INSTALLATION INSTRUCTIONS FOR *(D, M)VC8 GAS FURNACE
(CATEGORY I )
Installer: Affix all manuals adjacent to the unit.
These furnaces comply with requirements em-
bodied in theAmerican National Standard / Na-
®
tional Standard of Canada ANSI Z21.47·CSA-
2.3 Gas Fired Central Furnaces.
US
C
RECOGNIZE THIS SYMBOL AS A SAFETY PRECAUTION.
ATTENTION INSTALLING PERSONNEL
As a professional installer, you have an obligation to know the product better than the customer.
This includes all safety precautions and related items.
Prior to actual installation, thoroughly familiarize yourself with this Instruction Manual.
Pay special attention to all safety warnings. Often during installation or repair, it is possible to place yourself
in a position which is more hazardous than when the unit is in operation.
Remember, it is your responsibility to install the product safely and to know it well enough
to be able to instruct a customer in its safe use.
Safety is a matter of common sense...a matter of thinking before acting.
Most dealers have a list of specific, good safety practices...follow them.
The precautions listed in this Installation Manual are intended as supplemental to existing practices.
However, if there is a direct conflict between existing practices and the content of this manual,
the precautions listed here take precedence.
NOTE: Please contact your distributor or our website for the applicable Specification Sheet
referred to in this manual.
WARNING
GOODMAN WILL NOT BE RESPONSIBLE FOR ANY INJURY OR PROPERTY
DAMAGE ARISING FROM IMPROPER SERVICE OR SERVICE PROCEDURES.
IF YOU INSTALL OR PERFORM SERVICE ON THIS UNIT, YOU ASSUME
RESPONSIBILITY FOR ANY PERSONAL INJURY OR PROPERTY DAMAGE
WHICH MAY RESULT. MANY JURISDICTIONS REQUIRE A LICENSE TO
INSTALL OR SERVICE HEATING AND AIR CONDITIONING EQUIPMENT.
5151 San Felipe Suite 500 • Houston, TX 77056
IO-361C
© 2009-2010 Goodman Manufacturing Company, L.P.
12/10
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Table of Contents
CIRCULATION AIR FILTERS ................................................................................................................... 23
HORIZONTAL INSTALLATIONS ................................................................................................................ 23
START-UP PROCEDURE AND ADJUSTMENT ....................................................................................................... 23
HEAT ANTICIPATOR SETTING ................................................................................................................ 23
FURNACE OPERATION ......................................................................................................................... 23
GAS SUPPLY PRESSURE MEASUREMENT .................................................................................................. 23
GAS MANIFOLD PRESSURE MEASUREMENT AND ADJUSTMENT ....................................................................... 25
GAS INPUT RATE MEASUREMENT (NATURAL GAS ONLY) ............................................................................ 25
TEMPERATURE RISE ........................................................................................................................... 26
CIRCULATOR BLOWER SPEEDS ............................................................................................................. 26
BLOWER HEAT OFF DELAY TIMINGS ...................................................................................................... 28
COMFORTNET™ SYSTEM ......................................................................................................................... 29
OVERVIEW ....................................................................................................................................... 29
AIFRLOW CONSIDERATIONS .................................................................................................................. 29
FOSSIL FUEL APPLICATIONS ................................................................................................................ 30
CTK01AA WIRING .......................................................................................................................... 30
COMFORTNET SYSTEM ADVANCED FEATURES .......................................................................................... 30
NETWORK TROUBLESHOOTING ................................................................................................................ 33
SYSTEM TROUBLESHOOTING ................................................................................................................. 33
NORMAL SEQUENCE OF OPERATION .............................................................................................................. 34
POWER UP ...................................................................................................................................... 34
HEATING MODE ................................................................................................................................. 34
COOLING MODE ................................................................................................................................ 35
FAN ONLY MODE .............................................................................................................................. 35
OPERATIONAL CHECKS .............................................................................................................................. 35
SAFETY CIRCUIT DESCRIPTION .................................................................................................................... 36
INTEGRATED CONTROL MODULE ............................................................................................................. 36
PRIMARY LIMIT ................................................................................................................................ 36
AUXILIARY LIMIT ............................................................................................................................... 36
ROLLOUT LIMIT ................................................................................................................................ 36
PRESSURE SWITCHES ......................................................................................................................... 36
FLAME SENSOR ................................................................................................................................ 36
TROUBLESHOOTING ................................................................................................................................... 36
ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS ................................................................................... 36
DIAGNOSTIC CHART........................................................................................................................... 36
FAULT RECALL ................................................................................................................................ 37
RESETTING FROM LOCKOUT ................................................................................................................ 37
MAINTENANCE ......................................................................................................................................... 37
ANNUAL INSPECTION ........................................................................................................................... 37
FILTERS .......................................................................................................................................... 37
BURNERS ......................................................................................................................................... 38
INDUCED DRAFT AND CIRCULATOR BLOWERS ............................................................................................ 38
FLAME SENSOR (QUALIFIED SERVICER ONLY) .......................................................................................... 38
FLUE PASSAGES (QUALIFIED SERVICER ONLY) ......................................................................................... 38
BEFORE LEAVING AN INSTALLATION ............................................................................................................... 38
REPAIR AND REPLACEMENT PARTS .............................................................................................................. 38
TROUBLESHOOTING CHART ......................................................................................................................... 39
STATUS CODES ....................................................................................................................................... 44
AIR FLOW DATA .................................................................................................................................... 45
DIP SWITCHES ........................................................................................................................................ 45
*MVC8___AA WIRING DIAGRAM ............................................................................................................. 46
*MVC8___AB, *DVC8___AA WIRING DIAGRAM ..................................................................................... 47
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SAFETY PRECAUTIONS
Adhere to the following warnings and cautions when install-
ing, adjusting, altering, servicing, or operating the furnace.
To ensure proper installation and operation, thoroughly read
this manual for specifics pertaining to the installation and
application of this product.
WARNING
TO PREVENT PERSONAL INJURY OR DEATH DUE TO IMPROPER
INSTALLATION, ADJUSTMENT, ALTERATION, SERVICE OR MAINTENANCE,
REFER TO THIS MANUAL. FOR ADDITIONAL ASSISTANCE OR
INFORMATION, CONSULT A QUALIFIED INSTALLER, SERVICER AGENCY OR
THE GAS SUPPLIER.
CARBON MONOXIDE POISONING HAZARD
Special Warning for Installation of Furnace or Air Handling Units in
Enclosed Areas such as Garages, Utility Rooms or Parking Areas
WARNING
IF THE INFORMATION IN THESE INSTRUCTIONS IS NOT FOLLOWED
EXACTLY, A FIRE OR EXPLOSION MAY RESULT CAUSING PROPERTY
DAMAGE, PERSONAL INJURY OR LOSS OF LIFE.
DO NOT STORE OR USE GASOLINE OR OTHER FLAMMABLE VAPORS AND
LIQUIDS IN THE VICINITY OF THIS OR ANY OTHER APPLIANCE.
Carbon monoxide producing devices (such as an automobile, space
heater, gas water heater, etc.) should not be operated in enclosed areas
such as unventilated garages, utility rooms or parking areas because of
the danger of carbon monoxide (CO) poisoning resulting from the exhaust
emissions. If a furnace or air handler is installed in an enclosed area such
as a garage, utility room or parking area and a carbon monoxide producing
device is operated therein, there must be adequate, direct outside
ventilation.
WHAT TO DO IF YOU SMELL GAS:
DO NOT TRY TO LIGHT ANY APPLIANCE.
DO NOT TOUCH ANY ELECTRICAL SWITCH; DO NOT USE ANY PHONE
This ventilation is necessary to avoid the danger of CO poisoning which
can occur if a carbon monoxide producing device continues to operate in
the enclosed area. Carbon monoxide emissions can be (re)circulated
throughout the structure if the furnace or air handler is operating in any
mode.
IN YOUR BUILDING.
IMMEDIATELY CALL YOUR GAS SUPPLIER FROM A NEIGHBOR’S
PHONE. FOLLOW THE GAS SUPPLIER’S INSTRUCTIONS.
IF YOU CANNOT REACH YOUR GAS SUPPLIER, CALL THE FIRE
CO can cause serious illness including permanent brain damage or death.
DEPARTMENT.
B10259-216
INSTALLATION AND SERVICE MUST BE PERFORMED BY A QUALIFIED
INSTALLER, SERVICE AGENCY OR THE GAS SUPPLIER.
WARNING
WARNING
SHOULD OVERHEATING OCCUR OR THE GAS SUPPLY FAIL TO SHUT OFF,
TURN OFF THE MANUAL GAS SHUTOFF VALVE EXTERNAL TO THE
FURNACE BEFORE TURNING OFF THE ELECTRICAL SUPPLY.
THIS PRODUCT CONTAINS OR PRODUCES A CHEMICAL OR CHEMICALS
WHICH MAY CAUSE SERIOUS ILLNESS OR DEATH AND WHICH ARE
KNOWN TO THE STATE OF CALIFORNIA TO CAUSE CANCER, BIRTH
DEFECTS OR OTHER REPRODUCTIVE HARM.
WARNING
POSSIBLE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH DUE TO
FIRE, EXPLOSION, SMOKE, SOOT, CONDENSATION, ELECTRICAL SHOCK
OR CARBON MONOXIDE MAY RESULT FROM IMPROPER INSTALLATION,
REPAIR OPERATION, OR MAINTENANCE OF THIS PRODUCT.
WARNING
HEATING UNIT SHOULD NOT BE UTILIZED WITHOUT REASONABLE,
ROUTINE, INSPECTION, MAINTENANCE AND SUPERVISION. IF THE
BUILDING IN WHICH ANY SUCH DEVICE IS LOCATED WILL BE VACANT,
CARE SHOULD BE TAKEN THAT SUCH DEVICE IS ROUTINELY INSPECTED,
MAINTAINED AND MONITORED. IN THE EVENT THAT THE BUILDING
MAYBE EXPOSED TO FREEZING TEMPERATURES AND WILL BE VACANT,
ALL WATER‐BEARING PIPES SHOULD BE DRAINED, THE BUILDING SHOULD
BE PROPERLY WINTERIZED, AND THE WATER SOURCE CLOSED. IN THE
EVENT THAT THE BUILDING MAY BE EXPOSED TO FREEZING
WARNING
TO PREVENT PERSONAL INJURY OR DEATH DUE TO IMPROPER
INSTALLATION, ADJUSTMENT, ALTERATION, SERVICE OR MAINTENANCE,
REFER TO THIS MANUAL. FOR ADDITIONAL ASSISTANCE OR
INFORMATION, CONSULT A QUALIFIED INSTALLER, SERVICER AGENCY OR
THE GAS SUPPLIER.
TEMPERATURES AND WILL BE VACANT, ANY HYDRONIC COIL UNITS
SHOULD BE DRAINED AS WELL AND, IN SUCH CASE, ALTERNATIVE HEAT
SOURCES SHOULD BE UTILIZED.
WARNING
THIS UNIT MUST NOT BE USED AS A “CONSTRUCTION HEATER” DURING
THE FINISHING PHASES OF CONSTRUCTION ON A NEW STRUCTURE. THIS
TYPE OF USE MAY RESULT IN PREMATURE FAILURE OF THE UNIT DUE TO
EXTREMELY LOW RETURN AIR TEMPERATURES AND EXPOSURE TO
CORROSIVE OR VERY DIRTY ATMOSPHERES.
WARNING
TO PREVENT POSSIBLE PROPERTY DAMAGE, PERSONAL INJURY OR
DEATH DUE TO ELECTRICAL SHOCK, THE FURNACE MUST BE LOCATED TO
PROTECT THE ELECTRICAL COMPONENTS FROM WATER.
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PRODUCT APPLICATION
This procedure is applicable to both installed and non-installed
(ungrounded) furnaces.
1. Disconnect all power to the furnace. Do not touch the
integrated control module or any wire connected to the
control prior to discharging your body’s electrostatic
charge to ground.
2. Firmly touch a clean, unpainted, metal surface of the
furnaces near the control. Any tools held in a person’s
hand during grounding will be discharged.
3. Service integrated control module or connecting wiring
following the discharge process in step 2. Use caution
not to recharge your body with static electricity; (i.e., do
not move or shuffle your feet, do not touch ungrounded
objects, etc.). If you come in contact with an ungrounded
object, repeat step 2 before touching control or wires.
4. Discharge your body to ground before removing a new
control from its container. Follow steps 1 through 3 if
installing the control on a furnace. Return any old or
new controls to their containers before touching any
ungrounded object.
WARNING
TO PREVENT PERSONAL INJURY OR DEATH DUE TO ASPHYXIATION, THIS
FURNACE MUST BE CATEGORY
CATEGORY III VENTING.
I
VENTED. DO NOT VENT USING
PROVISIONS MUST BE MADE FOR VENTING COMBUSTION PRODUCTS
OUTDOORS THROUGH A PROPER VENTING SYSTEM. THE LENGTH OF
FLUE PIPE COULD BE A LIMITING FACTOR IN LOCATING THE FURNACE.
ADDITIONALSAFETY CONSIDERATIONS
•
•
This furnace is approved for Category I Venting only.
Provisions must be made for venting combustion
products outdoors through a proper venting system.
The length of flue pipe could be a limiting factor in
locating the furnace.
SHIPPINGINSPECTION
All units are securely packed in shipping containers tested
according to International Safe Transit Association specifica-
tions. The carton must be checked upon arrival for external
damage. If damage is found, a request for inspection by carrier’s
agent must be made in writing immediately.
TOTHE INSTALLER
The furnace must be carefully inspected on arrival for damage
and bolts or screws which may have come loose in transit. In
the event of damage the consignee should:
1. Make a notation on delivery receipt of any visible damage
to shipment or container.
2. Notify carrier promptly and request an inspection.
3. With concealed damage, carrier must be notified as soon
as possible - preferably within five days.
4. File the claim with the following support documents within
a nine month statute of limitations.
Before installing this unit, please read this manual thoroughly
to familiarize yourself with specific items which must be ad-
hered to, including but not limited to: unit maximum external
static pressure, gas pressures, BTU input rating, proper elec-
trical connections, circulating air temperature rise, minimum or
maximum CFM, and motor speed connections, and venting.
These furnaces are designed for Category I venting only.
IMPORTANTNOTE TOTHE OWNERREGARDING PRODUCT
WARRANTY
•
Original or certified copy of the Bill of Lading, or
indemnity bond.
Original paid freight bill or indemnity in lieu thereof.
Original or certified copy of the invoice, showing trade
and other discounts or reductions.
Complete warranty details and instructions are available from
hac.com. Your warranty certificate is supplied as a separate
document with the unit installed by your contractor. Read the
limited warranty certificate carefully to determine what is and is
not covered and keep the warranty certificate in a safe place. If
you are unable to locate the warranty certificate please contact
your installing contractor or contact customer service (877-254-
4729) to obtain a copy.
•
•
•
Copy of the inspection report issued by carrier’s
representative at the time damage is reported to carrier.
The carrier is responsible for making prompt inspection of dam-
age and for a thorough investigation of each claim. The distribu-
tor or manufacturer will not accept claims from dealers for trans-
portation damage.
To receive the Lifetime Heat Exchanger Limited Warranty, good
for as long as you own your home, and the 10-year Parts Lim-
ited Warranty, online registration must be completed within 60
days of installation. Online registration is not required in Cali-
fornia or Quebec.
Keep this literature in a safe place for future reference.
ELECTROSTATIC DISCHARGE (ESD)PRECAUTIONS
IMPORTANT: To register your Goodman brand unit, go to
on the left side of the home page. Next, click on the word
“Product Registration” located on the left side of the Warranty
page and complete the forms in the manner indicated on the
Product Registration page.
NOTE: Discharge body’s static electricity before touching unit.
An electrostatic discharge can adversely affect electrical com-
ponents.
Use the following precautions during furnace installation and
servicing to protect the integrated control module from dam-
age. By putting the furnace, the control, and the person at the
same electrostatic potential, these steps will help avoid expos-
ing the integrated control module to electrostatic discharge.
Click on the word “Warranty” located on the top right of the
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LOCATION REQUIREMENTS AND CONSIDERATIONS
home page. Next, click on the word “Product Registration”
located on the left side of the Warranty page and complete the
forms in the manner indicated on the Product Registration page.
•
•
•
It must be installed per the installation instructions
provided and per local and national codes.
It must be installed indoors in a building constructed
on site.
It must be part of a ducted system and not used in a
free air delivery application.
Product limited warranty certificates for models currently in pro-
hac.com. If your model is not currently in production or does
not appear on the website, please contact your installing con-
tractor or contact customer service at (877-254-4729) to obtain
a copy of your warranty certificate.
•
•
It must not be used as a “make-up” air unit.
All other warranty exclusions and restrictions apply.
This furnace may be used as a construction site heater ONLY
if the following conditions are met:
Each product overview page contains a Product Warranty link;
by clicking on it you will be able to view the limited warranty
coverage for that specific product. To view warranty registration
information, click on the Product Warranty text on the left navi-
gation panel on the home page of each website. The Online
Product Registration pages are located in this same section.
•
The vent system is permanently installed per these
installation instructions.
•
A room thermostat is used to control the furnace. Fixed
jumpers that provide continuous heating CANNOT be
used.
•
•
Return air ducts are provided and sealed to the furnace.
A return air temperature range between 60ºF (16ºC)
and 80ºF (27ºC) is maintained.
Air filters are installed in the system and maintained
during construction, replaced as appropriate during
construction, and upon completion of construction are
replaced.
The input rate and temperature rise are set per the
furnace rating plate.
100% outside air is provided for combustion air
requirements during construction. Temporary ducting
can be used.
NOTE: Do not connect the temporary duct directly to
the furnace. The duct must be sized for adequate
combustion and ventilation in accordance with the
latest edition of the National Fuel Gas Code NFPA54/
ANSI Z223.1 orCAN/CSA B149.1 Installation Codes.
The furnace heat exchanger, components, duct
system, air filters and evaporator coils are thoroughly
cleaned following final construction clean up.
WARNING
TO PREVENT PROPERTY DAMAGE, PERSONAL INJURY OR DEATH DUE TO
FIRE, DO NOT INSTALL THIS FURNACE IN A MOBILE HOME, TRAILER, OR
RECREATIONAL VEHICLE.
•
PRODUCT DESCRIPTION
•
•
FEATURES
This furnace is a part of the ComfortNet™ family of products.
The CTK01 ComfortNet thermostat kit allows this furnace to be
installed as part of a digitally communicating system. The
ComfortNet system provides automatic airflow configuration,
enhanced setup features, and enhanced diagnostics. It also
reduces the number of thermostat wires to a maximum of four.
It may be also installed as part of a “legacy” system using a
standard 24 VAC thermostat.
•
This product may also be installed with the ComfortNet ther-
mostat and a non-ComfortNet compatible single stage air con-
ditioning unit. However, this reduces the benefits of the
ComfortNet system as the enhancements will only apply to the
furnace.
•
All furnace operating conditions (including ignition, input
rate, temperature rise and venting) are verified
according to these installation instructions.
NOTE: The Commonwealth of Massachusetts requires that the
following additional requirements must also be met:
PRODUCT APPLICATION
•
Gas furnaces must be installed by a licensed plumber
or gas fitter.
AT-handle gas cock must be used.
If the unit is to be installed in an attic, the passageway
to and the service area around the unit must have
flooring.
This furnace is primarily designed for residential home-heating
applications. It is NOT designed or certified for use in mobile
homes, trailers or recreational vehicles. Neither is it designed
or certified for outdoor applications. The furnace must be in-
stalled indoors (i.e., attic space, crawl space, or garage area
provided the garage area is enclosed with an operating door).
•
•
This furnace can be used in the following non-industrial com-
mercial applications:
WARNING
Schools,Officebuildings,Churches,Retailstores,
TO PREVENT PROPERTY DAMAGE, PERSONAL INJURY OR DEATH DUE TO
FIRE, DO NOT INSTALL THIS FURNACE IN A MOBILE HOME, TRAILER, OR
RECREATIONAL VEHICLE.
