PAYNE Furnace/Heater, Gas Manual L0523315
User Manual: PAYNE PAYNE Furnace/Heater, Gas Manual PAYNE Furnace/Heater, Gas Owner's Manual, PAYNE Furnace/Heater, Gas installation guides
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PG8M/PG8J
Installation, Start-up, Operating, and
Service and Maintenance Instructions
-Series C
4@<
@© _@ 0@ <
4©<
@
The Payne PG8M/PG8J
80% AFUE Gas Furnaces feature 4way
multipoise
design
and
through-the-furnace
downflow
venting.
The PG8M/PG8J
furnaces are approved for use with
natural or propane gas and the PG8J is also approved for use in
Low Nox Air Quality Management Districts.
STANDARD FEATURES
•
•
•
•
Four-position
furnace: upflow, horizontal right, horizontal
left, downflow
Electronic control center
Adjustable heating air temperature rise
LED diagnostics and self test feature
Hot surface ignition (HSI)
Twinning in Upflow, Downflow and Horizontal
LIMITED WARRANTY
• 20-year warranty on "Super S TM''heat exchanger
• 5-year parts warranty on all other components
Catalog No: 53PG-8J5
Form No. IM-PG8J-05
5-05
Induced-Combustion
Cancers:
A
II 310A-45°4/IM-PG8J-04
li310_k-45-5/IM-PG8Jo0_5
{nstallation, Start-up, upera mng, ane
Service and Maintenance Instructions
Series 120/0
NOTE: Read the entire instruction
installation.
manual before starting the
This symbol --> indicates a change since the last issue,
--> PoItions of the text and tables are repiinted fiom NFPA 54/ANSI Z223 1-2002"<',
with permisslol_ of National Fire Protection Association, Quincy, MA 02269 and
Ameiican Gas Association. Washingto_ DC 20001 This reprinted material is l_ot/he
complete and official position of the NFPA or ANSI on the ref?renced suNect, which
is repiesented only by the standmd in its entirety
TABLE OF CONTENTS
SAFETY CONSIDERATIONS
2
INTRODUCTION
4
.....................................
CODES AND STANDARDS ........................................................
RSO 9001:2000
4
Safety .........................................................................................
General Installation ...................................................................
(onfhustion and Ventilation Air ..............................................
5
5
5
Duct Systems ............................................................................
Acoustical Lining and Fibrous Glass Duct ..............................
Gas Piping and Gas Pipe Pressure Testing ..............................
Electrical Connections ..............................................................
5
5
5
5
ELECTROSTATI(
DISCHARGE (ESD) PRECAUTIONS
PRO(EDURE ................................................................................
5
LOCATION ....................................................................................
General ......................................................................................
5
5
24-V Wiring .......................................................................
Accessories ........................................................................
Venting ....................................................................................
General Venting Requirements .........................................
Masonry (himney Requirements ......................................
Appliance Application Requirements ...............................
Additional Venting Requirements .....................................
Sidewall Venting ...............................................................
Location Relative to Cooling Equipment ................................ 7
AIR FOR COMBUSTION AND VENTILATION ...................... 7
INSTALLATION .........................................................................
L pftow Installation .................................................................
Bottom Return Air Inlet ....................................................
Side Return Air Inlet .........................................................
10
i0
i0
10
Leveling Legs (If Desired) ................................................
Downftow Installation ............................
Bottom Return Air Inlet .........................
Horizontal Installation .............................
Suspended Furnace Support ......................
Platfbrm Furnace Support ........................
Roll-Out Protection ..............................
Bottom Return Air Inlet .........................
Side Return Air Inlet ...........................
Filter Arrangement ................................
Air Ducts ........................................
General Requirements ............................
Ductwork Acoustical Treatment ....................
Supply Ai* (onnections .........................
Return Air Connections ..........................
Gas Piping ......................................
Electrical ( onnections ............................
10
10
11
11
11
i1
11
1l
11
11
11
11
12
12
14
15
19
115=V Wiring ................................
J°Box Relocation ..............................
Electrical Connection to J°Box .....................
Power Cord Installation in Furnace J=Box .............
BX Cable Installation in Furnace J°Box ..............
19
20
21
21
22
Manufacturer
B°°k 1h_
Tab
16al
reserves
PC 101
8a
the right
catalog
to discontinue,
No
See Cover
or change
START°UP, ADJE STMENT, AND SAFETY CHECK ............ 27
General ....................................................................................
27
Start-Up Procedures ................................................................
Adjustments .............................................................................
Check Safe w Controls .............................
Checklist ..........................................
SERVICE AND MAINTEiN'ANCE PROCEDURES ...........
Intro&ction .......................................
General ........................................
Electrical Controls and Wiring .....................
(are and Maintenance ..............................
or designs
58ST-13SI
without
notice
Pg 1
and without
5-05
35
35
35
37
37
Cleaning Heat Exchanger ........................
Sequence of Operation .............................
Wiring Diagrams ..................................
Troubleshooting ..................................
Form
27
3l
34
35
36
37
Cleaning and/or Replacing Air Fiher .................
Blower Motor and Wheel .........................
at any time, specifications
Printed in USA
22
22
22
23
23
24
26
26
40
44
45
45
incurring
obligations.
Replaces:
58S%12SI
28 7/8"
--
26 I/8"
(FLI JE COLLAR)
--
25 I/4"
_-
--
22 _/6"
_A--
--
--
D
--
5 15,q6" --
'I
9 5_8"
78"
DIA
I
I
3 15/6"
ACCESSORY
7
S
LEFT HAND GASJ
ENTRY
33 5¸'¸¸[6,`
24 7,8"
lOCATIONS
(TYP}
5 PLACES
78"
(TYP}
D]A ACCESSORY-
T
t
_i
/I
/,2"
/6"_
--/116"
21 5/8"
BOTTOM INLET
S]DEINLET
24"
CASING
A04037
NOTES:
1. Two additional 7/8-in diameter holes are located in the top plate.
2. Minimum return-air openings ar furnace, based on metal duct. If flex duct is used, see flex duct manufacturer's recommendations for equivalent diameters
a For 800 CFM-16qn round or 14 1/2 x 12qn. rectangle
b For 1200 CFM-20-in. round or 14 1/2 x 19 1/2qn rectangle.
c. For 1600 CFM-22qn. round or 14 1/2 x 22-in rectangle.
d For airflow requirements above 1800 CFM, see Air Delivery table in Product Data literature for spedfic
use of single side inlets. The use of both side inlets, a combination of 1 side and the bottom, or the
bottom only will ensure adequate return air openings for airflow requirements above 1800 CFM
-_ Fig. 1--Dimensional
SAFETY CONSIDERATIONS
Drawing
These
instructions
cover
national
standards
existing
these
instructions
especially
FIRE,
EXPLOSION,
CARBON
MONOXIDE
Failure
to follow
operatiom
nance,
d-fis warning
serious
Improper
ELECTRICAL
POISONING
injury,
installation,
death,
adjustment,
or use can cause
sion,
fire,
electrical
cause personal
shock,
agency,
local
branch
fbr infPm_ation
agency
must
use
gas
could
result
or property
supplier,
when modif}qng
service,
mainteexplo-
or your
or assistance.
The
local
codes
require
which
(:liT
may
a qualified
distributor
qualified
or
gas
electrical
and
personnel
should
Untrained
personnel
such as cleaning
be performed
heating
instMl,
precautions
perform
and replacing
attached
Only
repair,
can
by trained
equipment,
or* labels
components.
wear
appropriate
gloves
when
Wear
kits or
safety
available
calls.
observe
trained
basic
and
heating
maintenance
due to
qualified
personnel.
precautions
with
as
a
protective
handling
clothing,
parts
safety
and servicing
When
in literature,
£urnace
glasses
and
fhrnaces.
glasses
daring
and work
start-up
gloves.
Have
and ad.iustment
for personal
injury.
Understand
the signal
functions
must
working
on
on tags, and
and other
words
fire
extinguisher
procedures
DANGER,
and service
you see this syn_bol on
be alert to the potential
WARNING,
and (AU=
TION. These words are used with the safkty=alert
symbol. DANGER identifies the most serious hazards which will result in severe
personal
conld
injury
result
identify
tions
or death.
in personal
hazards
which
and property
which
will
WARNING
injury
may
damage.
result
signifies
or death.
result
NOTE
a hazard
CAUTION
in minor
personal
installation,
to
ir_jury or
is used to highlight
in enhanced
which
is used
sugges=
reliabili w,
or
operation.
eqnipment.
air filters. All other operations
service
to or shipped
that may apply.
can be hazardous
or service
residen=
instructions
service
and listed
this product.
equipment
ordinances,
HAZARD
product
heating
to
instances_
Failure to fbllow d_is caution may result in personal ir_jury.
Sheet metal parts may have sharp edges or butts Use care and
FURNACE RELIABILITY
HAZARD
Improper installation or misapplication of furnace may re=
quire excessive servicing or cause premature component
failure
Application of" this fftrnace should be indoors with special
attention given to vent sizing and material, gas input rate, air
temperature rise, unit leveling, and unit sizing
and servicing
and
these
This is the safety=alert syn£bol Z_ • When
the fhmace and in instructions
or manuals,
Installing
and con%,Tn
In some
that may not have kept up with changing
tial construction
practices
We
minimum
for a saf_ installation
AND
poisoning,
Consuh
only fSctory=authorized
certain
codes
in dangerous
conditions
damage.
exceed
those
requirements
and safety
damage
alteration,
monoxide
or other
inju W or property
service
accessories
carbon
SHOCK,
HAZARD
minimum
safety
1. Use only with type of gas approved
the [_urnace rating
tbr this filrnace.
Refkr
plate.
2. Install this Nrnace only in a location and position
in the "Location"
section of these instructions.
as specified
to
MINIMUMINCHESCLEARANCETO COMBUSTIBLECONSTRUCTION
DISTANCEMINIMALE ENPOUCESAUX CONSTRUCTIONSCOMBUSTIBLES
This forced air furnace is equippedfor use wi_
naturalgas at altitudes0-10,000ft (0-3,050m).
An accessory kit, supplied by
De
manuf_turer, shall be used to convert to propane
gas use or may be requiredfor some natural gas
applications.
This furnace is for indoor installation in a
PqisfiJmaceis approved
for UPFLOW,DOWNFLOW,and
HORIZONTAL
installations.
Cettefournaiseestapprouveepourl'installationHORIZONTALE
etlac£culation
d 'airVERSLEHAUTet VERSLEB._S.
/_,,_->
Clearance
arrows
/',,_
Lesfbchesded@gagement
donotchangew}th
L
_
nechangepasavec
furnace orientatior_
buildingconstructedon site.
This fumase may be installedon combustible
oonng
.
as indicated by the diagram from combusiible
msterial.
This furnacemay be used with a Type B-1 Vent
",_
Cet[e fournaisea air pulseest equipee
_
pour utilisaiJon avec gaz nafurel et altitudes
comprisesentre G3,050m (0-I0,000 pi).
Utiliserune trousse de conversion,foumie par
lefabrinant, pour passer au gaz propane ou pour
qu'indique
Cette
peut
@-e utilisee
de la feamaise,
,so_._._.
s=_
e\O_
co_
_.
oz_i
_ _ _./
<_//
b"
Clearance
ininches
D_agernent(po}.
<:_'/
Vent Clearanceto combustibles:
sur le diagramme.
fournaise
_
r_._,- i
"_
installeedans un b_lJmentconstruitsur place.
Cettefournaise peut 6tre install@e
sur
un planc'hercambusiJbledans une alc6ve ou
dans un garde-robeen respectantle minimum
d'espace libredes materiauxcombustibles,tel
I 'orientation
_
_
_.
and may be vented in common wi_ other gas
certainesinstallationsau
gaz naturel.
Cettefoumaiseest pr@ue
pour @e
z u._
For Single WalJ versts 6 inches (6 po).
avec
un
conduitd'@acuationde Type B-1 ou connectee
au conduit ommun d 'autres appareilsa gaz.
For Type B-1 vent type 1 inch (1 po).
Degagementde I'@entavec combustibles:
Pearconduitd'evacuationa paroi simpb 6 po (6 inches).
Pearcor_duit
d'@aeaation
deTypeB-11Fo(1 inch).
MINIMUM INCHES CLEARANCE TO COMBUSTIBLE CONSTRUCTION
I)OWNFLOW
POSITIONS:
1" InstallaiJon
on non-combusibiblefloors only.
For Installationon combustibleflooring only when installedon special base, Part No. KGASB020IALL,
Coil Assembly, PartNo. CD5 or CK5, or Coil Casing,Part [/o. KCAKC.
O 18 inchesfront clearancerequiredfor alcove.
_r Indicatessupply or returnsideswhen furnace is in [he horizontalposition. Line contactonly permissible
betweenlinesformed by intersectionsof the Top and bJvoSides of the furnacejacket, and buildingjoists,
studsor framing.
DC:GAGEMENTMINimUM EN POUCES AVEC €:LE_ENTS
DE CONSTRUCTION COMBUSTIBLES
POURLAPOSITIONCOURANT
DESCENDANT:
1" Pour rinstallationsur planchernon combus_bleseulement.
Pour rinstallationsur un planchercombusiJbleseulement quandon utilisela base spedale, piece
n° KGASB020IALL rensembleserpen_Jn,
piecen° CD5 ou CK5, ou le narterde serben_Jn,
piece
n° KCAKC.
Dans une alc6ve,on dolt maintenirun decjagementa ravant de 18po (450mm).
"/_ La poistion indiqueeconceme lec6te d'en_-eeou de retour quand lafournaiseestdans la
positionhorizontale.
Le contact n'est permis qu'entre les lignesformees par les intersectionsdu dessus et des
deux c6tes de lacherfise de la fournaiseet lessolives,montant sous cadre de charpenta.
k.
327590-101
REV.
C
A04123
--> Fig. 2--Clearances
to Combustibles
-_ Table 1--Dimensions
D
SUPPLY-AIR
WIDTH
(iN.)
E
RETURN-AiR
WIDTH
FURNACE
$tZE
A
CABINET W_DTH
(tN.)
(IN.)
045=08t024045
14-3/16
12=9/16
12-11/16
045=12t036045
14-%16
12-9/16
12-11/16
070=08t024070
14-3/16
12=9/16
070=12t036070
14-%16
070-161048070
FLUE
COLLAR*
{BN.}
SHIP W% (LB}
9=5/16
4
104
9=5/16
4
107
12-11/16
9=5/16
4
111
12-9/16
12-11/16
9-5/16
4
115
17-1/2
15-7/8
16
11-9/16
4
126
090_14/042090
17-1/2
15-7/8
16
11-9/16
4
127
090-18/048090
21
19-3/8
19=1/2
13-5/16
4
140
090-20t060090
21
19-3/8
19-1/2
13-5/16
4
146
t10-12/036110
17-1/2
15-7/8
16
11-9/16
4
135
110_181048110
21
19-3/8
19-1/2
13-5/16
4
146
t10=22/066110
21
19-3/8
19=1/2
13-5/16
4
152
135-16/048185
21
19-3/8
19-1/2
13-5/16
4
149
t35-22/066188
24-1/2
22-7/8
23
15-1/16
4
163
188-20t080155
24-1/2
22-7/8
23
15-1/16
4
170
* 5" or 6 _vent connector
4. (ombustion
this _i/mace
products must
to an approved
the "Venting"
section
air to the furnace
and Ventilation _'
13, These _amaces SHALL NOT be installed directly
ing, tile, or any other combustible
material other
flooring.
In downflow
installations,
base MUST be used when installed
be discharged
outdoors.
Connect
vent system only, as specified in
of these
and wood
tion of leaks to check all connections,
install Nmace
external
to operate
range
with
static pressure
fied in the "Start-Up,
See Nmace
circulated
a duct
within
system
so that
containing
air shall
casing
the Nrnace.
_lrnace
be installed
section.
range,
has
an
as speci-
Check"
supply
section.
also be handled
See "Air Ducts"
as specified
ducts
cat_T air
the space containing
and terminating
fbr installation
by duct(s)
outside
furnace
the space
120/(
is (SA
either
tion
&aw
section.
garage
must
box in the "Location _'
furnace
buildings
to be used
or stl_ctures
box regarding
10. These
is not
under
the heating
Multipoise
[br
temporary
construction.
of buildings
Gas-Fired
under
A.G.A.
and (LG.A0
propane
gases (see furnace
rating plate)
alcoves,
attics,
closets,
and garages.
design-certified
basements,
The
furnace
natural
gas. A CSA
convert
furnace
a l-in.
clearance
rooms,
gas conversion
chamber
from
equipped
and/or
with
this
information.
Category
I fan-assisted
an integral
mechanical
means
through
_he combus=
exchanger.
natural
I _m-assisted
A Category
of combustion
heat
fbr use with
listed gas conversion
The
gas. A CSA
kit is required
_urnace
(A.G.A.
to convert
furnace
is factor'-
[:urnace for use with
is no{ approved
fbr installation
vehicles, or outdoors.
This
for
Nrnace
such
is designed
as when
temperature
return-air
minimuna
of 60_>F db or intermittent
used
must
with
not
temperature
For accessoQ"
literature.
a night
exceed
continuous
operation
setback
85°F
down
thermostat.
db. Failure
installation
in
return-air
to 55°F db
Return-air
to follow
limits may afi:kct reliability
and controls.
to
and C.G.A.)
propane
gas. This Nmace
mobile homes, recreational
NOTE:
(fbrmerly
and
these
of heat exchang-
(See Fig. 3.)
details, re['cr to the applicable
instruction
to
gas.
materials
these
to
of 36 inches horizontally
or local code for Nrther
brackets
and materials
before
oper-
all national
ins{factions.
AND
and local
STANDARDS
codes and standards
The installation
must
comply
in addition
to
with regulations
of the serving gas supplier, local building, heating, plurnhing,
and
other codes. In absence
of local codes, the installation
must
comply
construction.
all shipping
CODES
Follow
with
kit is required
combustible
Remove
ating the furnace.
in
crawlspaces,
_br use
to combustible
supply air ductwork
J:br a distance
_?om the Nmace.
See NFPA 90B
requirements,
(SA
is factory°shipped
clearances
of
and for installation
utility
when
construction.
are
for use with natural
[or use with propane
11. See Fig. 2 for required
12, Maintain
listed
heating
See page 7 caution
Furnaces
required
constluction
multipoise
or force products
ers, motors,
9, The
4 way
design=certified.
is an appliance
temperature
in a residential
in the warning
is not
INTRODUCTION
Stoics
shipped
the remm
sealed to the _i/raace
8. A gas-fired
which
and Safety
by the t_urnace to areas outside
the furnace,
intended
plate.
is installed
base
_i_ctow- accessow- floor
on combustible
materials
to combustible
in the "Gas
the fmnace's
the allowable
Adjustments,
rating
a fitrnace
within
Special
Fig. 2 for clearance
--€ This
temperature-rise
7. When
as specified
section.
d. Always
flooring.
on carpetthan wood
_i/mace is installed on manu_hcturer's
(;oil Assernhly Part No.
(D5 or CK5, or when (Toil Box Part No. KCAKC is used. See
instructions.
5. Never test for gas leaks with an open flame. Use a commercially available
soap solution made specifically
for the detecPiping"
BOTTOM
FLUE COLLAR
(RN.}
may be required in some cases.
3. Provide adequate combustion and ventilation
space as specified
in "Air _br Combustion
section.
-->
F
TOP AND
C.L
having
with
the national
jurisdiction.
codes
listed
below
and all authorities
--> Step
MAX 85°F
8--Venting
*
US: NFGC:
*
(ANADA:
chapters
10 and 13
NSCNGPI(
ELECTROSTATIC
Part 7 and Appendix
DBSCHARGE
{ESD)
PROCEDURE
C
PRECAUTIONS
FRONT
-->
FURNACE
RELIABILITY
Improper
MIN 60°F
installation
ture thrnace
component
Electrostatic
discharge
Take precautions
protect
A02055
Fig. 3--Return
d_e thmace
which
Air Temperature
by putting
follow all codes
and standards
for
Step
•
US: National
Fuel
Gas Code
CANADA:
Natural
Step
•
CSA
Systems
NFPA
Standards,
National
Installation
90B
2
Standard
Codes
of
•
hstallation
Current
edition
of the NFGC
and the NFPA
90B.
--> *
for only the NFGC, contact the American Gas Association,
N. Capitol Street, N.W., Washington,
DC 20001
400
3--Combustion
US: Section
Ventilation
and Ventilation
8.3
of
the
NFGC,
4--Duct
NOT
US and CANADA:
Venting
Systems
Systems
90B as tested
Contractors
and Equipment
Handbook
Lining
Fibrous
current
and
US: NFGC;
Codes
•
CANADA:
NSCNGPIC
B, E and H
chapters
7--Electrical
•
US: National
•
CANADA:
and
edition
by UL Standard
Piping
body
will
discharge
and the person
at the same
Multiple
disconnects
may
your
and
removing
bo@'s
Gas
Pressure
of the fi.maace
held in a person's
discharged.
electricity
feet,
to service
as you
(for example;
do not
the
do nothing
touch
to
DO
ungrounded
(and recharge
touch
a clean,
your body
unpainted
again be:R_re touching
for installed
control
and uninstalled
with
metal
or wires.
(ungrounded)
a new contact
_i'om damage.
_i/mace,
_bltow items
in contact
into containers
also be used
to ground
If d_e control
1 through
befbre
discharge
to protect
is to be installed
4 befbre
with the furnace.
kit (available
to prevent
fi'om its container,
charge
touching
bringing
the
in a
the control
Put all used
and new
ungrounded
objects.
from commercial
sources)
may
ESD dan?age.
LOCATION
GENERAL
9 and 16.
Some assembly and modifications are required when used inany
of the four applications shown in Fig_ 4,
and NFPA
Testing
5, 6, 7, and 12 and National
Parts
Engineers
34 or 2000
181 fbr Class I Rigid Air Ducts
Pipe
as tong
ohjects
electrostatic
ConSoci-
Duct
of SMA(NA
Tools
you may proceed
your
firmly
control
or yourself
Association
Gtass
metal surface
with static
or shuffle
5. Use this procedure
and Air
Chapters
CHARGE
etc.).
7. An ESD service
•
Step
tools
_i/rnaces
D_ Sheet Metal and Air Conditioning
Association
(SMACNA),
or American
US and CANADA:
6--Gas
and hand
ELECTROSTATI(
wires
of the fiul_ace
controls
Air (onditioning
5--Acoustical
your
electricity),
surface
Sales,
(Tor-
(ombustion
ety of Heating, Refrigeration,
and Air Conditioning
(ASHRAE)
2001 Fundamentals
Handbook
Chapter
Step
to
pre-
precautions
will be satisfactorily
the chassis,
4. If you touch ungrounded
6. Before
for
BODY'S
grounding
move
objects,
Systems
(ACCA) Manual
tractors National
•
will
to electrostatic
to the furnace.
or connecting
recharge
Air
Air
CANADA:
Part 7 of NSCNGPIC,
Supply fbr Appliances
Step
These
is close to the control.
touching
static
CANADA:
NSCNGPIC.
For a copy, contact Standard
CSA International,
178 Rexdale Boulevard,
Etobicoke
onto), Ontario, M9W 1R3 Canada
HVAC
the control,
YOUR
which
control
For
Inc.,
or
Step
the control
all power
hand dtlring
(NSCNGPI()
Fire Protection
Association
MA 02269 (www.NFPA.org);
Step
ti'om personnel
the procedure.
Firmly touch the clean, unpainted,
chassis
Canada
(www.AGA.org).
--> •
Precautions
TO GROUND,
3. After
copies, contact the National
BattelTmarch
Park, Quincy,
•
components.
and servicing
potential.
CHARGING
54 2002/ANSI
Wam_ Air Heating
ANSI NFPA
B149.1-00
Gas and Propane
2--General
US:
(NFGC)
2002 and the Installation
and Air Conditioning
--> °
electronic
be required.
DO NOT TOUCH
THE CONTROL
OR ANY
WIRE C ONNE(TED
TO THE CONTROL
PRIOR TO DIS-
l--Safety
Z223.1
may cause prema-
installation
control.
discharges
exposing
1. Disconnect
the ibllowing:
affect
thrnace
electronic
the thmace,
electrostatic
In the [ nited States and Canada,
can
are held during
help to avoid
of furnace
failure
during
vent electrostatic
HAZARD
or service
Phnnbing
3, 4, and 5, and Appendices
This thmace must:
*
be installed so the electrical components
water
are protected from
*
not be installed directly on any combustible material other than
wood flooring (refer to SAFETY CONSIDERATIONS)
*
be located close to d-_echinmey or vent and attached to an air
distribution system, Refer to Air Ducts section,
*
be provided ample space fbr servicing and cleaning. Always
comply with mininmm fire protection clearances shown on the
fro'hate clearance to combustible consm/ction 1abel
A,
Connections
Electrical
Canadian
Code
Electrical
(NEC)
Code
ANSI NFPA
CSA C22
70
1
2002
AIRFLOW
THE BLOWER
LOCATED
BURNER
IS
BELOW
SECTION.
