Carrier 58CTW 100 Series Instruction manual

Carrier 58CTW 100 Series Instruction manual
58CTW/CTY
Variable---Speed, ECM
Induced---Combustion 2---Stage Deluxe
4---Way Multipoise Gas Furnace
Series 100
Installation, Start---up, Operating and
Service and Maintenance Instructions
SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . . . . . . . 2
ACCESSORIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
VENTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
CODES AND STANDARDS . . . . . . . . . . . . . . . . . . . . . . . . . . 4
START--UP, ADJUSTMENT, AND SAFETY CHECK . . . . . 35
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
General Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Start--Up Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Combustion and Ventilation Air . . . . . . . . . . . . . . . . . . . . . . 4
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Duct Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Check Safety Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Acoustical Lining and Fibrous Glass Duct . . . . . . . . . . . . . . . 4
Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Gas Piping and Gas Pipe Pressure Testing . . . . . . . . . . . . . . . 4
SERVICE AND MAINTENANCE PROCEDURES . . . . . . . 45
Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Venting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Care and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS
PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Sequence of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
AIR FOR COMBUSTION AND VENTILATION . . . . . . . . . 8
PARTS REPLACEMENT INFORMATION GUIDE . . . . . . . 57
Outdoor Combustion Air Method . . . . . . . . . . . . . . . . . . . . 9
Always Ask For
The Standard Method: . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Combination of Indoor and Outdoor Air . . . . . . . . . . . . . 10
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Bottom Return Air Inlet . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Side Return Air Inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Leveling Legs (If Desired) . . . . . . . . . . . . . . . . . . . . . . . . 11
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.
Bottom Return Air Inlet . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Suspended Furnace Support . . . . . . . . . . . . . . . . . . . . . . . 11
Platform Furnace Support . . . . . . . . . . . . . . . . . . . . . . . . . 11
Roll--Out Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
NOTE: Read the entire instruction manual before starting the
installation.
Portions of the text and tables are reprinted from NFPA 54/ANSI
Z223.1--2012E, 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.
Bottom Return Air Inlet . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Side Return Air Inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Filter Arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
AIR DUCTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
General Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Ductwork Acoustical Treatment . . . . . . . . . . . . . . . . . . . . 13
Supply Air Connections . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Upflow and Horizontal Furnaces . . . . . . . . . . . . . . . . . . . 14
Downflow Furnaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Return Air Connections . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Downflow Furnaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Upflow and Horizontal Furnaces . . . . . . . . . . . . . . . . . . . 20
GAS PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
ELECTRICAL CONNECTION . . . . . . . . . . . . . . . . . . . . . . . 21
1
SAFETY CONSIDERATIONS
!
to identify hazards which may result in minor personal injury or
product and property damage. NOTE is used to highlight
suggestions which will result in enhanced installation, reliability,
or operation.
1. Use only with type of gas approved for this furnace. Refer
to the furnace rating plate.
2. Install this furnace only in a location and position as specified in the “Location” section of these instructions.
3. Provide adequate combustion and ventilation air to the
furnace space as specified in “Air for Combustion and
Ventilation” section.
4. Combustion products must be discharged outdoors. Connect this furnace to an approved vent system only, as specified in the “Venting” section of these instructions.
5. Never test for gas leaks with an open flame. Use a commercially available soap solution made specifically for the
detection of leaks to check all connections, as specified in
the “Gas Piping” section.
6. Always install furnace to operate within the furnace’s intended temperature--rise range with a duct system which
has an external static pressure within the allowable range,
as specified in the “Start--Up, Adjustments, and Safety
Check” section. See furnace rating plate.
7. When a furnace is installed so that supply ducts carry air
circulated by the furnace to areas outside the space containing the furnace, the return air shall also be handled by
duct(s) sealed to the furnace casing and terminating outside the space containing the furnace. See “Air Ducts” section.
8. A gas--fired furnace for installation in a residential garage
must be installed as specified in the warning box in the
“Location” section.
9. The furnace may be used for construction heat provided
that the furnace installation and operation complies with
the first CAUTION in the LOCATION section of these instructions.
10. These Multipoise Gas--Fired Furnaces are CSA (formerly
A.G.A. and C.G.A.) design--certified for use with natural
and propane gases (see furnace rating plate) and for installation in alcoves, attics, basements, closets, utility rooms,
crawlspaces, and garages. The furnace is factory--shipped
for use with natural gas. A CSA (A.G.A. and C.G.A.) listed accessory gas conversion kit is required to convert furnace for use with propane gas.
11. See Fig. 1 for required clearances to combustible construction.
12. Maintain a 1--in. (25 mm) clearance from combustible materials to supply air ductwork for a distance of 36 in. (914
mm) horizontally from the furnace. See NFPA 90B or local code for further requirements.
13. These furnaces SHALL NOT be installed directly on carpeting, tile, or any other combustible material other than
wood flooring. In downflow installations, factory accessory floor base MUST be used when installed on combustible materials and wood flooring. Special base is not required when this furnace is installed on manufacturer’s
Coil Assembly Part No. CNRV, CNPV, CAP, or CAR or
when Coil Box Part No. KCAKC is used. See Fig. 1 for
clearance to combustible construction information.
WARNING
FIRE, EXPLOSION, ELECTRICAL SHOCK, AND
CARBON MONOXIDE POISONING HAZARD
Failure to follow this warning could result in dangerous
operation, personal injury, death, or property damage.
Improper installation, adjustment, alteration, service,
maintenance, or use can cause carbon monoxide poisoning,
explosion, fire, electrical shock, or other conditions which
may cause personal injury or property damage. Consult a
qualified service agency, local gas supplier, or your
distributor or branch for information or assistance. The
qualified service agency must use only factory--authorized
and listed kits or accessories when modifying this product.
!
CAUTION
FURNACE RELIABILITY HAZARD
Failure to follow this caution may result in unit component
damage.
Application of this furnace should be indoors with special
attention given to vent sizing and material, gas input rate,
air temperature rise, unit leveling, and unit sizing.
Installing and servicing heating equipment can be hazardous due
to gas and electrical components. Only trained and qualified
personnel should install, repair, or service heating equipment.
Untrained personnel can perform basic maintenance functions
such as cleaning and replacing air filters. All other operations
must be performed by trained service personnel. When working
on heating equipment, observe precautions in literature, on tags,
and on labels attached to or shipped with furnace and other safety
precautions that may apply.
These instructions cover minimum requirements and conform to
existing national standards and safety codes. In some instances,
these instructions exceed certain local codes and ordinances,
especially those that may not have kept up with changing
residential construction practices. We require these instructions as
a minimum for a safe installation.
!
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.
Wear safety glasses, protective clothing and work gloves. Have
fire extinguisher available during start--up and adjustment
procedures and service calls.
. When you see this symbol on
This is the safety--alert symbol
the furnace and in instructions or manuals, be alert to the potential
for personal injury.
Understand the signal words DANGER, WARNING, and
CAUTION. These words are used with the safety--alert symbol.
DANGER identifies the most serious hazards which will result in
severe personal injury or death. WARNING signifies a hazard
which could result in personal injury or death. CAUTION is used
2
A10269
Fig. 1 -- Clearances to Combustibles
3
INTRODUCTION
only the NFGC, contact the American Gas Association, 400 N.
Capitol Street, N.W., Washington, DC 20001 (www.AGA.org.) .
Combustion and Ventilation Air
Section 9.3 NFPA 54/ANSI Z223.1--2012, Air for Combustion
and Ventilation .
Duct Systems
Air Conditioning Contractors Association (ACCA) Manual D,
Sheet Metal and Air Conditioning Contractors National
Association (SMACNA), or American Society of Heating,
Refrigeration, and Air Conditioning Engineers (ASHRAE) 2001
Fundamentals Handbook Chapter 35 or 2005 HVAC Systems
and Equipment Handbook Chapters 9 and 16.
Acoustical Lining and Fibrous Glass Duct
Current edition of SMACNA and NFPA 90B as tested by UL
Standard 181 for Class I Rigid Air Ducts
Gas Piping and Gas Pipe Pressure Testing
NFPA 54/ANSI Z223.1--2012 ; chapters 5, 6, and 7 and National
Plumbing Codes .
Electrical Connections
National Electrical Code (NEC) ANSI/NFPA70--2011 .
Venting
NFPA 54/ANSI Z223.1--2012; chapters 12 and 13.
The Series 100 4--way multipoise Category I fan--assisted furnace
is CSA (formerly A.G.A. and C.G.A.) design--certified. A
Category I fan--assisted furnace is an appliance equipped with an
integral mechanical means to either draw or force products of
combustion through the combustion chamber and/or heat
exchanger. The furnace is factory--shipped for use with natural
gas. This furnace is not approved for installation in mobile
homes, recreational vehicles, or outdoors.
80
/ 27 C
60
/ 16 C
ELECTROSTATIC DISCHARGE (ESD)
PRECAUTIONS PROCEDURE
A06745
Fig. 2 -- Return Air Temperature
!
This furnace is designed for minimum continuous return--air
temperature of 60_F (15_C) db or intermittent operation down to
55_F (13_C)db such as when used with a night setback
thermostat. Return--air temperature must not exceed 80_F (27_C)
db. Failure to follow these return--air temperature limits may
affect reliability of heat exchangers, motors, and controls. (See
Fig. 2.)
For accessory installation details, refer to the applicable
instruction literature.
NOTE: Remove all shipping brackets and materials before
operating the furnace.
CAUTION
FURNACE RELIABILITY HAZARD
Failure to follow this caution may result in unit component
damage.
Electrostatic discharge can affect electronic components.
Take precautions during furnace installation and servicing
to protect the furnace electronic control. Precautions will
prevent electrostatic discharges from personnel and hand
tools which are held during the procedure. These
precautions will help to avoid exposing the control to
electrostatic discharge by putting the furnace, the control,
and the person at the same electrostatic potential.
CODES AND STANDARDS
Follow all national and local codes and standards in addition
to these instructions. The installation must comply with
regulations of the serving gas supplier, local building, heating,
plumbing, and other codes. In absence of local codes, the
installation must comply with the national codes listed below and
all authorities having jurisdiction.
In the United States, follow all codes and standards for the
following:
Safety
NFPA 54/ANSI Z223.1--2012 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
1. Disconnect all power to the furnace. Multiple disconnects
may be required. DO NOT TOUCH THE CONTROL OR
ANY WIRE CONNECTED TO THE CONTROL PRIOR
TO
DISCHARGING
YOUR
BODY’S
ELECTROSTATIC CHARGE TO GROUND.
2. Firmly touch the clean, unpainted, metal surface of the furnace chassis which is close to the control. Tools held in a
person’s hand during grounding will be satisfactorily discharged.
3. After touching the chassis, you may proceed to service the
control or connecting wires as long as you do nothing to
recharge your body with static electricity (for example;
DO NOT move or shuffle your feet, do not touch ungrounded objects, etc.).
4
5.1
[130.5]
2 1/16
[51.6]
1.7
[43.5]
5 15/16
[150.7]
5 1/2
[140.3]
8 7/16
[213.5]
9 7/8
[250.7]
27 3/4
[704.7]
FRONT OF CASING
FRONT OF CASING
C
Ø7/8
[22.2]
ACCESSORY (2)
1 15/16
[49.2]
2 5/16
3 7/16 [59]
[86.8]
5 7/8
[148.5]
TOP OF CASING
Ø7/8
[22.2]
JUNCTION BOX
LOCATION
AIR FLOW
Ø7/8
[22.2]
ACCESSORY
Ø1/2
[12.7]
THERMOSTAT WIRE ENTRY
5 7/8
[148.5]
AIR FLOW
5 7/16
[138.5]
A
B
TOP OF CASING
6 13/16
[172.3]
5 5/8
[143.3]
AIR FLOW
1 15/16
[49.2]
19
[481.7]
OUTLET
Ø1/2
[12.7]
THERMOSTAT WIRE ENTRY
Ø1 3/4
[44.5]
GAS ENTRY
4 13/16
[122.2]
9 9/16
[243.3]
27 3/4
[704.7]
Ø1 3/4
[44.5]
GAS ENTRY
29 9/16
[750.7]
33 1/4
[843.9]
Ø7/8
[22.2]
ACCESSORY
6.1
[155.7]
D
BOTTOM RETURN
WIDTH
3/4
[19.1]
7 13/16
9 11/16
[197.8]
[245.4]
11 7/16
[290.7]
Ø7/8
[22.2]
J.BOX PROVISION
Ø7/8
[22.2]
ACCESSORY
Ø7/8
[22.2]
ACCESSORY
21.6
[549.5]
BOTTOM INLET
28.39
[721.2]
29
[736.9]
8 5/8
[219]
KNOCK OUTS FOR
VENTING(5
PLACES)
22 1/16
[560]
SIDE INLET
(BOTH SIDES)
14 7/8
[337.3]
(BOTH SIDES)
1 1/4
[31.8]
1
[25.4]
A10290
NOTES:
1. Two additional 7/8 ---in. (22 mm) diameter holes are located in the top plate.
2. Minimum return ---air openings at furnace, based on metal duct. If flex duct is used, see flex duct manufacturer’s recommendations for equivalent diameters.
a. For 800 CFM ---16 ---in. (406 mm) round or 14 1/2 x 12 ---in. (368 x 305 mm) rectangle.
b. For 1200 CFM ---20 ---in. (508 mm) round or 14 1/2 x 19 1/2 ---in. (368 x 495 mm) rectangle.
c. For 1600 CFM ---22 ---in. (559 mm) round or 14 1/2 x 22 1/16 ---in. (368 x 560mm) rectangle.
d. For airflow requirements above 1800 CFM, see Air Delivery table in Product Data literature for specific use of single side inlets. The use of both side inlets,
a combination of 1 side and the bottom, or the bottom only will ensure adequate return air openings for airflow requirements above 1800 CFM.
A
B
FURNACE SIZE
CABINET
WIDTH
OUTLET
WIDTH
045--- 12/036045
070--- 16/048070
090--- 16/048090
110--- 22/066110
135--- 22/066135
14-3/16 (360)
17--- 1/2 (445)
21 (533)
21 (533)
24-1/2 (622)
12-9/16 (319)
15-7/8 (403)
19-3/8 (492)
19-3/8 (492)
22-7/8 (581
C
D
TOP AND
BOTTOM
BOTTOM FLUE
INLET WIDTH
COLLAR
9-5/16 (237)
12--- 11/16 (322)
11-9/16 (294)
16 (406)
13-5/16 (338)
19--- 1/2 (495)
13-5/16 (338)
19--- 1/2 (495)
15-1/16 (383)
23 (584)
VENT
CONNECTION
SIZE
4 (102)
4 (102)
4 (102)
4 (102)
4 (102)
SHIP WT. LB
(KG)
107 (49)
126 (57)
140 (64)
152 (69)
163 (74)
ACCESSORY
FILTER MEDIA
CABINET SIZE
16 (406)
16 (406)
20 (506)
20 (506)
24 (610)
*135 size furnaces require a 5 or 6 ---in. (127 or 152 mm) vent. Use a vent adapter between furnace and vent stack. See Installation Instructions for complete
installation requirements.
Fig. 3 -- Dimensional Drawing
LOCATION
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.
GENERAL
This multipoise furnace is shipped in packaged configuration.
Some assembly and modifications are required when used in any
of the four applications shown in Fig. 4.
NOTE:
For high--altitude installations, the high--altitude
conversion kit MUST be installed at or above 5500 ft. (1676 M)
above sea level. Obtain high--altitude conversion kit from your
area authorized distributor.
5
THE BLOWER IS
LOCATED BELOW THE
BURNER SECTION, AND
CONDITIONED AIR IS
DISCHARGED UPWARD.
THE BLOWER IS LOCATED
TO THE RIGHT OF THE
BURNER SECTION, AND
AIR CONDITIONED AIR IS
DISCHARGED TO THE LEFT.
THE BLOWER IS
LOCATED 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
If air is exposed to the following substances, it should not be used
for combustion air, and outdoor air may be required for
combustion:
This furnace must:
S
be installed so the electrical components are protected
from water.
S
not be installed directly on any combustible material
other than wood flooring (refer to SAFETY
CONSIDERATIONS).
S
be located close to the chimney or vent and attached to
an air distribution system. Refer to Air Ducts section.
S
be provided ample space for servicing and cleaning.
Always comply with minimum fire protection clearances shown on the furnace clearance to combustible
construction label.
!
S
S
S
S
S
S
S
S
S
S
S
S
S
WARNING
CARBON MONOXIDE POISONING / COMPONENT
DAMAGE HAZARD
Failure to follow this warning could result in personal injury
or death and unit component damage.
Chlorinated waxes and cleaners
Chlorine based swimming pool chemicals
Water softening chemicals
De--icing salts or chemicals
Carbon tetrachloride
Halogen type refrigerants
Cleaning solvents (such as perchloroethylene)
Printing inks, paint removers, varnishes, etc.
Hydrochloric acid
Cements and glues
Antistatic fabric softeners for clothes dryers
Masonry acid washing materials
All fuel--burning equipment must be supplied with air for fuel
combustion. Sufficient air must be provided to avoid negative
pressure in the equipment room or space. A positive seal must be
made between the furnace cabinet and the return--air duct to
prevent pulling air from the burner area and from draft safeguard
opening.
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.
!
WARNING
FIRE, INJURY OR DEATH HAZARD
Failure to follow this warning could result in personal
injury, death and/or property damage.
The following types of furnace installations may require
OUTDOOR AIR for combustion due to chemical exposures:
S
S
S
S
S
Permanent wave solutions
When the furnace is installed in a residential garage, the
burners and ignition sources must be located at least 18 in.
(457 mm) above the floor. The furnace must be located or
protected to avoid damage by vehicles. When the furnace is
installed in a public garage, airplane hangar, or other
building having a hazardous atmosphere, the furnace must
be installed in accordance with the NFPA 54/ANSI
Z223.1--2012 . (See Fig. 5.)
Commercial buildings
Buildings with indoor pools
Laundry rooms
Hobby or craft rooms, and
Chemical storage areas
6
!
CAUTION
PERSONAL INJURY AND/OR PROPERTY
DAMAGE HAZARD
Improper use or installation of this furnace may result in
premature furnace component failure. This gas furnace may
be used for heating buildings under construction provided
that:
--The furnace is permanently installed with all electrical
wiring, piping, venting and ducting installed according to
these installation instructions. A return air duct is provided,
sealed to the furnace casing, and terminated outside the
space containing the furnace. This prevents a negative
pressure condition as created by the circulating air blower,
causing a flame rollout and/or drawing combustion
products into the structure.
18-IN. (457.2 mm)
MINIMUM TO BURNERS
A93044
Fig. 5 -- Installation in a Garage
!
--The furnace is controlled by a thermostat. It may not be
“hot wired” to provide heat continuously to the structure
without thermostatic control.
WARNING
--Clean outside air is provided for combustion. This is to
minimize the corrosive effects of adhesives, sealers and
other construction materials. It also prevents the
entrainment of drywall dust into combustion air, which can
cause fouling and plugging of furnace components.
FIRE HAZARD
Failure to follow this warning could result in personal
injury, death and/or property damage.
--The temperature of the return air to the furnace is
maintained between 55_F (13_C) and 80_F (27_C), with
no evening setback or shutdown. The use of the furnace
while the structure is under construction is deemed to be
intermittent operation per our installation instructions.
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.)
--The air temperature rise is within the rated rise range on
the furnace rating plate, and the gas input rate has been set
to the nameplate value. --The filters used to clean the
circulating air during the construction process must be
either changed or thoroughly cleaned prior to occupancy.
LOCATION RELATIVE TO COOLING EQUIPMENT
The cooling coil must be installed parallel with, or on the
downstream side of the unit to avoid condensation in the heat
exchangers. When installed parallel with the furnace, dampers or
other flow control must prevent chilled air from entering the
furnace. If the dampers are manually operated, they must be
equipped with means to prevent operation of either unit unless
the damper is in the full--heat or full--cool position.
--The furnace, ductwork and filters are cleaned as necessary
to remove drywall dust and construction debris from all
HVAC system components after construction is completed.
--Verify proper furnace operating conditions including
ignition, gas input rate, air temperature rise, and venting
according to these installation instructions.
A02054
Fig. 6 -- Prohibit Installation on Back
7
Table 1 – Minimum Free Area Required for Each Combustion Air opening of Duct to Outdoors
TWO HORIZONTAL DUCTS
(1 SQ. IN./2,000 BTUH) (1,100 SQ. MM/KW)
Free Area of Opening
Round Duct
and Duct
Dia.
Sq. In. (Sq. mm)
In. (mm)
44,000
22 (14194)
6 (152)
66,000
33 (21290)
7 (178)
88,000
44 (28387)
8 (203)
110,000
55 (35484)
9 (229)
132,000
66 (42580)
10 (254)
154,000
77 (49677)
10 (254)
Note: Not all models have these sizes.
FURNACE
INPUT
(BTUH)
SINGLE DUCT OR OPENING
(1 SQ. IN./3,000 BTUH) (734 SQ. MM/KW)
Free Area of Opening
Round Duct
and Duct
Dia.
Sq. In. (Sq. mm)
In. (mm)
14.7 (9484)
5 (127)
22 (14193)
6 (152)
29.3 (18903)
7 (178)
36.7 (23677)
7 (178)
44 (28387)
8 (203)
51.3 (33096)
9 (229)
TWO OPENINGS OR VERTICAL DUCTS
(1 SQ. IN./4,000 BTUH) (550 SQ. MM/KW)
Free Area of Opening
Round Duct
and Duct
Dia.
