GOODMAN Furnace/Heater, Gas Manual L0806734

User Manual: GOODMAN GOODMAN Furnace/Heater, Gas Manual GOODMAN Furnace/Heater, Gas Owner's Manual, GOODMAN Furnace/Heater, Gas installation guides

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GMV95/GCV9

TWO-STAGE GAS-FIRED WARM AIR FURNACE

INSTALLATION INSTRUCTIONS

Installer. Affix all manuals adjacent to the unit.

(Type FSP CATEGORY IV Direct or Non Direct Vent Air Furnace)

April 17, 2008 @ 4:09 pm

These furnaces comply with requirements

embodied in the American National Standard

/National Standard of Canada ANSI

Z21.47.CSA-2.3 Gas Fired Central Furnaces.

_k RECOGNIZE THIS SYMBOL AS A SAFETY PRECAUTION.

ATTENTION INSTALLING PERSONNEL

As a professional installer you have an obligation to know the product better than the customer. This includes all safety

precautions and related items.

Prior to actual installation, thoroughly familiarize yourself with this Instruction Manual. Pay special attention to all safety

warnings. Often during installation or repair it is possible to place yourself in a position which is more hazardous than

when the unit is in operation.

Remember, it is your responsibility to install the product safely and to know it well enough to be able to instruct a

customer in its safe use.

Safety is a matter of common sense...a matter of thinking before acting. Most dealers have a list of specific good safety

practices...follow them.

The precautions listed in this Installation Manual are intended as supplemental to existing practices. However, if there is

a direct conflict between existing practices and the content of this manual, the precautions listed here take precedence.

*NOTE: Please contact your distributor or our

website for the applicable Specification Sheet

referred to in this manual.

IO-280J

Goodman Manufacturing Company, L.P.

5151 San Fetipe, Suite 500, Houston, TX 77056

www. cioodmanmfcL corn

Table of Contents

I. Component identification ............................................................................................................................................... 5

II. Safety .............................................................................................................................................................................. 6

ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS ................................................................................................... 6

ill. Product Application ...................................................................................................................................................... 6

IV. Location Requirements & Considerations .................................................................................................................. 7

GENERAL ......................................................................................................................................................... 7

CLEARANCES AND ACCESSIBILITY ........................................................................................................................... 8

FURNACE SUSPENSION ........................................................................................................................................ 8

EXISTING FURNACE REMOVAL .............................................................................................................................. 8

THERMOSTAT LOCATION ....................................................................................................................................... 9

V. Combustion & Ventilation Air Requirements ............................................................................................................... 9

VI. Installation Positions ................................................................................................................................................... 11

Vii. Horizontal Applications &Considerations ................................................................................................................ 11

GENERAL ........................................................................................................................................................ 11

DRAIN TRAP AND LINES ..................................................................................................................................... 11

LEVELING ........................................................................................................................................................ 11

ALTERNATE VENT/FLuE AND COMBUSTION AIR CONNECTIONS ..................................................................................... 11

ALTERNATE ELECTRICAL AND GAS LINE CONNECTIONS ............................................................................................ 12

DRAIN PAN ..................................................................................................................................................... 12

FREEZE PROTECTION ........................................................................................................................................ 12

FURNACE SUSPENSION ...................................................................................................................................... 12

Viii. Propane Gas/High Altitude installations ............................................................................................................... 12

iX. Vent]Flue Pipe & Combustion Air Pipe ..................................................................................................................... 12

GENERAL ....................................................................................................................................................... 12

DUAL CERTIFICATION: NoN=DIRECT/DIRECT VENT ................................................................................................... 12

MATERIALS AND JOINING METHODS ..................................................................................................................... 13

PROPER VENT/FLuE AND COMBUSTION AIR PiPiNG PRACTICES ................................................................................. 13

TERMINATION LOCATIONS ................................................................................................................................... 13

CANADIAN VENTING REQUIREMENTS ..................................................................................................................... 13

STANDARD FURNACE CONNECTIONS ..................................................................................................................... 14

ALTERNATE FURNACE CONNECTIONS ..................................................................................................................... 14

NoN=DIRECT VENT (SINGLE PIPE) PIPING ............................................................................................................ 16

DIRECT VENT (DUAL PIPE) PIPING ...................................................................................................................... 17

VENT/INTAKE TERMINATIONS FOR INSTALLATION OF MULTIPLE DIRECT VENT FURNACES .................................................. 18

CONCENTRIC VENT TERMINATION ......................................................................................................................... 19

SIDE WALL VENT KIT ........................................................................................................................................ 19

X. Condensate Drain Lines &Drain Trap ........................................................................................................................ 19

GENERAL ....................................................................................................................................................... 19

UPRIGHT _NSTALLATIONS ..................................................................................................................................... 19

HORIZONTAL INSTALLATIONS ................................................................................................................................ 20

Xi. Electrical Connections ................................................................................................................................................ 21

WiRiNG HARNESS ............................................................................................................................................ 21

115 VOLT LINE CONNECTIONS ............................................................................................................................ 22

24 VOLT THERMOSTAT WIRING ............................................................................................................................ 22

SINGLE-STAGE TH ERMOSTAT APPLICATION ............................................................................................................. 23

24 VOLT DEHUMIDISTAT WIRING .......................................................................................................................... 23

FOSSIL FUEL APPLICATIONS ............................................................................................................................... 23

115 VOLT LINE CONNECTION OF ACCESSORIES (HuMIDIFiER AND ELECTRONIC AIR CLEANER) ....................................... 23

24 VOLT HUMIDIFIER ........................................................................................................................................ 24

Xll. Gas Supply and Piping .............................................................................................................................................. 24

GENERAL ....................................................................................................................................................... 24

GAS PIPING CONNECTIONS ................................................................................................................................ 24

PROPANE GAS TANKS AND PIPING ...................................................................................................................... 26

Xlll. Circulating Air & Filters ............................................................................................................................................ 27

DUCTWORK =AIR FLOW ..................................................................................................................................... 27

BOTTOM RETURN AIR OPENING [UPFLOW MODELS] ............................................................................................... 27

FILTERS = READ THIS SECTION BEFORE _NSTALLING THE RETURN AIR DUCTWORK ....................................................... 27

UPRIGHT _NSTALLATIONS ..................................................................................................................................... 28

HORIZONTAL INSTALLATIONS ................................................................................................................................ 28

Table of Contents

XIV. Startup Procedure & Adjustment ............................................................................................................................. 28

HEATANTICIPATOR SETTING ................................................................................................................................ 28

DRAIN TRAP PRIMING .......................................................................................................................................28

FURNACE OPERATION ........................................................................................................................................28

GAS SUPPLY PRESSURE MEASUREMENT .............................................................................................................. 28

GAS MANIFOLD PRESSURE MEASUREMENT AND ADJUSTMENT .................................................................................. 29

GAS INPUT RATE MEASUREMENT (NATURAL GAS ONLY) .........................................................................................29

TEMPERATURERISE ......................................................................................................................................... 30

CIRCULATOR BLOWER SPEEDS ........................................................................................................................... 30

BLOWER HEAT OFF DELAY TIMINGS ................................................................................................................... 32

XV. Normal Sequence of Operation ................................................................................................................................ 32

POWERUP ..................................................................................................................................................... 32

HEATING MODE ............................................................................................................................................... 32

COOLING MODE .............................................................................................................................................. 33

FAN ONLY MODE ............................................................................................................................................. 33

XVl. Operational Checks .................................................................................................................................................. 33

BURNER FLAME ............................................................................................................................................... 33

XVll. Safety Circuit Description ....................................................................................................................................... 33

GENERAL ....................................................................................................................................................... 33

INTEGRATED CONTROL MODULE .......................................................................................................................... 33

PRIMARY LIMIT ................................................................................................................................................ 33

AUXILIARY LIMIT ............................................................................................................................................... 34

ROLLOUT LIMIT ................................................................................................................................................ 34

PRESSURE SWITCHES ........................................................................................................................................ 34

FLAME SENSOR ............................................................................................................................................... 34

XVlll. Troubleshooting ...................................................................................................................................................... 34

ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS ................................................................................................. 34

DIAGNOSTIC CHART .......................................................................................................................................... 34

RESETTING FROM LOCKOUT ............................................................................................................................... 34

XlX. Maintenance ............................................................................................................................................................. 34

ANNUAL INSPECTION .......................................................................................................................................... 34

FILTERS .......................................................................................................................................................... 35

BURNERS ....................................................................................................................................................... 35

INDUCED DRAFT AND CIRCULATOR BLOWERS ......................................................................................................... 35

CONDENSATE TRAP AND DRAIN SYSTEM (QUALIFIED SERVICER ONLY) ...................................................................... 35

FLAME SENSOR (QUALIFIED SERVICER ONLY) ...................................................................................................... 35

FLUE PASSAGES (QUALIFIED SERVICER ONLY) ..................................................................................................... 35

XX. Internal Filter Removal ............................................................................................................................................. 35

XXl. Before Leaving an Installation ................................................................................................................................ 36

XXII. Repair & Replacement Parts .................................................................................................................................. 36

APPENDIX

Troubleshooting Chart ...................................................................................................................................................... 37

Wiring Diagram ............................................................................................................................................................... 39

All, WARNING

GOODMAN WILL NOT BE RESPONSIBLE FOR ANY INJURY OR

PROPERTY DAMAGE ARISING FROM IMPROPER SERVICE OR SERVICE

PROCEDURES. IF YOU INSTALL OR PERFORM SERVICE ON THIS UNIT_

YOU ASSUME RESPONSIBILITY FOR ANY PERSONAL INJURY OR

PROPERTY DAMAGE WHICH MAY RESULT. MANY JURISDICTIONS

REQUIRE A LICENSE TO INSTALL OR SERVICE HEATING AND AIR

CONDITIONING EQUIPMENT.

_lb WARNING

IF THE INFORMATION IN THESE INSTRUCTIONS IS NOT FOLLOWED

EXACTLY_ A FIRE OR EXPLOSION MAY RESULT CAUSING PROPERTY

DAMAGE_ PERSONAL INJURY OR LOSS OF LIFE.

=Do NOT STORE OR USE GASOLINE OR OTHER FLAMMABLE VAPORS

AND LIQUIDS IN THE VICINITY OF THIS OR ANY OTHER APPLIANCE.

-WHAT TO DO IF YOU SMELL GAS:

* Do NOT TRY TO LIGHT ANY APPLIANCE.

* Do NOT TOUCH ANY ELECTRICAL SWITCH; DO NOT USE

ANY PHONE IN YOUR BUILDING.

*IMMEDIATELY CALL YOUR GAS SUPPLIER FROM A

NEIGHBORS PHONE. FOLLOW THE GAS SUPPLIERS

INSTRUCTIONS.

*IF YOU CANNOT READCH YOUR GAS SUPPLIER_ CALL THE

FIRE DEPARTMENT.

=INSTALLATION AND SERVICE MUST BE PERFORMED BY A QUALIFIED

INSTALLER_ SERVICE AGENCY OR THE GAS SUPPLIER

_lb WARNING

SHOULD OVERHEATING OCCUR OR THE GAS SUPPLY FAIL TO SHUT

OFF, TURN OFF THE MANUAL GAS SHUTOFF VALVE EXTERNAL TO THE

FURNACE BEFORE TURNING OFF THE ELECTRICAL SUPPLY.

CARBON MONOXIDE POISONING HAZARD

SpecialWarningfor Installationof FurnaceorAir HandlingUnitsin

EnclosedAreassuchas Garages,UtilityRoomsorParkingAreas

Carbon monoxide producing devices (such as an automobile, space

heater, gas water heater, etc.) should not be operated in enclosed areas

such as unventilated garages, utility rooms or parking areas because of

the danger of carbon monoxide (CO) poisoning resulting from the exhaust

emissions. If a furnace or air handler is installed in an enclosed area such

as a garage, utility room or parking area and a carbon monoxide producing

device is operated therein, there must be adequate, direct outside

ventilation.

This ventilation is necessary to avoid the danger of CO poisoning which

can occur if acarbon monoxide producing device continues to operate in

the enclosed area. Carbon monoxide emissions can be (re)circulated

throughout the structure if the furnace or air handler is operating in any

mode.

CO can cause serious illness including permanent brain damage or death.

B10259-216

To THE INSTALLER

Before installing this unit, please read this manual thoroughly to

familiarize yourself with specific items which must be adhered to,

including but not limited to: unit maximum external static pressure,

gas pressures, BTU input rating, proper electrical connections, cir-

culating air temperature rise, minimum or maximum CFM, and mo-

tor speed connections.

TRANSPORTATION DAMAGE

All units are securely packed in shipping containers tested accord-

ing to International Safe Transit Association specifications. The car-

ton must be checked upon arrival for external damage. If damage

is found, a request for inspection by carrier's agent must be made in

writing immediately.

The furnace must be carefully inspected on arrival for damage and

bolts or screws which may have come loose in transit. In the event

of damage the consignee should:

1. Make a notation on delivery receipt of any visible damage to

shipment or container.

2. Notify carrier promptly and request an inspection.

3. With concealed damage, carrier must be notified as soon as

possible - preferably within five days.

4. File the claim with the following support documents within a

nine month statute of limitations.

" Original or certified copy of the Bill of Lading, or indemnity

bond.

° Original paid freight bill or indemnity in lieu thereof.

" Original or certified copy of the invoice, showing trade and

other discounts or reductions.

° Copy of the inspection report issued by carrier's

representative at the time damage is reported to carrier.

The carrier is responsible for making prompt inspection of damage

and for a thorough investigation of each claim. The distributor or

manufacturer will not accept claims from dealers for transportation

damage.

Keep this literature in a safe place for futt;re reference.

I, COMPONENT IDENTIFICATION

1"_........ _,,

F-

__1

Upflow/Horizontal Cou nterflow/Horizontal

1 Two-Stage Gas Valve

2 Gas Line Entrance (Alternate)

3 Pressure Switch(es)

4 Gas Manifold

5 Combustion Air intake Connection

6 Hot Surface igniter

7 Rollout Limit

8 Burners

9 Flame Sensor

10 Flue Pipe Connection

11 Flue Pipe

12 Combustion Air Intake (Alternate)

13 Primary Limit

14 Gas Line Entrance

15 Flue Pipe Connection (Alternate)

16 Rubber Elbow

17 Two-Speed Induced Draft Blower

18 Electrical Connection Inlets (Alternate)

19 Coil Front Cover Pressure Tap

20 Coil Front Cover Drain Port

21 Drain Line Penetrations

22 Drain Trap

23 Blower Door Interlock Switch

24 Inductor (Not All Models)

25 Two-Stage Integrated Control Module

(with fuse and diagnostic LED)

26 24 Volt Thermostat Connections

27 Transformer (40 VA)

28 ECM Variable Speed Circulator Blower

29 Auxiliary Limit

30 Junction Box

31 Electrical Connection Inlets

32 Coil Front Cover

33 Combustion Air Inlet Pipe

il.SAFETY

Please adhere to the following warnings and cautions when in-

stalling, adjusting, altering, servicing, or operating the furnace.

i_lb WARNING

TO PREVENT PERSONAL INJURY OR DEATH DUE TO IMPROPER

INSTALLATION_ADJUSTMENT_ ALTERATION, SERVICE OR

MAINTENANCE, REFER TO THIS MANUAL. FOR ADDITIONAL

ASSISTANCE OR INFORMATION, CONSULT A QUALIFIED INSTALLER,

SERVICE AGENCY OR THE GAS SUPPLIER.

,_ WARNING

THIS PRODUCT CONTAINS OR PRODUCES A CHEMICAL OR CHEMICALS

WHICH MAY CAUSE SERIOUS ILLNESS OR DEATH AND WHICH ARE

KNOWN TO THE STATE OF CALIFORNIA TO CAUSE CANCER_ BIRTH

DEFECTS OR OTHER REPRODUCTIVE HARM.

I_lb WARNING

ITo PREVENT POSSIBLE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH

LO ,CCAo M "oOC NT?;R O%% USTBELOCATBDTOPROTECT

i_lb WARNING

Do NOT UTILIZE THE HEATING UNIT WITHOUT REASONABLE ROUTINE

INSPECTION, MAINTENANCE AND SUPERVISION. IF THE UNIT IS IN A

BUILDING THAT IS OR WILL BE VACANT, CARE SHOULD BE TAKEN TO

ROUTINELY INSPECT_ MAINTAIN AND MONITOR THE UNIT. IN THE

EVENT THAT THE BUILDING MAY BE EXPOSED TO FREEZING

TEMPERATURES AND WILL BE VACANT, DRAIN ALL WATER-BEARING

PIPES, PROPERLY WINTERIZE THE BUILDING_ AND TURN OFF ALL

WATER SOURCES. IN THE EVENT THAT THE BUILDING IS EXPOSED TO

FREEZING TEMPERATURES AND IS VACANT, ANY HYDRONIC COIL

UNITS SHOULD ALSO BE DRAINED AND AN ALTERNATIVE HEAT

SOURCES UTILIZED.

ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS

NOTE: Discharge static electricity accumulated in the body before

touching the unit. An electrostatic discharge can adversely affect

electrical components.

Use the following precautions during furnace installation and ser-

vicing to protect the integrated control module from damage. By

putting the furnace, the control, and the person at the same electro-

static potential, these steps will help avoid exposing the integrated

control module to electrostatic discharge. This procedure is appli-

cable to both installed and non-installed (ungrounded) furnaces.

1. Disconnect all power to the furnace. Do not touch the

integrated control module or any wire connected to the control

prior to discharging your body's electrostatic charge to

ground.

2. Firmly touch a clean, unpainted, metal surface of the furnace

near the control. Any tools held in a person's hand during

grounding will be discharged.

3. Service integrated control module or connecting wiring

following the discharge process in step 2. Use caution not

to recharge your body with static electricity; (i.e., do not move

or shuffle your feet, do not touch ungrounded objects, etc.).

If you come in contact with an ungrounded object, repeat

step 2 before touching control or wires.

4. Discharge your body to ground before removing a new

control from its container. Follow steps 1 through 3 if

installing the control on a furnace. Return any old or new

controls to their containers before touching any ungrounded

object.

III. PRODUCT APPLICATION

This furnace is primarily designed for residential home-heating

applications. It is NOT designed or certified for use in mobile

homes, trailers or recreational vehicles. This unit is NOT designed

or certified for outdoor applications. The furnace must be installed

indoors (i.e., attic space, crawl space, or garage area provided the

garage area is enclosed with an operating door).

This furnace can be used in the following non-industrial commer-

cial applications:

Schools, Office buildings, Churches, Retail stores

Nursing homes, Hotels/motels, Common or office areas

In such applications, the furnace must be installed with the follow-

ing stipulations:

It must be installed per the installation instructions

provided and per local and national codes.

It must be installed indoors in a building constructed on

site.

It must be part of a ducted system and not used in a free

air delivery application.

It must not be used as a "make-up" air unit.

It must be installed with two-pipe systems for combustion

air, especially if VOC's or other contaminants are present

in the conditioned space.

All other warranty exclusions and restrictions apply This

furnace is an ETL dual-certified appliance and is

appropriate for use with natural or propane gas (NOTE: If

using propane, a propane conversion kit is required).

Dual certification means that the combustion air inlet pipe is op-

tional and the furnace can be vented as a:

Non-direct vent (single pipe) central forced air furnace in

which combustion air is taken from the installation area

or from air ducted from the outside or,

Direct vent (dual pipe) central forced air furnace in which

all combustion air supplied directly to the furnace burners

through a special air intake system outlined in these

instructions.

This furnace may be used as a construction site heater ONLY if the

following conditions are met:

The vent system is permanently installed per these

installation instructions.

A room thermostat is used to control the furnace. Fixed

jumpers that provide continuous heating CANNOT be

used.

Return air ducts are provided and sealed to the furnace.

A return air temperature range between 60°F (16°C) and

80°F (27°C) is maintained.

Air filters are installed in the system and maintained

during construction, replaced as appropriate during

construction, and upon completion of construction are

replaced.. The input rate and temperature rise are set

per the furnace rating plate.

The input rate and temperature rise are set per the furnace

rating plate.

100% outside air is provided for combustion air

requirements during construction. Temporary ducting can

be used.

NOTE:Donotconnectthetemporaryductdirectlytothe

furnace.Theductmustbesizedaccordingto the

instructionsunderSection V, Combustion and Ventilation

Air Requirements, Section 5.3.3.

The furnace heat exchanger, components, duct system,

air filters and evaporator coils are thoroughly cleaned

following final construction clean up.

All furnace operating conditions (including ignition, input

rate, temperature rise and venting) are verified according

to these installation instructions.

NOTE: The Commonwealth of Massachusetts requires that the

following additional requirements must also be met:

Gas furnaces must be installed by a licensed plumber or

gas fitter.

A T-handle gas cock must be used.

If the unit is to be installed in an attic, the passageway to

and the service area around the unit must have flooring.

To ensure proper installation and operation, thoroughly read this

manual for specifics pertaining to the installation and application

of this product.

