Carrier 58CVA110---11120 Furnace installation Guide

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Document

58CVA/CVX

Variable—Speed, Induced—Combustion Deluxe

4—Way Multipoise Gas Furnace

Series 160

Carrier

turn to the IZA

Installation, Start—up, Operating and

Service and Maintenance Instructions

SAFETY CONSIDERATIONS . 2.0.0.0... 0.00000 00 ee ee 2

INTRODUCTION 2.00... 0.0 eee ees 4

CODES AND STANDARDS ......0.0..0. 000.00 eee 4

Safety... eee eee tenes 4

General Installation 2.2... 0.0.0... eee eee 4

Combustion and Ventilation Air 2.6.0.0... 00.0. eee 4

START-UP, ADJUSTMENT, AND SAFETY CHECK ..... 34

General 2... eee ene 34

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

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

Electrical Connections . 2.0.0... 0.0. eee eee 4

Venting oo. eee eee tenes 4

ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS

PROCEDURE 2.0... ee eens 4

AIR FOR COMBUSTION AND VENTILATION ......... 8

Outdoor Combustion Air Method ................000. 9

Checklist 2... eee 46

SERVICE AND MAINTENANCE PROCEDURES ....... 46

General 2. eee eae 46

Care and Maintenance . 2.6... eee 47

Sequence of Operation... 0.0... eee ee OZ

Wiring Diagram .. 6.0...

Troubleshooting»...

Accessory List... 0... ee eee 56 eens 59

PARTS REPLACEMENT INFORMATION GUIDE....... 60

Combination of Indoor and Outdoor Air ............. 10

INSTALLATION 2.0.0... eee

Bottom Return Air Inlet 22.0.0... eee 10

Side Return Air Inlet... eens 10

Platform Furnace Support .. 0.0.0.0... 0.00000 ee eee 11

SO 9001

——

5

Oo o

2 aun

www-ahridirestory.org

Use of the ATIRI Certified m Mark indicates a manufacturer’s participation in the program. For verification of certification for individual products, go to www-ahridirectory.org.

Bottom Return Air Inlet...

Side Return Air Inlet...

0.00... ee

00... 0... eee 12 eee 12

NOTE: Read the entire instruction manual before starting the installation.

Filter Arrangement .. 0.0.0.0. 0.0.0 0. eee 13 Portions of the text and tables are reprinted from NFPA 54/ANSI

Z223.1-2009©, with permission of National Fire Protection

AIR DUCTS . 0... eens 13

Association, Quincy, MA 02269 and American Gas Association,

Washington DC 20001. This reprinted material is not the complete and official position of the NFPA or ANSI on the Ductwork Acoustical Treatment ............. 0.0000. 13 referenced subject, which is represented only by the standard in

Supply Air Connections .. 0.0... 00.0.0. 14 its entirety.

Uptiow and Horizontal Furnaces ............ 0.0000. 14

Uptiow and Horizontal Furnaces ............ 0.0000. 18

ELECTRICAL CONNECTION ©... 00 ee 20

SAFETY CONSIDERATIONS

FIRE, EXPLOSION, ELECTRICAL SHOCK, AND

CARBON MONOXIDE POISONING HAZARD

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

Improper installation, adjustment, alteration, service, maintenance, or use can cause carbon monoxide poisoning, explosion, fire, electrical shock, or other conditions which may cause personal injury or property damage. Consult a qualified service agency, local gas supplier, or your distributor or branch for information or assistance. The qualified service agency must use only factory-authorized and listed kits or accessories when modifying this product.

4& CAUTION

FURNACE RELIABILITY HAZARD

Failure to follow this caution may result in unit component damage.

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

Installing and servicing heating equipment can be hazardous due to gas and electrical components. Only trained and qualified personnel should install, repair, or service heating equipment.

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

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

CUT HAZARD

Failure to follow this caution may result in personal injury.

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

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

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

Understand the signal words DANGER, WARNING, and

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

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

. 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. Con- nect this furnace to an approved vent system only, as specified in the “Venting” section of these instructions.

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

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

Check” section. See furnace rating plate.

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

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

“Location” section.

9, The furnace may be used for construction heat provided that the furnace installation and operation complies with the first CAUTION in the LOCATION section of these instructions.

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

A.G.A. and C.G.A.) design-certified for use with natural and propane gases (see furnace rating plate) and for installation in alcoves, attics, basements, closets, utility rooms, crawlspaces, and garages. The furnace is factory-shipped for use with natural gas. A CSA (A.G.A. and C.G.A.) listed accessory gas conversion kit is required to convert furnace for use with propane gas.

11. See Fig. 1 for required clearances to combustible construction.

12. Maintain a 1-in. (25 mm) clearance from combustible materials to supply air ductwork for a distance of 36 in. (914 mm) horizontally from the furnace. See NFPA 90B or local code for further requirements.

13. These furnaces SHALL NOT be installed directly on car- peting, 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. CNRV, CNPV, CAP, or CAR or when Coil Box Part No. KCAKC is used. See Fig. 1 for clearance to combustible construction information.

INSTALLATION

Improper adjustment, alteration, service, maintenance, or installation can cause serious injury or death.

MINIMUM INCHES CLEARANCE TO COMBUSTIBLE CONSTRUCTION

This forced air furnace is

This furnace is approved for

UPFLOW, DOWNFLOW, and equipped for use with natural gas at altitudes 0 - 10,000 ft

HORIZONTAL installations.

(0

- 3,050m).

An accessory kit, supplied by the manufacturer, shall be used

Clearance arrows do not change with furnace orientation.

Read and follow instructions and precautions in User's Information Manual to convert to propane gas use or may be required for some provided with this furnace. Installation and service must be performed by a natural gas applications.

This furnace is for indoor qualified service agency or the gas supplier.

fy CAUTION

Check entire gas assembly for leaks after lighting this appliance.

INSTALLATION

1. This furnace must be installed in accordance with the manufacturer's instructions and local codes. In the absence of local codes, follow the National

Fuel Gas Code ANSI 2223.1 / NFPA54 or CSA B-149. 1 Gas Installation Code.

2. This furnace rnust be installed so there are provisions for combustion and ventilation air. See manufacturer's installation information provided with this appliance.

OPERATION

This furnace is equipped with manual reset limit switch(es) in burner compartment to protect against overheat conditions that can result from inadequate combustion air supply or blocked vent conditions.

1. Do not bypass limit switches.

2. Ifa limit opens, call a quallified serviceman to correct the condition and reset limit switch. installation in a building constructed on site.

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

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

Clearance in inches

Vent Clearance to combustibles:

For Single Wall vents 6 inches (6 po).

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

MINIMUM INCHES CLEARANCE TO

COMBUSTIBLE CONSTRUCTION

DOWNFLOW POSITIONS:

T Installation on non-combustible floors only.

For Installation on combustible flooring only when installed on special base, Part No. KGASBO201ALL or NAHA01101SB, Coil Assembly,

Part No. CAR, CAP, CNPV, CNRV, END4X, ENW4X, WENC, WTNC,

WENW OR WTNW.

@ 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,

AAT

336996-101 REV. C

Fig. 1 - Clearances to Combustibles

A10269

INTRODUCTION

The Series 160 4-way multipoise Category I fan-assisted furnace is CSA (formerly A.G.A. and C.G.A.) design-certified. A

Category I fan-assisted furnace is an appliance equipped with an integral mechanical means to either draw or force products of exchanger. The furnace is factory-shipped for use with natural gas. This furnace is not approved for installation in mobile homes, recreational vehicles, or outdoors.

MAX80°F / 27 C combustion through the combustion chamber and/or heat

RETURN

AIR MIN6O°F /16C

A06745

Fig. 2 - Return Air Temperature

This furnace is designed for minimum continuous return-air temperature of 60°F (15°C) db or intermittent operation down to

55°F (13°C)db such as when used with a night setback thermostat. Return-air temperature must not exceed 80°F (27°C) db. Failure to follow these return-air temperature limits may affect reliability of heat exchangers, motors, and controls. (See

Fig. 2.)

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

NOTE: Remove all shipping brackets and materials before operating the furnace.

CODES AND STANDARDS

Follow all national and local codes and standards in addition to these instructions. The installation must comply with regulations of the serving gas supplier, local building, heating, plumbing, and other codes. In absence of local codes, the installation must comply with the national codes listed below and all authorities having jurisdiction.

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

Safety

NFPA 54/ANSI Z223.1-2009 and the Installation Standards,

Warm Air Heating and Air Conditioning Systems ANSI/NFPA

9OB .

General Installation

Current edition of the NFGC and the NFPA 90B. For copies, contact the National Fire Protection Association Inc.,

Batterymarch Park, Quincy, MA 02269; (www.NFPA.org) or for only the NFGC, contact the American Gas Association, 400 N.

Capitol Street, N.W., Washington, DC 20001 (www.AGA.org.) .

Combustion and Ventilation Air

Section 9.3 NFPA 54/ANSI Z223.1-2009, Air for Combustion and Ventilation .

Duct Systems

Air Conditioning Contractors Association (ACCA) Manual D,

Sheet Metal and Air Conditioning Contractors National

Association (SMACNA), or American Society of Heating,

Refrigeration, and Air Conditioning Engineers (ASHRAE) 2001

Fundamentals Handbook Chapter 34 or 2000 HVAC Systems and Equipment Handbook Chapters 9 and 16.

Acoustical Lining and Fibrous Glass Duct

Current edition of SMACNA and NFPA 90B as tested by UL

Standard 181 for Class I Rigid Air Ducts

Gas Piping and Gas Pipe Pressure Testing

NFPA 54/ANSI Z223.1-2009 ; chapters 5, 6, and 7 and National

Plumbing Codes .

Electrical Connections

National Electrical Code (NEC) ANSI/NFPA70-2011 .

Venting

NFPA 54/ANSI Z223.1-2009; chapters 12 and 13.

ELECTROSTATIC DISCHARGE (ESD)

PRECAUTIONS PROCEDURE

4& CAUTION

FURNACE RELIABILITY HAZARD

Failure to follow this caution may result in unit component damage.

Electrostatic discharge can affect electronic components.

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

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

ANY WIRE CONNECTED TO THE CONTROL PRIOR

TO DISCHARGING YOUR

ELECTROSTATIC CHARGE TO GROUND.

BODY’S

. Firmly touch the clean, unpainted, metal surface of the furnace chassis which is close to the control. Tools held in a person’s hand during grounding will be satisfactorily discharged.

3. After touching the chassis, you may proceed to service the control or connecting wires as long as you do nothing to recharge your body with static electricity (for example;

DO NOT move or shuffle your feet, do not touch ungrounded objects, etc.).

ey Bt

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AR FLOW i pm 57/8 faast

= TOP OF CASING ee

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LOCATION

9718 oF

BINS

213.51

O78 p2ay mm comm ln,

4! a

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NY = =

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2738 proagi

THERMOSTAT WARE ENTRY ova an

ACCESSORY.

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B87)

2339

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‘GAS ENTRY

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TOP GF CASING

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—,

BOTTOM RETURN

WIDTH

SIDE INLET

(BOTH SIDES)

A10290

NOTES:

1. Two additional 7/8—in. (22 mm) diameter holes are located in the top plate.

2. Minimum return—air openings at furnace, based on metal duct. If flex duct is used, see flex duct manufacturer’s recommendations for equivalent diameters. a. For 800 CFM—16—in. (406 mm) round or 14 1/2 x 12—in. (368 x 305 mm) rectangle. b. For 1200 CFM-—20-in. (508 mm) round or 14 1/2 x 19 1/2-in. (868 x 495 mm) rectangle. c. For 1600 CFM—22-in. (559 mm) round or 14 1/2 x 22 1/16—in. (868 x 560mm) rectangle. d. For airflow requirements above 1800 CFM, see Air Delivery table in Product Data literature for specific use of single side inlets. The use of both side inlets, a combination of 1 side and the bottom, or the bottom only will ensure adequate return air openings for airflow requirements above 1800 CFM.

Fig. 3 - Dimensional Drawing

Table 1 — Dimensions - In. (mm)

FURNACE SIZE

CABINET

WIDTH

OUTLET

WIDTH c

BOTTOM FLUE

COLLAR

BOTTOM

INLET WIDTH

VENT

CONNECTION

SIZE iB (kG)

ACCESSORY

FILTER MEDIA

CABINET SIZE

070—12/036070 | 14—3/16 (360) | 12-9/16 (319)

090—16/048090 17-1/2 (445) | 15—7/8 (403)

110—20/060110

135—22/066135

155—22/066155

21 (533) 19—3/8 (492)

24—1/2 (622) | 22—-7/8 (581)

9—5/16 (237)

11-9/16 (294)

13—5/16 (338)

15—1/16 (683)

12-11/16 (622)

16 (406)

19—1/2 (495)

23 (584)

4 (102

4 (102)

4 (102)*

115 62)

130 (59)

155 (70)

166 (75)

175 (79)

16 (406)

20 (508)

24 (610)

*135 and 155 size furnaces require a 5 or 6—in. (127 or 52 mm) vent. Use a vent adapter between furnace and vent stack. See Installation Instructions for complete installation requirements.

4. If you touch ungrounded objects (and recharge your body with static electricity), firmly touch a clean, unpainted metal surface of the furnace again before touching control or wires.

5. Use this procedure for installed and uninstalled (ungrounded) furnaces.

6. Before removing a new control from its container, discharge your body’s electrostatic charge to ground to protect the control from damage. If the control is to be installed in a furnace, follow items 1 through 4 before bringing the control or yourself in contact with the furnace. Put all used and new controls into containers before touching ungrounded objects.

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

LOCATION

GENERAL

This multipoise furnace is shipped in packaged configuration.

Some assembly and modifications are required when used in any

NOTE: For high-altitude installations, the high-altitude conversion kit MUST be installed at or above 5500 ft. (1676 M) above sea level. Obtain high-altitude conversion kit from your area authorized distributor. of the four applications shown in Fig. 4.

THE BLOWER IS LOCATED

TO THE RIGHT OF THE

BURNER SECTION, AND

AIR CONDITIONED AIR IS

DISCHARGED TO THE LEFT. gg

AIRFLOW

a

UPFLOW

THE BLOWER IS

LOCATED BELOW THE

BURNER SECTION, AND

~~ CONDITIONED AIR IS

DISCHARGED UPWARD. a

AIRFLOW

HORIZONTAL LEFT

THE BLOWER IS

LOCATED ABOVE THE

BURNER SECTION, AND

CONDITIONED AIR IS

DISCHARGED DOWNWARD

HORIZONTAL RIGHT

AIRFLOW

DOWNFLOW

V c>

THE BLOWER IS

LOCATED TO THE LEFT

OF THE BURNER SECTION,

AND CONDITIONED AIR IS

DISCHARGED TO THE RIGHT.

AIRFLOW

A02097

Fig. 4 - Multipoise Orientations

This furnace must:

CONSIDERATIONS).

Always comply with minimum fire protection clearances shown on the furnace clearance to combustible construction label.

A A Se

CARBON MONOXIDE POISONING / COMPONENT

DAMAGE HAZARD

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

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

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

The following types of furnace installations may require

OUTDOOR AIR for combustion due to chemical exposures:

If air is exposed to the following substances, it should not be used for combustion air, and outdoor air may be required for combustion:

® Chlorinated waxes and cleaners

*® Cleaning solvents (such as perchloroethylene)

* Printing inks, paint removers, varnishes, etc.

All fuel-burning equipment must be supplied with air for fuel combustion. Sufficient air must be provided to avoid negative pressure in the equipment room or space. A positive seal must be made between the furnace cabinet and the return-air duct to prevent pulling air from the burner area and from draft safeguard opening.

A A Se

FIRE, INJURY OR DEATH HAZARD

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

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

(457 mm) above the floor. The furnace must be located or protected to avoid damage by vehicles. When the furnace is installed in a public garage, airplane hangar, or other building having a hazardous atmosphere, the furnace must be installed in accordance with the NFPA 54/ANSI

Z223.1-2009 . (See Fig. 5.)

18-IN. (457.2 mm)

MINIMUM TO BURNERS

Ag3044

Fig. 5 - Installation in a Garage

4 WARNING

FIRE HAZARD

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

Do not install the furnace on its back or hang furnace with control compartment facing downward. Safety control operation will be adversely affected. Never connect return-air ducts to the back of the furnace. (See Fig. 6.)

LOCATION RELATIVE TO COOLING EQUIPMENT

The cooling coil must be installed parallel with, or on the downstream side of the unit to avoid condensation in the heat exchangers. When installed parallel with the furnace, dampers or other flow control must prevent chilled air from entering the furnace. If the dampers are manually operated, they must be equipped with means to prevent operation of either unit unless the damper is in the full-heat or full-cool position.

4 CAUTION

PERSONAL INJURY AND/OR PROPERTY

DAMAGE HAZARD

Improper use or installation of this furnace may result in premature furnace component failure. This gas furnace may be used for heating buildings under construction provided that:

-The furnace is permanently installed with all electrical wiring, piping, venting and ducting installed according to these installation instructions. A return air duct is provided, sealed to the furnace casing, and terminated outside the space containing the furnace. This prevents a negative pressure condition as created by the circulating air blower, causing a flame rollout and/or drawing combustion products into the structure.

-The furnace is controlled by a thermostat. It may not be

“hot wired” to provide heat continuously to the structure without thermostatic control.

-Clean outside air is provided for combustion. This is to minimize the corrosive effects of adhesives, sealers and other construction materials. It also prevents the entrainment of drywall dust into combustion air, which can cause fouling and plugging of furnace components.

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

-The air temperature rise is within the rated rise range on the furnace rating plate, and the gas input rate has been set to the nameplate value. -The filters used to clean the circulating air during the construction process must be either changed or thoroughly cleaned prior to occupancy.

-The furnace, ductwork and filters are cleaned as necessary to remove drywail dust and construction debris from all

HVAC system components after construction is completed.

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

Fig. 6 - Prohibit Installation on Back

A02054

Table 2 - Minimum Free Area Required for Each Combustion Air opening of Duct to Outdoors

TWO HORIZONTAL DUCTS SINGLE DUCT OR OPENING TWO OPENINGS OR VERTICAL DUCTS

FURNACE | (1 SG. IN/2,000 BTUR) (1,100 SG. MM/KW) | (1 SQ. IN./3,000 BTUR) (734 SG. MM/KW) (1 $0. IN/4,000 BTUH) (550 SG. MIM/KW)

INPUT Free Area of Opening Round Duct Free Area of Opening Round Duct Free Area of Opening Round Duct

(BTUH) and Duct Dia. and Duct Dia. and Duct Dia.

Sq. In. (Sq. mm) In. (mm) Sq. In. (Sq. mm) In. (mm) Sq. In. (Sq. mm) In. (mm)

44,000

66,000

22 (14194)

33 (21290)

6 (152)

7 (178)

147 (9484)

22 (14193)

5 (127)

6 (152)

11 (7096)

16.5 (10645)

4 (102)

5 (127)

88,000

110,000

132,000

154,000

44 (28387)

55 (35484)

66 (42580)

77 (49677)

8 (203)

9 (229)

10 (254)

29.3 (18903)

36.7 (23677)

44 (28387)

51.3 (83096)

7 (178)

8 (203)

9 (229)

22 (14193)

27.5 (17742)

33 (21290)

38.5 (24839)

6 (152)

7 (178)

8 (203)

EXAMPLES: Determining Free Area

FURNACE WATER HEATER TOTAL INPUT

410,000

66,000

30,000

40,000

(140,000 divided by 4,000)

(106,000 divided by 3,000)

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

35.3 Sq. In. for a Single Duct or Opening

88,000 + 30,000 = (118,000 divided by 2,000) = 59.0 Sq. In. for each of two Horizontal Ducts

Table 3 - Minimum Space Volumes for 100% Combustion, Ventilation, and Dilution from Indoors

OTHER THAN FAN-ASSISTED TOTAL

(1,000’S BTUH GAS INPUT RATE)

FAN-ASSISTED TOTAL

(1,000’S BTUH GAS INPUT RATE)

ACH 30 40 50 44 66 88 110 i32 ss

Space Volume Ft? (M*)

0.60 1,050 1.400 1,750 1,100 1,650 2,200 2,750 3,300 3,850

. (29.7) (39.6) (49,5) (31.1) (46.7) (62.2) (77.8) (93.4) (109.0)

0.50 1,260 1,680 2,100 1.320 1,980 2,640 3,300 3,960 4,620

. (35.6) (47.5) (59.4) (37.3) (56.0) (74.7) (93.4) (112.1) (130.8)

0.40 1,575 2,100 2,625 1,650 2,475 3,300 4,125 4,950 5,775

, (44.5) (59.4) (74.3) (46.7) (70.0) (93.4) (116.8) (140.1) (163.5)

0.30 2,100 2,800 3,500 2,200 3,300 4,400 5,500 6,600 7,700

‘ (59.4) (79.2) (99,1) (62.2) (93.4) (124.5) (155.7) (186.8) (218.0)

3,150 4,200 3,300 4,950 6,600 8,250 9,900 11,550

9.20 (89.1) (118.9) | 3-250 148.6) (93.4) (140.1) (186.8) (233.6) (280.3) (327.0)

0.10 6,300 8,400 10,500 6,600 9,900 13,200 16,500 19,800 23,100

. (178.3) (237.8) (297.3) (186.8) (280.3) (373.7) (467.2) (560.6) (654.1)

0.00 NP NP NP NP NP NP NP NP NP

NP = Not Permitted

AIR FOR COMBUSTION AND

VENTILATION

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

2223.1-2009 , Air for Combustion and Ventilation and applicable provisions of the local building codes.

FURNACE CORROSION HAZARD

Failure to follow this caution may result in furnace damage.

4& WARNING

CARBON MONOXIDE POISONING HAZARD

. ; . . .

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

The operation of exhaust fans, kitchen ventilation fans, clothes dryers, attic exhaust fans or fireplaces could create a

NEGATIVE PRESSURE CONDITION at the furnace.

Make-up air MUST be provided for the ventilation devices, in addition to that required by the furnace. Refer to the

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

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

METHOD.

PER 4000

BTUH

OUTDOORS

—

(305mm) 12” MAX

1 SQIN.

BTUH*

!

Sey

4&5

Sa oa

12”

!

_|_MAX

1SQIN

PER

G x

4000

BTUH*

305mm,

DUCTS

OUTDOORS

1SQIN

PER

4000

1SQIN.

PER 2000 i

BTUH* VI

(305mm) 12” MAX

El]

OT c {

12" MAX

| (305mm)

BTUH* a

Gee 1

12"

Max (805mm)

{

CIRCULATING AIR DUCTS

DUCT

OUTDOORS

1SQIN.

PER 4000

BTUH*

*Minimum dimensions of 3-in. (76 mm).

NOTE: Use any of the following combinations of openings:

A&BC&DD&EF&G

A08174

Fig. 7 - Air for Combustion, Ventilation, and Dilution for

Outdoors

STANDARD or KNOWN AIR INFILTRATION

METHOD.