CONDITIONED
THE
AND
AIR IS
DISCHARGED
UPWARD.
THE BLOWER IS LOCATED
TO THE RIGHT OF THE
BURNER
SECTION,
AND
AIR CONDITIONED
DISCHARGED
AIR IS
TO THE LEFT
HORIZONTAL
THE
BLOWER
LOCATED
LEF[
IS
ABOVE
THE
BURNER
SECTION,
AND
CONDITIONED
AIR IS
DISCHARGED
DOWNWARD
A02097
Fig. 4_Multipoise
Orientations
All
f_el-burning
combustion
--€
CARBON
Failure
MONOXIDE
to fbllow
or death,
POISONING
this warning
could result
and unit component
(mTosive
or contaminated
containing
flue gas, which
Air for confbustion
compounds,
which
must
could
fluoride,
chloride,
detergents,
bleaches,
in a corrosive
cleaning
household
of parts
leak into the living
sprays,
furnace
failure
not be contaminated
include
other
cause
by
n-rest be supplied
air must
be provided
with
air %r fuel
to avoid
negative
pressure in the equipment room or space A positive seal must be
made between
the filrnace
cabinet
and the return=air
duct to
prevent
air may
These elements
can con'ode
fhrnace life. Air contaminants
and
injuU
in personal
damage.
iodide.
shorten
fresheners,
HAZARD
equipment
Sufficient
pulling
air fi'om the burner
area and from draft safeguard
opening.
space.
halogen
bromid<
and
heat exchangers
and
are found in aerosol
solvents,
products.
or contaminated
Do
salts,
not
atmosphere.
sure all confbustion
and circulating
air requirements
in addition to all local codes and ordinances.
air
install
Make
are met,
--> The %llowing types of t\_rnace installations may require OLT=
DOOR AIR _br combustion due to chemical exposures:
Commercial buildings
Buildings with indoor pools
Laundv
rooms
Hobby or craft rooms, and
Chemical storage areas
18-1N. MINIMUM
TO BURNERS
--> If air is exposed to the/bllowing substances, it should not be used
tbr combustion air, and outdoor air may be required tbr combus=
tion:
A93044
Fig. 8--Installation
in a Garage
Permanent wave solutions
Chlorinated waxes and cleaners
Chlorine based swimming pool chemicals
Water softening chemicals
Deqcing salts or chemicals
FIRE,
INJURY
Carbon tetrachloride
Improper
Halogen type refrigerants
or explosion
Cleaning solvents (such as perchloroethylene)
When
the
burners
furnace
above
the floor
Hydrochloric
avoid
damage
Cements and glues
Antistatic ti_bric softeners tbr clothes dwers
Mason U- acid washing materials
public
garage,
HAZARD
or inadequate
and ignition
Printing inks, paint removers, varnishes, etc,
acid
OR DEATH
location
protection
is installed
sources
airplane
in a residential
must be located
The fi/rnace
by vehicles.
must
When
hangar,
hazardous
atmosphere,
accordance
with the NFGC
could result in fire
the
be located
the furnace
or other
_\trnace
must
or NS(NGPI(.
garage,
at least
the
18 inches
or protected
is installed
building
be
to
in a
having
installed
(See Fig
5)
a
in
HAZARD
Improper use or installation of this furnace may cause
premature_mmce componentf_tilure,
This gas fl/ruace may be used for heating buildings under
construction provided that:
-The furnace is permanently installed with all electrical
wiring, piping, venting and ducting installed according to
these installation instructions A return air duct is provided,
sealed to the f_mlace casing, and tem_inated outside the space
containing the f_/mace. This prevents a negative p*essure
condition as created by the circulating air blower, causing a
flame rollout and/or drawing combustion products into the
structure.
-The fhmaee is controlled by a thermostat It may not be "hot
wired" to provide heat continuously to the structure without
them_ostatic control
-Clean outside air is provided for combustion This is to
minimize the con'osive effects of'adhesives, sealers and other
construction materials It also prevents the entrainment of
&ywall dust into combustion air, which can cause fouling
and plugging of ihmace components.
-The temperature of the remm air to the furnace is main°
rained between 55°F (13%?) and 80_>F (27°C), with no
evening setback or shutdown. The use of the furnace while
the structure is under construction is deemed to be intermit°
tent operation per our installation instructions
-The air temperature rise is within the rated rise range on the
fl/mace rating plate, and the firing rate has been set to the
nameplate value.
-The filters used to clean the circulating air during the
construction process must be either changed or thoroughly
cleaned prior to occupancy.
-The fi/ruace, ductwork and filters are cleaned as necessaw
to remove d_-wall dust and construction debris fiom all
HVAC system components after construction is completed.
-Verify proper furnace operating conditions including igni=
tiom gas input rate, air temperature rise, and venting
according to these installation instructions.
--9
FIRE, INJURY OR DEATH HAZARD
Failm'e to fbllow this warning could resuh in unsafe furnace
operatiou.
DO NOT install the fm'nace on its back or hang fhmace with
control compartment facing downward. Safety control opera°
tion will be adversely affected Never connect retm'n=air ducts
to back of furnace. (See Fig 6.)
LOCATION RELATIVE
TO (OOLING
EQUIPMENT
The cooling coil must be installed parallel with, or on d_e
downstream side of the unit to avoid condensation in the heat
exchangers. When installed parallel with the furnace, dampers or
other flow contlol must prevent chilled air fi'om entering d_e
furnace If" the dampe*s are manually operated, they must be
equipped with means to prevent operation of either unit unless the
damper is in the full-heat or fldl-cool position.
BACK
A
A02054
Fig. 6--Prohibit
InstNlation
AIR FOR COMBUSTION
on Back
AND VENTILATION
Provisions %r adequate combustion, ventilation, and dilution air
must be provided in accordance with:
*
15.S. installations: Section 8.3 of the NFGC, Air for (ongbustion and Ventilatiom and applicable provisions of the local
building codes
*
(anadian
installations:
Part 7 of the NSCNGPI(,
Venting
Systems and Air Supply _br Appliances, and all authorities
having jurisdiction
-->
FI[ RNACE CORROSION HAZARD
Failure to fbllow this caution may resuh in furnace damage.
Air _br combustion must not be contaminated by halogen
compounds, which include fluoride, chloride, bromide, and
iodide. These elements can corrode heat exchangers and
shorten furuace 1ilk Air contaminants are found in aerosol
sprays, detergents, bleaches, cleaning solvents, salts, air
fi'esheners, and other household products
--9
CARBON
MONOXIDE
POISONING
HAZARD
Failure to follow this waruing coutd result in personal inju W
or death.
The operation of exhaust farts, kitchen ventilation gins,
clothes &yers, attic exhaust farts or fireplaces could create a
NEGATIVE PRESSURE
CONDITION
at the fm'nace.
Make-up air MLST be provided for the ventilation devices, in
addition to that required by the fl_ruace. Refer to (arbon
Monoxide Hazard warning in venting section of these instruc°
tions to determine if au adequate amount of make-up air is
available.
---> The requirements
whether
for combustion
or not the fhmace
of at least
50 cubic
appliances
installed
Spaces having
the OUTDOOR
and ventilation
is located
f_et per
1,000
air depend
in a space having
Btuh
input
rating
upou
a volume
for all gas
in the space.
less than 50 cubic
COMBUSTION
feet per 1,000 Btuh
AIR METHOD,
require
Spaces having at least 50 cubic f_et per 1,000 Btuh may use the
INDOOR
COMB!
STION AIR, STANDARD
or KNOWNAIR INFILTRATION
METHOD
-->
Table 2=Minimum
Free Area Required
TWO HORIZONTAL
FURNACE[
INPUT
{BTUH)
for Each Combustion
DUCTS
SINGLE
(1 SQ. IN.t2,000 BTUH) (1,100 SQ. MM/KW)
Free Area of
Opening and Duct
Round Duct
(Sq. in.)
(in. Dia)
Air Opening or Duct to Outdoors
DUCT OR OPENING
TWO OPENINGS
(1 SQ. IN.i3,000 BTUH) (734 SQ. NNIKW)
Free Area of
Opening and Duct
Round Duct
(sq in.)
(in. Dia)
OR VERTRCAL DUCTS
(1 $Q. IN./4,000 BTUH) (880 SQ. MM/KW)
Free Area of
Opening and Duct
Round Duct
(Sq In.)
(In. Dia)
44,000
22
6
14.7
5
11
4
88,000
33
7
22
6
16.5
5
88,000
44
8
29.3
7
22
6
110,000
55
9
36.7
7
27.5
6
132,000
184,000
66
77
10
10
44
51.3
8
9
33
38.5
7
8
EXAMPLES:
Determining
FURNACE
Free Area
WATER
HEATER
TOTAL INPUT
110,000
+
30,000
(t40,000
88,000
+
40,000
(106,000 divided by 3,000)
divided by 4,000)
35.0 Sq. In. for each two Verticat Ducts or Openings
35.3 Sq. In. for a Singte Duct or Opening
88,000
+
30,000
(118,000 divided by 2,000)
59.0 Sq. In. for each of two Horizontal
--> Table 3=Minimum Space Volumes for 100% Combustion,
Dilution from Indoors
OTHER THAN FAN=ASSISTED
(1,000'S
ACH
30
TOTAL
FAN-ASSISTED
BTUH GAS INPUT RATE)
I
40
I
Ventilation,
Ducts
and
TOTAL
(1,000'S BTUH GAS INPUT RATE)
50
44
166
Space Volume (ft 3)
I
88
1110
I
132
1154
0.80
1,050
1,400
1,750
1,100
1,650
2,200
2,750
3,300
3,850
0.80
1,260
1,680
2,100
1,320
1,980
2,640
3,300
3,960
4,620
0.40
1,575
2,100
2,625
1,650
2,475
3,300
4,125
4,950
5,775
0.30
2,100
2,800
3,500
2,200
3,300
4,400
5,500
6,600
7,700
0.20
3,150
4,200
5,250
3,300
4,950
6,600
8,250
9,900
11,550
0.10
0.00
6,300
NP
8,400
NP
10,500
NP
6,600
NP
9,900
NP
13,200
NP
16,500
NP
19,800
NP
23,100
NP
NP = Not Permitted
---> Outdoor
Combustion
1. Provide
the space
ventilation,
zontal
Air Method
with
and dilution
or vertical
duct(s)
ing with the ontdoors
the ontdoors.
b. Not less than the sum of the areas of all vent connectors
sufficient
air _br proper
of flue gases
or opening(s)
or spaces
directly
the space.
combustion,
using permanent
hori=
communicat=
that freely communicate
with
a. One
to the outdoors.
opening
MUST
commence
within
the ceiling and the second opening
within 12" (300 ram) of the floor.
b. Size openings
The opening
Appliances
ram) fiom
opening
2. Fig. 7 illustrates
how to provide TWO OUTDOOR
OPEN°
INGS, one inlet and one outlet combustion
and ventilation
air
opening,
12" (300
MUST
and ducts per Fig. 7 and Table
ram)
in
of
commence
shall
communicate
or spaces
outdoors.
Indoor
shall commence
within
12" (300 ram) of the ceiling.
in the space shall have clearances
of at least 1" (25
d-_esides and back and 6" (150 ram) from the front. The
directly
(crawl
a vertical
or
Combustion
---> Standard
communicate
through
attic)
Air<)
with
that
NFPA
fieely
or shall
duct to d_e outdoors
communicate
with
the
& AGA
and Known-Air-Infiltration
Rate
Indoor air is permitted
fbr combustion,
if the Standard
or Known=Air-Infiltration
2.
the outdoors
or horizontal
Methods
ventilation,
Method
and dilution,
is used.
c. TWO HORIZONTAL
DUCTS require
1 square inch of
flee area per 2,000 Bmh (1.100 mm2ikW)
of combined
input fbr all gas appliances
2.
in the space per Fig. 7 and Table
Failure
d. TWO OPENINGS
OR VERTICAL
DUCTS
require
1
square inch of flee area per 4,000 Bmh (550 mm2ikW) for
combined input of all gas appliances
7 and Table 2.
3. ONE OUTDOOR
a. 1 square
OPENING
input
in the space per Fig.
in death
Many
furnace
MONOXIDE
to supply
and/or
homes
POISONING
outdoor
personal
require
combustion,
air via grilles
HAZARD
or ducts
Btuh
of all gas appliances
(734 mm2&W)
in the space
per
could result
injury.
air to be supplied
ventilation,
from
and dilution
The /'umace combustion
air supply must
accordance
with this instruction
manual.
requires:
inch of flee area per 3,000
for combined
Table 2 and
CARBON
outdoors
for
of flue gases.
be provided
in
PER4000
BTUH*
TO
OUTDOORS
DUCTS
CIRCULATING AIR
I
-
I
I
I
t
12" MAX
] VENT THROUGH ROOF
r
I
I
I
I
I
I
I
I
I
LJl .L
12 _
MAX
1 SQ IN
A
PER2000
BTUH*
i
1 SO IN.
" PER 1000
BTUH* IN DOOR
OR WALL
SQ tN
PER
4000
BTUH*
c0
8d
UNCONFINED
SPACE
INTERIOR
HEATED
SPACE
o
o
DUCTS
TO
OUTDOORS
S
6" M[N
(FRONT)t
o
1 SO iN.
PER
4000
BTUH*
:
1 SQ IN.
PER 2000
BTUH
I[
1 SQ IN.
PER 1000
BTUH* tN DOOR
OR WALL
12 _
MAX
12" MAX
CIRCULATING
1 SQ IN.
PER 4000
BTUH*
TO
OUTDOORS
*Minimum
NOTE:
]l
AIR DUCTS
dimensions
of 3 in
Use any of the following
combinations
of openings:
A&B
C&D
D&E
The Stalidard
Bmh
for Combustion, Ventilation
Dilution for Outdoors
in the space
2. The air infiltration
changes
input
than 50 cubic
ratings
rate is not known
than 0.40 ACH
2. Equal
to or greater
Infiltration
rates
mininlum
required
volume
and
and
f'cet per
such as this fk/rnace:
appliances
1.000
_
to be less than 0.40 air
15fls
I ran
VolumeFa n - __
than
0.60 ACH
shall
of the space varies
together
not be used.
with the number
The
of
3 or Equations
1 and 2.
for each appliance in the
to get
the total
Space
fiom
Volumes
the
were
Yationa/
determined
by using the
F_el
Cn&_ zl:\i_7
Gas
appliances,
such
input of all fan-assisted
air changes
as a draft
heater:
per hour
--> The following requirements
the Known Air Infiltration
1. Adjoining
fan-assisted
water
I_.,, = combined
ACH
54-2002.&3.2.2:
than
If:
Ioti_ = combined input of all other than fan-assisted
ances in Btuhr
appliances
21fts
=
rooms
apply to the Standard
Rate Method
can be considered
a. There are no closable
b. (ombining
_
A-==0_p0_}
I °tt'er
in Btuhr
shall not exceed
(ACH
spaces
but not
A04002
less than
commence
second
within
opening
12" (300
ram)
shall commence
at least 3 in. (80 ram).
dimension
and to
if!
Each opening
shall
Btuh (2.000 mm2ikW)
of all gas appliances
100 in. 2 (0.0d
the floor. The minimum
Method
rooms.
on same floor level.
of the total input rating
}/
B-_/hr)
0.d0.)
part of a space
doors between
have fiee area of at least 1 in.2/1.000
Volumeother
appli-
n_inin-mm
for the space.
equations
other
if the
than 0.10 ACH
volume
Z223./-2002/iVFP_
hood-equipped
shall be used.
and
greater
3-Minimum
1. For
for Combustion, Ventilation
Dilution from indoors
A04003
and add the volumes
following
-> Fig. 8--Air
for all gas appliances
Method
A(H and shall be detem_ined per Table
Determine the mininmm required volume
Table
vent is used.
per hour (ACH)
1. Less
space
of 3 in. when type-B1
and
The Kno_n
Air Infiltration
Rate
infiltration
rate is known to be:
required
t Minimum
2. For fan-assisted
has no tess volume
of the maximum
installed
opening size is 100 sq in with
dimensions
of 3 in.
A03175
Method:
1. The space
* Minimum
minimum
F&G
A03174
-> Fig. 7--Air
CIRCULATING AIR DUCTS
m2). One
in the space.
opening
of the ceiling
within
12" (300
of air openings
(See Fig. S.)
shall
and the
ram) of
shall be
c.( ornbining
space
ondiff?rent
floorlevels.
Thevolumes
of
spaces
ondifferent
floorlevelsshallbeconsidered
as
communicating
spaces
if connected
byoneormore
perma=
nentopenings
indoors
orfloorshaving
fi'eearea
ofatleast
2 in.2/1,000
Bmh (4,400
mma&W)
of total
input rating
of
all gas appliances.
2. An attic or crawlspace
communicates
pet_nanent
may be considered
with the outdoors
ventilation
_?ee area of at least
all gas appliances
3. In spaces
a space
provided
openings
directly
i-in.2/4,000
Bmh
that fieely
there are adequate
to outdoors
having
of total input rating
for
in the space.
that
use
infiltration
should
pemlanent
ventilation
buildings
with
tlle
Indoor
Combustion
be adequate
to provide
and dilution
unusually
MUST
be provided
Outdoor
Combustion
Air
construction,
However,
is defined
in
additional
using
the methods
described
Air Method section.
Unusually tight construction
Construction
with:
and ceilings
ous_ sealed
and
b. Doors
exposed
vapor
barrier.
and openable
air
Fig. g--Removing
Openings
have a continu=
are gasketed
most
or sealed
are weatherstripped
Side
openings
are caulked
around
window
and door
floors,
between
wall-ceiling
penetrations
---> Combination
or sealed.
fi'ames,
openings
Combustion
3. Outdoor
Air Method
openings
a. (alculate
required
below.
joints
sole plates
and
wall panels,
and gas lines,
in DOWNFLOW
Leveling
Legs (If Desired)
position
NOTE:
etc.
closure
and,
is
bottom
1 minus
size
required
of
Outdoor
in Outdoor
openings
(ombusIiou
nmltiplied
by reduction
dimension
of air openings
Factor
shall
Air
be
corner
3. Install
the
the
Method
in b. above.
legs may be
bolts,
and nuts.
washers
most be used when leveling
and reinstall
legs are used.
bottom
closure
closure
panel,
panel
see Item
legs:
furnace
on its back.
of fi/mace.
another
Locate
and drill a hole in each
(See Fig. 10.)
4. Adjust
size
outside
5. Reinstall
above
The nlininlum
NOTE:
nut to provide
base. (Install
flat
desired
height, and tighten
inside
closure
panel
if removed.
INSTALLATION
For downflow
applications,
use on combustible
flooring
accessories
are used:
111111)
side of fi/rnace
arrallgement.
bottom
DOVvL\'FLOW
shall be not tess than 3 in. (80
nut on other
if desired.)
nut to secure
c. Minimum
leveling
2. For each leg, install nut on bolt and then install bolt and nut in
hole. (Install flat washer if desired.)
washer
Factor
inlet(s),
5/16 X 1-1/2 in. (max)
to remove
leveling
1. Position
as follows:
reduction
and
side return-air
field=supplied,
to install leveling legs. To remove bottom
1. in Bottom Return Air Inlet section.
the Ratio of all Indoor Space volume divided by
volume
_br Indoor
Combustion
Air Method
b. Outdoor
opening
size
Ratio in a. above.
in UPFLOW
Do not use
side remm
machine
Bottom
To install
shall be sized
with
con'osion-resistant
in tlle Outdoor
previously
can be used
at
Combustion
as required
mentioned
Closure Panel
configuration.
(See Fig. 10.) Install
It may be necessary
with tlle Indoor
openings
coni:igurations
openings
used.
Air
shall be located
Bottom
and
include
between
electrical
and Outdoor
1. Indoor openings shall comply
Air Method below and,
2. Outdoor
between
joints,
_br plumbing,
of Indoor
These
return=air
HORIZONTAL
In upfluw
c. Other
A02098
in the
as
to the outdoors
windows
BOTTOM CLOSURE
PANEL
BOTTOM FILLER
PANEL
NOTE:
a. Walls
I
air for combustion,
of flue gases.
tight
I
Method,
this furnace
when
is approved
fbr
any one of the following
3
INSTALLATION
L PFLOW
Bottom
These
Return
Air Inlet
fhmaces
are shipped
bottom
return-air
bottom
remm
perfbrrn
die following:
opening.
air
panel
2. Rotate
with bottom
Remove
is use&
1. Tilt or raise furnace
To
bottom
filler
panel installed
this panel
bottom
2 screws
panel downward
closm'e panel
4. Reinstall
bottom
filler panel
bottom
Special
°
Cased
Base, KGASB
°
(?oil Box Part No. KCAKC
closure
holding
bottom
in
are shipped
return=air
only side remm
Assembly
1. Determine
when
panel
filler
to release
holding
tabs.
application
opening.
This panel
closure
hole in floor per Table
MUST
be in place
in
when
install
It is recommended
be completely
that
to bend flange
3 and Fig.
or (Toil Box Part
in Fig. 13.
the perI:brated
the _i/rnace on a fhctory-supplied
of sharp edges.
or (K5
as shown
_blded over or removed
the supply-air
in Table
is used, install as shown in Fig.
No. K(AKC
is used,
3.
3 and Fig. 11.
Part No. (D5
seamers
10
KOASB
from Table
specified
12. If Coil Assernbly
To remove
air is used.
to dimensions
subbase,
or (K5
installed
plenum
flanges
panel installed
being
3. (onstruct
11.
installing
with bottom
Part No. (D5
2. (onstruct
NOTE:
and screws
Air Inlet
fk/rnaces
(oil
4. If downfluw
bottom
Side Return
remove
and remove
closure
and discard
(See Fig. 9.)
3. Remove
These
°
INSTALLATION
supply-air
duct
flora fi_rnace when
cased
coil or coil box.
dact flange, use wide duct pliers or hand
back and _:Prth until it breaks
(See Fig. 14.)
of L Be careful
Platfbrm
Furnace
Construct
Support
working
platform
clearances
are met.
clearance
requirement
blocks,
bricks
at location
(See Fig
on side,
or angle
where
all required
2 and 17.) For furnaces
iron
set fllmace
furnace
with
l-in.
on non=congbustible
For crawlspace
installations,
if the
fm'nace is not suspended
fi'om the floor joists, the ground underneath furnace must be level and the furnace set on blocks or bricks.
Roll=Out
/4 t,
Protection
Provide
a minimum
roll-out
protection
12 inches
closer
above
than
X 22" piece
to joists.
closure
panel
may be used
deck
The
casing
of sheet metal
area for fhmaces
combustible
the fhmace
bottom
larger
the
12-in.
underneath
The
17-3/4"
in fi'ont of burner
or suspended
sheet
metal
These
A02071
Fig. 10--Leveling
Bottom
Return
Legs
Return
on furnaces
for flame
ti_maces
These
furnaces
are shipped
bottom
return=air
bottom
return
perfbrm
the following:
Remove
is used.
1. Tilt or raise furnace
panel.
with bottom
opening.
air
To
closure
panel installed
and discard
remove
and remove
in
this panel
when
return=air
bottom
remm
perform
the following:
closure
panel,
bottom
2 screws holding
bottom
filler
bottom
of widths
roll-out
downward
3. Remove
bottom
closure
4. Reinstall
bottom
filler panel
HORIZONTAL
to release
holding
tabs.
air
Remove
is used.
bottom
To
closure
bottom
filler panel
of
17 for proper
closure
panel
remove
installed
in
this panel
when
closure
panel,
bottom
2 screws holding
bottom
filler
to release
holding
tabs.
panel.
and screws.
Air Inlet
furnaces
are shipped
with bottom
closure
panel
installed
in
opening. This panel MUST be in place when side
is used without a bottom return air linlet.
Not all horizontal
furnaces
connections
(See Fig. 20.)
INSTALLATION
See Fig.
filler panel downward
bottom
bottom return=air
return air inlet(s)
and screws.
in. and
when bottom
and discard
and remove
3. Remove
Side Return
panel.
17=i/2
protection
with bottom
opening.
4. Reinstall
These
filler panel
extend
(See Fig. 9.)
2. Rotate
(See Fig. 9.)
2. Rotate
are shipped
bottom
panel.
