Amana Furnace ACV9 User Manual

AMV9/ACV9  
TWO-STAGE VARIABLE SPEED  
GAS-FIRED WARM AIR FURNACE  
INSTALLATION INSTRUCTIONS  
Installer: Affix all manuals adjacent to the unit.  
(Type FSP CATEGORY IV Direct or Non Direct Vent Air Furnace)  
These furnaces comply with requirements  
embodied in theAmerican National Standard  
®
/ National Standard of Canada ANSI  
Z21.47·CSA-2.3 Gas Fired Central Furnaces.  
C
US  
RECOGNIZE THIS SYMBOL AS A SAFETY PRECAUTION.  
ATTENTION INSTALLING PERSONNEL  
As a professional installer you have an obligation to know the product better than the customer. This includes all safety  
precautions and related items.  
Prior to actual installation, thoroughly familiarize yourself with this Instruction Manual. Pay special attention to all safety  
warnings. Often during installation or repair it is possible to place yourself in a position which is more hazardous than  
when the unit is in operation.  
Remember, it is your responsibility to install the product safely and to know it well enough to be able to instruct a  
customer in its safe use.  
Safety is a matter of common sense...a matter of thinking before acting. Most dealers have a list of specific good safety  
practices...follow them.  
The precautions listed in this Installation Manual are intended as supplemental to existing practices. However, if there is  
a direct conflict between existing practices and the content of this manual, the precautions listed here take precedence.  
*NOTE: Please contact your distributor or our  
website for the applicable product data book  
referred to in this manual.  
®
is a trademark of Maytag Corporation and is used under  
license to Goodman Company, L.P. All rights reserved.  
IO-253H  
© 2004-2006 Goodman Company, L.P.  
07/06  
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Table of Contents  
XIV. Startup Procedure & Adjustment ............................................................................................................................. 28  
HEAT ANTICIPATOR SETTING ................................................................................................................................ 28  
DRAIN TRAP PRIMING ....................................................................................................................................... 28  
FURNACE OPERATION ......................................................................................................................................... 28  
GAS SUPPLY PRESSURE MEASUREMENT .............................................................................................................. 28  
GAS MANIFOLD PRESSURE MEASUREMENT AND ADJUSTMENT .................................................................................. 29  
GAS INPUT RATE MEASUREMENT (NATURAL GAS ONLY) ......................................................................................... 29  
TEMPERATURE RISE ......................................................................................................................................... 30  
CIRCULATOR BLOWER SPEEDS ........................................................................................................................... 30  
BLOWER HEAT OFF DELAY TIMINGS ................................................................................................................... 32  
XV. Normal Sequence of Operation................................................................................................................................ 32  
POWER UP ..................................................................................................................................................... 32  
HEATING MODE ............................................................................................................................................... 32  
COOLING MODE .............................................................................................................................................. 32  
FAN ONLY MODE ............................................................................................................................................. 33  
XVI. Operational Checks .................................................................................................................................................. 33  
BURNER FLAME ............................................................................................................................................... 33  
XVII. Safety Circuit Description ....................................................................................................................................... 33  
GENERAL ....................................................................................................................................................... 33  
INTEGRATED CONTROL MODULE .......................................................................................................................... 33  
PRIMARY LIMIT ................................................................................................................................................ 33  
AUXILIARY LIMIT ............................................................................................................................................... 33  
ROLLOUT LIMIT ................................................................................................................................................ 33  
PRESSURE SWITCHES........................................................................................................................................ 33  
FLAME SENSOR ............................................................................................................................................... 33  
XVIII. Troubleshooting...................................................................................................................................................... 33  
ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS ................................................................................................. 33  
DIAGNOSTIC CHART .......................................................................................................................................... 34  
RESETTING FROM LOCKOUT ............................................................................................................................... 34  
XIX. Maintenance ............................................................................................................................................................. 34  
ANNUAL INSPECTION .......................................................................................................................................... 34  
FILTERS .......................................................................................................................................................... 34  
BURNERS ....................................................................................................................................................... 34  
INDUCED DRAFT AND CIRCULATOR BLOWERS ......................................................................................................... 34  
CONDENSATE TRAP AND DRAIN SYSTEM (QUALIFIED SERVICER ONLY)...................................................................... 35  
FLAME SENSOR (QUALIFIED SERVICER ONLY) ...................................................................................................... 35  
FLUE PASSAGES (QUALIFIED SERVICER ONLY) ..................................................................................................... 35  
XX. Internal Filter Removal ............................................................................................................................................. 35  
XXI. Before Leaving an Installation ................................................................................................................................ 35  
XXII. Repair & Replacement Parts .................................................................................................................................. 35  
APPENDIX  
Troubleshooting Chart...................................................................................................................................................... 37  
Wiring Diagram ................................................................................................................................................................ 39  
3
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TO THE OWNER  
WARNING  
It is important that you fill out the owner’s registration card and mail  
it today. This will assist us in contacting you should any service or  
warranty information change in the future. When filling in the regis-  
tration card, be sure to include the model, manufacturing, and serial  
numbers, plus the installation date.  
Your warranty certificate is also supplied with the unit. Read the  
warranty carefully and note what is covered. Keep the warranty  
certificate in a safe location for future reference.  
F THE INFORMATION IN THESE INSTRUCTIONS IS NOT FOLLOWED EXACTLY, A  
I
FIRE OR EXPLOSION MAY RESULT CAUSING PROPERTY DAMAGE, PERSONAL  
INJURY OR LOSS OF LIFE.  
DO NOT STORE OR USE GASOLINE OR OTHER FLAMMABLE VAPORS AND  
LIQUIDS IN THE VICINITY OF THIS OR ANY OTHER APPLIANCE.  
:
WHAT TO DO IF YOU SMELL GAS  
If additional information or operating instructions are required, con-  
tact the dealer where the purchase was made.  
DO NOT TRY TO LIGHT ANY APPLIANCE.  
DO NOT TOUCH ANY ELECTRICAL SWITCH; DO NOT USE ANY  
Homeowner Notice:  
PHONE IN YOUR BUILDING.  
If the residence is left unattended for an extended period of time  
(i.e., 4 hours or greater), have your heating system periodically  
checked to ensure proper operation. Potential circumstances be-  
yond our control such as power outages, gas service interruptions,  
product installation, or component failures could result in heating  
system operational problems.  
IMMEDIATELY CALL YOUR GAS SUPPLIER FROM A NEIGHBOR’S  
PHONE. FOLLOW THE GAS SUPPLIER’S INSTRUCTIONS.  
IF YOU CANNOT REACH YOUR GAS SUPPLIER, CALL THE FIRE  
DEPARTMENT.  
INSTALLATION AND SERVICE MUST BE PERFORMED BY A QUALIFIED INSTALLER,  
SERVICE AGENCY OR THE GAS SUPPLIER.  
TO THE INSTALLER  
Before installing this unit, please read this manual thoroughly to  
familiarize yourself with specific items which must be adhered to,  
including but not limited to: unit maximum external static pressure,  
gas pressures, BTU input rating, proper electrical connections, cir-  
culating air temperature rise, minimum or maximum CFM, and mo-  
tor speed connections.  
WARNING  
HOULD OVERHEATING OCCUR OR THE GAS SUPPLY FAIL TO SHUT OFF, TURN  
S
OFF THE MANUAL GAS SHUTOFF VALVE EXTERNAL TO THE FURNACE BEFORE  
TURNING OFF THE ELECTRICAL SUPPLY.  
TRANSPORTATION DAMAGE  
All units are securely packed in shipping containers tested accord-  
ing to International Safe Transit Association specifications. The car-  
ton must be checked upon arrival for external damage. If damage  
is found, a request for inspection by carrier’s agent must be made in  
writing immediately.  
The furnace must be carefully inspected on arrival for damage and  
bolts or screws which may have come loose in transit. In the event  
of damage the consignee should:  
1. Make a notation on delivery receipt of any visible damage to  
shipment or container.  
CARBON MONOXIDE POISONING HAZARD  
2. Notify carrier promptly and request an inspection.  
3. With concealed damage, carrier must be notified as soon as  
possible - preferably within five days.  
Special Warning for Installation of Furnace or Air Handling Units in  
Enclosed Areas such as Garages, Utility Rooms or Parking Areas  
4. File the claim with the following support documents within a  
nine month statute of limitations.  
Carbon monoxide producing devices (such as an automobile, space  
heater, gas water heater, etc.) should not be operated in enclosed areas  
such as unventilated garages, utility rooms or parking areas because of  
the danger of carbon monoxide (CO) poisoning resulting from the exhaust  
emissions. If a furnace or air handler is installed in an enclosed area such  
as a garage, utility room or parking area and a carbon monoxide producing  
device is operated therein, there must be adequate, direct outside  
ventilation.  
Original or certified copy of the Bill of Lading, or indemnity  
bond.  
Original paid freight bill or indemnity in lieu thereof.  
Original or certified copy of the invoice, showing trade and  
other discounts or reductions.  
This ventilation is necessary to avoid the danger of CO poisoning which  
can occur if a carbon monoxide producing device continues to operate in  
the enclosed area. Carbon monoxide emissions can be (re)circulated  
throughout the structure if the furnace or air handler is operating in any  
mode.  
Copy of the inspection report issued by carrier’s  
representative at the time damage is reported to carrier.  
The carrier is responsible for making prompt inspection of damage  
and for a thorough investigation of each claim. The distributor or  
manufacturer will not accept claims from dealers for transportation  
damage.  
CO can cause serious illness including permanent brain damage or death.  
-
B10259-216  
Keep this literature in a safe place for future reference.  
4
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12  
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Intell-Ignition  
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TSTAT  
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ON  
S1  
OFF  
23  
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Counterflow/Horizontal  
Upflow/Horizontal  
1
2
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Two-Stage Gas Valve  
Gas Line Entrance (Alternate)  
Pressure Switch(es)  
Gas Manifold  
Combustion Air Intake Connection  
Hot Surface Igniter  
Rollout Limit  
22 Drain Trap  
23 Blower Door Interlock Switch  
24 Inductor (Not All Models)  
25 Two-Stage Integrated Control Module  
(with fuse and diagnostic LED)  
26 24 Volt Thermostat Connections  
27 Transformer (40 VA)  
Burners  
Flame Sensor  
28 ECM Variable Speed Circulator Blower  
29 Auxiliary Limit  
10 Flue Pipe Connection  
30 Junction Box  
11 Flue Pipe  
12 Combustion Air Intake (Alternate)  
13 Primary Limit  
31 Electrical Connection Inlets  
32 Coil Front Cover  
33 Combustion Air Inlet Pipe  
14 Gas Line Entrance  
15 Flue Pipe Connection (Alternate)  
16 Rubber Elbow  
17 Two-Speed Induced Draft Blower  
18 Electrical Connection Inlets (Alternate)  
19 Coil Front Cover Pressure Tap  
20 Coil Front Cover Drain Port  
21 Drain Line Penetrations  
5
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II. SAFETY  
If you come in contact with an ungrounded object, repeat  
step 2 before touching control or wires.  
Please adhere to the following warnings and cautions when in-  
stalling, adjusting, altering, servicing, or operating the furnace.  
4. Discharge your body to ground before removing a new  
control from its container. Follow steps 1 through 3 if  
installing the control on a furnace. Return any old or new  
controls to their containers before touching any ungrounded  
object.  
WARNING  
O PREVENT PERSONAL INJURY OR DEATH DUE TO IMPROPER INSTALLATION,  
T
ADJUSTMENT, ALTERATION, SERVICE OR MAINTENANCE, REFER TO THIS  
III. PRO D UC T APPLIC ATIO N  
MANUAL. OR ADDITIONAL ASSISTANCE OR INFORMATION, CONSULT A  
F
QUALIFIED INSTALLER, SERVICE AGENCY OR THE GAS SUPPLIER.  
This furnace is primarily designed for residential home-heating  
applications. It is NOT designed or certified for use in mobile  
homes, trailers or recreational vehicles. This unit is NOT designed  
or certified for outdoor applications. The furnace must be installed  
indoors (i.e., attic space, crawl space, or garage area provided the  
garage area is enclosed with an operating door).  
WARNING  
HIS PRODUCT CONTAINS OR PRODUCES A CHEMICAL OR CHEMICALS WHICH  
T
MAY CAUSE SERIOUS ILLNESS OR DEATH AND WHICH ARE KNOWN TO THE  
TATE OF ALIFORNIA TO CAUSE CANCER, BIRTH DEFECTS OR OTHER  
This furnace can be used in the following non-industrial commer-  
cial applications:  
S
C
REPRODUCTIVE HARM.  
Schools, Office buildings, Churches, Retail stores  
Nursing homes, Hotels/motels, Common or office areas  
WARNING  
In such applications , the furnace must be installed with the follow-  
ing stipulations:  
O PREVENT POSSIBLE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH  
T
It must be installed per the installation instructions  
provided and per local and national codes.  
It must be installed indoors in a building constructed on  
site.  
It must be part of a ducted system and not used in a free  
air delivery application.  
It must not be used as a “make-up” air unit.  
It must be installed with two-pipe systems for combustion  
air, especially if VOC’s or other contaminants are present  
in the conditioned space.  
All other warranty exclusions and restrictions apply This  
furnace is an ETL dual-certified appliance and is  
appropriate for use with natural or propane gas (NOTE: If  
using propane, a propane conversion kit is required).  
DUE TO ELECTRICAL SHOCK, THE FURNACE MUST BE LOCATED TO PROTECT  
THE ELECTRICAL COMPONENTS FROM WATER.  
WARNING  
EATING UNIT SHOULD NOT BE UTILIZED WITHOUT REASONABLE, ROUTINE,  
H
INSPECTION, MAINTENANCE AND SUPERVISION. F THE BUILIDNG IN WHICH ANY  
I
SUCH DEVICE IS LOCATED WILL BE VACANT, CARE SHOULD BE TAKEN THAT  
SUCH DEVICE IS ROUTINELY INSPECTED, MAINTAINED AND MONITORED. IN THE  
EVENT THAT THE BUILDING MAYBE EXPOSED TO FREEZING TEMPERATURES  
AND WILL BE VACANT, ALL WATER-BEARING PIPES SHOULD BE DRAINED, THE  
BUILDING SHOULD BE PROPERLY WINTERIZED, AND THE WATER SOURCE  
CLOSED. IN THE EVENT THAT THE BUILDING MAY BE EXPOSED TO FREEZING  
TEMPERATURES AND WILL BE VACANT, ANY HYDRONIC COIL UNITS SHOULD  
BE DRAINED AS WELL AND, IN SUCH CASE, ALTERNATIVE HEAT SOURCES  
SHOULD BE UTILIZED.  
Dual certification means that the combustion air inlet pipe is op-  
tional and the furnace can be vented as a:  
Non-direct vent (single pipe) central forced air furnace in  
which combustion air is taken from the installation area  
or from air ducted from the outside or,  
Direct vent (dual pipe) central forced air furnace in which  
all combustion air supplied directly to the furnace burners  
through a special air intake system outlined in these  
instructions.  
ELECTROSTATIC DISCHARGE(ESD)PRECAUTIONS  
NOTE: Discharge static electrictiy accumulated in the body before  
touching the unit. An electrostatic discharge can adversely affect  
electrical components.  
This furnace may be used as a construction site heater ONLY if the  
Use the following precautions during furnace installation and ser-  
vicing to protect the integrated control module from damage. By  
putting the furnace, the control, and the person at the same electro-  
static potential, these steps will help avoid exposing the integrated  
control module to electrostatic discharge. This procedure is appli-  
cable to both installed and non-installed (ungrounded) furnaces.  
following conditions are met:  
The vent system is permanently installed per these  
installation instructions.  
A room thermostat is used to control the furnace. Fixed  
jumpers that provide continuous heating CANNOT be  
used.  
1. Disconnect all power to the furnace. Do not touch the  
integrated control module or any wire connected to the control  
prior to discharging your body’s electrostatic charge to  
ground.  
Return air ducts are provided and sealed to the furnace.  
A return air temperature range between 60ºF (16ºC) and  
80ºF (27ºC) is maintained.  
Air filters are installed in the system and maintained  
during construction, replaced as appropriate during  
construction, and upon completion of construction are  
replaced.  
2. Firmly touch a clean, unpainted, metal surface of the furnace  
near the control. Any tools held in a person’s hand during  
grounding will be discharged.  
3. Service integrated control module or connecting wiring  
following the discharge process in step 2. Use caution not  
to recharge your body with static electricity; (i.e., do not move  
or shuffle your feet, do not touch ungrounded objects, etc.).  
The input rate and temperature rise are set per the furnace  
rating plate.  
100% outside air is provided for combustion air  
requirements during construction. Temporary ducting can  
be used.  
6
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NOTE: Do not connect the temporary duct directly to the  
furnace. The duct must be sized according to the  
instructions under Section V, Combustion and Ventilation  
Air Requirements, Section 5.3.3.  
IV  
                                                                                                                                               
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GENERAL  
WARNING  
The furnace heat exchanger, components, duct system,  
air filters and evaporator coils are thoroughly cleaned  
following final construction clean up.  
All furnace operating conditions (including ignition, input  
rate, temperature rise and venting) are verified according  
to these installation instructions.  
O PREVENT POSSIBLE EQUIPMENT DAMAGE, PROPERTY DAMAGE, PERSONAL  
T
INJURY OR DEATH, THE FOLLOWING BULLET POINTS MUST BE OBSERVED  
WHEN INSTALLING THE UNIT.  
Follow the instructions listed below when selecting a furnace loca-  
tion. Refer also to the guidelines provided in Section V, Combus-  
tion and Ventilation Air Requirements.  
NOTE: The Commonwealth of Massachusetts requires that the  
following additional requirements must also be met:  
Centrally locate the furnace with respect to the proposed  
or existing air distribution system.  
Ensure the temperature of the return air entering the  
furnace is between 55°F and 100°F when the furnace is  
heating.  
Gas furnaces must be installed by a licensed plumber or  
gas fitter.  
A T-handle gas cock must be used.  
If the unit is to be installed in an attic, the passageway to  
and the service area around the unit must have flooring.  
Provide provisions for venting combustion products  
outdoors through a proper venting system. Special  
consideration should be given to vent/flue pipe routing  
and combustion air intake pipe when applicable. Refer  
to Section IX, Vent/Flue Pipe and Combustion Air Pipe -  
Termination Locations for appropriate termination  
locations and to determine if the piping system from  
furnace to termination can be accomplished within the  
guidelines given. NOTE: The length of flue and/or  
combustion air piping can be a limiting factor in the  
location of the furnace.  
Locate the furnace so condensate flows downwards to  
the drain. Do not locate the furnace or its condensate  
drainage system in any area subject to below freezing  
temperatures without proper freeze protection. Refer to  
Section X, Condensate Drain Lines and Trap for further  
details.  
To ensure proper installation and operation, thoroughly read this  
manual for specifics pertaining to the installation and application  
of this product.  
WARNING  
OSSIBLE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH DUE TO FIRE,  
P
EXPLOSION, SMOKE, SOOT, CONDENSTAION, ELECTRICAL SHOCK OR CARBON  
MONOXIDE MAY RESULT FROM IMPROPER INSTALLATION, REPAIR, OPERATION,  
OR MAINTENANCE OF THIS PRODUCT.  
WARNING  
O PREVENT PROPERTY DAMAGE, PERSONAL INJURY OR DEATH DUE TO FIRE,  
T
DO NOT INSTALL THIS FURNACE IN A MOBILE HOME, TRAILER, OR RECREATIONAL  
Ensure adequate combustion air is available for the  
furnace. Improper or insufficient combustion air can  
expose building occupants to gas combustion products  
that could include carbon monoxide. Refer to Section V,  
Combustion and Ventilation Air Requirements.  
Set the furnace on a level floor to enable proper  
condensate drainage. If the floor becomes wet or damp  
at times, place the furnace above the floor on a concrete  
base sized approximately 1-1/2" larger than the base of  
the furnace. Refer to the Section VII, Horizontal  
Applications and Considerations for leveling of horizontal  
furnaces.  
Ensure upflow or horizontal furnaces are not installed  
directly on carpeting, or any other combustible material.  
The only combustible material allowed is wood.  
A special accessory subbase must be used for upright  
counterflow unit installations over any combustible  
material (including wood). Refer to subbase instructions  
for installation details. (NOTE: A subbase will not be  
required if an air conditioning coil is located beneath the  
furnace between the supply air opening and the  
combustible floor.  
VEHICLE.  
To ensure proper furnace operation, install, operate and maintain  
the furnace in accordance with these installation and operation  
instructions, all local building codes and ordinances. In their ab-  
sence, follow the latest edition of the National Fuel Gas Code  
(NFPA 54/ANSI Z223.1), and/or CAN/CSA B149 Installation Codes,  
local plumbing or waste water codes, and other applicable codes.  
A copy of the National Fuel Gas Code (NFPA 54/ANSI Z223.1) can  
be obtained from any of the following:  
American National Standards Institute  
1430 Broadway  
New York, NY 10018  
National Fire Protection Association  
1 Batterymarch Park  
Quincy, MA 02269  
CSA International  
8501 East Pleasant Valley  
Cleveland, OH 44131  
A copy of the CAN/CSA B149 Installation Codes can also be ob-  
tained from:  
CSA International  
178 Rexdale Boulevard  
Etobicoke, Ontario, Canada M9W 1R3  
Exposure to contaminated combustion air will result in  
safety and performance-related problems. Do not install  
the furnace where the combustion air is exposed to the  
following substances:  
chlorinated waxes or cleaners  
chlorine-based swimming pool chemicals  
water softening chemicals  
The rated heating capacity of the furnace should be greater than or  
equal to the total heat loss of the area to be heated. The total heat  
loss should be calculated by an approved method or in accor-  
dance with “ASHRAE Guide” or “Manual J-Load Calculations” pub-  
lished by the Air Conditioning Contractors of America.  
deicing salts or chemicals  
carbon tetrachloride  
7
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halogen type refrigerants  
cleaning solutions (such as perchloroethylene)  
printing inks  
paint removers  
varnishes  
construction, the clearance between the door and door frame is  
usually adequate to satisfy this ventilation requirement.  
FURNACE SUSPENSION  
If suspending the furnace from rafters or joists, use 3/8" threaded  
rod and 2”x2”x1/8” angle iron as shown below. The length of rod  
will depend on the application and the clearances necessary.  
hydrochloric acid  
cements and glues  
PROVIDE 8" MINMUM CLEARANCE BETWEEN  
CENTER ROD AND FURNACE CABINET  
antistatic fabric softeners for clothes dryers  
and masonry acid washing materials  
TO ALLOW FOR CIRCULATOR BLOWER REMOVAL  
3/8" DIAMETER  
ASSURE FURNACE IS LEVEL FROM  
THREADED ROD  
Seal off a non-direct vent furnace if it is installed near an  
area frequently contaminated by any of the above  
substances. This protects the non-direct vent furnace  
from airborne contaminants. To ensure that the  
enclosed non-direct vent furnace has an adequate supply  
of combustion air, vent from a nearby uncontaminated  
room or from outdoors. Refer to the Section V,  
Combustion and Ventilation Air Requirements for details.  
