
47
3.8/1.6
SPECIFIC GRAVITY OF NATURAL GAS
0.60
0.62
Manifold
Manifold
Orifice
Orifice
Pressure
Pressure
No.
No.
High/Low
High/Low
43
3.2/1.4
43
3.4/1.5
44
3.5/1.5
44
3.6/1.6
44
3.2/1.4
44
3.3/1.4
46
3.8/1.7
45
3.7/1.6
46
3.6/1.5
46
3.7/1.6
47
3.8/1.6
46
3.4/1.5
47
3.5/1.5
47
3.7/1.6
48
3.8/1.6
47
3.4/1.5
SPECIFIC GRAVITY OF NATURAL GAS
0.60
0.62
Manifold
Manifold
Orifice
Orifice
Pressure
Pressure
No.
No.
High/Low
High/Low
44
3.5/1.5
44
3.6/1.6
44
3.2/1.4
44
3.3/1.4
46
3.8/1.6
45
3.7/1.6
46
3.5/1.5
46
3.6/1.6
47
3.7/1.6
47
3.8/1.7
47
3.5/1.5
47
3.6/1.6
48
3.7/1.6
48
3.8/1.7
45
3.8/1.7
44
3.3/1.4
46
3.7/1.6
46
3.8/1.7
46
3.4/1.5
46
3.6/1.5
47
3.6/1.6
47
3.7/1.6
48
3.8/1.7
47
3.5/1.5
48
3.6/1.6
48
3.7/1.6
Check Safety Controls
The flame sensor, gas valve, and pressure switch were all checked
in the Start--up procedure section as part of normal operation.
1. Check Main Limit Switch
This control shuts off combustion system and energizes
air--circulating blower motor, if furnace overheats. By using this method to check limit control, it can be established
that limit is functioning properly and will operate if there
is a restricted return--air supply or motor failure. If limit
control does not function during this test, cause must be
determined and corrected.
a. Run furnace for at least 5 minutes.
b. Gradually block off return air with a piece of cardboard or sheet metal until the limit trips.
c. Unblock return air to permit normal circulation.
Orifice
No.
43
43
43
44
44
45
46
46
0.64
Manifold
Pressure
High/Low
3.7/1.6
3.5/1.5
3.3/1.4
3.5/1.5
3.3/1.4
3.8/1.6
3.7/1.6
3.5/1.5
0.64
Manifold
Orifice
Pressure
No.
High/Low
43
3.7/1.6
43
3.5/1.5
43
3.2/1.4
44
3.5/1.5
44
3.2/1.4
45
3.7/1.6
46
3.6/1.6
46
3.4/1.5
Orifice
No.
43
43
44
44
46
46
47
47
0.64
Manifold
Pressure
High/Low
3.5/1.5
3.2/1.4
3.4/1.5
3.2/1.4
3.8/1.6
3.6/1.5
3.8/1.6
3.6/1.5
0.64
Manifold
Orifice
Pressure
No.
High/Low
43
3.2/1.4
44
3.4/1.5
45
3.8/1.7
46
3.7/1.6
46
3.5/1.5
47
3.7/1.6
47
3.5/1.5
44
3.4/1.5
45
3.8/1.6
46
3.7/1.6
46
3.4/1.5
47
3.6/1.6
48
3.8/1.7
d. Burners will re--light when furnace cools down.
2. Check draft safeguard switch. The purpose of this control
is to cause the safe shutdown of the furnace during certain
blocked vent conditions.
a. Verify vent pipe is cool to the touch.
b. Disconnect power to furnace and remove vent connector from furnace vent elbow.
c. Restore power to furnace and set room thermostat
above room temperature.
d. After normal start--up, allow furnace to operate for 2
minutes, then block vent elbow in furnace 80 percent
of vent area with a piece of flat sheet metal.
e. Furnace should cycle off within 2 minutes. If gas does
not shut off within 2 minutes, determine reason draft
45
315A
ALTITUDE
RANGE
FT. (M)
315A
safeguard switch did not function properly and correct
condition.
f. Remove blockage from furnace vent elbow.
g. Switch will auto--reset when it cools.
h. Re--install vent connector.
NOTE: Should switch remain open longer than 3 minutes,
furnace control board will lockout the furnace for 3 hours. To
reset furnace control board, turn thermostat below room
temperature or from HEAT to OFF and turn 115--v power OFF,
then back ON.
3. Check Pressure Switch(es)
This control proves operation of the draft inducer blower.
a. Turn off 115--v power to furnace.
b. Disconnect inducer motor lead wires from wire harness.
c. Turn on 115--v power to furnace.
d. Set thermostat to “call for heat” and wait 1 minute.
When pressure switch is functioning properly, hot surface igniter should NOT glow and control diagnostic
light flashes a status code 32. If hot surface igniter
glows when inducer motor is disconnected, shut down
furnace immediately.
e. Determine reason pressure switch did not function
properly and correct condition.
f. Turn off 115--v power to furnace.
g. Reconnect inducer motor wires, replace outer door,
and turn on 115--v power.
h. Blower will run for 90 seconds before beginning the
call for heat again.
i. Furnace should ignite normally.
Checklist
1. Put away tools and instruments. Clean up debris.
2. Verify that switches SW1--1 and SW1--6 are OFF and other setup switches are set as desired. Verify that switches
SW1--7 and SW1--8 for the blower OFF DELAY are set as
desired per Table 8.
3. Verify that blower and burner access doors are properly installed.
4. Cycle test furnace with room thermostat.
5. Check operation of accessories per manufacturer’s instructions.
6. Review User’s Guide with owner.
7. Attach literature packet to furnace.
SERVICE AND MAINTENANCE
PROCEDURES
!
WARNING
FIRE, INJURY OR DEATH HAZARD
Failure to follow this warning could result in personal
injury, death and/or property damage.
The ability to properly perform maintenance on this
equipment requires certain knowledge, mechanical skills,
tools, and equipment. If you do not possess these, do not
attempt to perform any maintenance on this equipment
other than those procedures recommended in the User’s
Manual.
!
WARNING
ELECTRICAL SHOCK, FIRE OR EXPLOSION
HAZARD
Failure to follow this warning could result in personal
injury or death, or property damage.
Before servicing, disconnect all electrical power to furnace.
Verify proper operation after servicing.
!
CAUTION
ELECTRICAL OPERATION HAZARD
Failure to follow this caution may result in improper
furnace operation or failure of furnace.
Label all wires prior to disconnection when servicing
controls. Wiring errors can cause improper and dangerous
operation.
General
These instructions are written as if the furnace is installed in an
upflow application. An upflow furnace application is where the
blower is located below the combustion and controls section of
the furnace, and conditioned air is discharged upward. Since this
furnace can be installed in any of the 4 positions shown in Fig. 4,
you must revise your orientation to component location
accordingly.
Electrical Controls and Wiring
!
WARNING
ELECTRICAL SHOCK HAZARD
Failure to follow this warning could result in personal injury
or death.
There may be more than one electrical supply to the furnace.
Check accessories and cooling unit for additional electrical
supplies that must be shut off during furnace servicing.
The electrical ground and polarity for 115--v wiring must be
properly maintained. Refer to Fig. 26 for field wiring information
and to Fig. 59 for furnace wiring information.
NOTE: If the polarity is not correct, the STATUS LED on the
control will flash rapidly and prevent the furnace from heating.
The control system also requires an earth ground for proper
operation of the control and flame--sensing electrode.
The 24--v circuit contains an automotive--type, 3--amp. fuse
located on the control. (See Fig. 27.) Any shorts of the 24--v
wiring during installation, service, or maintenance will cause this
fuse to blow. If fuse replacement is required, use ONLY a 3--amp.
fuse. The control LED will display status code 24 when fuse
needs to be replaced.
Proper instrumentation is required to service electrical controls.
The control in this furnace is equipped with a Status Code LED
(Light--Emitting Diode) to aid in installation, servicing, and
troubleshooting. It can be viewed through the sight glass in
blower access door. The amber furnace control LED is either ON
continuously, rapid flashing, or a code composed of 2 digits. The
first digit is the number of short flashes, the second digit is the
number of long flashes.
For an explanation of status codes, refer to service label located
on blower access door or Fig. 58, and the troubleshooting guide
which can be obtained from your distributor.
46
!
e. After component test is completed, one or more status
codes (11, 25, or 41) will flash. See component test
section of service label for explanation of status codes.
NOTE: To repeat component test, turn setup switch SW1--6 OFF
then back ON.
f. Turn setup switch SW1--6 OFF.
7. RELEASE BLOWER ACCESS DOOR SWITCH, reattach wire to “R” terminal on furnace control board, replace
blower access door, and replace outer access door.
CARE AND MAINTENANCE
!
WARNING
FIRE OR EXPLOSION HAZARD
Failure to follow this warning could result in personal
injury, death and/or property damage.
Never store anything on, near, or in contact with the
furnace, such as:
1. Spray or aerosol cans, rags, brooms, dust mops,
vacuum cleaners, or other cleaning tools.
2. Soap powders, bleaches, waxes or other cleaning
compounds, plastic or plastic containers, gasoline,
kerosene, cigarette lighter fluid, dry cleaning fluids,
or other volatile fluids.
