Carrier bryant 830CA User Manual

830CA
4–Way Multipoise, Ultra Low Nox
Communicating, 80% AFUE Gas Furnace
Input Capacities 40,000 thru 100,000 Btuh
Series A
Installation, Start–Up, Operating and
Service and Maintenance Instructions
DE
S I GN
D
C
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TIFIE
Use of the AHRI Certified TM Mark indicates a
manufacturer’s participation in the program. For
verification of certification for individual products,
go to www.ahridirectory.org.
Approved for installations up to 5,400 feet (1646 meters)
NOTE: Read the entire instruction manual before starting the
installation.
SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
CODES AND STANDARDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS PROCEDURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
AIR FOR COMBUSTION AND VENTILATION . . . . . . . . . . . . 6
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
UPFLOW INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
HORIZONTAL INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . 10
AIR DUCTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
GENERAL REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . 11
SUPPLY AIR CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . 11
RETURN AIR CONNECTIONS. . . . . . . . . . . . . . . . . . . . . . . . . 12
GAS PIPING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
ELECTRICAL CONNECTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . 14
115-V WIRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
J-BOX RELOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
ACCESSORIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
NOTES FOR FIGURES 25 - 31 . . . . . . . . . . . . . . . . . . . . . . . . . 18
VENTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
GENERAL VENTING REQUIREMENTS . . . . . . . . . . . . . . . . . . . 18
Exterior Masonry Chimney FAN + NAT
Installations with Type-B Double Wall Vent
Connectors ©FPA & AGA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Venting Notes for Fig. 33 - Fig. 38 . . . . . . . . . . . . . . . . . . . . . . . 22
start-up, adjustment, and safety check . . . . . . . . . . . . . . . . . . . . . . . 22
SERVICE AND MAINTENANCE
PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
PARTS REPLACEMENT INFORMATION GUIDE . . . . . . . . . . . 39
Portions of the text and tables are reprinted from NFPA 54/ANSI
Z223.1E, with permission of National Fire Protection Association,
Quincy, MA 02269 and American Gas Association, Washington DC
20001. This reprinted material is not the complete and official position
of the NFPA or ANSI on the referenced subject, which is represented
only by the standard in its entirety.
! WARNING
CARBON MONOXIDE POISONING HAZARD
Failure to follow this warning could result in personal injury and/or
death.
Carbon Monoxide (CO) is a colorless, odorless, and tasteless poisonous
gas that can be fatal when inhaled. Follow all installation, maintenance,
and service instructions. See additional information below regarding
the installation of a CO Alarm.
Most states in the USA and jurisdictions in Canada have laws that
require the use of Carbon Monoxide (CO) alarms with fuel burning
products. Examples of fuel burning products are furnaces, boilers, space
heaters, generators, water heaters, stoves/ranges, clothes dryers,
fireplaces, incinerators, automobiles, and other internal combustion
engines. Even if there are no laws in your jurisdiction requiring a CO
Alarm, it’s highly recommended that whenever any fuel burning product
is used in or around the home or business that the dwelling be equipped
with a CO Alarm(s). The Consumer Product Safety Commission
recommends the use of CO Alarm(s). The CO Alarm(s) must be
installed, operated, and maintained according to the CO Alarm
manufacturer’s instructions. For more information about Carbon
Monoxide, local laws, or to purchase a CO Alarm online, please visit the
following website. https://www.kidde.com.
SAFETY CONSIDERATIONS
! CAUTION
FIRE, EXPLOSION, ELECTRICAL SHOCK, AND
CARBON MONOXIDE POISONING HAZARD
Failure to follow this warning could result in dangerous operation,
serious injury, death, or property damage.
Improper installation, adjustment, alteration, service, maintenance, or
use could 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.
830CA: Installation, Start–Up, Operating and Service and Maintenance Instructions
! CAUTION
FURNACE RELIABILITY HAZARD
Improper installation or misapplication of furnace may require
excessive servicing or cause premature component failure.
Application of this furnace should be indoors with special attention
given to vent sizing and material, gas input rate, air temperature rise,
unit leveling, and unit sizing.
Improper installation, adjustment, alteration, service, maintenance, or
use can cause explosion, fire, electrical shock, or other conditions which
may cause death, personal injury, or property damage. Consult a
qualified installer, service agency, or your distributor or branch for
information or assistance. The qualified installer or agency must use
factory-authorized kits or accessories when modifying this product.
Refer to the individual instructions packaged with the kits or accessories
when installing.
Follow all safety codes. Wear safety glasses, protective clothing, and
work gloves. Have a fire extinguisher available. Read these instructions
thoroughly and follow all warnings or cautions include in literature and
attached to the unit. Consult local building codes, the current editions of
the current edition of National Fuel Gas Code (NFGC) NFPA 54/ANSI
Z223.1 and the current edition of National Electrical Code (NEC) NFPA
70.
Recognize safety information. This is the safety-alert symbol . When
you see this symbol on the unit and in instructions or manuals, be alert to
the potential for personal injury.
Understand the signal words DANGER, WARNING, and CAUTION.
These words are used with the safety-alert symbol. DANGER identifies
the most serious hazards which will result in severe personal injury or
death. WARNING signifies hazards which could result in personal
injury or death. CAUTION is used to identify unsafe practices which
may result in minor personal injury or product and property damage.
NOTE is used to highlight suggestions which will result in enhanced
installation, reliability, or operation.
“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,
see Fig. 5.
9. The furnace is not permitted to be used for heating of buildings
under construction.
10. These Multipoise Gas-Fired Furnaces are CSA (formerly A.G.A.
and C.G.A). design-certified for use with natural gas (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 and cannot be converted
for use with propane.
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 inches (914 mm)
horizontally from the furnace. See current edition of NFPA 90B or
local code for further requirements.
13. These furnaces SHALL NOT be installed directly on carpeting, tile,
or any other combustible material other than wood flooring. In
downflow installations, factory accessory floor base MUST be
used when installed on combustible materials and wood flooring.
Special base is not required when this furnace is installed on
manufacturer’s approved coil assembly or a manufacturer’s coil
casing box is used. See Fig. 1 for clearance to combustible
construction.
! 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 following additional safety considerations should be followed for
gas furnaces:
1. Use only with type of gas approved for this furnace. Refer to the
furnace rating plate.
2. Install this furnace only in a location and position as specified in the
“Location” section of these instructions.
3. Provide adequate combustion and ventilation air to the furnace
space as specified in “Air for Combustion and Ventilation” section.
4. Combustion products must be discharged outdoors. Connect this
furnace to an approved vent system only, as specified in the
“Venting” section of these instructions.
5. Never test for gas leaks with an open flame. Use a commercially
available soap solution made specifically for the detection of leaks
to check all connections, as specified in the “Gas Piping” section.
6. Always install furnace to operate within the furnace’s intended
temperature-rise range with a duct system which has an external
static pressure within the allowable range, as specified in the
Fig. 1 – Clearances to Combustibles
Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations.
2
A190402
NOTE: ALL DIMENSIONS IN INCH (MM)
U.S. ECCN: Not Subject to Regulation (N.S.R.)
SD5550-4 REV. A
830CA: Installation, Start–Up, Operating and Service and Maintenance Instructions
A180207
Fig. 2 – Dimensional Drawing
Table 1 – Dimension
FURNACE
SIZE
A
CABINET
WIDTH
IN. (MM)
B
OUTLET WIDTH
IN. (MM)
C
TOP FLUE
COLLAR ONLY
IN. (MM)
D
BOTTOM
INLET WIDTH
IN. (MM)
VENT
CONNECTION
IN. (MM) SIZE
SHIP WT. LB.
(KG)
ACCESSORY
FILTER
MEDIA
CABINET SIZE
IN. (MM)
36040C17B
17-1/2 (445)
15-7/8 (403)
11-9/16 (294)
16 (406)
4 (102)
119 (54)
16 (406)
48060C17B
17-1/2 (445)
15-7/8 (403)
11-9/16 (294)
16 (406)
4 (102)
124 (56)
16 (406)
60080C21C
21 (533)
19-3/8 (492)
13-5/16 (338)
19-1/2 (495)
4 (102)
144 (65)
20 (508)
60100C21C
21 (533)
19-3/8 (492)
13-5/16 (338)
19-1/2 (495)
4 (102)
154 (70)
20 (508)
Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations.
3
830CA: Installation, Start–Up, Operating and Service and Maintenance Instructions
INTRODUCTION
Gas Piping and Gas Pipe Pressure Testing
This 4-way multipoise Category I fan-assisted furnace is CSA
design-certified. A Category I fan-assisted furnace is an appliance
equipped with an integral mechanical means to either draw or force
products of combustion through the combustion chamber and/or heat
exchanger. The furnace is factory-shipped for use with natural gas.
This furnace is not approved for installation in mobile homes,
recreational vehicles, or outdoors. The furnace is not permitted to be
used for heating of buildings under construction. This furnace is
designed for minimum continuous return-air temperature of 60°F (16°C)
db or intermittent operation down to 55°F (13°C) db such as when used
with a night setback thermostat. Return-air temperature must not exceed
80°F (27°C) db. Failure to follow these return-air temperature limits may
affect reliability of heat exchangers, motors, and controls, see Fig. 3.
For accessory installation details, refer to the applicable instruction
literature.
NOTE: Remove all shipping brackets and materials before operating the
furnace.
• Current edition of NFGC NFPA54/ANSI Z223.1; chapters 5, 6, 7, and
8 and National Plumbing Codes.
Electrical Connections
• Current edition of National Electrical Code (NEC) NFPA 70.
Venting
• Current edition of NFGC NFPA 54 / ANSI Z223.1; Chapters 12 and
13.
ELECTROSTATIC DISCHARGE (ESD)
PRECAUTIONS PROCEDURE
1. Disconnect all power to the furnace. Multiple disconnects maybe
required. DO NOT TOUCH THE CONTROL OR ANY WIRE
CONNECTED TO THE CONTROL PRIOR TO DISCHARGING
YOUR BODY’S ELECTROSTATIC CHARGE TO GROUND.
2. Firmly touch the clean, unpainted, metal surface of the furnace
chassis which is close to the control. Tools held in a person’s hand
during grounding will be satisfactorily discharged.
! CAUTION
Max 85ºF/ 29ºC
FURNACE RELIABILITY HAZARD
Min 60ºF / 16ºC
Fig. 3 – Return Air Temperature
A02055
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
• USA: Current edition of National Fuel Gas Code (NFGC) NFPA
54/ANSI Z223.1 and the Installation Standards, Warm Air Heating
and Air Conditioning Systems ANSI/NFPA 90B
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
• Current edition of NFGC NFPA54/ANSI Z223.1 Section 9.3, 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) 2005 Fundamentals Handbook
Chapter 35 or 2004 HVAC Systems and Equipment Handbook
Chapters 9 and 16.
Improper installation or service of furnace may cause premature
furnace component failure.
Electrostatic discharge can affect electronic components. Follow the
Electrostatic Discharge Precautions Procedure listed below during
furnace installation and servicing to protect the furnace electronic
control. Precautions will prevent electrostatic discharges from
personnel and hand tools which are held during the procedure. These
precautions will help to avoid exposing the control to electrostatic
discharge by putting the furnace, the control, and the person at the same
electrostatic potential.
3. After touching the chassis, you may proceed to service the control
or connecting wires as long as you do nothing to recharge your
body with static electricity (for example; DO NOT move or shuffle
your feet, do not touch ungrounded objects, etc).
4. If you touch ungrounded objects (and recharge your body with
static electricity), firmly touch a clean, unpainted metal surface of
the furnace again before touching control or wires.
5. Use this procedure for installed and uninstalled (ungrounded)
furnaces.
6. Before removing a new control from its container, discharge your
body’s electrostatic charge to ground to protect the control from
damage. If the control is to be installed in a furnace, follow items 1
through 4 before bringing the control or yourself in contact with the
furnace. Put all used and new controls into containers before
touching ungrounded objects.
7. An ESD service kit (available from commercial sources) may also
be used to prevent ESD damage.
LOCATION
GENERAL
This multipoise furnace is shipped in packaged configuration. Some
assembly and modifications are required when used in any of the four
applications, shown in Fig. 4.
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
Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations.
4
830CA: Installation, Start–Up, Operating and Service and Maintenance Instructions
• Antistatic fabric softeners for clothes dryers
• Masonry acid washing materials
All fuel-burning equipment must be supplied with air for fuel
combustion. Sufficient air must be provided to avoid negative pressure
in the equipment room or space. A positive seal must be made between
the furnace cabinet and the return-air duct to prevent pulling air from the
burner area and from draft safeguard opening.
THE BLOWER IS
LOCATED BELOW THE
BURNER SECTION, AND
CONDITIONED AIR IS
DISCHARGED UPWARD.
THE BLOWER IS LOCATED
TO THE RIGHT OF THE
BURNER SECTION, AND
AIR CONDITIONED AIR IS
DISCHARGED TO THE LEFT.
THE BLOWER IS
LOCATED TO THE LEFT
OF THE BURNER SECTION,
AND CONDITIONED AIR IS
DISCHARGED TO THE RIGHT.
THE BLOWER IS
LOCATED ABOVE THE
BURNER SECTION, AND
CONDITIONED AIR IS
DISCHARGED DOWNWARD
A02097
Fig. 4 – Multipoise Orientations
This furnace must:
• be installed so the electrical components are protected from water.
• not be installed directly on any combustible material other than
wood flooring for upflow applications. Downflow installations
require use of a factory-approved floor base or coil assembly when
installed on combustible materials or wood flooring (refer to
SAFETY CONSIDERATIONS).
• be located close to the chimney or vent and attached to an air
distribution system. Refer to Air Ducts section.
• be provided ample space for servicing and cleaning. Always
comply with minimum fire protection clearances shown on the
furnace clearance to combustible label.
! WARNING
! CAUTION
PERSONAL INJURY AND/OR PROPERTY DAMAGE
Improper use or installation of this furnace may cause premature
furnace component failure.
This furnace is not permitted to be used for heating of buildings under
construction.
! WARNING
FIRE HAZARD
Failure to follow this warning could result in personal injury, death,
and/or property damage.
When the furnace is installed in a residential garage, the burners and
ignition sources must be located at least 18 inches above the floor, see
Fig. 5. The furnace must be located or protected to avoid damage by
vehicles. When the furnace is installed in a public garage, airplane
hangar, or other building having a hazardous atmosphere, the furnace
must be installed in accordance with the NFGC.
CARBON MONOXIDE POISONING 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:
• Commercial buildings
• Buildings with indoor pools
• Laundry rooms
• Hobby or craft rooms, and
• Chemical storage areas
If air is exposed to the following substances, it should not be used for
combustion air, and outdoor air may be required for combustion:
• Permanent wave solutions
• Chlorinated waxes and cleaners
• Chlorine based swimming pool chemicals
• Water softening chemicals
• De-icing salts or chemicals
• Carbon tetrachloride
• Halogen type refrigerants
• Cleaning solvents (such as perchloroethylene)
• Printing inks, paint removers, varnishes, etc.
• Hydrochloric acid
• Cements and glues
18-IN. (457.2 mm)
MINIMUM TO BURNERS
Fig. 5 – Installation in a Garage
A93044
! 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.
Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations.
5
830CA: Installation, Start–Up, Operating and Service and Maintenance Instructions
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.
1 SQ IN.
PER 4000
BTUH*
FURNACE CORROSION HAZARD
Failure to follow this caution may result in furnace damage.
Air for combustion must not be contaminated by halogen compounds,
which include fluoride, chloride, bromide, and iodide. These elements
can corrode heat exchangers and shorten furnace life. Air contaminants
are found in aerosol sprays, detergents, bleaches, cleaning solvents,
salts, air fresheners, and other household products.
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.
AIR FOR COMBUSTION AND VENTILATION
Provisions for adequate combustion, ventilation, and dilution air must be
provided in accordance with:
• U.S. installations: Section 9.3 of the current edition of NFGC
NFPA54/ANSI Z223.1, Air for Combustion and Ventilation, and
applicable provisions of the local building codes.
! 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
Carbon Monoxide Poisoning Hazard warning in venting section of
these instructions to determine if an adequate amount of make-up air is
available.
The requirements for combustion and ventilation air depend upon
whether or not the furnace is located in a space having a volume of at
least 50 cubic feet per 1,000 Btuh input rating for all gas appliances
installed in the space.
• Spaces having less than 50 cubic feet per 1,000 Btuh require the
OUTDOOR COMBUSTION AIR METHOD.
• Spaces having at least 50 cubic feet per 1,000 Btuh may use the
INDOOR COMBUSTION AIR, STANDARD or KNOWN AIR
INFILTRATION METHOD.
