warning - Classic Air Conditioning

310A
SINGLE--STAGE DELUXE
INDUCED--COMBUSTION
4--WAY MULTIPOISE GAS FURNACE
Installation, Start--up, Operating, and
Service and Maintenance
Instructions Series 130/D
SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . . . . . . . 2
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
CODES AND STANDARDS . . . . . . . . . . . . . . . . . . . . . . . . . . 4
ama
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
General Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
ISO 9001:2000
Combustion and Ventilation Air . . . . . . . . . . . . . . . . . . . . . 5
CERTIFIED
Duct Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Acoustical Lining and Fibrous Glass Duct . . . . . . . . . . . . . 5
Gas Piping and Gas Pipe Pressure Testing . . . . . . . . . . . . . 5
REGISTERED
Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Venting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
AIR FOR COMBUSTION AND VENTILATION . . . . . . . . . 8
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Bottom Return Air Inlet . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Side Return Air Inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Leveling Legs (If Desired) . . . . . . . . . . . . . . . . . . . . . . . . 11
Bottom Return Air Inlet . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Suspended Furnace Support . . . . . . . . . . . . . . . . . . . . . . . 12
Platform Furnace Support . . . . . . . . . . . . . . . . . . . . . . . . . 13
Roll--Out Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Bottom Return Air Inlet . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Side Return Air Inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
General Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Ductwork Acoustical Treatment . . . . . . . . . . . . . . . . . . . . 14
Supply Air Connections . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Return Air Connections . . . . . . . . . . . . . . . . . . . . . . . . . . 20
START--UP, ADJUSTMENT, AND SAFETY CHECK . . . . . 31
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Start--Up Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Check Safety Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
SERVICE AND MAINTENANCE PROCEDURES . . . . . . . 46
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Care and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Sequence of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
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 Nation 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 entirely.
SAFETY CONSIDERATIONS
!
DANGER identifies the most serious hazards which will result in
severe personal injury or death. WARNING signifies hazards
which could result in personal injury or death. CAUTION is
used to identify unsafe practices which may result in minor
personal injury or product and property 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. CNPV, CNRV, CAR or CAP 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 personal
injury, death, or property damage.
310A
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.
!
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.
Improper
installation,
adjustment,
alteration,
service,
maintenance, or use can cause explosion, fire, electrical shock, or
other conditions which may cause death, personal injury, or
property damage. Consult a qualified installer, service agency, or
your distributor or branch for information or assistance. The
qualified installer or agency must use factory--authorized kits or
accessories when modifying this product. Refer to the individual
instructions packaged with the kits or accessories when installing.
Follow all safety codes. Wear safety glasses, protective clothing,
and work gloves. Have a fire extinguisher available. Read these
instructions thoroughly and follow all warnings or cautions
include in literature and attached to the unit. Consult local
building codes, the current editions of the National Fuel Gas
Code (NFGC) NFPA 54/ANSI Z223.1 and the National
Electrical Code (NEC) NFPA 70.
In Canada, refer to the current editions of the National Standards
of Canada CAN/CSA--B149.1 and .2 Natural Gas and Propane
Installation Codes, and Canadian Electrical Code CSA C22.1
Recognize safety information. This is the safety--alert symbol .
When you see this symbol on the unit and in instructions or
manuals, be alert to the potential for personal injury.
Understand the signal words DANGER, WARNING, and
CAUTION. These words are used with the safety--alert symbol.
2
(733mm)
28-7/8"
(664mm)
26-1/8"
(FLUE COLLAR)
(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
13/16"
(21mm)
19"
(483mm)
OUTLET
1/2" DIA. K.O.THERMOSTAT
WIRE ENTRY (13mm)
1-3/4" DIA.RIGHT HAND
GAS ENTRY (44mm)
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)
1-1/2" (38mm)
(560mm)
22-1/16"
SIDE INLET
3-3/4"
(95mm)
24"
CASING
(610mm)
310A
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. 1 --- Dimensional Drawing
INTRODUCTION
This furnace is designed for minimum continuous return--air
temperature of 60_F (16_C) db or intermittent operation down to
55_F (13_C) db such as when used with a night setback
thermostat. Return--air temperature must not exceed 85_F (29_C)
db. Failure to follow these return--air temperature limits may
affect reliability of heat exchangers, motors, and controls. (See
Fig. 3.)
Series 130/D 4--way multipoise Category I fan--assisted furnace is
CSA 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.
Table 1—Dimensions -- In. (mm)
FURNACE SIZE
A
CABINET WIDTH
IN (mm)
D
SUPPLY ---AIR
WIDTH
IN (mm)
E
RETURN---AIR
WIDTH
IN (mm)
045---08/024045
045---12/036045
070---08/024070
070---12/036070
070---16/048070
090---14/042090
090---16/048090
090---20/060090
110---12/036110
110---16/048110
110---22/066110
135---16/048135
135---22/066135
155---20/060155
14--- 3/16 (360)
14--- 3/16 (360)
14--- 3/16 (360)
14--- 3/16 (360)
17--- 1/2 (445)
17--- 1/2 (445)
21 (533)
21 (533)
17--- 1/2 (445)
21 (533)
21 (533)
21 (533)
24--- 1/2 (622)
24--- 1/2 (622)
12--- 9/16 (319)
12--- 9/16 (319)
12--- 9/16 (319)
12--- 9/16 (319)
15--- 7/8 (403)
15--- 7/8 (403)
19--- 3/8 (492)
19--- 3/8 (492)
15--- 7/8 (403)
19--- 3/8 (492)
19--- 3/8 (492)
19--- 3/8 (492)
22--- 7/8 (581)
22--- 7/8 (581)
12--- 11/16 (322)
12--- 11/16 (322)
12--- 11/16 (322)
12--- 11/16 (322)
16 (406)
16 (406)
19--- 1/2 (495)
19--- 1/2 (495)
16 (406)
19--- 1/2 (495)
19--- 1/2 (495)
19--- 1/2 (495)
23 (584)
23 (584)
* 5 ---in. or 6 ---in. (127 or 152 mm) vent connector may be required in some cases.
3
F
C.L. TOP AND
BOTTOM FLUE
COLLAR
IN (mm)
9--- 5/16 (237)
9--- 5/16 (237)
9--- 5/16 (237)
9--- 5/16 (237)
11--- 9/16 (294)
11--- 9/16 (294)
13--- 5/16 (338)
13--- 5/16 (338)
11--- 9/16 (294)
13--- 5/16 (338)
13--- 5/16 (338)
13--- 5/16 (338)
15--- 1/16 (383)
15--- 1/16 (383)
FLUE
COLLAR*
IN (mm)
4
4
4
4
4
4
4
4
4
4
4
4
4
4
(102)
(102)
(102)
(102)
(102)
(102)
(102)
(102)
(102)
(102)
(102)
(102)
(102)
(102)
SHIP WT
LB (KG)
104 (47)
107 (48)
111 (50)
115 (52)
126 (57)
127 (58)
140 (64)
146 (66)
135 (61)
146 (66)
152 (69)
149 (68)
163 (74)
170 (77)
310A
Fig. 2 --- Clearances to Combustibles
80
A08471
NOTE: Remove all shipping brackets and materials before
operating the furnace.
/ 27 C
CODES AND STANDARDS
Follow all national and local codes and standards in addition
to these instructions. The installation must comply with
regulations of the serving gas supplier, local building, heating,
plumbing, and other codes. In absence of local codes, the
installation must comply with the national codes listed below and
all authorities having jurisdiction. In the United States and
Canada, follow all codes and standards for the following:
60
Fig. 3 --- Return Air Temperature
Step 1 —Safety
S US: National Fuel Gas Code (NFGC) NFPA
/ 16 C
54--2006/ANSI Z223.1--2006 and the Installation
Standards, Warm Air Heating and Air Conditioning
Systems ANSI/NFPA 90B
A06745
S
For accessory installation details, refer to the applicable
instruction literature.
CANADA: CSA B149.1--05 National Standard of
Canada Natural Gas and Propane Installation Codes
(CAN/CSA--B149.1--05)
Step 2 —General Installation
4
S
Step 8 —Venting
S US: NFGC NFPA 54 / ANSI Z223.1--2006; chapters
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).
12 and 13
S
ELECTROSTATIC DISCHARGE (ESD)
PRECAUTIONS PROCEDURE
CANADA: CAN/CSA--B149.1--05. For a copy, contact Standard Sales, CSA International, 178 Rexdale
Boulevard, Etobicoke (Toronto), Ontario, M9W 1R3
Canada
!
Step 3 —Combustion and Ventilation Air
S US: Section 9.3 of the NFGC, NFPA 54 / ANSI
Failure to follow this caution may result in furnace
component damage.
CANADA: Part 8 of CAN/CSA--B149.1--05, Venting
Systems and Air Supply for Appliances
Electrostatic discharge can affect electronic components.
Follow the Electrostatic Discharge Precautions Procedure
listed below during furnace installation and servicing to
protect the furnace electronic control. Precautions will
prevent electrostatic discharges from personnel and hand
tools which are held during the procedure. These
precautions will help to avoid exposing the control to
electrostatic discharge by putting the furnace, the control,
and the person at the same electrostatic potential.
Step 4 —Duct Systems
S 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.
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.).
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.
Step 5 —Acoustical Lining and Fibrous Glass
Duct
S US and CANADA: current edition of SMACNA and
NFPA 90B as tested by UL Standard 181 for Class I
Rigid Air Ducts
Step 6 —Gas Piping and Gas Pipe Pressure
Testing
S US: NFGC; NFPA 54 / ANSI Z223.1--2006 chapters 5,
6, 7 and 8 and National Plumbing Codes
S
CANADA: CAN/CSA--B149.1--05 Parts 4, 5, and 6
and Appendices A, B, E, and H.
Step 7 —Electrical Connections
S US: National Electrical Code (NEC) ANSI/NFPA
70--2008
S
CAUTION
FURNACE RELIABILITY HAZARD
Z223.1--2006 Air for Combustion and Ventilation
S
CANADA: CAN/CSA--B149.1--05 Part 8 and Appendix C
CANADA: Canadian Electrical Code CSA C22.1
5
310A
S
THE BLOWER IS
LOCATED BELOW THE
BURNER SECTION, AND
CONDITIONED AIR IS
DISCHARGED UPWARD.
310A
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
Fig. 4 --- Multipoise Orientations
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.
S
not be installed directly on any combustible material
other than wood flooring (refer to SAFETY
CONSIDERATIONS).
S
be located as close to the chimney or vent and attached
to an air distribution system. Refer to Air Ducts section.
S
be provided ample space for servicing and cleaning.
Always comply with minimum fire protection clearances shown on the furnace clearance to combustible
label.
S
The following types of furnace installations may require OUTDOOR AIR for combustion due to chemical
exposures:
S
S
S
S
S
Commercial buildings
S
S
S
S
S
S
S
S
S
S
S
S
S
Permanent wave solutions
LOCATION
!
WARNING
CARBON MONOXIDE POISONING AND UNIT
DAMAGE HAZARD
Failure to follow this warning could result in personal
injury or death, and unit component damage.
