310AAV/JAV
Induced-Combustion
4-Way Multipoise Furnace
Installation, Start-up, Operating, and
Service and Maintenance Instructions
-Series A
The 310AAV/JAV 4-Way Multipoise Gas Furnace was designed by Bryant
dealers for Bryant dealers. Applications are easy with 4-way multipoise
design, through-the-furnace downflow venting, 13 different venting options,
and a door designed for easy service access. An inner blower door is
provided for tighter sealing in sensitive applications. The 310AAV/JAV
furnace is approved for use with natural or propane gas, and the 310JAV is
also approved for use in Low NOx Air Quality Management Districts.
STANDARD FEATURES
• Noise elimination combustion system
• Microprocessor based control center
Adjustable heating air temperature rise
LED diagnostics and self test feature
• Patented blocked vent safeguard to ensure proper furnace venting
• All models are Chimney Friendly when used with accessory vent kit
• Four-position furnace: upflow, horizontal right, horizontal left,
downflow
Thirteen different vent options
• Heat pump compatible
• Hot surface ignition (HSI)
• Residential installations eligible for consumer financing through the Comfort
Credit Program
• Twinning in Upflow, Downflow and Horizontal
LIMITED WARRANTY
• 20-year warranty on “Super S™” heat exchanger
• 5-year parts warranty on all other components
Catalog No: 5331-007
Form No. II 310A-45-3
12-02
Single-Stage
Induced-Combustion
4-Way Multipoise Furnace
Cancels: II 310A-45-2/IM-PG8J-02
45-3 / IM-PG8J-03
II 310A-
Installation, Start-up, Operating, and
Service and Maintenance Instructions
Series 100/A
NOTE: Read the entire instruction manual before starting the
installation.
EFFICIENCY
RATING
CERTIFIED
This symbol → indicates a change since the last issue.
TABLE OF CONTENTS
AIR FOR COMBUSTION AND VENTILATION ......................6
Unconfined Space .....................................................................7
Confined Space .........................................................................7
INSTALLATION ...........................................................................8
Upflow Installation ...................................................................8
Bottom Return Air Inlet ......................................................8
Side Return Air Inlet...........................................................8
Leveling Legs (If Desired)..................................................8
Downflow Installation ..............................................................8
Bottom Return Air Inlet ......................................................9
Horizontal Installation ..............................................................9
Suspended Unit Support......................................................9
Platform Unit Support .........................................................9
Roll-Out Protection..............................................................9
Bottom Return Air Inlet ......................................................9
Side Return Air Inlet...........................................................9
Filter Arrangement....................................................................9
Air Ducts...................................................................................9
General Requirements .........................................................9
Ductwork Acoustical Treatment .......................................11
Supply Air Connections ....................................................12
Return Air Connections.....................................................13
Gas Piping...............................................................................13
Electrical Connections ............................................................15
115-V Wiring.....................................................................16
J-Box Relocation ...............................................................16
Electrical Connection to J-Box .........................................16
For Power Cord Installation..............................................16
For BX Cable Installation .................................................17
For Power Cord Installation..............................................17
ti
M
®
IR
ST
SO
I
LOCATION....................................................................................5
General ......................................................................................5
Location Relative to Cooling Equipment ................................6
Cor pora
CERTIFIED
I
ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS
PROCEDURE ................................................................................5
ier
REG
CODES AND STANDARDS........................................................4
Safety.........................................................................................4
General Installation...................................................................4
Combustion and Ventilation Air ..............................................4
Duct Systems ............................................................................5
Acoustical Lining and Fibrous Glass Duct..............................5
Gas Piping and Gas Pipe Pressure Testing..............................5
Electrical Connections ..............................................................5
rr
on
INTRODUCTION ..........................................................................4
Ca
SAFETY CONSIDERATIONS .....................................................2
E R E D F8 3
900
1 #A28
REGISTERED QUALITY SYSTEM
24-V Wiring.......................................................................17
Accessories ........................................................................17
Venting ....................................................................................18
General Venting Requirements .........................................19
Masonry Chimney Requirements......................................19
Appliance Application Requirements ...............................21
Additional Venting Requirements.....................................21
Sidewall Venting ...............................................................21
START-UP, ADJUSTMENT, AND SAFETY CHECK ............21
General ....................................................................................21
Start-Up Procedures ................................................................23
Adjustments.............................................................................23
Check Safety Controls ............................................................29
Checklist..................................................................................30
SERVICE AND MAINTENANCE PROCEDURES..................30
Introduction .............................................................................30
General...............................................................................30
Electrical Controls and Wiring .........................................30
Care and Maintenance ............................................................31
Cleaning and/or Replacing Air Filter ...............................32
Blower Motor and Wheel..................................................32
Cleaning Heat Exchanger..................................................33
Sequence of Operation............................................................34
Wiring Diagrams.....................................................................35
Troubleshooting ......................................................................35
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
Book 1 4
PC 101
Catalog No. See Cover
Printed in U.S.A.
Form 58ST-11SI
Pg 1
12-02
Replaces: 58ST-2SI
Tab 6a 8a
28-7/8"
25-1/4"
1-9/16"
A
22-9/16"
JUNCTION BOX
LOCATION
F
2-9/16"
D
4-13/16"
7/8" DIA
ACCESSORY
8-7/16"
1/2" DIA THERMOSTAT
WIRE ENTRY
3-15/16"
1-7/16"
LEFT HAND GAS
ENTRY
33-5/16"
AIRFLOW
19"
13/16"
1-1/2" DIA.
RIGHT HAND
GAS ENTRY
1/2" DIA. THERMOSTAT
WIRE ENTRY
VENT OUTLET
5 PLACES (TYP)
7/8" DIA. ACCESSORY
3-3/4"
5-1/2"
21-5/8"
BOTTOM INLET
1-11/16"
11/16"
ALTERNATE
JUNCTION BOX
LOCATION (TYP)
24-7/8"
11/16"
13/16"
OUTLET
E
14-7/8"
7/8" DIA. ACCESSORY
11/16"
1-1/4"
22-1/16"
SIDE INLET
1"
A02304
NOTES:
1. Two additional 7/8-in. diameter holes are located in the top plate.
2. Minimum return-air openings ar 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-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. 1—Dimensional Drawing
SAFETY CONSIDERATIONS
Sheet metal parts may have sharp edges or burrs. Use care and
wear appropriate protective clothing and gloves when handling parts. Failure to follow this caution could result in
personal injury.
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
installer, service agency, local gas supplier, or your distributor or branch for information or assistance. The qualified
installer or agency must use only factory-authorized and
listed kits or accessories when modifying this product. Failure
to follow this warning could result in electrical shock, fire,
personal injury, or death.
→
Wear safety glasses and work gloves. Have fire extinguisher
available during start-up and adjustment procedures and service
calls.
. When you see this symbol on
This is the safety-alert symbol
the furnace and in instructions or manuals, be alert to the potential
for personal injury.
Understand the signal words DANGER, WARNING, CAUTION,
and NOTE. These words are used with the safety-alert symbol.
DANGER identifies the most serious hazards which will result in
severe personal injury or death. WARNING signifies a hazard
which could result in personal injury or death. CAUTION is used
to identify unsafe practices which would 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.
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. Improper
installation or misapplication of furnace can require excessive
servicing or cause premature component failure.
→ Installing and servicing heating equipment can be hazardous due to
1. Use only with type of gas approved for this furnace. Refer to
the furnace rating plate.
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 unit and other safety
precautions that may apply.
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.
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.
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.
2
INSTALLATION
TOP / PLENUM
DESSUS / CHAMBRED’AIR
MINIMUM INCHES CLEARANCE TO COMBUSTIBLE CONSTRUCTION
DISTANCE MINIMALE EN POUCES AUX CONSTRUCTIONS COMBUSTIBLES
This forced air furnace is equipped for use with This furnace is approved for UPFLOW, DOWNFLOW, and
HORIZONTAL installations.
natural gas at altitudes 0-10,000 ft (0-3,050m).
An accessory kit, supplied by the Cette fournaise est approuvée pour l´installation HORIZONTALE
manufacturer,shall be used to convert to propane et la circulation d´air VERS LE HAUT et VERS LE BAS.
gas use or may be required for some natural gas
1"
Les fléches de dégagement
Clearance arrows
applications.
ne changent pas avec
do not change with
This furnace is for indoor installation in a furnace orientation.
l´orientation de la fournaise.
building constructed on site.
This furnace may be installed on combustible
flooring in alcove or closet at minimum clearance
0"
0"
as indicated by the diagram from combustible
B
AC
material .
DE
A
R
SI T È *
K
R
IÈ
This furnace may be used with a Type B-1 Vent
E
CÔ
RE
AC SE
and may be vented in common with other gasRN A I
F U URN
fired appliances.
FO
NT
O
F R ANT
AV
F
R
A V ON
T
A
N
T
S
E
EN R V
I
TR
ET C E
IE
N
30"
3"MIN
MIN
Ø
Clearance in inches
Dégagement (po).
0"
BOTTOM
DESSOUS
* 0"
DE
SI
É
ÔT
C
†
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 commun d´autres appareils à gaz.
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-combustible floors only.
Ø
*
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.
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.
DÉGAGEMENT MINIMUM EN POUCES AVEC ÉLÉMENTS
DE CONSTRUCTION COMBUSTIBLES
POUR LA POSITION COURANT DESCENDANT:
† Pour l´installation sur plancher non combustible seulement.
Ø
*
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 (450 mm).
La position 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 chemise de la fournaise et les solives, montant sous cadre de charpente.
327590-101 REV. B
A02330
→ Fig. 2—Clearances to Combustibles
8. A gas-fired furnace for installation in a residential garage must
be installed as specified in the warning box in the “Location”
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.
9. The furnace is not to be used for temporary heating of
buildings or structures under construction.
→ 10.
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.
3
These Multipoise Gas-Fired Furnaces are CSA (A.G.A. and
C.G.A.) design-certified for 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
Table 1—Dimensions (IN.)
UNIT SIZE
A
B
C
045-08/024045
045-12/036045
070-08/024070
070-12/036070
070-16/048070
090-14/042090
090-16/048090
090-20/060090
110-12/036110
110-16/048110
110-22/066110
135-16/048135
135-22/066135
155-20/060155
14-3/16
14-3/16
14-3/16
14-3/16
17-1/2
17-1/2
21
21
17-1/2
21
21
21
24-1/2
24-1/2
12-9/16
12-9/16
12-9/16
12-9/16
15-7/8
15-7/8
19-3/8
19-3/8
15-7/8
19-3/8
19-3/8
19-3/8
22-7/8
22-7/8
12-11/16
12-11/16
12-11/16
12-11/16
16
16
19-1/2
19-1/2
16
19-1/2
19-1/2
19-1/2
23
23
VENT
CONN*
4
4
4
4
4
4
4
4
4
4
4
4
4
4
SHIP WT. (LB)
104
107
111
115
123
126
139
145
134
145
151
148
163
170
* 5” or 6” vent connector may be required in some cases.
→ 11.
→ 12.
→ 13.
CSA (A.G.A. and C.G.A.) listed gas conversion kit is required
to convert furnace for use with propane gas.
See Fig. 2 for required clearances to combustibles.
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.
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.
60
A02055
INTRODUCTION
Fig. 3—Return Air Temperature
→ This
4–way multipoise Category I fan-assisted furnace is CSA
(A.G.A. and C.G.A.) design-certified for natural and propane gas
and for installation in alcoves, attics, basements, closets, utility
rooms, crawlspaces, and garages. A 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. A CSA (A.G.A. and C.G.A.) listed gas
conversion kit is required to convert furnace for use with propane
gas. This furnace is not approved for installation in mobile homes,
recreational vehicles, or outdoors.
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
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 85°F db. Failure to follow these
return-air limits may affect reliability of heat exchangers, motors,
and controls. (See Fig. 3.)
• CANADA: CAN/CGA-B149.1–and .2–M00 National Standard
of Canada. Natural Gas and Propane Installation Codes (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; or for only the NFGC,
contact the American Gas Association, 400 N. Capitol, N.W.,
Washington DC 20001 or www.NFPA.org.
For accessory installation details, refer to the applicable instruction
literature.
NOTE: Remove all shipping brackets and materials before operating the furnace.
•
CODES AND STANDARDS
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
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
• US: Section 5.3 of the NFGC, Air for Combustion and
Ventilation
4
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 TO THE LEFT
OF THE BURNER SECTION,
AND CONDITIONED AIR IS
DISCHARGED TO THE RIGHT.
THE BLOWER IS
LOCATED ABOVE THE
BURNER SECTION, AND
CONDITIONED AIR IS
DISCHARGED DOWNWARD
A02097
Fig. 4—Multipoise Orientations
•
NOT move or shuffle your feet, do not touch ungrounded
objects, etc.).
CANADA: Part 7 of NSCNGPIC, Venting Systems and Air
Supply for Appliances
Step 4—Duct Systems
•
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.
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.
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.
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
7. An ESD service kit (available from commercial sources) may
also be used to prevent ESD damage.
CANADA: NSCNGPIC Parts 3, 4, 5, A, B, E and H.
LOCATION
Step 7—Electrical Connections
→
•
US: National Electrical Code (NEC) ANSI/NFPA 70–2002
•
CANADA: Canadian Electrical Code CSA C22.1
Step 1—General
Some assembly and modifications are required when used in any
of the four applications shown in Figure 4.
ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS
PROCEDURE
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 Introduction section.
• be located close to the chimney/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 label.
Electrostatic discharge can affect electronic components.
Take precautions during furnace installation and servicing to
protect the furnace electronic control. Precautions will prevent electrostatic discharges from personnel and hand tools
which are held during the procedure. These precautions will
help to avoid exposing the control to electrostatic discharge
by putting the furnace, the control, and the person at the same
electrostatic potential.
1. Disconnect all power to the furnace. Multiple disconnects may
be required. DO NOT TOUCH THE CONTROL OR ANY
WIRE CONNECTED TO THE CONTROL PRIOR TO DISCHARGING YOUR BODY’S ELECTROSTATIC CHARGE
TO GROUND.
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.
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
5
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.
This gas furnace may be used for construction heat 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 no less
than 55 degrees F, 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 firing 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.
→
AIR FOR COMBUSTION AND VENTILATION
Provisions for adequate combustion and ventilation air must be
provided in accordance with Section 5.3 of the NFGC, Air for
Combustion and Ventilation, or applicable provisions of the local
building codes.
Canadian installations must be installed in accordance with NSCNGPIC Part 7 and all authorities having jurisdiction.
18-IN. MINIMUM
TO BURNERS
A93044
Fig. 6—Installation in a Garage
When the furnace is installed in a residential garage, the
burners and ignition sources must be located at least 18 inches
above the floor. The furnace must be located or protected to
avoid damage by vehicles. When the furnace is installed in a
public garage, airplane hangar, or other building having a
hazardous atmosphere, the furnace must be installed in
accordance with the NFGC or NSCNGPIC. (See Fig. 6.)
DO NOT install the furnace on its back or facing down.
Safety control operation will be adversely affected. Never
connect return-air ducts to back of furnace. Failure to follow
this warning could result in fire, personal injury, or death.
(See Fig. 5.)
Air for combustion must not be contaminated by halogen
compounds, which include fluoride, chloride, bromide, and
iodide. These elements are found in aerosol sprays, detergents, bleaches, cleaning solvents, salts, air fresheners, and
other household products.
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 blocked vent
safeguard opening.
→
A02054
Fig. 5—Prohibit Installation on Back
Step 2—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
The operation of exhaust fans, kitchen ventilation fans,
clothes dryers, attic exhaust fans or fireplaces could create a
NEGATIVE PRESSURE CONDITION at the furnace.
Make-up air MUST be provided for the ventilation devices, in
addition to that required by the furnace. Refer to Carbon
Monoxide Hazard warning in venting section of these instructions to determine amount of make-up air required.
The requirements for combustion and ventilation air depend upon
whether the furnace is located in an unconfined or confined space.
6
Table 2–Minimum Free Area of Combustion Air Opening*
FURNACE
INPUT
(BTUH)
44,000
66,000
88,000
110,000
132,000
154,000
AIR FROM INDOOR
UNCONFINED SPACE
Free Area
of Opening
(Sq In.)