END TO END AND HAS  
A
SLIGHT  
(6 PLACES)  
FORWARD TILT WITH THE FRONT  
OF THE FURNACE 0"-3/4"  
BELOW THE BACK OF THE FURNACE  
HOLD DOWN  
NUTS  
SUPPORT  
NUTS  
If the furnace is used in connection with a cooling unit,  
install the furnace upstream or in parallel with the cooling  
unit. Premature heat exchanger failure will result if the  
cooling unit is placed ahead of the furnace.  
If the furnace is installed in a residential garage, position  
the furnace so that the burners and ignition source are  
located not less than 18 inches (457 mm) above the floor.  
Protect the furnace from physical damage by vehicles.  
2" 2" 1/8" ANGLE IRON  
X
X
(3 PLACES)  
TILT OUTWARD TO ALLOW FOR  
DOOR AND CIRCULATOR BLOWER  
REMOVAL  
POSITION AS CLOSE AS POSSIBLE  
TO BLOWER DECK TO ALLOW FOR  
CIRCULATOR BLOWER REMVOAL  
SuspendedFurnace  
EXISTING FURNACE REMOVAL  
NOTE: When an existing furnace is removed from a venting system  
serving other appliances, the venting system may be too large to  
properly vent the remaining attached appliances.  
The following vent testing procedure is reproduced from the American  
National Standard/National Standard of Canada for Gas-Fired Cen-  
tral Furnaces ANSI Z21.47b-2002, CSA-2.3b-2002 Section 1.23.1.  
The following steps shall be followed with each appliance connected to the  
venting system placed in operation, while any other appliances con-  
nected to the venting system are not in operation:  
If the furnace is installed horizontally, the furnace access  
doors must be vertical so that the burners fire horizontally  
into the heat exchanger. Do not install the unit with the  
access doors on the “up/top” or “down/bottom” side of  
the furnace.  
CLEARANCES AND ACCESSIBILITY  
Installations must adhere to the clearances to combustible mate-  
rials which this furnace has been design certified to. The mini-  
mum clearance information for this furnace is provided on the unit’s  
clearance label. These clearances must be permanently main-  
tained. Clearances must also accommodate an installation’s gas,  
electrical, and drain trap and drain line connections. If the alternate  
combustion air intake or vent/flue connections are used additional  
clearance must be provided to accommodate these connections.  
Refer to Section IX, Vent Flue Pipe and Combustion Air Pipe for  
details. NOTE: In addition to the required clearances to combus-  
tible materials, a minimum of 24 inches service clearance must be  
available in front of the unit.  
a. Seal any unused openings in the venting system;  
b. Inspect the venting system for proper size and horizontal pitch, as  
required by the National Fuel Gas Code, ANSI Z223.1 or the CSA  
B149 Installation Codes and these instructions. Determine that there  
is no blockage or restriction, leakage, corrosion and other deficien-  
cies which could cause an unsafe condition;  
c. In so 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. Turn on  
clothes dryers and any appliance not connected to the venting sys-  
tem. Turn on any exhaust fans, such as range hoods and bathroom  
exhausts, so they shall operate at maximum speed. Do not operate a  
summer exhaust fan. Close fireplace dampers;  
TOP  
TOP  
d. Follow the lighting instructions. Place the appliance being inspected  
in operation. Adjust thermostat so appliance shall operate continu-  
ously;  
SIDE  
SIDE  
SIDE  
BOTTO M  
Horizontal  
e. Test for draft hood equipped spillage at the draft hood relief opening  
after 5 minutes of main burner operation. Use the flame of a match  
or candle;  
BOTTO M  
Upflow  
Counterflow  
f. After it has been determined that each appliance connected to the  
venting system properly vents when tested as outlined above, re-  
turn doors, windows, exhaust fans, fireplace dampers and any other  
gas burning appliance to their previous conditions of use;  
A furnace installed in a confined space (i.e., a closet or utility room)  
must have two ventilation openings with a total minimum free area  
of 0.25 square inches per 1,000 BTU/hr of furnace input rating.  
Refer to Product Data Book applicable to your model* for minimum  
clearances to combustible surfaces. One of the ventilation open-  
ings must be within 12 inches of the top; the other opening must be  
within 12 inches of the bottom of the confined space. In a typical  
g. If improper venting is observed during any of the above tests, the  
common venting system must be corrected.  
*NOTE: Please contact your distributor or our website for the applicable  
product data book referred to in this manual.  
8
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Corrections must be in accordance with the latest edition of the ANSI Z223.1 (Section 5.3), or CSA B149 Installation Codes (Sec-  
National Fuel Gas Code NFPA 54/ANSI Z223.1 and/or CSA B149 tions 7.2, 7.3, or 7.4), or applicable provisions of the local building  
Installation Codes.  
codes for determining the combustion air requirements for the  
If resizing is required on any portion of the venting system, use the appliances.  
appropriate table in Appendix G in the latest edition of the National Most homes will require outside air be supplied to the furnace area  
Fuel Gas Code ANSI Z223.1 and/or CSA B149 Installation Codes. by means of ventilation grilles or ducts connecting directly to the  
outdoors or spaces open to the outdoors such as attics or crawl  
THERMOSTAT LOCATION  
spaces.  
The thermostat should be placed approximately five feet fom the  
The following information on air for combustion and ventilation is repro-  
duced from the National Fuel Gas Code NFPA 54/ANSI Z223.1 Section  
5.3.  
floor on a vibration-free, inside wall in an area having good air  
circulation. Do not install the thermostat where it may be influ-  
enced by any of the following:  
5.3.1 General:  
(a) The provisions of 5.3 apply to gas utilization equipment installed in  
Drafts, or dead spots behind doors, in corners, or under  
cabinets.  
buildings and which require air for combustion, ventilation and dilu-  
tion of flue gases from within the building. They do not apply to (1)  
direct vent equipment which is constructed and installed so that all  
air combustion is obtained from the outside atmosphere and all flue  
gases are discharged to the outside atmosphere, or (2) enclosed  
furnaces which incorporate an integral total enclosure and use only  
outside air for combustion and dilution of flue gases.  
Hot or cold air from registers.  
Radiant heat from the sun.  
Light fixtures or other appliances.  
Radiant heat from a fireplace.  
(b) Equipment shall be installed in a location in which the facilities for  
ventilation permit satisfactory combustion of gas, proper venting  
and the maintenance of ambient temperature at safe limits under  
normal conditions of use. Equipment shall be located so as not to  
interfere with proper circulation of air. When normal infiltration  
does not provide the necessary air, outside air shall be introduced.  
Concealed hot or cold water pipes, or chimneys.  
Unconditioned areas behind the thermostat, such as an  
outside wall.  
(c) In addition to air needed for combustion, process air shall be pro-  
vided as required for: cooling of equipment or material, controlling  
dew point, heating, drying, oxidation or dilution, safety exhaust,  
odor control, and air for compressors.  
DRAFTS OR DEAD SPOTS  
-BEHIND DOORS  
-IN CORNERS  
-UNDER CABINETS  
HOT  
(d) In addition to air needed for combustion, air shall be supplied for  
ventilation, including all air required for comfort and proper working  
conditions for personnel.  
COLD  
(e) While all forms of building construction cannot be covered in detail,  
air for combustion, ventilation and dilution of flue gases for gas  
utilization equipment vented by natural draft normally may be ob-  
tained by application of one of the methods covered in 5.3.3 and  
5.3.4.  
Thermostat Influences  
Consult the instructions packaged with the thermostat for mount-  
ing instructions and further precautions.  
(f) Air requirements for the operation of exhaust fans, kitchen ventila-  
tion systems, clothes dryers, and fireplaces shall be considered in  
determining the adequacy of a space to provide combustion air  
requirements.  
V. CO M BUSTIO N & VEN TILATIO N AIR REQ UIREM EN TS  
WARNING  
5.3.2 Equipment Located in Unconfined Spaces:  
In unconfined spaces (see definition below) in buildings, infiltration may  
be adequate to provide air for combustion ventilation and dilution of  
flue gases. However, in buildings of tight construction (for example,  
weather stripping, heavily insulated, caulked, vapor barrier, etc.), addi-  
tional air may need to be provided using the methods described in 5.3.3-  
b or 5.3.4.  
OSSIBLE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH MAY OCCUR  
P
IF THE FURNACE IS NOT PROVIDED WITH ENOUGH FRESH AIR FOR PROPER  
COMBUSTION AND VENTILATION OF FLUE GASES. MOST HOMES REQUIRE  
OUTSIDE AIR BE SUPPLIED TO THE FURNACE AREA.  
Improved construction and additional insulation in buildings have  
reduced heat loss by reducing air infiltration and escape around  
doors and windows. These changes have helped in reducing  
heating/cooling costs but have created a problem supplying com-  
bustion and ventilation air for gas fired and other fuel burning appli-  
ances. Appliances that pull air out of the house (clothes dryers,  
exhaust fans, fireplaces, etc.) increase the problem by starving  
appliances for air.  
Space, Unconfined.  
For purposes of this Code, a space whose volume is not less than 50  
cubic feet per 1,000 BTU per hour of the aggregate input rating of all  
appliances installed in that space. Rooms communicating directly with  
the space in which the appliances are installed through openings not  
furnished with doors, are considered a part of the unconfined space.  
House depressurization can cause back drafting or improper com-  
bustion of gas-fired appliances, thereby exposing building occu-  
pants to gas combustion products that could include carbon mon-  
oxide.  
If this furnace is to be installed in the same space with other gas  
appliances, such as a water heater, ensure there is an adequate  
supply of combustion and ventilation air for the other appliances.  
Refer to the latest edition of the National Fuel Gas Code NFPA 54/  
5.3.3 Equipment Located in Confined Spaces:  
(a) All Air from Inside the Building: The confined space shall be pro-  
vided with two permanent openings communicating directly with  
an additional room(s) of sufficient volume so that the combined  
volume of all spaces meets the criteria for an unconfined space. The  
total input of all gas utilization equipment installed in the combined  
space shall be considered in making this determination. Each open-  
ing shall have a minimum free area of 1 square inch per 1,000 BTU  
9
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Chimney or Gas Vent  
per hour of the total input rating of all gas utilization equipment in  
the confined space, but not less than 100 square inches. One open-  
ing shall be within 12 inches of the top and one within 12 inches of  
the bottom of the enclosure.  
Ventilation louvers  
(each end of attic)  
NOTE: The inlet and outlet air  
openings must each have a free  
area of not less than one square  
inch per 4000 BTU of the  
total input rating of all equipment  
in the enclosure.  
Chimney or Gas Vent  
NOTE: Each opening must have  
a free area of not less than one  
square inch per 1000 BTU of  
the total input rating of all equip-  
ment in the enclosure, but not  
Outlet Air  
less than 100 square inches.  
Water  
Heater  
Furnace  
Inlet air duct  
[ends 1 ft (300 mm)  
above floor]  
Opening  
Water  
Heater  
Furnace  
Equipment Located in Confined Spaces; All Air from Outdoors  
Through Ventilated Attic. See 5.3.3-b.  
Opening  
3. When communicating with the outdoors through horizontal ducts,  
each opening shall have a minimum free area of 1 square inch per  
2,000 BTU per hour of total input rating of all equipment in the  
enclosure.  
Equipment Located in Confined Spaces; All Air from Inside  
Building. See 5.3.3-a.  
Chimney or Gas Vent  
(b) All Air from Outdoors: The confined space shall be provided with  
two permanent openings, one commencing within 12 inches of the  
top and one commencing within 12 inches of the bottom of the  
enclosure. The openings shall communicate directly, or by ducts,  
with the outdoors or spaces (crawl or attic) that freely communicate  
with the outdoors.  
NOTE: The air duct openings  
must have a free area of not  
less than one square inch per  
2000 BTU of the total input  
rating of all equipment in the  
1. When directly communicating with the outdoors, each opening  
shall have a minimum free area of 1 square inch per 4,000 BTU  
per hour of total input rating of all equipment in the enclosure.  
enclosure*.  
Outlet air duct  
Water  
Heater  
Furnace  
Chimney or Gas Vent  
Ventilation louvers  
(each end of attic)  
Inlet air duct  
NOTE: The inlet and outlet air  
openings must each have a free  
area of not less than one square  
inch per 4000 BTU of the  
total input rating of all equipment  
in the enclosure.  
*Iftheapplianceroomislocatedagainstanoutsidewallandtheairopeningscommunicatedirectlywiththe  
outdoors,eachopeningshallhaveafreeareaofnotlessthanonesquareinchper4,000BTUperhourof  
thetotalinputratingofallappliancesintheenclosure.  
Outlet Air  
Equipment Located in Confined Spaces; All Air from Outdoors.  
See 5.3.3-b.  
Water  
Heater  
4. When ducts are used, they shall be of the same cross-sectional  
area as the free area of the openings to which they connect. The  
minimum dimension of rectangular air ducts shall not be less  
than 3 inches.  
Furnace  
Inlet Air  
Alternate  
air inlet  
NOTE: The single opening must have  
a free area of not less than one  
Chimney or Gas Vent  
Ventilation louvers for  
unheated crawl space  
square inch per 3000 BTU of  
the total input rating of all equip-  
ment in the enclosure, but not less than  
the sum of the areas of all vent  
connectors in the confined space.  
Equipment Located in Confined Spaces; All Air from Outdoors—  
Inlet Air from Ventilated Crawl Space and Outlet Air to Ventilated  
Attic. See 5.3.3-b  
2. When communicating with the outdoors through vertical ducts,  
each opening shall have a minimum free area of 1 square inch per  
4,000 BTU per hour of total input rating of all equipment in the  
enclosure.  
Opening  
Alternate  
Opening  
Location  
Water  
Heater  
Furnace  
Equipment Located in Confined Spaces; All Air from Outdoors -  
Single Air Opening. See 5.3.3-b.  
10  
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FURNACE MUST BE LEVEL  
FROM END TO END  
5. When directly communicating with the outdoors, the single open-  
ing shall have a minimum free area of 1 square inch per 3,000  
BTU per hour of total input rating of all equipment in the enclo-  
sure.  
ALTERNATE VENT/FLUE  
AND COMBUSTION AIR  
INTAKE LOCATIONS  
FURNACE MUST BE LEVEL  
OR SLIGHTLY TILTED FORWARD  
WITH THE DOORS 0" - 3/4"  
BELOW THE BACK PANEL  
5.3.4 Specially Engineered Installations:  
The requirements of 5.3.3 shall not necessarily govern when special engi-  
neering, approved by the authority having jurisdiction, provides an  
adequate supply of air for combustion, ventilation, and dilution of flue  
gases.  
4 3/4" MINIMUM  
DRAIN TRAP  
CLEARANCE  
GAS LINE WITH  
DRIP LEG (3" MINIMUM)  
5.3.5 Louvers and Grilles:  
In calculating free area in 5.3.3, consideration shall be given to the blocking  
effect of louvers, grilles or screens protecting openings. Screens used  
shall not be smaller than 1/4 inch mesh. If the area through a design of  
louver or grille is known, it should be used in calculating the size of  
opening required to provide the free area specified. If the design and free  
area is not known, it may be assumed that wood louvers will have 20-25  
percent free area and metal louvers and grilles will have 60-75 percent  
free area. Louvers and grilles shall be fixed in the open position or  
interlocked with the equipment so that they are opened automatically  
during equipment operation.  
DRAIN LINE WITH 1/4" PER FOOT  
DOWNWARD SLOPE  
DRAIN PAN  
MINIMUM SERVICE  
24"  
FURNACE MUST BE SUPPORTED  
AT BOTH ENDS AND MIDDLE  
CLEARANCE REQUIRED  
HorizontalFurnace  
DRAIN TRAP AND LINES  
In horizontal applications the condensate drain trap is secured to  
the furnace side panel, suspending it below the furnace. A mini-  
mum clearance of 4 3/4 inches below the furnace must be pro-  
vided for the drain trap. Additionally, the appropriate downward  
piping slope must be maintained from the drain trap to the drain  
location. Refer to Section X, Condensate Drain Trap and Lines for  
further details. If the drain trap and drain line will be exposed to  
temperatures near or below freezing, adequate measures must  
be taken to prevent condensate from freezing.  
5.3.6 Special Conditions Created by Mechanical Exhausting or Fire-  
places:  
Operation of exhaust fans, ventilation systems, clothes dryers, or fireplaces  
may create conditions requiring special attention to avoid unsatisfac-  
tory operation of installed gas utilization equipment. Air from Inside  
Building. See 5.3.3-a.  
LEVELING  
VI. IN STALLATIO N PO SITIO N S  
Leveling ensures proper condensate drainage from the heat ex-  
changer and induced draft blower. For proper flue pipe drainage,  
the furnace must be level lengthwise from end to end. The furnace  
should also be level from back to front or have a slight tilt with the  
access doors downhill (approximately 3/4 inches) from the back  
panel. The slight tilt allows the heat exchanger condensate, gen-  
erated in the recuperator coil, to flow forward to the recuperator coil  
front cover.  
This furnace may be installed in an upright position or horizontal  
on either the left or right side panel. Do not install this furnace on  
its back. For upright upflow furnaces, return air ductwork may be  
attached to the side panel(s) and/or basepan. For horizontal up-  
flow furnaces, return air ductwork must be attached to the basepan.  
For both upright or horizontal counterflow furnaces, return duct-  
work must be attached to the basepan (top end of the blower com-  
partment). NOTE: Ductwork must never be attached to the back of  
the furnace. Contact your distributor for proper airflow require- ALTERNATE VENT/FLUEANDCOMBUSTION AIR CONNECTIONS  
ments and number of required ductwork connections. Refer to  
In horizontal installations provisions for alternate flue and com-  
“Recommended Installation Positions” figure for appropriate in-  
bustion air piping are available for upflow furnaces with left dis-  
stallation positions, ductwork connections, and resulting airflow  
charge and counterflow furnaces with right air discharge. This con-  
figuration allows the flue and combustion air piping to be run verti-  
arrangements.  
cally through the furnace. Refer to the “Recommended Installation  
Positions” figure for further detail. The standard piping connec-  
VII. H O RIZO N TAL APPLIC ATIO N S & CO N SID ERATIO N S  
tions may also be used in these positions. Refer to Section IX,  
GENERAL  
Vent/Flue Pipe and Combustion Air Pipe for details concerning the  
Horizontal applications, in particular, may dictate many of the  
conversion to the alternate vent/flue and combustion air connec-  
installation’s specifics such as airflow direction, ductwork connec-  
tions.  
tions, flue and combustion air pipe connections, etc. The basic  
application of this furnace as a horizontal furnace differs only slightly  
from an upright installation. When installing a furnace horizontally,  
additional consideration must be given to the following:  
11  
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AIR  
DISCHARGE  
ALTERNATE FLUE AND  
COMBUSTION AIR PIPE  
LOCATIONS  
High altitude installations may require both a pressure switch and  
an orifice change. These changes are necessary to compensate  
for the natural reduction in the density of both the gas fuel and the  
combustion air at higher altitude.  
For installations above 7000 feet, please refer to your distributor  
for required kit(s).  
Side  
Return  
Duct  
Side  
Return  
Duct  
Connection  
Connection  
Bottom  
Return  
Duct  
Manifold Pressure  
Pressure  
Switch Change  
Connection  
Gas Altitude  
Kit  
Orifice  
High Stage Low Stage  
UPFLOW  
UPRIGHT  
Natural  
0-7000  
None  
#43  
#55  
3.5" w.c.  
1.9" w.c.  
6.0" w.c.  
None  
None  
ALTERNATE FLUE AND  
COMBUSTION AIR PIPE  
LOCATIONS  
Propane  
10.0" w.c.  
LPM-03B  
NOTE: In Canada, gas furnaces are only certified to 4500 feet.  
Contact the distributor for a tabular listing of appropriate  
manufacturer’s kits for propane gas and/or high altitude installa-  
tions. The indicated kits must be used to insure safe and proper  
furnace operation. All conversions must be performed by a quali-  
fied installer, or service agency.  
Bottom  
Return  
Duct  
AIR  
DISCHARGE  
Connection  
UPFLOW HORIZONTAL  
LEFT AIR DISCHARGE  
IX. VEN T/ FLUE PIPE & CO M BUSTIO N AIR PIPE  
Bottom  
Return  
Duct  
AIR  
DISCHARGE  
GENERAL  
Connection  
UPFLOW HORIZONTAL  
RIGHT AIR DISCHARGE  
WARNING  
RecommendedInstallationPositions  
NOTE:Alternate “vertical” piping connections can not be used when  
an upflow furnace is installed with supply air discharging to the  
right, or when a counterflow furnace is installed with supply air  
discharging to the left. In either case, use the standard flue and  
combustion air piping connections.  
AILURE TO FOLLOW THESE INSTRUCTIONS CAN RESULT IN BODILY INJURY OR  
F
DEATH.  
AREFULLY READ AND FOLLOW ALL INSTRUCTIONS GIVEN IN THIS  
C
SECTION.  
ALTERNATE ELECTRICAL AND GAS LINE CONNECTIONS  
WARNING  
This furnace has provisions allowing for electrical and gas line  
connections through either side panel. In horizontal applications  
the connections can be made either through the “top” or “bottom” of  
the furnace.  
PON COMPLETION OF THE FURNACE INSTALLATION, CAREFULLY INSPECT THE  
U
ENTIRE FLUE SYSTEM BOTH INSIDE AND OUTSIDE THE FURNACE TO ASSURE IT  
IS PROPERLY SEALED. EAKS IN THE FLUE SYSTEM CAN RESULT IN SERIOUS  
L
PERSONAL INJURY OR DEATH DUE TO EXPOSURE TO FLUE PRODUCTS,  
DRAIN PAN  
INCLUDING CARBON MONOXIDE.  
A drain pan must be provided if the furnace is installed above a  
conditioned area. The drain pan must cover the entire area under  
the furnace (and air conditioning coil if applicable).  
A condensing gas furnace achieves its high level of efficiency by  
extracting almost all of the heat from the products of combustion  
and cooling them to the point where condensation takes place.  
Because of the relatively low flue gas temperature and water con-  
densation requirements, PVC pipe is used as venting material.  
This furnace must not be connected to Type B, BW, or L vent or vent  
connector, and must not be vented into any portion of a factory built  
or masonry chimney except when used as a pathway for PVC as  
described later in this section. Never common vent this appliance  
with another appliance or use a vent which is used by a solid fuel  
appliance. Do not use commercially available “no hub connec-  
tors” other than those shipped with this product.  
It is the responsibility of the installer to follow the manufacturers’  
recommendations and to verify that all vent/flue piping and connec-  
tors are compatible with furnace flue products. Additionally, it is the  
responsibility of the installer to ensure that all piping and connec-  
tions possess adequate structural integrity and support to prevent  
flue pipe separation, shifting, or sagging during furnace operation.  
FREEZE PROTECTION  
Refer to Section VI, Horizontal Applications and Conditions - Drain  
Trap and Lines.  
