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

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The Payne PG8M/PG8J 80% AFUE Gas Furnaces feature 4-

way 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 STM''heat exchanger

• 5-year parts warranty on all other components

Catalog No: 53PG-8J5 Form No. IM-PG8J-05 5-05

Induced-Combustion

{nstallation,

Service and

Cancers: II 310A-45°4/IM-PG8J-04

A li310_k-45-5/IM-PG8Jo0_5

Start-up, upera mng, ane

Maintenance Instructions

Series 120/0

NOTE: Read the entire instruction manual before starting the

installation.

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 ........................................................ 4

Safety ......................................................................................... 5

General Installation ................................................................... 5

(onfhustion and Ventilation Air .............................................. 5

Duct Systems ............................................................................ 5

Acoustical Lining and Fibrous Glass Duct .............................. 5

Gas Piping and Gas Pipe Pressure Testing .............................. 5

Electrical Connections .............................................................. 5

ELECTROSTATI( DISCHARGE (ESD) PRECAUTIONS

PRO(EDURE ................................................................................ 5

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

General ...................................................................................... 5

Location Relative to Cooling Equipment ................................ 7

AIR FOR COMBUSTION AND VENTILATION ...................... 7

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

Lpftow Installation ................................................................. i0

Bottom Return Air Inlet .................................................... i0

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

Leveling Legs (If Desired) ................................................ 10

Downftow Installation ............................ 10

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

Horizontal Installation ............................. 11

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

Platfbrm Furnace Support ........................ i 1

Roll-Out Protection .............................. 11

Bottom Return Air Inlet ......................... 1l

Side Return Air Inlet ........................... 11

Filter Arrangement ................................ 11

Air Ducts ........................................ 11

General Requirements ............................ 11

Ductwork Acoustical Treatment .................... 12

Supply Ai* (onnections ......................... 12

Return Air Connections .......................... 14

Gas Piping ...................................... 15

Electrical ( onnections ............................ 19

115=V Wiring ................................ 19

J°Box Relocation .............................. 20

Electrical Connection to J°Box ..................... 21

Power Cord Installation in Furnace J=Box ............. 21

BX Cable Installation in Furnace J°Box .............. 22

RSO 9001:2000

24-V Wiring ....................................................................... 22

Accessories ........................................................................ 22

Venting .................................................................................... 22

General Venting Requirements ......................................... 23

Masonry (himney Requirements ...................................... 23

Appliance Application Requirements ............................... 24

Additional Venting Requirements ..................................... 26

Sidewall Venting ............................................................... 26

START°UP, ADJE STMENT, AND SAFETY CHECK ............ 27

General .................................................................................... 27

Start-Up Procedures ................................................................ 27

Adjustments ............................................................................. 3l

Check Safe w Controls ............................. 34

Checklist .......................................... 35

SERVICE AND MAINTEiN'ANCE PROCEDURES ........... 35

Intro&ction ....................................... 35

General ........................................ 35

Electrical Controls and Wiring ..................... 36

(are and Maintenance .............................. 37

Cleaning and/or Replacing Air Fiher ................. 37

Blower Motor and Wheel ......................... 37

Cleaning Heat Exchanger ........................ 40

Sequence of Operation ............................. 44

Wiring Diagrams .................................. 45

Troubleshooting .................................. 45

Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.

B°°k 1h_ PC 101 catalog No See Cover Printed in USA Form 58ST-13SI Pg 1 5-05 Replaces: 58S%12SI

Tab 16al 8a

28 7/8" --

26 I/8"

(FLI JE COLLAR)

5 15,q6" --

78" DIA I I

ACCESSORY 7

33 5¸'¸¸[6,`

/I /6"_

-- 25 I/4" --

_- 22 _/6" --

3 15/6" S

LEFT HAND GASJ

ENTRY

78" D]A ACCESSORY-

21 5/8"

BOTTOM INLET

24"

CASING

24 7,8"

_i /,2"

_A--

-- D --

lOCATIONS (TYP}

5 PLACES (TYP}

--/116"

S]DEINLET

9 5_8"

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 Drawing

SAFETY CONSIDERATIONS

FIRE, EXPLOSION, ELECTRICAL SHOCK, AND

CARBON MONOXIDE POISONING HAZARD

Failure to follow d-fis warning could result in dangerous

operatiom serious injury, death, or property damage

Improper installation, adjustment, alteration, service, mainte-

nance, or use can cause carbon monoxide poisoning, explo-

sion, fire, electrical shock, or other conditions which may

cause personal inju Wor property damage. Consuh a qualified

service agency, local gas supplier, or your distributor or

branch fbr infPm_ation or assistance. The qualified service

agency must use only fSctory=authorized and listed kits or

accessories when modif}qng this product.

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

Installing and servicing heating equipment can be hazardous due to

gas and electrical components. Only trained and qualified

personnel should instMl, repair, or service heating eqnipment.

Untrained personnel can perform basic maintenance functions

such as cleaning and replacing air filters. All other operations must

be performed by trained service personnel. When working on

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

or* labels attached to or shipped with £urnace and other safety

precautions that may apply.

These instructions cover minimum requirements and con%,Tn to

existing national standards and safety codes In some instances_

these instructions exceed certain local codes and ordinances,

especially those that may not have kept up with changing residen=

tial construction practices We require these instructions as a

minimum for a saf_ installation

(:liT HAZARD

Failure to fbllow d_is caution may result in personal ir_jury.

Sheet metal parts may have sharp edges or butts Use care and

wear appropriate protective clothing, safety glasses and

gloves when handling parts and servicing fhrnaces.

Wear safety glasses and work gloves. Have fire extinguisher

available daring start-up and ad.iustment procedures and service

calls.

This is the safety=alert syn£bol Z_ • When you see this syn_bol on

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

for personal injury.

Understand the signal words DANGER, WARNING, and (AU=

TION. These words are used with the safkty=alert symbol. DAN-

GER identifies the most serious hazards which will result in severe

personal injury or death. WARNING signifies a hazard which

conld result in personal injury or death. CAUTION is used to

identify hazards which may result in minor personal ir_jury or

product and property damage. NOTE is used to highlight sugges=

tions which will result in enhanced installation, reliabili w, or

operation.

1. Use only with type of gas approved tbr this filrnace. Refkr to

the [_urnace rating plate.

2. Install this Nrnace only in a location and position as specified

in the "Location" section of these instructions.

MINIMUMINCHESCLEARANCETO COMBUSTIBLECONSTRUCTION

DISTANCEMINIMALE ENPOUCESAUX CONSTRUCTIONSCOMBUSTIBLES

Thisforced air furnace is equippedfor use wi_ PqisfiJmaceisapprovedforUPFLOW,DOWNFLOW,and

naturalgas at altitudes0-10,000ft (0-3,050m). HORIZONTALinstallations.

An accessory kit, supplied by De Cettefournaiseestapprouveepourl'installationHORIZONTALE

manuf_turer, shall be used to convert to propane etlac£culationd 'airVERSLEHAUTet VERSLEB._S.

gas use or may be requiredfor some natural gas /_,,_->

applications. Clearancearrows /',,_ Lesfbchesded@gagement

This furnace is for indoor installation in a donotchangew}th L _ nechangepasavec

furnace orientatior_ z u._ I 'orientation de la feamaise,

buildingconstructedon site. ._

Thisfumase maybe installedon combustible _

oonng

as indicated by the diagram from combusiible _.

msterial.

Thisfurnacemay be used with a Type B-1 Vent

and may be vented in common wi_ other gas ",_ _ ,so_._._.

Cet[e fournaisea air pulseest equipee _ r_._,- i s=_

pour utilisaiJon avec gaz nafurel et altitudes

comprisesentre G3,050m (0-I0,000 pi). e\O_

Utiliserune trousse de conversion,foumie par co_

lefabrinant,pourpasserau gaz propane ou pour _.

certainesinstallationsau gaz naturel. "_ oz_i b"

Cettefoumaiseest pr@ue pour @e

installeedans un b_lJmentconstruitsur place. _ _ _./ Clearanceininches

Cettefournaise peut 6tre install@esur <_// D_agernent(po}.

un planc'hercambusiJbledansune alc6veou

dans un garde-robeen respectantle minimum <:_'/

d'espace libredes materiauxcombustibles,tel Vent Clearanceto combustibles:

qu'indique sur le diagramme. For Single WalJ versts 6 inches (6 po).

Cette fournaise peut @-e utilisee avec un For Type B-1 vent type 1 inch (1 po).

Degagementde I'@entavec combustibles:

conduitd'@acuationde Type B-1 ou connectee Pearconduitd'evacuationa paroi simpb 6 po(6 inches).

au conduit ommun d 'autres appareilsa gaz. Pearcor_duitd'@aeaationdeTypeB-11Fo(1inch).

MINIMUM INCHES CLEARANCE TO COMBUSTIBLE CONSTRUCTION

I)OWNFLOWPOSITIONS:

1" InstallaiJonon non-combusibiblefloorsonly.

For Installationon combustibleflooring only when installedon special base,Part No. KGASB020IALL,

Coil Assembly,PartNo. CD5 or CK5, or CoilCasing,Part [/o. KCAKC.

O 18 inchesfront clearancerequiredfor alcove.

_r Indicatessupplyor returnsideswhen furnace isin [he horizontalposition.Linecontactonly permissible

betweenlinesformed by intersectionsof the Top and bJvoSides of the furnacejacket,and buildingjoists,

studsor framing.

DC:GAGEMENTMINimUMEN POUCESAVEC €:LE_ENTS

DE CONSTRUCTION COMBUSTIBLES

POURLAPOSITIONCOURANTDESCENDANT:

1" Pour rinstallationsur planchernon combus_bleseulement.

Pour rinstallationsur un planchercombusiJbleseulementquandon utilisela basespedale, 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 lec6ted'en_-eeou de retourquand lafournaiseestdans la

positionhorizontale.

Le contact n'est permis qu'entreles lignesformees par les intersectionsdu dessus et des

deuxc6tes de lacherfise de la fournaiseet lessolives,montantsous cadre de charpenta.

k. 327590-101 REV. C

--> Fig. 2--Clearances to Combustibles

A04123

-_ Table 1--Dimensions (iN.)

D E C.L TOP AND FLUE

FURNACE A SUPPLY-AIR RETURN-AiR BOTTOM COLLAR* SHIP W% (LB}

$tZE CABINET W_DTH WIDTH WIDTH FLUE COLLAR {BN.}

(tN.) (IN.) (RN.}

045=08t024045 14-3/16 12=9/16 12-11/16 9=5/16 4 104

045=12t036045 14-%16 12-9/16 12-11/16 9=5/16 4 107

070=08t024070 14-3/16 12=9/16 12-11/16 9=5/16 4 111

070=12t036070 14-%16 12-9/16 12-11/16 9-5/16 4 115

070-161048070 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 may be required in some cases.

--> 9,

3. Provide adequate combustion and ventilation air to the furnace

space as specified in "Air _br Combustion and Ventilation _'

section.

4. (ombustion products must be discharged outdoors. Connect

this _i/mace to an approved vent system only, as specified in

the "Venting" section of these instructions.

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

cially available soap solution made specifically for the detec-

tion of leaks to check all connections, as specified in the "Gas

Piping" section.

d. Always install Nmace to operate within the fmnace's intended

temperature-rise range with a duct system which has an

external static pressure within the allowable range, as speci-

fied in the "Start-Up, Adjustments, and Safety Check" section.

See Nmace rating plate.

7. When a fitrnace is installed so that supply ducts cat_T air

circulated by the t_urnace to areas outside the space containing

the furnace, the remm air shall also be handled by duct(s)

sealed to the _i/raace casing and terminating outside the space

containing the Nrnace. See "Air Ducts" section.

8. A gas-fired _lrnace fbr installation in a residential garage must

be installed as specified in the warning box in the "Location _'

section.

The furnace is not to be used [br temporary heating of

buildings or stl_ctures under construction. See page 7 caution

box regarding the heating of buildings under construction.

10. These Multipoise Gas-Fired Furnaces are (SA (fbrmerly

A.G.A. and (LG.A0 design-certified for use with natural and

propane gases (see furnace rating plate) and for installation in

alcoves, attics, basements, closets, utility rooms, crawlspaces,

and garages. The furnace is factory°shipped _br use with

natural gas. A CSA listed gas conversion kit is required to

convert furnace [or use with propane gas.

11. See Fig. 2for required clearances to combustible construction.

12, Maintain a l-in. clearance from combustible materials to

supply air ductwork J:br a distance of 36 inches horizontally

_?om the Nmace. See NFPA 90B or local code for Nrther

requirements,

--€

13, These _amaces SHALL NOT be installed directly on carpet-

ing, tile, or any other combustible material other than wood

flooring. In downflow installations, _i_ctow- accessow- floor

base MUST be used when installed on combustible materials

and wood flooring. Special base is not required when this

_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

Fig. 2 for clearance to combustible constluction information.

INTRODUCTION

This Stoics 120/( 4 way multipoise Category I _m-assisted

furnace is (SA design=certified. A Category I fan-assisted furnace

is an appliance equipped with an integral mechanical means to

either &aw or force products of combustion through _he combus=

tion chamber and/or heat exchanger. The _urnace is factor'-

shipped fbr use with natural gas. A CSA (A.G.A. and C.G.A.)

listed gas conversion kit is required to convert [:urnace for use with

propane gas. This Nmace is no{ approved fbr installation in

mobile homes, recreational vehicles, or outdoors.

This Nrnace is designed for minimuna continuous return-air

temperature of 60_>F db or intermittent operation down to 55°F db

such as when used with a night setback thermostat. Return-air

temperature must not exceed 85°F db. Failure to follow these

return-air temperature limits may afi:kct reliability of heat exchang-

ers, motors, and controls. (See Fig. 3.)

For accessoQ" installation details, re['cr to the applicable instruction

literature.

NOTE: Remove all shipping brackets and materials before oper-

ating the furnace.

CODES AND STANDARDS

Follow all national and local codes and standards in addition to

these ins{factions. The installation must comply with regulations

of the serving gas supplier, local building, heating, plurnhing, and

other codes. In absence of local codes, the installation must

comply with the national codes listed below and all authorities

having jurisdiction.

FRONT

MAX 85°F

MIN 60°F

Fig. 3--Return Air Temperature

A02055

In the [ nited States and Canada, follow all codes and standards for

the ibllowing:

Step l--Safety

• US: National Fuel Gas Code (NFGC) NFPA 54 2002/ANSI

Z223.1 2002 and the Installation Standards, Wam_ Air Heating

and Air Conditioning Systems ANSI NFPA 90B

--> ° CANADA: CSA B149.1-00 National Standard of Canada

Natural Gas and Propane Installation Codes (NSCNGPI()

Step 2--General hstallation

• US: Current edition of the NFGC and the NFPA 90B. For

copies, contact the National Fire Protection Association Inc.,

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

for only the NFGC, contact the American Gas Association, 400

N. Capitol Street, N.W., Washington, DC 20001

(www.AGA.org).

• CANADA: NSCNGPIC. For a copy, contact Standard Sales,

CSA International, 178 Rexdale Boulevard, Etobicoke (Tor-

onto), Ontario, M9W 1R3 Canada

Step 3--Combustion and Ventilation Air

--> • US: Section 8.3 of the NFGC, Air for (ombustion and

Ventilation

• CANADA: Part 7 of NSCNGPIC, Venting Systems and Air

Supply fbr Appliances

Step 4--Duct Systems

--> * US and CANADA: Air (onditioning Contractors Association

(ACCA) Manual D_ Sheet Metal and Air Conditioning Con-

tractors National Association (SMACNA), or American Soci-

ety of Heating, Refrigeration, and Air Conditioning Engineers

(ASHRAE) 2001 Fundamentals Handbook Chapter 34 or 2000

HVAC Systems and Equipment Handbook Chapters 9 and 16.

Step 5--Acoustical Lining and Fibrous Gtass Duct

• US and CANADA: current edition of SMA(NA and NFPA

90B as tested by UL Standard 181 fbr Class I Rigid Air Ducts

Step 6--Gas Piping and Gas Pipe Pressure Testing

• US: NFGC; chapters 5, 6, 7, and 12 and National Phnnbing

Codes

• CANADA: NSCNGPIC Parts 3, 4, and 5, and Appendices A,

B, E and H

Step 7--Electrical Connections

• US: National Electrical Code (NEC) ANSI NFPA 70 2002

• CANADA: Canadian Electrical Code CSA C22 1

--> Step 8--Venting

*US: NFGC: chapters 10 and 13

* (ANADA: NSCNGPI( Part 7 and Appendix C

ELECTROSTATIC DBSCHARGE {ESD) PRECAUTIONS

PROCEDURE

--> FURNACE RELIABILITY HAZARD

Improper installation or service of furnace may cause prema-

ture thrnace component failure

Electrostatic discharge can affect electronic components.

Take precautions during thrnace installation and servicing to

protect d_e thmace electronic control. Precautions will pre-

vent electrostatic discharges ti'om personnel and hand tools

which are held during the procedure. These precautions will

help to avoid exposing the control to electrostatic discharge

by putting the thmace, the control, and the person at the same

electrostatic potential.

1. Disconnect all power to the furnace. Multiple disconnects may

be required. DO NOT TOUCH THE CONTROL OR ANY

WIRE C ONNE(TED TO THE CONTROL PRIOR TO DIS-

CHARGING YOUR BODY'S ELECTROSTATI( CHARGE

TO GROUND,

2 Firmly touch the clean, unpainted, metal surface of the fi.maace

chassis which is close to the control. Tools held in a person's

hand dtlring grounding will be satisfactorily discharged.

3. After touching the chassis, you may proceed to service the

control or connecting wires as tong as you do nothing to

recharge your body with static electricity (for example; DO

NOT move or shuffle your feet, do not touch ungrounded

objects, etc.).

4. If you touch ungrounded ohjects (and recharge your body with

static electricity), firmly touch a clean, unpainted metal

surface of the fiul_ace again be:R_re touching control or wires.

5. Use this procedure for installed and uninstalled (ungrounded)

_i/rnaces

6. Before removing a new contact fi'om its container, discharge

your bo@'s electrostatic charge to ground to protect the

control _i'om damage. If d_e control is to be installed in a

_i/mace, _bltow items 1 through 4 befbre bringing the control

or yourself in contact with the furnace. Put all used and new

controls into containers befbre touching ungrounded objects.

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

also be used to prevent ESD dan?age.

LOCATION

GENERAL

Some assembly and modifications are required when used inany

of the four applications shown in Fig_ 4,

This thmace must:

* be installed so the electrical components are protected from

water

* not be installed directly on any combustible material other than

wood flooring (refer to SAFETY CONSIDERATIONS)

* be located close to 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

THE BLOWER IS LOCATED

TO THE RIGHT OF THE

BURNER SECTION, AND

AIR CONDITIONED AIR IS

DISCHARGED TO THE LEFT

HORIZONTAL LEF[

AIRFLOW

THE BLOWER IS

LOCATED BELOW THE

BURNER SECTION. AND

CONDITIONED AIR IS

DISCHARGED UPWARD.

--€

THE BLOWER IS

LOCATED ABOVE THE

BURNER SECTION, AND

CONDITIONED AIR IS

DISCHARGED DOWNWARD

Fig. 4_Multipoise Orientations

CARBON MONOXIDE POISONING HAZARD

Failure to fbllow this warning could result in personal injuU

or death, and unit component damage.

(mTosive or contaminated air may cause failure of parts

containing flue gas, which could leak into the living space.

Air for confbustion must not be contaminated by halogen

compounds, which include fluoride, chloride, bromid< and

iodide. These elements can con'ode heat exchangers and

shorten fhrnace life. Air contaminants are found in aerosol

sprays, detergents, bleaches, cleaning solvents, salts, air

fresheners, and other household products. Do not install

furnace in a corrosive or contaminated atmosphere. Make

sure all confbustion and circulating air requirements are met,

in addition to all local codes and ordinances.