100
100
100
110
132
154
OUTDOOR AIR THROUGH
VERTICAL DUCTS
Free Area of
Round Pipe
Opening and Duct
(in. Dia)
(Sq. In.)
11
4
16.5
5
22.0
6
27.5
6
33
7
38.5
7
OUTDOOR AIR THROUGH
HORIZONTAL DUCTS
Free Area of
Round Pipe
Opening and Duct
(in. Dia)
(sq In.)
22
6
33
7
44.0
8
55
9
66
10
77
10
OUTDOOR AIR THROUGH
SINGLE DUCT
Free Area of
Round Pipe
Opening and Duct
(In. Dia)
(Sq In.)
14.7
5
22.0
6
29.3
7
36.7
7
44.0
8
51.3
8
* Free area shall be equal to or greater than the sum of the areas of all vent connectors in the confined space. Opening area must be increased if other gas appliances
in the space require combustion air.
AIR
DUCTS
Step 1—Unconfined Space
VENT THROUGH ROOF
An unconfined space has a volume of at least 50 cu ft for each
1000 Btuh total input for all appliances (furnaces, clothes dryers,
water heaters, etc.) in the space.
For example:
12″ MAX
MINIMUM WITH
7–1/2 FT CEILING (SQ. FT.)
294
441
587
734
881
1028
CONFINED
SPACE
FURNACE
INPUT (BTUH)
44,000
66,000
88,000
110,000
132,000
154,000
INTERIOR
HEATED
SPACE
1 SQ IN.
PER 1000
BTUH* IN DOOR
OR WALL
UNCONFINED
SPACE
6″ MIN
(FRONT) †
If the unconfined space is constructed unusually tight, air for
combustion and ventilation must come from either the outdoors or
spaces freely communicating with the outdoors. Combustion and
ventilation openings must be equivalent to those used for a
confined space (defined below). Return air must not be taken from
the room unless an equal or greater amount of air is supplied to the
room.
1 SQ IN.
PER 1000
BTUH* IN DOOR
OR WALL
12″ MAX
Step 2—Confined Space
AIR DUCTS
A confined space has a volume less than 50 cu ft per 1000 Btuh
of total input ratings of all appliances installed in that space. A
confined space must have provisions for supplying air for combustion, ventilation, and dilution of flue gases using one of the
following methods in Table 2 and Fig. 7 and 8.
* Minimum opening size is 100 sq in. with
minimum dimensions of 3 in.
† Minimum of 3 in. when type-B1 vent is used.
A02038
NOTE: When determining the free area of an opening, the
blocking effect of louvers, grilles, and screens must be considered.
If the free area of the louver or grille design is unknown, assume
wood louvers have a 20 percent free area and metal louvers or
grilles have a 60 percent free area. Screens must not be smaller
than 1/4-in. mesh. Louvers and grilles must be constructed so they
cannot be closed.
Fig. 7—Confined Space: Air for Combustion and
Ventilation from an Unconfined Indoor Space
c. If the furnace is installed on a raised platform to provide a
return-air plenum, and return air is taken directly from the
hallway or space adjacent to furnace, all air for combustion
must come from outdoors.
The opening size depends upon whether air comes from outside of
the structure or an unconfined space inside the structure.
1. Air from inside the structure requires 2 openings (for structures not of unusually tight construction):
2. Air from outside the structure requires 1 of the following:
a. If combustion air is taken from outdoors through 2 vertical
ducts, the openings and ducts must have at least 1 sq in. of
free area per 4000 Btuh of total input for all equipment
within the confined space. (See Fig. 8 and Table 2.)
a. Each opening must have a minimum free area of not less
than 1 sq in per 1000 Btuh of total input rating for all gas
utilization equipment in the confined space, but not less
than 100 sq in. The minimum dimension of air openings
should be no smaller than 3 in. (See Table 2 and Fig. 7 ).
b. If combustion air is taken from outdoors through 2 horizontal ducts, the openings and ducts must have at least 1 sq
in. of free area per 2000 Btuh of total input for all
equipment within the confined space. (See Fig. 8 and Table
2.)
b. If building construction is unusually tight, a permanent
opening directly communicating with the outdoors shall be
provided. (See next section).
7
1 SQ IN.
PER 4000
BTUH*
DUCTS
TO
OUTDOORS
AIR
DUCTS
12″
MAX
F
1 SQ IN.
PER
4000
BTUH*
OUTDOORS
A
D
VENT
THROUGH
ROOF
CONFINED
SPACE
12″ MAX
1 SQ IN.
PER 2000
BTUH*
DUCTS
TO
OUTDOORS
A02098
1 SQ IN.
PER
4000
BTUH*
1 SQ IN.
PER 2000
BTUH*
12″ MAX
E
B
Fig. 9—Removing Bottom Closure Panel
G
12″
MAX
C
SIDE RETURN AIR INLET
12″ MAX
AIR DUCTS
DUCT
TO
OUTDOORS
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.
1 SQ IN.
PER 4000
BTUH*
→ NOTE:
Side return-air openings can be used in UPFLOW and
most HORIZONTAL configurations. Do not use side return-air
openings in DOWNFLOW configuration.
*Minimum dimensions of 3 in.
NOTE: Use any of the following
combinations of openings:
A&B C&D D&E F&G
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.
A02165
Fig. 8—Confined Space: Air for Combustion and
Ventilation from Outdoors
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 Fig.
9.
c. If combustion air is taken from the outdoors through a
single opening or duct (horizontal or vertical) commencing
within 12 in. of the top of the confined space, the opening
and duct must have at least 1 sq in. of free area per 3000
Btuh of the total input for all equipment within the confined
space and not less than the sum of the areas of all vent
connectors in the confined space. Equipment clearances to
the structure shall be at least 1 in. from the sides and back
and 6 in. from the front of the appliances. See Table 2 and
Fig. 8.
To install leveling legs:
1. Position furnace on its back. Locate and drill a hole in each
bottom corner of furnace. (See Fig. 10.)
2. For each leg, install nut on bolt and then install bolt and nut in
hole. (Install flat washer if desired.)
3. Install another nut on other side of furnace base. (Install flat
washer if desired.)
4. Adjust outside nut to provide desired height, and tighten inside
nut to secure arrangement.
When ducts are used, they must be of the same cross sectional area
as the free area of the openings to which they connect. The
minimum dimension of ducts must not be less than 3 in.
5. Reinstall bottom closure panel if removed.
Step 2—Downflow Installation
Step 1—Upflow Installation
NOTE: For downflow applications, this furnace is approved for
use on combustible flooring when any one of the 3 accessories are
used:
BOTTOM RETURN AIR INLET
• Special Base, KGASB
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:
• Cased Coil Assembly Part No. CD5 or CK5
INSTALLATION
• Coil Box Part No. KCAKC
1. Determine application being installed from Table 3.
2. Construct hole in floor per Table 3 and Fig. 11.
1. Tilt or raise furnace and remove 2 screws holding bottom filler
panel. (See Fig. 9.)
3. Construct plenum to dimensions specified in Table 3 and Fig.
11.
2. Rotate bottom filler panel downward to release holding tabs.
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.
3. Remove bottom closure panel.
4. Reinstall bottom filler panel and screws.
8
5⁄16″
PLATFORM UNIT 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 unit on non-combustible blocks,
bricks or angle iron. For crawlspace installations, if the unit is not
suspended from the floor joists, the ground underneath unit must
be level and the unit set on blocks or bricks.
5⁄16″
1 3⁄4″
ROLL-OUT PROTECTION
1 3⁄4″
Provide a minimum 17 3/4″ X 22″ piece of sheet metal for roll-out
protection in front of burner area for units closer than 12 inches
above the combustible deck or suspended units closer than 12-in.
to joists. The sheet metal MUST extend underneath the furnace
casing by 1 in. with the door removed.
5⁄16″
The bottom closure pan on furnaces of widths 17 1/2 in. and larger
may be used for roll-out protection when bottom of furnace is used
for return air connection. See Fig. 17 for proper orientation of
roll-out shield.
5⁄16″
1
3⁄4″
1 3⁄4″
→ 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:
A02071
Fig. 10—Leveling Legs
1. Tilt or raise furnace and remove 2 screws holding bottom filler
panel. (See Fig. 9.)
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.)
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
→ BOTTOM 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 one side return air is used.
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:
→ Not
all horizontal furnaces are approved for side return air
connections (See Fig. 20.)
1. Tilt or raise furnace and remove 2 screws holding bottom filler
panel. (See Fig. 9.)
Step 4—Filter Arrangement
2. Rotate bottom filler panel downward to release holding tabs.
3. Remove bottom closure panel.
Never operate a furnace without a filter or with filter access
door removed. Failure to follow this warning could result in
fire, personal injury, or death.
4. Reinstall bottom filler panel and screws.
Step 3—Horizontal Installation
There are no provisions for an internal filter rack in these furnaces.
A field-supplied accessory external filter rack is required.
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. Failure to follow this warning
could result in fire, personal injury, or death.
This furnace requires KGAFR0301ALL 1″ external filter rack or a
suitable field-supplied substitute, such as the Media Cabinet.
Refer to the instructions supplied with external filter rack for
assembly and installation options.
The furnace can be installed horizontally in an attic or crawl space
on either the left-hand (LH) or right-hand (RH) side. The furnace
can be hung from floor joists, rafters or trusses or installed on a
platform, non-combustible blocks, bricks or pad.
Step 5—Air Ducts
GENERAL REQUIREMENTS
The duct system should be designed and sized according to
accepted national standards such as those published by: Air
Conditioning Contractors Association (ACCA), Sheet Metal and
Air Conditioning Contractors National Association (SMACNA) or
American Society of Heating, Refrigerating and Air Conditioning
Engineers (ASHRAE) or consult The Air Systems Design Guidelines reference tables available from your local distributor. The
duct system should be sized to handle the required system design
CFM at the design external static pressure.
SUSPENDED UNIT 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
unit from each bottom corner. To prevent screws from pulling out,
use 2 # 8 x ¾-in. screw into the side and 2 # 8 x ¾-in. screw in the
bottom of the furnace casing for each strap. (See Fig. 15 and 16.)
9
FURNACE
(OR COIL CASING
WHEN USED)
A
PLENUM
OPENING
B
COMBUSTIBLE
FLOORING
D
FLOOR
OPENING
DOWNFLOW
SUBBASE
C
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
A96284
Fig. 13—Furnace, Plenum, and Coil Assembly or Coil Box Installed on a Combustible Floor
Flexible connections should be used between ductwork and
furnace to prevent transmission of vibration. Ductwork passing
through unconditioned space should be insulated and sealed to
enhance system performance. When air conditioning is used, a
vapor barrier is recommended.
When a furnace is installed so that the supply ducts carry air to
areas outside the space containing the furnace, the return air must
also be handled by a 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.
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.
10
Table 3—Opening Dimensions (In.)
FURNACE
CASING
WIDTH
14–3/16
17–1/2
21
24-1/2
PLENUM OPENING
APPLICATION
Upflow Applications on Combustible or Noncombustible
Flooring (KGASB subbase not required)
Downflow Applications on Noncombustible Flooring
(KGASB subbase not required)
Downflow applications on combustible flooring (KGASB
subbase required)
Downflow Applications on Combustible Flooring with CD5 or
CK5 Coil Assembly or KCAKC coil box (KGASB subbase
not required)
Upflow Applications on Combustible or Noncombustible
Flooring (KGASB subbase not required)
Downflow Applications on Noncombustible Flooring
(KGASB subbase not required)
Downflow applications on combustible flooring (KGASB
subbase required)
Downflow Applications on Combustible Flooring with CD5 or
CK5 Coil Assembly or KCAKC coil box (KGASB subbase
not required)
Upflow Applications on Combustible or Noncombustible
Flooring (KGASB subbase not required)
Downflow Applications on Noncombustible Flooring
(KGASB subbase not required)
Downflow applications on combustible flooring (KGASB
subbase required)
Downflow Applications on Combustible Flooring with CD5 or
CK5 Coil Assembly or KCAKC coil box (KGASB subbase
not required)
Upflow Applications on Combustible or Noncombustible
Flooring (KGASB subbase not required)
Downflow Applications on Noncombustible Flooring
(KGASB subbase not required)
Downflow applications on Combustible flooring (KGASB
subbase required)
Downflow Applications on Combustible Flooring with CD5 or
CK5 Coil Assembly or KCAKC coil box (KGASB subbase
not required)
DOWNFLOW
UPFLOW
B
C
D
12-11/16
21-5/8
13-5/16
22-1/4
12-9/16
19
13-3/16
19-5/8
11-13/16
19
13-7/16
20-5/8
12-5/16
19
13-5/16
20
16
21-5/8
16-5/8
22-1/4
15-7/8
19
16-1/2
19-5/8
15-1/8
19
16-3/4
20-5/8
15-1/2
19
16-1/2
20
19-1/2
21-5/8
20-1/8
22-1/4
19-3/8
19
20
19-5/8
18-5/8
19
20-1/4
20-5/8
19
19
20
20
23
21-1/8
23-5/8
22-1/4
22-7/8
19
23-1/2
19-5/8
22-1/8
19
23-3/4
20-5/8
22-1/2
19
23-1/2
20
HORIZONTAL
90˚
90˚
PREFERRED
120˚
MIN
FLOOR OPENING
A
PREFERRED
PREFERRED
PREFERRED
120˚
MIN
PERMITTED
PREFERRED
120˚
MIN
PERMITTED
PREFERRED
PERMITTED
A02329
→ Fig. 14—Duct Flanges
DUCTWORK ACOUSTICAL TREATMENT
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.
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 edition of
11
" THREADED ROD
4 REQ.
1/4
OUTER DOOR
ASSEMBLY
SECURE ANGLE
IRON TO BOTTOM
OF FURNACE WITH
3 #8 x 3/4" SCREWS
TYPICAL FOR 2 SUPPORTS
8" MIN FOR DOOR
REMOVAL
1" SQUARE, 11/4" x 11/4" x 1/4" ANGLE IRON
OR UNI-STRUT MAY BE USED
(2) HEX NUTS, (2) WASHERS & (2) LOCK WASHERS
REQ. PER ROD
A02345
→ Fig. 15—Horizontal Unit Suspension
A02014
Fig. 16—Horizontal Suspension with Straps
SUPPLY AIR CONNECTIONS
Upflow and Horizontal Furnaces
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.
Connect supply-air duct to flange on furnace supply-air outlet.
Bend flange upward to 90° with wide duct pliers. The supply-air
duct attachment must ONLY be connected to furnace supplyoutlet-air duct flanges or air conditioning coil casing (when used).
DO NOT cut main furnace casing to attach supply side air duct,
humidifier, or other accessories. All accessories MUST be connected external to furnace main casing.
→ For a furnace not equipped with a cooling coil, the outlet duct shall
12
LINE CONTACT ONLY PERMISSIBLE BETWEEN
LINES FORMED BY INTERSECTIONS OF
THE TOP AND TWO SIDES OF THE FURNACE
JACKET AND BUILDING JOISTS,
STUDS, OR FRAMING.
17 3/4″ OVER ALL
4 3/4″ UNDER DOOR
1″ UNDER FURNACE
GAS
ENTRY
TYPE-B
VENT
EXTEND OUT 12″ OUT
FROM FACE OF DOOR
*
IN
6″ M
30-IN. MIN
WORK AREA
* WHEN USED WITH
SINGLE WALL VENT
CONNECTIONS
17 3/4″
SHEET
METAL
22″
MANUAL SHUTOFF
GAS VALVE
SEDIMENT
TRAP
A02164
Fig. 17—Typical Attic Installation
Step 6—Gas Piping
Downflow Furnaces
Connect supply-air duct to supply-air opening on furnace. The
supply-air duct attachment must ONLY be connected to furnace
supply/outlet or air conditioning coil casing (when used). When
installed on combustible material, supply-air duct attachment must
ONLY be connected to the accessory subbase, KGASB0201ALL,
or 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 external to
furnace casing.
→
Gas piping must be installed in accordance with national and local
codes. Refer to current edition of NFGC in the U.S., the NSCNGPIC in Canada.