FURNACE SUSPENSION  
If the furnace is installed in a crawl space it must be suspended  
from the floor joist or supported by a concrete pad. Never install the  
furnace on the ground or allow it to be exposed to water. Refer to  
Section IV, Location Requirements and Considerations - Furnace  
Suspension for further details.  
VIII. PRO PAN E G AS / H IG H ALTITUD E IN STALLATIO N S  
WARNING  
OSSIBLE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH MAY OCCUR IF  
P
DUAL CERTIFICATION:NON-DIRECT/DIRECT VENT  
THE CORRECT CONVERSION KITS ARE NOT INSTALLED. HE APPROPRIATE KITS  
T
This furnace is dual certified and may be installed as a non-direct  
vent (single pipe) or direct vent (dual pipe) appliance. A non-direct  
vent installation requires only a vent/flue pipe, while a direct vent  
installation requires both a vent/flue pipe and a combustion air  
intake pipe. Refer to the appropriate section for details concerning  
piping size, length, number of elbows, furnace connections, and  
terminations.  
MUST BE APPLIED TO INSURE SAFE AND PROPER FURNACE OPERATION. LL  
A
CONVERSIONS MUST BE PERFORMED BY A QUALIFIED INSTALLER OR SERVICE  
AGENCY.  
This furnace is shipped from the factory configured for natural gas  
at standard altitude. Propane gas installations require an orifice  
change to compensate for the energy content difference between  
natural and propane gas.  
12  
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located in this section for specific details on termination construc-  
tion.  
MATERIALS AND JOINING METHODS  
All terminations (flue and/or intake) must be located at  
least 12 inches above ground level or the anticipated  
snow level.  
Vent terminations (non-direct and direct vent) must  
terminate at least 3 feet above any forced air inlet located  
within 10 feet.  
NOTE: This provision does not apply to the combustion  
air intake termination of a direct vent application.  
The vent termination of a non-direct vent application must  
terminate at least 4 feet below, 4 feet horizontally from, or  
1 foot above any door, window, or gravity air inlet into any  
building.  
The vent termination of a direct vent application must  
terminate at least 12 inches from any opening through  
which flue gases may enter a building (door, window, or  
gravity air inlet).  
The vent termination of vent pipe run vertically through a  
roof must terminate at least 12 inches above the roof line  
(or the anticipated snow level) and be at least 12 inches  
from any vertical wall (including any anticipated snow  
build up).  
A vent termination shall not terminate over public walkways  
or over an area where condensate or vapor could create  
a nuisance or hazard or could be detrimental to the  
operation of regulators, relief valves, or other equipment.  
The combustion air intake termination of a direct vent  
application should not terminate in an area which is  
frequently dusty or dirty.  
WARNING  
O AVOID BODILY INJURY, FIRE OR EXPLOSION, SOLVENT CEMENTS MUST BE  
T
KEPT AWAY FROM ALL IGNITION SOURCES (I.E., SPARKS, OPEN FLAMES, AND  
EXCESSIVE HEAT) AS THEY ARE COMBUSTIBLE LIQUIDS.  
CEMENT VAPORS OR CONTACT WITH SKIN AND/OR EYES.  
VOID BREATHING  
A
Two- or three-inch nominal diameter PVC Schedule 40 pipe meet-  
ing ASTM D1785, PVC primer meeting ASTM F656, and PVC sol-  
vent cement meeting ASTM D2564 specifications must be used.  
Fittings must be DWV type fittings meetingASTM D2665 andASTM  
D3311. Carefully follow the manufacturer’s instructions for cutting,  
cleaning, and solvent cementing of PVC.  
As an alternative to PVC pipe, primer, solvent cement, and fittings,  
ABS materials which are in compliance with the following specifi-  
cations may be used. Two-or-three-inch ABS Schedule 40 pipe  
must meet ASTM D1527 and, if used in Canada, must be CSA  
listed. Solvent cement for ABS to ABS joints must meet ASTM  
D2235 and, if used in Canada, must be CSA listed. The solvent  
cement for the PVC to ABS transition joint must meet ASTM D3138.  
Fittings must be DWV type fittings meetingASTM D2661 andASTM  
D3311 and, if used in Canada, must be CSA listed. Carefully  
follow the manufacturers’ instructions for cutting, cleaning, and  
solvent cementing PVC and/or ABS.  
All 90° elbows must be medium radius (1/4 bend DWV) or long  
radius (Long sweep 1/4 bend DWV) types conforming to ASTM  
D3311. A medium radius (1/4 bend DWV) elbow measures 3 1/  
16” minimum from the plane of one opening to the centerline of the  
other opening for 2” diameter pipe, and 4 9/16” minimum for 3”  
pipe.  
Non-Direct Vent  
&
Direct Vent  
Vent/Flue Terminations  
PROPER VENT/FLUE AND COMBUSTION AIR PIPING PRACTICES  
Adhere to these instructions to ensure safe and proper furnace  
performance. The length, diameter, and number of elbows of the  
vent/flue pipe and combustion air pipe (when applicable) affects  
the performance of the furnace and must be carefully sized. All  
piping must be installed in accordance with local codes and these  
instructions.  
Piping must be adequately secured and supported to prohibit sag-  
ging, joint separation, and/or detachment from the furnace. Hori-  
zontal runs of vent/flue piping must be supported every three feet  
and must maintain a 1/4 inch per foot downward slope, back to-  
wards the furnace, to properly return condensate to the furnace’s  
drain system. Allowances should be made for minor expansion  
and contraction due to temperature variations. For this reason,  
particular care must be taken to secure piping when a long run is  
followed by a short offset of less than 40 inches.  
Non-Direct Vent  
Vent/Flue Termination  
No Terminations  
Above Walkway  
<10'  
3' min.  
4' min.  
12"  
4'  
min.  
12"  
min.  
Grade or Highest  
Anticipated  
Snow Level  
12" min.  
Non-Direct Vent  
Vent/Flue Termination  
12" min.  
Forced Air  
Inlet  
Direct Vent  
Vent/Flue Termination  
Vent Termination Clearances  
Precautions should be taken to prevent condensate from freezing  
inside the vent/flue pipe and/or at the vent/flue pipe termination. All  
vent/flue piping exposed to freezing temperatures below 35°F for  
extended periods of time must be insulated with 1/2” thick closed  
cell foam. Also all vent/flue piping exposed outdoors in excess of  
the terminations shown in this manual (or in unheated areas)  
must be insulated with 1/2” thick closed cell foam. Inspect piping  
for leaks prior to installing insulation.  
NOTE: In Canada, the Canadian Fuel Gas Code takes precedence  
over the preceding termination restrictions.  
CANADIAN VENTING REQUIREMENTS  
In Canada, venting must conform to the requirements of the cur-  
rent CAN/CSA-B149 Installation Code. Use only CSA listed two or  
three inch diameter PVC or ABS pipe, solvent cement, and fittings  
throughout. Carefully follow the manufacturers’ instructions for  
cutting, cleaning, and solvent cementing PVC and/or ABS.  
The vent can be run through an existing unused chimney provided  
the space between the vent pipe and the chimney is insulated and  
closed with a weather-tight, corrosion-resistant flashing.  
TERMINATION LOCATIONS  
NOTES: Refer to Section IV, Location Requirements and  
Considerations for combustion air contaminant restrictions.  
The following bullets and diagram describe the restrictions con-  
cerning the appropriate location of vent/flue pipe and combustion  
air intake pipe (when applicable) terminations. Refer to Non-Di-  
rect Vent (Single Pipe) Piping and Direct Vent (Dual Pipe) Piping  
13  
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NOTE: Standard and alternate locations can be combined (i.e., an  
installation may use the standard combustion air intake location  
but use the alternate vent/flue location or vice versa), if needed.  
STANDARD FURNACE CONNECTIONS  
It is the responsibility of the installer to ensure that the piping  
connections to the furnace are secure, airtight, and adequately  
supported.  
As shipped, attachment “couplings” for vent/flue and combustion  
air intake pipe connections are provided on the furnace’s top cover  
(upflow) or basepan (counterflow). To use the standard connec-  
tions, field supplied vent/flue pipe and combustion air intake pipe  
(when applicable) should be secured directly to the furnace at  
these locations.  
WARNING  
DGES OF SHEET METAL HOLES MAY BE SHARP. SE GLOVES AS A PRE-  
E
U
CAUTION WHEN REMOVING HOLE PLUGS.  
ALTERNATE VENT/FLUE LOCATION  
The alternate vent/flue location is the large hole directly in line with  
the induced draft blower outlet. To use the alternate vent/flue loca-  
tion refer to the following steps, the “Vent/Flue Pipe Cuts” figure,  
and the “Alternate Vent/Flue Location” figure.  
VENT/FLUE PIPE  
Vent/flue pipe can be secured to the vent/flue coupling using the  
rubber coupling and worm gear hose clamps provided with this  
furnace (see “Standard Connections” figure). The rubber coupling  
allows separation of the vent/flue pipe from the furnace during  
servicing. NOTE: Do not use other commercially available “no hub  
connectors” due to possible material conflicts. The vent/flue pipe  
can also be secured using a PVC or ABS elbow or coupling using  
the appropriate glue (see Section IX, Materials and Joining Meth-  
ods.  
NOTE: Counterflow instructions follow the upflow instructions.  
1. Remove and save the four screws securing the vent/flue  
coupling to the furnace top panel.  
Counterflow units.  
Remove and save the four screws securing the vent/flue  
coupling to the furnace basepan. Also remove the three  
screws securing the furnace’s internal vent/flue piping to  
the blower deck.  
NOTE: For non-direct vent installations, a minimum of one 90°  
elbow should be installed on the combustion air intake coupling  
to guard against inadvertent blockage.  
2. Upflow and Counterflow units.  
Loosen the worm gear hose clamps on the rubber elbow  
and detach it from both the induced draft blower and the  
vent/flue pipe.  
COMBUSTION AIR PIPE  
DIRECT VENT INSTALLATIONS  
3. Upflow and Counterflow units.  
On upflow units secure the combustion air intake pipe directly to  
the air intake coupling. On counterflow units secure the combus-  
tion air intake pipe to the air intake coupling using the rubber cou-  
pling and worm gear hose clamps provided with the unit. The  
counterflow rubber coupling allows service removal of air intake  
piping internal to the furnace blower compartment. NOTE: Be-  
cause of probable material conflicts, do not use other commer-  
cially available “no hub connectors”. The combustion air intake  
pipe can also be secured directly to the counterflow unit air intake  
pipe coupling.  
Remove the vent/flue pipe from the furnace.  
4. Cut the vent/flue pipe 3.75 inches from the flanged end of  
the pipe. See Vent/Flue Pipe Cuts figure. The section of  
pipe attached to the coupling will reach through the side  
panel to the induced draft blower. Discard remaining pipe  
and elbows.  
Counterflow units.  
Cut the vent/flue pipe 3.75 inches from the blower deck  
coupling. See Vent/Flue Pipe Cuts figure. Save vent/flue  
pipe attached to blower deck coupling for use in the alternate  
location. Discard remaining pipe and elbows.  
NON-DIRECTVENT INSTALLATIONS  
A minimum of one 90° elbow should be installed on the combus-  
tion air intake “coupling” to guard against inadvertent blockage.  
FLANGE  
COMBUSTION  
VENT/FLUE  
PIPE  
COMBUSTION  
AIR PIPE  
AIR PIPE  
(DIRECT VENT ONLY)  
VENT/FLUE  
PIPE  
3.75"  
(DIRECT VENT ONLY)  
CUT HERE  
90 PVC  
ELBOW  
(NON-DIRECT VENT)  
RUBBER  
90 PVC  
ELBOW  
(NON-DIRECT VENT)  
RUBBER  
COUPLING  
WITH WORM  
GEAR CLAMPS  
COUPLINGS  
WITH WORM  
GEAR CLAMPS  
OR  
OR  
Vent/Flue Pipe Cuts  
5. Remove plastic plug from alternate vent/flue location.  
Relocate and install plug in standard vent/flue location (top  
cover).  
UPFLOW  
COUNTERFLOW  
STANDARD CONNECTIONS  
StandardConnections  
Counterflow units.  
Remove plastic plug from alternate vent/flue location.  
Relocate and install plug in standard vent/flue location  
(basepan). Plug remaining hole in blower deck with plastic  
plug included in the drain kit bag.  
ALTERNATE FURNACE CONNECTIONS  
If the standard locations are undesirable for a specific installation,  
alternate side panel locations are available for both combustion  
air inlet and vent/flue pipe connections. These locations may be of  
particular benefit to upright upflow installations requiring additional  
access to an A coil, or to upright counterflow installations requiring  
additional access to a filter or electronic air cleaner, or to horizontal  
installations desiring vent/flue (and combustion air intake) piping  
run vertically from the side of the cabinet.  
6. Upflow and Counterflow units.  
Insert cut section of vent/flue pipe and coupling into alternate  
vent/flue location. Using a rubber coupling and worm gear  
hose clamps from the drain kit bag, attach the vent/flue  
pipe and coupling to the induced draft blower. Secure the  
14  
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coupling to the cabinet using the screws removed in step 1  
or with field-supplied 3/8” #8 self drilling screws.  
ALTERNATE COMBUSTION AIR INTAKE LOCATION  
The alternate combustion air intake location consists of a large,  
unobstructed hole (alternate vent connection is aligned with the  
Induced Draft Blower). To use the alternate combustion air intake  
location, refer to the following steps, and the “Alternate Combus-  
tion Air Intake Location” figure.  
NOTE: Counterflow unit instructions follow the upflow instructions.  
1. Remove and save the four screws securing the combustion  
air intake coupling to the furnace’s top panel (upflow).  
WARNING  
HE RUBBER ELBOW IS NOT DESIGNED TO SUPPORAT A LOAD.  
HEN THE  
W
T
RUBBER ELBOW IS MOUNTED EXTERNALLY TO THE FURNACE CABINET,  
EXTREME CARE MUST BE TAKEN TO ADEQUATELY SUPPORT FIELD-SUPPLIED  
VENT/FLUE PIPING, AS DAMAGE CAN RESULT IN LEAKS CAUSING BODILY  
INJURY OR DEATH DUE TO EXPOSURE TO FLUE GASES, INCLUDING CARBON  
MONOXIDE.  
Counterflow units.  
Remove and save the four screws securing the combustion  
air intake coupling to the basepan. Remove an additional  
three screws securing the furnace’s internal combustion  
air intake pipe to the blower deck.  
7. Upflow and Counterflow units.  
For upright installations, externally mount the rubber elbow  
to the vent/flue coupling using a worm gear hose clamp.  
Secure field supplied vent/flue piping to the rubber elbow  
using a worm gear hose clamp. NOTE: Use of the alternate  
vent/flue location for upright installations, requires the drain  
trap be installed on the same side of the unit as the flue  
pipe.  
2. Remove the combustion air intake coupling and gasket from  
the top panel.  
Counterflow units.  
Remove the combustion air intake pipe from the furnace  
and cut the pipe at the basepan coupling. Save the basepan  
coupling and gasket from the blower deck coupling for use  
in the alternate location. Discard the remaining pipe.  
8. Upflow and Counterflow units.  
For horizontal installations, externally secure the field-  
supplied vent/flue pipe directly to the vent/flue coupling using  
a PVC or ABS coupling or elbow.  
3. Remove plastic plug from alternate combustion air intake  
location. Relocate and install plug in standard air intake  
location (top cover).  
1.  
3
3
1
REMOVE  
4 SCREWS  
REMOVE  
PIPE  
REMOVE  
PIPE  
Counterflow units.  
REMOVE  
4 SCREWS  
1
Remove plastic plug from alternate combustion air intake  
location. Relocate and install plug in standard air intake  
location (basepan). Plug the remaining hole in the blower  
deck with the plastic plug included in the drain kit bag.  
REMOVE  
3 SCREWS  
5
5
REMOVE  
AND RELOCATE  
REMOVE  
AND RELOCATE  
4. Upflow and Counterflow units.  
2
2
With the gasket facing the cabinet side panel, and the  
flange’s flat spot facing forward, secure the combustion air  
intake coupling to the cabinet using the screws removed in  
step 1 or with field-supplied 3/8” #8 self -drilling screws.  
DETACH RUBBER  
ELBOW FROM  
ID BLOWER AND  
VENT/FLUE  
PIPE  
DETATCH RUBBER  
ELBOW FROM  
ID BLOWER AND  
VENT/FLUE  
PIPE  
UPFLOW  
COUNTERFLOW  
CAUTION  
5
ADDITIONAL PLUG  
FROM DRAIN KIT  
E SURE NOT TO DAMAGE INTERNAL WIRING OR OTHER COMPONENTS WHEN  
B
REINSTALLING COUPLING AND SCREWS.  
7
EXTERNALLY  
MOUNT  
RUBBER ELBOW  
5. Upflow and Counterflow units.  
For non-direct vent installations installed horizontally, a  
minimum of one 90° elbow should be installed on the  
combustion air intake coupling to guard against inadvertent  
blockage. No elbow is required on the alternate combustion  
air intake of upright installations, however, a minimum  
clearance of 2 inches is required to assure proper air supply.  
6
SECURE TO  
ID BLOWER WITH  
RUBBER COUPLING  
AND HOSE  
CLAMPS  
COUNTERFLOW/UPRIGHT  
(UPFLOW SIMILAR)  
6. Upflow and Counterflow units.  
For direct vent installations, secure field-supplied  
6
SECURE TO  
combustion air intake pipe directly to the air intake coupling.  
NOTE: A PVC coupling or elbow is required on counterflow  
units.  
ID BLOWER WITH  
RUBBER COUPLING  
AND HOSE  
6
SECURE TO  
CABINET WITH  
SCREWS  
CLAMPS  
UPFLOW/HORIZONTAL  
(COUNTERFLOW SIMILAR)  
AlternateVent/FlueLocation  
15  
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1
UPFLOW  
1
5
REMOVE  
4 SCREWS  
2
REMOVE  
4 SCREWS  
2" CLEARANCE  
REQUIRED  
(NON-DIRECT  
VENT)  
Non-Direct Vent (Single Pipe)  
Maximum Allowable Length of Vent/Flue Pipe (ft) (1)(2)  
REMOVE  
2
REMOVE  
AND CUT  
1
Pipe (4)  
(Inch)  
Number of Elbows (3)  
Unit Input  
1
2
3
4
5
6
7
8
3
REMOVE  
REMOVE  
AND  
RELOCATE  
3 SCREWS  
45,000  
70,000  
2
2
3
3
3
71  
49  
71  
71  
49  
68  
46  
68  
68  
46  
65 62  
43 40  
65 62  
65 62  
43 40  
59  
37  
59  
59  
37  
56 53  
34 31  
56 53  
56 53  
34 31  
50  
28  
50  
50  
28  
3
ADDITIONAL  
PLUG FROM  
DRAIN KIT  
90,000  
115,000  
3
.
REMOVE  
AND  
RELOCATE  
COUNTERFLOW  
Non-Direct Vent (Single Pipe)  
Maximum Allowable Length of Vent/Flue Pipe (ft) (1)(2)  
UPFLOW  
COUNTERFLOW  
5
4
SECURE  
TO CABINET  
Pipe (4)  
(Inch)  
Number of Elbows (3)  
Unit Input  
1
2
3
4
5
6
7
8
2
3
2
3
61  
71  
61  
71  
58  
68  
58  
68  
55 52  
65 62  
55 52  
65 62  
49  
59  
49  
59  
46 43  
56 53  
46 43  
56 53  
40  
50  
40  
50  
70,000  
90,000  
UPFLOW/HORIZONTAL SHOWN  
(COUNTERFLOW SIMILAR)  
(1) One 90° elbow should be secured to the combustion air intake con-  
nection.  
(2) Minimum vent length is five feet and one elbow/tee.  
(3) Tee used in the vent/flue termination must be included when determin-  
ing the number of elbows in the piping system.  
Alternate Combustion Air Intake Location  
NON-DIRECT VENT (SINGLE PIPE) PIPING  
Non-direct vent installations require only a vent/flue pipe. The  
vent pipe can be run horizontally with an exit through the side of  
the building or run vertically with an exit through the roof of the  
building. The vent can also be run through an existing unused  
chimney; however, it must extend a minimum of 12 inches above  
the top of the chimney. The space between the vent pipe and the  
chimney must be closed with a weather-tight, corrosion-resistant  
flashing. For details concerning connection of the vent/flue pipe  
to the furnace, refer to Section IX, Vent/Flue Pipe and Combustion  
Air - Standard Furnace Connections or Alternate Furnace Con-  
nections for specific details. Refer to the following Non-Direct  
Vent (Single Pipe) Piping - Vent/Flue Pipe Terminations for spe-  
cific details on termination construction.  
Although non-direct vent installations do not require a combus-  
tion air intake pipe, a minimum of one 90° elbow should be at-  
tached to the furnace’s combustion air intake if: an upright instal-  
lation uses the standard intake location, or a horizontal installa-  
tion uses the alternate air intake location. This elbow will guard  
against inadvertent blockage of the air intake.  
(4) 3” diameter pipe can be used in place of 2” diameter pipe.  
VENT/FLUE PIPE TERMINATIONS  
The vent/flue pipe may terminate vertically, as through a roof, or  
horizontally, as through an outside wall.  
Vertical vent/flue pipe terminations should be as shown in the  
following figure. Refer to Section IX, Vent/Flue Pipe and Com-  
bustion Air Pipe - Termination Locations for details concerning  
location restrictions. The penetration of the vent through the roof  
must be sealed tight with proper flashing such as is used with a  
plastic plumbing vent.  
Horizontal vent/flue pipe terminations should be as shown in the  
following figure. Refer to Section IX, Vent/Flue Pipe and Combus-  
tion Air Pipe - Termination Locations for details concerning loca-  
tion restrictions. A 2 3/8” diameter wall penetration is required for  
2” diameter pipe while a 3 1/2” diameter hole is required for 3”  
diameter pipe. To secure the pipe passing through the wall and  
prohibit damage to piping connections, a coupling should be in-  
stalled on either side of the wall and solvent cemented to a length  
of pipe connecting the two couplings. The length of pipe should  
be the wall thickness plus the depth of the socket fittings to be  
installed on the inside and outside of the wall. The wall penetra-  
tion should be sealed with silicone caulking material.  
In a basement installation, the vent/flue pipe can be run between  
joist spaces. If the vent pipe must go below a joist and then up  
into the last joist space to penetrate the header, two 45° elbows  
should be used to reach the header rather than two 90° elbows.  
TEE  
VENT/FLUE PIPE LENGTHS AND DIAMETERS  
Refer to the following table for applicable length, elbows, and  
pipe diameter for construction of the vent/flue pipe system of a  
non-direct vent installation. In addition to the vent/flue pipe, a  
single 90° elbow should be secured to the combustion air intake  
to prevent inadvertent blockage. The tee used in the vent/flue  
termination must be included when determining the number of  
elbows in the piping system.  
