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HomeMy WebLinkAboutPermit M02-041 - KATO RESIDENCEKATO RESIDENCE 5715 SOUTH 144 ST M02 -041 City of Tukwila Department of Community Development / 6300 Southcenter BL, Suite 100 / Tukwila, WA 98188 / (206) 431 -3670 MECHANICAL PERMIT z Parcel No.: 3365900592 Permit Number: MO2 -041 re 6 Address: 5715 S 144 ST TUKW Issue Date: 03/01/2002 ty V Suite No: Permit Expires On: 08/28/2002 0 Q co w Tenant: Name: RAY KATO Address: 5715 SOUTH 144TH STREET, TUKWILA, WA Owner: Name: KIER ALAN W+ MARY D Address: 5715 S 144TH ST, SEATTLE WA Contact Person: Name: CANDACE GALAGER Address: 2800 THORNDYKE AVE W, Contractor: Name: WASHINGTON ENERGY SERVICES CO Address: 2800 THORNDYKE AVE W, SEATTLE Contractor License No: WASHIES990CW DESCRIPTION OF WORK: REMOVE AND REPLACE GAS FURNACE. REPLACING LIKE FOR LIKE Value of Construction: Type of Fire Protection: $1,500.00 N/A Permit Center Authorized Signature: /�l��C� 1 Date: g I hereby certify that 1 have read and examine this permit and know the same to be true and correct. All provisions of law and ordinances governing this work will be complied with, whether specified herein or not. The granting of this per 't does not presume to giv- . rity to violate or cancel the provisions of any other state or local laws regulating construction r the performanc Signature: Print Name: ! ?A C' doc: Mech Fees Collected: Phone: Phone: Phone: 206 282 -4700 Expiration Date: 02/16/2003 Uniform Mechnical Code Edition: 1997 auth• 'zed to sign and obtain this mechanical permit. Date: A , This permit shall become null and void if the work is not commenced within 180 days from the date of issuance, or if the work is suspended or abandoned for a period of 180 days from the last inspection. MO2 -041 Printed: 03 -01 -2002 CO LL uw O j LL ? 21 d O ` 2 U o N ' 0 F— W W H U ' r z — O 1 Z u, $65.00 O� Z City of fE'ukwila Department of Community Development / 6300 Southcenter BL, Suite 100 / Tukwila, WA 98188 / (206) 431 -3670 Parcel No.: 3365900592 Address: 5715 S 144 ST TUKW Suite No: Tenant: RAY KATO PERMIT CONDITIONS Permit Number: MO2 -041 Status: ISSUED Applied Date: 03/01/2002 Issue Date: 03/01/2002 1: ** *BUILDING DEPARTMENT * ** 2: No changes will be made to the plans unless approved by the Engineer and the Tukwila Building Division. 3: Plumbing permits shall be obtained through the Seattle -King County Department of Public Health. Plumbing will be inspected by that agency, including all gas piping (296 - 4722). 4: Electrical permits shall be obtained through the Washington State Division of Labor and Industries and all electrical work will be inspected by that agency (248 - 6630). 5: All mechanical work shall be under separate permit issued by the City of Tukwila. 6: All permits, inspection records, and approved plans shall be available at the job site prior to the start of any construction. These documents are to be maintained and available until final inspection approval is granted. 7: All construction to be done in conformance with approved plans and requirements of the Uniform Building Code (1997 Edition) as amended, Uniform Mechanical Code (1997 Edition), and Washington State Energy Code (1997 Edition). 8: Validity of Permit. The issuance of a permit or approval of plans, specifications, and computations shall not be con- strued to be a permit for, or an approval of, any violation of any of the provisions of the building code or of any other ordinance of the jurisdiction. No permit presuming to give authority to violate or cancel the provisions of this code shall be valid. I hereby certify that I have read these conditions and will comply with them as outlined. All provisions of law and ordinances governing this work will be complied with, whether specified herein or not. The granting of this permit does not presume to give authority to violate or cancel the provision of any other work or local laws regulating construction • r the performance of work. Signature doc: Conditions j I' — v / Print Name: ! � 17780'C MO2 -041 Date: Printed: 03.01 -2002 Project Name/Tenant: OW c n ° I�ll� � Value of Mechanical Equipment: d I c O o0 Site Address : Fax i1: ( mr ) Ci Slate/Zi : st Ta Parcel Numl er: Property Owner: K ir,\.+c) ' I / Phone: (a) 2 p1 b6,.6 (0) t Street Address: // �-�'' � -i 1 , C Ci t t y at l e P / i : c� i ) ( �' � LU Fax #: (oN ) Contractor: k )9) cl.iv Phone Q ) o' 4 _ 7 6 ... 0 Street Address: o yo J . 1 Cit _ t / o) tt Fax 11: ( ) Contact Person: Phone: ( ) ()V--416--t) Fax 11: ( ) Street Address: n � ■ anm1 u k 'o_ Av , (A it ` ,tat % Zi kt � BUILDING O ER OR AUT. ORIZE AGENT Signa re: ��/ �� SP /�/ Date: ? 3 _) - / l� ` y Print name: - J a a- Q _ rha.v.1 Phone: 6 1 )3�_ (*�Qt �� r ► Fax i1: ( mr ) Address: 13 O 1 R ote_ City /State /Z ct ko /Ail 98 /AS 2 CITY OF T UKWI LA Permit Cenfe. 6300 Southcenter Boulevard, Suite 100 Tukwila, WA 98188 (206) 431 -3670 -- OR STAFF 4)SE ONLY Project Number. Permit Number. Mechanical Permit Application Application and plans must be complete in order to be accepted for plan review. Applications will not be accepted through the mail or facsimile. MECHANICAL PERMIT REVIEW AND APPROVAL REQUESTED: (TO BE FILLED OUT BY APPLICANT) Description of work to be done (please be specifiq • �Q ,p 1acL 9e2. I)) nao Q' Current copy of Washington Stale Department of Labor and Industries Valid Contractor's License. If not available at the time of application, a copy of this license will be required before the permit is issued OR submit Form 11 -4 "Affidavit in Lieu of Contractor Registration ". Building Owner /Authorized Agent: If the applicant is other than the owner, registered architect/engineer, or contractor licensed by the State of Washington, a notarized letter from the property owner authorizing the agent to submit this permit application and obtain the • permit will be required as part of this submittal. I HEREBY CERTIFY THAT I HAVE READ AND EXAMINED THIS APPLICATION AND KNOW THE SAME TO BE TRUE UNDER PENALTY OF PER JURY BY THE LAWS OF THE STATE OF WASHINGTON, AND I AM AUTHORIZED TO APPLY FOR THIS PERMIT. Expiration of Plan Review - Applications for which no permit is issued within 180 days following the date of application shall expire by limitation. The building official may extend the time for action by the applicant for a period not exceeding 1(1(1 days upon written request by the applicant as defined in Section 114.4 of the Uniform Mechanical Code (current edition). No application shall be extended more than once. Date application accepted: Date application expires: /— o� Application taken by: (initials) 11/2/99 meth permitdac ✓ Submittal Requirements Floor plan and system layout Roof plan required to identify individual equipment and the location of each installation (Uniform Mechanical Code 504 (e)) Details and elevations (for roof mounted equipment) and proposed screening Heat Loss Calculations or Washington State Energy Code Form #F1-7 H.V.A.C. over 2,000 CFM (approximately 5 ton and larger) must be provided with smoke detection shut- off and will be routed to the Fire Prevention division for additional comments (Uniform Mechanical Code 1009). Specifications must be provided to show that replacement equipment complies with the efficiency ratings and other applicable requirements of the Washington State Nonresidential Energy Code. Structural engineer's analysis is required for new and the replacement of existing roof equipment weighing 400 pounds and greater (Uniform Building Code 1632.1). Structural documentation shall be stamped by a Washington State licensed Structural Engineer. Mechanical Permits COMMERCIAL: Two complete sets of drawings and attachments required with application submittal NOTE: Water heaters and vents are included in the Uniform Mechanical Code — please include any water heaters or vents being installed or replaced. RESIDENTIAL: Two complete sets of attachments required with application submittal Heat Toss calculations or Form H -6. Equipment specifications. i I/2/99 ,ni.wpwGdnc Submittal Requirements Nety Single Family Residence Change -out or replacement of existing mechanical equipment I Narrative of work to be done, including modification to duct work. Installation of Gas Fireplace Narrative with specification of equipment and chimney type. If using existing chimney, provide a letter by a certified chimney sweep stating that the chimney is in safe condition. NOTE: Water heaters and vents are included in the Uniform Mechanical Code — please include any water heaters or vents being installed or replaced. Parcel No.: 3365900592 Address: 5715 S 144 ST TUKW Suite No: Applicant: RAY KATO Receipt No.: R020000289 Initials: SKS User ID: 1165 Payee: BLUE DOT SERVICES CO TRANSACTION LIST: ACCOUNT ITEM LIST: doc: Receipt City of Tukwila 6300 Southcenter BL, Suite 100 / Tukwila, WA 98188 / (206) 431 -3670 Current Pmts Amount MECHANICAL - RES PLAN CHECK - RES RECEIPT Type Method Description Payment Check 001482 65.00 Description Account Code 000/322.100 52.00 000/345.830 13.00 Permit Number: MO2 -041 Status: PENDING Applied Date: 03/01/2002 Issue Date: Payment Amount: 65.00 Payment Date: 03/01/2002 09:27 AM Balance: $0.00 Total: 65.00 436o 03/01 9716 TOTAL 65.00 Printed: 03 -01 -2002 t:. k T f Inspe Lion: _ ff A d ss /•C " /. J S � / 7 , ...3 Date c �7 Cc9 Special t -(fe Y' ?M �,. Date �atan :'� r . /0,9 e Reques er: Ph - 0 & •. V,J _ ?0,=.9q 1 INSPECTION RECORD Retain a copy with permit INSPECTION NO. CITY OF TUKWILA BUILDING DIVISION 6300 Southcenter Blvd, #100, Tukwila WA 98188 pproved per applicable codes. ❑ Corrections required prior to approval. COMMENTS: a 7 ; �=: 0 $47.06 REINSPECTI • E REQUIRED:- Prior to inspection, fee must be paid at 6300 Southcenter Blvd., Suite 100. Call to schedule reinspection. Receipt No: Date: • , r.i . r ,� �rr..�eur: + x'_J UAW; w y!3'S�s�k�!�r: _..,...c�I.,_,..On��xxitsr�' ,� ;;+�,��ri.�+_��. w> . �. r ,. Z 1 00 co tn u. w u_ a. O W W U O. 0 W W H -- - I I b. V co. O Project: Type of Inspection: l Address: 'r' 5 rs; 5. /44 5 � . Date 'et': —7 /5/02 :Special instructions: t Date anted: 7 / 2 / �am_,- Requester: 640 i Phone;_, 24g- `/v2 U • • INSPECTION RECORD Retain a copy with permit INSPECTION NO. CITY, OF TUKWILA BUILDING DIVISION 6300 Southcenter Blvd; #100, Tukwila, WA 98188 Approved per applicable codes. XCorrections required prior to approval. COMMENTS: y ,�,<,�( vk A M • J Ovv o V 1 _ ('i cr-t l 1 --V-o v-P sr A.4,1, �.p IN(' OA kpf.evi s4) $47.00 REINSPECTION UE REQUIRED. Prior to inspection, fee must be paid at 6300 Southcenter Blvd., Suite 100. Call to schedule reinspection. Receipt No: Date: rya-- a� I PERMIT NO. (206)431 -3670 1 �Jo.e57 Prpject: , , L :WA. („/ /L- a TY-) , T of Inspettion: 41m : it /yf il _5 paw... / Sp instructions: • •-• • - • 6d: . Date wan1 /. Request C a hd(s.c Phone: . 09 (X0 - 3 c il- elt7- .:11•07.1, <P INSPECTION RECOR Retain a copy with permit INSPECTION NO. - , CITY OF TUKWILA BUILDING DIVISION • 6300 Southcenter Blvd, #'I00, Tukwila, WA 98188 (206)431-3670 Approved per applicable codes. OCorrections required prior to approval. COMMENTS: — vevt+ of nOt kct 0-e k C \*PG trot vir 4r) CO wi bug: L -- r ct I n e) !Int wo ,4 I 1 ro 4- ?elle4rc.441 ., ( vt le)e_ ‘,/t•P W eCf \ 1/N5 C 1 s-e+ - "\ - kV Ou c,c -ref v‘ I -40 ecd! • 3 to * Lo let'‘ • Inspector: ' Date: ) $47.00 REINSPECTION FEE REQUIRED. Prior to inspection, fee must be paid at 6300 Southcenter Blvd., Suite 100. Call to schedule reinspection. Receipt No: Date: COMMENTS: - 0 71 0_ /I a-Q.4 r t 1 IA ; 4 Q (ose-( \._.st hAr2.r -e IA ^ APT 1. (S )ra i /.3 Pia-r bd ; -f A t\ i (-) S 7.{ p pillz)r - 44 (4-1 etl.) Q., a Ppo,A 1A1'J,(4, 1 i- (0 i ,)e0 re Adk +0 --1 a x_ii L7 A 4-r) it-H re pac 0 , Requ ster: _ „ r 4(D p, i A N,r) 7-- a_t..14 44 i'cp . .o (2..'. a kJ ( a 1 ,,,-/- r,-Q.,,, 1 Lisp , -eoz..t i C - T ( l KATO . Tr of Inspegtion: l r1Q, k 13cfress 5 i ( 4 q s 4_ Dttf_ctgli._ 0 2_ -----.. • Special instructions: .. ‘ - -" 1 Date wanted: Requ ster: Phone: INSPECTION NO. CITY OF TUKWILA BUILDING DIVISION 1 6300 Southcenter Blvd, #100, Tukwila, WA 98188 Approved per applicable codes. INSPECTION RECORD Retain a copy with permit Corrections required prior to approval. Date: f / to 1 (,), A 0 REINSPECTION fEE p EQUIRED. Prior to spection, fee must be paid 300 Southcenter Blvd., Suite 100. Call to schI1uIe reinspection. Date: (206)431-3670 C.J COMMENTS: 10) C trACtki If wt i # Ci V‘ A 1 b• 0-PC,4 ; 0 ref/ Li 1 Ire CI ..... _.... l :- /,) 1" c �Grt r c'Q i rr) r U4 S -Q Irr v . " � — V -P h-I- c r y C -e i \'t v./ V`r I r . ,r r c ..-,;.) \)Pyrk- C pNexv1 -er4-CY ' f 1� w C 't4h . C t1Qh( 04 �1 e tC1 r. UMr , Sc.4 \ 01S• I_ a q vJ Pfl . I.3 rc)rntt 6L0 I I Cr s sko re+ a nd 54Y1At L+ oS eD 1 pSc>l hi4 . Proj t: �, 4Ct -0 .P5 Type of Inspection: r • Address: Date called: 3 _ 1- --0.,.2 Special instructions: Date wanted: a.m. 3 — t e r - 042 p.m. Requester: \ Phone: a-06 322-- , - - I 31ng INSPECTION NO. 0 Approved per applicable codes. .. ' i2,?. re;.ic:Ylo..:aw;.;:•.i.%?.f:�. ntlblAr;.'. v, ?J. >:P:+t.., ..., rk.�i, .%. =,ii�ulLa.