RESIDENTIAL GAS FURNACE
MODELS: TM9V*MP
(96% AFUE Two Stage
Variable Speed ECM Multi-position)
LIST OF SECTIONS
SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
DUCTWORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
FILTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
GAS PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
ELECTRICAL POWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
CONDENSATE PIPING AND FURNACE
COMBUSTION AIR and VENT SYSTEM . . . . . . . . . . . . . . . . . 23
START-UP AND ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . 30
SAFETY CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
NORMAL OPERATION AND DIAGNOSTICS . . . . . . . . . . . . . 35
REPLACEMENT PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . 38
REPLACEMENT PART CONTACT INFORMATION . . . . . . . . 38
WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
VENTING CONFIGURATION . . . . . . . . . . . . . . . . . . . . . . . . . . 17
LIST OF FIGURES
Duct Attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Vertical Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Coil Flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Horizontal Right Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Horizontal Left Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
PC Series Upflow Coil Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Horizontal Left or Right application (Right Shown) . . . . . . . . . . . . . . 7
Combustible Floor Base Accessory . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Horizontal Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Typical Attic Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Typical Suspended Furnace / Crawl Space Installation . . . . . . . . . . . 8
Downflow Venting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Side Return Cutout Markings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Gas Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Gas Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Electrical Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Thermostat Chart - Single Stage Air Conditioners
Thermostat Chart - Two Stage HP with Two Stage
Variable Speed Furnace (Hot Heat Pump or Conventional) . . . . . . .16
Typical. Condensate drain, vertical installation . . . . . . . . . . . . . . . . .17
Typical. Combustion Pipe Drain Tee . . . . . . . . . . . . . . . . . . . . . . . .18
Upflow Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
Downflow Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
Horizontal Left Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
Horizontal Right Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
Home Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
Termination Configuration - 1 Pipe . . . . . . . . . . . . . . . . . . . . . . . . . .26
Termination Configuration - 2 Pipe . . . . . . . . . . . . . . . . . . . . . . . . . .26
Termination Configuration - 2 Pipe Basement . . . . . . . . . . . . . . . . .26
Double Horizontal Combustion Air Intake and Vent Termination . . .26
Double Vertical Combustion Air Intake and Vent Termination . . . . .26
Downward Venting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
Direct Vent Air Intake Connection and Vent Connection . . . . . . . . .27
Combustion Airflow Path Through The Furnace Casing . . . . . . . . .27
Outside and Ambient Combustion Air . . . . . . . . . . . . . . . . . . . . . . . .28
Attic and Crawl Space Combustion Air Termination . . . . . . . . . . . . .30
Gas Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
Reading Gas Pressure 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Furnace Control Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
with Two Stage Variable Speed Furnaces . . . . . . . . . . . . . . . . . . . . 13
Thermostat Chart - Single Stage Heat Pump with Two Stage
Variable Speed Furnace (Hot Heat Pump or Conventional) . . . . . . 14
Thermostat Chart - Two Stage AC with
Two Stage Variable Speed Furnace . . . . . . . . . . . . . . . . . . . . . . . . 15
LIST OF TABLES
Unit Clearances to Combustibles . . . . . . . . . . . . . . . . . . . . . . . . 4
Coil Projection Dimensions - PC Series Coils . . . . . . . . . . . . . . . 7
Cabinet and Duct Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Recommended Filter Sizes (High Velocity 600 FPM) . . . . . . . . . 9
Nominal Manifold Pressure - High Fire . . . . . . . . . . . . . . . . . . . 11
Nominal Manifold Pressure - Low Fire . . . . . . . . . . . . . . . . . . . 11
Ratings & Physical / Electrical Data . . . . . . . . . . . . . . . . . . . . . 12
Maximum Equivalent Pipe Length . . . . . . . . . . . . . . . . . . . . . . . 23
Elbow Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Equivalent Length of Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Combustion Air Intake and Vent Connection
Size at Furnace (All Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Estimated Free Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Unconfined Space Minimum Area . . . . . . . . . . . . . . . . . . . . . . . 28
Free Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Gas Rate (CU FT/HR) at Full Input . . . . . . . . . . . . . . . . . . . . . . 31
Inlet Gas Pressure Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Nominal Manifold Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Air Flow Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
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.
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.
These units are Category IV listed and may not be common vented with
another gas appliance as allowed by the National Fuel Gas Code.
701379-UIM-C-0712
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Furnaces for installation on combustible flooring shall not be
installed directly on carpeting, tile or other combustible material
other than wood flooring.
Check the rating plate and power supply to be sure that the elec-
trical characteristics match. All models use nominal 115 VAC, 1
Phase, 60-Hz power supply. DO NOT CONNECT THIS APPLI-
ANCE TO A 50-Hz POWER SUPPLY OR A VOLTAGE ABOVE
130 VOLTS.
When outdoor air is used for combustion, the combustion air intake duct
system termination must be located external to the building and in an
area where there will be no exposure to the substances listed above.
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.
•
•
Furnace shall be installed so the electrical components are pro-
tected from water.
Installing and servicing heating equipment can be hazardous due
to the electrical components and the gas fired components. Only
trained and qualified personnel should install, repair, or service
gas heating equipment. Untrained service personnel can perform
basic maintenance functions such as cleaning and replacing the
air filters. When working on heating equipment, observe precau-
tions in the manuals and on the labels attached to the unit and
other safety precautions that may apply.
In the United States and Canada, follow all codes and standards for the
following, using the latest edition available:
STEP 1 - Safety
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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
•
CANADA: CAN/CGA-B149.1 National Standard of Canada. Natu-
ral Gas and Propane Installation Codes (NSCNGPIC)
COMBUSTION AIR QUALITY
(LIST OF CONTAMINANTS)
STEP 2 - General Installation
•
US: Current edition of the NFGC and NFPA 90B. For copies, con-
tact the
National Fire Protection Association Inc.
Batterymarch Park
Quincy, MA 02269
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 furnace.
1. Spray or aerosol cans, rags, brooms, dust mops, vacuum clean-
ers or other cleaning tools.
or for only the NFGC, contact the
American Gas Association,
400 N. Capital, N.W.
2. Soap powders, bleaches, waxes or other cleaning compounds;
plastic items or containers; gasoline, kerosene, cigarette lighter
fluid, dry cleaning fluids or other volatile fluid.
3. Paint thinners and other painting compounds.
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.
Washington DC 20001
•
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
The furnace requires OUTDOOR AIR for combustion when the furnace
is located in any of the following environments.
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Buildings with indoor pools
Chemical exposure
Commercial buildings
Furnaces installed in hobby or craft rooms
Furnaces installed in laundry rooms
Furnaces installed near chemical storage areas
Restricted Environments
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.
STEP 5 - Acoustical Lining and Fibrous Glass Duct
The furnace requires OUTDOOR AIR for combustion when the furnace
is located in an area where the furnace is being exposed to the follow-
ing substances and / or chemicals.
•
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
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Antistatic fabric softeners for clothes dryers
Carbon tetrachloride
Cements and glues
Chlorine based swimming pool chemicals
Chlorinated waxes and cleaners
Cleaning solvents (such as perchloroethylene)
De-icing salts or chemicals
Halogen type refrigerants
Hydrochloric acid
Masonry acid washing materials
Permanent wave solutions
Printing inks, paint removers, varnishes, etc.
Water softening chemicals
•
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US: NFGC; chapters 2, 3, 4, & 9 and National Plumbing Codes
CANADA: NSCNGPIC Part 5
STEP 7 - Electrical Connections
•
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US: National Electrical Code (NEC) ANSI/NFPA 70
CANADA: Canadian Electrical Code CSA C22.1
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.
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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.
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.
FOR FURNACES INSTALLED IN THE COMMON-
WEALTH OF MASSACHUSETTS ONLY
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:
Installation in freezing temperatures:
1. Furnace shall be installed in an area where ventilation facilities pro-
vide for safe limits of ambient temperature under normal operating
conditions. Ambient temperatures must not fall below 32°F (0°C)
unless the condensate system is protected from freezing.