Outdoor Combustion Air Method

1. Provide the space with sufficient air for proper combustion, ventilation, and dilution of flue gases using permanent horizontal or vertical duct(s) or opening(s) directly communicating with the outdoors or spaces that freely communicate with the outdoors.

. Fig. 7 illustrates how to provide TWO OUTDOOR

OPENINGS, one inlet and one outlet combustion and ventilation air opening, to the outdoors. e. One opening MUST commence within 12 in. (300 mm) of the ceiling and the second opening MUST commence within 12 in. (300 mm) of the floor. f. Size openings and ducts per Fig. 7 and Table 2. g. TWO HORIZONTAL DUCTS require 1 sq. in. (645 sq. mm) of free area per 2,000 Btuh (1,100 mm2/kW) of combined input for all gas appliances in the space per Fig. 7 and Table 2. h. TWO OPENINGS OR VERTICAL DUCTS require 1 sq. in. (645 sq. mm) of free area per 4,000 Btuh (550 mm2/kW) for combined input of all gas appliances in the space per Fig. 7 and Table 2.

3. ONE OUTDOOR OPENING requires: a. 1 sq. in. (645 sq. mm) of free area per 3,000 Btuh

(734 mm2/kW) for combined input of all gas appli- b. Not less than the sum of the areas of all vent connectors in the space. ances in the space per Table 2 and

INTERIOR

HEATED

SPACE fo (1

VENT THROUGH ROOF

ot

1 SQIN.

PER 1000

_| BTUH* IN DOOR

OR WALL

6" MIN (152mm)

(FRONT)G

1 SQIN.

ER 1000

TUH* IN DOOR

ALL

12" MAX (305mm)

CIRCULATING AIR DUCTS

* Minimum opening size is 100 sq in. (64516 sq. mm)with minimum dimensions of 3 in. (76 mm)

+ Minimum of 3 in. (76 mm) when type-B1 vent is used.

A03175

Fig. 8 - Air for Combustion, Ventilation, and Dilution from

Indoors

The opening shall commence within 12 in. (300 mm) of the ceiling. Appliances in the space shall have clearances of at least 1 in. (25 mm) from the sides and back and 6 in. (150 mm) from the front. The opening shall directly communicate with the outdoors or shall communicate through a vertical or horizontal duct to the outdoors or spaces (crawl or attic) that freely communicate with the outdoors.

Indoor Combustion Air© NFPA & AGA

Standard and Known-Air-Infiltration Rate Methods

Indoor air is permitted for combustion, ventilation, and dilution, if the Standard or Known-Air-Infiltration Method is used.

CARBON MONOXIDE POISONING HAZARD

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

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

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

The Standard Method:

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

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

2. The air infiltration rate is not known to be less than 0.40 air changes per hour (ACH).

The Known Air Infiltration Rate Method shall be used, if the infiltration rate is known to be:

1. Less than 0.40 ACH and

2. Equal to or greater than 0.10 ACH

Infiltration rates greater than 0.60 ACH shall not be used. The minimum required volume of the space varies with the number of

ACH and shall be determined per Table 3 or Equations 1 and 2.

Determine the minimum required volume for each appliance in the space and add the volumes together to get the total minimum required volume for the space.

Table 3 - Minimum Space Volumes were determined by using the following equations from the National Fuel Gas Code ANSI

£223.1-2009/NFPA 54-2009, 9.3.2.2:

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

Volume

Othe ACH 11000 Btu/hr

Ao4002

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

Volume

Fan ACH |1000 Btu/hr

A04008

If: Iother = combined input of ail other than fan-assisted appliances in Btuh/hr

Ifan = combined input of all fan-assisted appliances in Btuh/hr

ACH = air changes per hour (ACH shail not exceed 0.60.)

The following requirements apply to the Standard Method and to the Known Air Infiltration Rate Method.

1. Adjoining rooms can be considered part of a space if: a. There are no closeable doors between rooms. b. Combining spaces on same floor level. Each opening shall have free area of at least 1 in.2/1,000 Btuh (2,000 mm2/kW) of the total input rating of all gas appliances in the space, but not less than 100 in.? (0.06 m2), One opening shall commence within 12 in. (300 mm) of the ceiling and the second opening shall commence within 12 in. (300 mm) of the floor. The minimum dimension of air openings shall be af least 3 in. (80 mm). (See Fig. 8.) c. Combining space on different floor levels. The volumes of spaces on different floor levels shall be considered as communicating spaces if connected by one or more permanent openings in doors or floors having free area of at least 2 in.2/1,000 Btuh (4,400 mm_2/kW) of total input rating of all gas appliances.

. An attic or crawlspace may be considered a space that freely communicates with the outdoors provided there are adequate permanent ventilation openings directly to outdoors having free area of at least 1-in.2/4,000 Btuh of total input rating for all gas appliances in the space.

3. In spaces that use the Indoor Combustion Air Method, infiltration should be adequate to provide air for combustion, permanent ventilation and dilution of flue gases.

However, in buildings with unusually tight construction, additional air MUST be provided using the methods described in the Outdoor Combustion Air Method section.

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

Combination of Indoor and Outdoor Air

1. Indoor openings shall comply with the Indoor Combus- tion Air Method below and,

2. Outdoor openings shall be located as required in the Out- door Combustion Air Method mentioned previously and,

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

Method below. b. Outdoor opening size reduction Factor is 1 minus the

Ratio in a. above. c. Minimum size of Outdoor openings shail be the size required in Outdoor Combustion Air Method above multiplied by reduction Factor in b. above. The minimum dimension of air openings shall be not less than

3 in. (80 mm).

INSTALLATION

UPFLOW INSTALLATION

Bottom Return Air Inlet

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

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

. Rotate bottom filler panel downward to release holding tabs.

3. Remove bottom closure panel.

4. Reinstall bottom filler panel and screws.

Side Return Air Inlet

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

Bottom

Closure Panel

Bottom Filler Panel

Fig. 9 - Removing Bottom Closure Panel

A10278

NOTE: Side return-air openings can be used in UPFLOW and most HORIZONTAL configurations. Do not use side return-air openings in DOWNFLOW configuration.

Leveling Legs (If Desired

In upfiow position with side return inlet(s), leveling legs may be used, (See Fig. 10.) Install field-supplied, 5/16 X 1-1/2 in. (8 X

38 mm) (max) corrosion-resistant machine bolts, washers and nuts.

Sie"

(8mm)

(44mm) 1 Sta r

Fig. 10 - Leveling Legs

NOTE: Bottom closure must be used when leveling legs are used. It may be necessary to remove and reinstall bottom closure panel to install leveling legs. To remove bottom closure panel, see

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

To install leveling legs:

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

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

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

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

5. Reinstall bottom closure panel if removed.

DOWNFLOW INSTALLATION

NOTE: For downtlow applications, this furnace is approved for use on combustible flooring when any one of the following 3 accessories are used:

CAR

Coil Box Part No. KCAKC

. Determine application being installed from Table 4.

. Construct hole in floor per Table 4 and Fig. 11.

. Construct plenum to dimensions specified in Table 4 and

Fig. 11.

4. If downtlow subbase, KGASB is used, install as shown in

Fig. 12. If Coil Assembly Part No. CPVP, CAPMP or

CNPVP Coil Box Part No. KCAKC is used, install as shown in Fig. 13.

A89014

NOTE: It is recommended that the perforated supply-air duct flanges be completely folded over or removed from furnace when installing the furnace on a factory-supplied cased coil or coil box.

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

Bottom Return Air Inlet

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

. Rotate bottom filler panel downward to release holding tabs.

3. Remove bottom closure panel.

4. Reinstall bottom filler panel and screws.

HORIZONTAL INSTALLATION

4 WARNING

FIRE, EXPLOSION, AND CARBON MONOXIDE

POISONING HAZARD

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

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

Suspended Furnace Support

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

16.) Secure angle iron to bottom of furnace as shown.

Heavy-gauge sheet metal straps (plumber’s straps) may be used to suspend the furnace from each bottom corner. To prevent screws from pulling out, use 2 #8 x in. screws into the side and 2

#8 x in. screws in the bottom of the furnace casing for each strap.

(See Fig. 15 and 16.)

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

Platform Furnace Support

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

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

eee

FURNACE

(OR COIL CASING

WHEN USED) wt A Li

PLENUM

OPENING

B D

FLOOR

OPENING

Fig. 11 - Floor and Plenum Opening Dimensions

Ag6283

Roll-Out Protection

Provide a minimum 17-3/4-in. X 22-in. (451 X 559 mm) piece of sheet metal for flame roll-out protection in front of burner area for furnaces closer than 12-in. (305 mm) above the combustible deck or suspended furnaces closer than 12-in. (305 mm) to joists.

The sheet metal MUST extend underneath the furnace casing by

1-in. (25 mm)with the door removed.

The bottom closure panel on furnaces of widths 17-1/2-in. (445 mm) and larger may be used for flame roll-out protection when bottom of furnace is used for return air connection. See Fig. 17 for proper orientation of roll-out shield.

Bottom Return Air Inlet

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

. Rotate bottom filler panel downward to release holding tabs.

3. Remove bottom closure panel.

4. Reinstall bottom filler panel and screws.

Side Return Air Inlet

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

COMBUSTIBLE

FLOORING

MN DOWNELOW 4

SUBBASE

“ SHEET METAL

PLENUM

FLOOR

OPENING

AQ6285

Fig. 12 - Furnace, Plenum, and Subbase Installed on a

Combustible Floor

FURNACE

APPROVED

COIL ASSEMBLY

COIL BOX

COMBUSTIBLE mney

FLOORING

4 x

rn

x x

\

“|

\

AO8556

Fig. 13 - Furnace, Plenum, and Coil Assembly or Coil Box

Installed on a Combustible Floor

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

Table 4 —- Opening Dimensions - In. (mm)

reReING:

WIDTH

APPLICATION

PLENUM OPENING FLOOR OPENING

A B c D

IN. (mm)

Upflow Applications on Combustible or Noncombustible Floor- 12-11/16 ing (KGASB subbase not required)

Downflow Applications on Noncombustible Flooring (KGASB

(822)

{2-—9/16

14-8/16

(360)

21-5/8

(549)

13-5/16

(838)

13-3/16 subbase not required)

Downflow applications on combustible flooring (KGASB sub-

(319)

11-18/16

base required)

Downflow Applications on Combustible Flooring with CNPV,

(284)

(483)

(835)

13-7/16

(341)

CNRV, CAR or CAP Coil Assembly or KCAKC coil box (KGASB | 1275/16

subbase not required)

Upflow Applications on Combustible or Noncombustible Floor- 16 21-5/8 16-—5/8

47-4/2

(445)

22-—1/4

(565)

{9-5/8

(498)

20-5/8

(600)

ing (KGASB subbase not required)

Downflow Applications on Noncombustible Flooring (KGASB

(406)

15-—7/8

(549)

(422)

16—1/2

22-—1/4

(565)

{9-5/8 subbase not required)

Downflow applications on combustible flooring (KGASB sub-

(408)

15-—1/8

base required)

Downflow Applications on Combustible Flooring with CNPV,

(384)

415—4/2

(483)

(419)

16-—3/4

(425)

46—1/2

(498)

20-5/8

(600)

(588)

24-4/2

(622)

(394) subbase not required)

Upflow Applications on Combustible or Noncombustible Floor- 19-—1/2 ing (KGASB subbase not required)

Downflow Applications on Noncombustible Flooring (KGASB

(495)

19-3/8

(483) (508)

22-—1/4

(565)

{9-5/8 subbase not required)

Downflow applications on combustible flooring (KGASB sub-

(492)

18-5/8

base required)

Downflow Applications on Combustible Flooring with CNPV,

(473)

(483)

(508)

20—1/4

(514)

(498)

20-5/8

(600)

(483) subbase not required)

Upflow Applications on Combustible or Noncombustible Floor- 23 ing (KGASB subbase not required)

Downflow Applications on Noncombustible Flooring (KGASB

(584)

22-7/8

21-5/8

(549)

(483)

21-1/8

(537)

(419)

20-1/8

(511)

(508)

23~5/8

(600)

23-—1/2 subbase not required)

Downflow applications on Combustible flooring (KGASB sub-

(581)

22-1/8

base required)

Downflow Applications on Combustible Flooring with CNPV,

(562)

(483)

(597)

23—~3/4

(603)

CNRV, CAR or CAP Coil Assembly or KCAKC coil box (KGASB

subbase not required)

(508)

22-—1/4

(565)

{9-5/8

(498)

20-5/8

(600)

Filter Arrangement the supply ducts carry air circulated by the furnace to areas outside the space containing the furnace, the return air shall also be handied by duct(s) sealed to the furnace casing and terminating outside the space containing the furnace.

CARBON MONOXIDE POISONING HAZARD

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

~ . ~ cag

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

There are no provisions for an internal filter rack in these furnaces. A field-supplied accessory external filter rack is required.

Refer to the instructions supplied with the external filter rack for assembly and installation options.

AIR DUCTS

General Requirements

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

Conditioning Contractors Association (ACCA), Sheet Metal and

Air Conditioning Contractors National Association (SMACNA) or American Society of Heating, Refrigerating and Air

Conditioning Engineers (ASHRAE) or consult The Air Systems

Design Guidelines reference tables available from your local distributor. The duct system should be sized to handle the required system design CFM at the design external static pressure.

The furnace airflow rates are provided in Table 5-Air

Delivery-CFM (With Filter). When a furnace is installed so that

Secure ductwork with proper fasteners for type of ductwork used.

Seal supply- and return-duct connections to furnace with code approved tape or duct sealer.

NOTE: Flexible connections should be used between ductwork and furnace to prevent transmission of vibration.

Ductwork passing through unconditioned space should be insulated to enhance system performance. When air conditioning is used, a vapor barrier is recommended.

Maintain a 1-in. (25 mm) clearance from combustible materials to supply air ductwork for a distance of 36-in. (914 mm) horizontally from the furnace. See NFPA 90B or local code for further requirements.

Ductwork Acoustical Treatment

NOTE: Metal duct systems that do not have a 90 degree elbow and 10 ft. (3 M) of main duct to the first branch take-off may require internal acoustical lining. As an alternative, fibrous ductwork may be used if constructed and installed in accordance with the latest edition of SMACNA construction standard on fibrous glass ducts. Both acoustical lining and fibrous ductwork shall comply with NFPA 90B as tested by UL Standard 181 for

Class 1 Rigid air ducts.

Supply Air Connections

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

Upflow and Horizontal Furnaces

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

Bend flange upward to 90° with wide duct pliers. (See Fig. 14.)

The supply-air duct must be connected to ONLY the furnace supply-outlet-air duct flanges or air conditioning coil casing

(when used), DO NOT cut main furnace casing side to attach supply air duct, humidifier, or other accessories. All accessories

MUST be connected to duct external to furnace main casing.

NOTE: For horizontal applications, the top most flange may be bent past 90° to allow the evaporator coil to hang on the flange temporarily while the remaining attachment and sealing of the coil are performed.

Downflow Furnaces

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

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

UPFLOW DOWNELOW. HORIZONTAL

YES a \

MIN

YES

Fig. 14 - Duct Flanges

YES aa

MIN

YES

A02020

OUTER DOOR

ASSEMBLY

Ya" (6mm) THREADED ROD

4 REQ. ae aa

2e7

8" (203mm) MIN

FOR DOOR REMOVAL

Lae

Ze ar a

Zee a

ZZ xr |

SECURE ANGLE

IRON TO BOTTOM

OF FURNACE WITH

3 #8 x9/s" (19mm) SCREWS

TYPICAL FOR 2 SUPPORTS z

1” (25mm) SQUARE, 1-1/4"x1-1/4"x1/8” (82x32x3mm)

ANGLE IRON OR UNI-STRUT MAY BE USED

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

REQ. PER ROD

Fig. 15 - Horizontal Unit Suspension

ouren.2o0n

\\ i

4 a

22 GAUGE GALVANIZED

STRAPS TYPICAL

FOR 4 STRAPS \

BACK OF

FURNACE

METHOD 4

FOLD ALL STRAPS UNDER

FURNACE AND SECURE WTH

(4) #8 x 3/4 (19 mm) SHEET METAL SCREWS

(2 SCREWS IN SIDE AND 2 SCREWS

IN BOTTOM).

AIR

OPENING

Menon 2

USE (4) #8 x 3/4 (19 mm) SHEET

METAL SCREWS FOR EACH

STRAP. THE STRAPS

SHOULD BE VERTICAL

AGAINST THE FURNACE

SIDES AND NOT PULL AWAY

FROM THE FURNACE

SIDES.

AIR OPENING

Fig. 16 - Horizontal Suspension with Straps

A10134

A10130

1S) ve] iw

LINE CONTACT ONLY PERMISSIBLE BETWEEN

LINES FORMED BY INTERSECTIONS OF

THE TOP AND TWO SIDES OF THE FURNACE

JACKET AND BUILDING JOISTS,

STUDS, OR FRAMING. 17 3/4” (451mm)OVERALL

4 3/4” (121mm) UNDER DOOR

1” (25mm) UNDER FURNACE

EXTEND OUT 12” (305mm)

FROM FACE OF DOOR

30-IN. (762mm)

MIN WORK AREA * WHEN USED WITH

SINGLE WALL VENT

CONNECTIONS

EQUIPMENT MANUAL

SHUT-OFF GAS VALVE NS

UNION

Fig. 17 - Typical Attic Installation

A10164

SUPPLY

AIR

]

— — — — | UPFLOW RETURN AIR CONFIGURATIONS AND RESTRICTIONS

—

== =

_- TT

AIRFLOW MODELS = RETURNAIR —- RETURNAIR RETURN AIR RETURN AIR

CONNECTION 1 CONNECTION2 CONNECTIONS COMBINATIONS

066.060, -22 AND

-20 MODELS

NLY

YES

ONLY

YES

ONLY

YES YES

ALL OTHER MODELS YES YES YES YES

RETURN

AIR

]

| eg

RETURN

AIR

RETURN

AIR ] @

UPrLOW

AESTRICTIONS

Fig. 18 - Upflow Return Air Configurations and Restrictions

A02075

RETURN

AIR

SIDE RETURN

NOT PERMITTED

FOR ANY MODEL,

SIDE RETURN

NOT PERMITTED

FOR ANY MODEL

DOWNFL_OW RETURNAIR CONFIGURATIONSANDRESTRICTIONS

—

= TS

_ _

AIR FLOW MODELS

ONLY

YES

ONLY

OF 1, 2, AND 3

ALL OTHER MODELS YES NO NO NO

SUPPLY

AIR

Fig. 19 - Downflow Return Air Configurations and Restrictions

A02163

RETURN

AIR

SIDE RETURN AIR

NOT PERMITTED FOR

066,060, -22-20

AIR FLOW MODELS

SUPPLY

AIR

RETURN

AIR

TTT

SIDE RETURN AIR

NOT PERMITTED FOR

086,060, -22-20

AIR FLOW MODELS

* NOTE: RESTRICTION SAME FOR

HORIZONAL LEFT | tn

HORIZONAL

RETURN AIR

RESTRICTIONS

HORIZONTAL RETURN AIR CONFIGURATIONS AND RESTRICTIONS

AIR FLOW MODELS RETURN AIR

CONNECTION 1

ONLY

RETURN AIR

CONNECTION2

ONLY.

RETURN AIR

CONNECTION3

ONLY

RETURN AIR

COMBINATIONS

OF 1,2, AND3

066.060, -22 AND

-20 MODELS

YES NO NO NO

ALL OTHER MODELS = ==YES YES YES YES

Fig. 20 - Horizontal Return Air Configurations and Restrictions

A02162

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

CFM

External

Static

External Static Pressure (ESP) (IN. W.C.)

Unit Size Operating Mode Airflow

Setting

Pressure

Range*

(In. W.C.) o1 | 02 | 03 | 04 | 05 | 06 1 tt Low Heat 735 (615)t 0—0.50 735 | 735 | 735 | 735 | 725

High Heat 1180 (1060)t 0-1.0 1160 | 1165 | 1175 | 1180 | 1180 | 1180 | 1180 | 1180 | 1180 | 1175 tt 1—1/2—Ton Cooling 525 0—0.50¢ 515 | 500 | 500 | 490 | 485 tt 2—Ton A/C Cooling 700 0—0.50¢ 690 | 680 | 675 | 680 | 675

2—1/2—Ton A/C Cooling 875 0-1.0+ 875 | 875 | 875 | 870 | 865 | 855 | 850 | 835 | 825 | 820

3—Ton A/C Cooling 1050 0-1.0+ 1050 | 1050 | 1050 | 1050 | 1050 | 1050 | 1045 | 1035 | 1020 | 1000

3—1/2—Ton A/C Cooling 1225 0-1.0 1220 | 1225 | 1225 | 1225 | 1225 | 1220 | 1205 | 1190 | 1185 | 1170

Maximum 1400 0-1.0 1395 | 1400 | 1400 | 1400 | 1395 | 1385 | 1370 | 1340 | 1300 | 1245

Low Heat 985 (825)t 0-1.0 950 | 970 | 985 | 985 | 985 | 985 | 985 | 985 | 985 | 980

High Heat 1210 (1090)t 0-1.0 1190 | 1205 | 1210 | 1210 | 1210 | 1210 | 1210 | 1210 | 1210 | 1200 tt 1—1/2—Ton A/C Cooling 525 0—0.50¢ 525 | 520 | 525 | 495 | 475 tt 2—Ton A/C Cooling 700 0—0.50¢ 680 | 680 | 680 | 675 | 670

2—1/2—Ton A/C Cooling 875 0-1.0+ 815 | 845 | 845 | 855 | 850 | 850 | 845 | 835 | 820 | 805

3—Ton A/C Cooling 1050 0-1.0+ 1005 | 1005 | 1015 | 1035 | 1040 | 1040 | 1035 | 1030 | 1025 | 1010

3—1/2—Ton A/C Cooling 1225 0-1.0 1190 | 1200 | 1200 | 1205 | 1205 | 1215 | 1205 | 1200 | 1185 | 1170

4—Ton A/C Cooling 1400 0-1.0 1350 | 1370 | 1390 | 1390 | 1400 | 1390 | 1380 | 1380 | 1360 | 1340

Maximum 1600 0-1.0 1595 | 1600 | 1600 | 1600 | 1595 | 1555 | 1505 | 1485 | 1430 | 1390

Low Heat 1320 (1110)T 0-1.0 1275 | 1295 | 1315 | 1320 | 1320 | 1320 | 1320 | 1320 | 1320 | 1315

High Heat 1475 (1330)T 0-1.0 1460 | 1465 | 1475 | 1475 | 1475 | 1475 | 1475 | 1475 | 1465 | 1465 tt 2—-Ton A/C Cooling 700 0-0.50¢ 700 700 700 700 700 tt 2-1/2—Ton A/C Cooling 875 0-0.50¢ 875 875 875 875 875

1050

3-1/2—Ton A/C Cooling 1225 0-1.0$ 1225 | 1225 | 1225 | 1225 | 1225 | 1225 | 1225 | 1225 | 1225 | 1225

4—-Ton A/C Cooling 1400 0-1.0$ 1400 | 1400 | 1400 | 1400 | 1400 | 1400 | 1400 | 1400 | 1400 | 1400

