Carrier 58CVA070 10012 User Manual FURNACE Manuals And Guides 1303133L

User Manual: Carrier 58CVA070---10012 58CVA070---10012 CARRIER FURNACE - Manuals and Guides View the owners manual for your CARRIER FURNACE #58CVA07010012. Home:Heating & Cooling Parts:Carrier Parts:Carrier FURNACE Manual

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Page Count: 60

Installation, Start-up, Operating and

Service and Maintenance Instructions

SAFETY CONSIDERATIONS ........................ 2 ACCESSORIES ................................... 22

INTRODUCTION .................................. 4 VENTING ....................................... 22

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

START-UP, ADJUSTMENT, AND SAFETY CHECK ..... 34

General ........................................ 34

Start-Up Procedures .............................. 37

Adjustments ..................................... 37

Check Safety Controls ............................. 45

Checklist ....................................... 46

SERVICE AND MAINTENANCE PROCEDURES ....... 46

General ........................................ 46

Venting ......................................... 4

ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS

PROCEDURE ..................................... 4

LOCATION ....................................... 5

AIR FOR COMBUSTION AND VENTILATION ......... 8

Outdoor Combustion Air Method .................... 9

The Standard Method: ............................ 9

Combination of Indoor and Outdoor Air ............. 10

INSTALLATION .................................. 10

Bottom Return Air Inlet .......................... 10

Care and Maintenance ............................. 47

Sequence of Operation ............................. 52

Wiring Diagram .................................. 56

Troubleshooting .................................. 56

Accessory List ................................... 59

PARTS REPLACEMENT INFORMATION GUIDE ....... 60

Always Ask For

Side Return Air Inlet ............................. 10

Leveling Legs (If Desired) ........................ 11

Bottom Return Air Inlet .......................... 11

Suspended Furnace Support ....................... 11

Platform Furnace Support ......................... 11

Roll-Out Protection ............................. 12

Bottom Return Air Inlet .......................... 12

Side Return Air Inlet ............................. 12

Filter Arrangement .............................. 13

AIR DUCTS ...................................... 13

General Requirements ............................ 13

Ductwork Acoustical Treatment .................... 13

Supply Air Connections .......................... 14

Upflow and Horizontal Furnaces ................... 14

Downflow Furnaces ............................. 15

ISO9001

Use of tile AIIR[ Cmlified 1-,iMark indicates a

manul_lcturer's pallicipation in tile program. ]or

verification of cmlificatkln lbr individual products,

go to www.ahridireclow.org.

NOTE: Read the entire instruction manual before starting the

installation.

Portions of the text and tables are reprinted from NFPA 54/ANSI

Z223.1-2009©, 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.

Return Air Connections .......................... 18

Downflow Furnaces ............................. 18

Upflow and Horizontal Furnaces ................... 18

GAS PIPING ..................................... 19

ELECTRICAL CONNECTION ....................... 20

SAFETY CONSIDERATIONS

FIRE, EXPLOSION, ELECTRICAL SHOCK, AND

CARBON MONOXIDE POISONING HAZARD

Failure to follow this warning could result in dangerous

operation, personal iniury, death, or property damage.

Improper installation, adjustment, alteration, service,

maintenance, or use can cause carbon monoxide poisoning,

explosion, fire, electrical shock, or other conditions which

may cause personal iniury 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.

FURNACE RELIABILITY HAZARD

Failure to follow this caution may result in unit component

damage.

Application of this furnace should be indoors with special

attention given to vent sizing and material, gas input rate,

air temperature rise, unit leveling, and unit sizing.

Installing and servicing heating equipment can be hazardous due

to gas and electrical components. Only trained and qualified

personnel should install, repair, or service heating equipment.

Untrained personnel can perform basic maintenance flmctions

such as cleaning and replacing air filters. All other operations

must be performed by trained service personnel. When working

on heating equipment, observe precautions in literature, on tags,

and on labels attached to or shipped with furnace and other safety

precautions that may apply.

These instructions cover minimum requirements and conform to

existing national standards and safety codes. In some instances,

these instructions exceed certain local codes and ordinances,

especially those that may not have kept up with changing

residential construction practices. We require these instructions as

a minimum for a safe installation.

CUT HAZARD

Failure to follow this caution may result in personal iniury.

Sheet metal parts may have sharp edges or burrs. Use care

and wear appropriate protective clothing, safety glasses and

gloves when handling parts, and servicing furnaces.

Wear safety glasses, protective clothing and work gloves. Have

fire extinguisher available during start-up and adjustment

procedures and service calls.

This is the safety-alert symbol /_ . When you see this symbol on

the furnace and in instructions or manuals, be alert to the potential

for personal iniury.

Understand the signal words DANGER, WARNING, and

CAUTION. These words are used with the safety-alert symbol.

DANGER identifies the most serious hazards which will result in

severe personal iniury or death. WARNING signifies a hazard

which could result in personal iniury or death. CAUTION is used

to identify hazards which may result in minor personal iniury or

product and property damage. NOTE is used to highlight

suggestions which will result in enhanced installation, reliability,

or operation.

1. Use only with type of gas approved for this furnace. Refer

to the furnace rating plate.

2. Install this furnace only in a location and position as spe-

cified 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. Con-

nect this furnace to an approved vent system only, as spe-

cified in the "Venting" section of these instructions.

5. Never test for gas leaks with an open flame. Use a com-

mercially available soap solution made specifically for the

detection of leaks to check all connections, as specified in

the "Gas Piping" section.

6. Always install furnace to operate within the furnace's in-

tended temperature-rise range with a duct system which

has an external static pressure within the allowable range,

as specified in the "Start-Up, Adjustments, and Safety

Check" section. See furnace rating plate.

7. When a furnace is installed so that supply ducts carry air

circulated by the furnace to areas outside the space con-

taining the furnace, the return air shall also be handled by

duct(s) sealed to the furnace casing and terminating out-

side the space containing the furnace. See "Air Ducts" sec-

tion.

8. A gas-fired furnace for installation in a residential garage

must be installed as specified in the warning box in the

"Location" section.

9. The furnace may be used for construction heat provided

that the furnace installation and operation complies with

the first CAUTION in the LOCATION section of these in-

structions.

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 install-

ation 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.) lis-

ted accessory gas conversion kit is required to convert fur-

nace for use with propane gas.

11. See Fig. 1 for required clearances to combustible construc-

tion.

12. Maintain a 1-in. (25 mm) clearance from combustible ma-

terials to supply air ductwork for a distance of 36 in. (914

mm) horizontally from the furnace. See NFPA 90B or loc-

al code for further requirements.

13. These furnaces SHALL NOT be installed directly on car-

peting, tile, or any other combustible material other than

wood flooring. In downflow installations, factory access-

ory floor base MUST be used when installed on combust-

ible materials and wood flooring. Special base is not re-

quired when this furnace is installed on manufacturer's

Coil Assembly Part No. CNRV, CNPV, CAP, or CAR or

when Coil Box Part No. KCAKC is used. See Fig. 1 for

clearance to combustible construction information.

iNSTALLATION

improper adjustment, alteration, service,

maintenance, or installation can cause

serious injury or death.

Read and follow instructions and

precautions in User's Information Manual

provided with this furnace. Installation

and service must be performed by a

qualified service agency or the gas

supplier.

Check entire gas assembly for leaks after

lighting this appliance.

iNSTALLATION

1. This furnace must be installed in

accordance with the manufacturer's

instructions and local codes. In the

absence of local codes, follow the National

Fuel Gas Code ANSI Z223.1 /NFPA54

or CSA B-149. 1 Gas Installation Code.

2. This furnace must be installed so there are

provisions for combustion and ventilation

air. See manufacturer's installation

information provided with this appliance.

OPERATION

This furnace is equipped with manual reset

limit switch(es) in burner compartment to

protect against overheat conditions that

can result from inadequate combustion air

supply or blocked vent conditions.

1. Do not bypass limit switches.

2. If alimit opens, call a quallified

serviceman to correct the condition

and reset limit switch.

MiNiMUMiNCHESCLEARANCETO COMBUSTIBLECONSTRUCTION

This forced air furnace is

equipped for use with natural

gas at altitudes 0 - 10,000 ft

(0 - 3,050m).

An accessory kit, supplied by

the manufacturer, shall be used

to convert to propane gas use

or may be required for some

natural gas applications.

This furnace is for indoor

installation in a building

constructed on site.

This furnace may be installed

on combustible flooring in alcove

or closet at minimum clearance

as indicated by the diagram

from combustible material.

This furnace may be used with

a Type B-1 Vent and may be

vented in common with other

gas fired appliances.

This furnace is approved for

UPFLOW, DOWNFLOW, and

HORIZONTAL installations.

Clearancearrows

do notchangewith

furnaceorientation.

Clearancein inches

Vent Clearance to combustibles:

For SingleWall vents 6 inches(6 po).

ForType B-1 venttype I inch (1 po).

MINIMUM INCHES CLEARANCE TO

COMBUSTIBLE CONSTRUCTION

DOWNFLOWPOSiTiONS:

Installation on non-combustible floors only.

For Installation on combustible flooring only when installed on special

base, Part No. KGASB0201ALL or NAHA01101SB, Coil Assembly,

Part No. CAR, CAP, CNPV, CNRV, END4X, ENW4X, WENC, WTNC,

WENW OR WTNW.

18 inches front clearance required for alcove.

Indicates supply or return sides when furnace is in the horizontal

position. 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. IIIIIIIIIIIIIIIIIIIIIIIIIII

336996-161 REV. C

Fig. 1 - Clearances to Combustibles

A10269

INTRODUCTION

The Series 160 4-way multipoise Category I fan-assisted furnace

is CSA (formerly A.G.A. and C.G.A.) design-certified. A

Category I fan-assisted furnace is an appliance equipped with an

integral mechanical means to either draw or force products of

combustion through the combustion chamber and/or heat

exchanger. The furnace is factory-shipped for use with natural

gas. This furnace is not approved for installation in mobile

homes, recreational vehicles, or outdoors.

'1_1! \ MAX80°F /27 C

MIN60°F /16 C

FRONT

Fig. 2 - Return Air Temperature

A06745

This furnace is designed for minimum continuous return-air

temperature of 60°F (15 oC) db or intermittent operation down to

55°F (13°C)db such as when used with a night setback

thermostat. Return-air temperature must not exceed 80 oF (27 oC)

db. Failure to follow these return-air temperature limits may

affect reliability of heat exchangers, motors, and controls. (See

Fig. 20

For accessory installation details, refer to the applicable

instruction literature.

NOTE: Remove all shipping brackets and materials before

operating 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, follow all codes and standards for the

following:

Safety

NFPA 54/ANSI Z223.1-2009 and the Installation Standards,

Warm Air Heating and Air Conditioning Systems ANSI/NFPA

90B.

General Installation

Current edition of the NFGC and the NFPA 90B. For copies,

contact the National Fire Protection Association Inc.,

Batterymarch Park, Quincy, MA 02269; (www.NFPA.org) or for

only the NFGC, contact the American Gas Association, 400 N.

Capitol Street, N.W., Washington, DC 20001 (www.AGA.org.).

Combustion and Ventilation Air

Section 9.3 NFPA 54/ANSI Z223.1-2009, Air for Combustion

and Ventilation.

Duct Systems

Air Conditioning Contractors Association (ACCA) Manual D,

Sheet Metal and Air Conditioning Contractors National

Association (SMACNA), or American Society of Heating,

Refrigeration, and Air Conditioning Engineers (ASHRAE) 2001

Fundamentals Handbook Chapter 34 or 2000 HVAC Systems

and Equipment Handbook Chapters 9 and 16.

Acoustical Lining and Fibrous Glass Duct

Current edition of SMACNA and NFPA 90B as tested by UL

Standard 181 for Class I Rigid Air Ducts

Gas Piping and Gas Pipe Pressure Testing

NFPA 54/ANSI Z223.1-2009 ; chapters 5, 6, and 7 and National

Plumbing Codes.

Electrical Connections

National Electrical Code (NEC) ANSI/NFPA70-2011

Venting

NFPA 54/ANSI Z223.1-2009; chapters 12 and 13.

ELECTROSTATIC DISCHARGE (ESD)

PRECAUTIONS PROCEDURE

FURNACE RELIABILITY HAZARD

Failure to follow this caution may result in unit component

damage.

Electrostatic discharge can affect electronic components.

Take precautions during furnace installation and servicing

to protect the furnace electronic control. Precautions will

prevent electrostatic discharges from personnel and hand

tools which are held during the procedure. These

precautions will help to avoid exposing the control to

electrostatic discharge by putting the furnace, the control,

and the person at the same electrostatic potential.

1. Disconnect all power to the furnace. Multiple disconnects

may be required. DO NOT TOUCH THE CONTROL OR

ANY WIRE CONNECTED TO THE CONTROL PRIOR

TO DISCHARGING YOUR BODY'S

ELECTROSTATIC CHARGE TO GROUND.

2. Firmly touch the clean, unpainted, metal surface of the fur-

nace chassis which is close to the control. Tools held in a

person's hand during grounding will be satisfactorily dis-

charged.

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 un-

grounded objects, etc.).

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A10290

NOTES:

1. Two additional 7/8-in. (22 mm) diameter holes are located in the top plate.

2. Minimum return-air openings at furnace, based on metal duct. if flex duct is used, see flex duct manufacturer's recommendations for equivalent diameters.

a, For 800 CFM-16-in. (406 mm) round or 14 1/2 x 12-in. (368 x 305 mm) rectangle.

b. For 1200 CFM-20-in. (508 mm) round or 14 1/2 x 19 1/2-in. (368 x 495 mm) rectangle.

c. For 1600 CFM-22-in. (559 mm) round or 14 1/2 x 22 1/16-in. (368 x 560mm) rectangle.

d. For airflow requirements above 1800 CFM, see Air Delivery table in Product Data literature for specific use of single side inlets. The use of both side inlets,

a combination of 1 side and the bottom, or the bottom only will ensure adequate return air openings for airflow requirements above 1800 CFM.

Fig. 3 -Dimensional Drawing

Table 1-Dimensions - In. (mm)

ABD VENT ACCESSORY

TOP AND SHIP WT.

FURNACE SIZE CABINET OUTLET BOTTOM CONNECTION FILTER MEDIA

WIDTH WIDTH BOTTOM FLUE INLET WIDTH SIZE LB (KG) CABINET SIZE

COLLAR

070-12/036070 14-3/16 (360) 12-9/16 (319) 9-5/16 (237) 12-11/16 (322) 4 (102) 115 (52) 16 (406)

090-16/048090 17-1/2 (445) 15-7/8 (403) 11-9/16 (294) 16 (406) 4 (102) 130 (59) 16 (406)

110-20/060110 21 (533) 19-3/8 (492) 13-5/16 (338) 19-1/2 (495) 4 (102) 155 (70) 20 (508)

135-22/066135 24-1/2 (622) 22-7/8 (581) 15-1/16 (383) 23 (584) 4 (102)* 166 (75) 24 (610)

155-22/066155 24-1/2 (622) 22-7/8 (581) 15-1/16 (383) 23 (584) 4 (102)* 175 (79) 24 (610)

"135 and 155 size furnaces require a 5 or 6-in. (127 or 152 mm) vent. Use a vent adapter between furnace and vent stack. See Installation Instructions for

complete installation requirements.

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 (ungroun-

ded) furnaces.

6. Before removing a new control from its container, dis-

charge your body's electrostatic charge to ground to pro-

tect the control from damage. If the control is to be in-

stalled in a furnace, follow items 1 through 4 before

bringing the control or yourself in contact with the fur-

nace. Put all used and new controls into containers before

touching ungrounded objects.

7. An ESD service kit (available from commercial sources)

may also be used to prevent ESD damage.

LOCATION

GENERAL

This multipoise furnace is shipped in packaged configuration.

Some assembly and modifications are required when used in any

of the four applications shown in Fig. 4.

NOTE: For high-altitude installations, the high-altitude

conversion kit MUST be installed at or above 5500 ft. (1676 M)

above sea level. Obtain high-altitude conversion kit from your

area authorized distributor.

AIRFLOW

THE BLOWER iS LOCATED

TOTHE RIGHT OFTHE

BURNER SECTION,AND

AIR CONDiTiONED AiR iS

DISCHARGED TOTHE LEFT.

THE BLOWER iS

LOCATEDABOVE THE

BURNERSECTION, AND

CONDiTiONED AIR iS

DISCHARGED DOWNWARD AIRFLOW

THE BLOWER iS

LOCATEDBELOW THE

BURNER SECTION,AND

CONDiTiONED AiR iS

DISCHARGED UPWARD.

AIRFLOW

THE BLOWER iS

LOCATED TO THE LEFT

OF THE BURNER SECTION,

AND CONDiTiONED AiR iS

DISCHARGED TO THE RIGHT.

A02097

Fig. 4 - Multipoise Orientations

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 clear-

ances shown on the furnace clearance to combustible

construction label.

CARBON MONOXIDE POISONING /COMPONENT

DAMAGE 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

OUTDOOR AIR for combustion due to chemical exposures:

• Commercial buildings

• Buildings with indoor pools

• Laundry rooms

• Hobby or craft rooms, and

• Chemical storage areas

If air is exposed to the following substances, it should not be used

for combustion air, and outdoor air may be required for

combustion:

• Permanent wave solutions

• Chlorinated waxes and cleaners

• Chlorine based swimming pool chemicals

• Water softening chemicals

• De-icing salts or chemicals

• Carbon tetrachloride

• Halogen type refrigerants

• Cleaning solvents (such as perchloroethylene)

• Printing inks, paint removers, varnishes, etc.

• Hydrochloric acid

• Cements and glues

• Antistatic fabric softeners for clothes dryers

• Masonry acid washing materials

All fuel-burning equipment must be supplied with air for fuel

combustion. Sufficient air must be provided to avoid negative

pressure in the equipment room or space. A positive seal must be

made between the furnace cabinet and the return-air duct to

prevent pulling air from the burner area and from draft safeguard

opening.

FIRE, INJURY OR DEATH HAZARD

Failure to follow this warning could result in personal

iniury, 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.

(457 mm) above the floor. The furnace must be located or

protected to avoid damage by vehicles. When the furnace is

installed in a public garage, airplane hangar, or other

building having a hazardous atmosphere, the furnace must

be installed in accordance with the NFPA 54/ANSI

Z223.1-2009. (See Fig. 5.)

18qN. (457.2 mm)

MINIMUM TO BURNERS

A93044

Fig. 5 - Installation in a Garage

FIRE HAZARD

Failure to follow this warning could result in personal

iniury, death and/or property damage.

Do not install the furnace on its back or hang furnace with

control compartment facing downward. Safety control

operation will be adversely affected. Never connect

return-air ducts to the back of the furnace. (See Fig. 6.)

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.

PERSONAL INJURY AND/OR PROPERTY

DAMAGE HAZARD

Improper use or installation of this furnace may result in

premature furnace component failure. This gas furnace may

be used for heating buildings under construction provided

that:

-The furnace is permanently installed with all electrical

wiring, piping, venting and ducting installed according to

these installation instructions. A return air duct is provided,

sealed to the furnace casing, and terminated outside the

space containing the furnace. This prevents a negative

pressure condition as created by the circulating air blower,

causing a flame rollout and/or drawing combustion

products into the structure.

-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

ignition, gas input rate, air temperature rise, and venting

according to these installation instructions.

BACK

Fig. 6 - Prohibit Installation on Back

A02054

Table 2 - Minimum Free Area Required for Each Combustion Air opening of Duct to Outdoors

TWO HORIZONTAL DUCTS SINGLE DUCT OR OPENING TWO OPENINGS OR VERTICAL DUCTS

FURNACE (1 SQ. IN./2,000 BTUH) (1,100 SQ. MM/KW) (1 SQ. IN./3,000 BTUH) (734 SQ. MM/KW) (1 SQ. IN./4,000 BTUH) (550 SQ. MM/KW)

iNPUT Free Area of Opening Round Duet Free Area of Opening Round Duet Free Area of Opening Round Duet

(BTUH) and Duet Dia. and Duet Dia. and Duet Dia.

Sq. In. (Sq. ram) In. (ram) Sq. In. (Sq. ram) In. (ram) Sq. In. (Sq. ram) In. (ram)

44,000 22 (14194) 6 (152) 14.7 (9484) 5 (127) 11 (7096) 4 (102)

66,000 33 (21290) 7 (178) 22 (14193) 6 (152) 16.5 (10645) 5 (127)

88,000 44 (28387) 8 (203) 29.3 (18903) 7 (178) 22 (14193) 6 (152)

110,000 55 (35484) 9 (229) 36.7 (23677) 7 (178) 27.5 (17742) 6 (152)

132,000 66 (42580) 10 (254) 44 (28387) 8 (203) 33 (21290) 7 (178)

154,000 77 (49677) 10 (254) 51.3 (33096) 9 (229) 38.5 (24839) 8 (203)

gE : Determining Free Area

FURNACE WATERHEATER TOTAL INPUT

110,000 + 30,000 = (140,000 divided by 4,000) = 35.0 Sq. In. for each two Vertical Ducts or Openings

66,000 + 40,000 = (106,000 divided by 3,000) =35.3 Sq. In. for a Single Duct or Opening

88,000 + 30,000 = (118,000 divided by 2,000) = 59.0 Sq. In. for each of two Horizontal Ducts

Table 3 -Minimum Space Volumes for 100 % Combustion, Ventilation, and Dilution from Indoors

OTHER THAN FAN-ASSISTED TOTAL FAN-ASSISTED TOTAL

(1,000'S BTUH GAS INPUT RATE) (1,000'S BTUH GAS INPUT RATE)

30 40 50 44 66 88 110 132 154

AOH Space Volume Ft 3 (M 3)

1,050 1,400 1,750 1,100 1,650 2,200 2,750 3,300 3,850

0.60 (29.7) (39.6) (49.5) (31.1) (46.7) (62.2) (77.8) (93.4) (109.0)

1,260 1,680 2,100 1,320 1,980 2,640 3,300 3,960 4,620

0.50 (35.6) (47.5) (59.4) (37.3) (56.0) (74.7) (93.4) (112.1) (130.8)

1,575 2,100 2,625 1,650 2,475 3,300 4,125 4,950 5,775

0.40 (44.5) (59.4) (74.3) (46.7) (70.0) (93.4) (116.8) (140.1) (163.5)

2,100 2,800 3,500 2,200 3,300 4,400 5,500 6,600 %700

0.30 (59.4) (79.2) (99.1) (62.2) (93.4) (124.5) (155.7) (186.8) (218.0)

3,150 4,200 3,300 4,950 6,600 8,250 %900 11,550

0.20 (89.1) (118.9) 5,250 (148.6) (93.4) (140.1) (186.8) (233.6) (280.3) (327.0)

6,300 8,400 10,500 6,600 %900 13,200 16,500 1%800 23,100

0.10 (178.3) (237.8) (297.3) (186.8) (280.3) (373.7) (467.2) (560.6) (654.1)

0.00 NP NP NP NP NP NP NP NP NP

NP = Not Permitted

AIR FOR COMBUSTION AND

VENTILATION

Provisions for adequate combustion, ventilation, and dilution air

must be provided in accordance with:

• U.S. Installations: Section 9.3 of the NFPA 54/ANSI

Z223.1-2009, Air for Combustion and Ventilation and

applicable provisions of the local building codes.

FURNACE CORROSION HAZARD

Failure to follow this caution may result in furnace damage.

Air for combustion nmst 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.

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.

PER 4000

OUTDOORS BTUH*

*Minimum dimensions of 3-in. (76 mm).

NOTE: Use any of the following combinations of openings:

A&BC&DD&EF&G

A03174

Fig. 7 - Air for Combustion, Ventilation, and Dilution for

Outdoors

•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 combus-

tion, ventilation, and dilution of flue gases using perman-

ent horizontal or vertical duct(s) or opening(s) directly

communicating with the outdoors or spaces that freely

communicate with the outdoors.

2. Fig. 7 illustrates how to provide TWO OUTDOOR

OPENINGS, one inlet and one outlet combustion and

ventilation air opening, to the outdoors.

e. One opening MUST commence within 12 in. (300

ram) of the ceiling and the second opening MUST

commence within 12 in. (300 ram) of the floor.

f. Size openings and ducts per Fig. 7 and Table 2.

g. TWO HORIZONTAL DUCTS require 1 sq. in. (645

sq. ram) of free area per 2,000 Btuh (1,100 mm2/kW)

of combined input for all gas appliances in the space

per Fig. 7 and Table 2.

h. TWO OPENINGS OR VERTICAL DUCTS require 1

sq. in. (645 sq. ram) of free area per 4,000 Btuh (550

mm2/kW) for combined input of all gas appliances in

the space per Fig. 7 and Table 2.

3. ONE OUTDOOR OPENING requires:

a. 1 sq. in. (645 sq. ram) of free area per 3,000 Btuh

(734 mm2/kW) for combined input of all gas appli-

ances in the space per Table 2 and

b. Not less than the sum of the areas of all vent connect-

ors in the space.

CIRCULATING AiR

DUCTS

I I

1 1

INTERIOR

HEATED

SPACE

VENT THROUGH ROOF

I I

(305ram)

•

F-Z_ ------1 SQ IN.