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
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.
a. In the event that the side wall horizontally vented gas fueled
equipment is installed in a crawl space or an attic, the hard
wired carbon monoxide detector with alarm and battery back-
up may be installed on the next adjacent floor level.
b. In the event that the requirements of this subdivision can not
be met at the time of completion of installation, the owner shall
have a period of thirty (30) days to comply with the above
requirements; provided, however, that during said thirty (30)
day period, a battery operated carbon monoxide detector with
an alarm shall be installed.
Liquid anti-freeze will cause damage to internal plastic parts of this
furnace. DO NOT attempt to winterize the furnace using liquid
anti-freeze.
Clearances for access/service:
2. APPROVED CARBON MONOXIDE DETECTORS. Each carbon
monoxide detector as required in accordance with the above pro-
visions shall comply with NFPA 720 and be ANSI/UL 2034 listed
and IAS certified.
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.
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 heat-
ing appliance or equipment. The sign shall read, in print size no
less than one-half (1/2) inch in size, "GAS VENT DIRECTLY
BELOW. KEEP CLEAR OF ALL OBSTRUCTIONS".
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.
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.
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.
INSPECTION
Table 1: Unit Clearances to Combustibles
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.
Application
Top
Upflow
Downflow
Horizontal
1"
0"
0"
0"
0"
0"
0"
Vent
0"
0"
Rear
0"
0"
Side
0"
1"
0"
Front*
Floor
0"
Combustible
Yes
Combustible1
FURNACE LOCATION AND CLEARANCES
The furnace shall be located using the following guidelines:
Combustible
Yes
Closet
Line Contact
Yes
No
1. Where a minimum amount of air intake/vent piping and elbows will
be required.
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).
No
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.
*
4
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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.
SECTION II: DUCTWORK
DUCTWORK GENERAL INFORMATION
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.
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.
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 Modular
Home installations, when a furnace is installed so that the supply
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.
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.
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.
If the flanges are not used, they must remain in the rotated down posi-
tion as shipped.
Factory
installed
For duct attachment,
if needed.
The cooling coil must be installed in the supply air duct, downstream
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.
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.
FIGURE 1: Duct Attachment
DUCTWORK INSTALLATION AND SUPPLY PLENUM
CONNECTION - UPFLOW/HORIZONTAL
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 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.
FLOOR BASE AND DUCTWORK INSTALLATION -
DOWNFLOW
The minimum plenum height is 12” (30.5 cm). The furnace will not
operate properly on a shorter plenum height. The minimum recom-
mended rectangular duct height is 4” (10.2 cm) attached to the ple-
num.
Installations on combustible material or directly on any
floors must use a combustible floor base shown in Figure 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.
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.
Downflow Air Conditioning Coil Cabinet
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.
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.
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.
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COIL INSTALLATION
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.
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 man-
ner as to prevent leaks.
Mounting Plate
COIL/FURNACE ASSEMBLY - MC/FC/PC SERIES
COILS
Furnace
FIGURE 4: Horizontal Right Application
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.
Mounting Plate
Furnace
UPFLOW
DOWNFLOW
FIGURE 2: Vertical Applications
FURNACE ASSEMBLY - MC & FC SERIES COILS
These coils are factory shipped for installation in either upflow or down-
FIGURE 5: Horizontal Left Application
FURNACE ASSEMBLY - PC SERIES COILS
flow applications with no conversion.
These upflow coils are designed for installation on top of upflow fur-
naces only.
Position the coil casing over or under the furnace opening as shown in
Figure 2 after configuring coil flanges as required see “Coil Flange” sec-
tion below.
If the coil is used with a furnace of a different size, use a 45° transition
to allow proper air distribution through the coil.
COIL FLANGE INSTALLATION
1. Position the coil casing over the furnace opening as shown in
Figure 6.
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 Figure 3.
2. Place the ductwork over the coil casing flange and secure.
3. Check for air leakage between the furnace and coil casing and seal
appropriately.
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 Figure 6
FACTORY
FLANGE
LOCATION
(Used for upflow
or horizontal
right installations)
ALTERNATE
FLANGE LOCATION
(Used for downflow or
horizontal left installations)
FIGURE 3: Coil Flange
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DOWNFLOW DUCT CONNECTORS
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.
C
(Min)
D
Flexible
Duct Collar
Field
Fabricated
Ductwork
Do not drill
or Screw
this flange
FURNACE
Upflow
Coil
WARM AIR PLENUM
WITH 1” FLANGES
Upflow
Furnace
FIBERGLASS
INSULATION
Alternate
Drain Location
Primary
Drain
Secondary
Drain
FIBERGLASS TAPE
UNDER FLANGE
FIGURE 6: PC Series Upflow Coil Installation
Table 2: Coil Projection Dimensions - PC Series Coils
COIL SIZE
DIMENSION “C” INCH
PC18
PC24
3-1/2
4-1/2
4-1/2
5-1/2
6-1/2
9
COMBUSTIBLE FLOOR
BASE ACCESSORY
PC30, PC32, PC35
PC42, PC43, PC36, PC37
PC48
FIGURE 8: Combustible Floor Base Accessory
PC60
RESIDENTIAL AND MODULAR HOME UPFLOW
RETURN PLENUM CONNECTION
Dimension “C” should be at least 2/3 of dimension “D”. See Figure 6.
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.
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 2.
SIDE RETURN APPLICATION
Side return applications pull return air through an opening cut in the
side of the furnace casing. This furnace is supplied with a bottom block-
off panel that should be left in place if a side return is to be used. If the
furnace is to be installed on a flat, solid surface, this bottom panel will
provide an adequate seal to prevent air leakage through the unused
bottom opening. However, if the furnace is to be installed on a surface
that is uneven, or if it is to be installed on blocks or otherwise raised off
the floor, it will be necessary to seal the edges of the bottom panel
to the casing using tape or other appropriate gasket material to
prevent air leakage.
COIL / FURNACE ASSEMBLY - HC SERIES COILS
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 7.
NOTICE
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 7.
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.
Use tie plate
supplied with coil
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.
Gas Furnace
FIGURE 7: Horizontal Left or Right application (Right Shown)
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HORIZONTAL APPLICATION
SUSPENDED FURNACE / CRAWL SPACE
INSTALLATION
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 Figure 11
for typical crawl space installation.
FIGURE 9: Horizontal Application
This furnace may be installed in a horizontal position on either side as
shown above. It must not be installed on its back.
ATTIC INSTALLATION
Support
Rod
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)
Support
Angle (x3)
Filter rack
must be a minimum
distance
Sheet metal in
front of furnace
combustion air
Openings is
Maintain 6” minimum
clearance between support
rods and front of furnace
Gas Piping
of 18” (45.7 cm)
from the
furnace
12”
Recommended
FIGURE 11: Typical Suspended Furnace / Crawl Space Installation
12”
DOWNFLOW APPLICATION
30” MIN.
Work Area
To apply the furnace in a downflow position, it will be necessary to
rotate the vent blower 90° left or right so that the vent pipe passes
through the side of the furnace casing. See Figure 12.
Return
Air
Sediment
Trap
FIGURE 10: Typical Attic Installation
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 Figure 10.
Rotate vent
blower 90°
either way
When a furnace is installed in an attic or other insulated space, keep
all insulating materials at least 12” (30.5 cm) away from furnace and
burner combustion air openings.
LEFT SIDE VENT
RIGHT SIDE VENT
During installation, doors should remain on the furnace when
moving or lifting.
FIGURE 12: Downflow Venting
When moving or handling this furnace prior to installation, always leave
the doors on the furnace to provide support and to prevent damage or
warping of the cabinet. When lifting the furnace, support the ends of the
furnace rather than lifting by the cabinet flanges at the return air open-
ings (bottom or sides) or supply air opening.
