HomeMy WebLinkAboutPermit M06-085 - GRETCHMAN RESIDENCEGRETCHMAN RESIDENCE
16049 51 AV S
EXPIRED 10 -24 -06
M06 -085
Parcel No.: 5379800300
Address: 16049 51 AV S TUKW
Suite No:
City in' Tukwila
Tenant:
Name: GRETCHMAN RESIDENCE
Address: 16049 51 AV S, TUKWILA WA
Department of Community Development
6300 Southcenter Boulevard, Suite #100
Tukwila, Washington 98188
Phone: 206 -431 -3670
Fax: 206 - 431 -3665
Web site: ci.tukwila.wa.us
Owner:
Name: BOLER 3ON L
Address: 16049 51ST AV S, SEATTLE WA 98188
Contact Person:
Name: KIYOMI DAMPER
Address: 2800 THORNDYKE AV W, SEATTLE WA
Contractor:
Name: WASHINGTON ENERGY SERVICES CO
Address: 2800 THORNDYKE AVE W, SEATTLE, WA
Contractor License No: WASHIES9710B
DESCRIPTION OF WORK:
INSTALL 70,000 BTU GAS FURNACE AND 50 GALLON GAS WATER HEATER, BOTH WITH GAS
PIPING.
Value of Mechanical: $8,523.00
Type of Fire Protection:
Furnace' <100K BTU 1
>100K BTU 0
Floor Furnace 0
Suspended/Wall /Floor Mounted Heater 0
Appliance Vent 0
Repair or Addition to Heat/Refrig /Cooling System
Air Handling Unit <10,000 CFM 0
>10,000 CFM 0
Evaporator Cooler 0
Ventilation Fan connected to single duct 0
Ventilation System 0
Hood and Duct 0
Incinerator: Domestic 0
Commercial /Industrial 0
doc: IMC-Permit
MECHANICAL PERMIT
EQUIPMENT TYPE AND QUANTITY
* *continued on next page **
M06 -085
Permit Number:
Issue Date:
Permit Expires On:
Phone:
Phone: 206 678 -6649
Phone: 206 282 -4200
Expiration Date:09 /02/2007
Steven M. Mullet, Mayor
Steve Lancaster, Director
M06 -085
04/27/2006
10/24/2006
Fees Collected: $212.44
International Mechanical Code Edition: 2003
Boiler Compressor:
0-3 HP /100,000 BTU 0
3 -15 HP /500,000 BTU 0
15 -30 HP /1,000,000 BTU.. 0
30 -50 HP /1,750,000 BTU.. 0
50+ HP /1,750,000 BTU 0
Fire Damper 0
Diffuser 0
Thermostat 0
Wood /Gas Stove 0
Water Heater 1
Emergency Generator 0
Other Mechanical Equipment... 0
Printed: 04 -27 -2006
Permit Center Authorized Signature:
I hereby certify that I have read and"x min is 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 permit does
regulating construction or the
Signature:
doc: IMC- Permit
City 6 Tukwila
Department of Community Development
6300 Southcenter Boulevard, Suite #100
Tukwila, Washington 98188
Phone: 206431 -3670
Fax: 206 - 431 -3665
Web site: cttukwila.wa.us
Print Name: tie fief / r`ffyn&U(Y
Jv p"' JAW
Steven M. Mullet, Mayor
Steve Lancaster, Director
Permit Number: M06 -085
Issue Date: 04/27/2006
Permit Expires On: 10/24/2006
Date: I2' -,6(p
presume to give authority to violate or cancel the provisions of any other state or local laws
ance of work. I am authorized to sign and obtain this mechanical rmit.
Date: Vt 74‘
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.
M06 -085 Printed: 04 -27 -2006
Tukwila
City of
Department of Community Development / 6300 Southcenter BL, Suite 100 / Tukwila, WA 98188 / (206) 431 -3670
Parcel No.: 5379800300
Address: 16049 51 AV S TUKW
Suite No:
Tenant: GRETCHMAN RESIDENCE
2: ** *BUILDING DEPARTMENT CONDITIONS * **
doc: Conditions
PERMIT CONDITIONS
* *continued on next page **
Permit Number: M06-085
Status: ISSUED
Applied Date: 04/27/2006
Issue Date: 04/27/2006
1: No changes shall be made to the approved plans unless approved by the design professional in responsible charge and the
Building Official.
3: All permits, inspection records, and approved plans shall be at the job site and available to the inspectors prior to
start of any construction These documents shall be maintained and made available until final inspection approval is
granted.
4: Manufacturers installation instructions shall be available on the job site at the time of inspection.
5: Except for direct -vent appliances that obtain all combustion air directly from the outdoors; fuel -fired appliances
shall not be located in, or obtain combustion air from, any of the following rooms or spaces: Sleeping rooms,
bathrooms, toilet rooms, storage closets, surgical rooms.
6: Equipment and appliances having an ignition source and located In hazardous locations and public garages, PRIVATE
GARAGES, repair garages, automotive motor -fuel dispensing facilities and parking garages shall be elevated such that
the source of ignition is not less than 18 inches above the floor surface on which the equipment or appliance rests.
7: Water heaters shall be anchored or strapped to resist horizontal displacement due to earthquake motion. Strapping shall
be at points within the upper one -third and lower one -third of the water heater's vertical dimension. A minimum
distance of 4- inches shall be maintained above the controls with the strapping.
8: All plumbing and gas piping work shall be inspected and approved under a separate permit Issued by the Cityof Tukwila
Permit Center.
9: All electrical work shall be inspected and approved under a separate permit issued by the Washington State Department
of Labor and Industries (206/248-6630).
10: VALIDITY OF PERMIT: The Issuance or granting of a permit shall not be construed to be a permit for, or an approval of,
any violation of any of the provisions of the building code or of any other ordinances of the City of Tukwila. Permits
presuming to give authority to violate or cancel the provisions of the code or other ordinances of the City of Tukwila
shall not be valid. The issuance of a permit based on construction documents and other data shall not prevent the
Building Official from requiring the correction of errors in the construction documents and other data.
M06 -085 Printed: 04 -27 -2006
City of Tukwila
Department of Community Development / 6300 Southcenter BL, Suite 100 / Tukwila, WA 98188 / (206) 431 -3670
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 or the performance of work.
Signature:
Print Name:
doc: Conditions
t
(4 k dr 77-i r6Ludfr
Date: g
M06 -085 Printed: 04-27 -2006
Company Name:
Mailing Address:
Contact Person:
E-Mail Address:
Contact Person:
E-Mail Address:
4bri
CITY OF TUKWILA
Community Development Department
Permit Center
6300 Southcenter Blvd., Suite 100
Tukwila, WA 98188
http://www.ctrukwila.wa.us
MECHANICAL PERMIT APPLICATION
Applications and plans must be complete in order to be accepted for plan review.
Applications will not be accepted through the mail or by fax.
**Please Print**
Site Address: /7D q 57 i4Vej
Tenant Name: Si-- re _i
Property Owners Name: \ river R 6 rekh #144.0
Mailing Address: ne °sty 57J 7 1-0-L Icn 1c
city
MECHANICAL CONTRACTOR INFORMATION-
Company Name: ata-Th et-tat/ \AVVIC.12X
Mailing Address: e lte 00 L tholtrefe--e_ 46ce cJ
Contact Person: 61 Daft er
E-Mail Address:
Contractor Registration Number: WW1-I lea'? Ota
Q:I.ApplicationstFonns-Applications On Line \ 3-2006. Mechanical Permit Application.doc
Revised: 4-2006
bb
King Co Assessor's Tax No.: c 37TONDO 0e)
Suite Number:
New Tenant: .... Yes ..No
g
State
[iecnrsictir
PE} ON 4 rho do,(5 ierins
Is iady to
Name: art) Pahl/e Day Telephone: 2. CP 77?
Mailing Address: 2-traO L 412 01 / 14 -4 4 \P- LW— %t 97
City State Zip
E-Mail Address: Fax Number:
4eN&C n
State Zip
Day Telephone:ft& itt c i f FOn
Fax Number:
Expiration Date:
[ARC'Diner OF ?'HI All plans must be wetataMped by tiflieCord
city
Day Telephone:
Fax Number:
State
rg:$001,Ent:F::-4.g oAD 4
Alt plans must be wet stamped by Engineer of Record. -
. ' - •
Company Name:
Mailing Address:
City
Day Telephone:
Fax Number:
State
Floor:
Zip
Zip
Zip
Page 1 of 2
Unit Type:
Qty
Unit Type:
Qty
Unit Type:
Qty
Boiler /Compressor:
Qty
Furnace<100K BTU
i
Air Handling Unit >10,000
CFM
Fire Damper
0-3 HP /100,000 BTU
Fumace>100K BTU
Evaporator Cooler
Diffuser
3 -15 HP /500,000 BTU
Floor Furnace
Ventilation Fan Connected
to Single Duct
Thermostat
15 -30 HP /1,000,000 BTU
Suspended/Wall/Floor
Mounted Heater
,Ventilation System
Wood/Gas Stove
30-50 HP /1,750,000 BTU
Appliance Vent
Hood and Duct
Water Heater
/
50+ HP/I,750,000 BTU
Repair or Addition to
Heat/Refrig/Cooling
System
Incinerator - Domestic
Emergency
Generator
Air Handling Unit
<10,000 CFM
Incinerator — Comm/Ind
Other Mechanical
Equipment
'r
Valuation of Project (contractor's bid price): $ �
&54Z 3
Scope of Work (please provide detailed information):
flail (t - 2G0. 5 0
5D 96(1104. ?a,/
Use: Residential: New ...X Replacement .... ❑
Commercial: New .... ❑ Replacement .... ❑
BUILDING OW ERORAUT DA • •a
I Date Application Accepted: o j I
Q: Applienia s Forms- Application. On LineV3006 - Mechanical Permit Appliutiondoc
aevined: 4-2006
bh
ka w <�
ee / - &VIA " /rd /9tny
Fuel Type: Electric ❑ Gas ....X Other:
Indicate type of mechanical work being installed and the quantity below:
Value of Construction —In all cases, a value of construction amount should be entered by the applicant. This figure will be reviewed and is subject
to possible revision by the Permit Center to comply with current fee schedules.
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 grant one or more extensions of time for additional periods not exceeding 90 days each. The extension shall be requested
in writing and justifiable cause demonstrated. Section 105.3.2 International Building Code (current edition).
I HEREBY CERTIFY THAT I HAVE READ AND EXAMINED THIS APPLICATION AND KNOW THE SAME TO BE TRUE UNDER
PENALTY OF PERJURY BY THE LAWS OF THE STATE OF WASHINGTON, AND I AM AUTHORIZED TO APPLY FOR THIS PERMIT.
Date: il ia 77
Signature: /a u LE -.Akit
h Mid Print Name: ,�� . p
Mailing Address: - pO &K 203 ¥ re A tC(a . J �& gal
Qty State Zip
Day Telephone: ( 7 1 2-ro 2 I T'
Date Application Expires: I DIli—I a/
Staff Initials:
Page 2 oft
RECEIPT NO: R06 -00573
Initials: JEM
Payment Date: 04 /27/2006
User ID: 1165 Total Payment:290.44
Payee: WASHINGTON ENERGY SERVICES COMPANY
SET ID: 5000000473 SET NAME: Tmp set/Initialized Activities
SET TRANSACTIONS:
Set Member Amount
M06 -085 0 212.44
PG06 -014 78.00
TOTAL: 290.44
TRANSACTION LIST:
Type Method Description
ACCOUNT ITEM LIST:
Description
MECHANICAL - RES
PLUMBING - RES
City of Tukwila
Department of Community Development
6300 Southcenter Boulevard, Suite #100
Tukwila, Washington 98188
Phone: 206-431-3670
Fax: 206431 -3665
SET RECEIPT
Amount
Payment Check 5858 290.44
TOTAL: 290.44
Account Code Current Pmts
- 000/322.100 212.44
000/322.100 78.00
TOTAL: 290.44
4913 04/27 9716 TOTAL 290.44
Steven M. Mullet, Mavor
Steve Lancaster, Director
Printed to USA
Residential Gas
Use & Care Manual
AWarning: This water beater is not
su itable for use in manufactured (mobile) homes! With Installation Instructions for the Installer
Direct Vent Water Heaters
The purpose of this manual is twofold: one, to provide the installer with the basic directions and
recommendations for the proper installation and adjustment of the water heater; and two, for the
owner —operator, to explain the features, operation, safety precautions, maintenance and troubleshooting
of the water heater. This manual also includes a parts list.
It is imperative that all persons who are expected to install, operate or adjust this water heater read the
instructions carefully so they may understand how to perform these operations. If you do not understand
these instructions or any tenns within it, seek professional advice.
Any questions regarding the operation, maintenance, service or warranty of this water heater should be
directed to the seller from whom it was purchased. If additional information is required, refer to the
section on "If you need service."
Do not destroy this manual. Please read carefully and keep in a safe place for future reference.
A Recognize this symbol as an Indication of Important Safety Information!
A California Proposition 68 Warning: This product contains chemicals known to the State of
California to cause cancer, birth defects or other reproductive ham).
A WARNING: If the information in these instructions is not followed exactly,
a fire or explosion may result causing property damage, personal injury or death.
A FOR YOUR SAFETY!
— Do not store or use gasoline or other
flammable vapors or liquids or other
combustible materials in the vicinity of this or
any other appliance. To do so may result in an
explosion or fire.
— 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.
• Do not return to your home until authorized
by the gas supplier or fire department.
— Improper installation, adjustment, alteration,
service or maintenance can cause property
damage, personal injury, or death . Refer to
this manual. Installation and service must be
performed by a qualified installer, service
agency or the gas supplier.
14NCEIVIZO
ern? of TUKWULA
APR 2 7 2006
AP10189 -12 (08/03)
Pr'AANT CENTER
Mar obi
nc) co,
FOR YOUR RECORDS
Write the model and serial numbers here:
You can find them on a label on the appliance.
Staple sales slip or cancelled check here.
Proof of the original purchase date is needed to obtain service under
the warranty.
READ THIS MANUAL
Inside you will find many helpful hints on how to use and
maintain your water heater properly. A little preventive care on
your part can save you time and money over the life of your
water heater.
You'll find many answers to common problems in the
Troubleshooting Guide. If you review the chart of
Troubleshooting Tips first, you may not need to call for service.
READ THE SAFETY INFORMATION
Your safety and the safety of others are very important. There
are many important safety messages in this manual and on
your appliance. Always read and obey alt safety messages.
This is the safety alert symbol. Recognize this symbol
A as an indication of Important Safety Information!
This symbol alerts you to potential hazards that can
kill or hurt you and others.
All safety messages will follow the safety alert symbol and
either the word "DANGER", "WARNING ", "CAUTION" or
"NOTICE ".
These words mean:
A DANGER
A WARNING
A CAUTION
Notice:
An imminently hazardous situation
that will result in death or serious
injury.
A potentially hazardous situation that
could result in death or serious injury
and/or damage to property.
A potentially hazardous situation that
may result in minor or moderate
injury.
Attention is called to observe a
specified procedure or maintain
a specific condition.
IMPORTANT SAFETY INFORMATION.
READ ALL INSTRUCTIONS BEFORE USING
Be sure to read and understand the entire Use and Care Manual before attempting to install or operate
this water beater. It may save you time and money. Pay particular attention to the Safety Instructions.
Failure to follow these warnings could result in serious bodily injury or death. Should you have
problems understanding the instructions in this manual, or have any questions, STOP, and get help
from a qualified service technician, or the local gas utility.
O
ADANGER!
INSTALL THE VENTING SYSTEM AND PROPERLY VENT
THE WATER HEATER.. •
Failure to Install the venting system and properly vent the water beater to the outdoors as
outlined in the Venting Section of the Installation Instructions in this manual can result in
unsafe operation of the water heater. To avoid the risk of fire, explosion, or asphyxiation
from carbon monoxide, never operate this water heater unless it is properly vented and
has an adequate air supply for proper operation. Be sure to inspect the vent system for
proper installation at initial start-up; and at least annually thereafter. Refer to the Care
and Cleaning section of this manual for more information regarding vent system
inspection.
AWARNING!
Gasoline, as well as other flammable materials and liquids (adhesives, solvents, paint
thinners etc.), and the vapors they produce are extremely dangerous. DO NOT handle,
use or store gasoline or other flammable or combustible materials anywhere near or in the
vicinity of a water heater or any other appliance. Be sure to read and follow warning label
pictured below and other labels on the water heater, as well as the warnings printed in
this manual Failure to do so can result in property damage, bodily injury or death.
A DANGER
AVapon from lhmmsble
Itpdds wn explode and
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mallr hoer. per.
4 Iran
fisd
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Lightly dosed and
lout al *fames meth
eoe4aara
Do nonmetal wslor hsalar
Whenlnn.be producer.
4 Oared anal Misss
min bnvod plat Ins
Waist herm11111• men
burner and plot aunt
its plot lino
1.Yanrs Ira And
a. NO lards laminable
vapors.
Wong
1 snot boloa.
2. ape haler than sir,
lane= vow Gotha
`art heradbum
Mr plat
Ian by alr sunset
real peal it .bores
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hunter r pact tams.
Road IS sowair le inni gs and ..ammo.rcams
and a mlaeap,metd fir Si aanbner.
3
•
IMPORTANT SAFETY INFORMATION.
READ ALL INSTRUCTIONS BEFORE USING
4
ADANGER!
WATER TEMPERATURE SETTING
Safety and energy conservation are factors to be considered when selecting the water
temperature setting of a water heater's gas control Water temperatures above 125 °F
can cause severe burns or death from scalding. Be sure to read and follow the warnings
outlined on the label pictured below. This label is also located on the water heater.
A DANGER
Water temperature over 125 °F can
cause severe burns Instantly or
death from scalds.
Children, disabled and elderly are
at highest risk of being scalded.
See Instruction manual before
setting temperature at water
heater.
Feel water before bathing or
showering.
Temperature limiting valves are
available, see manual.
Notice: Mixing valves are available for reducing point of
use water temperature by mixing hot and cold water in
branch water lines. Contact a licensed plumber or the
local plumbing authority for further information.
Time/Temperature Relationship in Scalds
Table courtesy of aamm aura Imam
The chart shown above may be used as a guide
in determining the proper water temperature for your
home.
A DANGER: Households with small children, disabled,
or elderly persons may require a 120 °F or lower gas control
(thermostat) setting to prevent contact with "HOT" water.
Maximum water temperatures occur just after the
burner has shut off. To fmd water temperature being
delivered, turn on a hot water faucet and place a
thermometer in the water stream and read the
thermometer.(See page 20 and 21 for more details.)
The temperature of the water in the heater can be
regulated by setting the temperature dial on the front
of the gas control (thermostat). To comply with
safety regulations the gas control (thermostat) was
set at its lowest setting
120°F before the water heater
� ` was shipped from the
130° —
140 ' , r 100°F
110°F factory.
F
�1� 90 °F
-a 30 °F
150°F I 70 °F
1
160°F
60 °F
Temperatures are approximate
The illustration at the left
details the approximate
water temperature
for each mark on the Gas
Control (Thermostat)
Temperature Dial.
ADANGER: Hotter water increases the potential for
Hot Water SCALDS.
: �8•�;`SC�',...
120°F
More than 5 minutes
125°F
11/2 to 2 minutes
130°F
About 30 seconds
135°F
About 10 seconds
140°F
rem than 5 seconds
145
Las than 3 seconds
150°F
About 1 seconds
155
About 1 second
IMPORTANT SAFETY INFORMATION.
READ ALL INSTRUCTIONS BEFORE USING
4
ADANGER!
WATER TEMPERATURE SETTING
Safety and energy conservation are factors to be considered when selecting the water
temperature setting of a water heater's gas control Water temperatures above 125 °F
can cause severe burns or death from scalding. Be sure to read and follow the warnings
outlined on the label pictured below. This label is also located on the water heater.
A DANGER
Water temperature over 125 °F can
cause severe burns Instantly or
death from scalds.
Children, disabled and elderly are
at highest risk of being scalded.
See Instruction manual before
setting temperature at water
heater.
Feel water before bathing or
showering.
Temperature limiting valves are
available, see manual.
Notice: Mixing valves are available for reducing point of
use water temperature by mixing hot and cold water in
branch water lines. Contact a licensed plumber or the
local plumbing authority for further information.
Time/Temperature Relationship in Scalds
Table courtesy of aamm aura Imam
The chart shown above may be used as a guide
in determining the proper water temperature for your
home.
A DANGER: Households with small children, disabled,
or elderly persons may require a 120 °F or lower gas control
(thermostat) setting to prevent contact with "HOT" water.
Maximum water temperatures occur just after the
burner has shut off. To fmd water temperature being
delivered, turn on a hot water faucet and place a
thermometer in the water stream and read the
thermometer.(See page 20 and 21 for more details.)
The temperature of the water in the heater can be
regulated by setting the temperature dial on the front
of the gas control (thermostat). To comply with
safety regulations the gas control (thermostat) was
set at its lowest setting
120°F before the water heater
� ` was shipped from the
130° —
140 ' , r 100°F
110°F factory.
F
�1� 90 °F
-a 30 °F
150°F I 70 °F
1
160°F
60 °F
Temperatures are approximate
The illustration at the left
details the approximate
water temperature
for each mark on the Gas
Control (Thermostat)
Temperature Dial.
ADANGER: Hotter water increases the potential for
Hot Water SCALDS.
ADANGER!
LIQUEFIED PETROLEUM (LP - PROPANE OR BUTANE)
AND NATURAL GAS MODELS
LP and Natural gas have an odorant added to aid in detecting a gas leak. Some people
may not physically be able to smell or recognize this odorant. If you are unsure or
unfamiliar with the smell of LP or natural gas, ask the gas supplier. Other conditions, such
as "odorant fade", which causes the odorant to diminish in intensity, can also hide or
camouflage a gas leak.
• Water heaters utilizing LP gas are
different from natural gas models. A
natural gas water heater will not function
safely on LP gas and vice versa.
• No attempt should ever be made to
convert the water heater from natural
gas to LP gas. To avoid possible
equipment damage, personal injury or
fire, do not connect the water heater to a
fuel type not in accordance with the unit
data plate. LP for LP units. Natural gas
for natural gas units. These units are not
certified for any other fuel type.
• LP appliances should not be Installed
below grade (for example, in a basement)
if such installation is prohibited by
federal, state and/or local laws, rules,
regulations or customs.
• LP gas must be used with great caution.
It is heavier than air and will collect first
in lower areas making it hard to detect at
nose level.
• Before attempting to light the water
heater, make sure to look and smell for
gas leaks. Use a soapy solution to check
all gas fittings and connections. Bubbling
at a connection indicates a leak that must
be corrected. When smelling to detect a
gas leak, be sure to sniff near the floor
also.
• Gas detectors are recommended in LP &
natural gas applications and their
installation should be in accordance with
the detector manufacturer's
recommendations and/or local laws,
rules, regulations or customs.
• It is recommended that more than one
method, such as soapy solution, gas
detectors, etc., be used to detect leaks in
gas applications.
ADANGER: If gas leak is present or
suspected:
! Do not attempt to find the cause yourself.
• Do Ad try to light any appliance.
• Po not touch any electrical switch.
• Do not use any phone in your building.
• Leave the house immediately and make
sure your family and pets leave also.
• Leave the doors open for ventilation and
contact the gas supplier, a qualified
service agency or the fire department.
• Stay away from the house (or building)
until the service call has been made, the
leak is corrected and a qualified agency
has determined the area to be safe.
5
6
IMPORTANT SAFETY INFORMATION.
READ ALL INSTRUCTIONS BEFORE USING
t
AWARNING!
For your safety, the information in this manual must be followed to minimize the risk of
fire or explosion, electric shock, or to prevent property damage, personal injury, or loss of
life.
FOR INSTALLATIONS IN THE STATE OF CALIFORNIA
California Law requires that residential water heaters must be braced, anchored or
strapped to resist falling or horizontal displacement due to earthquake motions. For
residential water heaters up to 52- gallon capacity, a brochure with generic earthquake
bracing instructions can be obtained from: Office of the State Architect, 400 P Street,
Sacramento, CA 95814 or you may call 916- 4454100 or ask a water heater dealer.
However, applicable local codes shall govern installation. For residential water heaters
of a capacity greater than 52 gallons, consult the Iocal building jurisdiction for acceptable
bracing procedures.
SAFETY PRECAUTIONS
Have the installer show you the location of the gas shut -off valve and how to shut it off if
necessary. Turn off the manual shut -off valve if the water heater has been subjected to
overheating, fire, flood, physical damage or if the gas supply fails to shut off.
0 Read this manual entirely before installing
or operating the water heater.
O Use this appliance only for its intended
purpose as described in this Use and Care
Manual.
® Be sure your appliance is properly installed
in accordance with local codes and the
provided installation instructions.
* Do not attempt to repair or replace any part
of your water heater unless it is specifically
recommended in this manual. All other
servicing should be referred to a qualified
technician.
READ AND FOLLOW THIS SAFETY INFORMATION
CAREFULLY.
SAVE THESE INSTRUCTIONS
Installing the water heater.
This water heater must be installed in accordance with these Instructions, local codes, utility company
requirements, and/or in the absence of local codes, use the latest edition of the American National
Standard/National Fuel Gas Code. A copy can be purchased from either the American Gas Association,
400 N. Capitol Street NW, Washington, DC 20001 as ANSI standard Z223.1 or National Fire Protection
Association, 1 Batterymarch Park, Quincy, MA 02269 as booklet NFPA 54.
The auxiliary catch pan
Installation MUST conform
to local codes.
AWARNING: Combustible
construction refers to
adjacent walls and ceilings
and should not be manned
with combustible or
flammable products and
materials. Combustible
and/or flammable products
and materials should never
be stored in the vicinity of
this or any gas appliance.
Location
The water beater should not be located
in an area where leakage from the tank
or connections will result In damage to
the area adjacent to the heater or to
lower floors of the structure.
When such areas cannot be avoided it is
recommended that a suitable catch pan,
adequately drained, must be installed
under the water heater.
The pan must not restrict the lower air
Inlet box located around the lower
perimeter of the water beater.
Catch pan kits are available from the store
where the water heater was purchased, or
any water heater distributor.
Make certain that the floor underneath the
water heater is strong enough to support
the weight of the water heater once it is
filled with water.
A gas fared water heater or any other
appliance should not be installed
in a space where liquids which give off
flammable vapors are to be used or stored.
Such liquids include gasoline, LP gas
(butane or propane), paint or adhesives
and their thinners, solvents or removers.
Because of natural air movement in a
room or other enclosed space, flammable
vapors can be carried some distance from
where liquids which give off flammable
vapors are to be used or stored. The open
flame of the water heater's pilot or main
burner can ignite these vapors.
The water heater must be located so it is
not subject to physical damage, for example,
by moving vehicles, area flooding, etc.
For these reasons installation of a gas fired
water heater in a garage is not desirable.
If local codes require the use of a stand kit
to raise the water heater 18" above the
floor, please contact the store where the
water heater was purchased, or any water
heater distributor. These kits must comply
with local codes.
• This water heater is of the direct vent
design. It therefore must be located next
to the outside wall, within the range of
the telescopic adjustments.
• Long hot water lines should be insulated
to conserve water and energy.
• The water heater and water lines should
be protected from exposure to freezing
temperatures.
• Do not install the water heater in
bathrooms, bedrooms, any occupied
rooms normally kept closed, or in
unprotected outdoor areas.
• Minimum clearance from combustible
construction is 0" sides, 0" rear; and 2"
from the front of the control. If the
clearances stated on the
Instruction/Warning Label, located on
the front of the heater differ, install the
water heater according to the clearances
stated on the label.
• The water heater may be installed on
combustible floors, but not directly on
carpeting. If the water heater must be
installed on carpeting, place a metal or
wood panel beneath the water heater,
extending beyond its full width and
depth at least 3" in all directions.
• If the water heater is installed in an
alcove or closet, the entire floor must
be covered by a wood or metal panel.
A minimum of 24" clearance from the
front and top should be available for
adequate inspection and servicing.
• If flexible connectors are used, the
maximum length shall not exceed 36 ".
• If lever type gas shutoffs are used,
they shall be T- Handle type.
7
Installing the water heater.
NOTICE: The water heater
should not be installed near
an air supply containing
halogenated hydrocarbons.
8
Inspect Shipment
Inspect the water heater for possible damage. Check the markings on the rating plate of
the water heater to be certain the type of gas supplied corresponds to the water heater
requirements.
Combustion and Ventilation Air
Proper operation of the water heater
requires air for combustion and
ventilation. Provisions for combustion
and ventilation air must comply with
referenced Bodes and standards.
NOTICE: If the water beater is installed in
an unconfined space within a building of
conventional frame, masonry or metal
construction, infiltration sir is normally
adequate for proper combustion and
ventilation. If the water beater is installed in
a confined apace, provisions for combustion
and ventilation air must be made.
All air for combustion and all products of
combustion are routed through the ducting
provided, directly from and to the outside
of the building.
Corrosive Atmospheres
The air in beauty shops, dry cleaning
establishments, photo processing labs,
and storage areas for liquid and powdered
bleaches or swimming pool chemicals
often contain such halogenated
hydrocarbons.
An air supply containing halogenated
hydrocarbons may be safe to breathe,
but when it passes through a gas flame
corrosive elements are released that
will shorten the life of any gas burning
appliance.
NOTICE: If the duct openings which supply
combustion and ventilation air are to be
covered with a protective screen or grill, the
net free area (openings in the material) of
the covering material must be used in
determining the size of the openings.
Protective screening for the openings MUST
NOT be smaller than 1/4 "mesh to prevent
clogging by Tint or other debris.
Propellants from common spray cans or
gas leaks from A/C and refrigeration
equipment are highly corrosive after
passing through a flame.
The water heater warranty is voided when
failure of the heater is due to operation in
a corrosive atmosphere.
The water heater must be installed with the factory supplied venting system.
ADANGER: Failure to
install the venting system
and properly vent the
water hater to the
outdoors as outlined in the
Venting section of this
manual will result In unsafe
operation of the water
heater causing bodily
injury, explosion, fire or
death. To avoid the risk of
fire, explosion, or
asphyxiation from carbon
monoxide, NEVER operate
the water heater unless It is
properly vented and has
adequate air supply for
proper operation as
outlined In the Venting
section of this manual.
Inside
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Venting
ACAUTION: If there are any
damaged parts, DO NOT install the
water heater. Report any shortage to
your distributor or damage to your
carrier.
NOTICE: The four fasteners that are
required to secure the vent cap to the
extemal wall are not provided. These
should be screw type (not nails) chosen
for the type of construction and obtained
locally.
Locating Clearance Hole for Vent
Q Twelve (12) inches above grade level and above
normal snow levels.
a Vat Terminal must be located Wi
ted at least 9" from dows,
Doors, or any other Opening through which flue gases
could enter the building.
Ten (10) feet from any forced air inlet to the
building. Any fresh or make-up alt inlet such as for a
dryer or furnace area is considered to be a forced air
inlet.
a Vent Terminal must be located at least 18" from any
overhang or building comer or other irregularity.
.
Vent Terminal must be bated at least 36" above any
Forced Air Inlet into the building within 10 feet of the
Vent Terminal.
w a DO NOT locate the Vent Terminal under any deck or
pat structure.
Locating Clearance Hole for Vent
a Cut a clearance hole, approximately 6 inches in
diameter, through the exterior wall for the 5 inch
diameter as tube.
9
Installing the Water Heater:
10
r sir° Elbow (Steal)
Moving water heater to its final
location
gh gp Move the water heater to its fmal installed location.
Make certain clearances from combustible material
am observed.
Installing 3" Steel Elbow
I®a Place the 3 inch steel elbow on the water heater flue
7 pipe and press it firmly downward until seated and
pointed in the desired direction. Apply silicone
sealant as shown. An improper oral can cause
nuisance pilot outages
Installing 5" Aluminum Elbow
gft Install the 5 inch aluminum elbow over the 3 inch
steel elbow. Be certain both are pointed in the
desired direction with the 3 inch centered inside the 5
inch elbow.
Leveling and attaching 5" Aluminum
Elbow
.
As an aid to leveling the 5 inch elbow, temporarily
place the 5 inch sliding tube onto the elbow.
el When leveled, drill a VC inch diameter hole thmughthe
elbow into the collar at the front and back. Secure with the
two 118 sheet metal screws provided.
1 Place the finishing collar on the 5 inch elbow, as it will be
W positioned later
Vent Twins) Base (Outside)
Vent Ten*.l Base (Cubicle)
$ Sheet Mete Bawes
111
Placing Main Vent Tube through
Exterior Wall
!4 Extend the 3 inch tube assembly to its maximum
w installed length, 20-% (48 ") inches. (F1)
Place the main vent tube trough the hole in the
6* external wall to the outside. (F2)
L Place the inner sliding tube fully onto the 3 inch
elbow. (F3)
• Apply silicone sealant as shown. (F4)
Assembling the 5" Tube / Base
Assembly
• Attach the 5 inch main tube to the vent cap base
(01)
O • Drill a X" inch diameter hole through the tube into the
O collar of the base. (G2)
m
a Secure with a #8 sheet metal screw, furnished.
Repeat with a second hole and screw approximately
180 from the first. (G3)
®
Reinstall the 5 inch inner sliding section at its
maximum extended length, 18 -1/8 inches.
Attaching the 5" Main Tube
®
From the outside of the building, insert the 5 inch
tube/base assembly through the hole in the exterior
wall and onto the 5 inch elbow. (111)
0 Then seat the vent terminal base onto the wall. (112)
An improper seal can cause nuisance pilot outages.
11
Installing the water heater.
+++ Sus Andrus
* sea teat Silicone Sealant
NOTICE: The manual gas
shut -off valve should be at
least 5 ft. above the floor
and readily accessible.
12
Wall
Typical Installation
Art Tube
Securing Vent Cap / Base Assembly
to the Exterior Wall
t Next place the 3 inch main tube fully onto the collar
lir of the vent cap. Then seat the cap against the base.
(J1)
a Secure the vent cap/base assembly to the exterior
wall with four screw anchors appropriate for the type
of wall construction. The 5 inch tube should be
essentially level. However, a small amount of upward
or downward pitch will not affect operation. (J2)
ft Caulk the junctions of the vent terminal base and the
exterior wall with silicone sealant. (13)
Final Assembly and Sealing of the
Vent System
girs Position and fasten the finishing collar, previously
installed on the 5 inch elbow, against the wall to
close the opening around the tube. (K)
a Make certain the 5 inch inner sliding air tube has
been fully engaged onto the 5 inch elbow.(L1)
Drill two 1/8" inch holes (180° apart) in the junction
of the two joints in the five inch tube. (L2)
Fasten with four #8 sheet metal screws furnished. (13)
w Seal all the 5 inch tube joints with silicone sealant
including the elbow joint to the collar on the heater's
air supply box. Again, an improper seal can cause
nuisance pilot outages. (M)
Heat Trap
6" Min.
Hot al
Outlet to
Fixtures Temperature
and Pressure
Relief Valve
Manual Gas Shut -Off
To Gas Supply ,_
Ground Joint Union
Sediment
Cap
Tlc,mtstat
Jacket Door
Auxiliary Catch Pan
Catch Pan Pipe to suitable drain.
Union
Vent Terminal Cap
(Outside)
w
Anode R.d (ranted
under top pan)
Union ■
Expansion Tank
(if wed)
Heal Thy
6" Mm.
Relief Valve Discharge Line
to Suitable Open Drain
Air Gap -6"
Shut-0a'Valve
To Cold water Supply
Drain Valve
IMPORTANT: Do not
apply heat to the HOT or
COLD water connections.
