Variable Speed Induced-Combustion Deluxe 4-Way Multipoise Furnace Installation, Start-up, Operating, and

Variable Speed

Induced-Combustion Deluxe

4-Way Multipoise Furnace

Cancels: II 315A-70-4 II 315A-70-5

4-06

Installation, Start-up, Operating, and

Service and Maintenance Instructions

Series 120/C

NOTE: Read the entire instruction manual before starting the

installation.

This symbol

→ indicates a change since the last issue.

Portions of the text and tables are reprinted from NFPA 54/ANSI Z223.1-2006©, with permission of National Fire Protection Association, Quincy, MA 02269 and American

Gas Association, Washington DC 20001. This reprinted material is not the complete and official position of the NFPA or ANSI on the referenced subject, which is represented only by the standard in its entirety.

TABLE OF CONTENTS

SAFETY CONSIDERATIONS .....................................................2

INTRODUCTION ..........................................................................2

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

Safety.........................................................................................4

General Installation...................................................................4

Combustion and Ventilation Air ..............................................4

Duct Systems ............................................................................4

Acoustical Lining and Fibrous Glass Duct..............................4

Gas Piping and Gas Pipe Pressure Testing..............................4

Electrical Connections ..............................................................4

ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS

PROCEDURE ................................................................................4

LOCATION....................................................................................5

General ......................................................................................5

Location Relative to Cooling Equipment ................................7

AIR FOR COMBUSTION AND VENTILATION ......................7

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

Upflow Installation .................................................................10

Bottom Return Air Inlet ....................................................10

Side Return Air Inlet.........................................................10

Leveling Legs (If Desired)................................................10

Downflow Installation ............................................................10


Horizontal Installation ............................................................11

Suspended Furnace Support ..............................................11

Platform Furnace Support .................................................11

Roll-Out Protection............................................................11


Side Return Air Inlet.........................................................14

Filter Arrangement..................................................................12

Air Ducts.................................................................................12

General Requirements .......................................................12

Ductwork Acoustical Treatment .......................................13

Supply Air Connections ....................................................13

Return Air Connections.....................................................15

Gas Piping...............................................................................18

Electrical Connections ............................................................19

115-V Wiring.....................................................................19

J-Box Relocation ...............................................................20

Electrical Connection to J-Box .........................................19

Power Cord Installation.....................................................20

BX Cable Installation ........................................................21

24-V Wiring.......................................................................21

Accessories ........................................................................21

Venting ....................................................................................21

General Venting Requirements .........................................24

Masonry Chimney Requirements......................................29

Appliance Application Requirements ...............................29

Additional Venting Requirements.....................................30

Sidewall Venting ...............................................................33

START-UP, ADJUSTMENT, AND SAFETY CHECK ............33

General ....................................................................................33

Start-Up Procedures ...............................................................35

Adjustments ...........................................................................36

Check Safety Controls ............................................................43

Checklist..................................................................................43

SERVICE AND MAINTENANCE PROCEDURES..................43

Introduction .............................................................................46

General...............................................................................46

Electrical Controls and Wiring .........................................46

Care and Maintenance ............................................................47

Cleaning and/or Replacing Air Filter ...............................47

Blower Motor and Wheel..................................................48

Cleaning Heat Exchanger..................................................49

Sequence of Operation............................................................50

Wiring Diagrams.....................................................................54

Troubleshooting ......................................................................54

Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.

Book 1 4

Tab 6a 8a

PC 101 Printed in U.S.A.

Pg 1 4-06

SAFETY CONSIDERATIONS

FIRE, EXPLOSION, ELECTRICAL SHOCK, AND

CARBON MONOXIDE POISONING HAZARD

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

Improper installation, adjustment, alteration, service, maintenance, or use 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.

FURNACE RELIABILITY HAZARD

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

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

Installing and servicing heating equipment can be hazardous due to gas and electrical components. Only trained and qualified

personnel should install, repair, or service heating equipment.

Untrained personnel can perform basic maintenance functions such as cleaning and replacing air filters. All other operations must be performed by trained service personnel. When working on heating equipment, observe precautions in literature, on tags, and on labels attached to or shipped with furnace and other safety precautions that may apply.

These instructions cover minimum requirements and conform to existing national standards and safety codes. In some instances, these instructions exceed certain local codes and ordinances, especially those that may not have kept up with changing residential construction practices. We require these instructions as a minimum for a safe installation.

CUT HAZARD

Failure to follow this caution may result in personal injury.

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

Wear safety glasses and work gloves. Have fire extinguisher available during start-up and adjustment procedures and service calls.

This is the safety-alert symbol . When you see this symbol on the furnace and in instructions or manuals, be alert to the potential for personal injury.

Understand the signal words DANGER, WARNING, and CAU-

TION. These words are used with the safety-alert symbol. DAN-

GER identifies the most serious hazards which will result in severe personal injury or death. WARNING signifies a hazard which

could result in personal injury or death. CAUTION is used to

identify hazards which may result in minor personal injury or product and property damage. NOTE is used to highlight suggestions which will result in enhanced installation, reliability, or operation.

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

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

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

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

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

Piping” section.

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

See furnace rating plate.

→

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

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

9. The furnace may be used for construction heat provided that the furnace installation and operation complies with the first

CAUTION in the LOCATION section of these instructions.

10. These Multipoise Gas-Fired Furnaces are CSA (formerly

A.G.A. and C.G.A.) design-certified for use with natural and propane gases (see furnace rating plate) and for installation in alcoves, attics, basements, closets, utility rooms, crawlspaces, and garages. The furnace is factory-shipped for use with natural gas. A CSA (A.G.A. and C.G.A.) listed 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. clearance from combustible materials to supply air ductwork for a distance of 36 inches 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.

CD5 or CK5, or when Coil Box Part No. KCAKC is used. See

Fig. 1 for clearance to combustible construction information.

INTRODUCTION

The Series 120/C 4–way multipoise Category I fan-assisted furnace is CSA (formerly A.G.A. and C.G.A.) design-certified. A

Category I fan-assisted furnace is an appliance equipped with an integral mechanical means to either draw or force products of combustion through the combustion chamber and/or heat exchanger. The furnace is factory-shipped for use with natural gas.

This furnace is not approved for installation in mobile homes, recreational vehicles, or outdoors.

2

†

INSTALLATION

MINIMUM INCHES CLEARANCE TO COMBUSTIBLE CONSTRUCTION

DISTANCE MINIMALE EN POUCES AUX CONSTRUCTIONS COMBUSTIBLES

This forced air furnace is equipped for use with natural gas at altitudes 0-10,000 ft (0-3,050m).

An accessory kit, supplied by the manufacturer, shall be used to convert to propane gas use or may be required for some natural gas applications.

This furnace is for indoor installation in a building constructed on site.

This furnace may be installed on combustible flooring in alcove or closet at minimum clearance as indicated by the diagram from combusitble material.

This furnace may be used with a Type B-1 Vent and may be vented in common with other gas fired appliances.

Cette fournaise à air pulsé est équipée pour utilisation avec gaz naturel et altitudes comprises entre 0-3,050m (0-10,000 pi).

Utiliser une trousse de conversion, fournie par le fabricant, pour passer au gaz propane ou pour certaines installations au gaz naturel.

Cette fournaise est prévue pour être installée dans un bâtiment construit sur place.

Cette fournaise peut être installée sur un plancher combustible dans une alcôve ou dans un garde-robe en respectant le minimum d'espace libre des matériaux combustibles, tel qu

´ indiqué sur le diagramme.

Cette fournaise peut être utilisée avec un conduit d

´

évacuation de Type B-1 ou connectée au conduit ommun d 'autres appareils à gaz.

This furnace is approved for UPFLOW, DOWNFLOW, and

HORIZONTAL installations.

Cette fournaise est approuvée pour l 'installation HORIZONTALE et la circulation d 'air VERS LE HAUT et VERS LE BAS.

Clearance arrows do not change with furnace orientation.

0"

A

R

B

A

R I

C

È

R

K

E

*

0"

S I

D E

É

C

Ô T

†

1"

Les fléches de dégagement ne change pas avec l 'orientation de la fournaise.

*

0"

E

D

S I

F

U

F O

R N

U

R N

F R

A

A

V

E

I

ON

A

E

T

N

T

C

Ô T

A

F

R

V

O

A

N

N

T

T

3"

Ø

EN

S

E

TR

R V

E

T

È

I

I

C

E

E

N 24"

MIN

0"

Clearance in inches

Dégagement (po).

Vent Clearance to combustibles:

For Single Wall vents 6 inches (6 po).

For Type B-1 vent type 1 inch (1 po).

Dégagement de l

´

évent avec combustibles:

Pour conduit d´évacuation à paroi simple 6 po (6 inches).

Pour conduit d´évacuation de Type B-1 1 po (1 inch).

MINIMUM INCHES CLEARANCE TO COMBUSTIBLE CONSTRUCTION

DOWNFLOW POSITIONS:

Installation on non-combusibible floors only.

For Installation on combustible flooring only when installed on special base, Part No. KGASB0201ALL,

Coil Assembly, Part No. CD5 or CK5, or Coil Casing, Part No. KCAKC.

Ø

*

18 inches front clearance required for alcove.

Indicates supply or return sides when furnace is in the horizontal position. 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.

Ø

*

†

DÉGAGEMENT MINIMUM EN POUCES AVEC ÉLÉMENTS

DE CONSTRUCTION COMBUSTIBLES

POUR LA POSITION COURANT DESCENDANT:

Pour l

´ installation sur plancher non combustible seulement.

Pour l

´ installation sur un plancher combustible seulement quand on utilise la base spéciale, pièce nº KGASB0201ALL, l

´ ensemble serpentin, pièce nº CD5 ou CK5, ou le carter de serpentin, pièce nº KCAKC.

Dans une alcôve, on doit maintenir un dégagement à l

´ avant de 18 po (450mm).

La poistion indiquée concerne le côté d

´ entrée ou de retour quand la fournaise est dans la position horizontale.

Le contact n

´ est permis qu

´ entre les lignes formées par les intersections du dessus et des deux côtés de la cherrise de la fournaise et les solives, montant sous cadre de charpente.

327590-101 REV. C

Fig. 1—Clearances to Combustibles

3

Fig. 2—Return Air Temperature

80

60

A04036

This furnace is designed for minimum continuous return-air temperature of 60°F db or intermittent operation down to 55°F db such as when used with a night setback thermostat. Return-air temperature must not exceed 80°F db. Failure to follow these return-air temperature limits may affect reliability of heat exchangers, motors, and controls. (See Fig. 2.)

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

NOTE: Remove all shipping brackets and materials before oper-

ating the furnace.

CODES AND STANDARDS

Follow all national and local codes and standards in addition to

these instructions. The installation must comply with regulations

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

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

Step 1—Safety

• US: National Fuel Gas Code (NFGC) NFPA 54–2002/ANSI

Z223.1–2002 and the Installation Standards, Warm Air Heating and Air Conditioning Systems ANSI/NFPA 90B

• CANADA: CSA B149.1-00 National Standard of Canada

Natural Gas and Propane Installation Code (NSCNGPIC)

Step 2—General Installation

• 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.)

• CANADA: NSCNGPIC. For a copy, contact Standard Sales,

CSA International, 178 Rexdale Boulevard, Etobicoke (Toronto), Ontario, M9W 1R3 Canada

Step 3—Combustion and Ventilation Air

• US: Section 8.3 of the NFGC, Air for Combustion and

Ventilation

• CANADA: Part 7 of NSCNGPIC, Venting Systems and Air

Supply for Appliances

4

Step 4—Duct Systems

• 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.

Step 5—Acoustical Lining and Fibrous Glass Duct

• 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

• US: NFGC; chapters 5, 6, 7, and 12 and National Plumbing

Codes

• CANADA: NSCNGPIC Parts 3, 4, and 5, and Appendices A,

B, E and H.

Step 7—Electrical Connections

• US: National Electrical Code (NEC) ANSI/NFPA 70–2002

• CANADA: Canadian Electrical Code CSA C22.1

Step 8—Venting

• US: NFGC; chapters 10 and 13

• CANADA: NSCNGPIC Part 7 and Appendix C

ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS

PROCEDURE

FURNACE RELIABILITY HAZARD

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

Electrostatic discharge can affect electronic components.

Take precautions during furnace installation and servicing to protect the furnace electronic control. Precautions will prevent electrostatic discharges from personnel and hand tools which are held during the procedure. These precautions will help to avoid exposing the control to electrostatic discharge by putting the furnace, the control, and the person at the same electrostatic potential.

1. Disconnect all power to the furnace. Multiple disconnects may be required. DO NOT TOUCH THE CONTROL OR ANY

WIRE CONNECTED TO THE CONTROL PRIOR TO DIS-

CHARGING 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.

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.

28-7/8"

26-1/8"

(FLUE COLLAR)

7/8" DIA

ACCESSORY

5-15/16"

25-1/4"

22-9/16"

JUNCTION BOX

LOCATION

F

A

D

13/16"

4-13/16"

2-7/16"

1-5/16"

1-1/8"

8-9/16"

AIRFLOW

19"

OUTLET

1/2" DIA. K.O.THERMOSTAT

WIRE ENTRY

1-3/4" DIA.RIGHT HAND

GAS ENTRY

13/16"

11/16"

7-3/4"

9-5/8"

11-1/2"

1/2" DIA THERMOSTAT

WIRE ENTRY

3-15/16"

LEFT HAND GAS

ENTRY

7/8" DIA. K.O. WIRE ENTRY

33-5/16"

24-7/8"

ALTERNATE

JUNCTION BOX

LOCATIONS (TYP)

VENT OUTLET

5 PLACES (TYP)

14-7/8"

7/8" DIA. ACCESSORY

7/8" DIA. ACCESSORY

5-1/2"

11/16"

21-5/8"

BOTTOM INLET

24"

CASING

1-11/16"

5-1/2"

E 11/16"

3-3/4"

1-1/2"

22-1/16"

SIDE INLET

1-1/4"

1"

NOTES:

1. Two additional 7/8-in. 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. round or 14 1/2 x 12-in. rectangle.

b. For 1200 CFM-20-in. round or 14 1/2 x 19 1/2-in. rectangle.

c. For 1600 CFM-22-in. round or 14 1/2 x 22 1/16-in. rectangle.

d. For airflow requirements above 1800 CFM, see Air Delivery table in Product Data literature for specific use of single side inlets. The use of both side inlets, a combination of 1 side and the bottom, or the bottom only will ensure adequate return air openings for airflow requirements above 1800 CFM.

Fig. 3—Dimensional Drawing

A04037

Table 1—Dimensions (IN.)

FURNACE SIZE

070-12/036070

090-16/048090

110-20/060110

A

CABINET WIDTH

(IN.)

14-3/16

17-1/2

21

D

SUPPLY-AIR

WIDTH

(IN.)

12-9/16

15-7/8

19-3/8

E

RETURN-AIR

WIDTH

(IN.)

12-11/16

16

19-1/2

F

C.L. TOP AND

BOTTOM FLUE COLLAR

(IN.)

9-5/16

11-9/16

13-5/16

135-22/066135

155-22/066155

24-1/2

24-1/2

22-7/8

22-7/8

23

23

15-1/16

15-1/16

* 5” or 6” vent connector may be required in some cases.

†5

″ or larger vent is required. Use a 4-5 or 4-6 inch vent adapter between furnace and vent connector.

FLUE COLLAR*

(IN.)

4

4

4

4†

4†

SHIP WT. (LB)

127

151

163

177

183

FILTER MEDIA

CABINET SIZE

(IN.)

16

16

20

24

24

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

LOCATION

GENERAL

This multipoise furnace is shipped in packaged configuration.

Some assembly and modifications are required when used in any of the four applications shown in Fig. 4.

NOTE: For high-altitude installations, the high-altitude conver-

sion kit MUST be installed at or above 5500 ft above sea level.

Obtain high-altitude conversion kit from your area authorized distributor.

This furnace must:

• be installed so the electrical components are protected from water.

•

not be installed directly on any combustible material other than

wood flooring (refer to SAFETY CONSIDERATIONS).

• be located close to the chimney or vent and attached to an air distribution system. Refer to Air Ducts section.

• be provided ample space for servicing and cleaning. Always comply with minimum fire protection clearances shown on the furnace clearance to combustible construction label.

5

THE BLOWER IS

LOCATED BELOW THE

BURNER SECTION, AND

CONDITIONED AIR IS

DISCHARGED UPWARD.

THE BLOWER IS LOCATED

TO THE RIGHT OF THE

BURNER SECTION, AND

AIR CONDITIONED AIR IS

DISCHARGED TO THE LEFT.

THE BLOWER IS

LOCATED ABOVE THE

BURNER SECTION, AND

CONDITIONED AIR IS

DISCHARGED DOWNWARD

THE BLOWER IS

LOCATED TO THE LEFT

OF THE BURNER SECTION,

AND CONDITIONED AIR IS

DISCHARGED TO THE RIGHT.

A02097

Fig. 4—Multipoise Orientations


Failure to follow this warning could result in personal injury or death and unit component damage.

Corrosive or contaminated air may cause failure of parts containing flue gas, which could leak into the living space.

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

• 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.

The following types of furnace installations may require OUT-

DOOR AIR for combustion due to chemical exposures:

• Commercial buildings

• 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:

• Permanent wave solutions

• Chlorinated waxes and cleaners

• Chlorine based swimming pool chemicals

FIRE, INJURY OR DEATH HAZARD

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

When the furnace is installed in a residential garage, the burners and ignition sources must be located at least 18 in.

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 NSCNGPIC. (See Fig. 5.)

6

18-IN. MINIMUM

TO BURNERS

Fig. 5—Installation in a Garage

A93044

FIRE HAZARD


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.)

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.

PERSONAL INJURY AND/OR PROPERTY DAMAGE

HAZARD

Improper use or installation of this furnace may cause premature furnace component failure.

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.

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

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

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

-The furnace, ductwork and filters are cleaned as necessary to remove drywall dust and construction debris from all HVAC system components after construction is completed.

-Verify proper furnace operating conditions including ignition, gas input rate, air temperature rise, and venting according to these installation instructions.

Fig. 6—Prohibit Installation on Back

A02054

7

AIR FOR COMBUSTION AND VENTILATION

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

•

U.S. Installations: Section 8.3 of the NFGC, Air for Combus-

tion and Ventilation and applicable provisions of the local building codes.

•

Canadian Installations: Part 7 of the NSCNGPIC, Venting

Systems and Air Supply for Appliances and all authorities having jurisdiction.

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.

Table 2–Minimum Free Area Required for Each Combustion Air Opening or 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 and Duct

(Sq. In.)

Round Duct

(in. Dia)

22

33

6

7

44

55

66

77

8

9

10

10

SINGLE DUCT OR OPENING

(1 SQ. IN./3,000 BTUH) (734 SQ. MM/KW)

Free Area of

Opening and Duct

(sq In.)