3. Paint thinners and other painting compounds, paper
bags, or other paper products. Exposure to these
materials could lead to corrosion of the heat
exchangers.
For continuing high performance and to minimize possible
furnace failure, periodic maintenance must be performed on this
furnace. Consult your local dealer about proper frequency of
maintenance and the availability of a maintenance contract.
!
WARNING
ELECTRICAL SHOCK AND FIRE HAZARD
Failure to follow this warning could result in personal injury,
death, and/or property damage.
Turn off the gas and electrical supplies to the furnace before
performing any maintenance or service. Follow the operating
instructions on the label attached to the furnace.
WARNING
!
ELECTRICAL SHOCK HAZARD
WARNING
Failure to follow this warning could result in personal injury,
or death.
CARBON MONOXIDE POISONING AND FIRE
HAZARD
Blower access door switch opens 115--v power to furnace
control. No component operation can occur unless switch is
closed. Exercise caution to avoid electrical shock from
exposed electrical components when manually closing this
switch for service purposes.
Failure to follow this warning could result in personal
injury, death and/or property damage.
Never operate furnace without a filter or with filter access
door removed.
6. Component Test sequence will function as follows:
a. Inducer motor starts on high--speed and continues to
run until Step (d.) of component test sequence.
b. Hot surface igniter is energized for 15 sec, then deenergized.
c. Blower operates for 10 sec, then turns off.
d. Inducer motor goes to low--speed for 10 seconds, then
turns off.
47
315A
See Fig. 64, a brief Troubleshooting Guide.
For 2--Stage Variable Speed ECM Controls the stored status
codes will NOT be erased from the control memory, when 115-or 24--v power is interrupted. The control will store up to the last
7 Status Codes in order of occurrence.
1. To retrieve status codes, proceed with the following:
NOTE: NO thermostat signal may be present at control, and all
blower--OFF delays must be completed.
a. Leave 115--v power to furnace turned on.
b. Remove outer access door.
c. Look into blower access door sight glass for current
amber LED status. Removing blower access door will
open blower access door switch and terminate 115--v
power to control so that status code is not displayed.
d. Remove blower access door.
NOTE: The Status Codes cannot be retrieved by disconnecting
the limit switch or draft safeguard switch. To retrieve Status
Codes, follow the procedure below.
2. Turn Setup Switch, SW1--1 “ON.”
3. Manually close blower access door switch.
4. Control will flash up to 7 Status Codes.
5. The last Status Code, or 8th Code, will be Code 11.
6. Turn SW1--1 “OFF.”
7. A continuously--lit Amber LED will appear and indicates
proper operation.
8. Release blower access door switch, install blower access
door and replace outer door or refer to the SERVICE label
on the front of the blower access door for more information.
Component Self--Test
Component Test can ONLY be initiated by performing the
following:
1. Remove outer access door.
2. Remove blower access door.
3. Remove the wire from the “R” terminal of the control
board.
4. Turn Setup Switch, SW--1--6 “ON.”
5. Manually close blower access door switch.
Blower access door switch opens 115--v power to control. No
component operation can occur unless switch is closed. Caution
must be taken when manually closing this switch for service
purposes.
Table 13 – Orifice Size and Manifold Pressure (In. wc) for Gas Input Rate
(Tabulated Data Based on 21,000 Btuh High--Heat/14,500 Btuh for Low--Heat Per Burner, Derated 4 Percent for Each 1000 Ft.
(305 M) Above Sea level)
ALTITUDE RANGE
FT. (M)
315A
USA
and
Canada
0 to
2000
(0 to 610)
ALTITUDE RANGE
FT. (M)
USA
and
Canada
USA
Altitudes
2001 to
3000 (610
to 914)or
Canada
Altitudes
2001 to
4500 (610
to 1372)
ALTITUDE RANGE
FT. (M)
USA
Only
3001 to
4000 (914
to 1219)
ALTITUDE RANGE
FT. (M)
USA
Only
4001 to
5000
(1219 to
1524)
AVG. GAS
HEAT VALUE
(BTUH/CU
FT.)
900
925
950
975
1000
1025
1050
1075
1100
SPECIFIC GRAVITY OF NATURAL GAS
0.58
Manifold
Orifice
Pressure
No.
High/Low
42
3.2/1.5
43
3.7/1.8
43
3.5/1.7
43
3.3/1.6
44
3.6/1.7
44
3.4/1.6
44
3.3/1.6
45
3.8/1.8
46
3.8/1.8
AVG. GAS
HEAT VALUE
(BTUH/CU FT.)
Orifice
No.
800
825
850
875
900
925
950
975
1000
43
43
43
43
44
44
45
46
46
AVG. GAS
HEAT VALUE
(BTUH/CU FT.)
Orifice
No.
775
800
825
850
875
900
925
950
43
43
44
44
45
46
46
46
AVG. GAS
HEAT VALUE
(BTUH/CU FT.)
750
775
800
825
850
875
900
925
* Orifice numbers 43 are factory installed
0.58
Manifold
Pressure
High/Low
3.8/1.8
3.5/1.7
3.3/1.6
3.2/1.5
3.4/1.6
3.2/1.5
3.7/1.8
3.7/1.8
3.5/1.7
0.58
Manifold
Pressure
High/Low
3.5/1.7
3.3/1.6
3.6/1.7
3.4/1.6
3.8/1.8
3.8/1.8
3.6/1.7
3.4/1.6
0.58
Manifold
Orifice
Pressure
No.
High/Low
43
3.3/1.6
44
3.6/1.7
44
3.3/1.6
45
3.8/1.8
46
3.8/1.8
46
3.5/1.7
47
3.8/1.8
47
3.6/1.7
0.60
0.62
Manifold
Manifold
Orifice
Orifice
Pressure
Pressure
No.
No.
High/Low
High/Low
42
3.3/1.6
42
3.4/1.6
43
3.8/1.8
42
3.2/1.5
43
3.6/1.7
43
3.7/1.8
43
3.4/1.6
43
3.5/1.7
43
3.3/1.6
43
3.4/1.6
44
3.6/1.7
43
3.2/1.5
44
3.4/1.6
44
3.5/1.7
44
3.2/1.5
44
3.3/1.6
45
3.7/1.8
44
3.2/1.5
SPECIFIC GRAVITY OF NATURAL GAS
0.60
0.62
Manifold
Manifold
Orifice
Orifice
Pressure
Pressure
No.
No.
High/Low
High/Low
42
3.2/1.5
42
3.3/1.6
43
3.7/1.7
43
3.8/1.8
43
3.5/1.6
43
3.6/1.7
43
3.3/1.6
43
3.4/1.6
44
3.5/1.7
43
3.2/1.5
44
3.3/1.6
44
3.5/1.6
45
3.8/1.8
44
3.3/1.6
46
3.8/1.8
45
3.8/1.8
46
3.6/1.7
46
3.8/1.8
SPECIFIC GRAVITY OF NATURAL GAS
0.60
0.62
Manifold
Manifold
Orifice
Orifice
Pressure
Pressure
No.
No.
High/Low
High/Low
43
3.7/1.7
43
3.8/1.8
43
3.4/1.6
43
3.5/1.7
43
3.2/1.5
43
3.3/1.6
44
3.5/1.7
44
3.6/1.7
44
3.3/1.6
44
3.4/1.6
45
3.8/1.8
44
3.2/1.5
46
3.7/1.8
45
3.7/1.8
46
3.5/1.7
46
3.7/1.7
SPECIFIC GRAVITY OF NATURAL GAS
0.60
0.62
Manifold
Manifold
Orifice
Orifice
Pressure
Pressure
No.
No.
High/Low
High/Low
43
3.4/1.6
43
3.5/1.7
43
3.2/1.5
43
3.3/1.6
44
3.4/1.6
44
3.6/1.7
44
3.2/1.5
44
3.4/1.6
45
3.7/1.8
45
3.8/1.8
46
3.7/1.7
46
3.8/1.8
46
3.5/1.7
46
3.6/1.7
47
3.7/1.8
47
3.8/1.8
48
0.64
Manifold
Orifice
Pressure
No.
High/Low
42
3.5/1.7
42
3.3/1.6
43
3.8/1.8
43
3.7/1.7
43
3.5/1.7
43
3.3/1.6
43
3.2/1.5
44
3.4/1.6
44
3.3/1.6
Orifice
No.
42
42
43
43
43
44
44
44
45
Orifice
No.
42
43
43
43
44
44
45
46
0.64
Manifold
Pressure
High/Low
3.4/1.6
3.2/1.5
3.7/1.8
3.5/1.7
3.3/1.6
3.6/1.7
3.4/1.6
3.2/1.5
3.7/1.8
0.64
Manifold
Pressure
High/Low
3.2/1.5
3.7/1.7
3.4/1.6
3.2/1.5
3.5/1.7
3.3/1.6
3.8/1.8
3.8/1.8
0.64
Manifold
Orifice
Pressure
No.
High/Low
43
3.6/1.7
43
3.4/1.6
43
3.2/1.5
44
3.5/1.6
44
3.3/1.6
45
3.7/1.8
46
3.7/1.8
46
3.5/1.7
Table 13 -- Orifice Size and Manifold Pressure (In. wc) for Gas Input Rate (Con’t.)
