International comfort products N80ESU Installation Instructions Manual

INSTALLATION INSTRUCTIONS
Single Stage, ECM Motor, Ultra Low NOx,
80% AFUE Gas Furnace
N80ESU (Minor Series 2)
SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . . . . . . . 2
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
CODES AND STANDARDS . . . . . . . . . . . . . . . . . . . . . . . 4
SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
GENERAL INSTALLATION . . . . . . . . . . . . . . . . . . . . . . 4
COMBUSTION AND VENTILATION AIR . . . . . . . . . . . 4
DUCT SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
ACOUSTICAL LINING AND FIBROUS GLASS DUCT 4
GAS PIPING AND GAS PIPE PRESSURE TESTING . . . 4
ELECTRICAL CONNECTIONS . . . . . . . . . . . . . . . . . . . 4
VENTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
ELECTROSTATIC DISCHARGE
PRECAUTIONS PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . 4
LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . . . . . . . 7
AIR FOR COMBUSTION AND VENTILATION . . . . . . . . . . 7
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
UPFLOW INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . 8
DOWNFLOW INSTALLATION . . . . . . . . . . . . . . . . . . . . 9
HORIZONTAL INSTALLATION . . . . . . . . . . . . . . . . . . 10
AIR DUCTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
GAS PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
ELECTRICAL CONNECTIONS . . . . . . . . . . . . . . . . . . 16
115--V WIRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
J--BOX RELOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . 16
24--V WIRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
ACCESSORIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
VENTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
MASONRY CHIMNEY REQUIREMENTS . . . . . . . . . . 19
APPLIANCE APPLICATION REQUIREMENTS . . . . . 20
ADDITIONAL VENTING REQUIREMENTS . . . . . . . . 22
SIDEWALL VENTING . . . . . . . . . . . . . . . . . . . . . . . . . . 22
START--UP, ADJUSTMENT, AND SAFETY CHECK . . . . . 23
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
START--UP PROCEDURES . . . . . . . . . . . . . . . . . . . . . . 24
ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
AIR DELIVERY -- CFM . . . . . . . . . . . . . . . . . . . . . . . . . 14
CHECK SAFETY CONTROLS . . . . . . . . . . . . . . . . . . . 26
CHECKLIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
SERVICE AND MAINTENANCE PROCEDURES . . . . . . . 29
ELECTRICAL CONTROLS AND WIRING . . . . . . . . . 29
CARE AND MAINTENANCE . . . . . . . . . . . . . . . . . . . . 30
COMPONENT TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
CLEANING AND/OR REPLACING AIR FILTER . 31
BLOWER MOTOR AND WHEEL . . . . . . . . . . . . . . 31
FLAME SENSOR CLEANING AND SERVICING . 32
CLEANING HEAT EXCHANGER . . . . . . . . . . . . . . 33
SEQUENCE OF OPERATION . . . . . . . . . . . . . . . . . . . . 34
SERVICE GUIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
WIRING DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
PARTS REPLACEMENT INFORMATION GUIDE . . . . 38
Approved for installations up to 5,400 feet (1646 meters)
NOTE: Read the entire instruction manual before starting the
installation.
Portions of the text and tables are reprinted from current edition
of NFPA 54/ANSI Z223.1E, with permission of National Fire
Protection Association, Quincy, MA 02269 and American Gas
Association, Washington DC 20001. This reprinted material is
not the complete and official position of the NFPA or ANSI on
the referenced subject, which is represented only by the standard
in its entirety.
441 01 1501 04 1/14/2020
SAFETY CONSIDERATIONS
!
WARNING
FIRE, EXPLOSION, ELECTRICAL SHOCK, AND
CARBON MONOXIDE POISONING HAZARD
Failure to follow this warning could result in dangerous
operation, serious injury, death, or property damage.
Improper installation, adjustment, alteration, service,
maintenance, or use could cause carbon monoxide
poisoning, explosion, fire, electrical shock, or other
conditions which may cause personal injury or property
damage. Consult a qualified service agency, local gas
supplier, or your distributor or branch for information or
assistance. The qualified service agency must use only
factory--authorized and listed kits or accessories when
modifying this product.
!
CAUTION
FURNACE RELIABILITY HAZARD
Improper installation or misapplication of furnace may
require excessive servicing or cause premature component
failure.
Application of this furnace should be indoors with special
attention given to vent sizing and material, gas input rate,
air temperature rise, unit leveling, and unit sizing.
Improper
installation,
adjustment,
alteration,
service,
maintenance, or use can cause explosion, fire, electrical shock, or
other conditions which may cause death, personal injury, or
property damage. Consult a qualified installer, service agency, or
your distributor or branch for information or assistance. The
qualified installer or agency must use factory--authorized kits or
accessories when modifying this product. Refer to the individual
instructions packaged with the kits or accessories when installing.
Follow all safety codes. Wear safety glasses, protective clothing,
and work gloves. Have a fire extinguisher available. Read these
instructions thoroughly and follow all warnings or cautions
include in literature and attached to the unit. Consult local
building codes, the current editions of the current edition of
National Fuel Gas Code (NFGC) NFPA 54/ANSI Z223.1 and the
current edition of National Electrical Code (NEC) NFPA 70.
Recognize safety information. This is the safety--alert symbol .
When you see this symbol on the unit and in instructions or
manuals, be alert to the potential for personal injury.
Understand the signal words DANGER, WARNING, and
CAUTION. These words are used with the safety--alert symbol.
DANGER identifies the most serious hazards which will result in
severe personal injury or death. WARNING signifies hazards
which could result in personal injury or death. CAUTION is
used to identify unsafe practices which may result in minor
personal injury or product and property damage. NOTE is used
to highlight suggestions which will result in enhanced
installation, reliability, or operation.
!
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. Use only with type of gas approved for this furnace. Refer
to the furnace rating plate.
2
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 (see Fig. 5).
9. The furnace is not permitted to be used for heating of
buildings under construction.
10. These Multipoise Gas--Fired Furnaces are CSA (formerly
A.G.A. and C.G.A). design--certified for use with natural
gas (see furnace rating plate) and for installation in
alcoves, attics, basements, closets, utility rooms,
crawlspaces, and garages. The furnace is factory--shipped
for use with natural gas and cannot be converted to
propane gas.
11. See Fig. 2 for required clearances to combustible
construction.
12. Maintain a 1--in. (25 mm) clearance from combustible
materials to supply air ductwork for a distance of 36
inches (914 mm) horizontally from the furnace. See
current edition of NFPA 90B or local code for further
requirements.
13. These furnaces SHALL NOT be installed directly on carpeting, tile, or any other combustible material other than
wood flooring. In downflow installations, factory accessory floor base MUST be used when installed on combustible materials and wood flooring. Special base is not required when this furnace is installed on manufacturer’s
approved coil assembly or a manufacturer’s coil casing
box is used. See Fig. 2 for clearance to combustible construction.
INTRODUCTION
This 4--way multipoise Category I fan--assisted furnace is CSA
design--certified. A Category I fan--assisted furnace is an
appliance equipped with an integral mechanical means to either
draw or force products of combustion through the combustion
chamber and/or heat exchanger. The furnace is factory--shipped
for use with natural gas.
This furnace is not approved for installation in mobile homes,
recreational vehicles, or outdoors. The furnace is not permitted to
be used for heating of buildings under construction. This furnace
is designed for minimum continuous return--air temperature of
60_F (16_C)db or intermittent operation down to 55_F (13_C)
db such as when used with a night setback thermostat. Return--air
temperature must not exceed 80_F (27_C) db. Failure to follow
these return--air temperature limits may affect reliability of heat
exchangers, motors, and controls. (See Fig. 3).
For accessory installation details, refer to the applicable
instruction literature.
NOTE: Remove all shipping brackets and materials before
operating the furnace.
Specifications are subject to change without notice.
441 01 1501 04
SD5507--- 4 ULN 80 REV. B
U.S. ECCN: Not Subject to Regulation (N.S.R.)
NOTE: ALL DIMENSIONS IN INCH (MM)
A190257
Fig. 1 -- Dimensional Drawing
Table 1 – Dimensions
A
FURNACE SIZE
0401712
0601716
0802120
1002120
441 01 1501 04
CABINET
WIDTH
IN. (MM)
17--1/2 (445)
17--1/2 (445)
21 (533)
21 (533)
B
C
D
OUTLET WIDTH
IN. (MM)
15--7/8 (403)
15--7/8 (403)
19--3/8 (492)
19--3/8 (492)
TOP FLUE
COLLAR ONLY
IN. (MM)
11--9/16 (294)
11--9/16 (294)
13--5/16 (338)
13--5/16 (338)
BOTTOM WIDTH
IN. (MM)
16 (406)
16 (406)
19--1/2 (495)
19--1/2 (495)
Specifications are subject to change without notice.
VENT
CONNECTION
SIZE*
IN. (MM)
4 (102)
4 (102)
4 (102)
4 (102)
SHIP WT
(LB / KG)
118 (54)
126 (57)
140 (64)
150 (68)
3
Duct Systems
S Air Conditioning Contractors Association (ACCA)
Manual D, Sheet Metal and Air Conditioning Contractors National Association (SMACNA), or American
Society of Heating, Refrigeration, and Air Conditioning Engineers (ASHRAE) 2005 Fundamentals Handbook Chapter 35 or 2004 HVAC Systems and Equipment Handbook Chapters 9 and 16.
Acoustical Lining and Fibrous Glass Duct
S 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
Current edition of NFGC NFPA54/ANSI Z223.1;
chapters 5, 6, 7, and 8 and National Plumbing Codes.
Electrical Connections
S Current edition of National Electrical Code (NEC) NFPA 70.
Venting
S Current edition of NFGC NFPA 54 / ANSI Z223.1;
Chapters 12 and 13.
S
A190402
Fig. 2 -- Clearances to Combustibles
ELECTROSTATIC DISCHARGE (ESD)
PRECAUTIONS PROCEDURE
!
A02055
Fig. 3 -- Return Air Temperature
CODES AND STANDARDS
Follow all national and local codes and standards in addition to
these instructions. The installation must comply with regulations
of the serving gas supplier, local building, heating, plumbing, and
other codes. In absence of local codes, the installation must
comply with the national codes listed below and all authorities
having jurisdiction.
In the United States, follow all codes and standards for the
following:
Safety
USA: Current edition of National Fuel Gas Code
(NFGC) NFPA 54/ANSI Z223.1 and the Installation
Standards, Warm Air Heating and Air Conditioning
Systems ANSI/NFPA 90B
General Installation
S
Current edition of the NFGC and the NFPA 90B. For
copies, contact the National Fire Protection Association
Inc., Batterymarch Park, Quincy, MA 02269;
(www.NFPA.org) or for only the NFGC, contact the
American Gas Association, 400 N. Capitol Street,
N.W., Washington, DC 20001 (www.AGA.org).
Combustion and Ventilation Air
S
S
4
Current edition of NFGC NFPA54/ANSI Z223.1 Section 9.3, Air for Combustion and Ventilation.
CAUTION
FURNACE RELIABILITY HAZARD
Improper installation or service of furnace may cause
premature furnace component failure.
Electrostatic discharge can affect electronic components.
Follow the Electrostatic Discharge Precautions Procedure
listed below during furnace installation and servicing to
protect the furnace electronic control. Precautions will
prevent electrostatic discharges from personnel and hand
tools which are held during the procedure. These
precautions will help to avoid exposing the control to
electrostatic discharge by putting the furnace, the control,
and the person at the same electrostatic potential.
1. Disconnect all power to the furnace. Multiple disconnects
maybe required. DO NOT TOUCH THE CONTROL OR
ANY WIRE CONNECTED TO THE CONTROL PRIOR
TO
DISCHARGING
YOUR
BODY’S
ELECTROSTATIC CHARGE TO GROUND.
2. Firmly touch the clean, unpainted, metal surface of the
furnace chassis which is close to the control. Firmly touch
the clean, unpainted, metal surface of the furnace chassis
which is close to the control. Tools held in a person’s hand
during grounding will be satisfactorily discharged.
3. After touching the chassis, you may proceed to service the
control or connecting wires as long as you do nothing to
recharge your body with static electricity (for example;
DO NOT move or shuffle your feet, do not touch
ungrounded objects, etc.).
4. If you touch ungrounded objects (and recharge your body
with static electricity), firmly touch a clean, unpainted
metal surface of the furnace again before touching control
or wires.
5. Use this procedure for installed and uninstalled
(ungrounded) furnaces.
6. Before removing a new control from its container,
discharge your body’s electrostatic charge to ground to
protect the control from damage. If the control is to be
installed in a furnace, follow items 1 through 4 before
bringing the control or yourself in contact with the
furnace. Put all used and new controls into containers
before touching ungrounded objects.
7. An ESD service kit (available from commercial sources)
may also be used to prevent ESD damage.
Specifications are subject to change without notice.
441 01 1501 04
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
LOCATION
GENERAL
This multipoise furnace is shipped in packaged configuration.
Some assembly and modifications are required when used in any
of the four applications shown in Fig. 4.
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 for upflow applications.
Downflow installations require use of a factory--approved floor base or coil assembly when installed on
combustible materials or wood flooring (refer to
SAFETY CONSIDERATIONS).
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
label.
!
WARNING
CARBON MONOXIDE POISONING HAZARD
Failure to follow this warning could result in personal
injury or death, and unit component damage.
Corrosive or contaminated air may cause failure of parts
containing flue gas, which could leak into the living space.
Air for combustion must not be contaminated by halogen
compounds, which include fluoride, chloride, bromide, and
iodide. These elements can corrode heat exchangers and
shorten furnace life. Air contaminants are found in aerosol
sprays, detergents, bleaches, cleaning solvents, salts, air
fresheners, and other household products. Do not install
furnace in a corrosive or contaminated atmosphere. Make
sure all combustion and circulating air requirements are met,
in addition to all local codes and ordinances.
441 01 1501 04
The following types of furnace installations may require
OUTDOOR AIR for combustion due to chemical exposures:
S Commercial buildings
S Buildings with indoor pools
S Laundry rooms
S Hobby or craft rooms, and
S Chemical storage areas
If air is exposed to the following substances, it should not be used
for combustion air, and outdoor air may be required for
combustion:
S Permanent wave solutions
S Chlorinated waxes and cleaners
S Chlorine based swimming pool chemicals
S Water softening chemicals
S De--icing salts or chemicals
S Carbon tetrachloride
S Halogen type refrigerants
S Cleaning solvents (such as perchloroethylene)
S Printing inks, paint removers, varnishes, etc.
S Hydrochloric acid
S Cements and glues
S Antistatic fabric softeners for clothes dryers
S 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.
!
CAUTION
PERSONAL
INJURY
AND/OR
PROPERTY
DAMAGE
Improper use or installation of this furnace may cause
premature furnace component failure.
This furnace is not permitted to be used for heating of
buildings under construction.
Specifications are subject to change without notice.
5
WARNING
!
FIRE HAZARD
Failure to follow this warning could result in personal
injury, death, and/or property damage.
When the furnace is installed in a residential garage, the
burners and ignition sources must be located at least 18
inches above the floor. (See Fig. 5) The furnace must be
located or protected to avoid damage by vehicles. When the
furnace is installed in a public garage, airplane hangar, or
other building having a hazardous atmosphere, the furnace
must be installed in accordance with the NFGC.