A02097

All f_el-burning equipment n-rest be supplied with air %r fuel

combustion Sufficient air must be provided to avoid negative

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

made between the filrnace cabinet and the return=air duct to

prevent pulling air fi'om the burner area and from draft safeguard

opening.

--> 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

--> 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:

Permanent wave solutions

Chlorinated waxes and cleaners

Chlorine based swimming pool chemicals

Water softening chemicals

Deqcing salts or chemicals

Carbon tetrachloride

Halogen type refrigerants

Cleaning solvents (such as perchloroethylene)

Printing inks, paint removers, varnishes, etc,

Hydrochloric acid

Cements and glues

Antistatic ti_bric softeners tbr clothes dwers

Mason U- acid washing materials

18-1N. MINIMUM

TO BURNERS

Fig. 8--Installation in a Garage

A93044

FIRE, INJURY OR DEATH HAZARD

Improper location or inadequate protection could result in fire

or explosion

When the furnace is installed in a residential garage, the

burners and ignition sources must be located at least 18 inches

above the floor The fi/rnace must be located or protected to

avoid damage by vehicles. When the furnace is installed in a

public garage, airplane hangar, or other building having a

hazardous atmosphere, the _\trnace must be installed in

accordance with the NFGC or NS(NGPI(. (See Fig 5)

--9

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.

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

A02054

Fig. 6--Prohibit InstNlation on Back

AIR FOR COMBUSTION 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 (ongbus-

tion 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 for combustion and ventilation air depend upou

whether or not the fhmace is located in a space having a volume

of at least 50 cubic f_et per 1,000 Btuh input rating for all gas

appliances installed in the space.

Spaces having less than 50 cubic feet per 1,000 Btuh require

the OUTDOOR COMBUSTION AIR METHOD,

Spaces having at least 50 cubic f_et per 1,000 Btuh may use the

INDOOR COMB! STION AIR, STANDARD or KNOWN-

AIR INFILTRATION METHOD

--> Table 2=Minimum Free Area Required for Each Combustion Air Opening or Duct to Outdoors

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

FURNACE[ (1 SQ. IN.t2,000 BTUH) (1,100 SQ. MM/KW) (1 SQ. IN.i3,000 BTUH) (734 SQ. NNIKW) (1 $Q. IN./4,000 BTUH) (880 SQ. MM/KW)

INPUT Free Area of Free Area of Free Area of

{BTUH) Opening and Duct Round Duct Opening and Duct Round Duct Opening and Duct Round Duct

(Sq. in.) (in. Dia) (sq in.) (in. Dia) (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 66 10 44 8 33 7

184,000 77 10 51.3 9 38.5 8

EXAMPLES: Determining Free Area

FURNACE WATER HEATER TOTAL INPUT

110,000 + 30,000 (t40,000 divided by 4,000) 35.0 Sq. In. for each two Verticat Ducts or Openings

88,000 + 40,000 (106,000 divided by 3,000) 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 Ducts

--> Table 3=Minimum Space Volumes for 100% Combustion, Ventilation, and

Dilution from Indoors

OTHER THAN FAN=ASSISTED TOTAL FAN-ASSISTED TOTAL

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

ACH 30 I 40 I 50 44 166 I 88 1110 I 132 1154

Space Volume (ft3)

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 6,300 8,400 10,500 6,600 9,900 13,200 16,500 19,800 23,100

0.00 NP NP NP NP NP NP NP NP NP

NP = Not Permitted

---> Outdoor Combustion Air Method

1. Provide the space with sufficient air _br proper combustion,

ventilation, and dilution of flue gases using permanent hori=

zontal or vertical duct(s) or opening(s) directly communicat=

ing with the ontdoors or spaces that freely communicate with

the ontdoors.

2. Fig. 7 illustrates how to provide TWO OUTDOOR OPEN°

INGS, one inlet and one outlet combustion and ventilation air

opening, to the outdoors.

a. One opening MUST commence within 12" (300 ram) of

the ceiling and the second opening MUST commence

within 12" (300 ram) of the floor.

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

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 in the space per Fig. 7 and Table

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 in the space per Fig.

7 and Table 2.

3. ONE OUTDOOR OPENING requires:

a. 1 square inch of flee area per 3,000 Btuh (734 mm2&W)

for combined input of all gas appliances in the space per

Table 2and

b. Not less than the sum of the areas of all vent connectors in

the space.

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

Appliances in the space shall have clearances of at least 1" (25

ram) fiom d-_esides and back and 6" (150 ram) from the front. The

opening shall directly communicate with the outdoors or shall

communicate through a vertical or horizontal duct to d_e outdoors

or spaces (crawl or attic) that fieely communicate with the

outdoors.

Indoor Combustion Air<) NFPA & AGA

---> Standard and Known-Air-Infiltration Rate Methods

Indoor air is permitted fbr combustion, ventilation, and dilution,

if the Standard or Known=Air-Infiltration Method is used.

CARBON MONOXIDE POISONING HAZARD

Failure to supply outdoor air via grilles or ducts could result

in death and/or personal injury.

Many homes require air to be supplied from outdoors for

furnace combustion, ventilation, and dilution of flue gases.

The /'umace combustion air supply must be provided in

accordance with this instruction manual.

OUTDOORS

PER4000

BTUH*

12" MAX

1 SQ IN A

PER2000

BTUH*

DUCTS

OUTDOORS

1 SQ IN.

PER 2000

BTUH I[

12 _

MAX

SQ tN

PER

4000

BTUH*

1 SO iN.

PER

4000

BTUH*

12 _

MAX

CIRCULATING AIR DUCTS

OUTDOORS

*Minimum dimensions of 3 in

NOTE: Use any of the following

combinations of openings:

A&B C&D D&E F&G

1 SQ IN.

PER 4000

BTUH*

A03174

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

Dilution for Outdoors

I CIRCULATING AIR

DUCTS

-r

I I

INTERIOR

HEATED

SPACE

] VENT THROUGH ROOF

I I

I I LJl .L

1 SO IN.

" PER 1000

BTUH* IN DOOR

OR WALL

UNCONFINED

SPACE

6" M[N

(FRONT)t

1 SQ IN.

PER 1000

: BTUH* tN DOOR

OR WALL

]l CIRCULATING AIR DUCTS

12" MAX

* Minimum opening size is 100 sq in with

minimum dimensions of 3 in.

t Minimum of 3 in. when type-B1 vent is used. A03175

-> Fig. 8--Air for Combustion, Ventilation and

Dilution from indoors

The Stalidard Method:

1. The space has no tess volume than 50 cubic f'cet per 1.000

Bmh of the maximum input ratings for all gas appliances

installed in the space and

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

changes per hour (ACH)

The Kno_n Air Infiltration Rate Method shall be used. if the

infiltration rate is known to be:

1. Less than 0.40 ACH and

2. Equal to or greater than 0.10 ACH

Infiltration rates greater than 0.60 ACH shall not be used. The

mininlum required volume of the space varies with the number of

A(H and shall be detem_ined per Table 3 or Equations 1 and 2.

Determine the mininmm required volume for each appliance in the

space and add the volumes together to get the total n_inin-mm

required volume for the space.

Table 3-Minimum Space Volumes were determined by using the

following equations fiom the Yationa/ F_el Gas Cn&_ zl:\i_7

Z223./-2002/iVFP_ 54-2002.&3.2.2:

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

hood-equipped water heater:

21fts _ I °tt'er }/

Volumeother = A-==0_p0_} B-_/hr)

A04002

2. For fan-assisted appliances such as this fk/rnace:

_ 15fls Iran

VolumeFa n - __

A04003

If:

Ioti_ = combined input of all other than fan-assisted appli-

ances in Btuhr

I_.,, =combined input of all fan-assisted appliances in Btuhr

ACH air changes per hour (ACH shall not exceed 0.d0.)

--> The following requirements apply to the Standard Method and to

the Known Air Infiltration Rate Method

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

a. There are no closable doors between rooms.

b. (ombining spaces on same floor level. Each opening shall

have fiee area of at least 1 in.2/1.000 Btuh (2.000 mm2ikW)

of the total input rating of all gas appliances in the space.

but not less than 100 in. 2 (0.0d m2). One opening shall

commence within 12" (300 ram) of the ceiling and the

second opening shall commence within 12" (300 ram) of

the floor. The minimum dimension of air openings shall be

at least 3 in. (80 ram). (See Fig. S.)

c.( ornbiningspaceondiff?rentfloorlevels.Thevolumesof

spacesondifferentfloorlevelsshallbeconsideredas

communicatingspacesif connectedbyoneormoreperma=

nentopeningsindoorsorfloorshavingfi'eeareaofatleast

2in.2/1,000 Bmh (4,400 mma&W) of total input rating of

all gas appliances.

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

communicates with the outdoors provided there are adequate

pet_nanent ventilation openings directly to outdoors having

_?ee area of at least i-in.2/4,000 Bmh of total input rating for

all gas appliances in the space.

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

infiltration should be adequate to provide air for combustion,

pemlanent ventilation and dilution of flue gases. However, in

buildings with unusually tight construction, additional air

MUST be provided using the methods described in the

Outdoor Combustion Air Method section.

Unusually tight construction is defined as

Construction with:

a. Walls and ceilings exposed to the outdoors have a continu=

ous_ sealed vapor barrier. Openings are gasketed or sealed

and

b. Doors and openable windows are weatherstripped and

c. Other openings are caulked or sealed. These include joints

around window and door fi'ames, between sole plates and

floors, between wall-ceiling joints, between wall panels, at

penetrations _br plumbing, electrical and gas lines, etc.

---> Combination of Indoor and Outdoor Air

1. Indoor openings shall comply with tlle Indoor Combustion

Air Method below and,

2. Outdoor openings shall be located as required in tlle Outdoor

Combustion Air Method mentioned previously and,

3. Outdoor openings shall be sized as follows:

a. (alculate the Ratio of all Indoor Space volume divided by

required volume _br Indoor Combustion Air Method

below.

b. Outdoor opening size reduction Factor is 1 minus the

Ratio in a. above.

c. Minimum size of Outdoor openings shall be the size

required in Outdoor (ombusIiou Air Method above

nmltiplied by reduction Factor in b. above. The nlininlum

dimension of air openings shall be not tess than 3 in. (80

111111)

INSTALLATION

LPFLOW INSTALLATION

Bottom Return Air Inlet

These fhmaces are shipped with bottom closure panel installed in

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

bottom remm air is use& To remove bottom closure panel

perfbrrn die following:

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

panel (See Fig. 9.)

2. Rotate bottom filler panel downward to release holding tabs.

3. Remove bottom closm'e panel

4. Reinstall bottom filler panel and screws

Side Return Air Inlet

These fk/rnaces are shipped with bottom closure panel installed in

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

only side remm air is used.

BOTTOM FILLER

PANEL

I I

BOTTOM CLOSURE

PANEL

A02098

Fig. g--Removing Bottom Closure Panel

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

most HORIZONTAL coni:igurations Do not use side return-air

openings in DOWNFLOW configuration.

Leveling Legs (If Desired)

In upfluw position with side remm inlet(s), leveling legs may be

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

con'osion-resistant machine bolts, washers and nuts.

NOTE: Bottom closure most be used when leveling legs are used.

It may be necessary to remove and reinstall bottom closure panel

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

1. in Bottom Return Air Inlet section.

To install leveling legs:

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

bottom corner of fi/mace. (See Fig. 10.)

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

hole. (Install flat washer if desired.)

3. Install another nut on other side of fi/rnace base. (Install flat

washer if desired.)

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

nut to secure arrallgement.

5. Reinstall bottom closure panel if removed.

DOVvL\'FLOW INSTALLATION

NOTE: For downflow applications, this furnace is approved fbr

use on combustible flooring when any one of the following 3

accessories are used:

° Special Base, KGASB

° Cased (oil Assembly Part No. (D5 or (K5

° (?oil Box Part No. KCAKC

1. Determine application being installed from Table 3.

2. (onstruct hole in floor per Table 3 and Fig. 11.

3. (onstruct plenum to dimensions specified in Table 3 and Fig.

11.

4. If downfluw subbase, KOASB is used, install as shown in Fig.

12. If Coil Assernbly Part No. (D5 or (K5 or (Toil Box Part

No. K(AKC is used, install as shown in Fig. 13.

NOTE: It is recommended that the perI:brated supply-air duct

flanges be completely _blded over or removed flora fi_rnace when

installing the _i/rnace on a fhctory-supplied cased coil or coil box.

To remove the supply-air dact flange, use wide duct pliers or hand

seamers to bend flange back and _:Prth until it breaks of LBe careful

of sharp edges. (See Fig. 14.)

/4 t,

A02071

Fig. 10--Leveling Legs

Bottom Return Air Inlet

These furnaces are shipped with bottom closure panel installed in

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

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

perfbrm the following:

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

panel. (See Fig. 9.)

2. Rotate bottom filler panel downward to release holding tabs.

3. Remove bottom closure panel.

4. Reinstall bottom filler panel and screws.

HORIZONTAL INSTALLATION

--€ FIRE, EXPLOSION, AND CARBON MONOXIDE

POISONING HAZARD

Failure to follow this warning could result in dangerous

operation, serious injury, death or property damage

Do not instal1 the fttrnace on its back or hang fimaace with

control compartment facing downward. Safety control opera=

tion will be adversely affected. Never connect return=air ducts

to the back of the furnace.

The furnace car* be installed horizontally in an attic or crawl space

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

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

non-combustible platfbrm, blocks, bricks or pad.

Suspended Furnace Suppmq _

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

angle iron or metal plumber's strap as shown. (See Fig. 15 and 16.)

Secure angle iron to bottom of l\tmace as shown. Heavy-gauge

sheet metal straps (plumber's straps) may be used to suspend the

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

in the bottom of the fhmace casing for each strap. (See Fig. 15 and

16,)

--> If the screws are attached to ONLY the fitmace sides and not the

bottom, the straps must be vertical against the fm'nace sides and

not pull away fiom the f_amace sides, so that the strap attachment

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

Platfbrm Furnace Support

Construct working platform at location where all required furnace

clearances are met. (See Fig 2and 17.) For furnaces with l-in.

clearance requirement on side, set fllmace on non=congbustible

blocks, bricks or angle iron For crawlspace installations, if the

fm'nace is not suspended fi'om the floor joists, the ground under-

neath furnace must be level and the furnace set on blocks or bricks.

Roll=Out Protection

Provide a minimum 17-3/4" X 22" piece of sheet metal for flame

roll-out protection in fi'ont of burner area for fhmaces closer than

12 inches above the combustible deck or suspended furnaces

closer than 12-in. to joists. The sheet metal MUST extend

underneath the fhmace casing by 1 in. with the door removed.

The bottom closure panel on furnaces of widths 17=i/2 in. and

larger may be used for flame roll-out protection when bottom of

furnace is used for remm air connection. See Fig. 17 for proper

orientation of roll=out shield.

Bottom Return Air Inlet

These ti_maces are shipped with bottom closure panel installed in

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

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

perform the following:

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

panel. (See Fig. 9.)

2. Rotate bottom filler panel downward to release holding tabs.

3. Remove bottom closure panel.

4. Reinstall bottom filler panel and screws.

Side Return Air Inlet

These furnaces are shipped with bottom closure panel installed in

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

return air inlet(s) is used without a bottom return air linlet.

Not all horizontal furnaces are approved for side return air

connections (See Fig. 20.)

FILTER ARRANGEMENT

FIRE, CARBON MONOXIDE AND POISONING

HAZARD

Failure to %tlow this warning could result in fire, personal

injury, or death.

Never operate a fire, ace without a filter or with filter access

door removed.

There are no provisions for an internal filter rack in these fhrnaces.

A field=supplied accessory external filter rack is required.

This furnace requires KGAFR0301ALL 1" external filter rack or a

suitable field-supplied substitute, such as the Media Cabinet.

Refer to the instructions supplied with external filter rack for

assembly and installation options

AIR DLCTS

General Requirements

The duct system should be designed and sized according to

accepted national standards such as those published by: Air

Conditioning Contractors Association (ACCA), Sheet Metal and

Air Conditioning Contractors National Association (SMACNA) or

American Society of Heating, Refrigerating and Air Conditioning

Engineers (ASHRAE) or consuh Yhe Ai_' .5)'stems Desigr_ G_ide-

!i_ve.s reference tables available fi'om your tocal distributor. The

duct system should be sized to handle the required system design

FURNACE

CASRNG

WIDTH

TaNe 4_Opening Dimensions (in.)

APPLICATION C

Upflow Applications on Combustible or Noncombustible

Flooring (KGASB subbase not required) 13-5/16

Downflow Applications on Noncombustible Flooring 13-3/16

(KGASB subbase not required)

t4-3/16 Downflow applications on combustible flooring (KGASB 13-7/16

subbase required)

Downflow Applications on Combustible Ftooring with CD5 or

CK5 Coil Assembly or KCAKC coil box (KGASB subbase 13-5/16

not required)

Upflow Applications on Combustible or Noncombustible 16-5/8

Flooring (KGASB subbase not required)

Downflow Applications on Noncombustible Flooring 16-1/2

(KGASB subbase not required)

17=1/2 Downflow applications on combustible flooring (KGASB 16-3/4

subbase required)

Downflow Applications on Combustible Ftooring with CD5 or

CK5 Coil Assembly or KCAKC coil box (KGASB subbase 16-1/2

not required)

Upflow Applications on Combustible or Noncombustible 20-1/8

Flooring (KGASB subbase not required)

Downflow Applications on Noncombustible Flooring 20

(KGASB subbase not required)

21 Downflow applications on combustible flooring (KGASB 20-1/4

subbase required)

Downflow Applications on Combustible Flooring with CD5 or

CK5 Coit Assembly or KCAKC coit box (KGASB subbase 20

not required)

Upflow Applications on Combustible or Noncombustible 23-5/8

Flooring (KGASB subbase not required)

Downflow Applications on Noncombustible Flooring 23-1/2

(KGASB subbase not required)

24-1/2 Downflow applications on Combustible flooring (KGASB 23-3/4

subbase required)

Downflow Applications on Combustible Ftoonng with CD5 or

CK5 Coil Assembly or KCAKC coil box (KGASB subbase 23-1/2

not required)

PLENUM OPENING

A B

12-11/16 21-5/8

12-9/16 19

11-13/16 19

12-5/16 19

16 21-5/8

15-7/8 19

15-1/8 19

15-1/2 19

19-1/2 21-5/8

19-%8 19

18-5/8 19

19 19

23 21-1/8

22-7/8 19

22-1/8 19

22-1/2 19

FLOOR OPENING

22-1/4

19-5/8

20-5/8

22-1/4

19-5/8

20-5/8

22-1/4

19-5/8

20-5/8

22-1/4

19-5/8

20-5/8

(FM at d_e design external static pressure The furnace airflow

rates are provided in Table 5=AIR DELIVERY=( FM (With Filter)

When a J:\lmace is installed so that the supply ducts car_- air

circulated by the J:\_mace to areas outside the space containing the

_/rnace, the return air shall also be handled by a duct(s) sealed to

the furnace casing and terminating outside the space containing the

_/rnace.

Secure ductwork with proper fasteners for type of doctwork used.

Seal supply- and return-duct connections to _./rnace with code

approved tape or duct sealer.

NOTE: Flexible connections should be used between ductwork

and/_urnace to prevent transmission of vibration. Ductwork pass=

ing through unconditioned space should be insulated and sealed to

enhance system perfbrmance. When air conditioning is used, a

vapor barrier is recommended.

Maintain a l-in. clearance fiom combustible materials to supply air

ductwork for a distance of 36 in. horizontally fiom the Nmace. See

NFPA 90B or local code _br Nrther requirements.

Ductwork Acoustical Treatment

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

and 10 ft of main duct to the first branch take-off may require

internal acoustical lining. As an alternative, fibrous ductwork may

be used if constructed and installed in accordance with the latest

edition of SMACNA construction standard on fibrous glass ducts.