PER t000

BTUH* IN DOOR

OR WALL

UNCONFINED

SPACE

6" MIN (152mm)

(FRONT)0

I I

CIRCULATING AIR DUCTS

1 SQ IN.

PER t000

BTUH* IN DOOR

-- OR WALL

L 12" MAX (305ram)

* Minimum opening size is 100 sq in. (64516 sq, mm)with minimum dimensions

of 3 in. (76 mm)

1-Minimum of 3 in. (76 mm) when type-B1 vent is used.

A03175

Fig. 8 - Air for Combustion, Ventilation, and Dilution from

Indoors

The opening shall commence within 12 in. (300 ram) of the

ceiling. Appliances in the space shall have clearances of at least 1

in. (25 ram) from the sides and back and 6 in. (150 ram) from the

front. The opening shall directly communicate with the outdoors

or shall conmmnicate through a vertical or horizontal duct to the

outdoors or spaces (crawl or attic) that freely communicate with

the outdoors.

Indoor Combustion Air© NFPA & AGA

Standard and Known-Air-Infiltration Rate Methods

Indoor air is pernfitted for combustion, ventilation, and dilution,

if the Standard or Known-Air-Infiltration Method is used,

CARBON MONOXIDE POISONING HAZARD

Failure to follow this warning could result in personal

iniury or death.

Many homes require air to be supplied from outdoors

for furnace combustion, ventilation, and dilution of flue

gases.

The furnace combustion air supply nmst be provided in

accordance with this instruction manual.

The Standard Method:

1. The space has no less volume than 50 cubic feet per 1,000

Btuh of the maximum input ratings for all gas appliances

installed in the space and

2. The air infiltration rate is not known to be less than 0.40

air changes per hour (ACH).

The Known Air Infiltration Rate Method shall be used, if the

infiltration rate is known to be:

1. Less than 0.40 ACH and

2. Equal to or greater than 0.10 ACH

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 deternfined per Table 3 or Equations 1 and 2.

Deternfine 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 deternfined by using

the following equations from the National Fuel Gas Code ANSI

Z223.1-2009/NFPA 54-2009, 9.3.2.2:

1. For other than fan-assisted appliances, such as a draft

hood-equipped water heater:

Volume - 21ft3 L_ !other

Other ACH H000 Btu/hr

A04002

2. For fan-assisted appliances such as this furnace:

Volume

Fat?

A04003

If: Iother =combined input of all other than fan-assisted

appliances in Btuh/hr

Ifan = combined input of all fan-assisted appliances in Btuh/hr

ACH = air changes per hour (ACH shall not exceed 0.60.)

The following requirements apply to the Standard Method and

to the Known Air Infiltration Rate Method.

1. Adjoining rooms can be considered part of a space if:

a. There are no closeable doors between rooms.

b. Combining spaces on same floor level. Each opening

shall have free area of at least 1 in.2/1,000 Btuh (2,000

mm2/kW) of the total input rating of all gas appliances

in the space, but not less than 100 in. 2 (0.06 m2). One

opening shall commence within 12 in. (300 ram) of

the ceiling and the second opening shall commence

within 12 in. (300 ram) of the floor. The minimum

dimension of air openings shall be at least 3 in. (80

ram). (See Fig. 8.)

c. Combining space on different floor levels. The

volumes of spaces on different floor levels shall be

considered as conmmnicating spaces if connected by

one or more permanent openings in doors or floors

having free area of at least 2 in.2/1,000 Btuh (4,400

mm2/kW) of total input rating of all gas appliances.

2. An attic or crawlspace may be considered a space that

freely conmmnicates with the outdoors provided there are

adequate permanent ventilation openings directly to out-

doors having free area of at least 1-in.2/4,000 Btuh of total

input rating for all gas appliances in the space.

3. In spaces that use the Indoor Combustion Air Method,

infiltration should be adequate to provide air for combus-

tion, permanent ventilation and dilution of flue gases.

However, in buildings with unusually tight construction,

additional air MUST be provided using the methods de-

scribed in the Outdoor Combustion Air Method section.

4. Unusually tight construction is defined as Construction

with:

a. Walls and ceilings exposed to the outdoors have a con-

tinuous, 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 Combus-

tion Air Method below and,

2. Outdoor openings shall be located as required in the Out-

door Combustion Air Method mentioned previously and,

3. Outdoor openings shall be sized as follows:

a. Calculate the Ratio of all Indoor Space volume divided

by required volume for Indoor Combustion Air

Method below.

b. Outdoor opening size reduction Factor is 1 nfinus the

Ratio in a. above.

c. Minimum size of Outdoor openings shall be the size

required in Outdoor Combustion Air Method above

nmltiplied by reduction Factor in b. above. The nfin-

imum dimension of air openings shall be not less than

3 in. (80 mm).

INSTALLATION

UPFLOW INSTALLATION

Bottom Return Air Inlet

These furnaces are shipped with bottom closure panel installed in

bottom return-air opening. Remove and discard this panel when

bottom return air is used. To remove bottom closure panel,

perform the following:

1. Tilt or raise furnace and remove 2 screws holding bottom

filler panel. (See Fig. 9.)

2. Rotate bottom filler panel downward to release holding

tabs.

3. Remove bottom closure panel.

4. Reinstall bottom filler panel and screws.

Side Return Air Inlet

These furnaces are shipped with bottom closure panel installed in

bottom return-air opening. This panel MUST be in place when

only side return air is used.

Bottom

Closure Panel

Bottom Filler Panel

Fig. 9 -Removing Bottom Closure Panel

A10273

NOTE: Side return-air openings can be used in UPFLOW and

most HORIZONTAL configurations. Do not use side return-air

openings in DOWNFLOW configuration,

Levelin_ Le_s (If Desired)

In upflow position with side return inlet(s), leveling legs may be

used. (See Fig. 10.) Install field-supplied, 5/16 X 1-1/2 in. (8 X

38 ram) (max) corrosion-resistant machine bolts, washers and

nuts.

(8ram)

13/4

(44ram)

(8ram)

5/16"

1 3/4"

(44ram)

(8ram)

(44mm) 1 3/4"

(44mm) 1

A89014

Fig. 10 -Leveling Legs

NOTE: Bottom closure must be used when leveling legs are

used. It may be necessary to remove and reinstall bottom closure

panel to install leveling legs. To remove bottom closure panel, see

Item 1 in Bottom Return Air Inlet section in Step 1 above.

To install leveling legs:

1. Position furnace on its back. Locate and drill a hole in

each bottom corner of furnace. (See Fig. 10.)

2. For each leg, install nut on bolt and then install bolt with

nut in hole. (Install flat washer if desired.)

3. Install another nut on other side of furnace base. (Install

flat washer if desired.)

4. Adjust outside nut to provide desired height, and tighten

inside nut to secure arrangement.

5. Reinstall bottom closure panel if removed.

DOWNFLOW INSTALLATION

NOTE: For downflow applications, this furnace is approved for

use on combustible flooring when any one of the following 3

accessories are used:

• Special Base, KGASB

• Cased Coil Assembly Part No. CNPV, CNRV, CAP, or

CAR

• Coil Box Part No. KCAKC

1. Deternfine 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. CPVP, CAPMP or

CNPVP 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 seamers to bend flange back and forth until it breaks off. Be

careful of sharp edges. (See Fig. 14 0

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 0

2. Rotate bottom filler panel downward to release holding

tabs.

3. Remove bottom closure panel.

4. Reinstall bottom filler panel and screws.

HORIZONTAL INSTALLATION

FIRE, EXPLOSION, AND CARBON MONOXIDE

POISONING HAZARD

Failure to follow this warning could result in personal

iniury, death, or property damage.

Do not install the furnace on its back or hang furnace with

control compartment facing downward. Safety control

operation will be adversely affected. Never connect

return-air ducts to the back of the furnace.

The furnace can be installed horizontally in an attic or crawlspace

on either the left-hand (LH) or right-hand (RH) side. The furnace

can be hung from floor joists, rafters or trusses or installed on a

non-combustible platform, blocks, bricks or pad.

Suspended Furnace Support

The furnace may be supported under each end with threaded rod,

angle iron or metal plumber's strap as shown. (See Fig. 15 and

16.) Secure angle iron to bottom of furnace as shown.

Heavy-gauge sheet metal straps (plumber's straps) may be used

to suspend the furnace from each bottom corner. To prevent

screws from pulling out, use 2 #8 x in. screws into the side and 2

#8 x in. screws in the bottom of the furnace casing for each strap.

(See Fig. 15 and 16.)

If the screws are attached to ONLY the furnace sides and not the

bottom, the straps nmst be vertical against the furnace sides and

not pull away from the furnace sides, so that the strap attachment

screws are not in tension (are loaded in shear) for reliable support.

Platform Furnace Support

Construct working platform at location where all required furnace

clearances are met. (See Fig. 2 and 170 For furnaces with 1-in.

(25 ram) clearance requirement on side, set furnace on

non-combustible blocks, bricks or angle iron. For crawlspace

installations, if the furnace is not suspended from the floor joists,

the ground underneath furnace must be level and the furnace set

on blocks or bricks.

A96283

Fig. 11 - Floor and Plenum Opening Dimensions

Roll- Out Protection

Provide a minimum 17-3/4-in. X 22-in. (451 X 559 ram) piece

of sheet metal for flame roll-out protection in front of burner area

for furnaces closer than 12-in. (305 ram) above the combustible

deck or suspended furnaces closer than 12-in. (305 ram) to joists.

The sheet metal MUST extend underneath the furnace casing by

l-in. (25 ram)with the door removed.

The bottom closure panel on furnaces of widths 17-1/2-in. (445

ram) and larger may be used for flame roll-out protection when

bottom of furnace is used for return air connection. See Fig. 17

for proper orientation of roll-out shield.

Bottom Return Air Inlet

These furnaces are shipped with bottom closure panel installed in

bottom return-air opening. Remove and discard this panel when

bottom return air is used. To remove bottom closure panel,

perform the following:

1. Tilt or raise furnace and remove two screws holding bot-

tom 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,

FURNACE

(OR COIL CASING

WHEN USED)

COMBUSTIBLE

FLOORING

DOWNFLOW

SUBBASE

SHEET METAL

PLENUM

__ FLOOR __

OPENING

A96285

Fig. 12 -Furnace, Plenum, and Subbase Installed on a

Combustible Floor

FURNACE

APPROVED

COIL ASSEMBLY

COIL BOX

/_ COMBUSTIBLE

FLOORING _N

SHEET METAL ____

PLENUM

FLOOR

OPENING i/

A08556

Fig. 13 -Furnace, Plenum, and Coil Assembly or Coil Box

Installed on a Combustible Floor

Not all horizontal furnaces are approved for side return air

connections (See Fig. 20.)

Table4-Opening Dimensions - In. (mm)

FURNACE

CASING

WIDTH

IN.(mm)

APPLICATION

PLENUM OPENING FLOOR OPENING

A B C D

Upflow Applications on Combustible or Noncombustible Floor- 12-11/16 21-5/8 13-5/16 22-1/4

ing (KGASB subbase not required) (322) (549) (338) (565)

Downflow Applications on Noncombustible Flooring (KGASB 12-9/16 19 13-3/16 19-5/8

subbase not required) (819) (483) (335) (498)

14-3/16 Downflow applications on combustible flooring (KGASB sub- 11 - 18/16 19 18- 7/16 20- 5/8

(360) base required) (284) (483) (341) (600)

Downflow Applications on Combustible Flooring with CNPV, 12-5/16 19 13-5/16 20

CNRV, CAR or CAP Coil Assembly or KCAKC coil box (KGASB

subbase not required) (819) (483) (338) (508)

Upflow Applications on Combustible or Noncombustible Floor- 16 21 -5/8 16-5/8 22-1/4

ing (KGASB subbase not required) (406) (549) (422) (565)

Downflow Applications on Noncombustible Flooring (KGASB 15-7/8 19 16-1/2 19-5/8

subbase not required) (403) (483) (419) (498)

17-1/2 Downflow applications on combustible flooring (KGAS B su b- 15-1/8 19 16-3/4 20-5/8

(445) base required) (384) (483) (425) (600)

Downflow Applications on Combustible Flooring with CNPV, 15-1/2 19 16-1/2 20

CNRV, CAR or CAP Coil Assembly or KCAKC coil box (KGASB

subbase not required) (394) (483) (419) (508)

Upflow Applications on Combustible or Noncombustible Floor- 19-1/2 21-5/8 20-1/8 22-1/4

ing (KGASB subbase not required) (495) (549) (511) (565)

Downflow Applications on Noncombustible Flooring (KGASB 19-3/8 19 20 19-5/8

subbase not required) (492) (483) (508) (498)

21 Downflow applications on combustible flooring (KGASB sub- 18-5/8 19 20-1/4 20-5/8

(533) base required) (473) (483) (514) (600)

Downflow Applications on Combustible Flooring with CNPV, 19 19 20 20

CNRV, CAR or CAP Coil Assembly or KCAKC coil box (KGASB

subbase not required) (483) (483) (508) (508)

Upflow Applications on Combustible or Noncombustible Floor- 23 21 - 1/8 28- 5/8 22-1/4

ing (KGASB subbase not required) (584) (537) (600) (565)

Downflow Applications on Noncombustible Flooring (KGASB 22-7/8 19 28-1/2 19-5/8

subbase not required) (581) (483) (597) (498)

24-1/2 Downflow applications on Combustible flooring (KGAS B su b- 22-1/8 19 28- 3/4 20-5/8

(622) base required) (562) (483) (603) (600)

Downflow Applications on Combustible Flooring with CNPV, 22-1/2 19 23-1/2 20

CNRV, CAR or CAP Coil Assembly or KCAKC coil box (KGASB

subbase not required) (572) (483) (597) (508)

Filter Arrangement

CARBON MONOXIDE POISONING HAZARD

Failure to follow this warning could result in personal

injury, or death.

Never operate a furnace without a filter or with filter access

door removed.

There are no provisions for an internal filter rack in these

furnaces. A field-supplied accessory external filter rack is

required.

Refer to the instructions supplied with the external filter rack for

assembly and installation options.

AIR DUCTS

General Requirements

The duct system should be designed and sized according to

accepted national standards such as those published by: Air

Conditioning Contractors Association (ACCA), Sheet Metal and

Air Conditioning Contractors National Association (SMACNA)

or American Society of Heating, Refrigerating and Air

Conditioning Engineers (ASHRAE) or consult The Air Systems

Design Guidelines reference tables available from your local

distributor. The duct system should be sized to handle the

required system design CFM at the design external static pressure.

The furnace airflow rates are provided in Table 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

ternfinating 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 transnfission of vibration.

Ductwork passing through unconditioned space should be

insulated to enhance system performance. When air conditioning

is used, a vapor barrier is recommended.

Maintain a 1-in. (25 ram) clearance from combustible materials

to supply air ductwork for a distance of 36-in. (914 ram)

horizontally from the furnace. See NFPA 90B or local code for

further requirements.

Ductwork Acoustical Treatment

NOTE: Metal duct systems that do not have a 90 degree elbow

and 10 ft. (3 M) of main duct to the first branch take-off may

require internal acoustical lining. As an alternative, fibrous

ductwork may be used if constructed and installed in accordance

with the latest edition of SMACNA construction standard on

fibrous glass ducts. Both acoustical lining and fibrous ductwork

shall comply with NFPA 90B as tested by UL Standard 181 for

Class 1 Rigid air ducts.

Supply Air Connections

For a furnace not equipped with a cooling coil, the outlet duct

shall be provided with aremovable access panel. This opening

shall be accessible when the furnace is installed and shall be of

such asize that the heat exchanger can be viewed for possible

openings using light assistance or aprobe can be inserted for

sampling the air stream. The cover attachment shall prevent leaks.

Upflow and Horizontal Furnaces

Connect supply-air duct to flanges on furnace supply-air outlet.

Bend flange upward to 90 ° with wide duct pliers. (See Fig. 14.)

The supply-air duct must be connected to ONLY the furnace

supply-outlet-air duct flanges or air conditioning coil casing

(when used). DO NOT cut main furnace casing side to attach

supply air duct, humidifier, or other accessories. All accessories

MUST be connected to duct external to furnace main casing.

NOTE: For horizontal applications, the top most flange may be

bent past 90 ° to allow the evaporator coil to hang on the flange

temporarily while the remaining attachment and sealing of the

coil are performed.

Downflow Furnaces

Connect supply-air duct to supply-air outlet on furnace. Bend

flange inward past 90 ° with wide duct pliers (See Fig. 14.) The

supply-air duct must be connected to ONLY the furnace supply

outlet or air conditioning coil casing (when used). When installed

on combustible material, supply-air duct must be connected to

ONLY the factory-approved accessory subbase, or a

factory-approved air conditioning coil casing. DO NOT cut main

furnace casing to attach supply side air duct, humidifier, or other

accessories. All accessories MUST be connected to duct external

to furnace casing.

UPFLOW DOWNFLOW HORIZONTAL

YES YES

I ......

YES

120°_

MIN

YES

12oo_

MIN

YES \

120°_

MIN

YES

NO NO NO

Fig. 14 - Duct Flanges

A02020

1/4'1 (6mm) THREADED ROD

4 REQ. J

UTER DOOF

ASSEMBLY

8" (203mm) MIN

FOR DOOR REMOVAL

SECURE ANGLE

IRON TO BOTTOM

OF FURNACE WITH

3 #8 xS/4'' (19ram) SCREWS

TYPICAL FOR 2 SUPPORTS

1" (25mm) SQUARE, 1-1/4"xt-1/4"xl/8" (32x32x3mm)

ANGLE IRON OR UNI-STRUT MAY BE USED

(2) HEX NUTS, (2) WASHERS & (2) LOCK WASHERS

REQ. PER ROD

Fig. 15 -Horizontal Unit Suspension

A10130

OUTER DOOR

ASSEMB_

22 GAUGE GALVANIZED

STRAPS TYPICAL

FOR 4 STRAPS

AIR

METHOD 2

USE (4) #8 x 3/4 (19 ram) SHEET

METAL SCREWS FOR EACH

STRAR THE STRAPS

SHOULD BE VERTICAL

AGAINST THE FURNACE

SIDES AND NOT PULL AWAY

FROM THE FURNACE

SIDES.

BACK OF

FURNACE

METHOD 1

FOLD ALL STRAPS UNDER

FURNACE AND SECURE WTH

(4) #8 x 3/4 (t9 ram) SHEET METAL SCREWS

(2 SCREWS IN SIDE AND 2 SCREWS

IN BOTTOM).

Fig. 16 - Horizontal Suspension with Straps

A10131

LINE CONTACT ONLY PERMISSIBLE BETWEEN

LINES FORMED BY INTERSECTIONS OF

THE TOP AND TWO SIDES OF THE FURNACE

JACKET AND BUILDING JOISTS,

STUDS, OR FRAMING.

EQUIPMENT MANUAL

SHUT-OFF GAS VALVE

SEDIMENT UNION

TRAP

ENTRY VENT

Fig. 17 - Typical Attic Installation

17 3/4" (451 mm)OVERALL

43/4" (121mm) UNDER DOOR

1" (25mm) UNDER FURNACE

EXTEND OUT 12" (305mm)

FROM FACE OF DOOR

_0-1N.(762mm)

MIN WORK AREA *WHEN USED WITH

SINGLE WALL VENT

CONNECTIONS

A10164

RETURN

AIR

UPFLOW RETURN AIR CONFIGURATIONS AND RESTRICTIONS

AIR FLOW MODELS RETURN AIR RETURN AIR RETURN AIR RETURN AIR

CONNECTION 1 CONNECTmON 2 CONNECTmON 3 COMBINATIONS

ONLY ONLY ONLY OF 1,2, AND 3

066.060, -22 AND YES YES YES YES

-20 MODELS

ALL OTHER MODELS YES YES YES YES

Fig. 18 - Upflow Return Air Configurations and Restrictions

A02075

DOWNFLCAN RETURN AiR CONFIGURAT1ONSAND RESTRICTIONS

AIR FLOW MODELS RETURN AIR RETURN AIR RETURN AIR RETURN AIR

CONNECTION 1 CONNECTION 2 CONNECTION 3 COMBINATIONS

ONLY ONLY ONLY OF 1, 2, AND 3

066,060, -22 AND YES NO NO NO

-20 MODELS

ALL OTHER MODELS YES NO NO NO

Fig. 19 - Downflow Return Air Configurations and Restrictions

A02163 g

RETURN

AIR

REIURN

AIR

@ £q/DTE.........

I 066.060.-22-20

/ ii

IVII©............. I IVI

NOTPERMITTEDFOR

066.060.-22-20

........................._ .......................... IIORIZONAL

RETURN RETURNAIR

HORIZONALNOIE:RESI RIC11ONLEFTSAMEFOR _ AIR RESTRICTIONS

"% /HORIZONTAL RETURN AIR CONFIGURATIONS AND RESTRICTIONS

AIR FLOW MODELS RETURN AIR RETURN AIR RETURN AIR RETURN AIR

CONNECTION 1 CONNECTION 2 CONNECTION 3 COMBINATIONS

ONLY ONLY ONLY OF 1, 2, AND 3

066.060, -22 AND YES NO NO NO

-20 MODELS

ALL OTHER MODELS YES YES YES YES

Fig. 20 -Horizontal Return Air Configurations and Restrictions

A02162

Table 5- Air Delivery - CFM (With Filter)*

External

CFM Static External Static Pressure (ESP) (IN. W.C.)

Unit Size Operating Mode Airflow Pressure

Setting Range* 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.6 0.9 1

(In. W.C.)

1-1- Low Heat 735 (615)1- 0-0.50 735 735 735 735 725

High Heat 1180 (1060)1- 0-1.0 1160 1165 1175 1180 1180 1180 1180 1180 1180 1175

1-1- 1-1/2-Ton Cooling 525 0-0.505 515 500 500 490 485

1-1- 2-Ton A/C Cooling 700 0-0.505 690 680 675 680 675

2-1/2-Ton A/C Cooling 875 0-1.05 875 875 875 870 865 855 850 835 825 820

3-Ton A/C Cooling 1050 0-1.05 1050 1050 1050 1050 1050 1050 1045 1035 1020 1000

3-1/2-Ton A/C Cooling 1225 0-1.0 1220 1225 1225 1225 1225 1220 1205 1190 1185 1170

Maximum 1400 0-1.0 1395 1400 1400 1400 1395 1385 1370 1340 1300 1245

Low Heat 985 (825)1- 0-1.0 950 970 985 985 985 985 985 985 985 980

High Heat 1210 (1090)1- 0-1.0 1190 1205 1210 1210 1210 1210 1210 1210 1210 1200

1-1- 1-1/2-Ton A/C Cooling 525 0-0.50_: 525 520 525 495 475

1-1- 2-Ton A/C Cooling 700 0-0.505 680 680 680 675 670

2-1/2-Ton A/C Cooling 875 0-1.05 815 845 845 855 850 850 845 835 820 805

3-Ton A/C Cooling 1050 0-1.05 1005 1005 1015 1035 1040 1040 1035 1030 1025 1010

3-1/2-Ton A/C Cooling 1225 0-1.0 1190 1200 1200 1205 1205 1215 1205 1200 1185 1170

4-Ton A/C Cooling 1400 0-1.0 1350 1370 1390 1390 1400 1390 1380 1380 1360 1340

Maximum 1600 0-1.0 1595 1600 1600 1600 1595 1555 1505 1465 1430 1390

Low Heat 1320 (1110)1- 0-1.0 1275 1295 1315 1320 1320 1320 1320 1320 1320 1315

High Heat 1475 (1330)1- 0-1.0 1460 1465 1475 1475 1475 1475 1475 1475 1465 1465

1-1- 2-Ton A/C Cooling 700 0-0.505 700 700 700 700 700

1-1- 2-1/2-Ton A/C Cooling 875 0-0.505 875 875 875 875 875

1-1- 3-Ton A/C Cooling 1050 0-0.505 1050 1050 1050 1050 1050

3-1/2-Ton A/C Cooling 1225 0-1.05 1225 1225 1225 1225 1225 1225 1225 1225 1225 1225

4-Ton A/C Cooling 1400 0-1.05 1400 1400 1400 1400 1400 1400 1400 1400 1400 1400

5-Ton A/C Cooling 1750 0-1.05 1750 1750 1750 1750 1750 1750 1750 1750 1740 1725

6-Ton A/C Cooling 2100 0-1.0 2100 2100 2100 2100 2090 2075 2055 2040 2005 1970

Maximum 2200 0-1.0 2200 2190 2190 2180 2155 2145 2125 2100 2080 2020

Low Heat 1700 (1430)1- 0-1.0 1700 1700 1700 1700 1700 1695 1700 1695 1685 1670

High Heat 1915 (1725)1- 0-1.0 1900 1905 1915 1915 1915 1915 1915 1915 1915 1915

1-1- 2-Ton A/C Cooling 700 0-0.505 700 700 700 700 665

1-1- 2-1/2-Ton A/C Cooling 875 0-0.505 870 870 865 865 865

1-1- 3-Ton A/C Cooling 1050 0-0.505 1010 1030 1050 1050 1050

3-1/2-Ton A/C Cooling 1225 0-1.05 1155 1180 1200 1210 1220 1225 1225 1225 1225 1225

4-Ton A/C Cooling 1400 0-1.05 1395 1400 1400 1400 1400 1400 1400 1390 1375 1355

5-Ton A/C Cooling 1750 0-1.05 1740 1750 1750 1750 1735 1740 1735 1730 1715 1700

6-Ton A/C 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

1705 1705 1695

1970 1970 1960

Low Heat 1715 (1440)1- 0-1.0 1715 1715 1715 1715 1715 1705 1710

High Heat 1970 (1775)1- 0-1.0 1955 1965 1965 1970 1970 1970 1970

2-Ton A/C Cooling 700 0-0.505 700 700 700 700 680

2-1/2-Ton A/C Cooling 875 0-0.505 865 875 875 865 865

3-Ton A/C Cooling 1050 0-0.505 1015 1020 1035 1045 1050

3-1/2-Ton A/C Cooling 1225 0-1.05 1160 1185 1215 1225 1225 1225 1225

4-Ton A/C Cooling 1400 0-1.05 1385 1400 1400 1400 1400 1400 1395

5-Ton A/C Cooling 1750 0-1.05 1745 1750 1750 1750 1745 1740 1745

6-Ton A/C Cooling 2100 0-1.0 2055 2070 2080 2085 2095 2100 2100

Maximum 2200 0-1.0 2175 2190 2200 2200 2200 2200 2200

1225 1225 1225

1395 1380 1360

1745 1740 1735

2100 2090 2065

2200 2180 2160

*Actual external static pressure (ESP) can be determined by using the fan laws (CFM 2 proportional to ESP); such as, a system with 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.

