Johnson Controls Furnace TM9V MP User Manual

INSTALLATION MANUAL

RESIDENTIAL GAS FURNACE MODELS

TM9V*MP

EFFICIENCY

RATING

CERTIFIED

ISO 9001

Certified Quality

Management System

(96% AFUE Two Stage Variable Speed Multi-position)

LIST OF SECTIONS

SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

DUCTWORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

FILTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

GAS PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

ELECTRICAL POWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

CONDENSATE PIPING AND FURNACE

COMBUSTION AIR and VENT SYSTEM . . . . . . . . . . . . . . . . . . . .22

START-UP AND ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . .29

SAFETY CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32

REPLACEMENT PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . .36

REPLACEMENT PART CONTACT INFORMATION . . . . . . . . . . . .36

WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37

VENTING CONFIGURATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

LIST OF FIGURES

Duct Attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Vertical Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Coil Flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Horizontal Right Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Horizontal Left Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

PC Series Upflow Coil Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Horizontal Left or Right application (Right Shown) . . . . . . . . . . . . . . 6

Combustible Floor Base Accessory . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Horizontal Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Typical Attic Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Typical Suspended Furnace / Crawl Space Installation . . . . . . . . . . . 7

Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Side Return Cutout Markings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Gas Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Upflow/Downflow Gas Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Horizontal Gas Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Electrical Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Thermostat Chart - Single Stage Air Conditioners

Thermostat Chart - Two Stage HP with Two Stage

Variable Speed Furnace (Hot Heat Pump or Conventional) . . . . . . .15

Typical. Condensate drain, vertical installation. . . . . . . . . . . . . . . . .16

Typical. Combustion Pipe Drain Tee. . . . . . . . . . . . . . . . . . . . . . . . .17

Upflow Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

Downflow Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19

Horizontal Left Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20

Horizontal Right Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21

Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22

Home Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24

Termination Configuration - 1 Pipe . . . . . . . . . . . . . . . . . . . . . . . . . .25

Termination Configuration - 2 Pipe . . . . . . . . . . . . . . . . . . . . . . . . . .25

Termination Configuration - 2 Pipe Basement . . . . . . . . . . . . . . . . .25

Double Horizontal Combustion Air Intake and Vent Termination . . .25

Double Vertical Combustion Air Intake and Vent Termination . . . . .25

Direct Vent Air Intake Connection and Vent Connection . . . . . . . . .26

Combustion Airflow Path Through The Furnace Casing . . . . . . . . .26

Outside and Ambient Combustion Air . . . . . . . . . . . . . . . . . . . . . . . .27

Attic and Crawl Space Combustion Air Termination . . . . . . . . . . . . .28

Gas Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31

Reading Gas Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31

Furnace Control Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32

Furnace Control Event Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . .35

Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37

with Two Stage Variable Speed Furnaces . . . . . . . . . . . . . . . . . . . . 12

Thermostat Chart - Single Stage Heat Pump with Two Stage

Variable Speed Furnace (Hot Heat Pump or Conventional) . . . . . . 13

Thermostat Chart - Two Stage AC with

Two Stage Variable Speed Furnace . . . . . . . . . . . . . . . . . . . . . . . . 14

LIST OF TABLES

Unit Clearances to Combustibles . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Coil Projection Dimensions - PC Series Coils . . . . . . . . . . . . . . . . . . 6

Cabinet and Duct Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Recommended Filter Sizes (High Velocity 600 FPM) . . . . . . . . . . . . 8

Nominal Manifold Pressure - High Fire . . . . . . . . . . . . . . . . . . . . . . 10

Nominal Manifold Pressure - Low Fire . . . . . . . . . . . . . . . . . . . . . . . 10

Ratings & Physical / Electrical Data . . . . . . . . . . . . . . . . . . . . . . . . . 11

Maximum Equivalent Pipe Length . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Elbow Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Equivalent Length of Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23

Combustion Air Intake and Vent Connection Size at

Furnace (All Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23

Estimated Free Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26

Unconfined Space Minimum Area in Square Inch . . . . . . . . . . . . . .27

Free Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27

Gas Rate (CU FT/HR) at Full Input . . . . . . . . . . . . . . . . . . . . . . . . . .30

Inlet Gas Pressure Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31

Nominal Manifold Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31

These high efficiency, compact units employ induced combustion, reli-

able hot surface ignition and high heat transfer aluminized tubular heat

exchangers. The units are factory shipped for installation in upflow or

horizontal applications and may be converted for downflow applica-

tions.

SECTION I: SAFETY

This is a safety alert symbol. When you see this symbol on

labels or in manuals, be alert to the potential for personal

injury.

Understand and pay particular attention to the signal words DANGER,

WARNING, or CAUTION.

These furnaces are designed for residential installation in a basement,

closet, alcove, attic, recreation room or garage and are also ideal for

commercial applications. All units are factory assembled, wired and

tested to assure safe dependable and economical installation and oper-

ation.

DANGER indicates an imminently hazardous situation, which, if not

avoided, will result in death or serious injury.

WARNING indicates a potentially hazardous situation, which, if not

avoided, could result in death or serious injury.

These units are Category IV listed and may not be common vented with

another gas appliance as allowed by the National Fuel Gas Code.

CAUTION indicates a potentially hazardous situation, which, if not

avoided may result in minor or moderate injury. It is also used to

alert against unsafe practices and hazards involving only property dam-

age.

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These instructions cover minimum requirements and conform to exist-

ing national standards and safety codes. In some instances these

instructions exceed certain local codes and ordinances, especially

those who have not kept up with changing residential and non-HUD

modular home construction practices. These instructions are required

as a minimum for a safe installation.

The furnace area must not be used as a broom closet or for any

other storage purposes, as a fire hazard may be created. Never

store items such as the following on, near or in contact with the fur-

nace.

1. Spray or aerosol cans, rags, brooms, dust mops, vacuum

cleaners or other cleaning tools.

FOR FURNACES INSTALLED IN THE COMMON-

WEALTH OF MASSACHUSETTS ONLY

2. Soap powders, bleaches, waxes or other cleaning com-

pounds; plastic items or containers; gasoline, kerosene, ciga-

rette lighter fluid, dry cleaning fluids or other volatile fluid.

3. Paint thinners and other painting compounds.

For all side wall horizontally vented gas fueled equipment installed in

every dwelling, building or structure used in whole or in part for resi-

dential purposes, including those owned or operated by the Com-

monwealth 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 require-

ments shall be satisfied:

4. Paper bags, boxes or other paper products

Never operate the furnace with the blower door removed. To

do so could result in serious personal injury and/or equipment

damage.

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

CODES AND STANDARDS

Follow all national, local codes and standards in addition to this installa-

tion manual. The installation must comply with regulations of the serv-

ing gas supplier, local building, heating, plumbing, and other codes. In

absence of local codes, the installation must comply with the national

codes listed below and all authorities having jurisdiction.

In the United States and Canada, follow all codes and standards for the

following, using the latest edition available:

STEP 1 -Safety

•

US: National Fuel Gas Code (NFGC) NFPA 54/ANSI Z223.1 and

the Installation Standards, Warm Air Heating and Air Conditioning

Systems ANSI/NFPA 90B

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.

•

CANADA: CAN/CGA-B149.1 National Standard of Canada. Natu-

ral Gas and Propane Installation Codes (NSCNGPIC)

STEP 2 -General Installation

•

US: Current edition of the NFGC and NFPA 90B. For copies, con-

tact the

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 mon-

oxide detector with an alarm shall be installed.

National Fire Protection Association Inc.

Batterymarch Park

Quincy, MA 02269

or for only the NFGC, contact the

American Gas Association,

400 N. Capital, N.W.

2. APPROVED CARBON MONOXIDE DETECTORS. Each car-

bon monoxide detector as required in accordance with the

above provisions shall comply with NFPA 720 and be ANSI/UL

2034 listed and IAS certified.

Washington DC 20001

or www.NFPA.org

3. SIGNAGE. A metal or plastic identification plate shall be perma-

nently 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 OBSTRUC-

TIONS".

•

CANADA: NSCNGPIC. For a copy contact:

Standard Sales, CSA International

178 Rexdale Boulevard

Etobicoke, (Toronto) Ontario Canada M9W 1RS

STEP 3 -Combustion and Ventilation Air

•

US: Section 5.3 of the NFGC, air for Combustion and Ventilation

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

for Appliances

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 car-

bon monoxide detectors and signage installed in accordance

with the provisions of 248 CMR 5.08(2)(a)1 through 4.

STEP 4 -Duct Systems

US and CANADA: Air Conditioning Contractors Association

•

(ACCA) Manual D, Sheet Metal and Air Conditioning Contractors

Association National Association (SMACNA), or American Soci-

ety of Heating, Refrigeration, and Air Conditioning Engineers

(ASHRAE) 1997 Fundamentals Handbook Chapter 32.

INSPECTION

STEP 5 -Acoustical Lining and Fibrous Glass Duct

As soon as a unit is received, it should be inspected for possible dam-

age during transit. If damage is evident, the extent of the damage

should be noted on the carrier’s freight bill. A separate request for

inspection by the carrier’s agent should be made in writing. Also, before

installation, the unit should be checked for screws or bolts which may

have loosened in transit. There are no shipping or spacer brackets

which need to be removed from the interior of this unit.

•

US and CANADA: Current edition of SMACNA and NFPA 90B as

tested by UL Standard 181 for Class I Rigid Air Ducts

STEP 6 -Gas Piping and Gas Pipe Pressure Testing

•

US: NFGC; chapters 2, 3, 4, & 9 and National Plumbing Codes

CANADA: NSCNGPIC Part 5

STEP 7 -Electrical Connections

•

US: National Electrical Code (NEC) ANSI/NFPA 70

CANADA: Canadian Electrical Code CSA C22.1

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FURNACE LOCATION AND CLEARANCES

Table 1: Unit Clearances to Combustibles

The furnace shall be located using the following guidelines:

Upflow

Downflow

Horizontal

Application

Top

1. Where a minimum amount of air intake/vent piping and elbows will

be required.

Vent

2. As centralized with the air distribution as possible.

3. Where adequate combustion air will be available (particularly

when the appliance is not using outdoor combustion air).

4. Where it will not interfere with proper air circulation in the confined

space.

5. Where the outdoor vent terminal will not be blocked or restricted.

Refer to “VENT CLEARANCES” located in SECTION VII of these

instructions. These minimum clearances must be maintained in

the installation.

Rear

Side

Front*

Floor

Combustible

Yes

Combustible¹

Combustible

Yes

Closet

Line Contact

Yes

1. For combustible floors only when used with special sub-base.

24" clearance in front and 18" on side recommended for service access.

All furnaces approved for alcove and attic installation.

6. Where the unit will be installed in a level position with no more than

1/4” (6.4 mm) slope side-to-side and front-to-back to provide

proper condensate drainage.

SECTION II: DUCTWORK

DUCTWORK GENERAL INFORMATION

Installation in freezing temperatures:

1. Furnace shall be installed in an area where ventilation facilities

provide for safe limits of ambient temperature under normal oper-

ating conditions. Ambient temperatures must not fall below 32°F

(0°C) unless the condensate system is protected from freezing.

The duct system’s design and installation must:

1. Handle an air volume appropriate for the served space and within

the operating parameters of the furnace specifications.

2. Be installed in accordance of National Fire Protection Association

as outlined in NFPA standard 90B (latest editions) or applicable

national, provincial, state, and local fire and safety codes.

3. Create a closed duct system. For residential and non-HUD Modu-

lar Home installations, when a furnace is installed so that the sup-

ply ducts carry air circulated by the furnace to areas outside the

space containing the furnace, the return air shall also be handled

by a duct(s) sealed to the furnace casing and terminating outside

the space containing the furnace.

Improper installation in an ambient below 32ºF (0.0° C) could create

a hazard, resulting in damage, injury or death.

2. Do not allow return air temperature to be below 55º F (13°C) for

extended periods. To do so may cause condensation to occur in

the main heat exchanger, leading to premature heat exchanger

failure.

3. If this furnace is installed in an unconditioned space and an

extended power failure occurs, there will be potential damage to

the internal components. Following a power failure situation, do

not operate the unit until inspection and repairs are performed.

4. Complete a path for heated or cooled air to circulate through the

air conditioning and heating equipment and to and from the condi-

tioned space.

4. Special precautions MUST be made if installing furnace in an area

which may drop below freezing. This can cause improper opera-

tion or damage to the equipment. If the furnace is installed in an

area that has the potential of freezing, the drain line must be pro-

tected. Use a 3 to 6 watt per foot at 115 vac, 40º F (4.4°C) self-reg-

ulating, shielded and waterproof heat tape. Wrap the drain line

outside of the furnace with the heat tape and secure with ties. Fol-

low the heat tape manufacturer's recommendations.

The cooling coil must be installed in the supply air duct, down-

stream of the furnace. Cooled air may not be passed over the heat

exchanger.

When the furnace is used with a cooling coil, the coil must be installed

parallel with, or in the supply air side of the furnace to avoid condensa-

tion in the primary heat exchanger. When a parallel flow arrangement is

used, dampers or other means used to control airflow must be ade-

quate to prevent chilled air from entering the furnace. If manually oper-

ated, the damper must be equipped with means to prevent the furnace

or the air conditioner from operating unless the damper is in full heat or

cool position.

Liquid anti-freeze will cause damage to internal plastic parts of this

furnace. DO NOT attempt to winterize the furnace using liquid

anti-freeze.

When replacing an existing furnace, if the existing plenum is not the

same size as the new furnace then the existing plenum must be

removed and a new plenum installed that is the proper size for the new

furnace. If the plenum is shorter than 12” (30.5 cm) the turbulent air flow

may cause the limit controls not to operate as designed, or the limit con-

trols may not operate at all.

Clearances for access/service:

Ample clearances should be provided to permit easy access to the unit.

The following minimum clearances are recommended:

1. Twenty-four (24) inches (61 cm) between the front of the furnace

and an adjacent wall or another appliance, when access is

required for servicing and cleaning.

The duct system is a very important part of the installation. If the duct

system is improperly sized the furnace will not operate properly.

The ducts attached to the furnace plenum, should be of sufficient size

so that the furnace operates at the specified external static pressure

and within the air temperature rise specified on the nameplate.

2. Eighteen (18) inches (46 cm) at the side where access is required

for passage to the front when servicing or for inspection or replace-

ment of flue/vent connections.