18-IN. (457.2 mm)
MINIMUM TO BURNERS
A93044
Fig. 5 -- Installation in a Garage
Table 2 – Minimum Free Area Required for Each Combustion Air Opening or Duct to Outdoors
TWO HORIZONTAL DUCTS
(1 SQ. IN./2,000 BTUH)
(1,100 SQ. MM/KW)
FURNACE
INPUT
(BTUH)
40,000
60,000
80,000
100,000
Free Area of Opening and Duct
Sq. In (Sq. mm)
20 (12904)
30 (19355)
40 (25807)
50 (32258)
SINGLE DUCT OR OPENING
(1 SQ. IN./3,000 BTUH)
(734 SQ. MM/KW)
Round
Duct
Free Area of OpenIn. (mm)
ing and Duct
Dia
Sq. In (Sq. mm)
14 (8696)
5 (127)
20 (13043)
5 (127)
27 (17391)
6 (152)
34 (21739)
7 (178)
Round Duct
In. (mm)
Dia
5 (127)
6 (152)
7 (178)
8 (203)
EXAMPLE: Determining Free Area
FURNACE
WATER HEATER
TWO OPENINGS OR
VERTICAL DUCTS
(1 SQ. IN./4,000 BTUH)
(550 SQ. MM/KW)
Free Area of Opening
and Duct
Sq. In (mm)
10 (6452)
15 (9678)
20 (12904)
25 (16130)
Round Duct
In. (mm) Dia.
4 (102)
5 (127)
5 (127)
6 (152)
TOTAL INPUT
100,000
+
30,000
=
(130,000 divided by 4,000)
=
60,000
80,000
+
+
40,000
30,000
=
=
(100,000 divided by 3,000)
(110,000 divided by 2,000)
=
=
32.5 Sq. In. for each two Vertical Ducts or
Openings
33.3 Sq. In. for each Single Duct or Opening
55.0 Sq. In. for each two Horizontal Ducts
Table 3 – Minimum Space volumes for 100% combustion, Ventilation, and Dilution from Indoors
OTHER THAN FAN---ASSISTED TOTAL
(1,000’S BTUH GAS INPUT RATE
ACH*
30
40
50
FAN---ASSISTED TOTAL
(1,000’S BTUH GAS INPUT RATE)
40
60
80
100
Space Volume (ft.3)
0.60
1,050
1,400
1,750
1,000
1,500
2,000
3,300
0.50
1,260
1,680
2,100
1,200
1,800
2,400
3,960
0.40
1,575
2,100
2,625
1,500
2,250
3,000
4,950
0.30
2,100
2,800
3,500
2,000
3,000
4,000
6,600
0.20
3,150
4,200
5,250
3,000
4,500
6,000
9,900
0.10
6,300
8,400
10,500
6,000
9,000
12,000
19,800
0.00
NP
NP
NP
NP
NP
NP
NP
*Air Changes/Hour
!
WARNING
FIRE HAZARD
Failure to follow this warning could result in personal
injury, death and/or property damage.
Do not install the furnace on its back or hang furnace with
control compartment facing downward. Safety control
operation will be adversely affected. Never connect
return--air ducts to the back of the furnace. (See Fig. 6)
A02054
Fig. 6 -- Prohibit Installation on Back
6
Specifications are subject to change without notice.
441 01 1501 04
!
b. Size openings and ducts per Fig. 7 and Table 2.
CAUTION
1 SQ IN.
PER 4000
BTUH*
DUCTS
TO
OUTDOORS
FURNACE CORROSION HAZARD
DUCTS
TO
OUTDOORS
1 SQ IN.
PER 2000
BTUH*
(305mm) 12″ MAX
!
WARNING
CARBON MONOXIDE POISONING HAZARD
Failure to follow this warning could result in personal injury
or death.
The operation of exhaust fans, kitchen ventilation fans,
clothes dryers, attic exhaust fans or fireplaces could create a
NEGATIVE PRESSURE CONDITION at the furnace.
Make--up air MUST be provided for the ventilation devices,
in addition to that required by the furnace. Refer to Carbon
Monoxide Poisoning Hazard warning in venting section of
these instructions to determine if an adequate amount of
make--up air is available.
The requirements for combustion and ventilation air depend upon
whether or not the furnace is located in a space having a volume
of at least 50 cubic feet per 1,000 Btuh input rating for all gas
appliances installed in the space.
S Spaces having less than 50 cubic feet per 1,000 Btuh
require the OUTDOOR COMBUSTION AIR
METHOD.
Spaces having at least 50 cubic feet per 1,000 Btuh
may use the INDOOR COMBUSTION AIR,
STANDARD or KNOWN AIR INFILTRATION
METHOD.
Outdoor Combustion Air Method
1. Provide the space with sufficient air for proper
combustion, ventilation, and dilution of flue gases using
permanent 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.
a. One opening MUST commence within 12--in. (300 mm)
of the ceiling and the second opening MUST commence
within 12--in. (300 mm) of the floor.
S
441 01 1501 04
A
12″ (305mm)
MAX
D
VENT
THROUGH
ROOF
F
1 SQ IN.
PER
4000
BTUH*
1 SQ IN.
PER
4000
BTUH*
E
G
12″ (305mm)
MAX
C
12″ MAX
(305mm)
AIR FOR COMBUSTION AND
VENTILATION
Provisions for adequate combustion, ventilation, and dilution air
must be provided in accordance with:
S U.S. installations: Section 9.3 of the current edition of
NFGC NFPA54/ANSI Z223.1, Air for Combustion
and Ventilation, and applicable provisions of the local
building codes.
B
OUTDOORS
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.
(305mm) 12″ MAX
1 SQ IN.
PER 2000
BTUH*
CLEARANCE IN FRONT
OF COMBUSTION AIR
OPENINGS SHALL BE
AT LEAST 3 IN.
(76mm)
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.
CIRCULATING
AIR DUCTS
Failure to follow this caution may result in furnace damage.
CIRCULATING AIR DUCTS
DUCT
TO
OUTDOORS
1 SQ IN.
PER 4000
BTUH*
*Minimum dimensions of 3 in. (76 mm).
NOTE: Use any of the following combinations of openings:
A&B, C&D, D&E, F&G
A03174
Fig. 7 -- Air for Combustion, Ventilation, and Dilution from
Outdoors
c. TWO HORIZONTAL DUCTS require 1 square inch of
free area per 2,000 Btuh (1,100 mm2/kW) of combined
input for all gas appliances in the space per Fig. 7 and
Table 2.
d. TWO OPENINGS OR VERTICAL DUCTS require 1
square inch of free area per 4,000 Btuh (550 mm2/kW)
for combined input of all gas appliances in the space per
Fig. 7 and Table 2.
3. ONE OUTDOOR OPENING requires:
a. 1 square inch of free area per 3,000 Btuh (734 mm2/kW)
for combined input of all gas appliances in the space per
Table 2 and
b. Not less than the sum of the areas of all vent connectors
in the space.
The opening shall commence within 12” (300 mm) of the ceiling.
Appliances in the space shall have clearances of at least 1” (25
mm) from the sides and back and 6” (150 mm) from the front.
The opening shall directly communicate with the outdoors or
shall communicate through a vertical or horizontal duct to the
outdoors or spaces (crawl or attic) that freely communicate with
the outdoors.
Indoor Combustion Air -- NFPA & AGA
Standard and Known--Air--Infiltration Rate Methods
Indoor air is permitted for combustion, ventilation, and dilution,
if the Standard or Known--Air--Infiltration Method is used.
!
WARNING
CARBON MONOXIDE POISONING HAZARD
Failure to follow this warning could result in death and/or
personal injury.
Many homes require air to be supplied from outdoors for
furnace combustion, ventilation, and dilution of flue gases.
The furnace combustion air supply must be provided in
accordance with this instruction manual.
Specifications are subject to change without notice.
7
VENT THROUGH ROOF
CLEARANCE IN FRONT OF COMBUSTION AIR
OPENINGS SHALL BE AT LEAST 3 IN.
CIRCULATING AIR
DUCTS
INTERIOR
HEATED
SPACE
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
12" MAX (305mm)
CIRCULATING AIR DUCTS
*Minimum opening size is 100 in.2 with minimum dimensions of 3 in. (76 mm).
*Minimum of 3 in. (76 mm), when type ---B1 vent is used.
A03175
Fig. 8 -- Air for Combustion, Ventilation, and Dilution from
Indoors
The Standard Method:
1. The space has no less volume than 50 cubic feet per 1,000
Btuh of the maximum input ratings for all gas appliances
installed in the space and
2. The air infiltration rate is not known to be less than 0.40
air changes per hour (ACH).
The Known Air Infiltration Rate Method shall be used, if the
infiltration rate is known to be:
1. Less than 0.40 ACH and
2. Equal to or greater than 0.10 ACH
Infiltration rates greater than 0.60 ACH shall not be used. The
minimum required volume of the space varies with the number of
ACH and shall be determined per Table 3 or Equations 1 and 2.
Determine the minimum required volume for each appliance in
the space and add the volumes together to get the total minimum
required volume for the space.
Table 3 -- Minimum Space Volumes were determined by using
the following equations from the current edition of National Fuel
Gas Code ANSI Z223.1/NFPA 54, 9.3.2.2:
1. For other than fan--assisted appliances, such as a draft
hood--equipped water heater:
Volume
3
I other
= 21ft
Other
ACH 1000 Btu/hr
A04002
2. For fan--assisted appliances such as this furnace:
Volume
Fan
3
I fan
= 15ft
ACH 1000 Btu/hr
INSTALLATION
UPFLOW INSTALLATION
A004003
If:
I
other = combined input of all other than fan--assisted appliances
in Btuh/hr
8
I
fan = 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” (300 mm) of the ceiling and the second opening shall commence within 12”
(300 mm) of the floor. The minimum dimension of air
openings shall be at least 3 in. (80 mm). (See Fig. 8)
c. Combining space on different floor levels. The volumes
of spaces on different floor levels shall be considered as
communicating spaces if connected by one or more permanent openings in doors or floors having free area of
at least 2 in.2/1,000 Btuh (4,400 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.
Unusually tight construction is defined as construction with:
a. Walls and ceilings exposed to the outdoors have a continuous, sealed vapor barrier. Openings are gasketed or
sealed and
b. Doors and openable windows are weatherstripped and
c. Other openings are caulked or sealed. These include
joints around window and door frames, between sole
plates and floors, between wall--ceiling joints, between
wall panels, at penetrations for plumbing, electrical and
gas lines, etc.
Combination of Indoor and Outdoor Air
1. Indoor openings shall comply with the Indoor
Combustion Air Method below and,
2. Outdoor openings shall be located as required in the
Outdoor Combustion Air Method mentioned previously
and,
3. Outdoor openings shall be sized as follows:
a. Calculate the Ratio of all Indoor Space volume divided
by required volume for Indoor Combustion Air
Method below.
b. Outdoor opening size reduction Factor is 1 minus the
Ratio in a. above.
c. Minimum size of Outdoor openings shall be the size
required in Outdoor Combustion Air Method above
multiplied by reduction Factor in b. above. The minimum
dimension of air openings shall be not less than 3 in. (80
mm).
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:
Specifications are subject to change without notice.
441 01 1501 04
1. Tilt or raise furnace and remove two screws holding bottom filler panel. (See Fig. 9)
Bottom
Closure Panel
2. For each leg, install nut on bolt and then install bolt and
nut in hole. (Install flat washer if desired.)
3. Install another nut on other side of furnace base. (Install
flat washer if desired.)
4. Adjust outside nut to provide desired height, and tighten
inside nut to secure arrangement.
5. Reinstall bottom closure panel if removed.
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:
Bottom Filler Panel
A10273
Fig. 9 -- Removing Bottom Closure Panel
2. Rotate bottom filler panel downward to release holding
tabs.
3. Remove bottom closure panel.
4. Reinstall bottom filler panel and screws.
Side Return Air Inlet
These furnaces are shipped with bottom closure panel installed in
bottom return--air opening. This panel MUST be in place when
only side return air is used.
NOTE: Side return--air openings can be used in UPFLOW and
most HORIZONTAL configurations. Do not use side return--air
openings in DOWNFLOW configuration.
Leveling Legs (If Desired)
In upflow position with side return inlet(s), leveling legs may be
used. (See Fig. 10) Install field--supplied, 5/16 x 1--1/2 in. (8 x 38
mm) (max) corrosion--resistant machine bolts, washers and nuts.
NOTE: Bottom closure must be used when leveling legs are
used. It may be necessary to remove and reinstall bottom closure
panel to install leveling legs. To remove bottom closure panel, see
Item 1. in Bottom Return Air Inlet section.
To install leveling legs:
1. Position furnace on its back. Locate and drill a hole in
each bottom corner of furnace. (See Fig. 10)
S
S
S
Downflow combustible floor subbase
Manufacturer’s approved Cased Coil
Manufacturer’s approved Coil Casing
1. Determine application being installed from Table 4.
2. Construct hole in floor per Table 4 and Fig. 11.
3. Construct plenum to dimensions specified in Table 4 and
Fig. 11.
4. If downflow subbase is used, install as shown in Fig. 12. If
Coil or Coil Casing, install as shown in Fig. 13.
NOTE: It is required that the perforated supply--air duct flanges
be completely folded over or removed from furnace when
installing the furnace on a factory--supplied cased coil or coil box.
To remove the supply--air duct flange, use wide duct pliers or
hand seamers to bend flange back and forth until it breaks off. Be
careful of sharp edges. (See Fig. 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 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
5/ 16
(8mm)
(8mm)
5/ 16
A
PLENUM
OPENING
1 3/4
(44mm)
D
B
FLOOR
OPENING
1 3/4
(44mm)
C
(8mm)
5/16
Fig. 11 -- Floor and Plenum Opening Dimensions
(8mm)
A96283
5/ 16
(44mm) 1 3/ 4
3/
(44mm) 1 4
A89014
Fig. 10 -- Leveling Legs
441 01 1501 04
Specifications are subject to change without notice.
9
FURNACE
FURNACE
(OR COIL CASING
WHEN USED)
APPROVED
COIL ASSEMBLY
OR
COIL BOX
COMBUSTIBLE
FLOORING
COMBUSTIBLE
FLOORING
SHEET METAL
PLENUM
DOWNFLOW
SUBBASE
FLOOR
OPENING
SHEET METAL
PLENUM
FLOOR
OPENING
A08556
Fig. 13 -- Furnace, Plenum, and Coil Assembly or
Coil Box Installed on a Combustible Floor
A96285
Fig. 12 -- Furnace, Plenum, and Subbase Installed
on a Combustible Floor
Table 4 – Opening Dimensions -- In. (mm)
FURNACE
CASING
WIDTH
Upflow Applications on Combustible or Noncombustible
Flooring (subbase not required)
Downflow Applications on Noncombustible Flooring (subbase
not required)
Downflow applications on combustible flooring (subbase
required)
Downflow Applications on Combustible Flooring with Coil
Assembly or coil box (subbase not required)
Upflow Applications on Combustible or Noncombustible
Flooring (subbase not required)
Downflow Applications on Noncombustible Flooring (subbase
not required)
Downflow applications on combustible flooring subbase
required)
Downflow Applications on Combustible Flooring with Coil
Assembly or coil box (subbase not required)
17–1/2
(445)
21
(533)
HORIZONTAL INSTALLATION
!
WARNING
FIRE, EXPLOSION, AND CARBON MONOXIDE
POISONING HAZARD
Failure to follow this warning could result in personal
injury, death, and/or property damage.