If sweat connections are
used, swat tubing to
adapter before fitting
adapter to the cold water
connections on heater. Any
heat applied to the cold
water supply fittings will
permanently damage the
dip tube.
Thermal Expansion
Determine if • check valve exists in the inlet water line. Check with your local water utility
company. It may have been installed in the cold water line as a separate back flow preventer, or
it may be part of a pressure reducing valve, water meter or water softener. A check valve located
in the cold water inlet line can cause what is refereed to as a "closed water system ". A cold water
inlet line with no check valve or back flow prevention device is referred to as an "open" water
system.
As water is heated, it expands in volume and creates an increase in the pressure within the water
system. This action is refined to as "thermal expansion ". In an "open" water system, expanding
water which exceeds the capacity of the water heater flows back into the city main where the
pressure is easily dissipated.
A "closed water system ", however, prevents the expanding water from flowing back into the
main supply line, and the result of "thermal expansion" can create a rapid and dangerous
pressure increase in the water heater and system piping. This rapid pressure increase can quickly
reach the safety setting of the relief valve, causing it to operate during each heating cycle.
Thermal expansion, and the resulting rapid, and repeated expansion and contraction of
components in the water heater and piping system can cause premature failure of the relief valve,
and possibly the heater itself. Replacing the relief valve wilt not correct the problem!
The suggested method of controlling thermal expansion is to install an expansion tank in the cold
water line between the water heater and the check valve (see illustration below). The expansion
tank is designed with an air cushion built in that compresses as the system pressure increases,
thereby relieving the over pressure condition and eliminating the repeated operation of the relief
valve. Other methods of controlling thermal expansion are also available. Contact your installing
contractor, water supplier or plumbing inspector for additional information regarding this subject.
Water Supply Connections
Refer to the illustration below for suggested typical installation. The installation of unions or
flexible copper connectors is recommended on the hot and cold water connections so that the
water heater may be easily disconnected for servicing if necessary. The HOT and COLD water
connections are clearly marked and are 3/4" NPT on all models. Install a shut-off valve in the cold
water line near the water heater.
A new combination temperature and pressure relief valve, complying with the Standard for Relief Valves
and Automatic Gas Shut -Off Devices for Hot Water Supply Systems, ANSI 221.22, is supplied and must
remain in the opening provided and marked for the purpose on the water beater. No valve of any type
should be installed between the relief valve and the tank. Local codes shall govern the installation of
relief valves.
Relief Valve
The pressure rating of the relief valve
must not exceed 150 PSI, the maximum
working pressure of the water heater as
marked on the rating plate.
The Btuh rating of the relief valve must
equal or exceed the Btuh input of the
water heater as marked on its rating plate.
Position the outlet of the relief valve
above a suitable open drain to eliminate
potential water damage. Piping used
should be of a type approved for hot water
distribution.
The discharge line must be no smaller
than the outlet of the valve and must pitch
downward from the valve to allow
complete drainage (by gravity) of the
relief valve and discharge line.
The end of the discharge line should not
be threaded or concealed and should be
protected from freezing. No valve of any
type, restriction, or reducer coupling
should be installed in the discharge line.
13
Installing the water heater.
AWARNING: The tank
must be full of water before
beater is turned on. The
water heater warranty does
not cover damage or failure
resulting from operation
with an empty or partially
empty tank.
AWARNING: Never use
an open flame to test for
gas Inks, as property
damage, personal injury, or
death could result.
14
To Fill the Water Heater
Make certain that the drain valve is
closed, then open the shut -off valve in the
cold water supply line.
Open each hot water faucet slowly to
allow the air to vent from the water
heater and piping.
Condensation
Condensation can form on the tank
when it is first filled with water.
Condensation might also occur with a
heavy water draw and very cold inlet
water temperatures.
Drops of water falling on the burner can
produce a sizzling or pinging sound.
This condition is not unusual, and will
disappear after the water becomes heated.
If, however, the condensation continues,
examine the piping and fittings for
possible leaks.
AWARNING: Do not attempt to convert this water heater for use with a
shown on the rating plate. Such conversion could result in hazardous ope
Gas Supply
The branch gas supply line to the water
heater should be clean 1/2" black steel
pipe or other approved gas piping
material.
A ground joint union or ANSI design
certified semi -rigid or flexible gas
appliance connector should be installed in
the gas line close to the water heater. A
manual gas shutoff valve should be at
least 5 ft. above the floor and readily
accessible.
Compound used on the threaded joints of
the gas piping must be of the type
resistant to the action of LP gas. Use
compound sparingly on male threads only.
Leak Testing
The water heater and its gas connections
must be leak tested at normal operating
pressures before it is placed in operation.
illts Turn on the manual gas shutoff
valve near the water heater.
el Use a soapy water solution to test for
leaks at all connections and fittings.
Bubbles indicate a gas leak that must
be corrected.
A steady flow of water from the hot water
faucet(s) indicates a full water heater.
Additional information on this subject
may be found at www.rheem.com_ under
"Library ", scroll down to the Technical
Service Bulletins 1400 Series Section and
choose Bulletin #1402.
different type of gas other than the type
rating conditions.
A sediment trap should be installed at the
bottom of the gas line.
Do not use excessive force (over 31.5 ft
lbs.) in tightening the pipe joint at the gas
control (thermostat) inlet, particularly if
teflon pipe compound is used, as the valve
body may be damaged.
The inlet gas pressure to the water heater
must not exceed (0.5" w.c. for natural gas,
or 14" w.c. for LP gas. For purposes of
input adjustment, the minimum inlet gas
pressure (with main burner on) is shown
on the water heater rating plate. If high or
low gas pressures are present, contact your
gas supplier for correction.
The factory connections to the gas control
(thermostat) should also be leak tested
after the water heater is placed in
operation.
AWARNING: Failure to
install a water heater
suitable for the altitude at
the location It V Intended to
serve, can result In
improper operation of the
appliance resulting in
property damage and/or,
producing carbon monoxide
gas, which could result in
personal injury, or death.
AWARNING: If local
codes require external
application of insulation
blanket kits the
manufacturer's instructions
included with the kit must
be carefully followed.
Pressure Testing the Gas Supply System
The water heater and its manual gas shut-
off valve must be Jliscnnnected from the
gas supply piping system during any
pressure testing of that system at
pressures in excess of 1/2 psi (14" w.c.)
for natural gas, or for LP gas.
High Altitude
Ratings of gas appliances are based
on sea level operation and need not be
changed for installations at elevations up
to 2,000 feet.
Insulation Blankets
Insulation blankets, available to the
general public, for external use on gas
water heaters are not necessary. The
purpose of an insulation blanket is to
reduce the standby heat loss encountered
with storage tank heaters. This water
heater meets or exceeds the National
Appliance Energy Conservation Act
standards with respect to insulation and
standby loss requirements making an
insulation blanket unnecessary.
The manufacturer's warranty does not
cover any damage or defect caused by
installation, attachment or use of
any type of energy saving or other
unapproved devices (other than those
authorized by the manufacturer) into, onto
or in conjunction with the water heater.
The use of unauthorized energy saving
devices may shorten the life of the water
heater and may endanger life and property.
The manufacturer disclaims any
responsibility for such loss or injury
resulting from the use of such
unauthorized devices.
The water heater must be isolated from
the gas piping system by closing the
manual gas shutoff valve during any
pressure testing of the gas supply piping
at pressures equal to or less than
1/2 psi (14" w.c.) for natural gas, or for
LP gas.
For installations above 2,000 feet, Please
contact your local distributor or place of
purchase for a high altitude model.
ACAUTION: If local codes require the
application of an external insulation
blanket to this water heater, pay careful
attention to the following so as not to
restrkt the proper function and
operation of the water heater
• Do not cover the operating or warning
labels attached to the water heater or
attempt to relocate them on the exterior
of insulation blanket.
• Do not apply insulation to the top of the
water heater. This will interfere with the
safe operation of the draft hood.
• Do not cover the burner access door,
jacket door, gas control (thermost at)/gas
valve or pressure and temperature relief
valve.
• Do not apply insulation to the bottom of
the water heater or the area where the
combustion air inlet openings are
located. This area must be unobstructed
so as not to restrict combustion air flow
to the burner.
• Inspect the insulation blanket frequently
making certain it has not sagged and is
restricting the air flow to the combustion
air inlet openings (perforation holes)
located around the lower perimeter of
the water heater jacket. This could result
in an unsafe operating condition.
15
Installing the water heater.
Hot and Cold Pipe Insulation Installation
Typical vertical piping nmogem nt
For increased energy efficiency, some
water heaters have been supplied with
two 24" sections of pipe insulation.
Heat Trap
For increased energy efficiency, some
water heaters have been supplied with
factory installed 3/4" NPT heat traps in
the hot outlet line and cold water inlet
line.
Typical horizontal piping amngement
Please install the insulation, according to
the illustrations above, that best meets
your requirements.
These heat traps may require a minimum
of one (1) 90° 3/4" NPT elbow and may
require an additional 90° 3/4" NPT elbow
or a 3/4" coupling depending on your
installation needs. See Illustration of
nipples and heat turps on page 23.
During Installation of this water heater
DO
16
❑ DO check inlet gas pressure to ensure
that it is within the range specified on the
rating plate.
❑ DO provide adequate air for combustion
and ventilation as discussed in the Use and
Care Manual and the National Fuel Gas
Code.
❑ DO maintain proper clearances to
combustibles as specified on the rating plate.
❑ DO ensure that the venting system
complies with the guidelines found in the
Use and Care Manual and National Fuel Gas
Code.
❑ DO contact a qualified service technician
if the pilot or main burner will not stay lit.
DON'T
❑ DON'T block or restrict the lower
portion of the water heater jacket.
❑ DON'T remove the Jacket or Inner
Door(s) unless absolutely necessary.
❑ DON'T install this water heater where
standing water may occur.
❑ DON'T operate the water heater if the
sight glass or inner door is damaged or
broken.
Installation Checklist
A. Water Heater Location
❑ Close to outside wall.
❑ Indoors and protected from freezing
temperatures.
❑ Proper clearance from combustible surfaces
observed and water heater not installed on
carpeted floor.
❑ Sufficient fresh air supply for proper
operation of water heater.
❑ Air supply free of corrosive elements and
flammable vapors.
B. Water Supply
❑ Water heater completely filled with water.
❑ Air purged from water beater and piping.
C. Gas Supply
D. Relief Valve
E. Venting
❑ Water connections tight and free of leaks.
❑ Gas line equipped with shutoff valve, union
and sediment trap.
❑ Approved pipe joint compound used.
❑ Temperature and Pressure Relief Valve
properly installed and discharge line run to
open drain
❑ Discharge line protected from freezing.
❑ Flue baffle properly hung in top of beater's
flue.
❑ Air tube and vent tube properly installed
O Provisions made to protect area from water
damage.
O Sufficient room to service heater.
❑ Combustible materials, such as clothing,
cleaning materials, rags, eta clear of the base
of the heater.
❑ Soap and water solution used to check all
connections and fittings for possible gas leak.
❑ Gas Company inspected installation (if
required).
O Vent terminal, air tube sealed with caulk.
O Air tube securely fastened with screws.
17
Supplemental instructions for gas water heaters installed
in potable /space heating applications.
Local codes or plumbing authority requirements may vary from the instructions or diagrams provided
in this manual and take precedent over these instructions.
Combination Potable and Space Heating Application
Tee fining for vertical hot
water supply lines.
Tee fitting for horizontal hot
water supply lines.
Typical Piping Diagram for Combination Potable/Space Heating Installation
Spring loaded check valve in heating
unit hot water supply line and cold
water retum line (not supplied with
comer heater)
NOTE: This check valve is
incorporated in some heating units.
Refer to the installation instructions
supplied with specific heating unit to
determine if it is required.
Isolation valve m hot water supply line
to heating unit
(not supplied with water heater)
18
See diagrams above for groper
pipe application for vertical
or horizontal supply lines
Temperature and Pressure
Relief Valve
Gas line to water heater
Water Heater Jacket
Temperature and pressure
relief valve discharge IS
Tee fitting must be installed as shown.
This ensures that any air in the water lines
will be purged through the domestic water
faucets and showers.
A DANGER: When this system
requires water for space heating at
elevated temperatures [above 125 °F
(52 °C.)J, a mixing or tempering valve
must be Installed in the hot water
supply line to the house in order to
reduce the scald hazard potential
ADANGER: Any piping or components
used in the installation of this water
heater in a combination potable and
space heating application must be
suitable for use with drinking water.
Au vent
6 " Air Gap
A DANGER If this water heater is
installed in an application intended to
supply domestic hot water needs and
hot water for space heating purposes,
do not connect the heater to an existing
heating unit or components of a heating
system that have previously been used
with a non drinking water system. Toxic
chemicals such as those used for boiler
treatment may be present and will
contaminate the drinking water supply
causing possible health Asks. Never
introduce toxic chemicals, such as those
used for boiler treatment, into this
system.
Domestic hot water supply
Cold water
return line f
hating unit
Hot water
supply line
into heating unit
Drain valve
(not supplied with water
heater)
Incoming cold
water supply
Thermal Expansion
Tank (if required-not
supplied with water
Mixing or
tempering
valve (refer
to warning
above)
Shut -Off
Wlve
Isolation valve in cold
water retum Tine from
heating unit (not
supplied with water
heater) A r
Heat Trap
j 6" Min.
Maim)
Heating unit
Lighting the water heater.
Before operating this water heater, be sure to read and follow the instructions on the label pictured
below and all other labels on the water heater, as well as the warnings printed in this manuaL Failure to
do so can result in unsafe operation of the water heater resulting in property damage, personal Injury,
or death . Should you have any problems reading or following the instructions in this manual, STOP,
and get help from a qualified person.
1
FOR YOUR SAFETY READ BEFORE LIGHTING
W ARNING: N you do not follow these Instructions exactly, a Sn or explosion
ma y result waxing property damage, personal Injury or loss of Mo.
A. Ms appliance has a pilot which must be NIhta
�n .mWhenn Wiling M OK taw Mein
B. WORE LIGHTING smell all around the appli-
ance ores for gas. Ile sure to smell next to the
Noor because some gas Is heavier Man air and
will settle en the Hoer.
• D T 00 to ngM an appl
• Do not touch any electric switch; do not use
any phone In your building.
• Immediately call your pas supplier from a
neighbor's phone. Follow the gas supplier's
Instructions.
LIGHTING INSTRUCTIONS
1. STOPI READ THE SAFETY INFORMATION
ABOVE ON THIS LABEL.
2. TURN GAS COCK KNOB CLOCKWISE \ TO
' OFF' POSITION.
lad IWIMaIr•fr
......,Tor
6.
S. TURN TEMPERATURE DULL COUNTERCLOCK-
WISE INTO LOWEST BETTNIG.
4. WAR FIVE (5) MINUTES TO CLEAR OUT ANY
GAS. W YOU BME I ILLS, STOP! FOL-
LOW 'B" IN THE SAFETY INFORMATION
ABOVE ON THIS LABEL. W YOU D0 NOT SMELL
GAS, 60 TO NEXT STEP. .. d
5. REMOVE THE OUTER 0008 FROM THE r c""'
WATER HEATER. D0 DOT
I DOOR.
ATTEMPT TO REMOVE "O1 i� M,:
��
B. LLOCATE PIEZO IGNITOR + ■ �'
STRIKER, IT IS DIRECTLY TO 1\ _4
O.
THE RIGHT OF GAS CONTROL. 10.
7. TURN THE GAS COCK KNOB COUNTER- 11
CLOCKWISE f TO 'PILOT' POSITION. •
• 11 you cannot reach your gas supplier, call
Me tare department.
C. Use only your band to turn the gas ewes! lamb. not turn by band.
doalrby Ise bob. II the bah b ',yak ad�a sagged service
technician. Farce or attempMd rep* wary result
M • lire or explosion.
0. Do not use this appliance N any part has been
under water. Immediately call s qualified ser-
vice beholden M Inspect the appliance and to
replace any pan of the control system and any
gas control which has been ender water.
PUSH DOWN ON THE 'RED BUTTON" IUFTIL.
11 COMES TO REST ON THE TOP OF CON-
TROL IF MUST CLEAR THE NOTCH PRO-
VIDED N THE 'GAS COCK KNOB' NOLO'WM
BUTTON" DOWN AND PRESS PIEZO
IGNITOR SEVERAL TIMES UNTIL PILOT
IS UT. (THE PWOT FLAME CAN ONLY
BE SEEN THRU THE SIGHT GLASS LOCATED
ON 'ME RIMER DOOR). CONHNUE TO HOLD
THE 'RED BUTTON' Di FOR ABOUT ONE
(1) MINUTE AFTER THE PILOT IS LEL
RELEASE BUTTON AND R WILL POP BACKUP.
PLOT SHOLRO REMAIN Ltl W IT GOES OUT,
REPEAT STEPS 2 THROUGH B.
• W BUTTON DOES 110T POP UP WHEN
RELEASED STOP AND IMMEDIATELY CALL
YOUR SERWCE TECHNICIAN 011 GAS
SUPPLIER.
• IF THE PILOT WILL NOT STAY UT AFTER
SEVERAL TRIES, TURN THE "GAS COCK
KNOB" TO 'OW ANO CALL YOUR SERVICE
TECHNICIAN OR GAS SUPPUER.
REPLACE OUTER 00011.
TURN 'GAS COCK KNOB" COUNTERCLOCK-
WISE f TO 'Or.
TURN THE TEMPERATURE DIAL TO THE
DESIRED SETTING.
® TO TURN OFF GAS TO APPLIANCE
1. TURN TEMPERATURE DIALCOUNTERCLOCK- 2. TURN OAS COCK KNOB CLOCKWISE \
WISE ITO LOWEST SETTING. TO 'OFF' POSITION.
Lighting Instructions w_Piezo (0)
19
Operating the water heater.
ACADTION: Hydrogen gas can be produced in a hot water system served by this water heater that has not been used for a
long period of time (generally two weeks or more). HYDROGEN GAS IS EXTREMELY FLAMMABLE!! To dissipate such
gss and to reduce risk of injury, it is recommended that the hot water faucet be opened for several minutes at the kitchen sink
before using any electrical appliance connected to the hot water system. If hydrogen is present, there will be an unusual sound
such as air escaping through the pipe as the water begins to flow. Do not smoke or use an open flame near the faucet at the
time It is open.
Safety Precautions
i gh Do turn off manual gas shut-off valve if water heater
milr has been subjected to over heating, fire, flood,
physical damage or if the gas supply fails
to shut off.
a Do Not turn on water heater unless it is completely
filled with water.
Do Not turn on water heater if cold water supply
- shutoff valve is closed.
it Do Not allow combustible materials such as
newspaper, rags or mops to accumulate near
water heater.
A DANGER: Hotter water
increases the Potential
for Hot Water SCALDS.
Households with small
children, disabled, or elderly
persons may require a 120°F
or lower gas control
(thermostat) setting to
prevent contact with HOT
water.
20
120°F
125°F
130°F
I35 °F
140°F
145 °F
150°F
155 °F
Lbte enemy of shii°m num Institute
a Do Not store or use gasoline or other flammable
vapors and liquids, such as adhesives or paint thinner,
in vicinity of this or any other appliance.
If such flammables must be used, open doors
and windows for ventilation, and all gas burning
appliances in the vicinity should be shut off including
their pilot burners, to avoid vapors lighting.
NOTICE: Flammable vapors can be drawn by air
currents from surrounding areas to the water heater.
If there is any difficulty in understanding or following
the Operating instructions or the Care and Cleaning
section, it is recommended that a qualified person or
serviceman perform the work.
Water Temperature Setting
The temperature of the water in the water
heater can be regulated by setting the
temperature dial on the front of the gas
control (thermostat).
Safety and energy conservation are factors
to be considered when selecting the water
temperature setting of the water heater's
gas control (thermostat(s)). The lower the
temperature setting, the greater the savings
in energy and operating costs.
To comply with safety regulations, the gas
control (thermostat) was set at its lowest
setting before the water heater was shipped
from the factory. The recommended
starting point temperature is 120°F.
Time/Temperature Relationship in Scalds
Water temperatures above 125 °F
can cause severe burns or death from
scalding. Be sure to read and follow the
warnings outlined in this manual and on
the label located on the water heater near
the gas control thermostat.
Mixing valves are available for reducing
point of use water temperature by mixing
hot and cold water in branch water lines.
Contact a licensed plumber or the local
plumbing authority for further
information. (See page 4 for more details.)
The chart below may be used as a guide in
determining the proper water temperature
for your home.
More than 5 minutes
11/2 to 2 minutes
About 30 seconds
About 10 seconds
Less than 5 seconds
Less than 3 seconds
About 14: seconds
About 1 second
Water Temperature Setting...
Maximum water temperatures occur just
after the burner has shut off. To determine
the water temperature, turn on a hot water
faucet and place a thermometer in the
water stream.
The wide reference mark near WARM
on the rim of the temperature dial,
represents an approximate water
temperature of 120 °F.
The long wide reference mark, to the left,
represents an approximate water
temperature of 130 °F.
Each reference mark above or below these
points indicates an approximate change of
10 °F.
To adjust the temperature, turn the
temperature dial to an initial setting of
120 °F.
A condition known as "stacking" or
"layering" can occur when a series of
short and frequent hot water draws are
taken.
The hottest temperature water will be at
the top of the tank, closest to the outlet
pipe delivering hot water to the home.
Stacking can cause this top layer of water
to be hotter than the water toward the
bottom of the tank near the gas control
(thermostat).
Red Button
130°F
140°F
150°F
160°F
empenture dial
(Temperatures are approximate)
Therefore, always remember to test the
water temperature with your hand before
use and remember that hotter water
increases the risk of scald injury.
Also, always supervise young children or
others who are incapacitated.
The gas control (thermostat) is constructed
with a built in safety shut -off device
designed to shut off the gas supply to the
burner if the pilot flame is extinguished
for any reason.
The gas control (thermostat) is also
equipped with a single use gas shut off
device that will shut off the gas supply to
the burner if the water heater exceeds
normal operating temperatures. Refer to
the (Before You Call For Service) section
of this manual, or contact your dealer.
AWARNING: Should overheating occur or
the gas supply fail to shut off, turn off the
manual gas control valve to the appliance.
If the water heater has been subjected to
fire, flood or physical damage, turn off the
manual gas control (shut-off) valve, and
do not operate the water heater again until
it has been checked by qualified
personnel.
Gas cock knob
120°F
110°F
100°F
90 °F
80°F
70°F
60 °F
21
Care and cleaning of the water heater.
DANGER: Before
manually operating the
relief valve, make certain
no one will be exposed to
the danger of the hot water
released by the valve. The
water may be hot enough to
create a scald hazard. The
water should be released
into a suitable drain to
prevent injury or property
damage.
ADANGER: Hotter water
increases the potential for
Hot Water Scalds.
ADANGER: Failure to
perform the recommended
Routine Preventative
Maintenance can harm the
proper operation of this
water heater, which can
cause carbon monoxide
dangers, excessive
hot water temperatures and
other potentially hazardous
conditions.
ADANGER: Combustible
materials, such as clothing,
cleaning materials, or
flammable liquids, etc., must
not be placed against or next
to the water heater.
22
Draining the Water Heater
ACAUfION: Shut off gas to the water
heater at the gas control (thermostat) gas
cock or manual shut-off valve before
draining water.
ADANGER: Before manually operating the
temperature and pressure relief valve, make
certain no one will be exposed to the hot
water released by the valve. The water
drained from the tank may be hot enough to
present a scald hazard and should be
directed to a suitable drain to prevent injury
or damage.
Routine Preventative Maintenance
Properly maintained, your water heater
will provide years of dependable trouble -
free service.
R is recommended that a periodic
inspection of the gas control (thermostat),
bumer, relief valve, intemal flue -way and
venting system should be made by service
personnel qualified in gas appliance repair.
It is suggested that a routine preventative
maintenance program be established and
followed by the user.
At least once a year, lift and release the
lever handle on the temperature pressure
relief valve, located near the top of the
water heater, to make certain the valve
operates freely. Allow several gallons to
flush through the discharge line to an open
drain.
NOTICE: If the temperature and
pressure relief valve on the hot water
heater discharges periodically, this may
be due to thermal expansion in a closed
water system. Contact the water
supplier or your plumbing contractor on
how to correct this. DO NOT plug the
relief valve outlet.
A water heater's tank can act as a settling
basin for solids suspended in the water. It
is therefore not uncommon for hard water
deposits to accumulate in the bottom of the
tank. If allowed to accumulate, these
solids can cover the gas control
Housekeeping
Vacuum around the base of the water
heater for dust, dirt and lint on a regular
basis. Visually inspect pilot burner and
relight if necessary.
To ensure sufficient ventilation and
combustion air supply, proper clearances
must be maintained.
In order to drain the water heater, tum off
the cold water supply. Open a hot water
faucet or lift the handle on the relief valve
to admit air to the tank.
Attach a garden hose to the drain
valve on the water heater and direct
the stream of water to a drain. Open
the valve.
(thermostat) sensors, causing the sensors to
operate erratically. Because accumulated
solids can prevent the gas control
(thermostat) sensors from accurately
reading the water temperature, the water
at the fixture can be hotter than the gas
control (thermostat) dial setting. It is
suggested that a few quarts of water be
drained from the water heater's tank every
month to clean the tank of these deposits.
Rapid closing of faucets or solenoid valves
in automatic water using appliances can
cause a banging noise heard in a water
pipe. Strategically located risers in the
water pipe system or water hammer
arresting devices can be used to minimize
the problem.
The anode rod should be removed from the
water heater's tank annually for inspection
and replaced when more than 6" of core
wire is exposed at either end of the rod.
Make sure the cold water supply is turned
off before removing anode rod.
Proper burner and pilot burner
pattern.
NOTICE: Refer to the
Hydrogen Gas Caution In the
Operating Instructions.
NOTICE: Do not remove
the anode rod from the water
heater's tank, except for
inspection and/or replacement,
as operation with the anode
rod removed will greatly
shorten the life of the glass
lined tank and will exclude
warranty coverage.
Venting System Inspection
It is recommended that the water heater's
internal flue be inspected annually to be
certain it is clean by removing the Upper
Air Inlet Box
When reinstalling the flue baffle make
certain it is hung securely by its hanger at
the top of the flue way.
Reinstall the Upper Air lifter Box.
Inspect the gas venting system and the
termination cap.
Make certain the vent system is properly
sealed and securely attached.
Burner Inspection
Visually inspect the pilot burner and main
bumers annually.
Through the site glass, inspect the pilot
burner flame with the main burner off and
inspect the main burner while firing.
If any unusual burner operation is noted,
the water heater should be shut off until
qualified service assistance can be
obtained.
Vacation and Extended Shut -Down
If the water heater is to remain idle for an
extended period of time, the power and
water to the appliance should be turned off
to conserve energy and prevent a build -up
of dangerous hydrogen gas.
The water heater and piping should be
drained if they might be subjected to
freezing temperatures.
Anode Rod
This water heater is equipped with an
anode rod designed to prolong the life of
the glass lined tank. The anode rod is
slowly consumed, thereby eliminating or
minimizing corrosion of the glass lined
tank.
If after inspection of the vent system
you found soot or deterioration;
call the local gas utility to correct the
problem and clean the flue, or replace the
flue, flue baffle, and venting system
before resuming operation of the water
heater.
ACAUTION: For your safety, cleaning of
the burner must be performed only by
qualified service personnel.
For cleaning, remove the bumer from the
water heater. A vacuum cleaner can be
used on the burner and floor shield inside
the water heater.The burner can also be
cleaned by scrubbing with mild detergent.
After a long shut-down period, the water
heater's operation and controls should be
checked by qualified service personnel.
Make certain the water heater is
completely filled again before placing h
in operation.
Water sometimes contains a high sulfate
and/or mineral content and together with
cathodic protection process can produce a
hydrogen sulfide, or rotten egg odor in the
heated water. Chlorination of the water
supply should minimize the problem.
23
Before You Call For Service...
Troubleshooting Tips
Save time and money! Review the charts on the following pages first and you may not need to call for service.
24
Possible Causes
This usually happens when
a new water heater is
filled for the first time.
Moisture from the products
of combustion condensing
on the tank surface.
An undersized water
heater will cause
condensation.
Flue or Combustion air inlet
openings are restricted.
Not enough combustion or
ventilation air supplied to
the water heater location.
clogged.
Gas cock knob not
Loose thermocouple.
What To Do
• This is normal. After the water in the tank warms
up, the condensation will disappear. If, however, the
condition persists, examine the piping and fittings
for possible leaks.
• This is normal and will disappear in time. Excessive
condensation can cause pilot burner outage.
• Use a water heater size that meets the requirements
of your needs.
Scale on top of the burner. • Contact a qualified service technician to remove scale.
• Remove obstruction or debris from flue or
combustion air inlet openings on water heater jacket.
• Proper operation of the water heater requires air for
combustion and ventilation. See the Combustion and
Ventilation Air information in the "Installing The
Water Heater" section of this manual.
Air in gas line. • Contact a qualified service technician to purge the air
from the gas line.
Pilot burner orifice clogged. • The pilot burner should be cleaned or replaced by a
qualified service technician.
Pilot burner tube pinched or • The pilot burner should be cleaned, repaired or
replaced by a qualified service technician.
• See the "Lighting The Water Heater" section of this
correctly positioned. manual.
• The connection at the gas control (thermostat) should lit
be tightened by a qualified service technician.
Thermocouple defective. • The thermocouple should be replaced by a qualified
service technician.
Safety magnet defective. • The gas control (thermostat) should be replaced by a
qualified service technician.
Gas Control's (Thermostat's) • The gas control (thermostat) should be replaced by a
single use gas shut -off device qualified service technician.
has opened.
A CAUTION: For your safety DO NOT attempt repair of gas piping, gas control (thermostat), burners, vent connectors or
other safety devices. Refer repairs to qualified service personnel
Possible Causes What To Do
Scale and sediment • Clean tank.
in tank.
Pressure build up
caused by thermal
expansion to a
closed system.
Water usage may have
exceeded the capacity
of the water heater.
The pilot burner may be out.
• This is an unacceptable condition and must be
corrected. Contact the water supplier or plumbing
contractor on how to correct this. Do not plug the
relief valve outlet.
• Wait for the water heater to recover after an
abnormal demand.
Low gas pressure. • Check gas supply pressure and manifold pressure.
• Check the pilot burner. If necessary, relight using the
instructions in the "Lighting The Water Heater"
section of this manual.
The gas control (thermostat) • See the "Water Temperature Setting" of The Water
may be set too low. Heater section of this manual.
Leaking or open hot • Make sure all faucets are closed.
water faucets.
The gas control (thermostat) • See the "Water Temperature Setting" of The Water
is set too high. Heater section of this manual.
Gas Control (Thermostat) • Contact a qualified service technician to replace the
Defective. gas control (thermostat).
ACAUTION: For your safety DO NOT attempt repair of gas piping, gas control (thermostat), burners, vent connectors or
other safety devices. Refer repairs to qualified service personnel.
25
Replacement Parts.
26
Vent
Terminal Cap
Main Air Tube
Upper Air
Inlet Box
Air Inlet Tube
Anode Rod
(On certain units. located underneath
the top pan and is not replaceable)
Lower Air
Inlet Box
Instructions For Placing a Parts Order
To place orders using a Visa/MasterCard
call 800431 -1549.
All parts orders should include:
O The model and serial number of the
water heater from the rating plate.
a Specify type of gas (natural or LP)
as marked on the rating plate.
Inner Door
Sliding Air Tube
Jacket Doo
Air Tube Elbow
Dip Tube
Dip Tube
Gasket
gp Part description (as noted below) and
�
W number of parts desired.
ACAUTION: For your safety, DO
NOT attempt repair of gas piping,
gas control (thermostat), burners,
vent connectors or other safety devices.
Refer repairs to qualified service
personnel.
Flue Battle
and
Hanger
®1 4 7 91 * T &P Relief Valve
Drain Valve
Shroud
Drain Valve
Burner
Burner Supply
Tube
Mounting l
Bracket
Piezo Ignitor
Snicker
N
Gas Control
(Thermostat)
Pilot Supply
Tube
Piezo
Ignitor Wire
Thermocouple
NOTES
27
IF YOU NEED SERVICE
28
1. Should you have any questions about your new water heater, or if it requires
adjustment, repair, or routine maintenance, it is suggested that you fast contact
your installer, plumbing contractor or previously agreed upon service agency. In
the event the firm has moved, or is unavailable, refer to the telephone directory,
commercial listings or kcal utility for qualified service assistance.
2. Should your problem not be solved to your complete satisfaction, you should
then contact the Manufacturer's National Service Department at the following
address:
2600 Gunter Park Drive
Montgomery, Alabama 36109 -1413
Phone: 1-800-432-8373.
When contacting the manufacturer, the following information will be requested:
a. Model and serial number of the water heater as shown on the rating plate attached
to the jacket of the heater.
b. Address where the water heater is located and physical location.
c. Name and address of installer and any service agency who performed service on
the water heater.
d. Date of original installation and dates any service work was performed.
e. Details of the problems as you can best describe them.
f. List of people, with dates, who have been contacted regarding your problem.
If you need a manual In Spanish, please refer to our websitr www.rheem.rom.
Si requiere de un manual de use y euldado en espanol, Usted puede obtanerlo
en www rheem.eom.
EVOUJTION"
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C er �s
315AAV /JAV
Plus 80v
4-Way Multipoise
Gas Furnace
Installation, Start-up, Operating, and
Service and Maintenance Instructions
- Series C
The Evolution Series 80% Gas Furnace
The 315AAV /JAV Variable -Speed 4-Way Multipolse Gas Furnace ` offers
outstanding comfort In an all% AFUE fumace. You get all the benefits of Perfect
Heat"" and Perfect Humidity"' : reduced drafts, reduced sound levels, longer, more
gentle cydes, less temperature swings between cydes, and less temperature
differences between rooms. It improves indoor air quality, plus provides outstanding
electrical effidency all year long. Homeowners can now economically run constant fan
to help eliminate temperature differences throughout the house and get better indoor
air quality. This Perfect Humidity fumace also increases comfort In the summer by
wringing out extra humidity. The 315AAV furnaces are approved for use with natural
or propane gas, and the 315JAV is approved for use In Low NOx Air Quality
Management Districts.
STANDARD FEATURES
• Perfect Heat, Perfect Humidity"' operation
Two -stage heating
Reduced operating sound through low -stage operation and sound elimination
combustion system
Variable -speed blower motor
Super -low electrical use, up to 80% less than standard models
Increased SEER ratings for AC and HP systems
Matches CFM to coding system at all static points
Provides full Perfect Heat/Perfect Humidity benefits including 'Super Dehumidiy
• Four - position fumace: upflow, horizontal right, horizontal left, downflow
Thirteen different vent options
• Shorter In height — only 33 1/3" tall
• Media Filter Cabinet Included
• Microprocessor based "smart" control center
Adapts heating stages to meet demand
Continuous fan speed adjustable from thermostat
Adjustable heating air temperature rise
Up to 12 cooling airflow selections with a wide range of capability
LED diagnostics, non- volatile fault code memory, and self test feature
• Patented blocked vent safeguard to ensure proper furnace venting
• All models are Chimney Friendly when used with accessory vent kit
• Insulated blower compartment
• Heat pump compatible
• Perfect Light"' Igniter
• Residential installations eligible for consumer financing through the Comfort
Credit Program
LIMITED WARRANTY
• 20 -year warranty on 'Super Wu' heat exchanger
• 5-year parts warranty on all other component
Form No./Catalog No. 11315A-70-4
MICENIED
0111 TVKWLA
APR 2 7
F2AAUT CENTER
AACfr UdS
Variable Speed
Induced - Combustion Deluxe
4 - Wav Multin °Ise Furnace
Cancels: 580V-451/11315A-70-3 58CV- 5S1/11315A -70-4
10-05
Installation, Start-up, Operating, and
Service and Maintenance Instructions
Series 120 /C
NOTE: Read the entire instruction manual before starting the
installation.
