HomeMy WebLinkAboutPermit M06-124 - GARDIPEE RESIDENCEVZI
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Parcel No.: 0042000074
Address: 4414 S 150 ST TUKW
Suite No:
City c r Tukwila
Tenant:
Name: GARDIPEE RESIDENCE
Address: 4414 S 150 ST, 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: MORRIS EDNA M
Address: 4412 S 150TH ST, TUKWILA WA
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:
FURNACE CHANGE OUT.
Value of Mechanical: $4,893.00
Type of Fire Protection: NONE
Furnace: <100K BTU 0
>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
* *continued on next page **
Permit Number:
Issue Date:
Permit Expires On:
Fees Collected: $175.56
International Mechanical Code Edition: 2003
EQUIPMENT TYPE AND QUANTITY
Phone:
Phone: 206 - 378 -6649
Phone: 206 282 -4200
Expiration Date:09 /02/2007
M06 -124
06/13/2006
12/10/2006
Boiler Compressor:
0 -3 HP /100,000 BTU
3 -15 HP /500,000 BTU
15 -30 HP /1,000,000 BTU..
30 -50 HP /1,750,000 BTU..
50+ HP/1,750,000 BTU
Fire Damper
Diffuser
Thermostat
Wood /Gas Stove
Water Heater
Emergency Generator
Other Mechanical Equipment
Steven M. Mullet, Mayor
Steve Lancaster, Director
M06-124 Printed: 06 -13 -2006
Permit Center Authorized Signature:
doc: IMO- Permit
City c r'Tukwila
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
Steven M. Mullet, Mayor
Steve Lancaster, Director
Permit Number: M06-124
Issue Date: 06/13/2006
Permit Expires On: 12/10/2006
m iN Date:
I hereby certify that I have read and examined this permit and know the same to be true and correct. All provisions of law and
ordinances governing this work will be complied with, whether specified herein or not.
The granting of this permit does not presume to give authority to violate or cancel the provisions of any other state or local laws
regulating con ctiionn, o�^rpath ormance of work. I am authorized to sign and obtain this mechanical) permit.
Signature: VI/lfi'ti - Date: (1 43/(7 C
Print Name: LI n Pp / t"t ar 6L I ; ll
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 -124 Printed: 06 -13 -2006
Parcel No.: 0042000074
Address: 4414 S 150 ST TUKW
Suite No:
Tenant: GARDIPEE RESIDENCE
1: ** *BUILDING DEPARTMENT CONDITIONS * **
doc: Conditions
City derukwila
Department of Community Development
6300 Southcenter Boulevard, Suite #100
Tukwila, Washington 98188
Phone: 206 -431 -3670
Fax: 206 - 431 -3665
Web site: et tukwila.wa.us
PERMIT CONDITIONS
4: Manufacturers installation instructions shall be available on the job site at the time of inspection.
* *continued on next page **
Steven M. Mullet, Mayor
Steve Lancaster, Director
Permit Number: M06 -124
Status: ISSUED
Applied Date: 06/13/2006
Issue Date: 06/13/2006
2: 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.
5: Ventilation is required for all new rooms and spaces of new or existing buildings and shall be in conformance with the
International Building Code and the Washington State Ventilation and Indoor Air Quality Code.
6: 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.
7: 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.
8: 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.
9: All plumbing and gas piping work shall be Inspected and approved under a separate permit issued by the Cityof Tukwila
Permit Center.
10: 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).
11: 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 -124 Printed: 06 -13 -2006
I hereby certify that I have read these conditions and will comply with them as outlined. All provisions
governing this work will be complied with, whether specified herein or not.
Signature:
Print Name:
City or/Tukwila
Department of Community Development
6300 Southcenter Boulevard, Suite #100
Tukwila, Washington 98188
Phone: 206 -431 -3670
Fax: 206 -431 -3665
Web site: et.tukwila.wa.us
The granting of this permit does not presume to give authority to violate or cancel the provision of any
regulating construction or the performance of work.
doc: Conditions Mo6-124
Steven M. Mullet, Mayor
Steve Lancaster, Director
of law and ordinances
other work or local laws
Date: ( /l' 0 6
Printed: 06 -13 -2006
Tenant Name:
CITY OF TUKWILA''S
Community Development Department
Public Works Department
Permit Center
6300 Southcenter Blvd., Suite 100
Tukwila, WA 98188
,CONTACT,PERSON
Name: ' / ty�
Mailing Address: � L MO Cetike
Contact Person:
E -Mail Address:
q:Wpamiu pU'icc dI.ag&pam[ a preation (74004)
awhd: 64-05
m
a
Page I
Building Permit No.
Mechanical Permit No.
Public Works Permit
No.
?,ar,lce;vse , n
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 LOCATION.
King Co Assessor's Tax No.: 00V Zak" 7S
Site Address: / W e i S /St 711 fi
Glyn t &,ar-cl /pew
Property Owners Name: Ga trt �i
Mailing Address: S l ro ' - / 774-44.8 774-44.8 p n /4- 4J� L �a v
Suite Number: Floor:
City
New Tenant: ❑ .... Yes ❑ ..No
State Zip
Day Teleph te: 2 66 3 7P 4 & R'
Cc) wt 1
City Slate Zip
E -Mail Address: Fax Number:
Company Name:
Mailing Address:
City State Zip
Contact Person: Day Telephone:
E -Mail Address: Fax Number:
Contractor Registration Number: Expiration Date:
' "An original or notarized copy of current Washington State Contractor License must be presented at the time of permit issuance**
ARCHITECT OF RECORD — All plans must be wet stamped by Architect of Record
Company Name:
Mailing Address:
State
City
Day Telephone:
Fax Number.
Zip
ENGINEER OF RECORD — All plans must be wet stamped by Engineer of Record
Company Name:
Mailing Address:
Zip
State
City
_ _ Contact Person: Day Telephone:
E -Mail Address: Fax Number
FIRE PROTECTION/HAZARDOUS MATERIALS:
D.. Sprinklers ❑ ..Automatic Fire Alarm
q:\tpemia pkis%c elwrga■penae application (14100)
Revised: 64.05
O ON - 206.431 -3670
Valuation of Project (contractor's bid price): $ Existing Building Valuation: $
Scope of Work (please provide detailed information):
Will there be new rack storage? ❑ ..Yes ❑ .. No If "yes ", see Handout No. for requirements.
Provide All Building Areas in Square Footage Below
PLANNING DIVISION:
Single- family building footprint (area of the foundation of all structures, plus any decks ova 18 inches and overhangs greater than 18 inches)
*For an Accessory dwelling, provide the following:
Lot Area (sq It): Floor area of principal dwelling: Floor area for accessory dwelling:
*Provide documentation that shows that the principal owner lives in one of the dwellings as his or her primary residence.
Number of Parking Stalls Provided: Standard: Compact: Handicap:
Will there be a change in use? ❑ ....Yes ❑ ..No If "yes", explain:
❑ ..None ❑ . Other (specify)
Will there be storage or use of flammable, combustible or hazardous materials in the building? ❑ .. Yes ❑ .. No
Ij"yes", attach list of materials and storage locations on a separate 8 -1!1 x /!paper indicating quantities and Material Safety Data Sheets.
Page 2
Existing
Interior
Remodel
Addition to
Existing
Structure
New
Type of
Construction
per IBC
Type of
Occupancy per
IBC
In Floor
Z Floor
- 3' Floor -
Floors thru
Basement
Accessory Structure
Attached
Attached Garage
Detached Garage '
Attached Carport -- - -
Detached Carport
Covered Deck
Uncovered Deck .
FIRE PROTECTION/HAZARDOUS MATERIALS:
D.. Sprinklers ❑ ..Automatic Fire Alarm
q:\tpemia pkis%c elwrga■penae application (14100)
Revised: 64.05
O ON - 206.431 -3670
Valuation of Project (contractor's bid price): $ Existing Building Valuation: $
Scope of Work (please provide detailed information):
Will there be new rack storage? ❑ ..Yes ❑ .. No If "yes ", see Handout No. for requirements.
Provide All Building Areas in Square Footage Below
PLANNING DIVISION:
Single- family building footprint (area of the foundation of all structures, plus any decks ova 18 inches and overhangs greater than 18 inches)
*For an Accessory dwelling, provide the following:
Lot Area (sq It): Floor area of principal dwelling: Floor area for accessory dwelling:
*Provide documentation that shows that the principal owner lives in one of the dwellings as his or her primary residence.
Number of Parking Stalls Provided: Standard: Compact: Handicap:
Will there be a change in use? ❑ ....Yes ❑ ..No If "yes", explain:
❑ ..None ❑ . Other (specify)
Will there be storage or use of flammable, combustible or hazardous materials in the building? ❑ .. Yes ❑ .. No
Ij"yes", attach list of materials and storage locations on a separate 8 -1!1 x /!paper indicating quantities and Material Safety Data Sheets.
Page 2
PUBLIC WORKS PERMIT INF RMATION — 206433-0179
Scope of Work (please provide detailed information):
Please refer to Public Works Bulletin #1 for fees and estimate sheet.
Water District
❑...Tukwila ❑...Water District #125
❑ ...Water Availability Provided
Sewer District
t] ...Tukwila ❑...ValVue ❑.. Renton ❑...Seattle
❑ ...Sewer Use Certificate 0... Sewer Availability Provided ❑ .. Approved Septic Plans Provided
❑...Septic System - For onsite septic system, provide 2 copies of a current septic design approval by King County Health Department.
Submitted with Application (mark boxes which apply):
❑...Civil Plans (Maximum Paper Size -22" x34 ")
❑ ...Technical Information Report (Storm Drainage)
❑ ...Bond ❑ .. Insurance ❑ .. Easement(s)
Proposed Activities (mark boxes that apply):
❑ ...Right -of -way Use - Nonprofit for less than 72 hours
❑ ...Right-of-way Use - No Disturbance
❑ ...Const ruction /Excavation/Fill - Right-of-way
Non Right-of-way
❑ ...Total Cut cubic yards ❑ .. Work in Flood Zone
❑ ...Total Fill cubic yards ❑ .. Storm Drainage
❑...Sanitary Side Sewer ❑
❑ ...Cap or Remove Utilities ❑
❑ ...Fronta Improvements ❑
❑...Traffic Control ❑
❑...Backflow Prevention - Fire Protection
Irrigation
Domestic Water
❑...Permanent Water Meter Size...
❑...Temporary Water Meter Size..
❑ ...Water Only Meter Size
❑...Sewer Main Extension Public _
❑ ...Water Main Extension Public _
(Opmmiu phu4ce dungn`pamit application (7-200
Raised: 64-05
be
Call before you Dig: 1- 800 - 424 -5555
.. Abandon Septic Tank
.. Curb Cut
.. Pavement Cut
.. Looped Fire Line
WO#
WO#
WO#
Private
Private
❑ .. Highline
❑...Renton
❑ .. Geotechnical Report ❑...Traffic Impact Analysis
❑ .. Maintenance Agreement(s) ❑...Hold Harmless
❑ .. Right -of -way Use - Profit for less than 72 hours
❑ .. Right-of-way Use — Potential Disturbance
❑ .. Grease Interceptor
❑ .. Channel nation
❑ .. Trench Excavation
❑ .. Utility Undergrounding
❑...Deduct Water Meter Size
FINANCE INFORMATION
Fire Line Size at Property Line
❑ ...Water ❑...Sewer 0 ...Sewage Treatment
Monthly Service Billing to:
Name:
Mailing Address:
Water Meter Refund/Billing:
Name:
Mailing Address:.
Number of Public Fire Hydrant(s)
City
bay Telephone:
City State rs
Day Telephone:
State
Page 3
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>10OK Bill
_
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 /1,750,000 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
Print Name: L.-IM 124 /
Mailing Address:
q:Upumih *Alec duageatyp,ait apV4ea r. (7-200e)
Revised 6445
sss
MECIANICAI''PERMIT:INFORMATION
MECHANICAL CONTRAgOR INFORM ON
06431:3670
Company Name: l ((q / z 9 j 1 &�
Mailing
Address: !ib � ZY [ k ✓ (" � V �
g c -(t (tick- 9ft99
City State 6 Zip
Contact Person: / M Day Telephone: 2oc' 6 3 7 IL- to c
E -Mail Address:
Contractor Registration Number: WTCV /'! le-./ Q W Expiration Date:
* *An original or notarized copy of current Washington State Contractor License must be presented at the time of permit issuance**
Valuation of Project (contractor's bid price): $ en
Scope of Work (please provide detailed information):
gaJ 4cn4Cce. C2.e. cc!
Use: Residential: New ....0 Replacement
Commercial: New .... ❑ Replacement
Fuel Type: Electric ❑ Gas ...k Other:
Indicate type of mechanical work being installed and the quantity below:
Page 4
City
Fax Number: OC 7 ?6FO 6 00
70, coo @Ai `/
..ERMITaPPLICATION NOTES. = ''Applicable to all permits in this aOlio
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.
BUILDING O R OR A t ' . D -, ENT: J� / /
Signature: till . - Date: C C q[
Day Telephone: � �� 7
c - 9/zr
State
1 Date Application Accepted:
T Date_ Application Expires;
Staff Initials:
ACCOUNT ITEM LIST:
Description
City of Tukwila
6300 Southcenter BL, Suite 100 / Tukwila, WA 98188 / (206) 431 -3670
Parcel No.: 0042000074
Address: 4414 S 150 ST TUKW
Suite No:
Applicant: GARDIPEE RESIDENCE
Receipt No.: R06 -00859 Payment Amount: 175.56
Initials: BLH Payment Date: 06/13/2006 01:34 PM
User ID: ADMIN Balance: $0.00
Payee: WSHINGTON ENERGY SERVICES
TRANSACTION LIST:
Type Method Description Amount
Payment Check 5989 175.56
MECHANICAL - RES
RECEIPT
Account Code Current Pmts
000/322.100 175.56
Permit Number: M06 -124
Status: APPROVED
Applied Date: 06/13/2006
Issue Date:
Total: 175.56
6387 06/13 9716 TOTAL 175.56
doe: Receipt Printed: 06 -13 -2006
Projp ec
i &ntcr
c tf s s
Type of Inspection:
/ 1 =A
Address:
y LO C/
, i 4`f
Date Called:
,.
Special Instructions:
r
a
Date Wa / f !f
E
Requester:
Phone No:
M06 2.-y
INSPECTION NO. PERMIT
CITY OF TUKWILA BUILDING DIVISION
6300 Southcenter Blvd., #100, Tukwila, WA 98188 (2 r 6)
".Qpp oved per applicable codes.
INSPECTION RECORD
Retain a copy with permit
U Corrections required prior to approval.
COMMENTS:
Inspect
' EE REQU
r Blvd., i
P 8.00 REINSPECTION
paid at 6300 Southcent
Receipt No.:
Date:
4,q /I // �t{.6
D. Prior to inspection, fee must be
e 100. Call to sechedule reinspection.
Date:
Variable Speed
Induced - Combustion Deluxe
4 -Way Multiooise Furnace
Cancels: II 315A -70-4 II 315A -70 -5
4-06
Installation, Start -up, Operating, and
Service and Maintenance Instructions
Series 120/C
NOTE: Read the entire instruction manual before starting the
installation.
This symbol —* indicates a change since the last issue.
Portions of the text and tables are reprinted from NFPA 54/ANSI Z223.1- 20060, with
permission of National Fire Protection Association, Quincy. MA 02269 and American
Gas Association, Washington DC 20001. This reprinted material is not the complete
and official position of the NFPA or ANSI on the referenced subject, which is
represented only by the standard in its entirety.
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
Bottom Return Air Inlet 10
Side Return Air Inlet 10
Leveling Legs (If Desired) 10
Downflow Installation 10
Bottom Return Air Inlet 11
Horizontal Installation 11
Suspended Furnace Support 11
Platform Furnace Support 11
Roll -Out Protection 11
Bottom Return Air Inlet 14
Side Return Air Inlet 14
Filter Arrangement 12
Air Ducts 12
General Requirements 12
Ductwork Acoustical Treatment 13
Supply Air Connections 13
Return Air Connections 15
Gas Piping 18
Electrical Connections 19
115 -V Wiring 19
J -Box Relocation 20
Electrical Connection to J -Box 19
G EFFICIE NCY
CERTIFIED
ama
ISO 9001:2000
Power Cord Installation 20
BX Cable Installation 21
24 -V Wiring 21
Accessories 21
Venting 21
General Venting Requirements 24
Masonry Chimney Requirements 29
Appliance Application Requirements 29
Additional Venting Requirements 30
Sidewall Venting 33
START -UP, ADJUSTMENT, AND SAFETY CHECK 33
General 33
Start -Up Procedures 35
Adjustments 36
Check Safety Controls 43
Checklist 43
SERVICE AND MAINTENANCE PROCEDURES 43
Introduction 46
General 46
Electrical Controls and Wiring 46
Care and Maintenance 47
Cleaning and/or Replacing Air Filter 47
Blower Motor and Wheel 48
Cleaning Heat Exchanger 49
Sequence of Operation 50
Wiring Diagrams 54
Troubleshooting 54
Manufacturer reserves the right to discontinue, or change st any time, specifications or designs without notice and without Incurring obligations.