_b WARNING

POSSIBLE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH DUE TO

FIRE_ EXPLOSION_ SMOKE_ SOOT_ CONDENSATION_ ELECTRICAL

SHOCK OR CARBON MONOXIDE MAY RESULT FROM IMPROPER

INSTALLATION_ REPAIR, OPERATION_ OR MAINTENANCE OF THIS

PRODUCT.

,_ WARNING

TO PREVENT PERSONAL INJURY, PROPERTY DAMAGE OR DEATH DUE

TO FIRE, DO NOT INSTALL THIS FURNACE IN A MOBILE HOME_

TRAILER OR RECREATIONAL VEHICLE.

To ensure proper furnace operation, install, operate and maintain

the furnace in accordance with these installation and operation

instructions, all local building codes and ordinances. In their ab-

sence, follow the latest edition of the National Fuel Gas Code

(NFPA 54/ANSI Z223.1 ), and/or CAN/CSA B 149.1-05 Installation

Codes, local plumbing or waste water codes, and other applicable

codes.

A copy of the National Fuel Gas Code (NFPA 54/ANSI Z223.1 ) can

be obtained from any of the following:

American National Standards Institute

1430 Broadway

NewYork, NY 10018

National Fire Protection Association

1 Batterymarch Park

Quincy, MA 02269

CSA International

8501 East Pleasant Valley

Cleveland, OH 44131

A copy of the CAN/CSA B149.1-05 Installation Codes can also be

obtained from:

CSA International

178 Rexdale Boulevard

Etobicoke, Ontario, Canada M9W 1R3

The rated heating capacity of the furnace should be greater than or

equal to the total heat loss of the area to be heated. The total heat

loss should be calculated by an approved method or in accor-

dance with "ASHRAE Guide" or "Manual J-Load Calculations" pub-

lished by the Air Conditioning Contractors of America.

IV.LOCATION REQUIREMENTS & CONSIDERATIONS

GENERAL

,_ WARNING

To PREVENT POSSIBLE EQUIPMENT DAMAGE, PROPERTY DAMAGE,

PERSONAL INJURY OR DEATH, THE FOLLOWING BULLET POINTS MUST

BE OBSERVED WHEN INSTALLING THE UNIT.

Follow the instructions listed below when selecting a furnace loca-

tion. Refer also to the guidelines provided in Section V, Combus-

tion and Ventilation Air Requirements.

Centrally locate the furnace with respect to the proposed

or existing air distribution system.

Ensure the temperature of the return air entering the

furnace is between 55°F and 100°F when the furnace is

heating.

Provide provisions for venting combustion products

outdoors through a proper venting system. Special

consideration should be given to vent/flue pipe routing

and combustion air intake pipe when applicable. Refer

to Section IX, Vent/Flue Pipe and Combustion Air Pipe -

Termination Locations for appropriate termination

locations and to determine if the piping system from

furnace to termination can be accomplished within the

guidelines given. NOTE: The length of flue and/or

combustion air piping can be a limiting factor in the

location of the furnace.

Locate the furnace so condensate flows downwards to

the drain. Do not locate the furnace or its condensate

drainage system in any area subject to below freezing

temperatures without proper freeze protection. Refer to

Section X, Condensate Drain Lines and Trap for further

details.

Ensure adequate combustion air is available for the

furnace. Improper or insufficient combustion air can

expose building occupants to gas combustion products

that could include carbon monoxide. Refer to Section V,

Combustion and Ventilation Air Requirements.

Set the furnace on a level floor to enable proper

condensate drainage. If the floor becomes wet or damp

at times, place the furnace above the floor on a concrete

base sized approximately 1-1/2" larger than the base of

the furnace. Refer to the Section VII, Horizontal

Appfications and Considerations for leveling of horizontal

furnaces.

Ensure upflow or horizontal furnaces are not installed

directly on carpeting, or any other combustible material.

The only combustible material allowed is wood.

A special accessory subbase must be used for upright

counterflow unit installations over any combustible

material (including wood). Refer to subbase instructions

for installation details. (NOTE: A subbase will not be

required if an air conditioning coil is located beneath the

furnace between the supply air opening and the

combustible floor.

Exposure to contaminated combustion air will result in

safety and performance-related problems. Do not install

the furnace where the combustion air is exposed to the

following substances:

chlorinated waxes or cleaners

chlorine-based swimming pool chemicals

water softening chemicals

deicingsaltsorchemicals

carbontetrachloride

halogentyperefrigerants

cleaningsolutions(suchasperchloroethylene)

printinginks

paintremovers

varnishes

hydrochloricacid

cementsandglues

antistaticfabricsoftenersforclothesdryers

andmasonryacidwashingmaterials

Sealoffanon-direct vent furnace if it is installed near an

area frequently contaminated by any of the above

substances. This protects the non-direct vent furnace

from airborne contaminants. To ensure that the

enclosed non-direct vent furnace has an adequate supply

of combustion air, vent from a nearby uncontaminated

room or from outdoors. Refer to the Section V,

Combustion and Ventilation Air Requirements for details.

If the furnace is used in connection with a cooling unit,

install the furnace upstream or in parallel with the cooling

unit. Premature heat exchanger failure will result if the

cooling unit is placed ahead of the furnace.

If the furnace is installed in a residential garage, position

the furnace so that the burners and ignition source are

located not less than 18 inches (457 mm) above the floor.

Protect the furnace from physical damage by vehicles.

If the furnace is installed horizontally, the furnace access

doors must be vertical so that the burners fire horizontally

into the heat exchanger. Do not install the unit with the

access doors on the "up/top" or "down/bottom" side of

the furnace.

CLEARANCES AND ACCESSIBILITY

Installations must adhere to the clearances to combustible mate-

rials which this furnace has been design certified to. The mini-

mum clearance information for this furnace is provided on the unit's

clearance label. These clearances must be permanently main-

tained. Clearances must also accommodate an installation's gas,

electrical, drain trap, and drain line connections. If the alternate

combustion air intake or vent/flue connections are used additional

clearance must be provided to accommodate these connections.

Refer to Section IX, Vent Flue Pipe and Combustion Air Pipe for

details. NOTE: In addition to the required clearances to combus-

tible materials, a minimum of 24 inches service clearance must be

available in front of the unit.

TOP

SIDESIDESIDE

TOP

11o0I I

BOTTOM

Upflow Counterflow Horizontal

A furnace installed in a confined space (i.e., a closet or utility room)

must have two ventilation openings with a total minimum free area

of 0.25 square inches per 1,000 BTU/hr of furnace input rating.

Refer to Specification Sheet applicable to your model* for mini-

mum clearances to combustible surfaces. One of the ventilation

openings must be within 12 inches of the top; the other opening

must be within 12 inches of the bottom of the confined space. In a

typical construction, the clearance between the door and door frame

is usually adequate to satisfy this ventilation requirement.

FURNACE SUSPENSION

If suspending the furnace from rafters or joists, use 3/8" threaded

rod and 2"x2"x1/8" angle iron as shown below. The length of rod

will depend on the application and the clearances necessary.

PROVIDE 8 M_NMM CLEARANCE BEW_,EEN

3_8"DIAf_ETER

THREADE0 ROD

(6PLACES}

HOLD DO_N

2"x2"x_/8"ANGL5 _RON

_3PLACES)

TOBLOWERDECKTOA_LO_FOR

CIRCULATORBLOWERREMVOA_

Suspended Furnace

EXISTING FURNACE REMOVAL

DOORA_D CIRCULATORBLOWER

REMOVAL

NOTE: When an existing furnace is removed from a venting system

serving other appliances, the venting system may be too large to

properly vent the remaining attached appliances.

The following vent testing procedure is reproduced from the American

National Standard/National Standard of Canada for Gas-Fired Cen-

tral Furnaces ANSI Z21.4, CSA-2.3 latest edition Section 1.23.1.

The following steps shall be followed with each appliance connected to the

venting system placed in operation, while any other appliances con-

nected to the venting system are not in operation:

a. Seal any unused openings in the venting system;

b. Inspect the venting system for proper size and horizontal pitch, as

required by the National Fuel Gas (;ode, ANSI Z223.1 or the CSA

B 149.1-05 Installation (?odes and these instrnctions. Deterlnine that

there is no blockage or restriction, leakage, corrosion and other defi-

ciencies which could cause an unsafe condition;

c. In so fhr 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. Turn on

clothes &yers and any appliance not connected to the venting sys-

tem. Turn on any exhaust fhns, such as range hoods and bathroom

exhausts, so they shall operate at maximum speed. Do not operate a

summer exhaust fan. (?lose fireplace dampers;

d. Follow the lighting instructions. Place the appliance being inspected

in operation. Adjust thermostat so appliance shall operate continu-

ously;

e. Test for draf_t hood equipped spillage at the &afi hood relief opening

after 5 minutes of main burner operation. Use the flame of a match

or candle;

f. After it has been determined that each appliance connected to the

venting system properly vents when tested as outlined above, re-

turn doors, windows, exhaust fans, fireplace dampers and any other

gas burning appliance to their previous conditions of use;

*NOTE: Please contact your distributor or our website for the applicable

Specification Sheet referred to in this manual.

g. If improper venting is observed during any of the above tests, the

common venting system must be corrected.

Corrections must be in accordance with the latest edition of the

National Fuel Gas Code NFPA 54/ANSI Z223.1 and/or CSA B149.1-

05 Installation Codes.

If resizing is required on any portion of the venting system, use the

appropriate table in Appendix G in the latest edition of the National

Fuel Gas Code ANSI Z223.1 and/or CSA B149.1-05 Installation

Codes.

THERMOSTAT LOCATION

The thermostst should be placed approximately five feet from the

floor on a vibration-free, inside wall in an area having good air

circulation. Do net install the thermostat where it may be influ-

enced by any of the following:

* Drafts, or dead spots behind doors, in corners, or under

cabinets.

" Hot or cold air from registers.

* Radiant heat from the sun.

" Light fixtures or other appliances.

• Radiant heat from a fireplace.

" Concealed hot or cold water pipes, or chimneys.

• Unconditioned areas behind the thermostat, such as an

outside wall.

Thermostat Influences

Consult the instructions packaged with the thermostat for mount-

ing instructions and further precautions.

V. COMBUSTION & VENTILATION AiR REQUIREMENTS

WARNING

TO AVOID PROPERTY DAMAGErPERSONAL INJURY OR DEATH_

SUFFICIENT FRESH AIR FOR PROPER COMBUSTION AND VENTILATION

OF FLUE GASES MUST BE SUPPLIED. MOST HOMES REQUIRE OUTSIDE

AIR BE SUPPLIED INTO THE FURNACE AREA.

Improved construction and additional insulation in buildings have

reduced heat loss by reducing air infiltration and escape around

doors and windows. These changes have helped in reducing

heating/cooling costs but have created a problem supplying com-

bustion and ventilation air for gas fired and other fuel burning appli-

ances. Appliances that pull air out of the house (clothes dryers,

exhaust fans, fireplaces, etc.) increase the problem by starving

appliances for air.

House depressurization can cause back drafting or improper com-

bustion of gas-fired appliances, thereby exposing building occu-

pants to gas combustion products that could include carbon mon-

oxide.

If this furnace is to be installed in the same space with other gas

appliances, such as a water heater, ensure there is an adequate

supply of combustion and ventilation air for the other appliances.

Refer to the latest edition of the National Fuel Gas Code NFPA 54/

ANSI Z223.1 (Section 5.3), or CSA B149.1-05 Installation Codes

(Sections 7.2, 7.3, or 7.4), or applicable provisions of the local

building codes for determining the combustion air requirements

for the appliances.

Most homes will require outside air be supplied to the furnace area

by means of ventilation grilles or ducts connecting directly to the

outdoors or spaces open to the outdoors such as attics or crawl

spaces.

The following information on air for combustion and ventilation is repro-

duced fi'om the National Fuel Gas (?ode NFPA 54/ANSI Z223.1 Section

5.3.

5.3.1 General:

(a) The provisions of 5.3 apply to gas utilization equipment installed in

buildings and which require air for combustion, ventilation and dilu-

tion of flue gases fi'om within the building. They do not apply to (1)

direct vent equipment which is constructed and installed so that all

air combustion is obtained from the outside atmosphere and all flue

gases are discharged to the outside atmosphere, or (2) enclosed

fhmaces which incorporate an integral total enclosure and use only

outside air for combustion and dilution of flue gases.

(b) Equipment shall be installed in a location in which the facilities for

ventilation permit satisfactory combustion of gas, proper venting

and the maintenance of ambient temperature at safe limits under

normal conditions of use. Equipment shall be located so as not to

interfere with proper circulation of air. When normal infiltration

does not provide the necessary air, outside air shall be introduced.

vided as required for: cooling of equipment or material, controlling

dew point, heating, &ying, oxidation or dilution, safety exhaust,

odor control, and air for compressors.

(d) In addition to air needed for combustion, air shall be supplied for

ventilation, including all air required for comfort and proper working

conditions for personneh

(e) While all fomas of building constrnction cannot be covered in detail,

air for combustion, ventilation and dilution of flue gases for gas

utilization equipment vented by natural &af_ normally may be ob-

tained by application of one of the methods covered in 5.3.3 and

5.3.4.

(f) Air requirements lbr the operation of exhaust fans, kitchen ventila-

tion systems, clothes &yers, and fireplaces shall be considered in

determining the adequacy of a space to provide combustion air

requirements.

5.3.2 Equipment Located in Unconfined Spaces:

In unconfined spaces (see definition below) in buildings, infiltration may

be adequate to provide air for combustion ventilation and dilution of

flue gases. However, in buildings of tight construction (for example,

weather stripping, heavily insulated, caulked, vapor barrier, etc.), addi-

tional air may need to be provided using the methods described in 5.3.3-

b or 5.3.4.

Space, Unconfined.

For purposes of this Code, a space whose volume is not less than 50

cubic feet per 1,000 BTU per hour of the aggregate input rating of all

appliances installed in that space. Rooms communicating directly with

the space in which the appliances are installed through openings not

furnished with doors, are considered a part of the unconfined space.

5.3.3 Equipment Located in Confined Spaces:

(a) Aft Aicfi'om In._ic]e the BzdMi,g: The confined space shall be pro-

vided with two pemaanent openings communicating directly with

an additional room(s) of sufficient volume so that the combined

volumeofallspacesmeetsthecriteria%r an unconfined space. The

total input of all gas utilization equipment installed in the combined

space shall be considered in making this determination. Each open-

ing shall have a minimum fi'ee area of I square inch per 1,000 BTU

per hour of the total input rating of all gas utilization equipment in

the confined space, but not less than 100 square inches. One open-

ing shall be within 12 inches of the top and one within 12 inches of

the bottom of the enclosure.

Chimney or Gas Vent

NOTE: Each opening must have

a free area of not tess than one

square inch per 1000 BTU of

the total input rating of all equip-

ment in the enclosure, but not

less than 100 square inches.

_OpeNng

Opening

Equipment Located in Confined Spaces; AI! Air from inside

Building. See s.a.a-a.

(b) .4//Ah'fi'om Oz¢Moors: The confined space shall be provided with

two permanent openings, one commencing within 12 inches of the

top and one commencing within 12 inches of the bottom of the

enclosure. The openings shall comnmnicate directly, or by ducts,

with the outdoors or spaces (crawl or attic) that fi'eely communicate

with the outdoors.

l. When directly communicating with the outdoors, each opening

shall have a mininmm free area of 1 square inch per 4,000 BTU

per hour of total input rating of all equipment in the enclosure.

Chimney or Gas Vent

Ventilation louvers

NOTE: The inlet and outlet air

openings must each have a free

area of not tess than one square

inch per 4000 BTU of the

total input rating of all equipment

in the enclosure.

Outlet Air

A_ternate

air inlet

inlet Air

unheated crawl space

Equipment Located in Confined Spaces; AH Air from Outdoors--

Inlet Air from Ventilated Crawl Space and Outlet Air to Ventilated

Attic. See 5.3.3-b

2. When conmmnicating with the outdoors through vertical ducts,

each opening shall have a minimum fi'ee area of 1 square inch per

4,000 BTU per hour of total input rating of all equipment in the

enclosure.

_CNmney or Gas Vent

_fd'l III1_ _% NOTE:Theinletandoutletair

r/ll II Illl_t _ openings must each have a free

IIII II' II '\_ "_-._ area of not less than one square

1111 II II "_l_ inchper4OOOBTUofthe

II I I It It l! "H_ total input rating of all equipment

h_"__.._ __ in the encl°sure.

--Ootlet ,,

Water

Furnace r --tnlet air duct

I a;e I ,end l , OO m,

Equipment Located in Confined Spaces; All Air from Outdoors

Through Ventilated Attic. See 5.3.3-b.

3. When communicating with the outdoors through horizontal ducts,

each opening shall have a mininmm fi'ee area of 1 square inch per

2,000 BTU per hour of total input rating of all equipment in the

enclosure.

_-* _J IWater

irnaee I Heater

h ,L

Outlet air duct

fnlet air duct

I I !,, I l,_ t III1

IIf II IfII l IIAI

NOTE: The air duct openings

must have a free area of not

less than one square inch per

2000 BTU of the total input

rating of all equipment in the

enclosure*.

*If the appliance room is located against an outside wall and the air openings comm unicate directly with the

outdoors, each opening sh all have a free a rea of not less than one sq ua re inch per 4.000 BTU per hou r of

the total input rating of all appliances in the enclosure

Equipment Located in Confined Spaces; All Air from Outdoors.

See 5.3.3-b.

4. When ducts are used, they shall be of the same cross-sectional

area as the fi'ee area of the openings to which they connect. The

minimum dimension of rectangular air ducts shall not be less

than 3 inches.

NOTE: The single opening must have

a free area of not less than one

square inch per 3000 BTU of

the total input rating of all equip-

ment in the enclosure

the sum of the areas of all vent

connectors in the confined space.

Chimney or Gas Vent

__ _ Opening

I "Alternate

Opening

Location

_ tl iI tl 11 ,IiI it ,I

p f I

Equipment Located in Confined Spaces; All Air from Outdoors -

Single Air Opening. See 5.&3-b.

5. When directly communicating with the outdoors, the single open-

ing shall have a minimum fi'ee area of 1 square inch per 3,000

BTU per hour of total input rating of all equipment in the enclo-

sure.

5.3.4 Specially Engineered Installations:

The requirements of 5.3.3 shall not necessarily govern when special engi-

neering, approved by the authority having jurisdiction, provides an

adequate supply of air fbr combustion, ventilation, and dilution of flue

gases.

5.3.5 Louvers and Grilles:

In calculating fi'ee area in 5.3.3, consideration shall be given to the blocking

effect of louvers, grilles or screens protecting openings. Screens used

shall not be smaller than 1/4 inch mesh. If the area through a design of

louver or grille is known, it should be used in calculating the size of

opening required to provide the fi'ee area specified. If the design and fi'ee

area is not known, it may be assumed that wood louvers will have 20-25

percent free area and metal louvers and grilles will have 60-75 percent

fi'ee area. Louvers and grilles shall be fixed in the open position or

interlocked with the equipment so that they are opened automatically

during equipment operation.

5.3.6 Special Conditions Created by Mechanical Exhausting or Fire-

places:

Operation of exhaust fans, ventilation systems, clothes dryers, or fireplaces

may create conditions requiring special attention to avoid unsatisfac-

tory operation of installed gas utilization equipment. Air from Inside

Building. See 5.3.3-a.

Vi. INSTALLATION POSITIONS

This furnace may be installed in an upright position or horizontal

on either the left or right side panel. Do not install this furnace on

its back. For upright upflow furnaces, return air ductwork may be

attached to the side panel(s) and/or basepan. For horizontal up-

flow furnaces, return air ductwork must be attached to the basepan.

For both upright or horizontal counterflow furnaces, return duct-

work must be attached to the basepan (top end of the blower com-

partment). NOTE: Ductwork must never be attached to the back of

the furnace. Contact your distributor for proper airflow require-

ments and number of required ductwork connections. Refer to

"Recommended Installation Positions" figure for appropriate in-

stallation positions, ductwork connections, and resulting airflow

arrangements.

VII. HORIZONTAL APPLICATIONS &CONSIDERATIONS

GENERAL

Horizontal applications, in particular, may dictate many of the

installation's specifics such as airflow direction, ductwork connec-

tions, flue and combustion air pipe connections, etc. The basic

application of this furnace as a horizontal furnace differs only slightly

from an upright installation. When installing a furnace horizontally,

additional consideration must be given to the following:

,_] Eqk ENEE ,@,E MEELE CLE?F,_I_CE BECUBED

Horizontal Furnace

DRAIN TRAP AN[) LINES

In horizontal applications the condensate drain trap is secured to

the furnace side panel, suspending it below the furnace. A mini-

mum clearance of 4 3/4 inches below the furnace must be pro-

vided for the drain trap. Additionally, the appropriate downward

piping slope must be maintained from the drain trap to the drain

location. Refer to Section X, Condensate Drain Trap and Lines for

further details. If the drain trap and drain line will be exposed to

temperatures near or below freezing, adequate measures must

be taken to prevent condensate from freezing.