This symbol —r indicates a change since the last issue.
Portions of the teat and labia we teprinud front NFPA 54/ANSI 22223.1- 20060, with
permission 0f National Fite Protection Association. Quincy. MA 02269 and American
6a Association. Washington DC 20101. This teptintal material is not the cmnplete
and official position of the NFPA or ANSI on the referenced subject, which is
tepesented only by the standard N its entirety.
TABLE OF CONTENTS
SAFETY CONSIDERATIONS 2
INTRODUCTION 2
CODES AND STANDARDS 4
Safety 4
General Installation 4
Combustion and Ventilation Air 4
Duct Systems 4
Acoustical Lining and Fibrous Glass Duct 4
Gas Piping and Gas Pipe Pressure Testing 4
Electrical Connections 4
ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS
PROCEDURE 4
LOCATION 5
General 5
Location Relative to Cooling Equipment 7
AIR FOR COMBUSTION AND VENTILATION 7
INSTALLATION 10
Upflow Installation 10
B1mom Return Air Inlet 10
Side Return Air Inlet 10
Leveling Legs (If Desired) 10
Downflow Installation 10
Bottom Return Air Inlet 11
Horizontal Installation 12
Suspended Furnace Support 12
Platform Furnace Support 12
Roll -Out Protection. 12
Bottom Rehm Air Inlet 14
Side Return Air Inlet _ 14
Filter Arrangement 16
Air Ducts 16
General Requirements 16
Ductwork Acoustical Treatment 16
Supply Air Connections 16
Return Air Connections 16
Gas Piping 16
Electrical Connections 19
115 -V Wiring 19
J -Box Relocation 20
Electrical Connection to J -Box .... ..............19
Gum:
ama
DO 90012000
Power Cord Installation 20
BX Cable Installation 021
24-V Wiring 21
Accessories 21
Venting 22
General Venting Requirements 23
Masonry Chimney Requirements 28
Appliance Application Requirements 28
Additional Venting Requirements 29
Sidewall Venting 33
START -UP, ADJUSTMENT, AND SAFETY CHECK 33
General 33
Start-Up Procedures 34
Adjustments 34
Check Safety Controls 43
Checklist 43
SERVICE AND MAINTENANCE PROCEDURES 44
Introduction 44
General 44
Electrical Controls and Wiring 44
Care and Maintenance 45
Cleaning and/or Replacing Air Filter 46
Blower Motor and Wheel 46
Cleaning Heat Exchanger 47
Sequence of Operation 49
Wiring Diagrams 53
Troubleshooting 53
Manufacturer reserves Um rlgM to discontinue, a change at any time, specifications or designs without notice and without inclining obligations.
Hook Sa 1 S41 e PC 101 Printed in U.S.A. Pg 1 10-05
leb
SAFETY CONSIDERATIONS
A WARNING
FIRE, EXPLOSION, ELECTRICAL SHOCK, AND
CARBON MONOXIDE POISONING HAZARD
Failure to follow this warning could result in dangerous
operation, serious injury, death, or property damage.
Improper installation, adjustment, alteration, service, mainte-
nance, or use can cause carbon monoxide poisoning, explo-
sion, fire, electrical shock, or other conditions which may
cause personal injury or property damage. Consult a qualified
service agency, Local gas supplier, or your distributor or
branch for information or assistance. The qualified service
agency must use only factory- authorized and listed kits or
accessories when modifying this product.
A CAUTION
FURNACE RELIABILITY HAZARD
Improper installation or misapplication of furnace may re-
quire excessive servicing or cause premature component
failure.
Application of this furnace should be indoors with special
attention given to vent sizing and material, gas input rate, air
temperature rise, unit leveling, and unit sizing.
Installing and servicing heating equipment can be hazardous due to
gas and electrical components. Only trained and qualified
personnel should install, repair, or service heating equipment.
Untrained personnel can perform basic maintenance functions
such as cleaning and replacing air filters. All other operations must
be performed by trained service personnel. When working on
heating equipment, observe precautions in literature, on tags, and
on labels attached to or shipped with furnace and other safety
precautions that may apply.
These instructions cover minimum requirements and conform to
existing national standards and safety codes. In some instances,
these instructions exceed certain local codes and ordinances.
especially those that may not have kept up with changing residen-
tial construction practices. We require these instructions as a
minimum for a safe installation.
A CAUTION
CUT HAZARD
Failure to follow this caution may result in personal injury.
Sheet metal parts may have sharp edges or burrs. Use care and
wear appropriate protective clothing, safety glasses and
gloves when handling parts, and servicing furnaces.
Wear safety glasses and work gloves. Have fire extinguisher
available during st art-up and adjustment procedures and service
calls.
This is the safety-alert symbol m. When you see this symbol on
the furnace and in instructions or manuals, be alert to the potential
for personal injury.
Understand the signal words DANGER, WARNING, and CAU-
TION. These words are used with the safety-alert symbol. DAN-
GER identifies the most serious hazards which will result in severe
personal injury or death. WARNING signifies a hazard which
could result in personal injury or death. CAUTION is used to
identify hazards which may result in minor personal injury or
product and property damage. NOTE is used to highlight sugges-
tions which will result in enhanced installation, reliability, or
operation.
2
1. Use only with type of gas approved for this furnace. Refer to
the furnace rating plate.
2. Install this furnace only in a location and position as specified
in the "Location" section of these instructions.
3. Provide adequate combustion and ventilation air to the furnace
space as specified in "Air for Combustion and Ventilation"
section.
4. Combustion products must be discharged outdoors. Connect
this furnace to an approved vent system only, as specified in
the " Venting" section of these instructions.
5. Never test for gas leaks with an open flame. Use a commer-
cially available soap solution made specifically for the detec-
tion of leaks to check all connections, as specified in the "Gas
Piping" section.
6. Always install furnace to operate within the furnace's intended
temperature -rise range with a duct system which has an
external static pressure within the allowable range, as speci-
fied in the "Start-Up, Adjustments, and Safety Check" section.
See furnace rating plate.
7. When a furnace is installed so that supply ducts carry air
circulated by the furnace to areas outside the space containing
the furnace, the return air shall also be handled by duct(s)
sealed to the furnace casing and terminating outside the space
containing the furnace. See "Air Ducts" section.
8. A gas -fired furnace for installation in a residential garage must
be installed as specified in the warning box in the "Location"
section.
9. The furnace is not to be used for temporary heating of
buildings or structures under construction. See page 7 caution
box regarding the heating of building under construction.
10. These Multipoise Gas-Fired Furnaces are CSA (formerly
A.G.A. and C.G.A.) design- certified for use with natural and
propane gases (see furnace rating plate) and for installation in
alcoves, attics, basements, closets, utility rooms. crawlspaces,
and garages. The furnace is factory- shipped for use with
natural gas. A CSA (A.G.A. and C.G.A.) listed gas conversion
kit is required to convert furnace for use with propane gas.
11. See Fig. 1 for required clearances to combustible construction.
12. Maintain a 1 -in. clearance from combustible materials to
supply air ductwork for a distance of 36 inches horizontally
from the furnace. See NFPA 90B or local code for further
requirements.
13. These furnaces SHALL NOT be installed directly on carpet-
ing, tile, or any other combustible material other than wood
flooring. In downflow installations, factory accessory floor
base MUST be used when installed on combustible materials
and wood flooring. Special base is not required when this
furnace is installed on manufacturer's Coil Assembly Part No.
CD5 or CKS, or when Coil Box Part No. KCAKC is used. See
Fig. 1 for clearance to combustible construction information.
INTRODUCTION
—4 The Series 120/C 4 —way multipoise Category I fan- assisted
furnace is CSA (formerly A.G.A. and C.G.A.) design-certified. A
Category I fan - assisted furnace is an appliance equipped with an
integral mechanical means to either draw or force products of
combustion through the combustion chamber and/or heat ex-
changer. The furnace is factory- shipped for use with natural gas.
This furnace is not approved for installation in mobile homes,
recreational vehicles, or outdoors.
Fig. 1 —Clearances to Combustibles
3
INSTALLATION
MINIMUM INCHES CLEARANCE TO COMBUSTIBLE CONSTRUCTION
• DISTANCE MINMALE EN MUMS AUX CONSTRUCTIONS COMBUSTIBLES
This faced ar fame b equipped tor use Mill
rend gasetWWes 610.0001(03,05O4
M Y Ids tippled cornet b a by
manufacturer, el ts be used b cornet propene
ges Lee a may be required br sue natural ges
Ill Mr b for Moor rebbUcn n •
bLldLg constructed m Sta.
This tame may Installed on antuset*.
lloarg In Score or doe* at minimum deems*
as Mrated by la dram tan cant dbb
vitt
This aoa may be used van a Type 8-1 Vent
M
a cn vsth d ter gas
Tttrace Is
NOR03NTPLfra
b waandWrVOTS1EIWlfdVERS
Ostrom
dsretdagev't
fumeorenelm
0'
s
eI e
e% es
co'
ep
Vent Clearance
FaS
FaTna
Digpenodderbvadavec
Par cat
Paw cerxk*die,d
rp;soedbrtPFLCW,
� e
es
1.
b combustibles:
el song*
d"aaadane
icne..
patsE
Q
1Si
ide
OCMMRO✓V,
Les Wee
I Ueaem
L
..N1
^�lel
ea
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11 PPSaI
rest singe
Tyre B -11
et
lTME
LE BAS.
ds ert
de brunch.
0"
*
co E a nrn
s
ar av
^E e
Es '.
e
aware, h was
Ofpeparatrpo}
6so(6irdm).
pop Inchl
Celle bmatsei
pour 1Neslon met gaz rebid et salvias
orates eroe 03,050m 10.10,000 M.
Laser we Sousse de csbR tune per
b blatant pour passer au gra pepasw pour
carbines rrblalos au gezmeal.
Cede bure5e ed peas parley
Staab dens m babaicaermeo rplace.
Cede braise peatlre Wales our
m Panther ant dens une *Om w
dos is gadesobe en reepeda't b mamma
despew by des rrrertdoorc)Ttcalble. It
Cate be
de braise peat be uAHsbe sec m
wait dbaN.lalan deIge 6l w mredae
au undue dnvnun d lures marsh a g¢
MINIMUM INCHES CLEARANCE TO COMBUSTIBLE CONSTRUCTION
00ANFLOx POSMO S:
t teblattcron mm busE6bt ors ay.
For rebblm on ronbuena toai g only when totaled m spacial bas, Pat No. KGASB0201ALL.
Coll Assembly, Pat No CD5a0(5. et Cd Casing Pat It KCNCC.
0 18 Infuse Sul deaare required tar Soave.
• iambs supply a arm ides elan Mace Is in be leataanel paAba e contact ally pan
barman Ilesbnsi by Waaedasdlie Top and Mo Was ate in ceJacet and brflig OS
sbdsoMtg.
DEGAGEMENT MINIMUM EN POLICES AVEC ELEMENTS
DE CONSTRUCTION COMBUSTIBLES
POUR LA POMRON COURANT DESCENDANT
t Par I1rubblm or plater ran oartaslbb salarat
Par llresl:dm arm trencher arntusshte seismal guard m rise b teas spiels, pine
re KGAS80201N1, raearbb eapert% piece re CD5w 00 w b aster de eaperSt gaze
It KCNCC
0 Doe use Solve, at ddt nritat m digegeaal a revert de 18 po (450nm).
* to poatal rrlqu6eaorraane b ode derteewde reburgasnd bbureiseeetdasla
palm hodzabla
Ls contact need penis queues bs ins Smiles per bs riasxfas du doses fides
dew cafe de b Manisa de Manisa atlas fovea nntat ewe Cade de dapaa
` 327590 -101 REV. C
Fig. 1 —Clearances to Combustibles
3
F
51LIf'! MAX80
Fig. 2— Return Air Temperature
This furnace is designed for minimum continuous return-air
temperature of 60 °F db or intermittent operation down to 55 °F db
such as when used with a night setback thermostat. Return-air
temperature must not exceed 80 °F db. Failure to follow these
return-air temperature limits may affect reliability of heat exchang-
ers, motors, and controls. (See Fig. 2.)
For accessory installation details. refer to the applicable instruction
literature.
NOTE: Remove all shipping brackets and materials before oper-
ating the furnace.
CODES AND STANDARDS
Follow all national and local codes and standards in addition to
these Instructions. The installation must comply with regulations
of the serving gas supplier, local building, heating, plumbing, and
other codes. In absence of local codes, the installation must
comply with the national codes listed below and all authorities
having jurisdiction.
In the United States and Canada, follow all codes and standards for
the following:
Step 1 — Safety
• US: National Fuel Gas Code (NFGC) NFPA 54- 2002/ANSI
Z223 1 -2002 and the Installation Standards, Warm Air Heating
and Air Conditioning Systems ANSI/NFPA 90B
• CANADA: CSA B149.1-00 National Standard of Canada
Natural Gas and Propane Installation Code (NSCNGPIC)
Step 2 General Installation
• US: Current edition of the NFGC and the NFPA 90B. For
copies, contact the National Fire Protection Association Inc.,
Batterymarch Park, Quincy, MA 02269; (www.NFPA.org) or
for only the NFGC, contact the American Gas Association, 400
N. Capitol Street, N.W., Washington, DC 20001
(wwwAGA.org.)
CANADA: NSCNGPIC. For a copy, contact Standard Sales,
CSA International, 178 Rexdale Boulevard, Etobicoke (Tor-
onto), Ontario, M9W 1R3 Canada
Step 3 Combustion and Ventilation Aar
• US: Section 8.3 of the NFGC, Air for Combustion and
Ventilation
• CANADA: Part 7 of NSCNGPIC, Venting Systems and Air
Supply for Appliances
4
Step 4 —Duct Systems
• US and CANADA: Air Conditioning Contractors Association
(ACCA) Manual D, Sheet Metal and Air Conditioning Con-
tractors National Association ( SMACNA), or American Soci-
ety of Heating, Refrigeration, and Air Conditioning Engineers
(ASHRAE) 2001 Fundamentals Handbook Chapter 34 or 2000
HVAC Systems and Equipment Handbook Chapters 9 and 16.
Step 5 Acoustical Lining and Fibrous Glass Duct
• US and CANADA: current edition of SMACNA and NFPA
90B as tested by UL Standard 181 for Class I Rigid Air Ducts
Step 6 — Gas Piping and Gas Pipe Pressure Testing
US: NFGC; chapters 5, 6, 7, and 12 and National Plumbing
Codes
CANADA: NSCNGPIC Parts 3, 4, and 5, and Appendices A,
B, E and H.
Step 7 — Electrical Connections
• US: National Electrical Code (NEC) ANSI/NFPA 70 -2002
• CANADA: Canadian Electrical Code CSA C22.1
Step 8 Venting
• US: NFGC; chapters 10 and 13
• CANADA: NSCNGPIC Pan 7 and Appendix C
ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS
PROCEDURE
A CAUTION
FURNACE RELIABILITY HAZARD
Improper installation or service of furnace may cause prema-
ture furnace component failure.
Electrostatic discharge can affect electronic components.
Take precautions during furnace installation and servicing to
protect the furnace electronic control. Precautions will pre-
vent electrostatic discharges from personnel and hand tools
which are held during the procedure. These precautions will
help to avoid exposing the control to electrostatic discharge
by putting the furnace, the control, and the person at the same
electrostatic potential.
I. Disconnect all power to the furnace. Multiple disconnects may
be required. DO NOT TOUCH THE CONTROL OR ANY
WIRE CONNECTED TO THE CONTROL PRIOR TO DIS-
CHARGING YOUR BODY'S ELECTROSTATIC CHARGE
TO GROUND.
2. Firmly touch the clean, unpainted, metal surface of the furnace
chassis which is close to the control. Tools held in a person's
hand during grounding will be satisfactorily discharged.
3. After touching the chassis, you may proceed to service the
control or connecting wires as long as you do nothing to
recharge your body with static electricity (for example; DO
NOT move or shuffle your feet, do not touch ungrounded
objects, etc.).
4. If you touch ungrounded objects (and recharge your body with
static electricity), firmly touch a clean, unpainted metal
surface of the furnace again before touching control or wires.
5. Use this procedure for installed and uninstalled (ungrounded)
furnaces.
6. Before removing a new control from its container, discharge
your body's electrostatic charge to ground to protect the
control from damage. If the control is to be installed in a
furnace, follow items 1 through 4 before bringing the control
or yourself in contact with the furnace. Put all used and new
controls into containers before touching ungrounded objects.
FURNACE FAZE
A
CABINET WIDTH
(IN)
D
SUPPLY-AIR
WIDTH
ON
e
AEIURN -AIR
WIDTH
(IN.)
(IN.)
a'
i
EWE COLLAR'
(IN.)
WT. (LB)
WIRE ENTRY
3-1Btr 111
LEFT NWT OAS
ENIRY
I I
I 1
1 nr DIA ACCESSORY
L.
n
12 -9/18
FURNACE FAZE
A
CABINET WIDTH
(IN)
D
SUPPLY-AIR
WIDTH
ON
e
AEIURN -AIR
WIDTH
(IN.)
(IN.)
F
C.1. TCP AND
BOTTOM FLUE COLLAR
1
EWE COLLAR'
(IN.)
WT. (LB)
FILTER
CAB SIZE
(IN.)
070. 121036070
14-3/18
12 -9/18
1211/16
9-5
4
127
18
090. 16/048090
17-112
15-7/8
18
11.9/18
4
161
18
110. 20/080110
21
19.3/8
19 -12
13 -5/18
4
163
20
135. 221066135
24-12
22 -7/8
23
15-1/18
at
177
24
155. 22/066155
24-12
22 -7/8
23
15-1/18
4t
183
24
a
(FLUE )
7m' DA
ACCESSORY
Ir
ttnr—
%.1N'
72 rtr
.,UNCTION 00
LOCATION
SOTTO
4„nS'
—' �
CASING
LOCATION
w
Ftrr
7. An ESD service tit (available from commercial sources) may
also be used to prevent ESD damage.
GENERAL
This multipoise furnace is shipped in packaged configuration.
Some assembly and modifications an required when used in any
of the four applications shown in Fig. 4.
NOTE: For high-altitude installations, the high - altitude conver-
sion kit MUST be installed at or above 5500 f above sea level.
Obtain high - altitude conversion kit from your area authorized
distributor.
This furnace must:
• be installed so the electrical components are protected from
water.
• not be installed directly on any combustible material other than
wood flooring (refer to SAFETY CONSIDERATIONS).
• be located close to the chimney or vent and attached to an air
distribution system. Refer to Air Ducts section.
5
–3
Table 1—Dlmenslons (!N.)
• S or r vent connector may be required m some cases. t5' car larger Lent le requred. Use a 4-5 or 4-6 :nth vent adapter between furnace and vent connector.
NOTES:
1. Two additional 7/&in. diameter hobs are bested it Ma by plate.
2. Minimum return-air openings at furnace, based on metal Acct. II Ilex duct Is used, see flex duct manufacturer's recommendations for equivalent diameters.
a. For 800 CFM -1e4n. round or 14 1/2 x 124n. rectangle.
b. For 1200 CFM -20-4i. round or 14 1/2 x ie t2-In. rectangle.
e. For 1800 CFM-22-in. round or 1412 x 22 1/164,. rectangle.
d. For ektIow requirements above 1800 CFM, see Alt Delivery table in Product Data literature for speceb
use of akgk sib Wets. The use of both aide Wets, a combination alt side and the bottom, or the
bottom only will ensure adequate return air openings for airflow requirements above 1800 CFM.
Fig. 3— Dimensional Drawing
A04037
• be provided ample space for servicing and cleaning. Always
comply with minimum fire protection clearances shown on the
furnace clearance to combustible construction label.
A WARNING
CARBON MONOXIDE POISONING AND UNIT DAM-
AGE HAZARD
Failure to follow this warning could result in personal injury
or death and furnace damage.
Corrosive or contaminated air may cause failure of parts
containing flue gas, which could leak into the living space.
Air for combustion must not be contaminated by halogen
compounds, which include fluoride. chloride, bromide, and
iodide. These elements can corrode heat exchangers and
shorten furnace life. Air contaminants are found in aerosol
sprays. detergents, bleaches, cleaning solvents, salts, air
fresheners, and other household products. Do not install
furnace in a corrosive or contaminated atmosphere. Make
sure all combustion and circulating air requirements are met,
in addition to all local codes and ordinances.
THE BLOWER IS LOCATED
TO THE RIGHT OF THE
BURNER SECTION, AND
AIR CONDITIONED AIR IS
DISCHARGED TO THE LEFT.
a
HORIZOICAL LEFT
THE BLOWER 1S
LOCATED ABOVE THE
BURNER SECTION, AND
CONDITIONED MR IS
DISCHARGED DOWNWARD
The following types of furnace installations may require OUT-
DOOR AIR for combustion due to chemical exposures:
• Commercial buildings
• Buildings with indoor pools
• Laundry rooms
• Hobby or craft rooms, and
• Chemical storage areas
If air is exposed to the following substances, it should not be used
for combustion air, and outdoor air may be required for combus-
tion:
• Permanent wave solutions
• Chlorinated waxes and cleaners
• Chlorine based swimming pool chemicals
• Water softening chemicals
• De -icing salts or chemicals
• Carbon tetrachloride
• Halogen type refrigerants
• Cleaning solvents (such as perchloroethylene)
• Printing inks, paint removers, varnishes, etc.
• Hydrochloric acid
• Cements and glues
• Antistatic fabric softeners for clothes dryers
• Masonry acid washing materials
All fuel - burning equipment must be supplied with air for fuel
combustion. Sufficient air must be provided to avoid negative
pressure in the equipment room or space. A positive seal must be
made between the furnace cabinet and the return-air duct to
prevent pulling air from the burner area and from draft safeguard
opening.
THE BLOWER IS
LOCATED BELOW THE
BURNER SECTION, AND
CONDTIONED AIR IS
DISCHARGED UPWARD.
DOPANFLOW
Q
Fig. 4— Multlpoise Orientations
6
HORIZONTAL RIGHT
THE BLOWER IS
LOCATED TO THE LEFT
OF THE BURNER SECTION.
AND CONDM NJED AIR IS
DISCHARGED TO THE RIGHT.
18-IN. MINIMUM
TO BURNERS
Fig. 5— Installation in a Garage
A02097
A93044
A WARNING
FIRE AND EXPLOSION HAZARD
Failure to follow this warning could result in personal injury,
death and/or property damage.
When the furnace is installed in a residential garage, the
burners and ignition sources must be located at least 18 inches
above the floor. The furnace must be located or protected to
avoid damage by vehicles. When the furnace is installed in a
public garage, airplane hangar, or other building having a
hazardous atmosphere, the furnace must be installed in
accordance with the NFGC or NSCNOPIC. (See Fig. 5.)
A CAUTION
PROPERTY DAMAGE HAZARD
Improper use or installation of this furnace may cause
premature furnace component failure.
This gas furnace may be used for heating buildings under
construction provided that:
-The furnace is permanently installed with all electrical
wiring, piping. venting and ducting installed according to
these installation instructions. A return air duct is provided,
sealed to the furnace casing, and terminated outside the space
containing the furnace. This prevents a negative pressure
condition as created by the circulating air blower. causing a
flame rollout and/or drawing combustion products into the
structure.
-The furnace is controlled by a thermostat. It may not be "hot
wired" to provide heat continuously to the structure without
thermostatic control.
-Clean outside air is provided for combustion. This is to
minimize the corrosive effects of adhesives, sealers and other
construction materials. It also prevents the entrainment of
drywall dust into combustion air, which can cause fouling
and plugging of furnace components.
-The temperature of the retum air to the furnace is maintained
between 55 °F (13 °C) and 80 °F (27 °C), with no evening
setback or shutdown. The use of the furnace while the
structure is under construction is deemed to be intermittent
operation per our installation instructions.
-The air temperature rise is within the rated rise range on the
furnace rating plate, and the gas input rate has been set to the
nameplate value.
-The filters used to clean the circulating air during the
construction process must be either changed or thoroughly
cleaned prior to occupancy.
-The furnace. ductwork and filters are cleaned as necessary to
remove drywall dust and construction debris from all HVAC
system components after construction is completed.
- Verify proper furnace operating conditions including igni-
tion, gas input rate, air temperature rise, and venting accord-
ing to these installation instructions.
A WARNING
FIRE HAZARD
Failure to follow this warning could result in unsafe furnace
operation, personal injury, death, and/or property damage.
Do not install the furnace on its back or hang furnace with
control compartment facing downward. Safety control opera-
tion will be adversely affected. Never connect retum-air ducts
to the back of the furnace. (See Fig. 6.)
LOCATION RELATIVE TO COOLING EQUIPMENT
The cooling coil must be installed parallel with, or on the
downstream side of the unit to avoid condensation in the heat
exchangers. When installed parallel with the furnace, dampers or
other flow control must prevent chilled air from entering the
furnace. If the dampen 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.
7
FRONT
A02054
Fig. 6— Prohibit Installation on Back
AIR FOR COMBUSTION AND VENTILATION
Provisions for adequate combustion, ventilation, and dilution air
must be provided in accordance with:
• US. Installations: Section 8.3 of the NFGC, Air for Combus-
tion and Ventilation and applicable provisions of the local
building codes.
• Canadian Installations: Part 7 of the NSCNGPIC, Venting
Systems and Air Supply for Appliances and all authorities
having jurisdiction.
A CAUTION
FURNACE CORROSION HAZARD
Failure to follow this caution may result in furnace damage.
Air for combustion must not be contaminated by halogen
compounds, which include fluoride, chloride, bromide, and
iodide. These elements can corrode heat exchangers and
shorten furnace life. Air contaminants are found in aerosol
sprays, detergents, bleaches, cleaning solvents, salts, air
fresheners, and other household products.
A WARNING
CARBON MONOXIDE POISONING HAZARD
Failure to follow this warning could result in personal injury
or death.
The operation of exhaust fans. kitchen ventilation fans,
clothes dryers, attic exhaust fans or fireplaces could create a
NEGATIVE PRESSURE CONDITION at the furnace.
Make -up air MUST be provided for the ventilation devices, in
addition to that required by the furnace. Refer to the Carbon
Monoxide Poisoning Hazard warning in the venting section
of these instructions to determine if an adequate amount of
make -up air is available.
The requirements for combustion and ventilation air depend upon
whether or not the furnace is located in a space having a volume
of at least 50 cubic feet per 1,000 Btuh input rating for all gas
appliances installed in the space.
• Spaces having less than 50 cubic feet per 1,000 Btuh require
the OUTDOOR COMBUSTION AIR METHOD.
• Spaces having at bast 50 cubic feet per 1,000 Btuh may use the
INDOOR COMBUSTION AIR, STANDARD or KNOWN -
AIR INFILTRATION METHOD.
FURNACE
INPUT
(BTUH)
TWO HORIZONTAL DUCTS
(1 SG. IN/2,000 BTUH) (1,100 S0. MM/KW)
SINGLE DUCT OR OPENING
(1 50. IN./3,000 BTUH) (734 SO. MMIKW)
TWO OPENINGS OR VERTICAL DUCTS
(1 50. IN./4,000 BTUH) (550 SO. MM/KW)
Free Area of
Opening and Duct
(Sq. In.)
Round Duct
(In. Dice)
Free Area of
Opening and Duct
(sq In.)
Round Duct
(in. Dia)
Free Area of
Opening and Duct
(Sq In.)
Round Duct
(In. Dice)
44,000
22
6
14.7
5
11
4
66,000
33
7
22
6
18.5
5
88,000
44
8
29.3
7
22
6
110,000
55
9
36.7
7
27.5
6
132,000
66
10
44
6
33
7
154,000
77
10
51.3
9
38.5
8
ACH
OTHER THAN FAN - ASSISTED TOTAL
(1,000'S BTUH GAS INPUT RATE)
30 40 50
FAN - ASSISTED TOTAL
(1,000'S BTUH GAS INPUT RATE)
44 66 88 110 132 154
Space Volume (0a)
0.60
1,050
1,400
1,750
1,100
1,650
2,200
2,750
3,300
3,850
0.50
1,260
1,680
2,100
1,320
1,980
2,640
3,300
3,960
4,620
0.40
1,575
2,100
2,625
1,650
2,475
3,300
4,125
4,950
5,775
0.30
2.100
2,800
3,500
2,200
3,300
4,400
5,500
6,600
7,700
0.20
3,150
4,200
5,250
3,300
4,950
6,600
8,250
9,900
11,550
0.10
6,300
8,400
10,500
6,600
9,900
13,200
18,500
19,800
23,100
0.00
NP
NP
NP
NP
NP
NP
NP
NP
NP
Table 2- Minimum Free Area Required for Each Combustion AIr Open ng or Duct to Outdoors
EXAMPLES: Determining Free Area
FURNACE
110,000
66,000
86,000
NP = Not Permitted
WATER HEATER
+ 30,000
+ 40.000
+ 30,000
TOTAL INPUT
(140,000 divided by 4,000)
(106,000 divided by 3,000)
(118,000 divided by 2,000)
Table 3- Minimum Space Volumes for 100% Combustion, Ventilation, and
Dilution from Indoors
Outdoor Combustion Air Method
1. Provide the space with sufficient a for proper combustion,
ventilation, and dilution of flue gases using permanent hori-
zontal or vertical duct(s) or opening(s) directly communicat-
ing with the outdoors or spaces that freely communicate with
the outdoors.
2. Fig. 7 illustrates how to provide TWO OUTDOOR OPEN-
INGS, one inlet and one outlet combustion and ventilation air
opening, to the outdoors.
a. One opening MUST commence within 12" (300 mm) of
the ceiling and the second opening MUST commence
within 12" (300 mm) of the floor.
b. Size openings and ducts per Fig. 7 and Table 2.
c. TWO HORIZONTAL DUCTS require 1 square inch of
free area per 2,000 Btuh (1,100 mm of combined
input for all gas appliances in the space per Fig. 7 and Table -)
2.
d. TWO OPENINGS OR VERTICAL DUCTS require 1
square inch of free area per 4,000 Btuh (550 mm for
combined input of all gas appliances in the space per Fig.
7 and Table 2.
3. ONE OUTDOOR OPENING requires:
a. I square inch of free area per 3,000 Btuh (734 mm
for combined input of all gas appliances in the space per
Table 2 and
8
35.0 Sq. In. for each two Vertical Ducts or Openings
35.3 Sq. In. for a Single Duct or Opening
59.0 Sq. In. for each of two Horizontal Ducts
b. Not less than the sum of the areas of all vent connectors in
the space.
The opening shall commence within 12" (300 mm) of the ceiling.
Appliances in the space shall have clearances of at least 1" (25
mm) from the sides and back and 8" (150 mm) from the front The
opening shall directly communicate with the outdoors or shall
communicate through a vertical or horizontal duct to the outdoors
or spaces (crawl or attic) that freely communicate with the
outdoors.
Indoor Combustion Aire NFPA & AGA
Standard and Known - Air - Infiltration Rate Methods
Indoor air is permitted for combustion, ventilation, and dilution,
if the Standard or Known- Air - Infiltration Method is used.
A WARNING
CARBON MONOXIDE POISONING HAZARD
Failure to supply outdoor air via grilles or ducts could result
in death and/or personal injury.
Many homes require an to be supplied from outdoors for
furnace combustion, ventilation, and dilution of flue gases.
The furnace combustion air supply must be provided in
accordance with this instruction manual.
'Minimum dimensions of 31n.
NOTE: Use any of the blowing
combinations M openings:
A&B CaD D8E FSO
Volume 21113 I( Ion.
0111111 Ti�l711000 Btu/hr
A03174
Fig. 7—AIr for Combustion, Ventilation, and
Dilution for Outdoors
The Standard Method:
1. The space has no less volume than 50 cubic feet per 1,000
Btuh of the maximum input ratings for all gas appliances
installed in the space and
2. The air infiltration rate is not known to be less than 0.40 air
changes per how (ACH).
The Known Air InNtradon Rate Method shall be used, if the
infiltration rate is known to be:
1. Less than 0.40 ACH and
2. Equal to or greater than 0.10 ACH
Infiltration rates greater than 0.60 ACH shall not be used. The
minimum requ volume of the space varies with the number of
ACH and shall be determined per Table 3 or Equations 1 and 2.
Determine the minimum required volume for each appliance W the
space and add the volumes together to get the total minimum
required volume for the space.
Table 3- Minimum Space Volumes were determined by using the
following equations from the National Fuel Gas Code ANSI
2223.1- 2002/NFPA 54- 20024322:
1. For other than fan- assisted appliances, such as a draft
hood- equipped water heater:
A04002
9
CIRCULATING AIR
DUCTS
VENT THROUGH ROOF
INTERIOR
HEATED
SPACE
CIRCULATING AIR DUCTS
Minimum opening size le 100 sq M. with
minimum dimension of 3 in.
Minimum of 3 in. when type -Bt vent is used.
16M I Volume r.. i 1 1000 Bt 3tumr
1 SO IN.
PER 1000
BTUH' IN DOOR
OR WALL
UNCONFINED
SPACE
IF MIN
(FRONT)t
2. For fan - assisted appliances such as this furnace:
1 SO IN.
PER 1000
BTUH' IN DOOR
OR WALL
12' MAX
A03175
Flg. 8—Air for Combustion, Ventilation, and
Dilution from Indoors
A04003
If:
= combined input of all other than fan - assisted appli-
ances in Btu/hr
I,,,, = combined input of all fan-assisted appliances in Btu/11r
ACH s air changes per hour (ACH shall not exceed 0.60.)
The following requirements apply to the Standard Method and to
the Known Air Infiltration Rate Method.
1. Adjoining rooms can be considered part of a space it
a. There are no closable doors between rooms.
b. Combining spaces on same floor level. Each opening shall
have free area of at least 1 in. Btuh (2,000 mm
of the total input rating of all gas appliances in the space,
but not less than 100 in . (0.06 m One opening shall
commence within 12' (300 rum) of the ceiling and the
second opening shall commence within 12" (300 mm) of
the floor. The minimum dimension of air openings shall be
at least 3 in. (80 mm). (See Fig. 8.)
c. Combining space on different floor levels. The volumes of
spaces on different floor levels shall be considered as
communicating spaces if connected by one or more perma-
nent openings in doors or floors having free area of at least
2 W. Btuh (4,400 mm of total input rating of
all gas appliances.
2. An attic or crawlspace may be considered a space that freely
communicates with the outdoors provided there are adequate
permanent ventilation openings directly to outdoors having
free area of at least 1- in. Btuh of total input rating for
all gas appliances in the space.
3. In spaces that use the Indoor Combustion Air Method,
infiltration should be adequate to provide air for combustion,
permanent ventilation and dilution of flue gases. However, in
buildings with unusually tight construction, additional air
MUST be provided using the methods described in the
Outdoor Combustion Air Method section.
Unusually tight constriction is defined as
Construction with:
a. Walls and ceilings exposed to the outdoors have a continu-
ous, sealed vapor barrier. Openings are gasketed or sealed
and
b. Doors and openable windows are weatherstripped and
c. Other openings are caulked or sealed. These include joints
around window and door frames, between sole plates and
floors, between wall- ceiling joints, between wall panels, at
penetrations for plumbing, electrical and gas lines, etc.