It is acceptable to use the primary heat exchanger tubes as a lifting
point provided that the tubes are lifted at the front of the heat exchang-
ers where attached to the vestibule panel. Do not use the top return
bend of the heat exchangers as lifting points as the tubes may shift out
of position or their location brackets/baffles.
8
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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
33
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”)
A
1.5”
.56”
23.8”
3”
Vent
Outlet
Combustion
Air Inlet
B
B
C
.56”
24.25”
.56”
20”
SUPPLY END
FIGURE 13: Dimensions
RETURN END
Table 3: Cabinet and Duct Dimensions
Approximate
Operating Weights
Cabinet Dimensions (Inches)
Nominal
CFM (m3/min)
BTUH (kW)
Input
Cabinet
Size
A (in)
14 1/2
17 1/2
17 1/2
21
A (cm)
36.8
44.4
44.4
53.3
53.3
53.3
62.2
B (in)
13 3/8
16 3/8
16 3/8
19 7/8
19 7/8
19 7/8
23 3/8
B (cm)
34.0
41.6
41.6
50.5
50.5
50.5
59.4
C (in)
11 3/4
13 1/4
14 3/4
16 1/2
18 1/4
18 1/4
21 3/4
C (cm)
29.8
33.7
37.5
41.9
46.4
46.4
55.2
Lbs (kg)
113 (51.2)
122 (55.3)
126 (57.1)
136 (61.7)
142 (64.4)
145 (65.8)
156 (70.7)
40 (11.7)
60 (17.6)
80 (23.4)
80 (23.4)
100 (29.3)
100 (29.3)
120 (35.1)
1000 (28.3)
1200 (34.0)
1200 (34.0)
1600 (45.3)
1600 (45.3)
2000 (56.6)
2000 (56.6)
A
B
B
C
C
C
D
21
21
24 1/2
Table 4: Recommended Filter Sizes (High Velocity 600 FPM)
SECTION III: FILTERS
CFM
(m³/min)
Cabinet
Size
Side
(in)
Bottom
(in)
FILTER INSTALLATION
All applications require the use of a field installed filter. All filters and
mounting provision must be field supplied.
1000 (28.3)
1200 (34.0)
1600 (45.3)
2000 (56.6)
2000 (56.6)
A
B
C
C
D
16 x 25
16 x 25
14 x 25
16 x 25
20 x 25
20 x 25
22 x 25
Filters must be installed external to the furnace cabinet. DO NOT
attempt to install filters inside the furnace.
16 x 25
(2) 16 x 25
(2) 16 x 25
NOTICE
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.
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.
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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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 Figure 14.
SECTION IV: GAS PIPING
GAS SAFETY
DANGER
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 exceeding
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.
Front of
Furnace
Side of
Furnace
Corner
Markings
FIGURE 14: Side Return Cutout Markings
HIGH STAGE REGULATOR
ADJUSTMENT
OUTLET
PRESSURE
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.
PORT
VENT
PORT
INLET
OUTLET
WRENCH
BOSS
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 Figure 13.
INLET
PRESSURE
PORT
LOW STAGE REGULATOR
ADJUSTMENT
ON OFF
SWITCH
HORIZONTAL APPLICATION
FIGURE 15: Gas Valve
Horizontal Filters
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.
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.
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.
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.
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 Figure 16.
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.
To Gas
Supply
NOTE: Ground Union maybe installed inside or outside unit.
To Gas
Supply
External
Manual
Shut-off
Valve
Ground
Union
To Gas
Supply
External
Manual
Shut-off
Valve
Ground
Union
To Gas
Supply
To Gas
Supply
Ground
Union
Drip Leg
Gas
Valve
External Manual
Shut-off Valve
Gas
Pipe
Ground
Union
Drip
Leg
Gas
Valve
Drip
Leg
Ground
Union
Gas
Valve
To Gas
Supply
Gas
Pipe
Drip
Leg
Gas
Pipe
Ground
Union
Drip
Leg
Downflow
Upflow
Horizontal
Drip
FIGURE 16: Gas Piping
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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.
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 ALTITUDE GAS ORIFICE CONVERSION
This furnace is constructed at the factory for natural gas-fired operation
at 0 –7,999 feet (0 – 2,438 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 7,999 feet (2,438 m) above sea level. Refer to
Table 5 for proper manifold pressure settings.
The gas valve body is a very thin casting that cannot take any exter-
nal pressure. Never apply a pipe wrench to the body of the gas valve
when installing piping. A wrench must be placed on the octagon 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 opera-
tion and/or the valve to leak.
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.
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
Figure 13.
Table 5: Nominal Manifold Pressure - High Fire
Manifold Pressures (in. w.c.)
Manifold Pressures (kPa)
Altitude (feet)
Altitude (m)
0-7999
3.5
8000-8999
3.5
9000-9999
3.5
0-2437
0.87
0.87
0.87
0.87
0.87
0.87
0.80
2.44
2438-2742
0.87
2743-3048
0.87
800
850
29.8
31.7
3.5
3.5
3.5
0.87
0.87
900
3.5
3.5
3.5
33.5
0.87
0.87
950
3.5
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
0.42
0.42
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
1.7
1.7
0.42
0.42
900
1.7
1.7
1.7
33.5
0.42
0.42
950
1.7
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
DANGER
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, caus-
ing premature heat exchanger burnout, high levels of carbon monoxide, excessive sooting, a fire hazard, personal injury, property damage and/or
death.
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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
these instructions for specific furnace electrical data.
SECTION V: ELECTRICAL POWER
ELECTRICAL POWER CONNECTIONS
Use copper conductors only.
Table 7: Ratings & Physical / Electrical Data
Input
High/Low
Output
High/Low
Nominal
Airflow
High Fire
Air Temp. Rise Air Temp. Rise
Low Fire
Cabinet Width
AFUE
Total Unit
Amps
m3/min
28.3
34
MBH
40/26
kW
MBH
38/25
kW
CFM
1000
in.
14-1/2
17-1/2
17-1/2
21
21
21
24-1/2
cm
%
°F
°C
°F
°C
12/8
11/7
36.8
44.4
44.4
53.3
53.3
53.3
62.2
9
9
9
96
96
96
96
96
96
96
30 - 60 17-33 20-50
11-28
60/39 18/11 58/37 17/11 1200
80/52 23/15 77/50 22/14 1200
80/52 23/15 77/50 22/14 1600
100/65 29/19 96/62 28/18 1600
100/65 29/19 96/62 28/18 2000
120/78 35/23 115/75 33/22 2000
35 - 65 19-36 35-65 19-36
40 - 70 22-39 35-65 19-36
35 - 65 19-36 35-65 19-36
35 - 65 19-36 30-60 17-33
35 - 65 19-36 35-65 19-36
35 - 65 19-36 35-65 19-36
Operating
34
45.3
45.3
56.6
56.6
12
12
14
14
Max.
Input
High/Low
Max. Outlet
Air Temp.
Min. Wire Size
Over-current (awg) @ 75 ft.
Blower
Blower Size
Weight
Protect
One Way
MBH
40/26
kW
12/8
°F
°C
HP
1/2
1/2
1/2
3/4
3/4
1
Amps
7
7
in.
cm
Lbs.
113
122
126
136
142
145
156
Kg.
180
170
175
175
175
175
170
82.2
76.7
79.4
79.4
79.4
79.4
76.7
11 x 8 27.9 x 20.3
11 x 8 27.9 x 20.3
11 x 8 27.9 x 20.3
11 x 10 27.9 x 25.4
11 x 10 27.9 x 25.4
11 x 11 27.9 x 27.9
11 x 11 27.9 x 27.9
15
15
15
15
15
20
20
14
14
14
14
14
12
12
51.2
55.3
57.1
61.7
64.4
65.7
70.7
60/39 18/11
80/52 23/15
80/52 23/15
100/65 23/15
100/65 29/19
120/78 35/23
7
10.2
10.2
12.7
12.7
1
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
Electrical Entry
LOW VOLTAGE CONTROL WIRING CONNECTIONS
BLK
WHT
L1-Hot
Neutral
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 - 21. Electronic
thermostats may require the common wire to be connected. Apply
strain relief to thermostat wires passing through cabinet. If air condition-
ing 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).