1-Comfort airflow values are shown in parenthesis. Comfort airflow is selected when the low-heat rise adjustment switch (SW1-3) is OFF and

the comfort/efficiency switch (SW1-4) is ON.

SDuctwork must be sized for high-heating CFM within the operational range of ESP.

1-1-Operation within the blank areas of the chart is not recommended because high-heat operation will be above 1.0 ESP.

***All airflow on 110 size furnace are 5% less on side return only installations.

Return Air Connections

FIRE HAZARD

A failure to follow this warning could cause personal injury,

death and/or property damage.

Never connect return-air ducts to the back of the furnace.

Follow instructions below.

Downflow Furnaces

The return-air duct nmst 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 pernfitted for only upflow and

certain horizontal furnaces. Bypass hunfidifier 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

FIRE OR EXPLOSION HAZARD

Failure to follow this warning could result in personal

injury, death, and/or property damage.

Never purge a gas line into a combustion chamber. Never

test for gas leaks with an open flame. Use a commercially

available soap solution made specifically for the detection

of leaks to check all connections. A fire or explosion may

result causing property damage, personal injury or loss of

life.

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.

FIRE OR EXPLOSION HAZARD

Failure to follow this warning could result in personal

iniury, 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 nmst be installed in accordance with national and

local codes. Refer to current edition of NFGC in the U.S.

Installations nmst 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 li-

censed plumber or gas fitter.

2. When flexible connectors are used, the maximum length

shall not exceed 36 in. (915 ram).

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 nmst be

used to connect to furnace and to meter. Support all gas piping

with appropriate straps, hangers, etc. Use a minimum of 1 hanger

every 6 ft. (1.8 M). Joint compound (pipe dope) should be

applied sparingly and only to male threads of joints. Pipe dope

must be resistant to the action of propane gas.

Table 6-Maximum Capacity of Pipe

NOMINAL

IRON PiPE

SIZE

IN. (MM)

1/2 (12.7)

3/4 (19.0)

1(25.4)

1-1/4

(31.8)

1-1/2

(38.1)

INTERNAL LENGTH OF PiPE - FT (M)

DIA. 10 20 30 40 50

IN. (MM) (3.0) (6.0) (9.1) (12.1) (15.2)

0.622(158) 175 120 97 82 73

0.824 (20.9) 360 250 200 170 151

1.049 (26.6) 680 465 375 320 285

1.380 (35.0) 1400 950 770 660 580

1.610 (40.9) 2100 1460 1180 990 900

*Cubic ft of gas per hr for gas pressures of 0.5 psig (14- In. W.C.) or less and

a pressure drop of 0.5-In. W.C. (based on a 0.60 specific gravity gas). Ref:

Table 6 and 9.2 NFGC.

FIRE OR EXPLOSION HAZARD

A failure to follow this warning could result in personal

iniury, 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 nfininmm of 2-in. (51 ram)

outside the furnace.

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 nfisalignment.

An accessible manual equipment shutoff valve MUST be

installed external to furnace casing and within 6 ft. (1.8 M) of

furnace. A 1/8-in. (3 ram) NPT plugged tapping, accessible for

test gauge connection, MUST be installed immediately upstream

of gas supply connection to furnace and downstream of manual

equipment shutoff valve.

NOTE: The furnace gas control valve inlet pressure tap

connection is suitable to use as test gauge connection providing

test pressure DOES NOT exceed maximum 0.5 psig (14-In.

W.C.) stated on gas control valve. (See Fig. 50.)

Some installations require gas entry on right side of furnace (as

viewed in upflow). (See Fig. 21.)

Install a sediment trap in riser leading to furnace as shown in Fig.

22. Connect a capped nipple into lower end of tee. Capped nipple

should extend below level of furnace gas controls. Place a ground

joint union between furnace gas control valve and exterior

manual equipment gas shutoff valve.

A 1/8-in. (3 ram) NPT plugged tapping, accessible for test gauge

connection, MUST be installed immediately upstream of gas

supply connection to furnace and downstream of manual

equipment shutoff valve.

Piping should be pressure and leak tested in accordance with the

current addition of the NFGC in the United States, local, and

national plumbing and gas codes before the furnace has been

connected. After all connections have been made, purge lines and

check for leakage at furnace prior to operating furnace.

If pressure exceeds 0.5 psig (14-In. W.C.), gas supply pipe nmst

be disconnected from furnace and capped before and during

supply pipe pressure test. If test pressure is equal to or less than

0.5 psig (14-In. W.C.), turn off electric shutoff switch located on

furnace gas control valve and accessible manual equipment

shutoff valve before and during supply pipe pressure test. After

all connections have been made, purge lines and check for

leakage at furnace prior to operating furnace.

The gas supply pressure shall be within the maximum and

minimum inlet supply pressures marked on the rating plate with

the furnace burners ON and OFF.

TOP VIEW OF BURNER AND MANIFOLD ASSEMBLY

90 ° Elbow

2"(51mm) Nipple

Street Elbow

L Gas Valve

Fig. 21 -Burner and Manifold

GAS _

SUPPLY/3f

MANUAL _/ II

SHUTOFF J_ _

VALVE

(REQUI RED)j2_'_'

SEDIMENT-- ]

TRAP [

UNION.-.J

Supply

A08551

Fig. 22 -Typical Gas Pipe Arrangement

A02035

ELECTRICAL CONNECTIONS

ELECTRICAL SHOCK HAZARD

Failure to follow this warning could result in personal

iniury or death.

Blower access panel door switch opens l15-v power to

control. No component operation can occur. Do not

bypass or close switch with panel removed.

See Fig. 25 for field wiring diagram showing typical field 115-v

wiring. Check all factory and field electrical connections for

tightness.

Field-supplied wiring shall conform with the linfitations of 63 °F

(33 ° C) rise.

ELECTRICAL SHOCK AND FIRE HAZARD

Failure to follow this warning could result in personal

iniury, death, or property damage.

The cabinet MUST have an uninterrupted or unbroken

ground according to NEC ANSI/NFPA 70-2011 or local

codes to nfininfize personal iniury if an electrical fault

should occur. This may consist of electrical wire, conduit

approved for electrical ground or a listed, grounded power

cord (where pernfitted 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.

FURNACE MAY NOT OPERATE HAZARD

Failure to follow this caution may result in internfittent

furnace operation,

Furnace control must be grounded for proper operation or

else control will lock out. Control nmst remain grounded

through green/yellow wire routed to gas valve and manifold

bracket screw,

llS-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.

U.S. Installations: Make all electrical connections in accordance

with National Electrical Code (NEC) ANSI/NFPA 70-2011 and

any local codes or ordinances that nfight apply.

Table7-Electrical Data

FURNACE

SiZE

070-12/036070

090-16/048090

110-20/060110

135 -22/066135

155 -22/066155

VOLTS-

HERTZ-

PHASE

115-60-1

OPERATING

VOLTAGE RANGE*

Max. Min.

127 lO4

MAX. UNiT

AMPS

9.0

9.6

15.1

14.9

15.0

Permissible limits of the voltage range at which the unit operates satisfactorily.

UNiT

AMPACITY

11.99

12.56

19.33

19.13

19.23

MAX. WiRE

LENGTH = FT (M):_

30 (9.0)

29 (8.8)

30 (9.0)

29 (8.8)

MIN.

MAX. FUSE OR WiRE

CKT BKR AMPS 1" GAUGE

15 14

20 12

# Unit ampacity = 125 percent of largest operating component's full load amps plus 100 percent of all other potential operating components' (EAC, humidifier,

etc.) full load amps.

1"Time-delay type is recommended.

:[:Length shown is as measured 1 way along wire path between furnace and service panel for maximum 2 percent voltage drop.

FIRE HAZARD

Failure to follow this warning could result in personal

iniury, death, or property damage.

Do not connect aluminum wire between disconnect

switch and furnace. Use only copper wire.

Use a separate, fused branch electrical circuit with a properly

sized fuse or circuit breaker for this furnace. See Table 7 for wire

size and fuse specifications. A readily accessible means of

electrical disconnect must be located within sight of the furnace.

NOTE: Proper polarity must be maintained for l15-v wiring. If

polarity is incorrect, control LED status indicator light will flash

rapidly and furnace will NOT operate.

J-Box Relocation

NOTE: If factory location of J-Box is acceptable, go to next

section (ELECTRICAL CONNECTION to J-Box).

NOTE: On 14-in. (356 mm) wide casing models, the J-Box

shall not be relocated to other side of furnace casing when the

vent pipe is routed within the casing.

1. Remove and save two screws holding J-Box. (See Fig.

23 .)

NOTE: The J-Box cover need not be removed from the J-Box

in order to move the J-Box. Do NOT remove green ground

screw inside J-Box. (See Fig. 23.)

2. Cut wire tie on loop in furnace wires attached to J-Box.

3. Move J-Box to desired location.

4. Fasten J-Box to casing with the two screws removed in

Step 1.

5. Route J-Box wires within furnace away from sharp edges,

rotating parts and hot surfaces.

Electrical Connection to J-Box

Electrical Box on Furnace Casing Side (See Fig. 24.)

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.

Factol

Ins_l

Fig. 23 - Relocating J-Box

A10291

1. Select and remove a hole knockout in the casing where the

electrical box is to be installed.

NOTE: Check that duct on side of furnace will not interfere with

installed electrical box.

2. Remove the desired electrical box hole knockout and posi-

tion the hole in the electrical box over the hole in the fur-

nace casing.

3. Fasten the electrical box to casing by driving two field-

supplied screws from inside electrical box into casing

steel.

4. Remove and save two screws holding J-Box. (See Fig.

23 .)

5. Pull furnace power wires out of 1/2-in. (12 mm) diameter

hole in J-Box. Do not loosen wires from strain-relief

wire-tie on outside of J-Box.

6. Route furnace power wires through holes in casing and

electrical box and into electrical box.

7. Pull field power wires into electrical box.

8. Remove cover from furnace J-Box.

9. Route field ground wire through holes in electrical box

and casing, and into furnace J-Box.

10. Reattach furnace J-Box to furnace casing with screws re-

moved in Step 4.

11. Secure field ground wire to J-Box green ground screw.

12. Complete electrical box wiring and installation. Connect

line voltage leads as shown in Fig. 24. Use best practices

(NEC in U.S. for wire bushings, strain relief, etc.

13. Reinstall cover to J-Box. Do not pinch wires between

cover and bracket.

A10141

Fig. 24 - Field-Supplied Electrical Box on Furnace Casing

Power Cord Installation in Furnace J-Box

NOTE: Power cords must be able to handle the electrical

requirements listed in Table 6. Refer to power cord

manufacturer's listings.

1. Remove cover from J-Box.

2. Route listed power cord through 7/8-in. (22 ram) diameter

hole in J-Box.

3. Secure power cord to J-Box bracket with a strain relief

bushing or a connector approved for the type of cord used.

4. Secure field ground wire to green ground screw on J-Box

bracket.

5. Connect line voltage leads as shown in Fig. 25.

6. Reinstall cover to J-Box. Do not pinch wires between

cover and bracket.

BX Cable Installation in Furnace ,[-Box

1. Remove cover from J-Box.

2. Route BX cable into 7/8-in. (22 ram) diameter hole in

J-Box.

3. Secure BX cable to J-Box bracket with connectors ap-

proved for the type of cable used.

4. Secure field ground wire to green ground screw on J-Box

bracket.

5. Connect line voltage leads as shown in Fig. 25.

6. Reinstall cover to J-Box. Do not pinch wires between

cover and bracket.

24-V Wiring

Make field 24-v connections at the 24-v ternfinal strip. (See Fig.

25 - 34.) Connect terminal Y/Y2 as shown in Fig. 27-34 for

proper cooling operation. Use only AWG No. 18, color-coded,

copper thermostat wire.

The 24-v circuit contains an automotive-type, 3-amp. fuse

located on the control. Any direct shorts during installation,

service, or maintenance could cause this fuse to blow. If fuse

replacement is required, use ONLY a 3-amp. fuse of identical

size.

ACCESSORIES

1. Electronic Air Cleaner (EAC)

Connect an accessory Electronic Air Cleaner (if used) us-

ing 1/4-in female quick connect ternfinals to the two male

1/4-in quick-connect ternfinals on the control board

marked EAC-1 and EAC-2. The ternfinals are rated for

115VAC, 1.0 amps maximum and are energized during

blower motor operation. (See Fig. 26.)

2. Humidifier (HUM)

Connect an accessory 24 VAC, 0.5 amp. maximum hu-

midifier (if used) to the 1/4-in male quick-connect HUM

terminal and COM-24V screw terminal on the control

board thermostat strip. The HUM terminal is energized

when blower is energized in heating. (See Fig. 26.)

NOTE: DO NOT connect furnace control HUM terminal to

HUM (humidifier) terminal on Thermidistat, Zone Controller or

similar device. See Thermidistat©, Zone Controller, thermostat,

or controller manufacturer's instructions for proper connection.

VENTING

The furnace shall be connected to a listed factory built chimney

or vent, or a clay-tile lined masonry or concrete chimney. Venting

into an unlined masonry chimney or concrete chimney is

prohibited.

When an existing Category I furnace is removed or replaced, the

original venting system, may no longer be sized to properly vent

the attached appliances. An improperly sized Category I venting

system could cause the formation of condensate in the furnace

and vent, leakage of condensate and combustion products, and

spillage of combustion products into the living space.

115-VOLT FIELD-

SUPPLIED

FUSED

DISCONNECT

JUNCTION

BOX @

CONTROL

BOX @

24-VOLT

TERMINAL

BLOCK

FURNACE

.... FIELD 24-VOLT WIRING

.... FIELD 115-, 208/230-, 460-VOLT WIRING

-- FACTORY 24-VOLT WIRING

FACTORY 115-VOLT WIRING

NOTE2

FIELD-SUPPLIED

FUSED DISCONNECT

208/230- OR

460-VOLT

PHASE

--__---1208/230-

_ _.[_rT-TI.__ __LVO LT

r _'u - -I (SINGLE

--_---_.--.._--- JPHASE

I -GNDI

CONDENSING

UNIT

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. n

Fig. 25 -Field Wiring Diagram

A95236

MODEL PLUG

CONNECTOR

SW1 SETUP

SWITCHES AND

BLOWER OFF-

DELAY

AIR CONDITIONING

(A/C) AIRFLOW

SETUP SWITCHES

USER INTERFACE

24-V THERMOSTAT

TERMINALS "<

STATUS AND COMM

LED LIGHTS

3-AMP FUSE _

TRANSFORMER 24-VAC

CONNECTIONS

115-VAC (L2) NEUTRAL

CONNECTIONS

CONTINUOUS FAN SW4 SETUP

OR ADVANCED (CF) AIRFLOW OAT SWITCHES

ONN C 'T'T

PL1 - LOW VOLTAGE MAIN EXAMPLE:

HARNESS CONNECTOR

SOFTWARE PART DATE

VERSION NUMBER CODE

NUMBER

HUMIDIFIER

I_ _ _ TERMINAL(24-VAC

_iI(_ I _ 0.5 AMP MAX.

_ ACRDJ -AIR

_i FII_II] HUM, _ _ CONDITIONING

I _ -4,-_ _ RELAY DISABLE

,IGI UMPER

_IFIQ III] ACRDJ

_I _ _ _ FLASH

_I I_I _ '_ _ UPGRADE

CONNECTOR

_ [-"_----1 _ (FACTORY

h_I_ONLY)

._ _> I-_II _F

PL3 - ECM BLOWER

_s_ , co._T_R

= =>_ BO A#uD_BEERI#L

_1/ It /=_ I vs._,,,_o_

_OJ/EAC-` TERMINAL X X

/%S-VAC,0AMPMAX.), \

x 115-VAC (L1) LINE PL2 - HOT SURFACE

VOLTAGE CONNECTIONS IGNITER INDUCER

MOTOR CONNECTOR

Fig. 26 -Variable Speed Furnace Control for ECM Blower Motor

A10286

THERMIDISTAT TWO-STAGE SINGLE-SPEED

FURNACE AIR CONDITIONER

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, NFPA 54/ANSI Z223.1-2009 and these

instructions. Deternfine 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

nfinutes of main burner operation. Use the flame of a

match or candle.

8. If improper venting is observed during any of the

above tests, the venting system nmst be corrected in

accordance with the National Fuel Gas Code, NFPA

54/ANSI Z223.1-2009.

9. After it has been deternfined 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 nfininmm

size as deternfined using appropriate table found in the current

edition of NFGC.

General Venting Requirements

Follow all safety codes for proper vent sizing and installation

requirements, including local building codes, the National Fuel

Gas Code NFPA 54/ANSI Z223.1-2009 (NFGC), Parts 12 and

13 in the United States, the local building codes, and furnace and

vent manufacturers' instructions.

The following information and warning nmst be considered in

addition to the requirements defined in the NFGC.

HEAT STAGE 2 _-.

./AFrmT]

HEAT STAGE 1 [_.

COOL STAGE 1 _.

FAN [_.

24 VAC HOT [_.

DEHUMIDIFY [_.

24 VAC COMM [_.

HUMIDIFY [_ .........

N/A [_

Os &OOR.........

CONNECT,ON C!C}

NOTE 11 -F q

-F q

HUM

_ HUMIDIFIER _'@

(24 VAC)

" i

Z_ OUTDOOR _z_

SENSOR E

See notes 2, 5, 7, 10, and 11

Fig. 27 - Two-Stage Furnace with Single-Speed

Air Conditioner

A00275

CARBON MONOXIDE POISONING HAZARD

Failure to follow this warning could result in personal

iniury or death.

Do not bypass the draft safeguard switch, as an unsafe

condition could exist which nmst be corrected.

1. If a vent (common or dedicated) becomes blocked, the fur-

nace will be shut off by the draft safeguard switch located

on the vent elbow.

2. Two-stage furnaces require Type B vent connectors out-

side the casing in all configurations. Single wall vent con-

nector 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 capa-

city is equal to or lower than the low fire rate of the fur-

nace 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 ded-

icated or common vent. The dedicated or common vent is

considered to be the vertical portion of the vent system

that ternfinates outdoors.

4. Vent connectors serving Category I furnaces shall not be

connected into any portion of a mechanical draft system

operating under positive pressure.

5. Do not vent this appliance with any solid fuel burning ap-

pliance.

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 china-

ney. Refer to Chinmey Inspection Chart, Fig. 35.

THERMIDISTAT TWO-STAGE TWO-SPEED THERMIDISTAT TWO-STAGE TWO-SPEED

FURNACE AIR CONDITIONER FURNACE HEAT PUMP

HEAT STAGE 2

COOL STAGE 1

HEAT STAGE 1

COOL STAGE 2

FAN [_

24 VAC HOT [_

DEHUMIDIFY [_

24 VAC COMM [_

HUMIDIFY

N/A

O_ET_sOOR_

CONNECT,ONL_

NOTE 11

NOTE 12

E2_

HUM -. ......

t_ HUMIDIFIER [___I I

(24 VAC)

OUTDOOR

SENSOR i

See notes 2, 5, 8, 10, 11 and 12

on the page following these figures

A03179

Fig. 28 -Two-Stage Furnace with Two-Speed Air Condi-

tioner

RVS COOLING

HEAT/COOL STAGE 1

(COMPRESSOR LO)

"EA_pSuTAGcEE_ rw_ _ .

HEATcOOOIES:_o_.II_q

FAN

24 VAC HOT

DEHUMIDIFY [_

24 VAC COMM [_

HUMIDIFY

N/A I_

os_E__sOo_R_--I_q

CONNECT,ONLEZ]

............. [_ ........

I HUM "'"-. ......

I:L]OUTDOOR_S_,

........ /SENSOR _ [[

See notes 1, 2, 3, 4, 6, 8, 9, 10, 12, 13 and 15

on the page folow[ng these figures

A03178

Fig. 30 -Two-Stage Furnace with Two-Speed Heat Pump

(Dual Fuel)

THERMIDISTAT TWO-STAGE SINGLE-SPEED

FURNACE HEAT PUMP

DUAL FUEL TWO-STAGE SINGLE-SPEED

THERMOSTAT FURNACE HEAT PUMP

RVS COOLING[__

HEATSTAGE3r_ _

(FURNACEHI)

HEAT STAGE 2

(FURNACE LO)

HEAT/CcOoCLpSTAsGoERI ) [_

FAN

24 VAC HOT

DEHUMIDIFY [_

24 VAC COMM _-

HUMIDIFY [_

N/A [_

CONNECT,ONLl_q

___EO_T_E_2)....

F_q

I HUM "'-. ......

........

See notes 1,2, 4, 6, 7, 9, 10, 11, and 15

on the page folowing these figures

A03180

Fig. 29 -Two-Stage Furnace with Single-Speed Heat Pump

(Dual Fuel)

RVS COOLING[_W_I--

HEATSTAGE3r_ _ -

(FURNACEHI)

HEAT STAGE 2rw _ _

(FURNACELO)

HEAT/COOL STAGE 1 [_1 r _

(COMPRESSOR)_

FAN[___

24VACHOT[___

24 MAC COMM [_-_

N/A S_]

RVS SENSING S_]

OsUT#sOO_-I:Z_-

CONNECT,ONLl_q.

-i_q

I HUM

_ DUTDDDR_

........ / SENSOR1_ I

See notes 1, 2, 4, 11,14,15, and 16

on the page fo/owJng these figures

A03181

Fig. 31 -Dual-Fuel Thermostat with Two-Stage Furnace

and Single-Speed Heat Pump

DUAL FUEL TWO-STAGE TWO-SPEED TWO-STAGE TWO-STAGE TWO-SPEED

THERMOSTAT FURNACE HEAT PUMP THERMOSTAT FURNACE AIR CONDITIONER

RVS COOLING

HEAT/COOL STAGE 1

(COMPRESSORLO)

HEAT STAGE 3

(FURNACE)

HEAT/COOL STAGE 2

(COMPRESSORHI) I I

FAN [_

24 VAC HOT I_

I I

24 VAC COMM

N/A [_

RVS SENSING [_

OsUETNDs_)£RR[-I--S-_

CONNECT,ONLi_q

NOTE 12

F_q

I-q

I HUM

_, ou_oooR,_

.........q SENSOR_ :I

See notes 1, 2, 3, 4,12, 13,14, 15, and 17

on the page following these figures

-:_-[B

_k_D

AO3182

Fig. 32 -Dual-Fuel Thermostat with Two-Stage Furnace

and Two-Speed Heat Pump

SINGLE-STAGE

THERMOSTAT

TWO-STAGE

FURNACE

[_-"

Fq-__.

[-_--]_.

NOTE 11

NOTE 12

-F q

_] HUM

#-s

See notes2, 11,and 12on the

pagefollowingthesefigures

AO3183

Fig. 33 - Two-Stage Thermostat with Two-Stage Furnace

and Two-Speed Air Conditioner

TWO-SPEED

AIR CONDITIONER

_Fq____

_1- 1

B HUM

-#-s

.__CLD

See notes 1 and 2 on the page

following these figures

Fig. 34 -Single-Stage Thermostat with Two-Stage Furnace and Two-Speed Air Conditioner

A03184

NOTES FOR FIGURES 27 - 34

1. Heat pump MUST have a high pressure switch for dual fuel applications.

2. Refer to outdoor equipment Installation Instructions for additional information and setup procedure.

3. If the heat pump date code is 1501E or earlier, select the "ZONE" position on the two-speed heat pump control. Heat pumps having

date codes 1601E and later do not have or require a "ZONE" selection.

4. Outdoor Air Temperature Sensor must be attached in all dual fuel applications.

5. Dip switch No. 1 on Thermidistat should be set in OFF position for air conditioner installations. This is factory default.

6. Dip switch No. 1 on Thermidistat should be set in ON position for heat pump installations.

7. Dip switch No. 2 on Thermidistat should be set in OFF position for single-speed compressor operation. This is factory default.

8. Dip switch No. 2 on Thermidistat should be set in ON position for two-speed compressor operation.

9. Configuration Option No. 10 "Dual Fuel Selection" must be turned ON in all dual fuel applications.

10. NO connection should be made to the furnace HUM terminal when using a Thermidistat.

11. Optional connection: If wire is connected, dip switch SWI-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.

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

Rebuild

crown.

