Bryant Furnace 310AAV User Manual

310AAV/JAV  
Induced-Combustion  
4-Way Multipoise Furnace  
Installation, Start-up, Operating, and  
Service and Maintenance Instructions  
-Series A  
The 310AAV/JAV 4-Way Multipoise Gas Furnace was designed by Bryant  
dealers for Bryant dealers. Applications are easy with 4-way multipoise  
design, through-the-furnace downflow venting, 13 different venting options,  
and a door designed for easy service access. An inner blower door is  
provided for tighter sealing in sensitive applications. The 310AAV/JAV  
furnace is approved for use with natural or propane gas, and the 310JAV is  
also approved for use in Low NOx Air Quality Management Districts.  
STANDARD FEATURES  
Noise elimination combustion system  
Microprocessor based control center  
Adjustable heating air temperature rise  
LED diagnostics and self test feature  
Patented blocked vent safeguard to ensure proper furnace venting  
All models are Chimney Friendly when used with accessory vent kit  
• Four-position furnace: upflow, horizontal right, horizontal left,  
downflow  
Thirteen different vent options  
• Heat pump compatible  
• Hot surface ignition (HSI)  
Residential installations eligible for consumer financing through the Comfort  
Credit Program  
Twinning in Upflow, Downflow and Horizontal  
LIMITED WARRANTY  
• 20-year warranty on “Super S™” heat exchanger  
• 5-year parts warranty on all other components  
Catalog No: 5331-007  
Form No. II 310A-45-3  
12-02  
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28-7/8"  
25-1/4"  
1-9/16"  
2-9/16"  
22-9/16"  
A
D
AIRFLOW  
19"  
13/16"  
11/16"  
JUNCTION BOX  
LOCATION  
13/16"  
OUTLET  
4-13/16"  
F
7/8" DIA  
ACCESSORY  
8-7/16"  
1-1/2" DIA.  
RIGHT HAND  
GAS ENTRY  
1/2" DIA THERMOSTAT  
WIRE ENTRY  
1/2" DIA. THERMOSTAT  
WIRE ENTRY  
3-15/16"  
1-7/16"  
LEFT HAND GAS  
ENTRY  
ALTERNATE  
JUNCTION BOX  
LOCATION (TYP)  
33-5/16"  
24-7/8"  
VENT OUTLET  
5 PLACES (TYP)  
14-7/8"  
7/8" DIA. ACCESSORY  
7/8" DIA. ACCESSORY  
3-3/4"  
5-1/2"  
11/16"  
11/16"  
1-1/4"  
1"  
E
21-5/8"  
BOTTOM INLET  
1-11/16"  
22-1/16"  
SIDE INLET  
A02304  
NOTES:  
1. Two additional 7/8-in. diameter holes are located in the top plate.  
2. Minimum return-air openings ar furnace, based on metal duct. If flex duct is used, see flex duct manufacturers recommendations for equivalent diameters.  
a. For 800 CFM-16-in. round or 14 1/2 x 12-in. rectangle.  
b. For 1200 CFM-20-in. round or 14 1/2 x 19 1/2-in. rectangle.  
c. For 1600 CFM-22-in. round or 14 1/2 x 22-in. rectangle.  
d. For airflow requirements above 1800 CFM, see Air Delivery table in Product Data literature for specific  
use of single side inlets. The use of both side inlets, a combination of 1 side and the bottom, or the  
bottom only will ensure adequate return air openings for airflow requirements above 1800 CFM.  
Fig. 1—Dimensional Drawing  
SAFETY CONSIDERATIONS  
Sheet metal parts may have sharp edges or burrs. Use care and  
wear appropriate protective clothing and gloves when han-  
dling parts. Failure to follow this caution could result in  
personal injury.  
Improper installation, adjustment, alteration, service, mainte-  
nance, or use can cause carbon monoxide poisoning, explo-  
sion, fire, electrical shock, or other conditions which may  
cause personal injury or property damage. Consult a qualified  
installer, service agency, local gas supplier, or your distribu-  
tor or branch for information or assistance. The qualified  
installer or agency must use only factory-authorized and  
listed kits or accessories when modifying this product. Failure  
to follow this warning could result in electrical shock, fire,  
personal injury, or death.  
Wear safety glasses and work gloves. Have fire extinguisher  
available during start-up and adjustment procedures and service  
calls.  
This is the safety-alert symbol  
. When you see this symbol on  
the furnace and in instructions or manuals, be alert to the potential  
for personal injury.  
Understand the signal words DANGER, WARNING, CAUTION,  
and NOTE. These words are used with the safety-alert symbol.  
DANGER identifies the most serious hazards which will result in  
severe personal injury or death. WARNING signifies a hazard  
which could result in personal injury or death. CAUTION is used  
to identify unsafe practices which would result in minor personal  
injury or product and property damage. NOTE is used to highlight  
suggestions which will result in enhanced installation, reliability,  
or operation.  
Application of this furnace should be indoors with special  
attention given to vent sizing and material, gas input rate, air  
temperature rise, unit leveling, and unit sizing. Improper  
installation or misapplication of furnace can require excessive  
servicing or cause premature component failure.  
Installing and servicing heating equipment can be hazardous due to  
gas and electrical components. Only trained and qualified  
personnel should install, repair, or service heating equipment.  
Untrained personnel can perform basic maintenance functions  
such as cleaning and replacing air filters. All other operations must  
be performed by trained service personnel. When working on  
heating equipment, observe precautions in literature, on tags, and  
on labels attached to or shipped with unit and other safety  
precautions that may apply.  
1. Use only with type of gas approved for this furnace. Refer to  
the furnace rating plate.  
2. Install this furnace only in a location and position as specified  
in the “Location” section of these instructions.  
3. Provide adequate combustion and ventilation air to the furnace  
space as specified in “Air for Combustion and Ventilation”  
section.  
4. Combustion products must be discharged outdoors. Connect  
this furnace to an approved vent system only, as specified in  
the “Venting” section of these instructions.  
These instructions cover minimum requirements and conform to  
existing national standards and safety codes. In some instances,  
these instructions exceed certain local codes and ordinances,  
especially those that may not have kept up with changing residen-  
tial construction practices. We require these instructions as a  
minimum for a safe installation.  
5. Never test for gas leaks with an open flame. Use a commer-  
cially available soap solution made specifically for the detec-  
tion of leaks to check all connections, as specified in the “Gas  
Piping” section.  
2
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INSTALLATION  
MINIMUM INCHES CLEARANCE TO COMBUSTIBLE CONSTRUCTION  
DISTANCE MINIMALE EN POUCES AUX CONSTRUCTIONS COMBUSTIBLES  
This forced air furnace is equipped for use with This furnace is approved for UPFLOW, DOWNFLOW, and  
HORIZONTAL installations.  
natural gas at altitudes 0-10,000 ft (0-3,050m).  
An accessory kit, supplied by the Cette fournaise est approuvée pour l´installation HORIZONTALE  
et la circulation d´air VERS LE HAUT et VERS LE BAS.  
manufacturer,shall be used to convert to propane  
gas use or may be required for some natural gas  
applications.  
This furnace is for indoor installation in a  
building constructed on site.  
1"  
Les fléches de dégagement  
ne changent pas avec  
l´orientation de la fournaise.  
Clearance arrows  
do not change with  
furnace orientation.  
This furnace may be installed on combustible  
flooring in alcove or closet at minimum clearance  
as indicated by the diagram from combustible  
material .  
This furnace may be used with a Type B-1 Vent  
and may be vented in common with other gas-  
fired appliances.  
0"  
A
0"  
*
B
A
C
R
K
R
I
E
E
A
È
C
R
A
S
I
E
N
R
U
N
F
R
U
O
F
Cette fournaise à air pulsé est équipée  
pour utilisation avec gaz naturel et altitudes  
comprises entre 0-3,050m (0-10,000 pi).  
Utiliser une trousse de conversion, fournie par  
le fabricant, pour passer au gaz propane ou pour  
certaines installations au gaz naturel.  
S
E
E
R
E
N
V
T
I
I
T
R
C
E
E
F
R
O
A
N 30"  
N
V
T
A
N
MIN  
T 3"MIN  
0"  
*
Ø
Cette fournaise est prévue pour être  
installée dans un bâtiment construit sur place.  
Cette fournaise peut être installée sur  
un plancher combustible dans une alcôve ou  
dans un garde-robe en respectant le minimum  
d'espace libre des matériaux combustibles, tel  
q. u'indiqué sur le diagramme.  
Cette fournaise peut être utilisée avec un  
conduit d´évacuation de Type B-1 ou connectée  
.au conduit commun d´autres appareils à gaz.  
Clearance in inches  
Dégagement (po).  
"
0
Vent Clearance to combustibles:  
For Single Wall vents 6 inches (6 po).  
For Type B-1 vent type 1 inch (1 po).  
Dégagement de l´évent avec combustibles:  
Pour conduit d´évacuation à paroi simple 6 po (6 inches).  
Pour conduit d´évacuation de Type B-1 1 po (1 inch).  
MINIMUM INCHES CLEARANCE TO COMBUSTIBLE CONSTRUCTION  
DOWNFLOW POSITIONS:  
Installation on non-combustible floors only.  
For Installation on combustible flooring only when installed on special base, Part No. KGASB0201ALL,  
Coil Assembly, Part No. CD5 or CK5, or Coil Casing, Part No. KCAKC.  
18 inches front clearance required for alcove.  
Ø
Indicates supply or return sides when furnace is in the horizontal position. Line contact only permissible  
between lines formed by intersections of the Top and two Sides of the furnace jacket, and building joists,  
studs or framing.  
*
DÉGAGEMENT MINIMUM EN POUCES AVEC ÉLÉMENTS  
DE CONSTRUCTION COMBUSTIBLES  
POUR LA POSITION COURANT DESCENDANT:  
Pour l´installation sur plancher non combustible seulement.  
Pour l´installation sur un plancher combustible seulement quand on utilise la base spéciale, pièce  
no KGASB0201ALL, l´ensemble serpentin, pièce no CD5 ou CK5, ou le carter de serpentin, pièce  
no KCAKC.  
Dans une alcôve, on doit maintenir un dégagement à l´avant de 18 po (450 mm).  
La position indiquée concerne le côté d´entrée ou de retour quand la fournaise est dans la  
position horizontale.  
Le contact n´est permis qu´entre les lignes formées par les intersections du dessus et des  
deux côtés de la chemise de la fournaise et les solives, montant sous cadre de charpente.  
Ø
*
327590-101 REV. B  
A02330  
Fig. 2Clearances to Combustibles  
6. Always install furnace to operate within the furnaces intended  
temperature-rise range with a duct system which has an  
external static pressure within the allowable range, as speci-  
fied in the Start-Up, Adjustments, and Safety Checksection.  
See furnace rating plate.  
8. A gas-fired furnace for installation in a residential garage must  
be installed as specified in the warning box in the Location”  
section.  
9. The furnace is not to be used for temporary heating of  
buildings or structures under construction.  
7. When a furnace is installed so that supply ducts carry air  
circulated by the furnace to areas outside the space containing  
the furnace, the return air shall also be handled by duct(s)  
sealed to the furnace casing and terminating outside the space  
containing the furnace. See Air Ductssection.  
10. These Multipoise Gas-Fired Furnaces are CSA (A.G.A. and  
C.G.A.) design-certified for natural and propane gases (see  
furnace rating plate) and for installation in alcoves, attics,  
basements, closets, utility rooms, crawlspaces, and garages.  
The furnace is factory-shipped for use with natural gas. A  
3
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Table 1Dimensions (IN.)  
VENT  
CONN*  
UNIT SIZE  
A
B
C
SHIP WT. (LB)  
045-08/024045  
045-12/036045  
070-08/024070  
070-12/036070  
070-16/048070  
090-14/042090  
090-16/048090  
090-20/060090  
110-12/036110  
110-16/048110  
110-22/066110  
135-16/048135  
135-22/066135  
155-20/060155  
14-3/16  
14-3/16  
14-3/16  
14-3/16  
17-1/2  
17-1/2  
21  
12-9/16  
12-9/16  
12-9/16  
12-9/16  
15-7/8  
15-7/8  
19-3/8  
19-3/8  
15-7/8  
19-3/8  
19-3/8  
19-3/8  
22-7/8  
22-7/8  
12-11/16  
12-11/16  
12-11/16  
12-11/16  
16  
4
4
4
4
4
4
4
4
4
4
4
4
4
4
104  
107  
111  
115  
123  
126  
139  
145  
134  
145  
151  
148  
163  
170  
16  
19-1/2  
19-1/2  
16  
21  
17-1/2  
21  
19-1/2  
19-1/2  
19-1/2  
23  
21  
21  
24-1/2  
24-1/2  
23  
* 5or 6vent connector may be required in some cases.  
CSA (A.G.A. and C.G.A.) listed gas conversion kit is required  
to convert furnace for use with propane gas.  
11. See Fig. 2 for required clearances to combustibles.  
12. Maintain a 1-in. clearance from combustible materials to  
supply air ductwork for a distance of 36 inches horizontally  
from the furnace. See NFPA 90B or local code for further  
requirements.  
13. These furnaces SHALL NOT be installed directly on carpet-  
ing, tile, or any other combustible material other than wood  
flooring. In downflow installations, factory accessory floor  
base MUST be used when installed on combustible materials  
and wood flooring. Special base is not required when this  
furnace is installed on manufacturers Coil Assembly Part No.  
CD5 or CK5, or when Coil Box Part No. KCAKC is used.  
60  
A02055  
INTRODUCTION  
Fig. 3Return Air Temperature  
This 4way multipoise Category I fan-assisted furnace is CSA  
(A.G.A. and C.G.A.) design-certified for natural and propane gas  
and for installation in alcoves, attics, basements, closets, utility  
rooms, crawlspaces, and garages. A fan-assisted furnace is an  
appliance equipped with an integral mechanical means to either  
draw or force products of combustion through the combustion  
chamber and/or heat exchanger. The furnace is factory-shipped for  
use with natural gas. A CSA (A.G.A. and C.G.A.) listed gas  
conversion kit is required to convert furnace for use with propane  
gas. This furnace is not approved for installation in mobile homes,  
recreational vehicles, or outdoors.  
other codes. In absence of local codes, the installation must  
comply with the national codes listed below and all authorities  
having jurisdiction.  
In the United States and Canada, follow all codes and standards for  
the following:  
Step 1Safety  
US: National Fuel Gas Code (NFGC) NFPA 542002/ANSI  
Z223.12002 and the Installation Standards, Warm Air Heating  
and Air Conditioning Systems ANSI/NFPA 90B  
This furnace is designed for minimum continuous return-air  
temperature of 60°F db or intermittent operation down to 55°F db  
such as when used with a night setback thermostat. Return-air  
temperature must not exceed 85°F db. Failure to follow these  
return-air limits may affect reliability of heat exchangers, motors,  
and controls. (See Fig. 3.)  
CANADA: CAN/CGA-B149.1and .2M00 National Standard  
of Canada. Natural Gas and Propane Installation Codes (NSC-  
NGPIC)  
Step 2General Installation  
US: Current edition of the NFGC and the NFPA 90B. For  
copies, contact the National Fire Protection Association Inc.,  
Batterymarch Park, Quincy, MA 02269; or for only the NFGC,  
contact the American Gas Association, 400 N. Capitol, N.W.,  
For accessory installation details, refer to the applicable instruction  
literature.  
NOTE: Remove all shipping brackets and materials before oper-  
CANADA: NSCNGPIC. For a copy, contact Standard Sales,  
CSA International, 178 Rexdale Boulevard, Etobicoke (Tor-  
onto), Ontario, M9W 1R3 Canada  
ating the furnace.  
CODES AND STANDARDS  
Step 3Combustion and Ventilation Air  
Follow all national and local codes and standards in addition to  
these instructions. The installation must comply with regulations  
of the serving gas supplier, local building, heating, plumbing, and  
US: Section 5.3 of the NFGC, Air for Combustion and  
Ventilation  
4
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THE BLOWER IS  
LOCATED BELOW THE  
BURNER SECTION, AND  
CONDITIONED AIR IS  
DISCHARGED UPWARD.  
THE BLOWER IS LOCATED  
TO THE RIGHT OF THE  
BURNER SECTION, AND  
AIR CONDITIONED AIR IS  
DISCHARGED TO THE LEFT.  
THE BLOWER IS  
THE BLOWER IS  
LOCATED ABOVE THE  
BURNER SECTION, AND  
CONDITIONED AIR IS  
DISCHARGED DOWNWARD  
LOCATED TO THE LEFT  
OF THE BURNER SECTION,  
AND CONDITIONED AIR IS  
DISCHARGED TO THE RIGHT.  
A02097  
Fig. 4Multipoise Orientations  
CANADA: Part 7 of NSCNGPIC, Venting Systems and Air  
Supply for Appliances  
NOT move or shuffle your feet, do not touch ungrounded  
objects, etc.).  
Step 4Duct Systems  
4. If you touch ungrounded objects (and recharge your body with  
static electricity), firmly touch a clean, unpainted metal  
surface of the furnace again before touching control or wires.  
US and CANADA: Air Conditioning Contractors Association  
(ACCA) Manual D, Sheet Metal and Air Conditioning Con-  
tractors National Association (SMACNA), or American Soci-  
ety of Heating, Refrigeration, and Air Conditioning Engineers  
(ASHRAE) 2001 Fundamentals Handbook Chapter 34.  
5. Use this procedure for installed and uninstalled (ungrounded)  
furnaces.  
6. Before removing a new control from its container, discharge  
your bodys electrostatic charge to ground to protect the  
control from damage. If the control is to be installed in a  
furnace, follow items 1 through 4 before bringing the control  
or yourself in contact with the furnace. Put all used and new  
controls into containers before touching ungrounded objects.  
Step 5Acoustical Lining and Fibrous Glass Duct  
US and CANADA: current edition of SMACNA and NFPA  
90B as tested by UL Standard 181 for Class I Rigid Air Ducts  
Step 6Gas Piping and Gas Pipe Pressure Testing  
US: NFGC; chapters 5, 6, 7, and 12 and National Plumbing  
Codes  
7. An ESD service kit (available from commercial sources) may  
also be used to prevent ESD damage.  
CANADA: NSCNGPIC Parts 3, 4, 5, A, B, E and H.  
Step 7Electrical Connections  
LOCATION  
Step 1General  
US: National Electrical Code (NEC) ANSI/NFPA 702002  
Some assembly and modifications are required when used in any  
of the four applications shown in Figure 4.  
CANADA: Canadian Electrical Code CSA C22.1  
ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS  
PROCEDURE  
This furnace must:  
be installed so the electrical components are protected from  
water.  
not be installed directly on any combustible material other than  
wood flooring. Refer to Introduction section.  
Electrostatic discharge can affect electronic components.  
Take precautions during furnace installation and servicing to  
protect the furnace electronic control. Precautions will pre-  
vent electrostatic discharges from personnel and hand tools  
which are held during the procedure. These precautions will  
help to avoid exposing the control to electrostatic discharge  
by putting the furnace, the control, and the person at the same  
electrostatic potential.  
be located close to the chimney/vent and attached to an air  
distribution system. Refer to Air Ducts section.  
be provided ample space for servicing and cleaning. Always  
comply with minimum fire protection clearances shown on the  
furnace clearance to combustible label.  
1. Disconnect all power to the furnace. Multiple disconnects may  
be required. DO NOT TOUCH THE CONTROL OR ANY  
WIRE CONNECTED TO THE CONTROL PRIOR TO DIS-  
CHARGING YOUR BODYS ELECTROSTATIC CHARGE  
TO GROUND.  