(Tabulated Data Based on 21,000 Btuh High--Heat/14,500 Btuh for Low--Heat Per Burner, Derated 4 Percent for Each 1000 Ft.
(305 M) Above Sea level)
USA
Only
5001 to
6000
(1524 to
1829)
ALTITUDE RANGE
FT. (M)
USA
Only
6001 to
7000
(1829 to
2134)
ALTITUDE RANGE
FT. (M)
USA
Only
7001 to
8000
(2134 to
2438)
ALTITUDE RANGE
FT. (M)
USA
Only
8001 to
9000
(2438 to
2743)
USA
Only
9001 to
10,000
(2743 to
3048)
AVG. GAS
HEAT VALUE
AT ALTITUDE
(BTUH/CU FT.)
675
700
725
750
775
800
825
850
0.58
Manifold
Orifice
Pressure
No.
High/Low
44
3.5/1.7
44
3.3/1.6
45
3.7/1.8
46
3.6/1.7
46
3.4/1.6
47
3.6/1.7
47
3.4/1.6
48
3.7/1.7
AVG. GAS
HEAT VALUE
AT ALTITUDE
(BTUH/CU FT.)
Orifice
No.
650
675
700
725
750
775
800
825
44
45
46
47
47
48
48
48
AVG. GAS
HEAT VALUE
AT ALTITUDE
(BTUH/CU FT.)
625
650
675
700
725
750
775
600
625
650
675
700
725
* Orifice numbers 43 are factory installed
!
0.58
Manifold
Orifice
Pressure
No.
High/Low
44
3.5/1.7
44
3.3/1.6
45
3.7/1.8
46
3.7/1.8
46
3.5/1.7
47
3.7/1.8
47
3.5/1.7
48
3.8/1.8
0.58
Manifold
Pressure
High/Low
3.3/1.6
3.7/1.8
3.6/1.7
3.8/1.8
3.5/1.7
3.8/1.8
3.6/1.7
3.3/1.6
0.58
Manifold
Orifice
Pressure
No.
High/Low
45
3.7/1.8
46
3.6/1.7
47
3.8/1.8
47
3.5/1.7
48
3.7/1.8
48
3.5/1.7
49
3.8/1.8
46
3.6/1.7
47
3.7/1.8
47
3.4/1.6
48
3.6/1.7
48
3.4/1.6
49
3.7/1.8
SPECIFIC GRAVITY OF NATURAL GAS
0.60
0.62
Manifold
Manifold
Orifice
Orifice
Pressure
Pressure
No.
No.
High/Low
High/Low
43
3.2/1.5
43
3.3/1.6
44
3.4/1.6
44
3.5/1.7
44
3.2/1.5
44
3.3/1.6
46
3.8/1.8
45
3.8/1.8
46
3.6/1.7
46
3.7/1.8
47
3.8/1.8
46
3.5/1.7
47
3.6/1.7
47
3.7/1.8
47
3.4/1.6
47
3.5/1.7
SPECIFIC GRAVITY OF NATURAL GAS
0.60
0.62
Manifold
Manifold
Orifice
Orifice
Pressure
Pressure
No.
No.
High/Low
High/Low
43
3.2/1.5
43
3.3/1.6
44
3.4/1.6
44
3.5/1.7
45
3.8/1.8
44
3.3/1.6
46
3.8/1.8
45
3.7/1.8
46
3.5/1.7
46
3.6/1.7
47
3.8/1.8
46
3.4/1.6
47
3.5/1.7
47
3.6/1.7
48
3.8/1.8
47
3.4/1.6
SPECIFIC GRAVITY OF NATURAL GAS
0.60
0.62
Manifold
Manifold
Orifice
Orifice
Pressure
Pressure
No.
No.
High/Low
High/Low
44
3.4/1.6
44
3.5/1.7
45
3.8/1.8
44
3.3/1.6
46
3.7/1.8
46
3.8/1.8
46
3.5/1.7
46
3.6/1.7
47
3.7/1.8
47
3.8/1.8
47
3.4/1.6
47
3.6/1.7
48
3.7/1.8
48
3.8/1.8
48
3.5/1.6
48
3.6/1.7
SPECIFIC GRAVITY OF NATURAL GAS
0.60
0.62
Manifold
Manifold
Orifice
Orifice
Pressure
Pressure
No.
No.
High/Low
High/Low
45
3.8/1.8
44
3.3/1.6
46
3.7/1.8
46
3.8/1.8
46
3.4/1.6
46
3.5/1.7
47
3.6/1.7
47
3.7/1.8
48
3.8/1.8
47
3.5/1.7
48
3.6/1.7
48
3.7/1.8
48
3.4/1.6
48
3.5/1.7
46
3.7/1.8
46
3.8/1.8
47
3.8/1.8
46
3.5/1.7
47
3.6/1.7
47
3.7/1.8
48
3.8/1.8
47
3.4/1.6
48
3.5/1.7
48
3.6/1.7
49
3.8/1.8
48
3.4/1.6
Orifice
No.
43
43
44
44
46
46
46
47
0.64
Manifold
Pressure
High/Low
3.4/1.6
3.2/1.5
3.4/1.6
3.2/1.5
3.8/1.8
3.6/1.7
3.4/1.6
3.7/1.7
0.64
Manifold
Orifice
Pressure
No.
High/Low
43
3.4/1.6
43
3.2/1.5
44
3.4/1.6
45
3.8/1.8
46
3.8/1.8
46
3.5/1.7
47
3.8/1.8
47
3.5/1.7
Orifice
No.
43
44
45
46
46
47
47
48
0.64
Manifold
Pressure
High/Low
3.2/1.5
3.4/1.6
3.8/1.8
3.7/1.8
3.5/1.6
3.7/1.7
3.4/1.6
3.7/1.8
0.64
Manifold
Orifice
Pressure
No.
High/Low
44
3.4/1.6
45
3.8/1.8
46
3.7/1.7
46
3.4/1.6
47
3.6/1.7
48
3.8/1.8
48
3.6/1.7
45
3.7/1.8
46
3.6/1.7
47
3.8/1.8
47
3.5/1.7
48
3.7/1.8
48
3.5/1.7
3. Check electrical connections for tightness and controls for
proper operation each heating season. Service as necessary.
4. Inspect burner compartment before each heating season
for rust, corrosion, soot or excessive dust. If necessary,
have furnace and burner serviced by a qualified service
agency.
5. Inspect the vent pipe/vent system before each heating season for rust, corrosion, water leakage, sagging pipes or
broken fittings. Have vent pipes/vent system serviced by a
qualified service agency.
6. Inspect any accessories attached to the furnace such as a
humidifier or electronic air cleaner. Perform any service or
maintenance to the accessories as recommended in the accessory instructions.
CAUTION
CUT HAZARD
Failure to follow this caution may result in personal injury.
Sheet metal parts may have sharp edges or burrs. Use care
and wear appropriate protective clothing, safety glasses and
gloves when handling parts, and servicing furnaces.
The minimum maintenance on this furnace is as follows:
1. Check and clean air filter each month or more frequently if
required. Replace if torn.
2. Check blower motor and wheel for cleanliness each heating and cooling season. Clean as necessary.
49
315A
ALTITUDE RANGE
FT. (M)
AVG. GAS
HEAT VALUE
AT ALTITUDE
(BTUH/CU
FT.)
725
750
775
800
825
850
875
900
Table 14 – Filter Size Information -- In. (mm)
FILTER SIZE
FURNACE CASING WIDTH
14 ---1/2 (368)
17 ---1/2 (445)
21 (533)
24 (610)
SIDE
RETURN
16 X 25 X 3/4
(406 X 635 X 19)
16 X 25 X 3/4
(406 X 635 X 19)
16 X 25 X 3/4
(406 X 635 X 19)
16 X 25 X 3/4
(406 X 635 X 19)
* Recommended
315A
Cleaning and/or Replacing Air Filter
The air filter arrangement will vary depending on the application.
NOTE: If the filter has an airflow direction arrow, the arrow
must point towards the blower.
!
CAUTION
CUT HAZARD
Failure to follow this caution may result in personal injury.
Sheet metal parts may have sharp edges or burrs. Use care
and wear appropriate protective clothing, safety glasses and
gloves when handling parts, and servicing furnaces.
Media cabinet filter procedures:
NOTE: Media cabinet is included with variable speed furnace.
1. Turn off electrical supply to furnace before removing filter
access door.
2. Remove filter cabinet door.
3. Slide filter out of cabinet.
4. If equipped with permanent, washable 3/4--in. (19 mm)
filter, clean filter by spraying cold tap water through filter
in opposite direction of airflow. Rinse filter and let dry.
Oiling or coating of the filter is not recommended. See
Table 13 for size information.
5. If equipped with factory--specified disposable media filter,
replace only with media filter having the same part number and size. For expandable replacement media, refer to
the instructions included with the replacement media. If
equipped with accessory KGAFR0301ALL external filter
rack, See Table 13.
6. Slide filter into cabinet.
7. Replace filter cabinet door.
8. Turn on electrical supply to furnace.
Blower Motor and Wheel
!
WARNING
ELECTRICAL SHOCK HAZARD
Failure to follow this warning could result in personal
injury or death.
Blower access door switch opens 115--v power to control.
No component operation can occur unless switch is closed.
Caution must be taken when manually closing this switch
for service purposes.