�:.'a��S. INSPECTION RECORD Retain a copy with permit CITY OF TUKWILA BUILDING DIVISION 6300 Southcenter Blvd, #100, Tukwila, WA 98188 �wmer�it..stu a cr- r ks ltft�id eldr l� x'rataiice°• itt.: Corrections required prior to approval. Inspector: ( q ,c,A j Date: ^ 0 ti $47.00 REINSPECTION FEE REQUIRED. Prior to inspection, fee must be paid at 6300 Southcenter Blvd., Suite 100. Call to schedule reinspection. Receipt No: Date: PERMIT NO. (206)431 -3670 • k Installation, Start -Up, and 376CAV Operating Instructions Series H &J DOWNFLOW /HORIZONTAL GAS -FIRED INDUCED - COMBUSTION FURNACES NOTE: Read the entire instruction manual before starting the installation. This symbol -a indicates a change since the last issue. TABLE OF CONTENTS SAFETY CONSIDERATIONS INTRODUCTION 1 CODES AND STANDARDS 3 ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS 3 LOCATION 4 General 4 Location Relative to Cooling Equipment 4 Hazardous Locations 4 Unconfined Space 4 Confined Space 5 AIR DUCTS 5 General Requirements 5 Ductwork Acoustical Treatment 5 Supply Air Connections 5 Return Air Connections 6 Downtlow Installation 6 Horizontal Attic Installation 6 Horizontal Crawlspace Installation 7 Filter Arrangement 8 Gas Piping 9 Electrical Connections 11 Venting 1 l START -UP PROCEDURES, ADJUSTEMENT, AND SAFETY CHECK 1 I General 11 Sequence of Operation 12 Start -Up Procedures 15 Adjustments 15 Check Safety Controls 19 Checklist 20 SAFETY CONSIDERATIONS Installing and servicing heating equipment can be hazardous due to gas and electrical components. Only trained and qualified person- nel should install, repair, or service heating equipment. Untrained personnel can perform basic maintenance functions such as cleaning and replacing air filters. All other operations must be performed by trained service personnel. When working on heating equipment, observe precautions in literature, on tags, and on labels attached to or shipped with unit and other safety precautions that may apply. In the United States, follow all safety codes including the National Fuel Gas Code (NFGC) NFPA 54- 1999 /ANSI Z223.1 -1999 and the Installation Standards, Warm Air Heating and Air Condition- ing Systems (NFPA 90B) ANSI /NFPA 90B. In Canada, refer to the current edition of the CAN /CGA- 13149.1- and .2 -M99 National Standard of Canada, Natural Gas and Propane Installation Codes (NSCNGPIC). —1— Cancels: 11 376C-50-3 G EFFICIENCY CERTIFIED ama c 9 001 #PZ REGISTERED QUALITY SYSTEM II 376C-50-5 10 -00 Wear safety glasses and work gloves. Have a fire extinguisher available during start-up and adjustment procedures and service calls. Recognize safety information. This is the safety -alert symbol 4 . When you see this symbol on the furnace and in instructions or manuals, be alert to the potential for personal injury. Understand these signal words; DANGER, WARNING, and CAUTION and NOTE. These words are used with the safety -alert symbol. DANGER identifies the most serious hazards which will result in severe personal injury or death. WARNING signifies a hazard which could result in personal injury or death. CAUTION is used to identify unsafe practices which would result in minor personal injury or product and property damage. NOTE is used to highlight suggestions which will result in enhanced installation, reliability, or operation These instructions cover minimum requirements and conform to existing national standards and safety codes. In some instances, these instructions exceed certain local codes and ordinances, especially those that may not have kept pace with changing residential construction practices. We require these instructions as a minimum for a safe installation. INTRODUCTION The Model 376CAV, Series H and J Furnace is available in sizes 46,000 through 135,000 Btuh input capacities. The design of the downflow/horizontal gas -fired furnace is (A.G.A. & C.S.A.) certified for natural and propane gases and for installation on noncombustible flooring. The furnace is factory- shipped for use with natural gas. A factory accessory gas conver- sion kit, as listed on the furnace rating plate is required to convert furnace for use with propane gas. These furnaces SHALL NOT be installed directly on carpeting, tile, or any combustible material other than wood flooring. In downflow installations, a factory accessory floor base, as listed on the furnace rating plate, MUST be used when installed on combustible materials and wood flooring. A factory base is not required when this furnace is installed on manufacturer's Coil Assembly Part No. CD5 or CK5, or when Coil Box Part No. KCAKC is used. This furnace is for installation in alcoves, attics, crawlspaces, basements, closets, or utility rooms. The design of this furnace line is not (A.G.A. /C.S.A.) certified for installation in mobile homes, recreation vehicles, or outdoors. z 1 re W J V U W i to LL WO u to 0 j W z � O Z I- W 0 0 I- W W H H L U N 0 — 0 z UNIT SIZE A D E VENT CONN SHIP. WT (LB) 024050 14 -3/16 12 -9/16 12 -11/16 4 123 036050 14 -3/16 12 -9/16 12 -11/16 4 128 024070 14 -3/16 12 -9/16 12 -11/16 4 130 036070 14 -3/16 12 -9/16 12 -11/16 4 139 036096 17 -1/2 15 -7/8 16 4 151 048096 17 -1/2 15 -7/8 16 4 153 048115 17-1/2 15 -7/8 16 4 161 060115 21 19 -3/8 19 -1/2 4 177 066115 21 19 -3/8 19-1/2 4 176 060135 24 -1/2 22 -7/8 23 5 193 1 - 28 1 t f - 20 t 13/16 INLET 39 7 /8 t 11/181 -►�� OUTLET r - 191 13 /1 6• VENT CONNECTION 2 1 / 8 t t ri f— 2 1 /g t 8 1 /41 11 /16t NOTE: ADDITIONAL 7 /8t DIA K.O.'s ARE LOCATED IN THE TOP PLATE AND BOTTOM PLATE f 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 E---_1 These instructions cover minimum requirements for a safe instal- lation and conform to existing national standards and safety codes. In some instances, these instructions exceed certain local codes and ordinances, especially those that may not have kept pace with changing residential construction practices. We require these instructions as a minimum for a safe installation. CAUTION: Application of this furnace should be in- doors with special attention given to vent sizing and material, gas input rate, air temperature rise, and unit sizing. Improper installation or misapplication of the furnace can require excessive servicing or cause prema- ture component failure. NOTE: These furnaces are designed for a minimum continuous return-air temperature of 60 °F or intermittent operation down to 55 °F such as when used with a night setback thermostat. Return-air temperature must not exceed a maximum of 85 °F. Failure to follow these return-air temperature limits may affect reliability of heat exchangers, motors, and controls. 16 1 /16t 7 /bt DIA ACCESSORY 7 /8 t DIA HOLE POWER ENTRY ,("" 1 1 /'11 DIA i d R.H. GAS ENTRY 7 /$ t DIA ACCESSORY —2— 4 3 /16 t 2 15/16t 113 5/ 6t _� /41 A 11/16t 10 1 11/16t -0- 1 /h t AIRFLOW DIMPLES TO DR LL HOLES FOR HANGER BOLTS (4 PLACES) IN HORIZONTAL POSITION NOTE: Minimum return -air openings at furnace, based on metal duct. If flex duct is used, see flex duct manufacturer's recommendations for equivalent diameters. a. For 800 CFM- 16 -in. round or 14 x 12 -in. rectangle. b. For 1200 CFM- 20 -in. round or 141 x 191 -in. rectangle. c. For 1600 CFM- 22 -in. round or 14 x 23 -in. rectangle. d. For airflow requirements above 1800 CFM, must use entire return air opening. TABLE 1— DIMENSIONS (IN.) Fig. 1— Dimensional Drawing 1 /2t DIA THERMOSTAT WIRE ENTRY 1 t TYP - TYP A99288 °F MAX 85 °F �f M1N55°F A93042 MINIMUM INCHES CLEARANCE TO This forced air furnace is equipped for use with natural gas at altitudes 0-10,000 ft (0- 3,050m). M accessory kit, supplied by the ma nufacturer,shall be used to convert to propane gas use or may be required for some natural gas applications. This fumace is for indoor installation in a building constructed on site. This fumace may be installed on contwstible flooring in alcove or closet at minimum clearance from combustible material. This furnace may be used with a Type B-1 Vent and may be vented in common with other gas -fined appliances. For installation on non- combustible floors only. For installation on combustible flooring only when installed on spedal base, Part No. KGASB0201ALL, Coil Assembly, Part No. CD5 or CK5, or Coil Casing, Part No. KCAKC. # For fumaces wider than 14.25 inches (362mm) may be 0 inches. Q 18 indies front dearance required for alcove. * Indcates supply or retum sides when fumace is in the horizontal position. Line oontad only permissible between lines formed by intersections of the Top and two Sides of the furnace jadcet, and bunting joists, studs or framing. ## For single wall vent type 6 inches. For Type B-1 vent type 3 inches. tt Clearance to Bade 0 inches in downflow and horizontal (attic/alcove & crawispaoe) positions and 3 inches in horizontal closet positions. t COMBUSTIBLE CONSTRUCTION This furnace Is approved for DOWNFLOW aril HORIZONTAL installations. Vent Clearance to combustibles: For Single Wall vents 6 inches. For Type B-1 vent type 1 inch . 322286-101 REV. F (LIT) WARNING: Improper installation, adjustment, alter- ation, service, maintenance, or use can cause carbon monoxide poisoning, explosion, fire, electrical shock, or other conditions which may cause personal injury or property damage. Consult a qualified installer, service agency, local gas supplier, or your distributor or branch for information or assistance. The qualified installer or agency must use only factory- authorized and listed kits or accessories when modifying this product. Failure to follow this warning could result in electrical shock, fire, personal injury, or death. For accessory installation details, refer to the applicable installa- tion literature. NOTE: Remove all shipping brackets and materials before oper- ating the furnace. CODES AND STANDARDS Before installing the furnace in the United States, refer to the current edition of the NFGC and the NFPA 90B. For further information the NFGC and NFPA 90B are available from National Fire Protection Association Inc., Batterymarch Park, Quincy, MA 02269; or for only the NFGC contact the American Gas Associa- tion, 400 N. Capitol St., N.W., Washington DC 20001. Before installing the furnace in Canada, refer to the current edition of the NSCNGPIC. For a copy of the NSCNGPIC, contact Standard Sales, CSA International, 178 Rexdale Boulevard, Eto- bicoke (Toronto), Ontario, M9W 1R3, Canada. Fig. 2 Clearances to Combustibles —3— A99262 Installation must comply with regulations of serving gas supplier and local building, heating, plumbing or other codes in effect in the area in which installation is made. In absence of local building codes, installation must comply with NFGC in the United States and the NSCNGPIC and all authorities having jurisdiction in Canada. ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS CAUTION: Electrostatic discharge can affect electronic components. Take precautions during furnace installation and servicing to protect the furnace electronic control. Precautions will prevent electrostatic discharges from personnel and hand tools which are held during the procedure. These precautions will help to avoid exposing the control to electrostatic discharge by putting the furnace, the control, and the person at the same electro- static potential. I. Disconnect all power to the furnace. 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 a 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 that t 1 t � HO Z I— W tu n 0 O- O W W g U. O tii co R. O 1— Z recharges your body with static electricity (for example; DO NOT move or shuffle your feet, DO NOT touch un- grounded objects, etc.). 4. If you touch ungrounded objects (and recharge your body with static electricity), firmly touch furnace again before touching control or wires. 5. Use this procedure for installed and uninstalled (un- grounded) furnaces. 6. Before removing a new control from its container, dis- charge 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 5 before bringing the control or yourself into 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. I. GENERAL LOCATION CAUTION: 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. Do not use this furnace during construction when adhe- sives, sealers, and/or new carpets are being installed. If the furnace is required during construction, use clean outside air for combustion and ventilation. Compounds of chlorine and fluorine when burned with combustion air form acids which cause corrosion of the heat exchangers and metal vent system. Some of these compounds are found in paneling and dry wall adhesives, paints, thin- ners, masonry cleaning materials, and many other sol- vents commonly used in the construction process. Excessive exposure to contaminated combustion air will result in safety and performance related problems. ZE WARNING: DO NOT install the furnace on its back or sides. Safety control operation will be adversely affected. A failure to follow this warning can cause a fire, personal injury, or death. This furnace must be installed so the electrical components are protected from water. Locate furnace as close to the chimney /vent and as near the center of the air distribution system as possible. The furnace should be installed as level as possible. Provide ample space for servicing and cleaning. Always comply with the minimum fire protection clearances shown on the unit rating plate. This furnace shall not be installed directly on carpeting, tile, or any combustible material other than wood flooring. The furnace may be installed on combustible flooring when installed with the accessory downflow subbase, which is available from your distributor or branch when required. II. 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 a furnace, dampers or other means used to control the flow of air must prevent chilled air from entering the unit. 