Nursinghomes,Hotels/motels,Commonorofficeareas
In such applications , the furnace must be installed with the
following stipulations:
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LOCATION REQUIREMENTS AND CONSIDERATIONS
To ensure proper furnace operation, install, operate and
LOCATION REQUIREMENTS AND CONSIDERATIONS
maintain the furnace in accordance with these installa-
tion and operation instructions, all local building codes
and ordinances. In their absence, follow the latest edition of
the National Fuel Gas Code (NFPA 54/ANSI Z223.1), and/or
CAN/CSA B149 Installation Codes, local plumbing or waste
water codes, and other applicable codes.
Your unit model type determines which installation procedures
must be used. For *MVC8 models, you must follow instruc-
tions for Horizontal Left, Horizontal Right or Upflow installa-
tions only. These furnaces are not approved for Downflow in-
stallations.
Downflow models *DVC8 ARE NOT APPROVED FOR HORI-
ZONTAL OR UPFLOW INSTALLATIONS. For these models,
use only the instructions for downflow installation only.
Acopy of the National Fuel Gas Code (NFPA54/ANSI Z223.1)
can be obtained from any of the following:
American National Standards Institute
1430 Broadway
New York, NY 10018
WARNING
TO PREVENT POSSIBLE EQUIPMENT DAMAGE, PROPERTY DAMAGE,
PERSONAL INJURY OR DEATH, THE FOLLOWING BULLET POINTS MUST BE
OBSERVED WHEN INSTALLING THIS UNIT.
National Fire Protection Association
1 Batterymarch Park
Quincy, MA 02269
CSA International
8501 East Pleasant Valley
Cleveland, OH 44131
Follow the instructions listed below when selecting a furnace
location. Refer also to the guidelines provided in Section V,
Combustion and Ventilation Air Requirements.
•
Centrally locate the furnace with respect to the
proposed or existing air distribution system.
Ensure the temperature of the return air entering the
furnace is between 55°F and 100°F when the furnace
is heating.
Provisions must be made for venting combustion
products outdoors through a proper venting system.
The length of flue pipe could be a limiting factor in
locating the furnace.
Ensure adequate combustion air is available for the
furnace. Improper or insufficient combustion air can
expose building occupants to gas combustion products
that could include carbon monoxide. Refer to
Combustion and Ventilation Air Requirements section.
The furnace must be level. If the furnace is to be set
on a floor that may become wet or damp at times, the
furnace should be supported above the floor on a
concrete base sized approximately 1-1/2" larger than
the base of the furnace.
Ensure upflow or horizontal furnaces are not installed
directly on carpeting, or any other combustible
material. The only combustible material allowed is
wood.
Exposure to contaminated combustion air will result
in safety and performance-related problems. Do not
install the furnace where the combustion air is exposed
to the following substances:
chlorinated waxes or cleaners
chlorine-based swimming pool chemicals
water softening chemicals
deicing salts or chemicals
carbon tetrachloride
halogen type refrigerants
cleaning solutions (such as perchloroethylene)
printing inks
A copy of the CAN/CSA B149 Installation Codes can also be
obtained from:
•
CSA International
178 Rexdale Boulevard
Etobicoke, Ontario, Canada M9W 1R3
•
•
The rated heating capacity of the furnace should be greater
than or equal to the total heat loss of the area to be heated.
The total heat loss should be calculated by an approved method
or in accordance with “ASHRAE Guide” or “Manual J-Load Cal-
culations” published by the Air Conditioning Contractors of
America.
In the USA, this furnace MUST be installed in accordance with
the latest edition of theANSI Z223.1 booklet entitled “National
Fuel Gas Code” (NFPA54), and the requirements or codes of
the local utility or other authority having jurisdiction. In Canada,
this furnace must be installed in accordance with the current
CAN/CGA-B149.1 & 2 Gas Installation Codes, local plumbing
or waste water codes and other applicable codes. Additional
helpful publications available from the NFPA are, NFPA 90A -
Installation ofAir Conditioning and Ventilating System and NFPA
90B - Warm Air Heating and Air Conditioning System.
•
•
•
All venting shall be in accordance with PART 7, Venting of Equip-
ment, of the National Fuel Gas Code, ANSI Z223.1, or appli-
cable local building and/or air conditioning codes. These pub-
lications are available from:
National Fire Protection Association, Inc.
Batterymarch Park, Quincy, MA 02269
NOTE: Furnaces with NOx screens meet the California NOx
emission standards and California seasonal efficiency stan-
dards.ANNUALinspections of the furnace and its vent system
is strongly recommended.
paint removers
varnishes
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LOCATION REQUIREMENTS AND CONSIDERATIONS
Vent Pipe Clearance to Combustibles-
6" using Single Wall Connector or 1"
using B-1 vent.
hydrochloric acid
cements and glues
antistatic fabric softeners for clothes dryers
and masonry acid washing materials
If the furnace is used in connection with a cooling unit,
install the furnace upstream or in parallel with the
cooling unit coil. Premature heat exchanger failure
will result if the cooling unit coil is placed ahead of the
furnace.
If the furnace is installed in a residential garage,
position the furnace so that the burners and ignition
source are located not less than 18 inches (457 mm)
above the floor. Protect the furnace from physical
damage by vehicles.
If the furnace is installed horizontally, the furnace
access doors must be vertical so that the burners fire
horizontally into the heat exchanger. Do not install
the unit with the access doors on the “up/top” or “down/
bottom” side of the furnace.
Do not connect this furnace to a chimney flue that
serves a separate appliance designed to burn solid
fuel.
For counterflow installations, the air conditioning coil
must be downstream from the heat exchanger of the
furnace.
Counterflow installation over a noncombustible floor.
Before setting the furnace over the plenum opening,
ensure the surface around the opening is smooth and
level.Atight seal should be made between the furnace
base and floor by using a silicon rubber caulking
compound or cement grout.
Top - 1"
•
•
•
Back - 0"
Side
Clearance - 1"
Front Clearance - 3"
•
•
Adequate combustion/ventilation air must be supplied
to the closet.
•
•
•
Furnace must be completely sealed to floor or base.
Combustion/ ventilation air supply pipes must
terminate 12" from top of closet and 12" from floor of
closet. DO NOT remove solid base plate for side
return.
•
Return air ducts must be completely sealed to the
furnace and terminate outside the enclosure surfaces.
CLEARANCES AND ACCESSIBILITY
Unobstructed front clearance of 24" for servicing is recom-
mended.
•
Counterflow installation over a combustible floor. If
installation over a combustible floor becomes
necessary, use an accessory subbase (see
Specification Sheet applicable to your model for details).
A special accessory subbase must be used for upright
counterflow unit installations over any combustible
material including wood. Follow the instructions with
the subbase for proper installations. Do not install the
furnace directly on carpeting, tile, or other combustible
material other than wood flooring. (NOTE: The subbase
will not be required if an air conditioning coil is installed
between the supply air opening on the furnace and the
floor.
VENT
B1-VENT SINGLE
TOP
(PLENUM)
SIDES
1"
FRONT
3"
BACK
0"
1"
6"
1"
Top clearance for horizontal configuration - 1"
HORIZONTAL INSTALLATION (*MVC8MODELS ONLY)
Line contact to framing is permitted when installed in the hori-
zontal configuration. Line contact is defined as the portion of
the cabinet that is formed by the intersection of the top and
side. ACCESSIBILITY CLEARANCE, WHERE GREATER,
SHOULD TAKE PRECEDENCE OVER MINIMUM FIRE PRO-
TECTION CLEARANCE. Agas-fired furnace for installation in
a residential garage must be installed so that the ignition source
and burners are located not less than eighteen inches (18")
above the floor and is protected or located to prevent physical
damage by vehicles. A gas furnace must not be installed di-
rectly on carpeting, tile, or other combustible materials other
than wood flooring.
FURNACESUSPENSION
If suspending the furnace from rafters or joist, use 3/8" threaded
rod and 2”x2”x3/8” angle iron as shown below. The length of
rod will depend on the application and the clearances neces-
sary.
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COMBUSTION & VENTILATION CATEGORY I VENTING AIR REQUIREMENTS
g. If improper venting is observed during any of the above
tests, the common venting system must be corrected.
Corrections must be in accordance with the latest edition of
the National Fuel Gas Code NFPA54/ANSI Z223.1 and/or CAN/
CSA B149 Installation Codes.
If resizing is required on any portion of the venting system, use
the appropriate table in Appendix G in the latest edition of the
National Fuel Gas Code ANSI Z223.1 and/or CAN/CSA B149
Installation Codes.
THERMOSTAT LOCATION
In an area having good air circulation, locate the thermostat
about five feet high on a vibration-free inside wall. Do not install
the thermostat where it may be influenced by any of the follow-
ing:
Suspended Furnace
EXISTING FURNACE REMOVAL
•
Drafts, or dead spots behind doors, in corners, or under
cabinets.
NOTE: When an existing furnace is removed from a venting
system serving other appliances, the venting system may be
too large to properly vent the remaining attached appliances.
•
•
•
•
•
•
Hot or cold air from registers.
Radiant heat from the sun.
Light fixtures or other appliances.
Radiant heat from a fireplace.
Concealed hot or cold water pipes, or chimneys.
Unconditioned areas behind the thermostat, such as
an outside wall.
The following vent testing procedure is reproduced from the
American National Standard/National Standard of Canada
for Gas-Fired Central Furnaces ANSI Z21.47-Latest Edi-
tion, CSA-2.3-Latest Edition Section 1.23.1. The following
steps shall be followed with each appliance connected to the
venting system placed in operation, while any other appliances
connected to the venting system are not in operation:
a. Seal any unused openings in the venting system;
b. Inspect the venting system for proper size and
horizontal pitch, as required by the National Fuel Gas
Code,ANSI Z223.1 or the CAN/CSAB149 Installation
Codes and these instructions. Determine that there is
no blockage or restriction, leakage, corrosion and other
deficiencies which could cause an unsafe condition;
c. In so far as practical, close all building doors and
windows and all doors between the space in which
the appliance(s) connected to the venting system are
located and other spaces of the building. Turn on
clothes dryers and any appliance not connected to
the venting system. Turn on any exhaust fans, such
as range hoods and bathroom exhausts, so they shall
operate at maximum speed. Do not operate a summer
exhaust fan. Close fireplace dampers;
HOT
COLD
Thermostat Influences
Consult the instructions packaged with the thermostat for mount-
ing instructions and further precautions.
d. Follow the lighting instructions. Place the appliance
being inspected in operation. Adjust thermostat so
appliance shall operate continuously;
COMBUSTION AND VENTILATION AIR REQUIREMENTS
e. Test for draft hood equipped appliance spillage at the
draft hood relief opening after 5 minutes of main burner
operation. Use the flame of a match or candle;
f. 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
burning appliance to their previous conditions of use;
WARNING
TO AVOID PROPERTY DAMAGE, PERSONAL INJURY OR DEATH,
SUFFICIENT FRESH AIR FOR PROPER COMBUSTION AND VENTILATION OF
FLUE GASES MUST BE SUPPLIED. MOST HOMES REQUIRE OUTSIDE AIR BE
SUPPLIED INTO THE FURNACE AREA.
Improved construction and additional insulation in buildings have
reduced heat loss by reducing air infiltration and escape around
doors and windows. These changes have helped in reducing
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EXTERIOR MASONRY CHIMNEYS - CATEGORY I FURNACES ONLY
heating/cooling costs but have created a problem supplying
combustion and ventilation air for gas fired and other fuel burn-
ing appliances. Appliances that pull air out of the house (clothes
dryers, exhaust fans, fireplaces, etc.) increase the problem by
starving appliances for air.
MINIMUM VENT
MODEL UPFLOW COUNTERFLOW
70
90
115
4 inch
4 inch
5 inch
4 inch
4 inch
4 inch
House depressurization can cause back drafting or improper
combustion of gas-fired appliances, thereby exposing building
occupants to gas combustion products that could include car-
bon monoxide.
Under some conditions, larger vents than those shown above
may be required or allowed. When an existing furnace is re-
moved from a venting system serving other appliances, the
venting system may be too large to properly vent the remaining
attached appliances.
If this furnace is to be installed in the same space with other
gas appliances, such as a water heater, ensure there is an
adequate supply of combustion and ventilation air for the other
appliances. Refer to the latest edition of the National Fuel Gas
Code NFPA 54/ANSI Z223.1 or CAN/CSA B149 Installation
Codes or applicable provisions of the local building codes for
determining the combustion air requirements for the appliances.
Upflow or Horizontal units are shipped with the induced draft
blower discharging from the top of the furnace. (“Top” is as
viewed for an upflow installation.) The induced draft blower can
be rotated 90 degrees for Category I venting. For horizontal
installations, a four inch single wall pipe can be used to extend
the induced draft blower outlet 1/2” beyond the furnace cabinet.
THIS PRODUCT IS NOT DESIGNED FOR COUNTERCLOCK-
WISE INDUCED DRAFT BLOWER ROTATION.
This furnace must use indoor air for combustion. It cannot be
installed as a direct vent (i.e., sealed combustion) furnace.
Most homes will require outside air be supplied to the furnace
area by means of ventilation grilles or ducts connecting directly
to the outdoors or spaces open to the outdoors such as attics
or crawl spaces.
Vent the furnace in accordance with the National Fuel Gas
Code NFPA 54/ANSI Z223.1 - latest edition. In Canada, vent
the furnace in accordance with the National Standard of Canada,
CAN/CSA B149.1 and CAN/CSA B149.2 - latest editions and
amendments.
CATEGORY I VENTING (VERTICAL VENTING)
Venting
WARNING
THIS FURNACE IS NOT DESIGN CERTIFIED TO BE HORI-
ZONTALLYVENTED.
TO PREVENT POSSIBLE PERSONAL INJURY OR DEATH DUE TO
ASPHYXIATION, THIS FURNACE MUST BE CATEGORY
VENT USING CATEGORY III VENTING.
I
VENTED. DO NOT
To rotate the induced draft blower clockwise, you will need to
purchase one (0270F01119) chimney transition bottom kit.
1. Disconnect electrical power from the furnace.
2. Disconnect the induced draft blower power leads, flue
pipe, and pressure switch tubing.
3. Remove the round cutout from the right side of the wrapper.
4. Remove and save the four screws that fasten the induced
draft blower to the flue collector box.
5. Remove and save the three screws that hold the chimney
assembly to the induced draft blower.
6. Remove and save the four screws that fasten the chimney
top to the chimney bottom.
7. Remove the chimney transition bottom from the transition
bottom kit.
8. Install the chimney top with the four screws retained
from step 6 onto the new chimney transition bottom from
the transition bottom kit.
Category I Venting is venting at a non-positive pressure. A
furnace vented as Category I is considered a fan-assisted ap-
pliance and the vent system does not have to be “gas tight.”
NOTE: Single stage gas furnaces with induced draft blowers
draw products of combustion through a heat exchanger allow-
ing, in some instances, common venting with natural draft ap-
pliances (i.e. water heaters).All installations must be vented in
accordance with National Fuel Gas Code NFPA54/ANSI Z223.1
- latest edition. In Canada, the furnaces must be vented in ac-
cordance with the National Standard of Canada, CAN/CSA
B149.1 and CAN/CSA B149.2 - latest editions and amendments.
NOTE: The vertical height of the Category I venting system
must be at least as great as the horizontal length of the venting
system.
WARNING
9. Install chimney assembly with the three screws retained
from step 5 onto the induced draft blower.
TO PREVENT POSSIBLE PERSONAL INJURY OR DEATH DUE TO
ASPHYXIATION, COMMON VENTING WITH OTHER MANUFACTURER’S
INDUCED DRAFT APPLIANCES IS NOT ALLOWED.
10. Reinstall the induced draft blower rotating it 90 degrees
clockwise from the original upflow configuration using
the four screws retained in step 3. Ensure the gasket
located between the induced draft blower and the collector
box is rotated accordingly.
The minimum vent diameter for the Category I venting system
is as shown:
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EXTERIOR MASONRY CHIMNEYS - CATEGORY I FURNACES ONLY
Wash
11. Reconnect the induced draft blower power leads. NOTE:
If the wires are not long enough, pull extra wire from the
wire bundle in the blower compartment.
Roof Line
Clay Tile Size: 8" x 8" x12"
(Each x 24" Length)
12. Reconnect the flue pipe, and the pressure switch tubing.
Ensure that all wires and the pressure switch tubing is
at least one inch from the flue pipe, or any other hot
surface.
Attic Floor
1/2" to 1" Air Space
13. Restore power to furnace.
Counterflow units are shipped with the induced draft blower
discharging from the top of the furnace. (“Top” as viewed for a
counterflow installation.)
Second Floor
Throat
Damper
Vent the furnace in accordance with the National Fuel Gas
Code NFPA54/ANSI Z223.1-latest edition. In Canada, vent the
furnace in accordance with the national standard of Canada,
CAN/CSA B149.1 and CAN/CSA B149.2- latest editions and
amendments.
First Floor
Water Heater
Vent Connector
F.A.F. Vent
Connector
Breech
Natural Draft
Water Heater
Fan Assisted
Forced Air
Furnace
Clean Out
Basement Floor
WARNING
Typical Multiple Flue Clay Tile Chimney
CHECKLIST SUMMARY
NEVER ALLOW THE PRODUCTS OF COMBUSTION, INCLUDING CARBON
MONOXIDE, TO ENTER THE RETURN DUCTWORK OR CIRCULATION AIR
SUPPLY.
This checklist serves as a summary of the items to be checked
before venting an 80+ furnace into a masonry chimney. In addi-
tion, we recommend that a qualified serviceman use this check-
list to perform a yearly inspection of the furnace venting sys-
tem.
E
XTERIORMASONRYCHIMNEYS (CATEGORYIFURNACESONLY
)
An exterior masonry chimney is defined as a “Masonry” chim-
ney exposed to the outdoors on one or more sides below the
roof line.” The ability to use a clay lined masonry chimney
depends on a parameter not associated with interior chimneys.
This variable is the geographic location of the installation. Re-
searchers have discovered that the winter design temperatures
have a direct impact on the suitability of this type of venting. In
most situations, the existing masonry chimneys will require a
properly sized metallic liner.
This checklist is only a summary. For detailed information on
each of the procedures mentioned, see the paragraph refer-
enced with each item.
This inspection is based upon a draft topical report, “Masonry
Chimney Inspection and Relining”, issued by the Gas Research
Institute. While not yet finalized, we believe this report repre-
sents the best information on this subject which is currently
available.
WARNING
POSSIBILITY OF PROPERTY DAMAGE, PERSONAL INJURY OR DEATH
DAMAGING CONDENSATION CAN OCCUR INSIDE MASONRY CHIMNEYS
WHEN A SINGLE FAN‐ASSISTED CATEGORY APPLIANCE (80% AFUE
I
FURNACE) IS VENTED WITHOUT ADEQUATE DILUTION AIR. DO NOT
CONNECT AN 80% FURNACE TO A MASONRY CHIMNEY UNLESS THE
FURNACE IS COMMON VENTED WITH A DRAFT HOOD EQUIPPED
APPLIANCE OR THE CHIMNEY IS LINED WITH A METAL LINER OR TYPE
B
METAL VENT. ALL INSTALLATIONS USING MASONRY CHIMNEYS MUST BE
SIZED IN ACCORDANCE WITH THE APPROPRIATE VENTING TABLES. IF AN
80% FURNACE IS COMMON VENTED WITH A DRAFT HOOD EQUIPPED
APPLIANCE, THE POTENTIAL FOR CONDENSATION DAMAGE MAY STILL
EXIST WITH EXTREMELY COLD CONDITIONS, LONG VENT CONNECTORS,
EXTERIOR CHIMNEYS, OR ANY COMBINATION OF THESE CONDITIONS.
THE RISK OF CONDENSATION DAMAGE IS BEST AVOIDED BY USING
MASONRY CHIMNEY AS A PATHWAY FOR PROPERLY SIZED METAL LINER
OR TYPE
B
METAL VENT.
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EXTERIOR MASONRY CHIMNEYS - CATEGORY I FURNACES ONLY
If the chimney does not meet these termination requirements,
Proper Chimney
Termination?
(Check 1)
but all other requirements in the checklist can be met, it may
be possible for a mason to extend the chimney. If this will not
be practical, see Fix 1.
10' or Less
2' Min.