Combination of Indoor and Outdoor Air
1. Indoor openings shall comply with the Indoor Combustion
Air Method below and,
2. Outdoor openings shall be located as required in the Outdoor
Combustion Air Method mentioned previously and,
3. Outdoor openings shall be sized as follows:
a. Calculate the Ratio of all Indoor Space volume divided by
required volume for Indoor Combustion Air Method
below.
b. Outdoor opening size reduction Factor is 1 minus the
Ratio in a. above.
c. Minimum size of Outdoor openings shall be the size
required in Outdoor Combustion Air Method above
multiplied by reduction Factor in b. above. The minimum
dimension of air openings shall be not less than 3 in. (80
mm).
INSTALLATION
UPFLOW INSTALLATION
Bottom Return Air Inlet
These furnaces are shipped with bottom closure panel installed in
bottom return-air opening. Remove and discard this panel when
bottom return air is used. To remove bottom closure panel,
perform die following:
1. Tilt or raise furnace and remove 2 screws holding bottom filler
panel. (See Fig. 9.)
2. Rotate bottom filler panel downward to release holding tabs.
3. Remove bottom closure panel.
4. Reinstall bottom filler panel and screws.
Side Return Air Inlet
These furnaces are shipped with bottom closure panel installed in
bottom return-air opening. This panel MUST be in place when
only side return air is used.
NOTE: Side return-air openings can be used in UPFLOW and
most HORIZONTAL configurations. Do not use side return-air
openings in DOWNFLOW configuration.
Leveling Legs (If Desired)
In upflow position with side return inlet(s), leveling legs may be
used. (See Fig. 10.) Install field - supplied, 5/16 X 1 -1/2 in. (max)
corrosion- resistant machine bolts, washers and nuts.
10
NOTE: Bottom closure must be used when leveling legs are used.
It may be necessary to remove and reinstall bottom closure panel
to install leveling legs. To remove bottom closure panel, see Item
1 in Bottom Return Air Inlet section in Step 1 above.
To install leveling legs:
1. Position furnace on its back. Locate and drill a hole in each
bottom corner of furnace. (See Fig. 10.)
2. For each leg, install nut on bolt and then install bolt with nut
in hole. (Install flat washer if desired.)
3. Install another nut on other side of furnace base. (Install flat
washer if desired.)
4. Adjust outside nut to provide desired height, and tighten inside
nut to secure arrangement.
5. Reinstall bottom closure panel if removed.
Fig. 9— Removing Bottom Closure Panel
Fig. 10 —Level ng Legs
A02071
DOWNFLOW INSTALLATION
NOTE: For downflow applications, this furnace is approved for
use on combustible flooring when any one of the following 3
accessories are used:
• Special Base, KGASB
• Cased Coil Assembly Part No. CD5 or CK5
Flg. 11 —Floor and Plenum Opening Dimensions 83
• Coil Box Part No. KCAKC
1. Determine application being installed from Table 4.
2. Construct hole in floor per Table 4 and Fig. 11.
3. Construct plenum to dimensions specified in Table 4 and Fig.
11.
4. If downflow subbase, KGASB is used, install as shown in Fig.
12. If Coil Assembly Part No. CDS or CK5 or Coil Box Pan
No. KCAKC is used, install as shown in Fig. 13.
NOTE: It is recommended that the perforated supply -air duct
flanges be completely folded over or removed from furnace when
installing the furnace on a factory- supplied cased coil or coil box.
To remove the supply -air duct flange, use wide duct pliers or hand
seamers to bend flange back and forth until it breaks off. Be careful
of sharp edges. (See Fig. 14.)
FURNACE
CO5 OR CK5
COIL ASSEMBLY
OR KCAKC
COIL BOX
COMBUSTIBLE
FLOORING
SHEET METAL
PLENUM
1
1
1 OPENING
Fig. 13—Fumace Plenum, and Coll Assembly or Coil
Box Installed on a Combustible Floor
11
A04140
Bottom Retum Air Inlet
FURNACE
(OR COIL CASING
WHEN USED)
COMBUSTIBLE
FLOORING
DOWNFLOW
SUBBASE
SHEET METAL
PLENUM
FLOOR
OPENING
Flg. 12— Furnace, Plenum, and Subbase Installecion
a Combustible Floor
A04140
These furnaces are shipped with bottom closure panel installed in
bottom return-air opening. Remove and discard this panel when
bottom return air is used. To remove bottom closure panel,
perform the following:
I. Tilt or raise furnace and remove 2 screws holding bottom filler
panel. (See Fig. 9.)
2. Rotate bottom filler panel downward to release holding tabs.
3. Remove bottom closure panel.
4. Reinstall bottom filler panel and screws.
FURNACE
CASING
WIDTH
APPLICATION
PLENUM OPENING
FLOOR OPENING
A
B
C
0
14-3/16
Upflow Applications on Combustible or Noncombustible
Flooring (KGASB subbase not required)
12 -11/16
21-5/8
13- 5/16
22 -1/4
Downflow Applications on Noncombustible Flooring
(KGASB subbase not required)
12-W16
19
13 -3/16
19-5/8
Downflow applications on combustible flooring (KGASB
subbase required)
11.13/18
19
13-7/16
20-5/8
Downflow Applications on Combustible Flooring with CD5 or
CK5 Coll Assembly or KCAKC coil box (KGASB subbase
not required)
12 -5116
19
13-5/16
20
17 -1/2
Upflow Applications on Combustible or Noncombustible
Flooring (KGASB subbase not required)
16
21-5/8
16 -5/8
22 -1/4
Downflow Applications on Noncombustible Flooring
(KGASB subbase not required)
15.7/8
19
16 -112
19-5/8
Downflow applications on combustible flooring (KGASB
subbase required)
15-1/8
19
16 -3/4
20-5/8
Downflow Applications on Combustible Flooring with CD5 or
CK5 Coll Assembly or KCAKC coil box (KGASB subbase
not required)
15 -1/2
19
16-1/2
20
21
Upflow Applications on Combustible or Noncombustible
Flooring (KGASB subbase not required)
19 -1/2
21 -5/8
20.1/8
22-1/4
Downflow Applications on Noncombustible Flooring
(KGASB subbase not required)
19-3/8
19
20
19-5/8
Downflow applications on combustible flooring (KGASB
subbase required)
18 -5/8
19
20-1/4
20-5/8
Downflow Applications on Combustible Flooring with CD5 or
CK5 Coll Assembly or KCAKC coil box (KGASB subbase
not required)
19
19
20
20
24-12
Upflow Applications on Combustible or Noncombustible
Rooting (KGASB subbase not required)
23
21 -1/8
23-5/8
22-1/4
Downflow Applications on Noncombustible Flooring
(KGASB subbase not required)
22 -7/8
19
23-1/2
19-5/8
Downflow applications on Combustible flooring (KGASB
subbase required)
22 -1/8
19
23-3/4
20-5/8
Downflow Applications on Combustible Flooring with CD5 or
0(5 Coil Assembly or KCAKC coil box (KGASB subbase
not required)
22-1/2
19
23-1/2
20
Table 4— Opening Dimensions (In.)
HORIZONTAL INSTALLATION
A WARNING
FIRE, EXPLOSION, AND CARBON MONOXIDE POI-
SONING HAZARD
Failure to follow this warning could result in dangerous
operation, serious injury, death, or property damage.
Do not install the furnace on its back or hang furnace with
control compartment facing downward. Safety control opera-
tion will be adversely affected. Never connect return-air ducts
to the back of the furnace.
The furnace can be installed horizontally in an attic or crawlspace
on either the left-hand (LH) or right -hand (RH) side. The furnace
can be hung from floor joists, rafters or trusses or installed on a
non- combustible platform, blocks, bricks or pad.
Suspended Furnace Support
The furnace may be supported under each end with threaded rod,
angle iron or metal plumber's strap as shown. (See Fig. 15 and 16.)
Secure angle iron to bottom of furnace as shown. Heavy -gauge
sheet metal straps (plumber's straps) may be used to suspend the
furnace from each bottom corner. To prevent screws from pulling
out, use 2 #8 x 34-in. screws into the side and 2 #8 x 44 -in. screws
in the bottom of the furnace casing for each strap. (See Fig. 15 and
16.)
12
If the screws are attached to ONLY the furnace sides and not the
bottom, the straps must be vertical against the furnace sides and
not pull away from the furnace sides, so that the strap attachment
screws are not in tension (are loaded in shear) for reliable support.
Platform Furnace Support
Construct waling platform at location where all required furnace
clearances are met. (See Fig. 2 and 17.) For furnaces with 1 -in.
clearance requirement on side, set furnace on noncombustible
blocks, bricks or angle iron. For crawlspace installations, if the
furnace is not suspended from the floor joists, the ground under-
neath furnace must be level and the furnace set on blocks or bricks.
Roll -Out Protection
Provide a minimum 17 -3/4" X 22" piece of sheet metal for flame
rollout protection in front of burner area for furnaces closer than
12 inches above the combustible deck or suspended furnaces
closer than 12 inches to joists. The sheet metal MUST extend
underneath the furnace casing by 1 in. with the door removed.
The bottom closure panel on furnaces of widths 17 -1/2 in. and
larger may be used for flame roll -out protection when bottom of
furnace is used for return air connection. See Fig. 17 for proper
orientation of roll-out shield.
120'
MN
UPFLOW DOWNFLOW HORIZONTAL
S MIN FOR DOOR
REMOVAL
PREFERRED
PERMITTED
PREFERRED 1200
MN
(2) HEX NUTS. (2) WASHERS & (2) LOCK WASHERS
REQ. PER ROD
PREFERRED
c1 PERMI
Fig. 14 —Duet Flanges
Fig. 15— Horizontal Unit Suspension
13
PREFERRED
PREFERRED 120 \\ 11 PREFERRED
MN
1/ THREADED ROD
/4REQ.
•
PERMITTED
SECURE ANGLE
IRON TO BOTTOM
OF FURNACE WITH
318 x Y: SCREWS
TYPICAL FOR 2 SUPPORTS
1' SQUARE, 1'/: x 1' /: x'A• ANGLE IRON
014 UNI•STRUT MAY BE USED
OUTER DOOR r
ASSEMBLY
/ II
Il
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.
EQUIPMENT MANUAL
SHUT -OFF GAS VALVE
SEDIMENT
TRAP
Bottom Return Air Inlet
NR OPENING
UNION
These furnaces are shipped with bottom closure panel installed in
bottom return-air opening. Remove and discard this panel when
bottom return air is used. To remove bottom closure panel,
perform the following:
1. Tilt or raise furnace and remove 2 screws holding bottom filler
panel. (See Fig. 9.)
2. Rotate bottom filler panel downward to release holding tabs.
3. Remove bottom closure panel.
4. Reinstall bottom filler panel and screws.
22 GAUGE GALVANIZED
/ STRAPS TYPICAL
FOR 4 STRAPS
Fig. 17— Typical Attic Installation
Side Return Air Inlet
14
AIR
OPENING
SACK OF
FURNACE
METXOO1
FOLD ALL STRAPS UNDER
FURNACE ND SECURE WTN
( SO • SN SHEET METAL SCREWS
12 SCREWS N SCE AND 2 SCREWS
N BOTTOM).
Fig. 16— Horizontal Suspension with Straps
USE (4) MI SHEET
METAL SCREWS FOR EA01
STRAP. THE STRAPS
SHOULD Be VERTICAL
AGAINST THE RJRNACE
SIDES AND NM PULAWAY
FROM THE FURNACE
SIDES.
30-IN. MIN
WORK AREA
17 4" OVER AU.
4 3/4" UNDER DOOR
1" UNDER FURNACE
EXTEND OUT 12" OUT
FROM FACE OF DOOR
• WHEN USED WITH
SINGLE WALL VENT
CONNECTIONS
A03178
M3177
These furnaces are shipped with bottom closure panel installed in
bottom return-air opening. This panel MUST be in place when side
return air inlet(s) are used without a bottom return air inlet.
Not all horizontal furnaces are approved for side return air
connections (See Fig. 20.)
UPFLOW RETURN AIR CONFIGURATIONS AND RESTRICTIONS
MR FLOW MODELS RETURN AIR RERIRN AM RETURN AM RETURN AIR
ONLY CONNECTION 1 ONLY 2 *ECTIOf 3 �S OF
066.050. 42 AND YES YES YES YES
-20 MODELS
ALL OTTER MODELS YES YES YES YES
Fig. 18— Upflow Retum Alr Configurations and Restrictions
Fig. 19— Downfiow Return AIr Configurations and Restrictions
AIRFLOW M00E18 CT L1 RETURN Panaw AIR RETURN MR
CONNECTION CONNECTION 3 COMBINATIONS
ONLY OMY ONLY OF I,ENOS
41 S YES
NO NO NO
ALL MEN MODELS YES YES YES YES
Fig. 20— Horizontal Return AIr Configurations and Restrictions
15
A02075
A02163
A02162
FILTER ARRANGEMENT
A WARNING
CARBON MONOXIDE POISONING HAZARD
Failure to follow this warning could result in personal injury,
or death.
Never operate a furnace without a filter or with filter access
door removed.
There are no provisions for an internal filter rack in these furnaces
An external filter rack is required.
This furnace is shipped with a factory- supplied Media Filter
Cabinet. The Media Filter Cabinet uses either a factory- supplied
standard I -inch filter or 4-inch wide Media Filter which can be
purchased separately.
Refer to the instructions supplied with Media Cabinet for assembly
and installation options.
AIR DUCTS
General Requirements
The duct system should be designed and sized according to
accepted national standards such as those published by: Air
Conditioning Contractors Association (ACCA), Sheet Metal and
Air Conditioning Contractors National Association (SMACNA) or
American Society of Heating, Refrigerating and Air Conditioning
Engineers (ASHRAE) or consult The Air Systems Design Guide-
lines reference tables available from your local distributor. The
duct system should be sized to handle the required system design
CFM at the design external static pressure. The furnace airflow
rates are provided in Table 5 -Air Delivery-CFM (With Filter).
When a furnace is installed so that the supply ducts carry air
circulated by the furnace to areas outside the space containing the
furnace, the return air shall also be handled by duct(s) sealed to the
furnace casing and terminating outside the space containing the
furnace.
Secure ductwork with proper fasteners for type of ductwork used.
Seal supply - and return-duct connections to furnace with code
approved tape or duct sealer.
NOTE: Flexible connections should be used between ductwork
and furnace to prevent transmission of vibration.
Ductwork passing through unconditioned space should be insu-
lated to enhance system performance. When air conditioning is
used, a vapor banter is recommended.
Maintain a 1 -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.
Ductwork Acoustical Treatment
NOTE: 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 altemative, fibrous ductwork may
be used if constructed and installed in accordance with the latest
edition of SMACNA contraction standard on fibrous glass ducts.
Both acoustical lining and fibrous ductwork shall comply with
NFPA 90B as tested by UL Standard 181 for Class 1 Rigid air
ducts.
Supply Air Connections
For a furnace not equipped with a cooling coil, the outlet duct shall
be provided with a removable access panel. This opening shall be
accessible when the furnace is installed and shall be of such a size
that the heat exchanger can be viewed for possible openings using
light assistance or a probe can be inserted for sampling the air
stream. The cover attachment shall prevent leaks.
16
Upflow and Horizontal Furnaces
Connect supply -air duct to flanges on furnace supply -air outlet.
Bend flange upward to 90° with wide duct pliers. (See Fig. 14.)
The supply -air duct must be connected to ONLY the furnace
supply- outlet -air duct flanges or air conditioning coil casing (when
used). DO NOT cut main furnace casing side to attach supply air
duct, humidifier, or other accessories. All accessories MUST be
connected to duct external to furnace main casing.
NOTE: For horizontal applications, the top most flange may be
bent past 90 degrees to allow the evaporator coil to hang on the
flange temporarily while the remaining attachment and sealing of
the coil are performed.
Downflow Furnaces
Connect supply -air duct to supply -air outlet on furnace. Bend
flange inward past 90° with wide duct pliers (See Fig. 14.) The
supply-air duct must be connected to ONLY the furnace supply
outlet or air conditioning coil casing (when used). When installed
on combustible material. supply -air duct must be connected to
ONLY the accessory subbase, KGASB020IALL, or a factory
approved au conditioning coil casing. 1)0 NOT cut main furnace
casing to attach supply side alt duct, humidifier, or other accesso-
ries. All accessories MUST be connected to duct external to
furnace casing.
Return Air Connections
A WARNING
FIRE HAZARD
A failure to follow this warning could result in personal
injury, or death and/or property damage.
Never connect return-air ducts to the back of the furnace.
Follow instructions below.
Downflow Furnaces
The return -air duct must be connected to return-air opening
(bottom inlet) as shown in Fig. 3. DO NOT cut into casing sides
(left or right). Side opening is permitted for only upflow and
certain horizontal furnaces. Bypass humidifier connections should
be made at ductwork or coil casing sides exterior to furnace. (See
Fig. 19.)
Upflow and Horizontal Furnaces
The return-air duct must be connected to bottom, sides (left or
right), or a combination of bottom and side(s) of main furnace
casing as shown in Fig. 3. Bypass humidifier may be attached into
unused return air side of the furnace casing. (See Fig. 18 and 20.)
Not all horizontal furnace models are approved for side return air
connections. (See Fig. 20.)
GAS PIPING
A WARNING
FIRE OR EXPLOSION HAZARD
A failure to follow this warning could result in personal
injury, death, and/or propetty damage.
Never purge a gas line into a combustion chamber. Never test
for gas leaks with an open flame. Use a commercially
available soap solution made specifically for the detection of
leaks to check all connections.
FURNACE
SIZE
Op M
CFM Airflow
Setting
External Static
Pmesure Range
EXTERNAL STATIC PRESSURE (In. wc)'•
0.1 02 I 0.7 ' 0.8 I 0.9 1.0
036070
MRFLOW (CFM)
11
Low Heat
735 (615)1
0 -0.5
....,
735
735
735
725
High Heat
1180 (1060)1
0 -1.0
1180
1185
1175
1180
1180
1180 1 1180 1 1180 1 1180 1 1175
11
1.12 Tans Coding
525
0 -0.5;
625
525
525
525
510
11
2 Tone Cooling
700
0 -0.5*
700
700
700
895
685
2 -12 Tons Cooling
875
0 -1.0;
Ell
875
1050
1215
Ell
875
1050
1225
dig
Ell
ill
840
3Tons Cooling
1050
0 -1.0;
1035
3.12 Tons Cooling
1225
0 -1.0
1210
Maximum
1400
0 -1.0
1395
1400
1400
1400
1400
1400
1400
1385
1360
1310
048090
Low Feat
985 (825)1
0 -1.0
950
970
985
985
985
985
985
985
985
980
High Heat
1210 (1000)1
0 -1.0
1190
1205
1210
1210
1210
1210
1210
1210
1210
1200
-
- one ✓?•' ng
-
(-z
•1.
.c1.
.r.
nY,
11
2Toro Cooling
700
0 -05;
890
895
700
700
890
2.12 Tone Cooling
875
0 -1.0;
830
855
875
875
875
875
870
865
850
820
3Tons Cooling
1050
0 -1.0;
1005
1025
1040
1050
1060
1050
1060
1050
1050
1050
3.12 Tons Coding
1225
0 -1.0;
1205
1220
1215
1225
1225
1225
1225
1225
1225
1220
4 Tons Coding
1400
0 -1.0
1370
1385
1395
1400
1400
1400
1400
1400
1400
1380
Maximum
1600
0 -1.0
1585
1580
1585
1595
1800
1600
1560
1520
1480
1430
080110•'•
Low Heat
1320 (1110)1
0 -1.0
1275
1295
1315
1320
1320
1320 1320
1320
1320
1315
High Feat
1475 (1330)1
0 -1.0
1480
1465
1475
1475
1476
1475 1475
1475
1465
1465
tt
2Tons Cooling
700
0 -054
700
700
700
885
800
44
2 -12 Tons Cooling
875
0 -0.5;
860
875
885
855
840
tt
3Tons Cooling
1050
0 -0.5;
1050
1050
1045
1050
1050
3.12 Tons Cooling
1225
0 -1A;
1185
1195
1215
1225
1225
1225
1225
1225
1225
1225
4 Tons Coding
1400
0 -1.04
1385
1395
1400
1400
1400
1400
1400
1400
1400
1400
5 Tons Coding
1750
0 -1.0;
1710
1730
1745
1745
1750
1760
1750
1750
1745
1740
6 Tbns Cooling
2100
0 -1.0
2090
2100
2100
2100
2095
2085
2065
2045
2020
1990
Maximum
2200
0 -1.0
2200
2200
2200
2190
2185
2175
2165
2130
2085
2015
088135
Lax Heat
1700 (1430)1
0 -1.0
1700
1700
1700
1700
1700
1895
1700
1695
1885
1870
High Heat
1915 (1725)1
0 -1.0
1900
1905
1915
1915
1915
1915
1915
1915
1915
1915
if
2Taks Cooling
700
0 -0.5;
700
700
700
700
885
tt
2 -12 Tons Coding
875
0 -0.5;
870
670
865
865
865
tt
3Tons Coding
1050
0 -0.54
1010
1030
1050
1050
1050
3.12 Tons Coolkg
1225
0 -1.0;
1155
1190
1200
1210
1220
1225
1225
1225
1225
1225
4 Tbns Cooling
1400
0 -1.04
1395
1400
1400
1400
1400
1400
1400
1390
1375
1355
5 Tons Coding
1750
0 -1.04
1740
1750
1750
1750
1735
1740
1735
1730
1715
1700
6 Tons Coding
2100
0 -1.0
2075
2085
2090
2100
2100
2100
2090
2080
2055
2025
Maximum
2200
0 -1.0
2180
2195
2200
2200
2200
2200
2185
2165
2140
2095
088155
Low Heat
1718 (1440)1
0 -1.0
1715
1715
1715
1715
1715
1705
1710
1705
1705
1895
High Heat
1970 (1775)1
0 -1.0
1955
1965
1905
1970
1970
1970
1970
1970
1970
1960
11
2Tbns Coding
700
0 -0.6;
700
700
700
700
680
it
2.12 Tone Cooling
875
0 -0.54
865
876
875
885
865
1t
3Tbne Cooling
1050
0 -05;
1015
1020
1035
1045
1050
312 Tons Cooling
1225
0 -1.0;
1180
1185
1215
1225
1225
1225
1225
1225
1225
1225
4 Tons Cooling
1400
0 -1.0;
1385
1400
1400
1400
1400
1400
1395
1395
1380
1380
5 Tons Coding
1750
0 -1A;
1745
1750
1750
1750
1745
1740
1745
1745
1740
1735
8 Tons Coding
2100
0 -1.0
2055
2070
2080
2085
2095
2100
2100
2100
2090
2085
Maximum
2200
0 -1.0
2175
2190
2200
2200
2200
2200
2200
2200
2180
2160
Table 5-Air Delivery - CFM (With Filter)*
Actual external static pnssure ( ESP) can be 644 mined by using the fan laws (CFM proportional to ESP); such as a
system with heating alrflow of 1180 CFM at 0.5 ESP would operate at cooling airflow of 1050 CFM at 0.4 ESP and bw. eating
airflow of 736 CFM at 0.19 ESP.
A Sher is required for each return -air connection to the furnace. Airflow perlormance rcludes 1' washable Otter media such as
contained in factory- authorized accessory Slier rack. lb determine airflow pedwmance without Sds Ater, assume an additional 0.1'
avaitede external static pressure.
1 'Comfort node' akliow values are shown In (parenthesis). 'Comfort mode' tallow is selected when the low -heat rbe
adjustment switch (SW1.3) is OFF end the comfort/efficiency eellch (SW1-4) Is ON. Furnaces are shipped in this configuration.
y Ductwork must be sized for the highest airflow, which Is high - heating CFM and Is greater than cooling CFM In this case.
Note also that heating ESP will be higher than coding ESP for Otis system.
11 Operation within the dank areas of the dart Is not recommended because high -heat airflow will be above 1.0 ESP.
^•
AU airflows on 110 eke furnace are 5% lesson side return only installations.
17
A04016
NOMINAL
IRON
PIPE
INTERNAL
DIAMETER
LENGTH OF PIPE (FT)
10
20
30
40
50
SIZE
(IN.)
(IN.)
1/2
0.622
175
120
97
82
73
314
0.824
380
250
200
170
151
1
1.049
880
485
375
320
285
1 -1/4
1.380
1400
950
770
860
580
1 -1/2
1.610
2100
1480
1180
990
900
A WARNING
FIRE OR EXPLOSION HAZARD
Failure to follow this warning could result in personal injury,
death. and/or property damage.
Use proper length of pipe to avoid stress on gas control
manifold and a gas leak.
A WARNING
FIRE OR EXPLOSION HAZARD
Failure to protect gas valve inlet from water and debris could
result in death, personal injury and/or property damage. Gas
valve inlet and/or inlet pipe must remain capped until gas
supply line is permanently installed to protect the valve from
moisture and debris. Mso, install a sediment trap in the gas
supply piping at the inlet to the gas valve.
Gas piping must be installed in accordance with national and local
codes. Refer to current edition of NFGC in the U.S. and the
NSCNGPIC in Canada.
Installations must be made in accordance with all authorities
having jurisdiction. If possible, the gas supply line should be a
separate line running directly from meter to furnace.
NOTE: In the state of Massachusetts:
1. Gas supply connections MUST be performed by a licensed
plumber or gas fitter.
2. When flexible connectors are used, the maximum length
shall not exceed 36 inches (915 mm).
3. When lever handle type manual equipment shutoff valves are
used, they shall be T- handle valves.
4. The use of copper tubing for gas piping is NOT approved by
the state of Massachusetts.
Refer to Table 6 for recommended gas pipe sizing. Risers must be
used to connect to furnace and to meter. Support all gas piping
with appropriate straps, hangers, etc. Use a minimum of 1 hanger
every 6 ft. Joint compound (pipe dope) should be applied sparingly
and only to male threads of joints. Pipe dope must be resistant to
the action of propane gas.
A WARNING
FIRE OR EXPLOSION HAZARD
A failure to follow this warning could result in personal
injury, death, and/or property damage.
If local codes allow the use of a flexible gas appliance
connector, always use a new listed connector. Do not use a
connector which has previously served another gas appliance.
Black iron pipe shall be installed at the furnace gas control
valve and extend a minimum of 2 in. outside the furnace.
A CAUTION
FURNACE DAMAGE HAZARD
Failure to follow this caution may result in furnace damage.
Connect gas pipe to furnace using a backup wrench to avoid
damaging gas controls and burner misalignment.
An accessible manual equipment shutoff valve MUST be installed
external to furnace casing and within 6 ft of furnace. A 1/8 -in. NPT
plugged tapping, accessible for test gauge connection, MUST be
installed immediately upstream of gas supply connection to
furnace and downstream of manual equipment shutoff valve.
Table 6— Maximum Capacity of Pipe'
' Cubic ft of natural gas per hr for gas pressures 010.5 pslg 4-In. wc) or less
and a pressure drop of 0.5-in we (based on a 0.60 vedfic gravity gas).
Ref: Table 12.2 ANSI Z223-2002MFPA 54 -2002.
NOTE: The furnace gas control valve inlet pressure tap connec-
tion is suitable to use as test gauge connection providing test
pressure DOES NOT exceed maximum 0.5 prig (14 -in. wc) stated
on gas control valve. (See Fig. 53.)
Some installations require gas entry on right side of furnace (as
-3 viewed in upflow). (See Fig. 21a and 21b.)
Install a sediment trap in riser leading to furnace as shown in Fig
— 21c. Connect a capped nipple into lower end of tee. Capped nipple
should extend below level of furnace gas controls. Place a ground
joint union between furnace gas control valve and exterior manual
equipment gas shutoff valve.
A 1/8 -in. NPT plugged tapping, accessible for test gauge connec-
tion, MUST be installed immediately upstream of gas supply
connection to furnace and downstream of manual equipment
shutoff valve.
Street Elbow
TOP VIEW OF BURNER AND MANIFOLD ASSEMBLY
—. Fig 21a —Right 90 S E ide Gas Entry Example Q 05028
loow
r
�i7 1
2' Nipple
Gas Valve
-3 Fig. 21b —Right Side Gas Entry Example 2
18
A02327
-, Fig. 21c— TypICai Gas Pipe Arrangement
GAS
SUPPLY
MANUAL
SHUTOFF
VALVE
(REQUIRED
SEDIMENT
TRAP
ELECTRICAL CONNECTIONS
UNION
A0•035
Piping should be pressure and leak tested in accordance with
NFGC in the United States or NSCNGPIC in Canada. local. and
national plumbing and gas codes before the furnace has been
connected. After all connections have been made, purge lines and
check for leakage at furnace prior to operating furnace.
If pressure exceeds 0.5 psig (14 -in. wc), gas supply pipe must be
disconnected from furnace and capped before and during supply
pipe pressure test. If test pressure is equal to or less than 0.5 psig
(14 -in. we), turn off electric shutoff switch located on furnace gas
control valve and accessible manual equipment shu toff valve
before and during supply pipe pressure test After all connections
have been made, purge lines and check for leakage at furnace prior
to operating furnace.
The gas supply pressure shall be within the maximum and
minimum inlet supply pressures marked on the rating plate with
the furnace burners ON and OFF.
A WARNING
ELECTRICAL SHOCK HAZARD
Failure to follow this warning could result in personal injury
or death.
Blower access panel door switch opens 115 -v power to
control. No component operation can occur. Do not bypass or
close switch with panel removed.
See Fig. 24 for field wiring diagram showing typical field 115 -v
wiring. Check all factory and field electrical connections to
tightness.
Field- supplied wiring shall conform with the limitations of 63°F
(33 °C) rise.
19
A WARNING
ELECTRICAL SHOCK AND FIRE HAZARD
Failure to follow this warning could result in injury, death, or
property damage.
The cabinet MUST have an uninterrupted or unbroken ground
according to NEC ANSI/NFPA 70 -2002 and Canadian Elec-
trical Code CSA C22.1 or local codes to minimize personal
injury if an electrical fault should occur. This may consist of
electrical wire, conduit approved for electrical ground or a
listed, grounded power cord (where permitted by local code)
when installed in accordance with existing electrical codes.
Refer to the power cord manufacturer's ratings for proper
wire gauge. Do not use gas piping as an electrical ground.
A CAUTION
FURNACE MAY NOT OPERATE
Failure to follow this caution may result in furnace operation
stopping and water pipes freezing during cold weather.
Furnace control must be grounded for proper operation or else
control will lock out. Control must remain grounded through
green/yellow wire routed to gas valve and manifold bracket
screw.
115 -V WIRING
Verify that the voltage, frequency, and phase correspond to that
specified on unit rating plate. Also, check to be sure that service
provided by utility is sufficient to handle load imposed by this
equipment. Refer to rating plate or Table 7 for equipment electrical
specifications.
US. Installations: Make all electrical connections in accordance
with National Electrical Code (NEC) ANSUNFPA 70-2002 and
any local codes or ordinances that might apply.
Canadian Installations: Make all electrical connections in accor-
dance with Canadian Electrical Code CSA C22.1 or authorities
having jurisdiction.
A WARNING
—� FIRE HAZARD
Failure on follow this warning could result in injury, death, or
property damage.
Do not connect aluminum wire between disconnect switch
and furnace. Use only copper wire.
Use a separate, fused branch electrical circuit with a properly sized
fuse or circuit breaker for this furnace. See Table 7 for wire size
and fuse specifications. A readily accessible means of electrical
disconnect must be located within sight of the furnace.
NOTE: Proper polarity must be maintained for 115 -v wiring. If
polarity is incorrect, control LED status indicator light will flash
rapidly and furnace will NOT operate.
J -BOX RELOCATION
NOTE: If factory location of J -Box is acceptable, go to next
section (ELECTRICAL CONNECTION to 1 -Box).
NOTE: On 14" wide casing models, the 1 -Box shall not be
relocated to other side of furnace casing when the vent pipe is
routed within the casing.
1. Remove and save two screws holding J -Box. (See Fig. 22.)
NOTE: The I -Box cover need not be removed from the J -Box in
order to move the J -Box. Do NOT remove green ground screw
inside J -Box. The ground screw is not threaded into the casing
flange and can be lifted out of the clearance hole in casing while
swinging the front edge of the J -Box outboard of the casing.
FURNACE SIZE
VOLTS-
HERTZ-
OPERATING
VOLTAGE RANGE
MAXIMUM
UNIT AMPS
UNIT
AMPACITV#
MAXIMUM
WIRE LENGTH (FT)$
MAXIMUM
FUSE OR CKT BKR
AMPS}
MINIMUM
WIRE GAUGE
PHASE
Maximum'
Minimum'
070. 12/036070
115 -60-1
127
104
9.0
11.99
30
15
14
090. 16/048090
115 -60.1
127
104
9.6
12.56
29
15
14
110-20/060110
115-60-1
127
104
15.1
19.33
29
20
12
135. 22/066135
115-60 -1
127
104
14.9
19.13
30
20
12
155. 22/066155
115.60 -1
127
104
15.0
19.23
29
20
12
• Permissible limas of the village range at which the unit operates satisfactorily.
e Una ampaclty. 126 percent of largest cperaang components full lead amps plus 100 percent of all other potential operadrg components' (EAC, humidifier, etc.) hill load
am &
t flue-delay type le recommended.
# Length shown Is as measured 1 way along wits path between /ornate and service panel for maximum 2 percent voltage drop.
Fig. 22- Relocating J -Box
TWO
ALTERNATE
FIELD
LOCATION
A02099
2. Cut wire tie on loop in furnace wires attached to J -Box.
3. Move J -Box to desired location.
4. Fasten J -Box to casing with the two screws removed in Step
1.
5. Route J -Box w within furnace away from sharp edges.
rotating pans and hot surfaces.
ELECTRICAL CONNECTION TO J -BOX
Field - Supplied Electrical Box on Furnace J -Box Bracket
See Fig. 24.
1. Remove cover from furnace J -Box.
2. Attach electrical box to furnace J -Box bracket with at least
two field - supplied screws through holes in electrical box into
holes in bracket. Use blunt -nose screws that will not pierce
wire insulation.
3. Route furnace power wires through holes in electrical box and
J -Box bracket, and make field-wire connections in electrical
box. Use best practices (NEC in U.S. and CSA C22.1 in
Canada) for wire bushings, strain relief, etc.
4. Route and secure field ground wire to green ground screw on
J -Box bracket.
5. Connect line voltage leads as shown in Fig. 24.
6. Reinstall cover to J -Box. Do not pinch wires between cover
and bracket.
Electrical Box on Furnace Casing Side
See Fig. 23.
Table 7- Electrical Data
20
A WARNING
FIRE OR ELECTRICAL SHOCK HAZARD
Failure to follow this warning could result in personal injury,
death, or property damage.
If field - supplied manual disconnect switch is to be mounted
on furnace casing side, select a location where a drill or
fastener cannot damage electrical or gas components.
1. Select and remove a hole knockout in the casing where the
electrical box is to be installed.
NOTE: Check that duct on side of furnace will not interfere with
installed electrical box.
2. Remove the desired electrical box hole knockout and position
the hole in the electrical box over the hole in the furnace
casing.
3. Fasten the electrical box to casing by driving two field -
supplied screws from inside electrical box into casing steel.
FIg. 23- Field - Supplied Electrcal Box on
Furnace Casing
1 16 -VOLT FIELD -
SUPPLIED
FUSED
DISCONNECT
FIVE
WIRE
THREE -WIRE
HEATING -
ONLY
JUNCTION
BOX
CONTRA
24 -VOLT
TERMINAL.