MUST
Air Inlet
1. Tilt or raise furnace
Air Inlet
than
furnaces
by 1 in. with the door removed.
furnace is used for remm air connection.
orientation
of roll=out shield.
Bottom
for flame
closer
are
approved
for
side
return
air
FILTER ARRANGEMENT
--€
FIRE, EXPLOSION,
AND
POISONING
HAZARD
Failure
to follow
operation,
control
this warning
serious
Do not instal1
CARBON
injury,
on either
car* be installed
the left-hand
can be hung
fiom
non-combustible
downward.
Suspended
The furnace
Safety
rafters
blocks,
or trusses
under
each
or death.
return=air
ducts
Never operate
door removed.
or installed
A field=supplied
on a
This furnace
suitable
of l\tmace
(plumber's
straps)
assembly
rod,
(See Fig. 15 and 16.)
as shown.
may be used
the
General
in the bottom
Conditioning
duct
accepted
for each strap. (See Fig. 15 and
16,)
system
are attached
the straps
not pull away fiom
must
to ONLY
be vertical
the f_amace sides,
screws are not in tension
(are loaded
the fitmace
against
sides
Contractors
Society
sides and
Engineers
(ASHRAE)
so that the strap attachment
!i_ve.s reference
support,
duct system
11
be
with
filter rack or a
external
designed
as
National
of Heating,
available
and
Cabinet.
filter
sized
those
rack
for
according
published
(ACCA),
to
by:
Air
Metal
and
(SMACNA)
or
Sheet
Association
Refrigerating
or consuh
tables
should
such
Association
Contractors
American
in shear) for reliable
1" external
such as the Media
options
standards
and not the
the fm'nace
filter rack in these fhrnaces.
filter rack is required.
supplied
should
national
Air Conditioning
--> If the screws
bottom,
instructions
access
Requirements
The
casing
external
substitute,
in fire, personal
a filter or with filter
KGAFR0301ALL
and installation
furnace fiom each bottom corner. To prevent screws fiom pulling
out, use 2 #S x _/_-in. screws into the side and 2 #8 x -%-in. screws
of the fhmace
requires
result
AIR DLCTS
Heavy-gauge
to suspend
could
for an internal
accessory
field-supplied
to the
AND POISONING
a fire, ace without
There are no provisions
The furnace
end with threaded
strap as shown.
iron to bottom
straps
to %tlow
injury,
Refer
Secure
sheet metal
Failure
or pad.
angle iron or metal plumber's
angle
this warning
with
Suppmq _
may be supported
MONOXIDE
opera=
fimaace
(RH) side
bricks
FIRE, CARBON
HAZARD
control
in an attic or crawl space
or right=hand
floor joists,
Furnace
in dangerous
damage
Never connect
horizontally
(LH)
platfbrm,
result
or property
on its back or hang
facing
tion will be adversely affected.
to the back of the furnace.
The furnace
could
death
the fttrnace
compartment
MONOXIDE
and Air Conditioning
Yhe Ai_' .5)'stems Desigr_ G_idefi'om your
be sized to handle
tocal
the required
distributor.
system
The
design
TaNe 4_Opening
FURNACE
CASRNG
WIDTH
Dimensions
(in.)
PLENUM OPENING
Upflow Applications on Combustible or Noncombustible
Flooring (KGASB subbase not required)
Downflow Applications on Noncombustible
(KGASB subbase not required)
t4-3/16
Flooring
Downflow applications on combustible flooring
subbase required)
(KGASB
Downflow Applications on Combustible Ftooring with CD5 or
CK5 Coil Assembly or KCAKC coil box (KGASB subbase
not required)
A
B
12-11/16
21-5/8
12-9/16
19
13-3/16
19-5/8
11-13/16
19
13-7/16
20-5/8
12-5/16
19
13-5/16
20
16
21-5/8
16-5/8
22-1/4
15-7/8
19
16-1/2
19-5/8
15-1/8
19
16-3/4
20-5/8
15-1/2
19
16-1/2
20
19-1/2
21-5/8
20-1/8
22-1/4
19-%8
19
20
19-5/8
18-5/8
19
20-1/4
20-5/8
19
19
20
20
23
21-1/8
23-5/8
22-1/4
22-7/8
19
23-1/2
19-5/8
22-1/8
19
23-3/4
20-5/8
22-1/2
19
23-1/2
2O
Upflow Applications on Combustible or Noncombustible
Flooring (KGASB subbase not required)
Downflow Applications on Noncombustible
(KGASB subbase not required)
17=1/2
Flooring
Downflow applications on combustible flooring
subbase required)
(KGASB
Downflow Applications on Combustible Ftooring with CD5 or
CK5 Coil Assembly or KCAKC coil box (KGASB subbase
not required)
Upflow Applications on Combustible or Noncombustible
Flooring (KGASB subbase not required)
Downflow Applications on Noncombustible
(KGASB subbase not required)
21
Flooring
Downflow applications on combustible flooring
subbase required)
(KGASB
Downflow Applications on Combustible Flooring with CD5 or
CK5 Coit Assembly or KCAKC coit box (KGASB subbase
not required)
Upflow Applications on Combustible or Noncombustible
Flooring (KGASB subbase not required)
Downflow Applications on Noncombustible
(KGASB subbase not required)
24-1/2
Downflow applications on Combustible
subbase required)
Flooring
flooring
(KGASB
Downflow Applications on Combustible Ftoonng with CD5 or
CK5 Coil Assembly or KCAKC coil box (KGASB subbase
not required)
(FM
at d_e design
external
static
rates are provided
in Table
When
is installed
a J:\lmace
circulated
_/rnace,
the furnace
_/rnace.
Seal
ductwork
approved
The
so that
and terminating
with proper
ducts
the space
outside
fasteners
and return-duct
furnace
airflow
car_-
air
containing
by a duct(s)
the
sealed
the space containing
for type of doctwork
connections
Both
FM (With Filter)
the supply
air shall also be handled
casing
supply-
to _./rnace
with
to
Flexible
connections
and/_urnace
to prevent
ing through
unconditioned
enhance
system
barrier
Maintain
should
transmission
be used between
of vibration.
space should
the
perfbrmance.
When
Acoustical
Air Connections
that the heat exchanger
code
light
pass=
The cover
and Horizontal
(onnect
Bend
air conditioning
is used,
The
materials
to supply
a
Metal
duct systems
and 10 ft of main
duct
supply-air
flange
that do not have
a 90 degree
take-off
internal acoustical lining. As an alternative,
fibrous
be used if constructed
and installed in accordance
edition
of SMACNA
construction
standard
fbr possible
with
1 Rigid
on
to 90 ° with wide
duct
air
must
DO NOT
cut main J:_m'nace casing
See
duct,
humidifier,
or other
elbow
flange
temporarily
while
the coil are performed.
ductwork may
with the latest
glass ducts.
12
outlet.
(See Fig. 14)
to ONLY
the
coil casing
side to attach
All accessories
furnace
(when
supply
air
MI_ST
be
main casing
applications,
Go allow
supply=air
or air conditioning
accessories
to furnace
For horizontal
fulnace
be connected
used)
external
using
the air
leaks.
duct pliers
air
connected
openings
for sampling
shall prevent
duct flanges
may require
on fibrous
comply
Furnaces
duct to flange
upward
supply-air
--€ NOTE:
to the first branch
shall
coil, the outlet duct shall
can be inserted
supply=outlet-air
Treatment
22-1/4
181 for (?lass
can be viewed
attachment
bent past 90 degrees
NOTE:
ductwork
Standard
with a cooling
or a probe
Upflow
and sealed to
fiom combustible
assistance
stream.
be insulated
ductwork for a distance of 36 in. horizontally
fiom the Nmace.
NFPA 90B or local code _br Nrther requirements.
Ductwork
Supply
D
13-5/16
and fibrous
by _L
used.
is recommended.
a l-in. clearance
lining
90B as tested
C
be provided with a removable
access panel. This opening shall be
accessible
when the furnace is installed and shall be of such a size
ductwork
Ductwork
acoustical
NFPA
ducts.
For a f_u'nace not equipped
tape or duct sealer.
NOTE:
vapor
pressure
5=AIR DELIVERY=(
by the J:\_mace to areas outside
the return
Secure
FLOOR OPENING
APPLICATION
the top-most
d_e evaporator
the remaining
flange
may be
coil to hang on the
attachment
and sealing
of
FURNACE
(OR COIL CASING
WHEN USED)
COMBUSTIBLE
FLOORING
SUBBASE
PLENUM
__
FLOOR __
OPENING
A96283
Fig. 11--Floor
and Plenum Opening
Dimensions
A96285
Fig. 12--Furnace,
Plenum, and Subbase
a Combustible
Floor
InstNted
on
FURNACE
CD5 OR CK5
COIL ASSEMBLY
OR KCAKC
COIL BOX
COMBUSTIBLE
FLOORING
SHEET METAL _
PLENUM
FLOOR
OPENING
A04140
Fig. 13--Furnace,
___>
Downflow
Connect
flange
outlet
supply-air
proved
duct
to supply-air
past 90 ° with wide
duct must be connected
or air conditioning
on combustible
ONLY
or Coil Box Installed
Furnaces
inward
supply=air
Plenum, and Coil AssemNy
coil casing
material,
the accessory
supply-air
subbase,
outlet
on
_iu_ace.
duct pliers_ (See Fig.
to ONLY
(when
the fi/rnace
used).
When
Bend
casing.
supply=
installed
be connected
to
KGASB0201ALL,
or _Sctory
ap=
coil casing.
DO NOT
Floor
cut main
furnace
casing to attach supply side air duct, humidifier,
or other accessories. All accessories
MUST
be connected
external
to furnace
14.) The
duct must
air conditioning
on a Combustible
13
UPFLOW
DOWNFLOW
HORIZONTAL
i i PREFERRED
PREFERRED
I.....
PREFERRED
120_.
PREFERRED
M_N
PERMITTED
PERMITTED
i PERMITTED
i
i
IJ
A02329
Fig. 14--Duct
Flanges
W' THREADED
4 REQ
ROD
I
I
I
I
I
<
SECURE ANGLE
IRON TO BOTTOM
OF FURNACE WITH
3 #8 x s/4"SCREWS
TYPICAL FOR 2 SUPPORTS
1" SQUARE, 1W' x 1 W' x %" ANGLE IRON
OR UNI-STRUT MAY BE USED
(2) HEX NUTS, (2)WASHERS
REQ PER ROD
& (2) LOCK
WASHERS
A05027
-_ Fig. 18--Horizontal
Return
Unit Suspension
Air Connections
horizontal
made
Upflow
The
FIRE
HAZARD
Failure
to %l!ow
this warning
could
injury, or death
Never connect return-air
ducts
Follow instl-t/ctions below.
DownJ:low
The
a fire, personal
to the back
of the ftmaace
duct
must
be
connected
to
(left or right).
Side opening
is pem_itted
return-air
opening
cut into casing
for only upflow
sides
and most
14
humidifier
connections
sides exterior
be connected
to bottom,
or a combination
of bottom
casing
as shown
lg and 20. Bypass
to unused
Fig
lg and 20.)
Not
all
horizontal
should
be
to ft_rnace
Furnaces
duct must
right),
connections.
inlet) as shown in Fig. 19. DO NOT
Bypass
or coil casing
and Horizontal
return-air
attached
Furnaces
return=air
(bottom
cause
Parnaces.
at ductwork
in Fig
side return
fm'naces
(See Fig
20.)
and side(s)
sides
of main
l"mmidi_]er
(left
may be
air side of the [:tm_ace casing
are
approved
for
side
or
furnace
return
(See
air
22 GAUGE GALVANIZED
FOR 4 STRAPS
x 3/4
SHEET METAL SCREWS
TYPICAL FOR ALL
STRAPS
BACK
OF
FURNACE
FOLD ALL STRAPS
UNDER FURNACE AND
SECURE W(2) #8 x 3/4
SHEET METAL SCREWS
A02014
Fig. 16--HorizontN
Suspension
with Straps
LINE CONTACT ONLY PERMISSIBLE BETWEEN
LINES FORMED BY INTERSECTIONS OF
STUDS, OR FRAMING.
17 s/4" OVER ALL
4 3/4" UNDER DOOR
1" UNDER FURNACE
EXTEND OUT t2'* OUT
FROM FACE OF DOOR
30-tN. MIN
* WHEN USED WITH
SINGLE WALL VENT
CONNECTIONS
GAS VALVE
SEDIMENT j
TRAP
A02164
Fig. 17--Typical
Attic Installation
GAS PIPING
,iU
_.
FIRE
OR
Failure
EXPLOSION
to l'ollow this warning
Never
a gas line into a combustion
leaks
with
in personal
death,
injury,
Ese
damage,
an
open
flame
available soap solution made specifically
leaks to check all connections.
FIRE
OR
Failure
could result
property
purge
--+
HAZARD
deatl-_ and/or
for gas
iiiiiil
chamber
Never
for the detection
and/or
proper
maniR_ld
test
Use a commercially
EXPLOSION
to %llow
HAZARD
this warning
property
length
coud result
in personal
inju W,
damage,
of pipe
to avoid
stress
on
gas contloi
and a gas leak,
Gas piping must be installed in accordance
with national and tocal
codes. Refer to current edition of NFG(
in the US, the NSCNGPIC in Canada,
of
15
-4_
Table 5--Air
FURNACE
SIZE
RETURN-AIR
INLET
0.9
1.0
770
640
555
675
555
470
565
440
360
390
250
190
195
---
1160
1115
1040
1070
1040
965
975
950
885
870
850
790
730
725
670
560
575
520
945
760
645
900
720
600
845
675
555
775
610
475
680
490
390
490
375
300
335
265
--
1320
1240
1145
1265
1205
1105
1200
1140
1050
1125
1075
990
1035
995
920
940
905
840
830
790
725
655
620
555
1740
1585
1420
1670
1530
1385
1600
1470
1325
1530
1405
1280
1445
1330
1220
1360
1255
1155
1280
1170
1080
1180
1080
995
1075
990
910
1650
1515
1385
1600
1485
1360
1535
1440
1320
1465
1380
1260
1385
1300
1195
1285
1220
1120
1175
1115
1025
1055
990
915
895
830
710
645
600
565
High
Med-High
Med-Low
2060
1790
1505
1985
1765
1505
1915
1715
1480
1820
1645
1440
1720
1560
1375
1610
1470
1300
1490
1345
1190
1340
1195
1045
1135
1010
890
925
820
740
High
Med-High
Med-Low
2405
2225
2020
2310
2155
1955
2220
2080
1880
2130
1995
1805
2025
1895
1730
1920
1785
1630
1790
1675
1535
1660
1565
1420
1530
1420
1275
1350
1260
1135
Both Sides or
1 Side & Bottom
High
Med-High
Med-Low
2530
2285
1995
2450
2215
1945
2365
2150
1900
2270
2075
1840
2165
1985
1770
2065
1890
1685
1940
1780
1600
1805
1660
1480
1670
1525
1350
1505
1360
1180
1 Side Only
High
Med-High
Med-Low
2475
2260
1950
2395
2190
1910
2300
2110
1855
2200
2035
1795
2090
1940
1730
1985
1845
1650
1865
1735
1555
1730
1620
1445
1585
1475
1310
1425
1325
1150
High
Med_High
Med-Low
1625
1510
1360
1575
1470
1335
1515
1415
1295
1445
1355
1250
1355
1285
1180
1260
1185
1100
1165
1070
985
990
890
810
785
725
....
---
High
Med-High
Med-Low
2035
1745
1530
1965
1710
1515
1880
1650
1470
1790
1560
1400
1680
1450
1310
1495
1340
1215
1365
1205
1095
1215
1090
990
1075
955
830
875
750
670
High
Med-High
Med-Low
2530
2230
1920
2470
2205
1900
2400
2165
1880
2320
2110
1845
2220
2035
1795
2115
1950
1730
2000
1855
1650
1865
1740
1555
1730
1615
1460
1590
1485
1340
Bottom Sides or
1 Side & Bottom
High
Med-High
Med-Low
....
2235
1920
2200
1900
2415
2155
1880
2350
2100
1845
2250
2040
1795
2145
1955
1730
2015
1850
1650
1875
1740
1555
1715
1595
1460
1560
1470
1340
1 Side Only
High
Med-High
Med-Low
2540
2125
2495
2120
1795
2430
2105
1790
2355
2060
1765
2265
2010
1720
2175
1940
1650
2065
1840
1585
1935
1730
1500
1785
1615
1390
1650
1485
1280
or
Side(s)
Bottom
038049
or
Side(s)
Bottom
024070
or
Bide(s)
Bottom
038070
or
Side(s)
Bottom
048070
or
Side(s)
Bottom
042090
or
Bide(s)
Bottom
048090
or
Side(s)
Bottom
Only
080090
Bottom
038110
or
Bide(s)
Bottom
048110
or
Side(s)
Bottom
Only
099110
- CFM (With Filter)*
(_N. WC)
0.7
0.8
Bottom
024045
Delivery
SPEED
EXTERNAL
0.4
STATIC
0.5
0.1
0.2
0.3
High
Med-High
Med-Low
1085
920
820
1035
875
775
975
830
730
915
770
680
845
710
620
High
Med-High
Med-Low
1440
1360
1250
1375
1300
1210
1305
1240
1160
1240
1175
1100
High
Med-High
Med_Low
1030
835
725
1010
815
700
980
790
675
High
Med-High
Med-Low
1425
1320
1200
1375
1280
1175
High
Med-High
Med-Low
1805
1630
1460
High
Med-High
Med-Low
*A filter is required for each return-air inlet Airflow performance included 1-in. washable
determine airflow pedormance without this filter, assume an additional 0 1 in. wc available
-- Indicates unstable operating conditions
16
PRESSURE
0.6
filter media such as contained
external static pressure
in factory-authorized
accessory
fi{ter rack. To
-+
Table5--Air
FURNACE
SIZE
RETURNoA_R
INLET
SPEED
EXTERNAL
0.4
STATIC PRESSURE (IN. WC)
0.5
0.6
0.7
0.8
0.2
0.3
0.9
1.0
High
Med-High
Med-Low
2090
1790
1545
2010
1755
1525
1930
1705
1500
1835
1640
1450
1710
1550
1380
1590
1465
1315
1470
1360
1215
1335
1210
1005
1025
945
855
835
785
670
High
Med-High
Med-Low
2485
2195
1880
2400
2150
1850
2310
2090
1820
2215
2000
1780
2110
1920
1715
2000
1825
1635
1880
1720
1540
1725
1565
1415
1535
1405
1290
1355
1255
1160
Bottom, Sides or
1 Side & Bottom
High
Med-High
Med-Low
....
2180
1880
2145
1850
2385
2060
1820
2305
2010
1780
2195
1945
1715
2085
1865
1635
1960
1765
1540
1825
1660
1415
1670
1515
1290
1465
1325
1160
1 Side Only
High
Med-High
Med-Low
....
2135
1880
2085
1850
2245
2035
1820
2155
1975
1780
2055
1895
1715
1940
1795
1635
1825
1685
1540
1695
1565
1415
1555
1445
1290
1385
1265
1160
Bottom
Onty
High
Med-High
Med-Low
2465
2115
1800
2430
2105
1790
2375
2075
1770
2305
2030
1735
2230
1980
1695
2110
1910
1640
2000
1830
1570
1865
1725
1465
1725
1590
1345
1545
1425
1225
Both Sides Or
1 Side & Bottom
High
Med-High
Med-Low
....
2155
1800
2135
1790
2375
2095
1770
2285
2040
1735
2200
1975
1695
2105
1895
1640
1995
1790
1570
1870
1685
1465
1730
1550
1345
1570
1400
1225
1 Side Only
High
Med-High
Med-Low
....
2140
1800
2095
1790
2260
2040
1770
2180
1975
1735
2085
1890
1695
1975
1810
1640
1865
1705
1570
1740
1595
1465
1605
1480
1345
1455
1325
1225
048185
or
Side(s)
Bottom
Onty
080155
- CFM (With Filter)* (Continued)
0.1
Bottom
868135
Delivery
*A filter is required for each return-air inlet Airflow performance included lqn washable filter media such as contained
determine airflow performance without this fi{ter, assume an additional 01 in wc available external static pressure.
Indicates unstable operating conditions.
Installations
having
must
be made
jurisdiction.
in accordance
If possible,
separate
line running
directly
--> NOTE:
In the state
of Massachusetts:
1. Gas
supply
plumber
with
the gas supply
fi'om meter
connections
MUST
all
authorities
line
should
be a
to f_/ruace.
be per_brmed
by a licensed
lever handle
type manual
the maximum
equipment
shutoff
is NOT
hangers,
every 6 J:'t.Joint compound
of joints.
length
connection
exceed
0.5 psig (14-in.
maximum
valves
are
approved
by
Some
installations
viewed
of 1 hanger
should be applied
Pipe dope
joint
FIRE
OR
Failure
injury
to
gas.
EXPLOSION
to %llow
an_or
extend
If local
connector,
connector
codes
allow
always
could
result
in death,
the
use
which has previously
manual
equipment
plugged
tapping,
DOES
to
NOT
valve.
a flexible
gas
connector.
served another
accessible
shutoff
and within
appliance
Do not use a
valve MUST
fbr test gauge
should be pressure
in the United States
equipment
valve
MUST
shutoff
Place
in Fig
a ground
and exterior
NPT
connection
manual
plugged
tapping,
be installed
to fi/mace
immediand down-
valve.
and leak tested in accordance
with
or NSCNGPIC
in Canada, local, and
plumbing
and gas
After
all connections
for leakage
as shown
gas controls.
connection.
of manual
codes
at fi/ruace
before
the
Nrnace
have been made.
prior
exceeds
fi'om Nmace
pipe pressure
test. If test pressure
before
be installed
MUST
be
17
0.5 psig (14-in.
disconnected
conhol
A 1/8-in. NPT
connection_
(as
end of tee. ( upped nipple
A 1/8-in.
of gas supply
Piping
NFG(
(14-in.
gas appliance
6 ft of fi/mace.
side of ftmaace
to fitrnace
into lower
valve.
sheam
--> If pressure
of
on right
level of furnace
fbr test gauge
upstream
to operating
purge
has been
lines and
ft_mace.
valve
and
and during
accessible
supply
purge
wc), gas supply
and capped
wc), turn off electric
shutoff
before
pipe must be
and during
supply
is equal to or less than 0.5 psig
switch
located
manual
equipment
pipe pressure
test. After
lines and check for leakage
on Nruace
shutoff
gas
valve
all connections
at furnace
prior
The gas supply
pressure
shall be within
the maximum
mininmm
inlet supply pressures
marked on the rating plate
the f_./ruace burners ON and OFF.
and
with
to operating
to fi_mace casing
is suitable
we) stated on gas control
tk_rnace gas control
accessible
have been made,
external
to
valve.
personal
damage.
use a new listed
below
gas shutoff
check
Black iron pipe shall be installed at the furnace gas control
valve and extend a minimum
of 2-in outside the f_/rnace.
An accessible
connection
shutoff
test pressure
gas entry
nipple
equipment
connected.
HAZARD
this warning
property
supply
tap connection
providing
trap in riser leading
a capped
union between
national
--€
gas
equipment
To
(See Fig. 21a.)
a sediment
ately
sparingly
must be resistant
require
in upflow).
2 lb. ( onnect
Risers must be
all gas piping
etc. Use a minimum
(pipe dope)
and only to male threads
of propane
of
of manual
The gas valve inlet pressuie
should
Refer to Table 6 for recommended
gas pipe sizing
used to connect to fiu'nace and to meter. Support
the action
upstleam
use as test gauge
Install
used, they shall be T-handle valves.
4. The use of copper robing _br gas piping
the state of Massachusetts.
straps,
and downstream
accessory filter rack
(See Fig. 46.)
2. When flexible
connectors
are used,
shall not exceed 36 inches (915 ram).
with appropriate
immediately
furnace
NOTE:
or gas fitter
3. When
installed
in factory-authorized
[:tm_ace.
UPFLOW
RETURN
AIR FLOW
R_TU_N
AIR
MODELS
CONFiGURATiONS
RETURN AIR
CONNECTION
ONLY
AND
1
RESTRiCTiONS
RETURN AIR
CONNECTION
ONLY
2
RETURN AIR
CONNECTION
ONLY
3
RETURN AIR
COMBIN,_]IONS
OF 1, 2, AND 3
06&060,
_22 AND
"20 MODELS
YES
YES
YES
YES
ALL
YES
YES
YES
YES
OTHER
i
i
AR
MODELS
_ETU_N
//.