12 " Min To  
Roof Or  
Highest Anticipated  
Snow Level  
Vertical Termination (Single Pipe)  
16  
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90º  
If the combustion air intake pipe is to be installed above a finished  
ceiling or other area where dripping of condensate will be objec-  
tionable, insulation of the combustion air pipe may be required.  
Use 1/2” thick closed cell foam insulation such as Armaflex™ or  
Insultube™ where required.  
MEDIUM RADIUS  
ELBOWS  
12" MIN.  
TO ROOF OR  
HIGHEST  
ANTICIPATED  
SNOW LEVEL  
UPFLOW  
Direct Vent (Dual Pipe) Maximum Allow able Length  
of Vent/Flue & Combustion Air Intake Pipe (ft)  
Number of Elbow s(1)(2)(3)  
Unit Input Termination Pipe(4)  
(Btu)  
Style  
(inch)  
Alternate Vertical Termination (Single Pipe)  
1
2
3
4
5
6
7
8
WALL  
Standard  
Alternate  
2
2
2
3
2
3
3
3
3
3
71 68 65 62 59 56 53 50  
58 55 52 49 46 43 40 37  
49 46 43 40 37 34 31 28  
71 68 65 62 59 56 53 50  
36 33 30 27 24 21 18 15  
57 54 51 48 45 42 39 36  
71 68 65 62 59 56 53 50  
57 54 51 48 45 42 39 36  
49 46 43 40 37 34 31 28  
35 32 29 26 23 20 17 14  
45,000  
OUTSIDE  
INSIDE  
TEE  
or  
90°ELBOW  
TURNED  
DOWN  
Standard  
Alternate  
70,000  
COUPLING  
MIN.  
12"  
FROM  
WALL  
Standard  
Alternate  
Standard  
Alternate  
12"  
90,000  
ELBOW OR  
COUPLING  
TO GROUND OR  
HIGHEST ANTICIPATED  
SNOW LEVEL  
115,000  
HorizontalTermination(SinglePipe)  
12" MIN.  
COUNTERFLOW  
Direct Vent (Dual Pipe) Maximum Allow able Length  
VENT/FLUE TEE  
or  
of Vent/Flue & Combustion Air Intake Pipe (ft)  
90° ELBOW TURNED  
DOWN  
Number of Elbow s(1)(2)(3)  
Unit Input Termination Pipe(4)  
(Btu)  
Style  
(inch)  
1
2
3
4
5
6
7
8
2
3
2
3
2
3
2
3
49 46 43 40 37 34 31 28  
71 68 65 62 59 56 53 50  
36 33 30 27 24 21 18 15  
57 54 51 48 45 42 39 36  
61 58 55 52 49 46 43 40  
71 68 65 62 59 56 53 50  
48 45 42 39 36 33 30 27  
57 54 51 48 45 42 39 36  
Standard  
70,000  
Alternate  
Standard  
Alternate  
HorizontalTermination(SinglePipe)  
AboveHighestAnticipatedSnowLevel  
90,000  
DIRECT VENT (DUAL PIPE) PIPING  
The inlet air screens provided in the installation instruction packet  
are available for the installer to use in the inlet of the combustion  
air pipe to prevent animals from building nests in the combustion  
air pipe. Installation of screens, while strongly recommended, is  
not required and will not affect performance of the unit.  
(1)  
Elbows and/or Tees used in the terminations must be included when  
determining the number of elbows in the piping system.  
Number of elbows tabulated are for each (Vent/Flue & Combustion air  
intake) pipe.  
(2)  
(3)  
Minimum length of each Vent/Flue & CombustionAir Intake pipe is five feet  
and one elbow/tee.  
(4) 3” diameter pipe can be used in place of 2” diameter pipe.  
Direct vent installations require both a combustion air intake and a  
vent/flue pipe. The pipes may be run horizontally and exit through  
the side of the building or run vertically and exit through the roof of  
the building. The pipes may be run through an existing unused  
chimney; however, they must extend a minimum of 12 inches  
above the top of the chimney. The space between the pipes and  
the chimney must be closed with a weather tight, corrosion resis-  
tant flashing. Both the combustion air intake and a vent/flue pipe  
terminations must be in the same atmospheric pressure zone.  
Refer to Section IX, Vent/Flue and Combustion Air Pipe - Termina-  
tion Locations or Concentric Vent Termination for specific details  
on termination construction. For details concerning connection of  
pipes to the furnace, refer to the Section IX, Vent/Flue Pipe and  
Combustion Pipe - Standard Furnace Connections or Alternate  
Furnace Connections.  
VENT/FLUE AND COMBUSTION AIR PIPE TERMINATIONS  
The vent/flue and combustion air pipes may terminate vertically, as  
through a roof, or horizontally, as through an outside wall.  
Vertical pipe terminations should be as shown in the following  
figure. Refer to Section IX, Vent/Flue Pipe and Combustion Pipe -  
Termination Locations for details concerning location restrictions.  
The penetrations through the roof must be sealed tight with proper  
flashing such as is used with a plastic plumbing vent.  
TEE  
VENT/FLUE  
90º  
COMBUSTION  
AIR INTAKE  
12" MIN.  
MEDIUM RADIUS  
ELBOWS  
VENT/FLUE AND COMBUSTION AIR PIPE LENGTHS AND DIAMETERS  
12" MIN.  
TO ROOF OR  
SCREEN  
HIGHEST  
ANTICIPATED  
SNOW LEVEL  
Refer to the following table for applicable length, elbows, and pipe  
diameter for construction of the vent/flue and combustion air intake  
pipe systems of a direct vent (dual pipe) installation. The number  
of elbows tabulated represents the number of elbows and/or tees  
in each (Vent/Flue & Combustion Air Intake) pipe. Elbows and/or  
tees used in the terminations must be included when determining  
the number of elbows in the piping systems.  
24" MAX.  
3" MIN.  
Vertical Terminations (Dual Pipe)  
17  
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Horizontal terminations should be as shown in the following fig-  
ure. Refer to Section IX, Vent/Flue Pipe and Combustion Pipe -  
Termination Location for location restrictions. A 2 3/8 inch diameter  
wall penetration is required for 2” diameter pipe while a 3 1/2 inch  
diameter hole is required for 3” diameter pipe. To secure the pipe  
passing through the wall and prohibit damage to piping connec-  
tions, a coupling should be installed on either side of the wall and  
solvent cemented to a pipe connecting the two couplings. The  
pipe length should be the wall thickness plus the depth of the  
socket fittings to be installed on the inside and outside of the wall.  
The wall penetration should be sealed with silicone caulking ma-  
terial.  
12" MIN  
Alternate Vent Termination Above Anticipated Snow Level  
(DualPipe)  
3" MIN  
24" MAX  
In a basement installation, the pipes may be run between the joist  
spaces. If the pipes must go below the joist and then up into the  
last joist space to penetrate the header, two 45° elbows should be  
used to reach the header rather than two 90° elbows.  
3" MIN  
24" MAX  
VENT/INTAKE TERMINATIONS FOR INSTALLATION OF MULTIPLE  
DIRECT VENTFURNACES  
If more than one direct vent furnace is to be installed vertically  
through a common roof top, maintain the same minimum clear-  
ances between the exhaust vent and air intake terminations of  
adjacent units as with the exhaust vent and air intake terminations  
of a single unit.  
Standard Horizontal Terminations (Dual Pipe)  
90°  
MEDIUM  
RADIUS  
ELBOW  
If more than one direct vent furnace is to be installed horizontally  
through a common side wall, maintain the clearances as in the  
following figure. Always terminate all exhaust vent outlets at the  
same elevation and always terminate all air intakes at the same  
elevation.  
24" MAX  
3" MIN  
24" MAX  
Vents  
90°  
Medium  
Radius  
Elbows  
AIR  
INTAKE  
3" Min.  
24" Max.  
3" Min.  
24" Max.  
3" Min.  
24" Max.  
Alternate Horizontal Vent Termination (Dual Pipe)  
Screen  
12" Min.  
12" MIN  
12" MIN.  
3" MIN.  
24" MAX.  
VENT/FLUE  
TEE  
HorizontalVentingOfMultipleUnits  
CONCENTRIC VENTTERMINATION  
SUPPORT  
STRAPS  
Refer to the directions provided with the Concentric Vent Kit (DCVK)  
for installation specifications.  
12" MIN. ABOVE  
HIGHEST ANTICIPATED  
SNOW LEVEL  
COMBUSTION  
AIR INTAKE.  
SCREEN  
12" MIN. ABOVE  
HIGHEST ANTICIPATED  
SNOW LEVEL  
X. CO N D EN SATE D RAIN LIN ES & D RAIN TRAP  
90°  
MEDIUM  
RADIUS  
ELBOWS  
GENERAL  
A condensing gas furnace achieves its high level of efficiency by  
extracting almost all of the heat from the products of combustion  
and cooling them to the point where condensation takes place.  
The condensate which is generated must be piped to an appropri-  
ate drain location.  
StandardHorizontalTerminationsAboveAnticipatedSnow  
Level (Dual Pipe)  
In upright installations, the furnace’s drain hoses may exit either  
the right or left side of the furnace. NOTE: If the alternate vent/flue  
outlet is utilized in an upright installation, the drain trap and drain  
connections must be located on the same side as the alternate  
vent/flue outlet.  
In horizontal installations, the drain hoses will exit through the  
bottom (down side) of the unit with the drain trap suspended be-  
neath the furnace. The field-supplied drain system must be in  
18  
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accordance with all local codes and the instructions in the follow-  
ing sections.  
RIGHT SIDE  
PANEL  
RUBBER  
ELBOW  
Follow the bullets listed below when installing the drain system.  
Refer to the following sections for specific details concerning fur-  
nace drain trap installation and drain hose hook ups.  
RUBBER ELBOW  
DRAIN PORT  
RED HOSE CLAMP  
TUBE 1  
The drain trap supplied with the furnace must be used.  
The drain line between furnace and drain location must  
be constructed of 3/4” PVC or CPVC.  
HOSE  
B
SIDE PANEL  
GROMMET  
HOLES  
The drain line between furnace and drain location must  
maintain a 1/4 inch per foot downward slope toward  
the drain.  
Do not trap the drain line in any other location than at  
the drain trap supplied with the furnace.  
TUBE(S) 2  
HOSE  
A
DRAIN  
TRAP  
RED HOSE  
CLAMP  
FRONT COVER  
DRAIN PORT  
GREEN  
HOSE  
CLAMPS  
(3 PLACES)  
UprightStandardConnections-RightSide  
(UpflowShown, CounterflowSimilar)  
Do not route the drain line outside where it may freeze.  
If the drain line is routed through an area which may  
see temperatures near or below freezing, precautions  
must be taken to prevent condensate from freezing  
within the drain line.  
If an air conditioning coil is installed with the furnace, a  
common drain may be used. An open tee must be  
installed in the drain line, near the cooling coil, to  
relieve positive air pressure from the coil’s plenum.  
This is necessary to prohibit any interference with the  
function of the furnace’s drain trap.  
LEFT  
SIDE PANEL  
FRONT COVER  
RUBBER  
DRAIN PORT  
ELBOW  
RED HOSE  
CLAMP  
RUBBER  
ELBOW  
DRAIN PORT  
HOSE A  
RED HOSE  
CLAMP  
SIDE PANEL  
DRAIN  
HOLES  
TUBE 1  
TUBE(S) 2  
UPRIGHT INSTALLATIONS  
GREEN HOSE  
CLAMPS  
(3 PLACES)  
In an upright installation drain hoses are connected to drain ports  
on the rubber elbow and the recuperator coil front cover. The drain  
lines are then routed through the right or left side panel and into  
the drain trap secured to the outside of the cabinet.  
NOTE: Refer to Section X, Condensate Drain Lines and Drain Trap  
- Alternate Vent/Flue Hose Connections for upright installations  
using an alternate vent/flue outlet.  
DRAIN  
TRAP  
HOSE B  
Upright “Standard” Connections - Left Side  
(UpflowShown, CounterflowSimilar)  
3. Cut and remove 1/4 inch from the end of the drain port on  
the rubber elbow.  
4. Insert Tube 1 into rubber elbow drain port and secure with  
red hose clamp. Angle tube outward toward front of furnace.  
STANDARD RIGHT OR LEFT SIDE DRAIN HOSE CONNECTIONS  
Upright installations using the standard vent/flue outlet require  
drain hoses to be connected as follows. The following quantity of  
hoses, tubes, and hose clamps are provided with the unit.  
5. Right side drains  
Cut 17 3/4 inches from the long end of Hose B and discard.  
Secure the remaining hose to Tube 1 with a green hose  
clamp. Route the other end of Hose B to front right side  
panel grommet hole.  
HOSE A  
QTY: 1  
Left side drains  
Cut “X” inches from the long end of Hose B and discard.  
Refer to table for appropriate length to cut. Secure remaining  
hose to Tube 1 with a green hose clamp. Route other end  
of Hose B to front left side panel grommet hole.  
HOSE B  
QTY: 1  
TUBE 1  
QTY: 1  
TUBE 2  
QTY: 2  
Cabinet Width  
(inches)  
Models  
(kBTU_Tons)  
"X" Length to Cut From Long  
End of Hose B  
GREEN  
RED  
HOSE CLAMPS  
HOSE CLAMPS  
17 1/2  
21  
45__30  
70__40  
7 inches  
QTY:  
3
QTY:  
2
3 1/2 inches  
Hose and Tube Identification  
090__50  
115__50  
24 1/2  
None  
1. Remove the rubber plug from the front cover drain port (right  
or left side, depending on the intended drain trap mounting).  
6. Insert short end of each Tube 2 through side panel grommet  
holes. Secure tubes to Hose A and Hose B with green  
hose clamps. Ensure hoses and tubes maintain a  
downward slope for proper drainage and that they are not  
kinked or binding.  
2. Secure Hose A to front cover drain port with a red hose  
clamp. Route hose to rear side panel grommet hole.  
NOTE: For left side drainage, grommets will have to be relocated to  
left side panel.  
For details concerning mounting of the drain trap, refer to Section  
X, Condensate Drain Lines and Drain Trap - Upright Drain Trap  
Mounting.  
ALTERNATE VENT/FLUE DRAIN HOSE CONNECTIONS  
Upright installations using the alternate vent/flue outlet will require  
19  
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“right-side only” drain hoses to be connected as follows. Refer to Make connections as follows:  
Section IX, Vent/Flue Pipe and Combustion Air Pipe for details on  
alternate vent/flue pipe connection.  
1. Remove the rubber plug from the coil front cover drain port.  
Counterflow furnaces  
1. Remove the rubber plug from the front cover right-side drain  
port. Save for use in step 3.  
2. Secure Hose A to front cover drain port with a red hose  
clamp. Route hose to rear right side panel grommet hole.  
3. Remove grommet from front right-side panel drain hole.  
Seal hole in grommet with large end of plug. Reinstall  
grommet and plug into side panel drain hole.  
4. Cut 1/4 inch from the end of the drain port on the externally  
mounted rubber elbow. Discard cut portion.  
5. Insert Tube 1 into rubber elbow drain port and secure with  
a red hose clamp. Angle tube outward toward front of furnace.  
6. Cut 17 7/8 inches from the long end of Hose B and discard.  
7. Secure remaining end of Hose B to exposed end of Tube 1  
with a green hose clamp. Route hose toward right side  
panel grommet holes.  
8. Insert short end of one Tube 2 through rear right side panel  
grommet drain hole. Secure tube to Hose A with a green  
hose clamp.  
Relocate the front cover pressure switch hose connection  
from the left side pressure tap to the right (down) side tap.  
The pressure switch hose must be connected to the down  
side to guard against blocked drain conditions. Cut hose  
to appropriate length to minimize sagging. Plug left  
(unused) pressure tap with plug removed from right side.  
2. Secure HoseAto front cover drain tap with a red hose clamp.  
Route hose to rear right (down) side panel grommet holes.  
3. Cut 1/4 inch from the end of the drain port on the rubber  
elbow and discard.  
4. Insert Tube 1 into rubber elbow drain port and secure with  
a red hose clamp. Angle tube outward toward front of  
furnace.  
5. Cut 17 3/4 inches from the long end of Hose B and discard.  
6. Secure remaining end of Hose B to exposed end of Tube 1  
with a green hose clamp. Route hose to front right down  
side panel grommet holes.  
7. Cut 5 1/2 inches straight length from the long end of each  
Tube 2.  
9. Insert short end of remaining Tube 2 into Hose B from  
rubber elbow and secure with green hose clamp. Ensure  
hoses and tubes maintain a downward slope for proper  
drainage and are not kinked or binding.  
FRONT COVER  
DRAIN PORT  
RED HOSE  
CLAMP  
HOSE A  
RUBBER ELBOW  
RUBBER  
FRONT  
COVER  
HOSE B  
(EXTERNALLY  
ELBOW  
DRAIN PORT  
MOUNTED)  
PRESSURE  
SIDE PANEL  
RUBBER  
FRONT COVER  
DRAIN PORT  
TAP  
GROMMET  
ELBOW  
HOLES  
RED HOSE CLAMP  
RIGHT  
SIDE  
PANEL  
GREEN HOSE  
TUBE 1  
TUBES 2  
CLAMPS  
(3 PLACES)  
RUBBER ELBOW  
DRAIN PORT  
GREEN  
HOSE  
CLAMP  
HOSE B  
TUBE 1  
RED HOSE  
CLAMP  
DRAIN TRAP  
SIDE PANEL  
GROMMET  
HOLES  
(3 PLACES)  
HorizontalConnections-RightSideDown  
(UpflowShown, CounterflowSimilar)  
HOSE A  
TUBE(S) 2  
RED HOSE  
CLAMP  
DRAIN TRAP  
8. Insert approximately one inch of each Tube 2 through the  
right down side panel grommet holes. Secure tubes to  
Hose A and Hose B using green hose clamps. Ensure  
hoses and tubes maintain a downward slope for proper  
drainage and are not kinked or bound.  
For details concerning mounting of the drain trap, refer to Section  
X, Condensate Drain Lines and Drain Trap - Upright Drain Trap  
Mounting.  
UprightAlternateConnections- RightSideOnly  
(UpflowShown, CounterflowSimilar)  
For details concerning mounting of the drain trap, refer to the fol-  
lowing section.  
UPRIGHT DRAIN TRAP MOUNTING (LEFT OR RIGHT SIDE PANEL)  
1. Insert drain tubes into drain trap and position the drain trap  
against the side panel. NOTE: Drain tubes must reach the  
bottom of the drain trap.  
2. Secure drain trap to side panel at the mounting holes  
(dimples or crosshairs on counterflow models) located  
below the grommet drain holes.  
LEFT SIDE DOWN  
Horizontal installations with the left side panel down will require  
drain hoses to be connected to the left side front cover drain port  
and the side drain port on the rubber elbow.  
3. Attach PVC drain line to drain trap outlet with either a 90°  
elbow or coupling.  
1. Remove the rubber plug from the coil front cover left (down)  
side drain port.  
HORIZONTAL INSTALLATIONS  
2. Relocate the front cover pressure switch hose connection  
from the right side (as shipped) pressure tap to the left  
(down) side tap. The pressure switch hose must be  
connected to the down side to guard against blocked drain  
conditions. Cut hose to appropriate length to minimize  
sagging. Plug right (unused) pressure tap with plug  
removed from left side.  
3. Secure Hose A to front cover drain port with a red hose  
clamp. Route hose to rear left (down) side panel grommet  
holes. NOTE: For left side drainage, grommets must be  
relocated to left side panel.  
RIGHT SIDE DOWN  
Horizontal installations with the right side down require that the  
drain hoses be connected to the right side front cover drain port  
and the rubber elbow drain port.  
NOTE: On counterflow models, relocation of the front cover pressure  
switch hose is required.  
20  
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CAUTION  
INDUCED  
DRAFT BLOWER  
DRAIN PORT  
ABEL ALL WIRES PRIOR TO DISCONNECTION WHEN SERVICING CONTROLS.  
IRING ERRORS CAN CAUSE IMPROPER AND DANGEROUS OPERATION.  
L
W
HOSE B  
ERIFY PROPER OPERATION AFTER SERVICING.  
V
FRONT  
COVER  
PRESSURE  
TAP  
HOSE A  
WIRING HARNESS  
The wiring harness is an integral part of this furnace. Field alter-  
ation to comply with electrical codes should not be required. Wires  
are color and number coded for identification purposes. Refer to  
the wiring diagram for wire routings. If any of the original wire as  
supplied with the furnace must be replaced, it must be replaced  
with wiring material having a temperature rating of at least 105°C.  
Any replacement wiring must be copper conductor.  
GREEN HOSE  
CLAMPS  
(3 PLACES)  
LEFT SIDE  
PANEL  
TUBE(S) 2  
FRONT COVER  
DRAIN PORT  
DRAIN TRAP  
RED HOSE CLAMP  
SIDE PANEL  
GROMMET  
HOLES  
115VOLT LINE CONNECTIONS  
Before proceeding with electrical connections, ensure that the sup-  
ply voltage, frequency, and phase correspond to that specified on  
the unit rating plate. Power supply to the furnace must be N.E.C.  
Class 1, and must comply with all applicable codes. The furnace  
must be electrically grounded in accordance with local codes or, in  
their absence, with the latest edition of The National Electric Code,  
ANSI NFPA 70 and/or The Canadian Electric Code CSA C22.1.  
Use a separate fused branch electrical circuit containing properly  
sized wire, and fuse or circuit breaker. The fuse or circuit breaker  
must be sized in accordance with the maximum overcurrent pro-  
tection specified on the unit rating plate. An electrical disconnect  
must be provided at the furnace location.  
Horizontal Connections - Left Side Down  
(UpflowShown, CounterflowSimilar)  
4. Remove the rubber cap from the side drain port on the rubber  
elbow.  
5. Secure the short end of Hose B to rubber elbow side drain  
port using a green hose clamp. NOTE: For left side drainage,  
route hose to far left (down) side panel grommet holes.  
NOTE: Horizontal left side connections (when using new  
side port drain elbow) does not require connecting a hose  
to the induced draft blower housing.  
6. Cut 5 1/2 inches straight length from the long end of each  
Tube 2.  
NOTE: Line polarity must be observed when making field  
connections.  
7. Insert approximately one inch of each Tube 2 through left  
side panel grommet hole. Secure tubes to Hose A and  
Hose B with a green hose clamps. NOTE: Tube must  
reach bottom of trap. Ensure hoses and tubes maintain a  
downward slope for proper drainage and that they are not  
kinked or binding.  
For details concerning mounting of the drain trap, refer to Section  
X, Condensate Drain Lines and Drain Trap - Upright Drain Trap  
Mounting.  
Connect hot, neutral, and ground wires as shown in the wiring  
diagram located on the unit’s blower door. For direct vent applica-  
tions, the cabinet opening to the junction box must be sealed air  
tight using either an UL approved bushing such as Heyco Liquid  
Tight or by applying non-reactive UL approved sealant to bushing.  
Line polarity must be observed when making field connections.  