Do not install furnace in a corrosive or contaminated atmo-  
sphere. Make sure all combustion and circulating air require-  
ments are met, in addition to all local codes and ordinances.  
2. Firmly touch the clean, unpainted, metal surface of the furnace  
chassis which is close to the control. Tools held in a persons  
hand during grounding will be satisfactorily discharged.  
3. After touching the chassis, you may proceed to service the  
control or connecting wires as long as you do nothing to  
recharge your body with static electricity (for example; DO  
5
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furnace. If the dampers are manually operated, they must be  
equipped with means to prevent operation of either unit unless the  
damper is in the full-heat or full-cool position.  
This gas furnace may be used for construction heat provided  
that:  
AIR FOR COMBUSTION AND VENTILATION  
Provisions for adequate combustion and ventilation air must be  
provided in accordance with Section 5.3 of the NFGC, Air for  
Combustion and Ventilation, or applicable provisions of the local  
building codes.  
-The furnace is permanently installed with all electrical  
wiring, piping, venting and ducting installed according to  
these installation instructions. A return air duct is provided,  
sealed to the furnace casing, and terminated outside the space  
containing the furnace. This prevents a negative pressure  
condition as created by the circulating air blower, causing a  
flame rollout and/or drawing combustion products into the  
structure.  
Canadian installations must be installed in accordance with NSC-  
NGPIC Part 7 and all authorities having jurisdiction.  
-The furnace is controlled by a thermostat. It may not be hot  
wiredto provide heat continuously to the structure without  
thermostatic control.  
-Clean outside air is provided for combustion. This is to  
minimize the corrosive effects of adhesives, sealers and other  
construction materials. It also prevents the entrainment of  
drywall dust into combustion air, which can cause fouling and  
plugging of furnace components.  
-The temperature of the return air to the furnace is no less  
than 55 degrees F, with no evening setback or shutdown. The  
use of the furnace while the structure is under construction is  
deemed to be intermittent operation per our installation  
instructions.  
-The air temperature rise is within the rated rise range on the  
furnace rating plate, and the firing rate has been set to the  
nameplate value.  
18-IN. MINIMUM  
TO BURNERS  
A93044  
-The filters used to clean the circulating air during the  
construction process must be either changed or thoroughly  
cleaned prior to occupancy.  
Fig. 6Installation in a Garage  
-The furnace, ductwork and filters are cleaned as necessary to  
remove drywall dust and construction debris from all HVAC  
system components after construction is completed.  
When the furnace is installed in a residential garage, the  
burners and ignition sources must be located at least 18 inches  
above the floor. The furnace must be located or protected to  
avoid damage by vehicles. When the furnace is installed in a  
public garage, airplane hangar, or other building having a  
hazardous atmosphere, the furnace must be installed in  
accordance with the NFGC or NSCNGPIC. (See Fig. 6.)  
DO NOT install the furnace on its back or facing down.  
Safety control operation will be adversely affected. Never  
connect return-air ducts to back of furnace. Failure to follow  
this warning could result in fire, personal injury, or death.  
(See Fig. 5.)  
Air for combustion must not be contaminated by halogen  
compounds, which include fluoride, chloride, bromide, and  
iodide. These elements are found in aerosol sprays, deter-  
gents, bleaches, cleaning solvents, salts, air fresheners, and  
other household products.  
All fuel-burning equipment must be supplied with air for fuel  
combustion. Sufficient air must be provided to avoid negative  
pressure in the equipment room or space. A positive seal must be  
made between the furnace cabinet and the return-air duct to  
prevent pulling air from the burner area and from blocked vent  
safeguard opening.  
The operation of exhaust fans, kitchen ventilation fans,  
clothes dryers, attic exhaust fans or fireplaces could create a  
NEGATIVE PRESSURE CONDITION at the furnace.  
Make-up air MUST be provided for the ventilation devices, in  
addition to that required by the furnace. Refer to Carbon  
Monoxide Hazard warning in venting section of these instruc-  
tions to determine amount of make-up air required.  
A02054  
Fig. 5Prohibit Installation on Back  
Step 2Location Relative to Cooling Equipment  
The cooling coil must be installed parallel with, or on the  
downstream side of the unit to avoid condensation in the heat  
exchangers. When installed parallel with the furnace, dampers or  
other flow control must prevent chilled air from entering the  
The requirements for combustion and ventilation air depend upon  
whether the furnace is located in an unconfined or confined space.  
6
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Table 2Minimum Free Area of Combustion Air Opening*  
AIR FROM INDOOR  
UNCONFINED SPACE  
OUTDOOR AIR THROUGH  
VERTICAL DUCTS  
OUTDOOR AIR THROUGH  
HORIZONTAL DUCTS  
OUTDOOR AIR THROUGH  
SINGLE DUCT  
FURNACE  
INPUT  
(BTUH)  
Free Area  
of Opening  
(Sq In.)  
Free Area of  
Round Pipe  
Opening and Duct  
(in. Dia)  
Free Area of  
Round Pipe  
Opening and Duct  
(in. Dia)  
Free Area of  
Round Pipe  
Opening and Duct  
(In. Dia)  
(Sq. In.)  
(sq In.)  
(Sq In.)  
44,000  
66,000  
100  
100  
100  
110  
132  
154  
11  
4
5
6
6
7
7
22  
33  
6
7
14.7  
22.0  
29.3  
36.7  
44.0  
51.3  
5
6
7
7
8
8
16.5  
22.0  
27.5  
33  
88,000  
44.0  
55  
8
110,000  
132,000  
154,000  
9
66  
10  
10  
38.5  
77  
* Free area shall be equal to or greater than the sum of the areas of all vent connectors in the confined space. Opening area must be increased if other gas appliances  
in the space require combustion air.  
AIR  
DUCTS  
VENT THROUGH ROOF  
Step 1Unconfined Space  
An unconfined space has a volume of at least 50 cu ft for each  
1000 Btuh total input for all appliances (furnaces, clothes dryers,  
water heaters, etc.) in the space.  
For example:  
12MAX  
FURNACE  
INPUT (BTUH)  
44,000  
MINIMUM WITH  
71/2 FT CEILING (SQ. FT.)  
1 SQ IN.  
PER 1000  
294  
441  
587  
734  
881  
1028  
BTUH IN DOOR  
*
OR WALL  
66,000  
88,000  
UNCONFINED  
SPACE  
INTERIOR  
HEATED  
SPACE  
110,000  
132,000  
154,000  
6MIN  
(FRONT) †  
If the unconfined space is constructed unusually tight, air for  
combustion and ventilation must come from either the outdoors or  
spaces freely communicating with the outdoors. Combustion and  
ventilation openings must be equivalent to those used for a  
confined space (defined below). Return air must not be taken from  
the room unless an equal or greater amount of air is supplied to the  
room.  
1 SQ IN.  
PER 1000  
BTUH IN DOOR  
*
OR WALL  
12MAX  
Step 2Confined Space  
AIR DUCTS  
A confined space has a volume less than 50 cu ft per 1000 Btuh  
of total input ratings of all appliances installed in that space. A  
confined space must have provisions for supplying air for com-  
bustion, ventilation, and dilution of flue gases using one of the  
following methods in Table 2 and Fig. 7 and 8.  
* Minimum opening size is 100 sq in. with  
minimum dimensions of 3 in.  
Minimum of 3 in. when type-B1 vent is used.  
A02038  
NOTE: When determining the free area of an opening, the  
blocking effect of louvers, grilles, and screens must be considered.  
If the free area of the louver or grille design is unknown, assume  
wood louvers have a 20 percent free area and metal louvers or  
grilles have a 60 percent free area. Screens must not be smaller  
than 1/4-in. mesh. Louvers and grilles must be constructed so they  
cannot be closed.  
Fig. 7Confined Space: Air for Combustion and  
Ventilation from an Unconfined Indoor Space  
c. If the furnace is installed on a raised platform to provide a  
return-air plenum, and return air is taken directly from the  
hallway or space adjacent to furnace, all air for combustion  
must come from outdoors.  
The opening size depends upon whether air comes from outside of  
the structure or an unconfined space inside the structure.  
1. Air from inside the structure requires 2 openings (for struc-  
tures not of unusually tight construction):  
2. Air from outside the structure requires 1 of the following:  
a. If combustion air is taken from outdoors through 2 vertical  
ducts, the openings and ducts must have at least 1 sq in. of  
free area per 4000 Btuh of total input for all equipment  
within the confined space. (See Fig. 8 and Table 2.)  
a. Each opening must have a minimum free area of not less  
than 1 sq in per 1000 Btuh of total input rating for all gas  
utilization equipment in the confined space, but not less  
than 100 sq in. The minimum dimension of air openings  
should be no smaller than 3 in. (See Table 2 and Fig. 7 ).  
b. If combustion air is taken from outdoors through 2 hori-  
zontal ducts, the openings and ducts must have at least 1 sq  
in. of free area per 2000 Btuh of total input for all  
equipment within the confined space. (See Fig. 8 and Table  
2.)  
b. If building construction is unusually tight, a permanent  
opening directly communicating with the outdoors shall be  
provided. (See next section).  
7
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1 SQ IN.  
PER 4000  
BTUH*  
DUCTS  
TO  
OUTDOORS  
12MAX  
1 SQ IN.  
PER 2000  
BTUH*  
D
12″  
MAX  
VENT  
A
THROUGH  
ROOF  
F
AIR  
DUCTS  
1 SQ IN.  
PER  
4000  
BTUH*  
DUCTS  
TO  
OUTDOORS  
A02098  
1 SQ IN.  
PER  
Fig. 9Removing Bottom Closure Panel  
4000  
BTUH*  
1 SQ IN.  
PER 2000  
BTUH*  
E
G
B
12″  
MAX  
12MAX  
C
SIDE RETURN AIR INLET  
12MAX  
These furnaces are shipped with bottom closure panel installed in  
bottom return-air opening. This panel MUST be in place when  
only side return air is used.  
AIR DUCTS  
DUCT  
TO  
1 SQ IN.  
PER 4000  
BTUH*  
NOTE: Side return-air openings can be used in UPFLOW and  
most HORIZONTAL configurations. Do not use side return-air  
openings in DOWNFLOW configuration.  
OUTDOORS  
*Minimum dimensions of 3 in.  
NOTE: Use any of the following  
LEVELING LEGS (IF DESIRED)  
combinations of openings:  
A & B C & D D & E F & G  
In upflow position with side return inlet(s), leveling legs may be  
used. (See Fig. 10.) Install field-supplied, 5/16 X 1 1/2 in. (max)  
corrosion-resistant machine bolts, washers and nuts.  
A02165  
Fig. 8Confined Space: Air for Combustion and  
Ventilation from Outdoors  
NOTE: Bottom closure must be used when leveling legs are used.  
It may be necessary to remove and reinstall bottom closure panel  
to install leveling legs. To remove bottom closure panel, see Fig.  
9.  
c. If combustion air is taken from the outdoors through a  
single opening or duct (horizontal or vertical) commencing  
within 12 in. of the top of the confined space, the opening  
and duct must have at least 1 sq in. of free area per 3000  
Btuh of the total input for all equipment within the confined  
space and not less than the sum of the areas of all vent  
connectors in the confined space. Equipment clearances to  
the structure shall be at least 1 in. from the sides and back  
and 6 in. from the front of the appliances. See Table 2 and  
Fig. 8.  
To install leveling legs:  
1. Position furnace on its back. Locate and drill a hole in each  
bottom corner of furnace. (See Fig. 10.)  
2. For each leg, install nut on bolt and then install bolt and nut in  
hole. (Install flat washer if desired.)  
3. Install another nut on other side of furnace base. (Install flat  
washer if desired.)  
4. Adjust outside nut to provide desired height, and tighten inside  
nut to secure arrangement.  
When ducts are used, they must be of the same cross sectional area  
as the free area of the openings to which they connect. The  
minimum dimension of ducts must not be less than 3 in.  
5. Reinstall bottom closure panel if removed.  
Step 2Downflow Installation  
NOTE: For downflow applications, this furnace is approved for  
use on combustible flooring when any one of the 3 accessories are  
used:  
INSTALLATION  
Step 1Upflow Installation  
Special Base, KGASB  
BOTTOM RETURN AIR INLET  
Cased Coil Assembly Part No. CD5 or CK5  
Coil Box Part No. KCAKC  
These furnaces are shipped with bottom closure panel installed in  
bottom return-air opening. Remove and discard this panel when  
bottom return air is used. To remove bottom closure panel,  
perform the following:  
1. Determine application being installed from Table 3.  
2. Construct hole in floor per Table 3 and Fig. 11.  
1. Tilt or raise furnace and remove 2 screws holding bottom filler  
panel. (See Fig. 9.)  
3. Construct plenum to dimensions specified in Table 3 and Fig.  
11.  
2. Rotate bottom filler panel downward to release holding tabs.  
3. Remove bottom closure panel.  
4. If downflow subbase, KGASB is used, install as shown in Fig.  
12. If Coil Assembly Part No. CD5 or CK5 or Coil Box Part  
No. KCAKC is used, install as shown in Fig. 13.  
4. Reinstall bottom filler panel and screws.  
8
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516″  
PLATFORM UNIT SUPPORT  
Construct working platform at location where all required furnace  
clearances are met. (See Fig. 2 and 17.) For furnaces with 1-in.  
clearance requirement on side, set unit on non-combustible blocks,  
bricks or angle iron. For crawlspace installations, if the unit is not  
suspended from the floor joists, the ground underneath unit must  
be level and the unit set on blocks or bricks.  
516″  
1 34″  
ROLL-OUT PROTECTION  
1 34″  
Provide a minimum 17 3/4X 22piece of sheet metal for roll-out  
protection in front of burner area for units closer than 12 inches  
above the combustible deck or suspended units closer than 12-in.  
to joists. The sheet metal MUST extend underneath the furnace  
casing by 1 in. with the door removed.  
516″  
The bottom closure pan on furnaces of widths 17 1/2 in. and larger  
may be used for roll-out protection when bottom of furnace is used  
for return air connection. See Fig. 17 for proper orientation of  
roll-out shield.  
516″  
1 34″  
1 34″  
BOTTOM RETURN AIR INLET  
These furnaces are shipped with bottom closure panel installed in  
bottom return-air opening. Remove and discard this panel when  
bottom return air is used. To remove bottom closure panel,  
perform the following:  
A02071  
Fig. 10Leveling Legs  
1. Tilt or raise furnace and remove 2 screws holding bottom filler  
panel. (See Fig. 9.)  
NOTE: It is recommended that the perforated supply-air duct  
flanges be completely folded over or removed from furnace when  
installing the furnace on a factory-supplied cased coil or coil box.  
To remove the supply-air duct flange, use wide duct pliers or hand  
seamers to bend flange back and forth until it breaks off. Be careful  
of sharp edges. (See Fig. 14.)  
2. Rotate bottom filler panel downward to release holding tabs.  
3. Remove bottom closure panel.  
4. Reinstall bottom filler panel and screws.  
SIDE RETURN AIR INLET  
BOTTOM RETURN AIR INLET  
These furnaces are shipped with bottom closure panel installed in  
bottom return-air opening. This panel MUST be in place when  
only one side return air is used.  
These furnaces are shipped with bottom closure panel installed in  
bottom return-air opening. Remove and discard this panel when  
bottom return air is used. To remove bottom closure panel,  
perform the following:  
Not all horizontal furnaces are approved for side return air  
connections (See Fig. 20.)  
1. Tilt or raise furnace and remove 2 screws holding bottom filler  
panel. (See Fig. 9.)  
Step 4Filter Arrangement  
2. Rotate bottom filler panel downward to release holding tabs.  
3. Remove bottom closure panel.  
Never operate a furnace without a filter or with filter access  
door removed. Failure to follow this warning could result in  
fire, personal injury, or death.  
4. Reinstall bottom filler panel and screws.  
Step 3Horizontal Installation  
There are no provisions for an internal filter rack in these furnaces.  
A field-supplied accessory external filter rack is required.  
Do not install the furnace on its back or hang furnace with  
control compartment facing downward. Safety control opera-  
tion will be adversely affected. Never connect return-air ducts  
to the back of the furnace. Failure to follow this warning  
could result in fire, personal injury, or death.  
This furnace requires KGAFR0301ALL 1external filter rack or a  
suitable field-supplied substitute, such as the Media Cabinet.  
Refer to the instructions supplied with external filter rack for  
assembly and installation options.  
The furnace can be installed horizontally in an attic or crawl space  
on either the left-hand (LH) or right-hand (RH) side. The furnace  
can be hung from floor joists, rafters or trusses or installed on a  
platform, non-combustible blocks, bricks or pad.  
Step 5Air Ducts  
GENERAL REQUIREMENTS  
The duct system should be designed and sized according to  
accepted national standards such as those published by: Air  
Conditioning Contractors Association (ACCA), Sheet Metal and  
Air Conditioning Contractors National Association (SMACNA) or  
American Society of Heating, Refrigerating and Air Conditioning  
Engineers (ASHRAE) or consult The Air Systems Design Guide-  
lines reference tables available from your local distributor. The  
duct system should be sized to handle the required system design  
CFM at the design external static pressure.  
SUSPENDED UNIT SUPPORT  
The furnace may be supported under each end with threaded rod,  
angle iron or metal plumbers strap as shown. (See Fig. 15 and 16.)  
Secure angle iron to bottom of furnace as shown. Heavy-gauge  
sheet metal straps (plumbers straps) may be used to suspend the  
unit from each bottom corner. To prevent screws from pulling out,  
use 2 # 8 x ¾-in. screw into the side and 2 # 8 x ¾-in. screw in the  
bottom of the furnace casing for each strap. (See Fig. 15 and 16.)  
9
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FURNACE  
(OR COIL CASING  
WHEN USED)  
A
PLENUM  
OPENING  
COMBUSTIBLE  
FLOORING  
B
D
FLOOR  
OPENING  
C
DOWNFLOW  
SUBBASE  
SHEET METAL  
PLENUM  
FLOOR  
OPENING  
A96283  
Fig. 11Floor and Plenum Opening Dimensions  
A96285  
Fig. 12Furnace, Plenum, and Subbase Installed on  
a Combustible Floor  
FURNACE  
CD5 OR CK5  
COIL ASSEMBLY  
OR KCAKC  
COIL BOX  
COMBUSTIBLE  
FLOORING  
SHEET METAL  
PLENUM  
FLOOR  
OPENING  
A96284  
Fig. 13Furnace, Plenum, and Coil Assembly or Coil Box Installed on a Combustible Floor  
When a furnace is installed so that the supply ducts carry air to  
areas outside the space containing the furnace, the return air must  
also be handled by a duct(s) sealed to the furnace casing and  
terminating outside the space containing the furnace.  
Flexible connections should be used between ductwork and  
furnace to prevent transmission of vibration. Ductwork passing  
through unconditioned space should be insulated and sealed to  
enhance system performance. When air conditioning is used, a  
vapor barrier is recommended.  
Secure ductwork with proper fasteners for type of ductwork used.  
Seal supply- and return-duct connections to furnace with code  
approved tape or duct sealer.  
Maintain a 1-in. clearance from combustible materials to supply air  
ductwork for a distance of 36 in. horizontally from the furnace. See  
NFPA 90B or local code for further requirements.  
10  
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Table 3Opening Dimensions (In.)  