RETURN AIR CONNECTIONS
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.
Never connect return-air ducts to the back of the furnace. A
failure to follow this warning can cause a fire, personal injury,
or death.
Refer to Table 4 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.
Downflow Furnaces
The return-air duct must be connected to return-air opening
(bottom inlet) as shown in Fig. 1. DO NOT cut into casing sides
(left or right). Side opening is permitted for only upflow and most
horizontal furnaces. Bypass humidifier connections should be
made at ductwork or coil casing sides exterior to furnace.
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 fire, explosion, personal injury, or
death.
→
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. 1. Bypass humidifier may be attached to
unused side return air portion of the furnace casing. (See Fig. 18,
19, and 20.)
Not all horizontal furnaces are approved for side return air
connections. (See Fig. 20.)
13
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 serviced another gas appliance. Black iron pipe shall be installed at the gas valve and
extend a minimum of 2-in. outside the furnace.
Fig. 18—Upflow Return Air Configurations and Restrictions
Fig. 19—Downflow Return Air Configurations and Restrictions
A02075
A02163
A02162
Fig. 20—Horizontal Return Air Configurations and Restrictions
14
→
Table 4—Maximum Capacity of Pipe*
NOMINAL
IRON
PIPE
SIZE
(IN.)
1/2
3/4
1
1-1/4
1-1/2
GAS
SUPPLY
MANUAL
SHUTOFF
VALVE
(REQUIRED
SEDIMENT
TRAP
UNION
LENGTH OF PIPE (FT)
INTERNAL
DIAMETER
(IN.)
10
20
30
40
50
0.622
0.824
1.049
1.380
1.610
175
360
680
1400
2100
120
250
465
950
1460
97
200
375
770
1180
82
170
320
660
990
73
151
285
580
900
* Cubic ft of gas per hr for gas pressures of 0.5 psig (14–in. wc) or less and a
pressure drop of 0.5–in wc (based on a 0.60 specific gravity gas).
Ref: Table 12.2 NFPA 54-2002.
A02035
Fig. 21b—Typical Gas Pipe Arrangement
Connect gas pipe to gas valve using a backup wrench to avoid
damaging gas controls.
Use proper length of pipe to avoid stress on gas control
manifold. Failure to follow this warning could result in a gas
leak resulting in fire, explosion, personal injury, or death.
→ An accessible manual shutoff valve MUST be installed external to
→ If pressure exceeds 0.5 psig (14-in. wc), gas supply pipe must be
disconnected from furnace and capped before pressure test. If test
pressure is equal to or less than 0.5 psig (14-in. wc), turn off
electric shutoff switch located on furnace gas control valve and
accessible manual shutoff valve before test. After all connections
have been made, purge lines and check for leakage.
furnace casing and within 6 ft of furnace. A 1/8-in. NPT plugged
tapping, accessible for test gage connection, MUST be installed
immediately upstream of gas supply connection to furnace and
downstream of manual shutoff valve.
→ NOTE:
The gas valve inlet pressure tap connection is suitable to
use as test gage connection providing test pressure DOES NOT
exceed maximum 0.5 psig (14-in. wc) stated on gas control valve.
(See Fig. 50.)
→ 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.
→ Some installations require gas entry on right side of furnace (as
Step 7—Electrical Connections
viewed in upflow). (See Fig. 21a.)
Install a sediment trap in riser leading to furnace as shown in Fig
21b. Connect a capped nipple into lower end of tee. Capped nipple
should extend below level of gas controls. Place a ground joint
union between gas control manifold and exterior manual equipment gas shutoff valve. A 1/8-in. NPT plugged tapping, accessible
for test gage connection, MUST be installed immediately upstream
of gas supply connection to furnace and downstream of manual
shutoff valve.
Blower access panel door switch opens 115-v power to
control center. No component operation can occur. Do not
bypass or close switch with panel removed. Failure to follow
this warning could result in personal injury or death.
See Fig. 24 for field wiring diagram showing typical field 115-v
wiring. Check all factory and field electrical connections for
tightness.
→ 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.
→ Field-supplied wiring shall conform with the limitations of 63°F
(33°C) rise.
90° Elbow
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 gage. Do not use gas piping as an electrical ground.
Failure to follow this warning could result in electrical shock,
fire, or death.
2" Nipple
Street Elbow
Gas Valve
A02327
→ Fig. 21a—Right Side Gas Entry Example
15
→ Table 5—Electrical Data
UNIT SIZE
VOLTSHERTZPHASE
045-08/024045
045-12/036045
070-08/024070
070-12/036070
070-16/048070**
090-14/042090
090-16/048090
090-20/060090**
110-12/036110
110-16/048110
110-22/066110
135-16/048135
135-22/066135
155-22/060155
115-60-1
115-60-1
115-60-1
115-60-1
115-60-1
115-60-1
115-60-1
115-60-1
115-60-1
115-60-1
115-60-1
115-60-1
115-60-1
115-60-1
OPERATING
MAXIMUM
MAXIMUM
UNIT
MAXIMUM
MINIMUM
VOLTAGE RANGE
FUSE OR CKT BKR
UNIT AMPS AMPACITY# WIRE LENGTH (FT)‡
WIRE GAGE
AMPS†
Maximum* Minimum*
127
104
5.6
7.77
47
15
14
127
104
7.0
9.47
39
15
14
127
104
5.0
7.06
52
15
14
127
104
6.7
9.19
40
15
14
127
104
9.8
12.59
28
15
14
127
104
8.1
10.83
34
15
14
127
104
9.8
12.95
28
15
14
127
104
12.9
17.60
34
20
12
127
104
8.2
10.75
34
15
14
127
104
10.1
13.12
28
15
14
127
104
13.7
17.62
32
20
12
127
104
10.1
13.12
28
15
14
127
104
14.4
18.55
30
20
12
127
104
15.0
19.33
29
20
12
* Permissible limits of the voltage range at which the unit operates satisfactorily.
# Unit ampacity = 125 percent of largest operating component’s full load amps plus 100 percent of all other potential operating components’ (EAC, humidifier, etc.) full load
amps.
† Time-delay type is recommended.
‡ Length shown is as measured 1 way along wire path between unit and service panel for maximum 2 percent voltage drop.
** Preliminary
Furnace control must be grounded for proper operation or
control will lock out. Control is grounded through
green/yellow wire routed to gas valve and manifold bracket
screw.
TWO
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 5 for equipment electrical
specifications. Make all electrical connections in accordance with
National Electrical Code (NEC) ANSI/NFPA 70-2002 and any
local codes or ordinances that might apply. For Canadian installations, all electrical connections must be made in accordance with
Canadian Electrical Code CSA C22.1 or authorities having jurisdiction.
A02099
Fig. 22—Relocating J-Box
3. Locate box to desired location.
Do not connect aluminum wire between disconnect switch
and furnace. Use only copper wire.
4. Fasten J-Box to casing with screws.
5. Route J-box wires within furnace away from sharp edges and
hot surfaces.
Use a separate, fused branch electrical circuit with a properly sized
fuse or circuit breaker for this furnace. See Table 5 for wire size
and fuse specifications. A readily accessible means of electrical
disconnect must be located within sight of the furnace.
ELECTRICAL CONNECTION TO J-BOX
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.
If manual disconnect switch is to be mounted on furnace,
select a location where a drill or fastener will not contact
electrical or gas components.
J-BOX RELOCATION
1. Attach electrical box to J-Box bracket.
NOTE: If factory location of J-Box is acceptable, go to next
section (J-Box Cover Installation).
2. Route wires through hole in electrical box and J-Box bracket.
3. Secure ground wire to green screw on J-Box bracket.
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.
4. Connect line voltage leads as shown in Fig. 24.
FOR POWER CORD INSTALLATION
1. Remove screws holding auxiliary J-box. (See Fig. 22.)
Power cords must be able to handle the electrical requirements
listed in Table 5. Refer to power cord manufacturer’s listings.
2. Cut wire tie on loop in wires to J-box.
16
TWINNING AND/OR
COMPONENT TEST
TERMINAL
BLOWER OFF-DELAY
J2 JUMPER
BLOWER OFF-DELAY
120 180
90 150
J2
HUMIDIFIER TERMINAL
(24-VAC 0.5 AMP MAX.)
G
Com
24V
24-V THERMOSTAT
TERMINALS
W
TRANSFORMER 24-VAC
CONNECTIONS
PLT
Y
TEST/TWIN
R
HUM
0.5 AMP@24VAC
NUETRAL BLW
STATUS CODE LED
3-AMP FUSE
FUSE 3-AMP
EAC-2
L2
PL1-LOW VOLTAGE MAIN
HARNESS CONNECTOR
1
115-VAC(L2)NEUTRAL
CONNECTIONS
SEC-2 SEC-1
PLT
LED OPERATION &
DIAGNOSTIC LIGHT
COOL
HEAT
COOL
HEAT
1-AMP@
EAC-1 115VAC
PR-1
L1
SPARE-1 SPARE-2
PL2
1
SPARE-1
BLOWER SPEED
SELECTION TERMINALS
115 VAC (L1) LINE
VOLTAGE CONNECTION
SPARE-2
PL2-HOT SURFACE
IGNITER & INDUCER
MOTOR CONNECTOR
EAC-1 TERMINAL
(115-VAC 1.0 AMP MAX.)
A02100
Fig. 23—Furnace Control
1. Route listed power cord through hole in J-Box.
maintenance could cause this fuse to blow. If fuse replacement is
required, use ONLY a 3-amp fuse of identical size.
ACCESSORIES
2. Secure power cord to J-Box bracket with a strain relief
bushing or a connector approved for the type of cord used.
1. Electronic Air Cleaner (EAC)
Connect an accessory Electronic Air Cleaner (if used) using
1/4-in female quick connect terminals to the two male 1/4-in
quick-connect terminals on the control board marked EAC-1
and EAC-2. The terminals are rated for 115 VAC, 1.0 amps
maximum and are energized during blower motor operation.
3. Secure ground wire to green screw on J-Box bracket.
4. Connect line voltage leads as shown in Fig. 24.
FOR BX CABLE INSTALLATION
1. Route BX cable to hole in J-Box.
2. Secure BX cable to J-Box bracket with connectors approved
for the type of cable used.
2. Humidifier (HUM)
Connect an accessory 24 VAC, 0.5 amp maximum humidifier
(if used) to the 1/4-in male quick-connect HUM terminal and
COM-24V screw terminal on the control board thermostat strip.
The HUM terminal is energized when pressure switch (PRS)
closes.
NOTE: A field-supplied, 115-v controlled relay connected to
EAC terminals may be added if humidifier operation is desired
during blower operation.
3. Secure ground wire to green screw on J-Box bracket.
4. Connect line voltage leads as shown in Fig. 24.
J-BOX COVER INSTALLATION
1. Remove J-Box cover from blower access door on furnace and
reinstall blower access door screw.
2. Fold tab on J-box cover to bracket with pliers.
3. Insert tab of J-box cover into slot of J-box bracket.
4. Secure J-Box cover to bracket with screw provided.
5. Remove U-shaped cut-out from outer door to clear J-box.
24-V WIRING
Make field 24-v connections at the 24-v terminal strip. (See Fig.
23.) Connect terminal Y as shown in Fig. 24 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
17
FIELD 24-V WIRING
FIELD 115-, 208/230-, 460-V WIRING
FACTORY 24-V WIRING
FACTORY 115-V WIRING
NOTE 2
W
FIVE WIRE
THREE-WIRE
HEATING-ONLY
C
R
G
Y
THERMOSTAT
TERMINALS
FIELD-SUPPLIED
DISCONNECT
208/230- OR
460-V
THREE
PHASE
BLOWER DOOR SWITCH
BLK
BLK
WHT
WHT
GND
115-V FIELDSUPPLIED
DISCONNECT
W
GND
AUXILIARY
J-BOX
C
O
N
T
R
O
L
R
208/230-V
SINGLE
PHASE
G
COM
GND
NOTE 1
CONDENSING
UNIT
Y/Y2
24-V
TERMINAL
BLOCK
FURNACE
TWO
WIRE
NOTES: 1. Connect Y-terminal in furnace as shown for proper blower operation.
2. Some thermostats require a "C" terminal connection as shown.
3. If any of the original wire, as supplied, must be replaced, use
same type or equivalent wire.
A99440
Fig. 24—Heating and Cooling Application Wiring Diagram with 1–Stage Thermostat
→ When
an existing furnace is removed or replaced in a venting
system, the venting system may not be properly sized to 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, etc.
DO NOT connect furnace control HUM terminal to HUM
(humidifier) terminal on Thermidistat™, Zone Controller or
similar device. See Thermidistat™, Zone Controller, thermostat, or controller manufacturer’s instructions for proper
connection.
Step 8—Venting
→ The furnace shall be connected to a factory built chimney or vent
complying with a recognized standard, or a masonry or concrete
chimney lined with a lining material acceptable to the authority
having jurisdiction. Venting into an unlined masonry chimney or
concrete chimney is prohibited.
18
CARBON MONOXIDE POISONING HAZARD
Failure to follow the steps outlined below for each appliance
connected to the venting system being placed into operation
could result in carbon monoxide poisoning or death.
The following steps shall be followed for each appliance
connected to the venting system being placed into operation,
while all other appliances connected to the venting system are
not in operation:
1. Seal any unused openings in venting system.
2. Inspect the venting system for proper size and horizontal
pitch, as required in the National Fuel Gas Code, ANSI
Z223.1/NFPA 54 or the CSA B149.1, Natural Gas and
Propane Installation Codes and these instructions. Determine that there is no blockage or restriction, leakage,
corrosion and other deficiencies, which could cause an
unsafe condition.
3. As far as practical, close all building doors and windows
and all doors between the space in which the appliance(s)
connected to the venting system are located and other
spaces of the building.
4. Close fireplace dampers.
5. Turn on clothes dryers and any appliance not connected to
the venting system. Turn on any exhaust fans, such as
range hoods and bathroom exhausts, so they are operating
at maximum speed. Do not operate a summer exhaust fan.
6. Follow the lighting instructions. Place the appliance being
inspected into operation. Adjust the thermostat so appliance is operating continuously.
7. Test for spillage from draft hood equipped appliances at the
draft hood relief opening after 5 minutes of main burner
operation. Use the flame of a match or candle.
8. If improper venting is observed during any of the above
tests, the venting system must be corrected in accordance
with the National Fuel Gas Code, ANSI Z223.1/NFPA 54
and/or CSA B149.1, Natural Gas and Propane Installation
Codes.
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.
The following information and warning must be considered in
addition to the requirements defined in the NFGC and the
NSCNGPIC.
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.
Do not bypass the draft safeguard switch, as an unsafe
condition could exist which must be corrected. Failure to
follow this warning could result in a build-up of carbon
monoxide and lead to personal injury or death.
2. Do not connect this appliance to a single-wall dedicated or
common vent. The dedicated or common vent is considered to
be the vertical portion of the vent system that terminates
outdoors.
3. Vent connectors serving Category I furnaces shall not be
connected into any portion of a mechanical draft system
operating under positive pressure.
→
→
4. In the 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.
5. Category I furnaces must be vented vertically or nearly
vertically unless equipped with a listed power ventor.
6. Do not vent this appliance into an unlined masonry chimney.
Refer to Chimney Inspection Chart, Fig. 25.
MASONRY CHIMNEY REQUIREMENTS
These furnaces are CSA design-certified for use in exterior
clay tile-lined masonry chimneys with a factory accessory
Chimney Adapter Kit. Refer to the furnace rating plate for
correct kit usage. The Chimney Adapter Kits are for use with
ONLY furnaces having a Chimney Adapter Kit 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 211-2000
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.
→ Vent system or vent connectors may need to be resized. For any
other appliances when resizing vent systems or vent connectors,
system or connector must be sized to approach minimum size as
determined using appropriate table found in the NFGC or NSCNGPIC.
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.
GENERAL VENTING REQUIREMENTS
Follow all safety codes for proper vent sizing and installation
requirements, including local building codes, the National Fuel
Gas Code (NFGC) ANSI Z223.1-2002/NFPA 54-2002, Parts 7 and
13 in the United States or the National Standard of Canada, Natural
Gas and Propane Installation Code (NSCNGPIC) CSA-B149.1-00,
Section 7 and Appendix C in Canada.