Line voltage connections can be made through either the right or  
left side panel. The furnace is shipped configured for a left side  
(right side for counterflows) electrical connection with the junction  
box located inside the burner compartment. To make electrical  
connections through the opposite side of the furnace, the junction  
box must be relocated to the other side of the burner compartment  
prior to making electrical connections. To relocate the junction box,  
follow the steps shown below.  
HORIZONTAL DRAIN TRAP MOUNTING (LEFT OR RIGHT SIDE PANEL)  
1. Position the drain trap against side panel with drain tubes  
inserted into trap. Note that the trap may be orientated with  
the outlet facing either the furnace’s top cover or base pan.  
2. Secure drain trap to side panel at the dimples or crosshairs  
located on either side of the grommet drain holes.  
CAUTION  
3. Confirm that tubes reach bottom of drain trap and that all  
hoses maintain a downward slope and are not kinked or  
binding.  
4. Attach PVC drain line to drain trap outlet with either a 90°  
elbow or coupling.  
DGES OF SHEET METAL HOLES MAY BE SHARP. SE GLOVES A PRECAUTION  
E
U
WHEN REMOVING HOLE PLUGS.  
1. Remove the burner compartment door.  
2. Remove and save the two screws securing the junction box  
to the side panel.  
XI. ELECTRICAL CO N N ECTIO N S  
3. Relocate junction box and associated plugs and grommets  
to opposite side panel. Secure with screws removed in  
step 2.  
WARNING  
O AVOID THE RISK OF ELECTRICAL SHOCK, WIRING TO THE UNIT MUST BE  
T
POLARIZED AND GROUNDED.  
WARNING  
O AVOID INJURY, ELECTRICAL SHOCK OR DEATH, DISCONNECT ELECTRICAL  
T
POWER BEFORE SERVICING OR CHANGING ANY ELECTRICAL WIRING.  
21  
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W 2  
Thermo stat  
Tw o-Sta ge H eating  
with  
(
)
Single-Stage C ooling  
W 1  
W 1  
Y
*
*
*
*
*
*
ALTERNATE  
JUNCTION BOX  
LOCATION  
STANDARD  
JUNCTION BOX  
LOCATION  
G
G
R
R
Furnace In tegrated  
C ontro l M odule  
D E HU M  
T W IN  
YLO  
O
Y
Y
B/C  
W 2  
NEU  
HO T  
D ehum idistat  
[O ptiona l]  
C
JunctionBoxRelocation  
WARNING  
R em ote  
Co nd ensing Unit  
(S ingle-Sta ge C ooling)  
Two-Stage H eating with Single-S tage C ooling  
O AVOID THE RISK OF INJURY, ELECTRICAL SHOCK OR DEATH, THE FURNACE  
T
Thermostat  
Two-Stage Heating  
with  
MUST BE ELECTRICALLY GROUNDED IN ACCORDANCE WITH LOCAL CODES OR,  
IN THEIR ABSENCE, WITH THE LATEST EDITION OF THE ATIONAL LECTRIC  
YLO  
W2  
N
E
( )  
Two-Stage Cooling  
ODE.  
C
W1  
W1  
Y
To ensure proper unit grounding, the ground wire should run from  
the furnace ground screw located inside the furnace junction box  
all the way back to the electrical panel. NOTE: Do not use gas  
piping as an electrical ground. To confirm proper unit grounding,  
turn off the electrical power and perform the following check.  
1. Measure resistance between the neutral (white) connection  
and one of the burners.  
G
G
R
R
Furnace Integrated  
Control Module  
D EHUM  
TWIN  
YLO  
YLO  
O
Y
B/C  
W2  
NEU  
HOT  
Dehumidistat  
[Optional]  
C
Y
2. Resistance should measure 10 ohms or less.  
Remote  
Condensing Unit  
(Two-Stage Cooling)  
This furnace is equipped with a blower door interlock switch which  
interrupts unit voltage when the blower door is opened for servic-  
ing. Do not defeat this switch.  
Two-Stage Heating with Two-Stage Cooling  
24VOLT THERMOSTAT WIRING  
Thermostat Diagrams  
NOTE: Wire routing must not interfere with circulator blower  
operation, filter removal, or routine maintenance.  
This furnace is equipped with a 40 VA transformer to facilitate use  
with most cooling equipment. Consult the wiring diagram, located  
on the blower compartment door, for further details of 115 Volt and  
24 Volt wiring.  
As a two-stage furnace, the furnace integrated control module pro-  
vides terminals for both “W1” and “W2”, and “YLO” and “Y” thermo-  
stat connections. This allows the furnace to support the following  
system applications: ‘Two-Stage Heating Only’, ‘Two-Stage Heat-  
ing with Single-Stage Cooling’, and ‘Two-Stage Heating with Two-  
Stage Cooling’. Refer to the following figures and table for proper  
connections to the integrated control module.  
Low voltage connections can be made through either the right or  
left side panel. Thermostat wiring entrance holes are located in the  
blower compartment. Wire routing must not interfere with circula-  
tor blower operation, filter removal, or routine maintenance.  
SINGLE-STAGE THERMOSTATAPPLICATION  
A single-stage thermostat with only one heating stage can be used  
to control this furnace. The application of a single-stage thermo-  
stat does not offer “true” thermostat-driven two-stage operation,  
but provides a timed transition from low to high fire. The furnace  
will run on low stage for a fixed period of time before stepping up to  
high stage to satisfy the thermostat’s call for heat. The delay pe-  
riod prior to stepping up can be set at either 5 or 10 minutes through  
the DIP switch adjacent to the Heat Off delay DIP switches on the  
integrated control module. To use a single-stage thermostat, turn  
off power to the furnace, move the thermostat selection jumper on  
the integrated control module from the “two-stage” position to the  
“single-stage” position, turn power back on. Refer to the following  
figures.  
T h e rm osta t  
S in gle -S ta ge H e ating  
w ith  
( )  
S in gle-S ta ge C oo ling  
W
Y
G
G
R
R
F u rn ac e In teg ra te d  
C on tro l M o du le  
D E H U M  
T W IN  
O
Y L O  
Y
Y
B /C  
W 1  
W 2  
T-Stat selection jumper in  
single-stage thermostat  
position.  
T
W
O
T
W
O
N E U  
H O T  
TSTAT  
TSTAT  
OFF  
D e hu m id ista t  
[O p tio na l]  
C
S
I
S
I
N
G
L
3
3
ON  
R e m o te  
C o nd e ns in g U n it  
(S in g le -S ta ge C o o lin g )  
N
G
L
2
1
2
1
E
E
S ing le-S ta ge H e a tin g w ith S in g le -S ta ge C o olin g  
N O T E :  
T o ap p ly  
a
sin gle-stag e he a tin g th e rm o stat, the  
th erm o sta t s ele ctor ju m p e r on th e inte g rate d C o n tro l  
m od u le m us t b e set o n sin gle s tag e .  
DIP switch position 3: ON  
Delay Period: 10 minutes.  
DIP switch position 3: OFF  
Delay Period: 5 minutes.  
24VOLT DEHUMIDISTAT WIRING  
The optional usage of a dehumidistat allows the furnace’s circula-  
tor blower to operate at a slightly lower speed during a combined  
thermostat call for cooling and dehumidistat call for dehumidifica-  
22  
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tion. This lower blower speed enhances dehumidification of the Turn OFF power to the furnace before installing any accessories.  
conditioned air as it passes through the AC coil. For proper func- Follow the humidifier or air cleaner manufacturers’ instructions for  
tion, a dehumidistat applied to this furnace must operate on 24 locating, mounting, grounding, and controlling these accessories.  
VAC and utilize a switch which opens on humidity rise.  
To install/connect a dehumidistat:  
1. Turn OFF power to furnace.  
2. Secure the dehumidistat neutral wire (typically the white  
lead) to the screw terminal marked “DEHUM” on the furnace  
integrated control module.  
Accessory wiring connections are to be made through the 1/4"  
quick connect terminals provided on the furnace integrated control  
module. The humidifier and electronic air cleaner hot and neutral  
terminals are identified as HUM and EAC. All field wiring must  
conform to applicable codes. Connections should be made as  
shown.  
3. Secure the dehumidistat hot wire (typically the black lead)  
to the screw terminal marked “R” on the furnace integrated  
control module.  
12 CIRCUIT  
CONNECTOR  
4. Secure the dehumidistat ground wire (typically the green  
lead) to the ground screw on the furnace junction box. NOTE:  
Ground wire may not be present on all dehumidistats.  
INTEGRATED  
CONTROL MODULE  
5. Turn ON power to furnace.  
To enable the dehumidify function on the integrated control mod-  
ule:  
1. Cut the jumper wire labeled “CUT FOR DEHUM” located  
adjacent to the DEHUM screw terminal.  
HUMIDIFIER  
Once the jumper wire is cut, the dehumidify function is enabled  
during a combination call for cooling (T-Stat) and dehumidification  
(Dehum-Stat). The yellow LED adjacent to the DEHUM screw ter-  
minal will be illuminated during dehumidification.  
DEHUM  
ELECTRONIC  
AIR CLEANER  
OPTIONAL ACCESSORIES  
TWIN  
0
YL0  
Y
B/C  
G
R
W1 W2  
Accessories Wiring  
1 T P  
DEHUMIDIFICATION  
LED (YELLOW)  
If it is necessary for the installer to supply additional line voltage  
wiring to the inside of the furnace, the wiring must conform to all  
local codes, and have a minimum temperature rating of 105°C. All  
line voltage wire splices must be made inside the furnace junction  
box.  
The integrated control module humidifier terminals (HUM) are en-  
ergized with 115 volts whenever the induced draft blower is ener-  
gized. The integrated control module electronic air cleaner termi-  
nals (EAC) are energized with 115 volts whenever the circulator  
blower is energized.  
0
YL0  
Y
B/C4 R 8  
G
R
W1 W2  
2 T P  
1 9 R 1  
7 S D  
W 3  
3 D S  
5 S D  
4
D S  
5 R 8  
2 R 2  
4
W 1  
1 2 R 8  
CUT FOR  
DEHUM 2 2 R 1  
DEHUMIDIFICATION  
JUMPER WIRE  
(CUT TO ENABLE)  
5 3 C R  
FOSSIL F UEL APPLICATIONS  
This furnace can be used in conjunction with a heat pump in a  
fossil fuel application. A fossil fuel application refers to a combined  
gas furnace and heat pump installation which uses an outdoor  
temperature sensor to determine the most cost efficient means of  
heating (heat pump, gas furnace, or both).  
A heat pump thermostat with three stages of heat is required  
to properly use a two-stage furnace in conjunction with a heat  
pump. Refer to the fossil fuel kit installation instructions for  
additionalthermostatrequirements.  
24 VOLT HUMIDIFIER  
A 5" long brown wire in the wire harness at the low fire pressure  
provides 24 VAC humidifier control. This wire is powered any time  
the pressure switch is closed. To connect 24 VAC HUM, connect  
the 24 VAC line of the humidifier to the 5” brown wire. The connec-  
tion can be made by either stripping the wire and using a wire nut  
or by using a field supplied quick connect terminal. The wiring  
must conform to all local and national codes. Connect the COM  
side of the humidifier to the B/C terminal on the furnace control  
board (or to the COM side of the 24 VAC transformer). Do not  
connect 115V humidifier to these terminals.  
Strictly follow the wiring guidelines in the fossil fuel kit installa-  
tioninstructions. Allfurnaceconnectionsmustbemadetothe  
furnace two-stage integrated control module and the “FUR-  
NACE” terminal strip on the fossil fuel control board.  
XII. G AS SUPPLY AN D PIPIN G  
115 VOLT LINE CONNECTION OF ACCESSORIES (HUMIDIFIER  
AND ELECTRONIC AIR CLEANER)  
GENERAL  
The furnace rating plate includes the approved furnace gas input  
rating and gas types. The furnace must be equipped to operate on  
the type of gas applied. This includes any conversion kits required  
for alternate fuels and/or high altitude.  
WARNING  
O AVOID INJURY, ELECTRICAL SHOCK OR DEATH, DISCONNECT ELECTRICAL  
T
POWER BEFORE SERVICING OR CHANGING ANY ELECTRICAL WIRING.  
CAUTION  
The furnace’s integrated control module is equipped with line volt-  
age accessory terminals for controlling power to an optional field-  
supplied humidifier and/or electronic air cleaner.  
O PREVENT UNRELIABLE OPERATION OR EQUIPMENT DAMAGE, THE INLET  
T
GAS SUPPLY PRESSURE MUST BE AS SPECIFIED ON THE UNIT RATING PLATE  
WITH ALL OTHER HOUSEHOLD GAS FIRED APPLIANCES OPERATING.  
The accessory load specifications are as follows:  
Humidifier  
Electronic Air Cleaner  
1.0 Amp maximum at 120 VAC  
1.0 Amp maximum at 120 VAC  
23  
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Inlet gas supply pressures must be maintained within the ranges down periods.  
specified below. The supply pressure must be constant and avail-  
GAS PIPING CONNECTIONS  
GENERAL  
able with all other household gas fired appliances operating. The  
minimum gas supply pressure must be maintained to prevent  
unreliable ignition. The maximum must not be exceeded to pre-  
vent unit overfiring.  
CAUTION  
Inlet Gas Supply Pressure  
O AVOID POSSIBLE UNSATISFACTORY OPERATION OR EQUIPMENT DAMAGE  
T
Natural Gas  
Minimum:5.0" W.C. Maximum :10.0" W.C.  
Propane Gas Minimum:11.0" W.C. Maximum :13.0" W.C.  
DUE TO UNDERFIRING OF EQUIPMENT, USE THE PROPER SIZE OF  
NATURAL/PROPANE GAS PIPING NEEDED WHEN RUNNING PIPE FROM THE  
METER/TANK TO THE FURNACE.  
HIGH ALTITUDE DERATE  
When sizing a trunk line, be sure to include all appliances which  
will operate simultaneously when sizing a trunk line.  
When this furnace is installed at high altitude, the appropriate High  
Altitude orifice kit must be applied. This is required due to the  
natural reduction in the density of both the gas fuel and combus-  
tion air as altitude increases. The kit will provide the proper design  
certified input rate within the specified altitude range.  
High altitude kits are purchased according to the installation alti-  
tude and usage of either natural or propane gas. Contact your  
distributor for a tabular listing of appropriate altitude ranges and  
corresponding manufacturer’s high altitude (Natural, propane gas,  
and/or Pressure Switch) kits.  
Do not derate the furnace by adjusting the manifold pressure to a  
lower pressure than specified on the furnace rating plate. The  
combination of the lower air density and a lower manifold pressure  
will prohibit the burner orifice from drawing the proper amount of  
air into the burner. This may cause incomplete combustion, flash-  
back, and possible yellow tipping.  
In some areas the gas supplier may artificially derate the gas in an  
effort to compensate for the effects of altitude. If the gas is artifi-  
cially derated, the appropriate orifice size must be determined  
based upon the BTU/ft3 content of the derated gas and the altitude.  
Refer to the National Fuel Gas Code, NFPA 54/ANSI Z223.1, and  
information provided by the gas supplier to determine the proper  
orifice size.  
The gas piping supplying the furnace must be properly sized based  
on the gas flow required, specific gravity of the gas, and length of  
the run. The gas line installation must comply with local codes, or  
in their absence, with the latest edition of the National Fuel Gas  
Code, NFPA 54/ANSI Z223.1.  
Natural Gas Capacity of Pipe  
In Cubic Feet of Gas Per Hour (CFH)  
Length of  
Nominal Black Pipe Size  
Pipe in Feet  
1/2"  
132  
92  
73  
63  
56  
50  
46  
43  
40  
38  
3/4"  
1"  
1 1/4"  
1 1/2"  
1600  
1100  
980  
10  
20  
30  
40  
50  
60  
70  
80  
90  
100  
278  
190  
152  
130  
115  
105  
96  
520  
350  
285  
245  
215  
195  
180  
170  
160  
150  
1050  
730  
590  
500  
440  
400  
370  
350  
320  
305  
760  
670  
610  
560  
530  
90  
84  
490  
79  
460  
(Pressure 0.5 psig or less and pressure drop of 0.3" W.C.; Based on  
0.60 Specific Gravity Gas)  
BTUH Furnace Input  
CFH =  
Heating Value of Gas (BTU/Cubic Foot)  
A different pressure switch may be required at high altitude regard-  
less of the BTU/ft3 content of the fuel used. Contact your distributor  
for a tabular listing of appropriate altitude ranges and correspond-  
ing manufacturer’s pressure switch kits.  
To connect the furnace to the building’s gas piping, the installer  
must supply a ground joint union, drip leg, manual shutoff valve,  
and line and fittings to connect to gas valve. In some cases, the  
installer may also need to supply a transition piece from 1/2" pipe  
to a larger pipe size.  
PROPANE GAS CONVERSION  
The following stipulations apply when connecting gas piping. Re-  
fer to Gas Piping Connections figure for typical gas line connec-  
tions to the furnace.  
WARNING  
OSSIBLE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH MAY OCCUR IF  
P
Use black iron or steel pipe and fittings for building piping.  
Where possible, use new pipe that is properly chamfered,  
reamed, and free of burrs and chips. If old pipe is used, be  
sure it is clean and free of rust, scale, burrs, chips, and old  
pipe joint compound.  
THE CORRECT CONVERSION KITS ARE NOT INSTALLED. HE APPROPRIATE KITS  
T
MUST BE APPLIED TO INSURE SAFE AND PROPER FURNACE OPERATION. LL  
A
CONVERSIONS MUST BE PERFORMED BY A QUALIFIED INSTALLER OR SERVICE  
AGENCY.  
This unit is configured for natural gas. The appropriate  
manufacturer’s propane gas conversion kit, must be applied for  
propane gas installations. Refer to the Section VIII, Propane Gas  
/ High Altitude Installations section for details.  
Use pipe joint compound on male threads ONLY. Always  
use pipe joint compound (pipe dope) that is APPROVED  
FORALL GASSES. DO NOT apply compound to the first two  
threads.  
GAS VALVE  
This unit is equipped with a 24 volt gas valve controlled during  
furnace operation by the integrated control module. As shipped,  
the valve is configured for natural gas. The valve is field convertible  
for use with propane gas by replacing the regulator spring with a  
propane gas spring from an appropriate manufacturer’s propane  
gas conversion kit. Taps for measuring the gas supply pressure  
and manifold pressure are provided on the valve.  
The gas valve has a manual ON/OFF control located on the valve  
itself. This control may be set only to the “ON” or “OFF” position.  
Refer to the lighting instructions label or Section XIV, Startup Pro-  
cedure & Adjustment for use of this control during start up and shut  
Use ground joint unions.  
Install a drip leg to trap dirt and moisture before it can enter  
the gas valve. The drip leg must be a minimum of three  
inches long.  
Install a 1/8" NPT pipe plug fitting, accessible for test gage  
connection, immediately upstream of the gas supply  
connection to the furnace.  
Always use a back-up wrench when making the connection  
to the gas valve to keep it from turning. The orientation of  
the gas valve on the manifold must be maintained as  
24  
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shipped from the factory. Maximum torque for the gas valve  
connection is 375 in-lbs; excessive over-tightening may  
damage the gas valve.  
CAUTION  
Install a manual shutoff valve between the gas meter and  
unit within six feet of the unit. If a union is installed, the  
union must be downstream of the manual shutoff valve,  
between the shutoff valve and the furnace.  
DGES OF SHEET METAL HOLES MAY BE SHARP. SE GLOVES A PRECAUTION  
E
U
WHEN REMOVING HOLE PLUGS.  
DIRECT/STANDARD INLET PIPING  
Tighten all joints securely.  
When gas piping enters directly to the gas valve through the stan-  
dard inlet hole, the installer must supply straight pipe with a ground  
joint union to reach the exterior of the furnace. The rigid pipe must  
be long enough to reach the outside of the cabinet to seal the  
grommet cabinet penetration. A semi-rigid connector to the gas  
piping can be used outside the cabinet per local codes.  
Connect the furnace to the building piping by one of the  
following methods:  
Rigid metallic pipe and fittings.  
Semi-rigid metallic tubing and metallic fittings.  
Aluminum alloy tubing must not be used in exterior  
locations. In order to seal the grommet cabinet  
penetration, rigid pipe must be used to reach the  
outside of the cabinet. A semi-rigid connector to the  
gas piping may be used from there.  
INDIRECT/ALTERNATE INLET PIPING  
When gas piping enters indirectly to the gas valve through the  
alternate gas inlet hole the following fittings (starting from the gas  
valve) to reach the outside of the cabinet must be supplied:  
Coupling.  
Use listed gas appliance connectors in accordance with  
their instructions. Connectors must be fully in the same  
room as the furnace.  
90 degree elbow.  
2 inch close nipple.  
90 degree elbow.  
Protect connectors and semirigid tubing against physical  
and thermal damage when installed. Ensure aluminum-  
alloy tubing and connectors are coated to protect against  
external corrosion when in contact with masonry, plaster, or  
insulation, or subjected to repeated wetting by liquids such  
as water (except rain water), detergents, or sewage.  
Straight pipe, with a ground joint union, to reach the exterior  
of the furnace. The rigid pipe must be long enough to reach  
the outside of the cabinet so as to seal the grommet cabinet  
penetration. A semi-rigid connector to the gas piping can  
be used outside the cabinet per local codes.  
MANUAL  
SHUT OFF VALVE  
GAS VALVE  
(UPSTREAM FROM  
GROUND JOINT  
PIPE UNION)  
ALTERNATE  
GAS LINE  
MANUAL  
MANIFOLD  
BURNERS  
SHUT OFF VALVE  
(UPSTREAM FROM  
GROUND JOINT  
PIPE UNION)  
LOCATION  
GAS PIPING CHECKS  
ALTERNATE  
GAS LINE  
LOCATION  
Before placing unit in operation, leak test the unit and gas connec-  
tions.  
PLUG IN  
ALTERNATE  
GAS LINE  
HOLE  
PLUG IN  
ALTERNATE  
GAS LINE  
HOLE  
HEIGHT REQUIRED  
BY LOCAL CODE  
HEIGHT REQUIRED  
BY LOCAL CODE  
*
*
GROMMET  
IN STANDARD  
GAS LINE HOLE  
WARNING  
GAS VALVE  
MANIFOLD  
GROUND JOINT  
PIPE UNION  
GROMMET  
IN STANDARD  
GAS LINE HOLE  
O AVOID THE POSSIBILITY OF EXPLOSION OR FIRE, NEVER USE A MATCH OR  
T
DRIP LEG  
DRIP LEG  
BURNERS  
GROUND JOINT  
PIPE UNION  
OPEN FLAME TO TEST FOR LEAKS.  
COUNTERFLOW  
UPFLOW  
Check for leaks using an approved chloride-free soap and water  
solution, an electronic combustible gas detector, or other approved  
testing methods.  