Sq. In. (Sq. mm)
In. (mm)
11 (7096)
4 (102)
16.5 (10645)
5 (127)
22 (14193)
6 (152)
27.5 (17742)
6 (152)
33 (21290)
7 (178)
38.5 (24839)
8 (203)
EXAMPLES: Determining Free Area
FURNACE
WATER HEATER
TOTAL INPUT
110,000
+
30,000
=
(140,000 divided by 4,000)
=
35.0 Sq. In. for each two Vertical Ducts or Openings
66,000
+
40,000
=
(106,000 divided by 3,000)
=
35.3 Sq. In. for a Single Duct or Opening
88,000
+
30,000
=
(118,000 divided by 2,000)
=
59.0 Sq. In. for each of two Horizontal Ducts
Table 2 – Minimum Space Volumes for 100% Combustion, Ventilation, and Dilution from Indoors
OTHER THAN FAN-ASSISTED TOTAL
(1,000’S BTUH GAS INPUT RATE)
FAN-ASSISTED TOTAL
(1,000’S BTUH GAS INPUT RATE)
30
40
50
110
132
154
1,750
(49.5)
66
88
Space Volume Ft3 (M3)
1,100
1,650
2,200
(31.1)
(46.7)
(62.2)
0.60
1,050
(29.7)
1,400
(39.6)
2,750
(77.8)
3,300
(93.4)
3,850
(109.0)
0.50
1,260
(35.6)
1,680
(47.5)
2,100
(59.4)
1,320
(37.3)
1,980
(56.0)
2,640
(74.7)
3,300
(93.4)
3,960
(112.1)
4,620
(130.8)
0.40
1,575
(44.5)
2,100
(59.4)
2,625
(74.3)
1,650
(46.7)
2,475
(70.0)
3,300
(93.4)
4,125
(116.8)
4,950
(140.1)
5,775
(163.5)
0.30
2,100
(59.4)
2,800
(79.2)
3,500
(99.1)
2,200
(62.2)
3,300
(93.4)
4,400
(124.5)
5,500
(155.7)
6,600
(186.8)
7,700
(218.0)
0.20
3,150
(89.1)
4,200
(118.9)
5,250 (148.6)
3,300
(93.4)
4,950
(140.1)
6,600
(186.8)
8,250
(233.6)
9,900
(280.3)
11,550
(327.0)
0.10
6,300
(178.3)
8,400
(237.8)
10,500
(297.3)
6,600
(186.8)
9,900
(280.3)
13,200
(373.7)
16,500
(467.2)
19,800
(560.6)
23,100
(654.1)
0.00
NP
NP
NP
NP
NP
NP
NP
NP
NP
ACH
44
NP = Not Permitted
Note: Not all models have these sizes.
AIR FOR COMBUSTION AND
VENTILATION
!
Provisions for adequate combustion, ventilation, and dilution air
must be provided in accordance with:
S
WARNING
CARBON MONOXIDE POISONING HAZARD
Failure to follow this warning could result in personal
injury or death.
U.S. Installations: Section 9.3 of the NFPA 54/ANSI
Z223.1--2012 , Air for Combustion and Ventilation and
applicable provisions of the local building codes.
Failure to follow this caution may result in furnace damage.
The operation of exhaust fans, kitchen ventilation fans,
clothes dryers, attic exhaust fans or fireplaces could create a
NEGATIVE PRESSURE CONDITION at the furnace.
Make--up air MUST be provided for the ventilation devices,
in addition to that required by the furnace. Refer to the
Carbon Monoxide Poisoning Hazard warning in the venting
section of these instructions to determine if an adequate
amount of make--up air is available.
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.
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.
!
CAUTION
FURNACE CORROSION HAZARD
S
8
Spaces having less than 50 cubic feet per 1,000 Btuh
require the OUTDOOR COMBUSTION AIR
METHOD.
1 SQ IN.
PER 4000
BTUH*
1 SQ IN.
PER 2000
BTUH*
(305mm) 12″ MAX
A
1 SQ IN.
PER
4000
BTUH*
INTERIOR
HEATED
SPACE
1 SQ IN.
PER
4000
BTUH*
E
12″ (305mm)
MAX
C
DUCT
TO
OUTDOORS
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
G
12" MAX (305mm)
12″ MAX
(305mm)
CIRCULATING AIR DUCTS
VENT THROUGH ROOF
CLEARANCE IN FRONT OF COMBUSTION AIR
OPENINGS SHALL BE AT LEAST 3 IN.
DUCTS
TO
OUTDOORS
F
OUTDOORS
B
CIRCULATING AIR
DUCTS
12″ (305mm)
MAX
D
VENT
THROUGH
ROOF
CLEARANCE IN FRONT
OF COMBUSTION AIR
OPENINGS SHALL BE
AT LEAST 3 IN.
(76mm)
(305mm) 12″ MAX
1 SQ IN.
PER 2000
BTUH*
CIRCULATING
AIR DUCTS
DUCTS
TO
OUTDOORS
CIRCULATING AIR DUCTS
1 SQ IN.
PER 4000
BTUH*
* Minimum opening size is 100 sq in. (64516 sq. mm)with minimum dimensions
of 3 in. (76 mm)
† Minimum of 3 in. (76 mm) when type-B1 vent is used.
*Minimum dimensions of 3--- in. (76 mm).
NOTE: Use any of the following combinations of openings:
A&BC&DD&EF&G
A03175
A03174
Fig. 7 -- Air for Combustion, Ventilation, and Dilution for
Outdoors
Fig. 8 -- Air for Combustion, Ventilation, and Dilution from
Indoors
Spaces having at least 50 cubic feet per 1,000 Btuh
may use the INDOOR COMBUSTION AIR,
STANDARD or KNOWN AIR INFILTRATION
METHOD.
Outdoor Combustion Air Method
1. Provide the space with sufficient air for proper combustion, ventilation, and dilution of flue gases using permanent horizontal or vertical duct(s) or opening(s) directly
communicating with the outdoors or spaces that freely
communicate with the outdoors.
2. Fig. 7 illustrates how to provide TWO OUTDOOR
OPENINGS, one inlet and one outlet combustion and
ventilation air opening, to the outdoors.
e. One opening MUST commence within 12 in. (300
mm) of the ceiling and the second opening MUST
commence within 12 in. (300 mm) of the floor.
f. Size openings and ducts per Fig. 7 and Table 1.
g. TWO HORIZONTAL DUCTS require 1 sq. in. (645
sq. mm) of free area per 2,000 Btuh (1,100 mm2/kW)
of combined input for all gas appliances in the space
per Fig. 7 and Table 1.
h. TWO OPENINGS OR VERTICAL DUCTS require 1
sq. in. (645 sq. mm) of free area per 4,000 Btuh (550
mm2/kW) for combined input of all gas appliances in
the space per Fig. 7 and Table 1.
3. ONE OUTDOOR OPENING requires:
a. 1 sq. in. (645 sq. mm) of free area per 3,000 Btuh
(734 mm2/kW) for combined input of all gas appliances in the space per Table 1 and
b. Not less than the sum of the areas of all vent connectors in the space.
The opening shall commence within 12 in. (300 mm) of the
ceiling. Appliances in the space shall have clearances of at least 1
in. (25 mm) from the sides and back and 6 in. (150 mm) from the
front. The opening shall directly communicate with the outdoors
or shall communicate through a vertical or horizontal duct to the
outdoors or spaces (crawl or attic) that freely communicate with
the outdoors.
Indoor Combustion AirE 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.
S
!
WARNING
CARBON MONOXIDE POISONING HAZARD
Failure to follow this warning could result in personal
injury or death.
Many homes require air to be supplied from outdoors
for furnace combustion, ventilation, and dilution of flue
gases.
The furnace combustion air supply must be provided in
accordance with this instruction manual.
The Standard Method:
1. The space has no less volume than 50 cubic feet per 1,000
Btuh of the maximum input ratings for all gas appliances
installed in the space and
2. The air infiltration rate is not known to be less than 0.40
air changes per hour (ACH).
The Known Air Infiltration Rate Method shall be used, if the
infiltration rate is known to be:
1. Less than 0.40 ACH and
2. Equal to or greater than 0.10 ACH
9
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 2 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--2012/NFPA 54--2012, 9.3.2.2:
1. For other than fan--assisted appliances, such as a draft
hood--equipped water heater:
Volume
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
plates and floors, between wall--ceiling joints, between
wall panels, at penetrations for plumbing, electrical
and gas lines, etc.
Combination of Indoor and Outdoor Air
1. Indoor openings shall comply with the Indoor Combustion Air Method below and,
2. Outdoor openings shall be located as required in the Outdoor Combustion Air Method mentioned previously and,
3. Outdoor openings shall be sized as follows:
a. Calculate the Ratio of all Indoor Space volume divided
by required volume for Indoor Combustion Air
Method below.
b. Outdoor opening size reduction Factor is 1 minus the
Ratio in a. above.
c. Minimum size of Outdoor openings shall be the size
required in Outdoor Combustion Air Method above
multiplied by reduction Factor in b. above. The minimum dimension of air openings shall be not less than
3 in. (80 mm).
INSTALLATION
A04003
If: Iother = combined input of all other than fan--assisted
appliances in Btuh/hr
Ifan = combined input of all fan--assisted appliances in Btuh/hr
ACH = air changes per hour (ACH shall not exceed 0.60.)
The following requirements apply to the Standard Method and
to the Known Air Infiltration Rate Method.
1. Adjoining rooms can be considered part of a space if:
a. There are no closeable doors between rooms.
b. Combining spaces on same floor level. Each opening
shall have free area of at least 1 in.2/1,000 Btuh (2,000
mm2/kW) of the total input rating of all gas appliances
in the space, but not less than 100 in.2 (0.06 m2). One
opening shall commence within 12 in. (300 mm) of
the ceiling and the second opening shall commence
within 12 in. (300 mm) of the floor. The minimum
dimension of air openings shall be at least 3 in. (80
mm). (See Fig. 8.)
c. Combining space on different floor levels. The
volumes of spaces on different floor levels shall be
considered as communicating spaces if connected by
one or more permanent openings in doors or floors
having free area of at least 2 in.2/1,000 Btuh (4,400
mm2/kW) of total input rating of all gas appliances.
2. An attic or crawlspace may be considered a space that
freely communicates with the outdoors provided there are
adequate permanent ventilation openings directly to outdoors having free area of at least 1--in.2/4,000 Btuh of total
input rating for all gas appliances in the space.
3. In spaces that use the Indoor Combustion Air Method,
infiltration should be adequate to provide air for combustion, permanent ventilation and dilution of flue gases.
However, in buildings with unusually tight construction,
additional air MUST be provided using the methods described in the Outdoor Combustion Air Method section.
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
UPFLOW INSTALLATION
Bottom Return Air Inlet
These furnaces are shipped with bottom closure panel installed in
bottom return--air opening. Remove and discard this panel when
bottom return air is used. To remove bottom closure panel,
perform the following:
1. Tilt or raise furnace and remove 2 screws holding bottom
filler panel. (See Fig. 9.)
2. Rotate bottom filler panel downward to release holding
tabs.
3. Remove bottom closure panel.
4. Reinstall bottom filler panel and screws.
Side Return Air Inlet
These furnaces are shipped with bottom closure panel installed in
bottom return--air opening. This panel MUST be in place when
only side return air is used.
Bottom
Closure Panel
Bottom Filler Panel
A10273
Fig. 9 -- Removing Bottom Closure Panel
NOTE: Side return--air openings can be used in UPFLOW and
most HORIZONTAL configurations. Do not use side return--air
openings in DOWNFLOW configuration.
Leveling Legs (If Desired)
In upflow position with side return inlet(s), leveling legs may be
used. (See Fig. 10.) Install field--supplied, 5/16 X 1--1/2 in. (8 X
38 mm) (max) corrosion--resistant machine bolts, washers and
nuts.
10
NOTE: It is recommended that the perforated supply--air duct
flanges be completely folded over or removed from furnace when
installing the furnace on a factory--supplied cased coil or coil box.
To remove the supply--air duct flange, use wide duct pliers or
hand seamers to bend flange back and forth until it breaks off. Be
careful of sharp edges. (See Fig. 14.)
Bottom Return Air Inlet
These furnaces are shipped with bottom closure panel installed in
bottom return--air opening. Remove and discard this panel when
bottom return air is used. To remove bottom closure panel,
perform the following:
1. Tilt or raise furnace and remove 2 screws holding bottom
filler panel. (See Fig. 9.)
2. Rotate bottom filler panel downward to release holding
tabs.
3. Remove bottom closure panel.
4. Reinstall bottom filler panel and screws.
HORIZONTAL INSTALLATION
5/ 16
(8mm)
(8mm)
5/ 16
1 3/4
(44mm)
1 3/4
(44mm)
(8mm)
5/16
(8mm)
5/ 16
(44mm) 1 3/ 4
3/
(44mm) 1 4
!
A89014
FIRE, EXPLOSION, AND CARBON MONOXIDE
POISONING HAZARD
Fig. 10 -- Leveling Legs
NOTE: Bottom closure must be used when leveling legs are
used. It may be necessary to remove and reinstall bottom closure
panel to install leveling legs. To remove bottom closure panel, see
Item 1 in Bottom Return Air Inlet section in Step 1 above.
To install leveling legs:
1. Position furnace on its back. Locate and drill a hole in
each bottom corner of furnace. (See Fig. 10.)
2. For each leg, install nut on bolt and then install bolt with
nut in hole. (Install flat washer if desired.)
3. Install another nut on other side of furnace base. (Install
flat washer if desired.)
4. Adjust outside nut to provide desired height, and tighten
inside nut to secure arrangement.
5. Reinstall bottom closure panel if removed.
DOWNFLOW INSTALLATION
NOTE: For downflow applications, this furnace is approved for
use on combustible flooring when any one of the following 3
accessories are used:
S
S
Special Base, KGASB
Cased Coil Assembly Part No. CNPV, CNRV, CAP, or
CAR
S Coil Box Part No. KCAKC
1. Determine application being installed from Table 3.
2. Construct hole in floor per Table 3 and Fig. 11.
3. Construct plenum to dimensions specified in Table 3 and
Fig. 11.
4. If downflow subbase, KGASB is used, install as shown in
Fig. 12. If Coil Assembly Part No. CPVP, CAPMP or
CNPVP Coil Box Part No. KCAKC is used, install as
shown in Fig. 13.
WARNING
Failure to follow this warning could result in personal
injury, death, or property damage.
Do not install the furnace on its back or hang furnace with
control compartment facing downward. Safety control
operation will be adversely affected. Never connect
return--air ducts to the back of the furnace.
The furnace can be installed horizontally in an attic or crawlspace
on either the left--hand (LH) or right--hand (RH) side. The furnace
can be hung from floor joists, rafters or trusses or installed on a
non--combustible platform, blocks, bricks or pad.
Suspended Furnace Support
The furnace may be supported under each end with threaded rod,
angle iron or metal plumber’s strap as shown. (See Fig. 15 and
16.) Secure angle iron to bottom of furnace as shown.
Heavy--gauge sheet metal straps (plumber’s straps) may be used
to suspend the furnace from each bottom corner. To prevent
screws from pulling out, use 2 #8 x in. screws into the side and 2
#8 x in. screws in the bottom of the furnace casing for each strap.
(See Fig. 15 and 16.)
If the screws are attached to ONLY the furnace sides and not the
bottom, the straps must be vertical against the furnace sides and
not pull away from the furnace sides, so that the strap attachment
screws are not in tension (are loaded in shear) for reliable support.
Platform Furnace Support
Construct working platform at location where all required furnace
clearances are met. (See Fig. 1 and 17.) For furnaces with 1--in.
(25 mm) clearance requirement on side, set furnace on
non--combustible blocks, bricks or angle iron. For crawlspace
installations, if the furnace is not suspended from the floor joists,
the ground underneath furnace must be level and the furnace set
on blocks or bricks.
11
FURNACE
(OR COIL CASING
WHEN USED)
A
COMBUSTIBLE
FLOORING
PLENUM
OPENING
D
B
DOWNFLOW
SUBBASE
FLOOR
OPENING
SHEET METAL
PLENUM
FLOOR
OPENING
C
A96285
A96283
Fig. 12 -- Furnace, Plenum, and Subbase Installed on a
Combustible Floor
Fig. 11 -- Floor and Plenum Opening Dimensions
Roll--Out Protection
Provide a minimum 17--3/4--in. X 22--in. (451 X 559 mm) piece
of sheet metal for flame roll--out protection in front of burner area
for furnaces closer than 12--in. (305 mm) above the combustible
deck or suspended furnaces closer than 12--in. (305 mm) to joists.
The sheet metal MUST extend underneath the furnace casing by
1--in. (25 mm)with the door removed.
The bottom closure panel on furnaces of widths 17--1/2--in. (445
mm) and larger may be used for flame roll--out protection when
bottom of furnace is used for return air connection. See Fig. 17
for proper orientation of roll--out shield.
Bottom Return Air Inlet
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) are used without a bottom return air inlet.
Not all horizontal furnaces are approved for side return air
connections (See Fig. 20.)
FURNACE
APPROVED
COIL ASSEMBLY
OR
COIL BOX
COMBUSTIBLE
FLOORING
SHEET METAL
PLENUM
FLOOR
OPENING
A08556
Fig. 13 -- Furnace, Plenum, and Coil Assembly or Coil Box
Installed on a Combustible Floor
12
Table 3 – Opening Dimensions -- In. (mm)
FURNACE
CASING
WIDTH
IN. (mm)
14–3/16
(360)
17–1/2
(445)
21
(533)
24--- 1/2
(622)
Upflow Applications on Combustible or Noncombustible Flooring (KGASB subbase not required)
Downflow Applications on Noncombustible Flooring (KGASB
subbase not required)
Downflow applications on combustible flooring (KGASB subbase required)
Downflow Applications on Combustible Flooring with CNPV,
CNRV, CAR or CAP Coil Assembly or KCAKC coil box (KGASB
subbase not required)
Upflow Applications on Combustible or Noncombustible Flooring (KGASB subbase not required)
Downflow Applications on Noncombustible Flooring (KGASB
subbase not required)
Downflow applications on combustible flooring (KGASB subbase required)
Downflow Applications on Combustible Flooring with CNPV,
CNRV, CAR or CAP Coil Assembly or KCAKC coil box (KGASB
subbase not required)
Upflow Applications on Combustible or Noncombustible Flooring (KGASB subbase not required)
Downflow Applications on Noncombustible Flooring (KGASB
subbase not required)
Downflow applications on combustible flooring (KGASB subbase required)
Downflow Applications on Combustible Flooring with CNPV,
CNRV, CAR or CAP Coil Assembly or KCAKC coil box (KGASB
subbase not required)
Upflow Applications on Combustible or Noncombustible Flooring (KGASB subbase not required)
Downflow Applications on Noncombustible Flooring (KGASB
subbase not required)
Downflow applications on Combustible flooring (KGASB subbase required)
Downflow Applications on Combustible Flooring with CNPV,
CNRV, CAR or CAP Coil Assembly or KCAKC coil box (KGASB
subbase not required)
Filter Arrangement
!
PLENUM OPENING
APPLICATION
WARNING
CARBON MONOXIDE 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 rack is
required.
Refer to the instructions supplied with the external filter rack for
assembly and installation options.
AIR DUCTS
General Requirements
The duct system should be designed and sized according to
accepted national standards such as those published by: Air
Conditioning Contractors Association (ACCA), Sheet Metal and
Air Conditioning Contractors National Association (SMACNA)
or American Society of Heating, Refrigerating and Air
Conditioning Engineers (ASHRAE) or consult The Air Systems
Design Guidelines reference tables available from your local
distributor. The duct system should be sized to handle the
required system design CFM at the design external static pressure.
The furnace airflow rates are provided in Table 4--Air
Delivery--CFM (With Filter). When a furnace is installed so that
FLOOR OPENING
A
B
C
D
12--- 11/16
(322)
12--- 9/16
(319)
11--- 13/16
(284)
21--- 5/8
(549)
19
(483)
19
(483)
13--- 5/16
(338)
13--- 3/16
(335)
13--- 7/16
(341)
22--- 1/4
(565)
19--- 5/8
(498)
20--- 5/8
(600)
12--- 5/16
(319)
19
(483)
13--- 5/16
(338)
20
(508)
16
(406)
15--- 7/8
(403)
15--- 1/8
(384)
21--- 5/8
(549)
19
(483)
19
(483)
16--- 5/8
(422)
16--- 1/2
(419)
16--- 3/4
(425)
22--- 1/4
(565)
19--- 5/8
(498)
20--- 5/8
(600)
15--- 1/2
(394)
19
(483)
16--- 1/2
(419)
20
(508)
19--- 1/2
(495)
19--- 3/8
(492)
18--- 5/8
(473)
21--- 5/8
(549)
19
(483)
19
(483)
20--- 1/8
(511)
20
(508)
20--- 1/4
(514)
22--- 1/4
(565)
19--- 5/8
(498)
20--- 5/8
(600)
19
(483)
19
(483)
20
(508)
20
(508)
23
(584)
22--- 7/8
(581)
22--- 1/8
(562)
21--- 1/8
(537)
19
(483)
19
(483)
23--- 5/8
(600)
23--- 1/2
(597)
23--- 3/4
(603)
22--- 1/4
(565)
19--- 5/8
(498)
20--- 5/8
(600)
22--- 1/2
(572)
19
(483)
23--- 1/2
(597)
20
(508)
the supply ducts carry air circulated by the furnace to areas
outside the space containing the furnace, the return air shall also
be handled by duct(s) sealed to the furnace casing and
terminating outside the space containing the furnace.
