Bryant Furnace 310AAV User Manual

310AAV/JAV

Induced-Combustion

4-Way Multipoise Furnace

Installation, Start-up, Operating, and

Service and Maintenance Instructions

-Series A

The 310AAV/JAV 4-Way Multipoise Gas Furnace was designed by Bryant

dealers for Bryant dealers. Applications are easy with 4-way multipoise

design, through-the-furnace downflow venting, 13 different venting options,

and a door designed for easy service access. An inner blower door is

provided for tighter sealing in sensitive applications. The 310AAV/JAV

furnace is approved for use with natural or propane gas, and the 310JAV is

also approved for use in Low NOx Air Quality Management Districts.

STANDARD FEATURES

• Noise elimination combustion system

• Microprocessor based control center

Adjustable heating air temperature rise

LED diagnostics and self test feature

• Patented blocked vent safeguard to ensure proper furnace venting

• All models are Chimney Friendly when used with accessory vent kit

• Four-position furnace: upflow, horizontal right, horizontal left,

downflow

Thirteen different vent options

• Heat pump compatible

• Hot surface ignition (HSI)

• Residential installations eligible for consumer financing through the Comfort

Credit Program

• Twinning in Upflow, Downflow and Horizontal

LIMITED WARRANTY

• 20-year warranty on “Super S™” heat exchanger

• 5-year parts warranty on all other components

Catalog No: 5331-007

Form No. II 310A-45-3

12-02

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28-7/8"

25-1/4"

1-9/16"

2-9/16"

22-9/16"

AIRFLOW

19"

13/16"

11/16"

JUNCTION BOX

LOCATION

13/16"

OUTLET

4-13/16"

7/8" DIA

ACCESSORY

8-7/16"

1-1/2" DIA.

RIGHT HAND

GAS ENTRY

1/2" DIA THERMOSTAT

WIRE ENTRY

1/2" DIA. THERMOSTAT

WIRE ENTRY

3-15/16"

1-7/16"

LEFT HAND GAS

ENTRY

ALTERNATE

JUNCTION BOX

LOCATION (TYP)

33-5/16"

24-7/8"

VENT OUTLET

5 PLACES (TYP)

14-7/8"

7/8" DIA. ACCESSORY

3-3/4"

5-1/2"

11/16"

1-1/4"

21-5/8"

BOTTOM INLET

1-11/16"

22-1/16"

SIDE INLET

A02304

NOTES:

1. Two additional 7/8-in. diameter holes are located in the top plate.

2. Minimum return-air openings ar furnace, based on metal duct. If flex duct is used, see flex duct manufacturer’s recommendations for equivalent diameters.

a. For 800 CFM-16-in. round or 14 1/2 x 12-in. rectangle.

b. For 1200 CFM-20-in. round or 14 1/2 x 19 1/2-in. rectangle.

c. For 1600 CFM-22-in. round or 14 1/2 x 22-in. rectangle.

d. For airflow requirements above 1800 CFM, see Air Delivery table in Product Data literature for specific

use of single side inlets. The use of both side inlets, a combination of 1 side and the bottom, or the

bottom only will ensure adequate return air openings for airflow requirements above 1800 CFM.

→ Fig. 1—Dimensional Drawing

SAFETY CONSIDERATIONS

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

wear appropriate protective clothing and gloves when han-

dling parts. Failure to follow this caution could result in

personal injury.

Improper installation, adjustment, alteration, service, mainte-

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

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

cause personal injury or property damage. Consult a qualified

installer, service agency, local gas supplier, or your distribu-

tor or branch for information or assistance. The qualified

installer or agency must use only factory-authorized and

listed kits or accessories when modifying this product. Failure

to follow this warning could result in electrical shock, fire,

personal injury, or death.

Wear safety glasses and work gloves. Have fire extinguisher

available during start-up and adjustment procedures and service

calls.

This is the safety-alert symbol

. When you see this symbol on

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

for personal injury.

Understand the signal words DANGER, WARNING, CAUTION,

and NOTE. These words are used with the safety-alert symbol.

DANGER identifies the most serious hazards which will result in

severe personal injury or death. WARNING signifies a hazard

which could result in personal injury or death. CAUTION is used

to identify unsafe practices which would result in minor personal

injury or product and property damage. NOTE is used to highlight

suggestions which will result in enhanced installation, reliability,

or operation.

→

Application of this furnace should be indoors with special

attention given to vent sizing and material, gas input rate, air

temperature rise, unit leveling, and unit sizing. Improper

installation or misapplication of furnace can require excessive

servicing or cause premature component failure.

→ ^{Installing and servicing heating equipment can be hazardous due to}

gas and electrical components. Only trained and qualified

personnel should install, repair, or service heating equipment.

Untrained personnel can perform basic maintenance functions

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

be performed by trained service personnel. When working on

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

on labels attached to or shipped with unit and other safety

precautions that may apply.

1. Use only with type of gas approved for this furnace. Refer to

the furnace rating plate.

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

in the “Location” section of these instructions.

3. Provide adequate combustion and ventilation air to the furnace

space as specified in “Air for Combustion and Ventilation”

section.

4. Combustion products must be discharged outdoors. Connect

this furnace to an approved vent system only, as specified in

the “Venting” section of these instructions.

These instructions cover minimum requirements and conform to

existing national standards and safety codes. In some instances,

these instructions exceed certain local codes and ordinances,

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

tial construction practices. We require these instructions as a

minimum for a safe installation.

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

cially available soap solution made specifically for the detec-

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

Piping” section.

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INSTALLATION

MINIMUM INCHES CLEARANCE TO COMBUSTIBLE CONSTRUCTION

DISTANCE MINIMALE EN POUCES AUX CONSTRUCTIONS COMBUSTIBLES

This forced air furnace is equipped for use with This furnace is approved for UPFLOW, DOWNFLOW, and

HORIZONTAL installations.

natural gas at altitudes 0-10,000 ft (0-3,050m).

An accessory kit, supplied by the Cette fournaise est approuvée pour l´installation HORIZONTALE

et la circulation d´air VERS LE HAUT et VERS LE BAS.

manufacturer,shall be used to convert to propane

gas use or may be required for some natural gas

applications.

This furnace is for indoor installation in a

building constructed on site.

Les fléches de dégagement

ne changent pas avec

l´orientation de la fournaise.

Clearance arrows

do not change with

furnace orientation.

This furnace may be installed on combustible

flooring in alcove or closet at minimum clearance

as indicated by the diagram from combustible

material .

This furnace may be used with a Type B-1 Vent

and may be vented in common with other gas-

fired appliances.

Cette fournaise à air pulsé est équipée

pour utilisation avec gaz naturel et altitudes

comprises entre 0-3,050m (0-10,000 pi).

Utiliser une trousse de conversion, fournie par

le fabricant, pour passer au gaz propane ou pour

certaines installations au gaz naturel.

^N30"

MIN

^T3"_MIN

Cette fournaise est prévue pour être

installée dans un bâtiment construit sur place.

Cette fournaise peut être installée sur

un plancher combustible dans une alcôve ou

dans un garde-robe en respectant le minimum

d'espace libre des matériaux combustibles, tel

q. u'indiqué sur le diagramme.

Cette fournaise peut être utilisée avec un

conduit d´évacuation de Type B-1 ou connectée

.au conduit commun d´autres appareils à gaz.

Clearance in inches

Dégagement (po).

Vent Clearance to combustibles:

For Single Wall vents 6 inches (6 po).

For Type B-1 vent type 1 inch (1 po).

Dégagement de l´évent avec combustibles:

Pour conduit d´évacuation à paroi simple 6 po (6 inches).

Pour conduit d´évacuation de Type B-1 1 po (1 inch).

MINIMUM INCHES CLEARANCE TO COMBUSTIBLE CONSTRUCTION

DOWNFLOW POSITIONS:

Installation on non-combustible floors only.

†

For Installation on combustible flooring only when installed on special base, Part No. KGASB0201ALL,

Coil Assembly, Part No. CD5 or CK5, or Coil Casing, Part No. KCAKC.

18 inches front clearance required for alcove.

Indicates supply or return sides when furnace is in the horizontal position. Line contact only permissible

between lines formed by intersections of the Top and two Sides of the furnace jacket, and building joists,

studs or framing.

DÉGAGEMENT MINIMUM EN POUCES AVEC ÉLÉMENTS

DE CONSTRUCTION COMBUSTIBLES

POUR LA POSITION COURANT DESCENDANT:

Pour l´installation sur plancher non combustible seulement.

†

Pour l´installation sur un plancher combustible seulement quand on utilise la base spéciale, pièce

n^oKGASB0201ALL, l´ensemble serpentin, pièce n^oCD5 ou CK5, ou le carter de serpentin, pièce

n^oKCAKC.

Dans une alcôve, on doit maintenir un dégagement à l´avant de 18 po (450 mm).

La position indiquée concerne le côté d´entrée ou de retour quand la fournaise est dans la

position horizontale.

Le contact n´est permis qu´entre les lignes formées par les intersections du dessus et des

deux côtés de la chemise de la fournaise et les solives, montant sous cadre de charpente.

327590-101 REV. B

A02330

→ Fig. 2—Clearances to Combustibles

6. Always install furnace to operate within the furnace’s intended

temperature-rise range with a duct system which has an

external static pressure within the allowable range, as speci-

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

See furnace rating plate.

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

be installed as specified in the warning box in the “Location”

section.

9. The furnace is not to be used for temporary heating of

buildings or structures under construction.

7. When a furnace is installed so that supply ducts carry air

circulated by the furnace to areas outside the space containing

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

sealed to the furnace casing and terminating outside the space

containing the furnace. See “Air Ducts” section.

→ ^{10. These Multipoise Gas-Fired Furnaces are CSA (A.G.A. and}

C.G.A.) design-certified for natural and propane gases (see

furnace rating plate) and for installation in alcoves, attics,

basements, closets, utility rooms, crawlspaces, and garages.

The furnace is factory-shipped for use with natural gas. A

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Table 1—Dimensions (IN.)

VENT

CONN*

UNIT SIZE

SHIP WT. (LB)

045-08/024045

045-12/036045

070-08/024070

070-12/036070

070-16/048070

090-14/042090

090-16/048090

090-20/060090

110-12/036110

110-16/048110

110-22/066110

135-16/048135

135-22/066135

155-20/060155

14-3/16

17-1/2

12-9/16

15-7/8

19-3/8

15-7/8

19-3/8

22-7/8

12-11/16

104

107

111

115

123

126

139

145

134

145

151

148

163

170

19-1/2

17-1/2

19-1/2

24-1/2

* 5” or 6” vent connector may be required in some cases.

CSA (A.G.A. and C.G.A.) listed gas conversion kit is required

to convert furnace for use with propane gas.

→ ^{11. See Fig. 2 for required clearances to combustibles.}

→ ^{12. Maintain a 1-in. clearance from combustible materials to}

supply air ductwork for a distance of 36 inches horizontally

from the furnace. See NFPA 90B or local code for further

requirements.

→ ^{13. These furnaces SHALL NOT be installed directly on carpet-}

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

flooring. In downflow installations, factory accessory floor

base MUST be used when installed on combustible materials

and wood flooring. Special base is not required when this

furnace is installed on manufacturer’s Coil Assembly Part No.

CD5 or CK5, or when Coil Box Part No. KCAKC is used.

A02055

INTRODUCTION

Fig. 3—Return Air Temperature

→ ^{This 4–way multipoise Category I fan-assisted furnace is CSA}

(A.G.A. and C.G.A.) design-certified for natural and propane gas

and for installation in alcoves, attics, basements, closets, utility

rooms, crawlspaces, and garages. A fan-assisted furnace is an

appliance equipped with an integral mechanical means to either

draw or force products of combustion through the combustion

chamber and/or heat exchanger. The furnace is factory-shipped for

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

conversion kit is required to convert furnace for use with propane

gas. This furnace is not approved for installation in mobile homes,

recreational vehicles, or outdoors.

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

comply with the national codes listed below and all authorities

having jurisdiction.

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

the following:

Step 1—Safety

•

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

Z223.1–2002 and the Installation Standards, Warm Air Heating

and Air Conditioning Systems ANSI/NFPA 90B

This furnace is designed for minimum continuous return-air

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

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

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

return-air limits may affect reliability of heat exchangers, motors,

and controls. (See Fig. 3.)

•

CANADA: CAN/CGA-B149.1–and .2–M00 National Standard

of Canada. Natural Gas and Propane Installation Codes (NSC-

NGPIC)

Step 2—General Installation

•

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

copies, contact the National Fire Protection Association Inc.,

Batterymarch Park, Quincy, MA 02269; or for only the NFGC,

contact the American Gas Association, 400 N. Capitol, N.W.,

Washington DC 20001 or www.NFPA.org.

For accessory installation details, refer to the applicable instruction

literature.

NOTE: Remove all shipping brackets and materials before oper-

•

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

CSA International, 178 Rexdale Boulevard, Etobicoke (Tor-

onto), Ontario, M9W 1R3 Canada

ating the furnace.

CODES AND STANDARDS

Step 3—Combustion and Ventilation Air

Follow all national and local codes and standards in addition to

these instructions. The installation must comply with regulations

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

•

US: Section 5.3 of the NFGC, Air for Combustion and

Ventilation

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THE BLOWER IS

LOCATED BELOW THE

BURNER SECTION, AND

CONDITIONED AIR IS

DISCHARGED UPWARD.

THE BLOWER IS LOCATED

TO THE RIGHT OF THE

BURNER SECTION, AND

AIR CONDITIONED AIR IS

DISCHARGED TO THE LEFT.

THE BLOWER IS

LOCATED ABOVE THE

BURNER SECTION, AND

CONDITIONED AIR IS

DISCHARGED DOWNWARD

LOCATED TO THE LEFT

OF THE BURNER SECTION,

AND CONDITIONED AIR IS

DISCHARGED TO THE RIGHT.

A02097

Fig. 4—Multipoise Orientations

•

CANADA: Part 7 of NSCNGPIC, Venting Systems and Air

Supply for Appliances

NOT move or shuffle your feet, do not touch ungrounded

objects, etc.).

Step 4—Duct Systems

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

static electricity), firmly touch a clean, unpainted metal

surface of the furnace again before touching control or wires.

•

US and CANADA: Air Conditioning Contractors Association

(ACCA) Manual D, Sheet Metal and Air Conditioning Con-

tractors National Association (SMACNA), or American Soci-

ety of Heating, Refrigeration, and Air Conditioning Engineers

(ASHRAE) 2001 Fundamentals Handbook Chapter 34.

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

furnaces.

6. Before removing a new control from its container, discharge

your body’s electrostatic charge to ground to protect the

control from damage. If the control is to be installed in a

furnace, follow items 1 through 4 before bringing the control

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

controls into containers before touching ungrounded objects.

Step 5—Acoustical Lining and Fibrous Glass Duct

•

US and CANADA: current edition of SMACNA and NFPA

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

Step 6—Gas Piping and Gas Pipe Pressure Testing

•

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

Codes

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

also be used to prevent ESD damage.

→ ^•CANADA: NSCNGPIC Parts 3, 4, 5, A, B, E and H.

Step 7—Electrical Connections

LOCATION

Step 1—General

•

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

Some assembly and modifications are required when used in any

of the four applications shown in Figure 4.

CANADA: Canadian Electrical Code CSA C22.1

→

ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS

PROCEDURE

This furnace must:

•

be installed so the electrical components are protected from

water.

not be installed directly on any combustible material other than

wood flooring. Refer to Introduction section.

Electrostatic discharge can affect electronic components.