NOTE: The blower wheel should not be dropped or bent as
balance will be affected.
The following steps should be performed by a qualified
service agency.
To ensure long life and high efficiency, clean accumulated dirt
and grease from blower wheel and motor annually.
BOTTOM
RETURN
14 X 25 X 3/4
(356 X 635 X 19)
16 X 25 X 3/4
(406 X 635 X 19)
20 X 25 X 3/4
(508 X 635 X 19)
24 X 25 X 3/4
(610 X 635 X 19)
FILTER TYPE
Washable*
Washable*
Washable*
Washable*
The inducer and blower motors are pre--lubricated and require no
additional lubrication. These motors can be identified by the
absence of oil ports on each end of the motor.
Clean blower motor and wheel as follows:
1. Turn off electrical supply to furnace.
2. Loosen the thumbscrew on outer door and then remove
outer door.
3. For downflow or horizontal furnaces having vent pipes
within the furnace that pass in front of the blower access
door:
a. Disconnect vent connector from furnace vent elbow.
b. Disconnect and remove short piece of vent pipe from
within furnace.
4. Remove 2 screws from blower access door and remove
blower access door.
5. Disconnect blower leads from furnace control. Record
wire color and location for reassembly. All other factory
wires can be left connected, but field thermostat connections may need to be disconnected depending on their
length and routing.
6. Remove 2 screws holding control box to blower shelf.
7. Hang control box from front of furnace casing and away
from blower compartment.
8. Remove 2 screws holding blower assembly to blower
deck and slide blower assembly out of furnace.
9. Clean blower wheel and motor using a vacuum with soft
brush attachment. Blower wheel blades may be cleaned
with a small paint or flux brush. Do not remove or disturb
balance weights (clips) on blower wheel blades.
10. Vacuum any loose dust from blower housing, wheel and
motor.
11. If a greasy residue is present on blower wheel, remove
wheel from the blower housing and wash it with an appropriate degreaser. To remove wheel:
NOTE: Before disassembly, mark blower mounting arms, motor,
and blower housing so motor and each arm is positioned at the
same location during reassembly.
a. Disconnect ground wire attached to blower housing.
b. Remove screws securing cutoff plate and remove
cutoff plate from housing.
c. Loosen set screw holding blower wheel on motor shaft
(160+/--20 in.--lb. when assembling).
d. Remove bolts holding motor to blower housing and
slide motor out of wheel (40+/--10 in.--lb. when reassembling).
e. Remove blower wheel from housing.
f. Clean wheel and housing.
12. Reassemble motor and blower by reversing steps 11e,
through 11a. Be sure to reattach ground wire to the blower
housing.
13. Verify that blower wheel is centered in blower housing
and set screw contacts the flat portion of the motor shaft.
50
!
WARNING
ELECTRICAL SHOCK HAZARD
Failure to follow this warning could result in personal
injury, or death.
Blower access door switch opens 115--v power to furnace
control. No component operation can occur unless switch is
closed. Exercise caution to avoid electrical shock from
exposed electrical components when manually closing this
switch for service purposes.
b. Manually close blower access door switch.
NOTE: If R--W/W1 thermostat terminals are jumpered at the
time blower access door switch is closed, blower will run for 90
sec before beginning a heating cycle.
c. Perform component self--test as shown at the bottom
of the SERVICE label, located on the front of blower
access door.
d. Verify blower is rotating in the correct direction
19. If furnace is operating properly, RELEASE BLOWER
ACCESS DOOR SWITCH. Remove any jumpers or reconnect any disconnected thermostat leads. Replace
blower access door.
20. Downflow or horizontal furnaces with vent pipe through
furnace only:
a. Install and connect short piece of vent pipe inside furnace to existing vent.
b. Connect vent connector to vent elbow.
21. Turn on gas supply and cycle furnace through one complete heating and cooling cycle. Verify the furnace temperature rise as shown in Adjustments Section. Adjust temperature rise as shown in Adjustments Section. If outdoor
temperature is below 70_F, turn off circuit breaker to outdoor unit before running furnace in the cooling cycle.
Turn outdoor circuit breaker on after completing cooling
cycle.
Cleaning Heat Exchanger
The following steps should be performed by a qualified
service agency:
NOTE: If the heat exchangers get a heavy accumulation of soot
and carbon, they should be replaced rather than trying to clean
them thoroughly. A build--up of soot and carbon indicates that a
problem exists which needs to be corrected, such as improper
adjustment of manifold pressure, insufficient or poor quality
combustion air, incorrect size or damaged manifold orifice(s),
improper gas, or a restricted heat exchanger. Action must be taken
to correct the problem.
If it becomes necessary to clean the heat exchangers because of
dust or corrosion, proceed as follows:
1. Turn OFF gas and electrical power to furnace.
2. Remove outer access door.
3. Disconnect vent connector from furnace vent elbow.
4. For downflow or horizontal furnace having an internal
vent pipe, remove internal vent pipe within the casing.
5. Disconnect wires to the following components. Mark
wires to aid in reconnection (be careful when disconnecting wires from switches because damage may occur):
a. Draft safeguard switch.
b. Inducer motor.
c. Pressure switches.
d. Limit overtemperature switch.
e. Gas valve.
f. Hot surface igniter.
g. Flame--sensing electrode.
h. Flame rollout switches.
6. Remove screws that fasten the collector box assembly to
the cell panel. Be careful not to damage the collector box.
Inducer assembly and elbow need not be removed from
collector box.
7. Disconnect gas line from gas manifold.
8. Remove the four screws that attach the burner assembly to
the cell panel. The gas valve and individual burners need
not be removed from support assembly. Remove NOx
baffles, if installed.
NOTE: Be very careful when removing burner assembly to
avoid breaking igniter. See Fig. 60 -- 61 for correct igniter
location.
9. Using field--provided 25--caliber rifle cleaning brush,
36--in. (914 mm) long, 1/4--in. (6 mm) diameter steel
spring cable, a variable speed, follows:
A05025
Fig. 60 -- Igniter Position -- Side View
1-7/8
(47.6 mm)
A05026
Fig. 61 -- Igniter Position -- Top View
51
315A
Loosen set screw on blower wheel and reposition if necessary.
14. Spin the blower wheel by hand to verify that the wheel
does not rub on the housing.
15. Reinstall blower assembly in furnace.
16. Reinstall control box assembly in furnace.
NOTE: Refer to Fig. 59 if leads were not identified before
disconnection.
17. Reconnect blower leads to furnace control. Refer to furnace wiring diagram, and connect thermostat leads if previously disconnected.
18. To check blower for proper rotation:
a. Turn on electrical supply.
315A
a. Remove metal screw fitting from wire brush to allow
insertion into cable.
b. Insert the twisted wire end of brush into end of spring
cable, and crimp tight with crimping tool or crimp by
striking with ball--peen hammer. TIGHTNESS IS
VERY IMPORTANT.
NOTE: The materials needed in item 9 can usually be purchased
at local hardware stores.
(1.) Attach variable--speed, reversible drill to the end
of spring cable (end opposite brush).
(2.) Insert brush end of cable into the outlet opening
of cell and slowly rotate with drill. DO NOT
force cable. Gradually insert cable into upper pass
of cell. (See Fig. 62.)
(3.) Work cable in and out of cell 3 or 4 times to obtain sufficient cleaning. DO NOT pull cable with
great force. Reverse drill and gradually work
cable out.
(4.) Insert brush end of cable in burner inlet opening
of cell, and proceed to clean 2 lower passes of
cell in same manner as upper pass.
(5.) Repeat foregoing procedures until each cell in
furnace has been cleaned.
(6.) Using vacuum cleaner, remove residue from each
cell.
(7.) Using vacuum cleaner with soft brush attachment,
clean burner assembly.
(8.) Clean flame sensor with fine steel wool.
(9.) Install NOx baffles (if removed).
A91252
Fig. 62 -- Cleaning Heat Exchanger Cell
(10.) Reinstall burner assembly. Center burners in cell
openings.
10. Remove old sealant from cell panel and collector box
flange.
11. Spray releasing agent on the heat exchanger cell panel
where collector box assembly contacts cell panel.
NOTE: A releasing agent such as cooking spray or equivalent
(must not contain corn or canola oil, aromatic or halogenated
hydrocarbons or inadequate seal may occur) and RTV sealant
(G.E. 162, 6702, or Dow--Corning 738) are needed before
starting installation. DO NOT substitute any other type of RTV
sealant. G.E. 162 (P771--9003) is available through RCD in 3--oz
tubes.
12. Apply new sealant to flange of collector box and attach to
cell panel using existing screws, making sure all screws
are secure.
13. Reconnect wires to the following components (Use connection diagram on wiring label, if wires were not marked
for reconnection locations.):
a. Draft safeguard switch.
14.
15.
16.
17.
18.
b. Inducer motor.
c. Pressure switches.
d. Limit overtemperature switch.
e. Gas valve.
f. Hot surface igniter.
g. Flame--sensing electrode.
h. Flame rollout switches.
Reinstall internal vent pipe, if applicable.
Reinstall vent connector on furnace vent elbow. Securely
fasten vent connector to vent elbow with 2 field--supplied,
corrosion--resistant, sheet metal screws located 180_ apart.
Replace blower access door only if it was removed.