These furnaces are design-certified as Category I furnaces in
accordance with ANSI Z21.47/CSA 2.3-2001 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.
19
NOTE: See the NFGC, 13.1.9 and 13.2.20 regarding alternative
venting design and the exception, which cover installations such as
the
Chimney
Adapter
Kits
KGACA02014FC
and
KGACA02015FC, which are listed for use with these furnaces.
Table B—Minimum Allowable Input Rating of
Space-Heating Appliance in
Thousands of BTU per Hour
The Chimney Adapter Kit is listed alternative venting design for
these furnaces. See the kit instructions for complete details.
VENT
HEIGHT (FT)
Canada-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:
INTERNAL AREA OF CHIMNEY
(SQ. IN.)
12
19
28
38
Local 99% Winter Design
Temperature: 17 to 26 degrees F*
0
55
99
141
8
52
74
111
154
10
NR
90
125
169
15
NR
NR
167
212
20
NR
NR
212
258
3. The combined appliance input rating is less than the maximum
capacity given in Table A, and
30
NR
NR
NR
362
4. The input rating of each space heating appliance is greater
than the minimum input rating given in the appropriate Table
B for Masonry Chimneys for the local 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
6
NR
78
121
166
8
NR
94
135
182
10
NR
111
149
198
15
NR
NR
193
247
20
NR
NR
NR
293
30
NR
NR
NR
377
17 to 26 F
6
1. Vent connector is Type-B double-wall, and
2. This furnace is common vented with at least 1 draft hoodequipped appliance, and
5 to 16 F
Local 99% Winter Design
Temperature: 5 to 16 degrees F*
Local 99% Winter Design
Temperature: -10 to 4 degrees F*
5. The authority having jurisdiction approves.
-10 to 4 F
If all of these conditions cannot be met, an alternative venting
design shall be used, such as the listed chimney adapter kit with
these furnaces listed for use with the kit, a listed chimney-lining
system, or a Type-B common vent.
Exterior Masonry Chimney,
FAN + NAT Installations with
Type-B Double-Wall Vent Connectors
NR
NR
145
8
NR
NR
159
196
213
10
NR
NR
175
231
15
NR
NR
NR
283
20
NR
NR
NR
333
30
NR
NR
NR
NR
-11 F or lower
Local 99% Winter Design
Temperature: -11 degrees F or lower*
Table A—Combined Appliance
Maximum Inut Rating in
Thousands of BTU per Hour
VENT
HEIGHT (FT)
6
INTERNAL AREA OF CHIMNEY
(SQ. IN.)
12
19
28
38
6
74
119
178
257
8
80
130
193
279
10
84
138
207
299
15
NR
152
233
334
20
NR
NR
250
368
30
NR
NR
NR
404
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).
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 Fig. 25 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.
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.
20
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
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.
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.
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.
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.
2. Vent the furnace with the appropriate connector as shown in
Fig. 26–38.
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.
Personal injury can result form sharp metal edges, etc. Be
careful when removing parts. Gloves and safety glasses
should be worn when servicing equipment.
3. Orient the door to determine the correct location of the door
cutout to be removed.
4. Use aviation-type tin snips to remove the correct U-shaped
cut-out on door.
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.
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.
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.
The horizontal portion of the venting system shall maintain a
minimum of 1/4-in. upward slope per linear ft and it shall be
rigidly supported every 5 ft or less with metal hangers or straps to
ensure there is no movement after installation.
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.
SIDEWALL VENTING
3. Adjust the air temperature rise range to the midpoint or
slightly above. Low air temperature rise can cause low vent
gas temperature and potential for condensation problems.
In the U.S.: Per the NFGC, any listed power venter may be used,
when approved by the authority having jurisdiction.
4. Set the thermostat heat anticipator or cycle rate to reduce short
cycling.
In Canada: Only power venters approved by the appliance
manufacturer and where allowed by the authority having jurisdiction may be used for sidewall venting.
This furnace is not approved for direct sidewall horizontal venting
without the use of an add-on power venter.
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.
The only approved power venter is the Field Controls SWG-4D
and SWG-5D sidewall power venter. Select the power venter to
match the btuh input of the appliance being vented. Follow all
manufacturer’s installation requirements for venting and termination included with the power venter.
START-UP, ADJUSTMENT, AND SAFETY CHECK
Step 1—General
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.
This furnace is equipped with manual reset limit switches in
the gas control area. The switches open and shut off power to
the gas valve if a flame rollout or overheating condition
occurs in the gas control area. DO NOT bypass the switches.
Correct inadequate combustion air supply problem and reset
the switches. Failure to follow this warning can cause fire,
explosion, personal injury, or death.
ADDITIONAL VENTING REQUIREMENTS
A 4″ round vent elbow is supplied with the furnace. A 5 inch or 6
inch 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. 26–38 Venting Orientation for approved vent
configurations.
21
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 Codes CSA-B149.1 in Canada.
Crown
condition:
Missing mortar
or brick?
Rebuild
crown.
Yes
No
Is chimney
property lined with
clay tile liner?
No
Yes
Is
liner and top
seal in good
condition?
No
Repair
liner or top seal
or reline chimney as
necessary.
Reline
Repair
Yes
Debris
in cleanout?
Mortar, tile, metal vent
fuel oil residue?
Mortar
or tile
debris?
Yes
No Remove metal vent
or liner.
Clay
tile misalignment,
missing sections,
gaps?
Yes
Remove mortar
and tile debris
No
Yes
No
No
Consult
Part B of
chimney adapter venting
instructions for
application
suitability.
Is chimney
lined with properly
sized, listed liner or
Type-B vent?
Condensate
drainage at bottom
of chimney?
Yes
Install chimney
adapter per
instructions.
No
Yes
Yes
Is chimney
to be dedicated to
a single
furnace?
Line chimney with property
sized, listed flexible metal
liner or Type-B vent per
NFGC or NSCNGPIC Vent
Sizing Tables and liner or
vent manufacturer’s
Installation instructions.
Suitable
Yes
Chimney
exposed to
outdoors below
roof line?
Not Suitable
No
Not Suitable
Consult
Part C of
chimney adapter venting
instructions for
application
suitability
Suitable
Install chimney
adapter per
instructions.
No
Chimney is
acceptable for use.
Fig. 25—Chimney Inspection Chart
22
A02101
6. Verify furnace restarts by raising thermostat setting above
room temperature.
Personal injury can result form sharp metal edges, etc. Be
careful when removing parts. Gloves and safety glasses
should be worn when servicing equipment.
Step 3—Adjustments
1. Maintain 115-v wiring and ground. Improper polarity will
result in rapid flashing LED and no furnace operation.
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.
2. Make thermostat wire connections at the 24-v terminal block
on the furance control. Failure to make proper connections
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).
4. Check all manual-reset switches for continuity.
5. Install blower compartment door. Door must be in place to
operate furnace.
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.
41.)
6. Replace outer door.
Step 2—Start-Up Procedures
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.
Never purge a gas 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. Failure to follow this warning can cause
fire, explosion, personal injury, or death.
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. In Canada,
input rating must be reduced by 10 percent for altitudes of 2,000
ft. to 4,500 ft. above sea level.
1. Purge gas lines after all connections have been made.
1. Determine the correct gas input rate.
In the U.S.:
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 6 for the correct
input rate.
2. Check gas lines for leaks.
→
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. Failure to follow this warning could result
in electrical shock, personal injury, or death.
In Canada:
At installation altitudes from 2000 to 4500 ft, this furnace must be
derated 10 percent by an authorized Gas Conversion Station or
Dealer. To determine correct input rate for altitude, see example 1
and use 0.90 as derate multiplier factor.
3. To Begin Component Self-Test: Disconnect the thermostat R
lead from furnace control board. Manually close the blower
door switch. Briefly short the TEST/TWIN terminal to the
COM 24V terminal until LED goes out. Remove jumper from
terminals. (See Fig. 23.)
EXAMPLE 1:
88,000 BTUH INPUT FURNACE INSTALLED AT 4300 FT.
Derate
Furnace Input Rate
Furnace Input Rate X Multiplier =
at Installation
at Sea Level
Factor
Altitude
88,000
X
0.90
=
79,200
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.
2. Determine the correct orifice and manifold pressure adjustment. There are two different orifice and manifold adjustment
tables.
All models in all positions, except Low NOx models in
downflow or horizontal positions, use Table 10 (22,000
BTUH/Burner)
Low NOx models in the downflow or horizontal positions
must use Table 11 (21,000BTUH/Burner). See input listed on
furnace rating plate.
Component test sequence is as follows:
Refer to service label attached to furnace or see Fig. 43.
a. LED will display previous status code 4 times.
b. Inducer motor starts and continues to run until Step f of
component test sequence.
a. Obtain average yearly gas heat value (at installed altitude)
from local gas supplier.
c. Hot surface ignitor is energized for 15 sec., then off.
d. Blower motor operates on HEAT speed for 10 sec.
e. Blower motor operates on COOL speed for 10 sec.
b. Obtain average yearly gas specific gravity from local gas
supplier.
f. Inducer motor stops.
c. Find installation altitude in Table 10 or 11.
g. Reconnect R lead to furnace control board, release blower
door switch and re-install blower door.
d. Find closest natural gas heat value and specific gravity in
Table 10 or 11.
4. Operate furnace per instruction on door.
e. Follow heat value and specific gravity lines to point of
intersection to find orifice size and manifold pressure
settings for proper operation.
5. Verify furnace shut down by lowering thermostat setting
below room temperature.
23
SEE NOTES: 1,2,4,7,8,9
SEE NOTES: 1,2,3,4,7,8,9
SEE NOTES:1,2,3,4,5,7,8,9
A02058
A02059
Fig. 26—Upflow ApplicationVent Elbow Up
Fig. 27—Upflow ApplicationVent Elbow Right
A02060
Fig. 28—Downflow
Application-Vent Elbow Up
then Left
SEE NOTES: 1,2,4,5,7,8,9
SEE NOTES: 1,2,4,5,6,7,8,9
A02061
Fig. 29—Downflow
Application-Vent Elbow Up
A02062
Fig. 30—Downflow
Application-Vent Elbow Left
then Up
See Venting Notes on page 26.
24
SEE NOTES: 1,2,3,4,7,8,9
Fig. 31—Downflow
Application-Vent Elbow
then Right
A02063
Up
SEE NOTES: 1,2,4,7,8,9
A02064
SEE NOTES: 1,2,4,5,7,8,9
Fig. 32—Horizontal Left Application-Vent Elbow Left
A02067
Fig. 35—Horizontal Left Application-Vent Elbow Right
SEE NOTES: 1,2,4,5,7,8,9
A02065
SEE NOTES: 1,2,4,5,7,8,9
Fig. 33—Horizontal Left Application-Vent Elbow Right
then Up
A02068
Fig. 36—Horizontal Right Application-Vent Elbow Left
See Venting Notes on Page 26
SEE NOTES: 1,2,4,5,7,8,9
A02066
Fig. 34—Horizontal Left Application-Vent Elbow Up
f. Check and verify burner orifice size in furnace. NEVER
ASSUME ORIFICE SIZE. ALWAYS CHECK AND
VERIFY.
c. Connect a water column manometer or similar device to
manifold pressure tap.
g. Replace orifice with correct size if required by Table 13 or
14. Use only factory-supplied orifices. See EXAMPLE 2.
e. Set thermostat to call for heat.
d. Turn gas valve ON/OFF switch to ON.
f. Jumper R and W thermostat connections on furnace control
board to start furnace.
22,000 BTUH burner applications use Table 10
EXAMPLE 2: (0–2000 ft altitude)
Heating value = 1000 Btu/cu ft
Specific gravity = 0.62
Therefore: Orifice No. 43*
Manifold pressure: 3.7-in. wc
* Furnace is shipped with No. 43 orifices. In this example
all main burner orifices are the correct size and do not need
to be changed to obtain proper input rate.
g. Remove regulator seal cap and turn regulator adjusting
screw counterclockwise (out) to decrease input rate of
clockwise (in) to increase input rate.
h. Install regulator seal cap.
i. Leave manometer or similar device connected and proceed
to Step 4.
NOTE: DO NOT set manifold pressure less than 3.2-in wc or
more than 3.8-in. wc for natural gas at sea level. If manifold
pressure is outside this range, change main burner orifices or refer
Table 10 or 11.
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.
3. Adjust manifold pressure to obtain correct input rate.
a. Turn gas valve ON/OFF switch to OFF
b. Remove manifold pressure tap plug from gas valve. (See
Fig. 40.)
25
Venting Notes for Fig. 26-38
1. For common vent, vent connector sizing and vent material: United
States, latest edition of the National Fuel Gas Code (NFGC), ANSI
Z223.1/NFPA 54. In Canada, latest edition of the National Standards
of Canada, Natural Gas and Propane Installation Code (NSCNGPIC),
CSA B149.1-00.
2. Immediately increase to 5–inch vent connector outside furnace
casing when 5-inch vent connector 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 is used in the downflow position.
4. Type B vent where required, refer to Note 1 above.
5. 4” 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 bottom vent configuration.
7. Chimney Adapter Kit required for exterior masonry chimney
applications. Refer to Chimney Adapter Kit, KGACA02014FC and
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.
A02069
SEE NOTES: 1,2,4,7,8,9
Fig. 37—Horizontal Right Application-Vent Elbow
Right
SEE NOTES: 1,2,4,5,7,8,9
A02070
Fig. 38—Horizontal Right Application-Vent Elbow Left
then Up
4. Verify natural gas input rate by clocking meter.
NOTE: Gas valve regulator adjustment cap must be in place for
proper input to be clocked.
Disconnect 115-v electrical power before changing speed tap.
Failure to follow this warning could result in personal injury.
a. Turn off all other gas appliances and pilots.
c. Adjust air temperature rise by adjusting blower speed.
Increase blower speed to reduce temperature rise. Decrease
blower speed to increase temperature rise.
b. Run furnace for 3 minutes in heating operation.
c. Measure time (in sec) for gas meter to complete 1 revolution and note reading. The 2 cubic feet dial provides a more
accurate measurement of gas flow.
d. Turn thermostat down below room temperature and remove blower access door.
d. Refer to Table 8 for cubic ft of gas per hr.
e. To change motor speed selection for heating, remove
blower motor lead from control HEAT terminal (See Fig.
39.) Select desired blower motor speed lead from one of the
other terminals and relocate it to the HEAT terminal (See
Table 7 for lead color identification). Reconnect original
lead to SPARE terminal.
e. Multiply gas rate (cu ft/hr) by heating value (Btu/cu ft) to
obtain input.
If clocked rate does not match required input from Step 1, increase
manifold pressure to increase input or decrease manifold pressure
to decrease input. Repeat steps b through e until correct input is
achieved. Re-install regulator seal cap on gas valve.
f. Repeat steps a through e.
5. Set temperature rise.
The furnace must operate within the temperature rise ranges
specified on the furnace rating plate. Do not exceed temperature rise range specified on unit rating plate. Determine the
temperature rise as follows:
g. When correct input rate and temperature rise is achieved,
turn gas valve ON/OFF switch to OFF.
h. Remove manometer or similar device from gas valve.
i. Re-install manifold pressure tap plug in gas valve.
a. Place thermometers in return and supply ducts as close to
furnace as possible. Be sure thermometers do not see
radiant heat from heat exchangers. Radiant heat affects
temperature rise readings. This practice is particularly
important with straight-run ducts.
Failure to reinstall manifold pressure tap plug in gas valve
will result in fire, explosion, personal injury, property damage
or death.
b. When thermometer readings stabilize, subtract return-air
temperature from supply-air temperature to determine air
temperature rise.
j. Re-install blower access door if removed.
k. Turn gas valve ON/OFF switch to ON.
NOTE: Blower access door must be installed for proper temperature rise measurement.
NOTE: If the temperature rise is outside this range, first check:
1.) Gas input for heating operation.
2.) Derate for altitude if applicable.
3.) Return and supply ducts for excessive restrictions causing static
pressures greater than 0.50-in. wc.
4.) Dirty filter.