2' Min.
3' Min.
Chimney channel
free of solid and
liquid fuel
Change venting
arrangements
(Fix 2)
appliances?
(Check 2)
Wall or
Parapet
Chimney
10' or Less
Rebuild crown
(Fix 3)
and/or Reline
(Fix 4)
Crown in good
condition
(Check 3)
2' Min.
3' Min.
Cleanout free of
debris?
Reline
(Fix 4)
Chimney
(Check 4)
Termination 10 Feet Or Less From Ridge, Wall or Parapet
More than 10’
Liner in good
condition?
(Check 5)
Reline
(Fix 4)
3’ Min.
NOTE: No Height
above parapet
required when distance
from walls or parapet is
more than 10 feet.
Chimney
Wall or
Parapet
Dilution air
available?
(Check 6)
Reline
(Fix 4)
More than 10’
10’
Height above any
roof surface within
10 feet horizontally.
Ridge
Complete the
installation.
(Check 7)
2” Min.
3’ Min.
CHECK 1 -PROPER CHIMNEY TERMINATION.
Chimney
A masonry chimney used as a vent for gas fired equipment
must extend at least three feet above the highest point where it
passes through the roof. It must extend at least two feet higher
than any portion of a building within a horizontal distance of 10
feet. In addition, the chimney must terminate at least 3 feet
above any forced air inlet located within 10 feet. The chimney
must extend at least five feet above the highest connected equip-
ment draft hood outlet or flue collar.
Termination More Than 10 Feet From Ridge, Wall or Parapet
CHECK 2-ANY SOLID OR LIQUID FUEL APPLIANCES VENTED
INTO THIS CHIMNEY CHANNEL
Solid fuel appliances include fireplaces, wood stoves, coal fur-
naces, and incinerators.
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EXTERIOR MASONRY CHIMNEYS - CATEGORY I FURNACES ONLY
Liquid fuel appliances include oil furnaces, oil-fired boilers and Next, use a flashlight and small mirror to sight up the liner. B
oil-fired water heaters.
vent must be supported so as to not come into direct contact
with the chimney walls or tile liner. If it is not, it can probably be
rehung so as to be acceptable. A thimble or fire stop may be
helpful here.
Appliances which burn propane (sometimes referred to as LP
(liquefied petroleum)) gas are considered gas-fired appliances.
CHECK 3-CHIMNEY CROWN CONDITION.
Flexible liners should be hung straight or nearly straight. If it is
spiraled in the chimney and in good condition, it should be
rehung. To do this, break the top seal; pull up and cut off the
excess liner length, and refit the top seal. Use caution when
doing this, as the cut edges of flexible liners may be sharp.
Damage from condensate usually shows up first in the crown.
If any of the following trouble signs are present, the condition of
the crown is not satisfactory:
a) Crown leaning
b) Bricks missing
c) Mortar missing
d) Tile liner cracked
e) No tile liner
f) Salt staining at mortar joints. (White stains, and mortar
becomes sandy and/or erodes.)
The surfaces of the liner must be physically sound. If gaps or
holes are present, the metal liner must be removed and re-
placed (Fix 4). Finally, confirm that the metal liner is the cor-
rect size for the appliances to be installed. Use the GAMA
tables and rules.
If a metal liner is not present, a clay tile liner must be present,
or the chimney must be lined (Fix 4).
For problems a, b, or c, see Fix 3. If problems d, e, or f are
present, see Fix 4. IMPORTANT: It may be necessary to follow
both Fix 3 and Fix 4.
Use a flashlight and small mirror at the cleanout or vent con-
nector to inspect the clay tile liner. If any of the following prob-
lems are present:
CHECK 4-DEBRIS IN CLEANOUT.
•
•
•
•
Tile sections misaligned
A cleanout (dropleg) must be present such that the upper edge
of the cleanout cover is at least 12 inches below the lower edge
of the lowest chimney inlet opening.
Tile sections missing
Gaps between tile sections
Signs of condensate drainage at the cleanout or vent
connectors
A chimney without a cleanout could become partially blocked
by debris. If no cleanout is present, the chimney must be re-
lined (Fix 4). Remove the cleanout cover, and examine the
cleanout for debris. If significant amounts of any of the following
are found:
•
•
Mortar protruding from between tile sections
Use of sewer pipe or drainage pipe rather than an
approved fire clay tile reline the chimney (Fix 4).
•
•
•
•
•
Fuel oil residue
Bricks
Mortar or sand
Pieces of the tile liner
Rusted pieces of the metallic liner - reline the chimney
(Fix 4).
Next, measure the size of the liner. It may be possible to do
this from the cleanout. The liner must be at least as large as
the minimum size established by the tables in National Fuel
Gas Code NFPA 54/ANSI Z223.1 - latest edition and in the
National Standard of Canada, CAN/CSAB149.1 and CAN/CSA
B149.2 - latest editions and amendments. If the liner is too
small or too large, then the chimney must be relined (Fix 4).
CHECK 5-LINER CONDITION.
CHECK 6-DILUTION AIR.
If a metal liner is present, it must be checked. It cannot be
assumed that all existing metal liners are correctly installed
and in good condition.
If gas-fired appliances are to be vented into a clay tile liner, a
source of dilution air is required.
Remove the lowest existing vent connector, and examine the
inside of the elbow or tee at the base of the liner.Asmall amount
of soot may be considered acceptable, provided the installer
vacuums it away. If rusted pieces of the liner have collected
here, the metal liner must be removed and replaced (Fix 4).
Dilution air cannot be obtained through:
•
•
Induced draft appliances
Natural draft appliances with vent dampers
Sufficient dilution air can ordinarily be obtained through the draft
hood of a natural draft appliance only if the appliance’s vent
connector does not include a vent damper. If dilution air will not
be available, the chimney must be relined (Fix 4).
Next, gently tap the inside of the liner with a Phillips screw-
driver. If the screwdriver perforates the liner, or if the tapping
does not sound like metal hitting metal, the liner must be re-
moved and replaced (Fix 4).
CHECK 7-COMPLETE THE INSTALLATION.
Remember that all appliances must be vented inside the liner.
Venting one appliance inside the liner and another appliance
outside the liner is not acceptable.
If Checks 1 through 6 have been satisfactory, and the liner is an
acceptable size as determined by the tables in National Fuel
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ELECTRICAL CONNECTIONS
Gas Code NFPA 54/ANSI Z223.1 - latest edition and in the
National Standard of Canada, CAN/CSAB149.1 and CAN/CSA
B149.2 - latest editions and amendments, then the clay tile
liner can probably be used as a vent for the gas appliances.
However, the installer must keep in mind the following factors
which may render the tile liner unsuitable for use as a vent:
FIX 3-REBUILD THE CROWN
If the chimney crown is damaged, a qualified mason must re-
pair it in accordance with nationally recognized building codes
or standards. One such standard which may be referenced is
the Standard for Chimneys, Fireplaces, Vents, and Solid Fuel
BurningAppliances,ANSI/NFPA211.
•
•
•
Extremely cold weather
Long vent connectors
FIX 4-RELINING
Masonry chimneys with no air gap between the liner
and the bricks. (In practice, this can be difficult to
detect.)
Relining options include B vent and flexible liners.
If the chimney has diagonal offsets, B vent probably cannot be
used.
•
Exterior chimneys (The tables in National Fuel Gas
Code NFPA54/ANSI Z223.1 - latest edition and in the
National Standard of Canada, CAN/CSAB149.1 and
CAN/CSA B149.2 - latest editions and amendments
assume interior chimneys.)
If B vent is to be used, it must be supported adequately. Sup-
ports (such as fire stops or thimbles) must be used to prevent
the B vent from coming into direct contact with the tile liner or
chimney walls. Direct contact would result in higher heat loss,
with an increased possibility of poor venting system perfor-
mance.
If, in the judgment of the local gas utility, installer, and/or local
codes; one or more of the above factors is likely to present a
problem, the chimney must be relined (Fix 4).
It is not acceptable to vent one appliance inside the B vent and
other appliances outside. The excess space between the B
vent and the chimney walls must be covered at the top of the
chimney by a weatherproof, corrosion resistant flashing.
FIX 1-LINER TERMINATION
Any cap or roof assembly used with a liner must be approved
by the liner manufacturer for such use. The liner and cap/roof
assembly must then terminate above the roof in accordance
with the manufacturer’s instructions.
The B vent should then be topped with a listed vent cap. The
listed vent cap will, when installed per the manufacturer’s in-
structions, prevent problems due to rain, birds, or wind effects.
In some cases, a shorter extension above the roof may be
possible with a liner than would be required with a masonry
chimney.
A B-vent installed as described in this section is considered to
be an enclosed vent system, and the sizing tables in National
Fuel Gas Code NFPA 54/ANSI Z223.1 - latest edition and in
the National Standard of Canada, CAN/CSAB149.1 and CAN/
CSA B149.2 - latest editions and amendments may be used.
For further information on relining, see Fix 4.
FIX 2-CHANGEVENTING ARRANGEMENTS
If a flexible liner is to be used, it must be made of the proper
materials:
If the masonry chimney has more than one channel, it may be
possible to vent the gas appliances into one channel and vent
the solid or liquid fuel appliance(s) into another channel(s). Do
not vent an 80+ Furnace inside of a metal liner with other appli-
ances vented outside the liner.
•
For most residential applications, an aluminum liner
should be acceptable.
•
If the combustion air supplied to the furnace will be
contaminated with compounds containing chlorine or
fluorine, a liner of AL 29-4C stainless steel should be
used. Common sources of chlorine and fluorine
compounds include indoor swimming pools and
chlorine bleaches, paint strippers, adhesives, paints,
varnishes, sealers, waxes (which are not yet dried)
and solvents used during construction and remodeling.
Various commercial and industrial processes may also
be sources of chlorine/fluorine compounds.
Alternatively, the homeowner may agree to discontinue use of
the fireplace (solid fuel appliance). If so, the tile liner must be
cleaned to remove creosote buildup. The fireplace opening must
then be permanently sealed.
If oil-fired appliance(s) are being replaced by gas-fired
appliance(s), the tile liner must first be cleaned to remove the
fuel oil residue.
•
Heavier gauge 300 and 400 series stainless steel liners
were developed for use with oil or solid fuel appliances.
They are not suitable for use with gas-fired appliances.
Flexible liners specifically intended and tested for gas
applications are listed in the UL “Gas and Oil
Equipment Directory”. (ULStandard 1777).
If none of the above options is practical, the furnace may need
to be vented vertically with a B Vent.
Under some conditions, a 90%+ furnace could be installed rather
than an 80% furnace. The 90%+ furnace can be vented hori-
zontally or vertically through PVC pipe.
For sizing of flexible liners, see Note 22 and the tables in the
National Fuel Gas Code NFPA54/ANSI Z223.1 - latest edition
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ELECTRICAL CONNECTIONS
and in the National Standard of Canada, CAN/CSAB149.1 and
CAN/CSA B149.2 - latest editions and amendments.
WARNING
HIGH VOLTAGE !
To install the liner, read and follow the liner manufacturer’s in-
structions and your local codes. Excess liner length should be
pulled out of the chimney and cut off. Use caution when doing
this, as the cut edges of flexible liners may be sharp. Do not
spiral excess liner inside of the chimney. Support the liner as
recommended by the liner manufacturer.
TO AVOID THE RISK OF INJURY, ELECTRICAL SHOCK OR
DEATH, THE FURNACE MUST BE ELECTRICALLY
GROUNDED IN ACCORDANCE WITH LOCAL CODES OR IN
THEIR ABSENCE, WITH THE LATEST EDITION OF THE
NATIONAL ELECTRIC CODE.
Some manufacturers of flexible liners offer an insulation sleeve
designed to be added to the liner before it is installed in the
WIRINGHARNESS
chimney. (Poured insulation, either vermiculite or other materi- The wiring harness is an integral part of this furnace. Field
als, is no longer recommended.) Insulation will need to be added alteration to comply with electrical codes should not be re-
to the flexible liner if:
quired. Wires are color coded for identification purposes. Re-
fer to the wiring diagram for wire routings. If any of the original
wire as supplied with the furnace must be replaced, it must be
replaced with wiring material having a temperature rating of at
least 105° C. Any replacement wiring must be a copper con-
ductor.
•
It is required by the liner manufacturer’s instructions.
•
The previous liner was properly sized and installed,
and suffered from condensation damage.
•
It is required by your local building codes.
Even if none of those three conditions exist which require addi-
tional liner insulation, the installer may wish to consider it if:
115VOLT LINE CONNECTIONS
•
•
•
The local climate is very cold.
The chimney is very tall.
The vent connectors used are very long or have a large
number of elbows.
Local experience indicates that flexible liners installed
without insulation are likely to have condensation
problems.
Before proceeding with electrical connections, ensure that the
supply voltage, frequency, and phase correspond to that speci-
fied on the unit rating plate. Power supply to the furnace must
be NEC Class 1, and must comply with all applicable codes.
The furnace must be electrically grounded in accordance with
local codes or, in their absence, with the latest edition of The
National Electric Code, ANSI NFPA 70 and/or The Canadian
Electric Code CSA C22.1.
•
Insulation must be selected and installed in accordance with
the liner manufacturer’s instructions.
Use a separate fused branch electrical circuit containing prop-
erly sized wire, and fuse or circuit breaker. The fuse or circuit
breaker must be sized in accordance with the maximum over-
current protection specified on the unit rating plate. An electri-
cal disconnect must be provided at the furnace location.
Finally, cap the chimney and terminate the liner in accordance
with the liner manufacturer’s instructions.
ELECTRICAL CONNECTIONS
Connect hot, neutral, and ground wires as shown in the wiring
diagram located on the unit’s blower door.
WARNING
Line polarity must be observed when making field connections.
Line voltage connections can be made through either the right
or left side panel. The furnace is shipped configured for a right
side electrical connection with the junction box located inside
the burner compartment (blower compartment for downflows).
To make electrical connections through the opposite side of
the furnace, the junction box must be relocated to the other
side of the burner (or blower) compartment prior to making
electrical connections. To relocate the junction box, follow the
steps shown below.
HIGH VOLTAGE !
TO AVOID THE RISK OF ELECTRICAL SHOCK, WIRING TO
THE UNIT MUST BE POLARIZED AND GROUNDED.
WARNING
HIGH VOLTAGE !
TO AVOID PERSONAL INJURY OR DEATH DUE TO
ELECTRICAL SHOCK, DISCONNECT ELECTRICAL POWER
BEFORE SERVICING OR CHANGING ANY ELECTRICAL
WIRING.
NOTE: Wire routing must not to interfere with circulator blower
operation, filter removal, or routine maintenance.
CAUTION
LABEL ALL WIRES PRIOR TO DISCONNECTION WHEN SERVICING
CONTROLS. WIRING ERRORS CAN CAUSE IMPROPER AND DANGEROUS
OPERATION. VERIFY PROPER OPERATION AFTER SERVICING.
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ELECTRICAL CONNECTIONS
To ensure proper unit grounding, the ground wire should run
from the furnace ground screw located inside the furnace junc-
tion box all the way back to the electrical panel. NOTE: Do
not use gas piping as an electrical ground. To confirm proper
unit grounding, turn off the electrical power and perform the
following check.
JUNCTION BOX RELOCATION
WARNING
EDGES OF SHEET METAL HOLES MAY BE SHARP. USE GLOVES AS A
PRECAUTION WHEN REMOVING HOLE PLUGS.
1. Measure resistance between the neutral (white)
connection and one of the burners.
2. Resistance should measure 10 ohms or less.
Line voltage connections can be made through either the right
or left side panel. The furnace is shipped configured for a right
side electrical connection. To make electrical connections
through the opposite side of the furnace, the junction box must
be relocated to the left side prior to making electrical connec-
tions. To relocate the junction box, perform the following steps.
This furnace is equipped with a blower door interlock switch
which interrupts unit voltage when the blower door is opened for
servicing. Do not defeat this switch.
24VOLT THERMOSTAT WIRING
IMPORTANT NOTE
WARNING
TO PREVENT PERSONAL INJURY OR DEATH DUE TO ELECTRIC SHOCK,
DISCONNECT ELECTRICAL POWER BEFORE INSTALLING OR SERVICING THIS
UNIT.
WIRE ROUTING MUST NOT INTERFERE WITH CIRCULATOR BLOWER
OPERATION, FILTER REMOVAL OR ROUTINE MAINTENANCE.
A
REMOVABLE PLUG CONNECTOR IS PROVIDED WITH THE CONTROL TO
1. Remove both doors from the furnace.
2. Remove and save the screws holding the junction box to
the right side of the furnace.
3. Models that have the junction box located in the burner
or blower compartment will need to move the junction
box directly over.
4. Attach the junction box to the left side of the furnace,
using the screws removed in step 2.
5. Check the location of the wiring. Confirm that it will not
be damaged by heat from the burners or by the rotation
of the fan. Also confirm that wiring location will not
interfere with filter removal or other maintenance.
MAKE THERMOSTAT WIRE CONNECTIONS. THIS PLUG MAY BE REMOVED,
WIRE CONNECTIONS MADE TO THE PLUG, AND REPLACED. IT IS
STRONGLY RECOMMENDED THAT MULTIPLE WIRES INTO A SINGLE
TERMINAL BE TWISTED TOGETHER PRIOR TO INSERTING INTO THE PLUG
CONNECTOR. FAILURE TO DO SO MAY RESULT IN INTERMITTENT
OPERATION.
As a two-stage non-communicating furnace, the furnace inte-
grated control module provides terminals for both “W1” and “W2”,
and “Y1” and “Y2” thermostat connections. This allows the
furnace to support the following system applications: ‘Two-
Stage Heating Only’, ‘Two-Stage Heating with Single Stage Cool-
ing’, and ‘Two-Stage Heating with Two-Stage Cooling’. Refer to
the following figures for proper connections to the integrated
control module.
After the junction box is in the desired location, use washers to
connect field-supplied conduit to the junction box in accordance
with NEC and local codes. Connect hot, neutral, and ground
wires as shown in the furnace wiring diagram. The wires and
ground screw are located in the furnace junction box.
Low voltage connections can be made through either the right
or left side panel. Thermostat wiring entrance holes are located
in the blower compartment. The following figure shows con-
nections for a “heat/cool system”.
NOTE: In downflow applications the power leads should be
routed through the supplied wire tabs when locating junction
box to the left side.
This furnace is equipped with a 40 VA transformer to facilitate
use with most cooling equipment. Consult the wiring diagram,
located on the blower compartment door, for further details of
115 Volt and 24 Volt wiring.
Low voltage wires may be connected to the terminal strip.
IMPORTANT NOTE: To avoid possible equipment malfunction,
route the low voltage wires to avoid interference with filter re-
moval or other maintenance.
NOTE: For single stage cooling applications, a jumper must
be located between Y1 and Y2 at the furnace control in order
to achieve the desired single stage cooling airflow. Use of
ramping profiles and dehumidification features require a
jumper between Y1 and O and Y1 and DEHUM, respectively.
WARNING
HIGH VOLTAGE !
TO AVOID THE RISK OF INJURY, ELECTRICAL SHOCK OR
DEATH, THE FURNACE MUST BE ELECTRICALLY
GROUNDED IN ACCORDANCE WITH LOCAL CODES OR IN
THEIR ABSENCE, WITH THE LATEST EDITION OF THE
NATIONAL ELECTRIC CODE.
NOTE:Thermostat“R”requiredifoutdoorunitisequipped
with a Comfort Alert™ module or if the out door unit is a part
of the ComfortNet™ family of equipment AND is wired as a
legacy system.
16
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ELECTRICAL CONNECTIONS
DIP switch to the desired ON/OFF position. Turn power back
on. Refer to the following figure.
Thermostat
Single Stage Heating with
Single Stage Cooling
R
R
OFF
ON
Move to the ON position
to select two-stage
thermostat or OFF to
select single stage
thermostat
Heat OFF Delay
DIP Switches
Furnace Integrated
Control Module
3
4
NEU
Thermostat
Stage Delay
Y
C
Dehumidistat
[Optional]
Move to the ON position
to select Auto transition
delay or OFF for 5 minute
transition delay
Remote
Condensing Unit
(Single-Stage Cooling)
S1
Single Stage Heating with Single Stage Cooling
24VOLT DEHUMIDISTAT WIRING
NOTE: To apply a single-stage Heating Thermostat,
the thermostat selector switch on the
Integrated Control Module must be set on
single-stage.