Book
b I 1 6a Ba 4 PC 101 Printed In U.SA. Pg 1 4
la
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 start-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
I. 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.
-3 9. The furnace may be used for construction heat provided that
the furnace installation and operation complies with the first
CAUTION in the LOCATION section of these instructions.
10. These Multipoise Gas -Fired Furnaces are CSA (formerly
A.G.A. and C.G.A.) design-certified for use with natural and
propane gases (see furnace rating plate) and for installation in
alcoves, attics, basements, closets, utility rooms, crawlspaces,
and garages. The furnace is factory- shipped for use with
natural gas. A CSA (A.G.A. and C.G.A.) listed 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.
CDS or CK5 or when Coil Box Part No. KCAKC is used. See
Fig. I for clearance to combustible construction information.
INTRODUCTION
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 COMBUSTBLE CONSTRUCi1N
DISTANCE MINIMALE EN POLICES AUX CONSTRUCTIONS COMBUSTIBLES
Th's broad 0i furnace Is mapped ix tee wth
natural gas atatCdes 0-1040011(0-3050m),
An accessary la suppled by tie
nerulac9rer, stair be used b cravat to propene
gas use a may be required for aces natural gas
The furnace s for indoor Installation In a
building W neaucied m site.
This furnace may be installed m cc busbble
touring In alcove a closet at stun dear me
e
as indicated by Its degram porn coitus/tie
material
The furnace may be used with a Type B-1 Vat
and n be in Wmmcn With other gas
tied appfances.
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24
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comprises at3.D
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m pbrdsrccnbtetble des the POMP w
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qu`adque am Is diagrams.
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model d'e�Pandon de Type B-lwmaai€e
au oondut amen d' sites apparels A gaz.
MINIMUM INCHES CLEARANCE TO COMBUSTIBLE CONSTRUCTION
DOYNFLOW POSMONS:
1- ksbbtion on ncri- comblet>tle bas a%'.
For Irdalabon on aombusbk flooring any when Staled m special base, Pat No. KGA.SB0201ALL,
CPI Assembly, Pat No. CO5 or CK5, or Col Casing, Pal No. KCAKC.
0 18 ides tent dearance required bralom
* kdoares supply or return sides when fleece IS b the hatental positm Lie confect My panSble
between free hired by i!>rseCtiors dbe Top at two Skies kits furnace jade!, at biking jolt,
studs eframing
DtGAGEMENT MINIMUM EN POUCES AVEC ELEMENTS
DE CONSTRUCTION COMBUSTIBLES
POUR LAPOS01ON COURANT DESCENDANT:
t Pour I'%sfalatice as p W der inn mnbusble eaiarat
Parr rw alafim of m Pander Wmbusate saieme tquad on u&e i! base speckle, pike
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* La pdsban kd'puAe wceme Is ode Mantels w de rebu quadd Is burets est dais Is
position 1loriratale.
Le correct nest per's qu'entre l s Ip es bones per bs tiasetllas du dews et des
dew sots de Is demise de Is borate et les flies, natant sous cadre de c aperte.
` 327590 -101 REV. C
Fig. 1 Clearances to Combustibles
3
Fig. 2— Return Air Temperature
MAX80•F
cur
MIN60°F
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
2223.1 -2002 and the installation Standards, Wann Air Heating
and Air Conditioning Systems ANSI/NFPA 9013
• 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
(www.AGA.org.)
• CANADA: NSCNGPIC. For a copy, contact Standard Sales,
CSA International, 178 Rexdale Boulevard, Etobicoke (Tor-
onto), Ontario, M9W 1R3 Canada
Step 9— Combustion and Ventilation Air
• 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 Part 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.
1. Disconnect all power to the furnace. Multiple disconnects may
be required. DO NOT TOUCH THE CONTROL OR ANY
WIRE CONNECTED TO THE CONTROL PRIOR TO 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 SIZE
A
CABINET WIDTH
O
D
SUPPLY -AIR
WIDTH
ON.)
E
RETURN -AIR
WIDTH
(IN.)
F
C.L TOP AND
BOTTOM FLUE COLLAR
(B4.)
FLUE COLLAR*
(IN.)
SHIP WT. (LB)
FILTER MEDIA
CABINET SIZE
(124.)
070. 12/036070
14-3/16
12 -9/16
12 -11 /16
9-5/16
4
127
16
090-16/048090
17-1/2
15.7/6
16
11 -9/16
4
151
16
110. 20/060110
21
19-3/8
19-1/2
13-5/16
4
163
20
135-22/066135
24-1/2
22 -7/8
23
15 -1/16
4T
177
24
155-22/066155
24-1/2
22 -7/8
23
15 -1/16
4T
183
24
26-118'
RUE COLLAR)
Ur DIA
ACCESSORY
5-talr
6
P
25-114'
-
22-9111&
JUNLTIDR BOX\
LOCATiON
I
3-15.16•
NAND ND GAS
ENTRY
25-715
1 DIATNERMOSTAT
WIRE ENTRY
718• DIA ACCESSORY •
21 5/11' -1
BOTTOM INLET
24
CASINO
1-11/16
24-719'
5-1?
Table 1— Dimensions (IN.)
NOTES:
1. Two additional 7/8 -in. diameter holes are located In the top plate.
2. Minimum return-air openings at furnace, based on metal duct. If flex duct is used, see flex duct manufacturer's recommendations for equivalent diameters.
a. For 800 CFM- 16-in. round or 14 1/2 x 12 -in. rectangle.
b. For 1200 CFM- 20-in. round or 141/2 x 19 1/2 -M. rectangle.
c. For 1800 CFM- 22 -In. round or 14 12 x 22 1 /16 -i1. rectangle.
O. For airflow requirements above 1800 CFM, see Air Delivery table In Product Data literature for specific
use of sirglo side Inlets. The use of both side Inlets, a combination of 1 side and the bottom, or the
bottom only will ensure adequate return air openings for airflow requirements above 1800 CFM.
Fig. 3— Dimensional Drawing
A04037
• S or 8' vent connector may be required In some cases.
T5' or larger vent is required. Use a 4-5 or 4-6 inch vent adapter between furnace and vent connector.
7. An ESD service kit (available from commercial sources) may
also be used to prevent ESD damage.
LOCATION
GENERAL
This multipoise furnace is shipped in packaged configuration.
Some assembly and modifications are requited 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 ft above sea level.
Obtain high - altitude conversion kit from your area authorized
distributor.
5
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.
• be provided ample space for servicing and cleaning. Always
comply with minimum fire protection clearances shown on the
furnace clearance to combustible construction label.
THE BLOWER IS LOCATED
TO THE RIGHT OF THE
BURNER SECTION, AND
AIR CONDITIONED AIR IS
DISCHARGED TO THE LEFT
THE BLOWER IS
LOCATED ABOVE THE
BURNER SECTION, AND
CONDITIONED AIR IS
DISCHARGED DOWNWARD
A WARNING
CARBON MONOXIDE POISONING HAZARD
Failure to follow this warning could result in personal injury
or death and unit component damage.
Corrosive or contaminated air may cause failure of parts
containing flue gas, which could leak into the living space.
Air for combustion must not be contaminated by halogen
compounds, which include fluoride, chloride, bromide, and
iodide. These elements can corrode heat exchangers and
shorten furnace life. Air contaminants are found in aerosol
sprays, detergents, bleaches, cleaning solvents, salts, air
fresheners, and other household products. Do not install
furnace in a corrosive or contaminated atmosphere. Make
sure all combustion and circulating air requirements are met,
in addition to all local codes and ordinances.
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 moms, 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-
don:
• Permanent wave solutions
• Chlorinated waxes and cleaners
• Chlorine based swimming pool chemicals
noarsL N
Fig. 4— Multipoise Orientations
• 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.
6
THE BLOWER IS
LOCATED BELOW THE
BURNER SECTION, AND
CONDITIONED AIR IS
DISCHARGED UPWARD.
HORZaat RIGHT
THE BLOWER IS
LOCATED TO THE LEFT
OF THE BURNER SECTION,
AND CONDITIONED AIR IS
DISCHARGED TO THE RIGHT.
A02097
A WARNING
FIRE, INJURY OR DEATH 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 in.
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 NSCNGPIC. (See Fig. 5.)
18-IN. MINIMUM
TO BURNERS
Fig. 5— Installation in a Garage
A93044
A CAUTION
PERSONAL INJURY AND /OR 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 return air to the furnace is maintained
between 55 °F (13 °C) and 80 °F (27 °C), with no evening
setback or shutdown. The use of the furnace while the
structure is under construction is deemed to be intermittent
operation per our installation instructions.
-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.
7
A WARNING
FIRE HAZARD
Failure to follow this warning could result in personal injury,
death and/or property damage.
Do not install the furnace on its back or hang furnace with
control compartment facing downward. Safety control opera-
tion will be adversely affected. Never connect return-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 dampers are manually operated, they must be
equipped with means to prevent operation of either unit unless the
damper is in the full -heat or full-cool position.
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.
FURNACE
INPUT
(BTUH)
TWO HORIZONTAL DUCTS
(1 SO. 1N)2,000 BTUH) (1,100 SO. MMACW)
SINGLE DUCT OR OPENING
(1 SO. IN13,000 BTUH) (734 SO. MMIKW)
TWO OPENINGS OR VERTICAL DUCTS
(1 SO. INJ4,000 BTUH) (550 SO. MMACW)
Free Area of
Opening and Duct
(Sq. In.)
Round Duct
(in. Dia)
Free Area of
Opening and Duct
(sq In.)
Round Duct
(in Dia)
Free Area of
Opening and Duct
(Sq In.)
Round Duct
(In. Dia)
44,000
22
6
14.7
5
11
4
66,000
33
7
22
6
16.5
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
8
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
16,500
19,800
23,100
0.00
NP
NP
NP
NP
NP
NP
NP
NP
NP
FURNACE
110,000
66,000
68,000
NP . Not Permitted
Table 2- Minimum Free Area Required for Each Combustion Air Open ng or Duct to Outdoors
EXAMPLES: Determining Free Area
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)
= 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
Table 3- Minimum Space Volumes for 100% Combustion, Ventilation, and
Dilution from indoors
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 least 50 cubic feet per 1,000 Btuh may use the
INDOOR COMBUSTION AIR, STANDARD or KNOWN -
AIR INFILTRATION METHOD.
Outdoor Combustion Air Method
1. Provide the space with sufficient air for proper combustion,
ventilation, and dilution of flue gases using permanent hori-
8
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 / 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 4,00D 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. 1 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
b. Not less than the sum of the areas of all vent connectors in
the space.
*Minimum dmensions of 3 in.
NOTE: Use any of the following
combinations of openings:
A &B C &D D&E F &G
A03174
Fig. 7 —Air for Combustion, Ventilation, and
Dilution for Outdoors
The opening shall commence within 12" (300 mm) of the ceiling.
Appliances in the space shall have clearances of at least I" (25
mm) from the sides and back and 6" (150 mm) from the front. The
opening shall directly communicate with the outdoors or shall
communicate through a vertical or horizontal duct to the outdoors
or spaces (crawl or attic) that freely communicate with the
outdoors.
Indoor Combustion 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 follow this warning could result in death and/or
personal injury.
Many homes require air to be supplied from outdoors for
furnace combustion, ventilation, and dilution of flue gases.
The furnace combustion air supply must be provided in
accordance with this instruction manual.
The Standard Method:
1. The space has no less volume than 50 cubic feet per 1,000
Btuh of the maximum input ratings for all gas appliances
installed in the space and
2. The air infiltration rate is not known to be less than 0.40 air
changes per hour (ACH).
The Known Air Infiltration Rate Method shall be used, if the
infiltration rate is known to be:
9
CIRCULATING AIR
DUCTS
INTERIOR
HEATED
SPACE
CIRCULATING AIR DUCTS
n
21 any I
volume _ A H 000 Btu hr
2. For fan assisted appliances such as this furnace:
1 5ft I tan V lume Fen ACH 1000 Btu/hr
VENT THROUGH ROOF
cc
12' 1.4AX
F FY t IN.
c° m - PER 1000
c BTUH' IN DOOR
OR WALL
UNCONFINED
SPACE
6' MIN
(FRONT)',
I SO IN.
cw ® PER 1000
0 - = BTUH• IN DOOR
e OR WALL
12' MM
Minimum opening size is 100 sq in. with
minimum dimensions of 3 in.
Minimum of 3 in. when type -B1 vent is used.
A03175
Fig. 8—Air for Combustion, Ventilation, and
Dilution from indoors
I. Less than 0.40 ACH and
2. Equal to or greater than 0.10 ACH
Infiltration rates greater than 0.60 ACH shall not be used. The
minimum required volume of the space varies with the number of
ACH and shall be determined per Table 3 or Equations 1 and 2.
Determine the minimum required volume for each appliance in the
space and add the volumes together to get the total minimum
required volume for the space.
Table 3- Minimum Space Volumes were determined by using the
following equations from the National Fuel Gas Code ANSI
2223.1 2002/NFPA 54 2002,8.3.2.2:
I. For other than fan - assisted appliances, such as a draft
hood-equipped water heater:
If:
= combined input of all other than fan- assisted appli-
ances in Bmlhr
= combined input of all fan - assisted appliances in Btu/hr
ACH = air changes per hour (ACH shall not exceed 0.60.)
A04002
A04003
The following requirements apply to the Standard Method and to
the Known Air Infiltration Rate Method.
1. Adjoining rooms can be considered part of a space if:
a. There are no closable doors between rooms.
b. Combining spaces on same floor level. Each opening shall
have free area of at least 1 in 2 /1,000 Btuh (2,000 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 mm) of the ceiling and the
second opening shall commence within 12" (300 mm) of
the floor. The minimum dimension of air openings shall be
at least 3 in. (80 mm). (See Fig. 8.)
c. Combining space on different floor levels. The volumes of
spaces on different floor levels shall be considered as
communicating spaces if connected by one or more perma-
nent openings in doors or floors having free area of at least
2 in 2 /1,000 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. /4,000 Btuh of total input rating for
all gas appliances in the space.
3. In spaces that use the Indoor Combustion Air Method,
infiltration should be adequate to provide air for combustion,
permanent ventilation and dilution of flue gases. However, in
buildings with unusually tight construction, additional air
MUST be provided using the methods described in the
Outdoor Combustion Air Method section.
Unusually tight construction is defined as
Construction with:
a. Walls and ceilings exposed to the outdoors have a 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 I minus the
Ratio in a. above.
c. Minimum size of Outdoor openings shall be the size
required in Outdoor Combustion Mr Method above
multiplied by Suction Factor in b. above. The minimum
dimension of air openings shall be not less than 3 in. (80
mm).
10
INSTALLATION
UPFLOW INSTALLATION
Bottom Return Air Inlet
These furnaces are shipped with bottom closure panel installed in
bottom retum-air opening. Remove and discard this panel when
bottom return air is used. To remove bottom closure panel,
perform the following:
1. Tilt or raise furnace and remove 2 screws holding bottom filler
panel. (See Fig. 9.)
2. Rotate bottom filler panel downward to release holding tabs.
3. Remove bottom closure panel.
4. Reinstall bottom filler panel and screws.
Side Return Air Inlet
These furnaces are shipped with bottom closure panel installed in
bottom return-air opening. This panel MUST be in place when
only side return air is used.
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.
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 I 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
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:
Fig. 10 —Level ng Legs
• Special Base, KGASB
• Cased Coil Assembly Part No. CD5 or CK5
• 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. CD5 or CK5 or Coil Box Part
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
reamers to bend flange back and forth until it breaks off. Be careful
of sharp edges. (See Fig. 14.)
Bottom Return Air Inlet
These furnaces are shipped with bottom closure panel installed in
bottom return-air opening. Remove and discard this panel when
bottom return air is used. To remove bottom closure panel,
perform the following:
1. Tilt or raise furnace and remove 2 screws holding bottom filler
panel. (See Fig. 9.)
2. Rotate bottom filler panel downward to release holding tabs.
3. Remove bottom closure panel.
4. Reinstall bottom filler panel and screws.
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.)
A02071 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 Ye-in. screws
in the bottom of the furnace casing for each strap. (See Fig. 15 and
16.)
If the screws are attached to ONLY the furnace sides and not the
bottom, the straps must be vertical against the furnace sides and
not pull away from the furnace sides, so that the strap attachment
screws are not in tension (are loaded in shear) for reliable support.
Platform Furnace Support
11
HORIZONTAL INSTALLATION
A WARNING
FIRE, EXPLOSION, AND CARBON MONOXIDE POI-
SONING HAZARD
Failure to follow this warning could result in personal injury,
death, or property damage.
Do not install the furnace on its back or hang furnace with
control compartment facing downward. Safety control opera-
tion will be adversely affected. Never connect return-air ducts
to the back of the furnace.