FIGURE 17: Electrical Wiring
1. Provide a power supply separate from all other circuits. Install over-
current protection and disconnect switch per local/national electrical
codes. The switch should be close to the unit for convenience in
servicing. With the disconnect or fused switch in the OFF position,
check all wiring against the unit wiring label. Refer to the wiring dia-
gram in this instruction.
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 furnace.
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 Figure 17.
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.
Some electronic thermostats do not have adjustable heat anticipa-
tors. They should be set to six cycles per hour. Follow the thermostat
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 Figure 17.
12
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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
1
C
C
C
C
C
C
24 – Volt Common
24 – Volt Common
24 – Volt Common
24 – Volt Common
24 – Volt Common
24 – Volt Common
Y1
Y
Y
Y
Y1
Y
Single Stage
Compressor
First Stage Compressor First Stage Compressor First Stage Compressor First Stage Compressor
Compressor Contactor
R
R
R
R
R
24 – Volt Hot
(Heat XFMR)
24 – Volt Hot
(Heat XFMR)
24 – Volt Hot
24 – Volt Hot
24 – Volt Hot
G
G
G
G
G
Fan
Fan
Fan
Fan
Fan
W
W
W
E/W1
W/W1
First Stage Heat
First Stage Heat
First Stage Heat
First Stage Heat
First Stage Heat
W2
W2
W2
W2
W2
Second Stage Heat
Second Stage Heat
Second Stage Heat
Second Stage Heat
Second Stage Heat
RC
RC
Y/Y2
24 – Volt Hot
(Cool XFMR)
24 – Volt Hot
(Cool XFMR)
Second or Full
Stage Compressor
O
Reversing Valve
X/L
Malfunction Light
Y2
Y2
Y2
Y2
Second Stage
Compressor
Second Stage
Compressor
Second Stage
Compressor
Second Stage
Compressor
External Humidistat
(Optional)
Open on Humidity Rise
2
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
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
2
1
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
THERMOSTAT
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
2
1
C
C
C
C
C
24 – Volt Common
24 – Volt Common
24 – Volt Common
24 – Volt Common
24 – Volt Common
Y1
Y1
Y
Y1
Y1
Single Stage
Compressor
Single Stage
Compressor
First Stage Compressor First Stage Compressor First Stage Compressor
R
R
R
R
R
24 – Volt Hot
(Heat XFMR)
24 – Volt Hot
24 – Volt Hot
24 – Volt Hot
24 – Volt Hot
G
G
G
G
Fan
Fan
Fan
Fan
E
E
E
W/W1
W1 OUT
Emergency Heat
Emergency Heat
Emergency Heat
First Stage Heat
First Stage Heat
W2
W2
W2 OUT
Third Stage Heat
Second Stage Heat
Second Stage Heat
RC
Y/Y2
Second or Full
Stage Compressor
Y2 OUT
Second Stage
Compressor
O
Reversing Valve
Energized in Cool
24 – Volt Hot
(Cool XFMR)
O
O
O/B
O
Reversing Valve
Energized in Cool
Reversing Valve
Energized in Cool
Reversing Valve
Reversing Valve
L
L
L
X/L
X/L
Malfunction Light
Malfunction Light
Malfunction Light
Malfunction Light
Malfunction Light
Y2
Y2
Y2
Second Stage
Compressor
W1
Second Stage
Aux. Heat
Second Stage
Compressor
Second Stage
Compressor
AUX
Auxiliary Heat
W2
W
Second Stage Heat
Auxiliary Heat
DHUM
Dehumidification
BSG
Bonnet Sensor
24VAC Humidifier
(Optional)
3
3
Bonnet Sensor Kit
(Optional)
S1-37309243000
External Humidistat
(Optional)
Open on Humidity Rise
BS
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:
1
SAP
126768 = 031-09137
18395 031-01996
340512 = 031-09178
=
Legacy
Part Numbers:
Part Number:
S1-2HU16700124
3
2
=
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)
14
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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
*PP32U71124
*PP32U72124
AIR
CONDITIONER
TWO STAGE
VARIABLE SPEED
FURNACE CONTROL
1
C
C
C
24 – Volt Common
24 – Volt Common
24 – Volt Common
Y1
Y1
Y1
Single Stage
Compressor
First Stage Compressor
First Stage Compressor
R
R
R
24 – Volt Hot
24 – Volt Hot
24 – Volt Hot
G
Fan
G
Fan
Comfort Alert Interface
(two pin connector)
E/W1
W/W1
First Stage Heat
First Stage Heat
W2
W2
Second Stage Heat
Second Stage Heat
Y/Y2
Second or Full
Stage Compressor
O
Reversing Valve
L
X/L
Malfunction Light
Malfunction Light
Y2
Y2
Second Stage
Compressor
Second Stage
Compressor
DHM
DHUM
Dehumidification
Dehumidification
HM
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:
1
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
2
1
C
C
C
24 – Volt Common
24 – Volt Common
24 – Volt Common
Y1
Y1
Y1
Single Stage
Compressor
Single Stage
Compressor
First Stage Compressor
R
R
R
24 – Volt Hot
24 – Volt Hot
24 – Volt Hot
G
G
Fan
Fan
W/W1
W1 OUT
First Stage Heat
First Stage Heat
W2
W2
W2 OUT
Second Stage Heat
Second Stage
Aux. Heat
Second Stage Heat
Y/Y2
Second or Full
Stage Compressor
Y2 OUT
Second Stage
Compressor
O
Reversing Valve
Energized in Cool
O
O
Reversing Valve
Energized in Cool
Reversing Valve
L
X/L
X/L
Malfunction Light
Malfunction Light
Malfunction Light
Y2
Y2
Second Stage
Compressor
Second Stage
Compressor
E/W1
W
First Stage Aux. Heat
Auxiliary Heat
DHM
DHUM
BSG
Bonnet Sensor Kit
(Optional)
Dehumidistat
Dehumidification
Bonnet Sensor
S1-37309243000
HM
Humidistat
24VAC Humidifier
(Optional)
BS
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:
1
SAP
126768 = 031-09137
18395 031-01996
340512 = 031-09178
=
Legacy
Part Numbers:
2
=
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.
The furnace, evaporator coil, and humidifier drains may be combined
and drained together. The evaporator coil drain may have an exter-
nal, field-supplied trap prior to the furnace drain connection to prevent
conditioned air leakage. 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. Regular maintenance
is required on condensate drainage system.
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.
Condensate must be disposed of properly. Follow local plumbing
or wastewater codes. The drain line must maintain a 1/4" per foot (20
mm/m) downward slope to the drain.
A mounting hole is provided on the control panel next to the furnace
control board for mounting a humidifier transformer if required.
SINGLE STAGE THERMOSTAT
If a single stage thermostat is used, the high/low input staging will be
controlled by the furnace control board, using the staging jumper. If the
staging jumper is set to the 10, 15, or 20 position, the furnace will switch
from low fire to high fire after 10, 15, or 20 minutes and will stay in high
fire until the thermostat is satisfied. If the staging jumper is left in the
OFF position and a single stage thermostat is used, the furnace will
only operate at low fire.
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 else-
where in this document.
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.
SECTION VI: CONDENSATE PIPING AND
FURNACE VENTING CONFIGURATION
CONDENSATE DRAIN LOCATION
As shipped from the factory:
Open
(Anti-siphon
Stand
Pipe
air vent)
•
For all 040, 060, & 080K input furnaces the main drain is plumbed
through the casing right-side opening when viewed from the front
of the furnace.