In all cases, accessibility clearances shall take precedence over clear-

ances for combustible materials where accessibility clearances are

greater.

The minimum plenum height is 12” (30.5 cm). The furnace will

not operate properly on a shorter plenum height. The minimum

recommended rectangular duct height is 4” (10.2 cm) attached to

the plenum.

Installation in a residential garage:

A gas-fired furnace for installation in a residential garage must be

installed so the burner(s) and the ignition source are located not less

than 18” (46 cm) above the floor, and the furnace must be located or

protected to avoid physical damage by vehicles.

If a matching cooling coil is used, it may be placed directly on the fur-

nace outlet and sealed to prevent leakage. If thermoplastic evaporator

‘A’ coil drain pans are to be installed in the upflow/horizontal configura-

tion, then extra 2” (5.1 cm) minimum spacing may be needed to ensure

against drain pan distortion.

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On all installations without a coil, a removable access panel is recom-

mended in the outlet duct such that smoke or reflected light would be

observable inside the casing to indicate the presence of leaks in the

heat exchanger. This access cover shall be attached in such a manner

as to prevent leaks.

Attach the air conditioning coil cabinet to the duct connector, and then

position the furnace on top of the coil cabinet. The connection to the fur-

nace, air conditioning coil cabinet, duct connector, and supply air duct

must be sealed to prevent air leakage.

COIL INSTALLATION

The duct system must be properly sized to obtain the correct airflow

for the furnace size that is being installed.

Refer to Table 7 or the furnace rating plate for the correct rise range

and static pressures.

If the ducts are undersized, the result will be high duct static pres-

sures and/or high temperature rises which can result in a heat

exchanger OVERHEATING CONDITION. This condition can result

in premature heat exchanger failure, which can result in personal

injury, property damage, or death.

On all installations without a coil, a removable access panel is rec-

ommended in the outlet duct such that smoke or reflected light

would be observable inside the casing to indicate the presence of

leaks in the heat exchanger. This access cover shall be attached in

such a manner as to prevent leaks.

COIL/FURNACE ASSEMBLY - MC/FC/PC SERIES

COILS

DUCT FLANGES

Four flanges are provided to attach ductwork to the furnace. These

flanges are rotated down for shipment. In order to use the flanges,

remove the screw holding an individual flange, rotate the flange so it is

in the upward position and reinstall the screw then repeat this for all 4

flanges.

If the flanges are not used, they must remain in the rotated down posi-

tion as shipped.

Factory

installed

For duct attachment,

if needed.

UPFLOW

DOWNFLOW

FIGURE 2: Vertical Applications

FURNACE ASSEMBLY - MC & FC SERIES COILS

These coils are factory shipped for installation in either upflow or down-

flow applications with no conversion.

Position the coil casing over or under the furnace opening as shown in

Figures 2 after configuring coil flanges as required see “Coil Flange”

section below.

FIGURE 1: Duct Attachment

DUCTWORK INSTALLATION AND SUPPLY PLENUM

CONNECTION - UPFLOW/HORIZONTAL

COIL FLANGE INSTALLATION

Attach the supply plenum to the furnace outlet. The use of

an approved flexible duct connector is recommended on all

installations. This connection should be sealed to prevent

air leakage. The sheet metal should be crosshatched to

eliminate any popping of the sheet metal when the indoor

fan is energized.

The coils include removable flanges to allow proper fit up with furnaces

having various inlet and outlet flange configurations. The two flanges

are attached to the top of the coil in the factory during production. For

proper configuration of flanges refer to Figures 3.

FLOOR BASE AND DUCTWORK INSTALLATION -

DOWNFLOW

Installations on combustible material or directly on any

floors must use a combustible floor base shown in Figures

8. Follow the instructions supplied with the combustible

floor base accessory. This combustible floor base can be

replaced with a matching cooling coil, properly sealed to

prevent leaks. Follow the instructions supplied with the

cooling coil cabinet for installing the cabinet to the duct con-

nector. Plug intake and vent pipe holes in bottom panel and

move grommet to desired vent side exit.

FACTORY

FLANGE

LOCATION

(Used for upflow

or horizontal

Downflow Air Conditioning Coil Cabinet

right installations)

ALTERNATE

FLANGE LOCATION

The furnace should be installed with coil cabinet part number specifi-

cally intended for downflow application. If a matching cooling coil is

used, it may be placed directly on the furnace outlet and sealed to pre-

vent leakage. For details of the coil cabinet dimensions and installation

requirements, refer to the installation instructions supplied with the coil

cabinet.

(Used for downflow or

horizontal left installations)

FIGURE 3: Coil Flange

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FURNACE ASSEMBLY - MC SERIES COILS ONLY

MC coils are supplied ready to be installed in a horizontal position. A

horizontal pan is factory installed. MC coils should be installed in all hor-

izontal applications with the horizontal drain pan side down.

(Min)

Mounting Plate

Flexible

Duct Collar

Field

Fabricated

Ductwork

Furnace

Do not drill

or Screw

this flange

Upflow

Coil

FIGURE 4: Horizontal Right Application

Upflow

Furnace

For horizontal left hand applications no conversion is required to an MC

coil when used with a downflow/horizontal furnace. A mounting plate,

supplied with every coil should always be installed on the side desig-

nated as top side. See Figures 4 & 5.

Alternate

Drain Location

Primary

Drain

Secondary

Drain

FIGURE 6: PC Series Upflow Coil Installation

Table 2: Coil Projection Dimensions - PC Series Coils

Mounting Plate

COIL SIZE

DIMENSION “C” INCH

PC18

PC24

3-1/2

4-1/2

5-1/2

6-1/2

Furnace

PC30, PC32, PC35

PC42, PC43, PC36, PC37

PC48

PC60

FIGURE 5: Horizontal Left Application

NOTE: Dimension “C” should be at least 2/3 of dimension “D”.

See Figures 6

FURNACE ASSEMBLY - PC SERIES COILS

These upflow coils are designed for installation on top of upflow fur-

naces only.

CRITICAL COIL PROJECTION

The coil assembly must be located in the duct such that a minimum dis-

tance is maintained between the top of the coil and the top of the duct.

Refer to Table 6.

If the coil is used with a furnace of a different size, use a 45° transition

to allow proper air distribution through the coil.

1. Position the coil casing over the furnace opening as shown in

Figures 6.

COIL / FURNACE ASSEMBLY - HC SERIES COILS

2. Place the ductwork over the coil casing flange and secure.

These coils are supplied ready to be installed in a right hand position or

a left hand position. When used in conjunction with a horizontal furnace

(blow through) application, the coil should be oriented with the opening

of the “A” coil closest to the furnace. See Figure 6.

3. Check for air leakage between the furnace and coil casing and

seal appropriately.

NOTE: Each coil is shipped with an external tie plate that should be

used to secure the coil to the furnace. It should be installed on the back

side of the coil using the dimpled pilot holes. See Figure 6.

Do not drill any holes or drive any screws into the front duct

flange on the coil in order to prevent damaging coil tubing. See

Figures 6

Use tie plate

supplied with coil

Gas Furnace

FIGURE 7: Horizontal Left or Right application (Right Shown)

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DOWNFLOW DUCT CONNECTORS

ATTIC INSTALLATION

All downflow installations must use a suitable duct connector approved

by the furnace manufacturer for use with this furnace. The duct connec-

tors are designed to be connected to the rectangular duct under the

floor and sealed. Refer to the instructions supplied with the duct con-

nector for proper installation. Refer to the separate accessory parts list

at the end of these instructions for the approved accessory duct con-

nectors.

Line contact only permissible

between lines formed by the

intersection of furnace top

and two sides and building

joists, studs or framing

Supply

Air

Vent (Maintain

required

clearances to

combustibles)

Filter rack

must be a minimum

distance

Sheet metal in

front of furnace

combustion air

Openings is

Gas Piping

of 18” (45.7 cm)

from the

furnace

12”

Recommended

12”

FURNACE

30” MIN.

Work Area

Return

Air

WARM AIR PLENUM

WITH 1” FLANGES

Sediment

Trap

FIGURE 10: Typical Attic Installation

FIBERGLASS

INSULATION

This appliance is certified for line contact when the furnace is installed

in the horizontal left or right position. The line contact is only permissible

between lines that are formed by the intersection of the top and two

sides of the furnace and the building joists, studs or framing. This line

may be in contact with combustible material. Refer to Figures 10.

FIBERGLASS TAPE

UNDER FLANGE

When a furnace is installed in an attic or other insulated space,

keep all insulating materials at least 12” (30.5 cm) away from fur-

nace and burner combustion air openings.

COMBUSTIBLE FLOOR

BASE ACCESSORY

SUSPENDED FURNACE / CRAWL SPACE

INSTALLATION

FIGURE 8: Combustible Floor Base Accessory

The furnace can be hung from floor joists or installed on suitable blocks

or pad. Blocks or pad installations shall provide adequate height to

ensure the unit will not be subject to water damage. Units may also be

suspended from rafters or floor joists using rods, pipe angle supports or

straps. Angle supports should be placed at the supply air end and near

the blower deck. Do not support at return air end of unit. All four sus-

pension points must be level to ensure quite furnace operation. When

suspending the furnace use a secure platform constructed of plywood

or other building material secured to the floor joists. Refer to for typical

crawl space installation.

RESIDENTIAL AND MODULAR HOME UPFLOW

RETURN PLENUM CONNECTION

Return air may enter the furnace through the side(s) or bottom depend-

ing on the type of application. Return air may not be connected into the

rear panel of the unit.

BOTTOM RETURN AND ATTIC INSTALLATIONS

Bottom return applications normally pull return air through a base plat-

form or return air plenum. Be sure the return platform structure or return

air plenum is suitable to support the weight of the furnace.

The internal bottom panel must be removed for this application.

Attic installations must meet all minimum clearances to combustibles

and have floor support with required service accessibility.

HORIZONTAL APPLICATION

Support

Rod

Support

Angle (x3)

Maintain 6” minimum

clearance between support

rods and front of furnace

FIGURE 9: Horizontal Application

FIGURE 11: Typical Suspended Furnace / Crawl Space Installation

This furnace may be installed in a horizontal position on either side

as shown above. It must not be installed on its back.

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RIGHT SIDE

Combustion Air Inlet

LEFT SIDE

Combustion Air Inlet

FRONT

Condensate Drain

(Downflow)

Gas Pipe

Entry

Gas Pipe

Entry

Condensate Drain

(Downflow)

Vent Outlet

Electrical

Entry

Electrical

Entry

Vent Outlet

23”

Condensate

Drain

Condensate

Drain

Thermostat

Wiring

Thermostat

Wiring

Optional Return Air

Cutout (Either side)

14”

1”

28.5”

29.5”

(For Cladded door add appoximately an additional .75”)

1.5”

.56”

23.8”

3”

Vent

Outlet

Combustion

Air Inlet

.56”

24.25”

.56”

20”

RETURN END

SUPPLY END

FIGURE 12: Dimensions

Table 3: Cabinet and Duct Dimensions

Approximate

Operating Weights

Cabinet Dimensions (Inches)

Nominal

CFM (m³/min)

BTUH (kW)

Input

Cabinet

Size

A (in)

17 1/2

A (cm)

44.4

53.3

62.2

B (in)

16 3/8

19 7/8

23 3/8

B (cm)

41.6

50.5

59.4

C (in)

13 1/4

14 3/4

16 1/2

18 1/4

21 3/4

C (cm)

33.7

37.5

41.9

46.4

55.2

Lbs (kg)

122 (55.3)

126 (57.1)

136 (61.7)

142 (64.4)

145 (65.8)

156 (70.7)

60 (17.6)

80 (23.4)

100 (29.3)

120 (35.1)

1200 (34.0)

1600 (45.3)

2000 (56.6)

24 1/2

SIDE RETURN

Locate the “L” shaped corner locators. These indicate the size of the cut-

out to be made in the furnace side panel. Refer to Figures 13.

SECTION III: FILTERS

FILTER INSTALLATION

All applications require the use of a field installed filter. All filters and

mounting provision must be field supplied.

Filters must be installed external to the furnace cabinet. DO NOT

attempt to install filters inside the furnace.

Front of

Furnace

NOTE: Single side return above 1800 CFM is approved as long as the

filter velocity does not exceed filter manufacturer’s recommendation

and a transition is used to allow use on a 20x25 filter.

Side of

Furnace

Corner

Markings

Table 4: Recommended Filter Sizes (High Velocity 600 FPM)

CFM

(m³/min)

Cabinet

Size

Side

(in)

Bottom

(in)

FIGURE 13: Side Return Cutout Markings

Install the side filter rack following the instructions provided with that

accessory. If a filter(s) is provided at another location in the return air

system, the ductwork may be directly attached to the furnace side

panel.

1200 (34.0)

1600 (45.3)

2000 (56.6)

16 x 25

(2) 16 x 25

16 x 25

20 x 25

22 x 25

NOTES:

1. Air velocity through throwaway type filters may not exceed 300 feet per

minute (91.4 m/min). All velocities over this require the use of high velocity

filters.

Some accessories such as electronic air cleaners and pleated

media may require a larger side opening. Follow the instructions

supplied with that accessory for side opening requirements. Do not

cut the opening larger than the dimensions shown in Figures 12.

2. Do not exceed 1800 CFM using a single side return and a 16x25 filter. For

CFM greater than 1800, you may use two side returns or one side and the

bottom or one side return with a transition to allow use of a 20x25 filter.

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HORIZONTAL APPLICATION

Horizontal Filters

External Manual

Shutoff Valve

To Gas

Supply

To Gas

Supply

All filters and mounting provision must be field supplied. All installa-

tions must have a filter installed.

Any branch duct (rectangular or round duct) attached to the plenum

must attach to the vertical plenum before the filter. The use of straps

and/or supports is required to support the weight of the external filter

box.

Grounded Joint Union

may be Installed

Inside or Outside Unit.

Drip Leg

FIGURE 15: Upflow/Downflow Gas Piping

Downflow Filters

Downflow furnaces typically are installed with the filters located above

the furnace, extending into the return air plenum or duct. Any branch

duct (rectangular or round duct) attached to the plenum must attach to

the vertical plenum above the filter height.

Manual

Shut-off

Valve

Drip

Leg

Filter(s) may be located in the duct system external to the furnace using

an external duct filter box attached to the furnace plenum or at the end

of the duct in a return filter grille(s). The use of straps and/or supports is

required to support the weight of the external filter box.