Construct working 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 non -combustible
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
roll-out 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.
Bottom Return Air Inlet
These furnaces are shipped with bottom closure panel installed in
bottom return-air opening. Remove and discard this panel when
bottom return air is used. To remove bottom closure panel,
perform the following:
1. Tilt or raise furnace and remove 2 screws holding bottom filler
panel. (See Fig. 9.)
2. Rotate bottom filler panel downward to release holding tabs.
3. Remove bottom closure panel.
4. Reinstall bottom filler panel and screws.
Side Return Air Inlet
These furnaces are shipped with bottom closure panel installed in
bottom return-air opening. This panel MUST be in place when side
return air inlet(s) are used without a bottom return air inlet.
4
A
PLENUM
OPENING
B A
FLOOR
OPENING
C
D
•
./
/J •
Fig. 11 —Floor and Plenum Opening Dimensions 83
Not all horizontal furnaces we approved for side return air
connections (See Fig. 20.)
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.
FURNACE
CD5 OR CK5
COIL ASSEMBLY
OR KCAKC
COIL BOX
COMBUSTIBLE
FLOORING
SHEET METAL
PLENUM
FLOOR
OPENING
Fig. 13—Furnace Plenum, and Coll Assembly or Coil
Box installed on a Combustible Floor
12
A
A04140
FURNACE
(OR COIL CAS
WHEN USED)
COMBUSTIBLE
FLOORING
DOWNFLOW
SUBBASE
_ SHEET METAL
PLENUM
FLOOR
OPENING
Fig. 12— Furnace, Plenum, and Subbase installer on
a Combustible Floor
A04140
This furnace is shipped with a factory- supplied Media Filter
Cabinet. The Media Filter Cabinet uses either a factory- supplied
standard 1 -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
FURNACE
CASING
WIDTH
APPLICATION
PLENUM OPENING
FLOOR OPENING
A
B
C
D
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 -9/16
19
13 -3/16
19-5/8
Downflow applications on combustible flooring (KGASB
subbase required)
11 -13/16
19
13- 7/16
20-5/8
Downflow Applications on Combustible Flooring with CD5 or
CK5 Coil Assembly or KCAKC coil box (KGASB subbase
not required)
12 -5/16
19
13- 5/16
20
17 -12
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
16-1/2
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 Coil 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 Coil Assembly or KCAKC coil box (KGASB subbase
not required)
19
19
20
20
24-12
Upflow Applications on Combustible or Noncombustible
Flooring (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
CK5 Coil Assembly or KCAKC coil box (KGASB subbase
not required)
22-1/2
19
23-1/2
20
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 bather 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 alternative, fibrous ductwork may
be used if constructed and installed in accordance with the latest
Table 4 — Opening Dimensions (In.)
13
edition of SMACNA construction standard on fibrous glass ducts.
Both acoustical lining and fibrous ductwork shall comply with
NFPA 90B as tested by UL Standard 181 for Class 1 Rigid air
ducts.
Supply Air Connections
For a furnace not equipped with a cooling coil, the outlet duct shall
be provided with a removable access panel. This opening shall be
accessible when the furnace is installed and shall be of such a size
that the heat exchanger can be viewed for possible openings using
light assistance or a probe can be inserted for sampling the air
stream. The cover attachment shall prevent leaks.
Upflow and Horizontal Furnaces
Connect supply -air duct to flanges on furnace supply -air outlet.
Bend flange upward to 90° with wide duct pliers. (See Fig. 14.)
The supply -air duct must be connected to ONLY the furnace
supply-outlet-air duct flanges or air conditioning coil casing (when
used). DO NOT cut main furnace casing side to attach supply air
duct, humidifier, or other accessories. All accessories MUST be
connected to duct external to furnace main casing.
NOTE: For horizontal applications, the top most flange may be
bent past 90 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
120'
MN
UPFLOW DOWNFLOW
4' MIN FOR DOOR
REMOVAL
PREFERRED
PREFERRED
PERMITTED PERMITTED
(2) HEX NUTS, (2) WASHERS & (2) LOCK WASHERS
REO. PER ROD
Fig. 14 —Duct Flanges
Fig. 15— Horizontal Unit Suspension
14
PREFERRED
PREFERRED 120
MIN
HORIZONTAL
'A' THREADED ROD
/4RED.
V SQUARE, 1 x tv: x VC ANGLE IRON
OR UNI -STRUT MAY BE USED
PREFERRED
PREFERRED
PERMITTED
SECURE ANGLE
IRON TO BOTTOM
OF FURNACE WITH
3*8 x Ve SCREWS
TYPICAL FOR 2 SUPPORTS
A02329
A02345
SEDIMENT
TRAP
OUTER DOOR
ASSEMBLY
NR OPENING
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.
Fig. 16— Horizontal Suspension with Straps
EQUIPMENT MANUAL
SHUT -OFF GAS VALVE
UNION
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, KGASB0201ALL, or a factory
approved air conditioning coil casing. DO NOT cut main furnace
casing to attach supply side air duct, humidifier, or other accesso-
ries. All accessories MUST be connected to duct external to
furnace casing.
15
22 GAUGE GALVANIZED
STRAPS TYPICAL
FOR 4 STRAPS
Fig. 17 Typical Attic Installation
METHOD 1
FOLD ALL STRAPS UNDER
FURNACE AND SECURE WTH
M 18. 3/4 SHEET METAL SCREWS
(2 SCREWS IN SCE AND 2 SCREWS
IN BOTTOM).
Return Air Connections
A WARNING
FIRE HAZARD
A failure to follow this warning could cause personal injury,
death and/or property damage.
Never connect return-air ducts to the back of the furnace.
Follow instructions below.
Downflow Furnaces
AIR
OPENING
BACK OF
FURNACE
30-IN. MIN
WORK AREA
METMOp2
USE IA) 15. 14 SHEET
METAL SCREWS FOR EACH
STRAP. THE STRAPS
SHOULD BE VERTICAL
AGAINST THE FURNACE
BIDES AND NOT PULL AWAY
FROM THE FURNACE
SIDES.
17 NC OVER ALL
4 3/4" UNDER DOOR
1 "UNDER FURNACE
EXTEND OUT 12" OUT
FROM FACE OF DOOR
WHEN USED WITH
SINGLE WALL VENT
CONNECTIONS
A03176
A03177
UP FLOW RETURN AIR CONFIGURATIONS AND RESTRICTIONS
AIR FLOW MODELS RETURN MR RETURN AIR RETURN MR RETURN MR
CONNECTION I CONNECTION 2 CONNECTION3 COMBINATIONS
ONLY ONLY ONLY OF 2. AND
066.060, -22 AND YES YES YES YES
.20 MODELS
ALL OTHER MODELS YES YES YES YES
Fig. 18— Upfiow Return Alr Configurations and Restrictions
Fig. 19— Downfiow Return Air Configurations and Restrictions
1
9a
x=�
1111111
1111111
1111111
1111111_4
N
HORIZONTAL RETURN MR CONFIGURATIONS AND RESTRICTIONS
MA ROW MODELS
RETURN MR RETURN NR RETURN AIR RETURN AR
CONNECTION CO DECTION 2 CONNECTION 3 COM9RMpNS
ONLY ONLY ONLY OF I.2 MO
060.880. -22 AIL)
.20 MODELS
YES
No No
ALL OTHER MODELS YES YES YES YES
Fig. 20— Horizontal Return Air Configurations and Restrictions
16
A02075
A02163
A02162
FURNACE
SIZE
Operating Mode
CFM Airflow
Setting
External Static
Pressure Range
EXTERNAL STATIC PRESSURE (In. we)**
0.1 0.2 0.3 0.4 0.5 0.6 1 0.7 1 0.8 I 0.9 I 1.0
036070
AIRFLOW (CFM)
tt
Low Heat
735 (615)f
0 -0.5
735
735
735
735
725
High Heat
1180 (1060)1
0 -1.0
1180
1165
1175
1180
1180
1180 i 1180 1 1180 i 1180 i 1175
tt
1 -1/2 Tons Coding
525
0 -0.54
525
525
525
525
510
tt
2 Tons Cooling
700
0 -0.54
700
700
700
695
685
2 -1/2 Tons Coding
875
0 -1.04
875
875
875
875
875
875
865
855
845
840
3 Tons Cooling
1050
0 -1.04
1050
1050
1050
1050
1050
1050
1050
1050
1045
1035
3-1/2 Tons Cooling
1225
0 -1.0
1205
1215
1225
1225
1225
1225
1225
1225
1225
1210
Maximum
1400
0 -1.0
1395
1400
1400
1400
1400
1400
1400
1385
1360
1310
048090
Low Heat
985 (825)t
0 -1.0
950
970
985
985
985
985
985
985
985
980
High Heat
1210(1090)4
0 -1.0
1190
1205
1210
1210
1210
1210
1210
1210
1210
1200
tt
1 -1/2 Tons Coding
525
0- 0.54
525
525
525
525
500
tt
2 Tons Cooling
700
0 -054
690
695
700
700
690
2 -1/2 Tons Coding
875
0- 1.04
830
855
875
875
875
875
870
865
850
820
3 Tons Coding
1050
0 -1.04
1005
1025
1040
1050
1050
1050
1050
1050
1050
1050
3.1/2 Tons Cooling
1225
0 -1.04
1205
1220
1215
1225
1225
1225
1225
1225
1225
1220
4 Tons Cooling
1400
0 -1.0
1370
1385
1395
1400
1400
1400
1400
1400
1400
1380
Maximum
1600
0 -1.0
1565
1580
1585
1595
1600
1800
1560
1520
1480
1430
060110"'
Low Heat
1320 (1110)t
0 -1.0
1275
1295
1315
1320
1320
1320
1320
1320
1320
1315
High Heat
1475 (1330)}
0 -1.0
1480
1485
1475
1475
1475
1475
1475
1475
1485
1465
if
2 Tons Cooling
700
0- 0.54
700
700
700
685
860
It
2 -1/2 Tons Cooling
875
0- 0.54
860
875
865
855
840
tt
3Tons Cooling
1050
0 -0.54
1050
1050
1045
1050
1050
3-1/2 Tons Cooling
1225
0 -1.04
1185
1195
1215
1225
1225
1225
1225
1225
1225
1225
4 Tons Cooling
1400
0 -1.04
1385
1395
1400
1400
1400
1400
1400
1400
1400
1400
5 Tons Cooling
1750
0 -1.04
1710
1730
1745
1745
1750
1750
1750
1750
1745
1740
6 Tons Coding
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
2155
2130
2085
2015
066135
Low Heat
1700 (1430)4
0 -1.0
1700
1700
1700
1700
1700
1695
1700
1695
1685
1870
High Heat
1915 (1725)t
0 -1.0
1900
1905
1915
1915
1915
1915
1915
1915
1915
1915
tt
2Tons Cooling
700
0- 0.54
700
700
700
700
665
tt
2 -1/2 Tons Cooling
875
0 -0.54
870
870
865
865
865
tt
3Tons Cooling
1050
0 -0.54
1010
1030
1050
1050
1050
3.1/2 Tons Coding
1225
0 -1.04
1155
1180
1200
1210
1220
1225
1225
1225
1225
1225
4 Tons Cooling
1400
0 -1.04
1395
1400
1400
1400
1400
1400
1400
1390
1375
1355
5 Tons Cooling
1750
0 -1.04
1740
1750
1750
1750
1735
1740
1735
1730
1715
1700
S Tons Cooling
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
086155
Low Heat
1715 (1440)4
0 -1.0
1715
1715
1715
1715
1715
1705
1710
1705
1705
1895
High Heat
1970 (1775)1
0 -1.0
1955
1965
1965
1970
1970
1970
1970
1970
1970
1960
tt
2 Tons Cooling
700
0 -0.54
700
700
700
700
680
tt
2.1/2 Tons Coding
875
0- 0.54
865
875
875
865
865
ft
3Tons Cooling
1050
0 -0.54
1015
1020
1035
1045
1050
3-112 Tons Cooling
1225
0 -1.04
1180
1185
1215
1225
1225
1225
1225
1225
1225
1225
4 Tons Cooling
1400
0 -1.04
1385
1400
1400
1400
1400
1400
1395
1395
1380
1360
5 Tons Coding
1750
0 - 1.04
1745
1750
1750
1750
1745
1740
1745
1745
1740
1735
6 Tons Cooling
2100
0 -1.0
2055
2070
2080
2085
2095
2100
2100
2100
2090
2065
Maximum
2200
0 -1.0
2175
2190
2200
2200
2200
2200
2200
2200
2180
2160
t
4
tt
Table 5-Air Delivery - CFM (With Filter)*
Actual ddemal static pressure (ESP) can be determined by using the fan laws (CFM proportional to ESP); such as a
system with heating airflow of 1180 CFM at 0.5 ESP would operate at cooling airflow of 1050 CFM at 0.4 ESP and low- heating
airflow of 735 CFM at 0.19 ESP.
A filter Is required for each retumair connection to the fumace. Airflow performance Includes r washable filter media such as
contained N factory accessory biter recto To determine airflow performance without this filter, assume an additional 0.1'
available external static pressure.
'Comfort mode' airflow values are shown in (parenthesis). 'Comfort mode' airflow Is selected when the low -heat rise
adjustment switch (SW1 -3) is OFF and the comfort/efficiency switch (SW1-4) S ON. Furnaces are shipped In this configuration.
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 cooling ESP for this system.
Operation within the blank areas of the chart Is not recommended because high -heat airflow will be above 1.0 ESP.
All airflows on 110 size furnace are 5% less on side return only Installations.
17
A04016
NOMINAL
IRON
PIPE
INTERNAL
DIAMETER
LENGTH OF PIPE (FT)
10
20
30
40
50
SIZE
(IN.)
(W4
1/2
0.622
175
120
97
82
73
3/4
0.824
360
250
200
170
151
1
1.049
680
465
375
320
285
1 -114
1.380
1400
950
770
660
580
1 -112
1.610
2100
1460
1180
990
900
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
Failure to follow this warning could result in personal injury,
death, and/or property damage.
Never purge a gas line into a combustion chamber. Never test
for gas leaks with an open flame. Use a commercially
available soap solution made specifically for the detection of
leaks to check all connections.
A 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 follow this warning could result in personal injury,
death, and/or property damage.
Gas valve inlet and/or inlet pipe must remain capped until gas
supply line is permanently installed to protect the valve from
moisture and debris. Also, install a sediment trap in the gas
supply piping at the inlet to the gas valve.
Gas piping must be installed in accordance with national and Iota
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.
18
Table 6— Maximum Capacity of Pipe*
• Cubic ft of natural gas per hr for gas pressures of 0.5 psig 4-in. wc) or less
and a pressure drop of 0.5-in wc (based on a 0.60 specific gravity gas).
Ref: Table 12.2 ANSI 2223- 2002/NFPA 54-2002.
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.
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 psig (14 -in. wc) stated
on gas control valve. (See Fig. 53.)
Some installations require gas entry on right side of furnace (as
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.
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. wc), turn off electric shutoff switch located on furnace gas
TOP VIEW OF BURNER AND MANIFOLD ASSEMBLY
Fig. 21a —Right 90' Side E aww Gas Entry Example tosoza
2' Nipple
Street Elbow
Gas Valve
Fig. 21b —Right Side Gas Entry Example 2
GAS
SUPPLY
MANUAL
SHUTOFF
VALVE
(REQUIRED
SEDIMENT
TRAP
UNION
Fig. 21c — Typical Gas Pipe Arrangement
A02327
A02035
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.
19
ELECTRICAL CONNECTIONS
A WARNING
ELECTRICAL SHOCK HAZARD
Failure to follow this warning could result in personal injury
or death.
Blower access panel door switch opens 1I5 -v power to
control. No component operation can occur. Do not bypass or
close switch with panel removed.
See Fig. 24 for field wiring diagram showing typical field 115 -v
wiring. Check all factory and field electrical connections for
tightness.
Field - supplied wiring shall conform with the limitations of 63 °F
(33 °C) rise.
A WARNING
ELECTRICAL SHOCK AND FIRE HAZARD
Failure to follow this warning could result in personal injury,
death, or property damage.
The cabinet MUST have an uninterrupted or unbroken ground
according to 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 intermitent
furnace operation.
Furnace control must be grounded for proper operation or else
control will lock out. Control must remain grounded through
green/yellow wire routed to gas valve and manifold bracket
screw.
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) ANSI/NFPA 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 to follow this warning could result in personal injury,
death, or property damage.
Do not connect aluminum wire between disconnect switch
and furnace. Use only copper wire.
Use a separate, fused branch electrical circuit with a properly sized
fuse or circuit breaker for this furnace. See Table 7 for wire size
and fuse specifications. A readily accessible means of electrical
disconnect must be located within sight of the furnace.