A02075
Fig. 18--Upflow
Return Air Configurat{ons
and Restrictions
EX_VNFLOWREq%IRNAmR
CONFmGU
RATONS ANDRESTR_CT_::)NS
AUR FLOW MODELS
RETURN AUR
CONNEC]ION
1
ONLY
RETURN AUR
CONNECTUON 2
OND/
RETURN AUR
CONNECTUON 3
ONLY
RETURN AR
COMBUN,_TIONS
OF 1, 2, AND 3
066.060, -22 AND
-20 MODELS
YES
NO
NO
NO
ALL OTHER MODELS
YES
NO
NO
NO
A02163
Fig. 19--Downflow
Return Air Configurations
and Restrictions
®
.
'i
"_ SliDERETURN
A_R
C_6O60-22-2O
'
RETURN
HORIZONAL•
NOTE
RESTRICTIONE?_ SAME
FOr_
_
@|
A_R
!J
/
i'
i
HORIZONA L
R
URNA_R
RESTR_CTIONS
HORIZONTAL RETURN A_RCONFIGURATIONS AND RESTRICTIONS
A_R FLOW
MODELS
RETURN
AIR
CONNECTION
ONLY
1
RETURN
A_R
CONNECTION
ONLY
2
RETURN
A_R
CONNECTION
ONLY
3
RETURN
A_R
COMBiNATiONS
OF 1,2_ AND 3
066.060,
-22 AND
-20 MODELS
YES
NO
NO
NO
ALL OTHER
YES
YES
YES
YES
Fig. 20--Horizonta{
MODELS
Return Air Configurations
lg
and Restrictions
A02162
-+
Table 6--Ma×imum
NOMINAL
IRON
PIPE
SIZE
Capacity of Pipe*
ELECTRICAL
LENGTH OF PRPE (FT}
iNTERNAL
DIAMETER
(BN.)
1/2
SHOCK
Failure
to follow
death,
or property
10
20
30
40
50
0.622
175
120
97
82
73
according
(7ode CSA (22.1
if an electrical
MUST
ANSI
3/4
0.824
360
250
200
170
151
tdcal
1
1.049
680
465
375
320
285
injury
1-1/4
1.380
1400
950
770
660
580
electrical
1-tt2
1.610
2100
1460
1180
990
900
listed,
grounded
when
installed
Refer
to the power
* Cubic ft of natural gas per hr for gas pressures of 0.5 psig (14-in. wc) or less
and a pressure drop of 0.5-in wc (based on a 0.60 specific gravity gas)
Ref: TaMe 122 ANSI Z223-2002/NFPA
54-2002
TOP VEW
OF BURNER
AND MANIFOLD
HAZARD
result
have an uninterrupted
to NEC
wire,
could
in serious
inju U,
damage.
(N.)
The cabinet
AND FIRE
this warning
NFPA
or unbroken
70-2002
or local codes
_Sult should
conduit
power
cord
permitted
with
Do not use gas piping
F[ RNACE
MAY
ground
of
or a
by local code)
existing
electrical
manufacturer's
wire gauge.
Elec=
personal
This may consist
for electrical
cord (where
in accordance
to minimize
occur.
approved
ground
and Canadian
ratings
codes.
for proper
as an electrical
ground.
ASSEMBLY
--->
Failure
To Gas
Supply
NOT
OPERATE
to _bllow this caution
stopping
and water
Furnace
control
control
will
pipes
must
lock
green@ellow
may result
fi'eezing
be grounded
out
operation
cold weather
_br proper
Control
wire routed
in £u'nace
during
is
operation
grounded
or
through
to gas valve and manifbld
bracket
SCrew,
2" Nipple
15-V Wiring
Verif}_" [l_at the voltage,
90° Elbow
/
Close NippBe
L
Gas Valve
A02327
on unit rating plate.
provided
by udlity
equipment.
--_ Fig. 2In--Right
Side Gas Entry Example
[.S.
is sufficient
installations:
any local
--->
Make
(?ode
or ordinances
installations:
dance
with
having
jurisdiction.
FIRE
HAZARD
or death.
Blower
access
control
No component
in serious
personal
with panel
door
switch
operation
opens
l15=v
power
can occur. Do not bypass
to
rapidly
and Nmace
J=BOX
RELOCATION
polarity
If factory
(Electrical
On
routed
14"
to other
within
wire
connections
C22.1
in accor-
or au[horities
result
between
in serious
inju W,
disconnect
switch
wire.
A readily
be located
Proper
relocated
or
must
is incorrect,
NOTE:
panel
and
Nsed branch electrical circuit with a properly sized
breaker for this Nrnace.
See Table 7 tbr wire size
polarity
section
could
Use only copper
NOTE:
NOTE:
could result
70-2002
apply.
(?ode CSA
this warning
specifications.
disconnect
CONNECTIONS
in.ju_
close switch
and Nse
Gas Pipe Arrangement
SHOCK
by this
electrical
in accordance
ANSI NFPA
all electrical
Electrical
to %llow
Use a separate,
Nse or circuit
A02035
connections
(NEC)
Make
Canadian
and Nrnace.
to _bllow this warning
toad imposed
7 _br equipment
that might
death, or property damage.
Do not connec[ aluminum
Failure
to that
HAZARD
Failure
ELECTRICAL
correspond
to be sure that service
to handle
all electrical
Electrical
codes
Canadian
_
VALVE
:D _:_=
(REQUIRED/#',
SEDIMENT -TRAP
/
UNION -_
ELECTRICAL
check
Refer to rating plate or Table
with National
GAS
Fig. 21b--Typical
and phase
Also,
specifications.
/.
SUPPLY
j'_
MANUAL =J
II
SHUTOFF
£
frequency,
specified
must
contIol
sight
means
location
status
for 115-v
indicator
light
wiring.
If
will flash
operate.
of J-Box
Connection
of electrical
of the furnace.
be maintained
LED
will NOT
wide
accessible
within
is acceptable,
go
to next
to J=Box).
casing
models,
side of furnace
the
J=Box
casing
when
holding
J-box.
shall
not
tiae vent pipe
be
is
the casing.
removed.
1. Remove
See Fig 25 %r field wiring diagram showing typical field 115-v
wiring. Check all factoQ' and field electrical connections for
tighmess,
---> NOTI=:
Field=snpplied wiring shall con£_m_ with the limitations of 63°F
(33°C) rise
order
to move
inside
J=Box.
flange
and can be lifted
swinging
19
and save two screws
The J=Box cover need not be removed
the J=Box.
The
ground
Do NOT
screw
remove
green
is not threaded
out of the clearance
the t?ont edge of the J-Box
outboard
(See Fig. 22.)
L'rom the J=Box in
ground
into
screw
the casing
hole in casing
of the casing.
while
--> TaNe 7--Electrical
OPERATING
VOLTAGE RANGE
VOLTSHERTZPHASE
Maximum*
Minimum*
045-081024045
115-60-1
127
104
045-12t036045
115-60-1
127
104
070-08t024070
115-60-1
127
070-t21036070
115-60-1
070-t0t048070
Data
UNW
AMPACITY#
MAXIMUIVl
WiRE LENGTH (FT}:_
MAXBMUM
FUSE OR CKT BKR
AMPSt
MiNiMUM
WiRE GAUGE
5.4
7.54
49
15
14
7.0
9.50
39
15
14
104
5.0
7.06
52
15
14
127
104
6.8
9.22
40
15
14
115-60-1
127
104
9.5
12.60
29
15
14
090-t4t042090
115-60-1
127
104
8.2
10.83
34
15
14
090-10/048090
115-60-1
127
104
10.0
13.13
28
15
14
000-20/060090
115-60-1
127
104
13.6
17.61
32
2O
12
110-12t036110
115-60-1
127
104
8.2
10.75
34
15
14
110-10t048110
115-60-1
127
104
10.1
13.12
28
15
14
110-22t066110
115-60-1
127
104
14.8
18.99
30
2O
12
135-101048135
115-60-1
127
104
10.2
13.27
27
15
14
135-22t066138
115-60-1
127
104
14.4
18.55
30
2O
12
155-20/060158
115-60-1
127
104
15.0
19.33
29
2O
12
FURNACE
SRZE
* Permissible limits of the voltage range at which the unit operates satisfactorily
# Unit ampacity = 125 percent of largest operating component's full load amps plus 100 percent of all other potential operating components'
amps
1 Time-delay type is recommended
$ Length shown is as measured 1 way along wire path between unit and service panel for maximum 2 percent voltage drop.
(EAC, humidifier,
etc ) full load
FACTORY
INSTALLED
LOCATION
TWO
ALTERNATE
FIELD
LOCATION
/
/
O
A02099
Fig. 22--Relocating
J=Bo×
2. Cut wire tie on loop in L_umace wires
3. Move
box to desired
4. Fasten
J-Box
to casing
5. Route
J-Box
wires
rotating
parts,
ELECTRICAL
with two screws
to J-Box.
within
furnace
removed
away
O
in Step 1.
fl'om sharp
edges,
and hot surfaces.
CONNECTION
--> Field-Supplied
attached
location.
Electrical
Box
A03221
TO J-BOX
on Furnace
J-Box
-_ Fig. 23--Field-Supplied
Electrical
Furnace Casing
Bracket
See Fig. 23.
1. Remove
cover
2. Attach
electrical
two field-supplied
holes in bracket.
wire insulation.
3. Route
J-Box
box.
fl'om furnace
box
to furnace
screws
4, Rou[e and secure
J-Box bracket,
J°Box.
through
ETse blunt-nose
J-Box
bracket
with
holes
in electrical
screws
that will
at least
5, (onnect
box into
furnace power wires through holes in electrical box and
bracket, and make field=wire connections
in electrical
Use
Canada)
best
practices
fbr wire bushings,
(NE(
strain
in U,S,
relief,
and CSA
(722.1
tine voltage
6, Reinstall cover
and bracket
not pierce
in
etc.
2O
field ground
wire to green
1cads as shown
to J°Box
Box on
ground
screw
on
in Fig. 25
Do not pinch
wires
between
cover
BLOWER
TWINNING
AND/OR
COMPONENT
TEST
TERMINAL
OFF-DELAY
J2 JUMPER
HUMIDIFIER TERMINAL
(24-VAC 05 AMP MAX.)
24-V THERMOSTAT
TERMINALS
TRANSFORMER24-VAC
CONNECTIONS
3-AMP
FUSE
o}
SEC 2 SEO /
LED OPERATION
&
DIAGNOSTIC
LIGHT
PL1-LOWVOLTAGE
MAIN
HARNESS CONNECTOR
115-VAO
CONNECTIONS
PL2-HOTSURFACE
IGNITER&INDUCER
MOTOR CONNECTOR
115 VAC (L1) LINE
VOLTAGE CONNECTION
SELECTION TERMINALS
"X_!
EAC-1 TERMINAL
15-VAC 1.0 AMP MAX.)
A02100
Fig. 24--Furnace
--)Electrical
Box on Furnace
Casing
Side
Control
9
10
OR
Failure
death,
ELECTRICAL
SHOCK
to lk)llow this warning
or property
on furnace
manual
casing
cannot
Check
installed
electrical
injuw_
disconnect
side,
damage
select
switch
a location
electrical
is to be mounted
U.S.
where
relief,
a drill
or
in the casing
that duct on side of furnace
where
will not interfere
with
box
supplied
4. Remove
screws
box
to casing
fi'om inside
and save two screws
electrical
holding
by
driving
two
box into casing
J-Box.
fieldsteel.
7. Pull field power
8. Remove
(ORD
Power
cover
listed
1. Remove
wires
fiom
into electrical
fhrnace
in
casing
casing
with
green ground
box
and
screws
re-
screw.
and installation.
Connect
in Fig. 25. Use best practices
in Canada)
for wire
to J-Box.
Do not pinch
INSTALLATION
line
(NEC
in
bushings,
strain
wires between
cover
IN FURNACE
cords must be able to handle
in Table
cover
Route listed
J=Box.
bushing
5. Refer
to power
J-BOX
the electrical
cord
require-
manufhcmrer's
and
--+
box.
J-Box.
2i
fi'om J-Box.
power
power
cord through
cord
to J=Box
or a connector
4. Secure field
bracket.
5. Connect
holes
to fire, ace
wire to J-Box
C22.1
in electrical
etc.
3. Secure
(See Fig. 22.)
of J-Box.
d. Route furnace
power
wires through
electrical box and into electrical box.
holes
listings.
-9
5. Pull fi_rnace power wires om of 1/2-inch diameter
hole in
J-Box.
Do not loosen wires from strain-relief
wire-tie
on
outside
and CSA
NOTE:
2_
electrical
through
J-Box.
box wiring
leads as shown
POWER
ments
casing.
the
ground
electrical
13. Reinstall cover
and bracket.
the
2. Remove the desired electrical box hole knockout and position
the hole in the electrical box over the hole in the furnace
3. Fasten
field
12. Complete
or gas components
wire
Reattach
furnace J-Box
moved in Step 4.
voltage
1. Select and remove a hole knockout
electrical box is to be installed
NOTE:
in personal
ground
and into furnace
11. Secure
HAZARD
could result
damage.
If field-supplied
fastener
field
casing,
See Fig. 23,
FIRE
Route
ground
line voltage
6. Reinstall cover
and bracket.
approved
wire
7/8=inch
bracket
hole
a strain
in
relief
for the type of cord used.
to green
leads as shown
to J-Box.
with
diameter
ground
screw
on J-Box
in Fig. 25.
Do not pinch
wires between
cover
....
....
--
FIELD 24-V WIRING
FIELD 115-, 208/230-, 460-V WtRING
FACTORY 24-V WIRING
FACTORY 115-V WIRING
FIELD-SUPPLIED
DISCONNECT
208/230-0R
460-V
THREE
PHASE
208/230-V
SINGLE
PHASE
115-VFIELDSUPPLIED
DISCONNECT
AUXILIARY
J-BOX
O
L @
NOTE 1
CONDENSING
UNIT
547
?WO
WIRE
TERMINA[
BLOCK
NOTES:I.
FURNACE
2.
3.
Connect YLterminal in furnace as shown for proper blower operation.
Some thermostats require a '%" terminal connection as shown.
tf any of the original wire, as supplied, must be replaced, use
same type or equivalent wire.
A99440
Fig. 25--Heating
BX CABLE
-->
INSTALLATION
1, Remove
2, Route
cover
from
BX cable
and Cooling
IN FURNACE
Application
Wiring Diagram with 1-Stage
J-BOX
2. Humidifier
Connect
J-Box.
into
7/8°inch
diameter
3, Secure BX cahle to J-Box bracket
Co_>24V
approved
Connect
5_
-->
ground
line voltage
WIRING
Make
field
24-v
24.) Connect
operation
to green
ground
screw
on J=Box
NOTE:
EAC
6. Reinstall
cover
and bracket.
24-V
closes
wire
leads
as shown
in Fig. 25.
to J=Box. Do not pinch
wires
connections
at the 24-v
Y as shown
Use only AWG
No
terminal
in Fig
during
between
cover
18, color-coded,
copper
terminal
on the contlol
is energized
A field-supplied,
terminals
l I5-v
may be added
blower
NOTE:
HUM
board
humidifier
terminal
and
thermostat
strip.
switch
(PRS)
when pressure
controlled
relay
if humidifier
connected
operation
to
is desired
operation
DO NOT connect
controller
strip. (See Fig.
25 _br proper
amp maxin-mm
(See Fig. 24)
(humidifier)
lar device.
terminal
24 VAC, 05
screw terminal
The HUM
_br the type of cable used.
4. Secure field
bracket.
(HI_M)
an accessm7
(if used) to the 1/4=in male quick-connect
hole in J-Box.
with connectors
Thermostat
furnace
control
terminal on ThermidistaF_L
See Thern_idistat TM, Zone
manuRtcmrer's
instl_actions
HUM tem_inal
to HUM
Zone Controller
or simiController,
thermostat,
or
_br proper
connection.
cooling
thermostat
VENTING
wire.
--> The fi/rnace
The 24-v
circuit
on the control
maintenance
required,
contains
Any
could
direct
an automotive=type,
shorts
during
a 3-amp
_ilse located
installation,
cause this fuse to blow
use ONLY
3-amp
service,
If _ime replacement
fuse of identical
or
an unlined
is
--> When
size.
original
ACCESSORIES
1. Electronic
Connect
Air Cleaner
an accessow
1/4=in female
quick-connect
and EAC-2
nlaxinmm
(See Fig
(EAC)
Electronic
Air Cleaner
(if used)
using
The temlinals
are rated
during
for 115 VAC,
blower
motor
an existing
venting
1.0 amps
24.)
22
chinmey
Category
system
or concrete
or concrete
I furnace
is removed
or replaced,
sized Category
cause the formation
of condensate
of condensate
and combustion
into the living
to properly
the
vent
I venting
in the furnace
products,
space.
into
is prohibited
An improperly
appliances.
products
chinmey
or
Venting
be sized
system
could
chimney
may no longer
the attached
of combustion
operation
to a listed facto1T built chimney
lined masonw
masonry
vent, leakage
quick connect terminals to the two male li4=in
terminals
on the control board marked EAC-1
and are energized
shall be connected
vent or a clay-tile
and
and spillage
The
CARBON
Failure
MONOXIDE
to follow
connected
to the venting
could result
The
in carbon
following
connected
while
POISONING
the steps outlined
system
being
monoxide
steps
shall
to the venting
be
connected
into operation
for each
placed
2 Inspect
openings
dae venting
to the venting
in venting
system
system
are
system,
for proper
Dv.stcd/atinn
('()de
and these
mine that there is no blockage
cmTosion
and other deficiencies,
unsafe
and all doors
connected
spaces
1
between
fireplace
Deter2
leakage,
cause an
the space
doors
in which
system
are
the appliance(s)
located
and
dryers
and any appliance
3
other
the venting
system.
range
and bathroom
hoods
at maximum
6. Follow
Turn
speed.
into
instructions.
operation.
is operating
7. Test for spillage
hood
a summer
exhaust
the appliance
the them_ostat
as
opening
after
venting
5 minutes
of a match
tim.
5
so appli:
is observed
of main
at the
9 Aker
to
CSt
B149.1,
into
operating
under
In the US:
burner
the
venting
system
above,
during
vents
doors,
system
systems
or vent
connectors
Check
or vent connectors
size as determined
NS(NGPI(.
GENERAL
using
VENTING
must
when
tested
gas-fired
of use
burning
need
be sized
appropriate
and 13 in the United
to (hirnney
:\'_mr_U
Gas
and
(NSCNGPI(),
building
codes,
These
i_> These
as
with
ANSI
a non:positive
found
]nslaliafion
Kit
Chimney
rating
Chimneys
Vent
for vent gas leakage.
Category
I Nmaces
not less than 17 percent
to minimize
in the venting
These
venting
hood
system.
and multistory
equipped
NSCNGPIC,
manufacturers'
appliances
venting
with
I Nmaces
fuel
jurisdiction
vertically
for
or
nearly
ventor.
masonry
having
If relining
Type-B
in
chimney.
Chimney
A02015FC,
a clay file:lined
other
fire assisted
with
and
the NFCG
Nmace
and
ONLY
marked
on the
might
be required.
for Chimneys,
Fireplaces..
ANSI NFPA
2! 1:2003
and to a Provincial
or Territorial
Building
the National
Building
(7ode
of
condition.
13.1.9
and 13.2.20
to
is required,
of the NFGC
detem_ine
whether
use a properly
or a listed
alternative
13.1.9
relining
is
sized listed metal
venting
and 13.2.20
or the
design.
regarding
alternative
which cover installations
such as
Adapter
Kits
KGACA02014FC
and
which are listed for use with these furnaces
Kit is listed alternative
(and U.S.A°):This
masonry
venting
[br complete
:gtrcmce is permitted
chimney
system
to be vented
that is exposed
for
details.
into
to the outdoors
the roof line, prm'ided:
1. Vent connector
2. This
or &aft
for correct
for use with
is being used and it is exposed
See the kit instl_ctions
Canada
for common
in
Appliances
Adapter
the potential
for condensation
use
accessory
rating plate
are
line, relining
and the exception,
fllmaces.
below
for
with a factoo
Kit number
to the Standard
See the NFG(,
design
to minimize
with a flue toss
chimney
jurisdiction
vent,
The Chimney
these
Kits
Adapter
(in its absence,
required.
venting
design:certified
to the furnace
the roof
to Sections
and operate
are approved
codes
be
Fig. 26
chimneys
Fuel Burning
authority
the
KGA(
up
condensation
100 percent
Excessive
brief periods
2. Adjust
in accordance
and codes.
be sized to provide
condensation
precautions
1. The return=air
are
not suffer from condensation
and all appliances
heating
can be made
REQ[
methods.
the fmTmce and/or
instructions.
following
appliances
NR
or UL
TaRe A--Combined
Appliance Naximum Input
Rating in Thousands of BTU per Hour
adjusted,
NR
liner.
Connectors
Appliance
F*
6
Not recommended for any vent
configuration
vent is used to line a chinmey,
be vented
and the metal
metal
-_ Exterior Masonry Chimney FAN + NAT
Installations with Type-B DouNe-WaH Vent
venting
55
NR
having
of the
0
Loea199%Winter
the chimney
F*
6
6
be relined
lined
(SQ. IN.)
i
iNTERNAL AREA OF CHIMNEY
NEIGNT(FT)12
[ 19 I 28 I a8
an alternative
Refur to Fig. 26 to perfbrm
If the inspection
a. Shows
furnaces.
approves.
as the listed
the acceptability
(re)lining.
t\trnace
for use with the kit, a listed chimney=lining
or a Type=B
Inspections
cannot
such
require
of these
B, and
having jurisdiction
shall be used,
system,
38
Table B--Ninimum
Alowable input Rating of
Space-Heating ApNiance in
Thousands of BTU per Hour
vent
gas
in the
from
instructions.
ihmace
rise to the midpoint
Low air temperature
and potential
a standby
temperatures,
only for altitudes
an_or
above
Low
causing
venting
2000 ft.
of the rise range
rise can cause
_br condensation
[br
at no lower
low vent
problems.
CHIMNEY iNSPECTiON
CHART
For additional requirements refer to the National Fuel Gas Code NFPA 54/ANSI Z223.1 and ANSI/NFPA 211
Chimneys, Fireplaces, Vents, and Solid Fuel Burning Appliances in the U.S.A. or to the Canadian
installation Code CSA-B149.1 in Canada.
Crown
condition:
Missing mortar
or brick?
Rebuild
crown
Is chimney
<_,_ _:_ePrOper
ty lined with
No
liner?
is
liner and top
seal in good
condition?
Repair
liner or top seat
or reline chimney as
necessary.
Yes
Reline
Repair
Debris
in cleanout?
Mortar, tile, metal venL
fuel oil residue?
Mortar
or tile
debris?
Remove mortar
and tile debris
Remove metal vent
or liner.
Clay
tile misalignment,
missing sections_
gaps?
Yes
Part B of
No
Not Suitable
instructions for
application
chimney
Condensate
drainage at bottom
lined with properly
Line chimney with property
sized, listed flexible metal
liner or Type-B vent per
NFGC or NSCNGPIC
Vent
Sizing Tables and liner or
vent manufacturer's
Installation
instructions.
;uitable
sized_ listed liner or
vent?
Install chimney
adapter per
instructions.
No
Yes
Chimney
exposed to
outdoors below
roof line?
4ot Suitable
Part C of
Is chimney
to be dedicated to
a single
furnace?
instructions for
application
>,Suitable
Install chimney
adapter per
instructions.
Chimney is
acceptable for use.
A03206
-->
Fig. 26--CMmney
Inspection
25
Chart
4. Set the thermostat
cycling.
heat anticipator
Air for confbustion
pounds
which
must
include
These compounds
as detergent,
glue,
using
to be exposed
ihilure
of the furnace
prodtlcts
compounds,
on appliances
VENTING
to the common
fitting
is required
is used.
See Fig.
when
5-inch
32 44 Venting
Do not
A 5-inch
model
or 6o
Nmaces.
sheet
A
metal
or 6oinch vent connector
Orientation
connector
vent elbow.
length
for
ibr approved
to position
desired,
vent elbow does
connector elbows.
NOT
The vent connector
the door.
1. Attach
elbow,
connector
The 4oinch vent elbow
configuration
and may be rotated
3 screws that secure vent elbow
elbow
vent
ibr other positions.
to fhmace,
rotate
re-install
count
sizing
is shipped
screws.
as part
at
Remove the
[hrnace vent
two
number
of
vent
one of 5 locations
screws
located
corrosion-resistant,
on
sheet
metal
180 ° apart.