Secure ductwork with proper fasteners for type of ductwork used.
Seal supply-- and return--duct connections to furnace with code
approved tape or duct sealer.
NOTE: Flexible connections should be used between ductwork
and furnace to prevent transmission of vibration.
Ductwork passing through unconditioned space should be
insulated to enhance system performance. When air conditioning
is used, a vapor barrier is recommended.
Maintain a 1--in. (25 mm) clearance from combustible materials
to supply air ductwork for a distance of 36--in. (914 mm)
horizontally from the furnace. See NFPA 90B or local code for
further requirements.
Ductwork Acoustical Treatment
NOTE: Metal duct systems that do not have a 90 degree elbow
and 10 ft. (3 M) of main duct to the first branch take--off may
require internal acoustical lining. As an alternative, fibrous
ductwork may be used if constructed and installed in accordance
with the latest edition of SMACNA construction standard on
fibrous glass ducts. Both acoustical lining and fibrous ductwork
shall comply with NFPA 90B as tested by UL Standard 181 for
Class 1 Rigid air ducts.
Supply Air Connections
For a furnace not equipped with a cooling coil, the outlet duct
shall be provided with a removable access panel. This opening
13
shall be accessible when the furnace is installed and shall be of
such a size that the heat exchanger can be viewed for possible
openings using light assistance or a probe can be inserted for
sampling the air stream. The cover attachment shall prevent leaks.
Upflow and Horizontal Furnaces
Connect supply--air duct to flanges on furnace supply--air outlet.
Bend flange upward to 90_ with wide duct pliers. (See Fig. 14.)
The supply--air duct must be connected to ONLY the furnace
supply--outlet--air duct flanges or air conditioning coil casing
(when used). DO NOT cut main furnace casing side to attach
supply air duct, humidifier, or other accessories. All accessories
MUST be connected to duct external to furnace main casing.
NOTE: For horizontal applications, the top most flange may be
bent past 90_ to allow the evaporator coil to hang on the flange
UPFLOW
temporarily while the remaining attachment and sealing of the
coil are performed.
Downflow Furnaces
Connect supply--air duct to supply--air outlet on furnace. Bend
flange inward past 90_ with wide duct pliers (See Fig. 14.) The
supply--air duct must be connected to ONLY the furnace supply
outlet or air conditioning coil casing (when used). When installed
on combustible material, supply--air duct must be connected to
ONLY the factory--approved accessory subbase, or a
factory--approved air conditioning coil casing. DO NOT cut main
furnace casing to attach supply side air duct, humidifier, or other
accessories. All accessories MUST be connected to duct external
to furnace casing.
DOWNFLOW
HORIZONTAL
90
90
YES
YES
120
MIN
YES
YES
120
MIN
NO
NO
YES
120
MIN
YES
NO
A02020
Fig. 14 -- Duct Flanges
14
/4" (6mm) THREADED ROD
4 REQ.
1
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. 15 -- Horizontal Unit Suspension
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).
A10131
Fig. 16 -- Horizontal Suspension with Straps
15
LINE CONTACT ONLY PERMISSIBLE BETWEEN
LINES FORMED BY INTERSECTIONS OF
THE TOP AND TWO SIDES OF THE FURNACE
JACKET AND BUILDING JOISTS,
STUDS, OR FRAMING.
17 3/4″ (451mm)OVERALL
4 3/4″ (121mm) UNDER DOOR
1″ (25mm) UNDER FURNACE
GAS
ENTRY
6″ M
IN
TYPE-B
VENT
m)
52m
* (1
EXTEND OUT 12″ (305mm)
FROM FACE OF DOOR
30-IN. (762mm)
MIN WORK AREA * WHEN USED WITH
SINGLE WALL VENT
CONNECTIONS
17 3/4″ (451mm)
SHEET
METAL
559
22″ (
mm
)
EQUIPMENT MANUAL
SHUT-OFF GAS VALVE
SEDIMENT
TRAP
UNION
A10164
Fig. 17 -- Typical Attic Installation
A02075
Fig. 18 -- Upflow Return Air Configurations and Restrictions
16
DOWNFLOW RETURN AIR CONFIGURATIONS AND RESTRICTIONS
A02163
Fig. 19 -- Downflow Return Air Configurations and Restrictions
A02162
Fig. 20 -- Horizontal Return Air Configurations and Restrictions
17
Table 4 – Air Delivery -- CFM (With Filter)*
Unit Size
COOLING4 AND HEATING AIR DELIVERY - CFM (Bottom Return5 With Filter)
(SW1-5 and SW2-2 set to OFF, except as indicated. See notes 1 and 2.)
Cooling Switch Settings
External Static Pressure (ESP)
SW2-8
SW2-7
SW2-6
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
1.0
665
525
045-12/
036045
OFF
OFF
OFF
1190
1140
1100
1065
1020
985
905
800
OFF
OFF
OFF
ON
620
560
520
455
410
355
305
255
ON
OFF
795
755
705
670
615
585
530
490
440
405
OFF
ON
ON
1020
955
930
890
840
805
755
715
645
490
ON
OFF
OFF
1190
1140
1100
1065
1020
985
905
800
665
525
ON
OFF
ON
1455
1390
1325
1255
1175
1085
1000
880
755
575
ON
ON
OFF
1455
1390
1325
1255
1175
1085
1000
880
755
575
ON
ON
ON
1455
1390
1325
1255
1175
1085
1000
880
755
575
Maximum Clg Airflow2
1455
1390
1325
1255
1175
1085
1000
880
755
575
High Heat Airflow3
915
860
825
790
735
700
650
610
550
450
Airflow3
780
730
685
635
585
545
495
450
400
370
External Static Pressure (ESP)
0.4
0.5
0.6
0.7
0.8
0.9
1.0
1325
1280
1210
Low Heat
Unit Size
See note 4
Cooling Switch Settings
SW2-8
SW2-7
SW2-6
0.1
0.2
0.3
1570
1530
070-16/
048070
OFF
OFF
OFF
1615
OFF
OFF
ON
640
OFF
ON
OFF
840
775
700
640
OFF
ON
ON
1045
980
920
860
805
750
690
640
ON
OFF
OFF
1220
1175
1120
1075
1025
970
925
875
820
ON
OFF
ON
1390
1335
1290
1245
1200
1155
1105
1055
1015
970
ON
ON
OFF
1615
1570
1530
1490
1450
1405
1365
1325
1280
1210
ON
ON
ON
1890
1850
1810
1750
1685
1615
1545
1475
1395
1275
Maximum Clg
Unit Size
Airflow2
1490
1450
1405
1365
See note 4
See note 4
See note 4
775
1890
1850
1810
1750
1685
1615
1545
1475
1395
1275
High Heat
Airflow3
1540
1490
1450
1410
1365
1320
1275
1235
1190
1140
Low Heat
Airflow3
1370
1320
1275
1225
1180
1135
1085
1040
995
950
0.8
0.9
1.0
1215
1070
910
Cooling Switch Settings
SW2-8
SW2-7
SW2-6
0.1
0.2
0.3
1580
1535
External Static Pressure (ESP)
0.4
0.5
0.6
0.7
090-16/
048090
OFF
OFF
OFF
1625
OFF
OFF
ON
555
OFF
ON
OFF
845
770
670
595
OFF
ON
ON
1010
950
880
790
725
670
580
ON
OFF
OFF
1210
1155
1105
1035
970
910
850
800
730
660
ON
OFF
ON
1405
1360
1305
1255
1185
1130
1070
1015
960
875
ON
ON
OFF
1625
1580
1535
1490
1445
1390
1325
1215
1070
910
ON
ON
ON
2095
2010
1935
1855
1770
1675
1540
1300
1120
940
Maximum Clg
Airflow2
1490
1445
1390
1325
See note 4
See note 4
See note 4
2095
2010
1935
1855
1770
1675
1540
1300
1120
940
High Heat Airflow3
1735
1685
1630
1580
1520
1455
1375
1235
1085
915
Low Heat Airflow3
780
730
685
635
585
545
495
450
400
370
18
Table 4 -- Air Delivery -- CFM (With Filter)* (CONTINUED)
Unit Size
Cooling Switch Settings
SW2-8
SW2-7
SW2-6
0.1
0.2
0.3
1950
External Static Pressure (ESP)
0.4
0.5
0.6
0.7
0.8
0.9
1.0
1675
1625
1565
110-22/
066110
OFF
OFF
OFF
2055
2000
OFF
OFF
ON
855
755
OFF
ON
OFF
1060
985
875
800
700
OFF
ON
ON
1250
1180
1095
1025
925
860
775
ON
OFF
OFF
1445
1380
1320
1235
1175
1100
1035
955
900
825
ON
OFF
ON
1685
1630
1560
1505
1445
1375
1320
1265
1195
1140
ON
ON
OFF
2055
2000
1950
1900
1840
1790
1740
1675
1625
1565
ON
ON
ON
2465
2415
2365
2305
2230
2140
2045
1925
1805
1655
Maximum Clg
Unit Size
Airflow2
1900
1840
1790
1740
See note 4
See note 4
715
See note 4
2465
2415
2365
2305
2230
2140
2045
1925
1805
1655
High Heat
Airflow3
2105
2055
2005
1955
1895
1850
1795
1735
1665
1580
Low Heat
Airflow3
1740
1685
1620
1560
1505
1440
1385
1325
1260
1205
0.8
0.9
1.0
1660
1595
1510
Cooling Switch Settings
SW2-8
SW2-7
SW2-6
0.1
0.2
0.3
1930
External Static Pressure (ESP)
0.4
0.5
0.6
0.7
135-22/
066135
OFF
OFF
OFF
2040
1985
OFF
OFF
ON
850
740
OFF
ON
OFF
1040
960
865
755
OFF
ON
ON
1245
1170
1080
1005
920
835
750
ON
OFF
OFF
1450
1385
1305
1245
1180
1085
1015
935
880
805
ON
OFF
ON
1670
1605
1540
1480
1425
1350
1280
1220
1135
1070
ON
ON
OFF
2040
1985
1930
1880
1830
1775
1715
1660
1595
1510
ON
ON
ON
2520
2455
2405
2350
2290
2195
2090
1965
1815
1615
Maximum Clg
Airflow2
1880
1830
1775
1715
See note 4
See note 4
See note 4
2520
2455
2405
2350
2290
2195
2090
1965
1815
1615
High Heat Airflow3
2260
2205
2150
2100
2045
1985
1925
1855
1745
1600
Low Heat Airflow3
2005
1950
1895
1845
1790
1735
1675
1620
1550
1475
1. Nominal 350 CFM/ton cooling airflow is delivered with SW1-5 and SW2-2 set to OFF.
Set both SW1-5 and SW2-2 to ON for +7% airflow (nominal 370 CFM/ton).
Set SW1-5 to ON and SW2-2 to OFF for +15% airflow (nominal 400 CFM/ton).
Set SW2-2 to ON and SW1-5 to OFF for -7% airflow (nominal 325 CFM/ton).
2. Maximum cooling airflow is achieved when switches SW2-6, SW2-7, SW2-8 and SW1-5 are set to ON, and SW2-2 is set to OFF.
3. All heating CFM's are when low heat rise adjustment switch (SW1-3) and comfort/efficiency adjustment switch (SW1-4) are both set to
OFF
4. Ductwork must be sized for high-heating CFM within the operational range of ESP. Operation within the blank areas of the chart is not
recommended because high-heat operation will be above 1.0 ESP.
5. All airflows on 21" casing size furnaces are 5% less on side return only installations.
6. Side returns for 24.5" casing sizes require two sides, or side and bottom, to allow sufficient airflow at the return of the furnace.
19
Return Air Connections
!
WARNING
FIRE HAZARD
A failure to follow this warning could cause personal injury,
death and/or property damage.
Never connect return--air ducts to the back of the furnace.
Follow instructions below.
Downflow Furnaces
The return--air duct must be connected to return--air opening
(bottom inlet). DO NOT cut into casing sides (left or right). Side
opening is permitted for only upflow and certain horizontal
furnaces. Bypass humidifier connections should be made at
ductwork or coil casing sides exterior to furnace. (See Fig. 19.)
Upflow and Horizontal Furnaces
The return--air duct must be connected to bottom, sides (left or
right), or a combination of bottom and side(s) of main furnace
casing. Bypass humidifier may be attached into unused return air
side of the furnace casing. (See Fig. 18 and 20.) Not all horizontal
furnace models are approved for side return air connections. (See
Fig. 20.)
GAS PIPING
!
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 in. (915 mm).
3. When lever handle type manual equipment shutoff valves
are used, they shall be T--handle valves.
4. The use of copper tubing for gas piping is NOT approved
by the state of Massachusetts.
Refer to Table 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. (1.8 M). Joint compound (pipe dope) should be
applied sparingly and only to male threads of joints. Pipe dope
must be resistant to the action of propane gas.
Table 5 – Maximum Capacity of Pipe
NOMINAL
IRON PIPE
SIZE
IN. (MM)
50
(15.2)
73
360
250
200
170
151
1 ( 25.4)
1.049 (26.6)
680
465
375
320
285
1-1/4
(31.8)
1.380 (35.0)
1400
950
770
660
580
1-1/2
(38.1)
1.610 (40.9)
2100
1460
1180
990
900
WARNING
CAUTION
FURNACE DAMAGE HAZARD
Use proper length of pipe to avoid stress on gas control
manifold and a gas leak.
Gas piping must be installed in accordance with national and
local codes. Refer to current edition of NFGC in the U.S.
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.
0.824 (20.9)
!
Failure to follow this warning could result in personal
injury, death, and/or property damage.
Gas valve inlet and/or inlet pipe must remain capped until
gas supply line is permanently installed to protect the valve
from moisture and debris. Also, install a sediment trap in the
gas supply piping at the inlet to the gas valve.
40
(12.1)
82
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.
FIRE OR EXPLOSION HAZARD
Failure to follow this warning could result in personal
injury, death, and/or property damage.
30
(9.1)
97
A failure to follow this warning could result in personal
injury, death, and/or property damage.
WARNING
FIRE OR EXPLOSION HAZARD
20
(6.0)
120
FIRE OR EXPLOSION HAZARD
Never purge a gas line into a combustion chamber. Never
test for gas leaks with an open flame. Use a commercially
available soap solution made specifically for the detection
of leaks to check all connections. A fire or explosion may
result causing property damage, personal injury or loss of
life.
WARNING
0.622(158)
3/4 (19.0)
!
Failure to follow this warning could result in personal
injury, death, and/or property damage.
!
1/2 (12.7)
10
(3.0)
175
* Cubic ft of gas per hr for gas pressures of 0.5 psig (14--- In. W.C.) or less and
a pressure drop of 0.5--- In. W.C. (based on a 0.60 specific gravity gas). Ref:
Table 6 and 9.2 NFGC.
WARNING
FIRE OR EXPLOSION HAZARD
!
LENGTH OF PIPE --- FT (M)
INTERNAL
DIA.
IN. (MM)
Failure to follow this caution may result in furnace damage.
Connect gas pipe to furnace using a backup wrench to
avoid damaging gas controls and burner misalignment.
An accessible manual equipment shutoff valve MUST be
installed external to furnace casing and within 6 ft. (1.8 M) of
furnace. A 1/8--in. (3 mm) NPT plugged tapping, accessible for
test gauge connection, MUST be installed immediately upstream
of gas supply connection to furnace and downstream of manual
equipment shutoff 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. 49.)
Some installations require gas entry on right side of furnace (as
viewed in upflow). (See Fig. 21.)
Install a sediment trap in riser leading to furnace as shown in Fig.
22. Connect a capped nipple into lower end of tee. Capped nipple
should extend below level of furnace gas controls. Place a ground
20
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 the
current addition of the NFGC in the United States, local, and
national plumbing and gas codes before the furnace has been
connected. After all connections have been made, purge lines and
check for leakage at furnace prior to operating furnace.
If pressure exceeds 0.5 psig (14--In. W.C.), gas supply pipe must
be disconnected from furnace and capped before and during
supply pipe pressure test. If test pressure is equal to or less than
0.5 psig (14--In. W.C.), turn off electric shutoff switch located on
furnace gas control valve and accessible manual equipment
shutoff valve before and during supply pipe pressure test. After
all connections have been made, purge lines and check for
leakage at furnace prior to operating furnace.
The gas supply pressure shall be within the maximum and
minimum inlet supply pressures marked on the rating plate with
the furnace burners ON and OFF.
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
disconnection. Reconnect wires correctly.
-- Verify proper operation after servicing.
!
WARNING
ELECTRICAL SHOCK HAZARD
Failure to follow this warning could result in personal
injury or death.
Blower access panel door switch opens 115--v power to
control. No component operation can occur. Do not
bypass or close switch with panel removed.
2” (51mm)
Street Elbow
A08551
See Fig. 25 for field wiring diagram showing typical field 115--v
wiring. Check all factory and field electrical connections for
tightness.
Field--supplied wiring shall conform with the limitations of 63_F
(33_C) rise.
Fig. 21 -- Burner and Manifold
!
WARNING
ELECTRICAL SHOCK AND FIRE HAZARD
GAS
SUPPLY
MANUAL
SHUTOFF
VALVE
(REQUIRED)
SEDIMENT
TRAP
UNION
Failure to follow this warning could result in personal
injury, death, or property damage.
The cabinet MUST have an uninterrupted or unbroken
ground according to NEC NFPA 70--2011 or local codes to
minimize personal injury if an electrical fault should occur.
This may consist of electrical wire, conduit approved for
electrical ground or a listed, grounded power cord (where
permitted by local code) when installed in accordance with
existing electrical codes. Refer to the power cord
manufacturer’s ratings for proper wire gauge. Do not use
gas piping as an electrical ground.
!
A02035
Fig. 22 -- Typical Gas Pipe Arrangement
CAUTION
FURNACE MAY NOT OPERATE HAZARD
Failure to follow this caution may result in intermittent
furnace operation.
Furnace control must be grounded for proper operation or
else control will lock out. Control must remain grounded
through green/yellow wire routed to gas valve and manifold
bracket screw.
21
Table 6 – Electrical Data
FURNACE SIZE
045--- 12/036045
070--- 16/048070
090--- 16/048090
110--- 22/066110
135--- 22/066135
VOLTS HERTZ PHASE
115-60-1
115-60-1
115-60-1
115-60-1
115-60-1
OPERATING VOLTAGE
RANGE *
Max.
Min.
127
104
127
104
127
104
127
104
127
104
MAX. UNIT
AMPS
UNIT
AMPACITY
8.0
9.6
10.2
13
13
10.85
12.85
13.42
16.84
16.84
MAX WIRE
MAX. FUSE
LENGTH FT OR CKT. BKR
(M)‡
AMPS †
34
15
28
15
27
15
34
20
34
20
MIN. WIRE
GAUGE
14
14
14
12
12
* Permissible limits of the voltage range at which the unit operates satisfactorily.
# Unit ampacity = 125 percent of largest operating component’s full load amps plus 100 percent of all other potential operating components’ (EAC, humidifier,
etc.) full load amps.
{Time ---delay type is recommended.
}Length shown is as measured 1 way along wire path between furnace and service panel for maximum 2 percent voltage drop.
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.
U.S. Installations: Make all electrical connections in accordance
with National Electrical Code (NEC) NFPA 70--2011 and any
local codes or ordinances that might apply.
!
Electrical Connection to J--Box
Electrical Box on Furnace Casing Side (See Fig. 24.)
WARNING
!
FIRE OR ELECTRICAL SHOCK HAZARD
Failure to follow this warning could result in personal
injury, death, or property damage.
If field--supplied manual disconnect switch is to be mounted
on furnace casing side, select a location where a drill or
fastener cannot damage electrical or gas components.
WARNING
FIRE HAZARD
Failure to follow this warning could result in personal
injury, death, or property damage.
Factory
Installed
Do not connect aluminum wire between disconnect
switch and furnace. Use only copper wire.
Use a separate, fused branch electrical circuit with a properly
sized fuse or circuit breaker for this furnace. See Table 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 flash
rapidly and furnace will NOT operate.
J--Box Relocation
NOTE: If factory location of J--Box is acceptable, go to next
section (ELECTRICAL CONNECTION to J--Box).
NOTE: On 14--in. (356 mm) wide casing models, the J--Box
shall not be relocated to other side of furnace casing when the
vent pipe is routed within the casing.
1. Remove and save two screws holding J--Box. (See Fig.
23.)
NOTE: The J--Box cover need not be removed from the J--Box
in order to move the J--Box. Do NOT remove green ground
screw inside J--Box. (See Fig. 23.)
2. Cut wire tie on loop in furnace wires attached to J--Box.
3. Move J--Box to desired location.
4. Fasten J--Box to casing with the two screws removed in
Step 1.
5. Route J--Box wires within furnace away from sharp edges,
rotating parts and hot surfaces.
Alternate
Location
A10291
Fig. 23 -- Relocating J--Box
1. Select and remove a hole knockout in the casing where the
electrical box is to be installed.
NOTE: Check that duct on side of furnace will not interfere with
installed electrical box.
2. Remove the desired electrical box hole knockout and position the hole in the electrical box over the hole in the furnace casing.