The optional usage of a dehumidistat allows the furnace’s
circulator blower to operate at a slightly lower speed (85%
of desired speed) during a combined thermostat call for cool-
ing and dehumidistat call for dehumidification. This can be
done through an independent dehumidistat or through a
thermostat’s DEHUM terminal (if available). This lower blower
speed enhances dehumidification of the conditioned air as
it passes through the AC coil. For proper function, a dehu-
midistat applied to this furnace must operate on 24 VAC
and utilize a switch which opens on humidity rise. Refer to
the “Thermostat Wiring Diagrams” figure for additional wir-
ing details.
Thermostat
Two-Stage Heating
with
R
R
Single-Stage Cooling
Furnace Integrated
Control Module
NEU
Y
C
Dehumidistat
[Optional]
Remote
Condensing Unit
(Single-Stage Cooling)
To install/connect a dehumidistat:
1. Turn OFF power to furnace.
Two-Stage Heating with Single-Stage Cooling
2. Secure the dehumidistat neutral wire (typically the
white lead) to the terminal marked “DEHUM” on the
furnace integrated control module.
3. Secure the dehumidistat hot wire (typically the black
lead) to the terminal marked “R” on the furnace
integrated control module.
4. Secure the dehumidistat ground wire (typically the
green lead) to the ground screw on the furnace junction
box. NOTE: Ground wire may not be present on all
dehumidistats.
Thermostat
Two-Stage Heating
Y2
W1 W2
with
( )
Two-Stage Cooling
Furnace Integrated
Y2
Y2
W1 W2
Control Module
NEU
Dehumidistat
[Optional]
Remote
Condensing Unit
(Two-Stage Cooling)
Two-Stage Heating with Two-Stage Cooling
5. Turn ON power to furnace.
Thermostat Wiring Diagrams
To enable the dehumidify function on the integrated control
module, set the dehumidification ENABLE dipswitch from
OFF to ON.
SINGLE-STAGE HEATING THERMOSTAT APPLICATION
A single-stage thermostat with only one heating stage may be
used to control this furnace. The application of a single-stage
thermostat offers a timed transition from low to high fire. The
furnace will run on low stage for a fixed period of time before
stepping up to high stage to satisfy the thermostat’s call for
heat. The delay period prior to stepping up can be set at either
a fixed 5 minute time delay or a load based variable time be-
tween 1 and 12 minutes (AUTO mode). If the AUTO mode is
selected, the control averages the cycle times of the previous
three cycles and uses the average to determine the time to
transition from low stage to high stage.
Once the switch is set, the dehumidify function is enabled
during a combination call for cooling (T-Stat) and dehumidi-
fication (DEHUM-Stat).
OFF ON
9
DEHUM
Unused
Move to the ON position
to enable dehumidification
10
S5
FOSSIL FUEL APPLICATIONS
This furnace can be used in conjunction with a heat pump in
a fossil fuel application. Afossil fuel application refers to a
combined gas furnace and heat pump installation which uses
an outdoor temperature sensor to determine the most cost
efficient means of heating (heat pump or gas furnace).
To use a single-stage thermostat, turn off power to the furnace,
move the thermostat selection DIP switch to the OFF position.
Set the desired transition time by setting the transition delay
17
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GAS SUPPLY AND PIPING
A heat pump thermostat with three stages of heat is required to to all local codes, and have a minimum temperature rating of
properly use a two-stage furnace in conjunction with a heat 105°C. All line voltage wire splices must be made inside the
pump. Refer to the fossil fuel kit installation instructions for furnace junction box.
additional thermostat requirements.
The integrated control module humidifier terminals (HUM) are
Strictly follow the wiring guidelines in the fossil fuel kit installa- energized with 115 volts whenever the induced draft blower is
tion instructions. All furnace connections must be made to the energized. The integrated control module electronic air cleaner
furnace two-stage integrated control module and the “FUR- terminals (EAC) are energized with 115 volts whenever the cir-
NACE” terminal strip on the fossil fuel control board.
culator blower is energized.
115VOLT LINE CONNECTION OF ACCESSORIES (HUMIDIFIER 24VOLT HUMIDIFIER
AND ELECTRONICAIR CLEANER)
A 5" long brown wire in the wire harness at the low fire pressure
switch provides 24 VAC humidifier control. This wire is pow-
ered any time the pressure switch is closed. To connect 24
VAC HUM, connect the 24 VAC line of the humidifier to the 5”
brown wire. The connection can be made by either stripping
the wire and using a wire nut or by using a field supplied quick
connect terminal. The wiring must conform to all local and
national codes. Connect the COM side of the humidifier to the
C terminal on the furnace control board (or to the COM side of
the 24 VAC transformer). Do not connect 115V humidifier to
these terminals.
WARNING
HIGH VOLTAGE !
TO AVOID PERSONAL INJURY OR DEATH DUE TO
ELECTRICAL SHOCK, DISCONNECT ELECTRICAL POWER
BEFORE SERVICING OR CHANGING ANY ELECTRICAL
WIRING.
The furnace integrated control module is equipped with line
voltage accessory terminals for controlling power to an optional
field-supplied humidifier and/or electronic air cleaner.
GAS SUPPLY AND PIPING
The accessory load specifications are as follows:
The furnace rating plate includes the approved furnace gas in-
put rating and gas types. The furnace must be equipped to
operate on the type of gas applied. This includes any conver-
sion kits required for alternate fuels and/or high altitude.
Humidifier
Electronic Air Cleaner
1.0 Amp maximum at 120 VAC
1.0 Amp maximum at 120 VAC
Turn OFF power to the furnace before installing any accesso-
ries. Follow the humidifier or air cleaner manufacturers’ in-
structions for locating, mounting, grounding, and controlling
these accessories. Accessory wiring connections are to be
made through the 1/4" quick connect terminals provided on the
furnace integrated control module. The humidifier and elec-
tronic air cleaner hot terminals are identified as HUM and EAC.
The humidifier and electronic air cleaner neutral terminals are
identified as NEUTRAL. All field wiring must conform to appli-
cable codes. Connections should be made as shown.
CAUTION
TO PREVENT UNRELIABLE OPERATION OR EQUIPMENT DAMAGE, THE
INLET GAS SUPPLY PRESSURE MUST BE AS SPECIFIED ON THE UNIT
RATING PLATE WITH ALL OTHER HOUSEHOLD GAS FIRED APPLIANCES
OPERATING.
Inlet gas supply pressures must be maintained within the ranges
specified in the following table. The supply pressure must be
constant and available with all other household gas fired appli-
ances operating. The minimum gas supply pressure must be
maintained to prevent unreliable ignition. The maximum must
not be exceeded to prevent unit overfiring.
Inlet Gas Supply Pressure
Natural Gas
Propane Gas
Minimum: 5.0" w.c. Maximum:10.0" w.c.
Minimum: 11.0" w.c. Maximum:13.0" w.c.
NOTE: Adjusting the minimum supply pressure below the limits
in the above table could lead to unreliable ignition. Gas input to
the burners must not exceed the rated input shown on the
rating plate. Overfiring of the furnace can result in premature
heat exchanger failure. Gas pressures in excess of 13 inches
water column can also cause permanent damage to the gas
valve.
Accessories Wiring
At all altitudes, the manifold pressure must be within 0.3 inches
w.c. of that listed in the Specification Sheet applicable to your
model for the fuel used.At all altitudes and with either fuel, the
If it is necessary for the installer to supply additional line volt-
age wiring to the inside of the furnace, the wiring must conform
18
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CIRCULATING AIR AND FILTERS
air temperature rise must be within the range listed on the fur-
nace nameplate. Should this appliance be converted to LP,
refer to the instructions included in the factory authorized LP
conversion kit.
GAS PIPING CONNECTIONS
WARNING
TO AVOID POSSIBLE UNSATISFACTORY OPERATION OF EQUIPMENT
DAMAGE DUE TO UNDERFIRING OR EQUIPMENT, USE THE PROPER SIZE
OF NATURAL/PROPANE GAS PIPING NEEDED WHEN RUNNING PIPE FROM
THE METER/TANK TO THE FURNACE.
HIGH ALTITUDE DERATE
IMPORTANT NOTE: The furnace will naturally derate itself with
altitude. Do not attempt to increase the firing rate by changing
orifices or increasing the manifold pressure. This can cause
poor combustion and equipment failure.
When sizing a trunk line, be sure to include all appliances
which will operate simultaneously.
High altitude installations may require both a pressure switch
and an orifice change. These changes are necessary to com-
pensate for the natural reduction in the density of both the gas
fuel and the combustion air at higher altitude.
The gas piping supplying the furnace must be properly sized
based on the gas flow required, specific gravity of the gas, and
length of the run. The gas line installation must comply with
local codes, or in their absence, with the latest edition of the
National Fuel Gas Code, NFPA54/ANSI Z223.1.
For installations above 7000 feet, please refer to your distribu-
tor for required kit(s).
Natural Gas Capacity of Pipe
In Cubic Feet of Gas Per Hour (CFH)
Manifold Pressure
Pressure
Switch Change
Gas Altitude
Kit
Orifice
#43
Length of
Pipe in Feet
Nominal Black Pipe Size
High Stage Low Stage
1/2"
132
92
73
63
56
50
46
43
40
38
3/4"
1"
1 1/4"
1 1/2"
1600
1100
980
Natural
None
3.5" w.c.
1.9" w.c.
None
10
20
30
40
50
60
70
80
90
100
278
190
152
130
115
105
96
520
350
285
245
215
195
180
170
160
150
1050
730
590
500
440
400
370
350
320
305
LPM-05*1
LPM-06*2
0-7000
Propane
#55
10.0" w.c.
6.0" w.c.
None
760
1 LPM-05* supports White-Rodgers 2-stage valve only
2 LPM-06* supports Honeywell and White-Rodgers 2-stage valves
In Canada, gas furnaces are only certified to 4500 feet.
670
610
560
NOTE:
90
84
530
490
Contact the distributor for a tabular listing of appropriate
manufacturer’s kits for propane gas and/or high altitude instal-
lations. The indicated kits must be used to insure safe and
proper furnace operation. All conversions must be performed
by a qualified installer, or service agency.
79
460
(Pressure 0.5 psig or less and pressure drop of 0.3" W.C.; Based on
0.60 Specific Gravity Gas)
BTUH Furnace Input
CFH =
Heating Value of Gas (BTU/Cubic Foot)
PROPANE GASCONVERSION
To connect the furnace to the building’s gas piping, the installer
must supply a ground joint union, drip leg, manual shutoff valve,
and line and fittings to connect to gas valve. In some cases,
the installer may also need to supply a transition piece from 1/
2" pipe to a larger pipe size.
WARNING
POSSIBLE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH MAY
OCCUR IF THE CORRECT CONVERSION KITS ARE NOT INSTALLED. THE
APPROPRIATE KITS MUST BE APPLIED TO ENSURE SAFE AND PROPER
FURNACE OPERATION. ALL CONVERSIONS MUST BE PERFORMED BY A
QUALIFIED INSTALLER OR SERVICE AGENCY.
The following stipulations apply when connecting gas piping.
•
Use black iron or steel pipe and fittings for the building
piping.
This unit is configured for natural gas. The appropriate
manufacturer’s propane gas conversion kit, must be applied for
propane gas installations. Refer to the “Propane Gas and/or
High Altitude Installations” section for details.
•
Use pipe joint compound on male threads only. Pipe
joint compound must be resistant to the action of the
fuel used.
•
•
Use ground joint unions.
Install a drip leg to trap dirt and moisture before it can
enter the gas valve. The drip leg must be a minimum
of three inches long.
Install a 1/8" NPT pipe plug fitting, accessible for test
gage connection, immediately upstream of the gas
supply connection to the furnace.
Use two pipe wrenches when making connection to
the gas valve to keep it from turning. The orientation
of the gas valve on the manifold must be maintained
as shipped from the factory.
Contact your distributor for a tabular listing of appropriate
manufacturer’s kits for propane gas and/or high altitude instal-
lations. The indicated kits must be used to insure safe and
proper furnace operation. All conversions must be performed
by a qualified installer, or service agency.
•
•
19
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GAS SUPPLY AND PIPING
•
Install a manual shutoff valve between the gas meter
and unit within six feet of the unit. If a union is installed,
the union must be downstream of the manual shutoff
valve, between the shutoff valve and the furnace.
Tighten all joints securely.
Connect the furnace to the building piping by one of
the following methods:
When the gas piping enters through the left side of the furnace,
the installer must supply the following fittings (starting from the
gas valve):
•
•
•
90 degree elbow.
•
•
Straight pipe to reach the exterior of the furnace.
A ground joint union, drip leg, and manual shutoff valve
must also be supplied by the installer. In some cases,
the installer may also need to supply a transition piece
from 1/2 inch to another pipe size.
– Rigid metallic pipe and fittings.
– Semi-rigid metallic tubing and metallic fittings.
COUNTERFLOWINSTALLATIONS
Aluminum alloy tubing must not be used in exterior
locations.
When the gas piping enters through the left side of the furnace,
the installer must supply a straight pipe and a 90 degree elbow
to reach the exterior of the furnace.
– Use listed gas appliance connectors in accordance
with their instructions. Connectors must be fully in
the same room as the furnace.
A ground joint union, drip leg and manual shutoff valve must
also be supplied by the installer. In most cases, the installer
may also need to supply a transition piece from ½” to another
pipe size. When the gas piping enters through the right side of
the furnace, the installer must supply the following fittings (start-
ing at the gas valve):
– Protect connectors and semi-rigid tubing against
physical and thermal damage when installed.
Ensure aluminum-alloy tubing and connectors are
coated to protect against external corrosion when
in contact with masonry, plaster, or insulation, or
subjected to repeated wetting by liquids such as
water (except rain water), detergents, or sewage.
•
•
•
Close Nipple
90 Degree Elbow
Straight Pipe to Reach Exterior of Furnace.
Location of Manual Valve
(Installed Ahead of
Ground Joint Pipe Union)
GAS PIPING CHECKS
Height Required
By Local Code
Before placing unit in operation, leak test the unit and gas con-
nections.
Ground Joint Pipe Union
To Be Installed Ahead of
Gas Valve
WARNING
TO AVOID THE POSSIBILITY OF EXPLOSION OR FIRE, NEVER USE A MATCH
OR OPEN FLAME TO TEST FOR LEAKS.
``
Drip Leg
Reducing Coupling
1/2” x 1/8” with 1/8”
Pipe Plug to Measure
Line Gas Pressure
Check for leaks using an approved chloride-free soap and wa-
ter solution, an electronic combustible gas detector, or other
approved testing methods.
General Furnace Layout
UPFLOW INSTALLATIONS
When the gas piping enters through the right side of the fur-
nace, the installer must supply the following fittings (starting
from the gas valve):
NOTE: Never exceed specified pressures for testing. Higher
pressure may damage the gas valve and cause subsequent
overfiring, resulting in heat exchanger failure.
•
•
•
Close nipple.
90 degree elbows.
Straight pipe to reach the exterior of the furnace .
Disconnect this unit and shutoff valve from the gas supply pip-
ing system before pressure testing the supply piping system
with pressures in excess of 1/2 psig (3.48 kPa).
A ground joint union, drip leg, and manual shutoff valve must
also be supplied by the installer. In some cases, the installer
may also need to supply a transition piece from 1/2" to another
pipe size.
This unit must be isolated from the gas supply system by clos-
ing its manual shutoff valve before pressure testing of gas sup-
ply piping system with test pressures equal to or less than 1/2
psig (3.48 kPa).
20
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CIRCULATING AIR AND FILTERS
PROPANE GAS TANKS AND PIPING
5 to 15 PSIG
First Stage
(20 PSIG Max.)
Regulator
Continuous
11" W.C.
WARNING
IF THE GAS FURNACE IS INSTALLED IN A BASEMENT, AN EXCAVATED
AREA OR CONFINED SPACE, IT IS STRONGLY RECOMMENDED TO
CONTACT A PROPANE SUPPLIER TO INSTALL A GAS DETECTING WARNING
DEVICE IN CASE OF A GAS LEAK.
200 PSIG
Maximum
Second Stage
Regulator
•
SINCE PROPANE GAS IS HEAVIER THAN AIR, ANY LEAKING GAS CAN
SETTLE IN ANY LOW AREAS OR CONFINED SPACES.
•
PROPANE GAS ODORANT MAY FADE, MAKING THE GAS UNDETECTABLE
EXCEPT WITH A WARNING DEVICE.
Propane Gas Installation (Typ.)
PROPANE GAS PIPING CHARTS
Sizing Between First and Second Stage Regulator*
Maximum Propane Capacities listed are based on 2 psig pressure drop at 10 psig setting.
Capacities in 1,000 BTU/hour.
A gas detecting warning system is the only reliable way to
detect a propane gas leak. Rust can reduce the level of odorant
in propane gas. Do not rely on your sense of smell. Contact a
local propane gas supplier about installing a gas detecting
warning system. If the presence of gas is suspected, follow
the instructions on Page 3 of this manual.
Pipe or
Nominal Pipe Size
Schedule 40
Tubing Size, O.D. Type L
Tubing
Length,
Feet
3/8"
1/2"
5/8"
3/4"
7/8"
1/2"
3/4"
10
20
30
40
50
730
500
400
370
330
300
260
220
200
190
170
160
1,700
1,100
920
850
770
700
610
540
490
430
400
380
3,200
2,200
2,000
1,700
1,500
1,300
1,200
1,000
900
5,300
3,700
2,900
2,700
2,400
2,200
1,900
1,700
1,400
1,300
1,200
1,100
8,300
5,800
4,700
4,100
3,700
3,300
2,900
2,600
2,300
2,100
1,900
1,800
3,200
2,200
1,800
1,600
1,500
1,300
1,200
1,000
900
7,500
4,200
4,000
3,700
3,400
310
2,600
2,300
2,100
1,900
1,700
1,500
All propane gas equipment must conform to the safety stan-
dards of the National Board of Fire Underwriters, NBFU Manual
58.
60
80
For satisfactory operation, propane gas pressure must be 10
inch WC at the furnace manifold with all gas appliances in
operation. Maintaining proper gas pressure depends on three
main factors:
100
125
150
175
200
830
780
730
830
770
720
Sizing Between Second Stage and Appliance Regulator*
Maximum Propane Capacities listed are based on 2 psig pressure drop at 10 psig setting.
Capacities in 1,000 BTU/hour.
1. Vaporization rate, depending on temperature of the liquid,
and “wetted surface” area of the container or containers.
Pipe or
Tubing
Length,
Feet
Nominal Pipe Size
Schedule 40
Tubing Size, O.D. Type L
2. Proper pressure regulation. (Two-stage regulation is
recommended for both cost and efficiency).
3/8"
1/2"
5/8"
3/4"
7/8" 1-1/8" 1/2"
3/4"
1"
1-1/4" 1-1/2"
10
20
30
40
50
39
26
21
19
18
16
13
11
10
9
92
62
50
41
37
35
29
26
24
21
19
17
199
131
107
90
79
72
62
55
48
43
329
216
181
145
131
121
104
90
81
72
66
60
501
346
277
233
198
187
155
138
122
109
100
93
935
630
500
427
376
340
289
255
224
202
187
172
275
189
152
129
114
103
89
78
69
63
54
567 1,071 2,205 3,307
3. Pressure drop in lines between regulators, and between
second stage regulator and the appliance. Pipe size will
depend on length of pipe run and total load of all
appliances.
393
315
267
237
217
185
162
146
132
112
100
732 1,496 2,299
590 1,212 1,858
504 1,039 1,559
448
409
346
307
275
252
209
185
91
1,417
60
80
834 1,275
724 1,066
100
125
150
200
250
630
567
511
439
390
976
866
787
665
590
Complete information regarding tank sizing for vaporization, rec-
ommended regulator settings, and pipe sizing is available from
most regulator manufacturers and propane gas suppliers.