Gas

Pipe

Gas Burners

Gas Valve

Gas

Pipe

SECTION IV: GAS PIPING

GAS SAFETY

Drip

Leg

Manual

Shut-off Valve

FIGURE 16: Horizontal Gas Piping

An overpressure protection device, such as a pressure regulator,

must be installed in the gas piping system upstream of the furnace

and must act to limit the downstream pressure to the gas valve so it

does not exceed 0.5 psig [14" w.c. (3.48 kPa)]. Pressures exceed-

ing 0.5 psig [14” w.c. (3.48 kPa)] at the gas valve will cause damage

to the gas valve, resulting in a fire or explosion or cause damage to

the furnace or some of its components that will result in property

damage and loss of life.

An accessible manual shutoff valve must be installed upstream of

the furnace gas controls and within 6 feet (1.8 m) of the furnace.

The furnace must be isolated from the gas supply piping system by

closing its individual external manual shutoff valve during any pressure

testing of the gas supply piping system at pressures equal to or less

than 0.5 psig (3.5 kPa).

HIGH STAGE REGULATOR

ADJUSTMENT

OUTLET

PRESSURE

PORT

VENT

PORT

The gas valve body is a very thin casting that cannot take any

external pressure. Never apply a pipe wrench to the body of the gas

valve when installing piping. A wrench must be placed on the octa-

gon hub located on the gas inlet side of the valve. Placing a wrench

to the body of the gas valve will damage the valve causing improper

operation and/or the valve to leak.

INLET

OUTLET

WRENCH

BOSS

INLET

PRESSURE

PORT

LOW STAGE REGULATOR

ADJUSTMENT

Gas piping may be connected from either side of the furnace using any

of the gas pipe entry knockouts on both sides of the furnace. Refer to

Figures 12.

ON OFF

SWITCH

FIGURE 14: Gas Valve

GAS ORIFICE CONVERSION FOR PROPANE (LP)

This furnace is constructed at the factory for natural gas-fired operation,

but may be converted to operate on propane (LP) gas by using a

factory-supplied LP conversion kit. Follow the instructions supplied with

the LP kit.

Plan your gas supply before determining the correct gas pipe entry.

Use 90-degree service elbow(s), or short nipples and conventional

90-degree elbow(s) to enter through the cabinet access holes.

HIGH ALTITUDE GAS ORIFICE CONVERSION

This furnace is constructed at the factory for natural gas-fired operation

GAS PIPING INSTALLATION

Properly sized wrought iron, approved flexible or steel pipe must be

used when making gas connections to the unit. If local codes allow the

use of a flexible gas appliance connection, always use a new listed con-

nector. Do not use a connector that has previously serviced another gas

appliance.

at 0 –5,000 feet (0 – 1,524 m) above sea level.

The manifold pressure must be changed in order to maintain proper

and safe operation when the furnace is installed in a location where the

altitude is greater than 5,000 feet (1,524 m) above sea level. Refer to

Table 5 for proper manifold pressure settings.

Some utility companies or local codes require pipe sizes larger than the

minimum sizes listed in these instructions and in the codes. The furnace

rating plate and the instructions in this section specify the type of gas

approved for this furnace - only use those approved gases. The instal-

lation of a drip leg and ground union is required. Refer to Figures 15.

HIGH ALTITUDE PRESSURE SWITCH CONVERSION

For installation where the altitude is less than 5,000 feet (1,524m), it is

not required that the pressure switch be changed unless you are in an

area subject to low pressure inversions.

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Table 5: Nominal Manifold Pressure - High Fire

Manifold Pressures (in. w.c.)

Manifold Pressures (kPa)

Altitude (m)

Altitude (feet)

0-7999

3.5

8000-8999

3.5

9000-9999

3.5

0-2437

0.87

0.80

2.44

2438-2742

0.87

2743-3048

0.87

800

850

29.8

31.7

3.5

0.87

900

3.5

33.5

0.87

950

3.5

3.3

35.4

0.87

0.81

1000

1050

1100

3.5

3.2

2.9

37.3

0.80

0.73

3.5

2.9

2.7

39.1

0.73

0.67

3.2

2.7

2.4

41.0

0.66

0.61

2500 (LP)

9.8

8.2

7.5

93.2 (LP)

2.03

1.86

TABLE 6: Nominal Manifold Pressure - Low Fire

First Stage Manifold Pressures (in. w.c.)

First Stage Manifold Pressures (kPa)

Altitude (feet)

Altitude (m)

0-7999

1.7

8000-8999

1.7

9000-9999

1.7

0-2437

0.42

0.41

0.37

0.34

1.03

2438-2742

0.42

2743-3048

0.42

800

850

29.8

31.7

1.7

0.42

900

1.7

33.5

0.42

950

1.7

1.5

35.4

0.42

0.38

1000

1050

1100

1.6

1.5

1.4

37.3

0.37

0.34

1.5

1.4

1.3

39.1

0.34

0.31

1.3

1.2

1.1

41.0

0.31

0.28

2500 (LP)

4.1

3.8

3.5

93.2 (LP)

0.95

0.87

PROPANE AND HIGH ALTITUDE CONVERSION KITS

It is very important to choose the correct kit and/or gas orifices for the altitude and the type of gas for which the furnace is being installed.

Only use natural gas in furnaces designed for natural gas. Only use propane (LP) gas for furnaces that have been properly converted to use pro-

pane (LP) gas. Do not use this furnace with butane gas.

Incorrect gas orifices or a furnace that has been improperly converted will create an extremely dangerous condition resulting in premature heat

exchanger failure, excessive sooting, high levels of carbon monoxide, personal injury, property damage, a fire hazard and/or death.

High altitude and propane (LP) conversions are required in order for the appliance to satisfactory meet the application.

An authorized distributor or dealer must make all gas conversions.

In Canada, a certified conversion station or other qualified agency, using factory specified and/or approved parts, must perform the conversion.

The installer must take every precaution to insure that the furnace has been converted to the proper gas orifice size when the furnace is installed.

Do not attempt to drill out any orifices to obtain the proper orifice size. Drilling out a gas orifice will cause misalignment of the burner flames,

causing premature heat exchanger burnout, high levels of carbon monoxide, excessive sooting, a fire hazard, personal injury, property damage

and/or death.

Field wiring to the unit must be grounded. Electric wires that are field

installed shall conform to the temperature limitation for 63°F (35°C) rise

wire when installed in accordance with instructions. Refer to Table 7 in

SECTION V: ELECTRICAL POWER

ELECTRICAL POWER CONNECTIONS

these instructions for specific furnace electrical data.

Use copper conductors only.

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Table 7: Ratings & Physical / Electrical Data

Input

High/Low

Output

High/Low

Nominal

Airflow

High Fire

Air Temp. Rise

Low Fire

Air Temp. Rise

Cabinet Width

AFUE

Total Unit

Amps

MBH

CFM

in.

17-1/2

°F

35 - 65 1.6 - 18.3 35 - 65 1.6 - 18.3

35 - 65 1.6 - 18.3 30 - 60 -1 - 15.5

35 - 65 1.6 - 18.3 35 - 65 1.6 - 18.3

35 - 65 1.6 - 18.3 30 - 60 -1 - 15.5

°C

°F

°C

m /min

60/39 18/11 58/37 17/11

80/52 23/15 77/50 22/14

100/65 29/19 96/62 28/18

120/78 35/23 115/75 33/22

1200

1600

2000

44.4

53.3

62.2

45.3

56.6

35 - 65 1.6 - 18.3 35 - 65 1.6 - 18.3

24-1/2

Input

High/Low

Max. Outlet

Air Temp.

Operating

Weight

Max.

Min. Wire Size

Blower

Blower Size

Over-current (awg) @ 75 ft.

Protect

One Way

MBH

60/39 18/11

80/52 23/15

100/65 23/15

100/65 29/19

120/78 35/23

°F

°C

1/2

3/4

Amps

in.

Lbs.

122

126

136

142

145

156

Kg.

170

175

170

76.7

79.4

76.7

11 x 8 27.9 x 20.3

11 x 10 27.9 x 25.4

11 x 11 27.9 x 27.9

55.3

57.1

61.7

64.4

65.7

70.7

10.2

12.7

Annual Fuel Utilization Efficiency (AFUE) numbers are determined in accordance with DOE test procedures.

Wire size and over current protection must comply with the National Electrical Code (NFPA-70-latest edition) and all local codes.

The furnace shall be installed so that the electrical components are protected from water.

SUPPLY VOLTAGE CONNECTIONS

The power connection leads and wiring box may be relocated to the

left side of the furnace. Remove the screws and cut wire tie holding

excess wiring. Reposition on the left side of the furnace and fasten

using holes provided.

Junction

Box

Connect ground

lead to screw

LOW VOLTAGE CONTROL WIRING CONNECTIONS

Install the field-supplied thermostat by following the instructions that

come with the thermostat. With the thermostat set in the OFF position

and the main electrical source disconnected, connect the thermostat

wiring from the wiring connections on the thermostat to the terminal

board on the ignition module, as shown in Figures 18. Electronic ther-

mostats may require the common wire to be connected. Apply strain

relief to thermostat wires passing through cabinet. If air conditioning

equipment is installed, use thermostat wiring to connect the Y and C

terminals on the furnace control board to the proper wires on the con-

densing unit (unit outside).

Electrical Entry

BLK

WHT

L1-Hot

Neutral

FIGURE 17: Electrical Wiring

1. Provide a power supply separate from all other circuits. Install

overcurrent protection and disconnect switch per local/national

electrical codes. The switch should be close to the unit for conve-

nience in servicing. With the disconnect or fused switch in the OFF

position, check all wiring against the unit wiring label. Refer to the

wiring diagram in this instruction.

Set the heat anticipator in the room thermostat to 0.4 amps. Setting

it lower will cause short cycles. Setting it higher will cause the room

temperature to exceed the set points.

2. Remove the wiring box cover screws. Route all power wiring

through a conduit connector or other proper bushing that has been

installed into the unit opening and the junction box. In the junction

box there is a black wire, a white wire and a green ground screw.

Connect the power supply as shown on the unit’s wiring label

located on the inside of the blower compartment door, or the wiring

schematic in this section. Connect the black wire to L1 (hot) from

the power supply. Connect the white wire to neutral. Connect the

ground wire (installer-supplied) to the green (equipment ground)

screw. An alternate wiring method is to use a field-provided 2”

(5.1 cm) x 4” (10.2 cm) box and cover on the outside of the fur-

nace. Route the furnace leads into the box using a protective

bushing where the wires pass through the furnace panel. After

making the wiring connections replace the wiring box cover and

screws. Refer to Figures 17.

Some electronic thermostats do not have adjustable heat anticipa-

tors. They should be set to six cycles per hour. Follow the thermo-

stat manufacturer's instructions.

The 24-volt, 40 VA transformer is sized for the furnace components

only, and should not be connected to power auxiliary devices such as

humidifiers, air cleaners, etc. The transformer may provide power for an

air conditioning unit contactor.

3. The furnace's control system requires correct polarity of the power

supply and a proper ground connection. Refer to Figures 17.

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the Product Catalog Section.

AC 9A

Single Stage Air Conditioner – Two Stage Variable Speed Furnace

ID MODELS

PV(8/9)

(F/L)*(8/9)V

(G/L)*(8/9)V

THERMOSTAT

*DN22U00124

THERMOSTAT

*PP32U70124

THERMOSTAT

*DN22C00124

THERMOSTAT

*DP22U70124

TM(8/9)V

TWO STAGE

VARIABLE SPEED

FURNACE

SINGLE STAGE

AIR

CONDITIONER

TWO STAGE

VARIABLE SPEED

FURNACE CONTROL

24 – Volt Common

Y Y

Single Stage

Compressor

First Stage Compressor First Stage Compressor First Stage Compressor First Stage Compressor

CompreCssoomr pCroenstsaocrtor

24 – Volt Hot

(Heat XFMR)

24 – Volt Hot

(Heat XFMR)

24 – Volt Hot

Fan

E/W1

W/W1

First Stage Heat

Second Stage Heat

Y/Y2

24 – Volt Hot

(Cool XFMR)

24 – Volt Hot

(Cool XFMR)

Second or Full

Stage Compressor

Reversing Valve

X/L

Malfunction Light

Second Stage

Compressor

Second Stage

Compressor

Second Stage

Compressor

Second Stage

Compressor

External Humidistat

(Optional)

Open on Humidity Rise

DHUM

Dehumidification

Connection of the “C”

terminal, 24-volt common

is optional when used with

batteries

Connection of the “C”

terminal, 24-Volt common

is optional when used with

batteries

Connection of the “C”

terminal, 24-Volt common terminal, 24-Volt common

is optional when used with is optional when used with

Connection of the “C”

Move DHUM

jumper to “YES”

if humidistat is to be used.

batteries

Thermostat Installer Setup

1-System Type-must

be set to 7-2 Heat/1 Cool

Thermostat Installer Setup

0170-System Type-must

be set to 9-2 Heat/1 Cool

Step 1 of Thermostat User

Configuration Menu must

be set to MS 2

Multistage Conventional Multistage Conventional

Thermostat Installer Setup

15-Compressor Protection

-must be set to 5

Part Numbers:

Part Number:

S1-2HU16700124

SAP

Legacy

265904 = 031-09169

449572

FIGURE 18: Thermostat Chart - Single Stage Air Conditioners with Two Stage Variable Speed Furnaces

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HP 15A

Single Stage Heat Pump – Two Stage Variable Speed Furnace (Hot Heat Pump or Conventional)

ID MODELS

OD MODELS

PV(8/9)

YZB

(F/L)*(8/9)V

(G/L)*(8/9)V

TM(8/9)V

YMB

H*3

THERMOSTAT

*BP21H50124

*BN21H00124

*DP21H40124

*DN21H00124

TWO STAGE

VARIABLE SPEED

FURNACE

SINGLE STAGE

HEAT PUMP

*DN22U00124

*DP32H70124

TWO STAGE

VARIABLE SPEED

FURNACE CONTROL

YORKGUARD VI

CONTROL

24 – Volt Common

Single Stage

Compressor

Single Stage

Compressor

First Stage Compressor First Stage Compressor First Stage Compressor

24 – Volt Hot

(Heat XFMR)

24 – Volt Hot

Fan

W/W1

W1 OUT

Emergency Heat

First Stage Heat

W2 OUT

Third Stage Heat

Second Stage Heat

Y/Y2

Second or Full

Stage Compressor

Y2 OUT

Second Stage

Compressor

Reversing Valve

Energized in Cool

24 – Volt Hot

(Cool XFMR)

O/B

Reversing Valve

Energized in Cool

Reversing Valve

Energized in Cool

Reversing Valve

X/L

Malfunction Light

Second Stage

Compressor

Second Stage

Aux. Heat

Second Stage

Compressor

Second Stage

Compressor

AUX

Auxiliary Heat

Second Stage Heat

Auxiliary Heat

DHUM

Dehumidification

BSG

Bonnet Sensor

24VAC Humidifier

(Optional)

Bonnet Sensor Kit

(Optional)

S1-37309243000

External Humidistat

(Optional)

Open on Humidity Rise

Bonnet Sensor

External Humidistat

(Optional)

Open on Humidity Rise

Step 1 of Thermostat

Installer / Configuration

Menu must be set to

Heat Pump 1

Thermostat Installer Setup

1-System Type-must be set

to 5 – 2 Heat/1 Heat Pump

Change FFuel jumper

on the heat pump control

to “ON”

B/O Switch on Thermostat

must be in the O position

Move HEAT PUMP

jumper to “YES”

Move DHUM

jumper to “YES”

if humidistat is to be used.