5—Ton A/C Cooling 1750 0-1.0$ 1750 | 1750 | 1750 | 1750 | 1750 | 1750 | 1750 | 1750 | 1740 | 1725

6—Ton A/C Cooling 2100 0-1.0 2100 | 2100 | 2100 | 2100 | 2090 | 2075 | 2055 | 2040 | 2005 | 1970

Maximum 2200 0-1.0 2200 | 2190 | 2190 | 2180 | 2155 | 2145 | 2125 | 2100 | 2080 | 2020

1700 (1430)T

High Heat 1915 (1725)T 0-1.0 1900 | 1905 | 1915 | 1915 / 1915 | 1915 | 1915 / 1915 | 1915 | 1915 tT 2—-Ton A/C Cooling 700 0-0.50¢ 700 700 700 700 665 tT 2-1/2—Ton A/C Cooling 875 0-0.50¢ 870 870 865 865 865

3-1/2—Ton A/C Cooling 1225 0-1.0$ 1155 | 1180 | 1200 | 1210 | 1220 | 1225 | 1225 | 1225 | 1225 | 1225

1715 (1440)t

1050

0-0.50¢

0-1.0

0-0.50¢

0-1.0

0-0.50¢

1050

4—-Ton A/C Cooling 1400 0-1.0$ 1395 | 1400 | 1400 | 1400 | 1400 | 1400 | 1400 | 1390 | 1375 | 1355

5—Ton A/C Cooling 1750 0-1.0$ 1740 | 1750 | 1750 | 1750 | 1785 | 1740 | 1735 | 1730 | 1715 | 1700

6—Ton A/C Cooling 2100 0-1.0 2075 | 2085 | 2090 | 2100 | 2100 | 2100 | 2090 | 2080 | 2055 | 2025

Maximum 2200 0-1.0 2180 | 2195 | 2200 | 2200 | 2200 | 2200 | 2185 | 2165 | 2140 | 2095

High Heat 1970 (1775)T 0-1.0 1955 | 1965 | 1965 | 1970 | 1970 | 1970 | 1970 | 1970 | 1970 | 1960 tT 2—-Ton A/C Cooling 700 0-0.50¢ 700 700 700 700 680 tT 2-1/2—Ton A/C Cooling 875 0-0.50¢ 865 875 875 865 865 tt tt tt

3—Ton A/C Cooling

Low Heat

3—Ton A/C Cooling

1050 | 1050 | 1050 | 1050 | 1050

1700 | 1700 | 1700 | 1700 | 1700 | 1695 | 1700 | 1695 | 1685 | 1670

1010 | 1030 | 1050 | 1050 | 1050

Low Heat

3—Ton A/C Cooling

1715 | 1715 | 1715 | 1715 | 1715 | 1705 | 1710 | 1705 | 1705 | 1695

1015 | 1020 | 1035 | 1045 | 1050

3-1/2—Ton A/C Cooling 1225 0-1.0$ 1160 | 1185 | 1215 | 1225 | 1225 | 1225 | 1225 | 1225 | 1225 | 1225

4—-Ton A/C Cooling 1400 0-1.0$ 1385 | 1400 | 1400 | 1400 | 1400 | 1400 | 1395 | 1395 | 1380 | 1360

5—Ton A/C Cooling 1750 0-1.0$ 1745 | 1750 | 1750 | 1750 | 1745 | 1740 | 1745 | 1745 | 1740 | 1735

6—Ton A/C Cooling 2100 0-1.0 2055 | 2070 | 2080 | 2085 | 2095 | 2100 | 2100 | 2100 | 2090 | 2065

Maximum 2200 0-1.0 2175 | 2190 | 2200 | 2200 | 2200 | 2200 | 2200 | 2200 | 2180 | 2160

*Actual external static pressure (ESP) can be determined by using the fan laws (CFM 2 proportional to ESP); such as, a system with 1180 CFM at 0.5 ESP would operate at cooling airflow of 1050 CFM at 0.4 ESP and low—heating airflow of 735 CFM at 0.19 ESP. tComfort airflow values are shown in parenthesis. Comfort airflow is selected when the low—heat rise adjustment switch (SW1—-3) is OFF and the comfort/efficiency switch (SW1—-4) is ON.

+Ductwork must be sized for high—heating CFM within the operational range of ESP. ttOperation within the blank areas of the chart is not recommended because high—heat operation will be above 1.0 ESP.

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

Return Air Connections

FIRE HAZARD

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

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

Follow instructions below.

Downflow Furnaces

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

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

(left or right). Side opening is permitted for only upflow and certain horizontal furnaces. Bypass humidifier connections should be made at ductwork or coil casing sides exterior to furnace. (See Fig. 19.)

Uptlow and Horizontal Furnaces

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

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

GAS PIPING

CUANDO:

FIRE OR EXPLOSION HAZARD

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

Never purge a gas line into a combustion chamber. Never test for gas leaks with an open flame. Use a commercially available soap solution made specifically for the detection of leaks to check all connections. A fire or explosion may result causing property damage, personal injury or loss of life.

Installations must be made in accordance with all authorities having jurisdiction. If possible, the gas supply line should be a separate line running directly from meter to furnace.

NOTE: In the state of Massachusetts:

1. Gas supply connections MUST be performed by a li- censed plumber or gas fitter.

. When flexible connectors are used, the maximum length shall not exceed 36 in. (915 mm).

3. When lever handle type manual equipment shutoff valves are used, they shall be T-handle valves.

4, The use of copper tubing for gas piping is NOT approved by the state of Massachusetts.

Refer to Table 6 for recommended gas pipe sizing. Risers must be used to connect to furnace and to meter. Support all gas piping with appropriate straps, hangers, etc. Use a minimum of 1 hanger every 6 ft. (1.8 M). Joint compound (pipe dope) should be applied sparingly and only to male threads of joints. Pipe dope must be resistant to the action of propane gas.

Table 6 - Maximum Capacity of Pipe

NOMINAL

ROME

IN. (MIM)

INTERNAL

; 1 cata

- (MM)

LENGTH OF PIPE — FT (M)

20 30 40 50

(3.0) | (6.0) | (4) | (12.4) | (15.2)

17212.) | 0.622(158) 175 | 120 o7

3/4 (49.0) | 0.824(209) | 360 | 250 | 200

1(25.4) | 1.049(268) | 680 | 465 | 375 a2 73

170 151

320 | 285

1-4/4

1.380 (35.0) | 1400 | 950 | 770 seo | 580

6a) 1.610 (40.9) | 2100 | 1460 | 1180 | 990 900

* Cubic f of gas per hr for gas pressures of 0.5 psig (14-In. W.C.) or less and a pressure drop of 0.5-In. W.C. (based on a 0.60 specific gravity gas). Ref:

Table 6 and 9.2 NFGC.

4 WARNING

FIRE OR EXPLOSION HAZARD

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

If local codes allow the use of a flexible gas appliance connector, always use a new listed connector. Do not use a connector which has previously served another gas appliance. Black iron pipe shail be installed at the furnace gas control valve and extend a minimum of 2-in. (51 mm) outside the furnace.

FIRE OR EXPLOSION HAZARD

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

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

FIRE OR EXPLOSION HAZARD

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

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

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

FURNACE DAMAGE HAZARD

Failure to follow this caution may result in furnace damage.

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

An accessible manual equipment shutoff valve MUST be installed external to furnace casing and within 6 ft. (1.8 M) of furnace. A 1/8-in. (3 mm) NPT plugged tapping, accessible for test gauge connection, MUST be installed immediately upstream of gas supply connection to furnace and downstream of manual equipment shutoff vaive.

NOTE: The furnace gas control valve inlet pressure tap connection is suitable to use as test gauge connection providing test pressure DOES NOT exceed maximum 0.5 psig (14-In.

W.C.) stated on gas control valve. (See Fig. 50.)

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

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

22. Connect a capped nipple into lower end of tee. Capped nipple should extend below level of furnace gas controls. Place a ground joint union between furnace gas control vaive and exterior manual equipment gas shutoff valve.

A 1/8-in. (3 mm) NPT plugged tapping, accessible for test gauge connection, MUST be installed immediately upstream of gas supply connection to furnace and downstream of manual equipment shutoff valve.

Piping should be pressure and leak tested in accordance with the current addition of the NFGC in the United States, local, and national plumbing and gas codes before the furnace has been connected. After all connections have been made, purge lines and check for leakage at furnace prior to operating furnace.

If pressure exceeds 0.5 psig (14-In. W.C.), gas supply pipe must be disconnected from furnace and capped before and during supply pipe pressure test. If test pressure is equal to or less than

0.5 psig (14-In. W.C.), turn off electric shutoff switch located on furnace gas control valve and accessible manual equipment shutoff valve before and during supply pipe pressure test. After all connections have been made, purge lines and check for leakage at furnace prior to operating furnace.

The gas supply pressure shall be within the maximum and minimum inlet supply pressures marked on the rating plate with the furnace burners ON and OFF,

TOP VIEW OF BURNER AND MANIFOLD ASSEMBLY

ELECTRICAL SHOCK HAZARD

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

Blower access panel door switch opens 115-v power to control. No component operation can occur. Do not bypass or close switch with panel removed.

See Fig. 25 for field wiring diagram showing typical field 115-v wiring. Check all factory and field electrical connections for tightness.

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

(33°C) rise.

4 WARNING

ELECTRICAL SHOCK AND FIRE HAZARD

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

The cabinet MUST have an uninterrupted or unbroken ground according to NEC ANSI/NFPA 70-2011 or local codes to minimize personal injury if an electrical fault should occur. This may consist of electrical wire, conduit approved for electrical ground or a listed, grounded power cord (where permitted by local code) when installed in accordance with existing electrical codes. Refer to the power cord manufacturer’s ratings for proper wire gauge.

Do not use gas piping as an electrical ground.

90° Elbow —_,

° 5 1]

2"(51mm) Nipple

Street Elbow

/ }

Gas Valve

Fig. 21 - Burner and Manifold

GAS

SUPPLY

MANUAL

SHUTOFF

VALVE

(REQUIRED)

SEDIMENT a

TRAP

UNION

—_—_——_—_—EV

=———_—_— eo

_ a

Fig. 22 - Typical Gas Pipe Arrangement

A02085

To Gas upply

A08551

FURNACE MAY NOT OPERATE HAZARD

Failure to follow this caution may result in intermittent furnace operation.

Furnace control must be grounded for proper operation or else control will lock out. Control must remain grounded through green/yellow wire routed to gas valve and manifold bracket screw.

115-V Wiring

Verify that the voltage, frequency, and phase correspond to that specified on unit rating plate. Also, check to be sure that service provided by utility is sufficient to handle load imposed by this equipment. Refer to rating plate or Table 7 for equipment electrical specifications.

U.S. Installations: Make all electrical connections in accordance with National Electrical Code (NEC) ANSI/NFPA 70-2011 and any local codes or ordinances that might apply.

Table 7 — Electrical Data

FURNACE

SIZE eRe

PHASE

VOL NOt RANGE

Max Min:

MAX. UNIT

AMPS

AMPACITY

MAX. WIRE MAX. FUSE OR

LENGTH — FT (M)t | CKT BKR AMPS Tf

Wine

GAUGE

070—12/036070 115-60-1 127 104 9.0 11.99 30 (9.0) 15 14

090—16/048090

110—20/060110

115-60-1

127

104

9.6

15.4

12.56

19.33

29 (8.8)

135 —22/066135

155—22/066155

115-60-1

127

104

14.9

15.0

19.13

19.23

30 (9.0)

29 (8.8)

* 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.

TTime—delay type is recommended.

Length shown is as measured 1 way along wire path between furnace and service panel for maximum 2 percent voltage drop.

4 WARNING

FIRE HAZARD

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

Do not connect aluminum wire between disconnect switch and furnace. Use only copper wire.

Use a separate, fused branch electrical circuit with a properly sized fuse or circuit breaker for this furnace. See Table 7 for wire size and fuse specifications. A readily accessible means of electrical disconnect must be located within sight of the furnace.

NOTE: Proper polarity must be maintained for 115-v wiring. If polarity is incorrect, control LED status indicator light will flash rapidly and furnace will NOT operate.

J-Box Relocation

NOTE: If factory location of J-Box is acceptable, go to next section (ELECTRICAL CONNECTION to J-Box).

NOTE: On 14-in. (356 mm) wide casing models, the J-Box shall not be relocated to other side of furnace casing when the vent pipe is routed within the casing.

1. Remove and save two screws holding J-Box. (See Fig.

23.)

NOTE: The J-Box cover need not be removed from the J-Box in order to move the J-Box. Do NOT remove green ground screw inside J-Box. (See Fig. 23.)

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

3. Move J-Box to desired location.

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

Step 1.

5. Route J-Box wires within furnace away from sharp edges, rotating parts and hot surfaces.

Electrical Connection to J-Box

Electrical Box on Furnace Casing Side (See Fig. 24.)

FIRE OR ELECTRICAL SHOCK HAZARD

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

If field-supplied manual disconnect switch is to be mounted on furnace casing side, select a location where a drill or fastener cannot damage electrical or gas components.

_ Alternate cation

A10204

Fig. 23 - Relocating J-Box

1. Select and remove a hole knockout in the casing where the electrical box is to be installed.

NOTE: Check that duct on side of furnace will not interfere with installed electrical box.

2. Remove the desired electrical box hole knockout and position the hole in the electrical box over the hole in the furnace casing.

3. Fasten the electrical box to casing by driving two field- supplied screws from inside electrical box into casing steel.

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

23.)

5. Pull furnace power wires out of 1/2-in. (12 mm) diameter hole in J-Box. Do not loosen wires from strain-relief wire-tie on outside of J-Box.

6. Route furnace power wires through holes in casing and electrical box and into electrical box.

7, Pull field power wires into electrical box.

8. Remove cover from furnace J-Box.

9, Route field ground wire through holes in electrical box and casing, and into furnace J-Box.

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

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

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

(NEC in U.S. for wire bushings, strain relief, etc.

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

AI0144

Fig. 24 - Field-Supplied Electrical Box on Furnace Casing

Power Cord Installation in Furnace J-Box

NOTE: Power cords must be able to handle the electrical requirements listed in Table 6. Refer to power cord manufacturer’s listings.

1. Remove cover from J-Box.

2. Route listed power cord through 7/8-in. (22 mm) diameter hole in J-Box.

3. Secure power cord to J-Box bracket with a strain relief bushing or a connector approved for the type of cord used.

4. Secure field ground wire to green ground screw on J-Box bracket.

5, Connect line voltage leads as shown in Fig. 25.

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

BX Cable Installation in Furnace J-Box

1. Remove cover from J-Box.

. Route BX cable into 7/8-in. (22 mm) diameter hole in

J-Box.

3. Secure BX cable to J-Box bracket with connectors approved for the type of cable used.

4. Secure field ground wire to green ground screw on J-Box bracket.

5, Connect line voltage leads as shown in Fig. 25.

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

24-V Wiring

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

25 - 34.) Connect terminal Y/Y2 as shown in Fig. 27-34 for proper cooling operation. Use only AWG No. 18, color-coded, copper thermostat wire.

The 24-v circuit contains an automotive-type, 3-amp. fuse located on the control. Any direct shorts during installation, service, or maintenance could cause this fuse to blow. If fuse replacement is required, use ONLY a 3-amp. fuse of identical size.

ACCESSORIES

1. Electronic Air Cleaner (EAC)

Connect an accessory Electronic Air Cleaner (if used) using 1/4-in female quick connect terminals to the two male

1/4-in quick-connect terminals on the control board marked EAC-1 and EAC-2. The terminals are rated for

11SVAC, 1.0 amps maximum and are energized during blower motor operation. (See Fig. 26.)

. Humidifier (HUM)

Connect an accessory 24 VAC, 0.5 amp. maximum humidifier (if used) to the 1/4-in male quick-connect HUM terminal and COM-24V screw terminal on the control board thermostat strip. The HUM terminal is energized when blower is energized in heating. (See Fig. 26.)

NOTE: 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.

VENTING

The furnace shall be connected to a listed factory built chimney or vent, or a clay-tile lined masonry or concrete chimney. Venting into an unlined masonry chimney or concrete chimney is prohibited.

When an existing Category I furnace is removed or replaced, the original venting system, may no longer be sized to properly vent the attached appliances. An improperly sized Category I venting system could cause the formation of condensate in the furnace and vent, leakage of condensate and combustion products, and spillage of combustion products into the living space.

~--~ FIELD 24-VOLT WIRING eom= FIELD 115-, 208/230-, 460-VOLT WIRING

——— FACTORY 24-VOLT WIRING moon FACTORY 115-VOLT WIRING

1-STAGE

TEEMINAS

FUSED DISCONNECT

FIVE

WIRE

THREE-WIRE

HEATING-

ONLY ro

PL @ef TT pet eh A ‘e—| 2) pL |

Wife ———

| yo dy |

208/230- OR

460-VOLT

THREE

PHASE

wn fnmg a= d-

= GND

115-VOLT FIELD- | JUNCTION

SUPPLIED | BOX

FUSED

HaA----- fo---4+--b--

Ht

ho i

ian yp NOTEA

i i!

LL, @—+e, eiHel---

, 4

(®)}}----------- bop Lg

CONTROL

|(@4+--------------

24-VOLT

e—el|--, @}— ==) 208/230-

=e ae ej--— VOLT

= pada

TERMINAL

FURNACE

BLOCK

NOTES: 1. Connect Y/Y2-terminal as shown for proper operation.

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

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

STATUS AND COMM =

LED LIGHTS

3-AMP FUSE

TRANSFORMER 24-VAC

CONNECTIONS

weet

SW1 SETUP

SWITCHES AND

DeLay

AIR CONDITIONING

(A/C) AIRFLOW

SETUP SWITCHES

24-V THERMOSTAT

TERMINALS

Fig. 25 - Field Wiring Diagram

CONTINUOUS FAN

(CF) AIRFLOW

SETUP SWITCHES

OAT

corn

sw4 SETUP

SWITCHES

USER INTERFACE

OR ADVANCED

on

CONNECTOR

= z

= x o

Nope

Se

>| ]]- ola

>) ABBEBBBB) [to

Pala]

= q

OAT.

[3]{o0n

®

2. Me a5

Baeees

HUMIDIFIER

|— TERMINAL (24-VAC

0.5 AMP MAX.

| ACRDJ

CONDITIONING

RELAY DISABLE

JUMPER

A95236

~

9

115-VAC (L2) NEUTRAL

CONNECTIONS

EAC-1 TERMINAL

(115 -VAC 1.0 AMP MAX.)

PLI- LS

HARNESS CONNECTOR

EXAMPLE:

SOFTWARE

VERSION

NUMBER vy en Alo

PART DATE

NUMBER CODE

115-VAC (L1) LINE

VOLTAGE CONNECTIONS

Fig. 26 - Variable Speed Furnace Control for ECM Blower Motor bo on

PL2 ~ HOT SURFACE

IGNITER INDUCER

MOTOR CONNECTOR

A10286

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, NFPA 54/ANSI Z223.1-2009 and _ these instructions. Determine that there is no blockage or restriction, leakage, corrosion and other deficiencies, which could cause an unsafe condition.

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

4. Close fireplace dampers.

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

Do not operate a summer exhaust fan.

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

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

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

54/ANSI Z223.1-2009.

9, After it has been determined that each appliance connected to the venting system properly vents when tested as outlined above, return doors, windows, exhaust fans, fireplace dampers and any other gas-fired burning appliance to their previous conditions of use.

Vent system or vent connectors may need to be resized. Vent systems or vent connectors must be sized to approach minimum size as determined using appropriate table found in the current edition of NFGC.

General Venting Requirements

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

Gas Code NFPA 54/ANSI Z223.1-2009 (NFGC), Parts 12 and

13 in the United States, the local building codes, and furnace and vent manufacturers’ instructions.

The following information and warning must be considered in addition to the requirements defined in the NFGC.

SINGLE-SPEED

AIR CONDITIONER

THERMIDISTAT TWO-STAGE

FURNACE

HEAT STAGE 2 [oma] |..NOTE 1 |

NIA [Y1/W2

HEAT STAGE 1 A

COOL STAGE 1 [ wv }4 -----------4 -[ ¥2 |] --[----- L

HUMIDIFY

N/A

24 VAC HOT [ ®

FAN [ s } ----+------4

DEHUMIDIFY [DRUM] | waee-------4 -/DHUM

-----------4

4j--------

OUTDOOR

SENSOR

S81

CONNECTION |[ S21.

[4--------

J... 20-2 nent!

See notes 2, 5, 7, 10, and 114

A00275

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

Air Conditioner

CUANDO:

CARBON MONOXIDE POISONING HAZARD

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

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

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

. Two-stage furnaces require Type B vent connectors outside the casing in all configurations. Single wall vent connector may be used inside the furnace casing with the transition to Type B vent outside the furnace casing. Size the connector so that the FAN-Min vent connector capacity is equal to or lower than the low fire rate of the furnace and the FAN-Max vent connector capacity is equal to or higher than the furnace high fire rate.

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

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

5. Do not vent this appliance with any solid fuel burning appliance.

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

See SIDEWALL VENTING section.

7. Do not vent this appliance into an unlined masonry chimney. Refer to Chimney Inspection Chart, Fig. 35.

THERMIDISTAT TWO-STAGE

FURNACE

TWO-SPEED

AIR CONDITIONER

HEAT STAGE 2

COOL STAGE 14 je---------4

HEAT STAGE 4

COOL STAGE 2 qoccrsrsrr

NOTE 72

Te |

FAN

24 VAC HOT [ R

24 VAC COMM j_----------]

} weed peHUMIDIFY [DHUM| |_.-----____| fo

HUMIDIFY

NIA [8 |

OUTDOOR

SENSOR

CONNECTION fo qocccccte

c\

HUMIDIFIER

(24 VAC)

mm

j__----------------------------!

‘

See notes 2, 5, 8, 10,44 and 12 on the page following these figures

A03179

Fig. 28 - Two-Stage Furnace with Two-Speed Air Condi- tioner

THERMIDISTAT TWO-STAGE

FURNACE

RVS COOLING

HEAT STAGE 3

PURNACE HI

HEAT STAGE 2

{FURNACE LO)

HEAT/COOL STAGE 1

(COMPRESSOR)

FAN

24 VAC HOT [Rh

DEHUMIDIFY [DHUM

24 VAC COMM

HUMIDIFY [ HUM}

NIA

OUTDOOR

SENSOR

CONNECTION CH

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

Fig. 29 - Two-Stage Furnace with Single-Speed Heat Pump

(Dual Fuel)

A08180

SINGLE-SPEED

HEAT PUMP bo a

THERMIDISTAT TWO-STAGE

FURNACE

TWO-SPEED

HEAT PUMP

RVS COOLING [om] ee

HEAT/COOL STAGE 1 [YA

(COMPRESSOR LO)

HEAT STAGE 3

(FURNACE)

HEAT/COOL STAGE 2

{COMPRESSOR HI)

FAN

24vacHoTT Rh

DEHUMIDIFY

24 VAC COMM

HUMIDIEY [HOI notre

[| HUM ~s se Swooeeee 5

[> proworer] 4 !