FURNACE  
CASING  
WIDTH  
PLENUM OPENING  
FLOOR OPENING  
APPLICATION  
A
B
C
D
Upflow Applications on Combustible or Noncombustible  
Flooring (KGASB subbase not required)  
12-11/16  
21-5/8  
13-5/16  
22-1/4  
Downflow Applications on Noncombustible Flooring  
(KGASB subbase not required)  
12-9/16  
19  
19  
13-3/16  
13-7/16  
19-5/8  
20-5/8  
143/16  
171/2  
21  
Downflow applications on combustible flooring (KGASB  
11-13/16  
subbase required)  
Downflow Applications on Combustible Flooring with CD5 or  
CK5 Coil Assembly or KCAKC coil box (KGASB subbase  
not required)  
12-5/16  
19  
13-5/16  
20  
Upflow Applications on Combustible or Noncombustible  
Flooring (KGASB subbase not required)  
16  
21-5/8  
19  
16-5/8  
16-1/2  
16-3/4  
22-1/4  
19-5/8  
20-5/8  
Downflow Applications on Noncombustible Flooring  
(KGASB subbase not required)  
15-7/8  
15-1/8  
Downflow applications on combustible flooring (KGASB  
19  
subbase required)  
Downflow Applications on Combustible Flooring with CD5 or  
CK5 Coil Assembly or KCAKC coil box (KGASB subbase  
not required)  
15-1/2  
19  
16-1/2  
20  
Upflow Applications on Combustible or Noncombustible  
Flooring (KGASB subbase not required)  
19-1/2  
19-3/8  
18-5/8  
21-5/8  
19  
20-1/8  
20  
22-1/4  
19-5/8  
20-5/8  
Downflow Applications on Noncombustible Flooring  
(KGASB subbase not required)  
Downflow applications on combustible flooring (KGASB  
19  
20-1/4  
subbase required)  
Downflow Applications on Combustible Flooring with CD5 or  
CK5 Coil Assembly or KCAKC coil box (KGASB subbase  
not required)  
19  
19  
20  
20  
Upflow Applications on Combustible or Noncombustible  
Flooring (KGASB subbase not required)  
23  
21-1/8  
19  
23-5/8  
23-1/2  
23-3/4  
22-1/4  
19-5/8  
20-5/8  
Downflow Applications on Noncombustible Flooring  
(KGASB subbase not required)  
22-7/8  
22-1/8  
24-1/2  
Downflow applications on Combustible flooring (KGASB  
19  
subbase required)  
Downflow Applications on Combustible Flooring with CD5 or  
CK5 Coil Assembly or KCAKC coil box (KGASB subbase  
not required)  
22-1/2  
19  
23-1/2  
20  
W
DOWNFLOW  
UPFLO  
HORIZONTAL  
90˚  
90˚  
PREFERRED  
PREFERRED  
PREFERRED  
PREFERRED  
PREFERRED  
PREFERRED  
120˚  
MIN  
120˚  
MIN  
120˚  
MIN  
PERMITTED  
PERMITTED  
PERMITTED  
A02329  
Fig. 14Duct Flanges  
DUCTWORK ACOUSTICAL TREATMENT  
SMACNA construction standard on fibrous glass ducts. Both  
acoustical lining and fibrous ductwork shall comply with NFPA  
90B as tested by UL Standard 181 for Class 1 Rigid air ducts.  
Metal duct systems that do not have a 90 degree elbow and 10 ft  
of main duct to the first branch take-off may require internal  
acoustical lining. As an alternative, fibrous ductwork may be used  
if constructed and installed in accordance with the latest edition of  
11  
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1/4" THREADED ROD  
4 REQ.  
OUTER DOOR  
ASSEMBLY  
SECURE ANGLE  
IRON TO BOTTOM  
OF FURNACE WITH  
3 #8 x 3/4" SCREWS  
TYPICAL FOR 2 SUPPORTS  
8" MIN FOR DOOR  
REMOVAL  
1" SQUARE, 11/4" x 11/4" x 1/4" ANGLE IRON  
OR UNI-STRUT MAY BE USED  
(2) HEX NUTS, (2) WASHERS & (2) LOCK WASHERS  
REQ. PER ROD  
A02345  
Fig. 15Horizontal Unit Suspension  
A02014  
Fig. 16Horizontal Suspension with Straps  
Upflow and Horizontal Furnaces  
SUPPLY AIR CONNECTIONS  
For a furnace not equipped with a cooling coil, the outlet duct shall  
be provided with a removable access panel. This opening shall be  
accessible when the furnace is installed and shall be of such a size  
that the heat exchanger can be viewed for possible openings using  
light assistance or a probe can be inserted for sampling the air  
stream. The cover attachment shall prevent leaks.  
Connect supply-air duct to flange on furnace supply-air outlet.  
Bend flange upward to 90° with wide duct pliers. The supply-air  
duct attachment must ONLY be connected to furnace supply-  
outlet-air duct flanges or air conditioning coil casing (when used).  
DO NOT cut main furnace casing to attach supply side air duct,  
humidifier, or other accessories. All accessories MUST be con-  
nected external to furnace main casing.  
12  
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LINE CONTACT ONLY PERMISSIBLE BETWEEN  
LINES FORMED BY INTERSECTIONS OF  
THE TOP AND TWO SIDES OF THE FURNACE  
JACKET AND BUILDING JOISTS,  
STUDS, OR FRAMING.  
17 3/4OVER ALL  
4 3/4UNDER DOOR  
1UNDER FURNACE  
GAS  
ENTRY  
TYPE-B  
VENT  
EXTEND OUT 12OUT  
FROM FACE OF DOOR  
MIN*  
6
30-IN. MIN  
WORK AREA  
* WHEN USED WITH  
SINGLE WALL VENT  
CONNECTIONS  
17 3/4  
SHEET  
METAL  
22″  
MANUAL SHUTOFF  
GAS VALVE  
SEDIMENT  
TRAP  
A02164  
Fig. 17Typical Attic Installation  
Downflow Furnaces  
Step 6Gas Piping  
Connect supply-air duct to supply-air opening on furnace. The  
supply-air duct attachment must ONLY be connected to furnace  
supply/outlet or air conditioning coil casing (when used). When  
installed on combustible material, supply-air duct attachment must  
ONLY be connected to the accessory subbase, KGASB0201ALL,  
or factory approved air conditioning coil casing. DO NOT cut  
main furnace casing to attach supply side air duct, humidifier, or  
other accessories. All accessories MUST be connected external to  
furnace casing.  
Never purge a gas line into a combustion chamber. Never test  
for gas leaks with an open flame. Use a commercially  
available soap solution made specifically for the detection of  
leaks to check all connections. A failure to follow this  
warning could result in fire, explosion, personal injury, or  
death.  
Gas piping must be installed in accordance with national and local  
codes. Refer to current edition of NFGC in the U.S., the NSCNG-  
PIC in Canada.  
RETURN AIR CONNECTIONS  
Installations must be made in accordance with all authorities  
having jurisdiction. If possible, the gas supply line should be a  
separate line running directly from meter to furnace.  
Never connect return-air ducts to the back of the furnace. A  
failure to follow this warning can cause a fire, personal injury,  
or death.  
Refer to Table 4 for recommended gas pipe sizing. Risers must be  
used to connect to furnace and to meter. Support all gas piping  
with appropriate straps, hangers, etc. Use a minimum of 1 hanger  
every 6 ft. Joint compound (pipe dope) should be applied sparingly  
and only to male threads of joints. Pipe dope must be resistant to  
the action of propane gas.  
Downflow Furnaces  
The return-air duct must be connected to return-air opening  
(bottom inlet) as shown in Fig. 1. DO NOT cut into casing sides  
(left or right). Side opening is permitted for only upflow and most  
horizontal furnaces. Bypass humidifier connections should be  
made at ductwork or coil casing sides exterior to furnace.  
If local codes allow the use of a flexible gas appliance  
connector, always use a new listed connector. Do not use a  
connector which has previously serviced another gas appli-  
ance. Black iron pipe shall be installed at the gas valve and  
extend a minimum of 2-in. outside the furnace.  
Upflow and Horizontal Furnaces  
The return-air duct must be connected to bottom, sides (left or  
right), or a combination of bottom and side(s) of main furnace  
casing as shown in Fig. 1. Bypass humidifier may be attached to  
unused side return air portion of the furnace casing. (See Fig. 18,  
19, and 20.)  
Not all horizontal furnaces are approved for side return air  
connections. (See Fig. 20.)  
13  
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A02075  
Fig. 18Upflow Return Air Configurations and Restrictions  
A02163  
Fig. 19Downflow Return Air Configurations and Restrictions  
A02162  
Fig. 20Horizontal Return Air Configurations and Restrictions  
14  
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Table 4Maximum Capacity of Pipe*  
GAS  
SUPPLY  
NOMINAL  
LENGTH OF PIPE (FT)  
MANUAL  
SHUTOFF  
VALVE  
(REQUIRED  
SEDIMENT  
TRAP  
IRON  
PIPE  
SIZE  
(IN.)  
INTERNAL  
DIAMETER  
(IN.)  
10  
20  
30  
40  
82  
50  
73  
1/2  
3/4  
0.622  
0.824  
1.049  
1.380  
1.610  
175  
360  
120  
250  
465  
950  
97  
200  
375  
770  
170 151  
320 285  
660 580  
UNION  
1
680  
1-1/4  
1-1/2  
1400  
2100 1460 1180 990 900  
* Cubic ft of gas per hr for gas pressures of 0.5 psig (14in. wc) or less and a  
pressure drop of 0.5in wc (based on a 0.60 specific gravity gas).  
Ref: Table 12.2 NFPA 54-2002.  
A02035  
Fig. 21bTypical Gas Pipe Arrangement  
Connect gas pipe to gas valve using a backup wrench to avoid  
damaging gas controls.  
Use proper length of pipe to avoid stress on gas control  
manifold. Failure to follow this warning could result in a gas  
leak resulting in fire, explosion, personal injury, or death.  
If pressure exceeds 0.5 psig (14-in. wc), gas supply pipe must be  
disconnected from furnace and capped before pressure test. If test  
pressure is equal to or less than 0.5 psig (14-in. wc), turn off  
electric shutoff switch located on furnace gas control valve and  
accessible manual shutoff valve before test. After all connections  
have been made, purge lines and check for leakage.  
An accessible manual shutoff valve MUST be installed external to  
furnace casing and within 6 ft of furnace. A 1/8-in. NPT plugged  
tapping, accessible for test gage connection, MUST be installed  
immediately upstream of gas supply connection to furnace and  
downstream of manual shutoff valve.  
NOTE: The gas valve inlet pressure tap connection is suitable to  
use as test gage connection providing test pressure DOES NOT  
exceed maximum 0.5 psig (14-in. wc) stated on gas control valve.  
(See Fig. 50.)  
The gas supply pressure shall be within the maximum and  
minimum inlet supply pressures marked on the rating plate with  
the furnace burners ON and OFF.  
Some installations require gas entry on right side of furnace (as  
Step 7Electrical Connections  
viewed in upflow). (See Fig. 21a.)  
Install a sediment trap in riser leading to furnace as shown in Fig  
21b. Connect a capped nipple into lower end of tee. Capped nipple  
should extend below level of gas controls. Place a ground joint  
union between gas control manifold and exterior manual equip-  
ment gas shutoff valve. A 1/8-in. NPT plugged tapping, accessible  
for test gage connection, MUST be installed immediately upstream  
of gas supply connection to furnace and downstream of manual  
shutoff valve.  
Blower access panel door switch opens 115-v power to  
control center. No component operation can occur. Do not  
bypass or close switch with panel removed. Failure to follow  
this warning could result in personal injury or death.  
See Fig. 24 for field wiring diagram showing typical field 115-v  
wiring. Check all factory and field electrical connections for  
tightness.  
Piping should be pressure and leak tested in accordance with  
NFGC in the United States or NSCNGPIC in Canada, local, and  
national plumbing and gas codes before the furnace has been  
connected. After all connections have been made, purge lines and  
check for leakage at furnace prior to operating furnace.  
Field-supplied wiring shall conform with the limitations of 63°F  
(33°C) rise.  
90° Elbow  
The cabinet MUST have an uninterrupted or unbroken ground  
according to NEC ANSI/NFPA 70-2002 and Canadian Elec-  
trical Code CSA C22.1 or local codes to minimize personal  
injury if an electrical fault should occur. This may consist of  
electrical wire, conduit approved for electrical ground or a  
listed, grounded power cord (where permitted by local code)  
when installed in accordance with existing electrical codes.  
Refer to the power cord manufacturers ratings for proper  
wire gage. Do not use gas piping as an electrical ground.  
Failure to follow this warning could result in electrical shock,  
fire, or death.  
2" Nipple  
Street Elbow  
Gas Valve  
A02327  
Fig. 21aRight Side Gas Entry Example  
15  
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Table 5Electrical Data  
OPERATING  
VOLTAGE RANGE  
VOLTS-  
HERTZ-  
PHASE  
MAXIMUM  
FUSE OR CKT BKR  
AMPS†  
MAXIMUM  
UNIT  
MAXIMUM  
MINIMUM  
WIRE GAGE  
UNIT SIZE  
UNIT AMPS AMPACITY# WIRE LENGTH (FT)‡  
Maximum* Minimum*  
045-08/024045 115-60-1  
045-12/036045 115-60-1  
070-08/024070 115-60-1  
070-12/036070 115-60-1  
070-16/048070** 115-60-1  
090-14/042090 115-60-1  
090-16/048090 115-60-1  
090-20/060090** 115-60-1  
110-12/036110 115-60-1  
110-16/048110 115-60-1  
110-22/066110 115-60-1  
135-16/048135 115-60-1  
135-22/066135 115-60-1  
155-22/060155 115-60-1  
127  
127  
127  
127  
127  
127  
127  
127  
127  
127  
127  
127  
127  
127  
104  
104  
104  
104  
104  
104  
104  
104  
104  
104  
104  
104  
104  
104  
5.6  
7.0  
7.77  
9.47  
47  
39  
52  
40  
28  
34  
28  
34  
34  
28  
32  
28  
30  
29  
15  
15  
15  
15  
15  
15  
15  
20  
15  
15  
20  
15  
20  
20  
14  
14  
14  
14  
14  
14  
14  
12  
14  
14  
12  
14  
12  
12  
5.0  
7.06  
6.7  
9.19  
9.8  
12.59  
10.83  
12.95  
17.60  
10.75  
13.12  
17.62  
13.12  
18.55  
19.33  
8.1  
9.8  
12.9  
8.2  
10.1  
13.7  
10.1  
14.4  
15.0  
* Permissible limits of the voltage range at which the unit operates satisfactorily.  
# Unit ampacity = 125 percent of largest operating components full load amps plus 100 percent of all other potential operating components(EAC, humidifier, etc.) full load  
amps.  
Time-delay type is recommended.  
Length shown is as measured 1 way along wire path between unit and service panel for maximum 2 percent voltage drop.  
** Preliminary  
Furnace control must be grounded for proper operation or  
control will lock out. Control is grounded through  
green/yellow wire routed to gas valve and manifold bracket  
screw.  
TWO  
115-V WIRING  
Verify that the voltage, frequency, and phase correspond to that  
specified on unit rating plate. Also, check to be sure that service  
provided by utility is sufficient to handle load imposed by this  
equipment. Refer to rating plate or Table 5 for equipment electrical  
specifications. Make all electrical connections in accordance with  
National Electrical Code (NEC) ANSI/NFPA 70-2002 and any  
local codes or ordinances that might apply. For Canadian instal-  
lations, all electrical connections must be made in accordance with  
Canadian Electrical Code CSA C22.1 or authorities having juris-  
diction.  
A02099  
Fig. 22Relocating J-Box  
3. Locate box to desired location.  
Do not connect aluminum wire between disconnect switch  
and furnace. Use only copper wire.  
4. Fasten J-Box to casing with screws.  
5. Route J-box wires within furnace away from sharp edges and  
Use a separate, fused branch electrical circuit with a properly sized  
hot surfaces.  
fuse or circuit breaker for this furnace. See Table 5 for wire size  
and fuse specifications. A readily accessible means of electrical  
ELECTRICAL CONNECTION TO J-BOX  
disconnect must be located within sight of the furnace.  
NOTE: Proper polarity must be maintained for 115-v wiring. If  
If manual disconnect switch is to be mounted on furnace,  
polarity is incorrect, control LED status indicator light will flash  
select a location where a drill or fastener will not contact  
rapidly and furnace will NOT operate.  
electrical or gas components.  
J-BOX RELOCATION  
1. Attach electrical box to J-Box bracket.  
NOTE: If factory location of J-Box is acceptable, go to next  
2. Route wires through hole in electrical box and J-Box bracket.  
3. Secure ground wire to green screw on J-Box bracket.  
4. Connect line voltage leads as shown in Fig. 24.  
FOR POWER CORD INSTALLATION  
section (J-Box Cover Installation).  
NOTE: On 14wide casing models, the J-Box shall not be  
relocated to other side of furnace casing when the vent pipe is  
routed within the casing.  
1. Remove screws holding auxiliary J-box. (See Fig. 22.)  
2. Cut wire tie on loop in wires to J-box.  
Power cords must be able to handle the electrical requirements  
listed in Table 5. Refer to power cord manufacturers listings.  
16  
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TWINNING AND/OR  
COMPONENT TEST  
TERMINAL  
BLOWER OFF-DELAY  
J2 JUMPER  
BLOWER OFF-DELAY  
HUMIDIFIER TERMINAL  
(24-VAC 0.5 AMP MAX.)  
24-V THERMOSTAT  
TERMINALS  
TRANSFORMER 24-VAC  
CONNECTIONS  
TEST/TWIN  
HUM  
0.5 AMP@24VAC  
3-AMP FUSE  
FUSE 3-AMP  
SEC-2 SEC-1  
LED OPERATION &  
DIAGNOSTIC LIGHT  
EAC-2  
L2  
PL1-LOW VOLTAGE MAIN  
HARNESS CONNECTOR  
115-VAC(L2)NEUTRAL  
CONNECTIONS  
COOL  
HEAT  
1-AMP@  
115VAC  
SPARE-1 SPARE-2  
PR-1  
EAC-1  
PL2  
1
SPARE-1  
SPARE-2  
PL2-HOT SURFACE  
IGNITER & INDUCER  
MOTOR CONNECTOR  
115 VAC (L1) LINE  
VOLTAGE CONNECTION  
BLOWER SPEED  
SELECTION TERMINALS  
EAC-1 TERMINAL  
(115-VAC 1.0 AMP MAX.)  
A02100  
Fig. 23Furnace Control  
1. Route listed power cord through hole in J-Box.  
maintenance could cause this fuse to blow. If fuse replacement is  
required, use ONLY a 3-amp fuse of identical size.  
2. Secure power cord to J-Box bracket with a strain relief  
bushing or a connector approved for the type of cord used.  
ACCESSORIES  
1. Electronic Air Cleaner (EAC)  
3. Secure ground wire to green screw on J-Box bracket.  
4. Connect line voltage leads as shown in Fig. 24.  
FOR BX CABLE INSTALLATION  
Connect an accessory Electronic Air Cleaner (if used) using  
1/4-in female quick connect terminals to the two male 1/4-in  
quick-connect terminals on the control board marked EAC-1  
and EAC-2. The terminals are rated for 115 VAC, 1.0 amps  
maximum and are energized during blower motor operation.  
1. Route BX cable to hole in J-Box.  
2. Secure BX cable to J-Box bracket with connectors approved  
for the type of cable used.  