Round Duct

(in. Dia)

14.7

22

5

6

29.3

36.7

44

51.3

7

7

8

9

TWO OPENINGS OR VERTICAL DUCTS

(1 SQ. IN./4,000 BTUH) (550 SQ. MM/KW)

Free Area of

Opening and Duct

(Sq In.)

Round Duct

(In. Dia)

11

16.5

4

5

22

27.5

33

38.5

6

6

7

8

EXAMPLES: Determining Free Area

FURNACE

110,000

66,000

88,000

+

+

+

WATER HEATER

30,000

40,000

30,000

=

=

=

TOTAL INPUT

(140,000 divided by 4,000)

(106,000 divided by 3,000)

(118,000 divided by 2,000)

=

=

=

35.0 Sq. In. for each two Vertical Ducts or Openings

35.3 Sq. In. for a Single Duct or Opening

59.0 Sq. In. for each of two Horizontal Ducts

ACH

0.60

0.50

0.40

0.30

0.20

0.10

0.00

NP = Not Permitted

1,050

1,260

1,575

2,100

3,150

6,300

NP

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 40 50

1,400

1,680

2,100

2,800

4,200

8,400

NP

1,750

2,100

2,625

3,500

5,250

10,500

NP

44 66

Space Volume (ft

3

)

FAN-ASSISTED TOTAL

(1,000’S BTUH GAS INPUT RATE)

88 110 132

1,100

1,320

1,650

1,650

1,980

2,475

2,200

2,640

3,300

2,750

3,300

4,125

3,300

3,960

4,950

2,200

3,300

6,600

NP

3,300

4,950

9,900

NP

4,400

6,600

13,200

NP

5,500

8,250

16,500

NP

6,600

9,900

19,800

NP


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 the Carbon

Monoxide Poisoning Hazard warning in the venting section of these instructions to determine if an adequate amount of make-up air is available.

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

• Spaces having less than 50 cubic feet per 1,000 Btuh require the OUTDOOR COMBUSTION AIR METHOD.

• Spaces having at least 50 cubic feet per 1,000 Btuh may use the

INDOOR COMBUSTION AIR, STANDARD or KNOWN-

AIR INFILTRATION METHOD.

Outdoor Combustion Air Method

1. Provide the space with sufficient air for proper combustion, ventilation, and dilution of flue gases using permanent hori-

8

154

3,850

4,620

5,775

7,700

11,550

23,100

NP zontal or vertical duct(s) or opening(s) directly communicating with the outdoors or spaces that freely communicate with the outdoors.

2. Fig. 7 illustrates how to provide TWO OUTDOOR OPEN-

INGS, one inlet and one outlet combustion and ventilation air opening, to the outdoors.

a. One opening MUST commence within 12

″ (300 mm) of the ceiling and the second opening MUST commence within 12

″ (300 mm) of the floor.

b. Size openings and ducts per Fig. 7 and Table 2.

c. TWO HORIZONTAL DUCTS require 1 square inch of free area per 2,000 Btuh (1,100 mm

2

/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 square inch of free area per 4,000 Btuh (550 mm

2

/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 mm

2

/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.

DUCTS

TO

OUTDOORS

1 SQ IN.

PER 4000

BTUH*

CIRCULATING AIR

DUCTS

VENT THROUGH ROOF

12

″ MAX

1 SQ IN.

PER 2000

BTUH*

B

D

VENT

THROUGH

ROOF

F

12

″

MAX

1 SQ IN.

PER

4000

BTUH*

DUCTS

TO

OUTDOORS

1 SQ IN.

PER 2000

BTUH*

12

″ MAX

A

E

G

C

12

″ MAX

1 SQ IN.

PER

4000

BTUH*

12

″

MAX

CIRCULATING AIR DUCTS

DUCT

TO

OUTDOORS

1 SQ IN.

PER 4000

BTUH*

*Minimum dimensions of 3 in.

NOTE:

Use any of the following combinations of openings:

A & B C & D D & E F & G

A03174

Fig. 7—Air for Combustion, Ventilation, and

Dilution for Outdoors

The opening shall commence within 12

″ (300 mm) of the ceiling.

Appliances in the space shall have clearances of at least 1

″ (25 mm) from the sides and back and 6

″ (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.


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

Many homes require air to be supplied from outdoors for furnace combustion, ventilation, and dilution of flue gases.

The furnace combustion air supply must be provided in accordance with this instruction manual.

The Standard Method:

1. The space has no less volume than 50 cubic feet per 1,000

Btuh of the maximum input ratings for all gas appliances installed in the space and

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:

9

INTERIOR

HEATED

SPACE

12" MAX

1 SQ IN.

PER 1000

BTUH* IN DOOR

OR WALL

UNCONFINED

SPACE

6" MIN

(FRONT)

†

1 SQ IN.

PER 1000

BTUH* IN DOOR

OR WALL

12" MAX

CIRCULATING AIR DUCTS

* Minimum opening size is 100 sq in. with

minimum dimensions of 3 in.

† Minimum of 3 in. . when type-B1 vent is used.

A03175

Fig. 8—Air for Combustion, Ventilation, and

Dilution from Indoors

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

Z223.1-2002/NFPA 54-2002,8.3.2.2:

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

Volume

Other

= 21ft

3

ACH

I other

1000 Btu/hr

A04002

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

Volume

Fan

= 15ft

3

ACH

I fan

1000 Btu/hr

A04003

If:

I other

= combined input of all other than fan-assisted appli-

ances in Btu/hr

I fan

= combined input of all fan-assisted appliances in Btu/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 closable 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 mm

2

/kW) of the total input rating of all gas appliances in the space, but not less than 100 in.

2

(0.06 m

2

). One opening shall commence within 12

″ (300 mm) of the ceiling and the second opening shall commence within 12

″ (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 mm

2

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

2. An attic or crawlspace may be considered a space that freely communicates with the outdoors provided there are adequate permanent ventilation openings directly to outdoors having free area of at least 1-in.

2

/4,000 Btuh of total input rating for all gas appliances in the space.

3. In spaces that use the Indoor Combustion Air Method, infiltration should be adequate to provide air for combustion, permanent ventilation and dilution of flue gases. However, in buildings with unusually tight construction, additional air

MUST be provided using the methods described in the

Outdoor Combustion Air Method section.

Unusually tight construction is defined as

Construction with: a. Walls and ceilings exposed to the outdoors have a continuous, sealed vapor barrier. Openings are gasketed or sealed and b. Doors and openable windows are weatherstripped and c. Other openings are caulked or sealed. These include joints around window and door frames, between sole plates and floors, between wall-ceiling joints, between wall panels, at penetrations for plumbing, electrical and gas lines, etc.

Combination of Indoor and Outdoor Air

1. Indoor openings shall comply with the Indoor Combustion

Air Method below and,

2. Outdoor openings shall be located as required in the Outdoor

Combustion Air Method mentioned previously and,

3. Outdoor openings shall be sized as follows: a. Calculate the Ratio of all Indoor Space volume divided by required volume for Indoor Combustion Air Method below.

b. Outdoor opening size reduction Factor is 1 minus the

Ratio in a. above.

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

INSTALLATION

UPFLOW INSTALLATION

Bottom Return Air Inlet

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

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

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

3. Remove bottom closure panel.

4. Reinstall bottom filler panel and screws.

Side Return Air Inlet

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

NOTE: Side return-air openings can be used in UPFLOW and

most HORIZONTAL configurations. Do not use side return-air openings in DOWNFLOW configuration.

Leveling Legs (If Desired)

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

NOTE: Bottom closure must be used when leveling legs are used.

It may be necessary to remove and reinstall bottom closure panel to install leveling legs. To remove bottom closure panel, see Item

1 in Bottom Return Air Inlet section in Step 1 above.

To install leveling legs:

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

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

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

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

5. Reinstall bottom closure panel if removed.

10

Fig. 9—Removing Bottom Closure Panel

A02098

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:

5

⁄

16

″

HORIZONTAL INSTALLATION

5

⁄

16

″

1 3

⁄

4

″

5

⁄

16

″

1

3

⁄

4

″

1

3

⁄

4

″

1 3

⁄

4

″

5

⁄

16

″

Fig. 10—Leveling Legs

A02071

• Special Base, KGASB

• Cased Coil Assembly Part No. CD5 or CK5

• 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. CD5 or CK5 or Coil Box Part

No. KCAKC is used, install as shown in Fig. 13.

NOTE: It is recommended that the perforated supply-air duct

flanges be completely folded over or removed from furnace when installing the furnace on a factory-supplied cased coil or coil box.

To remove the supply-air duct flange, use wide duct pliers or hand seamers to bend flange back and forth until it breaks off. Be careful of sharp edges. (See Fig. 14.)







11

FIRE, EXPLOSION, AND CARBON MONOXIDE POI-

SONING HAZARD

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

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

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

Suspended Furnace Support

The furnace may be supported under each end with threaded rod, angle iron or metal plumber’s strap as shown. (See Fig. 15 and 16.)

Secure angle iron to bottom of furnace as shown. Heavy-gauge sheet metal straps (plumber’s straps) may be used to suspend the furnace from each bottom corner. To prevent screws from pulling out, use 2 #8 x ¾-in. screws into the side and 2 #8 x ¾-in. screws in the bottom of the furnace casing for each strap. (See Fig. 15 and

16.)

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

Platform Furnace Support

Construct working platform at location where all required furnace clearances are met. (See Fig. 2 and 17.) For furnaces with 1-in.

clearance requirement on side, set furnace on non-combustible blocks, bricks or angle iron. For crawlspace installations, if the furnace is not suspended from the floor joists, the ground underneath furnace must be level and the furnace set on blocks or bricks.

Roll-Out Protection

Provide a minimum 17-3/4

″ X 22″ piece of sheet metal for flame roll-out protection in front of burner area for furnaces closer than

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

The bottom closure panel on furnaces of widths 17-1/2 in. 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.







Side Return Air Inlet

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

B

A

PLENUM

OPENING

D

FLOOR

C

OPENING

FURNACE

(OR COIL CASING

WHEN USED)

COMBUSTIBLE

FLOORING

DOWNFLOW

SUBBASE

SHEET METAL

PLENUM

FLOOR

OPENING

A96283

Fig. 11—Floor and Plenum Opening Dimensions

A96285

Fig. 12—Furnace, Plenum, and Subbase Installed on a Combustible Floor

FURNACE

CD5 OR CK5

COIL ASSEMBLY

OR KCAKC

COIL BOX

COMBUSTIBLE

FLOORING

SHEET METAL

PLENUM

FLOOR

OPENING

FILTER ARRANGEMENT

A04140

Fig. 13—Furnace, Plenum, and Coil Assembly or Coil

Box Installed on a Combustible Floor

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


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

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

There are no provisions for an internal filter rack in these furnaces.

An external filter rack is required.

12

A04140

This furnace is shipped with a factory-supplied Media Filter

Cabinet. The Media Filter Cabinet uses either a factory-supplied standard 1-inch filter or 4-inch wide Media Filter which can be purchased separately.

Refer to the instructions supplied with Media Cabinet for assembly and installation options.

AIR DUCTS

General Requirements

The duct system should be designed and sized according to accepted national standards such as those published by: Air

Conditioning Contractors Association (ACCA), Sheet Metal and

Air Conditioning Contractors National Association (SMACNA) or

American Society of Heating, Refrigerating and Air Conditioning

Engineers (ASHRAE) or consult The Air Systems Design Guide-

lines reference tables available from your local distributor. The

FURNACE

CASING

WIDTH

14–3/16

17–1/2

21

24-1/2

Table 4—Opening Dimensions (In.)

APPLICATION

PLENUM OPENING

A B

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 CD5 or

CK5 Coil Assembly or KCAKC coil box (KGASB subbase not required)





















Downflow applications on Combustible flooring (KGASB




12-11/16

12-9/16

11-13/16

12-5/16

16

15-7/8

15-1/8

15-1/2

19-1/2

19-3/8

18-5/8

19

23

22-7/8

22-1/8

22-1/2

21-5/8

19

19

19

21-5/8

19

19

19

21-5/8

19

19

19

21-1/8

19

19

19

20-1/8

20

20-1/4

20

23-5/8

23-1/2

23-3/4

23-1/2

FLOOR OPENING

C D

13-5/16 22-1/4

13-3/16

13-7/16

19-5/8

20-5/8

13-5/16 20

16-5/8

16-1/2

16-3/4

16-1/2

22-1/4

19-5/8

20-5/8

20

22-1/4

19-5/8

20-5/8

20

22-1/4

19-5/8

20-5/8

20 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 to enhance system performance. When air conditioning is used, a vapor barrier is recommended.

Maintain a 1-in. clearance from combustible materials to supply air ductwork for a distance of 36 in. horizontally from the furnace. See

NFPA 90B or local code for further requirements.

Ductwork Acoustical Treatment

NOTE: Metal duct systems that do not have a 90 degree elbow

and 10 ft 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

13 edition of SMACNA construction standard on fibrous glass ducts.

Both acoustical lining and fibrous ductwork shall comply with

NFPA 90B as tested by UL Standard 181 for Class 1 Rigid air ducts.

Supply Air Connections

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

Upflow and Horizontal Furnaces

Connect supply-air duct to flanges on furnace supply-air outlet.

Bend flange upward to 90° with wide duct pliers. (See 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 degrees to allow the evaporator coil to hang on the flange temporarily while the remaining attachment and sealing of the coil are performed.

Downflow Furnaces

UPFLOW

90˚

PREFERRED

D OWNFLOW

PREFERRED

HORIZONTAL

90˚

PREFERRED

120˚

MIN

PREFERRED

120˚

MIN

PREFERRED

120˚

MIN

PREFERRED

PERMITTED PERMITTED PERMITTED

Fig. 14—Duct Flanges

1

/

4

" THREADED ROD

4 REQ.

A02329

OUTER DOOR

ASSEMBLY

8" MIN FOR DOOR

REMOVAL

SECURE ANGLE

IRON TO BOTTOM

OF FURNACE WITH

3 #8 x 3

/

4

" SCREWS

TYPICAL FOR 2 SUPPORTS

1" SQUARE, 1 1

/

4

" x 1 1

/

4

" x 1

/

4

" ANGLE IRON

OR UNI-STRUT MAY BE USED

(2) HEX NUTS, (2) WASHERS & (2) LOCK WASHERS

REQ. PER ROD

Fig. 15—Horizontal Unit Suspension

14

A02345

METHOD 2

USE (4) #8 x 3/4 SHEET

METAL SCREWS FOR EACH

STRAP. THE STRAPS

SHOULD BE VERTICAL

AGAINST THE FURNACE

SIDES AND NOT PULL AWAY

FROM THE FURNACE

SIDES.

METHOD 1

FOLD ALL STRAPS UNDER

FURNACE AND SECURE WTH

(4) #8 x 3/4 SHEET METAL SCREWS

(2 SCREWS IN SIDE AND 2 SCREWS

IN BOTTOM).

A03176

Fig. 16—Horizontal Suspension with Straps

LINE CONTACT ONLY PERMISSIBLE BETWEEN

LINES FORMED BY INTERSECTIONS OF

THE TOP AND TWO SIDES OF THE FURNACE

JACKET AND BUILDING JOISTS,

STUDS, OR FRAMING.

GAS

ENTRY

TYPE-B

VENT

17

4

3

3

/

4

″ OVER ALL

/

4

″ UNDER DOOR

1

″ UNDER FURNACE

EXTEND OUT 12

″ OUT

FROM FACE OF DOOR

6″ MIN*

30-IN. MIN

WORK AREA

* WHEN USED WITH

SINGLE WALL VENT

CONNECTIONS

17

3

/

4

″

SHEET

METAL

22

″

EQUIPMENT MANUAL

SHUT-OFF GAS VALVE

SEDIMENT

TRAP

UNION

Fig. 17—Typical Attic Installation

A03177

Connect supply-air duct to supply-air outlet on furnace. Bend flange inward past 90° with wide duct pliers (See Fig. 14.) The supply-air duct must be connected to ONLY the furnace supply outlet or air conditioning coil casing (when used). When installed on combustible material, supply-air duct must be connected to

ONLY the accessory subbase, KGASB0201ALL, or a factory approved air conditioning coil casing. DO NOT cut main furnace casing to attach supply side air duct, humidifier, or other accessories. All accessories MUST be connected to duct external to furnace casing.

Return Air Connections

15

FIRE HAZARD

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

Never connect return-air ducts to the back of the furnace.

Follow instructions below.