(24 VAC)

' f

CONNECTION

wal 8 |

OUTDOOR

SENSOR

: '

‘

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

A03178

Fig. 30 - Two-Stage Furnace with Two-Speed Heat Pump

(Dual Fuel)

DUAL FUEL

THERMOSTAT

TWO-STAGE

FURNACE

SINGLE-SPEED

HEAT PUMP

RVS COOLING | O/W2 | J_--__---_---_--------------------

HEAT STAGE 3

(FURNACE HI)

HEAT STAGE 2 [WAW1|4_----------

(FURNACE LO)

. i \

HEAT/COOL STAGE 1

{COMPRESSOR) qi_---------J -

FAN fs } woeaea----4 zavaccomM[” Cc L4__---------4-[Com

[| HUM

L--[---------- -

N/A

RVS SENSING og

OUTDOOR

SENSOR

CONNECTION

See notes Lei 4,4 ree 1S. and 16 on the page following these figures op

~ oO

%

A08181

Fig. 31 - Dual-Fuel Thermostat with Two-Stage Furnace and Single-Speed Heat Pump

DUAL FUEL

THERMOSTAT

TWO-STAGE

FURNACE

RVS COOLING | O/w2

Dn

4 HEATICOOL STAGE 1 [Y1/W2]. J... ------- | Yt /--b---------- -

(COMPRESSOR LO) [Yt | i \ Nt

{FURNACE}

2] Y2

(COMPRESSOR HI)

NOTE 12

YN2 | .-[---------- -

[2]

24. VAC HOT } jnwnneneeeee -[ Rf

24. VAC COMM [° } ewenneee eee -[ cou } -- nonce eens - al

NIA | HUM

RVS SENSING [* ]

FAN [¢ } jenennnnene [2]

OUTDOOR

SENSOR

CONNECTION frrcrene 7

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

TWO-STAGE

THERMOSTAT

TWO-STAGE

FURNACE

TWO-SPEED

AIR CONDITIONER

Ww? |

Co}

NOTE 11

WW1}-4-----------4 -| WW4

NOTE 42

Y2 [Llivst te -| Y¥2 L--L--------

| Y2 |

| T

DHUM

-----------4 -}| Com lila

[--}-------- x Cc

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

A0g182

Fig. 32 - Dual-Fuel Thermostat with Two-Stage Furnace and Two-Speed Heat Pump

SINGLE-STAGE

THERMOSTAT

TWO-STAGE

FURNACE

A03183

Fig. 33 - Two-Stage Thermostat with Two-Stage Furnace and Two-Speed Air Conditioner

TWO-SPEED

AIR CONDITIONER

DHUM GUL

4-----------4 -| Com L--L----------

HUM

See notes 1 and 2 on the page following these figures

Fig. 34 - Single-Stage Thermostat with Two-Stage Furnace and Two-Speed Air Conditioner

A03184

NOTES FOR FIGURES 27 - 34

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

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

. If the heat pump date code is 1501E or earlier, select the “ZONE” position on the two-speed heat pump control. Heat pumps having date codes 1601E and later do not have or require a “ZONE” selection.

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

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

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

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

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

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

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

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

Thermostat to control furnace staging.

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

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

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

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

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

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

CHIMNEY INSPECTION CHART

For additional requirements refer to the National Fuel Gas Code NFPA 54/ANSI 2223.1 and ANSI/NFPA 211

Chimneys, Fireplaces, Vents, and Solid Fuel Burning Appliances

Crown condition:

Missing mortar

Rebuild crown. or brick?

Is chimney property lined with clay tile liner?

Yes

No ,

Repair liner or top seal or reline chimney as necessary.

Reline

Repair

Is liner and top seal in good condition?

Yes time? roof line?

Chi

Debris in cleanout?

Mortar, tile, metal vent,

Yes fuel oil residue?

4 No | Remove metal vent or liner.

Clay tile misalignment, missing sections, aps? gap

Condensate

¥ es

Yes

Mortar or tile debris?

Nes Remove ent >

Consult b>

“ PartBof chimney adapter venting

Not Suitable

Is chimney instructions for application suitability. c.

Line chimney with property lined with properly sized, listed liner or

Type-B vent?

NFGC Vent

Sizing Tables and liner or vent manufacturers

Installation instructions.

. Not Suitable

Yes p<

Is chimney a single to be dedicated to

Consult

Part C of ;

V_V_y “Chimney adapter ventingS Suitable instructions for furnace? application suitability

Install chimney a adapter per instructions.

Vv vv Chimney is acceptable for use.

Fig. 35 - Chimney Inspection Chart

A10133

Masonry Chimney Requirement

NOTE: These furnaces are CSA design-certified for use in exterior tile-lined masonry chimneys with a factory accessory

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

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

Fireplaces, Vents, and Solid Fuel Burning Appliances

ANSI/NFPA 211-2009 in the United States and must be in good condition.

U.S.A.-Refer to Sections 13.1.8 and 13.2.20 of the NFPA

54/ANSI Z223.1-2009 or the authority having jurisdiction to determine whether relining is required. If relining is required, use a properly sized listed metal liner, Type-B vent, or a listed alternative venting design.

NOTE: See the NFPA 54/ANSI Z223.1-2009 13.1.9 and

13.2.20 regarding alternative venting design and the exception, which cover installations such as our Chimney Adapter Kits which are listed for use with these furnaces. See Table 17 for accessory listing.

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

This furnace is permitted to be vented into a clay tile-lined masonry chimney that is exposed to the outdoors below the roof line, provided:

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

. This furnace is common vented with at least 1 draft hood equipped appliance, and

3. The combined appliance input rating is less than the maximum capacity given in Table 8, and

4. The input rating of each space heating appliance is greater than the minimum input rating given in Table 9 for the local 99% Winter Design Temperature. Chimneys having internal areas greater than 38 sq. in. (24516 sq. mm) require furnace input ratings greater than the input ratings of these furnaces. See footnote at bottom of Table 9, and

5. The authority having jurisdiction approves.

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

Inspections before the sale and at the time of installation will determine the acceptability of the chimney or the need for repair and/or (re)lining. Refer to the Fig. 33 to perform a chimney inspection. If the inspection of a previously used tile-lined chimney: a. Shows signs of vent gas condensation, the chimney should be relined in accordance with local codes and the authority having jurisdiction. The chimney should be relined with a listed metal liner, Type-B vent, or a listed chimney adapter kit shall be used to reduce condensation. If a condensate drain is required by local code, refer to the NFPA 54/ANSI Z223.1-2009, Sec- tion 12.10 for additional information on condensate drains. b. Indicates the chimney exceeds the maximum permissible size in the tables, the chimney should be rebuilt or relined to conform to the requirements of the equipment being installed and the authority having jurisdiction.

A chimney without a clay tile liner, which is otherwise in good condition, shall be rebuilt to conform to ANSI/NFPA 211 or be lined with a UL listed 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 shail be vented into the annular space between the chimney and the metal liner.

Exterior Masonry Chimney FAN + NAT

Installations with Type-B Double-Wall Vent

Connectors ONFPA & AGA

Table 8 - Combined Appliance Maximum Input

Rating in Thousands of Btuh per Hour

VENT HEIGHT

INTERNAL AREA OF CHIMNEY

SQ. IN. (SQ. MM)

FT (M) 12 19 28 38

(7741) (12258) (18064) (24516)

6 (1.8)

8 (2.4)

119

130

178

193

257

279

10 (3.0)

15 (4.5)

20 (6.0)

30 (9.1)

138

152

207

233

250

299

334

368

404

Appliance Application Requirements

Appliance operation has a significant impact on the performance of the venting system. If the appliances are sized, installed, adjusted, and operated properly, the venting system and/or the appliances should not suffer from condensation and corrosion.

The venting system and all appliances shall be installed in accordance with applicable listings, standards, and codes.

The furnace should be sized to provide 100 percent of the design heating load requirement plus any margin that occurs because of furnace model size capacity increments. Heating load estimates can be made using approved methods available from Air

Conditioning Contractors of America (Manual J); American

Society of Heating, Refrigerating, and Air-Conditioning

Engineers; or other approved engineering methods. Excessive oversizing of the furnace could cause the furnace and/or vent to fail prematurely.

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

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

1. The return-air temperature must be at least 60°F db except for brief periods of time during warm-up from setback at no lower than 55°F (13°C) db or during initial start-up from a standby condition.

. Adjust the gas input rate per the installation instructions.

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

2000 Ft. (610 M).

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

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

BURN HAZARD

Failure to follow this caution may result in personal injury.

Hot vent pipe is within reach of small children when installed in downflow position.

See the following instruction.

Table 9 - Minimum Allowable Input Rating of

Space-Heating Appliance in Thousands of Btuh per Hour

INTERNAL AREA OF CHIMNEY

VENT HEIGHT

FT. (M)

SQ. IN. (SQ. MM)

12 19 28 38

(7741) | (42258) | 18064) | (24516)

Local 99% Winter Design Temperature: 17 to 26 degrees F

6 0 55 99 141

141

125

154

169

15 NR

167

212

258

362

Local 99% Winter Design Temperature: 5 to 16 degrees F*

6 NR 78 121 166

8 NR

141

135

149

193

145

159

175

182

198

247

293

377

196

213

231

283

333

Local 99% Winter Design Temperature: —11 degrees F or

NR lower

Not recommended for any vent configuration.

*The 99.6% heating (db) temperatures found in the 1997 or 2001

ASHRAE Fundamentals Handbook, Climatic Design Information chapter,

Table 1A (United States) and 2A (Canada) or the 2005 ASHRAE Funda- mentals handbook, Climatic Design Information chapter, and the CD—

ROM included with the 2005 ASHRAE Fundamentals Handbook.

Air for combustion must not be contaminated by halogen compounds which include chlorides, fluorides, bromides, and iodides. These compounds are found in many common home products such as detergent, paint, glue, aerosol spray, bleach, cleaning solvent, salt, and air freshener, and can cause corrosion of furnaces and vents. Avoid using such products in the combustion-air supply. Furnace use during construction of the building could cause the furnace to be exposed to halogen compounds, causing premature failure of the furnace or venting system due to corrosion.

Vent dampers on any appliance connected to the common vent can cause condensation and corrosion in the venting system. Do not use vent dampers on appliances common vented with this furnace.

Additional Venting Requirements

A 4-in, (102 mm) round vent elbow is supplied with the furnace.

A 5-in. (127 mm) or 6- in. (152 mm) vent connector may be required for some model furnaces. A field-supplied 4-in. (102 mm) to 5-in. (127 mm) or 4-in. (102 mm) to 6-in. (152 mm) sheet metal increaser fitting is required when 5-in. (127 mm) or

6-in. (152 mm) vent connector is used. See Fig. 36 - 48, Venting

Orientation for approved vent configurations.

NOTE: Vent connector length for connector sizing starts at furnace vent elbow. The 4-in. (102 mm) vent elbow is shipped for upflow configuration and may be rotated for other positions.

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

The vent connector can exit the furnace through one of five locations on the casing. a ION

CUT HAZARD

Failure to follow this caution may result in personal injury.

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

1. Attach the single wall vent connector to the furnace vent elbow, and fasten the vent connector to the vent elbow with at least two field-supplied, corrosion-resistant, sheet metal screws located 180° apart.

NOTE: An accessory flue extension is available to extend from the furnace elbow to outside the furnace casing. See Table 17 for accessory listing. If flue extension is used, fasten the flue extension to the vent elbow with at least two field-supplied, corrosion-resistant, sheet metal screws located 180° apart. Fasten the vent connector to the flue extension with at least two field-supplied, corrosion resistant sheet metal screws located

180° apart.

2. Vent the furnace with the appropriate connector as shown in Fig. 36 - 48.

3. Determine the correct location of the knockout to be removed.

4. Use a hammer and screwdriver to strike a sharp blow between the tie points and work the slug back and forth until the slug breaks free.

An accessory Vent Guard Kit is REQUIRED for downflow applications for use where the vent exits through the lower portion of the furnace casing. Refer to the Vent Guard Kit

Instructions for complete details. See Table 17 for accessory listing.

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

. gs

Fig. 36 - Upflow Application - Vent Elbow Up

A03208

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

A03210

Fig. 38 - Downflow Application - Vent Elbow Up then Left

O ive]

Ts)

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

Fig. 37 - Upflow Application - Vent Elbow Right

A03209

CD

Zz Sng

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

Fig. 39 - Downflow Application - Vent Elbow Up

A0s2t1

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

A08207

Fig. 40 - Downflow Application - Vent Elbow Left then Up

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

A03212

Fig. 41 - Downflow Application - Vent Elbow Up then Right

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

A08213

Fig. 42 - Horizontal Left Application - Vent Elbow Left

4°

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

A08214

Fig. 43 - Horizontal Left Application - Vent Elbow Right then Up

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

A03218

Fig. 44 - Horizontal Right Application - Vent Elbow Right

i!

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

h

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

A0g215

Fig. 45 - Horizontal Left Application - Vent Elbow Up

A0g219

Fig. 47 - Horizontal Right Application - Vent Elbow Left then Up

Tul he

O

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

_ J

4

A03216

Fig. 46 - Horizontal Left Application - Vent Elbow Right

ES 4 f _

Pn

‘SN

CIE a,

tH

: sa 5

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

A02068

Fig. 48 - Horizontal Right Application- Vent Elbow Left

VENTING NOTES FOR FIG. 36 - 48

1. For common vent, vent connector sizing and vent material: United States--use the NFGC,

Immediately increase to 5-in. (102 mm) or 6-in. (152 mm) vent connector outside furnace casing when 5-in. (127 mm) vent connector is required, refer to Note 1 above.

. Side outlet vent for upflow and downflow installations must use Type B vent immediately after exiting the furnace, except when factory-approved Downtflow Vent Guard Kit is used in the downflow position. See Table 17 for accessory listing.

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

. A 4-in.(102 mm) single-wall (26 ga. min.) vent must be used inside furnace casing and when the factory-approved Downtlow Vent

Guard Kit is used external to the furnace. See Table 17 for accessory listing.

. Accessory Downflow Vent Guard Kit required in downflow installations with lower vent configuration. See Table 17 for accessory listing.

. Chimney Adapter Kit may be required for exterior masonry chimney applications. Refer to Chimney Adapter Kit for sizing and complete application details. See Table 17 for accessory listing.

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

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

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

Fig. 38.) wn ww

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

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

FURNACE VENT ORIENTATION FURNACE INPUT MIN. VENT MIN. VERTICAL VENT

ORIENTATION

(

BTUH/HR

)

DIAMETER HEIGHT

Downflow Vent ee a then up 454,000 132,000 110,000 5 (127) 12 (3.6)

Horizontal Left Vent ea 30. then up 454,000 132,000 5 (127) 7 (2.1)

Horizontal Left ven wo up 154,000 132,000 5 (127) 7 (2.4)

Horizontal Left Vent ee right ig. 41

454,000 5 (127) 7 (2.4)

Downflow Vent etpew up then left ig. 34

410,000 5 (127) 10 (8.0)

Downflow Vent ee aT right 410,000 5 (127) 10 (8.0)

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

*4—in. (102 mm) inside casing or vent guard

**Including 4 in. (102 mm) vent section(s)

The horizontal portion of the venting system shall slope upwards not less than 1/4-in. per linear ft. (21 mm/m) from the furnace to the vent and shall be rigidly supported every 5 ft. (1.5 M) or less with metal hangers or straps to ensure there is no movement after installation.

Sidewall Venting

This furnace is not approved for direct sidewall horizontal venting.

Per section 12.4.3 of the NFPA 54/ANSI Z223.1-2009, any listed mechanical venter may be used, when approved by the authority having jurisdiction.

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

START-UP, ADJUSTMENT, AND SAFETY

CHECK

General

3. Gas supply pressure to the furnace must be greater than

4.5-In. W.C, (0.16 psig ) but not exceed 14-In. W.C. (0.5 psig).

4, Check all manual-reset switches for continuity.

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

6. Setup switch descriptions The variable speed furnace control has DIP switches to select thermostat staging, blower off delay timings, air flow selection and other operational or service related functions. (See Fig. 26, 53 and Table

10.)

CUT HAZARD

Failure to follow this caution may result in personal injury.

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

PLASTIC ADJUST SCREW

FIRE HAZARD

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

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

Correct problem before resetting the switches.

1. Maintain 115-v wiring and ground. Improper polarity will result in rapid flashing LED and no furnace operation.

2. Make thermostat wire connections at the 24-v terminal block on the furnace control. Failure to make proper connections will result in improper operation. (See Fig. 25 -

34.)

ON/OFF SWITCH

HIGH STAGE GAS

[> PRESSURE REGULATOR

) ADJUSTMENT

LOW STAGE

GAS PRESSURE

REGULATOR ADJUSTMENT

MANIFOLD

PRESSURE TAP

Fig. 49 - Redundant Automatic Gas Control Valve

A04167

Start-Up Procedures

\ i |

BURNER

ORIFICE

FIRE OR EXPLOSION HAZARD

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

4 WARNING posose

Fig. 50 - Orifice Hole

ELECTRICAL SHOCK HAZARD

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

Blower access door switch opens 115-v power to control.

No component operation can occur unless switch is closed.

Caution must be taken when manually closing this switch for service purposes.

THERMOSTAT SUBBASE

TERMINALS WITH

THERMOSTAT REMOVED

HOOK-AROUND

AMMETER

: 7 :

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

2. Check gas lines for leaks.

3 . To Begin Component Self-Test:

Remove Blower Access Door. Disconnect the thermostat

R lead from furnace control board. Manually close blower door switch. Turn Setup DIP switch SW1-6 ON. (See Fig.

26, 53 and Table 10.)

NOTE: The furnace control allows ail components, except the gas valve, to be run for short period of time. This feature helps diagnose a system problem in case of a component failure.

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

Refer to service label attached to furnace or See Fig. 52.

Component test sequence is as follows: a. Inducer motor starts on high-speed and continues to

N run until Step d. of component test sequence. b. Hot surface igniter is energized for 15 sec., then off. c. Blower motor operates for 15 sec.

EROM UNIT 24-V

CONTROL TERMINALS d. Inducer motor goes to low-speed for 10 sec., then stops. e. After component test is completed, one or more status

EXAMPLE: 5:0: AMPS ON AMMETER _ _ 0.5 AMPS FOR THERMOSTAT

‘ 4OTURNS AROUND JAWS ~ ANTICIPATOR SETTING codes (11, 25, or 41) will flash. See component test section of service label (Fig. 52) in furnace for explanation of status codes.

Ag6316

Fig. 51 - Amp. Draw Check with Ammeter NOTE: To repeat component test, turn setup switch SW1-6

OFF, then back ON.

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

5. Operate furnace per instruction on inner door.

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

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

Table 10 — Furnace Setup Switch Description

Furnace Setup Switch Description

SETUP SWITCH SWITCH NAME NORMAL POSITION DESCRIPTION OF USE

‘Turn ON to retrieve up to 7 stored status codes for

SW1-1 Status Code Recovery OFF troubleshooting assistance when R thermostat lead is disconnected.

When SW1-2 is OFF allows low heat operation with a eZO

| a o bo

SW1-2

Low Heat Only

(Adaptive Heat Mode when SW1

2 is OFF)

OFF single stage thermostat. Turn ON when using two- stage thermostat to allow Low Heat operation when R to WAW1 closes and High Heat operation when R to

WW and W2 close.

Turn ON to increase Low Heat airflow by 18 percent.

SW1-3 Low Heat Rise Adjustment OFF

This compensates for increased return air temperature caused with bypass humidifier. This also eg os ae

= Cy i

‘Turn ON to decrease low heat airflow by 7 percent,

SW1-4 Comfort/Efficiency Adjustment ON increases the low heat inducer speed 15 percent. and high heat airflow 10 percent for maximum comfort.

SW1-5 CFM per ton adjust OFE

TI umm ON for 400 CFM per ton, Turn OFF for per ton. See also SW4. ton, Turn OFF for 350 CFM

‘Turn ON to initiate Component Self Test for mo

; ah a os y ox}

C op

SW1-6

SW1-7 & SW1-8

Component Self Test

Blower OFF delay perton Agus

OFF

ON or OFF

¢ tee S t | ol

= | Irn oo gen cs

CFM

OFF troubleshooting assistance when R thermostat lead is disconnected. Turn OFF when Self Test is completed.

Blower Off Delay time — adjustable 90 seconds to 180 seconds. See table in Adjustments section or refer to unit wiring diagram.

Allows additional CFM per ton selections when used with SW 1-5

325 CFM per ton (nominal) when SW 4-3 ON and SW

1-5 OFF

350 CFM per ton (nominal) when SW 4-3 OFF and

SW 1-5 OFF

370 CFM per ton (nominal) when SW4-3 ON and SW

1-5 ON

400 CFM per ton (nominal) when SW 1-5 ON and SW

4-3 OFF

See Air Delivery Tables for model specific CFM vs. static pressure

1P S60 a ~

= a» a

IPG a ]- ie)

=|} ET] a Bo).

AIR CONDITIONING (A/C) SETUP SWITCHES

SW 2, AC (Cooling Airflow) SETUP SWITCHES

The AC setup switch selects desired cooling or high stage cooling (two stage units) airflow.

See Cooling Air Delivery Tables for specific switch settings.

CONTINUOUS FAN (CF) SETUP SWITCHES

SW 3, CF (Continuous Fan) SETUP SWITCHES

The CF setup switch selects desired Continuous Fan Airflow

The CF switch position is the low cooling airflow selection for two stage cooling units.

The CFM values are shown in the Air Delivery Tables below for SW 3 settings.

SW 3 cannot be set for airflow higher than SW 2.

See Continuous Fan Air Flow Table for specific switch settings.

A12092

a I RT| MER

SERVICE

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

LED CODE STATUS

CONTINUOUS OFF - Check for 115VAC atL1 and L2, and 24VAC at SEC-1 and SEC-2.

CONTINUOUS ON - Control has 24VAC power.

RAPID FLASHING - Line voltage (115V AC) polarity reversed.

EB EACH OF THE FOLLOWING STATUS CODES ISA TWO DIGIT NUMBER WITH THE FIRST DIGIT DETERMINED BY THE NUMBER OF SHORT FLASHES AND THE SECOND DIGIT BY THE NUMBER OF LONG FLASHES. i 11 NO PREVIOUS CODE - Stored status codes are erased automatically after 72 32 Continued: Check for: - Low inducer voltage (116 VAC) hours or as specified above.