2. Humidifier (HUM)  
Connect an accessory 24 VAC, 0.5 amp maximum humidifier  
(if used) to the 1/4-in male quick-connect HUM terminal and  
COM-24V screw terminal on the control board thermostat strip.  
The HUM terminal is energized when pressure switch (PRS)  
closes.  
3. Secure ground wire to green screw on J-Box bracket.  
4. Connect line voltage leads as shown in Fig. 24.  
J-BOX COVER INSTALLATION  
1. Remove J-Box cover from blower access door on furnace and  
reinstall blower access door screw.  
NOTE: A field-supplied, 115-v controlled relay connected to  
EAC terminals may be added if humidifier operation is desired  
during blower operation.  
2. Fold tab on J-box cover to bracket with pliers.  
3. Insert tab of J-box cover into slot of J-box bracket.  
4. Secure J-Box cover to bracket with screw provided.  
5. Remove U-shaped cut-out from outer door to clear J-box.  
24-V WIRING  
Make field 24-v connections at the 24-v terminal strip. (See Fig.  
23.) Connect terminal Y as shown in Fig. 24 for proper cooling  
operation. Use only AWG No. 18, color-coded, copper thermostat  
wire.  
The 24-v circuit contains an automotive-type, 3-amp fuse located  
on the control. Any direct shorts during installation, service, or  
17  
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FIELD 24-V WIRING  
FIELD 115-, 208/230-, 460-V WIRING  
FACTORY 24-V WIRING  
FACTORY 115-V WIRING  
NOTE 2  
THERMOSTAT  
TERMINALS  
W
C
R
G
Y
FIVE WIRE  
FIELD-SUPPLIED  
DISCONNECT  
THREE-WIRE  
HEATING-ONLY  
208/230- OR  
460-V  
BLOWER DOOR SWITCH  
THREE  
PHASE  
W
BLK  
BLK  
WHT  
C
R
WHT  
O
N
T
208/230-V  
SINGLE  
PHASE  
GND  
GND  
G
R
AUXILIARY  
J-BOX  
115-V FIELD-  
SUPPLIED  
DISCONNECT  
O
COM  
GND  
L
NOTE 1  
CONDENSING  
UNIT  
Y/Y2  
TWO  
WIRE  
24-V  
TERMINAL  
BLOCK  
NOTES: 1. Connect Y-terminal in furnace as shown for proper blower operation.  
2. Some thermostats require a "C" terminal connection as shown.  
3. If any of the original wire, as supplied, must be replaced, use  
same type or equivalent wire.  
FURNACE  
A99440  
Fig. 24Heating and Cooling Application Wiring Diagram with 1Stage Thermostat  
When an existing furnace is removed or replaced in a venting  
system, the venting system may not be properly sized to vent the  
attached appliances. An improperly sized Category I venting  
system could cause the formation of condensate in the furnace and  
vent, leakage of condensate and combustion products, and spillage  
of combustion products into the living space, etc.  
DO NOT connect furnace control HUM terminal to HUM  
(humidifier) terminal on Thermidistat, Zone Controller or  
similar device. See Thermidistat, Zone Controller, thermo-  
stat, or controller manufacturers instructions for proper  
connection.  
Step 8Venting  
The furnace shall be connected to a factory built chimney or vent  
complying with a recognized standard, or a masonry or concrete  
chimney lined with a lining material acceptable to the authority  
having jurisdiction. Venting into an unlined masonry chimney or  
concrete chimney is prohibited.  
18  
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The following information and warning must be considered in  
addition to the requirements defined in the NFGC and the  
NSCNGPIC.  
CARBON MONOXIDE POISONING HAZARD  
Failure to follow the steps outlined below for each appliance  
connected to the venting system being placed into operation  
could result in carbon monoxide poisoning or death.  
The following steps shall be followed for each appliance  
connected to the venting system being placed into operation,  
while all other appliances connected to the venting system are  
not in operation:  
1. Seal any unused openings in venting system.  
2. Inspect the venting system for proper size and horizontal  
pitch, as required in the National Fuel Gas Code, ANSI  
Z223.1/NFPA 54 or the CSA B149.1, Natural Gas and  
Propane Installation Codes and these instructions. Deter-  
mine that there is no blockage or restriction, leakage,  
corrosion and other deficiencies, which could cause an  
unsafe condition.  
1. If a vent (common or dedicated) becomes blocked, the furnace  
will be shut off by the draft safeguard switch located on the  
vent elbow.  
Do not bypass the draft safeguard switch, as an unsafe  
condition could exist which must be corrected. Failure to  
follow this warning could result in a build-up of carbon  
monoxide and lead to personal injury or death.  
2. Do not connect this appliance to a single-wall dedicated or  
common vent. The dedicated or common vent is considered to  
be the vertical portion of the vent system that terminates  
outdoors.  
3. Vent connectors serving Category I furnaces shall not be  
connected into any portion of a mechanical draft system  
operating under positive pressure.  
3. As far as practical, close all building doors and windows  
and all doors between the space in which the appliance(s)  
connected to the venting system are located and other  
spaces of the building.  
4. In the US, do not vent this appliance with any solid fuel  
burning appliance. In Canada, check with the authority having  
jurisdiction for approval on use with solid fuel burning  
appliance.  
4. Close fireplace dampers.  
5. Turn on clothes dryers and any appliance not connected to  
the venting system. Turn on any exhaust fans, such as  
range hoods and bathroom exhausts, so they are operating  
at maximum speed. Do not operate a summer exhaust fan.  
6. Follow the lighting instructions. Place the appliance being  
inspected into operation. Adjust the thermostat so appli-  
ance is operating continuously.  
7. Test for spillage from draft hood equipped appliances at the  
draft hood relief opening after 5 minutes of main burner  
operation. Use the flame of a match or candle.  
5. Category I furnaces must be vented vertically or nearly  
vertically unless equipped with a listed power ventor.  
6. Do not vent this appliance into an unlined masonry chimney.  
Refer to Chimney Inspection Chart, Fig. 25.  
MASONRY CHIMNEY REQUIREMENTS  
8. If improper venting is observed during any of the above  
tests, the venting system must be corrected in accordance  
with the National Fuel Gas Code, ANSI Z223.1/NFPA 54  
and/or CSA B149.1, Natural Gas and Propane Installation  
Codes.  
9. After it has been determined that each appliance connected  
to the venting system properly vents when tested as  
outlined above, return doors, windows, exhaust fans,  
fireplace dampers and any other gas-fired burning appli-  
ance to their previous conditions of use.  
These furnaces are CSA design-certified for use in exterior  
clay tile-lined masonry chimneys with a factory accessory  
Chimney Adapter Kit. Refer to the furnace rating plate for  
correct kit usage. The Chimney Adapter Kits are for use with  
ONLY furnaces having a Chimney Adapter Kit number  
marked on the furnace rating plate.  
If a clay tile-lined masonry chimney is being used and it is exposed  
to the outdoors below the roof line, relining might be required.  
Chimneys shall conform to the Standard for Chimneys, Fireplaces,  
Vents, and Soild Fuel Burning Appliances ANSI/NFPA 211-2000  
in the United States and to a Provincial or Territorial Building  
Code in Canada (in its absence, the National Building Code of  
Canada) and must be in good condition.  
Vent system or vent connectors may need to be resized. For any  
other appliances when resizing vent systems or vent connectors,  
system or connector must be sized to approach minimum size as  
determined using appropriate table found in the NFGC or NSC-  
NGPIC.  
U.S.A.-Refer to Sections 13.1.9 and 13.2.20 of the NFGC or the  
authority having jurisdiction to determine whether relining is  
required. If relining is required, use a properly sized listed metal  
liner, Type-B vent, or a listed alternative venting design.  
GENERAL VENTING REQUIREMENTS  
Follow all safety codes for proper vent sizing and installation  
requirements, including local building codes, the National Fuel  
Gas Code (NFGC) ANSI Z223.1-2002/NFPA 54-2002, Parts 7 and  
13 in the United States or the National Standard of Canada, Natural  
Gas and Propane Installation Code (NSCNGPIC) CSA-B149.1-00,  
Section 7 and Appendix C in Canada.  
These furnaces are design-certified as Category I furnaces in  
accordance with ANSI Z21.47/CSA 2.3-2001 and operate with a  
non-positive vent static pressure to minimize the potential for vent  
gas leakage. Category I furnaces operate with a flue loss not less  
than 17 percent to minimize the potential for condensation in the  
venting system. These furnaces are approved for common venting  
and multi-story venting with other fan assisted or draft hood  
equipped appliances in accordance with the NFCG or the NSC-  
NGPIC.  
19  
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NOTE: See the NFGC, 13.1.9 and 13.2.20 regarding alternative  
venting design and the exception, which cover installations such as  
Table BMinimum Allowable Input Rating of  
Space-Heating Appliance in  
the  
Chimney  
Adapter  
Kits  
KGACA02014FC  
and  
Thousands of BTU per Hour  
KGACA02015FC, which are listed for use with these furnaces.  
INTERNAL AREA OF CHIMNEY  
The Chimney Adapter Kit is listed alternative venting design for  
these furnaces. See the kit instructions for complete details.  
VENT  
HEIGHT (FT)  
(SQ. IN.)  
12  
19  
28  
38  
Local 99% Winter Design  
Temperature: 17 to 26 degrees F*  
Canada-This furnace is permitted to be vented into a clay  
tile-lined masonry chimney that is exposed to the outdoors below  
the roof line, provided:  
6
0
55  
74  
99  
141  
154  
169  
212  
258  
362  
8
52  
111  
125  
167  
212  
NR  
1. Vent connector is Type-B double-wall, and  
10  
15  
20  
30  
NR  
NR  
NR  
NR  
90  
2. This furnace is common vented with at least 1 draft hood-  
equipped appliance, and  
NR  
NR  
NR  
3. The combined appliance input rating is less than the maximum  
capacity given in Table A, and  
Local 99% Winter Design  
Temperature: 5 to 16 degrees F*  
4. The input rating of each space heating appliance is greater  
than the minimum input rating given in the appropriate Table  
B for Masonry Chimneys for the local winter design tempera-  
ture. Chimneys having internal areas greater than 38 square  
inches require furnace input ratings greater than the input  
ratings of these furnaces. See footnote at bottom of Table B,  
and  
6
NR  
NR  
NR  
NR  
NR  
NR  
78  
94  
121  
135  
149  
193  
NR  
166  
182  
198  
247  
293  
377  
8
10  
15  
20  
30  
111  
NR  
NR  
NR  
NR  
Local 99% Winter Design  
Temperature: -10 to 4 degrees F*  
5. The authority having jurisdiction approves.  
6
NR  
NR  
NR  
NR  
NR  
NR  
NR  
NR  
NR  
NR  
NR  
NR  
145  
159  
175  
NR  
NR  
NR  
196  
213  
231  
283  
333  
NR  
If all of these conditions cannot be met, an alternative venting  
design shall be used, such as the listed chimney adapter kit with  
these furnaces listed for use with the kit, a listed chimney-lining  
system, or a Type-B common vent.  
8
10  
15  
20  
30  
Exterior Masonry Chimney,  
FAN + NAT Installations with  
Type-B Double-Wall Vent Connectors  
Local 99% Winter Design  
Temperature: -11 degrees F or lower*  
Not recommended for any vent  
configuration  
Table ACombined Appliance  
Maximum Inut Rating in  
Thousands of BTU per Hour  
INTERNAL AREA OF CHIMNEY  
VENT  
HEIGHT (FT)  
(SQ. IN.)  
*The 99% Winter Design Dry-Bulb (db) temperatures are found in the 1993  
ASHRAE Fundamentals Handbook, Chapter 24, Table 1 (United States) and  
2 (Canada), or use the 99.6% heating db temperatures found in the 1997 or  
2001 ASHRAE Fundamentals Handbook, Climatic Design Information chap-  
ter, Table 1A (United States) and 2A (Canada).  
12  
74  
19  
28  
38  
6
119  
130  
138  
152  
NR  
NR  
178  
193  
207  
233  
250  
NR  
257  
279  
299  
334  
368  
404  
8
80  
10  
15  
20  
30  
84  
Inspections before the sale and at the time of installation will  
determine the acceptability of the chimney or the need for repair  
and/or (re)lining. Refer to Fig. 25 to perform a chimney inspection.  
If the inspection of a previously used tile-lined chimney:  
NR  
NR  
NR  
a. Shows signs of vent gas condensation, the chimney should  
be relined in accordance with local codes and the authority  
having jurisdiction. The chimney should be relined with a  
listed metal liner, Type-B vent, or a listed chimney adapter  
kit shall be used to reduce condensation. If a condensate  
drain is required by local code, refer to the NFGC, Section  
10.9 for additional information on condensate drains.  
b. Indicates the chimney exceeds the maximum permissible  
size in the tables, the chimney should be rebuilt or relined  
to conform to the requirements of the equipment being  
installed and the authority having jurisdiction.  
20  
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A chimney without a clay tile liner, which is otherwise in good  
condition, shall be rebuilt to conform to ANSI/NFPA 211 or be  
lined with a UL listed (ULC listed in Canada) metal liner or UL  
listed Type-B vent. Relining with a listed metal liner or Type-B  
vent is considered to be a vent-in-a-chase.  
NOTE: Vent connector length for connector sizing starts at  
furnace vent elbow. The 4 inch vent elbow is shipped for upflow  
configuration and may be rotated for other positions. Remove the  
3 screws that secure vent elbow to furnace, rotate furnace vent  
elbow to position desired, re-install screws. The factory-supplied  
vent elbow does NOT count as part of the number of vent  
connector elbows.  
If a metal liner or Type-B vent is used to line a chimney, no other  
appliance shall be vented into the annular space between the  
chimney and the metal liner.  
The vent connector can exit the door through one of 5 locations on  
the door.  
1. Attach the single wall vent connector to the furnace vent  
elbow, and fasten the vent connector to the vent elbow with at  
least two field-supplied, corrosion-resistant, sheet metal  
screws located 180° apart.  
APPLIANCE APPLICATION REQUIREMENTS  
Appliance operation has a significant impact on the performance  
of the venting system. If the appliances are sized, installed,  
adjusted, and operated properly, the venting system and/or the  
appliances should not suffer from condensation and corrosion. The  
venting system and all appliances shall be installed in accordance  
with applicable listings, standards, and codes.  
2. Vent the furnace with the appropriate connector as shown in  
Fig. 2638.  
The furnace should be sized to provide 100 percent of the design  
heating load requirement plus any margin that occurs because of  
furnace model size capacity increments. Heating load estimates  
can be made using approved methods available from Air Condi-  
tioning Contractors of America (Manual J); American Society of  
Heating, Refrigerating, and Air-Conditioning Engineers; or other  
approved engineering methods. Excessive oversizing of the fur-  
nace could cause the furnace and/or vent to fail prematurely.  
Personal injury can result form sharp metal edges, etc. Be  
careful when removing parts. Gloves and safety glasses  
should be worn when servicing equipment.  
3. Orient the door to determine the correct location of the door  
cutout to be removed.  
4. Use aviation-type tin snips to remove the correct U-shaped  
cut-out on door.  
When a metal vent or metal liner is used, the vent must be in good  
condition and be installed in accordance with the vent manufac-  
turers instructions.  
An accessory Vent Guard Kit, KGAVG0101DFG is REQUIRED  
for downflow applications for use where the vent exits through the  
lower portion of the furnace casing door. Refer to the Vent Guard  
Kit Instructions for complete details.  
To prevent condensation in the furnace and vent system, the  
following precautions must be observed:  
1. The return-air temperature must be at least 60°F db except for  
brief periods of time during warm-up from setback at no lower  
than 55°F db or during initial start-up from a standby  
condition.  
The horizontal portion of the venting system shall maintain a  
minimum of 1/4-in. upward slope per linear ft and it shall be  
rigidly supported every 5 ft or less with metal hangers or straps to  
ensure there is no movement after installation.  
2. Adjust the gas input rate per the installation instructions. Low  
gas input rate causes low vent gas temperatures, causing  
condensation and corrosion in the furnace and/or venting  
system. Derating is permitted only for altitudes above 2000 ft.  
SIDEWALL VENTING  
This furnace is not approved for direct sidewall horizontal venting  
without the use of an add-on power venter.  
3. Adjust the air temperature rise range to the midpoint or  
slightly above. Low air temperature rise can cause low vent  
gas temperature and potential for condensation problems.  
In the U.S.: Per the NFGC, any listed power venter may be used,  
when approved by the authority having jurisdiction.  
In Canada: Only power venters approved by the appliance  
manufacturer and where allowed by the authority having jurisdic-  
tion may be used for sidewall venting.  
4. Set the thermostat heat anticipator or cycle rate to reduce short  
cycling.  
Air for combustion must not be contaminated by halogen com-  
pounds which include chlorides, fluorides, bromides, and iodides.  
These compounds are found in many common home products such  
as detergent, paint, glue, aerosol spray, bleach, cleaning solvent,  
salt, and air freshener, and can cause corrosion of furnaces and  
vents. Avoid using such products in the combustion-air supply.  
Furnace use during construction of the building could cause the  
furnace to be exposed to halogen compounds, causing premature  
failure of the furnace or venting system due to corrosion.  
The only approved power venter is the Field Controls SWG-4D  
and SWG-5D sidewall power venter. Select the power venter to  
match the btuh input of the appliance being vented. Follow all  
manufacturers installation requirements for venting and termina-  
tion included with the power venter.  
START-UP, ADJUSTMENT, AND SAFETY CHECK  
Step 1General  
Vent dampers on any appliance connected to the common vent can  
cause condensation and corrosion in the venting system. Do not  
use vent dampers on appliances common vented with this furnace.  
This furnace is equipped with manual reset limit switches in  
the gas control area. The switches open and shut off power to  
the gas valve if a flame rollout or overheating condition  
occurs in the gas control area. DO NOT bypass the switches.  
Correct inadequate combustion air supply problem and reset  
the switches. Failure to follow this warning can cause fire,  
explosion, personal injury, or death.  
ADDITIONAL VENTING REQUIREMENTS  
A 4round vent elbow is supplied with the furnace. A 5 inch or 6  
inch vent connector may be required for some model furnaces. A  
field-supplied 4 inch to 5 inch or 4 inch to 6 inch sheet metal  
increaser fitting is required when 5 inch or 6 inch vent connector  
is used. See Fig. 2638 Venting Orientation for approved vent  
configurations.  
21  
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CHIMNEY INSPECTION CHART  
For additional requirements refer to the National Fuel Gas Code NFPA 54/ANSI Z223.1 and ANSI/NFPA 211  
Chimneys, Fireplaces, Vents, and Solid Fuel Burning Appliances in the U.S.A. or to the Canadian  
installation Codes CSA-B149.1 in Canada.  
Crown  
Rebuild  
crown.  
condition:  
Missing mortar  
or brick?  
Yes  
No  
Is chimney  
property lined with  
clay tile liner?  
No  
Yes  
Repair  
Is  
Reline  
No  
liner or top seal  
or reline chimney as  
necessary.  
liner and top  
seal in good  
condition?  
Repair  
Yes  
Debris  
Mortar  
or tile  
debris?  
in cleanout?  
Yes  
Yes  
Remove mortar  
and tile debris  
Mortar, tile, metal vent  
fuel oil residue?  
No  
Remove metal vent  
or liner.  
No  
Clay  
Yes  
tile misalignment,  
missing sections,  
gaps?  