B
DUCTS
TO
OUTDOORS
1 SQ IN.
PER 2000
BTUH*
(305mm) 12″ MAX
A
12″ (305mm)
MAX
D
VENT
THROUGH
ROOF
F
1 SQ IN.
PER
4000
BTUH*
OUTDOORS
! CAUTION
(305mm) 12″ MAX
1 SQ IN.
PER 2000
BTUH*
CLEARANCE IN FRONT
OF COMBUSTION AIR
OPENINGS SHALL BE
AT LEAST 3 IN.
(76mm)
Fig. 6 – Prohibit Installation on Back
A02054
CIRCULATING
AIR DUCTS
DUCTS
TO
OUTDOORS
1 SQ IN.
PER
4000
BTUH*
E
G
12″ (305mm)
MAX
C
12″ MAX
(305mm)
CIRCULATING AIR DUCTS
DUCT
TO
OUTDOORS
1 SQ IN.
PER 4000
BTUH*
*Minimum dimensions of 3 in. (76 mm).
NOTE: Use any of the following combinations of openings:
A&B, C&D, D&E, F&G
A03174
Fig. 7 – Air for Combustion, Ventilation, and Dilution from
Outdoors
2. Fig. 7 illustrates how to provide TWO OUTDOOR OPENINGS,
one inlet and one outlet combustion and ventilation air opening, to
the outdoors.
a. One opening MUST commence within 12-in. (300 mm) of the
ceiling and the second opening MUST commence within 12-in.
(300 mm) of the floor.
b. Size openings and ducts per Fig. 7 and Table 2.
c. TWO HORIZONTAL DUCTS require 1 square inch of free area
per 2,000 Btuh (1,100 mm2/kW) of combined input for all gas
appliances in the space per Fig. 7 and Table 2.
d. TWO OPENINGS OR VERTICAL DUCTS require 1 square
inch of free area per 4,000 Btuh (550 mm2/kW) for combined
input of all gas appliances in the space per Fig. 7 and Table 2.
3. ONE OUTDOOR OPENING requires:
a. 1 square inch of free area per 3,000 Btuh (734 mm2/kW) for
combined input of all gas appliances in the space per Table 2 and
b. Not less than the sum of the areas of all vent connectors in the
space.
The opening shall commence within 12” (300 mm) of the ceiling.
Appliances in the space shall have clearances of at least 1” (25 mm)
from the sides and back and 6” (150 mm) from the front. The opening
shall directly communicate with the outdoors or shall communicate
through a vertical or horizontal duct to the outdoors or spaces (crawl or
attic) that freely communicate with the outdoors.
– Indoor Combustion Air© NFPA & AGA
– Standard and Known-Air-Infiltration Rate Methods
– Indoor air is permitted for combustion, ventilation, and dilution, if
the Standard or Known-Air-Infiltration Method is used.
Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations.
6
830CA: Installation, Start–Up, Operating and Service and Maintenance Instructions
! WARNING
Volume
CARBON MONOXIDE POISONING HAZARD
Failure to follow this warning could result in death and/or personal
injury.
Many homes require air to be supplied from outdoors for furnace
combustion, ventilation, and dilution of flue gases. The furnace
combustion air supply must be provided in accordance with this
instruction manual.
The Standard Method
Use the Standard Method if:
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).
Use the Known Air Infiltration Rate Method 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 2 - Minimum Space Volumes were determined by using the
following equations from the National Fuel Gas Code ANSI
Z223.1/NFPA 54, 9.3.2.2:
1. For other than fan-assisted appliances, such as a draft
hood-equipped water heater:
Other
3
I other
= 21ft
ACH 1000 Btu/hr
A04002
2. For fan-assisted appliances such as this furnace:
Volume
Fan
3
I fan
= 15ft
ACH 1000 Btu/hr
A04003
If the following is applied to either equation:
I
other = combined input of all other than fan-assisted appliances in
Btuh/hr
I
fan = combined input of all fan-assisted appliances in Btuh/hr
ACH = air changes per hour (ACH shall not exceed 0.60.)
Then the following requirements apply to the Standard Method and to
the Known Air Infiltration Rate Method.
1. Adjoining rooms can be considered part of a space if:
a. There are no closeable doors between rooms.
b. Combining spaces on same floor level. Each opening shall have
free area of at least 1 in.2/1,000 Btuh (2,000 mm2/kW) of the
total input rating of all gas appliances in the space, but not less
than 100 in.2 (0.06 m2). One opening shall commence within 12
in. (300 mm) of the ceiling and the second opening shall
commence within 12 in. (300 mm) of the floor. The minimum
dimension of air openings shall be at least 3 in. (80 mm), see
Fig. 8.
c. Combining space on different floor levels. The volumes of
spaces on different floor levels shall be considered as
communicating spaces if connected by one or more permanent
openings in doors or floors having free area of at least 2
in.2/1,000 Btuh (4,400 mm2/kW) of total input rating of all gas
Table 2 – Minimum Free Area Required for Each Combustion Air Opening or Duct to Outdoors
FURNACE INPUT
(BTUH)
TWO HORIZONTAL DUCTS
(1 SQ. IN./2,000 BTUH)
(1,100 SQ. MM/KW)
SINGLE DUCT OR OPENING
(1 SQ. IN./3,000 BTUH)
(734 SQ. MM/KW)
TWO OPENINGS OR
VERTICAL DUCTS
(1 SQ. IN./4,000 BTUH)
(550 SQ. MM/KW)
Free Area of
Opening and Duct
Sq. In (Sq. mm)
Round Duct
In. (mm) Dia
Free Area of
Opening and Duct
Sq. In (Sq. mm)
Round Duct
In. (mm) Dia
Free Area of
Opening and Duct
Sq. In (mm)
Round Duct
In. (mm) Dia.
40,000
20 (12904)
5 (127)
14 (8696)
5 (127)
10 (6452)
4 (102)
60,000
30 (19355)
6 (152)
20 (13043)
5 (127)
15 (9678)
5 (127)
80,000
40 (25807)
7 (178)
27 (17391)
6 (152)
20 (12904)
5 (127)
100,000
50 (32258)
8 (203)
34 (21739)
7 (178)
25 (16130)
6 (152)
FURNACE
100,000
60,000
80,000
+
+
+
WATER HEATER
30,000
40,000
30,000
=
=
=
EXAMPLE: Determining Free Area
TOTAL INPUT
(130,000 divided by 4,000)
=
(100,000 divided by 3,000)
=
(110,000 divided by 2,000)
=
32.5 Sq. In. for each two Vertical Ducts or Openings
33.3 Sq. In. for each Single Duct or Opening
55.0 Sq. In. for each two Horizontal Ducts
Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations.
7
830CA: Installation, Start–Up, Operating and Service and Maintenance Instructions
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
*
ACH
0.60
0.50
0.40
0.30
0.20
0.10
0.00
30
1,050
1,260
1,575
2,100
3,150
6,300
NP
40
FAN-ASSISTED TOTAL
(1,000’S BTUH GAS INPUT RATE)
50
40
Space Volume (ft.3)
1,750
1,000
2,100
1,200
2,625
1,500
3,500
2,000
5,250
3,000
10,500
6,000
NP
NP
1,400
1,680
2,100
2,800
4,200
8,400
NP
60
80
100
1,500
1,800
2,250
3,000
4,500
9,000
NP
2,000
2,400
3,000
4,000
6,000
12,000
NP
3,300
3,960
4,950
6,600
9,900
19,800
NP
*. Air Changes/Hour
Combination of Indoor and Outdoor Air
INTERIOR
HEATED
SPACE
1. Indoor openings shall comply with the Indoor Combustion Air
Method below and,
2. Outdoor openings shall be located as required in the Outdoor
Combustion Air Method mentioned previously and,
3. Outdoor openings shall be sized as follows:
a. Calculate the Ratio of all Indoor Space volume divided by
required volume for Indoor Combustion Air Method below.
b. Outdoor opening size reduction Factor is 1 minus the Ratio in a.
above.
c. Minimum size of Outdoor openings shall be the size required in
Outdoor Combustion Air Method above multiplied by reduction
Factor in b. above. The minimum dimension of air openings shall
be not less than 3 in. (80 mm).
VENT THROUGH ROOF
CLEARANCE IN FRONT OF COMBUSTION AIR
OPENINGS SHALL BE AT LEAST 3 IN.
CIRCULATING AIR
DUCTS
12" MAX (305mm)
1 SQ IN.
PER 1000
BTUH* IN DOOR
OR WALL
UNCONFINED
SPACE
6" MIN (152mm)
(FRONT)Ü
1 SQ IN.
PER 1000
BTUH* IN DOOR
OR WALL
INSTALLATION
UPFLOW INSTALLATION
Bottom Return Air Inlet
12" MAX (305mm)
CIRCULATING AIR DUCTS
*Minimum opening size is 100 in.2 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
2. An attic or crawlspace may be considered a space that freely
communicates with the outdoors provided there are adequate
permanent ventilation openings directly to outdoors having free
area of at least 1-in.2/4,000 Btuh of total input rating for all gas
appliances in the space.
3. In spaces that use the Indoor Combustion Air Method, infiltration
should be adequate to provide air for combustion, permanent
ventilation and dilution of flue gases. However, in buildings with
unusually tight construction, additional air MUST be provided
using the methods described in the Outdoor Combustion Air
Method section.
4. Unusually tight construction is defined as construction with:
a. Walls and ceilings exposed to the outdoors have a continuous,
sealed vapor barrier. Openings are gasketed or sealed and
b. Doors and openable windows are weatherstripped and
c. Other openings are caulked or sealed. These include joints
around window and door frames, between sole plates and floors,
between wall-ceiling joints, between wall panels, at penetrations
for plumbing, electrical and gas lines, etc.
These furnaces are shipped with bottom closure panel installed in bottom
return-air opening. Remove and discard this panel when bottom return
air is used. To remove bottom closure panel, perform the following:
1. Tilt or raise furnace and remove two screws holding bottom filler
panel see Fig. 9.
Bottom
Closure Panel
Bottom Filler Panel
Fig. 9 – Removing Bottom Closure Panel
2. Rotate bottom filler panel downward to release holding tabs.
3. Remove bottom closure panel.
4. Reinstall bottom filler panel and screws.
A10273
Side Return Air Inlet
These furnaces are shipped with bottom closure panel installed in bottom
return-air opening. This panel MUST be in place when only side return
air is used.
NOTE: Side return-air openings can be used in UPFLOW and most
HORIZONTAL configurations. Do not use side return-air openings in
DOWNFLOW configuration.
Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations.
8
830CA: Installation, Start–Up, Operating and Service and Maintenance Instructions
Leveling Legs (If Desired)
In upflow position with side return inlet(s), leveling legs may be used,
see Fig. 10. Install field-supplied, 5/16 x 1-1/2 in. (8 x 38 mm) (max)
corrosion-resistant machine bolts, washers and nuts.
NOTE: Bottom closure must be used when leveling legs are used. It
may be necessary to remove and reinstall bottom closure panel to install
leveling legs. To remove bottom closure panel, see Item 1. in Bottom
Return Air Inlet section.
To install leveling legs:
1. Position furnace on its back. Locate and drill a hole in each bottom
corner of furnace, see Fig. 10.
2. For each leg, install nut on bolt and then install bolt and nut in hole.
(Install flat washer if desired.)
3. Install another nut on other side of furnace base. (Install flat washer
if desired.)
4. Adjust outside nut to provide desired height, and tighten inside nut
to secure arrangement.
5. Reinstall bottom closure panel if removed.
A
PLENUM
OPENING
D
B
FLOOR
OPENING
C
Fig. 11 – Floor and Plenum Opening Dimensions
A96283
5/ 16
(8mm)
FURNACE
(OR COIL CASING
WHEN USED)
(8mm)
5/ 16
1 3/4
(44mm)
COMBUSTIBLE
FLOORING
1 3/4
(44mm)
DOWNFLOW
SUBBASE
SHEET METAL
PLENUM
FLOOR
OPENING
(8mm)
5/16
(8mm)
5/ 16
(44mm) 1 3/ 4
3/
(44mm) 1 4
Fig. 10 – Leveling Legs
A89014
DOWNFLOW INSTALLATION
NOTE: For downflow applications, this furnace is approved for use on
combustible flooring when any one of the following 3 accessories are
used:
• Downflow combustible floor subbase
• Manufacturer’s approved Cased Coil or Coil Casing
1. Determine application being installed from Table 4.
2. Construct hole in floor per Table 4 and Fig. 11.
3. Construct plenum to dimensions specified in Table 4 and Fig. 11.
4. If downflow subbase is used, install as shown in Fig. 12. If Coil or
Coil Casing, install as shown in Fig. 13.
NOTE: It is required 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. 17.
Fig. 12 – Furnace, Plenum, and Subbase Installed
on a Combustible Floor
A96285
FURNACE
APPROVED
COIL ASSEMBLY
OR
COIL BOX
COMBUSTIBLE
FLOORING
SHEET METAL
PLENUM
FLOOR
OPENING
Fig. 13 – Furnace, Plenum, and Coil Assembly or
Coil Box Installed on a Combustible Floor
Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations.
9
A08556
830CA: Installation, Start–Up, Operating and Service and Maintenance Instructions
Table 4 – Opening Dimensions - In. (mm)
FURNACE
CASING
WIDTH
17–1/2
(445)
21
(533)
PLENUM OPENING
APPLICATION
Upflow Applications on Combustible or Noncombustible Flooring
(subbase not required)
Downflow Applications on Noncombustible Flooring
(subbase not required)
Downflow applications on combustible flooring
(subbase required)
Downflow Applications on Combustible Flooring with Coil Assembly or coil
box (subbase not required)
Upflow Applications on Combustible or Noncombustible Flooring
(subbase not required)
Downflow Applications on Noncombustible Flooring
(subbase not required)
Downflow applications on combustible Flooring
(subbase required)
Downflow Applications on Combustible Flooring with Coil Assembly or coil
box (subbase not required)
Bottom Return Air Inlet
These furnaces are shipped with bottom closure panel installed in bottom
return-air opening. Remove and discard this panel when bottom return
air is used. To remove bottom closure panel, perform the following:
1. Tilt or raise furnace and remove two screws holding bottom filler
panel, see Fig. 9.
2. Rotate bottom filler panel downward to release holding tabs.
3. Remove bottom closure panel.
4. Reinstall bottom filler panel and screws
HORIZONTAL INSTALLATION
! WARNING
A
B
C
D
16
(406)
15-7/8
(403)
15-1/8
(384)
15-1/2
(394)
19-1/2
(495)
19-3/8
(492)
18-5/8
(473)
19
(483)
21-5/8
(549)
19
(483)
19
(483)
19
(483)
21-5/8
(549)
19
(483)
19
(483)
19
(483)
16-5/8
(422)
16-1/2
(419)
16-3/4
(425)
16-1/2
(419)
20-1/8
(511)
20
(508)
20-1/4
(514)
20
(508)
22-1/4
(565)
19-5/8
(498)
20-5/8
(600)
20
(508)
22-1/4
(565)
19-5/8
(498)
20-5/8
(600)
20
(508)
blocks, bricks or angle iron. For crawl space installations, if the furnace
is not suspended from the floor joists, the ground underneath furnace
must be level and the furnace set on blocks or bricks.
Roll-Out Protection
Provide a minimum 17-3/4 in. x 22 in. (451 mm x 559 mm) piece of
sheet metal for flame roll-out protection in front of burner area for
furnaces closer than 12 inches (305 mm) above the combustible deck or
suspended furnaces closer than 12 inches (305 mm) to joists. The sheet
metal MUST extend underneath the furnace casing by 1 in. (25 mm)
with the door removed.
The bottom closure panel on furnaces of widths 17-1/2 in. (445 mm) and
larger may be used for flame roll-out protection when bottom of furnace
is used for return air connection, see Fig. 16 for proper orientation of
roll-out shield.
FIRE, EXPLOSION, AND CARBON MONOXIDE
POISONING HAZARD
Bottom Return Air Inlet
The furnace can be installed horizontally in an attic or crawl space on
either the left-hand (LH) or right-hand (RH) side. The furnace can be
hung from floor joists, rafters or trusses or installed on a
non-combustible platform, blocks, bricks or pad.
Side Return Air Inlet
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.