Buildings with indoor pools
Laundry rooms
Hobby or craft rooms, and
Chemical storage areas
If air is exposed to the following substances, it should not be used
for combustion air, and outdoor air may be required for
combustion:
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.
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.
This furnace must:
S
A02097
be installed so the electrical components are protected
from water.
6
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.
!
WARNING
FIRE AND EXPLOSION HAZARD
Failure to follow this warning could result in personal
injury, death, and/or property damage.
When the furnace is installed in a residential garage, the
burners and ignition sources must be located at least 18
inches above the floor. The furnace must be located or
protected to avoid damage by vehicles. When the furnace is
installed in a public garage, airplane hangar, or other
building having a hazardous atmosphere, the furnace must
be installed in accordance with the NFGC or
CAN/CSA--B149.1--05. (See Fig. 5.)
!
18-IN. (457.2 mm)
MINIMUM TO BURNERS
!
CAUTION
A93044
310A
Fig. 5 --- Installation in a Garage
WARNING
FIRE HAZARD
PERSONAL INJURY AND/OR PROPERTY
DAMAGE HAZARD
Failure to follow this warning could result in personal
injury, death and/or property damage.
Failure to follow this caution may result in furnace
component damage.
Do not install the furnace on its back or hang furnace with
control compartment facing downward. Safety control
operation will be adversely affected. Never connect
return--air ducts to the back of the furnace. (See Fig. 6.)
This gas furnace may be used for heating buildings under
construction provided that:
--The furnace is permanently installed with all electrical
wiring, piping, venting and ducting installed according to
these installation instructions. A return air duct is provided,
sealed to the furnace casing, and terminated outside the
space containing the furnace. This prevents a negative
pressure condition as created by the circulating air blower,
causing a flame rollout and/or drawing combustion
products into the structure.
--The furnace is controlled by a thermostat. It may not be
hot wired to provide heat continuously to the structure
without thermostatic control.
--Clean outside air is provided for combustion. This is to
minimize the corrosive effects of adhesives, sealers and
other construction materials. It also prevents the
entrainment of drywall dust into combustion air, which can
cause fouling and plugging of furnace components.
Fig. 6 --- Prohibit Installation on Back
--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.
A02054
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 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.
AIR FOR COMBUSTION AND
VENTILATION
--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.
Provisions for adequate combustion, ventilation, and dilution air
must be provided in accordance with:
--Verify proper furnace operating conditions including
ignition, gas input rate, air temperature rise, and venting
according to these installation instructions.
7
S
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.
S
Canadian installations: Part 8 of CAN/CSA-B149.1--05, Venting Systems and Air Supply for Appliances, and all authorities having jurisdiction.
!
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. 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. 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 square inch 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 Air 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.
CAUTION
FURNACE CORROSION HAZARD
Failure to follow this caution may result in furnace damage.
Air for combustion must not be contaminated by halogen
compounds, which include fluoride, chloride, bromide, and
iodide. These elements can corrode heat exchangers and
shorten furnace life. Air contaminants are found in aerosol
sprays, detergents, bleaches, cleaning solvents, salts, air
fresheners, and other household products.
!
WARNING
310A
CARBON MONOXIDE POISONING HAZARD
Failure to follow this warning could result in personal
injury or death.
The operation of exhaust fans, kitchen ventilation fans,
clothes dryers, attic exhaust fans or fireplaces could create a
NEGATIVE PRESSURE CONDITION at the furnace.
Make--up air MUST be provided for the ventilation devices,
in addition to that required by the furnace. Refer to Carbon
Monoxide Poisoning Hazard warning in venting section of
these instructions to determine if an adequate amount of
make--up air is available.
The requirements for combustion and ventilation air depend
upon whether or not the furnace is located in a space having a
volume of at least 50 cu/ft. per 1,000 Btuh input rating for all gas
appliances installed in the space.
S
Spaces having less than 50 cu/ft. per 1,000 Btuh require the OUTDOOR COMBUSTION AIR
METHOD.
!
Spaces having at least 50 cu/ft. 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.
S
WARNING
CARBON MONOXIDE POISONING HAZARD
Failure to follow this warning could result in death and/or
personal injury.
Many homes require air to be supplied from outdoors for
furnace combustion, ventilation, and dilution of flue gases.
The furnace combustion air supply must be provided in
accordance with this instruction manual.
8
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
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)
30
ACH
40
FAN-ASSISTED TOTAL
(1,000’S BTUH GAS INPUT RATE)
50
44
66
88
110
132
154
Space Volume Ft3 (M3)
0.60
1,050
(29.7)
1,400
(39.6)
1,750
(49.5)
1,100
(31.1)
1,650
(46.7)
2,200
(62.2)
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
NP = Not Permitted
9
310A
FURNACE
310A
1 SQ IN.
PER 2000
BTUH*
(305mm) 12″ MAX
A
F
1 SQ IN.
PER
4000
BTUH*
INTERIOR
HEATED
SPACE
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
1 SQ IN.
PER
4000
BTUH*
E
G
12″ (305mm)
MAX
C
DUCT
TO
OUTDOORS
A03174
The Standard Method:
1. The space has no less volume than 50 cu/ft. 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).
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:
3
I other
= 21ft
Other
ACH 1000 Btu/hr
A04002
2. For fan--assisted appliances such as this furnace:
3
I fan
= 15ft
ACH 1000 Btu/hr
A04003
If:
6" MIN (152mm)
(FRONT)Ü
1 SQ IN.
PER 1000
BTUH* IN DOOR
OR WALL
* 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.
A03175
Fig. 7 --- Air for Combustion, Ventilation, and Dilution for
Outdoors
Fan
UNCONFINED
SPACE
1 SQ IN.
PER 4000
BTUH*
NOTE: Use any of the following combinations of openings:
A&BC&DD&EF&G
Volume
1 SQ IN.
PER 1000
BTUH* IN DOOR
OR WALL
CIRCULATING AIR DUCTS
*Minimum dimensions of 3--- in. (76 mm).
Volume
12" MAX (305mm)
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 4000
BTUH*
DUCTS
TO
OUTDOORS
Fig. 8 --- Air for Combustion, Ventilation, and Dilution from
Indoors
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.
10
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.
5/ 16″
(8mm)
(8mm)
5/ 16″
1 3/4″
(44mm)
1 3/4″
(44mm)
(8mm)
5/16″
(8mm)
5/ 16″
(44mm) 1 3/ 4″
3/
(44mm) 1 4″
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.)
Fig. 10 --- Leveling Legs
A89014
Leveling Legs (If Desired)
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 and
nut in hole. (Install flat washer if desired.)
3. Install another nut on other side of furnace base. (Install
flat washer if desired.)
4. Adjust outside nut to provide desired height, and tighten
inside nut to secure arrangement.
5. Reinstall bottom closure panel if removed.
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
Fig. 9 --- Removing Bottom Closure Panel
310A
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).
A02098
Special Base, KGASB
Cased Coil Assembly Part No. CNPV, CNRV, CAR,
or CAP
S 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. CNPV, CNRV, CAR,
or CAP or Coil Box Part No. KCAKC is used, install as
shown in Fig. 13.
2. Rotate bottom filler panel downward to release holding
tabs.
3. Remove bottom closure panel.
4. Reinstall bottom filler panel and screws.
Side Return Air Inlet
These furnaces are shipped with bottom closure panel installed in
bottom return--air opening. This panel MUST be in place when
only side return air is used.
NOTE: Side return--air openings can be used in UPFLOW and
most HORIZONTAL configurations. Do not use side return--air
openings in DOWNFLOW configuration.
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
11
FURNACE
APPROVED
COIL ASSEMBLY
OR
COIL BOX
A
COMBUSTIBLE
FLOORING
PLENUM
OPENING
D
B
FLOOR
OPENING
SHEET METAL
PLENUM
C
310A
FLOOR
OPENING
Fig. 11 --- Floor and Plenum Opening Dimensions
A96283
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.)
FURNACE
(OR COIL CASING
WHEN USED)
A08556
Fig. 13 --- Furnace, Plenum, and Coil Assembly or Coil Box
Installed on a Combustible Floor
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.
HORIZONTAL INSTALLATION
COMBUSTIBLE
FLOORING
!
WARNING
FIRE, EXPLOSION, AND CARBON MONOXIDE
POISONING HAZARD
DOWNFLOW
SUBBASE
Failure to follow this warning could result in personal
injury, death, or property damage.
SHEET METAL
PLENUM
FLOOR
OPENING
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.
A96285
Fig. 12 --- Furnace, Plenum, and Subbase Installed on a
Combustible Floor
The furnace can be installed horizontally in an attic or crawl
space on either the left--hand (LH) or right--hand (RH) side. The
furnace can be hung from floor joists, rafters or trusses or
installed on a non--combustible platform, blocks, bricks or pad.
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 3/4--in. (19 mm) screws into
the side and 2 #8 x 3/4--in. (19 mm) screws in the bottom of the
furnace casing for each strap. (See Fig. 15 and 16.)
12
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) is used without a bottom return air inlet.
Not all horizontal furnaces are approved for side return air
connections. (See Fig. 20.)
FILTER ARRANGEMENT
!
WARNING
CARBON MONOXIDE AND POISONING HAZARD
Failure to follow this warning could result in personal
injury, death and/or property damage.
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.
Refer to the instructions supplied with Media Cabinet for
assembly and installation options.
A field--supplied accessory external filter rack is required.
This furnace requires KGAFR030ALL 1 in. (25 mm) external
filter rack or a suitable field--supplied substitute, such as the
media cabinet.
Refer to the instructions supplied with external filter rack for
assembly and installation options.
13
310A
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 crawl space
installations, if the furnace is not suspended from the floor joists,
the ground underneath furnace must be level and the furnace set
on blocks or bricks.
Roll--Out Protection
Provide a minimum 17--3/4 in. x 22 in. (451 x 559 mm) piece of
sheet metal for flame roll--out protection in front of burner area
for furnaces closer than 12 inches (305 mm) above the
combustible deck or suspended furnaces closer than 12 inches
(305 mm) to joists. The sheet metal MUST extend underneath the
furnace casing by 1 in. (25 mm) with the door removed.
The bottom closure panel on furnaces of widths 17--1/2 in. (445
mm) and larger may be used for flame roll--out protection when
bottom of furnace is used for return air connection. See 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 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.
Table 4—Opening Dimensions -- In. (mm)
FURNACE
CASING
WIDTH
14–3/16
(360)
310A
17–1/2
(445)
21
(533)
24--- 1/2
(622)
PLENUM OPENING
APPLICATION
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)
AIR DUCTS
General Requirements
The duct system should be designed and sized according to
accepted national standards such as those published by: Air
Conditioning Contractors Association (ACCA), Sheet Metal and
Air Conditioning Contractors National Association (SMACNA)
or American Society of Heating, Refrigerating and Air
Conditioning Engineers (ASHRAE) or consult The Air Systems
Design Guidelines reference tables available from your local
distributor. The duct system should be sized to handle the
required system design CFM at the design external static pressure.
The furnace airflow rates are provided in Table 5--AIR
DELIVERY--CFM (With Filter).