Do not install the furnace on its back or hang furnace with
control compartment facing downward. Safety control
operation will be adversely affected. Never connect
return--air ducts to the back of the furnace.
The furnace can be installed horizontally in an attic or crawl space
on either the left--hand (LH) or right--hand (RH) side. The furnace
can be hung from floor joists, rafters or trusses or installed on a
non--combustible platform, blocks, bricks or pad.
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
10
PLENUM OPENING
APPLICATION
FLOOR OPENING
A
B
C
D
16
(406)
15--- 7/8
(403)
15--- 1/8
(384)
15--- 1/2
(394)
19--- 1/2
(495)
19--- 3/8
(492)
18--- 5/8
(473)
19
(483)
21--- 5/8
(549)
19
(483)
19
(483)
19
(483)
21--- 5/8
(549)
19
(483)
19
(483)
19
(483)
16--- 5/8
(422)
16--- 1/2
(419)
16--- 3/4
(425)
16--- 1/2
(419)
20--- 1/8
(511)
20
(508)
20--- 1/4
(514)
20
(508)
22--- 1/4
(565)
19--- 5/8
(498)
20--- 5/8
(600)
20
(508)
22--- 1/4
(565)
19--- 5/8
(498)
20--- 5/8
(600)
20
(508)
to suspend the furnace from each bottom corner. To prevent
screws from pulling out, use 2 #8 x 3/4--in. (19 mm) screws into
the side and 2 #8 x 3/4--in. (19 mm) screws in the bottom of the
furnace casing for each strap. (See Fig. 15 and 16) If the screws
are attached to ONLY the furnace sides and not the bottom, the
straps must be vertical against the furnace sides and not pull away
from the furnace sides, so that the strap attachment screws are not
in tension (are loaded in shear) for reliable support.
Platform Furnace Support
Construct working platform at location where all required furnace
clearances are met. (See Fig. 2 and 17) For furnaces with 1--in.
(25 mm) clearance requirement on side, set furnace on
noncombustible blocks, bricks or angle iron. For crawl space
installations, if the furnace is not suspended from the floor joists,
the ground underneath furnace must be level and the furnace set
on blocks or bricks.
Roll--Out Protection
Provide a minimum 17--3/4 in. x 22 in. (451 mm x 559 mm)
piece of sheet metal for flame roll--out protection in front of
burner area for furnaces closer than 12 inches (305 mm) above
the combustible deck or suspended furnaces closer than 12 inches
(305 mm) to joists. The sheet metal MUST extend underneath the
furnace casing by 1 in. (25 mm) with the door removed.
Specifications are subject to change without notice.
441 01 1501 04
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
Side Return Air Inlet
These furnaces are shipped with bottom closure panel installed in
bottom return--air opening. This panel MUST be in place when
side return air inlet(s) is used without a bottom return air inlet.
FILTER ARRANGEMENT
!
WARNING
CARBON MONOXIDE AND POISONING
HAZARD
Failure to follow this warning could result in personal
injury, or death.
Never operate a furnace without a filter or with filter access
door removed.
There are no provisions for an internal filter rack in these
furnaces.
A field--supplied accessory external filter is required.
Refer to the instructions supplied with the external filter rack for
assembly and installation options.
AIR DUCTS
General Requirements
The duct system should be designed and sized according to
accepted national standards such as those published by: Air
Conditioning Contractors Association (ACCA), Sheet Metal and
Air Conditioning Contractors National Association (SMACNA)
or American Society of Heating, Refrigerating and Air
Conditioning Engineers (ASHRAE) or consult The Air Systems
Design Guidelines reference tables available from your local
distributor. The duct system should be sized to handle the
required system design CFM at the design external static pressure.
The furnace airflow rates are provided in Table 5 -- AIR
DELIVERY--CFM (with filter).
When a furnace is installed so that the supply ducts carry air
circulated by the furnace to areas outside the space containing the
furnace, the return air shall also be handled by duct(s) sealed to
the furnace casing and terminating outside the space containing
the furnace.
Secure ductwork with proper fasteners for type of ductwork used.
Seal supply-- and return--duct connections to furnace with code
approved tape or duct sealer.
NOTE: Flexible connections should be used between ductwork
and furnace to prevent transmission of vibration. Ductwork
passing through unconditioned space should be insulated and
sealed to enhance system performance. When air conditioning is
used, a vapor barrier is recommended.
441 01 1501 04
Maintain a 1--in. (25 mm) clearance from combustible materials
to supply air ductwork for a distance of 36 in. (914 mm)
horizontally from the furnace. See NFPA 90B or local code for
further requirements.
Ductwork Acoustical Treatment
NOTE: Metal duct systems that do not have a 90 degree elbow
and 10 ft. (3 M) of main duct to the first branch take--off may
require internal acoustical lining. As an alternative, fibrous
ductwork may be used if constructed and installed in accordance
with the latest edition of SMACNA construction standard on
fibrous glass ducts. Both acoustical lining and fibrous ductwork
shall comply with NFPA 90B as tested by UL Standard 181 for
Class 1 Rigid air ducts.
Supply Air Connections
For a furnace not equipped with a cooling coil, the outlet duct
shall be provided with a removable access panel. This opening
shall be accessible when the furnace is installed and shall be of
such a size that the heat exchanger can be viewed for possible
openings using light assistance or a probe can be inserted for
sampling the airstream. The cover attachment shall prevent leaks.
Upflow and Horizontal Furnaces
Connect supply--air duct to flanges on furnace supply--air outlet.
Bend flange upward to 90_ with wide duct pliers. (See Fig. 14)
The supply--air duct must be connected to ONLY the furnace
supply--outlet--air duct flanges or air conditioning coil casing
(when used). DO NOT cut main furnace casing side to attach
supply air duct, humidifier, or other accessories. All accessories
MUST be connected to duct external to furnace main casing.
NOTE: For horizontal applications, the top--most flange may be
bent past 90 degrees to allow the evaporator coil to hang on the
flange temporarily while the remaining attachment and sealing of
the coil are performed.
Downflow Furnaces
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.
Specifications are subject to change without notice.
A190346
Fig. 14 -- Duct Flanges
11
/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
12
Specifications are subject to change without notice.
441 01 1501 04
A180240
Fig. 17 -- Typical Attic Installation
Return Air Connections
!
!
WARNING
FIRE OR EXPLOSION HAZARD
FIRE HAZARD
Failure to follow this warning could cause personal injury,
death and/or property damage.
Never connect return--air ducts to the back of the furnace.
Follow instructions below
Failure to follow this warning could result in personal
injury,death, and/or property damage.
Use proper length of pipe to avoid stress on gas control
assembly and a gas leak.
!
Downflow Furnaces
The return--air duct must be connected to return--air opening
(bottom inlet) as shown in Fig. 20. DO NOT cut into casing sides
(left or right). Side opening is permitted for only upflow and most
horizontal furnaces. (See Fig. 20) Bypass humidifier connections
should be made at ductwork or coil casing sides exterior to
furnace.
Upflow and Horizontal Furnaces
The return--air duct must be connected to bottom, sides (left or
right), or a combination of bottom and side(s) of main furnace
casing as shown in Fig. 19 and 21. Bypass humidifier may be
attached into unused return air side of the furnace casing. (See
Fig. 19 and 21)
GAS PIPING
!
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.
441 01 1501 04
WARNING
CAUTION
FURNACE OVERHEAT HAZARD
Failure to follow this caution may result in property
damage.
Connect gas pipe to gas valve using a backup wrench to
avoid damaging gas controls and burner misalignment.
!
WARNING
FIRE OR EXPLOSION HAZARD
Failure to follow this warning could result in personal
injury, death, and/or property damage.
If local codes allow the use of a flexible gas appliance
connector, always use a new listed connector. Do not use a
connector which has previously served another gas
appliance. Black iron pipe shall be installed at the furnace
gas control valve and extend a minimum of 2 in.(51 mm)
outside the furnace.
Gas piping must be installed in accordance with national and
local codes. Refer to current edition of NFGC.
Installations must be made in accordance with all authorities
having jurisdiction. If possible, the gas supply line should be a
separate line running directly from meter to furnace.
NOTE: In the state of Massachusetts:
1. Gas supply connections MUST be performed by a
licensed plumber or gas fitter.
2. When flexible connectors are used, the maximum length
shall not exceed 36 inches (915 mm).
Specifications are subject to change without notice.
13
3. When lever handle type manual equipment shutoff valves
are used, they shall be T--handle valves.
4. The use of copper tubing for gas piping is NOT approved
by the state of Massachusetts.
Refer to Table 6 for recommended gas pipe sizing. Risers must be
used to connect to furnace and to meter. Support all gas piping
with appropriate straps, hangers, etc. Use a minimum of 1 hanger
every 6 ft. (2 M). Joint compound (pipe dope) should be applied
sparingly and only to male threads of joints. Pipe dope must be
resistant to the action of propane gas.
An accessible manual equipment shutoff valve MUST be
installed external to furnace casing and within 6 ft. (2 M) of
furnace. A 1/8--in. (3 mm) NPT plugged tapping, accessible for
test gauge connection, MUST be installed immediately upstream
of gas supply connection to furnace and downstream of manual
equipment shutoff valve.
NOTE: The furnace gas control valve inlet pressure tap
connection is suitable to use as test gauge connection providing
test pressure DOES NOT exceed maximum 0.5 psig (14--In.
W.C.) stated on gas control valve. (See Fig. 32)
Install a sediment trap in riser leading to furnace as shown in Fig.
18. Connect a capped nipple into lower end of tee. Capped nipple
should extend below level of furnace gas controls. Place a ground
joint union between furnace gas control valve and exterior
manual equipment gas shutoff valve. A 1/8--in. (3 mm) NPT
plugged tapping, accessible for test gauge connection, MUST be
installed immediately upstream of gas supply connection to
furnace and downstream of manual equipment shutoff valve.
Table 5 – Air Delivery -- CFM (With Filter)
Test Airflow Delivery @ Various External Static Pressures
Wire Lead
Color2
Function
0401712
Gray
Yellow
Orange
Blue
Red
Cooling. Do not use for heating.
Alt Cooling or alt Heating
Heating or alt cooling
Alt Cooling or alt Heating
Alt Cooling or alt Heating
0601716
Gray
Yellow
Orange
Blue
Red
Cooling. Do not use for heating.
Alt Cooling or alt Heating
Alt Cooling or alt Heating
Heating or alt cooling
Alt Cooling or alt Heating
0802120
Gray
Yellow
Orange
Blue
Red
Cooling. Do not use for heating.
Alt Cooling or alt Heating
Alt Cooling or alt Heating
Heating or alt cooling
Alt Heating or alt cooling
1002120
Gray
Blue
Yellow
Orange
Red
Cooling. Do not use for heating.
Heating or alt cooling
Alt Cooling or alt Heating
Alt cooling or alt Heating
Alt cooling. Do not use for heating
Furnace
0.1
1535
1100
695
935
570
0.1
1720
1470
1305
1040
1135
0.1
2185
1885
1565
1365
1205
0.1
2230
1945
1835
1535
1095
0.2
1495
1055
645
885
455
0.2
1680
1425
1255
940
1090
0.2
2135
1830
1500
1295
1045
0.2
2180
1885
1775
1470
1060
External Static Pressure (IN. W.C.)
0.3
0.4
0.5
0.6
0.7
0.8
1455 1415 1370 1320 1280 1235
1005
955
905
855
800
740
585
510
450
390
325
270
830
775
720
655
595
540
380
310
250
180
110
--0.3
0.4
0.5
0.6
0.7
0.8
1635 1585 1545 1505 1455 1405
1385 1335 1290 1245 1200 1160
1215 1160 1115 1070 1025
975
890
835
790
740
675
620
1035
985
940
895
845
790
0.3
0.4
0.5
0.6
0.7
0.8
2085 2035 1990 1935 1880 1825
1780 1730 1675 1625 1575 1520
1440 1385 1330 1275 1220 1170
1230 1165 1100 1045
985
925
965
895
815
745
650
595
0.3
0.4
0.5
0.6
0.7
0.8
2120 2060 2005 1945 1880 1815
1830 1770 1715 1650 1585 1525
1720 1655 1595 1530 1470 1410
1395 1325 1265 1205 1140 1080
1020
985
950
915
880
845
0.9
1190
680
215
490
--0.9
1355
1110
925
565
730
0.9
1770
1470
1115
845
540
0.9
1755
1465
1350
1015
805
1.0
1145
625
155
430
--1.0
1305
1060
870
525
675
1.0
1715
1420
1055
780
480
1.0
1700
1405
1285
955
770
1. A filter is required for each return ---air inlet. Airflow performance included 3/4 ---in. (19 mm) washable filter media such as contained in factory ---authorized
accessory filter rack. To determine airflow performance without this filter, assume an additional 0.1 ---in. W.C. available external static pressure.
2. Adjust the blower speed tabs as necessary for the proper air temperature rise for each installation.
--- --- Indicates unstable operating conditions
3. If the same motor speed tap is needed for heating and cooling, a Jumper Wire accessory kit is available (see Specification Sheet for the current Jumper
Wire accessory part number, see Function column for applicable limitations.
Table 6 – Maximum Capacity of Pipe*
NOMINAL IRON
PIPE
SIZE IN. (mm)
1/2 (13)
3/4 (19)
1 (25)
1--- 1/4 (32)
1--- 1/2 (38)
INTERNAL
DIAMETER
In. (mm)
0.622 (16)
0.824 (21)
1.049 (27)
1.380 (35)
1.610 (41)
LENGTH OF PIPE --- FT. (M)
10
175 (53)
360 (110)
680 (207)
1400 (427)
2100 (640)
20
120 (37)
250 (76)
465 (142)
950 (290)
1460 (445)
30
97 (30)
200 (61)
375 (114)
770 (235)
1180 (360)
40
82 (25)
170 (52)
320 (98)
660 (201)
990 (301)
50
73 (22)
151 (46)
285 (87)
580 (177)
900 (274)
* Cubic ft. of natural gas per hr for gas pressures of 0.5 psig (14 ---In. W.C.) or less and a pressure drop of 0.5 ---In. W.C. (based on a 0.60 specific gravity
gas). Ref: Chapter 6 current edition of ANSI Z223/NFPA 54.
Piping should be pressure and leak tested in accordance with
NFGC in the United States, local, and national plumbing and gas
codes before the furnace has been connected. After all
connections have been made, purge lines and check for leakage at
furnace prior to operating furnace.
14
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
Specifications are subject to change without notice.
441 01 1501 04
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.
GAS
SUPPLY
MANUAL
SHUTOFF
VALVE
(REQUIRED)
SEDIMENT
TRAP
UNION
A02035
A190365
Fig. 18 -- Typical Gas Pipe Arrangement
Fig. 20 -- Downflow Return Air Configurations and Restrictions
A190366
Fig. 21 -- Horizontal Return Air Configurations and Restrictions
A190364
Fig. 19 -- Upflow Return Air Configurations and Restrictions
Table 7 – Electrical Data
Operating Voltage*
Range
VoltsHertzPhase
Maximum
Minimum
0401712
115-60-1
127
0601716
115-60-1
127
0802120
115-60-1
1002120
115-60-1
Unit Size
Maximum
Wire
Length‡ ft
(m)
26 (8)
Maximum
Fuse or
CKT BKR†
Amps
15
14
26 (8)
15
12
33 (10)
20
12
33 (10)
20
Maximum
Unit Amps
Unit
Ampacity#
Minimum
Wire Size
AWG
104
10.6
13.9
14
104
10.6
13.9
127
104
13.3
17.3
127
104
13.3
17.3
* 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 one way along wire path between unit and service panel for maximum 2 percent voltage drop.