BLOCK
FURNACE
J
'NOTE 1
4. Remove and save two screws holding 1 -Box. (See Fig. 22.)
5. Pull furnace power wires out of 1/2 -inch diameter hole in
J -Box. Do not loosen wires from strain -relief wire -tie on
outside of .1-Box.
6. Route furnace power wires through holes in casing and
electrical box and into electrical box.
7. Pull field power wires into electrical box.
8. Remove cover from furnace 1 -Box.
9. Route field ground wire through holes in electrical box and
casing, and into furnace J -Box.
10. Reattach furnace J -Box to furnace casing with screws re-
moved in Step 4.
11. Secure field ground wire to 1 -Box green ground screw.
12. Complete electrical box wiring and installation. Connect line
voltage leads u shown in Fig. 24. Use best practices (NEC in
U.S. and CSA C22.1 in Canada) for wire bushings, strain
relief, etc.
13. Reinstall cover to 1 -Box. Do not pinch wires between cover
and bracket.
POWER CORD INSTALLATION IN FURNACE J -BOX
NOTE: Power cords must be able to handle the electrical require-
ments listed in Table 7. Refer to power cord manufacturer's
listings.
1. Remove cover from 1 -Box.
2. Route listed power cord through 7/8 -inch diameter hole in
J -Box.
3. Secure power cord to J -Box bracket with a strain relief
bushing or a connector approved for the type of cord used.
4. Secure field ground wire to green ground screw on J -Box
bracket
5. Connect line voltage Leads as shown in Fig. 24.
6. Reinstall cover to 1 -Box. Do not pinch wires between cover
and bracket.
((wwN 2
��OTE 1 -STAG
T 4 I I (TERM
TERMINALS
1
NOTES: 1. Connect Y/Y2- termktal as shown for proper operation.
2. Some tlbmwstats require a rental connection as shown.
3. If any of the original wire, as supplled, must be replaced, use
same type or equivalent eke.
Fig. 24 -Field Wiring Diagram
21
- - -- FIELD 24-VOLT WIRING
- - -- FIELD 115-, 20W230 -, 460-VOLT WIRING
- FACTORY 24 -VOLT WIRING
FACTORY 115 -VOLT WIRING
t
CONDENSING
UNIT
FIELDSUPPLIED
FUSED DISCONNECT
208234 OR
-- 464voLT
PHASE
-
VOLT
-- SINGLE
OLT
PHASE
BX CABLE INSTALLATION IN FURNACE 1 -BOX
I. Remove cover from J -Box.
2. Route BX cable into 7/8 -inch diameter hole in 1 -Box.
3. Secure BX cable to J -Box bracket with connectors approved
for the type of cable used.
4. Secure field ground wire to green ground screw on J -Box
bracket.
5. Connect line voltage leads as shown in Fig. 24.
6. Reinstall cover to J -Box. Do not pinch wires between cover
and bracket
24-V WIRING
Make field 24-v connections at the 24-v terminal strip. (See Fig.
25.) Connect terminal Y/Y2 as shown in Fig. 26-33 for proper
cooling operation. Use only AWG No. 18, color - coded, copper
thermostat wire.
The 24-v circuit contains an automotive -type, 3 -amp fuse located
on the control. Any direct shorts during installation, service, or
maintenance could cause this fuse to blow. If fuse replacement is
requited, use ONLY a 3 fuse of identical size.
ACCESSORIES
1. Electronic Air Cleaner (BAC)
Connect an accessory Electronic Air Cleaner (if used) using
t /4-in female quick connect terminals to the two male 1 /4 -in
quick - connect terminals on the control board marked EAC -1
and EAC -2. The terminals are rated for 115VAC, 1.0 amps
maximum and are energized during blower motor operation.
(See Fig. 25.)
2. Humidifier (HUM)
Connect an accessory 24 VAC, 0.5 amp maximum humidifer
(if used) to the 1 /4-in male quick-connect HUM terminal and
Cos+ -24V screw terminal on the control board thermostat strip.
The HUM terminal is energized when blower is energized in
heating. (See Fig, 25.)
MODEL PLUG
CONNECTOR
SW1 SETUP
SWITCHES AND
BLOWER OFF -
DELAY
AIR CONDITIONING
(NC) AIRFLOW
SETUP SWITCHES
24 -V THERMOSTAT
TERMINALS
STATUS AND COMM
LED LIGHTS
115 -VAC (12) NEUTRAL
CONNECTIONS
COMMUNICATION CONTINUOUS FAN
(CF) AIRFLOW
SETUP SWITCHES
CONNECTOR
�1 PL4
f
to
.„
Room o
ISM
S SEC
3 -AMP FUSE SEC-2 Too
�1
EAC-21 _
TRANSFORMER 24-VAC
CONNECTIONS 0 0
O C=t
HUM
0
ACRDJ
PL1 - LOW VOLTAGE MAIN
HARNESS CONNECTOR
VENTING
The furnace shall be connected to a listed factory built chimney or
vent, or a clay -tile lined masonry or concrete chimney. Venting
into an unlined masonry chimney or concrete chimney is prohib-
ited.
When an existing Category 1 furnace is removed or replaced, the
original venting system, may no longer be sized to properly vent
the attached appliances. An improperly sized Category I venting
system could cause the formation of condensate in the furnace and
vent, leakage of condensate and combustion products, and spillage
of combustion products into the living space.
O
0 AT
m
eee
a
Mt* 'PVC
EAC-1
O
FUTURE
APPUCATIONS
a
EAC-1 TERMINAL
(115 -VAC 1.0 AMP MAX.)
22
O 0
00001
R \ \\ VS HSI HI LO
115 -VAC (L1) UNE
VOLTAGE CONNECTIONS
Fig. 25— Variable Speed Furnace Control for ECM Blower Motor
NOTE: DO NOT connect furnace control HUM terminal to HUM
(humidifier) terminal on Thermidistat, Zone Controller or similiar
device. See Them»distafm, Zone Controller, thermostat, or con-
troller manufacturer's instructions for proper connection.
HUMIDIFIER
TERMINAL (24 -VAC
0.5 AMP MAX
ACRDJ -AIR
CONDMONING
RELAY DISABLE
JUMPER
FLASH
UPGRADE
CONNECTOR
(FACTORY
ONLY)
PL3 - ECM BLOWER
HARNESS
CONNECTOR
PI2 - HOT SURFACE
IGNITER & INDUCER
MOTOR CONNECTOR
A02018
A WARNING
CARBON MONOXIDE POISONING HAZARD
Failure to follow the steps oudined below for each appliance
connected to the venting system being placed into operation
could result in carbon monoxide poisoning or death.
The following steps shall be followed for each appliance
connected to the venting system being placed into operation,
while all other appliances connected to the venting system are
not in operation:
1. Seal any unused openings in venting system.
2. Inspect the venting system for proper size and horizontal
pitch, as required in the National Fuel Gas Code, ANSI
2223.1- 2002MFPA 54 or the CSA B149.1, Natural Gas
and Propane Installation Code and these instructions.
Determine that there is no blockage or restriction, leakage,
corrosion and other deficiencies, which could cause an
unsafe condition.
3. As far as practical, close all building doors and windows
and all doors between the space in which the appliance(s)
connected to the venting system are located and other
spaces of the building.
4. Close fireplace dampers.
5. Turn on clothes dryers and any appliance not connected to
the venting system. Turn on any exhaust fans, such as
range hoods and bathroom exhausts, so they are operating
at maximum speed. Do not operate a summer exhaust fan.
6. Follow the lighting instructions. Place the appliance being
inspected into operation. Adjust the thermostat so
appliance is operating continuously.
7. Test for spillage from draft hood equipped appliances at the
draft hood relief opening after 5 minutes of main burner
operation. Use the flame of a match or candle.
8. If improper venting is observed during any of the above
tests, the venting system must be conected in accordance
with the National Fuel Gas Code, ANSI 7221.1-
2002/NFPA 54 and/or CSA B149.1, Natural Gas and
Propane Installation Code.
9. After it has been determined that each appliance connected
to the venting system properly vents when tested as
outlined above, return doors, windows, exhaust fans,
fireplace dampers and any other gas -fired burning
appliance to their previous conditions of use.
Vent system or vent connectors may need to be resized. Ven
systems or vent connectors must be sized to approach minimum
size as determined using appropriate table found in the NFGC or
NSCNGPIC.
GENERAL VENTING REQUIREMENTS
Follow all safety codes for proper vent sizing and installation
requirements, including local building codes, the National Fuel
Gas Code ANSI 7223.1- 2002/NFPA 54-2002 (NFGC), Parts 10
and 13 in the United States or the National Standard of Canada.
Natural Gar and Propane Installation Code CSA- B149.1.00
(NSCNGPIC) Section 7 and Appendix C in Canada, the local
building codes, and furnace and vent manufacturers' instnrctons.
These furnaces are design - certified as Category I furnaces in
--) accordance with ANSI Z21.47- 2003/CSA 2.3 -2003 and operate
with a non - positive vent static pressure to minimize the potential
for vent gas leakage. Category I furnaces operate with a flue loss
not less than 17 percent to minimize the potential for condensation
in the venting system. These furnaces are approved for common
venting and multi -story venting with other fan assisted or draft
hood equipped appliances in accordance with the NFCG or the
NSCNGPIC, the local building codes, and furnace and vent
manufacturers' instructions.
23
THERMDISTAT
NOTE 11
TWO-STAGE SINGLE -SPEED
FURNACE NR CONDITIONER
W2 1
I vi
1 ww.1 J
f
J 101
l R l
IDHUM1
.I ca. f
0 HUM
1 HUMIDIFER
(24 VAC)
506 MS 2. 5, 7.10. and 11
A00275
Fig. 26—Two-Stage Furnace with Single -Speed
Air Conditioner
The following information and wanting must be considered in
addition to the requirements defined in the NFGC or the NSCNG-
PIC.
—+ CARBON MONOXIDE POISONING HAZARD
Failure to follow this warning could result in personal injury
or death.
Do not bypass the draft safeguard switch, as an unsafe
condition could exist which must be corrected.
1. If a vent (common or dedicated) becomes blocked, the furnace
will be shut off by the draft safeguard switch located on the
vent elbow.
2. Two-stage furnaces require Type B vent connectors outside
the casing in all configurations. Single wall vent connector
may be used inside the furnace casing with the transition to
Type B vent outside the furnace casing. Size the connector so
that the FAN -Min vent connector capacity is equal to or lower
than the low fire rate of the furnace and the FAN -Max vent
connector capacity is equal to or higher than the furnace high
fire rate.
3. Do not vent this Category I furnace into a single wall
dedicated or common vent. The dedicated or common vent is
considered to be the vertical portion of the vent system that
terminates outdoors.
4. Vent connectors serving Category I furnaces shall not be
connected into any portion of a mechanical draft system
operating under positive pressure.
5. In the US: Do not vent this appliance with any solid fuel
burning appliance.
In Canada: Check with the authority having jurisdiction for
approval on use with solid fuel burning appliance.
THERMIDISTAT
HEAT STAGE 2 10/y2
COOL STAGE I IY„w21..
HEAT STAGE 1 Iwata h
COOL STAGE 2
FAN
24 VAC HOT R �.
DEHUMIDIFY IOHUM F.
24 VAC COMM C �-
HUMIDIFY
WA
wY2
I HUM I.
8
OOR - St
SENSOR
SENSOR
CONNECTION I 52 I.
ROTE 11
NOTE 12
TWO -STAGE TWO-SPEED
FURNACE AR CONDITIONER
O
1 R
4DHUM
1 Cal F -:
O HUM
See notes 2, 5, 8, 10. 11 and 12
on the page kfiottirq tees figures
-a
A03179
Fig. 27—Two-Stage Furnace with Two
Alr Conditioner
THERMIDISTAT
RVS COOLING
HEAT/COOL STAGE 1
(COMPRESSOR LO)
HEAT STAGE 3
(FURNACE)
HEAT/COOL STAGE 2
(COMPRESSOR HI
FAN
24 VAC HOT
DEHUMIDIFY
24 VAC COMA
HUMIDFY
WA
OUTDOOR
SENSOR -
CONNECTION
QM
I IVW2 1
Y/Y2
G
I HUM I.
(
8
51
1'
I S2
NOTE 12
THERMIDISTAT
RVS COOLING
HEAT STAGE 3
(FIMNACE tit
HEAT STAGE 2 M.
(FURNACE Lot
HEAT/COOL STAGE 1 I�I.
(COMRESSOR)
FAN S I �
24 VAC HOT l t.
DEHUMIDIFY I—},
24 VAC COMM f
I
HUMIDITY M.
WA
Ma
OUTDOOR =-
SENSOR
CONNECTION M.
Fig. 28— Two-Stage Furnace with Single Speed'
Heat Pump (Dual Fuel)
TWO-STAGE IWOSPEED
FURNACE HEAT PUAP
24
a
a
8 the e,o9inph,e figures
s. 19 end 15 notes on
NOTE 11
TWO-STAGE SINGLE-SPEED
FURNACE HEAT PUMP
Lia
till
1wm}
I Y3 l
I DHUMI
Si S UMIDIFIER
� •-{ I (24 VAC)
See notes 1 2, 4. 0, 7.9. 10. II. awl is
on the pegs Ma.Sq these Epees
Fig. 29— Two-Stage Furnace with Two -Speed Heat Pump (Dual Fuel)
1
FP a
A03178
DUAL FUEL
THERMOSTAT
RVS COOLING I�
HEAT STAGE 3FE}
(FL MACE ND
HEAT STAGE 2 FV/ti
(FURNACE UR ELI
.ILL
STAGE 1
(COISRESSOR)
Irm
FAN Fri
24 VAC HOT (
24 VAC COMA i7�I
WA Fri
MIS SENSING
11
OUTDOOR FEI
BENSOR pin
CONNECTION
L
NOTE 11
TWO-STAGE
FURNACE
ia
11
HUM
t r
1 OUTDOOR 'Ai
SENSOR
See noes 1.2.4.11, 14. 13. and 11
an M pee Mam.g Mee Nun
SINGLE -SPEED
HEAT PUMP
FIg. 30 —Dual Fuel Thermostat with TWO -Stag 181
Fumace and Single -Speed Heat Pump
DUAL FUEL
THERMOSTAT
RVS COOLING �21
HEAT/COOL STAGE 1
(COMPRESSOR LO)
HEAT STAGE 31
SRSPVCE)
HEAT/COOI. STAGE 2 in
(COIRRESSOR IR
FAN
24 VAC HOT 1 r-A-1 1
24 VAC COMA 1�
WA
RVH SENSOO
OUTDOOR
SENSOR I C
CONNECTON
0
NOTE 12
TWO-STAGE
FURNACE
0
a HUM
OUTDOOR
SENSOR
TWO-SPEED
IE+AT PIMP
Soo note 1.2.3.4, IR 13.14.1S. and 17
an te pee MO.aq Fro Spew
A03182
FIg. 31 —Dual Fuel Thermostat with Two -Stage
Fumace and Two -Speed Heat Pump
25
TWO-STAGE
THERMOSTAT
WM.
O
0
Q
SINGLE-STAGE
THERMOSTAT
NOTE 11
NOTE 12
TWO-STAGE
FURNACE
See notes 2.11. and 12 angle
pegs Mowing knee Wes
Fig. 32— Two -Stage Thermostat with Two- St/41
Furnace and Two-Speed AIr Condltloner
TWO-STAGE
FURNACE
TWO-SPEED
MR CONDITIONER
TWO-SPEED
AIR CONDITIONER
See wowing these awns page
A03184
Fig. 33—Single-Stage Thermostat with
Two -Stage Furnace and Two -Speed AIr Condltloner
NOTES FOR FIGURES 26-33
1. Heat pump MUST have a high pressure switch for dual fuel applications.
2. Refer to outdoor equipment Installation Instructions for additional information and setup procedure.
3. If the heat pump date code is 1501E or earlier, select the "ZONE" position on the two -speed heat pump control. Heat pumps having date codes
1601E and later do not have or require a "ZONE" selection.
4. Outdoor Air Temperature Sensor must be attached in all dual fuel applications.
5. Dip switch No. 1 on Thermidistat should be set in OFF position for alt conditioner installations. This is factory default.
6. Dip switch No. 1 on Thermidistat should be set in ON position for heat pump installations.
7. Dip switch No. 2 on Thermidistat should be set in OFF position for single -speed compressor operation. This is factory default.
8. Dip switch No. 2 on Thermidistat should be set in ON position for two-speed compressor operation.
9. Configuration Option No. 10 "Dual Fuel Selection" must be turned ON in all dual fuel applications.
10. NO connection should be made to the furnace HUM terminal when using a Thermidistat.
11. Optional connection: If wire is connected, dip switch SW 1 -2 on furnace control should be set in ON position to allow Thermidistat/Thermostat
to control furnace staging.
12. Optional connection: If wire is connected, ACRD) jumper on furnace control should be removed to allow Thermidistat/Thermostat to control
outdoor unit staging.
13. Furnace must control its own high -stage heating operation via fumace control algorithm.
14. The RVS Sensing terminal "L" should not be connected. This is internally used to sense defrost operation.
15. DO NOT SELECT the " FURNACE INTERFACE" or "BALANCE POINT' option on the two-speed heat pump control board. This is
controlled internally by the Thermidistat/Dual Fuel Thermostat.
16. Dip switch D on Dual Fuel Thermostat should be set in OFF position for single -speed compressor operation. This is factory default.
17. Dip switch D on Dual Fuel Thermostat should be set in ON position for two-speed compressor operation.
26
CHIMNEY INSPECTION CHART
For additional requirements refer to the National Fuel Gas Code NFPA 54 /ANSI Z223.1 and ANSI/NFPA 211
Chimneys, Fireplaces, Vents, and Solid Fuel Buming Appliances in the U.S.A. or to the Canadian
Installation Code CSA-B149.1 In Canada.
la cNmney
lined Met properly
sized, Need Nner or
lype•B vent?
Remove metal vent
or liner.
Reline
Yes Remove mortar
and tile debris
Not Suitable
Not Suitable
sized, listed flex'
liner orT vent per
NFGC or N CNOPIC Vent
Sizing Tables and liner or
vent manufacturers
Installation Instructions.
Suitable
C Chim t ptable for use.
Rebuild
Fig. 34—Chimney Inspection Chart
27
VENT HEIGHT (IT)
INTERNAL
12
AREA
(SO.
19
OF CHIMNEY
IN.)
28
38
8
74
119
178
257
8
80
130
193
279
10
84
138
207
299
15
NR
152
233
334
20
NR
NR
250
388
30
NR
NR
NR
404
6. Category I furnaces must be vented vertically or nearly
vertically unless equipped with a listed mechanical venter. See
SIDEWALL VENTING section.
7. Do not vent this appliance into an unlined masonry chimney.
Refer to Chimney Inspection Chart, Fig. 34.
MASONRY CHIMNEY REQUIREMENTS
NOTE: These furnaces are CSA design - certified for use in
exterior tile -lined masonry chimneys with a factory accessory
Chimney Adapter Kit Refer to the furnace rating plate for correct
kit usage. The Chimney Adapter Kits are for use with ONLY
furnaces having a Chimney Adapter Kit number marked on the
furnace rating plate.
If a clay tile -lined masonry chimney is being used and it is exposed
to the outdoors below the roof line, relining might be required.
Chimneys shall conform to the Standard for Chimneys, Fireplaces,
Vents, and Soild Fuel Burning Appliances ANSI/NFPA 211 -2003
in the United States and to a Provincial or Territorial Building
Code in Canada (in its absence, the National Building Code of
Canada) and must be in good condidon.
U.S.A.-Refer to Sections 13.1.9 and 13.2.20 of the NFGC or the
authority having jurisdiction to determine whether relining is
required. If relining is recruited, use a properly sized listed metal
liner, Type -B vent, or a listed alternative venting design.
NOTE: See the NFGC 13.1.9 and 13.2.20 regarding alternative
venting design and the exception, which cover installations such as
our Chimney Adapter Kits KGACA020I4FC and
KGACA02015FC. which are listed for use with these furnaces.
The Chimney Adapter Kit is a listed alternative venting system for
these furnaces. See the kit instructions for complete details.
Canada (and U.S.A.)-This furnace is permitted to be vented into
a clay tile -lined masonry chimney that is exposed to the outdoors
below the roof line, provided:
1. Vent connector is Type -B double -wall, and
2. This furnace is common vented with at least 1 draft hood -
equipped appliance, and
3. The combined appliance input rating is less than the maximum
capacity given in Table A, and
4. The input rating of each space heating appliance is greater
than the minimum input rating given in Table B for the local
99% Winter Design Temperature. Chimneys having internal
areas greater than 38 square inches require furnace input
ratings greater than the input ratings of these furnaces. See
footnote at bottom of Table B, and
5. The authority having jurisdiction approves.
If all of these conditions cannot be met, an alternative venting
design shall be used, such as the listed chimney adapter kit with a
furnace listed for use with the kit, a listed chimney - lining system,
or a Type -B common vent.
Inspections before the sale and at the time of installation will
determine the acceptability of the chimney or the need for repair
and/or ( re)iining. Refer to the Fig. 34 to perform a chimney
inspection. If the inspection of a previously used tile -lined chim-
ney:
a. Shows signs of vent gas condensation, the chimney should
be relined in accordance with local codes and the authority
having jurisdiction. The chimney should be relined with a
listed metal liner, Type-B vent, or a listed chimney adapter
kit shall be used to reduce condensation. If a condensate
drain is required by local code, refer to the NFGC, Section
10.9 for additional information on condensate drains.
28
b. Indicates the chimney exceeds the maximum permissible
size in the tables, the chimney should be rebuilt or relined
to conform to the requirements of the equipment being
installed and the authority having jurisdiction.
A chimney without a clay tile liner, which is otherwise in good
condition, shall be rebuilt to conform to ANSI/NEPA 211 or be
lined with a UL listed (ULC listed in Canada) metal liner or UL
listed Type -B vent. Relining with a listed metal liner or Type -B
vent is considered to be a vent-in-a-chase.
If a metal liner or Type -B vent is used to line a chimney, no other
appliance shall be vented into the annular space between the
chimney and the metal liner.
Exterior Masonry Chimney FAN + NAT
Installations with Type -B Double -Wail Vent
Connectors ats=PA a AGA
Table A—Comblned Appliance Maximum Input
Rating In Thousands of BTU per Hour
APPLIANCE APPLICATION REQUIREMENTS
Appliance operation has a significant impact on the performance
of the venting system. If the appliances are sized, installed,
adjusted, and operated properly, the venting system and/or the
appliances should not suffer from condensation and corrosion. The
venting system and all appliances shall be installed in accordance
with applicable listings, standards, and codes.
The furnace should be sized to provide 100 percent of the design
heating load requirement plus any margin that occurs because of
furnace model size capacity increments. Heating load estimates
can be made using approved methods available from Air Condi-
tioning Contractors of America (Manual 3); American Society of
Heating, Refrigerating, and Air-Conditioning Engineers; or other
approved engineering methods. Excessive oversizing of the fur-
nace could cause the furnace and/or vent to fail prematurely.
When a metal vent or metal liner is used, the vent must be in good
condition and be installed in accordance with the vent manufac-
turer's instructions.
To prevent condensation hi the furnace and vent system, the
following precautions must be observed:
1. The return-air temperature must be at least 60°F db except for
brief periods of time during warm -up from setback at no lower
than 55 °F db or during initial start-up from a standby
condition.
2. Adjust the gas input rate per the installation instructions. Low
gas input rate causes low vent gas temperatures, causing
condensation and corrosion in the furnace and/or venting
system. Derating is permitted only for altitudes above 2000 ft.
3. Adjust the air temperature rise to the midpoint of the rise range
or slightly above. Low air temperature rise can cause low vent
gas temperature and potential for condensation problems.
4. Set the thermostat heat anticipator or cycle rate to reduce short
cycling.
6
0
55
99
141
8
52
74
111
154
10
NR
90
125
189
2 15
NR
NR
187
212
v• 20
NR
NR
212
258
30
NR
NR
NR
362
1 .... ..r aa•_ YM .. ,Winn
Temperature: a W 1e CORMS r
8
NR
78
121
168
u. 8
NR
94
135
182
0 10
NR
111
149
198
2 15
NR
NR
193
247
on 20
NR
NR
NR
293
30
NR
NR
NR
377
6
NR
NR
145
196
u. 8
NR
NR
159
213
• 10
NR
NR
175
231
o 15
e
NR
NR
NR
283
• 20
NR
NR
NR
333
30
NR
NR
NR
NR
VENT INTERNAL AREA OF CHIMNEY
HEIGHT (FT) (80 N.)
12 1 19 ?8 I 38
Table B— MlnImum Alowable Input Rating of
Space- Heating Appliance In
Thousands of BTU per Hour
Loot 99% Winter Design
Temperature: 17 to 26 degrees P
Loral 99% Winter Design
Temperature: -10 to 4 degrees P
Local 994. Winter Design
Temperature: -11 degrees F or lower•
Not recommended for any vent
configuration
ASHRAE Fundamentals Ws HWMb Tale (United in and
2 (Canada), or use ate 99AX heating db temperatures found M the 1997 or
2001 AS RA Fu Handbook, m Climatic Design information chap-
An for combustion must not be contaminated by halogen com-
pounds which include chlorides, fluorides, bromides, and iodides.
These compounds are found in many common home products such
as detergent, paint, glue, aerosol spray, bleach, cleaning solvent,
salt, and air freshener, and can cause corrosion of furnaces and
vents. Avoid using such products in the combustion -air supply.
Furnace use during construction of the building could cause the
furnace to be exposed to halogen compounds, causing premature
failure of the furnace or venting system due to corrosion.
Vent dampers on any appliance connected to the common vent can
cause condensation and corrosion in the venting system. Do not
use vent dampers on appliances common vented with this furnace.
ADDMONAL VENTING REQUIREMENTS
A 4" round vent elbow is supplied with the furnace. A S -inch or 6-
inch vent connector may be required for some model furnaces. A
field - supplied 4 -inch to 5 -inch or 4 -inch to 6 -inch sheet metal
increaser fitting is required when 5 -inch or 6-inch vent connector
is used. See Fig. 3547, Venting Orientation for approved vent
configurations.
29
NOTE: Vent connector length for connector sizing starts at
furnace vent elbow. The 4 -inch vent elbow is shipped for upflow
configuration and may be rotated for other positions. Remove the
3 screws that secure vent elbow to furnace, rotate furnace vent
elbow to position desired, re- install screws. The factory- supplied
vent elbow does NOT count as part of the number of vent
connector elbows.
The vent connector can exit the door through one of 5 locations on
the door.
1. Attach the single wall vent connector to the furnace vent
elbow, and fasten the vent connector to the vent elbow with at
least two field - supplied, corrosion- resistant, sheet metal
screws located 180° apart.
NOTE: An accessory flue extension KGAFE0112UPH is avail-
able to extend from the furnace elbow to outside the furnace
casing. If flue extension is used fasten the flue extension to the
vent elbow with at least two field - supplied. corrosion- resistant,
sheet metal screws located 180° apart. Fasten the vent connector to
the flue extension with at least two field - supplied, corrosion -
resistant sheet metal screws located 180° apart.
2. Vent the furnace with the appropriate connector as shown in
Fig 35.47.
A CAUTION
CUT HAZARD
Failure to follow this caution may result in personal injury.
Sheet metal parts may have sharp edges or buns. Use care and
wear appropriate protective clothing, safety glasses and
gloves when handling parts, and servicing furnaces.
3. Orient the door to determine the correct location of the door
knockout to be removed.
4. Use aviation -type tin snips to remove the correct U- shaped
knockout in door.
— NOTE: A number of techniques can be used to remove these
knockouts as seen in Fig. 48 through 52. The knockout in the
bottom of the door is unique due to its flanging and is not easily
removed by first cutting the two tie points at the edge of the door,
using aviation -type tin snips. (See Fig. 48.) A sharp blow to the
rounded end of the knockout (See Fig. 49.) will separate more tie
points and allow the knockout to be pulled loose. (See Fig. 50.)
Remove any burrs and sharp edges.
For the rectangular J -box knockout, use tin snips along the door
edge and use a sharp blow with a hammer to remove the knockout.
Remove any burrs and sharp edges.
For the knockouts in the other locations on the door (top and
sides), tin snips can also be used along the door edges; however,
the preferred method is to use a hammer and screwdriver to strike
a sharp blow (See Fig. 51.) directly to the knockout tie points or
use a hammer in the upper left comer of the desired knockout. (See
Fig. 52.) Remove any buns and sharp edges.
— NOTE: If a knockout does not come out after two sharp blows,
pull and snip as needed to remove the knockout. Additional blows
may cause damage to the door.
SEE NOTES: 1,2,3,4,7,8,9
on the pages following
these figures
SEE NOTES: 1,2,4,7,8,9
on the page following
these figures
4103208
FIg. 35— Upflow Application -Vent Elbow Up
A03209
FIg. 36 —Upflow Application -Vent Elbow Right
SEE NOTES:1 ,2,3,4,5,7,8 9
on the pegs bgowtg
twee figures
FIg. 37— Downflow Application -
Vent Elbow Up then Left
30
SEE NOTES 1,44,5,7,5,9
on the page following
these figures
A03211
FIg. 38— Downflow Application -Vent Elbow Up
SEE NOTES: 12.4,5,8.7.8.9.10
on the page following these figures
Fig. 39— Downflow Application -
Vent Elbow Left then Up_
A03207
SEE NOTES:1,2,3,4,5,7,8,9
on the page following
these Nunn.
A03210 A03212
FIg. 40— Downflow Application-
Vent Elbow Up then Right
SEE NOTES: ,2.4.7,8,9 on the page
teasing these fgurea
A03213
Fig. 41— Horizontal Left Application -Vent Elbow Left
SEE NOTES: 12,4,5,7,8,9 on the page
following these figures
Fig. 42— Horizontal Left Application-
Vent Elbow Right then Up
SEE
ollowing these figures • B on M page
Fig. 45— Horizontal Right Appllcatlon-
Vent Elbow Right
A03214
A03218
SEE NOTES: 12,4,5,7 8,9
31
SEE NOTES 2,4,5,7,8,9 on the page
following these figures
Fig. 43— Horizontal Left Application -Vent Elbowp
SEE NOTES: 2,4,5,7.8.9 on the page
following these figures
Fig. 47— Horizontal Right Appllcatlon -Vent Elbow Left
0
Fig. 44— Horizontal Left Application -Vent Elbow Right
SEE NOTES: 1,2.4.5.7.8.9 on the page
blowing mess figures
Fig. 46— Horizontal Right Application-
Vent Elbow Lett then Up
A03216
A03219
A02068
FURNACE ORIENTATION
VENT ORIENTATION
FURNACE INPUT ( STUA)
VENT DIAME R (IN.p
MINIMUM VERTICAL VENT HEIGHT (FT)"
Downflow
Vent elbow left, Men up
Flg. 97
154,000
132,000
110,000(095/ -12 only)
5
12
Horizontal Left
Vent elbow right,
Men up
Flg. 40
154,000
132,000
5
7
Horizontal Lek
Vent Elbow up
Flg. 41
154,000
132,000
5
7
Horizontal Lek
Vem right
FM. 42
154,000
5
7
Downkow
Vent elbow up Men left
Flg. 95
110,000
(035/ -12 only)
5
10
Downflow
Vent elbow up, then tgM
Fig. 38
110,000
(03& -12 only)
5
10
Caution!! For the following applications, use the minimum vertical heights as specified below
For all other applications, follow exclusively the National Fuel Gas Code
NOTE M vent configurations must also meet National Fuel Gas Code venting requirements NFGC.
'4 In. Inside casing or vent guard
**Including 4 N. vent sectlon(s
Venting Notes for Fig. 35-47
1. For common vent, vent connector sizing and vent material:
United States - -use the NFGC
Canada - -use the NSCNGPIC
2. Immediately increase to 5 -inch or 6 -inch vent connector outside furnace casing when 5 -inch vent connector is required, refer to Note 1 above.
3. Side outlet vent for upflow and downflow installations must use Type B vent immediately after exiting the furnace, except when
KGAVG0101DFG, Downflow Vent Guard Kit, is used in the downflow position.
4. Type -B vent where required, refer to Note 1 above.
5. Four -inch single -wall (26 ga. min.) vent must be used inside furnace casing and when the KGAVG0101DFG Downflow Vent Guard Kit is
used external to the furnace.
6. Accessory Downflow Vent Guard Kit, KGAVG0101DFG required in downflow installations with lower vent configuration.
7. Chimney Adapter Kit may be required for exterior masonry chimney applications. Refer to Chimney Adapter Kit, KGACA02014FC or
KGACA020I5FC, for sizing and complete application de tails.
8. Secure vent connector to furnace elbow with (2) corrosion - resistant sheet metal screws, spaced approximately 180° apart.
9. Secure all other single wall vent connector joints with (3) corrosion resistant screws spaced approximately 120° apart. Secure Type -B vent
connectors per vent connector manufacturer's recommendations.
10. The total height of the vent and connector shall be at least seven feet for the 154,000 Btuh gas input rote model when installed in a downflow
application with furnace elbow turned to left side with the connector elbow outside furnace casing pointing upward. (See Fig. 39.)
Fig. 48 —Using Tin Sn ps to Cut Tie Points
32
A04127
Fig. 49— Rounded End of Knockout
Fig. 50— Knockout Pulled Loose
Fig. 51— Hammer and Screwdriver Used for
Knockout
A04128
A04129
A04130
33
Fig. 52— Remove Knockout with Hammer
A04131
A CAUTION
BURN HAZARD
Failure to follow this caution may result in personal injury.
Hot vent pipe is within reach of small children when installed
in downflow position. Vent pipe is HOT and will cause
personal injury.
See the following instruction.
An accessory Vent Guard Kit, KGAVG0101DFG is REQUIRED
for downflow applications for use where the vent exits through the
lower portion of the furnace casing door. Refer to the Vent Guard
Kit Instructions for complete details.
The horizontal portion of the venting system shall slope upwards
not less than I /4 -in. per linear It (21 mm/m) from the furnace to the
vent and shall be rigidly supported every 5 ft or less with metal
hangers or straps to ensure there is no movement after installation.
SIDEWALL VENTING
This furnace is not approved for direct sidewall horizontal venting.
In the US.: Per section 10.3.4 of the NFGC, any listed mechanical
venter may be used, when approved by the authority having
jurisdiction.
In Canada: Per section 7.24.2 of the NSCNGPIC, any listed
mechanical venter may be used when approved by the authority
having jurisdiction.
Select the listed mechanical venter to match the Btuh input of the
furnace being vented. Follow all manufacturer's installation re-
quirements for venting and termination included with the listed
mechanical venter.
START -UP, ADJUSTMENT, AND SAFETY CHECK
Step 1— General
A WARNING
FIRE HAZARD
Failure to follow this warning could result in property
damage. personal injury or death.
This furnace is equipped with manual reset limit switches in
the gas control area. The switches open and shut off power to
the gas valve, if a flame rollout or overheating condition
occurs in the gas control area. DO NOT bypass the switches.
Correct problem before resetting the switches.
1. Maintain 115 -v wiring and ground. Improper polarity will
result in rapid flashing LED and no furnace operation.
2. Make thermostat wire connections at the 24-v terminal block
on the furnace control. Failure to make proper connections
will result in improper operation. (See Fig. 24.)
3. Gas supply pressure to the furnace must be greater than 4.5 -in.
wc (0.16 psig ) but not exceed 14-in. wc (0.5 psig).
SETUP
SWITCH NO.