LEVELING

Leveling ensures proper condensate drainage from the heat ex-

changer and induced draft blower. For proper flue pipe drainage,

the furnace must be level lengthwise from end to end. The furnace

should also be level from back to front or have a slight tilt with the

access doors downhill (approximately 3/4 inches) from the back

panel. The slight tilt allows the heat exchanger condensate, gen-

erated in the recuperator coil, to flow forward to the recuperator coil

front cover.

ALTERNATE VENT/FLUE AND COMBUSTION AIR CONNECTIONS

In horizontal installations provisions for alternate flue and com-

bustion air piping are available for upflow furnaces with left dis-

charge and counterflow furnaces with right air discharge. This

configuration allows the flue and combustion air piping to be run

vertically through the side of the furnace. Refer to the "Recom-

mended Installation Positions" figure for further detail. The stan-

dard piping connections may also be used in these positions.

Refer to Section IX, Vent/Flue Pipe and Combustion Air Pipe for

details concerning the conversion to the alternate vent/flue and

combustion air connections.

A,R t_}

D_SOHARGE ALTERNATEFLUEAND

UPFLOW

UPRIGHT

ALTERNATE FLUE AND

COMBUSTION A[_ PIPE

LOCATIONS

A_R Durt

DISCHARGE _

UPFLOW HORIZONTAL

LEFT AIR DISCHARGE

_[_ AIR

D_SC_ARGE

UPFLOW HORIZONTAL

RIGHT AIR DISCHARGE

Recommended Installation Positions

NOTE: Alternate "vertical" piping connections can not be used when

an upflow furnace is installed with supply air discharging to the

right, or when a counterflow furnace is installed with supply air

discharging to the left. In either case, use the standard flue and

combustion air piping connections.

ALTERNATE ELECTRICAL AND GAS LINE CONNECTIONS

This furnace has provisions allowing for electrical and gas line

connections through either side panel. In horizontal applications

the connections can be made either through the "top" or "bottom" of

the furnace.

DRAIN PAN

A drain pan must be provided if the furnace is installed above a

conditioned area. The drain pan must cover the entire area under

the furnace (and air conditioning coil if applicable).

FREEZE PROTECTION

Refer to Section VII, Horizontal Appfications and Conditions -Drain

Trap and Lines.

FURNACE SUSPENSION

If the furnace is installed in a crawl space it must be suspended

from the floor joist or supported by a concrete pad. Never install the

furnace on the ground or allow it to be exposed to water. Refer to

Section IV, Location Requirements and Considerations -Furnace

Suspension for further details.

VIII, PROPANE GAS/HIGH ALTITUDE INSTALLATIONS

_i, WARNING

POSSIBLE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH MAY

OCCUR iF THE CORRECT CONVERSION KITS ARE NOT INSTALLED. THE

APPROPRIATE KITS MUST BE APPLIED TO ENSURE SAFE AND PROPER

FURNACE OPERATION. ALL CONVERSIONS MUST BE PERFORMED BY

A QUALIFIED INSTALLER OR SERVICE AGENCY.

This furnace is shipped from the factory configured for natural gas

at standard altitude. Propane gas installations require an orifice

change to compensate for the energy content difference between

natural and propane gas.

High altitude installations may require both a pressure switch and

an orifice change. These changes are necessary to compensate

for the natural reduction in the density of both the gas fuel and the

combustion air at higher altitude.

For installations above 7000 feet, please refer to your distributor

for required kit(s).

iII Manifold Pressure II Pressure li

Gas Altitude Kit Orifice , = .

II I_ Hi h Sta e Low Sta e _1

o_7ooo 13.5,,w.c. 1,.9,,w.c.1l None

_Propanell ILPM-93*J#55 II 10.0"w.c./ 6.0"w.c./I None IJ

NOTE: In Canada,gas furnaces are onlycertifiedto 4500 feet.

Contact the distributor for a tabular listing of appropriate

manufacturer's kits for propane gas and/or high altitude installa-

tions. The indicated kits must be used to insure safe and proper

furnace operation. All conversions must be performed by a quali-

fied installer, or service agency.

IX. VENT/FLUE PiPE & COMBUSTION AIR PiPE

GENERAL

I_WARNING

FAILURE TO FOLLOW THESE INSTRUCTIONS CAN RESULT IN BODILY

INJURY OR DEATH. CAREFULLY READ AND FOLLOW ALL

INSTRUCTIONS GIVEN IN THIS SECTION.

I_WARNING

UPON COMPLETION OF THE FURNACE INSTALLATION, CAREFULLY

INSPECT THE ENTIRE FLUE SYSTEM BOTH INSIDE AND OUTSIDE OF

THE FURNACE TO ASSURE IT IS PROPERLY SEALED. LEAKS IN THE

FLUE SYSTEM CAN RESULT iN SERIOUS PERSONAL INJURY OR DEATH

DUE TO EXPOSURE TO FLUE PRODUCTS, INCLUDING CARBON

MONOXIDE.

A condensing gas furnace achieves its high level of efficiency by

extracting almost all of the heat from the products of combustion

and cooling them to the point where condensation takes place.

Because of the relatively low flue gas temperature and water con-

densation requirements, PVC pipe is used as venting material.

This furnace must not be connected to Type B, BW, or L vent or vent

connector, and must not be vented into any portion of a factory built

or masonry chimney except when used as a pathway for PVC as

described later in this section. Never common vent this appliance

with another appliance or use a vent which is used by a solid fuel

appliance. Do not use commercially available "no hub connec-

tors" other than those shipped with this product.

It is the responsibility of the installer to follow the manufacturers'

recommendations and to verify that all vent/flue piping and connec-

tors are compatible with furnace flue products. Additionally, it is the

responsibility of the installer to ensure that all piping and connec-

tions possess adequate structural integrity and support to prevent

flue pipe separation, shifting, or sagging during furnace operation.

DUAL CERTIFICATION: N oN=DERECTIDIRECT VENT

This furnace is dual certified and may be installed as a non-direct

vent (single pipe) or direct vent (dual pipe) appliance. A non-direct

vent installation requires only a vent/flue pipe, while a direct vent

installation requires both a vent/flue pipe and a combustion air

intake pipe. Refer to the appropriate section for details concerning

piping size, length, number of elbows, furnace connections, and

terminations.

MATERIALS AND JOINING M ETNODS

,_ WARNING

TO AVOID BODILY INJURY, FIRE OR EXPLOSION, SOLVENT CEMENTS

MUST BE KEPT AWAY FROM ALL IGNITION SOURCES (I.E._ SPARKS,

OPEN FLAMES_ AND EXCESSIVE HEAT) AS THEY ARE COMBUSTIBLE

LIQUIDS. AVOID BREATHING CEMENT VAPORS OR CONTACT WITH

SKIN AND/OR EYES.

Two- or three-inch nominal diameter PVC Schedule 40 pipe meet-

ing ASTM D1785, PVC primer meeting ASTM F656, and PVC sol-

vent cement meeting ASTM D2564 specifications must be used.

Fittings must be DWV type fittings meeting ASTM D2665 and ASTM

D3311. Carefully follow the pipe manufacturer's instructions for

cutting, cleaning, and solvent cementing of PVC.

As an alternative to PVC pipe, primer, solvent cement, and fittings,

ABS materials which are in compliance with the following specifi-

cations may be used. Two-or-three-inch ABS Schedule 40 pipe

must meet ASTM D1527 and, if used in Canada, must be CSA

listed. Solvent cement for ABS to ABS joints must meet ASTM

D2235 and, if used in Canada, must be CSA listed. The solvent

cement for the PVC to ABS transition joint must meet ASTM D3138.

Fittings must be DWV type fittings meeting ASTM D2661 and ASTM

D3311 and, if used in Canada, must be CSA listed. Carefully

follow the manufacturers' instructions for cutting, cleaning, and

solvent cementing PVC and/or ABS.

All 90 ° elbows must be medium radius (1/4 bend DWV) or long

radius (Long sweep 1/4 bend DWV) types conforming to ASTM

D3311. A medium radius (1/4 bend DWV) elbow measures 3 1/

16" minimum from the plane of one opening to the centerline of the

other opening for 2" diameter pipe, and 4 9/16" minimum for 3"

pipe.

PROPER VENT/FLUE AND COMBUSTION AIR PIPING PRACTICES

Adhere to these instructions to ensure safe and proper furnace

performance. The length, diameter, and number of elbows of the

vent/flue pipe and combustion air pipe (when applicable) affects

the performance of the furnace and must be carefully sized. All

piping must be installed in accordance with local codes and these

instructions.

Piping must be adequately secured and supported to prohibit sag-

ging, joint separation, and/or detachment from the furnace. Hori-

zontal runs of vent/flue piping must be supported every three to five

feet and must maintain a 1/4 inch per foot downward slope, back

towards the furnace, to properly return condensate to the furnace's

drain system. Allowances should be made for minor expansion

and contraction due to temperature variations. For this reason,

particular care must be taken to secure piping when a long run is

followed by a short offset of less than 40 inches.

Precautions should be taken to prevent condensate from freezing

inside the vent/flue pipe and/or at the vent/flue pipe termination. All

vent/flue piping exposed to freezing temperatures below 35°F for

extended periods of time must be insulated with 1/2" thick closed

cell foam. Also all vent/flue piping exposed outdoors in excess of

the terminations shown in this manual (or in unheated areas)

must be insulated with 112" thick closed cell foam. Inspect piping

for leaks prior to installing insulation.

TERMINATION LOCATIONS

NOTES: Refer to Section IV, Location Requirements and

Considerations for combustion air contaminant restrictions.

The following bullets and diagram describe the restrictions con-

cerning the appropriate location of vent/flue pipe and combustion

air intake pipe (when applicable) terminations. Refer to Non-Di-

rect Vent (Single Pipe) Piping and Direct Vent (Dual Pipe) Piping

located in this section for specific details on termination construc-

tion.

All terminations (flue andtor intake) must be located at

least 12 inches above ground level or the anticipated

snow level.

Vent terminations (non-direct and direct vent) must

terminate at least 3 feet above any forced air inlet located

within 10 feet.

NOTE: This provision does not apply to the combustion

air intake termination of a direct vent application.

The vent termination of a non-direct vent application must

terminate at least 4 feet below, 4 feet horizontally from, or

1 foot above any door, window, or gravity air inlet into any

building.

The vent termination of a direct vent application must

terminate at least 12 inches from any opening through

which flue gases may enter a building (door, window, or

gravity air inlet).

The vent termination of vent pipe run vertically through a

roof must terminate at least 12 inches above the roof line

(or the anticipated snow level) and be at least 12 inches

from any vertical wall (including any anticipated snow

build up).

A vent termination shall not terminate over public walkways

or over an area where condensate or vapor could create

a nuisance or hazard or could be detrimental to the

operation of regulators, relief valves, or other equipment.

The combustion air intake termination of a direct vent

application should not terminate in an area which is

frequently dusty or dirty.

Non Direct Vent

Grade or Highest

Anticipated

Vent Termination Clearances

NOTE: In Canada, the Canadian Fuel Gas Code takes precedence

over the preceding termination restrictions.

CANADIAN VENTING REQUIREMENTS

In Canada, venting must conform to the requirements of the cur-

rent CAN/CSA-B149.1-05 Installation Code. Use only CSA-listed,

ULC-S636 compliant two- or three-inch diameter PVC crABS pipe,

solvent cement, and fittings throughout. The certified piping should

be clearly marked with the ULC Std "S636" on the pipe and fittings.

Carefully follow the pipe manufacturers' instructions for cutting,

cleaning, and solvent cementing PVC and/or ABS.

The vent can be run through an existing unused chimney provided

the space between the vent pipe and the chimney is insulated and

closed with a weather-tight, corrosion-resistant flashing.

STANDARD FURNACE CONNECTIONS

It is the responsibility of the installer to ensure that the piping

connections to the furnace are secure, airtight, and adequately

supported.

As shipped, attachment "couplings" for vent/flue and combustion

air intake pipe connections are provided on the furnace's top cover

(upflow) or basepan (counterflow). To use the standard connec-

tions, field supplied vent/flue pipe and combustion air intake pipe

(when applicable) should be secured directly to the furnace at

these locations.

VENT/FLuEPIpE

Vent/flue pipe can be secured to the vent/flue coupling using the

rubber coupling and worm gear hose clamps provided with this

furnace (see "Standard Connections" figure). The rubber coupling

allows separation of the vent/flue pipe from the furnace during

servicing. Combustion Air and Vent piping should be routed in a

manner to avoid contact with refrigerant lines, metering devices,

condensate drain lines, etc. if necessary, clearances may be

increased by utilizing two 45 deg. Long-Sweep Elbows and creat-

ing an "S" joint to provide additional space at connection loca-

tions. This joint can be rotated on the fitting to establish maxi-

mum clearance between refrigerant lines, metering devices, and

condensate drain lines, etc. This joint is the equivalent of one 90

deg. elbow when considering elbow count.

increased Clearance Configuration

NOTE: Do not use other commercially available "no hub connec-

tors" due to possible material conflicts. The vent/flue pipe can

also be secured using a PVC or ABS elbow or coupling using the

appropriate glue (see Section IX, Materials and Joining Methods.

NOTE: For non-direct vent installations, a minimum of one 90 °

elbow should be installed on the combustion air intake coupling

to guard against inadvertent blockage.

COMBUSTIONAIR PIPE

On upflow units secure the combustion air intake pipe directly to

the air intake coupling. On counterflow units secure the combus-

tion air intake pipe to the air intake coupling using the rubber cou-

pling and worm gear hose clamps provided with the unit. The

counterflow rubber coupling allows service removal of air intake

piping internal to the furnace blower compartment. NOTE: Be-

cause of probable material conflicts, do not use other commer-

cially available "no hub connectors". The combustion air intake

pipe can also be secured directly to the counterflow unit air intake

pipe coupling.

NoN-DIRECT VENT INS TALLATtONS

A minimum of one 90 ° elbow should be installed on the combus-

tion air intake "coupling" to guard against inadvertent blockage.

COMSUST_ON

AIR PIPE VENT/FLUE

(DIRECT VENT ONLY) PIPE

UPFLOW

COMBUSTION VENT/FLUE

A_RPIPE P_PE

(DIRECT VENT ONLY)

!F "_

COUNTERFLOW

STANDARD CONNECTIONS

ALTERNATE FURNACE CONNECTIONS

If the standard locations are undesirable for a specific installation,

alternate side panel locations are available for both combustion

air inlet and vent/flue pipe connections. These locations may be of

particular benefit to upright upflow installations requiring additional

access to an A coil, or to upright counterflow installations requiring

additional access to a filter or electronic air cleaner, or to horizontal

installations desiring vent/flue (and combustion air intake) piping

run vertically from the side of the cabinet.

NOTE: Standard and alternate locations can be combined (i.e., an

installation may use the standard combustion air intake location

but use the alternate vent/flue location or vice versa), if needed.

,_ WARNING

EDGES OF SHEET METAL HOLES MAY BE SHARP. USE GLOVES AS A

PRECAUTION WHEN REMOVING HOLE PLUGS.

ALTERNATE VENT/FLuE LOCATION

The alternate vent/flue location is the large hole directly in line with

the induced draft blower outlet. To use the alternate vent/flue loca-

tion refer to the following steps and the "Alternate Vent/Flue Loca-

tion" figure.

NOTE: Counterflow instructions follow the upfiow instructions.

1. Remove and save the four screws securing the vent/flue

coupling to the furnace top panel.

Counterflow units.

Remove and save the four screws securing the vent/flue

coupling to the furnace basepan. Also remove the three

screws securing the furnace's internal vent/flue piping to

the blower deck.

2. Upflow and Counterflow units.

Loosen the worm gear hose clamps on the rubber elbow

and detach it from both the induced draft blower and the

vent/flue pipe.

3. Upflow and Counterflow units.

Remove the vent/flue pipe from the furnace.

4. Cut the vent/flue pipe 3.75 inches from the flanged end of

the pipe. See Vent/Flue Pipe Cuts figure. The section of

pipe attached to the coupling will reach through the side

panel to the induced draft blower. Discard remaining pipe

and elbows.

Counterflow units.

Cut the vent/flue pipe 3.75 inches from the blower deck

coupling. See Vent/Flue Pipe Cuts figure. Save vent/flue pipe

attached to blower deck coupling for use in the alternate

location. Discard remaining pipe and elbows.

CUT _- --

Vent/Flue Pipe Cuts

Remove plastic plug from alternate vent/flue location.

Relocate and install plug in standard vent/flue location (top

cover).

Counterflow units.

Remove plastic plug from alternate vent/flue location.

Relocate and install plug in standard vent/flue location

(basepan). Plug remaining hole in blower deck with plastic

plug included in the drain kit bag.

Upflow and Counterflow units.

Insert cut section of vent/flue pipe and coupling into alternate

vent/flue location. Using a rubber coupling and worm gear

hose clamps from the drain kit bag, attach the vent/flue pipe

and coupling to the induced draft blower. Secure the

coupling to the cabinet using the screws removed in step 1

or with field-supplied 3/8" #8 self drilling screws.

_lb WARNING

THE RUBBER ELBOW IS NOT DESIGNED TO SUPPORT A LOAD. WHEN

THE RUBBER ELBOW IS MOUNTED EXTERNALLY TO THE FURNACE

CABINET_ EXTREME CARE MUST BE TAKEN TO ADEQUATELY SUPPORT

FIELD-SUPPLIED VENT/FLUE PIPING_ AS DAMAGE CAN RESULT IN

LEAKS CAUSING BODILY INJURY OR DEATH DUE TO EXPOSURE TO

FLUE GASES, INCLUDING CARBON MONOXIDE.

7. Upflow and Counterflow units.

For upright installations, externally mount the rubber elbow

to the vent/flue coupling using a worm gear hose clamp.

Secure field supplied vent/flue piping to the rubber elbow

using a worm gear hose clamp. NOTE: Use of the alternate

vent/flue location for upright installations, requires the drain

trap be installed on the same side of the unit as the flue

pipe.

8. Upflow and Counterflow units.

For horizontal installations, externally secure the field-

supplied vent/flue pipe directly to the vent/flue coupling using

a PVC or ABS coupling or elbow.

%eVEt

-__

UPFLOW

REMOVE

REMOVE 4SCREWS REMOVE

/4 SCREWS _ PIPE

__/ REMOVE

3 SCREWS

d_/_'REMOVE @

_ _ REMOVE

D RELOCATE

._ AND RELOCATE

DETACH RUBBER _f_

ELBOW FROM

ID BLOWER AND

VENT/FLUE

PIPE

COUNTERFLOW

DETATCH RUBBER

ELBOW FROM

ID BLOWER AND

VENT/FLUE

PIPE

,"ql • _1

ADDITIONAL PLUG

FROM DRAIN KiT

LEXTERNALLY

MOUNT

RUBBER ELBOW

SECURE TO

ID BLOWER WITH

_UBBER COUPLING

AND HOSE

CLAMPS

COUNTERFLOW/UPRIGHT

(UPFLOW SIMILAR)

SECURE TO

ID BLOWER WITH ®

RUBBER COUPLING SECURE TO

AND HOSE

UPFLOW/HORIZONTAL

(COUNTERFLOW SIMILAR)

Alternate Vent/Flue Location

ALTERNATE COMBUSTION AIR _NTAKE LOCATION

The alternate combustion air intake location consists of a large,

unobstructed hole (alternate vent connection is aligned with the

Induced Draft Blower). To use the alternate combustion air intake

location, refer to the following steps, and the "Alternate Combus-

tion Air Intake Location" figure.

NOTE: Counterflow unit instructions follow the upfiow instructions.

1. Remove and save the four screws securing the combustion

air intake coupling to the furnace's top panel (upflow).

Counterflow units.

Remove and save the four screws securing the combustion

air intake coupling to the basepan. Remove an additional

three screws securing the furnace's internal combustion

air intake pipe to the blower deck.

2. Remove the combustion air intake coupling and gasket from

the top panel.

Counterflow units.

Remove the combustion air intake pipe from the furnace

and cut the pipe at the basepan coupling. Save the basepan

coupling and gasket from the blower deck coupling for use

in the alternate location. Discard the remaining pipe.

3. Remove plastic plug from alternate combustion air intake

location. Relocate and install plug in standard air intake

location (top cover).

Counterflow units.

Remove plastic plug from alternate combustion air intake

location. Relocate and install plug in standard air intake

location (basepan). Plug the remaining hole in the blower

deck with the plastic plug included in the drain kit bag.

Upflew and Counterflew units.

With the gasket facing the cabinet side panel, and the

flange's flat spot facing forward, secure the combustion air

intake coupling to the cabinet using the screws removed in

step 1 or with field-supplied 3/8" #8 self -drilling screws.