Set thermostat above room temperature and check furnace
for proper operation.
Verify blower airflow and speed changes between heating
and cooling.
!
WARNING
FIRE OR EXPLOSION HAZARD
Failure to follow this warning could result in personal
injury, death and/or property damage. Never use a match or
other open flame to check for gas leaks. Use a
soap--and--water solution.
19. Check for gas leaks.
Sequence of Operation
NOTE: Furnace control must be grounded for proper operation
or else control will lock out. Control is grounded through
green/yellow wire routed to gas valve and burner box screw.
Using the schematic diagram in Fig. 59, follow the sequence of
operation through the different modes. Read and follow the
wiring diagram very carefully.
NOTE: If a power interruption occurs during a call for heat
(W/W1 or W/W1--and--W2), the control will start a 90--second
blower--only ON period two seconds after power is restored, if
the thermostat is still calling for gas heating. The amber LED
light will flash code 12 during the 90--second period, after which
the LED will be ON continuous, as long as no faults are detected.
After the 90--second period, the furnace will respond to the
thermostat normally.
The blower door must be installed for power to be conducted
through the blower door interlock switch ILK to the furnace
control CPU, transformer TRAN, inducer motor IDM, blower
motor BLWM, hot--surface igniter HSI, and gas valve GV.
1. Two--Stage Heating (Adaptive Mode) with Single--Stage
Thermostat
See Fig. 28 -- 35 for thermostat connections
NOTE: The low--heat only switch SW1--2 selects either the
low--heat only operation mode when ON, (see item 2. below) or
the adaptive heating mode when OFF in response to a call for
heat. (See Table 8.) When the W2 thermostat terminal is
energized it will always cause high--heat operation when the
R--to--W circuit is closed, regardless of the setting of the low--heat
only switch. This furnace can operate as a two--stage furnace with
a single--stage thermostat because the furnace control CPU
includes a programmed adaptive sequence of controlled
operation, which selects low--heat or high--heat operation. This
selection is based upon the stored history of the length of
previous gas--heating periods of the single--stage thermostat.
52
COOLING TONNAGE VS. AIRFLOW (CFM)
AIR CONDITIONING
TONS (12,000 BTU/HR)
AIRFLOW
(CFM)
070 MODEL
090 MODEL
110, 135,
& 155 MODELS
1-1/2
525
X2
X
2
700
X
X2
2-1/2
875
X
X
X2
3
1050
X1
X
X
3-1/2
1225
X
4
1400
5
1750
X1
6
2100
X
X
X1
X
X
X
X-INDICATES AN ALLOWABLE SELECTION.
070
DEF
5252
700
875
10501
1225
1225
1225
090
DEF
525
7002
875
1050
1225
14001
1400
110,135,155
DEF
700
8752
1050
1225
1400
17501
2100
315A
3 2 1
OFF
3 2 1
OFF
3 2 1
OFF
3 2 1
OFF
3 2 1
OFF
3 2 1
OFF
3 2 1
OFF
3 2 1
MODEL
SIZE
OFF
AIR CONDITIONING (A/C) OR CONTINUOUS-FAN (CF) AIRFLOW SELECTION CHART
BASED ON 350 CFM/TON
SW1-5 OFF
SWITCH SW3 POSITIONS
070
DEF
600 2
800
1000
12001
1400
1400
1400
090
DEF
600
8002
1000
1200
1400
16001
1600
110,135,155
DEF
800
10002
1200
1400
1600
20001
2200
3 2 1
OFF
3 2 1
OFF
3 2 1
OFF
3 2 1
OFF
3 2 1
OFF
3 2 1
OFF
3 2 1
OFF
3 2 1
MODEL
SIZE
OFF
BASED ON 400 CFM/TON
SW1-5 ON
SWITCH SW3 POSITIONS
1.DEFAULT A/C AIRFLOW WHEN A/C SWITCHES ARE IN OFF POSITION (FACTORY SETTING)
2.DEFAULT CONT. FAN AIRFLOW WHEN CF SWITCHES ARE IN OFF POSITION (FACTORY SETTING)
3. SWITCH POSITIONS ARE ALSO SHOWN ON FURNACE WIRING DIAGRAM
A08470
Fig. 63 -- Cooling (A/C) or Continuous--Fan (CF) Airflow Selection Chart
The furnace will start up in either low-- or high--heat. If the
furnace starts up in low--heat, the control CPU determines the
low--heat on--time (from 0 to 16 minutes) which is permitted
before switching to high--heat.
If the power is interrupted, the stored history is erased and the
control CPU will select low--heat for up to 16 minutes and then
switch to high--heat, as long as the thermostat continues to call for
heat. Subsequent selection is based on stored history of the
thermostat cycle times.
The wall thermostat “calls for heat”, closing the R--to--W circuit.
The furnace control performs a self--check, verifies the low--heat
and high--heat pressure switch contacts LPS and HPS are open,
and starts the inducer motor IDM in high--speed.
a. Inducer Prepurge Period
(1.) If the furnace control CPU selects low--heat operation the inducer motor IDM comes up to speed,
the low--heat pressure switch LPS closes, and the
furnace control CPU begins a 15--second prepurge period. If the low--heat pressure switch LPS
fails to remain closed the inducer motor IDM will
remain running at high--speed. After the low--heat
pressure switch re--closes the furnace control CPU
will begin a 15--second prepurge period, and con-
tinue to run the inducer motor IDM at high-speed.
(2.) If the furnace control CPU selects high--heat operation, the inducer motor IDM remains running
at high--speed, and the high--heat pressure switch
relay HPSR is de--energized to close the NC contact. When sufficient pressure is available the
high--heat pressure switch HPS closes, and the
high--heat gas valve solenoid GV--HI is energized. The furnace control CPU begins a
15--second
prepurge period after the low--heat pressure switch LPS closes. If
the high--heat pressure switch HPS fails to close and the low--heat
pressure switch LPS closes, the furnace will operate at low--heat
gas flow rate until the high--heat pressure switch closes for a
maximum of 2 minutes after ignition.
b. Igniter Warm--Up --At the end of the prepurge period,
the Hot--Surface Igniter HSI is energized for a
17--second igniter warm--up period.
c. Trial--For--Ignition Sequence --When the igniter
warm--up period is completed the main gas valve relay
contact GVR closes to energize the gas valve solenoid
GV--M. The gas valve solenoid GV--M permits gas
flow to the burners where it is ignited by the HSI. Five
53
315A
seconds after the GVR closes, a 2--second flame proving period begins. The HSI igniter will remain energized until the flame is sensed or until the 2--second
flame proving period begins. If the furnace control
CPU selects high--heat operation, the high--heat gas
valve solenoid GV--HI is also energized.
d. Flame--Proving -- When the burner flame is proved at
the flame--proving sensor electrode FSE, the inducer
motor IDM switches to low--speed unless the furnace
is operating in high--heat, and the furnace control CPU
begins the blower--ON delay period and continues to
hold the gas valve GV--M open. If the burner flame is
not proved within two seconds, the control CPU will
close the gas valve GV--M, and the control CPU will
repeat the ignition sequence for up to three more Trials--For--Ignition before going to Ignition--Lockout.
Lockout will be reset automatically after three hours,
by momentarily interrupting 115 vac power to the furnace, or by interrupting 24 vac power at SEC1 or
SEC2 to the furnace control CPU (not at W/W1, G, R,
etc.). If flame is proved when flame should not be
present, the furnace control CPU will lock out of Gas-Heating mode and operate the inducer motor IDM on
high speed until flame is no longer proved.
e. Blower--On delay -- If the burner flame is proven the
blower--ON delays for low--heat and high--heat are as
follows:
Low--heat -- 45 seconds after the gas valve GV--M is
opened the blower motor BLWM is turned ON at
low--heat airflow.
High--heat -- 25 seconds after the gas valve GV--M is
opened the BLWM is turned ON at high--heat airflow.
Simultaneously, the humidifier terminal HUM and
electronic air cleaner terminal EAC--1 are energized
and remain energized throughout the heating cycle.
f. Switching from Low-- to High--Heat -- If the furnace
control CPU switches from low--heat to high--heat, the
furnace control CPU will switch the inducer motor
IDM speed from low to high. The high--heat pressure
switch relay HPSR is de--energized to close the NC
contact. When sufficient pressure is available the high-heat pressure switch HPS closes, and the high--heat gas
valve solenoid GV--HI is energized. The blower motor
BLWM will transition to high--heat airflow five
seconds after the furnace control CPU switches from
low--heat to high--heat.
g. Switching from High-- to Low--Heat --The furnace
control CPU will not switch from high--heat to low-heat while the thermostat R--to--W circuit is closed
when using a single--stage thermostat.
h. Blower--Off Delay --When the thermostat is satisfied,
the R to W circuit is opened, de--energizing the gas
valve GV--M, stopping gas flow to the burners, and
de--energizing the humidifier terminal HUM. The inducer motor IDM will remain energized for a
5--second post--purge period. The blower motor
BLWM and air cleaner terminal EAC--1 will remain
energized at low--heat airflow or transition to low--heat
airflow for 90, 120, 150, or 180 seconds (depending
on selection at blower--OFF delay switches). The furnace control CPU is factory--set for a 120--second
blower--OFF delay.