8
8
39
36
48
CIRCULATING AIR AND FILTERS
Since propane gas will quickly dissolve white lead and most
standard commercial compounds, special pipe dope must be
used. Shellac-based compounds resistant to the actions of
liquefied petroleum gases such as Gasolac®, Stalactic®,
Clyde’s® or John Crane® are satisfactory.
WARNING
NEVER ALLOW THE PRODUCTS OF COMBUSTION, INCLUDING CARBON
MONOXIDE, TO ENTER THE RETURN DUCT WORK OR CIRCULATION AIR
SUPPLY.
Refer to the following illustration for typical propane gas instal-
lations and piping.
Duct systems and register sizes must be properly designed for
the CFM and external static pressure rating of the furnace.
Ductwork should be designed in accordance with the recom-
mended methods of “Air Conditioning Contractors ofAmerica”
Manual D.
Aduct system must be installed in accordance with Standards
of the National Board of Fire Underwriters for the Installation of
Air Conditioning, Warm Air Heating and Ventilating Systems.
Pamphlets No. 90A and 90B.
21
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START-UP PROCEDURE AND ADJUSTMENT
A closed return duct system must be used, with the return duct To determine total external duct static pressure, proceed as
connected to the furnace. NOTE: Ductwork must never be follows;
attached to the back of the furnace. For installations requiring
1. With clean filters in the furnace, use a draft gauge (inclined
more than 1800 CFM, use a bottom return or two sided return.
manometer) to measure the static pressure of the return
Supply and return connections to the furnace may be made
duct at the inlet of the furnace. (Negative Pressure)
with flexible joints to reduce noise transmission. To prevent the
blower from interfering with combustion air or draft when a cen-
tral return is used, a connecting duct must be installed be-
tween the unit and the utility room wall. A room, closet, or
alcove must not be used as a return air chamber.
2. Measure the static pressure of the supply duct. (Positive
Pressure)
3. The difference between the two numbers is .4” w.c.
Example:
When the furnace is used in connection with a cooling unit, the
furnace should be installed in parallel with or on the upstream
side of the cooling unit to avoid condensation in the heating
static reading from return duct = -.1" w.c.
element. With a parallel flow arrangement, the dampers or other static reading from supply duct = .3" w.c.
means used to control the flow of air must be adequate to
total external static pressure on this system = .4" w.c.
prevent chilled air from entering the furnace and, if manually
operated, must be equipped with means to prevent operation of
either unit unless the damper is in the full heat or cool position.
NOTE: Both readings may be taken simultaneously and read
directly on the manometer if so desired. If an air conditioner
coil or Electronic Air Cleaner is used in conjunction with the
furnace, the readings must also include theses components,
as shown in the following drawing.
When the furnace is installed without a cooling coil, it is rec-
ommended that a removable access panel be provided in the
outlet air duct. This opening shall be accessible when the fur-
nace is installed and shall be of such a size that the heat
exchanger can be viewed for visual light inspection or such that
a sampling probe can be inserted into the airstream. The ac-
cess panel must be made to prevent air leaks when the furnace
is in operation.
4. Consult proper tables for the quantity of air.
If the total external static pressure exceeds the maximum listed
on the furnace rating plate, check for closed dampers, regis-
ters, undersized and/or oversized poorly laid out duct work.
When the furnace is heating, the temperature of the return air
entering the furnace must be between 55°F and 100°F.
When a furnace is installed so that supply ducts carry air cir-
culated by the furnace to areas outside the space containing
the furnace, the return air shall also be handled by a duct sealed
to the furnace casing and terminating outside the space con-
taining the furnace.
CHECKING DUCT STATIC
Refer to your furnace rating plate for the maximum ESP (exter-
nal duct static) rating.
Total external static refers to everything external to the furnace
cabinet. Cooling coils, filters, ducts, grilles, registers must all
be considered when reading your total external static pres-
sure. The supply duct pressure must be read between the fur-
nace and the cooling coil. This reading is usually taken by
removing the “A” shaped block off plate from the end on the
coil; drilling a test hole in it and reinstalling the block off plate.
Take a duct static reading at the test hole. Tape up the test
hole after your test is complete. The negative pressure must be
read between the filter and the furnace blower.
Checking Static Pressure
(80% Furnace Shown, 90% Similar)
Too much external static pressure will result in insufficient air
that can cause excessive temperature rise. This can cause
limit switch tripping and heat exchanger failure.
FILTERS -READ THISSECTION BEFORE INSTALLING THE
RETURNAIR DUCTWORK
Filters must be used with this furnace. Discuss filter mainte-
nance with the building owner. Filters do not ship with this
furnace, but must be provided by the installer. Filters must com-
22
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START-UP PROCEDURE AND ADJUSTMENT
approved method. Verify that all required kits (propane gas,
high altitude, etc.) have been appropriately installed.
ply with UL900 or CAN/ULCS111 standards. If the furnace is
installed without filters, the warranty will be voided.
FURNACE STARTUP
NOTE:An undersized opening will cause reduced airflow. The
1. Close the manual gas shutoff valve external to the furnace.
2. Turn off the electrical power to the furnace.
3. Set the room thermostat to the lowest possible setting.
4. Remove the burner compartment door.
bottom return is set up as a knock out.
UPRIGHT INSTALLATIONS
Depending on the installation and/or customer preference, dif-
fering filter arrangements can be applied. Filters can be in-
stalled in the central return register or a side panel external
NOTE: This furnace is equipped with an ignition device which
automatically lights the burner. Do not try to light the burner by
filter rack kit (upflows), or the ductwork above a downflow fur- hand.
nace. As an alternative, a media air filter or electronic air cleaner
can be used as the primary filter.
5. Move the furnace gas valve manual control to the OFF
position.
6. Wait five minutes then smell for gas. Be sure check
near the floor as some types of gas are heavier than air.
CIRCULATION AIR FILTERS
One of the most common causes of a problem in a forced air 7. If you smell gas after five minutes, immediately follow
heating system is a blocked or dirty filter. Circulating air filters
must be inspected monthly for dirt accumulation and replaced
if necessary. Failure to maintain clean filters can cause prema-
ture heat exchanger failure.
the Safety Instructions on page 2 of this manual. If you
do not smell gas after five minutes, move the furnace
gas valve manual control to the ON position.
8. Replace the burner compartment door.
9. Open the manual gas shutoff valve external to the furnace.
10. Turn on the electrical power to the furnace.
11. Adjust the thermostat to a setting above room
temperature.
A new home may require more frequent replacement until all
construction dust and dirt is removed. Circulating air filters are
to be installed in the return air duct external to the furnace
cabinet.
MINIM UM FILTER SIZES for DISPOSABLE FILTERS
12. After the burners are lit, set the thermostat to desired
temperature.
FURNACE INPUT
FILTER SIZE
768 in2
70M
90M
115M
960 in2
FURNACE SHUTDOWN
1022 in2
1. Set the thermostat to the lowest setting.
DISP OSA B LE NOM INA L 300 F.M . FA CE VELOCITY
The integrated control will close the gas valve and
extinguish flame. Following a 15 second delay, the
induced draft blower will be de-energized. After a 120,
150, 180 or 210-second delay period (field selectable
delay OFF [90, 120, 150, 180] plus 30-second ramp
down), the circulator blower de-energizes.
HORIZONTAL INSTALLATIONS
Filters must be installed in either the central return register or
in the return air duct work.
2. Remove the burner compartment door and move the
furnace gas valve manual control to the OFF position.
3. Close the manual gas shutoff valve external to the furnace.
4. Replace the burner compartment door.
START-UP PROCEDURE AND ADJUSTMENT
Furnace must have a 115 VAC power supply properly connected
and grounded. Proper polarity must be maintained for correct
operation. In addition to the following start-up and adjustment
items, refer to further information in Operational Checks sec-
tion.
GASSUPPLYPRESSUREMEASUREMENT
CAUTION
HEAT ANTICIPATOR SETTING
TO PREVENT UNRELIABLE OPERATION OR EQUIPMENT DAMAGE, THE
INLET GAS SUPPLY PRESSURE MUST BE AS SPECIFIED ON THE UNIT
RATING PLATE WITH ALL OTHER HOUSEHOLD GAS FIRED APPLIANCES
OPERATING.
The heat anticipator in the room thermostat must be correctly
adjusted to obtain the proper number of cycles per hour and to
prevent “overshooting” of the setting. Set the heat anticipator
setting to 0.7 amps. Follow the thermostat manufacturer’s
instructions on how to adjust the heat anticipator setting.
The line pressure supplied to the gas valve must be within the
range specified below. The supply pressure can be measured
at the gas valve inlet pressure boss or at a hose fitting installed
in the gas piping drip leg. The supply pressure must be mea-
sured with the burners operating. To measure the gas supply
pressure, use the following procedure.
FURNACEOPERATION
Purge gas lines of air prior to startup. Be sure not purge lines
into an enclosed burner compartment.
Check for leaks using an approved chloride-free soap and wa-
ter solution, an electronic combustible gas detector, or other
23
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START-UP PROCEDURE AND ADJUSTMENT
Common
Terminal(C)
meter
Mano
en to
Op
Atmo
High Fire Coil
Terminal (HI)
e
Hos
sphere
INLET
OUTLET
Low Fire Coil
Terminal (LO)
i
Gas Valve On/Off
Selector Switch
Inlet Pressure Tap
1/8 NPT
White-Rodgers Model 36G54 (Two-Stage)
ter
anome
Hose
M
Open to
Atmosphere
ter
Manome
High Fire Regulator
Adjust
Outlet
Pressure Boss
Regulator
Vent
Outlet Pressure Tap
1/8 NPT
Honeywell Model VR9205 Connected to Manometer
1. Turn OFF gas to furnace at the manual gas shutoff valve
external to the furnace.
Low Fire
Regulator
Adjust
2. Connect a calibrated water manometer (or appropriate
gas pressure gauge) at either the gas valve inlet pressure
boss or the gas piping drip leg. See Honeywell VR9205
gas valve figure or White-Rodgers 36G54 gas valve figure
for location of inlet pressure boss.
Inlet
Pressure
Boss
High Fire Coil
inal (HI)
Coaxial Coil
Manometer
Term
Switch
inal (M)
Term
Common
Terminal(C)
On/Off
NOTE: If measuring gas pressure at the drip leg or Honeywell
VR9205 gas valve, a field-supplied hose barb fitting must be
installed prior to making the hose connection. If using the inlet
pressure boss on the White-Rodgers 36G54 gas valve, then
use the 36G Valve Pressure Check Kit, Goodman Part No.
0151K00000S.
White-Rodgers Model 36G54 Connected to Manometer
High Fire
Regulator
Regulator
Adjust
Vent
3. Turn ON the gas supply and operate the furnace and all
other gas consuming appliances on the same gas supply
line.
4. Measure furnace gas supply pressure with burners firing.
Supply pressure must be within the range specified in
the Inlet Gas Supply Pressure table.
Gas Valve On/Off
Selector Switch
Low Fire
Regulator
Adjust
Inlet Gas Supply Pressure
Natural Gas
Propane Gas
Minimum: 5.0" w.c. Maximum:10.0" w.c.
Minimum: 11.0" w.c. Maximum:13.0" w.c.
Honeywell Model VR9205 (Two-Stage)
If supply pressure differs from table, make the necessary ad-
justments to pressure regulator, gas piping size, etc., and/or
consult with local gas utility.
5. Turn OFF gas to furnace at the manual shutoff valve and
disconnect manometer. Reinstall plug before turning on
gas to furnace.
6. Turn OFF any unnecessary gas appliances stated in
step 3.
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START-UP PROCEDURE AND ADJUSTMENT
9. Close thermostat “R” and “W2” contacts to provide a
call for high stage heat.
Gas Line
Gas
10. Remove regulator cover screw from the high (HI) outlet
pressure regulator adjust tower and turn screw clockwise
to increase pressure or counterclockwise to decrease
pressure. Replace regulator cover screw.
11. Turn off all electrical power and gas supply to the system.
12. Remove the manometer hose from the hose barb fitting
or outlet pressure boss.
Shutoff
Valve
Gas Line
To Furnace
Open To
Atmosphere
13. Replace outlet pressure tap:
a. Honeywell VR9205 valve: Remove the 1/8" NPT hose
barb fitting from the outlet pressure tap. Replace the
outlet pressure boss plug and seal with a high quality
thread sealer.
Drip Leg Cap
With Fitting
Manometer Hose
b. White-Rodgers 36G54 valve: Turn outlet pressure test
screw in to seal pressure port (clockwise, 7 in-lb
minimum).
14. Turn on electrical power and gas supply to the system.
15. Close thermostat contacts “R” and “W1/W2” to energize
the valve.
Manometer
Measuring Inlet Gas Pressure (Alt. Method)
GAS MANIFOLDPRESSUREMEASUREMENTANDADJUSTMENT
Using a leak detection solution or soap suds, check for leaks
at outlet pressure boss plug (Honeywell valve) or screw (White-
Rodgers valve). Bubbles forming indicate a leak. SHUT OFF
GASAND REPAIRALL LEAKS IMMEDIATELY!
NOTE: For gas to gas conversion, consult your dealer for
appropriate conversion.
CAUTION
TO PREVENT UNRELIABLE OPERATION OR EQUIPMENT DAMAGE, THE
GAS MANIFOLD PRESSURE MUST BE AS SPECIFIED ON THE UNIT RATING
PLATE. ONLY MINOR ADJUSTMENTS SHOULD BE MADE BY ADJUSTING
THE GAS VALVE PRESSURE REGULATOR.
Only small variations in gas pressure should be made by ad-
justing the gas valve pressure regulator. The manifold pressure
must be measured with the burners operating. To measure
and adjust the manifold pressure, use the following procedure.
1. Turn OFF gas to furnace at the manual gas shutoff valve
external to the furnace.
Manifold Gas Pressure
Gas
Range
Nominal
1.9" w .c.
3.5" w .c.
6.0" w .c.
Natural
Low Stage 1.6 - 2.2" w .c.
High Stage 3.2 - 3.8" w .c.
Low Stage 5.7 - 6.3" w .c.
Propane
High Stage 9.7 - 10.3" w .c. 10.0" w .c.
2. Turn off all electrical power to the system.
3. Outlet pressure tap connections:
GAS INPUT RATE MEASUREMENT (NATURAL GAS ONLY)
a. Honeywell VR9205 valve: Remove the outlet pressure
boss plug. Install an 1/8" NPT hose barb fitting into
the outlet pressure tap.
b. White-Rodgers 36G54 valve: Back outlet pressure test
screw (inlet/outlet pressure boss) out one turn
(counterclockwise, not more than one turn).
4. Attach a hose and manometer to the outlet pressure
barb fitting (Honeywell valve) or outlet pressure boss
(White-Rodgers valve).
The gas input rate to the furnace must never be greater than
that specified on the unit rating plate. To measure natural gas
input using the gas meter, use the following procedure.
1. Turn OFF the gas supply to all other gas-burning
appliances except the furnace.
2. While the furnace is operating, time and record one
complete revolution of the smallest gas meter dial.
3. Calculate the number of seconds per cubic foot (sec/ft3)
of gas being delivered to the furnace. If the dial is a one
cubic foot dial, divide the number of seconds recorded in
step 2 by one. If the dial is a two cubic foot dial, divide
the number of seconds recorded in step 2 by two.
5. Turn ON the gas supply.
6. Turn on power and close thermostat “R” and “W1”
contacts to provide a call for low stage heat.
7. Measure the gas manifold pressure with burners firing.
Adjust manifold pressure using the Manifold Gas
Pressure table shown below.
8. Remove regulator cover screw from the low (LO) outlet
pressure regulator adjust tower and turn screw clockwise
to increase pressure or counterclockwise to decrease
pressure. Replace regulator cover screw.
25
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START-UP PROCEDURE AND ADJUSTMENT
HEAT EXCHANGER
RADIATION "LINE OF SIGHT"
4. Calculate the furnace input in BTUs per hour (BTU/hr).
Input equals the sum of the installation’s gas heating
value and a conversion factor (hours to seconds) divided
by the number of seconds per cubic foot. The measured
input must not be greater than the input indicated on the
unit rating plate.
SUPPLY
AIR
TSUPPLY
EXAMPLE:
Installation’s gas heating (HTG) value: 1,000 BTU/ft3
(Obtained from gas supplier)
RISE
=
TSUPPLY TRETURN
-
Installation’s seconds per cubic foot: 34 sec/ ft3
Conversion Factor (hours to seconds): 3600 sec/hr
Input = (Htg. value x 3600) ÷ seconds per cubic foot
Input = (1,000 BTU/ft3 x 3600 sec/hr) ÷ 34 sec/ ft3
Input = 106,000 BTU/hr
TRETURN
RETURN
AIR
Minor changes to the input rate may be accomplished through
manifold pressure adjustments at the gas valve. Refer to Sec-
tion XIV, Startup Procedure and Adjustment - Gas Manifold
Pressure Measurement and Adjustment for details. NOTE:
The final manifold pressure cannot vary by more than ± 0.3”
w.c. from the specified setting. Consult your local gas supplier
if additional input rate adjustment is required.
Temperature Rise Measurement
CIRCULATORBLOWER SPEEDS
WARNING
TO AVOID PERSONAL INJURY OR DEATH DUE TO ELECTRICAL SHOCK,
TURN OFF POWER TO THE FURNACE BEFORE CHANGING SPEED TAPS.
5. Repeat steps 2 through 4 on high stage.
6. Turn ON gas to and relight all other appliances turned off
in step 1. Be certain that all appliances are functioning
properly and that all pilot burners are operating.
This furnace is equipped with a multi-speed circulator blower.
This blower provides ease in adjusting blower speeds. The
Specification Sheet applicable to your model provides an air-
flow table, showing the relationship between airflow (CFM) and
external static pressure (E.S.P.), for the proper selection of
heating and cooling speeds. The heating blower speed is
shipped set at “B”, and the cooling blower speed is set at “D”.
These blower speeds should be adjusted by the installer to
match the installation requirements so as to provide the cor-
rect heating temperature rise and correct cooling CFM.
TEMPERATURE RISE
Temperature rise must be within the range specified on the unit
rating plate. An incorrect temperature rise may result in con-
densing in or overheating of the heat exchanger. An airflow and
temperature rise table is provided in the Specification Sheet
applicable to your model. Determine and adjust temperature
rise as follows:
1. Operate furnace with burners firing for approximately ten
minutes. Ensure all registers are open and all duct
dampers are in their final (fully or partially open) position.
2. Place thermometers in the return and supply ducts as
close to the furnace as possible. Thermometers must
not be influenced by radiant heat by being able to “see”
the heat exchanger.
Use the dual 7-segment LED display adjacent to the dipswitches
to obtain the approximate airflow quantity. The airflow quantity
is displayed as a number on the display, rounded to the near-
est 100 CFM. The display alternates airflow delivery indication
and the operating mode indication.
Example: The airflow being delivered is 1225 CFM. The dis-
play indicates 12. If the airflow being delivered is 1275, the
display indicates 13.
1. Determine the tonnage of the cooling system installed
with the furnace. If the cooling capacity is in BTU/hr divide
it by 12,000 to convert capacity to TONs.
3. Subtract the return air temperature from the supply air
temperature to determine the air temperature rise. Allow
adequate time for thermometer readings to stabilize.
4. Adjust temperature rise by adjusting the circulator blower
speed. Increase blower speed to reduce temperature rise.
Decrease blower speed to increase temperature rise.
Refer to Startup Procedure and Adjustment -Circulator
Blower Speeds for speed changing details.
Example: Cooling Capacity of 30,000 BTU/hr.
30,000/12,000 = 2.5 Tons
2. Determine the proper air flow for the cooling system.
Most cooling systems are designed to work with air flows
between 350 and 450 CFM per ton. Most manufacturers
recommend an air flow of about 400 CFM per ton.
Example: 2.5 tons X 400 CFM per ton = 1000 CFM
26
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START-UP PROCEDURE AND ADJUSTMENT
The cooling system manufacturer’s instructions must be
checked for required air flow. Any electronic air cleaners or
other devices may require specific air flows, consult installa-
tion instructions of those devices for requirements.
3. Knowing the furnace model, locate the high stage cooling
air flow charts in the Specification Sheet applicable to
your model. Look up the cooling air flow determined in
step 2 and find the required cooling speed and adjustment
setting.