Downflow Furnaces

Fig. 18—Upflow Return Air Configurations and Restrictions

A02075

Fig. 19—Downflow Return Air Configurations and Restrictions

A02163

Fig. 20—Horizontal Return Air Configurations and Restrictions

16

A02162

Table 5—Air Delivery - CFM (With Filter)*

FURNACE

SIZE

Operating Mode

036070

†† Low Heat

††

High Heat

1-1/2 Tons Cooling

CFM Airflow

Setting

735 (615)†

1180 (1060)†

525

700

875

1050

1225

1400

985 (825)†

1210 (1090)†

525

700

875

1050

1225

1400

1600

External Static

Pressure Range

0 – 0.5

0 – 1.0

0 – 0.5‡

0 – 0.5‡

0 – 1.0‡

0 – 1.0‡

0 – 1.0

0 – 1.0

0.1 0.2

EXTERNAL STATIC PRESSURE (In. wc)**

0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0

735 735 735 735 725

1160 1165 1175 1180 1180 1180 1180 1180 1180 1175

525

700

525

700

525

700

525

695

510

685

875 875 875 875 875 875 865 855 845 840

1050 1050 1050 1050 1050 1050 1050 1050 1045 1035

1205 1215 1225 1225 1225 1225 1225 1225 1225 1210

1395 1400 1400 1400 1400 1400 1400 1385 1360 1310

0 – 1.0

0 – 1.0

0 – 0.5‡

0 – 0.5‡

0 – 1.0‡

0 – 1.0‡

0 – 1.0‡

0 – 1.0

0 – 1.0

950 970 985 985 985 985 985 985 985 980

1190 1205 1210 1210 1210 1210 1210 1210 1210 1200

525

690

525

695

525

700

525

700

500

690

830 855 875 875 875 875 870 865 850 820

1005 1025 1040 1050 1050 1050 1050 1050 1050 1050

1205 1220 1215 1225 1225 1225 1225 1225 1225 1220

1370 1385 1395 1400 1400 1400 1400 1400 1400 1380

1565 1580 1585 1595 1600 1600 1560 1520 1480 1430

††

††

††

Low Heat

High Heat

2 Tons Cooling

2-1/2 Tons Cooling

3 Tons Cooling

3-1/2 Tons Cooling

4 Tons Cooling

5 Tons Cooling

1320 (1110)†

1475 (1330)†

700

875

1050

1225

1400

1750

0 – 1.0

0 – 1.0

0 – 0.5‡

0 – 0.5‡

0 – 0.5‡

0 – 1.0‡

0 – 1.0‡

0 – 1.0‡

1275 1295 1315 1320 1320 1320 1320 1320 1320 1315

1460 1465 1475 1475 1475 1475 1475 1475 1465 1465

700

860

700

875

700

865

685

855

660

840

1050 1050 1045 1050 1050

1185 1195 1215 1225 1225 1225 1225 1225 1225 1225

1385 1395 1400 1400 1400 1400 1400 1400 1400 1400

1710 1730 1745 1745 1750 1750 1750 1750 1745 1740

††

066135

††

††

††

066155

††

††

6 Tons Cooling

Maximum

Low Heat

High Heat

2 Tons Cooling

2-1/2 Tons Cooling

3 Tons Cooling

3-1/2 Tons Cooling

4 Tons Cooling

5 Tons Cooling

6 Tons Cooling

Maximum

Low Heat

High Heat

2 Tons Cooling

2-1/2 Tons Cooling

3 Tons Cooling

3-1/2 Tons Cooling

4 Tons Cooling

5 Tons Cooling

2100

2200

1700 (1430)†

1915 (1725)†

700

875

1050

1225

1400

1750

2100

2200

1715 (1440)†

1970 (1775)†

700

875

1050

1225

1400

1750

0 – 1.0

0 – 1.0

0 – 1.0

0 – 1.0

0 – 0.5‡

0 – 0.5‡

0 – 0.5‡

0 – 1.0‡

0 – 1.0‡

0 – 1.0‡

0 – 1.0

0 – 1.0

0 – 1.0

0 – 1.0

0 – 0.5‡

0 – 0.5‡

0 – 0.5‡

0 – 1.0‡

0 – 1.0‡

0 – 1.0‡

2090

2200

700

870

1010

1155

1395

1740

2075

2180

2100

2200

700

870

1030

1180

1400

1750

2085

2195

2100

2200

700

865

1050

1200

1400

1750

2090

2200

2100

2190

700

865

1050

1210

1400

1750

2100

2200

2095 2085

2185 2175

665

865

1050

1220 1225

1400 1400

1735 1740

2100 2100

2200 2200

2065

2155

1225

1400

1735

2090

2185

2045

2130

1225

1390

1730

2080

2165

2020

2085

1225

1375

1715

2055

2140

1990

2015

1700 1700 1700 1700 1700 1695 1700 1695 1685 1670

1900 1905 1915 1915 1915 1915 1915 1915 1915 1915

1225

1355

1700

2025

2095

1715 1715 1715 1715 1715 1705 1710 1705 1705 1695

1955 1965 1965 1970 1970 1970 1970 1970 1970 1960

700

865

1015

1160

1385

1745

700

875

1020

1185

1400

1750

700

875

1035

1215

1400

1750

700

865

1045

1225

1400

1750

680

865

1050

1225 1225

1400 1400

1745 1740

1225

1395

1745

1225

1395

1745

1225

1380

1740

1225

1360

1735

6 Tons Cooling

Maximum

2100

2200

0 – 1.0

0 – 1.0

2055 2070 2080 2085 2095 2100 2100 2100 2090 2065

2175 2190 2200 2200 2200 2200 2200 2200 2180 2160

* Actual external static pressure (ESP) can be determined by using the fan laws (CFM is proportional to ESP); such as a system with heating airflow of 1180 CFM at 0.5 ESP would operate at cooling airflow of 1050 CFM at 0.4 ESP and low-heating airflow of 735 CFM at 0.19 ESP.

** A filter is required for each return-air connection to the furnace. Airflow performance includes 1" washable filter media such as contained in factory-authorized accessory filter rack. To determine airflow performance without this filter, assume an additional 0.1" available external static pressure.

† "Comfort mode" airflow values are shown in (parenthesis). "Comfort mode" airflow is selected when the low-heat rise adjustment switch (SW1-3) is OFF and the comfort/efficiency switch (SW1-4) is ON. Furnaces are shipped in this configuration.

‡ Ductwork must be sized for the highest airflow, which is high-heating CFM and is greater than cooling CFM in this case.

Note also that heating ESP will be higher than cooling ESP for this system.

†† Operation within the blank areas of the chart is not recommended because high-heat airflow will be above 1.0 ESP.

*** All airflows on 110 size furnace are 5% less on side return only installations.

A04016

17

The return-air duct must be connected to return-air opening

(bottom inlet) as shown in Fig. 3. DO NOT cut into casing sides

(left or right). Side opening is permitted for only upflow and certain horizontal furnaces. Bypass humidifier connections should be made at ductwork or coil casing sides exterior to furnace. (See

Fig. 19.)

Upflow and Horizontal Furnaces

The return-air duct must be connected to bottom, sides (left or right), or a combination of bottom and side(s) of main furnace casing as shown in Fig. 3. Bypass humidifier may be attached into unused return air side of the furnace casing. (See Fig. 18 and 20.)

Not all horizontal furnace models are approved for side return air connections. (See Fig. 20.)

GAS PIPING

Table 6—Maximum Capacity of Pipe*

NOMINAL

IRON

PIPE

SIZE

(IN.)

1/2

3/4

1

1-1/4

1-1/2

INTERNAL

DIAMETER

(IN.)

0.622

0.824

1.049

1.380

1.610

10

175

360

680

1400

2100

LENGTH OF PIPE (FT)

20

120

250

465

950

1460

30

97

200

375

770

1180

40

82

170

320

660

990

50

73

151

285

580

900

* 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 12.2 ANSI Z223-2002/NFPA 54-2002.

FIRE OR EXPLOSION HAZARD

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

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


A 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. outside the furnace.



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



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

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

NSCNGPIC 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.

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. 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.

18

FURNACE DAMAGE HAZARD

Failure to follow this caution may result in furnace damage.

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

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

NOTE: The furnace gas control valve inlet pressure tap connec-

tion 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. 53.)

Some installations require gas entry on right side of furnace (as viewed in upflow). (See Fig. 21a and 21b.)

Install a sediment trap in riser leading to furnace as shown in Fig

21c. 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. NPT plugged tapping, accessible for test gauge connection, MUST be installed immediately upstream of gas supply connection to furnace and downstream of manual equipment shutoff valve.

Piping should be pressure and leak tested in accordance with

NFGC in the United States or NSCNGPIC 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

A05028

Fig. 21a—Right Side Gas Entry Example 1

90

° Elbow

ELECTRICAL CONNECTIONS

ELECTRICAL SHOCK HAZARD


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. 24 for field wiring diagram showing typical field 115-v wiring. Check all factory and field electrical connections for tightness.

Field-supplied wiring shall conform with the limitations of 63°F

(33°C) rise.

ELECTRICAL SHOCK AND FIRE HAZARD


The cabinet MUST have an uninterrupted or unbroken ground according to NEC ANSI/NFPA 70-2002 and Canadian Electrical Code CSA C22.1 or local codes to minimize personal injury if an electrical fault should occur. This may consist of electrical wire, conduit approved for electrical ground or a listed, grounded power cord (where permitted by local code) when installed in accordance with existing electrical codes.

Refer to the power cord manufacturer’s ratings for proper wire gauge. Do not use gas piping as an electrical ground.

2" Nipple

Street Elbow

Gas Valve

A02327

Fig. 21b—Right Side Gas Entry Example 2

GAS

SUPPLY

MANUAL

SHUTOFF

VALVE

(REQUIRED

SEDIMENT

TRAP

UNION

Fig. 21c—Typical Gas Pipe Arrangement

A02035

FURNACE MAY NOT OPERATE

Failure to follow this caution may result in intermitent 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 70-2002 and any local codes or ordinances that might apply.

Canadian Installations: Make all electrical connections in accor-

dance with Canadian Electrical Code CSA C22.1 or authorities having jurisdiction.

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.

19

FIRE HAZARD


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.

Table 7—Electrical Data

FURNACE SIZE

VOLTS-

HERTZ-

PHASE

070-12/036070

115-60-1

090-16/048090

115-60-1

110-20/060110

115-60-1

135-22/066135

115-60-1

155-22/066155

115-60-1

OPERATING

VOLTAGE RANGE

Maximum* Minimum*

127 104

127

127

127

127

104

104

104

104

MAXIMUM

UNIT AMPS

9.0

9.6

15.1

14.9

15.0

UNIT

AMPACITY#

11.99

12.56

19.33

19.13

19.23

MAXIMUM

WIRE LENGTH (FT)‡

30

29

29

30

29

MAXIMUM

FUSE OR CKT BKR

AMPS†

15

15

20

20

20

MINIMUM

WIRE GAUGE

14

14

12

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 furnace and service panel for maximum 2 percent voltage drop.

NOTE: Proper polarity must be maintained for 115-v wiring. If

polarity is incorrect, control LED status indicator light will flash rapidly and furnace will NOT operate.

J-BOX RELOCATION

NOTE: If factory location of J-Box is acceptable, go to next

section (ELECTRICAL CONNECTION to J-Box).

NOTE: On 14

″ 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. 22.)

NOTE: The J-Box cover need not be removed from the J-Box in

order to move the J-Box. Do NOT remove green ground screw inside J-Box. The ground screw is not threaded into the casing flange and can be lifted out of the clearance hole in casing while swinging the front edge of the J-Box outboard of the casing.

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

3. Move J-Box to desired location.

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

1.

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. 24.

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

Electrical Box on Furnace Casing Side

See Fig. 23.

Fig. 22—Relocating J-Box

TWO

A02099

20

FIRE OR ELECTRICAL SHOCK HAZARD


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 fieldsupplied screws from inside electrical box into casing steel.

4. Remove and save two screws holding J-Box. (See Fig. 22.)

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.

Fig. 23—Field-Supplied Electrical Box on

Furnace Casing

A03221

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

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

12. Complete electrical box wiring and installation. Connect line voltage leads as shown in Fig. 24. Use best practices (NEC in

U.S. and CSA C22.1 in Canada) for wire bushings, strain relief, etc.


POWER CORD INSTALLATION IN FURNACE J-BOX

NOTE: Power cords must be able to handle the electrical require-

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

1. Remove cover from J-Box.

2. Route listed power cord through 7/8-inch 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.



BX CABLE INSTALLATION IN FURNACE J-BOX

1. Remove cover from J-Box.

2. Route BX cable into 7/8-inch 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.



24-V WIRING

Make field 24-v connections at the 24-v terminal strip. (See Fig.

25.) Connect terminal Y/Y2 as shown in Fig. 26-33 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 115VAC, 1.0 amps maximum and are energized during blower motor operation.

(See Fig. 25.)

2. Humidifier (HUM)

Connect an accessory 24 VAC, 0.5 amp maximum humidifer

(if used) to the 1/4-in male quick-connect HUM terminal and

C

OM

-24V screw terminal on the control board thermostat strip.

The HUM terminal is energized when blower is energized in heating. (See Fig. 25.)

NOTE: DO NOT connect furnace control HUM terminal to HUM

(humidifier) terminal on Thermidistat, Zone Controller or similiar device. See Thermidistat™, 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.

21

FIELD 24-VOLT WIRING

FIELD 115-, 208/230-, 460-VOLT WIRING

FACTORY 24-VOLT WIRING

FACTORY 115-VOLT WIRING

FIVE

WIRE

THREE-WIRE

HEATING-

ONLY

NOTE 2

W C Y R G

1-STAGE

THERMOSTAT

TERMINALS

FIELD-SUPPLIED

FUSED DISCONNECT

208/230- OR

460-VOLT

THREE

PHASE

BLK BLK

W2

COM

WHT WHT

W/W1

GND

115-VOLT FIELD-

SUPPLIED

FUSED

DISCONNECT

JUNCTION

BOX

CONTROL

BOX

Y/Y2

R

G

24-VOLT

TERMINAL

BLOCK

FURNACE

NOTE 1

NOTES: 1.

2.

3.

CONDENSING

UNIT

GND

208/230-

VOLT

SINGLE

PHASE

Connect Y/Y2-terminal as shown for proper operation.

Some thermostats require a "C" terminal connection as shown.

If any of the original wire, as supplied, must be replaced, use same type or equivalent wire.

Fig. 24—Field Wiring Diagram

A95236

22

MODEL PLUG

CONNECTOR

SW1 SETUP

SWITCHES AND

BLOWER OFF-

DELAY

AIR CONDITIONING

(A/C) AIRFLOW

SETUP SWITCHES

COMMUNICATION

CONNECTOR

CONTINUOUS FAN

(CF) AIRFLOW

SETUP SWITCHES

FUTURE

APPLICATIONS

24-V THERMOSTAT

TERMINALS

HUMIDIFIER

TERMINAL (24-VAC

0.5 AMP MAX.

ACRDJ – AIR

CONDITIONING

RELAY DISABLE

JUMPER

FLASH

UPGRADE

CONNECTOR

(FACTORY

ONLY)

STATUS AND COMM

LED LIGHTS

3-AMP FUSE

TRANSFORMER 24-VAC

CONNECTIONS

PL3 – ECM BLOWER

HARNESS

CONNECTOR

115-VAC (L2) NEUTRAL

CONNECTIONS

PL1 – LOW VOLTAGE MAIN

HARNESS CONNECTOR

EAC-1 TERMINAL

(115-VAC 1.0 AMP MAX.)

115-VAC (L1) LINE

VOLTAGE CONNECTIONS

PL2 – HOT SURFACE

IGNITER & INDUCER

MOTOR CONNECTOR

A02018

Fig. 25—Variable Speed Furnace Control for ECM Blower Motor

23


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

Z223.1-2002/NFPA 54 or the CSA B149.1, Natural Gas and Propane Installation Code and these instructions.

Determine that there is no blockage or restriction, leakage, corrosion and other deficiencies, which could cause an unsafe condition.

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

4. Close fireplace dampers.

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

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

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

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

2002/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.

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

NSCNGPIC.

GENERAL VENTING REQUIREMENTS

Follow all safety codes for proper vent sizing and installation requirements, including local building codes, the National Fuel

Gas Code ANSI Z223.1-2002/NFPA 54-2002 (NFGC), Parts 10 and 13 in the United States or the National Standard of Canada,

Natural Gas and Propane Installation Code CSA-B149.1-00

(NSCNGPIC) Section 7 and Appendix C in Canada, the local building codes, and furnace and vent manufacturers’ instructions.

These furnaces are design-certified as Category I furnaces in accordance with ANSI Z21.47-2003/CSA 2.3-2003 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 multi-story venting with other fan assisted or draft hood equipped appliances in accordance with the NFCG or the

NSCNGPIC, the local building codes, and furnace and vent manufacturers’ instructions.

24

A00275

Fig. 26—Two-Stage Furnace with Single-Speed

Air Conditioner

The following information and warning must be considered in addition to the requirements defined in the NFGC or the NSCNG-

PIC.



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

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

2. Two-stage furnaces require Type B vent connectors outside the casing in all configurations. Single wall vent connector may be used inside the furnace casing with the transition to

Type B vent outside the furnace casing. Size the connector so that the FAN-Min vent connector capacity is equal to or lower than the low fire rate of the furnace and the FAN-Max vent connector capacity is equal to or higher than the furnace high fire rate.

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

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

5. In the US: Do not vent this appliance with any solid fuel burning appliance.

In Canada: Check with the authority having jurisdiction for approval on use with solid fuel burning appliance.

See notes 2, 5, 8, 10, 11 and 12 on the page following these figures

A03179

Fig. 27—Two-Stage Furnace with Two-Speed

Air Conditioner

See notes 1, 2, 4, 6, 7, 9, 10, 11, and 15 on the page following these figures

A03180

Fig. 28—Two-Stage Furnace with Single-Speed

Heat Pump (Dual Fuel)

See notes 1, 2, 3, 4, 6, 8, 9, 10, 12, 13 and 15 on the page following these figures

Fig. 29—Two-Stage Furnace with Two-Speed Heat Pump (Dual Fuel)

25

A03178

See notes 1, 2, 4, 11, 14, 15, and 16 on the page following these figures

A03181

Fig. 30—Dual Fuel Thermostat with Two-Stage

Furnace and Single-Speed Heat Pump

See notes 2, 11, and 12 on the page following these figures

A03183

Fig. 32—Two-Stage Thermostat with Two-Stage

Furnace and Two-Speed Air Conditioner

1

See notes 1 and 2 on the page following these figures

A03184

Fig. 33—Single-Stage Thermostat with

Two-Stage Furnace and Two-Speed Air Conditioner

See notes 1, 2, 3, 4, 12, 13, 14, 15, and 17 on the page following these figures

A03182

Fig. 31—Dual Fuel Thermostat with Two-Stage

Furnace and Two-Speed Heat Pump

26

NOTES FOR FIGURES 26-33

1. Heat pump MUST have a high pressure switch for dual fuel applications.

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

3. If the heat pump date code is 1501E or earlier, select the

″ZONE″ position on the two-speed heat pump control. Heat pumps having date codes 1601E and later do not have or require a

″ZONE″ selection.

4. Outdoor Air Temperature Sensor must be attached in all dual fuel applications.

5. Dip switch No. 1 on Thermidistat should be set in OFF position for air conditioner installations. This is factory default.

6. Dip switch No. 1 on Thermidistat should be set in ON position for heat pump installations.

7. Dip switch No. 2 on Thermidistat should be set in OFF position for single-speed compressor operation. This is factory default.

8. Dip switch No. 2 on Thermidistat should be set in ON position for two-speed compressor operation.

9. Configuration Option No. 10 “Dual Fuel Selection” must be turned ON in all dual fuel applications.

10. NO connection should be made to the furnace HUM terminal when using a Thermidistat.

11. Optional connection: If wire is connected, dip switch SW1-2 on furnace control should be set in ON position to allow

Thermidistat/Thermostat to control furnace staging.

12. Optional connection: If wire is connected, ACRDJ jumper on furnace control should be removed to allow Thermidistat/Thermostat to control outdoor unit staging.

13. Furnace must control its own high-stage heating operation via furnace control algorithm.

14. The RVS Sensing terminal “L” should not be connected. This is internally used to sense defrost operation.

15. DO NOT SELECT the “FURNACE INTERFACE” or “BALANCE POINT” option on the two-speed heat pump control board. This is controlled internally by the Thermidistat/Dual Fuel Thermostat.

16. Dip switch D on Dual Fuel Thermostat should be set in OFF position for single-speed compressor operation. This is factory default.

17. Dip switch D on Dual Fuel Thermostat should be set in ON position for two-speed compressor operation.

27

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?

No

Yes

Rebuild crown.

Is chimney property lined with clay tile liner?

No

Yes

Is liner and top seal in good condition?

Yes

No

Repair liner or top seal or reline chimney as necessary.

Reline

Repair

Debris in cleanout?

Mortar, tile, metal vent, fuel oil residue?

Yes

No

Remove metal vent or liner.

Mortar or tile debris?

No

Yes

Remove mortar and tile debris

Clay tile misalignment, missing sections, gaps?

Yes

No

Condensate drainage at bottom of chimney?

No

Chimney exposed to outdoors below roof line?

No

Yes

Yes

No

Is chimney lined with properly

Consult

Part B of chimney adapter venting instructions for application suitability.

Suitable sized, listed liner or

Type-B vent?