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. 14 and Fig. 15. Secure
angle iron to bottom of furnace as shown. Heavy-gauge sheet metal
straps (plumber’s straps) may be used to suspend the furnace from each
bottom corner. To prevent screws from pulling out, use 2 #8 x 3/4-in. (19
mm) screws into the side and 2 #8 x 3/4-in. (19 mm) screws in the
bottom of the furnace casing for each strap, see Fig. 14 and Fig. 15. 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. 1 and Fig. 16. For furnaces with 1-in. (25
mm) clearance requirement on side, set furnace on noncombustible
FLOOR OPENING
These furnaces are shipped with bottom closure panel installed in bottom
return-air opening. Remove and discard this panel when bottom return
air is used. To remove bottom closure panel, perform the following:
1. Tilt or raise furnace and remove two screws holding bottom filler
panel, see Fig. 9.
2. Rotate bottom filler panel downward to release holding tabs.
3. Remove bottom closure panel.
4. Reinstall bottom filler panel and screws. Side Return Air Inlet
These furnaces are shipped with bottom closure panel installed in bottom
return-air opening. This panel MUST be in place when side return air
inlet(s) is used without a bottom return air inlet.
Filter Arrangement
! WARNING
CARBON MONOXIDE AND POISONING
HAZARD
Failure to follow this warning could result in personal injury, or death.
Never operate a furnace without a filter or with filter access door
removed.
There are no provisions for an internal filter rack in these furnaces.
A field-supplied accessory external filter is required.
Refer to the instructions supplied with the external filter rack for
assembly and installation options.
Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations.
10
830CA: Installation, Start–Up, Operating and Service and Maintenance Instructions
1
/4" (6mm) THREADED ROD
4 REQ.
OUTER DOOR
ASSEMBLY
SECURE ANGLE
IRON TO BOTTOM
OF FURNACE WITH
3 #8 x 3/4" (19mm) SCREWS
TYPICAL FOR 2 SUPPORTS
8" (203mm) MIN
FOR DOOR REMOVAL
1” (25mm) SQUARE, 1-1/4”x1-1/4”x1/8” (32x32x3mm)
ANGLE IRON OR UNI-STRUT MAY BE USED
(2) HEX NUTS, (2) WASHERS & (2) LOCK WASHERS
REQ. PER ROD
A10130
Fig. 14 – Horizontal Unit Suspension
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 11 - AIR
DELIVERY-CFM (with filter).
When a furnace is installed so that the supply ducts carry air circulated
by the furnace to areas outside the space containing the furnace, the
return air shall also be handled by duct(s) sealed to the furnace casing
and terminating outside the space containing the furnace.
Secure ductwork with proper fasteners for type of ductwork used. Seal
supply- and return-duct connections to furnace with code approved tape
or duct sealer.
NOTE: Flexible connections should be used between ductwork and
furnace to prevent transmission of vibration. Ductwork passing through
unconditioned space should be insulated and sealed to enhance system
performance. When air conditioning is used, a vapor barrier is
recommended.
Maintain a 1-in. (25 mm) clearance from combustible materials to
supply air ductwork for a distance of 36 in. (914 mm) horizontally from
the furnace. See NFPA 90B or local code for further requirements.
Ductwork Acoustical Treatment
METHOD 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.
METHOD 1
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).
Fig. 15 – Horizontal Suspension with Straps
NOTE: Metal duct systems that do not have a 90 degree elbow and 10ft.
(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 airstream. The
cover attachment shall prevent leaks.
Upflow and Horizontal Furnaces
A10131
Connect supply-air duct to flanges on furnace supply-air outlet. Bend
flange upward to 90° with wide duct pliers, see Fig. 17. The supply-air
duct must be connected to ONLY the furnace supply-outlet-air duct
flanges or air conditioning coil casing (when used). DO NOT cut main
furnace casing side to attach supply air duct, humidifier, or other
accessories. All accessories MUST be connected to duct external to
furnace main casing.
NOTE: For horizontal applications, the top-most flange may be bent
past 90 degrees to allow the evaporator coil to hang on the flange
temporarily while the remaining attachment and sealing of the coil are
performed.
Downflow Furnaces
Fig. 16 – Typical Attic Installation
A180240
AIR DUCTS
GENERAL REQUIREMENTS
Connect supply-air duct to supply-air outlet on furnace. Bend flange
inward past 90° with wide duct pliers, see Fig. 17. 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.
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
Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations.
11
830CA: Installation, Start–Up, Operating and Service and Maintenance Instructions
UPFLOW/
HORIZONTAL
DOWNFLOW
Fig. 17 – Duct Flanges
A190346
RETURN AIR CONNECTIONS
! WARNING
FIRE HAZARD
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
A190364
Fig. 19 – Upflow Return Air Configurations and Restrictions
Downflow Furnaces
RETURN
AIR
The return-air duct must be connected to return-air opening (bottom inlet
as shown in Fig. 2). DO NOT cut into casing sides (left or right). Side
opening is permitted for only upflow and most horizontal furnaces, see
Fig. 18. Bypass humidifier connections should be made at ductwork or
coil casing sides exterior to furnace.
Upflow and Horizontal Furnaces
The return-air duct must be connected to bottom, sides (left or right), or a
combination of bottom and side(s) of main furnace casing, see Fig. 19
and Fig. 20. Bypass humidifier may be attached into unused return air
side of the furnace casing, see Fig. 19 and Fig. 20.
SUPPLY
AIR
RETURN
AIR
NOTE: RESTRICTION SAME FOR
HORIZONTAL-LEFT
RETURN
AIR
HORIZONTAL
RETURN AIR
RESTRICTIONS
A190366
Fig. 20 – Horizontal Return Air Configurations and Restrictions
GAS PIPING
A190365
Fig. 18 – Downflow Return Air Configurations and Restrictions
Gas piping must be installed in accordance with national and local
codes. Refer to current edition of NFGC.
Installations must be made in accordance with all authorities having
jurisdiction. If possible, the gas supply line should be a separate line
running directly from meter to furnace.
NOTE: In the state of Massachusetts:
1. Gas supply connections MUST be performed by a licensed
plumber or gas fitter.
2. When flexible connectors are used, the maximum length shall not
exceed 36 inches (915 mm).
3. When lever handle type manual equipment shutoff valves are used,
they shall be T-handle valves.
4. The use of copper tubing for gas piping is NOT approved by the
state of Massachusetts.
Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations.
12
830CA: Installation, Start–Up, Operating and Service and Maintenance Instructions
! WARNING
! CAUTION
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.
! WARNING
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 assembly and a
gas leak.
Refer to Table 5 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.
(2 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 5 – Maximum Capacity of Pipe*
FURNACE OVERHEAT HAZARD
Failure to follow this caution may result in property damage.
Connect gas pipe to gas valve using a backup wrench to avoid
damaging gas controls and burner misalignment.
An accessible manual equipment shutoff valve MUST be installed
external to furnace casing and within 6 ft. (2 M) of furnace. A 1/8-in. (3
mm) NPT plugged tapping, accessible for test gauge connection, MUST
be installed immediately upstream of gas supply connection to furnace
and downstream of manual equipment shutoff valve.
NOTE: The furnace gas control valve inlet pressure tap connection is
suitable to use as test gauge connection providing test pressure DOES
NOT exceed maximum 0.5 psig (14-In. W.C.) stated on gas control
valve, see Fig. 21.
INLET PRESSURE TAP SET
SCREW: 3/32” HEX HEAD.
ACCEPTS 5/16” HOSE
CONNECTION
1/2” NPT
INLET
1/2” NPT
OUTLET
REGULATOR
ADJUSTMENT
CAP (REGULATOR
ADJ. UNDER CAP)
GAS VALVE OUTLET
PRESSURE TAP
SET SCREW:
3/32” HEX HEAD.
ACCEPTS 5/16” HOSE
CONNECTION
NOMINAL
IRON PIPE
INTERNAL
DIAMETER
SIZE IN.
(mm)
In.
(mm)
10
20
30
40
50
1/2
(13)
0.622
(16)
175
(53)
120
(37)
97
(30)
82 (25)
73
(22)
3/4
(19)
0.824
(21)
360
(110)
250
(76)
200
(61)
170
(52)
151
(46)
1
(25)
1.049
(27)
680
(207)
465
(142)
375
(114)
320
(98)
285
(87)
1-1/4
(32)
1.380
(35)
1400
(427)
950
(290)
770
(235)
660
(201)
580
(177)
1-1/2
(38)
1.610
(41)
2100
(640)
1460
(445)
1180
(360)
990
(301)
900
(274)
LENGTH OF PIPE - FT. (M)
ON & OFF TOGGLE
GAS OUTPUT
* Cubic ft. of natural 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: Chapter 6 current
edition of ANSI Z223/NFPA 54.
! WARNING
FIRE OR EXPLOSION HAZARD
Failure to follow this warning could result in personal injury, death,
and/or property damage.
If local codes allow the use of a flexible gas appliance connector,
always use a new listed connector. Do not use a connector which has
previously served another gas appliance. Black iron pipe shall be
installed at the furnace gas control valve and extend a minimum of 2 in.
(51 mm) outside the furnace.
GAS INPUT
Fig. 21 – Gas Control Valve
A180231
Install a sediment trap in riser leading to furnace, see Fig. 22. Connect a
capped nipple into lower end of tee. Capped nipple should extend below
level of furnace gas controls. Place a ground joint union between furnace
gas control valve and exterior manual equipment gas shutoff valve. A
1/8-in. (3 mm) NPT plugged tapping, accessible for test gauge
connection, MUST be installed immediately upstream of gas supply
connection to furnace and downstream of manual equipment shutoff
valve.
Piping should be pressure and leak tested in accordance with 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.
Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations.
13
830CA: Installation, Start–Up, Operating and Service and Maintenance Instructions
! WARNING
GAS
SUPPLY
MANUAL
SHUTOFF
VALVE
(REQUIRED)
SEDIMENT
TRAP
UNION
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. 23 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 (35°C)
rise.
! WARNING
A02035
Fig. 22 – Typical Gas Pipe Arrangement
ELECTRICAL SHOCK AND FIRE HAZARD
ELECTRICAL CONNECTIONS
! WARNING
ELECTRICAL SHOCK, FIRE OR EXPLOSION HAZARD
Failure to follow safety warnings could result in dangerous operation,
serious injury, death or property damage.
Improper servicing could result in dangerous operation, serious injury,
death or property damage.
- Before servicing, disconnect all electrical power to furnace.
- When servicing controls, label all wires prior to disconnecting.
Reconnect wires correctly.
- Verify proper operation after servicing.
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 current edition of NEC NFPA 70 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.
FIELD 24-VOLT WIRING
FIELD 115-, 208/230-, 460-VOLT WIRING
FACTORY 24-VOLT WIRING
FACTORY 115-VOLT WIRING
NOTE 2
W
FIVE
WIRE
C
Y
R
G
1-STAGE
THERMOSTAT
TERMINALS
FIELD-SUPPLIED
FUSED DISCONNECT
THREE-WIRE
HEATINGONLY
BLK
W2
BLK
WHT
208/230- OR
460-VOLT
THREE
PHASE
COM
WHT
W/W1
GND
115-VOLT FIELDSUPPLIED
FUSED
DISCONNECT
Y/Y2
JUNCTION
BOX
CONTROL
BOX
NOTE 1
R
G
24-VOLT
TERMINAL
BLOCK
FURNACE
GND
208/230VOLT
SINGLE
PHASE
CONDENSING
UNIT
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.
Fig. 23 – Heating and Cooling Application Field Wiring Diagram
Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations.
14
A95236
830CA: Installation, Start–Up, Operating and Service and Maintenance Instructions
J-BOX RELOCATION
! CAUTION
FURNACE MAY NOT OPERATE
Failure to follow this caution may result in intermittent furnace
operation.
Furnace control must be grounded for proper operation or else control
will lock out. Control must remain grounded through green/yellow wire
routed to gas valve and gas valve mounting 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 6 for equipment electrical specifications.
Make all electrical connections in accordance with current edition of
National Electrical Code (NEC) NFPA 70 and any local codes or
ordinances that might apply.
! 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.
NOTE: If factory location of J-Box is acceptable, go to next section
(ELECTRICAL CONNECTION TO J-BOX).
1. Remove and save two screws holding J-Box.
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.
2. Cut wire tie on loop in furnace wires attached to J-box.
3. Move J-Box to desired location.
4. Fasten J-Box to casing with two screws removed in Step 1.
5. Route J-Box wires within furnace away from sharp edges, rotating
parts and hot surfaces.
Electrical Connection to J-Box
Electrical Box on Furnace Casing Side
! WARNING
FIRE OR ELECTRICAL SHOCK HAZARD
Failure to follow this warning could result in personal injury, death, or
property damage.
If field-supplied manual disconnect switch is to be mounted on furnace
casing side, select a location where a drill or fastener cannot damage
electrical or gas components.
1. Select and remove a hole knockout in the casing where the
electrical box is to be installed.
NOTE: Check that duct on side of furnace will not interfere with
installed electrical box.
2. Remove the desired electrical box hole knockout and position the
hole in the electrical box over the hole in the furnace casing.
3. Fasten the electrical box to casing by driving two field supplied
screws from inside electrical box into casing steel.
Use a separate, fused branch electrical circuit with a properly sized fuse
or circuit breaker for this furnace. See Table 6 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 rapidly flash RED
and furnace will NOT operate.
Table 6 – Electrical Data
Unit Size
VoltsHertz- Phase
036040
048060
060080
060100
115-60-1
115-60-1
115-60-1
115-60-1
Operating Voltage* Range
Maximum
Minimum
Maximum
Unit Amps
127
127
127
127
104
104
104
104
11.4
11.4
17.8
17.8
Unit
Ampacity†
Minimum
Wire Size
AWG
12.6
12.6
18.9
18.9
14
14
12
12
Maximum
Maximum
Wire Length‡ Fuse or CKT
ft
BKR** Amps
29
29
30
30
15
15
20
20
*. 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.
‡. Length shown is as measured one way along wire path between unit and service panel for maximum 2 percent voltage drop.
**. Time-delay type is recommended
4. Remove and save two screws holding J-Box.
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, see Fig. 24.
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, see Fig. 23. 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.
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.
Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations.
15
830CA: Installation, Start–Up, Operating and Service and Maintenance Instructions
5. Connect line voltage leads, see Fig. 23.
6. Reinstall cover to J-Box. Do not pinch wires between cover and
bracket.
BX Cable Installation in Furnace J-Box
1. Remove cover from J-Box.
2. Route BX cable into 7/8-inch 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, see Fig. 23.
6. Reinstall cover to J-Box. Do not pinch wires between cover and
bracket.
Fig. 24 – Field-Supplied Electrical Box on Furnace Casing
COMMUNICATION
CONNECTOR
MODEL PLUG
CONNECTOR
24-V WIRING
Make field 24-v connections at the 24-v terminal strip, see Fig. 23.
Connect terminal Y as shown in Fig. 45 for proper cooling operation.
Use only AWG No. 18, color-coded, copper thermostat wire.
The 24-v circuit contains an automotive-type, 3-amp. fuse located on the
control. Any direct shorts during installation, service, or maintenance
could cause this fuse to blow. If fuse replacement is required, use ONLY
a 3-amp. fuse of identical size.
ACCESSORIES
1. Electronic Air Cleaner (EAC)
Connect an accessory Electronic Air Cleaner (if used) using 1/4-in
female quick connect terminals to the two male 1/4-in
quick-connect terminals on the control board marked EAC-1 and
EAC-2. The terminals are rated for 115VAC, 1.0 amps maximum
and are energized during blower motor operation, see Fig. 25.
2. Humidifier (HUM)
The HUM terminal is a 24 VAC output, energized when the blower
is operating during a call for heat.
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, see
Fig. 25.
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.
A10141
CONTINUOUS FAN
(CF) AIRFLOW
SETUP SWITCHES
OUTDOOR
AIR TEMP
CONNECTOR
SW4 SETUP
SWITCHES
PL8 - PRESSURE
TRANSDUCER
CONNECTOR
SW1 SETUP
SWITCHES AND
BLOWER OFFDELAY
AIR CONDITIONING
(A/C) AIRFLOW
SETUP SWITCHES
HUMIDIFIER
TERMINAL (24-VAC
0.5 AMP MAX.
ACRDJ – AIR
CONDITIONING
RELAY DISABLE
JUMPER
24-V THERMOSTAT
TERMINALS
FLASH
UPGRADE
CONNECTOR
(FACTORY
ONLY)
STATUS AND COMM
LED LIGHTS
PL3 – ECM BLOWER
HARNESS
CONNECTOR
3-AMP FUSE
TRANSFORMER 24-VAC
CONNECTIONS
115-VAC (L2) NEUTRAL
CONNECTIONS
V02
HK42FZ063WWYY
PART NUMBER AND
DATE CODE WWYY
PL1 – LOW VOLTAGE MAIN
HARNESS CONNECTOR
SOFTWARE
VERSION
EAC-1 TERMINAL
(115-VAC 1.0 AMP MAX.)