--€

Both acoustical lining and fibrous ductwork shall comply with

NFPA 90B as tested by _L Standard 181 for (?lass 1 Rigid air

ducts.

Supply Air Connections

For a f_u'nace not equipped with a cooling coil, the outlet duct shall

be provided with a removable access panel. This opening shall be

accessible when the furnace is installed and shall be of such a size

that the heat exchanger can be viewed fbr possible openings using

light assistance or a probe can be inserted for sampling the air

stream. The cover attachment shall prevent leaks.

Upflow and Horizontal Furnaces

(onnect supply-air duct to flange on fulnace supply=air outlet.

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

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

supply=outlet-air duct flanges or air conditioning coil casing (when

used) DO NOT cut main J:_m'nace casing side to attach supply air

duct, humidifier, or other accessories All accessories MI_ST be

connected external to furnace main casing

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

bent past 90 degrees Go allow d_e evaporator coil to hang on the

flange temporarily while the remaining attachment and sealing of

the coil are performed.

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 InstNted on

a Combustible Floor

FURNACE

CD5 OR CK5

COIL ASSEMBLY

OR KCAKC

COIL BOX

COMBUSTIBLE

FLOORING

SHEET METAL _

PLENUM

FLOOR

OPENING

A04140

___> Fig. 13--Furnace, Plenum, and Coil AssemNy or Coil Box Installed on a Combustible Floor

Downflow Furnaces

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

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

supply=air duct must be connected to ONLY the fi/rnace supply=

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

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

ONLY the accessory subbase, KGASB0201ALL, or _Sctory ap=

proved air conditioning coil casing. DO NOT cut main furnace

casing to attach supply side air duct, humidifier, or other accesso-

ries. All accessories MUST be connected external to furnace

casing.

UPFLOW

PREFERRED

DOWNFLOW

i i PREFERRED

HORIZONTAL

I.....

PREFERRED 120_.

M_N

PREFERRED

PERMITTED i PERMITTED

Fig. 14--Duct Flanges

PERMITTED

W' THREADED ROD

4 REQ

A02329

SECURE ANGLE

IRON TO BOTTOM

OF FURNACE WITH

3 #8 x s/4"SCREWS

TYPICAL FOR 2 SUPPORTS

1" SQUARE, 1W' x 1W' x %" ANGLE IRON

OR UNI-STRUT MAY BE USED

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

REQ PER ROD

A05027

-_ Fig. 18--Horizontal Unit Suspension

Return Air Connections

FIRE HAZARD

Failure to %l!ow this warning could cause a fire, personal

injury, or death

Never connect return-air ducts to the back of the ftmaace

Follow instl-t/ctions below.

DownJ:low Furnaces

The return=air duct must be connected to return-air opening

(bottom inlet) as shown in Fig. 19. DO NOT cut into casing sides

(left or right). Side opening is pem_itted for only upflow and most

horizontal Parnaces. Bypass humidifier connections should be

made at ductwork or coil casing sides exterior to ft_rnace

Upflow and Horizontal Furnaces

The return-air duct must be connected to bottom, sides (left or

right), or a combination of bottom and side(s) of main furnace

casing as shown in Fig lg and 20. Bypass l"mmidi_]er may be

attached to unused side return air side of the [:tm_ace casing (See

Fig lg and 20.)

Not all horizontal fm'naces are approved for side return air

connections. (See Fig 20.)

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

Fig. 16--HorizontN Suspension with Straps

LINE CONTACT ONLY PERMISSIBLE BETWEEN

LINES FORMED BY INTERSECTIONS OF

A02014

STUDS, OR FRAMING.

30-tN. MIN

17 s/4" OVER ALL

4 3/4" UNDER DOOR

1" UNDER FURNACE

EXTEND OUT t2'* OUT

FROM FACE OF DOOR

* WHEN USED WITH

SINGLE WALL VENT

CONNECTIONS

GAS VALVE

SEDIMENT j

TRAP

Fig. 17--Typical Attic Installation

A02164

GAS PIPING

,iU

_. iiiiiil

FIRE OR EXPLOSION HAZARD

Failure to l'ollow this warning could result in personal injury,

deatl-_ and/or property damage,

Never purge a gas line into a combustion chamber Never test

for gas leaks with an open flame Use a commercially

available soap solution made specifically for the detection of

leaks to check all connections.

--+ FIRE OR EXPLOSION HAZARD

Failure to %llow this warning coud result in personal inju W,

death, and/or property damage,

Ese proper length of pipe to avoid stress on gas contloi

maniR_ld 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 NSCNG-

PIC in Canada,

-4_ Table 5--Air Delivery - CFM (With Filter)*

FURNACE

SIZE

024045

038049

024070

038070

048070

042090

048090

080090

038110

048110

099110

RETURN-AIR

INLET

Bottom

Side(s)

Bottom

Side(s)

Bottom

Bide(s)

Bottom

Side(s)

Bottom

Side(s)

Bottom

Bide(s)

Bottom

Side(s)

Bottom

Only

Both Sides or

1 Side & Bottom

1 Side Only

Bottom

Bide(s)

Bottom

Side(s)

Bottom

Only

Bottom Sides or

1 Side & Bottom

1 Side Only

EXTERNAL STATIC PRESSURE (_N. WC)

SPEED 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0

High 1085 1035 975 915 845 770 675 565 390 195

Med-High 920 875 830 770 710 640 555 440 250 --

Med-Low 820 775 730 680 620 555 470 360 190 --

High 1440 1375 1305 1240 1160 1070 975 870 730 560

Med-High 1360 1300 1240 1175 1115 1040 950 850 725 575

Med-Low 1250 1210 1160 1100 1040 965 885 790 670 520

High 1030 1010 980 945 900 845 775 680 490 335

Med-High 835 815 790 760 720 675 610 490 375 265

Med_Low 725 700 675 645 600 555 475 390 300 --

High 1425 1375 1320 1265 1200 1125 1035 940 830 655

Med-High 1320 1280 1240 1205 1140 1075 995 905 790 620

Med-Low 1200 1175 1145 1105 1050 990 920 840 725 555

High 1805 1740 1670 1600 1530 1445 1360 1280 1180 1075

Med-High 1630 1585 1530 1470 1405 1330 1255 1170 1080 990

Med-Low 1460 1420 1385 1325 1280 1220 1155 1080 995 910

High 1650 1600 1535 1465 1385 1285 1175 1055 895 645

Med-High 1515 1485 1440 1380 1300 1220 1115 990 830 600

Med-Low 1385 1360 1320 1260 1195 1120 1025 915 710 565

High 2060 1985 1915 1820 1720 1610 1490 1340 1135 925

Med-High 1790 1765 1715 1645 1560 1470 1345 1195 1010 820

Med-Low 1505 1505 1480 1440 1375 1300 1190 1045 890 740

High 2405 2310 2220 2130 2025 1920 1790 1660 1530 1350

Med-High 2225 2155 2080 1995 1895 1785 1675 1565 1420 1260

Med-Low 2020 1955 1880 1805 1730 1630 1535 1420 1275 1135

High 2530 2450 2365 2270 2165 2065 1940 1805 1670 1505

Med-High 2285 2215 2150 2075 1985 1890 1780 1660 1525 1360

Med-Low 1995 1945 1900 1840 1770 1685 1600 1480 1350 1180

High 2475 2395 2300 2200 2090 1985 1865 1730 1585 1425

Med-High 2260 2190 2110 2035 1940 1845 1735 1620 1475 1325

Med-Low 1950 1910 1855 1795 1730 1650 1555 1445 1310 1150

High 1625 1575 1515 1445 1355 1260 1165 990 785 --

Med_High 1510 1470 1415 1355 1285 1185 1070 890 725 --

Med-Low 1360 1335 1295 1250 1180 1100 985 810 ....

High 2035 1965 1880 1790 1680 1495 1365 1215 1075 875

Med-High 1745 1710 1650 1560 1450 1340 1205 1090 955 750

Med-Low 1530 1515 1470 1400 1310 1215 1095 990 830 670

High 2530 2470 2400 2320 2220 2115 2000 1865 1730 1590

Med-High 2230 2205 2165 2110 2035 1950 1855 1740 1615 1485

Med-Low 1920 1900 1880 1845 1795 1730 1650 1555 1460 1340

High .... 2415 2350 2250 2145 2015 1875 1715 1560

Med-High 2235 2200 2155 2100 2040 1955 1850 1740 1595 1470

Med-Low 1920 1900 1880 1845 1795 1730 1650 1555 1460 1340

High 2540 2495 2430 2355 2265 2175 2065 1935 1785 1650

Med-High 2125 2120 2105 2060 2010 1940 1840 1730 1615 1485

Med-Low 1795 1790 1765 1720 1650 1585 1500 1390 1280

*A filter is required for each return-air inlet Airflow performance included 1-in. washable filter media such as contained in factory-authorized accessory fi{ter rack. To

determine airflow pedormance without this filter, assume an additional 0 1 in. wc available external static pressure

-- Indicates unstable operating conditions

-+ Table5--Air Delivery - CFM (With Filter)* (Continued)

FURNACE

SIZE

048185

868135

080155

RETURNoA_R

INLET

Bottom

Side(s)

Bottom

Onty

Bottom, Sides or

1 Side & Bottom

1 Side Only

Bottom

Onty

Both Sides Or

1 Side & Bottom

1 Side Only

SPEED EXTERNAL STATIC PRESSURE (IN. WC)

0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0

High 2090 2010 1930 1835 1710 1590 1470 1335 1025 835

Med-High 1790 1755 1705 1640 1550 1465 1360 1210 945 785

Med-Low 1545 1525 1500 1450 1380 1315 1215 1005 855 670

High 2485 2400 2310 2215 2110 2000 1880 1725 1535 1355

Med-High 2195 2150 2090 2000 1920 1825 1720 1565 1405 1255

Med-Low 1880 1850 1820 1780 1715 1635 1540 1415 1290 1160

High .... 2385 2305 2195 2085 1960 1825 1670 1465

Med-High 2180 2145 2060 2010 1945 1865 1765 1660 1515 1325

Med-Low 1880 1850 1820 1780 1715 1635 1540 1415 1290 1160

High .... 2245 2155 2055 1940 1825 1695 1555 1385

Med-High 2135 2085 2035 1975 1895 1795 1685 1565 1445 1265

Med-Low 1880 1850 1820 1780 1715 1635 1540 1415 1290 1160

High 2465 2430 2375 2305 2230 2110 2000 1865 1725 1545

Med-High 2115 2105 2075 2030 1980 1910 1830 1725 1590 1425

Med-Low 1800 1790 1770 1735 1695 1640 1570 1465 1345 1225

High .... 2375 2285 2200 2105 1995 1870 1730 1570

Med-High 2155 2135 2095 2040 1975 1895 1790 1685 1550 1400

Med-Low 1800 1790 1770 1735 1695 1640 1570 1465 1345 1225

High .... 2260 2180 2085 1975 1865 1740 1605 1455

Med-High 2140 2095 2040 1975 1890 1810 1705 1595 1480 1325

Med-Low 1800 1790 1770 1735 1695 1640 1570 1465 1345 1225

*A filter is required for each return-air inlet Airflow performance included lqn washable filter media such as contained in factory-authorized accessory filter rack To

determine airflow performance without this fi{ter, assume an additional 01 in wc available external static pressure.

Indicates unstable operating conditions.

Installations must be made in accordance with all authorities

having jurisdiction. If possible, the gas supply line should be a

separate line running directly fi'om meter to f_/ruace.

--> NOTE: In the state of Massachusetts:

1. Gas supply connections MUST be per_brmed by a licensed

plumber or gas fitter

2. When flexible connectors are used, the maximum length

shall not exceed 36 inches (915 ram).

3. When lever handle type manual equipment shutoff valves are

used, they shall be T-handle valves.

4. The use of copper robing _br gas piping is NOT approved by

the state of Massachusetts.

Refer to Table 6 for recommended gas pipe sizing Risers must be

used to connect to fiu'nace and to meter. Support all gas piping

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

every 6 J:'t.Joint compound (pipe dope) should be applied sparingly

and only to male threads of joints. Pipe dope must be resistant to

the action of propane gas.

--€ FIRE OR EXPLOSION HAZARD

Failure to %llow this warning could result in death, personal

injury an_or property damage.

If local codes allow the use of a flexible gas appliance

connector, always use a new listed connector. Do not use a

connector which has previously served another gas appliance

Black iron pipe shall be installed at the furnace gas control

valve and extend a minimum of 2-in outside the f_/rnace.

installed immediately upstleam of gas supply connection to

furnace and downstream of manual equipment shutoff valve.

NOTE: The gas valve inlet pressuie tap connection is suitable to

use as test gauge connection providing test pressure DOES NOT

exceed maximum 0.5 psig (14-in. we) stated on gas control valve.

(See Fig. 46.)

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

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

Install a sediment trap in riser leading to fitrnace as shown in Fig

2 lb. ( onnect a capped nipple into lower end of tee. ( upped nipple

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

joint union between tk_rnace gas control valve and exterior manual

equipment gas shutoff valve. A 1/8-in. NPT plugged tapping,

accessible fbr test gauge connection. MUST be installed immedi-

ately upstream of gas supply connection to fi/mace and down-

sheam of manual equipment shutoff valve.

Piping should be pressure and leak tested in accordance with

NFG( in the United States or NSCNGPIC in Canada, local, and

national plumbing and gas codes before the Nrnace has been

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

check for leakage at fi/ruace prior to operating ft_mace.

--> If pressure exceeds 0.5 psig (14-in. wc), gas supply pipe must be

disconnected fi'om Nmace and capped before and during supply

pipe pressure test. If test pressure is equal to or less than 0.5 psig

(14-in. wc), turn off electric shutoff switch located on Nruace gas

conhol valve and accessible manual equipment shutoff valve

before and during supply pipe pressure test. After all connections

have been made, purge lines and check for leakage at furnace prior

to operating [:tm_ace.

The gas supply pressure shall be within the maximum and

mininmm inlet supply pressures marked on the rating plate with

the f_./ruace burners ON and OFF.

An accessible manual equipment shutoff valve MUST be installed

external to fi_mace casing and within 6 ft of fi/mace. A 1/8-in. NPT

plugged tapping, accessible fbr test gauge connection_ MUST be

R_TU_N

AIR

UPFLOW RETURN AR CONFiGURATiONS AND RESTRiCTiONS

AIR FLOW MODELS RETURN AIR RETURN AIR RETURN AIR RETURN AIR

CONNECTION 1 CONNECTION 2 CONNECTION 3 COMBIN,_]IONS

ONLY ONLY ONLY OF 1, 2, AND 3

06&060, _22 AND YES YES YES YES

"20 MODELS

ALL OTHER MODELS YES YES YES YES

i _ETU_N

i//.

Fig. 18--Upflow Return Air Configurat{ons and Restrictions A02075

EX_VNFLOWREq%IRNAmRCONFmGURATONSANDRESTR_CT_::)NS

AUR FLOW MODELS RETURN AUR RETURN AUR RETURN AUR RETURN AR

CONNEC]ION 1 CONNECTUON 2 CONNECTUON 3 COMBUN,_TIONS

ONLY OND/ ONLY OF 1, 2, AND 3

066.060, -22 AND YES NO NO NO

-20 MODELS

ALL OTHER MODELS YES NO NO NO

Fig. 19--Downflow Return Air Configurations and Restrictions

A02163

. 'i !J

"_ SliDERETURNA_R /

C_6O60-22-2O i ' i

' HORIZONA L

RETURN R URNA_R

HORIZONAL•NOTE RESTRICTIONE?_ SAME FOr_ _ A_R RESTR_CTIONS

@ | HORIZONTAL RETURN A_RCONFIGURATIONS AND RESTRICTIONS

A_R FLOW MODELS RETURN AIR RETURN A_R RETURN A_R RETURN A_R

CONNECTION 1 CONNECTION 2 CONNECTION 3 COMBiNATiONS

ONLY ONLY ONLY OF 1,2_ AND 3

066.060, -22 AND YES NO NO NO

-20 MODELS

ALL OTHER MODELS YES YES YES YES

Fig. 20--Horizonta{ Return Air Configurations and Restrictions

A02162

-+ Table 6--Ma×imum Capacity of Pipe*

NOMINAL

IRON

PIPE

SIZE

(BN.)

1/2

3/4

1-1/4

1-tt2

iNTERNAL

DIAMETER

(N.)

0.622

0.824

1.049

1.380

1.610

LENGTH OF PRPE (FT}

10 20 30 40 50

175 120 97 82 73

360 250 200 170 151

680 465 375 320 285

1400 950 770 660 580

2100 1460 1180 990 900

* 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

ELECTRICAL SHOCK AND FIRE HAZARD

Failure to follow this warning could result in serious inju U,

death, or property damage.

The cabinet MUST have an uninterrupted or unbroken ground

according to NEC ANSI NFPA 70-2002 and Canadian Elec=

tdcal (7ode CSA (22.1 or local codes to minimize personal

injury if an electrical _Sult should occur. This may consist of

electrical wire, conduit approved for electrical ground or a

listed, grounded power cord (where permitted by local code)

when installed in accordance with existing electrical codes.

Refer to the power cord manufacturer's ratings for proper

wire gauge. Do not use gas piping as an electrical ground.

TOP VEW OF BURNER AND MANIFOLD ASSEMBLY

2" Nipple

To Gas

Supply

90° Elbow /

Close NippBe L Gas Valve A02327

--_ Fig. 2In--Right Side Gas Entry Example

GAS

SUPPLY j'_

MANUAL =J II

SHUTOFF £ _

VALVE :D _:_=

(REQUIRED/#',

SEDIMENT --

TRAP /

UNION -_

A02035

Fig. 21b--Typical Gas Pipe Arrangement

ELECTRICAL CONNECTIONS

ELECTRICAL SHOCK HAZARD

Failure to _bllow this warning could result in serious personal

in.ju_ or death.

Blower access panel door switch opens l15=v power to

control No component operation can occur. Do not bypass or

close switch with panel removed.

See Fig 25 %r field wiring diagram showing typical field 115-v

wiring. Check all factoQ' and field electrical connections for

tighmess,

Field=snpplied wiring shall con£_m_ with the limitations of 63°F

(33°C) rise

---> F[ RNACE MAY NOT OPERATE

Failure to _bllow this caution may result in £u'nace operation

stopping and water pipes fi'eezing during cold weather

Furnace control must be grounded _br proper operation or

control will lock out Control is grounded through

green@ellow wire routed to gas valve and manifbld bracket

SCrew,

15-V Wiring

Verif}_" [l_at the voltage, frequency, and phase correspond to that

specified on unit rating plate. Also, check to be sure that service

provided by udlity is sufficient to handle toad imposed by this

equipment. Refer to rating plate or Table 7 _br equipment electrical

specifications.

[.S. installations: Make all electrical connections in accordance

with National Electrical (?ode (NEC) ANSI NFPA 70-2002 and

any local codes or ordinances that might apply.

Canadian installations: Make all electrical connections in accor-

dance with Canadian Electrical (?ode CSA C22.1 or au[horities

having jurisdiction.

---> FIRE HAZARD

Failure to %llow this warning could result in serious inju W,

death, or property damage.

Do not connec[ aluminum wire between disconnect switch

and Nrnace. Use only copper wire.

Use a separate, Nsed branch electrical circuit with a properly sized

Nse or circuit breaker for this Nrnace. See Table 7 tbr wire size

and Nse specifications. A readily accessible means of electrical

disconnect must be located within sight of the furnace.

NOTE: Proper polarity must be maintained for 115-v wiring. If

polarity is incorrect, contIol LED status indicator light will flash

rapidly and Nmace will NOT operate.

J=BOX RELOCATION

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

section (Electrical Connection to J=Box).

NOTE: On 14" wide casing models, the J=Box shall not be

relocated to other side of furnace casing when tiae vent pipe is

routed within the casing.