_h, CAUTION

BE SURE NOT TO DAMAGE INTERNAL WIRING OR OTHER

COMPONENTS WHEN REINSTALLING COUPLING AND SCREWS.

Pipe) Piping -Vent/Flue Pipe Terminations for specific details on

termination construction.

Although non-direct vent installations do not require a combustion

air intake pipe, a minimum of one 90 ° elbow should be attached to

the furnace's combustion air intake if: an upright installation uses

the standard intake location, or a horizontal installation uses the

alternate air intake location. This elbow will guard against inad-

vertent blockage of the air intake.

VENT/FLuE PIPE LENGTHS AND DIAMETERS

Refer to the following table for applicable length, elbows, and pipe

diameter for construction of the vent/flue pipe system of a non-

direct vent installation. In addition to the vent/flue pipe, a single 90 °

elbow should be secured to the combustion air intake to prevent

inadvertent blockage. The tee used in the vent/flue termination

must be included when determining the number of elbows in the

piping system.

5. Upflew and Counterflew units.

For non-direct vent installations installed horizontally, a

minimum of one 90 ° elbow should be installed on the

combustion air intake coupling to guard against inadvertent

blockage. No elbow is required on the alternate combustion

air intake of upright installations, however, a minimum

clearance of 2 inches is required to assure proper air supply.

6. Upflow and Counterflow units.

For direct vent installations, secure field-supplied

combustion air intake pipe directly to the air intake coupling.

NOTE: A PVC coupling or elbow is required on counterflow

units.

REMOVE _)

4 S 3REWS REMOVE

Q ®

REMOVE 2" CLEARANCE

JCREWS REQUIRED

@ -_ t (NON-DIRECT

REMOVE = _ VENT)

AND CUT

4-.-_.® ©

REMOVE --

REMOVE 3 SCREWS

AND /.4 L.

RELOCATE ® /

ADDITIONAL

PLUGFROM

DRAINKIT

UPFLOW

SECURE-_

TO CABINET

COUNTERFLOW

""- ®

REMOVE

AND

RELOCATE

UPFLOW/HORIZONTAL SHOWN

(COUNTERFLOW SIMILAR)

Alternate Combustion Air Intake Location

NoN-DIRECT VENT (SINGLE PIPE} PiPiNG

Non-direct vent installations require only a vent/flue pipe. The vent

pipe can be run horizontally with an exit through the side of the

building or run vertically with an exit through the roof of the building.

The vent can also be run through an existing unused chimney;

however, it must extend a minimum of 12 inches above the top of

the chimney. The space between the vent pipe and the chimney

must be closed with a weather-tight, corrosion-resistant flashing.

For details concerning connection of the vent/flue pipe to the fur-

nace, refer to Section IX, Vent/Flue Pipe and Combustion Air -

Standard Furnace Connections or Alternate Furnace Connections

for specific details. Refer to the following Non-Direct Vent (Single

UPFLOW

Non-Direct Vent (S ingle Pipe)

Maximum Allowable Length of Vent/Rue Pipe (ft)(1/(2)

Pipe(4) Numb er of Elbows(3)(_)

Unit Input (inch) 1121al4151 1718

45,00 0 2 71 68 65 62 59 56 53 50

2 49 46 43 40 37 34 31 28

70,00 0 3 71 68 65 62 59 56 53 50

90,00 0 3 71 68 65 62 59 56 53 50

115,000 3 49 46 43 40 37 34 31 28

COUNTERFLOW

Non-Direct Ve nt (S ingle Pipe)

Maximum Allowable Length of Vent/Rue Pipe (ft)(1)(2)

Unitlnput Pipe(4) Numb er of Elbow_ 3/(_)

(inch) 1 2 3 4 5 6 7 8

2 61 58 55 52 49 46 43 40

70,000 3 71 68 65 62 59 56 53 50

2 61 58 55 52 49 46 43 40

90,000 3 71 68 65 62 59 56 53 50

115,000 3 71 68 65 62 59 56 53 50

I ) One 90 ° elbow should be secured to the combustion air intake connec-

tion.

2) Minimum requirement for each vent pipe is five (5) feet in length and one

elbow/tee.

3) Tee used in the vent/flue termination must be included when determining

the number of elbows in the piping system.

4) 3" diameter pipe can be used in place of 2" diameter pipe.

5) Increased Clearance Configurations using (2) 45 deg. Long Sweep

elbows should be considered equivalent to one 90 deg. elbow.

VENT/FLuEPIpE TERMINATIONS

The vent/flue pipe may terminate vertically, as through a roof, or

horizontally, as through an outside wall.

Vertical vent/flue pipe terminations should be as shown in the fol-

lowing figure. Refer to Section IX, Vent/Flue Pipe and Combustion

Air Pipe -Termination Locations for details concerning location

restrictions. The penetration of the vent through the roof must be

sealed tight with proper flashing such as is used with a plastic

plumbing vent.

Horizontal vent/flue pipe terminations should be as shown in the

following figure. Refer to Section IX, Vent/Flue Pipe and Combus-

tion Air Pipe -Termination Locations for details concerning loca-

tion restrictions. A 2 3/8" diameter wall penetration is required for

2" diameter pipe while a 3 1/2" diameter hole is required for 3"

diameter pipe. To secure the pipe passing through the wall and

prohibit damage to piping connections, a coupling should be in-

stalled on either side of the wall and solvent cemented to a length

of pipe connecting the two couplings. The length of pipe should be

the wall thickness plus the depth of the socket fittings to be in-

stalled on the inside and outside of the wall. The wall penetration

should be sealed with silicone caulking material.

In a basement installation, the vent/flue pipe can be run between

joist spaces. If the vent pipe must go below a joist and then up into

the last joist space to penetrate the header, two 45 ° elbows should

be used to reach the header rather than two 90 ° elbows.

TEE

/2 ' Min To

Roof Or

Highest A ticipated

Snow Level

Vertical Termination (Single Pipe)

90°

MEDIUM RADIUS

ELBOWS

Direct vent installations require both a combustion air intake and a

vent/flue pipe. The pipes may be run horizontally and exit through

the side of the building or run vertically and exit through the roof of

the building. The pipes may be run through an existing unused

chimney; however, they must extend a minimum of 12 inches

above the top of the chimney. The space between the pipes and

the chimney must be closed with a weather tight, corrosion resis-

tant flashing. Both the combustion air intake and a vent/flue pipe

terminations must be in the same atmospheric pressure zone.

Refer to Section IX, Vent/Flue and Combustion Air Pipe -Termina-

tion Locations or Concentric Vent Termination for specific details

on termination construction. For details concerning connection of

pipes to the furnace, refer to the Section IX, Vent/Flue Pipe and

Combustion Pipe -Standard Furnace Connections or Alternate

Furnace Connections.

VENTYlFLuE AND COMBUSTION AIR PIPE LENGTHS AND DIAMETERS

Refer to the following table for applicable length, elbows, and pipe

diameter for construction of the vent/flue and combustion air intake

pipe systems of a direct vent (dual pipe) installation. The number

of elbows tabulated represents the number of elbows and/or tees

in each (Vent/Flue & Combustion Air Intake) pipe. Elbows and/or

tees used in the terminations must be included when determining

the number of elbows in the piping systems.

If the combustion air intake pipe is to be installed above a finished

ceiling or other area where dripping of condensate will be objec-

tionable, insulation of the combustion air pipe may be required.

Use 1/2" thick closed cell foam insulation such as Armaflex TM or

Insultube TM where required.

Alternate Vertical Termination (Single Pipe)

iNSiDE _ OUTSIDE

TEE

90°ELBOW

TURNED

DOWN

ELBOW OR _ ITOC_O_D OR

COUPLING _ I

SNOW E,E£

Horizontal Termination (Single Pipe)

12" MIN.

VENTIFLUE°___TEE

90 ° ELBOW TURNED

DOWN

Horizontal Termination (Single Pipe)

Above Highest Anticipated Snow Level

DIRECTVeNT(DUALPIP_)PIPING

The inlet air screens provided in the installation instruction packet

are available for the installer to use in the inlet of the combustion

air pipe to prevent animals from building nests in the combustion

air pipe. Installation of screens, while strongly recommended, is

not required and will not affect performance of the unit.

UPFLOW

Direct Vent (Dual Pipe) Maximum Allowable Length*

of Vent/Rue & Combustion Air Intake Pipe iftt

Unit Input Termination Pipe(4) Numberof EIbows(a<2)(3l(sI

Btu) Style(rich)1 14 15 17

Standard 2 71 68 65 62 59 56 53 50

45,000 Alternate 2 58 55 52 49 46 43 40 37

Standard 2 49 46 43 40 37 34 31 28

3 71 68 65 62 59 56 53 50

70,000 2 36 33 30 27 24 21 18 15

Alternate 3 57 54 51 48 45 42 39 36

Standard 3 71 68 65 62 59 56 53 50

9,000 Alternate 3 57 54 51 48 45 42 39 36

115,000 Standard 3 49 46 43 40 37 34 31 28

Alternate 3 35 32 29 26 23 20 17 14

*Ma:4mu m allowable _m_s listed are individual lengths for lelet & flue and NOTa combinat bn.

COU NTERFLOW

Direct Vent (Dual Pipe) Maximum Allowable Length*

of Vent/Rue & Combustion Air Intake Pipe iftt

Unit Input Termination pipe/4) Numberof EIbows(a<2/(3l/sI

Btu) Style(rich)1 14 15 17

2 49 46 43 40 37 34 31 28

Standard 3 71 68 65 62 59 56 53 50

70,000

Alternate 2 36 33 30 27 24 21 18 15

3 57 54 51 48 45 42 39 36

2 61 58 55 52 49 46 43 40

Standard 3 71 68 65 62 59 56 53 50

90,000 2 48 45 42 39 36 33 30 27

Alternate 3 57 54 51 48 45 42 39 36

115,000 Standard 3 71 68 65 62 59 56 53 50

Alternate 3 57 54 51 48 45 42 39 36

*Ma:4mum allowable Hm_s listed are individual lengths for _let & flue and NOTa combinat bn.

1) Elbows and/or tees used in terminations must be included when deter-

mining quantity of allowable elbows in the system.

2) Number of elbows tabulated are for each (Vent/Flue & Combustion Air

Intake) pipe.

3) Minimum requirements for each Vent/Flue & Combustion Air Intake pipe

is five (5) feet in length and one elbow/tee.

4) 3" diameter pipe can be used in place of 2" diameter pipe.

5) Increased Clearance Configurations using (2) 45 deg. Long Sweep

elbows should be considered equivalent to one 90 deg. elbow.

VENT/FLuE AND COMBUSTION AIR PIPE TERMINATIONS

The vent/flue and combustion air pipes may terminate vertically, as

through a roof, or horizontally, as through an outside wall.

Vertical pipe terminations should be as shown in the following

figure. Refer to Section IX, Vent/Flue Pipe and Combustion Pipe -

Termination Locations for details concerning location restrictions.

The penetrations through the roof must be sealed tight with proper

flashing such as is used with a plastic plumbing vent.

TEE

VENT/FLUE

_ COMBUSTION

AIR INTAKE

12" MIN

Vertical Terminations (Dual Pipe)

Horizontal terminations should be as shown in the following fig-

ure. Refer to Section IX, Vent/Flue Pipe and Combustion Pipe -

Termination Location for location restrictions. A 2 3/8 inch diameter

wall penetration is required for 2" diameter pipe while a 3 1/2 inch

diameter hole is required for 3" diameter pipe. To secure the pipe

passing through the wall and prohibit damage to piping connec-

tions, a coupling should be installed on either side of the wall and

solvent cemented to a pipe connecting the two couplings. The

pipe length should be the wall thickness plus the depth of the

socket fittings to be installed on the inside and outside of the wall.

The wall penetration should be sealed with silicone caulking ma-

terial.

Alternate Horizontal Vent Termination (Dual Pipe)

Standard Horizontal Terminations Above Anticipated Snow

Level (Dual Pipe)

900

MEDIUM RADIUS

Standard Horizontal Terminations (Dual Pipe)

Alternate Vent Termination Above Anticipated Snow Level

(Dual Pipe)

In a basement installation, the pipes may be run between the joist

spaces. If the pipes must go below the joist and then up into the

last joist space to penetrate the header, two 45 ° elbows should be

used to reach the header rather than two 90 ° elbows.

VENT/INTAKE TERMINATIONSFOR INSTALLATION OF MULTIPLE

DIRECTVENT FURNACES

If more than one direct vent furnace is to be installed vertically

through a common roof top, maintain the same minimum clear-

ances between the exhaust vent and air intake terminations of

adjacent units as with the exhaust vent and air intake terminations

of a single unit.

If more than one direct vent furnace is to be installed horizontally

through a common side wall, maintain the clearances as in the

following figure. Always terminate all exhaust vent outlets at the

same elevation and always terminate all air intakes at the same

elevation.

12,M1_A_OVE 12'¸M_

Horizontal Venting Of Multiple Units

CONCENTRIC VENT TERMINATION

Refer to the directions provided with the Concentric Vent Kit (DC VK)

for installation specifications.

SIDE WALL VENT KIT

This kit is to be used with 2" or 3" direct vent systems. The vent kit

must terminate outside the structure and may be installed with the

intake and exhaust pipes located side-by-side or with one pipe

above the other. This kit is NOT intended for use with single pipe

(indirect vent) installations.

Refer to the directions furnished with the Side Wall Vent Kit (pin

0170K00000S) for installation specifications.

X. CONDENSATE DRAIN LINES &DRAIN TRAP

GENERAL

A condensing gas furnace achieves its high level of efficiency by

extracting almost all of the heat from the products of combustion

and cooling them to the point where condensation takes place.

The condensate which is generated must be piped to an appropri-

ate drain location.

In upright installations, the furnace's drain hoses may exit either

the right or left side of the furnace. NOTE: If the alternate vent/flue

outlet is utilized in an upright installation, the drain trap and drain

connections must be located on the same side as the alternate

vent/flue outlet.

In horizontal installations, the drain hoses will exit through the

bottom (down side) of the unit with the drain trap suspended be-

neath the furnace. The field-supplied drain system must be in

accordance with all local codes and the instructions in the follow-

ing sections.

Follow the bullets listed below when installing the drain system.

Refer to the following sections for specific details concerning fur-

nace drain trap installation and drain hose hook ups.

The drain trap supplied with the furnace must be used.

The drain line between furnace and drain location must

be constructed of 3/4" PVC or CPVC.

The drain line between furnace and drain location must

maintain a 1/4 inch per foot downward slope toward

the drain.

Do not trap the drain line in any other location than at

the drain trap supplied with the furnace.

Do not route the drain line outside where it may freeze.

If the drain line is routed through an area which may

see temperatures near or below freezing, precautions

must be taken to prevent condensate from freezing

within the drain line.

If an air conditioning coil is installed with the furnace, a

common drain may be used. An open tee must be

installed in the drain line, near the cooling coil, to

relieve positive air pressure from the coil's plenum.

This is necessary to prohibit any interference with the

function of the furnace's drain trap.

U PRIGHT _NSTALLATIONS

In an upright installation drain hoses are connected to drain ports

on the rubber elbow and the recuperator coil front cover. The drain

lines are then routed through the right or left side panel and into

the drain trap secured to the outside of the cabinet.

NOTE: Refer to Section X, Condensate Drain Lines and Drain Trap

-Alternate Vent/Flue Hose Connections for upright installations

using an alternate vent/flue outlet.

STANDARD RIGHT OR LEFT SIDE DRAIN Hose CONNECTIONS

Upright installations using the standard vent/flue outlet require

drain hoses to be connected as follows. The following quantity of

hoses, tubes, and hose clamps are provided with the unit.

HOSE A

QTY: 1

HOSE B

QTY: 1

_TUBE 1

QTY: 1

"_ TUBE 2

UQTY: 2

bGREEN bRED

HOSE CLAMPS HOSE CLAMPS

QTY: 3QTY: 2

Hose and Tube Identification

1. Remove the rubber plug from the front cover drain port (right

or left side, depending on the intended drain trap mounting).

2. Secure Hose A to front cover drain port with a red hose

clamp. Route hose to rear side panel grommet hole.

NOTE: For left side drainage, grommets will have to be relocated to

left side panel.

Cabinet Width Models "X" Length to Cut From Long

(inches) (kBTU_Tons) End of Hose B

171/2 45__30 7 inches

21 70__40 31/2 inches

090__50

11550

24 1/2 None

Cabinet Width

(inches)

17 1/2

Models

(kBTU_Tons)

45__30

70__40

090__50

24 1/2 11 1/4 inches

11550

FRONT COVE_REE_N

DRAIN PORT CLAMP HOSE

CLAMPS

(3 PLACES)

Upright "Standard" Connections - Right Side

(Upflow Shown, Counterflow Similar)

"X" Length to Cut From Long

End of Hose B

18 5/8 inches

14 1/2 inches

RIGHT SIDE

fPANEL

RUBBER

_ELBOW

RUBBER ELBOW

IN PORT

_RED HOSE CLAMP

TUBE 1

I(_SE SIDE PANEL

GROMMET

_HOLES

TUBE(S) 2

DRAIN

_ J _"" TRAP

LEFT

SIDE PANEL

FRONT COVER

DRAIN PORT

RED HOSE

CLAMP

DRAIN

HOLES

TUBE(B) 2

DRAIN

TRAP HOSE B

RUBBER

/C=]°

ELBOW

7_DRAIN PORT

..RED HOSE

CLAMP

_TUBB 1

GREEN HOSE

_CLAMPS

(3 PLACES)

Upright "Standard" Connections - Left Side

(Upflow Shown, Counterflow Similar)

Cut and remove 1/4 inch from the end of the drain port on

the rubber elbow.

Insert Tube 1 into rubber elbow drain port and secure with

red hose clamp. Angle tube outward toward front of furnace.

Right side drains

Cut 17 3/4 inches from the long end of Hose B and discard.

Secure the remaining hose to Tube 1 with a green hose

clamp. Route the other end of Hose B to front right side

panel grommet hole.

Left side drains

Cut "X" inches from the long end of Hose B and discard.

Refer to table for appropriate length to cut. Secure remaining

hose to Tube 1 with a green hose clamp. Route other end

of Hose B to front left side panel grommet hole.

6. Insert short end of each Tube 2 through side panel grommet

holes. Secure tubes to Hose A and Hose B with green

hose clamps. Ensure hoses and tubes maintain a

downward slope for proper drainage and that they are not

kinked or binding.

For details concerning mounting of the drain trap, refer to Section

X, Condensate Drain Lines and Drain Trap -Upright Drain Trap

Mounting.

ALTERNATE VENT/FLuE DRAIN HOSE CONNECTIONS

Upright installations using the alternate vent/flue outlet will require

"right-side only" drain hoses to be connected as follows. Refer to

Section IX, Vent/Flue Pipe and Combustion Air Pipe for details on

alternate vent/flue pipe connection.

1. Remove the rubber plug from the front cover right-side drain

port. Save for use in step 3.

2. Secure Hose A to front cover drain port with a red hose

clamp. Route hose to rear right side panel grommet hole.

3. Remove grommet from front right-side panel drain hole.

Seal hole in grommet with large end of plug. Reinstall

grommet and plug into side panel drain hole.

4. Cut 1/4 inch from the end of the drain port on the externally

mounted rubber elbow. Discard cut portion.

5. Insert Tube 1 into rubber elbow drain port and secure with

a red hose clamp. Angle tube outward toward front of furnace.

6. Cut 17 7/8 inches from the long end of Hose B and discard.

7. Secure remaining end of Hose B to exposed end of Tube 1

with a green hose clamp. Route hose toward right side

panel grommet holes.

8. Insert short end of one Tube 2 through rear right side panel

grommet drain hole. Secure tube to Hose A with a green

hose clamp.

9. Insert short end of remaining Tube 2 into Hose B from

rubber elbow and secure with green hose clamp. Ensure

hoses and tubes maintain a downward slope for proper

drainage and are not kinked or binding.

O (RUBBER ELBOW

(EXTERNALLY

FRONT COVER MOUNTED)

RED HOSEJ HOSE A

CLAMP TUBE(S)

RUBBER

ELBOW

RAIN PORT

ED HOSE CLAMP

_T'TUBE 1 GREEN HOSE

_ CLAMPS

(3 PLACES)

_HOSE B

_ SIDE PANEL

GROMMET

HOLES

DRAIN TRAP

Upright "Alternate" Connections - Right Side Only

(Upflow Shown, Counterflow Similar)

For details concerning mounting of the drain trap, refer to the fol-

lowing section.

UPRIGHT DRAIN TRAP MOUNTING (LEFT OR RIGHT SIDE PANEL,}

1. Insert drain tubes into drain trap and position the drain trap

against the side panel. NOTE: Drain tubes must reach the

bottom of the drain trap.

2. Secure drain trap to side panel at the mounting holes

(dimples or crosshairs on counterfiow models) located

below the grommet drain holes.