FURNACE SIZE
VOLTS-
HERTZ-
PHASE
OPERATING
VOLTAGE RANGE
MAXIMUM
UNIT AMPS
UNIT
AMPACITVa
MAXIMUM
WIRE LENGTH (
MAXIMUM
FUSE OR CKT BKR
AMPSf
MINIMUM
WIRE GAUGE
Maximum*
Minimum*
070. 121036070
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 limits of the voltage range at which the unit operates satisfactorily.
# Unit ameacltv -125 percent of lamest operating comoonenrs full load arras plus 100 cement of alt other potential aoeraana components' fEAC. humidifier. etc] full load
Table 7- Electrical Data
amps.
1 Time -delay type Is recommended.
4 Length shown is as measured 1 way along wire path between furnace and service panel for maximum 2 percent voltage drop.
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 J -Box shall not be
relocated to other side of furnace casing when the vent pipe is
routed within the casing.
I. Remove and save two screws holding J -Box. (See Fig. 22.)
NOTE: The 1 -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.
2. Cut wire tie on loop in furnace wires attached to J -Box.
3. Move 1 -Box to desired location.
4. Fasten J -Box to casing with the two screws removed in Step
1.
5. Route 1 -Box wires within furnace away from sharp edges,
rotating parts and hot surfaces.
ELECTRICAL CONNECTION TO J -BOX
Field- Supplied Electrical Box on Furnace 1 -Box Bracket
See Fig. 24.
1. Remove cover from furnace .1-Box.
2. Attach electrical box to furnace 1 -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.
20
Fig. 22 Relocating J - Box
TWO
ALTERNATE
FIELD
LOCATION
A02099
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.
I. Select and remove a hole knockout in the casing where the
electrical box is to be installed.
NOTE- Check that duct on side of furnace will not interfere with
installed electrical box.
2. Remove the desired electrical box hole knockout and position
the hole in the electrical box over the hole in the furnace
casing.
3. Fasten the electrical box to casing by driving two field -
supplied screws from inside electrical box into casing steel.
4. Remove and save two screws holding J -Box. (See Fig. 22.)
5. Pull furnace power wires out of l2 -inch diameter hole in
1 -Box. Do not loosen wires from strain -relief wire -tie on
outside of J -Box.
6. Route furnace power wires through holes in casing and
electrical box and into electrical box.
7. Pull field power wires into electrical box.
8. Remove cover from furnace 1-Box.
9. Route field ground wire through holes in electrical box and
casing, and into furnace J -Box.
Fig. 23— Field - Supplied Electrical Box on
Furnace Casing
10. Reattach furnace 1 -Box to furnace casing with screws re-
moved in Step 4.
I I. Secure field ground wire to I -Box green ground screw.
12. Complete electrical box wiring and installation. Connect line
voltage leads as shown in Fig. 24. Use best practices (NEC in
U.S. 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.
I. Remove cover from 1 -Box.
2. Route listed power cord through 7/8 -inch diameter hole in
1 -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.
21
6. Reinstall cover to 1 -Box. Do not pinch wires between cover
and bracket.
BX CABLE INSTALLATION IN FURNACE J -BOX
I. Remove cover from 1 -Box.
2. Route BX cable into 7/8 -inch diameter hole in 1 -Box.
3. Secure BX cable to 1-Box bracket with connectors approved
for the type of cable used.
4. Secure field ground wire to green ground screw on 1 -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.
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
required, use ONLY a 3 -amp fuse of identical size.
ACCESSORIES
I. Electronic Air Cleaner (EAC)
Connect an accessory Electronic Air Cleaner (if used) using
1 /4 -in female quick connect terminals to the two male I /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
Cost -24V screw terminal on the control board thermostat strip.
The HUM terminal is energized when blower is energized in
heating. (See Fig. 25.)
NOTE: DO NOT connect furnace control HUM terminal to HUM
(humidifier) terminal on Thermidistat, Zone Controller or similiar
device. See ThermidistatTM, Zone Controller, thermostat, or con-
troller manufacturer's instructions for proper connection.
VENTING
The furnace shall be connected to a listed factory built chimney or
vent, or a clay -file lined masonry or concrete chimney. Venting
into an unlined masonry chimney or concrete chimney is prohib-
ited.
When an existing Category I furnace is removed or replaced, the
original venting system, may no longer be sized to properly vent
the attached appliances. An improperly sized Category I venting
system could cause the formation of condensate in the furnace and
vent, leakage of condensate and combustion products, and spillage
of combustion products into the living space.
115-VOLT FIELD -
SUPPLIED
FUSED
DISCONNECT
FIVE
WIRE
THREE -WIRE
HEATING -
ONLY
I
JUNCTION
BOX
CONTROL
BOX
FURNACE
24 -VOLT
TERMINAL
BLOCK
NOTE 2
Ippp
22
� r
I I I
PIE -- i 1 i
+,
I I I
NOTE 1
1-STAGE
THERMOSTAT
TERMINALS
Fig. 24 —Field Wiring Diagram
- - -- FIELD 24-VOLT WIRING
- - -- FIELD 115 -, 208/230-, 460 -VOLT WIRING
— FACTORY 24 -VOLT WIRING
— FACTORY 115 -VOLT WIRING
CONDENSING
UNIT
FIELD - SUPPLIED
FUSED DISCONNECT
1208/
230-
460 -VOLT
THREE
PHASE
VOLT
- - SINGLE
- - PHASE
NOTES: 1. Connect Y/Y2- terminal as shown for proper operation.
2. Some thermostats require a'C terminal connection as shown.
3. If any of the original wire, as supplied, must be replaced, use
same type or equivalent wire.
A95236
MODEL PLUG
CONNECTOR
SW1 SETUP
SWITCHES AND
BLOWER OFF -
DELAY
24-V THERMOSTAT
TERMINALS
STATUS AND COMM -----
LED LIGHTS
3-AMP FUSE
TRANSFORMER 24-VAC
CONNECTIONS
COMMUNICATION CONTINUOUS FAN
(CF) AIRFLOW
SETUP SWITCHES
CONNECTOR
AIR CONDITIONING
(A/C) AIRFLOW
SETUP SWITCHES " "" " "" • ,[ HUMIDIFIER
TERMINAL (24 -VAC
0.5 AMP MAX.
PL1 - LOW VOLTAGE MAIN
HARNESS CONNECTOR
115 -VAC (L2) NEUTRAL v EAC-1 TERMINAL
(11
CONNECTIONS 5 -VAC 1.0 AMP MAX.)
23
FUTURE
APPLICATIONS
115 -VAC (L1) LINE
VOLTAGE CONNECTIONS
Fig. 25— Variable Speed Furnace Control for ECM Blower Motor
ACRDJ - AIR
CONDITIONING
RELAY DISABLE
JUMPER
1:).
FLASH
UPGRADE
CONNECTOR
(FACTORY
ONLY)
PL3 - ECM BLOWER
HARNESS
CONNECTOR
PL2 - HOT SURFACE
IGNITER & INDUCER
MOTOR CONNECTOR
A02018
A WARNING
CARBON MONOXIDE POISONING HAZARD
Failure to follow the steps outlined below for each appliance
connected to the venting system being placed into operation
could result in carbon monoxide poisoning or death.
The following steps shall be followed for each appliance
connected to the venting system being placed into operation,
while all other appliances connected to the venting system are
not in operation:
1. Seal any unused openings in venting system.
2. Inspect the venting system for proper size and horizontal
pitch, as required in the National Fuel Gas Code, ANSI
Z223.1- 2002/NFPA 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.
S. If improper venting is observed during any of the above
tests, the venting system must be corrected in accordance
with the National Fuel Gas Code, ANSI Z223.1-
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. Vent
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 Z223.1- 2002NFPA 54.2002 (NFGC), Parts 10
and 13 in the United States or the National Standard of Canada,
Natural Gas 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' instructions.
These furnaces are design - certified as Category I furnaces in
accordance with ANSI 221.47- 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.
24
THERMIDISTAT
NOTE 11
TWO-STAGE SINGLE-SPEED
FURNACE AIR CONDITIONER
l W2
Y1
4 s I
P in
1
. R
1DHUMI
4 F,
0 HUM
1 HUMIDIFIER
y (74 VAC)
See notes 2, 5, 7, 10, and 11
A00275
Fig. 26—Two -Stage Furnace with Single -Speed
Air Conditioner
The following information and warning must be considered in
addition to the requirements defined in the NFGC or the NSCNG-
PIC.
A WARNING
CARBON MONOXIDE POISONING HAZARD
Failure to follow this warning could result in personal injury
or death.
Do not bypass the draft safeguard switch, as an unsafe
condition could exist which must be corrected.
1. If a vent (common or dedicated) becomes blocked, the furnace
will be shut off by the draft safeguard switch located on the
vent elbow.
2. Two-stage furnaces require Type B vent connectors outside
the casing in all configurations. Single wall vent connector
may be used inside the furnace casing with the transition to
Type B vent outside the furnace casing. Size the connector so
that the FAN -Min vent connector capacity is equal to or lower
than the low fire rate of the furnace and the FAN -Max vent
connector capacity is equal to or higher than the furnace high
fire rate.
3. Do not vent this Category I furnace into a single wall
dedicated or common vent. The dedicated or common vent is
considered to be the vertical portion of the vent system that
terminates outdoors.
4. Vent connectors serving Category I furnaces shall not be
connected into any portion of a mechanical draft system
operating under positive pressure.
5. 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
COOL STAGE 7 IxvW2 }.
HEAT STAGE 7
COOL STAGE 2 I Pa I..
FAN I G } .
24 VAC HOT
DEHUMIDIFY
24 VAC COMM I }.
HUMIDIFY
N/A
Or=
w&L1
a
S7
SENSOR O
OUTDOOR I }
CONNECTION I S2 I.
NOTE 11
NOTE 12
iWOSTAGE
FURNACE MR CONDITIONER
lia
_I Y1
WI1
.I Ya2 }' -
0
.I DHUMI
4
ij HUM
I HUMIDIFIER
(24 VAC)
See notes 2, 5, 8,10,11 and 12
on the page following these figures
THERMIDISTAT
TWO-SPEED
A03179
Fig. 27— Two-Stage Furnace with Two-Speed
Air Conditioner
RVS COOLING
HEAT/COOL STAGE 1
(COMPRESSOR LO)
HEAT STAGE 3
(FURNACE)
HEAT/COOL STAGE 2
(COWRESSOR HO
FAN
24 VAC HOT
DEHUMIDIFY
24 VAC COMM
HUMIDIFY
WA
a
NOTE 12
RVS COOLING I�
HEAT STAGE 3 �
(FURNACEN9
HEAT STAGE r
2 I
�
(FURNACE LO)
HEAT/COOL STAGE II
(COMrPESBOR)
FAN If
24 VAC HOT
DEHUMIDIFY
24 VAC COMM I---
HUMIDIFY
N/A
V1r7Q12
DRUM
a
OUTDOOR
SENSOR I �
CONNECTION I f
25
THERMIDISTAT
Fig. 28—Two-Stage Furnace with Single- Spee
Heat Pump (Dual Fuel)
TWO-STAGE TWO-SPEED
FURNACE HEAT PUMP
HUMIDIFIER
(24 VAC)
EFLI OUTDOOR
SENSOR
a
See notes 1.2, 3.4, 4 8, 9.10.12, 138nd 15
on the page following these S W rm
NOTE 11 )
7WOSTAGE SINGLE-SPEED
FURNACE HEAT PUMP
wW1
0
$ DHUMI
0 HUM
HUMIDIFIER
(24 VAC)
See �� o ovAng figures
15
Fig. 29— Two-Stage Furnace with Two-Speed Heat Pump (Dual Fuel)
A03178
DUAL FUEL
THERMOSTAT
RVS COOLING M.
HEAT STAGE 3
(FURNACE NI)
HEAT STAGE 2
(FURNACE LO)
HEAT/COOL STAGE 1 M.
(CoMwE9SOS)
FAN Imo,
24 VAC HOT II
24 VAC COMM
N/A
RVS SENSING
Q
0
OUTDOOR S1
SENSOR
CONNECTION
WILL FUEL
THERMOSTAT
RVS COOLING I T
HEAT/COOL STAGE 1 M.
(COMPRESSOR 10)
HEAT STAGE 3
/FURNACE)
HEAT/COOL STAGE 2 M.
(COMPRESSOR NR
FAN
24 VAC HOT
24 VAC COMM M.
N/A
RVS SENSING
OUTDOOR C.
SENSOR
CONNECTION r82
a
0
NOTE 11
NOTE 12
TWO-STAGE
FURNACE
fa
a
0
03
DHUM
HUM
OUTDOOR I
SENSOR r
See 110181 on e.� gInes* 18
Fig. 30—Dual Fuel Thermostat with Two -Stage 181
Furnace and Single -Speed Heat Pump
TWO-STAGE
FURNACE
O
1 ' r
CHUM
EDf
0 HUM
OUTDOOR
SENSOR
1 I
See �1 I. R
SINGLE-SPEED
HEAT PUMP
TWO-SPEED
HEAT PUMP
A03182
Fig. 31 —Dual Fuel Thermostat with Two-Stage
Furnace and Two-Speed Heat Pump
26
TWO-STAGE
THERMOSTAT
a
W W1
0
0
SINGLE-STAGE
THERMOSTAT
NOTE 11
NOTE 12
TWO-STAGE
FURNACE
TWO-SPEED
AIR CONDITIONER
See notes 2. 11, and 2 on the
Page following these figures
Fig. 32— Two -Stage Thermostat with Two -Stag 183
Furnace and Two-Speed Air Conditioner
TWO-STAGE
FURNACE
TWO-SPEED
AIR CONDITIONER
See notes 1 and 2 on the page
INbMng these figures A03184
Fig. 33—Single-Stage Thermostat with
Two-Stage Furnace and Two-Speed Alr Conditioner
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. I on Thermidistat should be set in OFF position for air conditioner installations. This is factory default.
6. Dip switch No. I 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.
I1. Optional connection: If wire is connected, dip switch SW1 -2 on furnace control should be set in ON position to allow
Thermidistat/Thermostat to control furnace staging.
12. Optional connection: If wire is connected, ACRDJ jumper on furnace control should be removed to allow Thermidistat/Thermostat to
control outdoor unit staging.
13. Furnace must control its own high -stage heating operation via furnace control algorithm.
14. The RVS Sensing terminal "L" should not be connected. This is internally used to sense defrost operation.
15. DO NOT SELECT the "FURNACE INTERFACE" or "BALANCE POINT' option on the two-speed heat pump control board. This is
controlled internally by the Thermidistat/Dual Fuel Thermostat.
16. Dip switch D on Dual Fuel Thermostat should be set in OFF position for single -speed compressor operation. This is factory default.
17. Dip switch D on Dual Fuel Thermostat should be set in ON position for two-speed compressor operation.
27
CHIMNEY INSPECTION CHART
For additional requirements refer to the National Fuel Gas Code NFPA 54 /ANSI Z223.1 and ANSI/NFPA 211
Chimneys, Fireplaces Vents, and Solid Fuel Burning Appliances in the U.S.A. or to the Canadian
installation Code CSA- B149.1 in Canada.
Debris
In cleanout?
Mortar, tile, metal vent,
fuel oil residue?
Mortar
or tile
debris?
Is chimney
lined with properly
sized, listed finer or
Type -B vent?
Remove metal vent
or liner.
Reline
Yes Remove mortar
and tile debris
Suitable
Rebuild
Fig. 34— Chimney Inspection Chart
28
Not Suitable
unable
Line chimney with property
sized, list ed flexible metal
liner or Type -B vent per
NFGC or NSCNGPIC Vent
Sizing Tables and liner or
vent manufacturers
Installation Instructions.
A03206
VENT HEIGHT (FT)
INTERNAL
12
AREA
(SO
19
OF CHIMNEY
IN.)
26
38
6
74
119
178
257
8
80
130
193
279
10
84
138
207
299
15
NR
152
233
334
20
NR
NR
250
368
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 condition.
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 required, 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 KGACA02014FC 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:
I. 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)fining. 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.
29
b. Indicates the chimney exceeds the maximum permissible
size in the tables, the chimney should be rebuilt or relined
to conform to the requirements of the equipment being
installed and the authority having jurisdiction.
A chimney without a clay tile liner, which is otherwise in good
condition, shall be rebuilt to conform to ANSI/NFPA 211 or be
lined with a UL listed (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 -Wall Vent
Connectors aIFPA & AGA
Table A —Combined 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
beating 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 J); 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 in the furnace and vent system, the
following precautions must be observed:
I. 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. Denting 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
LL 8
52
74
111
154
R 10
NR
90
125
169
s 15
NR
NR
167
212
r
20
NR
NR
212
258
30
NR
NR
NR
382
I anal MAL Wln,a lMelnn
8
NR
78
121
166
LL 8
NR
94
135
182
10
NR
111
149
198
2 15
NR
NR
193
247
1p 20
NR
NR
NR
293
30
NR
NR
NR
377
8
NR
NR
145
196
LL 8
NR
NR
159
213
10
NR
NR
175
231
o
0 15
NR
NR
NR
283
' 20
NR
NR
NR
333
30
NR
NR
NR
NR
Table B— Minimum Alowable Input Rating of
Space - Heating Appliance In
Thousands of BTU per Hour
VENT INTERNAL AREA OF CHIMNEY
HEIGHT (FT) (SO. IN.)