Consult  
Part B of  
Not Suitable  
chimney adapter venting  
instructions for  
application  
No  
No  
suitability.  
Is chimney  
lined with properly  
sized, listed liner or  
Type-B vent?  
Line chimney with property  
sized, listed flexible metal  
liner or Type-B vent per  
NFGC or NSCNGPIC Vent  
Sizing Tables and liner or  
vent manufacturers  
Condensate  
drainage at bottom  
of chimney?  
Suitable  
Yes  
Yes  
Install chimney  
adapter per  
instructions.  
No  
Installation instructions.  
Not Suitable  
Consult  
Yes  
Chimney  
exposed to  
outdoors below  
roof line?  
Part C of  
chimney adapter venting  
instructions for  
application  
Is chimney  
to be dedicated to  
a single  
No  
Suitable  
Yes  
furnace?  
suitability  
Install chimney  
adapter per  
instructions.  
No  
Chimney is  
acceptable for use.  
A02101  
Fig. 25Chimney Inspection Chart  
22  
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6. Verify furnace restarts by raising thermostat setting above  
room temperature.  
Personal injury can result form sharp metal edges, etc. Be  
careful when removing parts. Gloves and safety glasses  
should be worn when servicing equipment.  
Step 3Adjustments  
1. Maintain 115-v wiring and ground. Improper polarity will  
result in rapid flashing LED and no furnace operation.  
2. Make thermostat wire connections at the 24-v terminal block  
on the furance control. Failure to make proper connections  
will result in improper operation. (See Fig. 24.)  
DO NOT bottom out gas valve regulator adjusting screw.  
This can result in unregulated manifold pressure and result in  
excess overfire and heat exchanger failures.  
3. Gas supply pressure to the furnace must be greater than 4.5-in.  
wc (0.16 psig) but not exceed 14-in. wc (0.5 psig).  
4. Check all manual-reset switches for continuity.  
5. Install blower compartment door. Door must be in place to  
operate furnace.  
DO NOT redrill orifices. Improper drilling (burrs, out-of-  
round holes, etc.) can cause excessive burner noise and  
misdirection of burner flames. This can result in flame  
impingement of heat exchangers, causing failures. (See Fig.  
41.)  
6. Replace outer door.  
Step 2Start-Up Procedures  
Furnace gas input rate on rating plate is for installations at altitudes  
up to 2000 ft. Furnace input rate must be within ±2 percent of  
furnace rating plate input.  
Never purge a gas line into a combustion chamber. Never use  
matches, candles, flame, or other sources of ignition for the  
purpose of checking leakage. Use a soap-and-water solution  
to check for leakage. Failure to follow this warning can cause  
fire, explosion, personal injury, or death.  
In the U.S.A., the input rating for altitudes above 2,000 ft. must be  
reduced by 4 percent for each 1,000 ft. above sea level. In Canada,  
input rating must be reduced by 10 percent for altitudes of 2,000  
ft. to 4,500 ft. above sea level.  
1. Purge gas lines after all connections have been made.  
2. Check gas lines for leaks.  
1. Determine the correct gas input rate.  
In the U.S.:  
For installations below 2000 ft., refer to the unit rating plate.  
For installations above 2000 ft., multiply the input on the  
rating plate by the de-rate multiplier in Table 6 for the correct  
input rate.  
Blower access door switch opens 115-v power to control. No  
component operation can occur unless switch is closed.  
Caution must be taken when manually closing this switch for  
service purposes. Failure to follow this warning could result  
in electrical shock, personal injury, or death.  
In Canada:  
At installation altitudes from 2000 to 4500 ft, this furnace must be  
derated 10 percent by an authorized Gas Conversion Station or  
Dealer. To determine correct input rate for altitude, see example 1  
and use 0.90 as derate multiplier factor.  
3. To Begin Component Self-Test: Disconnect the thermostat R  
lead from furnace control board. Manually close the blower  
door switch. Briefly short the TEST/TWIN terminal to the  
COM 24V terminal until LED goes out. Remove jumper from  
terminals. (See Fig. 23.)  
EXAMPLE 1:  
88,000 BTUH INPUT FURNACE INSTALLED AT 4300 FT.  
Derate  
Multiplier  
Factor  
0.90  
Furnace Input Rate  
at Installation  
Altitude  
Furnace Input Rate  
at Sea Level  
88,000  
X
X
=
=
NOTE: The furnace control allows all components, except the gas  
valve, to be run for short period of time. This feature helps  
diagnose a system problem in case of a component failure.  
Component test feature will not operate if any thermostat signal is  
present at the control.  
79,200  
2. Determine the correct orifice and manifold pressure adjust-  
ment. There are two different orifice and manifold adjustment  
tables.  
All models in all positions, except Low NOx models in  
downflow or horizontal positions, use Table 10 (22,000  
BTUH/Burner)  
Low NOx models in the downflow or horizontal positions  
must use Table 11 (21,000BTUH/Burner). See input listed on  
furnace rating plate.  
Component test sequence is as follows:  
Refer to service label attached to furnace or see Fig. 43.  
a. LED will display previous status code 4 times.  
b. Inducer motor starts and continues to run until Step f of  
component test sequence.  
a. Obtain average yearly gas heat value (at installed altitude)  
from local gas supplier.  
c. Hot surface ignitor is energized for 15 sec., then off.  
d. Blower motor operates on HEAT speed for 10 sec.  
e. Blower motor operates on COOL speed for 10 sec.  
f. Inducer motor stops.  
b. Obtain average yearly gas specific gravity from local gas  
supplier.  
c. Find installation altitude in Table 10 or 11.  
g. Reconnect R lead to furnace control board, release blower  
door switch and re-install blower door.  
d. Find closest natural gas heat value and specific gravity in  
Table 10 or 11.  
4. Operate furnace per instruction on door.  
e. Follow heat value and specific gravity lines to point of  
intersection to find orifice size and manifold pressure  
settings for proper operation.  
5. Verify furnace shut down by lowering thermostat setting  
below room temperature.  
23  
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SEE NOTES: 1,2,4,7,8,9  
SEE NOTES: 1,2,3,4,7,8,9  
SEE NOTES:1,2,3,4,5,7,8,9  
A02060  
A02058  
A02059  
Fig. 26Upflow Application-  
Fig. 27Upflow Application-  
Fig. 28Downflow  
Application-Vent Elbow Up  
then Left  
Vent Elbow Up  
Vent Elbow Right  
SEE NOTES: 1,2,4,5,7,8,9  
A02061  
SEE NOTES: 1,2,4,5,6,7,8,9  
A02062  
SEE NOTES: 1,2,3,4,7,8,9  
A02063  
Fig. 29Downflow  
Application-Vent Elbow Up  
Fig. 30Downflow  
Application-Vent Elbow Left  
then Up  
Fig. 31Downflow  
Application-Vent Elbow Up  
then Right  
See Venting Notes on page 26.  
24  
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SEE NOTES: 1,2,4,7,8,9  
A02064  
SEE NOTES: 1,2,4,5,7,8,9  
Fig. 32Horizontal Left Application-Vent Elbow Left  
A02067  
Fig. 35Horizontal Left Application-Vent Elbow Right  
SEE NOTES: 1,2,4,5,7,8,9  
A02065  
SEE NOTES: 1,2,4,5,7,8,9  
Fig. 33Horizontal Left Application-Vent Elbow Right  
then Up  
A02068  
Fig. 36Horizontal Right Application-Vent Elbow Left  
See Venting Notes on Page 26  
SEE NOTES: 1,2,4,5,7,8,9  
A02066  
Fig. 34Horizontal Left Application-Vent Elbow Up  
f. Check and verify burner orifice size in furnace. NEVER  
ASSUME ORIFICE SIZE. ALWAYS CHECK AND  
VERIFY.  
c. Connect a water column manometer or similar device to  
manifold pressure tap.  
d. Turn gas valve ON/OFF switch to ON.  
e. Set thermostat to call for heat.  
g. Replace orifice with correct size if required by Table 13 or  
14. Use only factory-supplied orifices. See EXAMPLE 2.  
f. Jumper R and W thermostat connections on furnace control  
board to start furnace.  
22,000 BTUH burner applications use Table 10  
EXAMPLE 2: (02000 ft altitude)  
Heating value = 1000 Btu/cu ft  
Specific gravity = 0.62  
Therefore: Orifice No. 43*  
g. Remove regulator seal cap and turn regulator adjusting  
screw counterclockwise (out) to decrease input rate of  
clockwise (in) to increase input rate.  
h. Install regulator seal cap.  
Manifold pressure: 3.7-in. wc  
i. Leave manometer or similar device connected and proceed  
to Step 4.  
* Furnace is shipped with No. 43 orifices. In this example  
all main burner orifices are the correct size and do not need  
to be changed to obtain proper input rate.  
NOTE: DO NOT set manifold pressure less than 3.2-in wc or  
more than 3.8-in. wc for natural gas at sea level. If manifold  
pressure is outside this range, change main burner orifices or refer  
Table 10 or 11.  
3. Adjust manifold pressure to obtain correct input rate.  
a. Turn gas valve ON/OFF switch to OFF  
NOTE: If orifice hole appears damaged or it is suspected to have  
been redrilled, check orifice hole with a numbered drill bit of  
correct size. Never redrill an orifice. A burr-free and squarely  
aligned orifice hole is essential for proper flame characteristics.  
b. Remove manifold pressure tap plug from gas valve. (See  
Fig. 40.)  
25  
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Venting Notes for Fig. 26-38  
1. For common vent, vent connector sizing and vent material: United  
States, latest edition of the National Fuel Gas Code (NFGC), ANSI  
Z223.1/NFPA 54. In Canada, latest edition of the National Standards  
of Canada, Natural Gas and Propane Installation Code (NSCNGPIC),  
CSA B149.1-00.  
2. Immediately increase to 5inch vent connector outside furnace  
casing when 5-inch vent connector required, refer to Note 1 above.  
3. Side outlet vent for upflow and downflow installations must use  
Type B vent immediately after exiting the furnace, except when  
KGAVG0101DFG is used in the downflow position.  
A02069  
SEE NOTES: 1,2,4,7,8,9  
Fig. 37Horizontal Right Application-Vent Elbow  
Right  
4. Type B vent where required, refer to Note 1 above.  
5. 4single wall (26 ga. min.) vent must be used inside furnace casing  
and when the KGAVG0101DFG Downflow Vent Guard Kit is used  
external to the furnace.  
6. Accessory Downflow Vent Guard Kit, KGAVG0101DFG required  
in downflow installations with bottom vent configuration.  
7. Chimney Adapter Kit required for exterior masonry chimney  
applications. Refer to Chimney Adapter Kit, KGACA02014FC and  
KGACA02015FC for sizing and complete application details.  
8. Secure vent connector to furnace elbow with (2) corrosion-resistant  
sheet metal screws, spaced approximately 180° apart.  
9. Secure all other single wall vent connector joints with (3) corrosion  
resistant screws spaced approximately 120° apart. Secure Type B vent  
connectors per vent connector manufacturers recommendations.  
SEE NOTES: 1,2,4,5,7,8,9  
A02070  
Fig. 38Horizontal Right Application-Vent Elbow Left  
then Up  
4. Verify natural gas input rate by clocking meter.  
NOTE: Gas valve regulator adjustment cap must be in place for  
proper input to be clocked.  
Disconnect 115-v electrical power before changing speed tap.  
Failure to follow this warning could result in personal injury.  
a. Turn off all other gas appliances and pilots.  
b. Run furnace for 3 minutes in heating operation.  
c. Adjust air temperature rise by adjusting blower speed.  
Increase blower speed to reduce temperature rise. Decrease  
blower speed to increase temperature rise.  
c. Measure time (in sec) for gas meter to complete 1 revolu-  
tion and note reading. The 2 cubic feet dial provides a more  
accurate measurement of gas flow.  
d. Turn thermostat down below room temperature and re-  
move blower access door.  
d. Refer to Table 8 for cubic ft of gas per hr.  
e. To change motor speed selection for heating, remove  
blower motor lead from control HEAT terminal (See Fig.  
39.) Select desired blower motor speed lead from one of the  
other terminals and relocate it to the HEAT terminal (See  
Table 7 for lead color identification). Reconnect original  
lead to SPARE terminal.  
e. Multiply gas rate (cu ft/hr) by heating value (Btu/cu ft) to  
obtain input.  
If clocked rate does not match required input from Step 1, increase  
manifold pressure to increase input or decrease manifold pressure  
to decrease input. Repeat steps b through e until correct input is  
achieved. Re-install regulator seal cap on gas valve.  
f. Repeat steps a through e.  
5. Set temperature rise.  
g. When correct input rate and temperature rise is achieved,  
turn gas valve ON/OFF switch to OFF.  
The furnace must operate within the temperature rise ranges  
specified on the furnace rating plate. Do not exceed tempera-  
ture rise range specified on unit rating plate. Determine the  
temperature rise as follows:  
h. Remove manometer or similar device from gas valve.  
i. Re-install manifold pressure tap plug in gas valve.  
a. Place thermometers in return and supply ducts as close to  
furnace as possible. Be sure thermometers do not see  
radiant heat from heat exchangers. Radiant heat affects  
temperature rise readings. This practice is particularly  
important with straight-run ducts.  
Failure to reinstall manifold pressure tap plug in gas valve  
will result in fire, explosion, personal injury, property damage  
or death.  
b. When thermometer readings stabilize, subtract return-air  
temperature from supply-air temperature to determine air  
temperature rise.  
j. Re-install blower access door if removed.  
k. Turn gas valve ON/OFF switch to ON.  
NOTE: Blower access door must be installed for proper tempera-  
ture rise measurement.  
NOTE: If the temperature rise is outside this range, first check:  
1.) Gas input for heating operation.  
2.) Derate for altitude if applicable.  
3.) Return and supply ducts for excessive restrictions causing static  
pressures greater than 0.50-in. wc.  
Recheck temperature rise. It must be within limits specified  
on the rating plate. Recommended operation is at the mid-  
point of rise range or slightly above  
4.) Dirty filter.  
6. Set thermostat heat anticipator.  
26  
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. E  
R E V 9 - 1 0 1 2 3 7 5 5  
L 2  
L
R A U T N E  
PRINTED CIRCIUT BOARD  
L
Y E  
N A T R  
I
H S  
E L Y /  
G R N  
R E D  
U B L  
0 1  
1 1  
8
9
3
4
1 5 2 6  
7
J 2  
L
R A U T N E  
T E O # N 8  
W B L  
PRINTED CIRCIUT BOARD  
27  
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Caution!! For the following applications, use the minimum vertical vent sections as specified below.  
For all other applications, follow exclusively the National Fuel Gas Code.  
MINIMUM  
VENT DIAMETER (IN.)*  
FURNACE ORIENTATION  
VENT ORIENTATION  
FURNACE INPUT(BTU/HR)  
MINIMUM VERTICAL VENT HEIGHT (FT)**  
154,000  
132,000  
110,000(036/-12 only)  
Vent elbow left, then up  
Fig. 30  
Downflow  
5
12  
Vent elbow right,  
then up  
154,000  
132,000  
Horizontal Left  
5
7
Fig. 33  
Vent Elbow up  
Fig. 34  
154,000  
132,000  
Horizontal Left  
Horizontal Left  
Downflow  
5
5
5
5
7
7
Vent elbow right  
Fig. 35  
154,000  
Vent elbow up then left  
Fig. 28  
110,000  
(036/-12 only)  
10  
10  
Vent elbow up, then right  
Fig. 31  
110,000  
(036/-12 only)  
Downflow  
NOTE: All vent configurations must also meet National Fuel Gas Code venting requirements NFGC.  
*4 in. inside casing or vent guard  
**Including 4 in. vent section(s)  
Table 6Altitude Derate Multipler for U.S.A.  
ALTITUDE  
(FT)  
PERCENT  
OF DERATE  
DERATE MULTIPLIER  
FACTOR*  
02000  
0
1.00  
0.90  
0.86  
0.82  
0.78  
0.74  
0.70  
0.66  
0.62  
20013000  
30014000  
40015000  
50016000  
60017000  
70018000  
80019000  
900110,000  
812  
1216  
1620  
2024  
2428  
2832  
3236  
3640  
BURNER  
ORIFICE  
* Derate multiplier factors are based on midpoint altitude for altitude range.  
ON AND OFF  
SWITCH  
A93059  
Fig. 41Orifice Hole  
Table 7Speed Selection  
GAS PRESSURE  
COLOR  
White  
Black  
SPEED  
Common  
High  
AS SHIPPED  
BLW  
REGULATOR  
ADJUSTMENT  
COOL  
Yellow†  
Blue*  
Med-High  
Med-Low  
Low  
SPARE  
SPARE  
HEAT  
Red*  
* 1/5 HP motor models: BLUE to HEAT, RED to SPARE.  
Not available on 1/5 HP motors.  
NOTE: Continuous blower is the HEAT speed.  
(1.) Remove thermostat from subbase or from wall.  
INLET  
PRESSURE  
TAP  
(2.) Connect an amp meter as shown in Fig. 42 across the  
R and W terminals or R and W wires.  
MANIFOLD  
PRESSURE TAP  
A00157  
(3.) Record amp draw across terminals when furnace is in  
heating and after blower starts.  
Fig. 40Redundant Automatic Gas Control Valve  
(4.) Set heat anticapator on thermostat per thermostat  
instructions and install on subbase or wall.  
a. Mechanical thermostatSet thermostat heat anticipator to  
match the amp draw of the electrical components in the  
R-W circuit. Accurate amp draw readings can be obtained  
at the wires normally connected to thermostat subbase  
terminals, R and W. The thermostat anticipator should  
NOT be in the circuit while measuring current.  
b. Electronic thermostat: Set cycle rate for 4 cycles per hr.  
7. Adjust blower off delay  
The blower off delay has 4 adjustable settings from 90 sec to  
180 sec. The blower off delay jumpers are located on the  
furnace control board. (See Fig. 23.)  
28  
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Table 8GAS RATE (CU FT/HR)  
SIZE OF TEST DIAL  
SIZE OF TEST DIAL  
SECONDS  
FOR 1  
REVOLUTION  
SECONDS  
FOR 1  
REVOLUTION  
THERMOSTAT SUBBASE  
TERMINALS WITH  
THERMOSTAT REMOVED  
(ANITICIPATOR, CLOCK, ETC.,  
MUST BE OUT OF CIRCUIT.)  
