Instruction Manual for Goodman models including: Goodman, Single-Stage, Gas Furnace
precautions and related items. Prior to actual installation, thoroughly familiarize yourself with this Instruction Manual. Pay special attention to all safety warnings.
ONLY PERSONNEL THAT HAVE BEEN TRAINED TO INSTALL, ADJUST, SERVICE OR. REPAIR (HEREINAFTER, “SERVICE”) THE EQUIPMENT SPECIFIED IN THIS MANUAL.
Installation Instructions for *MES9* & *CES9* Single-Stage Gas Furnace (Type FSP CATEGORY IV Direct or Non Direct Vent Air Furnace) (Type FSP CATÉGORIE IV Direct ou four á air soufflé non direct) These furnaces comply with requirements embodied in the American National Standard / National Standard of Canada ANSI Z21.47·CSA-2.3 Gas Fired Central Furnaces. RECOGNIZE THIS SYMBOL AS A SAFETY PRECAUTION. *NOTE: Please contact your distributor or our website for the applicable Specification Sheet referred to in this manual. Installer: Affix all manuals adjacent to the unit. As a professional installer you have an obligation to know the product better than the customer. This includes all safety precautions and related items. Prior to actual installation, thoroughly familiarize yourself with this Instruction Manual. Pay special attention to all safety warnings. Often during installation or repair it is possible to place yourself in a position which is more hazardous than when the unit is in operation. Remember, it is your responsibility to install the product safely and to know it well enough to be able to instruct a customer in its safe use. Safety is a matter of common sense...a matter of thinking before acting. Most dealers have a list of specific good safety practices...follow them. The precautions listed in this Installation Manual are intended as supplemental to existing practices. However, if there is a direct conflict between existing practices and the content of this manual, the precautions listed here take precedence. ONLY PERSONNEL THAT HAVE BEEN TRAINED TO INSTALL, ADJUST, SERVICE OR REPAIR (HEREINAFTER, "SERVICE") THE EQUIPMENT SPECIFIED IN THIS MANUAL SHOULD SERVICE THE EQUIPMENT. THE MANUFACTURER WILL NOT BE RESPONSIBLE FOR ANY INJURY OR PROPERTY DAMAGE ARISING FROM IMPROPER SERVICE OR SERVICE PROCEDURES. IF YOU SERVICE THIS UNIT, YOU ASSUME RESPONSIBILITY FOR ANY INJURY OR PROPERTY DAMAGE WHICH MAY RESULT. IN ADDITION, IN JURISDICTIONS THAT REQUIRE ONE OR MORE LICENSES TO SERVICE THE EQUIPMENT SPECIFIED IN THIS MANUAL, ONLY LICENSED PERSONNEL SHOULD SERVICE THE EQUIPMENT. IMPROPER INSTALLATION, ADJUSTMENT, SERVICING OR REPAIR OF THE EQUIPMENT SPECIFIED IN THIS MANUAL, OR ATTEMPTING TO INSTALL, ADJUST, SERVICE OR REPAIR THE EQUIPMENT SPECIFIED IN THIS MANUAL WITHOUT PROPER TRAINING MAY RESULT IN PRODUCT DAMAGE, PROPERTY DAMAGE, PERSONAL INJURY OR DEATH. PROP 65 WARNING FOR CALIFORNIA CONSUMERS Cancer and Reproductive Harm www.P65Warnings.ca.gov 90% HEX 0140M00517-A DO NOT LIFT PRODUCT USING HEAT EXCHANGER IOG-2020F 01/2021 19001 Kermier Rd., Waller, TX 77484 www.goodmanmfg.com · www.amana-hac.com ©2019-2021 Goodman Manufacturing Company, L.P. Brand is a registered trademark of Maytag Corporation or its related companies and is used under license. All rights reserved. TABLE OF CONTENTS Safety Considerations ..................................... 3 Single-Stage Heating Thermostat Application........25 Shipping Inspection......................................... 5 Fossil Fuel Applications ..................................25 Electrostatic Discharge (ESD) Precautions.............. 5 Twinning ..................................................26 To The Installer ........................................... 5 Gas Supply and Piping ......................................26 Product Application.......................................... 5 High Altitude Installation .............................26 Location Requirements & Considerations .................. 6 Propane Gas Conversion..................................26 Clearances and Accessibility .............................. 8 Gas Piping Connections...................................27 Existing Furnace Removal ................................. 8 Propane Gas Tanks and Piping ...........................29 Thermostat Location...................................... 8 Circulating Air & Filters ..................................30 Combustion & Ventilation Requirements ................. 8 Duct work - Air Flow.....................................30 Installation Positions ......................................10 Checking Duct Static ....................................30 Horizontal Applications & Considerations...............10 Bottom Return Air Opening [Upflow Models]..........31 Furnace Suspension .......................................10 Filters - Read This Section Before Installing The Return Front Cover Pressure Switch Tube Location ........10 Air Duct work .............................................31 Drain Trap and Lines ......................................10 Horizontal Installations .................................33 Leveling ....................................................10 Startup Procedure & Adjustment..........................33 Alternate Electrical and Gas Line Connections .......11 Furnace Cabinet..........................................33 Drain Pan ..................................................11 Drain Trap Priming........................................33 Freeze Protection.........................................11 Furnace Operation ........................................33 Vent Pipe & Combustion Air Pipe ......................11 Gas Supply Pressure Measurement.......................34 Materials Installations In The U.S.A. ...............12 Gas Manifold Pressure Measurement and Adjustment.34 Materials Installations In Canada ...................12 Gas Input Rate Measurement (Natural Gas Only)......35 Pipe Installation ........................................12 Temperature Rise ..........................................35 Pipe Sizing .................................................13 Circulator Blower Speeds ..............................35 Vent Pipe Connection ...................................14 Blower Heat Off Delay Timings ..........................37 Combustion Air Pipe Connection ......................14 Normal Sequence of Operation ..........................37 Alternate Vent & Intake Pipe Connections ..........15 Power Up ..................................................37 Pipe Termination .........................................16 Heating Mode ..............................................37 Vent/Intake Terminations For Installation of Multiple Cooling Mode..............................................37 Direct Vent Furnaces ....................................18 Fan Only Mode ............................................37 Concentric Vent Termination............................18 Operational Checks .........................................37 Side Wall Vent Kit ........................................18 Safety Circuit Description ..................................38 Condensate Drain Lines & Drain Trap .....................18 Integrated Control Module .............................38 General Drain Information.............................19 Primary Limit ..............................................38 Field Supplied Drain .....................................19 Auxiliary Limit .............................................38 Upflow Model Installed Vertically ...................19 Rollout Limit ..............................................38 Drain Exiting Right Side ................................19 Pressure Switches .........................................38 Drain Exiting Left Side ..................................20 Flame Sensor ..............................................38 Upflow Model Installed Horizontally with Right Side Troubleshooting ............................................38 Down .....................................................20 Electrostatic Discharge (ESD) Precautions.............38 Upflow Model Installed Horizontally with Left Side Diagnostic Chart ..........................................38 Down .......................................................20 Fault Code Retrieval ....................................38 Upflow Model Installed Horizontally With Left Side Fault Code Reset ........................................38 Down - Alternate ........................................21 Resetting From Lockout..................................39 CounterFlow Model Installed Vertically............21 Maintenance..................................................39 Drain Exiting Left Side ..................................21 Annual Inspection.........................................39 Drain Exiting Right Side ................................22 Filters ......................................................39 Counterflow Model Installed Horizontally with Burners ....................................................39 Right Side Down..........................................22 Induced Draft and Circulator Blowers .................39 Counterflow Model Installed Horizontally with Left Condensate Trap and Drain System (Qualified Servicer Side Down .................................................23 Only) .......................................................40 Electrical Connections ...................................24 Flame Sensor (Qualified Servicer Only) .................40 Wiring Harness............................................24 Flue Passages (Qualified Servicer Only) ................40 115 Volt Line Connections ..............................24 Before Leaving an Installation ............................40 115 Volt Line Voltage Connection of Accessories (Hu- Repair and Replacement Parts..............................40 midifier and Electronic Air Cleaner) .................24 Troubleshooting Chart ....................................41 Connection of 24 Volt Humidifier.....................25 Wiring Diagram .............................................51 Junction Box Relocation ................................25 Special Instructions for Products Installed in the 24 Volt Thermostat Wiring .............................25 State of Massachusetts..................................52 2 Safety Considerations Adhere to the following warnings and cautions when installing, adjusting, altering, servicing, or operating the furnace. To ensure proper installation and operation, thoroughly read this manual for specifics pertaining to the installation and application of this product. This furnace is manufactured for use with natural gas. It may be field converted to operate on L.P. gas by using the appropriate L.P. conversion kit listed in the PROPANE GAS/ HIGH ALTITUDE INSTALLATIONS section of this manual Install this furnace only in a location and position as specified in LOCATION REQUIREMENTS & CONSIDERATIONS section and INSTALLATION POSITIONS section of this manual. Provide adequate combustion and ventilation air to the furnace as specified in COMBUSTION & VENTILATION AIR REQUIREMENTS section of this manual. Combustion products must be discharged to the outdoors. Connect this furnace to an approved vent system only, as specified in VENT/FLUE PIPE & COMBUSTION AIR PIPE section of this manual. 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, as specified in GAS SUPPLY AND PIPING section of this manual. Always install a furnace to operate within the furnace's intended temperature-rise range with a duct system which has external static pressure within the allowable range, as specified on the furnace rating plate and OPERATIONAL CHECKS section of these instructions. When a furnace is installed so that supply ducts carry air circulated by the furnace to areas outside the space containing the furnace, the return air shall also be handled by duct(s) sealed to the furnace casing and terminating outside the space containing the furnace. A gas-fired furnace for installation in a residential garage must be installed as specified in the LOCATION REQUIREMENTS AND CONSIDERATIONS section of this manual. This furnace may be used as a construction site heater only if certain conditions are met. These conditions are listed in the PRODUCT APPLICATION section of this manual. CAUTION FROZEN AND BURST WATER PIPE HAZARD FAILURE TO PROTECT AGAINST THE RISK OF FREEZING MAY RESULT IN PROPERTY DAMAGE. SPECIAL PRECAUTIONS MUST BE MADE IF INSTALLING FURNACE IN AN AREA WHICH MAY DROP BELOW FREEZING. THIS CAN CAUSE IMPROPER OPERATION OR DAMAGE TO EQUIPMENT. IF THE FURNACE ENVIRONMENT HAS THE POTENTIAL OF FREEZING, THE DRAIN TRAP AND DRAIN LINE MUST BE PROTECTED. THE USE OF ACCESSORY DRAIN TRAP HEATERS, ELECTRIC HEAT TAPE AND/OR RV ANTIFREEZE IS RECOMMENDED FOR THESE INSTALLATIONS. WARNING TO PREVENT PERSONAL INJURY OR DEATH DUE TO IMPROPER INSTALLATION, ADJUSTMENT, ALTERATION, SERVICE OR MAINTENANCE, REFER TO THIS MANUAL. FOR ADDITIONAL ASSISTANCE OR INFORMATION, CONSULT A QUALIFIED INSTALLER, SERVICER AGENCY OR THE GAS SUPPLIER. WARNING IF THE INFORMATION IN THESE INSTRUCTIONS IS NOT FOLLOWED EXACTLY, A FIRE OR EXPLOSION MAY RESULT CAUSING PROPERTY DAMAGE, PERSONAL INJURY OR LOSS OF LIFE. DO NOT STORE OR USE GASOLINE OR OTHER FLAMMABLE VAPORS AND LIQUIDS IN THE VICINITY OF THIS OR ANY OTHER APPLIANCE. WHAT TO DO IF YOU SMELL GAS: DO NOT TRY TO LIGHT ANY APPLIANCE. DO NOT TOUCH ANY ELECTRICAL SWITCH; DO NOT USE ANY PHONE IN YOUR BUILDING. IMMEDIATELY CALL YOUR GAS SUPPLIER FROM A NEIGHBOR'S PHONE. FOLLOW THE GAS SUPPLIER'S INSTRUCTIONS. IF YOU CANNOT REACH YOUR GAS SUPPLIER, CALL THE FIRE DEPARTMENT. INSTALLATION AND SERVICE MUST BE PERFORMED BY A QUALIFIED INSTALLER, SERVICE AGENCY OR THE GAS SUPPLIER. WARNING HEATING UNIT SHOULD NOT BE UTILIZED WITHOUT REASONABLE, ROUTINE, INSPECTION, MAINTENANCE AND SUPERVISION. IF THE BUILDING IN WHICH ANY SUCH DEVICE IS LOCATED WILL BE VACANT, CARE SHOULD BE TAKEN THAT SUCH DEVICE IS ROUTINELY INSPECTED, MAINTAINED AND MONITORED. IN THE EVENT THAT THE BUILDING MAYBE EXPOSED TO FREEZING TEMPERATURES AND WILL BE VACANT, ALL WATER-BEARING PIPES SHOULD BE DRAINED, THE BUILDING SHOULD BE PROPERLY WINTERIZED, AND THE WATER SOURCE CLOSED. IN THE EVENT THAT THE BUILDING MAY BE EXPOSED TO FREEZING TEMPERATURES AND WILL BE VACANT, ANY HYDRONIC COIL UNITS SHOULD BE DRAINED AS WELL AND, IN SUCH CASE, ALTERNATIVE HEAT SOURCES SHOULD BE UTILIZED. WARNING TO PREVENT POSSIBLE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH DUE TO ELECTRICAL SHOCK, THE FURNACE MUST BE LOCATED TO PROTECT THE ELECTRICAL COMPONENTS FROM WATER. Drain trap must be primed at time of installation. Trap is internally partitioned; add water to both inlet ports until water appears at both sides of the outlet opening. Failure to prime trap at time of installation may have a negative effect on combustion quality and pressure switch action. 3 WARNING FIRE OR EXPLOSION HAZARD Failure to follow the safety warnings exactly could result in serious injury, death or property damage. Never test for gas leaks with an open flame. Use a commercially available soap solution made specifically for the detection of leaks to check all connections. A fire or explosion may result causing property damage, personal injury or loss of life. AVERTISSEMENT RISQUE D'INCENDIE OU D'EXPLOSION Si les consignes de sécurité ne sont pas suivies à la lettre, cela peut entraîner la mort, de graves blessures ou des dommages matériels. Ne jamais vérifier la présence de fuites de gaz au moyen d'une flamme nue. Vérifier tous les raccords en utilisant une solution savonneuse commerciale conçue spécialement pour la détection de fuites. Un incendie ou une explosion risque de se produire, ce qui peut entraîner la mort, des blessures ou des dommages matériels. CO can cause serious illness including permanent brain damage or death. Advertencia especial para la instalación de calentadores ó manejadoras de aire en áreas cerradas como estacionamientos ó cuartos de servicio. Las emisiones de monóxido de carbono pueden circular a través del aparato cuando se opera en cualquier modo. El monóxido de carbono puede causar enfermedades severas como daño cerebral permanente ó muerte. RISQUE D'EMPOISONNEMENT AU MONOXYDE DE CARBONE Cette ventilation est nécessaire pour éviter le danger d'intoxication au CO pouvant survenir si un appareil produisant du monoxyde de carbone continue de fonctionner au sein de la zone confinée. Le monoxyde de carbone peut causer des maladies graves telles que des dommages permanents au cerveau et meme la mort. 4 Shipping Inspection All units are securely packed in shipping containers tested according to International Safe Transit Association specifications. The carton must be checked upon arrival for external damage. If damage is found, a request for inspection by carrier's agent must be made in writing immediately. The furnace must be carefully inspected on arrival for damage and bolts or screws which may have come loose in transit. In the event of damage the consignee should: 1. Make a notation on delivery receipt of any visible damage to shipment or container. 2. Notify carrier promptly and request an inspection. 3. With concealed damage, carrier must be notified as soon as possible - preferably within five days. 4. File the claim with the following support documents within a nine month statute of limitations. · Original or certified copy of the Bill of Lading, or indemnity bond. · Original paid freight bill or indemnity in lieu thereof. · Original or certified copy of the invoice, showing trade and other discounts or reductions. · Copy of the inspection report issued by carrier's representative at the time damage is reported to carrier. The carrier is responsible for making prompt inspection of damage and for a thorough investigation of each claim. The distributor or manufacturer will not accept claims from dealers for transportation damage. Electrostatic Discharge (ESD) Precautions WARNING SHOULD OVERHEATING OCCUR OR THE GAS SUPPLY FAIL TO SHUT OFF, TURN OFF THE MANUAL GAS SHUTOFF VALVE EXTERNAL TO THE FURNACE BEFORE TURNING OFF THE ELECTRICAL SUPPLY. WARNING POSSIBLE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH DUE TO FIRE, EXPLOSION, SMOKE, SOOT, CONDENSATION, ELECTRICAL SHOCK OR CARBON MONOXIDE MAY RESULT FROM IMPROPER INSTALLATION, REPAIR OPERATION, OR MAINTENANCE OF THIS PRODUCT. NOTE: Discharge your body's static electricity before touching unit. An electrostatic discharge can adversely affect electrical components. Use the following precautions during furnace installation and servicing to protect the integrated control module from damage. By putting the furnace, the control, and the person at the same electrostatic potential, these steps will help avoid exposing the integrated control module to electrostatic discharge. This procedure is applicable to both installed and non-installed (ungrounded) furnaces. 1. Disconnect all power to the furnace. Do not touch the integrated control module or any wire connected to the control prior to discharging your body's electrostatic charge to ground. 2. Firmly touch a clean, unpainted, metal surface of the furnaces near the control. Any tools held in a person's hand during grounding will be discharged. 3. Service integrated control module or connecting wiring following the discharge process in step 2. Use caution not to recharge your body with static electricity; (i.e., do not move or shuffle your feet, do not touch ungrounded objects, etc.). If you come in contact with an ungrounded object, repeat step 2 before touching control or wires. 4. Discharge your body to ground before removing a new control from its container. Follow steps 1 through 3 if installing the control on a furnace. Return any old or new controls to their containers before touching any ungrounded object. To The Installer Before installing this unit, please read this manual thoroughly to familiarize yourself with specific items which must be adhered to, including but not limited to: unit maximum external static pressure, gas pressures, BTU input rating, proper electrical connections, circulating air temperature rise, minimum or maximum CFM, and motor speed connections. Product Application This furnace is primarily designed for residential home-heating applications. It is NOT designed or certified for use in mobile homes, trailers or recreational vehicles. Neither is it designed or certified for outdoor applications. The furnace must be installed indoors (i.e., attic space, crawl space, or garage area provided the garage area is enclosed with an operating door). This furnace can be used in the following non-industrial commercial applications: Schools, Office buildings, Churches, Retail stores, Nursing homes, Hotels/motels, Common or office areas In such applications, the furnace must be installed with the following stipulations: · It must be installed per the installation instructions provided and per local and national codes. · It must be installed indoors in a building constructed on site. · It must be part of a ducted system and not used in a free air delivery application. · It must not be used as a "make-up" air unit. · It must be installed as a two-pipe systems for combustion air. · All other warranty exclusions and restrictions apply This furnace is an ETL dual-certified appliance and is appropriate for use with natural or propane gas (NOTE: If using propane, a propane conversion kit is required). 