12 I 19 I 28
Local 99% Winter Design
Temperature: 17 to 26 degrees P
I as
Temperature: 5 to 18 degrees P
Local 99% Winter Design
Temperature: -10 to 4 degrees P
Local 99% Winter Design
Temperature: -11 degrees F or lower
Not recommended for any vent
configuration
- The 99% WIMer Design Dry-Both (db) temperatures are found in the 1993
ASHRAE Fundamentals Handbook, Chapter 24, Table 1 (United States) and
2 (Canada), or use the 99.6% heating db temperatures found In the 1997 or
2001 ASHRAE Fundamentals Handbook, Climatic Design Information chap -
ter, Table lA (United States) end 2A (Canada).
Air 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 constriction of the building could cause the
furnace to be exposed to halogen compounds, causing premature
failure of the furnace or venting system due to corrosion.
Vent dampers on any appliance connected to the common vent can
cause condensation and corrosion in the venting system. Do not
use vent dampers on appliances common vented with this furnace.
ADDITIONAL VENTING REQUIREMENTS
A C round vent elbow is supplied with the furnace. A 5 -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.
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
30
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.
I. 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 KGAFEOI12UPH 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 3547.
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.
3. Orient the door to determine the correct location of the doo
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 1-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 corner of the desired knockout. (See
Fig. 52.) Remove any burrs 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.
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.
See the following instruction.
An accessory Vent Guard Kit, KGAVGOI01DFG 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.
SEE NOTES: 12,3,4,78,9
on the pages following
these figures
SEE NOTES: 1,2,4,7,8,9
on Maims following
these ngures
A03208
Fig. 35— Upflow Application -Vent Elbow Up
A03209
Fig. 36— Upflow ApplIcation -Vent Elbow Right
SEE NOTES:12,3,4,5,78,9
on the page following
these fguures
Fig. 37—Downflow Application -
Vent Elbow Up then Left
31
eel
SEE NOTES: 1,2,4.5,7,8,9
on the page following
these figures
A03211
Fig. 38— Downflow Application -Vent Elbow Up
SEE NOTES: 1,2,4,5,8,7,8,9,10
on the page following these figures
Fig. 39— Downflow Application -
Vent Elbow Left then Up
A03207
SEE NOTES:12,3,4,5,7,8 9
on the page following
these figures.
A03210 A03212
Fig. 40— Downflow Application -
Vent Elbow Up then Right
SEE NOTES: 2,4,7,8, on the page
following these figures
A03213
Fig. 41— Horizontal Left Application -Vent Elbow Left
SEE NOTES: 1,2,4,5,7,8,9 on the page
following these figures
Flg. 42— Horizontal Lett Application -
Vent Elbow Right then Up
A03214
SEE NOTES: 1,2,4,7,8,9 on the page
following these figures
Fig. 45—Horizontal Right Application -
Vent Elbow Right
A03218
Fig. 43— Horizontal Left Application -Vent Elbowlp
SEE NOTES: ,2,4,5,7,8,9 on the page
following these figures A03216
Fig. 44— Horizontal Left Application -Vent Elbow Right
32
SEE NOTES: ,2,4,5,7 8,9
Fig. 47— Horizontal Right Application -Vent Elbow Left
SEE NOTES: ,2,4,5,7,8,9 on the page
following these figures
SEE NOTES: 12,48,7,8,9 on the page
folmMn9 these figures
Fig. 46— Horizontal Right Application -
Vent Elbow Left then Up
A03219
A02088
FURNACE ORIENTATION
VENT ORIENTATION
FURNACE INPUT(BTU/HR)
VENT Y DIAM ETE R INIMUM (IN4•
MINIMUM VERTICAL VENT HEIGHT ((Fir
Downflow
Vent elbow lea, then up
Fig. 37
154,000
132,000
110,000(036/-12 only)
5
12
Horizontal Left
Vent ebow right,
then up
Fig. 40
154,000
132,000
5
7
Horizontal Left
Vent Elbow up
Fig. 41
154,000
192,000
5
7
Horizontal Left
Vent show right
Fig. 42
154,000
5
7
Downflow
Vent elbow up then !eft
Fig. 35
110,000
(0361 -12 only)
5
10
Downflow
Vent elbow up, then right
Fig. 38
110,000
(036/ -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: All vent configurations must also meet National Fuel Gas Code venting requirements NFGC.
•4 in. inside casing or vent guard
— Including 4 lei. vent section(s)
Venting Notes for Fig. 35-47
I. 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 details.
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 rate 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.)
The horizontal portion of the venting system shall slope upwards
not less than 1 /4-in. per linear ft (21 mm/m) from the furnace to the
vent and shall be rigidly supported every 5 ft 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.
33
START -UP, ADJUSTMENT, AND SAFETY CHECK
Step 1— General
A WARNING
FIRE HAZARD
Failure to follow this warning could result in personal injury,
death or property damage.
This furnace is equipped with manual reset limit switches in
the gas control area The switches open and shut off power to
the gas valve, if a flame rollout or overheating condition
occurs in the gas control area DO NOT bypass the switches.
Correct 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
Fig. 49— Rounded End of Knockout
4. Check all manual -reset switches for continuity.
Fig. 48 —Using Tin Sn ps to Cut Tie Points
A04128
A04129
Fig. 50— Knockout Pulled Loose
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).
A CAUTION
CUT HAZARD
Failure to follow this caution may result in personal injury.
Sheet metal parts may have sharp edges or burs. Use care and
wear appropriate protective clothing, safety glasses and
gloves when handling parts, and servicing furnaces.
34
Fig. 51— Hammer and Screwdriver Used for
Knockout
Fig. 52— Remove Knockout with Hammer
A04127
A04130
A04131
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.)
OWOFF SWITCH
1E NPT INLET
WLET
PRESSURE TAP
t? NPT OUTLET
a -••-- REGULATOR OOdES SOREN
PLASTIC ADJUST SCREW
® W — REGULATOR SPRING
HIGH STAGE GAS
PRESSURE REGULATOR
ADJUSTMENT
MANIFOLD
PRESSURE TAP
LOW STAGE
GAS PRESSURE
REGULATOR ADJUSTMENT
A04167
Fig. 53— Redundant Automatic Gas Control Valve
Fig. 54— Orifice Hole
10 TURNS
EXAMPLE: 5.0 AMPS ON AMMETER
10 TURNS AROUND JAWS
BURNER
ORIFICE
THERMOSTAT SUBBASE
TERMINALS WITH
THERMOSTAT REMOVED
(ANITICIPATOR, CLOCK, ETC.,
MUST BE OUT OF CIRCUIT.)
HOOK- AROUND
AMMETER
FROM UNIT 24-V
CONTROL TERMINALS
0.5 AMPS FOR THERMOSTAT
ANTICIPATOR SETTING
Fig. 55—Amp Draw Check With Ammeter
A93059
A96316
35
Step 2— Start-Up Procedures
A WARNING
FIRE AND EXPLOSION HAZARD
Failure to follow this warning could cause personal injury,
death or property damage.
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
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 S W 1-6 OFF,
then back ON
4. Turn setup DIP switch SW1 6 OFF. Reconnect R lead to
furnace control board, release blower door switch and reinstall
blower access door.
5. Operate furnace per instruction on inner door.
6. Verify furnace shut down by lowering thermostat setting
below room temperature.
7. Verify furnace restarts by raising thermostat setting above
room temperature.
LED CODE STATUS
C N1NWUS OFF- Che ek for 116VAC MO ed U. 4b 21VAC r SECA 4b SEC-2
CONTINUOUS ON -Cots hat 24VAC pawn
RAPID FLASHING -We • • 116VAC •.'..tly intend
•
M
— — —
SERVICE
nyse.mY.ess dm.Wnw01r.seylent
needed net poenadd setup win %Wl-rinew
Todrtentin WM9Mn• I.YSCH
ppmWtlbv�� mYllovptsap pu#n NKoper Mennen YnrYWSC.
WWr. *W VVTOnMSW1* Y M1 I
WI . mW1 Is Rohn
• .n. • T.. • V i.l
11 �n IXVI0FUy4dt(eOdDE Wan roles se nee aYw.eeaFVMMR
12 SLOWE R ON AFIERPOWERUP (115 VAC a 24 VAC) newer erne a 90
seconds Yank M ered up W let Mtl -WAVI dosed) or
13 LIMMT CIRCUIT inn. -Land oan I a '1* [NM FO4p4N,54ns
.oboe a 505.0 vent mach (I v..d)Y ape lager tun 3 Mottles or 10
P.®iw WM 1. p. mud noun NV.1y.L GOy wit W reset yid
kw hon. Refer to ts one ql
14 IGNITION LOCKOUT -Cored ea ...Ioant An three lopes. Rider b you
code #34
15 BLOWER MOTOR LOCKOUT - Woos the blower Wed ninth 250 RPM or
Se Moen lead to a— n.v. .ylin 30 womb a being bled ON Ii Iwo
4.oamiw heev� aides. Cairns ova !Klemm( On 3 born.
le statue 21 O S HEATING LOCKOUT MM -Caked .B NOT mat rent C1 foe
-MS-wired des nye cession mad (Nee nay )
22 ABNORMAL FLARE•ROVING SIGNAL -Fame a proved while pee wen•
Mws .Nl Syi H.yase�agWw w then br:
23 PRE .d S �n ' ..d ID M F SSWIITTaCeH L g M O p 1gTCPEN Cad. b:
24 SECONDARY VOLTAGE FUSE I S -Possum N Cwd. M Short &d.L In emamy
- . gCnind
25 INVRID�MOOEL SECECTIONORSf1W ERROR - Winne enter the model
plio Y .¢nsl a..MpwLd.5W1- 1•a5WI,YpyporNO
seledg. I ebt. nn o,ow.thwf b - �i cal with SPIN -1. SW1 O
bh. SW1 -1 t SW1-0 ON. - Board dale code 2103 or Mier required to cognize min
nba HIF 7. T pmee E o� .tnLS .d LAY m b DO lev v ow pvMnrq din's"
31 IYGA PRE SWrTCH OR PE N CLOSE OR
„St
33
41
45
. - rc•b. . - ., .,. .y.
Caa dMYM b84rnlebe • ••• La..YpMU.�w m*I.CC11
- OFYe.. poseurs palls. - hqy Hypo preens "Vetoed)
-Low ironer 116 VIL
LMT CIRCUIT FAULT ical.i emit A MR or
poked e ewedI 2 used 4 selsp ine el
( ( l w hen i Mew M n bee
del nbdedeb2mwloeMimi lope Slaver W.u.M1
nines a. Mt open Henn remakes ninny is boee n open Mont
en 3 antt m6 cermae to ofd H3. Stepan Ins ben 3 minutes
choirs code 1133 mnens b mall at blower nub do. Flame non switch
and BUSS require nen .coy. Cleo Inc -Lams Mawr wheel
-Restricted rent - Proper SP sizing - Emme mid.ay.uetlbn
Met cc cartuelion Sr wan (Rn. IOW rowan open)
PROVING FAILURE -Conn Mt n nee more then Wore
MW &14 mon. Mew Yon MY dente e Mont many pyaq Mower Check tor
Orbs endue a. Owen seneo blower den.M Pm steel .ml)
Rape tone chide mantra (S niauoY DC Mn.. 40- &a nailed/
Gnwibdyeelireabna an -Fan tenor -CatSm not be grounded
a..— Owen -had off -Me. -CaamDmM gn
ele ° zgr 0 I°p.
BLOWER MOT OR MUST bemn.ecYdbNnen MM mode
Who Sower Mod to FAULT - Wien ihe blower Med to north 230 RPIA
o nn.ti Me within to prescribed a.es Y4. Den
sewn yid Wry Land ON In
b PRFCSIIRE
.. ..
or semW myien.
LOW -EAT PRESSURE 8001T04 OPEN VMIL
SWITCH IS CLOSED -CI * -W.itd peuun nines M LOPSUM) ges pressure
• DSw..eded pretended pr a lung Hy
CONTROL CBICUtRV LOCKOUT Aisio set after ow hoer bNM due lot
p . s t dsY =rats once
32 OW E DID NOT CL� REOPENED ED :If open
luum Nun cow Mdn. Wooer nuke all b 15 Mattes bone Sty.. Totes
0.d
`- .g Mower Check for E
dFd Mowero . de: - Nn M .., - on Br t seM ded Sower -Proper vent
• E.m en wi nW Ss dnNrMwen wide
Allows 2 -stage operation with a single stage thermostat.
Turn ON when using opera -
tlon when R to W/VV1 doses and High Heat operation vMen R to
SW1-3
SETUP
SWITCH NO.
SWITCH
NAME
NORMAL
POSmON
DESCRIPTION
SW1 -1
Status Code Recovery
OFF
Turn ON to retrieve up to 7 stored status coles for looting
assistance when
SW1 -2
Adaptive Heat Mode
OFF
Allows 2 -stage operation with a single stage thermostat.
Turn ON when using opera -
tlon when R to W/VV1 doses and High Heat operation vMen R to
SW1-3
Low Heat
Rise Adjust
OFF
Turn ON to Increase Knpen-
sates for Increased return air temperature caused with bypass hu-
SWl•4
ComtorVEffiolency Adjustment
ON
Turn ON to decrease 1h Heat
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 Sell -Test
OFF
Turn ON to Initiate Component Self-Test for troubleshooting assis-
lance when R thermostat lead is disconnected.
Turn OFF when Sell -Test is completed.
SW1-7
Blower OFF delay
ON or OFF
Control blower Off Delay time. Used in conjunction with SW 1-8. See
Table 10.
SWI-S
Blower OFF delay
ON or OFF
Control blower Ott Delay time. Used in conjunction with SW1 -7. See
Table 10.
Table B— Furnace Setup Switch Description
Step 3— Adjustments
A WARNING
FIRE HAZARD
Failure to follow this warning could result in injury, death
and/or property damage.
DO NOT bottom out gas valve regulator adjusting screw.
This can result in unregulated manifold pressure and result in
excess overfire and heat exchanger failures.
Fig. 56 Label
36
A04015
A CAUTION
FURNACE DAMAGE HAZARD
Failure to follow this caution may result in reduced furnace
life.
DO NOT redrill orifices. Improper drilling (buns, 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 altitudes
up to 2000 ft. Furnace input rate must be within ±2 percent of
furnace rating plate input. For altitudes above 5500 ft., a field -
supplied high altitude pressure switch is requited.
1. Determine the correct gas input rate.
In the USA.:
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
a
i:6
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CU 700 075 1050 1128 lICE 17501 2100
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NOTE #3
R4 - MOOR PLUG CHART
ac
CONNECTION L AGRAM
30
GRN
R3
4
R1
Deoe�0U0oaoe000e0
I NC Conditioning (Aquae tile Mow e bw -CFM)
• ACR Ak Cadnig Relay. SPST (N 0.)
ACRDI As COdwnftg l Relay°deathlper
• &WM Beaver Meta (ECM)
• BUSS Blacked in Sefey&.ron. Memel Reset.
N SPST (HC)
CF CaMuoa Fan wiAalatie Aifpx CYM)
D COMMA Caanalceria Racy SPCA
CPU Mcfgxoceaa 7 Cavity
DHLM DiIIRA Connection (24VAC 002 Amps)
D% Pa11Safeguad 5w.. Auto-Reset 5751 (N.C.) '
MCI DsNaic N Cleaner Connection
(115VAC 1.0 Amp Met.)
EAC.2 Electron N Cleaner Connection (Common)
FRS Flame Rnlau Seth. Man. Reset, S SI(N C )
FSE Femefdeng Sensor Ekrtrode
FUSE Fuse, 3 Amp. Autalnawe Blade Type
' Fa L seed
GV Gas s Lake
GVR Gas Valve Relay.OPSt KO.)
)
HPS H4gti.Het Pressure Mh, assue SM 51 04
HPSR High-Heat Rmae Seidl Relay, SPST (N C.)
Hp It place kJrte C)
MIR It Surface Igniter Relay, Relay, (N. D)
MUM 24VAC Humidifier Connection (0.5 Amp Man)
MUMR IMml60er Relay, n (NO.)
IOM Incecer Raft Mda. a. 2.S peed Shaded Pole
IDR haler Meta Relay. SPAT (N.02
R IIdESQCMgg Seell
FLU
:AXIS.
AIRROW SELECION CHART NOSED ON 350 CFM/ION
RI
'WA 2. Default cart Ian adomwen CE watches are In QF Roston
MICE)
00.1.1
to
142 Y1 DMA G Can WAYI YM R STATUS
n
CODE
In
mu
IN Mower Door Interlock Swans, SPST (NO.)