441 01 1501 04
Specifications are subject to change without notice.
15
ELECTRICAL CONNECTIONS
!
Make all electrical connections in accordance with current edition
of National Electrical Code (NEC) NFPA 70 and any local codes
or ordinances that might apply.
WARNING
ELECTRICAL SHOCK, FIRE OR EXPLOSION
HAZARD
Failure to follow safety warnings could result in dangerous
operation, serious injury, death or property damage.
Improper servicing could result in dangerous operation,
serious injury, death or property damage.
-- Before servicing, disconnect all electrical power to
furnace.
-- When servicing controls, label all wires prior to
disconnecting. Reconnect wires correctly.
-- Verify proper operation after servicing.
!
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.
See Fig. 24 for field wiring diagram showing typical field 115--v
wiring. Check all factory and field electrical connections for
tightness.
Field--supplied wiring shall conform with the limitations of 63_F
(35_C) rise.
!
WARNING
!
FIRE HAZARD
Failure to follow this warning could result in personal
injury, death, or property damage.
Do not connect aluminum wire between disconnect switch
and furnace. Use only copper wire.
Use a separate, fused branch electrical circuit with a properly
sized fuse or circuit breaker for this furnace. See Table 7 for wire
size and fuse specifications. A readily accessible means of
electrical disconnect must be located within sight of the furnace.
NOTE: Proper polarity must be maintained for 115--v wiring. If
polarity is incorrect, control LED status indicator light will flash
10 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).
1. Remove and save two screws holding J--Box.
NOTE: The J--Box cover need not be removed from the J--Box
in order to move the J--Box. Do NOT remove green ground
screw inside J--Box.
2. Cut wire tie on loop in furnace wires attached to J--box.
3. Move J--Box to desired location.
4. Fasten J--Box to casing with two screws removed in Step 1.
5. Route J--Box wires within furnace away from sharp edges,
rotating parts and hot surfaces.
ELECTRICAL CONNECTION TO J--BOX
Electrical Box on Furnace Casing Side
ELECTRICAL SHOCK AND FIRE HAZARD
Failure to follow this warning could result in personal
injury, death, or property damage.
The cabinet MUST have an uninterrupted or unbroken
ground according to current edition of NEC NFPA 70 or
local codes to minimize personal injury if an electrical fault
should occur. This may consist of electrical wire, conduit
approved for electrical ground or a listed, grounded power
cord (where permitted by local code) when installed in
accordance with existing electrical codes. Refer to the
power cord manufacturer’s ratings for proper wire gauge.
Do not use gas piping as an electrical ground.
!
CAUTION
FURNACE MAY NOT OPERATE
Failure to follow this caution may result in intermittent
furnace operation.
Furnace control must be grounded for proper operation or
else control will lock out. Control must remain grounded
through green/yellow wire routed to gas valve and gas
valve mounting bracket screw.
115--V WIRING
Verify that the voltage, frequency, and phase correspond to that
specified on unit rating plate. Also, check to be sure that service
provided by utility is sufficient to handle load imposed by this
equipment. Refer to rating plate or Table 7 for equipment
electrical specifications.
16
WARNING
!
WARNING
FIRE OR ELECTRICAL SHOCK HAZARD
Failure to follow this warning could result in personal
injury, death, or property damage.
If field--supplied manual disconnect switch is to be mounted
on furnace casing side, select a location where a drill or
fastener cannot damage electrical or gas components.
1. Select and remove a hole knockout in the casing where the
electrical box is to be installed.
NOTE: Check that duct on side of furnace will not interfere with
installed electrical box.
2. Remove the desired electrical box hole knockout and position the hole in the electrical box over the hole in the furnace casing.
3. Fasten the electrical box to casing by driving two field
supplied screws from inside electrical box into casing
steel.
4. Remove and save two screws holding J--Box.
5. Pull furnace power wires out of 1/2--in. (12 mm) diameter
hole in J--Box. Do not loosen wires from strain--relief
wire--tie on outside of J--Box.
6. Route furnace power wires through holes in casing and
electrical box and into electrical box (see Fig. 22)
7. Pull field power wires into electrical box.
8. Remove cover from furnace J--Box.
9. Route field ground wire through holes in electrical box
and casing, and into furnace J--Box.
10. Reattach furnace J--Box to furnace casing with screws removed in Step 4.
11. Secure field ground wire to J--Box green ground screw.
Specifications are subject to change without notice.
441 01 1501 04
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.
POWER CORD INSTALLATION IN FURNACE J--BOX
NOTE: Power cords must be able to handle the electrical
requirements listed in Table 7. Refer to power cord
manufacturer’s listings.
1. Remove cover from J--Box.
2. Route listed power cord through 7/8--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. 24.
6. Reinstall cover to J--Box. Do not pinch wires between
cover and bracket.
BX CABLE INSTALLATION IN FURNACE J--BOX
1. Remove cover from J--Box.
2. Route BX cable into 7/8--inch diameter hole in J--Box.
3. Secure BX cable to J--Box bracket with connectors approved for the type of cable used.
4. Secure field ground wire to green ground screw on J--Box
bracket.
5. Connect line voltage leads as shown in Fig. 24.
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. 24)
Connect terminal Y as shown in Fig. 38 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
and NEUTRAL. The terminals are rated for 115 VAC, 1.0
amps maximum and are energized during blower motor operation. (See Fig. 23)
2. Humidifier (HUM 115 VAC)
Connect an accessory 115 VAC, 1 amp. maximum
humidifier (if used) to the 1/4--in male quick--connect HUM
terminal and NEUTRAL 1/4--in quick connect. The HUM
terminal is energized when the blower starts during a call for
heat. (See Fig. 23)
3. Humidifier (HUM 24 VAC)
Connect an accessory 24 VAC, 0.5 amp. maximum
humidifier (if used) to the 1/4--in male quick--connect HUM
24 VAC terminal and COM--24V screw terminal on the
control board thermostat strip. The HUM 24 VAC terminal is
energized when the blower starts during a call for heat. (See
Fig. 23)
NOTE: DO NOT connect furnace control HUM 115 VAC
terminal or HUM 24 VAC terminal to H (humidifier) terminal on
humidity sensing thermostat, or similar device. See humidity
sensing thermostat, thermostat, or controller manufacturer’s
instructions for proper connection.
A10141
Fig. 22 -- Field--Supplied Electrical Box on Furnace Casing
441 01 1501 04
Specifications are subject to change without notice.
17
A190409
Fig. 23 -- Furnace Control
Representative drawing only, some models may vary.
A180241
Fig. 24 -- Heating and Cooling Application Wiring Diagram with 1--Stage Thermostat
18
Specifications are subject to change without notice.
441 01 1501 04
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. The following steps shall be followed for each
appliance connected to the venting system being placed into
operation, while all other appliances connected to the
venting system are not in operation:
1. Seal any unused openings in venting system.
2. Inspect the venting system for proper size and
horizontal pitch, as required in the current edition of
National Fuel Gas Code, ANSI Z223.1/NFPA 54
and these instructions. Determine that there is no
blockage or restriction, leakage, corrosion and other
deficiencies, which could cause an unsafe condition.
3. As far as practical, close all building doors and
windows and all doors between the space in which
the appliance(s) connected to the venting system are
located and other spaces of the building.
4. Close fireplace dampers.
5. Turn on clothes dryers and any appliance not
connected to the venting system. Turn on any
exhaust fans, such as range hoods and bathroom
exhausts, so they are operating at maximum speed.
Do not operate a summer exhaust fan.
6. Follow the lighting instructions. Place the appliance
being inspected into operation. Adjust the thermostat
so appliance is operating continuously.
7. Test for spillage from draft hood equipped
appliances at the draft hood relief opening after 5
minutes of main burner operation. Use the flame of a
match or candle.
8. If improper venting is observed during any of the
above tests, the venting system must be corrected in
accordance with the current edition of National Fuel
Gas Code, ANSI Z223.1/NFPA 54.
9. After it has been determined that each appliance
connected to the venting system properly vents when
tested as outlined above, return doors, windows,
exhaust fans, fireplace dampers and any other
gas--fired burning appliance to their previous
conditions of use.
Vent system or vent connectors may need to be resized. Vent
systems or vent connectors, must be sized to approach minimum
size as determined using appropriate table found in the NFGC.
GENERAL VENTING REQUIREMENTS
Follow all safety codes for proper vent sizing and installation
requirements, including local building codes, the current edition
of National Fuel Gas Code ANSI Z223.1/NFPA 54 (NFGC),
Parts 12 and 13, the local building codes, and furnace and vent
manufacturers’ instructions.
These furnaces are design--certified as Category I furnaces in
accordance with current edition of ANSI Z21.47/CSA 2.3 and
441 01 1501 04
operate with a non--positive vent static pressure to minimize the
potential for vent gas leakage. Category I furnaces operate with a
flue loss not less than 17 percent to minimize the potential for
condensation in the venting system. These furnaces are approved
for common venting and multistory venting with other fan
assisted or draft hood equipped appliances in accordance with the
NFGC, the local building codes, and furnace and vent
manufacturers’ instructions. The following information and
warning must be considered in addition to the requirements
defined in the NFGC.
1. If a vent (common or dedicated) becomes blocked, the
furnace will be shut off by the draft safeguard switch
located on the vent elbow.
2. Do not vent this Category I furnace into a single--wall
dedicated or common vent. The dedicated or common
vent is considered to be the vertical portion of the vent
system that terminates outdoors.
3. Vent connectors serving Category I furnaces shall not be
connected into any portion of a mechanical draft system
operating under positive pressure.
4. Do not vent this appliance with any solid fuel burning
appliance.
5. Category I furnaces must be vented vertically or nearly
vertically unless equipped with a listed power venter.
6. Do not vent this appliance into an unlined masonry
chimney. Refer to Chimney Inspection Chart, Fig. 25.
MASONRY CHIMNEY REQUIREMENTS
If a clay tile--lined masonry chimney is being used and it is
exposed to the outdoors below the roof line, relining might be
required. Chimneys shall conform to the Standard for Chimneys,
Fireplaces, Vents, and Solid Fuel Burning Appliances current
edition of ANSI/NFPA 211 and must be in good condition.
USA -- Refer to Sections 13.1.8 and 13.2.20 of the current edition
of NFGC NFPA54/ANSI Z223.1 or the authority having
jurisdiction to determine whether relining is required. If relining
is required, use a properly sized listed metal liner, Type--B vent,
or a listed alternative venting design.
NOTE: See the current edition of NFPA54/ANSI Z223.1, 13.1.8
and 13.2.20 regarding alternative venting design and the
Exception.
This furnace is permitted to be vented into a clay tile--lined
masonry chimney that is exposed to the outdoors below the roof
line, provided:
1. Vent connector is Type--B double--wall, and
2. This furnace is common vented with at least 1 draft hood
equipped appliance, and
3. The combined appliance input rating is less than the maximum capacity given in Table 8, and
4. The input rating of each space heating appliance is greater
than the minimum input rating given in Table 9 for the local 99% Winter Design Temperature. Chimneys having internal areas greater than 38 square inches require furnace
input ratings greater than the input ratings of these furnaces. See footnote at bottom of Table 9, and
5. The authority having jurisdiction approves.
If all of these conditions cannot be met, an alternative venting
design shall be used, a listed chimney--lining system, or a Type--B
common vent.
Inspections before the sale and at the time of installation will
determine the acceptability of the chimney or the need for repair
and/or (re)lining. Refer to the Fig. 25 to perform a chimney
inspection. If the inspection of a previously used tile--lined
chimney:
a. Shows signs of vent gas condensation, the chimney
should be relined in accordance with local codes and the
authority having jurisdiction. The chimney should be relined with a listed metal liner, or a Type--B vent shall be
Specifications are subject to change without notice.
19
used to reduce condensation. If a condensate drain is required by local code, refer to the current edition of NFGC
NFPA54/ANSI Z223.1, Section 12.10 for additional information on condensate drains.
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 current edition of
ANSI/NFPA 211 or be lined with a UL listed metal liner or UL
listed Type--B vent. Relining with a listed metal liner or Type--B
vent is considered to be a vent--in--a--chase.
If a metal liner or Type--B vent is used to line a chimney, no other
appliance shall be vented into the annular space between the
chimney and the metal liner.
Exterior Masonry Chimney FAN + NAT
Installations with Type--B Double Wall Vent
Connectors NFPA & AGA
Table 8 – Combined Appliance Maximum Input Rating in
Thousands of BTUH per Hour
VENT HEIGHT
FT. (M)
6 (1.8)
8 (2.4)
10 (3.0)
15 (4.5)
20 (6.0)
30 (9.1)
INTERNAL AREA OF CHIMNEY
IN2 (MM2)
12
(7741)
74
80
84
NR
NR
NR
19
(12258)
119
130
138
152
NR
NR
28
(18064)
178
193
207
233
250
NR
38
(24516)
257
279
299
334
368
404
Table 9 – Minimum Allowable Input Rating of
Space--Heating Appliance in Thousands of BTUH per Hour
INTERNAL AREA OF CHIMNEY
IN2. (MM2)
12
19
28
38
(7741)
(12258) (18064) (24516)
Local 99% Winter Design
Temperature: 17 to 26_F* (---8 to ---3_C)
6 (1.8)
0
55
99
141
8 (2.4)
52
74
111
154
10 (3.0)
NR
90
125
169
15 (4.6)
NR
NR
167
212
20 (6.1)
NR
NR
212
258
30 (9.1)
NR
NR
NR
362
Local 99% Winter Design
Temperature: 5 to 16_F* (---15 to ---9_C)
6 (1.8)
NR
78
121
166
8 (2.4)
NR
94
135
182
10 (3.0)
NR
111
149
198
15 (4.6)
NR
NR
193
247
20 (6.1)
NR
NR
NR
293
30 (9.1)
NR
NR
NR
377
Local 99% Winter Design
Temperature: ---10 to 4_F* (---23 to ---16_C)
6 (1.8)
NR
NR
145
196
8 (2.4)
NR
NR
159
213
10 (3.0)
NR
NR
175
231
15 (4.6)
NR
NR
NR
283
20 (6.1)
NR
NR
NR
333
30 (9.1)
NR
NR
NR
NR
Local 99% Winter Design
Temperature: ---11_F (---24_C) or lower
Not recommended for any vent configuration.
VENT HEIGHT
FT (M)
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
(16_C)db except for brief periods of time during warm--up
from setback at no lower than 55_F (13_C) db or during
initial start--up from a standby condition.
2. Adjust the gas input rate per the installation instructions.
Low gas input rate causes low vent gas temperatures,
causing condensation and corrosion in the furnace and/or
venting system.
3. Adjust the air temperature rise to the midpoint of the rise
range or slightly above. Low air temperature rise can cause
low vent gas temperature and potential for condensation
problems.
4. Set the thermostat heat anticipator or cycle rate to reduce
short cycling.
Air for combustion must not be contaminated by halogen
compounds which include chlorides, fluorides, bromides, and
iodides. These compounds are found in many common home
products such as detergent, paint, glue, aerosol spray, bleach,
cleaning solvent, salt, and air freshener, and can cause corrosion
of furnaces and vents. Avoid using such products in the
combustion--air supply. Furnace use during construction of the
building could cause the furnace to be exposed to halogen
compounds, causing premature failure of the furnace or venting
system due to corrosion.