5 Dual certification means that the combustion air inlet pipe is optional and the furnace can be vented as a: Non-direct vent (single pipe) central forced air furnace in which combustion air is taken from the installation area or from air ducted from the outside or, Direct vent (dual pipe) central forced air furnace in which all combustion air supplied directly to the furnace burners through a special air intake system outlined in these instructions. WARNING TO PREVENT PROPERTY DAMAGE, PERSONAL INJURY OR DEATH DUE TO FIRE, DO NOT INSTALL THIS FURNACE IN A MOBILE HOME, TRAILER, OR RECREATIONAL VEHICLE. This furnace may be used as a construction site heater ONLY if all of the following conditions are met: · The vent system is permanently installed per these installation instructions. · A room thermostat is used to control the furnace. Fixed jumpers that provide continuous heating CANNOT be used and can cause long term equipment damage. Bimetal thermostats, or any thermostat affected by vibration, must not be used during construction. · Return air ducts are provided and sealed to the furnace. · A return air temperature range between 60ºF (16ºC) and 80ºF (27ºC) is maintained. · MERV 11 pleated minimum 4.0" thick (Example P/N AMP-11-2025-45) air filter(s) are installed in the system and inspected daily and replaced as needed during construction and upon completion of construction. · The input rate and temperature rise are set per the furnace rating plate. · The furnace must be installed as a two pipe system, using 100% outside air for combustion during construction. · The furnace heat exchanger, components, duct system, air filters and evaporator coils are thoroughly cleaned following final construction clean up by a qualified person. · All furnace operating conditions (including ignition, input rate, temperature rise and venting) are verified according to these installation instructions. · Furnace doors must be in place on the furnace while the furnace is operating in any mode. · Damage or repairs due to failure to comply with these requirements are not covered under the warranty. NOTE: The Commonwealth of Massachusetts requires that the following additional requirements must also be met: · Gas furnaces must be installed by a licensed plumber or gas fitter. · A T-handle gas cock must be used. · If the unit is to be installed in an attic, the passageway to and the service area around the unit must have flooring. To ensure proper furnace operation, install, operate and maintain the furnace in accordance with these installation and operation instructions, all local building codes and ordinances. In their absence, follow the latest edition of the National Fuel Gas Code (NFPA 54/ANSI Z223.1), and/ or CAN/CSA B149.1-15 Installation Codes, local plumbing or waste water codes, and other applicable codes. A copy of the National Fuel Gas Code (NFPA 54/ANSI Z223.1) can be obtained from any of the following: American National Standards Institute 23 West 43rd Street, 4th Floor New York, NY 10036 National Fire Protection Association 1 Batterymarch Park Quincy, MA 02169-7471 CSA International 8501 East Pleasant Valley Independence, OH 441311 The rated heating capacity of the furnace should be greater than or equal to the total heat loss of the area to be heated. The total heat loss should be calculated by an approved method or in accordance with "ASHRAE Guide" or "Manual J-Load Calculations" published by the Air Conditioning Contractors of America. A copy of the CAN/CSA B149.1-15 Installation Codes can also be obtained from: CSA International 178 Rexdale Boulevard Etobicoke, Ontario, Canada M9W 1R3 Location Requirements & Considerations Follow the instructions listed below and the guidelines provided in the Combustion and Ventilation Air Requirements section when selecting a furnace location. WARNING TO PREVENT POSSIBLE EQUIPMENT DAMAGE, PROPERTY DAMAGE, PERSONAL INJURY OR DEATH, THE FOLLOWING BULLET POINTS MUST BE OBSERVED WHEN INSTALLING THIS UNIT. WARNING POSSIBLE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH DUE TO FIRE, EXPLOSION, SMOKE, SOOT, CONDENSATION, ELECTRICAL SHOCK OR CARBON MONOXIDE MAY RESULT FROM IMPROPER INSTALLATION, REPAIR OPERATION, OR MAINTENANCE OF THIS PRODUCT. · Centrally locate the furnace with respect to the proposed or existing air distribution system. · Ensure the temperature of the return air entering the furnace is between 55°F and 100°F when the furnace is heating. · Provide provisions for venting combustion products outdoors through a proper venting system. Special consideration should be given to vent/flue pipe routing and combustion air intake pipe when applicable. Refer to Vent/Flue Pipe and Combustion Air Pipe -Termination Locations for appropriate termination 6 locations and to determine if the piping system from furnace to termination can be accomplished within the guidelines given. NOTE: The length of flue and/or combustion air piping can be a limiting factor in the location of the furnace. · Locate the furnace so condensate flows downwards to the drain. Do not locate the furnace or its condensate drainage system in any area subject to below freezing temperatures without proper freeze protection. · Ensure adequate combustion air is available for the furnace. Improper or insufficient combustion air can expose building occupants to gas combustion products that could include carbon monoxide. Refer to Combustion and Ventilation Air Requirements. · Set the furnace on a level floor to enable proper condensate drainage. If the floor becomes wet or damp at times, place the furnace above the floor on a concrete base sized approximately 1-1/2" larger than the base of the furnace. Refer to the Horizontal Applications and Considerations for leveling of horizontal furnaces. · Ensure upflow or horizontal furnaces are not installed directly on carpeting, or any other combustible material. The only combustible material allowed is wood. · A special accessory sub-base must be used for upright counterflow unit installations over any combustible material (including wood). Refer to sub-base instructions for installation details. (NOTE: A sub-base will not be required if an air conditioning coil is located beneath the furnace between the supply air opening and the combustible floor. · Exposure to contaminated combustion air will result in safety and performance-related problems. Do not install the furnace where the combustion air is exposed to the following substances: permanent wave solutions chlorinated waxes or cleaners chlorine-based carbon tetrachloride water softening chemicals swimming pool chemicals deicing salts or chemicals halogen type refrigerants printing inks cleaning solutions (such as perchloroethylene) paint removers varnishes hydrochloric acid cements and glues antistatic fabric softeners for clothes dryers masonry acid washing materials · Enclose a non-direct vent furnace if it is installed near an area frequently contaminated by any of the above substances. This protects the non- direct vent furnace from airborne contaminants. To ensure that the enclosed non-direct vent furnace has an adequate supply of combustion air, provide air from a nearby uncontaminated room or from outdoors. Refer to the Combustion and Ventilation Air Requirements for details. · If the furnace is used in connection with a cooling coil unit, install the furnace upstream or in parallel with the cooling coil unit. Premature heat exchanger failure will result if the cooling unit is placed ahead of the furnace. For vertical (upflow or downflow) applications, the minimum cooling coil width shall not be less than furnace width minus 1". Additionally, a coil installed above an upflow furnace or under a counterflow furnace may be the same width as the furnace or may be one size larger than the furnace. Example: a "C" width coil may be installed with a "B" width furnace. For upflow applications, the front of the coil and furnace must face the same direction. · If the furnace is installed in a residential garage, position the furnace so that the burners and ignition source are located not less than 18 inches (457 mm) above the floor. Protect the furnace from physical damage by vehicles. · If the furnace is installed horizontally, ensure the access doors are not on the "up/top" or "down/ bottom" side of the furnace. · Do not connect this furnace to a chimney flue that serves a separate appliance designed to burn solid fuel. · On Counterflow Installations, the air conditioning coil must be downstream on the supply (positive) side of the furnace heat exchanger. · Counterflow Installation over a noncombustible floor. Before setting the furnace over the plenum opening, ensure the surface around the opening is smooth and level. A tight seal should be made between the furnace base and floor by using a silicone rubber caulking compound or cement grout. · Counterflow Installation over a combustible floor. If installation over a combustible floor becomes necessary, use an accessory sub-base (see Specification Sheet applicable for your model for details.) A special accessory sub-base must be used for upright counterflow unit installations over any combustible material including wood. Refer to sub-base instructions for installation details. Follow the instructions with the sub-base for proper installation. Do not install the furnace directly on carpeting, tile, or other combustible material other than wood flooring. (NOTE: The sub-base will not be required if an air conditioning coil is installed between the supply air opening on the furnace and the floor.) 7 *MES[92 & 96]* MINIMUM CLEARANCES TO COMBUSTIBLE MATERIALS (INCHES) POSITION* SIDES REAR FRONT BOTTOM FLUE TOP Upflow 0" 0" 3" C 0" 1" Horizontal 6" 0" 3" C 0" 6" C = If placed on combustible floor, floor MUST be wood only. *CES[92 & 96]* MINIMUM CLEARANCES TO COMBUSTIBLE MATERIALS (INCHES) POSITION* SIDES REAR FRONT BOTTOM FLUE TOP Counterflow 0" 0" 3" NC 0" 1" Horizontal 6" 0" 3" C 0" 6" C = If placed on combustible floor, floor MUST be wood only. NC = For installation on non-combustible floors only. A combustible subbase must be used for installations on combustible flooring. TOP TOP NOTE: In addition to the required clearances to combustible materials, a minimum of 24 inches service clearance must be available in front of the unit. A furnace installed in a confined space (i.e., a closet or utility room) must have two ventilation openings with a total minimum free area of 0.25 square inches per 1,000 BTU/hr of furnace input rating. Refer to Specification Sheet applicable to your model for minimum clearances to combustible surfaces. One of the ventilation openings must be within 12 inches of the top; the other opening must be within 12 inches of the bottom of the confined space. In a typical construction, the clearance between the door and door frame is usually adequate to satisfy this ventilation requirement. Existing Furnace Removal NOTE: When an existing furnace is removed from a venting system serving other appliances, the venting system may be too large to properly vent the remaining attached appliances. SIDE SIDE SIDE BOTTOM BOTTOM Upflow Counterflow Horizontal Figure 1 Clearances and Accessibility NOTES: · For servicing or cleaning, a 24" front clearance is required. · Unit connections (electrical, flue and drain) may necessitate greater clearances than the minimum clearances listed above. · Clearance in accordance with local installation codes, the requirements of the gas supplier and the manufacturer's installation instructions. Dégaugement conforme aux codes d'installation locaux, aux exigences du fournisseur de gaz et aux instructions d'installation du fabricant. · In all cases, accessibility clearance must take precedence over clearances from the enclosure where accessibility clearances are greater. Installations must adhere to the clearances to combustible materials to which this furnace has been design certified. The minimum clearance information for this furnace is provided on the unit's clearance label. These clearances must be permanently maintained. Clearances must also accommodate an installation's gas, electrical, and drain trap and drain line connections. If the alternate combustion air intake or vent/flue connections are used additional clearance must be provided to accommodate these connections. Refer to Vent/Flue Pipe and Combustion Air Pipe for details. The following vent testing procedure is reproduced from the American National Standard/National Standard of Canada for Gas-Fired Central Furnaces ANSI Z21.47, CSA-2.3 latest edition Section 1.23.1. Thermostat Location The thermostat should be placed approximately five feet from the floor on a vibration-free, inside wall in an area having good air circulation. Do not install the thermostat where it may be influenced by any of the following: · Drafts, or dead spots behind doors, in corners, or under cabinets. · Hot or cold air from registers. · Radiant heat from the sun. · Light fixtures or other appliances. · Radiant heat from a fireplace. · Concealed hot or cold water pipes, or chimneys. · Unconditioned areas behind the thermostat, such as an outside wall. Consult the instructions packaged with the thermostat for mounting instructions and further precautions. Combustion & Ventilation Requirements Improved construction and additional insulation in buildings have reduced heat loss by reducing air infiltration and escape around doors and windows. These changes have helped in reducing heating/cooling costs but have created a problem supplying combustion and ventilation air for gas fired and other fuel burning appliances. Appliances that pull air out of the house (clothes dryers, exhaust fans, fireplaces, etc.) increase the problem by starving appliances for air. 8 WARNING CARBON MONOXIDE POISONING HAZARD Failure to follow the steps outlined below for each appliance connected to the venting system being placed into operation could result in carbon monoxide poisoning or death. The following steps shall be followed with each appliance connected to the venting system placed in operation, while any other appliances connected to the venting system are not in operation: 1. Seal any unused openings in the venting system. 2. Inspect the venting system for proper size and horizontal pitch, as required by the National Fuel Gas Code, ANSI Z223.1 or the Natural Gas and Propane Installation Code, CSA B149.1-15 and these instructions. Determine that there is no blockage or restriction, leakage, corrosion and other deficiencies which could cause an unsafe condition. 3. As far as practical, close all building doors and windows and all doors between the space in which the appliance(s) connected to the venting system are located and other spaces of the building. 4. Close fireplace dampers. 5. Turn on clothes dryers and any appliance not connected to the venting system. Turn on any exhaust fans, such as range hoods and bathroom exhausts, so they shall operate at maximum speed. Do not operate a summer exhaust fan. 6. Follow the lighting instructions. Place the appliance being inspected in operation. Adjust thermostat so appliance shall operate continuously. 7. Test for spillage from draft hood 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 corrected in accordance with the National Fuel Gas Code ANSI Z223.1/NFPA 54 and/or National Gas and Propane Installation Code CSA B149.1-15. 9. After it has been determined that each appliance connected to the venting system properly vents when tested as outlined above, return doors, windows, exhaust fans, fireplace dampers and any other gas burning appliance to their previous conditions of use. AVERTISSEMENT RISQUE D'INTOXICATION AU MONOXYDE DE CARBONE Si les étapes décrites ci-dessous ne sont pas suivies pour chacun des appareils raccordés au système de ventilation au moment de sa mise en marche, cela peut entraîner une intoxication au monoxyde de carbone ou la mort. Les étapes suivantes doivent être suivies pour chacun des appareils raccordés au système de ventilation au moment de sa mise en marche, alors que tous les autres appareils raccordés au système de ventilation ne sont pas en marche : 1) Sceller toutes les ouvertures inutilisées du système de ventilation. 2) Inspecter le système de ventilation afin de vérifier si la taille et l'inclinaison par rapport à l'horizontale sont conformes aux exigences du National Fuel Gas Code, ANSI Z223.1/NFPA 54 ou du Code d'installation du gaz naturel et du propane, CSA B149.1 et à ces instructions. Vérifier qu'il n'y a pas d'obstruction ou de restriction, de fuite, de corrosion et d'autres problèmes qui pourraient entraîner une situation dangereuse. 3) Si possible, fermer toutes les portes et fenêtres du bâtiment ainsi que toutes les portes séparant l'endroit où se trouvent les appareils raccordés au système de ventilation et les autres zones du bâtiment. 4) Fermer le registre des foyers. 5) Mettre les sécheuses en marche ainsi que tous les autres appareils qui ne sont pas raccordés au système de ventilation. Mettre en marche tous les ventilateurs de tirage, comme celui des hottes de cuisine et des salles de bains, et les régler à la puissance maximale. Ne pas mettre en marche les ventilateurs d'été. 6) Suivre les instructions d'allumage. Mettre en marche l'appareil soumis à l'inspection. Régler le thermostat de manière à ce que l'appareil fonctionne en continu. 7) Vérifier la présence de fuite au niveau de l'ouverture du coupe-tirage des appareils qui en sont dotés après 5 minutes de fonctionnement du brûleur principal. Utiliser la flamme d'une allumette ou d'une bougie. 8) Si un problème de ventilation est observé pendant l'un des essais décrits ci-dessus, des correctifs doivent être apportés au système de ventilation conformément au National Fuel Gas Code, ANSI Z223.1/NFPA 54 et (ou) au Code d'installation du gaz naturel et du propane, CSA B149.1. 9) Une fois qu'il a été déterminé que chaque appareil raccordé au système de ventilation fonctionne correctement au moyen des essais décrits ci-dessus, les portes, les fenêtres, les ventilateurs, les registres de foyer et tous les autres appareils de combustion alimentés au gaz doivent être remis dans leur état initial. 9 House depressurization can cause back drafting or improper combustion of gas-fired appliances, thereby exposing building occupants to gas combustion products that could include carbon monoxide. If this furnace is to be installed in the same space with other gas appliances, such as a water heater, ensure there is an adequate supply of combustion and ventilation air for the other appliances. Refer to the latest edition of the National Fuel Gas Code NFPA 54/ANSI Z223.1 or CAN/CSA B1491-15 Installation Codes or applicable provisions of the local building codes for determining the combustion air requirements for the appliances. Most homes will require outside air be supplied to the furnace area by means of ventilation grilles or ducts connecting directly to the outdoors or spaces open to the outdoors such as attics or crawl spaces. Installation Positions This furnace may be installed in an upright position or horizontal on either the left or right side panel. Do not install this furnace on its back. For upright upflow furnaces, return air ductwork may be attached to the side panel(s) and/ or basepan. For horizontal upflow furnaces, return air ductwork must be attached to the basepan. For both upright or horizontal counterflow furnaces, return ductwork must be attached to the basepan (top end of the blower compartment). NOTE: Ductwork must never be attached to the back of the furnace. Contact your distributor for proper airflow requirements and number of required ductwork connections. Refer to "Recommended Installation Positions" figure for appropriate installation positions, ductwork connections, and resulting airflow arrangements. Horizontal Applications & Considerations 2"X2"X3/8" ANGLE IRON (3 PLACES) When installing a furnace horizontally, additional consideration must be given to the following: Furnace Suspension If suspending the furnace from rafters or joists, use 3/8" threaded rod and 2"x2"x1/8" angle iron as shown in the following diagram. The length of rod will depend on the application and the clearances necessary. If the furnace is installed in a crawl space it must be suspended from the floor joist or supported by a concrete pad. Never install the furnace on the ground or allow it to be exposed to water. Front Cover Pressure Switch Tube Location When a furnace is installed horizontally with left side down, the front cover pressure switch tube must be re-located to the lower port of the collector box cover. 1. Remove tube from front cover pressure switch and collector box cover. 2. Remove rubber plug from bottom collector box port and install on top collector box port. 3. Locate 24" x 1/4" tube in bag assembly. 4. Install one end on front cover pressure switch. 5. Route tube to lower port on collector box cover and cut off excess tubing. Drain Trap and Lines In horizontal applications the condensate drain trap is secured to the furnace side panel, suspending it below the furnace. A minimum clearance of 5.5" below the furnace must be provided for the drain trap. Additionally, the appropriate downward piping slope must be maintained from the drain trap to the drain location. Refer to Condensate Drain Trap and Lines for further details. If the drain trap and drain line will be exposed to temperatures near or below freezing, adequate measures must be taken to prevent condensate from freezing. Leveling Leveling ensures proper condensate drainage from the heat exchanger. For proper flue pipe drainage, the furnace must be level lengthwise from end to end. The furnace should have a slight tilt from back to front with the access doors downhill from the back panel approximately 1/2 to 3/4 inches. The slight tilt allows the heat exchanger condensate, generated in the recuperator coil, to flow forward to the recuperator coil front cover. Figure 2 10 Figure 3A Figure 3B Freeze Protection If the drain line is routed through an area which may see temperatures near or below freezing, precautions must be taken to prevent condensate from freezing within the drain line. WARNING POSSIBLE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH MAY OCCUR IF THE CORRECT CONVERSION KITS ARE NOT INSTALLED. THE APPROPRIATE KITS MUST BE APPLIED TO ENSURE SAFE AND PROPER FURNACE OPERATION. ALL CONVERSIONS MUST BE PERFORMED BY A QUALIFIED INSTALLER OR SERVICE AGENCY. Gas Altitude Kit Orifice Manifold Pressure High Stage Low Stage Pressure Switch Change Natural None #45 3.5" w.c. 1.9" w.c. 0-7000 Propane LPM-07* 1 1.25mm 10.0" w.c. 6.0" w.c. None None 1 LPM-07* supports both Honeywell and White-Rodgers 1-stage valves NOTE: In Canada, gas furnaces are only certified to 4500 feet. Vent Pipe & Combustion Air Pipe Figure 3C Recommended Installation Positions Alternate Electrical and Gas Line Connections This furnace has provisions allowing for electrical and gas line connections through either side panel. In horizontal applications the connections can be made either through the "top" or "bottom" of the furnace. Drain Pan A drain pan must be provided if the furnace is installed above a conditioned area. The drain pan must cover the entire area under the furnace (and air conditioning coil if applicable). WARNING UPON COMPLETION OF THE FURNACE INSTALLATION, CAREFULLY INSPECT THE ENTIRE FLUE SYSTEM BOTH INSIDE AND OUTSIDE OF THE FURNACE TO ASSURE IT IS PROPERLY SEALED. LEAKS IN THE FLUE SYSTEM CAN RESULT IN SERIOUS PERSONAL INJURY OR DEATH DUE TO EXPOSURE TO FLUE PRODUCTS, INCLUDING CARBON MONOXIDE. WARNING FAILURE TO FOLLOW THESE INSTRUCTIONS CAN RESULT IN BODILY INJURY OR DEATH. CAREFULLY READ AND FOLLOW ALL INSTRUCTIONS GIVEN IN THIS SECTION. This manual will refer to the pipe that discharges products of combustion to the outdoors as the "vent" pipe or "flue" pipe. The pipe that supplies air for combustion to the furnace will be referred to as the "intake" pipe or "combustion air" pipe. This furnace is dual certified and may be installed as a non-direct vent (single pipe) or direct vent (dual pipe) appliance. 