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. III. HAZARDOUS LOCATIONS 18 -IN. MINIMUM TO BURNERS A93044 WARNING: When furnace is installed in a residential garage, it must be installed so that burners and ignition sources are located a minimum of 18 in. above floor. The furnace must be located or protected to avoid physical damage by vehicles. When furnace is installed in a public garage, airplane hangar, or other building having a hazardous atmosphere, unit must be installed in accor- dance with requirements of National Fire Protection Association, Inc. Air For Combustion And Ventilation Provisions for adequate combustion and ventilation air must be provided in accordance with Section 5.3 of the NFGC, Air for Combustion and Ventilation, or applicable provisions of the local building codes. Canadian installations must be installed in accordance with NSC- NGPIC and all authorities having jurisdiction. CAUTION: Air for combustion must not be contami- nated by halogen compounds, which include fluoride, chloride, bromide, and iodide. These elements are found in aerosol sprays, detergents, bleaches, cleaning solvents, salts, air fresheners, and other household products. CAUTION: The operation of exhaust fans, kitchen ven- tilation fans, clothes dryers, 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. All fuel - burning equipment must be supplied with air for combus- tion of the fuel. Sufficient air MUST be provided to ensure there will not be a negative pressure in the equipment room or space. In addition, a positive seal MUST be made between the furnace cabinet and the return-air duct to avoid pulling air from the burner area and blocked vent safeguard opening. The requirements for combustion and ventilation air depend upon whether the furnace is located in an unconfined or confined space. IV. UNCONFINED SPACE An unconfined space has volume of at least 50 cu ft for each 1000 Btuh of total input for all appliances (such as furnaces, clothes dryers, water heaters, etc.) in the space. 376CAV FURNACE INPUT BTUH MINIMUM SQ FT WITH 7 -1/2 FT CEILING 46,000 307 69,000 460 92,000 613 115,000 767 135,000 920 For Example: If the unconfined space is of unusually tight construction, air for combustion and ventilation MUST come from either the outdoors or spaces freely communicating with the outdoors. Combustion and ventilation openings must be sized the same as for a confined space as defined below. Return air must not be taken from the room unless an equal or greater amount of air is supplied to the room. V. CONFINED SPACE A confined space is defined as a space whose volume is less than 50 cu ft per 1000 Btuh of total input ratings of all appliances installed in that space. A confined space MUST have provisions for supplying air for combustion, ventilation, and dilution of flue gases using I of the following methods. (See Figs. 3, 4, and Table 2.) NOTE: In determining free area of an opening, the blocking effect of louvers, grilles, and screens must be considered. If free area of louver or grille design is unknown, assume that wood louvers have a 20 percent free area and metal louvers or grilles have a 60 percent free area. Screens, when used, must not be smaller than I /4 -in. mesh. Louvers and grilles must be constructed so they cannot be closed. The size of the openings depends upon whether air comes from outside of the structure or an unconfined space inside the structure. 1. All air from inside the structure requires 2 openings (for structures not usually tight): a. Each opening MUST have at least 1 sq in. of free area per 1000 Btuh of total input for all equipment within the confined space, but not less than 100 sq in. per opening. (See Fig. 3 and Table 2.) The minimum dimension of air openings shall not be less than 3 in. b. If building is constructed unusually tight, a permanent opening directly communicating with the outdoors shall be provided. See item 2 below. c. If furnace is installed on a raised platform to provide a return-air plenum, and return air is taken directly from hallway or space adjacent to furnace, all air for combus- tion must come from outdoors. 2. Air from outside the structure requires 1 of the following methods: a. If combustion air is taken from outdoors through 2 vertical ducts, the openings and ducts MUST have at least 1 sq in. of free area per 4000 Btuh of total input for all equipment within the confined space. (See Figs. 3, 4, and Table 2.) b. If combustion air is taken from outdoors through 2 horizontal ducts, the openings and ducts MUST have at least 1 sq in. of free area per 2000 Btuh of total input for all equipment within the confined space. (See Fig. 4 and Table 2.) c. If combustion air is taken from outdoors through a single opening or duct (horizontal or vertical) commencing within 12 in. of the top of the confined space, opening and duct MUST have at (east I sq in. of free area per —5— 3000 Btuh of the total input for all equipment within the confined space and not less than the sum of the areas of all vent connectors in the confined space. (See Fig. 4 and Table 2.) Equipment clearances to the structure shall be at least 1 in. from the sides and back and 6 in. from the front of the appliances. When ducts are used, they must be of the same cross - sectional area as the free area of the openings to which they connect. The minimum dimension of ducts must not be less than 3 in. (See Fig. 4.) AIR DUCTS This section covers installation of the 376CAV Series H and J furnace. I. 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 factory The Air Systems Design Guide /inesreference tables available from your local distributor. The duct system should be sized to handle the required system design airflow CFM at the design external static pressure. When a furnace is installed so that the supply ducts carry air to areas outside the space containing the furnace, the return air must also be handled by a duct(s) sealed to the furnace casing and terminating outside the space containing the furnace. Secure ductwork with proper fasteners for type of ductwork used. Seal supply- and return-duct connections to furnace with code approved tape or duct sealer. Flexible connections should be used between ductwork and furnace to prevent transmission of vibration. Ductwork passing through unconditioned space should be insulated to enhance system performance. When air conditioning is used, a vapor barrier is recommended. Maintain a I -in. clearance from combustible materials to supply air ductwork for a distance of 36 in. horizontally from the furnace. See NFPA 90B or local code for further requirements. II. DUCTWORK ACOUSTICAL TREATMENT Metal duct systems that do not have a 90 degree elbow and 10 ft of main duct to the first branch take -off may require internal acoustical lining. As an alternative, fibrous ductwork may be used if constructed and installed in accordance with the latest edition of 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. III. SUPPLY AIR CONNECTIONS A. Downflow Furnaces Connect supply -air duct to supply -air opening on furnace. The supply -air ducts attachment must ONLY be connected to furnace supply /outlet or air conditioning coil casing (when used), when installed on non - combustible material. When installed on combus- tible material, supply -air duct attachment must ONLY be con- nected to an accessory subbase or factory approved air condition- ing coil casing. DO NOT cut main furnace casing to attach supply side air duct, humidifier, or other accessories. All accessories MUST be connected external to the furnace main casing. B. Horizontal Furnaces Connect supply -air duct to supply -air opening on furnace. The supply -air ducts attachment must ONLY be connected to furnace supply /outlet or air conditioning coil casing (when used). DO NOT cut main furnace casing to attach supply side air duct, humidifier, or other accessories. All accessories MUST be connected external to the furnace main casing. 376CAV FURNACE INPUT (BTUH) AIR FROM INDOOR UNCONFINED SPACE OUTDOOR AIR THROUGH VERTICAL DUCTS OUTDOOR AIR THROUGH HORIZONTAL DUCTS OUTDOOR AIR THROUGH SINGLE DUCT Free Area of Opening (Sq. In.) Free Area of Opening and Duct (Sq. In.) Round Pipe (In. Dia.) Free Area of Opening and Duct (Sq. In.) Round Pipe (In. Dia) Free Area of Opening and Duct (Sq. In.) Round Pipe (In. Dia) 46,000 100 11.50 4 23.0 6 15.33 5 69,000 100 17.25 5 34.5 7 23.00 6 92,000 100 23.00 6 46.0 8 30.67 7 115,000 115 28.75 7 57.5 9 38.33 7 135,000 135 33.75 7 67.5 10 45.00 8 1 INTERIOR HEATED SPACE } SUPPLY AIR RETURN ~� AIR 1 VENT THROUGH ROOF (CATEGORY I) l i H12 MAX 1 SQ IN. PER 1000 BTUH* IN DOOR OR WALL UNCONFINED SPACE 6 "MIN (FRONT) t 1 SQ IN. PER 1000 BTUH* IN DOOR =OR WALL 1 12" MAX * Minimum opening size is 100 sq in. with minimum dimensions of 3 in. t Minimum of 3 in. when type B -1 vent is used. Fig. 3—Confined Space: Air for Combustion and Ventiiattion from an Unconfined Indoor Space IV. RETURN AIR CONNECTIONS The return-air duct must be connected to return air opening as shown in Fig. 1. DO NOT cut into casing sides or back to attach any portion of return-air duct. Bypass humidifier connections should be made at ductwork or coil casing sides exterior to furnace. WARNING: Do not install fumace on its back. Safety control operation will be adversely affected. Never con- nect return-air ducts to back of furnace. Failure to follow this warning could result in fire, personal injury, or death. V. DOWNFLOW INSTALLATION This furnace is approved for use on combustible materials or wood flooring. A factory accessory floor base, as listed on the furnace —6— 12" MAX 1 SQ IN. PER 2000 B ■ A DUCTS TO OUTSIDE 1 SQ IN. PER 2000 BTUH• 12" MAX DUCTS TO OUTDOORS A� RETURNIVENT AIR THROUGH (CATEGORY I ) I l w Z U zO. U *Minimum dimensions of 3 in. NOTE: Use any of the following combinations of openings: A &B C &D D &E F &G TABLE 2 MINIMUM FREE AREA OF COMBUSTION AIR OPENING* 1 SQ IN. PER 4000 BTUH* 1 12" ! MAX F r - 1 1 SQ IN. PER 4000 1 BTUH* OUTDOORS 11 SQ IN. PER 4000 BTUH* E 1 12" C I ! MAX ' 7 7 12" MAX t J ;DUCT -- TO '— 1 SQ IN. OUTDOORS PER 4000 BTUH Fig. 4 Confined Space: Air for Combustion and Ventiiafion from Outdoors • Free area shall be equal to or greater than the sum of the areas of all vent connectors in the confined space. Opening area must be increased if other gas appliances in the space require combustion air. rating plate, MUST be used. A factory accessory floor base is not required when this furnace is installed on manufacturer's Coil Assembly Part No. CD5 or CK5, or when Coil Box Part No. KCAKC is used. 1. Detennine application being installed from Table 3. 2. Construct hold in floor per dimensions specified in Table 3 and Fig. 5. 3. Construct plenum to dimensions specified in Table 3. 4. If downflow subbase (KGASB) is used, install as shown Fig. 6. If coil assembly CD5, CK5 or Coil Box KCAKC is used, install as shown in Fig. 7. VI. HORIZONTAL ATTIC INSTALLATION The furnace can be installed on either the left -hand (LH) or right -hand (RH) side. A typical attic installation is shown in Fig. 8. FURNACE CASING WIDTH APPLICATION PLENUM OPENING FLOOR OPENING A B C D 14 -3118 Non - Combustible Flooring 12 -11/16 19 13-3/8 19-5/8 Combustible Flooring Using KGASB Subbase 11 -13/16 19 13 -7/16 20-3/8 Combustible Flooring with CD5 or CK5 Coil Assembly or KCAKC Coil Box 12-5/16 19 13 -5/16 20 17-1/2 Non - Combustible Flooring 16 19 16-5/8 19-5/8 Combustible Flooring Using KGASB Subbase 15-1/8 19 16-3/4 20 -3/8 Combustible Flooring with CD5 or CK5 Coil Assembly or KCAKC Coil Box 15-1/2 19 16-1/2 20 21 Non - Combustible Flooring 19-1/2 19 20-1/8 19-5/8 Combustible Flooring Using KGASB Subbase 18 -5/8 19 20-1/4 20 -3/8 Combustible Flooring with CD5 or CK5 Coil Assembly or KCAKC Coil Box 19 19 20 20 24-1/2 Non - Combustible Flooring 23 19 23 -5/8 19 -5/8 Combustible Flooring Using KGASB Subbase 22 -1/8 19 23 -3/4 20-3/8 Combustible Flooring with CD5 or CK5 Coll Assembly or KCAKC Coil Box 22-1/2 19 23 -1/2 20 A. Construct a Working Platform Constructs a working platform, on location, where all required furnace clearances are met. (See Fig. 2 and 8.) B. Install Furnace 1. Position furnace in desired location. 2. Connect gas supply pipe. See Fig. 8 for typical piping entry. 3. Install field- supplied filter retainers as indicated in Fig. 11 and Table 4 before connecting return-air duct to furnace. 4. Connect supply- and return-air ducts. 5. Install 24- X 24–in. sheet metal shield on platfonn in front of louvered control panel as shown in Fig. 8. VII. HORIZONTAL CRAWLSPACE INSTALLATION A93043 The furnace can be installed horizontally with either LH or RH side up. In a crawlspace, furnace can either be hung from floor joist (see Fig. 10) or installed on suitable blocks or pad. (See Fig. Fig. 5 —Floor and Plenum Opening Dimensions TABLE 3— OPENING DIMENSIONS (IN.) —7— A96283 FURNACE (O WHEN U E CASING COMBUSTIBLE FLOORING DOWNFLOW SUBBASE SHEET METAL PLENUM — FLOOR OPENING — Fig. 6— Furnace, Plenum, and Subbase Installed on a m bustible Floor 9.) The furnace can be suspended from each corner by hanger bolts (4 each 3 /8 -in. all- thread rod) cut to desired length, 1- X 3 /8 —in. flat washer, 3 /8 —in. lockwasher, and 3 /8 —in. nut. Dimples are provided for hole locations. (See Fig. 1.) Since horizontal crawlspace installation is very similar to attic installation, refer to Section VI, "Horizontal Attic Installation ". The installation of a sheet metal shield in front of louvered control panel is covered in Section VI. For crawlspace installation, this same sheet metal shield must be installed above louvered control panel. Extend sheet metal shield over furnace top far enough to cover gas pipe entry hole. LINE CONTACT ONLY PERMISSIBLE BETWEEN LINES FORMED BY INTERSECTIONS OF THE TOP AND TWO SIDES OF THE FURNACE JACKET AND BUILDING JOISTS, STUDS, OR FRAMING. MANUAL SHUTOFF GAS VALVE SEDIMENT TRAP Fig. 8 Typical Attic Installation —8— FURNACE VIII. FILTER ARRANGEMENT 30 -IN. MIN WORK AREA CD5 OR CK5 COIL ASSEMBLY OR KCAKC COIL BOX COMBUSTIBLE FLOORING SHEET METAL PLENUM FLOOR OPENING Fig. 7— Furnace, Plenum, and Coil Assembly or Coil 9oz Installed on a Combustible Floor WARNING: Never operate unit without filter access door removed. Failure to follow this warning could result in fire, personal injury, or death. A97516 W 00 to J W Q O . u 1— W UJ ZO p O N 0 F- W W U. H • Z U� O The 2 factory- supplied filters are shipped in the blower compart- ment. After return -air duct has been connected to furnace, install filters in a V- formation inside return-air plenum. See Fig. 1 I and Table 4 for horizontal applications. Horizontal filter retainers must be field supplied. See Fig. 12 for downflow applications. IX. GAS PIPING Gas piping must be installed in accordance with national and local codes. Refer to the current edition of the NFGC. Canadian installations must be installed in accordance with NSC- NGPIC and all authorities having jurisdiction. Refer to Table 5 for recommended gas pipe sizing. Risers should be used to connect to the furnace and the meter. ANGLE IRON OR EQUIVALENT (B) (A) LOCATION USING DIMPLE LOCATORS (SEE DIMENSIONAL DWG FOR LOCATIONS) (A) PREFERRED ROD LOCATION (B) ALTERNATE ROD LOCATION 0 3 /8-IN. HEX NUT & WASHER (4) REQD PER ROD LIN CAUTION: If a flexible connector is required or al- lowed by the authority having jurisdiction, black iron pipe shall be installed at the gas valve and extend a minimum of 2 in. outside the furnace casing. WARNING: Use the proper length of pipes to avoid stress on the gas control manifold. Failure to follow this warning can result in a gas leak, causing fire, explosion, personal injury, or death. iVOVIiUVpV' 11111111111 IIIIIIIIII 111111111111111111 IUllpll I Fig. 9— Horizontal Installation on Blocks • ‘1\ (A) \— (B) (A) (B) Fig. 10— Horizontal Crawlspace Installation on Hanger Rods 3/4-IN. ROD NOTES: 1. A 1 In. clearance minimum between top of furnace and combustible material. 