Vent dampers on any appliance connected to the common vent
can cause condensation and corrosion in the venting system. Do
not use vent dampers on appliances common vented with this
furnace.
*The 99.6% heating db temperatures table found in the Appendix of the
Climatic Design Information chapter of the 2017 ASHRAE Fundamentals
Handbook.
20
Specifications are subject to change without notice.
441 01 1501 04
A180242
Fig. 25 -- Chimney Inspection Chart
441 01 1501 04
Specifications are subject to change without notice.
21
ADDITIONAL VENTING REQUIREMENTS
A 4” (101 mm) round vent elbow is supplied with the furnace. A
5--inch (127 mm) or 6-- inch (152 mm) vent connector may be
required for some model furnaces. A field--supplied
4--inch--to--5--inch (101 -- 127 mm) or 4--inch--to--6--inch (101 -152 mm) sheet metal increaser fitting is required when 5--inch
(127 mm) or 6--inch (152 mm) vent connector is used. See Fig.
26 -- 31 Venting Orientation for approved vent configurations.
NOTE: Vent connector length for connector sizing starts at
furnace vent elbow. The 4--inch vent elbow is shipped for upflow
configuration and may be rotated for other positions. Remove the
3 screws that secure vent elbow to furnace, rotate furnace vent
elbow to position desired, reinstall screws. The factory--supplied
vent elbow does NOT count as part of the number of vent
connector elbows.
The vent connector can exit the furnace through one of two
locations on the casing.
1. Attach the single wall vent connector to the furnace vent
elbow, and fasten the vent connector to the vent elbow
with at least two field--supplied, corrosion--resistant, sheet
metal screws located 180_ apart.
NOTE: An accessory flue extension is available to extend from
the furnace elbow to outside the furnace casing. See Specification
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. 26 -- 31.
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.
!
SIDEWALL VENTING
This furnace is not approved for direct sidewall horizontal
venting.
Per section 12.4.3 of the current edition of NFPA54/ANSI
Z223.1, any listed mechanical venter may be used, when
approved by the authority having jurisdiction.
Select the listed mechanical venter to match the Btuh input of the
furnace being vented. Follow all manufacturer’s installation
requirements for venting and termination included with the listed
mechanical venter.
SEE NOTES: 1,2,4,7,8,9
on the page following
these figures
Fig. 26 -- Upflow Application--Vent Elbow Up
A03208
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.
!
SEE NOTES: 1,2,3,4,7,8,9
on the pages following
these figures
CAUTION
Fig. 27 -- Upflow Application--Vent Elbow Right
BURN HAZARD
A03209
Failure to follow this caution may cause personal injury.
Hot vent pipe is within reach of small children when
installed in downflow position. See the following
instruction.
An accessory Vent Guard Kit is REQUIRED for downflow
applications where the vent exits through the lower portion of the
furnace casing. See Fig. 30 and Specification Sheet for accessory
listing. Refer to the Vent Guard Kit Instructions for complete
details.
The horizontal portion of the venting system shall slope upwards
not less than 1/4--in. per linear ft. (21 mm/M) from the furnace to
the vent and shall be rigidly supported every 5 ft. (2 M) or less
with metal hangers or straps to ensure there is no movement after
installation.
22
SEE NOTES: 1,2,4,7,8,9 on the page
following these figures
A03213
Fig. 28 -- Horizontal Left Application--Vent Elbow Left
Specifications are subject to change without notice.
441 01 1501 04
SEE NOTES: 1,2,4,7,8,9 on the page
following these figures
A03214
Fig. 29 -- Horizontal Right Application--Vent Elbow Right
SEE NOTES: 1,2,4,5,7,8,9 on the page
following these figures
A03215
Fig. 31 -- Horizontal Left Application--Vent Elbow Up
See NOTES following images.
SEE NOTES: 1,2,4,5,6,7,8,9
on the page following these figures
A03207
Fig. 30 -- Downflow Application--Vent Elbow Left then Up
VENTING NOTES FOR FIGURES 26 - 31
1. For common vent, vent connector sizing and vent material: United States----use the NFGC.
2. Immediately increase to 5--inch (127 mm) or 6--inch (152 mm) vent connector outside furnace casing when 5--inch (127 mm) vent connector is required, refer to Note 1
above.
3. Side outlet vent for upflow and downflow installations must use Type B vent immediately after exiting the furnace, except when factory--authorized, Downflow Vent
Guard Kit, is used in the downflow position. See Specification Sheet for accessory listing.
4. Type--B vent where required, refer to Note 1 above.
5. Four--inch single--wall (26 ga. min.) vent must be used inside furnace casing and when the Downflow Vent Guard Kit is used external to the furnace. See Specification
Sheet for accessory listing.
6. Factory--authorized accessory Downflow Vent Guard Kit required in downflow installations with lower vent configuration. See Specification Sheet for accessory listing.
7. Secure vent connector to furnace elbow with (2) corrosion--resistant sheet metal screws, spaced approximately 180_ apart.
8. Secure all other single wall vent connector joints with (3) corrosion resistant screws spaced approximately 120_ apart.
9. Secure Type--B vent connectors per vent connector manufacturer’s recommendations.
START--UP, ADJUSTMENT, AND SAFETY
CHECK
General
!
CAUTION
CUT HAZARD
WARNING
Failure to follow this caution may result in personal injury.
FIRE HAZARD
Failure to follow this warning could result in personal
injury, death and/or property damage.
This furnace is equipped with manual reset limit switches in
the gas control area. The switches open and shut off power
to the gas valve if a flame rollout or overheating condition
occurs in the gas control area. DO NOT bypass the
switches. Correct inadequate combustion air supply
problem before resetting the switches.
441 01 1501 04
!
Sheet metal parts may have sharp edges or burrs. Use care
and wear appropriate protective clothing, safety glasses and
gloves when handling parts and servicing furnaces.
1. Maintain 115--v wiring and ground. Improper polarity will
result in 10 LED flashing 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. 24)
Specifications are subject to change without notice.
23
3. Gas supply pressure to the furnace must be greater than
4.5--In. W.C. (0.16 psig ) but not exceed 14--In. W.C. (0.5
psig).
4. Check all manual--reset switches for continuity.
5. Install blower compartment door. Door must be in place to
operate furnace.
6. Replace outer door.
Start--Up Procedures
!
WARNING
Failure to follow this warning could cause personal injury,
death and/or property damage.
Never test for gas leaks with an open flame. Use a
commercially available soap solution made specifically for
the detection of leaks to check all connections. A fire or
explosion may result causing property damage, personal
injury or loss of life.
1. Purge gas lines after all connections have been made.
2. Check gas lines for leaks.
3. Verify furnace shut down by lowering thermostat setting
below room temperature.
4. Verify furnace restarts by raising thermostat setting above
room temperature.
Adjustments
WARNING
FIRE HAZARD
Failure to follow this warning could result in injury, death
and/or property damage.
DO NOT bottom out gas valve regulator adjusting screw.
This can result in unregulated gas valve outlet pressure and
result in excess overfire and heat exchanger failures.
!
CAUTION
FURNACE DAMAGE HAZARD
Failure to follow this caution may result in reduced furnace
life.
DO NOT redrill orifices. Improper drilling (burrs,
out--of--round holes, etc.) can cause excessive burner noise
and misdirection of inlet gas. (See Fig. 33)
Furnace gas input rate on rating plate is for installations at
altitudes up to 2,000 ft. (610 M). Furnace input rate must be
within +/--2 percent of furnace rating plate input.
1. Determine the correct gas input rate. Refer to the unit
rating plate. The input rating for altitudes above 2,000 ft.
(610 M) must be reduced by 2 percent for each 1,000 ft.
(305 M) above sea level. For installations below 2,000 ft.
(610 M), refer to the unit rating plate. For installation
above 2,000 ft. (610 M), multiply the input on the rating
plate by the derate multiplier in Table 10 for the correct
input rate.
2. Determine the correct outlet gas pressure adjustment.
a. Obtain average yearly gas heat value (at installed altitude)
from local gas supplier.
24
ALTITUDE
(FT. / M)
0–2000 (0--- 610)
2001–3000 (610--- 914)
3001–4000 (914--- 1219)
4001–5000 (1219--- 1524)
5001–5400 (1525--- 1646)
PERCENT
OF
DERATE
0
4--- 6
6--- 8
8--- 10
10--- 11
DERATE
MULTIPLIER
FACTOR*
1.00
0.95
0.93
0.91
0.90
* Derate multiplier factors are based on midpoint altitude for altitude
range.
FIRE AND EXPLOSION HAZARD
!
Table 10 – Altitude Derate Multiplier for U.S.A.
b. Obtain average yearly gas specific gravity from local gas
supplier.
c. Find closest natural gas heat value and specific gravity
in Tables 12 through 15.
d. Follow heat value and specific gravity lines to point of
intersection to find outlet pressure setting for proper
operation.
3. Check Inlet Gas Pressure
The inlet gas pressure must be checked with the furnace
operating. This is necessary to make sure the inlet gas pressure
does not fall below the minimum pressure of 4.5 in. w.c.
a. Make sure the gas supply is turned off to the furnace and
at the electric switch on the gas valve
b. Loosen set screw on inlet tower pressure tap no more than
one full turn with a 3/32− in. hex wrench or remove the
1/8− in. NPT plug from the inlet pressure tap on the gas
valve.
c. Connect a manometer to the inlet pressure tap on gas
valve.
d. Turn on furnace power supply.
e. Turn gas supply manual shutoff valve to ON position.
f. Turn furnace gas valve switch to ON position.
g. Jumper R and W thermostat connections at the furnace
control board.
h. When main burners ignite, confirm inlet gas pressure is
between 4.5 in. W.C. (1125 Pa) and 13.6 in. W.C. (3388
Pa).
i. Remove jumper across thermostat connections to
terminate call for heat. Wait until the blower off delay is
completed.
j. Turn furnace gas valve electric switch to OFF position.
k. Turn gas supply manual shutoff valve to OFF position.
l. Turn off furnace power supply.
m. Remove manometer from the inlet pressure tap of the gas
valve.
n. Tighten set screw on inlet tower pressure tap with
3/32− in. hex wrench, or if 1/8− in. NPT plug was
removed, apply pipe dope sparingly to end of plug and
re− install in the gas valve
!
WARNING
FIRE HAZARD
Failure to follow this warning could result in personal injury,
death, and/or property damage.
Inlet pressure tap set screw must be tightened and 1/8--in.
NPT pipe plug must be installed to prevent gas leaks.
4. Adjust gas valve outlet pressure determined in Step 2. to
obtain correct input rate.
a. Turn gas valve ON/OFF switch to OFF.
Specifications are subject to change without notice.
441 01 1501 04
b. Loosen set screw on outlet tower pressure tap no more
than one full turn with a 3/32 in. hex wrench. (See Fig.
32)
c. Connect a water column manometer or similar device to
pressure tap on the gas valve.
d. Turn gas valve ON/OFF switch to ON.
e. Manually close blower door switch.
f. Set thermostat to call for heat.
g. Remove regulator seal cap and turn regulator adjusting
screw counterclockwise (out) to decrease input rate of
clockwise (in) to increase input rate.
h. Install regulator seal cap.
i. Leave manometer or similar device connected and proceed to next step.
NOTE: If orifice hole appears damaged or it is suspected to have
been redrilled, check orifice hole with a numbered drill bit of
correct size. Never redrill an orifice. A burr--free and properly
sized orifice hole is essential for proper flame characteristics.
5. Verify natural gas input rate by clocking meter.
NOTE: Gas valve regulator adjustment cap must be in place for
proper input to be clocked.
a. Turn off all other gas appliances and pilots served by the
meter.
b. Run furnace for 3 minutes in heating operation.
c. Measure time (in seconds) for gas meter to complete 1
revolution and note reading. The 2 or 5 cubic feet dial
provides a more accurate measurement of gas flow.
d. Refer to Table 11 for cubic ft. of gas per hr.
e. Multiply gas rate (cu ft./hr) by heating value (Btuh/cu ft.)
to obtain input.
If clocked rate does not match required input from Step 1,
increase gas valve outlet pressure to increase input or decrease gas
valve outlet pressure to decrease input. Repeat steps b through e
until correct input is achieved. Reinstall regulator seal cap on gas
valve.
6. Set temperature rise. The furnace must operate within the
temperature rise ranges specified on the furnace rating
plate. Do not exceed temperature rise range specified on
unit rating plate. Determine the temperature rise as
follows:
NOTE: Blower access door must be installed when taking
temperature rise reading. Leaving blower access door off will
result in incorrect temperature measurements.
c.
d.
e.
f.
g.
h.
i.
(2.) Return and supply ducts for excessive restrictions
causing static pressures greater than the maximum
heating static listed on the rating plate.
Adjust air temperature rise by adjusting blower speed. Increase blower speed to reduce temperature rise. Decrease
blower speed to increase temperature rise
Turn thermostat down below room temperature and remove blower access door.
To change motor speed selection for heating, remove
blower motor lead from control HEAT terminal (See
Wiring Diagram -- Fig. 38) Select desired blower motor
speed lead from one of the other terminals and relocate
it to the HEAT terminal (See Table 5 for lead color identification). Reconnect original lead to SPARE terminal.
Repeat steps a through e.
When correct input rate and temperature rise is achieved,
turn gas valve ON/OFF switch to OFF.
Remove manometer or similar device from gas valve.
Tighten set screw on outlet tower pressure tap with 3/32
in. hex wrench.
A180231
!
WARNING
Fig. 32 -- Gas Control Valve
ELECTRICAL SHOCK HAZARD
Failure to follow this warning could result in personal injury
or death.
Disconnect 115--v electrical power and install lockout tag
before changing speed tap.
a. Place thermometers in return and supply ducts as close
to furnace as possible. Be sure thermometers do not see
radiant heat from heat exchangers. Radiant heat affects
temperature rise readings. This practice is particularly important with straight--run ducts.
b. When thermometer readings stabilize, subtract return--air
temperature from supply--air temperature to determine air
temperature rise.
NOTE: If the temperature rise is outside this range, first check:
(1.) Gas input for heating operation.
441 01 1501 04
Specifications are subject to change without notice.
A180238
Fig. 33 -- Orifice Hole
25
!
THERMOSTAT SUBBASE
TERMINALS WITH
THERMOSTAT REMOVED
(ANITICIPATOR, CLOCK, ETC.,
MUST BE OUT OF CIRCUIT.)
WARNING
FIRE HAZARD
HOOK-AROUND
AMMETER
Failure to follow this warning could result in personal
injury, death, and/or property damage.
Gas valve outlet pressure tap must be tightened to prevent
gas leak.
!
R Y W G
CAUTION
FURNACE OVERHEATING HAZARD
Failure to follow this caution may result in reduced furnace
life.
Recheck temperature rise. It must be within limits specified
on the rating plate. Recommended operation is at the
mid--point of rise range or slightly above.
7. Set thermostat heat anticipator.
a. Mechanical thermostat -- Set thermostat heat anticipator
to match the amp. draw of the electrical components in
the R--W 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.) Remove thermostat from subbase or from wall.
(2.) Connect an amp. meter as shown in Fig. 34 across
the R and W subbase terminals or R and W wires at
wall.