11 Materials Installations In The U.S.A. PVC, CPVC, or ABS pipe & fittings are typically used as venting and intake pipe materials. All 90° elbows must be medium or long radius types. A medium radius elbow should measure ~3-1/16" minimum from the plane of one opening to the center line of the other opening for 2" diameter pipe, and ~4-9/16" minimum for 3" pipe. In addition to these materials, Innoflue® by Centrotherm Eco Systems and PolyPro® by M&G Duravent are also approved vent and combustion air materials for installations in the U.S.A. Manufacturers Installation instructions for these products must be followed. These products have specific instructions for installing, joining and terminating. Do not mix materials or components of one manufacturer with materials or components of another manufacturer. Refer to the following chart for plastic pipe & fittings specifications. Materials Installations In Canada All installations in Canada must conform to the requirements of CAN/CSA B149.1-15 code. All vent components, including primer and cement, must be listed to ULC S636. The certified pipe and fittings should be clearly marked with the ULC standard "S636". The primer and cement used must be of the same manufacturer as the vent system. For Royal Pipe System 636; use GVS-65 Primer (Purple) and GVS-65 PVC Solvent Cement. For IPEX System 636, use PVC/CPVC Primer, Purple or clear. Use PVC Solvent cement (Gray). For Canadian installations, ABS may be used as a combustion air pipe only. ABS is not an approved vent material in Canada. If ABS is used as a combustion air pipe, it must be CSA certified. Always follow the manufacturer's instructions in the use of primer and cement. Do not use primer and cement around potential sources of ignition. Do not use primer or cement beyond its expiration date. VENTING MATERIAL REQUIREMENTS PVC ASTM STANDARD SCHEDULE 40 PIPE SCHEDULE 40 CELLULAR CORE PIPE SDR 21 OR 26 PIPE FITTINGS D1785 F891 D2241 D2466 ABS SCHEDULE 40 PIPE SCHEDULE 40 CELLULAR CORE PIPE FITTINGS D1527 F628 D2468 CPVC SCHEDULE 40 PIPE SDR 21 OR 26 PIPE F441 F442 FITTINGS F438 POLYPROPYLENE INNOFLUE® (CENTROTHERM) POLYPRO® (DURAVENT) PRIMER & SOLVENT CEMENT PVC PRIMER CPVC PRIMER PVC SOLVENT CEMENT CPVC SOLVENT CEMENT ABS SOLVENT CEMENT F656 F656 D2564 F493 D2235 ABS / PVC / CPVC ALL PURPOSE CEMENT (FOR PIPE & FITTINGS OF THE SAME MATERIAL) D2564, D2235, F493 TRANSITION CEMENT FOR ABS TO PVC or CPVC D3188 INSTALLATIONS IN CANADA PVC & CPVC PIPE & FITTINGS PVC & CPVC SOLVENT CEMENT TRANSITION CEMENT ULC S636 INNOFLUE® (CENTROTHERM) POLYPRO® (DURAVENT) Pipe Installation This furnace is manufactured with 2" CPVC vent & intake couplings. Use transition cement to connect PVC or ABS pipe to these fittings. For furnaces requiring installation of 3" pipe, the transition from 2" to 3" should be done as close to the furnace as possible, and only when the piping is sloped enough to prevent condensation from collecting. This furnace must not be connected to Type B, BW, or L vent or vent connector, and must not be vented into masonry chimney. A masonry chimney may be used as a chase or passage way for approved venting materials providing the masonry chimney is not also being used to vent products of combustion. Never common vent this appliance with another appliance. Never use a vent which is used by a solid fuel appliance. 12 Piping may run vertically or horizontally and must be adequately supported to prevent strain on joints, sagging, separation, and detachment from the furnace. Horizontal runs of piping must be supported every three to five feet. Condensation within the furnace secondary heat exchanger and in the vent pipe is a normal occurrence. Vent pipe must be installed to maintain a minimum 1/4 inch per foot downward slope toward the furnace to return condensate to the furnace's drain system. Condensation may also occur in the intake pipe. This commonly takes place during the summer months when humid air enters an intake pipe that runs through a cool basement or other conditioned space. If the combustion air intake pipe is to be installed above a finished ceiling or other area where dripping of condensate will be objectionable, insulating the combustion air pipe may be necessary. Use 1/2" thick closed cell foam insulation where required. Refer to intake pipe options for using the RF000142 kit and managing condensation. PREFERRED Precautions must be taken to prevent condensate from freezing inside the vent pipe. All vent piping exposed to freezing temperatures must be insulated with 1/2" thick closed cell foam. Inspect piping for leaks prior to installing insulation. WARNING TO AVOID BODILY INJURY, FIRE OR EXPLOSION, SOLVENT CEMENTS MUST BE KEPT AWAY FROM ALL IGNITION SOURCES (I.E., SPARKS, OPEN FLAMES, AND EXCESSIVE HEAT) AS THEY ARE COMBUSTIBLE LIQUIDS. AVOID BREATHING CEMENT VAPORS OR CONTACT WITH SKIN AND/OR EYES. Pipe Sizing Consult tables 4&5 to determine what diameter piping is required for your installation. Lengths shown in the chart apply to single pipe & two pipe installations. In a two pipe installation the length shown refers to only one pipe, vent or intake. Both pipes would normally be equal in length, if different, then the longest pipe must be within the limits of table 4. It is preferable to up-size from 2" to 2.5" or 3" pipe if the pipe length & elbow count are near maximum. This will help avoid nuisance pressure switch opening caused by prevailing winds & sudden changes in atmospheric pressure. Figure 4 ACCEPTABLE TRANSITION NO LESS THAN 45 DEGREES TO HORIZONTAL PLANE TO AVOID CREATING A WATER TRAP IN VENT PIPING. Figure 5 NO TRANSITION ON HORIZONTAL PLANE, THIS CREATES A WATER TRAP AND RESTRICTS FLUE GASES *MES92 Direct Vent (2-Pipe) and Non-Direct Vent (1-Pipe) (6) Maximum Allowable Length of Vent/Flue Pipe (1) (2) Number of Elbows (3) (5) M ODEL PIPE SIZE 1 2 3 4 5 6 7 8 (4) *M ES920403AN *M ES920603BN *M ES920803BN *M ES920804CN *M ES920805CN *M ES921004CN *M ES921005CN *M ES921205DN 2 75 70 65 60 55 50 45 40 3 114 107 100 93 86 79 72 65 2 55 50 45 40 35 30 25 20 3 127 120 113 106 99 92 85 78 2^ 30 25 20 15 10 5 N/A N/A 3^ 72 65 58 51 44 37 30 23 2^ 30 25 20 15 10 5 N/A N/A 3^ 72 65 58 51 44 37 30 23 2^ 40 35 30 25 20 15 10 5 3 72 65 58 51 44 37 30 23 2 60 55 50 45 40 35 30 25 3 168 161 154 147 140 133 126 119 2 30 25 20 15 10 5 N/A N/A 3 113 106 99 92 85 78 71 64 2 N/A N/A N/A N/A N/A N/A N/A N/A 3 65 58 51 44 37 30 23 16 7,000 ft altitude or above use 3" pipe ^ *MES920402BN - add 20' of 2" pipe for upflow position ^ *MES920803BN - add 10' of 2" pipe for upflow position, add 66' of 3" pipe for upflow position ^ *MES920804CN - add 25' of 2" pipe for upflow position, add 58' of 3" pipe for upflow position ^ *MES920805CN - add 15' of 2" pipe for upflow position, add 58' of 3" pipe for upflow position Table 4 Figure 6 13 *MES96 / *CES96 Direct Vent (2-Pipe) and Non-Direct Vent (1-Pipe) (6) Maximum Allowable Length of Vent/Flue Pipe (1) (2) M ODEL Number of Elbows (3) (5) PIPE SIZE 1 2 3 4 5 6 7 8 (4) *M ES960403AN 2 75 70 65 60 55 50 45 40 3 114 107 100 93 86 79 72 65 *M ES960603BN 2 45 40 35 30 25 20 15 10 3 168 161 154 147 140 133 126 119 *M ES960803BN 2^ 35 30 25 20 15 10 5 N/A 3 168 161 154 147 140 133 126 119 *M ES960804CN 2 60 55 50 45 40 35 30 25 3 113 106 99 92 85 78 71 64 *M ES960805CN 2 45 40 35 30 25 20 15 10 3 120 113 106 99 92 85 78 71 *M ES961004CN 2 N/A N/A N/A N/A N/A N/A N/A N/A 3 144 137 130 123 116 109 102 95 *M ES961005CN 2 40 35 30 25 20 15 10 5 3 151 144 137 130 123 116 109 102 *M ES961205DN 2 N/A N/A N/A N/A N/A N/A N/A N/A 3 158 151 144 137 130 123 116 109 *CES960603BN 2 45 40 35 30 25 20 15 10 3 168 161 154 147 140 133 126 119 *CES960804CN *CES961005CN *CES961205DN 2 40 35 30 25 20 15 10 5 3 120 113 106 99 92 85 78 71 2 N/A N/A N/A N/A N/A N/A N/A N/A 3 113 106 99 92 85 78 71 64 2 N/A N/A N/A N/A N/A N/A N/A N/A 3 110 103 96 89 82 75 68 61 Table 5 7^1,**0.MM00EESSftfM99a66olt00ait48ru00xd23eiBBinoNmNrl-a-ebaauoddtvddme22ua50s''aeonoff3l22d"l""poppipifippweleeuffaoorerbuupplfaflloeowwnplpdooissmiittNiiooinnOtsTliastceodmobniinnadtiivoind.ual lengths 2. Minimum requirement for each vent pipe if five (5) feet in length and one elbow/tee. 3. Tee used in the vent/flue termination must be included when determining the number of elbows in the piping system. 4. 2 ½" or 3" diameter pipe can be used in place of 2" diameter pipe. 5. Increased Clearance Configuration using (2) 45 deg. Long Sweep elbows should be considered equivalent to one 90 deg. elbow. 6. One 90° elbow should be secured to the combustion air intake connection. Vent Pipe Connection The vent pipe outlet is sized to accept 2" pipe. Secure vent pipe directly into the furnace fitting with the appropriate glue. Alternately, a small section of 2" pipe may be glued in the furnace socket and a rubber coupling installed to allow removal for future service. Piping should be routed in a manner to avoid contact with refrigerant lines, metering devices, condensate drain lines, etc. If necessary, clearances may be increased by creating an offset using two 45° elbows (Figure 7). 45 DEGREE ELBOWS Increased Clearance Configuration Figure 7 Combustion Air Pipe Connection If the furnace is being installed without a combustion air pipe, a 90° elbow should be used on the combustion air intake to guard against blockage. On up flow / horizontal models, secure the combustion air intake pipe to the air intake coupling using a rubber coupling supplied with the furnace. The rubber coupling may be omitted by inverting the intake coupling and gluing pipe directly to it. Piping may also be glued to the intake coupling in its original position by using a plastic coupling. On counterflow units secure the combustion air intake pipe to the air intake coupling using the rubber coupling and worm gear hose clamps provided with the unit. The counterflow rubber coupling allows service removal of air intake piping internal to the furnace blower compartment. The combustion air intake pipe can also be secured directly to the counterflow unit air intake pipe coupling. Combustion Air Intake Options The RF000142 coupling (Figure 9) can be secured directly to the furnace intake coupling if condensation/rain water is a concern. If the RF000142 is used on the combustion air inlet, it must be installed with the arrow pointing up. It should be noted, the combustion air will actually be moving in a direction opposite of the arrow on the RF000142 coupling. It must have a field supplied, trapped drain tube free-draining to a proper condensate disposal location. A loop in the drain tube can serve as a trap. The unused RF000142 drain fitting must be capped. A field supplied tee installed in the intake pipe is also an acceptable method of catching condensation. It must have a field supplied, trapped drain tube or pipe, free-draining to a proper condensate disposal location. A loop in the drain tube can serve as a trap. WARNING EDGES OF SHEET METAL HOLES MAY BE SHARP. USE GLOVES AS A PRECAUTION WHEN REMOVING HOLE PLUGS. 14 Alternate Vent & Intake Pipe Connections (Upflow/Horizontal models only) When installing a furnace horizontally with the left side down, alternate flue and combustion air pipe connections may be used. This method allows the flue and combustion air piping to be run vertically through the side of the furnace (facing up in horizontal left). The alternate vent location is the 3" hole directly in line with the induced draft blower outlet. When using the horizontal alternate vent configuration, you must use the RF000142 vent drain kit. See Figures 8-11 & follow steps below. NOTE: In the horizontal left installation position, a means of condensate collection must be provided to keep vent pipe condensate from entering the draft inducer housing. If the vent drain elbow is eliminated from the installation, the RF000142 kit must be used. Exhaust Combustion Air Insert flange. Cut 2 ½" long. RF000142 Figure 8 Tee Installation in Intake Pipe Figure 11 VENT-DRAIN Figure 9 Figure 10 1. Remove the four screws from the vent pipe flange on top the furnace. 2. Remove the internal elbow, vent pipe & gasket. 3. Cut the internal vent pipe 2 1/2" from the flange. Discard the un-flanged section. 4. Remove the 3" plastic plug (in line with the inducer outlet) and insert it in the space vacated by removal of the internal vent pipe. 5. Install the RF000142 drain coupling with arrow facing up, on the draft inducer outlet. 6. Insert the 2 ½" flanged section of pipe with gasket through the 3" hole and connect to RF000142 drain coupling. Secure it with gear clamp provided. 7. Use the four self-tapping screws removed in step 1 to secure flange to cabinet. 8. Connect drain hose to the uncapped port on the RF000142 coupling, refer to page xx, section entitled "Horizontal Installation with Left Side Down Alternate" for drain connection details When using the alternate venting location, either in a horizontal left side down installation or a vertical installation using down venting, the alternate combustion air opening can be used. A locating dimple is located on the right side of the furnace cabinet. The locating dimple is 1-7/8" measured from the front edge of the cabinet in line with the knock out. 15 To use the alternate combustion air location: 1. Remove screws and combustion air flange and gasket from cabinet. 2. Insert the 3" cabinet plug from the drain bag assembly in the unused combustion air hole. 3. Drill a pilot hole at the cabinet dimple (size dictated by knockout tool used). 4. Use a knockout tool to create a 3" diameter hole. 5. Secure the combustion air flange & gasket to the furnace cabinet using the self-tapping screws removed in step 1. WARNING THE RUBBER ELBOW IS NOT DESIGNED TO SUPPORT A LOAD. WHEN THE RUBBER ELBOW IS MOUNTED EXTERNALLY TO THE FURNACE CABINET, EXTREME CARE MUST BE TAKEN TO ADEQUATELY SUPPORT FIELDSUPPLIED VENT/FLUE PIPING, AS DAMAGE CAN RESULT IN LEAKS CAUSING BODILY INJURY OR DEATH DUE TO EXPOSURE TO FLUE GASES, INCLUDING CARBON MONOXIDE CAUTION BE SURE NOT TO DAMAGE INTERNAL WIRING OR OTHER COMPONENTS WHEN REINSTALLING COUPLING AND SCREWS. DOWN VENTING UPFLOW MODEL FURNACES ONLY Use alternate vent & combination air locations Vent Pipe 6' Max. Combustion Air Pipe Field Supplied Drain Tee on Vent Pipe Floor Basement / Crawlspace 1/4" per foot min. Condensate trapped slope to furnace to prevent flue gas from escaping and routed to field supplied condensate disposal All piping and fittings must be joined per material manufacturers specifications to prevent separation and flue gas leaks. Figure 13 Pipe Termination Products of combustion must always be vented outside. A vent pipe must never terminate in an attic, crawl space, or any other part of a dwelling. Follow the vent pipe & intake pipe termination requirements listed below as well as all applicable local, State and National codes. All terminations (vent and/or intake) must be located at least 12" above ground level or the anticipated snow level. All vent terminations (non-direct and direct vent) must terminate at least 3 feet above any forced air inlet located within 10 feet. The vent termination of a non-direct vent application must terminate at least 4 feet below, 4 feet horizontally from, or 1 foot above any door, window, or gravity air inlet into any building. The vent termination of a direct vent application must terminate at least 12" from any opening through which flue gases may enter a building (door, window, or gravity air inlet). The vent termination of vent pipe run vertically through a roof must terminate at least 12" above the roof line (or the anticipated snow level) and be at least 12" from any vertical wall (including any anticipated snow build up). A vent termination shall not terminate over public walkways or over an area where condensate or vapor could create a nuisance or hazard or could be detrimental to the operation of regulators, relief valves, or other equipment. The combustion air intake termination of a direct vent application should not terminate in an area which is frequently dusty or dirty. Vent & combustion air pipes may terminate vertically through a roof, or horizontally through an outside wall. The combustion air intake and vent pipe terminations must be in the same atmospheric pressure zone. Vertical vent pipe terminations should be as shown in figure 14. The penetration of pipes through the roof must be sealed water tight with proper flashing such as is used with a plastic plumbing vent. Horizontal vent pipe terminations should be as shown in the following figures. To secure the pipe passing through the wall and prohibit damage to piping connections, a coupling should be installed on either side of the wall and solvent cemented to a length of pipe connecting the two couplings. The length of pipe should be the wall thickness plus the depth of the socket fittings to be installed on the inside and outside of the wall. The wall penetration should be sealed with silicone caulking material. Non-Direct Vent & Direct Vent Vent/Flue Terminations Non-Direct Vent Vent/Flue Termination <10' 3' min. No Terminations Above Walkway 12" Grade or Highest Anticipated Snow Level Forced Air Inlet 12" min. 12" min. Direct Vent Vent/Flue Termination 4' min. 4' min. 12" min. Non-Direct Vent Vent/Flue Termination 16 Vent Termination Clearances Figure 12 TEE (OPTIONAL) COMBUSTION AIR INTAKE (OPTIONAL) *Not required for single pipe installation ROOF LINE 12" MIN HEIGHT DIFFERENCE 12" MIN TO ROOF OR HIGHEST ANTICIPATED SNOW LEVEL 96" MAX. - 3" MIN. Figure 14 ELBOWS STRAIGHT Figure 15 10"- 24" 6" MAX 4" MIN 90º OR 45° ELBOW 12" MIN. TO GRADE OR HIGHEST ANTICIPATED SNOW LEVEL Standard Horizontal Terminations (Dual Pipe) Figure 17 90° ELBOWS 3" - 24" Horizontal Termination (Single Pipe) Above Highest Anticipated Snow Level Figure 16 12" MIN. ABOVE HIGHEST ANTICIPATED SNOW LEVEL Alternate Horizontal Vent Termination (Dual Pipe) Figure 18 90° ELBOWS 3"-24" BETWEEN PIPES 12" MIN. ABOVE HIGHEST ANTICIPATED SNOW LEVEL Combustion Air Intake may also be snorkeled to obtain 12" min ground clearance. Alternate Vent Termination Above Anticipated Snow Level (Dual Pipe) Figure 19 17 Vent & Combustion Air Intake Measurements for Standard Horizontal Terminations (Dual Pipe) Center to center = 10" min / 24" max. Vertical separation: 0" - 24" Vent termination from wall = 8" min / 12" max. Combustion air intake from wall = 6" max. Vent and intake clearance to ground or anticipated snow level = 12" min. 3"MIN 24"MAX 3" MIN 12" MIN SEPARATION 12" MIN TO GRADE OR HIGHEST ANTICIPATED SNOW LEVEL Termination of Multiple Direct Vent Furnaces Figure 20 Vent/Intake Terminations For Installation of Multiple Direct Vent Furnaces If more than one direct vent furnace is to be installed vertically through a common roof top, maintain the same minimum clearances between the exhaust vent and air intake terminations of adjacent units as with the exhaust vent and air intake terminations of a single unit. If more than one direct vent furnace is to be installed horizontally through a common side wall, maintain the clearances as in the Figure 20. Always terminate all exhaust vent outlets at the same elevation and always terminate all air intakes at the same elevation. H orizontal Installation Side Wall Vent Kit This kit is to be used with 2" or 3" direct vent systems. The vent kit must terminate outside the structure and may be installed with the intake and exhaust pipes located sideby-side or with one pipe above the other. These kits are NOT intended for use with single pipe (non-direct vent) installations. Refer to the directions furnished with the Side Wall Vent Kit (p/n 0170K00000S or 0170K00001S) for installation specifications. Condensate Drain Lines & Drain Trap A condensing gas furnace achieves its high level of efficiency by extracting heat from the products of combustion to the point where condensation takes place. The condensate must be collected in the furnace drain trap and routed to an appropriate drain location in compliance with local and national codes. Follow the bullets listed below when installing the drain system. Refer to the following sections for specific details concerning furnace drain trap installation and drain hose hook ups. · The drain trap supplied with the furnace must be used. · The drain trap must be primed at time of installation. · The drain line between furnace and drain location must meet local and nation codes. · The drain line between furnace and drain location must maintain a 1/4 inch per foot downward slope toward the drain. · Do not trap the drain line in any other location than at the drain trap supplied with the furnace. · If the drain line is routed through an area which may see temperatures near or below freezing, precautions must be taken to prevent condensate from freezing within the drain line. · If an air conditioning coil is installed with the furnace, a common drain may be used. An open tee must be installed in the drain line, near the cooling coil, to relieve positive air pressure from the coil's plenum. This is necessary to prohibit any interference with the function of the furnace's drain trap. NOTE: In vertical installations, air conditioning coil condensate may drain into the furnace trap as long as there is a trap between the coil and the furnace trap and the drain pipe is not terminating below the water level of the furnace trap. Ve rtica l Ins tallation Side Wall Vent Kit Figure 21 Concentric Vent Termination Refer to the directions provided with the Concentric Vent Kit (DCVK) for installation specifications. 18 #1 #4 #2 #3 #5 #8 #7 #9 #10 Coupling 100 Degree #6 #11 Elbow Figure 22 NOTE: Drain components shown for information purposes only. General Drain Information All furnace models come with a factory installed drain trap. For vertical installations, the trap will remain in the factory position except for a counterflow when the installer desires the drain to exit the right side. All furnace models installed horizontally require the trap to be relocated. Many drain hoses have a builtin grommet which will provide a cabinet seal when installed. See instructions below for your model and installation position. NOTE: Both sides of the drain trap must be primed prior to initial furnace start up Field Supplied Drain Drain the furnace and air conditioning coil if applicable, in compliance with code requirements. In horizontal or counterflow installations, a field installed rubber coupling will allow the drain trap to be removed for cleaning. The drain trap must be primed before initial furnace start up. When an air conditioning coil drain is connected to the field supplied furnace drain, it must be vented. An open tee must be installed at a height no higher than the bottom of the furnace collector box to prevent air conditioning condensate from backing up into the furnace, if the common drain was blocked. Upflow Model Installed Vertically The trap and factory installed hoses remain as shipped. The furnace drain may exit either the right or left side of the furnace cabinet. Both sides of the cabinet have two .875" diameter holes which can be used interchangeably for drain and low voltage wiring purposes. If a higher drain exit is needed, a .875" diameter hole may be added in the area shown in Figure 24. Any unused cabinet opening must be sealed. Do not allow drain hose to sag or trap water. Drain Exiting Right Side 1. Locate and Install the 45º pipe / hose drain coupling from the outside of the cabinet (barbed end goes in the cabinet) through hole in the right side of the cabinet and secure with two field supplied #8 selftapping screws (see Figure 24). 