SWITCH
NAME
NORMAL
POSITION
DESCRIPTION
OF USE
SWt -1
Status Cosa Recovery
OFF
Tum ON lo retrieve up to 7 stored status codes for troubleshooting
assistance when R thermostat bad is disconnected.
SW7 -2
Adaptive Heat Mode
OFF
Allows 2 -stage operation wflh a single stage thermostat
Tum ON when using 2 stage thermostat to Slow Low Heat opera-
tion when R to WIWI doses and High Heat operation when R to
WNV1 and W2 close.
SW1-3
Low
Rise Ad stt
OFF
Tum ON to Maease Low Heat allow by 18 percent. This compel~
sates for deceased return Mr temperature caused with bypass hu-
nddHisr.
SWt•4
CombmEtliclency Adjustment
ON
Tum ON b decrease Low Heat *flow by 18 percent and High Heat
airflow 10 percent for maximum comfort
SW1-5
CFM per ton adjust
OFF
Turn ON for 400 CFM per ton. Tum OFF for 350 CFM per ton.
SW1-6
Component Self-Test
OFF
Turn ON to initiate Component Self-Test for troubleshooting asals-
Lance when R thermostat lead is disconnected.
Tum OFF when Sett -Ted Is completed.
SW1 -7
blower OFF delay
ON or OFF
Control btower Off Delay time. Used In conjunction with SW 141. See
Table 10.
SW1-8
Sower OFF delay
ON a OFF
Control bower Off Delay 1Me. Used In conjunction with SW 1.7. See
Table 10.
A CAUTION
CUT HAZARD
Failure to follow this caution may result in personal injury.
Sheet metal parts may have sharp edges or burrs. Use care and
wear appropriate protective clothing, safety glasses and
gloves when handling parrs, and servicing furnaces.
4. Check all manual -reset switches for continuity.
5. Replace blower compartment door. Door must be in place to
operate furnace.
6. Setup switch descriptions
The variable speed furnace control has DIP switches to select
thermostat staging, blower off delay timings, air flow selection
and other operational or service related functions. (See Fig.
25, 57 and Table 8.)
Step 2—Start-Up Procedures
A WARNING
FIRE AND EXPLOSION HAZARD
Failure to follow this warning could cause property damage,
personal injury, or death.
Never purge a line into a combustion chamber. Never use
matches, candles, flame, or other sources of ignition for the
purpose of checking leakage. Use a soap- and -water solution
to check for leakage.
I. Purge gas lines after all connections have been made.
2. Check gas lines for leaks.
A WARNING
ELECTRICAL SHOCK HAZARD
Failure to follow this warning could result in personal injury,
or death.
Blower access door switch opens 115 -v power to control. No
component operation can occur unless switch is closed.
Caution must be taken when manually closing this switch for
service purposes.
3. To Begin Component Self -Test:
Remove Blower Access Door. Disconnect the thermostat R
lead from furnace control board. Manually close blower door
Table 8— Furnace Setup Switch Description
34
switch. Turn Setup DIP switch SW1-6 ON. (See Fig. 25, 57
and Table 8.)
NOTE: The furnace control allows all components, except the gas
valve, to be run for short period of time. This feature helps
diagnose a system problem in case of a component failure.
Component test feature will not operate if any thermostat signal is
present at the control.
Refer to service label attached to furnace or See Fig. 56.
Component test sequence is as follows:
a. Inducer motor starts on high -speed and continues to run
until Step d. of component test sequence.
b. Hot surface igniter is energized for 15 sec., then off.
c. Blower motor operates for 15 sec.
d. Inducer motor goes to low -speed for 10 sec., then stops.
e. After component test is completed, one or more status
codes (11, 25, or 41) will flash. See component test section
of service label (Fig. 56) in furnace for explanation of
status codes.
NOTE: To repeat component test, turn setup switch SW1-6 OFF,
then back ON.
4. Tum setup DIP switch SW1-6 OFF. Reconnect R lead to
furnace control board, release blower door switch and reinstall
blower access door.
5. Operate furnace per instruction on inner door.
6. Verify furnace shut down by lowering thermostat setting
below room temperature.
7. Verify furnace restarts by raising thermostat setting above
room temperature.
Step 3— Adjustments
A WARNING
FIRE HAZARD
Failure to follow this warning could result in property
damage, personal injury, and death.
DO NOT bottom out gas valve regulator adjusting screw.
This can result in unregulated manifold pressure and result in
excess overtire and heat exchanger failures.
DESIRED HEATING MODE
SLOWER OFF DELAY (SEC.)
SETUP SWITCH (SW 7 AND 4) POSITION
SW1.7
Sw1.5 1
00
OFF
OFF
120
ON
OFF
150
OFF
ON
150
ON
ON
ALTITUDE
(FT)
PERCENT
OF DERATE
DERATE MULTIPUER
FACTOR'
0-2000
0
1.00
2001-3000
8-12
0.90
3001 -4000
12-18
0.86
4001 -6000
18-20
0.82
8001 -6000
20-24
0.78
9001 -7000
24-28
0.74
7001 -8000
28-32
0.70
8001-9000
32-38
0.88
9001 - 10,000
38-40
0.82
A CAUTION
FURNACE DAMAGE HAZARD
Failure to follow this caution may result in reduced furnace
life, property damage.
DO NOT redrill orifices. Improper drilling (burrs, out-of-
round holes, etc.) can cause excessive burner noise and
misdirection of burner flames. This can result in flame
impingement of heat exchangers, causing failures. (See Fig.
54.)
Furnace gas input rate on rating plate is for installations at altitude
up to 2000 ft. Furnace input rate must be within d:2 percent of
furnace rating plate input. For altitudes above 5500 ft., a field
supplied high altitude pressure switch is required.
1. Determine the correct gas input rate.
In the US.A.:
The input rating for altitudes above 2,000 ft. must be reduced
by 4 percent for each 1,000 ft above sea level.
For installations below 2000 ft.. refer to the unit rating plate.
For installations above 2000 ft., multiply the input on the
rating plate by the de -rate multiplier in Table 9 for the correct
input rate.
In Canada:
The input rating for altitudes from 2,000 to 4,500 ft above sea
level must be derated 10 percent by an authorized Gas
Conversion Station or Dealer.
To determine correct input rate for altitude, see example and
use 0.90 as dente multiplier factor.
EXAMPLE:
88,000 BTU/1 DMPUT FURNACE INSTALLED AT 4300 FT.
Derate Furnace Input Rate
Furnace Input Rate X Multiplier - at Installation
at Sea Level Factor Altitude
88,000 X 0.90 = 79,200
2. Determine the correct orifice and manifold pressure adjust-
ment. All models in all positions except Low NOx models in
downflow and horizontal positions use Table 12 (22,000 Btuh
per burner.) Low NOx models in downflow or horizontal
positions must use Table 13 (21,000 Btub per burner.)
See input listed on rating plate.
a. Obtain average yearly gas heat value (at installed altitude)
from local gas supplier.
b. Obtain average yearly gas specific gravity from local gas
supplier.
c. Find installation altitude in Table 12 or 13.
d. Find closest natural gas heat value and specific gravity in
Table 12 or 13.
Table 9-Altitude Derate Multiplier for U.S.A.
• Dente multiplier factors are based on midpoint altitude tar aamrde range.
35
Table 10- Blower Off Delay Setup Switch
e. Follow heat value and specific gravity lines to point of
intersection to find orifice size and low -and high -heat
manifold pressure settings for proper operation.
f. Check and verify burner orifice size in furnace. NEVER
ASSUME ORIFICE SIZE. ALWAYS CHECK AND
VERIFY.
g. Replace orifice with correct size, if required by Table 12 or
13. Use only factory- supplied orifices. See EXAMPLE 2.
EXAMPLE 2: (0 -2000 ft altitude)
For 22.000 Btuh per burner application use Table l2.
Heating value = 1000 Btu/cu ft
Specific gravity = 0.62
Therefore: Orifice No. 43•
Manifold pressure: 3.7 -in. wc for high -heat
1.6 -in. wc for low -heat
* Furnace is shipped with No. 43 orifices. In this example
all main burner orifices are the correct size and do not need
to be changed to obtain proper input rate.
3. Adjust manifold pressure to obtain low fire input rate. (See
Fig. 53.)
a. Turn gas valve ON/OFF switch to OFF.
b. Remove manifold pressure tap plug from gas valve.
c. Connect a water column manometer or similar device to
manifold pressure rap.
d. Turn gas valve ON/OFF switch to ON.
e. Move setup SW 1 -2 on furnace control to ON position to
lock furnace in low -heat operation. (See Table 8 and Fig.
25.)
f. Manually close blower door switch.
g. Jumper R and W/W1 thermostat connections on control to
start furnace. (See Fig. 25.)
-4 h. Remove regulator adjustment cap from low heat gas valve
pressure regulator (See Fig. 53.) and turn low -heat adjust-
ing screw (3/16 or smaller flat -tipped screwdriver) coun-
terclockwise (out) to decrease input rate or clockwise (in)
to increase input rate.
NOTE: 1)0 NOT set low -heat manifold pressure less than 1.4-in
wc or more than 1.7 -in. we for natural gas. If manifold pressure is
outside this range, change main burner orifices.
i. Install low -heat regulator adjustment cap.
j. Leave manometer or similar device connected and proceed
to Step 4.
NOTE: If orifice hole appears damaged or it is suspected to have
been rcdrilled, check orifice bole 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.
4. Verify natural gas low -heat input rate by clocking meter.
NOTE: Gas valve regulator adjustment caps must be in place for
proper input to be clocked.
OWIFF SWITCH
1W "NPT INLET
INLET
PRESSURE TAP
T ?NPT OUTLET
Flg. 54— Orifice Hole
REGULATOR COVER SCREW
PLASTIC ADJUST SCREW
REGULATOR SPRING
HIGH STAGE OAS
PRESSURE REGULATOR
ADJUSTMENT
MANIFOLD
PRESSURE TAP
-' Fig. 53— Redundant Automatic Gas Control Valve
BURNER
ORIFICE
LOW STAGE
LAS PRESSURE
REGULATOR ADJUSTMENT
A04167
Aq 'RRq
a. Turn off all other gas appliances and pilots served by the
meter.
b. Run furnace for 3 minutes in low -heat operation.
c. Measure time (in sec) for gas meter to complete 1 revolu-
tion and note reading. The 2 or 5 cubic feet dial provides a
mom accurate measurement of gas flow.
d. Refer to Table 11 for cubic ft of gas per hr.
e. Multiply gas rate cu ft/hr by heating value (Btu/cu ft) to
obtain input.
If clocked rate does not match required input from Step I,
increase manifold pressure to increase input or decrease
manifold pressure to decrease input. Repeat steps b through
e until correct low -heat input is achieved. Re- install low -
heat regulator seal cap on gas valve.
5. Set low heat temperature rise.
The furnace must operate within the temperature rise ranges
specified on the furnace rating plate. Do not exceed tempera-
ture rise ranges specified on furnace rating plate for high -and
low-fire. Determine the temperature rise as follows:
NOTE: Blower access door must be installed when taking tem-
perature rise reading. Leaving blower access door off will result in
incorrect temperature measurements.
a. Verify unit is running in low -heat per Step 4. Place
thermometers in return and supply ducts as close to furnace
as possible. Be sure thermometers do not see radiant heat
36
from heat exchangers. Radiant heat affects temperature rise
readings. This practice is particularly important with
straight -tun ducts.
b. When thermometer readings stabilize, subtract return -air
temperature from supply -air temperature to determine air
temperature rise.
A WARNING
ELECTRICAL SHOCK HAZARD
Failure to follow this warning could result in personal injury
or death.
Disconnect 115 -v electrical power before changing speed tap.
A CAUTION
FURNACE DAMAGE HAZARD
Failure to properly set air temperature rise may cause exces-
sive furnace temperatures and shorten furnace life.
Recheck temperature rise. It must be within limits specified
on the rating plate. Operation is within a few degrees of the
mid -point of rise range when setup switch SW 1-4 is OFF.
When setup switch SW 1-4 is ON, operation will be near the high
end of the rise range for improved comfort.
This furnace is capable of automatically providing proper airflow
to maintain the temperature rise within the range specified on unit
rating plate.
NOTE: If the temperature rise is outside this range, fast check:
1.) Gas input for low heat operation.
2.) Derate for altitude if applicable.
3.) Return and supply ducts for excessive restrictions
causing static pressures greater than 0.50-in. wc.
4.) Ensure low -heat rise adjust switch SW1 -3 is in ON
position when bypass humidifier is used. Refer to Table
8 and Fig. 25 and 57.
5.) Make sure proper model plug is installed.
6. Adjust Manifold Pressure to Obtain High Heat Rate
a. Remove high heat regulator adjustment cap from gas valve
pressure regulator.
b. Jumper R, W/W1 and W2 thermostat connections on
control to tun furnace in high heat (See Fig. 25 and 57.)
c. Turn high -heat adjusting screw (3/16 or smaller flat - tipped
screwdriver)) counterclockwise (out) to decrease input rate
or clockwise (in) to increase rate.
d. Re- install high -heat adjustment caps.
NOTE: DO NOT set high -heat manifold pressure less than 3.2 -in.
wc or more than 3.8 -in. wc for natural gas. If manifold pressure is
outside this range, change main burner orifices.
7. Verify natural gas high heat input rate by clocking meter.
NOTE: Gas valve regulator adjustment caps must be in place for
proper input to be clocked.
a. Turn off all other gas appliances and pilots served by the
meter.
b. Run for 3 minutes in high -heat operation.
c. Measure time (in sec) for gas meter to complete 1 revolu-
tion and note reading.
d. Refer to Table 11 for cubic ft of gas per hr.
e. Multiply gas rate cu ft/hr by beating value (Btu/cu ft) to
obtain input.
NOTE: Using the 2 cu. ft. or 5 cu. ft. gas meter dial provides
greater accuracy in verifying gas input rate.
SECONDS
FOR1
REVOLUTION
SIZE OF TEST DIAL
SECONDS
FOR1
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
348
13
277
555
1385
53
68
136
340
14
257
514
1286
54
67
193
333
15
240
480
1200
55
65
131
327
16
225
450
1125
56
64
129
321
17
212
424
1059
57
63
126
318
18
200
400
1000
58
62
124
310
19
189
379
947
59
61
122
305
20
180
380
900
60
60
120
300
21
171
343
857
62
58
116
290
22
184
327
818
84
56
112
281
23
157
913
783
66
54
109
273
24
150
300
750
68
63
108
265
25
144
288
720
70
51
103
257
26
138
277
892
72
60
100
250
27
133
287
667
74
48
97
243
28
129
257
643
76
47
95
237
29
124
248
621
78
46
92
231
30
120
240
800
60
45
90
225
31
116
232
581
62
44
88
220
32
113
225
563
84
43
88
214
33
109
218
545
66
42
84
209
34
106
212
529
86
41
82
205
35
103
206
514
90
40
80
200
36
100
200
500
92
39
78
196
37
97
195
486
94
38
78
192
39
95
189
474
96
38
75
188
39
92
185
462
98
37
74
184
40
90
180
450
100
36
72
180
41
68
178
439
102
35
71
178
42
88
172
429
104
35
ea
173
43
84
187
419
108
34
68
170
44
82
164
409
108
33
67
187
45
80
180
400
110
33
65
184
46
78
157
391
112
32
64
161
47
76
153
383
118
31
62
155
49
75
150
375
120
30
80
150
49
73
147
387
Table 11—GAS RATE (CU FT/HR)
If clocked rate does not match required input from Step 1, increase
manifold pressure to increase input or decrease manifold pressure
to decrease input. Repeat steps b through a until correct high heat
input is achieved. Re -instal high -heat regulator seal cap on gas
valve.
8. Set high heat temperature rise.
Jumper R to W/W l and W2 to check high- gas -heat tempera-
ture rise. Do not exceed temperature rise ranges specified on
furnace rating plate for high heat. The furnace must operate
within the temperature rise ranges specified on the furnace
rating plate.
Determine the air temperature rise as follows:
NOTE: Blower access door must be installed when taking tem-
perature rise reading. Leaving blower access door off will result in
incorrect temperature measurements.
a. Verify the unit is operating in high heat per Step 6. Place
thermometers in return and supply ducts as close to furnace
as possible. Be sure thermometers do not see radiant heat
37
from heat exchangers. Radiant heat affects temperature rise
readings. This practice is particularly important with
straight-run ducts.
b. When thermometer readings stabilize, subtract rctum -ace
temperature from supply-air temperature to determine air
temperature rise.
A CAUTION
FURNACE DAMAGE HAZARD
Failure to properly set temperature rise may cause excessive
furnace temperatures and shorten furnace life.
Recheck temperature rise. It must be within limits specified
on the rating plate. Operation is within a few degrees of the
mid -point of rise range when setup switch SW 14 is OFF.
When setup switch SW I-4 is ON, operation will be near the high
end of the rise range for improved comfort.
This furnace is capable of automatically providing proper airflow
to maintain the temperature rise within the range specified on unit
rating plate.
NOTE: If the temperature rise is outside this range. first check:
1.) Gas input for low -and high -heat operation.
2.) Derate for altitude if applicable.
3.) Return and supply ducts for excessive restrictions
causing static pressures greater than 0.50 -in. wc.
4.) Make sure proper model plug is installed.
c. Remove thermostat jumpers and release blower access door
switch.
d. Repeat Steps a through c as required to adjust for proper
rise.
e. When correct high heat input rate and temperature rise is
achieved, turn gas valve ON/OFF switch to OFF.
f. Release blower access door switch.
g. Remove manometer or similar device from gas valve.
h. Re-install manifold pressure tap plug in gas valve. (See
Fig. 53.)
A WARNING
FIRE HAZARD
Failure to reinstall manifold pressure tap plug in gas valve
could result in personal injury, property damage or death.
Reinstall manifold pressure tap plug in gas valve to prevent
gas leak.
i. Remove thermostat juniper wire from furnace control
board.
j. Turn gas valve ON/OFF switch to ON.
k. Proceed to Step 9, 'Set Blower Off Delay" before installing
blower access door.
A CAUTION
Failure to properly set air temperature rise may cause exces-
sive furnace temperatures and shorten furnace life.
Recheck temperature rise. It must be within limits specified
on the rating plate. Recommended operation is at the mid-
point of rise range or slightly above.
9. Set Blower Off Delay
a. Remove blower access door if installed.
b. Turn Dip switch SW-7 or SW -8 ON or OFF for desired
blower off delay. (See Table 10 and Fig. 25 and 57.)
ALTITUDE
RANGE
(FT)
AVG GAS
NEAT VALUE
(BTU/CU FT)
SPECIFIC GRAVITY OF NATURAL GAS
0.58
0.60
1162
0.64
Orifice
no.
Manifold
Pressure
Orifice
no.
Manifold
Pressure
Orifice
no.
Manifold
Pressure
Orifice
no.
Manifold
Pressure
U.S.A. and Canada
0
to
2000
900
42
3.5/1.5
42
3.6/1.6
42
3.7/1.6
41
3.5/1.5
925
42
3.3/1.4
42
3.4/1.5
42
3.5/1.5
42
3.7/1.6
950
43
3.8/1.7
42
3.3/1.4
42
3.4/1.5
42
3.5/1.5
975
43
3.6/1.6
43
3.8/1.6
42
3.2/1.4
42
3.3/1.4
1000
43
3.5/1.5
43
3.6/1.6
43
3.7/1.6
43
3.8/1.7
1025
43
3.3/1.4
43
3.4/1.5
43
3.5/1.5
43
3.6/1.6
1050
44
3.6/1.6
43
3.2/1.4
43
3.4/1.5
43
3.5/1.5
1075
44
3.4/1.5
44
3.5/1.6
43
3.2/1.4
43
3.3/1.4
1100
44
3.3/1.4
44
3.4/1.5
44
3.5/1.5
43
3.2/1.4
ALTITUDE
RANGE
(FT)
AVG GAS
HEAT VALUE
(BTU/CU FT)
SPECIFIC GRAVITY OF NATURAL GAS
0.58
0.60
0.62
0.64
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
2001
to
4500
800
42
3.4/1.5
42
3.5/1.5
42
3.6/1.6
42
3.7/1.6
825
42
3.2/1.4
42
3.3/1.4
42
3.4/1.5
42
3.5/1.5
850
43
3.7/1.6
43
3.8/1.6
42
3.2/1.4
42
3.3/1.4
875
43
3.5/1.5
43
3.6/1.6
43
3.7/1.6
43
3.8/1.7
900
43
3.3/1.4
43
3.4/1.5
43
3.5/1.5
43
3.6/1.6
925
44
3.5/1.5
43
3.2/1.4
43
3.3/1.4
43
3.4/1.5
950
44
3.4/1.5
44
3.5/1.5
44
3.6/1.6
43
32/1.4
975
44
3.2/1.4
44
3.3/1.4
44
3.4/1.5
44
3.5/1.5
1000
45
3.7/1.6
45
3.8/1.7
44
3.2/1.4
44
3.4/1.5
.TnVDE
UWGE
(FT)
AVG GAS
HEAT VALUE
(BTU/CU FT}
SPEC Ft GRAVITY OF NATURAL GAS
0.58
0.60
0.62
0.64
Orifice
rto.
Manifold
Pressure
Orifice
no.
Manifold
Pressure
Orifice
no.
Manifold
Pressure
Orifice
no.
Manifold
Pressure
Nao rrn
E 8
775
42
3.2/1.4
42
3.3/1.4
42
3.4/1.5
42
3.5/1.5
800
43
3.6/1.6
43
3.8/1.6
42
3.2/1.4
42
3.3/1.4
825
43
3.4/1.5
43
3.5/1.5
43
3.7/1.6
43
3.8/1.6
850
43
3.2/1.4
43
3.3/1.4
43
3.4/1.5
43
3.6/1.5
875
44
3.5/1.5
44
3.6/1.6
43
3.3/1.4
43
3.4/1.5
900
44
3.3/1.4
44
3.4/1.5
44
3.5/1.5
43
3.2/1.4
925
45
3.8/1.6
44
12/1.4
44
3.3/1.5
44
3.4/1.5
950
46
3.8/1.6
45
3.7/1.6
45
3.8/1.7
44
3.3/1.4
.TffUDE
FLANGE
(FT)
AVG GAS
HEAT VALUE
(BTU/CU FT)
SPECIFIC GRAVITY OF NATURAL GAS
158
0.60
0.62
0.64
Orifice
no.
Manifold
Pressure
Orifice
no.
Manifold
Pressure
Orifice
rto.
Manifold
Pressure
Orifice
no.
Manifold
Pressure
/quo nn
750
43
3.6/1.6
43
3.8/1.6
42
3.2/1.4
42
3.3/1.4
775
43
3.4/1.5
43
3.5/1.5
43
3.6/1.6
43
3.8/1.6
800
43
3.2/1.4
43
3.3/1.4
43
3.4/1.5
43
3.5/1.5
825
44
3.4/1.5
44
3.6/1.5
43
3.2/1.4
43
3.3/1.4
850
44
3.2/1.4
44
3.4/1.5
44
3.5/1.5
44
3.6/1.5
875
45
3.7/1.6
45
3.8/1.7
44
3.3/1.4
44
3.4/1.5
900
46
3.7/1.6
46
3.8/1.7
45
3.7/1.6
44
3.2/1.4
925
46
3.5/1.5
46
3.6/1.6
46
3.7/1.6
46 -
3.8/1.7
TABLE 12 —OrifIce Size and Manifold Pressure for Gas Input Rate
(Tabulated Data Based On 22,000 Btuh High- Heat/14,500 Btuh for Low -Heat Per Burner,
Oersted 4 Percent For Each 1000 Ft Above Sea Level)
• Orifice numbers 43 are factory installed
38
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
Orifice
No.
Manifold
Pressure
Orifice
No.
Manifold
Pressure
Orifice
No.
Manifold
Pressure
Orifice
No.
Manifold
Pressure
kuo Tsn
y 8
725
43
3.4/1.5
43
3.5/1.5
43
3.6/1.6
43
3.7/1.6
750
43
3.2/1.4
43
3.3/1.4
43
3.4/1.5
43
3.5/1.5
775
44
3.4/1.5
44
3.5/1.5
43
3.2/1.4
43
3.3/1.4
800
44
3.2/1.4
44
3.3/1.4
44
3.4/1.5
44
3.5/1.5
825
46
3.8/1.7
45
3.8/1.6
44
3.2/1A
44
3.3/1.4
850
48
3.6/1.6
46
3.7/1.6
46
3.8/1.7
45
3.8/1.6
875
47
3.8/1.7
46
3.5/1.5
46
3.6/1.6
46
3.7/1.6
900
47
3.6/1.8
47
3.8/1.6
46
3.4/1.5
46
3.5/1.5
ALTITUDE
RANGE
(Fn
AVG GAS
HEAT VALUE
AT ALTITUDE
(BTU/CU FT)
SPECIFIC GRAVITY OF NATURAL GAS
0.56
0.60
0.62
0 .64
Orifice
No.
Manifold
Pressure
Orifice
No.
Manifold
Pressure
Orifice
No.
Manifold
Pressure
Odtice
No.
Manifold
Pressure
/quo nn
$ 9
675
43
3.4/1.5
43
3.5/1.5
43
3.8/1.6
43
3.7/1.6
700
44
3.6/1.6
43
3.3/1.4
43
3.4/1.5
43
3.5/1.5
725
44
3.4/1.5
44
3.5/1.5
44
3.6/1.6
43
3.2/1.4
750
45
3.8/1.7
44
3.3/1.4
44
3.4/1.5
44
3.5/1.5
775
46
3.7/1.6
45
3.7/1.6
45
3.8/1.7
44
3.2/1.4
800
48
3.5/1.5
46
3.6/1.6
46
3.8/1.6
45
3.7/1.6
825
47
3.7/1.6
48
3.4/1.5
48
3.5/1.5
46
3.6/1.6
850
47
3.5/1.5
47
3.6/1.6
47
3.8/1.6
46
3.4/1.5
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
Orifice
No.
Malnifold
Pressure
Orifice
No.
Manifold
Pressure
Ortflce
No.
Manifold
Pressure
Orifice
No.
Manifold
Pressure
Rwo vsn
s9
650
44
3.6/1.6
43
3.2/1.4
43
3.4/1.5
43
3.5/1.5
675
44
3.3/1.5
44
3.5/1.5
44
3.6/1.6
43
3.2/1.4
700
45
3.8/1.6
44
3.2/1.4
44
3.3/1.4
44
3.4/1.5
725
46
3.7/1.6
48
3.8/1.7
45
3.7/1.6
44
3.2/1.4
750
46
3.4/1.5
46
3.6/1.5
46
3.7/1.6
46
3.8/1.6
775
47
3.6/1.6
47
3.8/1.6
46
3.4/1.5
46
3.6/1.5
800
47
3.4/1.5
47
3.5/1.5
47
3.7/1.6
47
3.8/1.6
825
48
3.7/1.6
48
31/1.6
47
3.4/1.5
47
3.6/1.5
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
Orifice
No.
Manifold
Pressure
Orifice
No.
Manifold
Pressure
Orifice
No.
Manifold
Pressure
Orifice
No.
Manifold
Pressure
Nuo nn
$y
625
44
3.3/1.5
44
3.5/1.5
44
3.6/1.6
43
3.2/1.4
650
45
3.7/1.6
44
3.2/1.4
44
3.3/1.4
44
3.4/1.5
675
46
3.6/1.6
46
3.8/1.6
45
3.7/1.6
45
3.8/1.7
700
47
3.8/1.7
46
3.5/1.5
46
3.6/1.6
46
3.7/1.6
725
47
3.6/1.6
47
3.7/1.6
47
3.8/1.7
46
3.5/1.5
750
48
3.8/1.7
47
3.5/1.5
47
3.6/1.6
47
3.7/1.6
775
48
3.6/1.5
48
3.7/1.6
48
3.8/1.7
47
3.5/1.5
TABLE 12 —Orifice Size and Manifold Pressure for Gas Input Rate
(Tabulated Data Based On 22,000 Btuh High- Heat/14,500 Btuh for Low -Heat Per Burner,
Derated 4 Percent For Each 1000 Ft Above Sea LeveixContinued)
• Orifice numbers 43 are factory Installed
39
ALTITUDE
RANGE
(�
AVG GAS
HEAT VALUE
AT ALTITUDE
(BTU/CU FT)
SPECIFIC GRAVITY OF NATURAL GAS
0.58
0.60
0.62
0.64
Orifice
No.
Manifold
Pressure
Orifice
No.
Manifold a
Pressure
Office
No.
Manifold
Pressure
Orifice
No.
Manifold
Pressure
Rrvo ro•s•n
9001
to
10,000
600
45
3.7/1.6
45
3.8/1.7
44
3.3/1.4
44
3.4/1.5
625
46
3.6/1.6
46
3.7/1.6
46
3.8/1.7
45
3.8/1.6
650
47
3.8/1.6
46
3.4/1.5
46
3.6/1.5
46
3.7/1.6
675
47
3.5/1.5
47
3.6/1.6
47
3.7/1.6
46
3.4/1.5
700
46
3.7/1.6
48
3.8/1.7
47
3.5/1.5
47
3.6/1.6
725
48
3.5/1.5
48
3.6/1.6
48
3.7/1.6
48
3.8/1.7
TABLE 12— Orifice Size and Manifold Pressure for Gas Input Rate
(Tabulated Data Based On 22,000 Btuh High-Heat/14,500 Btuh for Low -Heat Per Sumer,
Derated 4 Percent For Each 1000 Ft Above Sea Level)(Continued)
• Office numbers 43 are factory installed
10. Set thermostat heat anticipator.
a. Mechanical thermostat —Set thermostat heat anticipator to
match the amp draw of the electrical components in the
R -W/WI circuit. Accurate amp draw readings can be
obtained at the wires normally connected to thermostat
subbase terminals, R and W. The thermostat anticipator
should NOT be in the circuit while measuring current.
(1.) Set SW1 -2 switch on furnace control board to ON.
(2.) Remove thermostat from subbase or from wall.
(3.) Connect an amp meter as shown in Fig. 55 across the
R and W subbase terminals or R and W wires at wall.
(4.) Record amp draw across terminals when furnace is in
low heat and after blower starts.
(5.) Set heat anticipator on thermostat per thermostat
instructions and install on subbase or wall.
(6.) Turn SW t -2 switch OFF.
(7.) Install blower access door.
b. Electronic thermostat: Set cycle rate for 3 cycles per hr.
1I. Set Airflow for Air Conditioning - Single Stage and High
Stage Cooling
The ECM blower can be adjusted for a range of airflows for
Low Speed or High Speed cooling. See Table 5 -Air Delivery
- CFM (With Filter ). Depending on the model size, the
cooling airflow can be adjusted from I4 tons nominal cooling
40
to 3 Vs, to 4 or to 6 tons of nominal cooling based on 350 cfin
ton.
The cooling airflow is adjusted by turning Setup switches
SW2 -1, SW2 -2 and SW2 -3 either ON or OFF. Select the
required airflow from Fig. 61. Fig. 61 is based on 350 CFM
per ton. For airflow at 400 CFM per ton, tum Setup SW I -5
ON (See Table 8 and Hg. 25 and 57.)
NOTE: 6 ton airflow will truncate at 2200 cfm on applicable
models. For a complete explanation of cooling airflow, refer to the
section titled 'Sequence of Operation.'
12. Set Airflow For Continuous Fan/Low Speed Cooling Airflow
The ECM blower motor can be adjusted for continuous fan
speeds different than heating or cooling fan speed. See Table
5 - Air Delivery - CFM (With Filter). Select the required
continuous fan airflow from Fig. 61.
The continuous fan speed is also the fan speed for low speed
cooling when furnace is used with a 2 -speed cooling unit.
Adjust the Continuous Fan CFM to match the airflow required
for low speed cooling. Select the required airflow from Fig.
61. For airflow at 400 CFM per ton, turn Setup SW 1 -5 ON
(See Fig. 61.) The airflow selected for low speed cooling will
also be the airflow used for continuous fan.
The continuous fan speed can be further adjusted at the
thermostat using the 'Comfort Fan" select function. Changing
the continuous fan speed at the thermostat DOES NOT change
the low speed cooling airflow selected at the control board.
AL TITUDE
RANGE
(FT)
AVG GAS
HEAT VALUE
( BTU /CU FT)
SPECIFIC GRAVITY OF NATURAL GAS
0.58
0.60
0.62
0.64
Orifice
no.
Manifold
Pressure
Orifice
no.
Manifold
Pressure
Orifice
no.
Manifold
Pressure
Orifice
no.
Manifold
Pressure
ran* wa rosn
oat
900
42
3.2/1.5
42
3.3/1.6
42
3.4/1.6
42
3.5/1.7
925
43
3.7/1.8
43
3.8/1.8
42
3.2/1.5
42
3.3/1.6
950
43
3.5/1.7
43
3.6/1.7
43
3.7/1.8
43
3.8/1.8
975
43
3.3/1.6
43
3.4/1.6
43
3.5/1.7
43
3.7/1.7
1000
44
3.6/1.7
43
3.3/1.8
43
3.4/1.6
43
3.5/1.7
1025
44
3.4/1.6
44
3.6/1.7
43
3.21.5
43
3.3/1.6
1050
44
3.3/1.6
44
3.4/1.6
44
3.5/1.7
43
3.2/1.5
1075
45
3.8/1.8
'44
3.2/13
44
3.3/1.6
44
3.4/1.6
1100
48
3.8/1.8
45
3.7/1.8
44
3.2/1.5
44
3.3/1.6
ALTITUDE
RANGE
(FT)
AVG GAS
HEAT VALUE
( BTU/CU FT)
SPECIFIC GRAVITY OF NATURAL GAS
0.58
0.60
0.82
0.64
Orifice
no.
Manifold
Pressure
Orifice
no.
Manifold
Pressure
Orifice
no.
Manifold
Pressure
Orifice
no.
Manifold
Pressure
I spew* pa nn
800
43
3.8/1.8
42
3.2/1.5
42
3.3/1.6
42
3.4/1.6
825
43
35/1.7
43
3.7/1.7
43
3.8/1.8
42
3.2/1.5
850
43
3.3/1.6
43
3.5/1.6
43
3.6/1.7
43
3.7/1.8
875
43
3.2/1.5
43
3.3/1.6
43
3.4/1.6
43
3.5/1.7
�
;a 118
c3
900
44
3.4/1.6
44
3.5/1.7
43
3.2/1.5
43
3.3/1.6
925
44
3.2/1.5
44
3.3/1.6
44
3.5/1.6
44
3.6/1.7
950
45
3.7/1.8
45
3.8/1.8
44
3.3/1.6
44
3.4/1.8
975
48
3.7/1.8
46
3.8/1.8
45
3.8/1.8
44
3.2/1.5
1000
46
3.5/1.7
46
3.6/1.7
48
3.8/1.8
45
3.7/1.8
ALTITUDE
RANGE
(FT)
AVG OAS
HEAT VALUE
(BTU/CU FT)
SPECIFIC GRAVITY OF NATURAL GAS
0.58
0.80
0.62
0.64
Orifice
no.
Manifold
Pressure
Orifice
no.
Manifold
Pressure
Orifice
no.
Manifold
Pressure
Orifice
no.