Recheck temperature rise. It must be within limits specified
on the rating plate. Recommended operation is at the midpoint of rise range or slightly above
6. Set thermostat heat anticipator.
26
27
WHT
(COM)
LED
GND
GV
GVR
HSI
HSIR
HUM
IDM
IDR
ILK
J1
J2
JB
LED
LGPS
START
BLWM
EAC-1
BLU
PL1
RED
BRN
2
YEL
ORN
CAP
GRN/YEL
PR1
PL2
WHT
BRN
RED
PCB
GRN/YEL
1
BLK
WHT
BLK
WHT
ILK
JB
BLK
RED
BLK
NOTE #11
LS2
RED
BLK
WHT
ORG
GRN/YEL
IDM
(WHEN USED)
ORG
BVSS
NOTE #10
(WHEN USED)
RED
DSS
LS1
PLUG RECEPTACLE
FIELD SPLICE
EQUIPMENT GROUND
FIELD EARTH GROUND
FIELD WIRING SCREW TERMINAL
CONDUCTOR ON CONTROL PCB
FIELD WIRING (24VAC)
FIELD WIRING (115VAC)
FACTORY WIRING (24VAC)
FACTORY WIRING (115VAC)
PCB CONTROL TERMINAL
UNMARKED TERMINAL
LIMIT SWITCH, AUTO-RESET, SPST(N.C.)
AUTO-RESET INTERNAL MOTOR OVERLOAD
TEMPERATURE SWITCH (N.C.)
PRINTED CIRCUIT BOARD CONTROL
11-CIRCUIT PCB CONNECTOR
2-CIRCUIT CONNECTOR
2-CIRCUIT HSI, CONNECTOR
PRESSURE SWITCH, SPST-(N.O.)
COMPONENT TEST & TWIN TERMINAL
TRANSFORMER-115VAC/24VAC
JUNCTION
GND
FUSE OR CIRCUIT BREAKER &
DISCONNECT SWITCH (WHEN REQ’D)
NOTE #2
NEUTRAL
WHT
FU2
L1
BLK
WHT
WHT
(WHEN USED)
LGPS
RED
RED
FRS1
FRS2
IDR
13.
14.
10.
11.
12.
1.
2.
3.
4.
5.
6.
7.
8.
9.
SEC-2
PCB NOTE #5
CPU
24VAC
2
1
BHT/CLR
GVR
COOL
HEAT
SPARE-1
2
1
PL1-7
PL1-9
PL1-11
PL1-3
PL1-1
PL1-5
PL1-10
PL1-4
PL1-2
PL1-8
PL1-6
PL3
LS1
FSE
GV
L2
IDM
EAC-2
CAP
NOTE #3
PRS
NOTE #11
(WHEN USED)
LS2
NOTE #10
BVSS
(WHEN USED)
BLWM
DSS
START
LGPS
(WHEN USED)
FRS1
HSI
OL
FRS2
COM
MED LO
HI
LO
EQUIPMENT GROUND
SCHEMATIC DIAGRAM
(NATURAL & PROPANE GASES)
A02141
If any of the original equipment wire is replaced use wire rated for 105°C.
Use only copper wire between the disconnect switch and the furnace junction box (JB).
This wire must be connected to furnace sheet metal for control to prove flame.
Symbols are electrical representation only.
Solid lines inside PCB are printed circuit board conductors and are not included in legend.
Replace only with a 3 amp fuse.
Inducer (IDM) and blower (BLWM) motors contain internal auto-reset thermal overload switches (OL).
Neutral connections are interchangeable within the NEUTRAL connector block.
Blower motor speed selections are for average conditions, see installation instructions for details on
optimum speed selection.
Factory connected when BVSS (Chimney Adapter Accessory Kit) is not installed.
Factory connected when LGPS is not used.
Ignition-lockout will occur after four consecutive unsuccessful trials-for-ignition. Control will
auto-reset after three hours.
Blower-on delay: gas heating 25 seconds, cooling or heat pump 2 seconds.
Blower-off delay: gas heating selections are 90, 120, 150 or 180 seconds, cooling or heat pump
90 seconds or 5 seconds when J2 is cut.
NOTES:
COM 24V
G
Y
HUM
W
R
PL2
115VAC
NOTE #6
SEC-1
TRAN
PR1
HSIR
EAC-1
L2 NEUTRAL
TEST/TWIN
BLWR
L1
ILK
FU1
L1
TO 115VAC FIELD DISCONNECT SWITCH
Fig. 39—Furnace Wiring Diagram
PCB
PL1
PL2
PL3
PRS
TEST/TWIN
TRAN
LS 1, 2
OL
1
2
RED
BLU
RED
PL3
PRS
WHT (COM)
FSE
NOTE #5
GRN/YEL
GV
CONNECTION DIAGRAM
BLOWER MOTOR SPEED CHANGE RELAY, SPDT
BLOWER MOTOR RELAY, SPST-(N.O.)
BLOWER MOTOR, PERMANENT-SPLIT-CAPACITOR
BLOCKED VENT SHUTOFF SWITCH, MANUAL-RESET, SPST -(N.C.)
CAPACITOR
MICROPROCESSOR AND CIRCUITRY
DRAFT SAFE GUARD SWITCH, AUTO-RESET, SPST -(N.C.)
ELECTRONIC AIR CLEANER CONNECTION (115 VAC 1.0 AMP MAX.)
ELECTRONIC AIR CLEANER CONNECTION (COMMON)
FLAME ROLLOUT SW. -MANUAL RESET, SPST-(N.C.)
FLAME-PROVING ELECTRODE
FUSE, 3 AMP, AUTOMOTIVE BLADE TYPE, FACTORY INSTALLED
FUSE OR CIRCUIT BREAKER CURRENT INTERRUPT DEVICE
(FIELD INSTALLED & SUPPLIED)
EQUIPMENT GROUND
GAS VALVE-REDUNDANT
GAS VALVE RELAY, SPST-(N.O.)
HOT SURFACE IGNITER (115 VAC)
HOT SURFACE IGNITER RELAY, SPST-(N.O.)
24VAC HUMIDIFIER CONNECTION (0.5 AMP. MAX.)
INDUCED DRAFT MOTOR, SHADED-POLE
INDUCED DRAFT MOTOR RELAY, SPST-(N.O.)
BLOWER ACCESS PANEL INTERLOCK SWITCH, SPST-(N.O.)
BLOWER - OFF DELAY JUMPER SELECTOR - HEATING
BLOWER - OFF DELAY JUMPER - COOLING
JUNCTION BOX
LIGHT-EMITTING DIODE FOR STATUS CODES - RED
LOW GAS PRESSURE SWITCH, SPST-(N.O.)
RED (LO)
OL
SPARE 2
SPARE 1
BLK (HI)
L1
BLWR
L2
HUM
HEAT
BHT/CLR
COOL
J1
180
120
TEST/TWIN
150
SEC-1
EAC-2
SEC-2
BHT/CLR
BLWR
BLWM
BVSS
CAP
CPU
DSS
EAC-1
EAC-2
FRS 1, 2
FSE
FU 1
FU 2
BLU
(MED LO)
L
E
G
E
N
D
R
Y
FU1
NOTE #6
NOTE #8
TRAN
90
1 2 3 4 5 6 7 8 9 10 11
G
Com
24V
W
NEUTRAL
BLW
PRINTED CIRCIUT BOARD
HSI
J2
YEL
BLOWER OFF-DELAY
JUMPER SELECT OR
PRINTED CIRCIUT BOARD
327559-101 REV. E
L 2 NEUTRAL
Caution!! For the following applications, use the minimum vertical vent sections 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.)*
MINIMUM VERTICAL VENT HEIGHT (FT)**
Downflow
Vent elbow left, then up
Fig. 30
154,000
132,000
110,000(036/-12 only)
5
12
Horizontal Left
Vent elbow right,
then up
Fig. 33
154,000
132,000
5
7
Horizontal Left
Vent Elbow up
Fig. 34
154,000
132,000
5
7
Horizontal Left
Vent elbow right
Fig. 35
154,000
5
7
Downflow
Vent elbow up then left
Fig. 28
110,000
(036/-12 only)
5
10
Downflow
Vent elbow up, then right
Fig. 31
110,000
(036/-12 only)
5
10
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)
Table 6–Altitude Derate Multipler 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
BURNER
ORIFICE
* Derate multiplier factors are based on midpoint altitude for altitude range.
ON AND OFF
SWITCH
A93059
Fig. 41—Orifice Hole
Table 7—Speed Selection
GAS PRESSURE
REGULATOR
ADJUSTMENT
COLOR
SPEED
White
Common
AS SHIPPED
BLW
Black
High
COOL
Yellow†
Med-High
SPARE
Blue*
Med-Low
SPARE
Red*
Low
HEAT
* 1/5 HP motor models: BLUE to HEAT, RED to SPARE.
† Not available on 1/5 HP motors.
NOTE: Continuous blower is the HEAT speed.
(1.) Remove thermostat from subbase or from wall.
INLET
PRESSURE
TAP
(2.) Connect an amp meter as shown in Fig. 42 across the
R and W terminals or R and W wires.
MANIFOLD
PRESSURE TAP
A00157
(3.) Record amp draw across terminals when furnace is in
heating and after blower starts.
Fig. 40—Redundant Automatic Gas Control Valve
(4.) Set heat anticapator on thermostat per thermostat
instructions and install on subbase or wall.
a. Mechanical thermostat—Set thermostat heat anticipator to
match the amp draw of the electrical components in the
R-W circuit. Accurate amp draw readings can be obtained
at the wires normally connected to thermostat subbase
terminals, R and W. The thermostat anticipator should
NOT be in the circuit while measuring current.
b. Electronic thermostat: Set cycle rate for 4 cycles per hr.
7. Adjust blower off delay
The blower off delay has 4 adjustable settings from 90 sec to
180 sec. The blower off delay jumpers are located on the
furnace control board. (See Fig. 23.)
28
Table 8–GAS RATE (CU FT/HR)
SIZE OF TEST DIAL
SIZE OF TEST DIAL
SECONDS
SECONDS
FOR 1
FOR 1
1
2
5
1
2
5
REVOLUTION Cu Ft Cu Ft Cu Ft REVOLUTION Cu Ft Cu Ft Cu Ft
THERMOSTAT SUBBASE
TERMINALS WITH
THERMOSTAT REMOVED
(ANITICIPATOR, CLOCK, ETC.,
MUST BE OUT OF CIRCUIT.)
10
360
720
1800
50
72
144
360
11
327
655
1636
51
71
141
355
12
300
600
1500
52
69
138
346
13
277
555
1385
53
68
136
340
14
257
514
1286
54
67
133
333
15
240
480
1200
55
65
131
327
16
225
450
1125
56
64
129
321
17
212
424
1059
57
63
126
316
18
200
400
1000
58
62
124
310
19
189
379
947
59
61
122
305
20
180
360
900
60
60
120
300
21
171
343
857
62
58
116
290
22
164
327
818
64
56
112
281
23
157
313
783
66
54
109
273
24
150
300
750
68
53
106
265
25
144
288
720
70
51
103
257
26
138
277
692
72
50
100
250
27
133
267
667
74
48
97
243
28
129
257
643
76
47
95
237
29
124
248
621
78
46
92
231
30
120
240
600
80
45
90
225
31
116
232
581
82
44
88
220
32
113
225
563
84
43
86
214
33
109
218
545
86
42
84
209
34
106
212
529
88
41
82
205
35
103
206
514
90
40
80
200
36
100
200
500
92
39
78
196
37
97
195
486
94
38
76
192
38
95
189
474
96
38
75
188
39
92
185
462
98
37
74
184
a. Verify vent pipe is cool to the touch.
40
90
180
450
100
36
72
180
41
88
176
439
102
35
71
178
b. Disconnect power to furnace and remove vent connector
from furnace vent elbow.
42
86
172
429
104
35
69
173
43
84
167
419
106
34
68
170
44
82
164
409
108
33
67
167
45
80
160
400
110
33
65
164
46
78
157
391
112
32
64
161
47
76
153
383
116
31
62
155
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.
48
75
150
375
120
30
60
150
e. Furnace should cycle off within 2 minutes.
49
73
147
367
HOOK-AROUND
AMMETER
R Y W G
10 TURNS
FROM UNIT 24-V
CONTROL TERMINALS
EXAMPLE: 5.0 AMPS ON AMMETER
10 TURNS AROUND JAWS
= 0.5 AMPS FOR THERMOSTAT
ANTICIPATOR SETTING
A96316
Fig. 42—Amp Draw Check With Ammeter
d. Burners will re-light when furnace cools down.
2. Check draft safeguard switch.
The purpose of this control is to permit the safe shutdown of
the furnace during certain blocked vent conditions.
c. Restore power to furnace and set room thermostat above
room temperature.
f. Remove blockage and reconnect vent pipe to furnace vent
elbow.
g. Switch will auto-reset when it cools.
To change the blower off delay setting, move the jumper from
one set of pins on the control to the pins used for the selected
blower off delay. Factory off delay setting is 120 sec.
h. If control board locks out furnace, cycle 115 vac power to
reset control.
3. Check Pressure Switch(es)
This control proves operation of the draft inducer blower.
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.
a. Turn off 115-v power to furnace.
b. Disconnect inducer motor lead wires from wire harness.
1. Check Main Limit Switches
This control shuts off combustion control system and energizes air-circulating blower motor, if furnace overheats. By
using this method to check limit control, it can be established
that limit is functioning properly and will operate if there is a
restricted duct system or motor failure. If limit control does
not function during this test, cause must be determined and
corrected.
c. Turn on 115-v power to furnace.
d. Set thermostat to ″call for heat″ and wait 1 minute. When
pressure switch is functioning properly, hot surface igniter
should NOT glow and control diagnostic light flashes a
status code 32. If hot surface igniter glows when inducer
motor is disconnected, shut down furnace immediately.
e. Determine reason pressure switch did not function properly
and correct condition.
a. Run furnace for at least 5 minutes.
f. Turn off 115-v power to furnace.
b. Gradually block off return air with a piece of cardboard or
sheet metal until the limit trips.
g. Reconnect inducer motor wires, replace outer door, and
turn on 115-v power.
c. Unblock return air to permit normal circulation.
29
Step 5—Checklist
The control system also requires an earth ground for proper
operation of the control and flame-sensing electrode.
1. Put away tools and instruments. Clean up debris.
The 24-v circuit contains an automotive-type, 3-amp fuse located
on the control. (See Fig. 23.) Any shorts of the 24-v wiring during
installation, service, or maintenance will cause this fuse to blow. If
fuse replacement is required, use ONLY a 3-amp fuse. The control
LED will display status code 24 when fuse needs to be replaced.
2. Check that blower OFF-DELAY time is selected as desired.
3. Verify that blower and burner access doors are properly
installed.
4. Cycle test furnace with room thermostat.
5. Check operation of accessories per manufacturer’s instructions.
Proper instrumentation is required to service electrical controls.
The control in this furnace is equipped with a Status Code LED
(Light-Emitting Diode) to aid in installation, servicing, and
troubleshooting. It can be viewed through the sight glass in blower
access door. The furnace control LED is either ON continuously,
rapid flashing, or a code composed of 2 digits. The first digit is the
number of short flashes, the second digit is the number of long
flashes.
6. Review User’s Guide with owner.
7. Leave literature packet near furnace.
SERVICE AND MAINTENANCE PROCEDURES
For an explanation of status codes, refer to service label located on
blower access door or Fig. 43, and the troubleshooting guide at the
end of this procedure. The furnace control will store 1 status code
for 72 hours.
For Controls With a Red LED
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. FAILURE
TO FOLLOW THIS WARNING COULD RESULT IN
POSSIBLE DAMAGE TO THIS EQUIPMENT, SERIOUS
PERSONAL INJURY, OR DEATH.
→
The stored status codes WILL be erased from the control memory,
if 115- or 24-v power is interrupted.
1. To retrieve status code, proceed with the following:
NOTE: NO thermostat signal may be present at control, and all
blower-OFF delays must be completed.
a. Leave 115-v power to furnace turned on.
ELECTRICAL SHOCK, FIRE, OR EXPLOSION HAZARD
Failure to follow safety warnings exactly could result in
dangerous operation, serious injury, death, or property damage.