2. Locate the long drain hose #3 and cut at line "A" . 3. Install large end of hose #3 to trap outlet and secure with 1.25" clamp. Hose #1 Hose #2 Acceptable area for drain hole. 12" Side Cut-Out 3" Right side shown. Figure 23 45 degree barb-pipe adapter 45 degree barb-pipe adapter Installer selects right or left side drain and installs this hose accordingly. Figure 24 19 4. Install smaller end of hose #3 on 45º elbow and secure with 1" clamp. 5. Refer to Field Supplied Drain section for instructions on field supplied / installed drain on outlet of furnace trap. Drain Exiting Left Side 1. Install the 45 degree pipe / hose drain coupling from the outside of the cabinet (barbed end goes in the cabinet) through the hole in the left side of the cabinet and secure with two field supplied #8 selftapping screws (see Figure 24). 2. Locate the long drain hose #3 and cut at "B" line for a 17.5" cabinet; cut at line "C" for a 21" cabinet; do not cut for a "D" width cabinet. 3. Install large end of hose #3 to trap outlet and secure with 1.25" clamp. 4. Install smaller end of hose #3 on 45º elbow and secure with 1" clamp. 5. Refer to Field Supplied Drain section for instructions on field supplied / installed drain on outlet of furnace trap. Hose #11 Hose #2 6. For models *MSS920403AN and *MSS960403AN; locate the hose #2 (factory installed) and cut 1.5 length from the end of the hose. Insert hose #2 from outside the cabinet through the cabinet's drain hole nearest to the top. Secure it to the barbed fitting in the elbow with a red clamp. 7. (Draining the Collector Box) Install the non-grommet end of hose #11 from outside the cabinet in the bottom drain hole. Install on collector box and secure with a silver clamp. 8. Use two silver clamps and secure the hoses to drain trap. The trap outlet faces the front of the furnace. Secure the trap to the cabinet using two screws removed in step 2 by inserting the two screws through the large set of holes in the top mounting tabs of the trap into the two pre-drilled holes in the side of the cabinet. 9. Refer to Field Supplied Drain section for instructions on field supplied / installed drain on outlet of furnace trap. Upflow Model Installed Horizontally with Left Side Down Minimum 5 1/2" clearance is required for the drain trap beneath the furnace. *Also see Front Cover Pressure Switch Tube Location on page 10. 1. Remove the clamps from the two drain tubes on the trap. 2. Remove the two screws holding the drain trap to the blower deck. 3. Remove the trap and hoses from the blower deck. Figure 25 Upflow Model Installed Horizontally with Right Side Down Minimum 5 1/2" clearance is required for the drain trap beneath the furnace. 1. Remove the clamps from both ends of the drain hoses. 2. Remove the two screws holding the drain trap to the blower deck. 3. Remove the trap and two hoses from the blower deck 4. Remove the two plugs from the right side of the cabinet and install them in the blower deck. 5. (Draining the Vent Elbow ) Locate hose #2 (factory installed) and cut 1" away from the 45 degree bend, discard the 45 degree section. Insert hose #2 from outside the cabinet through the cabinet drain hole nearest the top, secure it to the barbed fitting in the elbow with a red clamp. Hose #6 Hose #5 Hose #11 Figure 26 4. Remove the two plugs from the left side of the cabinet and install them in the blower deck. 5. (Draining the Vent Elbow) Locate hose #6. Measuring from the non-grommet end; cut off and discard 1 ½" for a "D" width cabinet, 5" for a "C" width cabinet, 8 ½" for a "B" width cabinet. 20 6. Remove the rubber plug from vent drain elbow side port. Place hose #6 on the vent drain elbow side port and secure with a silver clamp . 7. Unused vent-drain elbow drip leg port must be sealed to prevent flue gases from escaping. Insert the rubber plug removed in step 6 into the unused elbow drain port. Inserting a blunt tool such as a 3/16'' Allen wrench into the center of the rubber plug will stretch the plug and allow complete insertion. 8. Locate hose #5 and cut 3" from the non-grommet end. Discard the section without the grommet. 9. Insert the cut end of tube #5 through the lower cabinet drain hole. 10. Connect hose #6 & hose #5 using 100º elbow and secure with two red clamps 11. (Draining the Collector Box) Remove cap from left side collector box drain port (bottom in horizontal left position) and install it on right side (top) collector box drain port. 12. Install the non-grommet end of hose #11 from outside the cabinet in the upper drain hole. Install on collector box and secure with a silver clamp. 13. Use two silver clamps and secure the hoses to drain trap. The trap outlet faces the front of the furnace. Secure the trap to the cabinet using two screws removed in step 2 by inserting the two screws through the large set of holes in the top mounting tabs of the trap into the two pre-drilled holes in the side of the cabinet. [Removed: Place cap on vent...] 14. Refer to Field Supplied Drain section for instructions on field supplied / installed drain on outlet of furnace trap. Upflow Model Installed Horizontally With Left Side Down - Alternate *Also see Front Cover Pressure Switch Tube Location on Page 10. 1. (Draining the RF000142 Coupling) Locate hose #2 (factory installed). Cut off and discard the 45° radius end. 2. Install 90°radius end of hose #2 on RF000142 drain outlet and secure with a red clamp. 3. Insert coupling in hose #2 and secure with a red clamp. 4. Locate hose #5 and cut 3" from the non-grommet end. Discard the section without the grommet. 5. Insert the cut end of tube #5 through the lower cabinet drain hole. 6. Insert 100 degree elbow in the cut end of hose #5. 7. Locate hose #6. Using red clamps, connect between the coupling and 100 degree elbow, cutting off excess tubing. 8. (Draining the Collector Box) Remove cap from left side collector box drain port (bottom in horizontal left position) and install it on right side (top) collector box drain port and secure with a red clamp. 9. Install the non-grommet end of hose #11 from outside the cabinet in the upper drain hole. Install on collector box and secure with a silver clamp. 10. Use two silver clamps and secure the hoses to drain trap. The trap outlet faces the front of the furnace. Secure the trap to the cabinet using two screws removed in step 2 by inserting the two screws through the large set of holes in the top mounting tabs of the trap. Insert flange. Cut 2 ½" long. RF000142 Figure 27 CounterFlow Model Installed Vertically The furnace drain may exit the right or left side of the furnace cabinet (left side preferred) Trap and factory installed hoses remain as shipped if the drain will exit the left side of the cabinet. Draining from the right side requires relocation of the trap to outside the cabinet. Drain Exiting Left Side (See Figure 28) 1. Install a field supplied rubber coupling secured with a 1 1/4" clamp to enable removing the trap for future cleaning. Alternately, a PVC fitting may be glued on the trap outlet. 2. Install drain per local and National codes. 21 Hose #4 x 3 Hose #5 Figure 28 Drain Exiting Right Side (See Figure 29) 1. Removing the gas manifold assembly will provide better access when re-locating the trap. To remove the gas manifold, remove the four screws that fasten the gas manifold assembly to the bracket. 2. Remove hose clamps and hoses from trap. 3. Remove trap. 4. (Draining the Vent Elbow) Insert the non-grommet end hose #10 into the cabinet back drain hole. Insert a coupling into the drip leg of the vent-drain elbow and secure with a silver clamp. Secure hose #10 on vent drain elbow barb fitting with a silver clamp. 5. (Draining the Collector Box) Insert non-grommet end of hose #9 into the cabinet front drain hole and secure on collector box drain port with a silver clamp. 6. Mate the drain trap inlets to the hoses and secure with silver clamps. 7. Line up the trap mounting holes with the pre-drilled holes in the furnace and secure with 2 screws removed in step 2. 8. Refer to Field Supplied Drain section for instructions on field supplied / installed drain on outlet of furnace trap. Figure 29 WARNING HIGH VOLTAGE ! TO AVOID PERSONAL INJURY OR DEATH DUE TO ELECTRICAL SHOCK, DISCONNECT ELECTRICAL POWER BEFORE SERVICING OR CHANGING ANY ELECTRICAL WIRING. CAUTION LABEL ALL WIRES PRIOR TO DISCONNECTION WHEN SERVICING CONTROLS. WIRING ERRORS CAN CAUSE IMPROPER AND DANGEROUS OPERATION. VERIFY PROPER OPERATION AFTER SERVICING. WARNING HIGH VOLTAGE ! TO AVOID THE RISK OF ELECTRICAL SHOCK, WIRING TO THE UNIT MUST BE POLARIZED AND GROUNDED. Counterflow Model Installed Horizontally with Right Side Down (See Figure 30) Minimum 5 1/2" clearance is required for the drain trap beneath the furnace. NOTE: For horizontal installations, some of the required hoses are found in the factory-installed hose assemblies. 22 Remove the hose clamps to obtain the respective hoses needed for installation, and install per the following directions. 1. Remove the drain trap and factory installed drain tube assemblies. 2. Remove two 1'' plugs from right side of cabinet. 3. (Draining the Collector Box) From outside the cabinet, insert the non-grommet end hose #7 into the back drain hole and secure to collector box drain port using a silver clamp. 4. (Draining the Vent Elbow) Insert the straight barbed coupling into the vent - drain elbow drip leg and secure with a red clamp. 5. Insert hose #2 from outside the cabinet in the front drain hole. 6. Connect hose #4 & hose #2 together using a straight barbed coupling and two gold clamps (factory installed). 7. (Draining the Vent Elbow) Remove rubber plug from vent drain elbow side port. 8. The unused vent-drain elbow drip leg port must be plugged to prevent flue gases from escaping. Insert rubber plug removed in step 7 into the 100° elbow. (Inserting a blunt tool such as a 3/16'' Allen wrench into the center of the rubber plug will stretch the plug and allow complete insertion) Hose #4 Figure 30 5. From outside the cabinet, insert the non-grommet end of hose #8 into the front cabinet drain hole and secure on the vent - drain elbow barb fitting using a red clamp. 6. Place the drain hoses on the trap inlets and secure with silver clamps. The outlet of the trap must face the original bottom of furnace. 7. Using the two sheet metal screws provided in the cabinet, secure the trap to the furnace. 8. Refer to Field Supplied Drain section for instructions on field supplied/installed drain on outlet of furnace trap. Counterflow Model Installed Horizontally with Left Side Down (See Figure 31) Minimum 5 1/2" clearance is required for the drain trap beneath the furnace. *Also see Front Cover Pressure Switch Tube Location on page 10. 1. Remove the factory installed drain trap and hose assemblies. Leave the 100° elbow inserted and clamped in the vent-drain elbow. 2. Remove two 1"plugs from left side of cabinet 3. (Draining the Collector Box) Remove the cap from the left side of the collector box drain port (bottom in horizontal left position) and install it on right side drain port. 4. Place radius end of hose #4 (factory installed) on the collector box drain port and secure with a silver clamp. Hose #4 Hose #5 Hose #2 Figure 31 9. Place radius end of hose #4 on the side port of vent drain elbow and secure with a gold clamp. 10. Insert a ½" diameter PVC pipe (factory installed) into hose #4 and secure with a gold clamp. 11. Insert the non-grommet end of hose #5 (factory installed) from outside the cabinet in the back drain hole. 12. Insert 100º elbow in hose #5 and secure with a red clamp. 13. Locate hose #4 and cut a cut off a 4" straight section and discard the radius end. 14. Connect the 4" straight section of hose #4 to the 100º elbow and the PVC pipe and secure with red clamps. 15. Connect the hoses to the trap inlets and secure with silver clamps, drain trap outlet must point to the original bottom of the furnace. 16. Using the two sheet metal screws provided in the cabinet, secure the trap to the furnace. 17. Refer to Field Supplied Drain section for instructions on field supplied / installed drain on outlet of furnace trap. 23 Electrical Connections Wiring Harness The wiring harness is an integral part of this furnace. Wires are color coded for identification purposes. Refer to the wiring diagram for wire routings. If any of the original wire as supplied with the furnace must be replaced, it must be replaced with wiring material having a temperature rating of at least 105° C. Any replacement wiring must be a copper conductor. 115 Volt Line Connections Before proceeding with electrical connections, ensure that the supply voltage, frequency, and phase correspond to that specified on the unit rating plate. Power supply to the furnace must be NEC Class 1, and must comply with all applicable codes. The furnace must be electrically grounded in accordance with local codes or, in their absence, with the latest edition of The National Electric Code, ANSI NFPA 70 and/or The Canadian Electric Code CSA C22.1. WARNING HIGH VOLTAGE ! TO AVOID PERSONAL INJURY OR DEATH DUE TO ELECTRICAL SHOCK, DISCONNECT ELECTRICAL POWER BEFORE SERVICING OR CHANGING ANY ELECTRICAL WIRING. Humidifier Electronic Air Cleaner 1.0 Amp maximum at 120 VAC 1.0 Amp maximum at 120 VAC Use a separate fused branch electrical circuit containing properly sized wire, and fuse or circuit breaker. The fuse or circuit breaker must be sized in accordance with the maximum overcurrent protection specified on the unit rating plate. An electrical disconnect must be provided at the furnace location. Connect hot, neutral, and ground wires as shown in the wiring diagram located on the unit's blower door. For direct vent applications, the cabinet opening to the junction box must be sealed air tight using either an UL approved bushing such as Heyco Liquid Tight or by applying non-reactive UL approved sealant to bushing. Line polarity must be observed when making field connections. Line voltage connections can be made through either the right or left side panel. The furnace is shipped configured for a left side (right side for counterflows) electrical connection with the junction box located inside the burner compartment. To make electrical connections through the opposite side of the furnace, the junction box must be relocated to the other side of the burner compartment prior to making electrical connections. To relocate the junction box, follow the steps shown in the Junction Box Relocation section. WARNING EDGES OF SHEET METAL HOLES MAY BE SHARP. USE GLOVES AS A PRECAUTION WHEN REMOVING HOLE PLUGS. WARNING TO PREVENT PERSONAL INJURY OR DEATH DUE TO ELECTRIC SHOCK, DISCONNECT ELECTRICAL POWER BEFORE INSTALLING OR SERVICING THIS UNIT. WARNING HIGH VOLTAGE ! TO AVOID THE RISK OF INJURY, ELECTRICAL SHOCK OR DEATH, THE FURNACE MUST BE ELECTRICALLY GROUNDED IN ACCORDANCE WITH LOCAL CODES OR IN THEIR ABSENCE, WITH THE LATEST EDITION OF THE NATIONAL ELECTRIC CODE. WARNING TO AVOID THE RISK OF INJURY, ELECTRICAL SHOCK OR DEATH, THE FURNACE MUST BE ELECTRICALLY GROUNDED IN ACCORDANCE WITH LOCAL CODES OR, IN THEIR ABSENCE, WITH THE LATEST EDITION OF THE NATIONAL ELECTRICAL CODE. 115 Volt Line Voltage Connection of Accessories (Humidifier and Electronic Air Cleaner) The furnace integrated control module is equipped with line voltage accessory terminals for controlling power to an optional field-supplied humidifier and/or electronic air cleaner. Turn OFF power to the furnace before installing any accessories. Follow the humidifier or air cleaner manufacturers' instructions for locating, mounting, grounding, and controlling these accessories. Accessory wiring connections are to be made through the 1/4" quick connect terminals provided on the furnace integrated control module. The humidifier hot terminal is identified as 120V HUM-H, its neutral terminal is identified as 120V HUM-N. The electronic air cleaner hot terminal is identified as EAC-H, its neutral terminal is identified as 120V EAC-N. All field wiring must conform to applicable codes. Connections should be made as shown. (See Figure 32) If it is necessary for the installer to supply additional line voltage wiring to the inside of the furnace, the wiring must conform to all local codes, and have a minimum temperature rating of 105°C. All line voltage wire splices must be made inside the furnace junction box. The integrated control module humidifier terminal 120V HUM-H is energized with 115 volts whenever the induced draft blower is energized. This terminal can also be used to provide 115 volt power to a humidifier transformer. The remaining primary transformer wire would be connected to the Line N on the control board. The integrated control module electronic air cleaner terminals EAC-H is energized with 115 volts whenever the circulator blower is energized. NOTE: Wire routing must not to interfere with circulator blower operation, filter removal, or routine maintenance. 24 120 HUM-H EAC-H 115 VAC HUM 115 VAC EAC 120V HUM-N EAC-N PCBBF145 CONTROL BOARD Figure 32 Connection of 24 Volt Humidifier The integrated control module single humidifier terminal "24 VHUM" is energized with 24 volts whenever the induced draft blower is energized. Connect the common side of the 24 volt humidifier to the "C" terminal of the thermostat terminal strip on the control board. PCBBF145 24VHUM Y/Y2 W R G C 24 VOLT HUM. & HUMIDISTAT IMPORTANT NOTE WIRE ROUTING MUST NOT INTERFERE WITH CIRCULATOR BLOWER OPERATION, FILTER REMOVAL OR ROUTINE MAINTENANCE. To ensure proper unit grounding, the ground wire should run from the furnace ground screw located inside the furnace junction box all the way back to the electrical panel. NOTE: Do not use gas piping as an electrical ground. To confirm proper unit grounding, turn off the electrical power and perform the following check. 1. Measure resistance between the neutral (white) connection and one of the burners. Resistance should measure 10 ohms or less. This furnace is equipped with a blower door interlock switch which interrupts unit voltage when the blower door is opened for servicing. Do not defeat this switch. 24 Volt Thermostat Wiring Low voltage connections can be made through either the right or left side panel. Thermostat wiring entrance holes are located in the blower compartment. The following figure shows connections for a "heat/cool system". This furnace is equipped with a 40 VA transformer to facilitate use with most cooling equipment. Consult the wiring diagram, located on the blower compartment door, for further details of 115 Volt and 24 Volt wiring. WARNING HIGH VOLTAGE ! TO AVOID PERSONAL INJURY OR DEATH DUE TO ELECTRICAL SHOCK, DISCONNECT ELECTRICAL POWER BEFORE SERVICING OR CHANGING ANY ELECTRICAL WIRING. Figure 33 Junction Box Relocation Line voltage connections can be made through either the right or left side panel. The furnace is shipped configured for a left side electrical connection. To make electrical connections through the opposite side of the furnace, the junction box must be relocated to the left side prior to making electrical connections. To relocate the junction box, perform the following steps. 1. Remove the burner compartment door. 2. Remove and save the two screws securing the junction box to the side panel. 3. Relocate junction box and associated plugs and grommets to opposite side panel. Secure with screws removed in step. Single-Stage Heating Thermostat Application A single-stage thermostat with only one heating stage is needed to control this furnace. Fossil Fuel Applications This furnace can be used in conjunction with a heat pump in a fossil fuel application. A fossil fuel application refers to a combined gas furnace and heat pump installation which uses an outdoor temperature sensor to determine the most cost efficient means of heating (heat pump or gas furnace). Strictly follow the wiring guidelines in the fossil fuel kit installation instructions. All furnace connections must be made to the furnace two-stage integrated control module and the "FURNACE" terminal strip on the fossil fuel control board. 25 Twinning Furnaces may be twinned without the use of a twinning kit. Furnaces must be the same model and equipped with PCBBF145 control boards. Follow the diagram provided in this manual. Connection of the "twin" terminals of each control together will allow simultaneous operation of two or more furnace indoor blowers to operate synchronously on a common duct system. Field installed low voltage thermostat wiring, 3/16" terminals are required to make this connection. An isolating relay (24 VAC coil & N/O SPST) contacts is also required if the furnaces are not fed from the same line voltage phase. A pulsing DC signal is used to share the call for fan operation between furnaces. The duration of the pulse width determines the speed that the reading control will energize its blower motor. CAUTION TO PREVENT UNRELIABLE OPERATION OR EQUIPMENT DAMAGE, THE GAS MANIFOLD PRESSURE MUST BE AS SPECIFIED ON THE UNIT RATING PLATE. ONLY MINOR ADJUSTMENTS SHOULD BE MADE BY ADJUSTING THE GAS VALVE PRESSURE REGULATOR. WARNING POSSIBLE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH MAY OCCUR IF THE CORRECT CONVERSION KITS ARE NOT INSTALLED. THE APPROPRIATE KITS MUST BE APPLIED TO ENSURE SAFE AND PROPER FURNACE OPERATION. ALL CONVERSIONS MUST BE PERFORMED BY A QUALIFIED INSTALLER OR SERVICE AGENCY. Gas Supply and Piping INLET GAS SUPPLY PRESSURE Natural Gas Minimum: 4.5" w.c. Maximum: 10.0" w.c. Propane Gas Minimum: 11.0" w.c. Maximum: 13.0" w.c. The furnace rating plate includes the approved furnace gas input rating and gas types. The furnace must be equipped to operate on the type of gas applied. This includes any conversion kits required for alternate fuels and/or high altitude. R Room Thermostat R Furnace Integrated Control Module YC Remote Condensing Unit (Single-Stage Cooling) Figure 34 Inlet gas supply pressures must be maintained within the ranges specified in the following table. The supply pressure must be constant and available with all other household gas fired appliances operating. The minimum gas supply pressure must be maintained to prevent unreliable ignition. The maximum must not be exceeded to prevent unit overfiring. WARNING TO AVOID POSSIBLE UNSATISFACTORY OPERATION OF EQUIPMENT DAMAGE DUE TO UNDERFIRING OR EQUIPMENT, USE THE PROPER SIZE OF NATURAL/PROPANE GAS PIPING NEEDED WHEN RUNNING PIPE FROM THE METER/TANK TO THE FURNACE. High Altitude Installation When this furnace is installed at high altitude, the appropriate High Altitude Kit including orifices and a pressure switch(s) must be installed. These changes are necessary to compensate for the natural reduction in the density of both the gas fuel and the combustion air at higher altitude. Installation of this furnace at altitudes above 7000 ft (2134 m), shall be made in accordance with the Listed High Altitude Conversion Kit available with this furnace. Do not de-rate the furnace by adjusting the manifold pressure to a lower pressure than specified on the furnace rating plate. The combination of the lower air density and a lower manifold pressure will prohibit the burner orifice from drawing the proper amount of air into the burner. This may cause incomplete combustion, flashback, and yellow tipping. In some areas the gas supplier may artificially derate the gas in an effort to compensate for the effects of altitude. If the gas is artificially derated, the appropriate orifice size must be determined based upon the BTU/ft³ content of the derated gas and the altitude. Refer to the National Fuel Gas Code, NFPA 54/ANSI Z223.1, and information provided by the gas supplier to determine the proper orifice size. A different pressure switch may be required at high altitude regardless of the BTU/ft³ content of the fuel used. Consult the furnace Specification Sheet. All conversions must be performed by a qualified installer, or service agency. Propane Gas Conversion This furnace is shipped from the factory configured for natural gas at standard altitude. To operate this furnace on L.P. gas, a LPM-07 LP Conversion kit must be used. Propane gas installations require an orifice and spring change to compensate for the energy content difference between natural and propane gas. For furnaces being converted to LP gas, it is strongly recommended that a LPLP03 kit also be installed. The use of this kit will prevent the furnace from firing when the LP gas supply pressure is too low to support proper combustion. All conversions must be performed by a qualified installer, or service agency. 