Manifold
Pressure
1 Auo rosn
ial
775
43
3.5/1.7
43
3.7/1.7
43
3.8/1.8
42
3.21.5
800
43
3.3/1.6
43
3.4/1.6
43
3.5/1.7
43
3.7/1.7
825
44
3.8/1.7
43
3.2/1.5
43
3.3/1.6
43
3.4/1.6
850
44
3.4/1.6
44
3.5/1.7
44
3.6/1.7
43
3.2/1.5
875
45
3.8/1.8
44
3.3/1.6
44
3.4/1.6
44
3.5/1.7
900
48
3.8/1.8
45
3.8/1.8
44
3.2/1.5
44
3.3/1.8
925
48
3.6/1.7
48
3.7/1.8
45
3.7/1.8
45
3.8/1.8
950
46
3.4/1.6
48
3.5/1.7
48
37/1.7
46
3.8/1.8
ALTITUDE
RANGE
(FT)
AVG GAS
HEAT VALUE
(BTU/CU FT)
SPECIFIC GRAVITY OF NATURAL GAS
0.58
0.80
0.62
0.84
Orifice
no.
Mangy
Pressure
Orifice
no.
Manifold
Pressure
Orifice
no.
Manifold
Pressure
Orifice
no.
Manifold
Pressure
1 Nuo rosn1
ial
750
43
33/1.8
43
3.4/1.6
43
3.5/1.7
43
36/1.7
775
44
38/1.7
43
32/1.5
43
3.3/1.6
43
3.4/1.6
800
44
3.3/1.6
44
3.4/1.8
44
3.6/1.7
43
3.2/1.5
825
45
3.8/1.8
44
3.2/1.5
44
3.4/1.6
44
3.5/1.6
850
46
3.8/1.8
45
3.7/1.8
45
3.8/1.8
44
3.3/1.6
875
46
3.5/1.7
48
3.7/1.7
48
3.8/1.8
45
3.7/1.8
900
47
3.8/13
48
3.5/1.7
46
3.8/1.7
46
3.7/1.8
925
47
3.6/1.7
47
3.7/1.8
47
3.8/1.8
46
3.5/1.7
TABLE 13- Orifice Size and Manifold Pressure for Gas Input Rate (Tabulated Data Based On 21,000 Btuh
High- Heat/14,500 Btuh for Low -Heat Per Burner,
Derated 4 Percent For Each 1000 Ft Above Sea Level)
• Orifice numbers 43 are factory Installed
41
-TITUDE
(�
(rn
AVG GAS
HEAT VALUE
A T ALTITUDE
(BTU/CU FT)
SPECIFIC GRAVITY OF NATURAL GAS
0.58
0.60
0.62
0.64
Orifice
No.
Manifold
Pressure
Orifice
No.
Manifold
Pressure
Orifice
No.
Manifold
Pressure
Orifice
No.
Manifold
Pressure
Auo nn
g 21
725
44
3.5/1.7
43
3.2/1.5
43
3.3/1.6
43
3.4/1.6
750
44
3.3/1.6
44
3.4/1.6
44
3.5/1.7
43
3.2/1.5
775
45
3.7/1.8
44
3.2/1.5
44
3.3/1.6
44
3.4/1.6
800
46
3.7/1.8
46
3.8/1.8
45
3.8/1.8
44
3.2/1.5
825
46
3.5/1.7
46
3.6/1.7
46
3.7/1.8
48
3.8/1.8
850
47
3.7/1.8
47
3.8/1.8
46
3.5/1.7
46
3.6/1.7
875
47
3.5/1.7
47
3.6/1.7
47
3.7/1.8
46
3.4/1.6
900
48
3.8/1.8
47
3.4/1.6
47
3.5/1.7
47
3.7/1.7
ALTITUDE
RANGE
(F7)
AVG GAS
HEAT VALUE
AT ALTITUDE
(BTU/CU FT)
SPECIFIC GRAVITY OF NATURAL GAS
0.58
0.60
0.62
0.64
Orifice
No.
Manifold
Pressure
Orifice
No.
Manifold
Pressure
Orifice
No.
Manifold
Pressure
Orifice
No.
Manifold
Pressure
Auo twn
g 9
675
44
3.5/1.7
43
3.2/1.5
43
3.3/1.6
43
3.4/1.6
700
44
3.3/1.6
44
3.4/1.6
44
3.5/1.7
43
3.2/1.5
725
45
3.7/1.8
45
3.8/1.8
44
3.3/1.6
44
3.4/1.6
750
46
3.6/1.7
46
3.8/1.8
45
3.7/1.8
45
3.8/1.8
775
46
3.4/1.6
46
3.5/1.7
46
3.6/1.7
46
3.8/1.8
800
47
3.6/1.7
47
3.8/1.8
46
3.4/1.6
46
3.5/1.7
825
47
3.4/1.6
47
3.5/1.7
47
3.6/1.7
47
3.8/1.8
850
48
3.7/1.7
48
3.8/1.8
47
3.4/1.6
47
3.5/1.7
ALTITUDE
RANGE
(F1)
AVG GAS
HEAT VALUE
AT ALTITUDE
AT
(BTU/CU FT)
SPECIFIC GRAVITY OF NATURAL GAS
0.58
0.60
0.62
0.64
No.
Manifold
Pressure
Orifice
No.
Manifold
Pressure
Orifice
No.
Manifold
Pressure
Orifice
No.
Manifold
Pressure
h uo ro'a'n
8 8
650
44
3.3/1.6
44
3.4/1.6
44
3.5/1.7
43
92/1.5
675
45
3.7/1.8
45
3.8/1.8
44
3.3/1.6
44
3.4/1.6
700
46
3.6/1.7
46
3.7/1.8
46
3.8/1.8
45
3.8/1.8
725
47
3.8/1.8
46
3.5/1.7
46
- 3.611.7
46
3.7/1.8
750
47
3.5/1.7
47
3.7/1.8
47
3.8/1.8
48
3.5/1.6
775
48
3.8/1.8
47
3.4/1.6
47
3.6/1.7
47
3.7/1.7
800
48
3.6/1.7
48
3.7/1.8
48
3.8/1.8
47
3.4/1.6
825
48
3.3/1.6
48
3.5/1.6
48
3.6/1.7
48
3.7/1.8
_ '3ITUDE
RANGE
(�
AVG GAS
HEAT VALUE
AT ALTITUDE
(BTU/CU FT)
SPECIFIC GRAVITY OF NATURAL GAS
0.58
0.60
0.62
0.64
Orifice
No.
Manifold
Pressure
Orifice
No.
Manifold
Pressure
Orifice
No.
Manifold
Pressure
Orifice
No.
Manifold
Pressure
Auo ro'a'n
i 21
625
45
3.7/1.8
45
3.8/1.8
44
3.3/1.6
44
3.4/1.6
650
46
3.6/1.7
46
3.7/1.8
46
3.8/1.8
45
3.8/1.8
675
47
3.8/1.8
46
3.4/1.6
46
3.5/17
46
3.7/1.7
700
47
3.5/1.7
47
3.6/1.7
47
3.7/1.8
46
3.4/1.6
725
48
3.7/1.8
48
3.8/1.8
47
3.5/1.7
47
3.6/1.7
750
48
3.5/1.7
48
3.6/1.7
48
3.7/1.8
48
3.8/1.8
775
49
3.8/1.8
48
3.4/1.6
48
3.5/1.7
48
3.6/1.7
TABLE 13- Orifice Size and Manifold Pressure for Gas Input Rate (Tabulated Data Based On 21,000 Btuh
High- Heat/14,500 Btuh for Low -Heat Per Burner,
Derated 4 Percent For Each 1000 Ft Above Sea Level)(Continued)
• Orifice numbers 43 are factory Installed
42
ALTITUDE
RANGE
TT)
AVG GAS
HEAT VALUE
AT ALTITUDE
(BTU/CU F1)
SPECIFIC GRAVITY OF NATURAL GAS
0.58
0.60
0.62
0.64
Orifice
No.
Manifold
Pressure
Orifice
No.
Manifold
Preasure
Orifice
No.
Manifold
Pressure
Orifice
No.
Manifold
Pressure
Ago ros» I
9001
W
10,000
600
48
3.6/1.7
48
3.7/1.8
46
3.8/1.8
45
3.7/1.8
825
47
3.7/1.8
47
3.8/1.8
48
3.5/1.7
46
3.6/1.7
650
47
3.4/1.6
47
3.6/1.7
47
3.7/1.8
47
3.8/1.8
675
48
3.6/1.7
48
&6/1.8
47
3.4/1.6
47
3.5/1.7
700
48
3.4/1.6
48
3.5/1.7
48
3.6/1.7
48
3.7/1.8
725
49
3.7/1.8
49
3.8/1.8
48
3.4/1.6
48
3.5/1.7
TABLE 13-Orifice Size and Manifold Pressure for Gas Input Rate (Tabulated Data Based On 21,000 Btuh
HIgh- HeaU14,500 Btuh for Low -Heat Per Burner,
berated 4 Percent For Each 1000 R Above Sea Level)(Continued)
' Orifice numbers 43 ars factory installed
ItroTTIA
10 TURNS
50 AMPS ON AMMETER
10 TUANS AROIINO JAWS
THERMOSTAT SUBBASE
TERMINALS WITH
THERMOSTAT REMOVED
ANITICIPATOR, CLOCK. ETC.,
MUST BE OUT OF CIRCUIT.)
HOOK- AROUND
AMMETER
FROM UNIT 24V
CONTROL TERMINALS
CIA AMPS FOR TtEN*OSTAT
ANTICIPATOR SETTING
A90316
FIg. 55—Amp Draw Check With Ammeter
Step 4 —Check Safety Controls
The f arnc sensor, gas valve, and pressure switch were all checked
in the Stan -up procedure section as part of normal operation.
1. Check Main Limit Switch
This control shuts off combustion system and energizes
air - circulating blower motor, if furnace overheats. By using
this method to check limit control, it can be established that
limit is futctioning properly and will operate if there is a
restricted return-air supply or motor failure. if limit control
does not function during this test. cause must be detennined
and corrected.
a. Run furnace for at least 5 minutes.
b. Gradually block off return air with a piece of cardboard or
sheet metal until the limit trips.
c. Unblock return air to permit normal circulation
d. Burners will re-light when furnace cools down.
2. Check draft safeguard switch.
The purpose of this control is to cause the safe shutdown of the
furnace during certain blocked vent conditions.
a. Verify vent pipe is cool to the touch.
43
b. Disconnect power to furnace and remove vent connector
from furnace vent elbow.
c. Restore power to furnace and set room thermostat above
MOM temperature.
d. After normal start-up, allow furnace to operate for 2
minutes, then block vent elbow in fumace 80 percent of
vent area with a piece of flat sheet metal.
e. Furnace should cycle off within 2 minutes. If gas does not
shut off within 2 minutes, determine reason draft safeguard
switch did not function properly and correct condition.
f. Remove blockage from furnace vent elbow.
g. Switch will auto-reset when it cools.
b. Re- install vent connector.
NOTE: Should switch remain open longer than 3 minutes,
furnace control board will lockout the furnace for 3 hours. To reset
furnace control board. turn thermostat below room temperature or
from HEAT to OFF and turn 115 -v power OFF, then back ON.
3. Check Pressure Switch(es)
This control proves operation of the draft inducer blower.
a. Turn off 115 -v power to furnace.
b. Disconnect inducer motor lead wires from wire harness.
c. Turn on 115 -v power to furnace.
d. Set thermostat to 'call for heat and wait 1 minute. When
pressure switch is functioning properly, hot surface igniter
should NOT glow and control diagnostic light flashes a
status code 32. If hot surface igniter glows when inducer
motor is disconnected, shut down furnace immediately.
e. Determine reason pressure switch did not function properly
and crn..,..t condition.
1. Turn off 115 - power to furnace.
g. Reconnect inducer motor wires, replace outer door. and
turn on 115 -v power.
h. Blower will tun for 90 seconds before beginning the call
for heat again.
i. Furnace should ignite normally.
Step 5— Checklist
1. Pm away tools and instruments. Clean up debris.
2. Verify that switches SWI -1 and SW1 -6 are OFF and other
setup switches are set as desired. Verify that switches SW1 -7
and SWI -8 for the blower OFF DELAY are set as desired per
Table 10.
3. Verify that blower and burner access doors are properly
installed.
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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. Attach literature packet to furnace.
SERVICE AND MAINTENANCE PROCEDURES
A WARNING
FIRE, PERSONAL INJURY AND UNIT - DAMAGE
HAZARD
Valium to follow this warning could result in personal injury,
or death and/or property damage.
The ability to properly perform maintenance on this equip-
ment requires certain knowledge, mechanical skills, tools, and
equipment. If you do not possess these, do not attempt to
perform any maintenance on this equipment other than those
procedures recommended in the User's Manual.
A WARNING
ELECTRICAL SHOCK, FIRE OR EXPLOSION HAZ-
ARD
Failure to follow this warning could result in personal injury
or death, or property damage.
Before servicing, disconnect all electrical power to furnace.
Verify proper operation after servicing.
A CAUTION
UNIT OPERATION HAZARD
Failure to follow this caution may result in improper unit
operation or failure of unit components.
Label all wires prior to disconnection when servicing con-
trols. Wiring errors can cause improper and dangerous
operation.
Step t— Introduction
GENERAL
These instructions are written as if the furnace is installed in an
upflow application. An upflow furnace application is where the
Fig. 56 —Service Label
44
blower is located below the combustion and controls section of the
furnace, and conditioned air is discharged upward. Since this
furnace can be installed in any of the 4 positions shown in Fig. 4,
you must revise your orientation to component location accord-
ingly.
ELECTRICAL CONTROLS AND WIRING
A04015
A WARNING
ELECTRICAL SHOCK HAZARD
Failure to follow this warning could result in personal injury
or death.
There may be more than 1 electrical supply to the furnace.
Check accessories and cooling unit for additional electrical
supplies that must be shut off during furnace servicing.
The electrical ground and polarity for 115 -v wiring must be
properly maintained. Refer to Fig. 24 for field wiring information
and to Fig. 57 for furnace wiring information.
NOTE: If the polarity is not correct, the STATUS LED on the
control will flash rapidly and prevent the furnace from beating.
The control system also requires an earth ground for proper
operation of the control and flame - sensing electrode.
The 24 -v circuit contains an automotive -type, 3 -amp fuse located
on the control. (See Fig. 25.) Any shorts of the 24 -v wiring during
installation, service, or maintenance will cause this fuse to blow. If
fuse replacement is required, use ONLY a 3 -amp fuse. The control
LED will display status code 24 when fuse needs to be replaced.
Proper instrumentation is required to service electrical controls.
The control in this furnace is equipped with a Status Code LED
(Light - Emitting Diode) to aid in installation, servicing, and
troubleshooting. It can be viewed through the sight glass in blower
access door. The amber furnace control LED is either ON
continuously, rapid flashing, or a code composed of 2 digits. The
first digit is the number of short flashes, the second digit is the
number of long flashes.
For an explanation of status codes, refer to service label located on
blower access door or Fig. 56, and the troubleshooting guide which
can be obtained from your distributor.
See Fig. 62, a brief Troubleshooting Guide.
For 2 -Stage Variable Speed ECM Controls the stored status codes
will NOT be erased from the control memory, when 115- or 24-v
power is interrupted. The control will store up to the last 7 Status
Codes in order of occurence.
L To retrieve status codes, proceed with the following:
NOTE: NO thermostat signal may be present at control, and all
blower -OFF delays must be completed.
a. Leave 115 -v power to furnace turned on.
b. Remove outer access door.
c. Look into blower access door sight glass for current amber
LED status. Removing blower access door will open
blower access door switch and terminate 1 15 -v power to
control so that status code is not displayed.
d. Remove blower access door.
NOTE: The Status Codes cannot be retrieved by disconnecting
the limit switch or draft safeguard switch. To retrieve Status
Codes, follow the procedure below.
2. Tutu Setup Switch, SWI -1 "ON."
3. Manually close blower access door switch.
4. Control will flash up to 7 Status Codes.
5. The last Status Code, or 8th Code, will be Code 11.
6. Turn SW1 -1 "OFF."
7. A continuously-lit Amber LED will appear and indicates
proper operation.
8. Release blower access door switch, install blower access door
and replace outer door or refer to the SERVICE label on the
front of the blower access door for more information.
Component Self -Test
Component Test can ONLY be initiated by performing the
following:
I. Remove outer access door.
2. Remove blower access door.
3. Remove the wire from the "R" terminal of the control board.
4. Turn Setup Switch, SW -1-6 "ON."
5. Manually close blower access door switch.
Blower access door switch opens 115 -v power to control. No
component operation can occur unless switch is closed. Caution
must be taken when manually closing this switch for service
purposes.
A WARNING
ELECTRICAL SHOCK HAZARD
Failure to follow this warning could result in personal injury,
or death.
Blower access switch opens 115 -v power to control. No
component operation can occur unless switch is closed.
Caution must be exercised to avoid electrical shock from
exposed electrical components when manually closing switch
for service purposes. There may be more than one electrical
supply to the unit. Check accessories and cooling unit for
additional electrical supplies.
6. Component Test sequence will function as follows:
a. Inducer motor starts on high -speed and continues to run
until Step (d.) of component test sequence.
b. Hot surface igniter is energized for 15 sec, then de-
energized.
c. Blower operates for 10 sec, then turns off.
45
d. Inducer motor goes to low -speed for 10 seconds, then turns
off.
e. After component test is completed, one or more status
codes (11, 25, or 41) will flash. See component test section
of service label for explanation of status codes.
NOTE: To repeat component test, turn setup switch S W 1 -6 OFF
then back ON.
f. Turn setup switch SW I -6 OFF. -
7. RELEASE BLOWER ACCESS DOOR SWITCH, reattach
wire to "R" terminal on furnace control board. replace blower
access door, and replace outer access door.
Step 2 —Care and Maintenance
A WARNING
FIRE OR EXPLOSION HAZARD
Failure to follow this warning could result in personal injury,
death and/or property damage.
Never store anything on, near, or in contact with the furnace,
such as:
1. Spray or aerosol cans, rags, brooms, dust mops, vacuum
cleaners, or other cleaning tools.
2. Soap powders, bleaches, waxes or other cleaning com-
pounds, plastic or plastic containers, gasoline, kerosene,
cigarette lighter fluid, dry cleaning fluids, or other volatile
fluids.
3. Paint thinners and other painting compounds, paper bags,
or other paper products.
Exposure to these materials could lead to corrosion of the
heat exchangers.
For continuing high performance and to minimize possible furnace
failure, periodic maintenance must be performed on this furnace.
Consult your local dealer about proper frequency of maintenance
and the availability of a maintenance contract.
A WARNING
ELECTRICAL SHOCK AND FIRE HAZARD
Failure to follow this warning could result in personal injury,
death, and/or property damage.
Turn off the gas and electrical supplies to the furnace before
performing any maintenance or service. Follow the operating
instructions on the label attached to the furnace.
A WARNING
CARBON MONOXIDE POISONING AND FIRE
HAZARD
Failure to follow this warning could result in personal injury,
death and/or property damage.
Never operate furnace without a filter or with filter access
door removed.
A CAUTION
CUT HAZARD
Failure to follow this caution may result in personal injury.
Sheet metal pars may have sharp edges or buns. Use care and
wear appropriate protective clothing, safety glasses and
gloves when handling parts, and servicing furnaces.
The minimum maintenance on this furnace is as follows:
1. Check and clean air filter each month or more frequently if
required. Replace if torn.
FURNACE
CASING WIDTR
FILTER SIZE
FILTER
TYPE
Side Return
Bottom Return
14.12
18 X25X1
14 X25 X1
Cleanable'
17 -12
18 X25X1
18 X25X1
Cleanable'
21
16X25X1
20 X25X1
Cleanable'
24
18 X25 X1
24X25X1
Cleanable'
• Recommended
Table 14— Filter Size Information (In.)
2. Check blower motor and wheel for cleanliness each heating
and cooling season. Clean as necessary.
3. Check electrical connections for tightness and controls for
proper operation each heating season. Service as necessary.
4. Inspect bumer compartment before each heating season for
rust, corrosion, soot or excessive dust. If necessary, have
furnace and burner serviced by a qualified service agency.
5. Inspect the vent pipe/vent system before each heating season
for rust, corrosion, water leakage, sagging pipes or broken
fittings. Have vent pipes/vent system serviced by a qualified
service agency.
6. Inspect any accessories attached to the furnace such as a
humidifier or electronic air cleaner. Perform any service or
maintenance to the accessories as recommended in the acces-
sory instructions.
CLEANING AND /OR REPLACING AIR FILTER
The air filter arrangement will vary depending on the application.
NOTE: If the filter has an airflow direction arrow, the arrow must
point towards the blower.
A CAUTION
CUT HAZARD
Failure to follow this caution may result in personal injury.
Sheet metal parts may have sharp edges or burrs. Use care and
wear appropriate protective clothing, safety glasses and
gloves when handling parts, and servicing furnaces.
Media cabinet filter procedures:
NOTE: Media cabinet is included with variable speed furnace.
1. Turn off electrical supply to furnace before removing filter
access door.
2. Remove filter cabinet door.
3. Slide filter out of cabinet.
4. If equipped with permanent, washable 1 -inch filter, clean filter
by spraying cold tap water through filter in opposite direction
of airflow. Rinse filter and let dry. Oiling or coating of the
filter is not recommended. See Table 14 for size information
5. If equipped with factory- specified disposable media filter,
replace only with media filter having the same part number
and size. For expandable replacement media, refer to the
instructions included with the replacement media. If equipped
with accessory KGAFRO301ALL external filter rack, See
Table 14.
6. Slide filter into cabinet.
7. Replace filter cabinet door.
8. Turn on electrical supply to furnace.
46
BLOWER MOTOR AND WHEEL
A WARNING
ELECTRICAL SHOCK HAZARD
Failure to follow this warning could result in personal injury
or death.
Blower access door switch opens 115 -v power to control. No
component operation can occur unless switch is closed.
Caution must be taken when manually closing this switch for
service purposes.
NOTE: The blower wheel should not be dropped or bent as
balance will be affected.
The following steps should be performed by a qualified service
agency.
To ensure long life and high efficiency, clean accumulated dirt and
grease from blower wheel and motor annually.
The inducer and blower motors are pre- lubricated and require no
additional lubrication. These motors can be identified by the
absence of oil ports on each end of the motor.
Clean blower motor and wheel as follows:
1. Turn off electrical supply to furnace.
2. Loosen the thumbscrew on outer door and then remove outer
door.
3. For downflow or horizontal furnaces having vent pipes within
the furnace that pass in front of the blower access door
a. Disconnect vent connector from furnace vent elbow.
b. Disconnect and remove short piece of vent pipe from
within furnace.
4. Remove 2 screws from blower access door and remove blower
access door.
5. Disconnect blower leads from furnace control. Record wire
color and location for reassembly. All other factory wires can
be left connected, but field thermostat connections may need
to be disconnected depending on their length and routing.
6. Remove 2 screws holding control box to blower shelf.
7. Hang control box from front of furnace casing and away from
blower compartment
8. Remove 2 screws holding blower assembly to blower deck
and slide blower assembly out of furnace.
9. Clean blower wheel and motor using a vacuum with soft brush
attachment. Blower wheel blades may be cleaned with a small
paint or flux brush. Do not remove or disturb balance weights
(clips) on blower wheel blades.
10. Vacuum any loose dust from blower housing, wheel and
motor.
I L If a greasy residue is present on blower wheel, remove wheel
from the blower housing and wash it with an appropriate
degreaser. To remove wheel:
NOTE: Before disassembly. mark blower mounting arms, motor,
and blower housing so motor and each arm is positioned at the
same location during reassembly.
a. Disconnect ground wire attached to blower housing.
b. Remove screws securing cutoff plate and remove cutoff
plate from housing.
c. Loosen set screw holding blower wheel on motor shaft
(160+/ -20 in.-lb. when assembling).
d. Remove bolts holding motor to blower housing and slide
motor out of wheel (40+ / -10 in.-lb. when reassembling).
e. Remove blower wheel from housing.
f. Clean wheel and housing.
12. Reassemble motor and blower by reversing steps Ile, through
1 la. Be sure to reattach ground wire to the blower housing.
13. Verify that blower wheel is centered in blower housing and set
screw contacts the flat portion of the motor shaft Loosen set
screw on blower wheel and reposition if necessary.
14. Spin the blower wheel by hand to verify that the wheel does
not rub on the housing.
15. Reinstall blower assembly in furnace.
16. Reinstall control box assembly in furnace.
NOTE: Refer to Fig. 57 if leads were not identified before
disconnection.
17. Reconnect blower leads to furnace control. Refer to furnace
wiring diagram, and connect thermostat leads if previously
disconnected.
18. To check blower for proper rotation:
a. Turn on electrical supply.
A WARNING
ELECTRICAL SHOCK HAZARD
Failure to follow this warning could result in personal injury,
or death.
Blower access door switch opens 115 -v power to furnace
control. No component operation can occur unless switch is
closed. Exercise caution to avoid electrical shock from
exposed electrical components when manually closing this
switch for service purposes.
b. Manually close blower access door switch.
NOTE: If R-W/W1 thermostat terminals are Jumpered at the time
blower access door switch is closed, blower will run for 90 sec
before beginning a beating cycle.
c. Perform component self -test as shown at the bottom of the
SERVICE label, located on the front of blower access door.
d. Verify blower is rotating in the correct direction
19. If furnace is operating properly. RELEASE BLOWER AC-
CESS DOOR SWITCH. Remove any jumpers or reconnect
any disconnected thermostat leads. Replace blower access
door.
20. Downflow or horizontal furnaces with vent pipe through
furnace only:
a. Install and connect short piece of vent pipe inside furnace
to existing vent.
b. Connect vent connector to vent elbow.
21. Turn on gas supply and cycle furnace through one complete
heating and cooling cycle. Verify the furnace temperature rise
as shown in Adjustments Section. Adjust temperature rise as
shown in Adjustments Section. If outdoor temperature is
below 70°F, turn off circuit breaker to outdoor unit before
running furnace in the cooling cycle. Turn outdoor circuit
breaker on after completing cooling cycle.
CLEANING HEAT EXCHANGER
The following steps should be performed by a qualified service
agency:
NOTE: If the heat exchangers get a heavy accumulation of soot
and carbon, they should be replaced rather than trying to clean
them thoroughly. A build -up of soot and carbon indicates that a
problem exists which needs to be corrected, such as improper
adjustment of manifold pressure, insufficient or poor quality
47
combustion air, incorrect size or damaged manifold orifice(s),
improper gas, or a restricted heat exchanger. Action must be taken
to correct the problem.
If it becomes necessary to clean the heat exchangers because of
dust or corrosion, proceed as follows:
1. Turn OFF gas and electrical power to furnace.
2. Remove outer access door.
3. Disconnect vent connector from furnace vent elbow.
4. For downflow or horizontal furnace having an internal vent
pipe, remove internal vent pipe within the casing.
5. Disconnect wires to the following components. Mark wires to
aid in reconnection (be careful when disconnecting wires from
switches because damage may occur):
a. Draft safeguard switch.
b. Inducer motor.
c. Pressure switches.
d. Limit overtemperature switch.
e. Gas valve.
f. Hot surface igniter.
g. Flame- sensing electrode
b. Flame rollout switches.
6. Remove screws that fasten the collector box assembly to the
cell panel. Be careful not to damage the collector box. inducer
assembly and elbow need not be removed from collector box.
7. Disconnect gas line from gas manifold.
8. Remove the 4 screws that attach the burner assembly to the
cell panel. The gas valve and individual burners need not be
removed from support assembly. Remove NOx baffles, if
installed.
NOTE: Be very careful when removing burner assembly to avoid
breaking igniter. See Fig. 58 and 59 for correct igniter location.
9. Using field- provided 25- caliber rifle cleaning brush, 36 in.
long, 1/4" diameter steel spring cable, a variable speed,
reversible electric drill, and vacuum cleaner, clean cells as
follows:
a. Remove metal screw fitting from wire brush to allow
insertion into cable.
b. Insert the twisted wire end of brush into end of spring
cable, and crimp tight with crimping tool or crimp by
striking with ball -peen hammer. TIGHTNESS IS VERY
IMPORTANT.
NOTE: The materials needed in item 9 can usually be purchased
at local hardware stores.
(l.) Attach variable- speed, reversible drill to the end of
spring cable (end opposite brush).
(2.) Insert brush end of cable into the outlet opening of cell
and slowly rotate with drill. DO NOT force cable.
Gradually insert cable into upper pass of cell. (See Fig.
60.)
(3.) Work cable in and out of cell 3 or 4 times to obtain
sufficient cleaning. DO NOT pull cable with great
force. Reverse drill and gradually work cable out.
(4.) Insert brush end of cable in burner inlet opening of
cell, and proceed to clean 2 lower passes of cell in
same manner as upper pass.
(5.) Repeat foregoing procedures until each cell in furnace
has been cleaned.
(6.) Using vacuum cleaner, remove residue from each cell.
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CONNECTION DIAGRAM
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CPM
C0& Caalwicao. Relay. SPDT
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055 Daft Safeguard 54 r.. AutoRaet. 531 INC.)
FAC -1 Electron° As Clean Cmlrerdm
RISMRC 1 . 0 l Amp IMO
MC-2 Demotic M Cbana Canedm (Common)
FRS flame RcIoM Welt Mn Rya. SP91N.C.)
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FUSE Fine. 3 M. Automatise wade Type.
Faddy Staled
GV Gas Valve
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IP5 Hsi-Heat Resne Switch. 951(140.)
1,516 FkghHea RraNae Wee Reel. SKI INC.)
Ion Itc( Surface gels (115VAC)
' NSA Ha Surface It Way. PSI 64.0.7
NUM 24MC Humid,* Conecaon (05 Amp Man
HUGH Hn Way, SP, (NO.)
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OR Seca Moto Relay. 951 INC.)
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IB) nwa (Note 17)
TED Up Wang Dade for Rates Cab
IGPS Law Gas Wave Swtcts 5P5i (140)
IPS 1pWnet Reeve Arta 5(151 (N.G)
151, 2 link Wick Auto-Reset 554(N .C)
PCB Rind Unit Board
R1 1204at Connector
P12 40aaltH49 &OM Canlecta
113 441st ECM 6.V44 Canada
114 4.Gdt Mode Rag Canada
117 4{1at Cm nncalnn Connector
P12 2C.at ON Connector
1110 20sai HSI COnreda
RII OMComectm(3. iat)
1112 18cut Inductor Spice Carlotta
1113 16CcuitECM Bbwa CM. Con ecta
1114 Stink ECM Namur Pova Connector
51W -1 Matt Wick Staves Code Recat PS INC.) .
SW1.2 Manual %s kit tan4leel ply. 5310&0.1
SW1.3 Manuel Ht4Idk. LawHeal Rise AA SPSi (N.0.)
9W14 MBn ie Haack C0mbUEllbiacyAdjustment.
SKI 04 04
HV1.5 Mau, Hatt. Cooling CM/Tn. 5(151140.)
SW14 Manual Stack Co noon(( lap. 5P51(NO)
SW 1.2.1 Manual Switch, Nava OB0tey. 951(140 )
9114-1 Marcel 5Mch. Ta** Men (MO S6° (Op
5W4-2&3 FOR MIRE 115E
IR mnIN.E15' 6/245 -
�— a
O IMAM
_ CONTROL
FACTORY POWER
WANG (115VAC)
FAa0RY CONING
WING (24VAC)
FIRO CONTROL
WIBNG MAC)
CONDUCIER 014
COHMC4
O RHDWaNG
SCREW TERMINAL
/i9 EpIP1.EN,
GROUND
— 4 F RUG RECEPTACLE
SENSATE DIAGRAM
1. 1. R any d the migktleplpnet We Isf4plemd use Smutted for 115G
2 Use er Me batmen Balm m 9etanm aid Be Neu spai0 box (JB). <
1 Slit Se ate nut b meeued 1Amen amt meted terminal a meekest
4. Srbols reatliml 818** SaBalNImaott
B • H aYost GS atOMt bowl ccablat atl amyl n legatl.
7. tltm)sS WM3/4 en01 tpEGAS:mannat 4 -„
1 Way =reeled Wien GPA rid mai
A Maley.
BOfemua wheeling 91414110111 m 120.
cal aath 780) 5emh axing or hat Pmp Ise
10 Ignlm Wag as aura ata far maedae 'successful Insist* 'gem Call WI
am4esetttrdnellors
11. klttamew gttl caters *Wm, alas, tllenW eebd 8 St
12 f today mlmmd Wen BVSSIs ra i®d BVSSusaly w annoy Mgr,Accessory I Is
tatallai
11 Myatt, Wires slow rain to MINT,/ Ube( an be caressed to any win, WRn e bur
aar� � aura i "ton re n's4 a�
Fig. 57— WIring Diagram
A04014
L
0I:MIMI
CI
111010111
0�
®a1':'nam
T h
f l
1050
®gy
L F..
700
B75a
1050
®
1400
17501
2100
r
1
1
:11: k "1111
1 1617 54321
MIS Fin SECT •• °• SEC2
5W147
BLOWER OFF DEW
SEEECIDN
R a j
A CD
R4. MODE( PPG CHART
1. Deicer A/C aloe Wen WC Neches are in aF po ion'
2. Delat can ad
ow fan aowwyen a s*ctie on n OFe F pod n
a
14OR 43
CONNECTION DIAGRAM
P12
NC OR a ARROW SELECTION 04
U g1
ilgg°llellaPiallao NV
NI? tCamg�YmM�'ga Rtla SPSI NQ)
G a Mamr CCF� yDmeuAmpa As
SP, �
N a Comonunean lABRMart maw
D
Microprocessor an
0,
Can WWI YM R C
C110E
L NC ASCaldeionwg(Adjustable Airflow GM)
E A y. 1
)
E DVSS Hocked tent S, Hatch. Manual Reset
N.C.)
CPM
C0& Caalwicao. Relay. SPDT
D R.1 0(04 Correction (24VAC 002 Amps)
055 Daft Safeguard 54 r.. AutoRaet. 531 INC.)
FAC -1 Electron° As Clean Cmlrerdm
RISMRC 1 . 0 l Amp IMO
MC-2 Demotic M Cbana Canedm (Common)
FRS flame RcIoM Welt Mn Rya. SP91N.C.)
ESE flameamig Seea Flecbode
FUSE Fine. 3 M. Automatise wade Type.
Faddy Staled
GV Gas Valve
GVR Gas VFW Relay. 0PS1 M.0.)
IP5 Hsi-Heat Resne Switch. 951(140.)
1,516 FkghHea RraNae Wee Reel. SKI INC.)
Ion Itc( Surface gels (115VAC)
' NSA Ha Surface It Way. PSI 64.0.7
NUM 24MC Humid,* Conecaon (05 Amp Man
HUGH Hn Way, SP, (NO.)
OM Inducer Del Maim 2- Speed. Shaded Pole
OR Seca Moto Relay. 951 INC.)
KU
BASED ON 350014/101
14171E 112
' ED 055 MED1
r ULU
WNi
ILK Nowt' Dom knakpk Watch. 951(140 )
IB) nwa (Note 17)
TED Up Wang Dade for Rates Cab
IGPS Law Gas Wave Swtcts 5P5i (140)
IPS 1pWnet Reeve Arta 5(151 (N.G)
151, 2 link Wick Auto-Reset 554(N .C)
PCB Rind Unit Board
R1 1204at Connector
P12 40aaltH49 &OM Canlecta
113 441st ECM 6.V44 Canada
114 4.Gdt Mode Rag Canada
117 4{1at Cm nncalnn Connector
P12 2C.at ON Connector
1110 20sai HSI COnreda
RII OMComectm(3. iat)
1112 18cut Inductor Spice Carlotta
1113 16CcuitECM Bbwa CM. Con ecta
1114 Stink ECM Namur Pova Connector
51W -1 Matt Wick Staves Code Recat PS INC.) .