115-VAC (L1) LINE
VOLTAGE CONNECTIONS
PL2 – HOT SURFACE
IGNITER & INDUCER
MOTOR CONNECTOR
Fig. 25 – Furnace Control
Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations.
16
A190350
830CA: Installation, Start–Up, Operating and Service and Maintenance Instructions
THERMOSTAT
THERMOSTAT
NOTE 11
See notes 1, 2, 3, 4, 6, 8, 9, 10, 11, 12, 14
A190367
Fig. 26 – 1-Speed Variable Furnace with Single-Speed Air
Conditioner
A190370
Fig. 29 – 1-Speed Variable Furnace with Two-Speed Heat Pump
(Dual Fuel)
THERMOSTAT
See notes 2, 11
See notes 1, 2, 4, 6, 7, 9, 10, 14
A190368
Fig. 27 – 1-Speed Variable Furnace with Single-Speed Heat Pump
(Dual Fuel)
A190371
Fig. 30 – Two-Stage Thermostat with 1-Speed Variable Furnace
and Two-Speed Air Conditioner
THERMOSTAT
See notes 2, 5, 8, 10, 11
A190369
Fig. 28 – 1-Speed Variable Furnace with Two-Speed Air Conditioner
A190173
Fig. 31 – Single-Stage Thermostat with 1-Speed Variable Furnace
and Two-Speed Air Conditioner
Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations.
17
830CA: Installation, Start–Up, Operating and Service and Maintenance Instructions
NOTES FOR FIGURES 25 - 31
1. Heat pump MUST have a high pressure switch for dual fuel
applications.
2. Refer to outdoor equipment Installation Instructions for additional
information and setup procedure.
3. If the heat pump date code is 1501E or earlier, select the “ZONE”
position on the two-speed heat pump control. Heat pumps having
date codes 1601E and later do not have or require a “ZONE”
selection.
4. Outdoor Air Temperature Sensor must be attached in all dual fuel
applications.
5. Dip switch No. 1 on Thermidistat should be set in OFF position for
air conditioner installations. This is factory default.
6. Dip switch No. 1 on Thermidistat should be set in ON position for
heat pump installations.
7. Dip switch No. 2 on Thermidistat should be set in OFF position for
single-speed compressor operation. This is factory default.
8. Dip switch No. 2 on Thermidistat should be set in ON position for
two-speed compressor operation.
9. Configuration Option No. 10 “Dual Fuel Selection” must be turned
ON in all dual fuel applications.
10. NO connection should be made to the furnace HUM terminal when
using a Thermidistat.
11. Optional connection: If wire is connected, ACRDJ jumper on
furnace
control
should
be
removed
to
allow
Thermidistat/Thermostat to control outdoor unit staging.
12. Furnace must control its own stage heating operation via furnace
control algorithm.
13. The RVS Sensing terminal “L” should not be connected. This is
internally used to sense defrost operation.
14. 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.
15. Dip switch D on Dual Fuel Thermostat should be set in OFF
position for single-speed compressor operation. This is factory
default.
16. Dip switch D on Dual Fuel Thermostat should be set in ON position
for two-speed compressor operation.
VENTING
The furnace shall be connected to a listed factory built chimney or vent,
or a clay-tile lined masonry or concrete chimney. Venting into an unlined
masonry chimney or concrete chimney is prohibited.
When an existing Category I furnace is removed or replaced, the original
venting system may no longer be sized to properly vent the attached
appliances. An improperly sized Category I venting system could cause
the formation of condensate in the furnace and vent, leakage of
condensate and combustion products, and spillage of combustion
products into the living space.
Vent system or vent connectors may need to be resized. Vent systems or
vent connectors, must be sized to approach minimum size as determined
using appropriate table found in the NFGC.
! WARNING
CARBON MONOXIDE POISONING HAZARD
Failure to follow the steps outlined below for each appliance connected
to the venting system being placed into operation could result in carbon
monoxide poisoning or death. The following steps shall be followed for
each appliance connected to the venting system being placed into
operation, while all other appliances connected to the venting system
are not in operation:
1. Seal any unused openings in venting system.
2. Inspect the venting system for proper size and horizontal pitch, as
required in the current edition of National Fuel Gas Code, ANSI
Z223.1/NFPA 54 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 current
edition of National Fuel Gas Code, ANSI Z223.1/NFPA 54.
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.
GENERAL VENTING REQUIREMENTS
Follow all safety codes for proper vent sizing and installation
requirements, including local building codes, the current edition of
National Fuel Gas Code ANSI Z223.1/NFPA 54 (NFGC), Parts 12 and
13, the local building codes, and furnace and vent manufacturers’
instructions.
These furnaces are design-certified as Category I furnaces in accordance
with current edition of ANSI Z21.47/CSA 2.3 and operate with a
non-positive vent static pressure to minimize the potential for vent gas
leakage. Category I furnaces operate with a flue loss not less than 17
percent to minimize the potential for condensation in the venting system.
These furnaces are approved for common venting and multistory venting
with other fan assisted or draft hood equipped appliances in accordance
with the NFGC, 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.
1. If a vent (common or dedicated) becomes blocked, the furnace will
be shut off by the draft safeguard switch located on the vent elbow.
2. Do not vent this Category I furnace into a single-wall dedicated or
common vent. The dedicated or common vent is considered to be
the vertical portion of the vent system that terminates outdoors.
Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations.
18
830CA: Installation, Start–Up, Operating and Service and Maintenance Instructions
3. Vent connectors serving Category I furnaces shall not be connected
into any portion of a mechanical draft system operating under
positive pressure.
4. Do not vent this appliance with any solid fuel burning appliance.
5. Category I furnaces must be vented vertically or nearly vertically
unless equipped with a listed power venter.
6. Do not vent this appliance into an unlined masonry chimney. Refer
to Chimney Inspection Chart, Fig. 32.
MASONRY CHIMNEY REQUIREMENTS
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 current edition of ANSI/NFPA 211 and must
be in good condition.
USA - Refer to Sections 13.1.8 and 13.2.20 of the current edition of
NFGC NFPA54/ANSI Z223.1 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 current edition of NFPA54/ANSI Z223.1, 13.1.8 and
13.2.20 regarding alternative venting design and the Exception.
Table 7 – Minimum Allowable Input Rating of Space-Heating
Appliance in Thousands of BTUH per Hour
VENT HEIGHT
FT (M)
6 (1.8)
8 (2.4)
10 (3.0)
15 (4.6)
20 (6.1)
30 (9.1)
6 (1.8)
8 (2.4)
10 (3.0)
15 (4.6)
20 (6.1)
30 (9.1)
INTERNAL AREA OF CHIMNEY
IN2. (MM2)
19
28
38
12 (7741)
(12258)
(18064)
(24516)
Local 99% Winter Design
Temperature: 17 to 26°F* (-8 to -3°C)
0
55
99
52
74
111
NR
90
125
NR
NR
167
NR
NR
212
NR
NR
NR
Local 99% Winter Design
Temperature: 5 to 16°F* (-15 to -9°C)
NR
78
121
NR
94
135
NR
111
149
NR
NR
193
NR
NR
NR
NR
NR
NR
Local 99% Winter Design
Temperature: -10 to 4°F* (-23 to -16°C)
NR
NR
145
NR
NR
159
NR
NR
175
NR
NR
NR
NR
NR
NR
NR
NR
NR
Local 99% Winter Design
Temperature: -11°F (-24°C) or lower
Not recommended for any vent configuration.
6 (1.8)
8 (2.4)
10 (3.0)
15 (4.6)
20 (6.1)
30 (9.1)
141
154
169
212
258
362
166
182
198
247
293
377
196
213
231
283
333
NR
*. The 99.6% heating db temperatures table found in the Appendix of the
Climatic Design Information chapter of the 2017 ASHRAE Fundamentals
Handbook.
This furnace is permitted to be vented into a clay tile-lined masonry
chimney that is exposed to the outdoors below the roof line, provided:
1. Vent connector is Type-B double-wall, and
2. This furnace is common vented with at least 1 draft hood equipped
appliance, and
3. The combined appliance input rating is less than the maximum
capacity given in Table 8, and
4. The input rating of each space heating appliance is greater than the
minimum input rating given in Table 7 for the local 99% Winter
Design Temperature. Chimneys having internal areas greater than
38 square inches require furnace input ratings greater than the input
ratings of these furnaces. See footnote at bottom of Table 7, and
5. The authority having jurisdiction approves.
If all of these conditions cannot be met, an alternative venting design
shall be used, 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. 32 to perform a chimney inspection. If the inspection of
a previously used tile-lined chimney:
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, or a Type-B vent
shall be used to reduce condensation. If a condensate drain is required by
local code, refer to the current edition of NFGC NFPA54/ANSI Z223.1,
Section 12.10 for additional information on condensate drains.
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 current edition of 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 shall be vented into the annular space between the chimney
and the metal liner.
Exterior Masonry Chimney FAN + NAT
Installations with Type-B Double Wall Vent
Connectors ©FPA & AGA
Table 8 – Combined Appliance Maximum Input Rating in
Thousands of BTUH per Hour
VENT HEIGHT
FT. (M)
6 (1.8)
8 (2.4)
10 (3.0)
15 (4.5)
20 (6.0)
30 (9.1)
INTERNAL AREA OF CHIMNEY
IN2 (MM2)
12
(7741)
74
80
84
NR
NR
NR
19
(12258)
119
130
138
152
NR
NR
28
(18064)
178
193
207
233
250
NR
38
(24516)
257
279
299
334
368
404
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
Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations.
19
830CA: Installation, Start–Up, Operating and Service and Maintenance Instructions
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 (16°C) db except
for brief periods of time during warm-up from setback at no lower
than 55°F (13°C) db or during initial start-up from a standby
condition.
2. Adjust the gas input rate per the installation instructions. Low gas
input rate causes low vent gas temperatures, causing condensation
and corrosion in the furnace and/or venting system.
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.
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” (101 mm) round vent elbow is supplied with the furnace. A 5-inch
(127 mm) or 6- inch (152 mm) vent connector may be required for some
model furnaces. A field-supplied 4-inch-to-5-inch (101 - 127 mm) or
4-inch-to-6-inch (101 - 152 mm) sheet metal increaser fitting is required
when 5-inch (127 mm) or 6-inch (152 mm) vent connector is used. See
Fig. 33 - Fig. 38 Venting Orientation for approved vent configurations.
NOTE: Vent connector length for connector sizing starts at furnace vent
elbow. The 4-inch vent elbow is shipped for upflow configuration and
may be rotated for other positions. Remove the 3 screws that secure vent
elbow to furnace, rotate furnace vent elbow to position desired, reinstall
screws. The factory-supplied vent elbow does NOT count as part of the
number of vent connector elbows.
The vent connector can exit the furnace through one of two locations on
the casing.
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 Product Data 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. 33
- Fig. 38.
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.
CHIMNEY INSPECTION CHART
For additional requirements refer to the National Fuel Gas Code NFPA 54/ANSI Z223.1 and ANSI/NFPA 211
Chimneys, Fireplaces, Vents, and Solid Fuel Burning Appliances
Crown
condition:
Missing mortar
or brick?
Rebuild
crown.
Yes
No
Is chimney
property lined with
clay tile liner?
No
Yes
Is
liner and top
seal in good
condition?
No
Repair
liner or top seal
or reline chimney as
necessary.
Reline
Repair
Yes
Debris
in cleanout?
Yes
Mortar, tile, metal vent,
fuel oil residue?
Mortar
or tile
debris?
No Remove metal vent
or liner.
Clay
tile misalignment,
missing sections,
gaps?
Yes
Remove mortar
and tile debris
No
Yes
No
No
Is chimney
lined with properly
sized, listed liner or
Type-B vent?
Condensate
drainage at bottom
of chimney?
Consult
venting instructions for
application
suitability.
Not Suitable
Line chimney with property
sized, listed flexible metal
liner or Type-B vent per
NFGC Vent
Sizing Tables and liner or
vent manufacturer’s
Installation instructions.
Suitable
Yes
Yes
No
Not Suitable
Yes
Chimney
exposed to
outdoors below
roof line?
Yes
Is chimney
to be dedicated to
a single
furnace?
No
Consult
venting instructions for
application
suitability
No
Suitable
Instal
instructions.
Chimney is
acceptable for use.
Fig. 32 – Chimney Inspection Chart
A180242
! 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.
! CAUTION
BURN HAZARD
Failure to follow this caution may cause personal injury.
Hot vent pipe is within reach of small children when installed in
downflow position. See the following instruction.
An accessory Vent Guard Kit is REQUIRED for downflow applications
where the vent exits through the lower portion of the furnace casing. See
Fig. 38 and Product Data for accessory listing. Refer to the Vent Guard
Kit Instructions for complete details.
The horizontal portion of the venting system shall slope upwards not less
than 1/4-in. per linear ft. (21 mm/M) from the furnace to the vent and
shall be rigidly supported every 5 ft. (2 M) or less with metal hangers or
straps to ensure there is no movement after installation.
Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations.
20
830CA: Installation, Start–Up, Operating and Service and Maintenance Instructions
SIDEWALL VENTING
This furnace is not approved for direct sidewall horizontal venting.
Per section 12.4.3 of the current edition of NFPA54/ANSI Z223.1, 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.
SEE NOTES: 1,2,4,7,8,9 on the page
following these figures
Fig. 35 – Horizontal Left Application-Vent Elbow Left
A03213
SEE NOTES: 1,2,4,5,7,8,9 on the page
following these figures
Fig. 36 – Horizontal Left Application-Vent Elbow Up
A03215
SEE NOTES: 1,2,4,7,8,9
on the page following
these figures
Fig. 33 – Upflow Application-Vent Elbow Up
A03208
SEE NOTES: 1,2,4,5,7,8,9 on the page
following these figures
Fig. 37 – Horizontal Right Application-Vent Elbow Right
A03214
SEE NOTES: 1,2,3,4,7,8,9
on the pages following
these figures
Fig. 34 – Upflow Application-Vent Elbow Right
A03209
SEE NOTES: 1,2,4,5,6,7,8,9
on the page following these figures
Fig. 38 – Downflow Application-Vent Elbow Left then Up
See NOTES following images.
Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations.
21
A03207
830CA: Installation, Start–Up, Operating and Service and Maintenance Instructions
Venting Notes for Fig. 33 - Fig. 38
1. For common vent, vent connector sizing and vent material: United
States-use the NFGC.
2. Immediately increase to 5-inch (127 mm) or 6-inch (152 mm) vent
connector outside furnace casing when 5-inch (127 mm) vent
connector is required, refer to Note 1 above.
3. Side outlet vent for upflow and downflow installations must use
Type B vent immediately after exiting the furnace, except when
factory-authorized, Downflow Vent Guard Kit, is used in the
downflow position. See Product Data for accessory listing.
4. Type-B vent where required, refer to Note 1 above.
5. Four-inch single-wall (26 ga. min.) vent must be used inside
furnace casing and when the Downflow Vent Guard Kit is used
external to the furnace. See Product Data for accessory listing.
6. Factory-authorized accessory Downflow Vent Guard Kit required
in downflow installations with lower vent configuration. See
Product Data for accessory listing.
7. Secure vent connector to furnace elbow with (2) corrosion-resistant
sheet metal screws, spaced approximately 180° apart.
8. Secure all other single wall vent connector joints with (3) corrosion
resistant screws spaced approximately 120° apart.
9. Secure Type-B vent connectors per vent connector manufacturer’s
recommendations.
START-UP, ADJUSTMENT, AND SAFETY
CHECK
General
! WARNING
FIRE HAZARD
Failure to follow this warning could result in personal injury, death
and/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 inadequate combustion air
supply problem before resetting the switches.
! CAUTION
CUT HAZARD
Failure to follow this caution may result in personal injury.
Sheet metal parts may have sharp edges or burrs. Use care and wear
appropriate protective clothing, safety glasses and gloves when
handling parts and servicing furnaces.
1. Maintain 115-v wiring and ground. Improper polarity will result in
rapid flashing LED and no furnace operation.
2. Make thermostat wire connections at the 24-v terminal block on the
furnace control. Failure to make proper connections will result in
improper operation, see Fig. 23.
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. Install blower compartment door. Door must be in place to operate
furnace.
6. Replace outer door.
Start-Up Procedures
! WARNING
FIRE AND EXPLOSION HAZARD
Failure to follow this warning could cause personal injury, death and/or
property damage.