1. Remove and save two screws holding J-box. (See Fig. 22.)

---> NOTI=: The J=Box cover need not be removed L'rom the J=Box in

order to move the J=Box. Do NOT remove green ground screw

inside J=Box. The ground screw is not threaded into the casing

flange and can be lifted out of the clearance hole in casing while

swinging the t?ont edge of the J-Box outboard of the casing.

VOLTS-

FURNACE SRZE HERTZ-

PHASE

045-081024045 115-60-1

045-12t036045 115-60-1

070-08t024070 115-60-1

070-t21036070 115-60-1

070-t0t048070 115-60-1

090-t4t042090 115-60-1

090-10/048090 115-60-1

000-20/060090 115-60-1

110-12t036110 115-60-1

110-10t048110 115-60-1

110-22t066110 115-60-1

135-101048135 115-60-1

135-22t066138 115-60-1

155-20/060158 115-60-1

* Permissible limits of the voltage range at

OPERATING

VOLTAGE RANGE

Maximum* Minimum*

127 104

which the

--> TaNe 7--Electrical Data

5.4

7.0

5.0

6.8

9.5

8.2

10.0

13.6

8.2

10.1

14.8

10.2

14.4

15.0

unit operates satisfactorily

UNW

AMPACITY#

MiNiMUM

WiRE GAUGE

MAXIMUIVl

WiRE LENGTH (FT}:_

MAXBMUM

FUSE OR CKT BKR

AMPSt

7.54 14

9.50 14

7.06 14

9.22 14

12.60 14

10.83 14

13.13 14

17.61 12

10.75 14

13.12 14

18.99 12

13.27 14

18.55 12

19.33 12

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

amps

1 Time-delay type is recommended

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

FACTORY

INSTALLED

LOCATION

TWO

ALTERNATE

FIELD

LOCATION

Fig. 22--Relocating J=Bo×

A02099

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

3. Move box to desired location.

4. Fasten J-Box to casing with two screws removed in Step 1.

5. Route J-Box wires within furnace away fl'om sharp edges,

rotating parts, and hot surfaces.

ELECTRICAL CONNECTION TO J-BOX

--> Field-Supplied Electrical Box on Furnace J-Box Bracket

See Fig. 23.

1. Remove cover fl'om furnace J°Box.

2. Attach electrical box to furnace J-Box bracket with at least

two field-supplied screws through holes in electrical box into

holes in bracket. ETse blunt-nose screws that will not pierce

wire insulation.

3. Route furnace power wires through holes in electrical box and

J-Box bracket, and make field=wire connections in electrical

box. Use best practices (NE( in U,S, and CSA (722.1 in

Canada) fbr wire bushings, strain relief, etc.

A03221

-_ Fig. 23--Field-Supplied Electrical Box on

Furnace Casing

4, Rou[e and secure field ground wire to green ground screw on

J-Box bracket,

5, (onnect tine voltage 1cads as shown in Fig. 25

6, Reinstall cover to J°Box Do not pinch wires between cover

and bracket

BLOWER OFF-DELAY

J2 JUMPER

TWINNING AND/OR

COMPONENT TEST

TERMINAL

24-V THERMOSTAT

TERMINALS

3-AMP FUSE

LED OPERATION &

DIAGNOSTIC LIGHT

115-VAO

CONNECTIONS

SELECTION TERMINALS

SEC 2 SEO / o}

115 VAC (L1) LINE

VOLTAGE CONNECTION

"X_! EAC-1 TERMINAL

15-VAC 1.0 AMP MAX.)

Fig. 24--Furnace Control

HUMIDIFIER TERMINAL

(24-VAC 05 AMP MAX.)

TRANSFORMER24-VAC

CONNECTIONS

PL1-LOWVOLTAGE MAIN

HARNESS CONNECTOR

PL2-HOTSURFACE

IGNITER&INDUCER

MOTOR CONNECTOR

A02100

--)Electrical Box on Furnace Casing Side

See Fig. 23,

FIRE OR ELECTRICAL SHOCK HAZARD

Failure to lk)llow this warning could result in personal injuw_

death, or property damage.

If field-supplied manual disconnect switch is to be mounted

on furnace casing side, select a location where a drill or

fastener cannot damage electrical or gas components

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

electrical box is to be installed

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

installed electrical box

2. Remove the desired electrical box hole knockout and position

the hole in the electrical box over the hole in the furnace

casing.

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

supplied screws fi'om inside electrical box into casing steel.

4. Remove and save two screws holding J-Box. (See Fig. 22.)

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 of J-Box.

d. Route furnace power wires through holes in casing and

electrical box and into electrical box.

7. Pull field power wires into electrical box.

8. Remove cover fiom fhrnace J-Box.

-9 1.

--+ 6.

9 Route field ground wire through holes in electrical box and

casing, and into furnace J-Box.

10 Reattach furnace J-Box to fire, ace casing with screws re-

moved in Step 4.

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

12. Complete electrical box wiring and installation. Connect line

voltage leads as shown in Fig. 25. Use best practices (NEC in

U.S. and CSA C22.1 in Canada) for wire bushings, strain

relief, etc.

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

and bracket.

POWER (ORD INSTALLATION IN FURNACE J-BOX

NOTE: Power cords must be able to handle the electrical require-

ments listed in Table 5. Refer to power cord manufhcmrer's

listings.

Remove cover fi'om J-Box.

Route listed power cord through 7/8=inch diameter hole in

J=Box.

Secure power cord to J=Box bracket with a strain relief

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

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

bracket.

Connect line voltage leads as shown in Fig. 25.

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

and bracket.

.... FIELD 24-V WIRING

.... FIELD 115-, 208/230-, 460-V WtRING

-- FACTORY 24-V WIRING

FACTORY 115-V WIRING

FIELD-SUPPLIED

DISCONNECT

115-VFIELD-

SUPPLIED

DISCONNECT

--> 1,

AUXILIARY O

J-BOX L @

--> 6.

547

TERMINA[

BLOCK

FURNACE

NOTE 1

NOTES:I. 2.

CONDENSING

UNIT

?WO

WIRE

208/230-0R

460-V

THREE

PHASE

208/230-V

SINGLE

PHASE

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.

Fig. 25--Heating and Cooling Application Wiring Diagram with 1-Stage Thermostat

CABLE INSTALLATION IN FURNACE J-BOX

Remove cover from J-Box.

Route BX cable into 7/8°inch diameter hole in J-Box.

Secure BX cahle to J-Box bracket with connectors approved

_br the type of cable used.

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

bracket.

Connect line voltage leads as shown in Fig. 25.

Reinstall cover to J=Box. Do not pinch wires between cover

and bracket.

24-V WIRING

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

24.) Connect terminal Y as shown in Fig 25 _br proper cooling

operation Use only AWG No 18, color-coded, copper thermostat

wire.

The 24-v circuit contains an automotive=type, 3-amp _ilse located

on the control Any direct shorts during installation, service, or

maintenance could cause this fuse to blow If _ime replacement is

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

ACCESSORIES

1. Electronic Air Cleaner (EAC)

Connect an accessow Electronic Air Cleaner (if used) using

1/4=in female quick connect terminals to the two male li4=in

quick-connect terminals on the control board marked EAC-1

and EAC-2 The temlinals are rated for 115 VAC, 1.0 amps

nlaxinmm and are energized during blower motor operation

(See Fig 24.)

A99440

2. Humidifier (HI_M)

Connect an accessm7 24 VAC, 05 amp maxin-mm humidifier

(if used) to the 1/4=in male quick-connect HUM terminal and

Co_>24V screw terminal on the contlol board thermostat strip.

The HUM terminal is energized when pressure switch (PRS)

closes (See Fig. 24)

NOTE: A field-supplied, l I5-v controlled relay connected to

EAC terminals may be added if humidifier operation is desired

during blower operation

NOTE: DO NOT connect furnace control HUM tem_inal to HUM

(humidifier) terminal on ThermidistaF_L Zone Controller or simi-

lar device. See Thern_idistat TM, Zone Controller, thermostat, or

controller manuRtcmrer's instl_actions _br proper connection.

-->

VENTING

The fi/rnace shall be connected to a listed facto1T built chimney or

vent or a clay-tile lined masonw or concrete chimney Venting into

an unlined masonry chinmey or concrete chinmey is prohibited

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

original venting system may no longer be sized to properly vent

the attached appliances. An improperly sized Category I venting

system could cause the formation of condensate in the furnace and

vent, leakage of condensate and combustion products, and spillage

of combustion products into the living space.

CARBON MONOXIDE POISONING HAZARD

Failure to follow the steps outlined below for each appliance

connected to the venting system being placed into operation

could result in carbon monoxide poisoning or death.

The following steps shall be followed for each appliance

connected to the venting system being placed into operation,

while all other appliances connected to the venting system are

not in operation:

1. Seal any unused openings in venting system,

2 Inspect dae venting system for proper size and horizontal

pitch, as required in the A'ational Fuel Gas Cod< AA'SS

Z223.1JiV_7<I 54 or the C%14 B149.1, A_t_n'al Gas and

Propane Dv.stcd/atinn ('()de and these instructions. Deter-

mine that there is no blockage or restrictiom leakage,

cmTosion and other deficiencies, which could cause an

unsafe condition.

3. As far as practical, close all building doors and windows

and all doors between the space in which the appliance(s)

connected to the venting system are located and other

spaces of the building.

4. Close fireplace dampers.

5. Turn on clothes dryers and any appliance not connected to

the venting system. Turn on any exhaust fires, such as

range hoods and bathroom exhausts, so they are operating

at maximum speed. Do not operate a summer exhaust tim.

6. Follow d_e lighting instructions. Place the appliance being

inspected into operation. Adjust the them_ostat so appli:

ance is operating continuously.

7. Test for spillage fiom &ak hood equipped appliances at the

draft hood relief opening after 5 minutes of main burner

operation. Use the flame of a match or candle.

8. If improper venting is observed during any of the above

tests, the venting system must be cot_'ected in accordance

with the Yc_tiona[ Fne[ Gas ('ode, A:V._7 Z223.1<\_1 54

andor CSt B149.1, :\'_:mra[ Gas and Propane Is_sta[iat/on

('()de.

9 Aker it has been determined tl'mt each appliance connected

to the venting system properly vents when tested as

outlined above, remm doors, windows, exhaust £ims,

fireplace dampers and any other gas-fired burning appli:

ance to their previous conditions of use

Vent system or vent connectors may need to be resized Vent

systems or vent connectors must be sized to approach minimum

size as determined using appropriate table found in the NFGC or

NS(NGPI(.

GENERAL VENTING REQUIREMENTS

Follow all safety codes for proper vent sizing and installation

requirements, including local building codes, the A'ationa/F_le[

Gas Code A_\L%7Z223.I-2002AVFPA 54-2002 (_VFGO, Pags 10

and 13 in the United States or the Y(_tinna[ Sl_md(_rd of Canada,

:\'_mr_U Gas and Propane ]nslaliafion ('ode CSA-BI49.1:00

(NSCNGPI(), Section 7, Appendix C in Canada, the local

building codes, and fl/mace and vent manufacturers' instructions.

i_> These Nmaces are design:certified as Category I Nmaces in

accordance with ANSI Z21.47:2003iCSA 2.3:2003 and operate

with a non:positive vent static pressure to minimize the potential

for vent gas leakage. Category I Nmaces operate with a flue toss

not less than 17 percent to minimize the potential for condensation

in the venting system. These Nrnaces are approved for common

venting and multistory venting with other fire assisted or &aft

hood equipped appliances in accordance with the NFCG or the

NSCNGPIC, the local building codes and Nmace and vent

manufacturers' instructions.

The %llowing in%rotation and warning must be considered in

addition to the requirements defined in the NFG( and the

NSCNGPI(

_, 1

CARBON MONOXIDE POISONING HAZARD

Failure to follow this warning could result in a build:up of

carbon monoxide and 1cad to personal injuW or death

Do not bypass the &afi safeguard switch, as an unsaf_

condition could exist which must be corrected.

1 Ifa vent (common or dedicated) becomes blocked, the fimmce

will be shut off by the draft safeguard switch located on the

vent elbow.

2Do not connect this Category I furnace into a single-wall

dedicated or common vent. The dedicated or commma vent is

considered to be the vertical portion of the vent system that

terminates outdoors.

3 Vent connectors serving (ategow- I furnaces shall not be

connected into any portion of a mechanical draft system

operating under positive pressure.

4 In the US: Do not vent this appliance with any solid fuel

burning appliance

In Canada: Check with the authority having jurisdiction for

approval on use with solid fhel bml_ing appliance.

5 Category I furnaces must be vented vertically or nearly

vertically unless equipped with a listed power ventor.

6 Do not vent this appliance into an unlined masonry chimney.

Refkr to (hirnney Inspectima (hart, Fig. 26

MASONRY CHIMNEY REQUIREMENTS

NOTE: These fl_rnaces are <SA design:certified for use in

exterior clay tile:lined masonry chimneys with a factoo accessory

(himney Adapter Kit Refer to the furnace rating plate for correct

kit usage The Chimney Adapter Kits are for use with ONLY

fimmces having a (himney Adapter Kit number marked on the

furnace rating plate.

Ifa clay tile:tined masonry chimney is being used and it is exposed

to the outdoors below the roof line, relining might be required.

Chimneys shall conform to the Standard for Chimneys, Fireplaces..

Vents, and Soild Fuel Burning Appliances ANSI NFPA 2! 1:2003

in the United States and to a Provincial or Territorial Building

(7ode in Canada (in its absence, the National Building (7ode of

Canada) and must be in good condition.

U.S.A.:Refer to Sections 13.1.9 and 13.2.20 of the NFGC or the

authority having jurisdiction to detem_ine whether relining is

required. If relining is required, use a properly sized listed metal

liner, Type-B vent, or a listed alternative venting design.

NOTI=: See the NFG(, 13.1.9 and 13.2.20 regarding alternative

venting design and the exception, which cover installations such as

the Chimney Adapter Kits KGACA02014FC and

KGA( A02015FC, which are listed for use with these furnaces

The Chimney Adapter Kit is listed alternative venting system for

these fllmaces. See the kit instl_ctions [br complete details.

Canada (and U.S.A°):This :gtrcmce is permitted to be vented into

a clay file:lined masonry chimney that is exposed to the outdoors

below the roof line, prm'ided:

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

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

equipped appliance, and

3. The combined appliance input rating is less than the maximum

capacity- given in Table A, and

4. Theinputratingof eachspaceheatingapplianceisgreater

thantheminimun_inputratinggiveninTableBforthelocal

99%WinterDesignTemperature. Chimneys having internal

areas greater than 38 square inches require t\trnace input

ratings greater d'mn the input ratings of these furnaces. See

fbotnote at bottom of Table B, and

5. The authority having jurisdiction approves.

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

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

these furnaces listed for use with the kit, a listed chimney=lining

system, or a Type=B common vent.

Inspections before the sale and at the time of installation will

detellr_ine the acceptability of the chimney or d-_e need for repair

and/or (re)lining. Refur to Fig. 26 to perfbrm a chimney inspection.

If the inspection of a previously used tile=lined chimney:

a. Shows signs of vent gas condensation, the chimney should

be relined in accordance with local codes and the authori V

having jurisdiction. The chimney should be relined with a

listed metal liner, Type-B vent, or a listed chimney adapter

kit shall be used to reduce condensation. If a condensate

&ain is required by local code, refer to the NFGC, Section

10.9 fbr additional infbm_ation on condensate &ains.

b. Indicates the chinmey exceeds the maxinmm permissible

size in the tables, the chimney should be rebuilt or relined

to con:_bm_ to the requirements of the equipment being

installed and the authority having jurisdiction.

A chimney without a clay tile liner, which is othepwise in good

condition, shall be rebuilt to confom? to ANSIiNFPA 211 or be

lined with a UL listed (ULC listed in Canada) metal liner or UL

listed Type=B vent. Relining with a listed metal liner or Type-B

vent is considered to be a vent-in=a=chase.

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

appliance shall be vented into the annular space between the

chimney and the metal liner.

-_ Exterior Masonry Chimney FAN + NAT

Installations with Type-B DouNe-WaH Vent

Connectors ©NFPA & AGA

TaRe A--Combined Appliance Naximum Input

Rating in Thousands of BTU per Hour

INT_CRNAL AREA OF CHMNEY

VENT HEIGHT (FT) ($Q. IN.)

74 119 178 257

80 130 193 279

84 138 207 299

NR 152 233 334

NR NR 250 368

NR NR NR 404

APPLIANCE APPLI(ATION REQ[ IREMENTS

Appliance operation has a significant impact on the per%finance

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

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

appliances should not suffer from condensation and corrosion. The

venting system and all appliances shall be installed in accordance

with applicable listings, standards, and codes.

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

heating load requirement plus any margin that occurs because of

Nnmce model size capacity increments. Heating load estimates

can be made using approved methods available ti'om Air Condi=

ta=

ta.

Table B--Ninimum Alowable input Rating of

Space-Heating ApNiance in

Thousands of BTU per Hour

iiNTERNAL AREA OF CHIMNEY

VENT (SQ. IN.)

NEIGNT(FT)12 [ 19 I 28 I a8

Local 99% Winter Design

Temperature: 17 to 26 degrees F*

6 0 55 99 141

8 52 74 111 154

10 NR 90 125 169

15 NR NR 167 212

20 NR NR 212 258

30 NR NR NR 362

Loea199%Winter Design

Temperature: 5 to 19 degrees F*

6 NR 78 121 166

8 NR 94 135 182

10 NR 111 149 198

15 NR NR 193 247

20 NR NR NR 293

30 NR NR NR 377

Loealgg%winter Design

Temperature:-10 to 4 degrees F*

6 NR NR 145 196

8 NR NR 159 213

10 NR NR 175 231

15 NR NR NR 283

20 NR NR NR 333

30 NR NR NR NR

Local 99% Winter Design

Temperature: -11 degrees F or lower*

Not recommended for any vent

configuration

*The 99% Winter Design Dry-Bulb (db) temperatures are found in the 1993

ASHRAE Fundamentals Handbook, Chapter 24, Tabte 1 (United States) and

2 (Canada), or use the 99.6% heating db temperatures found in the 1997 or

2001 AEHRAE Fundamentals Handbook, Climatic Design information chap-

ter, Table 1A (United States) and 2A (Canada)

tioning (ontractors of America (Manual J); American Society of

Heating, Refrigerating, and Air-(onditioning Engineers; or other

approved engineering methods. Excessive oversizing of the fur=

nace could cause the fmTmce and/or vent to fail prematurely.

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

condition and be installed in accordance with the vent manufac=

turer's instructions.

To prevent condensation in the fimaace and vent system, the

following precautions must be observed:

1. The return=air temperature must be at least 60°F db except [br

brief periods of time during warn>up from setback at no lower

than 55_F db or during initial start=up from a standby

condition.

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

gas input rate causes tow vent gas temperatures, causing

condensation and corrosion in the ihmace an_or venting

system. Derating is pem_itted only for altitudes above 2000 ft.

3. Adjust the air temperature rise to the midpoint of the rise range

or slightly above. Low air temperature rise can cause low vent

gas temperature and potential _br condensation 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: Rebuild

Missing mortar crown

or brick?

Is chimney No

<_,_ _:_ePrOperty lined with

liner?

is Repair

liner and top liner or top seat

seal in good or reline chimney as

condition? necessary.

Yes Repair

Reline

Debris

in cleanout? Mortar

Mortar, tile, metal venL or tile Remove mortar

fuel oil residue? debris? and tile debris

Remove metal vent

or liner.

-->

Clay

tile misalignment,

missing sections_

gaps?

Condensate

drainage at bottom

Chimney

exposed to

outdoors below

roof line?

Chimney is

acceptable for use.

Yes

chimney

lined with properly

sized_ listed liner or

vent?

Part B of

instructions for

application

;uitable

Not Suitable

Install chimney

adapter per

instructions.

Yes 4ot Suitable

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.

Is chimney

to be dedicated to

a single

furnace?

Part C of

instructions for

application

>,Suitable

Install chimney

adapter per

instructions.