When a furnace is installed so that the supply ducts carry air
circulated by the furnace to areas outside the space containing the
furnace, the return air shall also be handled by duct(s) sealed to
the furnace casing and terminating outside the space containing
the furnace.
Secure ductwork with proper fasteners for type of ductwork used.
Seal supply-- and return--duct connections to furnace with code
approved tape or duct sealer.
NOTE: Flexible connections should be used between ductwork
and furnace to prevent transmission of vibration. Ductwork
passing through unconditioned space should be insulated and
sealed 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.
FLOOR OPENING
A
12--- 11/16
(322)
12--- 9/16
(319)
11--- 13/16
(284)
B
21--- 5/8
(549)
19
(483)
19
(483)
C
13--- 5/16
(338)
13--- 3/16
(335)
13--- 7/16
(341)
D
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)
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.
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.
14
FURNACE
SIZE
RETURN---AIR
INLET
045---08 /
024045
Bottom or
Side(s)
045---12 /
036045
Bottom or
Side(s)
070---08 /
024070
Bottom or
Side(s)
070---12 /
036070
Bottom or
Side(s)
070---16 /
048070
Bottom or
Side(s)
090---14 /
042090
Bottom or
Side(s)
090---16 /
048090
Bottom or
Side(s)
Bottom Only
090---20 /
060090
Both Sides or 1
Side & Bottom
1Side Only
110---12 /
036110
Bottom or
Side(s)
110---16 /
048110
Bottom or
Side(s)
Bottom Only
110---22 /
066110
Bottom Sides
or 1 Side & Bottom
1Side Only
SPEED
High
Med --- High
Med --- Low
High
Med --- High
Med --- Low
High
Med --- High
Med --- Low
High
Med --- High
Med --- Low
High
Med --- High
Med --- Low
High
Med --- High
Med --- Low
High
Med --- High
Med --- Low
High
Med --- High
Med --- Low
High
Med --- High
Med --- Low
High
Med --- High
Med --- Low
High
Med --- High
Med --- Low
High
Med --- High
Med --- Low
High
Med --- High
Med --- Low
High
Med --- High
Med --- Low
High
Med --- High
Med --- Low
0.1
1085
920
820
1440
1360
1250
1030
835
725
1425
1320
1200
1805
1630
1460
1650
1515
1385
2060
1790
1505
2405
2225
2020
2530
2285
1995
2475
2260
1950
1625
1510
1360
2035
1745
1530
2530
2230
1920
--- --2235
1920
2540
2125
--- ---
0.2
1035
875
775
1375
1300
1210
1010
815
700
1375
1280
1175
1740
1585
1420
1600
1485
1360
1985
1765
1505
2310
2155
1955
2450
2215
1945
2395
2190
1910
1575
1470
1335
1965
1710
1515
2470
2205
1900
--- --220
1900
2495
2120
1795
EXTERNAL STATIC PRESSURE (IN. WC)
0.3
0.4
0.5
0.6
0.7
0.8
975
915
845
770
675
565
830
770
710
640
555
440
730
680
620
555
470
360
1305
1240
1160
1070
975
870
1240
1175
1115
1040
950
850
1160
1100
1040
965
885
790
980
945
900
845
775
680
790
760
720
675
610
490
675
645
600
555
475
390
1320
1265
1200
1125
1035
940
1240
1205
1140
1075
995
905
1145
1105
1050
990
920
840
1670
1600
1530
1445
1360
1280
1530
1470
1405
1330
1255
1170
1385
1325
1280
1220
1155
1080
1535
1465
1385
1285
1175
1055
1440
1380
1300
1220
1115
990
1320
1260
1195
1120
1025
915
1915
1820
1720
1610
1490
1340
1715
1645
1560
1470
1345
1195
1480
1440
1375
1300
1190
1045
2220
2130
2025
1920
1790
1660
2080
1995
1895
1785
1675
1565
1880
1805
1730
1630
1535
1420
2365
2270
2165
2065
1940
1805
2150
2075
1985
1890
1780
1660
1900
1840
1770
1685
1600
1480
2300
2200
2090
1985
1865
1730
2110
2035
1940
1845
1735
1620
1855
1795
1730
1650
1555
1445
1515
1445
1355
1260
1165
990
1415
1355
1285
1185
1070
890
1295
1250
1180
1100
985
810
1880
1790
1680
1495
1365
1215
1650
1560
1450
1340
1205
1090
1470
1400
1310
1215
1095
990
2400
2320
2220
2115
2000
1865
2165
2110
2035
1950
1855
1740
1880
1845
1795
1730
1650
1555
2415
2350
2250
2145
2015
1875
2155
2100
2040
1955
1850
1740
1880
1845
1795
1730
1650
1555
2430
2355
2265
2175
2065
1935
2105
2060
2010
1940
1840
1730
1790
1765
1720
1650
1585
1500
0.9
390
250
190
730
725
670
490
375
300
830
790
725
1180
1080
995
895
830
710
1135
1010
890
1530
1420
1275
1670
1525
1350
1585
1475
1310
785
725
--- --1075
955
830
1730
1615
1460
1715
1595
1460
1785
1615
1390
1.0
195
--- ----- --560
575
520
335
265
--- --655
620
555
1075
990
910
645
600
565
925
820
740
1350
1260
1135
1505
1360
1180
1425
1325
1150
--- ----- ----- --875
750
670
1590
1485
1340
1560
1470
1340
1650
1485
1280
* A filter is required for each return ---air inlet. Airflow performance included 3/4 ---in. (19 mm) washable filter media such as contained in factory ---authorized accessory filter rack. To determine airflow performance without this filter, assume an additional 0.1 in. wc available external static pressure.
--- --- Indicates unstable operating conditions.
15
310A
Table 5—Air Delivery -- CFM (with Filter)*
Table 5⎯ Air Delivery -- CFM (with Filter)* (Continued)
FURNACE
SIZE
048135
RETURN---AIR
INLET
Bottom or
Side(s)
Bottom Only
066135
Bottom, Sides
or 1 Side & Bottom
1 Side Only
310A
Bottom Only
060155
Both Sides Or 1
Side & Bottom
1Side Only
SPEED
High
Med --- High
Med --- Low
High
Med --- High
Med --- Low
High
Med --- High
Med --- Low
High
Med --- High
Med --- Low
High
Med --- High
Med --- Low
High
Med --- High
Med --- Low
High
Med --- High
Med --- Low
0.1
2090
1790
1545
2485
2195
1880
--- --“2180
1880
--- --2135
1880
2465
2115
1800
--- --2155
1800
--- --2140
1800
0.2
2010
1755
1525
2400
2150
1850
--- --2145
1850
--- --2085
1850
2430
2105
1790
--- --2135
1790
--- --2095
1790
EXTERNAL STATIC PRESSURE (IN. WC)
0.3
0.4
0.5
0.6
0.7
0.8
1930
1835
1710
1590
1470
1335
1705
1640
1550
1465
1360
1210
1500
1450
1380
1315
1215
1005
2310
2215
2110
2000
1880
1725
2090
2000
1920
1825
1720
1565
1820
1780
1715
1635
1540
1415
2385
2305
2195
2085
1960
1825
2060
2010
1945
1865
1765
1660
1820
1780
1715
1635
1540
1415
2245
2155
2055
1940
1825
1695
2035
1975
1895
1795
1685
1565
1820
1780
1715
1635
1540
1415
2375
2305
2230
2110
2000
1865
2075
2030
1980
1910
1830
1725
1770
1735
1695
1640
1570
1465
2375
2285
2200
2105
1995
1870
2095
2040
1975
1895
1790
1685
1770
1735
1695
1640
1570
1465
2260
2180
2085
1975
1865
1740
2040
1975
1890
1810
1705
1595
1770
1735
1695
1640
1570
1465
0.9
1025
945
855
1535
1405
1290
1670
1515
1290
1555
1445
1290
1725
1590
1345
1730
1550
1345
1605
1480
1345
1.0
835
785
670
1355
1255
1160
1465
1325
1160
1385
1265
1160
1545
1425
1225
1570
1400
1225
1455
1325
1225
* A filter is required for each return ---air inlet. Airflow performance included 3/4 ---in. (19 mm) washable filter media such as contained in factory ---authorized accessory filter rack. To determine airflow performance without this filter, assume an additional 0.1 in. wc available external static pressure.
--- --- Indicates unstable operating conditions.
DOWNFLOW
UPFLOW
HORIZONTAL
90˚
90˚
YES
YES
120˚
MIN
YES
120˚
MIN
NOT
RECOMMENDED
YES
YES
120˚
MIN
NOT
RECOMMENDED
Fig. 14 --- Duct Flanges
16
YES
NOT
RECOMMENDED
A02329
" (6mm) THREADED ROD
4 REQ.
1/4
310A
OUTER DOOR
ASSEMBLY
SECURE ANGLE
IRON TO BOTTOM
OF FURNACE WITH
3 #8 x 3/4" (19mm) SCREWS
TYPICAL FOR 2 SUPPORTS
8" (203mm) MIN
FOR DOOR REMOVAL
1” (25mm) SQUARE, 1-1/4”x1-1/4”x1/8” (32x32x3mm)
ANGLE IRON OR UNI-STRUT MAY BE USED
(2) HEX NUTS, (2) WASHERS & (2) LOCK WASHERS
REQ. PER ROD
Fig. 15 --- Horizontal Unit Suspension
Fig. 16 --- Horizontal Suspension with Straps
17
A05027
A02014
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-IN. (451 mm) OVER ALL
4 3/4−IN. (121 mm) UNDER DOOR
1-IN. (25 mm) UNDER FURNACE
GAS
ENTRY
6-IN.
TYPE-B
VENT
IN*
m) M
52 m
EXTEND OUT 12−IN. (305 mm)
OUT FROM FACE OF DOOR
(1
30-IN. MIN
WORK AREA
* WHEN USED WITH
SINGLE WALL VENT
CONNECTIONS
17 3/4 -IN. (451 mm)
SHEET
METAL
310A
22-IN. (559 mm)
MANUAL SHUTOFF
GAS VALVE
SEDIMENT
TRAP
Fig. 17 --- Typical Attic Installation
Fig. 18 --- Upflow Return Air Configurations and Restrictions
18
A02164
A02075
310A
Fig. 19 --- Downflow Return Air Configurations and Restrictions
Fig. 20 --- Horizontal Return Air Configurations and Restrictions
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
A02163
A02162
temporarily while the remaining attachment and sealing of the
coil are performed.
Downflow Furnaces
Connect supply--air duct to supply--air outlet on furnace. Bend
flange inward past 90_ with wide duct pliers. (See Fig. 14.) The
supply--air duct must be connected to ONLY the furnace
supplyoutlet 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
19
other accessories. All accessories MUST be connected to duct
external to furnace casing.
!
WARNING
FIRE HAZARD
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.
A failure to follow this warning could result in personal
injury, or death and/or property damage.
Table 6—Maximum Capacity of Pipe
NOMINAL
IRON
PIPE SIZE
IN. (MM)
310A
Never connect return--air ducts to the back of the
furnace. Follow instructions below.