Yes

Yes

Not Suitable

Install chimney adapter per instructions.

Not Suitable

Is chimney to be dedicated to a single furnace?

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.

Consult

Part C of chimney adapter venting instructions for application suitability

Suitable

Install chimney adapter per instructions.

Chimney is acceptable for use.

Fig. 34—Chimney Inspection Chart

28

A03206

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

SIDEWALL VENTING section.

7. Do not vent this appliance into an unlined masonry chimney.

Refer to Chimney Inspection Chart, Fig. 34.

MASONRY CHIMNEY REQUIREMENTS

NOTE: These furnaces are CSA design-certified for use in

exterior tile-lined masonry chimneys with a factory accessory

Chimney Adapter Kit. Refer to the furnace rating plate for correct kit usage. The Chimney Adapter Kits are for use with ONLY furnaces having a Chimney Adapter Kit number marked on the furnace rating plate.

If a clay tile-lined masonry chimney is being used and it is exposed to the outdoors below the roof line, relining might be required.

Chimneys shall conform to the Standard for Chimneys, Fireplaces,

Vents, and Soild Fuel Burning Appliances ANSI/NFPA 211-2003 in the United States and to a Provincial or Territorial Building

Code in Canada (in its absence, the National Building Code of

Canada) and must be in good condition.

U.S.A.-Refer to Sections 13.1.9 and 13.2.20 of the 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 NFGC 13.1.9 and 13.2.20 regarding alternative

venting design and the exception, which cover installations such as our Chimney Adapter Kits KGACA02014FC and

KGACA02015FC, which are listed for use with these furnaces.

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

Canada (and U.S.A.)-This furnace is permitted to be vented into

a clay tile-lined masonry chimney that is exposed to the outdoors below the roof line, provided:

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

2. This furnace is common vented with at least 1 draft hoodequipped 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 square inches require furnace input ratings greater than the input ratings of these furnaces. See footnote at bottom of Table B, and

5. The authority having jurisdiction approves.

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

Inspections before the sale and at the time of installation will determine the acceptability of the chimney or the need for repair and/or (re)lining. Refer to the Fig. 34 to perform a chimney inspection. If the inspection of a previously used tile-lined chimney: a. Shows signs of vent gas condensation, the chimney should be relined in accordance with local codes and the authority having jurisdiction. The chimney should be relined with a listed metal liner, Type-B vent, or a listed chimney adapter kit shall be used to reduce condensation. If a condensate drain is required by local code, refer to the NFGC, Section

10.9 for additional information on condensate drains.

29 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.

Exterior Masonry Chimney FAN + NAT

Installations with Type-B Double-Wall Vent

Connectors

©NFPA & AGA

Table A—Combined Appliance Maximum Input

Rating in Thousands of BTU per Hour

VENT HEIGHT (FT)

6

8

10

15

20

30

80

84

NR

NR

NR

INTERNAL AREA OF CHIMNEY

(SQ. IN.)

12

74

19

119

28

178

38

257

130

138

152

NR

NR

193

207

233

250

NR

279

299

334

368

404

APPLIANCE APPLICATION REQUIREMENTS

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

The furnace should be sized to provide 100 percent of the design heating load requirement plus any margin that occurs because of furnace model size capacity increments. Heating load estimates can be made using approved methods available from Air Conditioning Contractors of America (Manual J); American Society of

Heating, Refrigerating, and Air-Conditioning Engineers; or other approved engineering methods. Excessive oversizing of the furnace could cause the furnace and/or vent to fail prematurely.

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

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

1. The return-air temperature must be at least 60°F db except for brief periods of time during warm-up from setback at no lower than 55°F db or during initial start-up from a standby condition.

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

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

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

Table B—Minimum Alowable Input Rating of

Space-Heating Appliance in

Thousands of BTU per Hour

VENT

HEIGHT (FT)

12

INTERNAL AREA OF CHIMNEY

(SQ. IN.)

19 28 38

Local 99% Winter Design

Temperature: 17 to 26 degrees F*

6

8

10

15

20

30

6

8

10

15

20

0

52

NR

NR

NR

NR

55

74

90

NR

NR


Temperature: 5 to 16 degrees F*

NR

NR

NR

NR

NR

NR

78

94

111

NR

NR

99

111

125

167

212

NR

121

135

149

193

NR

141

154

169

212

258

362

166

182

198

247

293

377 30

6

8

10

15

NR NR


Temperature: -10 to 4 degrees F*

NR

NR

NR

NR

NR

NR

NR

NR

NR

20

30

NR

NR

NR

NR

NR

NR


Temperature: -11 degrees F or lower*

145

159

175

NR

196

213

231

283

333

NR

3 screws that secure vent elbow to furnace, rotate furnace vent elbow to position desired, re-install screws. The factory-supplied vent elbow does NOT count as part of the number of vent connector elbows.

The vent connector can exit the 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 avail-

able 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, corrosionresistant sheet metal screws located 180° apart.

2. Vent the furnace with the appropriate connector as shown in

Fig 35-47.

Not recommended for any vent configuration

*The 99% Winter Design Dry-Bulb (db) temperatures are found in the 1993

ASHRAE Fundamentals Handbook, Chapter 24, Table 1 (United States) and

2 (Canada), or use 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).

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

″ round vent elbow is supplied with the furnace. A 5-inch or 6inch vent connector may be required for some model furnaces. A field-supplied 4-inch to 5-inch or 4-inch to 6-inch sheet metal increaser fitting is required when 5-inch or 6-inch vent connector is used. See Fig. 35-47, Venting Orientation for approved vent configurations.

NOTE: Vent connector length for connector sizing starts at

furnace vent elbow. The 4-inch vent elbow is shipped for upflow configuration and may be rotated for other positions. Remove the

CUT HAZARD



3. Orient the door to determine the correct location of the door knockout to be removed.

4. Use aviation-type tin snips to remove the correct U-shaped knockout in door.

NOTE:

A number of techniques can be used to remove these knockouts as seen in Fig. 48 through 52. 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. 48.) A sharp blow to the rounded end of the knockout (See Fig. 49.) will separate more tie points and allow the knockout to be pulled loose. (See Fig. 50.)

Remove any burrs and sharp edges.

For the rectangular J-box knockout, use tin snips along the door edge and use a sharp blow with a hammer to remove the knockout.

Remove any burrs and sharp edges.

For the knockouts in the other locations on the door (top and sides), tin snips can also be used along the door edges; however, the preferred method is to use a hammer and screwdriver to strike a sharp blow (See Fig. 51.) directly to the knockout tie points or use a hammer in the upper left corner of the desired knockout. (See

Fig. 52.) Remove any burrs and sharp edges.

NOTE: If a knockout does not come out after two sharp blows,

pull and snip as needed to remove the knockout. Additional blows may cause damage to the door.

30

BURN HAZARD


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.

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

Fig. 35—Upflow Application-Vent Elbow Up

A03208

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

A03211

Fig. 38—Downflow Application-Vent Elbow Up

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

A03209

Fig. 36—Upflow Application-Vent Elbow Right

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

Fig. 39—Downflow Application-

Vent Elbow Left then Up

A03207

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


Vent Elbow Up then Left

A03210

31

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


Vent Elbow Up then Right

A03212


A03213

Fig. 41—Horizontal Left Application-Vent Elbow Left


A03215

Fig. 43—Horizontal Left Application-Vent Elbow Up


Fig. 42—Horizontal Left Application-

Vent Elbow Right then Up

A03214


A03216

Fig. 44—Horizontal Left Application-Vent Elbow Right


Fig. 45—Horizontal Right Application-

Vent Elbow Right

A03218


Fig. 46—Horizontal Right Application-

Vent Elbow Left then Up

A03219

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

Fig. 47—Horizontal Right Application-Vent Elbow Left

32

A02068

Caution!! For the following applications, use the minimum vertical heights as specified below

For all other applications, follow exclusively the National Fuel Gas Code

FURNACE ORIENTATION VENT ORIENTATION FURNACE INPUT(BTU/HR)

MINIMUM

VENT DIAMETER (IN.)*

Downflow

Vent elbow left, then up

Fig. 37

154,000

132,000

110,000(036/-12 only)

Horizontal Left

Horizontal Left

Vent elbow right, then up

Fig. 40

Vent Elbow up

Fig. 41

154,000

132,000

154,000

132,000

Horizontal Left

Downflow

Downflow

Vent elbow right

Fig. 42

Vent elbow up then left

Fig. 35

Vent elbow up, then right

Fig. 38

154,000

110,000

(036/-12 only)

110,000

(036/-12 only)

NOTE: All vent configurations must also meet National Fuel Gas Code venting requirements NFGC.

*4 in. inside casing or vent guard

**Including 4 in. vent section(s)

5

5

5

5

5

5

MINIMUM VERTICAL VENT HEIGHT (FT)**

12

7

7

7

10

10

Venting Notes for Fig. 35-47

1. For common vent, vent connector sizing and vent material:

United States--use the NFGC

Canada--use the NSCNGPIC

2. Immediately increase to 5-inch or 6-inch vent connector outside furnace casing when 5-inch vent connector is required, refer to Note 1 above.

3. Side outlet vent for upflow and downflow installations must use Type B vent immediately after exiting the furnace, except when

KGAVG0101DFG, Downflow Vent Guard Kit, is used in the downflow position.

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

5. Four-inch single-wall (26 ga. min.) vent must be used inside furnace casing and when the KGAVG0101DFG Downflow Vent Guard Kit is used external to the furnace.

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.

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

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

10. The total height of the vent and connector shall be at least seven feet for the 154,000 Btuh gas input rate model when installed in a downflow application with furnace elbow turned to left side with the connector elbow outside furnace casing pointing upward. (See Fig.

39.)

The horizontal portion of the venting system shall slope upwards not less than 1/4-in. per linear ft (21 mm/m) from the furnace to the vent and shall be rigidly supported every 5 ft 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 10.3.4 of the NFGC, any listed mechanical

venter may be used, when approved by the authority having jurisdiction.

In Canada: Per section 7.24.2 of the NSCNGPIC, any listed

mechanical venter may be used, when approved by the authority having jurisdiction.

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

33

START-UP, ADJUSTMENT, AND SAFETY CHECK

Step 1—General

FIRE HAZARD

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

This furnace is equipped with manual reset limit switches in the gas control area. The switches open and shut off power to the gas valve, if a flame rollout or overheating condition occurs in the gas control area. DO NOT bypass the switches.

Correct problem before resetting the switches.

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

Fig. 48—Using Tin Snips to Cut Tie Points

A04127

Fig. 49—Rounded End of Knockout

A04128

A04130

Fig. 51—Hammer and Screwdriver Used for

Knockout

Fig. 52—Remove Knockout with Hammer

A04131

A04129

Fig. 50—Knockout Pulled Loose

will result in improper operation. (See Fig. 24.)

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).

CUT HAZARD



4. Check all manual-reset switches for continuity.

34

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

6. Setup switch descriptions

The variable speed furnace control has DIP switches to select thermostat staging, blower off delay timings, air flow selection and other operational or service related functions. (See Fig.

25, 57 and Table 8.)

ON/OFF SWITCH

1/2˝ NPT INLET

INLET

PRESSURE TAP

MANIFOLD

PRESSURE TAP

1/2˝ NPT OUTLET

A04167

Fig. 53—Redundant Automatic Gas Control Valve

BURNER

ORIFICE

Fig. 54—Orifice Hole

THERMOSTAT SUBBASE

TERMINALS WITH

THERMOSTAT REMOVED

(ANITICIPATOR, CLOCK, ETC.,

MUST BE OUT OF CIRCUIT.)

HOOK-AROUND

AMMETER

A93059

R Y W G

10 TURNS

REGULATOR COVER SCREW

PLASTIC ADJUST SCREW

REGULATOR SPRING

HIGH STAGE GAS

PRESSURE REGULATOR

ADJUSTMENT

LOW STAGE

GAS PRESSURE

REGULATOR ADJUSTMENT

Step 2—Start-Up Procedures

FIRE AND EXPLOSION HAZARD

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

Never purge a line into a combustion chamber. Never use matches, candles, flame, or other sources of ignition for the purpose of checking leakage. Use a soap-and-water solution to check for leakage.

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

2. Check gas lines for leaks.

FROM UNIT 24-V

CONTROL TERMINALS

EXAMPLE:

5.0 AMPS ON AMMETER

10 TURNS AROUND JAWS

=

0.5 AMPS FOR THERMOSTAT

ANTICIPATOR SETTING

Fig. 55—Amp Draw Check With Ammeter

A96316



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 furnace control board. Manually close blower door switch. Turn Setup DIP switch SW1-6 ON. (See Fig. 25, 57 and Table 8.)

NOTE: The furnace control allows all components, except the gas

valve, to be run for short period of time. This feature helps diagnose a system problem in case of a component failure.

Component test feature will not operate if any thermostat signal is present at the control.

Refer to service label attached to furnace or See Fig. 56.

Component test sequence is as follows: a. Inducer motor starts on high-speed and continues to run until Step d. of component test sequence.

b. Hot surface igniter is energized for 15 sec., then off.

c. Blower motor operates for 15 sec.

d. Inducer motor goes to low-speed for 10 sec., then stops.

e. After component test is completed, one or more status codes (11, 25, or 41) will flash. See component test section of service label (Fig. 56) in furnace for explanation of status codes.

NOTE: To repeat component test, turn setup switch SW1-6 OFF,

then back ON.

4. Turn setup DIP switch SW1-6 OFF. Reconnect R lead to furnace control board, release blower door switch and reinstall blower access door.

5. Operate furnace per instruction on inner door.

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

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

35

SETUP

SWITCH NO.

SW1-1

SW1-2

SW1-3

SW1-4

SW1-5

SW1-6

SW1-7

SW1-8

SWITCH

NAME

Low Heat

Rise Adjust

Table 8—Furnace Setup Switch Description

Status Code Recovery

Adaptive Heat Mode

Comfort/Efficiency Adjustment

CFM per ton adjust

Component Self-Test

Blower OFF delay

Blower OFF delay

NORMAL

POSITION

OFF

OFF

OFF

ON

OFF

OFF

ON or OFF

ON or OFF

DESCRIPTION

OF USE

Turn ON to retrieve up to 7 stored status codes for troubleshooting assistance when R thermostat lead is disconnected.

Allows 2-stage operation with a single stage thermostat.

Turn ON when using 2 stage thermostat to allow Low Heat operation when R to W/W1 closes and High Heat operation when R to

W/W1 and W2 close.

Turn ON to increase Low Heat airflow by 18 percent. This compensates for increased return air temperature caused with bypass humidifier.

Turn ON to decrease Low Heat airflow by 16 percent and High Heat airflow 10 percent for maximum comfort.

Turn ON for 400 CFM per ton. Turn OFF for 350 CFM per ton.

Turn ON to initiate Component Self-Test for troubleshooting assistance when R thermostat lead is disconnected.

Turn OFF when Self-Test is completed.

Control blower Off Delay time. Used in conjunction with SW1-8. See

Table 10.

Control blower Off Delay time. Used in conjunction with SW1-7. See

Table 10.

SERVICE

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 FLA SHING - Line voltage (115VAC) polarity reversed.

If status code recall is needed disconnect the "R" thermostat lead, reset power, and put setup switch "SW1-1" in the ON position. To clear the status code history put setup switch "SW1-1" in the ON position and jumper thermostat terminals "R",

"W/W1", and "Y/Y2" simultaneously until status code #11 is flashed.

EACH OF THE FOLLOWING STATUS CODES IS A TWO DIGIT NUMBER WITH THE FIRST DIGIT DETERMINED BY THE NUMBER OF SHORT FLASHES AND THE SECOND DIGIT BY THE NUMBER OF LONG FLASHES.

11 NO PREVIOUS CODE - Stored status codes are erased automatically after 72 hours or as specified above.

12 BL OWER ON 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/W1 closed) or

(R-W/W1 opens) during blower on-delay period.

13 LIMIT CIRCUIT LOCKOUT - Lockout occurs if a limit, draft safeguard, flame rollout, or blocked vent switch (if used) is open longer than 3 minutes or 10 successive limit trips occurred during high-heat. Control will auto reset after three hours. Refer to status code #33.

14 IGNITION LOCKOUT - Control will auto-reset after three hours. Refer to status code #34.

15 BL OWER MOTOR LOCKOUT - Indicates the blower failed to reach 250 RPM or the blower failed to communicate within 30 seconds after being turned ON in two successive heating cycles. Control will auto reset after 3 hours.

Refer to status code #41.

21 GAS HEATING LOCKOUT - Control will NOT auto reset. Check for:

- Mis-wired gas valve -Defective control (valve relay)

22 ABNO RMAL FLAME-PROVING SIGNAL - Flame is proved while gas valve is de-energized. Inducer will run until fault is cleared. Check for:

- Leaky gas valve - Stuck-open gas valve

23 PRESSURE SWITCH DID NOT OPEN Check for:

- Obstructed pressure tubing - Pressure switch stuck closed

24 SECONDARY VOLTAGE FUSE IS OPEN Check for: - Short circuit in secondary voltage (24VAC) wiring.

25 INVAL ID MODEL SELECTION OR SETUP ERROR - Indicates either the model plug is missing or incorrect or, setup switch "SW1-1" or "SW1-6" is positioned improperly. If code flashes 4 times on power-up control is defaulting to model selection stored in memory.Check for: -Thermostat call with SW1-1, SW1-6 or

32 Cont in ued: Check for:

33

- Defective inducer motor

- Defective pressure switch

- Low inducer voltage (115 VAC)

- Low inducer voltage (115 VAC)

- Disconnected or obstructed pressure tubing

LIMIT CIRCUIT FAULT - Indicates a limit, draft safeguard, flame rollout, or blocked vent switch (if used) is open or the furnace is operating in high-heat only mode due to 2 successive low heat limit trips. Blower will run for 4 minutes or until open switch remakes whichever is longer. If open longer than 3 minutes, code changes to lockout #13. If open less than 3 minutes status code #33 continues to flash until blower shuts off. Flame rollout switch and BVSS require manual reset. Check for: - Loose blower wheel

- Restricted vent - Proper vent sizing - Excessive wind

- Dirty filter or restricted duct system - Defective switch or connections

- Inadequate combustion air supply (Flame Roll-out Switch open)

34 IGNITION PROVING FAILURE - Control will try three more times before lockout #14 occurs. If flame signal lost during blower on-delay period, blower will come on for the selected blower off-delay. Check for:

- Oxide buildup on flame sensor (clean with fine steel wool)

- Proper flame sense microamps (.5 microamps D.C. min., 4.0 - 6.0 nominal)

- Manual valve shut-off - Low inlet gas pressure - Control ground continuity

- Gas valve defective or turned off

- Inadequate combustion air supply

- Low inlet gas pressure (if LGPS used)

- Inadequate flame carryover or rough ignition

- Green/Yellow wire MUST be connected to furnace sheet metal

41 BL OWER MOTOR FAUL T - Indicates the blower failed to reach 250 RPM or the blower failed to communicate within the prescribed times limits. Thirty both SW1-1 & SW1-6 ON. - Board date code 2103 or later required to recognize model seconds after being turned ON or ten seconds during steady-state operation.