26 Gas Valve This unit is equipped with a 24 volt gas valve controlled during furnace operation by the integrated control module. As shipped, the valve is configured for natural gas. The valve is field convertible for use with propane gas by replacing the regulator spring with a propane gas spring from an appropriate manufacturer's propane gas conversion kit. Taps for measuring the gas supply pressure and manifold pressure are provided on the valve. The gas valve has a manual ON/OFF control located on the valve itself. This control may be set only to the "ON" or "OFF" position. Refer to the lighting instructions label or Startup Procedure & Adjustment for use of this control during start up and shut down periods. Gas Piping Connections The gas piping supplying the furnace must be properly sized based on the gas flow required, specific gravity of the gas, and length of the run. The gas line installation must comply with local codes, or in their absence, with the latest edition of the National Fuel Gas Code, NFPA 54/ANSI Z223.1 or CAN/CSA B149.1-15 in Canada. To connect the furnace to the building's gas piping, the installer must supply a ground joint union, drip leg, manual shutoff valve, and line and fittings to connect to gas valve. In some cases, the installer may also need to supply a transition piece from 1/2" pipe to a larger pipe size. The following stipulations apply when connecting gas piping. Refer to Gas Piping Connections figure for typical gas line connections to the furnace. · Gas piping must be supported external to the furnace cabinet so that the weight of the gas line does not distort the burner rack, manifold or gas valve. · Use black iron or steel pipe and fittings for building piping. Where possible, use new pipe that is properly chamfered, reamed, and free of burrs and chips. If old pipe is used, be sure it is clean and free of rust, scale, burrs, chips, and old pipe joint compound. · Use pipe joint compound on male threads ONLY. Always use pipe joint compound (pipe dope) that is APPROVED FOR ALL GASES. DO NOT apply compound to the first two threads. · Use ground joint unions. · Install a drip leg to trap dirt and moisture before it can enter the gas valve. The drip leg must be a minimum of three inches long. · Install a 1/8" NPT pipe plug fitting, accessible for test gauge connection, immediately upstream of the gas supply connection to the furnace. · Always use a back-up wrench when making the connection to the gas valve to keep it from turning. The orientation of the gas valve on the manifold must be maintained as shipped from the factory. Maximum torque for the gas valve connection is 375 in-lbs; excessive over-tightening may damage the gas valve. · Install a manual shutoff valve between the gas meter and unit within six feet of the unit. If a union is installed, the union must be downstream of the manual shutoff valve, between the shutoff valve and the furnace. · Tighten all joints securely. Natural Gas Capacity of Pipe In Cubic Feet of Gas Per Hour (CFH) Length of Nominal Black Pipe Size Pipe in Feet 1/2" 3/4" 1" 1 1/4" 10 132 278 520 1050 20 92 190 350 730 30 73 152 285 590 40 63 130 245 500 50 56 115 215 440 60 50 105 195 400 70 46 96 180 370 80 43 90 170 350 90 40 84 160 320 100 38 79 150 305 (Pressure 0.5 psig or less and pressure drop of 0.3" W.C.; Based on 0.60 Specific Gravity Gas) 1 1/2" 1600 1100 980 760 670 610 560 530 490 460 CFH = BTUH Furnace Input Heating Value of Gas (BTU/Cubic Foot) · Connection method must be in compliance with all local and national codes. US: National Fuel Gas Code (NFGC) NFPA 54-2012/ANSI Z223.1-2012 and the Installation Standards, Warm Air Heating and Air Conditioning Systems ANSI/NFPA 90B. In Canada, CANADA: National Standard of Canada, Natural Gas and Propane Installation Code (NSCNGPIC) CSA B149.1-15. Connect the furnace to the building piping by one of the following methods: Rigid metallic pipe and fittings. Semi-rigid metallic tubing and metallic fittings. Aluminum alloy tubing must not be used in exterior locations. In order to seal the grommet cabinet penetration, rigid pipe must be used to reach the outside of the cabinet. A semi-rigid connector to the gas piping may be used from there. · Use listed gas appliance connectors in accordance with their instructions. Connectors must be fully in the same room as the furnace. · Protect connectors and semi-rigid tubing against physical and thermal damage when installed. Ensure aluminum-alloy tubing and connectors are coated to protect against external corrosion when in contact with masonry, plaster, or insulation, or subjected to repeated wetting by liquids such as water (except rain water), detergents, or sewage. 27 The gas piping may enter the left or right side of the furnace cabinet. The installer must supply rigid pipe long enough to reach the outside of the cabinet to seal the grommet cabinet penetration. A semi-rigid connector to the gas piping can be used outside the cabinet per local codes. 1/2" NPT pipe and fittings are required. For models with an "L" shaped manifold, a 4 1/2" long nipple is required. For models with a hook shaped manifold, a 2" long nipple is required. A semi-rigid connector to the gas piping can be used outside the cabinet per local codes. From the elbow, the length of pipe and the fittings required will vary by the side chosen, location of union and cabinet width. The union may be placed inside or outside of the cabinet. Alternate Union Location Grommet in Standard Gas Line Hole Burners Manual Shut Off Valve (upstream from ground joint pipe union) Drip Leg Plug in Alternate Gas Line Hole Alternate Gas Line Location Manifold Burners Gas Valve *Ground Joint Pipe Union Manual Shut Off Valve (upstream from ground joint pipe union) *Ground Joint Pipe Union Drip Leg Grommet in Standard Gas Line Hole Manifold Gas Valve Plug in Main Gas Line Hole Drain Trap UPFLOW - HORIZONTAL LEFT Figure 37 Manual Shut Off Valve (upstream from ground joint pipe union) *NOTE: Union may be inside furnace cabinet where allowed by local codes. UPFLOW Figure 35 *Ground Joint Pipe Union Grommet in Standard Gas Line Hole Drip Leg Manual Shut Off Valve (upstream from ground joint pipe union) Alternate Gas Line Location *Ground Joint Pipe Union Plug in Alternate Gas Line Hole Gas Valve Burners *NOTE: Union may be inside furnace cabinet where allowed by local codes. COUNTERFLOW Figure 36 28 COUNTERFLOW - HORIZONTAL RIGHT Figure 38 TWINNING CONNECTION DIAGRAM CONDENSOR CONTACTOR COILS 59- 5240 REV.0 E E 1 2 03 RV1 E E2 E3 3 5 2 E3 7 1 K1 0 CR3 5 K1 C40 R1 5 U K R4 29 U C41 K3 R7 6 U C42 K4 U C4 3 R9 2 E4 2 2 3 4 5 R2 R5 R8 R9 8 2 0 3 CR1 8 1 E18 E3 8 R6 0 SW 1 1 2 R86 R85 R32 + + + K 6 K 7 R11 2 R11 0 R11 1 R15 1 R150 R113 R121 R115 R126 R125 R123 R12 0 R13 6 R14 4 E3 0 TVS 2 CR2 6 R168 R148 R17C02 R149 4 C2 R12 0 2 R15 Q1 R113 7 C 1 7 R139 CR27 R7 C0R4 CR1 2 3 CR3 4 R1 40 R11 C4 1 R 4 R152 R19 R169 5 0 R117 R118 Q8 C 1 6 CR2 4 R11 C61 R10 7 2 R119 Q 1 R2 9 LOW ER SLOT SIDE R 1 3 0 R7 2 CR1R1 96 1 R14 7 R98 R6 R173 2 TVS1 R56 R58 R R44 3 R 1 5 1 O OF RN 4 F 1 C R R7 1 0 R35 1 R48R57 R55 R65 C3 7 TP R9 U4 4 C1 0 11 C1 1 C 2 CR 2 1 R 3 R2 0 R1 8 R 8 C 1 R 4 R2 3 R1 1 R9 C4 R 1 R4 R7 Q 3 3 5 7 CR CR19 3 Q16 E4 Q 0 Q3 2 FLAME CR 7 Q4 R179 R176 R178 CR1 R1773 C28 CURRENT 1VDC=1UA R18 1 1 R2 1 C2 CR38 Q1 9 CR3 7 C3 4 R1 7 9 C3 0 R1 C2 2 5 R18 Q1 0 8 R21 R2 7 2 C4 4 R 1 0 R82 R1 7 C3 2 C 18 R1 3 Q 19 R154 CR R156 3 R1 1 46 R155 R15 9R14 3 TP C33 R134 R216 CR28 R213 R215 3 C1 R132 R19 R133 5 TP 2 R101 R210 9 C3 6 R20 1 E2 W 1 R19 8 R20 7 8 CR2 2 R20 0 R8 9 CR15 Q R175 5 CR3 6 R14 5 C2 6 RV 2 F 1 E2 6 O FF O N R40 R30 R1 85 O FF O N R184 R182 R53 R45 R 39 R 69 R27 CR4 R 91 CR 39 3 4 R61 R7 R5 R64 4 SW 3 3 C 3 2 R18 6 1 R18 7 R4 R5 R4 7 46 R183 1OFF 2 3 4 SW 2 TP 5 O N DS 1 TP 6 R C38 42 R50 R34 R164 R172 C31 CR9 CR 6 R1 93 R1 R63 R8 4 8 C1 3 E2 14 R10 2 TP 1 C1 4 R16 7 R12 8 R10 5 R16 1 C2 3 R7 9 CR1 6 R10 6 6 CR14 R1 03 R2 CR CR 123 R95 R9 7 Q13 CR 33 R171 RC1R2 398 C1 9 CR2 0 R100 R8 R R 1 R6 96 1 R3 R59 R16 R87 R78 CR8 3 C21 R158 C3 5 R16 6 C22 CR25 Q12 R10 9 R20 9 Q1 0 Q1 4 R12 9 R13 CR3 50 R160 R163 R157 Q 6 R10 4 K9 CR32 R162 CR5 D H U M Y 1 CR2 WR G C Y/Y2 R14 1 R14 2 R19 7 W 2 R20 4 R20 3 R21 2 R10 8 R20 2 R21 1 K 8 CR1 7 E2 9 R9 0 E1 5 R12 7 R12 4 R3 R37 R6 R6 R6 R2 8 R36 8 7 6 6 R25 R24 R9 R20 R20 R8 9 6 5 3 E2 2 59- 5240 REV.0 E E 1 2 03 RV1 E E2 E3 3 5 2 E3 7 1 K1 0 CR3 5 K1 C40 R1 5 U K 2 R4 9 U C41 K3 R7 6 U C42 K4 U C4 3 R9 2 E4 2 2 3 4 5 R2 R5 R8 R9 8 2 0 3 CR1 8 R 1 Q 3 R4 R7 R8 3 5 9 1 E18 E3 8 R6 0 SW 1 1 2 7 CR + + + K 6 K 7 C C 2 1 CR R 2 4 CR19 3 Q16 E4 Q 0 Q3 2 FLAME CURRENT CR 7 Q4 R179 R176 R178 CR1 R1773 C28 1 1VDC=1UA R18 R 1 1 R11 R11 3 2 0 R2 R2 Q1 R2 3 1 C2 9 R11 1 R15 1 R150 R113 R121 R115 R125 R123 R126 R12 0 0 R1 R1 7 9 C3 0 CR2 6 R168 R148 R17C02 R149 4 C2 R12 8 R117 R118 R119 Q8 R13 6 R14 4 E3 0 TVS 2 Q1 R113 7 C 1 7 R139 CR27 R7 C0R4 CR1 2 0 0 2 R R15 3 C 8 R1 1 CR3 40 R11 6 4 1C4 R CR2 4 4 R11 Q 1 R152 C61 R10 R19 R169 R2 5 7 2 9 R 1 R1 2 R1 1 R9 C4 C3 2 C 18 C2 5 C4 4 CR 3 R21 7 R154 R156 LOW ER SLOT SIDE R 1 3 0 R7 2 CR1R1 96 1 R14 7 R98 R6 R173 2 0 R1 3 Q R1 1 46 R155 R15 C R55 R R82 R1 7 19 9R14 3 TVS1 R56 R58 R7 1 R35 1 0 R65 R44 R 3 R48R57 R 1 C3 5 7 TP R9 U4 4 C1 0 11 TP C33 3 C1 R132 R19 5 9 C3 R134 R216 CR28 R133 R213 R215 E2 1 O OF RN 4 F 1 R86 R85 R32 6 TP R20 R19 8 R20 7 C1 1 2 1 R101 8 CR2 2 R20 R210 0 CR38 R18 Q1 0 8 R2 2 W 1 CR3 7 C3 4 CR15 Q R175 5 CR3 6 R14 5 C2 6 RV 2 F 1 E2 6 O FF O N R40 R30 3 4 R64 R61 R7 4 SW 3 3 C 3 R5 2 R18 6 1 R18 7 R4 R5 R4 7 46 R183 O 1OFF N R C38 42 R50 R34 R164 R172 C31 CR9 CR 6 R1 93 R1 R63 R8 4 8 E2 14 R1 03 R7 9 CR1 6 R10 6 6 CR14 C1 3 R10 2 R2 CR CR 123 TP 1 C1 4 R16 7 R12 8 R10 5 R16 1 C2 3 R95 R9 7 Q13 CR 33 R171 RC1R2 398 C1 9 CR2 0 R100 C21 R158 C3 5 R16 6 C22 CR25 Q12 R10 9 R20 9 Q1 R13 CR3 0 50 R160 R163 Q1 R157 4 R10 4 K9 R14 1 R14 2 R19 7 W 2 R20 4 R20 3 R21 2 R10 8 R20 2 R21 1 R1 85 O FF O N R184 R182 R53 R45 R 39 R 69 R27 CR4 R 91 CR 39 2 R8 R R R12 1 R6 96 9 Q 3 1 6 CR32 4 R3 R59 R16 R87 R78 CR8 R162 E2 9 SW 2 TP 5 DS 1 3 CR5 D H U M Y 1 CR2 WR G C K 8 CR1 TP Y/Y2 7 6 R9 0 E1 5 R12 7 R12 4 R3 R37 R6 R6 R6 R2 8 R36 8 7 6 6 R25 R24 R9 R20 R20 R8 9 6 5 3 E2 2 Y W R G C ROOM THERMOSTAT NOTES: 1. ISOLATING RELAY MAY BE ELIMINATED IF LINE VOLTAGE SUPPLY TO FURNACES IS THE SAME PHASE . TO VERIFY PHASING: A) VERIFY SOURCE IS EXACTLY THE SAME EITHER L1, L2, OR L3 FROM THE SAME TRANSFORMER OR B) CHECK WITH SCOPE OR PHASE METER C) IF IN DOUBT USE RELAY 2. IF ISOLATING RELAY IS NOT USED, CONNECT FURNACE "W" TERMINALS TOGETHER. ISOLATING RELAY (SEE NOTES) Figure 39 Gas Piping Checks WARNING Before placing unit in operation, leak test the unit and gas connections. IF THE GAS FURNACE IS INSTALLED IN A BASEMENT, AN EXCAVATED AREA OR CONFINED SPACE, IT IS STRONGLY RECOMMENDED TO Check for leaks using an approved chloride-free soap and water solution, an electronic combustible gas detector, or other approved testing methods. NOTE: Never exceed specified pressures for testing. Higher pressure may damage the gas valve and cause subsequent overfiring, resulting in heat exchanger failure. CONTACT A PROPANE SUPPLIER TO INSTALL A GAS DETECTING WARNING DEVICE IN CASE OF A GAS LEAK. · SINCE PROPANE GAS IS HEAVIER THAN AIR, ANY LEAKING GAS CAN SETTLE IN ANY LOW AREAS OR CONFINED SPACES. · PROPANE GAS ODORANT MAY FADE, MAKING THE GAS UNDETECTABLE EXCEPT WITH A WARNING DEVICE. Disconnect this unit and shutoff valve from the gas supply piping system before pressure testing the supply piping system with pressures in excess of 1/2 psig (3.48 kPa). Isolate this unit from the gas supply piping system by closing its external manual gas shutoff valve before pressure testing supply piping system with test pressures equal to or less than 1/2 psig (3.48 kPA). WARNING TO AVOID THE POSSIBILITY OF EXPLOSION OR FIRE, NEVER USE A MATCH OR OPEN FLAME TO TEST FOR LEAKS. Propane Gas Tanks and Piping A gas detecting warning system is the only reliable way to detect a propane gas leak. Rust can reduce the level of odorant in propane gas. Do not rely on your sense of smell. Contact a local propane gas supplier about installing a gas detecting warning system. If the presence of gas is suspected, follow the instructions listed in the Safety Considerations section of this manual. All propane gas equipment must conform to the safety standards of the National Board of Fire Underwriters, NBFU Manual 58. CANADA: National Standard of Canada, Natural Gas and Propane Installation Code (NSCNGPIC) CSA B149.1-15. 29 First Stage Regulator 5 to 15 PSIG (20 PSIG Max.) Continuous 11" W.C. 200 PSIG Maximum Second Stage Regulator Propane Gas Installation (Typ.) Figure 40 For satisfactory operation, propane gas pressure must be 10" WC at the furnace manifold with all gas appliances in operation. Maintaining proper gas pressure depends on three main factors: 1. Vaporization rate, depending on temperature of the liquid, and "wetted surface" area of the container or containers. 2. Proper pressure regulation. (Two-stage regulation is recommended for both cost and efficiency). 3. Pressure drop in lines between regulators, and between second stage regulator and the appliance. Pipe size will depend on length of pipe run and total load of all appliances. Complete information regarding tank sizing for vaporization, recommended regulator settings, and pipe sizing is available from most regulator manufacturers and propane gas suppliers. Since propane gas will quickly dissolve white lead and most standard commercial compounds, special pipe dope must be used. Always use a pipe thread sealant approved for all gases. Refer to the illustration for typical propane gas installations and piping. WARNING NEVER ALLOW THE PRODUCTS OF COMBUSTION, INCLUDING CARBON MONOXIDE, TO ENTER THE RETURN DUCT WORK OR CIRCULATION AIR SUPPLY. A closed return duct system must be used, with the return duct connected to the furnace. NOTE: Ductwork must never be attached to the back of the furnace. For upflow installations requiring 1800 CFM or more, use either two side returns or bottom return or a combination of side / bottom. Flexible joints may be used for supply and return connections to reduce noise transmission. To prevent the blower from interfering with combustion air or draft when a central return is used, a connecting duct must be installed between the unit and the utility room wall. Never use a room, closet, or alcove as a return air chamber. Checking Duct Static Refer to your furnace rating plate for the maximum ESP (external duct static) rating. Total external static refers to everything external to the furnace cabinet. Cooling coils, filters, ducts, grilles, registers must all be considered when reading your total external static pressure. The supply duct pressure must be read between the furnace and the cooling coil. This reading is usually taken by removing the "A" shaped block off plate from the end on the coil; drilling a test hole in it and reinstalling the block off plate. Take a duct static reading at the test hole. Tape up the test hole after your test is complete. The negative pressure must be read between the filter and the furnace blower. Too much external static pressure will result in insufficient air that can cause excessive temperature rise. This can cause limit switch tripping and heat exchanger failure. To determine total external duct static pressure, proceed as follows; 1. With clean filters in the furnace, use a draft gauge (inclined manometer) to measure the static pressure of the return duct at the inlet of the furnace. (Negative Pressure) 2. Measure the static pressure of the supply duct. (Positive Pressure) 3. The difference between the two numbers is .4" w.c. Example: Difference is 4 Circulating Air & Filters Duct work - Air Flow Duct systems and register sizes must be properly designed for the CFM and external static pressure rating of the furnace. Design the ductwork in accordance with the recommended methods of "Air Conditioning Contractors of America" Manual D. Install the duct system in accordance with Standards of the National Board of Fire Underwriters for the Installation of Air Conditioning, Warm Air Heating and Ventilating Systems. Pamphlets No. 90A and 90B. -1 0 1 2 3 Static reading from return duct = -.1" w.c. Static reading from supply duct = .3" w.c. Total external static pressure on this system = .4" w.c. NOTE: Both readings may be taken simultaneously and read directly on the manometer if so desired. If an air conditioner coil or Electronic Air Cleaner is used in conjunction with the furnace, the readings must also include theses components, as shown in the following drawing. 30 4. Consult proper tables for the quantity of air. If the total external static pressure exceeds the maximum listed on the furnace rating plate, check for closed dampers, registers, undersized and/or oversized poorly laid out duct work. The temperature rise of the furnace must be within the temperature rise range listed on the furnace rating plate. CUT USING TIN SNIPS CUT FOUR CORNERS AFTER REMOVING SHEET METAL PRESS OUT BY HAND SCRIBE LINES OUTLINING DUCT FLANGES Digital Manometer Checking Static Pressure (80% Furnace Shown, 90% Similar) Figure 41 WARNING EDGES OF SHEET METAL HOLES MAY BE SHARP. USE GLOVES AS A PRECAUTION WHEN REMOVING SHEET METAL FROM RETURN AIR OPENINGS. Bottom Return Air Opening [Upflow Models] The bottom return air opening on upflow models utilizes a "lance and cut" method to remove sheet metal from the duct opening in the base pan. To remove, simply press out the lanced sections by hand to expose the metal strips retaining the sheet metal over the duct opening. Using tin snips, cut the metal strips and remove the sheet metal covering the duct opening. In the corners of the opening, cut the sheet metal along the scribe lines to free the duct flanges. Using the scribe line along the duct flange as a guide, unfold the duct flanges around the perimeter of the opening using a pair of seamer pliers or seamer tongs. NOTE: Airflow area will be reduced by approximately 18% if duct flanges are not unfolded. This could cause performance issues and noise issues. Duct Flange Cut Outs Figure 42 When the furnace is used in connection with a cooling unit, the furnace should be installed in parallel with or on the upstream side of the cooling unit to avoid condensation in the heating element. With a parallel flow arrangement, the dampers or other means used to control the flow of air must be adequate to prevent chilled air from entering the furnace and, if manually operated, must be equipped with means to prevent operation of either unit unless the damper is in the full heat or cool position. When the furnace is installed without a cooling coil, it is recommended that a removable access panel be provided in the outlet air duct. This opening shall be accessible when the furnace is installed and shall be of such a size that the heat exchanger can be viewed for visual light inspection or such that a sampling probe can be inserted into the air stream. The access panel must be made to prevent air leaks when the furnace is in operation. When the furnace is heating, the temperature of the return air entering the furnace must be between 55°F and 100°F. Filters - Read This Section Before Installing The Return Air Duct work Filters must be used with this furnace. Discuss filter maintenance with the building owner. Filters do not ship with this furnace, but must be provided, sized and installed externally by the installer. Filters must comply with UL900 or CAN/ULCS111 standards. Damage or repairs due to the installation of the furnace without filters is not covered under the warranty. On upflow units, guide dimples locate the side return cutout locations. Use a straight edge to scribe lines connecting the dimples. Cut out the opening on these lines. NOTE: An undersized opening will cause reduced airflow. Refer to the Filter Sizing Chart to determine filter area requirements. 