Fig. 26--CMmney Inspection Chart A03206

4. Set the thermostat heat anticipator or cycle rate to reduce short

cycling.

Air for confbustion must not be contaminated by halogen como

pounds which include chlorides, fluorides, bromides, and iodides

These compounds are found in many common home products such

as detergent, paint, glue, aerosol spray, bleach, cleaning solvent,

salt, and air /ieshener, and can cause corrosion of furnaces and

vents. Avoid using such prodtlcts in the cornbustion=air supply.

Furnace use during construction of the building could cause the

ihmace to be exposed to halogen compounds, causing premature

ihilure of the furnace or venting system dtle to corrosion.

Vent dampers on any appliance connected to the common vent can

cause condensation and con'osion in the venting system. Do not

use vent dampers on appliances common vented with this Nrnace.

ADDITIONAL VENTING REQUIREMENTS

A 4" round vent elbow is supplied with the Nmace. A 5-inch or 6o

inch vent connector may be required %r some model Nmaces. A

field=supplied 4-inch-to-5-inch or 4=inch=to=6-inch sheet metal

increaser fitting is required when 5-inch or 6oinch vent connector

is used. See Fig. 32 44 Venting Orientation ibr approved vent

configurations.

NOTE: Vent connector length for connector sizing starts at

Nmace vent elbow. The 4oinch vent elbow is shipped ibr upflow

configuration and may be rotated ibr other positions. Remove the

3 screws that secure vent elbow to fhmace, rotate [hrnace vent

elbow to position desired, re-install screws. The factov-supplied

vent elbow does NOT count as part of the number of vent

connector elbows.

The vent connector can exit the door through one of 5 locations on

the door.

1. Attach the single walt vent connector to the fi/mace vent

elbow, and ihsten the vent connector to the vent elbow with at

least two fieldosupplied, corrosion-resistant, sheet metal

screws located 180 ° apart.

--> NOTE: An accessory flue extension KGAFE0112UPH is avail°

able to extend fiom the farnace elbow to outside the furnace

casing. If flue extension is used, _sten the flue extension to the

vent elbow with at least two field-supplied, corrosion-resistant,

sheet metal screws located 180 _>apart. Fasten the vent connector to

the flue extension with at least two field-supplied, con'osiono

resistant sheet metal screws located 180 ° apart.

2. Vent the furnace with the appropriate connector as shown in

Fig. 32 44.

--> (IT HAZARD

Failure to %11ow this caution may result in personal injury.

Sheet metal parts may have sharp edges or bun's Use care and

wear appropriate protective clothing, safety glasses, and

gloves when handling parts and servicing _/rnaces.

3. Orient the door to determine the correct location of the door

cutout to be removed

4. Use aviation-type tin snips to remove the correct U-shaped

cut-out in door.

--> NOTE: If this l_maace is equipped with knockouts in the door %r

the vent, a nmnber of techniques can be used to remove these

knockouts as seen in Fig. 27 through 31. The knockout in the

bottom of the door is unique due to its flanging and is not easily

removed by first cutting the two tie points at the edge of the door,

using aviation-type tin snips. (See Fig. 27.) A sharp blow to the

rounded end of the knockout (See Fig. 28.) will separate more tie

points and allow the knockout to be pulled loose. (See Fig. 29.)

Remove all burrs and sharp edges.

For the knockouts in the other locations on the door (top and

sides), tin snips can also be used along the door edges; however,

the preferred method is to use a hammer and screwdriver to strike

a sharp blow (See Fig. 30.) directly to the knockout tie points or

use a hammer in the upper left corner of the desired knockout. (See

Fig. 31.) Remove all bun's and sharp edges.

An accessoO' Vent Guard Kit, KGAVG0101DFG is REQUIRED

for downflow applications for use where the vent exits through the

lower portion of the It/mace casing door. Refer to the Vent Guard

Kit Instructions for complete details.

The horizontal portion of the venting system shall slope upwards

not less than li4oin, per linear ft (2 hum/m) fiom the fhrnace to the

vent and shall be rigidly supported every 5 ft or less with metal

hangers or straps to ensure there is no movement after installation.

SIDEWALL VENTING

This Nrnace is not approved for direct sidewall horizontal venting.

In the U.S.: Per section 10.3.4 of the NFGC, any listed mechanical

renter may be used, when approved by the authori V having

jurisdiction.

--> In Canada: Per section 7242 of the NSCNGPIC, any listed

renters may be used, when approved by the authority having

jurisdiction.

Select the listed mechanical renter to match the Bmh input of the

lhrnace being vented. Follow all manu_hcturer's installation re-

quirements for venting and termination included with the listed

mechanical renter.

-_ Fig, 27--Using Tin Snips to Cut Tie Points

A04127

-_ Fig, 28--Rounded End of Knockout

A04128

A04129

-_ Fig. 29--Knockout Pulled Loose

A04130

-+ Fig. 30--Hammer and Screwdriver Used for

Knockout

A04131

-_ Fig. 31--Remove Knockout with Hammer

START-UP, ADJUSTMENT, AND SAFETY CHECK

Step l--General

FIRE HAZARD

Failure to follow this warning could result in a fire and lead

to property damage, personal injury, or death

This _k/rnace is equipped with manual reset limit switches in

t!_e gas control area The switches open and shut offpower to

the gas valve if a flame rollout or overheating condition

occurs in the gas control area. DO NOT bypass the switches.

Con'ect inadequate combustion air supply problem and reset

the switches.

(:IT HAZARD

Failure to %llow d_is caution may result in personal ir_jury.

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

wear appropriate protective clothing, safety glasses, and

gloves when handling parts and sela'icing _/maces.

1 Maintain 115-v wiring and ground Improper polarity will

result in rapid flashing LED and no [_urnace operation.

2Make them_ostat wire connections at d'_e 24-v terminal block

on the furance control. Failure to make proper connections

will result in improper operation (See Fig. 25.)

3 Gas supply pressure to the furnace must be greater than 4.5-in.

wc (016 psig) but not exceed 14-in wc (05 psig)

4 (beck all manual-reset switches fbr continuity

5 Install blower compartment door. Door must be in place to

operate fnrnace

6. Replace outer door.

Step 2--Start-Up Procedures

FIRE AND EXPLOSION HAZARD

Failure to fbllow this warning could cause property damage,

personal injm 7, or death.

Never purge a gas line into a combustion chamber. Never use

matches, candles, flame, or other sources of ignition _br the

purpose of checking leakage Use a soap-and=water solution

to check for leakage.

1 Purge gas lines after all connections have been made

2(beck gas lines for leaks

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

on the page following

these figures A03208

Fig. 32--Upflow Application-Vent Elbow Up

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

on the page following

these figures

A03211

Fig. 35--Downflow Application-Vent Elbow Up

SEE NOTES: 1_2,3,4,7,8,9

on the pages following

these figures

A03209

Fig. 33--Upflow Application-Vent Elbow Right

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

on the page following these figures

Fig. 36--Downflow Application-

Vent Elbow Left then Up A03207

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

on the page following

these figures

Fig. 34--Downflow Application-

Vent Elbow Up then Left

A03210

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

on the page following

these figures

Fig. 37--Downflow Application-

Vent Elbow Up then Right

A03212

SEE NOTES: 1,2_4,7,8,9 on the page

following these figures

A03213

Fig. 38--Horizontal Left Application-Vent Elbow Left

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

following these figures

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 Application-

Vent Elbow Right then Up

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

following these figures

Fig. 42--Horizonta! Right Application-

Vent Elbow Right

A03214

A03218

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

following these figures A03216

Fig. 41--Horizontal Left Application-Vent Elbow Right

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

following these figures

Fig. 43--Horizontal Right Application-

Vent Elbow Left then Up

A03219

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

Fig. 44_Horizontal Right ApNication-Vent Elbow Left

A02068

Venting Notes for Figures 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 after exiting the furnace, except when

KGAVG0101DFG, Downflow Vent Guard Kit, is used in the downflow position

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

5 Four-inch single=wall (26 ga. rain) vent must be used inside _/rnace casing and when the KGAVG0101DFG Downftow Vent Guard Kit is

used external to the furnace

6 Accesso W Downt'low Vent Guard Kit, KGAVG0!01DFG required in downflow installations wit}*lower vent configuration

7 (hinmey Adapter Kit may be required [br exterior mason W chinmey applications Re*_r to Chimney Adapter Kit, KGACA02014FC or

KGA(A02015FC, for sizing and complete application details.

8 Secure vent connector to furnace elbow with (2) cm_'osion-resistant sheet metal screws, spaced approximately 1%° apart.

9. Secure al! other single wal! vent connector joints with (3) corrosion resistant screws spaced approximately 120° apart. Secure Type=B ",gent

connectors per vent connector manufacturers recommendations.

10. The total height of the vent and connector shall be at least seven feet for the 154,000 Btuh gas input rate model when installed in a downflow

application with Nmace elbow turned to left side with the connector elbow outside Nmace casing pointing upward. (See Fig. 36.)

Caution!! For the following applications, use the minimum vertieat vent heights as specified be{ow.

For aH other applications, follow exclusivemy the National Fuel Gas Code.

MINIMUM

FURNACE ORIENTAT{ON VENT ORIENTATION FURNACE INPUT(BTU/NR / VENT DIAMETER (IN.}* MININUM VERTICAL VENT HEIGHT (FT/**

Downflow Vent elbow left then up 154,000

132,000 5 12

Fig 36 110,000(036/-12 only)

Vent elbow right, 154,000 5 7

Horizontal Left then up 132,000

Fig 39

Herizontal Left Vent Elbow up 154,000 5 7

Fig 40 132,000

Horizontal Left Vent elbow right 154,000 5 7

Fig 41

Downflow Vent elbow up then left 110,000 5 10

Fig 34 (036/-12 only)

Downflew Vent elbow up, then right 110,000 5 10

Fig 37 (036/-12 only)

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

*4 in inside casing or vent guard

**Including 4 in. vent section(s)

____>

ELECTRICAL SHOCK HAZARD

Failure to %llow this warning could result in electrical shock,

personal irtjury, or death

Blower access door switch opens 115-v power to control. No

component operation can occur unless switch is closed

Caution must be taken when manually closing this switch for

service purposes.

3, To Begin Component Self=Test:

Remove blower access door, Disconnect the d_em_ostat R lead

f'om furnace conhol boaid, Manually close the blower door

switch. Short (lumper) the (ox_=24V terminal on control to the

TEST/TWIN 3/16-inch quick connect terminal on control

until LED goes out (approximately 2sec). Gas valve and

humidifier will not be turned on. (See Fig. 24.)

NOTE: The fiul_ace control allows all components, except the gas

valve, to be run for short period of time. This fkature helps

diagnose a system problem in case of a component fifilure.

Component test feature will not operate if any thermostat signal is

present at the control.

Component test sequence is as %llows:

Refer to service label attached to Nmace or see Fig. 49.

a. LED will display previous status code 4 times.

b. Inducer motor starts and continues to run until Step f of

component test sequence.

c. Hot surface igniter is energized %r 15 sec., then off,

d. Blower motor operates on HEAT speed for 10 sec.

e. Blower motor operates on (OOL speed for 10 sec.

£ Inducer motor stops.

g. Reconnect R lead to t'umace control board, release blower

door switch and re-install blower door.

4. Operate Nmace per instruction on door.

5. Verii) Nmace shut down by lowering thermostat setting

below room temperature.

6. Verii)- furnace restarts by raising thermostat setting above

roon'l temperature

Step 3--Ad}ustments

FIRE HAZARD

Failure to %llow this warning could result in reduced I_urnace

tifc, property damage, injury and death.

DO NOT bottom out gas valve regulator a_iiusting screw

This can result in unregulated mani%ld pressure and result in

excess overfire and heat exchanger failures

F[ RNACE DAMAGE HAZARD

Failure to %llow this caution may result in reduced furnace

tifc

DO NOT re&ill orifces Improper &illing (burrs, out-of=

round holes, etc.) can cause excessive burner noise and

misdirection of burner flames. This can result in flame

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

47.)

Furnace gas input rate on rating plate is %r installations at ahimdes

up to 2000 ft Furnace input rate must be within +2 percent of

furnace rating plate input. ___>

1 Determine the con'ect gas input rate.

In the l_ .S.A :

The input rating t'or ahimdes above 2,000 fL must be reduced

by 4 percent fbr each 1,000 it. above sea level. For installa-

tions below 2000 it, refer to the unit rating plate. For

installations above 2000 ft. multiply the input on the rating

plate by the de-rate muhiplier in Table 8 for the con'ect input

rate

In Canada:

The input rating nmst be derated by 10 percent t'or ahimdes of

2,000 it. to 4,500 fL above sea level by an authorized Gas

( onversion Station or Dealer. To determine correct input rate

%r altitude, see example 1 and use 0.90 as derate multiplier

fSctor

EXAMPLE 1:

88,000 BTUH INPUT FURNACE BNSTALL_=D AT 4300 FT.

Derate Furnace Input Rate

Furnace Input Rate X Multiplier at Installation

at Sea Leve_ Factor Altitude

88,000 X 0.90 79,200

2 Detenrline the correct orifice and manifold pressure adjust-

mont. There are two different orifice and manifbld adjustment

tables. All models in all positions, except Low NOx models in

downflow or horizontal positions, use Table 12 (22,000

BTUHiBumer)

Low NOx models in the downflow or horizontal positions

must use Table 13 (21,000 BTUHiBumer). See input listed on

rating plate.

a. Obtain average yearly gas heat value (at installed altitude)

fl'om local gas supplier.

b. Obtain average yearly gas specific gravity fi'om local gas

supplier.

c. Find installation altitude in Table 12 or 13.

d. Find closest natural gas heat value and specific gravity in

Table 12 or 13.

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

intersection to find orifice size and manifbld pressure

settings %r proper operation.

£ (hock and verif) burner orifice size in %mace. NEVER

ASSUME ORIFI(E SIZE. ALWAYS (HECK AND

VERIFY.

g. Replace orifice with correct size if required by Table 12 or

13. Use only fhctory=supplied orifices. See EXAMPLE 2.

For 22,000 BTUH burner applications use Table 12

EXAMPLE 2:(0 2000 ft ahimde)

Heating value 1000 Btuicu ft

Specific gravity 0.62

Therefore: Orifce No. 43*

Manifold pressure: 3.7-in. we

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

all main burner orifices are the correct size and do not need

to be changed to obtain proper input rate.

Adjust mani%ld pressure to obtain correct 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.

d Tufa gas valve ON/OFF switch to ON.

e Manually close blower door switch,

WHT

(COM)

BLOV'_:R OEF49ELAY

c. JUMPER SELECT OR

I'O

901

Com 150

24V 180

TEST/TVMN

HUM

FUI _ i

SEC-2 SEC-1

(_ LED

N EACh2 _

PCB

-FBCLR

RE 1 SPARE 2 EAC-I

i I

BLK (14) 1-

BLI_NM , L

RED (LO) \ _ Jp

\_ _NN

GRN/YEL

NOTE #5 /f[7

CONNECTIONDIAGRAM

ERS2 LS1 LS2

RIED _ RED _ RED"

(_N USED)

NOTE#_0_

FRS1 DSS BVSS I

O__ORG_OR i

RED ]

RED G

mEN USED)

BHT/CLR BLOWER MOTOR SPEED CHANGE REIJ_Y, SPDT

BLWR BLOWER MOTOR RELAY, SPST-(N O )

BLWM BLOWER MOTOR, PERMANENT-SPUT-CAPACITOR

BVSS BLOCKED VENT SHUTOFF SWITCH M_,NUAL RESET SPST (N C )

CAB CAPACITOR

CPU MICROPROCESSOR AND CiRCUiTRY

DSS DRAFT SAFE GUARD SW1TCH, AUTO-RESET, SPST-(N C)

EAC-1 ELECTRON C AiR CLEANER CONNECT ON ( 5 VAC 10 AMP MAX )

EAC-2 ELECTRON C AIR CLEANER CONNECT ON (COMMON)

FRSE2 FLAN1E ROLLOUT SW MANUAL RESET SPST (N C ) TESTEIWIN COMPONENT TEST & TWiN TERMINAL

FSE FLAN1E PROVING ELECTRODE TRAN TRANSFORMER 115VAC/24VAC

FU 1 FUSE 3 AMP A_OMOTI_ BLADE _PE FACTORY INST_LED _ JUNCTION

FU 2 FUSE OR CiRCUiT BR_KER CURRENT INTERRUPT D_]CE

(FIELD INSTN.I ED & SUPP! lED) O UND_RKED TERMI_L

GND EQUIPMENT GROUND i PCB CONTROt TERMiN_

GV _S _LVE-REDUNDANT i FACTORY W_RING (115£AC)

GVR GAS VALVE RELAY, SPST (N O ) FACTORY _ RING (24Y_C)

HSI HOT SURFACE iGNiTER (115 VAC)

HSIR HOT SURFACE IGNITER RELAY, SPST-(N O) F ELD W1R NG ( 5VAC)

HUM 24VAC HUMIDIFIER CONNECTION (0 5 AMP MAX) .... FIELD W1RING (24VAC)

IDM INDUCED DRAFT MOTOR, SHADED POLE CONDUCTOR ON CONTROL PCB

IDR NDUCED DRAFT MOTOR RELAY, SPST-(N O / _ FIELD W1R]NG SCREW TERMINAL

ILK BLO'WER ACCESS PANEL NTERLOCK S'_ITCH SPST-(N O ) j_

J1 BLOWER - OFF DELAY JUMPER SELECTOR - HEAl] NG _ FIELD EARTH GROUND

J2 BLOWER - OFF DELAY JUMPER - COOLING _-z EQUIPMENT GROUND

JB JUNCTION BOX

LED LIGHT-EMITTING DIODE FOR STATUS CODES - RED _ FIELD SPLICE

LGPS LOW GAS PRESSURE S'B_ITCH SPST-(N O ) -"-) )--- PLUG RECEPTACLE

('_NHEN USED)

PRS LGPS

BLK

]DM

_.__. GR_N/YEL

_dT

,Z T , I I

BLK

FUSE OR CIRCUITBREAKER &

DISCONNECT SVMTCH (VVHEN REQ D)

JB NOTE #2

r ....... I

I a_ _I I I _I I I FU2 ILI

iLK /7_ "_" --- GND -I-- II

LS 1, 2 LIMIT SWITCH AUTO-BESET, SPST(N C )

OL AUTO RESET INTERNAL MOTOR OVERLO, _

TEMPERATURE SWITCH (NO)

PCB PRINTED CIRCUIT BOARD CONTROL

PL1 11-CIRCUIT PCB CONNECTOR

PL2 2-CIRCUIT CONNECTOR

PL3 2-CIRCUIT HSI, CONNECTOR

PRS PRESSURE SWITCH SPST-(N O )

TO 115VAC FIELD DISCONNECT SWITCH SCHEMATIC DIAGRAM

(NATURAL & PROPANE GASES

LI LtI NELrrRAL /_7 EQUIPMENT GROUND

• _ CAP

ILK SPARE I •.

MEDLO/\

L i HI START L2 I

co.co. i

HSIR I_

PR1 _ I

FUI ( NO_

R®

w®

CoM 24v PCB NOTE#5

B'V'SS

FRS1 DSS (Vt,HEN USED)

PL_4_ q

_$2 LSl NOTE#10

_I_ LS2

I1[_) PL1-11

PL_-3

PLy-7

NOTES:

1 If any of the edginal equipment wlre is replaced u_ wire rated for 105 iC

2 Use only copper wire betwee_ the disconnect switch aed the fumace junctic_ box (JB)

3 This wire must be comected to furnace sheet metal for control to prove flame

4 Symbols are electrical representation only

5 Solid lines inside PCB are pnnted c4rcuit board coeductors and are not included in legeed ILl

6 Replace only with a 3 amp fuse

7 Inducer (IDM) and blower (BLV1A_I) motcrs contain intem_ autodeset thermal ovedoad switches (OL)

8 Nentral connections are interd_angeable within the NELFIPdkL connector block

9 Blower motor speed selectiops ae for average conditions, see installation instlllctions for details on __

optimum speed selection 0

10 Factory connected when BVSS (Chimney Adapter Accessory Kit) is nct installed

11 Factory connected when LGPS is not used

12 Ignition-lockout will occur after four consecutive unsuccessful trials-fordg_ition Control will

autoceset after three hours ¢,4

13 Blower-on delay: gas heating 25 seconds, cooling or heat pump 2 seconds e_

14 Blower-off delay: gas heating s_ections are 9& 120,150 or 180 seconds ccoling or heat pump

90 seconds or 5 seconds when J2 is cut

-> Fig. 4S--Furnace Wiring Diagram A05038

TaNe 8-AIt{tude Derate MuR{Ner for U.S.A.