MANUAL SHUT-OFF VALVE  
(UPSTREAM FROM GROUND  
JOINT PIPE UNION)  
MANUAL SHUT-OFF VALVE  
(UPSTREAMFROM GROUND  
JOINT PIPE UNION)  
GROUND JOINT  
PIPE UNION  
GROUND JOINT  
PIPE UNION  
DRIP LEG  
DRIP LEG  
GROMMET IN STANDARD  
GAS LINE HOLE  
GROMMET IN STANDARD  
GAS LINE HOLE  
GAS VALVE  
GAS VALVE  
NOTE: Never exceed specified pressures for testing. Higher  
pressure may damage the gas valve and cause subsequent  
overfiring, resulting in heat exchanger failure.  
BURNERS  
BURNERS  
Disconnect this unit and shutoff valve from the gas supply piping  
system before pressure testing the supply piping system with pres-  
sures in excess of 1/2 psig (3.48 kPa).  
Isolate this unit from the gas supply piping system by closing its  
external manual gas shutoff valve before pressure testing supply  
piping system with test pressures equal to or less than 1/2 psig  
(3.48 kPa).  
DRAIN TRAP  
DRAIN TRAP  
MANIFOLD  
PLUG INALTERNATE  
GAS LINE HOLE  
ALTERNATE  
GAS LINE LOCATION  
PLUG IN ALTERNATE  
GAS LINE HOLE  
MANIFOLD  
ALTERNATE GAS  
LINE LOCATION  
HORIZONTAL[COUNTERFLOW]  
HORIZONTAL [UPFLOW MODEL]  
PROPANE GAS TANKS AND PIPING  
2. DRIP LEG MAY TERMINATE WITH  
A 1/2" X 1/8" PIPE PLUG TO  
ACCOMMODATE LINE GAS  
NOTES: 1. WHEN GAS LINE IS IN THE ALTERNATE  
LOCATION, SWAP THE POSITION OF  
THE PLUG AND GROMMET.  
WARNING  
PRESSURE MEASUREMENT.  
GasPipingConnections  
ROPANE GAS IS HEAVIER THAN AIR AND ANY LEAKING GAS CAN SETTLE IN  
P
ANY LOW AREAS OR CONFINED SPACES.  
O PREVENT PROPERTY DAMAGE,  
T
PERSONAL INJURY, OR DEATH DUE TO FIRE OR EXPLOSION CAUSED BY A  
PROPANE GAS LEAK, INSTALL A GAS DETECTION WARNING DEVICE.  
A gas detecting warning system is the only reliable way to detect a  
propane gas leak. Rust can reduce the level of odorant in propane  
25  
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Sizing Between Single or Second Stage Regulator and Appliance*  
Maximum Propane Capacities Listed are Based on 1/2" W.C. pressure drop at 11" W.C. setting.  
Capacities in 1,000 BTU/hour.  
gas. Do not rely on your sense of smell. Contact a local propane  
gas supplier about installing a gas detecting warning system. If  
the presence of gas is suspected, follow the instructions on Page  
4 of this manual.  
All propane gas equipment must conform to the safety standards  
of the National Board of Fire Underwriters, NBFU Manual 58.  
For satisfactory operation, propane gas pressure must be 11 inch  
w.c. at the furnace manifold with all gas appliances in operation.  
Maintaining proper gas pressure depends on three main factors:  
1. Vaporization rate, depending on temperature of the liquid,  
and “wetted surface” area of the container or containers.  
2. Proper pressure regulation. (Two-stage regulation is  
recommended for both cost and efficiency).  
3. Pressure drop in lines between regulators, and between  
second stage regulator and the appliance. Pipe size will  
depend on length of pipe run and total load of all appliances.  
Complete information regarding tank sizing for vaporization, rec-  
ommended regulator settings, and pipe sizing is available from  
most regulator manufacturers and propane gas suppliers.  
Since propane gas will quickly dissolve white lead and most stan-  
dard commercial compounds, special pipe dope must be used.  
Shellac-based compounds resistant to the actions of liquefied pe-  
troleum gases such as Gasolac®, Stalactic®, Clyde’s® or John  
Crane® are satisfactory.  
Pipe or  
Tubing  
Length,  
Feet  
10  
20  
30  
40  
50  
Nominal Pipe Size  
Schedule 40  
Tubing Size, O.D. Type L  
3/8"  
1/2"  
5/8"  
3/4"  
7/8" 1-1/8" 1/2"  
3/4"  
1"  
1-1/4" 1-1/2"  
39  
26  
21  
19  
18  
16  
13  
11  
10  
9
92  
62  
50  
41  
37  
35  
29  
26  
24  
21  
19  
17  
199  
131  
107  
90  
79  
72  
62  
55  
48  
43  
329  
216  
181  
145  
131  
121  
104  
90  
81  
72  
66  
60  
501  
346  
277  
233  
198  
187  
155  
138  
122  
109  
100  
93  
935  
630  
500  
427  
376  
340  
289  
255  
224  
202  
187  
172  
275  
189  
152  
129  
114  
103  
89  
78  
69  
63  
54  
567  
393  
315  
267  
237  
217  
185  
162  
146  
132  
112  
100  
1,071 2,205 3,307  
732  
590  
504  
448  
409  
346  
307  
275  
252  
209  
185  
1,496 2,299  
1,212 1,858  
1,039 1,559  
913  
834  
724  
630  
567  
511  
439  
390  
1,417  
1,275  
1,066  
976  
866  
787  
60  
80  
100  
125  
150  
200  
250  
8
8
39  
36  
665  
590  
48  
*Data in accordance with NFPA pamphlet NO. 54  
Propane Gas Piping Chart II  
XIII. CIRCULATIN G AIR & FILTERS  
DUCTWORK -AIR FLOW  
Duct systems and register sizes must be properly designed for the  
CFM and external static pressure rating of the furnace. Design the  
ductwork in accordance with the recommended methods of “Air  
Conditioning Contractors of America” Manual D.  
Install the duct system in accordance with Standards of the Na-  
tional Board of Fire Underwriters for the Installation of Air Condi-  
tioning, Warm Air Heating and Ventilating Systems. Pamphlets No.  
90A and 90B.  
Refer to the following illustration for typical propane gas installa-  
tions.  
5 to 15 PSIG  
First Stage  
(20 PSIG Max.)  
A closed return duct system must be used, with the return duct  
connected to the furnace. NOTE: Ductwork must never be attached  
to the back of the furnace. Flexible joints may be used for supply  
and return connections to reduce noise transmission. To prevent  
the blower from interfering with combustion air or draft when a  
central return is used, a connecting duct must be installed be-  
tween the unit and the utility room wall. Never use a room, closet,  
or alcove as a return air chamber.  
Regulator  
Continuous  
11" W.C.  
200 PSIG  
Maximum  
Second Stage  
Regulator  
PropaneGasInstallation(Typ.)  
BOTTOM RETURN AIR OPENING [UPFLOW MODELS]  
Sizing Between First and Second Stage Regulator*  
The bottom return air opening on upflow models utilizes a “lance  
and cut” method to remove sheet metal from the duct opening in  
the base pan. To remove, simply press out the lanced sections by  
hand to expose the metal strips retaining the sheet metal over the  
duct opening. Using tin snips, cut the metal strips and remove the  
sheet metal covering the duct opening. In the corners of the open-  
ing, cut the sheet metal along the scribe lines to free the duct  
flanges. Using the scribe line along the duct flange as a guide,  
unfold the duct flanges around the perimeter of the opening using  
a pair of seamer pliers or seamer tongs. NOTE: Airflow area will be  
reduced by approximately 18% if duct flanges are not unfolded.  
This could cause performance issues and noise issues.  
Maximum Propane Capacities listed are based on 2 psig pressure drop at 10 psig setting.  
Capacities in 1,000 BTU/hour.  
Pipe or  
Tubing  
Length,  
Feet  
10  
20  
30  
40  
50  
Nominal Pipe Size  
Schedule 40  
Tubing Size, O.D. Type L  
3/8"  
1/2"  
5/8"  
3/4"  
7/8"  
1/2"  
3/4"  
730  
500  
400  
370  
330  
300  
260  
220  
200  
190  
170  
160  
1,700  
1,100  
920  
850  
770  
700  
610  
540  
490  
430  
400  
380  
3,200  
2,200  
2,000  
1,700  
1,500  
1,300  
1,200  
1,000  
900  
5,300  
3,700  
2,900  
2,700  
2,400  
2,200  
1,900  
1,700  
1,400  
1,300  
1,200  
1,100  
8,300  
5,800  
4,700  
4,100  
3,700  
3,300  
2,900  
2,600  
2,300  
2,100  
1,900  
1,800  
3,200  
2,200  
1,800  
1,600  
1,500  
1,300  
1,200  
1,000  
900  
7,500  
4,200  
4,000  
3,700  
3,400  
3,100  
2,600  
2,300  
2,100  
1,900  
1,700  
1,500  
60  
80  
100  
125  
150  
175  
200  
830  
780  
730  
830  
770  
720  
To convert to capacities at 15 psig settings - multiply by 1.130  
To convert to capacities at 5 psig settings - multiply by 0.879  
WARNING  
Propane Gas Piping Chart I  
DGES OF SHEET METAL MAY BE SHARP. SE GLOVES AS A PRECAUTION  
E
U
WHEN REMOVING SHEET METAL FROM THE DUCT OPENING.  
26  
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UPFLOW  
CUT USING TIN SNIPS  
COOLING AIRFLOW REQUIREMENT (CFM)  
PRESS OUT BY HAND  
600  
800  
384  
---  
1000 1200 1400 1600 2000  
0453__XA 376*  
480  
576  
---  
---  
---  
---  
0704__XA  
0905__XA  
1155__XA  
---  
---  
---  
627* 627*  
672  
768  
---  
---  
---  
836* 836* 836*  
940* 940* 940*  
960  
960  
---  
CUT FOUR CORNERS  
AFTER REMOVING SHEET  
METAL  
COUNTERFLOW  
COOLING AIRFLOW REQUIREMENT (CFM)  
SCRIBE LINES OUTLINING  
DUCT FLANGES  
600  
---  
800  
---  
1000 1200 1400 1600 2000  
DuctFlangeCutOuts  
0704__XA  
0905__XA  
320* 320*  
336  
384  
---  
When the furnace is used in connection with a cooling unit, the  
furnace should be installed in parallel with or on the upstream side  
of the cooling unit to avoid condensation in the heating element.  
With a parallel flow arrangement, the dampers or other means  
used to control the flow of air must be adequate to prevent chilled  
air from entering the furnace and, if manually operated, must be  
equipped with means to prevent operation of either unit unless the  
damper is in the full heat or cool position.  
---  
---  
--- 427* 427* 427*  
480  
*Minimum filter area dictated by heating airflow requirement.  
Permanent Minimum Filter Area (sq. in)  
[Based on a 600 ft/min filter face velocity]  
UPFLOW  
COOLING AIRFLOW REQUIREMENT (CFM)  
When the furnace is installed without a cooling coil, it is recom-  
mended that a removable access panel be provided in the outlet  
air duct. This opening shall be accessible when the furnace is  
installed and shall be of such a size that the heat exchanger can be  
viewed for visual light inspection or such that a sampling probe can  
be inserted into the airstream. The access panel must be made to  
prevent air leaks when the furnace is in operation.  
600  
800  
384  
---  
1000 1200 1400 1600 2000  
0453__XA 376*  
480  
564*  
---  
576  
564*  
752*  
940*  
---  
---  
---  
0704__XA  
0905__XA  
1155__XA  
---  
---  
---  
672  
752*  
940*  
768  
768  
940*  
---  
960  
960  
When the furnace is heating, the temperature of the return air enter-  
ing the furnace must be between 55°F and 100°F.  
---  
---  
COUNTERFLOW  
COOLING AIRFLOW REQUIREMENT (CFM)  
FILTERS - READ THIS SECTION BEFORE INSTALLING THE  
RETURN AIR DUCTWORK  
600  
---  
800  
---  
1000 1200 1400 1600 2000  
Filters must be used with this furnace. Discuss filter maintenance  
with the building owner. Filters do not ship with this furnace, but  
must be provided by the installer. Filters must comply with UL900  
or CAN/ULCS111 standards. If the furnace is installed without fil-  
ters, the warranty will be voided.  
0704__XA  
0905__XA  
641*  
---  
641*  
854*  
672  
768  
---  
---  
---  
854*  
854*  
960  
*Minimum filter area dictated by heating airflow requirement.  
On upflow units, guide dimples locate the side return cutout  
locations. Use a straight edge to scribe lines connecting the  
dimples. Cut out the opening on these lines. NOTE: An  
undersizedopeningwillcausereducedairflow.  
Disposable Minimum Filter area (sq. in)  
[Based on 300 ft/min filter face velocity]  
UPRIGHT INSTALLATIONS  
Refer to Minimum Filter Area tables to determine filter area require-  
ments.  
Depending on the installation and/or customer preference, differ-  
ing filter arrangements can be applied. Filters can be installed in  
the central return register or a side panel external filter rack kit  
(upflows). As an alternative a media air filter or electronic air cleaner  
can be used as the requested filter.  
The following figure shows possible filter locations.  
27  
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position.  
FILTER  
ACCESS  
DOOR  
6. Wait five minutes then smell for gas. Be sure check near  
the floor as some types of gas are heavier than air.  
7. If you smell gas after five minutes, immediately follow the  
instructions on page 4 of this manual. If you do not smell  
gas after five minutes, move the furnace gas valve manual  
control to the ON position.  
8. Replace the burner compartment door.  
9. Open the manual gas shutoff valve external to the furnace.  
10. Turn on the electrical power to the furnace.  
AIR FLOW  
RETURN  
DUCT  
CENTRAL  
RETURN  
GRILLE  
CENTRAL  
RETURN  
GRILLE  
FILTER  
SUPPORT  
BRACKET  
(PROVIDED)  
SIDE RETURN  
EXTERNAL FILTER  
RACK KIT  
(EITHER SIDE)  
11. Adjust the thermostat to a setting above room temperature.  
12. After the burners are lit, set the thermostat to desired  
temperature.  
FURNACE SHUTDOWN  
AIR FLOW  
1. Set the thermostat to the lowest setting.  
Possible Upright Upflow  
Counterflow  
Possible Upright  
The integrated control will close the gas valve and extinguish  
flame. Following a 15 second delay, the induced draft blower  
will be de-energized. After a 120, 150, 180 or 210-second  
delay period (field selectable delay OFF [90, 120, 150, 180]  
plus 30-second ramp down), the circulator blower de-  
energizes.  
FilterLocations  
NOTE: Internal filter retention is not provided on this furnace. If an  
internal installation is desired, an internal filter retention kit is avail-  
able as an accessory. Please see your distributor for details.  
2. Remove the burner compartment door and move the furnace  
gas valve manual control to the OFF position.  
3. Close the manual gas shutoff valve external to the furnace.  
4. Replace the burner compartment door.  
HORIZONTAL INSTALLATIONS  
Filters must be installed in either the central return register or in the  
return air duct work.  
GAS SUPPLY PRESSURE MEASUREMENT  
XIV. STARTUP PRO CED URE & AD JUSTM EN T  
Furnace must have a 115 VAC power supply properly connected  
and grounded. Proper polarity must be maintained for correct op-  
eration. In addition to the following start-up and adjustment items,  
refer to further information in Section XVI, Operational Checks.  
CAUTION  
O PREVENT UNRELIABLE OPERATION OR EQUIPMENT DAMAGE, THE INLET  
T
GAS SUPPLY PRESSURE MUST BE AS SPECIFIED ON THE UNIT RATING PLATE  
WITH ALL OTHER HOUSEHOLD GAS FIRED APPLIANCES OPERATING.  
HEAT ANTICIPATORSETTING  
The heat anticipator in the room thermostat must be correctly ad-  
justed to obtain the proper number of cycles per hour and to pre-  
vent “overshooting” of the setting. Set the heat anticipator setting to  
0.7 amps. Follow the thermostat manufacturer’s instructions on  
how to adjust the heat anticipator setting.  
WHITE-RODGERS 36G54 GAS VALVE  
The line pressure supplied to the gas valve must be within the  
range specified below. The supply pressure can be measured at  
the gas valve inlet pressure boss or at a hose fitting installed in the  
gas piping drip leg. The supply pressure must be measured with  
the burners operating. To measure the gas supply pressure, use  
the following procedure.  
DRAIN TRAP PRIMING  
The drain trap must be primed prior to furnace startup. To prime, fill  
the drain trap with water. This ensures proper furnace drainage  
upon startup and prohibits the possibility of flue gases escaping  
through the drain system.  
Open to  
Atmosphere  
meter  
Mano  
Hose  
FURNACE OPERATION  
High Fire Regulator  
Adjust  
Outlet  
Pressure Boss  
Regulator  
Vent  
Purge gas lines of air prior to startup. Be sure not purge lines into  
an enclosed burner compartment.  
Check for leaks using an approved chloride-free soap and water  
solution, an electronic combustible gas detector, or other approved  
method. Verify that all required kits (propane gas, high altitude,  
etc.) have been appropriately installed.  
A
FURNACE STARTUP  
Low Fire  
Regulator Adjust  
1. Close the manual gas shutoff valve external to the furnace.  
2. Turn off the electrical power to the furnace.  
3. Set the room thermostat to the lowest possible setting.  
4. Remove the burner compartment door.  
Inlet  
Pressure Boss  
High Fire  
Coil Terminal (HI)  
Coaxial Coil  
Terminal (M)  
Common  
Terminal (C)  
ometer  
Man  
On/Off Switch  
NOTE: This furnace is equipped with an ignition device which  
automatically lights the burner. Do not try to light the burner by  
hand.  
White-Rodgers Model 36G54 Connected to Manometer  
5. Move the furnace gas valve manual control to the OFF  
28  
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1. Turn OFF gas to furnace at the manual gas shutoff valve  
external to the furnace.  
1. Turn OFF gas to furnace at the manual gas shutoff valve  
external to the furnace.  
2. Connect a calibrated water manometer (or appropriate gas  
pressure gauge) at either the gas valve inlet pressure boss  
or the gas piping drip leg.  
2. Turn off all electrical power to the system.  
3. Back outlet pressure test screw (inlet/outlet pressure boss)  
out one turn (counterclockwise, not more than one turn).  
4. Attach a hose and manometer to the outlet pressure boss  
of the valve.  
Gas Line  
Gas  
Shutoff  
Valve  
5. Turn ON the gas supply.  
6. Turn on power and energize main (M) solenoid. Do not  
energize the HI solenoid.  
7. Measure gas manifold pressure with burners firing. Adjust  
manifold pressure using the Manifold Gas Pressure table  
shown below.  
Gas Line  
To Furnace  
8. Remove regulator cover screw from the low (LO) outlet  
pressure regulator adjust tower and turn screw clockwise  
to increase pressure, or counterclockwise to decrease  
pressure.  
Open To  
Atmosphere  
Drip Leg Cap  
With Fitting  
9. Energize main (M) solenoid as well as the HI terminal.  
10. Remove regulator cover screw from the HI outlet pressure  
regulator adjust tower and turn screw clockwise to increase  
pressure, or counterclockwise to decrease pressure.  
Manometer Hose  
11. Turn off all electrical power and gas supply to the system.  
12. Remove manometer hose from outlet pressure boss.  
Manometer  
13. Turn outlet pressure test screw in to seal pressure port  
(clockwise, 7 in-lb minimum).  
Measuring Inlet Gas Pressure (Alt. Method)  
NOTE: If measuring gas pressure at the drip leg, a field supplied  
hose barb fitting must be installed prior to making the hose  
connection. If using the inlet pressure boss on the gas valve,  
then use the 36G Valve Pressure Check Kit, Goodman Part No.  
0151K00000S.  
14. Turn on electrical power and gas supply to the system.  
15. Turn on system power and energize valve.  
16. Using a leak detection solution or soap suds, check for  
leaks at pressure boss screw. Bubbles forming indicate a  
leak. SHUTOFF GASAND FIXALL LEAKS IMMEDIATELY.  
3. Turn ON the gas supply and operate the furnace and all  
other gas consuming appliances on the same gas supply  
line.  
4. Measure furnace gas supply pressure with burners firing.  
Supply pressure must be within the range specified in the  
Inlet Gas Supply Pressure table.  
NOTE: For gas to gas conversion, consult your dealer for  
appropriate conversion.  
Manifold Gas Pressure  
Gas  
Range  
Nominal  
1.9" w .c.  
3.5" w .c.  
6.0" w .c.  
Natural  
Low Stage 1.6 - 2.2" w .c.  
High Stage 3.2 - 3.8" w .c.  
Low Stage 5.7 - 6.3" w .c.  
Inlet Gas Supply Pressure  
Propane  
High Stage 9.7 - 10.3" w .c. 10.0" w .c.  
Natural Gas  
Propane Gas  
Minimum: 5.0" w.c. Maximum:10.0" w.c.  
Minimum: 11.0" w.c. Maximum:13.0" w.c.  
GAS INPUT RATE MEASUREMENT (NATURAL GAS ONLY)  
If supply pressure differs from table, make the necessary adjust-  
ments to pressure regulator, gas piping size, etc., and/or consult  
with local gas utility.  
The gas input rate to the furnace must never be greater than that  
specified on the unit rating plate. To measure natural gas input  
using the gas meter, use the following procedure.  
5. Turn OFF gas to furnace at the manual shutoff valve and  
disconnect manometer. Reinstall plug before turning on  
gas to furnace.  
1. Turn OFF the gas supply to all other gas-burning appliances  
except the furnace.  
2. While the furnace is operating, time and record one  
complete revolution of the smallest gas meter dial.  
6. Turn OFF any unnecessary gas appliances stated in step  
3.  
3. Calculate the number of seconds per cubic foot (sec/ft3) of  
gas being delivered to the furnace. If the dial is a one cubic  
foot dial, divide the number of seconds recorded in step 2  
by one. If the dial is a two cubic foot dial, divide the number  
of seconds recorded in step 2 by two.  
GAS MANIFOLD PRESSURE MEASUREMENT AND ADJUSTMENT  
CAUTION  
4. Calculate the furnace input in BTUs per hour (BTU/hr). Input  
equals the sum of the installation’s gas heating value and  
a conversion factor (hours to seconds) divided by the  
number of seconds per cubic foot. The measured input  
must not be greater than the input indicated on the unit  
rating plate.  
O PREVENT UNRELIABLE OPERATION OR EQUIPMENT DAMAGE, THE GAS  
T
MANIFOLD PRESSURE MUST BE AS SPECIFIED ON THE UNIT RATING PLATE.  
NLY MINOR ADJUSTMENTS SHOULD BE MADE BY ADJUSTING THE GAS VALVE  
O
PRESSURE REGULATOR.  
Only small variations in gas pressure should be made by adjust-  
ing the gas valve pressure regulator. The manifold pressure must  
be measured with the burners operating. To measure and adjust  
the manifold pressure, use the following procedure.  