Is chimney No

property lined with

clay tile liner?

Yes

liner and top

seal in good

condition?

N_ Reline

Remove mortar

and tile debris

Clay

tile misalignment,

missing sections,

gaps?

Condensate

drainage at bottom

of chimney?

Chimney

exposed to

outdoors below

roof line?

Chimney is

acceptable for use.

_'es

_Suitable h

/[_No "'_ instructions for /_ _ "

/_ _ application /

/_,_ ,,,_÷h_,_,, _ V_ .... Line chimney with property

bultable

__'_. _'_ I bUlIaD,e sized, listed flexible metal

-._,L_u, ._ ..... ._' _'/Yes t liner orTyp_ B vent per

"_ype-_ venv/ _lr NFGC Vent

/_ Sizing Table. _ and liner or

a ey i

'n_'o_n_ mn eY vent manL

a pe pe i

_i[ a_rP_c_rioPner........ Installahon,

1Yes = ".............. . Nor _uJraDle

/Iq r.himn_/ _ r,l_ /Part C of

__himney adapter ventin_e

"_ asinale /I I " _ instructions for /I

._s _ furnace? /I t _ application /[

Install chimney

adapter per

instructions.

Fig. 35 - Chimney Inspection Chart

A10133

Masonry Chimney Requirement

NOTE: These furnaces are CSA design-certified for use in

exterior tile-lined masonry chimneys with afactory 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 aChimney Adapter Kit number marked on the

furnace rating plate.

If a clay tile-lined masonry chinmey is being used and it is

exposed to the outdoors below the roof line, relining nfight be

required. Chinmeys shall conform to the Standard for Chinmeys,

Fireplaces, Vents, and Solid Fuel Burning Appliances

ANSI/NFPA 211-2009 in the United States and must be in good

condition.

U.S.A.-Refer to Sections 13.1.8 and 13.2.20 of the NFPA

54/ANSI Z223.1-2009 or the authority having jurisdiction to

deternfine whether relining is required. If relining is required, use

a properly sized listed metal liner, Type-B vent, or a listed

alternative venting design.

NOTE: See the NFPA 54/ANSI Z223.1-2009 13.1.9 and

13.2.20 regarding alternative venting design and the exception,

which cover installations such as our Chinmey Adapter Kits

which are listed for use with these furnaces. See Table 17 for

accessory listing.

The Chinmey Adapter Kit is a listed alternative venting system

for these furnaces. See the kit instructions for complete details.

This furnace is pernfitted to be vented into a clay tile-lined

masonry chinmey that is exposed to the outdoors below the roof

line, provided:

1. Vent connector is Type-B double-wall, and

2. This furnace is common vented with at least 1 draft hood

equipped appliance, and

3. The combined appliance input rating is less than the max-

imum capacity given in Table 8, and

4. The input rating of each space heating appliance is greater

than the minimum input rating given in Table 9 for the

local 99% Winter Design Temperature. Chinmeys having

internal areas greater than 38 sq. in. (24516 sq. ram) re-

quire furnace input ratings greater than the input ratings of

these furnaces. See footnote at bottom of Table 9, and

5. The authority having jurisdiction approves.

If all of these conditions cannot be met, an alternative venting

design shall be used, such as the listed chinmey adapter kit with a

furnace listed for use with the kit, a listed chinmey-lining system,

or a Type-B common vent.

Inspections before the sale and at the time of installation will

deternfine the acceptability of the chinmey or the need for repair

and/or (re)lining. Refer to the Fig. 33 to perform a chinmey

inspection. If the inspection of a previously used tile-lined

chinmey:

a. Shows signs of vent gas condensation, the chinmey

should be relined in accordance with local codes and

the authority having jurisdiction. The chinmey should

be relined with a listed metal liner, Type-B vent, or a

listed chinmey adapter kit shall be used to reduce con-

densation. If a condensate drain is required by local

code, refer to the NFPA 54/ANSI Z223.1-2009, Sec-

tion 12.10 for additional information on condensate

drains.

b. Indicates the chinmey exceeds the maximum pernfiss-

ible size in the tables, the chinmey should be rebuilt or

relined to conform to the requirements of the equip-

ment being installed and the authority having jurisdic-

tion.

A chinmey without a clay tile liner, which is otherwise in good

condition, shall be rebuilt to conform to ANSI/NFPA 211 or be

lined with a UL listed metal liner or UL listed Type-B vent.

Relining with a listed metal liner or Type-B vent is considered to

be a vent-in-a-chase,

If a metal liner or Type-B vent is used to line a chinmey, no other

appliance shall be vented into the annular space between the

chinmey and the metal liner,

Exterior Masonry Chimney FAN + NAT

Installations with Type-B Double-Wall Vent

Connectors ©NFPA & AGA

Table 8 -Combined Appliance Maximum Input

Rating in Thousands of Btuh per Hour

iNTERNALAREA OF CHIMNEY

6 (1.8)

8 (2.4)

10 (3.0)

15 (4.5)

20 (6.0)

30 (9.1)

VENT HEIGHT

FT (M) 12

(7741)

SQ. iN. (SQ. MM)

19 28 38

(12258) (18084) (24518)

119 178 257

130 193 279

138 207 299

152 233 334

NR 250 388

NR NR 404

Appliance Application Requirements

Appliance operation has a significant impact on the performance

of the venting system, If the appliances are sized, installed,

adjusted, and operated properly, the venting system and/or the

appliances should not suffer from condensation and corrosion,

The venting system and all appliances shall be installed in

accordance with applicable listings, standards, and codes,

The furnace should be sized to provide 100 percent of the design

heating load requirement plus any margin that occurs because of

furnace model size capacity increments, Heating load estimates

can be made using approved methods available from Air

Conditioning Contractors of America (Manual J); American

Society of Heating, Refrigerating, and Air-Conditioning

Engineers; or other approved engineering methods, Excessive

oversizing of the furnace could cause the furnace and/or vent to

fail prematurely.

When a metal vent or metal liner is used, the vent must be in

good condition and be installed in accordance with the vent

manufacturer's instructions.

To prevent condensation in the furnace and vent system, the

following precautions must be observed:

1. The return-air temperature must be at least 60°F db except

for brief periods of time during warm-up from setback at

no lower than 55°F (13°C) db or during initial start-up

from a standby condition.

2. Adjust the gas input rate per the installation instructions.

Low gas input rate causes low vent gas temperatures, caus-

ing condensation and corrosion in the furnace and/or vent-

ing system. Derating is pernfitted only for altitudes above

2000 Ft. (610 M).

3. Adjust the air temperature rise to the nfidpoint 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.

BURN HAZARD

Failure to follow this caution may result in personal iniury.

Hot vent pipe is within reach of small children when

installed in downflow position.

See the following instruction.

Table 9 - Minimum Allowable Input Rating of

Space-Heating Appliance in Thousands of Btuh per Hour

INTERNAL AREA OF CHIMNEY

VENT HEIGHT SQ. IN. (SQ. MM)

FT. (M) 12 19 28 38

(7741) (12258) 18084) (24518)

Local 99% Winter Design Temperature: 17 to 26 degrees F

6 0 55 99 141

8 52 74 111 154

10 NR 90 125 169

15 NR NR 167 212

20 N R NR 212 258

30 NR NR NR 362

Local 99% Winter Design Temperature: 5 to 16 degrees F*

6 NR 78 121 166

8 N R 94 135 182

10 NR 111 149 198

15 N R NR 193 247

20 NR NR NR 293

30 NR NR NR 377

Local 99% Winter Design Temperature: -10 to 4 degrees F*

6 NR NR 145 196

8 NR NR 159 213

10 NR NR 175 231

15 NR NR NR 283

20 NR NR NR 333

30 NR NR NR NR

Local 99% Winter Design Temperature: -11 degrees F or

lower

Not recommended for any vent configuration.

*The 99.6% heating (db) temperatures found in the 1997 or 2001

ASHRAE Fundamentals Handbook, Climatic Design Information chapter,

Table 1A (United States) and 2A (Canada) or the 2005 ASHRAE Funda-

mentals handbook, Climatic Design Information chapter, and the CD-

ROM included with the 2005 ASHRAE Fundamentals Handbook.

Air for combustion must not be contaminated by halogen

compounds which include chlorides, fluorides, bromides, and

iodides. These compounds are found in many conmaon home

products such as detergent, paint, glue, aerosol spray, bleach,

cleaning solvent, salt, and air freshener, and can cause corrosion

of furnaces and vents. Avoid using such products in the

combustion-air supply. Furnace use during construction of the

building could cause the furnace to be exposed to halogen

compounds, causing premature failure of the furnace or venting

system due to corrosion.

Vent dampers on any appliance connected to the conmaon vent

can cause condensation and corrosion in the venting system. Do

not use vent dampers on appliances conmaon vented with this

furnace.

Additional Venting Requirements

A 4-in. (102 ram) round vent elbow is supplied with the furnace.

A5-in. (127 ram) or 6- in. (152 ram) vent connector may be

required for some model furnaces. A field-supplied 4-in. (102

ram) to 5-in. (127 ram) or 4-in. (102 ram) to 6-in. (152 ram)

sheet metal increaser fitting is required when 5-in. (127 ram) or

6-in. (152 ram) vent connector is used. See Fig. 36 - 48, Venting

Orientation for approved vent configurations.

NOTE: Vent connector length for connector sizing starts at

furnace vent elbow. The 4-in. (102 ram) vent elbow is shipped

for upflow configuration and may be rotated for other positions.

Remove the three screws that secure vent elbow to furnace, rotate

furnace vent elbow to position desired, reinstall screws. The

factory-supplied vent elbow does NOT count as part of the

number of vent connector elbows.

The vent connector can exit the furnace through one of five

locations on the casing.

CUT HAZARD

Failure to follow this caution may result in personal iniury.

Sheet metal parts may have sharp edges or burrs. Use care

and wear appropriate protective clothing, safety glasses and

gloves when handling parts, and servicing furnaces.

1. Attach the single wall vent connector to the furnace vent

elbow, and fasten the vent connector to the vent elbow

with at least two field-supplied, corrosion-resistant, sheet

metal screws located 180 ° apart.

NOTE: An accessory flue extension is available to extend from

the furnace elbow to outside the furnace casing. See Table 17 for

accessory listing. If flue extension is used, fasten the flue

extension to the vent elbow with at least two field-supplied,

corrosion-resistant, sheet metal screws located 180 ° apart. Fasten

the vent connector to the flue extension with at least two

field-supplied, corrosion resistant sheet metal screws located

180 ° apart.

2. Vent the furnace with the appropriate connector as shown

in Fig. 36 - 48.

3. Deternfine the correct location of the knockout to be re-

moved.

4. Use a hammer and screwdriver to strike a sharp blow

between the tie points and work the slug back and forth

until the slug breaks free.

An accessory Vent Guard Kit is REQUIRED for downflow

applications for use where the vent exits through the lower

portion of the furnace casing. Refer to the Vent Guard Kit

Instructions for complete details. See Table 17 for accessory

listing.

SEE NOTES: 1,2,4,7,8,9

on the page following

these figures

Fig. 36 - Upflow Application - Vent Elbow Up

A03208

SEE NOTES:1,2,3,4,5,7,8,9

on the page following

these figures

A03210

Fig. 38 - Downflow Application -Vent Elbow Up then Left

SEE NOTES: 1,2,3,4,7,8,9

on the pages following

these figures

A03209

Fig. 37 - Upflow Application - Vent Elbow Right

SEE NOTES: 1,2,4,5,7,8,9

on the page following

these figures

A03211

Fig. 39 - Downflow Application -Vent Elbow Up

I \

SEE NOTES: 1,2,4,5,6,7,8,9,10

on the page following these figures

A03207

Fig. 40 - Downflow Application - Vent Elbow Left then Up

o_o

SEE NOTES: 1,2,4,7,8,9 on the page

following these figures

A03213

Fig. 42 -Horizontal Left Application -Vent Elbow Left

SEE NOTES:1,2,3,4,5,7,8,9

on the page following

these figures.

A03212

Fig. 41 - Downflow Application - Vent Elbow Up then Right

i°

SEE NOTES: 1,2,4,5,7,8,9 on the page

following these figures

A03214

Fig. 43 - Horizontal Left Application - Vent Elbow Right

then Up

..... n

SEE NOTES: 1,2,4,7,8,9 on the page

following these figures

A03218

Fig. 44 - Horizontal Right Application - Vent Elbow Right

\./

SEE NOTES: 1,2,4,5,7,8,9 on the page

following these figures

"4 i"

SEE NOTES: 1,2,4,5,7,8,9 on the page

following these figures

A03215

Fig. 45 - Horizontal Left Application - Vent Elbow Up

o _

SEE NOTES: 1,2,4,5,7,8,9 on the page

following these figures

A03219

Fig. 47 - Horizontal Right Application - Vent Elbow Left

then Up

l[ i¸

SEE NOTES: 1,2,4,5,7,8,9

A03216

Fig. 46 - Horizontal Left Application - Vent Elbow Right

A02068

Fig. 48 - Horizontal Right Application-Vent Elbow Left

VENTING NOTES FOR FIG. 36 - 48

1. For common vent, vent connector sizing and vent material: United States--use the NFGC.

2. Immediately increase to 5-in. (102 ram) or 6-in. (152 ram) vent connector outside furnace casing when 5-in. (127 ram) vent

connector is required, refer to Note 1 above.

3. Side outlet vent for upflow and downflow installations must use Type B vent immediately after exiting the furnace, except when

factory-approved Downflow Vent Guard Kit is used in the downflow position. See Table 17 for accessory listing.

4. Type-B vent where required, refer to Note 1 above.

5. A 4-in.(102 ram) single-wall (26 ga. rain.) vent must be used inside furnace casing and when the factory-approved Downflow Vent

Guard Kit is used external to the furnace. See Table 17 for accessory listing.

6. Accessory Downflow Vent Guard Kit required in downflow installations with lower vent configuration. See Table 17 for accessory

listing.

7. Chimney Adapter Kit may be required for exterior masonry chimney applications. Refer to Chimney Adapter Kit for sizing and

complete application details. See Table 17 for accessory listing.

8. Secure vent connector to furnace elbow with (2) corrosion-resistant sheet metal screws, spaced approximately 180 ° apart.

9. Secure all other single wall vent connector joints with (3) corrosion resistant screws spaced approximately 120 ° apart. Secure Type-B

vent connectors per vent connector manufacturer's recommendations.

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. 38.)

Caution!! For the following applications, use the minimum vertical heights as specified below.

For all other applications, follow exclusively the National Fuel Gas Code.

MIN. VENT MiN. VERTICAL VENT

FURNACE VENT ORIENTATION FURNACE iNPUT DIAMETER HEIGHT

ORIENTATION (BTUH/HR) IN. (ram)* FT. (M)**

Downflow Vent elbow left, then up

Fig. 36 154,000 132,000 110,000 5 (127) 12 (3.6)

Horizontal Left Vent elbow right, then up

Fig. 39 154,000 132,000 5 (127) 7 (2.1)

Horizontal Left Vent Elbow up

Fig. 40 154,000 132,000 5 (127) 7 (2.1)

Horizontal Left Vent elbow right

Fig. 41 154,000 5 (127) 7 (2.1)

Vent elbow up then left

Downfiow Fig. 34 110,000 5 (127) 10 (3.0)

Vent elbow up, then right

Downfiow Fig. 37 110,000 5 (127) 10 (3.0)

NOTE: All vent configurations must also meet National Fuel Gas Code venting requirements NFGC.

*4-in. (102 mm) inside casing or vent guard

**Including 4 in. (102 mm) vent section(s)

The horizontal portion of the venting system shall slope upwards

not less than l/4-in, per linear ft. (21 nine/m) from the furnace to

the vent and shall be rigidly supported every 5 ft. (1.5 M) or less

with metal hangers or straps to ensure there is no movement after

installation.

Sidewall Venting

This furnace is not approved for direct sidewall horizontal

venting.

Per section 12.4.3 of the NFPA 54/ANSI Z223.1-2009, any

listed mechanical venter may be used, when approved by the

authority having jurisdiction.

Select the listed mechanical venter to match the Btuh input of the

furnace being vented. Follow all manufacturer's installation

requirements for venting and termination included with the listed

mechanical venter.

START-UP, ADJUSTMENT, AND SAFETY

CHECK

General

3. Gas supply pressure to the furnace nmst be greater than

4.5-In. W.C. (0.16 psig ) but not exceed 14-In. W.C. (0.5

psig).

4. Check all manual-reset switches for continuity.

5. Replace blower compartment door. Door must be in place

to operate furnace.

6. Setup switch descriptions The variable speed furnace con-

trol has DIP switches to select thermostat staging, blower

off delay timings, air flow selection and other operational

or service related functions. (See Fig. 26, 53 and Table

100

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.

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 con-

nections will result in improper operation, (See Fig. 25 -

34.)

ON/OFF SWITCH

1/2 NPT INLET

_-_--_ REGULATOR COVER SCREW

A04167

Fig. 49 - Redundant Automatic Gas Control Valve

BURNER --_

ORIFICE

Start-Up Procedures

FIRE OR EXPLOSION HAZARD

Failure to follow this warning could result in personal

iniury, death, and/or property damage.

Never purge a gas line into a combustion chamber. Never

test for gas leaks with an open flame. Use a commercially

available soap solution made specifically for the detection

of leaks to check all connections. A fire or explosion may

result causing property damage, personal iniury or loss of

life.

EXAMPLE:

Fig. 50 - Orifice Hole

A93059

SUBBASE

TERMINALS WITH

THERMOSTAT REMOVED

(ANITICIPATOR, CLOCK, ETC.,

MUST BE OUT OF CIRCUIT.)

AMMETER

10 TU RNS

FROM UNIT 24-V

CONTROL TERMINALS

5.0 AMPS ON AMMETER 0.5 AMPS FOR THERMOSTAT

10 TURNS AROUND JAWS ANTICIPATOR SETTING

A96316

Fig. 51 - Amp. Draw Check with Ammeter

ELECTRICAL SHOCK HAZARD

Failure to follow this warning could result in personal

iniury, or death.

Blower access door switch opens l15-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.

1. Purge gas lines after all connections have been made.

2. Check gas lines for leaks.

3. To Begin Component Self-Test:

Remove Blower Access Door. Disconnect the thermostat

R lead from furnace control board. Manually close blower

door switch. Turn Setup DIP switch SWI-6 ON. (See Fig.

26, 53 and Table 10.)

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. 52.

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 see., then off.

c. Blower motor operates for 15 sec.

d. Inducer motor goes to low-speed for 10 see., 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. 52) in furnace for explan-

ation of status codes.

NOTE: To repeat component test, turn setup switch SWI-6

OFF, then back ON.

4. Turn setup DIP switch SWI-6 OFF. Reconnect R lead to

furnace control board, release blower door switch and re-

install 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.

Table10-Furnace Setup Switch Description

SETUP SWITCH

SW1-1

SWITCH NAME

SWl-2

SW1-3

SW1-4

SW1-5

SW1-6

SW1-7 & SW1-8

SW4-3

Furnace Setup Switch Description

Status Code Recovery

Low Heat Only

(Adaptive Heat Mode when SW1

2 is OFF)

Low Heat Rise Adjustment

Comfort/Efficiency Adjustment

CFM per ton adjust

Component Self Test

Blower OFF delay

CFM per ton Adjust

NORMAL POSITION

OFF

ON or OFF

OFF

DESCRIPTION OF USE

Turn ON to retrieve up to 7 stored status codes for

Lroubleshooting assistance when R thermostat lead is

disconnected.

When SW1-2 is OFF allows low heat operation with a

single stage thermostat. Turn ON when using two-

stage thermostat to allow Low Heat operation when R

Lo W/W1 closes and High Heat operation when R to

W/W1 and W2 close.

Turn ON to increase Low Heat airflow by 18 percent.

This compensates for increased return air

Lemperature caused with bypass humidifier. This also

increases the low heat inducer speed 15 percent.

Turn ON to decrease low heat airflow by 7 percent,

and high heat airflow 10 percent for maximum

comfort.

Turn ON for 400 CFM per ton, Turn OFF for 350 CFM

_er ton. See also SW4.

Turn ON to initiate Component Self Test for

Lroubleshooting assistance when R thermostat lead is

disconnected. Turn OFF when Self Test is completed.

Blower Off Delay time adjustable 90 seconds to 180

seconds. See table in Adjustments section or refer to

unit wiring diagram.

&llows additional CFM per ton selections when used

with SW 1-5

325 CFM per ton (nominal) when SW 4-3 ON and SW

1-5 OFF

350 CFM per ton (nominal) when SW 4-3 OFF and

SW 1-5 OFF

370 CFM per ton (nominal) when SW4-3 ON and SW

1-5 ON

400 CFM per ton (nominal) when SW 1-5 ON and SW

4-3 OFF

See Air Delivery Tables for model specific CFM vs.

static pressure

1 _zo

1 _ZO

lr--I =

oo l--] co

AIR CONDITIONING (A/C) SETUP SWITCHES

SW 2, AC (Cooling Airflow) SETUP SWITCHES

The AC setup switch selects desired cooling or high stage cooling (two stage units) airflow.

See Cooling Air Delivery Tables for specific switch settings.

CONTINUOUS FAN (OF) SETUP SWITCHES

SW 3, CF (Continuous Fan) SETUP SWITCHES

The CF setup switch selects desired Continuous Fan Airflow

The CF switch position is the low cooling airflow selection for two stage cooling units.

The CFM values are shown in the Air Delivery Tables below for SW 3 settings.

SW 3 cannot be set for airflow higher than SW 2.

See Continuous Fan Air Flow Table for specific switch settings.

A12092

-" ---

LEDCODE STATUS ifatatuscoderecallisn__Wl 1"#1theON m

CONTINUOUS O FF - Check for 115MAC at L 1 and L2, and 24VAC at SEC- 1 and SEC-2 positioll. To d ear the status code hiatory put setup s_4tdl "SW1-1" in the ON position a_ldj umper themloat at terl_nals "R",

CONTINUOUS ON - Control has 24VAC power. '_V/WI", and 'h//Y2 " simuR_leousiy u_lil status code #11 isflashed, m

RAPID FLASHING - Line voltage (115VAC) polarity reversed. I

m ACH OFTHE FCdLOYYlNGSTATUS CODESISA TWO DIGIT NUMBERWITH THE FIRSTDIGIT DETERMINED BY THE NUMBER OF SHORT FLASHESAND THE SECOND DIG_TBY THE NUMBER OF LONG RASHES11 NO PREVIOUS CODE - Stored status codes are erased automatically after 72 32 Cont in ued: Check for: - Low inducer voltage (115 VAC) _ COM PO NaN T TEST

hours or as specified above. - Defective inducer motor - Inadequate combustion air supply

12 BL OWER ON AFTER POWER UP (115 VAC or 24 VAC) -Blower runs for 90 - Defective pressure switch - Low inlet gas pressure (if LGPS used)

seconds, if unit is powered up dudng a call for heat (R-W/W1 closed) or - Low inducer voltaae t115 VAC_ To initiate the component test sequence, shut

/ R;W/_V ! oxeens}du_!!_ .9.b!owe_ o!_-delay peric!d. ,.......... _ Disconnected o_ olas_ructed p_ssu_e tubing OFF the morn them]ostat o_disconnect the "R"

13 L_IWH £*IKt*UH LUt*_UU/ - LOCKOU_Occurs JIa IImJ[. aral[ saieguara, name

rollout, or blocked vent switch if used)is open longer than 3 minutes or 10 33 LIMIT CIRCUIT FAULT - Indicates a limit, draft safeguard, flame rollout, or thermostat lead. Reset power and then put setup B

successive limit trips occurred durin high-heat. Control will auto reset after blocked vent switch (if used) is open or the furnace is operating in high-heat switch "SW1-6" in the ON position to start the

three hours. Refer to status code #3_3. only mode due to 2 successive low heat limit tdps. Blower will run for 4 component test sequence. Once initiated the

14 IGNITIONLOCKOUT-Controlwillauto-resetafterthreehours. Refertoatatus minutes or until open switch remakes whichever is longer. If open longer furnace control will turn the inducer ON at high-

code#34, than 3 minutes, code changes to lockout #13. ff open less than 3 minutes heat speed. Theinducermotorwillrunfor the m

status code #33 continues to flash until blower shuts off. Flame rollout switch entire test. The hot surface igniter and blower iand BVSS require manual reset. Check for: - Loose blower wheel motor will be turned ON for 15 seconds each.

15 BL OWER MOTOR LOCKOUT - indicates the blower failed to reach 250 RPM or

the blower failed to communicate within 30 seconds after being turned ON in two

successive heafln c cles. Control will auto reset after 3 hours.

Refer to status co_e _,_1.

21 GAS HEATING LOCKOUT - Control will NOT auto reset. Check for:

- Mis-wired gas valve -Defective control (valve relay) 34

22 ABNO RMAL FLAME-PROVING SIGNAL - Flame is proved while gas valve is

de-energized, inducer will run ungl fault is cleared. Check for:

- Leak gas valve - Stuck-o en as valve

23 PRESSURE SWITCH DiD No}PoP_N Check for:

- Obstructed pressure tubing - Pressure switch stuck closed

_ 24 SECONDARY VOLTAGE FUSE iS OPEN Check for: - Short circuit in secondary

voltaagl(:e24VAC;) wiring.