43 LOW-HEAT PRESSURE SWITCH OPEN WHILE HIGH-HEAT PRESSURE

SWITCH IS CLOSED - Check for: - Mis-wired pressure switches

31 HIGH-HEAT PRESSURE SWITCH OR RELAY DID NOT CLOSE OR

REOPENED - Control relay may be defective. Refer to status code #32.

32 LOW-HEAT PRESSURE SWITCH DID NOT CLOSE OR REOPENED - If open longer than five minutes, inducer shuts off for 15 minutes before retry. If opens during blower on-delay period, blower will come on for the selected blower off-delay. Check for: - Excessive wind - Restricted vent - Proper vent sizing

- Low-heat pressure switch stuck open - Low inlet gas pressure (if LGPS used)

- Disconnected or obstructed pressure tubing

45 CONTROL CIRCUITRY LOCKOUT Auto-reset after one hour lockout due to;

- Gas valve relay stuck open - Flame sense circuit failure - Software check error

Reset power to clear lockout. Replace control if status code repeats.

COMPONENT TEST

To initiate the component test sequence, shut

OFF the room thermostat or disconnect the "R" thermostat lead. Reset power and then put setup switch "SW1-6" in the ON position to start the component test sequence. Once initiated the furnace control will turn the inducer ON at highheat speed. The inducer motor will run for the entire test. The hot surface igniter and blower motor will be turned ON for 15 seconds each.

When the blower is turned OFF the inducer will be switched to low-speed for 10 seconds. When the component test is completed one or more of the following codes will flash.

CODE

- Flame sensor must not be grounded

DESCRIPTION

11 Indicates the blower motor tested

OK. Visual check of inducer motor

and hot surface igniter required.

25 SETUP ERROR - Same as code 25 above.

41 BL OWER MOTOR FAUL T - Indicates

To repeat component test turn setup switch

"SW1-6" OFF and then back ON. After component test is completed put setup switch "SW1-6" in the lead.

blower motor failed test. Check

blower, wiring, and furnace control.

OFF position and reconnect the "R" thermostat

328787-101 REV. A

A04015

Fig. 56—Service Label

Step 3—Adjustments

FIRE HAZARD

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

DO NOT bottom out gas valve regulator adjusting screw.

This can result in unregulated manifold pressure and result in excess overfire and heat exchanger failures.

36


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

DO NOT redrill orifices. Improper drilling (burrs, out-ofround 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.

54.)

Furnace gas input rate on rating plate is for installations at altitudes up to 2000 ft. Furnace input rate must be within ±2 percent of furnace rating plate input. For altitudes above 5500 ft., a fieldsupplied high altitude pressure switch is required.

1. Determine the correct gas input rate.

In the U.S.A.:

The input rating for altitudes above 2,000 ft. must be reduced by 4 percent for each 1,000 ft. above sea level.

For installations below 2000 ft., refer to the unit rating plate.

For installations above 2000 ft., multiply the input on the rating plate by the de-rate multiplier in Table 9 for the correct

10 16

1 7

ACRDJ

7 8 7 8 7 8 7 8

OFF OFF OFF OFF

PRINTED CIRCIUT BOARD

YEL

RED

GRN

YEL

BLU

TRAN

LO HI HSI VS

RED

GRN

YEL

BLU

PL12

OFF

1 2 3

OFF

1 2 3

OFF

1 2 3

OFF

1 2 3

OFF

1 2 3

OFF

1 2 3

OFF

1 2 3

OFF

1 2 3

-1 EAC

SW4

OAT

PRINTED CIRCIUT BOARD

J ACRD

HUM

-1 SEC

-2 EAC

-AMP

-2 SEC

SE 3 FU

SW1

PL4

37

. A R EV 1 -10 328782

Table 9–Altitude Derate Multiplier for U.S.A.

ALTITUDE

(FT)

0–2000

2001–3000

3001–4000

4001–5000

5001–6000

6001–7000

7001–8000

8001–9000

9001–10,000

PERCENT

OF DERATE

0

8–12

12–16

16–20

20–24

24–28

28–32

32–36

36–40

DERATE MULTIPLIER

FACTOR*

1.00

0.90

0.86

0.82

0.78

0.74

0.70

0.66

0.62

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

input rate.

In Canada:

The input rating for altitudes from 2,000 to 4,500 ft above sea level must be derated 10 percent by an authorized Gas

Conversion Station or Dealer.

To determine correct input rate for altitude, see example and use 0.90 as derate multiplier factor.

EXAMPLE:

88,000 BTUH INPUT FURNACE INSTALLED AT 4300 FT.

Derate

Furnace Input Rate

X Multiplier =

at Sea Level

88,000

X

Factor

0.90

=

Furnace Input Rate at Installation

Altitude

79,200

2. Determine the correct orifice and manifold pressure adjustment. All models in all positions except Low NOx models in downflow and horizontal positions use Table 12 (22,000 Btuh per burner.) Low NOx models in downflow or horizontal positions must use Table 13 (21,000 Btuh per burner.)

See input listed on rating plate.

a. Obtain average yearly gas heat value (at installed altitude) from local gas supplier.

b. Obtain average yearly gas specific gravity from local gas supplier.

c. Find installation altitude in Table 12 or 13.

d. Find closest natural gas heat value and specific gravity in

Table 12 or 13.

e. Follow heat value and specific gravity lines to point of intersection to find orifice size and low-and high-heat manifold pressure settings for proper operation.

f. Check and verify burner orifice size in furnace. NEVER

ASSUME ORIFICE SIZE. ALWAYS CHECK AND

VERIFY.

g. Replace orifice with correct size, if required by Table 12 or

13. Use only factory-supplied orifices. See EXAMPLE 2.

Table 10—Blower Off Delay Setup Switch

DESIRED HEATING MODE

BLOWER OFF DELAY (SEC.)

SETUP SWITCH (SW-7 AND -8) POSITION

90

120

150

180

SW1-7

OFF

ON

OFF

ON

SW1-8

OFF

OFF

ON

ON

38

EXAMPLE 2: (0–2000 ft altitude)

For 22,000 Btuh per burner application use Table 12.

Heating value = 1000 Btu/cu ft

Specific gravity = 0.62

Therefore: Orifice No. 43*

Manifold pressure: 3.7-in. wc for high-heat

1.6-in. wc for low-heat

* Furnace is shipped with No. 43 orifices. In this example all main burner orifices are the correct size and do not need to be changed to obtain proper input rate.

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

Fig. 53.) a. Turn gas valve ON/OFF switch to OFF.

b. Remove manifold pressure tap plug from gas valve.

c. Connect a water column manometer or similar device to manifold pressure tap.

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

e. Move setup SW1–2 on furnace control to ON position to lock furnace in low-heat operation. (See Table 8 and Fig.

25.) f. Manually close blower door switch.

g. Jumper R and W/W1 thermostat connections on control to start furnace. (See Fig. 25.) h. Remove regulator adjustment cap from low heat gas valve pressure regulator (See Fig. 53.) and turn low-heat adjusting screw (3/16 or smaller flat-tipped screwdriver) counterclockwise (out) to decrease input rate or clockwise (in) to increase input rate.

NOTE: DO NOT set low-heat manifold pressure less than 1.4-in

wc or more than 1.7-in. wc for natural gas. If manifold pressure is outside this range, change main burner orifices.

i. Install low-heat regulator adjustment cap.

j. Leave manometer or similar device connected and proceed to Step 4.

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 low-heat input rate by clocking meter.

NOTE: Gas valve regulator adjustment caps must be in place for

proper input to be clocked.

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

b. Run furnace for 3 minutes in low-heat operation.

c. Measure time (in sec) for gas meter to complete 1 revolution and note reading. The 2 or 5 cubic feet dial provides a more accurate measurement of gas flow.

d. Refer to Table 11 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 low-heat input is achieved. Re-install lowheat regulator seal cap on gas valve.

5. Set low heat temperature rise.

The furnace must operate within the temperature rise ranges

specified on the furnace rating plate. Do not exceed temperature rise ranges specified on furnace rating plate for high-and low-fire. Determine the temperature rise as follows:

NOTE: Blower access door must be installed when taking tem-

perature rise reading. Leaving blower access door off will result in incorrect temperature measurements.

a. Verify unit is running in low-heat per Step 4. 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.



Disconnect 115-v electrical power before changing speed tap.


Failure to follow this caution may result in shorten furnace life. Set air temperature rise within limits specified on the rating plate to prevent reduced life of furnace components.

Operation is within a few degrees of the mid-point of rise range when setup switch SW1-4 is OFF.

When setup switch SW1-4 is ON, operation will be near the high end of the rise range for improved comfort.

This furnace is capable of automatically providing proper airflow to maintain the temperature rise within the range specified on unit rating plate.

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

1.) Gas input for low heat operation.

2.) Derate for altitude if applicable.

3.) Return and supply ducts for excessive restrictions causing static pressures greater than 0.50-in. wc.

4.) Ensure low-heat rise adjust switch SW1-3 is in ON position when bypass humidifier is used. Refer to Table

8 and Fig. 25 and 57.

5.) Make sure proper model plug is installed.

6. Adjust Manifold Pressure to Obtain High Heat Rate a. Remove high heat regulator adjustment cap from gas valve pressure regulator.

b. Jumper R, W/W1 and W2 thermostat connections on control to run furnace in high heat. (See Fig. 25 and 57.) c. Turn high-heat adjusting screw (3/16 or smaller flat-tipped screwdriver)) counterclockwise (out) to decrease input rate or clockwise (in) to increase rate.

d. Re-install high-heat adjustment caps.

NOTE: DO NOT set high-heat manifold pressure less than 3.2-in.

wc or more than 3.8-in. wc for natural gas. If manifold pressure is outside this range, change main burner orifices.

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

NOTE: Gas valve regulator adjustment caps must be in place for

proper input to be clocked.

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

39

Table 11—GAS RATE (CU FT/HR)

SECONDS

FOR 1

REVOLUTION

36

37

38

39

32

33

34

35

40

41

42

43

44

45

46

47

48

49

25

26

27

28

21

22

23

24

29

30

31

14

15

16

17

10

11

12

13

18

19

20

100

97

95

92

113

109

106

103

90

88

86

84

82

80

78

76

75

73

144

138

133

129

171

164

157

150

124

120

116

SIZE OF TEST DIAL

1

Cu Ft

2

Cu Ft

5

Cu Ft

257

240

225

212

360

327

300

277

200

189

180

720 1800

655 1636

600 1500

555 1385

514 1286

480 1200

450 1125

424 1059

400

379

360

1000

947

900

200

195

189

185

225

218

212

206

180

176

172

167

164

160

157

153

150

147

288

277

267

257

343

327

313

300

248

240

232

500

486

474

462

563

545

529

514

450

439

429

419

409

400

391

383

375

367

720

692

667

643

857

818

783

750

621

600

581

SECONDS

FOR 1

REVOLUTION

39

38

38

37

43

42

41

40

36

35

35

34

33

33

32

31

30

51

50

48

47

58

56

54

53

46

45

44

SIZE OF TEST DIAL

1

Cu Ft

2

Cu Ft

5

Cu Ft

67

65

64

63

72

71

69

68

62

61

60

144

141

138

136

133

131

129

126

124

122

120

333

327

321

316

360

355

346

340

310

305

300

78

76

75

74

86

84

82

80

72

71

69

68

67

65

64

62

60

103

100

97

95

116

112

109

106

92

90

88

196

192

188

184

214

209

205

200

180

178

173

170

167

164

161

155

150

257

250

243

237

290

281

273

265

231

225

220

92

94

96

98

84

86

88

90

100

102

104

106

108

110

112

116

120

70

72

74

76

62

64

66

68

78

80

82

54

55

56

57

50

51

52

53

58

59

60 b. Run for 3 minutes in high-heat operation.

c. Measure time (in sec) for gas meter to complete 1 revolution and note reading.

d. Refer to Table 11 for cubic ft of gas per hr.

e. Multiply gas rate cu ft/hr by heating value (Btu/cu ft) to obtain input.

NOTE: Using the 2 cu. ft. or 5 cu. ft. gas meter dial provides

greater accuracy in verifying gas input rate.

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

8. Set high heat temperature rise.

Jumper R to W/W1 and W2 to check high-gas-heat temperature rise. Do not exceed temperature rise ranges specified on furnace rating plate for high heat. The furnace must operate within the temperature rise ranges specified on the furnace rating plate.

Determine the air temperature rise as follows:

NOTE: Blower access door must be installed when taking tem-

perature rise reading. Leaving blower access door off will result in incorrect temperature measurements.

a. Verify the unit is operating in high heat per Step 6. Place thermometers in return and supply ducts as close to furnace as possible. Be sure thermometers do not see radiant heat from heat exchangers. Radiant heat affects temperature rise readings. This practice is particularly important with straight-run ducts.

b. When thermometer readings stabilize, subtract return-air temperature from supply-air temperature to determine air temperature rise.


Failure to follow this caution may result in shorten furnace life. Set air temperature rise within limits specified on the rating plate to prevent reduced life of furnace components.

Operation is within a few degrees of the mid-point of rise range when setup switch SW1-4 is OFF.

When setup switch SW1-4 is ON, operation will be near the high end of the rise range for improved comfort.

This furnace is capable of automatically providing proper airflow to maintain the temperature rise within the range specified on unit rating plate.

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

1.) Gas input for low-and high-heat operation.

2.) Derate for altitude if applicable.

3.) Return and supply ducts for excessive restrictions causing static pressures greater than 0.50-in. wc.

4.) Make sure proper model plug is installed.

c. Remove thermostat jumpers and release blower access door switch.

d. Repeat Steps a through c as required to adjust for proper rise.

e. When correct high heat input rate and temperature rise is achieved, turn gas valve ON/OFF switch to OFF.

f. Release blower access door switch.

g. Remove manometer or similar device from gas valve.

h. Re-install manifold pressure tap plug in gas valve. (See

Fig. 53.)

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.

i. Remove thermostat jumper wire from furnace control board.

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

k. Proceed to Step 9,

″Set Blower Off Delay″ before installing blower access door.

40

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 mid-point of rise range or slightly above.

9. Set Blower Off Delay a. Remove blower access door if installed.

b. Turn Dip switch SW-7 or SW-8 ON or OFF for desired blower off delay. (See Table 10 and Fig. 25 and 57.)

10. Set thermostat heat anticipator.

a. Mechanical thermostat—Set thermostat heat anticipator to match the amp draw of the electrical components in the

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

(1.) Set SW1-2 switch on furnace control board to ON.

(2.) Remove thermostat from subbase or from wall.

(3.) Connect an amp meter as shown in Fig. 55 across the

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

(4.) Record amp draw across terminals when furnace is in low heat and after blower starts.

(5.) Set heat anticipator on thermostat per thermostat instructions and install on subbase or wall.

(6.) Turn SW1-2 switch OFF.

(7.) Install blower access door.

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

11. Set Airflow for Air Conditioning -Single Stage and High

Stage Cooling

The ECM blower can be adjusted for a range of airflows for

Low Speed or High Speed cooling. See Table 5-Air Delivery

- CFM (With Filter ). Depending on the model size, the cooling airflow can be adjusted from 1½ tons nominal cooling to 3 ½, to 4 or to 6 tons of nominal cooling based on 350 cfm ton.

The cooling airflow is adjusted by turning Setup switches

SW2-1, SW2-2 and SW2-3 either ON or OFF. Select the required airflow from Fig. 61. Fig. 61 is based on 350 CFM per ton. For airflow at 400 CFM per ton, turn Setup SW1-5

ON (See Table 8 and Fig. 25 and 57.)

NOTE: 6 ton airflow will truncate at 2200 cfm on applicable

models. For a complete explanation of cooling airflow, refer to the section titled

″Sequence of Operation.″

12. Set Airflow For Continuous Fan/Low Speed Cooling Airflow

The ECM blower motor can be adjusted for continuous fan speeds different than heating or cooling fan speed. See Table

5 - Air Delivery - CFM (With Filter). Select the required continuous fan airflow from Fig. 61.

The continuous fan speed is also the fan speed for low speed cooling when furnace is used with a 2-speed cooling unit.

Adjust the Continuous Fan CFM to match the airflow required for low speed cooling. Select the required airflow from Fig.

61. For airflow at 400 CFM per ton, turn Setup SW1-5 ON

(See Fig. 61.) The airflow selected for low speed cooling will also be the airflow used for continuous fan.

The continuous fan speed can be further adjusted at the thermostat using the

″Comfort Fan″ select function. Changing the continuous fan speed at the thermostat DOES NOT change the low speed cooling airflow selected at the control board.

TABLE 12—Orifice Size and Manifold Pressure for Gas Input Rate

(Tabulated Data Based On 22,000 Btuh High-Heat/14,500 Btuh for Low-Heat Per Burner,

Derated 4 Percent For Each 1000 Ft Above Sea Level)

ALTITUDE

RANGE

(FT)

0 to

2000

ALTITUDE

RANGE

(FT)

U.S.A.

Altitudes

2001 to

3000 or

Canada

Altitudes

2001 to

4500

ALTITUDE

RANGE

(FT)

3001 to

4000

ALTITUDE

RANGE

(FT)

AVG GAS

HEAT VALUE

(BTU/CU FT)

AVG GAS

HEAT VALUE

(BTU/CU FT)

AVG GAS

HEAT VALUE

(BTU/CU FT)

775

800

825

850

875

900

925

950

AVG GAS

HEAT VALUE

(BTU/CU FT)

4001 to

5000

750

775

800

825

850

875

900

925

* Orifice numbers 43 are factory installed

900

925

950

975

1000

1025

1050

1075

1100

800

825

850

875

900

925

950

975

1000

43

43

44

44

44

Orifice no.

42

42

43

43

0.58

Manifold

Pressure

3.5/1.5

3.3/1.4

3.8/1.7

3.6/1.6

3.5/1.5

3.3/1.4

3.6/1.6

3.4/1.5

3.3/1.4

Orifice no.

42

42

43

43

43

44

44

44

45

0.58

Manifold

Pressure

3.4/1.5

3.2/1.4

3.7/1.6

3.5/1.5

3.3/1.4

3.5/1.5

3.4/1.5

3.2/1.4

3.7/1.6

Orifice no.

42

43

43

43

44

44

45

46

0.58

Manifold

Pressure

3.2/1.4

3.6/1.6

3.4/1.5

3.2/1.4

3.5/1.5

3.3/1.4

3.8/1.6

3.8/1.6

Orifice no.

43

43

43

44

44

45

46

46

0.58

Manifold

Pressure

3.6/1.6

3.4/1.5

3.2/1.4

3.4/1.5

3.2/1.4

3.7/1.6

3.7/1.6

3.5/1.5

SPECIFIC GRAVITY OF NATURAL GAS

0.60

0.62

Orifice no.

Manifold

Pressure

Orifice no.