100% CFM
100% CFM
1 min
OFF
OFF
•
Profile B ramps up to full cooling demand airflow by
first stepping up to 50% of the full demand for 30 seconds.
The motor then ramps to 100% of the required airflow. A
one (1) minute OFF delay at 100% of the cooling airflow
is provided.
Example: A *MVC80704BX furnace installed with a 2.5
ton air conditioning system. The air flow
needed is 1000 CFM. Looking at the cooling
speed chart for *MVC80704BX, find the air
flow closest to 1000 CFM. Acooling airflow
100% CFM
100% CFM
1 min
50% CFM
1/2 min
OFF
OFF
of 990 CFM can be attained by setting the
cooling speed to “C” and the adjustment to
“-” (minus).
•
Profile C ramps up to 85% of the full cooling demand
airflow and operates there for approximately 7 1/2
minutes. The motor then steps up to the full demand
airflow. Profile C also has a one (1) minute 100% OFF
delay.
4. Continuous fan speed is 30% of the furnace’s maximum
airflow capability.
Example: If the furnace’s maximum airflow capability
is 2000 CFM, the continuous fan speed will
be 0.30 x 2000 CFM = 600 CFM.
100% CFM
5. Locate the blower speed selection DIP switches on the
integrated control module. Select the desired “cooling”
speed tap by positioning switches 1 and 2 appropriately.
Select the desired “adjust” tap by positioning switches
3 and 4 appropriately. Refer to the following figure for
switch positions and their corresponding taps. Verify
CFM by noting the number displayed on the dual 7-
segment LED display.
OFF
OFF
Switch Bank: S3
DIP Switch No.
Cooling
Airflow
1
2
A
B
OFF
ON
OFF
OFF
ON
6. The multi-speed circulator blower also offers several
custom ON/OFF ramping profiles. These profiles may
be used to enhance cooling performance and increase
comfort level. The ramping profiles are selected using
DIP switches 5 and 6. Refer to the following figure for
switch positions and their corresponding taps. Refer to
the bullet points below for a description of each ramping
profile. Verify CFM by noting the number displayed on
the dual 7-segment LED display.
C
OFF
ON
D*
ON
(*Indicates factory setting)
Switch Bank: S3
DIP Switch No.
Adjust Taps
3
4
Normal*
10%
OFF
ON
OFF
ON
OFF
OFF
ON
ON
Switch Bank: S4
DIP Switch No.
Ramping
-10%
Profiles
Normal
5
6
(*Indicates factory setting)
A*
B
OFF
ON
OFF
OFF
ON
•
Profile D ramps up to 50% of the demand for 1/2 minute,
then ramps to 85% of the full cooling demand airflow
and operates there for approximately 7 1/2 minutes. The
motor then steps up to the full demand airflow. Profile D
has a 1/2 minute at 50% airflow OFF delay.
C
D
OFF
ON
ON
(*Indicates factory setting)
•
Profile A provides only an OFF delay of one (1) minute
at 100% of the cooling demand airflow.
OFF
OFF
27
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START-UP PROCEDURE AND ADJUSTMENT
In general lower heating speeds will: reduce electrical consump-
tion, lower operating sound levels of the blower, and increase
the outlet air temperature delivered to the home. The speeds
available allow the blower performance to be optimized for the
particular homeowner’s needs.
7. Select the heating speed for your model from the heating
speed chart in the Specification Sheet. The adjust setting
(already established by the cooling speed selection)
determines which set of speeds are available. The
selected speed must provide a temperature rise within
the rise range listed with the particular model.
Example: The *MVC80704BX is set for 990 CFM on
cooling, the “ADJUST” is set to “+” (plus).
BLOWER HEAT OFF DELAY TIMINGS
The integrated control module provides a selectable heat off
delay function. The heat off delay period may be set to 90, 120,
150, 180 seconds using the DIP switches or jumper provided
on the control module. The delay is factory shipped at 150
seconds but may be changed to suit the installation require-
ments and/or homeowner preference. Refer to the following fig-
ures for switch positions and corresponding delay times.
The four heating speeds available are “A
Plus”, “B Plus”, “C Plus”, and “D Plus”. “A
Plus” has a rise of 38°F for both stages
which is within the 20-50°F rise range for
the *MVC80704BX . This setting will keep
electrical consumption to a minimum. Set
the “Heat” speed DIP switches to “A”.
Switch Bank: S1
DIP Switch No.
Heat OFF Delay
Switch Bank: S4
1
2
DIP Switch No.
Heating
Airflow
90 seconds
120 seconds
150 seconds*
180 seconds
OFF
ON
OFF
ON
OFF
OFF
ON
ON
7
8
A
B*
C
OFF
ON
OFF
ON
OFF
OFF
ON
ON
(*Indicates factory setting)
D
Heat Off Delay Dipswitches
(*Indicates factory setting)
8. Select the desired “heating” speed tap by positioning
switches 7 and 8 appropriately. Refer to figure above.
Verify CFM by noting the number displayed on the dual
7-segment LED display.
Speed Selection Dip Switches
Model
Tap
Low Stage High Stage Low Stage High Stage
Cool
Cool
Heat
Heat
Cool
Selection
Switches
Adjust
Selection Selection
Switches Switches
Profile
Heat
Selection
Switches
A
B
C
D
390
520
650
780
600
735
1050
1150
1250
1350
800
1000
1200
805
875
935
*DVC80703BX*
*DVC80905CX*
TAP
1
2
3
4
5
6
7
8
A
OFF OFF OFF OFF OFF OFF
ON OFF ON OFF ON OFF
OFF ON OFF ON OFF ON
ON ON ON ON ON ON
OFF OFF
ON OFF
OFF ON
ON ON
800
1100
1400
1800
945
1015
1085
1155
1350
1450
1550
1650
A
B
C
D
520
715
910
B
C
1170
D
A
B
C
D
553
748
943
850
1150
1450
1850
1085
1155
1225
1260
1550
1650
1750
1800
Profiles
Pre-Run
-------
Short-Run
OFF Delay
60 sec/100%
60 sec/100%
60 sec/100%
30 sec/50%
*DVC81155CX*
*MVC80704BX*
A
B
C
D
--------
30 sec/50%
1203
-------
600
800
1100
1400
875
945
1015
1085
1250
1350
1450
1550
A
B
C
D
390
520
715
910
-------
7.5 min/82%
30 sec/50%
7.5 min/82%
To set airflow:
(1) Select model and desired
high stage cooling airflow. Determine the corresponding tap
( A, B, C, or D ). Set dip switches 1 and 2 to the appropriate
ON / OFF positions. (2) Select model and desired high stage
heating airflow. Determine the corresponding tap ( A, B, C, or
D ). Set dip switches 7 and 8 to the appropriate ON / OFF
positions. (3) Select the airflow adjustment factor taps A and
D are 1; Tap B is +10%; Tap C -10%. Set dip switches 3 and 4
to the appropriate ON / OFF positions.
A
B
C
D
520
715
910
800
1100
1400
1800
1050
1120
1190
1260
1500
1600
1700
1800
*MVC80905CX*
*MVC81155CX*
1170
800
1100
1400
1800
1210
1225
1245
1260
1725
1750
1775
1800
A
B
C
D
520
715
910
To set Comfort Mode: Select desired Comfort Mode profile
(see profiles above). Set switches 5 and 6 to the appropriate
ON / OFF positions.
1175
NOTE: Airflow data shown applies to legacy mode operation only. For a fully communicating
system, please see the outdoor unit’s installation instructions for cooling and pump heating
airflow data. See ComfortNet™ System - Airflow Consideration section for details.
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COMFORTNET™ SYSTEM
ECM motor. If the outdoor unit or thermostat is responsible
for determining the demand, it calculates the demand and
transmits the demand along with a fan request to the indoor
unit. The indoor unit then sends the demand to the ECM
motor. The table below lists the various ComfortNet sys-
tems, the operating mode, and airflow demand source.
COMFORTNET™ SYSTEM
OVERVIEW
The ComfortNet system (or CT system) is a system that in-
cludes a ComfortNet compatible furnace and air conditioner or
heat pump with a CTK01AA thermostat. A valid ComfortNet
system could also be a compatible furnace, CTK01AA thermo-
stat and non-compatible, single stage air conditioner. Any other
system configurations are considered invalid ComfortNet sys-
tems and must be connected as a traditional (or legacy) sys-
tem (see Electrical Connections for wiring connections). The
table below compares the valid CT systems.
System
Airflow Demand
Source
System
Operating Mode
Cooling
Heating
Air Conditioner
Furnace
Air Conditioner +
Furnace
Continuous Fan
Thermostat
CT compatible
Furnace
CT compatible
Air Conditioner
Full CT system
benefits and features
Cooling
Heat Pump
Heat Pump
Furnace
CT compatible
Furnace
CT compatible
Heat Pump
Full CT system
benefits and features
Heat Pump Heating
Only
Non-CT compatible
Single Stage
Air Conditioner
CT system
benefits and features
for furnace only
Heat Pump +
Furnace
CT compatible
Furnace
Auxiliary Heating
Continuous Fan
Thermostat
A ComfortNet heating/air conditioning system differs from a
legacy/traditional system in the manner in which the indoor
unit, outdoor unit and thermostat interact with one another. In
a traditional system, the thermostat sends commands to the
indoor and outdoor units via analog 24 VAC signals. It is a one-
way communication path in that the indoor and outdoor units
typically do not return information to the thermostat.
Cooling
Heating
Furnace
Furnace
Furnace + Non-
Comm 1stg Air
Conditioner
Continuous Fan
Thermostat
On the other hand, the indoor unit, outdoor unit, and thermo-
stat comprising a ComfortNet system “communicate” digitally
with one another. It is now a two-way communications path.
The thermostat still sends commands to the indoor and out-
door units. However, the thermostat may also request and
receive information from both the indoor and outdoor units. This
information may be displayed on the CT thermostat. The in-
door and outdoor units also interact with one another. The
outdoor unit may send commands to or request information
from the indoor unit. This two-way digital communications be-
tween the thermostat and subsystems (indoor/outdoor unit) and
between subsystems is the key to unlocking the benefits and
features of the ComfortNet system.
For example, assume the system is an air conditioner
matched with a furnace. With a call for low stage cooling,
the air conditioner will calculate the system’s low stage
cooling airflow demand. The air conditioner will then send a
fan request along with the low stage cooling airflow demand
to the furnace. Once received, the furnace will send the low
stage cooling airflow demand to the ECM motor. The ECM
motor then delivers the low stage cooling airflow. See the
applicable ComfortNet™ air conditioner or heat pump
installation manual for the airflow delivered during cooling or
heat pump heating.
In continuous fan mode, the CTK01AA thermostat provides
the airflow demand. The thermostat may be configured for a
low, medium, or high continuous fan speed. The low,
medium, and high fan speeds correspond to 25%, 50%, and
75%, respectively, of the furnaces’ maximum airflow capabil-
ity. During continuous fan operation, the thermostat sends a
fan request along with the continuous fan demand to the
furnace. The furnace, in turn, sends the demand to the ECM
motor. The ECM motor delivers the requested continuous
fan airflow.
Two-way digital communications is accomplished using only
two wires. The thermostat and subsystem controls are power
with 24 VAC. Thus, a maximum of 4 wires between the equip-
ment and thermostat is all that is required to operate the sys-
tem.
AIRFLOW CONSIDERATIONS
Airflow demands are managed differently in a fully communi-
cating system than they are in a legacy wired system. The
system operating mode (as determined by the thermostat)
determines which unit calculates the system airflow de-
mand. If the indoor unit is responsible for determining the
airflow demand, it calculates the demand and sends it to the
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COMFORTNET™ SYSTEM
Four wires are required between the indoor unit and thermo-
stat.
FOSSILFUELAPPLICATIONS
ThisfurnacecanbeusedinconjunctionwithaComfortNet™ com-
patible heat pump in a fossil fuel application. Afossil fuel applica-
tion refers to a combined gas furnace and heat pump installation
which uses an outdoor temperature sensor to determine the most
cost efficient means of heating (heat pump or gas furnace). When
used with the CTK01AA thermostat, the furnace/heat pump
system is automically configured as a fossil fuel system. The
balance point temperature may be adjusted via the CTK01AA
thermostat advanced user menus (see CTK01AA instructions
for additional information).
NOTE: Use of the CTK01AA transformer is recommended if
installing a dual fuel/fossil fuel system. Failure to use the
transformer in the outdoor unit could result in over loading of
the furnace transformer.
CTK01AA
Thermostat
1
1
2
2
R
R
C
C
CT Compatible
Furnace Integrated
Control Module
40VA Transformer (included in
CTK01AA kit)
CTK01AAWIRING
CT Compatible
AC/HP Integrated
Control Module
R
C
1
2
NOTE: Refer to Electrical Connections for 115 volt line
connections to the furnace.
24 VAC
208/230 VAC
NOTE: A removable plug connector is provided with the control
to make thermostat wire connections. This plug may be
removed, wire connections made to the plug, and replaced. It
is strongly recommended that multiple wires into a single
terminal be twisted together prior to inserting into the plug
connector. Failure to do so may result in intermittent operation.
System Wiring using Two-Wires between Furnace and AC/HP
and Four-Wires between Furnace and Thermostat
CT COMPATIBLE FURNACE WITH NON-CT COMPATIBLE SINGLE-
STAGE AIR CONDITIONER
Typical 18 AWG thermostat wire may be used to wire the sys-
tem components. One hundred (100) feet is the maximum
length of wire between indoor unit and outdoor unit, or between
indoor unit and thermostat. Wire runs over (100) feet require
larger gauge wire.
Four wires are required between the furnace and thermostat. Two
wires are required between the furnace control and single stage air
conditioner. For this system configuration, the “Y1” terminal on the
integrated furnace control becomes an output rather than an input.
The “Y1” connection to the outdoor unit is made using both 4-
position thermostat connectors in the CTK01AA kit. Remove the
red keying tabs from the on-board connector block and position
both 4-position connectors such that “1”, “2”, “R”, “C”, and “Y1”
positions are filled.
FOUR-WIRE INDOOR AND OUTDOOR WIRING
Typical ComfortNet™ wiring will consist of four wires between
the indoor unit and outdoor unit and between the indoor unit
and thermostat. The required wires are: (a) data lines, 1 and 2;
(b) thermostat “R” (24 VAC hot) and “C” (24 VAC common).
CTK01AA
Thermostat
4-Position Connectors
from CTK01AA
CTK01AA
Thermostat Kit
1
2
R
C
Thermostat
1
1
2
2
R
R
C
C
CT Compatible
Furnace Integrated
Control Module
CT Compatible Furnace
Integrated Control Module
W1 W2 Y1 Y2
O
1
2 R C G
CT Compatible AC/HP
Integrated Control Module
1
2
R
C
Non-CT Compatible
Single Stage AC
C
Y
System Wiring using Four-Wires
System Wiring between Furnace and Non-CT Compatible
SingleStageAirConditioner
TWO-WIRE OUTDOOR, FOUR-WIRE INDOOR WIRING
COMFORTNET SYSTEMADVANCED FEATURES
Two wires can be utilized between the indoor and outdoor units.
For this wiring scheme, only the data lines, 1 and 2, are needed
required between the indoor and outdoor units. A 40VA, 208/
230 VAC to 24VAC transformer must be installed in the out-
door unit to provide 24VAC power to the outdoor unit’s elec-
tronic control. The transformer is included with the CTK01AA
kit. See kit instructions for mounting and wiring instructions.
The ComfortNet system permits access to additional system
information, advanced setup features, and advanced diagnos-
tic/troubleshooting features. These advanced features are or-
ganized into a menu structure. The menus are accessed and
navigated as described in the following section.
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COMFORTNET™ SYSTEM
the change is not accepted, the display will show “FAIL” then
revert to the Fault Screen.
ACCESSING AND NAVIGATING THE ADVANCED FEATURES MENUS
The advanced system features are accessed using the
ComfortNet thermostat. These advanced features are accessed
as follows:
Some parameters being displayed switch between the item
name and the item value. Touch the Hold key to momentarily
stop the display from switching.
•
On the CT thermostat Home Screen Display, touch
the Menu key to display additional key choices.
To exit an equipment submenu and revert back to the equip-
ment menus, touch the Menu key. Touch Menu again to revert
back to the Thermostat Options Menu. Touch the Run Sched-
ule key to step out of all menus and back to the CT thermostat
Home Screen Display.
•
Touch and hold the Installer Config key for
approximately 3 seconds to enter the Thermostat
Options Configuration menu.
Touch and hold the Installer Config key again for
approximately 3 seconds to enter the Advanced
Installer Configuration menu.
•
THERMOSTAT MENU
If this furnace is installed with a CT compatible heat pump, the
system is recognized as a dual fuel system. The balance
point temperature should be set via the thermostat advanced
menu. Navigate to the THERMOSTAT menu. Press the IN-
STALLER CONFIG key. Navigate to the SETUP menu and
press the INSTALLER CONFIG button. Navigate to dF BAL
PNT. Adjust the dual fuel system balance point using the back/
forward arrows.
Set Time
Run
Set
Installer
Config
Clean Display
Schedule
Schedule
DIAGNOSTICS
Accessing the furnace’s diagnostics menu provides ready ac-
cess to the last six faults detected by the furnace. Faults are
stored most recent to least recent. Any consecutively repeated
fault is stored a maximum of three times. Example:Aclogged
return air filter causes the furnace limit to trip repeatedly. The
control will only store this fault the first three consecutive times
the fault occurs. Navigate to the diagnostics menu as described
above in Accessing and Navigating the Advanced Features
Menus.
Upon entering the advanced menus, theAdvanced Fault Menu
is displayed. The display will change to the Fault Screen and
indicate any faults that may be present in the indoor or outdoor
equipment. If a fault is present, the Fault Screen will show the
equipment and an error code with a description of the fault.
_
+
Touch
or
keys to view the fault status of any remaining
equipment. The text “NO FAULTS” will be scrolled if no errors
are present.
NOTE: It is highly recommended that the fault history be cleared
when performing maintenance or servicing the furnace.
Call for Service
Call for Service
Advanced
Advanced
Menu
Menu
Run
Run
Schedule
Schedule
Touch the
or
to step through the list of installed equip-
ment, including the thermostat. Touch the Installer Config
key to enter the submenus for the equipment displayed. The
text “WORKING” will be displayed in the scrolling display area
while the data is being retrieved. The first sub-menu is then
displayed. See tables below for listing of furnace submenus.
Touch the
or
to step through the list of submenus and
_
+
view settings. If a setting can be adjusted,
and
keys will
_
+
appear. Use the
or
keys to adjust the setting to the
or to step to the next item.
desired value. Touch the
“WORKING” will appear as the settings are being updated.
“DONE” will appear to indicate the change was accepted. If
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COMFORTNET™ SYSTEM
FURNACE ADVANCED FEATURES MENUS
CONFIGURATION
Submenu Item
Indication (for Display Only; not User Modifiable)
Number of Heat Stages (HT STG)
Displays the number of furnace heating stages
Input Rate (BTU/HR)
Displays the furnace input rate in kBtu/hr
Motor HP (1/2, ¾, or 1 MTR HP)
Displays the furnace indoor blower motor horsepower
DIAGNOSTICS
Submenu Item
Indication/User Modifiable Options
Comments
For display only
Fault 1 (FAULT #1)
Fault 2 (FAULT #2)
Fault 3 (FAULT #3)
Fault 4 (FAULT #4)
Fault 5 (FAULT #5)
Fault 6 (FAULT #6)
Most recent furnace fault
Next most recent furnace fault
Next most recent furnace fault
Next most recent furnace fault
Next most recent furnace fault
Least recent furnace fault
For display only
For display only
For display only
For display only
For display only
Selecting “YES” clears the fault
history
Clear Fault History (CLEAR)
NO or YES
Consecutively repeated faults are shown a maximum of 3 times
NOTE:
IDENTIFICATION
Submenu Item
Indication (for Display Only; not User Modifiable)
Model Number (MOD NUM)
Serial Number (SER NUM)
Software (SOFTWARE)
Displays the furnace model number
Displays the furnace serial number (Optional)
Displays the application software revision
SET-UP
Submenu Item
Heat Airflow Trim (HT TRM)
User Modifiable Options
-10% to +10% in 2% increments,
default is 0%
Comments
Trims the heating airflow by the selected
amount.