Take precautions during furnace installation and servicing to

protect the furnace electronic control. Precautions will pre-

vent electrostatic discharges from personnel and hand tools

which are held during the procedure. These precautions will

help to avoid exposing the control to electrostatic discharge

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

electrostatic potential.

be located close to the chimney/vent and attached to an air

distribution system. Refer to Air Ducts section.

be provided ample space for servicing and cleaning. Always

comply with minimum fire protection clearances shown on the

furnace clearance to combustible label.

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

be required. DO NOT TOUCH THE CONTROL OR ANY

WIRE CONNECTED TO THE CONTROL PRIOR TO DIS-

CHARGING YOUR BODY’S ELECTROSTATIC CHARGE

TO GROUND.

Do not install furnace in a corrosive or contaminated atmo-

sphere. Make sure all combustion and circulating air require-

ments are met, in addition to all local codes and ordinances.

2. Firmly touch the clean, unpainted, metal surface of the furnace

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

hand during grounding will be satisfactorily discharged.

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

control or connecting wires as long as you do nothing to

recharge your body with static electricity (for example; DO

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furnace. If the dampers are manually operated, they must be

equipped with means to prevent operation of either unit unless the

damper is in the full-heat or full-cool position.

This gas furnace may be used for construction heat provided

that:

AIR FOR COMBUSTION AND VENTILATION

Provisions for adequate combustion and ventilation air must be

provided in accordance with Section 5.3 of the NFGC, Air for

Combustion and Ventilation, or applicable provisions of the local

building codes.

-The furnace is permanently installed with all electrical

wiring, piping, venting and ducting installed according to

these installation instructions. A return air duct is provided,

sealed to the furnace casing, and terminated outside the space

containing the furnace. This prevents a negative pressure

condition as created by the circulating air blower, causing a

flame rollout and/or drawing combustion products into the

structure.

Canadian installations must be installed in accordance with NSC-

NGPIC Part 7 and all authorities having jurisdiction.

-The furnace is controlled by a thermostat. It may not be ″hot

wired″ to provide heat continuously to the structure without

thermostatic control.

-Clean outside air is provided for combustion. This is to

minimize the corrosive effects of adhesives, sealers and other

construction materials. It also prevents the entrainment of

drywall dust into combustion air, which can cause fouling and

plugging of furnace components.

-The temperature of the return air to the furnace is no less

than 55 degrees F, with no evening setback or shutdown. The

use of the furnace while the structure is under construction is

deemed to be intermittent operation per our installation

instructions.

-The air temperature rise is within the rated rise range on the

furnace rating plate, and the firing rate has been set to the

nameplate value.

18-IN. MINIMUM

TO BURNERS

A93044

-The filters used to clean the circulating air during the

construction process must be either changed or thoroughly

cleaned prior to occupancy.

Fig. 6—Installation in a Garage

-The furnace, ductwork and filters are cleaned as necessary to

remove drywall dust and construction debris from all HVAC

system components after construction is completed.

When the furnace is installed in a residential garage, the

burners and ignition sources must be located at least 18 inches

above the floor. The furnace must be located or protected to

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

public garage, airplane hangar, or other building having a

hazardous atmosphere, the furnace must be installed in

accordance with the NFGC or NSCNGPIC. (See Fig. 6.)

→

DO NOT install the furnace on its back or facing down.

Safety control operation will be adversely affected. Never

connect return-air ducts to back of furnace. Failure to follow

this warning could result in fire, personal injury, or death.

(See Fig. 5.)

Air for combustion must not be contaminated by halogen

compounds, which include fluoride, chloride, bromide, and

iodide. These elements are found in aerosol sprays, deter-

gents, bleaches, cleaning solvents, salts, air fresheners, and

other household products.

All fuel-burning equipment must be supplied with air for fuel

combustion. Sufficient air must be provided to avoid negative

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

made between the furnace cabinet and the return-air duct to

prevent pulling air from the burner area and from blocked vent

safeguard opening.

→

The operation of exhaust fans, kitchen ventilation fans,

clothes dryers, attic exhaust fans or fireplaces could create a

NEGATIVE PRESSURE CONDITION at the furnace.

Make-up air MUST be provided for the ventilation devices, in

addition to that required by the furnace. Refer to Carbon

Monoxide Hazard warning in venting section of these instruc-

tions to determine amount of make-up air required.

A02054

Fig. 5—Prohibit Installation on Back

Step 2—Location Relative to Cooling Equipment

The cooling coil must be installed parallel with, or on the

downstream side of the unit to avoid condensation in the heat

exchangers. When installed parallel with the furnace, dampers or

other flow control must prevent chilled air from entering the

The requirements for combustion and ventilation air depend upon

whether the furnace is located in an unconfined or confined space.

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Table 2–Minimum Free Area of Combustion Air Opening*

AIR FROM INDOOR

UNCONFINED SPACE

OUTDOOR AIR THROUGH

VERTICAL DUCTS

OUTDOOR AIR THROUGH

HORIZONTAL DUCTS

OUTDOOR AIR THROUGH

SINGLE DUCT

FURNACE

INPUT

(BTUH)

Free Area

of Opening

(Sq In.)

Free Area of

Round Pipe

Opening and Duct

(in. Dia)

Free Area of

Round Pipe

Opening and Duct

(in. Dia)

Free Area of

Round Pipe

Opening and Duct

(In. Dia)

(Sq. In.)

(sq In.)

(Sq In.)

44,000

66,000

100

110

132

154

14.7

22.0

29.3

36.7

44.0

51.3

16.5

22.0

27.5

88,000

44.0

110,000

132,000

154,000

38.5

* Free area shall be equal to or greater than the sum of the areas of all vent connectors in the confined space. Opening area must be increased if other gas appliances

in the space require combustion air.

AIR

DUCTS

VENT THROUGH ROOF

Step 1—Unconfined Space

An unconfined space has a volume of at least 50 cu ft for each

1000 Btuh total input for all appliances (furnaces, clothes dryers,

water heaters, etc.) in the space.

For example:

12″ MAX

FURNACE

INPUT (BTUH)

44,000

MINIMUM WITH

7–1/2 FT CEILING (SQ. FT.)

1 SQ IN.

PER 1000

294

441

587

734

881

1028

BTUH IN DOOR

OR WALL

66,000

88,000

UNCONFINED

SPACE

INTERIOR

HEATED

SPACE

110,000

132,000

154,000

6″ MIN

(FRONT) ^†

If the unconfined space is constructed unusually tight, air for

combustion and ventilation must come from either the outdoors or

spaces freely communicating with the outdoors. Combustion and

ventilation openings must be equivalent to those used for a

confined space (defined below). Return air must not be taken from

the room unless an equal or greater amount of air is supplied to the

room.

1 SQ IN.

PER 1000

BTUH IN DOOR

OR WALL

12″ MAX

Step 2—Confined Space

AIR DUCTS

A confined space has a volume less than 50 cu ft per 1000 Btuh

of total input ratings of all appliances installed in that space. A

confined space must have provisions for supplying air for com-

bustion, ventilation, and dilution of flue gases using one of the

following methods in Table 2 and Fig. 7 and 8.

* Minimum opening size is 100 sq in. with

minimum dimensions of 3 in.

^†Minimum of 3 in. when type-B1 vent is used.

A02038

NOTE: When determining the free area of an opening, the

blocking effect of louvers, grilles, and screens must be considered.

If the free area of the louver or grille design is unknown, assume

wood louvers have a 20 percent free area and metal louvers or

grilles have a 60 percent free area. Screens must not be smaller

than 1/4-in. mesh. Louvers and grilles must be constructed so they

cannot be closed.

Fig. 7—Confined Space: Air for Combustion and

Ventilation from an Unconfined Indoor Space

c. If the furnace is installed on a raised platform to provide a

return-air plenum, and return air is taken directly from the

hallway or space adjacent to furnace, all air for combustion

must come from outdoors.

The opening size depends upon whether air comes from outside of

the structure or an unconfined space inside the structure.

1. Air from inside the structure requires 2 openings (for struc-

tures not of unusually tight construction):

2. Air from outside the structure requires 1 of the following:

a. If combustion air is taken from outdoors through 2 vertical

ducts, the openings and ducts must have at least 1 sq in. of

free area per 4000 Btuh of total input for all equipment

within the confined space. (See Fig. 8 and Table 2.)

a. Each opening must have a minimum free area of not less

than 1 sq in per 1000 Btuh of total input rating for all gas

utilization equipment in the confined space, but not less

than 100 sq in. The minimum dimension of air openings

should be no smaller than 3 in. (See Table 2 and Fig. 7 ).

b. If combustion air is taken from outdoors through 2 hori-

zontal ducts, the openings and ducts must have at least 1 sq

in. of free area per 2000 Btuh of total input for all

equipment within the confined space. (See Fig. 8 and Table

2.)

b. If building construction is unusually tight, a permanent

opening directly communicating with the outdoors shall be

provided. (See next section).

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1 SQ IN.

PER 4000

BTUH*

DUCTS

OUTDOORS

12″ MAX

1 SQ IN.

PER 2000

BTUH*

12″

MAX

VENT

THROUGH

ROOF

AIR

DUCTS

1 SQ IN.

PER

4000

BTUH*

DUCTS

OUTDOORS

A02098

1 SQ IN.

PER

Fig. 9—Removing Bottom Closure Panel

4000

BTUH*

1 SQ IN.

PER 2000

BTUH*

12″

MAX

12″ MAX

SIDE RETURN AIR INLET

12″ MAX

These furnaces are shipped with bottom closure panel installed in

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

only side return air is used.

AIR DUCTS

DUCT

1 SQ IN.

PER 4000

BTUH*

→ ^{NOTE: Side return-air openings can be used in UPFLOW and}

most HORIZONTAL configurations. Do not use side return-air

openings in DOWNFLOW configuration.

OUTDOORS

*Minimum dimensions of 3 in.

NOTE: Use any of the following

LEVELING LEGS (IF DESIRED)

combinations of openings:

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

In upflow position with side return inlet(s), leveling legs may be

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

corrosion-resistant machine bolts, washers and nuts.

A02165

Fig. 8—Confined Space: Air for Combustion and

Ventilation from Outdoors

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

It may be necessary to remove and reinstall bottom closure panel

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

c. If combustion air is taken from the outdoors through a

single opening or duct (horizontal or vertical) commencing

within 12 in. of the top of the confined space, the opening

and duct must have at least 1 sq in. of free area per 3000

Btuh of the total input for all equipment within the confined

space and not less than the sum of the areas of all vent

connectors in the confined space. Equipment clearances to

the structure shall be at least 1 in. from the sides and back

and 6 in. from the front of the appliances. See Table 2 and

Fig. 8.

To install leveling legs:

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

bottom corner of furnace. (See Fig. 10.)

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

hole. (Install flat washer if desired.)

3. Install another nut on other side of furnace base. (Install flat

washer if desired.)

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

nut to secure arrangement.

When ducts are used, they must be of the same cross sectional area

as the free area of the openings to which they connect. The

minimum dimension of ducts must not be less than 3 in.

5. Reinstall bottom closure panel if removed.

Step 2—Downflow Installation

NOTE: For downflow applications, this furnace is approved for

use on combustible flooring when any one of the 3 accessories are

used:

INSTALLATION

Step 1—Upflow Installation

•

Special Base, KGASB

BOTTOM RETURN AIR INLET

Cased Coil Assembly Part No. CD5 or CK5

Coil Box Part No. KCAKC

These furnaces are shipped with bottom closure panel installed in

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

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

perform the following:

1. Determine application being installed from Table 3.

2. Construct hole in floor per Table 3 and Fig. 11.

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

panel. (See Fig. 9.)

3. Construct plenum to dimensions specified in Table 3 and Fig.

11.

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

3. Remove bottom closure panel.

4. If downflow subbase, KGASB is used, install as shown in Fig.

12. If Coil Assembly Part No. CD5 or CK5 or Coil Box Part

No. KCAKC is used, install as shown in Fig. 13.

4. Reinstall bottom filler panel and screws.

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⁵⁄16″

PLATFORM UNIT SUPPORT

Construct working platform at location where all required furnace

clearances are met. (See Fig. 2 and 17.) For furnaces with 1-in.

clearance requirement on side, set unit on non-combustible blocks,

bricks or angle iron. For crawlspace installations, if the unit is not

suspended from the floor joists, the ground underneath unit must

be level and the unit set on blocks or bricks.

⁵⁄16″

1 ³⁄4″

ROLL-OUT PROTECTION

1 ³⁄4″

Provide a minimum 17 3/4″ X 22″ piece of sheet metal for roll-out

protection in front of burner area for units closer than 12 inches

above the combustible deck or suspended units closer than 12-in.

to joists. The sheet metal MUST extend underneath the furnace

casing by 1 in. with the door removed.

⁵⁄16″

The bottom closure pan on furnaces of widths 17 1/2 in. and larger

may be used for roll-out protection when bottom of furnace is used

for return air connection. See Fig. 17 for proper orientation of

roll-out shield.

⁵⁄16″

1 ³⁄4″

→ ^{BOTTOM RETURN AIR INLET}

These furnaces are shipped with bottom closure panel installed in

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

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

perform the following:

A02071

Fig. 10—Leveling Legs

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

panel. (See Fig. 9.)

NOTE: It is recommended that the perforated supply-air duct

flanges be completely folded over or removed from furnace when

installing the furnace on a factory-supplied cased coil or coil box.

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

seamers to bend flange back and forth until it breaks off. Be careful

of sharp edges. (See Fig. 14.)

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

3. Remove bottom closure panel.

4. Reinstall bottom filler panel and screws.

→ ^{SIDE RETURN AIR INLET}

→ ^{BOTTOM RETURN AIR INLET}

These furnaces are shipped with bottom closure panel installed in

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

only one side return air is used.

These furnaces are shipped with bottom closure panel installed in

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

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

perform the following:

→ ^{Not all horizontal furnaces are approved for side return air}

connections (See Fig. 20.)

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

panel. (See Fig. 9.)

Step 4—Filter Arrangement

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

3. Remove bottom closure panel.

Never operate a furnace without a filter or with filter access

door removed. Failure to follow this warning could result in

fire, personal injury, or death.

4. Reinstall bottom filler panel and screws.

Step 3—Horizontal Installation

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

A field-supplied accessory external filter rack is required.

Do not install the furnace on its back or hang furnace with

control compartment facing downward. Safety control opera-

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

to the back of the furnace. Failure to follow this warning

could result in fire, personal injury, or death.

This furnace requires KGAFR0301ALL 1″ external filter rack or a

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

Refer to the instructions supplied with external filter rack for

assembly and installation options.

The furnace can be installed horizontally in an attic or crawl space

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

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

platform, non-combustible blocks, bricks or pad.

Step 5—Air Ducts

GENERAL REQUIREMENTS

The duct system should be designed and sized according to

accepted national standards such as those published by: Air

Conditioning Contractors Association (ACCA), Sheet Metal and

Air Conditioning Contractors National Association (SMACNA) or

American Society of Heating, Refrigerating and Air Conditioning

Engineers (ASHRAE) or consult The Air Systems Design Guide-

lines reference tables available from your local distributor. The

duct system should be sized to handle the required system design

CFM at the design external static pressure.

SUSPENDED UNIT SUPPORT

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

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

Secure angle iron to bottom of furnace as shown. Heavy-gauge

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

unit from each bottom corner. To prevent screws from pulling out,

use 2 # 8 x ¾-in. screw into the side and 2 # 8 x ¾-in. screw in the

bottom of the furnace casing for each strap. (See Fig. 15 and 16.)