(3.) Record amp. draw across terminals when furnace is
in heating and after blower starts.
(4.) Set heat anticipator on thermostat per thermostat instructions and install on subbase or wall.
b. Electronic thermostat: Set cycle rate for 4 cycles per hr.
8. Adjust blower off delay. The blower off delay has four (4)
adjustable settings from 90 seconds to 180 seconds. The
blower off delay jumpers are located on the furnace
control board. (See wiring diagram Fig. 38) Position A--90
seconds, B--120 seconds, C--150 seconds, D--180 seconds.
To change the blower off delay setting, move the jumper
from one set of pins on the control to the pins used for the
selected blower off delay. Factory off delay setting is 120
seconds.
9. Cooling On Delay is fixed at 2 seconds for either jumper
selection.
Check Safety Controls
1. Check Main Limit Switch(es)
This control shuts off combustion control system and energizes air--circulating blower motor, if furnace overheats.
By using this method to check limit control, it can be established that limit is functioning properly and will operate
if there is a restricted duct system or motor failure. If limit
control does not function during this test, cause must be
determined and corrected.
a. Run furnace for at least 5 minutes.
b. Gradually block off return air with a piece of cardboard
or sheet metal until the limit trips.
c. Unblock return air to permit normal circulation for 5
minutes.
d. Reset unit power to clear limit fault lockout.
26
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
Fig. 34 -- Amp. Draw Check With Ammeter
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.
i. Reset unit power to clear limit fault lockout.
Checklist
1. Put away tools and instruments. Clean up debris.
2. Verify blower off delay are set as desired. (See wiring
diagram Fig. 38) Position A--90 seconds, B--120 seconds,
C--150 seconds, D--180 seconds. Factory off delay setting
is 120 seconds.
3. Cooling On Delay is fixed at 2 seconds for either jumper
selection.
4. Verify that blower and burner access doors are properly
installed.
5. Cycle test furnace with room thermostat.
6. Check operation of accessories per manufacturer’s
instructions.
7. Review User’s Guide with owner.
8. Attach literature packet to furnace.
Specifications are subject to change without notice.
441 01 1501 04
2
Cu
Ft.
5 Cu
Ft.
SECONDS
FOR 1
REVOLUTION
1
Cu
Ft.
2
Cu
Ft.
5
Cu
Ft.
10
360
720
1800
50
72
144
360
11
327
655
1636
51
71
141
355
12
300
600
1500
52
69
138
346
13
277
555
1385
53
68
136
340
14
257
514
1286
54
67
133
333
15
240
480
1200
55
65
131
327
16
225
450
1125
56
64
129
321
17
212
424
1059
57
63
126
316
18
200
400
1000
58
62
124
310
19
189
379
947
59
61
122
305
20
180
360
900
60
60
120
300
21
171
343
857
62
58
116
290
22
164
327
818
64
56
112
281
23
157
313
783
66
54
109
273
24
150
300
750
68
53
106
265
25
144
288
720
70
51
103
257
26
138
277
692
72
50
100
250
27
133
267
667
74
48
97
243
28
129
257
643
76
47
95
237
29
124
248
621
78
46
92
231
30
120
240
600
80
45
90
225
31
116
232
581
82
44
88
220
32
113
225
563
84
43
86
214
33
109
218
545
86
42
84
209
34
106
212
529
88
41
82
205
35
103
206
514
90
40
80
200
36
100
200
500
92
39
78
196
37
97
195
486
94
38
76
192
38
95
189
474
96
38
75
188
39
92
185
462
98
37
74
184
40
90
180
450
100
36
72
180
41
88
176
439
102
35
71
178
42
86
172
429
104
35
69
173
43
84
167
419
106
34
68
170
44
82
164
409
108
33
67
167
45
80
160
400
110
33
65
164
46
78
157
391
112
32
64
161
47
76
153
383
116
31
62
155
48
75
150
375
120
30
60
150
49
73
147
367
Tabulated Data Based on 40,000 BTUH Input for 0---ft (0 M)
to 5400---ft (1646 M) above sea level
ALTITUDE
RANGE
ft (m)
0
(0)
U.S.A.
1
Cu
Ft.
to
2000
(610)
2001
(611)
to
3000
(914)
3001
(915)
to
4000
(1219)
4001
(1220)
U.S.A.
Only
SECONDS
FOR 1
REVOLUTION
Table 12 – Gas Valve Outlet Pressure for Gas Heat Values at
Altitude -- 40,000
U.S.A.
SIZE OF TEST DIAL
U.S.A.
Only
Table 11 – Gas Rate (Cu Ft./Hr.)
SIZE OF TEST DIAL
to
5000
(1524)
U.S.A.
Only
5001
(1220)
441 01 1501 04
to
5400
(1646)
Specifications are subject to change without notice.
AVG. GAS
HEAT
VALUE AT
ALTITUDE
(Btu/cu ft)
900
925
950
975
1000
1025
1050
1075
1100
SPECIFIC GRAVITY OF
NATURAL GAS
0.58
0.60
0.62
0.64
Manifold Pressure (in. W.C.)
3.0
3.1
3.2
3.3
2.8
2.9
3.0
3.1
2.7
2.8
2.9
3.0
2.6
2.6
2.7
2.8
2.4
2.5
2.6
2.7
2.3
2.4
2.5
2.5
2.2
2.3
2.4
2.4
2.1
2.2
2.2
2.3
2.0
2.1
2.1
2.2
800
825
850
875
900
925
950
975
1000
3.2
3.0
2.9
2.7
2.6
2.4
2.3
2.2
2.1
3.3
3.1
3.0
2.8
2.6
2.5
2.4
2.3
2.1
3.5
3.3
3.1
2.9
2.7
2.6
2.5
2.3
2.2
3.6
3.4
3.2
3.0
2.8
2.7
2.5
2.4
2.3
775
800
825
850
875
900
925
950
975
1000
3.2
3.0
2.8
2.6
2.5
2.4
2.2
2.1
2.0
1.9
3.3
3.1
2.9
2.7
2.6
2.4
2.3
2.2
2.1
2.0
3.4
3.2
3.0
2.8
2.7
2.5
2.4
2.3
2.2
2.0
3.5
3.3
3.1
2.9
2.8
2.6
2.5
2.3
2.2
2.1
750
775
800
825
850
875
900
925
950
975
1000
3.1
2.9
2.8
2.6
2.4
2.3
2.2
2.1
2.0
1.9
1.8
3.2
3.0
2.9
2.7
2.5
2.4
2.3
2.1
2.0
1.9
1.8
3.4
3.1
2.9
2.8
2.6
2.5
2.3
2.2
2.1
2.0
1.9
3.5
3.2
3.0
2.9
2.7
2.5
2.4
2.3
2.2
2.0
1.9
725
750
775
800
825
850
875
900
925
950
975
1000
3.2
2.9
2.8
2.6
2.4
2.3
2.1
2.0
1.9
1.8
1.7
1.8
3.3
3.0
2.8
2.7
2.5
2.4
2.2
2.1
2.0
1.9
1.8
1.8
3.4
3.1
2.9
2.8
2.6
2.4
2.3
2.2
2.1
1.9
1.8
1.8
3.5
3.3
3.0
2.9
2.7
2.5
2.4
2.2
2.1
2.0
1.9
1.8
27
Table 14 – Gas Valve Outlet Pressure for Gas Heat Values at
Altitude -- 80,000
Tabulated Data Based on 60,000 BTUH Input for 0---ft (0 M)
to 5400---ft (1646 M) above sea level
AVG. GAS
SPECIFIC GRAVITY OF
HEAT
ALTITUDE
NATURAL GAS
VALUE AT
RANGE
0.58
0.60
0.62
0.64
ALTITUDE
ft (m)
(Btu/cu ft)
Manifold Pressure (in. W.C.)
900
2.7
2.8
2.9
2.9
0
925
2.5
2.6
2.7
2.8
(0)
950
2.4
2.5
2.6
2.6
975
2.3
2.3
2.4
2.5
to
1000
2.2
2.2
2.3
2.4
1025
2.0
2.1
2.2
2.3
2000
1050
1.9
2.0
2.1
2.2
(610)
1075
1.9
1.9
2.0
2.1
1100
1.8
1.8
1.9
2.0
Tabulated Data Based on 80,000 BTUH Input, for 0---ft (0 M)
to 5400---ft (1646 M) above sea level
AVG. GAS
SPECIFIC GRAVITY OF
HEAT
ALTITUDE
NATURAL GAS
VALUE AT
RANGE
0.58
0.60
0.62
0.64
ALTITUDE
ft (m)
(Btu/cu ft)
Manifold Pressure (in. W.C.)
U.S.A.
Only
3000
(914)
3001
(915)
to
4000
(1219)
U.S.A.
Only
4001
(1220)
to
5000
(1524)
U.S.A.
Only
5001
(1524)
28
to
5400
(1646)
3.0
2.8
2.6
2.5
2.4
2.2
2.1
2.0
1.9
3.1
2.9
2.7
2.6
2.4
2.3
2.2
2.1
2.0
3.1
3.0
2.8
2.7
2.5
2.4
2.2
2.1
2.0
775
800
825
850
875
900
925
950
975
1000
2.8
2.7
2.5
2.4
2.2
2.1
2.0
1.9
1.8
1.8
2.9
2.8
2.6
2.4
2.3
2.2
2.0
1.9
1.8
1.8
3.0
2.9
2.7
2.5
2.4
2.2
2.1
2.0
1.9
1.8
3.1
2.9
2.8
2.6
2.5
2.3
2.2
2.1
2.0
1.9
750
775
800
825
850
875
900
925
950
975
1000
2.8
2.6
2.5
2.3
2.2
2.0
1.9
1.8
1.8
1.8
1.8
2.9
2.7
2.5
2.4
2.2
2.1
2.0
1.9
1.8
1.8
1.8
3.0
2.8
2.6
2.5
2.3
2.2
2.1
2.0
1.8
1.8
1.8
3.1
2.9
2.7
2.5
2.4
2.3
2.1
2.0
1.9
1.8
1.8
725
750
775
800
825
850
875
900
925
950
975
1000
2.8
2.6
2.4
2.3
2.1
2.0
1.9
1.8
1.8
1.8
1.8
1.8
2.9
2.7
2.5
2.3
2.2
2.1
1.9
1.8
1.8
1.8
1.8
1.8
3.0
2.8
2.6
2.4
2.3
2.1
2.0
1.9
1.8
1.8
1.8
1.8
3.0
2.8
2.7
2.5
2.3
2.2
2.1
2.0
1.9
1.8
1.8
1.8
U.S.A.
2001
(611)
U.S.A.
2.9
2.7
2.6
2.4
2.3
2.1
2.0
1.9
1.8
to
3000
(914)
U.S.A.
Only
to
800
825
850
875
900
925
950
975
1000
to
2000
(610)
3001
(915)
to
4000
(1219)
4001
(1220)
U.S.A.
Only
U.S.A.
2001
(611)
0
(0)
to
5000
(1524)
5001
(1524)
U.S.A.
Only
U.S.A.
Table 13 – Gas Valve Outlet Pressure for Gas Heat Values at
Altitude -- 60,000
to
5400
(1646)
Specifications are subject to change without notice.
900
925
950
975
1000
1025
1050
1075
1100
2.8
2.6
2.5
2.4
2.3
2.1
2.0
1.9
1.9
2.9
2.7
2.6
2.5
2.3
2.2
2.1
2.0
1.9
3.0
2.8
2.7
2.5
2.4
2.3
2.2
2.1
2.0
3.1
2.9
2.8
2.6
2.5
2.4
2.3
2.1
2.1
800
825
850
875
900
925
950
975
1000
3.0
2.8
2.7
2.5
2.4
2.2
2.1
2.0
1.9
3.1
2.9
2.8
2.6
2.5
2.3
2.2
2.1
2.0
3.1
3.0
2.9
2.7
2.5
2.4
2.3
2.2
2.1
3.1
3.1
3.0
2.8
2.6
2.5
2.4
2.2
2.1
775
800
825
850
875
900
925
950
975
1000
3.0
2.8
2.6
2.5
2.3
2.2
2.1
2.0
1.9
1.8
3.1
2.9
2.7
2.6
2.4
2.3
2.1
2.0
1.9
1.8
3.1
3.0
2.8
2.6
2.5
2.3
2.2
2.1
2.0
1.9
3.1
3.1
2.9
2.7
2.6
2.4
2.3
2.2
2.1
2.0
750
775
800
825
850
875
900
925
950
975
1000
2.9
2.7
2.6
2.4
2.3
2.1
2.0
1.9
1.8
1.8
1.8
3.0
2.8
2.7
2.5
2.4
2.2
2.1
2.0
1.9
1.8
1.8
3.1
2.9
2.8
2.6
2.4
2.3
2.2
2.0
1.9
1.8
1.8
3.1
3.0
2.8
2.7
2.5
2.4
2.2
2.1
2.0
1.9
1.8
725
750
775
800
825
850
875
900
925
950
975
1000
2.9
2.7
2.5
2.4
2.2
2.1
2.0
1.9
1.8
1.8
1.8
1.8
3.0
2.8
2.6
2.4
2.3
2.2
2.0
1.9
1.8
1.8
1.8
1.8
3.1
2.9
2.7
2.5
2.4
2.2
2.1
2.0
1.9
1.8
1.8
1.8
3.1
3.0
2.8
2.6
2.5
2.3
2.2
2.1
1.9
1.8
1.8
1.8
441 01 1501 04
Table 15 – Gas Valve Outlet Pressure for Gas Heat Values at
Altitude -- 100,000
U.S.A.
Only
U.S.A.
Only
U.S.A.
U.S.A.
Tabulated Data Based on 100,000 BTUH Input for 0---ft (0 M)
to 5400---ft (1646 M) above sea level
AVG. GAS
0.58
0.60
0.62
0.64
HEAT
ALTITUDE
VALUE AT
RANGE
ALTITUDE
ft (m)
Manifold Pressure (in. W.C.)
(Btu/cu ft)
900
3.3
3.4
3.5
3.6
0
925
3.1
3.2
3.3
3.4
(0)
950
2.9
3.0
3.1
3.2
975
2.8
2.9
3.0
3.1
to
1000
2.6
2.7
2.8
2.9
1025
2.5
2.6
2.7
2.8
2000
1050
2.4
2.5
2.6
2.6
(610)
1075
2.3
2.4
2.4
2.5
1100
2.2
2.3
2.3
2.4
800
3.5
3.7
3.8
3.9
2001
825
3.3
3.4
3.6
3.7
(611)
850
3.1
3.2
3.3
3.5
875
3.0
3.1
3.2
3.3
to
900
2.8
2.9
3.0
3.1
925
2.6
2.7
2.8
2.9
3000
950
2.5
2.6
2.7
2.8
(914)
975
2.4
2.5
2.5
2.6
1000
2.3
2.3
2.4
2.5
775
3.5
3.6
3.7
3.8
800
3.3
3.4
3.5
3.6
3001
825
3.1
3.2
3.3
3.4
(915)
850
2.9
3.0
3.1
3.2
to
875
2.7
2.8
2.9
3.0
900
2.6
2.7
2.8
2.8
4000
925
2.4
2.5
2.6
2.7
(1219)
950
2.3
2.4
2.5
2.6
975
2.2
2.3
2.3
2.4
1000
2.1
2.2
2.2
2.3
750
3.4
3.5
3.7
3.8
775
3.2
3.3
3.4
3.5
4001
800
3.0
3.1
3.2
3.3
(1220)
825
2.8
2.9
3.0
3.1
850
2.7
2.8
2.9
2.9
to
875
2.5
2.6
2.7
2.8
900
2.4
2.5
2.5
2.6
5000
925
2.3
2.3
2.4
2.5
(1524)
950
2.1
2.2
2.3
2.4
975
2.0
2.1
2.2
2.2
1000
1.9
2.0
2.1
2.1
U.S.A.