Manifold

Pressure

42

42

42

43

3.6/1.6

3.4/1.5

3.3/1.4

3.8/1.6

42

42

42

42

3.7/1.6

3.5/1.5

3.4/1.5

3.2/1.4

43

43

43

44

3.6/1.6

3.4/1.5

3.2/1.4

3.5/1.5

43

43

43

43

3.7/1.6

3.5/1.5

3.4/1.5

3.2/1.4

44 3.4/1.5

44 3.5/1.5

SPECIFIC GRAVITY OF NATURAL GAS

0.60

0.62

Orifice no.

42

42

43

43

43

43

44

44

Manifold

Pressure

3.5/1.5

3.3/1.4

3.8/1.6

3.6/1.6

3.4/1.5

3.2/1.4

3.5/1.5

3.3/1.4

Orifice no.

42

42

42

43

43

43

44

44

Manifold

Pressure

3.6/1.6

3.4/1.5

3.2/1.4

3.7/1.6

3.5/1.5

3.3/1.4

3.6/1.6

3.4/1.5

45 3.8/1.7

44 3.2/1.4


Orifice no.

42

43

0.60

Manifold

Pressure

3.3/1.4

3.8/1.6

Orifice no.

42

42

0.62

Manifold

Pressure

3.4/1.5

3.2/1.4

43

43

44

3.5/1.5

3.3/1.4

3.6/1.6

43

43

43

3.7/1.6

3.4/1.5

3.3/1.4

44

44

Orifice no.

43

3.4/1.5

3.2/1.4

44

44

Orifice no.

42

3.5/1.5

3.3/1.5

45 3.7/1.6

45 3.8/1.7


0.60

Manifold

Pressure

0.62

Manifold

Pressure

43

43

3.8/1.6

3.5/1.5

3.3/1.4

43

43

3.2/1.4

3.6/1.6

3.4/1.5

44

44

45

46

46

3.6/1.5

3.4/1.5

3.8/1.7

3.8/1.7

3.6/1.6

43

44

44

45

46

3.2/1.4

3.5/1.5

3.3/1.4

3.7/1.6

3.7/1.6

Orifice no.

41

42

42

42

43

43

43

43

43

0.64

Manifold

Pressure

3.5/1.5

3.7/1.6

3.5/1.5

3.3/1.4

3.8/1.7

3.6/1.6

3.5/1.5

3.3/1.4

3.2/1.4

Orifice no.

42

42

42

43

43

43

43

44

44

0.64

Manifold

Pressure

3.7/1.6

3.5/1.5

3.3/1.4

3.8/1.7

3.6/1.6

3.4/1.5

3.2/1.4

3.5/1.5

3.4/1.5

Orifice no.

42

42

43

43

43

43

44

44

0.64

Manifold

Pressure

3.5/1.5

3.3/1.4

3.8/1.6

3.6/1.5

3.4/1.5

3.2/1.4

3.4/1.5

3.3/1.4

Orifice no.

42

43

43

43

44

44

44

46

0.64

Manifold

Pressure

3.3/1.4

3.8/1.6

3.5/1.5

3.3/1.4

3.6/1.6

3.4/1.5

3.2/1.4

3.8/1.7

41

ALTITUDE

RANGE

(FT)

ALTITUDE

RANGE

(FT)

5001 to

6000

ALTITUDE

RANGE

(FT)

6001 to

7000

7001 to

8000

650

675

700

725

750

775

800

825

ALTITUDE

RANGE

(FT)

AVG GAS

HEAT VALUE

AT ALTITUDE

(BTU/CU FT)

8001 to

9000

625

650

675

700

725

750

775


AVG GAS

HEAT VALUE

AT ALTITUDE

(BTU/CU FT)

725

750

775

800

825

850

875

900

AVG GAS

HEAT VALUE

AT ALTITUDE

(BTU/CU FT)

675

700

725

750

775

800

825

850

AVG GAS

HEAT VALUE

AT ALTITUDE

(BTU/CU FT)



Derated 4 Percent For Each 1000 Ft Above Sea Level)(Continued)

Orifice

No.

43

43

44

44

46

46

47

47

0.58

Manifold

Pressure

3.4/1.5

3.2/1.4

3.4/1.5

3.2/1.4

3.8/1.7

3.6/1.6

3.8/1.7

3.6/1.6

Orifice

No.

43

44

44

45

46

46

47

47

0.58

Manifold

Pressure

3.4/1.5

3.6/1.6

3.4/1.5

3.8/1.7

3.7/1.6

3.5/1.5

3.7/1.6

3.5/1.5

Orifice

No.

44

44

45

46

46

47

47

48

0.58

Mainifold

Pressure

3.6/1.6

3.3/1.5

3.8/1.6

3.7/1.6

3.4/1.5

3.6/1.6

3.4/1.5

3.7/1.6

Orifice

No.

44

45

46

47

47

48

48

0.58

Manifold

Pressure

3.3/1.5

3.7/1.6

3.6/1.6

3.8/1.7

3.6/1.6

3.8/1.7

3.6/1.5


0.60

0.62

Orifice

No.

Manifold

Pressure

Orifice

No.

Manifold

Pressure

43

43

44

44

45

46

3.5/1.5

3.3/1.4

3.5/1.5

3.3/1.4

3.8/1.6

3.7/1.6

43

43

43

44

44

46

3.6/1.6

3.4/1.5

3.2/1.4

3.4/1.5

3.2/1.4

3.8/1.7

46

47

3.5/1.5

3.8/1.6

46

46

3.6/1.6

3.4/1.5


0.60

0.62

Orifice

No.

Manifold

Pressure

Orifice

No.

Manifold

Pressure

43

43

44

44

3.5/1.5

3.3/1.4

3.5/1.5

3.3/1.4

43

43

44

44

3.6/1.6

3.4/1.5

3.6/1.6

3.4/1.5

46

47

47

48

43

44

44

46

45

46

46

47

3.7/1.6

3.6/1.6

3.4/1.5

3.6/1.6

45

46

46

47

3.8/1.7

3.8/1.6

3.5/1.5

3.8/1.6


0.60

0.62

Orifice

No.

Manifold

Pressure

Orifice

No.

Manifold

Pressure

3.2/1.4

3.5/1.5

3.2/1.4

3.8/1.7

3.6/1.5

3.8/1.6

3.5/1.5

3.8/1.6

43

44

44

45

46

46

47

47

3.4/1.5

3.6/1.6

3.3/1.4

3.7/1.6

3.7/1.6

3.4/1.5

3.7/1.6

3.4/1.5


0.60

0.62

Orifice

No.

Manifold

Pressure

Orifice

No.

Manifold

Pressure

44

44

46

46

47

47

48

3.5/1.5

3.2/1.4

3.8/1.6

3.5/1.5

3.7/1.6

3.5/1.5

3.7/1.6

44

44

45

46

47

47

48

3.6/1.6

3.3/1.4

3.7/1.6

3.6/1.6

3.8/1.7

3.6/1.6

3.8/1.7

Orifice

No.

43

43

43

44

44

45

46

46

0.64

Manifold

Pressure

3.7/1.6

3.5/1.5

3.3/1.4

3.5/1.5

3.3/1.4

3.8/1.6

3.7/1.6

3.5/1.5

Orifice

No.

43

43

43

44

44

45

46

46

0.64

Manifold

Pressure

3.7/1.6

3.5/1.5

3.2/1.4

3.5/1.5

3.2/1.4

3.7/1.6

3.6/1.6

3.4/1.5

Orifice

No.

43

43

44

44

46

46

47

47

0.64

Manifold

Pressure

3.5/1.5

3.2/1.4

3.4/1.5

3.2/1.4

3.8/1.6

3.6/1.5

3.8/1.6

3.6/1.5

Orifice

No.

43

44

45

46

46

47

47

0.64

Manifold

Pressure

3.2/1.4

3.4/1.5

3.8/1.7

3.7/1.6

3.5/1.5

3.7/1.6

3.5/1.5

42




ALTITUDE

RANGE

(FT)

AVG GAS

HEAT VALUE

AT ALTITUDE

(BTU/CU FT)

9001 to

10,000

600

625

650

675

700

725


Orifice

No.

45

46

47

47

48

48

0.58

Manifold

Pressure

3.7/1.6

3.6/1.6

3.8/1.6

3.5/1.5

3.7/1.6

3.5/1.5


0.60

0.62

Orifice

No.

Manifold

Pressure

Orifice

No.

Manifold

Pressure

45

46

46

47

48

48

3.8/1.7

3.7/1.6

3.4/1.5

3.6/1.6

3.8/1.7

3.6/1.6

44

46

46

47

47

48

3.3/1.4

3.8/1.7

3.6/1.5

3.7/1.6

3.5/1.5

3.7/1.6

Orifice

No.

44

45

46

46

47

48

0.64

Manifold

Pressure

3.4/1.5

3.8/1.6

3.7/1.6

3.4/1.5

3.6/1.6

3.8/1.7

Step 4—Check Safety Controls

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

1. Check Main Limit Switch

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

a. Run furnace for at least 5 minutes.

b. Gradually block off return air with a piece of cardboard or sheet metal until the limit trips.

c. Unblock return air to permit normal circulation.

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

2. Check draft safeguard switch.

The purpose of this control is to cause the safe shutdown of the furnace during certain blocked vent conditions.

a. Verify vent pipe is cool to the touch.

b. Disconnect power to furnace and remove vent connector from furnace vent elbow.

c. Restore power to furnace and set room thermostat above room temperature.

d. After normal start-up, allow furnace to operate for 2 minutes, then block vent elbow in furnace 80 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 hours. To reset furnace control board, turn thermostat below room temperature or from HEAT to OFF and turn 115-v power OFF, then back ON.

3. Check Pressure Switch(es)

This control proves operation of the draft inducer blower.

a. Turn off 115-v power to furnace.

b. Disconnect inducer motor lead wires from wire harness.

c. Turn on 115-v power to furnace.

43 d. Set thermostat to

″call for heat″ and wait 1 minute. When pressure switch is functioning properly, hot surface igniter should NOT glow and control diagnostic light flashes a status code 32. If hot surface igniter glows when inducer motor is disconnected, shut down furnace immediately.

e. Determine reason pressure switch did not function properly and correct condition.

f. Turn off 115-v power to furnace.

g. Reconnect inducer motor wires, replace outer door, and turn on 115-v power.

h. Blower will run for 90 seconds before beginning the call for heat again.

i. Furnace should ignite normally.

Step 5—Checklist

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

2. Verify that switches SW1-1 and SW1-6 are OFF and other setup switches are set as desired. Verify that switches SW1-7 and SW1-8 for the blower OFF DELAY are set as desired per

Table 10.

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

4. Cycle test furnace with room thermostat.

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

6. Review User’s Guide with owner.

7. Attach literature packet to furnace.

SERVICE AND MAINTENANCE PROCEDURES

FIRE, INJURY OR DEATH HAZARD


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.

TABLE 13–Orifice Size and Manifold Pressure for Gas Input Rate (Tabulated Data Based On 21,000 Btuh

High-Heat/14,500 Btuh for Low-Heat Per Burner,

Derated 4 Percent For Each 1000 Ft Above Sea Level)

ALTITUDE

RANGE

(FT)

0 to

2000

ALTITUDE

RANGE

(FT)

U.S.A.

Altitudes

2001 to

3000 or

Canada

Altitudes

2001 to

4500

ALTITUDE

RANGE

(FT)

3001 to

4000

ALTITUDE

RANGE

(FT)

AVG GAS

HEAT VALUE

(BTU/CU FT)

900

925

950

975

1000

1025

1050

1075

1100

AVG GAS

HEAT VALUE

(BTU/CU FT)

800

825

850

875

900

925

950

975

1000

AVG GAS

HEAT VALUE

(BTU/CU FT)

775

800

825

850

875

900

925

950

AVG GAS

HEAT VALUE

(BTU/CU FT)

4001 to

5000

750

775

800

825

850

875

900

925


44

44

44

45

46

Orifice no.

42

43

43

43

0.58

Manifold

Pressure

3.2/1.5

3.7/1.8

3.5/1.7

3.3/1.6

3.6/1.7

3.4/1.6

3.3/1.6

3.8/1.8

3.8/1.8

Orifice no.

43

43

43

43

44

44

45

46

46

0.58

Manifold

Pressure

3.8/1.8

3.5/1.7

3.3/1.6

3.2/1.5

3.4/1.6

3.2/1.5

3.7/1.8

3.7/1.8

3.5/1.7

Orifice no.

43

43

44

44

45

46

46

46

0.58

Manifold

Pressure

3.5/1.7

3.3/1.6

3.6/1.7

3.4/1.6

3.8/1.8

3.8/1.8

3.6/1.7

3.4/1.6

Orifice no.

43

44

44

45

46

46

47

47

0.58

Manifold

Pressure

3.3/1.6

3.6/1.7

3.3/1.6

3.8/1.8

3.8/1.8

3.5/1.7

3.8/1.8

3.6/1.7


0.60

0.62

Orifice no.

Manifold

Pressure

Orifice no.

Manifold

Pressure

42

43

43

43

3.3/1.6

3.8/1.8

3.6/1.7

3.4/1.6

42

42

43

43

3.4/1.6

3.2/1.5

3.7/1.8

3.5/1.7

43

44

44

44

3.3/1.6

3.6/1.7

3.4/1.6

3.2/1.5

43

43

44

44

3.4/1.6

3.2/1.5

3.5/1.7

3.3/1.6

45 3.7/1.8

44 3.2/1.5


0.60

0.62

Orifice no.

42

43

43

43

44

44

45

Manifold

Pressure

3.2/1.5

3.7/1.7

3.5/1.6

3.3/1.6

3.5/1.7

3.3/1.6

3.8/1.8

Orifice no.

42

43

43

43

43

44

44

Manifold

Pressure

3.3/1.6

3.8/1.8

3.6/1.7

3.4/1.6

3.2/1.5

3.5/1.6

3.3/1.6

46

46

3.8/1.8

3.6/1.7

45

46

3.8/1.8

3.8/1.8


0.60

0.62

Orifice no.

Manifold

Pressure

Orifice no.

Manifold

Pressure

43

43

43

44

3.7/1.7

3.4/1.6

3.2/1.5

3.5/1.7

43

43

43

44

3.8/1.8

3.5/1.7

3.3/1.6

3.6/1.7

44

44

45

46

46

47

44

45

46

46

3.3/1.6

3.8/1.8

3.7/1.8

3.5/1.7

44

44

45

46

3.4/1.6

3.2/1.5

3.7/1.8

3.7/1.7


Orifice no.

43

43

0.60

Manifold

Pressure

3.4/1.6

3.2/1.5

Orifice no.

43

43

0.62

Manifold

Pressure

3.5/1.7

3.3/1.6

3.4/1.6

3.2/1.5

3.7/1.8

3.7/1.7

3.5/1.7

3.7/1.8

44

44

45

46

46

47

3.6/1.7

3.4/1.6

3.8/1.8

3.8/1.8

3.6/1.7

3.8/1.8

43

43

43

44

44

Orifice no.

42

42

43

43

0.64

Manifold

Pressure

3.5/1.7

3.3/1.6

3.8/1.8

3.7/1.7

3.5/1.7

3.3/1.6

3.2/1.5

3.4/1.6

3.3/1.6

Orifice no.

42

42

43

43

43

44

44

44

45

0.64

Manifold

Pressure

3.4/1.6

3.2/1.5

3.7/1.8

3.5/1.7

3.3/1.6

3.6/1.7

3.4/1.6

3.2/1.5

3.7/1.8

Orifice no.

42

43

43

43

44

44

45

46

0.64

Manifold

Pressure

3.2/1.5

3.7/1.7

3.4/1.6

3.2/1.5

3.5/1.7

3.3/1.6

3.8/1.8

3.8/1.8

Orifice no.

43

43

43

44

44

45

46

46

0.64

Manifold

Pressure

3.6/1.7

3.4/1.6

3.2/1.5

3.5/1.6

3.3/1.6

3.7/1.8

3.7/1.8

3.5/1.7

44

ALTITUDE

RANGE

(FT)

ALTITUDE

RANGE

(FT)

5001 to

6000

AVG GAS

HEAT VALUE

AT ALTITUDE

(BTU/CU FT)

725

750

775

800

825

850

875

900

AVG GAS

HEAT VALUE

AT ALTITUDE

(BTU/CU FT)

ALTITUDE

RANGE

(FT)

6001 to

7000

ALTITUDE

RANGE

(FT)

7001 to

8000

675

700

725

750

775

800

825

850

AVG GAS

HEAT VALUE

AT ALTITUDE

(BTU/CU FT)

650

675

700

725

750

775

800

825

AVG GAS

HEAT VALUE

AT ALTITUDE

(BTU/CU FT)

8001 to

9000

625

650

675

700

725

750

775





Orifice

No.

44

44

45

46

46

47

47

48

0.58

Manifold

Pressure

3.5/1.7

3.3/1.6

3.7/1.8

3.7/1.8

3.5/1.7

3.7/1.8

3.5/1.7

3.8/1.8

Orifice

No.

44

44

45

46

46

47

47

48

0.58

Manifold

Pressure

3.5/1.7

3.3/1.6

3.7/1.8

3.6/1.7

3.4/1.6

3.6/1.7

3.4/1.6

3.7/1.7

Orifice

No.

44

45

46

47

47

48

48

48

0.58

Manifold

Pressure

3.3/1.6

3.7/1.8

3.6/1.7

3.8/1.8

3.5/1.7

3.8/1.8

3.6/1.7

3.3/1.6

Orifice

No.

45

46

47

47

48

48

49

0.58

Manifold

Pressure

3.7/1.8

3.6/1.7

3.8/1.8

3.5/1.7

3.7/1.8

3.5/1.7

3.8/1.8


0.60

0.62

Orifice

No.

Manifold

Pressure

Orifice

No.

Manifold

Pressure

43

44

44

46

3.2/1.5

3.4/1.6

3.2/1.5

3.8/1.8

43

44

44

45

3.3/1.6

3.5/1.7

3.3/1.6

3.8/1.8

46

47

47

47

3.6/1.7

3.8/1.8

3.6/1.7

3.4/1.6

46

46

47

47

3.7/1.8

3.5/1.7

3.7/1.8

3.5/1.7


Orifice

No.

43

44

0.60

Manifold

Pressure

3.2/1.5

3.4/1.6

Orifice

No.

43

44

0.62

Manifold

Pressure

3.3/1.6

3.5/1.7

45

46

46

47

3.8/1.8

3.8/1.8

3.5/1.7

3.8/1.8

44

45

46

46

3.3/1.6

3.7/1.8

3.6/1.7

3.4/1.6

47 3.5/1.7

47 3.6/1.7

48 3.8/1.8

47 3.4/1.6


Orifice

No.

44

45

46

46

0.60

Manifold

Pressure

3.4/1.6

3.8/1.8

3.7/1.8

3.5/1.7

Orifice

No.