ND Muck: (Note 17)
LED Light Emitting Diode for Saws Codes
LGPS Low Gas Pressure Salton. SPST (NO )
LPS Lawlieat Pawn Seth SKI (N.0)
151,2 Net Stack Hato --Remy SPST (N.C.)
PCB Riled Crc,l Board
PL1 12.CkcuA Connecter
PI2 4Lrcuk HSI & IDM Connecta
R3 4Lkoa[CM &WM Connector
11.4 4.ChultModel Tag Connector
R7 4-Cirak Cammricatan Connecta
R9 2-Ciag ON Connecta
R10 2GcutH9Calnecta
P1.11 IOM Convector (3 -Circuit)
R12 1Licui Letter Spice Connector
P113 16LkcuE ECM Blower Ctrl Connector
R14 5 -Crca ECM Blower Pave Connecta
Sal -1 Manual SvAch. Sera Code Rttnp. SPAT (NO.)
SWI.2 Manual Snitch. LowHeet Ony. SPSI(N0.)
SW1.3 Manua Sefob. Low.Heat Rto Ad. SFST (HO.)
SW1-4 Manua Swatch. Comfort/Efficiency Anygmem
WSJ (NO)
SW1.5 Manual Smith. Cooing CFM/Ton, SPST (N.01
SWI-O Manual Smtcfl. Component lest 5K1 (NO.)
SW1 -7,8 ManuelS itches. Blown ORtDelay, SPSI(N.O.)
5W4 -I Manual Switch, Twnmg Main (OFF) / Sec. (ON)
5W4 -2 &3 FOR FUNNE USE
1F ii1R a mi m
0
11
-F UNCTION
O TERMINAL
_ COfMRCA TERMINAL
FACTORY POWER
`MENG (115VAC)
FACTORY CONTROL
IMWNG (24VAC)
HELD COMAE%
WIPING (24VAC)
CONDUCTOR ON
CONTROL
HELD WIPING
SCREW IE
n h EQUIPMENT
GROUND
( h PLUG RECEPTACLE
TO 115VAC REID pSCONECT SWITCH
I
mate /77
PCB
NDTEM
Rt -1
SCFEM411C DIAGRAM 1
1. 0 any dale alga/ egipmaR tire Is replaced tae are rated for 105t.
2. Use only toper ere beaten the bsaanaet %Meh at the Bnaoep real boa
3. Ns ate nom bewraeded to aaon furnace a sheet metal la sacra to Rama
ara
4. Syfrdds eedemral epr0realbnady.
G SSpo�liIer PCB are draft board arla[as and arena lndN a tl lewd. clay Path a 3
7. Indslta isused saN 3/ Epp and 1 hp EON Bats Indas.
& Oda cwaeced Man (LGPS) roused.
9. Bw.e al delay, gas hmaq sltain are (99 120, 150. 190) seconds. cooing a Moat plan
90serm6 or 5 seconds Mal della/idly call is active.
70. IgiUa i thatMB scar after farcanecise amlaess/a Per green Cetdei
atadeEa alter tree haa5.
11. Induce/ max (TOME manna Yiatbl anlese dent) wsead salten
12. Way =netted Men BUSS is net used. BV55 used Men CNmlley Maier Accessary Kiln
rmaled.
It A n y at the 5*es shawl Minnie NEUTRAL 12 bar c a n be c o n n e c t e d a a n y d walin the bar.
Fig. 57- Wiring Diagram
A04014
328782-101 MLA
ALTITUDE
(FT)
PERCENT
OF DERATE
DERATE MULTIPLIER
FACTOR'
0-2000
0
1.00
2001- 3000
8-12
0.90
3001 -4000
12 -16
0.86
4001 -6000
16-20
0.82
5001 -8000
20-24
0.78
6001 -7000
24-28
0.74
7001-8000
28-32
0.70
8001 -9000
32-36
0.66
9001- 10,000
36-40
0.62
DESIRED HEATING MODE
BLOWER OFF DELAY (SEC.)
SETUP SWITCH (SW 7 AND 4) POSNION
SW1 -7
SW1-8
90
OFF
OFF
120
ON
OFF
150
OFF
ON
180
ON
ON
Table 9- Altitude Derate Multiplier for U.S.A.
• Derate multiplier factors are based on midpoint altitude for altitude range.
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 derate multiplier factor.
EXAMPLE:
88,000 BTUH INPUT 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 Btuh per burner.)
See input listed on rating plate.
a. Obtain average yearly gas heat value (at installed altitude)
from local gas supplier.
b. Obtain average yearly gas specific gravity from local gas
supplier.
c. Find installation altitude in Table 12 or 13.
d. Find closest natural gas heat value and specific gravity in
Table 12 or 13.
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.
Table 10 Slower Off Delay Setup Switch
38
EXAMPLE 2: (0 -2000 ft altitude)
For 22,000 Btuh per burner application use Table 12.
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. we for low -heat
• Furnace is shipped with No. 43 orifices. In this example
all main burner orifices ate 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 tap.
d. Turn gas valve ON /OFF switch to ON.
e. Move setup SW1 -2 on furnace control to ON position to
lock furnace in low -heat operation. (See Table 8 and Fig.
25.)
f. Manually close blower door switch.
g. Jumper R and W/W 1 thermostat connections on control to
start furnace. (See Fig. 25.)
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: DO NOT set low -heat manifold pressure less than 1.4 -in
wc or more than 1.7 -in. wc 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 redrilled, check orifice hole with a numbered drill bit of
correct size. Never redrill an orifice. A burr -free and squarely
aligned orifice hole is essential for proper flame characteristics.
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.
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
more accurate measurement of gas flow.
d. Refer to Table 11 for cubic ft of gas per hr.
e. Multiply gas rate cu ft/hr by heating value (Btu/cu ft) to
obtain input.
If clocked rate does not match required input from Step 1,
increase manifold pressure to increase input or decrease
manifold pressure to decrease input. Repeat steps b through
e until correct low -heat input is achieved. Re- install low -
heat regulator seal cap on gas valve.
5. Set low heat temperature rise.
The furnace must operate within the temperature rise ranges
SECONDS
FOR 1
REVOLtRION
SIZE OF TEST DIAL
SECONDS
FOR 1
REVOLUTION
SIZE OF TEST DIAL
1
Cu Ft
2
Cu Ft
5
Cu Ft
1
Cu Ft
2
Cu Ft
5
Cu Ft
10
360
720
1800
50
72
144
380
11
327
655
1636
51
71
141
355
12
300
800
1500
52
69
138
346
13
277
565
1385
53
68
136
340
14
257
514
1286
54
87
133
333
15
240
480
1200
55
65
131
327
16
225
450
1125
58
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
360
900
60
80
120
300
21
171
343
857
62
58
118
290
22
164
327
818
84
56
112
281
23
157
313
783
68
54
109
273
24
150
300
750
68
53
108
265
25
144
288
720
70
51
103
257
26
138
277
692
72
50
100
250
27
133
287
687
74
48
97
243
28
129
257
843
76
47
95
237
29
124
248
621
78
46
92
231
30
120
240
600
80
45
90
225
31
118
232
581
82
44
88
220
32
113
225
583
84
43
86
214
33
109
218
545
86
42
84
209
34
106
212
529
e8
41
82
205
35
103
208
514
90
40
80
200
36
100
200
500
92
39
78
196
37
97
195
486
94
38
76
192
38
95
189
474
96
38
75
188
39
92
185
462
98
37
74
184
40
90
180
450
100
36
72
180
41
88
176
439
102
35
71
178
42
86
172
429
104
35
69
173
43
84
167
419
106
34
68
170
44
82
164
409
108
33
67
167
45
80
180
400
110
33
65
184
46
78
157
391
112
32
84
161
47
76
153
383
116
31
82
155
48
75
150
375
120
30
60
150
49
73
147
967
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
from heat exchangers. Radiant heat affects temperature rise
readings. This practice is particularly important with
straight -run ducts.
b. When thermometer readings stabilize, subtract return-air
temperature from supply -air temperature to determine air
temperature rise.
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 follow this caution may result in shorten furnace
life. Set air temperature rise within limits specified on the
rating plate to prevent reduced life of furnace components.
Operation is within a few degrees of the mid -point of rise
range when setup switch SW1-4 is OFF.
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, first check:
I.) 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 run 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 3S -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.
39
Table 11—GAS RATE (CU FT/HR)
b. Run for 3 minutes in high -heat operation.
c. Measure time (in sec) for gas meter to complete t 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 heating 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.
If clocked rate does not match required input from Step 1, increase
manifold pressure to increase input or decrease manifold pressure
to decrease input. Repeat steps b through e until correct high heat
input is achieved. Re- install high -heat regulator seal cap on gas
valve.
8. Set high heat temperature rise.
Jumper R to W/W1 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
from heat exchangers. Radiant heat affects temperature rise
readings. This practice is particularly important with
straight -run ducts.
b. When thermometer readings stabilize, subtract return-air
temperature from supply -air temperature to determine air
temperature rise.
A CAUTION
FURNACE DAMAGE HAZARD
Failure to follow this caution may result in shorten furnace
life. Set air temperature rise within limits specified on the
rating plate to prevent reduced life of furnace components.
Operation is within a few degrees of the mid -point of rise
range when setup switch SW14 is OFF.
When setup switch SW 14 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:
I.) 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 follow this warning could result in personal injury,
death, and/or property damage. Reinstall manifold pressure
tap plug in gas valve to prevent gas leak.
i. Remove thermostat jumper 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.
40
A CAUTION
FURNACE OVERHEATING HAZARD
Failure to follow this caution may result in reduced furnace
life. Recheck temperature rise.tt must be within limits speci-
fied 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.)
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 SW1 -2 switch OFF.
(7.) Install blower access door.
b. Electronic thermostat: Set cycle rate for 3 cycles per hr.
II. 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 11 tons nominal cooling
to 3 Vr, to 4 or to 6 tons of nominal cooling based on 350 cfm
ton.
The cooling airflow is adjusted by turning Setup switches
SW2 - 1, SW2 - 2 and SW2 - 3 either ON or OFF. Select the
required airflow from Fig. 61. Fig. 61 is based on 350 CFM
per ton. For airflow at 400 CFM per ton, turn Setup SW 1 -5
ON (See Table 8 and Fig. 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 SWI-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.
ALTITUDE
RANGE
(O
AVG GAS
HEAT VALUE
(BTU/CU F)
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
o2i
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
3.5/1.5
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
ALTITUDE
RANGE
(F
AVG GAS
HEAT VALUE
(BTU/CU Fn
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
RIuo YS'n
ii 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
3211.4
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
ALTITUDE
RANGE
(F1)
Ave GAS
HEAT VALUE
(BTU /CU
SPECIFIC GRAVITY OF NATURAL GAS
0.58
660
0.62
0. 64
Orifice
no.
Manifold
Pressure
Orifice
no.
Manifold
Pressure
Orifice
no.
Manifold
Pressure
Orifice
no.
Manifold
Pressure
Aluo vs•n
's1
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
32/1.4
43
3.3/1.4
850
44
3.2/1.4
44
3.4/1.5
44
3.5/1.5
44
3.6/1.6
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,
Dented 4 Percent For Each 1000 Ft Above Sea Level)
• Orifice numbers 43 are factory Installed
41
ALTITUDE
ATI
RANGE
( N
AVG GAS
HEAT VALUE
AT ALTITUDE
(BTU/CU Fl)
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
o Ys
5001
to
6000
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
3.5/13
43
3.2/1.4
43
3.3/1.4
800
44
32/1.4
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
3.2/1.4
44
3.3/1.4
850
46
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
3.6/1.6
47
3.8/1.6
46
3.4/1.5
46
3.5/1.5
ALTITUDE
RANGE
(FT)
AVG GAS
HEAT VALUE
(BTU/CU ALTITUDE
(BTU/CU Fl)
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
Ago •rwn
s$
675
43
3.4/1.5
43
3.5/1.5
43
3.6/1.6
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
46
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
46
3.4/1.5
46
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
(�
AVG GAS
HEAT VALUE
AT ALTITUDE
(BTU/CU FT)
SPECIFIC GRAVITY OF NATURAL GAS
0.58
0.60
0.62
0.64
Orifice
No.
Main'dold
Pressure
Orifice
No.
Manifold
Pressure
Orifice
No.
Manifold
Pressure
Orifice
No.
Manifold
Pressure
Nuo ros•n
7001
to
8000
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
46
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
3.8/1.6
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
O&M
No.
Manifold
Pressure
Orifice
No.
Manifold
Pressure
Orifice
No.
Manifold
Pressure
Nuolsn
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.A
44
33/1.4
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 LevelxContinued)
' Orifice numbers 43 are factory installed
42
ALTITUDE
RANGE
(rn
AVG GAS
HEAT VALUE
AT ALTITUDE
(BTU/CU Fl)
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
AIuo Y50
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
48
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 Burner,
Derated 4 Percent For Each 1000 Ft Above Sea Level)(Continued)
• Orifice numbers 43 are factory installed
Step 4—Check Safety Controls
The flame sensor, gas valve, and pressure switch were all checked
in the Start-up procedure section as part of normal operation.
1. Check Main Limit Switch
This control shuts off combustion system and energizes
air-circulating blower motor, if furnace overheats. By using
this method to check limit control, it can be established that
limit is functioning properly and will operate if there is a
restricted return-air supply or motor failure. If limit control
does not function during this test, cause must be determined
and corrected.
a. Run furnace for at least 5 minutes.
b. Gradually block off return air with a piece of cardboard or
sheet metal until the limit trips.
c. Unblock return air to permit normal circulation.
d. Burners will re-light when furnace cools down.
2. Check draft safeguard switch.
The purpose of this control is to cause the safe shutdown of the
furnace during certain blocked vent conditions.
a. Verify vent pipe is cool to the touch.
b. Disconnect power to furnace and remove vent connector
from furnace vent elbow.
c. Restore power to furnace and set mom thermostat above
room temperature.
d. After normal star -up, allow furnace to operate for 2
minutes, then block vent elbow in furnace 80 percent of
vent area with a piece of flat sheet metal.
e. Furnace should cycle off within 2 minutes. If gas does not
shut off within 2 minutes, determine reason draft safeguard
switch did not function properly and correct condition.
f. Remove blockage from furnace vent elbow.
g. Switch will auto-reset when it cools.
h. Re- install vent connector.
NOTE: Should switch remain open longer than 3 minutes,
furnace control board will lockout the furnace for 3 hours. To reset
furnace control board, turn thermostat below mom 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.
43
d. Set thermostat to "call for heat" and wait I minute. When
pressure switch is functioning properly, hot surface igniter
should NOT glow and control diagnostic light flashes a
status code 32. If hot surface igniter glows when inducer
motor is disconnected, shut down furnace immediately.
e. Determine reason pressure switch did not function properly
and correct condition.
f. Turn off 115 -v power to furnace.
g. Reconnect inducer motor wires, replace outer door, and
turn on 115 -v power.
h. Blower will run for 90 seconds before beginning the call
for heat again.
i. Furnace should ignite normally.
Step 5— Checklist
1. Put away tools and instruments. Clean up debris.
2. Verify that switches SW1 -1 and SWI -6 are OFF and other
setup switches are set as desired. Verify that switches SW 1 -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.
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, INJURY OR DEATH HAZARD
Failure to follow this warning could result in personal injury,
death and/or property damage.
The ability to properly perform maintenance on this 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.
.TtTUDE
RANGE
(FT)
AVG GAS
HEAT VALUE
( BTU/CU F7)
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
N
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
3.3/1.6
43
3.4/1.6
43
3.5/1.7
1025
44
3.4/1.6
44
3.6/1.7
43
3.2/1.5
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
3.2/1.5
44
3.3/1.6
44
3.4/1.6
1100
46
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 Fl)
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
t
4500
800
43
3.8/1.8
42
3.2/1.5
42
3.3/1.6
42
3.4/1.6
825
43
3.5/1.7
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
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
3.4/1.6
975
46
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
46
3.8/1.8
45
3.7/1.8
TITUDE
RANGE
(FT)
AVG GAS
HEAT VALUE
(BTU /CU Fj
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
Ago vs•n
is 1
775
43
3.5/1.7
43
3.7/1.7
43
3.8/1.8
42
3.2/1.5
800
43
3.3/1.6
43
3.4/1.6
43
3.5/1.7
43
3.7/1.7
825
44
3.6/1.7
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
46
3.8/1.8
45
3.8/1.8
44
3.2/1.5
44
3.3/1.6
925
46
3.6/1.7
46
3.7/1.8
45
3.7/1.8
45
3.8/1.8
950
46
3.4/1.6
46
3.5/1.7
46
3.7/1.7
46
3.8/1.8
RTUDE
RANGE
(FT)
AVG GAS
HEAT VALUE
(BTU/CU FT)
SPECIFIC GRAVITY OF NATURAL GAS
0.58
0.60
0.62
0.64
Orifi
no.
Manifold
Pressure
Orifice
no.
Manifold
Pressure
Orifice
no.
Manifold
Pressure
Orifice
no.