3. Fasten the electrical box to casing by driving two field-supplied screws from inside electrical box into casing
steel.
4. Remove and save two screws holding J--Box. (See Fig.
23.)
5. Pull furnace power wires out of 1/2--in. (12 mm) diameter
hole in J--Box. Do not loosen wires from strain--relief
wire--tie on outside of J--Box.
6. Route furnace power wires through holes in casing and
electrical box and into electrical box.
7. Pull field power wires into electrical box.
22
8. Remove cover from furnace J--Box.
9. Route field ground wire through holes in electrical box
and casing, and into furnace J--Box.
10. Reattach furnace J--Box to furnace casing with screws removed in Step 4.
11. Secure field ground wire to J--Box green ground screw.
12. Complete electrical box wiring and installation. Connect
line voltage leads as shown in Fig. 24. Use best practices
(NEC in U.S. for wire bushings, strain relief, etc.
13. Reinstall cover to J--Box. Do not pinch wires between
cover and bracket.
A10141
Fig. 24 -- Field--Supplied Electrical Box on Furnace Casing
Power Cord Installation in Furnace J--Box
NOTE: Power cords must be able to handle the electrical
requirements listed in Table 6. Refer to power cord
manufacturer’s listings.
1. Remove cover from J--Box.
2. Route listed power cord through 7/8--in. (22 mm) diameter
hole in J--Box.
3. Secure power cord to J--Box bracket with a strain relief
bushing or a connector approved for the type of cord used.
4. Secure field ground wire to green ground screw on J--Box
bracket.
5. Connect line voltage leads as shown in Fig. 25.
6. Reinstall cover to J--Box. Do not pinch wires between
cover and bracket.
BX Cable Installation in Furnace J--Box
1. Remove cover from J--Box.
2. Route BX cable into 7/8--in. (22 mm) diameter hole in
J--Box.
3. Secure BX cable to J--Box bracket with connectors approved for the type of cable used.
4. Secure field ground wire to green ground screw on J--Box
bracket.
5. Connect line voltage leads as shown in Fig. 25.
6. Reinstall cover to J--Box. Do not pinch wires between
cover and bracket.
24--V Wiring
Make field 24--v connections at the 24--v terminal strip. (See Fig.
25 -- 34.) Connect terminal Y/Y2 as shown in Fig. 27--34 for
proper cooling operation. Use only AWG No. 18, color--coded,
copper thermostat wire.
The 24--v circuit contains an automotive--type, 3--amp. fuse
located on the control. Any direct shorts during installation,
service, or maintenance could cause this fuse to blow. If fuse
replacement is required, use ONLY a 3--amp. fuse of identical
size.
ACCESSORIES
1. Electronic Air Cleaner (EAC)
Connect an accessory Electronic Air Cleaner (if used) using 1/4--in female quick connect terminals to the two male
1/4--in quick--connect terminals on the control board
marked EAC--1 and EAC--2. The terminals are rated for
115VAC, 1.0 amps maximum and are energized during
blower motor operation. (See Fig. 26.)
2. Humidifier (HUM)
Connect an accessory 24 VAC, 0.5 amp. maximum humidifier (if used) to the 1/4--in male quick--connect HUM
terminal and COM--24V screw terminal on the control
board thermostat strip. The HUM terminal is energized
when blower is energized in heating. (See Fig. 26.)
NOTE: DO NOT connect furnace control HUM terminal to
HUM (humidifier) terminal on Thermidistat, Zone Controller or
similar device. See ThermidistatE, Zone Controller, thermostat,
or controller manufacturer’s instructions for proper connection.
23
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
WHT
BLK
W2
WHT
COM
208/230- OR
460-VOLT
THREE
PHASE
W/W1
GND
NOTE 1
Y/Y2
115-VOLT FIELD- JUNCTION
SUPPLIED
BOX
FUSED
CONTROL
DISCONNECT
BOX
R
GND
208/230VOLT
SINGLE
PHASE
CONDENSING
UNIT
G
24-VOLT
TERMINAL
BLOCK
FURNACE
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.
A95236
Fig. 25 -- Field Wiring Diagram
MODEL PLUG
CONNECTOR
SW1 SETUP
SWITCHES AND
BLOWER OFFDELAY
OUTDOOR
AIR TEMP
CONNECTOR
AIR CONDITIONING (A/C) &
CONTINUOUS FAN (CF)
AIRFLOW SETUP SWITCHES
HUMIDIFIER
TERMINAL (24-VAC
0.5 AMP MAX.)
ACRDJ – AIR
CONDITIONING
RELAY DISABLE
JUMPER
COMMUNICATION
CONNECTOR
24-V THERMOSTAT
TERMINALS
FLASH
UPGRADE
CONNECTOR
(FACTORY
ONLY)
STATUS AND COMM
LED LIGHTS
PL1 – LOW VOLTAGE MAIN
HARNESS CONNECTOR
3-AMP FUSE
TRANSFORMER 24-VAC
CONNECTIONS
115-VAC (L2) NEUTRAL
CONNECTIONS
115-VAC (L1) LINE
VOLTAGE CONNECTIONS
EAC-1 TERMINAL
(115-VAC 1.0 AMP MAX.)
PL2 – HOT SURFACE
IGNITER & INDUCER
MOTOR CONNECTOR
SOFTWARE
VERSION
L14F003
Fig. 26 -- Variable Speed Furnace Control for ECM Blower Motor
24
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.
!
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.
General Venting Requirements
Follow all safety codes for proper vent sizing and installation
requirements, including local building codes, the National Fuel
Gas Code NFPA 54/ANSI Z223.1--2012 (NFGC), Parts 12 and
13 in the United States, the local building codes, and furnace and
vent manufacturers’ instructions.
These furnaces are design--certified as Category I furnaces in
accordance with ANSI Z21.47--2012/CSA 2.3--2012 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% to minimize the potential for condensation in
the venting system. These furnaces are approved for common
venting and multi--story venting with other fan assisted or draft
hood equipped appliances in accordance with the NFCG, 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.
!
The following steps shall be followed for each appliance
connected to the venting system being placed into
operation, while all other appliances connected to the
venting system are not in operation:
1. Seal any unused openings in venting system.
2. Inspect the venting system for proper size and
horizontal pitch, as required in the National Fuel Gas
Code, NFPA 54/ANSI Z223.1--2012 and these
instructions. Determine that there is no blockage or
restriction, leakage, corrosion and other deficiencies,
which could cause an unsafe condition.
3. As far as practical, close all building doors and
windows and all doors between the space in which
the appliance(s) connected to the venting system are
located and other spaces of the building.
4. Close fireplace dampers.
5. Turn on clothes dryers and any appliance not
connected to the venting system. Turn on any
exhaust fans, such as range hoods and bathroom
exhausts, so they are operating at maximum speed.
Do not operate a summer exhaust fan.
6. Follow the lighting instructions. Place the appliance
being inspected into operation. Adjust the thermostat
so appliance is operating continuously.
7. Test for spillage from draft hood equipped
appliances at the draft hood relief opening after 5
minutes of main burner operation. Use the flame of a
match or candle.
8. If improper venting is observed during any of the
above tests, the venting system must be corrected in
accordance with the National Fuel Gas Code, NFPA
54/ANSI Z223.1--2012.
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.
WARNING
CARBON MONOXIDE POISONING HAZARD
Failure to follow this warning could result in personal
injury or death.
Do not bypass the draft safeguard switch, as an unsafe
condition could exist which must be corrected.
1. If a vent (common or dedicated) becomes blocked, the furnace will be shut off by the draft safeguard switch located
on the vent elbow.
2. Two--stage furnaces require Type B vent connectors outside the casing in all configurations. Single wall vent connector may be used inside the furnace casing with the
transition to Type B vent outside the furnace casing. Size
the connector so that the FAN--Min vent connector capacity is equal to or lower than the low fire rate of the furnace and the FAN--Max vent connector capacity is equal
to or higher than the furnace high fire rate.
3. Do not vent this Category I furnace into a single wall dedicated or common vent. The dedicated or common vent is
considered to be the vertical portion of the vent system
that terminates outdoors.
4. Vent connectors serving Category I furnaces shall not be
connected into any portion of a mechanical draft system
operating under positive pressure.
5. Do not vent this appliance with any solid fuel burning appliance.
6. Category I furnaces must be vented vertically or nearly
vertically unless equipped with a listed mechanical venter.
See SIDEWALL VENTING section.
7. Do not vent this appliance into an unlined masonry chimney. Refer to Chimney Inspection Chart, Fig. 35.
Vent system or vent connectors may need to be resized. Vent
systems or vent connectors must be sized to approach minimum
size as determined using appropriate table found in the current
edition of NFGC.
25
See notes 1, 2, 4, 6, 7, 9, 10, 11, and 15
on the page following these figures
A00275
A03180
Fig. 27 -- Two--Stage Furnace with Single--Speed
Air Conditioner
Fig. 29 -- Two--Stage Furnace with Single--Speed Heat Pump
(Dual Fuel)
See notes 2, 5, 8, 10, 11 and 12
on the page following these figures
See notes 1, 2, 3, 4, 6, 8, 9, 10, 12, 13 and 15
on the page following these figures
A03179
A03178
Fig. 28 -- Two--Stage Furnace with Two--Speed Air Conditioner
Fig. 30 -- Two--Stage Furnace with Two--Speed Heat Pump
(Dual Fuel)
26
See notes 1, 2, 4, 11, 14, 15, and 16
on the page following these figures
See notes 2, 11, and 12 on the
page following these figures
A03181
A03183
Fig. 31 -- Dual--Fuel Thermostat with Two--Stage Furnace
and Single--Speed Heat Pump
Fig. 33 -- Two--Stage Thermostat with Two--Stage Furnace
and Two--Speed Air Conditioner
7
See notes 1 and 2 on the page
following these figures
See notes 1, 2, 3, 4, 12, 13, 14, 15, and 17
on the page following these figures
A03182
A03184
Fig. 32 -- Dual--Fuel Thermostat with Two--Stage Furnace
and Two--Speed Heat Pump
Fig. 34 -- Single--Stage Thermostat with Two--Stage Furnace
and Two--Speed Air Conditioner
27
NOTES FOR FIGURES 27 - 34
1. Heat pump MUST have a high pressure switch for dual fuel applications.
2. Refer to outdoor equipment Installation Instructions for additional information and setup procedure.
3. If the heat pump date code is 1501E or earlier, select the “ZONE” position on the two--speed heat pump control. Heat pumps having
date codes 1601E and later do not have or require a “ZONE” selection.
4. Outdoor Air Temperature Sensor must be attached in all dual fuel applications.
5. Dip switch No. 1 on Thermidistat should be set in OFF position for air conditioner installations. This is factory default.
6. Dip switch No. 1 on Thermidistat should be set in ON position for heat pump installations.
7. Dip switch No. 2 on Thermidistat should be set in OFF position for single--speed compressor operation. This is factory default.
8. Dip switch No. 2 on Thermidistat should be set in ON position for two--speed compressor operation.
9. Configuration Option No. 10 “Dual Fuel Selection” must be turned ON in all dual fuel applications.
10. NO connection should be made to the furnace HUM terminal when using a Thermidistat.
11. Optional connection: If wire is connected, dip switch SW1--2 on furnace control should be set in ON position to allow Thermidistat/
Thermostat to control furnace staging.
12. Optional connection: If wire is connected, ACRDJ jumper on furnace control should be removed to allow Thermidistat/Thermostat to
control outdoor unit staging.
13. Furnace must control its own high--stage heating operation via furnace control algorithm.
14. The RVS Sensing terminal “L” should not be connected. This is internally used to sense defrost operation.
15. DO NOT SELECT the “FURNACE INTERFACE” or “BALANCE POINT” option on the two--speed heat pump control board. This
is controlled internally by the Thermidistat/Dual Fuel Thermostat.
16. Dip switch D on Dual Fuel Thermostat should be set in OFF position for single--speed compressor operation. This is factory default.
17. Dip switch D on Dual Fuel Thermostat should be set in ON position for two--speed compressor operation.
28
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
Consult
Part B of
chimney adapter venting
instructions for
application
suitability.
Is chimney
lined with properly
sized, listed liner or
Type-B vent?
Condensate
drainage at bottom
of chimney?
Yes
Install chimney
adapter per
instructions.
No
Yes
Yes
Is chimney
to be dedicated to
a single
furnace?
Line chimney with property
sized, listed flexible metal
liner or Type-B vent per
NFGC Vent
Sizing Tables and liner or
vent manufacturer’s
Installation instructions.
Suitable
Yes
Chimney
exposed to
outdoors below
roof line?
Not Suitable
Not Suitable
Consult
Part C of
chimney adapter venting
instructions for
application
suitability
No
Suitable
Install chimney
adapter per
instructions.
No
Chimney is
acceptable for use.
A10133
Fig. 35 -- Chimney Inspection Chart
29
Masonry Chimney Requirement
NOTE: These furnaces are CSA design--certified for use in
exterior tile--lined masonry chimneys with a factory accessory
Chimney Adapter Kit. Refer to the furnace rating plate for correct
kit usage. The Chimney Adapter Kits are for use with ONLY
furnaces having a Chimney Adapter Kit number marked on the
furnace rating plate.
If a clay tile--lined masonry chimney is being used and it is
exposed to the outdoors below the roof line, relining might be
required. Chimneys shall conform to the Standard for Chimneys,
Fireplaces, Vents, and Solid Fuel Burning Appliances
ANSI/NFPA 211--2012 in the United States and must be in good
condition.
U.S.A.--Refer to Sections 13.1.8 and 13.2.20 of the NFPA
54/ANSI Z223.1--2012 or the authority having jurisdiction to
determine whether relining is required. If relining is required, use
a properly sized listed metal liner, Type--B vent, or a listed
alternative venting design.
NOTE:
See the NFPA 54/ANSI Z223.1--2012 13.1.9 and
13.2.20 regarding alternative venting design and the exception,
which cover installations such as our Chimney Adapter Kits
which are listed for use with these furnaces. See Product Data
Sheet for accessory listing.
The Chimney Adapter Kit is a listed alternative venting system
for these furnaces. See the kit instructions for complete details.
This furnace is permitted to be vented into a clay tile--lined
masonry chimney that is exposed to the outdoors below the roof
line, provided:
1. Vent connector is Type--B double--wall, and
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 7, and
4. The input rating of each space heating appliance is greater
than the minimum input rating given in Table 8 for the
local 99% Winter Design Temperature. Chimneys having
internal areas greater than 38 sq. in. (24516 sq. mm) require furnace input ratings greater than the input ratings of
these furnaces. See footnote at bottom of Table 8, and
5. The authority having jurisdiction approves.
If all of these conditions cannot be met, an alternative venting
design shall be used, such as the listed chimney adapter kit with a
furnace listed for use with the kit, a listed chimney--lining system,
or a Type--B common vent.
Inspections before the sale and at the time of installation will
determine the acceptability of the chimney or the need for repair
and/or (re)lining. Refer to the Fig. 33 to perform a chimney
inspection. If the inspection of a previously used tile--lined
chimney:
a. Shows signs of vent gas condensation, the chimney
should be relined in accordance with local codes and
the authority having jurisdiction. The chimney should
be relined with a listed metal liner, Type--B vent, or a
listed chimney adapter kit shall be used to reduce condensation. If a condensate drain is required by local
code, refer to the NFPA 54/ANSI Z223.1--2012, Section 12.10 for additional information on condensate
drains.
b. Indicates the chimney exceeds the maximum permissible size in the tables, the chimney should be rebuilt or
relined to conform to the requirements of the equipment being installed and the authority having jurisdiction.
A chimney without a clay tile liner, which is otherwise in good
condition, shall be rebuilt to conform to ANSI/NFPA 211 or be
lined with a UL listed 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 ENFPA & AGA
Table 7 – Combined Appliance Maximum Input
Rating in Thousands of Btuh per Hour
VENT HEIGHT
FT (M)
6 (1.8)
8 (2.4)
10 (3.0)
15 (4.5)
20 (6.0)
30 (9.1)
INTERNAL AREA OF CHIMNEY
SQ. IN. (SQ. MM)
12
19
28
38
(7741)
(12258)
(18064)
(24516)
74
119
178
257
80
130
193
279
84
138
207
299
NR
152
233
334
NR
NR
250
368
NR
NR
NR
404
Appliance Application Requirements
Appliance operation has a significant impact on the performance
of the venting system. If the appliances are sized, installed,
adjusted, and operated properly, the venting system and/or the
appliances should not suffer from condensation and corrosion.
The venting system and all appliances shall be installed in
accordance with applicable listings, standards, and codes.
The furnace should be sized to provide 100 percent of the design
heating load requirement plus any margin that occurs because of
furnace model size capacity increments. Heating load estimates
can be made using approved methods available from Air
Conditioning Contractors of America (Manual J); American
Society of Heating, Refrigerating, and Air--Conditioning
Engineers; or other approved engineering methods. Excessive
oversizing of the furnace could cause the furnace and/or vent to
fail prematurely.
When a metal vent or metal liner is used, the vent must be in
good condition and be installed in accordance with the vent
manufacturer’s instructions.
To prevent condensation in the furnace and vent system, the
following precautions must be observed:
1. The return--air temperature must be at least 60_F db except
for brief periods of time during warm--up from setback at
no lower than 55_F (13_C) db or during initial start--up
from a standby condition.
2. Adjust the gas input rate per the installation instructions.
Low gas input rate causes low vent gas temperatures, causing condensation and corrosion in the furnace and/or venting system. Derating is permitted only for altitudes above
2000 Ft. (610 M).
3. Adjust the air temperature rise to the midpoint of the rise
range or slightly above. Low air temperature rise can cause
low vent gas temperature and potential for condensation
problems.
4. Set the thermostat heat anticipator or cycle rate to reduce
short cycling.
!
CAUTION
BURN HAZARD
Failure to follow this caution may result in personal injury.
Hot vent pipe is within reach of small children when
installed in downflow position.
See the following instruction.
30
Table 8 – Minimum Allowable Input Rating of
Space--Heating Appliance in Thousands of Btuh per Hour
INTERNAL AREA OF CHIMNEY
VENT HEIGHT
FT. (M)
SQ. IN. (SQ. MM)
12
19
28
38
(7741)
(12258) 18064)
(24516)
Local 99% Winter Design Temperature: 17 to 26 degrees F
6
0
55
99
141
8
52
74
111
154
10
NR
90
125
169
15
NR
NR
167
212
20
NR
NR
212
258
30
NR
NR
NR
362
Local 99% Winter Design Temperature: 5 to 16 degrees F*
6
NR
78
121
166
8
NR
94
135
182
10
NR
111
149
198
15
NR
NR
193
247
20
NR
NR
NR
293
30
NR
NR
NR
377
Local 99% Winter Design Temperature: --- 10 to 4 degrees F*
6
NR
NR
145
196
8
NR
NR
159
213
10
NR
NR
175
231
15
NR
NR
NR
283
20
NR
NR
NR
333
30
NR
NR
NR
NR
Local 99% Winter Design Temperature: --- 11 degrees F or
lower
Not recommended for any vent configuration.
*The 99.6% heating (db) temperatures found in the 1997 or 2001
ASHRAE Fundamentals Handbook, Climatic Design Information chapter,
Table 1A (United States) and 2A (Canada) or the 2005 ASHRAE Fundamentals handbook, Climatic Design Information chapter, and the CD --ROM included with the 2005 ASHRAE Fundamentals Handbook.
Air for combustion must not be contaminated by halogen
compounds which include chlorides, fluorides, bromides, and
iodides. These compounds are found in many common home
products such as detergent, paint, glue, aerosol spray, bleach,
cleaning solvent, salt, and air freshener, and can cause corrosion
of furnaces and vents. Avoid using such products in the
combustion--air supply. Furnace use during construction of the
building could cause the furnace to be exposed to halogen
compounds, causing premature failure of the furnace or venting
system due to corrosion.
Vent dampers on any appliance connected to the common vent
can cause condensation and corrosion in the venting system. Do
not use vent dampers on appliances common vented with this
furnace.
Additional Venting Requirements
A 4--in. (102 mm) round vent elbow is supplied with the furnace.
A 5--in. (127 mm) or 6-- in. (152 mm) vent connector may be
required for some model furnaces. A field--supplied 4--in. (102
mm) to 5--in. (127 mm) or 4--in. (102 mm) to 6--in. (152 mm)
sheet metal increaser fitting is required when 5--in. (127 mm) or
6--in. (152 mm) vent connector is used. See Fig. 36 -- 48, Venting
Orientation for approved vent configurations.
NOTE: Vent connector length for connector sizing starts at
furnace vent elbow. The 4--in. (102 mm) vent elbow is shipped
for upflow configuration and may be rotated for other positions.
Remove the three screws that secure vent elbow to furnace, rotate
furnace vent elbow to position desired, reinstall screws. The
factory--supplied vent elbow does NOT count as part of the
number of vent connector elbows.
The vent connector can exit the furnace through one of five
locations on the casing.
!
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. 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
Sheet for accessory listing. If flue extension is used, fasten the
flue extension to the vent elbow with at least two field--supplied,
corrosion--resistant, sheet metal screws located 180_ apart. Fasten
the vent connector to the flue extension with at least two
field--supplied, corrosion resistant sheet metal screws located
180_ apart.
2. Vent the furnace with the appropriate connector as shown
in Fig. 36 -- 48.
3. Determine the correct location of the knockout to be removed.
4. Use a hammer and screwdriver to strike a sharp blow
between the tie points and work the slug back and forth
until the slug breaks free.