Thermostat Installer Setup

2-Changeover Valve-must

be set to 0 – O/B terminal

Energized in Cooling

Change Hot Heat Pump

jumper on the heat pump

control to “ON” if Hot Heat

Pump Operation is desired.

Part Numbers:

SAP

126768 = 031-09137

18395 031-01996

340512 = 031-09178

Legacy

Part Numbers:

Part Number:

S1-2HU16700124

SAP

Legacy

265904 = 031-09169

449572

FIGURE 19: Thermostat Chart - Single Stage Heat Pump with Two Stage Variable Speed Furnace (Hot Heat Pump or Conventional)

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AC 24C

Two Stage Air Conditioner – Two Stage Variable Speed Furnace

ID MODELS

PV(8/9)

(F/L)*(8/9)V

(G/L)*(8/9)V

THERMOSTAT

TM(8/9)V

TWO STAGE

VARIABLE SPEED

FURNACE

TWO STAGE

AIR

CONDITIONER

*PP32U71124

*PP32U72124

TWO STAGE

VARIABLE SPEED

FURNACE CONTROL

24 – Volt Common

Single Stage

Compressor

First Stage Compressor

24 – Volt Hot

Fan

Comfort Alert Interface

(two pin connector)

E/W1

W/W1

First Stage Heat

Second Stage Heat

Y/Y2

Second or Full

Stage Compressor

Reversing Valve

X/L

Malfunction Light

Second Stage

Compressor

Second Stage

Compressor

DHM

DHUM

Dehumidification

Humidistat

24VAC Humidifer

(Optional)

Optional Harness

Step 1 of Thermostat User

Configuration Menu must

be set to MLTISTG

Move DHUM

jumper to “YES”

if humidistat is to be used.

E2/P Switch must be in the

E2 position

Part Numbers:

SAP

265904

449572

Legacy

031-09169

FIGURE 20: Thermostat Chart - Two Stage AC with Two Stage Variable Speed Furnace

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HP 24A

Two Stage Heat Pump – Two Stage Variable Speed Furnace (Hot Heat Pump or Conventional)

ID MODELS

OD MODELS

PV(8/9)

YZE

(F/L)*(8/9)V

(G/L)*(8/9)V

TM(8/9)V

YZH

H*5

H*8

THERMOSTAT

TWO STAGE

VARIABLE SPEED

FURNACE

*PP32U71124

*PP32U72124

TWO STAGE

HEAT PUMP

TWO STAGE

VARIABLE SPEED

FURNACE CONTROL

YORKGUARD VI

CONTROL

24 – Volt Common

Single Stage

Compressor

Single Stage

Compressor

First Stage Compressor

24 – Volt Hot

Fan

W/W1

W1 OUT

First Stage Heat

W2 OUT

Second Stage Heat

Second Stage

Aux. Heat

Second Stage Heat

Y/Y2

Second or Full

Stage Compressor

Y2 OUT

Second Stage

Compressor

Reversing Valve

Energized in Cool

Reversing Valve

Energized in Cool

Reversing Valve

X/L

Malfunction Light

Second Stage

Compressor

Second Stage

Compressor

E/W1

First Stage Aux. Heat

Auxiliary Heat

DHM

DHUM

BSG

Bonnet Sensor Kit

(Optional)

Dehumidistat

Dehumidification

Bonnet Sensor

S1-37309243000

Humidistat

24VAC Humidifier

(Optional)

Bonnet Sensor

Step 1 of the Thermostat

Installer Table must be

set to Heat Pump

Change FFuel jumper

on the heat pump control

to “ON”

Move HEAT PUMP

jumper to “YES”

Step 2 of the Thermostat

Installer Table must be

set to 2

E2/P Switch must be in the

E2 position

Move DHUM

jumper to “YES”

if humidistat is to be used.

Change Hot Heat Pump

jumper on the heat pump

control to “ON” if Hot Heat

Pump Operation is desired.

Part Numbers:

SAP

126768 = 031-09137

18395 031-01996

340512 = 031-09178

Legacy

Part Numbers:

SAP

Legacy

265904 = 031-09169

449572

FIGURE 21: Thermostat Chart - Two Stage HP with Two Stage Variable Speed Furnace (Hot Heat Pump or Conventional)

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ACCESSORY CONNECTIONS

The furnace control will allow power-switching control of various

accessories.

If an external vent tee is being installed, then it must have its own

condensate trap before it is disposed into an open or vented drain.

This is not to be considered as a second trap as referenced

elsewhere in this document.

ELECTRONIC AIR CLEANER CONNECTION

Two 1/4” (6.4 mm) spade terminals (EAC and NEUTRAL) for electronic

air cleaner connections are located on the control board. The terminals

provide 115 VAC (1.0 amp maximum) during circulating blower

operation.

HUMIDIFIER CONNECTION

Two 1/4” (6.4 mm) spade terminals (HUM and NEUTRAL) for humidifier

connections are located on the control board. The terminals provide

115 VAC (1.0 amp maximum) during heating system operation.

A mounting hole is provided on the control panel next to the furnace

control board for mounting a humidifier transformer if required.

TWINNING

These furnaces are not to be twinned. If more than one furnace is

needed in an application, each furnace must have its own complete

duct system and its own wall thermostat.

Open

(Anti-siphon

Stand

Pipe

air vent)

SECTION VI: CONDENSATE PIPING AND

FURNACE VENTING CONFIGURATION

5” Min.

CONDENSATE DRAIN LOCATION

As shipped from the factory:

Tee

•

For all 060, & 080K input furnaces the main drain is plumbed

through the casing right-side opening when viewed from the front

of the furnace.

•

For all 100 & 120K input furnaces the main drain is plumbed

through the casing left-side opening when viewed from the front

of the furnace.

To Open Or

Vented Drain

NOTE: The Figures 24 - 27 show the condensate drain arrange-

ment for the various possible furnace and vent blower positions.

The condensate hoses must slope downwards at all points.

FIGURE 22: Typical. Condensate drain, vertical installation.

The furnace condensate pan is self priming and con-

tains an internal trap to prevent flue gas leaking. Do

not install an external condensate trap.

The condensate will flow to the drain better if an open stand pipe is

installed in the drain line. See Figure 23.

When drain hose routing changes are required (shown in Figures 24-

27), be sure to cap all un-used openings.

If evaporator coil or humidifier drains are combined with the furnace

drain, then the open stand pipe could be raised higher, above the 5”

minimum.

If rerouting hoses - excess length should be cut off so that no sagging

loops will collect and hold condensate - which will cause the furnace to

not operate.

No hose clamps are needed for connecting to the condensate pan.

It is possible for condensation to form inside the combustion air

(intake) pipe in the summer months if significant length of combus-

tion air pipe passes through conditioned space. This problem can

be averted by the addition of a simple drain tee, or a drain tee with a

drain on the combustion air pipe as close to the furnace as possi-

ble, as shown in Figure 24. This is true for all long horizontal vent-

ing in any furnace configuration. This will prevent the condensate

from entering the furnace.

The furnace, evaporator coil, and humidifier drains may be com-

bined and drained together. The evaporator coil drain must have

an external, field-supplied trap prior to the furnace drain connec-

tion. All drain connections (furnace, evaporator coil, or humidifier)

must be terminated into an open or vented drain as close to the

respective equipment as possible.

Condensate must be disposed of properly. Follow local plumbing

or wastewater codes. The drain line must maintain a 1/4" per foot

(21 mm/m) downward slope to the drain.

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CONDENSATE DRAIN TERMINATION

A condensate sump pump MUST be used if required by local codes, or

if no indoor floor drain is available. The condensate sump pump must

be approved for use with acidic condensate.

Exhaust Pipe

Combustion Air Pipe

Tee with Drain Trap

DO NOT terminate condensate drain in a chimney, or where the

drain line may freeze. The line must terminate at an inside drain to

prevent freezing of the condensate and possible property damage.

DO NOT trap the drain line at any other location than at the conden-

sate drain trap supplied with the furnace.

Trap

Connect to Drain

CONDENSATE DRAIN TRAP AND DRAIN FREEZE

PROTECTION

Special precautions MUST be made if installing furnace in an area

which may drop below freezing. This can cause improper operation or

damage to the equipment. If the furnace is installed in an area that has

the potential of freezing, the drain line must be protected. Use a 3 to 6

Watt per foot at 115 vac, 40ºF (4.4°C) self-regulating, shielded and

waterproof heat tape. Wrap the drain line outside of the furnace with the

heat tape and secure with ties. Follow the heat tape manufacturer's rec-

ommendations.

Liquid anti-freeze will cause damage to internal plastic parts of this

furnace. DO NOT attempt to winterize the furnace using liquid

anti-freeze.

FIGURE 23: Typical. Combustion Pipe Drain Tee.

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For 060 & 080K input furnaces, the condensate drain

is plumbed toward the right casing outlet from the factory.

p l u m b e d t o w a r d t h e l e f t c a s i n

F o r 1 0 0 , 1 2 0 K i n p u t f u r n a c e

FIGURE 24: Upflow Configuration

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FIGURE 25: Downflow Configuration

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FIGURE 26: Horizontal Left Configuration

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FIGURE 27: Horizontal Right Configuration

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4. All combustion air and vent pipe must conform to American

National Standards Institute (ANSI) and American Society for Test-

ing and Materials (ASTM) standards D1785 (Schedule 40 PVC),

D2665 (PVC-DWV), F891 (PVC-DWV Cellular Core), D2261

(ABS-DWV) or F628 (Schedule 40 ABS). Pipe cement and primer

must conform to ASTM Standard D2546 (PVC) or D2235 (ABS). If

ABS pipe is to be used, any joint where ABS pipe is joined to PVC

pipe must be glued with cement that is approved for use with

BOTH materials. Metallic materials must not be used for venting or

air intake.

SECTION VII: COMBUSTION AIR AND

VENT SYSTEM

COMBUSTION AIR AND VENT SAFETY

This Category IV, dual certified direct vent furnace is designed for resi-

dential application. It may be installed without modification to the con-

densate system in a basement, garage, equipment room, alcove, attic

or any other indoor location where all required clearance to combusti-

bles and other restrictions are met. The combustion air and the venting

system must be installed in accordance with Section 5.3, Air for Com-

bustion and Ventilation, of the National Fuel Gas Code Z223.1/NFPA 54

(latest edition), or Sections 7.2, 7.3 or 7.4 of CSA B149.1, National Gas

and Propane Codes (latest edition) or applicable provisions of the local

building code and these instructions.

5. If a flexible connector is used in the vent system, it must be made

of a material that is resistant to acidic exposure and to at least

225°F (107.2°C) temperature. Flexible connectors are also

allowed in the combustion air pipe.

6. All models are supplied with 2" (5.1 cm) vent connections. When

the pipe must be increased to 3" (7.6 cm) diameter, the transition

from 2" to 3" must be done as close to the furnace as possible. For

upflow models, the transition from 2" to 3" should be done immedi-

ately above the furnace. For downflow or horizontal models, the

transition from 2" to 3" pipe should be done immediately after exit-

ing the furnace.

The VENT SYSTEM must be installed as specified in these instruc-

tions for Residential and non-HUD Modular Homes. The direct vent

system is the only configuration that can be installed in a non-HUD

Modular Home.

7. In Canada, vents shall be certified to ULC S636, Standard for Type

BH Gas Venting Systems. IPEX System 636 PVC is certified to

this standard.

8. In Canada, the first three feet (91.4 cm) of the vent must be readily

accessible for inspection.

This furnace may not be common vented with any other appliance,

since it requires separate, properly sized air intake and vent lines.

The furnace shall not be connected to any type of B, BW or L vent

or vent connector, and not connected to any portion of a factory-

built or masonry chimney

9. For single pipe systems it is recommended to install the combus-

tion air coupling provided and install approximately 18” of PVC

pipe on the furnace.

The furnace shall not be connected to a chimney flue serving a sep-

arate appliance designed to burn solid fuel.

10. Minimum vent length for all models is 5 feet (1.5 m).

TABLE 8: Maximum Equivalent Pipe Length

Maximum

Equivalent

length feet (m)

Model Input

BTUH (kW)

Pipe Size

Inches (cm)

When combustion air pipe is installed above a suspended ceiling or

when it passes through a warm and humid space, the pipe must be

insulated with 1/2” Armaflex or other heat resistant type insulation if

two feet or more of pipe is exposed.

Vent piping must be insulated if it will be subjected to freezing tem-

peratures such as routing through unheated areas or through an

unused chimney.

60,000 (17.6)

80,000 (23.4)

100,000 (29.3)

120,000 (35.1)

2 (5.1)

3 (7.6)

2 (5.1)

3 (7.6)

2 (5.1)

3 (7.6)

2 (5.1)

3 (7.6)

65 (19.8)

90 (27.4)

65 (19.8)

90 (27.4)

30 (9.2)

90 (27.4)

30 (9.2)

COMBUSTION AIR/VENT PIPE SIZING

The size of pipe required will be determined by the furnace model, the

total length of pipe required and the number of elbows required.