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FURNACE

(OR COIL CASING

WHEN USED)

PLENUM

OPENING

COMBUSTIBLE

FLOORING

FLOOR

OPENING

DOWNFLOW

SUBBASE

SHEET METAL

PLENUM

FLOOR

OPENING

A96283

Fig. 11—Floor and Plenum Opening Dimensions

A96285

Fig. 12—Furnace, Plenum, and Subbase Installed on

a Combustible Floor

FURNACE

CD5 OR CK5

COIL ASSEMBLY

OR KCAKC

COIL BOX

COMBUSTIBLE

FLOORING

SHEET METAL

PLENUM

FLOOR

OPENING

A96284

Fig. 13—Furnace, Plenum, and Coil Assembly or Coil Box Installed on a Combustible Floor

When a furnace is installed so that the supply ducts carry air to

areas outside the space containing the furnace, the return air must

also be handled by a duct(s) sealed to the furnace casing and

terminating outside the space containing the furnace.

Flexible connections should be used between ductwork and

furnace to prevent transmission of vibration. Ductwork passing

through unconditioned space should be insulated and sealed to

enhance system performance. When air conditioning is used, a

vapor barrier is recommended.

Secure ductwork with proper fasteners for type of ductwork used.

Seal supply- and return-duct connections to furnace with code

approved tape or duct sealer.

Maintain a 1-in. clearance from combustible materials to supply air

ductwork for a distance of 36 in. horizontally from the furnace. See

NFPA 90B or local code for further requirements.

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Table 3—Opening Dimensions (In.)

FURNACE

CASING

WIDTH

PLENUM OPENING

FLOOR OPENING

APPLICATION

Upflow Applications on Combustible or Noncombustible

Flooring (KGASB subbase not required)

12-11/16

21-5/8

13-5/16

22-1/4

Downflow Applications on Noncombustible Flooring

(KGASB subbase not required)

12-9/16

13-3/16

13-7/16

19-5/8

20-5/8

14–3/16

17–1/2

Downflow applications on combustible flooring (KGASB

11-13/16

subbase required)

Downflow Applications on Combustible Flooring with CD5 or

CK5 Coil Assembly or KCAKC coil box (KGASB subbase

not required)

12-5/16

13-5/16

Upflow Applications on Combustible or Noncombustible

Flooring (KGASB subbase not required)

21-5/8

16-5/8

16-1/2

16-3/4

22-1/4

19-5/8

20-5/8

Downflow Applications on Noncombustible Flooring

(KGASB subbase not required)

15-7/8

15-1/8

Downflow applications on combustible flooring (KGASB

subbase required)

Downflow Applications on Combustible Flooring with CD5 or

CK5 Coil Assembly or KCAKC coil box (KGASB subbase

not required)

15-1/2

16-1/2

Upflow Applications on Combustible or Noncombustible

Flooring (KGASB subbase not required)

19-1/2

19-3/8

18-5/8

21-5/8

20-1/8

22-1/4

19-5/8

20-5/8

Downflow Applications on Noncombustible Flooring

(KGASB subbase not required)

Downflow applications on combustible flooring (KGASB

20-1/4

subbase required)

Downflow Applications on Combustible Flooring with CD5 or

CK5 Coil Assembly or KCAKC coil box (KGASB subbase

not required)

Upflow Applications on Combustible or Noncombustible

Flooring (KGASB subbase not required)

21-1/8

23-5/8

23-1/2

23-3/4

22-1/4

19-5/8

20-5/8

Downflow Applications on Noncombustible Flooring

(KGASB subbase not required)

22-7/8

22-1/8

24-1/2

Downflow applications on Combustible flooring (KGASB

subbase required)

Downflow Applications on Combustible Flooring with CD5 or

CK5 Coil Assembly or KCAKC coil box (KGASB subbase

not required)

22-1/2

23-1/2

DOWNFLOW

UPFLO

HORIZONTAL

90˚

PREFERRED

120˚

MIN

120˚

MIN

120˚

MIN

PERMITTED

A02329

→ Fig. 14—Duct Flanges

DUCTWORK ACOUSTICAL TREATMENT

SMACNA construction standard on fibrous glass ducts. Both

acoustical lining and fibrous ductwork shall comply with NFPA

90B as tested by UL Standard 181 for Class 1 Rigid air ducts.

Metal duct systems that do not have a 90 degree elbow and 10 ft

of main duct to the first branch take-off may require internal

acoustical lining. As an alternative, fibrous ductwork may be used

if constructed and installed in accordance with the latest edition of

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¹/4" THREADED ROD

4 REQ.

OUTER DOOR

ASSEMBLY

SECURE ANGLE

IRON TO BOTTOM

OF FURNACE WITH

3 #8 x ³/4" SCREWS

TYPICAL FOR 2 SUPPORTS

8" MIN FOR DOOR

REMOVAL

1" SQUARE, 1¹/4" x 1¹/4" x ¹/4" ANGLE IRON

OR UNI-STRUT MAY BE USED

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

REQ. PER ROD

A02345

→ Fig. 15—Horizontal Unit Suspension

A02014

Fig. 16—Horizontal Suspension with Straps

Upflow and Horizontal Furnaces

SUPPLY AIR CONNECTIONS

→ ^{For a furnace not equipped with a cooling coil, the outlet duct shall}

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

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

that the heat exchanger can be viewed for possible openings using

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

stream. The cover attachment shall prevent leaks.

Connect supply-air duct to flange on furnace supply-air outlet.

Bend flange upward to 90° with wide duct pliers. The supply-air

duct attachment must ONLY be connected to furnace supply-

outlet-air duct flanges or air conditioning coil casing (when used).

DO NOT cut main furnace casing to attach supply side air duct,

humidifier, or other accessories. All accessories MUST be con-

nected external to furnace main casing.

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LINE CONTACT ONLY PERMISSIBLE BETWEEN

LINES FORMED BY INTERSECTIONS OF

THE TOP AND TWO SIDES OF THE FURNACE

JACKET AND BUILDING JOISTS,

STUDS, OR FRAMING.

17 ³/4″ OVER ALL

4 ³/4″ UNDER DOOR

1″ UNDER FURNACE

GAS

ENTRY

TYPE-B

VENT

EXTEND OUT 12″ OUT

FROM FACE OF DOOR

MIN*

″

30-IN. MIN

WORK AREA

* WHEN USED WITH

SINGLE WALL VENT

CONNECTIONS

17 ³/4

″

SHEET

METAL

22″

MANUAL SHUTOFF

GAS VALVE

SEDIMENT

TRAP

A02164

Fig. 17—Typical Attic Installation

Downflow Furnaces

Step 6—Gas Piping

Connect supply-air duct to supply-air opening on furnace. The

supply-air duct attachment must ONLY be connected to furnace

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

installed on combustible material, supply-air duct attachment must

ONLY be connected to the accessory subbase, KGASB0201ALL,

or factory approved air conditioning coil casing. DO NOT cut

main furnace casing to attach supply side air duct, humidifier, or

other accessories. All accessories MUST be connected external to

furnace casing.

→

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

for gas leaks with an open flame. Use a commercially

available soap solution made specifically for the detection of

leaks to check all connections. A failure to follow this

warning could result in fire, explosion, personal injury, or

death.

Gas piping must be installed in accordance with national and local

codes. Refer to current edition of NFGC in the U.S., the NSCNG-

PIC in Canada.

RETURN AIR CONNECTIONS

Installations must be made in accordance with all authorities

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

separate line running directly from meter to furnace.

Never connect return-air ducts to the back of the furnace. A

failure to follow this warning can cause a fire, personal injury,

or death.

Refer to Table 4 for recommended gas pipe sizing. Risers must be

used to connect to furnace and to meter. Support all gas piping

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

every 6 ft. Joint compound (pipe dope) should be applied sparingly

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

the action of propane gas.

Downflow Furnaces

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

(bottom inlet) as shown in Fig. 1. DO NOT cut into casing sides

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

horizontal furnaces. Bypass humidifier connections should be

made at ductwork or coil casing sides exterior to furnace.

→

If local codes allow the use of a flexible gas appliance

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

connector which has previously serviced another gas appli-

ance. Black iron pipe shall be installed at the gas valve and

extend a minimum of 2-in. outside the furnace.

Upflow and Horizontal Furnaces

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

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

casing as shown in Fig. 1. Bypass humidifier may be attached to

unused side return air portion of the furnace casing. (See Fig. 18,

19, and 20.)

Not all horizontal furnaces are approved for side return air

connections. (See Fig. 20.)

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A02075

Fig. 18—Upflow Return Air Configurations and Restrictions

A02163

Fig. 19—Downflow Return Air Configurations and Restrictions

A02162

Fig. 20—Horizontal Return Air Configurations and Restrictions

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→

Table 4—Maximum Capacity of Pipe*

GAS

SUPPLY

NOMINAL

LENGTH OF PIPE (FT)

MANUAL

SHUTOFF

VALVE

(REQUIRED

SEDIMENT

TRAP

IRON

PIPE

SIZE

(IN.)

INTERNAL

DIAMETER

(IN.)

1/2

3/4

0.622

0.824

1.049

1.380

1.610

175

360

120

250

465

950

200

375

770

170 151

320 285

660 580

UNION

680

1-1/4

1-1/2

1400

2100 1460 1180 990 900

* Cubic ft of gas per hr for gas pressures of 0.5 psig (14–in. wc) or less and a

pressure drop of 0.5–in wc (based on a 0.60 specific gravity gas).

Ref: Table 12.2 NFPA 54-2002.

A02035

Fig. 21b—Typical Gas Pipe Arrangement

Connect gas pipe to gas valve using a backup wrench to avoid

damaging gas controls.

Use proper length of pipe to avoid stress on gas control

manifold. Failure to follow this warning could result in a gas

leak resulting in fire, explosion, personal injury, or death.

→ ^{If pressure exceeds 0.5 psig (14-in. wc), gas supply pipe must be}

disconnected from furnace and capped before pressure test. If test

pressure is equal to or less than 0.5 psig (14-in. wc), turn off

electric shutoff switch located on furnace gas control valve and

accessible manual shutoff valve before test. After all connections

have been made, purge lines and check for leakage.

→ An accessible manual shutoff valve MUST be installed external to

furnace casing and within 6 ft of furnace. A 1/8-in. NPT plugged

tapping, accessible for test gage connection, MUST be installed

immediately upstream of gas supply connection to furnace and

downstream of manual shutoff valve.

→ ^NOTE:The gas valve inlet pressure tap connection is suitable to

use as test gage connection providing test pressure DOES NOT

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

(See Fig. 50.)

→ ^{The gas supply pressure shall be within the maximum and}

minimum inlet supply pressures marked on the rating plate with

the furnace burners ON and OFF.

→ ^{Some installations require gas entry on right side of furnace (as}

Step 7—Electrical Connections

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

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

21b. Connect a capped nipple into lower end of tee. Capped nipple

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

union between gas control manifold and exterior manual equip-

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

for test gage connection, MUST be installed immediately upstream

of gas supply connection to furnace and downstream of manual

shutoff valve.

Blower access panel door switch opens 115-v power to

control center. No component operation can occur. Do not

bypass or close switch with panel removed. Failure to follow

this warning could result in personal injury or death.

See Fig. 24 for field wiring diagram showing typical field 115-v

wiring. Check all factory and field electrical connections for

tightness.

→ ^{Piping should be pressure and leak tested in accordance with}

NFGC in the United States or NSCNGPIC in Canada, local, and

national plumbing and gas codes before the furnace has been

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

check for leakage at furnace prior to operating furnace.

→ ^{Field-supplied wiring shall conform with the limitations of 63°F}

(33°C) rise.

90° Elbow

The cabinet MUST have an uninterrupted or unbroken ground

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

trical Code CSA C22.1 or local codes to minimize personal

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

electrical wire, conduit approved for electrical ground or a

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

when installed in accordance with existing electrical codes.

Refer to the power cord manufacturer’s ratings for proper

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

Failure to follow this warning could result in electrical shock,

fire, or death.

2" Nipple

Street Elbow

Gas Valve

A02327

→ Fig. 21a—Right Side Gas Entry Example

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→ Table 5—Electrical Data

OPERATING

VOLTAGE RANGE

VOLTS-

HERTZ-

PHASE

MAXIMUM

FUSE OR CKT BKR

AMPS†

MAXIMUM

UNIT

MAXIMUM

MINIMUM

WIRE GAGE

UNIT SIZE

UNIT AMPS AMPACITY# WIRE LENGTH (FT)‡

Maximum* Minimum*

045-08/024045 115-60-1

045-12/036045 115-60-1

070-08/024070 115-60-1

070-12/036070 115-60-1

070-16/048070** 115-60-1

090-14/042090 115-60-1

090-16/048090 115-60-1

090-20/060090** 115-60-1

110-12/036110 115-60-1

110-16/048110 115-60-1

110-22/066110 115-60-1

135-16/048135 115-60-1

135-22/066135 115-60-1

155-22/060155 115-60-1

127

104

5.6

7.0

7.77

9.47

5.0

7.06

6.7

9.19

9.8

12.59

10.83

12.95

17.60

10.75

13.12

17.62

13.12

18.55

19.33

8.1

9.8

12.9

8.2

10.1

13.7

10.1

14.4

15.0

* Permissible limits of the voltage range at which the unit operates satisfactorily.

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

amps.

† Time-delay type is recommended.

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

** Preliminary

Furnace control must be grounded for proper operation or

control will lock out. Control is grounded through

green/yellow wire routed to gas valve and manifold bracket

screw.

TWO

115-V WIRING

Verify that the voltage, frequency, and phase correspond to that

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

provided by utility is sufficient to handle load imposed by this

equipment. Refer to rating plate or Table 5 for equipment electrical

specifications. Make all electrical connections in accordance with

National Electrical Code (NEC) ANSI/NFPA 70-2002 and any

local codes or ordinances that might apply. For Canadian instal-

lations, all electrical connections must be made in accordance with

Canadian Electrical Code CSA C22.1 or authorities having juris-

diction.

A02099

Fig. 22—Relocating J-Box

3. Locate box to desired location.

Do not connect aluminum wire between disconnect switch

and furnace. Use only copper wire.

4. Fasten J-Box to casing with screws.

5. Route J-box wires within furnace away from sharp edges and

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

hot surfaces.

fuse or circuit breaker for this furnace. See Table 5 for wire size

and fuse specifications. A readily accessible means of electrical

ELECTRICAL CONNECTION TO J-BOX

disconnect must be located within sight of the furnace.

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

If manual disconnect switch is to be mounted on furnace,

polarity is incorrect, control LED status indicator light will flash

select a location where a drill or fastener will not contact

rapidly and furnace will NOT operate.

electrical or gas components.

J-BOX RELOCATION

1. Attach electrical box to J-Box bracket.

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

2. Route wires through hole in electrical box and J-Box bracket.

3. Secure ground wire to green screw on J-Box bracket.

4. Connect line voltage leads as shown in Fig. 24.

FOR POWER CORD INSTALLATION

section (J-Box Cover Installation).

NOTE: On 14″ wide casing models, the J-Box shall not be

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

routed within the casing.

1. Remove screws holding auxiliary J-box. (See Fig. 22.)

2. Cut wire tie on loop in wires to J-box.

Power cords must be able to handle the electrical requirements

listed in Table 5. Refer to power cord manufacturer’s listings.

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TWINNING AND/OR

COMPONENT TEST

TERMINAL

BLOWER OFF-DELAY

J2 JUMPER

BLOWER OFF-DELAY

HUMIDIFIER TERMINAL

(24-VAC 0.5 AMP MAX.)