2. Two--Stage Thermostat and Two--Stage Heating
See Fig. 28 -- 35 for thermostat connections.
NOTE: In this mode the low--heat only switch SW1--2 must be
ON to select the low--heat only operation mode in response to
closing the thermostat R--to--W1 circuit. Closing the thermostat
R--to-- W1--and--W2 circuits always causes high--heat operation,
regardless of the setting of the low--heat only switch.
The wall thermostat “calls for heat”, closing the R--to--W1 circuit
for low--heat or closing the R--to--W1--and--W2 circuits for
high--heat. The furnace control performs a self--check, verifies the
low--heat and high--heat pressure switch contacts LPS and HPS
are open, and starts the inducer motor IDM in high--speed.
The start up and shut down functions and delays described in
item 1. above apply to the 2--stage heating mode as well, except
for switching from low-- to high--Heat and vice versa.
a. Switching from Low-- to High--Heat -- If the thermostat R--to--W1 circuit is closed and the R--to--W2 circuit closes, the furnace control CPU will switch the
inducer motor IDM speed from low to high. The
high--heat pressure switch relay HPSR is de--energized
to close the NC contact. When sufficient pressure is
available the high--heat pressure switch HPS closes,
and the high--heat gas valve solenoid GV--HI is energized. The blower motor BLWM will transition to
high--heat airflow five seconds after the R--to--W2 circuit closes.
b. Switching from High-- to Low--Heat --If the thermostat R--to-- W2 circuit opens, and the R--to--W1 circuit
remains closed, the furnace control CPU will switch
the inducer motor IDM speed from high to low. The
high--heat pressure switch relay HPSR is energized to
open the NC contact and de--energize the high--heat
gas valve solenoid GV--HI. When the inducer motor
IDM reduces pressure sufficiently, the high--heat pressure switch HPS will open. The gas valve solenoid
GV--M will remain energized as long as the low--heat
pressure switch LPS remains closed. The blower motor
BLWM will transition to low--heat airflow five
seconds after the R--to--W2 circuit opens.
3. Cooling mode
The thermostat “calls for cooling”.
a. Single--Speed Cooling-See Fig. 28 for thermostat connections
The thermostat closes the R--to--G--and--Y circuits. The
R--to-- Y circuit starts the outdoor unit, and the R--to-G--and--Y/Y2 circuits start the furnace blower motor
BLWM on cooling airflow. Cooling airflow is based
on the A/C selection shown in Fig. 63. The electronic
air cleaner terminal EAC--1 is energized with 115 vac
when the blower motor BLWM is operating.
When the thermostat is satisfied, the R--to--G--and--Y
circuits are opened. The outdoor unit will stop, and the
furnace blower motor BLWM will continue operating
at cooling airflow for an additional 90 seconds. Jumper Y/Y2 to DHUM to reduce the cooling off--delay to
5 seconds. (See Fig. 27.)
b. Single--Stage Thermostat and Two--Speed Cooling
(Adaptive Mode) -See Fig. 35 for thermostat connections.
This furnace can operate a two--speed cooling unit
with a single--stage thermostat because the furnace
control CPU includes a programmed adaptive sequence of controlled operation, which selects low-cooling or high--cooling operation. This selection is
based upon the stored history of the length of previous
cooling period of the single--stage thermostat.
NOTE: The air conditioning relay disable jumper ACRDJ must
be connected to enable the adaptive cooling mode in response to
a call for cooling. (See Fig. 27.) When ACRDJ is in place the
furnace control CPU can turn on the air conditioning relay ACR
to energize the Y/Y2 terminal and switch the outdoor unit to
high--cooling.
54
55
315A
vac is detected by the furnace control on the DHUM input,
the furnace control operates in Thermidistat mode. If the
DHUM input is low for more than 48 hours, the furnace
control reverts back to non--Thermidistat mode.
The cooling operation described in item 3. above also applies to operation with a Thermidistat. The exceptions are
listed below:
a. Low cooling--When the R--to--G--and--Y1 circuit is
closed and there is a demand for dehumidification, the
furnace blower motor BLWM will drop the blower
airflow to 86 percent of low--cooling airflow which is
the true on--board CF (continuous fan) selection as
shown in Fig. 61.
b. High cooling--When the R--to--G--and Y/Y2 circuit is
closed and there is a demand for dehumidification, the
furnace blower motor BLWM will drop the blower
airflow to 86 percent of high--cooling airflow. High-cooling airflow is based on the A/C (air conditioning)
selection shown in Fig. 61.
c. Cooling off--delay--When the “call for cooling” is
satisfied and there is a demand for dehumidification,
the cooling blower--off delay is decreased from 90
seconds to 5 seconds.
5. Super--Dehumidify Mode
Super--Dehumidify mode can only be entered if the furnace control is in the Thermidistat mode and there is a demand for dehumidification. The cooling operation described in item 3. above also applies to operation with a
Thermidistat. The exceptions are listed below:
a. When the R--to--Y1 circuit is closed, R--to--G circuit is
open, and there is a demand for dehumidification, the
furnace blower motor BLWM will drop the blower
airflow to 65 percent of low--cooling airflow for a
maximum of 10 minutes each cooling cycle or until
the R--to--G circuit closes or the demand for dehumidification is satisfied. Low--cooling airflow is the true
on--board CF (continuous fan) selection as shown in
Fig. 63.
b. When the R--to--Y/Y2 circuit is closed, R--to--G circuit
is open, and there is a demand for dehumidification,
the furnace blower motor BLWM will drop the blower
airflow to 65 percent of high--cooling airflow for a
maximum of 10 minutes each cooling cycle or until
the R--to--G circuit closes or the demand for dehumidification is satisfied. High--cooling airflow is based on
the A/C (air conditioning) selection shown in Fig. 63.
c. When the “call for cooling” is satisfied and there is a
demand for dehumidification, the cooling blower--off
delay is decreased from 90 seconds to 5 seconds.
6. Continuous Blower Mode
When the R--to--G circuit is closed by the thermostat, the
blower motor BLWM will operate at continuous blower
airflow. Continuous blower airflow selection is initially
based on the CF (continuous fan) selection shown in Fig.
63. Factory default is shown in Fig. 63. Terminal EAC--1
is energized as long as the blower motor BLWM is energized.
During a call for heat, the furnace control CPU will transition the blower motor BLWM to continuous blower airflow, low--heat airflow, or the mid--range airflow,
whichever is lowest. The blower motor BLWM will remain ON until the main burners ignite then shut OFF and
remain OFF for the blower--ON delay (45 seconds in low-heat, and 25 seconds in high--heat), allowing the furnace
heat exchangers to heat up more quickly, then restarts at
the end of the blower--ON delay period at low--heat or
high--heat airflow, respectively.
The blower motor BLWM will revert to continuous--
The furnace control CPU can start up the cooling unit in either
low-- or high--cooling. If starting up in low--cooling, the furnace
control CPU determines the low--cooling on--time (from 0 to 20
minutes) which is permitted before switching to high--cooling. If
the power is interrupted, the stored history is erased and the
furnace control CPU will select low--cooling for up to 20 minutes
and then energize the air conditioning relay ACR to energize the
Y/Y2 terminal and switch the outdoor unit to high--cooling, as
long as the thermostat continues to call for cooling. Subsequent
selection is based on stored history of the thermostat cycle times.
The wall thermostat “calls for cooling”, closing the
R--to--G--and--Y circuits. The R--to--Y1 circuit starts the outdoor
unit on low--cooling speed, and the R--to--G--and--Y1 circuits
starts the furnace blower motor BLWM at low--cooling airflow
which is the true on--board CF selection as shown in Fig. 63.
If the furnace control CPU switches from low--cooling to
high--cooling, the furnace control CPU will energize the air
conditioning relay ACR. When the air conditioning relay ACR is
energized the R--to--Y1--and--Y2 circuits switch the outdoor unit
to high--cooling speed, and the R--to--G--and--Y1--and--Y/Y2
circuits transition the furnace blower motor BLWM to
high--cooling airflow. High--cooling airflow is based on the A/C
selection shown in Fig. 63.
NOTE: When transitioning from low--cooling to high--cooling
the outdoor unit compressor will shut down for 1 minute while
the furnace blower motor BLWM transitions to run at
high--cooling airflow.
The electronic air cleaner terminal EAC--1 is energized with 115
vac whenever the blower motor BLWM is operating.
When the thermostat is satisfied, the R--to--G--and--Y circuit are
opened. The outdoor unit stops, and the furnace blower BLWM
and electronic air cleaner terminal EAC--1 will remain energized
for an additional 90 seconds. Jumper Y1 to DHUM to reduce the
cooling off--delay to 5 seconds. (See Fig. 27.)
c. Two--Stage Thermostat and Two--Speed Cooling
See Fig. 34 for thermostat connections
NOTE: The air conditioning relay disable jumper ACRDJ must
be disconnected to allow thermostat control of the outdoor unit
staging. (See Fig. 27.)
The thermostat closes the R--to--G--and--Y1 circuits for
low--cooling or closes the R--to--G--and--Y1--and--Y2 circuits for
high--cooling. The R--to--Y1 circuit starts the outdoor unit on
low--cooling speed, and the R--to--G--and--Y1 circuit starts the
furnace blower motor BLWM at low--cooling airflow which is the
true on--board CF (continuous fan) selection as shown in Fig. 61.