Return Air Connections
Downflow Furnaces
The return--air duct must be connected to return--air opening
(bottom inlet) as shown in Fig. 19. DO NOT cut into casing sides
(left or right). Side opening is permitted for only upflow and most
horizontal furnaces. (See Fig. 19.) Bypass humidifier connections
should be made at ductwork or coil casing sides exterior to
furnace.
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. 18 and 20. Bypass humidifier may be
attached into unused return air side of the furnace casing. (See
Fig. 18 and 20.)
Not all horizontal furnaces are approved for side return air
connections. (See Fig. 20.)
GAS PIPING
!
175
120
97
82
73
3/4 (19.0)
0.824
(20.9)
360
250
200
170
151
1( 25.4)
1.049
(26.6)
680
465
375
320
285
1.380
(35.0)
1400
950
770
660
580
1.610
(40.9)
2100
1460
1180
990
900
WARNING
Failure to follow this warning could result in personal
injury, death, and/or property damage.
If local codes allow the use of a flexible gas appliance
connector, always use a new listed connector. Do not use a
connector which has previously served another gas
appliance. Black iron pipe shall be installed at the furnace
gas control valve and extend a minimum of 2 in. (51 mm)
outside the furnace.
!
CAUTION
FURNACE OVERHEAT HAZARD
Failure to follow this caution may result in unit component
damage.
WARNING
Gas piping must be installed in accordance with national and
local codes. Refer to current edition of NFGC in the U.S., 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.
NOTE: In the state of Massachusetts:
1. Gas supply connections MUST be performed by a licensed plumber or gas fitter.
2. When flexible connectors are used, the maximum length
shall not exceed 36 inches (915 mm).
3. When lever handle type manual equipment shutoff valves
are used, they shall be T--handle valves.
4. The use of copper tubing for gas piping is NOT approved
by the state of Massachusetts.
50
(15.2)
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.
Use proper length of pipe to avoid stress on gas control
manifold and a gas leak.
40
(12.1)
!
Failure to follow this warning could result in personal
injury, death, and/or property damage.
Failure to follow this warning could result in personal
injury, death, and/or property damage.
30
(9.1)
LENGTH OF PIPE --- FT (M)
* Cubic ft. of natural 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 6.2 ANSI Z223 ---2006/NFPA 54 ---2006.
WARNING
FIRE OR EXPLOSION HAZARD
20
(6.0)
1-1/4
(31.8)
1-1/2
(38.1)
FIRE OR EXPLOSION HAZARD
!
10
(3.0)
1/2 (12.7)
INTERNA
L
DIA.
IN. (MM)
0.622
(158)
Connect gas pipe to gas valve 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 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. 47.)
20
FACTORY
INSTALLED
LOCATION
TWO
ALTERNATE
FIELD
LOCATIONS
2” (51mm)
Street Elbow
Fig. 21 --- Burner and Manifold
A08551
Fig. 23 --- Relocating J--Box
A02099
310A
Some installations require gas entry on right side of furnace (as
viewed in upflow.) (See Fig. 21.)
Install a sediment trap in riser leading to furnace as shown in Fig
22. Connect a capped nipple into lower end of tee. Capped nipple
should extend below level of furnace gas controls. Place a ground
joint union between furnace gas control valve 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.
GAS
SUPPLY
MANUAL
SHUTOFF
VALVE
(REQUIRED)
SEDIMENT
TRAP
UNION
A03221
Fig. 24 --- Field--Supplied Electrical Box on Furnace Casing
Fig. 22 --- Typical Gas Pipe Arrangement
A02035
Piping should be pressure and leak tested in accordance with
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.
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.
See Fig. 26 for field wiring diagram showing typical field 115--v
wiring. Check all factory and field electrical connections for
tightness.
21
!
WARNING
ELECTRICAL SHOCK AND FIRE HAZARD
Failure to follow this warning could result in personal
injury, death, or property damage.
310A
The cabinet MUST have an uninterrupted or unbroken
ground according to NEC ANSI/NFPA 70--2008 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.
!
CAUTION
FURNACE MAY NOT OPERATE
Failure to follow this caution may result in intermittent
furnace operation.
Furnace control must be grounded for proper operation or
else control will lock out. Control must remain grounded
through green/yellow wire routed to gas valve and manifold
bracket screw.
115--V WIRING
Verify that the voltage, frequency, and phase correspond to that
specified on unit rating plate. Also, check to be sure that service
provided by utility is sufficient to handle load imposed by this
equipment. Refer to rating plate or Table 7 for equipment
electrical specifications.
U.S. installations: Make all electrical connections in accordance
with National Electrical Code (NEC) ANSI/NFPA 70--2008 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.
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.
23.)
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 two screws removed in Step
1.
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. 24.
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. 26.
6. Reinstall cover to J--Box. Do not pinch wires between
cover and bracket. Electrical Box on Furnace Casing Side
See Fig. 24.
!
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.
23.)
5. Pull furnace power wires out of 1/2--inch 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.
22
Table 7—Electrical Data
045---08/024045
045---12/036045
070---08/024070
070---12/036070
070---16/048070
090---14/042090
090---16/048090
090---20/060090
110---12/036110
110---16/048110
110---22/066110
135---16/048135
135---22/066135
155---20/060155
115--- 60--- 1
115--- 60--- 1
115--- 60--- 1
115--- 60--- 1
115--- 60--- 1
115--- 60--- 1
115--- 60--- 1
115--- 60--- 1
115--- 60--- 1
115--- 60--- 1
115--- 60--- 1
115--- 60--- 1
115--- 60--- 1
115--- 60--- 1
OPERATING VOLTAGE
RANGE
Maximum*
127
127
127
127
127
127
127
127
127
127
127
127
127
127
Minimum*
104
104
104
104
104
104
104
104
104
104
104
104
104
104
MAXIMUM
UNIT
AMPS
UNIT
AMPACITY#
5.4
7.0
5.0
6.8
9.5
8.2
10.0
13.6
8.2
10.1
14.8
10.2
14.4
15.0
7.54
9.50
7.06
9.22
12.60
10.83
13.13
17.61
10.75
13.12
18.99
13.27
18.55
19.33
MAXIMUM
WIRE
LENGTH
FT. (M)‡
49 (15)
39 (12)
52 (16)
40 (12)
29 (9)
34 (10)
28 (9)
32 (8)
34 (10)
28 (9)
30 (9)
27 (8)
30 (9)
29 (9)
MAXIMUM
FUSE OR
CKT BKR
AMPS†
15
15
15
15
15
15
15
20
15
15
20
15
20
20
MINIMUM
WIRE
GAUGE
14
14
14
14
14
14
14
12
14
14
12
14
12
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 unit and service panel for maximum 2 percent voltage drop.
12. Complete electrical box wiring and installation. Connect
line voltage leads as shown in Fig. 26. 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.
POWER CORD INSTALLATION IN FURNACE J--BOX
NOTE: Power cords must be able to handle the electrical
requirements listed in Table 7. Refer to power cord
manufacturer’s listings.
1. Remove cover from J--Box.
2. Route listed power cord through 7/8--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--inch (22 mm) diameter hole in
J--Box.
3. Secure BX cable to J--Box bracket with connectors approved for the type of cable used.
4. Secure field ground wire to green ground screw on J--Box
bracket.
5. Connect line voltage leads as shown in Fig. 26.
6. Reinstall cover to J--Box. Do not pinch wires between
cover and bracket.
23
310A
FURNACE SIZE
VOLTS--HERTZ--PHASE
TWINNING AND/OR
COMPONENT TEST
TERMINAL
BLOWER OFF-DELAY
J2 JUMPER
BLOWER OFF-DELAY
120 180
90 150
J2
G
24-V THERMOSTAT
TERMINALS
HUMIDIFIER TERMINAL
(24-VAC 0.5 AMP MAX.)
Com
24V
TRANSFORMER 24-VAC
CONNECTIONS
W
PLT
Y
TEST/TWIN
R
HUM
0.5 AMP@24VAC
310A
NUETRAL BLW
STATUS CODE LED
3-AMP FUSE
FUSE 3-AMP
SEC-2 SEC-1
L2
PL1-LOW VOLTAGE MAIN
HARNESS CONNECTOR
1
115-VAC(L2)NEUTRAL
CONNECTIONS
EAC-2
PLT
LED OPERATION &
DIAGNOSTIC LIGHT
COOL
HEAT
COOL
HEAT
1-AMP@
EAC-1 115VAC
SPARE-1
PL2
1
115 VAC (L1) LINE
VOLTAGE CONNECTION
SPARE-2
BLOWER SPEED
SELECTION TERMINALS
PR-1
L1
SPARE-1 SPARE-2
PL2-HOT SURFACE
IGNITER & INDUCER
MOTOR CONNECTOR
EAC-1 TERMINAL
(115-VAC 1.0 AMP MAX.)
A02100
Fig. 25 --- Furnace Control
FIELD 24-V WIRING
FIELD 115-, 208/230-, 460-V WIRING
FACTORY 24-V WIRING
FACTORY 115-V WIRING
NOTE 2
FIVE WIRE
THREE-WIRE
HEATING-ONLY
W
C
R
G
Y
THERMOSTAT
TERMINALS
FIELD-SUPPLIED
DISCONNECT
208/230- OR
460-V
THREE
PHASE
BLOWER DOOR SWITCH
BLK
W
BLK
WHT
WHT
GND
GND
115-V FIELDSUPPLIED
DISCONNECT
AUXILIARY
J-BOX
C
O
N
T
R
O
L
R
208/230-V
SINGLE
PHASE
G
COM
GND
NOTE 1
CONDENSING
UNIT
Y/Y2
24-V
TERMINAL
BLOCK
FURNACE
TWO
WIRE
NOTES: 1. Connect Y-terminal in furnace as shown for proper blower 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.
Fig. 26 --- Heating and Cooling Application Wiring Diagram with Single Stage Thermostat
24
A99440
!
WARNING
CARBON MONOXIDE POISONING HAZARD
Failure to follow the steps outlined below for each
appliance connected to the venting system being placed into
operation could result in carbon monoxide poisoning or
death.
The following steps shall be followed for each appliance
connected to the venting system being placed into
operation, while all other appliances connected to the
venting system are not in operation:
1. Seal any unused openings in venting system.
2. Inspect the venting system for proper size and horizontal
pitch, as required in the National Fuel Gas Code, ANSI
Z223.1/NFPA 54 or 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, ANSI Z223.1/NFPA 54
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.
These furnaces are design--certified as Category I furnaces in
accordance with ANSI Z21.47--2006/CSA 2.3--2006 and operate
with a non--positive vent static pressure to minimize the potential
for vent gas leakage. Category I furnaces operate with a flue loss
not less than 17 percent to minimize the potential for
condensation in the venting system. These furnaces are approved
for common venting and multistory venting with other fan
assisted or draft hood equipped appliances in accordance with the
NFGC or the CAN/CSA--B149.1--05, 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 and the
CAN/CSA--B149.1--05.
!
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.
25
310A
24--V WIRING
Make field 24--v connections at the 24--v terminal strip. (See Fig.