24-V THERMOSTAT

TERMINALS

TRANSFORMER 24-VAC

CONNECTIONS

TEST/TWIN

HUM

0.5 AMP@24VAC

3-AMP FUSE

FUSE 3-AMP

SEC-2 SEC-1

LED OPERATION &

DIAGNOSTIC LIGHT

EAC-2

PL1-LOW VOLTAGE MAIN

HARNESS CONNECTOR

115-VAC(L2)NEUTRAL

CONNECTIONS

COOL

HEAT

1-AMP@

115VAC

SPARE-1 SPARE-2

PR-1

EAC-1

PL2

SPARE-1

SPARE-2

PL2-HOT SURFACE

IGNITER & INDUCER

MOTOR CONNECTOR

115 VAC (L1) LINE

VOLTAGE CONNECTION

BLOWER SPEED

SELECTION TERMINALS

EAC-1 TERMINAL

(115-VAC 1.0 AMP MAX.)

A02100

Fig. 23—Furnace Control

1. Route listed power cord through hole in J-Box.

maintenance could cause this fuse to blow. If fuse replacement is

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

2. Secure power cord to J-Box bracket with a strain relief

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

ACCESSORIES

1. Electronic Air Cleaner (EAC)

3. Secure ground wire to green screw on J-Box bracket.

4. Connect line voltage leads as shown in Fig. 24.

FOR BX CABLE INSTALLATION

Connect an accessory Electronic Air Cleaner (if used) using

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

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

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

maximum and are energized during blower motor operation.

1. Route BX cable to hole in J-Box.

2. Secure BX cable to J-Box bracket with connectors approved

for the type of cable used.

2. Humidifier (HUM)

Connect an accessory 24 VAC, 0.5 amp maximum humidifier

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

C^OM-24V screw terminal on the control board thermostat strip.

The HUM terminal is energized when pressure switch (PRS)

closes.

3. Secure ground wire to green screw on J-Box bracket.

4. Connect line voltage leads as shown in Fig. 24.

J-BOX COVER INSTALLATION

1. Remove J-Box cover from blower access door on furnace and

reinstall blower access door screw.

NOTE: A field-supplied, 115-v controlled relay connected to

EAC terminals may be added if humidifier operation is desired

during blower operation.

2. Fold tab on J-box cover to bracket with pliers.

3. Insert tab of J-box cover into slot of J-box bracket.

4. Secure J-Box cover to bracket with screw provided.

5. Remove U-shaped cut-out from outer door to clear J-box.

24-V WIRING

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

23.) Connect terminal Y as shown in Fig. 24 for proper cooling

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

wire.

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

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

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FIELD 24-V WIRING

FIELD 115-, 208/230-, 460-V WIRING

FACTORY 24-V WIRING

FACTORY 115-V WIRING

NOTE 2

THERMOSTAT

TERMINALS

FIVE WIRE

FIELD-SUPPLIED

DISCONNECT

THREE-WIRE

HEATING-ONLY

208/230- OR

460-V

BLOWER DOOR SWITCH

THREE

PHASE

BLK

WHT

208/230-V

SINGLE

PHASE

GND

AUXILIARY

J-BOX

115-V FIELD-

SUPPLIED

DISCONNECT

COM

GND

NOTE 1

CONDENSING

UNIT

Y/Y2

TWO

WIRE

24-V

TERMINAL

BLOCK

NOTES: 1. Connect Y-terminal in furnace as shown for proper blower operation.

2. Some thermostats require a "C" terminal connection as shown.

3. If any of the original wire, as supplied, must be replaced, use

same type or equivalent wire.

FURNACE

A99440

Fig. 24—Heating and Cooling Application Wiring Diagram with 1–Stage Thermostat

→ ^{When an existing furnace is removed or replaced in a venting}

system, the venting system may not be properly sized to vent the

attached appliances. An improperly sized Category I venting

system could cause the formation of condensate in the furnace and

vent, leakage of condensate and combustion products, and spillage

of combustion products into the living space, etc.

DO NOT connect furnace control HUM terminal to HUM

(humidifier) terminal on Thermidistat™, Zone Controller or

similar device. See Thermidistat™, Zone Controller, thermo-

stat, or controller manufacturer’s instructions for proper

connection.

Step 8—Venting

→ ^{The furnace shall be connected to a factory built chimney or vent}

complying with a recognized standard, or a masonry or concrete

chimney lined with a lining material acceptable to the authority

having jurisdiction. Venting into an unlined masonry chimney or

concrete chimney is prohibited.

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The following information and warning must be considered in

addition to the requirements defined in the NFGC and the

NSCNGPIC.

CARBON MONOXIDE POISONING HAZARD

Failure to follow the steps outlined below for each appliance

connected to the venting system being placed into operation

could result in carbon monoxide poisoning or death.

The following steps shall be followed for each appliance

connected to the venting system being placed into operation,

while all other appliances connected to the venting system are

not in operation:

1. Seal any unused openings in venting system.

2. Inspect the venting system for proper size and horizontal

pitch, as required in the National Fuel Gas Code, ANSI

Z223.1/NFPA 54 or the CSA B149.1, Natural Gas and

Propane Installation Codes and these instructions. Deter-

mine that there is no blockage or restriction, leakage,

corrosion and other deficiencies, which could cause an

unsafe condition.

1. If a vent (common or dedicated) becomes blocked, the furnace

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

vent elbow.

Do not bypass the draft safeguard switch, as an unsafe

condition could exist which must be corrected. Failure to

follow this warning could result in a build-up of carbon

monoxide and lead to personal injury or death.

2. Do not connect this appliance to a single-wall dedicated or

common vent. The dedicated or common vent is considered to

be the vertical portion of the vent system that terminates

outdoors.

3. Vent connectors serving Category I furnaces shall not be

connected into any portion of a mechanical draft system

operating under positive pressure.

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

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

connected to the venting system are located and other

spaces of the building.

4. In the US, do not vent this appliance with any solid fuel

burning appliance. In Canada, check with the authority having

jurisdiction for approval on use with solid fuel burning

appliance.

4. Close fireplace dampers.

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

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

range hoods and bathroom exhausts, so they are operating

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

6. Follow the lighting instructions. Place the appliance being

inspected into operation. Adjust the thermostat so appli-

ance is operating continuously.

7. Test for spillage from draft hood equipped appliances at the

draft hood relief opening after 5 minutes of main burner

operation. Use the flame of a match or candle.

→ ^{5. Category I furnaces must be vented vertically or nearly}

vertically unless equipped with a listed power ventor.

→ ^{6. Do not vent this appliance into an unlined masonry chimney.}

Refer to Chimney Inspection Chart, Fig. 25.

MASONRY CHIMNEY REQUIREMENTS

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

tests, the venting system must be corrected in accordance

with the National Fuel Gas Code, ANSI Z223.1/NFPA 54

and/or CSA B149.1, Natural Gas and Propane Installation

Codes.

9. After it has been determined that each appliance connected

to the venting system properly vents when tested as

outlined above, return doors, windows, exhaust fans,

fireplace dampers and any other gas-fired burning appli-

ance to their previous conditions of use.

These furnaces are CSA design-certified for use in exterior

clay tile-lined masonry chimneys with a factory accessory

Chimney Adapter Kit. Refer to the furnace rating plate for

correct kit usage. The Chimney Adapter Kits are for use with

ONLY furnaces having a Chimney Adapter Kit number

marked on the furnace rating plate.

If a clay tile-lined masonry chimney is being used and it is exposed

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

Chimneys shall conform to the Standard for Chimneys, Fireplaces,

Vents, and Soild Fuel Burning Appliances ANSI/NFPA 211-2000

in the United States and to a Provincial or Territorial Building

Code in Canada (in its absence, the National Building Code of

Canada) and must be in good condition.

→ Vent system or vent connectors may need to be resized. For any

other appliances when resizing vent systems or vent connectors,

system or connector must be sized to approach minimum size as

determined using appropriate table found in the NFGC or NSC-

NGPIC.

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

authority having jurisdiction to determine whether relining is

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

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

GENERAL VENTING REQUIREMENTS

Follow all safety codes for proper vent sizing and installation

requirements, including local building codes, the National Fuel

Gas Code (NFGC) ANSI Z223.1-2002/NFPA 54-2002, Parts 7 and

13 in the United States or the National Standard of Canada, Natural

Gas and Propane Installation Code (NSCNGPIC) CSA-B149.1-00,

Section 7 and Appendix C in Canada.

These furnaces are design-certified as Category I furnaces in

accordance with ANSI Z21.47/CSA 2.3-2001 and operate with a

non-positive vent static pressure to minimize the potential for vent

gas leakage. Category I furnaces operate with a flue loss not less

than 17 percent to minimize the potential for condensation in the

venting system. These furnaces are approved for common venting

and multi-story venting with other fan assisted or draft hood

equipped appliances in accordance with the NFCG or the NSC-

NGPIC.

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NOTE: See the NFGC, 13.1.9 and 13.2.20 regarding alternative

venting design and the exception, which cover installations such as

Table B—Minimum Allowable Input Rating of

Space-Heating Appliance in

the

Chimney

Adapter

Kits

KGACA02014FC

and

Thousands of BTU per Hour

KGACA02015FC, which are listed for use with these furnaces.

INTERNAL AREA OF CHIMNEY

The Chimney Adapter Kit is listed alternative venting design for

these furnaces. See the kit instructions for complete details.

VENT

HEIGHT (FT)

(SQ. IN.)

Local 99% Winter Design

Temperature: 17 to 26 degrees F*

Canada-This furnace is permitted to be vented into a clay

tile-lined masonry chimney that is exposed to the outdoors below

the roof line, provided:

141

154

169

212

258

362

111

125

167

212

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

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

equipped appliance, and

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

capacity given in Table A, and

Local 99% Winter Design

Temperature: 5 to 16 degrees F*

4. The input rating of each space heating appliance is greater

than the minimum input rating given in the appropriate Table

B for Masonry Chimneys for the local winter design tempera-

ture. Chimneys having internal areas greater than 38 square

inches require furnace input ratings greater than the input

ratings of these furnaces. See footnote at bottom of Table B,

and

121

135

149

193

166

182

198

247

293

377

111

Local 99% Winter Design

Temperature: -10 to 4 degrees F*

5. The authority having jurisdiction approves.

145

159

175

196

213

231

283

333

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

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

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

system, or a Type-B common vent.

Exterior Masonry Chimney,

FAN + NAT Installations with

Type-B Double-Wall Vent Connectors

Local 99% Winter Design

Temperature: -11 degrees F or lower*

Not recommended for any vent

configuration

Table A—Combined Appliance

Maximum Inut Rating in

Thousands of BTU per Hour

INTERNAL AREA OF CHIMNEY

VENT

HEIGHT (FT)

(SQ. IN.)

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

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

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

2001 ASHRAE Fundamentals Handbook, Climatic Design Information chap-

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

119

130

138

152

178

193

207

233

250

257

279

299

334

368

404

Inspections before the sale and at the time of installation will

determine the acceptability of the chimney or the need for repair

and/or (re)lining. Refer to Fig. 25 to perform a chimney inspection.

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

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

be relined in accordance with local codes and the authority

having jurisdiction. The chimney should be relined with a

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

kit shall be used to reduce condensation. If a condensate

drain is required by local code, refer to the NFGC, Section

10.9 for additional information on condensate drains.

b. Indicates the chimney exceeds the maximum permissible

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

to conform to the requirements of the equipment being

installed and the authority having jurisdiction.

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

condition, shall be rebuilt to conform to ANSI/NFPA 211 or be

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

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

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

NOTE: Vent connector length for connector sizing starts at

furnace vent elbow. The 4 inch vent elbow is shipped for upflow

configuration and may be rotated for other positions. Remove the

3 screws that secure vent elbow to furnace, rotate furnace vent

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

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

connector elbows.

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

appliance shall be vented into the annular space between the

chimney and the metal liner.

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

the door.

1. Attach the single wall vent connector to the furnace vent

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

least two field-supplied, corrosion-resistant, sheet metal

screws located 180° apart.

APPLIANCE APPLICATION REQUIREMENTS

Appliance operation has a significant impact on the performance

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

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

appliances should not suffer from condensation and corrosion. The

venting system and all appliances shall be installed in accordance

with applicable listings, standards, and codes.

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

Fig. 26–38.

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

heating load requirement plus any margin that occurs because of

furnace model size capacity increments. Heating load estimates

can be made using approved methods available from Air Condi-

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

Heating, Refrigerating, and Air-Conditioning Engineers; or other

approved engineering methods. Excessive oversizing of the fur-

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

Personal injury can result form sharp metal edges, etc. Be

careful when removing parts. Gloves and safety glasses

should be worn when servicing equipment.

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

cutout to be removed.

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

cut-out on door.

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

condition and be installed in accordance with the vent manufac-

turer’s instructions.

An accessory Vent Guard Kit, KGAVG0101DFG is REQUIRED

for downflow applications for use where the vent exits through the

lower portion of the furnace casing door. Refer to the Vent Guard

Kit Instructions for complete details.

To prevent condensation in the furnace and vent system, the

following precautions must be observed:

1. The return-air temperature must be at least 60°F db except for

brief periods of time during warm-up from setback at no lower

than 55°F db or during initial start-up from a standby

condition.

The horizontal portion of the venting system shall maintain a

minimum of 1/4-in. upward slope per linear ft and it shall be

rigidly supported every 5 ft or less with metal hangers or straps to

ensure there is no movement after installation.

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

gas input rate causes low vent gas temperatures, causing

condensation and corrosion in the furnace and/or venting

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

SIDEWALL VENTING

This furnace is not approved for direct sidewall horizontal venting

without the use of an add-on power venter.

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

slightly above. Low air temperature rise can cause low vent

gas temperature and potential for condensation problems.

In the U.S.: Per the NFGC, any listed power venter may be used,

when approved by the authority having jurisdiction.

In Canada: Only power venters approved by the appliance

manufacturer and where allowed by the authority having jurisdic-

tion may be used for sidewall venting.

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

cycling.

Air for combustion must not be contaminated by halogen com-

pounds which include chlorides, fluorides, bromides, and iodides.

These compounds are found in many common home products such

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

salt, and air freshener, and can cause corrosion of furnaces and

vents. Avoid using such products in the combustion-air supply.

Furnace use during construction of the building could cause the

furnace to be exposed to halogen compounds, causing premature

failure of the furnace or venting system due to corrosion.

The only approved power venter is the Field Controls SWG-4D

and SWG-5D sidewall power venter. Select the power venter to

match the btuh input of the appliance being vented. Follow all

manufacturer’s installation requirements for venting and termina-

tion included with the power venter.

START-UP, ADJUSTMENT, AND SAFETY CHECK

Step 1—General

Vent dampers on any appliance connected to the common vent can

cause condensation and corrosion in the venting system. Do not

use vent dampers on appliances common vented with this furnace.

This furnace is equipped with manual reset limit switches in

the gas control area. The switches open and shut off power to

the gas valve if a flame rollout or overheating condition

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

Correct inadequate combustion air supply problem and reset

the switches. Failure to follow this warning can cause fire,

explosion, personal injury, or death.

ADDITIONAL VENTING REQUIREMENTS

A 4″ round vent elbow is supplied with the furnace. A 5 inch or 6

inch vent connector may be required for some model furnaces. A

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

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

is used. See Fig. 26–38 Venting Orientation for approved vent

configurations.

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CHIMNEY INSPECTION CHART

For additional requirements refer to the National Fuel Gas Code NFPA 54/ANSI Z223.1 and ANSI/NFPA 211

Chimneys, Fireplaces, Vents, and Solid Fuel Burning Appliances in the U.S.A. or to the Canadian

installation Codes CSA-B149.1 in Canada.

Crown

Rebuild

crown.

condition:

Missing mortar

or brick?

Yes

Is chimney

property lined with

clay tile liner?

Yes

Repair

Reline

liner or top seal

or reline chimney as

necessary.

liner and top

seal in good

condition?

Repair

Yes

Debris

Mortar

or tile

debris?

in cleanout?

Yes

Remove mortar

and tile debris

Mortar, tile, metal vent

fuel oil residue?

Remove metal vent

or liner.