12 BLOWER ON AFTER POWER UP (115 VAC or 24 VAC) -Blower runs for 90 seconds, if unit is powered up during a cail for heat (R-W/\W1 closed) or

13 LIMIT oe ocke Loc Such fused) open longer graftsafequard flame

Guccessive limit trips occurred durin fi igh heat Control will auto reset after

- Defective inducer motor

- Defective pressure switch

- Low inducer voltage (115 VAC)

- Inadequate combustion air supply

- Low inlet gas pressure (if LGPS used)

- Disconnected or obstructed pressure tubing

33 LIMIT CIRCUIT FAULT - indicates a limit, draft safeguard, flame rollout, or blocked vent switch (if used} is open or the furnace is operating in high-heat only mode due to 2 successive low heat limit trips. Blower will run for 4 minutes or until open switch remakes whichever is longer. Hf open longer

241 the blower failed to eyes Con within 30 seconds after being jumed ON in two successive heating cycles. Control will auto reset after 3 hours

Refer to status code

22 ERCRAE EUR rrovins SIENA Bate Spore thease

de-energized. inducer wil run until fault is cleared. Check for:

[ 23 phgak Bae pase Ob a wae for:

"Obstructed pressure tubing.” ~ Presstte Snitch stuck closed

Jug is missing or incorrect of, setup switch "SW1-1" ly. If code flashes 4 th

W1-6" is positioned

7 ‘i defaulting t del selechon ored in memory. Check fon power-up conta is deaunng Ny vic Sr lug 007. - Proper model plug number and resistance values per wiring diagram

341 PIS erear PRESSURE SWITCH OR RELAY DID NOT CLOSE OR

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

- If open longer than five minutes, inducer shuts off for 15 minutes before retry. If opens

COMPONENT TEST

To initiate the component test sequence, shut

OFF the room thermostat or disconnect the "R” thermostat lead. Reset power and then put setup switch "SW1-6" in the ON position to start the component test sequence. Once initiated the furnace control will turn the inducer ON at high-

- than 3 minutes, code changes to lockout #13. ff open less than 3 minutes status code #33 continues to flash until blower shuts off. Flame rollout switch and eves require manual reset. _ Check for - Loose Blower wheel

Restricted vent ~ Proper vent sizing

- Dirty filter or restricted duct system

=~ EXCessive Win

- Defective switch or connections

eee

entire test. The hot surface igniter and blower motor will be tured ON for 1 seconds each.

When the bi is t d OFF the ind:

eS ger | teflon coder ah

ill be switched to low-speed for 10 seconds, When the component test is completed one or more of jockou occurs. If flame signal lost during blower on-delay period, blower will come on for the selected blower off-delay. Check for:

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

"Gas valve defective or turned off

Flame sensor must not be grounded

CODE DESCRIPTION

«Motul valve chutof "Low mist gas pressure Contol ground contnutty | 17 indicates the blower motor tested

- Inadequate flame carryover or rough ignition

41 BLOWER MOTOR FAULT - Indicates the blower failed to reach 250 RPM or the blower failed to communicate within the prescribed times limits. Thirty

25 and hot surface ignfer required.

~ Indi

4“ BLOWER MOTOR FAULT « Indicates

- Mis-wired pressure switches

To repeat component test tum setup switch

- Low-heat pressure switch stuck open - Low inlet gas pressure {if LGPS used) [| “SW1-6" OFF and then back ON. After component

- Disconnected or obstructed pressure tubing

45 CONTROL CIRCUITRY LOCKOUT Auto-1 eset after one hour lockout due to; test is completed put setup switch “SW1-6" in the

OFF position and reconnect the "R” thermostat

328787-101 REV. A

A04015

Fig. 52 - Service Label

Adjustments

CUANDO:

FIRE HAZARD

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

DO NOT bottom out gas valve regulator adjusting screw.

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

4& CAUTION

FURNACE DAMAGE HAZARD

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

DO NOT = redrill orifices. Improper drilling (burrs, out-of-round holes, etc.) can cause excessive burner noise and misdirection of burner flames. This can result in flame impingement of heat exchangers, causing failures. (See Fig.

50.)

Furnace gas input rafe on rating plate is for installations at altitudes up to 2000 Ft. (610 M). Furnace input rate must be within +/-2 percent of furnace rating plate input. For altitudes above 5500 Ft. (1676 M), a field-supplied high altitude pressure switch is required.

1. Determine the correct gas input rate.

The input rating for altitudes above 2,000 ft. (610 M) must be reduced by 4 percent for each 1,000 ft. (305 M) above sea level.

For installations below 2000 Ft. (610 M), refer to the unit rating plate. For installations above 2000 Ft. (610 M), multiply the input on the rating plate by the de-rate multiplier in Table 10 for the correct input rate.

. Determine the correct orifice and manifold pressure adjustment. All models in all positions except Low NOx models in downflow and horizontal positions use Table 14

(22,000 Btuh per burner.) Low NOx models in downflow or horizontal positions must use Table 15 (21,000 Btuh per burner.) See input listed on rating plate. a. Obtain average yearly gas heat value (at installed altitude) from local gas supplier. b. Obtain average yearly gas specific gravity from local gas supplier. c. Find installation altitude in Table 14 or 15. d. Find closest natural gas heat value and specific gravity in Table 14 or 15. e. Follow heat value and specific gravity lines to point of intersection to find orifice size and low-and high-heat manifold pressure settings for proper operation. f. Check and verify burner orifice size in furnace.

NEVER ASSUME ORIFICE SIZE. ALWAYS

CHECK AND VERIFY.

NOTE: If orifice hole appears damaged or it is suspected to have been redrilled, check orifice hole with a numbered drill bit of correct size. Never redrill an orifice. A burr-free and squarely aligned orifice hole is essential for proper flame characteristics. g. Replace orifice with correct size, if required by Table

14 or 15. Use only factory-supplied orifices. See

EXAMPLE 1.

Table 11 - Altitude Derate Multiplier for U.S.A.

ALTITUDE PERCENT DERATE MULTIPLIER

FT. (M) OF DERATE FACTOR*

(o-610) 0 4.00 more | a sera) ae worse | seo soreness ae | eae

Tere | ase

Sere | see soo romme | geo ore a70

=

= ose

08 ore

S) wh

Table 12 — Blower Off Delay Setup Switch

SETUP SWITCH

DESIRED HEATING MODE

BLOWER OFF DELAY (SEC.)

(SW-7 AND -8)

POSITION

Swi-7 swi-8

120

OFF

150

180

OFF

EXAMPLE 1: 0-2000 ft. (0-610 M) altitude

For 22,000 Btuh per burner application use Table 14.

Heating value = 1000 Btuh/cu ft.

Specific gravity = 0.62

Therefore: Orifice No. 43*

Manifold pressure: 3.7-In. W.C. for high-heat

1.6-In. W.C. for low-heat

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

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

Fig. 49.) a. Turn gas valve ON/OFF switch to OFF. b. Remove manifold pressure tap plug from gas valve. c. Connect a water column manometer or similar device to manifold pressure tap. d. Turn gas valve ON/OFF switch to ON. e. Move setup SW1—2 on furnace control to ON position to lock furnace in low-heat operation. (See Table

10 and Fig. 24.) f. Manually close blower door switch. g. Jumper R and W/W1 thermostat connections on control to start furnace. (See Fig. 24.) h. Remove regulator adjustment cap from low heat gas valve pressure regulator (See Fig. 49.) and turn low- heat adjusting screw (3/16 or smaller flat-tipped screwdriver) counterclockwise (out) to decrease input rate or clockwise (in) to increase input rate.

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

1.4-In. W.C. or more than 1.7-In. W.C. for natural gas. If manifold pressure is outside this range, change main burner orifices. i. Install low-heat regulator adjustment cap. j. Move setup switch SW1-2 to off position after completing low-heat adjustment. k. Leave manometer or similar device connected and proceed to Step 4.

4, Adjust manifold pressure to obtain high fire input rate.

(See Fig. 49.) a. Jumper R to W/W1 and W2 thermostat connections on furnace control. This keeps furnace locked in high- heat operation. b. Remove regulator adjustment cap from high-heat gas valve pressure regulator (See Fig. 49) and turn high heat adjusting screw (3/16-in. or smaller flat-tipped screwdriver) counterclockwise (out) to decrease input rate or clockwise (in) to increase input rate.

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

3.2-In. W.C. or more than 3.8 In. W.C. for natural gas. If manifold pressure is outside this range, change main burner orifices to obtain manifold pressure in this range. c. When correct input is obtained, replace caps that con- ceal gas valve regulator adjustment screws. Main burner flame should be clear blue, almost transparent

(See Fig. 55.) d. Remove jumpers R to W/W1 and R to W2.

5. Verify natural gas input rate by clocking meter.

NOTE: Gas valve regulator adjustment caps must be in place for proper input to be clocked. a. Turn off all other gas appliances and pilots served by the meter. b. Move setup switch SW1-2 to ON position. This keeps furnace locked in low-heat operation. c. Jumper R to W/W1. d. Run furnace for 3 minutes in low-heat operation. e. Measure time (in sec) for gas meter to complete 1 revolution and note reading. The 2 or 5 cubic feet dial provides a more accurate measurement of gas flow. f. Refer to Table 13 for cubic ft. of gas per hr. g. Multiply gas rate cu ft./hr by heating value (Btuh/cu ft.) to obtain input. If clocked rate does not match required input from Step 1, increase manifold pressure to increase input or decrease manifold pressure to decrease input. Repeat steps b through e until correct low-heat input is achieved. Re-instail low heat regulator seal cap on gas valve. h. Move setup switch SW1-2 to OFF position and jumper R to W/W1, and W2. This keeps furnace locked in high-heat operation. Repeat items d through g for high-heat operation.

6. Set Temperature Rise

NOTE: Blower access door must be installed when taking temperature rise reading. Leaving blower access door off will result in incorrect temperature measurements.

FURNACE DAMAGE HAZARD

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

Set air temperature rise within limits specified on the rating plate to prevent reduced life of furnace components.

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

UNIT DAMAGE HAZARD

Failure to follow this caution may result in overheating the heat exchangers or condensing flue gases in heat exchanger areas not designed for condensate.

Temperature rise must be within limits specified on unit rating plate. Operation is within a few degrees of midpoint of rise range when setup switch SW1-4 is OFF.

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

Furnace must operate within ranges of temperature rise specified on the furnace rating plate. Determine air temperature rise as follows: a. Place thermometers in return and supply ducts as near furnace as possible. Be sure thermometers do not see heat exchanger so that radiant heat does not affect readings. This practice is particularly important with straight-run ducts.

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

NOTE: Temperature rise can be determined for low-heat operation by placing setup switch SW1-2 on furnace control in

ON position. For high-heat operation, place setup switch SW1-2 in OFF position and jumper R-W2 on furnace control. DO NOT forget to return setup switch to OFF position and remove R-W2 jumper upon completion of testing. c. This furnace is capable of automatically providing proper airflow to maintain the temperature rise within the range specified on furnace rating plate. If temperature rise is outside this range, proceed as follows:

(1.) Check gas input for low- and high-heat operation.

(2.) Check derate for altitude if applicable.

(3.) Check all return and supply ducts for excessive restrictions causing static pressure greater than

0.5-In. W.C..

(4.) Ensure Low Heat Rise Adjust switch SW1-3 on furnace control is in ON position when a bypass humidifier is used. (See Fig. 26 for switch location.)

(5.) Make sure proper model plug is installed. d. Remove thermostat jumpers and release blower access door switch. e. Repeat Steps a through c as required to adjust for high heat temperature rise. f. When correct high heat input rate and temperature rise is achieved, turn gas valve ON/OFF switch to OFF. g. Release blower access door switch. h. Remove manometer or similar device from gas valve. i. Re-install manifold pressure tap plug in gas valve.

(See Fig. 49.)

FIRE HAZARD

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

Reinstall manifold pressure tap plug in gas valve to prevent gas leak. j. Remove thermostat jumper wire from furnace control board. k. Turn gas valve ON/OFF switch to ON.

FURNACE OVERHEATING HAZARD

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

Recheck temperature rise. It must be within limits specified on the rating plate. Recommended operation is at the mid-point of rise range or slightly above.

1. Proceed to Step 6, “Set Blower Off Delay” before installing blower access door.

7, Set Blower Off Delay a. Remove blower access door if installed. b. Turn Dip switch SW-7 or SW-8 ON or OFF for desired blower off delay. (See Table 10 and Fig. 26 and

53.)

8. Set thermostat heat anticipator. a. Mechanical thermostat. Set thermostat heat anticipator to match the amp. draw of the electrical components in the R-W/W1 circuit. Accurate amp. draw readings can be obtained at the wires normally connected to thermostat subbase terminalis, R and W. The thermostat anticipator should NOT be in the circuit while measur- ing current.

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

ON.

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

(3.) Connect an amp. meter as shown in Fig. 51. across the R and W subbase terminals or R and

W wires at wall.

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

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

(6.) Turn SW1-2 switch OFF.

(7.) Install blower access door. b. Electronic thermostat: Set cycle rate for 3 cycles per hr.

9, Set Airflow for Air Conditioning -Single Stage and High

Stage Cooling

The ECM blower can be adjusted for a range of airflow for Low Speed or High Speed cooling. See Table 5-Air

Delivery - CFM (With Filter ), Depending on the model size, the cooling airflow can be adjusted from 1. tons nominal cooling to 3 ., to 4 or to 6 tons of nominal cooling based on 350 cfm ton.

The cooling airflow is adjusted by turning Setup switches

SW2-1, SW2-2 and SW2-3 either ON or OFF. Select the required airflow from Fig. 57. Fig. 57 is based on 350

CFM per ton. For airflow at 400 CFM per ton, turn Setup

SW1-5 ON (See Table 10 and Fig. 26 and 53.)

NOTE: 6 ton airflow will truncate at 2200 cfm on applicable models. For a complete explanation of cooling airflow, refer to the section titled “Sequence of Operation.”

10. Set Airflow For Continuous Fan/Low Speed Cooling Air- flow The ECM blower motor can be adjusted for continuous fan speeds different than heating or cooling fan speed.

See Table 5 - Air Delivery - CFM (With Filter). Select the required continuous fan airflow from Fig. 57.

The continuous fan speed is also the fan speed for low speed cooling when furnace is used with a 2-speed cooling unit. Adjust the Continuous Fan CFM to match the airflow required for low speed cooling. Select the required airflow from Fig. 55. For airflow at 400 CFM per ton, turn

Setup SW1-5 ON (See Fig. 57.) The airflow selected for low speed cooling will also be the airflow used for continuous fan.

The continuous fan speed can be further adjusted at the thermostat using the “Comfort Fan” select function.

Changing the continuous fan speed at the thermostat

DOES NOT change the low speed cooling airflow selected at the control board.

sys] 04]

|

TO 415VAC FIELD - DISCONNECT SWITCH SCHEMATIC DIAGRAM

}

BLOWER OFF DELAY

SELECTION i: 3 12

SEC.

120

SEC

150

| SEC |

180

SEC

NOTE #3

CONNECTION DIAGRAM NOTE #12

ORNC REI RED ORN

RED

FRSt pss

POTS TO

GRNIYEL YEL

BVSS 182

(WHEN USED) (WHEN USED)

ORN a tS FRE2

FUSE OR CIRCUIT

BREAKER DISCONNECT

WHO p>

FSE

LGPS (WHEN USED)

Lt) a ae

: i i Fu2,

I i

1 NEUTRAL

GND

2 = n

= g oq

PLU yur

3]

size | PLUG x

3 g q

AIC OR CF AIRFLOW SECTION CHART BASED ON 350 CFM/TON

090 DER,” 525 8751050 | 1225 1400

DER 700 © 8752] 1050 ; 1225 | 1400: 14

1, Default A/C airflow when A/C switches are in OFF position.

2100

2. Default cont. fan airflow when CF switches are in OFF position, lc

2|| 8

= oO

COMM a =

Sri dll o

& B oS Bile, G TNorews [

BLU

2 SU

Y1 DHUM G Sor Wt YY2 f Sus 2

WHT t

|

rr

ren ben fone fon ged =

kw i

I pt

TAQ

2 a o rh

Rr Puto 63) ix EQUIPMENT ht

GROUND gi2

OTE#S

HSI

1 e a

—

1H @

Ly»

3 COM

PCB LI PLA

IDM

>

etter mf

PLB it ee be fA ie.

IND

NOTE #7, ra Puzo

7 mel

EAC co EAC-1

BLWM

ch Lee

ERED

EAC-2 e+ |e {] 0

Ld 41svac L2 e

TRAN

SEC2 Pie ui

24VAC,

(WHEN USED) *- eee

HUMR a

L Ac Air Conditioning (Adjustable Airflow - CFM) ILK Blower Door Interlock Switch, SPST (N.O.) @ JUNCTION

E ACR Air Conditioning Relay, SPST (N.O.) IND Inductor (Note #7)

ACRDJ Air Conditioning Relay Defeat Jumper

BLWM

E BVSS

Blower Motor (ECM)

Blocked Vent Safety Switch, Manual Reset,

SPST (N.C.)

Continuous Fan (Adjustable Airflow - CFM)

LED

LGPS

LPS

LS1,2

PCB

Light Emitting Diode for Status Codes

Low Gas Pressure Switch, SPST (N.O.)

Low-Heat Pressure Switch, SPST (N.O.)

Limit Switch, Auto-Reset, SPST (N.C.}

Printed Circuit Board oO ee

TERMINAL

FACTORY POWER a a

3 a

CONTROL TERMINAL |?

5 COMMR Communication Relay, SPDT

CPU

DHUM

Dss

Microprocessor 7 Circultry

DHUM Connection (24VAC 0.02 Amps)

Draft Safeguard Sw., Auto-Reset, SPST (N.C.)

Pui

PL2

PL3

PL4

42-Cireuit Connector

4-Circuit HSI & IDM Connector

4-Circuit ECM BLWM Connector

4-Circuit Model Plug Connector ——

WIRING (115VAC}

FACTORY CONTROL NOTES:

EAC-1 Electronic Air Cleaner Connection

(V1SVAC 1.0 Amp Max,}

EAC-2 Electronic Air Cleaner Connection (Common)

FRS

FSE

FUSE

Flame Rollout Switch, Man. Reset, SPST (N.C.}

Flame-Proving Sensor Electrode

Fuse, 3 Amp, Automotive Blade Type,

Factory Installed

Gas Valve

GVR

HPS

HPSR

HSI

Gas Valve Relay, DPST(N.O.)

High-Heat Pressure Switch, SPST(N.O.)

_—_—High-Heat Pressure Switch Relay, SPST(N.C.}

Hot Surface Igniter (145VAC)}

HSIR Hot Surface Igniter Relay, SPST(N.O.)

HUM 24VAC Humidifier Connection (0.5 Amp Max.)

HUMR Humidifier Relay, SPST (N.O.)

PLT

PLO

PLI0

PL12

PLi3

2-Circuit HSI Connector

IDM Connector (3-Circuit)

1-Circuit Inductor Splice Connector

4-Circuit ECM Blower CTRL Connector

PL14 5-Circuit ECM Blower Power Connector ———

SW1-1 Manual Switch, Status Code Recall, SPST(N.O.) = 7777

SW1-2 Manual Switch, Low-Heat Only, SPST (N.0.}

SW1-3

SW1-4

Manual Switch, Low-Heat Rise Adj, SPST (N.0.)

Manual Switch, Comfort/Efficiency Adjustment,

SPST (N.O.)

$W1-5 Manual Switch, Cooling CFIM/Ton, SPST (N.O.)

SW1-6 Manual Switch, Component Test, SPST (N.O.)

SW1-7,8 Manual Switches, Slower Off-Delay, SPST (N.O.)

WIRING (24VAC)

FIELD CONTROL

WIRING (24VAC)

CONDUCTOR ON

CONTROL i. If any of the original eqquipment wire is replaced use wire rated for 105°C.

2, Use only copper wire between the disconnect switch and the furnace junction box (JB).

3. This wire must be connected fo furnace sheet metal for control to prove flame.

4. Symbols are electrical representation only.

5, Solid lines inside PCB are printed circuit ‘board conductors and are not included in legend.

8. Replace only with a 3 amp fuse.

7. Inductor is used with 3/4 hp and 1 hp ECM Blower motors.

8. Factory connected when (LGPS) not used. :

FIELD WIRING

9. Blower off-delay, gas heating selections are (90, 120, 150, 180) seconds, cooling or heat pump 90 seconds —

SCREW TERMINAL | 10. Ignition lockout will occur after four consecutive unsuccessful trials for ignition. Control

EQUIPMENT

GROUND will auto-reset after three hours. .

12, Factory connected when BYSS is not used, BVSS used when Chimney Adapeter

IDM

IDR

Inducer Draft Motor, 2-Speed, Shaded Pole

Inducer Motor Relay, SPST (N.O.)

{HI/LOR Inducer Motor Speed Change Relay, SPDT

Accessory Kit is installed. , ;

13. Any of the 5 wires shown within the NEUTRAL L2 box can be connected to any terminal within the box.

—<{€- — aiygrecepracte | 14. Blower motor (BLWM) is locked-rotor overload protected by redundant electronic control circults.

SW4-1 Manual Switch, Twinning Main (OFF) / Sec, (ON)

SW4-283 For Future Use

TRAN

Lu ao

2 e oS ro]

Table 13 — Gas Rate (CU ft./hr)

SECONDS G SIZE OF TEST DIAL SECONDS SIZE OF TEST DIAL

FOR 1 REVOLUTION 4 Cu Ft. 2 Cu Ft. 5 Cu Ft. FOR 1 REVOLUTION 4 Cu Ft. 2 Cu Ft. 5 Cu Ft.

360

327

720

655

1800

1636

144

141

360

355

300

277

257

240

225

212

200

189

600

555

514

480

450

424

400

1500

1385

1286

1200

1125

1059

1000

138

136

133

131

129

126

124

346

340

333

327

324

316

310

180

171

164

157

150

144

138

133

379

360

343

327

313

300

288

277

267

947

900

857

818

783

750

720

692

667

122

120

116

112

109

106

103

100

305

300

290

281

273

265

257

250

243

129

124

120

116

113

109

106

103

100

257

180

176

172

167

164

160

157

153

643

A19

409

400

301

383

100

102

104

106

108

110

112

116

248

240

232

225

218

212

206

200

195

189

185

624

600

581

563

545

529

514

500

486

474

462

450

439

429

234

225

220

214

209

205

200

196

192

188

237

184

180

178

173

170

167

164

161

155

150

147

375

367

120 30 60 150

Table 14 - Orifice Size and Manifold Pressure (In. W.C.) for Gas Input Rate

(Tabulated Data Based on 22,000 Btuh High-Heat/14,500 Btuh for Low-Heat per Burner, Derated 4 Percent for Each 1000 Ft.