Never test for gas leaks with an open flame. Use a commercially
available soap solution made specifically for the detection of leaks to
check all connections. A fire or explosion may result causing property
damage, personal injury or loss of life.
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. 25, Fig. 45 and
Table 10.
NOTE: The furnace control allows all components, except the gas
valve, to be run for short period of time. This feature helps diagnose a
system problem in case of a component failure. Component test feature
will not operate if any thermostat signal is present at the control.
Refer to service label attached to furnace or see Fig. 39.
Component test sequence is as follows:
a. Inducer motor turns on at 50% duty cycle for 15 secs, then stays
on for the entire test.
b. Hot surface igniter is energized for 15 sec., then off.
c. Blower motor operates for 15 sec.
d. After component test is completed, one or more status codes (11,
25, 41 or 42) will flash. See component test section of service
label ((Fig. 39) in furnace for explanation of status codes.
NOTE: To repeat component test, turn setup switch SW1-6 OFF, then
back ON.
4. Turn setup DIP switch SW1-6 OFF. Reconnect R lead to furnace
control board, release blower door switch and reinstall blower
access door.
5. Operate furnace per instruction on inner door.
6. Verify furnace shut down by lowering thermostat setting below
room temperature.
7. Verify furnace restarts by raising thermostat setting above room
temperature.
Adjustments
! WARNING
FIRE HAZARD
Failure to follow this warning could result in injury, death and/or
property damage.
DO NOT bottom out gas valve regulator adjusting screw. This can
result in unregulated gas valve outlet pressure and result in excess
overfire and heat exchanger failures.
! 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 inlet gas, See
Fig. 41.
Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations.
22
830CA: Installation, Start–Up, Operating and Service and Maintenance Instructions
reduced by 2 percent for each 1,000 ft. (305 M) above sea level. For
Furnace gas input rate on rating plate is for installations at altitudes up to
installations below 2,000 ft. (610 M), refer to the unit rating plate.
2,000 ft. (610 M). Furnace input rate must be within +/-2 percent of
For installations above 2,000 ft. (610 M), multiply the input on the
furnace rating plate input.
rating plate by the derate multiplier in Table 9 for the correct input
1. Determine the correct gas input rate. Refer to the unit rating plate.
rate.
The input rating for altitudes above 2,000 ft. (610 M) must be
Table 9 – Altitude Derate Multiplier for U.S.A.
ALTITUDE
(FT. / M)
PERCENT OF
DERATE
DERATE
MULTIPLIER FACTOR*
0–2000 (0-610)
2001–3000 (610-914)
3001–4000 (914-1219)
4001–5000 (1219-1524)
5001–5400 (1525-1646)
0
4-6
6-8
8-10
10-11
1.00
0.95
0.93
0.91
0.90
*. Derate multiplier factors are based on midpoint altitude for altitude range.
Table 10 – Furnace Setup Switch Description
A190351
Fig. 39 – Service Label
Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations.
23
A190348
830CA: Installation, Start–Up, Operating and Service and Maintenance Instructions
2. Determine the correct outlet gas pressure adjustment.
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 closest natural gas heat value and specific gravity in
Table 14 through Table 17.
d. Follow heat value and specific gravity lines to point of
intersection to find outlet pressure setting for proper operation.
3. Check Inlet Gas Pressure
The inlet gas pressure must be checked with the furnace operating. This
is necessary to make sure the inlet gas pressure does not fall below the
minimum pressure of 4.5 in. w.c.
a. Make sure the gas supply is turned off to the furnace and at the
electric switch on the gas valve
b. Loosen set screw on outlet tower pressure tap no more than one
full turn with a 3/32−in. hex wrench or remove the 1/8−in. NPT
plug from the inlet pressure tap on the gas valve.
c. Connect a manometer to the inlet pressure tap on gas valve.
d. Turn on furnace power supply.
e. Turn gas supply manual shutoff valve to ON position.
f. Turn furnace gas valve switch to ON position.
g. Jumper R and W thermostat connections at the furnace control
board.
h. When main burners ignite, confirm inlet gas pressure is between
4.5 in. W.C. (1125 Pa) and 13.6 in. W.C. (3388 Pa).
i. Remove jumper across thermostat connections to terminate call
for heat. Wait until the blower off delay is completed.
j. Turn furnace gas valve electric switch to OFF position.
k. Turn gas supply manual shutoff valve to OFF position.
l. Turn off furnace power supply.
m.Remove manometer from the inlet pressure tap of the gas valve.
n. Tighten set screw on inlet tower pressure tap with 3/32−in. hex
wrench, or if 1/8−in. NPT plug was removed, apply pipe dope
sparingly to end of plug and reinstall in the gas valve
! WARNING
FIRE HAZARD
Failure to follow this warning could result in personal injury, death,
and/or property damage.
Inlet pressure tap set screw must be tightened and 1/8-in. NPT pipe
plug must be installed to prevent gas leaks.
4. Adjust gas valve outlet pressure determined in Step 2 to obtain
correct input rate.
a. Turn gas valve ON/OFF switch to OFF.
b. Loosen set screw on inlet tower pressure tap no more than one
full turn with a 3/32 in. hex wrench, see Fig. 21
c. Connect a water column manometer or similar device to pressure
tap on the gas valve.
d. Turn gas valve ON/OFF switch to ON.
e. Manually close blower door switch.
f. Set thermostat to call for heat.
g. Remove regulator seal cap and turn regulator adjusting screw
counterclockwise (out) to decrease input rate of clockwise (in) to
increase input rate.
h. Install regulator seal cap.
i. Leave manometer or similar device connected and proceed to
next step.
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 properly sized orifice hole is
essential for proper flame characteristics.
5. Verify natural gas input rate by clocking meter.
NOTE: Gas valve regulator adjustment cap must be in place for proper
input to be clocked.
a. Turn off all other gas appliances and pilots served by the meter.
b. Run furnace for 3 minutes in heating operation.
c. Measure time (in seconds) for gas meter to complete 1 revolution
and note reading. The 2 or 5 cubic feet dial provides a more
accurate measurement of gas flow.
d. Refer to Table 13 for cubic ft. of gas per hr.
e. 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 gas
valve outlet pressure to increase input or decrease gas valve outlet
pressure to decrease input. Repeat steps b through e until correct input is
achieved. Reinstall regulator seal cap on gas valve.
6. Set temperature rise. The furnace must operate within the
temperature rise ranges specified on the furnace rating plate. Do not
exceed temperature rise range specified on unit rating plate.
Determine the temperature rise as follows:
NOTE: Blower access door must be installed when taking temperature
rise reading. Leaving blower access door off will result in incorrect
temperature measurements. 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 the temperature rise range specified on the furnace
rating plate.
! WARNING
ELECTRICAL SHOCK HAZARD
Failure to follow this warning could result in personal injury or death.
Disconnect 115-v electrical power and install lockout tag before
changing speed tap.
a. Place thermometers in return and supply ducts as close to furnace
as possible. Be sure thermometers do not see radiant heat from
heat exchangers. Radiant heat affects temperature rise readings.
This practice is particularly important with straight-run ducts.
b. When thermometer readings stabilize, subtract return-air
temperature from supply-air temperature to determine air
temperature rise.
NOTE: If the temperature rise is outside this range, first check:
(1.) Gas input for heating operation.
(2.) Return and supply ducts for excessive restrictions causing
static pressures greater than the maximum heating static
listed on the rating plate.
(3.) Ensure Comfort/Efficiency SW1-4 on furnace control is in
OFF = Efficiency position when a bypass humidifier is
used, see Table 10.
(4.) Make sure proper model plug is installed.
c. Adjust air temperature rise by adjusting blower speed. Increase
blower speed to reduce temperature rise. Decrease blower speed
to increase temperature rise.
d. Turn thermostat down below room temperature and remove
blower access door.
e. To increase heating airflow, set Comfort/Efficiency SW1-4 on
furnace control to OFF = Efficiency.
f. Repeat steps a through e.
g. When correct input rate and temperature rise is achieved, turn
gas valve ON/OFF switch to OFF.
h. Remove manometer or similar device from gas valve.
i. Tighten set screw on outlet tower pressure tap with 3/32 in. hex
wrench.
Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations.
24
830CA: Installation, Start–Up, Operating and Service and Maintenance Instructions
INLET PRESSURE TAP SET
SCREW: 3/32” HEX HEAD.
ACCEPTS 5/16” HOSE
CONNECTION
THERMOSTAT SUBBASE
TERMINALS WITH
THERMOSTAT REMOVED
(ANITICIPATOR, CLOCK, ETC.,
MUST BE OUT OF CIRCUIT.)
HOOK-AROUND
AMMETER
1/2” NPT
INLET
1/2” NPT
OUTLET
R Y W G
REGULATOR
ADJUSTMENT
CAP (REGULATOR
ADJ. UNDER CAP)
GAS VALVE OUTLET
PRESSURE TAP
SET SCREW:
3/32” HEX HEAD.
ACCEPTS 5/16” HOSE
CONNECTION
ON & OFF TOGGLE
10 TURNS
GAS OUTPUT
GAS INPUT
FROM UNIT 24-V
CONTROL TERMINALS
EXAMPLE: 5.0 AMPS ON AMMETER
10 TURNS AROUND JAWS
= 0.5 AMPS FOR THERMOSTAT
ANTICIPATOR SETTING
A96316
Fig. 40 – Gas Control Valve
A180231
BURNER
ORIFICE
Fig. 41 – Orifice Hole
A180238
! CAUTION
FURNACE OVERHEATING HAZARD
Failure to follow this caution may result in reduced furnace life.
Recheck temperature rise. It must be within limits specified on the
rating plate. Recommended operation is at the mid-point of rise range
or slightly above.
7. Set thermostat heat anticipator.
a. Mechanical thermostat - Set thermostat heat anticipator to match
the amp. draw of the electrical components in the R-W/W1
circuit. Accurate amp. draw readings can be obtained at the wires
normally connected to thermostat subbase terminals, R-W. The
thermostat anticipator should NOT be in the circuit while
measuring current.
(1.) Remove thermostat from subbase or from wall.
(2.) Connect an amp. meter as shown in Fig. 42. across the R
and W subbase terminals or R and W wires at wall.
Fig. 42 – Amp. Draw Check With Ammeter
(3.) Record amp. draw across terminals when furnace is in low
heat and after blower starts when furnace is heating and
after blower starts.
(4.) Set heat anticipator on thermostat per thermostat
instructions and install on subbase or wall.
(5.) Install blower access door.
b. Electronic thermostat: Set cycle rate for 4 cycles per hr.
8. 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. Table 11-Air Delivery - CFM (With
Filter). Depending on the model size, the cooling airflow can be
adjusted from 1.5 to 6 tons 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. 45. Fig. 45 is based on 350 CFM per ton. For airflow at
400 CFM per ton, turn Setup SW1-5 ON, see Table 10 and Fig. 25
and Fig. 45.
NOTE: 5.5 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.”
9. Set Airflow for Continuous Fan/Low Speed Cooling Airflow The
ECM blower motor can be adjusted for continuous fan speeds
different than heating or cooling fan speed. See Table 11 - Air
Delivery - CFM (With Filter). Select the required continuous fan
airflow from Fig. 45.
The continuous fan speed is also the switch setting 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. 45. For airflow
at 400 CFM per ton, turn Setup SW1-5 ON, see Fig. 45. 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.
Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations.
25
830CA: Installation, Start–Up, Operating and Service and Maintenance Instructions
Table 11 – Air Delivery - CFM (With Filter)
(SW1-5 and SW4-3 set to OFF, except as indicated. See Notes 1 and 2)
Size: 36040C17
Clg/CF Switch settings
External Static Pressure (ESP)
Clg Switches
SW2-3
SW2-2
SW2-1
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
1.0
Clg Default:
OFF
OFF
OFF
1275
1310
1305
1315
1310
1305
1305
1295
1290
1270
CF Switches
SW3-3
SW3-2
SW3-1
Low-Clg Default:
OFF
OFF
OFF
1275
1310
1305
1315
1310
1305
1305
1295
1290
1270
OFF
OFF
OFF
ON
ON
ON
ON
OFF
ON
ON
OFF
OFF
ON
ON
ON
OFF
ON
OFF
ON
OFF
ON
530
715
870
1100
1275
1445
1445
545
705
910
1090
1310
1480
1480
545
730
925
1080
1305
1480
1480
535
730
925
1110
1315
1480
1480
505
735
935
1120
1310
1475
1475
495
735
935
1120
1305
1455
1455
485
740
925
1110
1305
1415
1415
725
915
1110
1295
1375
1375
See Note 4
720
910
1100
1290
1335
1335
695
900
1095
1270
1295
1295
1635
1605
1565
1525
1490
1455
1415
1375
1335
1295
Cooling Airflow
(SW2)
Low-Cooling Airflow
(SW3)
Maximum Clg Airflow2
CF Switches
SW3-3
SW3-2
SW3-1
Cont. Fan Default:
OFF
OFF
OFF
530
545
545
535
505
495
485
Continuous Fan
Airflow
(SW3)
OFF
OFF
OFF
ON
ON
ON
ON
OFF
ON
ON
OFF
OFF
ON
ON
ON
OFF
ON
OFF
ON
OFF
ON
530
715
870
1100
1100
1100
1100
545
705
910
1090
1090
1090
1090
545
730
925
1080
1080
1080
1080
535
730
925
1110
1110
1110
1110
505
735
935
1120
1120
1120
1120
495
735
935
1120
1120
1120
1120
485
740
925
1110
1110
1110
1110
725
915
1110
1110
1110
1110
See Note 4
720
910
1100
1100
1100
1100
695
900
1095
1095
1095
1095
760
765
790
790
800
800
800
790
775
755
Heating Airflow3
Heating (SW1)
Size: 48060C17
Clg/CF Switch settings
See Note 4
External Static Pressure (ESP)
Clg Switches
SW2-3
SW2-2
SW2-1
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
1.0
Clg Default:
OFF
OFF
OFF
1460
1475
1500
1500
1480
1440
1395
1355
1310
1255
CF Switches
SW3-3
SW3-2
SW3-1
Low-Clg Default:
OFF
OFF
OFF
540
565
555
555
535
See Note 4
OFF
OFF
OFF
ON
ON
ON
ON
OFF
ON
ON
OFF
OFF
ON
ON
ON
OFF
ON
OFF
ON
OFF
ON
540
715
865
1120
1275
1460
1460
565
735
910
1125
1295
1475
1475
555
745
935
1130
1315
1500
1500
555
760
950
1145
1335
1500
1500
535
765
965
1160
1340
1480
1480
955
1165
1345
1440
1440
950
1165
1340
1395
1395
See Note 4
See Note 4
955
1160
1335
1355
1355
955
1150
1310
1310
1310
945
1150
1255
1255
1255
1620
1595
1565
1525
1480
1440
1395
1355
1310
1255
Cooling Airflow
(SW2)
Low-Cooling Airflow
(SW3)
Maximum Clg Airflow2
CF Switches
SW3-3
SW3-2
SW3-1
Cont. Fan Default:
OFF
OFF
OFF
540
565
555
555
535
See Note 4
Continuous Fan
Airflow
(SW3)
OFF
OFF
OFF
ON
ON
ON
ON
OFF
ON
ON
OFF
OFF
ON
ON
ON
OFF
ON
OFF
ON
OFF
ON
540
715
865
1120
1275
1460
1460
565
735
910
1125
1295
1475
1475
555
745
935
1130
1315
1500
1500
555
760
950
1145
1335
1500
1500
535
765
965
1160
1340
1480
1480
955
1165
1345
1440
1440
950
1165
1340
1395
1395
See Note 4
See Note 4
955
1160
1335
1355
1355
955
1150
1310
1310
1310
945
1150
1255
1255
1255
960
995
1015
1020
1030
1050
1055
1060
1055
1045
Heating (SW1)
Heating Airflow3
Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations.