44

44

46

46

0.62

Manifold

Pressure

3.5/1.7

3.3/1.6

3.8/1.8

3.6/1.7

47

47

48

3.7/1.8

3.4/1.6

3.7/1.8

47

47

48

3.8/1.8

3.6/1.7

3.8/1.8

48 3.5/1.6

48 3.6/1.7


Orifice

No.

45

46

0.60

Manifold

Pressure

3.8/1.8

3.7/1.8

Orifice

No.

44

46

0.62

Manifold

Pressure

3.3/1.6

3.8/1.8

46

47

48

48

48

3.4/1.6

3.6/1.7

3.8/1.8

3.6/1.7

3.4/1.6

46

47

47

48

48

3.5/1.7

3.7/1.8

3.5/1.7

3.7/1.8

3.5/1.7

Orifice

No.

43

43

44

44

46

46

46

47

0.64

Manifold

Pressure

3.4/1.6

3.2/1.5

3.4/1.6

3.2/1.5

3.8/1.8

3.6/1.7

3.4/1.6

3.7/1.7

Orifice

No.

43

43

44

45

46

46

47

47

0.64

Manifold

Pressure

3.4/1.6

3.2/1.5

3.4/1.6

3.8/1.8

3.8/1.8

3.5/1.7

3.8/1.8

3.5/1.7

Orifice

No.

43

44

45

46

46

47

47

48

0.64

Manifold

Pressure

3.2/1.5

3.4/1.6

3.8/1.8

3.7/1.8

3.5/1.6

3.7/1.7

3.4/1.6

3.7/1.8

Orifice

No.

44

45

46

46

47

48

48

0.64

Manifold

Pressure

3.4/1.6

3.8/1.8

3.7/1.7

3.4/1.6

3.6/1.7

3.8/1.8

3.6/1.7

45




ALTITUDE

RANGE

(FT)

AVG GAS

HEAT VALUE

AT ALTITUDE

(BTU/CU FT)

9001 to

10,000

600

625

650

675

700

725


Orifice

No.

46

47

47

48

48

49

0.58

Manifold

Pressure

3.6/1.7

3.7/1.8

3.4/1.6

3.6/1.7

3.4/1.6

3.7/1.8


0.60

0.62

Orifice

No.

Manifold

Pressure

Orifice

No.

Manifold

Pressure

46

47

47

48

48

49

3.7/1.8

3.8/1.8

3.6/1.7

3.8/1.8

3.5/1.7

3.8/1.8

46

46

47

47

48

48

3.8/1.8

3.5/1.7

3.7/1.8

3.4/1.6

3.6/1.7

3.4/1.6

Orifice

No.

45

46

47

47

48

48

0.64

Manifold

Pressure

3.7/1.8

3.6/1.7

3.8/1.8

3.5/1.7

3.7/1.8

3.5/1.7

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.

ELECTRICAL OPERATION HAZARD

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

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

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.

ELECTRICAL CONTROLS AND WIRING



There may be more than 1 electrical supply to the furnace.

Check accessories and cooling unit for additional electrical supplies that must be shut off during furnace servicing.

The electrical ground and polarity for 115-v wiring must be properly maintained. Refer to Fig. 24 for field wiring information and to Fig. 57 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

46 installation, service, or maintenance will cause this fuse to blow. If fuse replacement is required, use ONLY a 3-amp fuse. The control

LED will display status code 24 when fuse needs to be replaced.

Proper instrumentation is required to service electrical controls.

The control in this furnace is equipped with a Status Code LED

(Light-Emitting Diode) to aid in installation, servicing, and troubleshooting. It can be viewed through the sight glass in blower access door. The amber furnace control LED is either ON continuously, rapid flashing, or a code composed of 2 digits. The first digit is the number of short flashes, the second digit is the number of long flashes.

For an explanation of status codes, refer to service label located on blower access door or Fig. 56, and the troubleshooting guide which can be obtained from your distributor.

See Fig. 62, a brief Troubleshooting Guide.

For 2-Stage Variable Speed ECM Controls the stored status codes will NOT be erased from the control memory, when 115- or 24-v power is interrupted. The control will store up to the last 7 Status

Codes in order of occurence.

1. To retrieve status codes, proceed with the following:

NOTE: NO thermostat signal may be present at control, and all

blower-OFF delays must be completed.

a. Leave 115-v power to furnace turned on.

b. Remove outer access door.

c. Look into blower access door sight glass for current amber

LED status. Removing blower access door will open blower access door switch and terminate 115-v power to control so that status code is not displayed.

d. Remove blower access door.

NOTE: The Status Codes cannot be retrieved by disconnecting

the limit switch or draft safeguard switch. To retrieve Status

Codes, follow the procedure below.

2. Turn Setup Switch, SW1-1 “ON.”

3. Manually close blower access door switch.

4. Control will flash up to 7 Status Codes.

5. The last Status Code, or 8th Code, will be Code 11.

6. Turn SW1-1 “OFF.”

7. A continuously-lit Amber LED will appear and indicates proper operation.

8. Release blower access door switch, install blower access door and replace outer door or refer to the SERVICE label on the front of the blower access door for more information.

Component Self-Test

Component Test can ONLY be initiated by performing the following:

1. Remove outer access door.

2. Remove blower access door.

3. Remove the wire from the “R” terminal of the control board.

4. Turn Setup Switch, SW-1-6 “ON.”

5. Manually close blower access door switch.

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



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.

6. Component Test sequence will function as follows: a. Inducer motor starts on high-speed and continues to run until Step (d.) of component test sequence.

b. Hot surface igniter is energized for 15 sec, then deenergized.

c. Blower operates for 10 sec, then turns off.

d. Inducer motor goes to low-speed for 10 seconds, then turns off.

e. After component test is completed, one or more status codes (11, 25, or 41) will flash. See component test section of service label for explanation of status codes.

NOTE: To repeat component test, turn setup switch SW1-6 OFF

then back ON.

f. Turn setup switch SW1-6 OFF.

7. RELEASE BLOWER ACCESS DOOR SWITCH, reattach wire to “R” terminal on furnace control board, replace blower access door, and replace outer access door.

Step 2—Care and Maintenance



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

1. Spray or aerosol cans, rags, brooms, dust mops, vacuum cleaners, or other cleaning tools.

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

3. Paint thinners and other painting compounds, paper bags, or other paper products.

Exposure to these materials could lead to corrosion of the heat exchangers.

For continuing high performance and to minimize possible furnace failure, periodic maintenance must be performed on this furnace.

47

Consult your local dealer about proper frequency of maintenance and the availability of a maintenance contract.

ELECTRICAL SHOCK AND FIRE HAZARD


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

CARBON MONOXIDE POISONING AND FIRE

HAZARD


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

CUT HAZARD



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 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.

NOTE: If the filter has an airflow direction arrow, the arrow must

point towards the blower.

CUT HAZARD



Media cabinet filter procedures:

NOTE: Media cabinet is included with variable speed furnace.

1. Turn off electrical supply to furnace before removing filter access door.

Table 14—Filter Size Information (In.)

FURNACE

CASING WIDTH

14-1/2

17-1/2

21

24

* Recommended

FILTER SIZE

Side Return Bottom Return

16 X 25 X 1

16 X 25 X 1

16 X 25 X 1

16 X 25 X 1

14 X 25 X 1

16 X 25 X 1

20 X 25 X 1

24 X 25 X 1

FILTER

TYPE

Cleanable*

Cleanable*

Cleanable*

Cleanable*

2. Remove filter cabinet door.

3. Slide filter out of cabinet.

4. If equipped with permanent, washable 1-inch 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 14 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 14.

6. Slide filter into cabinet.

7. Replace filter cabinet door.

8. Turn on electrical supply to furnace.

BLOWER MOTOR AND WHEEL



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.

2. Loosen the thumbscrew on outer door and then remove outer door.

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

b. Disconnect and remove short piece of vent pipe from within furnace.

4. Remove 2 screws from blower access door and remove blower access door.

5. Disconnect blower leads from furnace control. Record wire color and location for reassembly. All other factory wires can be left connected, but field thermostat connections may need to be disconnected depending on their length and routing.

48

6. Remove 2 screws holding control box to blower shelf.

7. Hang control box from front of furnace casing and away from blower compartment.

8. Remove 2 screws holding blower assembly to blower deck and slide blower assembly out of furnace.

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

(clips) on blower wheel blades.

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

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

NOTE: Before disassembly, mark blower mounting arms, motor,

and blower housing so motor and each arm is positioned at the same location during reassembly.

a. Disconnect ground wire attached to blower housing.

b. Remove screws securing cutoff plate and remove cutoff plate from housing.

c. Loosen set screw holding blower wheel on motor shaft

(160+/-20 in.-lb. when assembling).

d. Remove bolts holding motor to blower housing and slide motor out of wheel (40+/-10 in.-lb. when reassembling).

e. Remove blower wheel from housing.

f. Clean wheel and housing.

12. Reassemble motor and blower by reversing steps 11e, through

11a. Be sure to reattach ground wire to the blower housing.

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

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

15. Reinstall blower assembly in furnace.

16. Reinstall control box assembly in furnace.

NOTE: Refer to Fig. 57 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.



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

b. Manually close blower access door switch.

NOTE: If R-W/W1 thermostat terminals are jumpered at the time

blower access door switch is closed, blower will run for 90 sec before beginning a heating cycle.

c. Perform component self-test as shown at the bottom of the

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

d. Verify blower is rotating in the correct direction

19. If furnace is operating properly, RELEASE BLOWER AC-

CESS DOOR SWITCH. Remove any jumpers or reconnect any disconnected thermostat leads. Replace blower access door.

20. Downflow or horizontal furnaces with vent pipe through furnace only: a. Install and connect short piece of vent pipe inside furnace to existing vent.

b. Connect vent connector to vent elbow.

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

CLEANING HEAT EXCHANGER

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

NOTE: If the heat exchangers get a heavy accumulation of soot

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

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

1. Turn OFF gas and electrical power to furnace.

2. Remove outer access door.

3. Disconnect vent connector from furnace vent elbow.

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

5. Disconnect wires to the following components. Mark wires to aid in reconnection (be careful when disconnecting wires from switches because damage may occur): a. Draft safeguard switch.

b. Inducer motor.

c. Pressure switches.

d. Limit overtemperature switch.

e. Gas valve.

f. Hot surface igniter.

g. Flame-sensing electrode h. Flame rollout switches.

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

7. Disconnect gas line from gas manifold.

8. Remove the 4 screws that attach the burner assembly to the cell panel. The gas valve and individual burners need not be removed from support assembly. Remove NOx baffles, if installed.

NOTE: Be very careful when removing burner assembly to avoid

breaking igniter. See Fig. 58 and 59 for correct igniter location.

9. Using field-provided 25-caliber rifle cleaning brush, 36 in.

long, 1/4

″ diameter steel spring cable, a variable speed,

49

9/32˝

5/16˝

Fig. 58—Igniter Position-Side View

A05025

1-7/8”

A05026

Fig. 59—Igniter Position-Top View

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.

60.)

(3.) Work cable in and out of cell 3 or 4 times to obtain sufficient cleaning. DO NOT pull cable with great force. Reverse drill and gradually work cable out.

(4.) Insert brush end of cable in burner inlet opening of cell, and proceed to clean 2 lower passes of cell in same manner as upper pass.

(5.) Repeat foregoing procedures until each cell in furnace has been cleaned.

(6.) Using vacuum cleaner, remove residue from each cell.

(7.) Using vacuum cleaner with soft brush attachment, clean burner assembly.

(8.) Clean flame sensor with fine steel wool.

(9.) Install NOx baffles (if removed).

Fig. 60—Cleaning Heat Exchanger Cell

A91252

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

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

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

NOTE: A releasing agent such as cooking spray or equivalent

(must not contain corn or canola oil, aromatic or halogenated hydrocarbons or inadequate seal may occur) and RTV sealant

(G.E. 162, 6702, or Dow-Corning 738) are needed before starting installation. DO NOT substitute any other type of RTV sealant.

G.E. 162 (P771-9003) is available through RCD in 3-oz tubes.

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

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

b. Inducer motor.

c. Pressure switches.

d. Limit overtemperature switch.

e. Gas valve.

f. Hot surface igniter.

g. Flame-sensing electrode.

h. Flame rollout switches.

14. Reinstall internal vent pipe, if applicable.

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

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.



Never use a match or other open flame to check for gas leaks.

Use a soap-and-water solution.

19. Check for gas leaks.

50

Step 3—Sequence of Operation

NOTE: Furnace control must be grounded for proper operation or

else control will lock out. Control is grounded through green/yellow wire routed to gas valve and burner box screw.

Using the schematic diagram in Fig. 57, follow the sequence of operation through the different modes. Read and follow the wiring diagram very carefully.

NOTE: If a power interruption occurs during a call for heat

(W/W1 or W/W1-and-W2), the control will start a 90-second blower-only ON period two seconds after power is restored, if the thermostat is still calling for gas heating. The amber LED light will flash code 12 during the 90-second period, after which the LED will be ON continuous, as long as no faults are detected. After the

90-second period, the furnace will respond to the thermostat normally.

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

1. Two-Stage Heating (Adaptive Mode) with Single-Stage

Thermostat

See Fig. 24 or 33 for thermostat connections

NOTE: The low-heat only switch SW1-2 selects either the

low-heat only operation mode when ON, (see item 2. below) or the adaptive heating mode when OFF in response to a call for heat.

(See Table 8.) When the W2 thermostat terminal is energized it will always cause high-heat operation when the R-to-W circuit is closed, regardless of the setting of the low-heat only switch.

This furnace can operate as a two-stage furnace with a single-stage thermostat because the furnace control CPU includes a programmed adaptive sequence of controlled operation, which selects low-heat or high-heat operation. This selection is based upon the stored history of the length of previous gas-heating periods of the single-stage thermostat.

The furnace will start up in either low- or high-heat. If the furnace starts up in low-heat, the control CPU determines the low-heat on-time (from 0 to 16 minutes) which is permitted before switching to high-heat.

If the power is interrupted, the stored history is erased and the control CPU will select low-heat for up to 16 minutes and then switch to high-heat, as long as the thermostat continues to call for heat. Subsequent selection is based on stored history of the thermostat cycle times.

The wall thermostat

″calls for heat″, closing the R-to-W circuit.

The furnace control performs a self-check, verifies the low-heat and high-heat pressure switch contacts LPS and HPS are open, and starts the inducer motor IDM in high-speed.

a. Inducer Prepurge Period

(1.) If the furnace control CPU selects low-heat operation the inducer motor IDM comes up to speed, the low-heat pressure switch LPS closes, and the furnace control CPU begins a 15-second prepurge period. If the low-heat pressure switch LPS fails to remain closed the inducer motor IDM will remain running at high-speed. After the low-heat pressure switch recloses the furnace control CPU will begin a 15-second prepurge period, and continue to run the inducer motor

IDM at high-speed.

(2.) If the furnace control CPU selects high-heat operation, the inducer motor IDM remains running at high-speed, and the high-heat pressure switch relay HPSR is de-energized to close the NC contact. When sufficient pressure is available the high-heat pressure switch

Cooling Tonnage vs. Airflow (CFM)

AIR CONDITIONING

TONS (12,000 BTU/HR)

1-1/2

2

2-1/2

3

AIRFLOW

(CFM)

525

700

875

1050

3-1/2

4

5

6

1225

1400

1750

2100

X-INDICATES AN ALLOWABLE SELECTION.

070 MODEL

X

2

X

X

X

1

X

1

090 MODEL

X

X

2

X

X

X

1

X

1

AIR CONDITIONING (A/C) OR CONTINUOUS-FAN (CF) AIRFLOW SELECTION CHART

BASED ON 350 CFM/TON

SW1-5 ON

SWITCH SW3 POSITIONS

MODEL

SIZE

070

090

DEF

DEF

110,135,155 DEF

525

2

525

700

700

700

2

875

2

875

875

1050

1050

1

1050

1225

1225

1225

1400

1225

1400

1

1750

1

1225

1400

2100

110, 135,

& 155 MODELS

X

X

2

X

X

X

X

X

1

BASED ON 400 CFM/TON

SW1-5 ON

SWITCH SW3 POSITIONS

MODEL

SIZE

070

090

110,135,155

DEF 600

2

800 1000 1200

1

DEF 600 800

DEF 800 1000

2

2

1000 1200

1400 1400 1400

1400 1600

1

1200 1400 1600 2000

1

1600

2200

1.DEFAULT A/C AIRFLOW WHEN A/C SWITCHES ARE IN OFF POSITION (FACTORY SETTING)

2.DEFAULT CONT. FAN AIRFLOW WHEN CF SWITCHES ARE IN OFF POSITION (FACTORY SETTING)

3. SWITCH POSITIONS ARE ALSO SHOWN ON FURNACE WIRING DIAGRAM

Fig. 61—Cooling (A/C) or Continuous-Fan (CF) Airflow Selection Chart

HPS closes, and the high-heat gas valve solenoid

GV-HI is energized. The furnace control CPU begins a 15-second prepurge period after the low-heat pressure switch LPS closes. If the high-heat pressure switch HPS fails to close and the low-heat pressure switch LPS closes, the furnace will operate at low-heat gas flow rate until the high-heat pressure switch closes for a maximum of 2 minutes after ignition.

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

Hot-Surface Igniter HSI is energized for a 17-second igniter warm-up period.

c. Trial-For-Ignition Sequence -When the igniter warm-up period is completed the main gas valve relay contact GVR closes to energize the gas valve solenoid GV-M. The gas valve solenoid GV-M permits gas flow to the burners where it is ignited by the HSI. Five seconds after the GVR closes, a 2-second flame proving period begins. The HSI igniter will remain energized until the flame is sensed or until the 2-second flame proving period begins.

If the furnace control CPU selects high-heat operation, the high-heat gas valve solenoid GV-HI is also energized.

d. Flame-Proving - When the burner flame is proved at the flame-proving sensor electrode FSE, the inducer motor

IDM switches to low-speed unless the furnace is operating in high-heat, and the furnace control CPU begins the blower-ON delay period and continues to hold the gas valve GV-M open. If the burner flame is not proved within

A03220 two seconds, the control CPU will close the gas valve

GV-M, and the control CPU will repeat the ignition sequence for up to three more Trials-For-Ignition before going to Ignition-Lockout. Lockout will be reset automatically after three hours, by momentarily interrupting

115 vac power to the furnace, or by interrupting 24 vac power at SEC1 or SEC2 to the furnace control CPU (not at

W/W1, G, R, etc.).

If flame is proved when flame should not be present, the furnace control CPU will lock out of Gas-Heating mode and operate the inducer motor IDM on high speed until flame is no longer proved.

e. Blower-On delay - If the burner flame is proven the blower-ON delays for low-heat and high-heat are as follows:

Low-heat - 45 seconds after the gas valve GV-M is opened

the blower motor BLWM is turned ON at low-heat airflow.

High-heat - 25 seconds after the gas valve GV-M is

opened the BLWM is turned ON at high-heat airflow.