5” Min.
•
For all 100, 120, & 130K input furnaces the main drain is plumbed
through the casing left-side opening when viewed from the front
of the furnace.
Tee
NOTICE
The Figures 24 - 27 show the condensate drain arrangement for the
various possible furnace and vent blower positions.
To Open Or
Vented Drain
The condensate hoses must slope downwards at all points.
The furnace condensate pan is self priming and contains an internal
trap to prevent flue gas leaking. Do not install an external condensate
trap.
FIGURE 22: Typical. Condensate drain, vertical installation
The condensate will flow to the drain better if an open stand pipe is
installed in the drain line. See Figure 22.
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.
NOTICE
A loop has been added to the pressure switch vacuum hose. How-
ever, ensure that all pressure switch hoses are routed such that they
prevent any condensate from entering the pressure switch.
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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.
It is possible for condensation to form inside the combustion air
(intake) pipe in the summer months if significant length of combustion
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 possible,
as shown in Figure 23. This is true for all long horizontal venting in
any furnace configuration. This will prevent the condensate from
entering the furnace.
DO NOT terminate the condensate drain in a chimney, or where the
drain line may freeze. If the drain line will be exposed to temperatures
below freezing, adequate measures must be taken to prevent the
drain line from freezing. Failure to provide proper protection from
freezing can result in improper operation or damage to the equipment
and possible property damage. When exposed to temperatures
below freezing, use of a 3 to 6 watt per foot at 115 VAC, 40°F (4.4°C)
self-regulating, shielded and waterproof heat tape is recommended
on the drain line outside the furnace.
Exhaust Pipe
Combustion Air Pipe
Tee with Drain Trap
DO NOT trap the drain line at any other location than at the conden-
sate drain trap supplied with the furnace.
Trap
Liquid anti-freeze will cause damage to internal plastic parts of this
furnace. DO NOT attempt to winterize the furnace using liquid
anti-freeze.
Connect to Drain
FIGURE 23: Typical. Combustion Pipe Drain Tee
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For 040, 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
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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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.
SECTION VII: COMBUSTION AIR AND
VENT SYSTEM
COMBUSTION AIR AND VENT SAFETY
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.
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.
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
8. In Canada, the first three feet (91.4 cm) of the vent must be readily
accessible for inspection.
9. For single pipe systems it is recommended to install the combustion
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 sepa-
rate 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 temper-
atures such as routing through unheated areas or through an unused
chimney.
40,000
40,000
40,000
60,000
60,000
60,000
80,000
80,000
80,000
100,000
100,000
100,000
120,000
120,000
120,000
2 (5.1)
3 (7.6)
4 (10.2)
2 (5.1)
3 (7.6)
4 (10.2)
2 (5.1)
3 (7.6)
4 (10.2)
2 (5.1)
3 (7.6)
4 (10.2)
2 (5.1)
3 (7.6)
4 (10.2)
65 (19.8)
90 (27.4)
150 (45.7)
65 (19.8)
90 (27.4)
150 (45.7)
65 (19.8)
90 (27.4)
150 (45.7)
30 (9.1)
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.
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.
90 (27.4)
150 (45.7)
30 (9.1)
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.
90 (27.4)
150 (45.7)
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.
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TABLE 11: Combustion Air Intake and Vent Connection Size at Furnace
A
(All Models)
A
FURNACE VENT CONNECTION SIZES
Furnace Input
Intake Pipe Size
Vent Pipe Size
All
2” (5.1 cm)
2” (5.1 cm)
STANDARD ELBOW
LONG (SWEEP) ELBOW
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 verti-
cal pipe section to allow proper drainage of condensate. An offset
using two 45º (degree) elbows will be required for plenum clearance
when the vent is increased to 3” (7.6 cm).
FIGURE 28: Dimensions
TABLE 9: Elbow Dimensions
Elbow
"A" Dimension
2-5/16"
2" Standard
3" Standard
2" Sweep
3" Sweep
3-1/16"
3-1/4"
Accessory concentric vent / intake termination kits 1CT0302 and
1CT0303, and for Canadian applications 1CT0302-636 and
1CT0303-636 are available and approved for use with these fur-
4-1/16"
Dimensions are those required in Standard ASTM D-3311.
naces. Horizontal sidewall vent terminations kits 1HT0901
1HT0902 are also approved for use with these furnaces.
&
TABLE 10: Equivalent Length of Fittings
Fitting
Equivalent Length
COMBUSTION AIR AND VENT PIPING ASSEMBLY
The final assembly procedure for the combustion air and vent piping is
as follows:
2" 90° sweep elbow
5 feet of 2" pipe
2-1/2 feet of 2" pipe
7 feet of 2" pipe
2" 45° sweep elbow
2" 90° standard elbow
2" 45° standard elbow
3" 90° sweep elbow
1. Cut piping to the proper length beginning at the furnace.
2. Deburr the piping inside and outside.
3-1/2 feet of 2" pipe
5 feet of 3" pipe
3. Chamfer (bevel) the outer edges of the piping.
3" 45° sweep elbow
2-1/2 feet of 3" pipe
7 feet of 3" pipe
4. Dry-fit the vent piping assembly from the furnace to the outside ter-
mination checking for proper fit support and slope.
3" 90° standard elbow
3" 45° standard elbow
4" 90° elbow (sweep or standard)
4" 45° elbow (sweep or standard)
2" corrugated connector
3" corrugated connector
4" corrugated connector
3-1/2 feet of 3" pipe
5 feet of 4" pipe
5. Dry-fit the combustion air piping assembly checking for proper fit,
support and slope on the following systems:
2-1/2 feet of 4" pipe
10 feet of 2" pipe
10 feet of 3" pipe
10 feet of 4" pipe
a. Sealed combustion air systems from the furnace to the outside
termination.
b. Ventilated combustion air systems from the furnace to the attic or
crawl space termination.
Example:
An 80,000 BTUH furnace requires 32 feet of pipe and five 90º elbows.
Using 2" 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 2" pipe =
5 - 90º standard 2" elbows = (5 x 7) =
Total =
32 equivalent feet
35 equivalent feet
67 equivalent feet of 2" 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 exceeds the 65 foot maximum equivalent length of 2" pipe allowed
for that model and is thus not acceptable.
By using sweep elbows, the total equivalent length will be:
7. All joints must provide a permanent airtight and watertight seal.
32 feet of 2" pipe =
5 - 90º sweep 2" elbows = (5 x 5) =
Total =
32 equivalent feet
25 equivalent feet
57 equivalent feet of 2" pipe
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.
This is less than the 65 foot maximum equivalent length of 2" pipe
allowed for that model and is thus acceptable.
9. Seal around the openings where the combustion air and / or vent
piping pass through the roof or sidewalls.
Alternatively, using 3" pipe and standard elbows, the total equivalent
length will be:
COMBUSTION AIR / VENTING
32 feet of 3" pipe =
5 - 90º standard 3" elbows = (5 x 7) =
Total =
32 equivalent feet
35 equivalent feet
67 equivalent feet of 3" pipe
The vent must be installed with the minimum required clearances,
and must comply with local codes and requirements.
This is less than the 90 foot maximum equivalent length of 3" pipe
allowed for that model and is thus acceptable.