If flue extension
vent elbow
with
sheet metal
screws located
the
flue
resistant
2. Vent
a nmnber
knockouts
as seen
at least
extension
sheet metal
the furnace
with
is used,
two
_sten
the flue extension
to the
field-supplied,
corrosion-resistant,
180 _>apart. Fasten
the vent connector
at least
screws
located
two
field-supplied,
using
connector
glasses,
and
_/rnaces.
the correct
tin snips
to remove
location
of the door
the correct
U-shaped
to
con'osiono
Fig. 32 44.
in
due to its flanging
to remove
these
knockout
in the
and is not easily
at the edge of the door,
tin snips. (See Fig. 27.) A sharp
and allow
the knockout
all burrs
and sharp
to be pulled
loose.
locations
tin snips can also be used
(See
along
is to use a hammer
(See Fig. 30.) directly
to the knockout
use a hammer
in the upper left corner
of the desired
and
however,
and screwdriver
to strike
tie points
knockout.
or
(See
and sharp edges.
An accessoO'
Vent Guard Kit, KGAVG0101DFG
for downflow
applications
lower
of the It/mace
is REQUIRED
for use where the vent exits through
casing
for complete
portion
(top
edges;
method
The horizontal
tie
Fig. 29.)
on the door
the door
a sharp blow
portion
to the
more
edges.
in the other
all bun's
blow
(See Fig. 28.) will separate
the preferred
door.
the
Refer to the Vent Guard
details.
of the venting
system
shall slope
upwards
not less than li4oin, per linear ft (2 hum/m)
fiom the fhrnace
to the
vent and shall be rigidly
5 ft or less with
metal
supported
or straps to ensure there
SIDEWALL
VENTING
This Nrnace
is not approved
In the U.S.: Per section
may
be used,
every
is no movement
for direct
sidewall
10.3.4 of the NFGC,
when
approved
by
after installation.
horizontal
venting.
any listed mechanical
the
authori V having
jurisdiction.
--> In
Canada:
renters
as shown
31. The
the two tie points
end of the knockout
the knockouts
sides),
in the door %r
can be used
in Fig. 27 through
aviation-type
Remove
with knockouts
of techniques
by first cutting
rounded
renter
180 ° apart.
with the appropriate
injury.
Use care and
safety
and servicing
to determine
of the door is unique
removed
hangers
--> NOTE:
An accessory
flue extension KGAFE0112UPH
is avail°
able to extend fiom the farnace elbow to outside
the furnace
casing.
clothing,
parts
If this l_maace is equipped
the vent,
Kit Instructions
fieldosupplied,
in personal
or bun's
to be removed
Fig. 31.) Remove
The factov-supplied
of the
can exit the door through
starts
ibr upflow
the single walt vent connector
to the fi/mace
vent
and ihsten the vent connector to the vent elbow with at
least
--> NOTE:
For
Vent
Nmace
protective
handling
the door
cutout
points
configurations.
NOTE:
3. Orient
bottom
%r some
when
4. Use aviation-type
cut-out in door.
with this Nrnace.
or 4=inch=to=6-inch
may result
vent can
system.
with the Nmace.
may be required
appropriate
gloves
the
REQUIREMENTS
4-inch-to-5-inch
increaser
vented
wear
premature
connected
A 4" round vent elbow is supplied
inch vent connector
causing
dtle to corrosion.
to %11ow this caution
Sheet metal parts may have sharp edges
and
cause
HAZARD
Failure
supply.
could
system
common
(IT
such
of furnaces
in the venting
-->
solvent,
in the cornbustion=air
to halogen
or venting
products
cleaning
corrosion
como
and iodides
home
of the building
and con'osion
use vent dampers
field=supplied
bromides,
bleach,
and can cause
on any appliance
condensation
ADDITIONAL
spray,
construction
ihmace
cause
aerosol
such
use during
Vent dampers
fluorides,
short
by halogen
are found in many common
paint,
Avoid
Furnace
not be contaminated
chlorides,
salt, and air /ieshener,
vents.
or cycle rate to reduce
Per
may
section
be used,
7242
when
of the NSCNGPIC,
approved
by
any listed
the authority
having
jurisdiction.
Select
the listed
lhrnace
being
quirements
mechanical
mechanical
vented.
for venting
renter.
renter
Follow
to match the Bmh input
all manu_hcturer's
and termination
included
of the
installation
with
re-
the listed
A04127
-_ Fig, 27--Using
Tin Snips to Cut Tie Points
26
A04131
-_ Fig. 31--Remove
START-UP,
Step
Knockout
ADJUSTMENT,
with Hammer
AND
SAFETY
CHECK
l--General
A04128
-_ Fig, 28--Rounded
End of Knockout
FIRE
HAZARD
Failure
to follow
to property
this warning
damage,
This _k/rnace is equipped
t!_e gas control
area
the
if a flame
gas valve
occurs
in the gas control
with manual
reset limit switches
or overheating
area. DO NOT
Pulled Loose
to %llow
d_is caution
wear appropriate
protective
gloves when handling parts
1
Maintain
2
115-v
result
in rapid
Make
them_ostat
on the furance
will result
3
wc (016
wiring
flashing
to
condition
the switches.
problem
and reset
may result
Failure
all manual-reset
5
Install
blower
Improper
and
polarity
at d'_e 24-v terminal
to make
operation
will
block
connections
must be greater than 4.5-in.
14-in
switches
compartment
proper
(See Fig. 25.)
to the furnace
(beck
operate
and ground
psig) but not exceed
4
ir_jury.
Use care and
clothing,
safety glasses,
and sela'icing _/maces.
wire connections
pressure
in personal
or burrs
LED and no [_urnace operation.
control.
in improper
Gas supply
wc (05
psig)
fbr continuity
door.
Door
must
be in place
fnrnace
6. Replace
Step
bypass
air supply
Sheet metal parts may have sharp edges
-_ Fig. 29--Knockout
in
open and shut offpower
rollout
combustion
in a fire and lead
or death
HAZARD
Failure
A04129
result
injury,
The switches
Con'ect inadequate
the switches.
(:IT
could
personal
outer door.
2--Start-Up
Procedures
A04130
-+ Fig. 30--Hammer
and Screwdriver
Knockout
Used for
FIRE
AND
Failure
personal
to fbllow
27
HAZARD
this warning
could cause
property
damage,
injm 7, or death.
Never purge
matches,
EXPLOSION
a gas line into a combustion
candles,
flame,
purpose
of checking
to check
for leakage.
or other
leakage
chamber.
sources
Use a soap-and=water
1
Purge
gas lines after all connections
2
(beck
gas lines for leaks
Never use
of ignition
_br the
solution
have been made
to
©
SEE NOTES: 1,2,4,5,7,8,9
on the page following
these figures
SEE NOTES: 1,2,4,7,8,9
on the page following
these figures
A03208
Fig. 32--Upflow
Application-Vent
A03211
Elbow Up
Fig. 35--Downflow
Application-Vent
Elbow Up
©
SEE NOTES: 1,2,4,5,6,7,8,9,10
on the page following these figures
SEE NOTES: 1_2,3,4,7,8,9
on the pages following
these figures
Fig. 36--Downflow ApplicationVent Elbow Left then Up
A03209
Fig. 33--Upflow
Application-Vent
A03207
Elbow Right
SEE NOTES:1,2,3 4,5,7,8,9
on the page following
these figures
SEE NOTES:l,2,3,4,5,7,8,9
on the page following
these figures
A03210
A03212
Fig. 34--Downflow
ApplicationVent Elbow Up then Left
Fig. 37--Downflow
ApplicationVent Elbow Up then Right
2S
©
SEE NOTES: 1,2_4,7,8,9 on the page
following these figures
SEE NOTES: 1,2,4,5,7,8,9
following these figures
A03213
Fig. 38--Horizontal
Left Application-Vent
on the page
Elbow Left
Fig. 40--Horizontal
Left Application-Vent
EJbov_°_2_5
I01
SEE NOTES: 1,2,4,5,7,8,9 on the page
following these figures
Fig. 39--Horizontal
Left ApplicationVent Elbow Right then Up
SEE NOTES: 1,2,4,7,8,9 on the page
following these figures
SEE NOTES: 1,2,4,5,7,8,9
following these figures
A03214
Fig. 41--Horizontal
on the page
A03216
Left Application-Vent
Elbow Right
A03218
SEE NOTES: 1 2,4,5,7,8
following
these figures
Fig. 42--Horizonta!
Right ApplicationVent Elbow Right
9 on the page
Fig. 43--Horizontal
Right ApplicationVent Elbow Left then Up
29
A03219
i
SEE NOTES: 1,2,4,5,7,8,9
A02068
Fig. 44_Horizontal
Right ApNication-Vent
Venting
Notes
for Figures
Elbow Left
32-44
1 For common vent, vent connector sizing and vent material:
[ hired SIates==use d_e NFGC
Canada=use the NSCNGPIC
2 Immediately increase to 5-inch or d=inch vent connector outside Parnace casing when 5=inch vent connector is required, refer to Note 1 above.
3
Side outtet vent for upflow and downflow installations must use Type B vent immediately
KGAVG0101DFG, Downflow Vent Guard Kit, is used in the downflow position
4
Type=B vent where required, refer to Note 1 above
after exiting the furnace,
5 Four-inch single=wall (26 ga. rain) vent must be used inside _/rnace casing and when the KGAVG0101DFG
used external to the furnace
6 Accesso W Downt'low Vent Guard Kit, KGAVG0!01DFG
7
except when
Downftow Vent Guard Kit is
required in downflow installations wit}* lower vent configuration
(hinmey Adapter Kit may be required [br exterior mason W chinmey applications
KGA(A02015FC,
for sizing and complete application details.
8 Secure vent connector to furnace elbow with (2) cm_'osion-resistant
Re*_r to Chimney Adapter Kit, KGACA02014FC
sheet metal screws, spaced approximately
9. Secure al! other single wal! vent connector joints with (3) corrosion resistant screws spaced approximately
connectors per vent connector manufacturers recommendations.
or
1%° apart.
120 ° apart. Secure Type=B ",gent
10. The total height of the vent and connector shall be at least seven feet for the 154,000 Btuh gas input rate model when installed in a downflow
application with Nmace elbow turned to left side with the connector elbow outside Nmace casing pointing upward. (See Fig. 36.)
Caution!!
FURNACE
For the following
For aH other
ORIENTAT{ON
Downflow
applications,
applications,
VENT ORIENTATION
Vent elbow left then up
Fig 36
use the minimum
follow exclusivemy
FURNACE
INPUT(BTU/NR
154,000
132,000
110,000(036/-12
/
vertieat vent heights
as specified
the National
Fuel Gas Code.
MINIMUM
VENT DIAMETER
(IN.}*
MININUM
VERTICAL
VENT HEIGHT
5
12
only)
Horizontal
Left
Vent elbow right,
then up
Fig 39
154,000
132,000
5
7
Herizontal
Left
Vent Elbow up
Fig 40
154,000
132,000
5
7
Horizontal
Left
Vent elbow right
Fig 41
154,000
5
7
Downflow
Vent elbow up then left
Fig 34
110,000
(036/-12 only)
5
10
Downflew
Vent elbow up, then right
Fig 37
110,000
(036/-12 only)
5
10
NOTE: All vent configurations must also meet National Fuel Gas Code venting requirements
*4 in inside casing or vent guard
**Including 4 in. vent section(s)
30
NFGC
be{ow.
(FT/**
1
ELECTRICAL
SHOCK
Failure to %llow
this warning
personal
or death
irtjury,
Blower
access
component
HAZARD
door switch
operation
The input rating
could result
opens
can
in electrical
115-v power
occur
unless
Caution
must be taken when manually
service
purposes.
switch
conhol
goes
humidifier
out
quick
will not be turned
to be run
diagnose
for
a system
Component
present
short
terminal
connect
door
on control
terminal
2 sec).
on
Gas
to the
control
valve
and
on. (See Fig. 24.)
except the gas
period
fkature
in
of
time.
case
of
will not operate
This
a component
helps
display
motor
component
signal
is
to Nmace
previous
starts
status
and continues
to run until
igniter
for 10 sec.
e. Blower
motor
operates
on (OOL
speed
for 10 sec.
£ Inducer
motor
stops.
Nmace
per instruction
Nmace
see example
EXAMPLE
1:
88,000
X
Detenrline
shut
down
release
NOx
by
lowering
thermostat
this warning
injury
out
thermostat
setting
could result in reduced
regulator
mani%ld
and heat exchanger
re&ill
a_iiusting
For 22,000
EXAMPLE
pressure
screw
Heating
and result in
heat
orifces
of heat exchangers,
in reduced
&illing
(burrs,
furnace
out-of=
pressure
and manifbld
adjust-
adjustment
or horizontal
positions
See input listed on
gas heat value (at installed
altitude)
gas specific
gravity
in Table
12 or 13.
fi'om local
gas
altitude
gas heat value and specific
value
and specific
orifice
size
gravity
lines
and
manifbld
gravity
in
to point
of
pressure
operation.
orifice
with correct
size if required
ft Furnace
input
orifices.
by Table
12 or
See EXAMPLE
2.
BTUH burner applications
2:(0 2000 ft ahimde)
value
1000 Btuicu
pressure:
use Table
12
ft
0.62
No. 43*
3.7-in.
we
causing
failures.
rate must
be within
proper
input rate.
a Turn gas valve ON/OFF switch to OFF
b Remove mani%ld pressure tap plug f'om gas valve, (See
Fig. 46)
c (onnect a water column manometer or similar device to
manifbld pressure tap.
(See Fig.
at ahimdes
+2 percent
to obtain
Adjust mani%ld pressure to obtain correct input rate
cause excessive
burner
noise and
flames.
This can result in flame
gas input rate on rating plate is %r installations
plate
orifice
BTUHiBumer).
yearly
%r proper
to be changed
47.)
rating
79,200
and manifold
* Furnace is shipped with No. 43 orifices. In this example
all main burner orifices are the correct size and do not need
Improper
impingement
furnace
at Installation
Altitude
in the downflow
to find
Specific gravity
Therefore:
Orifce
failures
may result
etc.) can
of burner
Furnace
BNSTALL_=D AT 4300 FT.
I_urnace
HAZARD
this caution
round
holes,
misdirection
up to 2000
input rate
multiplier
Furnace Input Rate
yearly
average
settings
above
and death.
gas valve
DAMAGE
DO NOT
correct
of
Gas
£ (hock and verif) burner orifice size in %mace. NEVER
ASSUME
ORIFI(E
SIZE.
ALWAYS
(HECK
AND
VERIFY.
damage,
to %llow
t'or ahimdes
Multiplier
Factor
13 (21,000
average
e. Follow
setting
Manifold
Failure
tifc
input
Derate
13. Use only fhctory=supplied
bottom
____> F[ RNACE
To determine
orifice
d. Find closest natural
Table 12 or 13.
HAZARD
overfire
models
c. Find installation
blower
on door.
by raising
This can result in unregulated
excess
For
by an authorized
1 and use 0.90 as derate
are two different
intersection
restarts
to %llow
by 10 percent
0.90
the correct
g. Replace
DO NOT
8 for the con'ect
sea level
or Dealer.
X
b. Obtain
3--Ad}ustments
tifc, property
plate.
on the rating
fl'om local gas supplier.
temperature.
furnace
Station
a. Obtain
roon'l temperature
Failure
the input
in Table
For installa-
rating
supplier.
g. Reconnect
R lead to t'umace control board,
door switch and re-install blower door.
____> FIRE
unit
ft. multiply
fL above
%r altitude,
fSctor
must use Table
%r 15 sec., then off,
speed
Step
the
rating plate.
is energized
on HEAT
6. Verii)-
to
nmst be derated
it. to 4,500
( onversion
Low
Step f of
operates
room
refer
fL must be reduced
sea level.
BTUHiBumer)
code 4 times.
motor
below
2,000
it. above
tables. All models in all positions,
except Low NOx models in
downflow
or horizontal
positions,
use Table
12 (22,000
or see Fig. 49.
d. Blower
5. Verii)
above
1,000
muhiplier
Furnace Input Rate
at Sea Leve_
2
test sequence.
c. Hot surface
4. Operate
2000
fifilure.
if any thermostat
is as %llows:
label attached
b. Inducer
above
mont. There
test sequence
a. LED will
it,
rate.
88,000 BTUH INPUT FURNACE
at the control.
Refer to service
2000
below
2,000
the d_em_ostat R lead
allows all components,
problem
test feature
Component
tions
plate by the de-rate
rate
for
close the blower
(approximately
The fiul_ace control
valve,
fbr each
installations
is closed
this switch
t'or ahimdes
by 4 percent
The input rating
Manually
the (ox_=24V
3/16-inch
LED
NOTE:
boaid,
Short (lumper)
TEST/TWIN
until
No
gas input
In Canada:
furnace
switch.
shock,
to control.
closing
3, To Begin Component
Self=Test:
Remove blower access door, Disconnect
f'om
Determine the con'ect
In the l_ .S.A :
of
d Tufa gas valve ON/OFF switch to ON.
input.
___>
31
e Manually close blower door switch,
CONNECTION DIAGRAM
BLOV'_:R OEF49ELAY
JUMPER SELECT OR
c.
I'O
TO 115VAC
ERS2
PCB
RIED
LS1
_
GRN/YEL
901
150
180
NOTE #5
FRS1
LtI NELrrRAL
LI
RED"
USED)
DSS
BVSS
/_7
SCHEMATIC
SPARE
]
Gi
mEN
HUM
DIAGRAM
EQUIPMENT GROUND
ILK
I ••
_
L
i
HI
USED)
CAP
.
MEDLO
/
\
co.co.
I
RED
RED O__ORG_OR
TEST/TVMN
i
START
L2 I
i
HSIR
I_
i
SEC-2
SEC-1
(_
N
SWITCH
NOTE#_0_
/f[7
Jl
FUI _
DISCONNECT
(NATURAL & PROPANE GASES
RED _
(_N
Com
24V
FIELD
LS2
('_NHEN USED)
LGPS
PRS
LED
PR1 _
EACh2 _
I
I
_.__.
SPARE 2
B'V'SS
(Vt,HEN USED)
DSS
NO_
PL_4_
q
_$2
GR_N/YEL
EAC-I
LSl
NOTE#10
I
,Z T
1-
BLK (14)
BLI_NM
,
,
BLK
L
II
I
\
_
\_
J
HU
FUSE OR
DISCONNECT
CIRCUITBREAKER
&
SVMTCH (VVHEN REQ D)
NOTE #2
r .......
I
JB
RED (LO)
LS2
R®
w®
_dT
i
r_
(
_I_
RE 1
WHT
(COM)
I
FUI
]DM
-FBCLR
_T
FRS1
II
BLK
_I
a_
I
I
_I
I
I
FU2
ILI
p
iLK
_NN
/7_ "_"
---
GND
-I--
II
T
G
E
N
D
BHT/CLR
BLWR
BLWM
BVSS
CA B
CPU
BLOWER MOTOR SPEED CHANGE REIJ_Y, SPDT
BLOWER MOTOR RELAY, SPST-(N O )
BLOWER MOTOR, PERMANENT-SPUT-CAPACITOR
BLOCKED VENT SHUTOFF SWITCH M_,NUAL RESET
CAPACITOR
MICROPROCESSOR
AND CiRCUiTRY
DSS
EAC-1
EAC-2
FRSE2
FSE
DRAFT SAFE GUARD SW1TCH, AUTO-RESET,
SPST-(N C)
ELECTRON C AiR CLEANER CONNECT ON ( 5 VAC 10 AMP MAX )
ELECTRON C AIR CLEANER CONNECT ON (COMMON)
FLAN1E ROLLOUT SW MANUAL RESET SPST (N C )
FLAN1E PROVING ELECTRODE
FU 1
FU 2
_
GND
FUSE 3 AMP A_OMOTI_
BLADE _PE
FACTORY INST_LED
FUSE OR CiRCUiT BR_KER
CURRENT INTERRUPT D_]CE
(FIELD INSTN.I ED & SUPP! lED)
EQUIPMENT GROUND
GV
_S
i
GVR
HSI
HSIR
GAS VALVE RELAY, SPST (N O )
HOT SURFACE iGNiTER (115 VAC)
HOT SURFACE IGNITER RELAY, SPST-(N
HUM
IDM
24VAC HUMIDIFIER CONNECTION (0 5 AMP MAX)
INDUCED DRAFT MOTOR, SHADED POLE
IDR
ILK
J1
NDUCED DRAFT MOTOR RELAY, SPST-(N O /
BLO'WER ACCESS PANEL NTERLOCK S'_ITCH
SPST-(N
BLOWER - OFF DELAY JUMPER SELECTOR - HEAl] NG
J2
JB
LED
BLOWER - OFF DELAY JUMPER - COOLING
JUNCTION BOX
LIGHT-EMITTING
DIODE FOR STATUS CODES - RED
_
LGPS
LOW GAS PRESSURE
-"-)
SPST
_LVE-REDUNDANT
S'B_ITCH SPST-(N
(N C )
LS 1, 2
OL
LIMIT SWITCH AUTO-BESET, SPST(N C )
AUTO RESET INTERNAL MOTOR OVERLO, _
PCB
PL1
PL2
TEMPERATURE
SWITCH (NO)
PRINTED CIRCUIT BOARD CONTROL
11-CIRCUIT PCB CONNECTOR
2-CIRCUIT CONNECTOR
PL3
2-CIRCUIT HSI, CONNECTOR
PRS
PRESSURE
TESTEIWIN
TRAN
COMPONENT TEST & TWiN TERMINAL
TRANSFORMER
115VAC/24VAC
SWITCH
SPST-(N
i
UND_RKED TERMI_L
PCB CONTROt TERMiN_
FACTORY W_RING (115£AC)
FACTORY _ RING (24Y_C)
O)
O )
F ELD W1R NG (
....
_
j_
_
O )
5VAC)
FIELD W1RING (24VAC)
CONDUCTOR ON CONTROL
_-z
PCB
NOTES:
1
If any of the edginal
2
3
Use only copper wire betwee_ the disconnect
This wire must be comected
to furnace sheet
4
Symbols
5
6
7
Solid lines inside PCB are pnnted c4rcuit board coeductors
Replace only with a 3 amp fuse
Inducer (IDM) and blower (BLV1A_I) motcrs contain intem_
8
Nentral
9
Blower motor speed selectiops
optimum speed selection
10
Factory
11
12
Factory connected
when LGPS is not used
Ignition-lockout
will occur after four consecutive
FIELD W1R]NG SCREW TERMINAL
FIELD EARTH
EQUIPMENT
GROUND
GROUND
PLUG RECEPTACLE
equipment
are electrical
connections
connected
autoceset
FIELD SPLICE
)---
wlre
is replaced
representation
after three
BVSS
Wiring
within
ae for average
(Chimney
105 iC
box (JB)
and are not included
autodeset
the NELFIPdkL
conditions,
Adapter
thermal
connector
unsuccessful
Kit)
switches
ILl
(OL)
block
see installation
Accessory
in legeed
ovedoad
instlllctions
for details
on
__
0
is nct installed
trials-fordg_ition
Control
will
hours
¢,4
13
Blower-on
delay:
gas heating
25 seconds,
14
Blower-off
delay:
gas heating
s_ections
Diagram
wire rated for
only
are interd_angeable
when
u_
switch aed the fumace junctic_
metal for control to prove flame
cooling
are 9&
or heat
120,150
90 seconds or 5 seconds when J2 is cut
-> Fig. 4S--Furnace
PL1-11
PL_-3
PLy-7
PCB NOTE#5
O )
JUNCTION
O
I1[_)
CoM 24v
A05038
pump 2 seconds
or 180 seconds
e_
ccoling
or heat pump
TaNe 8-AIt{tude
REGULATOR
Derate MuR{Ner for U.S.A.
ALTITUDE
(FT}
0-2000
PERCENT
OF DERATE
0
DERATE MULTIPLBER
FACTOR*
1.00
2001=3000
8-12
0.90
3001=4000
12-16
0.86
4001=8000
16-20
0.82
5001=6000
20-24
0.78
6001=7000
24-28
0.74
7001=8000
28-32
0.70
8001=9000
32-36
0.66
36-40
0.62
REGULATOR
ADJUSTMENT
SCREW
ON/OFF
9001=t0,000
* Derate multiplier
factors are based on midpoint altitude for altitude
REGULATOR SPRING
1/2
NPT INLET
GASPRESSURE
ADJUSTMENT
INLET
PRESSURE%&P
range
MANIFOLD
PRESSURE
TAP
1/2 NPT OUTLET_
£ Set them_ostat to call fk_rheat.
A04166
g. Jumper R and W thermostat connections on fk/mace cont*ol
board to start fi/mace.
-_ Fig. 46--Gas
1"1.Remove regulator seal cap and turn regulator adjusting
screw counterclockwise
(out) to decrease input rate of
clockwise (in) to increase input rate
radiant
heat
fi'om
temperature
important
i. Install regulator seal cap.
b
When
.i. Leave manomete* or similar device connected and proceed
to Step 4
rise
with
This
straight-rtm
ducts,
them_ometer
fiom
temperature
rise.