26
830CA: Installation, Start–Up, Operating and Service and Maintenance Instructions
Table 11 – Air Delivery - CFM (With Filter) (Continued)
(SW1-5 and SW4-3 set to OFF, except as indicated. See Notes 1 and 2)
Size: 30080C21
Clg/CF Switch settings
External Static Pressure (ESP)
Clg Switches
SW2-3
SW2-2
SW2-1
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
1.0
Clg Default:
OFF
OFF
OFF
1905
1920
1935
1945
1950
1945
1935
1930
1920
1905
CF Switches
SW3-3
SW3-2
SW3-1
Low-Clg Default:
OFF
OFF
OFF
1905
1920
1935
1945
1950
1945
1935
1930
1920
1905
OFF
OFF
OFF
ON
ON
ON
ON
OFF
ON
ON
OFF
OFF
ON
ON
ON
OFF
ON
OFF
ON
OFF
ON
785
930
1130
1345
1550
1905
2300
765
975
1155
1345
1560
1920
2315
775
990
1150
1350
1580
1935
2320
985
1175
1370
1575
1945
2325
990
1190
1370
1580
1950
2315
1000
1195
1365
1565
1945
2305
See Note 4
985
1215
1365
1555
1935
2280
1215
1355
1540
1930
2240
See Note 4
1215
1345
1535
1920
2245
1215
1335
1525
1905
2215
2405
2410
2415
2400
2390
2360
2305
2275
2255
2215
Cooling Airflow
(SW2)
Low-Cooling Airflow
(SW3)
Maximum Clg Airflow2
CF Switches
SW3-3
SW3-2
SW3-1
Cont. Fan Default:
OFF
OFF
OFF
785
765
775
Continuous Fan
Airflow
(SW3)
OFF
OFF
OFF
ON
ON
ON
ON
OFF
ON
ON
OFF
OFF
ON
ON
ON
OFF
ON
OFF
ON
OFF
ON
785
930
1130
1130
1130
1130
1130
765
975
1155
1155
1155
1155
1155
775
990
1150
1150
1150
1150
1150
985
1175
1175
1175
1175
1175
990
1190
1190
1190
1190
1190
1000
1195
1195
1195
1195
1195
See Note 4
985
1215
1215
1215
1215
1215
1215
1215
1215
1215
1215
See Note 4
1215
1215
1215
1215
1215
1215
1215
1215
1215
1215
1550
1570
1585
1580
1565
1555
1550
1545
1545
1535
Heating (SW1)
Heating Airflow3
Size: 60100C21
Clg/CF Switch settings
See Note 4
External Static Pressure (ESP)
Clg Switches
SW2-3
SW2-2
SW2-1
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
1.0
Clg Default:
OFF
OFF
OFF
1785
1800
1805
1830
1830
1845
1855
1860
1850
1840
CF Switches
SW3-3
SW3-2
SW3-1
Low-Clg Default:
OFF
OFF
OFF
1785
1800
1805
1830
1830
1845
1855
1860
1850
1840
OFF
OFF
OFF
ON
ON
ON
ON
OFF
ON
ON
OFF
OFF
ON
ON
ON
OFF
ON
OFF
ON
OFF
ON
635
785
1040
1205
1380
1785
2170
630
820
1045
1220
1425
1800
2155
865
1070
1245
1445
1805
2175
1085
1280
1465
1830
2195
1130
1290
1480
1830
2185
See Note 4
See Note 4
See Note 4
1295
1290
1280
See Note 4
1475
1490
1485
1455
1460
1845
1855
1860
1850
1840
2195
2190
2180
2160
2100
2200
2220
2245
2260
2260
2260
Cooling Airflow
(SW2)
Low-Cooling Airflow
(SW3)
Maximum Clg Airflow2
2255
2225
2170
2100
CF Switches
SW3-3
SW3-2
SW3-1
Cont. Fan Default:
OFF
OFF
OFF
635
630
Continuous Fan
Airflow
(SW3)
OFF
OFF
OFF
ON
ON
ON
ON
OFF
ON
ON
OFF
OFF
ON
ON
ON
OFF
ON
OFF
ON
OFF
ON
635
785
1040
1205
1380
1380
1380
630
820
1045
1220
1425
1425
1425
865
1070
1245
1445
1445
1445
1085
1280
1465
1465
1465
1130
1290
1480
1480
1480
See Note 4
See Note 4
See Note 4
1295
1290
1280
See Note 4
1475
1490
1485
1455
1460
1475
1490
1485
1455
1460
1475
1490
1485
1455
1460
1785
1800
1765
1785
1800
1820
Heating (SW1)
Heating Airflow3
See Note 4
1830
1835
1825
1810
See NOTES following table.
1.Nominal 350 CFM/ton cooling airflow is delivered with SW1-5 and SW4-3 set to OFF.
Set SW1-5 to ON for nominal 400 CFM/ton (+15% airflow).
Set SW4-3 to ON for nominal 325 CFM/ton (-7% airflow).
Set both SW1-5 and SW4-3 on ON for nominal 370 CFM/ton (+7% airflow).
This applies to Cooling and Low-Cooling airflow, but does not affect continuous fan airflow.
The above adjustments in airflow are subject to motor horsepower range/capacity.
2.Maximum cooling airflow is achieved when switches SW2-1, SW2-2, SW2-3 and SW1-5 are set to ON, and SW4-3 is set to OFF.
3.All heating CFM's are when comfort/efficiency adjustment switch (SW1-4) is set to OFF
4.Ductwork must be sized for heating CFM within the operational range of ESP. Operation within the blank areas of the chart is not recommended because heat operation will be above 1.0
ESP.
5.All airflows on 21" casing size furnaces are 5% less on side return only installations.
Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations.
27
830CA: Installation, Start–Up, Operating and Service and Maintenance Instructions
Check Safety Controls
Table 13 – Gas Rate (Cu Ft./Hr.)
1. Check Main Limit Switch(es)
This control shuts off combustion control system and energizes
air-circulating blower motor, if furnace overheats. By using this
method to check limit control, it can be established that limit is
functioning properly and will operate if there is a restricted duct
system or motor failure. If limit control does not function during
this test, cause must be determined and corrected.
a. Run furnace for at least 5 minutes.
b. Gradually block off return air with a piece of cardboard or sheet
metal until the limit trips.
c. Unblock return air to permit normal circulation.
d. Burners will re-light when furnace cools down.
2. Check draft safeguard switch.
The purpose of this control is to cause the safe shutdown of the
furnace during certain blocked vent conditions.
a. Verify vent pipe is cool to the touch.
b. Disconnect power to furnace and remove vent connector from
furnace vent elbow.
c. Restore power to furnace and set room thermostat above room
temperature.
d. After normal start-up, allow furnace to operate for 2 minutes,
then block vent elbow in furnace 80 percent of vent area with a
piece of flat sheet metal.
e. Furnace should cycle off within 2 minutes. If gas does not shut
off within 2 minutes, determine reason draft safeguard switch did
not function properly and correct condition.
f. Remove blockage from furnace vent elbow.
g. Switch will auto-reset when it cools.
h. Re-install vent connector.
Checklist
1. Put away tools and instruments. Clean up debris.
2. Verify that switches SW1-1 and SW1-6 are OFF and other setup
switches are set as desired. Verify that switches SW1-7 and SW1-8
for the blower OFF DELAY are set as desired per Table 10.
3. Verify that blower and burner access doors are properly installed.
4. Cycle test furnace with room thermostat.
5. Check operation of accessories per manufacturer’s instructions.
6. Review User’s Guide with owner.
7. Attach literature packet to furnace.
Table 12 – Blower Off Delay Setup Switch
DESIRED HEATING MODE
BLOWER OFF DELAY (SEC.)
90
120
150
180
SECONDS SIZE OF TEST DIAL
FOR 1
1
2 Cu 5 Cu
REV.
Cu Ft.
Ft.
Ft.
10
360
720
1800
11
327
655
1636
12
300
600
1500
13
277
555
1385
14
257
514
1286
15
240
480
1200
16
225
450
1125
17
212
424
1059
18
200
400
1000
19
189
379
947
20
180
360
900
21
171
343
857
22
164
327
818
23
157
313
783
24
150
300
750
25
144
288
720
26
138
277
692
27
133
267
667
28
129
257
643
29
124
248
621
30
120
240
600
31
116
232
581
32
113
225
563
33
109
218
545
34
106
212
529
35
103
206
514
36
100
200
500
37
97
195
486
38
95
189
474
39
92
185
462
40
90
180
450
41
88
176
439
42
86
172
429
43
84
167
419
44
82
164
409
45
80
160
400
46
78
157
391
47
76
153
383
48
75
150
375
49
73
147
367
SECONDS SIZE OF TEST DIAL
FOR 1
1 Cu 2 Cu 5 Cu
REV.
Ft.
Ft.
Ft.
50
72
144
360
51
71
141
355
52
69
138
346
53
68
136
340
54
67
133
333
55
65
131
327
56
64
129
321
57
63
126
316
58
62
124
310
59
61
122
305
60
60
120
300
62
58
116
290
64
56
112
281
66
54
109
273
68
53
106
265
70
51
103
257
72
50
100
250
74
48
97
243
76
47
95
237
78
46
92
231
80
45
90
225
82
44
88
220
84
43
86
214
86
42
84
209
88
41
82
205
90
40
80
200
92
39
78
196
94
38
76
192
96
38
75
188
98
37
74
184
100
36
72
180
102
35
71
178
104
35
69
173
106
34
68
170
108
33
67
167
110
33
65
164
112
32
64
161
116
31
62
155
120
30
60
150
SETUP SWITCH
(SW1-7 AND 1-8)
POSITION
SW1-7
SW1-8
OFF
OFF
ON
OFF
OFF
ON
ON
ON
Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations.
28
830CA: Installation, Start–Up, Operating and Service and Maintenance Instructions
Tabulated Data Based on 40,000 BTUH Input for 0-ft (0 M) to
5400-ft (1646-M) above sea level
SPECIFIC GRAVITY OF
AVG. GAS
NATURAL GAS
ALTITUDE
HEAT
RANGE
VALUE AT
0.58
0.60
0.62
0.64
ft (m)
ALTITUDE
Gas Valve Outlet Pressure
(Btu/cu ft)
(in. W.C.)
900
3.0
3.1
3.2
3.3
0
925
2.8
2.9
3.0
3.1
(0)
950
2.7
2.8
2.9
3.0
975
2.6
2.6
2.7
2.8
to
1000
2.4
2.5
2.6
2.7
1025
2.3
2.4
2.5
2.5
2000
1050
2.2
2.3
2.4
2.4
(610)
1075
2.1
2.2
2.2
2.3
1100
2.0
2.1
2.1
2.2
800
3.2
3.3
3.5
3.6
2001
825
3.0
3.1
3.3
3.4
(611)
850
2.9
3.0
3.1
3.2
875
2.7
2.8
2.9
3.0
to
900
2.6
2.6
2.7
2.8
925
2.4
2.5
2.6
2.7
3000
950
2.3
2.4
2.5
2.5
(914)
975
2.2
2.3
2.3
2.4
1000
2.1
2.1
2.2
2.3
775
3.2
3.3
3.4
3.5
800
3.0
3.1
3.2
3.3
3001
825
2.8
2.9
3.0
3.1
(915)
850
2.6
2.7
2.8
2.9
875
2.5
2.6
2.7
2.8
to
900
2.4
2.4
2.5
2.6
4000
925
2.2
2.3
2.4
2.5
(1219)
950
2.1
2.2
2.3
2.3
975
2.0
2.1
2.2
2.2
1000
1.9
2.0
2.0
2.1
750
3.1
3.2
3.4
3.5
775
2.9
3.0
3.1
3.2
4001
800
2.8
2.9
2.9
3.0
(1220)
825
2.6
2.7
2.8
2.9
850
2.4
2.5
2.6
2.7
to
875
2.3
2.4
2.5
2.5
900
2.2
2.3
2.3
2.4
5000
925
2.1
2.1
2.2
2.3
(1524)
950
2.0
2.0
2.1
2.2
975
1.9
1.9
2.0
2.0
1000
1.8
1.8
1.9
1.9
725
3.2
3.3
3.4
3.5
750
2.9
3.0
3.1
3.3
5001
775
2.8
2.8
2.9
3.0
(1524)
800
2.6
2.7
2.8
2.9
825
2.4
2.5
2.6
2.7
to
850
2.3
2.4
2.4
2.5
875
2.1
2.2
2.3
2.4
5400
900
2.0
2.1
2.2
2.2
(1646)
925
1.9
2.0
2.1
2.1
950
1.8
1.9
1.9
2.0
975
1.7
1.8
1.8
1.9
1000
1.8
1.8
1.8
1.8
Tabulated Data Based on 60,000 BTUH Input for 0-ft (0m) to
5400-ft (1646-M) above sea level
SPECIFIC GRAVITY OF
AVG. GAS
NATURAL GAS
HEAT
ALTITUDE
VALUE AT
0.58
0.60
0.62
0.64
RANGE ft (m)
ALTITUDE
Gas Valve Outlet Pressure
(Btu/cu ft)
(in. W.C.)
900
3.0
3.1
3.2
3.3
0
925
2.8
2.9
3.0
3.1
(0)
950
2.7
2.8
2.9
3.0
975
2.6
2.6
2.7
2.8
to
1000
2.4
2.5
2.6
2.7
1025
2.3
2.4
2.5
2.5
2000
1050
2.2
2.3
2.4
2.4
(610)
1075
2.1
2.2
2.2
2.3
1100
2.0
2.1
2.1
2.2
800
3.2
3.3
3.5
3.6
2001
825
3.0
3.1
3.3
3.4
(611)
850
2.9
3.0
3.1
3.2
875
2.7
2.8
2.9
3.0
to
900
2.6
2.6
2.7
2.8
925
2.4
2.5
2.6
2.7
3000
950
2.3
2.4
2.5
2.5
(914)
975
2.2
2.3
2.3
2.4
1000
2.1
2.1
2.2
2.3
775
3.2
3.3
3.4
3.5
3001
800
3.0
3.1
3.2
3.3
825
2.8
2.9
3.0
3.1
(915)
850
2.6
2.7
2.8
2.9
875
2.5
2.6
2.7
2.8
to
900
2.4
2.4
2.5
2.6
4000
925
2.2
2.3
2.4
2.5
(1219)
950
2.1
2.2
2.3
2.3
975
2.0
2.1
2.2
2.2
1000
1.9
2.0
2.0
2.1
750
3.1
3.2
3.4
3.5
775
2.9
3.0
3.1
3.2
4001
800
2.8
2.9
2.9
3.0
(1220)
825
2.6
2.7
2.8
2.9
850
2.4
2.5
2.6
2.7
to
875
2.3
2.4
2.5
2.5
900
2.2
2.3
2.3
2.4
5000
925
2.1
2.1
2.2
2.3
(1524)
950
2.0
2.0
2.1
2.2
975
1.9
1.9
2.0
2.0
1000
1.8
1.8
1.9
1.9
725
2.8
2.9
3.0
3.0
750
2.6
2.7
2.8
2.8
5001
775
2.4
2.5
2.6
2.7
(1524)
800
2.3
2.3
2.4
2.5
825
2.1
2.2
2.3
2.3
to
850
2.0
2.1
2.1
2.2
875
1.9
1.9
2.0
2.1
5400
900
1.8
1.8
1.9
2.0
(1646)
925
1.8
1.8
1.8
1.9
950
1.8
1.8
1.8
1.8
975
1.8
1.8
1.8
1.8
1000
1.8
1.8
1.8
1.8
U.S.A.
U.S.A. Only
U.S.A. Only
U.S.A. Only
U.S.A.
U.S.A. Only
U.S.A. Only
U.S.A. Only
U.S.A.
Table 15 – Gas Valve Outlet Pressure for Gas Heat Values at
Altitude - 60,000
U.S.A.
Table 14 – Gas Valve Outlet Pressure for Gas Heat Values at
Altitude - 40,000
Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations.
29
830CA: Installation, Start–Up, Operating and Service and Maintenance Instructions
Table 16 – Gas Valve Outlet Pressure for Gas Heat Values at
Altitude - 80,000
Table 17 – Gas Valve Outlet Pressure for Gas Heat Values at
Altitude - 100,000
Tabulated Data Based on 80,000 BTUH Input, for 0-ft (0-m) to
Tabulated Data Based on 100,000 BTUH Input, for 0-ft (0-m) to
5400-ft (1646-M) above sea level
5400-ft (1646-M) above sea level
U.S.A.
2001
(611)
to
U.S.A. Only
U.S.A. Only
U.S.A. Only
3000
(914)
3001
(915)
to
4000
(1219)
4001
(1220)
to
5000
(1524)
5001
(1524)
to
5400
(1646)
0.64
Gas Valve Outlet Pressure
(in. W.C.)