(305 M) Above Sea Level)

AVG. GAS 0.58

SPECIFIC GRAVITY OF NATURAL GAS

0.60 0.62 0.64

AT HEAT VALUE Orifice Manifold Orifice

(BTUH/CU FT.) No Pressure No

900 42

‘ High/Low

3.5/1.5 42

‘

Manifold

Pressure

High/Low

3.6/1.6

Orifice

‘

Manifold

Pressure

High/Low

3.7/1.6

Orifice

‘

Manifold

Pressure

High/Low

3.5/1.5

USA

Oto

2000

925

950

975

1000

3.3/1.4

3.8/1.7

3.6/1.6

3.5/1.5

3.4/1.5

3.3/1.4

3.8/1.6

3.6/1.6

3.5/1.5

3.4/1.5

3.2/1.4

3.7/1.6

3.5/1.5

3.3/1.4

3.8/1.7

(0 to 610) 1025

1050

1075

1100

3.3/1.4

3.6/1.6

3.4/1.5

3.3/1.4

3.4/1.5

3.2/1.4

3.5/1.5

3.4/1.5

3.5/1.5

3.4/1.5

3.2/1.4

3.5/1.5

3.6/1.6

3.5/1.5

3.3/1.4

3.2/1.4

ALTITUDE RANGE

FT. (M)

0.58 0.60 0.62 0.64

AVG. GAS

HEAT VALUE Orifice

Manifold Orifice

Manifold Orifice Pressure Orifice

Manifold

High/Low High/Low ighyLow High/Low

800 42 3.4/1.5 42 3.5/1.5 42 3.6/1.6 42 3.7/1.6

825

850

3.2/1.4

3.7/1.6

3.3/1.4

3.8/1.6

3.4/1.5

3.2/1.4

3.5/1.5

3.3/1.4

USA

2001 to

3000 (610 to 914)

875

900

925

950

975

1000

3.5/1.5

3.3/1.4

3.5/1.5

3.4/1.5

3.2/1.4

3.7/1.6

3.6/1.6

3.4/1.5

3.2/1.4

3.5/1.5

3.3/1.4

3.8/1.7

3.7/1.6

3.5/1.5

3.3/1.4

3.6/1.6

3.4/1.5

3.2/1.4

3.8/1.7

3.6/1.6

3.4/1.5

3.2/1.4

3.5/1.5

3.4/1.5

ALTITUDE RANGE

FT. (M)

AVG. GAS

0.58 0.60 0.62 0.64

: : :

High/Low High/Low ighyLow High/Low

775 42 3.2/1.4 42 3.3/1.4 42 3.4/1.5 42 3.5/1.5

3001 to

800

825

3.6/1.6

3.4/1.5

3.8/1.6

3.5/1.5

3.2/1.4

3.7/1.6

3.3/1.4

3.8/1.6

USA 4000

(914 to

1219)

850

875

900

925

3.2/1.4

3.5/1.5

3.3/1.4

3.6/1.6

3.4/1.5

3.3/1.4

3.5/1.5

3.8/1.6 44 3.2/1.4 44 3.3/1.5

950 46 3.8/1.6 45 3.7/1.6 45 3.8/1.7

SPECIFIC GRAVITY OF NATURAL GAS

3.6/1.5

3.4/1.5

3.2/1.4

3.4/1.5

3.3/1.4

ALTITUDE RANGE

FT. (M)

AVG. GAS

HEAT VALUE | Orifice | Manifold | oyificg | Manifold | oritice | Pressure | Orifice | Manifold

(BTUH/CU FT) No ove

: oe

: oe oe

Pressure No Pressure No High/Low No Pressure

‘ ‘ High/Low ‘ High/Low ‘ g ‘ High/Low

750

775

3.6/1.6

3.4/1.5

3.8/1.6

3.5/1.5

3.2/1.4

3.6/1.6

3.3/1.4

3.8/1.6

USA

4001 to

5000

800

825

3.2/1.4

3.4/1.5

3.3/1.4

3.6/1.5

3.4/1.5

3.2/1.4

3.5/1.5

3.3/1.4

(1219 to

1524)

850

875

3.2/1.4

3.7/1.6

3.4/1.5

3.8/1.7

3.5/1.5

3.3/1.4

3.6/1.6

3.4/1.5

900

925

3.7/1.6

3.5/1.5

3.8/1.7

3.6/1.6

3.7/1.6

3.2/1.4

3.8/1.7

* Orifice numbers 43 are actory installed

Table 14 - Orifice Size and Manifold Pressure (In. W.C.) for Gas Input Rate (Con’t.)

(Tabulated Data Based on 22,000 Btuh High-Heat/14,500 Btuh for Low-Heat per Burner, Derated 4 Percent for Each 1000 Ft.

Above Sea Level)

ALTITUDE

PT nD

5004 to

6000

Usa | (sea

1829)

AVG. GAS

HEAT VALUE 0.58

SPECIFIC GRAVITY OF NATURAL GAS

0.60 0.62 0.64

ATALTITUDE | Orifice | BEM | ontice | SEMUS | oritice | MEMOS | orifice | Pentel’

(BTUH/CUFT) | No. | High/Low

725

750

775

B00

B25

B50

875

900

46 a7 a7

3.4/1.5

3.2/1.4

3.4/1.5

3.2/1.4

3.8/1.7

3.6/1.6

3B/L.7

3.6/1.6

AVG. GAS

HEAT VALUE _

0.58

Manifold

No. | High/Low No. | High/Low

44 a5

46 a7

3.55

3.3/1.4

3.5/1.5

3.3/1.4

3.8/1.6

3.7/1.6

35/15

3.8/1.6

3.6/1.6

3.4/1.5

3.2/1.4

3.4/1.5

3.2/1.4

3.8/1.7

3.6/1.6

3.4/1.5

SPECIFIC GRAVITY OF NATURAL GAS

0.60

Manifold _

0.62

Manifold

No. | High/Low

44 a5

3.7/1.6

3.5/5

3.3/1.4

3.5/1.5

3.3/1.4

3.8/1.6

3.7/1.6

3.5/5

0.64

Manifold

ALTITUDE

RANGE

FT. (M) AT ALTITUDE

(BTUH/CU FT.)

Orifice Pressure

No. |) High/Low

Orifice Pressure

No. | High/Low

Orifice Pressure

No. | High/Low

Orifice Pressure

No. | High/Low

6001 to

7000

Usa | (1829

2134)

675

700

725

750

775

B00

825

B50

44 a5

46 a7 a7

3.4/1.5

3.6/1.6

3.4/1.5

3.8/1.7

3.7/1.6

3.5/5

3.7.6

3.5/5

44 a5

46 a7

3.55

3.3/1.4

3.5/1.5

3.3/1.4

3.7/1.6

3.6/1.6

3.4/1.5

3.6/1.6

44 a5

46 a7

3.6/1.6

3.4/1.5

3.6/1.6

3.4/1.5

3.8/1.7

3.8/1.6

35/15

3.8/1.6

SPECIFIC GRAVITY OF NATURAL GAS

44 a5

3.7/1.6

3.5/5

3.2/1.4

3.5/1.5

3.2/1.4

3.7/1.6

3.6/1.6

3.4/1.5

ALTITUDE

RANGE

AVG. GAS

HEAT VALUE _

0.58

Manifold _

0.60

Manifold _

0.62

Manifold _

0.64

Manifold

FT. (M)

7004 to

8000

Usa | (e134

2438)

ALTITUDE

RANGE

AT ALTITUDE

(BTUH/CU FT.)

650

675

700

725

750

775

B00

B25

AVG. GAS

HEAT VALUE

Orifice Pressure

No. |) High/Low

46 a7 a7

44 a5

3.6/1.6

3.3/1.5

3.8/1.6

3.7/1.6

3.4/1.5

3.6/1.6

3415

3.7/1.6

0.58

Manifold

Orifice Pressure

No. | High/Low

Orifice Pressure

No. | High/Low

46 a7 a7

3.2.4

3.5/1.5

3.2/1.4

3.8/1.7

3.6/1.5

3.8/1.6

35/15

3.8/1.6

44 a5

46 a7 a7

3.4/1.5

3.6/1.6

3.3/1.4

3.7/1.6

3.4/1.5

3.716

3.4/1.5

SPECIFIC GRAVITY OF NATURAL GAS

0.60

Manifold ~

0.62

Manifold ~

Orifice Pressure

No. | High/Low

46 a7 a7

3.55

3.2/1.4

3.4/1.5

3.2/1.4

3.8/1.6

3.6/1.5

3.8/1.6

3.6/1.5

0.64

Manifold

FT. (M) AT ALTITUDE

(BTUH/CU FT.)

Orifice Pressure

No. |) High/Low

Orifice Pressure

No. | High/Low

Orifice Pressure

No. | High/Low

Orifice Pressure

No. | High/Low

8001 to

9000

USA | (2438 to

2743)

625

650

675

700

725

750

775

600

625

650

675

700 qa a5

46 a7

46 a7 a7

48 a7

48 a5

3.3/1.5

3.7/1.6

3.6/1.6

3.8/1.7

3.6/1.6

3.8/1.7

3.6/1.5

3.7/1.6 a7 a7

48 a5 qa

44 a6

3.515

3.2/1.4

3.8/1.6

3.5/1.5

3.7/1.6

35/15

3.7/1.6

3.8/1.7 a7 a7

44 qa

44 a5

3.6/1.6

3.3/1.4

3.7/1.6

3.6/1.6

3.8/1.7

3.6/1.6

3.8/1.7

3.3/1.4

46 a7 a7

44 a5

3.2/1.4

3.4/1.5

3.8/1.7

3.7/1.6

35/15

3.7/1.6

35/15

3.4/1.5

9001 to usa | 10,000

2743 to

3048)

3.6/1.6

3.8/1.6

3.5/1.5

3.7/1.6

46 a7

3.7/1.6

3.4/1.5

3.6/1.6

3.8/1.7 a6

46 a7 a7

3.8/1.7

3.6/1.5

3.7/1.6

35/15 a5

46 a7

3.8/1.6

3.7/1.6

3.4/1.5

3.6/1.6

725

* Orifice numbers 43 are factory installed

48 35/15 48 3.6/1.6 48 3.7/1.6 48 3.8/1.7

Table 15 — Orifice Size and Manifold Pressure (In. W.C.) for Gas Input Rate

(Tabulated Data Based on 21,000 Btuh High-Heat/14,500 Btuh for Low-Heat Per Burner, Derated 4 Percent for Each 1000 Ft.

(305 M) Above Sea level)

SPECIFIC GRAVITY OF NATURAL GAS

ALTITUDE RANGE

FT. (M)

USA

0 to

2000

(0 to 610)

AVG. GAS

HEAT VALUE

1025

1050

1075

1100

0.58

(BTUH/CU Onif Manifold Onif Manifold Onif Manifold Onif Manifold

FT.)

900

N ice

°.

Pressure

High/Low

3.2/1.5

N ice Pressure

°. High/Low

42 3.3/1.6

N ice

°. High/Low

Pressure

3.4/1.6

N ice

°.

Pressure

High/Low

3.5/4.7

925

950

975

74000

3.7/1.8

3.5/4.7

3.3/1.6

3.6/1.7

3.8/1.8

3.6/1.7

3.4/1.6

3.3/1.6

3.2/1.5

3.7/1.8

3.5/4.7

3.4/1.6

3.3/1.6

3.8/1.8

3.7/4.7

3.5/4.7

3.4/1.6

3.3/1.6

3.8/1.8

0.60

3.6/1.7

3.4/1.6

3.2/1.5

3.7/1.8

0.62

3.2/1.5

3.5/4.7

3.3/1.6

3.2/1.5

0.64

3.3/1.6

3.2/1.5

3.4/1.6

3.3/1.6

0.58 0.60 0.62 0.64

ALTITUDE RANGE Orifice Orifice Orifice Orifice

FT. (M) (BTUH/CU FT) No Pressure

800

. High/Low

3.8/1.8

Pressure

High/Low

Pressure

High/Low

Pressure

High/Low

42 3.2/1.5 42 3.3/1.6 42 3.4/1.6

825

850

875

900

925

3.5/4.7

3.3/1.6

3.2/1.5

3.4/1.6

3.2/1.5

3.7/4.7

3.5/1.6

3.3/1.6

3.5/1.7

3.3/1.6

483

3.8/1.8

3.6/1.7

3.4/1.6

3.2/4.5

3.5/1.6

483

3.2/1.5

3.7/1.8

3.5/1.7

3.3/1.6

3.6/1.7

2001 to

USA | 3000 (610 to 914)

ALTITUDE RANGE

USA

74000

3.7/1.8 45 3.8/1.8 44 3.3/1.6

0.58 0.60 0.62 0.64

(BTUH/CU FT)

950

(BTUH/CU FT)

Orifice

3.5/4.7

Pressure

3.3/1.6

3.6/1.7

3.4/1.6

Pressure

3.6/1.7

3.3/7.6

Orifice

3.8/1.8

3.6/1.7

Pressure

High/Low

3.7/4.7

3.4/1.6

3.2/1.5

3.5/4.7

Pressure

High/Low

3.4/1.6

3.2/1.5

3.4/1.6

Orifice

3.8/1.8

Pressure

High/Low

3.8/1.8

3.5/1.7

3.3/7.6

3.7/4.7

Pressure

High/Low

3.5/4.7

3.3/7.6

3.6/1.7

Orifice

44 3.4/1.6

850

875

900

925

46

3.4/1.6

3.8/1.8

3.6/1.7

25

3.5/4.7

3.3/7.6

3.8/1.8

3.7/1.8

aa

3.6/1.7

3.4/1.6

3.2/1 5

3.7/1.8

aa

3.2/1.5

3.5/4.7

3.3/1.6

3.8/1.8

0.58 0.60 0.62 0.64

USA

FT. (M)

3001 to

4000 (914

to 1219)

ALTITUDE RANGE

FT. (M)

4001 to

5000

(1219 to

1524)

950

975

775

. High/Low

3.5/4.7

800

825

3.7/1.8

750

. High/Low

3.3/7.6

775

800

825

850

875

3.8/1.8

3.5/4.7

3.2/1.5

3.7/1.8

3.7/4.7

3.4/1.6

3.8/1.8

3.5/1.6

3.3/1.6

3.7/1.8

900 47 3.8/1.8 46 3.5/4.7 46 3.6/1.7 46 3.7/1.8

* Orifice numbers 43 are factory installed

3.2/1.5

3.7/1.8

Pressure

High/Low

3.2/1.5

3.7/4.7

3.4/1.6

3.8/1.8

Pressure

High/Low

3.6/1.7

3.4/1.6

3.2/1.5

925 47 3.6/1.7 47 3.7/1.8 47 3.8/1.8 46 3.5/4.7

Table 15 - Orifice Size and Manifold Pressure (In. W.C.) for Gas Input Rate (Con’t.)

(Tabulated Data Based on 21,000 Btuh High-Heat/14,500 Btuh for Low-Heat Per Burner, Derated 4 Percent for Each 1000 Ft.

(305 M) Above Sea level)

AVG. GAS

HEAT VALUE 0.58

SPECIFIC GRAVITY OF NATURAL GAS

0.60 0.62 0.64

cline iaiele ATALTITUDE | 5... | Manifold [5 .. | Manifold ~~ 54. | Manifold |_| Manifold

UsA

- (M)

5001 to

6000

(1524 to

4829)

(BTUH/CU

FT.)

725

750

775

B00

B25

B50

875

900

46 a7 a7

Pressure

High/Low

3.5/1.7

3.3/1.6

3.718

3.5/1.7

3.718

3.5/1.7

3.8/1.8

9. a3

46 a7 a7 a7

Pressure

High/Low

3.2/1.5

3.4/1.6

3.2/1.5

3.8/1.8

3.6/1.7

3.8/1.8

3.6/1.7

3.4/1.6

N Pressure

9. High/Low a3

46 a7 a7

3.3/1.6

3.5/1.7

3.3/1.6

3.8/1.8

3.718

3.5/1.7

3.718

3.5/1.7

°. a3

46 scrrupe eanee AVG. GAS -_ SPECIFIC GRAVITY OF NATURAL GAS a7

Pressure

High/Low

3.4/1.6

3.2/1.5

3.4/1.6

3.2/1.5

3.8/1.8

3.6/1.7

3.4/1.6

3.7/1.7

TM)

ALT TUDE

UsA

6001 to

7000

(1829 to

2134) scrrupe eanee

(BTUH/CU FT.)

675

700

725

750

775

B00

B25

B50

ANG. GAS

Orifice | Manifold (G. | Manifold 7G. | Manifold ~~ 5... | Manifold

46 a7 a7

Pressure

°. High/Low

3.5/1.7

3.3/1.6

3.718

3.6/1.7

3.4/1.6

3.6/1.7

3.4/1.6

3.7/1.7

N Pressure

°. High/Low

N Pressure

°. High/Low

46 a7 a7

3.2/1.5

3.4/1.6

3.8/1.8

3.5/1.7

3.8/1.8

3.5/1.7

3.8/1.8 a3

46 a7 a7

3.3/1.6

3.5/1.7

3.3/1.6

3.718

3.6/1.7

3.4/1.6

3.6/1.7

3.4/1.6

SPECIFIC GRAVITY OF NATURAL GAS

°.

46 a7 a7 a3

Pressure

High/Low

3.4/1.6

3.2/1.5

3.4/1.6

3.8/1.8

3.5/1.7

3.8/1.8

3.5/1.7

UsA

TM)

7001 to

8000

(2184 to

2438) nrupe eanee

TM)

ALT TUDE

(BTUH/CU FT.)

650

675

700

725

750

775

B00

B25

AVG. GAS

Orifice | Manifold (G. | Manifold 7G. | Manifold ~~ 5... | Manifold

N Pressure

°. High/Low

N Pressure

°. High/Low

N Pressure

°. High/Low

°.

Pressure

High/Low

46 a7

3.3/1.6

3.718

3.6/1.7

3.8/1.8

3.5/1.7

3.8/1.8

3.6/1.7

3.3/1.6

46 a7 a7

3.4/1.6

3.8/1.8

3.718

3.5/1.7

3.718

3.4/1.6

3.718

3.5/1.6

46 a7 a7

3.5/1.7

3.3/1.6

3.8/1.8

3.6/1.7

3.8/1.8

3.6/1.7

3.8/1.8

3.6/1.7 a3

46 a7 a7

3.2/1.5

3.4/1.6

3.8/1.8

3.718

3.5/1.6

3.7/1.7

3.4/1.6

3.718

5s SPECIFIC GRAVITY OF NATURAL GAS -

(BTUH/CU FT.)

N Pressure

°. High/Low

N Pressure

°. High/Low

N Pressure

°. High/Low

°.

Pressure

High/Low

USA

8001 to

3000

(2488 to

2743)

625

650

675

700

725

750

775

600

46 a7 a7

3.718

3.6/1.7

3.8/1.8

3.5/1.7

3.7/1.8

3.5/1.7

3.8/1.8

3.6/1.7 a8

46 a7

3.8/1.8

3.718

3.4/1.6

3.6/1.7

3.8/1.8

3.6/1.7

3.4/1.6

3.718 a7

46 a7

3.3/1.6

3.8/1.8

3.5/1.7

3.718

3.5/1.7

3.7/1.8

3.5/1.7

3.8/1.8 a7

3.4/1.6

3.8/1.8

3.7/1.7

3.4/1.6

3.6/1.7

3.8/1.8

3.6/1.7

3.718

UsA

9001 to

40,000

(2748 to

3048)

625

650

675

700 a7 a7

3.718

3.4/1.6

3.6/1.7

3.4/1.6 a7 a7

3.8/1.8

3.6/1.7

3.8/1.8

3.5/1.7

46 a7 a7

3.5/1.7

3.718

3.4/1.6

3.6/1.7

46 a7 a7

3.6/1.7

3.8/1.8

3.5/1.7

3.718

725

* Orifice numbers 43 are factory installed

49 3.718 49 3.8/1.8 48 3.4/1.6 48 3.5/1.7

Check Safety Controls

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

1. Check Main Limit Switch

This control shuts off combustion system and energizes air-circulating blower motor, if furnace overheats. By using this method to check limit control, it can be established that limit is functioning properly and will operate if there is a restricted return-air supply or motor failure. If limit control does not function during this test, cause must be determined and corrected. a. Run furnace for at least 5 minutes. b. Gradually block off return air with a piece of card- board or sheet metal until the limit trips. c. Unblock return air to permit normal circulation. d. Burners will re-light when furnace cools down.

Check draft safeguard switch. The purpose of this control is to cause the safe shutdown of the furnace during certain blocked vent conditions. a. Verify vent pipe is cool to the touch. b. Disconnect power to furnace and remove vent connector from furnace vent elbow. c. Restore power to furnace and set room thermostat above room temperature. d. After normal start-up, allow furnace to operate for 2 minutes, then block vent elbow in furnace 80 percent of vent area with a piece of flat sheet metal. e. Furnace should cycle off within 2 minutes. If gas does not shut off within 2 minutes, determine reason draft safeguard switch did not function properly and correct condition. f. Remove blockage from furnace vent elbow. g. Switch will auto-reset when it cools. h. Re-install vent connector.

NOTE: Should switch remain open longer than 3 minutes, furnace control board will lockout the furnace for 3 hours. To reset furnace control board, turn thermostat below room temperature or from HEAT to OFF and turn 115-v power OFF, then back ON.

3. Check Pressure Switch(es)

This control proves operation of the draft inducer blower. a. Turn off 115-v power to furnace. b. Disconnect inducer motor lead wires from wire harness. c. Turn on 115-v power to furnace. d. Set thermostat to “call for heat” and wait 1 minute.

When pressure switch is functioning properly, hot surface igniter should NOT glow and control diagnostic light flashes a status code 32. If hot surface igniter glows when inducer motor is disconnected, shut down furnace immediately. e. Determine reason pressure switch did not function properly and correct condition. f. Turn off 115-v power to furnace. g. Reconnect inducer motor wires, replace outer door, and turn on 115-v power. h. Blower will run for 90 seconds before beginning the call for heat again. i. Furnace should ignite normally.

Checklist

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

2. Verity that switches SW1-1 and SW1-6 are OFF and other setup switches are set as desired. Verity that switches

SW1-7 and SW1-8 for the blower OFF DELAY are set as desired per Table 10.

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

4. Cycle test furnace with room thermostat.

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

6. Review User’s Guide with owner.

7. Attach literature packet to furnace.

SERVICE AND MAINTENANCE

PROCEDURES

FIRE, INJURY OR DEATH HAZARD

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

The ability to properly perform maintenance on_ this equipment requires certain knowledge, mechanical skills, tools, and equipment. If you do not possess these, do not attempt to perform any maintenance on this equipment other than those procedures recommended in the User’s

Manual.

4& CAUTION

ENVIRONMENTAL HAZARD

Failure to follow this caution may result in environmental pollution.

Remove and recycle all components or materials (i.e. oil, refrigerant, control board, etc.) before unit final disposal.

ELECTRICAL SHOCK, FIRE OR EXPLOSION

HAZARD

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

Before installing, modifying, or servicing system, main electrical disconnect switch must be in the OFF position and install a lockout tag. There may be more than one disconnect switch. Lock out and tag switch with a suitable warning label. Verify proper operation after servicing.

ELECTRICAL OPERATION HAZARD

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

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

General

These instructions are written as if the furnace is installed in an upflow application. An upflow furnace application is where the blower is located below the combustion and controls section of

the furnace, and conditioned air is discharged upward. Since this furnace can be installed in any of the 4 positions shown in Fig. 4, you must revise your orientation to component location accordingly.

Electrical Controls and Wirin

ELECTRICAL SHOCK HAZARD

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

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

Check accessories and cooling unit for additional electrical supplies that must be shut off during furnace servicing. Lock out and tag switch with a suitable warning label.