3. Attach PVC drain line to drain trap outlet with either a 90 °

elbow or coupling.

HORIZONTAL INSTALLATIONS

RIGHT SIDE DOWN

Horizontal installations with the right side down require that the

drain hoses be connected to the right side front cover drain port

and the rubber elbow drain port.

NOTE: On counterflow models, relocation of the front cover pressure

switch hose is required.

Make connections as follows:

1. Remove the rubber plug from the coil front cover drain port.

Counterflow furnaces

Relocate the front cover pressure switch hose connection

from the left side pressure tap to the right (down) side tap.

The pressure switch hose must be connected to the down

side to guard against blocked drain conditions. Cut hose

to appropriate length to minimize sagging. Plug left

(unused) pressure tap with plug removed from right side.

2. Secure Hose A to front cover drain tap with a red hose clamp.

Route hose to rear right (down) side panel grommet holes.

3. Cut 1/4 inch from the end of the drain port on the rubber

elbow and discard.

4. Insert Tube 1 into rubber elbow drain port and secure with

a red hose clamp. Angle tube outward toward front of

furnace.

5. Cut 17 3/4 inches from the long end of Hose B and discard.

6. Secure remaining end of Hose B to exposed end of Tube 1

with a green hose clamp. Route hose to front right down

side panel grommet holes.

7. Cut 5 1/2 inches straight length from the long end of each

Tube 2.

FRONT COVER

DRAIN PORT

RED HOSE

HOSE A CLAMP

HOSE B

SIDE PANEL

GROMMET

HOLE

FRONT

• COVER

PRESSURE RUBBER

TAP _, ELBOW

".'i . RIGHT

_ SIDE

PANEL

RUBBERELBOW

GREEN _BE 1 _ DRAIN PORT

HOSE T RED HOSE

CLAMP CLAMP

Horizontal Connections =Right Side Down

(Upflow Shown, Counterflow Similar)

8. Insert approximately one inch of each Tube 2 through the

right down side panel grommet holes• Secure tubes to

HoseAand Hose B using green hose clamps• Ensure

hoses and tubes maintain a downward slope for proper

drainage and are not kinked or bound•

For details concerning mounting of the drain trap, refer to Section

X, Condensate Drain Lines and Drain Trap -Upright Drain Trap

Mounting.

LEFT SIDE DOWN

Horizontal installations with the left side panel down will require

drain hoses to be connected to the left side front cover drain port

and the side drain port on the rubber elbow.

Remove the rubber plug from the coil front cover left (down)

side drain port.

Relocate the front cover pressure switch hose connection

from the right side (as shipped) pressure tap to the left

(down) side tap. The pressure switch hose must be

connected to the down side to guard against blocked drain

conditions• Cut hose to appropriate length to minimize

sagging. Plug right (unused) pressure tap with plug

removed from left side.

Secure Hose A to front cover drain port with a red hose

clamp. Route hose to rear left (down) side panel grommet

holes• NOTE: For left side drainage, grommets must be

relocated to left side panel•

oseA

I " _ "_::_p,._-_ -- GREEN HOSE

II__h/ /CLAMPS

"1 j /' ;C_=_//. _ (3 PLACES)

LEFT SIDE _ I" '// ' '_J_:_TUBE(S) 2

PANEL FRONT COVERJ / //

DRAIN PORT /£_

RED HOSE CLAMP SIGID%i_A2EE_TTL_._/DRAIN TRAP

HOLES

Horizontal Connections =Left Side Down

(Upflow Shown, Counterflow Similar)

4. Remove the rubber cap from the side drain port on the rubber

elbow.

5. Secure the short end of Hose B to rubber elbow side drain

port using a green hose clamp. NOTE: For left side drainage,

route hose to far left (down) side panel grommet holes.

NOTE: Horizontal left side connections (when using new

side port drain elbow) does not require connecting a hose

to the induced draft blower housing•

6. Cut 5 1/2 inches straight length from the long end of each

Tube 2.

7. Insert approximately one inch of each Tube 2 through left

side panel grommet hole. Secure tubes to HoseA and

Hose B with a green hose clamps. NOTE: Tube must

reach bottom of trap. Ensure hoses and tubes maintain a

downward slope for proper drainage and that they are not

kinked or binding.

For details concerning mounting of the drain trap, refer to Section

X, Condensate Drain Lines and Drain Trap -Upright Drain Trap

Mounting.

HORIZONTAL DRAIN TRAP MOUNTING (LEFT OR RIGHT SIDE PANEL)

1. Position the drain trap against side panel with drain tubes

inserted into trap. Note that the trap may be orientated with

the outlet facing either the furnace's top cover or base pan.

2. Secure drain trap to side panel at the dimples or crosshairs

located on either side of the grommet drain holes.

3. Confirm that tubes reach bottom of drain trap and that all

hoses maintain a downward slope and are not kinked or

binding.

4. Attach PVC drain line to drain trap outlet with either a 90 °

elbow or coupling.

Xl. ELECTRICAL CONNECTIONS

,_ WARNING

HIGH VOLTAGE!

To AVOID THE RISK OF ELECTRICAL SHOCK_WIRING TO

THE UNIT MUST BE POLARIZED AND GROUNDED.

,_ll, WARNING

HIGH VOLTAGE! _ _1_

To AVOID PERSONAL INJURY OR DEATH DUE TO

ELECTRICAL SHOCK_DISCONNECT ELECTRICAL POWER

BEFORE SERVICING OR CHANGING ANY ELECTRICAL

WIRING,

i_# CAUTION

LABEL ALL WIRES PRIOR TO DISCONNECTION WHEN SERVICING

CONTROLS, WIRING ERRORS CAN CAUSE IMPROPER AND

DANGEROUS OPERATION. VERIFY PROPER OPERATION AFTER

SERVICING.

WIRING HARNESS

The wiring harness is an integral part of this furnace. Field alter-

ation to comply with electrical codes should not be required. Wires

are color and number coded for identification purposes• Refer to

the wiring diagram for wire routings. If any of the original wire as

supplied with the furnace must be replaced, it must be replaced

with wiring material having a temperature rating of at least 105°C.

Any replacement wiring must be copper conductor.

11 5 VOLT LINE CONNECTIONS

Before proceeding with electrical connections, ensure that the sup-

ply voltage, frequency, and phase correspond to that specified on

the unit rating plate. Power supply to the furnace must be N.E.C.

Class 1, and must comply with all applicable codes. The furnace

must be electrically grounded in accordance with local codes or, in

their absence, with the latest edition of The National Electric Code,

ANSi NFPA 70 and/or The Canadian Electric Code CSA C22.1.

Use a separate fused branch electrical circuit containing properly

sized wire, and fuse or circuit breaker. The fuse or circuit breaker

must be sized in accordance with the maximum overcurrent pro-

tection specified on the unit rating plate. An electrical disconnect

must be provided at the furnace location.

Connect hot, neutral, and ground wires as shown in the wiring

diagram located on the unit's blower door. For direct vent applica-

tions, the cabinet opening to the junction box must be sealed air

tight using either an UL approved bushing such as Heyco Liquid

Tight or by applying non-reactive UL approved sealant to bushing.

Line polarity must be observed when making field connections.

Line voltage connections can be made through either the right or

left side panel. The furnace is shipped configured for a left side

(right side for counterflows) electrical connection with the junction

box located inside the burner compartment. To make electrical

connections through the opposite side of the furnace, the junction

box must be relocated to the other side of the burner compartment

prior to making electrical connections. To relocate the junction box,

follow the steps shown below.

NOTE: Wire routing must not to interfere with circulator blower

operation, filter removal, or routine maintenance.

,_li, WARNING

EDGES OF SHEET METAL HOLES MAY BE SHARP. USE GLOVES AS A

PRECAUTION WHEN REMOVING HOLE PLUGS.

1. Remove the burner compartment door.

2. Remove and save the two screws securing the junction box

to the side panel.

3. Relocate junction box and associated plugs and grommets

to opposite side panel. Secure with screws removed in

step 2.

STANDARD

JUNCTION BOX

LOCATION

Junction Box Relocation

ALTERNATE

JUNCTION BOX

LOCATION

,_ll, WARNING

HIGH VOLTAGE! _ e

To AVOID THE RISK OF INJURY_ELECTRICAL SHOCK OR

DEATH_THE FURNACE MUST BE ELECTRICALLY

GROUNDED IN ACCORDANCE WITH LOCAL CODES OR IN

THEIR ABSENCE, WITH THE LATEST EDITION OF THE

NATIONAL ELECTRIC CODE.

To ensure proper unit grounding, the ground wire should run from

the furnace ground screw located inside the furnace junction box

all the way back to the electrical panel. NOTE: Do not use gas

piping as an electrical ground. To confirm proper unit grounding,

turn off the electrical power and perform the following check.

1. Measure resistance between the neutral (white) connection

and one of the burners.

2. Resistance should measure 10 ohms or less.

This furnace is equipped with a blower door interlock switch which

interrupts unit voltage when the blower door is opened for servic-

ing. Do not defeat this switch.

24 VOLT THERMOSTAT WIRING

NOTE: Wire routing must not interfere with circulator blower

operation, filter removal, or routine maintenance.

As a two-stage furnace, the furnace integrated control module pro-

vides terminals for both "WI" and "W2", and "YLO" and "Y" thermo-

stat connections. This allows the furnace to support the following

system applications: 'Two-Stage Heating Only', 'Two-Stage Heat-

ing with Single-Stage Cooling', and 'Two-Stage Heating with Two-

Stage Cooling'. Refer to the following figures and table for proper

connections to the integrated control module.

Low voltage connections can be made through either the right or

left side panel. Thermostat wiring entrance holes are located in the

blower compartment. Wire routing must not interfere with circula-

tor blower operation, filter removal, or routine maintenance.

Furn_{ce Integrated

,____i

.... ", ,*" De_umidistat

[Optional]

Remote

Condensing Unit

(Single Stage Cooling)

Single-Stage Heating with Single-Stage Cooling

NOTE: To apply a single stage heating thermostat the

thermostat selector jumper on tl_e integrated Contro_

module must be set on single stage

Thermostat

Two-Sta%Heat,o_)

Single-Stage Coolin

•[------", ,/* Dehumidistat

_ [Optiona,]

Remote

Condensing Unit

(Single-Stage Cooling)

Two-Stage Heating with Single-Stage Cooling

__ Thermostat

Tw°-StavgthHeating )

Two-Stage Cooling

IG Go G G d

_ ;_ ,I__.'@/ [Optinoidia:t]at

Remote

Condensing Unit

(Two-Stage Cooling)

Two-Stage Heating with Two-Stage Cooling

Thermostat Diagrams

This furnace is equipped with a 40 VA transformer to facilitate use

with most cooling equipment. Consult the wiring diagram, located

on the blower compartment door, for further details of 115 Volt and

24 Volt wiring.

SINGLE-STAGE THERMOSTAT APPLICATION

A single-stage thermostat with only one heating stage can be used

to control this furnace. The application of a single-stage thermo-

stat does not offer "true" thermostat-driven two-stage operation,

but provides a timed transition from low to high fire. The furnace

will run on low stage for a fixed period of time before stepping up to

high stage to satisfy the thermostat's call for heat. The delay pe-

riod prior to stepping up can be set at either 5 or 10 minutes through

the DIP switch adjacent to the Heat Off delay DIP switches on the

integrated control module. To use a single-stage thermostat, turn

off power to the furnace, move the thermostat selection jumper on

the integrated control module from the "two-stage" position to the

"single-stage" position, turn power back on. Refer to the following

figures.

T T-Star selection jumper in

W ingle-stage thermostat

_ositioo

N ON s

LDIP switch position 3: ON "DIP switch position 3: OFF

Delay Period: 10 minutes. Delay Period: 5 minutes.

24 VOLT D EHUMIDISTAT WIRING

The optional usage of a dehumidistat allows the furnace's circula-

tor blower to operate at a slightly lower speed during a combined

thermostat call for cooling and dehumidistat call for dehumidifica-

tion. This lower blower speed enhances dehumidification of the

conditioned air as it passes through the AC coil. For proper func-

tion, a dehumidistat applied to this furnace must operate on 24

VAC and utilize a switch which opens on humidity rise.

To install/connect a dehumidistat:

1. Turn OFF power to furnace.

2. Secure the dehumidistat neutral wire (typically the white

lead) to the screw terminal marked "DEHUM" on the furnace

integrated control module.

3. Secure the dehumidistat hot wire (typically the black lead)

to the screw terminal marked "R" on the furnace integrated

control module.

4. Secure the dehumidistat ground wire (typically the green

lead) to the ground screw on the furnace junction box. NOTE:

Ground wire may not be present on all dehumidistats.

5. Turn ON power to furnace.

To enable the dehumidify function on the integrated control mod-

ule:

1. Cut the jumper wire labeled "CUT FOR DEHUM" located

adjacent to the DEHUM screw terminal.

Once the jumper wire is cut, the dehumidify function is enabled

during a combination call for cooling (T-Stat) and dehumidification

(Dehum-Stat). The yellow LED adjacent to the DEHUM screw ter-

minal will be illuminated during dehumidification.

DEHUMIDIFICATION

LED(YELLOW)

DEHUMIDIFICATION

JUMPER WIRE

(CUTTO ENABLE)

FOSSIL FUEL APPLICATIONS

This furnace can be used in conjunction with a heat pump in a

fossil fuel application. A fossil fuel application refers to a combined

gas furnace and heat pump installation which uses an outdoor

temperature sensor to determine the most cost efficient means of

heating (heat pump, gas furnace, or both).

A heat pump thermostat with three stages of heat is required

to properly use a two-stage furnace in conjunction with a heat

pump. Refer to the fossil fuel kit installation instructions for

additional thermostat requirements.

Strictly follow the wiring guidelines in the fossil fuel kit installa-

tion instructions. All furnace connections must be made to the

furnace two-stage integrated control module and the "FUR-

NACE" terminal strip on the fossil fuel control board.

1 15 VOLT LINE CONNECTION OF ACCESSORIES (HUMIDIFIER

AND ELECTRONIC AIR CLEANER)

_WARNING

HIGH VOLTAGE! _ e

To AVOID PERSONAL INJURY OR DEATH DUE TO

ELECTRICAL SHOCK_DISCONNECT ELECTRICAL POWER

BEFORE SERVICING OR CHANGING ANY ELECTRICAL

WIRING.

The furnace's integrated control module is equipped with line volt-

age accessory terminals for controlling power to an optional field-

supplied humidifier and/or electronic air cleaner.

The accessory load specifications are as follows:

t Humidifier 1 .O Amp maximum at 120 VAC J

Electronic Air Cleaner 1.0 Amp maximum at 120 VAC

Turn OFF power to the furnace before installing any accessories.

Follow the humidifier or air cleaner manufacturers' instructions for

locating, mounting, grounding, and controlling these accessories.

Accessory wiring connections are to be made through the 1/4"

quick connect terminals provided on the furnace integrated control

module. The humidifier and electronic air cleaner hot and neutral

terminals are identified as HUM and EAC. All field wiring must

conform to applicable codes. Connections should be made as

shown.

12 CIRCUITCONNECTOR

INTEGRATED

CONTROL MODULE

OPTIONAL ACCESSORIES

Accessories Wiring

If it is necessary for the installer to supply additional line voltage

wiring to the inside of the furnace, the wiring must conform to all

local codes, and have a minimum temperature rating of 105°C. All

line voltage wire splices must be made inside the furnace junction

box.

The integrated control module humidifier terminals (HUM) are en-

ergized with 115 volts whenever the induced draft blower is ener-

gized. The integrated control module electronic air cleaner termi-

nals (EAC) are energized with 115 volts whenever the circulator

blower is energized.

24 VOLT HUMiDiFIER

A 5" long brown wire in the wire harness at the low fire pressure

provides 24 VAC humidifier control. This wire is powered any time

the pressure switch is closed. To connect 24 VAC HUM, connect

the 24 VAC line of the humidifier to the 5" brown wire. The connec-

tion can be made by either stripping the wire and using a wire nut

or by using a field supplied quick connect terminal. The wiring

must conform to all local and national codes. Connect the COM

side of the humidifier to the B/C terminal on the furnace control

board (or to the COM side of the 24 VAC transformer). Do not

connect 115V humidifier to these terminals.

Xll, GAS SUPPLYAND PIPING

GENERAL

The furnace rating plate includes the approved furnace gas input

rating and gas types. The furnace must be equipped to operate on

the type of gas applied. This includes any conversion kits required

for alternate fuels and/or high altitude.

_, CAUTION

TO PREVENT UNRELIABLE OPERATION OR EQUIPMENT DAMAGE, THE

INLET GAS SUPPLY PRESSURE MUST BE AS SPECIFIED ON THE UNIT

RATING PLATE WITH ALL OTHER HOUSEHOLD GAS FIRED APPLIANCES

OPERATING.

Inlet gas supply pressures must be maintained within the ranges

specified below. The supply pressure must be constant and avail-

able with all other household gas fired appliances operating. The

minimum gas supply pressure must be maintained to prevent

unreliable ignition. The maximum must not be exceeded to pre-

vent unit overfiring.

Inlet Gas Supply Pressure

Natural Gas Minimum:5.0" W.C. Maximum :10.0" W.C.

PropaneGas Mnmum:11.0 W.C. Max mum :13.0 W.C.

HIGH ALTITUDE DERATE

When this furnace is installed at high altitude, the appropriate High

Altitude orifice kit must be applied. This is required due to the

natural reduction in the density of both the gas fuel and combus-

tion air as altitude increases. The kit will provide the proper design

certified input rate within the specified altitude range.

High altitude kits are purchased according to the installation alti-

tude and usage of either natural or propane gas. Contact your

distributor for a tabular listing of appropriate altitude ranges and

corresponding manufacturer's high altitude (Natural, propane gas,

and/or Pressure Switch) kits.

Do not derate the furnace by adjusting the manifold pressure to a

lower pressure than specified on the furnace rating plate. The

combination of the lower air density and a lower manifold pressure

will prohibit the burner orifice from drawing the proper amount of

air into the burner. This may cause incomplete combustion, flash-

back, and possible yellow tipping.

In some areas the gas supplier may artificially derate the gas in an

effort to compensate for the effects of altitude. If the gas is artifi-

cially derated, the appropriate orifice size must be determined

based upon the BTU/ft 3 content of the derated gas and the altitude.

Refer to the National Fuel Gas Code, NFPA 54/ANSI Z223.1, and

information provided by the gas supplier to determine the proper

orifice size.

A different pressure switch may be required at high altitude regard-

less of the BTU/ft 3 content of the fuel used. Contact your distributor

for a tabular listing of appropriate altitude ranges and correspond-

ing manufacturer's pressure switch kits.

PROPANE GAS CONVERSION

i_lb WARNING

POSSIBLE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH MAY

OCCUR IF THE CORRECT CONVERSION KITS ARE NOT INSTALLED. THE

APPROPRIATE KITS MUST BE APPLIED TO ENSURE SAFE AND PROPER

FURNACE OPERATION. ALL CONVERSIONS MUST BE PERFORMED BY

A QUALIFIED INSTALLER OR SERVICE AGENCY.

This unit is configured for natural gas. The appropriate

manufacturer's propane gas conversion kit, must be applied for

propane gas installations. Refer to the Section WII, Propane Gas

/ High Altitude Instaflationa section for details.

GAS VALVE

This unit is equipped with a 24 volt gas valve controlled during

furnace operation by the integrated control module. As shipped,

the valve is configured for natural gas. The valve is field convertible

for use with propane gas by replacing the regulator spring with a

propane gas spring from an appropriate manufacturer's propane

gas conversion kit. Taps for measuring the gas supply pressure

and manifold pressure are provided on the valve.

The gas valve has a manual ON/OFF control located on the valve

itself. This control may be set only to the "ON" or "OFF" position.

Refer to the lighting instructions label or Section XIV,, Startup Pro-

cedure & Adjustment for use of this control during start up and shut

down periods.

GAS PiPiNG CONNECTIONS

GENERAL

i_lj CAUTION

TO AVOID POSSIBLE UNSATISFACTORY OPERATION OR EQUIPMENT

DAMAGE DUE TO UNDERFIRING OR EQUIPMENT, USE THE PROPER

SIZE OF NATURAL/PROPANE GAS PIPING NEEDED WHEN RUNNING

PIPE FROM THE METER/TANK TO THE FURNACE.

When sizing a trunk line, be sure to include all appliances which

will operate simultaneously when sizing a trunk line.

The gas piping supplying the furnace must be properly sized based

on the gas flow required, specific gravity of the gas, and length of

the run. The gas line installation must comply with local codes, or

in their absence, with the latest edition of the National Fuel Gas

Code, NFPA 54/ANSI Z223.1.

