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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I. CO
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33
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*
*
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*
*
*
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2
25
12
*
26
23
29
*
14
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1
15
18
32
24
31
30
20
3
17
3
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15
19
32
20
18
21
30
17
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31
CF
M
87
87
4
321
22
OF
ON
S3
F
CUT FOR
DEHUM
S4
12
4321
10
1
1
12
7
4
9
8
5
6
19
19
1
2
3
Intell-Ignition
20
TSTAT
20
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2
1
21
ON
S1
OFF
23
29
C
US
21
14
24
26
13
2
22
25
1
28
27
9
6
4
8
7
7
Counterflow/Horizontal
Upflow/Horizontal
1
2
3
4
5
6
7
8
9
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
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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)
Upright“Standard”Connections-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.
Upright“Alternate”Connections- 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.
30
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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
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TR
O
U
B
L
E
S
H
O
O
T
I
N
G
C
H
AR
T
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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TR
O
U
B
L
E
S
H
O
O
T
I
N
G
C
H
AR
T
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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