The electrical ground and polarity for 115-v wiring must be properly maintained. Refer to Fig. 25 for field wiring information and to Fig. 53 for furnace wiring information.

NOTE: If the polarity is not correct, the STATUS LED on the control will flash rapidly and prevent the furnace from heating.

The control system also requires an earth ground for proper operation of the control and flame-sensing electrode.

The 24-v circuit contains an automotive-type, 3-amp. fuse located on the control. (See Fig. 26.) Any shorts of the 24-v wiring during installation, service, or maintenance will cause this fuse to blow. If fuse replacement is required, use ONLY a 3-amp. fuse. The control LED will display status code 24 when fuse needs to be replaced.

Proper instrumentation is required to service electrical controls.

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

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

For an explanation of status codes, refer to service label located on blower access door or Fig. 52, and the troubleshooting guide which can be obtained from your distributor.

See Fig. 58, a brief Troubleshooting Guide.

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

7 Status Codes in order of occurrence.

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

NOTE: NO thermostat signal may be present at control, and all blower-OFF delays must be completed. a. Leave 115-v power to furnace turned on. b. Remove outer access door. c. Look into blower access door sight glass for current

LED status. d. Remove blower access door.

NOTE: The Status Codes cannot be retrieved by disconnecting the limit switch or draft safeguard switch. To retrieve Status

Codes, follow the procedure below.

2. Turn Setup Switch, SW1-1 “ON.”

. Manually close blower access door switch.

. Control will flash up to 7 Status Codes.

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

. Turn SW1-1 “OFF.”

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

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

Component Self-Test

Component Test can ONLY be initiated by performing the following:

. Remove outer access door.

. Remove blower access door.

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

4. Turn Setup Switch, SW-1-6 “ON.”

5. Manually close blower access door switch.

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

CUANDO:

ELECTRICAL SHOCK HAZARD

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

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

6. Component Test sequence will function as follows: a. Inducer motor starts on high-speed and continues to run until Step (d.) of component test sequence. b. Hot surface igniter is energized for 15 sec, then deen- ergized. c. Blower operates for 10 sec, then turns off. d. Inducer motor goes to low-speed for 10 seconds, then turns off. e. After component test is completed, one or more status codes (11, 25, or 41) will flash. See component test section of service label for explanation of status codes.

NOTE: To repeat component test, turn setup switch SW1-6 OFF then back ON. f. Turn setup switch SW1-6 OFF.

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

CARE AND MAINTENANCE

FIRE OR EXPLOSION HAZARD

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

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

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

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

3. Paint thinners and other painting compounds, paper bags, or other paper products. Exposure to these materials could lead to corrosion of the heat exchangers.

For continuing high performance and to minimize possible furnace failure, periodic maintenance must be performed on this furnace. Consult your local dealer about proper frequency of maintenance and the availability of a maintenance contract.

ELECTRICAL SHOCK AND FIRE HAZARD

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

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

A A Se

CARBON MONOXIDE POISONING AND FIRE

HAZARD

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

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

4& CAUTION

CUT HAZARD

Failure to follow this caution may result in personal injury.

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

The minimum maintenance on this furnace is as follows:

1. Check and clean air filter each month or more frequently if required. Replace if torn.

2. Check blower motor and wheel for cleanliness each heating and cooling season. Clean as necessary.

ELECTRICAL SHOCK HAZARD

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

Blower access door switch opens 115-v power to control.

No component operation can occur unless switch is closed.

Caution must be taken when manually closing this switch for service purposes.

NOTE: The blower wheel should not be dropped or bent as balance will be affected.

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

To ensure long life and high efficiency, clean accumulated dirt and grease from blower wheel and motor annually.

3. Check electrical connections for tightness and controls for proper operation each heating season. Service as necessary.

4, Inspect burner compartment before each heating season for rust, corrosion, soot or excessive dust. If necessary, have furnace and burner serviced by a qualified service agency.

5. Inspect the vent pipe/vent system before each heating season for rust, corrosion, water leakage, sagging pipes or broken fittings. Have vent pipes/vent system serviced by a qualified service agency.

6. Inspect any accessories attached to the furnace such as a humidifier or electronic air cleaner. Perform any service or maintenance to the accessories as recommended in the accessory instructions.

Cleaning and/or Replacing Air Filter

The air filter arrangement will vary depending on the application.

NOTE: If the filter has an airflow direction arrow, the arrow must point towards the blower.

4& CAUTION

CUT HAZARD

Failure to follow this caution may result in personal injury.

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

Media cabinet filter procedures:

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

. Remove filter cabinet door.

. Slide filter out of cabinet.

. If equipped with permanent, washable 3/4-in. (19 mm) filter, clean filter by spraying cold tap water through filter in opposite direction of airflow. Rinse filter and let dry.

Oiling or coating of the filter is not recommended. See

Table 15 for size information.

5. If equipped with factory-specified disposable media filter, replace only with media filter having the same part number and size. For expandable replacement media, refer to the instructions included with the replacement media.

6. Slide filter into cabinet.

7, Replace filter cabinet door.

8. Turn on electrical supply to furnace.

Blower Motor and Wheel

FURNACE CASING WIDTH

14—1/2 (368)

17-172 (445)

21 (633)

Table 16 — Filter Size Information - In. (mm)

FILTER SIZE

SIDE

RETURN

16 X 25 X 3/4

(406 X 635 X 19)

16 X 25 X 3/4

(406 X 635 X 19)

16 X 25 X 3/4

(406 X 635 X 19)

BOTTOM

RETURN

14 X 25 X 3/4

(356 X 635 X 19)

16 X 25 X 3/4

(406 X 635 X 19)

20 X 25 X 3/4

(508 X 635 X 19)

16 X 25 X 3/4 X 3/4

* Recommended

24 (610) (406 X 635 X 19) (610 X 635 X 19)

The inducer and blower motors are pre-lubricated and require no

FILTER TYPE

Washable*

15. Reconnect blower leads to furnace control. Refer to fur- additional lubrication. These motors can be identified by the absence of oil ports on each end of the motor. nace wiring diagram, and connect thermostat leads if previously disconnected.

Clean blower motor and wheel as follows:

1. Turn off electrical supply to furnace.

16. To check blower for proper rotation: a. Turn on electrical supply.

. Remove outer door.

. For downflow or horizontal furnaces having vent pipes within the furnace that pass in front of the blower access door: a. Disconnect vent connector from furnace vent elbow. b. Disconnect and remove short piece of vent pipe from within furnace.

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

5. All factory wires can be left connected, but field thermostat connections may need to be disconnected depending on their length and routing.

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

7, 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.

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

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

NOTE: Before disassembly, mark blower mounting arms, motor, and blower housing so motor and each arm is positioned at the same location during reassembly. a. Disconnect ground wire attached to blower housing. b. Remove screws securing cutoff plate and remove cutoff plate from housing. c. Loosen set screw holding blower wheel on motor shaft

(160+/-20 in.-Ib. when assembling). d. Remove bolts holding motor to blower housing and slide motor out of wheel (40+/-10 in.-Ib. when reas- sembling). e. Remove blower wheel from housing. f. Clean wheel and housing.

10. Reassemble motor and blower by reversing steps 9a, through 9e. Be sure to reattach ground wire to the blower housing.

11. 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.

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

13. Reinstall blower assembly in furnace.

14. Reinstall 2 screws securing blower assembly to blower deck.

4 WARNING

ELECTRICAL SHOCK HAZARD

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

NOTE: If R-W/W1 thermostat terminals are jumpered at the time blower access door switch is closed, blower will run for 90 sec before beginning a heating cycle. c. Perform component self-test as shown at the bottom of the SERVICE label, located on the front of blower access door. d. Verify blower is rotating in the correct direction

17. If furnace is operating properly, RELEASE BLOWER

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

18. 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.

19. Reinstall outer door.

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

Turn outdoor circuit breaker on after completing cooling cycle.

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

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

— 9/32”

7.1mm roti

5/167

7.9mm

Fig. 54 - Igniter Position - Side View

A05025

9, Using field-provided 25-caliber rifle cleaning brush,

36-in. (914 mm) long, 1/4-in. (6 mm) diameter steel spring cable, a variable speed, follows: a. Remove metal screw fitting from wire brush to allow insertion into cable. b. Insert the twisted wire end of brush into end of spring cable, and crimp tight with crimping tool or crimp by striking with ball-peen hammer. TIGHTNESS IS

VERY IMPORTANT.

NOTE: The materials needed in item 9 can usually be purchased at local hardware stores.

(1.) Attach variable-speed, reversible drill to the end of spring cable (end opposite brush).

(2.) Insert brush end of cable into the outlet opening of cell and slowly rotate with drill. DO NOT force cable. Gradually insert cable into upper pass of cell. (See Fig. 57.)

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

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

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

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

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

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

A05026

Fig. 55 - Igniter Position - Top View

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

1. Turn OFF gas and electrical power to furnace.

. Remove outer access door.

. Disconnect vent connector from furnace vent elbow.

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

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

. Pressure switches.

. Limit overtemperature switch.

. Gas valve.

. Hot surface igniter.

. Flame-sensing electrode.

. Flame rollout switches.

6. Remove screws that fasten the collector box assembly to the cell panel. Be careful not to damage the collector box.

Inducer assembly and elbow need not be removed from collector box.

7, Disconnect gas line from gas manifold.

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

NOTE: Be very careful when removing burner assembly to avoid breaking igniter. See Fig. 54-55 for correct igniter location.

Ne

Ag1252

Fig. 56 - Cleaning Heat Exchanger Cell

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

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

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

NOTE: A releasing agent such as cooking spray or equivalent

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

(GE. 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 3-0z tubes.

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

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

. Pressure switches.

. Limit overtemperature switch.

. Gas valve.

. Hot surface igniter.

. Flame-sensing electrode.

. Flame rollout switches.

14. Reinstall internal vent pipe, if applicable.

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

16. Replace blower access door only if it was removed.

17. Set thermostat above room temperature and check furnace for proper operation.

18. Verify blower airflow and speed changes between heating and cooling.

4 WARNING

FIRE OR EXPLOSION HAZARD

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

19. Check for gas leaks.

NOTE: Furnace control must be grounded for proper operation or else control will lock out. Control is grounded through green/yellow wire routed to gas valve and burner box screw.

Using the schematic diagram in Fig. 53, follow the sequence of operation through the different modes. Read and follow the wiring diagram very carefully.

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

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

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

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

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

Thermostat

See Fig. 27 - 34 for thermostat connections

NOTE: The low-heat only switch SW1-2 selects either the low-heat only operation mode when ON, (see item 2. below) or the adaptive heating mode when OFF in response to a call for heat. (See Table 10.) When the W2 thermostat terminal is energized it will always cause high-heat operation when the

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

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

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

The wail thermostat “calls for heat”, closing the R-to-W circuit.

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

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

(2.) If the furnace control CPU selects high-heat operation, the inducer motor IDM remains running at high-speed, and the high-heat pressure switch relay HPSR is de-energized to close the NC contact. When sufficient pressure is available the high-heat pressure switch HPS closes, and the high-heat gas valve solenoid GV-HI is energized. The furnace control CPU begins a

15-second prepurge period after the low-heat pressure switch LPS closes. If the high-heat pressure switch HPS fails to close and the low-heat pressure switch LPS closes, the furnace will operate at low-heat gas flow rate until the high-heat pressure switch closes for a maximum of 2 minutes after ignition. b. Igniter Warm-Up -At the end of the prepurge period, the Hot-Surface Igniter HSI is energized for a

17-second igniter warm-up period. c. Trial-For-Ignition Sequence -When the igniter warm-up period is completed the main gas valve relay contact GVR closes to energize the gas valve solenoid

GV-M. The gas valve solenoid GV-M permits gas flow to the burners where it is ignited by the HSI. Five seconds after the GVR closes, a 2-second flame proving period begins. The HSI igniter will remain energized until the flame is sensed or until the 2-second flame proving period begins. If the furnace control

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

COOLING TONNAGE VS. AIRFLOW (CFM)

110, 135,

& 155 MODELS ome

AIR CONDITIONING

TONS (12,000 BTU,

1-1/2

2-1/2

AIRFLOW

525

700

875

1050

3-1/2

1225

1400

1750

2100

X-INDICATES AN ALLOWABLE SELECTION.

070 MODEL 090 MODEL x

BASED ON 350 CFIW/TON (SETUP SWITCH SW1 -5 OFF, SW4-3 OFF)

SETUP SWITCH SW2 OR SW3 POSITIONS

“se (Soe oe oe oa oS eas

Teco] Mo] Mg cof gc] Moco TM | Mc Tc]

070 DEF. | 5252 700

090 DEF. | 5252

110, 135, 155) DEF. 700

700 875

875 | 1050, | 1225 | 1225 | 1225

1050 | 1225 | 1400, |] 1400

875. | 1050 | 1225 | 1400 | 1750, | 2100

BASED ON 400 CFIW/TON (SETUP SWITCH SW1 -5 ON, SW4-3 OFF)

SETUP SWITCH SW2 OR SW3 POSITIONS

“sie [Soe om ooo ooo oa

Tg co) Tg cof Tg cof gc] Moco) Meco) Meco] Mo}

070 DEF. | 600. 800

090 DEF. | 600.

10, 135, 155] DEF.

800

1000 | 1200, ] 1400 | 1400 | 1400

1000 | 1200 | 1400 | 1600, | 1600

800 | 1000. ] 1200 | 1400 | 1600 | 2000, | 2200

BASED ON 325 CFM/TON (SETUP SWITCH SW1-5 OFF, SW4-3 ON)

SETUP SWITCH SW2 OR SW3 POSITIONS

“size [eee om oa oom

Me co] co] gr cof cof co Mo cof Maco} Ta co}

070 DEF. | 488. 651 814

090 DEF. | 488.

110, 135, 155 DEF. 651

651

814,

814

976

976, | 1139 | 1139 | 1139

976 1139 | 1302, | 1302

1139 | 1302 | 1627, ] 1950

BASED ON 370 CFM/TON (SETUP SWITCH SW1-5 ON, SW4-3 ON)

SETUP SWITCH SW2 OR SW3 POSITIONS

“se [SS oes om ooo ea oS eae

Te cof gy cof cof cof Moco] Moe] | TM oo]

070 DEF. | 558. 744

090 DEF. | 558.

110, 135, 155) DEF. 744

744 930

930 | 1116; | 1302 | 1302 | 1302

1116 | 1302 | 1488, |] 1488

9302 | 1116 | 1302 | 1488 | 1860, | 2200

1. DEFAULT A/C AIRFLOW WHEN A/C SWITCHES ARE IN OFF POSITION

2, DEFAULT CONT. FAN AIRFLOW WHEN CF SWITCHES ARE IN OFF POSITION

3. SWITCH POSITIONS ARE ALSO SHOWN ON FURNACE WIRING DIAGRAM

A13055

Fig. 57 - Cooling (A/C) or Continuous-Fan (CF) Airflow Selection Chart d. Flame-Proving - When the burner flame is proved at the flame-proving sensor electrode FSE, the inducer motor IDM switches to low-speed unless the furnace is operating in high-heat, and the furnace control CPU begins the blower-ON delay period and continues to close the gas valve GV-M, and the control CPU will repeat the ignition sequence for up to three more Tri- als-For-Ignition before going to Ignition-Lockout.

Lockout will be reset automatically after three hours, or by momentarily interrupting 115 vac power to the hold the gas valve GV-M open. If the burner flame is not proved within two seconds, the control CPU will furnace, or by interrupting 24 vac power at SEC1 or

SEC2 to the furnace control CPU (not at W/W1, G, R,

etc.). If flame is proved when flame should not be present, the furnace control CPU will lock out of Gas-

Heating mode and operate the inducer motor IDM on high speed until flame is no longer proved. e. Blower-On delay - If the burner flame is proven the blower-ON delays for low-heat and high-heat are as follows:

Low-heat - 45 seconds after the gas valve GV-M is opened the blower motor BLWM is turned ON at low-heat airflow.

High-heat - 25 seconds after the gas valve GV-M is opened the BLWM is turned ON at high-heat airflow.

Simultaneously, the humidifier terminal HUM and electronic air cleaner terminal EAC-1 are energized and remain energized throughout the heating cycle. f. Switching from Low- to High-Heat - If the furnace control CPU switches from low-heat to high-heat, the furnace control CPU will switch the inducer motor

IDM speed from low to high. The high-heat pressure switch relay HPSR is de-energized to close the NC contact. When sufficient pressure is available the high- heat pressure switch HPS closes, and the high-heat gas valve solenoid GV-HI is energized. The blower motor

BLWM will transition to high-heat airflow five seconds after the furnace control CPU switches from low-heat to high-heat. g. Switching from High- to Low-Heat -The furnace control CPU will not switch from high-heat to low- heat while the thermostat R-to-W circuit is closed when using a single-stage thermostat. h. Blower-Off Delay -When the thermostat is satisfied, the R to W circuit is opened, de-energizing the gas valve GV-M, stopping gas flow to the burners, and de-energizing the humidifier terminal HUM. The inducer motor IDM will remain energized for a

5-second post-purge period. The blower motor

BLWM and air cleaner terminal EAC-1 will remain energized at low-heat airflow or transition to low-heat airflow for 90, 120, 150, or 180 seconds (depending on selection at blower-OFF delay switches). The furnace control CPU is factory-set for a 120-second blower-OFF delay.

2. Two-Stage Thermostat and Two-Stage Heating

See Fig. 27-34 for thermostat connections.

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

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

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

The wall thermostat “calls for heat”, closing the R-to-W1 circuit for low-heat or closing the R-to-W1-and-W2 circuits for high-heat. The furnace control performs a self-check, verifies the low-heat and high-heat pressure switch contacts LPS and HPS are open, and starts the inducer motor IDM in high-speed.

The start up and shut down functions and delays described in item 1. above apply to the 2-stage heating mode as well, except for switching from low- to high-Heat and vice versa. a. Switching from Low- to High-Heat - If the thermostat R-to-W1 circuit is closed and the R-to-W2 circuit closes, the furnace contro! CPU will switch the inducer motor IDM speed from low to high. The high-heat pressure switch relay HPSR is de-energized to close the NC contact. When sufficient pressure is available the high-heat pressure switch HPS closes, and the high-heat gas valve solenoid GV-HI is energized. The blower motor BLWM will transition to

53 high-heat airflow five seconds after the R-to-W2 circuit closes. b. Switching from High- to Low-Heat -If the thermostat R-to- W2 circuit opens, and the R-to-W1 circuit remains closed, the furnace control CPU will switch the inducer motor IDM speed from high to low. The high-heat pressure switch relay HPSR is energized to open the NC contact and de-energize the high-heat gas valve solenoid GV-HI. When the inducer motor

IDM reduces pressure sufficiently, the high-heat pressure switch HPS will open. The gas valve solenoid

GV-M will remain energized as long as the low-heat pressure switch LPS remains closed. The blower motor

BLWM will transition to low-heat airflow five seconds after the R-to-W2 circuit opens.

3. Cooling mode

The thermostat “calls for cooling”. a. Single-Speed Cooling-

See Fig. 27 for thermostat connections

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

R-to- Y circuit starts the outdoor unit, and the R-to-

G-and-Y/Y2 circuits start the furnace blower motor

BLWM on cooling airflow. Cooling airflow is based on the A/C selection shown in Fig. 57. The electronic air cleaner terminal EAC-1 is energized with 115 vac when the blower motor BLWM is operating.

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

5 seconds. (See Fig. 26.) b. Single-Stage Thermostat and Two-Speed Cooling

(Adaptive Mode) -

See Fig. 34 for thermostat connections.

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

NOTE: The air conditioning relay disable jumper ACRDJ must be connected to enable the adaptive cooling mode in response to a call for cooling. (See Fig. 26.) When ACRDJ is in place the furnace control CPU can turn on the air conditioning relay ACR to energize the Y/Y2 terminal and switch the outdoor unit to high-cooling.

The furnace control CPU can start up the cooling unit in either low- or high-cooling. If starting up in low-cooling, the furnace control CPU determines the low-cooling on-time (from 0 to 20 minutes) which is permitted before switching to high-cooling. If the power is interrupted, the stored history is erased and the furnace control CPU will select low-cooling for up to 20 minutes and then energize the air conditioning relay ACR to energize the

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

The wall thermostat “calls for cooling”, closing the

R-to-G-and-Y circuits. The R-to-Y1 circuit starts the outdoor unit on low-cooling speed, and the R-to-G-and-Y1 circuits starts the furnace blower motor BLWM at low-cooling airflow which is the true on-board CF selection as shown in Fig. 57.

If the furnace control CPU switches from low-cooling to high-cooling, the furnace control CPU will energize the air conditioning relay ACR. When the air conditioning relay ACR is energized the R-to-Y1-and-Y2 circuits switch the outdoor unit

to high-cooling speed, and the R-to-G-and-Y1-and-Y/Y2 circuits transition the furnace blower motor BLWM_ to high-cooling airflow. High-cooling airflow is based on the A/C selection shown in Fig. 57.

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

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

When the thermostat is satisfied, the R-to-G-and-Y circuit are opened, The outdoor unit stops, and the furnace blower BLWM and electronic air cleaner terminal EAC-1 will remain energized for an additional 90 seconds. Jumper Y1 to DHUM to reduce the cooling off-delay to 5 seconds. (See Fig. 26.) c. Two-Stage Thermostat and Two-Speed Cooling

See Fig. 33 for thermostat connections

NOTE: The air conditioning relay disable jumper ACRDJ must be disconnected to allow thermostat contro! of the outdoor unit staging. (See Fig. 26.)

The thermostat closes the R-to-G-and-Y1 circuits for low-cooling or closes the R-to-G-and-Y1-and-Y2 circuits for high-cooling. The R-to-Y1 circuit starts the outdoor unit on low-cooling speed, and the R-to-G-and-Y1 circuit starts the furnace blower motor BLWM at low-cooling airflow which is the true on-board CF (continuous fan) selection as shown in Fig. 55.

The R-to-Y1-and-Y2 circuits start the outdoor unit on high-cooling speed, and the R-to- G-and-Y/Y2 circuits start the furnace blower motor BLWM _ at high-cooling airflow.

High-cooling airflow is based on the A/C (air conditioning) selection shown in Fig. 57.

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

When the thermostat is satisfied, the R-to-G-and-Y1 or R-to-

G-and-Y1-and-Y2 circuits are opened. The outdoor unit stops, and the furnace blower BLWM and electronic air cleaner terminal

EAC-1 will remain energized for an additional 90 seconds.

Jumper Y1 to DHUM to reduce the cooling off-delay to 5 seconds. (See Fig. 26.)

4, Thermidistat Mode

See Fig. 27-29 for thermostat connections.

The dehumidification output, DHUM on the Thermidistat should be connected to the furnace contro! thermostat terminal DHUM. When there is a dehumidify demand, the

DHUM input is activated, which means 24 vac signal is removed from the DHUM input terminal. In other words, the DHUM input logic is reversed. The DHUM input is turned ON when no dehumidify demand exists. Once 24 vac is detected by the furnace control on the DHUM input, the furnace control operates in Thermidistat mode. If the

DHUM input is low for more than 48 hours, the furnace control reverts back to non-Thermidistat mode.