SW1.2 Manual %s kit tan4leel ply. 5310&0.1
SW1.3 Manuel Ht4Idk. LawHeal Rise AA SPSi (N.0.)
9W14 MBn ie Haack C0mbUEllbiacyAdjustment.
SKI 04 04
HV1.5 Mau, Hatt. Cooling CM/Tn. 5(151140.)
SW14 Manual Stack Co noon(( lap. 5P51(NO)
SW 1.2.1 Manual Switch, Nava OB0tey. 951(140 )
9114-1 Marcel 5Mch. Ta** Men (MO S6° (Op
5W4-2&3 FOR MIRE 115E
IR mnIN.E15' 6/245 -
�— a
O IMAM
_ CONTROL
FACTORY POWER
WANG (115VAC)
FAa0RY CONING
WING (24VAC)
FIRO CONTROL
WIBNG MAC)
CONDUCIER 014
COHMC4
O RHDWaNG
SCREW TERMINAL
/i9 EpIP1.EN,
GROUND
— 4 F RUG RECEPTACLE
SENSATE DIAGRAM
1. 1. R any d the migktleplpnet We Isf4plemd use Smutted for 115G
2 Use er Me batmen Balm m 9etanm aid Be Neu spai0 box (JB). <
1 Slit Se ate nut b meeued 1Amen amt meted terminal a meekest
4. Srbols reatliml 818** SaBalNImaott
B • H aYost GS atOMt bowl ccablat atl amyl n legatl.
7. tltm)sS WM3/4 en01 tpEGAS:mannat 4 -„
1 Way =reeled Wien GPA rid mai
A Maley.
BOfemua wheeling 91414110111 m 120.
cal aath 780) 5emh axing or hat Pmp Ise
10 Ignlm Wag as aura ata far maedae 'successful Insist* 'gem Call WI
am4esetttrdnellors
11. klttamew gttl caters *Wm, alas, tllenW eebd 8 St
12 f today mlmmd Wen BVSSIs ra i®d BVSSusaly w annoy Mgr,Accessory I Is
tatallai
11 Myatt, Wires slow rain to MINT,/ Ube( an be caressed to any win, WRn e bur
aar� � aura i "ton re n's4 a�
Fig. 57— WIring Diagram
A04014
a Flg. 58— Igniter Position -Side View
-. Fig. 59— Igniter Position -Top View
A05025
(7.) Using vacuum cleaner with soft brush attachment,
clean burner assembly.
(8.) Clean flame sensor with fine steel wool.
(9.) Install NOx baffles (if removed).
(10.) Reinstall burner assembly. Center burners in cell
openings.
10. Remove old sealant from cell panel and collector box flange.
11. Spray releasing agent on the heat exchanger cell panel where
collector box assembly contacts cell panel.
NOTE: A releasing agent such as cooking spray or equivalent
(must not contain can or canola oil, aromatic or halogenated
hydrocarbons or inadequate seal may occur) and RTV sealant
(G.E. 162, 6702, or Dow-Corning 738) are needed before starting
installation. DO NOT substitute any other type of RTV sealant.
G.E. 162 (P771 -9003) is available through RCD in 3-oz tubes.
12. Apply new sealant to flange of collector box and attach to cell
panel using existing screws, making sure all screws are secure.
13. Reconnect wires to the following components (Use connection
diagram on wiring label, if wires were not marked for
reconnection locations.):
c Draft safeguard switch.
b. Inducer motor.
c. Pressure switches.
d. Limit overtemperature switch.
e. Gas valve.
f. Hot surface igniter.
g. Flame- sensing electrode.
h. Flame rollout switches.
49
A91252
Fig. 60— Cleaning Heat Exchanger CeII
14. Reinstall internal vent pipe. if applicable.
15. Reinstall vent connector on furnace vent elbow. Securely
fasten vent connector to vent elbow with 2 field-supplied,
corrosion - resistant, sheet metal screws located 180° apart.
16. Replace blower access door only if it was removed.
17. Set thermostat above room temperature and check furnace for
proper operation.
18. Verify blower airflow and speed changes between heating and
cooling.
A WARNING
FIRE OR EXPLOSION HAZARD
Failure to follow this warning could result in personal injury,
death and/or property damage.
Never use a match or other open flame to check for gas leaks.
Use • soap- and -water solution.
19. Check for gas leaks.
Step S-- Sequence of Operation
NOTE: Furnace control must be grounded for proper operation or
else control will lock out. Control is grounded through
green/yellow wire routed to gas valve and burner box screw.
Using the schematic diagram in Fig. 57, follow the sequence of
operation through the different modes. Read and follow the wiring
diagram very carefully.
NOTE: If a power interruption occurs during a call for heat
(W/WI or W/W1 and - W2). the control will start a 90 second
blower -only ON period two seconds after power is restored, if the
thermostat is still calling for gas heating. The amber LED light will
flash code 12 during the 90- second period after which the LED
will be ON continuous, as long as no faults are detected. After the
90- second period the furnace will respond to the thermostat
normally.
The blower door must be installed for power to be conducted
through the blower door interlock switch ILK to the furnace
control CPU, transformer IRAN, inducer motor IBM, blower
motor BLWM, hot - surface igniter HSI, and gas valve GV.
1. Two Heating (Adaptive Mode) with Single
Thermostat
See Fig. 24 or 33 for thermostat connections
NOTE: The low -heat only switch SW1 -2 selects either the
low -heat ody operation mode when ON, (see item 2. below) or the
adaptive heating mode when OFF in response to a call for heat
(See Table 8.) When the W2 thermostat terminal is energized it
will always cause high -heat operation when the R -to-W circuit is
closed regardless of the setting of the low -beat only switch.
This furnace can operate as a two-stage furnace with a single -stage
thermostat because the furnace control CPU includes a pro-
grammed adaptive sequence of controlled operation, which selects
low -heat or high -heat operation. This selection is based upon the
stored history of the length of previous gas - heating periods of the
single -stage thermostat.
The furnace will start up in either low- or high -heat If the furnace
starts up in low -heat, the control CPU determines the low -heat
on -time (from 0 to 16 minutes) which is permitted before switch-
ing to high -heat.
If the power is interrupted, the stored history is erased and the
control CPU will select low -heat for up to 16 minutes and then
switch to high -heat, as long as the thermostat continues to call for
heat. Subsequent selection is based on stored history of the
thermostat cycle times.
The wall thermostat 'calls for heat", closing the R -to-W circuit.
The furnace control performs a self- check, verifies the low -heat
and high -heat pressure switch contacts LPS and HPS are open, and
starts the inducer motor IDM in high- speed.
a. Inducer Prepurge Period
(1.) If the furnace control CPU selects low -heat operation
the inducer motor IDM comes up to speed, the
low -heat pressure switch LPS closes, and the furnace
control CPU begins a 15- second prepurge period. If
the low -heat pressure switch LPS fails to remain
closed the inducer motor IDM will remain running at
high - speed. After the low -heat pressure switch re-
closes the furnace control CPU will begin a 15- second
prepurge period, and continue to run the inducer motor
IDM at high - speed.
(2.) If the furnace control CPU selects high -heat operation,
the inducer motor IDM remains running at high speed,
and the high-heat pressure switch relay HPSR is
de- energized to close the NC contact. When sufficient
pressure is available the high -heat pressure switch
HPS closes, and the high -heat gas valve solenoid
GV -HI is energized. The furnace control CPU begins
a l5- second prepurge period after the low -hem pres-
sure switch LPS closes. If the high -heat pressure
switch HPS fails to close and the low-heat pressure
switch LPS closes, the furnace will operate at low -heat
gas flow rate until the high-heat pressure switch closes
for a maximum of 2 minutes after ignition.
b. Igniter Warm -Up -At the end of the prepurge period, the
Hot- Surface Igniter HSI is energized for a 17- second
igniter warm -up period.
c. Trial- For - Ignition Sequence -When the igniter warm -up
period is completed the main gas valve relay contact GVR
closes to energize the gas valve solenoid GV -M. The gas
valve solenoid GV -M permits gas flow to the burners
—4 where it is ignited by the HSI. Five seconds after the GVR
closes, a 2- second flame proving period begins. The HSI
igniter will remain energized until the flame is sensed or
until the 2- second flame proving period begins.
If the furnace control CPU selects high -heat operation, the
high -heat gas valve solenoid GV -HI is also energized.
d. Flame- Proving - When the burner flame is proved at the
flame - proving sensor electrode FSE, the inducer motor
1DM switches to low -speed unless the furnace is operating
in high -heat, and the fumace control CPU begins the
blower-ON delay period and continues to hold the gas
valve GV -M open. If the burner flame is not proved within
two seconds, the control CPU will close the gas valve
GV -M, and the control CPU will repeat the ignition
sequence for up to three more Trials- For - Ignition before
going to Ignition - Lockout. Lockout will be reset auto-
50
matically after three hours, by momentarily interrupting
115 vac power to the furnace, or by interrupting 24 vac
power at SECT or SEC2 to the furnace control CPU (not at
W/W1, G, R, etc.).
If flame is proved when flame should not be present, the
furnace control CPU will lock out of Gas - Heating mode
and operate the inducer motor IBM on high speed until
flame is no longer proved.
e. Blower -On delay - If the burner flame is proven the
blower -ON delays for low -heat and high -heat are as fol-
lows:
Low -heat - 45 seconds after the gas valve GV -M is opened
the blower motor BLWM is turned ON at low -heat airflow.
High -heat - 25 seconds after the gas valve GV -M is
opened the BLWM is turned ON at high -heat airflow.
Simultaneously, the humidifier terminal HUM and elec-
tronic air cleaner terminal EAC -1 are energized and remain
energized throughout the heating cycle.
f. Switching from Low- to High -Heat - If the furnace
control CPU switches from low -heat to high -heat, the
furnace control CPU will switch the inducer motor IDM
speed from low to high. The high -heat pressure switch relay
HPSR is de- energized to close the NC contact. When
sufficient pressure is available the high -heat pressure
switch HPS closes, and the high -heat gas valve solenoid
GV -111 is energized. The blower motor BLWM will tran-
sition to high -heat airflow five seconds after the furnace
control CPU switches from low -heat to high -heat.
Switching from High- to Low -Heat -The furnace control
CPU will not switch from high -heat to low -heat while the
thermostat R -to-W circuit is closed when using a single -
stage thermostat
h. Blower -Off Delay - When the thermostat is satisfied, the R
to W circuit is opened, de- energizing the gas valve GV -M,
stopping gas flow to the burners, and de- energizing the
humidifier terminal HUM. The inducer motor IDM will
remain energized for a 5- second post -purge period. The
blower motor BLWM and air cleaner terminal EAC -1 will
remain energized at low -hem airflow or transition to
low -heat airflow for 90, 120, 150, or 180 seconds (depend-
ing on selection at blower-OFF delay switches). The
furnace control CPU is factory-set for a 120 - second
blower-OFF delay.
2. Two-Stage Thermostat and Two-Stage Heating
See Fig. 32 for thermostat connections.
NOTE: In this mode the low -heat only switch SW I -2 must be ON
to select the low -heat only operation mode in response to closing
the thermostat R -to-Wt circuit. Closing the thermostat R -to-
W 1- and -W2 circuits always causes high-heat operation, regardless
of the setting of the low -heat only switch.
The wall thermostat "calls for heat", closing the R -to-W 1 circuit
for low -heat or closing the R -to-W 1- and -W2 circuits for high -heat.
The furnace control performs a self-check, verifies the low -heat
and high -heat pressure switch contacts LPS and HPS are open, and
starts the inducer motor IDM in high- speed.
The start up and shut down functions and delays described in item
1. above apply to the 2 -stage heating mode as well, except for
switching from low- to high -Heat and vice versa.
a. Switching from Low- to High -Heat - If the thermostat R-
to-W 1 circuit is closed and the R -to -W2 circuit closes, the
furnace control CPU will switch the inducer motor IDM
speed from low to high. The high -heat pressure switch
relay HPSR is de-energized to close the NC contact. When
sufficient pressure is available the high -heat pressure
g.
MR CONDITIONING
TONS (12000 BTUMR)
AIRFLOW
(CFM)
070 MODEL
090 MODEL
110135.
8155 MODELS
1 -12
525
X2
X
—
2
700
X
X2
X
2 -12
875
X
X
X2
3
1050
X,
X
X
3-12
1225
X,
X,
X
4
1100
8752
X,
X
6
1750
—
—
X,
8
2100
—
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DEL
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875
1060,
1225
1225
1225
090
DEF
625
7002
876
1060
1225
1400,
1400
110.135155
DEF
700
8752
1050
1225
1400
1750,
2100
DEL
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1000
1200,
1400
1400
1400
090
DEF
000
000
1000
1200
1100
1000,
1600
110.135.155
DEF
600
10302
1200
1100
1000
2300
2200
Cooling Tonnage vs. Airflow (CFM)
X- INDICATES AN ALLOWABLE SELECTION.
switch HPS closes, and the high -heat gas valve solenoid
GV -111 is energized. The blower motor BLWM will tran-
sition to high -heat airflow five seconds after the R -to-W2
circuit closes.
b. Switching from High- to Low -Heat -If the thermostat R-
to-W2 circuit opens, and the R -to-Wl circuit remains
closed, the &mace control CPU will switch the inducer
motor IDM speed from high to low. The high -heat pressure
switch relay HPSR is energized to open the NC contact and
de- energize the high -heat gas valve solenoid GV -H1. When
the inducer motor IDM reduces pressure sufficiently, the
high -heat pressure switch HPS will open. The gas valve
solenoid GV -M will remain energized as long as the
low -heat pressure switch LPS remains closed. The blower
motor BLWM will tramition to low -heat airflow five
seconds after the R -to-W2 circuit opens.
3. Cooling mode
The thermostat 'calls for cooling'.
a. Single-Speed Cooling-
See Fig. 24 for thermostat connections
The thermostat closes the R -to-G -and -Y circuits. The R-to-
Y circuit starts the outdoor unit, and the R -to-G- and -Y/Y2
circuits start the furnace blower motor BLWM on cooling
airflow. Cooling airflow is based on the A/C selection
shown in Fig. 61. The electronic air cleaner terminal
EAC -1 is energized with 115 vac when the blower motor
AIR CONDITIONING (NC) OR CONTINUOUS -FAN (CF) AIRFLOW SELECTION CHART
BASED ON 350 CFA RON
SW 1a ON
BASED ON 400 CFLI?ON
SW1-5 ON
1.DEFAULT A/C AIRFLOW WHEN A/C SWITCHES ARE IN OFF POSITION (FACTORY SETTING)
2.DEFAULT CONT. FAN AIRFLOW WHEN CF SWITCHES ARE I l OFF POSITION (FACTORY SETTING)
3. SWITCH POSITIONS ARE ALSO SHOWN ON FURNACE WIRING DIAGRAM
Fig. 81— Cooling (A/C) or Continuous -Fan (CF) Airflow Selection Chart
51
A03220
BLWM is operating.
When the thermostat is satisfied, the R- to-G - and -Y circuits
are opened. The outdoor unit will stop, and the furnace
blower motor BLWM will continue operating at cooling
airflow for an additional 90 seconds. Jumper Y/Y2 to
DHUM to reduce the cooling off -delay to 5 seconds. (See
Fig. 25.)
b. Single - Stage Thermostat and Two-Speed Cooling
(Adaptive Mode) -
See Fig. 33 for thermostat connections
This furnace can operate a two-speed cooling unit with a
single-stage thermostat because the furnace control CPU
includes a programmed adaptive sequence of controlled
operation, which selects low-cooling or high-cooling op-
eration. This selection is based upon the stored history of
the length of previous cooling period of the single -stage
thermostat.
NOTE: The air conditioning relay disable jumper ACRDJ must
be connected to enable the adaptive cooling mode in response to a
call for cooling. (See Fig. 25.) When ACRDI is in place the
furnace control CPU can turn on the air conditioning relay ACR to
energize the Y/Y2 terminal and switch the outdoor unit to
high- cooling.
The furnace control CPU can start up the cooling unit in either
low- or high - cooling. If starting ti in low-cooling, the furnace
control CPU determines the low-cooling on -time (from 0 to 20
minutes) which is permitted before switching to high - cooling.
If the power is interrupted, the stored history is erased and the
furnace control CPU will select low - cooling for up to 20 minutes
and then energize the air conditioning relay ACR to energize the
Y/Y2 terminal and switch the outdoor unit to high-cooling, as long
as the thermostat continues to call for cooling. Subsequent
selection is based on stored history of the thermostat cycle times.
The wall thermostat "calls for cooling", closing the R -to-G -and -Y
circuits. The R -to-Y1 circuit starts the outdoor unit on low - tooling
speed. and the R- to-G - and -YI circuits starts the furnace blower
motor BLWM at low - cooling airflow which is the true on -board
CF selection as shown in Fig. 61.
If the furnace control CPU switches from low- cooling to high -
cooling, the furnace control CPU will energize the air conditioning
relay ACR. When the air conditioning relay ACR is energized the
R -to-YI- and -Y2 circuits switch the outdoor unit to high - cooling
speed, and the R- to- G- and -Y1- and -Y/Y2 circuits transition the
furnace blower motor BLWM to high-cooling airflow. High -
cooling airflow is based on the A/C selection shown in Fig. 61.
NOTE: When transitioning from bow - cooling to high-cooling the
outdoor unit compressor will shut down for 1 minute while the
furnace blower motor BLWM transitions to run at high- cooling
airflow.
The electronic air cleaner terminal EAC- is energized with 115
vac whenever the blower motor BLWM is operating.
When the thermostat is satisfied, the R -to-G- and -Y circuit are
opened. The outdoor unit stops, and the furnace blower BLWM
and electronic air cleaner terminal EAC -t will remain energized
for an additional 90 seconds. Jumper Y1 to DHUM to reduce the
cooling off -delay to 5 seconds. (See Fig. 25.)
c. Two-Stage Thermostat and Two-Speed Cooling
See Fig. 32 for thermostat connections
NOTE: The air conditioning relay disable jumper ACRDJ must
be disconnected to allow thermostat control of the outdoor unit
staging. (See Fig. 25.)
The thermostat closes the R- to-G - and -Y1 circuits for low- cooling
or closes the R-to-G-and-YI-and-Y2 circuits for high - cooling. The
R -to-Y1 circuit starts the outdoor unit on low-cooling speed, and
the R -to-G -and -Y 1 c starts the furnace blower motor BLWM
at low- cooling airflow which is the true on -board CF (continuous
fan) selection as shown in Fig. 61. The R -to-Y1- and -Y2 circuits
start the outdoor unit on high-cooling speed, and the It-to-
G-and-Y/Y2 circuits start the furnace blower motor BLWM at
high - cooling airflow. High - cooling airflow is based on the A/C (air
conditioning) selection shown in Fig. 61.
The electronic air cleaner terminal EAC -1 is energized with 115
vac whenever the blower motor BLWM is operating.
When the thermostat is satisfied, the R -to-G- and -Y1 or R -to-
G -and -Y I- and -Y2 circuits are opened. The outdoor unit stops, and
the furnace blower BLWM and electronic air cleaner terminal
EAC -1 will remain energized for an additional 90 seconds. Jumper
YI to DHUM to reduce the cooling off -delay to 5 seconds. (See
Fig. 25.)
4. Thermidistat Mode
See Fig. 26-29 for thermostat connections
The dehumidification output, DHUM on the Thermidistat
should be connected to the furnace control thermostat terminal
DHUM. When there is a dehumidify demand, the DRUM
input is activated, which means 24 vac signal is removed from
the DHUM input terminal. In other words, the DHUM input
logic is reversed. The DHUM input is turned ON when no
dehumidify demand exists. Once 24 vac is detected by the
furnace control on the DHUM input, the furnace control
operates in Thermidistat mode. If the DHUM input is low for
52
more than 48 hours, the furnace control reverts back to
non- Thermidistat mode.
The cooling operation described in item 3. above also applies
to operation with a Thermidistat. The exceptions are listed
below:
a. Low cooling -When the R-to-G-and-Y 1 circuit is closed
and there is a demand for dehumidification, the furnace
blower motor BLWM will drop the blower airflow to 86
percent of low - cooling airflow which is the true on -board
CF (continuous fan) selection as shown in Fig. 61.
b. High cooling -When the R -to-G -and Y/Y2 circuit is closed
and there is a demand for dehumidification, the furnace
blower motor BLWM will drop the blower airflow to 86
percent of high-cooling airflow. High - cooling airflow is
based on the A/C (air conditioning) selection shown in Fig.
61.
c. Cooling off - delay -When the "call for cooling" is satisfied
and there is a demand for dehumidification, the cooling
blower -off delay is decreased from 90 seconds to 5
seconds.
5. Super - Dehumidify Mode
Super- Dehumidify mode can only be entered if the furnace
control is in the Thermidistat mode and there is a demand for
dehumidification. The cooling operation described in item 3.
above also applies to operation with a Thermidistat. The
exceptions are listed below:
a. When the R -to-YI circuit is closed, R -to-G circuit is open,
and there is a demand for dehumidification, the furnace
blower motor BLWM will drop the blower airflow to 65
percent of low- cooling airflow for a maximum of 10
minutes each cooling cycle or until the R -to-G circuit
closes or the demand for dehumidification is satisfied.
Low-cooling airflow is the true on -board CF (continuous
fan) selection as shown in Fig. 61.
b. When the R- to-Y/Y2 circuit is closed, R -to-G circuit is
open, and them is a demand for dehumidification, the
furnace blower motor BLWM will drop the blower airflow
to 65 percent of high-cooling airflow for a maximum of 10
minutes each cooling cycle or until the R -to-G circuit
closes or the demand for dehumidification is satisfied.
High - cooling airflow is based on the A/C (ar conditioning)
selection shown in Fig. 61.
c. When the "call for cooling" is satisfied and there is a
demand for dehumidification, the cooling blower-off delay
is decreased from 90 seconds to 5 seconds.
6. Continuous Blower Mode
When the R -to-G circuit is closed by the thermostat, the
blower motor BLWM will operate at continuous blower
airflow. Continuous blower airflow selection is initially based
on the CF (continuous fan) selection shown in Fig. 61. Factory
default is shown in Fig. 61. Terminal EAC -I is energized as
long as the blower motor BLWM is energized.
During a call for heat, the furnace control CPU will transition
the blower motor BLWM to continuous blower airflow,
low -heat airflow, or the midrange airflow, whichever is
lowest. The blower motor BLWM will remain ON until the
main burners ignite then shut OFF and remain OFF for the
blower -ON delay (45 seconds in low -heat, and 25 seconds in
high - heat), allowing the furnace heat exchangers to heat up
more quickly, then restarts at the end of the blower -ON delay
period at low -heat or high -heat airflow, respectively.
The blower motor BLWM will revert to continuous - blower
airflow after the heating cycle is completed. In high -heat, the
furnace control CPU will drop the blower motor BLWM to
low -heat airflow during the selected blower -OFF delay period
before transitioning to continuous - blower airflow.
When the thermostat "calls for low- cooling ", the blower motor
BLWM will switch to operate at low- cooling airflow. When
the thermostat is satisfied, the blower motor BLWM will
operate an additional 90 seconds at tow- cooling airflow before
transitioning back to continuous- blower airflow.
When the thermostat 'calls for high - cooling ", the blower
motor BLWM will operate at high cooling airflow. When the
thermostat is satisfied, the blower motor BLWM will operate
an additional 90 seconds at high-cooling airflow before
transitioning back to continuous - blower airflow.
When the R-to-G circuit is opened, the blower motor BLWM
will continue operating for an additional 5 seconds. if no other
function requires blower motor BLWM operation.
Continuous Blower Speed Selection from Thermostat -To
select different continuous - blower airflows from the room
thermostat, momentarily turn off the FAN switch or push-
button on the room thermostat for 1 -3 seconds after the blower
motor BLWM is operating. The furnace control CPU will shift
the continuous - blower airflow from the factory setting to the
next highest CF selection airflow as shown in Fig. 61.
Momentarily coming off the FAN switch again at the thermo-
stat will shift the continuous - blower airflow up one more
increment. If you repeat this procedure enough you will
eventually shift the continuous-blower airflow to the lowest
CF selection as shown in Table 1. The selection can be
changed as many times as desired and is stored in the memory
to be automatically used following a power interruption.
NOTE: if the blower-off delay is set to the maximum. the
adjustable continuous -fan feature is locked (i.e., fan speed cannot
be changed from its current setting).
7. Heat pump
See Fig. 28 -31 for thermostat connections.
When installed with a heat pump, the furnace control auto-
matically changes the timing sequence to avoid long blower
off times during demand defrost cycles. Whenever W/Wl is
energized along with Yt or Y/Y2, the furnace control CPU
will transition to or bring on the blower motor BLWM at
cooling airflow, low -heat airflow, or the midrange airflow,
whichever is lowest. Tire blower motor BLWM will remain on
until the main burners ignite then shut OFF and remain OFF
for 25 seconds before coming back on at heating airflow.
When the W/W 1 input signal disappears, the furnace control
begins a normal inducer post-purge period while changing the
blower airflow. If Y/Y2 input is still energized the furnace
control CPU will transition the blower motor BLWM airflow
to cooling airflow. If Y/Y2 input signal disappears and the Yl
input is still energized the furnace control CPU will transition
53
the blower motor BLWM to low- cooling airflow. If both the
YI and Y/Y2 signals disappear at the same time, the blower
motor BLWM will remain on at low -heat airflow for the
selected Wower -OFF delay period. At the end of the blower -
OFF delay, the blower motor BLWM will shut OFF unless G
is still energized, in which case the blower motor BLWM will
operate at continuous blower airflow.
8. Component test
The furnace features a component test system to help diagnose
a system problem in the case of a component failure. To
initiate the component test procedure, ensure that there are no
thermostat inputs to the control and all time delays have
expired. Turn on setup switch SW 1.6. (See Fig. 25.)
NOTE: The component test feature will not operate if the control
is receiving any thermostat signals or until all time delays have
expired.
The component test sequence is as follows:
a. The furnace control CPU turns the inducer motor ON at
high -heat speed and keeps it ON through step c.
b. After waiting 10 seconds the furnace control CPU turns the
hot surface igniter ON for 15 seconds, then OFF.
c. The furnace control CPU then turns the blower motor
BLWM on at midrange airflow for 15 seconds, then OFF.
d. After shutting the blower motor OFF the furnace control
CPU switches the inducer to low -heat speed for 10 sec-
onds, then OFF.
NOTE: The EAC terminals are energized when the blower is
operating.
After the component test is completed, 1 or more status codes (1l,
25, or 41) will flash. See component test section or Service Label
(Fig. 56.) for explanation of status codes.
NOTE: To repeat component test, turn setup switch SWI.6 to
OFF and then back ON.
Step 4 Wiring Diagram
Refer to wiring diagram Fig. 57.
Step 5 Troubleshooting
Refer to the service label. (See Fig. 56— Service Label.)
The Troubleshooting Guide (See Fig. 62.) can be a useful tool in
isolating furnace operation problems. Beginning with the word
"Star," answer each question and follow the appropriate arrow to
the next item.
The Guide will help to identify the problem or failed component.
After replacing any component, verify correct operation sequence.
A more detailed Troubleshooting Guide is available from your
distributor.
START
Is AMBER LED stag tight on?
YES
1 Is AMBER LED status light blhakg
rankly without • pause
lNo
Is AMBER LED status light blldng DNOFF
slowly with a combnedon of short and
long flashes?
1 YES
Determine status code. TM aatrn cola is
a2 dgt nabw with Me hp d211 deamYwd
by to number of short flashes and Me
awed digit by the number of long Noses?
Go to section below bubo status cola
that was Lashed
yit
NO
Fig. 62— Troubleshooting Gulde - Variable Speed
Cola for °coact Ins voltage polarity.
S units as twinned, check tor proper
kw'coMgs (24V) transformer phasing.
To recall previous slants codes Reconnect
the R thermostat connection. rests powr.
and pa setup witch SW1 -1 in to ON
position. TM AMBER LED eB Sash te
status °odes n.. Of of °ccummo .
Record Neu codes until status code 111
Whws (1 shed and 1 log lseh). Alter Mann
cods all Noshes M stabs codse w1 west.
Sea codas am wand alts 72 Mss or
an be manually erased by porting setup
Balkh SW1.1 in to ON position and
Aarparng R, WNy1, and YH2 snxIwansy
until .stun cods 111 s lashed Warn dose
pt setup switch SW -1 in to OFF position.
Was glove a previous status code Mbar
ten 111?
r
Dose to control reposed to WAY', W2, Y1
WYE and G (24V) t end osat Saha
1 1 „ YES
Run rosin though • IaNwt, hgRhaN,
or cooing cycle to aaa apara nos Sato
codes we rased Mir 72 Maws or an be
manually .rased by pig snip twitch
SWI-1 n to ON position an assuming R.
WMW1. and YW2 Maivaaaly uY Sinn
code St t is WSW.
5
I coos aaut breaker as go back to START Id—
1 Check room thermostat �
t NO
1s 24V present at WWI. W2,21.YN2 or G l
ND tima.at *mina's on Ms lumen* control?
YES
Disconnect et the awmostatt from the
furnace antra.
The twmodtl is not compatible with Me
lumen* cats. Either MAY aWest resistor.
connect 1n* Dam24V thermostat sunhat to
to temaels4 or aaas the mmmnsts
NO
A02108b
i
I
WWII
I 1
i 1 i
loth
olik
f , ow°°° A> al
WM India pin to Waco q Am* AWE
sail
!
ow
mini!
!bilk!
1
1
1
i;J
‘ 11
41
ifl
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weaponf alnelald -
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1 119
*SON «4
W A (p-Sp
wroa
1 a AMU
11 - (AIM SC
uivwsr
x Spro WI
pWOO
din WI S
A Pt
A p4+g711
it 0, 1
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K AMA St
wpo Q•
and pave
101001 NC
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a
k i lin ii
11Hili
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llvv
V
F
A
A
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vu pSUOI An SWAM SS6 W W veto
I 1
i 1 i
loth
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WM India pin to Waco q Am* AWE
sail
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1
1
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55
1
1
t
1
25 INVALID MODEL SELECTION OR
SETUP ERROR — M state code 25 only
fishes s Imes on powar-up the control
Is Miming Its model plug PLA and Is
dsladbq to the model selection Maur
e memory. K seam code 26 flashes
continuously It could Indicate any of the
- Model plug PL4 a Pining and there
is M valid model stored In parmwwe
memory. TN. will happen If you to Install the model plug P1A n forget
wrote replacement control
• ThsnncaM al with SW1•1 ON.
• Thermoset cal with SW1-6 ON.
- SW1 -1 lord SWl -eboth ON.
31 HIGH -HEAT PRESSURE SWITCH OR
RELAY DID NOT CLOSE OR
REOPENED -Check for:
- Crud relay may be detective.
- Gas valve is masked.
• See Makes cods 32.
—►
41 BLOWER MOTOR FAULT —hidden the YES Tern power bark on. b then 115VAC at
blower bled to reach 250 RPM or the P1-145 and PL1•4?
bbrwr bbd to communicate within the
pmeabed Irre belts. TNry seconds
after being tamed ON rtn seconds
during tlrtly asac endkn. Tin power
off and check the following brew Ent
before prowsdeg to te next step.
. Ru60og blower wheel.
• Loon blower wheel.
• Wing from furnace wool to blower
Rene the R thendtat connection
from the Jumada W herd, detained both
connectors from be blower motor P1.13
end P110. Does the blower *had lore
WIMP
4
Replace to Some control modes attached
to the Sower MOM. Follow the Instructions
with the blower =Oral module to male sure
the sore blower motor does not need to be
replaced.
YOU have an Peru w» or bed limiest on the
BLUE wire between the furnace control and
the blower motor.
Replace the furnace aumrd.
£
P40
H Caked • DC voltmeter across P13-4 BLUE
ES (+) Pl32 GREEN leo steps b the wogs
V
NO
P� the voltage fermate a dsntbed a the
YES
Replace the blower Ganef module attached
to the New motor. Fobw the MbudbM
MN the blower coned mixed* to mate van
the rues blower motet does not need to be
replaced.
4
VES
VES
l YES
I Is then 12-VDC MPL137 RED (a) and PL13-
1 GREEN (1?
lN°
VES You haw en open Mm or bad Senn, on
Is there 12-VDC at PL3-1 RED (4 and PL3- I Whales REDr GREEN Mn between the
x GREEN (•)? ' Iwnace control and the blower motor.
4 NO
Replace the furnace cot
Is Owe 5-VDC M PL13-15 YELLOW(?) and
PLl3.1 GREEN (-)?
1
VES
The voltage just reassured should be very
stable and Mond no fluctuate mom than
.02•VDC. the voltage Medusaea more than
this gala different voltmeter been
proceeding.
Turn power of, recaaed P113 and PL14 to
the blower motor. Ivan hen power balk on.
Caber a DC voltmeter raw PL33
YELLOW (+) and P1.3-2 GREEN ( -). Don
the Waage Actuate awe ben It de la the
puWme step?
Ito
Turn power off, disconnect PL13 and PL14
horn the blower molar ben man power bark
on. Creed a DC voltmeter ads PL13-
16 BLUE (a) she PL 3.1 GREEN (4. The
voltage should be near 0-VDC but ft
fluctuate briefly several times • second. 11
you hem an analog vdneerthe needle wB
In • we high several Bess • awed. dgeW wNMbr With bon graph y I tau
wl show a large dung* in nept de on
the bar graph several Imes • second. I you
sow • Stdrd dlybl vabnMr B MI slow
• brief bechuedon a voltage and to
magnitude may wry dapetdng an Iva
solemner used.
`Mu have an open here or bed temmal on
either the BLACK or WHITE poway ea0s
between the hence control and the Screw
motor. 14ou have a power chola deconnect
It and dwch ounnuly.
NO
NO Is them 5-VOC M P13- 3 YELLOW (v) and
PL3•2 GREEN (-)?
VES
You Man open wirer bed learned on the
YELLOW NYe between de fumed control
and the blower molar.
A0210Bc
•
09 -05 -2006
KIYOMI DAMPER
2800 THORNDYKE AV W
SEATTLE WA 98199
RE: Permit No. M06 -085
16049 51 AV S TUKW
Dear Permit Holder:
In reviewing our current records the above noted permit has not received a fmal inspection by the City of Tukwila Building Division..
Per the International Building Code and/or the International Mechanical Code, every permit issued by the Building Division under the
provisions of this code shall expire by limitation and become null and void if the building or work authorized by such permit is not ,
commenced within 180 days from the date of such permit; or, if the building or work authorized by such pennit is suspended or
abandoned at any time after the work is commenced for a period of 180 days.
Based on the above, you are hereby advised to:
Call the City of Tukwila Inspection Request Line at 206 -431 -2451 to schedule for the next or final inspection.
This inspection is intended to determine if substantial work has been accomplished since issuance of the permit or last inspection; or if
the project should be considered abandoned.
If such determination is made, the Building Code does allow the Building Official to approve one or more extensions of time for
additional periods not exceeding 90 days each. Extension requests must be in writing and provide satisfactory reasons why
circumstances beyond the applicants control have prevented action from being taken.
In the event you do not call for the above inspection and receive an extension prior to 10/24/2006, your permit will become null and
void and any further work on the project will require a new permit and associated fees.
Thank you for your cooperation in this matter.
XC:
Permit File No. M06-035
City of Tukwila Steven M. Mullet, Mayor
Department of Community Development Steve Lancaster, Director
6300 Southcenter Boulevard, Suite #100 • Tukwila, Washington 98188 • Phone: 206- 431 -3670 • Fax: 206- 431 -3665