Heat ON Delay (HT ON
Heat OFF Delay (HT OFF)
Heat Airflow (HT ADJ)
5, 10, 15, 20, 25, or 30 seconds,
default is 30 seconds
30, 60, 90, 120, 150, or 180 seconds, Selects the indoor blower heat OFF delay
default is 150 seconds
Selects the indoor blower heat ON delay
1, 2, 3, or 4
Selects the nominal heating airflow (see
Startup Procedure and Adjustment –
Circulator Blower Speeds for addition
information)
STATUS
Submenu Item
Indication (for Display Only; not User Modifiable)
Mode (MODE)
CFM (CFM)
Displays the current furnace operating mode
Displays the airflow for the current operating mode
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COMFORTNET™ SYSTEM
NON-COMM (APPLIES ONLY TO A CT COMPATIBLE FURNACE MATCHED
WITH A NON-CT COMPATIBLE SINGLE STAGE AIR CONDITIONER)
Submenu Item
User Modifiable Options
Comments
Cool Airflow (CL CFM)
18, 24, 30, 36, 42, 48, or 60, default Selects the airflow for the non-CT
is 18
compatible single stage AC unit
Cool Airflow Trim (CL TRM)
Cool Airflow Profile (CL PRFL)
Cool ON Delay (CL ON)
-10% to +10% in 2% increments,
default is 0%
A, B, C, or D, default is A
Selects the airflow trim amount for the non-
CT compatible single stage AC unit
Selects the airflow profile for the non-CT
compatible single stage AC unit
Selects the indoor blower ON delay for the
non-CT compatible single stage AC unit
5, 10, 20, or 30 seconds, default is
5 seconds
Cool OFF Delay (CL OFF)
30, 60, 90, or 120 seconds, default
is 30 seconds
Selects the indoor blower OFF delay for the
non-CT compatible single stage AC unit
shoot the network may arise. The integrated furnace control
has some on-board tools that may be used to troubleshoot the
network. These tools are: red communications LED, green
receive (Rx) LED, and learn button.
NETWORKTROUBLESHOOTING
Communications is achieved by taking the difference
between two dc signals. The signals and transmission lines
are referred to as “data 1” and “data 2”. Each transmission
line is biased to approximately 2.5Vdc. During data recep-
tion/transmission, the data lines vary between +5V and
ground. (When data 1 is increasing towards +5V, data 2 is
decreasing towards ground and when data 1 is decreasing
towards ground, data 2 is increasing towards +5V. Typically,
the data 1 line is approximately 2.6Vdc and the data 2
transmission line is approximately 2.3Vdc. The voltage
difference between data 1 and data 2 is typically 0.2 to 0.6
Vdc.
•
•
•
Red communications LED – Indicates the status of
the network. The table below indicates the LED status
and the corresponding potential problem.
Green receive LED – Indicates network traffic. The
table below indicates the LED status and the
corresponding potential problem.
Learn button – Used to reset the network. Depress
the button for approximately 2 seconds to reset the
network.
SYSTEM TROUBLESHOOTING
The indoor control is equipped with a bank of three
dipswitches that provide biasing and termination functions for
the communications transmission lines. The outdoor control
in the CT compatible unit is equipped with a bank of two
dipswitches that provide termination functions for the com-
munications transmission lines. Communications errors will
result if these switches are not correctly set. The table
below indicates the switch position for the bias and termina-
tion dipswitches along with the expected voltages. Note that
the ON position is the correct position for all bias and
termination dipswitches.
NOTE: Refer to the instructions accompanying the CT
compatible outdoorAC/HP unit for troubleshooting information.
Refer to the Troubleshooting Chart in theAppendix for a listing
of possible furnace error codes, possible causes and correc-
tive actions.
OFF ON
1
BIAS
BIAS
2
3
TERM
Indoor Unit BIAS and TERMINATION Dipswitches
The ComfortNet system is a fully communicating system, and
thus, constitutes a network. Occasionally the need to trouble-
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OPERATIONAL CHECKS & SAFETY CIRCUIT DESCRIPTION
LED
LED
Status
Off
Indication
Possible Causes
x None
x Communications
Failure
Corrective Action(s)
Notes & Cautions
x Normal condition
x Communications
Failure
x None
x None
1 Flash
x Depress Learn Button x Depress once
x Verify that bus BIAS
and TERM
dipswitches are in the
ON position.
quickly for a power-
up reset
x Depress and hold
for 2 seconds for
an out-of-box reset
x None
Red
Communications
LED
2 Flashes
Off
x Out-of-box reset
x Control power up
x Learn button
depressed
x No power to furnace
x Open fuse
x Communications error
x None
x No power
x Communications
error
x Check fuses and
circuit breakers;
replace/reset
x Turn power OFF
prior to repair
x Replace blown fuse
x Check for shorts in
low voltage wiring in
furnace/system
x Reset network by
depressing learn
button
x Check data 1/ data 2
voltages
1 Steady
Flash
x No network found
x Broken/ disconnected
data wire(s)
x Furnace is installed as
a legacy/ traditional
system
x Check
x Turn power OFF
prior to repair
x Verify wires at
terminal blocks are
securely twisted
together prior to
inserting into
communications
wiring (data 1/ data 2
wires)
x Check wire
connections at
terminal block
Green Receive
LED
terminal block
x Verify furnace
installation type
(legacy/ traditional or
communicating)
x Check data 1/ data 2
voltages
x Verify data1 and
data voltages as
described above
Rapid
Flashing
On Solid
x Normal network
traffic
x Data 1/ Data 2
miss-wire
x Control is “talking” on
network as expected
x Data 1 and data 2
wires reversed at
furnace, thermostat,
or CT™ compatible
outdoor AC/HP
x Short between data 1
and data 2 wires
x Short between data 1
or data 2 wires and R
(24VAC) or C (24VAC
common)
x None
x None
x Check
x Turn power OFF
prior to repair
x Verify wires at
terminal blocks are
securely twisted
together prior to
inserting into
communications
wiring (data 1/ data 2
wires)
x Check wire
connections at
terminal block
x Check data 1/ data 2
voltages
terminal block
x Verify data1 and
data voltages as
described above
HEATINGMODE
NORMAL SEQUENCE OF OPERATION
The normal operational sequence in heating mode is as fol-
lows:
POWER UP
•
R and W1 (or R and W1/W2) thermostat contacts close,
initiating a call for heat.
The normal power up sequence is as follows:
•
•
•
115 VAC power applied to furnace.
•
•
Integrated control module performs safety circuit checks.
Integrated control module performs internal checks.
Induced draft blower is energized on high speed for a 15-
second prepurge. Humidifier terminal is energized with
induced draft blower.
Integrated control module displays88on dual 7-segment
display LED’s.
•
•
Integrated control module monitors safety circuits
continuously.
•
•
Induced draft blower steps to low speed following
prepurge. Low stage pressure switch contacts are
closed.
Furnace awaits call from thermostat. Dual 7-segment
LED’s display 0Pwhile awaiting call from thermostat.
Igniter warm up begins upon step to low speed and
presence of closed low stage pressure switch contacts.
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OPERATIONAL CHECKS & SAFETY CIRCUIT DESCRIPTION
•
•
•
Gas valve opens at end of igniter warm up period, delivering
gas to burners and establishing flame.
COOLINGMODE
The normal operational sequence in cooling mode is as fol-
lows:
Integrated control module monitors flame presence. Gas
valve will remain open only if flame is detected.
•
R and Y1/G or Y2/G thermostat contacts close, initiating
a call for cool.
If the thermostat call is for low heat, gas valve and induced
draft blower will continue on low stage. If the call is for
high heat, the gas valve and induced draft blower will
change to high stage.
•
•
Integrated control module performs safety circuit checks.
Outdoor fan and compressor are energized to their
appropriate speed.
•
Circulator blower is energized on heat speed following a
thirty (30) second blower on delay. The circulator blower
requires thirty seconds to ramp up to full speed.
Electronic air cleaner terminal is energized with circulator
blower.
•
Circulator blower is energized on the appropriate cool
speed at the level and time determined by the selected
ramping profile. Electronic air cleaner terminal is
energized with circulator blower.
•
•
Furnace circulator blower and outdoor cooling unit run
their appropriate speeds, integrated control module
monitors safety circuits continuously.
•
•
•
Furnace is now operating on the specified stage called
for by the two-stage thermostat.
Furnace runs, integrated control module monitors safety
circuits continuously.
R and Y1/G or Y2/G thermostat contacts open,
completing the call for cool.
If the two-stage thermostat changes the call from low
heat to high heat, the integrated control module will
immediately switch the induced draft blower, gas valve,
and circulator blower to their high stage settings.
•
•
Outdoor fan and compressor are de-energized.
Circulator blower continues running during a cool off delay
period. The OFF delay time and airflow level are
determined by the selected ramping profile.
Electronic air cleaner terminal and circulator blower are
de-energized.
•
•
If the two-stage thermostat changes the call from high
heat to low heat, the control will immediately switch the
induced draft blower and gas valve to their low stage
settings. The circulator blower will remain on high
heating speed for thirty (30) seconds before switching to
•
•
Furnace awaits next call from thermostat.
FANONLY MODE
the low heat circulating speed.
R and W1 (or R and W1/W2) thermostat contacts open,
completing the call for heat.
The normal operational sequence in fan only mode is as fol-
lows:
•
•
Gas valve closes, extinguishing flame.
•
R and G thermostat contacts close, initiating a call for
fan.
Induced draft blower is de-energized following a fifteen
second post purge. Humidifier terminals are de-energized.
•
•
Integrated control module performs safety circuit checks.
•
Circulator blower continues running for the selected heat
off delay period (90, 120, 150 or 180 seconds). The
speed run during this period depends on the last heat
call provided by the thermostat.
Circulator blower is energized on continuous fan speed
(30% of the furnace’s maximum airflow capability)
following a five (5) second delay. Electronic air cleaner
terminal is energized.
If the last call for heat was a call for low heat, the air
circulator motor will run on low heat speed for the duration
of the heat off delay period (90, 120, 150 or 180 seconds).
If the last call for heat was a call for high heat, the air
circulating motor will run on the high heating speed for
thirty (30) seconds and then switch to the low heating
speed for the balance of the heat off delay period (60,
90, 120 or 150 seconds).
•
•
•
•
Circulator blower runs, integrated control module
monitors safety circuits continuously.
R and G thermostat contacts open, completing the call
for fan.
Circulator blower is de-energized. Electronic air cleaner
terminal is de-energized.
Furnace awaits next call from thermostat.
•
•
Circulator blower and electronic air cleaner terminal is
de-energized.
OPERATIONAL CHECKS
Circulator blower ramps down to OFF during the 30
seconds following the heat off delay period.
Furnace awaits next call from thermostat.
The burner flames should be inspected with the burner com-
partment door installed. Flames should be stable, quiet, soft,
and blue (dust may cause orange tips but they must not be
yellow). Flames should extend directly outward from the burn-
ers without curling, floating, or lifting off. Flames must not
impinge on the sides of the heat exchanger firing tubes.
•
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TROUBLESHOOTING & MAINTENANCE
FLAME SENSOR
The flame sensor is a probe mounted to the burner/manifold
assembly which uses the principle of flame rectification to de-
termine the presence or absence of flame.
TROUBLESHOOTING
ELECTROSTATIC DISCHARGE (ESD)PRECAUTIONS
NOTE: Discharge body’s static electricity before touching unit.
An electrostatic discharge can adversely affect electrical
components.
Burner Flame
SAFETY CIRCUIT DESCRIPTION
Use the following precautions during furnace installation and
servicing to protect the integrated control module from dam-
age. By putting the furnace, the control, and the person at the
same electrostatic potential, these steps will help avoid expos-
ing the integrated control module to electrostatic discharge.
This procedure is applicable to both installed and uninstalled
(ungrounded) furnaces.
1. Disconnect all power to the furnace. Do not touch the
integrated control module or any wire connected to the
control prior to discharging your body’s electrostatic
charge to ground.
A number of safety circuits are employed to ensure safe and
proper furnace operation. These circuits serve to control any
potential safety hazards and serve as inputs in the monitoring
and diagnosis of abnormal function. These circuits are con-
tinuously monitored during furnace operation by the integrated
control module.
INTEGRATED CONTROLMODULE
The integrated control module is an electronic device which, if
a potential safety concern is detected, will take the necessary
precautions and provide diagnostic information through an LED.
2. Firmly touch a clean, unpainted, metal surface of the
furnace away from the control. Any tools held in a
person’s hand during grounding will be discharged.
PRIMARY LIMIT
3. Service integrated control module or connecting wiring
following the discharge process in step 2. Use caution
not to recharge your body with static electricity; (i.e., do
not move or shuffle your feet, do not touch ungrounded
objects, etc.). If you come in contact with an ungrounded
object, repeat step 2 before touching control or wires.
The primary limit control is located on the partition panel and
monitors heat exchanger compartment temperatures. It is a
normally-closed (electrically), automatic reset, temperature-ac-
tivated sensor. The limit guards against overheating as a result
of insufficient conditioned air passing over the heat exchanger.
AUXILIARY LIMIT
4. Discharge your body to ground before removing a new
control from its container. Follow steps 1 through 3 if
installing the control on a furnace. Return any old or
new controls to their containers before touching any
ungrounded object.
The auxiliary limit controls are located on or near the circulator
blower and monitors blower compartment temperatures. They
are a normally-closed (electrically), auto-reset sensors. These
limits guard against overheating as a result of insufficient con-
ditioned air passing over the heat exchanger.
DIAGNOSTIC CHART
ROLLOUT LIMIT
WARNING
The rollout limit controls are mounted on the burner/manifold
assembly and monitor the burner flame. They are normally-
closed (electrically), manual-reset sensors. These limits guard
against burner flames not being properly drawn into the heat
exchanger.
HIGH VOLTAGE !
TO AVOID PERSONAL INJURY OR DEATH DUE TO
ELECTRICAL SHOCK, DISCONNECT ELECTRICAL POWER
BEFORE PERFORMING ANY SERVICE OR MAINTENANCE.
PRESSURE SWITCHES
Refer to the Troubleshooting Chart at the end of this manual for
assistance in determining the source of unit operational prob-
lems. The dual 7-segment LED display will display an error
code that may contain a letter and number. The error code may
be used to assist in troubleshooting the unit.
The pressure switches are normally-open (closed during op-
eration) negative air pressure-activated switches. They moni-
tor the airflow (combustion air and flue products) through the
heat exchanger via pressure taps located on the induced draft
blower and the coil front cover. These switches guard against
insufficient airflow (combustion air and flue products) through
the heat exchanger and/or blocked condensate drain condi-
tions.
36
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MISCELLANEOUS
•
Flue pipe system. Check for blockage and/or leakage.
Check the outside termination and the connections at
and internal to the furnace.
Heat exchanger. Check for corrosion and/or buildup
within the heat exchanger passageways.
Burners. Check for proper ignition, burner flame, and
flame sense.
Drainage system. Check for blockage and/or leakage.
Check hose connections at and internal to furnace.
Wiring. Check electrical connections for tightness and/
or corrosion. Check wires for damage.
Filters.
FAULT RECALL
The ignition control is equipped with a momentary push-button
switch that can be used to display the last six faults on the
dual 7-segment LED’s. The control must be in Standby Mode
(no thermostat inputs) to use the feature. Depress the switch
for approximately 2 seconds. Release the switch when the
LED’s are turned off. The last six faults will be displayed most
recent to least recent on the dual 7-segment LED’s.
•
•
•
•
•
NOTE: Consecutively repeated faults are stored a maximum of
three times. Example: A clogged return air filter causes the
furnace limit to trip repeatedly. The control will only store this
fault the first three consecutive times the fault occurs.
FILTERS
RESETTINGFROM LOCKOUT
CAUTION
Furnace lockout results when a furnace is unable to achieve
ignition after three attempts during a single call for heat. It is
characterized by a non-functioning furnace and a E0code dis-
played on the dual 7-segment display. If the furnace is in “lock-
out”, it will (or can be) reset in any of the following ways.
1. Automatic reset. The integrated control module will
automatically reset itself and attempt to resume normal
operations following a one hour lockout period.
TO ENSURE PROPER UNIT PERFORMANCE, ADHERE TO THE FILTER SIZES
GIVEN IN THE RECOMMENDED MINIMUM FILTER SIZE TABLE OR
SPECIFICATION SHEET APPLICABLE TO YOUR MODEL.
FILTER MAINTENANCE
Improper filter maintenance is the most common cause of in-
adequate heating or cooling performance. Filters should be
cleaned (permanent) or replaced (disposable) every two months
or as required. When replacing a filter, it must be replaced with
a filter of the same type and size.
2. Manual power interruption. Interrupt 115 volt power to
the furnace.
3. Manual thermostat cycle. Lower the thermostat so that
there is no longer a call for heat for 1 -20 seconds then
reset to previous setting.
FILTER REMOVAL
NOTE: If the condition which originally caused the lockout still
exists, the control will return to lockout. Refer to the Diagnostic
Chart for aid in determining the cause.
Depending on the installation, differing filter arrangements can
be applied. Filters can be installed in either the central return
register or a side panel external filter rack (upflow only). A
media air filter or electronic air cleaner can be used as an alter-
nate filter. Follow the filter sizes given in the Recommended
Minimum Filter size table to ensure proper unit performance.
MAINTENANCE
WARNING
To remove filters from an external filter rack in an upright upflow
installation, follow the directions provided with external filter
rack kit.
TO AVOID ELECTRICAL SHOCK, INJURY OR DEATH,
DISCONNECT ELECTRICAL POWER BEFORE PERFORMING ANY
MAINTENANCE. IF YOU MUST HANDLE THE IGNITER,
HANDLE WITH CARE. TOUCHING THE IGNITER ELEMENT
WITH BARE FINGERS, ROUGH HANDLING OR VIBRATION
COULD DAMAGE THE IGNITER RESULTING IN PREMATURE
FAILURE. ONLY A QUALIFIED SERVICER SHOULD EVER
HANDLE THE IGNITER.
HORIZONTAL UNIT FILTER REMOVAL
Filters in horizontal installations are located in the central re-
turn register or the ductwork near the furnace.
To remove:
1. Turn OFF electrical power to furnace.
2. Remove filter(s) from the central return register or
ductwork.
3. Replace filter(s) by reversing the procedure for removal.
4. Turn ON electrical power to furnace.
ANNUALINSPECTION
The furnace should be inspected by a qualified installer, or ser-
vice agency at least once per year. This check should be per-
formed at the beginning of the heating season. This will ensure
that all furnace components are in proper working order and
that the heating system functions appropriately. Pay particular
attention to the following items. Repair or service as neces-
sary.
MEDIA AIR FILTER OR ELECTRONIC AIR CLEANER REMOVAL
Follow the manufacturer’s directions for service.
37
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MISCELLANEOUS
9. Severe heat exchanger fouling is an indication of an
operational problem. Perform the checks listed in
Startup Procedure and Adjustments to reduce the
chances of repeated fouling.
BURNERS
Visually inspect the burner flames periodically during the heat-
ing season. Turn on the furnace at the thermostat and allow
several minutes for flames to stabilize, since any dislodged
dust will alter the flames normal appearance. Flames should
be stable, quiet, soft, and blue (dust may cause orange tips
but they must not be yellow). They should extend directly
outward from the burners without curling, floating, or lifting off.
Flames must not impinge on the sides of the heat exchanger
firing tubes.
BEFORE LEAVING AN INSTALLATION
•
•
•
Cycle the furnace with the thermostat at least three
times. Verify cooling and fan only operation.
Review the Owner’s Manual with the homeowner and
discuss proper furnace operation and maintenance.
INDUCED DRAFTAND CIRCULATOR BLOWERS
Leave literature packet near furnace.
The bearings in the induced draft blower and circulator blower
motors are permanently lubricated by the manufacturer. No fur-
ther lubrication is required. Check motor windings for accumu-
lation of dust which may cause overheating. Clean as neces-
sary.