EXAMPLE:  
Installation’s gas heating (HTG) value: 1,000 BTU/ft3  
(Obtained from gas supplier)  
29  
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Installation’s seconds per cubic foot: 34 sec/ ft3  
Conversion Factor (hours to seconds): 3600 sec/hr  
Input = (Htg. value x 3600) ÷ seconds per cubic foot  
Input = (1,000 BTU/ft3 x 3600 sec/hr) ÷ 34 sec/ ft3  
Input = 106,000 BTU/hr  
CIRCULATOR BLOWER SPEEDS  
WARNING  
O AVOID PERSONAL INJURY OR DEATH DUE TO ELECTRICAL SHOCK, TURN  
T
OFF POWER TO THE FURNACE BEFORE CHANGING SPEED TAPS.  
Minor changes to the input rate may be accomplished through  
manifold pressure adjustments at the gas valve. Refer to Section  
XIV, Startup Procedure and Adjustment - Gas Manifold Pressure  
Measurement and Adjustment for details. NOTE: The final mani-  
fold pressure cannot vary by more than ± 0.3” w.c. from the speci-  
fied setting. Consult your local gas supplier if additional input rate  
adjustment is required.  
This furnace is equipped with a multi-speed circulator blower. This  
blower provides ease in adjusting blower speeds. The Product  
Data Book applicable to your model* provides an airflow table,  
showing the relationship between airflow (CFM) and external static  
pressure (E.S.P.), for the proper selection of heating and cooling  
speeds. The heating blower speed is shipped set at “B”, and the  
cooling blower speed is set at “D”. These blower speeds should  
be adjusted by the installer to match the installation requirements  
so as to provide the correct heating temperature rise and correct  
cooling CFM.  
5. Repeat steps 2 through 4 on high stage.  
6. Turn ON gas to and relight all other appliances turned off in  
step 1. Be certain that all appliances are functioning properly  
and that all pilot burners are operating.  
Use the CFM LED (green), adjacent to the integrated control mod-  
ule fuse to verify airflow quantity. The green CFM LED blinks once  
for each 100 CFM of airflow.  
1. Determine the tonnage of the cooling system installed with  
the furnace. If the cooling capacity is in BTU/hr divide it by  
12,000 to convert capacity to TONs.  
TEMPERATURE RISE  
Temperature rise must be within the range specified on the unit  
rating plate. An incorrect temperature rise may result in condens-  
ing in or overheating of the heat exchanger. An airflow and tem-  
perature rise table is provided in the Product Data Book applicable  
to your model*. Determine and adjust temperature rise as follows:  
1. Operate furnace with burners firing for approximately ten  
minutes. Ensure all registers are open and all duct  
dampers are in their final (fully or partially open) position.  
2. Place thermometers in the return and supply ducts as close  
to the furnace as possible. Thermometers must not be  
influenced by radiant heat by being able to “see” the heat  
exchanger.  
Example: Cooling Capacity of 30,000 BTU/hr.  
30,000/12,000 = 2.5 Tons  
2. Determine the proper air flow for the cooling system. Most  
cooling systems are designed to work with air flows between  
350 and 450 CFM per ton. Most manufacturers recommend  
an air flow of about 400 CFM per ton.  
Example: 2.5 tons X 400 CFM per ton = 1000 CFM  
The cooling system manufacturer’s instructions must be checked  
for required air flow. Any electronic air cleaners or other devices  
may require specific air flows, consult installation instructions of  
those devices for requirements.  
HEAT EXCHANGER  
RADIATION "LINE OF SIGHT"  
SUPPLY  
AIR  
3. Knowing the furnace model, locate the high stage cooling  
air flow charts in the Product Data Book applicable to your  
model*. Look up the cooling air flow determined in step 2  
and find the required cooling speed and adjustment setting.  
TSUPPLY  
RISE  
=
TSUPPLY TRETURN  
-
Example:  
A *MV90704BXA furnace installed with a 2.5  
ton air conditioning system. The air flow  
needed is 1000 CFM. Looking at the cooling  
speed chart for *MV90704BXA, find the air flow  
closest to 1000 CFM. A cooling airflow of 990  
CFM can be attained by setting the cooling  
speed to “C” and the adjustment to “-” (minus).  
TRETURN  
RETURN  
AIR  
Temperature Rise Measurement  
NOTE: Continuous Fan Speed will be 56% of  
3. Subtract the return air temperature from the supply air  
temperature to determine the air temperature rise. Allow  
adequate time for thermometer readings to stabilize.  
4. Adjust temperature rise by adjusting the circulator blower  
speed. Increase blower speed to reduce temperature rise.  
Decrease blower speed to increase temperature rise. Refer  
to Section XIV, Startup Procedure and Adjustment -Circulator  
Blower Speeds for speed changing details.  
high stage cooling.  
4. Locate the blower speed selection DIP switches on the  
integrated control module. Select the desired “cooling”  
speed tap by positioning switches 1 and 2 appropriately.  
Select the desired “adjust” tap by positioning switches 3  
and 4 appropriately. Refer to the following figure for switch  
positions and their corresponding taps. Turn off power to  
furnace for a minimum of 10 seconds, allowing motor to  
reset and recognize new speed selection. Turn on power  
to furnace. Verify CFM by counting the number of times the  
green CFM LED blinks.  
*NOTE: Please contact your distributor or our website for the applicable product data book referred to in this manual.  
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8
7
6
5
4
3
2
1
8
7
6
5
4
3
2
1
Cooling  
Speed  
Tap A  
100% CFM  
100% CFM  
1 min  
Normal  
*
OFF  
OFF  
50% CFM  
1/2 min  
O O  
O O  
F
F
F
F
F
F
F
F
8
8
7
7
6
6
5
5
4
4
3
3
2
1
4
3
2
2
1
1
8
8
7
7
6
6
5
5
Cooling  
Speed  
Tap B  
Cooling Demand  
+ (Plus)  
Adjust  
Profile C ramps up to 82% of the full cooling demand airflow  
and operates there for approximately 7 1/2 minutes. The  
motor then steps up to the full demand airflow. Profile C  
also has a one (1) minute 100% OFF delay.  
O O  
O O  
F
F
F
F
2
N
N
1
4
3
Cooling  
Speed  
Tap C  
- (Minus)  
Adjust  
O O  
N
O O  
N F  
F
82% CFM  
7 1/2 min  
100% CFM  
100% CFM  
1 min  
F
F
1
OFF  
8
7
6
5
4
3
2
*
Cooling  
Speed  
Tap D  
Adjust Taps  
indicates factory setting)  
Cooling Demand  
*
(
O O  
Profile D ramps up to 50% of the demand for 1/2 minute,  
then ramps to 82% of the full cooling demand airflow and  
operates there for approximately 7 1/2 minutes. The motor  
then steps up to the full demand airflow. Profile D has a 1/  
2 minute at 50% airflow OFF delay.  
N
N
8
7
6
5
4
3
2
1
Heating  
Speed  
Tap A  
Cooling Speed Taps  
(* indicates factory setting)  
O O  
F
F
F
F
8
7
6
6
5
5
4
4
3
3
2
2
1
1
82% CFM  
7 1/2 min  
100% CFM  
50% CFM  
OFF  
50% CFM  
1/2 min  
OFF  
Heating  
Speed  
Tap B  
*
1/2 min  
O O  
Cooling Demand  
F
F
8
N
7
8
7
6
5
4
3
2
1
Heating  
Speed  
Tap C  
Ramping  
Profile  
Tap A  
*
O O  
O O  
N
F
F
F
F
F
F
8
7
6
5
4
3
2
1
8
8
7
7
6
5
4
4
3
3
2
2
1
1
Heating  
Speed  
Tap D  
Ramping  
Profile  
Tap B  
O O  
N N  
O O  
F
F
6
N
5
Ramping  
Profile  
Tap C  
Heating Speed Taps  
(* indicates factory setting)  
O O  
N F  
F
5. The multi-speed circulator blower also offers several  
custom ON/OFF ramping profiles. These profiles may be  
used to enhance cooling performance and increase comfort  
level. The ramping profiles are selected using DIP switches  
5 and 6. Refer to the following figure for switch positions  
and their corresponding taps. Refer to the bullet points  
below for a description of each ramping profile. Turn OFF  
power to the furnace for a minimum of 10 seconds, allowing  
motor to reset and recognize the new profile selection. Turn  
ON power to the furnace. Verify profile selection by counting  
the green CFM LED blinks and timing each step of the  
ramping profile.  
8
7
6
5
4
3
2
1
Ramping  
Profile  
Tap D  
O O  
N
N
Ramping Profiles  
(* indicates factory setting)  
6. Select the heating speed from the heating speed chart in  
the Product Data Book applicable to your model* for your  
model. The adjust setting (already established by the  
cooling speed selection) determines which set of speeds  
are available. The selected speed must provide a  
temperature rise within the rise range listed with the  
particular model.  
Profile A provides only an OFF delay of one (1) minute at  
100% of the cooling demand airflow.  
100% CFM  
100% CFM  
1 min  
Example:  
The *MV90704BXA is set for 990 CFM on  
cooling, the “ADJUST” is set to “-” (minus).  
The four heating speeds available are “A  
Minus”, “B Minus”, “C Minus”, and “D Minus”.  
“A Minus” has a rise of 56°F for both stages  
which is within the 30-60°F rise range for the  
*MV90704BXA. This setting will keep electrical  
consumption to a minimum. Set the “Heat”  
speed DIP switches to “A”.  
OFF  
OFF  
Cooling  
Demand  
Profile B ramps up to full cooling demand airflow by first  
stepping up to 50% of the full demand for 30 seconds. The  
motor then ramps to 100% of the required airflow. A one (1)  
minute OFF delay at 100% of the cooling airflow.  
7. Select the desired “heating” speed tap by positioning  
switches 7 and 8 appropriately. Refer to figure above. Turn  
off power to furnace for a minimum of 10 seconds, allowing  
31  
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motor to reset and recognize new speed selection. Turn on  
power to furnace. Verify selected CFM by counting the green  
CFM LED blinks.  
Gas valve opens at end of igniter warm up period, delivering  
gas to burners and establishing flame.  
Integrated control module monitors flame presence. Gas  
valve will remain open only if flame is detected.  
In general lower heating speeds will: reduce electrical consump-  
tion, lower operating sound levels of the blower, and increase the  
outlet air temperature delivered to the home. The speeds avail-  
able allow the blower performance to be optimized for the particu-  
lar homeowner’s needs.  
If the thermostat call is for low heat, gas valve and induced  
draft blower will continue on low stage. If the call is for high  
heat, the gas valve and induced draft blower will change to  
high stage.  
BLOWER HEAT OFF DELAY TIMINGS  
Circulator blower is energized on heat speed following a  
fixed thirty second blower on delay. The circulator blower  
requires thirty (30) seconds to ramp up to full speed.  
Electronic air cleaner terminals are energized with circulator  
blower.  
The integrated control module provides a selectable heat off delay  
function. The heat off delay period may be set to 90, 120, 150, 180  
seconds using the DIP switches or jumper provided on the control  
module. The delay is factory shipped at 150 seconds but may be  
changed to suit the installation requirements and/or homeowner  
preference. Refer to the following figures for switch positions and  
corresponding delay times.  
Furnace is now operating on the specified stage called for  
by the two-stage thermostat.  
Furnace runs, integrated control module monitors safety  
circuits continuously.  
Heat Off  
3
Delay  
90 Seconds  
ON  
ON  
2
1
If the two-stage thermostat changes the call from low heat  
to high heat, the integrated control module will immediately  
switch the induced draft blower, gas valve, and circulator  
blower to their high stage settings.  
3
Heat Off  
Delay  
120 Seconds  
ON  
OFF  
2
1
If the two-stage thermostat changes the call from high heat  
to low heat, the control will immediately switch the induced  
draft blower and gas valve to their low stage settings. The  
circulator blower will remain on high heating speed for thirty  
(30) seconds before switching to the low heat circulating  
*
3
Heat Off  
Delay  
OFF  
ON  
2
1
150 Seconds  
speed.  
3
Heat Off  
Delay  
180 Seconds  
R and W1 (or R and W1/W2) thermostat contacts open,  
completing the call for heat.  
OFF  
OFF  
2
1
Gas valve closes, extinguishing flame.  
Heat Off Delay  
(* indicates factory setting)  
Induced draft blower is de-energized following a fifteen  
second post purge. Humidifier terminals are de-energized.  
Heat Off Delay Switches  
Circulator blower continues running for the selected heat  
off delay period (90, 120, 150 or 180 seconds). The speed  
run during this period depends on the last heat call provided  
by the thermostat.  
If the last call for heat was a call for low heat, the air circulator  
motor will run on low heat speed for the duration of the heat  
off delay period (90, 120, 150 or 180 seconds).  
XV. N O RM AL SEQ UEN CE O F O PERATIO N  
POWER UP  
The normal power up sequence is as follows:  
115 VAC power applied to furnace.  
Integrated control module performs internal checks.  
Integrated control module flashes LED one time.  
If the last call for heat was a call for high heat, the air  
circulating motor will run on the high heating speed for thirty  
(30) seconds and then switch to the low heating speed for  
the balance of the heat off delay period (60, 90, 120 or 150  
seconds).  
Integrated control module monitors safety circuits  
continuously.  
Furnace awaits call from thermostat.  
Circulator blower and electronic air cleaner terminals are  
de-energized.  
HEATING MODE  
The normal operational sequence in heating mode is as follows:  
Circulator blower ramps down to OFF during the 30 seconds  
following the heat off delay period.  
R and W1 (or R and W1/W2) thermostat contacts close,  
initiating a call for heat.  
Furnace awaits next call from thermostat.  
Integrated control module performs safety circuit checks.  
COOLING MODE  
Induced draft blower is energized on high speed for a 10-  
second prepurge. Humidifier terminals are energized with  
induced draft blower.  
The normal operational sequence in cooling mode is as follows:  
R and YLO/G or Y/G thermostat contacts close, initiating a  
call for cool.  
Induced draft blower steps to low speed following prepurge.  
Low stage pressure switch contacts are closed.  
Integrated control module performs safety circuit checks.  
Igniter warm up begins upon step to low speed and  
presence of closed low stage pressure switch contacts.  
Outdoor fan and compressor are energized to their  
appropriate speed.  
32  
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sis of abnormal function. These circuits are continuously moni-  
tored during furnace operation by the integrated control module.  
Circulator blower is energized on the appropriate cool speed  
at the level and time determined by the selected ramping  
profile. Electronic air cleaner terminals are energized with  
circulator blower.  
INTEGRATED CONTROL MODULE  
The integrated control module is an electronic device which, if a  
potential safety concern is detected, will take the necessary pre-  
cautions and provide diagnostic information through an LED.  
Furnace circulator blower and outdoor cooling unit run their  
appropriate speed, integrated control module monitors  
safety circuits continuously.  
PRIMARY LIMIT  
R and YLO/G or Y/G thermostat contacts open, completing  
the call for cool.  
The primary limit control is located on the partition panel and moni-  
tors heat exchanger compartment temperatures. It is a normally-  
closed (electrically), automatic reset, temperature-activated sen-  
sor. The limit guards against the overheating as a result of insuffi-  
cient conditioned air passing over the heat exchanger.  
Outdoor fan and compressor are de-energized.  
Circulator blower continues running during a cool off delay  
period. The OFF delay time and airflow level are determined  
by the selected ramping profile.  
AUXILIARY LIMIT  
Electronic air cleaner terminals and circulator blower are  
de-energized.  
The auxiliary limit controls are located on or near the circulator  
blower and monitors blower compartment temperatures. They are  
a normally-closed (electrically), manual-reset sensors. These lim-  
its guard against overheating as a result of insufficient conditioned  
air passing over the heat exchanger.  
Furnace awaits next call from thermostat.  
FAN ONLY MODE  
The normal operational sequence in fan only mode is as follows:  
ROLLOUT LIMIT  
R and G thermostat contacts close, initiating a call for fan.  
Integrated control module performs safety circuit checks.  
The rollout limit controls are mounted on the burner/manifold as-  
sembly and monitor the burner flame. They are normally-closed  
(electrically), manual-reset sensors. These limits guard against  
burner flames not being properly drawn into the heat exchanger.  
Circulator blower is energized on continuous fan speed  
(56% of high stage cooling) following a five (5) second delay.  
Electronic air cleaner terminals are energized.  
PRESSURE SWITCHES  
Circulator blower runs, integrated control module monitors  
safety circuits continuously.  
The pressure switches are normally-open (closed during opera-  
tion) negative air pressure-activated switches. They monitor the  
airflow (combustion air and flue products) through the heat ex-  
changer via pressure taps located on the induced draft blower and  
the coil front cover. These switches guard against insufficient air-  
flow (combustion air and flue products) through the heat exchanger  
and/or blocked condensate drain conditions.  
R and G thermostat contacts open, completing the call for  
fan.  
Circulator blower is de-energized. Electronic air cleaner  
terminals are de-energized.  
Furnace awaits next call from thermostat.  
FLAME SENSOR  
XVI. O PERATIO N AL CH ECKS  
The flame sensor is a probe mounted to the burner/manifold as-  
sembly which uses the principle of flame rectification to determine  
the presence or absence of flame.  
BURNER FLAME  
The burner flames should be inspected with the burner compart-  
ment door installed. A sight glass is provided for inspection pur-  
poses. Flames should stable, quiet, soft, and blue (dust may  
cause orange tips but they must not be yellow). Flames should  
extend directly outward from the burners without curling, floating, or  
lifting off. Flames must not impinge on the sides of the heat ex-  
changer firing tubes.  
XVIII. TRO UBLESH O O TIN G  
ELECTROSTATIC DISCHARGE(ESD)PRECAUTIONS  
NOTE: Discharge body’s static electricity before touching unit. An  
electrostatic discharge can adversely affect electrical components.  
Use the following precautions during furnace installation and ser-  
vicing to protect the integrated control module from damage. By  
putting the furnace, the control, and the person at the same electro-  
static potential, these steps will help avoid exposing the integrated  
control module to electrostatic discharge. This procedure is appli-  
cable to both installed and uninstalled (ungrounded) furnaces.  
1. Disconnect all power to the furnace. Do not touch the  
integrated control module or any wire connected to the control  
prior to discharging your body’s electrostatic charge to  
ground.  
Check the burner flames for:  
1. Good adjustment  
2. Stable, soft and blue  
3. Not curling, floating, or lifting off.  
2. Firmly touch a clean, unpainted, metal surface of the  
furnaces near the control. Any tools held in a person’s  
hand during grounding will be discharged.  
BurnerFlame  
XVII. SAFETY CIRCUIT D ESCRIPTIO N  
3. Service integrated control module or connecting wiring  
following the discharge process in step 2. Use caution not  
to recharge your body with static electricity; (i.e., do not move  
or shuffle your feet, do not touch ungrounded objects, etc.).  
If you come in contact with an ungrounded object, repeat  
GENERAL  
A number of safety circuits are employed to ensure safe and proper  
furnace operation. These circuits serve to control any potential  
safety hazards and serve as inputs in the monitoring and diagno-  
33  
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step 2 before touching control or wires.  
Drainage system. Check for blockage and/or leakage.  
Check hose connections at and internal to furnace.  
4. Discharge your body to ground before removing a new  
control from its container. Follow steps 1 through 3 if  
installing the control on a furnace. Return any old or new  
controls to their containers before touching any ungrounded  
object.  
Wiring. Check electrical connections for tightness and/or  
corrosion. Check wires for damage.  
Filters.  
DIAGNOSTIC CHART  
FILTERS  
WARNING  
CAUTION  
O AVOID ELECTRICAL SHOCK, INJURY OR DEATH, DISCONNECT ELECTRICAL  
T
O ENSURE PROPER UNIT PERFORMANCE, ADHERE TO THE FILTER SIZES  
T
POWER BEFORE PERFORMING ANY SERVICE OR MAINTENANCE.  
GIVEN IN THE  
RECOMMENDED MINIMUM FILTER SIZE TABLE OR  
RODUCT ATA OOK APPLICABLE TO YOUR MODEL*.  
P
D
B
Refer to the Troubleshooting Chart at the end of this manual for  
assistance in determining the source of unit operational problems.  
The red diagnostic LED blinks to assist in troubleshooting the unit.  
The number of blinks refers to a specific fault code.  
MAINTENANCE  
Improper filter maintenance is the most common cause of inad-  
equate heating or cooling performance. Filters should be cleaned  
(permanent) or replaced (disposable) every two months or as re-  
quired. When replacing a filter, it must be replaced with a filter of  
the same type and size.  
RESETTING FROM LOCKOUT  
Furnace lockout results when a furnace is unable to achieve igni-  
tion after three attempts. It is characterized by a non-functioning  
furnace and a one flash diagnostic LED code. If the furnace is in  
“lockout”, it will (or can be) reset in any of the following ways.  
1. Automatic reset. The integrated control module will  
automatically reset itself and attempt to resume normal  
operations following a one hour lockout period.  
2. Manual power interruption. Interrupt 115 volt power to the  
furnace for 0 - 20 seconds.  
3. Manual thermostat cycle. Lower the thermostat so that  
there is no longer a call for heat then reset to previous setting.  
Interrupt thermostat signal to the furnace for 0 - 20 seconds.  
FILTER REMOVAL  
Depending on the installation, differing filter arrangements can be  
applied. Filters can be installed in either the central return register  
or a side panel external filter rack (upflow only). A media air filter or  
electronic air cleaner can be used as an alternate filter. Follow the  
filter sizes given in the Recommended Minimum Filter size table to  
ensure proper unit performance.  
To remove filters from an external filter rack in an upright upflow  
installation, follow the directions provided with external filter rack  
kit. To remove internal filters see Internal Filter Removal section.  
Internal filters are an accessory item and are not included with  
your furnace. For further details, see your distributor.  
NOTE: If the condition which originally caused the lockout still  
exists, the control will return to lockout. Refer to Section XVIII,  
Troubleshooting - Diagnostic Chart for aid in determining the cause.  
HORIZONTAL UNIT FILTER REMOVAL  
Filters in horizontal installations are located in the central return  
register or the ductwork near the furnace.  
To remove:  
XIX. M AIN TEN AN CE  
WARNING  
1. Turn OFF electrical power to furnace.  
2. Remove filter(s) from the central return register or ductwork.  
3. Replace filter(s) by reversing the procedure for removal.  
4. Turn ON electrical power to furnace.  
O AVOID ELECTRICAL SHOCK, INJURY OR DEATH, DISCONNECT ELECTRICAL  
T
POWER BEFORE PERFORMING ANY MAINTENANCE. IF YOU MUST HANDLE THE  
IGNITER, HANDLE WITH CARE. OUCHING THE IGNITER ELEMENT WITH BARE  
T
FINGERS, ROUGH HANDLING, OR VIBRATION COULD DAMAGE THE IGNITER  
MEDIA AIR FILTER OR ELECTRONIC AIR CLEANER REMOVAL  
RESULTING IN PREMATURE FAILURE.  
EVER HANDLE THE IGNITER.  
NLY A QUALIFIED SERVICER SHOULD  
O
Follow the manufacturer’s directions for service.  