24
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701379-UIM-C-0712
VENT CLEARANCES
G
V
A
V
VENT TERMINAL
AIR SUPPLY
H
D
FIXED
CLOSED
X
E
B
V
B
B
I
AREA WHERE TERMINAL IS NOT PERMITTED
X
B
M
V
V
V
L
C
V
K
V
X
V
J
FIXED
CLOSED
V
F
B
B
OPERABLE
FIGURE 29: Home Layout
Canadian Installations1,3
US Installation2,3
Direct Vent Terminal Clearances
A. Clearance above grade, veranda, porch, deck, or
balcony
12” (30.5 cm)
12” (30.5 cm)
Two-pipe (direct vent) applications: 9” (23 cm) for
12” (30.5 cm) for models 100,000 BTUH (30 kW),
36” (91.4 cm) for models >100,000 BTUH (30 kW).
models 50,000 BTUH (15 kW), 12” (30.5 cm) for
models >50,000 BTUH (15 kW). ††
B. Clearance to window or door that may be opened
Single-pipe applications: 4 feet (1.2 m).
C. Clearance to permanently closed window
12” (30.5 cm)
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)
3 feet (91.4 cm)
Above a meter/regulator assembly within 3 feet
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.
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 surface to
prevent movement of the vent pipe.
Johnson Controls Unitary Products
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701379-UIM-C-0712
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
anticipated snow
level or grade,
whichever is higher
1. Observe all clearances listed in vent clearances in these instruc-
tions.
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
pipe configuration or a two-pipe configuration.
4. Termination should be located where it will not be damaged or
exposed to flying stones, balls, etc.
The combustion air side of the single pipe configuration shown in Figure
30 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 30. 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 Fig-
ures 31 or 32.
The combustion air side of the two-pipe configuration shown in Figure
31 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 33 or 34. 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.
Maintain 12” minimum clearance
above highest anticipated snow level.
Maximum 24” above roof.
12” Min.
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
MIN.
6”
anticipated snow
level or grade,
whichever is higher.
FIGURE 31: Termination Configuration - 2 Pipe
FIGURE 34: Double Vertical Combustion Air Intake and Vent
Termination
26
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DOWNWARD VENTING
Outdoor Combustion Air
In some applications, it may be necessary to run the vent pipe and air
intake downwards. If this is to be done, the following rules must be fol-
lowed.
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 35) 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 35) is the furnace
vent pipe.
•
•
•
•
A condensate trap hose must be connected to both the air intake
pipe and the vent pipe at the lowest part of the horizontal run.
The condensate drain trap must have a trap of a minimum of six
inches.
The total vertical downward distance must not exceed sixteen
feet.
The condensate drain hose must be connected to a condensate
drain pump, a open or vented drain or into the condensate drain
line from the furnace.
NOTICE
An optional plastic birdscreen is shipped in the loose parts bag with
every furnace. This may be installed in the intake collar to prevent any
small objects from entering the furnace.
•
•
The condensate drain lines must not pass through unconditioned
spaces where the temperature may fall below freezing.
The condensate drain line must be primed at the initial start-up
prior to the start of heating season.
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
16’ MAX
6” MIN.
FIGURE 36: Direct Vent Air Intake Connection and Vent Connection
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.
6” MIN.
FIGURE 35: Downward Venting
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.”
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.
Ambient Combustion Air Supply
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.
This furnace is certified to be installed with one of three possible com-
bustion air intake configurations.
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 35.
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 30 for vent termina-
tions. Refer to "Ambient Combustion Air Supply" for proper installa-
tion. Refer to Figure 36.
COMBUSTION AIR
Vent pipe cements
into socket just
above top panel
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 38 for attic
and crawl space termination. Only the combustion air intake may
terminate in the attic. The vent must terminate outside.
Or vent pipe may be
clamped into outlet
of drain coupling
FIGURE 37: Combustion Airflow Path Through The Furnace Casing
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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.
This type of installation requires that the supply air to the appliance(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 create 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 appliance to soot and gen-
erate dangerous levels of CARBON MONOXIDE, which can lead to
serious injury, property damage and / or death.
When a Category I furnace is removed or replaced, the original vent-
ing system may no longer be correctly sized to properly vent the
attached appliances.
An improperly sized vent system can cause CARBON MONOXIDE to
spill into the living space causing personal injury, and or death.
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.
Table 13: Unconfined Space Minimum Area
BTUH Input Rating Minimum Free Area Required for Each Opening
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.
40 in2 (258 cm2)
40,000
60 in2 (387 cm2)
60,000
80 in2 (516 cm2)
80,000
100 in2 (645 cm2)
100,000
120 in2 (742 cm2)
120,000
Combustion Air Source From Outdoors
Table 14: Free Area
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.
Minimum Free Area Required for Each Opening
BTUH Input
Rating
Vertical Duct or
Opening to Outside
(4,000 BTUH)
Horizontal Duct
(2,000 BTUH)
Round Duct
(4,000 BTUH)
Table 12: Estimated Free Area
Wood or Metal
Louvers or Grilles
Wood 20-25%*
Metal 60-70% *
20 in2 (129 cm2)
30 in2 (193 cm2)
40 in2 (258 cm2)
50 in2 (322 cm2)
60 in2 (387 cm2)
10in2(64cm2)
15 in2 (97 cm2)
20 in2 (129 cm2)
25 in2 (161 cm2)
30 in2 (193 cm2)
40,000
60,000
80,000
100,000
120,000
4” (10 cm)
5” (13 cm)
5” (13 cm)
6” (15 cm)
7” (18 cm)
1/4” (6.4 mm)
mesh or larger 100%
Screens+
* 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.
EXAMPLE: Determining Free Area.
Appliance 1 Appliance 2 Total Input
100,000 +30,000 = (130,000 4,000) = 32.5 Sq. In. Vertical
Appliance 1 Appliance 2 Total Input
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.
2. Apertures in a fixed louver, a grille, or screen shall have no dimen-
sion smaller than 1/4” (6.4 mm).
100,000 +30,000 = (130,000 2,000) = 65 Sq. In. Horizontal
Gas
Vent
Gas
Vent
Gas
Vent
Gable
Vent
Gable
Vent
Ventilated
Attic
Top Above
Insulation
Ventilated
Attic
Optional
Inlet (a)
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 38: Outside and Ambient Combustion Air
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.
Air Supply Openings and Ducts
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 appliance.
Refer to “AIR SOURCE FROM OUTDOORS AND VENT AND
SUPPLY AIR SAFETY CHECK” in these instructions for additional
information and safety check procedure.
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.
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).
2. The duct shall be either metal, or a material meeting the class 1
requirements of CAN4-S110 Standard for Air Ducts.
28
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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.
Ventilated Combustion Air
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.
7. An air supply inlet opening from the outdoors shall be located not
less than 12” (30.5 cm) above the outside grade level.
Combustion Air Source from Outdoors
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:
Ventilated Combustion Air Termination
Refer to Figure 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. 1 square in. per 3000 Btu per hour (6.45 cm3 per 0.879 kW) of
the total input rating of all equipment located in the enclosure.
b. Not less than the sum of all vent connectors in the confined
space.
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.
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.
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 defi-
ciencies, 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 continu-
ously.
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 CO2 and CO levels of each appliance. Use a draft gauge to check for a downdraft or inad-
equate draft condition.
6. After it has been determined that each appliance properly vents when tested as outlined above, return doors, windows, exhaust fans, fireplace
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: A 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 appro-
priate tables in Appendix G of the above codes or for this appliance.
Johnson Controls Unitary Products
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701379-UIM-C-0712
It is recommended that when the gas supply is first connected to the
furnace, the ground union be loosened until the odor of gas is detected.
When gas is detected, immediately tighten the union and check for gas
leaks. Allow five minutes for any gas to dissipate before continuing with
the startup procedure. Be sure that proper ventilation is available to
dilute and carry away any vented gas.
12” minimum
between bottom
of air intake and
any material below.
12” Min.
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.
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).
FIGURE 39: Attic and Crawl Space Combustion Air Termination
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.
Specially Engineered Installations
The above requirements shall be permitted to be waived where special
engineering, approved by the authority having jurisdiction, provides an
adequate supply of air for combustion and ventilation.