ALTITUDE PERCENT DERATE MULTIPLBER

(FT} OF DERATE FACTOR*

0-2000 0 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

9001=t0,000 36-40 0.62

* Derate multiplier factors are based on midpoint altitude for altitude range

ON/OFF

1/2 NPT INLET

INLET

PRESSURE%&P

REGULATOR

ADJUSTMENT

SCREW

REGULATOR SPRING

GASPRESSURE

ADJUSTMENT

£Set them_ostat to call fk_rheat.

g. Jumper R and W thermostat connections on fk/mace cont*ol

board to start fi/mace.

1"1.Remove regulator seal cap and turn regulator adjusting

screw counterclockwise (out) to decrease input rate of

clockwise (in) to increase input rate

i. Install regulator seal cap.

.i. Leave manomete* or similar device connected and proceed

to Step 4

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: 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.

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

a Turn off all other gas appliances and pilots so*red by the

meter

b. Run iqu_ace fPr 3 minutes in heating operation.

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.

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 tempera-

ture rise range specified on unit rating plate. Determine the

temperature rise as follows:

--> NOTE: Blower access door must be installed when taking tern-

perature rise reading. Leaving blower access door offwill result in

incot_'ect temperature nleasnrements.

a. Place thermometers in remm and supply ducts as close to

_/rnace as possible. Be sure them_ometers do not see

1/2 NPT OUTLET_

MANIFOLD

PRESSURE TAP

A04166

-_ Fig. 46--Gas Control Valve

radiant heat fi'om heat exchangers Radiant heat affects

temperature rise readings This practice is particularly

important with straight-rtm ducts,

b When them_ometer readings stabilize, subtlact return-air

temperature fiom supply=air temperature to detem_ine air

temperature rise.

NOTE: Blower access door must be installed for proper tempera-

ture rise measurement

NOTE: If the temperature rise is outside this range, first check:

1.) Gas input _br heating operation.

2.) Derate _Pr altitude if applicable.

3.) Return and supply ducts for excessive restrictions causing static

pressures greater than 0.50=in. wc.

4.) Dirty filter.

ELECTRICAL SHOCK HAZARD

Failure to follow this warning could result in personal injury

or death.

Disconnect 115=v electrical power befPre changing speed tap.

c Adjust air temperature rise by adjusting blo_er speed.

Increase blower speed to reduce temperature rise. Decrease

blower speed to increase temperature rise

BURNER J

UORIFICE

Fig. 47--Orifice Hole

A93059

Table 9--Speed Selection

COLOR SPEED AS SHIPPED

White Common BLW

Black High COOL

Yel]owt Med-High SPARE

Blue* Med-Low SPARE

Red* Low HEAT

* 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 and re-

move blowm access door.

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.

fi Repeat steps a through e.

g. When correct input rate and temperature rise is achieved,

mrn gas valve ON/OFF switch to OFF

h. Remove manometer or similar device f?om gas valve.

i. Reinstall manifold pressu*e tap plug in gas valve.

FIRE HAZARD

Leaking gas could be ignited and cause fire, explosion,

personal injury, property damage or death.

Reinstall manifold pressure tap plug in gas valve to prevent

gas leak.

j. Reinstall blower access door if remoxed

k. Turn gas valve ONOFF switch to ON.

F1. RNA(E OVERHEATING HAZARD

Failure to properly set temperature rise may cause excessive

furnace temperatures and shorten fi/mace life.

Recheck temperature rise. It must be within limits specified

on the rating plate Recommended operation is at the mid=

point of rise range or slightly above

6. Set thermostat heat anticipator.

a. Mechanical thermosta_Set thermostat heat anticipator to

match the amp draw of the electrical components in the

R-W circuit Accurate amp &aw readings can be obtained

at the wires nom_ally connected to themaostat subbase

terminals, R and W The thermostat anticipator should

NOT be in the circuit while measuring cmTent.

(1) Remove thermostat fi'om subbase or fl'om wall

(2) Connect an amp meter as shown in Fig. 4g across the

R and W terminals or R and W wires at wall

(3) Record amp &aw across terminals when furnace is in

heating and after blower starts.

(4) Set heat anticapator on thermostat per thermostat

instructions and install on subbase or wall.

b. Electronic thermostat: Set cycle rate for 4 cycles per hr.

7. Adjust blower off delay

The blower off delay has 4 adiustable settings fi'om 90 sec to

180 sec. The blower off delay jumpers are located on the

-->

TERMINALS WITH

THERMOSTAT REMOVED

(ANITICIPATOR, CLOCK, ETC.,

MUST BE OUT OF CIRCUIT.)

AMMETER

10 TURNS

FROM UNIT 24-V

CONTROL TERMINALS

EXAMPLE: 50 AMPS ON AMMETER = 0.5 AMPS FOR THERMOSTAT

10 TURNS AROUND JAWS ANTICIPATOR SETTING

A96316

Fig. 48--Amp Draw Check With Ammeter

fhrnace contlol board. (See Fig 24.)

To change the blower off delay setting, move the jumper from

one set of pins on the control to the pins used for the selected

blower off delay. Factory off delay setting is 120 sec.

8. Set airflow CFM fbr cooling

Select the desired blower motor speed lead for cooling

airflow. See Table 5=Air Delivery=CFM (With Filter). See

Table 9 for lead color identification.

Step 4_Cheek Safety Controls

The flame sensor, gas yah-e, and pressure switch were all checked

in d_e Start=up procedure section as part of normal operation.

1. Check Main Limit Switch(es)

This control shuts off combustion control system and ener-

gizes air-circulating blower motor, if fhrnace overheats. By

using this method to check limit control, it can be established

that limit is functioning properly and will operate if there is a

restricted duct system or motor failure. If limit contlol does

not fhnction during this test, cause must be determined and

corrected

a. Rm'_ furnace for at least 5 minutes.

b. Gradually block off return air with a piece of cardboard or

sheet metal until the limit trips.

c. Unblock return air to cause normal circulation.

d. Burners will re-tight when fhrnace cools down.

2. Check &aft safeguard switch.

The purpose of d-fis contlol is to cause the safk shutdown of the

furnace during cellain blocked vent conditions.

a. Vet!f) vent pipe is cool to the touch.

b. Disconnect power to f:urnace and remove vent connector

fi'om furnace vent elbow.

c. Restore power to fhrnace and set room thermostat above

roonl temperature.

d. After nom_al start-up, allow furnace to operate for 2

minutes, then block vent elbow in fllrnace 80 percent of

vent area with a piece of flat sheet metal

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

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

15 240 480 1200 55 65 131 327

16 225 450 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

20 180 360 900 60 60 120 300

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

36 100 200 500 92 39 78 196

37 97 195 486 94 38 76 192

38 95 189 474 96 38 75 188

39 92 185 462 98 37 74 184

40 90 180 450 100 36 72 180

41 88 176 439 102 35 71 178

42 86 172 429 104 35 69 173

43 84 167 419 106 34 68 170

44 82 164 409 108 33 67 167

45 80 160 400 110 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

---5 e Furnace should cycle off within 2 minutes. If gas does not

shut offwithin 2 minutes, detem_ine reason &aft safeguard

switch did not function properly and correct condition.

f\ Remove blockage fl'om furnace vent elbow.

g. Switch will autooreset when it cools.

--> h. Reoinstall vent connector.

---5 NOTE: Should switch remain open longer than 3 minutes,

furnace control board will lockout the f:urnace for 3 hours. To reset

furnace control board, turn thermostat below room temperature or

from HEAT to OFF and mrn 115v power OFF, then back ON.

3. (hock Pressure Switch

This contlol proves operation of the &aft inducer blower.

a. Turn off l!5ov power to fhrnace.

b. Disconnect inducer motor lead wires from wire harness.

c. Turn on 115or power to furnace.

d. Set thermostat to "call for heat" and wait 1 minute. When

pressure switch is flmctioning properly, hot surface igniter

should NOT glow and control diagnostic light flashes a

--€

status code 32. If hot surfSce igniter glows when inducer

motor is disconnected, shut down furnace immediately

e DeteImine reason pressure switch did not function properly

and con'ect condition.

f\ Turn off 115or power to ft_rnace.

g. Reconnect inducer motor wires, replace outer door, and

turn on 115-v power.

h. Blower will run for 90 sec befbre beginning the call fbr

heat again.

i. Furnace should ignite nom_ally.

Step 5--ChecHist

1 Put away tools and instruments. Clean up debris.

2. (hock that blower OFFoDELAY time is selected as desired.

3. Verii) that blower and burner access doors are properly

installed.

4 (ycle test fhmac¢ with room thermostat.

5. (hock operation of accessories per manuitacturer's instruc=

tions

6 Review /se*'s Guide with owner

7 Attach literature packet to fhmace.

SERVBCE AND MAINTENANCE PROCEDURES

FIRE, INJURY, OR DEATH HAZARD

Failure to fbllow this warning could result in possible damage

to this equipment, serious personal injury, or death

The ability- to properly perform maintenance on this equip°

ment requires certain knowledge, mechanical skills, tools, and

equipment. If you do not possess these, do not attempt to

perform any maintenance on this equipment other than those

procedures recommended in the User's Manual.

ELECTRICAL SHOCK, FIRE, OR EXPLOSION

HAZARD

Failure to follow this warning could result in personal injury,

death, or property damage

Before servicing_ disconnect all electrical power to ftlmace

Verif)- proper operation after servicing.

ELECTRICAL OPERATION HAZARD

Failure to fbllow this caution may result in improper furnace

operation or failure of tim_ace

Label all wires prior to disconnection when selwicing con-

tIols Wiring errors can cause improper and dangerous

operation.

Step l--htroduction

GENERAL

These instructions are written as if the furnace is installed in an

upflow application. An upflow furnace application is where the

blower is located below the combustion and controls section of the

furnace, and conditioned air is discharged upward. Since this

ff_rnace can be installed in any of the 4 positions shown in Fig 4,

you must revise your orientation to component location accord-

ingly.

SERVICE

if status code recall is needed, bc_et]y remove then recoqnect one main Iirr_t vdre to display stored status code Of 1 RED LEO boards do not re_ove power or b_ower door before initiating status cede recall After

stafuscoderecalliscomplstedcomponenttestwlloccurLED CODE STATUS

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 kit instructions

EACH OF THE FOLLOWING STATUS CODES IS A TWO DIGIT NUMBER VvlTH THE FIRST DIGIT DETERMINED BY THE NUMBER OF SHORT FLASHES AND THE SECOND DIGIT BY THE NUMBER OF LONG FLASHES

11 NO PREVIOUS CODE - Stored status code is erased automatically after 72 hours On 31 PRESSURE SWITCH DID NOT CLOSE OR RBOPENBD - If open longer than five minutes

RED LED boards stored status codes can also be erased when power

(115 VAC or 24 VAC) to control is interrupted

12 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

13 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 33

14 IGNITION LOCKOUT - Control wilJ auto-reset after three hours. Refer to #34

21 GAS HEATING LOCKOUT - Control will NOT auto reset.

Check for: -Mis-wired gas valve -Defective control (valve relay)

22 ABNORMAL FLAME-PROVING SIGNAL - Flame is proved while gas valve is de-

energized Inducer will run unti} fault is cleared. Check for: - Leaky gas valve

- Stuck-open gas valve

23 PRBSSURB SWITCH DID NOT OPEN Check for:

- Obstructed pressure tubing. - Pressure switch stuck dosed.

24 8BCONDARY VOLTAGB FUSB 18 OPEN Check for:

- Short circuit in secondary voltage (24VAC) wiring 34

COMPONENT TEST

To initiate the component test sequence, shut OFF the room thermostat or disconnect the "R"

thermostat lead Briefly short the TEST/TWIN terminal to the 'Corn 24V" terminal. Status LED

component test The hot surface ignitor, blower motor fan speed (on AMBER LED boards

will flash code and then turn ON the inducer motor The inducer motor will run for the entire

only) blower motor-heat speed, and blower motor-coo} speed will be turned ON for 10-15 I45

seconds each. Gas Valve and Humidifier will not be turned on I

327596-101 REV. B

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¸

A04223

-_ Fig. 49--Service Label

ELECTRICAL CONTROLS AND WIRING

--€ ELECTRICAL SHOCK HAZARD

Failure to follow this warning could result in personal injuQ'

or death.

There may be more than one electrical supply to the/_t_rnace.

Check accessories and cooling unit for additional electFical

supplies that must be shut off during furnace servicing.

The electrical ground and polarity fbr 115-v wiring must be

properly maintained. Refer to Fig. 25 fbr field wiring infbm_ation

and to Fig 45 for furnace wiring infi_rmation

NOTE: If the polarity is not correct, the STATUS LED on d-xe

control will flash rapidly and prevent the tk_mace fiom heating

The control system also requires an earth ground for proper

operation of the control and flameosensing electlode

The 24_v circuit contains an automotiveotype, 3°amp _klse located

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 is required, use ONLY a 3oamp J:k/se The control

LED will display status code 24 when fuse needs to be replaced

Proper instrumentation is required to service electrical controls

The control in this furnace is equipped with a Stares (ode LED

(Light-Emitting Diode) to aid in installation, servicing, and

troubleshooting It can be viewed through the sight glass in blower

access door The fm'nace control LED is either ON continuously,

rapid flashing, or a code composed of 2digits. The first digit is the

nm'nber of short flashes, the second digit is the number of tong

flashes

For an explanation of status codes, ref¢r to service label located on

blower access door or Fig 49_ and the tloubleshooting guide which

can be obtained from your distFibutor The ftmaace control will

store 1 stares code fbr 72 hours.

For (ontrols With a Red LED

The stored status codes WILL be erased from the control memory,

if 115- or 24-v power is interrupted.

1. To retrieve the stares code, proceed with the _bllowing:

NOTE: NO them_ostat signal may be present at control, and all

blower_OFF delays must be completed

a Leave l15ov power to fi_rcmce mined on

b. Remove outer access door

c Look into blower access door sight glass fbr current LED

stares. DO NOT remove blower access door or tem_inate

115_v power to control or stares code will be lost

d. BRIEFLY remove insulated terminal wire fiom the draft

safeguard switch (DSS) until LED goes out (1 to 2sec),

then reconnect it

2. When above items have been completed, the LED flashes

status code 4 times. Record this stares code fbr fi/rther

troubleshooting.

3. (omponent self=test will begin. Refer to COMPONENT

TEST section for complete test sequence.

4. Check LED stares.

5. Refer to d_e SERVICE label on the front of the blower access

door for more infbrmation.

6. Check LED status. If no previous fault is in history, control

will flash stares code 11.

7. If LED status indicates proper operation, RELEASE

BLOWER ACCESS DOOR SWITCH, reattach wire to "R"

terminal on fi/rnace control board, replace blower access door,

and replace burner access door.

-9 See Fig. 53, a brief Troubleshooting Guide

--€

TaNe l 1--FILTER SIZE _NFORMATION (iN.)

FURNACE

CASBNG W_DTH

14-1/2

17-1/2

24**

* Recommended

** Some furnaces may have 2 filters

FILTER QUANTITY AND S_ZE

Side Return Bottom Return

(1) 16X25X I (1) 14X25X 1

(1) 16X25X I (1) 16X25X 1

(1) 16X25X 1 (1) 20X25X 1

(I) 16X25X I (I) 24X25X 1

FILTER

TYPE

Cteanabte*

Cleanable*

Step 2--Care and Maintenance

FIRE OR EXPLOSION HAZARD

Failure to %llow this warning could result in corrosion of heat

exchanger, fire, personal inju_', or death

Never store anything on, near, or in contact with the I:t_rnace,

such as:

1. Spray or aerosol cans, rags, brooms, dnst mops, vacuum

cleaners, or other cleaning tools.

2. Soap powders, bleaches, waxes or other cleaning corn=

pounds, plastic or plastic containers, gasoline, kerosene,

cigarette lighter fluid, dry cleaning fluids, or other volatile

fluids.

3. Paint thinners and other painting compounds, paper bags,

or other paper products.

For continuing high per%rmance and to minimize possible equip=

ment fg_ilure, periodic maintenance must be performed on this

equipment. Consult your local dealer ahont proper fiequency of

maintenance and the availability of a maintenance contract

ELECTRICAL SHOCK HAZARD

Failure to follow this warning could result in personal injury,

death or product damage.

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 MONOXIDE POISONING AND FIRE

HAZARD

Failure to follow this warning could result in fire, personal

injury, or death

Never operate unit without a filter or with filter access door

removed.

(IT HAZARD

Failure to %llow this caution may result in personal iRiury

Sheet metal parts may have sharp edges or bun's Use care and

wear appropriate protective clothing, safety glasses, and

gloves when handling parts and servicing fimaaces.

The minimnn_ maintenance on this fm_aace is as %llows:

1. (hock and clean air filter each month or more fiequently if

required. Replace if torn.

2. Check blower motor and wheel for cleanliness each heating

and cooling season. Clean as necessm 7.

3. (hock electrical connections _br tighmess and controls for

proper operation each heating season. Service as necessm_-.

--€

4. Inspect burner compartment be%re each heating season %r

rnst, corrosion, soot or excessive dust. If necessa_, have

_ul_ace and burner serviced by a qualified service agency.

5 Inspect the vent pipe/vent system before each heating season

_br rust, corrosion, water leakage, sagging pipes or broken

fittings. Have vent pipes/vent system serviced by a qualified

service agency.

6. Inspect any accessories attached to the t_t_mace such as a

humidifier or electronic air cleaner. Pert'ram any service or

maintenance to the accessories as recommended in the acces-

so_- instractions.

CLEANING AND/OR REPLACING AIR FILTER

The air filter arrangement will vary depending on the application.

The filter is exterior to the J:i/mace casing.

NOTE: If the filter has an airflow direction an'ow, the arrow must

point towards the blower.

CUT HAZARD

Failure to %llow this caution may result in personal injury.

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

wear appropriate protective clothing, safety glasses, and

gloves when handling parts and sela'icing I:_/maces.

Media cabinet filter procedures:

NOTE: Media cabinet or 1" Filter Rack are accessories and are

not included t'rom the factory with the standard _ilrnace model

1 Turn off electIical supply to furnace before removing filter

access door.

2Remove filter cabinet door

3 Slide filter out of cabinet.

4 If equipped with permanent, washable 1-inch filter, clean filter

by spraying cold tap water through filter in opposite direction

of airflow. Rinse filter and let dry. Oiling or coating of the

filter is not recommended. See Table 11 for size int'ornaation.

5. If equipped with _bctory=specified disposable media filter,

replace only with media filter having the same part number

and size. For expandable replacement media, refer to the

instrnctions included with the replacement media. If equipped

with KGAFR0301ALL external filter rack, See Table 11.

6. Slide filter into cabinet.

7. Replace filter cabinet door.

8. Turn on electrical supply to ft_rnace.

BLOWER MOTOR AND WHEEL

ELECTRICAL SHOCK HAZARD

Failure to follow this warning could result in personal injury

or death.

Blower access door switch opens 115=v power to control. No

component operation can occur unless switch is closed.

(aution must be taken when manually closing this switch for

service purposes.

NOTE: The blower wheel should not be dropped or bent as

balance will be affected.