Manifold
Pressure
Aim vS•n
750
43
3.3/1.6
43
3.4/1.6
43
3.5/1.7
43
3.6/1.7
775
44
3.6/1.7
43
3.2/1.5
43
3.3/1.6
43
3.4/1.6
800
44
3.3/1.6
44
3.4/1.6
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
46
3.7/1.7
46
3.8/1.8
45
3.7/1.8
900
47
3.8/1.8
46
3.5/1.7
46
3.6/1.7
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
44
TITUDE
ALT
ATUE
(FT)
AVG GAS
HEAT VALUE
AT ALTITUDE
(BTU/CU Fl)
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
Mu° •Irs
1 g
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
46
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
( N
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
Aiuo ro's'n
6001
to
7000
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
(FT
AVG GAS
HEAT VALUE
A T 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
Auo'V's'n
7001
to
8000
650
44
3.3/1.6
44
3.4/1.6
44
3.5/1.7
43
3.2/1.5
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
3.511.7
46
3.6/13
46
3.7/1.8
750
47
3.5/1.7
47
3.7/1.8
47
3.8/1.8
46
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
ALTITUDE
RANGE
Fl)
AVG GAS
HEAT VALUE
AT ALTITUDE
(BTU/CU FT)
SPEC
FIC 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
I _ /quo w'stn
�88
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
3.5/1.7
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 LeveixContinued)
• OnlIce numbers 43 are tamely installed
45
ALTITUDE
RANGE
(Fn
AVG GAS
HEAT VALUE
pT ALTITUDE
(BTU/CU f�
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
nrvv - v s-n
9001
to
10,000
600
46
3.6/1.7
46
3.7/1.8
46
3.8/1.8
45
3.7/1.8
625
47
3.7/1.8
47
3.8/1.8
46
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
3.8/1.8
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- Heat/14,500 Btuh for Low -Heat Per Burner,
Derated 4 Percent For Each 1000 Ft Above Sea LevelxContinued)
• Orifice numbers 43 are factory Installed
A WARNING
ELECTRICAL SHOCK, FIRE OR EXPLOSION
HAZARD
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
ELECTRICAL OPERATION HAZARD
Failure to follow this caution may result in improper furnace
operation or failure of furnace.
Label all wires prior to disconnection when servicing con-
trols. Wiring errors can cause improper and dangerous
operation.
Step 1 —Introduction
GENERAL
These instructions are written as if the furnace is installed in an
upflow application. An upflow furnace application is where the
blower is located below the combustion and controls section of the
furnace, and conditioned air is discharged upward. Since this
furnace can be installed in any of the 4 positions shown in Fig. 4,
you must revise your orientation to component location accord-
ingly.
ELECTRICAL CONTROLS AND WIRING
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 heating.
The control system also requires an earth ground for proper
operation of the control and flame - sensing electrode.
The 24 -v circuit contains an automotive -type, 3 -amp fuse located
on the control. (See Fig. 25.) Any shorts of the 24-v wiring during
46
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.
1. To retrieve status codes, proceed with the following:
NOTE: NO thermostat signal may be present at control, and all
blower -OFF delays must be completed.
a. Leave 115 -v power to furnace turned on.
b. Remove outer access door.
c. Look into blower access door sight glass for current amber
LED status. Removing blower access door will open
blower access door switch and terminate 115 -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. Turn 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 SW 1-1 "OFF."
7. A continuously -lit Amber LED will appear and indicates
proper operation.
8. Release blower access door switch, install blower access door
and replace outer door or refer to the SERVICE label on the
front of the blower access door for more information.
Component Self -Test
Component Test can ONLY be initiated by performing the
following:
1. Remove outer access door.
2. Remove blower access door.
3. Remove the wire from the "R" terminal of the control board.
4. Turn Setup Switch, SW -1 -6 "ON."
5. Manually close blower access door switch.
Blower access door switch opens 115 -v power to control. No
component operation can occur unless switch is closed. Caution
must be taken when manually closing this switch for service
purposes.
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.
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.
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 SW t -6 OFF
then back ON.
f. Turn setup switch SW 1-6 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.
47
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 'cress
door removed.
A CAUTION
CUT HAZARD
Failure to follow this caution may result in personal injury.
Sheet metal pars may have sharp edges or burrs. Use care and
wear appropriate protective clothing, safety glasses and
gloves when handling parts, and servicing furnaces.
The minimum maintenance on this furnace is as follows:
1. Check and clean air filter each month or more frequently if
required. Replace if torn.
2. Check blower motor and wheel for cleanliness each heating
and cooling season. Clean as necessary.
3. Check electrical connections for tightness and controls for
proper operation each heating season. Service as necessary.
4. Inspect burner compartment before each heating season for
rust, corrosion, soot or excessive dust. If necessary, 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.
FURNACE
CASING WIDTH
FILTER SIZE
FILTER
TYPE
Side Return
Bottom Return
14-1/2
16 X25 X 1
14 X 25 X 1
Cleanable'
17 -12
16X25 X1
16 X25X1
Cleanable
21
16 X25 X1
20 X25X1
Cleanable'
24
16 X25X1
24 X25X1
Cleanable'
• Recommended
Table 14— Filter Size Information (In.)
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 KGAFR0301ALL external filter rack, See
Table 14.
6. Slide filter into cabinet.
7. Replace filter cabinet door.
8. Turn on electrical supply to furnace.
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 pm- 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.
48
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.
11. 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+1 -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 1 le, through
I 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/WI thermostat terminals are jumpered at the time
blower access door switch is closed, blower will run for 90 sec
before beginning a heating cycle.
c. Perform component self -test as shown at the bottom of the
SERVICE label, located on the front of blower access door.
d. Verify blower is rotating in the correct direction
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
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
h. Flame rollout switches.
6. Remove screws that fasten the collector box assembly to the
cell panel. Be careful not to damage the collector box. Inducer
assembly and elbow need not be removed from collector box.
7. Disconnect gas line from gas manifold.
8. Remove the 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,
49
5/16"
A05025
Fig. 58— Igniter Position -Side View
Fig. 59— Igniter Position -Top View
A05026
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.
(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).
e
Fig. 60— Cleaning Heat Exchanger Cell
(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 corn or canola oil, aromatic or halogenated
hydrocarbons or inadequate seal may occur) and RTV sealant
(G.E. 162, 6702, or Dow- Corning 738) are needed before starting
installation. DO NOT substitute any other type of RTV sealant.
G.E. 162 (P771 -9003) is available through RCD in 3 -oz tubes.
12. Apply new sealant to flange of collector box and attach to cell
panel using existing screws, making sure all screws are secure.
13. Reconnect wires to the following components (Use connection
diagram on wiring label, if wires were not marked for
reconnection locations.):
a. Draft safeguard switch.
b. Inducer motor.
c. Pressure switches.
d. Limit overtemperature switch.
e. Gas valve.
f. Hot surface igniter.
g. Flame- sensing electrode.
h. Flame rollout switches.
14. Reinstall internal vent pipe, if applicable.
15. Reinstall vent connector on furnace vent elbow. Securely
fasten vent connector to vent elbow with 2 field - supplied,
corrosion- resistant, sheet metal screws located 180° apart.
16. Replace blower access door only if it was removed.
17. Set thermostat above room temperature and check furnace for
proper operation.
18. Verify blower airflow and speed changes between heating and
cooling.
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 a soap - and -water solution.
19. Check for gas leaks.
A91252
50
Step 3 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/Wl- and -W2), the control will start a 90- second
blower -only ON period two seconds after power is restored, if the
thermostat is still calling for gas heating. The amber LED light will
flash code 12 during the 90- second period, after which the LED
will be ON continuous, as long as no faults are detected. After the
90- second period, the furnace will respond to the thermostat
normally.
The blower door must be installed for power to be conducted
through the blower door interlock switch ILK to the furnace
control CPU, transformer TRAN, inducer motor IDM, blower
motor BLWM, hot - surface igniter USI, and gas valve GV.
1. Two-Stage Heating (Adaptive Mode) with Single -Stage
Thermostat
See Fig. 24 or 33 for thermostat connections
NOTE: The low -heat only switch SW1 -2 selects either the
low -heat only operation mode when ON, (see item 2. below) or the
adaptive heating mode when OFF in response to a call for heat.
(See Table 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 -heat 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 -lime (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
(l.) 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 I5- 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
AIR CONDITIONING
TONS (12,000 BTUMR)
AIRFLOW
(CFM)
070 MODEL
090 MODEL
110, 135,
8 155 MODELS
1-1/2
525
X2
X
—
2
700
X
%2
X
2-1/2
875
X
X
X2
3
1050
X,
X
X
3-1/2
1225
Xi
Xi
X
4
1400
—
X,
X
5
1750
—
—
X,
6
2100
—
—
X
MODEL
SWITCH SW3 POSITIONS
tic.
MC
Oao.,
Ma ry
O••.,
n
licry
oa
u. Clam
Oran
an
ry
vn
MO,,
070
DEF
6002
800
1000
1200,
1400
1400
1400
090
DEF
600
800
1000
1200
1400
1600,
1600
110,135,155
DEF
800
10002
1200
1400
1600
2000
2200
MODEL
SIZE
SWITCH SW3 POSITIONS
c-
a
V
LL _
ocn
LL B -
t
070
DEF
525
700
875
1050,
1225
1225
1225
090
DEF
525
700
875
1050
1225
1900
1400
110,135,155
DEF
700
8752
1050
1225
1400
1750
2100
Cooling Tonnage vs. Airflow (CFM)
X- INDICATES AN ALLOWABLE SELECTION.
HPS closes, and the high -heat gas valve solenoid
GV -HI is energized. The furnace control CPU begins
a 15- second prepurge period after the low -heat 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
where it is ignited by the HSI. Five seconds after the GVR
closes, a 2- second flame proving period begins. The HSI
igniter will remain energized until the flame is sensed or
until the 2- second flame proving period begins.
If the furnace control CPU selects high -heat operation, the
high -heat gas valve solenoid GV -HI is also energized.
d. Flame - Proving - When the burner flame is proved at the
flame - proving sensor electrode FSE, the inducer motor
IDM switches to low -speed unless the furnace is operating
in high -heat, and the furnace control CPU begins the
blower -ON delay period and continues to hold the gas
valve GV -M open. If the burner flame is not proved within
MR CONDITIONING (NC) OR CONTINUOUS -F N (CF) AIRFLOW SELECTION CHART
BASED ON 350 CFMTON
SW1-5 ON
BASED ON 400 CFM/TON
SW1-5 ON
1.DEFAULTNC AIRFLOW WHEN NC SWITCHES ARE IN OFF POSITION (FACTORY SETTING)
2.DEFAULT CONT. FAN AIRFLOW WHEN CF SWITCHES ARE IN OFF POSITION (FACTORY SETTING)
3. SWITCH POSITIONS ARE ALSO SHOWN ON FURNACE WIRING DIAGRAM
Fig. 61 —Cooling (NC) or Continuous -Fan (CF) Airflow Selection Chart
51
A03220
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-
matically after three hours, by momentarily interrupting
115 vac power to the furnace, or by interrupting 24 vac
power at SEC1 or SEC2 to the furnace control CPU (not at
W/W1, G, R, etc.).
If flame is proved when flame should not be present, the
furnace control CPU will lock out of Gas - Heating mode
and operate the inducer motor 1DM 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-Beat - If the furnace
control CPU switches from low -heat to high -heat, the
furnace control CPU will switch the inducer motor 1DM
speed from low to high. The high -heat pressure switch relay
HPSR is de-energized to close the NC contact. When
sufficient pressure is available the high -heat pressure
switch HPS closes, and the high -heat gas valve solenoid
GV -HI is energized. The blower motor BLWM will tran-
sition to high -heat airflow five seconds after the furnace
control CPU switches from low -heat to high -heat.
g. Switching from High- to Low -Heat -The furnace control
CPU will not switch from high -heat to low -heat while the
thermostat R -to -W circuit is closed when using a single -
stage thermostat.
h. Blower -Off Delay - When the thermostat is satisfied, the R
to W circuit is opened, de- energizing the gas valve GV -M,
stopping gas flow to the burners, and de- energizing the
humidifier terminal HUM. The inducer motor IDM will
remain energized for a 5- second post -purge period. The
blower motor BLWM and air cleaner terminal EAC -1 will
remain energized at low -heat airflow or transition to
low -heat airflow for 90, 120, 150, or 180 seconds (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 -W I circuit. Closing the thermostat R -to-
W I- 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 -WI circuit
for low -heat or closing the R -to -W I -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
I. 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 I circuit is closed and the R -to -W2 circuit closes, the
furnace control CPU will switch the inducer motor IDM
speed from low to high. The high -heat pressure switch
relay HPSR is de- energized to close the NC contact. When
sufficient pressure is available the high -heat pressure
switch HPS closes, and the high -heat gas valve solenoid
GV -HI is energized. The blower motor BLWM will 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 c remains
closed, the furnace control CPU will switch the inducer
motor IDM speed from high to low. The high -heat pressure
switch relay HPSR is energized to open the NC contact and
de- energize the high -heat gas valve solenoid GV -HI. When
the inducer motor IDM reduces pressure sufficiently, the
high -heat pressure switch HPS will open. The gas valve
solenoid GV -M will remain energized as long as the
low -heat pressure switch LPS remains closed. The blower
motor BLWM will transition to low -heat airflow five
seconds after the R -to -W2 circuit opens.
3. Cooling mode
The thermostat "calls for cooling ".
a. Single -Speed Cooling -
See Fig. 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
52
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
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
DRUM 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 ACRDI must
be connected to enable the adaptive cooling mode in response to a
call for cooling. (See Fig. 25.) When ACRD) is in place the
furnace control CPU can turn on the air conditioning relay ACR to
energize the Y/Y2 terminal and switch the outdoor unit to
high - cooling.
The furnace control CPU can start up the cooling unit in either
low- or high-cooling. If starting up in low - cooling, the furnace
control CPU determines the low - cooling on -time (from 0 to 20
minutes) which is permitted before switching to high - cooling.
If the power is interrupted, the stored history is erased and the
furnace control CPU will select low - cooling for up to 20 minutes
and then energize the air conditioning relay ACR to energize the
Y/Y2 terminal and switch the outdoor unit to high - cooling, as long
as the thermostat continues to call for cooling. Subsequent
selection is based on stored history of the thermostat cycle times.
The wall thermostat "calls for cooling", closing the R -to -G -and -Y
circuits. The R -to -Y I circuit starts the outdoor unit on low - cooling
speed, and the R -to -G -and -Y1 circuits starts the furnace blower
motor BLWM at low - cooling airflow which is the true on -board
CF selection as shown in Fig. 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-Y1- and -Y2 circuits switch the outdoor unit to high - cooling
speed, and the R -to -G- and -Yl- 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 low - cooling to high- cooling the
outdoor unit compressor will shut down for 1 minute while the
furnace blower motor BLWM transitions to run at high - cooling
airflow.
The electronic air cleaner terminal EAC -1 is energized with 115
vac whenever the blower motor BLWM is operating.
When the thermostat is satisfied, the R -to -G -and -Y circuit are
opened. The outdoor unit stops, and the furnace blower BLWM
and electronic air cleaner terminal EAC -1 will remain energized
for an additional 90 seconds. Jumper Y I to DRUM 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-O- and -Y I circuits for low-cooling
or closes the R -to-G- and -Y1- and -Y2 circuits for high-cooling. The
R -to-Y1 circuit starts the outdoor unit on low - cooling speed, and
the R -to-O- and -Y1 circuit starts the furnace blower motor BLWM
at low - cooling airflow which is the true on -board CF (continuous
fan) selection as shown in Fig. 61. The R -to-Y1- and -Y2 circuits
start the outdoor unit on high-cooling speed, and the R -to-
G- and -Y/Y2 circuits start the furnace blower motor BLWM at
high - cooling airflow. High - cooling airflow is based on the A/C (air
conditioning) selection shown in Fig. 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 It-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
Y I 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, DRUM on the Thermidistat
should be connected to the furnace control thermostat terminal
DRUM. When there is a dehumidify demand, the DHUM
input is activated, which means 24 vac signal is removed from
the DHUM input terminal. In other words, the DRUM input
logic is reversed. The DRUM input is turned ON when no
dehumidify demand exists. Once 24 vac is detected by the
furnace control on the DRUM input, the furnace control
operates in Thermidistat mode. If the DRUM input is low for
more than 48 hours, the furnace control reverts back to
non - Thermidistat mode.
The cooling operation described in item 3. above also applies
to operation with a Thermidistat. The exceptions are listed
below:
a. Low cooling -When the R -to-G -and -Y1 circuit is closed
and there is a demand for dehumidification, the furnace
blower motor BLWM will drop the blower airflow to 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 It-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 them 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-Yl 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.
53
b. When the R- to-Y/Y2 circuit is closed, R -to-G circuit is
open, and there is a demand for dehumidification, the
furnace blower motor BLWM will drop the blower airflow
to 65 percent of high - cooling airflow for a maximum of 10
minutes each cooling cycle or until the R -to -G circuit
closes or the demand for dehumidification is satisfied.