90 (27.4)

Table 8 lists the maximum equivalent length of pipe allowed for each

model of furnace. The equivalent length of elbows is shown in Table 10.

The equivalent length of the vent system is the total length of straight

pipe PLUS the equivalent length of all of the elbows.

The following rules must also be followed:

1. Long radius (sweep) elbows are recommended. Standard elbows

may be used, but since they have a longer equivalent length, they

will reduce the total length of pipe that will be allowed. Short radius

(plumbing vent) elbows are not allowed. The standard dimensions

of the acceptable elbows are shown below.

2. The maximum equivalent length listed in Table 8 is for the vent pip-

ing and the air intake piping separately. For example, if the table

allows 65 equivalent feet for a particular model, then the vent can

have 65 equivalent feet of pipe, AND the combustion air intake can

have another 65 equivalent feet of pipe.

STANDARD ELBOW

LONG (SWEEP) ELBOW

FIGURE 28: Dimensions

TABLE 9: Elbow Dimensions

3. Three vent terminal elbows (two for the vent and one for the com-

bustion air intake) are already accounted for and need not be

included in the equivalent length calculation.

Elbow

"A" Dimension

2" Standard

3" Standard

2" Sweep

3" Sweep

2-5/16"

3-1/16"

3-1/4"

4-1/16"

Dimensions are those required in Standard ASTM D-3311.

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TABLE 10: Equivalent Length of Fittings

Fitting

Equivalent Length

5 feet of 2" pipe

2-1/2 feet of 2" pipe

10 feet of 2" pipe

5 feet of 2" pipe

5 feet of 3" pipe

2-1/2 feet of 3" pipe

10 feet of 3" pipe

5 feet of 3" pipe

10 feet of 2" pipe

10 feet of 3" pipe

Accessory concentric vent / intake termination kits 1CT0302 and

1CT0303 are available and approved for use with these furnaces.

Horizontal sidewall vent terminations kits 1HT0901 & 1HT0902 are

also approved for use with these furnaces.

2" 90º sweep elbow

2" 45º sweep elbow

2" 90º standard elbow

2" 45º standard elbow

3" 90º sweep elbow

3" 45º sweep elbow

3" 90º standard elbow

3" 45º standard elbow

2" corrugated connector

3" corrugated connector

Furnace vent pipe connections are sized for 2” (5.1 cm). pipe. Any

pipe size change must be made outside the furnace casing in a ver-

tical pipe section to allow proper drainage of condensate. An offset

using two 45º (degree) elbows will be required for plenum clear-

ance when the vent is increased to 3” (7.6 cm).

COMBUSTION AIR AND VENT PIPING ASSEMBLY

Example:

The final assembly procedure for the combustion air and vent piping is

as follows:

An 80,000 BTUH furnace requires 32 feet of pipe and four 90º elbows.

Using 2" pipe and standard elbows, the total equivalent length will be:

1. Cut piping to the proper length beginning at the furnace.

2. Deburr the piping inside and outside.

32 feet of 2" pipe =

4 - 90º standard 2" elbows = (4x10) =

Total =

32 equivalent feet

40 equivalent feet

72 equivalent feet of 2" pipe

3. Chamfer (bevel) the outer edges of the piping.

4. Dry-fit the vent piping assembly from the furnace to the outside ter-

mination checking for proper fit support and slope.

This exceeds the 65 foot maximum equivalent length of 2" pipe allowed

for that model and is thus not acceptable.

5. Dry-fit the combustion air piping assembly checking for proper fit,

support and slope on the following systems:

By using sweep elbows, the total equivalent length will be:

a. Sealed combustion air systems from the furnace to the out-

side termination.

32 feet of 2" pipe =

4 - 90º sweep 2" elbows = (4x5) =

Total =

32 equivalent feet

20 equivalent feet

52 equivalent feet of 2" pipe

b. Ventilated combustion air systems from the furnace to the

attic or crawl space termination.

This is less than the 65 foot maximum equivalent length of 2" pipe

allowed for that model and is thus acceptable.

Alternatively, using 3" pipe and standard elbows, the total equivalent

length will be:

Solvent cements are flammable and must be used in well-ventilated

areas only. Keep them away from heat, sparks and open flames.

Do not breathe vapors and avoid contact with skin and eyes.

32 feet of 3" pipe =

4 - 90º standard 2" elbows = (4x5) =

Total =

32 equivalent feet

40 equivalent feet

72 equivalent feet of 3" pipe

6. Disassemble the combustion air and vent piping, apply cement

primer and the cement per the manufactures instructions. Primer

and cement must conform to ASTM D2564 for PVC, or ASTM

D2235 for ABS piping.

This is less than the 90 foot maximum equivalent length of 3" pipe

allowed for that model and is thus acceptable.

TABLE 11: Combustion Air Intake and Vent Connection Size at Furnace

7. All joints must provide a permanent airtight and watertight seal.

(All Models)

8. Support the combustion air and vent piping such that it is angled a

minimum of 1/4” per foot (21 mm/m) so that condensate will flow

back towards the furnace. Piping should be supported with pipe

hangers to prevent sagging.

FURNACE VENT CONNECTION SIZES

40 - 100 MBH

120 - 130 MBH

(35.2 - 39.6 kW)

Furnace Input

(17.5 - 29.3 kW)

9. Seal around the openings where the combustion air and / or vent

piping pass through the roof or sidewalls.

Intake Pipe Size

Vent Pipe Size

2” (5.1 cm)

3” (7.6 cm)

2” (5.1 cm)

COMBUSTION AIR / VENTING

*. Vent pipe size must be increased to 3” diameter after connection to furnace

on this model.

The vent must be installed with the minimum required clearances,

and must comply with local codes and requirements.

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VENT CLEARANCES

VENT TERMINAL

FIXED

CLOSED

AIR SUPPLY

AREA WHERE TERMINAL IS NOT PERMITTED

FIXED

CLOSED

OPERABLE

FIGURE 29: Home Layout

Canadian Installations^1,3

US Installation^2,3

Direct Vent Terminal Clearances

A. Clearance above grade, veranda, porch, deck, or

balcony

12” (30.5 cm)

Two-pipe (direct vent) applications: 9” (23 cm) for

12” (30.5 cm) for models 100,000 BTUH (30 kW),

models 50,000 BTUH (15 kW), 12” (30.5 cm) for

B. Clearance to window or door that may be opened

C. Clearance to permanently closed window

36” (91.4 cm) for models >100,000 BTUH (30 kW).

models >50,000 BTUH (15 kW). ††

Single-pipe applications: 4 feet (1.2 m).

12” (30.5 cm)

D. Vertical clearance to ventilated soffit located

above the terminal within a horizontal distance

of 2 feet (61 cm) from the center line of the terminal

12” (30.5 cm) or in accordance with local installation

codes and the requirements of the gas supplier.

12” (30.5 cm) or in accordance with local installation

codes and the requirements of the gas supplier.

12” (30.5 cm) or in accordance with local installation

codes and the requirements of the gas supplier.

12” (30.5 cm) or in accordance with local installation

codes and the requirements of the gas supplier.

E. Clearance to unventilated soffit

12” (30.5 cm) or in accordance with local installation

codes and the requirements of the gas supplier.

12” (30.5 cm) or in accordance with local installation

codes and the requirements of the gas supplier.

F. Clearance to outside corner

G. Clearance to inside corner

3 feet (91.4 cm)

Above a meter/regulator assembly within 3 feet

H. Clearance to each side of center line

extended above meter/regulator assembly

(91.4 cm) horizontally of the vertical center-line of the (91.4 cm) horizontally of the vertical center-line of the

regulator vent outlet to a maximum vertical distance of regulator vent outlet to a maximum vertical distance of

15 feet (4.5 m) above the meter/regulator assembly.

3 feet (91.4 cm) or in accordance with local installation

codes and the requirements of the gas supplier.

I. Clearance to service regulator vent outlet

3 feet (91.4 cm)

Two-pipe (direct vent) applications: 9” (23 cm) for

models 50,000 BTUH (15 kW), 12” (30.5 cm) for

models >50,000 BTUH (15 kW).

J. Clearance to nonmechanical air supply inlet to

building or the combustion air inlet to any other

appliance

12” (30.5 cm) for models 100,000 BTUH (30 kW),

3 feet (91.4 cm) for models >100,000 BTUH (30 kW).

Single-pipe applications: 4 feet (1.2 m).

3 feet (91.4 cm) above if within 10 feet (3 m)

horizontally.

K. Clearance to a mechanical supply inlet

6 feet (1.83 m)

7 feet (2.13 m)†

L. Clearance above paved sidewalk or paved

driveway located on public property

7 feet (2.13 m) or in accordance with local installation

codes and the requirements of the gas supplier.

12” (30.5 cm) or in accordance with local installation

codes and the requirements of the gas supplier.

M. Clearance under veranda, porch, deck, or balcony 12” (30.5 cm)‡

1. In accordance with the current CSA B149.1-00, Natural Gas and Propane Installation Code.

2. In accordance with the current ANSI Z223.1 / NFPA 54, National Gas Code.

3. In accordance with the current ANSI Z21.47 * CSA 2.3 American National Standard.

†

A vent shall not terminate directly above a sidewalk or paved driveway that is located between two single family dwellings and serves both dwellings.

†† 12” (30.5 cm) up from the bottom edge of the structure for Two-pipe (direct vent) applications per ANSI Z223.1 / NFPA 54, National Gas Code.

Permitted only if veranda, porch, deck, or balcony is fully open on a minimum of two sides beneath the floor and the distance between the top of the vent termina-

‡

tion and the underside of the veranda, porch, or deck is greater than 12” (30.5 cm) as specified in CSA B149.1-00.

A vent shall not terminate less than 12” (30.5 cm) above a grade level.

Any fresh air or make up inlet for dryer or furnace area is considered to be forced air inlet.

Avoid areas where condensate drippage may cause problems such as above planters, patios, or adjacent to windows where steam may cause fogging.

A terminus of a vent shall be fitted with a cap in accordance with the vent manufacturer’s installation instructions, or in accordance with the installation instructions for a

special venting system.

Responsibility for the provision of proper adequate venting and air supply for application shall rest with the installer.

Vent shall extend high enough above building, or a neighboring obstruction, so that wind from any direction will not create a positive pressure in the vicinity of the vent.

Consideration must be given for degradation of building materials by flue gases. Sidewall termination may require sealing or shielding of building

surfaces with a corrosion resistant material to protect against combustion product corrosion. Consideration must be given to wind direction in

order to prevent flue products and/or condensate from being blown against the building surfaces. If a metal shield is used it must be a stainless

steel material at a minimum dimension of 20” (51 cm). It is recommended that a retaining type collar be used that is attached to the building sur-

face to prevent movement of the vent pipe.

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VENT SYSTEM

This furnace is certified to be installed with one of two possible vent

configurations.

12” MIN.

1. Horizontal vent system. This vent system can be installed com-

pletely horizontal or combinations of horizontal, vertical, or offset

using elbows.

12” Minimum

below overhang

12” MIN.

12” Minimum

separation between

bottom of

combustion air

intake and

bottom of vent

2. Vertical vent system. This vent system can be installed completely

vertical or a combination of horizontal, vertical, or offset using

elbows.

VENT APPLICATIONS AND TERMINATION

When selecting the location for a combustion air / vent termination, the

following should be considered:

Maintain 12”

minimumclearance

above highest

1. Observe all clearances listed in vent clearances in these instruc-

tions.

anticipated snow

level or grade,

whichever is higher

2. Termination should be positioned where vent vapors will not dam-

age plants or shrubs or air conditioning equipment.

FIGURE 32: Termination Configuration - 2 Pipe Basement

3. Termination should be located where it will not be affected by wind

gusts, light snow, airborne leaves or allow recirculation of flue

gases.

VENTING MULTIPLE UNITS

Multiple units can be installed in a space or structure as either a single

4. Termination should be located where it will not be damaged or

exposed to flying stones, balls, etc.

pipe configuration or a two-pipe configuration.

The combustion air side of the single pipe configuration shown in Figure

29 is referred to in these instructions as ambient combustion air supply.

Follow the instructions for ambient combustion air installations, paying

particular attention to the section on air source from inside the building.

The vent for a single pipe system must be installed as specified in the

venting section of these instructions with the vent terminating as shown

in Figure 29. Each furnace must have a separate vent pipe. Under NO

circumstances can the two vent pipes be tied together.

5. Termination should be positioned where vent vapors are not objec-

tionable.

6. Horizontal portions of the vent system must slope upwards and be

supported to prevent sagging.

7. Direct vent systems must be installed so the vent and the combus-

tion air pipes terminate in the same atmospheric zone. Refer to

Figures 13 or 14.

Maintain 12” minimum clearance

above highest anticipated snow level.

Maximum 24” above roof.

The combustion air side of the two-pipe configuration shown in Figure

30 can be installed so the combustion air pipe terminates as described

in outdoor combustion air or ventilated combustion air sections in these

instructions. Follow the instructions for outdoor combustion air or venti-

lated combustion air and the instructions for installing the vent system

with the vent terminating as shown in Figures 32 or 33. The two-pipe

system must have a separate combustion air pipe and a separate vent

pipe for each furnace. Under NO circumstances can the two combus-

tion air or vent pipes be tied together. The combustion air and vent

pipes must terminate in the same atmospheric zone.

12” Min.

VENT

FIGURE 30: Termination Configuration - 1 Pipe

12” vertical separation

between combustion air

intake and vent.

COMBUSTION AIR

Maintain 12” minimum

clearance above

highest anticipated

snow level.

12” minimum

below overhang

2”

MIN.

12” minimum

separation between

bottom of

combustion air pipe

and bottom of vent.

FIGURE 33: Double Horizontal Combustion Air Intake and Vent

Termination

Maintain 12”

minimum clearance

above highest

anticipated snow

level or grade,

whichever is higher.

MIN.

6”

FIGURE 31: Termination Configuration - 2 Pipe

FIGURE 34: Double Vertical Combustion Air Intake and Vent

Termination

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COMBUSTION AIR SUPPLY

All installations must comply with Section 5.3, Air for Combustion and

Ventilation of the National Fuel Gas Code, ANSI Z223.1 or Sections

7.2, 7.3 or 7.4 of CAN/CGA B149.1 or .2 Installation Code - latest edi-

tions.