Improper servicing could result in dangerous operation,
serious injury, death, or property damage.
- Before servicing, disconnect all electrical power to furnace.
- When servicing controls, label all wires prior to disconnecting. Reconnect wires correctly.
- Verify proper operation after servicing.
b. Remove outer access door.
c. Look into blower access door sight glass for current LED
status. DO NOT remove blower access door or terminate
115-v power to control or status code will be lost.
d. BRIEFLY remove insulated terminal wire from the draft
safeguard switch (DSS) until LED goes out (1 to 2 sec),
then reconnect it.
2. When above items have been completed, the LED flashes
status code 4 times. Record this status code for further
troubleshooting.
3. Component self-test will begin. Refer to COMPONENT
TEST section for complete test sequence.
Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous
operation.
4. Check LED status.
5. Refer to the SERVICE label on the front of the blower access
door for more information.
Step 1—Introduction
Component Self-Test
GENERAL
Component Test can also be initiated by performing the following:
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.
1. Remove outer access door.
2. Remove blower access door.
3. Remove the wire from the ″R″ terminal of the control board.
4. Manually close blower access door switch.
ELECTRICAL CONTROLS AND WIRING
There may be more than 1 electrical supply to the unit. Check
accessories and cooling unit for additional electrical supplies
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. Failure to follow this warning could result
in electrical shock, personal injury, or death.
The electrical ground and polarity for 115-v wiring must be
properly maintained. Refer to Fig. 24 for field wiring information
and to Fig. 39 for furnace wiring information.
5. BRIEFLY short (jumper) TEST/TWIN, 3/16-in. quickconnect male terminal on control (behind Y terminal) to the
COM-24V terminal on furnace control. (See Fig. 23.)
NOTE: If the polarity is not correct, the STATUS LED on the
control will flash rapidly and prevent the furnace from heating.
30
SERVICE
If status code recall is needed, briefly remove then reconnect one main limit wire to display stored status code. On RED LED boards do not remove power or blower door before initiating status code recall. After
status code recall is completed component test will occur.
LED CODE
STATUS
CONTINUOUS OFF - Check for 115VAC at L1 and L2, and 24VAC at SEC-1 and SEC-2.
CONTINUOUS ON - Control has 24VAC power.
RAPID FLASHING - Line voltage (115VAC) polarity reversed. If twinned, refer to twinning kit instructions.
EACH OF THE FOLLOWING STATUS CODES IS A TWO DIGIT NUMBER WITH THE FIRST DIGIT DETERMINED BY THE NUMBER OF SHORT FLASHES AND THE SECOND DIGIT BY THE NUMBER OF LONG FLASHES.
11 NO PREVIOUS CODE - Stored status code is erased automatically after 72 hours. On
RED LED boards stored status codes can also be erased when power
(115 VAC or 24 VAC) to control is interrupted.
12 BLOWER ON AFTER POWER UP (115 VAC or 24 VAC) -Blower runs for 90 seconds,
if unit is powered up during a call for heat (R-W closed) or R-W opens during blower
on-delay.
13 LIMIT CIRCUIT LOCKOUT - Lockout occurs if the limit, draft safeguard, flame rollout, or
blocked vent switch (if used) is open longer than 3 minutes or 10 successive limit trips
occurred during high-heat. - Control will auto reset after three hours.
- Refer to #33.
14 IGNITION LOCKOUT - Control will auto-reset after three hours. Refer to #34.
21 GAS HEATING LOCKOUT - Control will NOT auto reset.
Check for: - Mis-wired gas valve
-Defective control (valve relay)
22 ABNORMAL FLAME-PROVING SIGNAL - Flame is proved while gas valve is deenergized. Inducer will run until fault is cleared. Check for: - Leaky gas valve
- Stuck-open gas valve
23 PRESSURE SWITCH DID NOT OPEN Check for:
- Obstructed pressure tubing.
- Pressure switch stuck closed.
24 SECONDARY VOLTAGE FUSE IS OPEN Check for:
- Short circuit in secondary voltage (24VAC) wiring.
COMPONENT TEST
To initiate the component test sequence, shut OFF the room thermostat or disconnect the "R"
thermostat lead. Briefly short the TEST/TWIN terminal to the "Com 24V" terminal. Status LED
will flash code and then turn ON the inducer motor. The inducer motor will run for the entire
component test. The hot surface ignitor, blower motor fan speed (on AMBER LED boards
only) blower motor-heat speed, and blower motor-cool speed will be turned ON for 10-15
seconds each. Gas Valve and Humidifier will not be turned on.
327596-101 REV. A
31
PRESSURE SWITCH DID NOT CLOSE OR REOPENED - If open longer than five minutes,
inducer shuts off for 15 minutes before retry. Check for: - Excessive wind
- Proper vent sizing
- Defective inducer motor
- Low inducer voltage (115VAC)
- Defective pressure switch
- Inadequate combustion air supply
- Disconnected or obstructed pressure tubing
- Low inlet gas pressure (if LGPS used)
- Restricted vent
If it opens during blower on-delay period, blower will come on for the selected blower
off-delay.
33 LIMIT CIRCUIT FAULT - Indicates the limit, draft safeguard, flame rollout, or blocked vent
switch (if used) is open or the furnace is operating in high-heat only mode due to 2
successive low heat limit trips. Blower will run for 4 minutes or until open switch remakes
whichever is longer. If open longer than 3 minutes, code changes to lockout #13.
If open less than 3 minutes status code #33 continues to flash until blower shuts off.
Flame rollout switch and BVSS require manual reset. Check for:
- Restricted vent
- Proper vent sizing
- Loose blower wheel.
- Excessive wind
- Dirty filter or restricted duct system.
- Defective blower motor or capacitor. - Defective switch or connections.
- Inadequate combustion air supply (Flame Roll-out Switch open).
34 IGNITION PROVING FAILURE - Control will try three more times before lockout #14
occurs. If flame signal lost during blower on-delay period, blower will come on for the
selected blower off-delay. Check for: - Flame sensor must not be grounded
- Oxide buildup on flame sensor (clean with fine steel wool).
- Proper flame sense microamps (.5 microamps D.C. min., 4.0 - 6.0 nominal).
- Gas valve defective or gas valve turned off
- Manual valve shut-off
- Defective Hot Surface Ignitor
- Control ground continuity
- Low inlet gas pressure
- Inadequate flame carryover or rough ignition
- Green/Yellow wire MUST be connected to furnace sheet metal
45 CONTROL CIRCUITRY LOCKOUT Auto-reset after one hour lockout due to;
- Gas valve relay stuck open
- Flame sense circuit failure
- Software check error
Reset power to clear lockout. Replace control if status code repeats.
A02027
Fig. 43—Service Label
NOTE: If TEST/TWIN to COM-24V terminals are jumpered
longer than 2 sec, LED will flash rapidly, and test request will be
ignored.
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.
A failure to follow this warning could result in corrosion of
the heat exchanger, fire, personal injury, or death.
6. Component Test will function as follows:
a. LED flashes a status code 4 times. Record this status code
for further troubleshooting.
b. Inducer motor starts and continues to run until step f of
component test sequence.
c. Hot surface igniter is energized for 15 sec, then deenergized.
d. Blower operates at HEAT speed for 10 sec, then turns off.
e. Blower operates at COOL speed for 10 sec, then turns off.
f. Inducer motor turns off.
Items a through f above will assist in furnace troubleshooting since
all components are functionally operated except the gas valve. This
procedure is also referred to as ″Component Test Sequence.″
Turn off the gas and electrical supplies to the unit before
performing any maintenance or service. Follow the operating
instructions on the label attached to the furnace. A failure to
follow this warning could result in personal injury.
7. Check LED status. If no previous fault is in history, control
will flash status code 11.
8. If LED status indicates proper operation, RELEASE
BLOWER ACCESS DOOR SWITCH, reattach wire to ″R″
terminal on furnace control board, replace blower access door,
and replace burner access door.
Step 2—Care and Maintenance
Never operate unit without a filter or with filter access door
removed. A failure to follow this warning could result in fire,
personal injury, or death.
For continuing high performance and to minimize possible equipment failure, periodic maintenance must be performed on this
equipment. Consult your local dealer about proper frequency of
maintenance and the availability of a maintenance contract.
→
Personal injury can result from sharp metal edges, etc. Be
careful when removing parts. Gloves and safety glasses
should be worn when servicing equipment
The minimum maintenance on this equipment 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.
31
BLOWER MOTOR AND WHEEL
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 professional.
→
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
professional.
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.
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. Failure to follow this warning could result
in personal injury or death.
The blower wheel should not be dropped or bent as balance
will be affected.
The following steps should be performed by a qualified service
technician.
CLEANING AND/OR REPLACING AIR FILTER
The air filter arrangement may vary depending on the application.
The filter is exterior to the furnace casing.
To ensure long life and high efficiency, clean accumulated dirt and
grease from blower wheel and motor annually.
NOTE: If the filter has an airflow direction arrow, the arrow must
point towards the blower.
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:
Personal injury can result from sharp metal edges, etc. Be
careful when removing parts. Gloves and safety glasses
should be worn when servicing equipment
1. Turn off electrical supply to furnace.
2. Unscrew the thumbscrew on outer door and remove outer
door.
Media cabinet filter procedures:
3. For downflow or horizontal furnaces having vent pipes within
the furnace that pass in from of the blower access door:
NOTE: Media cabinet or 1″ Filter Rack are accessories and are
not included from the factory with the standard furnace model.
a. Disconnect vent connector from furnace vent elbow.
1. Turn off electrical supply to furnace before removing filter
access door.
b. Disconnect and remove short piece of vent pipe from
within furnace.
2. Remove filter cabinet door.
3. Slide filter out of cabinet.
4. Remove 2 screws from blower access door and remove blower
access door.
4. If equipped with permanent, washable 1″ 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 9 for size information.
5. Disconnect blower leads from furnace control. Note 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.
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 KGAFR0301ALL external filter rack, See Table 9.
6. Remove 2 screws from 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.
6. Slide filter into cabinet.
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.
7. Replace filter cabinet door.
8. Turn on electrical supply to furnace.
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:
Table 9—FILTER SIZE INFORMATION (IN.)
FURNACE
CASING WIDTH
14-1/2
17-1/2
21
24**
FILTER QUANTITY AND SIZE
Side Return
Bottom Return
(1) 16 X 25 X 1 (1) 14 X 25 X 1
(1) 16 X 25 X 1 (1) 16 X 25 X 1
(1) 16 X 25 X 1 (1) 20 X 25 X 1
(1) 16 X 25 X 1 (1) 24 X 25 X 1
FILTER
TYPE
NOTE: Before disassembly, mark blower motor, and blower
housing so motor and each arm is positioned at the same location
during reassembly.
Cleanable*
Cleanable*
Cleanable*
Cleanable*
a. Disconnect capacitor wires and ground wire attached to
blower housing.
* Recommended
** Some furnaces may have 2 filters
b. Remove screws securing cutoff plate and remove cutoff
plate from housing.
c. Loosen set screw holding blower wheel on motor shaft.
d. Remove bolts holding motor to blower housing and slide
motor out of wheel.
32
e. Remove blower wheel from housing.
CLEANING HEAT EXCHANGER
f. Clean wheel and housing.
The following steps should be performed by a qualified service
technician:
12. Reassemble motor and blower by reversing steps 11f, finishing with 11a. Be sure to reattach ground wire to the blower
housing.
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.
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.
If it becomes necessary to clean the heat exchangers because of
dust or corrosion, proceed as follows:
16. Reinstall control box assembly in furnace.
1. Turn OFF gas and electrical power to furnace.
2. Remove outer access door.
Heating fan speed(s) MUST be adjusted to provide proper air
temperature rise as specified on the rating plate. Failure to
adjust the heating speed(s) may shorten heat exchanger life.
Recommended operation is at the midpoint of the rise range
or slightly above. Refer to ″SET TEMPERATURE RISE″
under START-UP, ADJUSTMENT, and SAFETY CHECK.
3. Disconnect vent connector from furnace vent elbow.
4. For downflow or horizontal furnace having an internal vent
pipe, remove internal vent pipe within the casing.
5. Disconnect wires to the following components. Mark wires to
aid in reconnection of:
a. Draft safeguard switch.
NOTE: Refer to Table 7 for motor speed lead relocation if leads
were not identified before disconnection.
b. Inducer motor.
17. Reconnect blower leads to furnace control. Refer to furnace
wiring diagram, and connect thermostat leads if previously
disconnected. (See Fig. 39.)
c. Pressure switch(es).
18. To check blower for proper rotation:
f. Hot surface igniter.
d. Limit overtemperature switch.
e. Gas valve.
a. Turn on electrical supply.
g. Flame-sensing electrode
h. Flame rollout switches.
i. Remove NOx baffles on low NOx models.
Blower access door switch opens 115-v power to furnace
control. No component operation can occur. Caution must be
taken when manually closing this switch for service purposes.
Failure to follow this warning could result in electrical shock,
personal injury, or death.
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.
b. Manually close blower access door switch.
NOTE: If thermostat terminals are jumpered at the time blower
access door switch is closed, blower will run for 90 sec before
beginning a heating or cooling cycle.
NOTE: Be very careful when removing burner assembly to avoid
breaking igniter. See Fig. 44 and 45 for correct igniter location.
c. Perform component self-test as shown at the bottom of the
SERVICE label, located on the front of blower access door.
9/32”
d. Verify blower is rotating in the correct direction.
11/32”
19. If furnace is operating properly, RELEASE BLOWER ACCESS DOOR SWITCH. Replace blower access door and
remove any jumpers or reconnect any disconnected thermostat
leads.
20. Downflow or horizontal furnaces with vent pipe through
furnace only:
a. Install and connect short piece of vent pipe inside furnace
to existing vent.
b. Connect vent connector to vent elbow.
21. Reinstall casing door.
22. Turn on gas supply and cycle furnace through one complete
heating and cooling cycle. Verify the unit 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.
A02150
Fig. 44—Position of Igniter to Burner
33
7/8”
A02151
A91252
Fig. 45—Position of Igniter to Burner
Fig. 46—Cleaning Heat Exchanger Cell
9. Using field-provided 25-caliber rifle cleaning brush, 1/4″
diameter steel spring cable, 36 in. long, a variable speed,
reversible electric drill, and vacuum cleaner, clean cells as
follows:
13. Reconnect wires to the following components (Use connection
diagram on wiring label, if wires were not marked for
reconnection locations.):
a. Remove metal screw fitting from wire brush to allow
insertion into cable.
a. Draft safeguard switch.
b. Inducer motor.
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.
c. Pressure switch(es).
d. Limit overtemperature switch.
e. Gas valve.
NOTE: The materials needed in item 9 can usually be purchased
at local hardware stores.
f. Hot surface igniter.
g. Flame-sensing electrode.
(1.) Attach variable-speed, reversible drill to the end of
spring cable (end opposite brush).
h. Flame rollout switches.
i. Install NOx baffles (if removed).
(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.
46.)
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.
(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.
16. Replace blower access door only.
17. Set thermostat above room temperature and check furnace for
proper operation.
(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.
18. Verify blower airflow and speed changes between heating and
cooling.
(5.) Repeat foregoing procedures until each cell in furnace
has been cleaned.
19. Check for gas leaks.
(6.) Using vacuum cleaner, remove residue from each cell.
Never use a match or other open flame to check for gas leaks.
Use a soap-and-water solution. A failure to follow this
warning could result in fire, personal injury, or death.
(7.) Using vacuum cleaner with soft brush attachment,
clean burner assembly.
(8.) Clean flame sensor with fine steel wool.
(9.) Reinstall burner assembly. Center burners in cell
openings.
10. Remove old sealant from cell panel and inducer backing plate
flange.
20. Replace outer access door.
Step 3—Sequence of Operation
→ NOTE:
Furnace control must be grounded for proper operation or
control will lock out. Control is grounded through green/yellow
wire routed to gas valve and manifold bracket screw.
11. Spray releasing agent on the heat exchanger cell panel where
collector box assembly contacts cell panel.
Using the schematic diagram in Fig. 39, follow the sequence of
operation through the different modes. Read and follow the wiring
diagram very carefully.