2. The entire length of fumace must be supported when furnace Is used in horizontal position. A95235 A96633 re O 0 9 W == ta W O 2 g j • d ILI Z 0 W U co O — D 1— = W Lk F— ti Z O NOMINAL IRON PIPE SIZE INTERNAL DIAMETER LENGTH OF PIPE (FT) 10 20 30 40 50 (IN.) (IN.) 1/2 0.622 175 120 97 82 73 3/4 0.824 360 250 200 170 151 1 1.049 680 465 375 320 285 1 -1/4 1.380 1400 950 770 660 580 1 -1/2 1.610 2100 1460 1180 990 900 FURNACE CASING WIDTH FILTER SIZE AND QUANTITY D 14 -3/16 (2) 16 X 20 X 1 15-3/8 17 -1/2 (2) 16 X 20 X 1 14-3/4 21 (2) 16 X 20 X 1 13-3/4 24-1/2 (2) 16 X 20 X 1 12 -1/2 Fig. 11— Horizontal Filter Arrangement TABLE 4— FILTER INFORMATION (IN.) INSTALLATION POSITION OF FILTERS RETURN -AIR PLENUM ACCESS DOOR FIELD - SUPPLIED FILTER RETAINERS AIRFLOW 'eV 1 %W ‘0&iii34 1;1 Fig. 12— Downflow Filter Arrangement A82173 A68486 ®I CAUTION: Connect the gas pipe to the furnace using a backup wrench to avoid damaging gas controls. —10— TABLE 5— MAXIMUM CAPACITY OF PIPE* • Cubic ft of gas per h for gas pressu es of 0.5 psig (14 -in. wc) or less, and a pressure drop of 0.54n. wc (based on a 0,60 specific gravity gas). Ref: Table 10 -2 NFPA 54 /ANSI Z223.1-1996. WARNING: Never purge a line into a combustion chamber. Never use matches, candles, flame, or other sources of ignition for to check for gas leakage. Use a soap - and -water solution to check for gas leaks. Failure to follow this warning could result in fire, explosion, per- sonal injury, or death. Joint compounds (pipe dope) should be applied sparingly and only to the male threads of the joints. This pipe dope must be resistant to the action of propane gas. An accessible manual shutoff valve MUST be installed upstream of the furnace gas controls and within 72 in. of the furnace. A I /8 -in. NPT plugged tapping, accessible for test gage connection, MUST be installed immediately upstream of the gas supply connection to the furnace and downstream of the manual shutoff valve. Place a ground joint union between the gas control manifold and the manual shutoff. Install a sediment trap in the riser leading to the furnace. The trap can be installed by connecting a tee to the riser leading from the furnace. Connect a capped nipple into the lower end of the tee. The capped nipple should extend below the level of the gas controls. (See Fig. 13.) GAS SUPPLY MANUAL SHUTOFF VALVE (REQUIRED) SEDIMENT TRAP UNION A89414 Fig. 13— Typical Gas Pipe Arrangement Piping should be pressure tested in accordance with local and national plumbing and gas codes before the furnace has been attached. If the pressure exceeds 0.5 psig (14 -in. wc), the gas supply pipe must be disconnected from the furnace and capped SIZE VOLTS— HERTZ— PHASE OPERATING VOLTAGE RANGE MAXIMUM UNIT AMPS MIN WIRE GAGE WIRE LENGTH (FT)$ MAXIMUM FUSE OR CKT BKR AMPSt Maximum* Minimum* 024050 115 -60-1 127 104 6.6 14 42 15 036050 115 -60-1 127 104 8.1 14 34 15 024070 115 -60-1 127 104 6.7 14 42 15 036070 115 -60-1 127 104 8.4 14 33 15 036096 115 -60-1 127 104 9.2 14 30 15 048096 115 -60-1 127 104 10.2 14 28 15 048115 115 -60-1 127 104 10.1 14 28 15 060115 115 -60-1 127 104 13.3 12 33 20 066115 115 -60-1 127 104 15.2 12 29 20 060135 115 -60-1 127 104 14.3 12 31 20 • Permissible limits of voltage range at which unit will operate satisfactorily. t Time -delay type is recommended. t Length shown is a measured 1 way along wire path between unit and service panel for maximum 2 percent voltage drop. before the pressure test. If the test pressure is equal to or less than 0.5 psig (14 -in. wc), turn off electric shutoff switch located on the gas valve before the test. It is recommended that the ground joint union be loosened before pressure testing. After all connections have been made, purge the lines and check for gas leakage with regulated gas supply pressure. X. ELECTRICAL CONNECTIONS This section covers the electrical connections necessary to install the 376C503 furnace. A. 115-V Wiring Refer to the unit rating plate or Table 6 for equipment electrical requirements. The control system requires an earth ground for proper operation. L CAUTION: Do not connect aluminum wire between disconnect switch and fumace. Use only copper wire. Make all electrical connections in accordance with the current edition of the National Electrical Code (NEC) ANSI /NFPA 70 -1999 and any local codes or ordinances that might apply. For Canadian installations, all electrical connections must be made in accordance with Canadian Electrical Code CSA C22.I, or authori- ties having jurisdiction. NOTE: Proper polarity must be maintained for 115 -v wiring. If polarity is incorrect, control board status code indicator light will flash rapidly and the furnace will not operate. WARNING: The cabinet MUST have an uninterrupted or unbroken ground according to NEC, ANSI /NFPA 70 -1999 and Canadian Electrical Code, CSA C22.1 or local codes to minimize personal injury if an electrical fault should occur. This may consist of electrical wire or conduit approved for electrical ground when installed in accordance with existing electrical codes. Do not use gas piping as an electrical ground. Failure to follow this warning could result in electrical shock, fire, or death. B. 24 Wiring Make field 24 -v connections at the 24 -v tenninal strip. (See Fig. 14.) Connect terminal Y as shown in Fig. 15 or proper cooling operation in cooling mode. Use only AWG No. 18, color- coded, copper thermostat wire. The 24 -v circuit contains an automotive -type, 3 -amp fuse located on the main control board. 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. TABLE 6 ELECTRICAL DATA —1 I — C. Accessories 1. Electronic Air Cleaner (EAC) Two quick- connect terminals marked EAC -1 and EAC -2 are provided for EAC connection. (See Fig. 14.) These terminals are energized with 115 -v, (1.5 -amp maximum) during blower motor operation. 2. Humidifier (HUM) A quick- connect terminal (HUM) and screw terminal (CoM) are provided for 24 -v humidifier connection. (See Fig. 16.) HUM terminal is energized with 24 -v (0.5 -amp maximum) after inducer pressure switch closes. WARNING: DO NOT connect furnace control HUM terminal to HUM (humidifier) terminal on Thermidis- tatTM, Zone Controller or similar device. See Thermidis- tat, Zone Controller, thermostat, or controller manufac- turer's instructions for proper connection. A failure to follow this warning could result in fire. NOTE: A field- supplied, 115 -v controlled relay connected to EAC tenninals may be added if humidifier operation is desired during blower operation. XI. VENTING Refer to the national or local installation code such as N FGC in the United States, or the NSCNGPIC in Canada for proper vent sizing and installation requirements. Use the enclosed installation In- structions (Single -Stage Vent Tables for Category 1 Fan - Assisted Furnaces) for a quick, easy reference. After fully assembling the vent connector to the furnace flue collar, securely fasten the vent connector to the collar with two field - supplied, corrosion- resistant, sheet metal screws located 180° apart and midway up the collar. The horizontal portion of the venting system shall maintain a minimum of 1 /4 -in. upward slope per linear ft and it shall be rigidly supported every 5 11 or less with hangers or straps to ensure that there will be no movement after installation. START -UP PROCEDURES, ADJUSTEMENT, AND SAFETY CHECK I. GENERAL NOTE: Proper polarity must be maintained for 1 15-v wiring. If polarity is incorrect, control status indicator light will flash rapidly and furnace will not operate. The furnace must have a 1 15 -v power supply properly connected and grounded. Proper polarity must be maintained for correct operation. Thermostat wire connections at R, W, C, and Y must be made at the 24 -v terminal block on the furnace control. The gas service pressure trust not exceed 0.5 psig (14 -in. wc), but must be no less than 0.16 psig (4.5 -in. wc). • O 0 0 0 0 0 0 0 0 0 id 115 -VAC (L1) POWER SUPPLY 0 0 0 0 TEST/TWIN 00 3 -AMP FUSE HOT SURFACE IGNITOR CONNECTOR II. SEQUENCE OF OPERATION R Y W Co 24V 000 000 D O D 1 Before operating the furnace, check each manual reset switch for continuity. If necessary, press the button to reset the switch. The blower compartment door must be in place to complete the 115 -v circuit to the furnace. LL CAUTION: This furnace is equipped with 2 manual reset limit switches in the gas control area. The switches will open and shut off power to the gas valve if a flame rollout or an overheating condition occurs in the gas control area. DO NOT bypass the switches. Correct inadequate combustion air supply problem and reset the switches. CAUTION: Furnace control must be grounded for proper operation, or control will lockout. Control is grounded through green wire routed to gas valve and burner bracket screw. 0 a a Using the schematic diagram shown in Fig. 16, follow the sequence of operation through the different modes. Read and follow the wiring diagram very carefully. NOTE: If there is a power interruption and any thermostat call, the control will initiate a 90 -sec blower only on period before starting another cycle. BLOWER OFF DELAY ADJUSTMENT SWITCH INDUCER MOTOR CONNECTOR Fig. 14 Furnace Control —12— 24 -V THERMOSTAT TERMINALS HUMIDIFIER TERMINAL (24 -VAC 0.5 AMP MAX) LED OPERATION & DIAGNOSTIC LIGHT HARNESS CONNECTOR SEC -1 1 24 -V TRANSFORMER SEC -2 i lJ — SPARE -1 COOL �= 1 H EAT ��® BLOWER SPEED 1 SELECTION TERMINALS = — SPARE -2 = EAC -1 (BLACK) EAC- ELECTRONIC AIR CLEANER TERMINALS (115 -VAC 1 AMP MAX) EAC -2 (WHITE) 115 -VAC (L2) NEUTRAL CONNECTION A00292 1. Heating mode When the thermostat "calls for heat," the R -W circuit closes. The furnace control performs a self - check, verifies the pressure switch contacts are open, and starts inducer motor. a. Prepurge period —As the inducer motor comes up to speed, the pressure switch contacts close to begin a I5 -sec prepurge period. b. Igniter warm -up —At the end of the prepurge period, the igniter is energized for a 1 7-sec igniter warm -up period. c. Ignition sequence —When the igniter warm -up period is completed, the gas valve opens, permitting gas flow to the burners where it is ignited. After 5 sec, the igniter is de- energized and a 2 -sec flame - sensing period begins. d. HUM terminal is energized with the gas valve. See Accessories in the Electrical Connections section. e. Flame- sensing —When burner flame is sensed, the con- trol begins the blower on delay period and continues holding the gas valve open. If burner flame is not sensed, the control closes the gas valve and repeats ignition cycle. NOTE: Ignition sequence will repeat 3 additional time before a lockout occurs. Lockout automatically resets after 3 hr, or can be manually reset by turning 115—v off (not at thermostat) for 3 sec minimum, then on again. f. Blower on delay— Forty -five sec after burner fame is proven, the blower motor is energized on heating speed. Simultaneously, terminals HUM and CoM -24V for hu- midifier, and EAC -1 and EAC -2 for EAC are energized. If jumper is on pin 6 and pin 9, blower on delay period is 66 sec. g. Blower off delay —When the thermostat is satisfied, the circuit between R -W is broken, de- energizing the gas valve stopping gas flow to the burners. The blower motor and EAC remain energized 90, 135, 180, or 225 sec (depending on the blower off -time selection). The furnace is factory set for a 135 -sec blower off delay period. h. Post-purge--The inducer motor remains energized 5 sec after the burners are extinguished. If jumper is on pin 6 and pin 9, the post -purge period is 15 sec. 2. Cooling mode When the thermostat "calls for cooling," R -G and R -Y circuits close. The R -Y circuit starts the outdoor condensing unit and the combined R -Y and R -G circuits start the furnace blower motor on cooling speed. The EAC -I termi- nal is energized with 115-v when the blower is operating on cooling speed. When the thermostat is satisfied, R -G and R -Y circuits are broken. The furnace blower and EAC continue operating on cooling speed for an additional 90 sec. NOTE: EAC -1 terminal in energized with 1 15-v whenever blower is operating. 