1
2
5
1
2
5
Cu Ft Cu Ft Cu Ft  
Cu Ft Cu Ft Cu Ft  
10  
11  
12  
13  
14  
15  
16  
17  
18  
19  
20  
21  
22  
23  
24  
25  
26  
27  
28  
29  
30  
31  
32  
33  
34  
35  
36  
37  
38  
39  
40  
41  
42  
43  
44  
45  
46  
47  
48  
49  
360  
327  
300  
277  
257  
240  
225  
212  
200  
189  
180  
171  
164  
157  
150  
144  
138  
133  
129  
124  
120  
116  
113  
109  
106  
103  
100  
97  
720  
655  
600  
555  
514  
480  
450  
424  
400  
379  
360  
343  
327  
313  
300  
288  
277  
267  
257  
248  
240  
232  
225  
218  
212  
206  
200  
195  
189  
185  
180  
176  
172  
167  
164  
160  
157  
153  
150  
147  
1800  
1636  
1500  
1385  
1286  
1200  
1125  
1059  
1000  
947  
900  
857  
818  
783  
750  
720  
692  
667  
643  
621  
600  
581  
563  
545  
529  
514  
500  
486  
474  
462  
450  
439  
429  
419  
409  
400  
391  
383  
375  
367  
50  
51  
72  
71  
69  
68  
67  
65  
64  
63  
62  
61  
60  
58  
56  
54  
53  
51  
50  
48  
47  
46  
45  
44  
43  
42  
41  
40  
39  
38  
38  
37  
36  
35  
35  
34  
33  
33  
32  
31  
30  
144  
141  
138  
136  
133  
131  
129  
126  
124  
122  
120  
116  
112  
109  
106  
103  
100  
97  
360  
355  
346  
340  
333  
327  
321  
316  
310  
305  
300  
290  
281  
273  
265  
257  
250  
243  
237  
231  
225  
220  
214  
209  
205  
200  
196  
192  
188  
184  
180  
178  
173  
170  
167  
164  
161  
155  
150  
HOOK-AROUND  
AMMETER  
52  
53  
54  
55  
R
Y
W
G
56  
57  
58  
59  
60  
62  
64  
66  
10 TURNS  
68  
70  
72  
FROM UNIT 24-V  
CONTROL TERMINALS  
74  
76  
95  
0.5 AMPS FOR THERMOSTAT  
ANTICIPATOR SETTING  
5.0 AMPS ON AMMETER  
10 TURNS AROUND JAWS  
=
EXAMPLE:  
78  
92  
80  
90  
A96316  
82  
88  
84  
86  
Fig. 42Amp Draw Check With Ammeter  
86  
84  
88  
82  
d. Burners will re-light when furnace cools down.  
90  
80  
2. Check draft safeguard switch.  
92  
78  
The purpose of this control is to permit the safe shutdown of  
the furnace during certain blocked vent conditions.  
94  
76  
95  
96  
75  
a. Verify vent pipe is cool to the touch.  
92  
98  
74  
90  
100  
102  
104  
106  
108  
110  
112  
116  
120  
72  
b. Disconnect power to furnace and remove vent connector  
from furnace vent elbow.  
88  
71  
86  
69  
c. Restore power to furnace and set room thermostat above  
room temperature.  
84  
68  
82  
67  
d. After normal start-up, allow furnace to operate for 2  
minutes, then block vent elbow in furnace 80 percent of  
vent area with a piece of flat sheet metal.  
80  
65  
78  
64  
76  
62  
75  
60  
e. Furnace should cycle off within 2 minutes.  
73  
f. Remove blockage and reconnect vent pipe to furnace vent  
elbow.  
g. Switch will auto-reset when it cools.  
To change the blower off delay setting, move the jumper from  
one set of pins on the control to the pins used for the selected  
blower off delay. Factory off delay setting is 120 sec.  
h. If control board locks out furnace, cycle 115 vac power to  
reset control.  
3. Check Pressure Switch(es)  
Step 4Check Safety Controls  
This control proves operation of the draft inducer blower.  
The flame sensor, gas valve, and pressure switch were all checked  
in the Start-up procedure section as part of normal operation.  
a. Turn off 115-v power to furnace.  
b. Disconnect inducer motor lead wires from wire harness.  
c. Turn on 115-v power to furnace.  
1. Check Main Limit Switches  
This control shuts off combustion control system and ener-  
gizes air-circulating blower motor, if furnace overheats. By  
using this method to check limit control, it can be established  
that limit is functioning properly and will operate if there is a  
restricted duct system or motor failure. If limit control does  
not function during this test, cause must be determined and  
corrected.  
d. Set thermostat to call for heatand wait 1 minute. When  
pressure switch is functioning properly, hot surface igniter  
should NOT glow and control diagnostic light flashes a  
status code 32. If hot surface igniter glows when inducer  
motor is disconnected, shut down furnace immediately.  
e. Determine reason pressure switch did not function properly  
and correct condition.  
a. Run furnace for at least 5 minutes.  
b. Gradually block off return air with a piece of cardboard or  
sheet metal until the limit trips.  
f. Turn off 115-v power to furnace.  
g. Reconnect inducer motor wires, replace outer door, and  
turn on 115-v power.  
c. Unblock return air to permit normal circulation.  
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Step 5Checklist  
The control system also requires an earth ground for proper  
operation of the control and flame-sensing electrode.  
1. Put away tools and instruments. Clean up debris.  
2. Check that blower OFF-DELAY time is selected as desired.  
The 24-v circuit contains an automotive-type, 3-amp fuse located  
on the control. (See Fig. 23.) Any shorts of the 24-v wiring during  
installation, service, or maintenance will cause this fuse to blow. If  
fuse replacement is required, use ONLY a 3-amp fuse. The control  
LED will display status code 24 when fuse needs to be replaced.  
3. Verify that blower and burner access doors are properly  
installed.  
4. Cycle test furnace with room thermostat.  
5. Check operation of accessories per manufacturers instruc-  
Proper instrumentation is required to service electrical controls.  
The control in this furnace is equipped with a Status Code LED  
(Light-Emitting Diode) to aid in installation, servicing, and  
troubleshooting. It can be viewed through the sight glass in blower  
access door. The furnace control LED is either ON continuously,  
rapid flashing, or a code composed of 2 digits. The first digit is the  
number of short flashes, the second digit is the number of long  
flashes.  
tions.  
6. Review Users Guide with owner.  
7. Leave literature packet near furnace.  
SERVICE AND MAINTENANCE PROCEDURES  
For an explanation of status codes, refer to service label located on  
blower access door or Fig. 43, and the troubleshooting guide at the  
end of this procedure. The furnace control will store 1 status code  
for 72 hours.  
The ability to properly perform maintenance on this equip-  
ment requires certain knowledge, mechanical skills, tools, and  
equipment. If you do not possess these, do not attempt to  
perform any maintenance on this equipment other than those  
procedures recommended in the Users Manual. FAILURE  
TO FOLLOW THIS WARNING COULD RESULT IN  
POSSIBLE DAMAGE TO THIS EQUIPMENT, SERIOUS  
PERSONAL INJURY, OR DEATH.  
For Controls With a Red LED  
The stored status codes WILL be erased from the control memory,  
if 115- or 24-v power is interrupted.  
1. To retrieve status code, proceed with the following:  
NOTE: NO thermostat signal may be present at control, and all  
blower-OFF delays must be completed.  
a. Leave 115-v power to furnace turned on.  
b. Remove outer access door.  
ELECTRICAL SHOCK, FIRE, OR EXPLOSION HAZARD  
Failure to follow safety warnings exactly could result in  
dangerous operation, serious injury, death, or property dam-  
age.  
Improper servicing could result in dangerous operation,  
serious injury, death, or property damage.  
- Before servicing, disconnect all electrical power to furnace.  
- When servicing controls, label all wires prior to disconnect-  
ing. Reconnect wires correctly.  
c. Look into blower access door sight glass for current LED  
status. DO NOT remove blower access door or terminate  
115-v power to control or status code will be lost.  
d. BRIEFLY remove insulated terminal wire from the draft  
safeguard switch (DSS) until LED goes out (1 to 2 sec),  
then reconnect it.  
2. When above items have been completed, the LED flashes  
status code 4 times. Record this status code for further  
troubleshooting.  
- Verify proper operation after servicing.  
3. Component self-test will begin. Refer to COMPONENT  
TEST section for complete test sequence.  
Label all wires prior to disconnection when servicing con-  
trols. Wiring errors can cause improper and dangerous  
operation.  
4. Check LED status.  
5. Refer to the SERVICE label on the front of the blower access  
door for more information.  
Step 1Introduction  
Component Self-Test  
GENERAL  
Component Test can also be initiated by performing the following:  
1. Remove outer access door.  
These instructions are written as if the furnace is installed in an  
upflow application. An upflow furnace application is where the  
blower is located below the combustion and controls section of the  
furnace, and conditioned air is discharged upward. Since this  
furnace can be installed in any of the 4 positions shown in Fig. 4,  
you must revise your orientation to component location accord-  
ingly.  
2. Remove blower access door.  
3. Remove the wire from the Rterminal of the control board.  
4. Manually close blower access door switch.  
ELECTRICAL CONTROLS AND WIRING  
Blower access door switch opens 115-v power to control. No  
component operation can occur unless switch is closed.  
Caution must be taken when manually closing this switch for  
service purposes. Failure to follow this warning could result  
in electrical shock, personal injury, or death.  
There may be more than 1 electrical supply to the unit. Check  
accessories and cooling unit for additional electrical supplies  
The electrical ground and polarity for 115-v wiring must be  
properly maintained. Refer to Fig. 24 for field wiring information  
and to Fig. 39 for furnace wiring information.  
5. BRIEFLY short (jumper) TEST/TWIN, 3/16-in. quick-  
connect male terminal on control (behind Y terminal) to the  
COM-24V terminal on furnace control. (See Fig. 23.)  
NOTE: If the polarity is not correct, the STATUS LED on the  
control will flash rapidly and prevent the furnace from heating.  
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SERVICE  
If status code recall is needed, briefly remove then reconnect one main limit wire to display stored status code. On RED LED boards do not remove power or blower door before initiating status code recall. After  
status code recall is completed component test will occur.  
LED CODE  
STATUS  
CONTINUOUS OFF - Check for 115VAC at L1 and L2, and 24VAC at SEC-1 and SEC-2.  
CONTINUOUS ON - Control has 24VAC power.  
RAPID FLASHING - Line voltage (115VAC) polarity reversed. If twinned, refer to twinning kit instructions.  
EACH OF THE FOLLOWING STATUS CODES IS A TWO DIGIT NUMBER WITH THE FIRST DIGIT DETERMINED BY THE NUMBER OF SHORT FLASHES AND THE SECOND DIGIT BY THE NUMBER OF LONG FLASHES.  
11 NO PREVIOUS CODE - Stored status code is erased automatically after 72 hours. On  
RED LED boards stored status codes can also be erased when power  
(115 VAC or 24 VAC) to control is interrupted.  
12 BLOWER ON AFTER POWER UP (115 VAC or 24 VAC) -Blower runs for 90 seconds,  
if unit is powered up during a call for heat (R-W closed) or R-W opens during blower  
on-delay.  
13 LIMIT CIRCUIT LOCKOUT - Lockout occurs if the limit, draft safeguard, flame rollout, or  
blocked vent switch (if used) is open longer than 3 minutes or 10 successive limit trips  
31 PRESSURE SWITCH DID NOT CLOSE OR REOPENED - If open longer than five minutes,  
inducer shuts off for 15 minutes before retry. Check for: - Excessive wind  
- Proper vent sizing  
- Defective inducer motor  
- Low inducer voltage (115VAC)  
- Inadequate combustion air supply  
- Low inlet gas pressure (if LGPS used)  
- Defective pressure switch  
- Disconnected or obstructed pressure tubing  
- Restricted vent  
If it opens during blower on-delay period, blower will come on for the selected blower  
off-delay.  
occurred during high-heat. - Control will auto reset after three hours.  
- Refer to #33.  
33 LIMIT CIRCUIT FAULT - Indicates the limit, draft safeguard, flame rollout, or blocked vent  
switch (if used) is open or the furnace is operating in high-heat only mode due to 2  
successive low heat limit trips. Blower will run for 4 minutes or until open switch remakes  
whichever is longer. If open longer than 3 minutes, code changes to lockout #13.  
If open less than 3 minutes status code #33 continues to flash until blower shuts off.  
14 IGNITION LOCKOUT - Control will auto-reset after three hours. Refer to #34.  
21 GAS HEATING LOCKOUT - Control will NOT auto reset.  
Check for: - Mis-wired gas valve  
-Defective control (valve relay)  
22 ABNORMAL FLAME-PROVING SIGNAL - Flame is proved while gas valve is de-  
energized. Inducer will run until fault is cleared. Check for: - Leaky gas valve  
- Stuck-open gas valve  
Flame rollout switch and BVSS require manual reset. Check for:  
- Proper vent sizing - Loose blower wheel.  
- Dirty filter or restricted duct system.  
- Restricted vent  
- Excessive wind  
23 PRESSURE SWITCH DID NOT OPEN Check for:  
- Obstructed pressure tubing.  
- Pressure switch stuck closed.  
- Defective blower motor or capacitor. - Defective switch or connections.  
- Inadequate combustion air supply (Flame Roll-out Switch open).  
24 SECONDARY VOLTAGE FUSE IS OPEN Check for:  
- Short circuit in secondary voltage (24VAC) wiring.  
34 IGNITION PROVING FAILURE - Control will try three more times before lockout #14  
occurs. If flame signal lost during blower on-delay period, blower will come on for the  
selected blower off-delay. Check for: - Flame sensor must not be grounded  
- Oxide buildup on flame sensor (clean with fine steel wool).  
COMPONENT TEST  
To initiate the component test sequence, shut OFF the room thermostat or disconnect the "R"  
thermostat lead. Briefly short the TEST/TWIN terminal to the "Com 24V" terminal. Status LED  
will flash code and then turn ON the inducer motor. The inducer motor will run for the entire  
component test. The hot surface ignitor, blower motor fan speed (on AMBER LED boards  
only) blower motor-heat speed, and blower motor-cool speed will be turned ON for 10-15  
seconds each. Gas Valve and Humidifier will not be turned on.  
- Proper flame sense microamps (.5 microamps D.C. min., 4.0 - 6.0 nominal).  
- Gas valve defective or gas valve turned off  
- Manual valve shut-off  
- Defective Hot Surface Ignitor  
- Low inlet gas pressure  
- Control ground continuity  
- Inadequate flame carryover or rough ignition  
- Green/Yellow wire MUST be connected to furnace sheet metal  
45 CONTROL CIRCUITRY LOCKOUT Auto-reset after one hour lockout due to;  
- Gas valve relay stuck open  
- Flame sense circuit failure  
- Software check error  
Reset power to clear lockout. Replace control if status code repeats.  
327596-101 REV. A  
A02027  
Fig. 43Service Label  
NOTE: If TEST/TWIN to COM-24V terminals are jumpered  
longer than 2 sec, LED will flash rapidly, and test request will be  
ignored.  
Never store anything on, near, or in contact with the furnace,  
such as:  
1. Spray or aerosol cans, rags, brooms, dust mops, vacuum  
cleaners, or other cleaning tools.  
2. Soap powders, bleaches, waxes or other cleaning com-  
pounds, plastic or plastic containers, gasoline, kerosene,  
cigarette lighter fluid, dry cleaning fluids, or other volatile  
fluids.  
3. Paint thinners and other painting compounds, paper bags,  
or other paper products.  
6. Component Test will function as follows:  
a. LED flashes a status code 4 times. Record this status code  
for further troubleshooting.  
b. Inducer motor starts and continues to run until step f of  
component test sequence.  
c. Hot surface igniter is energized for 15 sec, then de-  
energized.  
d. Blower operates at HEAT speed for 10 sec, then turns off.  
e. Blower operates at COOL speed for 10 sec, then turns off.  
f. Inducer motor turns off.  
A failure to follow this warning could result in corrosion of  
the heat exchanger, fire, personal injury, or death.  
Items a through f above will assist in furnace troubleshooting since  
all components are functionally operated except the gas valve. This  
procedure is also referred to as Component Test Sequence.″  
7. Check LED status. If no previous fault is in history, control  
will flash status code 11.  
Turn off the gas and electrical supplies to the unit before  
performing any maintenance or service. Follow the operating  
instructions on the label attached to the furnace. A failure to  
follow this warning could result in personal injury.  
8. If LED status indicates proper operation, RELEASE  
BLOWER ACCESS DOOR SWITCH, reattach wire to R″  
terminal on furnace control board, replace blower access door,  
and replace burner access door.  
Never operate unit without a filter or with filter access door  
removed. A failure to follow this warning could result in fire,  
personal injury, or death.  
Step 2Care and Maintenance  
For continuing high performance and to minimize possible equip-  
ment failure, periodic maintenance must be performed on this  
equipment. Consult your local dealer about proper frequency of  
maintenance and the availability of a maintenance contract.  
Personal injury can result from sharp metal edges, etc. Be  
careful when removing parts. Gloves and safety glasses  
should be worn when servicing equipment  
The minimum maintenance on this equipment is as follows:  
1. Check and clean air filter each month or more frequently if  
required. Replace if torn.  
2. Check blower motor and wheel for cleanliness each heating  
and cooling season. Clean as necessary.  
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3. Check electrical connections for tightness and controls for  
proper operation each heating season. Service as necessary.  
BLOWER MOTOR AND WHEEL  
4. Inspect burner compartment before each heating season for  
rust, corrosion, soot or excessive dust. If necessary, have  
furnace and burner serviced by a qualified professional.  
Blower access door switch opens 115-v power to control. No  
component operation can occur unless switch is closed.  
Caution must be taken when manually closing this switch for  
service purposes. Failure to follow this warning could result  
in personal injury or death.  
5. Inspect the vent pipe/vent system before each heating season  
for rust, corrosion, water leakage, sagging pipes or broken  
fittings. Have vent pipes/vent system serviced by a qualified  
professional.  
6. Inspect any accessories attached to the furnace such as a  
humidifier or electronic air cleaner. Perform any service or  
maintenance to the accessories as recommended in the acces-  
sory instructions.  
The blower wheel should not be dropped or bent as balance  
will be affected.  
The following steps should be performed by a qualified service  
technician.  
CLEANING AND/OR REPLACING AIR FILTER  
The air filter arrangement may vary depending on the application.  
The filter is exterior to the furnace casing.  
To ensure long life and high efficiency, clean accumulated dirt and  
grease from blower wheel and motor annually.  
NOTE: If the filter has an airflow direction arrow, the arrow must  
The inducer and blower motors are pre-lubricated and require no  
additional lubrication. These motors can be identified by the  
absence of oil ports on each end of the motor.  
point towards the blower.  
Clean blower motor and wheel as follows:  
1. Turn off electrical supply to furnace.  
Personal injury can result from sharp metal edges, etc. Be  
careful when removing parts. Gloves and safety glasses  
should be worn when servicing equipment  
2. Unscrew the thumbscrew on outer door and remove outer  
door.  
Media cabinet filter procedures:  
3. For downflow or horizontal furnaces having vent pipes within  
the furnace that pass in from of the blower access door:  
NOTE: Media cabinet or 1Filter Rack are accessories and are  
not included from the factory with the standard furnace model.  
a. Disconnect vent connector from furnace vent elbow.  
1. Turn off electrical supply to furnace before removing filter  
access door.  
b. Disconnect and remove short piece of vent pipe from  
within furnace.  
2. Remove filter cabinet door.  
3. Slide filter out of cabinet.  
4. Remove 2 screws from blower access door and remove blower  
access door.  
4. If equipped with permanent, washable 1filter, clean filter by  
spraying cold tap water through filter in opposite direction of  
airflow. Rinse filter and let dry. Oiling or coating of the filter  
is not recommended. See Table 9 for size information.  
5. Disconnect blower leads from furnace control. Note wire color  
and location for reassembly. All other factory wires can be left  
connected, but field thermostat connections may need to be  
disconnected depending on their length and routing.  
5. If equipped with factory-specified disposable media filter,  
replace only with media filter having the same part number  
and size. For expandable replacement media, refer to the  
instructions included with the replacement media. If equipped  
with KGAFR0301ALL external filter rack, See Table 9.  
6. Remove 2 screws from control box to blower shelf.  
7. Hang control box from front of furnace casing and away from  
blower compartment.  
8. Remove 2 screws holding blower assembly to blower deck  
and slide blower assembly out of furnace.  