An accessory Vent Guard Kit is REQUIRED for downflow
applications for use where the vent exits through the lower
portion of the furnace casing. Refer to the Vent Guard Kit
Instructions for complete details. See Product Data Sheet for
accessory listing.
31
SEE NOTES: 1,2,4,7,8,9
on the page following
these figures
SEE NOTES:1,2,3,4,5,7,8,9
on the page following
these figures
A03208
A03210
Fig. 36 -- Upflow Application -- Vent Elbow Up
Fig. 38 -- Downflow Application -- Vent Elbow Up then Left
SEE NOTES: 1,2,4,5,7,8,9
on the page following
these figures
SEE NOTES: 1,2,3,4,7,8,9
on the pages following
these figures
A03209
A03211
Fig. 37 -- Upflow Application -- Vent Elbow Right
Fig. 39 -- Downflow Application -- Vent Elbow Up
32
SEE NOTES: 1,2,4,7,8,9 on the page
following these figures
A03213
Fig. 42 -- Horizontal Left Application -- Vent Elbow Left
SEE NOTES: 1,2,4,5,6,7,8,9,10
on the page following these figures
A03207
Fig. 40 -- Downflow Application -- Vent Elbow Left then Up
SEE NOTES: 1,2,4,5,7,8,9 on the page
following these figures
A03214
Fig. 43 -- Horizontal Left Application -- Vent Elbow Right
then Up
SEE NOTES:1,2,3,4,5,7,8,9
on the page following
these figures.
SEE NOTES: 1,2,4,7,8,9 on the page
following these figures
A03212
A03218
Fig. 41 -- Downflow Application -- Vent Elbow Up then Right
Fig. 44 -- Horizontal Right Application -- Vent Elbow Right
33
SEE NOTES: 1,2,4,5,7,8,9 on the page
following these figures
SEE NOTES: 1,2,4,5,7,8,9 on the page
following these figures
A03215
A03219
Fig. 45 -- Horizontal Left Application -- Vent Elbow Up
Fig. 47 -- Horizontal Right Application -- Vent Elbow Left
then Up
SEE NOTES: 1,2,4,5,7,8,9
SEE NOTES: 1,2,4,5,7,8,9 on the page
following these figures
A02068
A03216
Fig. 48 -- Horizontal Right Application--Vent Elbow Left
Fig. 46 -- Horizontal Left Application -- Vent Elbow Right
VENTING NOTES FOR FIG. 36 - 48
1. For common vent, vent connector sizing and vent material: United States----use the NFGC.
2. Immediately increase to 5--in. (102 mm) or 6--in. (152 mm) vent connector outside furnace casing when 5--in. (127 mm) vent
connector is required, refer to Note 1 above.
3. Side outlet vent for upflow and downflow installations must use Type B vent immediately after exiting the furnace, except when
factory--approved Downflow Vent Guard Kit is used in the downflow position. See Product Data Sheet for accessory listing.
4. Type--B vent where required, refer to Note 1 above.
5. A 4--in.(102 mm) single--wall (26 ga. min.) vent must be used inside furnace casing and when the factory--approved Downflow Vent
Guard Kit is used external to the furnace. See Product Data Sheet for accessory listing.
6. Accessory Downflow Vent Guard Kit required in downflow installations with lower vent configuration. See Product Data Sheet for
accessory listing.
7. Chimney Adapter Kit may be required for exterior masonry chimney applications. Refer to Chimney Adapter Kit for sizing and
complete application details. See Product Data Sheet for accessory listing.
8. Secure vent connector to furnace elbow with (2) corrosion--resistant sheet metal screws, spaced approximately 180_ apart.
9. Secure all other single wall vent connector joints with (3) corrosion resistant screws spaced approximately 120_ apart. Secure Type--B
vent connectors per vent connector manufacturer’s recommendations.
34
Caution!! For the following applications, use the minimum vertical heights as specified below.
For all other applications, follow exclusively the National Fuel Gas Code.
FURNACE
ORIENTATION
Downflow
Horizontal Left
Horizontal Left
Downflow
Downflow
VENT ORIENTATION
FURNACE INPUT
(BTUH/HR)
MIN. VENT
DIAMETER
IN. (mm)*
MIN. VERTICAL VENT
HEIGHT
FT. (M)**
132,000 110,000
5 (127)
12 (3.6)
132,000
5 (127)
7 (2.1)
132,000
5 (127)
7 (2.1)
110,000
5 (127)
10 (3.0)
110,000
5 (127)
10 (3.0)
Vent elbow left, then up
Fig. 40
Vent elbow right, then up
Fig. 43
Vent Elbow up
Fig. 45
Vent elbow up then left
Fig. 38
Vent elbow up, then right
Fig. 41
NOTE: All vent configurations must also meet National Fuel Gas Code venting requirements NFGC.
*4 ---in. (102 mm) inside casing or vent guard
**Including 4 in. (102 mm) vent section(s)
The horizontal portion of the venting system shall slope upwards
not less than 1/4--in. per linear ft. (21 mm/m) from the furnace to
the vent and shall be rigidly supported every 5 ft. (1.5 M) or less
with metal hangers or straps to ensure there is no movement after
installation.
Sidewall Venting
This furnace is not approved for direct sidewall horizontal
venting.
Per section 12.4.3 of the NFPA 54/ANSI Z223.1--2012, 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.
3. Gas supply pressure to the furnace must be greater than
4.5--In. W.C. (0.16 psig ) but not exceed 14--In. W.C. (0.5
psig).
4. Check all manual--reset switches for continuity.
5. Replace blower compartment door. Door must be in place
to operate furnace.
6. Setup switch descriptions The variable speed furnace control has DIP switches to select thermostat staging, blower
off delay timings, air flow selection and other operational
or service related functions. (See Fig. 26, 55 and Table
52.)
!
CUT HAZARD
START--UP, ADJUSTMENT, AND SAFETY
CHECK
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.
General
!
CAUTION
WARNING
FIRE HAZARD
REGULATOR COVER SCREW
Failure to follow this warning could result in personal injury,
death or property damage.
PLASTIC ADJUST SCREW
This furnace is equipped with manual reset limit switches in
the gas control area. The switches open and shut off power to
the gas valve, if a flame rollout or overheating condition
occurs in the gas control area. DO NOT bypass the switches.
Correct problem before resetting the switches.
ON/OFF SWITCH
REGULATOR SPRING
1/2˝ NPT INLET
INLET
PRESSURE TAP
1. Maintain 115--v wiring and ground. Improper polarity will
result in rapid flashing LED and no furnace operation.
2. Make thermostat wire connections at the 24--v terminal
block on the furnace control. Failure to make proper connections will result in improper operation. (See Fig. 25 -34.)
HIGH STAGE GAS
PRESSURE REGULATOR
ADJUSTMENT
LOW STAGE
GAS PRESSURE
REGULATOR ADJUSTMENT
MANIFOLD
PRESSURE TAP
1/2˝ NPT OUTLET
A04167
Fig. 49 -- Redundant Automatic Gas Control Valve
35
Start--Up Procedures
!
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.
BURNER
ORIFICE
!
A93059
Fig. 50 -- Orifice Hole
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.
THERMOSTAT SUBBASE
TERMINALS WITH
THERMOSTAT REMOVED
(ANITICIPATOR, CLOCK, ETC.,
MUST BE OUT OF CIRCUIT.)
HOOK-AROUND
AMMETER
R Y W G
10 TURNS
FROM UNIT 24-V
CONTROL TERMINALS
EXAMPLE: 5.0 AMPS ON AMMETER
10 TURNS AROUND JAWS
= 0.5 AMPS FOR THERMOSTAT
ANTICIPATOR SETTING
A96316
Fig. 51 -- Amp. Draw Check with Ammeter
1. Purge gas lines after all connections have been made.
2. Check gas lines for leaks.
3. To Begin Component Self--Test:
Remove Blower Access Door. Disconnect the thermostat
R lead from furnace control board. Manually close blower
door switch. Turn Setup DIP switch SW1--6 ON. (See Fig.
26, 55 and Table 52.)
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. 54.
Component test sequence is as follows:
a. Inducer motor starts on high--speed and continues to
run until Step d. of component test sequence.
b. Hot surface igniter is energized for 15 sec., then off.
c. Blower motor operates for 15 sec.
d. Inducer motor goes to low--speed for 10 sec., then
stops.
e. After component test is completed, one or more status
codes (11 or 25) will flash. See component test section
of service label (Fig. 54) 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.
36
Furnace Setup Switch Description
SETUP
SWITCH
SWITCH NAME
NORMAL
POSITION
SW1-1
Status Code Recovery
OFF
Turn ON to retrieve up to 7 stored status codes for troubleshooting
assistance when R thermostat lead is disconnected.
SW1-2
Low Heat Only
(Adaptive Heat Mode
when SW1-2 is OFF)
OFF
When SW1-2 is OFF allows two-stage operation with a single stage
thermostat. Turn ON when using two- stage thermostat to allow
Low Heat operation when R to W/W1 closes and High Heat
operation when R to W/W1 and W2 close.
SW1-3
Low Heat Rise
Adjustment
OFF
Turn ON to increase Low Heat airflow by 18 percent. This
compensates for increased return air temperature caused with
bypass humidifier.
SW1-4
Comfort/Efficiency
Adjustment
ON
Turn ON to decrease low heat airflow by approximately 7 percent
and high heat by approximately 10 percent for maximum comfort
SW1-5
CFM per ton adjust
OFF
Turn ON for 400 CFM per ton, Turn OFF for 350 CFM per ton. See
also SW2.
SW1-6
Component Self Test
OFF
Turn ON to initiate Component Self Test for troubleshooting
assistance when R thermostat lead is disconnected. Turn OFF
when Self Test is completed.
SW1-7 & SW18
Blower OFF delay
ON or OFF
Blower Off Delay time – adjustable 90 seconds to 180 seconds.
See table in Adjustments section or refer to unit wiring diagram.
SW2-1
Twinning
OFF
DESCRIPTION OF USE
Allows for selection of furnace Main (OFF) or Secondary (ON) when
Twinned furnace setup is required. See kit instructions for further
directions on installation and setup.
Allows additional CFM per ton selections when used with SW 1-5
325 CFM per ton (nominal) when SW 2-2 ON and SW 1-5 OFF
350 CFM per ton (nominal) when SW 2-2 OFF and SW 1-5 OFF
SW2-2
CFM per ton Adjust
OFF
370 CFM per ton (nominal) when SW2-2 ON and SW 1-5 ON
400 CFM per ton (nominal) when SW 2-2 OFF and SW 1-5 ON
See Air Delivery Tables for model specific CFM vs. static pressure
SW 2-6, 7, 8
AC (Cooling Airflow)
OFF
The AC setup switches select desired cooling or high stage cooling
(two stage units) airflow. See Cooling Air Delivery Tables for
specific switch settings.
The CF setup switches select desired Continuous Fan Airflow
The CF switch position is the low cooling airflow selection for two
stage cooling units.
SW 2-3, 4, 5
CF (Continuous Fan)
OFF
The CFM values are shown in the Air Delivery Tables below for
SW 2 settings. SW 2-3, 4, 5 cannot be set for airflow higher than
SW 2-6, 7, 8. See Continuous Fan Air Flow Table for specific
switch settings.
A14312
Fig. 52 -- Furnace Setup Switch Description
SW2
A/C (8 7 6)
CF (5 4 3)
SW2
A/C (8 7 6)
CF (5 4 3)
SW2
A/C (8 7 6)
CF (5 4 3)
SW2
A/C (8 7 6)
CF (5 4 3)
SW2
A/C (8 7 6)
CF (5 4 3)
SW2
A/C (8 7 6)
CF (5 4 3)
SW2
A/C (8 7 6)
CF (5 4 3)
MODEL SIZE
045-12 / 036045
DEF
5252
700
875
10501
1150
1150
070-16 / 048070
DEF
5252
700
875
1050
1225
14001
090-16 / 048090
DEF
5252
700
875
1050
1225
14001
*110-22 / 066110
DEF
7002
875
1050
1225
1400
17501
*135-22 / 066135
DEF
7002
875
1050
1225
1400
17501
1. Default A/C airflow when A/C switches (SW2-6, 7, 8) are in OFF position
2. Default continuous fan airflow when CF switches (SW2-3, 4, 5) are in OFF position
* Continuous fan (CF) airflow for 110 and 135 models is the same as 090-16 / 048090
NOTE: CF airflow will not be higher than the selected A/C airflow
SW2
A/C (8 7 6)
CF (5 4 3)
1175
1685
1750
1925
1925
A14313
Fig. 53 -- Airflow Selection (based on 350 CFM/TON) for A/C (SW2--6, 7, 8) and *CF (SW2--3, 4, 5)
37
A14310
Fig. 54 -- Service Label
Adjustments
!
WARNING
FIRE HAZARD
Failure to follow this warning could result in personal
injury, death and/or property damage.
DO NOT bottom out gas valve regulator adjusting screw.
This can result in unregulated manifold pressure and result
in excess overfire and heat exchanger failures.
!
CAUTION
FURNACE DAMAGE HAZARD
Failure to follow this caution may result in reduced furnace
life.
c. Find installation altitude in Table 12.
d. Find closest natural gas heat value and specific gravity
in Table 12.
e. Follow heat value and specific gravity lines to point of
intersection to find orifice size and low--and high--heat
manifold pressure settings for proper operation.
f. Check and verify burner orifice size in furnace.
NEVER ASSUME ORIFICE SIZE. ALWAYS
CHECK AND VERIFY.
NOTE: If orifice hole appears damaged or it is suspected to have
been redrilled, check orifice hole with a numbered drill bit of
correct size. Never redrill an orifice. A burr--free and squarely
aligned orifice hole is essential for proper flame characteristics.
g. Replace orifice with correct size, if required by Table
12. Use only factory--supplied orifices. See
EXAMPLE 1.
Table 9 – Altitude Derate Multiplier for U.S.A.
DO NOT redrill orifices. Improper drilling (burrs,
out--of--round holes, etc.) can cause excessive burner noise
and misdirection of burner flames. This can result in flame
impingement of heat exchangers, causing failures. (See Fig.
50.)
ALTITUDE
FT. (M)
0–2000
(0--- 610)
2001–3000
(610--- 914)
3001–4000
(914--- 1219)
4001–5000
(1219--- 1524)
5001–6000
1524--- 1829)
6001–7000
(1829--- 2134)
7001–8000
(2134--- 2438)
8001–9000
(2438--- 2743)
9001–10,000
(2743--- 3048)
Furnace gas input rate on rating plate is for installations at
altitudes up to 2000 Ft. (610 M). Furnace input rate must be
within +/--2 percent of furnace rating plate input. For altitudes
above 5500 Ft. (1676 M), a field--supplied high altitude pressure
switch is required.
1. Determine the correct gas input rate.
The input rating for altitudes above 2,000 ft. (610 M) must
be reduced by 4 percent for each 1,000 ft. (305 M) above
sea level.
For installations below 2000 Ft. (610 M), refer to the unit
rating plate. For installations above 2000 Ft. (610 M),
multiply the input on the rating plate by the de--rate multiplier in Table 9 for the correct input rate.
2. Determine the correct orifice and manifold pressure adjustment. All models in all positions use Table 12 (22,000
Btuh per burner.) See input listed on rating plate.
a. Obtain average yearly gas heat value (at installed altitude) from local gas supplier.
b. Obtain average yearly gas specific gravity from local
gas supplier.
38
PERCENT
OF DERATE
DERATE MULTIPLIER
FACTOR*
0
1.00
8–12
0.90
12–16
0.86
16–20
0.82
20–24
0.78
24–28
0.74
28–32
0.70
32–36
0.66
36–40
0.62
EXAMPLE 1: 0–2000 ft. (0--610 M) altitude
For 22,000 Btuh per burner application use Table 12.
Heating value = 1000 Btuh/cu ft.
Specific gravity = 0.62
Therefore: Orifice No. 43*
Manifold pressure: 3.7--In. W.C. for high--heat
1.6--In. W.C. for low--heat
* Furnace is shipped with No. 43 orifices. In this example all
main burner orifices are the correct size and do
not need to be changed to obtain proper input rate.
3. Adjust manifold pressure to obtain low fire input rate. (See
Fig. 49.)
a. Turn gas valve ON/OFF switch to OFF.
b. Remove manifold pressure tap plug from gas valve.
c. Connect a water column manometer or similar device
to manifold pressure tap.
d. Turn gas valve ON/OFF switch to ON.
e. Move setup SW1—2 on furnace control to ON position to lock furnace in low--heat operation. (See Table
52 and Fig. 26.)
f. Manually close blower door switch.
g. Jumper R and W/W1 thermostat connections on control to start furnace. (See Fig. 26.)
h. Remove regulator adjustment cap from low heat gas
valve pressure regulator (See Fig. 49.) and turn low-heat adjusting screw (3/16 or smaller flat--tipped
screwdriver) counterclockwise (out) to decrease input
rate or clockwise (in) to increase input rate.
NOTE: DO NOT set low--heat manifold pressure less than
1.4--In. W.C. or more than 1.7--In. W.C. for natural gas. If
manifold pressure is outside this range, change main burner
orifices.
i. Install low--heat regulator adjustment cap.
j. Move setup switch SW1--2 to off position after completing low--heat adjustment.
k. Leave manometer or similar device connected and
proceed to Step 4.
4. Adjust manifold pressure to obtain high fire input rate.
(See Fig. 49.)
a. Jumper R to W/W1 and W2 thermostat connections on
furnace control. This keeps furnace locked in high-heat operation.
b. Remove regulator adjustment cap from high--heat gas
valve pressure regulator (See Fig. 49) and turn high
heat adjusting screw (3/16--in. or smaller flat--tipped
screwdriver) counterclockwise (out) to decrease input
rate or clockwise (in) to increase input rate.
NOTE: DO NOT set high--heat manifold pressure less than
3.2--In. W.C. or more than 3.8 In. W.C. for natural gas. If
manifold pressure is outside this range, change main burner
orifices to obtain manifold pressure in this range.
c. When correct input is obtained, replace caps that conceal gas valve regulator adjustment screws. Main
burner flame should be clear blue, almost transparent.
d. Remove jumpers R to W/W1 and R to W2.
5. Verify natural gas input rate by clocking meter.
NOTE: Gas valve regulator adjustment caps must be in place for
proper input to be clocked.
a. Turn off all other gas appliances and pilots served by
the meter.
b. Move setup switch SW1--2 to ON position. This
keeps furnace locked in low--heat operation.
c. Jumper R to W/W1.
d. Run furnace for 3 minutes in low--heat operation.
e. Measure time (in sec) for gas meter to complete 1
revolution and note reading. The 2 or 5 cubic feet dial
provides a more accurate measurement of gas flow.
f. Refer to Table 11 for cubic ft. of gas per hr.
g. Multiply gas rate cu ft./hr by heating value (Btuh/cu
ft.) to obtain input. If clocked rate does not match required input from Step 1, increase manifold pressure to
increase input or decrease manifold pressure to decrease input. Repeat steps b through e until correct
low--heat input is achieved. Re--install low heat regulator seal cap on gas valve.
h. Move setup switch SW1--2 to OFF position and jumper R to W/W1, and W2. This keeps furnace locked in
high--heat operation. Repeat items d through g for
high--heat operation.
6. Set Temperature Rise
NOTE: Blower access door must be installed when taking
temperature rise reading. Leaving blower access door off will
result in incorrect temperature measurements.
!
CAUTION
FURNACE DAMAGE HAZARD
Failure to follow this caution may result in shorten furnace
life.
Set air temperature rise within limits specified on the rating
plate to prevent reduced life of furnace components.
Operation is within a few degrees of the mid--point of rise
range when setup switch SW1--4 is OFF.
!
CAUTION
UNIT DAMAGE HAZARD
Failure to follow this caution may result in overheating the
heat exchangers or condensing flue gases in heat exchanger
areas not designed for condensate.
Temperature rise must be within limits specified on unit
rating plate. Operation is within a few degrees of midpoint
of rise range when setup switch SW1--4 is OFF.
When setup switch SW1--4 is ON, operation will be near the high
end of the rise range for improved comfort.
Furnace must operate within ranges of temperature rise specified
on the furnace rating plate. Determine air temperature rise as
follows:
a. Place thermometers in return and supply ducts as near
furnace as possible. Be sure thermometers do not see
heat exchanger so that radiant heat does not affect
readings. This practice is particularly important with
straight--run ducts.
b. When thermometer readings stabilize, subtract return-air temperature from supply--air temperature to determine air temperature rise.
NOTE: Temperature rise can be determined for low--heat
operation by placing setup switch SW1--2 on furnace control in
ON position. For high--heat operation, place setup switch SW1--2
in OFF position and jumper R--W2 on furnace control. DO NOT
forget to return setup switch to OFF position and remove R--W2
jumper upon completion of testing.
c. This furnace is capable of automatically providing
proper airflow to maintain the temperature rise within
39
d.
e.
f.
g.
h.
i.
the range specified on furnace rating plate. If temperature rise is outside this range, proceed as follows:
(1.) Check gas input for low-- and high--heat operation.
(2.) Check derate for altitude if applicable.
(3.) Check all return and supply ducts for excessive
restrictions causing static pressure greater than
0.5--In. W.C..
(4.) Ensure Low Heat Rise Adjust switch SW1--3 on
furnace control is in ON position when a bypass
humidifier is used. (See Fig. 26 for switch location.)