3. Continuous blower mode When the R -G circuit is made, the blower motor operates on heating speed. During a call for heat, the blower stops, allowing the furnace heat exchangers to heat up more quickly, then restarts at the end of the 45 -sec blower on delay period. If jumper is on pin 6 and pin 9, the blower on delay is 66 sec. The blower reverts to continuous operation after the heating cycle is completed. FIVE WIRE THREE -WIRE HEATING -ONLY BLOWER DOOR SWITCH 115 -V FIELD - SUPPLIED DISCONNECT BLK m GND AUXILIARY J -BOX FURNACE NOTE 2 C 0 N T R 0 L R- G 1 C) Y ' 24 -V TERMINAL BLOCK -1 }- NOTE 1 NOTES: 1. 2. 3. —13— When the thermostat "calls for cooling," the blower oper- ates on cooling speed. When the thermostat is satisfied, the blower operates an additional 90 sec before reverting back to continuous operation on heating speed. 4. Heat pump mode When installed with a heat pump, the furnace control automatically changes the timing sequence to avoid long blower off time during demand defrost cycles. When the W -Y or W -Y -G thermostat inputs are received at the same time, the control changes the blower to heating speed or starts the blower if it was off, and begins a heating cycle. The blower remains on until the end of the prepurge period, then shuts off until the end of the ignition warm -up and trial for ignition periods (a total of 24 sec). The blower then conies back on at heating speed. When the W input signal disappears, the control begins the normal inducer post -purge period and the blower changes to cooling speed after a I -sec delay. If the W -Y -G signals disappear at the same time, the blower remains on for the selected heating blower off delay period and the inducer goes through its normal post -purge period. If the W -Y inputs should disappear, leaving the G signal input, the control goes into continuous blower and the inducer re- mains on for the normal post -purge period. Anytime the control senses false flame, the control locks out of the heating mode. This occurs because the control cannot sense the W input due to the false flame signal, and as a result, sees only the Y input and goes into cooling mode blower off delay. All other control functions remain in standard format. NOTE: EAC -1 terminal is energized whenever blower operates. HUM terminal is only energized when gas valve is energized. FIELD 24 -V WIRING - - -- FIELD 115 -, 208/230 -, 460 -V WIRING — FACTORY 24 -V WIRING — FACTORY 115 -V WIRING THERMOSTAT TERMINALS FIELD - SUPPLIED DISCONNECT TWO WIRE CONDENSING UNIT - 208/230- OR - 460 -V - THREE PHASE 208/230 -V SINGLE PHASE Connect Y-termlnal In fumace as shown for proper blower operation. Some thermostats require a "C" terminal connection as shown. If any of the original wire, as supplied, must be replaced, use same type or equivalent wire. Fig. 15— Heating and Cooling Application Wiring Diagram A99521 HSIR R Y W _ Coi t• HUM TEST/TWIN — O LED I SEC-1 OM f= 1 IDR GVR BLWR HI /LO RELAY FUSE I ALS BLWR BLW A BVSS CAP CPU DSS EAC-1 PAC-2 FL FRS FSE FUT FU2 GV GVR HALO HSI Ii5IR HIM IDM IDR ILK JB LED LGPS LS oL AUXILIARY UNIT SWITCH, OVERTEMP. -MANUAL RESET. SFST .(N.C.) BLOWER MOTOR RELAY, SPST- (N.0.) BLOWER MOTOR BLOOD VENT SHUTOFF SWITCH, SPST- (N.C.) CAA4CITCR MCRDPROCESSOR AND CIRCUITRY DRAFT SAFEGUARD SWTCH ELECTRONIC AIR CIFMER OOMECTION (115 VAC 1.5 AMP MAX) ELECTRONIC AIR CLEANER CONNECTION (COWI N) FUSIBLE UM( FLAME ROLLOUT SW. -MAHYiL RESET; SPST{N.C.) FLAME PROVING ELECTRODE FLEE, 3 AMP, AUTOMOTNE BLADE TYPE, FACTORY INSTALLED FUSE OR CIRCUIT BREAKER CURRENT INTERRUPT DEVICE (FIELD INSTALLED It SLPPULD) GAS VALVE-REDUNDANT OPERATCRS CAS VALVE RELAY, DPST-(N.0.) BLOWER MOTOR SPEED C -V NGE RELAY, SPDT HOT SURFACE IGMTCR (115 VAC) HOT SURFACE IGMTOR RELAY, SPST(NO.) 24VAC )IJMDW1ER CONFECTION (.5 AMP. MAX.) INDUCED DRAFT MOTOR INDUCED DRAFT RELAY,SPST {NO.) BUNKER N FFS PANEL INTERLOCK SWITCH, SPST-(N.0.) JUNCTION BOX LIGHT-EMTIINO DIODE FOR STATUS CODES LOW GAS PRESSURE SUITOR, SPST {NO.) UMT SWITCH AUTO RESET, SPST(N.C.) AUTO-RESET INTERNAL MOTOR OVERLOAD TEMP. SW. PCB PL1 PL2 PL3 FL5 PRS TEST/TWIN IRAN 0 0 1 PRINTED CIRCUIT BOARD 9-CIRCUIT CONNECTOR 2-CIRCUIT PCS CONNECTOR 34ORCUIT IDM CONFECTOR 2-CIRCUT HSUPCB CONNECTOR PRESSURE SWITCFL SP'ST {NO.) COMPONENT TEST 6 TWIN TERMNAL TRANFORAER- 115 JUNCTION UNMARKED TERMINAL. PCBTERMNAL FACTORYLMRING (115VAC) FACTORY WIRING (24VAC) FIELD WIRING (115VAC) FIELD WRING (24VAC) CONDUCTOR CN PCB FIELD WIRING TERMINAL FIELD GROIN° EOUPMENT GROUND FIELD SFUCE PLUG RECEPTACLE TO 115VAC FIELD DISCONNECT L1 L2I 1L , NOTE#4 ,h EOUPMENT GROUND ILX 11 1FST/WW NOTE 512 HUM Cat BLWR SCHEMATIC DIAGRAM (NATURAL GAS & PROPANE) NOTES: 1. If any of the original equipment wire is replaced use wire rated for 105 °C. 2. Inducer (IDM) and dower (BLW? 1) motors contain internal auto-reset thermal overload switches (01). 3. Blower motor speed selections are for average conditions, see installation irotnrction s for details on optimum speed selection. 4. Use only copper wire between the dscomect switch and the fumacejulct junction box (JB). 5. This wire mat be comeded to funace sheetmetal for control to detect flame. 6. Replace ony with a 3 arrp fuse. T. Yellow lead not on all =tom. B. Blow a-on delay, gas heating 45 seconds, cooling or heat pump 2 seconds. 9. ( Bb o hwer s delay, gas x 35,180 or 225 seconds, cooling an heat pump 90 seconds. ) 10. Ignition-lockout itbrNockout will max after four calseadive unsuccessful trials4a -ig ttian. Contra will auto-reset after three bus. 11. When used, auxiliary limit switch (ALS) is on some downflow models only. Men used, FL is on upttow models only. 12. Sonia models may have spade quids connect terminals. 13. Factory connected when LGPS is not used 14. Factory connected when BVSS Is not used. BVSS used when Chimney Adapter Accessory Kt is Installed. 15. Gas valve leads are interchangeable on single stage valves. 322869.101 REV. H Fig. 16— Furnace Wiring Diagram h:: u.:�a a:„:t;s t::?: :+w,•: r A00304 m III. START -UP PROCEDURES 1. Purge gas lines —After all connections have been made, purge the lines and check for leaks. WARNING: Never purge a line into a combustion chamber. Never use matches, candles, flame, or other sources of ignition to check for gas leakage. Use a soap- and -water solution to check for gas leaks. Failure to follow this warning could result in fire, explosion, per- sonal injury, or death. 2. Component test —The furnace control allows all compo- nents, except gas valve, to be run for a short period of time. This feature helps diagnose a system problem in case of a component failure. To initiate component test procedure, short (jumper) the TEST 3 /16 -in. quick connect terminal on control (adjacent to diagnostic light) and the CoM -24V terminal on furnace thermostat connection block for ap- proximately 2 sec. (See Fig. 14.) NOTE: Component test feature will not operate if any thermostat signal is present at control. Component test sequence is as follows. a. Momentarily jumper TEST and CoM -24V terminals until LED goes off. b. LED will display previous status code 4 times. c. Inducer motor starts and continues to run for entire component test. d. Hot surface igniter is energized for 15 sec, then de- energized. e. Blower motor operates on cooling speed for 10 sec, then stops. f. Blower motor operates on heating speed for 10 sec, then stops. g. Inducer motor stops. 3. To operate furnace, follow procedures on operating instruc- tion label attached to furnace. 4. With furnace operating, set thermostat below room tem- perature and observe that furnace goes off. Set thermostat above room temperature and observe that furnace restarts. IV. ADJUSTMENTS 1. Set gas input rate Furnace gas input rate on rating plate is for installations at altitudes up to 2000 ft. Furnace input rate must be within ±2 percent of input on furnace rating plate. a. Determine natural gas orifice size and manifold pressure for correct input. (I.) Obtain average yearly gas heat value (at installed altitude) from local gas supplier. (2.) Obtain average yearly gas specific gravity from local gas supplier. Verify furnace model. Table 7 can only be used for model 376CAV Furnaces. (4.) Find installation altitude in Table 7. NOTE: For Canada altitudes of 2000 to 4500 ft, use U.S.A. altitudes of 2001 to 3000 fl in Table 7. (5.) Find closest natural gas heat value and specific gravity in Table 7. (6.) Follow heat value and specific gravity lines to point of intersection to find orifice size and manifold pressure settings for proper operation. (3.) —15— EXAMPLE: (0 -2000 ft altitude) Heating value = 1025 Btu /cu ft Specific gravity = 0.62 Therefore: Orifice No. 43* Manifold pressure 3.6 -in. wc • Furnace is shipped with No. 43 orifices. In this example all main burner orifices are the correct size and do not need to be changed to obtain proper input rate. (7.) Check and verify burner orifice size in furnace. NEVER ASSUME ORIFICE SIZE. ALWAYS CHECK AND VERIFY. NOTE: If orifice hole appears damaged or it is suspected to have been redrilled, check orifice hole with a numbered drill bit of correct size. Never redrill an orifice. A burr -free and squarely aligned orifice hole is essential for proper flame characteristics. BURNER ORIFICE A93059 CAUTION: DO NOT redrill orifices. Improper drilling (burrs, out -of -round holes, etc.) can cause excessive burner noise and misdirection of burner flames. This can result in flame impingement of burners and heat exchang- ers causing failures. b. Adjust manifold pressure to obtain input rate. (1.) Remove regulator adjustment seal cap. (See Fig. 17.) (2.) Turn adjusting screw, counterclockwise (out) to decrease manifold pressure or clockwise (in) to increase manifold pressure. NOTE: This furnace has been approved for a manifold pressure of 3.2 -in. wc to 3.8 -in. wc when installed at altitudes up to 2000 ft. For altitudes above 2000 ft, the manifold pressure can be adjusted from 2.0 -in. wc to 3.8 -in. wc. CAUTION: DO NOT bottom out gas valve regulator adjusting screw. This can result in unregulated manifold pressure and result in excess overfire and heat exchanger failures. (3.) After correct manifold pressure is obtained, replace gas valve regulator adjustment screw cap and verify adjusted gas input rate using method outlined in item c. ALTITUDE RANGE (FT) AVG GAS HEAT VALUE (BTU /CU FT) SPECIFIC GRAVITY OF NATURAL GAS 0.58 0.60 0.62 0.64 0.66 Orifice no. Manifold Pressure Orifice no. Manifold Pressure Orifice no. Manifold Pressure Orifice no. Manifold Pressure Orifice no. Manifold Pressure U.S.A. and Canada 0 to 2000 850 41 3.6 41 3.7 41 3.8 40 3.6 40 3.8 875 42 3.8 41 3.5 41 3.6 41 3.7 41 3.8 900 42 3.5 42 3.7 42 3.8 41 3.5 41 3.6 925 42 3.4 42 3.5 42 3.6 42 3.7 42 3.8 950 42 3.2 42 3.3 42 3.4 42 3.5 42 3.6 975 43 3.7 43 3.8 42 3.2 42 3.3 42 3.4 1000 43 3.5 43 3.6 43 3.7 42 3.2 42 3.3 1025 ' . 43 : 3.3 43 3.4 43 ' . 3.6 43 3.7 . `43 3.8 1050 43 '" " 3.2 43 3.3 43 : 3.4 43 3.5 43 3.6 1075 44 3.5 44 3.6 43.. 3.2 43 3.3 43. 3.4 1100 44 3.3 44 3.4 44 3.5 43 3.2 43 3.3 ALTITUDE RANGE (FT) AVG GAS HEAT VALUE (BTU /CU FT) SPECIFIC GRAVITY OF NATURAL GAS 0.58 0.60 0.62 0.64 0.66 Orifice no. Manifold Pressure Orifice no. Manifold Pressure Orifice no. Manifold Pressure Orifice no. Manifold Pressure Orifice no. Manifold Pressure U.S.A. and Canada U.S.A. Altitudes 2001 to 3000 or Canada Altitudes 2000 to 4500 775 42 3.7 42 3.8 41 3.5 41 3.6 41 3.8 800 42 3.4 42 3.6 42 3.7 42 3.8 41 3.5 825 42 3.2 42 3.3 42 3.5 42 3.6 42 3.7 850 ': 43 '.: 3.7 43 3.8 42 3.3 42 3.4 42 3.5 875 : , 43::':' 3.5 . 43 3.6 43 3.7 42 3.2 42 3.3 900 : ;' 43. -. 3.3 . 43 3.4 43 3.5 . 43 3.7 43 3.8 925 't;43r'•-:" 3.1 : '.43 3.2 43 3.4 43" 3.5 . 43" 3.6 950 ■' , "43 j 3.0 43 3.1 43 3.2 - 43 3.3 ' 43 3.4 975 - 43 :.: " 2.8 43 2.9 43 3.0 43 3.1 43 3.2 1000 .. :43 2.7 43 2.8 43 2.9 43 3.0 43 3.1 1025 43 : ' . 2.6 43 2.6 43 2.7 43 2.8 43 2.9 ALTITUDE RANGE (FT) AVG GAS HEAT VALUE (BTU /CU FT) SPECIFIC GRAVITY OF NATURAL GAS 0.58 0.60 0.62 0.64 0.66 Orifice no. Manifold Pressure Orifice no. Manifold Pressure Orifice no. Manifold Pressure Orifice no. Manifold Pressure Orifice no. Manifold Pressure A1u0 v s n 3001 to 4000 750 42 3.4 42 3.6 42 3.7 42 3.8 41 3.5 775 42 3.2 42 3.3 42 3.5 42 3.6 42 3.7 800 43 3.7 43 3.8 42 3.2 42 3.3 42 3.4 825 ''.. 43 `- 3.5 43 . 3.6 43 3.7 43 3.8 42 3.2 850 %'. '43 • , 3.3 43 " ': 3.4 43 3.5 43 3.6 43 3.7 875 2 43 `.: 3.1 43 3.2 :43 . 3.3 43 " 3.4 43' 3.5 900 '.' : 43' :: ' 2.9 43 " 3.0 43 3.1 .43 3.2 43 :' : 3.3 925 ' 43:' :: 2.8 . 43 2.9 43 3.0 43 3.0 ... 3.1 950 , >- 43 -' 2.6 43 2.7 43 2.8 43 . 2.9 . 43 ` 3.0 975 '. 43 ` " 2.5 43 2.6 43 2.7 43 2.7 43 2.8 1000 43 2.4 43 2.4 43 2.5 43 2.6 43 2.7 ALTITUDE RANGE (FT) AVG GAS HEAT VALUE (BTU /CU FT) SPECIFIC GRAVITY OF NATURAL GAS 0.58 0.60 0.62 0.64 0.66 Orifice no. Manifold Pressure Orifice no. Manifold Pressure Orifice no. Manifold Pressure Orifice no. Manifold Pressure Orifice no. Manifold Pressure I U.S.A. Only 4001 to 5000 725 42 3.2 42 3.3 42 3.5 42 3.6 42 3.7 750 ,:43.. ' 3.7 43. 3.8 42 3.2 42 3.3 42 3.4 775 > 43 ; ' 3.4 43 3.6 43 3.7 43 3.8 42 3.2 800 • :: 43 ... 3.2 43 3.3 43 3.5 43 3.6 43 3.7 825 ':.43. 3.0 43. 3.1 43 3.2 43 3.4 43 3.5 850 43 . 2.9 43 3.0 43 3.1 .43 3.2 43 3.3 875 , " 43 2.7 43 2.8 43 2.9 43 3.0 43 3.1 900 , ,_ 43 . ' 2.6 43 2.6 43 2.7 43 2.8 43 2.9 925 ... 