Natural Gas Capacity of Pipe

In Cubic Feet of Gas Per Hour (CFH)

Length of Nominal Btack Ripe Size

Ripe in Feet 1/2" 3/4" 1" 1 1/4" 1 1/2"

10 132 278 520 1050 1600

20 92 190 350 730 1100

30 73 152 285 590 980

40 63 130 245 500 760

50 56 115 215 440 670

60 50 105 195 400 610

70 46 96 180 370 560

80 43 90 170 350 530

90 40 84 160 320 490

100 38 79 150 305 460

Pressure 0.5 psig or tess and pressure drop of 0.3" WC; Based OR

060 Specific Gravity Gas)

CFH = BTUH Furnace Input

Heating VaIue of Gas (BTU/Cubic Foot)

To connect the furnace to the building's gas piping, the installer

must supply a ground joint union, drip leg, manual shutoff valve,

and line and fittings to connect to gas valve. In some cases, the

installer may also need to supply a transition piece from 1/2" pipe

to a larger pipe size.

The following stipulations apply when connecting gas piping. Re-

fer to Gas Piping Connections figure for typical gas line connec-

tions to the furnace.

" Use black iron or steel pipe and fittings for building piping.

Where possible, use new pipe that is properly chamfered,

reamed, and free of burrs and chips. If old pipe is used, be

sure it is clean and free of rust, scale, burrs, chips, and old

pipe joint compound.

°Use pipe joint compound on male threads ONLY. Always

use pipe joint compound (pipe dope) that is APPROVED

FOR ALL GASSES. DO NOT apply compound to the first two

threads.

°Use ground joint unions.

" Install a drip leg to trap dirt and moisture before it can enter

the gas valve. The drip leg must be a minimum of three

inches long.

" Install a 1/8" NPT pipe plug fitting, accessible for test gage

connection, immediately upstream of the gas supply

connection to the furnace.

" Always use a back-up wrench when making the connection

to the gas valve to keep it from turning. The orientation of

the gas valve on the manifold must be maintained as

shipped from the factory. Maximum torque for the gas valve

connection is 375 in-lbs; excessive over-tightening may

damage the gas valve.

" Install a manual shutoff valve between the gas meter and

unit within six feet of the unit. If a union is installed, the

union must be downstream of the manual shutoff valve,

between the shutoff valve and the furnace.

" Tighten all joints securely.

Connect the furnace to the building piping by one of the

following methods:

-- Rigid metallic pipe and fittings.

-- Semi-rigid metallic tubing and metallic fittings.

Aluminum alloy tubing must not be used in exterior

locations. In order to seal the grommet cabinet

penetration, rigid pipe must be used to reach the

outside of the cabinet. A semi-rigid connector to the

gas piping may be used from there.

Use listed gas appliance connectors in accordance with

their instructions. Connectors must be fully in the same

room as the furnace.

Protect connectors and semirigid tubing against physical

and thermal damage when installed. Ensure aluminum-

alloy tubing and connectors are coated to protect against

external corrosion when in contact with masonry, plaster, or

insulation, or subjected to repeated wetting by liquids such

as water (except rain water), detergents, or sewage.

_Rc,_r_J_r_zJ

e_r_E_s

UPFLOW COUNTERFLOW

........... /;;;_>_:_%

HORIZONTAL [UPFLOW MODEL]

NOTES 1 WHEN GAS LINE IS IN THE ALTERNATE

LOCATION SWAP THE POSITION OF

THE PLUG AND GROMMET

HORIZONTAL[COUNTERFLOW]

2 DRIP LEG MAY TERMINATE WITH

A 1/2" X 1/8" PIPE PLUG TO

ACCOMMODATE LINE GAS

PRESSURE MEASUREMENT

Gas Piping Connections

_WARNING

EDGES OF SHEET METAL HOLES MAY BE SHARP. USE GLOVES AS A

PRECAUTION WHEN REMOVING HOLE PLUGS.

DIRECT/STANDARD _NLET PIPING

When gas piping enters directly to the gas valve through the stan-

dard inlet hole, the installer must supply straight pipe with a ground

joint union to reach the exterior of the furnace. The rigid pipe must

be long enough to reach the outside of the cabinet to seal the

grommet cabinet penetration. A semi-rigid connector to the gas

piping can be used outside the cabinet per local codes.

INDIRECT/ALTERNATE INLET P/PING

When gas piping enters indirectly to the gas valve through the

alternate gas inlet hole the following fittings (starting from the gas

valve) to reach the outside of the cabinet must be supplied:

*Coupling.

" 90 degree elbow.

*2 inch close nipple.

" 90 degree elbow.

*Straight pipe, with a ground joint union, to reach the exterior

of the furnace. The rigid pipe must be long enough to reach

the outside of the cabinet so as to seal the grommet cabinet

penetration. A semi-rigid connector to the gas piping can

be used outside the cabinet per local codes.

GAS P/PING CHECKS

Before placing unit in operation, leak test the unit and gas connec-

tions.

,_ WARNING

TO AVOID THE POSSIBILITY OF EXPLOSION OR FIRE, NEVER USE A

MATCH OR OPEN FLAME TO TEST FOR LEAKS.

Check for leaks using an approved chloride-free soap and water

solution, an electronic combustible gas detector, or other approved

testing methods.

NOTE: Never exceed specified pressures for testing. Higher

pressure may damage the gas valve and cause subsequent

overfiring, resulting in heat exchanger failure.

Disconnect this unit and shutoff valve from the gas supply piping

system before pressure testing the supply piping system with pres-

sures in excess of 1/2 psig (3.48 kPa).

Isolate this unit from the gas supply piping system by closing its

external manual gas shutoff valve before pressure testing supply

piping system with test pressures equal to or less than 1/2 psig

(3.48 kPa).

PROPANE GAS TANKS AND PIPING

_WARNING

IF THE GAS FURNACE IS INSTALLED IN A BASEMENT, AN EXCAVATED

AREA OR A CONFINED SPACE_ IT IS STRONGLY RECOMMENDED TO

CONTACT A PROPANE SUPPLIER TO INSTALL A GAS DETECTING

WARNING DEVICE IN CASE OF A GAS LEAK.

• SINCE PROPANE GAS IS HEAVIER THAN AIR_ ANY LEAKING AS CAN

SETTLE IN ANY LOW AREAS OR CONFINED SPACES.

• PROPANE GAS ODORANT MAY FADE_ MAKING THE GAS

UNDETECTABLE EXCEPT FOR WITH A WARNING DEVICE.

A gas detecting warning system is the only reliable way to detect a

propane gas leak. Rust can reduce the level of odorant in propane

gas. Do not rely on your sense of smell. Contact a local propane

gas supplier about installing a gas detecting warning system. If

the presence of gas is suspected, follow the instructions on Page

4 of this manual.

All propane gas equipment must conform to the safety standards

of the National Board of Fire Underwriters, NBFU Manual 58.

For satisfactory operation, propane gas pressure must be 11 inch

w.c. at the furnace manifold with all gas appliances in operation.

Maintaining proper gas pressure depends on three main factors:

1. Vaporization rate, depending on temperature of the liquid,

and "wetted surface" area of the container or containers.

2. Proper pressure regulation. (Two-stage regulation is

recommended for both cost and efficiency).

3. Pressure drop in lines between regulators, and between

second stage regulator and the appliance. Pipe size will

depend on length of pipe run and total load of all appliances.

Complete information regarding tank sizing for vaporization, rec-

ommended regulator settings, and pipe sizing is available from

most regulator manufacturers and propane gas suppliers.

Since propane gas will quickly dissolve white lead and most stan-

dard commercial compounds, special pipe dope must be used.

Shellac-based compounds resistant to the actions of liquefied pe-

troleum gases such as Gasolac _, Stalactic ®, Clyde's ® or John

Crane ® are satisfactory.

Refer to the following illustration for typical propane gas installa-

tions.

5to t5 PSIG

F_ ;tu Sttagre (20 PS,G Max) Conti .....

_ _200 PStG Second Stage

Propane Gas Installation (Typ.)

Sizing Between First and Second Stage Regulator*

Maximum Propane Capacities listed are based or_ 2 psEg pressure drop at 10 psEg setting

Capacities ir_ I 000 BTU hour

Pipe or Nominal Pipe Size

Tubing Tubing Size, O.D. Type L Schedule 40

Length

Feet 3/8" 112" 5/8" 3/4" 7/8" 1/2" 3/4"

10 730 1,700 3,200 5,300 8.300 3,200 7,500

20 500 1,100 220 3,700 5,800 2,200 4,200

30 400 920 2,000 2,900 4.700 1,800 4,500

40 370 850 1,700 2,700 4.100 1,600 3,700

50 330 770 1,500 2,400 3.700 1,500 3,400

60 300 700 1,300 2,200 3.300 1,300 3,100

80 280 610 1,200 1,900 2,900 1,200 2,600

100 220 540 1,000 1,700 2,600 1,000 2,300

125 200 490 900 1,400 2.300 900 2,100

150 190 430 830 1,300 2.100 830 1,900

175 170 400 780 1,200 1.900 770 1,700

200 160 380 730 1,100 1.800 720 1,500

To convert to capacities at 15 psig settings - multiply by 1 130

To convert to capacities at 5 psig settings - multiply by 0¸879

Propane Gas Piping Chart I

Sizing Between Second or Second Stage Regulator & Appliance*

Maximum Propane Capacities listed are based on 1/2" WC pressure drop at 1l'r WC setting

Capacities in 1,000 BTU/hour

Pipe or Nominal Pipe Size

Tubing Tubing Size, O.D. Type L Schedule 40

Length

Feet 3/8" 112" 5/8" 3/4" 7/8" 1/2" 314" 1" 1-1/4" 1=1/2"

10 39 92 199 329 501 275 567 1,071 2,205 3,307

20 28 62 131 216 346 189 393 732 1,496 2,299

30 21 50 107 181 277 152 315 590 1,212 1,858

40 19 41 90 145 233 129 267 504 1,039 1,559

50 18 37 79 131 198 114 237 448 913 1,417

60 18 35 72 1,211 187 103 217 409 834 1,275

80 13 29 62 104 155 89 185 346 724 1,066

100 11 26 55 90 138 78 162 307 630 976

125 10 24 48 81 122 69 146 275 587 886

150 9 21 43 72 109 63 132 252 511 787

200 8 19 39 86 100 54 112 209 439 885

250 8 17 36 80 93 48 100 185 390 590

*Datain accordance with NPPA pamphlet No54

Propane Gas Piping Chart II

XilLCIRCULATINGAIR&FILTERS

DUCTWORK -AIR FLOW

Duct systems and register sizes must be properly designed for the

CFM and external static pressure rating of the furnace. Design the

ductwork in accordance with the recommended methods of "Air

Conditioning Contractors of America" Manual D.

Install the duct system in accordance with Standards of the Na-

tional Board of Fire Underwriters for the Installation of Air Condi-

tioning, Warm Air Heating and Ventilating Systems. Pamphlets No.

90A and 90B.

A closed return duct system must be used, with the return duct

connected to the furnace. NOTE: Ductwork must never be attached

to the back of the furnace. Flexible joints may be used for supply

and return connections to reduce noise transmission. To prevent

the blower from interfering with combustion air or draft when a

central return is used, a connecting duct must be installed be-

tween the unit and the utility room wall. Never use a room, closet,

or alcove as a return air chamber.

BOTTOM RETURN AIR OPENING [UPFLOW MODELS]

The bottom return air opening on upflow models utilizes a "lance

and cut" method to remove sheet metal from the duct opening in

the base pan. To remove, simply press out the lanced sections by

hand to expose the metal strips retaining the sheet metal over the

duct opening. Using tin snips, cut the metal strips and remove the

sheet metal covering the duct opening. In the corners of the open-

ing, cut the sheet metal along the scribe lines to free the duct

flanges. Using the scribe line along the duct flange as a guide,

unfold the duct flanges around the perimeter of the opening using

a pair of seamer pliers or seamer tongs. NOTE: Airflow area will be

reduced by approximately 18% if duct flanges are not unfolded.

This could cause performance issues and noise issues.

,_ WARNING

EDGES OF SHEET METAL MAY BE SHARP. USE GLOVES AS A PRECAUTION

WHEN REMOVING SHEET METAL FROM THE DUCT OPENING,

viewed for visual light inspection or such that a sampling probe

can be inserted into the airstream. The access panel must be

made to prevent air leaks when the furnace is in operation.

When the furnace is heating, the temperature of the return air en-

tering the furnace must be between 55°F and 100°F.

FILTERS - READ THIS SECTION BEFORE INSTALLING THE

RETURN AiR DUCTWORK

0453 XA

Filters must be used with this furnace. Discuss filter maintenance

with the building owner. Filters do not ship with this furnace, but

must be provided by the installer. Filters must comply with UL900

or CAN/ULCS111 standards. If the furnace is installed without fil-

ters, the warranty will be voided.

On upflow units, guide dimples locate the side return cutout loca-

tions. Use a straight edge to scribe lines connecting the dimples.

Cut out the opening on these lines. NOTE: An undersized opening

will cause reduced airflow.

Refer to Minimum Filter Area tables to determine filter area require-

ments.

UPFLOW J

COOLING AIRFLOW REQUIREMENT (CFM)

I.ool I,ooo1,2ooIt4oo1,6oo12oooI

376* 384 480 576 .........

0704 XA ...... 627* 627* 672 768 ---

0905 XA

1155 XA

......... 836* 836* 836* 960

......... 940* 940* 940* 960

COUNTERFLOW

COOLING AIRFLOW REQUIREMENT (CFM)

I.ool6ooI,ooo1,2oo1,4oo1,6ooI oooI

...... 320* 320* 336 384 ---

...... 427* 427* 427* 480

CUT USING TiN SNIPS

PRESS OUT BY HAND

*Minimum filter area dictated by heating airflow requirement.

Permanent Minimum Filter Area (sq. in)

[Based on a 600 ft/min filter face velocity]

UPFLOW

COOLING AIRFLOW REQUIREMENT (CFM)

6001 I,oooI, oo1,4oo1,6ooI ooo

CUT FOUR CORNERS

AFTER REMOVING SHEET

METAL

SCRIBE LINES OUTLINING

DUCT FLANGES

0453XA 376* 384 480 576 .........

i0704 XA ...... 564* 564* 672 768

I 0905 XA ......... 752* 752* 768 960

-- 1155 XA ......... 940* 940* 940* 960

Duet Flange Cut Outs

When the furnace is used in connection with a cooling unit, the

furnace should be installed in parallel with or on the upstream side

of the cooling unit to avoid condensation in the heating element.

With a parallel flow arrangement, the dampers or other means

used to control the flow of air must be adequate to prevent chilled

air from entering the furnace and, if manually operated, must be

equipped with means to prevent operation of either unit unless the

damper is in the full heat or cool position.

When the furnace is installed without a cooling coil, it is recom-

mended that a removable access panel be provided in the outlet

air duct. This opening shall be accessible when the furnace is

installed and shall be of such a size that the heat exchanger can be

"_ _o 0704 XA

i _ 0905 XA

COUNTERFLOW

COOLING AIRFLOW REQUIREMENT (CFM)

6001.oi,oooi, ooi,4ooi,6oo12ooo

...... 641" 64!* 672 768 ---

......... 854* 854* 854* 960

*Minimum filter area dictated by heating airflow requirement.

Disposable Minimum Filter area (sq. in)

[Based on 300 ft/min filter face velocity]

UPRIGHT _NSTALLATIONS

Depending on the installation and/or customer preference, differ-

ing filter arrangements can be applied. Filters can be installed in

the central return register or a side panel external filter rack kit

(upflows). As an alternative a media air filter or electronic air cleaner

can be used as the requested filter.

The following figure shows possible filter locations.

CENTRAL

RETURN

j GRILLE

SIDE_TURN

EXTERNALFILTER

__RACK KIT

FILTER_

ACCESS

DOOR

AIRFLOW RETURN -jj

,_ DUCT

FILTER /

SUPPORT

BRACKET

(PROVIDED)

Possible Upright Upflow

Counterflow

Filter Locations

I '

CIENIilR'AL i?.3u "N

AIR FLOW

Possible Upright

NOTE: Internal filter retention is not provided on this furnace. If an

internal installation is desired, an internal filter retention kit is avail-

able as an accessory. Please see your distributor for details.

HORIZONTAL INSTALLATIONS

Filters must be installed in either the central return register or in the

return air duct work.

XiV. STARTUP PROCEDURE &ADJUSTMENT

Furnace must have a 115 VAC power supply properly connected

and grounded. Proper polarity must be maintained for correct op-

eration. In addition to the following start-up and adjustment items,

refer to further information in Section XVI, Operational Checks.

HEAT ANTICIPATOR SETTING

The heat anticipator in the room thermostat must be correctly ad-

justed to obtain the proper number of cycles per hour and to pre-

vent "overshooting" of the setting. Set the heat anticipator setting to

0.7 amps. Follow the thermostat manufacturer's instructions on

how to adjust the heat anticipator setting.

DRAIN TRAP PRIMING

The drain trap must be primed prior to furnace startup. To prime, fill

the drain trap with water. This ensures proper furnace drainage

upon startup and prohibits the possibility of flue gases escaping

through the drain system.

FURNACE OPERATION

Purge gas lines of air prior to startup. Be sure not purge lines into

an enclosed burner compartment.

Check for leaks using an approved chloride-free soap and water

solution, an electronic combustible gas detector, or other approved

method. Verify that all required kits (propane gas, high altitude,

etc.) have been appropriately installed.

FURNACE STARTUP

1. Close the manual gas shutoff valve external to the furnace.

2. Turn off the electrical power to the furnace.

3. Set the room thermostat to the lowest possible setting.

4. Remove the burner compartment door.

NOTE: This furnace is equipped with an ignition device which

automatically lights the burner. Do not try to light the burner by

hand.

5. Move the furnace gas valve manual control to the OFF

position.

6. Wait five minutes then smell for gas. Be sure check near

the floor as some types of gas are heavier than air.

7. If you smell gas after five minutes, immediately follow the

instructions on page 4 of this manual. If you do not smell

gas after five minutes, move the furnace gas valve manual

control to the ON position.

8. Replace the burner compartment door.

9. Open the manual gas shutoff valve external to the furnace.

10. Turn on the electrical power to the furnace.

11. Adjust the thermostat to a setting above room temperature.

12. After the burners are lit, set the thermostat to desired

temperature.

FURNACE SHUTDOWN

1. Set the thermostat to the lowest setting.

The integrated control will close the gas valve and extinguish

flame. Following a 15 second delay, the induced draft blower

will be de-energized. After a 120, 150, 180 or 210-second

delay period (field selectable delay OFF [90, 120, 150, 180]

plus 30-second ramp down), the circulator blower de-

energizes.

2. Remove the burner compartment door and move the furnace

gas valve manual control to the OFF position.

3. Close the manual gas shutoff valve external to the furnace.

4. Replace the burner compartment door.

GAS SUPPLY PRESSURE MEASUREMENT

_[ll, CAUTION

To PREVENT UNRELIABLE OPERATION OR EQUIPMENT DAMAGE rTHE

INLET GAS SUPPLY PRESSURE MUST BE AS SPECIFIED ON THE UNIT

RATING PLATE WITH ALL OTHER HOUSEHOLD GAS FIRED APPLIANCES

OPERATING.

WH/TE=RODGERS 36G54 GAS VALVE

The line pressure supplied to the gas valve must be within the

range specified below. The supply pressure can be measured at

the gas valve inlet pressure boss or at a hose fitting installed in the

gas piping drip leg. The supply pressure must be measured with

the burners operating. To measure the gas supply pressure, use

the following procedure.

Open to

Atmo._ _here Manometer

Hose _r

l_lIOutlet _ \ High Fire Regulator Regulator

Pressure Boss \Vent

Low Fire

Regulator Adjust

inlet

Pressure Boss

Coaxial Coil

anometer Coil Terminal (HI) Terminal (M)

On/Off Switch Common

Terminal (C)

White-Rodgers Model 36G54 Connected to Manometer

Turn OFF gas to furnace at the manual gas shutoff valve

external to the furnace.

Connect a calibrated water manometer (or appropriate gas

pressure gauge) at either the gas valve inlet pressure boss

or the gas piping drip leg.

Gas Line

Gas

Shutoff

Valve _

To Furnace

Drip Leg Ca_

With

Open To

Manometer Hose

Manometer

Measuring Inlet Gas Pressure (AIt. Method)

NOTE: If measuring gas pressure at the drip leg, a field supplied

hose barb fitting must be installed prior to making the hose

connection. If using the inlet pressure boss on the gas valve, then

use the 36G Valve Pressure Check Kit, Goodman Part No.

0151KOOOOOS.

3. Turn ON the gas supply and operate the furnace and all

other gas consuming appliances on the same gas supply

line.

4. Measure furnace gas supply pressure with burners firing.

Supply pressure must be within the range specified in the

Inlet Gas Supply Pressure table.

Inlet Gas Supply Pressure I

Natural Gas I Minimum: 5.0" w.c. Maximum:10.0" w.c. J

Propane Gasl Minimum: 11.0" w.c. Maximum:13.0" w.c.