REPAIR AND REPLACEMENT PARTS
•
•
•
When ordering any of the listed functional parts, be sure
to provide the furnace model, manufacturing, and serial
numbers with the order.
FLAME SENSOR (QUALIFIED SERVICER ONLY)
Although only functional parts are shown in the parts
list, all sheet metal parts, doors, etc. may be ordered by
description.
Under some conditions, the fuel or air supply can create a
nearly invisible coating on the flame sensor. This coating acts
as an insulator causing a drop in the flame sense signal. If the
Parts are available from your distributor.
flame sense signal drops too low the furnace will not sense Functional Parts List-
flame and will lock out. The flame sensor should be carefully
cleaned by a qualified servicer using emery cloth or steel wool.
Following cleaning, the flame sense signal should be as indi-
cated in the Specifications Sheet.
Gas Valve
Gas Manifold
Natural Gas Orifice
Propane Gas Orifice
Igniter
Blower Motor
Blower Wheel
Blower Mounting Bracket
Blower Cutoff
Blower Housing
Inductor
FLUE PASSAGES (QUALIFIED SERVICER ONLY)
Flame Sensor
Rollout Limit Switch
Primary Limit Switch
Pressure Switch
Induced Draft Blower
Door Switch
Heat Exchanger
Auxiliary Limit Switch
Integrated Control Module
Transformer
The heat exchanger flue passageways should be inspected at
the beginning of each heating season. If necessary, clean the
passageways as outlined below.
1. Turn OFF the electrical power and gas supply to the
furnace.
2. Disconnect the gas line and remove the burner/ manifold
assembly by removing the screws securing the assembly
to the partition panel.
3. Disconnect the flue pipe system from the induced draft
blower.
4. Remove the induced draft blower and collector box cover.
5. Clean the primary heat exchanger tubes using a wire
brush attached to a length of high grade stainless steel
cable, such as drain cleanout cable. Attach a variable
speed reversible drill to the other end of the cable. Slowly
rotate the cable with the drill and insert it into one of the
heat exchanger tubes. While reversing the drill, work
the cable in and out several times to obtain sufficient
cleaning. Repeat for each tube.
6. Clean residue from furnace using a vacuum cleaner.
7. Replace the parts removed in the previous steps in
reverse order.
8. Turn on electrical power and gas to furnace. Check for
leaks and proper unit operation.
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TROUBLESHOOTING CHART
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TROUBLESHOOTING CHART
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TROUBLESHOOTING CHART
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TROUBLESHOOTING CHART
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TROUBLESHOOTING CHART
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STATUS CODES
INTERNAL CONTROL FAULT/NO POWER
NORMAL OPERATION
O P
E 0
E 1
E 2
E 3
E 4
E 5
E 6
E 7
E 8
E 9
E A
d 0
d 4
b 0
b 1
b 2
b 3
b 4
b 5
b 6
b 7
b 9
C 1
C 2
LOCKOUT DUE TO EXCESSIVE RETRIES
LOW STAGE PRESSURE SWITCH STUCK CLOSED AT START OF HEATING CYCLE
LOW STAGE PRESSURE SWITCH STUCK OPEN
OPEN HIGH LIMIT SWITCH
FLAME DETECTED WHEN NO FLAME SHOULD BE PRESENT
OPEN FUSE
LOW FLAME SIGNAL
IGNITER FAULT OR IMPROPER GROUNDING
HIGH STAGE PRESSURE SWITCH STUCK CLOSED AT START OF HEATING CYCLE
HIGH STAGE PRESSURE SWITCH STUCK OPEN
REVERSED 115 VAC POLARITY
DATA NOT YET ON NETWORK
INVALID MEMORY CARD DATA
BLOWER MOTOR NOT RUNNING
BLOWER COMMUNICATION ERROR
BLOWER HP MIS-MATCH
BLOWER MOTOR OPERATING IN POWER, TEMPERATURE, OR SPEED LIMIT
BLOWER MOTOR CURRENT TRIP OR LOST ROTOR
BLOWER MOTOR LOCKED ROTOR
OVER/UNDER VOLTAGE TRIP OR OVER TEMPERATURE TRIP
INCOMPLETE PARAMETERS SENT TO MOTOR
LOW INDOOR AIRFLOW
LOW STAGE COOL
HIGH STAGE COOL
LOW STAGE HEAT
L 0
H I
F
HIGH STAGE HEAT
CONTINUOUS FAN
CFM/100; ALTERNATES WITH
,
,
,
,
H I
C 2 L O
F
1 2
C 1
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AIR FLOW DATA
Speed Selection Dip Switches
Model
Tap
Low Stage High Stage Low Stage High Stage
Cool
Cool
Heat
Heat
Cool
Selection
Switches
Adjust
Selection Selection
Switches Switches
Profile
Heat
Selection
Switches
A
B
C
D
390
520
650
780
600
735
1050
1150
1250
1350
800
1000
1200
805
875
935
*DVC80703BX*
*DVC80905CX*
TAP
1
2
3
4
5
6
7
8
A
OFF OFF OFF OFF OFF OFF
ON OFF ON OFF ON OFF
OFF ON OFF ON OFF ON
ON ON ON ON ON ON
OFF OFF
ON OFF
OFF ON
ON ON
800
1100
1400
1800
945
1015
1085
1155
1350
1450
1550
1650
A
B
C
D
520
715
910
B
C
1170
D
A
B
C
D
553
748
943
850
1150
1450
1850
1085
1155
1225
1260
1550
1650
1750
1800
Profiles
Pre-Run
-------
Short-Run
OFF Delay
60 sec/100%
60 sec/100%
60 sec/100%
30 sec/50%
*DVC81155CX*
*MVC80704BX*
A
B
C
D
--------
30 sec/50%
1203
-------
600
800
1100
1400
875
945
1015
1085
1250
1350
1450
1550
A
B
C
D
390
520
715
910
-------
7.5 min/82%
30 sec/50%
7.5 min/82%
To set airflow:
(1) Select model and desired
high stage cooling airflow. Determine the corresponding tap
( A, B, C, or D ). Set dip switches 1 and 2 to the appropriate
ON / OFF positions. (2) Select model and desired high stage
heating airflow. Determine the corresponding tap ( A, B, C, or
D ). Set dip switches 7 and 8 to the appropriate ON / OFF
positions. (3) Select the airflow adjustment factor taps A and
D are 1; Tap B is +10%; Tap C -10%. Set dip switches 3 and 4
to the appropriate ON / OFF positions.
A
B
C
D
520
715
910
800
1100
1400
1800
1050
1120
1190
1260
1500
1600
1700
1800
*MVC80905CX*
*MVC81155CX*
1170
800
1100
1400
1800
1210
1225
1245
1260
1725
1750
1775
1800
A
B
C
D
520
715
910
To set Comfort Mode: Select desired Comfort Mode profile
(see profiles above). Set switches 5 and 6 to the appropriate
ON / OFF positions.
1175
NOTE: Airflow data shown applies to legacy mode operation only. For a fully communicating system,
please see the outdoor unit’s installation instructions for cooling and pump heating airflow data. See
ComfortNet™ System - Airflow Consideration section for details.
DIP SWITCHES
DIP Sw itch No.
Sw itch
Bank
Purpos e
Function
1
OFF
ON
OFF
ON
---
2
OFF
OFF
ON
ON
---
3
---
4
---
5
---
---
---
---
---
---
---
---
---
---
---
---
---
---
---
---
---
---
OFF
ON
OFF
ON
---
---
---
---
---
---
6
---
---
---
---
---
---
---
---
---
---
---
---
---
---
---
---
---
---
OFF
OFF
ON
ON
---
---
---
---
---
---
7
---
---
---
---
---
---
---
---
---
---
---
---
---
---
---
---
---
---
---
---
---
---
OFF
ON
OFF
ON
---
---
8
---
---
---
---
---
---
---
---
---
---
---
---
---
---
---
---
---
---
---
---
---
---
OFF
OFF
ON
ON
---
---
9
---
---
---
---
---
---
---
---
---
---
---
---
---
---
---
---
---
---
---
---
---
---
---
---
---
---
OFF
ON
10
---
90 seconds
120 seconds
150 seconds*
180 seconds
1-Stage T-stat
Heat OFF
Delay
---
---
---
---
---
---
---
---
---
S1
S2
S3
OFF
ON
---
---
---
Thermostat 2-Stage T-Stat
---
---
---
---
Setup
5-Min Delay
---
---
OFF
ON
---
---
A uto Delay
---
---
---
---
Bus BIA S
TERM
BIA S
ON*
---
ON*
---
---
---
Bus Termination
ON*
---
---
---
A
OFF
ON
OFF
ON
---
OFF
OFF
ON
ON
---
---
---
Cooling
B
---
---
---
Speed Tap
C
---
---
---
D*
---
---
---
Normal*
OFF
ON
OFF
ON
---
OFF
OFF
ON
ON
---
---
A djust
Taps
10%
---
---
---
-10%
---
---
---
Normal
---
---
---
A *
---
---
---
Ramping
Profiles
B
---
---
---
---
---
C
---
---
---
---
---
D
---
---
---
---
---
S4
A
---
---
---
---
---
Heating
Speed Tap
B*
C
---
---
---
---
---
---
---
---
---
---
D
---
---
---
---
---
Disabled*
Enabled
---
---
---
---
Unused
Unused
S5
DEHUM
---
---
---
---
(*Indicates factory setting)
---
Not applicable
45
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*MVC8_AA WIRING DIAGRAM
TO
1
15
V
AC/ 1
POWER SUPP
LY W
ITH
PROTECTI
ON DEV
ICE
BK
24V HUM.
YL
C
WH
C
NO
NO
2 1
TO 115VAC/ 1Ø /60 HZ POWER SUPPLY WITH
YL
OVERCURRENT PROTE
ON DEV
CTI
ICE
3
2
H
I
WH
GND
C
1
PM
DISCONNECT
PU
PU
RD
DOOR
SWITCH
JUNCTION BOX
INDUCTO
L
R COI
PU
70kBTU,90kBTU,
115kBTU MODELS
ONLY
INDOOR
AIR
CIRCULATOR
BLWR
3
2
1
RD
GND
B
UR
N
E
R C
O
M
PARTMENT
NEUTRAL
NEUTRAL
LINE
EAC
ELECTRONIC
AIR CLEANER
BLO
W
E
R C
O
M
PARTMENT
PU
AUTO RESET
AUXILIARY
LIMIT CONTROL
IND HI
NEUTRAL
ID
BLWR
IND LO
24
V
THERMOSTAT CONNECTIONS
FUSE
24 V
3 A
HUM
IGN
NEUTRAL
NEUTRAL
HUMIDIFIER
HOT SURFACE
IGNITER
YL
SEE
NOTE 5
DIAGNOSTIC
LED'S
FS
2
3
1
4
RD
FLAME SENSOR
115 VAC
6
5
RD
YL
2ND STG DLY
T-STAT
NEUTRAL
LINE
9
12
15
7
8
HEAT OFF
DELAY
10
40 VA
TRANSFORMER
11
RD
BR
FUSE 3 A
TH (4)
UNUSED
DEHUM
R
13
14
24 VAC
B
L
HEAT
TO
+VDC
WH
1
2
YL
HLO (10)
PSO (7)
Y1
DELAY
BL
3
4
ADJUST
COOL
LOW FIRE PRESS.
SWITCH
C
24V HUM.
NO
W1
W2
PS1 (2)
OR
NO
LINE
PS2 (12)
TO
MICRO
1
2
3
4
5
C
BK
Y2
G
HIGH FIRE
PRESS. SWTICH
HLI (1)
FS
WH
O
NEUTRAL
WH
DEHUM
MVL (13)
PM
HI
MVH (14)
MVC (8)
RD
C
BL
ECM MT
R
WH
C
H
A
RNE
S
S
WH
GAS
VALVE
GND (5)
TR (11)
GY
BK
BK
B
K
GND
B
K
5
BK
TO
GND (4)
+ VDC (1)
4
3
2
1
WH
R
GR
PK
GND
BLOWER
INDOOR
AIR
RX(2)
TX (3)
COMPARTMENT
DOOR SWITCH
(OPEN WHEN
DOOR OPEN)
TO
MICRO
CIRCULATOR
BLWR
CIRCULATOR
BLOW ER
INDUCTOR COIL
70kBTU,90kBTU,
115kBTU MODELS
ONLY
INTEGRATED CONTROL MODULE
HUMIDIFIER
NOTES:
1. SET HEAT ANTICIPATOR ON RO
2. MANUFACTURER'S SPECIFIED REPLACEMENT PARTS MUST BE
USED WHEN SERVICING.
3. IF ANY OF THE ORIGINAL WIRE AS SUPPLIED WITH THE
FURNACE MUST BE REPLACED, IT MUST BE REPLACED WITH
WIRING MATERIAL HAVING ATEMPERATURE RATING OF AT
LEAST 105°C. USE COPPER CONDUCTORS ONLY.
EQUIPMENT GND
FIELD G
LOW VOLTAGE (24 V)
LOW VOLTAGE FIE LD
COLOR CODES:
PK PINK
STAT AT 0.7 AMPS.
OM THERMO
ND
B
R BROW N
WH WHITE
BL BLUE
GY GRAY
RD RED
HI VOLTAGE (115
V)
FIELD SPLICE
SWITCH (TEMP.)
IGNITER
V
E
LD
H
I
OLTAGE F
JUNCTION
TE MINAL
INTERN TO
I
4. UNITMUST BE PERMANENTLY GROUNDED AND CONFOR
N.E.C. AND LOCAL CODES.
5. TO RECALL THE LAST 6 FAULTS, MOST RECENTTO LEAST
RECENT, DEPRESS SWITCH FOR MORE THAN 2 SECONDS WHILE
IN STANDBY (NO THERMOSTAT INPUTS)
O
M T
YL YELLOW
R
O
R
OR
A
GE
N
SWITCH (PRESS
.)
AL
NTROL
PU PURPLE
GN GREEN
BK BLACK
INTEGRAT
ED CO
OVERC
U
R
R
ENT
PLUG CONNECTION
PROT. DEVICE
0140F
00
06
REV. A
6
Wiring is subject to change. Always refer to the wiring diagram on the unit for the most up-to-date wiring.
46
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*MVC8_AB, *DVC8_AA WIRING DIAGRAM
TO
GND
115 VAC/ 1 Ø /60 HZ
POWER SUPPLY WITH
OVERCURRENT
PROTECTION DEVICE
ID BLOWER TWO-STAGE PRESSURE
SWITCH ASSEMBLY
L
WARNING:DISCONNECT
POWER BEFORE
SERVICING. WIRING
TO UNIT MUST BE
PROPERLY POLARIZED
AND GROUNDED.
BK
24V HUM.
HIGH FIRE
PRESSURE
SWITCH
YL
HOT
SURFACE
IGNITER
LOW FIRE
PRESSURE
SWITCH
N
C
WH
C
NO
NO
DISCONNECT
2 CIRCUIT
2 1
CONNECTOR
TO 115VAC/ 1 Ø /60 HZ POWER SUPPLY WITH
OVERCURRENT PROTECTION DEVICE
YL
2
HI
WH
GND
L
N
TWO STAGE
GAS VALVE
(HONEY WELL)
3
BL
C
FLAME
SENSOR
WARNING:
DISCONNECT POWER
BEFORE SERVICING.
WIRING TO UNIT
1
PM
BR
MUST BE PROPERLY
POLARIZED AND
GROUNDED.
DISCONNECT
MANUAL RESET ROLLOUT LIMIT
CONTROLS
PU
PU
RD
DOOR
SWITCH
JUNCTION BOX
AUTO RESET PRIMARY
LIMIT CONTROL
INDUCTOR COIL
70kBTU,90kBTU,
115kBTU MODELS
ONLY
PU
INDUCED
DRAFT
BLOWER
INDOOR
AIR
CIRCULATOR
BLWR
3
2
1
WH
RD
BK
GND
GND
BURNER COMPARTMENT
BLOWER COMPARTMENT
LINE
EAC
NEUTRAL
NEUTRAL
ELECTRONIC
AIR CLEANER
PU
AUTO RESET
AUXILIARY
LIMIT CONTROL
IND HI
NEUTRAL
ID
BLWR
IND LO
HUM
24 V THERMOSTAT CONNECTIONS
FUSE
24 V
3 A
NEUTRAL
NEUTRAL
HUMIDIFIER
IGN
FS
HOT SURFACE
IGNITER
YL
SEE
NOTE 5
DIAGNOSTIC
LED'S
2
3
6
1
4
RD
RD
YL
FLAME SENSOR
115 VAC
5
2ND STG DLY
T-STAT
NEUTRAL
LINE
9
12
15
8
7
HEAT OFF
DELAY
10
40 VA
TRANSFORMER
11
RD
FUSE 3 A
TH (4)
UNUSED
DEHUM
R
13
BR
BL
14
24 VAC
AUTO RESET PRIMARY
AUTO RESET AUXILIARY LIMIT
CONTROLS
LIMIT CONTROL
HEAT
TO +VDC
WH
1
2
YL
HLO (10)
Y1
DELAY
RD
BL
3
4
PSO (7)
PS1 (2)
ADJUST
COOL
24
LOW FIRE PRESS.
SWITCH
C
VAC
24V HUM.
NO
W1
W2
115
VAC
OR
NO
LINE
PS2 (12)
40 VA
TRANSFORMER
TO
MICRO
1
2
3
4
5
C
BK
Y2
G
HIGH FIRE
PRESS. SWTICH
HLI (1)
MANUAL RESET ROLLOUT
LIMIT CONTROLS
FS
WH
O
NEUTRAL
WH
DE HUM
MVL (13)
PM
HI
MVH (14)
MVC (8)
RD
C
BL
ECM MTR
HARNESS
WH
C
WH
GAS
VALVE
GND (5)
TR (11)
GY
BK
BK
BK
GND
BK
5
BK
TO
GND (4)
+ VDC (1)
4
3
2
1
WH
R
GR
PK
GND
BLOWER
INDOOR
AIR
RX (2)
TX (3)
COMPARTMENT
DOOR SWITCH
(OPEN WHEN
DOOR OPEN)
TO
MICRO
CIRCULATOR
BLWR
CIRCULATOR
BLOWER
INDUCTOR COIL
70kBTU,90kBTU,
115kBTU MODELS
ONLY
INTEGRATED CONTROL MODULE
HUMIDIFIER
NOTES:
1. SET HEAT ANTICIPATOR ON ROOM THERMOSTAT AT 0.7 AMPS.
2. MANUFACTURER'S SPECIFIED REPLACEMENT PARTS MUST BE
USED WHEN SERVICING.
EQUIPMENT GND
FIELD GND
COLOR CODES:
PK PINK
BR BROWN
WH WHITE
BL BLUE
LOW VOLTAGE (24V)
LOW VOLTAGE FIELD
HI VOLTAGE (115V)
HI VOLTAGE FIELD
FIELD SPLICE
SWITCH (TEMP.)
IGNITER
3. IF ANY OF THE ORIGINAL WIRE AS SUPPLIED WITH THE
FURNACE MUST BE REPLACED, IT MUST BE REPLACED WITH
WIRING MATERIAL HAVING A TEMPERATURE RATING OF AT
LEAST 105 C. USE COPPER CONDUCTORS ONLY.
GY GRAY
RD RED
JUNCTION
TERMINAL
INTERNAL TO
4. UNIT MUST BE PERMANENTLY GROUNDED AND CONFORM TO
N.E.C. AND LOCAL CODES.
5. TO RECALL THE LAST 6 FAULTS, MOST RECENT TO LEAST
RECENT, DEPRESS SWITCH FOR MORE THAN 2 SECONDS WHILE
IN STANDBY (NO THERMOSTAT INPUTS)
YL YELLOW
OR ORANGE
PU PURPLE
GN GREEN
BK BLACK
SWITCH (PRESS.)
INTEGRATED CONTROL
OVERCURRENT
PROT. DEVICE
PLUG CONNECTION
0140F00660
REV. A
Wiring is subject to change. Always refer to the wiring diagram on the unit for the most up-to-date wiring.
47
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Goodman Manufacturing Company, L.P.
5151 San Felipe, Suite 500, Houston, TX 77056
© 2009-2010 Goodman Manufacturing Company, L.P.
48
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