High-cooling airflow is based on the A/C (air conditioning)
selection shown in Fig. 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 -1 is energized as
long as the blower motor BLWM is energized.
During a call for heat, the furnace control CPU will transition
the blower motor BLWM to continuous blower airflow,
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 low - cooling airflow before
transitioning back to continuous - blower airflow.
When the thermostat "calls for high-cooling", the blower
motor BLWM will operate at high cooling airflow. When the
thermostat is satisfied, the blower motor BLWM will operate
an additional 90 seconds at high-cooling airflow before
transitioning back to continuous - blower airflow.
When the R -to-G circuit is opened, the blower motor BLWM
will continue operating for an additional 5 seconds. if no other
function requires blower motor BLWM operation.
Continuous Blower Speed Selection from Thermostat - To
select different con tinuous - 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 turning 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/W1 is
energized along with Yl 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. The blower motor BLWM will remain on
until the main burners ignite then shut OFF and remain OFF
for 25 seconds before coming back on at heating airflow.
When the W/W1 input signal disappears, the furnace control
begins a normal inducer post -purge period while changing the
blower airflow. If Y/Y2 input is still energized the furnace
control CPU will transition the blower motor BLWM airflow
to cooling airflow. If Y/Y2 input signal disappears and the Yl
input is still energized the furnace control CPU will transition
the blower motor BLWM to low - cooling airflow. If both the
Y1 and Y/Y2 signals disappear at the same time, the blower
motor BLWM will remain on at low -heat airflow for the
selected blower -OFF delay period. At the end of the blower -
OFF delay, the blower motor BLWM will shut OFF unless G
is still energized, in which case the blower motor BLWM will
operate at continuous blower airflow.
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 SW1-6. (See Fig. 25.)
NOTE: The component test feature will not operate if the control
is receiving any thermostat signals or until all time delays have
expired.
54
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 (11,
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 SW1 -6 to
OFF and then back ON.
Step 4 Wiring Diagram
Refer to wiring diagram Fig. 57.
Step 5
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
"Start," answer each question and follow the appropriate arrow to
the next item.
The Guide will help to identify the problem or failed component.
After replacing any component, verify correct operation sequence.
A more detailed Troubleshooting Guide is available from your
distributor.
START
It AMBER LED status IBM on?
YES
Is AMBER LED dohs light blinking
rapdywXlaut a pause?
T NO
S MISER LED stats light Mntbg ON/OFF
*My with • rombinatkm of short and
long Bashes?
YES
Beginning status code. The status code is
• 2 daft somber with the first digit delem
by number by tr�mb long lasts?
G010 section below lot the status code
that As fleshed.
Fig. 62— Troubleshooting Guide-Variable Speed
Where I I 5V at Ll and l27
W here 24V at SEC-1 and SEC-2?
Replace funtace control.
W door switch dosed?
W there 115V going to snitch?
Replace door switch
W door switch dosed?
Is drat beaker tlwed?
YES
YES
Check for cared line aotape polarity.
If units ere twinned, check for proper
low- wltsge (24V) transformer phasing
To recall predau status codes dxanned
the R thermostat xnredton, resat power,
and put setup switch SW1.1 M the ON
position. The AMBER LED will flash he
status codes in the order of occurrence.
Record status codes until status rode 011
flashes (1 shit and 1 long Sash). After sauce
code SI1 flashes the status (Wessell repeat.
Statue codes are erased after 72 hours or
can be manually erased by putting setp
switch SW 1 -1 M the ON position and
)w pert g R, W/W1, end YM2sMNtrsa4y
write status code 011 W Bashed. When done
put setup switch SWt -1 M the OFF position.
Was here a iambus code other
YES then el l? I NO
Replace transformer.
YES
Does the control reaped to WW1, W2, Y1
Y/Y2, and 0 (24V) thermostat signals?
Replace furnace control.
YES
l i r
Run system crap a lowMeaL high-heat,
or cooling cycle to deck operation. Status
Codes are erased after 72 hours or can be
manually erased by putting setup swath
SW1.1 M he ON position and junpemg R,
WAV1, sod Yell simultaneously until status
code el1 Is flashed
I Close dro tit breaker and go beck to START I♦
NO
ES
YES
Check for mntlnuly in wire hom drat
breaker to furnace.
Chedo room thermostat Or
inWnworedlnp cede.
I NO
Is 24V present at IN/W1, W2, YI, Y/Y2 or 0
hemostat terminals on the furnace control?
YES
( Disconnect at the thermostat wires
trance control
Does the problem repeat when using
a jumper wire?
NO
The thermostat S not compatible with the
furnace aced. Eder Instal a ballast resistor,
connect the Com24V thermostat terminal to
the thermostat, or replace the thermostat.
NO
A02108b
11
NO PREVIOUS CODE — Status codes
are cued after 72 hours or can be
manually erased by putting seep switch
SW1 -1 in me ON
Check for
position and Impaling
R, WAN1, endYY2 simultaneously all
status code all le flashed. Rue system
through a love-heat, high-heat or cooling
cycle to check system.
Igratiert
•
12
BLOWER ON AFTER POWER UP—
(115V OR 24V)— Normal operation.
to check for intermittent operation.
Blower runs for 90 seconds„ If unit 4
Check connections and retry. If current is
W�t�dosed) henn( WAN opens)
during the blower on delay perlod
If OK, check burner carryover and game
sensor location.
13
LIMIT CIRCUIT LOCKOUT — Lockout
on If Me limit, draft safeguard, flame
rollout or blocked sun switch' (t used)
Is
open longer than 3 minutes or 10
successive MI hips occurred dump
NpMSat. Control w1 auto-reset alter 3
hours. See code 33.
14
IGNITION LOCKOUT — System fated to
Otte gas and prop Isms In 4 attempts.
Control aid auto-reset alter 3 hours.
See status code 34.
15
BLOWER MOTOR LOCKOUT — Imitates
the dower failed to mash 250 RPM or
the NOW failed to communicate within
30 seconds ate being t rned ON in Iwo
successive heating cycles. Control MI
auto -resat after 3 hour See code 41.
2t
GAS HEATING LOCKOUT —TUm off
power and wait S minutes to retry.
Check for:
- Stilt dosed gas have relay on mod.
• M4wire or shorts gas valvewire.
22
ABNORMAL FLAME-PROVING SIGNAL
Flame Is proved while gas valve is de-
energlzed. Inducer fault is
will net until
cleared. Check for
• Stuck open or leaky gas valve.
23
PRESSURE SWITCH DID NOT OPEN
Check Ion
• Obstructed pressure tube.
• Pressure switch stuck dosed.
24
SECONDARY VOLTAGE FUSE IS OPEN
Check for:
• Short circuit in secondary voltage
(24V) wiring ndudkp thermostat
leads. Disconnect thermostat leads
to Isolate start circuit
Check that el gas values are turned on.
Replace valve.
Check for
- Inadequate tame carryover or rough
Igratiert
•
pressure.
Proper
- firing raate.
- Blocked or incorrect tarty- over gap
(.045' nominal)
Mew blower to come on and repeat test
to check for intermittent operation.
Check connections and retry. If current is
near typical value (4.04.0 nonfnal) and
burners w1 not stay on, repeat check n NM
heat I burners will still not stay on replace
coned. B burners operate In high -heat men
switch to low -teat heck meiMd pressure.
If OK, check burner carryover and game
sensor location.
Replace electrode.
a
8
9
32 LOW -HEAT PRESSURE SWITCH DID
HOT CLOSE OR REOPENED —11 open
longer than 5 minutes, inducer err aa p b e u un tf
s s of for 15 f
minutes
kaer be ortde ev p uoc „ dower w1
come on forcis blower oft-delay.
Check for
Proper vent siting.
Low Inducer voltage (115V).
Low inlet gas pease (rt LGPS used).
Inadequate combustion air supply.
Disconnected or obstructed pressure
tubing.
Def w inducer motor.
Defective pressure switch.
Excessive wind.
Restricted vent
33 LIMIT CIRCUIT FAULT— Indicates the
Inat, drat safeguard, game rollout, or
blocked vent shut off switch' (t used)
Is open a tee furnace is operating In
high-heat only mode de to 2 succes-
sive low•oet lint trips. Blower e1 mat
for 4 mei. or until open switch (Wekea
whichever Is longer. If open longer than
3 min., code changes to lockout
*t3. If open less than 3 min. status code
t33 continues to flash until blower shuts
off. Flame rollout switch and BVSS
requires Check for
restricted
- Loose blower wheel. system.
- Defective switch or connections
• Inadequate combustion air supply
(flame rollout switch open).
• Restricted vent.
• Proper vent sizing.
- Excessive wind.
IGNITION PROVING FAILURE —If flame
4 not sensed during the trial for Ignition
period, me control wIl repeat the ignition
sequence 3 mite tines before lockout
*14 occur K here signal seat dump
the Nom on-delay perked, Mower will
came an forte selected broker off-delay.
Check the slowing tame first before
proceeding to the next step.
- Gas retie fumed off.
- Manual shut-off valve.
• GreeVYebw wire MUST be connected
to furnace sheet motet
• Flame sensor most not be grounded.
To determine whether the problem 4 in
the gas valve, Igniter, or Verne sensor the
system an be operated in component
test mode. To check the igniter remove
the R thermostat connection from the
cmtml, reset power, and put setup switch
SW1-6 in the ON position to Hart the
component test. Does me igniter glow
orange/white by the end hits 15 second
warm -up period?
NO
YES
•
' Blocked vent shut off switch used In Chimney Adapter Kit
i
43 LOW -HEAT PRESSURE SWITCH OPEN
WHILE HIGH -HEAT PRESSURE
SWITCH IS CLOSED - Check for
- Low -feet pressure etch stuck open.
- Disconnected or obstructed pressure
tube.
- Mswlred pressure switches.
• Low inlet gas pressure Of LGPS used).
Unplug Igniter harness from control and
repeat com onet teat by wing setup switch
SW 141 OFF and then Writ ON. Check for
115V between pin 3 and NEUTRAL -L2 on
the control. Was 115V present for the 15
second period?
Reconnect the R thermostat lead end set
' Reconnect
thermostat to cal for heel Canedwbnater
acres gas valve connections. Does gas
valve receive 24V?
Y S
Does gas valve open and slow gas to law? ' NO
YES
Do the main burners ignite?
YES
Do the man burners stay on?
Repeat cell for heat and check flame sensor
anent during trial for Ignition period. Is me
DC miramps below 0.5?
j YES
Clean hams sensor with be steel wool and
recheck current Nominal current Is 4.0 to
6.0 microamps.
Is anent near typical value?
NO
YES
NO
NO
i
45 CONTROL CIRCUITRY LOCKOUT
Auto-reset after 1 hour lockout due to:
- Rams circuit failure.
- Gas valve relay stuck open.
• Software check error.
Reset powers clear lockout
Replace control if code repeats.
Replace furnace control
ck t r
continuity in the harness and
cur. Replace detective component.
If CK replace control.
Replace furnace control.
A021OSb
1
% INVALID MODEL SELECTION OR
SETUP ERROR —1 status code 25 only
lashes 4 limes on Power•up W control
is missing its model pig PL4 and Is
defaulting to the model selection stored
In memory. Katats code 25 flashes
coMMeusly It could indicate any of the
• Model plug PL4 Is missing and Mere
is no veld model stored N permanent
memory. This a happen if you forget
to instal the model pig P1.4 on a
service re we tcontrol
• Thermostat al with S W 1.1 ON.
- Thermostat with al with SW1 •6 ON.
• SW1.1 and SWlfi boll ON.
HIGH -HEAT PRESSURE SWRCH OR
RELAY DID NOT CLOSE OR
REOPENED • Check for
• Control relay may be defective.
• Gas valve Is nsdred.
• See statue code at
41 BLOWER MOTOR FAULT— Indicates the VES J Tim power back on. Is there 115VAC at
blower failed to reach 250 RPM or the PL14•6 and PL14.4?
blower felled to communicate within to
prescribed Urns pmts. Thirty seconds 1 YES
after being armed ON oten seconds YES
ding ebadyatte operation. Turn power
off and check the blowing Items Brat
before proceeding to the need step
• Rubbing dower wheel.
- Lora dower wheel.
- Wiring from furnace control to bower
motor.
Remove the R thermostat connection
from the furnace conbol, disconnect both
connectors from the blower motor P1.73
and P114. Does the blower wheel turn
1N°
Replace the blower control module attached
to the blower motor. Folow the Instructions
al the blower control module to make sun
the entire bower motor does not need to be
nplead.
You have an open wire or bad br mini on the
BLUE win between the furnace control and
be blower motor.
Replace the enact control.
A
NO
H Connect a DC elm far across PL3-4 BLUE
(+) and P1.3-2 GREEN ( -). Does the voltage
YES luctuate as described two steps beck?
t NO
Does the voltage fluctuate as described In the
Previous step?
4, YES
Replace the blower control module attached
to the blower motor. Folow the Instructions
worm the blower control module to make sure
the entire blower motor does not need to be
replaced.
Y
Is there 12-VDC at PL13 -7 RED (+) and P113.
1 GREEN (•)?
1 N°
Is there 12 -VDC at P1.3•1 RED (.) end P1.3.
2 GREEN 0?
Replace the furnace control
Is Here 5-VDC at PL13 •16 YELLOW (+•) and
PL13 -1 GREEN (4?
1
NO
YES
The voltage lust measured should be very
stable and should not fluctuate more than
.02•VDC. If the voltage fluctuates more than
Ole get a different voltmeter before
proceeding.
Tun power off, reconnect PL13 and PL14 to
the blower motor, then turn power back on.
Connect a DC voltmeter across P133
YELLOW (+) and P1.3•2 GREEN (4. Does
the voltage fluctuate more than ft did In the
previous step?
1 N°
Tom power oft, disconnect P1.13 and PL14
from tie blower motor, then tum power bark
on. Connect a DC voltmeter across P113.
16 BLUE (s) and PLt3.1 GREEN ( -). The
voltage should be near 0•VDC but ft will
fluctuate briefly several times a second. If
you have an analog voltmeter to nestle will
briery go high several *nes a second. If you
have a digital voltmeter with a bar graph it
win show a large change In magnitude on
the bar graph several times a second. If you
have a standard digital voltmeter it ell show
a brief fluctuation in voltage and the
magnitude may vary depending on the
voltmeter used.
NO You have an open wire or bad terminal on
either the BLACK or WHITE power beds
between the furnace control and the blower
motor. If you have a power choke disconnect
It end Check continuity.
YES
NO
You have an open wire or bad terminal on
either the RED or GREEN wire between the
furnace control end the blower motor.
I
Is there 5-VDC at P1.33 YELLOW (.) end
Pt3•2 GREEN ( -)?
YES
You have an open woe or bad terminal on the
YELLOW wire between the furnace control
and The blower motor.
A02108c
Copyright 2006 Carder Corporation
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
Tab
Book Be l 6a 1 4 PC 101 Printed In U.S.A. Pg 58 4-06
11 -01 -2006
KIYOMI DAMPER
2800 THORNDYKE AV W
SEATTLE WA 98199
RE: Permit No. M06 -124
4414 S 150 ST TUKW
Dear Permit Holder:
In reviewing our current records the above noted permit has not received a final 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 permit 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 12/10/2006, 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.
Sincerely,
shall,
Permit Technician
xc: Permit File No. M06 -1 24
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
License Information
License
WASHIES97lOB
Licensee Name
WASHINGTON ENERGY SERVICES CO
Licensee Type
CONSTRUCTION CONTRACTOR
UBI
602320560
Ind. Ins. Account Id
SECRETARY
Business Type
CORPORATION
Address 1
2800 THORNDYKE AVE W
Address 2
City
SEATTLE
County
KING
State
WA
Zip
98199
Phone
2062824700
Status
ACTIVE
Specialty I
GENERAL
Specialty 2
UNUSED
Effective Date
9/2/2003
Expiration Date
9/2/2007
Suspend Date
Separation Date
Parent Company
Previous License
Next License
Associated License
Business Owner Information
Name
Role
Effective
Date
Expiration
Date
OLSON, CRAIG
PRESIDENT
09 /02/2003
HEAGLE, RANDY
SECRETARY
09 /02/2003
CHRISTIANSON,
STEVE
TREASURER
09 /02/2003
OLSON, VERN
VICE
PRESIDENT
09 /02/2003
Look Up a Contractor, Electrician or Plumber License Detail Page 1 of 2
Washington State Department of Labor and Industries
General/Specialty Contractor
A business registered as a construction contractor with L &I to perform
construction work within the scope of its specialty. A General or Specialty
construction Contractor must maintain a surety bond or assignment of
account and carry general liability insurance.
Bond Information
Bond I Bond I
https: // fortress .wa.gov /lni/bbip /printer.aspx ?License= WASHIES97IOB 06/13/2006