NOTE: DO NOT set manifPld pressure less than 32-in wc or
more than 38=in. wc fbr natural gas at sea level. If' manifold
pressure is outside this range, change main burner orifices or refer
to Table 12 or 13.
NOTE:
Blower access
ture rise measurement
NOTE: If'orifice hole appears damaged or it is suspected to have
been re&illed, check orifice hole with a numbered &ill bit of
cmTect size. Never redrill an orifice A bun'-flee and squarely
aligned orifice hole is essential for proper flame cha*acteristics.
2.) Derate
readings
supply=air
If the temperature
_Pr altitude
pressures
greater
4.) Dirty
filter.
Radiant
practice
stabilize,
rise is outside
heat
affects
is particularly
subtlact
temperature
door must be installed
1.) Gas input _br heating
3.) Return and supply
exchangers
readings
temperature
NOTE:
heat
Control Valve
return-air
to detem_ine
for proper
this range,
air
tempera-
first check:
operation.
if applicable.
ducts for excessive
restrictions
causing
static
than 0.50=in. wc.
4. Veri*}' natural gas input rate by clocking meter.
NOTE: Gas valve regulator adjustment cap must be in place for
proper input to be clocked
ELECTRICAL
SHOCK
HAZARD
Failure to follow this warning could result in personal injury
or death.
a Turn off all other gas appliances and pilots so*red by the
meter
Disconnect 115=v electrical power befPre changing speed tap.
b. Run iqu_ace fPr 3 minutes in heating operation.
c
c Measm'e time (in sec) for gas meter to complete 1 revolu=
tion and note reading The 2 or 5 cubic feet dial provides a
nlore accurate nleasnrenlent of gas flow.
Adjust
Increase
blower
air
temperature
blower
speed
speed
rise
by
to reduce
to increase
adjusting
temperature
temperature
blo_er
speed.
rise. Decrease
rise
d. Refer to Table 10 fbr cubic f_ of gas per hr.
e. Multiply gas rate (cu f_&r) by heating value (Btuicu ft) to
obtain input.
If clocked rate does not match required input from Step 1, increase
manifold pressure to increase input or decrease manifold pressure
to decrease input. Repeat steps b through e until correct input is
achieved. Reinstall regulator seal cap on gas valve.
\
5. Set temperatore rise.
The furnace must operate within t!_etemperature rise ranges
specified on the filmace rating plate. Do not exceed temperature rise range specified on unit rating plate. Determine the
temperature rise as follows:
BURNER J
U
--> NOTE: Blower access door must be installed when taking ternperature rise reading. Leaving blower access door offwill result in
incot_'ect temperature nleasnrements.
ORIFICE
A93059
a. Place thermometers in remm and supply ducts as close to
_/rnace as possible. Be sure them_ometers do not see
Fig. 47--Orifice
33
Hole
Table 9--Speed
Selection
COLOR
SPEED
White
Common
BLW
Black
High
COOL
Yel]owt
Med-High
SPARE
Blue*
Med-Low
SPARE
Red*
Low
HEAT
TERMINALS WITH
THERMOSTAT REMOVED
(ANITICIPATOR, CLOCK, ETC.,
MUST BE OUT OF CIRCUIT.)
AS SHIPPED
AMMETER
* 1/5 HP motor models: BLUE to HEAT, RED to SPARE
t Not available on 1/5 HP motors.
NOTE: Continuous blower is the HEAT speed.
& Turn thermostat down below room temperature
move blowm access door.
and re-
e. To change motto speed selection fbr heating, remove
blower motor lead fiom contlol HEAT terminal (See Fig.
24.) Select desired blower motor speed lead fi'om one of the
other terminals and relocate it to dte HEAT terminal (See
Table 9 for lead color identification). Reconnect original
lead to SPARE terminal.
10 TURNS
FROM UNIT 24-V
CONTROL TERMINALS
fi Repeat steps a through e.
EXAMPLE:
50 AMPS ON AMMETER
10 TURNS AROUND JAWS
g. When correct input rate and temperature rise is achieved,
mrn gas valve ON/OFF switch to OFF
h. Remove manometer
= 0.5 AMPS FOR THERMOSTAT
ANTICIPATOR
SETTING
A96316
or similar device f?om gas valve.
Fig. 48--Amp
Draw Check With Ammeter
i. Reinstall manifold pressu*e tap plug in gas valve.
fhrnace
--€
FIRE
contlol
To change
HAZARD
Leaking
gas
could
personal
injury,
Reinstall
manifold
be ignited
property
and
damage
pressure
cause
fire,
-->
in gas valve to prevent
8. Set airflow
gas leak.
CFM
switch to ON.
Step
4_Cheek
in d_e Start=up
F1. RNA(E
OVERHEATING
Failure
to properly
furnace
temperatures
Recheck
on the rating
point
and shorten
plate
of rise range
6. Set thermostat
rise may cause
fi/mace
Recommended
excessive
life.
It must be within
or slightly
limits
operation
specified
Accurate
at the wires
terminals,
nom_ally
R and W
NOT be in the circuit
is at the mid=
thermostat
of the electrical
amp &aw readings
connected
The
while
to themaostat
thermostat
measuring
fi'om subbase
Record
amp &aw
heating
and after blower
across
terminals
to
blower
180 sec.
anticipator
blower
were all checked
of normal
operation.
off delay
control
shuts
off combustion
gizes
air-circulating
should
or fl'om wall
when furnace
rate for 4 cycles
control
motor,
during
properly
block
if there
If limit
is a
contlol
does
must be determined
and
5 minutes.
off return
metal until
By
it can be established
failure.
this test, cause
and ener-
overheats.
and will operate
or motor
for at least
system
if fhrnace
to check limit control,
duct system
air with a piece
of cardboard
or
the limit trips.
c. Unblock
return
d. Burners
will re-tight
2. Check
the
&aft
The purpose
furnace
air to cause normal
is in
a. Vet!f)
when fhrnace
circulation.
cellain
per hr.
is to cause the safk shutdown
blocked
c. Restore
power
roonl
temperature.
nom_al
to fhrnace
start-up,
then block
vent area with a piece
34
down.
of the
vent conditions.
vent pipe is cool to the touch.
minutes,
on the
cools
switch.
of d-fis contlol
b. Disconnect
power to f:urnace
fi'om furnace vent elbow.
fi'om 90 sec to
are located
safeguard
during
d. After
settings
jumpers
blower
cmTent.
off delay
off delay has 4 adiustable
The
This
sheet
Set heat anticapator
on thermostat
per thermostat
instructions
and install on subbase or wall.
The blower
Switch(es)
b. Gradually
subbase
starts.
Set cycle
Limit
a. Rm'_ furnace
can be obtained
Connect an amp meter as shown in Fig. 4g across
R and W terminals or R and W wires at wall
7. Adjust
switch
as part
Main
not fhnction
corrected
in the
(2)
thermostat:
and pressure
section
that limit is functioning
heat anticipator
components
Remove
b. Electronic
procedure
restricted
(1)
(4)
thermostat
for cooling
Filter).
See
Controls
gas yah-e,
using this method
above
thermosta_Set
the amp draw
R-W circuit
(3)
1. Check
heat anticipator.
a. Mechanical
match
rise.
from
HAZARD
set temperature
temperature
move the jumper
fbr cooling
Safety
The flame sensor,
--€
24.)
Select the desired
blower
motor speed lead
airflow.
See Table 5=Air Delivery=CFM
(With
Table 9 for lead color identification.
j. Reinstall blower access door if remoxed
k. Turn gas valve ONOFF
(See Fig
off delay setting,
one set of pins on the control to the pins used for the selected
blower off delay. Factory off delay setting is 120 sec.
explosion,
or death.
tap plug
board.
the blower
and remove
and set room
allow
vent elbow
furnace
vent connector
thermostat
above
to
for
in fllrnace
of flat sheet metal
operate
80 percent
2
of
status
motor
Tab{e 10-GAS RATE (CU FTfHR)
SECONDS
SIZE OF TEST DIAL
SECONDS
SIZE OF TEST DIAL
FOR 1
1
2
5
FOR 1
1
2
5
REVOLUTION Cu Ft Cu Ft Cu Ft REVOLUTION Cu Ft Cu Ft Cu Ft
---5
10
360
720
1800
50
72
144
360
11
327
655
1636
51
71
141
355
12
300
600
1500
52
69
138
346
13
277
555
1385
53
68
136
340
14
257
514
1286
54
67
133
333
g. Reconnect
inducer
h. Blower
55
65
131
327
1125
56
64
129
321
17
212
424
1059
57
63
126
316
18
200
400
1000
58
62
124
310
19
189
379
947
59
61
122
305
1
20
180
360
900
60
60
120
300
2. (hock
21
171
343
857
62
58
116
290
22
164
327
818
64
56
112
281
23
157
313
783
66
54
109
273
24
150
300
750
68
53
106
265
25
144
288
720
70
51
103
257
26
138
277
692
72
50
100
250
27
133
267
667
74
48
97
243
28
129
257
643
76
47
95
237
29
124
248
621
78
46
92
231
30
120
240
600
80
45
90
225
31
116
232
581
82
44
88
220
32
113
225
563
84
43
86
214
33
109
218
545
86
42
84
209
34
106
212
529
88
41
82
205
35
103
206
514
90
40
80
200
FIRE,
INJURY,
36
100
200
500
92
39
78
196
Failure
to fbllow this warning
37
97
195
486
94
38
76
192
to this equipment,
38
95
189
474
96
38
75
188
The
39
92
185
462
98
37
74
184
ment requires
40
90
180
450
100
36
72
180
equipment.
41
88
176
439
102
35
71
178
perform
42
86
172
429
104
35
69
173
procedures
43
84
167
419
106
34
68
170
44
82
164
409
108
33
67
167
45
80
160
400
110
33
65
164
46
78
157
391
112
32
64
161
47
76
153
383
116
31
62
155
48
75
150
375
120
30
60
150
49
73
147
367
did not function
f\ Remove
g. Switch
blockage
will
h. Reoinstall
properly
from HEAT
3. (hock
board,
and mrn
This contlol
off l!5ov
should
inducer
and
beginning
the call fbr
nom_ally.
tools and instruments.
(ycle
6
Review
7
Attach
Clean
OFFoDELAY
blower
and
up debris.
time is selected
burner
access
test fhmac¢
with room
thermostat.
operation
of accessories
per
/ se*'s Guide with
literature
SERVBCE
packet
AND
are
properly
instruc=
to fhmace.
serious
HAZARD
personal
perform
do not
any maintenance
PROCEDURES
could result in possible
injury,
on this equip°
mechanical
possess
these,
skills, tools, and
do not
on this equipment
recommended
in the User's
ELECTRICAL
HAZARD
SHOCK,
FIRE,
Failure
to follow
this warning
death,
or property
damage
Before
servicing_
disconnect
damage
or death
maintenance
certain knowledge,
operation
doors
owner
OR DEATH
If you
as desired.
manuitacturer's
MAINTENANCE
ability- to properly
Verif)- proper
not
ignite
that blower
5. (hock
tions
attempt
to
other than those
Manual.
OR EXPLOSION
could result
all electrical
in personal
power
injury,
to ftlmace
after servicing.
&aft safeguard
condition.
--€
below room
temperature
ELECTRICAL
OPERATION
Failure
this caution
to fbllow
then back
or failure
Label
all wires
tIols
Wiring
HAZARD
may result in improper
furnace
of tim_ace
prior
to disconnection
errors
can
cause
when
improper
selwicing
and
con-
dangerous
operation.
or
ON.
Step
of the &aft
lead wires
l--htroduction
is flmctioning
glow
GENERAL
blower.
from wire harness.
to furnace.
to "call for heat"
switch
inducer
to fhrnace.
motor
on 115or power
NOT
Put away
4
open longer
than 3 minutes,
the f:urnace for 3 hours. To reset
operation
power
d. Set thermostat
pressure
door,
5--ChecHist
operation
OFF,
should
3. Verii)
that
installed.
vent elbow.
115v power
outer
Switch
proves
b. Disconnect
i. Furnace
Step
when it cools.
turn thermostat
to OFF
c. Turn
-->
vent connector.
Pressure
a. Turn
If gas does
reason
and correct
fl'om furnace
autooreset
Should
switch
remain
control board will lockout
control
2 minutes.
detem_ine
replace
will run for 90 sec befbre
1200
off within
wires,
heat again.
450
cycle
properly
turn on 115-v power.
480
2 minutes,
did not function
to ft_rnace.
225
should
switch
motor
240
switch
furnace
f\ Turn off 115or power
16
e Furnace
---5 NOTE:
furnace
DeteImine reason pressure
and con'ect condition.
15
shut offwithin
-->
e
code 32. If hot surfSce igniter glows when inducer
is disconnected,
shut down furnace immediately
and control
These
instructions
upflow
blower
application.
An upflow furnace application
is located below the combustion
and controls
furnace,
and wait 1 minute.
properly,
hot surface
diagnostic
light
and
are written
conditioned
When
ff_rnace can be installed
igniter
you must
flashes
a
ingly.
35
revise
your
as if the furnace
air is discharged
is installed
orientation
is where the
section of the
upward.
in any of the 4 positions
to component
in an
Since
shown
location
in Fig
this
4,
accord-
SERVICE
if status code recall
is needed,
bc_et]y remove
then recoqnect
one main Iirr_t vdre to display stored status
code
stafuscoderecalliscomplstedcomponenttestwlloccur
LED CODE
Of 1 RED LEO boards
do not re_ove
power or b_ower door before initiating
CONTINUOUS
OFF - Check for 115MAC
at L1 and L2. and 24VAC
at SEC-1
and SEC-2
CONTINUOUS
ON - Control
has 24VAC
power.
RAPID FLASHING
- Line vNtage
(115VAC)
poladty
reversed
If twinned,
refer to twinning
EACH OF THE FOLLOWING
11
12
13
14
21
22
23
24
STATUS
CODES IS A TWO DIGIT NUMBER VvlTH THE FIRST DIGIT DETERMINED
NO PREVIOUS
CODE - Stored
status code is erased
automatically
after 72 hours
On
RED LED boards
stored status
codes can also be erased
when power
(115 VAC or 24 VAC) to control is interrupted
BLOWERONAFTERPOWERUP
(115 VAC or 24 VAC)
-Blower
runs for 90 seconds,
if unit is powered
up during a call for heat (R-W closed)
or R-W opens during blower
on-delay
LIMIT CIRCUIT
LOCKOUT
- Lockout occurs
if the limit, draft safeguard,
flame
rollout, or
blocked
vent switch (if used) is open longer than 3 minutes
- Control
will auto reset after three hours
- Refer to #33
IGNITION
LOCKOUT
- Control
wilJ auto-reset
after three hours. Refer to #34
GAS HEATING
LOCKOUT
- Control
will NOT auto reset.
Check for: - Mis-wired
gas valve
-Defective
control (valve relay)
ABNORMAL
FLAME-PROVING
SIGNAL
- Flame is proved while gas valve is deenergized
Inducer
will run unti} fault is cleared.
Check for:
- Leaky gas valve
- Stuck-open
gas valve
PRBSSURB
SWITCH
DID NOT OPEN
Check for:
- Obstructed
pressure
tubing.
- Pressure
switch stuck
8BCONDARY
VOLTAGB
FUSB 18 OPEN Check for:
- Short circuit in secondary
voltage
(24VAC)
wiring
COMPONENT
To initiate
the component
test
sequence,
shut
BY THE NUMBER
31
33
dosed.
34
TEST
OFF
the room
thermostat
or disconnect
the "R"
thermostat
lead Briefly short the TEST/TWIN
terminal
to the 'Corn 24V" terminal.
Status LED
will flash code
ON the
inducer
will run LED
for the
entire
component
test andThethen
hot turn
surface
ignitor,
blowermotor
motorThefaninducer
speed motor
(on AMBER
boards
only)
blower
seconds
motor-heat
each.
speed,
Gas Valve
and
and
blower
motor-coo}
Humidifier
will
speed
will
not be turned
status
cede recall
After
STATUS
be turned
ON for
10-15
I
on
45
I
327596-101
REV.
B
I
OF SHORT FLASHES
kit instructions
AND THE SECOND DIGIT BY THE NUMBER
OF LONG FLASHES
PRESSURE
SWITCH
DID NOT CLOSE
OR RBOPENBD
- If open longer than five minutes
inducer
shuts off for I5 minutes
before retry
Check for:
- Excessive
wind
- Proper vent sizing
- Defective
inducer
motor
- Low inducer voltage
(I 15VAC)
- Defective
pressure
switch
- Inadequate
combustion
air supply
- Disconnected
or obstructed
pressure
tubing
- Low inlet gas pressure
(if LGPS used)
- Restricted
vent
If it opens dedng blower
on-delay
period¸ blower
will come on for the selected
blower
off-delay.
LIMIT CIRCUIT
FAULT
- Indicates
a limit, draft safeguard,
flame rol_out or blocked
vent
switch (if used) is open.
Blower will run for 4 minutes
or until open switch remakes
whichever
is longer
If open longer than 3 minutes,
code changes
to lockout
#13.
If open less than 3 minutes
status code #33 continues
to flash until blower
shuts off
Flame rollout
switch and BVSS
require manual
reset.
Check for:
- Restricted
vent
- Proper vent sizing
- Loose blower
wheel¸
- Excessive
wind
- Dirty filter or restricted
duct system.
- Defective
blower
motor or capacitor¸
- Defective
switch or connections¸
- Inadequate
combustion
air supply (Flame
Roll-out
Switch
open).
IGNITION
PROVING
FAILURE
- Control
will try three more times before
lockout
#14
occurs¸
If flame signal lost during blower
on-de_ay period,
blower will come on for the
selected
blower off-delay
Check for:
- Flame sensor must not be grounded
- Oxide buildup
on flame sensor (clean
with fine steel wool).
- Proper flame
sense microamps
(5 microamps
DC
rain., 40 - S0 nominal)
- Gas valve defective
or gas valve turned off
- Manual valve shut-off
- Defective
Hot Surface
Ignitor
- Control
ground
continuity
- Low inlet gas pressure
- Inadequate
flame carryover
or rough ignition
- Green/Yedow
wire MUST be connected
to furnace
sheet
metal
CONTROL
CIRCUITRY
LOCKOUT
Auto-reset
after one hour
lockout
due to;
- Gas valve relay stuck open
- Flame sense circuit failure
- Software
check error
Reset power to clear lockout
Replace
control if status code
repeats¸
J
\
1
A04223
-_ Fig. 49--Service
ELECTRICAL
CONTROLS
AND WIRING
Label
For (ontrols
With a Red LED
The stored status
codes WILL
if 115- or 24-v
--€
ELECTRICAL
SHOCK
HAZARD
Failure to follow
or death.
this warning
1. To retrieve
could result
accessories
supplies
The
NOTE:
and
45 for furnace
will
control
operation
for additional
polarity
wiring
furnace
fbr
115-v
system
electFical
wiring
the tk_mace
requires
an
earth
contains
must
LED
fiom
3°amp
is required,
LED will display
Proper
status
instrumentation
The control
use ONLY
for proper
2. When
status
_klse located
in this furnace
is equipped
(Light-Emitting
Diode)
troubleshooting
It can be viewed
access
door
rapid flashing,
nm'nber
flashes
The fm'nace
aid
control
in
flashes,
with a Stares
installation,
through
LED
TEST
(ode
LED
servicing,
and
is either
digit
5. Refer
access
of status
door or Fig 49_ and the tloubleshooting
can be obtained
from your distFibutor
store 1 stares code fbr 72 hours.
-9 See Fig. 53, a brief Troubleshooting
The
ftmaace
insulated
code will be lost
terminal
until
LED
wire
goes
completed,
this stares
fiom
the draft
out (1 to 2 sec),
the LED
code fbr
flashes
fi/rther
will
begin.
Refer
to
COMPONENT
test sequence.
LED stares.
label on the front of the blower
status
indicates
ACCESS
DOOR
on fi/rnace
and replace
on
guide which
control
or stares
for complete
to d_e SERVICE
7. If LED
BLOWER
of tong
label located
door sight glass fbr current LED
blower access door or tem_inate
6. Check LED status. If no previous
will flash stares code 11.
The first digit is the
codes, ref¢r to service
remove
on
access
door for more infbrmation.
ON continuously,
is the number
and all
door
to control
self=test
section
4. Check
controls
the sight glass in blower
of 2 digits.
the second
3. (omponent
to be replaced
electrical
to fi_rcmce mined
above items have been
code 4 times. Record
terminal
For an explanation
blower
to
or a code composed
of short
fuse needs
to service
at control,
troubleshooting.
a 3oamp J:k/se The control
code 24 when
is required
with the _bllowing:
may be present
safeguard
switch (DSS)
then reconnect
it
on the control. (See Fig 24) Any shorts of the 24-v wiring during
installation,
service, or maintenance
will cause this fi/se to blow If
_k/se replacement
memory,
be completed
outer access
d. BRIEFLY
on d-xe
heating
electlode
an automotiveotype,
signal
must
c Look into blower access
stares. DO NOT remove
be
infbm_ation
ground
code, proceed
l15ov power
b. Remove
115_v power
the STATUS
and flameosensing
delays
a Leave
infi_rmation
and prevent
also
of the control
the stares
NO them_ostat
blower_OFF
servicing.
is not correct,
flash rapidly
The 24_v circuit
unit
be erased from the control
is interrupted.
injuQ'
to the/_t_rnace.
Refer to Fig. 25 fbr field wiring
If the polarity
control
supply
be shut off during
ground
maintained.
and to Fig
The
and cooling
that must
electrical
properly
in personal
NOTE:
There may be more than one electrical
Check
power
will
Guide
36
burner
control
access
fault is in history,
proper
operation,
SWITCH,
reattach
board, replace
door.
blower
control
RELEASE
wire to "R"
access
door,
TaNe l 1--FILTER
FURNACE
CASBNG W_DTH
4. Inspect
SIZE _NFORMATION (iN.)
FILTER QUANTITY AND S_ZE
Side Return
Bottom Return
rnst,
FILTER
TYPE
5
14-1/2
(1) 16X25X
I
(1) 14X25X
1
Cteanabte*
17-1/2
(1) 16X25X
I
(1) 16X25X
1
Cteanabte*
21
(1) 16X25X
1
(1) 20X25X
1
Cteanabte*
I
(I) 24X25X
1
Cleanable*
24**
(I) 16X25X
* Recommended
** Some furnaces may have 2 filters
burner
compartment
corrosion,
soot
_ul_ace
and burner
Inspect
the vent pipe/vent
_br rust,
serviced
corrosion,
fittings.
Have
service
agency.
6. Inspect
be%re
water
before
attached
%r
service
have
agency.
each heating
sagging
system
season
If necessa_,
by a qualified
leakage,
accessories
heating
dust.
system
vent pipes/vent
any
each
or excessive
pipes
serviced
to the
season
or broken
by a qualified
t_t_mace such
as a
humidifier
or electronic
air cleaner. Pert'ram any service or
maintenance
to the accessories
as recommended
in the accesso_- instractions.
Step
2--Care
and
Maintenance
CLEANING
AND/OR
REPLACING
The air filter arrangement
FIRE
OR
Failure
EXPLOSION
to %llow
exchanger,
this warning
fire, personal
Never store anything
such as:
1. Spray
2. Soap
waxes
containers,
plastic
or plastic
cigarette
fluids.
lighter
fluid,
thinners
ment
Failure
death or product
gasoline,
fluids,
--€
CUT
local
must
dealer
corn=
paper
to %llow
wear
appropriate
gloves
bags,
possible
proper
Media
when
of a maintenance
on this
contract
could result
in personal
injury,
filter
Media
damage.
cabinet
or 1" Filter
t'rom the factory
supply
Remove
3
Slide filter
out of cabinet.
4
If equipped
with permanent,
by spraying
cold tap water
filter cabinet
and
are accessories
to furnace
and are
_ilrnace model
before
removing
filter
door
5. If equipped
replace
with
only
washable
through
1-inch filter, clean filter
filter in opposite
size.
_bctory=specified
with media
For
FIRE
6. Slide filter
filter
expandable
included
disposable
having
direction
replacement
external
media
the same part
media,
with the replacement
with KGAFR0301ALL
AND
Rack
with the standard
2
instrnctions
POISONING
glasses,
I:_/maces.
procedures:
Turn off electIical
access door.
and
MONOXIDE
safety
and sela'icing
injury.
Use care and
of airflow. Rinse filter and let dry. Oiling or coating of the
filter is not recommended.
See Table 11 for size int'ornaation.