Clay

Yes

tile misalignment,

missing sections,

gaps?

Consult

Part B of

Not Suitable

chimney adapter venting

instructions for

application

suitability.

Is chimney

lined with properly

sized, listed liner or

Type-B vent?

Line chimney with property

sized, listed flexible metal

liner or Type-B vent per

NFGC or NSCNGPIC Vent

Sizing Tables and liner or

vent manufacturer’s

Condensate

drainage at bottom

of chimney?

Suitable

Yes

Install chimney

adapter per

instructions.

Installation instructions.

Not Suitable

Consult

Yes

Chimney

exposed to

outdoors below

roof line?

Part C of

chimney adapter venting

instructions for

application

Is chimney

to be dedicated to

a single

Suitable

Yes

furnace?

suitability

Install chimney

adapter per

instructions.

Chimney is

acceptable for use.

A02101

Fig. 25—Chimney Inspection Chart

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6. Verify furnace restarts by raising thermostat setting above

room temperature.

Personal injury can result form sharp metal edges, etc. Be

careful when removing parts. Gloves and safety glasses

should be worn when servicing equipment.

Step 3—Adjustments

1. Maintain 115-v wiring and ground. Improper polarity will

result in rapid flashing LED and no furnace operation.

2. Make thermostat wire connections at the 24-v terminal block

on the furance control. Failure to make proper connections

will result in improper operation. (See Fig. 24.)

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.

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

wc (0.16 psig) but not exceed 14-in. wc (0.5 psig).

4. Check all manual-reset switches for continuity.

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

operate furnace.

DO NOT redrill orifices. Improper drilling (burrs, out-of-

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

misdirection of burner flames. This can result in flame

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

41.)

6. Replace outer door.

Step 2—Start-Up Procedures

Furnace gas input rate on rating plate is for installations at altitudes

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

furnace rating plate input.

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

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

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

to check for leakage. Failure to follow this warning can cause

fire, explosion, personal injury, or death.

In the U.S.A., the input rating for altitudes above 2,000 ft. must be

reduced by 4 percent for each 1,000 ft. above sea level. In Canada,

input rating must be reduced by 10 percent for altitudes of 2,000

ft. to 4,500 ft. above sea level.

1. Purge gas lines after all connections have been made.

2. Check gas lines for leaks.

1. Determine the correct gas input rate.

In the U.S.:

For installations below 2000 ft., refer to the unit rating plate.

For installations above 2000 ft., multiply the input on the

rating plate by the de-rate multiplier in Table 6 for the correct

input rate.

→

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

component operation can occur unless switch is closed.

Caution must be taken when manually closing this switch for

service purposes. Failure to follow this warning could result

in electrical shock, personal injury, or death.

In Canada:

At installation altitudes from 2000 to 4500 ft, this furnace must be

derated 10 percent by an authorized Gas Conversion Station or

Dealer. To determine correct input rate for altitude, see example 1

and use 0.90 as derate multiplier factor.

3. To Begin Component Self-Test: Disconnect the thermostat R

lead from furnace control board. Manually close the blower

door switch. Briefly short the TEST/TWIN terminal to the

C^OM24V terminal until LED goes out. Remove jumper from

terminals. (See Fig. 23.)

EXAMPLE 1:

88,000 BTUH INPUT FURNACE INSTALLED AT 4300 FT.

Derate

Multiplier

Factor

0.90

Furnace Input Rate

at Installation

Altitude

Furnace Input Rate

at Sea Level

88,000

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

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

diagnose a system problem in case of a component failure.

Component test feature will not operate if any thermostat signal is

present at the control.

79,200

2. Determine the correct orifice and manifold pressure adjust-

ment. There are two different orifice and manifold adjustment

tables.

All models in all positions, except Low NOx models in

downflow or horizontal positions, use Table 10 (22,000

BTUH/Burner)

Low NOx models in the downflow or horizontal positions

must use Table 11 (21,000BTUH/Burner). See input listed on

furnace rating plate.

Component test sequence is as follows:

Refer to service label attached to furnace or see Fig. 43.

a. LED will display previous status code 4 times.

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

component test sequence.

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

from local gas supplier.

c. Hot surface ignitor is energized for 15 sec., then off.

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

e. Blower motor operates on COOL speed for 10 sec.

f. Inducer motor stops.

b. Obtain average yearly gas specific gravity from local gas

supplier.

c. Find installation altitude in Table 10 or 11.

g. Reconnect R lead to furnace control board, release blower

door switch and re-install blower door.

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

Table 10 or 11.

4. Operate furnace per instruction on door.

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

intersection to find orifice size and manifold pressure

settings for proper operation.

5. Verify furnace shut down by lowering thermostat setting

below room temperature.

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

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

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

A02060

A02058

A02059

Fig. 26—Upflow Application-

Fig. 27—Upflow Application-

Fig. 28—Downflow

Application-Vent Elbow Up

then Left

Vent Elbow Up

Vent Elbow Right

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

A02061

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

A02062

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

A02063

Fig. 29—Downflow

Application-Vent Elbow Up

Fig. 30—Downflow

Application-Vent Elbow Left

then Up

Fig. 31—Downflow

Application-Vent Elbow Up

then Right

See Venting Notes on page 26.

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

A02064

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

Fig. 32—Horizontal Left Application-Vent Elbow Left

A02067

Fig. 35—Horizontal Left Application-Vent Elbow Right

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

A02065

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

Fig. 33—Horizontal Left Application-Vent Elbow Right

then Up

A02068

Fig. 36—Horizontal Right Application-Vent Elbow Left

See Venting Notes on Page 26

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

A02066

Fig. 34—Horizontal Left Application-Vent Elbow Up

f. Check and verify burner orifice size in furnace. NEVER

ASSUME ORIFICE SIZE. ALWAYS CHECK AND

VERIFY.

c. Connect a water column manometer or similar device to

manifold pressure tap.

d. Turn gas valve ON/OFF switch to ON.

e. Set thermostat to call for heat.

g. Replace orifice with correct size if required by Table 13 or

14. Use only factory-supplied orifices. See EXAMPLE 2.

f. Jumper R and W thermostat connections on furnace control

board to start furnace.

22,000 BTUH burner applications use Table 10

EXAMPLE 2: (0–2000 ft altitude)

Heating value = 1000 Btu/cu ft

Specific gravity = 0.62

Therefore: Orifice No. 43*

g. Remove regulator seal cap and turn regulator adjusting

screw counterclockwise (out) to decrease input rate of

clockwise (in) to increase input rate.

h. Install regulator seal cap.

Manifold pressure: 3.7-in. wc

i. Leave manometer or similar device connected and proceed

to Step 4.

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

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

to be changed to obtain proper input rate.

NOTE: DO NOT set manifold pressure less than 3.2-in wc or

more than 3.8-in. wc for natural gas at sea level. If manifold

pressure is outside this range, change main burner orifices or refer

Table 10 or 11.

3. Adjust manifold pressure to obtain correct input rate.

a. Turn gas valve ON/OFF switch to OFF

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

been redrilled, check orifice hole with a numbered drill bit of

correct size. Never redrill an orifice. A burr-free and squarely

aligned orifice hole is essential for proper flame characteristics.

b. Remove manifold pressure tap plug from gas valve. (See

Fig. 40.)

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Venting Notes for Fig. 26-38

1. For common vent, vent connector sizing and vent material: United

States, latest edition of the National Fuel Gas Code (NFGC), ANSI

Z223.1/NFPA 54. In Canada, latest edition of the National Standards

of Canada, Natural Gas and Propane Installation Code (NSCNGPIC),

CSA B149.1-00.

2. Immediately increase to 5–inch vent connector outside furnace

casing when 5-inch vent connector required, refer to Note 1 above.

3. Side outlet vent for upflow and downflow installations must use

Type B vent immediately after exiting the furnace, except when

KGAVG0101DFG is used in the downflow position.

A02069

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

Fig. 37—Horizontal Right Application-Vent Elbow

Right

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

5. 4” single wall (26 ga. min.) vent must be used inside furnace casing

and when the KGAVG0101DFG Downflow Vent Guard Kit is used

external to the furnace.

6. Accessory Downflow Vent Guard Kit, KGAVG0101DFG required

in downflow installations with bottom vent configuration.

7. Chimney Adapter Kit required for exterior masonry chimney

applications. Refer to Chimney Adapter Kit, KGACA02014FC and

KGACA02015FC for sizing and complete application details.

8. Secure vent connector to furnace elbow with (2) corrosion-resistant

sheet metal screws, spaced approximately 180° apart.

9. Secure all other single wall vent connector joints with (3) corrosion

resistant screws spaced approximately 120° apart. Secure Type B vent

connectors per vent connector manufacturer’s recommendations.

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

A02070

Fig. 38—Horizontal Right Application-Vent Elbow Left

then Up

4. Verify natural gas input rate by clocking meter.

NOTE: Gas valve regulator adjustment cap must be in place for

proper input to be clocked.

Disconnect 115-v electrical power before changing speed tap.

Failure to follow this warning could result in personal injury.

a. Turn off all other gas appliances and pilots.

b. Run furnace for 3 minutes in heating operation.

c. Adjust air temperature rise by adjusting blower speed.

Increase blower speed to reduce temperature rise. Decrease

blower speed to increase temperature rise.

c. Measure time (in sec) for gas meter to complete 1 revolu-

tion and note reading. The 2 cubic feet dial provides a more

accurate measurement of gas flow.

d. Turn thermostat down below room temperature and re-

move blower access door.

d. Refer to Table 8 for cubic ft of gas per hr.

e. To change motor speed selection for heating, remove

blower motor lead from control HEAT terminal (See Fig.

39.) Select desired blower motor speed lead from one of the

other terminals and relocate it to the HEAT terminal (See

Table 7 for lead color identification). Reconnect original

lead to SPARE terminal.

e. Multiply gas rate (cu ft/hr) by heating value (Btu/cu ft) to

obtain input.

If clocked rate does not match required input from Step 1, increase

manifold pressure to increase input or decrease manifold pressure

to decrease input. Repeat steps b through e until correct input is

achieved. Re-install regulator seal cap on gas valve.

f. Repeat steps a through e.

5. Set temperature rise.

g. When correct input rate and temperature rise is achieved,

turn gas valve ON/OFF switch to OFF.

The furnace must operate within the temperature rise ranges

specified on the furnace rating plate. Do not exceed tempera-

ture rise range specified on unit rating plate. Determine the

temperature rise as follows:

h. Remove manometer or similar device from gas valve.

i. Re-install manifold pressure tap plug in gas valve.

a. Place thermometers in return and supply ducts as close to

furnace as possible. Be sure thermometers do not see

radiant heat from heat exchangers. Radiant heat affects

temperature rise readings. This practice is particularly

important with straight-run ducts.

Failure to reinstall manifold pressure tap plug in gas valve

will result in fire, explosion, personal injury, property damage

or death.

b. When thermometer readings stabilize, subtract return-air

temperature from supply-air temperature to determine air

temperature rise.

j. Re-install blower access door if removed.

k. Turn gas valve ON/OFF switch to ON.

NOTE: Blower access door must be installed for proper tempera-

ture rise measurement.

NOTE: If the temperature rise is outside this range, first check:

1.) Gas input for heating operation.

2.) Derate for altitude if applicable.

3.) Return and supply ducts for excessive restrictions causing static

pressures greater than 0.50-in. wc.

Recheck temperature rise. It must be within limits specified

on the rating plate. Recommended operation is at the mid-

point of rise range or slightly above

4.) Dirty filter.

6. Set thermostat heat anticipator.

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. E

R E V 9 - 1 0 1 2 3 7 5 5

L 2

R A U T N E

PRINTED CIRCIUT BOARD

Y E

N A T R

H S

E L Y /

G R N

R E D

U B L

0 1

1 1

1 5 2 6

J 2

R A U T N E

T E O # N 8

W B L

PRINTED CIRCIUT BOARD

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Caution!! For the following applications, use the minimum vertical vent sections as specified below.

For all other applications, follow exclusively the National Fuel Gas Code.

MINIMUM

VENT DIAMETER (IN.)*

FURNACE ORIENTATION

VENT ORIENTATION

FURNACE INPUT(BTU/HR)

MINIMUM VERTICAL VENT HEIGHT (FT)**

154,000

132,000

110,000(036/-12 only)

Vent elbow left, then up

Fig. 30

Downflow

Vent elbow right,

then up

154,000

132,000

Horizontal Left

Fig. 33

Vent Elbow up

Fig. 34

154,000

132,000

Horizontal Left

Downflow

Vent elbow right

Fig. 35

154,000

Vent elbow up then left

Fig. 28

110,000

(036/-12 only)

Vent elbow up, then right

Fig. 31

110,000

(036/-12 only)

Downflow

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

*4 in. inside casing or vent guard

**Including 4 in. vent section(s)

Table 6–Altitude Derate Multipler for U.S.A.

ALTITUDE

(FT)

PERCENT

OF DERATE

DERATE MULTIPLIER

FACTOR*

0–2000

1.00

0.90

0.86

0.82

0.78

0.74

0.70

0.66

0.62

2001–3000

3001–4000

4001–5000

5001–6000

6001–7000

7001–8000

8001–9000

9001–10,000

8–12

12–16

16–20

20–24

24–28

28–32

32–36

36–40

BURNER

ORIFICE

* Derate multiplier factors are based on midpoint altitude for altitude range.

ON AND OFF

SWITCH

A93059

Fig. 41—Orifice Hole

Table 7—Speed Selection

GAS PRESSURE

COLOR

White

Black

SPEED

Common

High

AS SHIPPED

BLW

REGULATOR

ADJUSTMENT

COOL

Yellow†

Blue*

Med-High

Med-Low

Low

SPARE

HEAT

Red*

* 1/5 HP motor models: BLUE to HEAT, RED to SPARE.

† Not available on 1/5 HP motors.

NOTE: Continuous blower is the HEAT speed.

(1.) Remove thermostat from subbase or from wall.

INLET

PRESSURE

TAP

(2.) Connect an amp meter as shown in Fig. 42 across the

R and W terminals or R and W wires.

MANIFOLD

PRESSURE TAP

A00157

(3.) Record amp draw across terminals when furnace is in

heating and after blower starts.

Fig. 40—Redundant Automatic Gas Control Valve

(4.) Set heat anticapator on thermostat per thermostat

instructions and install on subbase or wall.

a. Mechanical thermostat—Set thermostat heat anticipator to

match the amp draw of the electrical components in the

R-W circuit. Accurate amp draw readings can be obtained

at the wires normally connected to thermostat subbase

terminals, R and W. The thermostat anticipator should

NOT be in the circuit while measuring current.

b. Electronic thermostat: Set cycle rate for 4 cycles per hr.

7. Adjust blower off delay

The blower off delay has 4 adjustable settings from 90 sec to

180 sec. The blower off delay jumpers are located on the

furnace control board. (See Fig. 23.)

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Table 8–GAS RATE (CU FT/HR)

SIZE OF TEST DIAL

SECONDS

FOR 1

REVOLUTION

SECONDS

FOR 1

REVOLUTION

THERMOSTAT SUBBASE

TERMINALS WITH

THERMOSTAT REMOVED

(ANITICIPATOR, CLOCK, ETC.,

MUST BE OUT OF CIRCUIT.)

Cu Ft Cu Ft 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

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

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

144

141

138

136

133

131

129

126

124

122

120

116

112

109

106

103

100

360

355

346

340

333

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

HOOK-AROUND

AMMETER

10 TURNS

FROM UNIT 24-V

CONTROL TERMINALS

0.5 AMPS FOR THERMOSTAT

ANTICIPATOR SETTING

5.0 AMPS ON AMMETER

10 TURNS AROUND JAWS

EXAMPLE:

A96316

Fig. 42—Amp Draw Check With Ammeter

d. Burners will re-light when furnace cools down.