COMBUSTION AIR

Vent pipe cements

into socket just

above top panel

This furnace is certified to be installed with one of three possible com-

bustion air intake configurations.

Or vent pipe may be

clamped into outlet

of drain coupling

1. OUTDOOR COMBUSTION AIR: This is a direct vent configuration

where the combustion air is supplied through a PVC or ABS pipe

that is connected to the PVC coupling attached to the furnace and

is terminated in the same atmospheric zone as the vent. This type

of installation is approved on all models. Refer to Figure 36.

2. AMBIENT COMBUSTION AIR: Combustion air is supplied from

the area surrounding the furnace through openings in the furnace

casing. The combustion air and the vent pipes are not terminated

in the same atmospheric zone. Refer to Figure 21 for vent termina-

tions. Refer to "Ambient Combustion Air Supply" for proper instal-

lation. Refer to Figure 36.

FIGURE 36: Combustion Airflow Path Through The Furnace Casing

3. VENTILATED COMBUSTION AIR: Combustion air is supplied

through a PVC or ABS pipe that is connected to the PVC coupling

attached to the burner box and is terminated in a ventilated attic or

crawl space. The combustion air and the vent pipes are not termi-

nated in the same atmospheric zone. Refer to Figure 37 for attic

and crawl space termination. Only the combustion air intake may

terminate in the attic. The vent must terminate outside.

This type of installation requires that the supply air to the appli-

ance(s) be of a sufficient amount to support all of the appliance(s)

in the area. Operation of a mechanical exhaust, such as an exhaust

fan, kitchen ventilation system, clothes dryer or fireplace may cre-

ate conditions requiring special attention to avoid unsatisfactory

operation of gas appliances. A venting problem or a lack of supply

air will result in a hazardous condition, which can cause the appli-

ance to soot and generate dangerous levels of CARBON MONOX-

IDE, which can lead to serious injury, property damage and / or

death.

Outdoor Combustion Air

Combustion Air Intake/Vent Connections

This installation requires combustion air to be brought in from outdoors.

This requires a properly sized pipe (Shown in Figure 30) that will bring

air in from the outdoors to the furnace combustion air intake collar on

the burner box. The second pipe (Shown in Figure 30) is the furnace

vent pipe.

An unconfined space is not less than 50 cu.ft (1.42 m³) per 1,000 Btu/

hr (0.2928 kW) input rating for all of the appliances installed in that

area.

Rooms communicating directly with the space containing the appli-

ances are considered part of the unconfined space, if doors are fur-

nished with openings or louvers.

A confined space is an area with less than 50 cu.ft (1.42 m³) per 1,000

Btu/hr (0.2928 kW) input rating for all of the appliances installed in that

area. The following must be considered to obtain proper air for combus-

tion and ventilation in confined spaces.

Connects to

collar on top

of burner box

Vent pipe cements

into socket just

above top panel

Or vent pipe may be

clamped into outlet

of drain coupling

Combustion Air Source From Outdoors

The blocking effects of louvers, grilles and screens must be given con-

sideration in calculating free area. If the free area of a specific louver or

grille is not known, refer to Table 12, to estimate free area.

Table 12: Estimated Free Area

Wood or Metal

Louvers or Grilles

Wood 20-25%*

Metal 60-70% *

FIGURE 35: Direct Vent Air Intake Connection and Vent Connection

1/4” (6.4 mm)

mesh or larger 100%

Screens+

The combustion air intake pipe should be located either through the

wall (horizontal or side vent) or through the roof (vertical vent). Care

should be taken to locate side vented systems where trees or shrubs

will not block or restrict supply air from entering the terminal.

* Do not use less than 1/4” (6.4 mm) mesh

+ Free area of louvers and grille varies widely; the installer should follow

louver or grille manufacturer’s instructions.

Also, the terminal assembly should be located as far as possible from a

swimming pool or a location where swimming pool chemicals might be

stored. Be sure the terminal assembly follows the outdoor clearances

listed in Section #1 “Outdoor Air Contaminants.”

Dampers, Louvers and Grilles (Canada Only)

1. The free area of a supply air opening shall be calculated by sub-

tracting the blockage area of all fixed louvers grilles or screens

from the gross area of the opening.

Ambient Combustion Air Supply

2. Apertures in a fixed louver, a grille, or screen shall have no dimen-

sion smaller than 1/4” (6.4 mm).

This type installation will draw the air required for combustion from

within the space surrounding the appliance and from areas or rooms

adjacent to the space surrounding the appliance. This may be from

within the space in a non-confined location or it may be brought into the

furnace area from outdoors through permanent openings or ducts. It is

not piped directly into the furnace. A single, properly sized pipe from the

furnace vent connector to the outdoors must be provided. It is recom-

mended that the supplied intake coupling and 18” (46 cm) of pipe be

attached to the furnace to prevent accidental blockage of the combus-

tion air intake.

3. A manually operated damper or manually adjustable louvers are

not permitted for use.

4. A automatically operated damper or automatically adjustable lou-

vers shall be interlocked so that the main burner cannot operate

unless either the damper or the louver is in the fully open position.

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Table 14: Free Area

Minimum Free Area Required for Each Opening

Vertical Duct or

When a Category I furnace is removed or replaced, the original

venting system may no longer be correctly sized to properly vent

the attached appliances.

BTUH Input

Rating

Horizontal Duct

(2,000 BTUH)

Round Duct

Opening to Outside

(4,000 BTUH)

An improperly sized vent system can cause CARBON MONOXIDE

to spill into the living space causing personal injury, and or death.

30 in²(193 cm²)

40 in²(258 cm²)

50 in²(322 cm²)

60 in²(387 cm²)

15 in²(97 cm²)

20 in²(129 cm²)

25 in²(161 cm²)

30 in²(193 cm²)

60,000

80,000

5” (13 cm)

6” (15 cm)

7” (18 cm)

Table 13: Unconfined Space Minimum Area in Square Inch

100,000

120,000

Minimum Free Area in Square Inches

BTUH Input Rating

Required for Each Opening

EXAMPLE: Determining Free Area.

Appliance 1 Appliance 2 Total Input

60 (387 cm²)

60,000

100,000 +30,000 = (130,000  4,000) = 32.5 Sq. In. Vertical

Appliance 1 Appliance 2 Total Input

100,000 +30,000 = (130,000  2,000) = 65 Sq. In. Horizontal

80 (516 cm²)

80,000

100 (645 cm²)

100,000

120 (742 cm²)

120,000

Gas

Vent

Gas

Vent

Gas

Vent

Gable

Vent

Gable

Vent

Ventilated

Attic

Ventilated

Attic

Optional

Inlet (a)

Top Above

Insulation

Top Above

Insulation

Outlet

Air (a)

Soffit

Vent

Soffit

Vent

Outlet

Air (b)

Outlet

Air (a)

Gas

Water

Heater

Gas

Water

Heater

Gas

Water

Heater

Inlet

Air (b)

Inlet

Air (b)

Inlet

Air (a)

Inlet

Air (a)

Ventilated

Crawl Space

FIGURE 37: Outside and Ambient Combustion Air

Air Supply Openings and Ducts

Combustion Air Source from Outdoors

1. An opening may be used in lieu of a duct to provide to provide the

outside air supply to an appliance unless otherwise permitted by

the authority having jurisdiction. The opening shall be located

within 12” (30.5 cm) horizontally from, the burner level of the appli-

ance. Refer to “AIR SOURCE FROM OUTDOORS AND VENT

AND SUPPLY AIR SAFETY CHECK” in these instructions for

additional information and safety check procedure.

1. Two permanent openings, one within 12” (30.5 cm) of the top and

one within 12” (30.5 cm) of bottom of the confined space, Two per-

manent openings, shall communicate directly or by means of ducts

with the outdoors, crawl spaces or attic spaces.

2. One permanent openings, commencing within 12” (30.5 cm) of the

top of the enclosure shall be permitted where the equipment has

clearances of at least 1” (2.54 cm) from the sides and back and 6”

(15.2 cm) from the front of the appliance. The opening shall com-

municate directly with the outdoors and shall have a minimum free

area of:

2. The duct shall be either metal, or a material meeting the class 1

requirements of CAN4-S110 Standard for Air Ducts.

3. The duct shall be least the same cross-sectional area as the free

area of the air supply inlet opening to which it connects.

a. 1 square in. per 3000 Btu per hour (6.45 cm³per 0.879 kW)

of the total input rating of all equipment located in the enclo-

sure.

4. The duct shall terminate within 12” (30.5 cm) above, and within 24”

(61 cm) horizontally from, the burner level of the appliance having

the largest input.

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

space.

5. A square or rectangular shaped duct shall only be used when the

required free area of the supply opening is 9 in²(58.06 cm²) or

larger. When a square or rectangular duct is used, its small dimen-

sion shall not be less than 3” (7.6 cm).

3. The duct shall be least the same cross-sectional area as the free

area of the air supply inlet opening to which it connects.

4. The blocking effects of louvers, grilles and screens must be given

consideration in calculating free area. If the free area of a specific

louver or grille is not known. Refer to Table 12.

6. An air inlet supply from outdoors shall be equipped with a means

to prevent the direct entry of rain and wind. Such means shall not

reduce the required free area of the air supply opening.

7. An air supply inlet opening from the outdoors shall be located not

less than 12” (30.5 cm) above the outside grade level.

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Ventilated Combustion Air

Ventilated Combustion Air Termination

The ventilated attic space or a crawl space from which the combustion

air is taken must comply with the requirements specified in “AIR

SOURCE FROM OUTDOORS” in this instruction or in Section 5.3, Air

for Combustion and Ventilation of the National Fuel Gas Code, ANSI

Z223.1 (latest edition). This type installation requires two properly sized

pipes. One brings combustion air from a properly ventilated attic space

or crawl space and a second pipe that extends from the furnace vent

connection (top right of unit) to the exterior of the building. Refer to

Table 8 for intake pipe sizing, allowable length and elbow usage. Follow

all notes, procedures and required materials in the "COMBUSTION

AIR/VENT PIPE SIZING" section in these instructions when installing

the combustion air pipe from the unit and into a ventilated attic space or

crawl space. DO NOT terminate vent pipe in an Attic or Crawl Space.

Refer to Figures 38 for required attic termination for the combustion air

intake pipe. For attic termination, use two 90° elbows with the open end

in a downward position. Be sure to maintain 12” (30.5 cm) clearance

above any insulation, flooring or other material.

A crawl space combustion air installation consists of a straight pipe from

the PVC coupling on the burner box that extends into the crawl space

and terminates with a 1/4” (6.4 mm) mesh screen and no elbows.

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-

monxide poisoning or death.

The following steps shall be followed for each appliance connected to the venting system being placed into operation, while all other appliances

connected to the venting system are not in operation:

1. Inspect the venting system for proper size and horizontal pitch. Determine that there is no blockage, restriction, leakage, corrosion or other

deficiencies, which could cause an unsafe condition

2. Close all building doors and windows and all doors.

3. Turn on clothes dryers and TURN ON any exhaust fans, such as range hoods and bathroom exhausts, so they shall operate at maximum

speed. Open the fireplace dampers. Do not operate a summer exhaust fan.

4. Follow the lighting instructions. Place the appliance being inspected in operation. Adjust thermostat so the appliance shall operate contin-

uously.

5. Test each appliance (such as a water heater) equipped with a draft hood for spillage (down-draft or no draft) at the draft hood relief opening

after 5 minutes of main burner operation. Appliances that do not have draft hoods need to be checked at the vent pipe as close to the

appliance as possible. Use a combustion analyzer to check the CO₂and CO levels of each appliance. Use a draft gauge to check for a

downdraft or inadequate draft condition.

6. After it has been determined that each appliance properly vents when tested as outlined above, return doors, windows, exhaust fans, fire-

place dampers and any other gas burning appliance to their normal condition.

7. If improper venting is observed during any of the above tests, a problem exists with either the venting system or the appliance does not

have enough combustion air (Supply Air from outside) to complete combustion. This condition must be corrected before the appliance can

function safely.

NOTE: An unsafe condition exists when the CO reading exceeds 40 ppm and the draft reading is not in excess of - 0.1 in. w.c. (-25 kPa) with all

of the appliance(s) operating at the same time.

8. Any corrections to the venting system and / or to the supply (outside) air system must be in accordance with the National Fuel Gas Code

Z223.1 or CAN/CGA B149.1 Natural Gas and Propane Installation Code (latest editions). If the vent system must be resized, follow the

appropriate tables in Appendix G of the above codes or for this appliance.

Specially Engineered Installations

The above requirements shall be permitted to be waived where special

engineering, approved by the authority having jurisdiction, provides an

12” minimum

between bottom

adequate supply of air for combustion and ventilation.

of air intake and

any material below.

12” Min.

Be sure to instruct the owner not to block this intake pipe.

VENT BLOWER ROTATION

For ease of venting, the vent blower may be rotated 90° in either direc-

tion. For upflow installations the vent may exit through the top or either

side of the cabinet. For downflow installations, the vent blower must be

rotated so that the vent exits through either side of the cabinet. See Fig-

ures 24-27 for details.

FIGURE 38: Attic and Crawl Space Combustion Air Termination

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IGNITION SYSTEM SEQUENCE

SECTION VIII: START-UP AND

ADJUSTMENTS

1. Turn the gas supply ON at external valve and main gas valve.

2. Set the thermostat above room temperature to call for heat.

3. System start-up will occur as follows:

The initial start-up of the furnace requires the following additional

procedures:

a. The induced draft blower motor will start and come up to

speed. Shortly after inducer start-up, the hot surface igniter

will glow for about 17 seconds.

All electrical connections made in the field and in the factory should

be checked for proper tightness.

b. After this warm up, the ignition module will energize (open)

the main gas valve.

c. After flame is established, the supply air blower will start in

about 30 seconds.

When the gas supply is initially connected to the furnace, the gas piping

may be full of air. In order to purge this air, it is recommended that the

ground union be loosened until the odor of gas is detected. When gas is

detected, immediately retighten the union and check for leaks. Allow

five minutes for any gas to dissipate before continuing with the start-up

procedure. Be sure proper ventilation is available to dilute and carry

away any vented gas.

CALCULATING THE FURNACE INPUT

(NATURAL GAS)

Burner orifices are sized to provide proper input rate using natural gas

with a heating value of 1030 BTU/cu.ft. (38.4 MJ/m³). If the heating

value of your gas is significantly different, it may be necessary to

replace the orifices.