IGNITION SYSTEM SEQUENCE
1. Turn the gas supply ON at external valve and main gas valve.
2. Set the thermostat above room temperature to call for heat.
Be sure to instruct the owner not to block this intake pipe.
3. System start-up will occur as follows:
VENT BLOWER ROTATION
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.
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.
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.
SECTION VIII: START-UP AND
ADJUSTMENTS
The initial start-up of the furnace requires the following additional
procedures:
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.
All electrical connections made in the field and in the factory should
be checked for proper tightness.
CALCULATING THE FURNACE INPUT (NAT. GAS)
Burner orifices are sized to provide proper input rate using natural gas
with a heating value of 1030 BTU/Ft3 (38.4 MJ/m3). If the heating value
of your gas is significantly different, it may be necessary to replace the
orifices.
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.
NOTICE
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.
GAS PIPING LEAK CHECK
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.
NOTICE
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.
DO NOT bottom out gas valve regulator adjusting screw. This can
result in unregulated manifold pressure and result in excess overfire
and heat exchanger failures.
Burner ignition may not be satisfactory on first startup due to residual
air in the gas line or until gas manifold pressure is adjusted. The igni-
tion control will make three attempts to light before locking out.
30
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Verify natural gas input rate by clocking meter.
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.
1. Turn off all other gas appliances and pilots.
2. Run furnace for a minimum of 3 minutes in heating operation.
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.
Be sure to relight any gas appliances that were turned off at the start
of this input check.
4. Refer to Table 15 for cubic feet of gas per hour.
5. Multiply cubic feet per hour by heating valve (BTU/cu ft) to obtain
input.
Table 15: Gas Rate (CU FT/HR) at Full Input
Size of Test Dial
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
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
97
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
65
64
63
62
61
60
58
56
54
53
51
50
48
47
46
45
44
43
42
41
40
39
38
38
37
36
35
35
34
33
33
32
31
30
29
28
27
26
25
24
23
22
21
20
2 Cu Ft
131
129
126
124
122
120
116
112
109
106
103
100
97
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
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
62
64
66
68
70
72
74
76
95
78
92
80
90
82
88
84
86
86
84
88
82
90
80
92
78
94
76
96
75
98
74
100
102
104
106
108
110
112
116
120
124
128
133
138
144
150
157
164
171
180
72
71
69
95
68
92
67
90
65
88
64
86
62
84
60
82
58
80
56
78
54
76
52
75
50
73
48
72
46
71
44
69
42
68
40
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This gas valve has separate regulator adjustment screws for high fire
and low fire, as shown in Figure 39. 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 Figure 39 for a
drawing of the locations of the pressure ports on the gas valve.
1. Refer to Figure 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 instruc-
tions 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.
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.
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.
3. Adjust manifold pressure by adjusting gas valve regulator screw for
the appropriate gas per the following:
Table 17: Nominal Manifold Pressure
NOMINAL MANIFOLD PRESSURE
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)
Propane (LP) Gas (High Fire)
Propane (LP) Gas (Low Fire)
Read the inlet gas pressure
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 Figure 40 for connec-
tion details.
HIGH STAGE REGULATOR
ADJUSTMENT
OUTLET
PRESSURE
PORT
VENT
PORT
1. Turn gas and electrical supplies on and follow the operating instruc-
tions to place the unit back in operation.
Table 16: Inlet Gas Pressure Range
INLET
OUTLET
INLET GAS PRESSURE RANGE
WRENCH
BOSS
Natural Gas
Propane (LP)
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)
INLET
PRESSURE
PORT
LOW STAGE REGULATOR
ADJUSTMENT
ON OFF
SWITCH
FIGURE 40: Gas Valve
The inlet gas pressure operating range table specifies what the mini-
mum and maximum gas line pressures must be for the furnace to
operate safely. The gas line pressure MUST BE a minimum of:
•
•
7” w.c. (1.74 kPA) for Natural Gas
11” w.c. (2.74 kPA) for Propane (LP) Gas
If gas valve regulator is turned in (clockwise), manifold pressure is
increased. If screw is turned out (counterclockwise), manifold pres-
sure will decrease.
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 fur-
nace 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 Figure 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
NOTICE
The regulated outlet pressure has been calibrated at the factory.
Additional pressure adjustment should not be necessary. If adjust-
ment is necessary, set to the following specifications. After adjust-
ment, check for gas leakage.
GAS
BURNERS
U-TUBE
MANOMETER
FIGURE 41: 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.
DANGER
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
The supply air temperature cannot exceed the “Maximum Supply
Air Temperature” specified in these instructions and on the furnace
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 pre-
mature heat exchanger failure, high levels of Carbon Monoxide, a fire
hazard, personal injury, property damage, and/or death.
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.
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.
HI HEAT DELAY
JUMPER
BLOWER OFF
DELAY JUMPER
CONTINUOUS FAN
SPEED JUMPER
LAST
ERROR
STAGING
STATUS
NEUTRALS
CFM
LOW VOLTAGE
TERMINALS
HUM
LINE
XFMR
BLOWER SPEED
JUMPERS
EAC
ADJ COOL RELAY HEAT
D
C
B
A
D
C
B
A
D
C
B
A
HEAT
PUMP
JUMPER
DEHUMIDISTAT
JUMPER
COOLING
PROFILE JUMPER
FIGURE 42: Furnace Control Board
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Table 18: Air Flow Data
HIGH / LOW SPEED COOLING AND HEAT PUMP CFM
060B12
040A10
High
1080
960
980
870
890
770
790
650
080B12
100C20
120D20
Jumper Settings
Low
750
680
690
620
620
550
560
480
500
440
450
400
High
1343
1116
1235
1026
1079
889
900
787
814
712
Low
865
727
791
661
709
590
599
531
542
490
499
456
High
1320
1093
1203
1001
1080
880
910
803
836
738
Low
882
755
810
693
730
641
642
585
597
557
561
529
COOL Tap
ADJ Tap*
A
B
A
B
A
C
B
D
C
D
C
D
B
B
A
A
C
B
C
B
A
A
C
C
700
590
640
540
725
641
749
682
080C16
High
1787
1503
1620
1405
1462
1217
1245
940
100C16
Jumper Settings
Low
1171
987
1053
914
964
785
818
608
702
551
626
544
High
1818
1545
1661
1427
1497
1234
1265
977
1116
884
1019
791
Low
1192
1030
1083
936
991
819
832
648
728
572
666
519
High
2019
1790
1818
1630
1649
1269
1432
1078
1169
986
Low
1290
1174
1195
1068
1082
848
956
704
770
638
COOL Tap
ADJ Tap*
A
B
A
B
A
C
B
D
C
D
C
D
B
B
A
A
C
B
C
B
A
A
C
C
1091
852
983
1062
866
685
576
764
Jumper Settings
High
2006
1687
1845
1552
1694
1502
1400
1365
1364
1232
1225
1117
Low
1397
1131
1282
1050
1157
1011
944
922
931
808
808
COOL Tap
ADJ Tap*
A
B
A
B
A
C
B
D
C
D
C
D
B
B
A
A
C
B
C
B
A
A
C
C
718
HIGH / LOW HEAT CFM
040A10
High
960
840
740
060B12
100C16
80B12
100C20
120D20
Jumper Settings
Low
670
590
520
450
High
1364
1253
1102
1014
Low
843
745
660
607
High
1433
1320
1223
1134
Low
945
887
840
768
HEAT Tap
ADJ Tap*
Any
Any
Any
Any
A
B
C
D
640
80C16
Jumper Settings
High
1684
1542
1426
Low
1095
1011
927
High
1803
1686
1530
1427
Low
1182
1084
1016
936
High
2194
1999
1799
1614
Low
1417
1290
1182
1062
HEAT Tap
ADJ Tap*
Any
Any
Any
Any
A
B
C
D
1289
832
Jumper Settings
High
1937
1757
1594
1429
Low
1323
1199
1062
957
HEAT Tap
ADJ Tap*
Any
Any
Any
Any
A
B
C
D
All CFM’s are shown at 0.5” w.c. external static pressure.These units have variable speed motors that automatically adjust to provide constant CFM from 0.0” to 0.6”
w.c. static pressure. From 0.6” to 1.0” static pressure, CFM is reduced by 2% per 0.1” increase in static. Operation on duct systems with greater than 1.0” w.c. external
static pressure is not recommended.