If supply pressure differs from table, make the necessary adjust-

ments to pressure regulator, gas piping size, etc., and/or consult

with local gas utility.

5. Turn OFF gas to furnace at the manual shutoff valve and

disconnect manometer. Reinstall plug before turning on

gas to furnace.

6. Turn OFF any unnecessary gas appliances stated in step

GAS MANIFOLD PRESSURE MEASUREMENT AND ADJUSTMENT

_, CAUTION

TO PREVENT UNRELIABLE OPERATION OR EQUIPMENT DAMAGE_ THE

GAS MANIFOLD PRESSURE MUST BE AS SPECIFIED ON THE UNIT

RATING PLATE, ONLY MINOR ADJUSTMENTS SHOULD BE MADE BY

ADJUSTING THE GAS VALVE PRESSURE REGULATOR.

Only small variations in gas pressure should be made by adjust-

ing the gas valve pressure regulator. The manifold pressure must

be measured with the burners operating. To measure and adjust

the manifold pressure, use the following procedure.

1. Turn OFF gas to furnace at the manual gas shutoff valve

external to the furnace.

2. Turn off all electrical power to the system.

3. Back outlet pressure test screw (inlet/outlet pressure boss)

out one turn (counterclockwise, not more than one turn).

4. Attach a hose and manometer to the outlet pressure boss

of the valve.

5. Turn ON the gas supply.

6. Turn on power and energize main (M) solenoid. Do not

energize the HI solenoid.

7. Measure gas manifold pressure with burners firing. Adjust

manifold pressure using the Manifold Gas Pressure table

shown below.

8. Remove regulator cover screw from the low (LO) outlet

pressure regulator adjust tower and turn screw clockwise

to increase pressure, or counterclockwise to decrease

pressure.

9. Energize main (M) solenoid as well as the HI terminal.

10. Remove regulator cover screw from the HI outlet pressure

regulator adjust tower and turn screw clockwise to increase

pressure, or counterclockwise to decrease pressure.

11. Turn off all electrical power and gas supply to the system.

12. Remove manometer hose from outlet pressure boss.

13. Turn outlet pressure test screw in to seal pressure port

(clockwise, 7 in-lb minimum).

14. Turn on electrical power and gas supply to the system.

15. Turn on system power and energize valve.

16. Using a leak detection solution or soap suds, check for

leaks at pressure boss screw. Bubbles forming indicate a

leak. SHUT OFF GASAND FIXALL LEAKS IMMEDIATELY.

NOTE: For gas to gas conversion, consult your dealer for

appropriate conversion.

Manifold Gas Pressure

Gas I Range I Nom inal

Natural Low Stage 1.6 - 2.2" w .c 1.9" w .c.

High Stage 3.2- 3.8" w.c 3.5" w.c.

Propane Low Stage 5.7 - 6.3" w .c 6.0" w .c.

High Stage &7- 10.3"w.c 10.0"w.c.

GAS INPUT RATE MEASUREMENT (NATURAL GAS ONLY)

The gas input rate to the furnace must never be greater than that

specified on the unit rating plate. To measure natural gas input

using the gas meter, use the following procedure.

1. Turn OFF the gas supply to all other gas-burning appliances

except the furnace.

2. While the furnace is operating, time and record one

complete revolution of the smallest gas meter dial.

3. Calculate the number of seconds per cubic foot (sec/ft 3) of

gas being delivered to the furnace. If the dial is a one cubic

foot dial, divide the number of seconds recorded in step 2

by one. If the dial is a two cubic foot dial, divide the number

of seconds recorded in step 2 by two.

4. Calculate the furnace input in BTUs per hour (BTU/hr). Input

equals the sum of the installation's gas heating value and

a conversion factor (hours to seconds) divided by the

number of seconds per cubic foot. The measured input

must not be greater than the input indicated on the unit

rating plate.

EXAMPLE:

Installation's gas heating (HTG) value: 1,000 BTU/ft 3

(Obtained from gas supplier)

Installation's seconds per cubic foot: 34 sec/ft 3

Conversion Factor (hours to seconds): 3600 sec/hr

Input = (Htg. value x 3600) + seconds per cubic foot

Input = (1,000 BTU/ft 3 x 3600 sec/hr) + 34 sec/ft 3

Input = 106,000 BTU/hr

Minor changes to the input rate may be accomplished through mani-

fold pressure adjustments at the gas valve. Refer to Section )(IV,

Startup Procedure and Adjustment -Gas Manifold Pressure Mea-

surement and Adjustment for details. NOTE: The final manifold

pressure cannot vary by more than + 0.3" w.c. from the specified

setting. Consult your local gas supplier if additional input rate

adjustment is required.

5. Repeat steps 2 through 4 on high stage.

6. Turn ON gas to and relight all other appliances turned off in

step 1. Be certain that all appliances are functioning properly

and that all pilot burners are operating.

TEMPERATURE RISE

Temperature rise must be within the range specified on the unit

rating plate. An incorrect temperature rise may result in condens-

ing in or overheating of the heat exchanger. An airflow and tem-

perature rise table is provided in the Specification Sheet applicable

to your model*. Determine and adjust temperature rise as follows:

1. Operate furnace with burners firing for approximately ten

minutes. Ensure all registers are open and all duct

dampers are in their final (fully or partially open) position.

2. Place thermometers in the return and supply ducts as close

to the furnace as possible. Thermometers must not be

influenced by radiant heat by being able to "see" the heat

exchanger.

HEAT EXCHANGER

RADiATiON "LINE OF SIGHT"

@R_SE = TsuPPty TR_TURN

__ <_ RETURN

AIR

Temperature Rise Measurement

3. Subtract the return air temperature from the supply air

temperature to determine the air temperature rise. Allow

adequate time for thermometer readings to stabilize.

4. Adjust temperature rise by adjusting the circulator blower

speed. Increase blower speed to reduce temperature rise.

Decrease blower speed to increase temperature rise. Refer

to Section )(IV, Startup Procedure and Adjustment -Circulator

Blower Speeds for speed changing details.

CIRCULATOR BLOWER SPEEDS

I a.WAR.,.G

To AVOID PERSONAL INJURY OR DEATH DUE TO ELECTRICAL SHOCK, TURN

[ OFF POWER TO THE FURNACE BEFORE CHANG NG SPEED TAPS,

This furnace is equipped with a multi-speed circulator blower. This

blower provides ease in adjusting blower speeds. The Specifica-

tion Sheet applicable to your model* provides an airflow table,

showing the relationship between airflow (CFM) and external static

pressure (E.S.R), for the proper selection of heating and cooling

speeds. The heating blower speed is shipped set at "B", and the

cooling blower speed is set at "D". These blower speeds should

be adjusted by the installer to match the installation requirements

so as to provide the correct heating temperature rise and correct

cooling CFM.

Use the CFM LED (green), adjacent to the integrated control mod-

ule fuse to verify airflow quantity. The green CFM LED blinks once

for each 100 CFM of airflow.

1. Determine the tonnage of the cooling system installed with

the furnace. If the cooling capacity is in BTU/hr divide it by

12,000 to convert capacity to TONs.

Example: Cooling Capacity of 30,000 BTU/hr.

30,000/12,000 = 2.5 Tons

2. Determine the proper air flow for the cooling system. Most

cooling systems are designed to work with air flows between

350 and 450 CFM per ton. Most manufacturers recommend

an air flow of about 400 CFM per ton.

Example: 2.5 tons X 400 CFM per ton = 1000 CFM

The cooling system manufacturer's instructions must be checked

for required air flow. Any electronic air cleaners or other devices

may require specific air flows, consult installation instructions of

those devices for requirements.

3. Knowing the furnace model, locate the high stage cooling

air flow charts in the Specification Sheet applicable to your

model*. Look up the cooling air flow determined in step 2

and find the required cooling speed and adjustment setting.

Example: A *MV90704BXA furnace installed with a 2.5

ton air conditioning system. The air flow

needed is 1000 CFM. Looking at the cooling

speed chart for *MV90704BXA, find the air flow

closest to 1000 CFM. A cooling airflow of 990

CFM can be attained by setting the cooling

speed to "C" and the adjustment to "-" (minus).

NOTE: Continuous Fan Speed will be 56% of

high stage cooling.

4. Locate the blower speed selection DIP switches on the

integrated control module. Select the desired "cooling"

speed tap by positioning switches 1 and 2 appropriately.

Select the desired "adjust" tap by positioning switches 3

and 4 appropriately. Refer to the following figure for switch

positions and their corresponding taps. Turn off power to

*NOTE: Please contact your distributor or our website for the applicable Specification Sheet referred to in this manual.

furnace for a minimum of 10 seconds, allowing motor to

reset and recognize new speed selection. Turn on power

to furnace. Verify CFM by counting the number of times the

green CFM LED blinks.

The multi-speed circulator blower also offers several

custom ON/OFF ramping profiles. These profiles may be

used to enhance cooling performance and increase comfort

level. The ramping profiles are selected using DIP switches

5 and 6. Refer to the following figure for switch positions

and their corresponding taps. Refer to the bullet points

below for a description of each ramping profile. Turn OFF

power to the furnace for a minimum of 10 seconds, allowing

motor to reset and recognize the new profile selection. Turn

ON power to the furnace. Verify profile selection by counting

the green CFM LED blinks and timing each step of the

ramping profile.

DIP Switch No.

Ramping Profiles

A* OFF

B ON

C OFF

D ON

(* indicates factory setting)

[.1

OFF

Profile A provides only an OFF delay of one (1) minute at

100% of the cooling demand airflow.

Oq100% CFM_t_100% CFM_ _FFOFF

Cooling ,-_1 min_

Demand I

Profile B ramps up to full cooling demand airflow by first

stepping up to 50% of the full demand for 30 seconds. The

motor then ramps to 100% of the required airflow. A one (1)

minute OFF delay at 100% of the cooling airflow.

_100% CFM _-_ 100%CFM_

OFF '_50% CFM_'-

_1/2 min_ _1 min_

CoolingDemand_

Profile C ramps up to 82% of the full cooling demand airflow

and operates there for approximately 7 1/2 minutes. The

motor then steps up to the full demand airflow. Profile C

also has a one (1) minute 100% OFF delay.

OFF

Cooling Demand

Selection Dip Switches

Cool Acliust Profile Heat

Selection Selection Selection Selection

Switches Switches Switches Switches

Tap 1 2 3 4 5 6 7 8

A OFF OFF OFF OFF OFF OFF OFF OFF

B ON OFF ON OFF ON OFF ON OFF

( OFF ON OFF ON OFF ON OFF ON

Not Not

D ON ON u_a u_*a ON ON ON ON

Profiles Pre-Rtm Shox_-Rtm OFF Delay

A 50seci100%

B 30see 50% 60see/100%

C 7.5mini82% 50sec,'100%

D 30see/50% 7.5mini82qa 30seci50%

To set airflow: (1) Select model and desired

aixflow. Determine the conespondmg

tap (A. B. (. or D) Set switches 1 and 2 to the

appropriate ONOFF positions (2) Select model

and desired low stase he_tins airflow. Detemline

the conesponding tap (A, B, C, or D). Set switches

7 and 8 to the appropriate ON/OFF positions

Model

GMV95453BX*

GMV95704CX* (

GMV95905DX* B

GMV951155DX* C

GCV90704CX* C

G(V90905DX* B

(

Tap Low Stage

Coot

A 390

B 520

C 650

D 780

A 390

B 520

715

930

52O

715

910

1170

52O

715

910

1170

390

520

715

930

520

715

910

1170

High Stage

Cool

600

800

1000

1200

600

800

1100

1430

800

1100

1400

1800

800

1100

1400

1800

6O0

8OO

1100

1430

800

1t00

1400

1800

Low Stage

Heat

55O

600

650

700

840

920

1000

1080

1125

1195

1265

1335

1230

1265

1300

1335

83O

915

1000

1085

1110

1185

1260

1335

High Stage

Heat

79O

865

935

1000

1210

1325

1440

1555

1620

1720

1820

1920

1770

1825

1875

1925

1195

1320

1440

1565

1600

1700

1815

1925

(3) Select the airflow adjustment t:actor: Tap A is 1 ; Tap B is _10%; Tap C 10%

Set dip switches 3 and 4 to the appropriate ON'OFF positions.

To set Comfort M_le: Select desired Comtbl_ Mode profile (see profiles above).

Set switches 5 and 6 to the appl_priate ON/OFF positions.

DIP Switch No.

Cooling Speed Tap _

A OFF OFF

B ON QFF

C QFF ON

D* ON ON

(* indicates factory setting)

DtP Switch No.

Adiust Taps _-

Normal* OFF OFF

+ 10% Adjust ON OFF

- 10% Adiust QFF QN

(* indicates factory setting)

Profile D ramps up to 50% of the demand for 1/2 minute,

then ramps to 82% of the full cooling demand airflow and

operates there for approximately 7 1/2 minutes. The motor

then steps up to the full demand airflow. Profile D has a 1/

2 minute at 50% airflow OFF delay.

/00% CFM 50% CFM OFF

Select the heating speed from the heating speed chart in

the Specification Sheet applicable to your model* for your

model. The adjust setting (already established by the

cooling speed selection) determines which set of speeds

are available. The selected speed must provide a

temperature rise within the rise range listed with the

particular model.

Example: The GMV95704BXA is set for 990 CFM on

cooling, the "ADJUST" is set to "-" (minus).

The four heating speeds available are "A

Minus", "B Minus", "C Minus", and "D Minus".

"A Minus" has a rise of 56°F for both stages

which is within the 30-60°F rise range for the

GMV95704BXA. This setting will keep

electrical consumption to a minimum. Set the

"Heat" speed DIP switches to "A".

Heating Speed Tap

DIP Switch No.

IrA [:!

OFF OFF

ON OFF

OFF ON

ON ON

(* indicates factory setting)

7. Select the desired "heating" speed tap by positioning

switches 7 and 8 appropriately. Refer to figure above. Turn

off power to furnace for a minimum of 10 seconds, allowing

motor to reset and recognize new speed selection. Turn on

power to furnace. Verify selected CFM by counting the green

CFM LED blinks.

In general lower heating speeds will: reduce electrical consump-

tion, lower operating sound levels of the blower, and increase the

outlet air temperature delivered to the home. The speeds avail-

able allow the blower performance to be optimized for the particu-

lar homeowner's needs.

BLOWER HEAT OFF DELAY TiMiNGS

The integrated control module provides a selectable heat off delay

function. The heat off delay period may be set to 90, 120, 150, 180

seconds using the DIP switches or jumper provided on the control

module. The delay is factory shipped at 150 seconds but may be

changed to suit the installation requirements and/or homeowner

preference. Refer to the following figures for switch positions and

corresponding delay times.

*NOTE:

ON _!_

OFF 1

OFF [J_ 2

ON 1

3 Heat Off

Delay

2 90 Seconds

3 Heat Off

2 Delay

120 Seconds

Heat Off *

Delay

150 Seconds

_i Heat Off

OFF Delay

OFF 180 Seconds

Heat Off Delay

(* indicates factory setting)

Heat Off Delay Switches

XV, NORMAL SEQUENCE OF OPERATION

POWER UP

The normal power up sequence is as follows:

• 115 VAC power applied to furnace.

'_ Integrated control module performs internal checks.

° Integrated control module flashes LED one time.

'_ Integrated control module monitors safety circuits

continuously.

° Furnace awaits call from thermostat.

HEATING MODE

The normal operational sequence in heating mode is as follows:

'_ R and W1 (or R and WI/W2) thermostat contacts close,

initiating a call for heat.

° Integrated control module performs safety circuit checks.

'_ Induced draft blower is energized on high speed for a 15-

second prepurge. Humidifier terminals are energized with

induced draft blower.

'_ Induced draft blower steps to low speed following prepurge.

Low stage pressure switch contacts are closed.

° Igniter warm up begins upon step to low speed and

presence of closed low stage pressure switch contacts.

° Gas valve opens at end of igniter warm up period, delivering

gas to burners and establishing flame.

'_ Integrated control module monitors flame presence. Gas

valve will remain open only if flame is detected.

• If the thermostat call is for low heat, gas valve and induced

draft blower will continue on low stage. If the call is for high

heat, the gas valve and induced draft blower will change to

high stage.

'_ Circulator blower is energized on heat speed following a

fixed thirty second blower on delay. The circulator blower

requires thirty (30) seconds to ramp up to full speed.

Electronic air cleaner terminals are energized with circulator

blower.

° Furnace is now operating on the specified stage called for

by the two-stage thermostat.

Please contact your distributor or our website for the applicable Specification Sheet referred to in this manual.

" Furnace runs, integrated control module monitors safety

circuits continuously.

° If the two-stage thermostat changes the call from low heat

to high heat, the integrated control module will immediately

switch the induced draft blower, gas valve, and circulator

blower to their high stage settings.

" If the two-stage thermostat changes the call from high heat

to low heat, the control will immediately switch the induced

draft blower and gas valve to their low stage settings. The

circulator blower will remain on high heating speed for thirty

(30) seconds before switching to the low heat circulating

speed.

° R and W1 (or R and WI/W2) thermostat contacts open,

completing the call for heat.

" Gas valve closes, extinguishing flame.

° Induced draft blower is de-energized following a fifteen

second post purge. Humidifier terminals are de-energized.

" Circulator blower continues running for the selected heat

off delay period (90, 120, 150 or 180 seconds). The speed

run during this period depends on the last heat call provided

by the thermostat.

If the last call for heat was a call for low heat, the air circulator

motor will run on low heat speed for the duration of the heat

off delay period (90, 120, 150 or 180 seconds).

If the last call for heat was a call for high heat, the air

circulating motor will run on the high heating speed for thirty

(30) seconds and then switch to the low heating speed for

the balance of the heat off delay period (60, 90, 120 or 150

seconds).

" Circulator blower and electronic air cleaner terminals are

de-energized.

° Circulator blower ramps down to OFF during the 30 seconds

following the heat off delay period.

" Furnace awaits next call from thermostat.

COOLING MODE

The normal operational sequence in cooling mode is as follows:

° R and YLO/G or Y/G thermostat contacts close, initiating a

call for cool.

° Integrated control module performs safety circuit checks.

" Outdoor fan and compressor are energized to their

appropriate speed.

° Circulator blower is energized on the appropriate cool speed

at the level and time determined by the selected ramping

profile. Electronic air cleaner terminals are energized with

circulator blower.

" Furnace circulator blower and outdoor cooling unit run their

appropriate speed, integrated control module monitors

safety circuits continuously.

" R and YLO/G or Y/G thermostat contacts open, completing

the call for cool.

° Outdoor fan and compressor are de-energized.

" Circulator blower continues running during a cool off delay

period. The OFF delay time and airflow level are determined

by the selected ramping profile.

Electronic air cleaner terminals and circulator blower are

de-energized.

" Furnace awaits next call from thermostat.

FAN ONLY MODE

The normal operational sequence in fan only mode is as follows:

" R and G thermostat contacts close, initiating a call for fan.

" Integrated control module performs safety circuit checks.

" Circulator blower is energized on continuous fan speed

(56% of high stage cooling) following a five (5) second delay.

Electronic air cleaner terminals are energized.

" Circulator blower runs, integrated control module monitors

safety circuits continuously.

" R and G thermostat contacts open, completing the call for

fan.

° Circulator blower is de-energized. Electronic air cleaner

terminals are de-energized.

° Furnace awaits next call from thermostat.

XVl. OPERATIONAL CHECKS

BURNER FLAME

The burner flames should be inspected with the burner compart-

ment door installed. A sight glass is provided for inspection pur-

poses. Flames should stable, quiet, soft, and blue (dust may

cause orange tips but they must not be yellow). Flames should

extend directly outward from the burners without curling, floating, or

lifting off. Flames must not impinge on the sides of the heat ex-

changer firing tubes.

Check the burner flames for:

1. Good adjustment

2. Stable, soft and blue

3. Not curling, floating, or lifting off.

Burner Flame

XVIL SAFETY CIRCUIT DESCRIPTION

GENERAL

A number of safety circuits are employed to ensure safe and proper

furnace operation. These circuits serve to control any potential

safety hazards and serve as inputs in the monitoring and diagno-

sis of abnormal function. These circuits are continuously moni-

tored during furnace operation by the integrated control module.

_NTEGRATED CONTROL MODULE

The integrated control module is an electronic device which, if a

potential safety concern is detected, will take the necessary pre-

cautions and provide diagnostic information through an LED.

PRIMARY LIMIT

The primary limit control is located on the partition panel and moni-

tors heat exchanger compartment temperatures. It is a normally-

closed (electrically), automatic reset, temperature-activated sen-

sor. The limit guards against the overheating as a result of insuffi-

cient conditioned air passing over the heat exchanger.

AUXILIARY LIMIT

The auxiliary limit controls are located on or near the circulator

blower and monitors blower compartment temperatures. They are

a normally-closed (electrically), manual-reset sensors. These lim-

its guard against overheating as a result of insufficient conditioned

air passing over the heat exchanger.