GAS PIPING LEAK CHECK

NOTE: DO NOT set manifold pressure less than 3.2” w.c. or more than

3.8” w.c. for natural gas at sea level. If manifold pressure is outside this

range, change main burner orifices.

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

redrilled, check orifice hole with a numbered drill bit of correct size.

Never redrill an orifice. A burr-free and squarely aligned orifice hole is

essential for proper flame characteristics.

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.

DO NOT bottom out gas valve regulator adjusting screw. This can

result in unregulated manifold pressure and result in excess over-

fire and heat exchanger failures.

Burner ignition may not be satisfactory on first startup due to resid-

ual air in the gas line or until gas manifold pressure is adjusted. The

ignition control will make three attempts to light before locking out.

Verify natural gas input rate by clocking meter.

1. Turn off all other gas appliances and pilots.

2. Run furnace for a minimum of 3 minutes in heating operation.

With furnace in operation, check all of the pipe joints, gas valve connec-

tions and manual valve connections for leakage using an approved gas

detector, a non-corrosive leak detection fluid or other leak detection

methods. Take appropriate action to stop any leak. If a leak persists,

replace the faulty component.

3. Measure time (in sec) for gas meter to complete 1 revolution and

note reading. The 2 cubic feet dial provides a more accurate mea-

surement of gas flow.

4. Refer to Table 9 for cubic feet of gas per hour.

5. Multiply cubic feet per hour by heating valve (BTU/cu.ft.) to obtain

input.

The furnace and its equipment shutoff valve must be disconnected from

the gas supply during any pressure testing of that system at test pres-

sures in excess of 0.5 psig (3.45 kPa).

If clocked rate does not match the input rate from the unit nameplate.

follow steps in next section to adjust the manifold pressure. Repeat

steps 2 - 5 until correct input is achieved.

The furnace must be isolated from the gas supply piping system by

closing the equipment shutoff valve during any pressure testing of the

gas supply system.

Be sure to relight any gas appliances that were turned off at the

start of this input check.

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Table 15: Gas Rate (CU FT/HR) at Full Input

Size of Test Dial

Seconds For

1 Revolution

Seconds For

1 Revolution

1 Cu Ft

360

327

300

277

257

240

225

212

200

189

180

171

164

157

150

144

138

133

129

124

120

116

113

109

106

103

100

2 Cu Ft

720

655

600

555

514

480

450

424

400

379

360

343

327

313

300

288

277

267

257

248

240

232

225

218

212

206

200

195

189

185

180

176

172

167

164

160

157

153

150

147

144

141

138

136

133

5 Cu Ft

1800

1636

1500

1385

1286

1200

1125

1059

1000

947

900

857

818

783

750

720

692

667

643

621

600

581

563

545

529

514

500

486

474

462

450

439

429

419

409

400

391

383

375

367

360

355

346

340

333

1 Cu Ft

2 Cu Ft

131

129

126

124

122

120

116

112

109

106

103

100

5 Cu Ft

327

321

316

310

305

300

290

281

273

265

257

250

243

237

231

225

220

214

209

205

200

196

192

188

184

180

178

173

170

167

164

161

155

150

145

141

135

130

125

120

115

110

105

100

102

104

106

108

110

112

116

120

124

128

133

138

144

150

157

164

171

180

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This gas valve has separate regulator adjustment screws for high fire

and low fire, as shown in Figure 37. The procedure below is used to

adjust either the high fire manifold pressure or the low fire manifold

pressure.

ADJUSTMENT OF MANIFOLD GAS PRESSURE &

INPUT RATE

Inlet and manifold gas pressure may be measured by connecting the

“U” tube manometer to the gas valve with a piece of tubing. Follow the

appropriate section in the instructions below. Refer to Figures 39 for a

drawing of the locations of the pressure ports on the gas valve.

1. Refer to Figures 39 for location of pressure regulator adjustment

cap and adjustment screws on main gas valve.

2. Turn gas and electrical supplies on and follow the operating

instructions to place the unit back in operation.

Turn gas off at the ball valve or gas cock on gas supply line

before the gas valve. Find the pressure ports on the gas

valve marked Out P and In P.

3. Adjust manifold pressure by adjusting gas valve regulator screw

for the appropriate gas per the following:

1. The manifold pressure must be taken at the port marked OUT P.

2. The gas line pressure must be taken at the port marked IN P.

Table 17: Nominal Manifold Pressure

NOMINAL MANIFOLD PRESSURE

3. Using a 3/32” (2.4 mm) Allen wrench, loosen the set screw by turn-

ing it 1 turn counter clockwise. DO NOT REMOVE THE SET

SCREW FROM THE PRESSURE PORT.

Natural Gas (High Fire)

Natural Gas (Low Fire)

3.5" w.c. (0.87 kPa)

1.6" w.c. (0.40 kPa)

9.8" w.c. (2.488 kPa)

4.0" w.c. (0.99 kPa)

Read the inlet gas pressure

Propane (LP) Gas (High Fire)

Propane (LP) Gas (Low Fire)

Connect the positive side of the manometer to the IN P Tap on the gas

valve. Do not connect any tubing to the negative side of the manometer,

as it will reference atmospheric pressure. Refer to Figures 40 for con-

nection details.

HIGH STAGE REGULATOR

ADJUSTMENT

OUTLET

PRESSURE

PORT

1. Turn gas and electrical supplies on and follow the operating

instructions to place the unit back in operation.

VENT

PORT

Table 16: Inlet Gas Pressure Range

INLET

OUTLET

INLET GAS PRESSURE RANGE

WRENCH

BOSS

Natural Gas

Propane (LP)

INLET

PRESSURE

PORT

Minimum

Maximum

4.5” w.c. (1.12 kPa)

10.5” w.c. (2.61 kPa)

8.0” w.c. (1.99 kPa)

13.0” w.c. (3.24 kPa)

LOW STAGE REGULATOR

ADJUSTMENT

ON OFF

SWITCH

FIGURE 39: Gas Valve

The inlet gas pressure operating range table specifies what the

minimum and maximum gas line pressures must be for the furnace

to operate safely. The gas line pressure MUST BE a minimum of:

If gas valve regulator is turned in (clockwise), manifold pressure is

increased. If screw is turned out (counterclockwise), manifold pres-

sure will decrease.

•

7” w.c. (1.74 kPA) for Natural Gas

11” w.c. (2.74 kPA) for Propane (LP) Gas

in order to obtain the BTU input specified on the rating plate and/or

the nominal manifold pressure specified in these instructions and

on the rating plate.

4. After the manifold pressure has been adjusted, re-calculate the

furnace input to make sure you have not exceeded the specified

input on the rating plate. Refer to “CALCULATING THE FURNACE

INPUT (NATURAL GAS)”.

2. Once the correct gas inlet pressure has been established, see

Table 16, turn the gas valve to OFF and turn the electrical supply

switch to OFF; then remove the flexible tubing from the gas valve

pressure tap and tighten the pressure tap plug using the 3/32” (2.4

mm) Allen wrench.

5. Once the correct BTU (kW) input has been established, turn the

gas valve to OFF and turn the electrical supply switch to OFF; then

remove the flexible tubing from the gas valve pressure tap and

tighten the pressure tap plug using the 3/32” (2.4 mm) Allen

wrench.

3. Turn the electrical and gas supplies back on, and with the burners

in operation, check for gas leakage around the gas valve pressure

port for leakage using an approved non-corrosive gas leak detec-

tion fluid, or other non-flammable leak detection methods.

6. Turn the electrical and gas supplies back on, and with the burners

in operation, check for gas leakage around the gas valve pressure

port for leakage using an approved non-corrosive gas leak detec-

tion fluid, or other non-flammable leak detection methods.

Read the manifold gas pressure

Connect the positive side of the manometer to the adapter previously

installed in the OUT P Tap on the gas valve. Do not connect any tubing

to the negative side of the manometer, as it will reference atmospheric

pressure. Refer to Figures 40 for connection details.

MANIFOLD PRESSURE “U” TUBE CONNECTION

OUTLET

PRESSURE TAP

GAS VALVE

1/4” TUBING

MAINIFOLD

PIPE

FLAME

SENSOR

The cap for the pressure regulator must be removed entirely to gain

access to the adjustment screw. Loosening or tightening the cap

does not adjust the flow of gas.

3.5 IN

WATER

COLUMN

GAS

PRESSURE

SHOWN

NOTE: The regulated outlet pressure has been calibrated at the factory.

Additional pressure adjustment should not be necessary. If adjustment

is necessary, set to the following specifications. After adjustment, check

for gas leakage.

GAS

BURNERS

U-TUBE

MANOMETER

FIGURE 40: Reading Gas Pressure

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ADJUSTMENT OF TEMPERATURE RISE

VARIABLE SPEED MOTORS

The variable speed motor must be configured so the blower will provide

a sufficient airflow so that the furnace operates with in the temperature

rise range on the rating plate and within the application limitations

shown in Table 7 in these Instructions.

The temperature rise, or temperature difference between the return

air and the supply (heated) air from the furnace, must be within the

range shown on the furnace rating plate and within the application

limitations shown in Table 7 “ELECTRICAL AND PERFORMANCE

DATA”.

ADJUSTMENT OF FAN CONTROL SETTINGS

Heating Indoor Fan Off Delay

This furnace is equipped with a time-on/time-off heating fan control. The

fan on delay is fixed at 30 seconds. The fan off delay has 4 settings (60,

90, 120 and 180 seconds). The fan off delay is factory set to 120 sec-

onds. The fan-off setting must be long enough to adequately cool the

furnace, but not so long that cold air is blown into the heated space. The

fan-off timing may be adjusted by positioning the jumper on two of the

four pins as shown in Figure 41.

The supply air temperature cannot exceed the “Maximum Supply

Air Temperature” specified in these instructions and on the fur-

nace rating plate. Under NO circumstances can the furnace be

allowed to operate above the Maximum Supply Air Temperature.

Operating the furnace above the Maximum Supply Air Temperature

will cause premature heat exchanger failure, high levels of Carbon

Monoxide, a fire hazard, personal injury, property damage, and/or

death.

After about 5 minutes of operation, determine the furnace temperature

rise. Take readings of both the return air and the heated air in the ducts,

about six feet (1.83 m) from the furnace where they will not be affected

by radiant heat. Increase the blower speed to decrease the temperature

rise; decrease the blower speed to increase the rise.

BLOWER OFF

DELAY JUMPER

HI HEAT DELAY

JUMPER

CONTINUOUS FAN

SPEED JUMPER

LOW VOLTAGE

TERMINALS

BLOWER SPEED

JUMPERS

HEAT

DELAY

JUMPER

DEHUMIDISTAT JUMPER

COOLING PROFILE JUMPER

FIGURE 41: Furnace Control Board

Electrical supply to this unit is dependent upon the panel that covers the

blower compartment being in place and properly positioned.

SECTION IX: SAFETY CONTROLS

CONTROL CIRCUIT FUSE

A 3-amp fuse is provided on the control circuit board to protect the 24-

volt transformer from overload caused by control circuit wiring errors.

This is an ATO 3, automotive type fuse and is located on the control

board.

ROLLOUT SWITCH CONTROLS

These controls are mounted on the burner assembly. If the temperature

in the area surrounding burner exceeds its set point, the gas valve is

de-energized. The operation of this control indicates a malfunction in

the combustion air blower, heat exchanger or a blocked vent pipe con-

nection. Corrective action is required. These are manual reset controls

that must be reset before operation can continue.

BLOWER DOOR SAFETY SWITCH

PRESSURE SWITCHES

This furnace is supplied with three pressure switches, which monitor the

flow through the combustion air/vent piping and condensate drain sys-

tem. These switches de-energize the gas valve if any of the following

conditions are present. Refer to SECTION VI, "CONDENSATE PIPING

AND FURNACE VENTING CONFIGURATION" for tubing connections.

Main power to the unit must still be interrupted at the main power

disconnect switch before any service or repair work is to be done to

the unit. Do not rely upon the interlock switch as a main power dis-

connect.

Blower and burner must never be operated without the blower

panel in place.

1. Blockage of vent piping or terminal.

2. Failure of combustion air blower motor.

3. Blockage of combustion air piping or terminals.

4. Blockage of condensate drain piping.

This unit is equipped with an electrical interlock switch mounted in the

burner compartment. This switch interrupts all power at the unit when

the panel covering the blower compartment is removed.

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LIMIT CONTROLS

Intermittent Blower Cooling

There is a high temperature limit control located on the furnace vesti-

bule panel near the gas valve. This is an automatic reset control that

provides over temperature protection due to reduced airflow. This may

be caused by:

On cooling/ heating thermostats with a fan switch, when the fan switch

is set in the auto position and the thermostat calls for cooling, a circuit is

completed between the R, Y and G terminals. The motor is energized

through the Y1 cool terminal and runs on the speed selected on the

COOL tap of the control board. The fan off setting is fixed at 60 seconds

for SEER enhancement. The control board can accommodate two-

stage cooling. When a two-stage cool thermostat is connected to the Y1

and Y2 terminals on the board, the blower will operate on LOW COOL

speed when Y1 is energized and on HI COOL speed when Y1 and Y2

are energized.

1. A dirty filter.

2. If the indoor fan motor should fail.

3. Too many supply or return registers closed or blocked off.

The control module will lockout if the limit trips 5 consecutive times.

If this occurs, control will reset & try ignition again after 1 hour.

SEQUENCE OF OPERATION

Intermittent Blower Heating

Heating and Cooling Airflow

On cooling/ heating thermostats with a fan switch, when the fan switch

is set in the auto position and the thermostat calls for heating, a circuit is

completed between the R and W terminals. The indoor fan motor is

energized through the W1 heat terminal and runs on the speed selected

on the HEAT tap of the control board.

The heating and the cooling airflows are preset at the factory. The heat-

ing airflow is set to the maximum CFM. The cooling airflow is set to pro-

vide 90 percent of the maximum CFM. The heating and cooling airflows

must be field adjusted to match the HVAC system at installation. See

Table 17 for the HEAT, COOL and ADJ jumper settings to use for spe-

cific airflows.

Humidistat

When a humidistat is installed in the system, the “Humidistat Installed?”

jumper on the control board should be moved to the YES position.

The cooling CFM will then be reduced by 15% whenever the humidistat

indicates high humidity.