(5.) Make sure proper model plug is installed.
Remove thermostat jumpers and release blower access
door switch.
Repeat Steps a through c as required to adjust for high
heat temperature rise.
When correct high heat input rate and temperature rise
is achieved, turn gas valve ON/OFF switch to OFF.
Release blower access door switch.
Remove manometer or similar device from gas valve.
Re--install manifold pressure tap plug in gas valve.
(See Fig. 49.)
!
WARNING
FIRE HAZARD
Failure to follow this warning could result in personal
injury, death, and/or property damage.
Reinstall manifold pressure tap plug in gas valve to prevent
gas leak.
j. Remove thermostat jumper wire from furnace control
board.
k. Turn gas valve ON/OFF switch to ON.
!
CAUTION
FURNACE OVERHEATING HAZARD
Failure to follow this caution may result in reduced furnace
life.
Recheck temperature rise. It must be within limits specified
on the rating plate. Recommended operation is at the
mid--point of rise range or slightly above.
l. Proceed to Step 6, “Set Blower Off Delay” before installing blower access door.
7. Set Blower Off Delay
a. Remove blower access door if installed.
b. Turn Dip switch SW--7 or SW--8 ON or OFF for desired blower off delay. (See Table 52 and Fig. 26 and
55.)
Table 10 – Blower Off Delay Setup Switch
DESIRED HEATING MODE
BLOWER OFF DELAY (SEC.)
90
120
150
180
SETUP SWITCH
(SW --- 7 AND --- 8)
POSITION
SW1--- 7
SW1--- 8
OFF
OFF
ON
OFF
OFF
ON
ON
ON
8. Set thermostat heat anticipator.
a. Mechanical thermostat. Set thermostat heat anticipator
to match the amp. draw of the electrical components in
the R--W/W1 circuit. Accurate amp. draw readings can
be obtained at the wires normally connected to thermostat subbase terminals, R and W. The thermostat
anticipator should NOT be in the circuit while measuring current.
(1.) Set SW1--2 switch on furnace control board to
ON.
(2.) Remove thermostat from subbase or from wall.
(3.) Connect an amp. meter as shown in Fig. 51.
across the R and W subbase terminals or R and
W wires at wall.
(4.) Record amp. draw across terminals when furnace
is in low heat and after blower starts.
(5.) Set heat anticipator on thermostat per thermostat
instructions and install on subbase or wall.
(6.) Turn SW1--2 switch OFF.
(7.) Install blower access door.
b. Electronic thermostat: Set cycle rate for 3 cycles per
hr.
9. Set Airflow for Air Conditioning --Single Stage and High
Stage Cooling
The ECM blower can be adjusted for a range of airflow
for Low Speed or High Speed cooling. See Table 4--Air
Delivery -- CFM (With Filter ). Depending on the model
size, the cooling airflow can be adjusted from 1. tons nominal cooling to 3 ., to 4 or to 6 tons of nominal cooling
based on 350 cfm ton.
The cooling airflow is adjusted by turning Setup switches
SW2--6, SW2--7 and SW2--8 either ON or OFF. Select the
required airflow from Fig. 53.
NOTE: 6 ton airflow will truncate at 2200 cfm on applicable
models. For a complete explanation of cooling airflow, refer to
the section titled “Sequence of Operation.”
10. Set Airflow For Continuous Fan/Low Speed Cooling Airflow The ECM blower motor can be adjusted for continuous fan speeds different than heating or cooling fan speed.
See Table 4 -- Air Delivery -- CFM (With Filter). Select the
required continuous fan airflow from Fig. 53.
The continuous fan speed is also the fan speed for low
speed cooling when furnace is used with a 2--speed cooling unit. Adjust the Continuous Fan CFM to match the
airflow required for low speed cooling. Select the required
airflow from Fig. 53. 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.
40
A14327
Fig. 55 -- Wiring Diagram
41
Table 11 – Gas Rate (CU ft./hr)
SECONDS G
FOR 1 REVOLUTION
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
1 Cu Ft.
360
327
300
277
257
240
225
212
200
189
180
171
164
157
150
144
138
133
129
124
120
116
113
109
106
103
100
97
95
92
90
88
86
84
82
80
78
76
75
73
SIZE OF TEST DIAL
2 Cu Ft.
5 Cu Ft.
720
1800
655
1636
600
1500
555
1385
514
1286
480
1200
450
1125
424
1059
400
1000
379
947
360
900
343
857
327
818
313
783
300
750
288
720
277
692
267
667
257
643
248
621
240
600
232
581
225
563
218
545
212
529
206
514
200
500
195
486
189
474
185
462
180
450
176
439
172
429
167
419
164
409
160
400
157
391
153
383
150
375
147
367
SECONDS
FOR 1 REVOLUTION
50
51
52
53
54
55
56
57
58
59
60
62
64
66
68
70
72
74
76
78
80
82
84
86
88
90
92
94
96
98
100
102
104
106
108
110
112
116
120
42
1 Cu Ft.
72
71
69
68
67
65
64
63
62
61
60
58
56
54
53
51
50
48
47
46
45
44
43
42
41
40
39
38
38
37
36
35
35
34
33
33
32
31
30
SIZE OF TEST DIAL
2 Cu Ft.
5 Cu Ft.
144
360
141
355
138
346
136
340
133
333
131
327
129
321
126
316
124
310
122
305
120
300
116
290
112
281
109
273
106
265
103
257
100
250
97
243
95
237
92
231
90
225
88
220
86
214
84
209
82
205
80
200
78
196
76
192
75
188
74
184
72
180
71
178
69
173
68
170
67
167
65
164
64
161
62
155
60
150
Table 12 – Orifice Size and Manifold Pressure (In. W.C.) for Gas Input Rate
(Tabulated Data Based on 22,000 Btuh High--Heat/14,500 Btuh for Low--Heat per Burner, Derated 4 Percent for Each 1000 Ft.
(305 M) Above Sea Level)
ALTITUDE RANGE
FT. (M)
USA
0 to
2000
(0 to 610)
ALTITUDE RANGE
FT. (M)
USA
2001 to
3000 (610
to 914)
ALTITUDE RANGE
FT. (M)
USA
3001 to
4000
(914 to
1219)
ALTITUDE RANGE
FT. (M)
USA
4001 to
5000
(1219 to
1524)
AVG. GAS
HEAT VALUE
(BTUH/CU FT.)
900
925
950
975
1000
1025
1050
1075
1100
AVG. GAS
HEAT VALUE
(BTUH/CU FT.)
800
825
850
875
900
925
950
975
1000
AVG. GAS
HEAT VALUE
(BTUH/CU FT.)
775
800
825
850
875
900
925
950
AVG. GAS
HEAT VALUE
(BTUH/CU FT.)
750
775
800
825
850
875
900
925
* Orifice numbers 43 are factory installed
0.58
Manifold
Orifice
Pressure
No.
High/Low
42
3.5/1.5
42
3.3/1.4
43
3.8/1.7
43
3.6/1.6
43
3.5/1.5
43
3.3/1.4
44
3.6/1.6
44
3.4/1.5
44
3.3/1.4
0.58
Orifice
No.
Manifold
Pressure
High/Low
42
42
43
43
43
44
44
44
45
3.4/1.5
3.2/1.4
3.7/1.6
3.5/1.5
3.3/1.4
3.5/1.5
3.4/1.5
3.2/1.4
3.7/1.6
0.58
Orifice
No.
Manifold
Pressure
High/Low
42
43
43
43
44
44
45
46
3.2/1.4
3.6/1.6
3.4/1.5
3.2/1.4
3.5/1.5
3.3/1.4
3.8/1.6
3.8/1.6
0.58
Orifice
No.
Manifold
Pressure
High/Low
43
43
43
44
44
45
46
46
3.6/1.6
3.4/1.5
3.2/1.4
3.4/1.5
3.2/1.4
3.7/1.6
3.7/1.6
3.5/1.5
SPECIFIC GRAVITY OF NATURAL GAS
0.60
0.62
Manifold
Manifold
Orifice
Orifice
Pressure
Pressure
No.
No.
High/Low
High/Low
42
3.6/1.6
42
3.7/1.6
42
3.4/1.5
42
3.5/1.5
42
3.3/1.4
42
3.4/1.5
43
3.8/1.6
42
3.2/1.4
43
3.6/1.6
43
3.7/1.6
43
3.4/1.5
43
3.5/1.5
43
3.2/1.4
43
3.4/1.5
44
3.5/1.5
43
3.2/1.4
44
3.4/1.5
44
3.5/1.5
SPECIFIC GRAVITY OF NATURAL GAS
0.60
0.62
Manifold
Manifold
Orifice
Orifice
Pressure
Pressure
No.
No.
High/Low
High/Low
42
3.5/1.5
42
3.6/1.6
42
3.3/1.4
42
3.4/1.5
43
3.8/1.6
42
3.2/1.4
43
3.6/1.6
43
3.7/1.6
43
3.4/1.5
43
3.5/1.5
43
3.2/1.4
43
3.3/1.4
44
3.5/1.5
44
3.6/1.6
44
3.3/1.4
44
3.4/1.5
45
3.8/1.7
44
3.2/1.4
SPECIFIC GRAVITY OF NATURAL GAS
0.60
0.62
Manifold
Manifold
Orifice
Orifice
Pressure
Pressure
No.
No.
High/Low
High/Low
42
3.3/1.4
42
3.4/1.5
43
3.8/1.6
42
3.2/1.4
43
3.5/1.5
43
3.7/1.6
43
3.3/1.4
43
3.4/1.5
44
3.6/1.6
43
3.3/1.4
44
3.4/1.5
44
3.5/1.5
44
3.2/1.4
44
3.3/1.5
45
3.7/1.6
45
3.8/1.7
SPECIFIC GRAVITY OF NATURAL GAS
0.60
0.62
Manifold
Manifold
Orifice
Orifice
Pressure
Pressure
No.
No.
High/Low
High/Low
43
43
43
44
44
45
46
46
3.8/1.6
3.5/1.5
3.3/1.4
3.6/1.5
3.4/1.5
3.8/1.7
3.8/1.7
3.6/1.6
43
42
43
43
43
44
44
45
46
3.2/1.4
3.6/1.6
3.4/1.5
3.2/1.4
3.5/1.5
3.3/1.4
3.7/1.6
3.7/1.6
Orifice
No.
41
42
42
42
43
43
43
43
43
0.64
Manifold
Pressure
High/Low
3.5/1.5
3.7/1.6
3.5/1.5
3.3/1.4
3.8/1.7
3.6/1.6
3.5/1.5
3.3/1.4
3.2/1.4
0.64
Orifice
No.
Manifold
Pressure
High/Low
42
42
42
43
43
43
43
44
44
3.7/1.6
3.5/1.5
3.3/1.4
3.8/1.7
3.6/1.6
3.4/1.5
3.2/1.4
3.5/1.5
3.4/1.5
0.64
Orifice
No.
Manifold
Pressure
High/Low
42
42
43
43
43
43
44
44
3.5/1.5
3.3/1.4
3.8/1.6
3.6/1.5
3.4/1.5
3.2/1.4
3.4/1.5
3.3/1.4
0.64
Orifice
No.
Manifold
Pressure
High/Low
42
43
43
43
44
44
44
46
3.3/1.4
3.8/1.6
3.5/1.5
3.3/1.4
3.6/1.6
3.4/1.5
3.2/1.4
3.8/1.7
Table 12 -- Orifice Size and Manifold Pressure (In. W.C.) for Gas Input Rate (Con’t.)
(Tabulated Data Based on 22,000 Btuh High--Heat/14,500 Btuh for Low--Heat per Burner, Derated 4 Percent for Each 1000 Ft.
Above Sea Level)
ALTITUDE
RANGE
FT. (M)
USA
5001 to
6000
(1524
to
1829)
ALTITUDE
RANGE
FT. (M)
USA
6001 to
7000
(1829
to
2134)
ALTITUDE
RANGE
FT. (M)
USA
7001 to
8000
(2134
to
2438)
ALTITUDE
RANGE
FT. (M)
USA
8001 to
9000
(2438
to
2743)
USA
9001 to
10,000
2743 to
3048)
AVG. GAS
HEAT VALUE
AT ALTITUDE
(BTUH/CU FT.)
725
750
775
800
825
850
875
900
AVG. GAS
HEAT VALUE
AT ALTITUDE
(BTUH/CU FT.)
675
700
725
750
775
800
825
850
AVG. GAS
HEAT VALUE
AT ALTITUDE
(BTUH/CU FT.)
650
675
700
725
750
775
800
825
AVG. GAS
HEAT VALUE
AT ALTITUDE
(BTUH/CU FT.)
625
650
675
700
725
750
775
600
625
650
675
700
725
0.58
Manifold
Orifice
Pressure
No.
High/Low
43
3.4/1.5
43
3.2/1.4
44
3.4/1.5
44
3.2/1.4
46
3.8/1.7
46
3.6/1.6
47
3.8/1.7
47
3.6/1.6
0.58
Manifold
Orifice
Pressure
No.
High/Low
43
3.4/1.5
44
3.6/1.6
44
3.4/1.5
45
3.8/1.7
46
3.7/1.6
46
3.5/1.5
47
3.7/1.6
47
3.5/1.5
0.58
Manifold
Orifice
Pressure
No.
High/Low
44
3.6/1.6
44
3.3/1.5
45
3.8/1.6
46
3.7/1.6
46
3.4/1.5
47
3.6/1.6
47
3.4/1.5
48
3.7/1.6
0.58
Manifold
Orifice
Pressure
No.
High/Low
44
3.3/1.5
45
3.7/1.6
46
3.6/1.6
47
3.8/1.7
47
3.6/1.6
48
3.8/1.7
48
3.6/1.5
45
3.7/1.6
46
3.6/1.6
47
3.8/1.6
47
3.5/1.5
48
3.7/1.6
48
3.5/1.5
SPECIFIC GRAVITY OF NATURAL GAS
0.60
0.62
Manifold
Manifold
Orifice
Orifice
Pressure
Pressure
No.
No.
High/Low
High/Low
43
3.5/1.5
43
3.6/1.6
43
3.3/1.4
43
3.4/1.5
44
3.5/1.5
43
3.2/1.4
44
3.3/1.4
44
3.4/1.5
45
3.8/1.6
44
3.2/1.4
46
3.7/1.6
46
3.8/1.7
46
3.5/1.5
46
3.6/1.6
47
3.8/1.6
46
3.4/1.5
SPECIFIC GRAVITY OF NATURAL GAS
0.60
0.62
Manifold
Manifold
Orifice
Orifice
Pressure
Pressure
No.
No.
High/Low
High/Low
43
3.5/1.5
43
3.6/1.6
43
3.3/1.4
43
3.4/1.5
44
3.5/1.5
44
3.6/1.6
44
3.3/1.4
44
3.4/1.5
45
3.7/1.6
45
3.8/1.7
46
3.6/1.6
46
3.8/1.6
46
3.4/1.5
46
3.5/1.5
47
3.6/1.6
47
3.8/1.6
SPECIFIC GRAVITY OF NATURAL GAS
0.60
0.62
Manifold
Manifold
Orifice
Orifice
Pressure
Pressure
No.
No.
High/Low
High/Low
43
3.2/1.4
43
3.4/1.5
44
3.5/1.5
44
3.6/1.6
44
3.2/1.4
44
3.3/1.4
46
3.8/1.7
45
3.7/1.6
46
3.6/1.5
46
3.7/1.6
47
3.8/1.6
46
3.4/1.5
47
3.5/1.5
47
3.7/1.6
48
3.8/1.6
47
3.4/1.5
SPECIFIC GRAVITY OF NATURAL GAS
0.60
0.62
Manifold
Manifold
Orifice
Orifice
Pressure
Pressure
No.
No.
High/Low
High/Low
44
3.5/1.5
44
3.6/1.6
44
3.2/1.4
44
3.3/1.4
46
3.8/1.6
45
3.7/1.6
46
3.5/1.5
46
3.6/1.6
47
3.7/1.6
47
3.8/1.7
47
3.5/1.5
47
3.6/1.6
48
3.7/1.6
48
3.8/1.7
45
3.8/1.7
44
3.3/1.4
46
3.7/1.6
46
3.8/1.7
46
3.4/1.5
46
3.6/1.5
47
3.6/1.6
47
3.7/1.6
48
3.8/1.7
47
3.5/1.5
48
3.6/1.6
48
3.7/1.6
* Orifice numbers 43 are factory installed
44
0.64
Manifold
Orifice
Pressure
No.
High/Low
43
3.7/1.6
43
3.5/1.5
43
3.3/1.4
44
3.5/1.5
44
3.3/1.4
45
3.8/1.6
46
3.7/1.6
46
3.5/1.5
0.64
Manifold
Orifice
Pressure
No.
High/Low
43
3.7/1.6
43
3.5/1.5
43
3.2/1.4
44
3.5/1.5
44
3.2/1.4
45
3.7/1.6
46
3.6/1.6
46
3.4/1.5
0.64
Manifold
Orifice
Pressure
No.
High/Low
43
3.5/1.5
43
3.2/1.4
44
3.4/1.5
44
3.2/1.4
46
3.8/1.6
46
3.6/1.5
47
3.8/1.6
47
3.6/1.5
0.64
Manifold
Orifice
Pressure
No.
High/Low
43
3.2/1.4
44
3.4/1.5
45
3.8/1.7
46
3.7/1.6
46
3.5/1.5
47
3.7/1.6
47
3.5/1.5
44
3.4/1.5
45
3.8/1.6
46
3.7/1.6
46
3.4/1.5
47
3.6/1.6
48
3.8/1.7
Check Safety Controls
The flame sensor, gas valve, and pressure switch were all checked
in the Start--up procedure section as part of normal operation.
1. Check Main Limit Switch
This control shuts off combustion system and energizes
air--circulating blower motor, if furnace overheats. By using this method to check limit control, it can be established
that limit is functioning properly and will operate if there
is a restricted return--air supply or motor failure. If limit
control does not function during this test, cause must be
determined and corrected.
a. Run furnace for at least 5 minutes.
b. Gradually block off return air with a piece of cardboard or sheet metal until the limit trips.
c. Unblock return air to permit normal circulation.
d. Burners will re--light when furnace cools down.
2. Check draft safeguard switch. The purpose of this control
is to cause the safe shutdown of the furnace during certain
blocked vent conditions.
a. Verify vent pipe is cool to the touch.
b. Disconnect power to furnace and remove vent connector from furnace vent elbow.
c. Restore power to furnace and set room thermostat
above room temperature.
d. After normal start--up, allow furnace to operate for 2
minutes, then block vent elbow in furnace 80 percent
of vent area with a piece of flat sheet metal.
e. Furnace should cycle off within 2 minutes. If gas does
not shut off within 2 minutes, determine reason draft
safeguard switch did not function properly and correct
condition.
f. Remove blockage from furnace vent elbow.
g. Switch will auto--reset when it cools.
h. Re--install vent connector.
NOTE: Should switch remain open longer than 3 minutes,
furnace control board will lockout the furnace for 3 hours. To
reset furnace control board, turn thermostat below room
temperature or from HEAT to OFF and turn 115--v power OFF,
then back ON.
3. Check Pressure Switch(es)
This control proves operation of the draft inducer blower.
a. Turn off 115--v power to furnace.
b. Disconnect inducer motor lead wires from wire harness.
c. Turn on 115--v power to furnace.
d. Set thermostat to “call for heat” and wait 1 minute.
When pressure switch is functioning properly, hot surface igniter should NOT glow and control diagnostic
light flashes a status code 32. If hot surface igniter
glows when inducer motor is disconnected, shut down
furnace immediately.
e. Determine reason pressure switch did not function
properly and correct condition.
f. Turn off 115--v power to furnace.
g. Reconnect inducer motor wires, replace outer door,
and turn on 115--v power.
h. Blower will run for 90 seconds before beginning the
call for heat again.
i. Furnace should ignite normally.
Checklist
1. Put away tools and instruments. Clean up debris.
2. Verify that switches SW1--1 and SW1--6 are OFF and other setup switches are set as desired. Verify that switches
3.
4.
5.
6.
7.
SW1--7 and SW1--8 for the blower OFF DELAY are set as
desired per Table 10.
Verify that blower and burner access doors are properly installed.
Cycle test furnace with room thermostat.
Check operation of accessories per manufacturer’s instructions.
Review User’s Guide with owner.
Attach literature packet to furnace.
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.
!
CAUTION
ENVIRONMENTAL HAZARD
Failure to follow this caution may result in environmental
pollution.
Remove and recycle all components or materials (i.e. oil,
refrigerant, control board, etc.) before unit final disposal.
!
WARNING
ELECTRICAL SHOCK, FIRE OR EXPLOSION
HAZARD
Failure to follow this warning could result in personal
injury or death, or property damage.
Before installing, modifying, or servicing system, main
electrical disconnect switch must be in the OFF position and
install a lockout tag. There may be more than one
disconnect switch. Lock out and tag switch with a suitable
warning label. Verify proper operation after servicing.
!
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.
45
General
These instructions are written as if the furnace is installed in an
upflow application. An upflow furnace application is where the
blower is located below the combustion and controls section of
the furnace, and conditioned air is discharged upward. Since this
furnace can be installed in any of the 4 positions shown in Fig. 4,
you must revise your orientation to component location
accordingly.
Electrical Controls and Wiring
!
WARNING
ELECTRICAL SHOCK HAZARD
Failure to follow this warning could result in personal injury
or death.