2. Check draft safeguard switch.

The purpose of this control is to permit the safe shutdown of

the furnace during certain blocked vent conditions.

a. Verify vent pipe is cool to the touch.

100

102

104

106

108

110

112

116

120

b. Disconnect power to furnace and remove vent connector

from furnace vent elbow.

c. Restore power to furnace and set room thermostat above

room temperature.

d. After normal start-up, allow furnace to operate for 2

minutes, then block vent elbow in furnace 80 percent of

vent area with a piece of flat sheet metal.

e. Furnace should cycle off within 2 minutes.

f. Remove blockage and reconnect vent pipe to furnace vent

elbow.

g. Switch will auto-reset when it cools.

To change the blower off delay setting, move the jumper from

one set of pins on the control to the pins used for the selected

blower off delay. Factory off delay setting is 120 sec.

h. If control board locks out furnace, cycle 115 vac power to

reset control.

3. Check Pressure Switch(es)

Step 4—Check Safety Controls

This control proves operation of the draft inducer blower.

The flame sensor, gas valve, and pressure switch were all checked

in the Start-up procedure section as part of normal operation.

a. Turn off 115-v power to furnace.

b. Disconnect inducer motor lead wires from wire harness.

c. Turn on 115-v power to furnace.

1. Check Main Limit Switches

This control shuts off combustion control system and ener-

gizes air-circulating blower motor, if furnace overheats. By

using this method to check limit control, it can be established

that limit is functioning properly and will operate if there is a

restricted duct system or motor failure. If limit control does

not function during this test, cause must be determined and

corrected.

d. Set thermostat to ″call for heat″ and wait 1 minute. When

pressure switch is functioning properly, hot surface igniter

should NOT glow and control diagnostic light flashes a

status code 32. If hot surface igniter glows when inducer

motor is disconnected, shut down furnace immediately.

e. Determine reason pressure switch did not function properly

and correct condition.

a. Run furnace for at least 5 minutes.

b. Gradually block off return air with a piece of cardboard or

sheet metal until the limit trips.

f. Turn off 115-v power to furnace.

g. Reconnect inducer motor wires, replace outer door, and

turn on 115-v power.

c. Unblock return air to permit normal circulation.

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Step 5—Checklist

The control system also requires an earth ground for proper

operation of the control and flame-sensing electrode.

1. Put away tools and instruments. Clean up debris.

2. Check that blower OFF-DELAY time is selected as desired.

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

on the control. (See Fig. 23.) Any shorts of the 24-v wiring during

installation, service, or maintenance will cause this fuse to blow. If

fuse replacement is required, use ONLY a 3-amp fuse. The control

LED will display status code 24 when fuse needs to be replaced.

3. Verify that blower and burner access doors are properly

installed.

4. Cycle test furnace with room thermostat.

5. Check operation of accessories per manufacturer’s instruc-

Proper instrumentation is required to service electrical controls.

The control in this furnace is equipped with a Status Code LED

(Light-Emitting Diode) to aid in installation, servicing, and

troubleshooting. It can be viewed through the sight glass in blower

access door. The furnace control LED is either ON continuously,

rapid flashing, or a code composed of 2 digits. The first digit is the

number of short flashes, the second digit is the number of long

flashes.

tions.

6. Review User’s Guide with owner.

7. Leave literature packet near furnace.

SERVICE AND MAINTENANCE PROCEDURES

For an explanation of status codes, refer to service label located on

blower access door or Fig. 43, and the troubleshooting guide at the

end of this procedure. The furnace control will store 1 status code

for 72 hours.

The ability to properly perform maintenance on this equip-

ment requires certain knowledge, mechanical skills, tools, and

equipment. If you do not possess these, do not attempt to

perform any maintenance on this equipment other than those

procedures recommended in the User’s Manual. FAILURE

TO FOLLOW THIS WARNING COULD RESULT IN

POSSIBLE DAMAGE TO THIS EQUIPMENT, SERIOUS

PERSONAL INJURY, OR DEATH.

For Controls With a Red LED

The stored status codes WILL be erased from the control memory,

if 115- or 24-v power is interrupted.

1. To retrieve status code, proceed with the following:

NOTE: NO thermostat signal may be present at control, and all

blower-OFF delays must be completed.

a. Leave 115-v power to furnace turned on.

b. Remove outer access door.

→

ELECTRICAL SHOCK, FIRE, OR EXPLOSION HAZARD

Failure to follow safety warnings exactly could result in

dangerous operation, serious injury, death, or property dam-

age.

Improper servicing could result in dangerous operation,

serious injury, death, or property damage.

- Before servicing, disconnect all electrical power to furnace.

- When servicing controls, label all wires prior to disconnect-

ing. Reconnect wires correctly.

c. Look into blower access door sight glass for current LED

status. DO NOT remove blower access door or terminate

115-v power to control or status code will be lost.

d. BRIEFLY remove insulated terminal wire from the draft

safeguard switch (DSS) until LED goes out (1 to 2 sec),

then reconnect it.

2. When above items have been completed, the LED flashes

status code 4 times. Record this status code for further

troubleshooting.

- Verify proper operation after servicing.

3. Component self-test will begin. Refer to COMPONENT

TEST section for complete test sequence.

Label all wires prior to disconnection when servicing con-

trols. Wiring errors can cause improper and dangerous

operation.

4. Check LED status.

5. Refer to the SERVICE label on the front of the blower access

door for more information.

Step 1—Introduction

Component Self-Test

GENERAL

Component Test can also be initiated by performing the following:

1. Remove outer access door.

These instructions are written as if the furnace is installed in an

upflow application. An upflow furnace application is where the

blower is located below the combustion and controls section of the

furnace, and conditioned air is discharged upward. Since this

furnace can be installed in any of the 4 positions shown in Fig. 4,

you must revise your orientation to component location accord-

ingly.

2. Remove blower access door.

3. Remove the wire from the ″R″ terminal of the control board.

4. Manually close blower access door switch.

ELECTRICAL CONTROLS AND WIRING

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

component operation can occur unless switch is closed.

Caution must be taken when manually closing this switch for

service purposes. Failure to follow this warning could result

in electrical shock, personal injury, or death.

There may be more than 1 electrical supply to the unit. Check

accessories and cooling unit for additional electrical supplies

The electrical ground and polarity for 115-v wiring must be

properly maintained. Refer to Fig. 24 for field wiring information

and to Fig. 39 for furnace wiring information.

5. BRIEFLY short (jumper) TEST/TWIN, 3/16-in. quick-

connect male terminal on control (behind Y terminal) to the

C^OM-24V terminal on furnace control. (See Fig. 23.)

NOTE: If the polarity is not correct, the STATUS LED on the

control will flash rapidly and prevent the furnace from heating.

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SERVICE

If status code recall is needed, briefly remove then reconnect one main limit wire to display stored status code. On RED LED boards do not remove power or blower door before initiating status code recall. After

status code recall is completed component test will occur.

LED CODE

STATUS

CONTINUOUS OFF - Check for 115VAC at L1 and L2, and 24VAC at SEC-1 and SEC-2.

CONTINUOUS ON - Control has 24VAC power.

RAPID FLASHING - Line voltage (115VAC) polarity reversed. If twinned, refer to twinning kit instructions.

EACH OF THE FOLLOWING STATUS CODES IS A TWO DIGIT NUMBER WITH THE FIRST DIGIT DETERMINED BY THE NUMBER OF SHORT FLASHES AND THE SECOND DIGIT BY THE NUMBER OF LONG FLASHES.

11 NO PREVIOUS CODE - Stored status code is erased automatically after 72 hours. On

RED LED boards stored status codes can also be erased when power

(115 VAC or 24 VAC) to control is interrupted.

12 BLOWER ON AFTER POWER UP (115 VAC or 24 VAC) -Blower runs for 90 seconds,

if unit is powered up during a call for heat (R-W closed) or R-W opens during blower

on-delay.

13 LIMIT CIRCUIT LOCKOUT - Lockout occurs if the limit, draft safeguard, flame rollout, or

blocked vent switch (if used) is open longer than 3 minutes or 10 successive limit trips

31 PRESSURE SWITCH DID NOT CLOSE OR REOPENED - If open longer than five minutes,

inducer shuts off for 15 minutes before retry. Check for: - Excessive wind

- Proper vent sizing

- Defective inducer motor

- Low inducer voltage (115VAC)

- Inadequate combustion air supply

- Low inlet gas pressure (if LGPS used)

- Defective pressure switch

- Disconnected or obstructed pressure tubing

- Restricted vent

If it opens during blower on-delay period, blower will come on for the selected blower

off-delay.

occurred during high-heat. - Control will auto reset after three hours.

- Refer to #33.

33 LIMIT CIRCUIT FAULT - Indicates the limit, draft safeguard, flame rollout, or blocked vent

switch (if used) is open or the furnace is operating in high-heat only mode due to 2

successive low heat limit trips. Blower will run for 4 minutes or until open switch remakes

whichever is longer. If open longer than 3 minutes, code changes to lockout #13.

If open less than 3 minutes status code #33 continues to flash until blower shuts off.

14 IGNITION LOCKOUT - Control will auto-reset after three hours. Refer to #34.

21 GAS HEATING LOCKOUT - Control will NOT auto reset.

Check for: - Mis-wired gas valve

-Defective control (valve relay)

22 ABNORMAL FLAME-PROVING SIGNAL - Flame is proved while gas valve is de-

energized. Inducer will run until fault is cleared. Check for: - Leaky gas valve

- Stuck-open gas valve

Flame rollout switch and BVSS require manual reset. Check for:

- Proper vent sizing - Loose blower wheel.

- Dirty filter or restricted duct system.

- Restricted vent

- Excessive wind

23 PRESSURE SWITCH DID NOT OPEN Check for:

- Obstructed pressure tubing.

- Pressure switch stuck closed.

- Defective blower motor or capacitor. - Defective switch or connections.

- Inadequate combustion air supply (Flame Roll-out Switch open).

24 SECONDARY VOLTAGE FUSE IS OPEN Check for:

- Short circuit in secondary voltage (24VAC) wiring.

34 IGNITION PROVING FAILURE - Control will try three more times before lockout #14

occurs. If flame signal lost during blower on-delay period, blower will come on for the

selected blower off-delay. Check for: - Flame sensor must not be grounded

- Oxide buildup on flame sensor (clean with fine steel wool).

COMPONENT TEST

To initiate the component test sequence, shut OFF the room thermostat or disconnect the "R"

thermostat lead. Briefly short the TEST/TWIN terminal to the "Com 24V" terminal. Status LED

will flash code and then turn ON the inducer motor. The inducer motor will run for the entire

component test. The hot surface ignitor, blower motor fan speed (on AMBER LED boards

only) blower motor-heat speed, and blower motor-cool speed will be turned ON for 10-15

seconds each. Gas Valve and Humidifier will not be turned on.

- Proper flame sense microamps (.5 microamps D.C. min., 4.0 - 6.0 nominal).

- Gas valve defective or gas valve turned off

- Manual valve shut-off

- Defective Hot Surface Ignitor

- Low inlet gas pressure

- Control ground continuity

- Inadequate flame carryover or rough ignition

- Green/Yellow wire MUST be connected to furnace sheet metal

45 CONTROL CIRCUITRY LOCKOUT Auto-reset after one hour lockout due to;

- Gas valve relay stuck open

- Flame sense circuit failure

- Software check error

Reset power to clear lockout. Replace control if status code repeats.

327596-101 REV. A

A02027

Fig. 43—Service Label

NOTE: If TEST/TWIN to COM-24V terminals are jumpered

longer than 2 sec, LED will flash rapidly, and test request will be

ignored.

Never store anything on, near, or in contact with the furnace,

such as:

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

cleaners, or other cleaning tools.

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

pounds, plastic or plastic containers, gasoline, kerosene,

cigarette lighter fluid, dry cleaning fluids, or other volatile

fluids.

3. Paint thinners and other painting compounds, paper bags,

or other paper products.

6. Component Test will function as follows:

a. LED flashes a status code 4 times. Record this status code

for further troubleshooting.

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

component test sequence.

c. Hot surface igniter is energized for 15 sec, then de-

energized.

d. Blower operates at HEAT speed for 10 sec, then turns off.

e. Blower operates at COOL speed for 10 sec, then turns off.

f. Inducer motor turns off.

A failure to follow this warning could result in corrosion of

the heat exchanger, fire, personal injury, or death.

Items a through f above will assist in furnace troubleshooting since

all components are functionally operated except the gas valve. This

procedure is also referred to as ″Component Test Sequence.″

7. Check LED status. If no previous fault is in history, control

will flash status code 11.

Turn off the gas and electrical supplies to the unit before

performing any maintenance or service. Follow the operating

instructions on the label attached to the furnace. A failure to

follow this warning could result in personal injury.

8. If LED status indicates proper operation, RELEASE

BLOWER ACCESS DOOR SWITCH, reattach wire to ″R″

terminal on furnace control board, replace blower access door,

and replace burner access door.

Never operate unit without a filter or with filter access door

removed. A failure to follow this warning could result in fire,

personal injury, or death.

Step 2—Care and Maintenance

For continuing high performance and to minimize possible equip-

ment failure, periodic maintenance must be performed on this

equipment. Consult your local dealer about proper frequency of

maintenance and the availability of a maintenance contract.

→

Personal injury can result from sharp metal edges, etc. Be

careful when removing parts. Gloves and safety glasses

should be worn when servicing equipment

The minimum maintenance on this equipment is as follows:

1. Check and clean air filter each month or more frequently if

required. Replace if torn.

2. Check blower motor and wheel for cleanliness each heating

and cooling season. Clean as necessary.

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3. Check electrical connections for tightness and controls for

proper operation each heating season. Service as necessary.

BLOWER MOTOR AND WHEEL

4. Inspect burner compartment before each heating season for

rust, corrosion, soot or excessive dust. If necessary, have

furnace and burner serviced by a qualified professional.

→

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

component operation can occur unless switch is closed.

Caution must be taken when manually closing this switch for

service purposes. Failure to follow this warning could result

in personal injury or death.

5. Inspect the vent pipe/vent system before each heating season

for rust, corrosion, water leakage, sagging pipes or broken

fittings. Have vent pipes/vent system serviced by a qualified

professional.

6. Inspect any accessories attached to the furnace such as a

humidifier or electronic air cleaner. Perform any service or

maintenance to the accessories as recommended in the acces-

sory instructions.

The blower wheel should not be dropped or bent as balance

will be affected.

The following steps should be performed by a qualified service

technician.

CLEANING AND/OR REPLACING AIR FILTER

The air filter arrangement may vary depending on the application.

The filter is exterior to the furnace casing.

To ensure long life and high efficiency, clean accumulated dirt and

grease from blower wheel and motor annually.

NOTE: If the filter has an airflow direction arrow, the arrow must

The inducer and blower motors are pre-lubricated and require no

additional lubrication. These motors can be identified by the

absence of oil ports on each end of the motor.

point towards the blower.

Clean blower motor and wheel as follows:

1. Turn off electrical supply to furnace.

Personal injury can result from sharp metal edges, etc. Be

careful when removing parts. Gloves and safety glasses

should be worn when servicing equipment

2. Unscrew the thumbscrew on outer door and remove outer

door.

Media cabinet filter procedures:

3. For downflow or horizontal furnaces having vent pipes within

the furnace that pass in from of the blower access door:

NOTE: Media cabinet or 1″ Filter Rack are accessories and are

not included from the factory with the standard furnace model.

a. Disconnect vent connector from furnace vent elbow.

1. Turn off electrical supply to furnace before removing filter

access door.

b. Disconnect and remove short piece of vent pipe from

within furnace.