CFM Board - Delay Taps Selection

The set of jumper pins on the control board labeled DELAY are used to

set the delay profiles for the furnace. These can be chosen so as to

maximize the comfort and sound levels for various regions of the coun-

try.

Heating Cycle

When the thermostat switch is set on HEAT and the fan is set on AUTO,

and there is a call for heat, a circuit is completed between terminals R

and W of the thermostat. When the proper amount of combustion air is

being provided, the pressure switch will close, the ignition control pro-

vides a 17-second ignitor warm-up period, the gas valve then opens,

the gas starts to flow, ignition occurs and the flame sensor begins its

sensing function. The blower motor will energize 30 seconds after the

gas valve opens, if a flame is detected. Normal furnace operation will

continue until the thermostat circuit between R and W is opened, which

causes the ignition system and gas valve to de-energize and the burner

flames to be extinguished. The vent motor will operate for 15 seconds

and the blower motor will operate for the amount of time set by the fan-

off delay jumper located on the control board. See Figure 36. The heat-

ing cycle is now complete, and ready for the start of the next heating

cycle.

Tap A is the default profile. It provides a 30-second ramp-up from zero

airflow to full capacity and a 30-second ramp-down from full capacity

back to zero airflow. Whenever there is a change in airflow mode, such

as from low heat to high heat, the motor will take 30 seconds to ramp

from one speed to the other.

Tap B is the humid profile. This profile is best-suited for installations

where the humidity is frequently very high during cooling season, such

as in the southern part of the country. On a call for cooling, the blower

will ramp up to 50% of full capacity and will stay there for two minutes,

then will ramp up to 82% of full capacity and will stay there for five min-

utes, and then will ramp up to full capacity, where it will stay until the

wall thermostat is satisfied. In every case, it will take the motor 30 sec-

onds to ramp from one speed to another.

Tap C is the dry profile. This profile is best suited to parts of the country

where excessive humidity is not generally a problem, where the sum-

mer months are usually dry. On a call for cooling the motor will ramp up

to full capacity and will stay there until the thermostat is satisfied. At the

end of the cooling cycle, the blower will ramp down to 50% of full capac-

ity where it will stay for 60 seconds. Then it will ramp down to zero. In

every case, it will take the motor 30 seconds to ramp from one speed to

another.

If the flame is not detected within 7 seconds of the gas valve opening,

the gas valve is shut off and a retry operation begins. Also, if the flame

is lost for 2 seconds during the 10-second stabilization period, the gas

valve is shut off and a retry operation begins. During a retry operation,

the vent motor starts a 15 second inter-purge and the ignitor warm-up

time is extended to 27 seconds. If the flame is established for more than

10 seconds after ignition during a retry, the control will clear the ignition

attempt (retry) counter. If three retries occur during a call for heat, the

furnace will shut down for one hour. If at the end of the one hour shut

down there is a call for heat, the furnace will initiate a normal start cycle.

If the problem has not been corrected the furnace will again lockout

after three retries.

Tap D is the normal profile, best suited for most of the country, where

neither excessive humidity nor extremely dry conditions are the norm.

On a call for cooling, the motor will ramp up to 63% of full capacity and

will stay there for 90 seconds, then will ramp up to full capacity. At the

end of the cooling cycle, the motor will ramp down to 63% of full capac-

ity and will stay there for 30 seconds, then will ramp down to zero. In

every case, it will take the motor 30 seconds to ramp from one speed to

another.

A momentary loss of gas supply, flame blowout, or a faulty flame probe

circuit will result in a disruption in the flame and be sensed within 1.0

seconds. The gas valve will de-energize and the control will begin a

recycle operation. A normal ignition sequence will begin after a 15 sec-

ond inter-purge. If during the five recycles the gas supply does not

return, or the fault condition is not corrected the ignition control will lock-

out for 60 minutes.

Continuous Blower Operation

The blower will run continuously whenever the wall thermostat fan

switch is in the ON position. The furnace blower will run at the speed

selected on the FAN SPEED jumpers on the main control board

(HI COOL, LO COOL, HI HEAT or LO HEAT). When the jumper is in the

VS G position, the blower will run at 50% of the high cool speed.

During burner operation, a momentary loss of power for 50 milliseconds

or longer will de-energize the gas valve. When the power is restored,

the gas valve will remain de-energized and the ignition sequence will

immediately restart.

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3 RED FLASHES: This indicates the normally open pressure switch

contact did not close after the inducer was energized. This could be

caused by a number of problems: faulty inducer, blocked vent pipe, bro-

ken pressure switch hose or faulty pressure switch.

Hot Surface Ignition System

4 RED FLASHES: This indicates that the main limit switch has opened

its normally closed contacts. The control will operate the supply air

blower and inducer. This condition may be caused by: dirty filter,

improperly sized duct system, incorrect blower speed setting, incorrect

firing rate or faulty blower motor. Also, this fault code could be caused

by a blown fuse located on the control board.

HOT SURFACE IGNITION SYSTEM

Do not attempt to light this furnace by hand (with a

match or any other means). There may be a potential

shock hazard from the components of the hot surface

ignition system. The furnace can only be lit automatically

by its hot surface ignition system.

5 RED FLASHES: This fault is indicated if the normally closed contacts

in the rollout switch opens. The rollout control is manually reset. If it has

opened, check for proper combustion air, proper inducer operation, and

primary heat exchanger failure or burner problem. Be sure to reset the

switch and cycle power (24 VAC) to the control after correcting the fail-

ure condition. Also, this fault code could be caused by a blown fuse

located on the control board.

TROUBLESHOOTING

The following visual checks should be made before troubleshooting:

1. Check to see that the power to the furnace and the ignition control

module is ON.

2. The manual shut-off valves in the gas line to the furnace must be

open.

6 RED FLASHES: This indicates that after the unit was operating, the

pressure switch opened 4 times during the call for heat. If the main

blower is in a “Delay on” mode, it will complete it, and any subsequent

delay off period. The furnace will lock out for one hour and then restart.

3. Make sure all wiring connections are secure.

4. Review the sequence of operation. Start the system by setting the

thermostat above the room temperature. Observe the system’s

response. Then use the troubleshooting section in this manual to

check the system’s operation.

7 RED FLASHES: This fault code indicates that the flame could not be

established. This no-light condition occurred 3 times (2 retries) during

the call for heat before locking out. Low gas pressure, faulty gas valve,

dirty or faulty flame sensor, faulty hot surface ignitor or burner problem

may cause this. The furnace will lock out for one hour and then restart.

Never bypass any safety control to allow furnace opera-

tion. To do so will allow furnace to operate under poten-

tially hazardous conditions.

Do not try to repair controls. Replace defective controls

with UPG Source 1 Parts.

8 RED FLASHES: This fault is indicated if the flame is lost 5 times (4

recycles) during the heating cycle. This could be caused by low gas

pressure, dirty or faulty flame sensor or faulty gas valve. The furnace

will lock out for one hour and then restart.

Never adjust pressure switch to allow furnace operation.

9 RED FLASHES: Indicates reversed line voltage polarity or grounding

problem. Both heating and cooling operations will be affected. Check

polarity at furnace and branch. Check furnace grounding. Check that

flame probe is not shorted to chassis.

FURNACE CONTROL DIAGNOSTICS

The furnace has built-in, self-diagnostic capability. If a system problem

occurs, a blinking LED can flash red, green or amber to indicate various

conditions.

10 RED FLASHES: Flame sensed with no call for heat. Check gas

valve and gas valve wiring.

The control continuously monitors its own operation and the operation

of the system. If a failure occurs, the LED will indicate the failure code. If

the failure is internal to the control, the light will stay on continuously. In

this case, the entire control should be replaced, as the control is not

field repairable.

11 RED FLASHES: This indicates that a primary or auxiliary limit switch

has opened its normally-closed contacts and has remained open for

more than five minutes. This condition is usually caused by a failed

blower motor or blower wheel. Cycle power (24 VAC) to the control to

reset the hard lockout condition after correcting the failure condition.

Flash sequence codes 1 through 11 are as follows: LED will turn ON for

1/4 second and OFF for 1/4 second. This pattern will be repeated the

number of times equal to the code. For example, six ON flashes equals

a number 6 fault code. All flash code sequences are broken by a 2 sec-

ond OFF period.

12 RED FLASHES: This code indicates an open igniter circuit, which

could be a disconnected or loose wire or a cracked or broken igniter.

STEADY ON RED: Control failure. Replace control board.

60-MINUTE AUTOMATIC RESET FROM LOCKOUT: This control

includes a “watchdog” type circuit that will reset from a lockout condition

after 60 minutes. Operational faults 6, 7, 8 will be reset. This provides

protection to an unoccupied structure if a temporary condition exists

causing a furnace malfunction. An example would be a low incoming

gas supply pressure preventing unit operation. When the gas pressure

is restored, at some point the “watchdog” would restart the unit and pro-

vide heat for the house.

SLOW GREEN FLASH: Normal operation.

SLOW AMBER FLASH: Normal operation with call for heat.

RAPID RED FLASH: Twinning error, incorrect 24V phasing. Check

twinning wiring.

RAPID AMBER FLASH: Flame sense current is below 1.5 microamps.

Check and clean flame sensor. Check for proper gas flow. Verify that

current is greater than 1.5 microamps at flame current test pad.

NOTE: If a flame is detected the control flashes the LED for 1/8 of a

second and then enters a flame stabilization period.

4 AMBER FLASHES: The control is receiving a “Y” signal from the

thermostat without a “G” signal, indicating improper thermostat wiring.

IGNITION CONTROL FLAME SENSE LEVELS

Normal flame sense current is approximately

3.7 microamps DC (µa)

Low flame signal warning starts at 1.5 microamps.

Low flame signal control lockout point is

0.1 microamps DC (µa)

1 RED FLASH: This indicates that flame was sensed when there was

not a call for heat. The control will turn on both the inducer motor and

supply air blower. A gas valve that leaks or is slow closing would typi-

cally cause this fault.

2 RED FLASHES: This indicates that the normally open pressure

switch contacts are stuck in the closed position. The control confirms

these contacts are open at the beginning of each heat cycle. This would

indicate a faulty pressure switch or miswiring.

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To retrieve the error codes, push the LAST ERROR button. The LED on

the control will then flash the error codes that are in memory, starting

with the most recent. There will be a two-second pause between each

flash code. After the error codes have all been displayed, the LED will

resume the normal slow green flash after a five second pause. To

repeat the series of error codes, push the button again.

DIAGNOSTIC FAULT CODE STORAGE AND

RETRIEVAL

The control in this furnace is equipped with memory that will store up to

five error codes to allow a service technician to diagnose problems

more easily. This memory will be retained even if power to the furnace

is lost. This feature should only be used by a qualified service tech-

nician.

If there are no error codes in memory, the LED will flash two green

flashes. To clear the memory, push the LAST ERROR button and hold it

for more than five seconds. The LED will flash three green flashes when

the memory has been cleared, then will resume the normal slow green

flash after a five-second pause.

If more than five error codes have occurred since the last reset, only the

five most recent will be retained. The furnace control board has a but-

ton, labeled LAST ERROR that is used to retrieve error codes. This

function will only work if there are no active thermostat signals. So any

call for heating, cooling or continuous fan must be terminated before

attempting to retrieve error codes.

Thermostat Calling for Heat

Thermostat Satisfied

(Seconds)

0 2

Fan on Delay

30 Seconds

THERMOSTAT

INDUCER

OFF

Sec.

Post

Purge

IGNITOR

OFF

MAIN VALVE

OFF

HUMIDIFIER

OFF

ELECTRONIC

AIR CLEANER

OFF

CIRCULATING

BLOWER

60, 90, 120, 180 SEC.

Selectable Fan Off Delay

FIGURE 42: Furnace Control Event Schedule

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SECTION X: REPLACEMENT PARTS LIST

DESCRIPTION

FABRICATED PARTS Continued

MANIFOLD, GAS

DESCRIPTION

MOTOR

MOTOR, DIRECT DRIVE BLOWER

BLOWER, COMBUSTION 2-STAGE

ELECTRICAL

PAN, BOTTOM

PANEL, TOP

PANEL, DOOR (2 Req’d)

PANEL, BLOCKOFF

CAPACITOR, RUN

SWITCH, LIMIT

MISCELLANEOUS

CONTROL, FURNACE 2-STAGE VS

IGNITER

ORIFICE, BURNER (Natural #45)

SIGHT GLASS, OVAL (2 Req’d)

GASKET, FOAM (Door) (1.5 ft req’d)

PAN, CONDENSATE

BRACKET, DOOR

SENSOR, FLAME

SWITCHES, PRESSURE

SWITCH, DOOR

TRANSFORMER

HARNESS, WIRING

VALVE, GAS 2-STAGE

CONTROL, TEMPERATURE

AIR MOVING

FERRULE (3 Req’d)

GROMMET (3 Req’d)

MOTOR MOUNT

HOUSING, BLOWER

TUBING, SILICON

WHEEL, BLOWER

HOSE, RAIN GUTTER

HOSE, CONDENSATE

PLUG, SEAL, 7/8”

FABRICATED PARTS

RESTRICTOR, COMBUSTION BLOWER

BURNER, MAIN GAS

BRACKET, IGNITER

PLUG, SEAL, 2-3/8”

PLUG, VENT PIPE

SHELF, BLOWER

BAG, PARTS

RAIL, BLOWER (2 Req’d)

BRACKET, BLOWER TRACK (2 Req’d)

HEAT EXCHANGER ASS’Y

KNOB, QUARTER TURN (4 Req’d)

DIAGRAM, WIRING 2-STAGE VS

REPLACEMENT PART CONTACT INFORMATION

This is a generic parts list. To request a complete parts list, refer to the contact information below:

•

Visit our website at www.source1parts.com for the following information:

1. Search for a part or browse the catalog.

2. Find a dealer or distributor.

3. Customer Service contact information.

a. Click on the “Brand Links” button

b. Click on the “Customer Service” button

•

You can contact us by mail. Just send a written request to:

Johnson Controls Unitary Products

Consumer Relations

5005 York Drive

Norman, OK 73069

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SECTION XI: WIRING DIAGRAM

FIGURE 43: Wiring Diagram

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NOTES

Subject to change without notice. Published in U.S.A

438335-UIM-B-0509

Supersedes: 438335-UIM-A-0209

Johnson Controls Unitary Products

5005 York Drive

Norman, OK 73069

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