Only
5001
(1524)
to
5400
(1646)
725
750
775
800
825
850
875
900
925
950
975
1000
3.4
3.2
3.0
2.8
2.6
2.5
2.4
2.2
2.1
2.0
1.9
1.8
3.6
3.3
3.1
2.9
2.7
2.6
2.4
2.3
2.2
2.1
1.9
1.9
3.7
3.4
3.2
3.0
2.8
2.7
2.5
2.4
2.2
2.1
2.0
1.9
3.8
3.6
3.3
3.1
2.9
2.8
2.6
2.5
2.3
2.2
2.1
2.0
SERVICE AND MAINTENANCE
PROCEDURES
Untrained personnel can perform basic maintenance functions
such as cleaning and replacing air filters. All other operations
must be performed by trained service personnel. A qualified
service person should inspect the furnace once a year.
!
WARNING
FIRE, INJURY, OR DEATH HAZARD
Failure to follow this warning could result in personal
injury, death and/or property damage.
The ability to properly perform maintenance on this
equipment requires certain knowledge, mechanical skills,
tools, and equipment. If you do not possess these, do not
attempt to perform any maintenance on this equipment
other than those procedures recommended in the User’s
Manual.
!
WARNING
ELECTRICAL SHOCK, FIRE OR EXPLOSION
HAZARD
Failure to follow this warning could result in personal
injury or death.
Before installing, modifying, or servicing system, main
electrical disconnect switch must be in the OFF position and
install a lockout tag. There may be more than one
disconnect switch. Lock out and tag switch with a suitable
warning label. Verify proper operation after servicing.
!
CAUTION
ELECTRICAL OPERATION HAZARD
Failure to follow this caution may result in improper
furnace operation or failure of furnace.
Label all wires prior to disconnection when servicing
controls. Wiring errors can cause improper and dangerous
operation.
INTRODUCTION
GENERAL
These instructions are written as if the furnace is installed in an
upflow application. An upflow furnace application is where the
blower is located below the combustion and controls section of
the furnace, and conditioned air is discharged upward. Since this
furnace can be installed in any of the 4 positions shown in Fig. 4,
you must revise your orientation to component location
accordingly.
ELECTRICAL CONTROLS AND WIRING
!
WARNING
ELECTRICAL OPERATION HAZARD
Failure to follow this warning could result in personal
injury or death.
There may be more than one electrical supply to the
furnace. Check accessories and cooling unit for additional
electrical supplies that must be shut off during furnace
servicing. Lock out and tag switch with a suitable warning
label.
441 01 1501 04
Specifications are subject to change without notice.
29
The electrical ground and polarity for 115--v wiring must be
properly maintained. Refer to Fig. 24 for field wiring information
and to Fig. 38 for furnace wiring information.
NOTE: If the polarity is not correct, the STATUS LED on the
control will flash 10 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. 38) 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 be OFF 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. The furnace control LED is either Heartbeat, 10
or displaying 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. 35 and the Service guide at the end
of this manual.
See Fig. 35 for a summary of fault codes and a brief explanation
of fault codes.
The stored status code will not be erased from the control
memory, if 115-- or 24--v power is interrupted.
1. To retrieve status code, proceed with the following:
NOTE: NO thermostat signal may be present at control, and all
blower--OFF delays must be completed.
a. Remove outer access door.
b. Remove inner blower door.
c. Close blower door interlock switch.
d. Using a length of wire, briefly short the TEST/TWIN
terminal to the C terminal on the furnace control.
2. When above items have been completed, the LED flashes
the fault code history (up to 5 fault codes from newest to
oldest). Record the status code(s) for further troubleshooting.
3. Check LED status. If no previous faults in the history,
control will flash heartbeat.
4. Component self--test will begin. Refer to Component Test
section of service label for complete test sequence.
A190413
Fig. 35 -- Service Label
CARE AND MAINTENANCE
!
For continuing high performance and to minimize possible
equipment failure, periodic maintenance must be performed on
this equipment. Consult your local dealer about proper frequency
of maintenance and the availability of a maintenance contract.
WARNING
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.
30
!
WARNING
ELECTRICAL SHOCK AND FIRE HAZARD
Failure to follow this warning could result in personal
injury, death or property damage.
Turn off the gas and electrical supplies to the unit and
install lockout tag before performing any maintenance
or service. Follow the operating instructions on the label
attached to the furnace.
Specifications are subject to change without notice.
441 01 1501 04
BLOWER MOTOR AND WHEEL
WARNING
!
!
CARBON MONOXIDE POISONING AND
FIRE HAZARD
Failure to follow this warning could result in personal
injury, death and/or property damage.
Never operate unit without a filter or with filter access door
removed.
CAUTION
!
CUT HAZARD
Failure to follow this caution may result in personal injury.
Sheet metal parts may have sharp edges or burrs. Use care
and wear appropriate protective clothing, safety glasses and
gloves when handling parts and servicing furnaces.
The minimum maintenance on this furnace is as follows:
1. Check and clean/replace air filter each month or more frequently if required. Replace if torn.
2. Check burner inlet elbow opening for cleanliness and any
visible debris. Burner assembly removal should only be
performed for troubleshooting and diagnosis of operational issues. Refer to troubleshooting and service guide.
3. Check blower motor and wheel for cleanliness each
heating and cooling season. Clean as necessary.
4. Check electrical connections for tightness and controls for
proper operation each heating season. Service as
necessary.
5. Inspect the vent pipe/vent system before each heating
season for rust, corrosion, water leakage, sagging pipes or
broken fittings. Have vent pipes/vent system serviced by a
qualified service agency.
6. Inspect any accessories attached to the furnace such as a
humidifier or electronic air cleaner. Perform any service or
maintenance to the accessories as recommended in the
accessory instructions.
CLEANING AND/OR REPLACING AIR FILTER
The air filter arrangement will vary depending on the application.
The filter is exterior to the furnace casing.
NOTE: If the filter has an airflow direction arrow, the arrow
must point towards the blower.
Table 16 – Filter Size Information (In. / mm)
FURNACE
CASING
WIDTH
In. (mm)
17 ---1/2
(445)
21 (533)
FILTER SIZE (In. / mm)
Side Return
Bottom Return
16 X 25 X 3/4
(406 x 635 x 19)
16 x 25 x 3/4
(406 x 635 x 19)
16 X 25 X 3/4
(406 x 635 x 19)
20 X 25 X 3/4
(508 x 635 x 19)
* Recommended
441 01 1501 04
FILTER
TYPE
Washable*
Washable*
WARNING
ELECTRICAL SHOCK HAZARD
Failure to follow this warning could result in personal injury
or death.
Blower access door switch opens 115--v power to control.
No component operation can occur unless switch is closed.
Caution must be taken when manually closing this switch
for service purposes.
NOTE: The blower wheel should not be dropped or bent as
balance will be affected. The following steps should be performed
by a qualified service agency.
To ensure long life and high efficiency, clean accumulated dirt
and grease from blower wheel and motor annually.
The inducer and blower motors are pre--lubricated and require no
additional lubrication. These motors can be identified by the
absence of oil ports on each end of the motor.
Clean blower motor and wheel as follows:
1. Turn off electrical supply to furnace.
2. Remove outer door.
3. Remove two screws from blower access door and remove
blower access door.
4. All factory wires can be left connected, but field thermostat connections may need to be disconnected depending
on their length and routing.
5. Remove two screws holding blower assembly to blower
deck and slide blower assembly out of furnace.
6. Clean blower wheel and motor using a vacuum with soft
brush attachment. Blower wheel blades may be cleaned
with a small paint or flux brush. Do not remove or disturb
balance weights (clips) on blower wheel blades.
7. Vacuum any loose dust from blower housing, wheel and
motor.
8. If a greasy residue is present on blower wheel, remove
wheel from the blower housing and wash it with an appropriate degreaser. To remove wheel:
NOTE: Before disassembly, mark blower motor, and blower
housing so motor and each arm is positioned at the same location
during reassembly.
a. Disconnect power choke wires (if used) and ground wire
attached to blower housing.
b. Remove screws securing cutoff plate and remove cutoff
plate from housing.
c. Loosen set screw holding blower wheel on motor shaft
(160+/--20 in.--lb. when reassembling).
d. Remove bolts holding motor to blower housing and slide
motor out of wheel (40+/--10 in.--lb. when reassembling).
e. Remove blower wheel from housing.
f. Clean wheel and housing.
9. Reassemble motor and blower by reversing steps 8f
finishing with 8a. Be sure to reattach ground wire to the
blower housing.
10. Verify that blower wheel is centered in blower housing
and set screw contacts the flat portion of the motor shaft.
Loosen set screw on blower wheel and reposition if necessary.
Specifications are subject to change without notice.
31
11. Spin the blower wheel by hand to verify that the wheel
does not rub on the housing.
12. Reinstall blower assembly in furnace.
13. Reinstall two screws securing blower assembly to blower
deck.
!
CAUTION
UNIT DAMAGE HAZARD
Failure to follow this caution may result in shortened heat
exchanger life.
Heating fan speed(s) MUST be adjusted to provide proper
air temperature rise as specified on the rating plate.
Recommended operation is at the midpoint of the rise range
or slightly above. Refer to “SET TEMPERATURE RISE”
under START--UP, ADJUSTMENT, and SAFETY
CHECK.
NOTE: Refer to Table 5 for motor speed lead relocation if leads
were not identified before disconnection.
14. Refer to furnace wiring diagram, and connect thermostat
leads if previously disconnected.
15. To check blower for proper rotation:
a. Turn on electrical supply.
!
WARNING
ELECTRICAL SHOCK HAZARD
Failure to follow this warning could result in personal
injury, or death.
Blower access door switch opens 115--v power to
furnace control. No component operation can occur
unless switch is closed. Exercise caution to avoid
electrical shock from exposed electrical components
when manually closing this switch for service purposes.
b. Manually close blower access door switch.
c. Verify blower is rotating in the correct direction.
16. If furnace is operating properly, RELEASE BLOWER
ACCESS DOOR SWITCH. Remove any jumpers or
reconnect any disconnected thermostat leads. Replace
blower access door.
17. Reinstall outer door.
18. Cycle furnace through one complete heating and cooling
cycle. Verify the furnace temperature rise as shown in
“Adjustments” Section. Adjust temperature rise as shown
in “Adjustments” Section. If outdoor temperature is below
70_F, (21_C) turn off circuit breaker to outdoor unit before running furnace in the cooling cycle. Turn outdoor
circuit breaker on after completing cooling cycle.
FLAME SENSOR CLEANING AND SERVICING
IGNITOR
Cleaning Flame Sensor
The following items must be performed by a qualified service
technician. If the flame sensor develops an accumulation of light
dirt or dust, it may be cleaned by using the following procedure:
32
!
WARNING
ELECTRICAL SHOCK AND FIRE HAZARD
Failure to follow this warning could result in personal injury,
death, and/or property damage.
Turn off the gas and electrical supplies to the furnace and
install lockout tag before performing any maintenance or
service. Follow the operating instructions on the label
attached to the furnace.
Refer to Fig. 36.
1. Disconnect power at external disconnect, fuse or circuit
breaker.
2. Turn off gas at external shut-off or gas meter.
3. Remove control door and set aside.
4. Turn electric switch on gas valve to OFF.
5. Disconnect Flame Sensor wire from Flame Sensor.
6. Remove the flame sensor from the burner assembly.
7. (Optional) Remove the Hot Surface Ignitor (HSI) and
bracket with ignitor gasket from the burner assembly.
8. Check ignitor resistance. Nominal resistance is 40 to 70
ohms at room temperature and is stable over the life of the
ignitor.
9. Clean the flame sensor with fine steel wool (0000 grade).
Do not use sand paper or emery cloth.
To reinstall ignitor and flame sensor:
1. Install the Hot Surface Ignitor (HSI) and bracket with
ignitor gasket into burner assembly.
2. Install flame sensor into burner assembly.
3. When installing the HSI and flame sensor, ¼” screws that
are the same size of those removed must be used. Do not
use longer screws.
NOTE: If insulation assembly is damaged, do not attempt to
repair, must be replaced with insulation kit.
NOTE: Proper use of Personal Protective Equipment (PPE)
must be followed, including safety glasses, gloves, and dust mask
when removing and reinstalling the heat exchanger insulation
assembly.
4. Connect the wire for the flame sensor.
5. Connect the wire for the Hot Surface Ignitor.
!
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.
6. Turn gas on at electric switch on gas valve and at external
shut-off or meter
7. Turn power on at external disconnect, fuse or circuit
breaker.
8. Run the furnace through two complete heating cycles to
check for proper operation
9. Install control door when complete.
Specifications are subject to change without notice.
441 01 1501 04
CLEANING HEAT EXCHANGER
The following steps should be performed by a qualified
service agency:
NOTE: If the heat exchangers get a heavy accumulation of soot
and carbon, they should be replaced rather than trying to clean
them thoroughly. A heavy build--up of soot and carbon indicates
that a problem exists which needs to be corrected, such as
improper adjustment of gas valve outlet pressure, insufficient or
poor quality combustion air, incorrect size or damaged orifice(s),
improper gas, or a restricted heat exchanger. Action must be taken
to correct the problem.
If it becomes necessary to clean the heat exchangers because of
dust or corrosion, proceed as follows:
1. Turn OFF gas and electrical power to furnace.
2. Remove outer access door.
3. Disconnect vent connector from furnace vent elbow.
4. Disconnect wires to the following components. Mark
wires to aid in reconnection of (be careful when disconnecting wires from switches because damage may occur):
a. Inducer motor
b. Transducer
c. Limit over--temperature switch
d. Gas valve
e. Hot surface ignitor
f. Flame--sensing electrode
g. Burner thermal switch
h. DSS Draft Safeguard
5. Remove screws that fasten the inducer cover assembly to
the cell panel. Be careful not to damage the collector box.
Inducer assembly and elbow need not be removed from
collector box.
6. Disconnect gas supply line from gas valve.
7. Remove screws that attach the burner assembly to the cell
panel. The gas valve and burners tube need not be removed from burner box.
NOTE: Be very careful when removing burner assembly to
avoid breaking ignitor.
8. Remove insulation assembly from burner tube inlets.
NOTE: Proper use of Personal Protective Equipment (PPE)
must be followed, including safety glasses, gloves, and dust mask
when removing and reinstalling the heat exchanger insulation
assembly.
9. Using field--provided large caliber rifle cleaning brush,
36--in. (914 mm) long steel spring cable, a variable speed,
reversible electric drill, and vacuum cleaner, clean cells as
follows:
NOTE: The materials needed in item 9. can usually be
purchased at local hardware stores.
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.
441 01 1501 04
A180230
Fig. 36 -- Ignitor Position
(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. 37)
(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 two lower passes of cell
in same manner as upper pass.
(5.) Repeat foregoing procedures until each cell in
furnace has been cleaned.
(6.) Using vacuum cleaner, remove residue from each
cell.