2.9
2.7
2.6
2.5
2.3
2.2
2.1
2.0
1.9
3.1
2.9
2.8
2.6
2.5
2.3
2.2
2.1
2.0
3.1
2.9
2.7
2.6
2.4
2.3
2.1
2.0
1.9
1.8
3.0
2.8
2.7
2.5
2.4
2.2
2.1
2.0
1.9
1.8
1.8
3.0
2.8
2.6
2.4
2.3
2.2
2.0
1.9
1.8
1.8
1.8
1.8
3.0
2.8
2.7
2.5
2.4
2.3
2.2
2.1
2.0
3.1
3.0
2.9
2.7
2.5
2.4
2.3
2.2
2.1
3.1
3.0
2.8
2.6
2.5
2.3
2.2
2.1
2.0
1.9
3.1
2.9
2.8
2.6
2.4
2.3
2.2
2.0
1.9
1.8
1.8
3.1
2.9
2.7
2.5
2.4
2.2
2.1
2.0
1.9
1.8
1.8
1.8
3.1
2.9
2.8
2.6
2.5
2.4
2.3
2.1
2.1
3.1
3.1
3.0
2.8
2.6
2.5
2.4
2.2
2.1
3.1
3.1
2.9
2.7
2.6
2.4
2.3
2.2
2.1
2.0
3.1
3.0
2.8
2.7
2.5
2.4
2.2
2.1
2.0
1.9
1.8
3.1
3.0
2.8
2.6
2.5
2.3
2.2
2.1
1.9
1.8
1.8
1.8
ALTITUDE
RANGE ft (m)
0
(0)
U.S.A.
2.8
2.6
2.5
2.4
2.3
2.1
2.0
1.9
1.9
3.0
2.8
2.7
2.5
2.4
2.2
2.1
2.0
1.9
3.0
2.8
2.6
2.5
2.3
2.2
2.1
2.0
1.9
1.8
2.9
2.7
2.6
2.4
2.3
2.1
2.0
1.9
1.8
1.8
1.8
2.9
2.7
2.5
2.4
2.2
2.1
2.0
1.9
1.8
1.8
1.8
1.8
0.62
to
2000
(610)
2001
(611)
U.S.A.
2000
(610)
900
925
950
975
1000
1025
1050
1075
1100
800
825
850
875
900
925
950
975
1000
775
800
825
850
875
900
925
950
975
1000
750
775
800
825
850
875
900
925
950
975
1000
725
750
775
800
825
850
875
900
925
950
975
1000
0.60
to
3000
(914)
U.S.A. Only
to
0.58
U.S.A. Only
U.S.A.
0
(0)
AVG. GAS
HEAT
VALUEAT
ALTITUDE
(Btu/cu ft)
U.S.A. Only
ALTITUDE
RANGE ft (m)
SPECIFIC GRAVITY OF
NATURAL GAS
3001
(915)
to
4000
(1219)
4001
(1220)
to
5000
(1524)
5001
(1524)
to
5400
(1646)
SPECIFIC GRAVITY OF
NATURAL GAS
AVG. GAS
HEAT
VALUEAT
ALTITUDE
(Btu/cu ft)
0.58
900
925
950
975
1000
1025
1050
1075
1100
800
825
850
875
900
925
950
975
1000
775
800
825
850
875
900
925
950
975
1000
750
775
800
825
850
875
900
925
950
975
1000
725
750
775
800
825
850
875
900
925
950
975
1000
3.3
3.1
2.9
2.8
2.6
2.5
2.4
2.3
2.2
3.5
3.3
3.1
3.0
2.8
2.6
2.5
2.4
2.3
3.5
3.3
3.1
2.9
2.7
2.6
2.4
2.3
2.2
2.1
3.4
3.2
3.0
2.8
2.7
2.5
2.4
2.3
2.1
2.0
1.9
3.4
3.2
3.0
2.8
2.6
2.5
2.4
2.2
2.1
2.0
1.9
1.8
0.60
0.62
0.64
Gas Valve Outlet Pressure
(in. W.C.)
3.4
3.2
3.0
2.9
2.7
2.6
2.5
2.4
2.3
3.7
3.4
3.2
3.1
2.9
2.7
2.6
2.5
2.3
3.6
3.4
3.2
3.0
2.8
2.7
2.5
2.4
2.3
2.2
3.5
3.3
3.1
2.9
2.8
2.6
2.5
2.3
2.2
2.1
2.0
3.6
3.3
3.1
2.9
2.7
2.6
2.4
2.3
2.2
2.1
1.9
1.9
Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations.
30
3.5
3.3
3.1
3.0
2.8
2.7
2.6
2.4
2.3
3.8
3.6
3.3
3.2
3.0
2.8
2.7
2.5
2.4
3.7
3.5
3.3
3.1
2.9
2.8
2.6
2.5
2.3
2.2
3.7
3.4
3.2
3.0
2.9
2.7
2.5
2.4
2.3
2.2
2.1
3.7
3.4
3.2
3.0
2.8
2.7
2.5
2.4
2.2
2.1
2.0
1.9
3.6
3.4
3.2
3.1
2.9
2.8
2.6
2.5
2.4
3.9
3.7
3.5
3.3
3.1
2.9
2.8
2.6
2.5
3.8
3.6
3.4
3.2
3.0
2.8
2.7
2.6
2.4
2.3
3.8
3.5
3.3
3.1
2.9
2.8
2.6
2.5
2.4
2.2
2.1
3.8
3.6
3.3
3.1
2.9
2.8
2.6
2.5
2.3
2.2
2.1
2.0
830CA: Installation, Start–Up, Operating and Service and Maintenance Instructions
SERVICE AND MAINTENANCE
PROCEDURES
Untrained personnel can perform basic maintenance functions such as
cleaning and replacing air filters. All other operations must be performed
by trained service personnel. A qualified service person should inspect
the furnace once a year.
! WARNING
FIRE, INJURY, OR DEATH HAZARD
Failure to follow this warning could result in personal injury, death
and/or property damage.
The ability to properly perform maintenance on this equipment requires
certain knowledge, mechanical skills, tools, and equipment. If you do
not possess these, do not attempt to perform any maintenance on this
equipment other than those procedures recommended in the User’s
Manual.
! WARNING
ELECTRICAL SHOCK, FIRE OR EXPLOSION HAZARD
Failure to follow this warning could result in personal injury or death.
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.
! CAUTION
ELECTRICAL OPERATION HAZARD
Failure to follow this caution may result in improper furnace operation
or failure of furnace.
Label all wires prior to disconnection when servicing controls. Wiring
errors can cause improper and dangerous operation.
GENERAL
INTRODUCTION
These instructions are written as if the furnace is installed in an upflow
application. An upflow furnace application is where the blower is
located below the combustion and controls section of the furnace, and
conditioned air is discharged upward. Since this furnace can be installed
in any of the 4 positions shown in Fig. 4, you must revise your
orientation to component location accordingly.
ELECTRICAL CONTROLS AND WIRING
! WARNING
ELECTRICAL OPERATION 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.
system also requires an earth ground for proper operation of the control
and flame-sensing electrode.
The 24-v circuit contains an automotive-type, 3-amp. fuse located on the
control, see Fig. 25. Any shorts of the 24-v wiring during installation,
service, or maintenance will cause this fuse to blow. If fuse replacement
is required, use ONLY a 3-amp. fuse. The control LED will display
status code 24 when fuse needs to be replaced.
Proper instrumentation is required to service electrical controls. The
control in this furnace is equipped with a Status Code LED
(Light-Emitting Diode) to aid in installation, servicing, and
troubleshooting. Status codes can be viewed at the sight glass in blower
access door. The furnace control LED is either ON continuously, rapid
flashing, or a code composed of 2 digits. The first digit is the number of
short flashes, the second digit is the number of long flashes.
For an explanation of status codes, refer to service label located on
blower access door or Fig. 39 and the troubleshooting guide which can
be obtained from your distributor.
See Fig. 39, a brief Troubleshooting Guide.
For 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.”
3. Manually close blower access door switch.
4. Control will flash up to 7 Status Codes.
5. The last Status Code, or 8th Code, will be code 11.
6. Turn SW1-1 “OFF.”
7. The Amber LED will be continuously-lit which indicates proper
operation.
8. Release blower access door switch, install blower access door and
replace outer door or refer to the SERVICE label on the front of the
blower access door for more information.
Component Self-Test
Component Test can ONLY be initiated by performing the following:
1. Remove outer access door.
2. Remove blower access door.
3. Remove the wire from the “R” terminal of the control board.
4. Turn Setup Switch, SW-1-6 “ON.”
5. Manually close blower access door switch.
Blower access door switch opens 115-v power to control. No component
operation can occur unless switch is closed. Caution must be taken when
manually closing this switch for service purposes.
The electrical ground and polarity for 115-v wiring must be properly
maintained. Refer to Fig. 23 for field wiring information and to Fig. 45
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
Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations.
31
830CA: Installation, Start–Up, Operating and Service and Maintenance Instructions
! WARNING
ELECTRICAL SHOCK HAZARD
Failure to follow this warning could result in personal injury, or death.
Blower access door switch opens 115-v power to furnace control. No
component operation can occur unless switch is closed. Exercise
caution to avoid electrical shock from exposed electrical components
when manually closing this switch for service purposes.
6. Component Test sequence will function as follows:
a. Inducer motor turns on at 50% duty cycle for 15 secs, then stays
on for the entire test.
b. Hot surface igniter is energized for 15 sec, then deenergized.
c. Blower operates for 15 sec, then turns off.
d. After component test is completed, one or more status codes (11,
25, 41 or 42) 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.
7. Turn setup switch SW1-6 OFF.
8. RELEASE BLOWER ACCESS DOOR SWITCH, reattach wire to
“R” terminal on furnace control board, replace blower access door,
and replace outer access door.
CARE AND MAINTENANCE
! WARNING
FIRE OR EXPLOSION HAZARD
Failure to follow this warning could result in personal injury, death
and/or property damage.
Never store anything on, near, or in contact with the furnace, such as:
1. Spray or aerosol cans, rags, brooms, dust mops, vacuum
cleaners, or other cleaning tools.
2. Soap powders, bleaches, waxes or other cleaning compounds,
plastic or plastic containers, gasoline, kerosene, cigarette lighter
fluid, dry cleaning fluids, or other volatile fluids.
3. Paint thinners and other painting compounds, paper bags, or
other paper products.
For continuing high performance and to minimize possible equipment
failure, periodic maintenance must be performed on this equipment.
Consult your local dealer about proper frequency of maintenance and the
availability of a maintenance contract.
! WARNING
ELECTRICAL SHOCK AND FIRE HAZARD
Failure to follow this warning could result in personal injury, death or
property damage.
Turn off the gas and electrical supplies to the unit and install lockout tag
before performing any maintenance or service. Follow the operating
instructions on the label attached to the furnace.
! WARNING
CARBON MONOXIDE POISONING AND FIRE
HAZARD
! 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/replace air filter each month or more frequently if
required. Replace if torn.
2. Check burner inlet elbow opening for cleanliness and any visible
debris. Burner assembly removal should only be performed for
troubleshooting and diagnosis of operational issues. Refer to
troubleshooting and service guide.
3. Check blower motor and wheel for cleanliness each heating and
cooling season. Clean as necessary.
4. Check electrical connections for tightness and controls for proper
operation each heating season. Service as necessary.
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. The
filter is exterior to the furnace casing.
NOTE: If the filter has an airflow direction arrow, the arrow must point
towards the blower.
Table 18 – Filter Size Information (In. / mm)
FURNACE
CASING
WIDTH
In. (mm)
17-1/2 (445)
21 (533)
FILTER SIZE (In. / mm)
Side Return
Bottom 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)
20 X 25 X 3/4
(508 x 635 x 19)
FILTER TYPE
Washable*
Washable*
*. Recommended
Accessory media cabinet filter procedures:
1. Turn off electrical supply to furnace before removing filter access
door.
2. Remove filter cabinet door.
3. Slide filter out of cabinet.
4. If equipped with permanent, washable 3/4-in. (19 mm) filter, clean
filter by spraying cold tap water through filter in opposite direction
of airflow. Rinse filter and let dry. Oiling or coating of the filter is
not recommended. See Table 18 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.
Failure to follow this warning could result in personal injury, death
and/or property damage.
Never operate unit without a filter or with filter access door removed.
Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations.
32
830CA: Installation, Start–Up, Operating and Service and Maintenance Instructions
BLOWER MOTOR AND WHEEL
! WARNING
ELECTRICAL SHOCK HAZARD
Failure to follow this warning could result in personal injury or death.
Blower access door switch opens 115-v power to control. No
component operation can occur unless switch is closed. Caution must
be taken when manually closing this switch for service purposes.
NOTE: The blower wheel should not be dropped or bent as balance will
be affected. The following steps should be performed by a qualified
service agency.
To ensure long life and high efficiency, clean accumulated dirt and
grease from blower wheel and motor annually.
The inducer and blower motors are pre-lubricated and require no
additional lubrication. These motors can be identified by the absence of
oil ports on each end of the motor.
Clean blower motor and wheel as follows:
1. Turn off electrical supply to furnace.
2. Remove outer door.
3. Remove two screws from blower access door and remove blower
access door.
4. All factory wires can be left connected, but field thermostat
connections may need to be disconnected depending on their length
and routing.
5. Remove two screws holding blower assembly to blower deck and
slide blower assembly out of furnace.
6. Clean blower wheel and motor using a vacuum with soft brush
attachment. Blower wheel blades may be cleaned with a small paint
or flux brush. Do not remove or disturb balance weights (clips) on
blower wheel blades.
7. Vacuum any loose dust from blower housing, wheel and motor.
8. If a greasy residue is present on blower wheel, remove wheel from
the blower housing and wash it with an appropriate degreaser. To
remove wheel:
NOTE: Before disassembly, mark blower motor, and blower housing so
motor and each arm is positioned at the same location during
reassembly.
9. Reassemble motor and blower by reversing steps 9d finishing with
9a. Be sure to reattach ground wire to the blower housing.
a. Disconnect power choke wires (if used) and ground wire
attached to blower housing.
b. Remove screws securing cutoff plate and remove cutoff plate
from housing.
c. Loosen set screw holding blower wheel on motor shaft (160+/-20
in.-lb. when reassembling).
d. Remove bolts holding motor to blower housing and slide motor
out of wheel (40+/-10 in.-lb. when reassembling).
e. Remove blower wheel from housing.
f. Clean wheel and housing.
10. 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.
11. Spin the blower wheel by hand to verify that the wheel does not rub
on the housing.
12. Reinstall blower assembly in furnace.
13. Reinstall two screws securing blower assembly to blower deck.
! CAUTION
UNIT DAMAGE HAZARD
Failure to follow this caution may result in shortened heat exchanger
life.
Heating fan speed(s) MUST be adjusted to provide proper air
temperature rise as specified on the rating plate. Recommended
operation is at the midpoint of the rise range or slightly above. Refer to
“SET TEMPERATURE RISE” under START-UP, ADJUSTMENT, and
SAFETY CHECK.
NOTE: Refer to Table 11 for motor speed lead relocation if leads were
not identified before disconnection.
14. Refer to furnace wiring diagram, and connect thermostat leads if
previously disconnected.
15. To check blower for proper rotation:
a. Turn on electrical supply.
! WARNING
ELECTRICAL SHOCK HAZARD
Failure to follow this warning could result in personal injury, or death.
Blower access door switch opens 115-v power to furnace control. No
component operation can occur unless switch is closed. Exercise
caution to avoid electrical shock from exposed electrical components
when manually closing this switch for service purposes.
b. Manually close blower access door switch.
c. Verify blower is rotating in the correct direction.
16. If furnace is operating properly, RELEASE BLOWER ACCESS
DOOR SWITCH. Remove any jumpers or reconnect any
disconnected thermostat leads. Replace blower access door.
17. Reinstall outer door.
18. Cycle furnace through one complete heating and cooling cycle.
Verify the furnace temperature rise as shown in “Adjustments”
Section. Adjust temperature rise as shown in “Adjustments”
Section. If outdoor temperature is below 70_F, (21_C) turn off
circuit breaker to outdoor unit before running furnace in the cooling
cycle. Turn outdoor circuit breaker on after completing cooling
cycle.
FLAME SENSOR CLEANING AND SERVICING IGNITER
Cleaning Flame Sensor
The following items must be performed by a qualified service
technician. If the flame sensor develops an accumulation of light dirt or
dust, it may be cleaned by using the following procedure:
! WARNING
ELECTRICAL SHOCK AND FIRE HAZARD
Failure to follow this warning could result in personal injury, death,
and/or property damage.
Turn off the gas and electrical supplies to the furnace and install lockout
tag before performing any maintenance or service. Follow the operating
instructions on the label attached to the furnace.
Refer to Fig. 43.
1. Disconnect power at external disconnect, fuse or circuit breaker.
2. Turn off gas at external shut-off or gas meter.
3. Remove control door and set aside.
4. Turn electric switch on gas valve to OFF.
Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations.