25.) Connect terminal Y as shown in Fig. 26 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.
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
115 VAC, 1.0 amps maximum and are energized during
blower motor operation. (See Fig. 24.)
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 gas valve relay (GVR) is energized. (See Fig. 24.)
NOTE: A field--supplied, 115--v controlled relay connected to
EAC terminals may be added if humidifier operation is desired
during blower operation.
NOTE: DO NOT connect furnace control HUM terminal to
HUM (humidifier) terminal on Thermidistatt, Zone Controller
or similar device. See Thermidistatt, 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.
Vent system or vent connectors may need to be resized. Vent
systems or vent connectors, must be sized to approach minimum
size as determined using appropriate table found in the NFGC 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 ANSI Z223.1--2006/NFPA 54--2006 (NFGC), Parts 12
and 13 in the United States or the National Standard of Canada,
Natural Gas and Propane Installation Code CSA--B149.1--05
(CAN/CSA--B149.1--05), Section 8 and Appendix C in Canada,
the local building codes, and furnace and vent manufacturers’
instructions.
310A
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. Do not connect 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.
3. Vent connectors serving Category I furnaces shall not be
connected into any portion of a mechanical draft system
operating under positive pressure.
4. In the U.S.: 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.
5. Category I furnaces must be vented vertically or nearly
vertically unless equipped with a listed power venter.
6. Do not vent this appliance into an unlined masonry chimney. Refer to Chimney Inspection Chart, Fig. 27.
MASONRY CHIMNEY REQUIREMENTS
NOTE: These furnaces are CSA design--certified for use in
exterior clay 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 numbers 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 13.1.8 and 13.2.20 of the NFGC 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, 13.1.8 and
13.2.20 regarding alternative venting design and the Exception,
which cover installations such as the Chimney Adapter Kits
KGACA02014FC and KGACA02015FC, which are listed for
use with these furnaces. The Chimney Adapter Kit is 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 in2 (24516 mm2) 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
these furnaces, which are 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. 27 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
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.
26
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
No
No
310A
Is chimney
property lined with
clay tile liner?
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.
Fig. 27 --- Chimney Inspection Chart
27
A03206
310A
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:
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
(7741)
74
80
84
NR
NR
NR
19
(12258)
119
130
138
152
NR
NR
28
(18064)
178
193
207
233
250
NR
38
(24516)
257
279
299
334
368
404
Table B—Minimum Allowable Input Rating of
Space--Heating Appliance in
Thousands of Btuh per Hour
INTERNAL AREA OF CHIMNEY
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_F (16_C) or
lower
Not recommended for any vent configuration.
VENT HEIGHT
FT. (M)
1. The return--air temperature must be at least 60_F (16_C)
db except for brief periods of time during warm--up from
setback at no lower than 55_F (13_C) db or during initial
start--up from a standby condition.
2. Adjust the gas input rate per the installation instructions.
Low gas input rate causes low vent gas temperatures, causing condensation and corrosion in the furnace and/or venting system. Derating is permitted only for altitudes above
2000 ft. (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 thermostat heat anticipator or cycle rate to reduce short
cycling.
*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.
28
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. 33--45 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 3 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.
The vent connector can exit the door through one of 5 locations
on the door.
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. 33--45.
!
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.
3. Orient the door to determine the correct location of the
door cutout to be removed.
4. Use aviation--type tin snips to remove the correct
U--shaped cut--out in door.
NOTE: If this furnace is equipped with knockouts in the door
for the vent, a number of techniques can be used to remove these
knockouts as seen in Fig. 28 through 32. 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. 28.) A sharp blow to the
rounded end of the knockout (See Fig. 29.) will separate more tie
points and allow the knockout to be pulled loose. (See Fig. 30.)
Remove all burrs and sharp edges.
29
310A
A04127
Fig. 28 --- Using Tin Snips to Cut Tie Points
310A
Fig. 29 --- Rounded End of Knockout
A04128
Fig. 30 --- Knockout Pulled Loose
A04129
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. 31.) directly to the knockout tie points or
use a hammer in the upper left corner of the desired knockout.
(See Fig. 32.) Remove all burrs and sharp edges.
!
CAUTION
BURN HAZARD
Failure to follow this caution may cause personal injury.
Hot vent pipe is within reach of small children when
installed in downflow position.
See the following instruction.
An accessory Vent Guard Kit, 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.
The horizontal portion of the venting system shall slope upwards
not less than 1/4--in. (6 mm) 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 venters 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.
A04130
Fig. 31 --- Hammer and Screwdriver Used for Knockout
Fig. 32 --- Remove Knockout with Hammer
30
A04131
START--UP, ADJUSTMENT, AND SAFETY
CHECK
Step 1 —General
WARNING
!
FIRE HAZARD
ELECTRICAL SHOCK HAZARD
Failure to follow this warning could result in personal
injury, death and/or property damage.
Failure to follow this warning could result in personal
injury, or death.
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 inadequate combustion air supply
problem before resetting the switches.
!
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. 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. Install blower compartment door. Door must be in place to
operate furnace.
6. Replace outer door.
Step 2 —Start--Up Procedures
!
WARNING
WARNING
Blower access door switch opens 115--v power to control.
No component operation can occur unless switch is closed.
Caution must be taken when manually closing this switch
for service purposes.
3. To Begin Component Self--Test: Remove blower access
door. Disconnect the thermostat R lead from the furnace
control board. Manually close the blower door switch.
Short (jumper) the COM--24v terminal on control to the
TEST/TWIN 3/16--inch quick connect terminal on control
until LED goes out (approximately 2 sec). Gas valve and
humidifier will not be turned on. (See Fig. 25.)
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.
Component test sequence is as follows:
Refer to service label attached to furnace or see Fig. 50.
a. LED will display previous status code 4 times.
b. Inducer motor starts and continues to run until Step f
of component test sequence.
c. Hot surface igniter is energized for 15 sec., then off.
d. Blower motor operates on HEAT speed for 10 sec.
e. Blower motor operates on COOL speed for 10 sec.
f. Inducer motor stops.
g. Reconnect R lead to furnace control board, release
blower door switch and re--install blower door.
4. Operate furnace per instruction on door.
5. Verify furnace shut down by lowering thermostat setting
below room temperature.
6. Verify furnace restarts by raising thermostat setting above
room temperature.
FIRE AND EXPLOSION HAZARD
Failure to follow this warning could result in personal
injury, death and or property damage.
Never test for gas leaks with an open flame. Use a
commercially available soap solution made specifically for
the detection of leaks to check all connections.
31
310A
!
1. Purge gas lines after all connections have been made.
2. Check gas lines for leaks.
310A
SEE NOTES: 1,2,4,7,8,9
on the page following
these figures
Fig. 33 --- Upflow Application--Vent Elbow Up
SEE NOTES: 1,2,4,5,7,8,9
on the page following
these figures
A03208
Fig. 36 --- Downflow Application--Vent Elbow Up
SEE NOTES: 1,2,4,5,6,7,8,9,10
on the page following these figures
SEE NOTES: 1,2,3,4,7,8,9
on the pages following
these figures
Fig. 34 --- Upflow Application--Vent Elbow Right
A03211
A03209
A03207
Fig. 37 --- Downflow Application--Vent Elbow Left then Up
SEE NOTES:1,2,3,4,5,7,8,9
on the page following
these figures
SEE NOTES:1,2,3,4,5,7,8,9
on the page following
these figures.
A03210
A03212
Fig. 35 --- Downflow Application--Vent Elbow Up then Left
Fig. 38 --- Downflow Application--Vent Elbow Up then Right
32
SEE NOTES: 1,2,4,7,8,9 on the page
following these figures
SEE NOTES: 1,2,4,7,8,9 on the page
following these figures
A03213
A03218
Fig. 43 --- Horizontal Right Application--Vent Elbow Right
310A
Fig. 39 --- Horizontal Left Application--Vent Elbow Left
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
A03214
Fig. 44 --- Horizontal Right Application--Vent Elbow Left
then Up
Fig. 40 --- Horizontal Left Application--Vent Elbow Right
then Up
SEE NOTES: 1,2,4,5,7,8,9
A02068
Fig. 45 --- Horizontal Right Application--Vent Elbow Left
1. For common vent, vent connector sizing and vent material:
United States-- - Use the NFGC
Canada-- - use the CAN/CSA-- B149.1-- 05
SEE NOTES: 1,2,4,5,7,8,9 on the page
following these figures
2. Immediately increase to 5--in. (127 mm) or 6--in. (152 mm) vent
A03215
connector outside furnace casing when 5-- in. (127 mm) vent
connector is required, refer to Note 1 above.
Fig. 41 --- Horizontal Left Application--Vent Elbow Up
3. 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
4. Type--B vent where required, refer to the Note 1 above.
5. A 4--in. (102 mm) single--wall (26 ga. minimum) vent must be
used inside furnace casing and when the KGAVG0101DFG
Downflow Vent Guard Kit is used external to the furnace.
6. Accessory Downflow Vent Guard Kit, KGAVG0101DFG required in downflow installations with lower vent configuration.
7. Chimney Adapter Kit may be required for exterior masonry
chimney applications. Refer to Chimney Adapter Kit,
KGACA02014FC or KGACA02015FC, for sizing and complete
application details.
SEE NOTES: 1,2,4,5,7,8,9 on the page
following these figures
A03216
Fig. 42 --- Horizontal Left Application--Vent Elbow Right
33
Caution!! for the following applications, use the minimum vertical vent
heights as specified below.
For all other applications, follow exclusively the national fuel gas code.
FURNACE
ORIENTATION
VENT
ORIENTATION
Downflow
Vent elbow left, then
up Fig. 36
Horizontal Left
Horizontal Left
Horizontal Left
310A
Downflow
Downflow
Vent elbow right,
then up Fig. 39
Vent Elbow up Fig.
40
Vent elbow right Fig.
41
Vent elbow up then
left Fig. 34
Vent elbow up, then
right Fig. 37
FURNACE
INPUT (BTUH/HR)
154,000
132,000
110,000(036/--- 12 only)
154,000
132,000
154,000
132,000
154,000
110,000
(036/--- 12 only)
110,000
(036/--- 12 only)
MINIMUM VENT
DIAMETER
IN. (mm)*
MINIMUM VERTICAL VENT
HEIGHT
FT. (M)**
5 (127)
12 (3.6)
5 (127)
7 (.65)
5 (127)
7 (,65)
5 (127)
7 (.65)
5 (127)
10 (3.0)
5 (127)
10 (3.0)
* 4 in. (102 mm) inside casing or vent guard
** Including 4 in. (102 mm) vent section (s)
NOTE: All vent configurations must also meet National Fuel Gas Code venting requirements NFGC
8. Secure vent connector to furnace elbow with (2) corrosion--res-
!
istant sheet metal screws, spaced approximately 180° apart.
9. Secure all other single wall vent connector joints with (3) corro-
FIRE HAZARD
sion resistant screws spaced approximately 120° apart. Secure
Type-- B vent connectors per vent connector manufacturer’s recommendations.