(7.) Using vacuum cleaner with soft brush attachment,
clean burner assembly.
(8.) Clean flame sensor with fine steel wool.
(9.) Reinstall the insulation assembly.
NOTE: If insulation assembly is damaged, do not attempt to
repair, must be replaced with insulation kit.
NOTE: Proper use of Personal Protective Equipment (PPE)
must be followed, including safety glasses, gloves, and dust mask
when removing and reinstalling the heat exchanger insulation
assembly.
(10.) Reinstall burner assembly.
10. Remove old sealant from cell panel and collector box
flange.
11. Spray releasing agent on the heat exchanger cell panel
where inducer cover assembly contacts cell panel.
NOTE: A releasing agent such as cooking spray or equivalent
(must not contain corn or canola oil, aromatic or halogenated
hydrocarbons or inadequate seal may occur) and RTV sealant
(G.E. 162, 6702, or Dow--Corning 738) are needed before
starting installation.
NOTE: DO NOT substitute any other type of RTV sealant.
12. Apply new sealant to flange of collector box and attach to
cell panel using existing screws, making sure all screws
are secure.
13. Reconnect wires to the following components. (Use
connection diagram on wiring label, if wires were not
marked for reconnection locations.):
a. Burner thermal switch
b. Inducer motor
c. Transducer
Specifications are subject to change without notice.
33
14.
15.
16.
17.
18.
19.
d. Limit over--temperature switch
e. Gas valve
f. Hot surface ignitor
g. Flame--sensing electrode
h. DSS Draft Safeguard
Reinstall vent connector on furnace vent elbow. Securely
fasten vent connector to vent elbow with two (2)
field--supplied, corrosion--resistant, sheet metal screws
located 180_ apart.
Replace blower access door only, if it was removed.
Set thermostat above room temperature and check furnace
for proper operation.
Verify blower airflow and speed changes between heating
and cooling.
Check for gas leaks.
Replace outer access door.
Representative drawing only, some models may vary in appearance.
A190291
Fig. 37 -- Cleaning Heat Exchanger Cell
!
WARNING
FIRE OR EXPLOSION HAZARD
Failure to follow this warning could result in personal injury,
death and/or property damage.
Never purge a gas line into a combustion chamber. Never
test for gas leaks with an open flame. Use a commercially
available soap solution made specifically for the detection of
leaks to check all connections.
SEQUENCE OF OPERATION
NOTE: Furnace control must be grounded for proper operation
of furnace control and flame sensing electrode. Control is
grounded through green/yellow wire routed to gas valve and
burner box screw. Using the schematic diagram in Fig. 38, 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,
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 LED light will flash 1+2 during the 90--second
period, after which the LED will flash heartbeat (bright--dim), as
long as no faults are detected. After the 90--second blower--on
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 ignitor HSI, and gas valve GV.
34
Sequence of Operation -- Heating
1. Call for Heat:
The wall thermostat “calls for heat”, closing the R-W
circuit. The furnace control performs a self--check, verifies
the transducer reads no pressure present, and starts the
inducer motor IDM ramp to prepurge
a. Inducer Prepurge Period: The furnace control CPU
ramps up the inducer motor IDM to prepurge pressure
then the furnace control CPU begins a 15--second
prepurge period. If the transducer fails to reach target
pressure the inducer motor IDM will remain running until
target pressure is maintained.
b. Ignitor Warm--Up: At the end of the prepurge period,
the Hot--Surface Ignitor HSI is energized for a 17--second
ignitor warm--up period. Inducer maintains pressure
during ignitor warm--up.
c. Trial for Ignition: When the ignitor warm--up period is
completed the main gas valve relay contact GVR closes
to energize the gas valve solenoid GV. The gas valve
solenoid GV 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 ignitor
will remain energized until the flame is sensed or until the
2--second flame proving period begins.
d. Flame Proving: When the burner flame is proved at the
flame sensor electrode FSE, the inducer motor IDM will
increase speed (after a short delay of 14 seconds on some
models) to a higher RUN pressure. The control will
maintain this pressure once reached, and the furnace
control CPU will begin the blower--ON delay period
while continuing to hold the gas valve GV open. If the
burner flame is not proved within the 2--second flame
proving period, the control CPU will open the gas valve
relay GVR, de--energizing the gas valve solenoid GV.
The control CPU will repeat the ignition sequence for up
to three more Trials--For--Ignition before going to an
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, G,
R, etc.). If flame is proved when flame should not be
present, the furnace control CPU will lock out of Heating
mode and operate the inducer motor IDM until flame is
no longer proved.
e. Blower-On-Delay: If the burner flame is proven a
25--second blower--ON delay begins from when the gas
valve GV is opened. The blower motor BLWM is turned
ON at heat airflow. Simultaneously, the humidifier
terminal HUM and electronic air cleaner terminal EAC--1
are energized and remain energized throughout the
heating cycle.
f. Blower-Off-Delay: When the thermostat is satisfied, the
R to W circuit is opened, de--energizing the gas valve GV,
stopping gas flow to the burners, and de--energizing the
humidifier terminal HUM. The inducer motor IDM will
remain energized for a 15--second post--purge period.
The blower motor BLWM and air cleaner terminal
EAC--1 will remain energized at heat airflow for 90, 120,
150, or 180 seconds (depending on selection at
blower--OFF delay switches). The furnace control CPU
is factory--set for a 120--second blower--OFF delay.
2. Cooling Mode
The thermostat closes the R-G and -Y circuit for cooling.
The R-Y circuit starts the outdoor unit on cooling speed,
and the R-G and -Y circuit starts the furnace blower motor
BLWM at cooling airflow. Cooling airflow (Table 5) is
based on the motor wire lead selection used on the COOL
terminal. The electronic air cleaner terminal EAC--1 is
energized with 115 vac whenever the blower motor
Specifications are subject to change without notice.
441 01 1501 04
BLWM is operating. When the thermostat is satisfied, the
R-G and -Y circuit is 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. Remove J2 Jumper to reduce the cooling
off--delay to 5 seconds. (See Fig. 38)
3. Continuous Blower Mode
When the R-G circuit is closed by the thermostat, the
blower motor BLWM will operate at FAN tap (See Fig.
38). 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 FAN tap. 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
HEAT tap. The blower motor BLWM will revert to FAN
tap after the heating cycle blower off--delay is completed.
When the thermostat “calls for cooling”, the blower motor
BLWM will switch to operate at COOL tap. When the
thermostat is satisfied, the blower motor BLWM will
operate an additional 90 seconds at cooling airflow before
transitioning back to FAN tap. When the R-G circuit is
opened, the blower motor BLWM will continue operating
for an additional 5 seconds, if no other function required
blower motor BLWM operation.
4. Heat Pump: When installed with a heat pump, the
furnace control automatically changes the timing sequence
to avoid long blower off times during demand defrost
cycles. Whenever the R-Wcircuit is closed along with the
R-Y circuit, the furnace control CPU will transition to or
bring on the blower motor BLWM at COOL tap. 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 HEAT tap. When the
R-W connection is opened, the furnace control begins a
normal inducer post--purge period while changing the
blower airflow. If R-Y circuit is still closed, the furnace
control CPU will transition the blower motor BLWM
airflow to COOL tap. If R-G circuit is open, the blower
motor BLWM will remain on HEAT tap for the selected
blower--OFF delay period. At the end of the blower--OFF
441 01 1501 04
delay, the blower motor BLWM will shut OFF unless R-G
is circuit is closed, in which case the blower motor BLWM
will operate at FAN tap.
5. Component Test: The furnace features a component test
feature to help diagnose a system problem in the case of a
component failure. To initiate the component test
sequence, shut OFF the room thermostat or disconnect the
R thermostat lead. Briefly short the TEST/TWIN terminal
to the C terminal. Status LED will flash most recent code 4
times and then turn ON the inducer motor.
The inducer motor will run for the entire component test.
The hot surface ignitor, blower motor fan speed, blower
motor--heat speed, and blower motor--cool speed will be
turned ON for 10--15 seconds each. Gas Valve and
Humidifier will not be turned on. (See Fig. 38).
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:
Sequence of Operation -- Fan Only
1. Inducer relay ON 50% ULN80 for 15 seconds then
proceed to Step 2. Inducer to remain ON throughout the
test.
2. HSI relay ON for 15 sec., then OFF.
3. Blower motor FAN Speed for 10 sec., then OFF.
4. Blower motor HEAT Speed for 10 sec., then OFF.
5. Blower motor COOL Speed for 10 sec., then OFF.
6. Inducer OFF, end of test
NOTE: The EAC terminals are energized when the blower is
operating.
Wiring Diagrams
Refer to Fig. 38 for wiring diagram.
Troubleshooting
Refer to the service label. (Fig. 35), wiring diagram (Fig. 38), and
the Service Guide (Page 37) can be a useful tool in isolating
furnace operation problems. The Guide will help to identify the
problem or failed component. After replacing any component,
verify correct operation sequence.
Specifications are subject to change without notice.
35
A190414
Fig. 38 -- Wiring Diagram
36
Specifications are subject to change without notice.
441 01 1501 04
SERVICE GUIDE
LED CODES
STATUS
CONTINUOUS OFF
Check for 115VAC at L1 and L2, and 24VAC at SEC--1 and SEC--2.
HEARTBEAT
Control has 24VAC power.
10
Line voltage (115VAC) polarity reversed.
If status code recall is needed, briefly (2--3 seconds) remove then reconnect one main limit wire to display stored status code. After status code
recall is completed test will occur.
EACH OF THE FOLLOWING STATUS CODES IS A SINGLE OR TWO DIGIT NUMBER WITH THE FIRST DIGIT DETERMINED BY THE
NUMBER OF SHORT FLASHES AND THE SECOND DIGIT AFTER THE PLUS (+) SIGN IS THE NUMBER OF LONG FLASHES.
LED ACTIVITY (CFH = Call for Heat)
Heartbeat
NO PREVIOUS CODE - Stored status codes are erased automatically after 72 hours or as specified above.
1+2
BLOWER ON AFTER POWER UP (115VAC or 24VAC) - Blower runs for 90 seconds, if unit is powered up during a call for heat (R-- W closed)
or (R-- W opens) during a blower on-- delay period.
7
LIMIT CIRCUIT LOCKOUT - Lockout occurs if a limit, draft safeguard, burner thermal switch or blocked vent switch (if used) is open.
Control will auto-- reset after three hours. Check for:
- Loose blower wheel
- Restricted vent
- Proper vent sizing
- Excess wind
- Dirty filter or restricted duct system
- Defective switch or connections
- Inadequate combustion air supply (Burner thermal switch open)
6+1
IGNITION LOCKOUT - Control will auto-- reset after three hours. Refer to status code #34.
8
GAS HEATING LOCKOUT - Control will NOT auto-- reset. Check for:
- Mis-- wired gas valve
- Defective control (valve relay)
- 24VAC sensed at gas valve when should not be present
5
ABNORMAL FLAME - PROVING SIGNAL - Flame is provided while gas valve is de-- energized, inducer will run until fault is cleared. Check
for:
- Leaky gas valve
- Stuck-- open gas valve
2
PRESSURE > 0.15” w.c. AT START-- UP. Check for:
- Obstruction in pressure tubing or Transducer vent holes
- Defective Transducer
- Transducer wiring
OFF
SECONDARY VOLTAGE FUSE IS OPEN. Check for:
- Short circuit in secondary voltage (24VAC) wiring
2+5
INVALID MODEL SELECTION OR SETUP ERROR - Indicated either the model plug is missing or incorrect. If code flashes 4 times on
power-- up control is defaulting to model selection stored in memory
3
PRESSURE TRANSDUCER INPUT DOES NOT SENSE TARGET PRESSURE OR PRESSURE IS OUT OF RANGE. Check for:
- Excessive wind
- Proper vent sizing
- Restricted vent
- Defective inducer motor
- Inadequate combustion air supply
- Defective pressure transducer
- Low inlet gas pressure (if LGPS used)
- Low inducer voltage (115VAC)
- Disconnected or obstructed pressure tubing
6
IGNITION PROVING FAILURE - Control will try ignition four times before lockout #14 occurs. If flame signal lost during blower on-- delay
period, blower will come on for the selected blower off-- delay. Check for:
- Oxide buildup on flame sensor (clean with fine steel wool)
- Proper flame sense microamps (.5 microamps D.C. Min., 4.0 - 6.0 nominal)
- Manual valve shut-- off
- Low inlet gas pressure
- Control ground continuity
- Gas valve defective or turned off
- Flame sensor must not be grounded or touching casing
- Inadequate flame carryover or rough ignition
- Green/Yellow wire MUST be connected to furnace sheet metal
4+2
INDUCER MOTOR FAULT the RPM pulses are not detected from the inducer motor within 20 seconds after a heat request, the inducer is
outside of its valid range of operation, or the inducer RPM signal was lost for 5 seconds during operation. Check for:
- Proper vent sizing
- Restricted combustion air supply
- Failed inducer motor
- Improper or loose motor wiring or bad connection
ON Solid CONTROL CIRCUITARY LOCKOUT Auto-- reset after one hour lockout due to:
- Gas valve relay stuck open
- Flame sense circuit failure
- Software check error
Reset power to clear lockout. Replace control if status code repeats.
COMPONENT TEST
To initiate the component test sequence, shut OFF the room thermostat or disconnect the “R” thermostat lead. Briefly short the TEST/TWIN terminal to the
“C” terminal. Status LED will flash most recent code 4 times and then turn ON the inducer motor.
The inducer motor will run for the entire component test. The hot surface igniter, blower motor fan speed, blower motor-- heat speed, and blower motor-- cool
speed will be turned ON for 10-- 15 seconds each. Gas Valve and Humidifier will not be turned on.
LED CODES
STATUS
Heartbeat
2+5
4+2
Indicated the blower motor tested OK. Visual check of inducer motor and hot surface igniter required.
SETUP ERROR - Reference code 25 on left
INDUCER MOTOR FAULT - Indicates inducer motor failed test. Check inducer, wiring, furnace control and tubing for
poor connections
441 01 1501 04
Specifications are subject to change without notice.
37
PARTS REPLACEMENT INFORMATION GUIDE
GAS CONTROL GROUP
Burner assembly
Orifice
Flame sensor
Hot surface ignitor
Gas valve
Manual reset limit switches
Burner support assembly
HEAT EXCHANGER GROUP
Heat exchanger cell
Cell panel
INDUCER GROUP
Housing assembly
Transducer
Inducer motor
Inducer wheel
Vent elbow 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
BLOWER GROUP
Blower housing
Blower cutoff
Blower motor
Blower wheel
Grommet
Power choke (where used)
Auxiliary limit switches
MODEL
HEATING SIZE
WIDTH
COOLING SIZE
N/R80ESU
060
17
16
MAJOR
SERIES
A
MINOR
SERIES
1
TO OBTAIN INFORMATION ON PARTS: Consult your installing dealer or the classified section of your local telephone directory under the “Heating
Equipment“ or “Air Conditioning Contractors and Systems” headings for dealer listing by brand name, or contact:
International Comfort Products
Consumer Relations Department
P.O. Box 128
Lewisburg, TN 37091, USA
931--270--4100
Have available the product/model number and the serial number located on the unit rating plate to ensure correct replacement parts.
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.
Copyright 2019 International Comfort Products
Lewisburg, TN 37091 USA
38
Specifications are subject to change without notice.
441 01 1501 04