2. Remove filter cabinet door.

3. Slide filter out of cabinet.

4. Remove 2 screws from blower access door and remove blower

access door.

4. If equipped with permanent, washable 1″ filter, clean filter by

spraying cold tap water through filter in opposite direction of

airflow. Rinse filter and let dry. Oiling or coating of the filter

is not recommended. See Table 9 for size information.

5. Disconnect blower leads from furnace control. Note wire color

and location for reassembly. All other factory wires can be left

connected, but field thermostat connections may need to be

disconnected depending on their length and routing.

5. If equipped with factory-specified disposable media filter,

replace only with media filter having the same part number

and size. For expandable replacement media, refer to the

instructions included with the replacement media. If equipped

with KGAFR0301ALL external filter rack, See Table 9.

6. Remove 2 screws from control box to blower shelf.

7. Hang control box from front of furnace casing and away from

blower compartment.

8. Remove 2 screws holding blower assembly to blower deck

and slide blower assembly out of furnace.

6. Slide filter into cabinet.

9. Clean blower wheel and motor using a vacuum with soft brush

attachment. Blower wheel blades may be cleaned with a small

paint or flux brush. Do not remove or disturb balance weights

(clips) on blower wheel blades.

7. Replace filter cabinet door.

8. Turn on electrical supply to furnace.

10. Vacuum any loose dust from blower housing, wheel and

motor.

11. If a greasy residue is present on blower wheel, remove wheel

from the blower housing and wash it with an appropriate

degreaser. To remove wheel:

Table 9—FILTER SIZE INFORMATION (IN.)

FILTER QUANTITY AND SIZE

Side Return Bottom Return

FURNACE

CASING WIDTH

FILTER

TYPE

NOTE: Before disassembly, mark blower motor, and blower

housing so motor and each arm is positioned at the same location

during reassembly.

14-1/2

17-1/2

(1) 16 X 25 X 1 (1) 14 X 25 X 1 Cleanable*

(1) 16 X 25 X 1 (1) 16 X 25 X 1 Cleanable*

(1) 16 X 25 X 1 (1) 20 X 25 X 1 Cleanable*

(1) 16 X 25 X 1 (1) 24 X 25 X 1 Cleanable*

a. Disconnect capacitor wires and ground wire attached to

blower housing.

24**

* Recommended

** Some furnaces may have 2 filters

b. Remove screws securing cutoff plate and remove cutoff

plate from housing.

c. Loosen set screw holding blower wheel on motor shaft.

d. Remove bolts holding motor to blower housing and slide

motor out of wheel.

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e. Remove blower wheel from housing.

f. Clean wheel and housing.

CLEANING HEAT EXCHANGER

The following steps should be performed by a qualified service

technician:

12. Reassemble motor and blower by reversing steps 11f, finish-

ing with 11a. Be sure to reattach ground wire to the blower

housing.

NOTE: If the heat exchangers get a heavy accumulation of soot

and carbon, they should be replaced rather than trying to clean

them thoroughly. A build-up of soot and carbon indicates that a

problem exists which needs to be corrected, such as improper

adjustment of manifold pressure, insufficient or poor quality

combustion air, incorrect size or damaged manifold orifice(s),

improper gas, or a restricted heat exchanger. Action must be taken

to correct the problem.

13. Verify that blower wheel is centered in blower housing and set

screw contacts the flat portion of the motor shaft. Loosen set

screw on blower wheel and reposition if necessary.

14. Spin the blower wheel by hand to verify that the wheel does

not rub on the housing.

15. Reinstall blower assembly in furnace.

If it becomes necessary to clean the heat exchangers because of

dust or corrosion, proceed as follows:

16. Reinstall control box assembly in furnace.

1. Turn OFF gas and electrical power to furnace.

2. Remove outer access door.

Heating fan speed(s) MUST be adjusted to provide proper air

temperature rise as specified on the rating plate. Failure to

adjust the heating speed(s) may shorten heat exchanger life.

Recommended operation is at the midpoint of the rise range

or slightly above. Refer to ″SET TEMPERATURE RISE″

under START-UP, ADJUSTMENT, and SAFETY CHECK.

3. Disconnect vent connector from furnace vent elbow.

4. For downflow or horizontal furnace having an internal vent

pipe, remove internal vent pipe within the casing.

5. Disconnect wires to the following components. Mark wires to

aid in reconnection of:

a. Draft safeguard switch.

b. Inducer motor.

NOTE: Refer to Table 7 for motor speed lead relocation if leads

were not identified before disconnection.

c. Pressure switch(es).

17. Reconnect blower leads to furnace control. Refer to furnace

wiring diagram, and connect thermostat leads if previously

disconnected. (See Fig. 39.)

d. Limit overtemperature switch.

e. Gas valve.

18. To check blower for proper rotation:

a. Turn on electrical supply.

f. Hot surface igniter.

g. Flame-sensing electrode

h. Flame rollout switches.

i. Remove NOx baffles on low NOx models.

Blower access door switch opens 115-v power to furnace

control. No component operation can occur. Caution must be

taken when manually closing this switch for service purposes.

Failure to follow this warning could result in electrical shock,

personal injury, or death.

6. Remove screws that fasten the collector box assembly to the

cell panel. Be careful not to damage the collector box. Inducer

assembly and elbow need not be removed from collector box.

7. Disconnect gas line from gas manifold.

8. Remove the 4 screws that attach the burner assembly to the

cell panel. The gas valve and individual burners need not be

removed from support assembly.

b. Manually close blower access door switch.

NOTE: If thermostat terminals are jumpered at the time blower

access door switch is closed, blower will run for 90 sec before

beginning a heating or cooling cycle.

NOTE: Be very careful when removing burner assembly to avoid

breaking igniter. See Fig. 44 and 45 for correct igniter location.

c. Perform component self-test as shown at the bottom of the

SERVICE label, located on the front of blower access door.

9/32”

d. Verify blower is rotating in the correct direction.

19. If furnace is operating properly, RELEASE BLOWER AC-

CESS DOOR SWITCH. Replace blower access door and

remove any jumpers or reconnect any disconnected thermostat

leads.

11/32”

20. Downflow or horizontal furnaces with vent pipe through

furnace only:

a. Install and connect short piece of vent pipe inside furnace

to existing vent.

b. Connect vent connector to vent elbow.

21. Reinstall casing door.

22. Turn on gas supply and cycle furnace through one complete

heating and cooling cycle. Verify the unit temperature rise as

shown in Adjustments Section. Adjust temperature rise as

shown in Adjustments Section. If outdoor temperature is

below 70° F, turn off circuit breaker to outdoor unit before

running furnace in the cooling cycle. Turn outdoor circuit

breaker on after completing cooling cycle.

A02150

Fig. 44—Position of Igniter to Burner

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7/8”

A02151

A91252

Fig. 45—Position of Igniter to Burner

Fig. 46—Cleaning Heat Exchanger Cell

9. Using field-provided 25-caliber rifle cleaning brush, 1/4″

diameter steel spring cable, 36 in. long, a variable speed,

reversible electric drill, and vacuum cleaner, clean cells as

follows:

13. Reconnect wires to the following components (Use connection

diagram on wiring label, if wires were not marked for

reconnection locations.):

a. Remove metal screw fitting from wire brush to allow

insertion into cable.

a. Draft safeguard switch.

b. Inducer motor.

b. Insert the twisted wire end of brush into end of spring

cable, and crimp tight with crimping tool or crimp by

striking with ball-peen hammer. TIGHTNESS IS VERY

IMPORTANT.

c. Pressure switch(es).

d. Limit overtemperature switch.

e. Gas valve.

NOTE: The materials needed in item 9 can usually be purchased

at local hardware stores.

f. Hot surface igniter.

g. Flame-sensing electrode.

h. Flame rollout switches.

i. Install NOx baffles (if removed).

14. Reinstall internal vent pipe, if applicable.

(1.) Attach variable-speed, reversible drill to the end of

spring cable (end opposite brush).

(2.) Insert brush end of cable into the outlet opening of cell

and slowly rotate with drill. DO NOT force cable.

Gradually insert cable into upper pass of cell. (See Fig.

46.)

15. Reinstall vent connector on furnace vent elbow. Securely

fasten vent connector to vent elbow with 2 field-supplied,

corrosion-resistant, sheet metal screws located 180° apart.

(3.) Work cable in and out of cell 3 or 4 times to obtain

sufficient cleaning. DO NOT pull cable with great

force. Reverse drill and gradually work cable out.

16. Replace blower access door only.

17. Set thermostat above room temperature and check furnace for

proper operation.

(4.) Insert brush end of cable in burner inlet opening of

cell, and proceed to clean 2 lower passes of cell in

same manner as upper pass.

18. Verify blower airflow and speed changes between heating and

cooling.

(5.) Repeat foregoing procedures until each cell in furnace

has been cleaned.

19. Check for gas leaks.

(6.) Using vacuum cleaner, remove residue from each cell.

Never use a match or other open flame to check for gas leaks.

Use a soap-and-water solution. A failure to follow this

warning could result in fire, personal injury, or death.

(7.) Using vacuum cleaner with soft brush attachment,

clean burner assembly.

(8.) Clean flame sensor with fine steel wool.

20. Replace outer access door.

(9.) Reinstall burner assembly. Center burners in cell

openings.

Step 3—Sequence of Operation

10. Remove old sealant from cell panel and inducer backing plate

flange.

→ ^{NOTE: Furnace control must be grounded for proper operation or}

control will lock out. Control is grounded through green/yellow

wire routed to gas valve and manifold bracket screw.

11. Spray releasing agent on the heat exchanger cell panel where

collector box assembly contacts cell panel.

Using the schematic diagram in Fig. 39, follow the sequence of

operation through the different modes. Read and follow the wiring

diagram very carefully.

NOTE: A releasing agent such as cooking spray or equivalent

(must not contain corn or canola oil, aromatic or halogenated

hydrocarbons or inadequate seal may occur) and RTV sealant

(G.E. 162, 6702, or Dow-Corning 738) are needed before starting

installation. DO NOT substitute any other type of RTV sealant.

G.E. 162 (P771-9003) is available through RCD in 3-oz tubes.

NOTE: If a power interruption occurs during a call for heat (W),

the control will start a 90-second blower-only ON period two

seconds after power is restored, if the thermostat is still calling for

gas heating. The red LED light will flash code 12 during the

90-second period, after which the LED will be ON continuous, as

long as no faults are detected. After the 90-second period, the

furnace will respond to the thermostat normally.

12. Apply new sealant to flange of inducer assembly and attach to

cell panel using existing screws, making sure all screws are

secure.

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The blower door must be installed for power to be conducted

through the blower door interlock switch ILK to the furnace

control CPU, transformer TRAN, inducer motor IDM, blower

motor BLWM, hot-surface igniter HSI, and gas valve GV.

circuit starts the outdoor unit, and the R-to-G and Y circuits

start the furnace blower motor BLWM on COOL speed.

The electronic air cleaner terminal EAC-1 is energized with

115 vac when the blower motor BLWM is operating.

When the thermostat is satisfied, the R-to-G-and-Y circuits are

opened. The outdoor unit will stop, and the furnace blower

motor BLWM will continue operating on the COOL speed for

an additional 90 seconds. Cut jumper J2 to reduce the cooling

off-delay to 5 seconds. (See Fig. 23.)

1. Heating

(See Fig. 24 for thermostat connections.)

The wall thermostat ″calls for heat″, closing the R to W

circuit. The furnace control performs a self-check, verifies the

pressure switch contacts PRS is open, and starts the inducer

motor IDM.

3. Continuous Blower Mode

When the R-to-G circuit is closed by the thermostat, the

blower motor BLWM will operate on continuous-blower

speed (same as HEAT speed). Terminal EAC-1 is energized as

long as the blower motor BLWM is energized.

During a call for heat, the blower BLWM will stop during

igniter warm-up (17 seconds), ignition, and blower-ON delay

(25 seconds), allowing the furnace heat exchangers to heat up

more quickly, then restarts at the end of the blower-ON delay

period at HEAT speed.

a. Inducer Prepurge Period- As the inducer motor IDM

comes up to speed, the pressure switch contacts PRS close,

24 vac power is supplied for a field installed humidifier at

the HUM terminal and the control begins a 15-second

prepurge period.

b. Igniter Warm-Up- At the end of the prepurge period, the

Hot-Surface Igniter HSI is energized for a 17-second

igniter warm-up period.

c. Trial-for-Ignition Sequence- When the igniter warm-up

period is completed the main gas valve relay contacts GVR

close to energize the gas valve GV, the gas valve opens.

The gas valve GV permits gas flow to the burners where it

is ignited. After 5 seconds, the igniter HSI is de-energized

and a 2-second Flame-Proving period begins.

When the thermostat ″calls for cooling″, the blower motor

BLWM will operate at COOL speed. When the thermostat is

satisfied, the blower motor BLWM will operate an additional

90 seconds on COOL speed before reverting back to

continuous-blower speed.

When the R-to-G circuit is opened, the blower motor BLWM

will continue operating for an additional 5 seconds, if no other

function requires blower motor BLWM operation.

d. Flame-Proving- When the burner flame is proved at the

flame-proving sensor electrode FSE, the furnace control

CPU begins the blower-ON delay period and continues to

hold the gas valve GV open. If the burner flame is not

proved within two seconds, the control CPU will close the

gas valve GV, and the control CPU will repeat the ignition

sequence for up to three more Trials-For-Ignition before

going to Ignition-Lockout. Lockout will be reset auto-

matically after three hours, by momentarily interrupting

115 vac power to the furnace, or by interrupting 24 vac

power at SEC1 or SEC2 to the furnace control CPU (not at

W, G, R, etc.)

4. Heat Pump

When installed with a heat pump, the furnace control auto-

matically changes the timing sequence to avoid long blower

off times during demand defrost cycles. When the R-to-W-

and-Y or R-to-W-and-Y-and-G circuits are energized the

furnace control CPU will continue to turn on the blower motor

BLWM at HEAT speed, and begin a heating cycle. The

blower motor BLWM will remain on until the end of the

prepurge period, then shut off for 24 seconds then come back

on at HEAT speed. When the W input signal disappears, the

furnace control begins a normal inducer post-purge period and

the blower switches to COOL speed after a 3 second delay. If

the R-to-W-and-Y-and-G signals disappear at the same time,

the blower motor BLWM will remain on for the selected

blower-OFF delay period. If the R-to-W-and-Y signals disap-

pear, leaving the G signal, the blower motor BLWM will

continue running the blower motor BLWM at HEAT speed

after the selected blower-OFF delay period is completed.

If flame is proved when flame should not be present, the

furnace control CPU will lock out of Gas-Heating mode

and operate the inducer motor IDM until flame is no longer

proved.

e. Blower-On Delay- If the burner flame is proven, the

blower motor is energized on HEAT speed 25 seconds after

the gas valve GV is energized.

Simultaneously, the electronic air cleaner terminal EAC-1

is energized and remains energized as long as the blower

motor BLWM is energized.

Step 4—Wiring Diagrams

f. Blower-Off Delay- When the thermostat is satisfied, the

R-to-W circuit is opened, de-energizing the gas valve GV,

stopping gas flow to the burners, and de-energizing the

humidifier terminal HUM. The inducer motor IDM will

remain energized for a 5-second post-purge period. The

blower motor BLWM and air cleaner terminal EAC-1 will

remain energized for 90, 120, 150, or 180 seconds (depend-

ing on the blower-OFF delay selection). The furnace

control CPU is factory-set for a 120-second blower-OFF

delay.

Refer to Fig. 24 and 39 for wiring diagrams.

Step 5—Troubleshooting

Refer to the service label. (See Fig. 43—Service Label.)