Failure to follow this warning could result in injury, death
and/or property damage.
10. The total height of the vent and connector shall be at least seven
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.
ft. (2.1 M) 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. 36.)
Step 3 —Adjustments
!
Table 8—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
* Derate multiplier factors are based on midpoint altitude for altitude
range.
WARNING
CAUTION
FURNACE DAMAGE HAZARD
Failure to follow this caution may result in reduced furnace
life.
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.
48.)
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.
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., refer to the unit
rating plate. For installations above 2000 ft. (610 M), multiply the input on the rating plate by the derate multiplier
in Table 8 for the correct input rate.
In Canada:
The input rating must be derated by 10 percent for altitudes of 2,000 ft. (610 M) to 4,500 ft. (1372 M) above sea
level by an authorized Gas Conversion Station or Dealer.
To determine correct input rate for altitude, see Example 1
and use 0.90 as derate multiplier factor.
34
88,000 BTUH INPUT FURNACE INSTALLED AT 4300 FT.
Furnace Input
Rate at Sea Level
88,000
X Derate Multiplier =
Factor
X
0.90
=
Furnace Input
Rate at Installation Altitude
79,200
2. Determine the correct orifice and manifold pressure adjustment. There are two different orifice and manifold adjustment tables. All models in all positions, except Low NOx
models in downflow or horizontal positions, use Table 12
(22,000 Btuh/Burner).
Low NOx models in the downflow or horizontal positions
must use Table 13 (21,000 Btuh/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.
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 manifold pressure
settings for proper operation.
f. Check and verify burner orifice size in furnace.
NEVER ASSUME ORIFICE SIZE. ALWAYS
CHECK AND VERIFY.
g. Replace orifice with correct size if required by Table
12 or 13. Use only factory--supplied orifices. See
EXAMPLE 2.
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
*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 correct input rate.
a. Turn gas valve ON/OFF switch to OFF.
b. Remove manifold pressure tap plug from gas valve.
(See Fig. 47.)
c. Connect a water column manometer or similar device
to manifold pressure tap.
d. Turn gas valve ON/OFF switch to ON.
e. Manually close blower door switch.
f. Set thermostat to call for heat.
g. Jumper R and W thermostat connections on furnace
control board to start furnace.
h. Remove regulator seal cap and turn regulator adjusting
screw counterclockwise (out) to decrease input rate of
clockwise (in) to increase input rate.
i. Install regulator seal cap.
j. Leave manometer or similar device connected and
proceed to Step 4.
NOTE: DO NOT set manifold pressure less than 3.2--in wc or
more than 3.8--in. wc for natural gas at sea level. If manifold
pressure is outside this range, change main burner orifices or refer
Table 12 or 13.
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.
4. Verify natural gas input rate by clocking meter.
NOTE: Gas valve regulator adjustment cap must be in place for
proper input to be clocked.
a. Turn off all other gas appliances and pilots served by
the meter.
b. Run furnace for 3 minutes in heating operation.
c. Measure time (in sec) for gas meter to complete 1 revolution and note reading. The 2 or 5 cubic feet dial
provides a more accurate measurement of gas flow.
d. Refer to Table 10 for cubic ft. of gas per hr.
e. Multiply gas rate (cu ft./hr) by heating value (Btu/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
input is achieved. Reinstall regulator seal cap on gas valve.
5. Set temperature rise. The furnace must operate within the
temperature rise ranges specified on the furnace rating
plate. Do not exceed temperature rise range specified on
unit rating plate. Determine the temperature rise as follows:
NOTE: Blower access door must be installed when taking
temperature rise reading. Leaving blower access door off will
result in incorrect temperature measurements.
a. Place thermometers in return and supply ducts as close
to furnace as possible. Be sure thermometers do not
see radiant heat from heat exchangers. Radiant heat
affects temperature rise readings. This practice is particularly important with straight--run ducts.
b. When thermometer readings stabilize, subtract return-air temperature from supply--air temperature to determine air temperature rise.
NOTE: Blower access door must be installed for proper
temperature rise measurement.
NOTE: If the temperature rise is outside this range, first check:
1.) Gas input for heating operation.
2.) Derate for altitude if applicable.
3.) Return and supply ducts for excessive restrictions causing
static pressures greater than 0.50--in. wc.
4.) Dirty filter.
!
WARNING
ELECTRICAL SHOCK HAZARD
Failure to follow this warning could result in personal
injury or death.
Disconnect 115--v electrical power before changing speed
tap.
c. Adjust air temperature rise by adjusting blower speed.
Increase blower speed to reduce temperature rise.
Decrease blower speed to increase temperature rise.
d. Turn thermostat down below room temperature and
remove blower access door.
e. To change motor speed selection for heating, remove
blower motor lead from control HEAT terminal (See
Fig. 25.) Select desired blower motor speed lead from
one of the other terminals and relocate it to the HEAT
terminal (See Table 9 for lead color identification).
Reconnect original lead to SPARE terminal.
35
310A
EXAMPLE 1:
Table 9—Speed Selection
COLOR
White
Black
Yellow{
Blue*
Red*
SPEED
Common
High
Med --- High
Med --- Low
Low
AS SHIPPED
BLW
COOL
SPARE
SPARE
HEAT
* 1/5 HP motor models: BLUE to HEAT, RED to SPARE
{ Not available on 1/5 HP motors.
NOTE: Continuous blower is the HEAT speed.
f. Repeat steps a through e.
g. When correct input rate and temperature rise is
achieved, turn gas valve ON/OFF switch to OFF.
h. Remove manometer or similar device from gas valve.
i. Reinstall manifold pressure tap plug in gas valve.
310A
!
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.
j. Reinstall blower access door if removed.
k. Turn gas valve ON/OFF switch to ON.
!
CAUTION
FURNACE OVERHEATING HAZARD
Failure to follow this caution may result in reduced furnace
life.
Recheck temperature rise. It must be within limits specified
on the rating plate. Recommended operation is at the
midpoint of rise range or slightly above.
6. Set thermostat heat anticipator.
a. Mechanical thermostat -- Set thermostat heat anticipator to match the amp. draw of the electrical components
in the R--W 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.) Remove thermostat from subbase or
from wall. (2.) Connect an amp. meter as shown in
Fig. 49 across the R and W subbase terminals or R and
W wires at wall.
(3.) Record amp. draw across terminals when furnace
is in heating and after blower starts.
(4.) Set heat anticipator on thermostat per thermostat
instructions and install on subbase or wall.
b. Electronic thermostat: Set cycle rate for 4 cycles per
hr.
7. Adjust blower off delay The blower off delay has 4 adjustable settings from 90 sec to 180 sec. The blower off
delay jumpers are located on the furnace control board.
(See Fig. 25.) To change the blower off delay setting,
move the jumper from one set of pins on the control to the
pins used for the selected blower off delay. Factory off
delay setting is 120 sec.
8. Set airflow CFM for cooling Select the desired blower
motor speed lead for cooling airflow. See Table 5--Air Delivery--CFM (With Filter). See Table 9 for lead color identification.
36
310A
Fig. 46 --- Wiring Diagram
37
A08411
310A
BURNER
ORIFICE
Fig. 47 --- Gas Control Valve
A06666
Fig. 48 --- Orifice Hole
A93059
THERMOSTAT SUBBASE
TERMINALS WITH
THERMOSTAT REMOVED
(ANITICIPATOR, CLOCK, ETC.,
MUST BE OUT OF CIRCUIT.)
HOOK-AROUND
AMMETER
R Y W G
10 TURNS
FROM UNIT 24-V
CONTROL TERMINALS
EXAMPLE:
5.0 AMPS ON AMMETER
10 TURNS AROUND JAWS
= 0.5 AMPS FOR THERMOSTAT
ANTICIPATOR SETTING
Fig. 49 --- Amp. Draw Check With Ammeter
38
A96316
The flame sensor, gas valve, and pressure switch were all checked
in the Start--up procedure section as part of normal operation.
1. Check Main Limit Switch(es)
This control shuts off combustion control 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 duct system or motor failure. If limit
control does not function during this test, cause must be
determined and corrected.
a. Run furnace for at least 5 minutes.
b. Gradually block off return air with a piece of cardboard or sheet metal until the limit trips.
c. Unblock return air to permit normal circulation.
d. Burners will re--light when furnace cools down.
2. Check draft safeguard switch.
The purpose of this control is to cause the safe shutdown
of the furnace during certain blocked vent conditions.
a. Verify vent pipe is cool to the touch.
b. Disconnect power to furnace and remove vent connector from furnace vent elbow.
c. Restore power to furnace and set room thermostat
above room temperature.
d. After normal start--up, allow furnace to operate for 2
minutes, then block vent elbow in furnace 80 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
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 hrs. To reset
furnace control board, turn thermostat below room temperature or
from HEAT to OFF and turn 115v power OFF, then back ON.
3. Check Pressure Switch 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 sec before beginning the call
for heat again.
i. Furnace should ignite normally.
Step 5 —Checklist
1. Put away tools and instruments. Clean up debris.
2. Verify that blower OFF--DELAY time is selected as desired.
3. Verify that blower and burner access doors are properly installed.
4. Cycle test furnace with room thermostat.
5. Check operation of accessories per manufacturer’s instructions.
6. Review User’s Guide with owner.
7. Attach literature packet to furnace.
39
310A
Step 4 —Check Safety Controls
310A
Table 10—Gas Rate (cu ft./hr)
SIZE OF TEST DIAL
SECONDS FOR 1
REVOLUTION
1 Cu Ft
2 Cu Ft
5 Cu Ft
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
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
720
655
600
555
514
480
450
424
400
379
360
343
327
313
300
288
277
267
257
248
240
232
225
218
212
206
200
195
189
185
180
176
172
167
164
160
157
153
150
147
1800
1636
1500
1385
1286
1200
1125
1059
1000
947
900
857
818
783
750
720
692
667
643
621
600
581
563
545
529
514
500
486
474
462
450
439
429
419
409
400
391
383
375
367
SIZE OF TEST DIAL
SECONDS FOR 1
REVOLUTION
1 Cu Ft
2 Cu Ft
5 Cu Ft
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
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
144
141
138
136
133
131
129
126
124
122
120
116
112
109
106
103
100
97
95
92
90
88
86
84
82
80
78
76
75
74
72
71
69
68
67
65
64
62
60
360
355
346
340
333
327
321
316
310
305
300
290
281
273
265
257
250
243
237
231
225
220
214
209
205
200
196
192
188
184
180
178
173
170
167
164
161
155
150
Table 11—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 x25 x3/4
(406 x635 x19)
16 x25 x3/4
(406 x635 x19)
16 x25 x3/4
(406 x635 x19)
16 x25 x3/4
(406 x635 x19)
BOTTOM
RETURN
14 x25 x3/4
(356 x635 x19)
16 x25 x3/4
(406 x635 x19)
20 x25 x3/4
(508 x635 x19)
24 x25 x3/4
(610 x635 x19)
* Recommended
** Some furnaces may have 2 filters.
40
FILTER TYPE
Washable*
Washable*
Washable*
Washable*
310A
Table 12—Orifice Size* and Manifold Pressure (In. wc) for Gas Input Rate
(Tabulated data based on 22,000 Btuh per burner, derated 4 percent for each
1000 ft. (305 M) above sea level)
A08484
41
310A
Table 12–Orifice size* and Manifold Pressure (In wc) for Gas Input Rate (Continued)
(Tabulated data based on 22,000 Btuh per burner, derated 4 percent for each 1000 ft. (305 M) above sea level)
A08484a
42
310A
Table 13—Orifice Size* and Manifold Pressure (In. wc) for Gas Input Rate
(Tabulated data based on 22,000 Btuh High Heat / 14,5000 BTUH Low Heat per burner,
derated 4 percent for each 1000 ft. (305 M) above sea level)
A08485
43
310A
Table 13 -- Orifice Size* and Manifold Pressure (In. wc) for Gas Input Rate (Continued)
(Tabulated data based on 22,000 Btuh High Heat / 14,500 Btuh Low Heat per burner,
derated 4 percent for each 1000 ft. (305 M) above sea level)
A08485a
SERVICE
If status code recall is needed, briefly remove then reconnect one main limit wire to display stored status code. On RED LED boards do not remove power or blower door before initiating status code recall. After
status code recall is completed component test will occur.