There may be more than one electrical supply to the furnace.
Check accessories and cooling unit for additional electrical
supplies that must be shut off during furnace servicing. Lock
out and tag switch with a suitable warning label.
The electrical ground and polarity for 115--v wiring must be
properly maintained. Refer to Fig. 25 for field wiring information
and to Fig. 55 for furnace wiring information.
NOTE: If the polarity is not correct, the STATUS LED on the
control will flash rapidly and prevent the furnace from heating.
The control system also requires an earth ground for proper
operation of the control and flame--sensing electrode.
The 24--v circuit contains an automotive--type, 3--amp. fuse
located on the control. (See Fig. 26.) Any shorts of the 24--v
wiring during installation, service, or maintenance will cause this
fuse to blow. If fuse replacement is required, use ONLY a 3--amp.
fuse. The control LED will display status code 24 when fuse
needs to be replaced.
Proper instrumentation is required to service electrical controls.
The control in this furnace is equipped with a Status Code LED
(Light--Emitting Diode) to aid in installation, servicing, and
troubleshooting. Status codes can be viewed at the sight glass in
blower access door. The amber furnace control LED is either ON
continuously, rapid flashing, or a code composed of 2 digits. The
first digit is the number of short flashes, the second digit is the
number of long flashes.
For an explanation of status codes, refer to service label located
on blower access door or Fig. 54.
See Fig. 59, a brief Troubleshooting Guide.
For 2--Stage Variable Speed ECM Controls the stored status
codes will NOT be erased from the control memory, when 115-or 24--v power is interrupted. The control will store up to the last
7 Status Codes in order of occurrence.
1. To retrieve status codes, proceed with the following:
NOTE: NO thermostat signal may be present at control, and all
blower--OFF delays must be completed.
a. Leave 115--v power to furnace turned on.
b. Remove outer access door.
c. Look into blower access door sight glass for current
LED status.
d. Remove blower access door.
NOTE: The Status Codes cannot be retrieved by disconnecting
the limit switch or draft safeguard switch. To retrieve Status
Codes, follow the procedure below.
2. Turn Setup Switch, SW1--1 “ON.”
3. Manually close blower access door switch.
4. Control will flash up to 7 Status Codes.
5. The last Status Code, or 8th Code, will be Code 11.
6. Turn SW1--1 “OFF.”
7. A continuously--lit Amber LED will appear and indicates
proper operation.
8. Release blower access door switch, install blower access
door and replace outer door or refer to the SERVICE label
on the front of the blower access door for more information.
Component Self--Test
Component Test can ONLY be initiated by performing the
following:
1. Remove outer access door.
2. Remove blower access door.
3. Remove the wire from the “R” terminal of the control
board.
4. Turn Setup Switch, SW--1--6 “ON.”
5. Manually close blower access door switch.
Blower access door switch opens 115--v power to control. No
component operation can occur unless switch is closed. Caution
must be taken when manually closing this switch for service
purposes.
!
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 starts on high--speed and continues to
run until Step (d.) of component test sequence.
b. Hot surface igniter is energized for 15 sec, then deenergized.
c. Blower operates for 10 sec, then turns off.
d. Inducer motor goes to low--speed for 10 seconds, then
turns off.
e. After component test is completed, one or more status
codes (11 or 25) will flash. See component test section
of service label for explanation of status codes.
NOTE: To repeat component test, turn setup switch SW1--6 OFF
then back ON.
f. Turn setup switch SW1--6 OFF.
7. RELEASE BLOWER ACCESS DOOR SWITCH, reattach wire to “R” terminal on furnace control board, replace
blower access door, and replace outer access door.
46
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. Exposure to these
materials could lead to corrosion of the heat
exchangers.
For continuing high performance and to minimize possible
furnace failure, periodic maintenance must be performed on this
furnace. Consult your local dealer about proper frequency of
maintenance and the availability of a maintenance contract.
!
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.
!
WARNING
CARBON MONOXIDE POISONING AND FIRE
HAZARD
Failure to follow this warning could result in personal
injury, death and/or property damage.
have furnace and burner serviced by a qualified service
agency.
5. Inspect the vent pipe/vent system before each heating season for rust, corrosion, water leakage, sagging pipes or
broken fittings. Have vent pipes/vent system serviced by a
qualified service agency.
6. Inspect any accessories attached to the furnace such as a
humidifier or electronic air cleaner. Perform any service or
maintenance to the accessories as recommended in the accessory instructions.
Cleaning and/or Replacing Air Filter
The air filter arrangement will vary depending on the application.
NOTE: If the filter has an airflow direction arrow, the arrow
must point towards the blower.
!
CUT HAZARD
Failure to follow this caution may result in personal injury.
Sheet metal parts may have sharp edges or burrs. Use care
and wear appropriate protective clothing, safety glasses and
gloves when handling parts, and servicing furnaces.
Media cabinet filter procedures:
1. Turn off electrical supply to furnace before removing filter
access door.
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 13 for size information.
5. If equipped with factory--specified disposable media filter,
replace only with media filter having the same part number and size. For expandable replacement media, refer to
the instructions included with the replacement media.
6. Slide filter into cabinet.
7. Replace filter cabinet door.
8. Turn on electrical supply to furnace.
Blower Motor and Wheel
!
Never operate furnace without a filter or with filter access
door removed.
!
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.
CUT HAZARD
Failure to follow this caution may result in personal injury.
The minimum maintenance on this furnace is as follows:
1. Check and clean air filter each month or more frequently if
required. Replace if torn.
2. Check blower motor and wheel for cleanliness each heating and cooling season. Clean as necessary.
3. Check electrical connections for tightness and controls for
proper operation each heating season. Service as necessary.
4. Inspect burner compartment before each heating season
for rust, corrosion, soot or excessive dust. If necessary,
WARNING
ELECTRICAL SHOCK HAZARD
CAUTION
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
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.
47
Table 13 – Filter Size Information -- In. (mm)
FILTER SIZE
FURNACE CASING WIDTH
14 ---1/2 (368)
17 ---1/2 (445)
21 (533)
24 (610)
SIDE
RETURN
16 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)
16 X 25 X 3/4
(406 X 635 X 19)
BOTTOM
RETURN
14 X 25 X 3/4
(356 X 635 X 19)
16 X 25 X 3/4
(406 X 635 X 19)
20 X 25 X 3/4
(508 X 635 X 19)
24 X 25 X 3/4
(610 X 635 X 19)
* Recommended
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. For downflow or horizontal furnaces having vent pipes
within the furnace that pass in front of the blower access
door:
a. Disconnect vent connector from furnace vent elbow.
b. Disconnect and remove short piece of vent pipe from
within furnace.
4. Remove screws from blower access door and remove
blower access door.
5. All factory wires can be left connected, but field thermostat connections may need to be disconnected depending
on their length and routing.
6. Remove 2 screws holding blower assembly to blower
deck and slide blower assembly out of furnace.
7. Clean blower wheel and motor using a vacuum with soft
brush attachment. Blower wheel blades may be cleaned
with a small paint or flux brush. Do not remove or disturb
balance weights (clips) on blower wheel blades.
8. Vacuum any loose dust from blower housing, wheel and
motor.
9. If a greasy residue is present on blower wheel, remove
wheel from the blower housing and wash it with an appropriate degreaser. To remove wheel:
NOTE: Before disassembly, mark blower mounting arms, motor,
and blower housing so motor and each arm is positioned at the
same location during reassembly.
a. Disconnect ground wire attached to blower housing.
b. Remove screws securing cutoff plate and remove
cutoff plate from housing.
c. Loosen set screw holding blower wheel on motor shaft
(160+/--20 in.--lb. when assembling).
d. Remove bolts holding motor to blower housing and
slide motor out of wheel (40+/--10 in.--lb. when reassembling).
e. Remove blower wheel from housing.
f. Clean wheel and housing.
10. Reassemble motor and blower by reversing steps 9a,
through 9e. Be sure to reattach ground wire to the blower
housing.
11. Verify that blower wheel is centered in blower housing
and set screw contacts the flat portion of the motor shaft.
Loosen set screw on blower wheel and reposition if necessary.
12. Spin the blower wheel by hand to verify that the wheel
does not rub on the housing.
13. Reinstall blower assembly in furnace.
14. Reinstall 2 screws securing blower assembly to blower
deck.
FILTER TYPE
Washable*
Washable*
Washable*
Washable*
15. Reconnect blower leads to furnace control. Refer to furnace wiring diagram, and connect thermostat leads if previously disconnected.
16. To check blower for proper rotation:
a. Turn on electrical supply.
!
WARNING
ELECTRICAL SHOCK HAZARD
Failure to follow this warning could result in personal
injury, or death.
Blower access door switch opens 115--v power to furnace
control. No component operation can occur unless switch is
closed. Exercise caution to avoid electrical shock from
exposed electrical components when manually closing this
switch for service purposes.
b. Manually close blower access door switch.
NOTE: If R--W/W1 thermostat terminals are jumpered at the
time blower access door switch is closed, blower will run for 90
sec before beginning a heating cycle.
c. Perform component self--test as shown at the bottom
of the SERVICE label, located on the front of blower
access door.
d. Verify blower is rotating in the correct direction
17. If furnace is operating properly, RELEASE BLOWER
ACCESS DOOR SWITCH. Remove any jumpers or reconnect any disconnected thermostat leads. Replace
blower access door.
18. Downflow or horizontal furnaces with vent pipe through
furnace only:
a. Install and connect short piece of vent pipe inside furnace to existing vent.
b. Connect vent connector to vent elbow.
19. Reinstall outer door.
20. Turn on gas supply and cycle furnace through one complete heating and cooling cycle. Verify the furnace temperature rise as shown in Adjustments Section. Adjust temperature rise as shown in Adjustments Section. If outdoor
temperature is below 70_F, turn off circuit breaker to outdoor unit before running furnace in the cooling cycle.
Turn outdoor circuit breaker on after completing cooling
cycle.
Cleaning Heat Exchanger
The following steps should be performed by a qualified
service agency:
NOTE: If the heat exchangers get a heavy accumulation of soot
and carbon, they should be replaced rather than trying to clean
them thoroughly. A build--up of soot and carbon indicates that a
problem exists which needs to be corrected, such as improper
adjustment of manifold pressure, insufficient or poor quality
combustion air, incorrect size or damaged manifold orifice(s),
improper gas, or a restricted heat exchanger. Action must be taken
to correct the problem.
48
A05025
Fig. 56 -- Igniter Position -- Side View
1-7/8
(47.6 mm)
A05026
9. Using field--provided 25--caliber rifle cleaning brush,
36--in. (914 mm) long, 1/4--in. (6 mm) diameter steel
spring cable, a variable speed, follows:
a. Remove metal screw fitting from wire brush to allow
insertion into cable.
b. Insert the twisted wire end of brush into end of spring
cable, and crimp tight with crimping tool or crimp by
striking with ball--peen hammer. TIGHTNESS IS
VERY IMPORTANT.
NOTE: The materials needed in item 9 can usually be purchased
at local hardware stores.
(1.) Attach variable--speed, reversible drill to the end
of spring cable (end opposite brush).
(2.) Insert brush end of cable into the outlet opening
of cell and slowly rotate with drill. DO NOT
force cable. Gradually insert cable into upper pass
of cell. (See Fig. 58.)
(3.) Work cable in and out of cell 3 or 4 times to obtain sufficient cleaning. DO NOT pull cable with
great force. Reverse drill and gradually work
cable out.
(4.) Insert brush end of cable in burner inlet opening
of cell, and proceed to clean 2 lower passes of
cell in same manner as upper pass.
(5.) Repeat foregoing procedures until each cell in
furnace has been cleaned.
(6.) Using vacuum cleaner, remove residue from each
cell.
(7.) Using vacuum cleaner with soft brush attachment,
clean burner assembly.
(8.) Clean flame sensor with fine steel wool.
Fig. 57 -- Igniter Position -- Top View
If it becomes necessary to clean the heat exchangers because of
dust or corrosion, proceed as follows:
1. Turn OFF gas and electrical power to furnace.
2. Remove outer access door.
3. Disconnect vent connector from furnace vent elbow.
4. For downflow or horizontal furnace having an internal
vent pipe, remove internal vent pipe within the casing.
5. Disconnect wires to the following components. Mark
wires to aid in reconnection (be careful when disconnecting wires from switches because damage may occur):
a. Draft safeguard switch.
b. Inducer motor.
c. Pressure switches.
d. Limit overtemperature switch.
e. Gas valve.
f. Hot surface igniter.
g. Flame--sensing electrode.
h. Flame rollout switches.
6. Remove screws that fasten the collector box assembly to
the cell panel. Be careful not to damage the collector box.
Inducer assembly and elbow need not be removed from
collector box.
7. Disconnect gas line from gas manifold.
8. Remove the four screws that attach the burner assembly to
the cell panel. The gas valve and individual burners need
not be removed from support assembly. Remove NOx
baffles, if installed.
NOTE: Be very careful when removing burner assembly to
avoid breaking igniter. See Fig. 56--57 for correct igniter location.
A91252
Fig. 58 -- Cleaning Heat Exchanger Cell
(9.) Reinstall burner assembly. Center burners in cell
openings.
10. Remove old sealant from cell panel and collector box
flange.
11. Spray releasing agent on the heat exchanger cell panel
where collector box assembly contacts cell panel.
NOTE: A releasing agent such as cooking spray or equivalent
(must not contain corn or canola oil, aromatic or halogenated
hydrocarbons or inadequate seal may occur) and RTV sealant
(G.E. 162, 6702, or Dow--Corning 738) are needed before
starting installation. DO NOT substitute any other type of RTV
sealant. G.E. 162 (P771--9003) is available through RCD in 3--oz
tubes.
12. Apply new sealant to flange of collector box and attach to
cell panel using existing screws, making sure all screws
are secure.
49
13. Reconnect wires to the following components (Use connection diagram on wiring label, if wires were not marked
for reconnection locations.):
a. Draft safeguard switch.
b. Inducer motor.
c. Pressure switches.
d. Limit overtemperature switch.
e. Gas valve.
f. Hot surface igniter.
g. Flame--sensing electrode.
h. Flame rollout switches.
14. Reinstall internal vent pipe, if applicable.
15. Reinstall vent connector on furnace vent elbow. Securely
fasten vent connector to vent elbow with 2 field--supplied,
corrosion--resistant, sheet metal screws located 180_ apart.
16. Replace blower access door only if it was removed.
17. Set thermostat above room temperature and check furnace
for proper operation.
18. Verify blower airflow and speed changes between heating
and cooling.
!
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.
19. Check for gas leaks.
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. 55, follow the sequence of
operation through the different modes. Read and follow the
wiring diagram very carefully.
NOTE: If a power interruption occurs during a call for heat
(W/W1 or W/W1--and--W2), the control will start a 90--second
blower--only ON period two seconds after power is restored, if
the thermostat is still calling for gas heating. The amber LED
light will flash code 12 during the 90--second period, after which
the LED will be ON continuous, as long as no faults are detected.
After the 90--second period, the furnace will respond to the
thermostat normally.
The blower door must be installed for power to be conducted
through the blower door interlock switch ILK to the furnace
control CPU, transformer TRAN, inducer motor IDM, blower
motor BLWM, hot--surface igniter HSI, and gas valve GV.
1. Two--Stage Heating (Adaptive Mode) with Single--Stage
Thermostat
See Fig. 27 -- 34 for thermostat connections
NOTE: The low--heat only switch SW1--2 selects either the
low--heat only operation mode when ON, (see item 2. below) or
the adaptive heating mode when OFF in response to a call for
heat. (See Table 52.) When the W2 thermostat terminal is
energized it will always cause high--heat operation when the
R--to--W circuit is closed, regardless of the setting of the low--heat
only switch. This furnace can operate as a two--stage furnace with
a single--stage thermostat because the furnace control CPU
includes a programmed adaptive sequence of controlled
operation, which selects low--heat or high--heat operation. This
selection is based upon the stored history of the length of
previous gas--heating periods of the single--stage thermostat.
The furnace will start up in either low-- or high--heat. If the
furnace starts up in low--heat, the control CPU determines the
low--heat on--time (from 0 to 16 minutes) which is permitted
before switching to high--heat.
If the power is interrupted, the stored history is erased and the
control CPU will select low--heat for up to 16 minutes and then
switch to high--heat, as long as the thermostat continues to call for
heat. Subsequent selection is based on stored history of the
thermostat cycle times.
The wall thermostat “calls for heat”, closing the R--to--W circuit.
The furnace control performs a self--check, verifies the low--heat
and high--heat pressure switch contacts LPS and HPS are open,
and starts the inducer motor IDM in high--speed.
a. Inducer Prepurge Period
(1.) If the furnace control CPU selects low--heat operation the inducer motor IDM comes up to speed,
the low--heat pressure switch LPS closes, and the
furnace control CPU begins a 15--second prepurge period. If the low--heat pressure switch LPS
fails to remain closed the inducer motor IDM will
remain running at high--speed. After the low--heat
pressure switch re--closes the furnace control CPU
will begin a 15--second prepurge period, and continue to run the inducer motor IDM at high-speed.
(2.) If the furnace control CPU selects high--heat operation, the inducer motor IDM remains running
at high--speed, and the high--heat pressure switch
relay HPSR is de--energized to close the NC contact. When sufficient pressure is available the
high--heat pressure switch HPS closes, and the
high--heat gas valve solenoid GV--HI is energized. The furnace control CPU begins a
15--second prepurge period after the low--heat
pressure switch LPS closes. If the high--heat pressure switch HPS fails to close and the low--heat
pressure switch LPS closes, the furnace will operate at low--heat gas flow rate until the high--heat
pressure switch closes for a maximum of 2 minutes after ignition.
b. Igniter Warm--Up --At the end of the prepurge period,
the Hot--Surface Igniter HSI is energized for a
17--second igniter warm--up period.
c. Trial--For--Ignition Sequence --When the igniter
warm--up period is completed the main gas valve relay
contact GVR closes to energize the gas valve solenoid
GV--M. The gas valve solenoid GV--M permits gas
flow to the burners where it is ignited by the HSI. Five
seconds after the GVR closes, a 2--second flame proving period begins. The HSI igniter will remain energized until the flame is sensed or until the 2--second
flame proving period begins. If the furnace control
CPU selects high--heat operation, the high--heat gas
valve solenoid GV--HI is also energized.
d. Flame--Proving -- When the burner flame is proved at
the flame--proving sensor electrode FSE, the inducer
motor IDM switches to low--speed unless the furnace
is operating in high--heat, and the furnace control CPU
begins the blower--ON delay period and continues to
hold the gas valve GV--M open. If the burner flame is
not proved within two seconds, the control CPU will
close the gas valve GV--M, and the control CPU will
50
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 on
high speed until flame is no longer proved.
e. Blower--On delay -- If the burner flame is proven the
blower--ON delays for low--heat and high--heat are as
follows:
Low--heat -- 45 seconds after the gas valve GV--M is
opened the blower motor BLWM is turned ON at
low--heat airflow.
High--heat -- 25 seconds after the gas valve GV--M is
opened the BLWM is turned ON at high--heat airflow.
Simultaneously, the humidifier terminal HUM and
electronic air cleaner terminal EAC--1 are energized
and remain energized throughout the heating cycle.
f. Switching from Low-- to High--Heat -- If the furnace
control CPU switches from low--heat to high--heat, the
furnace control CPU will switch the inducer motor
IDM speed from low to high. The high--heat pressure
switch relay HPSR is de--energized to close the NC
contact. When sufficient pressure is available the high-heat pressure switch HPS closes, and the high--heat gas
valve solenoid GV--HI is energized. The blower motor
BLWM will transition to high--heat airflow five
seconds after the furnace control CPU switches from
low--heat to high--heat.
g. Switching from High-- to Low--Heat --The furnace
control CPU will not switch from high--heat to low-heat while the thermostat R--to--W circuit is closed
when using a single--stage thermostat.
h. Blower--Off Delay --When the thermostat is satisfied,
the R to W circuit is opened, de--energizing the gas
valve GV--M, stopping gas flow to the burners, and
de--energizing the humidifier terminal HUM. The inducer motor IDM will remain energized for a
5--second post--purge period. The blower motor
BLWM and air cleaner terminal EAC--1 will remain
energized at low--heat airflow or transition to low--heat
airflow for 90, 120, 150, or 180 seconds (depending
on selection at blower--OFF delay switches). The furnace control CPU is factory--set for a 120--second
blower--OFF delay.
2. Two--Stage Thermostat and Two--Stage Heating
See Fig. 27--34 for thermostat connections.
NOTE: In this mode the low--heat only switch SW1--2 must be
ON to select the low--heat only operation mode in response to
closing the thermostat R--to--W1 circuit. Closing the thermostat
R--to-- W1--and--W2 circuits always causes high--heat operation,
regardless of the setting of the low--heat only switch.
The wall thermostat “calls for heat”, closing the R--to--W1 circuit
for low--heat or closing the R--to--W1--and--W2 circuits for
high--heat. The furnace control performs a self--check, verifies the
low--heat and high--heat pressure switch contacts LPS and HPS
are open, and starts the inducer motor IDM in high--speed.