43 2.4 43 2.5 43 2.6 43 2.7 43 2.8 950 '. " 43 2.3 43 2.4 43 2.5 43 2.5 43 2.6 TABLE 7 -MODEL 376CAV ORIFICE SIZEt AND MANIFOLD PRESSURE FOR CORRECT INPUT (TABULATED DATA BASED ON 23,000 BTUH PER BURNER, DERATED 4 PERCENT FOR EACH 1000 FT ABOVE SEA LEVEL)* • For size 060135 only, input is 22,500 B uh per burner. Deduct 0.1 -in. wc from manifold pressure shown in table. Change orifice size if manifold pressure falls below 3.2 -in wc on altitudes up to 2000 ft, otherwise change orifce size If manifold pressure falls below 2.0 -In. wc. tOrifice sizes shown In SHADING are factory Installed. -16- ALTITUDE RANGE (FT) AVG GAS SPECIFIC GRAVITY OF NATURAL GAS HEAT VALUE AT ALTITUDE (BTU /CU FT) 0.58 0,60 0.62 0,64 0.66 Orifice No. Manifold Pressure Orifice No. Manifold Pressure Orifice No. Manifold Pressure Orifice No. Manifold Pressure Orifice No. Manifold Pressure Aiuo ro's'n 5001 to 6000 700 43 3.7 43 3.8 42 3.2 42 3.3 42 3.4 725 43 3.4 43 3.6 43 3.7 43 3.8 42 3.2 750 43 3.2 43 3.3 43 3.4 43 3.5 43 3.6 775 43 3.0 43 3.1 43 3.2 43 3.3 43 3.4 800 43 2.8 43 2.9 43 3.0 43 3.1 43 3.2 825 .. 43 2.7 43 2.7 43 2.8 43. 2.9 43 3.0 850 43 2.5 43 2.6 43 2.7 43 2.8 .43 2.8 875 43 2.4 43 2.4 43 2.5 43 2.6 , 43 2.7 900 . 43.. 2.2 43 2.3 43 • 2.4 43 2.5 43 2.5 925 43. 2.1 43 2.2 43 2.3 43 2.3 43 2.4 950 48 3.8 • 43 2.1 43 2.1 43 2.2 : 43 2.3 975 48 3.6 48 3.7 '43 : 2.0 43 • 2.1 . : : 43` : 2.2 1000 48 3.4 48 3.5 48 3.6 48 3.7 '" 43 - 2.1 ALTITUDE RANGE (FT) AVG GAS HEAT VALUE AT ALTITUDE BTU /CU FT ( FT) SPECIFIC GRAVITY OF NATURAL GAS 0.58 0.60 0.62 0.64 0.66 Orifice No. Manifold Pressure Orifice No. Manifold Pressure Orifice No. Manifold Pressure Orifice No. Manifold Pressure Orifice No. Manifold Pressure Awo ro s•n 6001 to 7000 650 "43. 3.7 43 3.8 42 3.2 42 3.3 42 3.5 675 43 3.4 43 3.5 43.. 3.7 43 3.8 42 3.2 700 43. 3.2 43 3.3 43. 3.4 43 3.5 43 3.6 725 43:.: 3.0 43 3.1 43. 3.2 43. 3.3 43 3.4 750 43 2.8 43 2.9 43 3.0 43 3.1 43 3.2 775 43 2.6 43 2.7 43 • 2.8 43 2.9 43 3.0 800 43 2.4 43 2.5 43 2.6 43 2.7 43 2.8 825 • 43 2.3 43 2.4 43 2.5 43 2.5 43 2.6 850 ":43 ' . 2.2 43 2.2 43 : ' : 2.3 43 _ 2.4 43 2.5 875 43 ' • 2.0 43 2.1 43 2.2 43 2.3 43 2.3 ALTITUDE RANGE (FT) AVG GAS HEAT VALUE AT ALTITUDE (BTU /CU FT) SPECIFIC GRAVITY OF NATURAL GAS 0.58 0.60 0.62 0.64 0.66 Orifice No. Manifold Pressure Orifice No. Manifold Pressure Orifice No. Manifold Pressure Orifice No. Manifold Pressure Orifice No. Manifold Pressure Alluo ro"s'n 7001 to 8000 625 43. 3.4 43 3.6 43 3.7 43 3.8 42 3.2 650 43. 3.2 43. 3.3 43. 3.4 43 3.5 ,43 3.6 675 '43 3.0 43 3.1 43. 3.2 43 3.3 : 43 3.4 700 43 2.7 43 2.8 43 2.9 43 3.0 43 3.1 725 43 2.6 ' 43 2.6 43 ' 2.7 43 2.8 43 2.9 750 ' .43 2.4 43 2.5 43 2.6 43 2.6 . 43 2.7 775 '- '43. . 2.2 43 2.3 .43 . 2.4 43 2.5 . - '43 2.5 800 . , :43 ." 2.1 43 2.2 43 ' 2.2 .43: 2.3 43 2.4 825 48 3.7 ' 43 2.0 . 43 .. 2.1 43 2.2 . '43 2.2 850 48 3.5 48 3.6 48 3.7 43 2.1 ' . '43 2.1 ALTITUDE RANGE (FT) AVG GAS HEAT VALUE AT ALTITUDE (BTU/CU FT ( FT) SPECIFIC GRAVITY OF NATURAL GAS 0.58 0.60 0.62 0.64 0.66 Orifice No. Manifold Pressure Orifice No. Manifold Pressure Orifice No. Manifold Pressure Orifice No. Manifold Pressure Orifice No. Manifold Pressure U.S.A. Only 8001 to 9000 600 . 43 3.2 43 3.3 43 3.4 43 3.5 43 3.6 625 43 3.0 43 3.1 43 3.2 43 3.3 43 3.4 650 43 ' 2.7 43 2.8 43 2.9 43 3.0 43 3.1 675 43 ' 2.5 43 2.6 43 2.7 43 2.8 43 2.9 700 43 2.4 43 2.4 43 2.5 43 2.6 43 2.7 725 43 2.2 43 2.3 43 2.3 43 2.4 43 2.5 750 '43 2.0 43 ' 2.1 43 2.2 43 2.3 43 2.3 775 48 3.6 48 3.7 43 2.1 43. 2.1 43 2.2 800 48 3.4 48 3.5 48 3.6 48 3.7 43 2.0 TABLE 7 -MODEL 376CAV ORIFICE SIZEt AND MANIFOLD PRESSURE FOR CORRECT INPUT (CONTINUED) TABULATED DATA BASED ON 23,000 BTUH PER BURNER, DERATED 4 PERCENT FOR EACH 1000 FT ABOVE SEA LEVEL)* For size 060135 only, Input Is 22,500 Btuh per burner. Deduct 0.1 -in. we from manifold pressure shown in table. Change orifice size if manifold pressure falls below 3.2 -In wc on altitudes up o 2000 ft, otherwise change orifice size if manifold pressure falls below 2.0 -in. wc. tOrifice sizes shown in SHADING are factory installed. -17- ALTITUDE RANGE (FT) AVG GAS HEAT VALUE AT LTI ALTITUDE AT TUDE ( FT ) SPECIFIC GRAVITY OF NATURAL GAS 0.58 0.60 0.62 0.64 0.66 Orifice No. Manifold Pressure Orifice No. Manifold Pressure Orifice No. Manifold Pressure Orifice No. Manifold Pressure Orifice No. Manifold Pressure AWO - vs n I 9001 to 10,000 575 , 43 ' 3.0 43 . ' 3.1 43 ,. 3.2 '43 :. 3.3 43 3.4 600 -.43 2.7 43 2.8 43 2.9 43 3.0 . ;43 3.1 625 43:. 2.5 43 2.6 43 2.7 . 43 2.8 43 ' 2.8 650 .. 43 - 2.3 43 2.4 43 2.5 .. 43 2.6 43 • 2.6 675 ' . "43 . ' 2.1 43 2.2 43 2.3 43 ' 2.4 43 2.4 700 48 3.8 . 43 . 2.1 43 2.1 ' . 43 : 2.2 ' 43. 2.3 725 48 3.5 48 3.6 48 3.7 43 .: 2.1 ' .43 ' 2.1 750 49 3.8 48 3.4 48 3.5 48 3.6 48 3.7 775 49 3.6 49 3.7 49 3.8 48 3.4 48 3.5 ALTITUDE (FT) PERCENT OF DERATE DEBATE MULTIPLIER FACTOR FOR U.S.A.• 0-2000 0 1.00 2001 - 3000 8-12 0.90 3001 -4000 12 -16 0.86 4001 -5000 16-20 0.82 5001 -6000 20-24 0.78 6001 -7000 24-28 0.74 7001 -8000 28 -32 0.70 8001 -9000 32 -36 0.66 9001 - 10,000 36-40 0.62 TABLE 7 -MODEL 376CAV ORIFICE SIZEt AND MANIFOLD PRESSURE FOR CORRECT INPUT (CONTINUED) (TABULATED DATA BASED ON 23,000 BTUH PER BURNER, DERATED 4 PERCENT FOR EACH 1000 FT ABOVE SEA For s ze 060135 only, input is 22,500 Btuh per burner. Deduct 0.1 -In. wc from manifold pressure shown In table. Change orifice s ze if manifold pressure falls below 3.2 -in we on altitudes up o 2000 ft, otherwise change orifice size if manifold pressure falls below 2.0 -in. wc. tOriBce sizes shown In SHADING are factory Installed. Fig. 17- Redundant Automatic Gas Control Valve Fig. 18- Burner Flame A00238 A89020 -18- (4.) Burner flame should be clear blue, almost transpar- ent. (See Fig. 18.) c. Verify natural gas input rate by clocking gas meter. NOTE: High - Altitude Adjustment UNITED STATES At installation altitudes above 2000 ft, this furnace has been approved for a 4 percent derate for each 1000 ft above sea level. See Table 8 for derate multiplier factor. TABLE 8- ALTITUDE DEBATE MULTIPLIER FOR U.S.A. Derate multiplier factor is based on midpoint altitude for altitude range. EXAMPLE: 92,000 BTUH INPUT FURNACE INSTALLED AT 4300 FT. Furnace Input Derate Fumace Input Rate Rate at X Multiplier = at Installation Sea Level Factor Altitude 92,000 0.82 75,440 CANADA At installation altitudes from 2000 to 4500 ft, this furnace must be derated 10 percent by an authorized Gas Conversion Station. To determine correct input rate for altitude, see example above and use 0.90 as derate multiplier factor. a. Turn off all other gas appliances and pilots. b. Start furnace and let operate for 3 minutes. c. Measure time (in sec) for gas meter test dial to complete I revolution. d. Refer to Table 9 for cu ft of gas per hr. e. Multiply gas rate (cu ft/hr) X heating value (Btu /cu ft) using natural gas heating value from local gas utility /supplier. SECONDS FOR 1 REVOLUTION SIZE OF TEST DIAL SECONDS FOR 1 REVOLUTION SIZE OF TEST DIAL 1 Cu Ft 2 Cu Ft 5 Cu Ft 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 28 138 277 692 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 38 100 200 500 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 48 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 COLOR SPEED FACTORY - ATTACHED TO Black High COOL Yellow (When Present) Medium -High SPARE Blue Medium -Low HEAT Red Low SPARE White Common L2 /COM EXAMPLE: (0 -2000 ft altitude) Btu heating input = Btu/cu ft X cu Mir Heating value of gas = 1050 Btu/cu ft Time for 1 revolution of 2 -cu 11 dial = 82 sec Gas rate = 88 cu fl/hr (from Table 9) Btu heating input = 88 X 1050 = 92,400 Btuh In this example, the orifice size and manifold pressure adjustment is within ±2 percent of the furnace input rate. TABLE 9 RATE (CU FT /HR) 2. Set temperature rise. Furnace must operate within range of temperature rise specified on the unit rating plate. Determine the air tem- perature rise as follows. a. Place duct thermometers in return and supply ducts as near furnace as possible. Be sure thermometers do not "see" heat exchangers so that radiant heat will not affect thermometer readings. This is particularly important with straight -run ducts. b. When thermometer readings stabilize, subtract return-air temperature from supply -air temperature to determine temperature rise. c. Adjust air temperature rise by adjusting blower speed. Increase blower speed to reduce temperature rise. De- crease blower speed to increase temperature rise. WARNING: Disconnect the electrical power before changing the speed tap. A failure to follow this warning could result in personal injury. —19— d. To change blower motor speed selections for heating mode, remove blower motor lead from control board HEAT terminal. (See Fig. 14.) Select desired blower motor speed lead from 1 of the other terminals and relocate it to HEAT terminal. See Table I0 for lead color identification. Reconnect original lead on SPARE termi- nal. Follow this same procedure for proper selection of COOL speed selection. CAUTION: If Model 376CAV066115 is installed in 0.50 -in. we or lower static pressure ductwork, evaporator coil condensate blow off can occur during cooling opera- tion. When installed in this manner, do not use high blower speed tap for cooling. TABLE 10 — SPEED SELECTOR LL CAUTION: Recheck temperature rise. It must be within limits specified on unit rating plate. Recommended op- eration is at midpoint of rise or above. 3. Set thernostat heat anticipator. The thermostat heat anticipator must be set to match the amp draw of the electrical components in the R -W circuit. Accurate amp draw readings can be obtained at thermostat subbase terminals R and W. Fig. 19 illustrates an easy method of obtaining the actual amp draw. The amp reading should be taken after the blower motor has started. See the thermostat manufacturer's instructions for adjusting the heat anticipator and for varying the heating cycle length. NOTE: When using an electronic thermostat, set cycle rate for 3 cycles per hr. V. CHECK SAFETY CONTROLS The flame sensor, gas valve, and pressure switch were all checked in the Start-Up Procedures section as part of normal operation. 1. Check primary limit control. This control shuts off the combustion control system and energizes the circulating -air blower motor if the furnace overheats. The preferred method of checking the limit control is to gradually block off the return air after the furnace has been operating for a period of at least 5 minutes. As soon as the limit has shut off the burners, the return -air opening should be unblocked. By using this method to check the limit control, it can be established that the limit is functioning properly and operates if there is a motor failure. 2. Check blocked vent safeguard switch. The purpose of this control is to permit the safe shutdown of the furnace during certain blocked vent conditions. a. Disconnect power to furnace and remove vent connector from furnace outlet collar. Be sure to allow time for vent pipe to cool down before removing. I Z rdd W J 0 00 0 0 to w W LL W 0 4 2 LL 7 Sild W Z� O W 0 0 0E- W W g_ LL 0 , Z 0- 0I z u OfiA THERMOSTAT SUBBASE TERMINALS WITH THERMOSTAT REMOVED (ANITICIPATOR, CLOCK, ETC., MUST BE OUT OF CIRCUIT.) HOOK- AROUND AMMETER EXAMPLE: 10 TURNS FROM UNIT 24 -V CONTROL TERMINALS 5.0 AMPS ON AMMETER _ 0.5 AMPS FOR THERMOSTAT 10 TURNS AROUND JAWS ANTICIPATOR SETTING Fig. 19—Amp Draw Check With Ammeter b. Restore power to furnace and set room thermostat above room temperature. c. After normal start-up, allow furnace to operate for 2 minutes, then block flue outlet 100 percent. Furnace should cycle off within 2 minutes. d. Remove blockage and reconnect vent pipe to furnace outlet collar. e. Wait 5 minutes and then reset blocked vent safeguard switch. 3. Check pressure switch. This control proves operation of draft inducer blower. a. Turn off 115 -v power to furnace. b. Remove control door and disconnect inducer motor lead wires from wire harness. c. Turn on 115-v power to furnace. —20— d. Set thermostat to "call for heat" and wait 1 minute. When pressure switch is functioning properly, hot sur- face igniter should NOT glow and control diagnostic light flashes a status code 31. If hot surface igniter glows when inducer motor is disconnected, shut down furnace immediately. Determine reason pressure switch did not function properly and correct condition. e. Turn off 1 15 -v power to furnace. f. Reconnect inducer motor wires, replace control door, and tum on 115 -v power. 4. Check auxiliary limits (when used). a. Turn off 1 l5 -v power to furnace. b. Remove blower access door. c. Disconnect red motor lead at blower speed selector. Mark terminal for proper re- connection. d. Replace blower access door. e. Turn on 1 15 -v power to furnace. Be sure room thermo- stat is calling for heat. f. Allow furnace to operate until auxiliary limit activates, but DO NOT operate furnace longer than 4 minutes. A96316 g. If furnace operates for 4 minutes, check/replace switch(es). h. Turn off 1 15 -v power to furnace. i. Remove blower access door. j. Reconnect red motor lead, reset switch, and replace door. k. Turn on 115 -v power to furnace VI. CHECKLIST 1. Put away tools and instruments and clean up debris. 2. Verify manual reset switches has continuity. 3. Ensure blower and control access doors are properly in- stalled. 4. Cycle test furnace with room thermostat. 5. Check operation of accessories per manufacturer's instruc- tions. 6. Review User's Guide with owner. 