LED CODE
STATUS
CONTINUOUS OFF - Check for 115VAC at L1 and L2, and 24VAC at SEC-1 and SEC-2.
CONTINUOUS ON - Control has 24VAC power.
RAPID FLASHING - Line voltage (115VAC) polarity reversed. If twinned, refer to twinning kit instructions.
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 code is erased automatically after 72 hours. On
RED LED boards stored status codes can also be erased when power
(115 VAC or 24 VAC) to control is interrupted.
12 BLOWER ON AFTER POWER UP (115 VAC or 24 VAC) -Blower runs for 90 seconds,
if unit is powered up during a call for heat (R-W closed) or R-W opens during blower
on-delay.
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.
- Control will auto reset after three hours.
- Refer to #33.
14 IGNITION LOCKOUT - Control will auto-reset after three hours. Refer to #34.
21 GAS HEATING LOCKOUT - Control will NOT auto reset.
Check for: - Mis-wired gas valve
-Defective control (valve relay)
22 ABNORMAL FLAME-PROVING SIGNAL - Flame is proved while gas valve is deenergized. 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.
COMPONENT TEST
To initiate the component test sequence, shut OFF the room thermostat or disconnect the "R"
thermostat lead. Briefly short the TEST/TWIN terminal to the "Com 24V" terminal. Status LED
will flash code and then turn ON the inducer motor. The inducer motor will run for the entire
component test. The hot surface ignitor, blower motor fan speed (on AMBER LED boards
only) blower motor-heat speed, and blower motor-cool speed will be turned ON for 10-15
seconds each. Gas Valve and Humidifier will not be turned on.
31
PRESSURE SWITCH DID NOT CLOSE OR REOPENED - If open longer than five minutes,
inducer shuts off for 15 minutes before retry. Check for: - Excessive wind
- Proper vent sizing
- Defective inducer motor
- Low inducer voltage (115VAC)
- Defective pressure switch
- Inadequate combustion air supply
- Disconnected or obstructed pressure tubing
- Low inlet gas pressure (if LGPS used)
- Restricted vent
If it opens during blower on-delay period, blower will come on for the selected blower
off-delay.
33 LIMIT CIRCUIT FAULT - Indicates a limit, draft safeguard, flame rollout, or blocked vent
switch (if used) is open. 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:
- Restricted vent
- Proper vent sizing
- Loose blower wheel.
- Excessive wind
- Dirty filter or restricted duct system.
- Defective blower motor or capacitor. - 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: - Flame sensor must not be grounded
- Oxide buildup on flame sensor (clean with fine steel wool).
- Proper flame sense microamps (.5 microamps D.C. min., 4.0 - 6.0 nominal).
- Gas valve defective or gas valve turned off
- Manual valve shut-off
- Defective Hot Surface Ignitor
- Control ground continuity
- Low inlet gas pressure
- Inadequate flame carryover or rough ignition
- Green/Yellow wire MUST be connected to furnace sheet metal
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.
327596-101 REV. B
Fig. 50 --- Service Label
44
A04223
!
ELECTRICAL CONTROLS AND WIRING
!
WARNING
WARNING
ELECTRICAL SHOCK HAZARD
FIRE, EXPLOSION, ELECTRICAL SHOCK
HAZARD
Failure to follow this warning could result in personal
injury or death.
Failure to follow this warning could result in personal
injury, death and/or property damage.
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 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.
Label all wires prior to disconnection when servicing
controls. Wiring errors can cause improper and dangerous
operation.
!
CAUTION
ENVIRONMENTAL HAZARD
Failure to follow this caution may result in environmental
pollution.
Remove and recycle all components or materials (i.e. oil,
refrigerant, et.) before unit final disposal.
Step 1 —Introduction
GENERAL
These instructions are written as if the furnace is installed in an
upflow application. An upflow furnace application is where the
blower is located below the combustion and controls section of
the furnace, and conditioned air is discharged upward. Since this
furnace can be installed in any of the 4 positions shown in Fig. 4,
you must revise your orientation to component location
accordingly.
The electrical ground and polarity for 115--v wiring must be
properly maintained. Refer to Fig. 26 for field wiring information
and to Fig. 46 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. 25.) 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 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. 50 and the troubleshooting guide
which can be obtained from your distributor. The furnace control
will store 1 status code for 72 hrs.
See Fig. 54, a brief Troubleshooting Guide.
For Controls With a RED LED
The stored status code will be erased from the control memory, if
115-- or 24--v power is interrupted.
1. To retrieve status code, proceed with the following:
NOTE: NO thermostat signal may be present at control, and all
blower--OFF delays must be completed.
a. Leave 115--v power to furnace turned on.
b. Remove outer access door.
c. Look into blower access door sight glass for current
LED status. Do not remove blower access door or terminate 115--v power to control or status code will be
lost.
d. BRIEFLY remove insulated terminal wire from the
draft safeguard (DSS) switch until LED goes out (1 to
2 sec), then reconnect it.
2. When above items have been completed, the LED flashes
status code 4 times. Record this status code for further
troubleshooting.
3. Component self--test will begin. Refer to component
TEST section for complete test sequence.
4. Check LED status.
5. Refer to SERVICE label on front of the blower access
door for more information.
6. Check LED status. If no previous faults in history, control
will flash status code 11.
7. If LED status indicates proper operation, RELEASE
BLOWER ACCESS DOOR SWITCH, reattach wire to R
45
310A
SERVICE AND MAINTENANCE
PROCEDURES
terminal on furnace control board, replace blower access
door, and replace burner access door.
Step 2 —Care and Maintenance
WARNING
!
FIRE OR EXPLOSION HAZARD
310A
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.
For continuing high performance and to minimize possible
equipment failure, periodic maintenance must be performed on
this equipment. 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 or property damage.
Turn off the gas and electrical supplies to the unit before
performing any maintenance or service. Follow the
operating instructions on the label attached to the furnace.
!
WARNING
CARBON MONOXIDE POISONING AND FIRE
HAZARD
Failure to follow this warning could result in personal
injury, death and/or property damage.
Never operate unit without a filter or with filter access door
removed.
!
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.
CLEANING AND/OR REPLACING AIR FILTER
The air filter arrangement will vary depending on the application.
The filter is exterior to the furnace casing.
NOTE: If the filter has an airflow direction arrow, the arrow
must point towards the blower.
!
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 or 3/4--in. (19 mm) filter rack are
accessories and are not included from the factory with standard
furnace model.
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 11 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 11.
6. Slide filter into cabinet.
7. Replace filter cabinet door.
8. Turn on electrical supply to furnace.
BLOWER MOTOR AND WHEEL
CAUTION
!
WARNING
ELECTRICAL SHOCK HAZARD
CUT HAZARD
Failure to follow this warning could result in personal injury
or death.
Failure to follow this caution may result in personal injury.
Sheet metal parts may have sharp edges or burrs. Use care
and wear appropriate protective clothing, safety glasses and
gloves when handling parts and servicing furnaces.
The minimum maintenance on this furnace is as follows:
1. Check and clean air filter each month or more frequently if
required. Replace if torn.
2. Check blower motor and wheel for cleanliness each heating
and cooling season. Clean as necessary.
3. Check electrical connections for tightness and controls for
proper operation each heating season. Service as necessary.
4. Inspect burner compartment before each heating season for
rust, corrosion, soot or excessive dust. If necessary, have furnace
and burner serviced by a qualified service agency.
5. Inspect the vent pipe/vent system before each heating season
for rust, corrosion, water leakage, sagging pipes or broken
CAUTION
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.
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.
46
!
CAUTION
UNIT DAMAGE HAZARD
Failure to follow this caution may result in shortened heat
exchanger life.
Heating fan speed(s) MUST be adjusted to provide proper
air temperature rise as specified on the rating plate.
Recommended operation is at the midpoint of the rise range
or slightly above. Refer to SET TEMPERATURE RISE
under START--UP, ADJUSTMENT, and SAFETY
CHECK.
NOTE: Refer to Table 9 for motor speed lead relocation 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.
!
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 thermostat terminals are jumpered at the time blower
access door switch is closed, blower will run for 90 sec before
beginning a heating or cooling cycle.
c. Perform component self--test as shown at the bottom
of the SERVICE label, located on the front of blower
access door.
d. Verify blower is rotating in the correct direction
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. Reinstall casing door.
22. Turn on gas supply and cycle furnace through one complete heating and cooling cycle. Verify the furnace temperature rise as shown in Adjustments Section. Adjust temperature rise as shown in Adjustments Section. If outdoor
temperature is below 70_F, (21_C) turn off circuit breaker
to outdoor unit before running furnace in the cooling
cycle. Turn outdoor circuit breaker on after completing
cooling cycle.
47
310A
2. Loosen the thumbscrew on outer door and 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 motor, and blower
housing so motor and each arm is positioned at the same location
during reassembly.
a. Disconnect capacitor wires and ground wire attached
to blower housing.
b. Remove screws securing cutoff plate and remove
cutoff plate from housing.
c. Loosen set screw holding blower wheel on motor shaft
(160+/--20 in.--lb. when reassembling).
d. Remove bolts holding motor to blower housing and
slide motor out of wheel (40+/--10 in.--lb. when reassembling).
e. Remove blower wheel from housing.
f. Clean wheel and housing.
12. Reassemble motor and blower by reversing steps 11f
through 11a, finishing with 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.
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.
310A
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 heavy build--up of soot and carbon indicates
that a problem exists which needs to be corrected, such as
improper adjustment of manifold pressure, insufficient or poor
quality combustion air, incorrect size or damaged manifold
orifice( s), improper gas, or a restricted heat exchanger. Action
must be taken to correct the problem.
If it becomes necessary to clean the heat exchangers because of
dust or corrosion, proceed as follows:
1. Turn OFF gas and electrical power to furnace.
2. Remove outer access door.
3. Disconnect vent connector from furnace vent elbow.
4. For downflow or horizontal furnace having an internal
vent pipe, remove internal vent pipe within the casing.