25 iNVALID MODEL SELECTION OR SETUP ERROR - indicates either the model

plug is missing or incorrect or,. setup switch "BWl -1" or "SWl -6" is. positioned 41

improperly, if code flashes 4 times on power-up control is defaulting to model

selection stored in memoat.Check for: -Thermostat call with SWl-1, SWl-6 or

both SW1-1 & SW1-6 ON. - Board date code 21O3 or later required to recognize model

_;g_lu0O7 - Proper modelpJug_lunumber and resistance values perwidng diagram 43

31 HIGH-HEAT PRESSURE SWITCH OR RELAY DID NOT CLOSE OR

- Restricted vent - Proper vent sizing - Excessive wind

- Dirty filter or restricted duct system - Defective switch or connections

- inadequate combustion air supply (Flame Roll-out Switch open)

IGNITION PROVING FAILURE - Control will try three more times before

lockout #14 occurs, if flame signal lost dodng blower on-delay period, blower

will come on for the selected blower off-delay. Check for:

- Oxide buildup on flame sensor (clean with fine steel wool)

- Proper flame sense microamps (.5 microamps D.C. min., 4.0 - 6.0 nominal)

- Manual valve shut-off - Low inlet gas pressure - Control ground continuity

- Gas valve defective or turned off - Flame sensor must not be grounded

- Inadequate flame carwover or rough ignition

- Green/Yellow wire MUST be connected to furnace sheet metal

BL OWER MOTOR FAULT - indicates the blower failed to reach 25O RPM

or the blower failed to communicate within the prescribed times limits. Thirty

seconds after being turned ON or ten seconds dodng steady-state operation.

LOW-HEAT PRESSURE SWITCH OPEN WHILE HIGH-HEAT PRESSURE

SWITCH iS CLOSED - Check for: - Mis-wired pressure switches

REOPENED - Control rela ma be defective. Refer to status code #32.

tYWlav H - Low-heat pressure switch stuck open - Low inlet gas pressure (if LGPS used)32 LOW-HEAT PRESSURE SIC DID NOT CLOSE OR REOPENED if ope_] - Disconnected or obstructed pressure tubing

Ion er than five minutes inducer shuts off for 15 minutes before retat if opens 45 CONTROL CIRCUITRY LOCKOUT Auto-reset after one hour lockout due to;

dulr_g blower on-delay Period, blower will come on for the selected blower - Gas valve relay stuck open - Flame sense circuit failure - Software check error

off-delay. Check for: - Excessive wind - Restricted vent - Proper vent sizing Reset ower to clear lockout. Replace control if status code repeats.

When the blower is turned OFF the inducer will

be switched to low-speed for 10 seconds. When II

the component test is completed one or more of i

the following codes will flash.

CODE DESCRIPTION Ill

11 indicates the blower motor tested

OK. Visual check of inducer motor m

and hot surface igniter required.

25 SETUP ERROR - Same as code 25 above |

41 BLOWER MOTOR FAULT - indicates

blower motor failed test. Check

blower, wiring, and furnace control. |

"SWl-6" OFF and then back ON. After component

To repe at component test turn setup switch

test is completed put setup switch "SW1-6" in the

OFF position and reconnect the "R" thermostat

lead. 328787-101 REV. A J

A04015

Fig. 52 - Service Label

Adjustments

FIRE HAZARD

Failure to follow this warning could result in personal

iniury, 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.

FURNACE DAMAGE HAZARD

Failure to follow this caution may result in reduced furnace

life.

DO NOT redrill orifices. Improper drilling (burrs,

out-of-round holes, etc.) can cause excessive burner noise

and misdirection of burner flames. This can result in flame

impingement of heat exchangers, causing failures. (See Fig.

50.)

a. Obtain average yearly gas heat value (at installed alti-

tude) from local gas supplier.

b. Obtain average yearly gas specific gravity from local

gas supplier.

c. Find installation altitude in Table 14 or 15.

d. Find closest natural gas heat value and specific gravity

in Table 14 or 15.

e. Follow heat value and specific gravity lines to point of

intersection to find orifice size and low-and high-heat

manifold pressure settings for proper operation.

f. Check and verify burner orifice size in furnace.

NEVER ASSUME ORIFICE SIZE. ALWAYS

CHECK AND VERIFY.

NOTE: If orifice hole appears damaged or it is suspected to have

been redrilled, check orifice hole with a numbered drill bit of

correct size. Never redrill an orifice. A burr-free and squarely

aligned orifice hole is essential for proper flame characteristics.

g. Replace orifice with correct size, if required by Table

14 or 15. Use only factory-supplied orifices. See

EXAMPLE 1.

Table 11 - Altitude Derate Multiplier for U.S.A.

Furnace gas input rate on rating plate is for installations at

altitudes up to 2000 Ft. (610 M). Furnace input rate must be

within +/-2 percent of furnace rating plate input. For altitudes

above 5500 Ft. (1676 M), a field-supplied high altitude pressure

switch is required.

1. Determine the correct gas input rate.

The input rating for altitudes above 2,000 ft. (610 M) must

be reduced by 4 percent for each 1,000 ft. (305 M) above

sea level.

For installations below 2000 Ft. (610 M), refer to the unit

rating plate. For installations above 2000 Ft. (610 M),

multiply the input on the rating plate by the de-rate multi-

plier in Table 10 for the correct input rate.

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 14

(22,000 Btuh per burner.) Low NOx models in downflow

or horizontal positions must use Table 15 (21,000 Btuh

per burner.) See input listed on rating plate.

ALTITUDE PERCENT DERATE MULTIPLIER

FT.(M) OF DERATE FACTOR*

0-2000 0 1.00

(0- 610)

2001-3000 8-12 0.90

(610- 914)

3001-4000 12-16 0.86

(914-1219)

4001-5000 16-20 0.82

(1219-1524)

5001-6000 20-24 0.78

1524-1829)

6001-7000 24-28 0.74

(1829-2134)

7001-8000 28-32 0.70

(2134- 2438)

8001-9000 32-36 0.66

(2438-2743)

9001-10,000 36-40 0.62

(2743-3048)

Table 12 - Blower Off Delay Setup Switch

DESIRED HEATING MODE

BLOWER OFF DELAY (SEC.)

120

150

180

SETUP SWITCH

(SW-7 AND -8)

POSiTiON

SW1-7 SW1-8

OFF OFF

ON OFF

OFF ON

ON ON

EXAMPLE 1:0-2000 It. (0-610 M) altitude

For 22,000 Btuh per burner application use Table 14.

Heating value = 1000 Btuh/cu t't.

Specific gravity = 0.62

Therefore: Orifice No. 43"

Manifold pressure: 3.7-In. W.C. for high-heat

1.6-In. W.C. for low-heat

* Furnace is shipped with No. 43 orifices. In this example all

main burner orifices are the correct size and do

not need to be changed to obtain proper input rate.

3. Adjust manifold pressure to obtain low fire input rate. (See

Fig. 49.)

a. Turn gas valve ON/OFF switch to OFF.

b. Remove manifold pressure tap plug from gas valve.

c. Connect a water column manometer or similar device

to manifold pressure tap.

d. Turn gas valve ON/OFF switch to ON.

e. Move setup SWl--2 on furnace control to ON posi-

tion to lock furnace in low-heat operation. (See Table

10 and Fig. 24.)

f. Manually close blower door switch.

g. Jnmper R and W/W1 thermostat connections on con-

trol to start furnace. (See Fig. 24.)

h. Remove regulator adjustment cap from low heat gas

valve pressure regulator (See Fig. 49.) and turn low-

heat adjusting screw (3/16 or smaller fiat-tipped

screwdriver) counterclockwise (out) to decrease input

rate or clockwise (in) to increase input rate.

NOTE: DO NOT set low-heat manifold pressure less than

1.4-In. W.C. or more than 1.7-In. W.C. for natural gas. If

manifold pressure is outside this range, change main burner

orifices.

i. Install low-heat regulator adjustment cap.

j. Move setup switch SWl-2 to off position after com-

pleting low-heat adjustment.

k. Leave manometer or similar device connected and

proceed to Step 4.

4. Adjust manifold pressure to obtain high fire input rate.

(See Fig. 49.)

a. Jumper R to W/W1 and W2 thermostat connections on

furnace control. This keeps furnace locked in high-

heat operation.

b. Remove regulator adjustment cap from high-heat gas

valve pressure regulator (See Fig. 49) and turn high

heat adjusting screw (3/16-in. or smaller fiat-tipped

screwdriver) counterclockwise (out) to decrease input

rate or clockwise (in) to increase input rate.

NOTE: DO NOT set high-heat manifold pressure less than

3.2-In. W.C. or more than 3.8 In. W.C. for natural gas. If

manifold pressure is outside this range, change main burner

orifices to obtain manifold pressure in this range.

c. When correct input is obtained, replace caps that con-

ceal gas valve regulator adjustment screws. Main

burner flame should be clear blue, almost transparent

(See Fig. 55.)

d. Remove jumpers R to W/WI and R to W2.

5. Verify natural gas input rate by clocking meter.

NOTE: Gas valve regulator adjustment caps must be in place for

proper input to be clocked.

a. Turn off all other gas appliances and pilots served by

the meter.

b. Move setup switch SWl-2 to ON position. This

keeps furnace locked in low-heat operation.

c. Jnmper R to W/W1.

d. Run furnace for 3 minutes in low-heat operation.

e. Measure time (in sec) for gas meter to complete 1

revolution and note reading. The 2 or 5cubic feet dial

provides a more accurate measurement of gas flow.

f. Refer to Table 13 for cubic ft. of gas per hr.

g. Multiply gas rate cu ft./hr by heating value (Btuh/cu

ft.) to obtain input. If clocked rate does not match re-

quired input from Step 1, increase manifold pressure to

increase input or decrease manifold pressure to de-

crease input. Repeat steps b through e until correct

low-heat input is achieved. Re-install low heat regu-

lator seal cap on gas valve.

h. Move setup switch SWl-2 to OFF position and jump-

er R to W/W1, and W2. This keeps furnace locked in

high-heat operation. Repeat items d through g for

high-heat operation.

6. Set Temperature Rise

NOTE: Blower access door must be installed when taking

temperature rise reading. Leaving blower access door off will

result in incorrect temperature measurements.

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 SWl-4 is OFF.

UNIT DAMAGE HAZARD

Failure to follow this caution may result in overheating the

heat exchangers or condensing flue gases in heat exchanger

areas not designed for condensate.

Temperature rise must be within limits specified on unit

rating plate. Operation is within a few degrees of midpoint

of rise range when setup switch SWl-4 is OFF.

When setup switch SWl-4 is ON, operation will be near the high

end of the rise range for improved comfort.

Furnace must operate within ranges of temperature rise specified

on the furnace rating plate, Determine air temperature rise as

follows:

a. Place thermometers in return and supply ducts as near

furnace as possible, Be sure thermometers do not see

heat exchanger so that radiant heat does not affect

readings, This practice is particularly important with

straight-run ducts.

b. When thermometer readings stabilize, subtract return-

air temperature from supply-air temperature to determ-

ine air temperature rise.

NOTE: Temperature rise can be determined for low-heat

operation by placing setup switch SWl-2 on furnace control in

ON position. For high-heat operation, place setup switch SWl-2

in OFF position and jumper R-W2 on furnace control. DO NOT

forget to return setup switch to OFF position and remove R-W2

jumper upon completion of testing.

c. This furnace is capable of automatically providing

proper airflow to maintain the temperature rise within

the range specified on furnace rating plate. If temperat-

ure rise is outside this range, proceed as follows:

(1.) Check gas input for low- and high-heat opera-

tion.

(2.) Check derate for altitude if applicaMe.

(3.) Check all return and supply ducts for excessive

restrictions causing static pressure greater than

0.5-In. W.C..

(4.) Ensure Low Heat Rise Adjust switch SWl-3 on

furnace control is in ON position when a bypass

humidifier is used. (See Fig. 26 for switch loca-

tion.)

(5.) Make sure proper model plug is installed.

d. Remove thermostat jumpers and release blower access

door switch.

e. Repeat Steps a through c as required to adjust for high

heat temperature rise.

f. When correct high heat input rate and temperature rise

is achieved, turn gas valve ON/OFF switch to OFF.

g. Release blower access door switch.

h. Remove manometer or similar device from gas valve.

i. Re-install manifold pressure tap plug in gas valve.

(See Fig. 49.)

FIRE HAZARD

Failure to follow this warning could result in personal

injury, death, and/or property damage.

Reinstall manifold pressure tap plug in gas valve to prevent

gas leak.

j. Remove thermostat jumper wire from furnace control

board.

k. Turn gas valve ON/OFF switch to ON.

FURNACE OVERHEATING HAZARD

Failure to follow this caution may result in reduced furnace

life.

Recheck temperature rise. It must be within limits specified

on the rating plate. Recommended operation is at the

mid-point of rise range or slightly above.

1. Proceed to Step 6, "Set Blower Off Delay" before in-

stalling blower access door.

7. Set Blower Off Delay

a. Remove blower access door if installed,

b. Turn Dip switch SW-7 or SW-8 ON or OFF for de-

sired blower off delay, (See Table 10 and Fig. 26 and

53.)

8. Set thermostat heat anticipator.

a. Mechanical thermostat. Set thermostat heat anticipator

to match the amp. draw of the electrical components in

the R-W/W1 circuit. Accurate amp. draw readings can

be obtained at the wires normally connected to ther-

mostat subbase terminals, R and W. The thermostat

anticipator should NOT be in the circuit while measur-

ing current.

(1.) Set SWl-2 switch on furnace control board to

ON.

(2.) Remove thermostat from subbase or from wall.

(3.) Connect an amp. meter as shown in Fig. 51.

across the R and W subbase terminals or R and

W wires at wall.

(4.) Record amp. draw across terminals when furnace

is in low heat and after blower starts.

(5.) Set heat anticipator on thermostat per thermostat

instructions and install on subbase or wall.

(6.) Turn SWl-2 switch OFF.

(7.) Install blower access door.

b. Electronic thermostat: Set cycle rate for 3 cycles per

hr.

9. Set Airflow for Air Conditioning -Single Stage and High

Stage Cooling

The ECM blower can be adjusted for a range of airflow

for Low Speed or High Speed cooling. See TaMe 5-Air

Delivery - CFM (With Filter ). Depending on the model

size, the cooling airflow can be adjusted from 1. tons nom-

inal cooling to 3., to 4 or to 6 tons of nominal cooling

based on 350 cfm ton.

The cooling airflow is adjusted by turning Setup switches

SW2-1, SW2-2 and SW2-3 either ON or OFF. Select the

required airflow from Fig. 57. Fig. 57 is based on 350

CFM per ton. For airflow at 400 CFM per ton, turn Setup

SWl-5 ON (See Table 10 and Fig. 26 and 53.)

NOTE: 6 ton airflow will truncate at 2200 cfm on applicable

models. For a complete explanation of cooling airflow, refer to

the section titled "Sequence of Operation."

10. Set Airflow For Continuous Fan/Low Speed Cooling Air-

flow The ECM blower motor can be adjusted for continu-

ous 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. 57.

The continuous fan speed is also the fan speed for low

speed cooling when furnace is used with a 2-speed cool-

ing unit. Adjust the Continuous Fan CFM to match the

airflow required for low speed cooling. Select the required

airflow from Fig. 55. For airflow at 400 CFM per ton, turn

Setup SW1-5 ON (See Fig. 57.) The airflow selected for

low speed cooling will also be the airflow used for con-

tinuous 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 selec-

ted at the control board.

,e"

SW1-7.8

5LOWER OFF DELAY

SELECTION

PL4 - MODEL PLUG CHART

IMODELCOOLINGIMODEL FIN RESSTANCE KZZl

SIZE PLUG i..................................

SIZE IHKTOEZI 1-4 2-_

l _ _

li_ -:- i _ _1

PL8

i......

o Zqo_>

CONNECTION DIAGRAM

M BLU--

90 GV HPS

120 BRN--

SEC GRN/YEL HI GRY

150

SEC

180 GRN/YEL

SEC

PLI _,,

m_ _ mmm_

NOTE#12, ]

FRS1 DSS BVSS LS2 FRS2

RED

_DL I_Jc

I ACR

IALC J

:ss

COMMR

cpu

DHUM

DSS

EAC-1

EAC-2

FRS

FSE

FUSE

_]co

_ i_ A/C OR CF AIRFLOW SECTION CHART BASED ON 350 CFM/TON

070 DE_, 5252 700 875 1050 1225 t I225 122_

PL9 , n,lq090 DE_ 525 i 7002

11,_5 DEF. 700 8752 1050 '1225 11400 i 1750_ 2100

....-- .........................I I .........

........_[ ..... 1. Default ,Arc airilow when A/C switches are in OFF position.

iooo o_i 2 Default cont fan airflow when CF switches are in OFF posifion

_VI " "

ABCD _

1' ....... _ _ COMM

_J_l 1 _F _ LEDS

[_?R W2 Y1 DHUM G Corn WNVl Y/Y2 R STATUS

AC 24V CODE WHT

GVR

HPS

HPSR

HSI

HSIR

HUM

HUMR

IDM

IDR

iHI/LOR

Air Conditioning (Adjustable Ai_ow - CFM)

Air Conditioning Relay, SPST (N.O.)

Air Conditioning Relay Defeat Jumper

Blower Motor (ECM)

Blocked Vent Safety Switch, Manual Reset,

SPST (N.C.)

Continuous Fan (Adjustable Airflow- CFM)

Communication Relay, SPDT

Microprocessor 7 Circuitry

DHUM Connection (24VAC 0.02 Amps)

Draft Safeguard Sw., Auto-Reset, SPST (N.C.)

Electronic Air Cleaner Connection

(115VAC 1.0Amp Max.)

Electronic Air Cleaner Connection (Common)

Flame Rollout Switch, Man. Reset, SPST (N.C.)

Flame-Proving Sensor Electrode

Fuse, 3 Amp, Automotive Blade Type,

Factory Installed

Gas Valve

Gas Valve Relay, DPST(N.O.)

High-Heat Pressure Switch, SPST(N.O.)

High-Heat Pressure Switch Relay, SPST(N.C.)

Hot Surface Igniter (115VAC)

Hot Surface Igniter Relay, SPST(N.O.) SW1-5

24VAC Humidifier Connection (0.5 Amp Max.) SW1-6

Humidifier Relay, SPST (N.O) SW1-7,8

Inducer Draft Motor, 2-Speed, Shaded Pole SW4-1

Inducer Motor Relay, SPST (N.O.) SW4-2&3

Inducer Motor Speed Change Relay, SPDT TRAN

;Ill1

m m m

FUSE OR CIRCUIT

BREAKER DISCONNECT

SWITCH/WHEN REQ'D)

NOTE #2

L11 ,NEbTRAL

;-....... rf.....

" FU21 I '[

L--1.... y-[-_ +

ILK Blower Door interlock Switch, SPST (N.O.) _ JUNCTION

IND Inductor (Note #7)

LED Light Emitting Diode for Status Codes O TERMINAL

LGPS Low Gas Pressure Switch, SPST (N.O.)

LPS Low-Heat Pressure Switch, SPST (N.O.) _ CONTROLTERMINAL

LS1,2 Limit Switch Auto-Reseb SPST (N.C.)

PCB Printed Circuit Board FACTORYPOWER

PL1 12-Circuit Connector WIRING (115MAC)

PL2 4-Circuit HSI & IDM Connector

PL3 4-Circuit ECM BLWM Connector

PL4 4-Circuit Model Plug Connector FACTORYCONTROL

PL7 4-Circuit Communication Connector WIRING (24VAC)

PL9 2-Circuit OAT Connector

PL10 2-Circuit HSI Connector RELD CONTROL

PL11 IDM Connector (3-Circuit) .... WIRING(24VAC)

PLI 2 1-Circuit Inductor Splice Connector

PL13 4-Circuit ECM B;ower CTRL Connector

PL14 5-Circuit ECM Blower Power Connector CONDUCTORON

SW1-1 Manual Switch. Status Code Recall, SPST (N.O.) CONTROL

SWf-2 Manual Switch, Low-Heat Only, SPST (N.O.)

SW1-3 Manual Switch, Low-Heat Rise Adj, SPST (N.O.)

SW1-4 Manual Switch, ComforttEfficiency Adjustment, (_) FIELD WIRING

SPST (N.O.) SCREWTERMINAL

Manual Switch, Coding CFM/Ton, SPST (N.O.)

Manual Switch, Component Test, SPST (N.O.) ,_JL_, EQUIPMENT

Manual Switches, Blower Off-Delay, SPST (N.O.) _z" GROUND

Manual Switch, Twinning Main (OFF) /Sec. (ON)

For Future Use

Transformer. 115MAC /24VAC -'-( _'- PLUGRECEPTACLE

TO1115VAC FIELD - DISCONNECT/L2EQUIPMENTISWITCH SCHEMATIC DIAGRAM I

)L_LK _ GROUND /_7

PL12 PL12 BL_M

EAC EAC-I[_ EAC-2[_ L__

LS2 BVSS

NOTES:

1. If aey of the original eqquipment wire is replaced use wire rated for 105°C.

2. Use only copper wire between the disconnect switch and the furnace junction box (JB). <

3. This wire must be connected to furnace sheet metal for control to prove flame. _

i: Symbols are electrical representation only.

LU i

Solid lines inside PCB are printed circuit board conductors and are not included in legend, rY

Replace only with a 3 amp fuse.

7: Inductor is used with 3/4 hp and 1 hp ECM Blower motors.

8. Factory connected when (LGPS) not used. _

9. Blower off-delay, gas heating selections are (90, !20, I50, 180) seconds, cooling or heat _

pump 90 seconds or 5 seconds when dehumidify call is active, !

10. Ignition lockout will occur after four consecutive unsuccessful trials for ignition. Control

will auto-reset after three hours. 03

11, Inducer motor (IDM) contains internal auto-reset thermal overload switch, co

12. Factory connected when BVSS is not used. BVSS used when ChimneyAdapeter

Accessory Kit is installed. I13. Any of the 5 wires shown within the NEUTRAL L2 box can be connected to any terminal within the box.

14, Blower motor (BLWM) is locked-rotor overload protected by redundant electronic control circuits.

SECONDS G

FOR 1 REVOLUTION

Table 13 - Gas Rate (CU ft./hr)

CuFf,

SIZE OF TEST DIAL

2 Cu Ft. 5 Cu Ft.

SECONDS

FOR 1REVOLUTION lCu Ft.

360 720 1800 50 72

327 655 1636 51 71

300 600 1500 52 69

277 555 1385 53 68

257 514 1286 54 67

240 480 1200 55 65

225 450 1125 56 64

212 424 1059 57 63

200 400 1000 58 62

189 379 947 59 61

180 360 900 60 60

171 343 857 62 58

164 327 818 64 56

157 313 783 66 54

150 300 750 68 53

144 288 720 70 51

138 277 692 72 50

133 267 667 74 48

129 257 643 76 47

124 248 621 78 46

120 240 600 80 45

116 232 581 82 44

113 225 563 84 43

109 218 545 86 42

106 212 529 88 41

103 206 514 90 40

100 200 500 92 39

97 195 486 94 38

95 189 474 96 38

92 185 462 98 37

90 180 450 100 36

88 176 439 102 35

86 172 429 104 35

84 167 419 106 34

82 164 409 108 33

80 160 400 110 33

78 157 391 112 32

76 153 383 116 31

75 150 375 120 30

73 147 367

SIZE OF TEST DIAL

2 Cu Ft.

144

141

138

136

133

131

129

126

124

122

120

116

112

109

106

103

100

5 Cu Ft.

36O

355

346

34O

333

327

321

316

310

3O5

3OO

29O

281

273

265

257

250

243

237

231

225

220

214

209

205

200

196

192

188

184

180

178

173

170

167

164

161

155

150

Table 14 - Orifice Size and Manifold Pressure (In. W.C.) for Gas Input Rate

(Tabulated Data Based on 22,000 Btuh High-Heat/14,500 Btuh for Low-Heat per Burner, Derated 4 Percent for Each 1000 Ft.

(305 M) Above Sea Level)

ALTITUDE RANGE

FT. (M)

0 to

USA 2000

(0 to 610)

ALTITUDE RANGE

FT. (M)

2001 to

USA 6000 (610

to 914)

ALTITUDE RANGE

FT. (M)

6001 to

4000

USA (914 to

1219)

ALTITUDE RANGE

FT. (M)

4001 to

5000

USA (1219 to

1524)

imbers 43 are

AVG. GAS

HEAT VALU E

(BTUH/CU FT.)

900

925

950

975

1000

1025

1050

1075

1100

AVG. GAS

HEAT VALU E

(BTUH/CU FT.)

8OO

825

85O

875

9OO

925

95O

975

1000

AVG. GAS

HEAT VALU E

(BTUH/CU FT.)

775

8OO

825

85O

875

9OO

925

95O

AVG. GAS

HEAT VALU E

(BTUH/CU FT.)