31 Model *MES9*0403AN* *MES9*0603BN* *MES9*0803BN* *MES9*0804CN* *MES9*0805CN* *MES9*1004CN* *MES9*1005CN* *MES9*1205DN* Filter Sizing Chart Minimum Recommended Filter Size^ 1 - 16 X 25 Side or 1 - 14 x 25 Bottom 1 - 16 X 25 Side or Bottom 1 - 16 X 25 Side or Bottom 1 - 16 X 25 Side or Bottom 1 - 20 X 25 Bottom / 2 - 16 X 25 Side Return 1 - 16 X 25 Side or Bottom 1 - 20 X 25 Bottom / 2 - 16 X 25 Side Return 1 - 20 X 25 Bottom / 2 - 16 X 25 Side Return The following figures show possible filter locations: AIR FLOW SIDE RETURN EXTERNAL FILTER RACK KIT (EITHER SIDE) *CES9*0603BN* 2 - 10 X 20 or 1 - 16 X 25 Top Return *CES9*0804CN* 2 - 10 X 20 or 1 - 16 X 25 Top Return *CES9*1005CN* 2 - 14 X 20 or 1 - 20 X 25 Top Return *CES961205DN* 2 - 14 X 20 or 1 - 20 X 25 Top Return ^ Larger filters may be used, filters may also be centrally located. Change filters before occupants take ownership of a new home! Consider installing an air cleaner with deep-pleated media filter at the time of furnace installation. A deep-pleated filter with a MERV rating of 8 (minimum) will often provide better filtration to protect equipment and the air distribution system than a standard 1" filter and often has lower static pressure loss than a 1" filter. Also a deep-pleated filter will typically require less frequent replacement intervals. Avoid using highly restrictive 1" filters which produce static pressure loss greater than .25" W.C. In some installations the minimum filter size required (consult filter sizing chart above) will not lend itself to a filter installation on the side of the furnace. The installation of a centrally installed air cleaner cabinet or a return duct filter installation may offer more practicality. Clean ComfortTM brand MERV 11 air cleaners have 5¼" media filters and are available in the following configurations. Consult your distributor for information on our complete line of IAQ Clean ComfortTM products. Depending on the installation and/or customer preference, differing filter arrangements can be applied. Filters can be installed in the central return register or a side panel external filter rack kit (upflows). As an alternative a media air filter or electronic air cleaner can be used as the requested filter. Possible Upright Upflow 32 FILTER SUPPORT BRACKET (Field Supplied) CENTRAL RETURN GRILLE Check for leaks using an approved chloride-free soap and water solution, an electronic combustible gas detector, or other approved method. Verify that all required kits (propane gas, high altitude, etc.) have been appropriately installed. Furnace Startup 1. Close the manual gas shutoff valve external to the furnace. 2. Turn off the electrical power to the furnace. 3. Set the room thermostat to the lowest possible setting. 4. Remove the burner compartment door. NOTE: This furnace is equipped with an ignition device which automatically lights the burner. Do not try to light the burner by hand. AIR FLOW CAUTION TO PREVENT UNRELIABLE OPERATION OR EQUIPMENT DAMAGE, THE INLET GAS SUPPLY PRESSURE MUST BE AS SPECIFIED ON THE UNIT RATING PLATE WITH ALL OTHER HOUSEHOLD GAS FIRED APPLIANCES OPERATING. Possible Upright Counterflow Filter Locations Horizontal Installations Filters must be installed in either the central return register or in the return air duct work. Startup Procedure & Adjustment Furnace must have a 115 VAC power supply properly connected and grounded. Proper polarity must be maintained for correct operation. In addition to the following start-up and adjustment items, refer to further information in Operational Checks section. Furnace Cabinet Check that all furnace cabinet sealing components are in place (plugs, grommets, gaskets). NOTE; If the furnace bottom panel has not been removed for a return duct connection, all perforations must be sealed with duct sealant compound or other suitable method to prevent air leakage. For optimal performance verify that all do gaskets are properly in place and replace as needed to prevent air leakage. Drain Trap Priming The drain trap MUST be primed prior to furnace startup. To prime, fill both sides of the drain trap with water. This ensures proper furnace drainage upon startup and prohibits the possibility of flue gases escaping through the drain system. Furnace Operation Purge gas lines of air prior to startup. Be sure not purge lines into an enclosed burner compartment. Follow NFPA 54, National Fuel Gas Code 8.1 for proper purging methods. In Canada, follow approved purging methods in B149.1-15. 5. Move the furnace gas valve manual control to the OFF position. 6. Wait five minutes then smell for gas. Be sure check near the floor as some types of gas are heavier than air. 7. If you smell gas after five minutes, immediately follow the safety instructions in the Safety Considerations on page 3 of this manual. If you do not smell gas after five minutes, move the furnace gas valve manual control to the ON position. 8. Replace the burner compartment door. 9. Open the manual gas shutoff valve external to the furnace. 10. Turn on the electrical power to the furnace. 11. Adjust the thermostat to a setting above room temperature. 12. After the burners are lit, set the thermostat to desired temperature. Furnace Shutdown 1. Set the thermostat to the lowest setting. The integrated control will close the gas valve and extinguish flame. Following a 15 second delay, the induced draft blower will be de-energized. The indoor blower will shut down when the time delay expires (selectable on 96% models). 2. Remove the burner compartment door and move the furnace gas valve manual control to the OFF position. 3. Close the manual gas shutoff valve external to the furnace. 4. Replace the burner compartment door. 33 Gas Supply Pressure Measurement Gas Pressure Test The line pressure supplied to the gas valve must be within the range specified below. The supply pressure can be measured at the gas valve inlet pressure tap or at a hose fitting installed in the gas piping drip leg. The supply pressure must be measured with the burners operating. To measure the gas supply pressure, use the following procedure. 1. Turn OFF gas to furnace at the manual gas shutoff valve external to the furnace. 2. Connect a calibrated water manometer (or appropriate gas pressure gauge) at either the gas valve inlet pressure tap or the gas piping drip leg. See White-Rodgers 36J22 gas valve figure for location of inlet pressure tap. Gas Valve ON/OFF Selector Switch Inlet Pressure Manifold Gas Pressure Gas Range No min al Natural 3.2 - 3.8" w.c. 3.5" w.c. Propane 9.7 - 10.3" w.c. 10.0" w.c. If supply pressure differs from table, make the necessary adjustments to pressure regulator, gas piping size, etc., and/or consult with local gas utility. 5. Turn OFF gas to furnace at the manual shutoff valve and disconnect manometer. Reinstall plug before turning on gas to furnace. 6. Turn OFF any unnecessary gas appliances stated in step 3. OUTLET INLET Regulator Cover Screw Outlet Pressure White-Rodgers Model 36J22 OUTLET INLET White-Rodgers Model 36J22 Connected to Manometer NOTE: If measuring gas pressure at the drip leg, a fieldsupplied hose barb fitting must be installed prior to making the hose connection. If using the inlet pressure tap on the White-Rodgers 36J22 gas valve, then use the 36G/J Valve Pressure Check Kit, Part No. 0151K00000S. 3. Turn ON the gas supply and operate the furnace and all other gas consuming appliances on the same gas supply line. 4. Measure furnace gas supply pressure with burners firing. Supply pressure must be within the range specified in the Inlet Gas Supply Pressure table. Measuring Inlet Gas Pressure (Alt. Method) Figure 43 Gas Manifold Pressure Measurement and Adjustment Only small variations in gas pressure should be made by adjusting the gas valve pressure regulator. The manifold pressure must be measured with the burners operating. To measure and adjust the manifold pressure, use the following procedure. 1. Turn OFF gas to furnace at the manual gas shutoff valve external to the furnace. 2. Turn off all electrical power to the system. 3. Outlet pressure tap connections: White-Rodgers 36J22 valve: Back outlet pressure test screw (inlet/outlet pressure tap) out one turn (counterclockwise, not more than one turn). 4. Attach a hose and manometer to the outlet pressure tap (White-Rodgers valve). 5. Turn ON the gas supply. 6. Turn on power and close thermostat "R" and "W" contacts to provide a call for heat. 7. Measure the gas manifold pressure with burners firing. Adjust manifold pressure using the Manifold Gas Pressure table shown on this page. 8. Remove regulator cover screw from the outlet pressure regulator adjust tower and turn screw clockwise to increase pressure or counterclockwise to decrease pressure. Replace regulator cover screw. 9. Turn off all electrical power and gas supply to the system. 34 10. Remove the manometer hose from the hose barb fitting or outlet pressure tap. 11. Replace outlet pressure tap: White-Rodgers 36J22 valve: Turn outlet pressure test screw in to seal pressure port (clockwise, 7 in-lb minimum). 12. Turn on electrical power and gas supply to the system. 13. Close thermostat contacts "R" and "W" to energize the valve. Using a leak detection solution or soap suds, check for leaks at outlet or screw (White-Rodgers valve). Bubbles forming indicate a leak. SHUT OFF GAS AND REPAIR ALL LEAKS IMMEDIATELY! NOTE: For gas to gas conversion, consult your dealer for appropriate conversion. CAUTION TO PREVENT UNRELIABLE OPERATION OR EQUIPMENT DAMAGE, THE INLET GAS SUPPLY PRESSURE MUST BE AS SPECIFIED ON THE UNIT RATING PLATE WITH ALL OTHER HOUSEHOLD GAS FIRED APPLIANCES OPERATING. Gas Input Rate Measurement (Natural Gas Only) The actual gas input rate to the furnace must never be greater than that specified on the unit rating plate. To measure natural gas input using the gas meter, use the following procedure. 1. Turn OFF the gas supply to all other gas-burning appliances except the furnace. 2. While the furnace is operating at high fire rate, time and record one complete revolution of the gas meter dial, measuring the smallest quantity, usually the dial that indicates 1/2 cu. ft. per revolution. You will use this number to calculate the quantity of gas in cubic ft. if the furnace would consume if it ran steadily for one hour (3600 seconds). 3. If the 1/2 cu. ft. dial was used, multiply your number x 2. EXAMPLE: If it took 23 seconds to complete one revolution of the 1/2 ft. dial (23 x 2 = 46). This tells us that at this rate, it would take 46 seconds to consume one cu. ft. of gas. 3600 / 46 = 78. This tells us that in one hour, the furnace would consume 78 cu. ft. of gas. The typical value range for 1 cu. ft. of natural gas is around 1000 BTU. Check with your gas utility, if possible. In this example, the furnace is consuming 78,000 BTUH. NOTE: The final manifold pressure cannot vary by more than ± 0.3" w.c. for Natural and + 0.5" for LP from the specified setting. Consult your local gas supplier if additional input rate adjustment is required. 4. Turn ON gas to and relight all other appliances turned off in step 1. Be certain that all appliances are functioning properly and that all pilot burners are operating. Temperature Rise Temperature rise must be within the range specified on the unit rating plate. An incorrect temperature rise may result in condensing in or overheating of the heat exchanger. An airflow and temperature rise table is provided in the Specification Sheet applicable to your model. Determine and adjust temperature rise as follows: 1. Operate furnace with burners firing for approximately ten minutes. Ensure all registers are open and all duct dampers are in their final (fully or partially open) position. 2. Place thermometers in the return and supply ducts as close to the furnace as possible. Thermometers must not be influenced by radiant heat by being able to "see" the heat exchanger. 3. Subtract the return air temperature from the supply air temperature to determine the air temperature rise. Allow adequate time for thermometer readings to stabilize. 4. Adjust temperature rise by adjusting the circulator blower speed. Increase blower speed to reduce temperature rise. Decrease blower speed to increase temperature rise. Refer to Startup Procedure and Adjustment - Circulator Blower Speeds for speed changing details. SUPPLY AIR RETURN AIR Temperature Rise Measurement Figure 44 Circulator Blower Speeds This furnace is equipped with a multi-speed circulator blower. This blower provides ease in adjusting blower speeds. The Specification Sheet applicable to your model provides an airflow table, showing the relationship between airflow (CFM) and external static pressure (E.S.P.), for the proper selection of heating and cooling speeds. 35 WARNING TO AVOID PERSONAL INJURY OR DEATH DUE TO ELECTRICAL SHOCK, TURN OFF POWER TO THE FURNACE BEFORE CHANGING SPEED TAPS. 1. Determine the tonnage of the cooling system installed with the furnace. If the cooling capacity is in BTU/hr divide it by 12,000 to convert capacity to tons. Example: Cooling Capacity of 30,000 BTU/hr. 30,000/12,000 = 2.5 Tons 2. Determine the proper air flow for the cooling system. Most cooling systems are designed to work with air volume between 350 and 450 CFM per ton. Most manufacturers recommend an air flow of about 400 CFM per ton. Example: 2.5 tons X 400 CFM per ton = 1000 CFM 3. Select the heating speed for your model from the heating speed chart in the Specification Sheet. The selected speed must provide a temperature rise within the rise range listed with the particular model. To adjust the circulator blower speed, proceed as follows: 1. Motor speed Tap wiring must remain in factory position on the control board and motor. 2. There are 4 speed Tap wires to the motor T1, T2, T3, T4. 3. There are 5 speeds available, depending on DIP switch settings and found in air flow table for each size furnace. 4. Cooling Speed can be adjusted by adjusting S1-1, S1-2, S1-3 (see cooling airflow Chart for reference). 5. Heating Speed can be adjusted by adjusting S2-1 , S2-2 (see heating airflow Chart). 6. Circulation / Continuous Fan speed can be adjusted by adjusting S2-3 , S2-4 (see Circulation airflow Chart) 7. Verify proper temperature rise as outlined in the Temperature Rise section of Startup Procedure and Adjustment. Motor Tap Identification CONNECTOR ID DESCRIPTION CONNECTOR VOLTAGE L LINE, L1 LINE, L1 G GROUND CHASSIS GROUND N LINE, L2 LINE, L2 C SIGNAL COMMON 24VAC COMMON 1 TAP 1 24VAC 2 TAP 2 24VAC 3 TAP 3 24VAC 4 TAP 4 24VAC 5 TAP 5 24VAC Heat Off Delay (S1-4) S1-4 Min Nom Max Units ON *150 Seconds OFF 100 Seconds * = DEFAULT SETTING HEAT MOTOR SPEED DIP SWITCH SETTING (S2-1, S2-2) 1 2 *1 2 1 2 1 2 OFF Position OFF ON OFF ON ON OFF ON Motor Speed W T1 T2 T3 T4 HEAT *=DEFAULT SETTING FAN MOTOR SPEEED DIP SWITCH SETTING (S2-3, S2-4) *3 4 3 4 3 4 3 4 OFF Position OFF ON OFF OFF ON ON ON Motor Speed G T1 T2 FAN T4 T1+T2 *=DEFAULT SETTING Motor Speed COOL Position Y COOL MOTOR SPEED DIP SWITCH SETTING (S1-1, S1-2, S1-3) 1 2 3 1 2 3 1 23 1 2 3 *1 2 3 1 2 3 OFF OFF OFF ON OFF OFF ON ON OFF OFF ON OFF OFF OFF ON OFF ON ON T1 T2 T3 T4 T1+T2 T1 * = DEFAULT SETTING 1 2 3 ON OFF ON T1 1 2 3 ON ON ON T1 36 Cooling Dip Switches Heat Dip Switches Fan Dip Switches In general lower heating speeds will: reduce electrical consumption, lower operating sound levels of the blower, and increase the outlet air temperature delivered to the home. The speeds available allow the blower performance to be optimized for the particular homeowner's needs. Blower Heat Off Delay Timings This integrated control module offers selectable heat off delay function. The heat delay may be set to 100 or 150 seconds by adjusting DIP Switch S1-4 on the Control Module. The delay is factory shipped at 150 seconds but may be changed to suit the installation requirements and/or homeowner preference. Normal Sequence of Operation Power Up The normal power up sequence is as follows: · 115 VAC power applied to furnace. · Integrated control module performs internal checks. · LED will flash once at power up then remain on. · Integrated control module monitors safety circuits continuously. · Furnace awaits call from thermostat. Heating Mode The normal operational sequence in heating mode is as follows: · R and W thermostat contacts close, initiating a call for heat. · Integrated control module performs safety circuit checks · Induced draft blower is energized for a 15-second prepurge. · Igniter warn up begins upon presence of closed pressure switch contacts. · Gas valve opens at end of igniter warm up period, delivering gas to burners and establishing flame. · Integrated control module monitors flame presence. Gas valve will remain open only if flame is detected. · Circulator blower is energized on heat speed following a thirty (30) second blower on delay. · Furnace runs, integrated control module monitors safety circuits continuously. · R and W thermostat contacts open, completing the call for heat. · Gas valve closes, extinguishing flame. · Induced draft blower is de-energized following a fifteen second post purge. · 96% models HUM terminal is de-energized. · For 96% Models: Circulator blower continues running for the selected heat off delay period Factory set at 150 seconds. · EAC terminal is de-energized · Furnace awaits next call from thermostat. Cooling Mode The normal operational sequence in cooling mode is as follows: · R,Y, G thermostat contacts close, initiating a call for cool. · Integrated control module performs safety circuit checks. · Outdoor fan and compressor are energized. · Circulator blower is energized on the cool speed. · 96% models 115 VAC EAC terminal is energized. · Furnace circulator blower and outdoor cooling unit run their appropriate speeds, integrated control module monitors safety circuits continuously. · R,Y, G thermostat contacts open, completing the call for cool. · Outdoor fan and compressor are de-energized. · Circulator blower continues running during a cool off delay period of 65 seconds. · Furnace awaits next call from thermostat. Fan Only Mode The normal operational sequence in fan only mode is as follows: · R and G thermostat contacts close, initiating a call for fan. · Integrated control module performs safety circuit checks. · Circulator blower is energized on heat speed. · 96% models 115 VAC EAC terminal is energized. · Circulator blower runs, integrated control module monitors safety circuits continuously. · R and G thermostat contacts open, completing the call for fan. · Circulator blower is de-energized. · EAC terminal is de-energized. · Furnace awaits next call from thermostat. Operational Checks The burner flames should be inspected with the burner compartment door installed. Flames should be stable, quiet, soft, and blue (dust may cause orange tips but they must not be yellow). Flames should extend directly outward from the burners without curling, floating, or lifting off. Flames must not impinge on the sides of the heat exchanger firing tubes. 37 Safety Circuit Description A number of safety circuits are employed to ensure safe and proper furnace operation. These circuits serve to control any potential safety hazards and serve as inputs in the monitoring and diagnosis of abnormal function. These circuits are continuously monitored during furnace operation by the integrated control module. Integrated Control Module The integrated control module is an electronic device which, if a potential safety concern is detected, will take the necessary precautions and provide diagnostic information through an LED. Primary Limit The primary limit control is located on the partition panel and monitors heat exchanger compartment temperatures. It is a normally-closed (electrically), automatic reset, temperature-activated sensor. The limit guards against overheating as a result of insufficient conditioned air passing over the heat exchanger. Auxiliary Limit The auxiliary limit controls are located on or near the circulator blower and monitors blower compartment temperatures. They are a normally-closed (electrically), manual-reset sensors. These limits guard against overheating as a result of insufficient conditioned air passing over the heat exchanger. Rollout Limit The rollout limit controls are mounted on the burner/manifold assembly and monitor the burner flame. They are normally-closed (electrically), manual-reset sensors. These limits guard against burner flames not being properly drawn into the heat exchanger. Pressure Switches The pressure switches are normally-open (closed during operation) negative air pressure-activated switches. They monitor the airflow (combustion air and flue products) through the heat exchanger via pressure taps located on the induced draft blower and the coil front cover. These switches guard against insufficient airflow (combustion air and flue products) through the heat exchanger and/or blocked condensate drain conditions. Flame Sensor The flame sensor is a probe mounted to the burner/manifold assembly which uses the principle of flame rectification to determine the presence or absence of flame. Troubleshooting Electrostatic Discharge (ESD) Precautions NOTE: Discharge body's static electricity before touching unit. An electrostatic discharge can adversely affect electrical components. Use the following precautions during furnace installation and servicing to protect the integrated control module from damage. By putting the furnace, the control, and the person at the same electrostatic potential, these steps will help avoid exposing the integrated control module to electrostatic discharge. This procedure is applicable to both installed and uninstalled (ungrounded) furnaces. 1. Disconnect all power to the furnace. Do not touch the integrated control module or any wire connected to the control prior to discharging your body's electrostatic charge to ground. 2. Firmly touch a clean, unpainted, metal surface of the furnace away from the control. Any tools held in a person's hand during grounding will be discharged. 3. Service integrated control module or connecting wiring following the discharge process in step 2. Use caution not to recharge your body with static electricity; (i.e., do not move or shuffle your feet, do not touch ungrounded objects, etc.). If you come in contact with an ungrounded object, repeat step 2 before touching control or wires. 4. Discharge your body to ground before removing a new control from its container. Follow steps 1 through 3 if installing the control on a furnace. Return any old or new controls to their containers before touching any ungrounded object. Diagnostic Chart Refer to the Diagnostic Codes chart for assistance in determining the source of unit operational problems. ERROR CODE Red LED Flash Error / Condition Flash Codes stored in memory (auto-erased after 14 days) 1 System Lockout (Retries Exceeded) 2 Pressure Switch stuck Closed 3 Pressure Switch stuck Open 4 Open Main or Auxillary Temperature Limit Switch 5 Flame Sensed>4.25 Seconds with Gas Valve De-Energized 6 Open Rollout Temperature Limit Switch 8 Igniter Relay Fault 10 Open Fuse 11 Igniter Open 12 Inducer Relay Error/Improper Grounding Flash Codes NOT stored in memory 7 Low Flame Sense Signal 9 Twinning Fault Control Failure / No Power / Internal Fault / IRQ Loss. Gas Heating OFF Lockout (Gas valve energized when it should be de-energized) Or Gas Valve De-energized when it should be Energized Rapid Flash Reverse Polarity Continuous On Normal Operation Fault Code Retrieval Fault recall shall be via momentary push button switch when held depressed for 25 seconds while control is in standby mode. The control shall flash the last five status codes that have occurred. The control will flash the most recent error first and the oldest error last (last in first out). There shall be 2 seconds between codes. Fault Code Reset The last five fault codes can be erased from memory by depressing the fault recall switch for 510 seconds. At 5 seconds the LED will be rapid flashed (100 mS on, 100 mS off) to indicate that the switch should be released to erase the fault codes. Once the switch is released the rapid flash will stop and the fault codes will be erased. The control shall acknowledge the reset of the fault codes by turning off the LED for 2 seconds after the switch is released. The LED status will then return to the normal mode. 38 WARNING HIGH VOLTAGE ! TO AVOID PERSONAL INJURY OR DEATH DUE TO ELECTRICAL SHOCK, DISCONNECT ELECTRICAL POWER BEFORE PERFORMING ANY SERVICE OR MAINTENANCE. Resetting From Lockout Furnace lockout results when a furnace is unable to achieve ignition after three attempts during a single call for heat. It is characterized by a non-functioning furnace and a fault code displayed. If the furnace is in "lockout", it will (or can be) reset in any of the following ways. 1. Automatic reset. The integrated control module will automatically reset itself and attempt to resume normal operations following a one hour lockout period. 