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.
NOTE: If a power interruption occurs during a call for heat (W),
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 red 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.
12. Apply new sealant to flange of inducer assembly and attach to
cell panel using existing screws, making sure all screws are
secure.
34
circuit starts the outdoor unit, and the R-to-G and Y circuits
start the furnace blower motor BLWM on COOL speed.
The electronic air cleaner terminal EAC-1 is energized with
115 vac when the blower motor BLWM is operating.
When the thermostat is satisfied, the R-to-G-and-Y circuits are
opened. The outdoor unit will stop, and the furnace blower
motor BLWM will continue operating on the COOL speed for
an additional 90 seconds. Cut jumper J2 to reduce the cooling
off-delay to 5 seconds. (See Fig. 23.)
The blower door must be installed for power to be conducted
through the blower door interlock switch ILK to the furnace
control CPU, transformer TRAN, inducer motor IDM, blower
motor BLWM, hot-surface igniter HSI, and gas valve GV.
1. Heating
(See Fig. 24 for thermostat connections.)
The wall thermostat ″calls for heat″, closing the R to W
circuit. The furnace control performs a self-check, verifies the
pressure switch contacts PRS is open, and starts the inducer
motor IDM.
3. Continuous Blower Mode
When the R-to-G circuit is closed by the thermostat, the
blower motor BLWM will operate on continuous-blower
speed (same as HEAT speed). Terminal EAC-1 is energized as
long as the blower motor BLWM is energized.
During a call for heat, the blower BLWM will stop during
igniter warm-up (17 seconds), ignition, and blower-ON delay
(25 seconds), allowing the furnace heat exchangers to heat up
more quickly, then restarts at the end of the blower-ON delay
period at HEAT speed.
When the thermostat ″calls for cooling″, the blower motor
BLWM will operate at COOL speed. When the thermostat is
satisfied, the blower motor BLWM will operate an additional
90 seconds on COOL speed before reverting back to
continuous-blower speed.
When the R-to-G circuit is opened, the blower motor BLWM
will continue operating for an additional 5 seconds, if no other
function requires blower motor BLWM operation.
a. Inducer Prepurge Period- As the inducer motor IDM
comes up to speed, the pressure switch contacts PRS close,
24 vac power is supplied for a field installed humidifier at
the HUM terminal and the control begins a 15-second
prepurge period.
b. Igniter Warm-Up- At the end of the prepurge period, the
Hot-Surface Igniter HSI is energized for a 17-second
igniter warm-up period.
c. Trial-for-Ignition Sequence- When the igniter warm-up
period is completed the main gas valve relay contacts GVR
close to energize the gas valve GV, the gas valve opens.
The gas valve GV permits gas flow to the burners where it
is ignited. After 5 seconds, the igniter HSI is de-energized
and a 2-second Flame-Proving period begins.
d. Flame-Proving- When the burner flame is proved at the
flame-proving sensor electrode FSE, the furnace control
CPU begins the blower-ON delay period and continues to
hold the gas valve GV open. If the burner flame is not
proved within two seconds, the control CPU will close the
gas valve GV, and the control CPU will repeat the ignition
sequence for up to three more Trials-For-Ignition before
going to Ignition-Lockout. Lockout will be reset automatically after three hours, by momentarily interrupting
115 vac power to the furnace, or by interrupting 24 vac
power at SEC1 or SEC2 to the furnace control CPU (not at
W, G, R, etc.)
4. Heat Pump
When installed with a heat pump, the furnace control automatically changes the timing sequence to avoid long blower
off times during demand defrost cycles. When the R-to-Wand-Y or R-to-W-and-Y-and-G circuits are energized the
furnace control CPU will continue to turn on the blower motor
BLWM at HEAT speed, and begin a heating cycle. The
blower motor BLWM will remain on until the end of the
prepurge period, then shut off for 24 seconds then come back
on at HEAT speed. When the W input signal disappears, the
furnace control begins a normal inducer post-purge period and
the blower switches to COOL speed after a 3 second delay. If
the R-to-W-and-Y-and-G signals disappear at the same time,
the blower motor BLWM will remain on for the selected
blower-OFF delay period. If the R-to-W-and-Y signals disappear, leaving the G signal, the blower motor BLWM will
continue running the blower motor BLWM at HEAT speed
after the selected blower-OFF delay period is completed.
If flame is proved when flame should not be present, the
furnace control CPU will lock out of Gas-Heating mode
and operate the inducer motor IDM until flame is no longer
proved.
e. Blower-On Delay- If the burner flame is proven, the
blower motor is energized on HEAT speed 25 seconds after
the gas valve GV is energized.
Simultaneously, the electronic air cleaner terminal EAC-1
is energized and remains energized as long as the blower
motor BLWM is energized.
Step 4—Wiring Diagrams
Refer to Fig. 24 and 39 for wiring diagrams.
f. Blower-Off Delay- When the thermostat is satisfied, the
R-to-W circuit is opened, de-energizing the gas valve GV,
stopping gas flow to the burners, and de-energizing the
humidifier terminal HUM. The inducer motor IDM will
remain energized for a 5-second post-purge period. The
blower motor BLWM and air cleaner terminal EAC-1 will
remain energized for 90, 120, 150, or 180 seconds (depending on the blower-OFF delay selection). The furnace
control CPU is factory-set for a 120-second blower-OFF
delay.
Step 5—Troubleshooting
Refer to the service label. (See Fig. 43—Service Label.)
The Troubleshooting Guide can be a useful tool in isolating
furnace operation problems. Beginning with the word “Start,”
answer each question and follow the appropriate arrow to the next
item.
The Guide will help to identify the problem or failed component.
After replacing any component, verify correct operation sequence.
2. Cooling Mode
(See Fig. 24 for thermostat connections)
The thermostat closes the R-to-G-and-Y circuits. The R-to-Y
35
TABLE 10—Orifice Size* and Manifold Pressure For Gas Input Rate
(Tabulated Data Based On 22,000 Btuh Per Burner, Derated 4 Percent For Each 1000 Ft Above Sea Level)
U.S.A. and Canada
ALTITUDE
RANGE
(FT)
AVG GAS
HEAT VALUE
(BTU/CU FT)
0
to
2000
U.S.A. and Canada
ALTITUDE
RANGE
(FT)
AVG GAS
HEAT VALUE
(BTU/CU FT)
U.S.A.
Altitudes
2001
to
3000
or
Canada
Altitudes
2000
to
4500
ALTITUDE
RANGE
(FT)
U.S.A. Only
800
825
850
875
900
925
950
975
1000
AVG GAS
HEAT VALUE
(BTU/CU FT)
775
800
825
850
875
900
925
950
3001
to
4000
ALTITUDE
RANGE
(FT)
U.S.A. Only
900
925
950
975
1000
1025
1050
1075
1100
AVG GAS
HEAT VALUE
(BTU/CU FT)
4001
to
5000
750
775
800
825
850
875
900
925
0.58
Orifice
Manifold
No.
Pressure
42
42
43
43
43
43
44
44
44
Orifice
No.
42
42
43
43
43
43
43
43
43
Orifice
No.
42
43
43
43
43
43
43
43
Orifice
No.
43
43
43
43
43
43
43
43
3.5
3.3
3.8
3.6
3.5
3.3
3.6
3.4
3.3
0.58
Manifold
Pressure
3.4
3.2
3.7
3.5
3.3
3.1
2.9
2.8
2.6
0.58
Manifold
Pressure
3.2
3.6
3.4
3.2
3.0
2.9
2.7
2.6
0.58
Manifold
Pressure
SPECIFIC GRAVITY OF NATURAL GAS
0.60
0.62
Orifice
Manifold
Orifice
Manifold
No.
Pressure
No.
Pressure
42
3.6
42
3.7
42
3.4
42
3.5
42
3.3
42
3.4
43
3.8
42
3.2
43
3.6
43
3.7
43
3.4
43
3.5
43
3.2
43
3.4
44
3.5
43
3.2
44
3.4
44
3.5
SPECIFIC GRAVITY OF NATURAL GAS
0.60
0.62
Orifice
Manifold
Orifice
Manifold
No.
Pressure
No.
Pressure
42
3.5
42
3.6
42
3.3
42
3.4
43
3.8
42
3.2
43
3.6
43
3.7
43
3.4
43
3.5
43
3.2
43
3.3
43
3.0
43
3.1
43
2.9
43
3.0
43
2.7
43
2.8
SPECIFIC GRAVITY OF NATURAL GAS
0.60
0.62
Orifice
Manifold
Orifice
Manifold
No.
Pressure
No.
Pressure
42
3.3
42
3.4
43
3.8
42
3.2
43
3.5
43
3.7
43
3.3
43
3.4
43
3.1
43
3.3
43
3.0
43
3.1
43
2.8
43
2.9
43
2.7
43
2.8
SPECIFIC GRAVITY OF NATURAL GAS
0.60
0.62
Orifice
Manifold
Orifice
Manifold
No.
Pressure
No.
Pressure
3.6
3.4
3.2
3.0
2.8
2.7
2.5
2.4
43
43
43
43
43
43
43
43
* Orifice numbers 43 are factory installed
36
3.8
3.5
3.3
3.1
2.9
2.8
2.6
2.5
42
43
43
43
43
43
43
43
3.2
3.6
3.4
3.2
3.0
2.9
2.7
2.6
Orifice
No.
41
42
42
42
43
43
43
43
43
Orifice
No.
42
42
42
43
43
43
43
43
43
Orifice
No.
42
42
43
43
43
43
43
43
Orifice
No.
42
43
43
43
43
43
43
43
0.64
Manifold
Pressure
3.5
3.7
3.5
3.3
3.8
3.6
3.5
3.3
3.2
0.64
Manifold
Pressure
3.7
3.5
3.3
3.8
3.6
3.4
3.2
3.1
2.9
0.64
Manifold
Pressure
3.5
3.3
3.8
3.6
3.4
3.2
3.0
2.8
0.64
Manifold
Pressure
3.3
3.8
3.5
3.3
3.1
2.9
2.8
2.6
Table 10—Orifice Size* And Manifold Pressure For Gas Input Rate (Continued)
(Tabulated Data Based On 22,000 Btuh Per Burner, Derated 4 Percent For Each 1000 Ft Above Sea Level)
U.S.A. Only
ALTITUDE
RANGE
(FT)
5001
to
6000
U.S.A. Only
ALTITUDE
RANGE
(FT)
6001
to
7000
U.S.A. Only
ALTITUDE
RANGE
(FT)
7001
to
8000
U.S.A. Only
ALTITUDE
RANGE
(FT)
8001
to
9000
AVG GAS
HEAT VALUE
AT ALTITUDE
(BTU/CU FT)
0.58
Orifice
Manifold
No.
Pressure
725
750
775
800
825
850
875
900
43
43
43
43
43
43
43
43
AVG GAS
HEAT VALUE
AT ALTITUDE
(BTU/CU FT)
Orifice
No.
675
700
725
750
775
800
825
850
43
43
43
43
43
43
43
43
AVG GAS
HEAT VALUE
AT ALTITUDE
(BTU/CU FT)
Orifice
No.
650
675
700
725
750
775
800
825
43
43
43
43
43
43
43
48
AVG GAS
HEAT VALUE
AT ALTITUDE
(BTU/CU FT)
625
650
675
700
725
750
775
Orifice
No.
43
43
43
43
43
43
48
3.4
3.2
3.0
2.8
2.6
2.5
2.3
2.2
0.58
Manifold
Pressure
3.4
3.1
2.9
2.7
2.6
2.4
2.3
2.1
0.58
Manifold
Pressure
3.1
2.9
2.7
2.5
2.4
2.2
2.1
3.7
0.58
Manifold
Pressure
2.9
2.7
2.5
2.3
2.2
2.0
3.6
SPECIFIC GRAVITY OF NATURAL GAS
0.60
0.62
Orifice
Manifold
Orifice
Manifold
No.
Pressure
No.
Pressure
43
3.5
43
3.6
43
3.3
43
3.4
43
3.1
43
3.2
43
2.9
43
3.0
43
2.7
43
2.8
43
2.5
43
2.6
43
2.4
43
2.5
43
2.3
43
2.3
SPECIFIC GRAVITY OF NATURAL GAS
0.60
0.62
Orifice
Manifold
Orifice
Manifold
No.
Pressure
No.
Pressure
43
3.5
43
3.6
43
3.3
43
3.4
43
3.0
43
3.1
43
2.8
43
2.9
43
2.7
43
2.7
43
2.5
43
2.6
43
2.3
43
2.4
43
2.2
43
2.3
SPECIFIC GRAVITY OF NATURAL GAS
0.60
0.62
Orifice
Manifold
Orifice
Manifold
No.
Pressure
No.
Pressure
43
3.2
43
3.4
43
3.0
43
3.1
43
2.8
43
2.9
43
2.6
43
2.7
43
2.4
43
2.5
43
2.3
43
2.4
43
2.1
43
2.2
43
2.0
43
2.1
SPECIFIC GRAVITY OF NATURAL GAS
0.60
0.62
Orifice
Manifold
Orifice
Manifold
No.
Pressure
No.
Pressure
43
3.0
43
3.1
43
2.8
43
2.9
43
2.6
43
2.7
43
2.4
43
2.5
43
2.2
43
2.3
43
2.1
43
2.2
48
3.7
43
2.0
* Orifice numbers 43 are factory installed
37
Orifice
No.
43
43
43
43
43
43
43
43
Orifice
No.
43
43
43
43
43
43
43
43
Orifice
No.
43
43
43
43
43
43
43
43
Orifice
No.
43
43
43
43
43
43
43
0.64
Manifold
Pressure
3.7
3.5
3.3
3.1
2.9
2.7
2.6
2.4
0.64
Manifold
Pressure
3.7
3.5
3.2
3.0
2.8
2.7
2.5
2.4
0.64
Manifold
Pressure
3.5
3.2
3.0
2.8
2.6
2.4
2.3
2.2
0.64
Manifold
Pressure
3.2
3.0
2.8
2.6
2.4
2.2
2.1
Table 10—Orifice Size* And Manifold Pressure For Gas Input Rate (Continued)
(Tabulated Data Based On 22,000 Btuh Per Burner, Derated 4 Percent For Each 1000 Ft Above Sea Level)
U.S.A. Only
ALTITUDE
RANGE
(FT)
9001
to
10,000
AVG GAS
HEAT VALUE
AT ALTITUDE
(BTU/CU FT)
600
625
650
675
700
725
0.58
Orifice
Manifold
No.
Pressure
43
43
43
43
48
48
2.7
2.5
2.3
2.1
3.7
3.5
SPECIFIC GRAVITY OF NATURAL GAS
0.60
0.62
Orifice
Manifold
Orifice
Manifold
No.
Pressure
No.
Pressure
43
43
43
43
43
48
* Orifice numbers 43 are factory installed
38
2.8
2.6
2.4
2.2
2.0
3.6
43
43
43
43
43
48
2.9
2.6
2.4
2.3
2.1
3.7
Orifice
No.
43
43
43
43
43
43
0.64
Manifold
Pressure
3.0
2.7
2.5
2.3
2.2
2.0
TABLE 11—Orifice Size* and Manifold Pressure For Gas Input Rate
(Tabulated Data Based On 21,000 Btuh Per Burner, Derated 4 Percent For Each 1000 Ft Above Sea Level)
U.S.A. and Canada
ALTITUDE
RANGE
(FT)
AVG GAS
HEAT VALUE
(BTU/CU FT)
0
to
2000
U.S.A. and Canada
ALTITUDE
RANGE
(FT)
AVG GAS
HEAT VALUE
(BTU/CU FT)
U.S.A.
Altitudes
2001
to
3000
or
Canada
Altitudes
2000
to
4500
ALTITUDE
RANGE
(FT)
U.S.A. Only
800
825
850
875
900
925
950
975
1000
AVG GAS
HEAT VALUE
(BTU/CU FT)
775
800
825
850
875
900
925
950
3001
to
4000
ALTITUDE
RANGE
(FT)
U.S.A. Only
900
925
950
975
1000
1025
1050
1075
1100
AVG GAS
HEAT VALUE
(BTU/CU FT)
4001
to
5000
750
775
800
825
850
875
900
925
SPECIFIC GRAVITY OF NATURAL GAS
0.60
0.62
Orifice
Manifold
Orifice
Manifold
No.