75O

775

8OO

825

85O

875

9OO

925

_actory installed

SPECIFIC GRAVITY OF NATURAL GAS

0.58 0.60 0.62 0.64

Orifice Manifold Orifice Manifold Orifice Manifold Orifice Manifold

No. Pressure No. Pressure No. Pressure No. Pressure

High/Low High/Low High/Low High/Low

42 3.5/1.5 42 3.6/1.6 42 3.7/1.6 41 3.5/1.5

42 3.6/1.4 42 3.4/1.5 42 3.5/1.5 42 3.7/1.6

46 3.8/1.7 42 3.6/1.4 42 3.4/1.5 42 3.5/1.5

43 3.6/1.6 43 3.8/1.6 42 3.2/1.4 42 3.3/1.4

43 3.5/1.5 43 3.6/1.6 43 3.7/1.6 43 3.8/1.7

43 3.3/1.4 43 3.4/1.5 43 3.5/1.5 43 3.6/1.6

44 3.6/1.6 43 3.2/1.4 43 3.4/1.5 43 3.5/1.5

44 3.4/1.5 44 3.5/1.5 46 3.2/1.4 46 3.6/1.4

44 3.6/1.4 44 3.4/1.5 44 3.5/1.5 46 3.2/1.4

SPECIFIC GRAVITY OF NATURAL GAS

0.58 0.60 0.62 0.64

Manifold Manifold

Orifice Manifold Orifice Manifold Orifice Pressure Orifice

Pressure Pressure Pressure

No. High/Low No. High/Low No. High/Low No. High/Low

42 3.4/1.5 42 3.5/1.5 42 3.6/1.6 42 3.7/1.6

42 6.2/1.4 42 3.6/1.4 42 6.4/1.5 42 6.5/1.5

43 3.7/1.6 43 3.8/1.6 42 3.2/1.4 42 3.3/1.4

43 3.5/1.5 43 3.6/1.6 43 3.7/1.6 43 3.8/1.7

43 3.3/1.4 43 3.4/1.5 43 3.5/1.5 43 3.6/1.6

44 3.5/1.5 43 3.2/1.4 43 3.3/1.4 43 3.4/1.5

44 3.4/1.5 44 3.5/1.5 44 3.6/1.6 46 3.2/1.4

44 6.2/1.4 44 3.6/1.4 44 6.4/1.5 44 6.5/1.5

45 6.7/1.6 45 6.8/1.7 44 6.2/1.4 44 6.4/1.5

SPECIFIC GRAVITY OF NATURAL GAS

0.58 0.60 0.62 0.64

Manifold Manifold

Orifice Manifold Orifice Manifold Orifice Pressure Orifice

Pressure Pressure Pressure

No. High/Low No. High/Low No. High/Low No. High/Low

42 6.2/1.4 42 3.6/1.4 42 6.4/1.5 42 6.5/1.5

43 3.6/1.6 43 3.8/1.6 42 3.2/1.4 42 3.3/1.4

43 3.4/1.5 43 3.5/1.5 43 3.7/1.6 43 3.8/1.6

43 3.2/1.4 43 3.3/1.4 43 3.4/1.5 43 3.6/1.5

44 3.5/1.5 44 3.6/1.6 46 3.6/1.4 46 3.4/1.5

44 3.6/1.4 44 6.4/1.5 44 6.5/1.5 46 6.2/1.4

45 6.8/1.6 44 6.2/1.4 44 3.6/1.5 44 6.4/1.5

46 3.8/1.6 45 3.7/1.6 45 3.8/1.7 44 3.6/1.4

SPEC FIC GRAVITY OF NATURAL GAS

0.58 0.60 0.62 0.64

Manifold Manifold

Orifice Manifold Orifice Manifold Orifice Pressure Orifice

Pressure Pressure Pressure

No. High/Low No. High/Low No. High/Low No. High/Low

43 3.6/1.6 43 3.8/1.6 42 3.2/1.4 42 3.3/1.4

43 3.4/1.5 43 3.5/1.5 43 3.6/1.6 43 3.8/1.6

43 3.2/1.4 43 3.3/1.4 43 3.4/1.5 43 3.5/1.5

44 3.4/1.5 44 3.6/1.5 46 3.2/1.4 46 3.6/1.4

44 6.2/1.4 44 6.4/1.5 44 6.5/1.5 44 6.6/1.6

45 6.7/1.6 45 6.8/1.7 44 3.6/1.4 44 6.4/1.5

46 6.7/1.6 46 6.8/1.7 45 6.7/1.6 44 6.2/1.4

46 3.5/1.5 46 3.6/1.6 46 3.7/1.6 46 3.8/1.7

Table 14 -Orifice Size and Manifold Pressure (In. W.C.) for Gas Input Rate (Con't.)

(Tabulated Data Based on 22,000 Btuh High-Heat/14,500 Btuh for Low-Heat per Burner, Derated 4 Percent for Each 1000 Ft.

Above Sea Level)

USA

ALTITUDE

RANGE

FT. (M)

5001 to

6000

(1524

1829)

ALTITUDE

RANGE

FT. (M)

6001 to

7000

(1829

2134)

ALTITUDE

RANGE

FT. (M)

7001 to

8000

(2134

2438)

ALTITUDE

RANGE

FT. (M)

AVG, GAS

HEAT VALU E

AT ALTITUDE

(BTUH/CU FT.)

725

750

775

800

825

850

875

900

AVG. GAS

H EAT VALU E

AT ALTITUDE

(BTUH/CU FT.)

675

7OO

725

75O

775

8OO

825

85O

AVG. GAS

H EAT VALU E

AT ALTITUDE

(BTUH/CU FT.)

65O

675

7OO

725

75O

775

8OO

825

AVG. GAS

HEAT VALU E

AT ALTITUDE

(BTUH/CU FT.)

625

8001to 650

9000 675

USA (2438 700

to 725

2743) 750

775

6OO

9001to 625

10,000 650

USA 2743to 675

3048) 700

725

* Qrificenumbers43arefactoryinstalled

SPECIFIC GRAVITY OF NATURAL GAS

0.58 0.60

Manifold Manifold

Orifice Orifice

Pressure Pressure

No. No.

High/Low High/Low

43 3.4/1.5 43 3.5/1.5

43 3.2/1.4 43 3.3/1.4

44 3.4/1.5 44 3.5/1.5

44 3.2/1.4 44 3.3/1.4

46 3.8/1.7 45 3.8/1.6

46 3.6/1.6 46 3.7/1.6

47 3.8/1.7 46 3.5/1.5

47 3.6/1.6 47 3.8/1.6

SPECIFIC GRAVITY OF

0.58 0.60

Manifold Manifold

Orifice Orifice

Pressure Pressure

No. No.

High/Low High/Low

43 3.4/1.5 43 3.5/1.5

44 3.6/1.6 43 3.3/1.4

44 3.4/1.5 44 3.5/1.5

45 3.8/1.7 44 3.3/1.4

46 3.7/1.6 45 3.7/1.6

46 3.5/1.5 46 3.6/1.6

47 3.7/1.6 46 3.4/1.5

47 3.5/1.5 47 3.6/1.6

SPECIFIC GRAVITY OF

0.58

Manifold

Orifice Orifice

Pressure

No. No.

High/Low

44 3.6/1.6 43

44 3.3/1.5 44

45 3.8/1.6 44

46 3.7/1.6 46

46 3.4/1.5 46

47 3.6/1.6 47

47 3.4/1.5 47

48 3.7/1.6 48

0.58

Manifold

Orifice Pressure

No. High/Low

44 3.3/1.5

0.60

Manifold

Pressure

High/Low

3.2/1.4

3.5/1.5

3.2/1.4

3.8/1.7

3.6/1.5

3.8/1.6

3.5/1.5

3.8/1.6

SPECIFIC GRAVITY OF

0.60

Orifice

No.

Manifold

Pressure

High/Low

3.5/1.5

0.62

Manifold

Orifice Pressure

No. High/Low

43 3.6/1.6

43 3.4/1.5

43 3.2/1.4

44 3.4/1.5

44 3.2/1.4

46 3.8/1.7

46 3.6/1.6

46 3.4/1.5

NATURAL GAS

0.62

Manifold

Orifice Pressure

No. High/Low

43 3.6/1.6

43 3.4/1.5

44 3.6/1.6

44 3.4/1.5

45 3.8/1.7

46 3.8/1.6

46 3.5/1.5

47 3.8/1.6

NATURAL GAS

0.62

Manifold

Orifice Pressure

No. High/Low

43 3.4/1.5

44 3.6/1.6

44 3.3/1.4

45 3.7/1.6

46 3.7/1.6

46 3.4/1.5

47 3.7/1.6

47 3.4/1.5

NATURAL GAS

0.62

Manifold

Orifice Pressure

No. High/Low

44 3.6/1.6

Orifice

No.

Orifice

No.

Orifice

No.

Orifice

No.

0.64

Manifold

Pressure

High/Low

3.7/1.6

3.5/1.5

3.3/1.4

3.5/1.5

3.3/1.4

3.8/1.6

3.7/1.6

3.5/1.5

0.64

Manifold

Pressure

High/Low

3.7/1.6

3.5/1.5

3.2/1.4

3.5/1.5

3.2/1.4

3.7/1.6

3.6/1.6

3.4/1.5

0.64

Manifold

Pressure

High/Low

3.5/1.5

3.2/1.4

3.4/1.5

3.2/1.4

3.8/1.6

3.6/1.5

3.8/1.6

3.6/1.5

0.64Manifold

Pressure

High/Low

3.2/1.4

45 3.7/1.6 44

46 3.6/1.6 46

47 3.8/1.7 46

47 3.6/1.6 47

48 3.8/1.7 47

48 3.6/1.5 48

45 3.7/1.6 45

46 3.6/1.6 46

47 3.8/1.6 46

47 3.5/1.5 47

48 3.7/1.6 48

3.2/1.4

3.8/1.6

3.5/1.5

3.7/1.6

3.5/1.5

3.7/1.6

3.8/1.7

3.7/1.6

3.4/1.5

3.6/1.6

3.8/1.7

44 3.3/1.4

45 3.7/1.6

46 3.6/1.6

47 3.8/1.7

47 3.6/1.6

48 3.8/1.7

44 3.3/1.4

46 3.8/1.7

46 3.6/1.5

47 3.7/1.6

47 3.5/1.5

3.4/1

3.8/1

3.7/1

3.5/1

3.7/1

3.5/1

3.4/1

3.8/1

3.7/1

3.4/1

3.6/1

48 3.5/1.5 48 3.6/1.6 48 3.7/1.6 48

3.8/1.7

Table 15 - Orifice Size and Manifold Pressure (In. W.C.) 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.

(305 M) Above Sea level)

ALTITUDE RANGE

FT. (M)

0 to

USA 2000

(0 to 61 O)

ALTITUDE RANGE

FT. (M)

2001 to

USA 3000 (610

to 914)

ALTITUDE RANGE

FT. (M)

3001 to

USA 4O00 (914

to 1219)

ALTITUDE RANGE

FT. (M)

4001 to

5000

USA (1219 to

1524)

umbers 43 are

AVG. GAS

HEAT VALUE

(BTUH/CU

FT.)

900

925

950

975

1000

1025

1050

1075

1100

AVG. GAS

H EAT VALU E

(BTUH/CU FT.)

8OO

825

85O

875

9OO

925

95O

975

1000

AVG. GAS

H EAT VALU E

(BTUH/CU FT.)

775

800

825

85O

875

9OO

925

95O

AVG. GAS

H EAT VALU E

(BTUH/CU FT.)

75O

775

8OO

825

85O

875

9OO

925

_actory installed

SPECIFIC GRAVITY OF NATURAL GAS

0.58 0.80 0.82 0.84

Manifold Manifold Manifold Manifold

Orifice Orifice Orifice Orifice

Pressure Pressure Pressure Pressure

No. No. No. No.

High/Low High/Low High/Low High/Low

42 3.2/1.5 42 3.3/1.6 42 3.4/1.6 42 3.5/1.7

43 3.7/1.8 43 3.8/1.8 42 3.2/1.5 42 3.3/1.6

43 3.5/1.7 43 3.6/1.7 43 3.7/1.8 43 3.8/1.8

43 3.3/1.6 43 3.4/1.6 43 3.5/1.7 43 3.7/1.7

44 3.6/1.7 43 3.3/1.6 43 3.4/1.6 43 3.5/1.7

44 3.4/1.6 44 3.6/1.7 43 3.2/1.5 43 3.3/1.6

44 3.3/1.6 44 3.4/1.6 44 3.5/1.7 43 3.2/1.5

45 3.8/1.8 44 3.2/1.5 44 3.3/1.6 44 3.4/1.6

46 3.8/1.8 45 3.7/1.8 44 3.2/1.5 44 3.3/1.6

SPECIFIC GRAVITY OF NATURAL GAS

0.58 0.60 0.62 0.64

Manifold Manifold Manifold Manifold

Orifice Orifice Orifice Orifice

Pressure Pressure Pressure Pressure

No. No. No. No.

High/Low High/Low High/Low High/Low

43 3.8/1.8 42 3.2/1.5 42 3.3/1.6 42 3.4/1.6

43 3.5/1.7 43 3.7/1.7 43 3.8/1.8 42 3.2/1.5

43 3.3/1.6 43 3.5/1.6 43 3.6/1.7 43 3.7/1.8

43 3.2/1.5 43 3.3/1.6 43 3.4/1.6 43 3.5/1.7

44 3.4/1.6 44 3.5/1.7 43 3.2/1.5 43 3.3/1.6

44 3.2/1.5 44 3.3/1.6 44 3.5/1.6 44 3.6/1.7

45 3.7/1.8 45 3.8/1.8 44 3.3/1.6 44 3.4/1.6

46 3.7/1.8 46 3.8/1.8 45 3.8/1.8 44 3.2/1.5

46 3.5/1.7 46 3.6/1.7 46 3.8/1.8 45 3.7/1.8

SPECIFIC GRAVITY OF NATURAL GAS

0.58 0.60 0.62 0.64

Manifold Manifold Manifold Manifold

Orifice Orifice Orifice Orifice

Pressure Pressure Pressure Pressure

No. No. No. No.

High/Low High/Low High/Low High/Low

43 3.5/1.7 43 3.7/1.7 43 3.8/1.8 42 3.2/1.5

43 3.3/1.6 43 3.4/1.6 43 3.5/1.7 43 3.7/1.7

44 3.6/1.7 43 3.2/1.5 43 3.3/1.6 43 3.4/1.6

44 3.4/1.6 44 3.5/1.7 44 3.6/1.7 43 3.2/1.5

45 3.8/1.8 44 3.3/1.6 44 3.4/1.6 44 3.5/1.7

46 3.8/1.8 45 3.8/1.8 44 3.2/1.5 44 3.3/1.6

46 3.6/1.7 46 3.7/1.8 45 3.7/1.8 45 3.8/1.8

46 3.4/1.6 46 3.5/1.7 46 3.7/1.7 46 3.8/1.8

SPECIFIC GRAVITY OF NATURAL GAS

0.58 0.60 0.62 0.64

Manifold Manifold Manifold Manifold

Orifice Orifice Orifice Orifice

Pressure Pressure Pressure Pressure

No. No. No. No.

High/Low High/Low High/Low High/Low

43 3.3/1.6 43 3.4/1.6 43 3.5/1.7 43 3.6/1.7

44 3.6/1.7 43 3.2/1.5 43 3.3/1.6 43 3.4/1.6

44 3.3/1.6 44 3.4/1.6 44 3.6/1.7 43 3.2/1.5

45 3.8/1.8 44 3.2/1.5 44 3.4/1.6 44 3.5/1.6

46 3.8/1.8 45 3.7/1.8 45 3.8/1.8 44 3.3/1.6

46 3.5/1.7 46 3.7/1.7 46 3.8/1.8 45 3.7/1.8

47 3.8/1.8 46 3.5/1.7 46 3.6/1.7 46 3.7/1.8

47 3.6/1.7 47 3.7/1.8 47 3.8/1.8 46 3.5/1.7

Table 15 -Orifice Size and Manifold Pressure (In. W.C.) for Gas Input Rate (Con't.)

(Tabulated Data Based on 21,000 Btuh High-Heat/14,500 Btuh for Low-Heat Per Burner, Derated 4 Percent for Each 1000 Ft.

(305 M) Above Sea level)

ALTITUDE RANGE

FT. (M)

5001 to

6000

USA (1524 to

1829)

ALTITUDE RANGE

FT. (M)

6001 to

7000

USA (1829 to

2134)

ALTITUDE RANGE

FT. (M)

7001to

8000

USA (2134to

2438)

AVG. GAS

H EAT VALUE

AT ALTITUDE

(BTUH/CU

FT.)

725

75O

775

8OO

825

85O

875

9OO

AVG. GAS

H EAT VALU E

AT ALTITUDE

(BTUH/CU FT.)

675

7OO

725

75O

775

8OO

825

85O

AVG. GAS

H EAT VALU E

AT ALTITUDE

(BTUH/CU FT.)

65O

675

7OO

725

75O

775

8OO

825

AVG. GAS

ALTITUDE RANGE HEAT VALUE

FT. (M) AT ALTITUDE

(BTUH/CU FT.)

625

65O

8001 to 675

USA 9000 700

(2438 to 725

2743) 750

775

6OO

9001 to 625

10,000 650

USA (2743 to 675

3048) 700

725

* Orifice numbers 43 are factory installed

0.58

Manifold

Orifice Pressure

No. High/Low

44 3.5/1.7

44 3.3/1.6

45 3.7/1.8

46 3.7/1.8

46 3.5/1.7

47 3.7/1.8

47 3.5/1.7

48 3.8/1.8

0.58

Manifold

Orifice Pressure

No. High/Low

44 3.5/1.7

44 3.3/1.6

45 3.7/1.8

46 3.6/1.7

46 3.4/1.6

47 3.6/1.7

47 3.4/1.6

48 3.7/1.7

0.58

Manifold

Orifice Pressure

No. High/Low

44 3.3/1.6

45 3.7/1.8

46 3.6/1.7

47 3.8/1.8

47 3.5/1.7

48 3.8/1.8

48 3.6/1.7

48 3.3/1.6

Orifice

No.

0.58

Manifold

Pressure

High/Low

3.7/1.8

3.6/1.7

3.8/1.8

3.5/1.7

3.7/1.8

3.5/1.7

3.8/1.8

3.6/1.7

3.7/1.8

3.4/1.6

3.6/1.7

3.4/1.6

3.7/1.8

SPECIFIC GRAVITY OF NATURAL GAS

0.60 0.62 0.64

Manifold Manifold Manifold

Orifice Orifice Orifice

Pressure Pressure Pressure

No. No. No.

High/Low High/Low High/Low

43 3.2/1.5 43 3.3/1.6 43 3.4/1.6

44 3.4/1.6 44 3.5/1.7 43 3.2/1.5

44 3.2/1.5 44 3.3/1.6 44 3.4/1.6

46 3.8/1.8 45 3.8/1.8 44 3.2/1.5

46 3.6/1.7 46 3.7/1.8 46 3.8/1.8

47 3.8/1.8 46 3.5/1.7 46 3.6/1.7

47 3.6/1.7 47 3.7/1.8 46 3.4/1.6

47 3.4/1.6 47 3.5/1.7 47 3.7/1.7

SPECIFIC GRAVITY OF NATURAL GAS

0.60 0.62 0.64

Manifold Manifold Manifold

Orifice Orifice Orifice

Pressure Pressure Pressure

No. No. No.

High/Low High/Low High/Low

43 3.2/1.5 43 3.3/1.6 43 3.4/1.6

44 3.4/1.6 44 3.5/1.7 43 3.2/1.5

45 3.8/1.8 44 3.3/1.6 44 3.4/1.6

46 3.8/1.8 45 3.7/1.8 45 3.8/1.8

46 3.5/1.7 46 3.6/1.7 46 3.8/1.8

47 3.8/1.8 46 3.4/1.6 46 3.5/1.7

47 3.5/1.7 47 3.6/1.7 47 3.8/1.8

48 3.8/1.8 47 3.4/1.6 47 3.5/1.7

SPECIFIC GRAVITY OF NATURAL GAS

0.60 0.62 0.64

Manifold Manifold Manifold

Orifice Orifice Orifice

Pressure Pressure Pressure

No. No. No.

High/Low High/Low High/Low

44 3.4/1.6 44 3.5/1.7 43 3.2/1.5

45 3.8/1.8 44 3.3/1.6 44 3.4/1.6

46 3.7/1.8 46 3.8/1.8 45 3.8/1.8

46 3.5/1.7 46 3.6/1.7 46 3.7/1.8

47 3.7/1.8 47 3.8/1.8 46 3.5/1.6

47 3.4/1.6 47 3.6/1.7 47 3.7/1.7

48 3.7/1.8 48 3.8/1.8 47 3.4/1.6

48 3.5/1.6 48 3.6/1.7 48 3.7/1.8

SPECIFIC GRAVITY OF NATURAL GAS

0.60 0.62 0.64

Manifold Manifold Manifold

Orifice Orifice Orifice

Pressure Pressure Pressure

No. No. No.

High/Low High/Low High/Low

45 3.8/1.8 44 3.3/1.6 44 3.4/1.6

46 3.7/1.8 46 3.8/1.8 45 3.8/1.8

46 3.4/1.6 46 3.5/1.7 46 3.7/1.7

47 3.6/1.7 47 3.7/1.8 46 3.4/1.6

48 3.8/1.8 47 3.5/1.7 47 3.6/1.7

48 3.6/1.7 48 3.7/1.8 48 3.8/1.8

48 3.4/1.6 48 3.5/1.7 48 3.6/1.7

46 3.7/1.8 46 3.8/1.8 45 3.7/1.8

47 3.8/1.8 46 3.5/1.7 46 3.6/1.7

47 3.6/1.7 47 3.7/1.8 47 3.8/1.8

48 3.8/1.8 47 3.4/1.6 47 3.5/1.7

48 3.5/1.7 48 3.6/1.7 48 3.7/1.8

49 3.8/1.8 48 3.4/1.6 48 3.5/1.7

Check Safety Controls

The flame sensor, gas valve, and pressure switch were all checked

in the Start-up procedure section as part of normal operation.

1. Check Main Limit Switch

This control shuts off combustion system and energizes

air-circulating blower motor, if furnace overheats. By us-

ing this method to check limit control, it can be established

that limit is flmctioning properly and will operate if there

is a restricted return-air supply or motor failure. If limit

control does not flmction during this test, cause must be

determined and corrected.

a. Run furnace for at least 5 minutes.

b. Gradually block off return air with apiece of card-

board 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 con-

nector from furnace vent elbow.

c. Restore power to furnace and set room thermostat

above room temperature.

d. After normal start-up, allow furnace to operate for 2

minutes, then block vent elbow in furnace 80 percent

of vent area with a piece of flat sheet metal.

e. Furnace should cycle off within 2 minutes. If gas does

not shut off within 2 minutes, determine reason draft

safeguard switch did not function properly and correct

condition.

f. Remove blockage from furnace vent elbow.

g. Switch will auto-reset when it cools.

h. Re-install vent connector.

NOTE: Should switch remain open longer than 3 minutes,

furnace control board will lockout the furnace for 3 hours. To

reset furnace control board, turn thermostat below room

temperature or from HEAT to OFF and turn l15-v power OFF,

then back ON.

3. Check Pressure Switch(es)

This control proves operation of the draft inducer blower.

a. Turn off l15-v power to furnace.

b. Disconnect inducer motor lead wires from wire har-

ness.

c. Turn on l15-v power to furnace.

d. Set thermostat to "call for heat" and wait 1 minute.

When pressure switch is functioning properly, hot sur-

face igniter should NOT glow and control diagnostic

light flashes a status code 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.

CheeMist

1. Put away tools and instruments. Clean up debris.

2. Verify that switches SWI-I and SWI-6 are OFF and oth-

er setup switches are set as desired. Verify that switches

SW1-7 and SW1-8 for the blower OFF DELAY are set as

desired per Table 10.

3. Verify that blower and burner access doors are properly in-

stalled.

4. Cycle test furnace with room thermostat.

5. Check operation of accessories per manufacturer's instruc-

tions.

6. Review User's Guide with owner.

7. Attach literature packet to furnace.

SERVICE AND MAINTENANCE

PROCEDURES

FIRE, INJURY OR DEATH HAZARD

Failure to follow this warning could result in personal

iniury, death and/or property damage.

The ability to properly perform maintenance on this

equipment requires certain knowledge, mechanical skills,

tools, and equipment. If you do not possess these, do not

attempt to perform any maintenance on this equipment

other than those procedures recommended in the User's

Manual.

ENVIRONMENTAL HAZARD

Failure to follow this caution may result in environmental

pollution.

Remove and recycle all components or materials (i.e. oil,

refrigerant, control board, etc.) before unit final disposal.

ELECTRICAL SHOCK, FIRE OR EXPLOSION

HAZARD

Failure to follow this warning could result in personal

iniury or death, or property damage.

Before installing, modifying, or servicing system, main

electrical disconnect switch must be in the OFF position and

install a lockout tag. There may be more than one

disconnect switch. Lock out and tag switch with a suitable

warning label. Verify proper operation after servicing.

ELECTRICAL OPERATION HAZARD

Failure to follow this caution may result in improper

furnace operation or failure of furnace.

Label all wires prior to disconnection when servicing

controls. Wiring errors can cause improper and dangerous

operation.

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

thefurnace,andconditionedairisdischargedupward.Sincethis

furnacecanbeinstalledinanyofthe4positionsshowninFig.4,

youmustreviseyourorientationto componentlocation

accordingly.