6. Slide filter into cabinet.  
9. Clean blower wheel and motor using a vacuum with soft brush  
attachment. Blower wheel blades may be cleaned with a small  
paint or flux brush. Do not remove or disturb balance weights  
(clips) on blower wheel blades.  
7. Replace filter cabinet door.  
8. Turn on electrical supply to furnace.  
10. Vacuum any loose dust from blower housing, wheel and  
motor.  
11. If a greasy residue is present on blower wheel, remove wheel  
from the blower housing and wash it with an appropriate  
degreaser. To remove wheel:  
Table 9FILTER SIZE INFORMATION (IN.)  
FILTER QUANTITY AND SIZE  
Side Return Bottom Return  
FURNACE  
CASING WIDTH  
FILTER  
TYPE  
NOTE: Before disassembly, mark blower motor, and blower  
housing so motor and each arm is positioned at the same location  
during reassembly.  
14-1/2  
17-1/2  
(1) 16 X 25 X 1 (1) 14 X 25 X 1 Cleanable*  
(1) 16 X 25 X 1 (1) 16 X 25 X 1 Cleanable*  
(1) 16 X 25 X 1 (1) 20 X 25 X 1 Cleanable*  
(1) 16 X 25 X 1 (1) 24 X 25 X 1 Cleanable*  
21  
a. Disconnect capacitor wires and ground wire attached to  
blower housing.  
24**  
* Recommended  
** Some furnaces may have 2 filters  
b. Remove screws securing cutoff plate and remove cutoff  
plate from housing.  
c. Loosen set screw holding blower wheel on motor shaft.  
d. Remove bolts holding motor to blower housing and slide  
motor out of wheel.  
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e. Remove blower wheel from housing.  
f. Clean wheel and housing.  
CLEANING HEAT EXCHANGER  
The following steps should be performed by a qualified service  
technician:  
12. Reassemble motor and blower by reversing steps 11f, finish-  
ing with 11a. Be sure to reattach ground wire to the blower  
housing.  
NOTE: If the heat exchangers get a heavy accumulation of soot  
and carbon, they should be replaced rather than trying to clean  
them thoroughly. A build-up of soot and carbon indicates that a  
problem exists which needs to be corrected, such as improper  
adjustment of manifold pressure, insufficient or poor quality  
combustion air, incorrect size or damaged manifold orifice(s),  
improper gas, or a restricted heat exchanger. Action must be taken  
to correct the problem.  
13. Verify that blower wheel is centered in blower housing and set  
screw contacts the flat portion of the motor shaft. Loosen set  
screw on blower wheel and reposition if necessary.  
14. Spin the blower wheel by hand to verify that the wheel does  
not rub on the housing.  
15. Reinstall blower assembly in furnace.  
If it becomes necessary to clean the heat exchangers because of  
dust or corrosion, proceed as follows:  
16. Reinstall control box assembly in furnace.  
1. Turn OFF gas and electrical power to furnace.  
2. Remove outer access door.  
Heating fan speed(s) MUST be adjusted to provide proper air  
temperature rise as specified on the rating plate. Failure to  
adjust the heating speed(s) may shorten heat exchanger life.  
Recommended operation is at the midpoint of the rise range  
or slightly above. Refer to SET TEMPERATURE RISE″  
under START-UP, ADJUSTMENT, and SAFETY CHECK.  
3. Disconnect vent connector from furnace vent elbow.  
4. For downflow or horizontal furnace having an internal vent  
pipe, remove internal vent pipe within the casing.  
5. Disconnect wires to the following components. Mark wires to  
aid in reconnection of:  
a. Draft safeguard switch.  
b. Inducer motor.  
NOTE: Refer to Table 7 for motor speed lead relocation if leads  
were not identified before disconnection.  
c. Pressure switch(es).  
17. Reconnect blower leads to furnace control. Refer to furnace  
wiring diagram, and connect thermostat leads if previously  
disconnected. (See Fig. 39.)  
d. Limit overtemperature switch.  
e. Gas valve.  
18. To check blower for proper rotation:  
a. Turn on electrical supply.  
f. Hot surface igniter.  
g. Flame-sensing electrode  
h. Flame rollout switches.  
i. Remove NOx baffles on low NOx models.  
Blower access door switch opens 115-v power to furnace  
control. No component operation can occur. Caution must be  
taken when manually closing this switch for service purposes.  
Failure to follow this warning could result in electrical shock,  
personal injury, or death.  
6. Remove screws that fasten the collector box assembly to the  
cell panel. Be careful not to damage the collector box. Inducer  
assembly and elbow need not be removed from collector box.  
7. Disconnect gas line from gas manifold.  
8. Remove the 4 screws that attach the burner assembly to the  
cell panel. The gas valve and individual burners need not be  
removed from support assembly.  
b. Manually close blower access door switch.  
NOTE: If thermostat terminals are jumpered at the time blower  
access door switch is closed, blower will run for 90 sec before  
beginning a heating or cooling cycle.  
NOTE: Be very careful when removing burner assembly to avoid  
breaking igniter. See Fig. 44 and 45 for correct igniter location.  
c. Perform component self-test as shown at the bottom of the  
SERVICE label, located on the front of blower access door.  
9/32  
d. Verify blower is rotating in the correct direction.  
19. If furnace is operating properly, RELEASE BLOWER AC-  
CESS DOOR SWITCH. Replace blower access door and  
remove any jumpers or reconnect any disconnected thermostat  
leads.  
11/32”  
20. Downflow or horizontal furnaces with vent pipe through  
furnace only:  
a. Install and connect short piece of vent pipe inside furnace  
to existing vent.  
b. Connect vent connector to vent elbow.  
21. Reinstall casing door.  
22. Turn on gas supply and cycle furnace through one complete  
heating and cooling cycle. Verify the unit temperature rise as  
shown in Adjustments Section. Adjust temperature rise as  
shown in Adjustments Section. If outdoor temperature is  
below 70° F, turn off circuit breaker to outdoor unit before  
running furnace in the cooling cycle. Turn outdoor circuit  
breaker on after completing cooling cycle.  
A02150  
Fig. 44Position of Igniter to Burner  
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7/8”  
A02151  
A91252  
Fig. 45Position of Igniter to Burner  
Fig. 46Cleaning Heat Exchanger Cell  
9. Using field-provided 25-caliber rifle cleaning brush, 1/4″  
diameter steel spring cable, 36 in. long, a variable speed,  
reversible electric drill, and vacuum cleaner, clean cells as  
follows:  
13. Reconnect wires to the following components (Use connection  
diagram on wiring label, if wires were not marked for  
reconnection locations.):  
a. Remove metal screw fitting from wire brush to allow  
insertion into cable.  
a. Draft safeguard switch.  
b. Inducer motor.  
b. Insert the twisted wire end of brush into end of spring  
cable, and crimp tight with crimping tool or crimp by  
striking with ball-peen hammer. TIGHTNESS IS VERY  
IMPORTANT.  
c. Pressure switch(es).  
d. Limit overtemperature switch.  
e. Gas valve.  
NOTE: The materials needed in item 9 can usually be purchased  
at local hardware stores.  
f. Hot surface igniter.  
g. Flame-sensing electrode.  
h. Flame rollout switches.  
i. Install NOx baffles (if removed).  
14. Reinstall internal vent pipe, if applicable.  
(1.) Attach variable-speed, reversible drill to the end of  
spring cable (end opposite brush).  
(2.) Insert brush end of cable into the outlet opening of cell  
and slowly rotate with drill. DO NOT force cable.  
Gradually insert cable into upper pass of cell. (See Fig.  
46.)  
15. Reinstall vent connector on furnace vent elbow. Securely  
fasten vent connector to vent elbow with 2 field-supplied,  
corrosion-resistant, sheet metal screws located 180° apart.  
(3.) Work cable in and out of cell 3 or 4 times to obtain  
sufficient cleaning. DO NOT pull cable with great  
force. Reverse drill and gradually work cable out.  
16. Replace blower access door only.  
17. Set thermostat above room temperature and check furnace for  
proper operation.  
(4.) Insert brush end of cable in burner inlet opening of  
cell, and proceed to clean 2 lower passes of cell in  
same manner as upper pass.  
18. Verify blower airflow and speed changes between heating and  
cooling.  
(5.) Repeat foregoing procedures until each cell in furnace  
has been cleaned.  
19. Check for gas leaks.  
(6.) Using vacuum cleaner, remove residue from each cell.  
Never use a match or other open flame to check for gas leaks.  
Use a soap-and-water solution. A failure to follow this  
warning could result in fire, personal injury, or death.  
(7.) Using vacuum cleaner with soft brush attachment,  
clean burner assembly.  
(8.) Clean flame sensor with fine steel wool.  
20. Replace outer access door.  
(9.) Reinstall burner assembly. Center burners in cell  
openings.  
Step 3Sequence of Operation  
10. Remove old sealant from cell panel and inducer backing plate  
flange.  
NOTE: Furnace control must be grounded for proper operation or  
control will lock out. Control is grounded through green/yellow  
wire routed to gas valve and manifold bracket screw.  
11. Spray releasing agent on the heat exchanger cell panel where  
collector box assembly contacts cell panel.  
Using the schematic diagram in Fig. 39, follow the sequence of  
operation through the different modes. Read and follow the wiring  
diagram very carefully.  
NOTE: A releasing agent such as cooking spray or equivalent  
(must not contain corn or canola oil, aromatic or halogenated  
hydrocarbons or inadequate seal may occur) and RTV sealant  
(G.E. 162, 6702, or Dow-Corning 738) are needed before starting  
installation. DO NOT substitute any other type of RTV sealant.  
G.E. 162 (P771-9003) is available through RCD in 3-oz tubes.  
NOTE: If a power interruption occurs during a call for heat (W),  
the control will start a 90-second blower-only ON period two  
seconds after power is restored, if the thermostat is still calling for  
gas heating. The red LED light will flash code 12 during the  
90-second period, after which the LED will be ON continuous, as  
long as no faults are detected. After the 90-second period, the  
furnace will respond to the thermostat normally.  
12. Apply new sealant to flange of inducer assembly and attach to  
cell panel using existing screws, making sure all screws are  
secure.  
34  
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The blower door must be installed for power to be conducted  
through the blower door interlock switch ILK to the furnace  
control CPU, transformer TRAN, inducer motor IDM, blower  
motor BLWM, hot-surface igniter HSI, and gas valve GV.  
circuit starts the outdoor unit, and the R-to-G and Y circuits  
start the furnace blower motor BLWM on COOL speed.  
The electronic air cleaner terminal EAC-1 is energized with  
115 vac when the blower motor BLWM is operating.  
When the thermostat is satisfied, the R-to-G-and-Y circuits are  
opened. The outdoor unit will stop, and the furnace blower  
motor BLWM will continue operating on the COOL speed for  
an additional 90 seconds. Cut jumper J2 to reduce the cooling  
off-delay to 5 seconds. (See Fig. 23.)  
1. Heating  
(See Fig. 24 for thermostat connections.)  
The wall thermostat calls for heat, closing the R to W  
circuit. The furnace control performs a self-check, verifies the  
pressure switch contacts PRS is open, and starts the inducer  
motor IDM.  
3. Continuous Blower Mode  
When the R-to-G circuit is closed by the thermostat, the  
blower motor BLWM will operate on continuous-blower  
speed (same as HEAT speed). Terminal EAC-1 is energized as  
long as the blower motor BLWM is energized.  
During a call for heat, the blower BLWM will stop during  
igniter warm-up (17 seconds), ignition, and blower-ON delay  
(25 seconds), allowing the furnace heat exchangers to heat up  
more quickly, then restarts at the end of the blower-ON delay  
period at HEAT speed.  
a. Inducer Prepurge Period- As the inducer motor IDM  
comes up to speed, the pressure switch contacts PRS close,  
24 vac power is supplied for a field installed humidifier at  
the HUM terminal and the control begins a 15-second  
prepurge period.  
b. Igniter Warm-Up- At the end of the prepurge period, the  
Hot-Surface Igniter HSI is energized for a 17-second  
igniter warm-up period.  
c. Trial-for-Ignition Sequence- When the igniter warm-up  
period is completed the main gas valve relay contacts GVR  
close to energize the gas valve GV, the gas valve opens.  
The gas valve GV permits gas flow to the burners where it  
is ignited. After 5 seconds, the igniter HSI is de-energized  
and a 2-second Flame-Proving period begins.  
When the thermostat calls for cooling, the blower motor  
BLWM will operate at COOL speed. When the thermostat is  
satisfied, the blower motor BLWM will operate an additional  
90 seconds on COOL speed before reverting back to  
continuous-blower speed.  
When the R-to-G circuit is opened, the blower motor BLWM  
will continue operating for an additional 5 seconds, if no other  
function requires blower motor BLWM operation.  
d. Flame-Proving- When the burner flame is proved at the  
flame-proving sensor electrode FSE, the furnace control  
CPU begins the blower-ON delay period and continues to  
hold the gas valve GV open. If the burner flame is not  
proved within two seconds, the control CPU will close the  
gas valve GV, and the control CPU will repeat the ignition  
sequence for up to three more Trials-For-Ignition before  
going to Ignition-Lockout. Lockout will be reset auto-  
matically after three hours, by momentarily interrupting  
115 vac power to the furnace, or by interrupting 24 vac  
power at SEC1 or SEC2 to the furnace control CPU (not at  
W, G, R, etc.)  
4. Heat Pump  
When installed with a heat pump, the furnace control auto-  
matically changes the timing sequence to avoid long blower  
off times during demand defrost cycles. When the R-to-W-  
and-Y or R-to-W-and-Y-and-G circuits are energized the  
furnace control CPU will continue to turn on the blower motor  
BLWM at HEAT speed, and begin a heating cycle. The  
blower motor BLWM will remain on until the end of the  
prepurge period, then shut off for 24 seconds then come back  
on at HEAT speed. When the W input signal disappears, the  
furnace control begins a normal inducer post-purge period and  
the blower switches to COOL speed after a 3 second delay. If  
the R-to-W-and-Y-and-G signals disappear at the same time,  
the blower motor BLWM will remain on for the selected  
blower-OFF delay period. If the R-to-W-and-Y signals disap-  
pear, leaving the G signal, the blower motor BLWM will  
continue running the blower motor BLWM at HEAT speed  
after the selected blower-OFF delay period is completed.  
If flame is proved when flame should not be present, the  
furnace control CPU will lock out of Gas-Heating mode  
and operate the inducer motor IDM until flame is no longer  
proved.  
e. Blower-On Delay- If the burner flame is proven, the  
blower motor is energized on HEAT speed 25 seconds after  
the gas valve GV is energized.  
Simultaneously, the electronic air cleaner terminal EAC-1  
is energized and remains energized as long as the blower  
motor BLWM is energized.  
Step 4Wiring Diagrams  
f. Blower-Off Delay- When the thermostat is satisfied, the  
R-to-W circuit is opened, de-energizing the gas valve GV,  
stopping gas flow to the burners, and de-energizing the  
humidifier terminal HUM. The inducer motor IDM will  
remain energized for a 5-second post-purge period. The  
blower motor BLWM and air cleaner terminal EAC-1 will  
remain energized for 90, 120, 150, or 180 seconds (depend-  
ing on the blower-OFF delay selection). The furnace  
control CPU is factory-set for a 120-second blower-OFF  
delay.  
Refer to Fig. 24 and 39 for wiring diagrams.  
Step 5Troubleshooting  
Refer to the service label. (See Fig. 43Service Label.)  
The Troubleshooting Guide can be a useful tool in isolating  
furnace operation problems. Beginning with the word Start,”  
answer each question and follow the appropriate arrow to the next  
item.  
The Guide will help to identify the problem or failed component.  
After replacing any component, verify correct operation sequence.  
2. Cooling Mode  
(See Fig. 24 for thermostat connections)  
The thermostat closes the R-to-G-and-Y circuits. The R-to-Y  
35  
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TABLE 10Orifice Size* and Manifold Pressure For Gas Input Rate  
(Tabulated Data Based On 22,000 Btuh Per Burner, Derated 4 Percent For Each 1000 Ft Above Sea Level)  
SPECIFIC GRAVITY OF NATURAL GAS  
ALTITUDE  
RANGE  
(FT)  
AVG GAS  
HEAT VALUE  
(BTU/CU FT)  
0.58  
Manifold  
0.60  
0.62  
0.64  
Manifold  
Orifice  
No.  
Orifice  
No.  
Manifold  
Pressure  
Orifice  
No.  
Manifold  
Pressure  
Orifice  
No.  
Pressure  
Pressure  
900  
925  
42  
42  
43  
43  
43  
43  
44  
44  
44  
3.5  
3.3  
3.8  
3.6  
3.5  
3.3  
3.6  
3.4  
3.3  
42  
42  
42  
43  
43  
43  
43  
44  
44  
3.6  
3.4  
3.3  
3.8  
3.6  
3.4  
3.2  
3.5  
3.4  
42  
42  
42  
42  
43  
43  
43  
43  
44  
3.7  
3.5  
3.4  
3.2  
3.7  
3.5  
3.4  
3.2  
3.5  
41  
42  
42  
42  
43  
43  
43  
43  
43  
3.5  
3.7  
3.5  
3.3  
3.8  
3.6  
3.5  
3.3  
3.2  
950  
0
to  
2000  
975  
1000  
1025  
1050  
1075  
1100  
SPECIFIC GRAVITY OF NATURAL GAS  
0.60 0.62  
Manifold Manifold  
ALTITUDE  
RANGE  
(FT)  
AVG GAS  
HEAT VALUE  
(BTU/CU FT)  
0.58  
0.64  
Orifice  
No.  
Manifold  
Pressure  
Orifice  
No.  
Orifice  
No.  
Orifice  
No.  
Manifold  
Pressure  
Pressure  
Pressure  
U.S.A.  
800  
825  
850  
875  
900  
925  
950  
975  
1000  
42  
42  
43  
43  
43  
43  
43  
43  
43  
3.4  
3.2  
3.7  
3.5  
3.3  
3.1  
2.9  
2.8  
2.6  
42  
42  
43  
43  
43  
43  
43  
43  
43  
3.5  
3.3  
3.8  
3.6  
3.4  
3.2  
3.0  
2.9  
2.7  
42  
42  
42  
43  
43  
43  
43  
43  
43  
3.6  
3.4  
3.2  
3.7  
3.5  
3.3  
3.1  
3.0  
2.8  
42  
42  
42  
43  
43  
43  
43  
43  
43  
3.7  
3.5  
3.3  
3.8  
3.6  
3.4  
3.2  
3.1  
2.9  
Altitudes  
2001  
to  
3000  
or  
Canada  
Altitudes  
2000  
to  
4500  
SPECIFIC GRAVITY OF NATURAL GAS  
0.60 0.62  
Manifold Manifold  
ALTITUDE  
RANGE  
(FT)  
AVG GAS  
HEAT VALUE  
(BTU/CU FT)  
0.58  
0.64  
Orifice  
No.  
Manifold  
Pressure  
Orifice  
No.  
Orifice  
No.  
Orifice  
No.  