Tile foHmving steps should be performed by a quMified service

agenc?°

To ensure tong life and high eNciency, clean accumulated dirt and

grease from blower wheel and motor annually.

TABLE 12--Orifice Size* and Manifold Pressure For Gas input Rate

(Tabulated Data Based On 22,000 Btuh Per Burner, Derated 4 Percent For Each 1000 Ft Above Sea Level)

U.S.A. Only

ALTITUDE

RANGE

(FT)

o 0

-o to

2000

AVG GAS

NEAT VALUE

(BTUiCU FT)

900

925

95O

975

1000

1025

1050

1075

1100

ALTITUDE AVG GAS

RANGE HEAT VALUE

(FT) (BTU/CU FT)

U.S.A.

Altitudes

"o 2001

o 3000

"o or

Canada

Altitudes

2000

4500

8OO

825

85O

875

900

925

950

975

1000

ALTITUDE AVG GAS

RANGE HEAT VALUE

(FT) (BTU/CU FT)

3001

4000

775

8OO

825

85O

875

900

925

950

ALTITUDE AVG GAS

RANGE HEAT VALUE

(FT) (BTU/CU FT)

4001

5000

* Orifice numbers 43 are factory installed

0.58

Orifice Manifold

No. Pressure

42 I

43 I

4:3 I

44 I

SPECIFIC GRAVITY OF NATURAL GAS

0.60 0.62 0.64

Orifice Manifold Orifice Manifold Orifice Manifold

No. Pressure No. Pressure No. Pressure

0.58

Orifice

No.

42 I

4:3 I

4_3 I

4,3 I

4:3 I

4,3 I

4:3 I

3.5 42

3.3 42

3.8 42

3.6 43

3.5 43

3.3 43

3.6 43

3.4 44

3.3 44

SPECIFIC GRAVITY

3.6 42

3.4 42

3.3 42

3.8 42

3.6 43

3.4 43 3.5

3.2 43 3.4

3.5 43 3.2

3.4 44 3.5

OF NATURAL GAS

Manifold

Pressure

3.7 41 3.5

3.5 42 3.7

3.4 42 3.5

3.2 42 3.3

3.7 43 3.8

43 3.6

43 3.5

43 3.3

43 3.2

0.60 0.62 0.64

Orifice Manifold Orifice Manifold Orifice Manifold

No. Pressure No. Pressure No. Pressure

3.4 42 3.5 42

3.2 42 3.3 42

3.7 43 3.8 42

3.5 43 3.6 43

3.3 43 3.4 43

3.1 43 3.2 43

2.9 43 3.0 43

2.8 43 2.9 43

2.6 43 2.7 43

0.58

Orifice Manifold

No. Pressure

42 I

43 I

4:3 I

3.3

3.1

3.0

2.8

SPECIFIC GRAVITY OF NATURAL GAS

3.6 42 3.7

3.4 42 3.5

3.2 42 3.3

3.7 43 3.8

3.5 43 3.6

43 3.4

43 3.2

43 3.1

43 2.9

0.60 0.62 0.64

Orifice Manifold Orifice Manifold Orifice Manifold

No. Pressure No. Pressure No. Pressure

0.58

Orifice

No.

750 43

775 43

800 43

825 43

850 43

875 43

900 43

925 43

3.2 42

3.6 43

3.4 43

3.2 43

3.0 43

2.9 43

2.7 43

2.6 43

SPECIFIC GRAVITY

3.3 42

3.8 42

3.5 43

3.3 43

3.1 43 3.3

3.0 43 3.1

2.8 43 2.9

2.7 43 2.8

OF NATURAL GAS

Manifold

Pressure

3.4 42 3.5

3.2 42 3.3

3.7 43 3.8

3.4 43 3.6

43 3.4

43 3.2

43 3.0

43 2.8

0.60 0.62 0.64

Orifice Manifold Orifice Manifold Orifice Manifold

No. Pressure No. Pressure No. Pressure

3.6 43 3.8 42

3.4 43 3.5 43

3.2 43 3.3 43

3.0 43 3.1 43

2.8 43 2.9 43

2.7 43 2.8 43

2.5 43 2.6 43

2.4 43 2.5 43

3.2

3.6

3.4

3.2

3.0

2.9

2.7

2.6

3.3

3.8

3.5

3.3

3.1

2.9

2.8

2.6

The inducer and blower motors are pro-lubricated and require no

additional lubrication. These motors can be identified by the

absence of oil ports on each end of the motor.

(?lean blower motor and wheel as fbllows:

1. Turn off electrical supply to furnace.

2. Loosen the thumbscrew on outer door and remove outer door.

For downflow or horizontal filrcmces having vent pipes within

the furnace that pass in fiont of the blower access door:

a Disconnect vent connector flora fire, ace vent elbow.

b. Disconnect and remove short piece of vent pipe from

within i_/rnace,

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)

ALTITUDE

RANGE

{FT)

AVG GAS

NEAT VALUE

AT ALTITUDE

{BTU/CU FT) Orifice

No. Orifice

No.

725

75O

775

800

825

85O

875

9OO

AVG GAS

HEAT VALUE

AT ALTITUDE

(BTU/CU FT)

43 43

O 5001

to 43 43

m@ 6000 43 43

43 43

Orifice

No.

675

7OO

725

75O

775

80O

825

85O

AVG GAS

HEAT VALUE

AT ALTITUDE

(BTU/CU FT)

0.58

l ManifoldPressure

3.4

3.2

3.0

2.8

2.6

2.5

2.3

2.2

0.62

ManifoldPressure

43 3.6

43 3.4

43 3.2

43 3.0

43 2.8

43 2.6

43 2.5

43 2.3

NATURAL GAS

0.62

ALTITUDE

RANGE

(FT) Orifice

No.

43 43

O 6001

to 43 43

_ 7000 43 43

43 43

0.58

l ManifoldPressure

3.4

3.1

2.9

2.7

2.6

2.4

2.3

2.1

Orifice

No.

ALTITUDE

RANGE

(FT) Orifice

No.

43 43

O 7001

to 43 43

_ 8000 43 43

43 43

48 43

0.58

l Manifold

Pressure

3.1

2.9

2.7

2.5

2.4

2.2

2.1

3.7

0.58

Manifold

Pressure

2.9

2.7

2.5

2.3

2.2

2.0

3.6

SPECIFIC GRAVITY OF NATURAL GAS

0.60

Orifice / Manifotd Orifice

No. J Pressure No.

43 3.5

43 3.3

43 3.1

43 2.9

43 2.7

43 2.5

43 2.4

43 2.3

SPECIFIC GRAVITY OF

0.60

Orifice I Marfifold Orifice J ManifoldNo. Pressure No. Pressure

43 3.5 43 3.6

43 3.3 43 3.4

43 3.0 43 3.1

43 2.8 43 2.9

43 2.7 43 2.7

43 2.5 43 2.6

43 2.3 43 2.4

43 2.2 43 2.3

SPECIFIC GRAVITY OF NATURAL GAS

0.60 0.62

Orifice _ Manifotd Orifice Manifold

No. _ Pressure No.

43 3.2 43

43 3.0 43

43 2.8 43

43 2.6 43

43 2.4 43

43 2.3 43

43 2.1 43

43 2.0 43

SPECIFIC GRAVITY OF NATURAL GAS

0.60 0.62

Orifice

No.

Manifold

Pressure

3.0

2.8

2.6

2.4

2.2

2.1

3.7

Orifice

No.

J Pressure

3.1

2.9

2.7

2.5

2.4

2.2

2.1

Manifold

Pressure

3.1

2.9

2.7

2.5

2.3

2.2

2.0

Orifice

No.

65O

675

7OO

725

75O

775

8OO

825

AVG GAS

HEAT VALUE

AT ALTITUDE

(BTU/CU FT)

625

65O

675

7OO

725

75O

775

ALTITUDE

RANGE

(FT}

O 8001

4 to

9000

Orifice

No.

0.64

l ManifoldPressure

3.7

3.5

3.3

3.1

2.9

2.7

2.6

2.4

0.64

l ManifoldPressure

3.7

3.5

3.2

3.0

2.8

2.7

2.5

2.4

0.64

l Manifold

Pressure

3.5

3.2

3.0

2.8

2.6

2.4

2.3

2.2

0.64

Manifold

Pressure

3.2

3.0

2.8

2.6

2.4

2.2

2.1

* Orifice numbers 43 are factory installed

4, Remove 2 screws i:i"om blower access door and remove blower

access door

5. Disconnect blower leads from f_/rnace contlol Record wire

color and location _k_rreassembly. All other factory wires can

be left connected, but field tiaem_ostat connections may need

to be disconnected depending on their length and routing.

6. Remove 2screws holding control box to blower shel£

7. Hang control box from fiont of furnace casing and away from

blower compartment.

g. Remove 2 screws holding blower assembly to blower deck

and slide blower assembly out of ftmaace.

9 (;lean blower wheel and motor using a vacuum with soft brush

attaciament Blower wiaeel blades may be cleaned with a small

paint or flux brusia. Do not remove or disturb balance weights

(clips) on blower wiaeel blades

10 Vacuum any loose dust fiom blower housing_ wheel and

nlotor.

Table 12--Orifice Size* And Manifold 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)

ALTITUDE

RANGE

(FT}

AVG GAS

NEAT VALUE

AT ALTITUDE

(BTU/CU FT}

SPECIFIC

0.60

Orifice

No.

i Orifice

No.

0.58

Manifold

Pressure

2.7

2.5

2.3

2.1

3.7

3.5

GRAVITY OF NATURAL GAS

0.62

Orifice

No.

Manifold

Pressure

2.8

2.6

2.4

2.2

2.0

3.6

Orifice Manifotd

No. Pressure

43 2.9

43 2.6

43 2.4

43 2.3

43 2.1

48 3.7

600 43 43

c 625 43 43

O 9001

to 650 43 43

m 10,000 675 43 43

D 700 43 43

725 48 43

0.64

Manifold

Pressure

3.0

2.7

2.5

2.3

2.2

2.0

* Orifice numbers 43 are factory installed

___>

11. If a greasy residue is present on blower wheel, remove wheel

from d_e blower housing and wash it with an appropriate

degrease> To remove wheel:

NOTE: Befbre disassembly, mark blower motor, and blower

housing so motor and each arm is positioned at the same location

during reassembly.

a. Disconnect capacitor wires and ground wire attached to

blower housing.

b. Remove screws securing cutoff plate and remove cutoff"

plate from housing.

c. Loosen set screw holding blower wheel on motor shaft

(160+/-20 in°lb when reassembling).

d. Remove bolts holding motor to blower housing and slide

motor out of wheel (40÷/-20 in-lb when reassembling).

e. Remove blower wheel fiom housing.

f Clean wheel and housing.

12. Reassemble motor and blower by reversing steps 1if d-_rough

1 in, finishing with 1 la. Be sure to reattach ground wire to the

blower housing.

13. Verif) that blower wheel is centered in blower housing and set

screw contacts the flat portion of d-_emotor shaft. Loosen set

screw on blower wheel and reposition if necessary.

14. Spin the blower wheel by hand to verif}- that the wheel does

not tab on the housing.

15. Reinstall blower assembly in fhrnace.

16. Reinstall control box assembly in f_/mace.

[NIT DAMAGE HAZARD

Failure to £bllow this caution may shorten heat exchanger life

Heating £m speed(s) MUST be adjusted to provide proper air

temperature rise as specified on d_e rating plate. Recom°

mended operation is at d-_e rni@oint of the rise range or

slightly above Refer to "SET TEMPERATURE RISE" under

START-UP, ADJUSTMENT, and SAFETY CHECK.

NOTE: Refer to Table 9 fbr motor speed tend relocation if leads

were not identified before disconnection.

17. Reconnect blower leads to fimaace control Refer to furnace

wiring diagram, and connect them_ostat leads if previously

disconnected.

18. To check blower fbr proper rotation:

a. Turn on electrical supply.

-->

ELECTRICAL SHOCK HAZARD

Failure to fbllow this warning could result in electrical shock,

personal injury, or death

Blower access door switch opens 115-v power to furnace

contIoL No component operation can occur unless switch is

closed. Exercise caution to avoid electrical shock from

exposed electrical components when manually closing this

switch for service purposes.

b. Manually close blower access door switch.

NOTE: If d_em_ostat temainals are jumpered at the dine blower

access door switch is closed, blower wilt run for 90 sec befbre

beginning a heating or cooling cycle

c. Perfbrm component self-test as shown at the bottom of the

SERVI(E label, located on the front of blower access door.

d. Verify blower is rotating in the cmTect direction

19. If furnace is operating properly, RELEASE BLOWER AC-

CESS DOOR SWIT(H. Remove any junipers or reconnect

any disconnected thermostat leads Replace blower access

door

20. Downflow or horizontal furnaces with vent pipe through

fhmace only:

a Install and connect short piece of vent pipe inside f:urnace

to existing vent.

b. Connect vent connector to vent elbow.

21. Reinstall casing door.

22. Turn on gas supply and cycle fhrnace through one complete

heating and cooling cycle. Verify the furnace temperature rise

as shown in "Adjustments" Section. Adjust temperature rise as

shown in "Adjustments" Section. If outdoor temperature is

below 70°F, tnrn off" circuit breaker to outdoor unit befbre

running Nrnace in the cooling cycle. Turn outdoor circuit

breaker on after completing cooling cycle.

CLEANING HEAT EXCHANGER

The following s{eps should be performed by a qualified service

agency:

NOTE: If" the heat exchangers get a heavy accumulation of soot

and carbon, they should be replaced rather than trying to clean

them tho*oughly. A build-up of soot and carbon indicates that a

problem exists which needs to be corrected, such as improper

adjustment of manifold pressure, insufficient or poor quality

combustion air, incorrect size or damaged manifold orifice(s),

improper gas, or a restricted heat exchanger. Action must be taken

to correct the problem.

TABLE 13--Or{fice Size* and Manifold Pressure For Gas Input Rate

(Tabulated Data Based On 21,000 Btuh Per Burner, Derated 4 Percent For Each 1000 Ft Above Sea Leve0

U.S.A. Only

ALTITUDE

RANGE

{FT)

o 0

2000

AVG GAS

NEAT VALUE

(BTU/CU FT)

9OO

925

95O

975

1000

1025

1050

1075

1100

ALTITUDE AVG GAS

RANGE HEAT VALUE

{FT) (BTU/CU FT)

U.S.A.

Altitudes

•u 2001

o 3000

"o or

Canada

Altitudes

2000

4500

80O

825

85O

875

9OO

925

95O

975

1000

ALTITUDE AVG GAS

RANGE HEAT VALUE

{FT) (BTU/CU FT)

3001

4000

775

800

825

850

875

900

925

950

ALTITUDE AVG GAS

RANGE HEAT VALUE

(FT) (BTU/CU FT)

4001

5000

SPECIFIC GRAVITY OF NATURAL GAS

0.58 0.60 0.62

Orifice Manifold Orifice Manifold Orifice Manifold

No. Pressure No. Pressure No. Pressure

42 I 3.2

43 N 3.7

43 I 3.5

43 I 3.3

44- I 3.6

44 i 3.4

44 I 3.3

4b N 3.8

46 I 3.8

0.64

Orifice Manifold

No. Pressure

42 3.3 42

43 3.8 42

43 3.6 43

43 3.4 43

43 3.3 43

44 3.6 43 3.2

44 3.4 44 3.5

44 3.2 44 3.3

45 3.7 44 3.2

SPECIFIC GRAVITY OF NATURAL GAS

3.4 42 3.5

3.2 42 3.3

3.7 43 3.8

3.5 43 3.7

3.4 43 3.5

43 3.3

43 3.2

44 3.4

44 3.3

0.58 0.60 0.62

Orifice Manifold Orifice Manifold Orifice Manifotd

No. Pressure No. Pressure No. Pressure

43 I 3.8

43 N 3.5

43 I 3.3

43 I 3.2

43 I 3.0

43 N 2.8

43 I 2.7

43 I 2.5

43 I 2.4

0.64

Orifice Manifold

No. Pressure

42 3.2 42

43 3.7 43

43 3.5 43

43 3.3 43

43 3.1 43

43 2.9 43 3.0

43 2.8 43 2.9

43 2.6 43 2.7

43 2.5 43 2.6

SPECIFIC GRAVITY OF NATURAL GAS

3.3 42 3.4

3.8 42 3.2

3.6 43 3.7

3.4 43 3.5

3.2 43 3.3

43 3.1

43 2.9

43 2.8

43 2.7

0.58 0.60 0.62

Orifice Manifold Orifice Manifold Orifice Manifoid

No. Pressure No. Pressure No. Pressure

43 I 3.5 43

43 I 3.3 43

43 I 3.1 43

43 I 2.9 43

43 I 2.8 43

43 I 2.6 43

43 I 2.5 43

43 I 2.4 43

0.64

Orifice ManJfotd

No. Pressure

3.7 43

3.4 43

3.2 43

3.0 43

2.9 43 3.0

2.7 43 2.8

2.6 43 2.7

2.4 43 2.5

3.8 42 3.2

3.5 43 3.7

3.3 43 3.4

3.1 43 3.2

43 3.1

43 2.9

43 2.7

43 2.6

SPECIFIC GRAVITY OF NATURAL GAS

0.58 0.60 0.62

Orifice Manifold Orifice Manifold Onrice Manifold

No. Pressure No. Pressure No. Pressure

750 43 3.3 43

775 43 3.1 43

800 43 2.9 43

825 43 2.7 43

850 43 2.6 43

875 43 2.4 43

900 43 2.3 43

925 43 2.2 43

0.64

Orifice Manifold

No. Pressure

3.4 43

3.2 43

3.0 43

2.8 43

2.7 43

2.5 43

2.4 43

2.2 43

3.5 43

3.3 43

3.1 43

2.9 43

2.8 43

2.6 43

2.5 43

2.3 43

3.6

3.4

3.2

3.0

2.8

2.7

2.5

2.4

* Orifice numbers 43 are factory installed

If it becomes necessary Go clean the heat exchangers because of

dust or corrosiom proceed as follows:

1. Turn OFF gas and electrical power to ffmaace

2. Remove outer access door.

3. Disconnect vent connector flora flul_ace vent elbow.

4. For downflow or horizontal furnace having an internal vent

pipe, remove internal vent pipe within the casing.

5 Disconnect wires to the following components. Mark wires to

aid in reconnection of (be caref_ul when disconnecting wires

flora switches because damage may occur):

a Draft safeguard switch.

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}

AVG GAS

NEAT VALUE

AT ALTITUDE

(BTUiCU FT} Orifice

No.

= 43

O 5001

to 43

6000 43

725

75O

775

800

825

850

875

900

AVG GAS

HEAT VALUE

AT ALTITUDE

(BTU/CU FT)

i Orifice

No.

Orifice

No.

675

7OO

725

75O

775

8OO

825

85O

AVG GAS

HEAT VALUE

AT ALTITUDE

(BTU/CU FT)

0.58

Manifold

Pressure

3.1

2.9

2.7

2.5

2.4

2.2

2.1

2.0

0.62

Manifotd

Pressure

43 3.3

43 3.1

43 2.9

43 2.7

43 2.5

43 2.4

43 2.3

43 2.1

NATURAL GAS

0.62

ALTITUDE

RANGE

(FT) Orifice

No.

43 43

c 43 43

O 6001

to 43 43

_ 7000 43 43

43 43

48 43

0.58

ManifoldPressure

3.1

2.9

2.7

2.5

2.3

2.2

2.1

3.7

Orifice

No.

ALTITUDE

RANGE

(FT} Orifice

No.

0.58

Manifold

Pressure

2.9

2.7

2.5

2.3

2.1

2.0

3.6

3.3

SPECIFIC GRAVITY OF NATURAL GAS

0.60

Orifice Manifold Orifice

No. Pressure No.