Electrical Controls and Wiring

ELECTRICALSHOCK HAZARD

Failure to follow this warning could result in personal iniury

or death.

There may be more than one electrical supply to the furnace.

Check accessories and cooling unit for additional electrical

supplies that must be shut off during furnace servicing. Lock

out and tag switch with a suitable warning label.

The electrical ground and polarity for 115-v wiring must be

properly maintained. Refer to Fig. 25 for field wiring information

and to Fig. 53 for furnace wiring information.

NOTE: If the polarity is not correct, the STATUS LED on the

control will flash rapidly and prevent the furnace from heating.

The control system also requires an earth ground for proper

operation of the control and flame-sensing electrode.

The 24-v circuit contains an automotive-type, 3-amp. fuse

located on the control. (See Fig. 26.) Any shorts of the 24-v

wiring during installation, service, or maintenance will cause this

fuse to blow. If fuse replacement is required, use ONLY a 3-amp.

fuse. The control LED will display status code 24 when fuse

needs to be replaced.

Proper instrumentation is required to service electrical controls.

The control in this furnace is equipped with a Status Code LED

(Light-Enfitting Diode) to aid in installation, servicing, and

troubleshooting. Status codes can be viewed at the sight glass in

blower access door. The amber furnace control LED is either ON

continuously, rapid flashing, or a code composed of 2 digits. The

first digit is the number of short flashes, the second digit is the

number of long flashes.

For an explanation of status codes, refer to service label located

on blower access door or Fig. 52, and the troubleshooting guide

which can be obtained from your distributor.

See Fig. 58, a brief Troubleshooting Guide.

For 2-Stage Variable Speed ECM Controls the stored status

codes will NOT be erased from the control memory, when 115-

or 24-v power is interrupted. The control will store up to the last

7 Status Codes in order of occurrence.

1. To retrieve status codes, proceed with the following:

NOTE: NO thermostat signal may be present at control, and all

blower-OFF delays must be completed.

a. Leave 115-v power to furnace turned on.

b. Remove outer access door.

c. Look into blower access door sight glass for current

LED status.

d. Remove blower access door.

NOTE: The Status Codes cannot be retrieved by disconnecting

the limit switch or draft safeguard switch. To retrieve Status

Codes, follow the procedure below.

2. Turn Setup Switch, SWI-I "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 SWI-I "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 informa-

tion.

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" ternfinal of the control

board.

4. Turn Setup Switch, SW-I-6 "ON."

5. Manually close blower access door switch.

Blower access door switch opens l15-v power to control. No

component operation can occur unless switch is closed. Caution

nmst be taken when manually closing this switch for service

purposes.

ELECTRICALSHOCK HAZARD

Failure to t\_llow this warning could result in personal iniury,

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 deen-

ergized.

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 SWI-6 OFF

then back ON.

f. Turn setup switch SWI-6 OFF.

7. RELEASE BLOWER ACCESS DOOR SWITCH, reat-

tach wire to "R" ternfinal on furnace control board, replace

blower access door, and replace outer access door.

CARE AND MAINTENANCE

FIRE OR EXPLOSION HAZARD

Failure to follow this warning could result in personal

injury, death and/or property damage.

Never store anything on, near, or in contact with the

furnace, such as:

1. Spray or aerosol cans, rags, brooms, dust mops,

vacuum cleaners, or other cleaning tools.

2. Soap powders, bleaches, waxes or other cleaning

compounds, plastic or plastic containers, gasoline,

kerosene, cigarette lighter fluid, dry cleaning fluids,

or other volatile fluids.

3. Paint thinners and other painting compounds, paper

bags, or other paper products. Exposure to these

materials could lead to corrosion of the heat

exchangers.

For continuing high performance and to nfininfize possible

furnace failure, periodic maintenance nmst be performed on this

furnace. Consult your local dealer about proper frequency of

maintenance and the availability of a maintenance contract.

ELECTRICAL SHOCK AND FIRE HAZARD

Failure to follow this warning could result in personal injury,

death, and/or property damage.

Turn off the gas and electrical supplies to the furnace and

install lockout tag before perfornfing any maintenance or

service. Follow the operating instructions on the label

attached to the furnace.

CARBON MONOXIDE POISONING AND FIRE

HAZARD

Failure to follow this warning could result in personal

injury, death and/or property damage.

Never operate furnace without a filter or with filter access

door removed.

CUT HAZARD

Failure to follow this caution may result in personal injury.

Sheet metal parts may have sharp edges or burrs. Use care

and wear appropriate protective clothing, safety glasses and

gloves when handling parts, and servicing furnaces.

The minimum maintenance on this furnace is as follows:

1. Check and clean air filter each month or more frequently if

required. Replace if torn.

2. Check blower motor and wheel for cleanliness each heat-

ing and cooling season. Clean as necessary.

3. Check electrical connections for tightness and controls for

proper operation each heating season. Service as neces-

sary.

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 sea-

son 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

hunfidifier or electronic air cleaner. Perform any service or

maintenance to the accessories as recommended in the ac-

cessory instructions.

Cleaning and/or Replacing Air Filter

The air filter arrangement will vary depending on the application.

NOTE: If the filter has an airflow direction arrow, the arrow

must point towards the blower.

CUT HAZARD

Failure to follow this caution may result in personal injury.

Sheet metal parts may have sharp edges or burrs. Use care

and wear appropriate protective clothing, safety glasses and

gloves when handling parts, and servicing furnaces.

Media cabinet filter procedures:

1. Turn off electrical supply to furnace before removing filter

access door.

2. Remove filter cabinet door.

3. Slide filter out of cabinet.

4. If equipped with permanent, washable 3/4-in. (19 ram)

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 15 for size information.

5. If equipped with factory-specified disposable media filter,

replace only with media filter having the same part num-

ber and size. For expandable replacement media, refer to

the instructions included with the replacement media.

6. Slide filter into cabinet.

7. Replace filter cabinet door.

8. Turn on electrical supply to furnace.

Blower Motor and Wheel

ELECTRICALSHOCK 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.

FURNACE CASING WIDTH

14-1/2 (388)

17-1/2 (445)

21 (533)

24 (610)

Table 16 - Filter Size Information - In. (mm)

FILTERSIZE

SIDE

RETURN

18 X 25 X 3/4

(406 X 635 X 19)

18 X 25 X 3/4

(406 X 635 X 19)

18 X 25 X 3/4

(406 X 635 X 19)

18 X 25 X 3/4

(406 X 635 X 19)

Recommended

The inducer and blower motors are pre-lubricated and require no

additional lubrication. These motors can be identified by the

absence of oil ports on each end of the motor.

Clean blower motor and wheel as follows:

1. Turn off electrical supply to furnace.

2. Remove outer door.

3. For downflow or horizontal furnaces having vent pipes

within the furnace that pass in front of the blower access

door:

a. Disconnect vent connector from furnace vent elbow.

b. Disconnect and remove short piece of vent pipe from

within furnace.

4. Remove 2 screws from blower access door and remove

blower access door.

5. All factory wires can be left connected, but field thermo-

stat connections may need to be disconnected depending

on their length and routing.

6. Remove 2 screws holding blower assembly to blower

deck and slide blower assembly out of furnace.

7. Clean blower wheel and motor using a vacuum with soft

brush attachment. Blower wheel blades may be cleaned

with a small paint or flux brush. Do not remove or disturb

balance weights (clips) on blower wheel blades.

8. Vacuum any loose dust from blower housing, wheel and

motor.

9. If a greasy residue is present on blower wheel, remove

wheel from the blower housing and wash it with an appro-

priate degreaser. To remove wheel:

NOTE: Before disassembly, mark blower mounting arms, motor,

and blower housing so motor and each arm is positioned at the

same location during reassembly.

a. Disconnect ground wire attached to blower housing.

b. Remove screws securing cutoff plate and remove

cutoff plate from housing.

c. Loosen set screw holding blower wheel on motor shaft

(160+/-20 in.-lb, when assembling).

d. Remove bolts holding motor to blower housing and

slide motor out of wheel (40+/-10 in.-lb, when reas-

sembling).

e. Remove blower wheel from housing.

f. Clean wheel and housing.

10. Reassemble motor and blower by reversing steps 9a,

BOTTOM

RETURN

14 X 25 X 3/4

(356 X 835 X 19)

18 X 25 X 3/4

(406 X 635 X 19)

20 X 25 X 3/4

(508 X 635 X 19)

24 X 25 X 3/4

(610 X 835 X 19)

FILTER TYPE

Washable*

15. Reconnect blower leads to furnace control. Refer to fur-

nace wiring diagram, and connect thermostat leads if pre-

viously disconnected.

16. To check blower for proper rotation:

a. Turn on electrical supply.

ELECTRICALSHOCK HAZARD

Failure to follow this warning could result in personal

iniury, or death.

Blower access door switch opens l15-v power to furnace

control. No component operation can occur unless switch is

closed. Exercise caution to avoid electrical shock from

exposed electrical components when manually closing this

switch for service purposes.

b. Manually close blower access door switch.

NOTE: If R-W/W1 thermostat ternfinals are jumpered at the

time blower access door switch is closed, blower will run for 90

sec before beginning a heating cycle.

17.

18.

19.

20.

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

If furnace is operating properly, RELEASE BLOWER

ACCESS DOOR SWITCH. Remove any jumpers or re-

connect any disconnected thermostat leads. Replace

blower access door.

Downflow or horizontal furnaces with vent pipe through

furnace only:

a. Install and connect short piece of vent pipe inside fur-

nace to existing vent.

b. Connect vent connector to vent elbow.

Reinstall outer door.

Turn on gas supply and cycle furnace through one com-

plete heating and cooling cycle. Verify the furnace temper-

ature rise as shown in Adjustments Section. Adjust tem-

perature rise as shown in Adjustments Section. If outdoor

temperature is below 70°F, turn off circuit breaker to out-

door unit before running furnace in the cooling cycle.

Turn outdoor circuit breaker on after completing cooling

cycle.

through 9e. Be sure to reattach ground wire to the blower

housing.

11. Verify that blower wheel is centered in blower housing

and set screw contacts the flat portion of the motor shaft.

Loosen set screw on blower wheel and reposition if neces-

sary.

12. Spin the blower wheel by hand to verify that the wheel

does not rub on the housing.

13. Reinstall blower assembly in furnace.

14. Reinstall 2 screws securing blower assembly to blower

deck.

Cleaning Heat Exchanger

The following steps should be performed by a qualified

service agency:

NOTE: If the heat exchangers get aheavy 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.

__- [-5/16"

7.9 mm

Fig. 54 - Igniter Position - Side View

A05025

1-7/8

(47.6 mm)

Fig. 55 -Igniter Position -Top View

A05026

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 disconnect-

ing wires from switches because damage may occur):

a. Draft safeguard switch.

b. Inducer motor.

c. Pressure switches.

d. Limit overtemperature switch.

e. Gas valve.

f. Hot surface igniter.

g. Flame-sensing electrode.

h. Flame rollout switches.

6. Remove screws that fasten the collector box assembly to

the cell panel. Be careful not to damage the collector box.

Inducer assembly and elbow need not be removed from

collector box.

7. Disconnect gas line from gas manifold.

8. Remove the four screws that attach the burner assembly to

the cell panel. The gas valve and individual burners need

not be removed from support assembly. Remove NOx

baffles, if installed.

NOTE: Be very careful when removing burner assembly to

avoid breaking igniter. See Fig. 54-55 for correct igniter location.

9. Using field-provided 25-caliber rifle cleaning brush,

36-in. (914 mm) long, l/4-in. (6 mm) diameter steel

spring cable, a variable speed, follows:

a. Remove metal screw fitting from wire brush to allow

insertion into cable.

b. Insert the twisted wire end of brush into end of spring

cable, and crimp tight with crimping tool or crimp by

striking with ball-peen hammer. TIGHTNESS IS

VERY IMPORTANT.

NOTE: The materials needed in item 9 can usually be purchased

at local hardware stores.

(1.) Attach variable-speed, reversible drill to the end

of spring cable (end opposite brush).

(2.) Insert brush end of cable into the outlet opening

of cell and slowly rotate with drill. DO NOT

force cable. Gradually insert cable into upper pass

of cell. (See Fig. 57.)

(3.) Work cable in and out of cell 3 or 4 times to ob-

tain 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).

Fig. 56 - Cleaning Heat Exchanger Cell

A91252

(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.Reconnectwirestothefollowingcomponents(Usecon-

nectiondiagramonwiringlabel,if wireswerenotmarked

forreconnectionlocations.):

a.Draftsafeguardswitch.

b.Inducermotor.

c.Pressureswitches.

d.Limitovertemperatureswitch.

e.Gasvalve.

f. Hotsurfaceigniter.

g.Flame-sensingelectrode.

h.Flamerolloutswitches.

14.Reinstallinternalventpipe,ifapplicable.

15.Reinstallventconnectoronfurnaceventelbow.Securely

fastenventconnectortoventelbowwith2field-supplied,

corrosion-resistant,sheetmetalscrewslocated180° apart.

16.Replacebloweraccessdooronlyifitwasremoved.

17.Setthermostataboveroomtemperatureandcheckfurnace

forproperoperation.

18.Verifyblowerairfowandspeedchangesbetweenheating

andcooling.

FIREOREXPLOSIONHAZARD

Failureto followthiswarningcouldresultin personal

iniury,death,and/orpropertydamage.

Neverpurgeagaslineintoacombustionchamber.Never

testforgasleakswithanopenflame.Useacommercially

availablesoapsolutionmadespecificallyforthedetection

ofleakstocheckallconnections.Afireorexplosionmay

resultcausingpropertydamage,personaliniuryorlossof

life.

19.Checkforgasleaks.

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. 53, 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 HSI, and gas valve GV.

1. Two-Stage Heating (Adaptive Mode) with Single-Stage

Thermostat

See Fig. 27 - 34 for thermostat connections

NOTE: The low-heat only switch SWI-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 10.) When the W2 thermostat terminal is

energized it will always cause high-heat operation when the

R-to-W circuit is closed, regardless of the setting of the low-heat

only switch. This furnace can operate as a two-stage furnace with

a single-stage thermostat because the furnace control CPU

includes a programmed adaptive sequence of controlled

operation, which selects low-heat or high-heat operation. This

selection is based upon the stored history of the length of

previous gas-heating periods of the single-stage thermostat.

The furnace will start up in either low- or high-heat. If the

furnace starts up in low-heat, the control CPU determines the

low-heat on-time (from 0 to 16 minutes) which is permitted

before switching to high-heat.

If the power is interrupted, the stored history is erased and the

control CPU will select low-heat for up to 16 minutes and then

switch to high-heat, as long as the thermostat continues to call for

heat. Subsequent selection is based on stored history of the

thermostat cycle times.

The wall thermostat "calls for heat", closing the R-to-W circuit.

The furnace control performs a self-check, verifies the low-heat

and high-heat pressure switch contacts LPS and HPS are open,

and starts the inducer motor IDM in high-speed.

a, Inducer Prepurge Period

(1.) If the furnace control CPU selects low-heat oper-

ation the inducer motor IDM comes up to speed,

the low-heat pressure switch LPS closes, and the

furnace control CPU begins a 15-second prepur-

ge period. If the low-heat pressure switch LPS

fails to remain closed the inducer motor IDM will

remain running at high-speed. After the low-heat

pressure switch re-closes the furnace control CPU

will begin a 15-second prepurge period, and con-

tinue to run the inducer motor IDM at high-

speed.

(20 If the furnace control CPU selects high-heat op-

eration, the inducer motor IDM remains running

at high-speed, and the high-heat pressure switch

relay HPSR is de-energized to close the NC con-

tact. When sufficient pressure is available the

high-heat pressure switch HPS closes, and the

high-heat gas valve solenoid GV-HI is ener-

gized. The furnace control CPU begins a

15-second prepurge period after the low-heat

pressure switch LPS closes. If the high-heat pres-

sure switch HPS fails to close and the low-heat

pressure switch LPS closes, the furnace will oper-

ate at low-heat gas flow rate until the high-heat

pressure switch closes for a maximum of 2 min-

utes 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 prov-

ing period begins. The HSI igniter will remain ener-

gized 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,

COOLING TONNAGE VS. AIRFLOW (CFM)

AIR CONDITIONING AIRFLOW 070 MODEL 090 MODEL 110, 135,

TONS (12,000 BTU/HR) (CFM) & 155 MODELS

1-1/2 525 X2 X

2 700 X X2 X

2-1/2 875 X X X 2

31050 X 1 X X

3-1/2 1225 X Xl X

4 1400 _ X X

51750 _ _ X 1

6 2100 _ _ X

X-INDICATES AN ALLOWABLE SELECTION.

BASED ON 350 CFM/TON (SETUP SWITCH SW1-5 OFF, SW4-3 OFF)

SETUP SWITCH SW2 OR SW3 POSITIONS

MODEL

SIZE oE=_ oE=. o__._ o__.. oE=_ oE=. o__.. o__._

mm._nco mm._noj mm._no: mm._no, ml:_mco ml:_mcc ml:_m_ ml:_mco

070 DEF. 5252 700 875 10501 1225 1225 1225

090 DEF. 5252 700 875 1050 1225 14001 1400

10, 135, 15_ DEF. 700 8752 1050 1225 1400 17501 2100

BASED ON 400 CFM/TON (SETUP SWITCH SW1-5 ON, SW4-3 OFF)

SETUP SWITCH SW2 OR SW3 POSiTiONS

MODEL m'_n_ i:_m _ m'_n_ i:_m _ m'_n_ i:_m _ m'_n_ I:_m_

070 DEF. 6002 800 1000 12001 1400 1400 1400

090 DEF. 6002 800 1000 1200 1400 16001 1600

10, 135, 155 DEF. 800 10002 1200 1400 1600 20001 2200

BASED ON 325 CFM/TON (SETUP SWITCH SW1-5 OFF, SW4-3 ON)

SETUP SWITCH SW2 OR SW3 POSITIONS

MODEL _ I:_1_ _ r--m_ _ r--m_ _ r--m_

SIZE oE=_ oE=. o__.. o__._ oE=_ oE=. o__.. o__._

mm._nco mm._no_ mm._no: mm._nco ml:_mco ml:_mo: ml:_mo, ml:_mco

070 DEF. 4882 651 814 9761 1139 1139 1139

090 DEF. 4882 651 814 976 1139 13021 1302

10, 135, 155 DEF. 651 8142 976 1139 1302 16271 1950

BASED ON 370 CFM/TON (SETUP SWITCH SW1-5 ON, SW4-3 ON)

SETUP SWITCH SW2 OR SW3 POSITIONS

MODEL _ I:_1_ _= r--m_ _ r--m_ _= r--m_

SIZE o_=_ o_=. o__.. o__._ o_=_ o_=_ o__.. o__._

m_co m_cc m_c< m_co ml:_lco ml:_loc ml:_lc_ ml:_lco

070 DEF. 5582 744 930 11161 1302 1302 1302

090 DEF. 5582 744 930 1116 1302 14881 1488

10, 135, 155 DEF. 744 9302 1116 1302 1488 18601 2200

1. DEFAULT A/C AIRFLOW WHEN A/C SWITCHES ARE IN OFF POSITION

2. DEFAULT CONT. FAN AIRFLOW WHEN CF SWITCHES ARE IN OFF POSITION

3. SWITCH POSITIONS ARE ALSO SHOWN ON FURNACE WIRING DIAGRAM

Fig. 57 - Cooling (A/C) or Continuous-Fan (CF) Airflow Selection Chart

A13055

d. Flame-Proving -When the burner flame is proved at

the flame-proving sensor electrode FSE, the inducer

motor IDM switches to low-speed unless the furnace

is operating in high-heat, and the furnace control CPU

begins the blower-ON delay period and continues to

hold the gas valve GV-M open. If the burner flame is

not proved within two seconds, the control CPU will

close the gas valve GV-M, and the control CPU will

repeat the ignition sequence for up to three more Tri-

als-For-Ignition before going to Ignition-Lockout.

Lockout will be reset automatically after three hours,

or by momentarily interrupting 115 vac power to the

furnace, or by interrupting 24 vac power at SECI or

SEC2 to the furnace control CPU (not at W/WI, G, R,

etc.).If flameisprovedwhenflameshouldnotbe

present,thefurnacecontrolCPUwilllockoutofGas-

HeatingmodeandoperatetheinducermotorIDMon

highspeeduntilflameisnolongerproved.

e.Blower-Ondelay- Iftheburnerflameisproventhe

blower-ONdelaysforlow-heatandhigh-heatareas

follows:

Low-heat- 45secondsafterthegasvalveGV-Mis

openedtheblowermotorBLWMisturnedONat

low-heatairflow.

High-heat- 25secondsafterthegasvalveGV-Mis

openedtheBLWMisturnedONathigh-heatairflow.

Sinmltaneously,thehumidifierterminalHUMand

electronicaircleanerterminalEAC-1areenergized

andremainenergizedthroughouttheheatingcycle.

f. SwitchingfromLow- to High-Heat - If the furnace

control CPU switches from low-heat to high-heat, the

furnace control CPU will switch the inducer motor

IDM speed from low to high. The high-heat pressure

switch relay HPSR is de-energized to close the NC

contact. When sufficient pressure is available the high-

heat pressure switch HPS closes, and the high-heat gas

valve solenoid GV-HI is energized. The blower motor

BLWM will transition to high-heat airflow five

seconds after the furnace control CPU switches from

low-heat to high-heat.

g. Switching from High- to Low-Heat -The furnace

control CPU will not switch from high-heat to low-

heat while the thermostat R-to-W circuit is closed

when using a single-stage them_ostat.

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 in-

ducer motor IDM will remain energized for a

5-second post-purge period. The blower motor

BLWM and air cleaner terminal EAC-I will remain

energized at low-heat airflow or transition to low-heat

airflow for 90, 120, 150, or 180 seconds (depending

on selection at blower-OFF delay switches). The fur-

nace control CPU is factory-set for a 120-second

blower-OFF delay.

2. Two-Stage Thermostat and Two-Stage Heating

See Fig. 27-34 for thermostat connections.

NOTE: In this mode the low-heat only switch SWI-2 must be

ON to select the low-heat only operation mode in response to

closing the thermostat R-to-Wl circuit. Closing the thermostat

R-to- Wl-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-Wl circuit

for low-heat or closing the R-to-Wl-and-W2 circuits for

high-heat. The furnace control perfom_s a self-check, verifies the

low-heat and high-heat pressure switch contacts LPS and HPS

are open, and starts the inducer motor IDM in high-speed.

The start up and shut down functions and delays described in

item 1. above apply to the 2-stage heating mode as well, except

for switching from low- to high-Heat and vice versa.

a. Switching from Low- to High-Heat - If the thermo-

stat R-to-Wl circuit is closed and the R-to-W2 cir-

cuit 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 ener-

gized. The blower motor BLWM will transition to

high-heat airflow five seconds after the R-to-W2 cir-

cuit closes.

b. Switching from High- to Low-Heat -If the thermo-

stat R-to- W2 circuit opens, and the R-to-Wl circuit

remains closed, the furnace control CPU will switch

the inducer motor IDM speed from high to low. The

high-heat pressure switch relay HPSR is energized to

open the NC contact and de-energize the high-heat

gas valve solenoid GV-HI. When the inducer motor

IDM reduces pressure sufficiently, the high-heat pres-

sure switch HPS will open. The gas valve solenoid

GV-M will remain energized as long as the low-heat

pressure switch LPS remains closed. The blower motor

BLWM will transition to low-heat airflow five

seconds after the R-to-W2 circuit opens.

3. Cooling mode

The thermostat "calls for cooling".

a. Single-Speed Cooling-

See Fig. 27 for thermostat connections

The thermostat closes the R-to-G-and-Y circuits. The

R-to- Y circuit starts the outdoor unit, and the R-to-

G-and-Y/Y2 circuits start the furnace blower motor

BLWM on cooling airflow. Cooling airflow is based

on the A/C selection shown in Fig. 57. The electronic

air cleaner terminal EAC-I 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. Jump-

er Y/Y2 to DHUM to reduce the cooling off-delay to

5 seconds. (See Fig. 26.)

b. Single-Stage Thermostat and Two-Speed Cooling

(Adaptive Mode) -

See Fig. 34 for thermostat connections.

This furnace can operate a two-speed cooling unit

with a single-stage thermostat because the furnace

control CPU includes a programmed adaptive se-

quence of controlled operation, which selects low-

cooling or high-cooling operation. This selection is

based upon the stored history of the length of previous

cooling period of the single-stage thermostat.

NOTE: The air conditioning relay disable jumper ACRDJ nmst

be connected to enable the adaptive cooling mode in response to

a call for cooling. (See Fig. 26.) When ACRDJ is in place the

furnace control CPU can turn on the air conditioning relay ACR

to energize the Y/Y2 terminal and switch the outdoor unit to

high-cooling.

The furnace control CPU can start up the cooling unit in either

low- or high-cooling. If starting up in low-cooling, the furnace

control CPU determines the low-cooling on-time (from 0 to 20

minutes) which is permitted before switching to high-cooling. If

the power is interrupted, the stored history is erased and the

furnace control CPU will select low-cooling for up to 20 minutes

and then energize the air conditioning relay ACR to energize the

Y/Y2 terminal and switch the outdoor unit to high-cooling, as

long as the thermostat continues to call for cooling. Subsequent

selection is based on stored history of the thermostat cycle times.