Pressure
No.
Pressure
0.58
Orifice
Manifold
No.
Pressure
42
43
43
43
44
44
44
45
46
Orifice
No.
43
43
43
43
43
43
43
43
43
Orifice
No.
43
43
43
43
43
43
43
43
Orifice
No.
43
43
43
43
43
43
43
43
3.2
3.7
3.5
3.3
3.6
3.4
3.3
3.8
3.8
42
3.3
42
3.4
43
3.8
42
3.2
43
3.6
43
3.7
43
3.4
43
3.5
43
3.3
43
3.4
44
3.6
43
3.2
44
3.4
44
3.5
44
3.2
44
3.3
45
3.7
44
3.2
SPECIFIC GRAVITY OF NATURAL GAS
0.60
0.62
Orifice
Manifold
Orifice
Manifold
No.
Pressure
No.
Pressure
0.58
Manifold
Pressure
3.8
3.5
3.3
3.2
3.0
2.8
2.7
2.5
2.4
42
3.2
42
3.3
43
3.7
43
3.8
43
3.5
43
3.6
43
3.3
43
3.4
43
3.1
43
3.2
43
2.9
43
3.0
43
2.8
43
2.9
43
2.6
43
2.7
43
2.5
43
2.6
SPECIFIC GRAVITY OF NATURAL GAS
0.60
0.62
Orifice
Manifold
Orifice
Manifold
No.
Pressure
No.
Pressure
0.58
Manifold
Pressure
3.5
3.3
3.1
2.9
2.8
2.6
2.5
2.4
43
3.7
43
3.8
43
3.4
43
3.5
43
3.2
43
3.3
43
3.0
43
3.1
43
2.9
43
3.0
43
2.7
43
2.8
43
2.6
43
2.7
43
2.4
43
2.5
SPECIFIC GRAVITY OF NATURAL GAS
0.60
0.62
Orifice
Manifold
Orifice
Manifold
No.
Pressure
No.
Pressure
0.58
Manifold
Pressure
3.3
3.1
2.9
2.7
2.6
2.4
2.3
2.2
43
43
43
43
43
43
43
43
* Orifice numbers 43 are factory installed
39
3.4
3.2
3.0
2.8
2.7
2.5
2.4
2.2
43
43
43
43
43
43
43
43
3.5
3.3
3.1
2.9
2.8
2.6
2.5
2.3
Orifice
No.
42
42
43
43
43
43
43
44
44
Orifice
No.
42
42
43
43
43
43
43
43
43
Orifice
No.
42
43
43
43
43
43
43
43
Orifice
No.
43
43
43
43
43
43
43
43
0.64
Manifold
Pressure
3.5
3.3
3.8
3.7
3.5
3.3
3.2
3.4
3.3
0.64
Manifold
Pressure
3.4
3.2
3.7
3.5
3.3
3.1
2.9
2.8
2.7
0.64
Manifold
Pressure
3.2
3.7
3.4
3.2
3.1
2.9
2.7
2.6
0.64
Manifold
Pressure
3.6
3.4
3.2
3.0
2.8
2.7
2.5
2.4
Table 11—Orifice Size* And Manifold Pressure For Gas Input Rate (Continued)
(Tabulated Data Based On 21,000 Btuh Per Burner, Derated 4 Percent For Each 1000 Ft Above Sea Level)
U.S.A. Only
ALTITUDE
RANGE
(FT)
5001
to
6000
U.S.A. Only
ALTITUDE
RANGE
(FT)
6001
to
7000
U.S.A. Only
ALTITUDE
RANGE
(FT)
7001
to
8000
U.S.A. Only
ALTITUDE
RANGE
(FT)
8001
to
9000
AVG GAS
HEAT VALUE
AT ALTITUDE
(BTU/CU FT)
0.58
Orifice
Manifold
No.
Pressure
725
750
775
800
825
850
875
900
43
43
43
43
43
43
43
43
AVG GAS
HEAT VALUE
AT ALTITUDE
(BTU/CU FT)
Orifice
No.
675
700
725
750
775
800
825
850
43
43
43
43
43
43
43
48
AVG GAS
HEAT VALUE
AT ALTITUDE
(BTU/CU FT)
Orifice
No.
650
675
700
725
750
775
800
825
43
43
43
43
43
43
48
48
AVG GAS
HEAT VALUE
AT ALTITUDE
(BTU/CU FT)
Orifice
No.
625
650
675
700
725
750
775
43
43
43
43
48
48
49
3.1
2.9
2.7
2.5
2.4
2.2
2.1
2.0
0.58
Manifold
Pressure
3.1
2.9
2.7
2.5
2.3
2.2
2.1
3.7
0.58
Manifold
Pressure
2.9
2.7
2.5
2.3
2.1
2.0
3.6
3.3
0.58
Manifold
Pressure
2.7
2.5
2.3
2.1
3.7
3.5
3.8
SPECIFIC GRAVITY OF NATURAL GAS
0.60
0.62
Orifice
Manifold
Orifice
Manifold
No.
Pressure
No.
Pressure
43
3.2
43
3.3
43
3.0
43
3.1
43
2.8
43
2.9
43
2.6
43
2.7
43
2.5
43
2.5
43
2.3
43
2.4
43
2.2
43
2.3
43
2.1
43
2.1
SPECIFIC GRAVITY OF NATURAL GAS
0.60
0.62
Orifice
Manifold
Orifice
Manifold
No.
Pressure
No.
Pressure
43
3.2
43
3.3
43
3.0
43
3.1
43
2.8
43
2.9
43
2.6
43
2.7
43
2.4
43
2.5
43
2.3
43
2.3
43
2.1
43
2.2
43
2.0
43
2.1
SPECIFIC GRAVITY OF NATURAL GAS
0.60
0.62
Orifice
Manifold
Orifice
Manifold
No.
Pressure
No.
Pressure
43
3.0
43
3.1
43
2.7
43
2.8
43
2.6
43
2.6
43
2.4
43
2.5
43
2.2
43
2.3
43
2.1
43
2.2
48
3.7
43
2.0
48
3.5
48
3.6
SPECIFIC GRAVITY OF NATURAL GAS
0.60
0.62
Orifice
Manifold
Orifice
Manifold
No.
Pressure
No.
Pressure
43
43
43
43
43
48
48
* Orifice numbers 43 are factory installed
40
2.7
2.5
2.4
2.2
2.0
3.6
3.4
43
43
43
43
43
48
48
2.8
2.6
2.4
2.3
2.1
3.7
3.5
Orifice
No.
43
43
43
43
43
43
43
43
Orifice
No.
43
43
43
43
43
43
43
43
Orifice
No.
43
43
43
43
43
43
43
48
Orifice
No.
43
43
43
43
43
43
48
0.64
Manifold
Pressure
3.4
3.2
3.0
2.8
2.6
2.5
2.3
2.2
0.64
Manifold
Pressure
3.4
3.2
2.9
2.8
2.6
2.4
2.3
2.1
0.64
Manifold
Pressure
3.2
2.9
2.7
2.5
2.4
2.2
2.1
3.7
0.64
Manifold
Pressure
2.9
2.7
2.5
2.3
2.2
2.0
3.6
Table 11—Orifice Size* And Manifold Pressure For Gas Input Rate (Continued)
(Tabulated Data Based On 21,000 Btuh Per Burner, Derated 4 Percent For Each 1000 Ft Above Sea Level)
U.S.A. Only
ALTITUDE
RANGE
(FT)
9001
to
10,000
AVG GAS
HEAT VALUE
AT ALTITUDE
(BTU/CU FT)
600
625
650
675
700
725
0.58
Orifice
Manifold
No.
Pressure
43
43
43
48
48
49
2.4
2.3
2.1
3.6
3.4
3.7
SPECIFIC GRAVITY OF NATURAL GAS
0.60
0.62
Orifice
Manifold
Orifice
Manifold
No.
Pressure
No.
Pressure
43
43
43
48
48
49
* Orifice numbers 43 are factory installed
41
2.5
2.3
2.2
3.8
3.5
3.8
43
43
43
43
48
48
2.6
2.4
2.2
2.1
3.6
3.4
Orifice
No.
43
43
43
43
48
48
0.64
Manifold
Pressure
2.7
2.5
2.3
2.1
3.7
3.5
42
YES
Go to section below for the status code that
was flashed.
Determine status code. The status code is a
2 digit number with the first digit determined
by the number of short flashes and the second
digit by the number of long flashes?
YES
Is LED status light blinking ON/OFF slowly
with a combination of short and long flashes?
NO
Is LED status light blinking rapidly without a
pause?
Is LED status light on?
START
YES
NO
YES
NO
NO
YES
Replace furnace control.
Run system through a heating or cooling cycle
to check operation. Status codes are erased
after 72 hours. On RED LED boards stored
status codes can also be erased whenever
(115V or 24V) is interrupted.
YES
Does the control respond to W, Y1 (if present),
Y/Y2, and G (24V) thermostat signals?
To recall status code briefly remove and reconnect one RED wire from the draft
safeguard switch to display stored status code. On RED LED control do not
remove power or blower access panel before initiating status code recall. You
can also recall the previous status code by momentarily shorting the TEST/TWIN
terminal to Com24V terminal until the LED goes out. LED will flash the status
code of the previous fault or status code #11 (1 short and 1 long flash) if there
was no previous fault. After the control repeats the code 4 times, the control
will go through a brief component test sequence. The inducer will start and run
for the entire component test. The HSI, blower motor FAN speed (AMBER LED
boards only) HEAT speed, and COOL speed will run for 10 – 15 seconds each.
Gas valve and humidifier will not be turned on.
Replace transformer.
Check for correct line voltage polarity. If units
are twinned, check for proper low-voltage
(24V) transformer phasing.
Was there a previous status code
other than #11?
YES
Is there 115V going to switch?
Is door switch closed?
Replace door switch.
NO
NO
Replace furnace control.
YES
Is there 24V at SEC-1 and SEC-2?
YES
Is there 115V at L1 and L2?
TROUBLESHOOTING GUIDE
YES
NO
NO
NO
YES
The thermostat is not compatible with the
furnace control. Either install a ballast resistor,
connect the Com24V thermostat terminal to
the thermostat, or replace the thermostat.
NO
Does the problem repeat when using
a jumper wire?
Disconnect all the thermostat wires from the
furnace control.
YES
Is 24V present at W, Y1 (if present), Y/Y2 or
G thermostat terminals on the furnace control?
NO
Check room thermostat or
interconnecting cable.
Close circuit breaker and go back to START.
Check for continuity in wire from circuit breaker
to furnace.
Is circuit breaker closed?
Is door switch closed?
A02106a
NO
43
24 SECONDARY VOLTAGE FUSE IS OPEN
Check for:
- Short circuit in secondary voltage (24V)
wiring including thermostat leads.
Disconnect thermostat leads to isolate
short circuit.
23 PRESSURE SWITCH DID NOT OPEN
Check for:
- Obstructed pressure tube.
- Pressure switch stuck closed.
22 ABNORMAL FLAME-PROVING SIGNAL
Flame is proved while gas valve is deenergized. Inducer will run until fault is
cleared. Check for:
- Stuck open or leaky gas valve.
21 GAS HEATING LOCKOUT – Turn off
power and wait 5 minutes to retry.
Check for:
- Stuck closed gas valve relay on control.
- Miswire or short to gas valve wire.
14 IGNITION LOCKOUT – System failed to
ignite gas and prove flame in 4 attempts.
Control will auto-reset after 3 hours.
See status code 34.
13 LIMIT CIRCUIT LOCKOUT – Lockout
occurs if the limit, draft safeguard, flame
rollout, or blocked vent switch*(if used) is
open longer than 3 minutes. Control will
auto-reset after 3 hours. See code 33.
12 BLOWER ON AFTER POWER UP –
(115V OR 24V) – Normal operation.
Blower runs for 90 seconds, if unit is
powered up during a call for heat (R-W
closed) or when (R-W opens) during the
blower on-delay period.
11 NO PREVIOUS CODE – Stored codes
are erased after 72 hours. On RED LED
boards stored status codes can also be
erased whenever power (115V or 24V)
is interrupted. Run system through a
heating or cooling cycle to check system.
* Blocked vent switch used in Chimney Adapter Kit
34 IGNITION PROVING FAILURE – If flame
is not sensed during the trial for ignition
period, the control will repeat the ignition
NO
sequence 3 more times before lockout
#14 occurs. If flame signal is lost during
YES
the blower on-delay period, blower will
come on for the selected blower off-delay.
Check the following items first before
proceeding to the next step.
- Gas valve turned off.
- Manual shut-off valve.
- Green/Yellow wire MUST be connected
to furnace sheet metal.
- Flame sensor must not be grounded.
To determine whether the problem is in
the gas valve, igniter, or flame sensor the
system can be operated in the component
test mode to check the igniter. First
remove the R thermostat connection from
the control and initiate the component
test sequence. Does the igniter glow
orange/white by the end of the 15 second
warm-up period?
33 LIMIT CIRCUIT FAULT – Indicates the
limit, draft safeguard, flame rollout, or
blocked vent switch* (if used) is open.
Blower will run for 4 minutes or until open
switch remakes whichever is longer. If
open longer than 3 minutes, code
changes to lockout #13. If open less
than 3 min. status code #33 continues
to flash until blower shuts off. Flame
rollout switch and BVSS requires manual
reset. Check for:
- Dirty filter or restricted duct system.
- Loose blower wheel.
- Defective switch or connections.
- Defective blower motor or capacitor.
- Inadequate combustion air supply
(flame rollout switch open).
- Restricted vent.
- Proper vent sizing.
- Excessive wind.
31 PRESSURE SWITCH DID NOT CLOSE
OR REOPENED – If open longer than 5
minutes, inducer shuts off for 15 minutes
before retry. If opens during blower ondelay period, blower will come on for the
selected blower off-delay. Check for:
- Proper vent sizing.
- Low inducer voltage (115V).
- Low inlet gas pressure (if LGPS used).
- Inadequate combustion air supply.
- Disconnected or obstructed pressure
tubing.
- Defective inducer motor.
- Defective pressure switch.
- Excessive wind.
- Restricted vent.
Fixed.
YES
Will main burners ignite and stay on?
YES
Is current near typical value?
Clean flame sensor with fine steel wool and
recheck current. Nominal current is 4.0 to 6.0
microamps.
YES
Repeat call for heat and check flame sensor
current during trial for ignition period. Is the
DC microamps below 0.5?
NO
Do the main burners stay on?
YES
Do the main burners ignite?
YES
Does gas valve open and allow gas to flow?
YES
Reconnect the R thermostat lead and set
thermostat to call for heat. Connect voltmeter
across gas valve connections. Does gas valve
receive 24V?
Unplug igniter harness from control and initiate
another component test sequence. Check
for 115V between pin 1 and NEUTRAL-L2 on
the control. Was 115V present for the 15
second period?
NO
NO
NO
YES
NO
NO
NO
YES
NO
Replace furnace control.
Replace electrode.
A02106b
Check connections and retry. If current is
near typical value (4.0-6.0 nominal) and
burners will not stay on, replace control.
Allow blower to come on and repeat test to
check for intermittent operation.
Check for:
- Inadequate flame carryover or rough
ignition.
- Low inlet gas pressure.
- Proper firing rate.
- Blocked or incorrect carry- over gap.
(.045” nominal)
Check that all gas valves are turned on.
Replace valve.
Check connections. If OK, replace control.
Check for continuity in the harness and igniter.
Replace defective component.
Replace furnace control.
45 CONTROL CIRCUITRY LOCKOUT
Auto-reset after 1 hour lockout due to:
Flame circuit failure.
- Gas valve relay stuck open.
Software check error.
Reset power to clear lockout. Replace
control if code repeats.
Copyright 2002 Carrier Corporation
58st11si
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
Book 1 4
PC 101
Catalog No. See Cover
Printed in U.S.A.
Form 58ST-11SI
Pg 44
12-02
Replaces: 58ST-2SI
Tab 6a 8a