33
830CA: Installation, Start–Up, Operating and Service and Maintenance Instructions
5. Disconnect Flame Sensor wire from Flame Sensor.
6. Remove the flame sensor from the burner assembly.
7. (Optional) Remove the Hot Surface Igniter (HSI) and bracket from
the burner assembly.
8. Check igniter resistance. Nominal resistance is 40 to 70 ohms at
room temperature and is stable over the life of the igniter.
9. Clean the flame sensor with fine steel wool (0000 grade). Do not
use sand paper or emery cloth.
To reinstall igniter and flame sensor:
1. Install the Hot Surface Igniter (HSI) and bracket with gasket in
burner assembly.
2. Install flame sensor in burner assembly.
3. When installing the HSI and flame sensor, ¼” screws that are the
same size of those removed must be used. Do not use longer
screws.
NOTE: If insulation assembly is damaged, do not attempt to repair,
must be replaced with insulation kit.
NOTE: Proper use of Personal Protective Equipment (PPE) must be
followed, including safety glasses, gloves, and dust mask when
removing and reinstalling the heat exchanger insulation assembly.
4. Connect the wire for the flame sensor.
5. Connect the wire for the Hot Surface Igniter.
! WARNING
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.
e. Hot surface igniter
f. Flame-sensing electrode
g. Burner thermal switch
h. DSS Draft Safeguard
5. Remove screws that fasten the inducer cover assembly to the cell
panel. Be careful not to damage the collector box. Inducer assembly
and elbow need not be removed from collector box.
6. Disconnect gas supply line from gas valve.
7. Remove screws that attach the burner assembly to the cell panel.
The gas valve and burners tube need not be removed from burner
box.
NOTE: Be very careful when removing burner assembly to avoid
breaking igniter.
8. Remove insulation assembly from burner tube inlets.
NOTE: Proper use of Personal Protective Equipment (PPE) must be
followed, including safety glasses, gloves, and dust mask when
removing and reinstalling the heat exchanger insulation assembly.
9. Using field-provided large caliber rifle cleaning brush, 36-in. (914
mm) long steel spring cable, a variable speed, reversible electric
drill, and vacuum cleaner, clean cells as follows:
NOTE: The materials needed in item NO TAG can usually be purchased
at local hardware stores.
Remove metal screw fitting from wire brush to allow insertion into
cable.
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.
IGNITOR
POSITION
6. Turn gas on at electric switch on gas valve and at external shut-off
or meter
7. Turn power on at external disconnect, fuse or circuit breaker.
8. Run the furnace through two complete heating cycles to check for
proper operation
9. Install control door when complete.
CLEANING HEAT EXCHANGER
The following steps should be performed by a qualified service agency:
NOTE: If the heat exchangers get a heavy accumulation of soot and
carbon, they should be replaced rather than trying to clean them
thoroughly. A heavy build-up of soot and carbon indicates that a
problem exists which needs to be corrected, such as improper adjustment
of gas valve outlet pressure, insufficient or poor quality combustion air,
incorrect size or damaged orifice(s), improper gas, or a restricted heat
exchanger. Action must be taken to correct the problem.
If it becomes necessary to clean the heat exchangers because of dust or
corrosion, proceed as follows:
1. Turn OFF gas and electrical power to furnace.
2. Remove outer access door.
3. Disconnect vent connector from furnace vent elbow.
4. Disconnect wires to the following components. Mark wires to aid in
reconnection of (be careful when disconnecting wires from
switches because damage may occur):
a. Inducer motor
b. Transducer
c. Limit over-temperature switch
d. Gas valve
A180230
(1.)
(2.)
(3.)
(4.)
(5.)
(6.)
(7.)
(8.)
Fig. 43 – Igniter Position
Attach variable-speed, reversible drill to the end of spring
cable (end opposite brush).
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. 44.
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.
Insert brush end of cable in burner inlet opening of cell, and
proceed to clean two lower passes of cell in same manner as
upper pass.
Repeat foregoing procedures until each cell in furnace has
been cleaned.
Using vacuum cleaner, remove residue from each cell.
Using vacuum cleaner with soft brush attachment, clean
burner assembly.
Clean flame sensor with fine steel wool.
Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations.
34
830CA: Installation, Start–Up, Operating and Service and Maintenance Instructions
(9.) Reinstall the insulation assembly.
NOTE: If insulation assembly is damaged, do not attempt to repair,
must be replaced with insulation kit.
NOTE: Proper use of Personal Protective Equipment (PPE) must be
followed, including safety glasses, gloves, and dust mask when
removing and reinstalling the heat exchanger insulation assembly.
(10.)Reinstall burner assembly.
10. Remove old sealant from cell panel and collector box flange.
11. Spray releasing agent on the heat exchanger cell panel where
inducer cover assembly contacts cell panel.
NOTE: A releasing agent such as cooking spray or equivalent (must not
contain corn or canola oil, aromatic or halogenated hydrocarbons or
inadequate seal may occur) and RTV sealant (G.E. 162, 6702, or
Dow-Corning 738) are needed before starting installation.
NOTE: DO NOT substitute any other type of RTV sealant.
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. Inducer motor
b. Transducer
c. Limit over-temperature switch
d. Gas valve
e. Hot surface igniter
f. Flame-sensing electrode
g. Burner thermal switch
h. DSS Draft Safeguard
14. Reinstall vent connector on furnace vent elbow. Securely fasten
vent connector to vent elbow with two (2) field-supplied,
corrosion-resistant, sheet metal screws located 180_ apart.
15. Replace blower access door only, if it was removed.
16. Set thermostat above room temperature and check furnace for
proper operation.
17. Verify blower airflow and speed changes between heating and
cooling.
18. Check for gas leaks.
19. Replace outer access door.
Fig. 44 – Cleaning Heat Exchanger Cell
A190291
! WARNING
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.
SEQUENCE OF OPERATION
NOTE: Furnace control must be grounded for proper operation or else
control will lock out. Control is grounded through green/yellow wire
routed to gas valve and burner box screw. Using the schematic diagram
in Fig. 45, 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, the
control will start a 90-second blower-only ON period two seconds after
power is restored, if the thermostat is still calling for gas heating. The
Amber LED light will flash code 12 during the 90-second period, after
which the LED will be ON continuous, as long as no faults are detected.
After the 90-second period, the furnace will respond to the thermostat
normally.
The blower door must be installed for power to be conducted through the
blower door interlock switch ILK to the furnace control CPU,
transformer TRAN, inducer motor IDM, blower motor BLWM,
hot-surface igniter HSI, and gas valve GV.
1. Heating with Single-Stage Thermostat
See Fig. 31 for thermostat connections
The wall thermostat “calls for heat”, closing the R-to-W circuit. The
furnace control performs a self-check, verifies the transducer reads no
pressure present, and starts the inducer motor IDM ramp to prepurge.
a. Inducer Prepurge Period
(1.) The furnace control CPU ramps up the inducer motor IDM
to prepurge pressure then the furnace control CPU begins a
15-second prepurge period. If the transducer fails to reach
target pressure the inducer motor IDM will remain running
until target pressure is maintained. After the transducer
maintains pressure target, the furnace control CPU will
begin a 15-second prepurge period, and continue to run the
inducer motor IDM at that pressure.
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. Inducer maintains pressure during igniter
warm-up.
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.
c. Flame-Proving - When the burner flame is proved at the
flame-proving sensor electrode FSE, the inducer motor IDM will
increase speed (after a short delay of 14 seconds on some modes)
to a higher RUN pressure where the control will maintain this
pressure once reached, and the furnace control CPU begins the
blower-ON delay period and continues to hold the gas valve
GV-M open. If the burner flame is not proved within two second
flame proving period, the control CPU will de-energize the gas
valve GV-M, and the control CPU will repeat the ignition
sequence for up to three more Trials-For-Ignition before going to
Ignition-Lockout. Lockout will be reset automatically after three
hours, or by momentarily interrupting 115 vac power to the
furnace, or by interrupting 24 vac power at SEC1 or SEC2 to the
furnace control CPU (not at W/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 until flame is no longer proved.
d. Blower-On delay - If the burner flame is proven the blower-ON
delays for heat are as follows:
Heating - 25 seconds after the gas valve GV-M is opened the
BLWM is turned ON at heat airflow. Simultaneously, the
Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations.
35
830CA: Installation, Start–Up, Operating and Service and Maintenance Instructions
humidifier terminal HUM and electronic air cleaner terminal
EAC-1 are energized and remain energized throughout the
heating cycle.
e. 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 15-second post-purge period. The blower motor BLWM and
air cleaner terminal EAC-1 will remain energized at 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. Cooling mode
The thermostat “calls for cooling”.
a. Single-Speed CoolingSee Fig. 26 for thermostat connections
The thermostat closes the R-to-G-and-Y circuits. The R-to- Y
circuit starts the outdoor unit, and the R-to-G-and-Y/Y2 circuits
start the furnace blower motor BLWM on cooling airflow.
Cooling airflow is based on the A/C selection shown in Fig. 45.
The electronic air cleaner terminal EAC-1 is energized with 115
vac when the blower motor BLWM is operating.
When the thermostat is satisfied, the R-to-G-and-Y circuits are
opened. The outdoor unit will stop, and the furnace blower motor
BLWM will continue operating at cooling airflow for an
additional 90 seconds. Jumper Y/Y2 to DHUM to reduce the
cooling off-delay to 5 seconds, see Fig. 26.
b. Single-Stage Thermostat and Two-Speed Cooling (Adaptive
Mode)
See Fig. 29 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. 45.
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. 45.
NOTE: When transitioning from low-cooling to high-cooling the
outdoor unit compressor will shut down for 1 minute while the furnace
blower motor BLWM transitions to run at high-cooling airflow.
The electronic air cleaner terminal EAC-1 is energized with 115 vac
whenever the blower motor BLWM is operating.
When the thermostat is satisfied, the R-to-G-and-Y circuit are opened.
The outdoor unit stops, and the furnace blower BLWM and electronic air
cleaner terminal EAC-1 will remain energized for an additional 90
seconds. Jumper Y1 to DHUM to reduce the cooling off-delay to 5
seconds, see Fig. 25.
c. Two-Stage Thermostat and Two-Speed Cooling
See Fig. 30 for thermostat connections
NOTE: The air conditioning relay disable jumper ACRDJ must be
disconnected to allow thermostat control of the outdoor unit staging. see
Fig. 25.
The thermostat closes the R-to-G-and-Y1 circuits for low-cooling or
closes the R-to-G-and-Y1-and-Y2 circuits for high-cooling. The
R-to-Y1 circuit starts the outdoor unit on low-cooling speed, and the
R-to-G-and-Y1 circuit starts the furnace blower motor BLWM at
low-cooling airflow which is the true on-board CF (continuous fan)
selection as shown in Fig. 45. 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. 45.
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-toG-and-Y1-and-Y2 circuits are opened. The outdoor unit stops, and the
furnace blower BLWM and electronic air cleaner terminal EAC-1 will
remain energized for an additional 90 seconds. Jumper Y1 to DHUM to
reduce the cooling off-delay to 5 seconds., see Fig. 25.
3. Dehumidfy Mode
See Fig. 26-Fig. 28 for thermostat connections.
The dehumidification output, DHUM on the thermostat should be
connected to the furnace control thermostat terminal DHUM. When
there is a dehumidify demand, the DHUM input is activated, which
means 24 vac signal is removed from the DHUM input terminal. In
other words, the DHUM input logic is reversed. The DHUM input
is turned ON when no dehumidify demand exists. Once 24 vac is
detected by the furnace control on the DHUM input, the furnace
control operates in Dehumidify mode. If the DHUM input is low
for more than 48 hours, the furnace control reverts back to
non-Dehumidify mode.
The cooling operation described in item 2 above also applies to
operation with a thermostat. 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 cooling
airflow which is the true on-board CF (continuous fan) selection
as shown in Fig. 45.
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 cooling
airflow. Cooling airflow is based on the A/C (air conditioning)
selection shown in Fig. 45.
c. Cooling off-delay-When the “call for cooling” is satisfied and
there is a demand for dehumidification, the cooling blower-off
delay is decreased from 90 seconds to 5 seconds.
4. Super-Dehumidify Mode
Super-Dehumidify mode can only be entered if the furnace control
is in the Dehumidify mode and there is a demand for
dehumidification. The cooling operation described in item 3. above
also applies to operation with a Thermostat. The exceptions are
listed below:
Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations.
36
830CA: Installation, Start–Up, Operating and Service and Maintenance Instructions
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. 45.
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. 45.
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.
5. 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. 45. Factory default is
shown in Fig. 45. 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, heating 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 (25 seconds in heat),
allowing the furnace heat exchangers to heat up more quickly, then
restarts at the end of the blower-ON delay period at heating airflow.
The blower motor BLWM will revert to continuous-blower airflow
after the heating cycle blower off-delay is completed.
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 cooling airflow before transitioning back
to continuous-blower airflow.
When the thermostat “calls for high-cooling”, the blower motor
BLWM will operate at high cooling airflow. When the thermostat is
satisfied, the blower motor BLWM will operate an additional 90
seconds at high-cooling airflow before transitioning back to
continuous-blower airflow. When the R-to-G circuit is opened, the
blower motor BLWM will continue operating for an additional 5
seconds, if no other function requires blower motor BLWM
operation.
a. 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. 45. 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. 45. 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 (SW1-7 and 8 are
ON), the adjustable continuous-fan feature is locked (i.e., fan speed
cannot be changed from its current setting).
6. Heat pump
See Fig. 28 or Fig. 29 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, 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 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.
7. Component test
The furnace features a component test system to help diagnose a
system problem in the case of a component failure. To initiate the
component test procedure, ensure that there are no thermostat
inputs to the control and all time delays have expired. Turn on setup
switch SW1-6, see Fig. 25.
NOTE: The component test feature will not operate if the control is
receiving any thermostat signals or until all time delays have expired.
The component test sequence is as follows:
a. The furnace control CPU turns the inducer motor ON at 50%
torque and keeps it ON through step c.
b. After waiting for 15 seconds of inducer only operation, 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 OFF.
NOTE: The EAC terminals are energized when the blower is operating.
After the component test is completed, 1 or more status codes (11, 25,
41 or 42) will flash. See component test section or Service Label
(Fig. 39) for explanation of status codes.
NOTE: To repeat component test, turn setup switch SW1-6 to OFF and
then back ON.
Wiring Diagrams
Refer to Fig. 45 for wiring diagram.
Troubleshooting
Refer to the service label. (Fig. 39), and wiring diagram (Fig. 45) can be
a useful tool in isolating furnace operation problems. The Guide will
help to identify the problem or failed component. After replacing any
component, verify correct operation sequence.
Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations.
37
830CA: Installation, Start–Up, Operating and Service and Maintenance Instructions
Fig. 45 – Wiring Diagram
Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations.
38
A190349
830CA: Installation, Start–Up, Operating and Service and Maintenance Instructions
PARTS REPLACEMENT INFORMATION GUIDE
Casing Group
Grommet
Power choke (where used)
Auxiliary limit switches
Outer door
Blower door
Top filler plate
Bottom filler plate
Bottom enclosure
Gas Control Group
Burner assembly
Orifice
Flame sensor
Hot surface igniter
Gas valve
Manual reset limit switches
Burner support assembly
Electrical Group
Control bracket
Junction box
Limit switch(es)
Circuit board
Door switch
Transformer
Wiring harness 115v
Wiring harness 24v
Heat Exchanger Group
Heat exchanger cell
Cell panel
Inducer Group
Blower Group
Housing assembly
Transducer
Blower housing
Inducer motor
Blower cutoff
Inducer wheel
Blower motor
Vent elbow assembly
Blower wheel
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:
BRYANT HEATING & COOLING SYSTEMS
Consumer Relations Department
P.O. Box 4952
Syracuse, New York 13221-4952
1-800-428-4326
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
830CA
COOLING SIZE
(AIRFLOW)
48
HEATING SIZE
MOTOR
WIDTH
VARIATION
060
C
17
A
! WARNING
FIRE, EXPLOSION, ELECTRICAL SHOCK AND CARBON MONOXIDE POISONING HAZARD
Failure to follow this warning could result in dangerous operation, personal injury, death or property damage.
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.
Training
My Learning Center is your central location for professional residential HVAC training resources that help strengthen careers and businesses. We
believe in providing high quality learning experiences both online and in the classroom.
Access My Learning Center with your HVACpartners credentials at www.mlctraining.com. Please contact us a [email protected] with
questions.
Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations.
39
830CA: Installation, Start–Up, Operating and Service and Maintenance Instructions
© 2020 Carrier. All rights reserved.
A Carrier Company
Edition Date: 10/20
Catalog No:II830CA-03
Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations.
40
Replaces:II830CA-02