7. Leave literature packet near furnace. limit CHECKLIST—INSTALLATION LOAD CALCULATION Heating Load (Btuh) Cooling Load (Btuh) Fumace Model Selection AIR FOR COMBUSTION AND VENTILATION Unconfined Space Confined Space VENTING NFGC (United States) NSCNGPIC (Canada) Local Codes 1 /4 -in. Upward Slope Joints Secure See Vent Table Instructions CHECKLIST— START -UP Gas Input Rate (Set Within 2 percent of Rating Plate) Temperature Rise Adjusted Thermostat Anticipator Setting or Thermostat Cycle Rate (3 cycles per Hr) CHECK SAFETY CONTROLS OPERATION Primary Limit Pressure Switches Draft Safeguard Switch Auxiliary Limit Switch(es) Thermostat Manufacturer Model number —2 I— t NOTICE: IF THE DOCUMENT IN THIS FRAME IS LESS CLEAR THAN THIS NOTICE IT IS DUE TO THE QUALITY OF THE DOCUMENT. NOTICE: IF THE DOCUMENT IN THIS FRAME IS LESS CLEAR THAN THIS NOTICE IT IS DUE TO THE QUALITY OF THE DOCUMENT. SERVICE TRAINING Packaged Service Training programs are an excellent way to increase your knowledge of the equipment discussed in this manual, including: • Unit Familiarization • Maintenance • Installation Overview • Operating Sequence A large selection of product, theory, and skills programs is available, using popular video -based formats and materials. All include video and/or slides, plus companion book. Classroom Service Training plus "hands -on" the products in our labs can mean increased confidence that really pays dividends in faster troubleshooting, fewer callbacks. Course descriptions and schedules are in our catalog. CALL FOR FREE CATALOG 1 800 - 962 - 9212 [ ] Packaged Service Training [ ] Classroom Service Training 02000 Bryant Heating & Cooling Systems 7310 W. Monis St. Indianapolis, IN 46231 Printed In U.S.A. 376c503 Catalog No. 5337 -605 1 R'S I \I:OIZ■I \I ION \1.\ MODELS 373LAV, 376CAV DOWNFLOW /HORIZONTAL and 383KAV, 395CAV UPFLOW GAS FURNACE Heating& Cooling Systems 0 Upflow • 11111 0 �o p° ,=o o� Downflow/ Horizontal NOTE TO INSTALLER: This manual must be left with the equipment user. /\ WARNING: If the information in this man- ual is not followed exactly, a fire or explosion may result causing property damage, personal injury or loss of life. — Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance. — WHAT TO DO IF YOU SMELL GAS: — Do not try to light any appliance. — Do not touch any electrical switch; do not use any phone in your building. • Immediately call your gas supplier from a neighbor's phone. Follow the gas supplier's instructions. • If you cannot reach your gas supplier, call the fire department. — Installation and service must be performed by a qualified installer, service agency or the gas supplier. Do not use this furnace if any part has been under water. Immediately call a qualified service technician to inspect the furnace and to replace any part of the control system and gas control which has been under water. WELCOME TO TODAY'S GENERATION OF COMFORT Congratulations! Your new, higher efficiency gas furnace is a sound investment which will reward you and your family with years of warm memories winter after winter. Not only is your new furnace energy efficient, it is also extremely reliable. Spend just a few minutes with this booklet to learn about the operation of your new furnace —and the small amount of maintenance it takes to keep it operating at peak efficiency. Years went into the development of your new furnace. Take a little time now to assure its most efficient oper- ation for years to come. UPFLOW FURNACE COMPONENTS 11 Relief Box Rating Plate I ' 1 Gas Valve Control Knob or Electric Switch (On/Off) 5 - 1 Gas Valve Gas Burner Flame Sensor Filter Retainer 181 Air Filter Blower and Blower Motor Blocked Vent Safeguard Tube and Switch Gas Manifold 12 Manual Reset Limit Switch Hot Surface Ignitor 14 Blower Door Safety Switch 2 6 9 10 m m MODEL 383KAV and 395CAV Upflow Fumace 2 1 0 v p ooc7 O O eC=Z 0 2 MODEL 373LAV and 376CAV Downflow /Horizontal Furnace 3 IMPORTANT FACTS Your furnace must have adequate air- flow for efficient combustion and safe ventilation. Do not enclose it in an airtight room or "seal" it behind solid doors. To minimize the possibility of serious personal injury, fire, damage to your furnace, or improper operation; carefully follow these safety rules: • Keep the area around your furnace free of combustible materials, gasoline, and other flammable liquids and vapors. 5 • Do not cover the furnace, store trash or debris near it, or in any way block the flow of fresh air to the unit. • Combustion air must be clean and uncontaminated with chlorine or fluo- rine. These compounds are present in 3 DOWNFLOW /HORIZONTAL FURNACE COMPONENTS 1 2 3 0 5 6 7 8 9 10 11 12 13 4 many products around the home, such as: water softener salts, laundry bleaches, detergents, adhesives, paints, varnishes, paint strippers, waxes, and plastics. Make sure the combustion air for your furnace does not contain any of these compounds. During remodeling be sure the combustion air is fresh and un- contaminated. If these compounds are burned in your furnace, the heat ex- changers and metal vent system may deteriorate. • A furnace installed in the attic or other insulated space must be kept free and clear of the insulating material. Examine the furnace area when install- ing the furnace or adding more insula- tion. Some materials may be combustible. NOTE: Do not use this furnace if any part has been under water. Immediately call a qualified service technician to in- spect the furnace and to replace any part of the control system and any gas control which has been under water. NOTE: The qualified installer or agency must use only factory- authorized re- placement parts, kits, and accessories when modifying or repairing this product. This furnace contains safety devices which must be manually reset. If the fur- Manual -Reset Auxiliary Limit Switch (When Used) Blower and Blower Motor Relief Box Gas Valve Control Knob or Electric Switch (On/Off) Gas Valve Gas Burner Rating Plate Blower Door Safety Switch Blocked Vent Safeguard Tube and Switch Gas Manifold Manual Reset Limit Switch (2) Hot Surface Ignitor Flame Sensor nace is left unattended for an extended period of time, have it checked periodi- cally for proper operation. This precau- tion will prevent problems associated with no heat, such as frozen water pipes, etc. See "Before You Request a Service Call" section in this manual. SAFETY CONSIDERATIONS Installing and servicing heating equipment can be hazardous due to gas and electrical components. Only trained and qualified personnel should install, repair, or service heating equipment. Untrained personnel can perform basic maintenance functions such as clean- ing and replacing air filters. All other operations must be performed by trained service personnel. Observe safety precautions in this manual, on tags, and on labels attached to the fur- nace and other safety precautions that may apply. Recognize safety information: This is the safety-alert symbol ©. When you see this symbol on the furnace and in instructions or manuals, be alert to the potential for personal injury. Understand the signal words —DAN- GER, WARNING, and CAUTION. These words are used with the z 1 00 N O W D g Q _ ° I— W z I— O Z I— ll/ w ON 0 I— W W Hr- w z 0 - O I -. z safety-alert symbol. DANGER identi- fies 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 would result in minor personal injury or product and property damage. STARTING YOUR FURNACE Instead of a continuously burning pilot flame, your furnace uses an automatic hot surface ignition system to light the burners each time the thermostat sig- nals the furnace to start. Follow these important safeguards: • Never attempt to manually light the burners with a match or other source of flame. 6 • Read and follow the operating in- structions on the furnace, especially the item that reads as follows: Wait 5 minutes to clear out any gas. Then smell for gas, including near the floor. If you smell gas, STOP! Follow "B" in the safety information above on this label. If you don't smell gas, go to the next step. • If a suspected malfunction occurs with your gas control system, such as the burners do not light when they should, refer to the shutdown proce- dures on the furnace, or in the next sec- tion, to turn off your system, then call your dealer as soon as possible. WARNING Should overheating occur, or the gas valve fail to shut off the gas supply, turn off the manual gas valve (See Fig. 8) to the fur- nace BEFORE turning off the electrical supply. A failure to follow this warning could re- sult in a fire or explosion, and personal injury or death. • CHECK AIR FILTER: Before at- tempting to start your furnace, be sure the furnace filter is clean and in place. (See the maintenance section of this manual.) Then proceed as follows: ( 1O EMI 0 J STEPS FOR STARTING YOUR FURNACE 1. Set your room thermostat to the lowest temperature setting. (See Fig. 7.) 2. Close the external manual gas valve. (See Fig. 8.) 3. Turn OFF the electrical supply to your furnace. (See Fig. 9.) 00 o ° moo 4 7 8 9 10 0 0 •1 11 4. Remove the furnace access door(s). a. Downflow /Horizontal— remove blower door after removing 2 screws first, then remove the control door. (See Fig. 10.) b. Upflow— remove control door. (See Fig. 11.) 5. The gas valve will have EITHER a control knob or control switch to turn off and on. Turn the control knob or switch on the gas valve to the OFF position and wait 5 min- utes. (See Fig. 12 or 13.) 6. After waiting 5 minutes, turn the control knob or switch on the gas valve to the ON position. (See Fig. 14 or 15.) 7. Replace the access door(s). See Fig. 16 for upflow and Fig. 17 for downflow. Replace control door first on downflow furnaces. Then replace blower door (secure with 2 screws). 8. Turn ON the electrical supply to the furnace. (See Fig. 18.) 9. Open the external manual gas valve. (See Fig. 19.) 10. Set the room thermostat to a tem- perature slightly above the room temperature. This will automati- cally signal the furnace to start. The inducer motor will start, and the hot surface ignitor will energize. When hot, the ignitor will have an orange glow. 12 o'�o o o ° ©,moo © o 0 0 14 16 18 OR OR o_ ° ° o o 0 0 ° o 0 1 ', 5 13 15 17 19 11. After 15 to 70 sec, the gas valve permits gas to flow to the main burners where it is ignited. Hot flames begin to warns the furnace's heat exchanger. After a time delay of approximately 45 sec, the fur- nace blower is switched on. NOTE: If the main burners fail to ig- nite, the furnace control system will go through 3 more ignition cycles. Then, if burners fail to ignite, the system will lockout. If lockout occurs, or the blower doesn't come on —shut down your fur- nace and call your dealer for service. 12. Set your thermostat to the tempera- ture that satisfies your comfort re- quirements. SUGGESTION: Setting the thermostat back a few degrees —and compensating for the difference with warmer clothing — can make a big difference in your fuel consumption on extremely cold days. The few degrees at the top of your thermostat "comfort level" are the most costly degrees to obtain. When the room temperature drops below the temperature selected on the thermostat, the furnace will be switched on automatically. When the room temperature reaches the degree selected on the thermostat, the furnace will be switched off automatically. Some thermostats have a "fan" mode with 2 selections: AUTO or ON. When set on AUTO, the furnace blower cy- cles on and off, controlled by the ther- mostat. In the ON position, the furnace blower runs continuously except for a 45 -sec delay at the "call for heat." This keeps the temperature level in your home more evenly balanced. It also continuously filters the indoor air. SHUTTING DOWN YOUR FURNACE Should you ever suspect a malfunction in your furnace, you will need to turn the furnace off. The following proce- dures must be followed: 1. Set your room thermostat to the lowest temperature setting. (See Fig. 20.) 2. Close the external manual gas valve. (See Fig. 8 on page 4.) 3. Turn OFF the electrical supply to your furnace. (See Fig. 21.) 4. Remove the control access door on your furnace. (Sec Fig. 10 or 11.) On upflow furnaces, removing the blower access door is not required. 5. Turn the control knob or switch on the gas valve to the OFF position. (See Fig. 22 or 23.) ' l 0 20 21 22 23 6. Replace the control access door. (See Fig. 16 or 17.) 7. If the furnace is being shut down because of a malfunction, call your dealer as soon as possible. PERFORMING ROUTINE MAINTENANCE With the proper maintenance and care, your furnace will operate economically and dependably. Basic maintenance, which can easily be accomplished by someone who follows the directions, is found on this and the following pages. However, before beginning mainte- nance, follow these safety precautions: A WARNING Turn off electrical power sup- ply to your furnace before re- moving the access doors to service or perform mainte- nance. A failure to follow this warning could result in per- sonal injury or death. A CAUTION Although special care has been taken to minimize sharp edges, be extremely careful when handling parts or reach- ing into the furnace. FILTERING OUT TROUBLE A dirty filter will cause excessive stress on the furnace blower motor and can cause it to overheat and automatically shut down. The furnace filter should be checked every 3 or4 weeks and cleaned if necessary. If installed with factory specified disposable media filter, check or replace filter before each heating and cooling season. Replace disposable media filter at least once a year. If installed with factory specified dis- posable media filter, check or replace filter before each heating and cooling OR season. Replace disposable media filter at least once a year. If your furnace filter needs replacing, be sure to use the same size and type of fil- ter that was originally supplied. Use the Furnace Filter Table and compare your 6 furnace size with the proper filter size. A CAUTION Never operate your furnace without a filter in place. Doing so may damage the furnace blower motor. An accumula- tion of dust and lint on internal parts of your furnace can cause a Toss of efficiency. The air filter for upflow furnaces is nor- mally located in the blower compart- ment (See Fig. 03.) or in the factory- supplier filter cabinet attached to the side or bottom of the blower cabinet. Filters for the downflow furnaces are normally located in the return -air ple- num above the blower. If air filter has been installed in another location, con- tact your dealer for instructions. To in- spect, clean, and /or replace the air filter(s). follow these steps: UPFLOW FURNACES ONLY: 1. Turn off electrical supply to fur- nace. (See Fig. 9) 2. Remove door /access panel. • AIR FILTER(S) LOCATED IN BLOWER COMPARTMENT Remove control and blower access doors. (See Fig. 10 and 11) • AIR FILTER LOCATED IN FIL- TER CABINET Remove filter cabinet door (See Fig. 30 and 31) NOTE: It will be necessary to remove 1 thumbscrew 24 25 r� 1r 0 X01 5. Turn the control knob or switch on the gas valve to the OFF position. (See Fig. 22 or 23.) ' l 0 20 21 22 23 6. Replace the control access door. (See Fig. 16 or 17.) 