The wall thermostat "calls for cooling", closing the

R-to-G-and-Y circuits. The R-to-Yl circuit starts the outdoor

unit on low-cooling speed, and the R-to-G-and-Yl circuits

starts the furnace blower motor BLWM at low-cooling airflow

which is the true on-board CF selection as shown in Fig. 57.

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-Yl-and-Y2 circuits switch the outdoor unit

to high-coolingspeed,andtheR-to-G-and-Yl-and-Y/Y2

circuitstransitionthe furnaceblowermotorBLWMto

high-coolingairflow.High-coolingairflowisbasedontheA/C

selectionshowninFig.57.

NOTE:Whentransitioningfromlow-coolingtohigh-cooling

theoutdoorunitcompressorwillshutdownfor1minutewhile

thefurnaceblowermotorBLWMtransitionsto run at

high-coolingairflow.

TheelectronicaircleanerterminalEAC-Iisenergizedwith115

vacwhenevertheblowermotorBLWMisoperating.

Whenthethermostatissatisfied,theR-to-G-and-Ycircuitare

opened.Theoutdoorunitstops,andthefurnaceblowerBLWM

andelectronicaircleanerterminalEAC-Iwillremainenergized

foranadditional90seconds.JumperYI toDHUMtoreducethe

coolingoff-delayto5seconds.(SeeFig.26.)

c.Two-StageThermostatandTwo-SpeedCooling

SeeFig.33forthermostatconnections

NOTE:TheairconditioningrelaydisablejumperACRDJnmst

bedisconnectedtoallowthermostatcontroloftheoutdoorunit

staging.(SeeFig.26.)

The thermostatclosesthe R-to-G-and-Ylcircuitsfor

low-coolingorclosestheR-to-G-and-Yl-and-Y2circuitsfor

high-cooling.TheR-to-Ylcircuitstartstheoutdooruniton

low-coolingspeed,andtheR-to-G-and-Ylcircuitstartsthe

furnaceblowermotorBLWMatlow-coolingairflowwhichisthe

trueon-boardCF(continuousfan)selectionasshowninFig.55.

TheR-to-Yl-and-Y2circuitsstarttheoutdoorunit on

high-coolingspeed,andtheR-to-G-and-Y/Y2circuitsstartthe

furnaceblowermotorBLWMat high-coolingairflow.

High-coolingairflowis basedontheA/C(airconditioning)

selectionshowninFig.57.

TheelectronicaircleanerterminalEAC-Iisenergizedwith115

vacwhenevertheblowermotorBLWMisoperating.

Whenthethermostatissatisfied,theR-to-G-and-YlorR-to-

G-and-Yl-and-Y2circuitsareopened.Theoutdoorunitstops,

andthefurnaceblowerBLWMandelectronicaircleanerterminal

EAC-Iwill remainenergizedforanadditional90seconds.

JumperYI to DHUM to reduce the cooling off-delay to 5

seconds. (See Fig. 26.)

4. Thermidistat Mode

See Fig. 27-29 for thermostat connections.

The dehumidification output, DHUM on the Thermidistat

should be connected to the furnace control thermostat ter-

minal DHUM. When there is a dehumidify demand, the

DHUM input is activated, which means 24 vac signal is

removed from the DHUM input terminal. In other words,

the DHUM input logic is reversed. The DHUM input is

turned ON when no dehumidify demand exists. Once 24

vac is detected by the furnace control on the DHUM input,

the furnace control operates in Thermidistat mode. If the

DHUM input is low for more than 48 hours, the furnace

control reverts back to non-Thermidistat mode.

The cooling operation described in item 3. above also ap-

plies 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. 55.

b. High cooling-When the R-to-G-and Y/Y2 circuit is

closed and there is a demand for dehumidification, the

furnace blower motor BLWM will drop the blower

airflow to 86 percent of high-cooling airflow. High-

cooling airflow is based on the A/C (air conditioning)

selection shown in Fig. 55.

c. Cooling off-delay-When the "call for cooling" is

satisfied and there is a demand for dehumidification,

the cooling blower-off delay is decreased from 90

seconds to 5 seconds.

5. Super-Dehumidify Mode

Super-Dehumidify mode can only be entered if the fur-

nace control is in the Thermidistat mode and there is a de-

mand for dehumidification. The cooling operation de-

scribed in item 3. above also applies to operation with a

Them_idistat. 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

n_axinmm of 10 minutes each cooling cycle or until

the R-to-G circuit closes or the demand for dehumidi-

fication is satisfied. Low-cooling airflow is the true

on-board CF (continuous fan) selection as shown in

Fig. 57.

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

n_axinmm of 10 minutes each cooling cycle or until

the R-to-G circuit closes or the demand for dehumidi-

fication is satisfied. High-cooling airflow is based on

the A/C (air conditioning) selection shown in Fig. 57.

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.

57. Factory default is shown in Fig. 57. Terminal EAC-I

is energized as long as the blower motor BLWM is ener-

gized.

During a call for heat, the furnace control CPU will trans-

ition the blower motor BLWM to continuous blower air-

flow, low-heat airflow, or the mid-range airflow,

whichever is lowest. The blower motor BLWM will re-

main 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 continu-

ous-blower airflow.

When the themmstat "calls for low-cooling", the blower

motor BLWM will switch to operate at low-cooling air-

flow. When the thermostat is satisfied, the blower motor

BLWM will operate an additional 90 seconds at low-cool-

ing airflow before transitioning back to continuous-

blower airflow.

When the themmstat "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

BLWMoperation.

ContinuousBlower Speed Selection from Thermostat

To select different continuous-blower airflow from the

room thermostat, momentarily turn off the FAN switch or

push button on the room thermostat for 1-3 seconds after

the blower motor BLWM is operating. The furnace control

CPU will shift the continuous-blower airflow from the

factory setting to the next highest CF selection airflow as

shown in Fig. 57. Momentarily turning off the FAN switch

again at the thermostat will shift the continuous-blower

airflow up one more increment. If you repeat this proced-

ure enough you will eventually shift the continuous-

blower airflow to the lowest CF selection as shown in Fig.

57. The selection can be changed as many times as desired

and is stored in the memory to be automatically used fol-

lowing 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. 29 -32 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/WI is energized along with YI or Y/Y2, the furnace

control CPU will transition to or bring on the blower mo-

tor BLWM at cooling airflow, low-heat airflow, or the

mid-range 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/Wl 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 air-

flow. If Y/Y2 input signal disappears and the YI 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 dia-

gnose a system problem in the case of a component fail-

ure. 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 SWI-6. (See

Fig. 26.)

NOTE: The component test feature will not operate if the control

is receiving any thermostat signals or until all time delays have

expired.

The component test sequence is as follows:

a. The furnace control CPU turns the inducer motor ON

at high-heat speed and keeps it ON through step c.

b. After waiting 10 seconds the furnace control CPU

turns the hot surface igniter ON for 15 seconds, then

OFF.

c. The furnace control CPU then turns the blower motor

BLWM on at mid-range airflow for 15 seconds, then

OFF.

d. After shutting the blower motor OFF the furnace con-

trol CPU switches the inducer to low-heat speed for

10 seconds, then OFF.

NOTE: The EAC terminals are energized when the blower is

operating.

After the component test is completed, 1 or more status codes (11,

25, or 41) will flash. See component test section or Service Label

(Fig. 52) for explanation of status codes.

NOTE: To repeat component test, turn setup switch SWI-6 to

OFF and then back ON.

Wiring Diagram

Refer to wiring diagram Fig. 53.

Troubleshooting

Refer to the service label. (See Fig. 52--Service Label.)

The Troubleshooting Guide (See Fig. 58.) can be auseful 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

Is AMBER LED status on?

light

YES

N_Q [ Is there 115V at L1 and L2?

YES

I Is there 24V at SEC-1 and SEC-2?

YES

I Replace furnace control.

ls door switch closed?

YES

}-_ [ Is there 115V going to switch?

YES

I I Replace door switch.

'_ls door switch closed?

-_ Is circuit breaker closed?

YES

I [ Check for continuity in wire from circuit

breaker to furnace. NO

_°

l s AMBER LED status light blinking

rapidly without a pause?

I Is AMBER LED status light blinking ON/OFF

slowly with a combination of short and

long flashes?

YES

Determine status code. The status code is I

a 2 digit number with the first digit determined I

by the number of short flashes and the

second digit by the number of long flashes?

I o to section below for the status code

that was flashed.

Y_ES_ Check for correct line voltage polarity.

If units are twinned, check for proper

low-voltage (24V) transformer phasing.

N_O To recall previous status codes disconnect

the R thermostat connection, reset power,

and put setup switch SWl-1 in the ON

position. The AMBER LED will flash the

status codes in the order of occurrence.

Record status codes until status code #11

flashes (1 short and 1 long flash). After status

code #11 flashes the status codes will repeat.

Status codes are erased after 72 hours or

can be manually erased by putting setup

switch SWI-1 in the ON position and

jumpering R, W/W1, and Y/Y2 simultaneously

until status code #11 is flashed. When done

put setup switch SWl-1 in the OFF position.

-_ as there a previous status code other

than #11 ?

I -_[ Replace transformer. I Close circuit breaker and go back to START.

YES

Run system through a low-heat, high-heat,

or cooling cycle to check operation. Status

codes are erased after 72 hours or can be

manually erased by putting setup switch

SWI-1 in the ON position and jumpering R,

W/W1, and Y/Y2 simultaneously until status

code #11 is flashed.

Check room thermostat or

interconnecting cable.

_1 _ Is 24V present at WfWl, W2,Y1 ,Y/Y2 or G

Does the control respond to W/W1, W2, Y1, I NQ_I thermostat terminals on the furnace contro ?

Y/Y2, and G (24V) thermostat signals?

I YES

Disconnect all the thermostat wires from the I

furnace contro. I

Replace furnace control. | Does the problem repeat when using

_ESI a jumper wire?

I The thermostat is not compatible with the

furnace control. Either install a ballast resistor,

connect the Com24V thermostat terminal to

the thermostat, or replace the thermostat.

---3

_,!

€

NO PREVIOUS CODE - Status codes I

are erased after 72 hours or can be

manually erased by putting setup switch I

SWI-1 in the ON position and jumpering I

R, W/W1, and Y/Y2 simultaneously until I

status code #11 is flashed, Run system I

through a low-heat, high-heat, or cooling

cycle to check system,

BLOWER ON AFTER POWER UP

(115V OR 24V) Normal operation,

Blower runs for 90 seconds, if unit is

powered up during a call for heat (R-

W/W1 closed) or when (R-W/W1 opens)

during the blower on-delay period,

32 LOW-HEAT PRESSURE SWITCH DID

NOT CLOSE OR REOPENED If open

longer than 5 minutes, inducer shuts off

for 15 minutes before retry. If opens

during blower on-delay period, blower will

come on for the selected blower off-delay.

Check for:

- Proper vent sizing,

- Low inducer voltage (115V),

- Low inlet gas pressure (if LGPS used).

- Inadequate combustion air supply,

- Disconnected or obstructed pressure

tubing.

- Defective inducer motor,

- Defective pressure switch,

- Excessive wind,

- Restricted vent,

33 LIMIT CIRCUIT FAULT- indicates the

43 LOW-HEAT PRESSURE SWITCH OPEN

WHILE HIGH-HEAT PRESSURE

SWITCH IS CLOSED - Check for:

- Low-heat pressure switch stuck open,

- Disconnected or obstructed pressure

tube

- Miswired pressure switches.

- Low inlet gas pressure (if LGPS used),

_t Unplug igniter harness from control and

repeat component test by turning setup switch

SW1-6 OFF and then back ON, Check for

115V between pin 3 and NEUTRAUL2 on

the control, Was 115V present for the 15

second period?

LIMIT CIRCUIT LOCKOUT Lockout

occurs if the limit, draft[ safeguard flame

rollouL or blocked vent switch* (if used)

is open longer than 3 minutes or 10

successive limit trips occurred during

high-heat, Control will auto-reset after 3

hours, See code 33,

IGNITION LOCKOUT - System failed to

ignite gas and prove flame in 4 attempts.

Control will auto-reset after 3 hours,

See status code 34,

BLOWER MOTOR LOCKOUT- Indicates

the blower failed to reach 250 RPM or

the blower failed to communicate within

30 seconds after being turned ON in two

successive heating cycles. Control will

auto-reset after 3 hours, See code 41,

GAS HEATING LOCKOUT Turn off

power and wait 5 minutes to retry

Check for:

- Stuck closed gas valve relay on control,

Miswire or short to gas valve wire.

ABNORMAL FLAME-PROVING SIGNAL

Flame is proved while gas valve is de-

energized, inducer will run until fault is

cleared, Check for:

- Stuck open or leaky gas valve.

PRESSURE SWITCH DID NOT OPEN

Check for:

- Obstructed pressure tube

- Pressure switch stuck closed.

SECONDARYVOLTAGE FUSE IS OPEN

Check for:

- Short circuit in secondary voltage

(24V) wiring including thermostat

leads, Disconnect thermostat leads

to isolate short circuit,

limit, draft safeguard, flame rollout, or

blocked vent switch* (if used) is open or

the furnace is operating in high-heat only

mode due to 2 successive low-heat limit

trips, Blower will run for 4 min, or until

open switch remakes whichever is longer,

If open longer than 3 min. code changes

to lockout #13 if open less than 3 min,

status code #33 continues to flash until

blower shuts off, Flame rollout switch and

BVSS requires manual reset, Check for:

- Dirty filter or restricted duct system,

- Loose blower wheel,

- Defective switch or connections,

- inadequate combustion air supply

(flame rollout switch open).

- Restricted vent,

- Proper vent sizing,

! econnect the R thermostat lead and set

thermostat to call for heat, Connect voltmeter

across gas valve connections, Does gas

valve receive 24V?

YES

Does gas valve open and allow gas to flow?

YES

I Do the main burners ignite?

,_ YES

I Do the main burners stay on?

45 CONTROL CIRCUITRY LOCKOUT

Auto-reset after 1 hour lockout due to:

- Flame circuit failure.

- Gas valve relay stuck open,

- Softwvare check error,

Reset power to clear lockout,

Replace control if code repeats,

._ Replace furnace control, J

___ Check for continuity in the harness and ]igniter, Replace defective component,

_._ Check connections, If OK, replace control, I

__ NO

Check that all gas valves are turned on,

Replace valve

Check for:

- Inadequate flame carryover or rough

ignition,

- Low inlet gas pressure.

Proper firing rate.

- Blocked or incorrect carry- over gap.

(,045" nominal)

Allow blower to come on and repeat test

to check for intermittent operation,- Excessive wind.

34 IGNITION PROVING FAILURE - If flame

is not sensed during the trial for ignition

period, the control will repeat the ignition

sequence 3 more times before lockout

fl14 occurs, If flame signal is lost during

the blower on-delay period, blower will

come on for the selected blower off-delay.

Check the following items first before

proceeding to the next step.

- Gas valve turned off,

- Manual shut-offvalve.

- Green/Yellow wire MUST be connected

to furnace sheet metal,

- Flame sensor must not be grounded.

To determine whether the problem is in

the gas valve igniter, or flame sensor the

system can be operated in component

test mode To check the igniter remove

the R thermostat connection from the

control, reset power, and put setup switch

SW1-6 in the ON position to start the

component test. Does the igniter glow

orange/white by the end of the 15 second

warm-up period?

YE_

I Repeat call for heat and check flame sensor

current during trial for ignition period Is the Check connections and retry. If current is

DC microamps below 0,5? near typical value (4,0-6,0 nominal) and

,_ YES burners will not stay on, repeat check in high-

heat, If burners will still not stay on replace

I Clean flame sensor with fine steel wool and control, If burners operate in high-heat then

recheck current, Nominal current is 4,0 to switch to low-heat,check manifold pressure

6,0 microamps, If OK, check burner carryover and flame

,_ sensor location,

I ls current near typical value? _ Replace electrode

YES

I Will main burners ignite and stay on?

YES

Fixed.

Replace furnace control,

* Blocked vent switch used in Chimney Adapter Kit

---€

25 INVALID MODEL SELECTION OR

SETUP ERROR If status code 25 only

flashes 4 times on power-up the control

is missing its model plug PL4 and is

defaulting to the model selection stored

in memory. If status code 25 flashes

continuously it could indicate any of the

following:

- Model plug PL4 is missing and there

is no valid model stored in permanent

memory. This will happen if you forget

to install the model plug PL4 on a

service replacement control.

- Thermostat call with SWI-1 ON.

- Thermostat call with SW1-6 ON.

- SWI-1 and SW1-6 both ON.

HIGH-HEAT PRESSURE SWITCH OR

RELAY DID NOT CLOSE OR

REOPENED - Check for:

- Control relay may be defective.

- Gas valve is miswired.

- See status code 32.

41 BLOWER MOTOR FAULT Indicates the

blower failed to reach 250 RPM or the

blower failed to communicate within the

prescribed time limits. Thirty seconds

after being turned ON or ten seconds

during steady-state operation. Turn power

off and check the following items first

before proceeding to the next step.

- Rubbing blower wheel.

- Loose blower wheel.

- Wiring from furnace control to blower

motor,

Remove the R thermostat connection

from the furnace control, disconnect both

connectors from the blower motor PL13

and PL14, Does the blower wheel turn

freely?

Replace the blower control module attached

to the blower motor. Follow the instructions

with the blower control module to make sure

the entire blower motor does not need to be

replaced.

._1_ You have an open wire or bad terminal on the 1

BLUE wire between the furnace control and ]

the blower motor. J

I Replace furnace control.

the

Connect a DC voltmeter across PL3-4 BLUE

(+) and PL3-2 GREEN (-). Does the voltage

fluctuate as described two steps back?

Does the voltage fluctuate as described in the _

previous step? ITM

YES

Replace the blower control module attached

to the blower motor. Follow the instructions

with the blower control module to make sure

the entire blower motor does not need to be

replaced.

YES /NO

Turn power back on. Is there 115VAC at _ You have an open wire or bad terminal on

_"l PL14-5 and PL14-4? _1 either the BLACK or WHITE power leads

_V | between the furnace control and the blower

YES I motor. If you have a power choke disconnect

YES ] I it and check continuity.

Is there 12-VDC at PL13-7 RED (+) and PL13-

1 GREEN (-)?

[2Is there 12-VDC atPL3-1GREEN- ? RED (+) and PL3- ] YES "[furnace_l Y°u have an °pen wire °r bad terminal°neitherthecontroiREDOrandGREENtheblowerWiremotor.betweenthe ]

Replace the furnace control, t_

._[Is there 5-VDC at PL13-16YELLOW (+)and I.d NO I Is there 5-VDC at PL3-3 YELLOW (+)and

PL13-1 GREEN (-)? P [ PL3-2 GREEN (-)?

YES ; YES

Th vo,t o,ust s r dshou, w I ouh v o nwireor te in ,o th l

stable and should not fluctuate more than YELLOW wire between the furnace control

.02-VDC. If the voltage fluctuates more than and the blower motor.

this get a different voltmeter before

proceed ng.

YES ITurn power off, reconnect PL13 and PL14 to

1the blower motor, then turn power back on.

I I "----Connecta DC voltmeter across PL3-3

YELLOW (+) and PL3-2 GREEN (-). Does

I the voltage fluctuate more than it did in the

[previous step?

, NO

Turn power off, disconnect PL]3 and PL]4

from the blower motor, then turn power back

on. Connect a DC voltmeter across PL13-

16 BLUE (+) and PL13-1 GREEN (-). The

voltage should be near 0-VDC but it will

fluctuate briefly several times a second. If

you have an analog voltmeter the needle will

briefly go high several times a second. If you

have a digital voltmeter with a bar graph it

will show a large change in magnitude on

the bar graph several times a second. Ifyou

have a standard digital voltmeter it will show

a brief fluctuation in voltage and the

magnitude may vary depending on the

voltmeter used.

DESCRIPTION

Media Filter Cabinet

Cartridge Media Filter

EZ Flex Media Filter with End Caps

Replacement EZ Flex Filter Media

External Bottom Return Filter Rack

External Side Return Filter Rack

Unframed Filter 3/4-in. (19 mm)

Flue Extension

*Twinning Kit

Combustible Floor Base

Downflow Vent Guard

Vent Extension Kit

Chimney Adapter Kit

Natural-to- Propane Conversion Kit

Propane-to- Natural Conversion Kit

Label Kit

**ECM Motor Simulator

**Advanced Product Monitor

Table 17 - Accessory List

PART NUMBER

Not for ECM or variable-speed ECM models

** Variable-speed ECM models only

FILCABXXO016

FILCABXXO020

FILCABXXO024

FILXXCARO016

FILXXCARO020

FILXXCARO024

EXPXXUNVO016

EXPXXUNVO020

EXPXXUNVO024

EXPXXFILO016

EXPXXFILO020

EXPXXFILO024

KGAFR0401 B14

KGAFR0501 B17

KGAFR0601 B21

KGAFR0701 B24

KGAFR0801SRE

KGAWF1301 UFR1-

KGAWF1401 UFR

KGAWF1501 UFR

KGAWF1306UFR1-

KGAWF1406UFR

KGAWF1506UFR

KGAFE0112UPH

KGATW0601 HSI

KGASBO201ALL

KGBVG0101DFG

KGAVE0101 DN H

KGACA02014FC

KGACA02015FC

KGAN P4601ALL

KGAPN3901ALL

KGALB0101 KIT

KGASD0301FMS

KGAFPO301APM

NOTES

Filter cabinet 16" (406 mm) for 4" (102 mm) wide filter

Filter cabinet 20" (508 mm) for 4" (102 mm) wide filter

Filter cabinet 24" (610 mm) for 4" (102 mm) wide filter

Filter Cartridge replacements for FILCAB media cabinet

16" (406 mm) Replacement Expandable Filter assembly

20" (508 mm) Replacement Expandable Filter assembly

24" (610 mm) Replacement Expandable Filter assembly

16" (406 mm) Replacement filter for EXPUNV assembly

20" (508 mm) Replacement filter for EXPUNV assembly

24" (610 mm) Replacement filter for EXPUNV assembly

Bottom return filter rack 14" (356 mm) casing

Bottom return filter rack 17" (432 mm) casing

Bottom return filter rack 21" (533 mm) casing

Bottom return filter rack 24" (610 mm) casing

Ext. Side filter rack- all casings- includes filter

(1) unframed filter 16x25x3/4 (406x635xl 9 mm)

(1) unframed filter 20x25x3/4 (508x635xl 9 mm)

(1) unframed filter 24x25x3/4 (610x635xl 9 mm)

(6) unframed filter 16x25x3/4 (406x635x19 mm)

(6) unframed filter 20x25x3/4 (508x635x19 mm)

(6) unframed filter 24x25x3/4 (61Ox635xl 9 mm)

(12) vent extension 4" (102 mm) dia. x 3-1/2" (89 mm)

Single or two stage PSC equipped units only

Adjustable floor base - fits all casing sizes

Vent flue shield - downflow venting outside casing

Downflow, through casing vent extension

Masonry chimney adapter 4" (102 mm)

Masonry chimney adapter 5" (127 mm)

Gas conversion natural to propane all

Gas conversion propane to natural all

Downflow orientation label replacement

ECM blower and inducer simulator - variable speed units

PC software and hardware for Troubleshooting variable speed units

PARTS REPLACEMENT INFORMATION GUIDE

CASING GROUP

Outer door

Blower door

Top filler plate

Bottom filler plate

Bottom enclosure

ELECTRICAL GROUP

Control bracket

Junction box

Linfit switch(es)

Circuit board

Door switch

Transformer

Wiring harness l15v

Wiring harness 24v

BLOWER GROUP

Blower housing

Blower cutoff

Blower motor

Blower wheel

Capacitor (where used)

Capacitor strap (where used)

Grommet

Power choke (where used)

GAS CONTROL GROUP

Manifold

Burner assembly

Orifice

Flame sensor

Hot surface igniter

Gas valve

Manual reset linfit switches

Burner support assembly

HEAT EXCHANGER GROUP

Heat exchanger cell

Cell panel

Lox NOx baffle (California models only)

INDUCER GROUP

Housing assembly

Pressure switch

Inducer motor

Inducer wheel

Vent elbow assembly

Draft safeguard switch

TO OBTAIN INFORMATION ON PARTS: Consult your installing dealer or classified section of your local telephone directory under

"Heating Equipment" or "Air Conditioning Contractors and Systems" headings for dealer listing by brand name or contact:

CARRIER CORPORATION

Consumer Relations Department

P.O. Box 4808

Syracuse, New York 13221-4808

1 - 800 - CARRIER

Have available the model number, series number, and serial number located on the unit rating plate to ensure correct replacement part.

Example of Model Number

HEATING COOLING

MODEL VARIATION VOLTAGE SERIES PACKAGING AIRFLOW

SIZE (CFM)

58CVA 155 --- 1 51 22

WARNING: Improper installation, adjustment, alteration, service, or maintenance can cause personal injury, property damage, or death.

Consult a qualified installer, service agency, or your local gas supplier for information or assistance. The qualified installer or service agency

must use only factory-authorized replacement parts, kits, or accessories when modifying this product.

Manufacturer reserves the right to change, at any time, specification8 and design8 without notice and without obligations,

Catalo_ No: 58CV-12SI

Replaces: 58(V I1SI

Carrier 58CVA070 10012 User Manual FURNACE Manuals And Guides 1303133L

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