Turn off the gas and electlical
supplies to the unit before
performing
any maintenance
or service Follow the operating
instructions
on the label attached to the ftmaace.
(ARBON
in personal
or burrs
clothing,
parts
1
of
HAZARD
this warning
an'ow, the arrow must
may result
protective
handling
cabinet
not included
equip=
fiequency
this caution
Sheet metal parts may have sharp edges
kerosene,
be performed
ahont
direction
the blower.
HAZARD
Failure
or other volatile
compounds,
maintenance
your
SHOCK
to follow
vacuum
cleaning
and to minimize
and the availability
ELECTRICAL
mops,
NOTE:
high per%rmance
Consult
maintenance
dnst
products.
fg_ilure, periodic
equipment.
dry cleaning
on the application.
with the I:t_rnace,
or other
and other painting
or other paper
For continuing
brooms,
will vary depending
to the J:i/mace casing.
If the filter has an airflow
point towards
tools.
bleaches,
pounds,
NOTE:
of heat
or death
cans, rags,
or other cleaning
powders,
3. Paint
could result in corrosion
inju_',
on, near, or in contact
or aerosol
cleaners,
The filter is exterior
HAZARD
AIR FILTER
media.
filter rack,
filter,
number
refer
to the
If equipped
See Table
11.
into cabinet.
HAZARD
Failure to follow
injury,
this warning
could
result
7. Replace
in fire, personal
8. Turn on electrical
or death
Never operate
removed.
filter cabinet
unit without
a filter or with filter
access
door
BLOWER
MOTOR
door.
to ft_rnace.
supply
AND
WHEEL
1
--€
(IT
HAZARD
Failure
to %llow
this caution
may result
in personal
iRiury
ELECTRICAL
SHOCK
HAZARD
Failure to follow
or death.
this warning
could result
in personal
injury
Sheet metal parts may have sharp edges or bun's
Use care and
Blower
wear
glasses,
component
operation
can occur unless switch
is closed.
(aution
must be taken when manually closing this switch for
appropriate
gloves
when
The minimnn_
1. (hock
required.
2. Check
protective
handling
parts
maintenance
and clean
blower
safety
and servicing
and
fimaaces.
month
or more
fiequently
if
NOTE:
balance
if torn.
motor
season.
and wheel
Clean
for cleanliness
each
heating
electrical
connections
_br tighmess
proper
operation
each heating
season.
Service
door switch
opens
115=v power
to control.
No
purposes.
The blower wheel
will be affected.
Tile foHmving
as necessm 7.
3. (hock
access
service
on this fm_aace is as %llows:
air filter each
Replace
and cooling
clothing,
steps should
should
not
be performed
be
dropped
or bent
by a quMified
as
service
agenc?°
and
controls
for
To ensure
as necessm_-.
grease
37
tong life and high eNciency,
from blower
wheel
and motor
clean accumulated
annually.
dirt and
TABLE 12--Orifice
Size* and Manifold Pressure For Gas input Rate
Data Based On 22,000 Btuh Per Burner, Derated 4 Percent For Each 1000 Ft Above Sea Level)
(Tabulated
SPECIFIC GRAVITY
ALTITUDE
RANGE
(FT)
AVG GAS
NEAT VALUE
(BTUiCU FT)
0.58
Orifice
No.
Manifold
Pressure
Orifice
No.
0.60
Manifold
Pressure
OF NATURAL
Orifice
No.
GAS
0.62
Manifold
Pressure
Orifice
No.
0.64
Manifold
Pressure
900
42
I
3.5
42
3.6
42
3.7
41
3.5
925
42
I
3.3
42
3.4
42
3.5
42
3.7
95O
43
3.8
42
3.3
42
3.4
42
3.5
975
4:3
3.6
43
3.8
42
3.2
42
3.3
1000
4:3
I
3.5
43
3.6
43
3.7
43
3.8
1025
4:3
I
3.3
43
3.4
43
3.5
43
3.6
1050
44
I
3.6
43
3.2
43
3.4
43
3.5
1075
44
44
I
I
3.4
44
3.5
43
3.2
43
3.3
3.3
44
3.4
44
3.5
43
3.2
J
o
-o
I
E
0
to
2000
I
i
<:
J
E
1100
SPECIFIC
ALTITUDE
RANGE
AVG GAS
HEAT VALUE
(FT)
(BTU/CU
U.S.A.
o
Altitudes
2001
to
3000
"o
or
"o
_f
Canada
Altitudes
2000
to
4500
FT)
0.58
Orifice
No.
0.60
Manifold
Pressure
0.62
Manifold
Pressure
0.64
Manifold
Pressure
Orifice
No.
3.4
42
3.5
42
3.6
42
3.7
3.2
42
3.3
42
3.4
42
3.5
3.7
43
3.8
42
3.2
42
3.3
I
Orifice
No.
Orifice
No.
8OO
42
825
85O
42 I
4:3 I
875
4_3
I
3.5
43
3.6
43
3.7
43
3.8
900
4,3
I
3.3
43
3.4
43
3.5
43
3.6
925
4:3
I
3.1
43
3.2
43
3.3
43
3.4
950
4,3
I
2.9
43
3.0
43
3.1
43
3.2
975
4:3
I
2.8
43
2.9
43
3.0
43
3.1
1000
4:3
I
2.6
43
2.7
43
2.8
43
2.9
AVG GAS
HEAT VALUE
(FT)
GAS
Manifold
Pressure
SPECIFIC
ALTITUDE
RANGE
GRAVITY OF NATURAL
(BTU/CU
FT)
0.58
Orifice
No.
775
42
8OO
43
825
43
85O
43
875
43
900
43
925
43
950
4:3
GRAVITY OF NATURAL
0.60
Manifold
Pressure
0.62
Manifold
Pressure
Orifice
No.
0.64
Manifold
Pressure
Manifold
Pressure
Orifice
No.
3.2
42
3.3
42
3.4
42
3.5
3.6
43
3.8
42
3.2
42
3.3
3.4
43
3.5
43
3.7
43
3.8
3.2
43
3.3
43
3.4
43
3.6
3.0
43
3.1
43
3.3
43
3.4
2.9
43
3.0
43
3.1
43
3.2
2.7
43
2.8
43
2.9
43
3.0
2.6
43
2.7
43
2.8
43
2.8
I
Orifice
No.
GAS
J
I
E
3001
to
4000
U.S.A. Only
I
E
I
J
I
E
I
E
I
J
I
SPECIFIC
ALTITUDE
RANGE
(FT)
O
<:
AVG GAS
HEAT VALUE
(BTU/CU FT)
4001
to
5000
0.58
GRAVITY OF NATURAL
0.60
Manifold
Pressure
GAS
0.62
Manifold
Pressure
0.64
Manifold
Pressure
Orifice
No.
Manifold
Pressure
Orifice
No.
750
43
3.6
43
3.8
42
3.2
42
3.3
775
43
3.4
43
3.5
43
3.6
43
3.8
800
43
3.2
43
3.3
43
3.4
43
3.5
825
43
3.0
43
3.1
43
3.2
43
3.3
850
43
2.8
43
2.9
43
3.0
43
3.1
875
43
2.7
43
2.8
43
2.9
43
2.9
900
43
2.5
43
2.6
43
2.7
43
2.8
925
43
2.4
43
2.5
43
2.6
43
2.6
Orifice
No.
Orifice
No.
* Orifice numbers 43 are factory installed
The inducer
and blower
motors
are pro-lubricated
additional
lubrication.
These motors
can be
absence of oil ports on each end of the motor.
(?lean blower
motor
1. Turn off electrical
2. Loosen
and wheel
supply
the thumbscrew
and require
identified
by
no
For downflow
the
the furnace
a
as fbllows:
vent connector
b. Disconnect
and
within i_/rnace,
to furnace.
on outer door and remove
Disconnect
or horizontal
outer door.
38
filrcmces having vent pipes within
that pass in fiont of the blower
remove
flora
short
access
door:
fire, ace vent elbow.
piece
of vent
pipe
from
Table 12--Orifice
Size* And Nanifold Pressure For Gas input Rate (Continued)
(Tabulated Data Based On 22,000 Btuh Per Burner, Derated 4 Percent For Each 1000 Ft Above Sea Level)
O
m@
{BTU/CU
_
Pressure
Manifold
No.
J
Pressure
No.
Pressure
Manifold
Orifice
No.
l
Pressure
Manifold
3.5
43
3.6
43
3.7
43
3.3
43
3.4
43
3.5
775
43
3.0
43
3.1
43
3.2
43
3.3
2.8
43
2.9
43
3.0
43
2.7
43
2.8
43
3.1
43
2.5
43
2.5
43
2.6
43
43
2.9
85O
43
43
2.6
875
43
2.3
43
2.4
43
2.5
43
2.6
9OO
43
2.2
43
2.3
43
2.3
43
2.4
675
7OO
SPECIFIC
GRAVITY OF NATURAL
0.60
0.62
0.58
2.7
GAS
0.64
Pressure
Manifold
Orifice
No.
43
3.6
43
3.7
43
3.4
43
3.5
3.0
43
3.1
43
3.2
43
2.8
43
2.9
43
3.0
2.6
43
2.7
43
2.7
2.8
2.4
43
2.5
43
2.6
43
43
43
2.3
43
2.3
43
2.4
43
2.5
43
2.1
43
2.2
43
2.3
43
2.4
Pressure
Manifold
Orifice
No.
Pressure
Marfifold
Orifice
No.
43
3.4
43
3.1
43
3.5
43
3.3
725
43
2.9
43
75O
43
2.7
775
80O
43
43
825
85O
l
I
SPECIFIC
0.58
J
GRAVITY OF NATURAL
0.60
Orifice
Manifold
Pressure
No.
_
Pressure
No.
0.64
65O
43
3.1
43
3.2
43
3A
43
3.5
675
43
2.9
43
3.0
43
3.1
43
3.2
7OO
43
2.7
43
2.8
43
2.9
43
3.0
43
2.5
43
2.6
43
2.7
43
2.8
2.4
43
2.4
43
2.5
2.2
43
2.3
43
2.4
43
43
75O
Manifotd
2.7
(BTU/CU FT)
l
_
Pressure
Manifold
GAS
0.62
Orifice
l
Orifice
No.
725
J
Manifold
Pressure
Orifice
No.
l
Manifold
Pressure
2.6
775
43
43
8OO
43
2.1
43
2.1
43
2.2
43
2.3
825
48
3.7
43
2.0
43
2.1
43
2.2
SPECIFIC
GRAVITY OF NATURAL
2.4
GAS
AVG GAS
HEAT VALUE
AT ALTITUDE
(BTU/CU FT)
Orifice
No.
Manifold
Pressure
Orifice
No.
Manifold
Pressure
Orifice
No.
Manifold
Pressure
Orifice
No.
Manifold
Pressure
625
43
2.9
43
3.0
43
3.1
43
3.2
65O
43
2.7
43
2.8
43
2.9
43
3.0
675
43
2.5
43
2.6
43
2.7
43
2.8
to
7OO
43
2.3
43
2.4
43
2.5
43
2.6
9000
725
43
2.2
43
2.2
43
2.3
43
2.4
75O
43
2.0
43
2.1
43
2.2
43
2.2
775
48
3.6
48
3.7
43
2.0
43
2.1
ALTITUDE
RANGE
(FT}
O
Orifice
43
Orifice
No.
8000
Manifotd
3.2
AVG GAS
HEAT VALUE
AT ALTITUDE
(BTU/CU FT)
7001
to
/
3.4
AVG GAS
HEAT VALUE
AT ALTITUDE
ALTITUDE
RANGE
(FT)
l
0.64
Orifice
43
6000
7000
O
FT)
GAS
0.62
43
825
6001
to
_
Orifice
No.
OF NATURAL
0.60
75O
800
(FT)
0.58
725
5001
to
ALTITUDE
RANGE
O
SPECIFIC GRAVITY
AVG GAS
NEAT VALUE
AT ALTITUDE
ALTITUDE
RANGE
{FT)
8001
4
0.58
0.60
0.62
0.64
* Orifice numbers 43 are factory installed
4, Remove 2 screws i:i"om blower
access
access door and remove blower
5. Disconnect
blower
leads
from
f_/rnace
_k_rreassembly.
be left connected,
but field tiaem_ostat
to be disconnected
2 screws
7. Hang control
blower
2 screws
and slide blower
color and location
6. Remove
g. Remove
door
depending
holding
on their
control
contlol
Record
All other factory
connections
length
casing
wire
9
can
may need
blower
blower
wheel and motor
Blower
(clips)
10
from
compartment.
39
Vacuum
nlotor.
on blower
any
assembly
to blower
deck
out of ftmaace.
using a vacuum
wiaeel blades
with soft brush
may be cleaned
paint or flux brusia. Do not remove
shel£
and away
(;lean
attaciament
and routing.
box to blower
box from fiont of furnace
wires
holding
assembly
or disturb
with a small
balance
weights
wiaeel blades
loose
dust
fiom
blower
housing_
wheel
and
Table 12--Orifice
Size* And Manifold Pressure For Gas input Rate (Continued)
Data Based On 22,000 Btuh Per Burner, Derated 4 Percent For Each 1000 Ft Above Sea Level)
(Tabulated
c
O
10,000
0.58
GRAVITY
OF NATURAL
0.60
GAS
0.62
0.64
Orifice
No.
Manifold
Pressure
Orifice
No.
Manifold
Pressure
Orifice
No.
Manifotd
Pressure
Orifice
No.
Manifold
Pressure
600
43
2.7
43
2.8
43
2.9
43
3.0
625
43
2.5
43
2.6
43
2.6
43
2.7
650
43
2.3
43
2.4
43
2.4
43
2.5
675
700
43
2.1
43
2.3
3.7
2.0
43
2.1
43
43
2.3
48
43
43
2.2
725
48
3.5
48
3.6
48
3.7
43
2.0
(BTU/CU
9001
to
m
D
SPECIFIC
AVG GAS
NEAT VALUE
AT ALTITUDE
ALTITUDE
RANGE
(FT}
i
FT}
2.2
* Orifice numbers 43 are factory installed
11. If a greasy
from
residue
degrease>
NOTE:
during
housing
To remove
Befbre
housing
is present
d_e blower
wheel,
remove
it with
wheel
an appropriate
-->
wheel:
disassembly,
so motor
on blower
and wash
mark
blower
motor,
and each arm is positioned
and
blower
at the same location
reassembly.
a. Disconnect
blower
capacitor
wires
and
ground
wire
attached
to
housing.
b. Remove
c. Loosen
___>
d. Remove
screws
securing
motor
cutoff
out of wheel
f Clean
blower
wheel
plate
blower
motor
and remove
wheel
to blower
(40÷/-20
wheel
cutoff"
on motor
shaft
housing
and slide
screw contacts
screw
Blower
access
door
contIoL
closed.
No component
operation
can occur unless switch is
Exercise
caution
to avoid electrical
shock from
by reversing
wheel
is centered
wheel
19. If furnace
ground
wire to the
CESS
of d-_emotor
and reposition
shaft.
15. Reinstall
blower
assembly
16. Reinstall
control
box assembly
DAMAGE
Failure
to £bllow this caution
Loosen
set
20.
if necessary.
Downflow
fhmace
does
a
Heating
in f_/mace.
mended
slightly
HAZARD
£m speed(s)
temperature
rise
operation
above
START-UP,
MUST
be adjusted
as specified
on
to provide
d_e rating
is at d-_e rni@oint
of the
and SAFETY
air
Recom°
rise range
Refer to "SET TEMPERATURE
ADJUSTMENT,
life
proper
plate.
manually
closing
this
cycle
or
or
Install
horizontal
and connect
BLOWER
any junipers
leads
with
AC-
or reconnect
Replace
furnaces
blower
vent
pipe
access
through
short piece
of vent pipe inside
f:urnace
vent.
vent connector
casing
to vent elbow.
Reinstall
22.
Turn on gas supply
and cycle
heating
door.
cycle.
and cooling
shown
in "Adjustments"
below
70°F,
tnrn
Adjust
Section.
off" circuit
Nrnace
breaker
on after completing
through
the furnace
Section.
running
HEAT
fhrnace
Verify
in "Adjustments"
The following
CHECK.
thermostat
direction
RELEASE
Remove
21.
CLEANING
RISE" under
in the cmTect
only:
b. Connect
heat exchanger
to furnace
door switch.
properly,
SWIT(H.
to existing
in fhrnace.
may shorten
access
is rotating
is operating
DOOR
as shown
[NIT
115-v power
when
or cooling
any disconnected
door
and set
14. Spin the blower wheel by hand to verif}- that the wheel
not tab on the housing.
opens
close blower
blower
1if d-_rough
housing
switch
shock,
purposes.
a heating
steps
in blower
could result in electrical
components
for service
d. Verify
and blower
the flat portion
on blower
or death
c. Perfbrm component
self-test as shown at the bottom of the
SERVI(E
label, located on the front of blower access door.
fiom housing.
with 1 la. Be sure to reattach
that blower
injury,
beginning
in-lb when reassembling).
housing.
13. Verif)
personal
electrical
HAZARD
NOTE:
If d_em_ostat temainals are jumpered
at the dine blower
access door switch is closed, blower wilt run for 90 sec befbre
and housing.
motor
1 in, finishing
this warning
switch
in°lb when reassembling).
12. Reassemble
blower
holding
bolts holding
e. Remove
to fbllow
b. Manually
set screw
(160+/-20
SHOCK
Failure
exposed
plate from housing.
___>
ELECTRICAL
in the cooling
temperature
If outdoor
breaker
Turn
rise
rise as
temperature
to outdoor
cycle.
cooling
one complete
temperature
is
unit befbre
outdoor
circuit
cycle.
EXCHANGER
s{eps should
be performed
by a qualified
service
agency:
NOTE:
Refer to Table 9 fbr motor speed
were not identified before disconnection.
17. Reconnect
blower
wiring diagram,
disconnected.
18. To check blower
a. Turn
leads
to fimaace
and connect
fbr proper
on electrical
tend relocation
control
them_ostat
NOTE:
if leads
If" the heat exchangers
and carbon,
Refer
leads
they
them tho*oughly.
to furnace
problem
if previously
rotation:
supply.
4O
exists
should
A build-up
which
of soot
needs
adjustment
of
combustion
air, incorrect
get a heavy
be replaced
manifold
improper
gas, or a restricted
to correct
the problem.
accumulation
rather
than
and carbon
to be corrected,
pressure,
size
heat exchanger.
to clean
indicates
such
insufficient
or damaged
of soot
trying
or poor
manifold
that a
as improper
quality
orifice(s),
Action must be taken
TABLE 13--Or{fice Size* and Manifold Pressure For Gas Input Rate
Data Based On 21,000 Btuh Per Burner, Derated 4 Percent For Each 1000 Ft Above Sea Leve0
(Tabulated
SPECIFIC
ALTITUDE
RANGE
{FT)
o
AVG GAS
NEAT VALUE
(BTU/CU FT)
0
to
2000
<:
0.58
Manifold
Pressure
Orifice
No.
Orifice
No.
GRAVITY
0.60
Manifold
Pressure
OF NATURAL
Orifice
No.
GAS
0.62
Manifold
Pressure
Orifice
No.
0.64
Manifold
Pressure
9OO
42
I
3.2
42
3.3
42
3.4
42
3.5
925
43
N
3.7
43
3.8
42
3.2
42
3.3
95O
43
I
3.5
43
3.6
43
3.7
43
3.8
975
43
I
3.3
43
3.4
43
3.5
43
3.7
1000
44-
I
3.6
43
3.3
43
3.4
43
3.5
1025
44
i
3.4
44
3.6
43
3.2
43
3.3
1050
44
I
3.3
44
3.4
44
3.5
43
3.2
1075
4b
N
3.8
44
3.2
44
3.3
44
3.4
1100
46
I
3.8
45
3.7
44
3.2
44
3.3
SPECIFIC
GRAVITY OF NATURAL GAS
ALTITUDE
RANGE
AVG GAS
HEAT VALUE
{FT)
(BTU/CU FT)
Orifice
No.
80O
43
I
3.8
42
3.2
42
3.3
42
3.4
825
43
N
3.5
43
3.7
43
3.8
42
3.2
85O
I
I
3.3
3.2
43
3.5
43
3.6
43
3.7
875
43
43
43
3.3
43
3.4
43
3.5
9OO
43
I
3.0
43
3.1
43
3.2
43
3.3
925
43
N
2.8
43
2.9
43
3.0
43
3.1
95O
I
I
2.7
2.5
43
2.8
43
2.9
43
2.9
975
43
43
43
2.6
43
2.7
43
2.8
1000
43
I
2.4
43
2.5
43
2.6
43
2.7
U.S.A.
o
Altitudes
2001
to
3000
"o
or
•u
&l
Canada
Altitudes
2000
to
4500
0.58
Manifold
Pressure
Orifice
No.
0.60
Manifold
Pressure
SPECIFIC
Orifice
No.
0.62
Manifotd
Pressure
Orifice
No.
0.64
Manifold
Pressure
GRAVITY OF NATURAL GAS
ALTITUDE
RANGE
AVG GAS
HEAT VALUE
{FT)
(BTU/CU FT)
Orifice
No.
775
43
I
3.5
43
3.7
43
3.8
42
3.2
800
43
I
3.3
43
3.4
43
3.5
43
3.7
825
43
I
3.1
43
3.2
43
3.3
43
3.4
850
43
I
2.9
43
3.0
43
3.1
43
3.2
875
43
I
2.8
43
2.9
43
3.0
43
3.1
900
43
I
2.6
43
2.7
43
2.8
43
2.9
925
43
I
2.5
43
2.6
43
2.7
43
2.7
950
43
I
2.4
43
2.4
43
2.5
43
2.6
3001
to
4000
U.S.A. Only
0.58
Manifold
Pressure
Orifice
No.
0.60
Manifold
Pressure
Orifice
No.
0.62
Manifoid
Pressure
Orifice
No.
0.64
ManJfotd
Pressure
SPECIFIC GRAVITY OF NATURAL GAS
ALTITUDE
RANGE
(FT)
AVG GAS
HEAT VALUE
(BTU/CU FT)
>,
4001
to
5000
O
<.
* Orifice
numbers
If it becomes
43
are factory
necessary
dust or corrosiom
proceed
3. Disconnect
outer
access
Orifice
No.
0.60
Manifold
Pressure
Onrice
No.
0.62
Manifold
Pressure
Orifice
No.
0.64
Manifold
Pressure
750
43
3.3
43
3.4
43
3.5
43
3.6
775
43
3.1
43
3.2
43
3.3
43
3.4
800
43
2.9
43
3.0
43
3.1
43
3.2
825
43
2.7
43
2.8
43
2.9
43
3.0
850
43
2.6
43
2.7
43
2.8
43
2.8
875
43
2.4
43
2.5
43
2.6
43
2.7
900
43
2.3
43
2.4
43
2.5
43
2.5
925
43
2.2
43
2.2
43
2.3
43
2.4
installed
Go clean
the heat exchangers
because
of
4. For downflow
as follows:
1. Turn OFF gas and electrical
2. Remove
0.58
Manifold
Pressure
Orifice
No.
power
pipe, remove
to ffmaace
5
flora flul_ace
flora switches
vent elbow.
a
41
Draft
furnace
damage
switch.
an internal
vent
the casing.
components.
of (be caref_ul when
because
safeguard
having
vent pipe within
wires to the following
aid in reconnection
door.
vent connector
Disconnect
or horizontal
internal
Mark wires to
disconnecting
may occur):
wires
Table 13--Orifice
Size* And Nanifold Pressure For Gas input Rate (Continued)
(Tabulated Data Based On 21,000 Btuh Per Burner, Derated 4 Percent For Each 1000 Ft Above Sea Level)
ALTITUDE
RANGE
(FT}
=
O
AVG GAS
NEAT VALUE
AT ALTITUDE
to
6000
ALTITUDE
RANGE
(FT)
c
O
_
ALTITUDE
RANGE
(FT}
c
O
(FT}
0.64
Orifice
No.
Orifice
No.
Manifotd
Pressure
Orifice
No.
Manifold
Pressure
725
43
3.1
43
3.2
43
3.3
43
3.4
75O
43
2.9
43
3.0
43
3.1
43
3.2
775
43
2.7
43
2.8
43
2.9
43
3.0
800
43
2.5
43
2.6
43
2.7
825
43
2.4
43
2.5
43
2.5
850
43
2.2
43
2.3
43
2.4
43
43
43
875
43
2.1
43
2.2
43
2.3
43
2.3
900
43
2.0
43
2.1
43
2.1
43
2.2
FT}
i
SPECIFIC GRAVITY
Pressure
Manifold
Orifice
No.