The R--to--Y1--and--Y2 circuits start the outdoor unit on
high--cooling speed, and the R--to-- G--and--Y/Y2 circuits start the
furnace blower motor BLWM at high--cooling airflow.
High--cooling airflow is based on the A/C (air conditioning)
selection shown in Fig. 63.
The electronic air cleaner terminal EAC--1 is energized with 115
vac whenever the blower motor BLWM is operating.
When the thermostat is satisfied, the R--to--G--and--Y1 or R--to-G--and--Y1--and--Y2 circuits are opened. The outdoor unit stops,
and the furnace blower BLWM and electronic air cleaner terminal
EAC--1 will remain energized for an additional 90 seconds.
Jumper Y1 to DHUM to reduce the cooling off--delay to 5
seconds. (See Fig. 27.)
4. Thermidistat Mode
See Fig. 28--30 for thermostat connections.
The dehumidification output, DHUM on the Thermidistat
should be connected to the furnace control thermostat terminal DHUM. When there is a dehumidify demand, the
DHUM input is activated, which means 24 vac signal is
removed from the DHUM input terminal. In other words,
the DHUM input logic is reversed. The DHUM input is
turned ON when no dehumidify demand exists. Once 24
315A
blower airflow after the heating cycle is completed. In
high--heat, the furnace control CPU will drop the blower
motor BLWM to low--heat airflow during the selected
blower--OFF delay period before transitioning to continuous--blower airflow.
When the thermostat “calls for low--cooling”, the blower
motor BLWM will switch to operate at low--cooling airflow. When the thermostat is satisfied, the blower motor
BLWM will operate an additional 90 seconds at low--cooling airflow before transitioning back to continuous-blower airflow.
When the thermostat “calls for high--cooling”, the blower
motor BLWM will operate at high cooling airflow. When
the thermostat is satisfied, the blower motor BLWM will
operate an additional 90 seconds at high--cooling airflow
before transitioning back to continuous--blower airflow.
When the R--to--G circuit is opened, the blower motor
BLWM will continue operating for an additional 5
seconds, if no other function requires blower motor
BLWM operation.
Continuous Blower Speed Selection from Thermostat
To select different continuous--blower airflows from the
room thermostat, momentarily turn off the FAN switch or
push button on the room thermostat for 1--3 seconds after
the blower motor BLWM is operating. The furnace control
CPU will shift the continuous--blower airflow from the
factory setting to the next highest CF selection airflow as
shown in Fig. 63. Momentarily turning off the FAN switch
again at the thermostat will shift the continuous--blower
airflow up one more increment. If you repeat this procedure enough you will eventually shift the continuous-blower airflow to the lowest CF selection as shown in Fig.
63. The selection can be changed as many times as desired
and is stored in the memory to be automatically used following a power interruption.
NOTE: If the blower--off delay is set to the maximum, the
adjustable continuous--fan feature is locked (i.e., fan speed cannot
be changed from its current setting).
7. Heat pump
See Fig. 30--33 for thermostat connections.
When installed with a heat pump, the furnace control automatically changes the timing sequence to avoid long
blower off times during demand defrost cycles. Whenever
W/W1 is energized along with Y1 or Y/Y2, the furnace
control CPU will transition to or bring on the blower motor BLWM at cooling airflow, low--heat airflow, or the
mid--range airflow, whichever is lowest. The blower motor
BLWM will remain on until the main burners ignite then
shut OFF and remain OFF for 25 seconds before coming
back on at heating airflow. When the W/W1 input signal
disappears, the furnace control begins a normal inducer
post--purge period while changing the blower airflow. If
Y/Y2 input is still energized the furnace control CPU will
transition the blower motor BLWM airflow to cooling airflow. If Y/Y2 input signal disappears and the Y1 input is
still energized the furnace control CPU will transition the
blower motor BLWM to low--cooling airflow. If both the
Y1 and Y/Y2 signals disappear at the same time, the
blower motor BLWM will remain on at low--heat airflow
for the selected blower--OFF delay period. At the end of
the blower-- OFF delay, the blower motor BLWM will
shut OFF unless G is still energized, in which case the
blower motor BLWM will operate at continuous blower
airflow.
8. Component test
The furnace features a component test system to help diagnose a system problem in the case of a component failure. To initiate the component test procedure, ensure that
there are no thermostat inputs to the control and all time
delays have expired. Turn on setup switch SW1--6. (See
Fig. 27.)
NOTE: The component test feature will not operate if the control
is receiving any thermostat signals or until all time delays have
expired.
The component test sequence is as follows:
a. The furnace control CPU turns the inducer motor ON
at high--heat speed and keeps it ON through step c.
b. After waiting 10 seconds the furnace control CPU
turns the hot surface igniter ON for 15 seconds, then
OFF.
c. The furnace control CPU then turns the blower motor
BLWM on at mid--range airflow for 15 seconds, then
OFF.
d. After shutting the blower motor OFF the furnace control CPU switches the inducer to low--heat speed for
10 seconds, then OFF.
NOTE: The EAC terminals are energized when the blower is
operating.
After the component test is completed, 1 or more status codes (11,
25, or 41) will flash. See component test section or Service Label
(Fig. 58.) for explanation of status codes.
NOTE: To repeat component test, turn setup switch SW1--6 to
OFF and then back ON.
Wiring Diagram
Refer to wiring diagram Fig. 59.
Troubleshooting
Refer to the service label. (See Fig. 58—Service Label.)
The Troubleshooting Guide (See Fig. 64.) can be a useful tool in
isolating furnace operation problems. Beginning with the word
“Start,” answer each question and follow the appropriate arrow to
the next item.
The Guide will help to identify the problem or failed component.
After replacing any component, verify correct operation
sequence.
A more detailed Troubleshooting Guide is available from your
distributor.
56
A02108A
57
Go to section below for the status code
that was flashed.
Determine status code. The status code is
a 2 digit number with the first digit determined
by the number of short flashes and the
second digit by the number of long flashes?
YES
Is AMBER LED status light blinking ON/OFF
slowly with a combination of short and
long flashes?
NO
Is AMBER LED status light blinking
rapidly without a pause?
YES
Is AMBER LED status light on?
START
YES
NO
YES
NO
Was there a previous status code other
than #11?
YES
Replace furnace control.
Run system through a low-heat, high-heat,
or cooling cycle to check operation. Status
codes are erased after 72 hours or can be
manually erased by putting setup switch
SW1-1 in the ON position and jumpering R,
W/W1, and Y/Y2 simultaneously until status
code #11 is flashed.
YES
Does the control respond to W/W1, W2, Y1,
Y/Y2, and G (24V) thermostat signals?
Replace transformer.
Check for correct line voltage polarity.
If units are twinned, check for proper
low-voltage (24V) transformer phasing.
To recall previous status codes disconnect
the R thermostat connection, reset power,
and put setup switch SW1-1 in the ON
position. The AMBER LED will flash the
status codes in the order of occurrence.
Record status codes until status code #11
flashes (1 short and 1 long flash). After status
code #11 flashes the status codes will repeat.
Status codes are erased after 72 hours or
can be manually erased by putting setup
switch SW1-1 in the ON position and
jumpering R, W/W1, and Y/Y2 simultaneously
until status code #11 is flashed. When done
put setup switch SW1-1 in the OFF position.
YES
Is there 115V going to switch?
Is door switch closed?
Replace door switch.
NO
NO
NO
Replace furnace control.
YES
Is there 24V at SEC-1 and SEC-2?
YES
Is there 115V at L1 and L2?
NO
Check room thermostat or
interconnecting cable.
Close circuit breaker and go back to START.
Check for continuity in wire from circuit
breaker to furnace.
YES
Is circuit breaker closed?
Is door switch closed?
The thermostat is not compatible with the
furnace control. Either install a ballast resistor,
connect the Com24V thermostat terminal to
the thermostat, or replace the thermostat.
NO
Does the problem repeat when using
a jumper wire?
Disconnect all the thermostat wires from the
furnace control.
YES
Is 24V present at W/W1, W2, Y1, Y/Y2 or G
thermostat terminals on the furnace control?
315A
YES
NO
NO
NO
NO
A02108B
58
24 SECONDARY VOLTAGE FUSE IS OPEN
Check for:
- Short circuit in secondary voltage
(24V) wiring including thermostat
leads. Disconnect thermostat leads
to isolate short circuit.
23 PRESSURE SWITCH DID NOT OPEN
Check for:
- Obstructed pressure tube.
- Pressure switch stuck closed.
22 ABNORMAL FLAME-PROVING SIGNAL
Flame is proved while gas valve is deenergized. Inducer will run until fault is
cleared. Check for:
- Stuck open or leaky gas valve.
21 GAS HEATING LOCKOUT – Turn off
power and wait 5 minutes to retry.
Check for:
- Stuck closed gas valve relay on control.
- Miswire or short to gas valve wire.
15 BLOWER MOTOR LOCKOUT – Indicates
the blower failed to reach 250 RPM or
the blower failed to communicate within
30 seconds after being turned ON in two
successive heating cycles. Control will
auto-reset after 3 hours. See code 41.
14 IGNITION LOCKOUT – System failed to
ignite gas and prove flame in 4 attempts.