The Troubleshooting Guide can be a useful tool in isolating

furnace operation problems. Beginning with the word “Start,”

answer each question and follow the appropriate arrow to the next

item.

The Guide will help to identify the problem or failed component.

After replacing any component, verify correct operation sequence.

2. Cooling Mode

(See Fig. 24 for thermostat connections)

The thermostat closes the R-to-G-and-Y circuits. The R-to-Y

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TABLE 10—Orifice Size* and Manifold Pressure For Gas Input Rate

(Tabulated Data Based On 22,000 Btuh Per Burner, Derated 4 Percent For Each 1000 Ft Above Sea Level)

SPECIFIC GRAVITY OF NATURAL GAS

ALTITUDE

RANGE

(FT)

AVG GAS

HEAT VALUE

(BTU/CU FT)

0.58

Manifold

0.60

0.62

0.64

Manifold

Orifice

No.

Orifice

No.

Manifold

Pressure

Orifice

No.

Manifold

Pressure

Orifice

No.

Pressure

900

925

3.5

3.3

3.8

3.6

3.5

3.3

3.6

3.4

3.3

3.6

3.4

3.3

3.8

3.6

3.4

3.2

3.5

3.4

3.7

3.5

3.4

3.2

3.7

3.5

3.4

3.2

3.5

3.7

3.5

3.3

3.8

3.6

3.5

3.3

3.2

950

2000

975

1000

1025

1050

1075

1100

SPECIFIC GRAVITY OF NATURAL GAS

0.60 0.62

Manifold Manifold

ALTITUDE

RANGE

(FT)

AVG GAS

HEAT VALUE

(BTU/CU FT)

0.58

0.64

Orifice

No.

Manifold

Pressure

Orifice

No.

Orifice

No.

Orifice

No.

Manifold

Pressure

U.S.A.

800

825

850

875

900

925

950

975

1000

3.4

3.2

3.7

3.5

3.3

3.1

2.9

2.8

2.6

3.5

3.3

3.8

3.6

3.4

3.2

3.0

2.9

2.7

3.6

3.4

3.2

3.7

3.5

3.3

3.1

3.0

2.8

3.7

3.5

3.3

3.8

3.6

3.4

3.2

3.1

2.9

Altitudes

2001

3000

Canada

Altitudes

2000

4500

SPECIFIC GRAVITY OF NATURAL GAS

0.60 0.62

Manifold Manifold

ALTITUDE

RANGE

(FT)

AVG GAS

HEAT VALUE

(BTU/CU FT)

0.58

0.64

Orifice

No.

Manifold

Pressure

Orifice

No.

Orifice

No.

Orifice

No.

Manifold

Pressure

775

800

825

850

875

900

925

950

3.2

3.6

3.4

3.2

3.0

2.9

2.7

2.6

3.3

3.8

3.5

3.3

3.1

3.0

2.8

2.7

3.4

3.2

3.7

3.4

3.3

3.1

2.9

2.8

3.5

3.3

3.8

3.6

3.4

3.2

3.0

2.8

3001

4000

U.S.A. Only

SPECIFIC GRAVITY OF NATURAL GAS

0.60 0.62

Manifold Manifold

ALTITUDE

RANGE

(FT)

AVG GAS

HEAT VALUE

(BTU/CU FT)

0.58

0.64

Orifice

No.

Manifold

Pressure

Orifice

No.

Orifice

No.

Orifice

No.

Manifold

Pressure

750

775

800

825

850

875

900

925

3.6

3.4

3.2

3.0

2.8

2.7

2.5

2.4

3.8

3.5

3.3

3.1

2.9

2.8

2.6

2.5

3.2

3.6

3.4

3.2

3.0

2.9

2.7

2.6

3.3

3.8

3.5

3.3

3.1

2.9

2.8

2.6

4001

5000

* Orifice numbers 43 are factory installed

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Table 10—Orifice Size* And Manifold Pressure For Gas Input Rate (Continued)

(Tabulated Data Based On 22,000 Btuh Per Burner, Derated 4 Percent For Each 1000 Ft Above Sea Level)

SPECIFIC GRAVITY OF NATURAL GAS

AVG GAS

ALTITUDE

RANGE

(FT)

HEAT VALUE

AT ALTITUDE

(BTU/CU FT)

0.58

0.60

0.62

0.64

Manifold

Orifice

No.

Manifold

Pressure

Orifice

No.

Manifold

Pressure

Orifice

No.

Manifold

Pressure

Orifice

No.

Pressure

725

750

775

800

825

850

875

900

3.4

3.2

3.0

2.8

2.6

2.5

2.3

2.2

3.5

3.3

3.1

2.9

2.7

2.5

2.4

2.3

3.6

3.4

3.2

3.0

2.8

2.6

2.5

2.3

3.7

3.5

3.3

3.1

2.9

2.7

2.6

2.4

5001

6000

SPECIFIC GRAVITY OF NATURAL GAS

0.60 0.62

Manifold Manifold

AVG GAS

HEAT VALUE

AT ALTITUDE

(BTU/CU FT)

ALTITUDE

RANGE

(FT)

0.58

0.64

Orifice

No.

Manifold

Pressure

Orifice

No.

Orifice

No.

Orifice

No.

Manifold

Pressure

675

700

725

750

775

800

825

850

3.4

3.1

2.9

2.7

2.6

2.4

2.3

2.1

3.5

3.3

3.0

2.8

2.7

2.5

2.3

2.2

3.6

3.4

3.1

2.9

2.7

2.6

2.4

2.3

3.7

3.5

3.2

3.0

2.8

2.7

2.5

2.4

6001

7000

SPECIFIC GRAVITY OF NATURAL GAS

0.60 0.62

Manifold Manifold

AVG GAS

HEAT VALUE

AT ALTITUDE

(BTU/CU FT)

ALTITUDE

RANGE

(FT)

0.58

0.64

Orifice

No.

Manifold

Pressure

Orifice

No.

Orifice

No.

Orifice

No.

Manifold

Pressure

650

675

700

725

750

775

800

825

3.1

2.9

2.7

2.5

2.4

2.2

2.1

3.7

3.2

3.0

2.8

2.6

2.4

2.3

2.1

2.0

3.4

3.1

2.9

2.7

2.5

2.4

2.2

2.1

3.5

3.2

3.0

2.8

2.6

2.4

2.3

2.2

7001

8000

SPECIFIC GRAVITY OF NATURAL GAS

0.60 0.62

Manifold Manifold

AVG GAS

HEAT VALUE

AT ALTITUDE

(BTU/CU FT)

ALTITUDE

RANGE

(FT)

0.58

0.64

Orifice

No.

Manifold

Pressure

Orifice

No.

Orifice

No.

Orifice

No.

Manifold

Pressure

625

650

675

700

725

750

775

2.9

2.7

2.5

2.3

2.2

2.0

3.6

3.0

3.1

3.2

3.0

2.8

2.6

2.4

2.2

2.1

2.8

2.9

2.6

2.7

8001

9000

2.4

2.5

2.2

2.3

2.1

2.2

3.7

2.0

* Orifice numbers 43 are factory installed

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Table 10—Orifice Size* And Manifold Pressure For Gas Input Rate (Continued)

(Tabulated Data Based On 22,000 Btuh Per Burner, Derated 4 Percent For Each 1000 Ft Above Sea Level)

SPECIFIC GRAVITY OF NATURAL GAS

AVG GAS

ALTITUDE

RANGE

(FT)

HEAT VALUE

AT ALTITUDE

(BTU/CU FT)

0.58

0.60

0.62

0.64

Manifold

Orifice

No.

Manifold

Pressure

Orifice

No.

Manifold

Pressure

Orifice

No.

Manifold

Pressure

Orifice

No.

Pressure

600

625

650

675

700

725

2.7

2.5

2.3

2.1

3.7

3.5

2.8

2.6

2.4

2.2

2.0

3.6

2.9

2.6

2.4

2.3

2.1

3.7

3.0

2.7

2.5

2.3

2.2

2.0

9001

10,000

* Orifice numbers 43 are factory installed

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TABLE 11—Orifice Size* and Manifold Pressure For Gas Input Rate

(Tabulated Data Based On 21,000 Btuh Per Burner, Derated 4 Percent For Each 1000 Ft Above Sea Level)

SPECIFIC GRAVITY OF NATURAL GAS

ALTITUDE

RANGE

(FT)

AVG GAS

HEAT VALUE

(BTU/CU FT)

0.58

Manifold

0.60

0.62

0.64

Manifold

Orifice

No.

Orifice

No.

Manifold

Pressure

Orifice

No.

Manifold

Pressure

Orifice

No.

Pressure

900

925

3.2

3.7

3.5

3.3

3.6

3.4

3.3

3.8

3.3

3.8

3.6

3.4

3.3

3.6

3.4

3.2

3.7

3.4

3.2

3.7

3.5

3.4

3.2

3.5

3.3

3.2

3.5

3.3

3.8

3.7

3.5

3.3

3.2

3.4

3.3

950

2000

975

1000

1025

1050

1075

1100

SPECIFIC GRAVITY OF NATURAL GAS

0.60 0.62

Manifold Manifold

ALTITUDE

RANGE

(FT)

AVG GAS

HEAT VALUE

(BTU/CU FT)

0.58

0.64

Orifice

No.

Manifold

Pressure

Orifice

No.

Orifice

No.

Orifice

No.

Manifold

Pressure

U.S.A.

Altitudes

2001

3000

Canada

Altitudes

2000

800

825

850

875

900

925

950

975

1000

3.8

3.5

3.3

3.2

3.0

2.8

2.7

2.5

2.4

3.2

3.7

3.5

3.3

3.1

2.9

2.8

2.6

2.5

3.3

3.8

3.6

3.4

3.2

3.0

2.9

2.7

2.6

3.4

3.2

3.7

3.5

3.3

3.1

2.9

2.8

2.7

4500

SPECIFIC GRAVITY OF NATURAL GAS

0.60 0.62

Manifold Manifold

ALTITUDE

RANGE

(FT)

AVG GAS

HEAT VALUE

(BTU/CU FT)

0.58

0.64

Orifice

No.

Manifold

Pressure

Orifice

No.

Orifice

No.

Orifice

No.

Manifold

Pressure

775

800

825

850

875

900

925

950

3.5

3.3

3.1

2.9

2.8

2.6

2.5

2.4

3.7

3.4

3.2

3.0

2.9

2.7

2.6

2.4

3.8

3.5

3.3

3.1

3.0

2.8

2.7

2.5

3.2

3.7

3.4

3.2

3.1

2.9

2.7

2.6

3001

4000

U.S.A. Only

SPECIFIC GRAVITY OF NATURAL GAS

0.60 0.62

Manifold Manifold

ALTITUDE

RANGE

(FT)

AVG GAS

HEAT VALUE

(BTU/CU FT)

0.58

0.64

Orifice

No.

Manifold

Pressure

Orifice

No.

Orifice

No.

Orifice

No.

Manifold

Pressure

750

775

800

825

850

875

900

925

3.3

3.1

2.9

2.7

2.6

2.4

2.3

2.2

3.4

3.2

3.0

2.8

2.7

2.5

2.4

2.2

3.5

3.3

3.1

2.9

2.8

2.6

2.5

2.3

3.6

3.4

3.2

3.0

2.8

2.7

2.5

2.4

4001

5000

* Orifice numbers 43 are factory installed

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Table 11—Orifice Size* And Manifold Pressure For Gas Input Rate (Continued)

(Tabulated Data Based On 21,000 Btuh Per Burner, Derated 4 Percent For Each 1000 Ft Above Sea Level)

SPECIFIC GRAVITY OF NATURAL GAS

AVG GAS

ALTITUDE

RANGE

(FT)

HEAT VALUE

AT ALTITUDE

(BTU/CU FT)

0.58

0.60

0.62

0.64

Manifold

Orifice

No.

Manifold

Pressure

Orifice

No.

Manifold

Pressure

Orifice

No.

Manifold

Pressure

Orifice

No.

Pressure

725

750

775

800

825

850

875

900

3.1

2.9

2.7

2.5

2.4

2.2

2.1

2.0

3.2

3.0

2.8

2.6

2.5

2.3

2.2

2.1

3.3

3.1

2.9

2.7

2.5

2.4

2.3

2.1

3.4

3.2

3.0

2.8

2.6

2.5

2.3

2.2

5001

6000

SPECIFIC GRAVITY OF NATURAL GAS

0.60 0.62

Manifold Manifold

AVG GAS

HEAT VALUE

AT ALTITUDE

(BTU/CU FT)

ALTITUDE

RANGE

(FT)

0.58

0.64

Orifice

No.

Manifold

Pressure

Orifice

No.

Orifice

No.

Orifice

No.

Manifold

Pressure

675

700

725

750

775

800

825

850

3.1

2.9

2.7

2.5

2.3

2.2

2.1

3.7

3.2

3.0

2.8

2.6

2.4

2.3

2.1

2.0

3.3

3.1

2.9

2.7

2.5

2.3

2.2

2.1

3.4

3.2

2.9

2.8

2.6

2.4

2.3

2.1

6001

7000

SPECIFIC GRAVITY OF NATURAL GAS

0.60 0.62

Manifold Manifold

AVG GAS

HEAT VALUE

AT ALTITUDE

(BTU/CU FT)

ALTITUDE

RANGE

(FT)

0.58

0.64

Orifice

No.

Manifold

Pressure

Orifice

No.

Orifice

No.

Orifice

No.

Manifold

Pressure

650

675

700

725

750

775

800

825

2.9

2.7

2.5

2.3

2.1

2.0

3.6

3.3

3.0

2.7

2.6

2.4

2.2

2.1

3.7

3.5

3.1

2.8

2.6

2.5

2.3

2.2

2.0

3.6

3.2

2.9

2.7

2.5

2.4

2.2

2.1

3.7

7001

8000

SPECIFIC GRAVITY OF NATURAL GAS

0.60 0.62

Manifold Manifold

AVG GAS

HEAT VALUE

AT ALTITUDE

(BTU/CU FT)

ALTITUDE

RANGE

(FT)

0.58

0.64

Orifice

No.

Manifold

Pressure

Orifice

No.

Orifice

No.

Orifice

No.

Manifold

Pressure

625

650

675

700

725

750

775

2.7

2.5

2.3

2.1

3.7

3.5

3.8

2.7

2.5

2.4

2.2

2.0

3.6

3.4

2.8

2.6

2.4

2.3

2.1

3.7

3.5

2.9

2.7

2.5

2.3

2.2

2.0

3.6

8001

9000

* Orifice numbers 43 are factory installed

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Table 11—Orifice Size* And Manifold Pressure For Gas Input Rate (Continued)

(Tabulated Data Based On 21,000 Btuh Per Burner, Derated 4 Percent For Each 1000 Ft Above Sea Level)

SPECIFIC GRAVITY OF NATURAL GAS

AVG GAS

ALTITUDE

RANGE

(FT)

HEAT VALUE

AT ALTITUDE

(BTU/CU FT)

0.58

0.60

0.62

0.64

Manifold

Orifice

No.

Manifold

Pressure

Orifice

No.

Manifold

Pressure

Orifice

No.

Manifold

Pressure

Orifice

No.

Pressure

600

625

650

675

700

725

2.4

2.3

2.1

3.6

3.4

3.7

2.5

2.3

2.2

3.8

3.5

3.8

2.6

2.4

2.2

2.1

3.6

3.4

2.7

2.5

2.3

2.1

3.7

3.5

9001

10,000

* Orifice numbers 43 are factory installed

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58st11si

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

Book

Tab 6a 8a

PC 101

Catalog No. See Cover

Printed in U.S.A.

Form 58ST-11SI

Pg 44

12-02

Replaces: 58ST-2SI

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