BURNERS  
ANNUAL INSPECTION  
Visually inspect the burner flames periodically during the heating  
season. Turn on the furnace at the thermostat and allow several  
minutes for flames to stabilize, since any dislodged dust will alter  
the flames normal appearance. Flames should be stable, quiet,  
soft, and blue (dust may cause orange tips but they must not be  
yellow). They should extend directly outward from the burners with-  
out curling, floating, or lifting off. Flames must not impinge on the  
sides of the heat exchanger firing tubes.  
The furnace should be inspected by a qualified installer, or service  
agency at least once per year. This check should be performed at  
the beginning of the heating season. This will ensure that all fur-  
nace components are in proper working order and that the heating  
system functions appropriately. Pay particular attention to the fol-  
lowing items. Repair or service as necessary.  
Flue pipe system. Check for blockage and/or leakage. Check  
the outside termination and the connections at and internal  
to the furnace.  
INDUCED DRAFT AND CIRCULATOR B LOWERS  
The bearings in the induced draft blower and circulator blower  
motors are permanently lubricated by the manufacturer. No further  
lubrication is required. Check motor windings for accumulation of  
dust which may cause overheating. Clean as necessary.  
Heat exchanger. Check for corrosion and/or buildup within  
the heat exchanger passageways.  
Burners. Check for proper ignition, burner flame, and flame  
sense.  
*NOTE: Please contact your distributor or our website for the applicable product data book referred to in this manual.  
34  
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5. Replace filter by reversing the procedure.  
CONDENSATE TRAP AND DRAIN SYSTEM (QUALIFIED SERVICER  
ONLY)  
BLOWER COMPARTMENT REMOVAL  
Annually inspect the drain tubes, drain trap, and field-supplied drain  
line for proper condensate drainage. Check drain system for hose  
connection tightness, blockage, and leaks. Clean or repair as  
necessary.  
1. Turn OFF electrical power to furnace.  
2. Remove blower compartment door.  
3. Grasp lower portion of filter and lift up.  
FLAME SENSOR (QUALIFIED SERVICER ONLY)  
Front of Furnace  
Front of Furnace  
Under some conditions, the fuel or air supply can create a nearly  
invisible coating on the flame sensor. This coating acts as an  
insulator causing a drop in the flame sense signal. If the flame  
sense signal drops too low the furnace will not sense flame and  
will lock out. The flame sensor should be carefully cleaned by a  
qualified servicer using emery cloth or steel wool. Following clean-  
ing, the flame sense signal should be as indicated in the Specifi-  
cations Sheet.  
Blower  
Blower  
FLUE PASSAGES (QUALIFIED SERVICER ONLY)  
Grab Here  
And Lift  
The heat exchanger flue passageways should be inspected at the  
beginning of each heating season. If necessary, clean the pas-  
sageways as outlined below.  
4. Angle filter toward the blower until filter clears bottom rail.  
5. Lower filter down and pull outward.  
1. Turn OFF the electrical power and gas supply to the furnace.  
2. Disconnect the gas line and remove the burner/ manifold  
assembly by removing the screws securing the assembly  
to the partition panel.  
Front of Furnace  
Front of Furnace  
3. Disconnect the flue pipe system from the induced draft  
blower.  
4. Remove the induced draft blower and, drain and pressure  
tap hoses from the recuperator coil front cover.  
Blower  
Blower  
5. Remove the recuperator coil front cover to expose the coil  
tubes and turbulators.  
6. Remove the recuperator coil turbulators individually by slowly  
pulling each turbulator forward firmly.  
7. Clean the recuperator coil tubes using a long handle wire  
brush, such as a gun cleaning brush.  
8. Clean the primary heat exchanger tubes using a wire brush  
attached to a length of high grade stainless steel cable,  
such as drain cleanout cable. Attach a variable speed  
reversible drill to the other end of the cable. Slowly rotate  
the cable with the drill and insert it into one of the heat  
exchanger tubes. While reversing the drill, work the cable  
in and out several times to obtain sufficient cleaning. Repeat  
for each tube.  
6. Replace filter by reversing procedure.  
XXI. BEFO RE LEAVIN G AN IN STALLATIO N  
Cycle the furnace with the thermostat at least three times.  
Verify cooling and fan only operation.  
Review the Owner’s Manual with the homeowner and  
discuss proper furnace operation and maintenance.  
9. Clean residue from furnace using a vacuum cleaner.  
10. Replace the parts removed in the previous steps in reverse  
order.  
Leave literature packet near furnace.  
XXII. REPAIR & REPLACEM EN T PARTS  
11. Turn on electrical power and gas to furnace. Check for  
leaks and proper unit operation.  
12. Severe heat exchanger fouling is an indication of an  
operational problem. Perform the checks listed in Section  
XIV, Startup Procedure and Adjustments to reduce the  
chances of repeated fouling.  
When ordering any of the listed functional parts, be sure to  
provide the furnace model, manufacturing, and serial  
numbers with the order.  
Although only functional parts are shown in the parts list, all  
sheet metal parts, doors, etc. may be ordered by description.  
Parts are available from your distributor.  
XX. IN TERN AL FILTER REM O VAL  
Functional Parts List-  
Gas Valve  
Internal filters are an accessory item and are not included with your  
furnace. For further details, see your distributor.  
Blower Motor  
Gas Manifold  
Blower Wheel  
Blower Mounting Bracket  
Blower Cutoff  
Blower Housing  
Capacitor  
Natural Gas Orifice  
Propane Gas Orifice  
Igniter  
BOTTOM RETURN REMOVAL  
1. Turn OFF electrical power to furnace.  
2. Remove blower compartment door.  
Flame Sensor  
3. Push back and up on the wire filter retainer to release it  
from under the front lip of the furnace basepan.  
4. Slide filter forward and out.  
35  
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Rollout Limit Switch  
Primary Limit Switch  
Auxiliary Limit Switch  
Pressure Switch  
Induced Draft Blower  
Door Switch  
Heat Exchanger  
Recuperator Coil  
Coil Front Cover  
Integrated Control Module  
Transformer  
36  
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E
                                                                                                                           
                                                                                                                             
S
                                                                                                                             
                                                                                                                               
H
                                                                                                                               
                                                                                                                                   
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Associated  
LED Code2  
Symptoms of Abnormal  
Operation  
Fault Description(s)  
Possible Causes  
Corrective Action  
Cautions and Notes  
NONE  
• Furnace fails to operate.  
• No 115 volt power to • Manual disconnect switch  
furnace, or no 24 volt OFF, door switch open, or  
• Assure 115 and 24 volt • Turn power OFF  
power to furnace  
integrated control  
module.  
prior to repair.  
• Integrated control  
module diagnostic LED  
provides no signal.  
power to integrated  
control module.  
24 volt wires improperly  
connected or loose.  
• Replace integrated  
control module  
• Blown fuse or circuit • Blown fuse or circuit  
• Check integrated control fuse with 3A  
breaker.  
breaker.  
module fuse (3A).  
automotive fuse.  
Replace if necessary.  
• Read precautions  
• Integrated control  
module has an  
internal fault.  
• Check for possible shorts in “Electrostatic  
in 115 and 24 volt circuits. Discharge” section  
• Integrated control module  
has an internal fault.  
Repair as necessary.  
of manual.  
• Replace bad integrated  
control module.  
LED is steady ON.  
• Normal operation.  
• None.  
• Normal operation.  
• Normal operation.  
ON  
CONTINUOUS  
ON  
• Turn power  
OFF prior to  
repair.  
• Furnace fails to operate.  
• Furnace lockout due • Failure to establish flame.  
• Locate and correct gas  
interruption.  
to an excessive  
number of ignition  
“retries” (3 total)1 .  
Cause may be no gas to  
burners, front cover  
pressure switch stuck  
open, bad igniter or igniter  
alignment, improper  
1
• Integrated control  
module diagnostic LED  
is flashing ONE (1) flash.  
• Check front cover  
pressure switch  
operation (hose, wiring,  
contact operation).  
Correct if necessary.  
1 FLASH  
orifices, or coated/oxidized  
or improperly connected  
flame sensor.  
• Replace or realign  
igniter.  
• Igniter is  
fragile, handle  
with care.  
• Check flame sense  
signal. Sand sensor if  
coated and/or oxidized.  
• Loss of flame after  
• Sand flame  
sensor with  
emery cloth.  
establishment. Cause may  
be interrupted gas supply,  
lazy burner flames  
(improper gas pressure or  
restriction in flue and/or  
combustion air piping),  
front cover pressure  
switch opening, or  
improper induced draft  
blower performance.  
• Check flue piping for  
blockage, proper  
length, elbows, and  
termination.  
• See “Vent/Flue  
Pipe” section  
for piping  
• Verify proper induced  
draft blower perfor-  
mance.  
details.  
• Furnace fails to operate.  
• Pressure switch  
circuit is closed.  
• Induced draft  
blower is not  
• Induced draft blower  
pressure switch contacts  
sticking.  
• Replace induced draft • Turn power OFF  
blower pressure  
switch.  
prior to repair.  
• Integrated control  
module diagnostic LED  
is flashing TWO (2)  
flashes.  
2
• Replace pressure  
switch with proper  
replacement part.  
• Shorts in pressure switch  
circuit.  
2 FLASHES  
operating.  
• Repair short.  
• Induced draft blower runs  
continuously with no  
further furnace operation.  
• Pressure switch  
circuit not closed.  
• Induced draft blower connected improperly.  
• Pressure switch hose  
blocked, pinched or  
• Inspect pressure  
switch hose. Repair, if  
necessary,  
• Turn power  
OFF prior to  
repair.  
3
is operating.  
• Integrated control  
module diagnostic LED  
is flashing THREE (3)  
flashes.  
• Blocked flue and/or inlet air  
pipe, blocked drain system,  
or weak induced draft  
blower.  
• Inspect flue and/or inlet • Replace  
3 FLASHES  
air piping for blockage,  
proper length, elbows,  
pressure  
switch with  
and termination. Check proper  
drain system. Correct  
as necessary.  
replacement  
part.  
• Correct pressure  
switch setpoint or  
contact motion.  
• Incorrect pressure switch  
setpoint or malfunctioning  
switch contacts.  
• Tighten or correct  
wiring connection.  
• Loose or improperly  
connected wiring.  
1Integrated control module will automatically attempt to reset from lockout after one hour.  
37  
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Associated  
LED Code2  
Symptoms of Abnormal  
Operation  
Fault Description(s)  
Possible Causes  
Corrective Action  
Cautions and Notes  
• Circulator blower runs  
continuously. No furnace  
operation.  
• Primary or auxiliary  
limit circuit is open.  
• Check filters and  
ductwork for blockage.  
Clean filters or remove  
obstruction.  
• Turn power OFF  
prior to repair.  
• Insufficient conditioned air  
over the heat exchanger.  
Blocked filters, restrictive  
ductwork, improper  
circulator blower speed, or  
failed circulator blower.  
4
• See Product Data  
Book applicable  
to your model* for  
allowable rise  
range and proper  
circulator speed.  
• Integrated control module  
diagnostic LED is flashing  
FOUR (4) flashes.  
4 FLASHES  
• Check circulator blower  
speed and performance.  
Correct speed or replace  
blower if necessary.  
• Flame rollout.  
• Check burners for proper  
alignment.  
• Misaligned burners, blocked  
flue and/or air inlet pipe, or  
failed induced draft blower.  
• See “Vent/Flue  
Pipe” section for  
piping details.  
• Rollout limit circuit is  
open.  
• Check flue and air inlet  
piping for blockage,  
proper length, elbows,  
and termination. Correct  
as necessary.  
• Loose or improperly  
connected wiring.  
• Replace pressure  
switch with proper  
replacement part.  
• Check induced draft  
blower for proper  
performance. Replace, if  
necessary.  
• Tighten or correct wiring  
connection.  
• Correct short at flame  
sensor or in flame  
sensor wiring.  
• Induced draft blower and  
circulator blower runs  
continuously. No furnace  
operation.  
• Short to ground in flame  
sense circuit.  
• Flame sensed with  
no call for heat.  
• Turn power OFF  
prior to repair.  
5
• Lingering burner flame.  
• Slow closing gas valve  
• Check for lingering  
flame  
5 FLASHES  
• Integrated control module  
diagnostic LED is flashing  
FIVE (5) flashes.  
• Verify proper operation  
of gas valve  
• Sand flame sensor is  
coated/oxidized.  
• Normal furnace operation.  
• Flame sense  
microamp signal is  
low.  
• Flame sensor is coated/  
oxidized.  
• Turn power OFF  
prior to repair.  
• Integrated control module  
diagnostic LED is flashing  
SEVEN (7) flashes.  
• Inspect for proper sensor  
alignment.  
• Flame sensor incorrectly  
positioned in burner flame.  
• Sand flame  
sensor with  
emery clot.  
7
• Check inlet air piping for  
blockage, proper length,  
elbows, and termination.  
• Lazy burner flame due to  
improper gas pressure or  
combustion air.  
7 FLASHES  
• See “Vent/Flue  
Pipe” section for  
piping details.  
• Compare current gas  
pressure to rating plate  
info. Adjust as needed.  
• See rating plate  
for proper gas  
pressure.  
• Check and correct wiring  
from integrated control  
module to igniter  
• Improperly connected  
igniter  
• Turn power OFF  
prior to repair.  
• Furnace not operating.  
• Problem with  
igniter circuit.  
• Integrated control module  
diagnostic LED is flashing  
EIGHT (8) flashes.  
• Replace igniter  
with proper silicon  
nitride replace-  
ment part.  
8
• Replace bad igniter  
• Bad igniter  
• Check and correct unit  
ground wiring  
• Poor unit ground  
8 FLASHES  
• Inspect pressure switch hose. • Turn power OFF  
• Pressure switch hose blocked,  
pinched or connected  
improperly.  
• Furnace operating on  
low stage gas with high  
stage induced draft blower  
• High stage pressure  
switch circuit does not  
close in response to  
high stage induced  
Repair, if necessary.  
prior to repair.  
9
• Inspect flue and/or inlet air • Replace pressure  
piping for blockage, proper  
length, elbows, and termina-  
tion. Check drain system.  
Correct as necessary.  
switch with proper  
replacement part.  
• Blocked flue and/or inlet air  
pipe, blocked drain system, or  
weak induced draft blower.  
• High stage circulator  
blower (temperature, of  
conditioned air, lower than  
typical).  
9 FLASHES  
draft blower operation.  
• Incorrect pressure switch  
setpoint or malfunctioning  
switch contacts.  
• Correct pressure switch  
setpoint or contact motion.  
• Integrated control module  
diagnostic LED is flashing  
NINE (9) flashes.  
• Tighten or correct wiring  
connection.  
• Loose or improperly connected  
wiring.  
• Review wiring diagram to  
correct polarity.  
• Polarity of 115 volt AC  
power to furnace or  
integrated control module is  
reversed.  
• Polarity of 115 volt  
power is reversed.  
• Furnace fails to operate.  
• Turn power OFF  
prior to repair.  
• Integrated control module  
diagnostic LED is flashing  
SIX (6) flashes.  
C
• Verify proper ground.  
Correct if necessary.  
CONTINUOUS  
FLASHING  
• Poor unit ground.  
• Check and correct wiring.  
38  
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WIRIN  
                                                                                                                                  
G
                                                                                                                                  
                                                                                                                                       
D
                                                                                                                                       
                                                                                                                                          
I
                                                                                                                                           
                                                                                                                                            
AG  
                                                                                                                                            
                                                                                                                                               
                                                                                                                                               
                                                                                                                                                   
R
                                                                                                                                                   
                                                                                                                                                      
A
                                                                                                                                                      
                                                                                                                                                         
M
                                                                                                                                                         
TO  
ID BLOWER  
TWO-STAGE PRESSURE  
SWITCH ASSEMBLY  
GND  
115 VAC/ 1Ø /60 HZ  
POWER SUPPLY WITH  
PROTECTION DEVICE  
OVERCURRENT  
HOT  
SURFACE  
IGNITER  
HIGH FIRE  
PRESS. SWITCH  
C
L
NO  
BK  
-1  
OR  
BR  
WARNING:DISCO  
PROPERLY POLA  
NNECT  
RIZED  
NG  
2 CIRCUIT  
2
1
CONNECTOR  
3
2
HI  
VT  
GY  
SERVICING. WIRI  
TO UNIT MUST B  
N
E
C
WH-5  
AND GROUNDED  
POWER BEFORE  
.
DISCONNECT  
TWO STAGE  
GAS VALVE  
FLAME  
SENSOR  
C
1
GY  
PM  
NO  
TO 115VAC/ 1Ø /60 HZ POWER SUPPLY WIT  
H
C
OVERCURRENT PROTECTION  
DEVICE  
FRONT COVER  
PRESSURE SWITCH  
NO  
L
N
GND  
WARNING:  
DISCONNECT PO  
MANUAL RESET ROLLOUT  
LIMIT CONTROLS  
RD  
WER  
RLY  
LOW FIRE  
PRESS.  
SWITCH  
MUST BE PROPE  
(SINGLE CONTROL ON 45 kBTU)  
BEFORE SERVIC  
WIRING TO UNIT  
POLARIZED AND  
GROUNDED.  
ING.  
BU  
PK  
OR  
DISCONNECT  
AUTO RESET PRIMARY  
LIMIT CONTROL  
VT  
DOOR  
SWITCH  
INDUCED  
DRAFT  
3
JUNCTION BOX  
WH  
2
1
BLOWER  
RD  
BK  
115kBTU MODELS  
INDUCTOR COIL  
70kBTU,90kBTU,  
ONLY  
GND  
INDOOR  
AIR  
CIRCULATOR  
BLWR  
BURNER COMPARTMENT  
BLOWER COMPARTMENT  
VT  
GND  
MANUAL RESET  
AUXILIARY  
LIMIT CONTROL  
YL  
LINE-H  
EAC-H  
LINE-N  
EAC-N  
24V HUM.  
ELECTRONIC  
AIR CLEANER  
24 V THERMOSTAT CONNECTIONS  
FUSE  
24 V  
IND HI  
IND-N  
ID  
BLWR  
3 A  
PK  
IND LO  
HUM-N  
IGN-N  
HUM-H  
IGN-H  
10  
7
11  
8
12  
BU  
OR  
HUMIDIFIER  
GY  
9
GY  
HOT SURFACE  
IGNITER  
4
5
6
BR  
VT  
GN  
FP (3)  
1
2
3
BU  
FLAME SENSOR  
115 VAC  
YL  
XFMR-N  
XFMR-H  
OR  
VT  
PK  
T-STAT SELECTOR  
40 VA  
TRANSFORMER  
TH (5)  
2
1
4
R
HEAT OFF DELAY  
DIP SWITCHES  
AUTORESET  
PRIMARYLIMIT  
CONTROL  
24 VAC  
MANUALRESETAUXILIAR  
FUSE 3 A  
1
2
3
4
5
RD  
YLIMIT  
CONTROLS  
OR  
GY  
3
BK  
RD  
WH  
W1  
YLO  
HLO (11)  
24  
VAC  
MANUALRESETROLLO  
UT  
LIMITCONTROL(S)  
WH  
115  
VAC  
DIAGNOSTIC  
LED  
HL1 (6)  
W2  
BK  
TO  
MICRO  
40 VA  
TWO-STAGE  
INTEGRATED  
CONTROL  
Y
TRANS-  
FORMER  
24V HUM.  
PS1 (12)  
C
LOW FIRE  
PRESSURE  
SWITCH  
G
HOT  
NEUTRAL  
NO  
MODULE  
FRONT COVER  
PRESSURE SWITCH  
BK  
BK  
WH  
NO  
CIRCULATOR  
BLOWER  
C
MVL(7)  
C
PM  
HI  
WH  
WH  
NO  
6
MVH (1)  
PS2 (2)  
WH  
16 WIRE  
ECM MTR  
HARNESS  
C
5
BK  
HIGH FIRE  
PRESSURE SWITCH  
5
BK  
BK  
MVC (8)  
4
3
2
1
WH  
C
GN  
PK  
GND (10)  
TR (9)  
GAS  
VALVE  
GND  
BLOWER  
GND  
COMPARTMENT  
DOOR SWITCH  
(OPEN WHEN  
DOOR OPEN)  
INDUCTOR COIL  
70kBTU,90kBTU,  
115kBTU MODELS  
ONLY  
INTEGRATED CONTROL MODULE  
0
STEADY ON = NORMAL OPER  
ATION  
LOW VOLTAGE (24V)  
EQUIPMENT GND  
FIELD GND  
1
2
3
4
6
7
8
9
C
1 FLASH = SYSTEM LOCKOUT (RETRIES  
/RECYCLES EXCEEDED)  
SURE SWITCH STUCK CLOSED  
SURE SWITCH STUCK OPEN  
ECTIVE DEVICE OPEN  
LOW VOLTAGE FIELD  
HI VOLTAGE (115V)  
HI VOLTAGE FIELD  
2 FLASHES = LOW FIRE PRES  
3 FLASHES = LOW FIRE PRES  
4 FLASHES = THERMAL PROT  
5 FLASHES = FLAME SENSED  
FIELD SPLICE  
SWITCH (TEMP.)  
IGNITER  
WITH GAS VALVE DE-ENERGIZED  
NSE SIGNAL  
JUNCTION  
TERMINAL  
7 FLASHES = LOW FLAME SE  
8 FLASHES = CHECK IGNITER  
9 FLASHES = HIGH FIRE PRES  
CONTINUOUS FLASHES = 115  
OR IMPROPER GROUNDING  
SURE SWITCH STUCK OPEN  
VOLT AC POWER REVERSED  
INTERNAL TO  
INTEGRATED CONTROL  
SWITCH (PRESS.)  
OVERCURRENT  
PROT. DEVICE  
PLUG CONNECTION  
PK PINK  
NOTES:  
COLOR CODES:  
YL YELLOW  
BR BROWN  
WH WHITE  
BU BLUE  
GY GRAY  
RD RED  
1. SET HEAT ANTICIPATOR O  
2. MANUFACTURER'S SPECIF  
N ROOM THERMOSTAT AT 0.7 AMPS.  
OR ORANGE  
VT VIOLET  
GN GREEN  
BK BLACK  
IED REPLACEMENT PARTS MUST BE USED WHEN SERVICING  
.
3. IF ANY OF THE ORIGINAL W  
REPLACED, IT MUST BE RE  
RATING OF AT LEAST 105  
IRE AS SUPPLIED WITH THE FURNACE MUST BE  
PLACED WITH WIRING MATERIAL HAVING A TEMPERATURE  
°C. USE COPPER CONDUCTO  
RS ONLY.  
4. UNIT MUST BE PERMANEN  
TLY GROUNDED AND CONFORM TO N.E.C. AND LOCAL CODE  
S.  
22314701 REV.00  
Wiring is subject to change, always refer to the wiring diagram on the unit for the most up-to-date wiring.  
39  
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®
is a trademark of Maytag Corporation and is used under  
license to Goodman Company, L.P. All rights reserved.  
2550 North Loop West, Suite 400  
Houston, TX 77092  
© 2004-2006 Goodman Company, L.P.  
40  
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