675
43
3.1
7OO
43
2.9
725
43
75O
775
0.58
OF NATURAL
0.60
[
2.8
2.6
2.5
GAS
0.62
Pressure
Manifotd
Pressure
Manifold
Pressure
Manifold
Odfice
No.
43
3.2
43
3.3
43
3.4
43
3.0
43
3.1
43
3.2
2.7
43
2.8
43
2.9
43
2.9
43
2.5
43
2.6
43
2.7
43
2.8
2.3
43
2.4
43
2.5
2.2
43
2.3
43
2.3
43
43
2.6
8OO
43
43
825
43
2.1
43
2.1
43
2.2
43
2.3
85O
48
3.7
43
2.0
43
2.1
43
2.1
SPECIFIC GRAVITY
[
0.64
Orifice
No.
OF NATURAL
2.4
GAS
AVG GAS
HEAT VALUE
AT ALTITUDE
(BTU/CU FT)
Orifice
No.
Manifold
Pressure
Orifice
No.
Manifold
Pressure
Orifice
No.
Manifold
Pressure
Orifice
No.
Manifold
Pressure
650
43
2.9
43
3.0
43
3.1
43
3.2
675
43
2.7
43
2.7
43
2.8
43
2.9
700
43
2.5
43
2.6
43
2.6
43
2.7
2.3
43
2.4
43
2.5
2.1
43
2.2
43
2.3
2.0
43
2.1
43
2.2
43
43
43
7001
to
8000
ALTITUDE
RANGE
GAS
0.62
Manifold
Pressure
Orifice
No.
7000
OF NATURAL
Orifice
No.
AVG GAS
HEAT VALUE
AT ALTITUDE
(BTU/CU FT)
6001
to
GRAVITY
0.60
Manifold
Pressure
(BTUiCU
5001
SPECIFIC
0.58
725
0.58
0.60
0.62
0.64
2.5
775
43
43
43
80O
48
3.6
48
3.7
43
2.0
43
2.1
825
48
3.3
48
3.5
48
3.6
48
3.7
750
SPECIFIC GRAVITY
AVG GAS
HEAT VALUE
AT ALTITUDE
(BTU/CU FT)
Orifice
No.
Pressure
Manifold
Orifice
No.
625
43
2.7
650
43
2.5
0.58
OF NATURAL
0.60
2.4
2.2
GAS
0.62
0.64
Pressure
Manifold
Orifice
No.
43
2.7
43
2.8
43
2.9
43
2.5
43
2.6
43
2.7
[
l
Pressure
Manifold
Orifice
No.
Pressure
Manifold
c
O
8001
675
43
2.3
43
2.4
43
2.4
43
2.5
'
to
9000
700
43
2.1
43
2.2
43
2.3
43
2.3
725
48
3.7
43
2.0
43
2.1
43
2.2
750
48
3.5
48
3.6
48
3.7
43
2.0
775
49
3.8
48
3.4
48
3.5
48
3.6
* Orifice numbers 43 are factory installed
b, Inducer motor
6, Remove
cell panel,
c, Pressure switch(es)
d, Limit overtemperamre
e. Gas valve,
assembly
switch,
screws
--€
8, Remove
need not be removed
the 5 screws
that attach
to d_e
box, Inducer
from collector
the burner
The gas valve and individual
g. Flame=sensing electrode,
h, Flame rollout switches
NOTE:
Be ve W careful
i, Remove NOx baffles on low NOx models.
breaking
igniter,
42
box assembly
the collector
box,
gas line _i'om gas mani_bld,
cell panel.
removed
the collector
not to damage
and elbow
7, Disconnect
fi Hot sm'fhce igniter.
that fasten
Be carefi/l
['tom support
assembly
burners
to the
need not be
assen_bly,
when removing
bumm
See Fig, 50 and 51 _br correct
assembly
igniter
to avoid
tocation
Table 13--Orifice
Size* And Manifold Pressure For Gas input Rate (Continued)
(Tabulated Data Based On 21,000 Btuh Per Burner, Derated 4 Percent For Each 1000 Ft Above Sea Level)
ALTITUDE
RANGE
{FT)
O
AVG GAS
HEAT VALUE
AT ALTITUDE
{BTU/CU
9001
to
m_
FT)
Orifice
No.
l
OF NATURAL
0.60
GAS
0.62
Pressure
Manifold
Orifice
No.
Pressure
Manifotd
Orifice
No.
[
0.64
Pressure
Manifold
Orifice
No.
Pressure
Manifold
l
600
43
2.4
43
2.5
43
2.6
43
2.7
625
43
2.3
43
2.3
43
2.4
43
2.5
43
2.1
43
2.2
43
2.2
43
2.3
675
700
48
48
3.6
43
2.1
3.5
48
3.6
43
48
2.1
3.4
48
48
3.8
725
49
3.7
49
3.8
48
3.4
48
3.5
650
10,000
SPECIFIC GRAVITY
0.58
3.7
* Orifice numbers 43 are factory installed
(2.)
9/32"
Insert brush
end of cable
into the outlet opening
of cell
and slowly rotate with &ill DO NOT force cable.
Gradual!y insert cable into upper pass of cell (See Fig.
52)
5/16"
(3)
Work
cable
in and out of cell 3 or 4 dines
to obtain
sufficient
cleaning.
DO NOT pull cable with great
force Reverse drill and gradually
work cable out.
(4)
Insert
brush
end of cable
col!, and proceed
as upper
sal*le nlanner
inlet
2 lower
passes
opening
of
of cell in
pass.
(5.)
Repeat foregoing procedures
has been cleaned.
(6)
Using
(7)
Using vacuum
cleaner
clean burner assernbly
(8)
(?lean flame
sensor
(9)
Install
baffles,
vacuum
in burner
to clean
cleaner,
until each celt in Nrnace
remove
residr/e
with
soft
from each cell.
brush
attachment,
A05025
Fig. 80--Igniter
Position-Side
View
-->
(i0.)
NOx
Reinstall
with
fine steel wool
if removed
burner
assembly.
from
cell panel
Center
burners
in celt
openings.
10. Remove
old sealant
11. Spray releasing
collector
NOTE:
(must
A05026
Position-Top
View
G.E.
--> 12
13
9. Lsing field-provided 25-caliber rifle cleaning brush, 3d-in.
long, 1/4" diameter steel spring cable, a variable speed,
reversible electric dri!l, and vacuum cleaner, clean cells as
fol!ows:
corn
such
or inadequate
as cooking
seal
DO NOT
to flange
panel using existing
screws,
Reconnect
on
wiring
reconnect!on
a. Drafl
a. Remove metal screw fitting _i'om wire brush to a!low
insertion into cable.
b
b. Insert the twisted wire end of brush into end of spring
cable, and crimp tight with crimping tool or crimp by
striking with ball-peon hammer. TIGHTNESS IS VERY
IMPORTANT.
d
occur)
any other
through
of collector
making
label,
switch
e. Gas valve.
NOTE: The materials needed in item 9 can usually be purchased
at local hardware stores.
(1) Attach variable-speed, reversible &il! to the end of
spring cable (end opposite brush).
elect*ode.
1t. Flame
rollout
switches.
i. Install
NOx
14. Reinstall
43
igniter.
g. Flame-sensing
ba*tles
internal
(if removed).
vent pipe,
sea!ant.
were
switch(es).
f[Hot surface
type of RTV
box and attach to cell
switch.
overtemperature
sealant
starting
sure al! screws are secure.
motor
c. Pressure
and RTV
before
components
if wires
or equivalent
or halogenated
RCD in 3-oz robes.
locations.):
safeguard
Inducer
Limit
may
wires to the _bltowing
diagram
spray
oi!, aromatic
is available
Apply new sealant
cell panel where
738) are needed
substitute
162 (P771-9003)
box flange.
cell panel.
or canola
162, 6702, or Dow=Corning
installation.
Fig. 51--1gNter
contacts
agent
contain
hydrocarbons
(G.E.
agent on the heat exchanger
box assembly
A releasing
not
and collector
if applicable.
(T_se connection
not
marked
_br
_Z
b. Igniter
Warm-Up-
Hot-Surface
igniter
--9
c
At the end of the prepurge
Igniter
warn>up
the main gas valve relay contacts
the gas valve
GV permits
flame
energized
flame
until
ihsten
vent
vent
connector
con'osion=resistant_
ld. Replace
blower
vent
elbow
elbow
with
2 field-supplied,
sheet metal
screws
located
access
17. Set thermostat
proper
ihmace
to vent
connector
on
door
above room
sequence
180 c_aparL
going
airflow
and check [hmace
and speed changes
between
for
heating
EXPLOSION
Failure
to ibllow
injury,
or death
Never
Use
use a match
19. Check
Step
outer
Furnace
control
wire routed
[f flame
is proved
ihmace
control
operation
through
diagram
very- carefully.
NOTE:
If a power
the control
will
after power
gas heating.
90=second
long
The
period,
The
blower
through
the
control
(PU,
motor
BLWM,
or
screw
the sequence
LED
during
of
the wiring
light
will
flash
door
is still calling
for
d_e
as
Afier
TRAN,
igniter
25 [br thermostat
thermostat
walt
code
the 90-second
period,
circuit.
a. Inducer
comes
up to speed,
for power
switch
HI_M
prepurge
tenninai
on HEAT
flame
is proven,
the
speed
25 seconds
after
the electronic
air cleaner
energized
terminal
EAC-!
as tong as the blower
is energized.
energized
on
perfbnns
the pressure
As
blower-OFF
CPU
is fhctory=set
selection).
(depend=
The
for a 120-second
furnace
blower-OFF
the
starts
the outdoor
start the furnace
unit,
blower
motor
air cleaner
circuits.
and the R=to-G
BLWM
terminal
on COOL
EAC-I
The R=to=Y
and Y circuits
speed.
is energized
with
furnace
IDM,
blower
opened.
a self-check,
and starts
inducer
GV.
motor
the R to W
The outdoor
BLWM
verifies
the
When
blower
contacts
motor
IDM
will continue
to 5 seconds.
the
Blower
R=to-G
motor
the control
a 15-second
During
at
igniter
period.
44
and the furnace
operating
on the (OOL
J2 to reduce
are
blower
speed fbr
the cooling
(See Fig. 24.)
Mode
circuit
as HEAT
is closed
will
speed).
motor
a call for heat,
warm-up
stop,
(ut jumper
BLWM
long as the blower
PRS close,
humidifier
unit will
90 seconds.
Continuous
the inducer
ibr a field installed
begins
delay
Mode
off'delay
switch
ibr 90, !20, 150, or 180 seconds
the
to the
closing
the
period.
EAC-I
115 vac when the blower motor BLWM is operating.
When the thermostat is satisfied, the R=to-G-and=Y circuits
motor
for heat",
Period-
and
the burner
remain
circuit
to be condacted
ILK
inducer
PRS is open,
is supplied
If
The
will
speed (same
Prepurge
24 vac power
the
contacts
_he
mode
IDM until flame is no longer
(See Fig. 25 _br thermostat
connections)
The thermostat
closes the R-to=G=and-Y
connections.)
The _:hmace control
pressure
switch
motor IDM.
motor
not be present,
of Gas-Heating
energized
for a 5=second post-purge
motor BLWM and air cleaner terminal
The electronic
HSI, and gas vah'e
"calls
should
remain
blower
an additional
The
24 vac
CPU (not at
the
will
Cooling
1, Heating
(See Fig
control
delay.
normally
interlock
hot-surface
two
12 during
be installed
transibrmer
ON period
the LED will be ON continuous,
to the thermostat
must
auto=
interrupting
stopping
gas flow to the buraers,
and de-energizing
humidifier
terminal
HUM. The inducer motor IDM
ing
a call for heat (W),
blower-only
if the thermostat
are detected.
blower
green/yellow
Read and ibllow
occurs
after which
door
operation
through
bracket
modes.
a 90-second
red
will respond
fbr proper
in Fig. 45, _Pllow
is restored,
as no faults
fl/mace
and manifold
intemlption
before
reset
or by intem/pting
flame
and remains
BLWM
control
start
be
i_ Blower-Off
Delay= When the thermostat
is satisfied,
the
R=to-W circuit is opened, de-energizing
the gas valve GV,
is grounded
the different
will
GV is energized.
Simultaneously,
must be grounded
diagram
to
is not
CPU will close the
by momentarily
will lock out
is energized
the gas valve
of Operation
to gas valve
flame
Trials-For-Ignition
Lockout
when
CPU
Delay=
motor
motor
Control
more
hours,
the inducer
e. Blower-On
door
control
at the
control
CPU will repeat the ignition
to the flu_aace,
is energized
access
the schematic
seconds
in fire, personal
solution.
will lock out
Using
result
or other open flame to check for gas leaks
a--Sequence
NOTE:
could
%r gas leaks,
20, Replace
the
and continues
If the burner
or SEC2 to the [hrnace
blower
a soap=and-water
is proved
the flmaace
115 vac power
at SECI
or until
proved.
HAZARD
this warning
flame
power
and operate
OR
is sensed
the control
ibr up to three
three
a
The HSI igniter will
W, G, R, etc.)
and
cooling.
FIRE
two seconds,
after
it
delay period
GV open.
to Ignition=Lockout.
matically
operation.
18. Verify7 blower
within
where
aker the GVR closes,
FSE,
gas valve GV, and the control
only, if it was removed.
temperature
eleckode
the blower=ON
opens.
begins.
the burner
sensor
the gas valve
proved
Securely
the flame
GVR
the gas valve
begins.
period
When
flame-proving
hold
period
proving
warn>up
gas flow to the burners
2-second
proving
the igniter
GV,
by the HSI. Five seconds
d. Flame-Proving-
15. Reinstall
When
is ignited
CPU begins
the
17-second
Sequence=
is completed
2-second
Cell
period,
a
period
remain
Heat Exchanger
ibr
period.
The gas valve
Fig. 52--CleaNng
is energized
Trial-for-Ignition
close to energize
A91252
HSI
Terminal
EAC-!
the blower
(25 seconds),
allowing
more quickly,
then restarts
the
on
BLWM
(17 seconds),
by
operate
the
is energized
as
is energized.
BLWM
ignition,
the Nrnace
thermostat,
continuous-blower
will
stop during
and blower-ON
heat exchangers
delay
to heat up
at the end of the blower-ON
delay
period
atHEATspee&
Whenthethermostat
"calls%r
BLWM
will operate
satisfie&
90
seconds
on
_mction
4, Heat
speed
BLWM
speed
the blower
When
the them_ostat
will operate
befbre
motor
is
an additional
reverting
back
circuit
operating
blower-OFF
to
pear,
requires
is opened,
the blower
blower
motor
motor
5 seconds,
BLWM
BLWM
if no other
with
changes
off times
during
a heat pump,
the timing
demand
the _/mace
sequence
defrost
cycles.
and-Y or R-to°W°and-Y-and-G
fi/mace control CPU will continue
prepurge
control
auto°
to avoid
long blower
When
the R-to-W-
If the R-to°W-and-Y
the G signal,
the blower
the blower
motor
after the selected
blower-OFF
delay
If
signals
motor
disap-
BLWM
BLWM
at HEAT
period
is completed.
will
speed
Diagrams
period,
then shut off for 24 seconds
speed.
f_/mace control
When
begins
the W input
a normal
inducer
signal
post-purge
period
5--Troubleshooting
Refkr
to the sela'ice
answer
item
the
and
45
label.
Troubleshooting
fm'nace
then come back
disappears,
Step
The
circuits
are energized
the
to turn on the blower motor
at HEAT speed, and begin a heating cycle. The
motor BLWM will remain on until the end of the
on at HEAT
delay
Refkr to Fig. 25 and 45 fbr wiring diagrams
installed
matically
BLWM
blower
speed after a 3 second
rtmning
Step 4--Wiring
operation
Pump
When
to (OOL
delay period.
leaving
continue
for an additional
switches
the R°to-W-and°Y°and°G
signals disappear
at the same time,
the blower motor BLWM
will remain
on for the selected
speed.
the R°to-G
will continue
motor
COOL
continuous-blower
When
at COOL
the blower
the blower
cooling",
operation
(See Fig
Guide
problems.
each question
can
49
be
Beginning
and fbllow
Service
a useful
with
the appropriate
The Guide will help to identiI:)
the problem
After replacing
veri_y con'ect
any component,
Label.)
tool
in isolating
tl_e word
"Start,"
arrow to the next
or _i_iled component.
operation
sequence.
Fig. 53--Troubleshooting
Guide
START
NO
is LED status light on?
,_
NO
Is there 115V at L1 and L2?
_
Is door switch closed?
._1_
ts door switch closed?
YES
NO
I Is there 24V at SEC-1 and SEC-2?
_
I Is there 115V going to switch?
'_Is
P
circuit breaker closed?
YES
LBepl
furoace
ce
cootrol
I
NO
LBepl cedoorswdch
J
Check for continuity in wire from circuit breaker
to furnace
Ir
is LED status light blinking
pause?
rapidly without a
I _E_J Oh_kfor
cor_ectline_oltage
poI_r,_
,f_oi_
1 --_ RopIace
#aosforme,
are twinned, check for proper low-voltage
[_1_
(24V) transfOrmer
phas'ng
I Close circuit breaker
and go back to START
safeguard
switchcode
to display
stored status
code Onone
RED
LED
To recall status
briefly remove
and reconnect
RED
wirecontrol
from do
the not
draft
remove power or blower access panel before ini_ating status code recall You
can also recall the previous status code by momentarily shorting the TEST, q-_N
terminal to Com24V terminal until the LED goes out LED will flash the status
code of the previous fault or status code #11 (1 shorf and 1 long flash) if there
YES
4_
Determine status code The status code is a
2 digit number with the first digit determined
by the number of short flashes and the second
was no previous fault After the control repeats the code 4 t#nes, the control
will go through a brief component test sequence The inducer will start and run
for the entire component test The HSl blower motor FAN speed (AMBER LED
dig t by the number of teng flashes?
boards
only)and
HEAT
speed will
and not
COOL
speed on
will run for I0Gas valve
humidifier
be turned
$
YES
wasfl shedfi°n below for the status code that
G°t°aSel
I
1
Was there a previous
_L,
_EB I other
than #11?
I5 ......
ds each
[ interconnecting
Check room thermostat
cable
I
status code
I
i
NO
I
and control
G (24V)
th .......to WtatY1
signals?
. I Y/Y2,
Does the
respond
(if present),
i
or
]
I
I'_1_
I NO
I/
I
......... YIY2trst?
_1 G
Is thermostat
24V presentterminals
at W, Y1on(iftbefu
present),
or II
$ ES
t
I
Run system through a heating or cooling cycle
to check operation
Status codes are erased
after 72 hours On RED LED boards stored
Disconnect
all the thermostat
furnace control
wires
from the 1
I
(115V or 24V) is interrupted
status codes can also be erased whenever
/
YES
I Replace
f...........
trol
_-E.q
Does the problem repeat when using
a jum pot wire ?
furnace control Either install a ballast resistor,
connect the Com24V thermostat
terminal to
L The
thermostat
is not
compatible
with the
the thermostat,
or
replace
the thermostat
A02106a
1
NO
PREVIOUS
CODE
-Stored
codes
are
erased
atter
72hours
On
RED
LED
boards
stored
status
codes
can
also
be
erased
whenever
power
(115V
or24V)
isinterrupted
Run
system
through
a
heating
orcooling
cycle
tocheck
system
BLOWER
ON
AFTER
POWER
UP(115V
OR
24V)
- No_mal operation.
Blower runs for 90 seconds,
31
LOCKOUT
occurs if the limt.
rollout, or blocked
open longer than
auto reset atter 3
if unit s
- Lockout
33
draft sateguard, flame
vent switch*(it used) is
3 minutes. Control will
hours See code 33
LOCKOUT
- Turn off
LIM IT CIRCUIT
DID NOT CLOSE
45
flame to,lout,
Reset power to clear lockout
control if code repeats
another
component
tot 115V between
test sequence
Reconnect
thermostat
blocked vent shutoff sw tch* (if used) is
open
Blower will run tot 4 minutes or
untii open swtch remakes whichever is
onger
If open longer than 3 minutes.
code changes to lockout #13
If open
less than 3 rain status code #33
continues to flash until blower shuts oft
receiveaCr°ss
gaS24v?Vaive
connections.
Dirty filter or restr cted duct system
Loose blower wheel
Detective swtch or connections.
to retry
|
-
Detective b_ower motor or capacitor
Inadequate
combustion
ar supply
(flame rollout switch open)
Restricted vent
Stuck closed gas valve relay on con_ol
t
Miswire
J
or short to gas valve wi e
-
Proper vent szing
Excessive wnd
1
ABNORMAL
FLAME-PROVING
SIGNAL |
Flame is proved while gas vane s deenergized
Inducer wil! run untl faut is
cleared
Check for:
- Stuck
open or leaky' gas valve
PRESSURE
SWITCH DID NOT OPEN
Check tot:
- Obstructed
pressure tube
- Pressure switch stuck closed
t
34
IGNITION
PROVING
FAILURE
Does gas valve
• YES
Does gas valve open and allow gas to flow?
1
YES
_
L
Do the main
burners
gnite?
_ NC_
r
_..g.:.2........_
Check
connections
I
_._
that all gas valves are turned
.
I .........
I
_NO
"
burners
stay on?
is not sensed during the trial for ignition
period, the contro} will repeat the ignition
sequence 3 more times before lockout
I DC microamps
_
,_
YE_
1
control
on
valve
Proper firng
_
or rough
rate.
(.045' nominal)
B_ocked or incorrect
carp!_ over gap.
Allow blower to come on and repeat
check for ntermittent
operation
NQ
aNO
_ne
below 05?
i
t
/
Replace
ignit
on.
Inadequate
flame carryover
Low inlet gas pressure.
Repeat call for heat and check flame sensor
I cu rent during tr,aifor,gn,t,on
pe,iod
,sthe
- F flame
Check
If OK. replace
1_
YES
I Do the main
Replace
_ I Cbeckforcontmuityinthehamessandigniter
Replace defective component
YES
/
power and wait 5 minutes
Check for:
on
the R thermostat
lead and set
to call for heat Connect voltmeter
Fame rol!out swtch and BVSS requires
manual reset
Check tot:
1
|
Check
pin 1 and NEUTRAL-L2
thecontro_
15
Unplug igniter Was115Vpresenttortbe
harness from control and initiate
second period?
_
or
-
CONTROL
CIRCUITRY
LOCKOUT
Auto-reset
after 1 hour lockout due to:
Flame c rcuit ta lure
- Gas valve relay stuck open
Sottware check error
FAULT - Ind cares the
limit, draft sateguard,
IGNITION LOCKOUTSystem fai_ed to
ignite gas and prove flame in 4 attempts
Control will auto-reset after 3 hours
See status code 34
GAS HEATING
SWITCH
before retry If opens durng b[cwer onde_ay period, b_ower wH come on for the
selected blower off-delay
Check for:
- Proper vent szing.
- Low inducer voltage (115V).
- Low inlet gas pressure (it LGPS used)
- Inadequate
combuston
air supply
- Disconnected
or obstructed
pressure
tubing
- Defective inducer motor
- Defective pressure switch
- Excessve
wind.
- Restricted vent.
powered up during a cali for heat (R-W
c_osed) or when (R-W opens) during the
Mower omdelay per od.
LIMIT CIRCUIT
PRESSURE
test to
Check connections
and retry. If current is
r typica, va,ue (4 0-6 0 nominal) and
_ I burners
wll
not stay on. replace
control
YES
microan]ps
1
SECONDARY
Check for:
VOLTAGE FUSE IS OPEN
- Short c4rcuit in secondary
to furnace
vo!tage (24V) _
wirng fllcluding
thermostat
leads
|
D scon_lect thermostat leads to isolate
short circuit
!
sheet metal
Flame sensor must not be grounded
To determine
whether the problem is in
the gas valve, igniter, or
system can be operated
test mode to check the
remove the R thermostat
the control
and nitiate
Is current
flame sensor the
in the component
igniter
First
connection from
near typical
value?
_
Replace
electrode
_
Replace
furnace
YES
[ _¢v111
main burners
ignite
and stay on?
contro_
the component
test sequence
Does the igniter glow
orange/wh te by the end of the 15 second
warm-up
period?
YES
[Fixed
* Blocked vent shutoff switch used in Chimney
Adapter
1
Kit
A05032
Copyright
2005
Carrier
Manufacturer
Corporation
reserves
PC
101
the
58st13sJ
right
Catalog
to discontinue,
No
See
Cover
or
change
at any
Printed
time,
Jn USA
specifications
Form
or designs
58ST-13SI
without
notice
Pg 48
and
without
5-05
incurring
obligations.
Replaces:
58ST-12SI
Source Exif Data:
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