Manifold  
Pressure  
Pressure  
Pressure  
775  
800  
825  
850  
875  
900  
925  
950  
42  
43  
43  
43  
43  
43  
43  
43  
3.2  
3.6  
3.4  
3.2  
3.0  
2.9  
2.7  
2.6  
42  
43  
43  
43  
43  
43  
43  
43  
3.3  
3.8  
3.5  
3.3  
3.1  
3.0  
2.8  
2.7  
42  
42  
43  
43  
43  
43  
43  
43  
3.4  
3.2  
3.7  
3.4  
3.3  
3.1  
2.9  
2.8  
42  
42  
43  
43  
43  
43  
43  
43  
3.5  
3.3  
3.8  
3.6  
3.4  
3.2  
3.0  
2.8  
3001  
to  
4000  
U.S.A. Only  
SPECIFIC GRAVITY OF NATURAL GAS  
0.60 0.62  
Manifold Manifold  
ALTITUDE  
RANGE  
(FT)  
AVG GAS  
HEAT VALUE  
(BTU/CU FT)  
0.58  
0.64  
Orifice  
No.  
Manifold  
Pressure  
Orifice  
No.  
Orifice  
No.  
Orifice  
No.  
Manifold  
Pressure  
Pressure  
Pressure  
750  
775  
800  
825  
850  
875  
900  
925  
43  
43  
43  
43  
43  
43  
43  
43  
3.6  
3.4  
3.2  
3.0  
2.8  
2.7  
2.5  
2.4  
43  
43  
43  
43  
43  
43  
43  
43  
3.8  
3.5  
3.3  
3.1  
2.9  
2.8  
2.6  
2.5  
42  
43  
43  
43  
43  
43  
43  
43  
3.2  
3.6  
3.4  
3.2  
3.0  
2.9  
2.7  
2.6  
42  
43  
43  
43  
43  
43  
43  
43  
3.3  
3.8  
3.5  
3.3  
3.1  
2.9  
2.8  
2.6  
4001  
to  
5000  
* Orifice numbers 43 are factory installed  
36  
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Table 10Orifice Size* And Manifold Pressure For Gas Input Rate (Continued)  
(Tabulated Data Based On 22,000 Btuh Per Burner, Derated 4 Percent For Each 1000 Ft Above Sea Level)  
SPECIFIC GRAVITY OF NATURAL GAS  
AVG GAS  
ALTITUDE  
RANGE  
(FT)  
HEAT VALUE  
AT ALTITUDE  
(BTU/CU FT)  
0.58  
0.60  
0.62  
0.64  
Manifold  
Orifice  
No.  
Manifold  
Pressure  
Orifice  
No.  
Manifold  
Pressure  
Orifice  
No.  
Manifold  
Pressure  
Orifice  
No.  
Pressure  
725  
750  
775  
800  
825  
850  
875  
900  
43  
43  
43  
43  
43  
43  
43  
43  
3.4  
3.2  
3.0  
2.8  
2.6  
2.5  
2.3  
2.2  
43  
43  
43  
43  
43  
43  
43  
43  
3.5  
3.3  
3.1  
2.9  
2.7  
2.5  
2.4  
2.3  
43  
43  
43  
43  
43  
43  
43  
43  
3.6  
3.4  
3.2  
3.0  
2.8  
2.6  
2.5  
2.3  
43  
43  
43  
43  
43  
43  
43  
43  
3.7  
3.5  
3.3  
3.1  
2.9  
2.7  
2.6  
2.4  
5001  
to  
6000  
SPECIFIC GRAVITY OF NATURAL GAS  
0.60 0.62  
Manifold Manifold  
AVG GAS  
HEAT VALUE  
AT ALTITUDE  
(BTU/CU FT)  
ALTITUDE  
RANGE  
(FT)  
0.58  
0.64  
Orifice  
No.  
Manifold  
Pressure  
Orifice  
No.  
Orifice  
No.  
Orifice  
No.  
Manifold  
Pressure  
Pressure  
Pressure  
675  
700  
725  
750  
775  
800  
825  
850  
43  
43  
43  
43  
43  
43  
43  
43  
3.4  
3.1  
2.9  
2.7  
2.6  
2.4  
2.3  
2.1  
43  
43  
43  
43  
43  
43  
43  
43  
3.5  
3.3  
3.0  
2.8  
2.7  
2.5  
2.3  
2.2  
43  
43  
43  
43  
43  
43  
43  
43  
3.6  
3.4  
3.1  
2.9  
2.7  
2.6  
2.4  
2.3  
43  
43  
43  
43  
43  
43  
43  
43  
3.7  
3.5  
3.2  
3.0  
2.8  
2.7  
2.5  
2.4  
6001  
to  
7000  
SPECIFIC GRAVITY OF NATURAL GAS  
0.60 0.62  
Manifold Manifold  
AVG GAS  
HEAT VALUE  
AT ALTITUDE  
(BTU/CU FT)  
ALTITUDE  
RANGE  
(FT)  
0.58  
0.64  
Orifice  
No.  
Manifold  
Pressure  
Orifice  
No.  
Orifice  
No.  
Orifice  
No.  
Manifold  
Pressure  
Pressure  
Pressure  
650  
675  
700  
725  
750  
775  
800  
825  
43  
43  
43  
43  
43  
43  
43  
48  
3.1  
2.9  
2.7  
2.5  
2.4  
2.2  
2.1  
3.7  
43  
43  
43  
43  
43  
43  
43  
43  
3.2  
3.0  
2.8  
2.6  
2.4  
2.3  
2.1  
2.0  
43  
43  
43  
43  
43  
43  
43  
43  
3.4  
3.1  
2.9  
2.7  
2.5  
2.4  
2.2  
2.1  
43  
43  
43  
43  
43  
43  
43  
43  
3.5  
3.2  
3.0  
2.8  
2.6  
2.4  
2.3  
2.2  
7001  
to  
8000  
SPECIFIC GRAVITY OF NATURAL GAS  
0.60 0.62  
Manifold Manifold  
AVG GAS  
HEAT VALUE  
AT ALTITUDE  
(BTU/CU FT)  
ALTITUDE  
RANGE  
(FT)  
0.58  
0.64  
Orifice  
No.  
Manifold  
Pressure  
Orifice  
No.  
Orifice  
No.  
Orifice  
No.  
Manifold  
Pressure  
Pressure  
Pressure  
625  
650  
675  
700  
725  
750  
775  
43  
43  
43  
43  
43  
43  
48  
2.9  
2.7  
2.5  
2.3  
2.2  
2.0  
3.6  
43  
43  
43  
43  
43  
43  
48  
3.0  
43  
43  
43  
43  
43  
43  
43  
3.1  
43  
43  
43  
43  
43  
43  
43  
3.2  
3.0  
2.8  
2.6  
2.4  
2.2  
2.1  
2.8  
2.9  
2.6  
2.7  
8001  
to  
9000  
2.4  
2.5  
2.2  
2.3  
2.1  
2.2  
3.7  
2.0  
* Orifice numbers 43 are factory installed  
37  
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Table 10Orifice Size* And Manifold Pressure For Gas Input Rate (Continued)  
(Tabulated Data Based On 22,000 Btuh Per Burner, Derated 4 Percent For Each 1000 Ft Above Sea Level)  
SPECIFIC GRAVITY OF NATURAL GAS  
AVG GAS  
ALTITUDE  
RANGE  
(FT)  
HEAT VALUE  
AT ALTITUDE  
(BTU/CU FT)  
0.58  
0.60  
0.62  
0.64  
Manifold  
Orifice  
No.  
Manifold  
Pressure  
Orifice  
No.  
Manifold  
Pressure  
Orifice  
No.  
Manifold  
Pressure  
Orifice  
No.  
Pressure  
600  
625  
650  
675  
700  
725  
43  
43  
43  
43  
48  
48  
2.7  
2.5  
2.3  
2.1  
3.7  
3.5  
43  
43  
43  
43  
43  
48  
2.8  
2.6  
2.4  
2.2  
2.0  
3.6  
43  
43  
43  
43  
43  
48  
2.9  
2.6  
2.4  
2.3  
2.1  
3.7  
43  
43  
43  
43  
43  
43  
3.0  
2.7  
2.5  
2.3  
2.2  
2.0  
9001  
to  
10,000  
* Orifice numbers 43 are factory installed  
38  
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TABLE 11Orifice Size* and Manifold Pressure For Gas Input Rate  
(Tabulated Data Based On 21,000 Btuh Per Burner, Derated 4 Percent For Each 1000 Ft Above Sea Level)  
SPECIFIC GRAVITY OF NATURAL GAS  
ALTITUDE  
RANGE  
(FT)  
AVG GAS  
HEAT VALUE  
(BTU/CU FT)  
0.58  
Manifold  
0.60  
0.62  
0.64  
Manifold  
Orifice  
No.  
Orifice  
No.  
Manifold  
Pressure  
Orifice  
No.  
Manifold  
Pressure  
Orifice  
No.  
Pressure  
Pressure  
900  
925  
42  
43  
43  
43  
44  
44  
44  
45  
46  
3.2  
3.7  
3.5  
3.3  
3.6  
3.4  
3.3  
3.8  
3.8  
42  
43  
43  
43  
43  
44  
44  
44  
45  
3.3  
3.8  
3.6  
3.4  
3.3  
3.6  
3.4  
3.2  
3.7  
42  
42  
43  
43  
43  
43  
44  
44  
44  
3.4  
3.2  
3.7  
3.5  
3.4  
3.2  
3.5  
3.3  
3.2  
42  
42  
43  
43  
43  
43  
43  
44  
44  
3.5  
3.3  
3.8  
3.7  
3.5  
3.3  
3.2  
3.4  
3.3  
950  
0
to  
2000  
975  
1000  
1025  
1050  
1075  
1100  
SPECIFIC GRAVITY OF NATURAL GAS  
0.60 0.62  
Manifold Manifold  
ALTITUDE  
RANGE  
(FT)  
AVG GAS  
HEAT VALUE  
(BTU/CU FT)  
0.58  
0.64  
Orifice  
No.  
Manifold  
Pressure  
Orifice  
No.  
Orifice  
No.  
Orifice  
No.  
Manifold  
Pressure  
Pressure  
Pressure  
U.S.A.  
Altitudes  
2001  
to  
3000  
or  
Canada  
Altitudes  
2000  
to  
800  
825  
850  
875  
900  
925  
950  
975  
1000  
43  
43  
43  
43  
43  
43  
43  
43  
43  
3.8  
3.5  
3.3  
3.2  
3.0  
2.8  
2.7  
2.5  
2.4  
42  
43  
43  
43  
43  
43  
43  
43  
43  
3.2  
3.7  
3.5  
3.3  
3.1  
2.9  
2.8  
2.6  
2.5  
42  
43  
43  
43  
43  
43  
43  
43  
43  
3.3  
3.8  
3.6  
3.4  
3.2  
3.0  
2.9  
2.7  
2.6  
42  
42  
43  
43  
43  
43  
43  
43  
43  
3.4  
3.2  
3.7  
3.5  
3.3  
3.1  
2.9  
2.8  
2.7  
4500  
SPECIFIC GRAVITY OF NATURAL GAS  
0.60 0.62  
Manifold Manifold  
ALTITUDE  
RANGE  
(FT)  
AVG GAS  
HEAT VALUE  
(BTU/CU FT)  
0.58  
0.64  
Orifice  
No.  
Manifold  
Pressure  
Orifice  
No.  
Orifice  
No.  
Orifice  
No.  
Manifold  
Pressure  
Pressure  
Pressure  
775  
800  
825  
850  
875  
900  
925  
950  
43  
43  
43  
43  
43  
43  
43  
43  
3.5  
3.3  
3.1  
2.9  
2.8  
2.6  
2.5  
2.4  
43  
43  
43  
43  
43  
43  
43  
43  
3.7  
3.4  
3.2  
3.0  
2.9  
2.7  
2.6  
2.4  
43  
43  
43  
43  
43  
43  
43  
43  
3.8  
3.5  
3.3  
3.1  
3.0  
2.8  
2.7  
2.5  
42  
43  
43  
43  
43  
43  
43  
43  
3.2  
3.7  
3.4  
3.2  
3.1  
2.9  
2.7  
2.6  
3001  
to  
4000  
U.S.A. Only  
SPECIFIC GRAVITY OF NATURAL GAS  
0.60 0.62  
Manifold Manifold  
ALTITUDE  
RANGE  
(FT)  
AVG GAS  
HEAT VALUE  
(BTU/CU FT)  
0.58  
0.64  
Orifice  
No.  
Manifold  
Pressure  
Orifice  
No.  
Orifice  
No.  
Orifice  
No.  
Manifold  
Pressure  
Pressure  
Pressure  
750  
775  
800  
825  
850  
875  
900  
925  
43  
43  
43  
43  
43  
43  
43  
43  
3.3  
3.1  
2.9  
2.7  
2.6  
2.4  
2.3  
2.2  
43  
43  
43  
43  
43  
43  
43  
43  
3.4  
3.2  
3.0  
2.8  
2.7  
2.5  
2.4  
2.2  
43  
43  
43  
43  
43  
43  
43  
43  
3.5  
3.3  
3.1  
2.9  
2.8  
2.6  
2.5  
2.3  
43  
43  
43  
43  
43  
43  
43  
43  
3.6  
3.4  
3.2  
3.0  
2.8  
2.7  
2.5  
2.4  
4001  
to  
5000  
* Orifice numbers 43 are factory installed  
39  
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Table 11Orifice Size* And Manifold Pressure For Gas Input Rate (Continued)  
(Tabulated Data Based On 21,000 Btuh Per Burner, Derated 4 Percent For Each 1000 Ft Above Sea Level)  
SPECIFIC GRAVITY OF NATURAL GAS  
AVG GAS  
ALTITUDE  
RANGE  
(FT)  
HEAT VALUE  
AT ALTITUDE  
(BTU/CU FT)  
0.58  
0.60  
0.62  
0.64  
Manifold  
Orifice  
No.  
Manifold  
Pressure  
Orifice  
No.  
Manifold  
Pressure  
Orifice  
No.  
Manifold  
Pressure  
Orifice  
No.  
Pressure  
725  
750  
775  
800  
825  
850  
875  
900  
43  
43  
43  
43  
43  
43  
43  
43  
3.1  
2.9  
2.7  
2.5  
2.4  
2.2  
2.1  
2.0  
43  
43  
43  
43  
43  
43  
43  
43  
3.2  
3.0  
2.8  
2.6  
2.5  
2.3  
2.2  
2.1  
43  
43  
43  
43  
43  
43  
43  
43  
3.3  
3.1  
2.9  
2.7  
2.5  
2.4  
2.3  
2.1  
43  
43  
43  
43  
43  
43  
43  
43  
3.4  
3.2  
3.0  
2.8  
2.6  
2.5  
2.3  
2.2  
5001  
to  
6000  
SPECIFIC GRAVITY OF NATURAL GAS  
0.60 0.62  
Manifold Manifold  
AVG GAS  
HEAT VALUE  
AT ALTITUDE  
(BTU/CU FT)  
ALTITUDE  
RANGE  
(FT)  
0.58  
0.64  
Orifice  
No.  
Manifold  
Pressure  
Orifice  
No.  
Orifice  
No.  
Orifice  
No.  
Manifold  
Pressure  
Pressure  
Pressure  
675  
700  
725  
750  
775  
800  
825  
850  
43  
43  
43  
43  
43  
43  
43  
48  
3.1  
2.9  
2.7  
2.5  
2.3  
2.2  
2.1  
3.7  
43  
43  
43  
43  
43  
43  
43  
43  
3.2  
3.0  
2.8  
2.6  
2.4  
2.3  
2.1  
2.0  
43  
43  
43  
43  
43  
43  
43  
43  
3.3  
3.1  
2.9  
2.7  
2.5  
2.3  
2.2  
2.1  
43  
43  
43  
43  
43  
43  
43  
43  
3.4  
3.2  
2.9  
2.8  
2.6  
2.4  
2.3  
2.1  
6001  
to  
7000  
SPECIFIC GRAVITY OF NATURAL GAS  
0.60 0.62  
Manifold Manifold  
AVG GAS  
HEAT VALUE  
AT ALTITUDE  
(BTU/CU FT)  
ALTITUDE  
RANGE  
(FT)  
0.58  
0.64  
Orifice  
No.  
Manifold  
Pressure  
Orifice  
No.  
Orifice  
No.  
Orifice  
No.  
Manifold  
Pressure  
Pressure  
Pressure  
650  
675  
700  
725  
750  
775  
800  
825  
43  
43  
43  
43  
43  
43  
48  
48  
2.9  
2.7  
2.5  
2.3  
2.1  
2.0  
3.6  
3.3  
43  
43  
43  
43  
43  
43  
48  
48  
3.0  
2.7  
2.6  
2.4  
2.2  
2.1  
3.7  
3.5  
43  
43  
43  
43  
43  
43  
43  
48  
3.1  
2.8  
2.6  
2.5  
2.3  
2.2  
2.0  
3.6  
43  
43  
43  
43  
43  
43  
43  
48  
3.2  
2.9  
2.7  
2.5  
2.4  
2.2  
2.1  
3.7  
7001  
to  
8000  
SPECIFIC GRAVITY OF NATURAL GAS  
0.60 0.62  
Manifold Manifold  
AVG GAS  
HEAT VALUE  
AT ALTITUDE  
(BTU/CU FT)  
ALTITUDE  
RANGE  
(FT)  
0.58  
0.64  
Orifice  
No.  
Manifold  
Pressure  
Orifice  
No.  
Orifice  
No.  
Orifice  
No.  
Manifold  
Pressure  
Pressure  
Pressure  
625  
650  
675  
700  
725  
750  
775  
43  
43  
43  
43  
48  
48  
49  
2.7  
2.5  
2.3  
2.1  
3.7  
3.5  
3.8  
43  
43  
43  
43  
43  
48  
48  
2.7  
2.5  
2.4  
2.2  
2.0  
3.6  
3.4  
43  
43  
43  
43  
43  
48  
48  
2.8  
2.6  
2.4  
2.3  
2.1  
3.7  
3.5  
43  
43  
43  
43  
43  
43  
48  
2.9  
2.7  
2.5  
2.3  
2.2  
2.0  
3.6  
8001  
to  
9000  
* Orifice numbers 43 are factory installed  
40  
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Table 11Orifice Size* And Manifold Pressure For Gas Input Rate (Continued)  
(Tabulated Data Based On 21,000 Btuh Per Burner, Derated 4 Percent For Each 1000 Ft Above Sea Level)  
SPECIFIC GRAVITY OF NATURAL GAS  
AVG GAS  
ALTITUDE  
RANGE  
(FT)  
HEAT VALUE  
AT ALTITUDE  
(BTU/CU FT)  
0.58  
0.60  
0.62  
0.64  
Manifold  
Orifice  
No.  
Manifold  
Pressure  
Orifice  
No.  
Manifold  
Pressure  
Orifice  
No.  
Manifold  
Pressure  
Orifice  
No.  
Pressure  
600  
625  
650  
675  
700  
725  
43  
43  
43  
48  
48  
49  
2.4  
2.3  
2.1  
3.6  
3.4  
3.7  
43  
43  
43  
48  
48  
49  
2.5  
2.3  
2.2  
3.8  
3.5  
3.8  
43  
43  
43  
43  
48  
48  
2.6  
2.4  
2.2  
2.1  
3.6  
3.4  
43  
43  
43  
43  
48  
48  
2.7  
2.5  
2.3  
2.1  
3.7  
3.5  
9001  
to  
10,000  
* Orifice numbers 43 are factory installed  
41  
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42  
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43  
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Copyright 2002 Carrier Corporation  
58st11si  
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.  
Book  
Tab 6a 8a  
1
4
PC 101  
Catalog No. See Cover  
Printed in U.S.A.  
Form 58ST-11SI  
Pg 44  
12-02  
Replaces: 58ST-2SI  
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