The start up and shut down functions and delays described in
item 1. above apply to the 2--stage heating mode as well, except
for switching from low-- to high--Heat and vice versa.
a. Switching from Low-- to High--Heat -- If the thermostat R--to--W1 circuit is closed and the R--to--W2 circuit closes, the furnace control CPU will switch the
inducer motor IDM speed from low to high. The
high--heat pressure switch relay HPSR is de--energized
to close the NC contact. When sufficient pressure is
available the high--heat pressure switch HPS closes,
and the high--heat gas valve solenoid GV--HI is energized. The blower motor BLWM will transition to
high--heat airflow five seconds after the R--to--W2 circuit closes.
b. Switching from High-- to Low--Heat --If the thermostat R--to-- W2 circuit opens, and the R--to--W1 circuit
remains closed, the furnace control CPU will switch
the inducer motor IDM speed from high to low. The
high--heat pressure switch relay HPSR is energized to
open the NC contact and de--energize the high--heat
gas valve solenoid GV--HI. When the inducer motor
IDM reduces pressure sufficiently, the high--heat pressure switch HPS will open. The gas valve solenoid
GV--M will remain energized as long as the low--heat
pressure switch LPS remains closed. The blower motor
BLWM will transition to low--heat airflow five
seconds after the R--to--W2 circuit opens.
3. Cooling mode
The thermostat “calls for cooling”.
a. Single--Speed Cooling-See Fig. 27 for thermostat connections
The thermostat closes the R--to--G--and--Y circuits. The
R--to-- Y circuit starts the outdoor unit, and the R--to-G--and--Y/Y2 circuits start the furnace blower motor
BLWM on cooling airflow. Cooling airflow is based
on the A/C selection shown in Fig. 53. 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. 34 for thermostat connections.
This furnace can operate a two--speed cooling unit
with a single--stage thermostat because the furnace
control CPU includes a programmed adaptive sequence of controlled operation, which selects low-cooling or high--cooling operation. This selection is
based upon the stored history of the length of previous
cooling period of the single--stage thermostat.
NOTE: The air conditioning relay disable jumper ACRDJ must
be connected to enable the adaptive cooling mode in response to
a call for cooling. (See Fig. 26.) When ACRDJ is in place the
furnace control CPU can turn on the air conditioning relay ACR
to energize the Y/Y2 terminal and switch the outdoor unit to
high--cooling.
The furnace control CPU can start up the cooling unit in either
low-- or high--cooling. If starting up in low--cooling, the furnace
control CPU determines the low--cooling on--time (from 0 to 20
minutes) which is permitted before switching to high--cooling. If
the power is interrupted, the stored history is erased and the
furnace control CPU will select low--cooling for up to 20 minutes
and then energize the air conditioning relay ACR to energize the
Y/Y2 terminal and switch the outdoor unit to high--cooling, as
long as the thermostat continues to call for cooling. Subsequent
selection is based on stored history of the thermostat cycle times.
The wall thermostat “calls for cooling”, closing the
R--to--G--and--Y circuits. The R--to--Y1 circuit starts the outdoor
unit on low--cooling speed, and the R--to--G--and--Y1 circuits
starts the furnace blower motor BLWM at low--cooling airflow
51
which is the true on--board CF selection as shown in Fig. 53.
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. 53.
NOTE: When transitioning from low--cooling to high--cooling
the outdoor unit compressor will shut down for 1 minute while
the furnace blower motor BLWM transitions to run at
high--cooling airflow.
The electronic air cleaner terminal EAC--1 is energized with 115
vac whenever the blower motor BLWM is operating.
When the thermostat is satisfied, the R--to--G--and--Y circuit are
opened. The outdoor unit stops, and the furnace blower BLWM
and electronic air cleaner terminal EAC--1 will remain energized
for an additional 90 seconds. Jumper Y1 to DHUM to reduce the
cooling off--delay to 5 seconds. (See Fig. 26.)
c. Two--Stage Thermostat and Two--Speed Cooling
See Fig. 33 for thermostat connections
NOTE: The air conditioning relay disable jumper ACRDJ must
be disconnected to allow thermostat control of the outdoor unit
staging. (See Fig. 26.)
The thermostat closes the R--to--G--and--Y1 circuits for
low--cooling or closes the R--to--G--and--Y1--and--Y2 circuits for
high--cooling. The R--to--Y1 circuit starts the outdoor unit on
low--cooling speed, and the R--to--G--and--Y1 circuit starts the
furnace blower motor BLWM at low--cooling airflow which is the
true on--board CF (continuous fan) selection as shown in Fig. 57.
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. 53.
The electronic air cleaner terminal EAC--1 is energized with 115
vac whenever the blower motor BLWM is operating.
When the thermostat is satisfied, the R--to--G--and--Y1 or R--to-G--and--Y1--and--Y2 circuits are opened. The outdoor unit stops,
and the furnace blower BLWM and electronic air cleaner terminal
EAC--1 will remain energized for an additional 90 seconds.
Jumper Y1 to DHUM to reduce the cooling off--delay to 5
seconds. (See Fig. 26.)
4. Thermidistat Mode
See Fig. 27--29 for thermostat connections.
The dehumidification output, DHUM on the Thermidistat
should be connected to the furnace control thermostat terminal DHUM. When there is a dehumidify demand, the
DHUM input is activated, which means 24 vac signal is
removed from the DHUM input terminal. In other words,
the DHUM input logic is reversed. The DHUM input is
turned ON when no dehumidify demand exists. Once 24
vac is detected by the furnace control on the DHUM input,
the furnace control operates in Thermidistat mode. If the
DHUM input is low for more than 48 hours, the furnace
control reverts back to non--Thermidistat mode.
The cooling operation described in item 3. above also applies to operation with a Thermidistat. The exceptions are
listed below:
a. Low cooling--When the R--to--G--and--Y1 circuit is
closed and there is a demand for dehumidification, the
furnace blower motor BLWM will drop the blower
airflow to 90 percent of low--cooling airflow which is
the true on--board CF (continuous fan) selection as
shown in Fig. 53.
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 90 percent of high--cooling airflow. High-cooling airflow is based on the A/C (air conditioning)
selection shown in Fig. 53.
c. Cooling off--delay--When the “call for cooling” is
satisfied and there is a demand for dehumidification,
the cooling blower--off delay is decreased from 90
seconds to 5 seconds.
5. 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.
53. Factory default is shown in Fig. 53. 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 or low--heat airflow whichever is lowest. The blower
motor BLWM will remain ON until the main burners ignite then shut OFF and remain OFF for the blower--ON
delay (45 seconds in low--heat, and 25 seconds in high-heat), allowing the furnace heat exchangers to heat up
more quickly, then restarts at the end of the blower--ON
delay period at low--heat or high--heat airflow, respectively.
The blower motor BLWM will revert to continuous-blower airflow after the heating cycle is completed. In
high--heat, the furnace control CPU will drop the blower
motor BLWM to low--heat airflow during the selected
blower--OFF delay period before transitioning to continuous--blower airflow.
When the thermostat “calls for low--cooling”, the blower
motor BLWM will switch to operate at low--cooling airflow. When the thermostat is satisfied, the blower motor
BLWM will operate an additional 90 seconds at low--cooling airflow before transitioning back to continuous-blower airflow.
When the thermostat “calls for high--cooling”, the blower
motor BLWM will operate at high cooling airflow. When
the thermostat is satisfied, the blower motor BLWM will
operate an additional 90 seconds at high--cooling airflow
before transitioning back to continuous--blower airflow.
When the R--to--G circuit is opened, the blower motor
BLWM will continue operating for an additional 5
seconds, if no other function requires blower motor
BLWM operation.
Continuous Blower Speed Selection from Thermostat
To select different continuous--blower 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. 53. 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.
53. The selection can be changed as many times as desired
and is stored in the memory to be automatically used following a power interruption.
NOTE: If the blower--off delay is set to the maximum, the
adjustable continuous--fan feature is locked (i.e., fan speed cannot
be changed from its current setting).
52
6. Heat pump
See Fig. 29 -- 32 for thermostat connections.
When installed with a heat pump, the furnace control automatically changes the timing sequence to avoid long
blower off times during demand defrost cycles. Whenever
W/W1 is energized along with Y1 or Y/Y2, the furnace
control CPU will transition to or bring on the blower motor BLWM at cooling airflow or low--heat airflow,
whichever is lowest. The blower motor BLWM will remain on until the main burners ignite then shut OFF and
remain OFF for 25 seconds before coming back on at
heating airflow. When the W/W1 input signal disappears,
the furnace control begins a normal inducer post--purge
period while changing the blower airflow. If Y/Y2 input is
still energized the furnace control CPU will transition the
blower motor BLWM airflow to cooling airflow. If Y/Y2
input signal disappears and the Y1 input is still energized
the furnace control CPU will transition the blower motor
BLWM to low--cooling airflow. If both the Y1 and Y/Y2
signals disappear at the same time, the blower motor
BLWM will remain on at low--heat airflow for the selected
blower--OFF delay period. At the end of the blower-- OFF
delay, the blower motor BLWM will shut OFF unless G is
still energized, in which case the blower motor BLWM
will operate at continuous blower airflow.
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. 26.)
NOTE: The component test feature will not operate if the control
is receiving any thermostat signals or until all time delays have
expired.
The component test sequence is as follows:
a. The furnace control CPU turns the inducer motor ON
at high--heat speed and keeps it ON through step c.
b. After waiting 10 seconds the furnace control CPU
turns the hot surface igniter ON for 15 seconds, then
OFF.
c. The furnace control CPU then turns the blower motor
BLWM on at 50 percent torque for 15 seconds, then
OFF.
d. After shutting the blower motor OFF the furnace control CPU switches the inducer to low--heat speed for
10 seconds, then OFF.
NOTE: The EAC terminals are energized when the blower is
operating.
After the component test is completed, 1 or more status codes (11
or 25) will flash. See component test section or Service Label
(Fig. 54) for explanation of status codes.
NOTE: To repeat component test, turn setup switch SW1--6 to
OFF and then back ON.
Wiring Diagram
Refer to wiring diagram Fig. 55.
Troubleshooting
Refer to the service label. (See Fig. 54—Service Label.)
The Troubleshooting Guide (See Fig. 59.) can be a useful tool in
isolating furnace operation problems. Beginning with the word
“Start,” answer each question and follow the appropriate arrow to
the next item.
The Guide will help to identify the problem or failed component.
After replacing any component, verify correct operation
sequence.
53
Fig. 59 -- Troubleshooting Guide
A14311A
54
YES
NO
YES
NO
NO
NO
Was there a previous status code other
than #11?
14 IGNITION LOCKOUT – System failed to ignite gas and
prove flame in 4 attempts. Control will auto-reset after
3 hours. See status code 34.
13 LIMIT CIRCUIT LOCKOUT – Lockout occurs if the limit,
draft safeguard, flame rollout, or blocked vent switch (if
used) is open longer than 3 minutes or 10 successive
limit trips occurred during high-heat. Control will autoreset after 3 hours. See code 33.
12 BLOWER ON AFTER POWER UP – (115V OR 24V) –
Normal operation. Blower runs for 90 seconds, if unit is
powered up during a call for heat (R-W/W1 closed) or
when (R-W/W1 opens) during the blower on-delay
period.
NO
To recall previous status codes disconnect the R
thermostat connection, reset power, and put setup
switch SW1-1 in the ON position. The AMBER LED
will flash the status codes in the order of occurrence.
Record status codes until status code #11 flashes (1
short and 1 long flash). After status code #11
flashes the status codes will repeat. Status codes
are erased after 72 hours or can be manually erased
by putting setup switch SW1-1 in the ON position
and jumpering R, W/W1, and Y/Y2 simultaneously
until status code #11 is flashed. When done put
setup switch SW1-1 in the OFF position.
Check for correct line voltage polarity. If
units are twinned, check for proper lowvoltage (24V) transformer phasing.
Replace furnace control.
YES
Is there 24V at SEC-1 and SEC-2?
YES
Is there 115V at L1 and L2?
YES
Replace furnace control.
Run system through a low-heat, highheat, or cooling cycle to check operation.
Status codes are erased after 72 hours
or can be manually erased by putting
setup switch SW1-1 in the ON position
and jumpering R, W/W1, and Y/Y2
simultaneously until status code #11 is
flashed.
YES
Does the control respond to W/W1, W2,
Y1, Y/Y2, and G (24V) thermostat
signals?
Replace transformer.
Replace door switch.
YES
Is there 115V going to switch?
Is door switch closed?
Troubleshooting Guide – Variable Speed
11 NO PREVIOUS CODE – Status codes are erased after
72 hours or can be manually erased by putting setup
switch SW1-1 in the ON position and jumpering R,
W/W1, and Y/Y2 simultaneously until status code #11
is flashed. Run system through a low-heat, high-heat,
or cooling cycle to check system.
Go to section below for the status code
that was flashed.
Determine status code. The status code
is a 2 digit number with the first digit
determined by the number of short
flashes and the second digit by the
number of long flashes?
YES
Is AMBER LED status light blinking
ON/OFF slowly with a combination of
short and long flashes?
NO
Is AMBER LED status light blinking
rapidly without a pause?
YES
Is AMBER LED status light on?
START
YES
NO
NO
NO
The thermostat is not compatible with the
furnace control. Either install a ballast
resistor, connect the Com24V thermostat
terminal to the thermostat, or replace the
thermostat.
NO
Does the problem repeat when using a
jumper wire?
Disconnect all the thermostat wires from
the furnace control.
YES
Is 24V present at W/W1, W2, Y1, Y/Y2 or
G thermostat terminals on the furnace
control?
NO
Check room thermostat or
interconnecting cable.
Close circuit breaker and go back to
START.
Check for continuity in wire from circuit
breaker to furnace.
YES
Is circuit breaker closed?
Is door switch closed?
NO
Fig. 59 -- Troubleshooting Guide (Continued)
A14311B
55
31 HIGH-HEAT PRESSURE SWITCH OR
RELAY DID NOT CLOSE OR
REOPENED - Check for:
- Control relay may be defective.
- Gas valve is miswired.
- See status code 32.
25 INVALID MODEL SELECTION OR
SETUP ERROR – If status code 25 only
flashes 4 times on power-up the control is
missing its model plug PL4 and is
defaulting to the model selection stored in
memory. If status code 25 flashes
continuously it could indicate any of the
following:
- Model plug PL4 is missing and there is
no valid model stored in permanent
memory. This will happen if you forget
to install the model plug PL4 on a
service replacement control.
- Thermostat call with SW1-1 ON.
- Thermostat call with SW1-6 ON.
- SW1-1 and SW1-6 both ON.
- Two different furnace models twinned.
- If replacing a control, be sure to use
correct version (V##) located on control
board) Models supported should be
listed.
24 SECONDARY VOLTAGE FUSE IS OPEN
Check for:
- Short circuit in secondary voltage (24V)
wiring including thermostat leads.
Disconnect thermostat leads to isolate
short circuit.
23 PRESSURE SWITCH DID NOT OPEN –
Check for:
- Obstructed pressure tube.
- Pressure switch stuck closed.
22 ABNORMAL FLAME-PROVING SIGNAL
Flame is proved while gas valve is deenergized. Inducer will run until fault is
cleared. Check for:
- Stuck open or leaky gas valve.
21 GAS HEATING LOCKOUT – Turn off
power and wait 5 minutes to retry. Check
for:
- Stuck closed gas valve relay on control.
- Miswire or short to gas valve wire.
YES
NO
* Blocked vent switch used in Chimney Adapter Kit
34 IGNITION PROVING FAILURE – If flame is
not sensed during the trial for ignition
period, the control will repeat the ignition
sequence 3 more times before lockout #14
occurs. If flame signal is lost during the
blower on-delay period, blower will come on
for the selected blower off-delay. Check
the following items first before proceeding
to the next step.
- Gas valve turned off.
- Manual shut-off valve.
- Green/Yellow wire MUST be connected
to furnace sheet metal.
- Flame sensor must not be grounded.
To determine whether the problem is in the
gas valve, igniter, or flame sensor the
system can be operated in component test
mode. To check the igniter remove the R
thermostat connection from the control,
reset power, and put setup switch SW1-6 in
the ON position to start the component test.
Does the igniter glow orange/white by the
end of the 15 second warm-up period?
33 LIMIT CIRCUIT FAULT – Indicates the
limit, draft safeguard, flame rollout, or
blocked vent switch* (if used) is open or
the furnace is operating in high-heat only
mode due to 2 successive low-heat limit
trips. Blower will run for 4 min. or until
open switch remakes whichever is longer.
If open longer than 3 min., code changes
to lockout #13. If open less than 3 min.
status code #33 continues to flash until
blower shuts off. Flame rollout switch and
BVSS requires manual reset. Check for:
- Dirty filter or restricted duct system.
- Loose blower wheel.
- Defective switch or connections.
- Inadequate combustion air supply
(flame rollout switch open).
- Restricted vent.
- Proper vent sizing.
- Excessive wind.
- Blower motor not operating
32 LOW-HEAT PRESSURE SWITCH DID
NOT CLOSE OR REOPENED – If open
longer than 5 minutes, inducer shuts off
for 15 minutes before retry. If opens
during blower on-delay period, blower will
come on for the selected blower off-delay.
Check for:
- Proper vent sizing.
- Low inducer voltage (115V).
- Low inlet gas pressure (if LGPS used).
- Inadequate combustion air supply.
- Disconnected or obstructed pressure
tubing.
- Defective inducer motor.
- Defective pressure switch.
- Excessive wind.
- Restricted vent.
Fixed.
YES
Will main burners ignite and stay on?
YES
Is current near typical value?
Clean flame sensor with fine steel wool
and recheck current. Nominal current is
4.0 to 6.0 microamps.
Repeat call for heat and check flame
sensor current during trial for ignition
period. Is the DC microamps below 0.5?
NO
Do the main burners stay on?
YES
Do the main burners ignite?
YES
Does gas valve open and allow gas to
flow?
YES
Reconnect the R thermostat lead and set
thermostat to call for heat. Connect
voltmeter across gas valve connections.
Does gas valve receive 24V?
Unplug igniter harness from control and
repeat component test by turning setup
switch SW1-6 OFF and then back ON.
Check for 115V between pin 3 and
NEUTRAL-L2 on the control. Was 115V
present for the 15 second period?
43 LOW-HEAT PRESSURE SWITCH
OPEN WHILE HIGH-HEAT
PRESSURE SWITCH IS CLOSED Check for:
- Low-heat pressure switch stuck
open.
- Disconnected or obstructed
pressure tube.
- Miswired pressure switches.
- Low inlet gas pressure (if LGPS
used).
NO
NO
NO
YES
NO
NO
NO
YES
NO
Replace furnace control.
Replace electrode.
Check connections and retry.
If current is near typical value
(4.0-6.0 nominal) and burners
will not stay on, repeat check
in high-heat. If burners will
still not stay on replace
control. If burners operate in
high-heat then switch to lowheat, check manifold
pressure. If OK, check
burner carryover and flame
sensor location.
Allow blower to come on and
repeat test to check for
intermittent operation.
Check for:
- Inadequate flame carryover
or rough ignition.
- Low inlet gas pressure.
- Proper firing rate.
- Blocked or incorrect carryover gap. (.045” nominal)
Check that all gas valves are
turned on. Replace valve.
Check connections. If OK,
replace control.
Check for continuity in the
harness and igniter. Replace
defective component.
Replace furnace control.
45 CONTROL CIRCUITRY
LOCKOUT Auto-reset
after 1 hour lockout due
to:
- Flame circuit failure.
- Gas valve relay stuck
open.
- Software check error.
Reset power to clear
lockout. Replace control
if code repeats.
PARTS REPLACEMENT INFORMATION GUIDE
GAS CONTROL GROUP
Manifold
Burner assembly
Orifice
Flame sensor
Hot surface igniter
Gas valve
Manual reset limit switches
Burner support assembly
CASING GROUP
Outer door
Blower door
Top filler plate
Bottom filler plate
Bottom enclosure
ELECTRICAL GROUP
Control bracket
Junction box
Limit switch(es)
Circuit board
Door switch
Transformer
Wiring harness 115v
Wiring harness 24v
HEAT EXCHANGER GROUP
Heat exchanger cell
Cell panel
Lox NOx baffle (California models only)
INDUCER GROUP
Housing assembly
Pressure switch
Inducer motor
Inducer wheel
Vent elbow assembly
Draft safeguard switch
BLOWER GROUP
Blower housing
Blower cutoff
Blower motor
Blower wheel
Capacitor (where used)
Capacitor strap (where used)
Grommet
Power choke (where used)
TO OBTAIN INFORMATION ON PARTS: Consult your installing dealer or classified section of your local telephone directory under
“Heating Equipment” or “Air Conditioning Contractors and Systems” headings for dealer listing by brand name or contact:
CARRIER CORPORATION
Consumer Relations Department
P.O. Box 4808
Syracuse, New York 13221--4808
1--800--CARRIER
Have available the model number, series number, and serial number located on the unit rating plate to ensure correct replacement part.
Example of Model Number
COOLING
AIRFLOW
(CFM)
58CTW
135
--1
1
1
22
WARNING: Improper installation, adjustment, alteration, service, or maintenance can cause personal injury, property damage, or death.
Consult a qualified installer, service agency, or your local gas supplier for information or assistance. The qualified installer or service agency
must use only factory--authorized replacement parts, kits, or accessories when modifying this product.
MODEL
HEATING
SIZE
VARIATION
Copyright 2014 Carrier Corp. S 7310 W. Morris St. S Indianapolis, IN 46231
VOLTAGE
SERIES
Edition Date: 06/14
Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations.
56
PACKAGING
Catalog No: 58CTW---03SI
Replaces: 58CTW--02SI
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