The cooling operation described in item 3. above also applies to operation with a Thermidistat. The exceptions are listed below: a. Low cooling- When the R-to-G-and-Y1 circuit is closed and there is a demand for dehumidification, the furnace blower motor BLWM will drop the blower airflow to 86 percent of low-cooling airflow which is the true on-board CF (continuous fan) selection as shown in Fig. 55. b. High cooling-When the R-to-G-and Y/Y2 circuit is closed and there is a demand for dehumidification, the furnace blower motor BLWM will drop the blower airflow to 86 percent of high-cooling airflow. High- cooling airflow is based on the A/C (air conditioning) selection shown in Fig. 55. c. Cooling off-delay-When the “call for cooling” is satisfied and there is a demand for dehumiditication, the cooling blower-off delay is decreased from 90 seconds to 5 seconds.

. Super-Dehumidify Mode

Super-Dehumidify mode can only be entered if the furnace control is in the Thermidistat mode and there is a demand for dehumidification. The cooling operation described in item 3. above also applies to operation with a

Thermidistat. The exceptions are listed below: a. When the R-to-Y1 circuit is closed, R-to-G circuit is open, and there is a demand for dehumidification, the furnace blower motor BLWM will drop the blower airflow to 65 percent of low-cooling airflow for a maximum of 10 minutes each cooling cycle or until the R-to-G circuit closes or the demand for dehumidification is satisfied. Low-cooling airflow is the true on-board CF (continuous fan) selection as shown in

Fig. 57. b. When the R-to-Y/Y2 circuit is closed, R-to-G circuit is open, and there is a demand for dehumidification, the furnace blower motor BLWM will drop the blower airflow to 65 percent of high-cooling airflow for a maximum of 10 minutes each cooling cycle or until the R-to-G circuit closes or the demand for dehumidification is satisfied. High-cooling airflow is based on the A/C (air conditioning) selection shown in Fig. 57. c. When the “call for cooling” is satisfied and there is a demand for dehumidification, the cooling blower-off delay is decreased from 90 seconds to 5 seconds.

. Continuous Blower Mode

When the R-to-G circuit is closed by the thermostat, the blower motor BLWM will operate at continuous blower airflow. Continuous blower airflow selection is initially based on the CF (continuous fan) selection shown in Fig.

57. Factory default is shown in Fig. 57. Terminal EAC-1 is energized as long as the blower motor BLWM is energized.

During a call for heat, the furnace control CPU will transition the blower motor BLWM to continuous blower airflow, low-heat airflow, or the mid-range airflow, whichever is lowest. The blower motor BLWM will remain ON until the main burners ignite then shut OFF and remain OFF for the blower-ON delay (45 seconds in low- heat, and 25 seconds in high-heat), allowing the furnace heat exchangers to heat up more quickly, then restarts at the end of the blower-ON delay period at low-heat or high-heat airflow, respectively.

The blower motor BLWM will revert to continuous- blower airflow after the heating cycle is completed. In high-heat, the furnace control CPU will drop the blower motor BLWM to low-heat airflow during the selected blower-OFF delay period before transitioning to continuous-blower airflow.

When the thermostat “calls for low-cooling”, the blower motor BLWM will switch to operate at low-cooling airflow. When the thermostat is satisfied, the blower motor

BLWM will operate an additional 90 seconds at low-cooling airflow before transitioning back to continuous- blower airflow.

When the thermostat “calls for high-cooling”, the blower motor BLWM will operate at high cooling airflow. When the thermostat is satistied, the blower motor BLWM will operate an additional 90 seconds at high-cooling airflow before transitioning back to continuous-blower airflow.

When the R-to-G circuit is opened, the blower motor

BLWM will continue operating for an additional 5 seconds, if no other function requires blower motor

BLWM operation.

Continuous Blower Speed Selection from Thermostat

To select different continuous-blower airflow from the room thermostat, momentarily turn off the FAN switch or push button on the room thermostat for 1-3 seconds after the blower motor BLWM is operating. The furnace control

CPU will shift the continuous-blower airflow from the factory setting to the next highest CF selection airflow as shown in Fig. 57, Momentarily turning off the FAN switch again at the thermostat will shift the continuous-blower airflow up one more increment. If you repeat this procedure enough you will eventually shift the continuous- blower airflow to the lowest CF selection as shown in Fig.

57. The selection can be changed as many times as desired and is stored in the memory to be automatically used following a power interruption.

NOTE: If the blower-off delay is set to the maximum, the adjustable continuous-fan feature is locked (i.e., fan speed cannot be changed from its current setting).

7. Heat pump

See Fig. 29 - 32 for thermostat connections.

When installed with a heat pump, the furnace control automatically changes the timing sequence to avoid long blower off times during demand defrost cycles. Whenever

W/W1 is energized along with Y1 or Y/Y2, the furnace control CPU will transition to or bring on the blower motor BLWM at cooling airflow, low-heat airflow, or the mid-range airflow, whichever is lowest. The blower motor

BLWM will remain on until the main burners ignite then shut OFF and remain OFF for 25 seconds before coming back on at heating airflow. When the W/W1 input signal disappears, the furnace control begins a normal inducer post-purge period while changing the blower airflow. If

Y/Y2 input is still energized the furnace control CPU will transition the blower motor BLWM airflow to cooling airflow. If Y/Y2 input signal disappears and the Y1 input is still energized the furnace control CPU will transition the blower motor BLWM to low-cooling airflow. If both the

Y1 and Y/Y2 signals disappear at the same time, the blower motor BLWM will remain on at low-heat airflow for the selected blower-OFF delay period. At the end of the blower- OFF delay, the blower motor BLWM will shut OFF unless G is still energized, in which case the blower motor BLWM will operate at continuous blower airflow.

8. Component test

The furnace features a component test system to help diagnose a system problem in the case of a component failure. To initiate the component test procedure, ensure that there are no thermostat inputs to the control and ail time delays have expired. Turn on setup switch SW1-6. (See

Fig. 26.)

NOTE: The component test feature will not operate if the control is receiving any thermostat signals or until all time delays have expired.

The component test sequence is as follows: a. The furnace control CPU turns the inducer motor ON at high-heat speed and keeps it ON through step c. b. After waiting 10 seconds the furnace control CPU turns the hot surface igniter ON for 15 seconds, then

OFF. c. The furnace control CPU then turns the blower motor

BLWM on at mid-range airflow for 15 seconds, then

OFF. d. After shutting the blower motor OFF the furnace control CPU switches the inducer to low-heat speed for

10 seconds, then OFF.

NOTE: The EAC terminalis are energized when the blower is operating.

After the component test is completed, 1 or more status codes (11,

25, or 41) will flash. See component test section or Service Label

(Fig. 52) for explanation of status codes.

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

OFF and then back ON.

Wiring Diagram

Refer to wiring diagram Fig. 53.

Troubleshooting

Refer to the service label. (See Fig. 52—Service Label.)

The Troubleshooting Guide (See Fig. 58.) can be a useful tool in isolating furnace operation problems. Beginning with the word

“Start,” answer each question and follow the appropriate arrow to the next item.

The Guide will help to identify the problem or failed component.

After replacing any component, verify correct operation sequence.

A more detailed Troubleshooting Guide is available from your distributor. an a

sys] 04]

START ls AMBER LED status light on?

YES

ho

Is there 115V at Li and L2?

J YES

Is there 24V at SEC-1 and SEC-2?

J YES

Replace furnace control.

|-—Pr Is door switch closed?

J YES

Is there 115V going to switch?

J YES

Replace door switch.

NO > 2 is circuit breaker closed?

J YES

Check for continuity in wire from circuit breaker to furnace.

Replace transformer. Close circuit breaker and go back to START.

If units are twinned, check for proper low-voltage (24V) transformer phasing. vv ls AMBER LED status light blinking Check for correct line voltage polarity. rapidly without a pause? is AMBER LED status light blinking ON/OFF To recall previous status codes disconnect slowly with a combination of short and long flashes? vv

YES

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?

NO the R thermostat connection, reset power, and put setup switch SW1-1 in the ON position. The AMBER LED will flash the status codes in the order of occurrence.

Record status codes until status code #11 flashes (1 short and 1 long flash). After status code #11 flashes the status codes will repeat.

Status codes are erased after 72 hours or can be manually erased by putting setup switch SW1-1 in the ON position and jumpering R, WAW1, and Y/Y2 simultaneously until status code #11 is flashed. When done put setup switch SW1-1 in the OFF position.

Check room thermostat or interconnecting cable.

v

Go to section below for the status code ie— that was flashed.

YES

Was there a previous status code other than #11? NO

Does the control respond to W/W1, W2, Y1,

Y/Y2, and G (24V) thermostat signals? is 24V present at W/AW1, W2, Y1, Y/Y2 or G

NO thermostat terminals on the furnace control?

1 YES

YES

v

Run system through a low-heat, high-heat, or cooling cycle to check operation. Status codes are erased after 72 hours or can be manually erased by putting setup switch

SW1-1 in the ON position and jumpering R,

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

Disconnect all the thermostat wires from the furnace control.

Replace furnace control.

Does the problem repeat when using

It a jumper wire? v

The thermostat is not compatible with the furnace control. Either install a ballast resistor, connect the Com24¥V thermostat terminal to the thermostat, or replace the thermostat.

¥ v

NO PREVIOUS CODE - Status codes are erased after 72 hours or can be

32 LOW-HEAT PRESSURE SWITCH DID

NOT CLOSE OR REOPENED -— HF open

43 LOW-HEAT PRESSURE SWITCH OPEN

WHILE HIGH-HEAT PRESSURE

45 CONTROL CIRCUITRY LOCKOUT

Auto-reset after 1 hour lockout due to: manually erased by putting setup switch

SW1-1 in the ON position and jumpering

R, W/W1, and Y/Y2 simultaneously until longer than 5 minutes, inducer shuts off for 15 minutes before retry. If opens during blower on-delay period, blower will come on for the selected blower off-delay.

v

status code #11 is flashed. Run system

SWITCH IS CLOSED - Check for:

- Low-heat pressure switch stuck open.

Disconnected or obstructed pressure tube.

- Flame circuit failure.

- Gas valve relay stuck open.

- Software check error.

Reset power to clear lockout. through a low-heat, high-heat, or cooling cycle to check system.

Check for:

- Proper vent sizing.

- Low inducer voltage (115V).

Low inlet gas pressure (if LGPS used).

—p

Miswired pressure switches.

Low inlet gas pressure (if LGPS used).

Replace control if code repeats.

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/W1 closed) or when (R-W/W1 opens) during the blower on-delay period.

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

Inadequate combustion air supply.

- Disconnected or obstructed pressure tubing.

- Defective inducer motor.

Defective pressure switch.

Excessive wind.

Restricted vent.

33 LIMIT CIRCUIT FAULT - Indicates the trips. Blower will run for 4 min. or until to lockout #13. If open less than 3 min.

Unplug igniter harness from control and repeat component test by turning setup switch pele, SW 1-6 OFF and then back ON. Check for

115V between pin 3 and NEUTRAL-L2 on the control. Was 115V present for the 15 second period?

Reconnect the R thermostat lead and set

> thermostat to call for heat. Connect voltmeter across gas valve connections. Does gas valve receive 24V? wy YES

Does gas valve open and allow gas to flow?

YES

Replace furnace control.

Check for continuity in the harness and igniter. Replace defective component.

Check connections. H OK, replace control.

Check that all gas valves are turned on.

Replace valve.

Check for: high-heat. Control will auto-reset after 3 hours. See code 33. 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 open switch remakes whichever is longer. lf open longer than 3 min., code changes to isolate short circuit. status code #33 continues to flash until

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. the blower failed to reach 250 RPM or the blower failed to communicate within

30 seconds after being turned ON in two successive heating cycles. Control will auto-reset after 3 hours. See code 41.

34 IGNITION PROVING FAILURE - If flame

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.

22 ABNORMAL FLAME-PROVING SIGNAL

Flame is proved while gas valve is de- energized. Inducer will run until fault is cleared. Check for:

- Stuck open or leaky gas valve.

23 PRESSURE SWITCH DID NOT OPEN

Check for:

- Obstructed pressure tube.

- Pressure switch stuck closed.

24 SECONDARY VOLTAGE FUSE IS OPEN

Check for:

- Short circuit in secondary voltage

(24V) wiring including thermostat leads. Disconnect thermostat leads

—p

Ps blower shuts off. Flame rollout switch and

BVSS requires manual reset. Check for:

- Dirty filter or restricted duct system.

- Loose blower wheel.

Defective switch or connections.

Inadequate combustion air supply

{flame rollout switch open).

- Restricted vent.

- Proper vent sizing.

Excessive wind. is not sensed during the trial for ignition period, the control will repeat the ignition sequence 3 more times before lockout

#14 occurs. If flame signal is lost during 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 component test mode. To check the igniter remove the R thermostat connection from the control, reset power, and put setup switch

SW 1-6 in the ON position to start the component test. Does the igniter glow orange/white by the end of the 15 second warm-up period?

YES

¥ YES

| Do the main burners ignite? v YES

| Do the main burners stay on? y No

Repeat call for heat and check flame sensor current during trial for ignition period. Is the

DC microamps below 0.5? y YES

Clean flame sensor with fine steel wool and recheck current. Nominal current is 4.0 to

6.0 microamps. ts current near typical value?

¥ YES

Will main burners ignite and stay on?

Fixed.

¥ YES

LYES

- Inadequate flame carryover or rough ignition.

Low inlet gas pressure.

- Proper firing rate.

- Blocked or incorrect carryover gap.

(.045” nominal)

Allow blower to come on and repeat test to check for intermittent operation.

Check connections and retry. If current is near typical value (4.0-6.0 nominal) and burners will not stay on, repeat check in high- heat. Hf burners will still not stay on replace control. if burners operate in high-heat then switch to low-heat,check manifold pressure. lf OK, check burner carryover and flame sensor location.

Replace electrode.

Replace furnace control.

* Blocked vent switch used in Chimney Adapter Kit sys] 04]

sys] 04]

25 INVALID MODEL SELECTION OR

SETUP ERROR -~ If status code 25 only flashes 4 times on power-up the control is missing its model plug PL4 and is defaulting to the model selection stored in memory. If status code 25 flashes continuously it could indicate any of the following:

- Model plug PL4 is missing and there is no valid model stored in permanent memory. This will happen if you forget to install the model plug PL4 on a service replacement control.

Thermostat call with SW1-1 ON.

Thermostat call with SW1-6 ON.

SW1-1 and SW1-6 both ON.

31 HIGH-HEAT PRESSURE SWITCH OR

RELAY DID NOT CLOSE OR

REOPENED - Check for:

- Control relay may be defective.

- Gas valve is miswired.

- See status code 32.

YES

41 BLOWER MOTOR FAULT ~ Indicates the blower failed to reach 250 RPM or the blower failed to communicate within the prescribed time limits. Thirty seconds after being turned ON or ten seconds during steady-state operation. Turn power off and check the following items first before proceeding to the next step.

- Rubbing blower wheel.

- Loose blower wheel.

- Wiring from furnace control to blower motor.

Remove the R thermostat connection from the furnace control, disconnect both conneciors from the blower motor PL13 and PL14. Does the blower wheel turn

YES NO

You have an open wire or bad terminal on either the BLACK or WHITE power leads p Turn power back on. Is there 115VAC at

PL14-5 and PL14-4?

¥ YES between the furnace control and the blower motor. If you have a power choke disconnect it and check continuity. YES

Is there 12-VDC at PL13-7 RED (+) and PL13-

1 GREEN (-)?

¥ NO

Is there 12-VDC at PL3-1 RED (+) and PL3-

2 GREEN ()? a

¥ NO

You have an open wire or bad terminal on either the RED or GREEN wire between the furnace control and the blower motor.

| Replace the furnace control.

¥ NO

Is there 5-VDC at PL13-16 YELLOW (+) and

Pi PLi3-1 GREEN ()?

Replace the blower control module attached replaced. freely? to the blower motor. Follow the instructions with the blower control module to make sure the entire blower motor does not need to be

You have an open wire or bad terminal on the

BLUE wire between the furnace control and the blower motor.

1 YES

The voltage just measured should be very stable and should not fluctuate more than

.02-VDC. If the voltage fluctuates more than this get a different voltmeter before proceeding.

YES Turn power off, reconnect PL13 and PL14 to

Replace the furnace control. Nonny the blower moter, then turn power back on.

Jinn

Is there 5-VDC at PL3-3 YELLOW (+) and

PL3-2 GREEN (-)?

1 YES

You have an open wire or bad terminal on the

YELLOW wire between the furnace control and the blower motor.

Connect a DC voltmeter across PL3-4 BLUE

(+) and PL3-2 GREEN (-). Does the voltage fluctuate as described two steps back? =

Connect a DC voltmeter across PL3-3

YELLOW (+) and PL3-2 GREEN (-). Does the voltage fluctuate more than it did in the previous step?

4 NO

Turn power off, disconnect PL13 and PL14 fromm the blower motor, then turn power back on. Connect a DC voltmeter across PL13-

16 BLUE (+) and PL13-1 GREEN (-). The voltage should be near 0-VDC but it will fluctuate briefly several times a second. If you have an analog voltmeter the needle will

Does the voltage fluctuate as described in the previous step? briefly go high several times a second. If you i have a digital voltmeter with a bar graph it will show a large change in magnitude on y YES

Replace the blower control module attached to the blower motor. Follow the instructions with the blower control module to make sure the entire blower motor does not need to be replaced. the bar graph several times a second. If you have a standard digital voltmeter it will show a brief fluctuation in voltage and the magnitude may vary depending on the voltmeter used.

DESCRIPTION PART NUMBER NOTES

FILCABXX0016 Filter cabinet 16” (406 mm) for 4” (102 mm) wide filter

Media Filter Cabinet FILCABXX0020 Filter cabinet 20” (608 mm) for 4” (102 mm) wide filter

FILCABXX0024 Filter cabinet 24” (610 mm) for 4” (102 mm) wide filter

FILXXCARO016 Filter Cartridge replacements for FILCAB media cabinet

Cartridge Media Filter FILXXCAR0020 Filter Cartridge replacements for FILCAB media cabinet

FILXXCAR0024 Filter Cartridge replacements for FILCAB media cabinet

EXPXXUNV0016 16” (406 mm) Replacement Expandable Filter assembly

EZ Flex Media Filter with End Caps

Replacement EZ Flex Filter Media

External Bottom Return Filter Rack

EXPXXUNV0020

EXPXXUNV0024

( )

EXPXXFILO016

(

)

EXPXXFILO020 20” (508 mm) Replacement filter for EXPUNV assembly

EXPXXFILO024 24” (610 mm) Replacement filter for EXPUNV assembly

KGAFR0401B14

KGAFRO501B17

KGAFRO601B21

Bottom return filter rack 14” (856 mm) casing

Bottom return filter rack 17” (482 mm) casing

- -

Bottom return filter rack 21” (683 mm) casing

KGAFRO701B24 Bottom return filter rack 24” (610 mm) casing

External Side Return Filter Rack KGAFRO801 SRE Ext. Side filter rack— all casings— includes filter

Unframed Filter 3/4—-in. (49 mm)

Flue Extension

*Twinning Kit

Combustible Floor Base KGASB0201 ALL Adjustable floor base - fits all casing sizes

Downflow Vent Guard

Vent Extension Kit

Chimney Adapter Kit

Natural—to—Propane Conversion Kit

Label Kit

KGAWF1301UFRT

KGAWF1401UFR

KGAWF1501UFR

KGAWF1306UFRT

KGAWF1406UFR

KGAWF1506UFR

KGAFE0O112UPH

KGATW0601 HSI

KGBVG0101DFG

KGAVE0101DNH

KGANP4601ALL

KGALBO101 KIT

(1) unframed filter 16x25x3/4 (406x685x19 mm)

(1) unframed filter 20x25x3/4 (608x685x19 mm)

(1) unframed filter 24x25x3/4 (610x685x19 mm)

(6) unframed filter 16x25x3/4 (406x685x19 mm)

(6) unframed filter 20x25x3/4 (608x685x19 mm)

(6) unframed filter 24x25x3/4 (610x685x19 mm)

(12) vent extension 4” (102 mm) dia. x 3-1/2” (89 mm)

Single or two stage PSC equipped units only

Vent flue shield — downflow venting outside casing

Downflow, through casing vent extension

KGACA02014FC

KGACA02015FC

Masonry chimney adapter 4” (102 mm)

Masonry chimney adapter 5” (127 mm)

Gas conversion natural to propane all

Propane—to—Natural Conversion Kit KGAPN3901 ALL Gas conversion propane to natural all

Downflow orientation label replacement

**ECM Motor Simulator KGASD0301FMS ECM blower and inducer simulator — variable speed units

**Advanced Product Monitor KGAFP0301APM PC software and hardware for Troubleshooting variable speed units

* Not for ECM or variable—speed ECM models

** Variable—speed ECM models only

PARTS REPLACEMENT INFORMATION GUIDE

CASING GROUP

Outer door

Blower door

Top filler plate

Bottom filler plate

Bottom enclosure

ELECTRICAL GROUP

Control bracket

Junction box

Limit switch(es)

Circuit board

Door switch

Transformer

Wiring harness 115v

Wiring harness 24v

BLOWER GROUP

Blower housing

Blower cutoff

Blower motor

Blower wheel

Capacitor (where used)

Capacitor strap (where used)

Grommet

Power choke (where used)

GAS CONTROL GROUP

Manifold

Burner assembly

Orifice

Flame sensor

Hot surface igniter

Gas vaive

Manual reset limit switches

Burner support assembly

HEAT EXCHANGER GROUP

Heat exchanger cell

Cell panel

Lox NOx baffle (California models only)

INDUCER GROUP

Housing assembly

Pressure switch

Inducer motor

Inducer wheel

Vent elbow assembly

Draft safeguard switch

TO OBTAIN INFORMATION ON PARTS: Consult your installing dealer or classified section of your local telephone directory under

“Heating Equipment” or “Air Conditioning Contractors and Systems” headings for dealer listing by brand name or contact:

CARRIER CORPORATION

Consumer Relations Department

P.O. Box 48 08

Syracuse, New York 13221-4808

1-800-CARRIER

Have available the model number, series number, and serial number located on the unit rating plate to ensure correct replacement part.

Example of Model Number

MODEL

HEATING

SIZE

VARIATION VOLTAGE SERIES PACKAGING

S8CVA

(CFM)

--- 1 5 22

WARNING: Improper installation, adjustment, alteration, service, or maintenance can cause personal injury, property damage, or death.

Consult a qualified installer, service agency, or your local gas supplier for information or assistance. The qualified installer or service agency must use only factory-authorized replacement parts, kits, or accessories when modifying this product. c opyright 2013 Carrier Corp. + 7310 W. Morris St. * Indianapolis, IN 46234

Edition Date: 03/13

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

Catalog No: 58CV-12SI

Replaces: 58CV-L1ST

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