Control will auto-reset after 3 hours.
See status code 34.
13 LIMIT CIRCUIT LOCKOUT – Lockout
occurs if the limit, draft safeguard, flame
rollout, or blocked vent switch* (if used)
is open longer than 3 minutes or 10
successive limit trips occurred during
high-heat. Control will auto-reset after 3
hours. See code 33.
12 BLOWER ON AFTER POWER UP –
(115V OR 24V) – Normal operation.
Blower runs for 90 seconds, if unit is
powered up during a call for heat (RW/W1 closed) or when (R-W/W1 opens)
during the blower on-delay period.
11 NO PREVIOUS CODE – Status codes
are erased after 72 hours or can be
manually erased by putting setup switch
SW1-1 in the ON position and jumpering
R, W/W1, and Y/Y2 simultaneously until
status code #11 is flashed. Run system
through a low-heat, high-heat, or cooling
cycle to check system.
* Blocked vent switch used in Chimney Adapter Kit
34 IGNITION PROVING FAILURE – If flame
is not sensed during the trial for ignition
period, the control will repeat the ignition
sequence 3 more times before lockout
#14 occurs. If flame signal is lost during
NO
the blower on-delay period, blower will
come on for the selected blower off-delay.
Check the following items first before
proceeding to the next step.
- Gas valve turned off.
- Manual shut-off valve.
- Green/Yellow wire MUST be connected
to furnace sheet metal.
- Flame sensor must not be grounded.
To determine whether the problem is in
the gas valve, igniter, or flame sensor the YES
system can be operated in component
test mode. To check the igniter remove
the R thermostat connection from the
control, reset power, and put setup switch
SW1-6 in the ON position to start the
component test. Does the igniter glow
orange/white by the end of the 15 second
warm-up period?
33 LIMIT CIRCUIT FAULT – Indicates the
limit, draft safeguard, flame rollout, or
blocked vent switch* (if used) is open or
the furnace is operating in high-heat only
mode due to 2 successive low-heat limit
trips. Blower will run for 4 min. or until
open switch remakes whichever is longer.
If open longer than 3 min., code changes
to lockout #13. If open less than 3 min.
status code #33 continues to flash until
blower shuts off. Flame rollout switch and
BVSS requires manual reset. Check for:
- Dirty filter or restricted duct system.
- Loose blower wheel.
- Defective switch or connections.
- Inadequate combustion air supply
(flame rollout switch open).
- Restricted vent.
- Proper vent sizing.
- Excessive wind.
32 LOW-HEAT PRESSURE SWITCH DID
NOT CLOSE OR REOPENED – If open
longer than 5 minutes, inducer shuts off
for 15 minutes before retry. If opens
during blower on-delay period, blower will
come on for the selected blower off-delay.
Check for:
- Proper vent sizing.
- Low inducer voltage (115V).
- Low inlet gas pressure (if LGPS used).
- Inadequate combustion air supply.
- Disconnected or obstructed pressure
tubing.
- Defective inducer motor.
- Defective pressure switch.
- Excessive wind.
- Restricted vent.
Fixed.
YES
Will main burners ignite and stay on?
YES
Is current near typical value?
Clean flame sensor with fine steel wool and
recheck current. Nominal current is 4.0 to
6.0 microamps.
YES
Repeat call for heat and check flame sensor
current during trial for ignition period. Is the
DC microamps below 0.5?
NO
Do the main burners stay on?
YES
Do the main burners ignite?
YES
Does gas valve open and allow gas to flow?
YES
Reconnect the R thermostat lead and set
thermostat to call for heat. Connect voltmeter
across gas valve connections. Does gas
valve receive 24V?
Unplug igniter harness from control and
repeat component test by turning setup switch
SW1-6 OFF and then back ON. Check for
115V between pin 3 and NEUTRAL-L2 on
the control. Was 115V present for the 15
second period?
43 LOW-HEAT PRESSURE SWITCH OPEN
WHILE HIGH-HEAT PRESSURE
SWITCH IS CLOSED - Check for:
- Low-heat pressure switch stuck open.
- Disconnected or obstructed pressure
tube.
- Miswired pressure switches.
- Low inlet gas pressure (if LGPS used).
315A
NO
NO
NO
YES
NO
NO
NO
YES
NO
Replace furnace control.
Replace electrode.
Check connections and retry. If current is
near typical value (4.0-6.0 nominal) and
burners will not stay on, repeat check in highheat. If burners will still not stay on replace
control. If burners operate in high-heat then
switch to low-heat,check manifold pressure.
If OK, check burner carryover and flame
sensor location.
Allow blower to come on and repeat test
to check for intermittent operation.
Check for:
- Inadequate flame carryover or rough
ignition.
- Low inlet gas pressure.
- Proper firing rate.
- Blocked or incorrect carry- over gap.
(.045” nominal)
Check that all gas valves are turned on.
Replace valve.
Check connections. If OK, replace control.
Check for continuity in the harness and
igniter. Replace defective component.
Replace furnace control.
45 CONTROL CIRCUITRY LOCKOUT
Auto-reset after 1 hour lockout due to:
- Flame circuit failure.
- Gas valve relay stuck open.
- Software check error.
Reset power to clear lockout.
Replace control if code repeats.
A02108C
59
31 HIGH-HEAT PRESSURE SWITCH OR
RELAY DID NOT CLOSE OR
REOPENED - Check for:
- Control relay may be defective.
- Gas valve is miswired.
- See status code 32.
25 INVALID MODEL SELECTION OR
SETUP ERROR – If status code 25 only
flashes 4 times on power-up the control
is missing its model plug PL4 and is
defaulting to the model selection stored
in memory. If status code 25 flashes
continuously it could indicate any of the
following:
- Model plug PL4 is missing and there
is no valid model stored in permanent
memory. This will happen if you forget
to install the model plug PL4 on a
service replacement control.
- Thermostat call with SW1-1 ON.
- Thermostat call with SW1-6 ON.
- SW1-1 and SW1-6 both ON.
YES
Replace the blower control module attached
to the blower motor. Follow the instructions
with the blower control module to make sure
the entire blower motor does not need to be
replaced.
YES
Does the voltage fluctuate as described in the
previous step?
NO
Connect a DC voltmeter across PL3-4 BLUE
(+) and PL3-2 GREEN (-). Does the voltage
fluctuate as described two steps back?
NO
Replace the furnace control.
You have an open wire or bad terminal on the
BLUE wire between the furnace control and
the blower motor.
Replace the blower control module attached
to the blower motor. Follow the instructions
with the blower control module to make sure
the entire blower motor does not need to be
replaced.
NO
41 BLOWER MOTOR FAULT – Indicates the
blower failed to reach 250 RPM or the
blower failed to communicate within the
prescribed time limits. Thirty seconds
after being turned ON or ten seconds
during steady-state operation. Turn power
off and check the following items first
before proceeding to the next step.
- Rubbing blower wheel.
- Loose blower wheel.
- Wiring from furnace control to blower
motor.
Remove the R thermostat connection
from the furnace control, disconnect both
connectors from the blower motor PL13
and PL14. Does the blower wheel turn
freely?
YES
YES
YES
315A
Turn power off, disconnect PL13 and PL14
from the blower motor, then turn power back
on. Connect a DC voltmeter across PL1316 BLUE (+) and PL13-1 GREEN (-). The
voltage should be near 0-VDC but it will
fluctuate briefly several times a second. If
you have an analog voltmeter the needle will
briefly go high several times a second. If you
have a digital voltmeter with a bar graph it
will show a large change in magnitude on
the bar graph several times a second. If you
have a standard digital voltmeter it will show
a brief fluctuation in voltage and the
magnitude may vary depending on the
voltmeter used.
NO
Turn power off, reconnect PL13 and PL14 to
the blower motor, then turn power back on.
Connect a DC voltmeter across PL3-3
YELLOW (+) and PL3-2 GREEN (-). Does
the voltage fluctuate more than it did in the
previous step?
The voltage just measured should be very
stable and should not fluctuate more than
.02-VDC. If the voltage fluctuates more than
this get a different voltmeter before
proceeding.
YES
Is there 5-VDC at PL13-16 YELLOW (+) and
PL13-1 GREEN (-)?
Replace the furnace control.
NO
Is there 12-VDC at PL3-1 RED (+) and PL32 GREEN (-)?
NO
Is there 12-VDC at PL13-7 RED (+) and PL131 GREEN (-)?
YES
Turn power back on. Is there 115VAC at
PL14-5 and PL14-4?
NO
YES
NO
You have an open wire or bad terminal on the
YELLOW wire between the furnace control
and the blower motor.
YES
Is there 5-VDC at PL3-3 YELLOW (+) and
PL3-2 GREEN (-)?
NO
You have an open wire or bad terminal on
either the RED or GREEN wire between the
furnace control and the blower motor.
You have an open wire or bad terminal on
either the BLACK or WHITE power leads
between the furnace control and the blower
motor. If you have a power choke disconnect
it and check continuity.
315A
E2008 Bryant Heating & Cooling Systems 7310 W. Morris St. Indianapolis, IN 46231
Printed in U.S.A.
Edition Date: 11/08
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
60
Catalog No. II315A ---70---10
Replaces: II315A--- 70--- 9