NOTE: At some settings, LOW COOL and/or LOW HEAT airflow may be lower that what is required to operate an airflow switch on certain models of electronic air
cleaners. Consult the instructions for the electronic air cleaner for further details.
* The ADJ “D” tap should not be used.
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CFM Board - Delay Taps Selection
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.
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.
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.
BLOWER DOOR SAFETY SWITCH
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.
Main power to the unit must still be interrupted at the main power dis-
connect 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 discon-
nect.
Blower and burner must never be operated without the blower panel
in place.
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.
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.
Electrical supply to this unit is dependent upon the panel that covers the
blower compartment being in place and properly positioned.
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.
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.
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.
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.
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.
Intermittent Blower Cooling
LIMIT CONTROLS
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.
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:
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.
Intermittent Blower Heating
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.
SECTION X: NORMAL OPERATION AND
DIAGNOSTICS
NORMAL OPERATION SEQUENCE
Heating and Cooling Airflow
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 18 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.
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Heating Cycle
FURNACE CONTROL DIAGNOSTICS
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 41. The heat-
ing cycle is now complete, and ready for the start of the next heating
cycle.
The furnace has built-in, self-diagnostic capability. A blinking LED light
on the control board can flash red, green or amber to indicate various
conditions. The control continuously monitors its own operation and the
operation of the system. If a failure occurs, the LED light will indicate
the failure code.
The SLOW flash speed is two seconds on and two seconds off.
The other flash codes listed below have the following timing: LED light
will turn on for 1/3 second and off for 1/3 second. This pattern will be
repeated the number of times equal to the code. There will be a two-
second pause between codes. For example, the six red flash code will
flash the LED light on and off six times, then will be off for two seconds.
This pattern will repeat as long as the fault condition remains. The con-
tinuous flash codes listed below will flash the LED light on and off con-
tinuously, with no breaks or longer pauses.
SLOW GREEN FLASH: Normal operation, no thermostat calls.
SLOW AMBER FLASH: Normal operation with call for heat.
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.
LED STEADY OFF – If the LED light does not flash at all, check for
power to the board and check for a blown fuse on the board. If the
board is properly powered and the fuse is not blown, the control board
may need to be replaced.
STEADY ON ANY COLOR: Control failure. Turn power to the furnace
off and back on. If the fault code returns, the control board must be
replaced. The control board is not field-repairable.
CONTINUOUS 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.
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.
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. Check for a leaking or slow-closing gas valve.
2 RED FLASHES: This indicates that the pressure switch is closed
when it should be open. The control confirms that the pressure switch
contacts are open at the beginning of each heat cycle and will not let
the ignition sequence continue if the pressure switch contacts are
closed when they should be open. Check for a faulty pressure switch or
miswiring.
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.
3 RED FLASHES: This indicates the pressure switch contacts are open
when they should be closed. Check for faulty inducer, blocked vent
pipe, broken pressure switch hose, disconnected pressure switch or
inducer wires or faulty pressure switch.
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.
4 RED FLASHES: This indicates that the main limit switch has opened
its normally closed contacts. The control will turn on the supply air
blower and inducer. Check for a dirty filter, improperly sized duct sys-
tem, incorrect blower speed setting, incorrect firing rate, loose limit
switch wiring or faulty blower motor.
2. The manual shut-off valves in the gas line to the furnace must be
open.
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.
If the limit switch has not closed within five minutes, the control will
assume that the blower is not functioning, will start a hard lockout and
will begin to flash the 11 Red Flashes error code. If, after fifteen min-
utes, the main limit still has not closed, the control will assume that a
manual-reset rollout switch has opened and will begin to flash the 5 Red
Flash error code. See the description of “5 Red Flashes” and “11Red
Flashes” below.
Never bypass any safety control to allow furnace operation. To
do so will allow furnace to operate under potentially hazardous
conditions.
Do not try to repair controls. Replace defective controls with
UPG Source 1 Parts.
If the main limit switch opens five times within a single call for heat, the
control will indicate 4 Red Flashes and will enter a one-hour soft lock-
out.
Never adjust pressure switch to allow furnace operation.
36
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5 RED FLASHES: This fault is indicated if the limit circuit is open for
more than fifteen minutes, usually indicating that a manual-reset rollout
switch has opened. Check for proper combustion air, proper inducer
operation, and primary heat exchanger failure or burner problem. The
control will enter a hard lockout and power will have to be cycled off and
on to reset the control after the problem has been corrected.
SOFT LOCKOUT: This control includes a soft lockout that will reset
automatically after one hour. This provides protection to an unoccupied
structure if a temporary condition exists causing a furnace malfunction.
An example of this is a temporary interruption in gas supply that would
prevent the furnace from lighting. The control will keep trying to light
each hour and will resume normal operation if the gas supply is
restored.
6 RED FLASHES: This indicates that while the unit was operating, the
pressure switch opened four times during the call for heat. Check for
faulty inducer, blocked vent pipe or faulty pressure switch. The furnace
will lock out for one hour and then restart.
HARD LOCKOUT: Some fault conditions result in a hard lockout, which
requires power to the control to be turned off and then back on to reset
the control. The control will not automatically restart.
7 RED FLASHES: This fault code indicates that the flame could not be
established during three trials for ignition. Check that the gas valve
switch is in the ON position. Check for low or no gas pressure, faulty
gas valve, dirty or faulty flame sensor, faulty hot surface ignitor, loose
wires or a burner problem. The furnace will lock out for one hour and
then restart.
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)
8 RED FLASHES: This fault is indicated if the flame is lost five times
(four recycles) during the heating cycle. Check for low gas pressure,
dirty or faulty flame sensor or faulty gas valve. The furnace will lock out
for one hour and then restart.
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.
9 RED FLASHES: Indicates reversed line voltage polarity, grounding
problem or reversed low voltage transformer wires. 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. The furnace will not start the ignition sequence until
this problem is corrected.
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.
10 RED FLASHES: Gas valve energized with no call for heat. The main
blower and inducer blower will run and no ignition sequence will be
started as long as this condition exists. Check gas valve and gas valve
wiring.
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.
11 RED FLASHES: This indicates that the limit circuit has remained
open for more than five minutes and less than fifteen minutes. This con-
dition is usually caused by a failed blower motor or blower wheel. The
control will enter a hard lockout and power will have to be cycled off and
on to reset the control after the problem has been corrected.
13 RED FLASHES: This indicates that the high-fire pressure switch is
open when it should be closed. Check for a partially blocked vent pipe
or a loose or disconnected wire before replacing pressure switch.
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 and the button is released, then will
resume the normal slow green flash after a five-second pause.
4 AMBER FLASHES: The control is receiving a “Y” signal from the
thermostat without a “G” signal. The furnace will operate normally in
both heating and cooling, but this fault code will be displayed in order to
alert the user that there is a wiring problem. Verify that the “G” wire from
the thermostat is connected properly.
Johnson Controls Unitary Products
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SECTION XI: 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:
•
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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701379-UIM-C-0712
SECTION XII: WIRING DIAGRAM
H U M
E A C
X F M R
L 1
G N D
G N D
FIGURE 43: Wiring Diagram
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Subject to change without notice. Published in U.S.A
701379-UIM-C-0712
Copyright © 2012 by Johnson Controls, Inc. All rights reserved.
Supersedes: 701379-UIM-B-1211
York International Corp.
5005 York Drive
Norman, OK 73069
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