5. Disconnect wires to the following components. Mark
wires to aid in reconnection of (be careful when disconnecting wires from switches because damage may occur):
a. Draft safeguard switch.
b. Inducer motor.
c. Pressure switch(es).
d. Limit overtemperature switch.
e. Gas valve.
f. Hot surface igniter.
g. Flame--sensing electrode.
h. Flame rollout switches.
i. Remove NOx baffles on low NOx models.
6. Remove screws that fasten the collector box assembly to
the cell panel. Be careful not to damage the collector box.
Inducer assembly and elbow need not be removed from
collector box.
7. Disconnect gas line from gas manifold.
8. Remove the 5 screws that attach the burner assembly to
the cell panel. The gas valve and individual burners need
not be removed from support assembly.
NOTE: Be very careful when removing burner assembly to
avoid breaking igniter. See Fig. 51 and 52 for correct igniter
location.
9. Using field--provided 25--caliber rifle cleaning brush,
36--in. (914 mm) long, 1/4 in. (6 mm) diameter steel
spring cable, a variable speed, reversible electric drill, and
vacuum cleaner, clean cells as follows:
a. Remove metal screw fitting from wire brush to allow
insertion into cable.
b. Insert the twisted wire end of brush into end of spring
cable, and crimp tight with crimping tool or crimp by
striking with ball--peen hammer. TIGHTNESS IS
VERY IMPORTANT.
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. 53.)
(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.
Fig. 51 --- Igniter Position--Side View
A05025
1-7/8
(47.6 mm)
Fig. 52 --- Igniter Position--Top View
A05026
A01050
Fig. 53 --- Cleaning Heat Exchanger Cell
(4) Insert brush end of cable in burner inlet opening of cell, and
proceed to clean 2 lower passes of cell in same manner as upper
pass.
(5) Repeat foregoing procedures until each cell in furnace has
been cleaned.
(6) Using vacuum cleaner, remove residue from each cell.
(7) Using vacuum cleaner with soft brush attachment, clean
burner assembly.
(8) Clean flame sensor with fine steel wool.
(9) Install NOx baffles (if removed).
(10) Reinstall burner assembly. Center burners in cell openings.
10. Remove old sealant from cell panel and collector box
flange.
11. Spray releasing agent on the heat exchanger cell panel
where collector box assembly contacts cell panel.
NOTE: A releasing agent such as cooking spray or equivalent
(must not contain corn or canola oil, aromatic or halogenated
hydrocarbons or inadequate seal may occur) and RTV sealant
48
!
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.
20. Replace outer access door.
Step 3 —Sequence of Operation
NOTE: Furnace control must be grounded for proper operation
or control will lock out. Control is grounded through
green/yellow wire routed to gas valve and manifold bracket
screw.
Using the schematic diagram in Fig. 46, 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),
the control will start a 90--sec blower--only ON period two
seconds after power is restored, if the thermostat is still calling for
gas heating. The red LED light will flash code 12 during the
90--sec period, after which the LED will be ON continuous, as
long as no faults are detected. After the 90--sec 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. Heating
(See Fig. 26 for thermostat connections.) The wall thermostat “calls for heat,” closing the R--to--W circuit. The furnace control performs a self--check, verifies the pressure
49
310A
switch contacts PRS are open, and starts the inducer motor
IDM.
a. Inducer Prepurge Period-- As the inducer motor
IDM comes up to speed, the pressure switch contacts
PRS close, 24 VAC power is supplied for a field installed humidifier at the HUM terminal and the control
begins a 15--sec prepurge period.
b. Igniter Warm--Up-- At the end of the prepurge period,
the Hot--Surface igniter HSI is energized for a
17--second igniter warm--up period.
c. Trial--for--Ignition Sequence-- When the igniter
warm--up period is completed, the main gas valve relay contacts GVR close to energize the gas valve GV,
the gas valve opens, The gas valve GV permits gas
flow to the burners where it is ignited by the HSI. Five
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.
d. Flame--Proving-- When the burner flame is proved at
the flame--proving sensor electrode FSE, the furnace
control CPU begins the blower--ON delay period and
continues to hold the gas valve GV open. If the burner
flame is not proved within two seconds, the control
CPU will close the gas valve GV, and the control CPU
will repeat the ignition sequence for up to three more
Trials--For--Ignition before going to Ignition--Lockout.
Lockout will be reset automatically after three hours
or by momentarily interrupting 115 vac power to the
furnace, or by interrupting 24 vac power at SEC1 or
SEC2 to the furnace control CPU (not at W, 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 until flame
is no longer proved.
e. Blower--On Delay-- If the burner flame is proven, the
blower motor is energized on HEAT speed 25 sec after
the gas valve GV is energized.
Simultaneously, the electronic air cleaner terminal
EAC--1 is energized and remains energized as long as
the blower motor BLWM is energized.
f. Blower--Off Delay-- When the thermostat is satisfied,
the R--to--W circuit is opened, de--energizing the gas
valve GV, 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 for 90,
120, 150, or 180 seconds (depending on the blower-OFF delay selection). The furnace control CPU is factory--set for a 120--second blower--OFF delay.
2. Cooling Mode
(See Fig. 26 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 circuits start
the furnace blower motor BLWM on COOL speed. 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 on the
COOL speed for an additional 90 sec. Cut jumper J2 to
reduce the cooling off--delay to 5 sec. (See Fig. 25.)
3. Continuous Blower Mode
When the R--to--G circuit is closed by the thermostat, the
blower motor BLWM will operate on continuous--blower
speed (same as HEAT speed). Terminal EAC--1 is energized as long as the blower motor BLWM is energized.
(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.
b. Inducer motor.
c. Pressure switch(es).
d. Limit over--temperature switch.
e. Gas valve.
f. Hot surface igniter.
g. Flame--sensing electrode.
h. Flame rollout switches.
i. Install NOx baffles (if removed).
14. Reinstall internal vent pipe, if applicable.
15. Reinstall vent connector on furnace vent elbow. Securely
fasten vent connector to vent elbow with 2 field--supplied,
corrosion--resistant, sheet metal screws located 180_ apart.
16. Replace blower access door only, if it was removed.
17. Set thermostat above room temperature and check furnace
for proper operation.
18. Verify blower airflow and speed changes between heating
and cooling.
310A
During a call for heat, the blower BLWM will stop during
igniter warm--up (17 sec), ignition, and blower--ON delay
(25 sec), allowing the furnace heat exchangers to heat up
more quickly, then restarts at the end of the blower--ON
delay period at HEAT speed.
When the thermostat “calls for cooling”, the blower motor
BLWM will operate at COOL speed. When the thermostat
is satisfied, the blower motor BLWM will operate an additional 90 sec, on COOL speed before reverting back to
continuous blower speed.
When the R--to--G circuit is opened, the blower motor
BLWM will continue operating for an additional 5 sec, if
no other function requires blower motor BLWM operation.
4. Heat Pump
When installed with a heat pump, the furnace control automatically changes the timing sequence to avoid long
blower off times during demand defrost cycles. When the
R--to--Wand-- Y or R--to--W--and--Y--and--G circuits are
energized the furnace control CPU will continue to turn on
the blower motor BLWM at HEAT speed, and begin a
heating cycle. The blower motor BLWM will remain on
until the end of the prepurge period, then shut off for 24
sec then come back on at HEAT speed. When the W input
signal disappears, the furnace control begins a normal inducer post--purge period and the blower switches to
COOL speed after a 3 sec delay. If the R--to--W--and-Y--and--G signals disappear at the same time, the blower
motor BLWM will remain on for the selected blower-OFF delay period. If the R--to--W--and--Y signals disappear, leaving the G signal, the blower motor BLWM will
continue running the blower motor at HEAT speed after
the selected blower--OFF delay period is completed.
Step 4 —Wiring Diagrams
Refer to Fig. 24 and 45 for wiring diagrams.
Step 5 —Troubleshooting
Refer to the service label. (See Fig. 50–Service Label.)
The Troubleshooting Guide 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.
50
51
YES
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 LED status light blinking ON/OFF slowly
with a combination of short and long flashes?
NO
Is LED status light blinking rapidly without a
pause?
Is LED status light on?
START
YES
NO
YES
NO
NO
YES
Replace furnace control.
310A
Run system through a heating or cooling cycle
to check operation. Status codes are erased
after 72 hours. On RED LED boards stored
status codes can also be erased whenever
(115V or 24V) is interrupted.
YES
Does the control respond to W, Y1 (if present),
Y/Y2, and G (24V) thermostat signals?
To recall status code briefly remove and reconnect one RED wire from the draft
safeguard switch to display stored status code. On RED LED control do not
remove power or blower access panel before initiating status code recall. You
can also recall the previous status code by momentarily shorting the TEST/TWIN
terminal to Com24V terminal until the LED goes out. LED will flash the status
code of the previous fault or status code #11 (1 short and 1 long flash) if there
was no previous fault. After the control repeats the code 4 times, the control
will go through a brief component test sequence. The inducer will start and run
for the entire component test. The HSI, blower motor FAN speed (AMBER LED
boards only) HEAT speed, and COOL speed will run for 10 – 15 seconds each.
Gas valve and humidifier will not be turned on.
Replace transformer.
Check for correct line voltage polarity. If units
are twinned, check for proper low-voltage
(24V) transformer phasing.
Was there a previous status code
other than #11?
YES
Is there 115V going to switch?
Is door switch closed?
Replace door switch.
NO
NO
Replace furnace control.
YES
Is there 24V at SEC-1 and SEC-2?
YES
Is there 115V at L1 and L2?
YES
NO
NO
NO
YES
A02106a
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, Y1 (if present), Y/Y2 or
G thermostat terminals on the furnace control?
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.
Is circuit breaker closed?
Is door switch closed?
NO
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
EBryant Heating & Cooling Systems 7310 W. Morris St. Indianapolis, IN 46231
Printed in U.S.A.
52
Edition Date: 10/08
Replaces: II310A--- 45--- 9
Catalog No. II310A ---45---10
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.
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. 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 (R-W
closed) or when (R-W opens) during the
blower on-delay period.
11 NO PREVIOUS CODE Stored codes
are erased after 72 hours. On RED LED
boards stored status codes can also be
erased whenever power (115V or 24V)
is interrupted. Run system through a
heating or cooling cycle to check system.
Fig. 54
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 initiate
another component test sequence. Check
for 115V between pin 1 and NEUTRAL-L2 on
the control. Was 115V present for the 15
second period?
Troubleshooting Guide
* Blocked vent shutoff 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
NO
sequence 3 more times before lockout
#14 occurs. If flame signal is lost during
YES
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
system can be operated in the component
test mode to check the igniter. First
remove the R thermostat connection from
the control and initiate the component
test sequence. 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 shutoff switch* (if used) is
open. 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 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.
- Defective blower motor or capacitor.
- Inadequate combustion air supply
(flame rollout switch open).
- Restricted vent.
- Proper vent sizing.
- Excessive wind.
31 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 ondelay 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.
310A
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, replace control.
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.