Simultaneously, the humidifier terminal HUM and electronic air cleaner terminal EAC-1 are energized and remain energized throughout the heating cycle.

f. Switching from Low- to High-Heat - If the furnace control CPU switches from low-heat to high-heat, the furnace control CPU will switch the inducer motor IDM speed from low to high. The high-heat pressure switch relay

HPSR is de-energized to close the NC contact. When

51

sufficient pressure is available the high-heat pressure switch HPS closes, and the high-heat gas valve solenoid

GV-HI is energized. The blower motor BLWM will transition to high-heat airflow five seconds after the furnace control CPU switches from low-heat to high-heat.

g. Switching from High- to Low-Heat -The furnace control

CPU will not switch from high-heat to low-heat while the thermostat R-to-W circuit is closed when using a singlestage thermostat.

h. Blower-Off Delay - When the thermostat is satisfied, the R to W circuit is opened, de-energizing the gas valve GV-M, stopping gas flow to the burners, and de-energizing the humidifier terminal HUM. The inducer motor IDM will remain energized for a 5-second post-purge period. The blower motor BLWM and air cleaner terminal EAC-1 will remain energized at low-heat airflow or transition to low-heat airflow for 90, 120, 150, or 180 seconds (depending on selection at blower-OFF delay switches). The furnace control CPU is factory-set for a 120-second blower-OFF delay.

2. Two-Stage Thermostat and Two-Stage Heating

See Fig. 32 for thermostat connections.

NOTE: In this mode the low-heat only switch SW1-2 must be ON

to select the low-heat only operation mode in response to closing the thermostat R-to-W1 circuit. Closing the thermostat R-to-

W1-and-W2 circuits always causes high-heat operation, regardless of the setting of the low-heat only switch.

The wall thermostat

″calls for heat″, closing the R-to-W1 circuit for low-heat or closing the R-to-W1-and-W2 circuits for high-heat.

The furnace control performs a self-check, verifies the low-heat and high-heat pressure switch contacts LPS and HPS are open, and starts the inducer motor IDM in high-speed.

The start up and shut down functions and delays described in item

1. above apply to the 2-stage heating mode as well, except for switching from low- to high-Heat and vice versa.

a. Switching from Low- to High-Heat - If the thermostat Rto-W1 circuit is closed and the R-to-W2 circuit closes, the furnace control CPU will switch the inducer motor IDM speed from low to high. The high-heat pressure switch relay HPSR is de-energized to close the NC contact. When sufficient pressure is available the high-heat pressure switch HPS closes, and the high-heat gas valve solenoid

GV-HI is energized. The blower motor BLWM will transition to high-heat airflow five seconds after the R-to-W2 circuit closes.

b. Switching from High- to Low-Heat -If the thermostat Rto-W2 circuit opens, and the R-to-W1 circuit remains closed, the furnace control CPU will switch the inducer motor IDM speed from high to low. The high-heat pressure switch relay HPSR is energized to open the NC contact and de-energize the high-heat gas valve solenoid GV-HI. When the inducer motor IDM reduces pressure sufficiently, the high-heat pressure switch HPS will open. The gas valve solenoid GV-M will remain energized as long as the low-heat pressure switch LPS remains closed. The blower motor BLWM will transition to low-heat airflow five seconds after the R-to-W2 circuit opens.

3. Cooling mode

The thermostat

″calls for cooling″.

a. Single-Speed Cooling-

See Fig. 24 for thermostat connections

The thermostat closes the R-to-G-and-Y circuits. The R-to-

Y circuit starts the outdoor unit, and the R-to-G-and-Y/Y2 circuits start the furnace blower motor BLWM on cooling

52 airflow. Cooling airflow is based on the A/C selection shown in Fig. 61. The electronic air cleaner terminal

EAC-1 is energized with 115 vac when the blower motor

BLWM is operating.

When the thermostat is satisfied, the R-to-G-and-Y circuits are opened. The outdoor unit will stop, and the furnace blower motor BLWM will continue operating at cooling airflow for an additional 90 seconds. Jumper Y/Y2 to

DHUM to reduce the cooling off-delay to 5 seconds. (See

Fig. 25.) b. Single-Stage

Thermostat and Two-Speed Cooling

(Adaptive Mode) -


This furnace can operate a two-speed cooling unit with a single-stage thermostat because the furnace control CPU includes a programmed adaptive sequence of controlled operation, which selects low-cooling or high-cooling operation. This selection is based upon the stored history of the length of previous cooling period of the single-stage thermostat.

NOTE: The air conditioning relay disable jumper ACRDJ must

be connected to enable the adaptive cooling mode in response to a call for cooling. (See Fig. 25.) When ACRDJ is in place the furnace control CPU can turn on the air conditioning relay ACR to energize the Y/Y2 terminal and switch the outdoor unit to high-cooling.

The furnace control CPU can start up the cooling unit in either low- or high-cooling. If starting up in low-cooling, the furnace control CPU determines the low-cooling on-time (from 0 to 20 minutes) which is permitted before switching to high-cooling.

If the power is interrupted, the stored history is erased and the furnace control CPU will select low-cooling for up to 20 minutes and then energize the air conditioning relay ACR to energize the

Y/Y2 terminal and switch the outdoor unit to high-cooling, as long as the thermostat continues to call for cooling. Subsequent selection is based on stored history of the thermostat cycle times.

The wall thermostat

″calls for cooling″, closing the R-to-G-and-Y circuits. The R-to-Y1 circuit starts the outdoor unit on low-cooling speed, and the R-to-G-and-Y1 circuits starts the furnace blower motor BLWM at low-cooling airflow which is the true on-board

CF selection as shown in Fig. 61.

If the furnace control CPU switches from low-cooling to highcooling, the furnace control CPU will energize the air conditioning relay ACR. When the air conditioning relay ACR is energized the

R-to-Y1-and-Y2 circuits switch the outdoor unit to high-cooling speed, and the R-to-G-and-Y1-and-Y/Y2 circuits transition the furnace blower motor BLWM to high-cooling airflow. Highcooling airflow is based on the A/C selection shown in Fig. 61.

NOTE: When transitioning from low-cooling to high-cooling the

outdoor unit compressor will shut down for 1 minute while the furnace blower motor BLWM transitions to run at high-cooling airflow.

The electronic air cleaner terminal EAC-1 is energized with 115 vac whenever the blower motor BLWM is operating.

When the thermostat is satisfied, the R-to-G-and-Y circuit are opened. The outdoor unit stops, and the furnace blower BLWM and electronic air cleaner terminal EAC-1 will remain energized for an additional 90 seconds. Jumper Y1 to DHUM to reduce the cooling off-delay to 5 seconds. (See Fig. 25.) c. Two-Stage Thermostat and Two-Speed Cooling


NOTE: The air conditioning relay disable jumper ACRDJ must

be disconnected to allow thermostat control of the outdoor unit staging. (See Fig. 25.)

The thermostat closes the R-to-G-and-Y1 circuits for low-cooling or closes the R-to-G-and-Y1-and-Y2 circuits for high-cooling. The

R-to-Y1 circuit starts the outdoor unit on low-cooling speed, and the R-to-G-and-Y1 circuit starts the furnace blower motor BLWM at low-cooling airflow which is the true on-board CF (continuous fan) selection as shown in Fig. 61. The R-to-Y1-and-Y2 circuits start the outdoor unit on high-cooling speed, and the R-to-

G-and-Y/Y2 circuits start the furnace blower motor BLWM at high-cooling airflow. High-cooling airflow is based on the A/C (air conditioning) selection shown in Fig. 61.

The electronic air cleaner terminal EAC-1 is energized with 115 vac whenever the blower motor BLWM is operating.

When the thermostat is satisfied, the R-to-G-and-Y1 or R-to-

G-and-Y1-and-Y2 circuits are opened. The outdoor unit stops, and the furnace blower BLWM and electronic air cleaner terminal

EAC-1 will remain energized for an additional 90 seconds. Jumper

Y1 to DHUM to reduce the cooling off-delay to 5 seconds. (See

Fig. 25.)

4. Thermidistat Mode

See Fig. 26-29 for thermostat connections

The dehumidification output, DHUM on the Thermidistat should be connected to the furnace control thermostat terminal

DHUM. When there is a dehumidify demand, the DHUM input is activated, which means 24 vac signal is removed from the DHUM input terminal. In other words, the DHUM input logic is reversed. The DHUM input is turned ON when no dehumidify demand exists. Once 24 vac is detected by the furnace control on the DHUM input, the furnace control operates in Thermidistat mode. If the DHUM input is low for more than 48 hours, the furnace control reverts back to non-Thermidistat mode.

The cooling operation described in item 3. above also applies to operation with a Thermidistat. The exceptions are listed below: a. Low cooling-When the R-to-G-and-Y1 circuit is closed and there is a demand for dehumidification, the furnace blower motor BLWM will drop the blower airflow to 86 percent of low-cooling airflow which is the true on-board

CF (continuous fan) selection as shown in Fig. 61.

b. High cooling-When the R-to-G-and Y/Y2 circuit is closed and there is a demand for dehumidification, the furnace blower motor BLWM will drop the blower airflow to 86 percent of high-cooling airflow. High-cooling airflow is based on the A/C (air conditioning) selection shown in Fig.

61.

c. Cooling off-delay-When the

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

5. Super-Dehumidify Mode

Super-Dehumidify mode can only be entered if the furnace control is in the Thermidistat mode and there is a demand for dehumidification. The cooling operation described in item 3.

above also applies to operation with a Thermidistat. The exceptions are listed below: a. When the R-to-Y1 circuit is closed, R-to-G circuit is open, and there is a demand for dehumidification, the furnace blower motor BLWM will drop the blower airflow to 65 percent of low-cooling airflow for a maximum of 10 minutes each cooling cycle or until the R-to-G circuit closes or the demand for dehumidification is satisfied.

Low-cooling airflow is the true on-board CF (continuous fan) selection as shown in Fig. 61.

b. When the R-to-Y/Y2 circuit is closed, R-to-G circuit is open, and there is a demand for dehumidification, the furnace blower motor BLWM will drop the blower airflow to 65 percent of high-cooling airflow for a maximum of 10 minutes each cooling cycle or until the R-to-G circuit closes or the demand for dehumidification is satisfied.

High-cooling airflow is based on the A/C (air conditioning) selection shown in Fig. 61.

c. When the

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

6. Continuous Blower Mode

When the R-to-G circuit is closed by the thermostat, the blower motor BLWM will operate at continuous blower airflow. Continuous blower airflow selection is initially based on the CF (continuous fan) selection shown in Fig. 61. Factory default is shown in Fig. 61. Terminal EAC-1 is energized as long as the blower motor BLWM is energized.

During a call for heat, the furnace control CPU will transition the blower motor BLWM to continuous blower airflow, low-heat airflow, or the midrange airflow, whichever is lowest. The blower motor BLWM will remain ON until the main burners ignite then shut OFF and remain OFF for the blower-ON delay (45 seconds in low-heat, and 25 seconds in high-heat), allowing the furnace heat exchangers to heat up more quickly, then restarts at the end of the blower-ON delay period at low-heat or high-heat airflow, respectively.

The blower motor BLWM will revert to continuous-blower airflow after the heating cycle is completed. In high-heat, the furnace control CPU will drop the blower motor BLWM to low-heat airflow during the selected blower-OFF delay period before transitioning to continuous-blower airflow.

When the thermostat

″calls for low-cooling″, the blower motor

BLWM will switch to operate at low-cooling airflow. When the thermostat is satisfied, the blower motor BLWM will operate an additional 90 seconds at low-cooling airflow before transitioning back to continuous-blower airflow.

When the thermostat

″calls for high-cooling″, the blower motor BLWM will operate at high cooling airflow. When the thermostat is satisfied, the blower motor BLWM will operate an additional 90 seconds at high-cooling airflow before transitioning back to continuous-blower airflow.

When the R-to-G circuit is opened, the blower motor BLWM will continue operating for an additional 5 seconds, if no other function requires blower motor BLWM operation.

Continuous Blower Speed Selection from Thermostat -To

select different continuous-blower airflows from the room thermostat, momentarily turn off the FAN switch or pushbutton on the room thermostat for 1-3 seconds after the blower motor BLWM is operating. The furnace control CPU will shift the continuous-blower airflow from the factory setting to the next highest CF selection airflow as shown in Fig. 61.

Momentarily turning off the FAN switch again at the thermostat will shift the continuous-blower airflow up one more increment. If you repeat this procedure enough you will eventually shift the continuous-blower airflow to the lowest

CF selection as shown in Table 1. The selection can be changed as many times as desired and is stored in the memory to be automatically used following a power interruption.

NOTE: If the blower-off delay is set to the maximum, the

adjustable continuous-fan feature is locked (i.e., fan speed cannot be changed from its current setting).

53

7. Heat pump

See Fig. 28-31 for thermostat connections.

When installed with a heat pump, the furnace control automatically changes the timing sequence to avoid long blower off times during demand defrost cycles. Whenever W/W1 is energized along with Y1 or Y/Y2, the furnace control CPU will transition to or bring on the blower motor BLWM at cooling airflow, low-heat airflow, or the midrange airflow, whichever is lowest. The blower motor BLWM will remain on until the main burners ignite then shut OFF and remain OFF for 25 seconds before coming back on at heating airflow.

When the W/W1 input signal disappears, the furnace control begins a normal inducer post-purge period while changing the blower airflow. If Y/Y2 input is still energized the furnace control CPU will transition the blower motor BLWM airflow to cooling airflow. If Y/Y2 input signal disappears and the Y1 input is still energized the furnace control CPU will transition the blower motor BLWM to low-cooling airflow. If both the

Y1 and Y/Y2 signals disappear at the same time, the blower motor BLWM will remain on at low-heat airflow for the selected blower-OFF delay period. At the end of the blower-

OFF delay, the blower motor BLWM will shut OFF unless G is still energized, in which case the blower motor BLWM will operate at continuous blower airflow.

8. Component test

The furnace features a component test system to help diagnose a system problem in the case of a component failure. To initiate the component test procedure, ensure that there are no thermostat inputs to the control and all time delays have expired. Turn on setup switch SW1-6. (See Fig. 25.)

NOTE: The component test feature will not operate if the control

is receiving any thermostat signals or until all time delays have expired.

The component test sequence is as follows: a. The furnace control CPU turns the inducer motor ON at high-heat speed and keeps it ON through step c.

b. After waiting 10 seconds the furnace control CPU turns the hot surface igniter ON for 15 seconds, then OFF.

c. The furnace control CPU then turns the blower motor

BLWM on at midrange airflow for 15 seconds, then OFF.

d. After shutting the blower motor OFF the furnace control

CPU switches the inducer to low-heat speed for 10 seconds, then OFF.

NOTE: The EAC terminals are energized when the blower is

operating.

After the component test is completed, 1 or more status codes (11,

25, or 41) will flash. See component test section or Service Label

(Fig. 56.) for explanation of status codes.

NOTE: To repeat component test, turn setup switch SW1-6 to

OFF and then back ON.

Step 4—Wiring Diagram

Refer to wiring diagram Fig. 57.

Step 5—Troubleshooting

Refer to the service label. (See Fig. 56—Service Label.)

The Troubleshooting Guide (See Fig. 62.) can be a useful tool in isolating furnace operation problems. Beginning with the word

“Start,” answer each question and follow the appropriate arrow to the next item.

The Guide will help to identify the problem or failed component.

After replacing any component, verify correct operation sequence.

A more detailed Troubleshooting Guide is available from your distributor.

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Copyright 2006 Carrier Corporation


Book 1 4

Tab 6a 8a


Pg 56 4-06

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Copyright 2006 Carrier Corporation


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Variable Speed Induced-Combustion Deluxe 4-Way Multipoise Furnace Installation, Start-up, Operating, and

Variable Speed

Induced-Combustion Deluxe

4-Way Multipoise Furnace

Installation, Start-up, Operating, and

Service and Maintenance Instructions

Series 120/C

NOTE: Read the entire instruction manual before starting the

TABLE OF CONTENTS

SAFETY CONSIDERATIONS

FIRE, EXPLOSION, ELECTRICAL SHOCK, AND

CARBON MONOXIDE POISONING HAZARD

FURNACE RELIABILITY HAZARD

personnel should install, repair, or service heating equipment.

CUT HAZARD

could result in personal injury or death. CAUTION is used to

→

INTRODUCTION

INSTALLATION

MINIMUM INCHES CLEARANCE TO COMBUSTIBLE CONSTRUCTION

DÉGAGEMENT MINIMUM EN POUCES AVEC ÉLÉMENTS

DE CONSTRUCTION COMBUSTIBLES

Fig. 1—Clearances to Combustibles

Fig. 2—Return Air Temperature

NOTE: Remove all shipping brackets and materials before oper-

CODES AND STANDARDS

Follow all national and local codes and standards in addition to

these instructions. The installation must comply with regulations

Step 1—Safety

Step 2—General Installation

Step 3—Combustion and Ventilation Air

Step 4—Duct Systems

Step 5—Acoustical Lining and Fibrous Glass Duct

Step 6—Gas Piping and Gas Pipe Pressure Testing

Step 7—Electrical Connections

Step 8—Venting

ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS

PROCEDURE

FURNACE RELIABILITY HAZARD

Fig. 3—Dimensional Drawing

Table 1—Dimensions (IN.)

LOCATION

NOTE: For high-altitude installations, the high-altitude conver-

not be installed directly on any combustible material other than

Fig. 4—Multipoise Orientations

CARBON MONOXIDE POISONING HAZARD

FIRE, INJURY OR DEATH HAZARD

Fig. 5—Installation in a Garage

FIRE HAZARD

PERSONAL INJURY AND/OR PROPERTY DAMAGE

HAZARD

Fig. 6—Prohibit Installation on Back

AIR FOR COMBUSTION AND VENTILATION

U.S. Installations: Section 8.3 of the NFGC, Air for Combus-

Canadian Installations: Part 7 of the NSCNGPIC, Venting

FURNACE CORROSION HAZARD

Table 2–Minimum Free Area Required for Each Combustion Air Opening or Duct to Outdoors

EXAMPLES: Determining Free Area

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

Dilution from Indoors

CARBON MONOXIDE POISONING HAZARD

INDOOR COMBUSTION AIR, STANDARD or KNOWN-

AIR INFILTRATION METHOD.

Outdoor Combustion Air Method

Fig. 7—Air for Combustion, Ventilation, and

Dilution for Outdoors

Indoor Combustion Air© NFPA & AGA

Standard and Known-Air-Infiltration Rate Methods

Indoor air is permitted for combustion, ventilation, and dilution,

CARBON MONOXIDE POISONING HAZARD

Fig. 8—Air for Combustion, Ventilation, and

Dilution from Indoors

Table 3-Minimum Space Volumes were determined by using the

ances in Btu/hr

Outdoor Combustion Air Method section.

Combination of Indoor and Outdoor Air

Air Method below and,

Combustion Air Method mentioned previously and,

Ratio in a. above.

INSTALLATION