2. Manual power interruption. Interrupt 115 volt power to the furnace. 3. Manual thermostat cycle. Lower the thermostat so that there is no longer a call for heat for 1 -20 seconds then reset to previous setting. NOTE: If the condition which originally caused the lockout still exists, the control will return to lockout. Refer to the Troubleshooting Chart for aid in determining the cause. Maintenance Annual Inspection The furnace should be inspected by a qualified installer, or service agency at least once per year. This check should be performed at the beginning of the heating season. This will ensure that all furnace components are in proper working order and that the heating system functions appropriately. Pay particular attention to the following items. Repair or service as necessary. · Flue pipe system. Check for blockage and/or leakage. Check the outside termination and the connections at and internal to the furnace. · Heat exchanger. Check for corrosion and/or buildup within the heat exchanger passageways. · Burners. Check for proper ignition, burner flame, and flame sense. · Drainage system. Check for blockage and/or leakage. Check hose connections at and internal to furnace. · Wiring. Check electrical connections for tightness and/ or corrosion. Check wires for damage. · Filters. Filters Filter Maintenance Improper filter maintenance is the most common cause of inadequate heating or cooling performance. Filters should be cleaned (permanent) or replaced (disposable) every two months or as required. When replacing a filter, it must be replaced with a filter of the same type and size. Filter Removal Depending on the installation, differing filter arrangements can be applied. Filters can be installed in either the central return register or a side panel external filter rack (upflow only). A media air filter or electronic air cleaner can be used as an alternate filter. Follow the filter sizes given in the Recommended Minimum Filter size table to ensure proper unit performance. To remove filters from an external filter rack in an upright upflow installation, follow the directions provided with external filter rack kit. Horizontal Unit Filter Removal Filters in horizontal installations are located in the central return register or the ductwork near the furnace. To remove: 1. Turn OFF electrical power to furnace. 2. Remove filter(s) from the central return register or ductwork. 3. Replace filter(s) by reversing the procedure for removal. 4. Turn ON electrical power to furnace. Media Air Filter or Electronic Air Cleaner Removal Follow the manufacturer's directions for service. Burners Visually inspect the burner flames periodically during the heating season. Turn on the furnace at the thermostat and allow several minutes for flames to stabilize, since any dislodged dust will alter the flames normal appearance. Flames should be stable, quiet, soft, and blue (dust may cause orange tips but they must not be yellow). They should extend directly outward from the burners without curling, floating, or lifting off. Flames must not impinge on the sides of the heat exchanger firing tubes. Induced Draft and Circulator Blowers The bearings in the induced draft blower and circulator blower motors are permanently lubricated by the manufacturer. No further lubrication is required. Check motor windings for accumulation of dust which may cause overheating. Clean as necessary. Burner Flame Figure 45 39 Condensate Trap and Drain System (Qualified Servicer Only) Annually inspect the drain tubes, drain trap, and field-supplied drain line for proper condensate drainage. Check drain system for hose connection tightness, blockage, and leaks. Clean or repair as necessary. Flame Sensor (Qualified Servicer Only) Under some conditions, the fuel or air supply can create a nearly invisible coating on the flame sensor. This coating acts as an insulator causing a drop in the flame sense signal. If the flame sense signal drops too low the furnace will not sense flame and will lock out. The flame sensor should be carefully cleaned by a qualified servicer using emery cloth or steel wool. Following cleaning, the flame sense signal should be as indicated in the Specifications Sheet. Flue Passages (Qualified Servicer Only) The heat exchanger flue passageways should be inspected at the beginning of each heating season. Before Leaving an Installation · Cycle the furnace with the thermostat at least three times. Verify cooling and fan only operation. · Review the Owner's Manual with the homeowner and discuss proper furnace operation and maintenance. · Leave literature packet near furnace. Repair and Replacement Parts · When ordering any of the listed functional parts, be sure to provide the furnace model, manufacturing, and serial numbers with the order. · Although only functional parts are shown in the parts list, all sheet metal parts, doors, etc. may be ordered by description. · Parts are available from your distributor. Functional Parts List- Gas Valve Gas Manifold Blower Motor Blower Wheel Natural Gas Orifice Propane Gas Orifice Blower Mounting Bracket Blower Cutoff Igniter Blower Housing Flame Sensor Pressure Switch Rollout Limit Switch Door Switch Primary Limit Switch Auxiliary Limit Switch Coil Front Cover Integrated Control Module Transformer Door Switch Induced Draft Blower Heat Exchanger with Recuperator Coil 40 Troubleshooting Chart PCBBF145 Symptoms of Abnormal Operation · Furnace fails to operate. · Integrated control module diagnostic LED provides no signal. Associated LED Code2 Fault Description(s) Possible Causes Corrective Action Cautions and Notes OFF · No 115 volt power · Manual disconnect · Assure 115 and 24 volt · Turn power OFF to furnace, or no switch OFF, door power to furnace prior to repair. 24 volt power to switch open, or integrated control · Replace integrated integrated control 24 volt wires improperly module. control module fuse module. connected or loose. · Check integrated with 3A automotive · Blown fuse or circuit · Blown fuse or circuit control module fuse fuse. breaker. breaker. (3A). Replace if · Read precautions in ·Integrated control · Integrated control necessary. "Electrostatic module has an module has an · Check for possible Discharge" section of internal fault. internal fault. shorts in 115 and 24 manual. volt circuits. Repair as necessary. · Replace bad integrated control module. · LED is Steady On. · Furnace fails to operate. · Integrated control module diagnostic LED is flashing ONE (1) flash. · Normal Operation · Normal Operation · None ON · Normal Operation CONTINUOUS ON 1 1 FLASH · Furnace lockout due to · Failure to establish · Locate and correct · Turn power OFF prior an excessive number of flame. Cause may be no gas interruption. to repair. ignition "retries" gas to burners, front · Check front cover · Igniter is fragile, (3 total)1. cover pressure switch stuck open, bad igniter pressure switch handle with care. operation (hose, wiring, · Sand flame sensor with or igniter alignment, contact operation). emery cloth. improper orifices, Correct if necessary. · See "Vent/ Flue Pipe" coated/oxidized or · Replace or realign section for piping improperly connected igniter. details. flame sensor. · Check flame sense · Loss of flame after signal. Sand sensor if establishment. Cause coated and/or oxidized. may be interrupted gas · Check flue piping for supply, lazy burner blockage, proper flames (improper gas length, elbows, and pressure or restriction termination. in flue and/or · Verify proper induced combustion air piping), draft blower front cover pressure performance. switch opening, improper induced draft blower performance. · Furnace fails to operate. · Integrated control module diagnostic LED is flashing TWO (2) flashes. · Induced draft blower runs continuously with no further furnace operation. · Integrated control module diagnostic LED is flashing THREE (3) flashes. 2 2 FLASHES 3 3 FLASHES · Pressure switch circuit · Induced draft blower is closed. pressure switch · Induced draft blower is contacts sticking. not operating. · Shorts in pressure switch circuit. · Pressure switch circuit · Pressure switch hose not closed. blocked, pinched or · Induced draft blower is connected improperly. operating. · Blocked flue and/or inlet air pipe, blocked drain system, or weak induced draft blower. · Incorrect pressure switch setpoint or malfunctioning switch contacts. · Loose or improperly connected wiring. · Replace induced draft · Turn power OFF prior blower pressure switch. to repair. · Repair short. · Replace pressure switch with proper replacement part. · Inspect pressure switch · Turn power OFF prior hose. Repair, if to repair. necessary. · Replace pressure ·Inspect flue and/or inlet switch with proper air piping for blockage, replacement part. proper length, elbows, and termination. Check drain system. Correct as necessary. · Correct pressure switch setpoint or contact motion. · Tighten or correct wiring connection. 1Integrated control module will automatically attempt to reset from lockout after one hour. 2LED Flash code will cease if power to the control module is interrupted through the disconnect or door switch. 41 Troubleshooting Chart · Circulator blower runs continuously. No furnace operation. · Integrated control module diagnostic LED is flashing FOUR (4) flashes. · Induced draft blower and circulation blower runs continuously. No furnace operation. · Integrated control module diagnostic LED is flashing FIVE (5) flashes. · Furnace fails to operate. · Integrated control module diagnostic LED is flashing SIX (6) flashes. · No furnace operation. · Normal furnace operation. · Integrated control module diagnostic LED is flashing SEVEN (7) flashes. 4 4 FLASHES 5 5 FLASHES 6 6 FLASHES 7 7 FLASHES · Primary or auxiliary limit circuit is open. · Flame sensed with no call for heat. · Faulty primary or · Check primary/ · Turn power OFF prior auxiliary limit switch. auxiliary limit. to repair. · Insufficient conditioned Replace if necessary. · Replace primary/ air over the heat · Check filters and auxiliary limit with exchanger. Blocked ductwork for blockage. proper replacement filters, restrictive Clean filters or remove part. ductwork, improper obstruction. · Replace blower with circulator blower speed, · Check circulator blower correct replacement or failed circulator speed and performance. part. blower. Correct speed or · Loose or improperly replace connected wiring. blower if necessary. · Tighten or correct · Short to ground in · Ciorirect short ai t flame · Turn power OFF prior flame sense circuit. sensor or in flame to repair. sensor wiring. ·Rollout limit open. · Flame rollout. · Check burners for · Turn power OFF prior ·Integrated control · Misaligned burners, proper alignment. to repair. module fuse is blown. blocked flue and/or air · Check flue and air inlet · See "Vent/Flue Pipe" inlet pipe, or failed piping for blockage, section for piping induced draft blower. proper length, elbows, details. · Loose or improperly and termination. · Replace induced draft connected wiring. Correct as necessary. blower with correct · Short in 24 volt AC · Check rollout limit. replacement part. control circuits or Replace if necessary. · Replace integrated safety circuits. · Check induced draft control module fuse · Faulty rollout limit. blower for proper with 3A automotive performance. Replace, fuse. if necessary. · Read precautions in · Tighten or correct "Electrostatic wiring connection. Discharge" section of manual. · Replace rollout limit with correct replacement part. · Flame sense microamp · Flame sensor is · Sand flame sensor. · Turn power OFF prior signal is low. coated/oxidized. · Inspect for proper to repair. · Flame sensor sensor alignment. · Clean flame sensor incorrectly positioned · Compare current gas with steel wool. in burner flame. pressure to rating plate · See "Vent/Flue Pipe" · Lazy burner flame info. Adjust as needed. section for due to improper gas piping details. pressure or · See rating plate for combustion air. proper gas pressure. · Furnace not operating. · Integrated control module diagnostic LED is flashing EIGHT (8) flashes. · Igniter Relay Fault 8 FLASHES ·Improperly connected igniter. · Bad igniter. · Poor unit ground. · Poor burner ground. · Faulty integrated control module. ·Check and correct · Turn power OFF prior wiring from integrated to repair. control module · Replace igniter to igniter. w/proper replacement ·Replace bad igniter. part. ·Check & correct unit · Read precautions in ground wire. "Electrostatic · Replace bad integrated Discharge" section control module. of manual. 42 Troubleshooting Chart Symptoms of Abnormal Operation · Circulating blowers not operating simultaneously. No blower operation. Associated LED Code2 Fault Description(s) Possible Causes Corrective Action Cautions and Notes ·Twinning Fault · Furnace twin terminals · Install field wiring · Verify line voltage not connected together connecting twin supply is turned off by field wiring. terminals, check before proceeding · Isolating relay not used continuity of wiring. with corrections 9 FLASHES or improperly installed · Verify each furnace fan motor is operable without twinning connection. · Wire per twinning diagram in this installation manual · Furnace not operating. · Integrated control module diagnostic LED is flashing TEN (10) flashes. · Open Fuse / No 24V power to integrated control module 10 FLASHES · High voltage surge blows off the fuse. · Replace the Fuse. · Verify line voltage supply is turned off before proceeding with corrections · Furnace not operating. · Integrated control module diagnostic LED is flashing ELEVEN (11) flashes. · Igniter Open 11 FLASHES · Furnace not operating. · Integrated control module diagnostic LED is flashing TWELVE (12) flashes. · Inducer Relay Fault · Improper Grounding 12 FLASHES ·Improperly connected igniter. · Bad igniter. · Poor unit ground. · Poor burner ground. ·Improperly connected inducer. · Bad inducer. · Poor unit ground. · Faulty integrated control module. ·Check and correct · Turn power OFF prior wiring from integrated to repair. control module · Replace igniter to igniter. w/proper replacement ·Replace bad igniter. part. ·Check & correct unit · Read precautions in ground wire. "Electrostatic · Replace bad integrated Discharge" section control module. of manual. ·Check and correct · Turn power OFF prior wiring from integrated to repair. control module · Replace inducer to inducer. w/proper replacement · Check for Blockage in part. inducer & in Vent / · Read precautions in replace Inducer. "Electrostatic ·Check & correct unit Discharge" section ground wire. of manual. · Replace bad integrated control module. · Furnace fails to operate. · Integrated control module diagnostic LED is flashing continuously. · Polarity of 115 or 24 volt power is reversed. CONTINOUS RAPID FLASH · Polarity of 115 volt AC power to furnace or integrated control module is reversed. · Orange and gray wires to transformer are reversed. · Poor unit ground. · Review wiring diagram to correct polarity. · Reverse orange and gray wires going to transformer. · Verify proper ground. Correct if necessary. · Turn power OFF prior to repair 1Integrated control module will automatically attempt to reset from lockout after one hour. 2LED Flash code will cease if power to the control module is interrupted through the disconnect or door switch. 43 Heating Airflow *MES92*** DIP MODEL SWITCHES 0.1 S2-1 , S2-2 CFM RISE OFF OFF 628 54 GMES92 / AMES92 0403A ON OFF* ON ON** 806 927 42 N/A OFF ON** 1111 N/A OFF OFF** 725 N/A GMES92 / AMES92 0603B ON OFF* ON ON 1068 940 48 54 OFF ON** 1139 N/A OFF OFF 737 N/A GMES92 / AMES92 0803B ON OFF* ON ON 1223 56 983 N/A OFF ON 1160 59 OFF OFF** 795 N/A GMES92 / AMES92 0804C ON OFF* ON ON** 1417 1587 48 N/A OFF ON** 1794 N/A OFF OFF** 761 N/A GMES92 / AMES92 0805C ON OFF* ON ON** 1439 1596 47 N/A OFF ON** 1800 N/A OFF OFF** 814 N/A GMES92 / AMES92 1004C ON OFF* ON ON 1596 1434 53 59 OFF ON** 1796 N/A OFF OFF** 804 N/A GMES92 / AMES92 1005C ON OFF* ON ON 1624 1440 52 59 OFF ON** 1812 N/A OFF OFF** 1250 N/A GMES92 / AMES92 1205D ON OFF* ON ON** 2110 1536 48 N/A OFF ON 1884 54 * Default & Recommended ** Not recommended EXTERNAL STATIC PRESSURE, (INCHES WATER COLUMN) 0.2 0.3 0.4 0.5 0.6 CFM RISE CFM RISE CFM RISE CFM RISE CFM 582 59 530 N/A 478 N/A 428 N/A 370 762 45 719 47 676 50 633 54 594 883 N/A 844 N/A 808 N/A 793 N/A 756 1071 N/A 1033 N/A 1002 N/A 971 N/A 936 662 N/A 599 N/A 519 N/A 479 N/A 418 1018 50 971 53 926 55 880 58 834 891 57 836 61 787 65 762 N/A 714 1089 N/A 1040 N/A 998 N/A 958 N/A 911 669 N/A 609 N/A 550 N/A 490 N/A 425 1171 58 1125 61 1081 63 1036 66 987 922 N/A 870 N/A 818 N/A 793 N/A 747 1112 61 1066 64 1020 67 977 N/A 933 721 N/A 646 N/A 580 N/A 507 N/A 399 1378 49 1324 51 1284 53 1238 55 1191 1541 N/A 1496 N/A 1450 N/A 1411 N/A 1383 1733 N/A 1694 N/A 1661 N/A 1623 N/A 1591 685 N/A 608 N/A 540 N/A 471 N/A 369 1395 49 1364 50 1316 52 1270 54 1227 1552 N/A 1508 N/A 1467 N/A 1425 N/A 1405 1757 N/A 1716 N/A 1680 N/A 1644 N/A 1605 741 N/A 661 N/A 592 N/A 523 N/A 451 1539 55 1485 57 1443 59 1401 61 1372 1369 62 1317 65 1273 N/A 1228 N/A 1178 1744 N/A 1691 N/A 1648 N/A 1606 N/A 1568 750 N/A 671 N/A 598 N/A 539 N/A 471 1560 55 1508 56 1465 58 1422 60 1389 1390 61 1335 64 1288 N/A 1236 N/A 1186 1755 N/A 1708 N/A 1662 N/A 1623 N/A 1585 1003 N/A 868 N/A 788 N/A 669 N/A 572 2058 50 2008 51 1957 52 1906 54 1852 1462 N/A 1408 N/A 1335 N/A 1258 N/A 1185 1821 56 1757 58 1698 60 1628 63 1550 0.7 CFM 319 551 719 905 348 789 666 870 361 945 696 889 326 1146 1339 1544 302 1181 1354 1570 377 1325 1129 1533 390 1338 1137 1548 488 1800 1109 1492 0.8 CFM 282 506 680 871 285 767 619 829 303 905 645 849 275 1092 1298 1508 262 1135 1314 1528 306 1280 1081 1493 322 1295 1090 1507 406 1750 1026 1422 1. CFM in chart is without filter(s). Filters do not ship with this furnace, but must be provided by the installer. If the furnace requires two return filters, this chart assumes both filters are installed. 2. All furnaces ship as high speed cooling and medium-speed heating. Installer must adjust blower cooling & heating speed as needed. 3. For most jobs, about 400 CFM per ton when cooling is desirable. 4. INSTALLATION IS TO BE ADJUSTED TO OBTAIN TEMPERATURE RISE WITHIN THE RANGE SPECIFIED ON THE RATING PLATE. 5. The chart is for information only. For satisfactory operation, external static pressure must not exceed value shown on rating plate. The shaded area indicates ranges in excess of maximum external static pressure allowed when heating. The data for 0.6" w.c. to 0.8" w.c. is shown for air conditioning purposes only. 6. At higher altitudes, a properly derated unit will have approximately the same temperature rise at a particular CFM, while the ESP at that CFM will be lower. 