43 3.2

43 3.0

43 2.8

43 2.6

43 2.5

43 2.3

43 2.2

43 2.1

SPECIFIC GRAVITY OF

0.60

Orifice [ Manifold Odfice [ ManifotdNo. Pressure No. Pressure

43 3.2 43 3.3

43 3.0 43 3.1

43 2.8 43 2.9

43 2.6 43 2.7

43 2.4 43 2.5

43 2.3 43 2.3

43 2.1 43 2.2

43 2.0 43 2.1

SPECIFIC GRAVITY OF NATURAL GAS

0.60 0.62

Orifice Manifold Orifice Manifold

No. Pressure No. Pressure

43 3.0 43 3.1

43 2.7 43 2.8

43 2.6 43 2.6

43 2.4 43 2.5

43 2.2 43 2.3

43 2.1 43 2.2

48 3.7 43 2.0

48 3.5 48 3.6

SPECIFIC GRAVITY OF NATURAL GAS

0.60 0.62

43 43

c 43 43

O 7001

to 43 43

8000 43 43

43 43

48 43

48 48

Orifice [ ManifoldNo. Pressure

Orifice

No.

650

675

700

725

750

775

80O

825

AVG GAS

HEAT VALUE

AT ALTITUDE

(BTU/CU FT) l ManifoldPressure

2.8

2.6

2.4

2.3

2.1

3.7

3.5

ALTITUDE

RANGE

(FT} Orifice

No.

Orifice

No.

0.58

ManifoldPressure

2.7

2.5

2.3

2.1

3.7

3.5

3.8

625 43 43 2.7 43 43

650 43 43 2.5 43 43

O 8001 675 43 43 2.4 43 43

to 700 43 43 2.2 43 43

' 9000 725 48 43 2.0 43 43

750 48 48 3.6 48 43

775 49 48 3.4 48 48

0.64

Manifold

Pressure

3.4

3.2

3.0

2.8

2.6

2.5

2.3

2.2

0.64

ManifoldPressure

3.4

3.2

2.9

2.8

2.6

2.4

2.3

2.1

0.64

Manifold

Pressure

3.2

2.9

2.7

2.5

2.4

2.2

2.1

3.7

0.64

ManifoldPressure

2.9

2.7

2.5

2.3

2.2

2.0

3.6

* Orifice numbers 43 are factory installed

b, Inducer motor

c, Pressure switch(es)

d, Limit overtemperamre switch,

e. Gas valve,

fi Hot sm'fhce igniter.

g. Flame=sensing electrode,

h, Flame rollout switches

i, Remove NOx baffles on low NOx models.

--€

6, Remove screws that fasten the collector box assembly to d_e

cell panel, Be carefi/l not to damage the collector box, Inducer

assembly and elbow need not be removed from collector box,

7, Disconnect gas line _i'om gas mani_bld,

8, Remove the 5 screws that attach the burner assembly to the

cell panel. The gas valve and individual burners need not be

removed ['tom support assen_bly,

NOTE: Be ve W careful when removing bumm assembly to avoid

breaking igniter, See Fig, 50 and 51 _br correct igniter 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)

AVG GAS

HEAT VALUE

AT ALTITUDE

{BTU/CU FT)

Orifice

No.

SPECIFIC

0.60

Orifice

No.

0.58

l ManifoldPressure

2.4

2.3

2.1

3.6

3.4

3.7

GRAVITY OF

Orifice

No.ManifotdPressure

2.5

2.3

2.2

3.8

3.5

3.8

NATURAL GAS

0.62

Orifice [ ManifoldNo. Pressure

43 2.6

43 2.4

43 2.2

43 2.1

48 3.6

48 3.4

600 43 43 43

625 43 43 43

O 9001

to 650 43 43 43

m_ 10,000 675 48 48 43

700 48 48 48

725 49 49 48

0.64

l ManifoldPressure

2.7

2.5

2.3

2.1

3.7

3.5

* Orifice numbers 43 are factory installed

9/32"

5/16"

A05025

Fig. 80--Igniter Position-Side View

A05026

Fig. 51--1gNter Position-Top View

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:

a. Remove metal screw fitting _i'om wire brush to a!low

insertion into cable.

b. Insert the twisted wire end of brush into end of spring

cable, and crimp tight with crimping tool or crimp by

striking with ball-peon hammer. TIGHTNESS IS VERY

IMPORTANT.

NOTE: The materials needed in item 9 can usually be purchased

at local hardware stores.

(1) Attach variable-speed, reversible &il! to the end of

spring cable (end opposite brush).

(2.) Insert brush end of cable into the outlet opening of cell

and slowly rotate with &ill DO NOT force cable.

Gradual!y insert cable into upper pass of cell (See Fig.

52)

(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 in burner inlet opening of

col!, and proceed to clean 2lower passes of cell in

sal*le nlanner as upper pass.

(5.) Repeat foregoing procedures until each celt in Nrnace

has been cleaned.

(6) Using vacuum cleaner, remove residr/e from each cell.

(7) Using vacuum cleaner with soft brush attachment,

clean burner assernbly

(8) (?lean flame sensor with fine steel wool

--> (9) Install NOx baffles, if removed

(i0.) Reinstall burner assembly. Center burners in celt

openings.

10. Remove old sealant from cell panel and collector box flange.

11. Spray releasing agent on the heat exchanger cell panel where

collector box assembly contacts cell panel.

NOTE: A releasing agent such as cooking spray or equivalent

(must not contain corn or canola oi!, aromatic or halogenated

hydrocarbons or inadequate seal may occur) and RTV sealant

(G.E. 162, 6702, or Dow=Corning 738) are needed before starting

installation. DO NOT substitute any other type of RTV sea!ant.

G.E. 162 (P771-9003) is available through RCD in 3-oz robes.

--> 12 Apply new sealant to flange of collector box and attach to cell

panel using existing screws, making sure al! screws are secure.

13 Reconnect wires to the _bltowing components (T_se connection

diagram on wiring label, if wires were not marked _br

reconnect!on locations.):

a. Drafl safeguard switch.

b Inducer motor

c. Pressure switch(es).

d Limit overtemperature switch

e. Gas valve.

f[Hot surface igniter.

g. Flame-sensing elect*ode.

1t. Flame rollout switches.

i. Install NOx ba*tles (if removed).

14. Reinstall internal vent pipe, if applicable.

A91252

Fig. 52--CleaNng Heat Exchanger Cell

15. Reinstall vent connector on ihmace vent elbow Securely

ihsten vent connector to vent elbow with 2 field-supplied,

con'osion=resistant_ sheet metal screws located 180 c_aparL

ld. Replace blower access door only, if it was removed.

17. Set thermostat above room temperature and check [hmace for

proper operation.

18. Verify7 blower airflow and speed changes between heating and

cooling.

FIRE OR EXPLOSION HAZARD

Failure to ibllow this warning could result in fire, personal

injury, or death

Never use a match or other open flame to check for gas leaks

Use a soap=and-water solution.

19. Check %r gas leaks,

20, Replace outer access door

Step a--Sequence of Operation

NOTE: Furnace control must be grounded fbr proper operation or

control will lock out Control is grounded through green/yellow

wire routed to gas valve and manifold bracket screw

Using the schematic diagram in Fig. 45, _Pllow the sequence of

operation through the different modes. Read and ibllow the wiring

diagram very- carefully.

NOTE: If a power intemlption occurs during a call for heat (W),

the control will start a 90-second blower-only ON period two

seconds after power is restored, if the thermostat is still calling for

gas heating. The red LED light will flash code 12 during d_e

90=second period, after which the LED will be ON continuous, as

long as no faults are detected. Afier the 90-second period, the

fl/mace will respond to the thermostat normally

The blower door must be installed for power to be condacted

through the blower door interlock switch ILK to the furnace

control (PU, transibrmer TRAN, inducer motor IDM, blower

motor BLWM, hot-surface igniter HSI, and gas vah'e GV.

1, Heating

(See Fig 25 [br thermostat connections.)

The walt thermostat "calls for heat", closing the R to W

circuit. The _:hmace control perfbnns a self-check, verifies the

pressure switch contacts PRS is open, and starts the inducer

motor IDM.

a. Inducer Prepurge Period- As the inducer motor IDM

comes up to speed, the pressure switch contacts PRS close,

24 vac power is supplied ibr a field installed humidifier at

the HI_M tenninai and the control begins a 15-second

prepurge period.

--9

b. Igniter Warm-Up- At the end of the prepurge period, the

Hot-Surface Igniter HSI is energized ibr a 17-second

igniter warn>up period.

c Trial-for-Ignition Sequence= When the igniter warn>up

period is completed the main gas valve relay contacts GVR

close to energize the gas valve GV, the gas valve opens.

The gas valve GV permits gas flow to the burners where it

is ignited by the HSI. Five seconds aker the GVR closes, a

2-second flame proving period begins. The HSI igniter will

remain energized until the flame is sensed or until the

2-second flame proving period begins.

d. Flame-Proving- When the burner flame is proved at the

flame-proving sensor eleckode FSE, the flmaace control

CPU begins the blower=ON delay period and continues to

hold the gas valve GV open. If the burner flame is not

proved within two seconds, the control CPU will close the

gas valve GV, and the control CPU will repeat the ignition

sequence ibr up to three more Trials-For-Ignition before

going to Ignition=Lockout. Lockout will be reset auto=

matically after three hours, by momentarily interrupting

115 vac power to the flu_aace, or by intem/pting 24 vac

power at SECI or SEC2 to the [hrnace control CPU (not at

W, G, R, etc.)

[f flame is proved when flame should not be present, _he

ihmace control CPU will lock out of Gas-Heating mode

and operate the inducer motor IDM until flame is no longer

proved.

e. Blower-On Delay= If the burner flame is proven, the

blower motor is energized on HEAT speed 25 seconds after

the gas valve GV is energized.

Simultaneously, the electronic air cleaner terminal EAC-!

is energized and remains energized as tong as the blower

motor BLWM is energized.

i_ Blower-Off Delay= When the thermostat is satisfied, the

R=to-W circuit is opened, de-energizing the gas valve GV,

stopping gas flow to the buraers, and de-energizing the

humidifier terminal HUM. The inducer motor IDM will

remain energized for a 5=second post-purge period. The

blower motor BLWM and air cleaner terminal EAC-I will

remain energized ibr 90, !20, 150, or 180 seconds (depend=

ing on the blower-OFF delay selection). The furnace

control CPU is fhctory=set for a 120-second blower-OFF

delay.

Cooling Mode

(See Fig. 25 _br thermostat connections)

The thermostat closes the R-to=G=and-Y circuits. The R=to=Y

circuit starts the outdoor unit, and the R=to-G and Y circuits

start the furnace blower motor BLWM on COOL speed.

The electronic air cleaner terminal EAC-I is energized with

115 vac when the blower motor BLWM is operating.

When the thermostat is satisfied, the R=to-G-and=Y circuits are

opened. The outdoor unit will stop, and the furnace blower

motor BLWM will continue operating on the (OOL speed fbr

an additional 90 seconds. (ut jumper J2 to reduce the cooling

off'delay to 5 seconds. (See Fig. 24.)

Continuous Blower Mode

When the R=to-G circuit is closed by the thermostat, the

blower motor BLWM will operate on continuous-blower

speed (same as HEAT speed). Terminal EAC-! is energized as

long as the blower motor BLWM is energized.

During a call for heat, the blower BLWM will stop during

igniter warm-up (17 seconds), ignition, and blower-ON delay

(25 seconds), allowing the Nrnace heat exchangers to heat up

more quickly, then restarts at the end of the blower-ON delay

periodatHEATspee&

Whenthethermostat"calls%r cooling", the blower motor

BLWM will operate at COOL speed When the them_ostat is

satisfie& the blower motor BLWM will operate an additional

90 seconds on COOL speed befbre reverting back to

continuous-blower speed.

When the R°to-G circuit is opened, the blower motor BLWM

will continue operating for an additional 5 seconds, if no other

_mction requires blower motor BLWM operation

4, Heat Pump

When installed with a heat pump, the _/mace control auto°

matically changes the timing sequence to avoid long blower

off times during demand defrost cycles. When the R-to-W-

and-Y or R-to°W°and-Y-and-G circuits are energized the

fi/mace control CPU will continue to turn on the blower motor

BLWM at HEAT speed, and begin a heating cycle. The

blower motor BLWM will remain on until the end of the

prepurge period, then shut off for 24 seconds then come back

on at HEAT speed. When the W input signal disappears, the

f_/mace control begins a normal inducer post-purge period and

the blower switches to (OOL speed after a 3 second delay If

the R°to-W-and°Y°and°G signals disappear at the same time,

the blower motor BLWM will remain on for the selected

blower-OFF delay period. If the R-to°W-and-Y signals disap-

pear, leaving the G signal, the blower motor BLWM will

continue rtmning the blower motor BLWM at HEAT speed

after the selected blower-OFF delay period is completed.

Step 4--Wiring Diagrams

Refkr to Fig. 25 and 45 fbr wiring diagrams

Step 5--Troubleshooting

Refkr to the sela'ice label. (See Fig 49 Service Label.)

The Troubleshooting Guide can be a useful tool in isolating

fm'nace operation problems. Beginning with tl_e word "Start,"

answer each question and fbllow the appropriate arrow to the next

item

The Guide will help to identiI:) the problem or _i_iled component.

After replacing any component, veri_y con'ect operation sequence.

Fig. 53--Troubleshooting Guide

START

is LED status on?

light

YES

is LED status light blinking rapidly without a

pause?

YES

NO NO

,_ Is there 115V at L1 and L2? _ Is door switch closed?

I Is there 24V at SEC-1 and SEC-2? _ I Is there 115V going to switch?

LBepl cefuroacecootrol ILBepl cedoorswdch

I _E_J Oh_kforcor_ectline_oltagepoI_r,_,f_oi_1 --_ RopIace#aosforme,

are twinned, check for proper low-voltage

[_1_ (24V) transfOrmer phas'ng 1

._1_ ts door switch closed?

'_Is circuit breaker closed?

YES

J Check for continuity in wire from circuit breaker

to furnace

I I Close circuit breaker and go back to START

To recall status code briefly remove and reconnect one RED wire from the draft

safeguard switch to display stored status code On RED LED control do not

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

Determine status code The status code is a was no previous fault After the control repeats the code 4 t#nes, the control

2 digit number with the first digit determined will go through a brief component test sequence The inducer will start and run

by the number of short flashes and the second for the entire component test The HSl blower motor FAN speed (AMBER LED

dig t by the number of teng flashes? boards only) HEAT speed and COOL speed will run for I0- I5 ...... ds each [ Check room thermostat or ]

Gas valve and humidifier will not be turned on interconnecting cable

$YES Was there a previous status code

wasfl shedG°t°aSel fi°n below for the status code that _L,_EB Iother than #11? INO .I Does the control respond to W Y1 (if present), I NO _1 Is 24V present at W, Y1 (if present), YIY2 or I

I I I I

Y/Y2, and G (24V) th ....... tat signals? I'_1_ G thermostat terminals on tbefu ......... trst? I

i i I/ t

$ ES

Run system through a heating or cooling cycle Disconnect all the thermostat wires from the 1

to check operation Status codes are erased furnace control

Iafter 72 hours On RED LED boards stored

(115V or 24V) is interrupted

status codes can also be erased whenever /

YES Does the problem repeat when using

I Replace f........... trol _-E.q a jum pot wire ? 1

L The thermostat is not compatible with the

furnace control Either install a ballast resistor,

connect the Com24V thermostat terminal to

the thermostat, or replace the thermostat

A02106a

NOPREVIOUSCODE-Storedcodes

areerasedatter72hoursOnREDLED

boardsstoredstatuscodescanalsobe

erasedwheneverpower(115Vor24V)

isinterruptedRunsystemthrougha

heatingorcoolingcycletochecksystem

BLOWERONAFTERPOWERUP-

(115VOR24V)-No_mal operation.

Blower runs for 90 seconds, if unit s

powered up during a cali for heat (R-W

c_osed) or when (R-W opens) during the

Mower omdelay per od.

LIMIT CIRCUIT LOCKOUT - Lockout

occurs if the limt. draft sateguard, flame

rollout, or blocked vent switch*(it used) is

open longer than 3 minutes. Control will

auto reset atter 3 hours See code 33

IGNITION LOCKOUT- System fai_ed to

ignite gas and prove flame in 4 attempts

Control will auto-reset after 3 hours

See status code 34

GAS HEATING LOCKOUT - Turn off |

power and wait 5 minutes to retry |

Check for: t

Stuck closed gas valve relay on con_ol

Miswire or short to gas valve wi e J

ABNORMAL FLAME-PROVING SIGNAL |

Flame is proved while gas vane s de-

energized Inducer wil! run untl faut is

cleared Check for:

- Stuck open or leaky' gas valve

PRESSURE SWITCH DID NOT OPEN /

Check tot: 1

- Obstructed pressure tube

- Pressure switch stuck closed

SECONDARY VOLTAGE FUSE IS OPEN

Check for:

- Short c4rcuit in secondary vo!tage (24V) _

wirng fllcluding thermostat leads |

D scon_lect thermostat leads to isolate !

short circuit

31 PRESSURE SWITCH DID NOT CLOSE

before retry If opens durng b[cwer on-

de_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.

33 LIM IT CIRCUIT FAULT - Ind cares the

limit, draft sateguard, flame to,lout, or

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

Fame rol!out swtch and BVSS requires

manual reset Check tot:

-Dirty filter or restr cted duct system

-Loose blower wheel

-Detective swtch or connections.

-Detective b_ower motor or capacitor

-Inadequate combustion ar supply

(flame rollout switch open)

-Restricted vent

- Proper vent szing

-Excessive wnd

34 IGNITION PROVING FAILURE - F flame

is not sensed during the trial for ignition

period, the contro} will repeat the ignition

sequence 3 more times before lockout

to furnace sheet metal

Flame sensor must not be grounded

To determine whether the problem is in

the gas valve, igniter, or flame sensor the

system can be operated in the component

test mode to check the igniter First

remove the R thermostat connection from

the control and nitiate the component

test sequence Does the igniter glow

orange/wh te by the end of the 15 second

warm-up period?

YE_

* Blocked vent shutoff switch used in Chimney Adapter Kit

45 CONTROL CIRCUITRY LOCKOUT

Auto-reset after 1 hour lockout due to:

Flame c rcuit ta lure

- Gas valve relay stuck open

Sottware check error

Reset power to clear lockout Replace

control if code repeats

_ Unplug igniter harness from control and initiate

another component test sequence Check 1

tot 115V between pin 1 and NEUTRAL-L2 on

thecontro_ Was115Vpresenttortbe 15 YES _ I Cbeckforcontmuityinthehamessandigniter

second period? _ Replace defective component

_ NC_ r

Reconnect the R thermostat lead and set _..g.:.2........_ Check connections If OK. replace control

thermostat to call for heat Connect voltmeter I "

receiveaCr°ssgaS24v?Vaiveconnections. Does gas valve I _._ Check that all gas valves are turned on

.I ......... Replace valve

• YES _NO 1_

Does gas valve open and allow gas to flow?

Inadequate flame carryover or rough

YES ignit on.

Low inlet gas pressure.

Do the main burners gnite? _ Proper firng rate.

B_ocked or incorrect carp!_ over gap.

YES (.045' nominal)

I Do the main burners stay on? _ Allow blower to come on and repeat test to

check for ntermittent operation

Repeat call for heat and check flame sensor Check connections and retry. If current is

I cu rent during tr,aifor,gn,t,on pe,iod ,sthe NQ _neaNO r typica, va,ue (4 0-6 0 nominal) and

I DC microamps below 05? _ I burners wll not stay on. replace control

,_ YES

microan]ps

Is current near typical value? _ Replace electrode

YES

[ _¢v111main burners ignite and stay on? _ Replace furnace contro_

YES

[Fixed 1

A05032

Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.

PC 101 Catalog No See Cover Printed Jn USA Form 58ST-13SI Pg 48 5-05 Replaces: 58ST-12SI

PAYNE Furnace/Heater, Gas Manual L0523315

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