7. If the furnace is being shut down because of a malfunction, call your dealer as soon as possible. PERFORMING ROUTINE MAINTENANCE With the proper maintenance and care, your furnace will operate economically and dependably. Basic maintenance, which can easily be accomplished by someone who follows the directions, is found on this and the following pages. However, before beginning mainte- nance, follow these safety precautions: A WARNING Turn off electrical power sup- ply to your furnace before re- moving the access doors to service or perform mainte- nance. A failure to follow this warning could result in per- sonal injury or death. A CAUTION Although special care has been taken to minimize sharp edges, be extremely careful when handling parts or reach- ing into the furnace. FILTERING OUT TROUBLE A dirty filter will cause excessive stress on the furnace blower motor and can cause it to overheat and automatically shut down. The furnace filter should be checked every 3 or4 weeks and cleaned if necessary. If installed with factory specified disposable media filter, check or replace filter before each heating and cooling season. Replace disposable media filter at least once a year. If installed with factory specified dis- posable media filter, check or replace filter before each heating and cooling OR season. Replace disposable media filter at least once a year. If your furnace filter needs replacing, be sure to use the same size and type of fil- ter that was originally supplied. Use the Furnace Filter Table and compare your 6 furnace size with the proper filter size. A CAUTION Never operate your furnace without a filter in place. Doing so may damage the furnace blower motor. An accumula- tion of dust and lint on internal parts of your furnace can cause a Toss of efficiency. The air filter for upflow furnaces is nor- mally located in the blower compart- ment (See Fig. 03.) or in the factory- supplier filter cabinet attached to the side or bottom of the blower cabinet. Filters for the downflow furnaces are normally located in the return -air ple- num above the blower. If air filter has been installed in another location, con- tact your dealer for instructions. To in- spect, clean, and /or replace the air filter(s). follow these steps: UPFLOW FURNACES ONLY: 1. Turn off electrical supply to fur- nace. (See Fig. 9) 2. Remove door /access panel. • AIR FILTER(S) LOCATED IN BLOWER COMPARTMENT Remove control and blower access doors. (See Fig. 10 and 11) • AIR FILTER LOCATED IN FIL- TER CABINET Remove filter cabinet door (See Fig. 30 and 31) NOTE: It will be necessary to remove 1 thumbscrew 24 25 AIR FILTER LOCATED IN FILTER CABINET FILTER CABINET HEIGHT (IN) FILTER SIZE (IN.) FILTER TYPE 16 (I) I6 x 25 x 1 • or (1)16 x 25 x 4 -5/16 Cleanable Disposable 20 (I)20x25x 1•or (1) 20 x 25 x 4 -5/16 Cleanable Disposable 24 (1) 24 x 25 x l • or (1) 24 x 25 x 4 -5/16 Cleanable Disposable AIR FILTER LOCATED IN BLOWER COMPARTMENT FURNACE CASING WIDTH FILTER SIZE (IN.) FILTER TYPE Side Return Bottom Retum 14.3/16 (I)16x25x1• (I)14x25x1 Cleanable 17-1/2 (I)16x25x1• (1)16x25xIs Cleanable 21 (I)16x25x1 (1)20x25x1 Cleanable 24-1/2 (1 or2) 16x25x1 (I)24x25x1• Cleanable FURNACE CASING WIDTH FILTER SIZE FILTER TYPE 14 -3/16 (2)16x20x1• Cleanable 17 -1/2 (2)16x20x1• Cleanable 21 (2)16x20x1• Cleanable 24-1/2 (2) 16x20x1• Cleanable 3. Remove air filter from furnace. • AIR FILTER LOCATED IN BLOWER COMPARTMENT: a) Slide filter retainer sideways un- til it is free of latch. (See Fig. 24) b) Gently remove air filter and carefully turn the dirty side up (if dirty) to avoid spilling dirt from the filter. (see Fig. 25) • AIR FILTER LOCATED IN FIL- TER CABINET: a) Slide air filter out of furnace. Keep dirty side up (if dirty) to avoid spilling dirt. (See Fig. 32 and 33) 26 4. Inspect the filter. If torn, replace it. NOTE: If washable filter that was shipped with the furnace has been re- placed by: a) Factory specified disposable media filter – Do not clean. If dirty, replace only with media filter having the same part num- ber and size. Install with airflow direction arrow pointing to- wards blower. b) Electronic air cleaner (EAC) – Refer to EAC owner's Manual for maintenance information. 5. Wash filter (if dirty) in sink, bath- tub, or outside with a garden hose. Always use cold tap water. A mild liquid detergent may be used if nec- essary. Spray water through filter in the opposite direction of airflow. Allow filter to dry. 6. Reinstall clean air filter 7. Reinstall filter retainer (for blower compartment locations only) 8. Replace control and blower doors (See Fig. 16 and 17) or filter cabinet door (Fig. 34 and 35) 9. Turn on electrical supply to furnace (see Fig 18). NOTE: For upflow models only —if side return ducts are used, 2 filters may be required in some models. The pro- cedure listed above may be used to remove side filters. 27 28 DOWNFLOW /HORIZONTAL FURNACES ONLY: Two filters are located in the return-air plenum above the blower (above line - of- sight) resting in the V-shaped chan- nel on top of the furnace. (See Fig. 27.) 1. Turn OFF electrical supply to the furnace. (See Fig. 21.) 2. Remove blower access door after removing 2 screws. 3. Remove the left -side filter by tip- ping the filter toward the center — raise it from the V-shaped channel in which it rests. (See Fig. 27 and 28.) 4. Lower filter down along side of the blower and remove from the furnace. 5. To remove the second filter, lift from V-shaped channel and remove the same way as left side filter. 6. Inspect the filters. If torn, replace the filter. 7. Wash the filters (if dirty) in a sink, bathtub, or outside with a garden hose. Always use cold tap water. A mild liquid detergent may be used if necessary. Spray water through the filter in the opposite direction of airflow. Allow filter to dry. 8. Reinstall clean filters. 9. Replace blower door (secure with 2 screws) and turn ON electrical power to your furnace. UPFLOW FURNACE AIR FILTER TABLE 7 DOWNFLOWIHORIZONTAL FURNACE FILTER TABLE • Factory provided with the furnace. Filters may be field modified by cutting filter material and support rods (3) In filters. Alternate sizes and additional filters may be ordered from your dealer. A CAUTION Use care when cutting support rods in filters to protect against flying pieces and sharp rod ends. Wear safety glasses, gloves, and appropri- ate protective clothing. Failure to follow this caution could re- sult in personal injury. COMBUSTION AREA AND VENT SYSTEM Inspect the combustion area and vent system before each heating season. An accumulation of dirt, soot, or rust can mean a loss of efficiency and improper performance. Buildups on the main burners can cause faulty firing. This "delayed ignition" is characterized by an alarmingly loud sound. If your fur- nace makes a loud noise when the main burners are ignited, shut down the fur- nace --call your servicing dealer. Use your flashlight and follow these steps for inspecting the combustion area and vent system of your furnace: 1. Turn off the electrical supply to the furnace and remove the access doors. (See Fig. 9 and 10, or 11.) 2. Carefully inspect the gas burner (see Fig. 29) for dirt, rust, or scale. Then inspect the relief box, flue Z ~ W UO W F u. WO 2 u Sa d H Z F O W W M O N CI E- U/ W 1- IL. O w Z U = O ~ Z connection arca, and the vent pipe for rust. Mb 1 29 NOTE: If dirt, rust, soot, or scale accu- mulations are found, call your servic- ing dealer. DO NOT OPERATE THE FURNACE. 3. Inspect the vent pipe for a sag, holes, or a disconnection. A hori- zontal vent pipe must scope up- ward. If rusty joints or seams, or signs of water leakages are found call your dealer for service. A WARNING If holes are found —or if the vent pipe is obstructed or is not connected —toxic fumes can escape into your home. DO NOT OPERATE YOUR FUR- NACE. Call your dealer for ser- vice. A failure to follow this warning could result in per- sonal injury or death. 4. Replace the access doors and re- store electrical power to the fur- nace. Be sure bottom door flange is inside of the furnace casing. (See Fig. 16, 17, and 26.) 5. Start the furnace and observe its operation. If possible, watch the burner flames. Are they burning bright blue? If not (or if you suspect some other malfunction), call your servicin dealer. 30 8 31 32 33 34 35 BEFORE YOU REQUEST A "SERVICE CALL" BEFORE YOU CALL FOR SERVICE, CHECK FOR SEVERAL EASILY SOLVED PROBLEMS: • Check for sufficient airflow. Check the air filter for dirt. Check for blocked re- turn-air or supply -air grilles. Be sure they are open and unobstructed. If this isn't the cause, call your servicing dealer. If your furnace isn't operating at all, check the following list for easily solved problems: • Is your thermostat set above room temperature? Is the HEAT mode selected? • Is the electrical power supply switch ON? Is the blower access door firmly in place? Are any fuses blown? (There is a fuse on the furnace control board.) Has a circuit breaker tripped? • Is the manual shutoff valve in the gas supply pipe leading to the furnace is open? Does the lever point in the same direction that the pipe runs (open)? Or is it at right angles (closed)? NOTE: Before proceeding with the next checks, turn OFF the electrical power supply to the furnace. Remove the access doors. • Is the control knob or switch on the gas valve turned to the ON position? If this or the preceding check shows an interruption in the gas supply, make sure the gas has not been shut off for safety reasons. If nothing else seems to be wrong, follow the startup proce- dures found on pages 4 and 5 of this booklet. • If for some reason the vent is blocked, the draft safeguard switch will shut off the furnace. Reset the switch by pushing the button located on top of the switch. (See page 2 or 3 for switch location.) If the switch trips a second time, turn off the furnace and call for service. DOWNFLOW /HORIZONTAL ONLY —Check the manual -reset aux- iliary limit switch (when used) located on the blower housing. If the blower motor fails, this switch will shut off the furnace. Reset it by pushing the button on the switch. If it trips again, turn off the furnace and call for service. • Check the manual -reset limit switch(es) located near the burners. If the furnace has experienced a high - temperature condition, due to inade- quate combustion air, these switches will shut off the furnace. Reset the switch(es) by pushing the button on the switch. If the switch trips a second time, turn off the furnace and call for service. • If your furnace still fails to operate, call your servicing dealer for troubleshooting and repairs. Tell your dealer the model and serial numbers for your furnace. (You should have them recorded on page 12 of this booklet.) By knowing exactly which furnace you have, the dealer may be able to offer suggestions over the phone, or save valuable time through knowledgeable preparation for the ser- vice call. REGULAR DEALER MAINTENANCE In addition to the type of routine main- tenance you might be willing to do, your furnace should be inspected regularly by a properly trained service technician. An annual inspection (or biennial inspection, at least) should include the following: 1. Inspection of all flue product pas- sages— including the burners, heat exchanger, relief box, and vent pipe. 2. Inspection of all combustion and ventilation air passages and openings. 3. Close check of all gas pipes leading to (and inside of) your furnace. 9 4. Inspection, cleaning, and lubrica- tion (when required) of the blower motor and wheel. NOTE: Refer to the unit Service Proce- dures for blower motor oiling informa- tion. Whcn required, the motor must be oiled by a qualified service technician. 5. Routine inspection and cleaning/ replacement of the air filter. 6. Inspection of all supply- and return-air ducts for obstructions, air leaks, and insulation. Any prob- lems found should be resolved at this time. 7. Inspection of furnace installation for proper support and any obvi- ous deterioration of the furnace. The support must be sound and without sags, gaps, cracks, etc., around the furnace base so as to provide an air seal between the support and furnace. 8. A check for loose connections attaching individual components. Inspection of all electrical wiring and their connections. 9. Operational check of the furnace itself to determine working condi- tion. Repair or adjustment should be made at this time. Ask your servicing dealer for further details about an economical service contract that covers seasonal inspections. reW UO coo cow 9 N W WO 2 � U � � Z� O Z W W U O � 0 I— W H 1 . = O LIJ Z U= O ~ Z