44 Circulation Airflow *MES92*** EXTERNAL STATIC PRESSURE, (INCHES WATER COLUMN) MODEL DIP SWITCHES 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1 S2-3 , S2-4 GMES92 / AMES92 0403A GMES92 / AMES92 0603B GMES92 / AMES92 0803B GMES92 / AMES92 0804C GMES92 / AMES92 0805C GMES92 / AMES92 1004C GMES92 / AMES92 1005C GMES92 / AMES92 1205D OFF OFF ON OFF OFF ON ON ON OFF OFF ON OFF OFF ON ON ON OFF OFF ON OFF OFF ON ON ON OFF OFF ON OFF OFF ON ON ON OFF OFF ON OFF OFF ON ON ON OFF OFF ON OFF OFF ON ON ON OFF OFF ON OFF OFF ON ON ON OFF OFF ON OFF OFF ON ON ON CFM 628 806 1111 1359 725 1068 1139 1378 737 1223 1160 1431 795 1417 1794 1819 761 1439 1800 2186 814 1596 1796 1833 804 1624 1812 2223 1250 2110 1884 2233 CFM 582 762 1071 1322 662 1018 1089 1337 669 1171 1112 1394 721 1378 1733 1771 685 1395 1757 2148 741 1539 1744 1772 750 1560 1755 2176 1003 2058 1821 2177 CFM 530 719 1033 1290 599 971 1040 1301 609 1125 1066 1358 646 1324 1694 1727 608 1364 1716 2113 661 1485 1691 1724 671 1508 1708 2127 868 2008 1757 2129 CFM 478 676 1002 1258 519 926 998 1264 550 1081 1020 1322 580 1284 1661 1689 540 1316 1680 2082 592 1443 1648 1677 598 1465 1662 2084 788 1957 1698 2085 CFM 428 633 971 1229 479 880 958 1223 490 1036 977 1281 507 1238 1623 1653 471 1270 1644 2016 523 1401 1606 1636 539 1422 1623 2046 669 1906 1628 2036 CFM 370 594 936 1203 418 834 911 1188 425 987 933 1241 399 1191 1591 1615 369 1227 1605 2005 451 1372 1568 1601 471 1389 1585 2014 572 1852 1550 1981 CFM 319 551 905 1176 348 789 870 1150 361 945 889 1204 326 1146 1544 1574 302 1181 1570 1981 377 1325 1533 1563 390 1338 1548 1993 488 1800 1492 1928 CFM 282 506 871 1148 285 767 829 1113 303 905 849 1163 275 1092 1508 1538 262 1135 1528 1952 306 1280 1493 1521 322 1295 1507 1977 406 1750 1422 1881 CFM 239 463 839 1122 239 725 806 1073 251 859 824 1131 235 1055 1469 1497 224 1093 1488 1936 272 1241 1445 1484 276 1253 1466 1948 330 1697 1375 1833 CFM 201 418 807 1095 207 679 771 971 208 838 780 1098 207 1010 1426 1465 187 1051 1450 1903 215 1192 1409 1441 221 1211 1425 1913 236 1646 1305 1783 45 Cooling Airflow DIP SWITCHES MODEL GMES92 / AMES92 0403A GMES92 / AMES92 0603B GMES92 / AMES92 0803B GMES92 / AMES92 0804C GMES92 / AMES92 0805C GMES92 / AMES92 1004C GMES92 / AMES92 1005C GMES92 / AMES92 1205D S1-1 , S1-2 , 0.1 S1-3 CFM OFF OFF OFF 628 OFF ON ON 628 ON OFF ON 628 ON ON ON 628 ON OFF OFF 806 ON ON OFF 927 OFF ON OFF 1111 OFF OFF ON* 1359 OFF OFF OFF 725 OFF ON ON 725 ON OFF ON 725 ON ON ON 725 ON OFF OFF 1068 ON ON OFF 940 OFF ON OFF 1139 OFF OFF ON* 1378 OFF OFF OFF 737 OFF ON ON 737 ON OFF ON 737 ON ON ON 737 ON OFF OFF 1223 ON ON OFF 983 OFF ON OFF 1160 OFF OFF ON* 1431 OFF OFF OFF 795 OFF ON ON 795 ON OFF ON 795 ON ON ON 795 ON OFF OFF 1417 ON ON OFF 1587 OFF ON OFF 1794 OFF OFF ON* 1819 OFF OFF OFF 761 OFF ON ON 761 ON OFF ON 761 ON ON ON 761 ON OFF OFF 1439 ON ON OFF 1596 OFF ON OFF 1800 OFF OFF ON* 2186 OFF OFF OFF 814 OFF ON ON 814 ON OFF ON 814 ON ON ON 814 ON OFF OFF 1596 ON ON OFF 1434 OFF ON OFF 1796 OFF OFF ON* 1833 OFF OFF OFF 804 OFF ON ON 804 ON OFF ON 804 ON ON ON 804 ON OFF OFF 1624 ON ON OFF 1440 OFF ON OFF 1812 OFF OFF ON* 2223 OFF OFF OFF 1250 OFF ON ON 1250 ON OFF ON 1250 ON ON ON 1250 ON OFF OFF 2110 ON ON OFF 1536 OFF ON OFF 1884 OFF OFF ON* 2233 * Default *MES92*** EXTERNAL STATIC PRESSURE, (INCHES WATER COLUMN) 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 CFM CFM CFM CFM CFM CFM CFM CFM 582 530 478 428 370 319 282 239 582 530 478 428 370 319 282 239 582 530 478 428 370 319 282 239 582 530 478 428 370 319 282 239 762 719 676 633 594 551 506 463 883 844 808 793 756 719 680 646 1071 1033 1002 971 936 905 871 839 1322 1290 1258 1229 1203 1176 1148 1122 662 599 519 479 418 348 285 239 662 599 519 479 418 348 285 239 662 599 519 479 418 348 285 239 662 599 519 479 418 348 285 239 1018 971 926 880 834 789 767 725 891 836 787 762 714 666 619 570 1089 1040 998 958 911 870 829 806 1337 1301 1264 1223 1188 1150 1113 1073 669 609 550 490 425 361 303 251 669 609 550 490 425 361 303 251 669 609 550 490 425 361 303 251 669 609 550 490 425 361 303 251 1171 1125 1081 1036 987 945 905 859 922 870 818 793 747 696 645 598 1112 1066 1020 977 933 889 849 824 1394 1358 1322 1281 1241 1204 1163 1131 721 646 580 507 399 326 275 235 721 646 580 507 399 326 275 235 721 646 580 507 399 326 275 235 721 646 580 507 399 326 275 235 1378 1324 1284 1238 1191 1146 1092 1055 1541 1496 1450 1411 1383 1339 1298 1261 1733 1694 1661 1623 1591 1544 1508 1469 1771 1727 1689 1653 1615 1574 1538 1497 685 608 540 471 369 302 262 224 685 608 540 471 369 302 262 224 685 608 540 471 369 302 262 224 685 608 540 471 369 302 262 224 1395 1364 1316 1270 1227 1181 1135 1093 1552 1508 1467 1425 1405 1354 1314 1272 1757 1716 1680 1644 1605 1570 1528 1488 2148 2113 2082 2016 2005 1981 1952 1936 741 661 592 523 451 377 306 272 741 661 592 523 451 377 306 272 741 661 592 523 451 377 306 272 741 661 592 523 451 377 306 272 1539 1485 1443 1401 1372 1325 1280 1241 1369 1317 1273 1228 1178 1129 1081 1030 1744 1691 1648 1606 1568 1533 1493 1445 1772 1724 1677 1636 1601 1563 1521 1484 750 671 598 539 471 390 322 276 750 671 598 539 471 390 322 276 750 671 598 539 471 390 322 276 750 671 598 539 471 390 322 276 1560 1508 1465 1422 1389 1338 1295 1253 1390 1335 1288 1236 1186 1137 1090 1042 1755 1708 1662 1623 1585 1548 1507 1466 2176 2127 2084 2046 2014 1993 1977 1948 1003 868 788 669 572 488 406 330 1003 868 788 669 572 488 406 330 1003 868 788 669 572 488 406 330 1003 868 788 669 572 488 406 330 2058 2008 1957 1906 1852 1800 1750 1697 1462 1408 1335 1258 1185 1109 1026 941 1821 1757 1698 1628 1550 1492 1422 1375 2177 2129 2085 2036 1981 1928 1881 1833 1 CFM 201 201 201 201 418 605 807 1095 207 207 207 207 679 520 771 971 208 208 208 208 838 546 780 1098 207 207 207 207 1010 1215 1426 1465 187 187 187 187 1051 1237 1450 1903 215 215 215 215 1192 983 1409 1441 221 221 221 221 1211 999 1425 1913 236 236 236 236 1646 853 1305 1783 46 Heating Airflow MODEL *MES960403AN *MES960603BN *MES960803BN *MES960804CN *MES960805CN *MES961005CN *MES961205DN *CES960403BN *CES960603BN *CES960804CN *CES961005CN *CES961205DN DIP SWITCHES S2-1 , S2-2 OFF OFF ON OFF* ON ON OFF ON** OFF OFF ON OFF* ON ON OFF ON** OFF OFF ON OFF* ON ON OFF ON** OFF OFF ON OFF* ON ON OFF ON** OFF OFF ON OFF* ON ON OFF ON** OFF OFF ON OFF* ON ON OFF ON OFF OFF ON OFF* ON ON OFF ON OFF OFF ON OFF* ON ON OFF ON** OFF OFF ON OFF* ON ON OFF ON OFF OFF ON OFF* ON ON OFF ON** OFF OFF ON OFF* ON ON OFF ON** OFF OFF ON OFF* ON ON** OFF ON** 0.1 CFM RISE 715 50 1110 32 913 39 1191 N/A 785 N/A 1240 43 972 55 1155 N/A 747 N/A 1206 57 985 N/A 1149 N/A 1010 N/A 1621 44 1439 49 1826 N/A 1012 N/A 1836 39 1431 50 1836 39 1012 N/A 1826 49 1465 N/A 1602 55 1121 N/A 1969 54 1688 63 1865 57 629 N/A 949 37 733 49 1126 N/A 754 N/A 1332 40 972 55 1155 46 760 N/A 1390 51 1397 51 1581 N/A 1211 N/A 1650 54 1457 61 1860 N/A 1296 N/A 1917 56 1611 N/A 2011 N/A *MES96& *CES96 EXTERNAL STATIC PRESSURE, (INCHES WATER COLUMN) 0.2 0.3 0.4 0.5 CFM RISE CFM RISE CFM RISE CFM RISE 666 53 609 N/A 558 N/A 500 N/A 1081 33 1042 34 1003 35 965 37 871 41 833 43 807 44 765 46 1168 N/A 1135 N/A 1112 N/A 1081 N/A 717 N/A 648 N/A 587 N/A 520 N/A 1194 45 1153 46 1104 48 1069 50 922 58 864 62 811 N/A 767 N/A 1105 N/A 1056 N/A 1006 N/A 958 N/A 676 N/A 602 N/A 529 N/A 453 N/A 1157 59 1111 61 1059 62 1009 65 931 N/A 875 N/A 823 N/A 782 N/A 1095 N/A 1051 N/A 1003 N/A 951 N/A 935 N/A 861 N/A 785 N/A 721 N/A 1570 45 1521 47 1467 48 1414 50 1400 51 1347 53 1291 55 1234 N/A 1775 N/A 1726 N/A 1684 N/A 1634 N/A 937 N/A 861 N/A 801 N/A 722 N/A 1787 40 1746 41 1699 42 1653 43 1389 51 1335 53 1283 55 1226 N/A 1787 40 1746 41 1699 42 1653 43 940 N/A 863 N/A 800 N/A 715 N/A 1783 50 1730 51 1685 53 1642 54 1402 N/A 1360 N/A 1306 N/A 1250 N/A 1556 57 1510 59 1460 N/A 1411 N/A 1018 N/A 933 N/A 839 N/A 762 N/A 1913 56 1862 57 1807 59 1756 61 1626 N/A 1564 N/A 1500 N/A 1448 N/A 1812 59 1755 61 1692 63 1638 65 566 N/A 509 N/A 450 N/A 388 N/A 899 40 853 42 809 44 786 45 672 53 613 N/A 563 N/A 512 N/A 1086 N/A 1044 N/A 1006 N/A 968 N/A 684 N/A 615 N/A 542 N/A 471 N/A 1291 41 1252 43 1218 44 1173 45 922 58 864 62 811 N/A 767 N/A 1105 48 1056 51 1006 53 958 56 686 N/A 613 N/A 542 N/A 459 N/A 1342 53 1292 55 1254 57 1201 59 1361 52 1318 54 1266 56 1224 58 1537 N/A 1492 N/A 1452 N/A 1413 N/A 1129 N/A 1045 N/A 964 N/A 890 N/A 1592 56 1530 58 1478 60 1428 62 1394 64 1338 66 1294 69 1236 N/A 1810 N/A 1755 N/A 1702 N/A 1656 N/A 1190 N/A 1076 N/A 960 N/A 839 N/A 1843 58 1759 61 1686 63 1600 67 1521 N/A 1433 N/A 1347 N/A 1246 N/A 1936 N/A 1858 N/A 1779 N/A 1692 N/A 0.6 0.7 CFM 438 386 933 893 722 675 1055 1024 457 400 1019 971 718 651 908 857 386 329 966 913 723 673 900 845 631 553 1378 1327 1182 1125 1588 1538 630 552 1607 1561 1176 1117 1607 1561 627 561 1596 1548 1197 1138 1372 1315 671 592 1705 1647 1393 1334 1587 1527 327 269 742 697 454 404 925 885 411 343 1134 1088 718 651 908 857 376 310 1157 1112 1181 1139 1387 1347 812 764 1389 1327 1171 1110 1611 1553 760 653 1513 1420 1145 1044 1610 1531 0.8 CFM 333 856 629 998 327 929 597 808 281 863 606 812 483 1274 1065 1492 485 1514 1055 1514 496 1504 1073 1261 519 1599 1267 1476 228 652 349 849 276 1049 597 808 266 1072 1095 1305 702 1270 1048 1511 559 1348 953 1442 1. CFM in chart is without filter(s). Filters do not ship with this furnace, but must be provided by the installer. If the furnace requires two return filters, this chart assumes both filters are installed. 2. All furnaces ship as high speed cooling and medium-speed heating. Installer must adjust blower cooling & heating speed as needed. 3. For most jobs, about 400 CFM per ton when cooling is desirable. 4. INSTALLATION IS TO BE ADJUSTED TO OBTAIN TEMPERATURE RISE WITHIN THE RANGE SPECIFIED ON THE RATING PLATE. 5. The chart is for information only. For satisfactory operation, external static pressure must not exceed value shown on rating plate. The shaded area indicates ranges in excess of maximum external static pressure allowed when heating. The data for 0.6" w.c. to 0.8" w.c. is shown for air conditioning purposes only. 6. At higher altitudes, a properly derated unit will have approximately the same temperature rise at a particular CFM, while the ESP at that CFM will be lower. 47 Circulation Airflow MODEL *MES960403AN *MES960603BN *MES960803BN *MES960804CN *MES960805CN *MES961005CN *MES961205DN *CES960403BN *CES960603BN *CES960804CN *CES961005CN *CES961205DN DIP SWITCHES S2-3 , S2-4 OFF OFF ON OFF OFF ON ON ON OFF OFF ON OFF OFF ON ON ON OFF OFF ON OFF OFF ON ON ON OFF OFF ON OFF OFF ON ON ON OFF OFF ON OFF OFF ON ON ON OFF OFF ON OFF OFF ON ON ON OFF OFF ON OFF OFF ON ON ON OFF OFF* ON OFF OFF ON ON ON OFF OFF* ON OFF OFF ON ON ON OFF OFF* ON OFF OFF ON ON ON OFF OFF* ON OFF OFF ON ON ON OFF OFF* ON OFF OFF ON ON ON 0.1 CFM 715 1110 1191 1344 785 1240 1155 1384 747 1206 1149 1414 1010 1621 1826 1843 1012 1836 1836 2215 1012 1826 1602 2225 1121 1969 1865 2268 629 949 1126 1359 754 1332 1155 1384 760 1390 1581 1800 1211 1650 1860 2230 1296 1917 2011 2317 0.2 CFM 666 1081 1168 1312 717 1194 1105 1338 676 1157 1095 1380 935 1570 1775 1798 937 1787 1787 2171 940 1783 1556 2180 1018 1913 1812 2214 566 899 1086 1321 684 1291 1105 1338 686 1342 1537 1758 1129 1592 1810 2176 1190 1843 1936 2257 *MES96& *CES96 EXTERNAL STATIC PRESSURE, (INCHES WATER COLUMN) 0.3 0.4 0.5 0.6 0.7 0.8 CFM CFM CFM CFM CFM CFM 609 558 500 438 386 333 1042 1003 965 933 893 856 1135 1112 1081 1055 1024 998 1278 1247 1215 1178 1143 1114 648 587 520 457 400 327 1153 1104 1069 1019 971 929 1056 1006 958 908 857 808 1300 1257 1215 1169 1125 1080 602 529 453 386 329 281 1111 1059 1009 966 913 863 1051 1003 951 900 845 812 1333 1305 1260 1223 1180 1137 861 785 721 631 553 483 1521 1467 1414 1378 1327 1274 1726 1684 1634 1588 1538 1492 1753 1710 1666 1618 1574 1526 861 801 722 630 552 485 1746 1699 1653 1607 1561 1514 1746 1699 1653 1607 1561 1514 2137 2098 2060 2022 1986 1948 863 800 715 627 561 496 1730 1685 1642 1596 1548 1504 1510 1460 1411 1372 1315 1261 2141 2105 2070 2033 1996 1957 933 839 762 671 592 519 1862 1807 1756 1705 1647 1599 1755 1692 1638 1587 1527 1476 2173 2117 2068 2022 1978 1924 509 450 388 327 269 228 853 809 786 742 697 652 1044 1006 968 925 885 849 1284 1251 1218 1181 1147 1114 615 542 471 411 343 276 1252 1218 1173 1134 1088 1049 1056 1006 958 908 857 8080 1300 1257 1215 1189 1169 1125 613 542 459 376 310 266 1292 1254 1201 1157 1112 1072 1492 1452 1413 1387 1347 1305 1716 1678 1636 1601 1565 1529 1045 964 890 812 764 702 1530 1478 1428 1389 1327 1270 1755 1702 1656 1611 1553 1511 2125 2086 2038 1999 1958 1917 1076 960 839 760 653 559 1759 1686 1600 1513 1420 1348 1858 1779 1692 1610 1531 1442 2196 2122 2061 1990 1914 1762 0.9 CFM 276 820 978 1081 269 893 772 1040 186 834 762 1091 423 1221 1448 1481 420 1471 1471 1908 437 1455 1207 1923 447 1544 1411 1874 195 609 827 1080 214 1013 772 1080 224 1022 1267 1491 639 1213 1454 1880 452 1258 1365 1523 1 CFM 220 803 N/A 1049 206 N/A 723 994 N/A 784 707 1047 350 1167 1398 1432 353 1419 1419 1869 374 1406 1156 1883 371 1481 1351 1832 153 575 792 1045 N/A N/A 723 1040 190 985 1225 1457 583 1159 1405 1829 351 1173 1266 1232 48 Cooling Airflow MODEL *MES960403AN *MES960603BN *MES960803BN *MES960804CN *MES960805CN *MES961005CN *MES961205DN DIP SWITCHES S1-1 , S1-2 , S1-3 OFF OFF OFF OFF ON ON ON OFF ON ON ON ON ON OFF OFF ON ON OFF OFF ON OFF OFF OFF ON* OFF OFF OFF OFF ON ON ON OFF ON ON ON ON ON OFF OFF ON ON OFF OFF ON OFF OFF OFF ON* OFF OFF OFF OFF ON ON ON OFF ON ON ON ON ON OFF OFF ON ON OFF OFF ON OFF OFF OFF ON* OFF OFF OFF OFF ON ON ON OFF ON ON ON ON ON OFF OFF ON ON OFF OFF ON OFF OFF OFF ON* OFF OFF OFF OFF ON ON ON OFF ON ON ON ON ON OFF OFF ON ON OFF OFF ON OFF OFF OFF ON* OFF OFF OFF OFF ON ON ON OFF ON ON ON ON ON OFF OFF ON ON OFF OFF ON OFF OFF OFF ON* OFF OFF OFF OFF ON ON ON OFF ON ON ON ON ON OFF OFF ON ON OFF OFF ON OFF OFF OFF ON* 0.1 CFM 715 715 715 715 1110 913 1191 1344 785 785 785 785 1240 972 1155 1384 747 747 747 747 1206 985 1149 1414 1010 1010 1010 1010 1621 1439 1826 1843 1012 1012 1012 1012 1836 1431 1836 2215 1012 1012 1012 1012 1826 1465 1602 2225 1121 1121 1121 1121 1969 1688 1865 2268 0.2 CFM 666 666 666 666 1081 871 1168 1312 717 717 717 717 1194 922 1105 1338 676 676 676 676 1157 931 1095 1380 935 935 935 935 1570 1400 1775 1798 937 937 937 937 1787 1389 1787 2171 940 940 940 940 1783 1402 1556 2180 1018 1018 1018 1018 1913 1626 1812 2214 *MES96& *CES96 EXTERNAL STATIC PRESSURE, (INCHES WATER COLUMN) 0.3 0.4 0.5 0.6 0.7 0.8 CFM CFM CFM CFM CFM CFM 609 558 500 438 386 333 609 558 500 438 386 333 609 558 500 438 386 333 609 558 500 438 386 333 1042 1003 965 933 893 856 833 807 765 722 675 629 1135 1112 1081 1055 1024 998 1278 1247 1215 1178 1143 1114 648 587 520 457 400 327 648 587 520 457 400 327 648 587 520 457 400 327 648 587 520 457 400 327 1153 1104 1069 1019 971 929 864 811 767 718 651 597 1056 1006 958 908 857 808 1300 1257 1215 1169 1125 1080 602 529 453 386 329 281 602 529 453 386 329 281 602 529 453 386 329 281 602 529 453 386 329 281 1111 1059 1009 966 913 863 875 823 782 723 673 606 1051 1003 951 900 845 812 1333 1305 1260 1223 1180 1137 861 785 721 631 553 483 861 785 721 631 553 483 861 785 721 631 553 483 861 785 721 631 553 483 1521 1467 1414 1378 1327 1274 1347 1291 1234 1182 1125 1065 1726 1684 1634 1588 1538 1492 1753 1710 1666 1618 1574 1526 861 801 722 630 552 485 861 801 722 630 552 485 861 801 722 630 552 485 861 801 722 630 552 485 1746 1699 1653 1607 1561 1514 1335 1283 1226 1176 1117 1055 1746 1699 1653 1607 1561 1514 2137 2098 2060 2022 1986 1948 863 800 715 627 561 496 863 800 715 627 561 496 863 800 715 627 561 496 863 800 715 627 561 496 1730 1685 1642 1596 1548 1504 1360 1306 1250 1197 1138 1073 1510 1460 1411 1372 1315 1261 2141 2105 2070 2033 1996 1957 933 839 762 671 592 519 933 839 762 671 592 519 933 839 762 671 592 519 933 839 762 671 592 519 1862 1807 1756 1705 1647 1599 1564 1500 1448 1393 1334 1267 1755 1692 1638 1587 1527 1476 2173 2117 2068 2022 1978 1924 0.9 CFM 276 276 276 276 820 574 978 1081 269 269 269 269 893 556 772 1040 186 186 186 186 834 548 762 1091 423 423 423 423 1221 1000 1448 1481 420 420 420 420 1471 993 1471 1908 437 437 437 437 1455 1016 1207 1923 447 447 447 447 1544 1199 1411 1874 1 CFM 220 220 220 220 803 535 N/A 1049 206 206 206 206 N/A 511 723 994 N/A N/A N/A N/A 784 508 707 1047 350 350 350 350 1167 930 1398 1432 353 353 353 353 1419 924 1419 1869 374 374 374 374 1406 947 1156 1883 371 371 371 371 1481 1125 1351 1832 49 Cooling Airflow MODEL *CES960403BN *CES960603BN *CES960804CN *CES961005CN *CES961205DN DIP SWITCHES S1-1 , S1-2 , S1-3 OFF OFF OFF OFF ON ON ON OFF ON ON ON ON ON OFF OFF ON ON OFF OFF ON OFF OFF OFF ON* OFF OFF OFF OFF ON ON ON OFF ON ON ON ON ON OFF OFF ON ON OFF OFF ON OFF OFF OFF ON* OFF OFF OFF OFF ON ON ON OFF ON ON ON ON ON OFF OFF ON ON OFF OFF ON OFF OFF OFF ON* OFF OFF OFF OFF ON ON ON OFF ON ON ON ON ON OFF OFF ON ON OFF OFF ON OFF OFF OFF ON* OFF OFF OFF OFF ON ON ON OFF ON ON ON ON ON OFF OFF ON ON OFF OFF ON OFF OFF OFF ON* 0.1 CFM 629 629 629 629 949 733 1126 1359 754 754 754 754 1332 972 1155 1384 760 760 760 760 1390 1397 1581 1800 1211 1211 1211 1211 1650 1457 1860 2230 1296 1296 1296 1296 1917 1611 2011 2317 0.2 CFM 566 566 566 566 899 672 1086 1321 684 684 684 684 1291 922 1105 1338 686 686 686 686 1342 1361 1537 1758 1129 1129 1129 1129 1592 1394 1810 2176 1190 1190 1190 1190 1843 1521 1936 2257 *MES96& *CES96 EXTERNAL STATIC PRESSURE, (INCHES WATER COLUMN) 0.3 0.4 0.5 0.6 0.7 0.8 CFM CFM CFM CFM CFM CFM 509 450 388 327 269 228 509 450 388 327 269 228 509 450 388 327 269 228 509 450 388 327 269 228 853 809 786 742 697 652 613 563 512 454 404 349 1044 1006 968 925 885 849 1284 1251 1218 1181 1147 1114 615 542 471 411 343 276 615 542 471 411 343 276 615 542 471 411 343 276 615 542 471 411 343 276 1252 1218 1173 1134 1088 1049 864 811 767 718 651 597 1056 1006 958 908 857 808 1300 1257 1215 1189 1169 1125 613 542 459 376 310 266 613 542 459 376 310 266 613 542 459 376 310 266 613 542 459 376 310 266 1292 1254 1201 1157 1112 1072 1318 1266 1224 1181 1139 1095 1492 1452 1413 1387 1347 1305 1716 1678 1636 1601 1565 1529 1045 964 890 812 764 702 1045 964 890 812 764 702 1045 964 890 812 764 702 1045 964 890 812 764 702 1530 1478 1428 1389 1327 1270 1338 1294 1236 1171 1110 1048 1755 1702 1656 1611 1553 1511 2125 2086 2038 1999 1958 1917 1076 960 839 760 653 559 1076 960 839 760 653 559 1076 960 839 760 653 559 1076 960 839 760 653 559 1759 1686 1600 1513 1420 1348 1433 1347 1246 1145 1044 953 1858 1779 1692 1610 1531 1442 2196 2122 2061 1990 1914 1762 0.9 CFM 195 195 195 195 609 306 827 1080 214 214 214 214 1013 556 772 1080 224 224 224 224 1022 1050 1267 1491 639 639 639 639 1213 986 1454 1880 452 452 452 452 1258 876 1365 1523 1 CFM 153 153 153 153 575 261 792 1045 N/A N/A N/A N/A N/A 511 723 1040 190 190 190 190 985 1003 1225 1457 583 583 583 583 1159 919 1405 1829 351 351 351 351 1173 790 1266 1232 50 Wiring Diagram *MES92**, CES96**, *MES96** (WITH PCBBF145 CONTROL) Wiring is subject to change. Always refer to the wiring diagram on the unit for the most up-to-date wiring. 51 HIGH VOLTAGE! Disconnect ALL power before servicing or installing this unit. Multiple power sources may be present. Failure to do so may cause property damage, personal injury or death. Special Instructions for Products Installed in the State of Massachusetts For all side wall horizontally vented gas fueled equipment installed in every dwelling, building or structure used in whole or in part for residential purposes, including those owned or operated by the Commonwealth and where the side wall exhaust vent termination is less than seven (7) feet above finished grade in the area of the venting, including but not limited to decks and porches, the following requirements shall be satisfied: VENT/FLUE TEE 1. INSTALLATION OF CARBON MONOXIDE DETECTORS. At the time of installation of the side wall horizontal vented gas fueled equipment, the installing plumber or gasfitter shall observe that a hard wired carbon monoxide detector with an alarm and battery back-up is installed on the floor level where the gas equipment is to be installed. In addition, the installing plumber or gasfitter shall observe that a battery operated or hard wired carbon monoxide detector with an alarm is installed on each additional level of the dwelling, building or structure served by the side wall horizontal vented gas fueled equipment. It shall be the responsibility of the property owner to secure the services of qualified licensed professionals for the installation of hard wired carbon monoxide detectors COMBUSTION AIR INTAKE. DISTANCE BETWEEN COMBUSTION AIR INTAKE AND GRADE DISTANCE BETWEEN VENT AND GRADE a. In the event that the side wall horizontally vented gas fueled equipment is installed in a crawl space or an attic, the hard wired carbon monoxide detector with alarm and battery back-up may be installed on the next adjacent floor level. b. In the event that the requirements of this subdivision can not be met at the time of completion of installation, the owner shall have a period of thirty (30) days to comply with the above requirements; provided, however, that during said thirty (30) day period, a battery operated carbon monoxide detector with an alarm shall be installed. 2. APPROVED CARBON MONOXIDE DETECTORS. Each carbon monoxide detector as required in accordance with the above provisions shall comply with NFPA 720 and be ANSI/UL 2034 listed and IAS certified. 3. SIGNAGE. A metal or plastic identification plate shall be permanently mounted to the exterior of the building at a minimum height of eight (8) feet above grade directly in line with the exhaust vent terminal for the horizontally vented gas fueled heating appliance or equipment. The sign shall read, in print size no less than one-half (1/2) inch in size, "GAS VENT DIRECTLY BELOW. KEEP CLEAR OF ALL OBSTRUCTIONS". 4. INSPECTION. The state or local gas inspector of the side wall horizontally vented gas fueled equipment shall not approve the installation unless, upon inspection, the inspector observes carbon monoxide detectors and signage installed in accordance with the provisions of 248 CMR 5.08(2)(a)1 through 4. EXEMPTIONS The following equipment is exempt from 248 CMR 5.08(2)(a)1 through 4: 1. The equipment listed in Chapter 10 entitled "Equipment Not Required To Be Vented" in the most current edition of NFPA 54 as adopted by the Board; and 2. Product Approved side wall horizontally vented gas fueled equipment installed in a room or structure separate from the dwelling, building or structure used in whole or in part for residential purposes. (c) MANUFACTURER REQUIREMENTS - GAS EQUIPMENT VENTING SYSTEM PROVIDED. When the manufacturer of Product Approved side wall horizontally vented gas equipment provides a venting system design or venting system components with the equipment, the instructions provided by the manufacturer for installation of the equipment and the venting system shall include: 3. Detailed instructions for the installation of the venting system design or the venting system components; and 4. A complete parts list for the venting system design or venting system. (d) MANUFACTURER REQUIREMENTS - GAS EQUIPMENT VENTING SYSTEM NOT PROVIDED. When the manufacturer of a Product Approved side wall horizontally vented gas fueled equipment does not provide the parts for venting the flue gases, but identifies "special venting systems", the following requirements shall be satisfied by the manufacturer: 5. The referenced "special venting system" instructions shall be included with the appliance or equipment installation instructions; and 6. The "special venting systems" shall be Product Approved by the Board, and the instructions for that system shall include a parts list and detailed installation instructions. (e) A copy of all installation instructions for all Product Approved side wall horizontally vented gas fueled equipment, all venting instructions, all parts lists for venting instructions, and/or all venting design instructions shall remain with the appliance or equipment at the completion of the installation. NOTE: SPECIFICATIONS AND PERFORMANCE DATA LISTED HEREIN ARE SUBJECT TO CHANGE WITHOUT NOTICE. 19001 Kermier Rd., Waller, TX 77484 www.goodmanmfg.com · www.amana-hac.com © 2019-2021 Goodman Manufacturing Company, L.P. Brand is a registered trademark of Maytag Corporation or its related companies and is used under license. All rights reserved. 52 THIS PAGE LEFT INTENTIONALLY BLANK. 53 THIS PAGE LEFT INTENTIONALLY BLANK. 54 THIS PAGE LEFT INTENTIONALLY BLANK. 55 CUSTOMER FEEDBACK We are very interested in all product comments. Please fill out the feedback form on one of the following links: Goodman® Brand Products: (http://www.goodmanmfg.com/about/contact-us). Amana® Brand Products: (http://www.amana-hac.com/about-us/contact-us). You can also scan the QR code on the right for the product brand you purchased to be directed to the feedback page. GOODMAN® BRAND AMANA® BRAND PRODUCT REGISTRATION Thank you for your recent purchase. Though not required to get the protection of the standard warranty, registering your product is a relatively short process, and entitles you to additional warranty protection, except that failure by California and Quebec residents to register their product does not diminish their warranty rights. For Product Registration, please register as follows: Goodman® Brand products: (https://www.goodmanmfg.com/product-registration). GOODMAN® BRAND Amana® Brand products: (http://www.amana-hac.com/product-registration) You can also scan the QR code on the right for the product brand you purchased to be directed to the Product Registration page. AMANA® BRAND 19001 Kermier Rd., Waller, TX 77484 www.goodmanmfg.com · www.amana-hac.com © 2019-2021 Goodman Manufacturing Company, L.P. Brand is a registered trademark of Maytag Corporation or its related companies and is used under license. All rights reserved.Adobe PDF Library 15.0 Adobe InDesign 15.1 (Windows)