ROLLOUTLIMIT

The rollout limit controls are mounted on the burner/manifold as-

sembly and monitor the burner flame. They are normally-closed

(electrically), manual-reset sensors. These limits guard against

burner flames not being properly drawn into the heat exchanger.

PRESSURE SWITCHES

The pressure switches are normally-open (closed during opera-

tion) negative air pressure-activated switches. They monitor the

airflow (combustion air and flue products) through the heat ex-

changer via pressure taps located on the induced draft blower and

the coil front cover. These switches guard against insufficient air-

flow (combustion air and flue products) through the heat exchanger

and/or blocked condensate drain conditions.

FLAME SENSOR

The flame sensor is a probe mounted to the burner/manifold as-

sembly which uses the principle of flame rectification to determine

the presence or absence of flame.

XVIII. TROUBLESHOOTING

ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS

NOTE: Discharge body's static electricity before touching unit. An

electrostatic discharge can adversely affect electrical components.

Use the following precautions during furnace installation and ser-

vicing to protect the integrated control module from damage. By

putting the furnace, the control, and the person at the same electro-

static potential, these steps will help avoid exposing the integrated

control module to electrostatic discharge. This procedure is appli-

cable to both installed and uninstalled (ungrounded) furnaces.

1. Disconnect all power to the furnace. Do not touch the

integrated control module or any wire connected to the control

prior to discharging your body's electrostatic charge to

ground.

2. Firmly touch a clean, unpainted, metal surface of the

furnaces near the control. Any tools held in a person's

hand during grounding will be discharged.

3. Service integrated control module or connecting wiring

following the discharge process in step 2. Use caution not

to recharge your body with static electricity; (i.e., do not move

or shuffle your feet, do not touch ungrounded objects, etc.).

If you come in contact with an ungrounded object, repeat

step 2 before touching control or wires.

4. Discharge your body to ground before removing a new

control from its container. Follow steps 1 through 3 if

installing the control on a furnace. Return any old or new

controls to their containers before touching any ungrounded

object.

DIAGNOSTIC CHART

,_, WARNING

HIGH VOLTAGE! _ _i_

To AVOID PERSONAL INJURY OR DEATH DUE TO

ELECTRICAL SHOCK_ DISCONNECT ELECTRICAL POWER

BEFORE PERFORMAING ANY SERVICE OR MAINTENANCE.

Refer to the Troubleshooting Chart at the end of this manual for

assistance in determining the source of unit operational problems.

The red diagnostic LED blinks to assist in troubleshooting the unit.

The number of blinks refers to a specific fault code.

RESETTING FROM LOCKOUT

Furnace lockout results when a furnace is unable to achieve igni-

tion after three attempts. It is characterized by a non-functioning

furnace and a one flash diagnostic LED code. If the furnace is in

"lockout", it will (or can be) reset in any of the following ways.

1. Automatic reset. The integrated control module will

automatically reset itself and attempt to resume normal

operations following a one hour lockout period.

2. Manual power interruption. Interrupt 115 volt power to the

furnace for 1 - 20 seconds.

3. Manual thermostat cycle. Lower the thermostat so that

there is no longer a call for heat then reset to previous setting.

Interrupt thermostat signal to the furnace for 1 -20 seconds.

NOTE: If the condition which originally caused the lockout still

exists, the control will return to lockout. Refer to Section >(VIII,

Troubleshooting -Diagnostic Chart for aid in determining the cause.

XIX. MAINTENANCE

_WARNING

HIGH VOLTAGE!

To AVOID PERSONAL INJURY OR DEATH DUE TO

ELECTRICAL SHOCK, DISCONNECT ELECTRICAL POWER _

BEFORE PERFORMING ANY MAINTENANCE, IF YOU MUST

HANDLE THE IGNITER, HANDLE WITH CARE, TOUCHING

THE IGNITER ELEMENT WITH BARE FINGERS, ROUGH

HANDLING OR VIBRATION COULD DAMAGE THE IGNITER

RESULTING IN PREMATURE FAILURE, ONLY A QUALIFIED

SERVICER SHOULD EVER HANDLE THE IGNITER.

ANNUAL INSPECTION

The furnace should be inspected by a qualified installer, or service

agency at least once per year. This check should be performed at

the beginning of the heating season. This will ensure that all fur-

nace components are in proper working order and that the heating

system functions appropriately. Pay particular attention to the fol-

lowing items. Repair or service as necessary.

• Flue pipe system. Check for blockage and/or leakage. Check

the outside termination and the connections at and internal

to the furnace.

" Heat exchanger. Check for corrosion and/or buildup within

the heat exchanger passageways.

• Burners. Check for proper ignition, burner flame, and flame

sense.

• Drainage system. Check for blockage and/or leakage.

Check hose connections at and internal to furnace.

" Wiring. Check electrical connections for tightness and/or

corrosion. Check wires for damage.

" Filters.

FILTERS

,_ CAUTION

To ENSURE PROPER UNIT PERFORMANCE, ADHERE TO THE FILTER

SIZES GIVEN IN THE RECOMMENDED MINIMUM FILTER SIZE TABLE OR

SPECIFICATION SHEET APPLICABLE TO YOUR MODEL*

MAINTENANCE

Improper filter maintenance is the most common cause of inad-

equate heating or cooling performance. Filters should be cleaned

(permanent) or replaced (disposable) every two months or as re-

quired. When replacing a filter, it must be replaced with a filter of

the same type and size.

FILTER REMOVAL

Depending on the installation, differing filter arrangements can be

applied. Filters can be installed in either the central return register

or a side panel external filter rack (upflow only). A media air filter or

electronic air cleaner can be used as an alternate filter. Follow the

filter sizes given in the Recommended Minimum Filter size table to

ensure proper unit performance.

To remove filters from an external filter rack in an upright upflow

installation, follow the directions provided with external filter rack

kit. To remove internal filters see Internal Filter Removal section.

Internal filters are an accessory item and are not included with

your furnace. For further details, see your distributor.

HORIZONTAL UNIT FILTER REMOVAL

Filters in horizontal installations are located in the central return

To remove:

1. Turn OFF electrical power to furnace.

2. Remove filter(s) from the central return register or ductwork.

3. Replace filter(s) by reversing the procedure for removal.

4. Turn ON electrical power to furnace.

MEDIA AIR FILTER OR ELECTRONIC AIR CLEANER REMOVAL

Follow the manufacturer's directions for service.

BURNERS

Visually inspect the burner flames periodically during the heating

season. Turn on the furnace at the thermostat and allow several

minutes for flames to stabilize, since any dislodged dust will alter

the flames normal appearance. Flames should be stable, quiet,

soft, and blue (dust may cause orange tips but they must not be

yellow). They should extend directly outward from the burners with-

out curling, floating, or lifting off. Flames must not impinge on the

sides of the heat exchanger firing tubes.

INDUCED DRAFT AND CIRCULATOR BLOWERS

The bearings in the induced draft blower and circulator blower

motors are permanently lubricated by the manufacturer. No further

lubrication is required. Check motor windings for accumulation of

dust which may cause overheating. Clean as necessary.

CONDENSATE TRAP AND BRAIN SYSTEM (QUALIFIED SERVICER

ONLY)

Annually inspect the drain tubes, drain trap, and field-supplied drain

line for proper condensate drainage. Check drain system for hose

connection tightness, blockage, and leaks. Clean or repair as

necessary.

FLAME SENSOR (QUALIFIED SERVICER ONLY)

Under some conditions, the fuel or air supply can create a nearly

invisible coating on the flame sensor. This coating acts as an

insulator causing a drop in the flame sense signal. If the flame

sense signal drops too low the furnace will not sense flame and

will lock out. The flame sensor should be carefully cleaned by a

qualified servicer using emery cloth or steel wool. Following clean-

ing, the flame sense signal should be as indicated in the Specifi-

cations Sheet.

FLUE PASSAGES (QUALIFIED SERVICER ONLY)

The heat exchanger flue passageways should be inspected at the

beginning of each heating season. If necessary, clean the pas-

sageways as outlined below.

1. Turn OFF the electrical power and gas supply to the furnace.

2. Disconnect the gas line and remove the burner/ manifold

assembly by removing the screws securing the assembly

to the partition panel.

3. Disconnect the flue pipe system from the induced draft

blower.

4. Remove the induced draft blower and, drain and pressure

tap hoses from the recuperator coil front cover.

5. Remove the recuperator coil front cover to expose the coil

tubes and turbulators.

6. Remove the recuperator coil turbulators individually by slowly

pulling each turbulator forward firmly.

7. Clean the recuperator coil tubes using a long handle wire

brush, such as a gun cleaning brush.

8. Clean the primary heat exchanger tubes using a wire brush

attached to a length of high grade stainless steel cable,

such as drain cleanout cable. Attach a variable speed

reversible drill to the other end of the cable. Slowly rotate

the cable with the drill and insert it into one of the heat

exchanger tubes. While reversing the drill, work the cable

in and out several times to obtain sufficient cleaning. Repeat

for each tube.

9. Clean residue from furnace using a vacuum cleaner.

10. Replace the parts removed in the previous steps in reverse

order.

11. Turn on electrical power and gas to furnace. Check for

leaks and proper unit operation.

12. Severe heat exchanger fouling is an indication of an

operational problem. Perform the checks listed in Section

>(IV, Startup Procedure and Adjustments to reduce the

chances of repeated fouling.

XX. INTERNAL FILTER REMOVAL

Internal filters are an accessory item and are not included with your

furnace. For further details, see your distributor.

BOTTOM RETURN REMOVAL

1. Turn OFF electrical power to furnace.

2. Remove blower compartment door,

3. Push back and up on the wire filter retainer to release it

from under the front lip of the furnace basepan.

4. Slide filter forward and out.

5. Replace filter by reversing the procedure.

BLOWER COMPARTMENT REMOVAL

1. Turn OFF electrical power to furnace.

2. Remove blower compartment door.

*NOTE: Please contact your distributor or our website for the applicable Specification Sheet referred to in this manual.

3. Grasp lower portion of filter and lift up.

Front of Furnace

Blower

Grab Here

And Lift

Front of Furnace

4. Angle filter toward the blower until filter clears bottom rail.

5. Lower filter down and pull outward.

Front of Furnace

Blower

Front of Furnace

Blower

6. Replace filter by reversing procedure.

XXL BEFORE LEAVINGAN INSTALLATION

• Cycle the furnace with the thermostat at least three times.

Verify cooling and fan only operation.

• Review the Owner's Manual with the homeowner and

discuss proper furnace operation and maintenance.

• Leave literature packet near furnace.

XXIL REPAIR & REPLACEMENT PARTS

" When ordering any of the listed functional parts, be sure to

provide the furnace model, manufacturing, and serial

numbers with the order.

" Although only functional parts are shown in the parts list, all

sheet metal parts, doors, etc. may be ordered by description.

Parts are available from your distributor.

Functional Parts List-

Gas Valve

Gas Manifold

Natural Gas Orifice

Propane Gas Orifice

Igniter

Flame Sensor

Rollout Limit Switch

Primary Limit Switch

Auxiliary Limit Switch

Pressure Switch

Induced Draft Blower

Door Switch

Blower Motor

Blower Wheel

Blower Mounting Bracket

Blower Cutoff

Blower Housing

Capacitor

Heat Exchanger

Recuperator Coil

Coil Front Cover

Integrated Control Module

Transformer

TROUBLESHOOTINGCHART

,Furnace fails to operate.

,Integrated control

module diagnostic LED

provides no signal.

• Normal Steady On

, Furnace fails to operate.

, Integrated control

module diagnostic LED

is flashing ONE (1) flash.

, Furnace fails to operate.

, Integrated control

module diagnostic LED

is flashing TWO (2)

flashes.

, Induced draft blower runs

continuously with no

further furnace operation.

, Integrated control

module diagnostic LED

is flashing THREE (3)

flashes.

NONE

CONTINUOUS

1 FLASH

12 FLASHES

3 FLASHES

°No 115 volt power to

furnace, or no 24 volt

power to integrated

control module.

*Blown fuse or circuit

breaker.

*Integrated control

module has an

internal fault.

• Normal Operation

*Furnace lockout due

to an excessive

number of ignition

"retries" (3 total) _

and "recycles

infinite".

• Pressure switch

circuit is closed.

• Induced draft

blower is not

operating.

• Pressure switch

circuit not closed.

• Induced draft blower

is operating.

• Manual disconnect switch

OFF, door switch open, or

24 volt wires improperly

connected or loose.

• Blown fuse or circuit

breaker.

• Integrated control module

has an internal fault.

°Normal operation.

• Failure to establish flame.

Cause may be no gas to

burners, front cover

pressure switch stuck

open, bad igniter or igniter

alignment, improper

orifices, or coated/oxidized

or improperly connected

flame sensor.

• Loss of flame after

establishment. Cause may

be interrupted gas supply,

lazy burner flames

(improper gas pressure or

restriction in flue and/or

combustion air piping),

front cover pressure

switch opening, or

improper induced draft

blower performance.

• Induced draft blower

pressure switch contacts

sticking.

• Shorts in pressure switch

circuit.

• Pressure switch hose

blocked, pinched or

connected improperly.

• Blocked flue and/or inlet air

pipe, blocked drain system,

or weak induced draft

blower.

• Incorrect pressure switch

setpoint or malfunctioning

switch contacts.

• Loose or improperly

connected wiring.

• Assure 115 and 24 volt

power to furnace

integrated control

module.

• Check integrated control

module fuse (3A).

Replace if necessary.

• Check for possible shorts

in 115 and 24 volt circuits

Repair as necessary.

• Replace bad integrated

control module.

• None.

• Locate and correct gas

interruption.

• Check front cover

pressure switch

operation (hose, wiring,

contact operation).

Correct if necessary.

• Replace or realign

igniter.

• Check flame sense

signal. Sand sensor if

coated and/or oxidized.

• Check flue piping for

blockage, proper

length, elbows, and

termination.

• Verify proper induced

draft blower perfor-

mance.

• Replace induced draft

blower pressure

switch.

• Repair short.

• Inspect pressure

switch hose. Repair, if

necessary,

• Inspect flue and/or inlet

air piping for blockage,

proper length, elbows,

and termination. Check

drain system. Correct

as necessary.

• Correct pressure

switch setpoint or

contact motion.

• Tighten or correct

wiring connection.

, Turn power OFF

prior to repair.

, Replace integratec

control module

fuse with 3A

automotive fuse.

, Read precautions

in "Electrostatic

Discharge" section

of manual.

*Normal operation.

*Turn power

OFF prior to

repair.

*Igniter is

fragile, handle

with care.

. Sand flame

sensor with

emery cloth.

See "Vent/Flue

Pipe" section

for piping

details.

*Turn power OFF

prior to repair.

*Replace pressure

switch with proper

replacement part.

• Turn power

OFF prior to

repair.

• Replace

pressure

switch with

proper

replacement

part.

1Integrated control module will automatically attempt to reset fi'om lockout after one hour.

*Circulator blower runs

continuously. No furnace

operation.

.Integrated control module

diagnostic LED is flashing

FOUR (4) flashes.

• Induced draft blower and

circulator blower runs

continuously. No furnace

operation.

• Integrated control module

diagnostic LED is flashing

FIVE (5) flashes.

• Normal furnace operation.

• Integrated control module

diagnostic LED is flashing

SEVEN (7) flashes.

• Furnace not operating.

• Integrated control module

diagnostic LED is flashing

EIGHT (8) flashes.

• Furnace operating on

tow stage gas with high

stage induced draft blower

• High stage circulator

blower (temperature, of

conditioned air, lower than

typical).

• Integrated control module

diagnostic LED is flashing

NiNE (9) flashes.

• Furnace fails to operate.

• Integrated control module

diagnostic LED is flashing

continuously.

TROUBLESHOOTING CHART

°Primary or auxiliary °Insufficient conditioned air

limit circuit is open. over the heat exchanger.

4 FLASHES

• Roltout limit circuit is

Blocked filters, restrictive

ductwork, improper

circulator blower speed, or

failed circulator blower.

°Flame roltout.

°Misaligned burners, blocked

flue and/or air inlet pipe, or

failed induced draft blower.

°Loose or improperly

connected wiring.

• Short to ground in flame

sense circuit.

• Lingering burner flame.

• Stow closing gas valve

•Flame sensor is coated/

oxidized.

°Flame sensor incorrectly

positioned in burner flame.

°Lazy burner flame due to

improper gas pressure or

combustion air.

°Improperly connected

igniter

°Bad igniter

°Poor unit ground

°Pressure switch hose blocked,

pinched or connected

improperly.

°Blocked flue and/or inlet air

pipe, blocked drain system, or

weak induced draft blower.

°Incorrect pressure switch

setpoint or malfunctioning

switch contacts.

°Loose or improperly connected

wiring.

5 FLASHES

7 FLASHES

8 FLASHES

9 FLASHES

CONTINUOUS

FLASHING

open.

*Flame sensed with

no call for heat.

• Flame sense

microamp signal is

tow.

• Problem with

igniter circuit.

• High stage pressure

switch circuit does not

close in response to

high stage induced

draft blower operation.

• Polarity of 115 volt

power is reversed.

°Polarity of 115 volt AC

power to furnace or

integrated control module is

reversed.

°Poor unit ground.

*Check filters and

ductwork for blockage.

Clean filters or remove

obstruction.

°Check circulator blower

speed and performance.

Correct speed or replace

blower if necessary.

.Check burners for proper

alignment.

*Check flue and air inlet

piping for blockage,

proper length, elbows,

and termination. Correct

as necessary.

.Check induced draft

blower for proper

performance. Replace, if

necessary.

.Tighten or correct wiring

connection.

• Correct short at flame

sensor or in flame

sensor wiring.

• Check for lingering

flame

• Verify proper operation

of gas valve

.Sand flame sensor is

coated/oxidized.

.Inspect for proper sensor

alignment.

.Check inlet air piping for

blockage, proper length,

elbows, and termination.

.Compare current gas

pressure to rating plate

info. Adjust as needed.

• Check and correct wiring

from integrated control

module to igniter

• Replace bad igniter

• Check and correct unit

ground wiring

• Inspect pressure switch hose.

Repair, if necessary.

• Inspect flue and/or inlet air

piping for blockage, proper

length, elbows, and termina-

tion. Check drain system.

Correct as necessary.

• Correct pressure switch

setpoint or contact motion.

• Tighten or correct wiring

connection.

*Review wiring diagram to

correct polarity.

*Verify proper ground.

Correct if necessary.

*Check and correct wiring.

Turn power OFF

prior to repair.

• See Specification

Sheet applicable

to your model* for

allowable rise

range and proper

circulator speed.

,See "Vent/Flue

Pipe" section for

piping details.

, Replace pressure

switch with proper

replacement part.

. Turn power OFF

prior to repair.

,Turn power OFF

prior to repair.

,Sand flame

sensor with

emery clot.

,See "Vent/Flue

Pipe" section for

piping details.

,See rating plate

for proper gas

pressure.

,Turn power OFF

prior to repair.

,Replace igniter

with proper

replacement part.

,Turn power OFF

prior to repair.

,Replace pressure

switch with proper

replacement part.

,Turn power OFF

prior to repair.

WiRiNG DIAGRAM

ID BLOV_R @TO

qll GND 1/5 VAC'I@/60 HZ

t_.. I-

-J..I

n_W

n,'W

wn,'

o-0

_Jo.

,-I w

LOW VOLTAGE (24V) .....

LOW VOLTAGE FIELD

HI VOLTAGE (115V)

HI VOLTAGE FIELD .....

JUNCTION

TERMINAL

INTERNAL TO

INTEGRATED CONTROL

PLUG CONNECTION

EQUIPMENT GND

F_ELD GND

FIELD SPLICE

SWITCH (TEMP }

IGNITER

SWITCH (PRESS }

OVERCURRENT

PRO3" DEVICE

COLOR CODES PK PINK

YL YELLOW BR BROWN

OR ORANGE WH WHITE

VT V_OLET BU BLUE

GN GREEN GY GRAY

BK BLACK RD RED

22314701 REV.00

NOTES:

1 SET HEAT ANTICIPATOR ON ROOM THERMOSTAT AT 07 AMPS

2 MANUFACTURER'S SPECIFIED REPLACEMENT PARTS MUST BE USED WHEN SERVIC_NG

3 IF ANY OF THE ORIGINAL W_RE AS SUPPLIED WITH THE FURNACE MUST BE

REPLACED, IT MUST BE REPLACED WITH W_RING MATER_AL HAVING A TEMPERATURE

RATING OF AT LEAST 105'C USE COPPER CONDUCTORS ONLY¸

4 UNiT MUST BE PERMANENTLY GROUNDED AND CONFORM TO N E C AND LOCAL CODES

Wiring is subject to change, always refer to the wiring diagram on the unit for the most up-to-date wiring.

5151 San Felipe, Suite 500

Houston, TX 77056

www.goodmanmf_, corn

GOODMAN Furnace/Heater, Gas Manual L0806734

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